Component Parts Removal

COMPONENTS

Part 1:

Part 2:

Part 3:

BASIC SUBASSEMBLY SEPARATION




1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH




3. REMOVE SPEED SENSOR
a. Remove the set bolt and lock plate.
b. Remove the speed sensor.
4. REMOVE THREE BOLTS AND SHIFT CONTROL BRACKET




5. REMOVE SELECTING BELLCRANK ASSEMBLY




6. REMOVE BREATHER PLUG
7. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY




a. Remove the lock bolt.




b. Remove the four bolts and pull out the shift and select lever shaft assembly.




8. REMOVE TRANSMISSION CASE COVER
9. REMOVE LOCK NUT




a. Unstake the lock nut.




b. Engage the gear double meshing.




c. Remove the lock nut.
d. Disengage the gear double meshing.

10. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK




a. Remove the No.3 shift fork set bolt.




b. Remove the No.3 hub sleeve and No.3 shift fork.




11. REMOVE FIFTH DRIVEN GEAR Using SST, remove the 5th driven gear.
SST 09310-17010 (09310-07010, 09310-07020, 09310-07040, 0931 0-07050)
12. MEASURE FIFTH GEAR THRUST CLEARANCE AND OIL CLEARANCE




a. Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 in.)

Maximum clearance: 0.65 mm (0.0256 in.)




b. Using a dial indicator, measure the oil clearance.

Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 in.)

Maximum clearance: 0.070 mm (0.0028 in.)

13. REMOVE NO.3 CLUTCH HUB AND FIFTH GEAR




a. Using two screwdrivers and a hammer, tap out the snap ring.




b. Using SST, remove the No.3 clutch hub with synchronizer ring and 5th gear.
SST 09310-17010 (09310-07010, 09310-07020, 09310-07040, 09310-07050)
c. Remove the 5th gear.

14. REMOVE NEEDLE ROLLER BEARING
15. REMOVE REAR BEARING RETAINER




a. Using a torx wrench, remove the seven torx screws and bearing retainer.
Torx wrench T45 09042-00050
b. Remove the adjust shim.

16. REMOVE SNAP RING




a. Using a snap ring expander, remove the snap ring.




b. Using two screwdriver and a hammer, remove the three snap rings.

17. REMOVE PLUG, SEAT, SPRING AND LOCKING BALL




a. Using SST, remove the plug.
SST 09313-30021




b. Using a magnetic finger, remove the seat, spring and locking ball.




18. REMOVE REVERSE IDLER GEAR SHAFT RETAINING BOLT
19. REMOVE TRANSMISSION CASE




a. Remove the three bolts from transaxle case side.




b. Remove the fourteen bolts from the transmission case side and tap off the case with a plastic hammer.




20. REMOVE OUTPUT SHAFT REAR TAPERED ROLLER BEARING OUTER RACE
Using a plastic hammer, tap out the outer race.




21. REMOVE NO.2 OIL PIPE
a. Remove the gasket.
b. Remove the two bolts and oil pipe.




22. REMOVE REVERSE SHIFT ARM BRACKET
Remove the bolt and pull off the bracket.




23. REMOVE REVERSE IDLER GEAR AND SHIFT
Pull out the shift, remove the reverse idler gear and thrust washer.

24. REMOVE TWO PLUGS, LOCKING BALLS AND SPRINGS




a. Using SST, remove the two plugs.
SST 09313-30021




b. Using a magnetic finger, remove the two spring seats, springs and balls.

25. REMOVE NO.1 SHIFT FORK SHAFT




a. Remove the set bolt.




b. Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.




26. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the reverse shift fork.
27. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD AND NO.1 SHIFT FORK




a. Remove the two set bolts.




b. Pull out the No.2 shift fork shaft.
c. Remove the shift head and No.1 shift fork.




28. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO.2 SHIFT FORK
a. Pull out the No.3 shift fork shaft with reverse shift fork.
b. Remove the No.2 shift fork.




29. REMOVE SNAP RINGS
a. Using two screwdriver and a hammer, remove the snap ring and reverse shift fork from the No.3 shift fork shaft.
b. Using two screwdriver and a hammer, remove the snap rings from the No.1, No.2 and No.3 shift fork shaft.

30. REMOVE INPUT AND OUTPUT SHAFT ASSEMBLY




a. Leaning the output shaft to the differential side remove the input shaft assembly.




b. Lift up the differential case assembly, remove the output shaft.




31. REMOVE DIFFERENTIAL ASSEMBLY
a. Remove the oil pump drive gear.




b. Remove the differential case assembly.




32. REMOVE MAGNET FROM TRANSAXLE CASE
33. REMOVE OIL PUMP ASSEMBLY




a. Remove the two bolts and oil pipe.




b. Remove the two bolts and oil pump.

34. REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB




a. Remove the No.5 synchronizer ring with key spring from No.3 clutch hub.




b. Using a screwdriver, remove the snap ring.

HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.

c. Remove the synchronizer rings.

COMPONENT PARTS INSPECTION




1. INSPECT NO.5 SYNCHRONIZER RINGS
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring.
Turn the middle No.5 synchronizer ring in one direction while pushing it to the outer No.5 synchronizer ring and check that the ring is locked.

If the braking effect is insufficient, replace the synchronizer ring.




2. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 in.)

If the clearance exceeds the limit, replace the shift fork or hub sleeve.

3. IF NECESSARY, REPLACE INPUT SHAFT BEARING AND OIL SEAL




a. Remove the three bolts and transaxle case receiver.




b. Using SST, pull out the bearing.
SST 09612-65014




c. Using a screwdriver, remove the oil seal.




d. Using SST, drive in a new oil seal.
SST 09608-12010 (09608-00020, 09608-00080)
e. Coat the lip of seal with MP grease.




f. Using SST, drive in a new bearing.
SST 09608-12010 (09608-00020, 09608-00060)




g. Install the transaxle case receiver.
h. Install and torque the three bolts.

Torque: 7.4 N.m (75 kgf-cm, 65 in.-lbf)




i. Using SST and a press, remove the inner race.
SST 09950-00020




j. Using SST and a press, install a new input shaft front bearing inner race.
SST 09316-60010 (09316-00020)




4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING AND OUTPUT SHAFT FRONT COVER
a. Using SST, pull out the output shaft front bearing outer race.
SST 09308-00010
b. Remove the output shaft front cover.




c. Install a new output shaft front cover.

HINT: Install the output shaft front cover projection into the case side groove.




d. Using SST and a hammer, drive in a new output shaft front bearing outer race.
SST 09316-60010 (09316-00010, 09316-00020)




e. Using SST and a socket wrench, remove the output shaft front bearing.
SST 09950-00020, 09950-00030




f. Using SST and a press, install a new output shaft front bearing.
SST 09316-60010 (09316-00070)

5. IF NECESSARY, REPLACE REVERSE RESTRICT PIN




a. Using SST, remove the screw plug.
SST 09313-30021




b. Using a pin punch and hammer, drive out the slotted spring pin.




c. Replace the reverse restrict pin.
d. Using a pin punch, drive in the slotted spring pin.




e. Apply sealant to the screw plug threads.

Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

f. Using SST, install the screw plug.
SST 09313-30021