Part 2

RA62 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSMISSION UNIT: DISASSEMBLY

PART 2

25. REMOVE REVERSE IDLER GEAR SHAFT BOLT

(a) Remove the reverse idler gear shaft bolt and gasket from the center transmission case sub-assembly.





26. REMOVE CENTER TRANSMISSION CASE SUB-ASSEMBLY

(a) Remove the 11 bolts.





(b) Using a plastic hammer, carefully tap out the center transmission case sub-assembly.





(c) Remove the center transmission case.

27. REMOVE TRANSMISSION DRAIN PLUG

(a) Remove the drain plug and gasket from the center transmission case sub-assembly.





28. REMOVE NO. 2 OIL RECEIVER PIPE

(a) Remove the No. 2 oil receiver pipe from the center transmission case sub-assembly.





29. REMOVE SHIFT AND SELECT LEVER SHAFT

(a) Using a screwdriver, remove the E-ring from the shift and select lever shaft.





Text in Illustration





(b) Remove the bolt from the shift and select lever.

(c) Using a pin punch (5 mm (0.197 in.)) and a hammer, remove the slotted spring pin from the shift and select lever.

(d) Slide the shift and select lever shaft up until it can be removed from the front transmission case.





(e) Remove the shift and select lever shaft, shift inter lock plate, shift and select cam and shift and select lever from the front transmission case.





(f) Remove the lock ball pin and compression spring from the shift and select lever.





Text in Illustration





30. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE Transmission Unit

31. REMOVE REVERSE IDLER GEAR

(a) Remove the reverse idler gear shaft, reverse idler gear bearing and reverse idler gear.





32. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE Transmission Unit

33. REMOVE FRONT TRANSMISSION CASE

(a) Using a hexagon wrench (27 mm), remove the plug from the front transmission case.





(b) Remove the 4 bolts from the shift interlock bracket.





(c) Tie the input shaft, counter gear and control assembly with a rope or string.





(d) Expand the 2 snap rings, and lift up the output shaft, input shaft, counter gear and control assembly.





(e) Remove the output shaft, input shaft, counter gear shaft and control assembly while gently tapping the front transmission case with a plastic hammer.





NOTICE:
Take care not to subject the output shaft, input shaft, counter gear shaft and control assembly to any impact. This may cause the ball and spring to come out.

(f) Separate the output shaft, input shaft, counter gear shaft and control assembly.

34. REMOVE NO. 1 OIL RECEIVER PIPE

(a) Remove the No. 1 oil receiver pipe from the front transmission case.





35. REMOVE FRONT BEARING SHAFT SNAP RING

(a) Using snap ring pliers, remove the 2 snap rings.





36. REMOVE TRANSMISSION CASE OIL SEAL

(a) Using SST, remove the transmission case oil seal from the front transmission case.





SST : 09308-00010

37. REMOVE FRONT TRANSMISSION CASE BEARING

(a) Using SST, remove the front transmission case bearing from the front transmission case.





SST : 09319-60020

SST : 09350-32014

09351-32180

Text in Illustration





38. REMOVE NO. 3 GEAR SHIFT FORK

(a) Using 2 screwdrivers, remove the 4 snap rings.





(b) Remove the bolt and No. 3 gear shift fork.





39. REMOVE NO. 1 GEAR SHIFT HEAD

(a) Using a pin punch (5 mm (0.197 in.)) and hammer, tap out the slotted spring pin.





40. REMOVE NO. 1 GEAR SHIFT FORK SHAFT

(a) Remove the No. 1 gear shift fork shaft, No. 1 gear shift head, ball and spring.





41. REMOVE NO. 2 GEAR SHIFT FORK

(a) Remove the bolt and No. 2 gear shift fork.





42. REMOVE NO. 2 GEAR SHIFT FORK SHAFT

(a) Remove the No. 2 gear shift fork shaft, ball and spring.





43. REMOVE NO. 3 GEAR SHIFT HEAD

(a) Using a pin punch (5 mm (0.197 in.)) and hammer, tap out the slotted spring pin.





44. REMOVE NO. 3 GEAR SHIFT FORK SHAFT

(a) Remove the No. 3 gear shift fork shaft, ball, spring and No. 3 gear shift head.





45. REMOVE NO. 1 GEAR SHIFT FORK

(a) Using a pin punch (5 mm (0.197 in.)) and hammer, tap out the slotted spring pin.





(b) Remove the No. 2 gear shift head and No. 1 gear shift fork.





46. REMOVE NO. 4 GEAR SHIFT FORK

(a) Using a pin punch (5 mm (0.197 in.)) and hammer, tap out the slotted spring pin.





(b) Remove the No. 4 gear shift fork.

47. REMOVE NO. 4 GEAR SHIFT FORK SHAFT

(a) Remove the No. 4 gear shift fork shaft, ball and spring.





48. REMOVE NO. 1 RELEASE ARM

(a) Using a screwdriver, remove the E-ring.





(b) Remove the No. 1 release arm pivot and No. 1 release arm.