Part 1

Disassembly Steps 1-10:

Disassembly Steps 11-24:

Disassembly Steps 25-38:

Required Special Tools:

1. Drive a screwdriver into the center of the sealing cap.
2. Use the screwdriver back to pry off the sealing cap.

<> TRANSAXLE CASE REMOVAL

1. Remove all sixteen bolts securing the transaxle case to the clutch housing.
2. Use snap ring pliers to expand the indicated snap ring. The snap ring will release the grooved ball bearing, and the output shaft assembly will fall under its own weight.

CAUTION: Do not use a scraper or chisel to remove the transaxle case.

3. Remove the transaxle case from the clutch housing by gently prying on opposite sides at the same time.

<> 3RD-4TH SPEED SHIFT RAIL/3RD-4TH SPEED SHIFT FORK/5TH SPEED-REVERSE SHIFT RAIL/5TH SPEED-REVERSE SHIFT FORK REMOVAL

1. Shift the 3rd-4th speed shift fork and 5th speed-reverse shift fork in the direction shown.

2. Pull up on the 3rd-4th speed shift rail and 5th speed-reverse shift rail and take them out of the hole in the clutch housing.
3. Slide the 3rd-4th speed shift rail and 5th speed-reverse shift rail in the direction shown and remove them together with the shift forks.

<> INPUT SHAFT AND OUTPUT SHAFT REMOVAL

Remove the input and output shafts together.

ADJUSTMENT BEFORE ASSEMBLY
SPACER SELECTION FOR DIFFERENTIAL CASE PRELOAD ADJUSTMENT

1. Put solders [1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long] in the illustrated positions of the transaxle case.
2. Install the taper bearing outer race and

differential assembly into the transaxle case.

NOTE: If necessary, replace the differential case and taper bearing before carrying out these adjustments.

3. Install the clutch housing and tighten the bolts to the specified torque.
Tightening torque: 44 ± 5 Nm (32 ± 4 ft. lbs.)

4. Remove the clutch housing, and then remove the differential assembly.
5. Remove the taper bearing outer race and take out crushed solders.
6. If the solders have not crushed, use thicker solders [1.6 mm (0.063 inch) diameter, about 10 mm (0.39 inch) long] and repeat steps 2 to 5.
7. Measure the thickness of the crushed solder with a micrometer and select a spacer that will provide the standard preload value.
Standard value: 0.05 - 0.11 mm (0.0020 - 0.0043 inch) preload

1. Put plastigage [about 10 mm (0.39 inch) long] in the illustrated positions of the transaxle case.
2. Install the thinnest spacer.
3. Install the taper bearing outer race and differential assembly into the transaxle case.

NOTE: If necessary, replace the differential case and taper bearing before carrying out these adjustments.

4. Install the clutch housing and tighten the bolts to the specified torque.
Tightening torque: 44 ± 5 Nm (32 ± 4 ft. lbs.)
5. Remove the clutch housing, and then remove the differential assembly.
6. Remove taper bearing outer race and the spacer.
7. If the Plastigages have not crushed, replace the spacer with a thicker one and repeat steps 2 to 7.

8. Measure the width of the crushed Plastigage at its widest part using a scale printed on the Plastigage package.
Standard value: 0.05 - 0.11 mm (0.0020 - 0.0043 inch) preload