Clutch Housing

Clutch Housing

Assembly





1. Remove transaxle case from clutch housing.
2. Remove check plugs, check springs, check pins, and check balls from housing.





3. Remove 3rd & 4th bracket retaining pin using Tool.





4. Remove 3rd & 4th shift fork stopper ring.
5. Remove 3rd & 4th fork rod.
6. Remove 3rd & 4th shift fork and bracket.





7. Remove interlock plunger and check ball.
8. Remove 5th & reverse bracket stopper ring.





9. Remove retaining pin from 5th & reverse shift fork and reverse switch bracket using Tool.
10. Remove 5th & reverse fork rod.
11. Remove interlock pin from 5th & reverse fork rod using Tool.
12. Remove reverse switch bracket and 5th & reverse bracket.





13. Remove check ball from housing.
14. Remove retaining pin for 1st & 2nd shift fork and bracket using Tool.
15. Remove 1st & 2nd fork rod.
16. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd bracket.





17. Remove both input shaft and mainshaft assemblies from housing.





18. Remove final drive assembly from housing.
19. Remove oil pocket from housing.





20. Remove mainshaft bearing retainer from housing.
21. Cut off oil channel using a cutter as shown in the figure.





22. Remove mainshaft front bearing from housing using Tool.





23. Using a magnet or other suitable tool, remove selector pin from selector shaft.





24. Remove selector shaft and plug, then remove selector using Tool.





25. Remove reamer bolts, then remove select check leaf spring, return spring, steel ball, reverse gate, selector arm, bearing, and bushing.

CAUTION: Be careful not to lose the steel ball.





26. Remove retaining pin and plug from striking lever using Tool.
27. Remove striking rod, then striking lever from housing.





28. Using a flat-head screwdriver or other suitable tool, remove dust seal, input shaft oil seal, and striking rod oil seal from housing.

CAUTION: When removing dust and oil seals, be careful not to damage mounting surfaces of dust seal and oil seal.





29. Remove differential oil seal from housing using Tool.





30. Remove differential side outer race from housing using Tool.

Reassembly





1. Hammer the striking rod oil seal into clutch housing as far as it will go using Tool.

CAUTION: Do not reuse striking rod oil seal.





2. Hammer the differential oil seal into clutch housing with a suitable tool until it becomes flush with clutch housing end face.

CAUTION: Do not reuse differential oil seal.





3. Hammer input shaft oil seal into clutch housing as far as it will go with a suitable tool.

CAUTION: Do not reuse input shaft oil seal.





4. Hammer the dust seal into clutch housing as far as it will go using Tool.

CAUTION: Do not reuse dust seal.





5. Install outer race of differential side bearing using Tool.





6. Install new oil channel (mainshaft).

CAUTION: Pay attention to installation direction of oil channel.





7. Align the notches on mainshaft front bearing and transaxle case. Then, install mainshaft front bearing with a suitable tool.





8. Install mainshaft bearing retainer, and tighten bolts with specified torque.





9. Attach boot, striking rod, and striking lever to clutch housing. And install retaining pin for selector lever using Tool.

CAUTION:
- Before installing striking rod, wrap the end with a vinyl tape or similar product to prevent oil seal from being damaged.
- Do not reuse retaining pin.






10. Hammer the Welch plug (striking lever side) with a general-purpose drift [OD: 12 mm (0.47 inch)] with a suitable tool.

CAUTION: Do not reuse Welch plug.





11. Install selector, selector shaft, and selector shaft pin into clutch housing.





12. Hammer the Welch plug (selector shaft side) with a general-purpose drift [OD: 12 mm (0.47 inch)] with a suitable tool.

CAUTION: Do not reuse Welch plug.








13. Install select check leaf spring, return spring, steel ball, reverse gate, selector arm, bushing, and return bearing. Then, tighten two reamer bolts with specified torque.

CAUTION: Use correct reamer bolts for each installation point, because each bolt has a different length.





14. Install oil pocket.





15. Install differential assembly, input shaft assembly, and mainshaft assembly into clutch housing.

CAUTION: Be careful not to damage input shaft oil seal during installation of input shaft assembly.





16. Install 5th & reverse shift fork.
17. Install 1st & 2nd shift fork, bracket, and fork rod using Tool.
18. Install retaining pin for 1st & 2nd bracket.

CAUTION: Do not reuse retaining pin.

19. Install two check balls.





20. Install interlock pin into 5th & reverse fork rod using Tool.
21. Install reverse switch bracket, 5th & reverse bracket, and fork rod using Tool.
22. Install retaining pin for 5th & reverse shift fork and reverse switch bracket using Tool.

CAUTION: Do not reuse retaining pin.

23. Install 5th & reverse bracket stopper ring.

CAUTION: Do not reuse stopper pin.





24. Install check ball and interlock plunger.
25. Install 3rd & 4th shift fork, bracket, and fork rod using Tool.
26. Install 3rd & 4th bracket retaining pin.

CAUTION: Do not reuse retaining pin.





27. Install 3rd & 4th shift fork stopper ring.

CAUTION: Do not reuse stopper ring.

28. Install check ball, check pin, and check spring, and apply Three Bond TB1215, Loctite Part No. 51813 or equivalent onto check plug. Then, tighten it with specified torque.