Disassembly

DISASSEMBLY
1. Remove drain plug and gasket from clutch housing using the socket, and drain oil.
2. Remove filler plug and gasket from transaxle case.
3. Remove CSC from clutch housing.





4. Remove retaining pin from shift lever (1) using a suitable tool.
5. Remove shift lever (1).
6. Remove bracket (2) and position switch (3) from transaxle case.





7. Remove bolts.





8. Remove reverse idler shaft bolt (<-) and seal washer.





9. Remove transaxle case (1) upward while rotating select lever (2).





10. Remove spring (1) of selector from return bushing (2).





11. Move 1st-2nd fork rod (1), 3rd-4th and 5th-6th fork rod (2), and reverse fork rod (3) to neutral position.
12. Remove selector (4) from clutch housing.





13. Remove retaining pin from 5th-6th shift fork using a suitable tool.





14. Remove 3rd-4th and 5th-6th fork rod assembly according to the following.
a. Lift the fork rod (1) up.
b. Remove 3rd-4th and 5th-6th fork rod assembly from clutch housing.





15. Remove reverse gear assembly (1) according to the following.
a. Lift the input shaft assembly (2) and mainshaft assembly (3) up.
b. Remove reverse gear assembly (1) and reverse fork rod (4) from clutch housing.
16. Remove spring washer located under the reverse idler shaft.





17. Remove input shaft assembly (1), mainshaft assembly (2), and 1st-2nd fork rod (3) from clutch housing.





18. Remove final drive assembly (1) from clutch housing.
19. Remove magnet from clutch housing.





20. Remove differential side oil seals (1) from clutch housing and transaxle case using a suitable tool.

CAUTION: Be careful not to damage clutch housing and transaxle case.





21. Remove differential side bearing outer race (1) from clutch housing using a suitable tool.

CAUTION: Be careful not to damage clutch housing.





22. Remove differential side bearing outer race (1) and shim (2) from transaxle case using a brass bar as shown.

CAUTION: Be careful not to damage transaxle case.





23. Remove retaining pin from select lever (1) using a suitable tool.
24. Remove select lever.





25. Remove shift finger (1) from transaxle case.





26. Remove select lever oil seal and bushings from transaxle case using a suitable tool.





27. Remove oil gutter (1) from transaxle case.





28. Remove shift lever oil seal (1) from transaxle case.





29. Remove bushings (1) from transaxle case using a suitable tool.





30. Remove mainshaft rear bearing outer race and bearing preloading shim from transaxle case using a suitable tool.

CAUTION: Be careful not to damage transaxle case.





31. Remove snap ring (1) and oil channel (2) from transaxle case.





32. Remove input shaft oil seal (1) from clutch housing using a suitable tool.





33. Remove mainshaft front bearing outer race (1) and oil channel (2) from clutch housing using Tool (A) and suitable tool (B).
Tool number A: KV381054S0 (J-34286)





34. Remove bushings (1) from clutch housing using a suitable tool.





35. Remove two way connector (1) from clutch housing.





36. Remove pinion gear (1) and pinion shaft (2) from clutch housing.