Part 2

Transmission Disassemble




56. Remove the No. 1 gear shift fork (1).




57. Remove the No. 3 gear shift fork shaft (1) from the manual transaxle case.




58. Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft.
59. Remove the reverse shift fork from the No. 3 gear shift fork shaft.




60. Remove the No. 2 gear shift fork (1) from the input shaft assembly.




61. Tilt the output shaft, and then remove the input shaft from the manual transaxle case.




62. Lift the differential case assembly with the output shaft assembly leaned.
63. Remove the output shaft assembly from the manual transaxle case.




64. Remove the differential case assembly from the manual transaxle case.




65. Remove the bolts (1) and manual transaxle case receiver from the manual transaxle case.




66. Using a suitable puller (1), remove the input shaft front bearing (outer race) from the manual transaxle case.




67. Using a suitable puller (1), remove the front transaxle case cover oil seal from the manual transaxle case.




68. Using a suitable puller (1), remove the output shaft front bearing (outer race) from the manual transaxle case.




69. Remove the output shaft cover from the manual transaxle case.




70. Using a suitable driver (1) and a hammer, remove the output shaft rear bearing from the manual transmission case (outer race).




71. Using a suitable puller (1), remove the transmission case oil seal from the manual transmission case.




72. Using a screwdriver, remove the transaxle case oil seal.




73. Using a brass bar and a hammer, remove the front differential case front tapered roller bearing (outer race) from the manual transaxle case.




74. Using a suitable puller (1), remove the front differential case front tapered roller bearing from the front differential case.




75. Using a suitable driver (1) and a hammer, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear shim from the manual transmission case.




76. Using a suitable puller (1), remove the front differential case rear tapered roller bearing (inner race) from the front differential case.




77. Remove the No. 3 transmission hub sleeve (1) from the No. 3 transmission clutch hub.




78. Remove the No. 3 synchromesh shifting key springs (1) from the No. 3 transmission clutch hub while pushing on the No. 3 synchromesh shifting key spring.




79. Using a screwdriver, remove the synchronizer pull ring snap ring.
80. Remove the synchronizer pull ring, No. 5 synchronizer ring outer, No. 5 synchronizer ring inner, and No. 5 synchronizer ring middle from the No. 5 synchronizer ring inner.




81. Using a dial indicator, inspect the 5th gear thrust clearance.

Standard clearance - 0.10-0.65 mm (0.0039-0.0256 in)
If clearance is not as specified, replace the No. 3 transmission clutch hub, 5th gear, or input shaft rear radial ball bearing.




82. Using a dial indicator, inspect the 5th gear radial clearance.

Standard clearance - 0.009-0.050 mm (0.0004-0.0020 in)
If clearance is not as specified, replace the 5th gear, 5th gear needle roller bearing, or input shaft.
83. Using a caliper gage, measure the inside diameter of the reverse idler gear.

* Standard inside diameter - 20.056-20.074 mm (0.7896-0.7903 in)
* Maximum inside diameter - 20.074 mm (0.7903 in)

84. If the inside diameter exceeds the maximum, replace the reverse idler gear.




85. Using a micrometer, measure the outside diameter of the reverse idler gear shaft.

* Standard outside diameter - 19.984-20.000 mm (0.7868-0.7874 in)
* Minimum outside diameter - 19.984 mm (0.7868 in)

86. If the outside diameter is less than the minimum, replace the reverse idler gear shaft.




87. Inspect the sliding condition between the No. 3 transmission clutch hub and the No. 3 transmission hub sleeve.
88. Inspect the tip of the spline gear on the No. 3 transmission hub sleeve for wear.




89. Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove and the thickness of the claw on the No. 3 gear shift fork, and calculate the clearance.

Standard clearance - 0.15-0.35 mm (0.0059-0.0138 in) (A-B)
If clearance is not as specified, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork with new ones.




90. Using a caliper gage, measure the inside diameter of the 5th gear.

* Standard inside diameter - 34.981-34.997 mm (1.3772-1.3778 in)
* Maximum inside diameter - 34.997 mm (1.3778 in)

91. If the inside diameter exceeds the maximum, replace the 5th gear.




92. Check that the No. 5 synchronizer ring rotates smoothly.




93. Check that the No. 5 synchronizer ring does not rotate while pushing it against the No. 3 clutch hub.




94. Hold the input shaft assembly in a vise using aluminum plates.
95. Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.




96. Using a press (1), remove the input shaft rear bearing and 4th gear.




97. Remove the 4th gear needle roller bearing from the input shaft.




98. Remove the No. 4 synchronizer ring from the No. 2 transmission clutch hub.




99. Remove the 4th gear bearing spacer from the No. 2 transmission clutch hub.




100. Using 2 screwdrivers and a hammer, remove the No. 2 clutch hub setting shaft snap ring from the input shaft.




101. Using a press (1), remove the No. 2 transmission clutch hub and 3rd gear from the input shaft.




102. Remove the 3rd gear needle roller bearing from the input shaft.




103. Remove the No. 3 synchronizer ring from the 3rd gear.




104. Remove the No. 2 transmission hub sleeve, No. 2 synchromesh shifting keys, and No. 2 synchromesh shifting key springs from the No. 2 transmission clutch hub.




105. Using a press (1), remove the input shaft front bearing (inner race) from the input shaft.




106. Using a feeler gage, measure the 4th gear thrust clearance.

Standard clearance - 0.10-0.57 mm (0.0039-0.0224 in)
If the clearance is out of specification, replace the No. 2 transmission clutch hub, 4th gear, or input shaft rear radial ball bearing.




107. Using a dial indicator, measure the 3rd gear thrust clearance.

Standard clearance - 0.10-0.35 mm (0.0039-0.0138 in)
If the clearance is out of specification, replace the No. 2 transmission clutch hub, 3rd gear, or input shaft.




108. Using a dial indicator, measure the 4th gear radial clearance.

* Standard clearance, KOYO made bearing - 0.009-0.053 mm (0.0004-0.0021 in)
* Standard clearance, NSK made bearing - 0.009-0.051 mm (0.0004-0.0020 in)

109. If clearance is out of specification, replace the 4th gear, needle roller bearing, or input shaft.




110. Using a dial indicator, measure the 3rd gear radial clearance.

* Standard clearance, KOYO made bearing - 0.009-0.053 mm (0.0004-0.0021 in)
* Standard clearance, NSK made bearing - 0.009-0.051 mm (0.0004-0.0020 in)