Countershaft Disassembly and Reassembly
Countershaft Disassembly and Reassembly
Manual Transaxle Assembly Disassembly and Reassembly
Input Shaft Components
Disassembly
NOTE:
Supporting the gear on the concave side of the puller can cause damage to the gear.
Be sure to support the gear on the flat side of the puller.
1) Remove circlip (1) using special tool and then remove washer.
Special Tool
(A): 09900-06107
2) Remove left bearing (2) and 6th gear (3) using puller (4) and hydraulic press, and then remove 5th gear spacer.
CAUTION:
Using an inappropriate hydraulic press or bearing puller could cause personal injury.
Make sure that both the hydraulic press and bearing puller are capable of safely bearing a load of at least 5 tons (11,000 lbs).
3) Apply puller (3) to 4th gear (2) and remove 5th gear (1) with 4th gear using hydraulic press.
4) Remove circlip (1) using special tool.
Special Tool
(A): 09900-06107
5) Apply puller (3) to 2nd gear (2) and remove 3rd gear (1) with 2nd gear using hydraulic press.
6) Apply puller (4) to reverse gear (3) and remove low speed synchronizer sleeve & hub assembly (1), 1st gear (2) with reverse gear using hydraulic press.
7) Grind portion "a" of right bearing (1) using grinder (2) as shown.
NOTE:
The shaft (3) will be damaged if the bearing is ground too much.
Limit the amount of grinding to the minimum amount necessary.
8) Break the thinnest portion of bearing inner race (2) with a chisel (1) and remove bearing.
Reassembly
Countershaft Inspection
Gear Shift Shaft and Fork Inspection
1) Fit low speed synchronizer sleeve (1) to hub (2) and 3 keys (3) as shown in figure.
NOTE:
No specific direction is assigned to low speed synchronizer hub and each key but it is assigned as assembly.
Synchronizer key installation position
2) Install reverse gear (1) to countershaft (2) using puller (3) and hydraulic press.
3) Install 1st gear spacer (1) using special tool and hydraulic press.
Special Tool
(A): 09940-54910
4) Install 1st gear needle bearing and apply transaxle oil to it, and then install 1st gear synchronizer inner ring (2), 1st gear synchronizer center cone (3), 1st gear synchronizer outer ring (4) and 1st gear (1) to countershaft.
NOTE:
Make sure claws on 1st gear synchronizer center cone fit into the holes on 1st gear.
5) Install low speed sleeve & hub assembly (1) using special tool and hydraulic press.
NOTE:
- Support lower speed synchronizer hub with special tool as shown in figure.
- Make sure that synchronizer ring key slots are aligned with keys (5) while press-fitting sleeve & hub assembly.
- Check free rotation of 1st gear (3) after press-fitting sleeve & hub assembly.
Special Tool
(A): 09944-77030
6) Install 2nd gear spacer (1) using special tool and hydraulic press.
Special Tool
(A): 09945-55410
7) Install 3rd gear (5), 2nd gear (1), 2nd gear synchronizer inner ring (2), 2nd gear synchronizer center cone (3) and 2nd gear synchronizer outer ring (4) to countershaft using special tool and hydraulic press.
NOTE:
Make sure claws on 2nd gear synchronizer center cone fit into the holes on 2nd gear.
Special Tool
(A): 09944-77030
8) Select new circlip (1) that makes thrust clearance "a" of bearing 0.15 mm (0.0059 in) or less and install it.
Available circlip thickness
9) Install 4th gear (1) using puller and hydraulic press.
10) Install 5th gear by the same procedure at step 7).
11) Install 6th gear (1) and 5th gear spacer (2) using special tool and hydraulic press.
Special Tool
(A): 09945-55410
12) Install countershaft left bearing (1) and washer using special tool and hydraulic press.
Special Tool
(A): 09913-84510
13) Install countershaft right bearing (1) using special tool and hydraulic press.
Special Tool
(A): 09913-84510
14) Select new circlip (1) that makes thrust clearance "a" of bearing 0.1 mm (0.0039 in) or less and install it.
Available circlip thickness
