With S53 Transaxle/2WD

1. REMOVE RELEASE FORK, BEARING, BACK-UP LIGHT SWITCH AND SPEEDOMETER DRIVEN GEAR




2. REMOVE RELEASE BEARING RETAINER




3. REMOVE SELECTING BELLCRANK AND ENGINE MOUNT BRACKET
a. Remove the two bolts and selecting bellcrank.
b. Remove the three bolts and engine mount bracket.




4. REMOVE TRANSMISSION CASE COVER
a. Remove the eight bolts.
b. Using a plastic hammer, tap off the transmission case cover.




5. INSPECT FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)
Maximum clearance: 0.45 mm (0.0177 in.)




6. INSPECT FIFTH GEAR OIL CLEARANCE
Using a dial indicator, measure the oil clearance.

Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)

If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.




7. REMOVE NO.1 AND NO.2 LOCK BALL ASSEMBLIES
a. Loosen the lock nut and remove the No.1 lock ball.




b. Using SST, remove the No.2 lock ball. SST 09313-30021




8. REMOVE SHIFT AND SELECT LEVER ASSEMBLY




9. REMOVE OUTPUT SHAFT LOCK NUT
a. Unstake the nut.
b. Engage the gear double meshing.




c. Turn the lock nut clockwise and remove it.

HINT: The lock nut has LH threads.

d. Disengage the gear double meshing.




10. REMOVE NO.3 HUB SLEEVE ASSEMBLY AND NO.3 SHIFT FORK
a. Using two screwdrivers and a hammer, tap out the snap ring.
b. Remove the shifting key retainer.
c. Remove the bolt from the No.3 shift fork.




d. Using the three case cover set bolts, tighten the three bolts a little at a time and remove the No.3 hub sleeve assembly and shift fork.
11. REMOVE FIFTH GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS AND SPACER




12. REMOVE FIFTH DRIVEN GEAR
Using SST, remove the 5th driven gear. SST 09950-20017




13. REMOVE REAR BEARING RETAINER




14. REMOVE SNAP RING FROM NO.1 SHIFT FORK SHAFT
Using two screwdrivers and a hammer, tap out the snap ring.




15. REMOVE BEARING SNAP RINGS
Using a snap ring expander, remove the two snap rings.

HINT: if it is difficult to remove the snap rings, pull up the shafts.




16. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT




17. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM




18. REMOVE TRANSMISSION CASE
a. Remove the seventeen bolts.
b. Using a plastic hammer, tap off the transmission case.




19. REMOVE REVERSE IDLER GEAR AND SHAFT
a. Pull out the shaft.
b. Remove the idler gear and thrust washer.




20. REMOVE REVERSE SHIFT ARM
a. Shift the fork shaft into the reverse.
b. Remove the two bolts and pull off the reverse shift arm.




21. REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS, REVERSE SHIFT FORK WITH INTERLOCK PIN. INPUT AND OUTPUT SHAFT ASSEMBLY
Remove the input shaft assembly and output shaft assembly together with the No.1 fork shaft, shift head and shift forks with the interlock pin from the transaxle case.




22. REMOVE DIFFERENTIAL ASSEMBLY




23. REMOVE MAGNET FROM TRANSAXLE CASE




24. REMOVE NO.2 FORK SHAFT
a. Using SST, remove the straight screw plug.
SST 09312-30021




b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Pull out the shaft.




25. SEPARATE NO.1 FORK SHAFT. NO.1 SHIFT HEAD,
NO.1, NO.2 SHIFT FORKS AND REVERSE SHIFT FORK
a. Mount the shift forks to the vise.
b. Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft.




c. Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft as shown in the figure.




d. Separate the No.1 shift fork shaft, No.1 shift head, No.1, No.2 shift forks and reverse shift fork.




26. REMOVE NO.3 HUB SLEEVE, SHIFTING KEYS AND SPRINGS FROM NO.3 CLUTCH HUB
Using a screwdriver, remove the three shifting keys and springs from the No.3 clutch hub.