Removal of Component Parts

REMOVAL OF COMPONENT PARTS




1. REMOVE TRANSFER ASSEMBLY
a. Remove the three bolts and five nuts.
b. Using a plastic hammer, remove the transfer assembly from the transaxle.




2. REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT
a. Screw in a suitable bolt with washer into the side gear intermediate shaft.
b. Using SST, remove the side gear intermediate shaft.
SST 09910-00015 (09911-00011, 09912-00010)




3. REMOVE RELEASE FORK, BEARING AND BOOT




4. REMOVE BACK-UP LIGHT SWITCH
a. Remove the back-up light switch.
b. Remove the gasket from the back-up light switch.
5. REMOVE SPEEDOMETER DRIVEN GEAR




6. REMOVE NO.2 SELECTING BELLCRANK WITH SELECTING BELLCRANK SUPPORT




7. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK BOLT
a. Remove the shift and select lever shaft lock bolt.
b. Remove the gasket from the bolt.




8. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Remove the four bolts and the shift and select lever shaft assembly.
b. Remove the gasket from the shift and select lever shaft assembly.




9. REMOVE TRANSMISSION CASE COVER
a. Remove the ten bolts.
b. Using a plastic hammer, remove the case cover.

10. REMOVE OUTPUT SHAFT LOCK NUT



a. Engage the gear double meshing.




b. Using a chisel and hammer, unstake the lock nut.




c. Remove the lock nut.
d. Disengage the gear double meshing.




11. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
a. Remove the No.3 shift fork set bolt.
b. Remove the No.3 hub sleeve and No.3 shift fork.




12. REMOVE FIFTH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09310-17010 (09310-07010, 09310-07020 09310-07040, 09310-07050)




13. MEASURE FIFTH GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 in.)
Maximum clearance: 0.65 mm (0.0256 in.)




b. 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.)




14. REMOVE NO.3 CLUTCH HUB AND FIFTH GEAR
a. Using two screwdrivers and a hammer, tap out the snap ring.




b. Using SST, remove the No. 3 clutch hub with synchronizer ring and 5th gear.
SST 09310-17010 (09310-07010, 09310-07020, 09310-07030)




15. REMOVE NEEDLE ROLLER BEARING AND SPACER




16. REMOVE REAR BEARING RETAINER
a. Using a torx wrench, remove the seven torx screws and bearing retainer.
(Torx socket wrench T45 09042-00050)




b. Remove the adjusting shim.




17. REMOVE SNAP RING
a. Using snap ring pliers, remove the snap ring of the input shaft rear bearing.




b. Using two screwdrivers and a hammer, remove the two snap rings of the shift fork shafts.




18. REMOVE PLUG, SEAT, SPRING AND LOCKING BALL
a. Using SST, remove the plug.
SST 09313-30021




b. Using a magnetic finger, remove the seat, spring and ball.




19. REMOVE REVERSE IDLER GEAR SHAFT RETAINING BOLT
a. Remove the reverse idler gear shaft retaining bolt.
b. Remove the gasket from the bolt.




20. REMOVE TRANSMISSION CASE
Remove the seventeen bolts and tap off the case with a plastic hammer.
- Transmission case side: Fourteen bolts
- Transaxle case side: Three bolts




21. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE
Using a plastic hammer, remove the output shaft rear bearing outer race.




22. REMOVE NO.2 OIL PIPE
a. Remove the gasket.




b. Remove the two bolts and oil pipe.




23. REMOVE REVERSE SHIFT ARM BRACKET
Remove the bolt and pull off the bracket.




24. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust washer.

25. REMOVE PLUGS, SEATS, SPRINGS AND BALLS



a. Using SST, remove the two plugs.
SST 09313-30021




b. Using a magnetic finger, remove the two seats, springs and balls.




26. REMOVE SET BOLTS
Remove the three set bolts.




27. REMOVE NO.1 SHIFT FORK SHAFT
Pull up No.3 shift fork shaft, remove the No.1 shift fork shaft.




28. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the reverse shift fork.




29. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD AND NO.1 SHIFT FORK
a. Pull out the No.2 shift fork shaft.




b. Remove the shift head and No.1 shift fork.




30. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO.2 SHIFT FORK
a. Pull out the No.3 shift fork shaft with reverse shift fork.
b. Remove the No.2 shift fork.




31. REMOVE SNAP RING
Using two screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No.3 shift fork shaft.

32. REMOVE INPUT AND OUTPUT SHAFT ASSEMBLY



a. Leaning the output shaft to the differential side, remove the input shaft assembly.




b. Lift up the differential case assembly, remove the output shaft assembly.

33. REMOVE DIFFERENTIAL CASE ASSEMBLY



a. Remove the oil pump drive gear.




b. Remove the differential case assembly.




34. REMOVE MAGNET FROM TRANSAXLE CASE

35. REMOVE OIL PUMP ASSEMBLY



a. Remove the two bolts and oil pipe.




b. Remove the two bolts and oil pump.