Unit

DISASSEMBLY





1. Remove the rear cover, lock nut and retainer ring.
2. Remove the detent plug, spring and steel ball.





3. Remove the back-up lamp switch.
4. Remove the bolts holding the rear case to the main case.
5. Remove the reverse idler shaft and gear.





6. Remove the reverse lever spring set.





7. Remove the change rod and the control case.





8. Carefully remove the roll pins from the rod/fork assembly with a pin punch.





9. Refer to the order of removal in the figure. Discard the used pins.





10. Remove the 5/R shift rod, 5/R shift fork and 5/R shift rod end.





11. Remove the 3/4 shift rod, 3/4 shift fork, 3/4 shift rod end.





12. Remove the 1/2 shift rod, 1/2 shift fork and 1/2 shift rod end.





13. Remove gears and clutch hub assemblies of the input and output shaft in order and then remove the primary shaft (Remove the gears and hubs from both the input shaft and output shaft).





14. Remove the rings, bearings, and clutch hub assemblies of the input shaft. Loosen the four bearing cover screws and then remove the output shaft.





15. Remove the differential assembly.
16. Remove the speedometer driven gear after loosening the bolt.





17. Remove the input shaft oil seal with a screwdriver or suitable tool.
18. Remove the seating cap.
19. Remove the change rod oil seal with a screwdriver or suitable tool.





20. Remove the differential oil seal with a screwdriver or suitable tool.





21. Remove the output shaft bearing outer race of the transaxle case with a screwdriver or suitable tool.

REASSEMBLY





1. Install the drive shaft oil seal.





2. Apply transaxle oil to the bearing, and install in the differential case using the special tool.





3. Apply transaxle oil to each bearing race, and install them to the transaxle case using the special tool.
4. Install the oil seal
5. Install the speedometer driven gear.





6. Apply transaxle oil to the input shaft oil seal, and install it to transaxle case using the special tool.





7. Set the differential into the clutch housing.





8. Install the input and output shafts in the clutch housing.
9. Install the gears and clutch hub assemblies into the input and output shaft in order.





10. Install the 1/2 shift rod, 1/2 shift fork and 1/2 shift rod end.





11. Install the 3/4 shift rod, 3/4 shift fork and 3/4 shift rod end.





12. Install the 5/R shift rod, 5/R shift fork and 5/R shift rod end.





13. Install the roll pins to the rod/fork assembly with a pin punch in the order shown in the figure.
14. Install the control case assembly and the change rod and then tighten the two control case assembly bolts.
15. Install the reverse shift lever and tighten the two reverse shift lever bolts.
16. Install the reverse lever spring set.





17. Install the reverse idler shaft and gear.
18. Attach the magnet to the clutch housing.
19. Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case.





20. Tighten the transaxle installation bolts.
21. Install the backup lamp switch.





22. Install the detent plug, spring and steel ball.
23. Install the output shaft lock nut.





24. Install the rear cover.