Disassembly
DisassemblyCaution:
a) Clean transaxle exterior thoroughly with steam cleaner or cleaning solvent before disassembly.
b) Clean removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
c) Clean out all holes and passages with compressed air and verify that there are no obstructions.
Warning: Using compressed air can cause dirt and other particles to fly out, causing injury to eyes. Wear protective eye wear whenever using compressed air.
5th/Reverse gear and housing parts
1. Measure 5th gear thrust clearance.
2. Disassemble in order shown in figure.
3. Assembly will be performed in reverse order of disassembly.
Preinspection
5th gear thrust clearance
1. Measure 5th gear thrust clearance by using dial indicator.
Clearance: 0.004 - 0.009 inch (0.10 - 0.22 mm)
Maximum: 0.011 inch (0.27 mm)
2. If clearance exceeds maximum, check contact surfaces of 5th gear and clutch hub. Replace worn or damaged parts.
Disassembly note
Locknut
1. Mount transaxle on SST(OK130 990 007).
2. Lock primary shaft using SST(OK201 323 021 / K94A-4205-MT).
3. Shift to 1st gear to lock rotation of secondary shaft.
4. Uncrimp tabs of locknuts.
5. Remove locknuts from primary and secondary shafts.
Shift fork and shift rod assembly
1. Align ends of interlock sleeve and control lever (arrow). Turn shift rod counterclockwise.
2. While holding 1strand shift fork with one hand and 3rd/4th shift fork with other, raise them both at same time and shift both clutch hub sleeves.
3. Lift shift rod end and remove detent ball and, at same time, remove shift rod from clutch housing.
4. Separate shift rod and shift fork assemblies from both clutch hub sleeves.
CLUTCH housing and transaxle case components
Caution: Do not remove an oil seal if not necessary.
1. Disassemble in order on figure.
2. Assembly will be in reverse order of disassembly.
Disassembly note
Bearing outer race (primary shaft side)
1. Remove bearing outer race by using SST(OK130 170 012).
Reverse lever shaft
1. Remove roll pin using pliers.
2. Protect reverse lever shaft with rag and remove shaft with pliers.
Oil seal (Change rod)
1. Remove oil seal with screwdriver.
Funnel and bearing outer race (Secondary shaft)
1. Remove bearing outer race by lifting out funnel and race together.
Notice: Remove bearing outer race with screwdriver if necessary.
- Insert screwdriver between clutch housing and bearing outer race.
- Pry bearing outer race free.
Oil seal (Primary shaft)
Caution: Do not damage clutch housing.
1. Remove oil seal with screwdriver.
Oil seal (Differential)
1. Remove oil seal with screwdriver
Bearing outer race (Differential)
1. Install SST(OK130 170 012) to bearing outer race.
2. Remove bearing outer race.
Bearing outer race and adjust shim (Differential)
1. Install SST(OK130 170 012) to bearing outer race.
2. Remove bearing outer race and adjust shim.
Oil seal (Speedometer gear case)
1. Remove oil seal.
Assembly note
Transaxle case oil seal (Differential side)
1. Assemble oil seal using SST (OK201 170 AA1 I K94A-4204-T).
Primary shaft assembly
1. Measure thrust clearance of all gears before disassembly.
2. Disassemble in order shown in figure.
Caution: Check thrust clearance of all gears before disassembly and after assembly.
Preinspection
3rd gear thrust clearance
1. Measure clearance between 3rd gear and 2nd gear.
Clearance: 0.002 - 0.008 inch (0.05 - 0.20 mm)
Maximum: 0.010 inch (0.25 mm)
2. If clearance exceeds maximum, check contact surfaces of 3rd gear, 2nd gear and clutch hub (3rd/4th). Replace worn and damaged parts.
4th gear thrust clearance
1. Measure clearance between 4th gear and ball bearing.
Clearance: 0.007 - 0.015 inch (0.17 - 0.37 mm)
Maximum: 0.017 inch (0.42 mm)
2. If clearance exceeds maximum, check contact surfaces of 4th gear, ball bearing, and clutch hub (3rdl4th). Replace worn and damaged parts.
Disassembly note
Bearing (4th gear end)
Remove bearing by using SST(OK130 171 013).
3rd/4th clutch hub assembly, 3rd synchronizer ring and 3rd gear
1. Remove retaining ring.
2. Remove 3rd/4th clutch hub assembly, 3rd synchronizer ring, and 3rd gear by using SST(OK130 175 008).
Bearing (first gear end)
Remove bearing by using SST(OK670 990 AAO).
Secondary shaft assembly
1. Measure thrust clearance of 1st gear and 2nd gear before disassembly.
2. Disassemble in order shown in figure.
Preinspection
Secondary 1st gear thrust clearance
1. Measure clearance between secondary 1st gear and differential drive gear.
Clearance: 0.002 - 0.011 inch (0.05 - 0.28 mm)
Maximum: 0.013 inch (0.33 mm)
2. If clearance exceeds maximum, check contact surfaces of secondary 1st gear, differential drive gear of secondary shaft, and 1st/2nd clutch hub assembly. Replace worn and damaged parts.
Secondary 2nd gear thrust clearance
1. Measure clearance between secondary 2nd gear and secondary 3rd gear.
Clearance: 0.007 - 0.018 inch (0.18 - 0.46 mm)
Maximum: 0.020 inch (0.51 mm)
2. If clearance exceeds maximum, check contact surfaces of secondary 2nd gear, secondary 3rd gear, and 1st/2nd clutch hub assembly. Replace worn and damaged parts.
Disassembly note
Bearing and secondary 4th gear
Remove bearing and secondary 4th gear by using SST(OK201 172 008).
Secondary 3rd gear and Secondary 2nd gear
1. Remove retaining ring.
2. Shift gears to 1st gear.
3. Remove secondary 3rd gear and secondary 2nd gear by using SST(OK201 172 008).
1st/2nd clutch hub assembly, 1st synchronizer ring, and secondary 1st gear
1. Remove retaining ring.
2. Remove 1stand clutch hub assembly, 1st gear synchronizer ring, and secondary 1st gear using press.
Bearing (differential drive gear end)
1. Remove bearing by using SSTs.
Inspection
Notice: Inspect all parts and repair or replace as necessary.
Gears
1. Inspect synchronizer cones for wear.
2. Inspect gear teeth for damage, wear and cracks.
3. Inspect synchronizer ring matching teeth for damage and wear.
Synchronizer ring
1. Inspect synchronizer ring teeth for damage, wear and cracks.
2. Inspect tapered surface for wear and cracks.
3. Set synchronizer ring squarely in gear.
4. Measure clearance between synchronizer ring and flank surface of gear.
Standard clearance: 0.059 inch (1.5 mm)
Minimum: 0.031 inch (0.8 mm)
Clutch hub assembly
1. Inspect clutch hub sleeve and hub operation.
2. Inspect gear teeth for damage, wear, and cracks.
3. Inspect synchronizer keys for damage, wear and cracks.
4. Measure clearance between clutch hub sleeves and shift forks.
Clearance
Reverse idle gear and reverse lever
1. inspect gear teeth for damage, wear and cracks.
2. Measure clearance between reverse idle gear bushing and reverse lever.
Standard clearance: 0.004 - 0.013 inch (0.10 - 0.32 mm)
Maximum: 0.020 inch (0.5 mm)
Bearing
1. Inspect for damage and rough rotation.
Primary shaft and secondary shaft
1. Inspect gear contact surface for damage and wear.
2. Inspect splines for damage and wear.
3. Inspect gear teeth for damage, wear and cracks.
4. Inspect oil passage for clogging.
5. Measure primary and secondary shaft runout.
Primary shaft runout: 0.002 inch (0.05 mm) maximum
Secondary shaft runout: 0.0006 inch (0.015 mm) maximum
Notice: If shaft is replaced, adjust bearing preload.
6. Determine clearance between shafts and gears.
Clearance
Vehicle speed sensor (speedometer driven gear)
1. Inspect teeth for damage and wear.
2. Inspect O-ring for damage and wear.