Part I
Disassembly Precaution1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
3. Clean out all holes and passages with compressed air, and verify that there are no obstructions.
Assembly Precaution
1. Replace all O-rings and gaskets with the new ones included in the overhaul kit.
2. Verify that all parts are completely cleaned before assembly.
3. Assemble parts within 10 minutes after applying sealant. Allow all sealants to cure for at least 30 minutes after assembly before filling the transaxle with transaxle oil.
4. Replace bearing races and bearings as sets.
5th/Reverse Gear and Housing Parts
1. Rear cover
2. Locknut (primary shaft)
3. Reverse synchronizer gear sleeve
4. Primary reverse synchronizer cone assembly
5. Reverse synchronizer ring
6. Locknut (secondary shaft)
7. 5th/reverse shift fork
8. 5th/reverse clutch hub assembly
9. 5th synchronizer ring
10. 5th gear
11. Gear sleeve
12. Secondary 5th gear
13. Guide bolt and washer
14. Back-up light switch
15. [1][2]Neutral switch
16. Lock bolt
17. Transaxle case assembly
18. Magnet
19. Reverse idler shaft
20. Reverse idler gear
21. 5th/reverse shift rod
22. 5th/reverse shift rod end
23. Pin
24. Crank lever shaft
25. Crank lever assembly
26. Shift fork and shift rod assembly
27. Steel ball
28. Spring
29. Primary shaft gear assembly
30. Secondary shaft gear assembly
31. Differential assembly
32. Clutch housing
33. Synchronizer key springs
34. Clutch hub
35. Synchronizer keys
36. Clutch hub sleeve
37. 3rd/4th shift fork
38. Interlock sleeve
39. Control lever
40. 1st/2nd shift fork
41. Control rod
42. Control end
1. Disassemble in the order shown in the image, referring to Preinspection and Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.
Preinspection
5th gear thrust clearance
1. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.08 - 0.15 mm (0.0032 - 0.0059 in)
Maximum: 0.20 mm (0.0079 in)
2. If the clearance exceeds the the maximum, check the contact surfaces of the 5th gear and the clutch hub. Replace worn or damaged parts.
Disassembly note
Locknut
1. Mount the transaxle on the SST.
2. Lock the primary shaft by using the SST
3. Shift to 1st or 2nd gear to lock the rotation of the primary shaft.
CAUTION: Do not reuse the removed locknut.
4. Uncrimp the tabs of the locknuts.
5. Remove the locknuts from the primary and secondary shafts.
Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the control lever (arrow). Turn the shift rod counterclockwise.
2. While holding the 1st/2nd shift fork with one hand and the 3rd/4th shift fork with the other, raise them both at the same time and shift each of the clutch hub sleeves.
3. Lift the control end and remove the steel ball, and, at the same time, remove the shift rod from the clutch housing.
4. Separate the shift rod and shift fork assembly from each of the clutch hub sleeves.
Assembly note
Primary shaft gear assembly and secondary shaft gear assembly
Install the primary shaft gear assembly and the secondary shaft gear assembly together.
Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod assembly as shown.
2. Insert the spring seat and spring into the reverse lever shaft; then install the steel ball, and place a scraper so that it contacts the steel ball.
3. With the edge of the control end against the scraper, push the control end in the direction of the arrow in the image so that the ball goes into the shaft. The rod will line up with the shift rod coupling hole in the clutch housing.
4. Set each clutch hub sleeve to the neutral position, and tap the shift rod from above so that the steel ball goes into the center groove of the 3 grooves in the control end.
5. Pull the ball part of the control end forward so that the steel ball goes into the detent in the groove.
Crank lever assembly and crank lever shaft
NOTE: Use a new O-ring for the crank lever shaft.
1. Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank lever.
2. Align the pin holes of the crank lever shaft and the clutch housing, and insert the new pin.
5th/reverse shift rod end and 5th/reverse shift rod
NOTE: The marks (indicated by the arrows) and the shift rod end mounting bolt hole must face the same direction.
Install the shift rod end (1) and the shift rod (2), and tighten the gate mounting bolt.
Reverse idler gear and reverse idler shaft
1. Install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.
3. Align the end of the interlock sleeve with the control lever (indicated by the arrow), and, at the same time, face the reverse idler shaft screw hole in the direction shown in the image.
Transaxle case assembly
Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case; then tighten the transaxle case installation bolts to the specified torque.
Tightening torque: 19 - 25 N-m (1.9 - 2.6 kgf-m, 14 - 18 ft-lbf)
5th/reverse clutch hub assembly and
5th/reverse shift fork
Install the 5th/reverse clutch hub assembly and the 5th/reverse shift fork together.
Locknut
1. Shift to 1st gear.
2. Lock the primary shaft by using the SST.
3. Tighten new locknuts on the primary and secondary shafts.
Tightening torque: 128 - 205 N-m (13 - 21 kgf-m, 95 - 151 ft-lbf)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.06 - 0.26 mm (0.0024 - 0.0102 in)
Maximum: 0.31 mm (0.0122 in)
6. If not as specified, reassemble the transaxle.
Clutch Housing and Transaxle Case Components
1. Vehicle speedometer sensor (speedometer driven gear)
2. Oil seal (differential)
3. Pivot pin
4. Bleeder
5. Bleeder cover
6. Gasket
7. Roll pin
8. Blind plug
9. Reverse lever shaft
10. Lever set spring
11. Reverse lever
12. Guide plate assembly
13. Roll pin
14. Selector
15. Change arm
16. Change rod assembly
17. Boot
18. Oil seal (change rod)
19. Bushing
20. Oil seal (primary shaft gear)
21. Bearing race
22. Funnel
23. Bearing race (differential)
24. Clutch housing
25. Oil passage
26. Oil seal (differential)
27. Bearing race (secondary shaft gear)
28. Adjustment shim (secondary shaft gear)
29. Adjustment shim (primary shaft gear)
30. Bearing race (differential)
31. Adjustment shim (differential)
32. Transaxle case
33. Joint
34. Change rod
NOTE: The oil seals do not need to be removed unless you are replacing them.
1. Disassemble in the order shown in the image, referring to Disassembly Note.
2. Select adjustment shim(s), referring to Bearing Preload Adjustment.
3. Assemble in the reverse order of disassembly, referring to Assemble Note.
Disassembly note
Blind plug
Remove the roll pin with pliers.
Reverse lever shaft
Protect the reverse lever shaft with a rag and remove the shaft with pliers.
Oil seal (change rod)
Remove the oil seal with a screwdriver.
Funnel and bearing race (secondary shaft)
NOTE: Remove the bearing race with a screwdriver if necessary.
1. Insert a screwdriver between the clutch housing and bearing race.
2. Pry the bearing race free.
Remove the bearing race by lifting out the funnel and race together.
Oil seal (primary shaft)
CAUTION: Do not damage the clutch housing.
Remove the oil seal with a screwdriver.
Oil seal (differential)
Remove the oil seal with a screwdriver.
Bearing race and adjustment shim (differential)
1. Install the SST to the bearing race.
2. Remove the bearing race and adjustment shim.
Bearing preload adjustment
Adjust the bearing preload and select the shim(s) as follows.
Primary shaft assembly
1. Set the primary shaft assembly into the clutch housing.
2. Install the transaxle case to the clutch housing and tighten the bolts to the specified torque.
Tightening torque: 19 - 25 N-m (1.9 - 2.6 kgf-m, 14 - 18 ft-lbf)
3. Mount a dial indicator to the transaxle hanger and measure the primary shaft thrust clearance.
Clearance: 0.005 - 0.100 mm (0.0002 - 0.0039 in)
4. Select the closest shim on the thin side from the image.
Secondary shaft bearing preload
1. Install the funnel and bearing race into the clutch housing.
2. Set the secondary shaft into the clutch housing.
3. Install the secondary shaft bearing race into the transaxle case.
4. Install the transaxle case to the clutch housing and tighten the bolts to the specified torque.
Tightening torque: 19 - 25 N-m (1.9 - 2.6 kgf-m, 14 - 18 ft-lbf)
5. Mount a dial indicator to the transaxle case and measure the secondary shaft end play.
6. Select the shim as follows.
a. Add 0.03 mm (0.0012 in) to the thrust clearance.
b. Add 0.08 mm (0.0031 in) to the thrust clearance.
c. Select the thickest adjustment shim in the range from (a) to (b) from the image.
Example: 0.22 mm (0.009 in)
0.22 mm (0.009 in) + 0.03 mm (0.001 in) = 0.25 mm (0.010 in)
0.22 mm (0.009 in) + 0.08 mm (0.003 in) = 0.30 mm (0.012 in)
Range: 0.25 mm (0.010 in) - 0.30 mm (0.012 in)
Select the 0.30 mm (0.012 in) adjustment shim.
Differential
1. Install the bearing race into the clutch housing.
2. Set the differential assembly into the clutch housing.
NOTE: Turn (A) and (B) until the gap shown in the image is eliminated.
3. Install the transaxle case side bearing race to the SST (selector).
4. Set the SSTs (collars) in the positions shown in the image.
5. Tighten the SSTs (bolts) to the specified torque.
Tightening torque: 19 - 25 N-m (1.9 - 2.6 kgf-m, 14 - 18 ft-lbf)
NOTE: Turn the bars until the SST (selector) can no longer be moved.
6. To seat the bearings, mount the bars on parts (A) and (B) of the selector, and turn the selector so the gap is widened.
7. Turn in the reverse direction until the gap is eliminated.
8. Install the SST to the differential pinion gear through the transaxle case.
9. Turn the SST with a torque wrench. Adjust the SST (selector) with the bars until the specified preload is obtained.
Preload: 0.03 - 0.74 N-m (0.3 - 7.6 kgf-cm, 0.26 - 6.59 in-lbf)
10. Remove the SST.
11. Measure the clearance around the entire circumference of the SST (selector).
12. Select the proper adjustment shim(s) to be used for the differential by referring to the image and selecting the shim which is nearest (on the thick side) to the largest measured clearance in the selector.
13. Remove the SSTs (bolts).
14. Remove the transaxle case and the SSTs (collars).
15. Remove the bearing race from the SST (selector).
16. Install the selected shim(s) and bearing race to the transaxle case.