Component Parts Removal

1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH
Remove the back-up light switch and gasket.




3. REMOVE SPEEDOMETER DRIVEN GEAR
a. Remove the retaining bolt and plate.
b. Pull out the speedometer driven gear.




4. REMOVE RELEASE BEARING RETAINER
Remove the three bolts.




5. REMOVE SELECTING BELLCRANK ASSEMBLY AND ENGINE MOUNTING BRACKET




6. REMOVE SHIFT LEVER
a. Loosen the lock nut as far as the tip of the lock pin.
b. Using a brass bar and hammer, tap out the lock pin.
c. Pull out the shift lever with dust boot from shift and select lever 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 SHAFT ASSEMBLY
a. Remove the control shaft cover.
b. Remove the O-ring from control shaft cover.




c. Pull out the shift and select lever shaft assembly.




9. REMOVE TRANSMISSION CASE COVER
a. Remove the eight bolts.
b. Tap on the circumference of the transmission case cover with a plastic hammer to remove the transmission case cover.




10. MEASURE 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.)




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




c. Remove the lock nut.

HINT: The lock nut has LH threads.

d. Disengage the gear double meshing.




12. REMOVE SHIFTING KEY RETAINER
a. Using two screwdrivers and a hammer, tap out the snap ring.
b. Remove the shifting key retainer.




13. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
a. Remove the No.3 shift fork set bolt.
b. Using the three case cover bolts, tighten the three bolts a little at a time and remove No.3 hub sleeve assembly.




14. REMOVE FIFTH GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS AND SPACER




15. REMOVE FIFTH DRIVEN GEAR
Using SST, remove the fifth driven gear.
SST 09950-20017




16. REMOVE REAR BEARING RETAINER
Remove the five bolts and bearing retainer.




17. REMOVE SNAP RINGS
Using snap ring pliers, remove the two snap rings




18. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT




19. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM




20. REMOVE TRANSMISSION CASE
Remove the seventeen bolts and tap off the case with plastic hammer.

HINT: Remove the two bolts from the transaxle case side.




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




22. REMOVE REVERSE IDLER GEAR AND SHAFT




23. REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS, INPUT SHAFT AND OUTPUT SHAFT
a. Drive out the slotted spring pin from No.1 fork shaft.




b. Remove the input shaft and output shaft together with No.1 fork shaft and shift head and shift forks from the transaxle case.




24. SEPARATE NO.1 FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS
a. Mount the shift forks in a vise.
b. Drive out the slotted spring pin from No.1 fork shaft as shown.




c. Separate the No.1 shift fork shaft No.1 shift head, No.1 and No.2 shift fork.




25. CHECK OIL CLEARANCE OF REVERSE SHIFT FORK

Maximum clearance: 0.70 mm (0.0276 in.)

26. REMOVE REVERSE SHIFT FORK AND INTERLOCK PIN




27. REMOVE NO.2 FORK SHAFT
a. Using SST, remove the screw plug.
SST 09313-30021




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




28. REMOVE DIFFERENTIAL ASSEMBLY




29. REMOVE MAGNET




30. REMOVE TRANSAXLE OIL RECEIVER AND PLATE




31. REMOVE NO.1 OIL RECEIVER PIPE FROM TRANSMISSION CASE