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Disassembly and Assembly

MANUAL TRANSAXLE ASSEMBLY














Components


Disassembly
1. 4WD:
REMOVE TRANSFER ASSEMBLY
a. Remove the 3 bolts.

Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)

b. Remove the 5 nuts.

Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)

c. Using a plastic hammer, remove the transfer assembly from the transaxle.

HINT: At the time of reassembly, please refer to the following item. Shift into the 4th gear, and install the transfer assembly while turning the input shaft of the transaxle.





FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

2. 4WD:
REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT
a. Screw in a suitable bolt with a washer into the side gear intermediate shaft.





b. Using SST, remove the side gear intermediate shaft.
SST 09910-00015 (09911-00011, 09912-00010)
c. Remove the snap ring from the differential side gear intermediate shaft.





HINT: At the time of reassembly, please refer to the following item. Keeping the intermediate shaft on the differential pinion shaft, measure the dimension, as shown in the illustration.

Protrusion length: 255.5 mm (10.06 inch)

3. REMOVE RELEASE FORK AND BEARING
4. REMOVE BACK-UP LIGHT SWITCH WITH GASKET

Torque: 40 Nm (410 kgf-cm, 30 ft. lbs.)

5. REMOVE BOLT AND VEHICLE SPEED SENSOR

Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)

6. REMOVE NO.2 SELECTING BELLCRANK WITH SELECTING BELLCRANK SUPPORT
Remove the 2 bolts and No.2 selecting bell crank with the selecting bellcrank support.

Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)

7. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK BOLT WITH GASKET

Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

8. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY WITH GASKET
Remove the 4 bolts, shift and select lever shaft assembly and gasket.

Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)





9. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.

FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)

10. REMOVE BREATHER PLUG WITH GASKET

Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





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

Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)

d. Disengage the gear double meshing.
12. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
a. Remove the No.3 shift fork set bolt.

Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)

b. Remove the No.3 hub sleeve and No.3 shift fork.





13. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-30010
14. MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE





a. Using a dial indicator, measure the thrust clearance.

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





b. Using a dial indicator, measure the radial clearance.

Standard clearance: 0.009-0.050 mm (0.0004-0.0020 inch)
Maximum clearance: 0.070 mm (0.0028 inch)

15. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
a. Using 2 screwdrivers and a hammer, tap out the snap ring.








HINT: At the time of the reassembly, please refer to the following item. Select a snap ring that allows the minimum axial play.





b. Using SST, remove the No.3 clutch hub with the synchronizer ring and 5th gear.
SST 09950-30010
16. REMOVE NEEDLE ROLLER BEARING AND SPACER
17. REMOVE REAR BEARING RETAINER
Using a torx socket wrench (T45), remove the 7 torx screws and rear bearing retainer.

Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)





18. REMOVE SNAP RING
a. Using a snap ring expander, remove the input shaft rear bearing snap ring.
b. Using 2 screwdrivers and a hammer, remove the 2 snap rings.





19. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING AND LOCKING BALL
a. Using a hexagon wrench (6 mm), remove the plug.

Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

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





20. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT

Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





21. REMOVE TRANSMISSION CASE
Remove the 17 bolts and tap the case with a plastic hammer.

FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





22. REMOVE SHIM

HINT: At the time of reassembly, please refer to the following item. Install the previously selected shim by adjusting output shaft preload.





23. REMOVE OUTPUT SHAFT REAR TAPER ROLLER BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear taper roller bearing outer race.
SST 09316-60011 (09316-00011)
24. REMOVE TRANSMISSION OIL PIPE
a. Remove the gasket from the oil pipe.
b. Remove the 2 bolts and oil pipe.

Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)





25. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
Remove the bolt and pull off the reverse shift arm and bracket.

Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)

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





HINT: At the time of reassembly, please refer to the following item. Align the matchmarks, as shown.





27. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL AND SPRING
a. Using a hexagon wrench (6 mm), remove the 2 plugs.

Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

b. Using a magnetic finger, remove the 2 seats, springs and balls.





28. REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD SET BOLT

Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)

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

HINT: At the time of reassembly, please refer to the following item. When it is difficult to push the fork shaft through the reverse shift fork, pull up the No.3 shift fork shaft.





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





31. 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.





32. 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 the reverse shift fork.
b. Remove the No.2 shift fork.
33. REMOVE SNAP RING
a. Using 2 screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No.3 shift fork shaft.
b. Using 2 screwdrivers and a hammer, remove the 3 snap rings from the No. 1, No.2 and No.3 shift fork shafts.
34. REMOVE INPUT AND OUTPUT SHAFTS 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.
35. REMOVE DIFFERENTIAL CASE ASSEMBLY
a. Remove the oil pump drive gear.
b. Remove the differential case assembly.
36. REMOVE MAGNET FROM TRANSAXLE CASE
37. REMOVE TRANSMISSION OIL PUMP ASSEMBLY AND OIL PIPE
a. Remove the 2 bolts and oil pipe.

Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)

b. Remove the 2 bolts and oil pump assembly.

Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)





38. REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB
a. Remove the No.5 synchronizer ring with the key spring from the No.3 clutch hub.
b. Using a screwdriver, remove the snap ring.

HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.

c. Remove the synchronizer rings.

Inspection





1. INSPECT NO.5 SYNCHRONIZER RING
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring. Turn the middle No.5 synchronizer ring in one direction while pushing it to the outer No.5 synchronizer ring. Check that the ring locks. If it does not lock, replace the synchronizer ring.





2. MEASURE SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 inch)

If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
3. IF NECESSARY, REPLACE INPUT SHAFT BEARING AND OIL SEAL
a. Remove the 3 bolts and transaxle case receiver.





b. Using SST, pull out the bearing.
SST 09612-65014
c. Using a screwdriver, remove the oil seal.





d. Using SST, drive in a new oil seal.
SST 09608-00081, 09950-70010 (09951-07150)
e. Coat the lip of seal with MP grease.





f. Using SST, drive in a new bearing.
SST 09950-60010 (09951-00580), 09950-70010 (09951-07150)
g. Install the transaxle case receiver.
h. Install and torque the 3 bolts. An

Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)





i. Using SST and a press, remove the inner race.
SST 09950-00020





j. Using SST and a press, install a new input shaft front bearing inner race.
SST 09316-60011 (09316-00021)
4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING OUTER RACE AND OUTPUT SHAFT FRONT COVER





a. Using SST, pull out the output shaft front bearing outer race.
SST 09308-00010
b. Remove the output shaft cover.





c. Install a new output shaft cover.

HINT: Install the output shaft cover projection into the case side groove.





d. Using SST and a hammer, drive in a new output shaft front bearing outer race.
SST 09316-60011(09316-00011,09316-00021)





e. Using SST and a socket wrench, remove the output shaft front bearing.
SST 09950-00020, 09950-00030





f. Using SST and a press, install a new output shaft front bearing.
SST 09316-60011 (09316-00071)
5. IF NECESSARY, REPLACE REVERSE RESTRICT PIN





a. Using a hexagon wrench (6 mm), remove the screw plug.
b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Replace the reverse restrict pin.





d. Using a pin punch and hammer, drive in the slotted spring pin.
e. Apply sealant to the screw plug threads.

Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

f. Using a hexagon wrench (6 mm), install and torque the screw plug.

Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)

Reassembly
Reassembly is in the reverse order of disassembly.

NOTICE: When working with FIPG material, you must observe the following items.
- Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
- Thoroughly clean all components to remove all the loose material.
- Clean both sealing surfaces with a non-residue solvent.
- Apply FIPG in an approx. 1 mm (0.04 inch) wide bead along the sealing surface.
- Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.

HINT:
- Before reassembly, select a shim by adjusting output shaft preload.
- Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. ADJUST OUTPUT SHAFT PRELOAD
a. Install the output shaft assembly to the transaxle case.
b. Install the transmission case to the transaxle case.

HINT: If necessary, tap on the case with a plastic hammer.

c. Install and torque the 17 bolts.

Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)

d. Install the output shaft rear taper roller bearing outer race.
e. Install the adjusting shim.

HINT: When reusing the output shaft bearing, first install a shim of the same thickness as before. If installing a new taper roller bearing, first select and install a shim of lesser thickness than before.

f. Install the rear bearing retainer.
g. Using a torx wrench J45), install and torque the 7 torx screws.

Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)

h. Install a new lock nut to the output shaft.
i. Turn the output shaft right and left 2 or 3 times to allow the bearing to settle.





j. Using a torque wrench, measure the preload.

Preload (at starting):
New bearing 0.8 - 1.6 Nm (8 - 16 kgf.cm, 6.9 - 13.9 inch lbs.)
Reused bearing 0.5 - 1.0 Nm (5 - 10 kgf-cm, 4.3 - 8.7 inch lbs.)

If the preload is not within the specification, select an appropriate adjusting shim.





The preload will change about 0.4 - 0.5 Nm (4 - 5 kgf-cm, 3.5 - 4.3 inch lbs.) for every 0.05 mm change in adjusting shim thickness.
k. Remove the lock nut.
l. Remove these parts. Removal is in the reverse order of installation. Rear bearing retainer Shim Transmission case Output shaft assembly Output shaft rear bearing outer race
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