Disassembly and Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

Remove drain plug and gasket from clutch housing.

Fig 1: Locating Drain Plug
Remove plug mounting bolt and then plug (with ABS models) or speedometer pinion gear (without ABS models) and O-ring from clutch housing.

Fig 2: Locating Plug Mounting Bolt
Remove plug and gasket from transaxle case.

Fig 3: Locating Plug
Remove park/neutral position (PNP) switch (1) from transaxle case.
Remove back-up lamp switch (2) and plunger from transaxle case.
CAUTION: Never lose plunger.
Remove air breather tube (3) from transaxle case.

Fig 4: Identifying Park/Neutral Position (PNP) Switch, Back-Up Lamp Switch And Air Breather Tube
Remove guide bolt from transaxle case.

Fig 5: Locating Guide Bolt
Remove retaining pin using a pin punch and then remove selector lever from transaxle case.

Fig 6: Locating Retaining Pin
Remove transaxle case mounting bolts.

Fig 7: Locating Transaxle Case Mounting Bolts
Remove bore plug from transaxle case.
CAUTION:
- Never damage transaxle case.
- Access bore plug from cutout (A) of transaxle case when removing.
Fig 8: Removing Bore Plug From Transaxle Case
Remove transaxle case following the procedures below.
1. Expand snap ring at mainshaft rear bearing accessing from the bore plug hole. Then pull up transaxle case from clutch housing until snap ring comes off.
  
  Fig 9: Identifying Snap Ring At Mainshaft Rear Bearing
2. With shifter lever A (1) held in the position shown in the figure, remove transaxle case from clutch housing.
  CAUTION: Never drop each adjusting shim.
  
  NOTE: Make sure to hold shifter lever A in the position shown in the figure. Otherwise transaxle case cannot be removed from clutch housing.
  
  Fig 10: Identifying Shifter Lever Position
Remove oil gutter A (1) and oil gutter B (2) from transaxle case.
A : Tab of oil gutter

Fig 11: Identifying Oil Gutter
Remove snap ring from transaxle case.

Fig 12: Identifying Snap Ring
Remove retaining pin using a pin punch and then remove shifter lever A and shifter lever B from transaxle case.

Fig 13: Locating Retaining Pin
Remove differential side bearing outer race (transaxle case side) from transaxle case using the puller and then remove differential side bearing adjusting shim from transaxle case.
CAUTION: Never damage transaxle case and differential side bearing outer race.

Fig 14: Identifying Special Tool On Differential Side Bearing Adjusting Shim
Remove differential side oil seal from transaxle case.
CAUTION: Never damage transaxle case.

Fig 15: Identifying Differential Oil Seal
Remove shifter lever oil seal (1) and striking rod oil seal (2) from transaxle case.
CAUTION: Never damage transaxle case.

Fig 16: Identifying Shifter Lever Oil Seal And Striking Rod Oil Seal
Remove striking rod shim (1), striking rod adjusting shim (2), mainshaft rear bearing adjusting shim (3), input shaft rear bearing adjusting shim (4), and reverse idler gear adjusting shim (5).

Fig 17: Identifying Striking Rod Adjusting Shim
Remove retaining pin of reverse shift fork (1) using a pin punch.
2 : Reverse fork rod

Fig 18: Identifying Retaining Pin Of Reverse Shift Fork
Rotate striking lever of striking rod assembly as shown in the figure. Then rotate reverse fork rod to a position where bracket of reverse fork rod does not interfere with striking lever of striking rod assembly.
Pull out reverse shift fork and reverse fork rod.

Fig 19: Rotating Striking Lever Of Striking Rod Assembly
Remove retaining pin of 5th-6th shift fork (1) using a pin punch.
2 : 5th-6th fork rod

Fig 20: Locating Retaining Pin Of 5th-6th Shift Fork
Remove retaining pin of 3rd-4th shift fork (1) using a pin punch.
Pull out 3rd-4th fork rod (2).

Fig 21: Identifying Retaining Pin Of 3rd-4th Shift Fork
Pull out 5th-6th shift fork (1) and 5th-6th fork rod (2).

Fig 22: Identifying 5th-6th Shift Fork And 5th-6th Fork Rod
Pull out 3rd-4th shift fork (1).

Fig 23: Identifying 3rd-4th Shift Fork
Remove retaining pin of 1st-2nd shift fork (1) using a pin punch.
Pull out 1st-2nd shift fork and 1st-2nd fork rod (2).

Fig 24: Identifying 1st-2nd Shift Fork And 1st-2nd Fork Rod
Remove striking rod assembly (1).

Fig 25: Identifying Striking Rod Assembly
Remove gear components from clutch housing in the following procedure.
1. Remove a set of input shaft assembly, mainshaft assembly, and reverse idler gear assembly by tapping the tip of input shaft from the back of the clutch housing with a plastic hammer.
  CAUTION: Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.
2. Remove final drive assembly.
  
  Fig 26: Identifying Input Shaft Assembly, Mainshaft Assembly And Reverse Idler Gear Assembly Into Clutch Housing
Remove magnet from clutch housing.

Fig 27: Locating Magnet From Clutch Housing
Remove mainshaft bearing retainer and then mainshaft front bearing from clutch housing using the puller.
CAUTION: Never damage clutch housing, mainshaft front bearing, and oil channel.
Remove oil channel from clutch housing.

Fig 28: Identifying Puller On Mainshaft Bearing Retainer
Remove differential side bearing outer race (clutch housing side) from clutch housing using the puller.
CAUTION: Never damage clutch housing and differential side bearing outer race.

Fig 29: Identifying Puller On Differential Side Bearing Outer Race
Remove input shaft oil seal from clutch housing.
CAUTION: Never damage clutch housing.

Fig 30: Identifying Input Shaft Oil Seal
Remove differential side oil seal from clutch housing.
CAUTION: Never damage clutch housing.

Fig 31: Identifying Differential Side Oil Seal