Nova 5SPD Manual Transaxle

1. Install transaxle in suitable holding fixture, then remove release fork, bearing and speedometer drive gear.

2. Remove back-up light switch using a suitable tool, then the transaxle case cover.

Figure 4:

3. Measure 5th gear thrust clearance as shown in above figure. Clearance should be 0.0039-0.0224 inch. If clearance is not within specifications, record measurement for use during assembly.




4. Remove selecting bellcrank, then the shift and select lever assembly lock bolt.

5. Remove shaft and select lever assembly, then the engage gears, lock nut and disengage gears.

6. Remove shift fork No. 3 attaching bolt and lock washer, then using two screwdrivers and a hammer, tap out snap ring.

7. Remove 5th gear hub sleeve, driven gear and drive gear using a suitable puller.




8. Remove rear bearing retainer, then the two bearing snap rings.

9. Remove reverse idle gear shaft bolt, then the snap ring from No. 2 shift fork shaft.




10. Remove four plugs, seal, spring, ball and lock ball assembly. It may be necessary to use a magnet to remove the four seats, springs and balls.

11. Remove 16 case attaching bolts, then tap off case using a plastic hammer.

12. Remove reverse shift arm bracket, then the reverse idler gear and shaft.

13. Remove shift forks an shift fork shaft as follows:

a. Using two screwdrivers and a hammer, tap out the three snap rings.

b. Pry out three lock washer, then remove the three shaft attaching bolts.




c. Remove fork shaft No. 2 and shift head, then the two balls using a suitable magnet.

d. Remove fork shaft No. 3 and reverse shift fork, then pull out fork shaft No. 1.

e. Remove shift forks Nos. 1 and 2.

14. Remove input and output shaft together from transaxle case.

15. Remove differential assembly, then the magnet and oil receiver.

Figure 9:

16. Measure 3rd and 4th gear thrust clearance as shown in above image. Clearance should be 0.0039-0.0138 inch for 3rd gear and 0.0039-0.0217 inch for 4th gear. If clearance is not within specifications, record measurements for use during assembly.

17. Remove snap ring from input shaft.




18. Remove radial ball bearing and 4th gear using a suitable press, then the needle roller bearings and synchronizer ring.




19. Remove snap ring, then using a suitable press, remove hub sleeve No. 2, 3rd gear, synchronizer ring and needle roller bearings.

Figure 12:

20. Measure 1st and 2nd gear thrust clearance as shown in above image. Clearance should be 0.0039-0.0157 inch for 1st gear and 0.0039-0.0177 inch for 2nd gear. If clearance is not within specifications, record measurements for use during assembly.




21. Remove radial ball bearing, 4th driven gear and spacer using a suitable press.




22. Remove 3rd driven gear, 2nd gear, needle roller bearing, spacer and synchronizer ring using a suitable press.




23. Remove snap ring, then the hub sleeve No. 1, 1st gear and synchronizer ring, needle roller bearing, thrust washer and locking ball.