Disassembly

1. Remove the rear cover bolts and rear cover.





2. Remove the backup light switch, gasket and mounting bracket.





3. Remove the poppet plugs, poppet springs and poppet balls.





4. Remove the speedometer driven gear assembly.





5. Remove the spring pin using the special tool (09414 - 11000) or equivalent.
6. Removal of the lock nuts, as follows:





a. Unstake lock nuts of the input shaft and intermediate shaft.





b. Shift the transaxle in reverse using the control lever and select lever.





c. Install the special tool (09432 - 21101) or equivalent, onto the input shaft.
d. Screw a bolt 10 mm (0.39 inch) into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.
e. Remove the lock nut, while using the bolt as a spinner handle stopper.





7. Remove the fifth speed synchronizer sleeve and fifth speed shift fork.
8. Remove the fifth speed synchronizer hub, synchronizer ring, 5th speed gear and needle bearing.





9. Remove the intermediate gear using the special tool (09455 - 21000) or equivalent.





10. Remove the reverse idler gear shaft bolt and restriction ball assembly.





11. Remove the transaxle case fixing bolts in the clutch housing and then remove the transaxle case.





12. Remove the differential oil seal and oil guide.





13. Remove the output shaft bearing outer race and spacer using the special tool (09455 - 32200) or equivalent.
14. Remove the intermediate shaft bearing outer race and spacer.
15. Remove the differential bearing outer race and spacer.





16. Remove the reverse shift lever and the reverse shift shoe.





17. Remove the reverse gear shaft and reverse gear.





18. Remove the spring pins using the special tool (09414 - 11000) or equivalent.
19. Disassembly of the shift rail and fork assembly, as follows:





a. Shift the first-second gear shift fork into the second gear.
b. Shift the third-fourth gear shift fork into the fourth gear.





c. Remove the first-second gear shift rail and fork assembly with the select lever pushed to fifth-reverse gear shift rail.
d. Remove the shift rail and fork assembly of the third-fourth/ fifth/reverse gear with the select lever pushed to first-second gear shift rail.





20. Remove the bearing retainer.





21. Lift up the input shaft assembly and remove the intermediate shaft assembly.





22. Remove the output shaft assembly and differential gear assembly.





23. Remove the intermediate shaft bearing outer race and spacer and oil guide using the special tool (09455 - 32200) or equivalent.





24. Remove the output shaft bearing outer race and spacer using the special tool (09455 - 32200) or equivalent.





25. Remove the differential bearing oil seal.





26. Remove the input shaft oil seal.