Basic Subassembly Separation

BASIC SUBASSEMBLY SEPARATION












1. Remove release fork and bearing.
2. Remove back-up light switch with gasket.
Torque: 40 N.m (30 ft. lbs.)
3. Remove bolt and vehicle speed sensor.
Torque: 17 N.m (13 ft. lbs.)
4. Remove No.2 Selecting bellcrank with selecting bellcrank support.
Remove the 2 bolts and No.2 selecting bellcrank with the selecting bellcrank support.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
5. Remove shift and select lever shaft lock bolt with gasket.
Torque: 49 N.m (36 ft. lbs.)
6. Remove shift and select lever shaft assembly with gasket.
Remove the 4 bolts, shift and select lever shaft assembly and gasket.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque: 20 N.m (14 ft. lbs.)





7. Remove transmission case cover.
Remove the 10 bolts and transmission case cover.
FIPG: THREE BOND 1281 or equivalent.
Torque: 29 N.m (22 ft. lbs.)
8. Remove breather plug with gasket.
Torque: 49 N.m (36 ft. lbs.)





9. Remove output shaft lock nut.
Unstake the lock nut.
Engage the gear double meshing.
Remove the lock nut.
Torque: 123 N.m (90 ft. lbs.)
Disengage the gear double meshing.
10. Remove No.3 hub sleeve and No.3 fork.
a. Remove the No.3 shift fork set bolt.
Torque: 24 N.m (17 ft. lbs.)
b. Remove the No.3 hub sleeve and No.3 shift fork.





11. Remove 5th driven gear.
Using SST 09950 - 30010, remove the 5th driven gear.





12. 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 in.)
Maximum clearance: 0.65 mm (0.0256 in.)





b. Using a dial indicator, measure the radial clearance
Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
13. Remove No.3 clutch hub and 5th gear.
a. Using 2 screwdrivers and a hammer, tap out the snap ring.









INSTALLATION HINT: Select a snap ring that will allow minimum axial play.





b. Using Special Service Tool (SST) 09950 - 30010 or equivalent, remove the No.3 clutch hub with the synchronizer ring and 5th gear.
14. Remove needle roller bearing and spring.
15. Remove rear bearing retainer.
Using a torx socket wrench (T45), remove the 7 torx screws and rear bearing retainer.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque: 42 N.m (31 ft. lbs.)





16. 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.





17. Remove straight screw plug, seat, spring and locking ball.
a. Using a hexagon wrench (6 mm), remove the plug.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque:25 N.m (18 ft. lbs.)
b. Using a magnetic finger, remove the seat, spring and locking ball.





18. Remove reverse idler gear shaft lock bolt.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque: 29 N.m (22 ft. lbs.)





19. Remove transmission case.
Remove the 17 bolts and tap the case with a plastic hammer.
FIPG: THREE BOND 1281 or equivalent
Torque: 29 N.m (22 ft. lbs.)





20. Remove shim.

INSTALLATION HINT: Install the previously selected shim by adjusting output shaft preload.






21. Remove output shaft rear taper roller bearing outer race.
Using SST 09316 - 60011 (09316 - 00011) and a hammer, remove the output shaft rear taper roller bearing outer race.
22. Remove transmission oil pipe.
a. Remove the gasket from the oil pipe.
b. Remove the 2 bolts and oil pipe.
Torque: 17 N.m (13 ft. lbs.)





23. Remove reverse shift arm bracket assembly.
Remove the bolt and pull off the reverse shift arm and bracket.
Torque: 17 N.m (13 ft. lbs.)
24. Remove reverse idler gear and shaft.
Pull out the shaft, remove the reverse idler gear and thrust washer.






INSTALLATION HINT: Align the matchmarks, as shown.






25. Remove straight screw plug, locking ball and spring.
a. Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque: 25 N.m (18 ft. lbs.)
b. Using a magnetic finger, remove the 2 seats, springs and balls.





26. Remove No.1, No. 2 shift forks and shift head set bolt.
Torque: 24 N.m (17 ft. lbs.)
27. Remove no.1 shift fork shaft.
Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.

INSTALLATION HINT: When it is difficult to push the fork shaft through the reverse shift fork, pull up the No.3 shift fork shaft.






28. Remove interlock roller.
Using a magnetic finger, remove the interlock roller from the reverse shift fork.





29. Remove No.2 shift fork shaft, shift head and N0.1 shift fork.
a. Pull out the No.2 shift fork shaft.
b. Remove the shift head and No.1 shift fork.





30. 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.
31. 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.
32. 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.
33. Remove differential case assembly.
a. Remove the oil pump drive gear.
b. Remove the differential case assembly.
34. Remove magnet from transaxle case.
35. Remove transmission oil pump assembly and oil pipe.
a. Remove the 2 bolts and oil pipe.
Torque: 17 N.m (13 ft. lbs.)
b. Remove the 2 bolts and oil pump assembly.
Torque: 17 N.m (13 ft. lbs.)





36. 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.