Special Tools

1. Remove the transaxle from the vehicle. Refer to Transmission Replacement.
2. Remove the shift control cable bracket, the washer, and the bolts.



3. Remove the bolt and the speedometer driven gear.



4. Remove the clutch release fork bolt.



5. Remove the clutch release lever.



6. Remove the clutch release fork and the thrust clutch bearing.



7. Remove the release lever shaft bushings.



8. Remove the thrust bearing guide bolts.



9. Remove the thrust bearing guide and the O-ring.




Note: Puncture the seal in the center to prevent damage to the transaxle.

10. Knock a hole in the sealing plug of the interm shaft with a suitable tool.



11. Remove the interm shaft sealing plug and the oil pipe using a suitable tool. Discard the sealing plug and the oil pipe.



12. Hold the input shaft with the DT-48180  (1).
13. Remove the retainer plug from the interm shaft. Discard the retainer plug.

Shift the transaxle into any gear.

14. Remove the DT-48180 holder .



15. Remove the transaxle rear cover bolts.



16. Remove the transaxle rear cover and the oil pipe.



17. Hold the input shaft with the DT-48180  (1).
18. Remove the input shaft retainer plug and the output shaft retainer plug. Discard the retainer plugs.

Shift the transaxle into any gear.

19. Remove the DT-48180 .



20. Remove the shift shaft assembly.

20.1.

Position the transaxle into neutral.

20.2.

Remove the shift guide bolt (1).

20.3.

Remove the shift retaining bolts.

20.4.

Remove the select control lever (2).

20.5.

Remove the shift shaft assembly (3).




21. Remove the backup lamp switch and the washer from the transaxle housing.



22. Remove the 12 bolts from the clutch housing side.



23. Remove the 7 bolts from the transaxle housing side.



24. Remove the transaxle housing from the clutch housing.

24.1.

Install the DT-48188 onto the transaxle housing.

•	Tighten the 4 bolts.

•	Screw the spindles into the input and output shaft.

24.2.

Separate the transaxle housing from the clutch housing.

•	Hold the spindles (1) using a suitable tool.

•	Turn via nuts (2) in direction of arrow.

24.3.

Remove the DT-48188 from the transaxle housing.

•	Unscrew the spindles into the input and output shaft.

•	Remove the 4 bolts.





Note: This step prevents the 3rd/4th synchro body assembly falling apart.

25. Install the DT-48190  (1) and the retainer plug to the input shaft.




Note: Hold the input and output shaft assembly firmly.

26. Remove the interm (1), input (2) and output (3) shaft assembly with the respective shift forks out of the clutch housing.

26.1.

Knock interm shaft out of interm shaft groove ball bearing using the DT-48186 .

26.2.

Remove the output shaft assembly and the shift fork.

26.3.

Remove the interm and input shaft assembly with the respective shift forks.

27. Remove the DT-48190 and the retainer plug from the input shaft.



28. Remove the differential (1) and the output shaft roller bearing (2) from the clutch housing.



29. Remove the magnet from the transaxle housing.



30. Remove the drain channel (1) from the transaxle housing.
31. Remove the idle shift rail bushing (2) from the transaxle housing.
32. Remove the idle shift rail (3) from the transaxle housing.



33. Remove the thread pin (3), the torsion spring (2), and the reverse shifting blocker (1) from the transaxle housing. Discard the thread pin.



34. Remove the needle sleeve from the transaxle housing using the DT-48179  (2) and the DT-48182  (1).



35. Remove the input shaft and output shaft groove ball bearings from the transaxle housing using the DT-48179  (1) and the DT-48181  (2).



36. Remove the differential bearing race from the transaxle housing.

36.1.

Install the DT-48189 .

36.2.

Turn the nut (1) in the direction of the arrow.

36.3.

Install the DT-48183 to the DT-48189 .

36.4.

Hold the spindle using a suitable tool.

36.5.

Turn the nut (2) in the direction of the arrow.




37. Remove the shim from the transaxle housing.



38. Remove the shaft seal ring from the transaxle housing. Discard the shaft seal ring.



39. Remove the input shaft roller bearing from the clutch housing using the DT-48179  (1) and the DT-48184  (2).



40. Remove the snap ring from the interm shaft groove ball bearing.



41. Remove the interm shaft groove ball bearing from the clutch housing using the DT-48179  (1) and the DT-48184  (2).



42. Remove the differential bearing race from the clutch housing.

•	Install the DT-48189 .

•	Turn the nut (1) in the direction of the arrow.

•	Install the DT-48183 to the DT-48189 .

•	Hold the spindle using a suitable tool.

•	Turn the nut (2) in the direction of the arrow.




43. Remove the shim from the clutch housing.



44. Remove the shaft seal ring from the clutch housing. Discard the shaft seal ring.




Note: Observe the orientation of the coiled pin before removal.

45. Remove the coiled pin (6). Discard the coiled pin.
46. Remove the coiled pin (5). Discard the coiled pin.
47. Remove the shift interlock (3).
48. Remove the shift finger (4).
49. Remove the outer spring seat (2).
50. Remove the 5th/reverse pressure spring (1).



51. Remove the coiled pin (2). Discard the coiled pin.
52. Remove the shift lever (1).
53. Remove the vent cap (3).
54. Remove the shift cover (4).



55. Remove the snap rings (1). Discard the snap rings.
56. Remove the inner spring seat (2).
57. Remove the 1st/2nd pressure spring (3).
58. Remove the angle disc (4) from the shift rod (5).



59. Clean all components in a suitable solution.
60. Inspect all components for wear or damage.



61. Press off the 1st gear assembly and the 2nd gear assembly as a unit, from the interm shaft using the gear and bearing separator plate, the DT-48191  (1) , and a hydraulic press.



62. Put the 1st gear assembly and the 2nd gear assembly, as a unit, on the bench.
63. Remove the thrust washer (1).
64. Remove the roller bearing (2).
65. Remove the 1st gear (3).
66. Remove the roller bearing (4).
67. Remove the bearing collar (5).
68. Remove the thrust washer (6).



69. Remove the 1st gear inner cone (1).
70. Remove the 1st gear blocking ring (2).
71. Remove the 1st gear outer cone (3).
72. Remove the 1st/2nd synchronizer assembly (4).



73. Remove the 2nd gear outer cone (1).
74. Remove the 2nd gear blocking ring (2).
75. Remove the 2nd gear inner cone (3).
76. Remove the 2nd gear.



77. Remove the needle bearings from the interm shaft.



78. Remove the thrust washer (1) from the input shaft.
79. Remove the 4th gear (2).
80. Remove the needle bearing (3).
81. Remove the 4th gear blocking ring (4).



82. Remove the bearing collar and the 3rd/4th synchronizer from the input shaft using the gear and bearing separator plate under the 3rd speed gear, the DT-48192  (1) , and a hydraulic press.



83. Remove the following components as an assembly:

•	The bearing collar (1)

•	The 3rd/4th synchronizer assembly (2)

•	The thrust washer (3)

•	The thrust bearing (4)

•	The 3rd gear blocking ring (5)

•	The 3rd gear (6)




84. Remove the needle bearing (1).
85. Remove the thrust bearing (2).



86. Press off the 5th gear using the gear and bearing separator plate, the DT-48192  (1) , and a hydraulic press.




Note: The 4th driven gear is a very tight press.

87. Press off the 4th driven gear from the output shaft using the gear and bearing separator plate, the DT-48192  (1) , and a hydraulic press.




Note: The 3rd driven gear is a very tight press.

88. Remove the 3rd driven gear using the gear and bearing separator plate, the DT-48192  (1) , and a hydraulic press.



89. Remove the 5th gear (1) and the 2 needle bearings (2).




Note: Do not contact the thrust washer under the reverse gear.

90. Remove the bearing collar using the gear and bearing separator plate, the DT-48192  (1) , and a hydraulic press.



91. Remove the following components as an assembly:

•	The bearing collar (1)

•	The 5th gear blocking ring (2)

•	The 5th/Reverse synchronizer assembly (3)

•	The reverse blocking ring (4)

•	The reverse gear (5)

•	The needle bearing (6)





Note: Ensure that the gear and bearing separator plate is not making contact with the pinion gear before pressing off the collar and thrust washer.

92. Remove the collar and the thrust washer using the gear and bearing separator plate, the DT-48192  (1) , and a hydraulic press.



93. Inspect the clutch housing and the differential housing and replace any part that exhibits any of the following conditions:

•

Cracks

•

Porosity

•	Damaged mating surface

•	Stripped bolt threads

•	Distortion




94. Inspect the gear teeth and the gear splines for excessive wear or damage.

Remove minor nicks or scratches with an oil stone. Replace worn or damaged gears.




95. Inspect the thrust washer for wear or damage. Replace worn or damaged thrust washers.

Note: Do not allow the bearings to spin. Turn the bearings slowly by hand. Spinning bearings may cause damage to the rollers.

96. Inspect the condition of all thrust bearings, input shaft bearing, and output shaft bearing. Wash the bearings thoroughly in a cleaning solvent. Apply compressed air to the bearings. Lubricate the bearings with light oil. Check the bearings for roughness by slowly turning the race by hand.



97. Clean the synchronizer with clean solvent.
98. Air dry the components.
99. Inspect the synchronizer teeth for the following conditions. If any of the conditions exist, replace the synchronizer.

•

Wear

•

Scuffing

•

Nicks

•

Burrs

•

Breaking

100. Inspect the keys or the springs for the following conditions. If any of the conditions exist, replace the synchronizer.

•

Wear

•

Cracks

•	Distortion




101. Inspect the shift forks, shafts, and the rubber end for wear or damage. Replace any part that is worn or damaged.