Remove No Clutch Hub And Th Gear

(a) Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT:

Select a snap ring that will allow minimum axial play.

Mark

Thickness mm (in.)

Mark

Thickness mm (in.)

A

2.25 (0.0886)

E

2.49 (0.0980)

B

2.31 (0.0909)

F

2.55 (0.1004)

C

2.37 (0.0933)

G

2.61 (0.1028)

D

2.43 (0.0957)

-

-

(b) Using SST, remove the 5th gear, No.3 clutch hub, synchronizer ring, needle roller bearings and spacer. SST 09950-40010

HINT:

• Install the No.3 clutch hub and shifting keys to the hub sleeve.

• Install the shifting key springs under the shifting keys. NOTICE:

At the time of reassembly, position the key springs so that their end gaps are not in line.

• Support the tip of the input shaft with a spacer or such to raise the transaxle assembly.

• Using SST and a hammer, drive in the No.3 hub sleeve assembly with the No.3 shift fork.

SST 09612-2201 1 NOTICE:

At the time of reassembly, align the synchronizer ring slots with the shifting keys.

REMOVE 5TH DRIVEN GEAR

Using SST and a socket wrench, remove the 5th driven gear. SST 09950-40010

HINT:

At the time of reassembly, please refer to the following item. Using SST, install the 5th driven gear. SST 09309-12020

14. REMOVE REAR BEARING RETAINER

Remove the 5 bolts and retainer.

Torque: 27 Nm (280 kgfcm, 20 ftlbf)

15. REMOVE BEARING SNAP RING

Using a snap ring expander, remove the 2 snap rings. HINT:

If it is difficult to remove and install the snap rings, pull up the shafts.

16. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT Torque: 29 Nm (300 kgfcm, 22 ftlbf)

17. REMOVE SNAP RING FROM NO.2 SHIFT FORK SHAFT

Using 2 screwdrivers and a hammer, remove the snap ring.

18. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING AND BALL

(a) Using a hexagon wrench, remove the 4 plugs. Sealant:

Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 25 Nm (250 kgfcm, 18 ftlbf)

C141 Plug, As Shown:

Torque: 13 Nm (130 kgfcm, 9 ftlbf)

(b) Using a magnetic finger, remove the 3 seats, springs and balls.

Q06524

19. REMOVE STRAIGHT SCREW PLUG (C141) OR LOCK BALL ASSEMBLY (C151)

Using a hexagon wrench, remove the straight screw plug (C141) or lock ball assembly (C151). Sealant:

Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 39 Nm (400 kgfcm, 29 ftlbf)

Q06524

20. REMOVE TRANSMISSION CASE

(a) Remove the 16 bolts.

Torque: 29 Nm (300 kgfcm, 22 ftlbf)

(b) Carefully tap the transmission case with a plastic hammer and remove it.

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