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Transaxle Assembly: Disassembly

  1. Remove drain plug and gasket from clutch housing.
  2. Remove plug mounting bolt and then plug (with ABS models) or speedometer pinion gear (without ABS models) and O-ring from clutch housing.
    Fig 1: Locating Drain Plug
    G04888862
  3. Remove plug and gasket from transaxle case.
    Fig 2: Locating Plug And Gasket From Transaxle Case
    G04888863
  4. Remove park/neutral position (PNP) switch (1) from transaxle case.
  5. Remove back-up lamp switch (2) and plunger from transaxle case.
    CAUTION: Be careful not to lose plunger.
  6. Remove air breather tube (3) from transaxle case.
    Fig 3: Identifying Air Breather Tube From Transaxle Case
    G04888864
  7. Remove guide bolt from transaxle case.
    Fig 4: Identifying Guide Bolt From Transaxle Case
    G04888865
  8. Remove retaining pin using a pin punch and then remove selector lever from transaxle case.
    Fig 5: Locating Selector Lever From Transaxle Case
    G04888866
  9. Remove transaxle case mounting bolts.
    Fig 6: Locating Transaxle Case Mounting Bolts
    G04888867
  10. Remove bore plug from transaxle case.
    CAUTION:
    • Be careful not to damage transaxle case.
    • Access bore plug from cutout (A) of transaxle case when removing.
      Fig 7: Identifying Bore Plug From Transaxle Case
      G04888868
  11. Remove transaxle case following the procedures below.
    1. Expand snap ring at mainshaft rear bearing accessing from the bore plug hole. Then pull up transaxle case from clutch housing until snap ring comes off.
      Fig 8: Identifying Transaxle Case
      G04888869
    2. With shifter lever A (1) held in the position shown in the figure, remove transaxle case from clutch housing.
      CAUTION: Do not drop each adjusting shim.
      NOTE: Make sure to hold shifter lever A in the position shown in the figure. Otherwise transaxle case cannot be removed from clutch housing.
      Fig 9: Identifying Transaxle Case From Clutch Housing
      G04888870
  12. Remove oil gutter A (1) and oil gutter B (2) from transaxle case.

    A: Tab of oil gutter

    Fig 10: Identifying Oil Gutter A And Oil Gutter B From Transaxle Case
    G04888871
  13. Remove snap ring from transaxle case.
    Fig 11: Identifying Snap Ring From Transaxle Case
    G04888872
  14. Remove retaining pin using a pin punch and then remove shifter lever A and shifter lever B from transaxle case.
    Fig 12: Locating Shifter Lever A And Shifter Lever B From Transaxle Case
    G04888873
  15. Remove differential side bearing outer race from transaxle case using the puller and then remove differential side bearing adjusting shim from transaxle case.
    CAUTION: Be careful not to damage transaxle case.
    Fig 13: Identifying Special Tool KV381054S0 (J-34286)
    G04888874
  16. Remove differential side oil seal from transaxle case.
    CAUTION: Be careful not to damage transaxle case.
    Fig 14: Identifying Differential Oil Seal
    G04888875
  17. Remove shifter lever oil seal (1) and striking rod oil seal (2) from transaxle case.
    CAUTION: Be careful not to damage transaxle case.
    Fig 15: Identifying Shifter Lever Oil Seal, Striking Rod Oil Seal And Transaxle Case
    G04888876
  18. Remove striking rod shim (1), striking rod adjusting shim (2), mainshaft rear bearing adjusting shim (3), input shaft rear bearing adjusting shim (4), and reverse idler gear adjusting shim (5).
    Fig 16: Identifying Striking Rod Shim, Striking Rod Adjusting Shim And Mainshaft Rear Bearing Adjusting Shim
    G04888877
  19. Remove retaining pin of reverse shift fork (1) using a pin punch.

    2: Reverse fork rod

    Fig 17: Locating Fork Rod
    G04888878
  20. Rotate striking lever of striking rod assembly as shown in the figure. Then rotate reverse fork rod to a position where bracket of reverse fork rod does not interfere with striking lever of striking rod assembly.
  21. Pull out reverse shift fork and reverse fork rod.
    Fig 18: Identifying Shift Fork And Fork Rod
    G04888879
  22. Remove retaining pin of 5th-6th shift fork (1) using a pin punch.

    2: 5th-6th fork rod

    Fig 19: Identifying Retaining Pin Of 5th-6th Shift Fork
    G04888880
  23. Remove retaining pin of 3rd-4th shift fork (1) using a pin punch.
  24. Pull out 3rd-4th fork rod (2).
    Fig 20: Locating Retaining Pin Of 3rd-4th Shift Fork
    G04888881
  25. Pull out 5th-6th shift fork (1) and 5th-6th fork rod (2).
    Fig 21: Identifying 5th-6th Shift Fork And 5th-6th Fork Rod
    G04888882
  26. Pull out 3rd-4th shift fork (1).
    Fig 22: Identifying 3rd-4th Shift Fork
    G04888883
  27. Remove retaining pin of 1st-2nd shift fork (1) using a pin punch.
  28. Pull out 1st-2nd shift fork and 1st-2nd fork rod (2).
    Fig 23: Identifying 1st-2nd Shift Fork And 1st-2nd Fork Rod
    G04888884
  29. Remove striking rod assembly (1).
    Fig 24: Identifying Striking Rod Assembly
    G04888885
  30. Remove gear components from clutch housing in the following procedure.
    1. Remove a set of input shaft assembly, main shaft assembly, and reverse idler gear assembly by tapping the tip of input shaft from the back of the clutch housing with a plastic hammer.
      CAUTION: Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.
    2. Remove final drive assembly.
      Fig 25: Identifying Input Shaft Assembly, Mainshaft Assembly And Reverse Idler Gear Assembly Into Clutch Housing
      G04888886
  31. Remove magnet from clutch housing.
    Fig 26: Locating Magnet From Clutch Housing
    G04888887
  32. Remove mainshaft bearing retainer and then mainshaft front bearing from clutch housing using the puller.
    CAUTION: Be careful not to damage clutch housing, mainshaft front bearing, and oil channel.
  33. Remove oil channel from clutch housing.
    Fig 27: Removing Mainshaft Bearing Retainer With Puller
    G04888888
  34. Remove differential side bearing outer race from clutch housing using the puller.
    CAUTION: Be careful not to damage clutch housing and differential side bearing outer race.
    Fig 28: Removing Differential Side Bearing With Puller
    G04888889
  35. Remove input shaft oil seal from clutch housing.
    CAUTION: Be careful not to damage clutch housing.
    Fig 29: Identifying Input Shaft Oil Seal
    G04888890
  36. Remove differential side oil seal from clutch housing.
    CAUTION: Be careful not to damage clutch housing.
    Fig 30: Removing Differential Side Oil Seal From Clutch Housing
    G04888891
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