Exploded View

Exploded View

1.	Input shaft front bearing	2.	Input shaft	3.	3rd input gear
4.	Spacer	5.	Snap ring	6.	3rd baulk ring
7.	3rd-4th coupling sleeve	8.	3rd-4th synchronizer hub	9.	Insert key
10.	4th baulk ring	11.	4th input gear	12.	5th input gear
13.	5th baulk ring	14.	5th-6th coupling sleeve	15.	5th-6th synchronizer hub
16.	6th baulk ring	17.	Needle bearing	18.	6th input gear
19.	Input shaft rear bearing	A.	First step	B.	Final step

Disassembly

Disassembly

CAUTION:

• Fix input shaft in a vise with back plate, and then remove gears and snap rings.

• For removal of snap ring, set snap ring pliers and flat pliers at both sides of snap ring. While expanding snap ring with snap ring pliers, move snap ring with flat pliers.

  

• Disassemble gear components putting direction marks on the parts that do not affect any functions.

Remove input shaft rear bearing bolt (1), using Tool (A).

CAUTION:

Do not reuse rear bearing bolt.

Tool number (A)

: KV32300QAM (  —  )

Remove input shaft rear bearing (1) with the following procedure. Set a suitable tool to input shaft rear bearing. Remove input shaft rear bearing using suitable tool (A).

Remove spacer (1), 6th input gear (2), needle bearing, 6th baulk ring, and 5th-6th synchronizer hub assembly (3).

Remove insert keys and 5th-6th coupling sleeve from 5th-6th synchronizer hub.

Remove snap ring (1).

CAUTION:

Do not reuse snap ring.

Remove spacer, 5th baulk ring, 5th input gear (2), and spacer.

Remove snap ring (1).

CAUTION:

Do not reuse snap ring.

Remove spacer, 4th input gear (2), 4th baulk ring, and 3rd-4th synchronizer hub assembly (3).

Remove insert keys and 3rd-4th coupling sleeve from 3rd-4th synchronizer hub.

Remove snap ring (1).

CAUTION:

Do not reuse snap ring.

Remove spacer, 3rd baulk ring, and 3rd input gear (2).

Set a suitable tool to input shaft front bearing (1), and then remove input shaft front bearing.

Assembly

Assembly

Assembly is in the reverse order of disassembly.

CAUTION:

• Replace transaxle assembly when replacing input shaft.

• For installation of snap ring, set snap ring pliers and flat pliers at both sides of snap ring. While expanding snap ring with snap ring pliers, move snap ring with flat pliers.

  

• Do not reuse snap ring.

• Check that snap ring is securely installed in a groove.

• Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer hub as a set.

• Replace 5th-6th coupling sleeve and 5th-6th synchronizer hub as a set.

• Be careful to install 3rd-4th synchronizer hub according to the specified direction.

  

  (A)	: 3rd input gear side
  (B)	: 4th input gear side

• Be careful to install 5th-6th synchronizer hub according to the specified direction.

  (A)	: 5th input gear side
  (B)	: 6th input gear side

  

• Install input shaft front bearing (1) using a suitable tool (A).

  

• Install input shaft rear bearing (1) using a suitable tool (A) and Tool (B).

  

  Tool number

  : ST36720030 (  —  )

• Apply gear oil to 3rd baulk ring, 4th baulk ring, 5th baulk ring, and 6th baulk ring.

• Install input shaft rear bearing bolt (1), as per the following procedure.

  

  CAUTION:

  Follow the procedures. Otherwise it may cause a transaxle malfunction.

  Do not reuse rear bearing bolt.

Fix the Tool (A) in a vise and set input shaft assembly.

Tool number

: KV32300QAM (  —  )

Install input shaft rear bearing bolt and tighten it to the specified torque of the first step.

Loosen input shaft rear bearing bolt by a half turn.

Tighten input shaft rear bearing bolt to the specified torque of the final step.

Inspection

Inspection

Input Shaft and Gear

Check the following items and replace if necessary.

Damage, peeling, bend, uneven wear, and distortion of shaft.

Excessive wear, damage, and peeling of gear.

INSPECTION AFTER DISASSEMBLY

Synchronizer Hub and Coupling Sleeve

Check the following items and replace if necessary.

• Breakage, damage, and unusual wear on contact surface of coupling sleeve, synchronizer hub, and insert key.

• Coupling sleeve and synchronizer hub move smoothly.

Baulk Ring

Check contact surface of baulk ring cam and insert key for excessive wear, uneven wear, bend, and damage. Replace if necessary.

Bearing

Check bearing for damage and uneven rotation. Replace if necessary.