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

: Apply gear oil.

: Replace the parts as a set.

: Always replace after every
disassembly.

: N·m (kg-m, ft-lb)

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.

1. Remove input shaft rear bearing mounting bolt (1), using the drift (A) [SST: KV32300QAM].

2. Remove input shaft rear bearing (1), as per the following procedure.

a. Set a puller [Commercial service tool] to input shaft rear bearing.

b. Remove input shaft rear bearing, using a drift (A) [Commercial service tool].

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

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

5. Remove snap ring (1).

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

7. Remove snap ring (1).

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

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

10. Remove snap ring (1).

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

12. Set a puller [Commercial service tool] to input shaft front bearing (1), and then remove input shaft front bearing.

Assembly

Note the following procedures, and assemble 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.

• Never 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 drift (A) [Commercial service tool].

• Install input shaft rear bearing (1), using a drift (A) [Commercial service tool] and the drift (B) [SST: ST36720030].

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

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

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

1. Fix the drift (A) [SST: KV32300QAM] in a vise, and then set input shaft assembly.

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

3. Loosen input shaft rear bearing mounting bolt by a half turn.

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

Inspection

INSPECTION AFTER DISASSEMBLY

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.

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 unsmooth rotation. Replace if necessary.