Necessary equipment
- DT-48179 Universal guide handle
- DT-48182 Needle bearing puller/installer
- DT-48183 Demolition bridge
- DT-48189 Differential bearing race puller
- DT-48225 Driver for input shaft
- DT-48226 Gearbox housing ball bearing remover/installer assembly
- DT-48227 Roller bearing puller/installer
- DT-48228 Clutch housing ball bearing puller/installer
- DT-48229 Intermediate shaft puller
- DT-48231 Pusher / puller of the primary and secondary shaft
- DT-48232 Input Shaft Synchronizer Housing Protector
Disassembly order
1. Remove the gearbox from the car. See «Gearbox with final drive assembly» in this section.
2. Remove bolts, washer and shift control cable bracket.
3. Remove the bolts securing the concentric clutch release cylinder.
4. Disconnect the tube from the concentric clutch release cylinder.
Important: When removing the sleeve, do not apply excessive force.
5. Remove the bushing from the tube of the concentric slave cylinder.
6. Remove the pipe from the concentric clutch release cylinder.
7. Remove the O-ring and concentric clutch release cylinder.
8. Tap the hole in the intermediate shaft sealing plug with a suitable tool.
Important: Pierce the sealing plug in the center to prevent damage to the transaxle assembly.
9. Remove the intermediate shaft seal and oil line using a suitable tool. Discard sealing plug and oil line.
10. Hold input shaft with DT-48225.
11. Remove the fixing plug from the intermediate shaft. Discard the fixing plug.
- Shift into any gear.
12. Remove DT-48225.
13. Unscrew the bolts securing the rear cover of the gearbox with final drive assembly.
14. Remove the transaxle rear cover assembly and oil line.
15. Hold input shaft with DT-48225.
16. Remove the input shaft retaining plug and output shaft retaining plug. Discard the fixing plugs.
- Shift into any gear.
17. Remove DT-48225.
18. Remove the shift shaft assembly.
- Shift into neutral.
- Remove the shift guide bolt (1).
- Loosen the gearshift bolts.
- Remove gear selector lever (2).
- Remove shift shaft assembly (3).
19. Remove the reverse light switch and washer from the transaxle case assembly.
20. Remove the eight bolts on the side of the clutch housing.
21. Remove the twelve bolts from the transaxle housing side.
22. Remove the transaxle housing assembly from the clutch housing.
- Install DT-48231 to the transaxle case assembly.
- Tighten four bolts (1).
- Screw in spindles (2) into the primary and secondary shafts.
- Separate the transaxle housing assembly from the clutch housing.
- Hold spindles (2) with the right tool.
- Turn the nuts (3) in the direction of the arrow.
- Remove DT-48231 from transaxle case assembly.
- Unscrew the spindles (2) from the primary and secondary shaft.
- Remove four screws (1).
23. Install DT-48232 and retaining plug into input shaft.
Important: This is to prevent the 3rd/4th synchro housing assembly from falling apart.
24. Remove the intermediate, input and output shaft assemblies, along with their respective shift forks, from the clutch housing.
- Drive the countershaft out of the countershaft ball bearing using DT-48229.
Important: Firmly hold the input and output shaft assembly.
25. Remove DT-48232 and retaining plug from input shaft.
26. Remove differential (1) and roller bearing (2) output shaft from the clutch housing.
27. Remove magnet from transaxle case assembly.
28. Remove drain channel (1) from the crankcase of the gearbox with final drive assembly.
29. Remove the idle gear shift rod bushing (2) from the crankcase of the gearbox with final drive assembly.
30. Remove the idle gear shift rod (3) from the crankcase of the gearbox with final drive assembly.
31. Remove grub screw (3), torsion spring (2) and reverse gear blocking device (1) from the crankcase of the gearbox with final drive assembly. Discard grub screw.
32. Remove the needle bearing from the transaxle case assembly using DT-48179 and DT-48182.
33. Remove the input and output shaft ball bearings from the transaxle case assembly using DT-48179 and DT-48226.
34. Remove the differential bearing race from the transaxle case assembly.
- Install DT-48189.
- turn the nut (1) in the direction of the arrow.
- Install DT-48183 into DT-48189.
- Hold the spindle with a suitable tool.
- turn the nut (2) in the direction of the arrow.
35. Remove the shim from the transaxle case assembly.
36. Remove the driveshaft oil seal from the transaxle case assembly. Discard the drive shaft seal.
37. Remove the input shaft roller bearing from the clutch housing using DT-48179 and DT-48227.
38. Remove the circlip from the intermediate shaft ball bearing.
39. Remove the intermediate shaft ball bearing from the clutch housing using DT-48179 and DT-48228.
40. Remove the differential bearing race from the clutch housing.
- For four wheel drive version install DT-48189; for all wheel drive version install DT-48532.
- turn the nut (1) in the direction of the arrow.
- Install DT-48183 on DT-48189 (for the four-wheel drive version) or DT-48532 (for the version with all-wheel drive).
- Hold the spindle with a suitable tool.
- turn the nut (2) in the direction of the arrow.
41. Remove the shim from the clutch housing.
42. Remove the drive shaft seal from the clutch housing. Discard the drive shaft seal.