Transmission gears do not engage

Welcome to 2CarPros.

Here are the directions for removal and replacement of the clutch. The first picture is an exploded view of the system.

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COMPONENTS

REMOVAL

pic 1

1. REMOVE TRANSAXLE FROM ENGINE
2. REMOVE CLUTCH COVER AND DISC
a. Place matchmarks on the flywheel and clutch cover.
B. Loosen each set bolt one turn at a time until spring tension is released.
C. Remove the set bolts, and pull off the clutch cover with the clutch disc.

NOTICE: Do not drop the clutch disc.

Pic 2

3. REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE
Remove the release bearing together with the fork and then separate them.

INSPECTION

pic 3

1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.

Minimum rivet depth: 0.3 mm (0.012 inch)

If necessary, replace the clutch disc.

Pic 4

2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.

Maximum runout: 0.8 mm (0.031 inch)

If necessary, replace the clutch disc.

Pic 5

3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.

Maximum runout: 0.1 mm (0.004 inch)

If necessary, replace the flywheel.

Pic 6

4. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and width of wear.

Maximum depth: A: 0.6 mm (0.024 inch)
Maximum width: B: 5.0 mm (0.197 inch)

If necessary, replace the clutch cover.

Pic 7

5. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direction.

HINT: The bearing is permanently lubricated and requires no cleaning or lubrication.
If necessary, replace the release bearing.

INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL

pic 8

a. Insert Special Service Tool (SST) in the clutch disc, and then set them.
SST 09301-00210

pic 9

b. Align the matchmark on the clutch cover with the one on the flywheel.
C. Torque the bolts on the clutch cover in the order shown.

Torque: 19 Nm (195 kgf-cm, 14 ft. Lbs.)

HINT: Temporarily tighten the No.1 and No.2 bolts.

Pic 10

2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.

Maximum non-alignment: 0.5 mm (0.020 inch)

If alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
SST 09333-00013

pic 11

3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO.2)
a. Apply release hub grease to these parts:
Release fork and hub contact point
Release fork and push rod contact point
Release fork pivot point

pic 12

b. Apply clutch spline grease.
Clutch disc spline

HINT: Recommended grease part number 08887-01706 (100 g).

4. INSTALL RELEASE BEARING AND FORK TO TRANSAXLE
Install the bearing to the release fork, and then install them to the transaxle.

5. INSTALL TRANSAXLE TO ENGINE

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Let me know if this is what you needed or have other questions.

Joe

Welcome back:

You are very welcome. However, make sure you focus on college. That needs to be your priority at this point. There will always be cars to fix. LOL They all break.

We will always be here, so you are welcome to come back any time if you need help or have questions. And yes, I feel confident you can do it. Just take your time.

Feel free to let me know if you need anything.

Take care,
Joe

Welcome back:

I'm not sure which part you are referring to. I do see the disconnected cables. Take a look at the pictures to see if you can identify which part it is. Let me know. I believe you are looking at the shift lever assembly, but I'm not sure.

Let me know,
Joe