remove the big nut on the end w/ a 1/2" drive ratchet or bar


remove the two bolts on the bottom side, and use a magnet to get the little ball bearing out of each hole



remove this bolt that holds the reverse idler shaft


use snap-ring pliers to pop this ring open. you'll hear a thud as the countershaft drops.


untorque the case bolts


remove the reverse sensor


all the case bolts are the same, so don't bother marking them


here's the pliers


and here's the ring, popped


pry here


and lift up





remove the reverse gear changer, 10mm, 2 bolts


then remove the main gear changer, 10mm also, 3 bolts




then pull and wiggle a little on the mainshaft, countershaft, and 3 shift forks, and they all pop out together, and you're left with this


now pull the diff out STRAIGHT or it will get hung up since the bearings are fit just so. now disassemble your KAAZ and rearrange the clutches, and installation is the reverse of removal. note that there is a tab on the countershaft that must be facing a certain direction. when you put the outer case back on, bolt it down to about 1-2mm from closed with 4-6 bolts, then pick it up, and drop it gently on the outercase side (the input shaft should be facing you). this will pop the clip around the countershaft.

above all, don't **** up! this **** isn't cheap to replace! really this isn't a child's game, although some treat it that way . . .

edit: oh yeah, and you'll need some hondabond or permatex ultra grey ( ) to put the cases back together.

 

Thanks for the write-up, should be starting this in the next few days, i need to change my kaaz dif, its at 100 percent lock and its hard as hell to drive around so i'm looking to put it at 65 percent, if anybody needs the diagram from kaaz i have it....thanks again..

 

just be careful, and if it won't go back together easily, with no force, don't force it. if you get stuck, take it to a tranny shop rather than ******* up your tranny.