Transmission Disassemble

Transmission Disassemble

Tools Required
* J 6125-B Slide Hammer
* J 22888-20A Bearing Puller with J 22888-35 Puller Legs
* KM-553-A Fifth Gear Puller
* J 36633 Snap Ring Retainer
* J 3289-20 (KM 113-2) Holding Fixture
* J 42469 Shift Rod Remover
* KM-552 Fixture


Disassembly Procedure




1. Remove the transaxle from the vehicle. Refer to Transmission Replacement (D16 - Manual Transaxle).
2. Remove the filler plug at the cover.




3. Remove the bolts from the gearshift lever cover.




4. Remove the gearshift lever cover.




5. Bolt the gearshift lever cover to the KM-552 (1).
6. Position the KM-552 into the J 3289-20 (2).




7. Remove the snap ring, the bushing, the spring, and the intermediate lever.




8. Remove the shift finger lever pin (2).




9. Remove the gearshift rod (1) and the shift finger lever.




10. Remove the bolt and the speedometer-driven gear from the transaxle housing.




11. Remove the transaxle cover bolts.




12. Remove the transaxle cover.




13. Shift the transaxle into 2nd gear.
14. Remove the bearing plate bolts.




15. Remove the bearing plate from the case with the shafts attached.




16. Shift the transaxle into reverse (R).
17. Bolt the bearing plate to the KM-552 (2) and install the KM-552 (2) into theJ 3289-20 (1).




18. Remove the bolts and the 5th gear fork from the bearing plate.




19. Remove the mainshaft-driven 5th speed assembly snap ring.




20. Remove the 5th driven gear synchronizer sleeve and the synchronizer gear using the J 22888-20A (1) with the puller legs J 22888-35.




21. Remove the mainshaft-driven 5th gear assembly (4).




22. Remove the brass synchronizer ring.




23. Remove the needle bearing, the retaining ring, and the thrust washers.




24. Remove the input drive 5th gear snap ring.




25. Remove the input drive 5th gear using the KM-553-A (1).




26. Remove the bolts and the 5th gearshift connector from the bearing plate using the pawl.




27. Remove the 4 shift-rod plugs using the J 42469 (1) and the J 6125-B (2).




28. Remove the spring and the rod lock pin from the small plug hole.




29. Remove the pin from the reverse gearshift rod/fork assembly.




30. Remove the reverse gearshift rod/fork assembly from the bearing plate.




31. Remove the bolts from the support bracket.




32. Remove the 1st-2nd gearshift fork holding pin.




33. Drive the 1st-2nd gearshift rod out until it is just free of the bearing plate.




34. Remove the support bracket from the bearing plate.




35. Remove the 3rd-4th gearshift fork holding pin and the 3rd-4th gearshift rod.




36. Remove the 5th gearshift lever from the bearing plate.




37. Remove the 1st-2nd gearshift rod.




38. Compress the snap ring holding the mainshaft and secure it with the J 36633 (1).




39. Hold the snap ring open at the base of the input shaft using the snap ring pliers (2).
40. Remove the mainshaft assembly and the input shaft assembly from the bearing plate.