1. Transmission Case Disassemble

Transmission Case Disassemble

Special Tools
* J 7079-2 - Universal Driver Handle - Non-Threaded
* J 8092 - Universal Driver Handle - 3/4 in - 10
* J 23907 - Slide Hammer with Bearing Adapter
* J 44375 - Assembly Pallet
* J 44376 - Bearing Pusher/Puller
* J 44377 - Input Shaft Anti-Rotation Tool
* J 44380 - Differential Bearing Race Puller
* J 44381 - Shifter Bearing/Input and Output Bearing Remover
* J 44382 - Countershaft Needle Bearing Puller
* J 44385 - Differential Bearing Race and Seal Installer
For equivalent regional tools, refer to Special Tools (Tools and Equipment)




1. Remove the transmission filler cap.




2. Remove the transmission drain plug and drain the fluid.




3. Remove the shift cable bracket (4), the spacers (2), the isolators (3) and the bolt (1).




4. Remove the vehicle speed sensor and bolt.




5. Position the transmission, with the transaxle case side facing up, on a bench.
6. Remove the seven bolts from the transaxle case side of the housing.




7. Turn the transmission over.

Caution: Puncture the seal in the center to prevent damage to the transmission.

8. Remove the intermediate shaft seal using a suitable tool. Discard the seal.




9. Remove the plastic oil guide from the intermediate shaft using a suitable tool. Discard the oil guide.




10. Turn the transmission so the shifter is on top.
11. Shift the transmission into any gear.




12. Hold the input shaft with J 44377 - tool.
13. Using the appropriate tool remove the bolt from the intermediate shaft.




14. Remove the actuator and tube bolts.
15. Remove the actuator and tube.
16. Inspect the input shaft seal for cuts, nicks, and damage. If damaged, replace the actuator.




17. Shift the transmission into neutral.
18. Remove the shifter guide bolt.




19. Remove the five shifter retaining bolts.
20. Remove the shifter.




21. Remove the rear cover bolts.
22. Remove the rear cover.
23. Remove the oil guide.




24. Shift the transmission into 4th and 5th gear using a screwdriver in an upward direction.
25. Remove the input and output shaft bolts while holding the transmission into 4th and 5th gear with a screwdriver in an upward direction.




26. Turn the transmission over and remove the remainder of the transmission housing bolts from the clutch housing side.





Note: In line with the intermediate shaft, use two suitable tools to assist in the case separation.

27. Remove the clutch housing from the transaxle case.




28. Remove the roller bearing from the output shaft.




29. Remove the differential from the transaxle case.




30. Remove the magnet from the transaxle case.




31. Slide outward and unhook the shift rod from the shift fork.




32. Remove the oil tube from the transaxle case.





Note: Ensure all of the shafts are in the proper slots on the holding fixture.

33. Install the J 44375 - assembly pallet onto the gear shafts and the shift forks.




34. Turn the transaxle case over on the J 44375 - assembly pallet.




35. Remove the reverse lamp switch.





Note: Alternate the tightening of the jack screws on the J 44376 - pusher/puller to ensure proper removal of the transaxle case.

36. Remove the transaxle case from the shafts using the J 44376-1, J 44376-2, and J 44376-3.




37. Remove the intermediate shaft and shift fork from the input shaft, the output shaft, and the J 44375 - assembly pallet.




38. Remove the shift forks from the gear assemblies.
39. Remove the remaining gear assemblies from the holding fixtures.




40. Using the J 44380 - race puller (2) and the J 23907 - bearing adapter (1), remove the differential bearing outer race from the clutch housing. Discard the race.




41. Remove the differential output shaft seal from the clutch housing. Discard the seal.




42. Remove the output shaft bearing race and bolts from the clutch housing using the J 23907 - bearing adapter (1) and the J 44380 - race puller (2).




43. Remove the input shaft bearing from the clutch housing using the J 44381 - bearing remover and J 7079-2 - driver handle.




44. Remove the snap ring from the counter shaft bearing.
45. Remove the counter shaft bearing from the clutch housing using the J 44381 - bearing remover (2) and the J 7079-2 - driver handle (1).




46. Remove the differential bearing outer race from the transmission housing using the J 44380 - race puller (2) and the J 23907 - bearing adapter (1). Discard the race.




47. Remove the differential output shaft seal from the transmission housing. Discard the seal.




48. Remove the reverse lockout lever bolt (1), lever (3) and spring (2) from the transmission housing, if equipped.




49. Remove the shifter bearing from the transmission housing using the J 44381 - bearing remover (1) and the J 7079-2 - driver handle (2).




50. Remove the intermediate shaft needle bearing from the transmission housing using the J 44382 - bearing puller (2) and the J 23907 - bearing adapter (1).




51. Remove the shift rod bushing and the shift rod from the transmission housing.




52. Remove the input and output shaft bearing with snap ring from the transmission housing using the J 44385 - installer (2) and the J 8092 - handle (1).