Disassembly

DISASSEMBLY











1. Remove clutch release lever and bearing (Fig. 26). Inspect release lever pivot balls and replace if necessary (Fig. 27). Use slide hammer C-3752 and remover/installer 6891 (Fig. 28) if pivot ball replacement is necessary.





2. Remove input shaft bearing retainer (Fig. 29).

NOTE: Place transaxle in neutral before shift cover removal.





3. Remove shift cover-to-case bolts and remove shift cover assembly (Fig. 30).





4. Using a suitable screwdriver, remove extension housing axle oil seal (Fig. 31).





5. Remove extension housing-to-case and differential cover bolts (Fig. 32).
6. Place transaxle with bellhousing surface down.





7. Remove backup lamp switch (Fig. 33).





8. Remove end plate (Fig. 34).





9. Set up lifting bar (tool 8489) as shown in (Fig. 35).
10. Lift up on bar (input shaft bearing side) and remove input shaft bearing snap ring.
11. Lift up on bar (intermediate shaft side) and remove intermediate shaft bearing snap ring.
12. Remove lifting bar 8489.





13. Remove end cover-to-case bolts 12. (Fig. 36).





14. Remove end cover from transaxle (Fig. 37).





15. Remove 3/4 shift rail bushing from end cover using slide hammer C-3752 and remover 6786 (Fig. 38).





16. Remove reverse idler bolt (Fig. 39). Remove reverse idler gear, washers, and shaft upon geartrain removal.





17. Remove 1-2/5-R shift rail (Fig. 40).
18. Install lifting bar 8489.





19. Lift geartrain (w/reverse idler gear Assy.) out of transaxle and install on fixture 8487 (Fig. 41).
20. Remove remaining shift rail and forks from geartrain (Fig. 41).
21. Remove lifting bar from geartrain.

NOTE: At this point, differential bearing turning torque should be measured to ensure proper shim selection upon reassembly.

22. Reinstall and torque extension housing and measure differential turning torque.
23. Remove differential cover bolts.
24. Remove differential cover. If necessary, use a soft tipped hammer to aid in removal.
25. Remove extension housing.





26. Remove differential assembly. Note orientation of shim, oil slinger, and differential side bearing races (Fig. 42).





27. Remove differential chip collector magnet and clean (Fig. 43). Magnet is adhered with RTV, and may require force to remove.





28. Remove intermediate shaft bearing race with puller 8472 (Fig. 44).





29. Remove shift rail bushing from case with remover 6786 and slide hammer C-3752 (Fig. 45).





30. Remove input shaft bearing using an arbor press and tool 8474 (Fig. 46).