Part 2

DISASSEMBLY




Figure 35 Remove Rear Cover Bolts






39. Remove transfer gear cover-to-case bolts (1) (Figure 35).




Figure 36 Remove Rear Cover






40. Remove transfer gear cover (1) (Figure 36).




Figure 37 Remove Transfer Shaft Gear Nut






41. Using Holder 6259(3) (Figure 37).




Figure 38 Transfer Shaft Gear Nut and Coned Washer






42. Remove transfer shaft gear-to-shaft nut (3) (Figure 38) and coned washer (2).




Figure 39 Remove Transfer Shaft Gear






43. Using Gear Puller L-4407A (3) (Figure 39), remove transfer shaft gear.




Figure 40 Remove Transfer Shaft Gear and (Select) Shim






44. Remove transfer gear shim (select) (3) (Figure 40).




Figure 41 Remove Bearing Cup Retainer






45. Remove bearing cup retainer (2) (Figure 41).




Figure 42 Remove Transfer Gear Bearing Cone






46. Remove transfer gear bearing cone using Puller Set 5048 with jaws 5048-4 and button -4539-2(Figure 42).




Figure 43 Remove Transfer Shaft Bearing Cup






47. Remove transfer shaft bearing cup from retainer using Remover 6062 (2) (Figure 43).




Figure 44 Remove Transfer Shaft Bearing Snap Ring






48. Using Snap Ring Pliers 6051(1) (Figure 44), remove transfer shaft bearing snap ring (2).




Figure 45 Remove Transfer Shaft






49. Using Remover/Installer 5049A (1) (Figure 45), remove transfer shaft (2) from transaxle.




Figure 46 Bearing Cup Removed






50. Slip bearing cup retainer and oil baffle off of shaft (Figure 46).




Figure 47 Remove Transfer Shaft Bearing Cone






51. Using Bearing Splitter P-334(3) (Figure 47), press transfer shaft bearing cone (4) off of shaft (2).




Figure 48 Remove Strap Bolts






52. Bend output gear retaining strap (1) (Figure 48) ears flat to allow bolt removal.
53. Remove output shaft stirrup strap bolts (3).




Figure 49 Remove Stirrup Strap






54. Remove stirrup (3) (Figure 49) and strap (2).




Figure 50 Remove Output Gear Bolt






55. Using Holder 6259 (2) (Figure 50).




Figure 51 Output Gear Bolt and Washer






56. Remove output shaft gear-to-shaft bolt (2) (Figure 51) and washer (3).




Figure 52 Remove Output Gear






57. Using Gear Puller L4407A (4) (Figure 52), and button 6055 (2), remove output gear (1) from shaft.




Figure 53 Output Gear and (Select) Shim






58. Remove output gear bearing shim (select) (2) (Figure 53).




Figure 54 Remove Bearing Cone






59. Using Puller Set 5048 with jaws 5048-5 and button L-4539-2(1) (Figure 54), remove output gear bearing cone.




Figure 55 Remove Rear Carrier Assembly

1 - REAR CARRIER ASSEMBLY

60. Remove rear carrier assembly (1) (Figure 55) from transaxle.




Figure 56 Remove Rear Carrier Bearing Cone






61. Remove rear carrier assembly (3) bearing cone using Puller Set 5048 with jaws 5048-3 and button 6055(Figure 56).




Figure 57 Low/Reverse Spring Compressor Tool






62. Low/reverse spring compressor Disk 6057(1) (Figure 57), Compressor 5059 (2) and Compressor 5058-3 (3).




Figure 58 Compressor Tool in Use






63. Install low/reverse spring compressor 6057 (1) (Figure 58), compressor 5059 (2) and compressor 5058-3 (3).




Figure 59 Install Snap Ring






64. Compress low/reverse piston return spring and remove snap ring (1) (Figure 59).




Figure 60 Low/Reverse Piston






65. Remove low/reverse spring compressor tool and low reverse piston return spring (1) (Figure 60).




Figure 61 Remove Anchor Shaft and Plug






66. Using a suitable punch ,drive out park guide bracket pivot shaft (2) plug(Figure 61).




Figure 62 Pivot Shaft and Guide Bracket






67. Using ordinary pliers, remove pivot shaft (3) (Figure 62) and guide bracket assembly (2).




Figure 63 Guide Bracket Disassembled






68. Inspect guide bracket (2) (Figure 63) components for excessive wear and replace if necessary.




Figure 64 Remove Low/Reverse Clutch Piston







NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

69. Remove low/reverse clutch piston (1) (Figure 64).




Figure 65 Remove Piston Retainer-to-Case Screws






70. Remove low/reverse piston retainer-to-case screws (3) (Figure 65).




Figure 66 Remove Piston Retainer






71. Remove low/reverse piston retainer (1) (Figure 66).




Figure 67 Remove Piston Retainer Gasket






72. Remove low/reverse piston retainer-to-case gasket (2) (Figure 67).




Figure 68 Remove Output Bearing Inner Cup






73. Using a hammer (2) (Figure 68) and suitable drift (3), drive out inner output bearing cup (1).




Figure 69 Remove Output Bearing Outer

1 - REMOVER 6062

74. Using Remover 6062 (1) (Figure 69), remove outer output bearing cup.