C514 Manual Transaxle - Disassembly

DISASSEMBLY

Special Tools:






1. Place the transaxle on a bench.





2. Remove the release bearing (1).





3. Remove the clutch actuation lever. Discard the retention clip (1).





4. Remove the outside bushing (1) from the case (2).





5. Remove the release bearing fork (1) from the inner pivot bushing (2).





6. Remove the inner clutch fork pivot bushing (1) using (9609) - Bearing Remover (2) and a (C-637) Slide Hammer.





7. Remove the rear cover bolts.





NOTE:
Use a heat gun or the equivalent to soften the gasket material prior to removal.

8. Carefully pry off the rear cover (2) using a gasket scraper (1) or the equivalent.

9.




Remove the gear selector (1).





10. Remove the fifth gear fork retaining bolt (1).





NOTE:
Engage two gears, locking the transmission, prior to removing the shaft nuts.

11. Remove the staking on both gear shaft locking nuts (1).

12. Remove the nuts from the transmission assembly and discard.

13.




Remove the fifth gear shift fork and synchronizer hub assembly (1).

14. Remove the fifth gear synchronizer ring (2).





15. Remove fifth gear (1).





16. Remove the reverse idler shaft bolt (1).





17. Remove the case bolts (1).





18. Partially separate the case halves to access the reverse gear engagement fork bolts.

19. Remove the reverse gear engagement fork bolts (1).

20. Separate the bell housing from the case, the gear shafts will stay with the case.





NOTE:
The bearings will stay with the case and will be removed later.

21. Separate the gear shafts (2) from the case using an arbor press and (10285) Press Bridge (1).





22. Remove the input shaft oil seal (1) using Bearing Remover (9609) (3) and Brace (8915) (2).





23. Remove the retaining plate bolts (1).





24. Remove the bearings from the case halve by removing the retainer plate (1).

25. Remove the bearings and snap rings, discard the snap rings.





26. Remove the differential cover bolts (1).





27. Remove the differential seal plate bolts (1), plate and shim.





NOTE:
It may be necessary to tap the housing lightly with a plastic hammer to loosen.

28. Separate the differential housing (1) from the case (2).





29. Remove the differential assembly (1).

30. Remove the bearing cups and right side oil seal.