Disassembly
DISASSEMBLE1. Mount transaxle on bench mounting fixture tool No. T57L-500-B, or equivalent, then remove drain plug and drain remaining fluid from case.
Exploded View Of Transaxle:
2. Remove case cover bolts, then pry cover from case.
3. Shift transaxle into first gear to lock input shaft and main shafts, then use input shaft holder tool No. T88C-7025-GH, or equivalent, to hold input shaft.
4. Uncrimp input shaft and main shaft locknut tabs, then remove input shaft locknut and place aside. Save input and main shaft locknuts for use when adjusting differential bearing preload.
5. Remove input shaft holder from input shaft, then the sleeve from top of main shaft reverse synchronizer gear.
6. Remove main shaft reverse synchronizer gear, then the synchronizer blocking ring.
7. Remove reverse synchronizer first speed gear, then the fifth gear/reverse shift fork roll pin using punch. Discard roll pin.
8. Remove fifth gear/reverse shift fork and synchronizer, then the fifth gear synchronizer ring from main shaft.
9. Remove fifth speed cluster gear and gear sleeve from main shaft, then the fifth speed gear from input shaft.
10. Remove reverse idler shaft lock bolt, and 3-4 shift fork guide bolt from side of case.
11. Remove detent spring screw, shifter interlock spring, and ball from transaxle case. If ball cannot be removed now, remove when transaxle case is removed from clutch housing.
12. Remove back-up lamp switch from case and park/neutral position switch from clutch housing, then discard copper washers.
13. Remove transaxle case-to-clutch housing bolts and pry case apart. When case halves are separated, ball from case may fall into bottom of clutch housing.
14. Remove magnet from side of clutch housing, then the reverse idler gear and bushing and reverse idler gear shaft from clutch housing
15. Remove fifth/reverse shift rod lock bolt from fifth/reverse shift rod end, then remove fifth/reverse shift rod and shift rod end.
16. Remove and discard roll pin from shift lever shaft, then pry shift lever shaft from clutch housing case.
17. Remove shift fork selector lever from shift lever shaft, then the two case vent bolts.
18. Remove 3-4 shift fork and shift rod with input shaft and main shaft assemblies.
19. Remove differential from clutch housing, then the control selector plate bolts, control selector plate, and reverse idler gear spacer.
20. Remove input shift shaft selector plate arm to input shift shaft bolt, then the arm from clutch housing.
21. Remove and discard shift gate selector roll pin, then slide input shaft from clutch housing and remove selector plate arm and shift gate selector.
22. Remove bleeder from clutch housing, then the vehicle speed sensor bolt and sensor.
23. Remove oil passage bolt and passage from transaxle case, then the main shaft bearing cup and funnel.
24. Remove reverse lever shaft plug, then the reverse lever shaft and assembly from clutch housing. Discard 0-ring.
25. Remove input and main shaft bearing races, diaphragm springs and shims using impact slide hammer tool No. T5OT-100-A and puller tool No. T58L-101-B, or equivalents.
26. Use screwdriver to remove input shaft and extension housing seal. Do not damage clutch housing when removing seal.
27. Using actuator pin tool No. D80L-100-G, collet tool No. D80L-100-Q and slide hammer tool No. D8OL-100-D, or equivalents, remove shifter shaft seal.
28. Using impact slide hammer tool No. T5OT-100-A and bearing cup puller tool No. T77F-01102-A, or equivalents, to remove differential oil seal and differential bearing race from clutch housing, then the differential bearing race from transaxle case.
29. Remove adjustment shim(s) from transaxle case, then use slide hammer and puller to remove differential oil seal from transaxle case.