Disassembly

DISASSEMBLY
Transaxle





Disassembly
1. General note Use vice jaw protectors when performing all the operations. Use a copper or plastic hammer.





2. Using the special tool, install the transaxle.





3. Remove the clutch slave cylinder.
1. Remove the bolts.
2. Remove the clutch slave cylinder.





4. Remove the Vehicle Speed Sensor (VSS).
1. Remove the retaining pin.
2. Remove the VSS.





5. Remove the gearshift cable cover.





6. Remove the selector lever.
1. Remove the protective cap.
2. Remove the snap-ring.
- Discard the snap ring.





7. Remove selector the cable bracket.





8. Remove the lever.
- Remove the gaiter.





9. Remove the selector interlock mechanisms.





10. Remove the fifth gear cover.
- Loosen the bolts and carefully separate the fifth gear cover by tapping lightly.





11. Remove the fifth gear synchronizer unit and the selector fork.
1. Remove the fifth gear synchronizer unit retaining ring.
2. Remove the selector fork retaining bolt. Discard the retaining ring. Discard the retaining bolt.





12. NOTE: Mark the installation position of the gear synchronizer before disassembling.

Disassemble the fifth gear synchronizer unit.
1. Remove the snap-ring
2. Remove the retaining plate
3. Remove the gear synchronizer
4. Remove the synchronizer ring
5. Remove the gear wheel (fifth gear)





13. Remove the fifth gear wheel retaining ring.
- Discard the retaining ring





14. Using the special tool, remove the fifth gear wheel.





15. CAUTION: Do not strike directly on the mating face.

Remove the fifth gear housing.
1. Loosen the bolts and carefully separate the fifth gear housing sections by tapping lightly.
2. Use metal surface cleaner, clean the mating face. Discard the bolts.





16. CAUTION: Do not strike directly on the mating face.

Remove the gasket.
1. Detach the input shaft retaining ring.
2. Detach the output shaft retaining ring. Discard the retaining rings.





17. Using the special tool, remove both halfshaft oil seals (left-hand side shown, right-hand side similar).
- The reversing lamp switch only needs to be removed for sealing purposes.





18. CAUTION: Do not use metal scrapers to clean the transaxle mating faces.

NOTE: Slightly turn the transmission housing to raise it.

Separate the transmission housing from the clutch housing. Use metal surface cleaner, clean the mating face.





19. Remove the upper snap-ring from the selector rod guide sleeve.
1. Remove the upper snap-ring
2. Push the selector rod guide sleeve downwards. Discard the upper snap-ring.





20. Remove the selector rod guide sleeve.
1. Remove the lower snap-ring from the guide sleeve.
2. Pull off the selector rod guide sleeve.
- Discard the lower snap-ring.





21. NOTE: Install a rubber belt to the auxiliary selector shaft to aid disassembly.

Remove the input and output shaft with the selector forks.





22. Remove the differential and the permanent magnet.





23. Remove the reverse idle gear.





24. Remove the selector rod and locking plate.
1. Shift selector interlock plate.
2. Fifth and reverse gear selector rod.





25. Remove the input shaft oil seal.
- Discard the input shaft oil seal.





26. Remove output shaft roller bearing.
- Press out the track rollers from the bearing cage.
- Remove the bearing cage.





27. CAUTION: Only use the special tool in the position indicated, otherwise the blanking plug will be forced out of the housing.

Using the special tool, remove the output shaft bearing cone.
- Remove the oil thrower.





28. Remove the bearing cone.





29. Using the special tool, remove the differential bearing cone.