Disassembly

Transaxle





NOTE: Clean the transaxle exterior before disassembly.

NOTE: Clean all removed parts and all sealing surfaces with solvent, and dry with compressed air.

NOTE: Clean out all holes and passages with compressed air and verify that there are no obstructions.

1. Mount the transaxle to the Holding Fixture.





2. Remove the clutch release fork and bearing.

NOTE: May need to use a screwdriver to pry the clutch release fork off the anchor bolt, if needed.

1. Remove the clutch release bearing.

2. Remove the clutch release fork and diaphragm.





3. If necessary, remove the anchor bolt.





4. Remove the bolt and the Vehicle Speed Sensor (VSS).





5. Remove the reversing lamp switch wiring harness retainer bolt and reversing lamp switch.





6. Shift the transaxle into the NEUTRAL position.

7. Remove the 9 case cover bolts and the case cover.





8. Remove and discard the 5th/6th gear shift fork roll pin.





9. Shift the 5th/6th gear shift fork to 5th.





10. NOTE: Do not reuse locknuts.

Remove the primary and secondary shaft locknuts.

1. Using the Transmission Turning Torque Socket, keep the input shaft from turning.

2. Using a punch, release the locking tabs from the shafts. Remove and discard the primary and secondary shaft locknuts.





11. NOTICE: Make sure the tabs of the suitable tool are securely positioned on the gear or damage to the gear may occur.

Using a suitable tool, remove the bearing and 6th gear from the secondary shaft.





12. NOTICE: Make sure the tabs of the suitable tool are securely positioned on the gear or damage to the gear may occur.

Using a suitable tool, remove the bearing and 6th gear from the primary shaft.





13. Remove the gear sleeve.





14. Remove the 5th/6th shift fork and synchronizer assembly.





15. Remove the spacer and the gear sleeve.





16. Remove the 5th speed primary and secondary gears.





NOTE: Make sure the transaxle is in neutral.

17. Remove the reverse idler shaft lock bolt and shift rail guide bolt.





18. Remove the shift detent bolt, spring and ball.





19. Remove the 15 transaxle case bolts and separate the transaxle case.
- After separating the transaxle cases, position the removed case on its side. Use care not to damage the funnel.





20. Remove the funnel bolt and the funnel.





21. Remove the magnet.





22. Remove the shift lever shaft pin, then remove the shift lever shaft and shift fork selector lever.





23. Remove the shift gate bolt.





24. Remove the shift control shaft and remove the shift gate.





25. Move the shift forks upward into 2nd and 4th gears.





26. Remove the reverse idler gear assembly and shift fork.





27. Rotate the main shift control shaft clockwise to free the interlock from the 1-2 and 3-4 shift forks.

28. Raise the main shift control shaft until it clears the bore in the transaxle case and remove the main shift control shaft assembly, shift forks.





29. Remove the primary and secondary shafts at the same time.





30. Remove the differential.





31. For further disassembly of the transaxle case, refer to Transaxle Case Transaxle Case.