Disassembly

1. Clean the transaxle exterior with solvent before disassembly.
2. Clean all removed parts (except sealed bearings) and all sealing surfaces with solvent, and dry with compressed air.

WARNING: USING COMPRESSED AIR CAN CAUSE DIRT AND OTHER PARTICLES TO FLY OUT, CAUSING INJURY TO THE EYES. WEAR PROTECTIVE EYE WEAR WHENEVER USING COMPRESSED AIR.

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





4. Mount the transaxle on Bench Mounted Holding Fixture T57L-500-B.





5. Remove the case cover.
(1) Remove the nine bolts.
(2) Remove the case cover.
6. Shift the transaxle into first gear.

CAUTION: Do not reuse locknuts.





7. Use Input shaft Holder T88C-7025-GH to remove the input and output locknuts. Discard the input and output locknuts.





8. Remove the reverse synchronizer blocking ring retainer.





9. Remove the synchronizer blocking ring.





10. Remove and discard the shift fork roll pin.





11. Remove the shift fork and synchronizer hub assembly.





12. Remove the synchronizer blocking ring.





13. Remove the input shaft fifth gear.





14. Remove the fifth gear bushing.





15. Remove the output shaft fifth gear spacer and fifth gear.





16. Remove the reverse idler shaft lock bolt.





17. Remove the shift rail guide bolt.





18. Remove the lock bolt, spring, and ball.





19. Remove the backup lamp switch.





20. Remove the transaxle mount.
(1) Remove the two transaxle mount bolts.
(2) Remove the transaxle mount.





21. Remove the bolt and bracket.





22. Remove the transaxle case.
(1) Remove the thirteen transaxle case bolts.
(2) Remove the transaxle case.





23. Remove the magnet.





24. Remove the reverse idler shaft and gear.





25. Remove the shift gate bolt.





26. Remove the shift rod and gate.





27. Remove the pin.





28. Remove the shift lever shaft and shift fork selector lever.
29. Shift into second and fourth gears.





30. Remove the shift fork shaft assembly and detent ball.

WARNING: WHEN REMOVING THE SHIFT FORK AND SHAFT ASSEMBLY THE DETENT BALL WILL FLY OUT. HOLD A SHOP TOWEL OVER THE DETENT BALL AND SPRING TO PREVENT THE BALL FROM BECOMING AIRBORNE.





31. Remove the output shaft gear assembly.





32. Remove the input shaft gear assembly.





33. Remove the differential.





34. Remove the input bearing cups.





35. Use (A) Puller T58L-101-B to remove the (B) input shaft oil seal.





36. Remove the output shaft bearing cup and fifth shaft funnel.





37. Remove the control selector plate and spacer.
(1) Remove the two bolts.
(2) Remove the control selector plate and spacer.





38. Remove the shift shaft selector lever.
(1) Remove the shift shaft selector lever bolt.
(2) Remove the shift shaft selector lever.





39. Remove and discard the roll pin.





40. Remove the shift shaft and boot.





41. Use (A) Collet D80L-100-Q, (B) Actuator Pin D80L-100-G and (C) Hammer D80L-100-D to remove the (D) shifter shaft seal.





42. Remove the vent tube.
(1) Remove the two bolts.
(2) Remove the vent tube.





43. Remove the vehicle speed sensor (VSS).





44. Use (A) Stator and Driven Sprocket Bearing Replacer T86P-70043-A, (B) Disc Brake Piston Remover T73L-2196-A, and (C) Impact Slide Hammer T50T-100-A to remove the (D) differential bearing cups.





45. Remove and discard the roll pin.





46. Remove the reverse shaft lever and rod.





47. Remove the park/neutral position (PNP) switch and gasket.





48. Use (A) Bearing Cup Puller T77F-1102-A and (B) Impact Slide Hammer T50T-100-A to remove the (C) differential seals.





49. Use (A) Puller T58L-101-B to remove the (B) input and output shaft bearing cups.