1. Transaxle Assembly Disassemble

^ Tools Required
^ J 22888-20 Universal Puller
^ J 22888-30 Puller Legs

Notice: If the transaxle side cover is frozen to the left case, tap around the side cover with a rubber mallet until the side cover is free of the left case. DO NOT attempt to pry the side cover away from the left case with metal tools or damage to the left case and side cover mating surfaces could result.





1. Remove the 6 bolts and 2 nuts/washers. Remove the transaxle side cover from the left case.





2. Remove the following components from the input shaft:
2.1. The fifth speed synchronizer retainer
2.2. The fifth speed synchronizer hub plate
3. Engage the transaxle by pushing in on the gearshift shaft.
4. Engage the fifth gear by sliding the fifth speed sleeve down. The transaxle is now locked in two gears, preventing input shaft rotation and permitting countershaft nut removal.
5. Use a center punch and a hammer in order to unstake the countershaft nut.
6. Remove the countershaft nut from the countershaft.





Important: Use a magnet in order to help remove the guide ball from the fifth speed gearshift fork.

7. Remove the gearshift fork plug and the guide ball from the fifth speed gearshift fork.
8. Move the transaxle gearshift shaft to the neutral position.
9. Use a standard drift punch and a hammer in order to remove the gearshift fork roll pin.





10. Using your hands, remove the following components from the input shaft (if you cannot remove the assembly manually, use J 22888-20 with two J 22888-30):
^ The fifth speed gearshift fork
^ The fifth speed sleeve and hub
^ The synchronizer ring spring
^ The high speed synchronizer ring spring
^ The fifth speed synchronizer ring
^ The input shaft fifth gear
^ The fifth gear bearing
11. Remove the fifth speed gearshift fork from the fifth speed sleeve and hub assembly.
12. Remove the synchronizer ring spring and the fifth speed hub from the fifth speed sleeve.





13. Using your hands, remove the countershaft fifth gear from the countershaft (if you cannot remove the gear manually, use J 22888-20 with J 22888-30.

Important: If the screws are damaged during removal, replace with new screws.

14. Remove the following components from the left case in order:
^ The 6 screws
^ The bearing set shim
^ The left case plate
^ The 3 bolts
^ The left case cap
^ The O-ring





15. Remove the gearshift yoke bolt from the gearshift yoke.

Important: The locating springs are of various sizes for ease of assembly. Remember the location and position of each spring in order to ensure correct installation.





16. Remove the following components from the right case:
^ The gearshift shaft screws with the washers
^ The 3 locating springs
^ The 3 steel balls

Important: Do NOT remove the fifth-to-reverse interlock bolt for removal of the gearshift guide case.





17. Remove the following components from the left case:
17.1. The 4 bolts
17.2. The harness bracket
17.3. The gearshift guide case
17.4. The backup lamp switch with O-ring





18. Remove the gearshift interlock bolt and the washer from the left case.
19. Remove the gearshift and select shaft assembly from the left case.





20. Remove the reverse idler shaft bolt (2) and the washer from the left case.
21. Remove the eleven case bolts (1) from the left case.
22. Remove the two case bolts from inside of the right case.

Important: Separate the transaxle cases with the right case (clutch housing) facing downward so that all of the internal components remain in the right case.

23. Remove the left case from the right case by lifting the left case up and off of the right case.





24. Remove the gearshift yoke from the gearshift arm.
25. Remove the following components from the right case:
^ Reverse idler gear shaft with the washer
^ The reverse idler gear





26. Remove the reverse idler lever bolts and assembly.

Important: When removing the 5th and reverse gearshift shaft and guide shaft, push the high speed gearshift shaft in. Shift the high speed gearshift shaft to 4th gear in order to remove the 5th and reverse gearshift shaft and guide shaft.

27. Remove the following components simultaneously from the right case:
^ The fifth and reverse gearshift guide shaft
^ The fifth and reverse gearshift shaft
28. Tap the input end of the assembly with a plastic mallet.





29. Remove the following components simultaneously as a cluster:
^ The input shaft assembly
^ The countershaft assembly
^ The high speed and low speed gearshift shafts
30. Remove the following components from the input shaft and countershaft assemblies:
^ The high speed gearshift shaft
^ The low speed gearshift shaft
31. Separate the input shaft assembly from the countershaft assembly.





32. Remove the differential assembly from the right case.
^ Grasp the differential assembly (1) .
^ Lift the differential assembly up and out of the right case (2) .