5TH Gear and 5TH Gear Synchronizer Assembly

Tools Required
- J25031A - 5th Gear Synchronizer Hub Puller

REMOVAL
1. Place transaxle in 3rd gear.





CAUTION: MAKE SURE VEHICLE IS PROPERLY POSITIONED ON HOIST.

2. Raise vehicle. Drain transaxle fluid by removing transaxle drain plug (1).
3. Remove rear cover.





4. Using a punch and hammer, tap out 5th gear fork retaining pin and discard.

IMPORTANT: Before removing 5th gear shift fork and synchronizer sleeve, mark position of sleeve relative to synchronizer hub to assist in reassembly.

IMPORTANT: Make sure 5th gear shift shaft does not come out of the transaxle when 5th gear shift fork is removed.

5. Remove 5th gear fork and synchronizer sleeve together.





6. Remove 5th gear synchronizer hub snap ring and discard. This will be easier if hub is tapped down first.
7. Use puller J 25031A to remove 5th gear synchronizer hub.
8. Remove blocking ring, blocking ring spring, 5th gear, and 5th gear bearing assembly.

INSTALLATION





IMPORTANT: Lubricate bearing assembly with manual transaxle fluid (P/N 21018899) during assembly.

1. Install 5th drive gear bearing assembly and 5th drive gear.
2. Install blocking ring and blocking ring spring on 5th gear.

IMPORTANT: Gaps in synchronizer hub must align with blocking ring lugs.

3. Carefully tap synchronizer hub onto input shaft using a mallet and large socket.
4. Install a new 5th gear synchronizer hub snap ring.





IMPORTANT: The 5th gear synchronizer sleeve can only be placed on hub when tall teeth on sleeve are aligned with deep teeth on hub.

5. Install 5th gear fork and synchronizer sleeve together. Reference sleeve alignment mark made during disassembly.
6. Install a new 5th gear fork retaining pin.
7. Install rear cover.





8. Clean and apply thread sealant (P/N 21485278) to transaxle drain plug (1) and install.
Torque: 50 Nm (37 ft. lbs.)
9. Remove transaxle level plug (2) and, using a funnel with a flexible spout or a quart bottle hand pump, add manual transaxle fluid (P/N 21018899) until fluid begins to flow out of level plug opening.
10. Clean and apply thread sealant (P/N 21485278) to transaxle level plug (2) and install.
Torque: 50 Nm (37 ft. lbs.)