Disassembly

Tools Required
- J43707-Transmission Support Fixture
- 87-91-410-Output Shaft Protector
- J25031A-Gear Puller
- 87-92-129-Lifting Eyes
- 87-91-287-Puller
- 87-91-303-Puller Arms, 150mm
- 87-91-295-Puller Arms, 300 mm
- 87-92-202-Output Shaft Bearing Race Sleeve
- 87-91-204-Output Shaft Bearing Race Sleeve
- 87-91-188-Screw Press Support
- 87-91-972-Assembly Ring
- 87-91-261-Output Shaft Remover
- J43964-Engine Stand Fixture Adapter
- J3289-20-Transmission Support Fixture Base
- 87-92-103-Output Shaft Assembly Tool

DISASSEMBLY





NOTICE: In all work involving disassembly of the transaxle, a new output shaft nut and crush sleeve must be installed during reassembly.

1. Remove back up lamp switch to prevent switch from being damaged during disassembly.
2. Cover holes for clutch hydraulics, axles, and reverse lamp switch, and clean transaxle if necessary.





3. Mount transaxle on holding fixture J43707. Mount transaxle and fixture in either engine stand fixture adapter J43964 or bench fixture J3289-20.





4. Remove clutch actuator cylinder pipe.
a. Remove pipe from slave cylinder.
b. Using pliers, pinch together the bottom halves of the pipe sleeve.
c. Move pipe and sleeve upward.
d. Pry up the locking tabs on sleeve and remove pipe.
5. Remove slave cylinder bolts and slave cylinder.
6. Remove reverse idler gear shaft bolt with O-ring.





7. Remove transaxle rear cover and discard gasket.





NOTICE: Do not shift gears using the 1st/2nd, 3rd/4th, or 5th shift shafts. All shifting should be done using the shift control shaft.

8. Put transaxle in 3rd gear with shift control shaft by pulling straight out on shift control shaft. Note the location of shift shafts to determine when transaxle is in 3rd gear.





9. Using a punch and hammer, tap out the 5th gear fork retaining pin.
10. Engage 5th gear by pressing synchronizer sleeve and fork down onto 5th gear. Two gears must be engaged at the same time to allow removal of output shaft nut.
11. Pry up locking tab on output shaft nut and remove nut.

IMPORTANT: Before removing the 5th gear synchronizer sleeve, mark its position relative to the 5th gear 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.

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





13. Remove 5th gear synchronizer hub snap ring. This will be easier if hub is tapped down first.
14. Use puller J25031A to remove 5th gear synchronizer hub.
15. Remove blocking ring, blocking ring spring, 5th gear, and 5th gear bearing assembly.





16. Remove differential bearing retainer and fasteners. Retainer will be removed after case removal.
17. Remove case-to-reverse idler gear shaft bracket bolt.
18. Remove case to clutch housing bolts and tap down two case to clutch housing alignment sleeves.





19. Check that 3rd gear is engaged. Install pulling eyes 87-92-129 to case. Install shaft protector 87-91-410 to output shaft. Install puller 87-91-287 with short arms 87-91-303 into pulling eyes and carefully pull case until output shaft bearing releases from output shaft.
20. Remove tools. Lift off transaxle case.
21. Remove differential bearing retainer from transaxle case.





22. Tap out differential bearing race using tools 87-92-202 and 87-91-204.





23. Remove reverse gear fork and shaft.





24. Put transaxle in 4th gear and remove reverse shift lever assembly.





25. Engage reverse gear on shift linkage assembly to access shift control shaft bolt.

NOTICE: Make sure TORTS socket fully engages the bolt prior to attempting removal.

26. Remove shift shaft bolt, remove shift shaft and shaft block.





27. Disengage reverse on shift linkage assembly. Remove remaining shift linkage bolt and lift mechanism slightly. Remove locating sleeves.
28. Put transaxle in 2nd gear and remove shift linkage assembly by moving it rearward (towards the differential) and angling it out while lifting.





29. Lift input shaft far enough to allow removal of reverse idler gear shaft assembly. Remove reverse idler gear shaft.





30. Remove 4th driven gear, crush sleeve, and spacer sleeve from output shaft.





31. Install output shaft assembly tool 87-92-103 around 1st and 2nd driven gears as shown. This tool holds the 1st and 2nd synchronizer assemblies together. Secure tool with plastic tie.





32. Install shaft protector 87-91-410 on output shaft. Install puller 87-91-287 with long arms 87-91-295 under 1st driven gear. Pull remaining output shaft gears up far enough to allow removal of input shaft (approximately 15 mm).
33. Remove input shaft.





NOTICE: Note up/down orientation of 3rd driven gear; if old gear is reinstalled, it must be reinstalled in same orientation to avoid noise concerns.

34. Continue pulling driven gears on output shaft until all gears are loose.
35. Remove puller and gears from output shaft.





NOTICE: The output shaft bearing retainer bolts were installed using a threadlocker at the factory. An impact driver J43483 (or equivalent) must be used to remove these bolts or bolt heads may strip out requiring additional repair time.

36. Remove output shaft bearing retainer bolts using impact driver J43483 (or equivalent) and remove retainer.





37. Remove output shaft using tools 87-91-188, 87-91-972, and 87-91-261.
38. Remove differential assembly.