On-Vehicle Service
5TH GEAR AND 5TH GEAR SYNCHRONIZER ASSEMBLY- TOOLS REQUIRED
- J 25031-A Three Jaw Puller
REMOVAL
1. Place transaxle in 3rd gear.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
2. Raise vehicle. Drain transaxle lubricant 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.
- 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 is easier if hub is tapped down first.
7. Use Three Jaw Puller J 25031-A to remove 5th gear synchronizer hub.
8. Remove blocking ring, blocking ring spring, 5th gear, and 5th gear bearing assembly.
When a manual transaxle with a serial number before T02075 is repaired for a 5th gear synchronizer failure, it must be determined whether the synchronizer components are of the 1st design or the 2nd design.
The illustrations show the 1st (left half of illustration) and 2nd (right half of illustration) design of the 5th gear synchronizer components.
Note: All transaxles built prior to the T02075 serial number will be of the 1st design unless they have been previously repaired for this condition. All service parts are of the 2nd design.
9. If the 5th synchronizer sleeve removed from then transaxle looks like the sleeve on the left, then it is a 1st design. The identification mark for the 2nd design is the extra groove on the top of the 5th gear sleeve.
10. If the 5th gear blocking ring removed from the transaxle does not have a part number embossed on the bottom of the blocking ring, then it is a 1st design.
If either the 5th synchronizer sleeve or blocking ring is a 1st design and needs to be replaced, then both the sleeve and the blocking ring must be replaced with the 2nd design parts as a unit. If the blocking rings and sleeve have already been replaced with the 2nd design components, then only replace parts as needed.
INSTALLATION
IMPORTANT: Lubricate bearing assembly with manual transaxle lubricant (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:
Transaxle Drain Plug: 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 lubricant (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:
Transaxle Level Plug: 50 Nm (37 ft. lbs.)