Disassembly
TRANSAXLE DISASSEMBLY- TOOLS REQUIRED
- 87-91-188 Screw Press Support
- 87-91-204 Output Shaft Bearing Race Sleeve
- 87-91-261 Output Shaft Remover
- 87-91 -287 Puller
- 87-91-295 Puller Arms, 300mm
- 87-91-303 Puller Arms, 150 mm
- 87-91-410 Output Shaft Protector
- 87-91-972 Assembly Ring
- 87-92-103 Output Shaft Assembly Tool
- 87-92-129 Lifting Eyes
- 87-92-202 Output Shaft Bearing Race Sleeve
- J25031-A Three Jaw Puller
- J43483 Impact Driver
- J43707 Transmission Support Fixture
- J43964 Engine Stand Fixture Adapter
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 Transmission Support Fixture J43707. Mount transaxle and fixture in Engine Stand Fixture Adapter J43964.
4. Remove pipe from slave cylinder.
5. Using pliers, pinch together the bottom halves of the pipe sleeve and move the pipe and sleeve upward.
6. Pry up the locking tabs on sleeve and remove pipe.
7. Remove the slave cylinder bolts, slave cylinder, and the reverse idler gear shaft bolt with an O-ring.
8. 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.
9. Put transaxle into 3rd gear by pulling the shift control shaft out. Other gears can be selected as follows:
Even gears = push shaft in
Odd gears = pull shaft out
1st/2nd shift gate = turn shaft counter-clockwise
5th and reverse gears = turn shaft clockwise.
10. Using a punch and hammer, tap out the 5th gear fork retaining pin.
11. 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.
12. 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.
^ Make sure 5th gear shift shaft does not come out of the transaxle when 5th gear shift fork is removed.
13. Remove 5th gear shift fork and synchronizer sleeve together.
14. Remove 5th gear synchronizer hub snap ring. This will be easier if hub is tapped down first.
15. Use Three Jaw Puller J25031-A to remove 5th gear synchronizer hub.
16. 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.
17. If the 5th synchronizer sleeve removed from the 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.
18. 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.
19. Remove differential bearing retainer fasteners. Retainer will be removed after case removal.
20. Remove case-to-reverse idler gear shaft bracket bolt.
21. Remove case-to-clutch housing bolts and tap down two case-to-clutch housing alignment sleeves.
22. Check that 3rd gear is engaged. Install Lifting Eyes 87-92-129 to case. Install Output Shaft Protector 87-91-410 to output shaft. Install Puller 87-91-287 with Puller Arms, 150 mm 87-91-303 into pulling eyes and carefully pull case until output shaft bearing releases from output shaft.
23. Remove tools. Lift off transaxle case.
24. Remove differential bearing retainer from transaxle case.
25. Tap out differential bearing race using Output Shaft Bearing Race Sleeve 87-92-202 and Output Shaft Bearing Race Sleeve 87-91-204.
26. Remove reverse gear fork and shaft.
27. Put transaxle in 4th gear and remove reverse shift lever assembly.
28. Engage reverse gear on shift linkage assembly to access shift control shaft bolt.
NOTICE: Make sure Torx(r) socket fully engages the bolt prior to attempting removal.
IMPORTANT: Note orientation of the shift shaft block.
29. Remove shift shaft bolt, remove shift shaft and shaft block.
30. Disengage reverse on shift linkage assembly. Remove remaining shift linkage bolt and lift mechanism slightly. Remove locating sleeves.
31. Put transaxle in 2nd gear and remove shift linkage assembly by moving it rearward (towards the differential) and angling it out while lifting.
32. Lift input shaft far enough to allow removal of reverse idler gear shaft assembly. Remove reverse idler gear shaft.
33. Remove 4th driven gear, crush sleeve, and spacer sleeve from output shaft.
34. Install Output Shaft Assembly Tool 87-92-103 around 1st gear and 1st/2nd gear synchronizer sleeve as shown. This tool holds the 1st and 2nd synchronizer assemblies together. Secure tool with plastic tie.
35. Install Output Shaft Protector 87-91-410 on output shaft. Install Puller 87-91-287 with Puller Arms, 300mm 87-91-295 under 1st driven gear. Pull remaining output shaft gears up far enough to allow removal of input shaft (approximately 15 mm).
36. 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.
37. Continue pulling driven gears on output shaft until all gears are loose.
38. Remove puller and gears from output shaft.
NOTICE: The output shaft bearing retainer bolts were installed using a thread locker 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.
39. Remove output shaft bearing retainer bolts using impact driver J43483 (or equivalent) and remove retainer.
40. Remove output shaft using Screw Press Support 87-91-188, Assembly Ring 87-91-972, and Output Shaft Remover 87-91-261.
41. Remove differential assembly.