Overhaul (Major Component)

Major Component Disassembly Disassembly

Tools Required:
J-6125-B Slide Hammer
J-22888-20-A Bearing Puller with J-22888-35 Puller Legs
KM-553-A Fifth Gear Puller
J-36633 Snap Ring Retainer
KM-113-2 Base
J-42469 Shift Rod Remover
KM-552 Fixture

Disassembly
1. Remove the transaxle from the vehicle.





2. Remove the filler plug at the cover.





3. Remove the bolts from the gearshift lever cover.





4. Remove the gearshift lever cover.
5. Bolt the gearshift lever cover to the fixture KM-552.





6. Position the fixture KM-552 into the base KM-113-2.





7. Remove the snap ring, the bushing, the spring, and the intermediate lever.





8. Remove the shift finger lever pin.





9. Remove the gearshift rod and the shift finger lever.





10. Remove the bolt and the speedometer-driven gear from the transaxle housing.





11. Remove the transaxle cover bolts.





12. Remove the transaxle cover.
13. Shift the transaxle into second gear.





14. Remove the bearing plate bolts.





15. Remove the bearing plate from the case with the shafts attached.
16. Shift the transaxle into reverse (R).





17. Bolt the bearing plate to the fixture KM-552 and install the fixture KM-552 into the base KM-113-2.





18. Remove the bolts and the fifth-gear fork from the bearing plate.





19. Remove the mainshaft-driven fifth-speed assembly snap ring.





20. Remove the fifth driven gear synchronizer sleeve and the synchronizer gear using the bearing puller J-22888-20 A with the puller legs J-22888-35.





21. Remove the mainshaft-driven fifth-gear assembly.





22. Remove the brass synchronizer ring.





23. Remove the needle bearing, the retaining ring, and the thrust washers.





24. Remove the input drive fifth-gear snap ring.





25. Remove the input drive fifth gear using the fifth-gear puller KM-553-A.





26. Remove the bolts and the fifth-gearshift connector from the bearing plate using the pawl.





27. Remove the four shift-rod plugs using the shift rod remover J-42469 and the slide hammer J-6125-B.





28. Remove the spring and the rod lock pin from the small plug hole.





29. Remove the pin from the reverse gearshift rod/fork assembly.





30. Remove the reverse gearshift rod/fork assembly from the bearing plate.





31. Remove the bolts from the support bracket.





32. Remove the first-second gearshift fork holding pin.





33. Drive the first-second gearshift rod out until it is just free of the bearing plate.





34. Remove the support bracket from the bearing plate.





35. Remove the third-fourth gearshift fork holding pin and the third-fourth gearshift rod.





36. Remove the fifth gearshift lever from the bearing plate.





37. Remove the first-second gearshift rod.





38. Compress the snap ring holding the mainshaft and secure it with the snap ring retainer J-36633.
39. Hold the snap ring open at the base of the input shaft using the snap ring pliers.





40. Remove the mainshaft assembly and the input shaft assembly from the bearing plate.