Subassembly-Recondition

SUBASSEMBLY-RECONDITION
Follow the images below to overhaul the transmission.

Remove Input Shaft Front Bearing Cup:

Install Input Shaft Front Bearing Cup:

Remove Or Install Bearing Retainer Strap:

Remove Intermediate Shaft Front Bearing:

Oil Feeder:

Use Tool C-4660-2A Screw. The screw has a larger hole in the lower end to fit over the larger oil feeder nipple.

Install Intermediate Shaft Front Bearing:

TRANSAXLE CASE

Intermediate Shaft Bearing Snap Ring:

Remove Intermediate Shaft Rear Bearing:

Install Intermediate Shaft Rear Bearing:

Synchronizer Hub Snap Ring:

Remove 3-4 Synchronizer Hub And 3rd Speed Gear:

Install 3-4 Synchronizer Hug And 3rd Speed Gear:

INTERMEDIATE SHAFT ASSEMBLY

Intermediate shaft ball bearing seal color: A-525/A-523/A-543 Black, A-568 Blue.

2nd Speed Gear:

Synchronizer Hub Snap Ring:

1-2 SYNCHRONIZER (DUAL-CONE)

1st Speed Gear And 1-2 Synchronizer Assembly:

Split Thrust Washer:

Intermediate Shaft Assembly:

1-2 And 3-4 Synchronizer Sleeves And Hubs:

5th Speed Synchronizer:

Synchronizer Identification:

Synchronizers:

CAUTION: 1-2 synchronizer assembly components must NOT be interchanged with any other synchronizer assembly, or with previous model years transaxles; they will NOT function correctly.

GEARSHIFT HOUSING

Gearshift Housing Disassembled:

Remove Or Install Roll Pin And Lever:

Roll pin must be flush with top of lever.

Dust Boot:

Remove Oil Seal:

The C-clip grooves in the selector shaft will damage the oil seal. Install oil seal after selector shaft is installed. Always use a new oil seal when selector shaft is removed.

Install Oil Seal:

Remove Vent Cap:

Crossover Shaft Roll Pin:

5-R Blocker Attaching Bolts:

Blocker Attaching Bolts:

Proper torque to the 5-R blocker attaching bolts is very important.

Crossover Shaft:

Selector Shaft C-Clip:

Selector Assembly Roll Pin:

For Disassembly: Drive roll pin out far enough to clear the selector shaft, but not through. The pin must remain in the selector so not to break the housing.

Remove Or Install Selector Shaft:

Disassembled View:

Remove Differential Bearing Retainer Seal:

Install Differential Bearing Retainer Seal:

Remove Differential Bearing Retainer Cup:

Differential Bearing Retainer:

Install Oil Baffle:

Insert (Select) Shim And Differential Bearing Retainer Cup:

Remove Extension Seal:

Install New Seal Into Extension:

Remove Extension Bearing Cup:

Extension:

Install Extension Oil Baffle:

Install Extension Bearing Cup:

INPUT SHAFT

Shim thickness need only be determined if any of the following parts are replaced:
^ Transaxle case
^ Input shaft seal retainer
^ Bearing retainer plate
^ Rear end cover
^ Input shaft
^ Input shaft bearings

Refer to Differential/Service and Repair, for Bearing Adjustment Procedure to determine proper shim thickness for correct bearing end play and proper turning torque.

Remove Input Shaft Rear Bearing Cone:

Install Input Shaft Rear Bearing Cone:

Remove Input Shaft Front Bearing Cone:

Install Input Shaft Front Bearing Cone:

Remove Input Shaft Rear Bearing Cup:

Install Input Shaft Rear Bearing Cup:

CAUTION: Bolt on bearing support plate before installing input shaft rear bearing cup.