Disassembly

DISASSEMBLY

1. Remove clutch release lever and bearing (Figure 1). Inspect release lever pivot balls and replace if necessary (Figure 2). Use slide hammer C-3752 and remover/installer 6891 (Figure 3) if pivot ball replacement is necessary.




Figure 1 Release Bearing and Lever










Figure 2 Pivot Ball Orientation


1 - PIVOT BALL (1)





Figure 3 Pivot Ball Removal/Installation






2. Remove input shaft bearing retainer (Figure 4).




Figure 4 Input Bearing Retainer


1 - INPUT BEARING RETAINER


NOTE: Place transaxle in neutral before shift cover removal. It may be necessary to remove selector lever from cover to gain access to and remove one fastener.

3. Remove shift cover-to-case bolts and remove shift cover assembly (Figure 5).




Figure 5 Shift Cover Removal/Installation


1 - SHIFT COVER ASSEMBLY

4. Using a suitable screwdriver, remove and discard extension housing axle oil seal (Figure 6).




Figure 6 Extension Housing Seal






5. Remove extension housing-to-case and differential cover bolts (Figure 7).




Figure 7 Extension Housing-to-Case Bolts


1 - EXTENSION HOUSING

6. Place transaxle with bellhousing surface down.
7. Remove backup lamp switch (Figure 8).




Figure 8 Back-Up Lamp Switch - Typical


1 - BACK-UP LAMP SWITCH

8. Remove end plate (Figure 9).




Figure 9 End Plate Bolts


1 - BOLT (11)

9. Set up lifting bar (tool 8489) as shown in (Figure 10).
10. Lift up on bar (input shaft bearing side) and remove input shaft bearing snap ring.
11. Lift up on bar (intermediate shaft side) and remove intermediate shaft bearing snap ring.




Figure 10 Input Bearing Snap Ring






12. Remove lifting bar 8489.
13. Remove end cover-to-case bolts (12) (Figure 11).




Figure 11 End Cover Bolts


1 - BOLT (12)

14. Remove end cover from transaxle (Figure 12).




Figure 12 End Cover Removal/Installation






15. Remove 3/4 shift rail bushing from end cover using slide hammer C-3752 and remover 6786 (Figure 13).




Figure 13 3/4 Shift Rail Bushing Removal






16. Remove intermediate shaft bearing snap ring (Figure 14).




Figure 14 Intermediate Shaft Bearing Snap Ring






17. Remove intermediate shaft bearing using Puller 1026 (Figure 15).




Figure 15 Intermediate Shaft Bearing Removal






18. Remove reverse idler outer washer (Figure 16).




Figure 16 Outer Washer Removal/Installation






19. Remove reverse idler gear (Figure 17).




Figure 17 Reverse Idler Gear Removal/Installation


1 - REVERSE IDLER GEAR

20. Remove reverse idler needle bearing (Figure 18).




Figure 18 Outer Pin and Needle Bearing






21. Remove inner washer and pin (Figure 19) (Figure 20).




Figure 19 Inner Washer Removal/Installation










Figure 20 Inner Pin Removal/Installation


1- PIN (2)

22. Remove reverse idler shaft (Figure 21).




Figure 21 Reverse Shaft Removal/Installation






23. Remove 1-2/5-R shift rail (Figure 22).




Figure 22 1/2-5/R Shift Rail Removal/Installation


1 - 1/2-5/R SHIFT RAIL

24. Install lifting bar 8489.
25. Lift geartrain (w/reverse idler gear assy.) out of transaxle and install on fixture 8487 (Figure 23).
26. Remove remaining shift rail and forks from geartrain (Figure 23).




Figure 23 Shift Fork/Rail Orientation






27. Remove lifting bar from geartrain.

NOTE: At this point, differential bearing turning torque should be measured to ensure proper shim selection upon reassembly.

28. Reinstall and torque extension housing and measure differential turning torque.
29. Remove impact blocker (if equipped) (Figure 24).




Figure 24 Impact Blocker (SRT-4 Models)






30. Remove differential cover bolts.
31. Remove differential cover. If necessary, use a soft tipped hammer to aid in removal.
32. Remove extension housing.
33. Remove differential assembly. Note orientation of shim, oil slinger, and differential side bearing races (Figure 25).




Figure 25 Differential Shim/Slinger Orientation






34. Remove differential chip collector magnet and clean (Figure 26). Magnet is adhered with RTV, and may require force to remove.




Figure 26 Differential Magnet


1 - MAGNET

35. Remove intermediate shaft bearing race with puller 8472 (Figure 27).




Figure 27 Intermediate Shaft Bearing Race Removal


1 - REMOVER 8472

36. Remove shift rail bushing from case with remover 6786 and slide hammer C-3752 (Figure 28).




Figure 28 Shift Rail Bushing Removal






37. Remove input shaft bearing using an arbor press and tool 8474 (Figure 29).




Figure 29 Input Shaft Bearing Removal