Disassembly

Transaxle

Special Tool(s):

Disassembly
1. Clean the transaxle exterior with solvent before disassembly.
2. Clean all removed parts and all sealing surfaces with solvent, and dry with compressed air.
3. Clean out all holes and passages with compressed air and verify that there are no obstructions.
4. Mount the transaxle to the special tool.





5. Remove the drain plug and drain the transaxle.
6. Remove the clutch release fork and bearing.
1 Remove the boot.
2 Remove the clutch release fork and bearing.





7. Remove the anchor bolt.





8. Remove the bolt and the vehicle speed sensor (VSS).





9. Rotate the transaxle 180 degrees.
10. Remove the reversing lamp switch.





11. Shift the transaxle into the NEUTRAL position.
12. Remove the 9 case cover bolts and the case cover.





13. NOTE: Do not reuse locknuts.

Remove the input and output shaft locknuts.
1 Using the special tool, keep the input shaft from turning.
2 Using a punch, release the locking tabs from the shafts. Remove and discard the input and output shaft locknuts.





14. Remove and discard the reverse/5th shift fork roll pin.





15. Remove the reverse/5th shift fork and synchronizer hub assembly.





16. Remove the synchronizer blocking ring.





17. Remove the 5th speed cluster gear.





18. Remove the 5th gear bushing.





19. Remove the 5th speed gear.





20. Remove the reverse idler shaft lock bolt and shift rail guide bolt.





21. Remove the bolt, spring and ball.





22. Remove the 15 transaxle case bolts and separate the transaxle case.
^ After separating the transaxle cases, position the removed case on its side.

23. Remove the funnel bolt and the funnel.





24. Remove the magnet.





25. Remove the reverse idler gear and the reverse idler gear shaft.





26. Remove the shift gate bolt.





27. Remove the shift control shaft and shift gate.
1 Remove the shift control shaft.
2 Remove the shift gate.





28. Remove the shift lever shaft roll pin, then remove the shift lever shaft and shift fork selector lever.
^ Use a screwdriver to aid removal.





29. Move the shift forks upward into 2nd and 4th gears.





30. Remove the gear shifter fork and main shift control shaft assembly.
^ Lift the rail out of the rail pocket.





31. Remove the shift detent and spring.





32. Remove the shift lever roll pin.





33. Remove the reverse shift lever shaft and the reverse lever.





34. Remove the output and input shafts as an assembly.





35. Remove the differential.





36. For further disassembly of the transaxle case, refer to Transaxle Case.