In-Car Transaxle Disassemble/Assemble

IN-CAR TRANSAXLE DISASSEMBLE/ASSEMBLE

The following items can be serviced without removing the transaxle from the vehicle:
^ Gear shift housing
^ Synchronizers
^ Intermediate shaft speed gears
^ Input shaft
^ Reverse idler gear and shaft
^ Shift forks and pads
^ Shift rails
^ Roller detents
^ Speedometer pinion
^ All external covers Observe following procedure:

1. Disconnect negative cable from battery.
2. Remove both shift cables from shift cover levers.
3. Remove left front wheel and tire assembly and left splash shield.
4. Place drain pan under transaxle and remove transaxle rear end cover.
5. Push out the fifth fork roll pin and slide the fifth fork and synchronizer sleeve off the rail/hub.
6. Remove the fifth hub snap ring, hub assembly and speed gear.
7. Remove fifth gear nut and fifth input gear.
8. Remove the bearing retainer plate, interlock plate and shuttles.

CAUTION: Before removing the gearshift housing assembly, reverse the lock pin (so the long end is down) and insert lock pin into the same threaded hole. This procedure will save time when the gear shift housing assembly is reinstalled.

9. Remove selector shaft housing bolts (note the two pilot bolts) and remove housing.
10. Remove roller detents and springs, noting that the rollers align with the shift rails.
11. Push out the 1-2 and 3-4 lug roll pins, remove the reverse pivot lever and fifth rail C-Clip. If a roll pin or C-Clip falls, be sure to remove it from the bottom of the case.
12. Pull out the fifth shift rail and remove the fifth shift lug and interlock pin.If the pin falls, be sure to remove it from the bottom of the case.
13. Remove the intermediate shaft ball bearing snap ring and the bearing support plate.
14. Remove reverse shift rail and lug assembly.
15. Remove the reverse idler shaft and gear assembly.
16. Rotate the 1-2 shift lug and rail, and 3-4 shift lug towards the front of the vehicle.
17. Firmly grasp both the input and intermediate shaft assemblies and pull them out of the transmission with the 1-2 and 3-4 shift rails, lugs and forks.

The differential assembly can only be serviced by removing the complete transaxle from the vehicle because bearing preload must be reset.

To reassemble the transaxle in the vehicle, reverse the above procedure using the proper sealants. Fill the transaxle with SAE 5W-30 engine oil to the bottom of the fill hole in the end cover.