Operation CHARM: Car repair manuals for everyone.

Disassemble






1. Remove clutch fork and bearing assembly.

2. Remove shift housing, vehicle speed sensor, then the rear cover. Discard gaskets.

3. Move two shift forks to lock transaxle in two gears.

4. Remove and discard input and output shaft nuts.

5. Remove reverse cone, thrust washer and reverse blocker assembly.

6. Remove fifth/reverse fork retainer and discard. There may be two retaining rings or a one piece retainer.

7. Remove fifth/reverse shift fork.

8. Remove fifth/reverse synchronizer sleeve, hub, blocker assembly, and fifth gear. Synchronizer hub and sleeve must be kept together as a matched set. The fifth/reverse hub may be a press fit on input shaft.

9. Remove fifth driven gear. If a puller is necessary, release bearing snap ring and lift shaft to provide clearance for puller.

10. Remove case to clutch housing bolts.

11. Remove case as follows:

a. Use suitable snap ring pliers to open output and input shaft bearing snap rings.

b. Use pry slots to separate case and clutch housing, then remove case and, if necessary, case gasket.

12. Remove snap ring retaining left axle seal, then remove seal from case.






13. Remove fifth/reverse actuator retainer, then the shift fork shaft. Discard retainer.

14. Remove 1-2 and 3-4 forks and fifth/reverse actuator, then the flow tube.






15. Remove reverse shift lever bolts, then the reverse idler gear shift lever assembly.

16. Remove reverse idler thrust washer, reverse idler gear, then the reverse idler gear shaft.

17. Lift and remove input and output shafts from clutch housing.

18. Remove differential and transaxle magnet.