Transaxle Disassembly

1. Remove clutch fork and bearing assembly.





2. Remove shift housing bolts, shift housing and discard gasket.
3. Remove vehicle speed sensor.





4. Remove rear cover bolts, rear cover and discard gasket.





5. Move two shift forks to lock the transaxle in two gears.
6. Remove input shaft nut and discard.

IMPORTANT: To hold transaxle in place while removing nuts, drill two holes in bench top to align with the two top of transaxle to engine mounting holes and put bolts through the transaxle into the holes.

7. Remove output shaft nut and discard.
8. Remove reverse cone, thrust washer, and reverse blocker assembly.
9. Remove 5th/Reverse fork retainer clip and discard.
10. Remove 5th/Reverse shift fork, 5th/Reverse synchronizer sleeve, 5th/Reverse hub, blocker assembly, and 5th drive gear.
11. Remove 5th gear bearing assembly.
12. Remove 5th/Reverse synchronizer.





IMPORTANT: Synchronizer hub and sleeve must be kept together as a matched set. (3/4 synchronizer shown, 5th/Reverse synchronizer similar.) If alignment marks are not visible, put new marks on hub and sleeve before they are separated.

IMPORTANT: The 5th/Reverse hub is press fit on the input shaft:
a. Install shaft protector, SA921 1T-3 on the end of the input shaft with the counter bore in the shaft protector going over the input shaft.
b. Install the 5th driven gear remover, SA9211T-2 on the input shaft. Engage the legs of the puller under the clutching teeth ring on the 5th drive gear and center the forcing screw on the shaft protector.
c. Tighten the forcing screw to remove the 5th drive gear along with the 5th/Reverse hub.

13. Remove 5th driven gear.

IMPORTANT: The 5th driven gear is press fit on the input shaft:
a. Install shaft protector, SA9211T-3 on the end of the output shaft with the counter bore in the shaft protector going over the output shaft.
b. Install the 5th driven gear remover, SA9211T-2 on the output shaft. Engage the legs of the puller under the 5th driven gear and center the forcing screw on the shaft protector.

IMPORTANT: It may be necessary to release the bearing snap-ring and pull the shaft out to provide access for the puller under the 5th driven gear.

c. Tighten the forcing screw on the puller to remove the 5th driven gear.





14. Remove case-to-clutch housing bolts.
15. Use snap ring pliers to open output and input shaft bearing snap rings to allow the bearing snapping grooves to drop below the snap rings. Use pry slots to separate case and clutch housing, and remove case.
16. Remove the snap ring retaining the left axle seal and remove the left axle seal from the case using SA9133T.
17. Remove differential selective snap ring from case.





18. Remove oil trough.





19. Remove 5th/Reverse actuator retainer and discard.
20. Remove shift fork shaft.





21. Remove 1/2, 3/4 forks and 5th/Reverse actuator.





22. Remove reverse shift lever bolts, and remove reverse idler gear shift lever assembly.
23. Remove reverse idler gear shaft.





24. Lift input and output shafts out of the clutch housing together.

IMPORTANT: Lift shafts out carefully to prevent damage to output shaft machined surface.





25. Lift differential out of clutch housing.
26. Remove transaxle magnet.