Disassembly

TOOLS REQUIRED
- SA9118T Quill Bearing Replacer
- SA9120T Differential Bearing Installer
- SA9128T Quill Bearing Remover
- SA9129T Support Fixture
- SA9133T Axle Seal Puller
- SA9173G Slide Hammer
- SA9191T M/T Case Output Shaft Bearing Puller
- SA9211T-25th Gear Remover
- SA9211 T-3 Shaft Protector

TRANSAXLE DISASSEMBLE





1. Remove clutch fork and bearing assembly.





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





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





5. Move two shift forks to lock the transaxle in two gears.

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.

6. Remove input shaft nut and retain for clearance measurements.
7. Remove output shaft nut and retain for clearance measurements.
8. Remove reverse cone, thrust washer, and reverse blocker ring.
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 (indicated by the arrow) are not visible, put new marks on hub and sleeve before they are separated.

IMPORTANT: If the 5th/Reverse hub is press fit on the input shaft:





12.1 Install Shaft Protector SA9211T-3 on the end of the input shaft with the counter bore in the shaft protector going over the input shaft.
12.2 Install the 5th 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.
12.3 Tighten the forcing screw to remove the 5th drive gear along with the 5th/Reverse hub.
13. Remove 5th driven gear.

IMPORTANT: If the 5th driven gear is press fit on the input shaft:

13.1 Install Shaft Protector, SA921IT-3 on the end of the output shaft with the counter bore in the shaft protector going over the output shaft.
13.2 Install the 5th Gear Remover, SA921IT-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.

13.3 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 snap ring grooves to drop below the snap rings. Use pry slots to separate case and clutch housing, and remove case.
16. Remove the left axle seal retainer (snap ring) and remove the left axle seal from the case using Axle Seal Puller SA9133T.
17. Remove differential selective snap ring from case.





18. Remove oil trough.





19. Remove 5th/Reverse actuator retainer clip 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.

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





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





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