5th Gear and 5th Gear Synchronizer Assembly Replacement

5th Gear and 5th Gear Synchronizer Assembly Replacement

Tools Required

J 25031-A Three Jaw Puller

Removal Procedure





1. Place the transaxle in 3rd gear.
2. Raise the vehicle. Refer to Vehicle Lifting.
3. Drain the transaxle lubricant by removing the transaxle drain plug (1).
4. Remove the rear cover.





5. Using a punch and hammer, tap out the 5th gear fork retaining pin and discard.

Important: Before removing the 5th gear shift fork and synchronizer sleeve, mark the position of the sleeve relative to the synchronizer hub to assist in reassembly.

Important: Make sure the 5th gear shift shaft does not come out of the transaxle when the 5th gear shift fork is removed.

6. Remove the 5th gear fork and synchronizer sleeve together.





7. Remove the 5th gear synchronizer hub snap ring and discard. This is easier if the hub is tapped down first.
8. Use the J 25031-A to remove the 5th gear synchronizer hub.
9. Remove the blocking ring, blocking ring spring, 5th gear, and 5th gear bearing assembly.

Installation Procedure





Important: Lubricate the bearing assembly with manual transaxle lubricant P/N 21018899 during assembly.

1. Install the 5th drive gear bearing assembly and the 5th drive gear.
2. Install the blocking ring and blocking ring spring on the 5th gear.

Important: Gaps in the synchronizer hub must align with the blocking ring lugs.

3. Carefully tap the synchronizer hub onto the input shaft using a mallet and large socket.
4. Install a new 5th gear synchronizer hub snap ring.





Important: The 5th gear synchronizer sleeve can only be placed on the hub when tall teeth on the sleeve are aligned with deep teeth on the hub.

5. Install the 5th gear fork and synchronizer sleeve together. Reference the sleeve alignment mark made during disassembly.
6. Install a new 5th gear fork retaining pin.
7. Install the rear cover.
8. Fill the transmission to proper level.