Part 1 of 2
CASE DISASSEMBLY
1. Place transaxle on bench.
2. Remove transaxle case half bolts.
3. Place two screwdrivers in the slots of case halves near the dowels. Separate the case halves.
4. Remove bellhousing half.
5. Remove output shaft roller bearing from output shaft.
6. Remove differential assembly.
7. Remove reverse idler shaft bolt. Remove reverse idler gear.
8. Remove two screws retaining reverse fork bracket. Remove reverse fork bracket and reverse cam blockout assembly.
9. Use snap ring pliers to remove selector shaft spacer.
10. Push the selector shaft shift pin out of the slot in the blocker assembly and turn selector shaft up and out of the way.
11. Remove transaxle end cover.
12. Remove two snap rings retaining the output shaft and the input shaft to the bearing.
13. Using pallet fixture and shims provided (Miller tool #6785-1, 6785-2, 6785-3), turn transaxle over and install transaxle onto pallet fixture. Verify shim spacers are in position on pallet fixture. Install transaxle into shop press.
14. lnstall base plate holding fixture (Miller tool #6768) onto transaxle end bearings.
CAUTION: The oil feed trough in the input shaft can be damaged while pressing on the shaft.
15. lnstall transaxle gear case into shop press. Press output and input shaft assemblies out of case.
16. Remove transaxle from press.
17. Remove blocker assembly from gear case.
18. Remove input and output shaft assemblies from gear case. The fork and rail assemblies will come out of case with the geartrain.
CAUTION: The output shaft assembly is serviced as an assembly. Do not try to repair any component on the output shaft. If the 1-2 synchronizer or gear fails, it Is necessary to replace the complete output shaft assembly.
19. Remove reverse brake assembly from gear case.
INPUT SHAFT DISASSEMBLY
The input shaft incorporates the 3rd, 4th, and 5th speed gears and synchronizers on the assembly.
1. Install bearing splitter behind 5th speed gear. Remove snap ring at 5th synchronizer hub on input shaft.
2. Remove synchronizer and gear using shop press.
3. Remove caged needle bearing.
4. Remove 4-5 gears split thrust washer ring.
5. Remove split thrust washer.
8. Remove split thrust washer separation pin.
7. Remove 4th gear.
8. Remove 4th gear caged needle bearing. Check the caged needle bearing for a broken retention spring.
9. Remove blocking ring. Remove 3-4 synchronizer hub retaining snap ring.
1O. Install input shaft in shop press. Use bearing splitter to remove 3-4 synchronizer and 3rd gear.
11. Remove 3rd gear caged needle bearing. Check the caged needle bearing for a broken retention spring.
12. Inspect the input shaft for worn or damaged bearing races or chipped gear teeth. Replace as necessary.
OUTPUT GEAR DISASSEMBLY
The output shaft incorporates the 1st and 2nd gears and synchronizers on the assembly.
CAUTION: The output shaft assembly is serviced as an assembly. Do not try to repair any component on the output shaft. If the 1-2 synchronizer or gear fails, it is necessary to replace the complete output shaft assembly.
TRANSAXLE CLEANING AND CHECK
- Clean the gears, bearings, shafts, synchronizers, thrust washers, oil feeder, shifter mechanism, gear case, and bellhousing with solvent.
- Dry all parts except the bearings with compressed air. Either allow the bearings to dry in air or wipe them dry with clean shop towels.
- Inspect the gears, bearings, shafts and thrust washers.
- Replace the bearings and cups if the rollers are worn, chipped cracked, flat spotted, or brinnelled or if the bearing cage is damaged or distorted.
- Replace the thrust washers if cracked, chipped, or worn. Replace the gears if the teeth are chipped, cracked, or wore thin.
- Inspect the synchronizers Replace the sleeve if worn or damaged in any way. Replace the stop rings if the friction material is burned, flaking off or worn.
- Check the condition of the synchro. keys and springs Replace these parts if worn, cracked, or distorted.
DIFFERENTIAL OVERHAUL
NOTE: Shim thickness need only be determined if any of the following parts are replaced:
- Transaxle gear case
- Clutch bellhousing case
- Differential case
- Differential bearing
Refer to Bearing Adjustment Procedure to determine proper shim thickness. This will provide correct bearing preload and proper bearing turning torque.
CAUTION: Always install new ring gear bolts. Tighten ring gear bolts to 81 Nm (60 ft.lbs.).
Assemble the differential side gears and pinion gears with the pinion gear washers. Rotate the assembly two full revolutions both clockwise and counterclockwise.
Set up dial indicator as shown and record end play. Rotate side gear 90 degrees and record another end play. Again, rotate side gear 90 degrees and record a final end play. Using the smallest end play recorded, shim that side gear to within 0.25 mm (0.0098 in) to 0.33 mm (0.0130 in). The other side gear should be checked using the same procedure.
CAUTION: Side gear end play must be within 0.25 mm (0.0098 in) to 0.33mm (0.0130 in). Four select thrust washers are available: 0.81 mm (0.0319 in), 0.94 mm (0.0370 In), 1.07 mm (0.0421 in) and 1.19 mm (0.0469 in).