Overhaul (Disassembly)

Special Tool(s)

Disassembly

1. WARNING: Wear protective eyewear whenever using compressed air.

Clean the transaxle exterior with solvent, then dry with compressed air.

2. WARNING: Wear protective eyewear whenever using compressed air.

Clean all parts removed with solvent, and dry with compressed air.





3. Remove and discard the clutch slave cylinder.





4. Install the special tool.





5. NOTE: Position the selector in the neutral position.

Remove the gearshift mechanism.





6. Remove the Vehicle Speed Sensor (VSS).





7. NOTE: Rotate the transaxle with the input shaft pointing upward.

Remove the 16 transaxle housing bolts.





8. CAUTION: Take care not to damage the transaxle housing.

Carefully pry the transaxle housing from the transaxle main case.





9. Remove the transaxle housing.





10. Remove the differential.





11. Remove and clean the magnetic disc.





12. Remove the shift rails and the first and second gear shift fork.





13. Remove the shift forks.
1. Move the fifth and reverse gear selector fork to the side.
2. Rotate the third and fourth gear selector fork and remove.
^ Remove the fifth and reverse gear selector fork.





14. Remove the input and the output shaft.
^ Lift out the input and the output shaft from transaxle housing together.





15. Remove the reverse idler gear bolts, then remove the reverse idler gear retainer.
^ Lift out the idler gear.





16. Remove the following:
1. Upper thrust washers.
2. Reverse idler gear.
3. Reverse idler gear bearing.
4. Lower thrust washer.








17. Remove and discard the halfshaft oil seals.





18. NOTE: Use a heat gun on the case bearing cup area to aid removal.

Using the special tools, remove the differential bearing race from the case (clutch side).





19. NOTE: Use a heat gun on the case bearing cup area to aid removal.

Using the special tools, remove the output shaft bearing race (clutch side).





20. NOTE: Use a heat gun on the case bearing cup area to aid removal.

Using the special tools, remove the input shaft bearing race (clutch side).





21. Remove the shims.





22. NOTE: Use a heat gun on the case bearing area to aid removal.

Using the special tools, remove the input shaft bearing race from the case (transmission side).





23. NOTE: Use a heat gun on the case bearing area to aid removal.

Using the special tools, remove the output shaft bearing race from the case (transmission side).





24. NOTE: Use a heat gun on the case bearing area to aid removal.





Using the special tools, remove the differential bearing race from the case (transmission side).





25. NOTE: Only remove the reverse gear idler shaft if there is evidence of damage or leaks.

Remove the reverse gear idler shaft cover.





26. NOTE: Only remove the reverse gear idler shaft if there is evidence of damage or leaks.

Using a wooden drift, remove the reverse gear idler shaft.