Transaxle Disassembly
NOTE:
During disassembly, all gaskets must be removed and discarded. Thoroughly clean all traces of gasket material from mating surfaces of transaxle case.
- Mount transaxle in holding fixture. Remove drain plug and drain any remaining transaxle fluid. Position transaxle with rear cover facing upward. Remove rear cover bolts. Loosen rear cover gasket seal with a plastic mallet and remove rear cover. See Fig 1 .
- Shift to 1st gear. Use Input Shaft Holder (T88C-7025-GH) to hold input shaft. Uncrimp tabs and remove output shaft lock nut, input shaft lock nut and sleeve. Remove input shaft holder.
- Using punch, remove and discard shift fork roll pin. Remove input reverse synchronizer gear and output shaft reverse synchronizer gear. Remove shift fork, synchronizer ring and synchronizer hub. Remove synchronizer ring and input 5th gear.
- Remove gear sleeve. Remove output shaft 5th gear. Remove lock bolts, washers, guide bolt, springs and balls. See Fig 1 . Remove back-up light switch and park/neutral position switch. Remove transaxle case bolts and transaxle case-to-clutch housing retainer. Tap transaxle case lightly with a plastic hammer to loosen gasket seal and remove case.
- Remove magnet from case. Remove reverse idler shaft and gear. Remove lock bolt from 5th gear shift rod gate. Remove 5th-reverse shift rod. Remove 5th-reverse shift gate. Remove shift lever shaft roll pin. Carefully pry shift lever shaft from case. Remove shift fork selector lever from shaft.
- Remove case vent. Remove 3rd-4th shift fork, main shift control shaft along with input shaft and output shaft assemblies. Remove differential assembly. Remove control selector plate and reverse idler gear spacer. Remove input shift shaft selector plate arm.NOTE: Remove case components as necessary for repair. Label bearing races and shims for reassembly reference.
- Align selector arm roll pin with groove in clutch housing case. Remove and discard roll pin. Remove input shift shaft, boot and selector arm from case. Remove vehicle speed sensor. Remove oil passage bolt and oil passage from case.
- Remove output shaft bearing race and funnel by pulling up on funnel. Remove reverse lever shaft plug and reverse lever shaft assembly from case. Using bearing race puller and slide hammer, remove input shaft and output shaft bearing races and shims from both cases. Remove input shaft oil seal.
- Using Collet (D80L-100-Q), actuator pin and slide hammer, remove input shift shaft oil seal. Using bearing race puller and slide hammer, remove differential oil seals. Using bearing remover, puller and slide hammer, remove differential bearing races from both cases. Remove adjustment shim(s).