Transaxle Disassembly

1. Remove back-up light switch. Cover holes for clutch hydraulics, drive axles and back-up light switch. Clean outside of transaxle. Mount transaxle on stand.
2. Disconnect fluid supply line from slave cylinder. Using pliers, squeeze bottom halves of supply line sleeve. See Fig 1 . Move supply line and sleeve upward. Pry locking tabs on sleeve upward and remove supply line. Remove slave cylinder mounting bolts and slave cylinder. Remove reverse gear shaft bolt with "O" ring. Remove rear cover mounting bolts and rear cover.
CAUTION: DO NOT shift gears using individual shift shafts. All shifting should be done using shift control shaft.
3. Engage transaxle into 3rd gear by pulling straight out on shift control shaft. Note location of shift shafts to verify transaxle is in 3rd gear. See Fig 2 . Using hammer and punch, tap out 5th gear fork retaining pin. See Figure . Engage transaxle into 5th gear by pressing synchronizer sleeve and fork down onto 5th gear. The 2 gears must be engaged at same time to allow removal of output shaft nut. Pry up on output shaft nut locking tab. Remove output shaft nut.
4. To assist in reassembly, reference mark position of synchronizer sleeve relative to 5th gear synchronizer hub. Remove 5th gear selector fork with 5th gear synchronizer sleeve, ensuring 5th gear shift shaft does not come out of transaxle. Gently tap down on 5th gear synchronizer hub. Remove 5th gear synchronizer hub snap ring. Using Puller (J-25031A), remove 5th gear synchronizer hub. Remove 5th gear synchronizer blocking ring and spring. Remove 5th gear and 5th gear needle bearing.
5. Remove differential bearing retainer fasteners. Remove reverse gear shaft support bolt. See Fig 3 . Remove transaxle case-to-clutch case bolts and tap down guide sleeves. Ensure 3rd gear is engaged. Install Pulling Eyes (87-92-129) onto transaxle case. See Fig 4 . Install Shaft Protector (87-91-410) onto output shaft. Install Puller (87-91-287) with Short Arms (87-91-303) into pulling eyes. Carefully pull case until output shaft bearing releases from output shaft. Remove puller, short arms and pulling eyes. Lift off transaxle case. Remove differential bearing retainer from transaxle case.
6. Tap out differential bearing race using Output Shaft Bearing Race Sleeve (87-92-202) and Handle (87-91-204). Remove reverse gear fork and shaft. Engage transaxle into 4th gear. Remove 2 reverse shift lever assembly bolts and reverse shift lever assembly. Engage reverse gear on shift linkage assembly to access shift control shaft bolt. See Fig 5 . Remove shift shaft bolt, shift shaft and shift shaft block.
7. Disengage reverse gear on shift linkage assembly. Remove remaining gear change mechanism retaining bolt and lift mechanism slightly. See Fig 6 . Remove locating sleeves. Engage transaxle into 2nd gear. Remove gear change mechanism by moving it rearward, toward differential and angling it out while lifting. Lift up input shaft and remove reverse gear shaft assembly.
8. Remove 4th driven gear, crush sleeve and spacer sleeve from output shaft. Install Assembly Fixture (87-92-103) around 1st and 2nd driven gears. See Fig 7 . Fit retaining strap around assembly fixture. Install Shaft Protector (87-91-410) onto output shaft. Install Puller (87-91-287) with Long Arms (87-91-295) under 1st driven gear. Pull up on output shaft driven gears approximately .591" (15 mm) to allow for input shaft removal. Remove input shaft. Continue pulling until driven gears on output shaft come loose. Remove driven gears, puller and assembly fixture. Reference mark orientation of driven gears for reassembly.
9. Using impact driver, remove output shaft bearing support bolts, using care so as not to strip out bolt heads. Remove output shaft bearing support. Using Support (87-91-188), Input/Output Shaft Driver (87-91-428) and Output Shaft Remover/Installer (87-91-261), remove output shaft. Remove differential assembly.