Transaxle Disassemble

Tools Required
• SA9118T Quill Bearing Replacer
• SA9120T Differential Bearing Installer
• SA9128T Quill Bearing Remover
• SA9129T Support Fixture
• SA9133T Axle Seal Puller
• SA9137G Slide Hammer
• SA9191T M/T Case Output Shaft Bearing Puller
• SA9211T-2 5th Gear Remover
• SA9211T-3 Shaft Protector

1. Remove the clutch fork and bearing assembly.
2. Remove the shift housing bolts, shift housing and discard gasket.
3. Remove the vehicle speed sensor.




4. Remove the end cover bolts, end cover and discard gasket.




5. Move the two shift forks to lock the transaxle in two gears.

Important

To hold transaxle in place while removing nuts, drill two holes in bench top to align with the two top of transaxle to engine mounting holes and put bolts through the transaxle into the holes.

6. Remove the input shaft nut and retain for clearance measurements.
7. Remove the output shaft nut and retain for clearance measurements.
8. Remove the reverse cone, thrust washer, and reverse blocker ring.
9. Remove the 5th/Reverse fork retainer clip and discard.
10. Remove the 5th/Reverse shift fork, 5th/Reverse synchronizer sleeve, 5th/Reverse hub, blocker assembly, and 5th drive gear.
11. Remove the 5th gear bearing assembly.
12. Remove the 5th/Reverse synchronizer.
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  Important

  Synchronizer hub and sleeve must be kept together as a matched set. 3/4 synchronizer shown, 5th/Reverse synchronizer similar. If alignment marks, indicated by the arrow, are not visible, put new marks on hub and sleeve before they are separated.

  Important

  If the 5th/Reverse hub is press fit on the input shaft:

  Install the Shaft Protector SA9211T-3 on the end of the input shaft with the counter bore in the shaft protector going over the input shaft.
• Install the SA9211T-2 on the input shaft. Engage the legs of the puller under the clutching teeth ring on the 5th drive gear and center the forcing screw on the shaft protector.
• Tighten the forcing screw to remove the 5th drive gear along with the 5th/Reverse hub.
13. Remove the 5th driven gear.

• Important

  If the 5th driven gear is press fit on the input shaft:

  Install the Shaft Protector SA9211T-3 on the end of the output shaft with the counter bore in the shaft protector going over the output shaft.
• Install the SA9211T-2 on the output shaft. Engage the legs of the puller under the 5th driven gear and center the forcing screw on the shaft protector.
• Tighten the forcing screw on the puller to remove the 5th driven gear




14. Remove the case-to-clutch housing bolts.
15. Use the snap ring pliers to open output and input shaft bearing snap rings to allow the bearing snap ring grooves to drop below the snap rings. Use pry slots to separate case and clutch housing, and remove case.
16. Remove the left axle seal retainer, snap ring, and remove the left axle seal from the case using SA9133T .
17. Remove the differential selective snap ring from case.




18. Remove the oil trough.




19. Remove the 5th/Reverse actuator retainer clip and discard.
20. Remove the shift fork shaft.




21. Remove the 1/2, 3/4 forks and 5th/Reverse actuator.




22. Remove the reverse shift lever bolts, and remove reverse idler gear shift lever assembly.
23. Remove the reverse idler gear shaft.





Important

Lift shafts out carefully to prevent damage to output shaft machined surface.

24. Lift the input and output shafts out of the clutch housing together.




25. Remove the transaxle magnet.