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Transaxle Disassembly

  1. Remove bolts and transaxle side cover. Remove snap ring and hub plate. See Fig 1. Remove shift fork plug and guide ball. Drive out roll pin.
  2. Using gear puller, remove shift fork, sleeve and hub assembly, synchronizer ring spring, synchronizer ring and 5th gear all together from input shaft. Install input shaft 5th gear. Unstake countershaft lock nut and remove. Remove lock nut wrench and input shaft 5th gear. Remove needle bearing and countershaft 5th gear using gear puller and gear puller legs.
  3. Remove screws, left case plate and bearing shim. Remove bolts and left case cap. Remove gear shift yoke bolt and 3 gear shift fork shaft bolts with washers, springs and steel balls. See Fig 2.
    NOTE: Springs are color coded. Note which spring goes into each hole to aid in reassembly.
    Fig 1: Snap Ring, Hub Plate, Roll Pin & Ball Plug
    G93E24848Courtesy of GENERAL MOTORS CORP.
    Fig 2: Identifying Gear Shift Bolts Locations
    G93F24849Courtesy of GENERAL MOTORS CORP.
  4. Remove bolts, wiring harness clamp and gear shift guide case. Remove gear shift interlock bolt with washer. Remove back-up light switch. Remove gear shift and select shaft assembly.
  5. Remove reverse shaft bolt with washer. See Fig 3. Remove 11 case bolts from outside of transaxle and 2 bolts from clutch housing side. Separate case halves.
  6. Remove gear shift yoke, reverse gear shaft with washer and reverse idler gear. See Fig 4. Remove 5th and reverse gear shift guide shaft together with 5th and reverse gear shift shaft by pushing up high speed gear shift shaft and shift to 4th gear to remove.
  7. Remove input shaft assembly, countershaft assembly, high speed gear shift and low speed shift shaft together. Remove differential gear assembly and speedometer driven gear case.
  8. Remove input shaft oil seal using slide hammer. Remove countershaft RH bearing race using Bearing Race Remover (Geo J29369-2, Suzuki 09923-64511) with slide hammer. Remove magnet.
  9. Drive out roll pin and remove gear shift arm from gear shift shaft. Remove gear shift shaft bolt with washer, spring and steel ball. See Fig 5. Remove gear shift shaft, boot and oil seal. Remove differential side RH oil seal from right case.
  10. Remove bolts and reverse gear shift lever. See Fig 4. Remove bolt and oil gutter. See Fig 6.
Fig 3: Removing & Installing Case Bolts
G93J24850Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing Reverse Idler Gear
G93A24851Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing & Installing Gear Shift Shaft
G93B24852Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing & Installing Oil Gutter
G93C24853Courtesy of GENERAL MOTORS CORP.
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