Transaxle Disassembly
- Remove bolts and transaxle side cover. Remove snap ring and hub plate. See Fig 1. Engage transaxle by pushing in on gear shift shaft. Engage 5th gear by sliding 5th speed sleeve down to lock transaxle in 2 gears. This allows countershaft nut removal.
- Unstake countershaft lock nut and remove. Remove shift fork plug and guide ball. Move transaxle gear shift shaft to Neutral position. Drive out roll pin from shift fork.
- Using a 2-jaw puller, remove 5th speed shift fork, 5th speed sleeve and hub, synchronizer unit, input shaft 5th gear and bearing as an assembly. Remove 5th speed shift fork from 5th speed sleeve and hub assembly. Remove synchronizer ring spring and 5th speed hub from 5th speed sleeve.
- Using a 2-jaw gear puller, remove countershaft 5th gear from counter shaft. Remove 6 screws, bearing set shim and left case plate from left-side case. Remove 3 bolts, left case cap and "O" ring from left-side case. 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.
- Remove 4 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.
- 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 with right-side case (clutch housing) facing downward.
- Remove gear shift yoke, reverse idler 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 shifting to 4th gear.
- Remove differential gear assembly by lifting upward. Remove input shaft assembly, countershaft assembly, high and low speed gear shift shafts together.
- Remove high and low speed shift shafts from input shaft and countershaft assemblies. Separate input shaft assembly from countershaft assembly.
- Remove speedometer driven gear from right-side case. Using a slide hammer, remove input shaft oil seal from right-side case. Remove 2 bolts and reverse shift lever from right-side case. Remove countershaft RH bearing race. Remove magnet.
- Remove one bolt, then 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-side case.
- Remove bolts and reverse gear shift lever. See Fig 4. Remove bolt and oil gutter. See Fig 6.