A. Main Components Disassembly
REMOVE OR DISCONNECT^ Tools Required:
- J 22888-20 Universal Puller
- J 22888-30 Puller Legs
1. Eight bolts and transaxle side cover from left case.
NOTICE: If the transaxle side cover is frozen to the left case, tap around the side cover with a rubber mallet until the side cover is free of the left case. DO NOT attempt to pry the side cover away from the left case with metal tools or damage to the left case and side cover mating surfaces could result.
2. 5th speed synchronizer retainer and 5th speed synchronizer hub plate from the input shaft.
3. Engage the transaxle by pushing in on the gear-shift shaft.
4. Engage 5th gear by sliding the 5th speed sleeve down. The transaxle is now locked in two gears, preventing input shaft rotation and permitting countershaft nut removal.
5. Unstake countershaft nut using a center punch and hammer.
6. Countershaft nut from countershaft.
7. Gearshift fork plug and guide ball from 5th speed gearshift fork.
Important
- Use of a magnet will facilitate the removal of the guide ball from the 5th speed gearshift fork.
8. Move the transaxle gearshift shaft to the neutral position.
9. Gearshift fork roll pin using a standard drift punch and hammer.
10. 5th speed gearshift fork, 5th speed sleeve and hub, synchronizer ring spring, high speed synchronizer ring spring, 5th speed synchronizer ring, input shaft 5th gear and 5th gear bearing simultaneously from the input shaft using a J 22888-20 with two J 22888-30.
11. 5th speed gearshift fork from 5th speed sleeve and hub assembly.
12. Synchronizer ring spring and 5th speed hub from 5th speed sleeve.
13. Countershaft 5th gear from countershaft using the J 22888-20 with the J 23888-30.
14. Six screws, bearing set shim and left case plate from left case.
15. Three bolts, left case cap and O-ring from left case.
16. Gearshift yoke bolt from gearshift yoke.
17. Three gearshift shaft screws with washers, three locating springs and three steel balls from the right case.
Important
- Locating springs are color coded for ease of assembly. Make note of each spring and its position to ensure correct installation.
18. Four bolts, one retaining clamp and gearshift guide case from left case.
Important
- It is not necessary to remove the 5th-to-reverse interlock bolt for gearshift guide case removal.
19. Backup lamp switch from the left case.
20. Gearshift interlock bolt and washer from the left case.
21. Gearshift and select shaft assembly from the left case.
22. Reverse idler shaft bolt and washer from the left case.
23. Eleven case bolts from left case.
24. Two case bolts from inside of right case.
Important
- Separate the transaxle cases with the right case (clutch housing) facing downward. All internal components should remain in the right case.
25. Left case from right case by lifting the left case up and off of right case.
26. Gearshift yoke from gearshift arm.
27. Reverse idler gear shaft with washer and reverse idler gear from the right case.
28. 5th and reverse gearshift guide shaft simultaneously with 5th and reverse gearshift shaft from the right case.
Important
- When removing 5th and reverse gearshift shaft and guide shaft, push the high speed gearshift shaft in, shifting it to 4th gear to remove the 5th and reverse gearshift shaft and guide shaft.
29. Differential assembly from the right case by grasping the differential assembly and lifting upward.
30. Input shaft assembly by tapping the input end with a plastic mallet and push the assembly out of the right case. Once the input shaft is free of the right case, remove the input shaft assembly, countershaft assembly, high speed and low speed gearshift shafts simultaneously as a cluster.
31. High speed and low speed gearshift shafts from the input shaft and countershaft assemblies and separate the input shaft assembly from the countershaft assembly.