Disassembly

Exploded View Of Transaxle:

1. Mount transaxle into bench mounting fixture tool No. T57L-500-B or equivalent.
2. Remove drain plug and drain any remaining fluid from transaxle. Shift to 1st or 2nd, then position transaxle with input shaft down and rear cover facing up.
3. Remove bolts retaining rear cover to the transaxle case. Tap cover with a rubber mallet to loosen gasket cover. Remove rear cover.
4. Measure 5th gear thrust clearance with a dial indicator. Correct clearance is within 0.0024-0.0122 inch.
5. If clearance exceeds maximum, check contact surfaces of 5th gear and the clutch hub. Replace worn or damaged parts.

Locking Input Shaft:

6. Bend down tang on the stop plate or lock washer, below the 5th gear locknut. Lock input shaft with torque adapter tool No. T87C-7025-A or equivalent. Remove and discard locknut, then remove stop plate.
7. Drive out roll pin and remove 5th gear shift fork with the clutch hub assembly. Remove synchronizer ring, 5th gear and the gear sleeve as an assembly by sliding it off the shift rod.
8. Lock input shaft as described in step 6. Remove locknut on input shaft gear. Remove input gear by sliding it off.

Lock Bolt & Guide Bolt Locations:

9. Remove lock bolt, guide bolt, neutral start switch and backup light switch from side of transaxle case.
10. Remove all of the transaxle housing to clutch housing bolts. Note location of bolts for installation.
11. Tap transaxle case lightly with a soft mallet to loosen gasket seal. Remove case by sliding it straight up from clutch housing.
12. To disassemble gear assembly proceed as follows:
a. Remove magnet from bottom of clutch housing. Remove reverse idler shaft and reverse idler gear.
b. Remove roll pin from crank lever shaft, then remove crank lever shaft and crank lever assembly. Remove and discard O-ring.

Shift Rod Assembly Removal:

c. Remove retaining bolt from 5th gear shift rod end and remove rod end. Insert a pin punch or suitable rod into roll pin hole of the shift rod. Pull out the shift rod assembly while turning the pin punch or the rod.

Interlock Sleeve & Control Lever Alignment:

d. Align ends of interlock sleeve and control lever. Turn shift rod counterclockwise.
e. Remove two bolts retaining breather cover, then remove cover and gasket.
13. Lift out main shaft, input shaft and shift rail as an assembly.
14. Steel ball will fall into clutch housing.

Control End, Ball & Spring Removal:

15. Separate shift rod and shift fork assembly from each of the clutch hub sleeves. Retrieve steel ball from clutch housing.
16. With a soft hammer, drive out reverse lever shaft and blind plug. Remove spring from reverse lever shaft and remove differential assembly.
17. Remove speedometer drive gear assembly from case Remove reverse lever shaft roll in and drive the reverse lever shaft out of case.
18. Retrieve the reverse lever and lever set spring from the case.
19. Remove bearing races, if necessary, as follows:
a. Remove the differential front bearing race from the clutch housing using bearing puller tool No. T86-70043-A puller tool No. T58L-101-B and slide hammer tool No. T50T-100-A or equivalents.
b. Remove the input shaft rear bearing puller race from the transaxle case using bearing puller toll No. T77F-1102-A and slide hammer tool No. T50T-100-A or equivalents.
c. Following removal of input shaft rear bearing race, remove the diaphragm spring and adjusting shim. Note original position for assembly.
d. Remove differential rear bearing race adjusting shim. Remove left and right differential oil seals from transaxle case using bearing puller tool No. T77F-1102-A and slide hammer tool No. T50T-100-A or equivalents.
e. Remove main shaft rear bearing race from transaxle case using bearing puller tool No. T77F-1102-A and slide hammer tool No. T50T-100-A or equivalents.