Gear Case Overhaul

The sealant used to seal the transaxle case halves is Loctite 51817 or equivalent. The sealant used for the bearing end plate cover is Loctite 18718 or equivalent.
The components that are left in the gear cases when the gear train is pulled out are the:
Axle shaft seals
Output bearing race and retainer
Input bearing and sleeve
Differential bearing cones
Shifter rail bushings
Shifter shafts
Shifter shaft seals
Shifter shaft bushings
Rear bearing oil feed trough

AXLE SHAFT SEALS




REMOVAL
1. Insert a flat blade pry tool at outer edge of axle shaft seal.
2. Tap on the pry tool with a small hammer and remove axle shaft seal.




INSTALLATION
1. Clean axle shaft seal bore of any excess sealant.
2. Align axle shaft seal with axle shaft seal bore.
3. Install axle seal on tool MD998812, MD998826 and insert into axle shaft seal bore.
4. Tap seal into position.

OUTPUT BEARING

REMOVAL




1. Note the position of the output shaft bearing. The bearing is not identical end to end. Remove caged roller bearing from output bearing race.




2. Remove screws at output bearing retainer strap.




3. Install tool MB995031, MB995052. Tighten tool to output bearing race.




INSTALLATION
1. Line up output bearing race to race bore.
2. Insert tool MB990933, MB990938 into output bearing race. Tap race into bore. Position bearing retaining strap. Tighten bolts to 11 N.m (9.6 ft-lbs.).




INPUT BEARING AND SLEEVE
The input bearing is a one-piece bearing and sleeve unit.
The sleeve is the slide point for the clutch release bearing and lever.




REMOVAL
1. Install tool MB990927, MB990938 over input bearing on the gear case side of the transaxle clutch housing.
2. Tap the input bearing out of the housing.




INSTALLATION
1. Apply coating of Loctite sealant on bearing outer diameter. Position sleeve and bearing assembly at input bearing bore.
2. Install tool MB995033 over input bearing.




3. Using the spacer tool and shop press, install input bearing into bore until it is fully seated.

DIFFERENTIAL BEARING CUPS

REMOVAL




1. Install MB995048 into the differential bearing cup.




2. Install the tool cup over the tool.
3. Tighten the tool until the race is removed from the case.

INSTALLATION
1. Position the bearing cup into the case.
2. Install the bearing cup onto MB990933.
3. Using MB990933, MB990938 driver, install differential bearing cup into the transaxle case.




SHIFTER RAIL BUSHINGS

REMOVAL
1. Thread tool MB995040 into shifter rail bushing.
2. Install MB995031 onto tool.
3. Remove bushing using slide hammer and tool assembly.

INSTALLATION
1. Line up replacement bushing in bore.
2. Using tool MD998343, tap bushing into bore until flush with the chamfer in the case.

SHIFTER SHAFT SEALS
It is not necessary to remove the shifter shafts from the transaxle to service the shifter shaft seals.

REMOVAL
1. Using a pick tool, pry up on the shifter shaft seal and remove seal from bore.

INSTALLATION
1. Position new shifter shaft seal in bore.
2. Install shifter shaft seal into bore using an appropriate size deep well socket.

SHIFTER SELECTOR SHAFT

REMOVAL
1. With the transaxle disassembled, remove the selector shaft by pushing on the shaft from the outside and pulling shaft out from the inside.
Reverse removal procedure to install selector shaft.

SHIFTER CROSSOVER SHAFT




REMOVAL
1. With the transaxle disassembled, remove the crossover shaft seal.
2. Using snap ring pliers, remove the snap ring at the crossover shaft bore.
3. Push the crossover shaft in the case and remove the crossover assembly.

Reverse removal procedure to install crossover shaft.

SHIFTER SELECTOR SHAFT BUSHING




REMOVAL
1. Thread MB995040 into bushing.
2. Install MB995031 onto tool and remove bushing using slide hammer.




INSTALLATION
1. Position replacement bushing over selector shaft bore.
2. Using an appropriate size deep well socket, install bushing in selector shaft bore.




SHIFTER CROSSOVER SHAFT BUSHING

REMOVAL
1. Install MB995031 through the crossover bushing.
2. Thread nut and washer onto MB995031.
3. Using the MB995031, remove the crossover shaft bushing.

INSTALLATION
1. Position the replacement crossover shaft bushing over the crossover shaft bushing bore.
2. Using an appropriate size deep well socket, install the crossover shaft bushing into the bushing bore.

REAR BEARING OIL FEED TROUGH




REMOVAL
The bearing oil feed trough is retained in the case by a pin that is molded into the case and clips that are part of the trough.
1. Using light plier pressure, squeeze the clips together at the rear of the trough.
2. Slide the trough over the retaining pin that locates the trough in the case.
Reverse removal procedure to install oil feed trough.