Part 1

TRANSAXLE

DISASSEMBLY AND ASSEMBLY

Disassembly Steps 1-17:

Disassembly Steps 18-26:

Disassembly Steps 27-50:

Required Special Tools:
^ MB992038: Preload socket

DISASSEMBLY





1. Remove the speedometer driven gear assembly.





2. Remove the clamp.





3. Remove the backup light switch assembly.
4. Remove the backup light switch harness connector from control cable bracket.





5. Remove the lock ball assembly.





6. Remove the wiring harness clamp bracket.





7. Remove the control cable bracket with transaxle case hanger No.1.





8. Remove the selecting bell crank assembly and the control bell crank dust cover.





9. Remove the straight screw plug with head.





10. Using the 27 mm (1.06 inches) socket, remove the straight screw plug with head.





11. Remove the drain plug and the gasket.





12. Remove the filler plug and the gasket.





13. Remove the lock ball assembly.





14. Remove the straight pin.





15. Remove the shift and select lever shaft assembly.





16. Remove the reverse idler gear mounting bolt and gasket.





17. Use snap ring pliers to expand the indicated hole snap rings. The hole snap rings will release the radial ball bearings, and the input shaft and output shaft No.1 will fall under its own weight.





18. Remove the transaxle case.








19. Remove the oil separator.





20. Remove the straight screw plug with head, the shift detent ball spring seat No.1, the compression spring and ball (four places).





21. Remove the washer based hexagon bolt.





22. Remove the gear shift fork shaft No.4 and the gear shift fork shaft No.3.





23. Remove the gear shift fork assembly No.3 and the reverse shift fork.





24. Remove the washer based hexagon bolt and then remove the gear shift fork shaft No.1





25. Remove the slotted spring pins (three places).
26. Remove the gear shift fork shaft No.2 and gear shift head No.2.





27. Remove the gear shift fork assembly No.2.





28. Remove the E-ring.
29. Remove the pivot and shift arm.





30. Remove the gear shift fork shaft No.5 and gear shift head No.3.





31. Remove the gear shift fork assembly No.1.





32. Remove the reverse idler gear shaft, reverse idler thrust washer, needle roller bearing and reverse idler gear.





33. Remove the output shaft No.2 sub-assembly.





34. Slide the synchronizer sleeve to the 3rd gear and then remove the input shaft.





35. Remove the output shaft No.1 sub-assembly
36. Remove the differential sub-assembly.