Disassembly

1. Remove transaxle release fork, bearing, back-up light switch and speedometer driven gear, then the release bearing retainer.
2. Remove transmission case cover, then the No. 3 shift fork attaching bolt.
3. Measure 5th gear thrust clearance using a suitable dial indicator. Clearance should be .0079-.0157 inch.
4. Unstake output shaft locknut, then push No. 3 hub sleeve downward to engage 5th gear. Remove locknut (LH threads), then disengage double meshing gear.
5. Tap snap ring from No. 3 hub sleeve and shift fork assembly using suitable screwdrivers and mallet, then remove shifting key retainer. Remove No. 3 hub sleeve and shift fork by inserting and tightening 3 case cover bolts.
6. Remove 5th gear, synchronizer ring, needle roller bearings and spacer.
7. Remove 5th driven gear using tool No. SST 09950-20015, then loosen locknut and remove lock ball.
8. Remove selecting bellcrank.
9. Move shift and selector levers to neutral position, then roll back shift and select lever cover and loosen large locknut.
10. Remove rear bearing retainer, then the bearing snap rings.
11. Remove reverse idler gear shaft lock bolt, then the differential side bearing retainer and shim.
12. Separate transmission case by removing seventeen attaching bolts and tapping case with a suitable mallet.
13. Place reverse fork shaft in reverse position, then remove two retaining bolts and the reverse shift arm bracket. Remove reverse idler gear and shaft.
14. Drive out slotted spring pin from No. 1 fork shaft and shift head, then remove No.1 fork shaft shaft with shift head and shift forks.
15. Remove reverse shift fork and interlock pin.
16. Remove No. 2 fork shaft straight screw plug, then drive out slotted spring pin using suitable tool. Remove No. 2 fork shaft.
17. Remove input and output shafts from case, then remove differential assembly.
18. Remove carrier cover bolt, then the cover.
19. Using a suitable dial indicator, measure side gear backlash while holding one pinion toward transaxle case. Backlash reading should be .0020-.0079 inch.
20. Remove left hand side bearing retainer bolts. Using a soft faced mallet, tap bearing retainer from transaxle case. Using a suitable tool, remove O-ring from bearing retainer.
21. Remove right hand side bearing cap bolts, then the bearing cap from transaxle case.
22. Remove differential case, outer race and adjusting shim from transaxle case.
23. Using a suitable torque wrench, measure and note driven pinion preload reading. Driven pinion preload for new bearings should be 8.7-13.9 inch lbs. Driven pinion preload for used bearings should be 4.3-6.9 inch lbs.