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Transaxle Disassembly

Fig 1: Exploded View Of Transaxle

G02181191

Clean the transaxle exterior with solvent before disassembly.
Clean all removed parts (except sealed bearings) and all sealing surfaces with solvent, and dry with compressed air.

WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.

Clean out all holes and passages with compressed air and verify that there are no obstructions.
Mount the transaxle on Bench Mounted Holding Fixture.

Fig 2: Mounting Transaxle On Bench Mounted Holding Fixture
Remove the case cover.
1. Remove the bolts.
2. Remove the case cover.
  
  Fig 3: Removing Case Cover
Shift the transaxle into first gear.

CAUTION: Do not reuse locknuts.

Fig 4: Removing Input & Output Locknuts

G02181194

Use Input Shaft Holder to remove the input and output locknuts. Discard the input and output locknuts.
Remove the reverse synchronizer blocking ring retainer assembly.
1. Remove the spacer.
2. Remove the reverse synchronizer blocking ring retainer assembly.
  
  Fig 5: Removing Reverse Synchronizer Blocking Ring Retainer Assembly
Remove the reverse synchronizer blocking ring.

Fig 6: Removing Reverse Synchronizer Blocking Ring.
Remove and discard the reverse/fifth shift fork roll pin.

Fig 7: Removing & Discard The Reverse/Fifth Shift Fork Roll Pin
Remove the reverse/fifth shift fork and synchronizer hub assembly.

Fig 8: Removing Reverse/Fifth Shift Fork & Synchronizer Hub Assembly
Remove the synchronizer blocking ring.

Fig 9: Removing Synchronizer Blocking Ring
Remove the input shaft fifth gear.

Fig 10: Removing Input Shaft Fifth Gear
Remove the fifth gear bushing.

Fig 11: Remove Fifth Gear Bushing
Remove the output shaft fifth gear spacer and fifth gear.
1. Remove the fifth gear spacer.
2. Remove the fifth output shaft gear.
  
  Fig 12: Removing Output Shaft Fifth Gear Spacer & Fifth Gear
Remove the reverse idler shaft lock bolt.

Fig 13: Removing Reverse Idler Shaft Lock Bolt
Remove the shift rail guide bolt.

Fig 14: Removing Shift Rail Guide Bolt
Remove the lock bolt, spring, and ball.

Fig 15: Removing Lock Bolt, Spring, & Ball
Remove the backup lamp switch.

Fig 16: Removing Backup Lamp Switch
Remove the transaxle mount bracket.
1. Remove the bolts.
2. Remove the transaxle mount bracket.
  
  Fig 17: Removing Transaxle Mount Bracket
Separate the transaxle case.
1. Remove the thirteen transaxle case bolts.
2. Separate the transaxle case.
  
  Fig 18: Separating Transaxle Case
Remove the magnet.

Fig 19: Removing Magnet
Remove the reverse idler gear.
1. Remove the reverse idler shaft.
2. Remove the reverse idler gear.
  
  Fig 20: Removing Reverse Idler Gear
Remove the shift gate bolt.

Fig 21: Removing Shift Gate Bolt
Remove the shift control rod and gate.
1. Remove the shift control rod.
2. Remove the shift gate.
  
  Fig 22: Removing Shift Control Rod & Gate
Remove the shift control shaft roll pin.

Fig 23: Removing Shift Control Shaft Roll Pin
Remove the shift control shaft and shift fork selector lever.
1. Remove the shift control rod.
2. Remove the shift fork selector lever.
  
  Fig 24: Removing Shift Control Shaft & Shift Fork Selector Lever
Shift into second and fourth gears.

WARNING: When removing the shift fork and shaft assembly the detent ball will fly out. Hold a shop towel over the detent ball and spring to prevent the ball from becoming airborne.

Fig 25: Removing Shift Fork Shaft Assembly, Detent Ball & Spring

G02181215

Remove the shift fork shaft assembly, detent ball and spring.
Remove the output and input shafts as an assembly.

Fig 26: Removing Output & Input Shafts As An Assembly
Remove the differential.

Fig 27: Removing The Differential
Remove the input bearing cups.

Fig 28: Removing Input Bearing Cups
Remove the input shaft oil seal.
1. Attach Puller to the input shaft oil seal.
2. Remove the input shaft oil seal.
  
  Fig 29: Removing Input Shaft Oil Seal
Remove the fifth shaft funnel.
1. Remove the output shaft bearing cup.
2. Remove the fifth shaft funnel.
  
  Fig 30: Removing Fifth Shaft Funnel
Remove the control selector plate and spacer.
1. Remove the bolts.
2. Remove the control selector plate and spacer.
  
  Fig 31: Removing Control Selector Plate & Spacer
Remove the shift control shaft selector lever.
1. Remove the bolt.
2. Remove the shift control shaft selector lever.
  
  Fig 32: Removing Shift Control Shaft Selector Lever
Remove and discard the roll pin.

Fig 33: Removing & Discarding Roll Pin
Remove the shift control shaft assembly.

Fig 34: Removing Shift Control Shaft Assembly
Use (A) collet, (B) actuator pin and (C) hammer from Blind Hole Puller Set to remove the (D) shifter shaft seal.

Fig 35: Removing (D) Shifter Shaft Seal
Remove the vent tube.
1. Remove the bolts.
2. Remove the vent tube.
  
  Fig 36: Removing Vent Tube
Remove the retaining bolt and the vehicle speed sensor (VSS).

Fig 37: Removing Retaining Bolt & Vehicle Speed Sensor (VSS)
Use (A) Stator and Driven Sprocket Bearing Remover, (B) Disc Brake Piston Remover, and (C) Impact Slide Hammer to remove the (D) differential bearing cups.

Fig 38: Removing (D) Differential Bearing Cups
Remove and discard the reverse lever roll pin.

Fig 39: Removing Reverse Lever Roll Pin
Remove the reverse lever shaft.
1. Remove the reverse lever shaft.
2. Remove the reverse lever.
  
  Fig 40: Removing Reverse Lever Shaft
Remove the park/neutral position (PNP) switch and gasket.

Fig 41: Removing Park/Neutral Position (PNP) Switch
Use (A) Bearing Cup Puller and (B) Impact Slide Hammer to remove the (C) differential seals.

Fig 42: Removing (C) Differential Seals
Use (A) Puller to remove the (B) input and output shaft bearing cups.

Fig 43: Removing (B) Input & Output Shaft Bearing Cups