Disassembly (1 - 25)

TRANSAXLE-4x4








Disassembly

1. Clean the transaxle exterior with solvent before disassembly.
2. 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. Failure to follow these instructions may result in personal injury.

3. Clean out all holes and passages with compressed air and verify that there are no obstructions.





4. Using the special tool or equivalent, mount the transaxle to a bench.





5. Remove the power take off unit.
^ Remove the two nuts and two bolts.





6. Remove the clutch release fork and bearing.
1. Remove the boot.
2. Remove the clutch release fork and bearing.





7. Remove the anchor bolt.





8. Remove the park/neutral position (PNP) switch.





9. Remove the bolt and the vehicle speed sensor (VSS).
10. Rotate the transaxle 180 degrees.





11. Remove the clutch slave cylinder line bracket.
1. Remove the bolts.
2. Remove the clutch slave cylinder line bracket.





12. Remove the bolts and the shift cable bracket.





13. Remove the bolts and the shift cable bracket.
14. Shift the transaxle into first gear.





15. Remove the case cover.
1. Remove the bolts.
2. Remove the case cover.





Caution:
^ Do not reuse locknuts.

16. Remove the input and output shaft locknuts and discard.
1. Using the special tool or equivalent, keep the input shaft from turning.
2. Remove the input and output shaft locknuts and discard.





Caution:
^ The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.

17. Remove the fifth/reverse gear synchronizer blocking ring.





18. Remove and discard the fifth/reverse shift fork roll pin.





19. Remove the fifth/reverse shift fork and synchronizer hub assembly.





20. Remove the synchronizer blocking ring and the fifth speed cluster gear.





21. Remove the fifth gear bushing.





22. Remove the fifth speed gear.





23. Remove the four bolts and the shifter housing.





24. Remove three detent springs.





25. Remove three detent balls.