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Installation and of
Installer 100
tool
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Page 978 of 2103
MANUAL TRANSAXLE Case .
(1) Place transaxle on bench.
(2) Remove shift levers. bolts.’
(3) Place two screwdrivers in the slots provided in the case
halves near the dowels.
the case halves.’
(4) Remove bell housing case half, from
(5) Remove output shaft roller bearing from output shaft.
(6) Remove differential assembly.
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Page 979 of 2103
MANUAL TRANSAXLE
blockerassembly
Selector shaftspacer (Plastic)
( 7 ) R e m o v e r e v e r s e i d l e r s h a f t ,
Remove reverse idler gear.
(8) Remove two screws retaining
fork bracket.
Remove reverse fork bracket and reverse cam
assembly.
(9) Using snap ring pliers, remove shaft
. .
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Page 980 of 2103
MANUAL TRANSAXLE Case
Case
the selector shaft shift in theblocker,
assembly. Turn selector up out of the
(11) Remove transaxle end cover.
.
.
. . two snap rings retaining the output shaft and’
the input shaft to the bearing.
bench fixture and shims provided
transaxle over., Install trans-
axle onto bench fixture. Verify
are in
on bench fixture. Install transaxle into .
. .
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Page 981 of 2103
MANUAL TRANSAXLE
blockerassemblyI
bearing fixture
bearings. Verify tool is property and
shaft.
dams in the input and can be
damaged while pressing
if the bearing
fixture is not
used.
transaxle gear case and bench fixture
press. Press output and assemblies out
transaxle from press.
remove transaxle case from the shaft assemblies
and bench fixture.
sure the oil feed trough to end bearings is not
damaged.
the shift blocker assembly from the bench fixture.
Revision.
Page 982 of 2103
MANUAL TRANSAXLE Case Disassembly
and
the shift the output ,
input and output shaft assemblies from
f i x t u r e .
Caution
The output shaft assembly is
Do not try to repair any component on ‘the
shaft. If the synchronizer gear fails, it is
to replace the complete output shaft assembly.
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Page 983 of 2103
M A N U A L T R A N S A X L E
speed
speed
Sleeve speed
gearStop ring gear
Caged
INPUT SHAFT
Before disassembly of the input shaft, it to
the synchronizer stop ring gap. Use a to measure
the gaps between the stop rings and the speed gears .
The correct gaps are listed below:, ,
m m
m m i n . )
1 . 3 7 - 1 . 9 3 m m
1.41-1.97 mm
1 . 3 7 - 1 . 9 3 m m
If a stop ring gap does not fall within. the it
must be insepcted for wear and
If or
synchronizer stop ring is worn the
plete output shaft assembly must be
The input shaft incorporates the and speed.
gears and synchronizers on the assembly..
.
(1) Install behind speed gear. Remove snap
ring at
synchronizer hub on input shaft,
(2) Remove synchronizer and gear using shop press.
(3) Remove caged needle bearing.
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Page 984 of 2103
MANUAL TRANSAXLE Shaft Disassembly
Thrust washerInput shaft
Separation pinInput shaft
Input shaft
gear
Caged needle
bearing
(4) Remove 4-5 gears split thrust washer
.
(5) Remove split thrust washer.
(6) Remove split thrust washer separation pin.
(7) Remove
gear.
(8)Remove gear caged needle bearing. Check the
needle bearing for a broken retention spring.
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