Page 985 of 2103
MANUAL TRANSAXLE
Snap ring .pliers
shaft
caged
needle bearing
(9) Remove blocking
input shaft in shop press. Using to
remove
synchronizer and gear.
(11) Remove gear caged needle bearing. Check the caged
needle bearing for a broken retention spring.
the input shaft for worn or damaged bearing races
or chipped gear teeth. Replace as necessary.
I Revision I
Page 986 of 2103

Output Disassembly/
MANUAL TRANSAXLE
Stop ring speedgear
Reverse gearIt is necessary to check the gap. Use
a feeler gauge to measure the gaps
the stop rings
and the speed gears.
The correct gaps are listed below:
.
m m
mm
m m
m m
1.37-1.93 mm .If a stop ring gap does not fall specifications it
must be inspected for wear and
and
synchronizer stop ring is worn beyond the
plete output shaft assembly must be
The output shaft incorporates the gears
synchronizers on the assembly.
.
.. .
TRANSAXLE CLEANING AND CHECK
Clean the gears, bearings, shafts, synchronizers, t hrust wash-
ers, oil feeder, shifter mechanism, gear case, and
with solvent. Dry all parts except the bearings with compressed
air. Allow the bearings to either air dry or wipe t
hem dry
with clean shop towels. Inspect the gears, bearings, shafts and thrust wash ers.
Replace the bearings and cups if the rollers are wo rn, chipped,
cracked, flat spotted or brinnelled, or if the bearing cage
is damaged or distorted. Replace the thrust washers if cracked,
chipped, or worn. Replace the gears if the teeth are chipped,
cracked, or wore thin. Inspect the synchronizers. R eplace
the sleeve if worn or damaged in any way. Replace t he stop
rings if the friction material is burned, flaking off, or worn.
Check the condition of the synchronizer keys and sp rings.
Replace these
if worn, cracked, or distorted.
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Page 987 of 2103
Differentialassembly
25
gear bolts
Soeedometer
Pinion shaftDifferential
. . ,
( 1 ) R e m o v e d i f f e r e n t i a l b e a r i n g ,,
(2) Remove ring gear bolts and ring gear.
(3)Pry the drive gear off
using a flat blade .
NOTE
drive gear
differential case in order
(4) Remove pinion shaft solid pin.
,
.,
Removepinionshaft.
Page 988 of 2103
MANUAL TRANSAXLE
DifferentialassemblySide,
Pinion
wash
Pinion
Ring gear
thrust washer
Pinion shaft
Speedometer
drive gear
gear
Rotate side gears to opening in differential.
(7)Remove pinion gears, side gears’ thrust washers
rotating side gears to case.
. .
REASSEMBLY
(1) Assemble the differential side gears, gears and
pinion gears with the pinion gears
, ,
(2) Install pinion shaft.
(3) Stake pinion shaft solid pin with a
. .
(4) Rotate the assembly two full revolutions both
and counterclockwise.’
(5) Set up dial indicator as shown and end play.
(6) Rotate side gear 90
(7) Again, rotate side gear 90 degrees a final:
end play.
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Page 989 of 2103
MANUAL TRANSAXLE . .
Move sideg e a r u pand down
Bearing cone.(6) Using the smallest end play record, shim that s
ide gear
to within 0.25 mm
in.) to 0.33 mm in.).
(9) The other side gear should be checked using the same
procedure.
Side gear end play must be within 0.25 mm in.)
to 0.33 mm
in.). Five select thrust washers are
available:
0.69 mm in.), 0.61 mm in.), 0.94 mm
in.), 1.07 mm in.) and 1.19 mm in.)
the end play is measured and adjusted, replace
drive gear with a new one.
(11) Install drive gear lip downward.
differential bearingcone.
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Page 990 of 2103
MANUAL TRANSAXLE Synchronizer
DISASSEMBLY
Place synchronizer in a clean shop,, towel Wrap. Press
on inner hub. Carefully open up shop. towel and remove
springs, balls, keys, hub, and sleeve.
CLEAN
Do not attempt to clean the blocking rings in solve nt. The
friction material will become contaminated. Place synchronizer
components in a suitable holder and clean with solv ent. Then
let them air, dry.
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Page 991 of 2103
MANUAL TRANSAXLE
SleeveASSEMBLY
(1) Position synchronizer hub onto a suitable holding fixture
(input shaft). The synchronizer hubs are directiona l. The
hubs must be installed with the facing upward.
(2) Install springs into hub slot
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
balls
into each key.
(5)Slide sleeve over the hub and depress balls as you careful-
ly slip the sleeve into position.
(6) Line up stop ring tang over the keys in the hub . Install‘
stop rings. Center the keys and balls by pushing on both
stop rings.
.INSPECT
Proper inspections of components involved:
Teeth, for wear, scuffed, nicked, burred or broken teeth keys,
for wear or distortion.
Balls and springs, for distortion, cracks or wear’
If any of these conditions exists in these replace
as necessary.
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Page 992 of 2103

Shifter Rails Overhaul/
MANUAL
SHIFTER
Disassemble the transaxle case using the procedures’
provided in this group.
(2) Remove shifter rails from the
(3) To service the shift rail, remove the retaining
the reverse shift lever arm. Remove the
“shift fork
roll pin and remove the
shift fork.
Remove the shift lug roll pin and remove the shift lug.’
Replace parts as necessary.
(4) To service the
shift rail, remove the roll pin retaining’
the
shift fork. Remove the shift fork.,, Remove the
shift lug roll pin and remove shift lug. Replace pa rts as,
necessary.
(5) To service the shift rail, remove roll pin retaining,
the shift fork. Remove the shift replace parts
as necessary.
GEAR CASE
The sealant used to seal the transaxle case halves is Loctite
51817 or equivalent. The sealant used for the bearing end
plate cover is Loctite
or equivalent.
The components that are left in the gear cases when the
gear train is pulled out are the:
Axle shaft seals
Output bearing race and retainer Input bearing and sleeve
Differential bearing cones
Shifter rail bushings ,
Shifter shafts
Shifter shaft seals
Shifter shaft bushings
Rear bearing oil feed trough
AXLE SHAFT SEALS
REMOVAL
a flat blade pry tool at outer axle shaft
seal.
(2) Tap on the pry tool with a small and
axle shaft seal.
INSTALLATION
Clean axle shaft seal bore of any excess sealant.
(2) Align axle shaft seal with axle shaft seal bore .
(3) Install axle seal on tool and insert
shaft seal bore.
(4) Tap seal into position.
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