Page 993 of 2103
MANUAL TRANSAXLE Case Overhaul
outputbearing
Bearing
Input shaftb e a r i n g .
REMOVAL
(1) Note the position of the output shaft
The bearing is not identical to end.
Remove caged roller bearing from output bearing “race.
(2) Remove screws at output bearing strap.
(3) Install tool tool to
bearing race.
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Page 994 of 2103
MANUAL TRANSAXLE Case
I \Differential
ing
(1) Line up bearing race race bore.
(2) tool into output bearing
race. Tap race into bore.
Tighten bolts to’ 11 Nm
__
,
INPUT BEARING AND SLEEVE
The input bearing is a one-piece bearing and sleeve
The sleeve is the slide point for the clutch release bearing
and lever.
__
R E M O V A L
tool over input bearing on.
the gear case side of the transaxle clutch housing.
(2) Tap the input bearing out housing.’
INSTALLATION.
(1)Apply coating of Loctite sealant
Position sleeve and bearing
bore.
(2) Install tool input
.
.
,
(3)Using the spacer tool and shop press, install input bearing
into bore until it is fully seated.
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Page 995 of 2103
MANUAL TRANSAXLE Case
Gear case
REMOVAL
(1) Install into the differential bearing cup.
(2) Install the tool cup over the tool.
(3) Tighten the tool until the race is removed from the case.
INSTALLATION
(1) Position the bearing cup into case.
(2) Install the bearing cup onto
(3) Using driver, install differential
bearing cup into the transaxle
,
REMOVAL
(1) Thread tool into shifter rail bushing.
(2) Install
onto tool.
(3) Remove bushing using slide hammer and tool asse mbly.
bearing
INSTALLATION
(1) Line up replacement bushing in bore.
(2) Using tool
tap bushing into bore until flush
with the chamfer in the case.
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Page 996 of 2103
MANUAL TRANSAXLE Gear Case
SHAFT SEALS
It is not necessary to remove the shifter the trans-
axle to service the shifter shaft seals.
REMOVAL
(1) Using a pick tool, pry up the shifter seal and
remove seal from bore.
INSTALLATION
(1) Position new shifter shaft seal in bore.
(2) Install shifter shaft seal
bore using an
size deep well socket.
REMOVAL
(1) With the transaxle disassembled, remove the sel ector
shaft by pushing on the shaft from the outside and pulling
shaft out from the inside.
Reverse removal procedure to install selector shaft .
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REMOVAL
(1) With the transaxle disassembled, remove the crossover
shaft seal.
(2) Using snap ring pliers, remove the snap ring at the cross-
over shaft bore.
(3) Push the crossover shaft in the case and remove the
crossover assembly.
Reverse removal procedure to install crossover shaft.
Page 997 of 2103

MANUAL TRANSAXLE Gear Case Overhaul
SHIFTER SELECTOR SHAFT
REMOVAL
(1) Thread into bushing.
(2) Install
onto tool and remove bushing using
slide hammer.
INSTALLATION
(1) Position replacement over selector shaft bore.
(2)Using an appropriate size deep well socket, install bushing
in selector shaft bore.
SHIFTER CROSSOVER
REMOVAL
(1) Install through the crossover bushing.
(2) Thread nut and washer onto
(3) Using the remove the crossover shaft bush-
ing.
INSTALLATION
(1 Position the replacement crossover shaft bushing o ver
the crossover shaft bushing bore.
(2) Using an appropriate size deep
socket, install the
crossover shaft bushing into the bushing bore.
.
REAR BEARING OIL FEED TROUGH
REMOVAL
The bearing oil feed trough is retained in the case by a pin
that is molded into the case and clips that are par t of the
trough.
(1) Using light plier pressure, squeeze the clips together at
the rear of the trough.
Slide the trough over the retaining’ pin that locates the
trough in the case.
Reverse removal procedure to
feed
Revision
Page 998 of 2103
MANUAL TRANSAXLE Shaft Reassembly
Input shaft
Input shaft
input shaft
gear cagedneedle bearing
gear
INPUT SHAFT REASSEMBLY
The snap rings that are used the input available
in select fit sizes. Use the thicknest that will fit
in each ‘snap ring groove.
(1) Place input shaft into shop press. (2) Install
gear caged needle on input shaft.
(3) Install gear and synchronizer onto input shaft.
Install 3, shaft
and press on synchronizer hub
gear. The
nizer hub has the letter the top
of the hub.
This designates that the hub
be installed with the
“U” facing upward.
(4) Install synchronizer snap ring into input shaft.
(5) Install blocking ring into synchronizer. gear
caged needle bearing.
(6) Install
gear onto input shaft.
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Page 999 of 2103
Separation pinInput shaft
Input shaft
InputCagedneedle
bearing
(7) split thrust washer pin.
. .,
.
, ,.
(8) Install split thrust washer onto input shaft.
(9) Install split thrust washer retaining ring.
gear caged needle bearing.
(11) Using 2, install speed gear and
synchronizer. The
gear synchronizer hub has the letter
stamped on the top face of the hub. This designate s
that hub must be installed with the facing upward.
Page 1000 of 2103
MANUAL TRANSAXLE Shaft Reassembly
gear synchronizer snap ririg.
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