Operation CHARM: Car repair manuals for everyone.
Hosted by mcallihan.com

Disassembly








Special Tools

Disassembly





1. Install the special tool.





2. Remove the selector mechanism.
^ Shift the transaxle in neutral.
^ Remove the bolts.





3. Using the special tool, remove the halfshaft oil seals.





4. Remove the Vehicle Speed Sensor (VSS).

5. NOTE: Do not drive out guide pegs.





Remove the transaxle housing bolts.

6. CAUTION: Take care not to damage transaxle housing.





Separate the transaxle housing.
1. Place supports underneath.
2. Separate transaxle housing using two tire bars.





7. Remove the differential.
^ Remove magnetic disc.





8. Remove the selector rods and the first/second gear selector fork.





9. Remove the selector forks.
1. Move the fifth/reverse gear selector fork to the side.
2. Rotate third/fourth gear selector fork and remove.
^ Remove fifth/reverse gear selector forks





10. Remove reverse idler gear.
1. Remove the snap-ring.
^ Tilt input and output shafts to the side.
2. Lift out the idler gear.





11. Remove the input and the output shaft.
^ Lift out the input and the output shaft from transaxle housing together.
^ Take out the bearing block and reverse idler gear together with needle roller bearing and thrust washers.





12. Using the special tools, remove the differential bearing outer race.
^ Attach the special tool in housing recesses.





13. Using the special tools, remove the bearing outer races from input and output shaft.
^ Attach the special tool in housing recesses.

14. NOTE: Discard clutch slave cylinder.





Remove clutch slave cylinder (with thrust bearing).





15. Using the special tools, remove the bearing outer races from the differential and input shaft together with shim.
^ Attach the special tool in housing recesses.





16. Using the special tools, remove output shaft bearing outer race together with shim.
^ Attach the special tool in housing recesses.

17. NOTE: In the event of damage or leaks only.





Remove reverse idler gear shaft.

18. NOTE: In the event of damage or leaks only.





Remove the reverse idler gear shaft.
^ Drive out using solid piece of wood.