Removal

REMOVE OR DISCONNECT

- Tools Required:
- J 35455 Holding Fixture
- J 3289-20 Bench Mount Holding Fixture Base
- J 35451 Backup Switch Socket
- J 8001 Dial Indicator
- J 26900- 13 Magnetic Base
- J 35274-A Fifth Gear Puller
- J 22912-01 Bearing Remover





1. Attach holding fixture J 35455 to transaxle and attach to J 3389-20 fixture base.
2. Release fork and bearing.
3. One retaining bolt and vehicle speed sensor (VSS) from transaxle case.
4. Backup switch using a J 35451 socket.
5. Front bearing retainer.
6. Side case cover.

Selective Snap Ring Table (A):

7. Measure fifth gear thrust clearance using a J 8001 dial indicator with a J 26900-13 magnetic base. If clearance is not 0.10 to 0.65 mm (0.0039 to 0.0256 inch), a selective snap ring will have to be used on reassembly. Refer Selective Snap Ring Table (A).
8. Selecting bellcrank.





9. Lock bolt.
10. Shift and select lever assembly.
11. Engage gears.
12. Fifth gear lock nut.
13. Disengage gears.
14. Snap ring from above number 3 hub assembly using two screwdrivers and a hammer.
15. Number 3 shift fork bolt.
16. Number 3 hub sleeve and shift fork.





17. Using a J 35274-A gear puller, remove the fifth drive gear with the number 3 hub sleeve and synchronizer ring.
18. Needle roller bearing and spacer.
19. Using a J 35274-A gear puller, remove the fifth driven gear.
20. Rear bearing retainer.





21. Two bearing snap rings.
22. Reverse idler gear shaft lock bolt.
23. Using two screwdrivers and a hammer, remove the snap ring from the number 2 shift fork shaft.





24. Three plugs and lock ball and lock ball assembly.
25. Using a magnetic finger, remove the 3 seats, springs, and balls.
26. Case cover by removing 16 bolts and tapping off the case with a plastic hammer.





27. Reverse shift arm bracket.
28. Reverse idler gear, thrust washer, and shaft.








29. Using two screwdrivers and a hammer, remove 3 snap rings and 3 set bolts from the shift forks.
30. Number 2 shift fork shaft and shift head.
31. Using a magnetic finger, remove the 2 balls.
32. Number 3 shift fork shaft and reverse shift fork.
33. Pull out the number 1 shift fork shaft.
34. Number 1 and number 2 shift fork shaft.
35. Input and output shafts together.
36. Differential assembly.
37. Magnet and oil receiver.





Measure
- Using a feeler gage, measure the following thrust clearances:
A. First gear clearance. If clearance is not 0.10 to 0.45 mm (0.0039 to 0.00177 inch), replace both the first and second gear.
B. Second gear clearance. If clearance is not 0.10 to 0.50 mm (0.0039 to 0.0197 inch), replace both the second and third gear.





C. Third gear clearance. If clearance is not 0.10 to 0.40 mm (0.0039 to 0.0157 inch), replace both the third and fourth gears.
D. Fourth gear clearance. If clearance is not 0.10 to 0.60 mm (0.0039 to 0.0236 inch), replace both the fourth and fifth gears.





38. Using a J 8001 dial indicator, measure the oil clearance between the gear and input shaft with the needle roller bearing installed. If clearance is not 0.015 to 0.070 mm (0.0006 to 0.0028 inch), replace gear, needle roller bearing or shaft.





39. Snap ring from the input shaft and using a J 22912-01 bearing remover with a press, remove the radial ball bearing.
40. Fourth gear, needle roller bearing, and synchronizer ring.





41. Snap ring from shaft and using a J22912-01 bearing remover with a press, remove the number 2 hub sleeve, third gear synchronizer ring, and needle roller bearing.





42. Radial ball bearing and fourth driver gear using J 22912-01 bearing remover and a press.
43. Spacer.
44. Shift number 1 hub sleeve into the first gear.





45. Third driven gear and second gear using a J 22912-01 bearing remover and a press.
46. Needle roller bearing, spacer, and synchronizer ring.





47. Snap ring number 1 hub sleeve assembly.
48. Using a press, remove the number 1 hub, first gear, and synchronizer ring.
49. Needle roller bearing, thrust washer, and locking ball.