Manual Transaxle 4WD
DISASSEMBLY-STEP 1
Disassemble in the sequence shown in the image.
Transaxle
Position the SST and mount the transaxle on the SST.
Switch
Remove the neutral switch, center differential lock sensor switch, and backup lamp switch.
Center Differential Lock Assembly
1. Remove the bolt.
2. Turn the differential lock shift rod 90° clockwise with flat-tipped screwdriver.
3. Remove the differential lock assembly.
Cover
1. Remove the side cover.
2. Remove the rear cover.
5th Gear
1. Shift the lever into 1st gear.
2. Uncrimp the tab of the locknuts.
3. Lock the primary shaft with the SST, and remove the locknuts.
4. Drive the spring pin out and remove the primary reverse synchronizer gear, gear sleeve, and synchronizer ring.
5. Remove the secondary reverse synchronizer gear.
6. Remove the roll pin and the shift fork and clutch hub assembly.
7. Remove the synchronizer ring, the 5th gear, and gear sleeve.
8. Remove the secondary 5th gear.
9. Remove the bolt.
10. Remove the bolt, spring, and ball.
11. Remove the bolt.
Transaxle Case
1. Remove the idle gear shaft mount bolt and inter lock sleeve mount bolt.
2. Disconnect the idle gear from the transaxle case by tapping lightly with a plastic hammer.
3. Remove the transaxle case.
4. Remove the magnet.
Reverse Idle Gear
Remove the reverse idle shaft and reverse idle gear.
Idle Gear
Remove the idle gear and 0-ring.
Primary Shaft Gear Assembly, Secondary Shaft Gear Assembly and Shift Fork Assembly
1. Remove the set bolt.
2. To remove the reverse shift rod wrap it with a cloth and turn it with pliers while pulling out.
3. Remove the shift gate and reverse lever support assembly.
4. Remove the bolt, spring and ball.
5. Remove the spring pin.
6. Lift the primary shaft, secondary shaft, and shift fork assemblies out as a unit.
Center Differential
1. Remove the set bolt and remove the center differential assembly.
2. Remove the center differential lock shift fork.
Transfer Carrier
1. Remove the speedometer driven gear
2. Remove the transfer carrier.