Output Shaft

Output Shaft





Special Tool(s)





Material

Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.

1. General note
- If replacement of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.





2. CAUTION: Only loosely attach the special tool to avoid damaging the synchronizer ring.

Using the special tool, remove the taper roller bearing together with the reverse gear wheel.





3. Remove the needle roller bearing and the synchronizer ring.
1. Remove the needle roller bearing.
2. Remove the synchronizer ring.





4. Remove the fifth and reverse gear synchronizer assembly.
1. Remove the snap ring.
2. Remove the synchronizer assembly.
- Discard the snap ring.





5. Remove the fifth gear.
1. Remove the synchronizer ring.
2. Remove the fifth gear.
3. Remove the roller bearing.





6. NOTE: Use the special tool with the flat side upward.

Using the special tool, remove the fourth gear wheel.
- Discard the snap ring.





7. NOTE: Use the special tool with the flat side upward.
Using the special tool, remove the second and the third gear wheel.





8. CAUTION: Be extremely careful when handling the inner synchronizer ring and synchronizer cone. Remove the second gear wheel.

1. Remove the outer synchronizer ring.
2. Remove the synchronizer cone.
3. Remove the inner synchronizer ring.
4. Remove the second gear wheel.
5. Remove the needle roller bearing.





9. Remove the first and the second gear synchronizer hub assembly.
1. Discard the snap ring.
2. Remove the synchronizer hub assembly.





10. CAUTION: Be extremely careful when handling the inner synchronizer ring and synchronizer cone.

Remove the first gear wheel.
1. Remove the outer synchronizer ring.
2. Remove the inner synchronizer ring.
3. Remove the synchronizer cone.
4. Remove the first gear wheel.
5. Remove the needle roller bearing.





11. Using the special tool, remove the clutch housing roller bearing.





12. CAUTION: Take care when removing the selector ring from the synchronizer hub assembly. The detent balls are spring-loaded.

NOTE: Mark the installed position of the selector ring. Disassemble the synchronizer hub assembly.

1. Remove the shift ring.
2. Remove the synchronizer hub.
3. Remove the compression springs.
4. Remove the blocker bars.
5. Remove the detent balls.

Assembly

1. CAUTION: Handle the inner synchronizer ring and the synchronizer cone with extreme care.

NOTE: Do not lubricate new roller bearings.

Carefully clean and check all sliding parts and lubricate them with manual transmission fluid before assembly.





2. CAUTION: Handle the inner synchronizer ring and synchronizer cone very carefully.

Install the first gear wheel.
1. Install the needle roller bearing.
2. Install the first gear wheel.
3. Install the inner synchronizer ring.
4. Install the synchronizer cone.
5. Install the outer synchronizer ring.





3. NOTE: Observe the markings.

Assemble the synchronizer hub assembly.
1. Install the compression springs.
2. Install the blocker bar and the detent balls in the gear synchronizer hub against the force of the spring.
3. Install the spring ring the correct way round and push it on.





4. NOTE: Install the synchronizer hub assembly with the larger collar facing outward (toward the second gear wheel).

NOTE: Install a new snap ring. Install the first and the second gear synchronizer hub assembly.

1. Install the synchronizer hub assembly.
2. Install the snap ring.





5. Install the second gear wheel.
1. Install the needle roller bearing.
2. Install the outer synchronizer ring.
3. Install the synchronizer cone.
4. Install the inner synchronizer ring.
5. Install the second gear wheel.





6. Using the special tool, install the third gear wheel.





7. NOTE: Install a new snap ring.

Using the special tool, install the fourth gear wheel.





8. Install the fifth gear wheel.
1. Install the needle roller bearing.
2. Install the fifth gear wheel.
3. Install the synchronizer ring.





9. NOTE: Install the synchronizer hub assembly with the small collar and the ring groove facing outward.

NOTE: Install a new snap ring. Install the fifth and the reverse gear synchronizer assembly.

1. Install the synchronizer hub assembly.
2. Install the snap ring.





10. Install the reverse gear wheel.
1. Install the synchronizer ring.
2. Install the needle roller bearing.
3. Install the reverse gear wheel.





11. Using a length of a suitable tube, install the transaxle housing roller bearing.





12. Using a length of a suitable tube, install a new clutch housing roller bearing.