Tools Required

1. Mount the input shaft in a vise with soft jaws.
2. Remove the bearing retaining ring and discard.




Important: The input shaft bearing can not be reused after removal. It must be replaced.

Important: Loosen the 87 92 152 until the tool sits flush on the 4th drive gear before tightening the tool onto the bearing.

3. Remove the input shaft bearing using the 87 92 152 and the 87 91 642 .



4. Remove the 4th drive gear, 4th gear blocking ring, and 4th gear bearing.




Caution: The synchronizer detent inserts may be forced out by spring pressure and could injure someone. To help avoid injury, always cover the synchronizer hub detent openings during disassembly.

5. Move the 3rd/4th gear synchronizer sleeve down, toward third gear, far enough to remove the synchronizer detent inserts with a small screwdriver.




Important: Note the orientation of the 3rd/4th gear synchronizer sleeve. It needs to be installed in the same orientation.

6. Remove the 3rd/4th gear synchronizer sleeve.



7. Remove the 3rd/4th gear synchronizer insert pins and springs.



8. Remove the 3rd/4th gear synchronizer hub retaining ring and washer. Remove the 3rd/4th synchronizer hub using the 87 91 287 under the 3rd gear.



9. Remove the 3rd gear blocking ring, 3rd drive gear, and 3rd gear bearing assembly.



10. Press off the input shaft bearing, next to 1st drive gear, using the 87 91 121 and the 87 90 636 .




Important:  When a manual transaxle with a serial number before T02075 is repaired for a 3rd/4th gear synchronizer concern, it must be determined whether the synchronizer components are on the 1st design or the 2nd design.

The following illustrations show the 1st design, the left half of the illustration, and the 2nd design, the right half of the illustration, of the 3rd/4th gear synchronizer components.

Important: All transaxles built prior to the T02075 serial number will be of the 1st design unless they have been previously repaired for this condition. All service parts are of the 2nd design.

11. If the 3rd/4th synchronizer sleeve removed from the transaxle has the profile of the sleeve shown on the left, then it is a 1st design. The 2nd design synchronizer sleeve will have a symmetrical profile.



12. If the 3rd/4th gear blocking ring removed from the transaxle looks like the blocking ring shown on the left half of illustration, then it is of the 1st design.

If any of these 3rd/4th shifting components are a 1st design and need to be replaced, then both blocking rings, the sleeve, and the shift fork must be replaced with the 2nd design parts as a unit. If the blocking rings, sleeve, and shift fork have already been replaced with the 2nd design components then only replace the parts as needed.

13. Inspect the condition of the gears and synchronizers. Refer to Gear Synchronizer Blocker Ring Inspection .