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Remove restrict ball assembly
(bolt). Save the ball. |
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Remove reverse idler gear shaft
bolt (I used vice-grips, didnt have a hex wrench on me or torx) |

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Remove these dozen bolts (12mm)
holding the transaxle case to the base. They are all the same size |
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Using a mallet or screwdriver
pry up this level of tranny carefully. |



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Pull up the center diff.
This should come up easily. Notice the Oil Guide. Only one in
our trannies. It 'slips' into a detent on the bottom there.
The underside of this case has shims under the bearing races. The
'top' side (or side away from the clutch) doesnt have spacers beneath the
bearing races. |

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Broken 4th gear and debris
laying around the base :( |
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Once the lower case is out, you
are left with the base and the gear stacks. Pull up on the Front
Diff. It will have a shim on the top. The bearing race may/maynot
have come off the case. |
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Pull up on the front output
shaft assembly. Lower bearing race is not shimmed. |

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The bottom of the "upper
level" and the "center section" ONLY, have shims under the
bearing races. When shimmying the tranny, the bottom of the shafts
and diffs dont get shimmed. This is important. |
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Remember how this looks.
Left is the Input shaft, middle is the reverse idler gear/shaft, right is
the Intermediate shaft. You will notice there are 3 shift forks.
5th fork is cast, 1-2 and 3-4 forks are aluminum. Note where
the reverse idler gear bolt hole is pointing. It should point towards
the front diff when assembling. On the left
(input shaft) you have 3rd/4th synchro. Top is the 4th gear, lower
is the 3rd gear. On the opposite shaft (right shaft aka
intermediate shaft), the 3rd/4th mating gears are part of the shaft.
The same holds the other way around. The left shaft carries the
1st/2nd gear, while the right shaft has the mating gears, which are molded
into the shaft. |
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Another view of the
assembly. note the longest shift rail. once these rails are
separated, they're easily identifiable as to where they came from. |
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Punch out these locking pins
from both the forks. |


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Remove these 2 bolts holding
the reverse shift lever assembly down. Remove the assembly and the
reverse idler gear. |

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Remove this interlock plate
bolt |

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Move the shift rails as you see
here. You may lift the right most rail a bit, this will let you move
the middle rail to the right even more, and the left rail, to the left,
clearing the interlock plate. |
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Hold everything together and
lift the entire assembly up and out, carefully. |
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Shift rail/fork assembly |
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Intermediate shaft assembly,
left to right: Bearing, 4th gear, 3rd gear, 2nd gear, synchro, 1st
gear, bearing. 4th/3rd gear on this shaft are molded onto the
shaft. Note how the synchro slider's teeth face the clutch side of
the shaft. |
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Input shaft assembly, left to
right: 4th gear, synchro, 3rd gear, 2nd gear, reverse gear, 1st
gear, bearing. Note on the synchro sleeve, the indent line side of
the synchro points away from the clutch. Thats important. |
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