Gearbox with axle (vehicles after 08.2000) — dismantling

Special tool

	Drive gear seal remover 205-078 (15-048)
	Differential bearing inner ring puller 205-176 (15-074)
	Engine/Differential Support Bracket 205-329 (15-105A)
	Oil sump puller 303-428 (21-179)
	Stand 303-435 (21-187)
	Support bracket for 303-435 303-435-06 (21-031V)
	Bushing/Boom Seal Installer 308-045 (16-015)
	Pinion puller 5th gear input shaft 308-082 (16-035)
	Plugs for the gearbox housing in the block with the drive axle 308-152 (16-070)

CAUTION: Use vise guards.

CAUTION: Use a copper or plastic mallet to avoid damage.

1. Using the special tools, install the transaxle assembly on the assembly stand.



2. Remove all grease and foreign material from the input shaft.


3.

WARNING: If brake fluid comes into contact with the paintwork, the affected area must be washed immediately with cold water.

CAUTION: Cover the input shaft splines using appropriate adhesive tape to prevent damage to the clutch slave cylinder seal.

Remove the clutch slave cylinder.



4. Remove adhesive tape from input shaft splines.

5. Remove the vehicle speed sensor (VSS) (in the presence of).

• 1. Remove the pin.
• 2. Remove the VSS sensor.

6. Remove the gear selector cover.



7. Remove the shift lever.

• 1. Remove the protective cover.
• 2. Remove the retaining ring and discard it as no longer needed.

8. Remove the shift cable bracket.



9. Remove the gear selection lever. Remove the cover.



10. Remove the mechanism of blocking of a choice of transfers.



11. Turn out bolts of fastening of a cover of a case of 5th transfer.




12. Using the special tool, remove the 5th gear case cover.



13. Remove the 5th gear synchronizer assembly, selector fork and 5th gear.

• 1. Remove the retaining ring and discard it as no longer needed.
• 2. Remove the pin and discard it as no longer needed.

14.

NOTE: For ease of assembly, mark the position of the 5th synchro assembly.

Disassemble the 5th gear synchronizer.

• 1. Remove the retaining ring and discard it as no longer needed.
• 2. Remove the mounting plate.
• 3. Remove the synchronizer assembly.
• 4. Remove the synchronizer ring.
• 5. Remove the 5th gear.

15. Remove the 5th gear circlip. Discard the retaining ring as it is no longer needed.



16. Using the special tool, remove the 5th gear.



17.

CAUTION: Do not hit the mating surface.

Remove the 5th gear housing. Discard the bolts as they are no longer needed.



18.

CAUTION: Do not hit the mating surface.

Remove retaining rings.

• 1. Remove the gasket and discard it as no longer needed.
• 2. Remove the output shaft circlip and discard it as no longer needed.
• 3. Remove the input shaft retaining ring and discard it as no longer needed.
• 4. Remove the process plug.

19. Using the special tool, remove the oil seals from both axle shafts (left side shown).

• Remove the reversing light switch only if there are signs of leakage.

20.

NOTE: To prevent damage, lift the transaxle case and rotate it slightly.

Separate the two sections of the gearbox housing in the block with the drive axle (13 bolts).

• Carefully disengage the transaxle housing in the drive axle assembly.
• Clean the mating surface.

21. Remove the upper circlip of the gear selection shaft guide bushing.

• 1. Remove the top retaining ring and discard it as no longer needed.
• 2. Slide the selector shaft guide bushing down.

22. Remove the gear selector shaft guide bush.

• 1. Remove the lower circlip of the selector shaft guide bushing and discard it as no longer needed.
• 2. Remove the selector shaft guide bush.

23.

NOTE: Install a rubber band on the selector output shaft to facilitate assembly.

Remove input shaft, output shaft and selector forks.



24. Remove the input shaft oil seal and discard it as no longer needed.

25. Remove the differential assembly and permanent magnet.



26. Remove the reverse idle gear.



27. Remove the gear selection shaft and shift lock bushing.

• 1. Remove the shift lock bushing.
• 2. Remove the 5th gear and reverse gear selection shaft.

28. Remove the output shaft tapered roller bearing.

• Disconnect the bearing from the bearing housing and remove the bearing housing.

29.

CAUTION: Use the special tool as shown in the figure to prevent damage to the plugs.

Using the special tool, remove the output shaft bearing outer race. Remove the oil funnel.



30. Using the special tool, remove the differential bearing outer race.



31.

NOTE: Install the special tool in the grooves of the transaxle case in the drive axle assembly.

Using the special tool, remove the differential bearing outer race.