Gearbox with axle (cars after 08.2000) — disassembly

Special tool

	Pinion Seal Remover 205-078 (15-048)
	Differential Bearing Inner Race Puller 205-176 (15-074)
	Engine/Differential Mounting Bracket 205-329 (15-105A)
	Oil pan puller 303-428 (21-179)
	Booth 303-435 (21-187)
	Support bracket for 303-435 303-435-06 (21-031B)
	Crankcase Bushing/Seal Installation Tool 308-045 (16-015)
	5th gear puller of primary shaft 308-082 (16-035)
	Plugs for the gearbox housing in the block with the driving axle 308-152 (16-070)

WARNING: Use protective pads for the vise.

CAUTION: To avoid damage, use a brass or plastic mallet.

1. Using special tools, install the gearbox in block with the drive axle on the assembly stand.



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


3.

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

CAUTION: Using suitable tape, cover the input shaft splines to prevent damage to the clutch slave cylinder seal.

Remove the clutch slave cylinder.



4. Remove the adhesive tape from the input shaft splines.

5. Remove the vehicle speed sensor (VSS) (if equipped).

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

6. Remove the gear selector mechanism cover.



7. Remove the gear shift lever.

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

8. Remove the gear shift cable bracket.



9. Remove the gear selector lever. Remove the boot.



10. Remove the gear selector lock mechanism.



11. Remove the 5th gear housing cover mounting bolts.




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



13. Remove the 5th gear synchronizer assembly, gear 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: To facilitate assembly, mark the position of the 5th gear synchronizer 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 retaining ring. Discard the retaining ring as it is no longer needed.



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



17.

CAUTION: Do not strike the mating surface.

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



18.

CAUTION: Do not strike the mating surface.

Remove the retaining rings.

• 1. Remove the gasket and discard it as no longer needed.
• 2. Remove the secondary shaft retaining ring and discard it as no longer needed.
• 3. Remove the primary shaft retaining ring and discard it as no longer needed.
• 4. Remove the technological plug.

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

• The reverse light switch should only be removed if there are signs of a leak.

20.

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

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

• Carefully separate the gearbox housing from the drive axle.
• Clean the mating surface.

21. Remove the upper retaining ring of the gear selector shaft guide sleeve.

• 1. Remove the upper retaining ring and discard it as no longer needed.
• 2. Slide the gear selector shaft guide sleeve downwards.

22. Remove the gear selector shaft guide sleeve.

• 1. Remove the lower retaining ring of the gear selector shaft guide sleeve and discard it as no longer needed.
• 2. Remove the gear selector shaft guide sleeve.

23.

NOTE: To facilitate assembly, install a rubber boot on the secondary gear selector shaft.

Remove the input shaft, output shaft and gear 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 gear intermediate gear.



27. Remove the gear selector shaft and gear shift lock sleeve.

• 1. Remove the gear shift lock sleeve.
• 2. Remove the 5th gear and reverse gear selector shaft.

28. Remove the secondary 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 a special tool, remove the outer ring of the secondary shaft bearing. Remove the oil funnel.



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



31.

NOTE: Install the special tool into the grooves of the transaxle housing.

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