Special tool
 | Bearing outer ring puller 205-078 (15-048) |
 | Adapter 205-078-01 (15-048-01) |
 | Bearing Outer Ring Puller 205-176 (15-074) |
 | Assembly stand for engine/differential 205-329 (15-105A) |
 | Support bracket (used with 303-435) 303-435-06 (21-031B) |
 | Axle shaft oil seal remover 308-208 (16-074) |
Disassembly
All cars
1.
NOTE: 1.8L Endura-DI offered beginning with the 1999 model year.
Install special tools.
Cars manufactured up to 01.2000.
2.
NOTE: Shift the transmission to neutral.
Remove the gear shift mechanism.
- Remove the bolts.
- Pry it up with a screwdriver.
Cars manufactured since 02.2000.
3. Remove the shift mechanism cover.
4.
NOTE: Shift the transmission to neutral.
Remove the gear shift mechanism.
All cars
5. Using a special tool, remove the oil seals of the front drive axle shafts.
Diesel Engine Cars
6.
NOTE: Only necessary when repairing leaks
Remove the speedometer drive gear.
Cars with 2.0L engine
7.
NOTE: Only necessary when repairing leaks
Remove the vehicle speed sensor (VSS).
All cars
8.
NOTE: Do not remove the guide pins.
Remove the gearbox housing bolts.
9.
CAUTION: Be careful not to damage the transmission housing.
Disconnect the gearbox housing.
1. Use supports.
2. Disconnect the gearbox housing using two mounting keys ("crowbars").
10.
NOTE: Tilt the differential slightly.
Remove the differential assembly. Remove the magnetic disk.
11. Remove the 1/2nd gear selector shafts and the gear selector fork.
12. Remove the gear selection forks.
- 1. Move the 5th/Reverse gear selection fork to the side and remove it.
- 2. Turn the 3/4th gear shift fork and remove it.
13. Remove the retaining ring from the reverse gear intermediate gear.
14. Remove the primary and secondary shafts.
- Remove the primary and secondary shafts together from the gearbox housing.
- Remove the reverse idler gear together with the needle roller bearing and thrust washers.
15. Remove the outer race of the differential bearing.
- Install the special tool into the crankcase recess.
16. Remove the outer bearing rings from the primary and secondary shafts.
- Install the special tool into the crankcase recess.
17. Clean and degrease the input shaft splines.
18.
CAUTION: Avoid contact with skin or eyes with brake fluid. If brake fluid contacts skin or eyes, rinse immediately with water. Failure to follow these instructions may result in injury.
CAUTION: Apply adhesive tape to the input shaft splines to prevent damage to the input shaft seal.
NOTE: Discard the clutch slave cylinder as it is no longer needed.
Remove the clutch slave cylinder (with thrust bearing).
19. Remove the adhesive tape from the input shaft splines.
20. Remove the outer bearing rings together with the adjusting shim from the differential and input shaft.
- Install the special tool into the crankcase recess.
21. Remove the outer ring of the secondary shaft bearing together with the adjusting shim.
- Install the special tool into the crankcase recess.
22.
NOTE: Only in case of damage or leaks
Remove the reverse gear intermediate gear shaft.
23.
NOTE: Only in case of damage or leaks
Remove the reverse gear intermediate gear shaft.
- Remove the axle using a hard wooden block.
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