Chapter 11 Manual Transaxle Problems, Troubleshooting, and Service 231 Copyright by Goodheart-Willcox Co., Inc. Transaxle Transmission jack Special Tools Muncie (5-speed) Transaxle Tool Name Item Number Universal driver handle Side bearing puller adapter, differential Bearing remover Bearing remover leg (two) Bearing remover leg set Input/output shaft gears remover Differential inner bearing installer Differential and output shaft bearing cup installer Side bearing puller adapter, differential Slide hammer and adapter set Metric dial depth gage Shim selection set Differential shimming gage Shim selection set spacers (seven) Bolts, M8 × 1.25-6g/length – 160 mm (seven) Seal and race, differential, installer Shift shaft seal installer Input bearing assembly remover/installer/shaft support bearing installer Shift shaft bearing remover Shift rail bushing remover/installer Adapter to drive handle Install/remover adapter Cap screw, 1/4-20 × 2 1/2 Reverse shift rail bushing installer Bearing retainer bolt hex socket Clutch shaft inner reverse shift rail bushing remover Clutch shaft inner bushing installer Sliding sleeve bushing remover/installer Clutch shaft upper bushing remover/installer Output shaft bearing cup remover Shift detent lever bushing remover/installer Differential bearing cup remover Input/output shaft remover/installer assembly set Pallet Disassembly adapter (two) Input shaft remover/installer press tube Output shaft remover/installer adapter press tube reducer Input/output shaft bearing remover Shift shaft bearing installer Universal driver handle 21 34 5 7 6 4 10 15 35 3 16 23 24 26 25 8 22 36 27 37 40 39 38 28 33 2 31 29 19 1 30 9 11 12 13 18 14 17 32 20 2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 25 26 24 23 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Figure 11-6. The service tools shown here are used to repair a common make of manual transaxle. The type of tools needed for the job will vary with the type of transaxle. (General Motors) 13. Remove the last bolts holding the transaxle to the engine. Raise or lower the transmission jack until there is no binding between the splines on the transaxle input shaft and the clutch disc. Caution: Do not let the transaxle weight rest on the clutch assembly. This will damage the clutch disc hub and possibly the transaxle input shaft. 14. Slide the transaxle away from the engine until the input shaft clears the clutch disc. Then, lower the transaxle, watching clearances, which are usually close on front-wheel drive vehicles. Also, watch for any component that you may have forgotten to disconnect, especially any electrical connectors, ground wires, or other wiring connected to the transaxle. 15. As soon as the transaxle is clear of the vehicle, lower it to the floor and transport it to the workbench in the lowered position. If the transaxle is very dirty, you may want to remove some of the outside dirt before beginning disassembly. Manual Transaxle Disassembly Once the transaxle is removed, it can be disassembled for cleaning, inspection, and repair. The procedure outlined here is general and does not specifically cover any one transaxle. You should always consult the manufacturer’s service information for exact disassembly procedures and specifications. In addition, the tools needed for servicing vary with each transaxle. These tools are covered in detail in the service manual. A typical set of special service tools is shown in Figure 11-6. Figure 11-5. A transmission jack must be used to remove the transaxle. Always secure the transaxle to the jack before remov- ing the final transaxle case-to-engine bolts. (Ford)