232 Manual Drive Trains and Axles Copyright by Goodheart-Willcox Co., Inc. Tap transaxle case to break seal Soft-faced hammer or mallet If possible, mount the transaxle in a holding fixture before beginning disassembly. If a holding fixture is not available, make sure the transaxle is securely mounted on the workbench. One way to secure the transaxle is to tighten one of the projecting parts of the case in a vise, letting the transaxle weight rest on the workbench. Removing External Components Start the disassembly by removing the external parts of the transaxle, such as the speedometer driven gear, Figure 11-7. If the clutch throwout bearing and clutch fork were removed from the vehicle with the transaxle, remove the throwout bearing from its hub and from the clutch fork then, remove the clutch fork from its installation. Remove any sheet metal or cast aluminum covers. Before taking the case apart, shift the transaxle through its gears. This will make it easier to spot any defects in the shift linkage. Then, take the case apart. Many transaxle cases are made in two halves or as a center support with end covers. Remove the through bolts and pry the case halves apart. Sometimes, the case halves can be separated by lightly tapping them with a soft-faced hammer, Figure 11-8. Note that some cases contain ball bearings or tapered roller bearings to support the shafts. The shafts may be held to the bearings with large nuts that resemble rear axle pinion nuts. These nuts must be removed before the case can be removed. Some retaining nuts have left-hand threads. Make sure the bearings are not damaged during disassembly. Note: As you disassemble the transaxle, carefully note the position of all parts. If necessary, mark mating parts to ensure proper reassembly. Once the case has been taken apart, the transaxle inter- nals can be inspected for obvious damage. Figure 11-9 shows a common transaxle gearset as it appears after the upper half of the case has been removed. Removing Internal Components Transaxles are often easier to disassemble than manual transmissions, since most moving parts are revealed once the case halves are separated. To begin removing internal parts, you must often remove the snap rings that hold gears to their shafts. The gears can then be removed. In some instances, certain gears are held in place by other types of fasteners. Figure 11-10 shows the methods necessary to remove gears pressed to a shaft or shafts held in the case by a retaining bolt. The differential case assembly can also be removed when the transmission internal parts are removed. In some designs, it is removed first in others, it is removed after the transmission internal parts. Figure 11-11 through Speedometer driven gear and retainer Gently pry out of case Inspect case magnet for debris Inspect all parts before disassembly Figure 11-9. After the case is removed, the internal parts can be inspected and removed. All internal parts should be carefully checked for wear and damage before disassembly. (Ford) Figure 11-7. Remove all external parts before opening the trans- axle case. Many parts are connected to the transaxle shafts and gears, and they will be damaged if not removed beforehand. (Ford) Figure 11-8. Many cases must be split apart by lightly tapping on them after the retaining bolts are removed. Some cases are two-piece units, while others consist of a central support housing with two outer ends. (Ford)