Chapter 11 Manual Transaxle Problems, Troubleshooting, and Service 233 Copyright by Goodheart-Willcox Co., Inc. Hold special puller stationary Socket Breaker bar Inspect parts as they are removed Idler gear A B Retaining bolt Case Magnet Differential cover Differential case assembly 1/8-Inch bead of RTV sealant for gasket Figure 11-11. The transaxle differential case assembly is often installed under a special cover, as shown here. It must be removed to gain access to this differential unit. The cover contains a magnet to pick up metal particles. (Chrysler) Figure 11-13 shows the removal of a differential case assembly from a common make of transaxle. Most differentials are simple units, using helical gears for the ring and pinion. If the transaxle is used with a longi- tudinal engine, it probably has a hypoid ring and pinion. This type of differential assembly is overhauled in the same manner as one on a rear-wheel drive vehicle. The differen- tial used with the longitudinal engine is in its own hous- ing, separate from the transmission, and it does not require disassembly unless it, too, is defective. Many hypoid-type differentials used with front-wheel drive vehicles develop case cracks, so they must be checked closely. Disassembling the Components The next step in transaxle overhaul is to disassemble the individual components. Disassembly techniques are similar to those used to overhaul manual transmissions. Some transaxle bearings are pressed onto shafts and must be removed by using a press and the proper adapters, Figure 11-14. Since the removal process usually damages the bearings, do not remove the bearings unless they are going to be replaced. Many tapered roller bearings used on transaxles have outer races, or bearing cups, placed in the transaxle case. These also should not be removed unless the bearing is replaced. Always mark the bearing cups if they are removed. This will ensure that they are reinstalled in their original positions, Figure 11-15. Some gears may need to be pressed off their shafts, while other gears are integral with their shaft. Most gears are held onto their shaft by snap rings. Pay particular attention to the synchronizer blocking rings during gear removal to pre- vent damage to the soft brass. The gears and synchronizers should be laid on the workbench in order of disassembly. See Figure 11-16. Careful disassembly of parts makes reassem- bly easier. Inspect all parts as you disassemble them. This enables you to determine which parts require replacement. Other parts that require disassembly are the internal shift linkage and any bearings that were not removed in pre- vious steps. Damaged shift forks or shift rails may require further disassembly, Figure 11-17. The differential case assembly should also be dis- assembled for inspection. If necessary, the differential side bearings can be removed using the proper puller, Figure 11-18. Since the removal process usually dam- ages the bearings, they should not be removed unless they are going to be replaced. Transaxle seals should be removed from their housings once all other parts are removed. Most seals can be pried from their housings with a screwdriver. When removing seals, be careful not to nick or dent any gasket sealing sur- faces or seal housings. Figure 11-10. Transaxle shafts and gears are installed by many methods. Removal methods vary accordingly. A—Pressed-on gears may be removed with a special puller. B—Removing a special retainer bolt will release a shaft and gear in this trans- axle. (General Motors)