236 Manual Drive Trains and Axles Copyright by Goodheart-Willcox Co., Inc. Inspect all ball and needle bearings for wear or loose- ness. The transaxle bushings and thrust washers should also be checked for wear and scoring. Do not forget to check the condition and fit of all bearing surfaces that contact and turn against their supporting shaft. See Figure 11-21. The differential requires inspection when the transaxle is overhauled, unless it is contained in a separate housing. Check the differential gears for wear or damage and the differential case for problems. If necessary, remove the ring gear from the differential case, Figure 11-22. Replace any damaged or worn differential parts. Replace seals or gaskets used for separating differential lubricant from transaxle lubricant. Check the transaxle case and all other stationary parts at this time for cracks and any distortion, which may cause leaks, poor sealing surfaces, or misalignment of the moving parts. Also, check the clutch throwout bearing and any clutch linkage that is attached to the transaxle case. Measurement Inspection Many transaxles have parts that should be checked with measuring instruments. Feeler gauges, micrometers, sliding calipers, and dial indicators are often necessary to identify defective parts that would otherwise be unno- ticed. Use of these instruments help ensure a good repair job. Measurement instruments are covered in Chapter 3. Measurement checks performed are similar, in many cases, to those for overhauling manual transmissions and differen- tial assemblies of rear-wheel drive vehicles. Consult Chapter 9 and Chapter 17 for typical examples. Manual Transaxle Assembly This section covers the general details of manual transaxle reassembly. Before beginning reassembly, make sure you have the correct replacement parts by comparing them to the old parts. Always use new gaskets and seals and lubricate all the moving parts before reassembling them. Install the differential case assembly—before or after assembling the transaxle transmission, as required. To put the transmission back together, reassemble all the trans- mission gears, synchronizers, and shafts. Once assembled, ensure that synchronizers work properly. Reassemble the shift forks and shift rails and install them on the input and output shaft gear assemblies. Then, place the entire assem- bly in position in the case, Figure 11-23. Note that some gear assembly parts may need to be installed individually into the case, as shown in Figure 11-24. Some shift forks, for example, are installed after the gears are in place. In this instance, be sure to properly align them before tightening the set screw, Figure 11-25. Reinstall all washers in the position and direction shown in the factory service manual. Some washers used Check every gear tooth closely Check all bearing surfaces Breaker bar Soft lead vise caps Differential side gear Ring gear cap screws Ring gear Figure 11-21. Bushing surfaces should be checked for wear. Replace any gear with worn out bushing surfaces, even if the teeth are in good condition. Figure 11-22. The differential case and ring gear can be taken apart by removing the cap screws. This should not be done unless one of the components must be replaced. Figure 11-20. Check gears for damage at the teeth. This gear has both drive and synchronizer teeth. Both sets of teeth should be carefully checked.