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Transaxle Disassembly

  1. Install transaxle on Holding Fixture (J-33366) and attach fixture to Base Plate (J-3389-20). Remove rear cover bolts and cover. Remove gearshift box assembly along with 4 bolts from transaxle case.
  2. Using a screwdriver, shift transaxle into gear. Remove 5th gear drive and driven gear retaining nuts from input and output shafts. Discard retaining nuts.
  3. Shift transaxle into Neutral. Remove detent spring retaining bolts for 1st-2nd gear, 3rd-4th gear, and 5th gear. Remove detent springs and balls. See Fig 1 .
  4. Remove reverse detent spring retaining bolt from side of case. Remove detent spring and ball. Remove 1st-2nd gear, and 3rd-4th gear switches. Use a magnet to remove pins from 3rd-4th gear switch hole.
    Fig 1: Removing Detent Bolts, Springs & Balls
    G95A55640Courtesy of GENERAL MOTORS CORP.
  5. Place 5th gear synchronizer in neutral. Remove roll pin at 5th gear shift fork. Remove 5th gear synchronizer hub, sleeve, roller bearing, gear, and shift fork from output shaft as an assembly.
  6. Using Puller (J-35274), remove 5th gear from input shaft. Remove 7 screws Using a No. 45 Torx bit, remove 7 screws from bearing retainer. Remove bearing retainer and shims from input and output shafts.
  7. Remove bolt retaining reverse idler shaft from side of case. Using Puller (J-22888 & J-22888-30), remove collar and thrust washer from output shaft. Remove transaxle case bolts and separate case from clutch housing.
  8. Remove reverse idler gear and shaft. With shaft detents aligned and facing the same way, remove 5th and reverse shafts. See Fig 2 .
    Fig 2: Removing 5th & Reverse Shift Shafts
    G95B55641Courtesy of GENERAL MOTORS CORP.
  9. Using a punch and hammer, remove roll pin from 1st-2nd shift fork. Slide 1st-2nd shaft upward and remove fork and shaft from case. Remove roll pin and reverse shift lever. See Fig 3 .
  10. Remove input shaft, output shaft, and 3rd-4th shift fork and shaft as an assembly. Remove differential assembly. Remove reverse shift bracket, and remove 3 interlock pins. Remove rear bearing outer races from transaxle case.
  11. Remove outer races for input shaft front bearing, output shaft front and differential side bearings. Use Bearing Cup Remover (J-26941) with Puller (J-33367) for input, output, and differential bearing race removal. Use bearing cup remover and slide hammer to remove differential bearing race in housing.
  12. Remove input shaft seals from housing. Remove clutch shaft seal only if replacement is required. Using Bushing Replacer (J-28412), drive out bushing toward inside of case. Remove fork assembly only if replacing clutch fork assembly.
Fig 3: Exploded View Of Transaxle Shift Lever & Shift Fork Assys.
G95C55642Courtesy of GENERAL MOTORS CORP.
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