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Transaxle Disassembly

NOTE: On KM 162 transaxle, 5th gear shift rail and fork are part of 3rd-4th rail and fork assemblies.
  1. Remove clutch cable bracket and transaxle mounting bracket. Remove back-up light switch and steel ball from case. On KM 162 transaxle, remove selector switch. Remove select actuator bracket bolts.
  2. Pull on actuator until gear shifts into "HIGH" position. Remove snap ring and pin and remove actuator. On all transaxles, remove rear cover and bearing spacers. Remove transaxle case.
  3. Place shift rails in neutral, remove plugs from side of case and remove springs and 3 steel balls. Remove reverse idler shaft and gear. Remove reverse shift lever assembly and reverse shift rail.
  4. Remove 3rd-4th shift rail spacer collar. On KM 162 transaxle, mark position of, and remove 5th gear shift lug. On all transaxles, using a flat punch, remove spring pins from 1st-2nd and 3rd-4th shift forks.
  5. Remove 1st-2nd shift rail from case. Shift fork and rail cannot be removed from case as a unit. Remove 3rd-4th shift rail from case. Remove 1st-2nd shift rail and fork with 3rd-4th shift rail.
  6. Shift 3rd-4th synchronizer sleeve to 4th gear position and remove output shaft assembly. Remove differential assembly. Remove input shaft poppet plug, spring and ball (KM 165).
  7. Remove input shaft bearing retainer. Remove input shaft assembly and shift rail and fork (KM 165) with intermediate shaft. Remove shift shaft spring retainer.
  8. Pull out shift shaft spring pin with pliers, then remove shift shaft through case hole. When shift shaft is removed, place finger over control finger hole to prevent poppet ball from falling out. Remove control finger, springs, spacer, poppet spring and ball.
  9. Remove selector finger lock pin, selector shaft and selector finger (KM 165). Place identification mark on bearing outer race and remove bearing. Outer race must be installed in original position. Remove speedometer driven gear assembly.
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