Transaxle Overhaul - General Information

The authors of this Manual do not recommend that vehicle owners attempt a complete overhaul of the manual transaxle on their own. Disassembly and assembly of the transmission require removing and then installing many small components. Numerous precise measurements must be made, and a large number of clearances must be set accurately by selecting shims, rings, and spacers. For all of the above reasons, a complete manual transmission overhaul is best left to a professional automotive service facility. Note that in many cases a rebuilt unit can be obtained on an exchange basis, which is often cheaper than performing a complex repair.

Nevertheless, a complete manual transmission overhaul by a home mechanic is not entirely impossible. The only essential requirements are the necessary special tools and careful attention to every procedure.

Tools required for a manual transmission overhaul include snap ring pliers for internal and external snap rings, a bearing puller, a slide hammer, a set of punches and center punches, a DTI gauge and, possibly, a hydraulic press. In addition, a sturdy workbench equipped with a vise, or a special assembly stand, will be needed.

During disassembly, make a note, or preferably record, the installation order of each part as it is removed.

Before disassembling the transmission, it is advisable to analyze the symptoms of the failure in order to approximately determine its cause. Many failures are clearly associated with the failure of specific components. See also the Section on manual transmission troubleshooting at the beginning of this Manual.