How do you split the manual transaxle case? I.

ANONYMOUS

MEMBER
1998 CHEVROLET CAVALIER
10,000 MILES

How do you split the manual transaxle case? I can't find a diagram anywhere. The transaxle has been removed from the car and I have removed all the bolts but there seems to be something with the internal gears stopping the two parts from coming apart.

1 Reply

HMAC300

MECHANIC
48,601 POSTS

TRANSAXLE� DISASSEMBLY

1. Remove� clutch� release� bearing.� Place� transaxle� assembly� into� holding� fixture.� Remove� 7� bolts� retaining� rear� cover� assembly� to� transaxle� case.� Remove� rear� cover� assembly.
2. Remove� 4� bolts� retaining� control� box� assembly� to� transaxle� case.� See Fig.� 1� and Fig.� 3�.� Shift� transaxle� into� gear.� Remove� 5th� gear� drive� and� driven� gear� retaining� nuts� from� input� and� output� shaft.� Discard� retaining
nuts.

Fig.� 1:� Removing� Control� Box� Assembly
Courtesy� of� GENERAL� MOTORS� CORP.

3. Shift� transaxle� to� Neutral� position� so� detents� of� shift� rails� are� aligned.� Remove� detent� spring� retaining� bolts� for� 1st 2nd, � 3rd 4th� and� 5th� gears.� Remove� detent� springs� and� detent� balls� from� cavities.� Remove� reverse
detent� spring� and� detent� ball.� Place� 5th� gear� synchronizer� in� Neutral� position.
4. Remove� 5th� gear� shift� fork� roll� pin� and� discard� roll� pin.� Remove� 5th� gear� synchronizer� hub, � sleeve, � roller� bearing� and� gear� with� shift� fork� assembly� from� output� shaft.� Using� gear� puller, � remove� 5th� gear� from� input
shaft.
5. Remove� 7� Torx� screws� from� bearing� retainer.� Remove� bearing� retainer� and� shims� from� input� and� output� shafts.� Remove� bolt� retaining� reverse� idler� gear� to� transaxle� case.� Remove� collar� and� thrust� washer� from
output� shaft� using� puller.� Remove� snap� ring� from� input� bearing� groove.� Remove� 14� bolts� holding� transaxle� case� together, � and� separate� case� from� clutch� housing.� Remove� back up� switch.� See Fig.� 2�.
6. Remove� reverse� gear� shift� rail� snap� ring.� Pull� up� on� rail� until� interlock� pin� aligns� with� reverse� gear� shift� rail� detent.� Remove� 5th� gear� shift� rail� and� reverse� gear� shift� rail.� Remove� reverse� idler� gear� and� reverse� idler
shaft.� Remove� roll� pin� from� 1st 2nd� shift� fork, � and� discard� roll� pin.� See Fig.� 3�.� Slide� 1st 2nd� shift� rail� upward� to� clear� housing, � and� remove� rail� from� case.
7. Remove� cotter� pin� and� roll� pin� from� reverse� shift� lever.� Remove� input� and� output� shafts� with� 3rd 4th� shift� forks� and� rail� as� an� assembly.� See Fig.� 3�.� Remove� differential� from� clutch� housing.� Remove� 4� bolts
retaining� reverse� shift� bracket, � and� collect� 3� interlock� pins.
8. Using� bearing� remover, � drive� out� rear� outer� bearing� races� for� input� and� output� bearing.� Using� puller, � remove� outer� races� of� input� and� output� shaft� front� bearings.
9. Using� slide� hammer� and� puller, � remove� differential� bearing� races� from� case.� Remove� input� shaft� seal� from� housing.� Remove� clutch� shaft� seal� only� when� replacement� is� necessary.� Drive� out� clutch� shaft� bushing
toward� outside� of� case� (if� required).� Using� puller, � remove� clutch� shaft� needle� bearings� (if� required).

Fig.� 2:� Exploded� View� Of� Isuzu� 76MM� 5 Speed� Manual� Transaxle
Courtesy� of� GENERAL� MOTORS� CORP.
You probably have the sanp ring holding the bearings so it won't come apart.

Images (Click to make bigger)