Section 5 (T355 Manual Transmission (Service Information)): Disassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

Fig 1: Concentric Slave Cylinder Location

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Remove bolts from slave cylinder-to-clutch bellhousing and remove slave cylinder (1) from transaxle.

Fig 2: Case Bolts
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1 - CASE BOLTS

The T355 transaxle internal components can be serviced only by separating the gear case from the bellhousing case.

CAUTION:
The transaxle output shaft is serviced as a unit. No disassembly and reassembly is possible. Damage to the transaxle may result.
Place transaxle on bench.
Remove transaxle case half bolts (1).

Fig 3: Separating Case Halves Using Screwdrivers
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1 - PRY TOOL

2 - CASE HALVES

3 - PRY SLOT

Place two screwdrivers (1) into the slots (3) provided in the case halves (2) near the dowels. Separate the case halves.

Fig 4: Bellhousing Case Half Removed

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1 - INPUT SHAFT

2 - OUTPUT SHAFT

3 - DIFFERENTIAL ASSEMBLY

4 - GEARTRAIN HOUSING

Remove bellhousing half from gear case half (4).

Fig 5: Removing/Installing Differential

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1 - INPUT SHAFT

2 - OUTPUT SHAFT

3 - DIFFERENTIAL ASSEMBLY

4 - GEARTRAIN HOUSING

Remove differential assembly (3) from housing (4).

Fig 6: Reverse Idler Shaft

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1 - CASE

2 - REVERSE IDLER SHAFT

3 - REVERSE IDLER SHAFT BOLT

Remove reverse idler shaft bolt (3).

Fig 7: Removing/Installing Reverse Idler Shaft
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1 - REVERSE IDLER SHAFT

2 - SPACER
Remove reverse idler shaft (1).

Fig 8: Reverse Idler Gear & Spacer
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1 - SPACER

2 - REVERSE IDLER GEAR
Remove reverse idler gear (2) and spacer (1).

Fig 9: Linkage Tie Bar Clips
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Remove the clips (1) at the linkage tie bar (2).

Fig 10: Linkage Tie Bar
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Remove the linkage tie bar (1).
Remove the plug (3) at the selector shaft (2).

Fig 11: Screws Retaining Reverse Fork Bracket
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1 - SCREWS (2)

2 - REVERSE FORK BRACKET

Remove two screws (1) retaining reverse fork bracket (2).

Fig 12: Removing/Installing Reverse Fork Bracket & Reverse Cam Block-Out Assembly

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1 - REVERSE FORK BRACKET

2 - REVERSE CAM BLOCKOUT

3 - SHIFT BLOCKER ASSEMBLY

Remove reverse fork bracket (1) and reverse cam block-out assembly (2).

Fig 13: Removing/Installing Selector Shaft Spacer

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1 - SHIFT BLOCKER ASSEMBLY

2 - SELECTOR SHAFT SPACER (PLASTIC)

3 - SNAP RING PLIERS

Using snap-ring pliers (3), remove link shaft spacer (2).

Fig 14: Selector Shaft
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1 - SHIFT ASSEMBLY

2 - SELECTOR SHAFT
Pull the link shaft shift pin out of the slot in the blocker assembly. Turn selector shaft (2) up and out of the way.

Fig 15: End Cover And Shaft Bolts
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Remove transaxle end cover (2) and rear detent assembly bolts (1).

Fig 16: Backup Lamp Switch
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Remove the backup lamp switch (2).

Fig 17: Snap Rings Retaining Bearings
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1 - SNAP RING PLIERS

2 - SNAP RINGS
Remove two snap rings (2) retaining the output shaft and the input shaft to the bearings.

Fig 18: Bench Fixture T355
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The Bench Fixture (special tool #6785, Assembly, Pallet) (4) and adaptors (special tool #9761-1, Pad, Shift Rail Support) (1), (special tool #9761-2, Spacer) (3), (special tool #9761-3, Spacer) (2), (special tool #9761-6, Stand Off) (5) and (special tool #9761-7, Stand Off) (6) will be used to remove input and output shafts from the case.

Fig 19: Trans On Fixture T355
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Turn transaxle over. Install transaxle (1) onto Bench Fixture (special tool #6785, Assembly, Pallet) (2). Verify shim spacers and adaptors are in position on Bench Fixture (special tool #6785, Assembly, Pallet). Install transaxle into shop press.

Fig 20: Bearing Fixture
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1 - BEARING FIXTURE

2 - TRANSAXLE CASE

Install Bearing Remover (special tool #6768, Remover, Bearings) (1) onto transaxle end bearings. Verify tool is properly aligned to input and output shafts.

CAUTION:

The oil dams in the input and output shafts can be damaged while pressing on the shafts if the bearing fixture is not used properly.

Fig 21: Pressing Gears Out Of Case

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1 - BEARING FIXTURE

2 - PRESS RAM

3 - TRANSAXLE CASE

4 - BENCH FIXTURE

Install transaxle gear case (3) into shop press. Press (2) output and input shaft assemblies out of case.
Remove transaxle from press.

Fig 22: Trans On Fixture T355
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Carefully remove transaxle case (1) from the shaft assemblies and Bench Fixture (special tool #6785, Assembly, Pallet) (2).

Fig 23: Oil Feed Trough
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1 - OIL FEED TROUGH
Be sure the oil-feed trough (1) to the end bearings is not damaged.

Fig 24: Reverse Brake Friction Cone & Blocking Ring At Input Shaft Assembly
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Remove the reverse brake friction cone (1) from the input shaft assembly.
Remove the blocking ring (2) from the input shaft assembly.

Fig 25: Input/Output Shaft Assemblies, Shift Blocker Assembly, Reverse Shift Fork, & Detent Assembly
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Remove the shift blocker assembly, the reverse shift fork (5) and the detent assembly from the bench fixture (4).
Remove input (2) and output shaft (1) assemblies from Bench Fixture (special tool #6785, Assembly, Pallet).

CAUTION:

The output shaft assembly is serviced as an assembly. Do not try to repair any component on the output shaft. If the 1-2 synchronizer or gear fails, it is necessary to replace the complete output shaft assembly.