Transaxle Reassembly
- Install oil pump drive gear (4WD). Install transaxle case receiver (2WD). Install differential assembly. Install input and output shaft assemblies.
- Coat the gear shift fork No. 2 with gear oil and install it to the input shaft assembly. Install gear shift fork No. 3 to gear shift fork shaft No. 3. See Figure. Using a brass bar and hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft.
- Apply gear oil to each sliding part of gear shift fork shaft No. 3 and install it to transaxle case. Apply gear oil to each sliding part of gear shift fork No. 1 and install it to output shaft assembly. Install gear shift head No. 1 to gear shift fork shaft No. 2. Apply gear oil to each sliding part of the gear shift fork shaft No. 2 and install it to the transaxle case.
- Install 2 shift fork bolts to gear shift head No. 1. Tighten to 18 ft. lbs. (24 N.m). Using a magnetic finger, install reverse shift fork roller to reverse shift fork. Using a brass bar and hammer, install the shift fork shaft snap ring to the shift fork shaft No. 1. Install gear shift fork shaft No. 1 to transaxle case. Install shift fork bolt to gear shift fork No. 1.
- Install reverse idler gear and shaft. Ensure reference marks on idler gear and clutch housing are aligned. See Fig 1. Place reverse shift fork pivot into reverse shift arm and install reverse shift arm bracket to clutch housing. Install No. 1 and No. 2 oil pipes. See Figure.
- Using a pin punch (5 mm), install the reverse restrict pin and reverse restrict pin assembly. See Fig 2. Clearance should be .49-.53" (12.5-13.5). Coat the reverse restrict pin plug with appropriate sealant and install in transaxle case.NOTE: This transaxle uses no gasket between major cases; use Three Bond (1281) sealant. Assemble cases within 10 minutes after applying liquid gasket. Allow 30 minutes curing time before filling with oil.
- Apply Three Bond (1281) sealant to transaxle case. Install transaxle case to clutch housing. Install reverse idler gear shaft retaining bolt.
- Install output shaft rear bearing outer race. Install appropriate adjusting shim. Install snap ring to input shaft rear bearing. Install rear bearing retainer. Install needle bearing and 5th gear. Install synchronizer ring and key spring to No. 3 clutch hub. Install No. 3 clutch hub with synchronizer assembly.
- Select a snap ring that will allow minimum axial play and install snap ring on shaft. Snap rings are available in .002" (.05 mm) increments from .069" (1.75 mm) to .085" (2.15 mm) thick. Shims are stamped "a"-"j". See Figure.
- Recheck 5th gear thrust clearance. Standard clearance is .004-.026" (.10-.65 mm). Install 5th driven gear. Install No. 3 hub sleeve and No. 3 shift fork. Tighten No. 3 hub sleeve set bolt to specification. Lock transaxle in 2 gears. See Figure. Install and tighten NEW output shaft lock nut to specification. See TORQUE SPECIFICATIONS . Stake lock nut. Unlock transaxle.
- Apply Three Bond (1281) sealant to transaxle case cover. Install cover. Install shift and select lever shaft. Install control shaft cover. Install lock bolt. Install boot to control shaft oil seal. Ensure boot is installed in correct direction. Position air bleed of boot downward. Align shaft notch with pin groove, and install pin. Install and tighten nut to 106 INCH lbs. (12 N.m). Install selecting bellcrank.
- Install back-up light switch, breather plug, lock ball assembly and vehicle speed sensor. See Figure. See TORQUE SPECIFICATIONS . Remove clutch release fork assembly with bearing. See Figure and Figure .