Assembly

ASSEMBLY




Figure 1 Input Shaft Assembly







NOTE: When servicing the input shaft assembly, all snap rings MUST be replaced with new ones upon assembly. 5th gear nut must also be replaced.

NOTE: When installing 3/4 synchronizer hub to shaft, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.

NOTE: Refer to (Figure 1) for input shaft assembly reference.

1. Install input shaft into fixture 8487.
2. Install thrust washer if removed upon disassembly.
3. Install 3rd gear and needle bearing (Figure 2) (Figure 3).




Figure 2 3rd Gear Needle Bearing Removal/Installation










Figure 3 3rd Gear Removal/Installation






4. Install 3rd gear blocker ring (Figure 4).




Figure 4 3rd Gear Blocker Ring


1 - 3RD GEAR BLOCKER RING

5. Install 3/4 synchronizer (Figure 5). When installing 3/4 synchronizer hub to shaft, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.




Figure 5 3/4 Synchro Assembly


1 - 3/4 SYNCHRONIZER

6. Install NEW 3/4 synchronizer snap ring (Figure 6).




Figure 6 3/4 Synchro Snap Ring






7. Install 4th gear blocker ring (Figure 7).




Figure 7 4th Gear Blocker Ring


1 - 4th GEAR BLOCKER RING

8. Install 4th gear and needle bearing (Figure 8) (Figure 9).




Figure 8 4th Gear Needle Bearing Removal/Installation


1 - 4TH GEAR NEEDLE BEARING





Figure 9 4th Gear Removal/Installation






9. Install 5th gear and press into position using installer 8481 (Figure 10).




Figure 10 5th Gear Installation






10. Install NEW 5th gear nut and torque to 262 Nm (193 ft. lbs.) using wrench 8478 (Figure 11).




Figure 11 5th Gear Nut Removal/Installation






11. Stake 5th Gear nut in four (4) places as follows:
a. Install staking tool 8479 to 5th gear nut.
b. Tighten upper thumb screw by hand (Figure 12).
c. Tighten two (2) side thumb screws by hand.
d. Tighten both staking screws until they bottom on tool body (Figure 13).
e. Loosen staking screws and thumb screws. Remove tool and visually inspect stake (Figure 14).
f. Remove tool, rotate 90�, and repeat process to stake in four (4) places.




Figure 12 Staking Tool Set-Up










Figure 13 Tighten Stake Screws


1 - STAKING TOOL 8479





Figure 14 5th Gear Nut Stake (Four Places)


1 - STAKE


NOTE: The input shaft sealed roller bearing and snap ring do not get installed until transaxle assembly to facilitate installation of the reverse idler gear mechanism.