Assembly
ASSEMBLE1. Install park/neutral position switch and gasket, drain plug and washer, and back-up lamp switch. Tighten to specifications.
2. Install differential seals using differential seal replacer tool No. T87C-77000-H, or equivalent.
3. Install input shaft seal using bell housing seal replacer tool No. T77J-7025-G, or equivalent.
4. Adjust input shaft and main shaft bearing preload as follows:
a. Install differential bearing cup into clutch housing using driver handle tool No. T80T-4000-W and differential bearing cup replacer Tool No. T88C-77000-FH, or equivalent.
b. Install oil funnel and main shaft front bearing cup into clutch housing.
c. Install input gear shaft front bearing cup into clutch housing. Ensure bearing cups are fully seated.
d. Install input shaft gear assembly into clutch housing, then place rear bearing cup on input shaft bearing.
e. Position shim selection gauge tool No. T88C-77000-CH3, or equivalent, on top of input shaft gear assembly.
Clutch Housing Collar Locations:
f. Install six collars on clutch housing at positions shown in the Clutch Housing Collar Locations image, then install washers and bolts. Torque to 13-14 ft lbs.
g. Mount dial indicator tool No. 4201-C, or equivalent, on input shaft.
h. Rotate input shaft gear assembly several times to seat bearings, then zero dial indicator at lowest point on end of input shaft.
i. Raise input shaft gear assembly by hand, then read endplay. Turn input shaft gear several times, until dial indicator returns to zero.
j. Raise input shaft gear assembly and obtain second reading. Average at least three readings to obtain endplay reading.
k. Subtract 0.028 inch from endplay reading to obtain final shim size required.
l. Select shim closest or slightly larger than final shim reading.
NOTE: Do not use more than two shims.
m. Remove bolts and washers securing transaxle case to clutch housing, then the transaxle case, gauge, rear bearing cup, and input shaft assembly.
NOTE: Do not remove bearing cups.
n. Repeat above procedure for main shaft.
5. Install adjustment shim(s), then the rear differential bearing cup using differential bearing cup replacer tool No. T88C-77000-FH, or equivalent.
Diaphragm Spring Installation:
6. Install adjustment shim(s), diaphragm spring, and input shaft bearing cup.
7. Install breather and cover, then the change rod seal using pilot bearing installer tool No. T88C-7025-EH, and driver handle tool No. T80T-4000-W, or equivalents.
8. Install change rod and boot, spring, reverse gate, selector, and new roll pin.
9. Install change arm and guide plate.
10. Install reverse lever and lever shaft, then a new roll pin.
11. Install speedometer driven gear, or vehicle speed sensor, as equipped.
12. Install magnet, differential, input shaft, and main shaft.
Shift Fork And Shift Rod Assembly Orientation:
13. Shift transaxle into second and fourth gears, then position the shift fork and shift rod assembly.
Spring Seat And Spring Installation:
14. Install spring seat and springs into reverse lever shaft, then the ball holding it in place with a scraper knife. Push control end, in direction shown in the Spring Seat And Spring Installation image, until ball is in shaft.
15. Place each clutch hub sleeve in the neutral position, then tap shift rod from above so steel ball goes into center groove.
16. Install crank lever shaft and assembly, then insert the pin.
17. Install gate and fifth/reverse shift rod, then tighten gate mounting bolt.
NOTE: Ensure shift rod and gate mounting hole are aligned.
18. Install reverse idler gear and shaft.
19. Align end of interlock sleeve with control lever.
Interlock Sleeve And Control Lever Alignment:
NOTE: Ensure reverse idler shaft screw hole is as shown in the Interlock Sleeve And Control Lever Alignment image.
20. Clean clutch housing and transaxle mating surfaces, then apply thin bead of suitable sealant.
21. Install transaxle case on clutch housing.
22. Install two transaxle plugs tool No. T88C-7025-AH, or equivalent, between differential side gears.
NOTE: Failure to install plugs may allow side gears to become improperly positioned.
23. Install lock bolt, then the guide bolt. Tighten bolts to specifications.
24. Install ball, springs, and lock bolt. Tighten lock bolt to specifications.
25. Install main fifth gear, gear sleeve and input fifth gear.
26. Install synchronizer ring, shift fork, clutch hub assembly, and synchronizer ring.
27. Install roll pin, main reverse synchronizer gear, and input reverse synchronizer gear.
28. Shift transaxle to first gear; then, using torque adapter tool No. T88C-7025-GH, or equivalent, lock up input shaft and install locknuts. Tighten locknuts to specifications.
29. Clean transaxle case and rear cover mating surfaces, then apply thin coat of suitable sealant.
30. Install rear cover and bolts. Tighten bolts to specifications.