Assembly
ASSEMBLE1. Install input shaft bearing race, main shaft bearing race, and oil funnel into clutch housing.
2. Set differential bearing race into clutch housing and seat it with differential bearing cup replacer tool No. T88C-7025-BH and driver handle tool No. T80T-4000-W, or equivalents.
3. Place remaining bearing races into shim selection gauge tool No. T88C-77000-CH2, or equivalent. Turn halves of gauge to ensure there is no gap.
4. Set bearing race and gauge onto differential.
5. Set gauge on clutch housing end of input shaft and main shaft, then set input shaft and main shaft into clutch housing.
Transaxle Case Collar Locations:
6. Set collars from shim selection set tool No. T87C-77000-J, or equivalent, onto clutch housing.
7. Seat bearings for measurement by placing transaxle case onto collars and tighten bolts from shim set to tighten gauge.
8. Turn gauge to eliminate gap between halves, then ensure both shafts and differential turn smoothly.
9. Turn gauge by hand until it no longer turns, then use feeler gauge to measure gap in gauge. Use this measurement below to determine shim thicknesses.
NOTE: Measure gap around entire gauge.
10. Adjust input and main shaft bearing preload as follows:
a. Subtract diaphragm spring thickness 0.026 inch from gap determined above.
b. Select shim from kit part No. E92Z-76172-A, or equivalent, to create gap within specified range. Shims are available in sizes ranging from 0.008 inch-0.028 inch in 0.002 inch increments.
11. Adjust differential bearing preload as follows:
a. Install differential rotator tool No. T90P-7025-BH, or equivalent, into differential.
b. Use adjusting bars inserted into shim gauge to torque gauge to specified preload of 4.3 ft lbs.
c. Using torque wrench, turn rotator and check differential preload. Preload should be 4.3 ft lbs.
d. Use feeler gauge to measure gap in gauge.
NOTE: Measure entire circumference of gauge.
e. Add 0.0059 inch to average of measured gaps and select shim(s) closest to value. Shims are available in sizes ranging between 0.004 inch-0.030 inch, and between 0.031 and 0.047 inch, in 0.002 inch increments.
f. Remove case, differential rotator, and shim gauges, then the bearing races from gauges.
g. Remove input and main shafts, then the differential.
12. Use differential seal replacer tool No. T87C-77000-H, or equivalent, and a hammer to install differential oil seal, then lubricate inner seal lip with transaxle fluid.
13. Install input shaft and extension housing seal using bell housing seal replacer tool No. T77J-7025-G, or equivalent, then lubricate inner seal lip with transaxle fluid.
14. Install adjustment shims, diaphragm springs, then the input and main shaft bearing races into transaxle case. Use soft-faced hammer to install bearing race, tapping circumference lightly until fully seated.
15. Install differential bearing race into case using driver handle tool No. T80T-4000-W and differential bearing cup replacer tool No. T88C-7025-BH, or equivalents.
16. Install shifter shaft seal using pilot bearing installer tool No. T88C-7025-EH and driver handle tool No. T80T-4000-W, or equivalents, then slide input shift shaft into clutch housing.
NOTE: Ensure gear shift control shaft boot drain hole will be facing downward when transaxle is mounted in vehicle.
17. Install shift gate selector and input shift shaft selector plate arm onto input shift shaft, then drive new roll pin into selector.
18. Install shift rod bolt. Tighten to specifications.
19. Install control selector plate, two bolts and reverse idler gear spacer, then the differential into case.
20. Check input shaft bearing preload as follows:
a. If input shaft and differential are to be checked, install differential and input shaft at the same time. Then both can be checked without opening case again.
b. Set input shaft into clutch housing, then install case.
c. Install old locknut onto input shaft, then place socket and torque wrench over nut to measure bearing preload. Preload should measure 0.9-2.1 in lbs. If it is not, repeat preload at beginning of this procedure.
21. Check differential preload as follows:
a. Set differential rotator tool No. T90P-7025-BH, or equivalent, into differential.
b. Use torque wrench to measure preload. Preload should be 13-17 in lbs. If it is not, repeat preload at beginning of this procedure.
22. Check main shaft preload as follows:
a. Install mainshaft into clutch housing, then set case on housing and install bolts.
b. Place old mainshaft nut on shaft.
c. Use socket and torque wrench to measure preload. Preload should be 1.8-3.4 in lbs. If it is not, repeat preload at beginning of this procedure.
3-4 Shift Fork And Rod W/Input And Mainshaft Installation:
23. Align shift forks and rails with input and mainshaft, then install 3-4 shift fork and shift rod with input shaft and mainshaft assemblies.
24. Install shift fork selector lever assembly onto shift lever shaft.
25. Place new shift shaft lever seal on shaft, then lubricate seal and shaft with transaxle fluid.
26. Install shift lever shaft through side of clutch housing and into shift fork selector lever, then the new roll pin.
27. Place fifth/reverse shift rod end onto case and slide shift control shaft into rod end, then align bolt holes and install shift rod lock bolt.
28. Place reverse idler gear and bushing, reverse idler gear shaft, and magnet into clutch housing.
29. Install reverse lever assembly and, partially, the reverse lever shaft, then insert ball and spring into reverse lever shaft.
NOTE: Use new seal on lever shaft and lubricate with transaxle fluid.
30. Compress spring with punch and insert new roll pin into shaft.
31. Lightly coat reverse lever shaft plug, then install and stake plug.
32. Install breather cover, then new vent into case.
33. Align oil passage and install bolt. Tighten bolt to specifications.
34. Place case onto clutch housing, then install bolts.
35. Install back-up lamp switch and park/neutral position switch with new copper washers. Tighten to specifications.
36. Install 3-4 shift fork guide bolt, then the reverse idler shaft detent ball, shifter interlock spring, and reverse idler shaft lock bolts.
37. Install ball, shifter interlock spring, and detent spring screw into case.
38. Install input shaft fifth speed gear, then the fifth speed cluster gear sleeve, and gear onto main shaft.
NOTE: Ensure grooved side of clutch hub assembly is facing down toward fifth gear.
39. Install synchronizer, rings and fifth gear/reverse shift fork onto main shaft, then align shift fork to shaft and insert new roll pin.
40. Install reverse synchronizer first speed gear, then the main shaft synchronizer gear and ring.
41. Install main shaft reverse synchronizer gear and sleeve, then loosely install main and input shaft nuts.
42. Turn transaxle and install input shaft holder tool No. T88C-7025-GH, or equivalent, then tighten mainshaft locknut to specifications and stake.
43. Tighten input shaft locknut to specifications, then stake.
44. Remove shaft holder, then ensure case and case cover mating surfaces are clean.
45. Apply continuous bead of sealant to case, then install case cover. Tighten bolts to specifications.