Assembly

Transaxle

Special Tools:

Special Tools:

Material:

CAUTION: Whenever the transaxle has been disassembled, the bearing preload must be adjusted. The input shaft, output shaft and differential bearing preload can be adjusted by selecting shims to insert between the bearing races and the case on the case side.

1. Using the special tool, install the input shaft seal.





2. Install the input shaft bearing cup into the flywheel housing.





3. Install the input shaft.





4. Install the bearing cup onto the bearing.





5. Install the special tools.





6. Install the transaxle case.
1. Position the transaxle case to the input shaft and the special tools.
2. Install the bolts.
^ Tighten to 45 Nm (33 ft. lbs.).





7. Mount the special tool to the transaxle case.





8. Rotate the input shaft to seat the bearings.
9. Zero the dial indicator.





10. CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.

Rotate the input shaft until the dial indicator returns to zero then raise the input shaft and read the end play.
- Take and record 3 readings within 0.10 mm (0.004 inch) of each other. Use the formula below to select the correct shim size.











11. CAUTION: Do not use more than 2 shims.

From the Shim Selection Set, select the shim(s) that is closest to (or slightly thinner than) the final shim size calculated in the previous step.
12. Remove the transaxle case, special tools, bearing cup, and input shaft.

13. Install the input shaft shim(s).





14. Using the special tools, install the input shaft bearing cup.





15. Install the funnel.





16. Using the special tools, install the output shaft bearing cup.





17. Install the output shaft.





18. Install the bearing cup onto the bearing.





19. NOTE: The gauge halves must be turned to eliminate any gap between them.

Install the special tools.





20. Install the transaxle case.
1. Position the transaxle case to the output shaft and the special tools.
2. Install the bolts.
^ Tighten to 45 Nm (33 ft. lbs.).





21. Mount the special tools on the transaxle case.





22. Rotate the output shaft to seat the bearings.
23. Zero the dial indicator.





24. CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.

Rotate the output shaft until the dial indicator returns to zero then raise the output shaft and read the end play.
- Take and record 3 readings within 0.10 mm (0.004 inch) of each other. Use the formula below to select the correct shim size.





25. CAUTION: Do not use more than 2 shims.

From the Shim Selection Set, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in the previous step.
26. Remove the transaxle case, special tools, bearing cup and output shaft.
27. Install the shim.





28. Using the special tools, install the output shaft bearing cup.





29. Using the special tools, install the differential bearing cup into the flywheel housing.








30. Install the differential.





31. Install the bearing cup onto the bearing.





32. NOTE: The gauge halves must be turned to eliminate any gap between them.

Install the special tools.





33. Install the transaxle case.
1. Position the transaxle case to the differential and the special tools.
2. Install the bolts.
^ Tighten to 45 Nm (33 ft. lbs.).





34. Using the special tool, adjust gauge until the free play is removed. Turn gauge back together.





35. Insert the special tool through the transaxle case and engage the differential pinion shaft.





36. Using the special tools, adjust gauge until the differential rotation is within specification.





37. Measure the gap in the special tool.





38. CAUTION: Do not use more than 2 differential shims.

Add 0.15 mm (0.0059 inch) to the measurement to achieve the final clearance.
- Using the following chart, select the differential bearing shims that are closest to (or slightly larger than) the final shim size.

Shim Thickness (Part 1):

Shim Thickness (Part 2):

39. Remove the transaxle case, special tools, bearing cup and differential.
40. Install the differential bearing cup shim(s) into the transaxle case.





41. Using the special tools, install the differential bearing cup into the transaxle case.





42. NOTE: Transaxle case side shown, flywheel housing side similar.

Using the special tool, install the halfshaft seals.





43. Install the output shaft, the input shaft and the differential together.





44. Install the reverse lever and the reverse lever shaft.





45. Install the reverse lever roll pin.





46. Install the spring and the shift detent.





47. Shift the synchronizers into the 2nd and 4th gear positions.
48. Install the gear shifter fork and main shift control shaft assembly.
- Rotate the shaft clockwise, disengaging the shift finger from the shift fork. Pull the rail upward and insert the shift rail into the rail bore. Depress the detent and rotate the shift assembly into position.





49. Install the shift fork selector lever.
1. Install the shift fork selector lever.
2. Install the shift lever shift lever shaft.
^ Position the shift fork selector lever socket(s) to the main shift control shaft pivot ball and the change shaft.





50. Install the shift lever shaft pin.
- Shift lever shaft uses a solid pin.
- Use a screwdriver to aid installation.





51. Install the shift control shaft and shift gate.
1. Install the shift gate.
2. Install the shift control shaft.
3. Install the shift gate bolt.
^ Make sure to align the shift gate at the bottom and the shift gate with the main shift control.
^ Tighten to 13 Nm (10 ft. lbs.).





52. Install the reverse idler gear and reverse idler gear shaft.





53. Install the magnet.





54. Align the end of the gear selector interlock sleeve with the gear selector arm. The reverse idler gear shaft hole should face outward. Position the gear selector arm and reverse idler gear shaft.
55. Position the 2nd and 4th gear synchronizers into NEUTRAL, then shift 1st/2nd gear synchronizer into 1st gear.
56. Install the oil funnel.

57. CAUTION: The transaxle case must be installed within 4 minutes after applying silicone gasket and sealant.

Apply a small bead of silicone gasket and sealant to the transaxle mating surface.

Install the transaxle case and the 2 transaxle case bolts.
- Make sure to align the shift lever to the shift lever shaft. Do not move the shaft outward to the stop. The washer can slide off of the shaft into the case.
- Tighten to 45 Nm (33 ft. lbs.).





58. CAUTION: Make sure that the shift rail guide bolt is in the groove of the shift rail.

CAUTION: Do not shift the transaxle until the bolts are installed.

Position the bolts into the transaxle case.
1. Install the reverse idler shaft bolt.
2. Install the shift rail guide bolt.
^ Tighten the reverse idler shaft bolt to 22 Nm (16 ft. lbs.).
^ Tighten the shift rail guide bolts to 12 Nm (9 ft. lbs.).





59. Check the shift function.
60. Install the remaining 13 transaxle case bolts.
- Tighten to 45 Nm (33 ft. lbs.).





61. Install the shift lock bolt, spring and ball.
- Tighten to 18 Nm (13 ft. lbs.).





62. Install the shift lever assembly.
- Tighten to 22 Nm (16 ft. lbs.).
63. Install 5th gear.





64. Install the 5th gear bushing.





65. Install the 5th speed cluster gear.





66. Install the reverse/5th shift fork and synchronizer hub as an assembly.





67. Install a new reverse/5th shift fork roll pin.

68. CAUTION: Do not reuse locknuts.

CAUTION: Stake the locknuts.

Use the special tool 308-160, to keep the input shaft from turning. Install new input and output shaft locknuts. Stake the locknuts.
- Tighten to 160 Nm (118 ft. lbs.).





69. CAUTION: The case cover must be installed within 4 minutes after applying silicone gasket and sealant.

Apply a small bead of silicone gasket and sealant to the case and cover mating surface.
70. Install the 9 case cover bolts and the case covers.





71. Install the anchor bolt.
- Tighten to 10 Nm (89 inch lbs.).





72. Install the clutch release fork and bearing.
1. Install the boot.
2. Install the clutch release fork and bearing.





73. Remove the transaxle from the special tool.