Assembly

Transaxle

























NOTE: 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.

1. Install the input shaft.





2. Install the bearing cup onto the bearing.





3. Install the Shim Selection Set.





4. Install the transaxle case.

1. Position the transaxle case in place.

2. Install the Shim Selection Set bolts.
- Tighten to 45 Nm (33 lb-ft).





5. Mount the Dial Indicator Gauge with Holding Fixture to the transaxle case.





6. Rotate the input shaft to seat the bearings.

7. Zero the Dial Indicator Gauge with Holding Fixture.

8. NOTE: The shaft must be lifted equally on both sides or it may bind on one side, resulting in an incorrect reading.

Rotate the input shaft until the Dial Indicator Gauge returns to zero, then raise the input shaft and read the end play.

- Take and record 3 readings within 0.10 mm (0.003 in) of each other. Use the formula below to select the correct shim size.









9. NOTE: 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.

10. Remove the transaxle case, Shim Selection Set, bearing cup and input shaft.

11. Install the input shaft shim(s).





12. Install the input shaft bearing cup.





13. Install the funnel and the output shaft bearing cup.





14. Install the output shaft.





15. Install the bearing cup onto the bearing.





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

Install the Shim Selection Set.





17. Install the transaxle case.

1. Position the transaxle case in place.

2. Install the Shim Selection Set bolts.
- Tighten to 45 Nm (33 lb-ft).





18. Mount the Dial Indicator Gauge with Holding Fixture on the transaxle case.





19. Rotate the output shaft to seat the bearings.

20. Zero the Dial Indicator Gauge.

21. NOTE: The shaft must be lifted equally on both sides or it may bind on one side, resulting in an incorrect reading.

Rotate the output shaft until the Dial Indicator Gauge returns to zero, then raise the output shaft and read the end play.

- Take and record 3 readings within 0.10 mm (0.003 in) of each other. Use the formula below to select the correct shim size.









22. NOTE: 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.

23. Remove the transaxle case, Shim Selection Set, bearing cup and output shaft.

24. Install the shim.





25. Install the funnel and the output shaft bearing cup.





26. Install the differential.





27. Install the bearing cup onto the bearing.





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

Install the Shim Selection Set.





29. Install the transaxle case.

1. Position the transaxle case in place.

2. Install the Shim Selection Set bolts.
- Tighten to 45 Nm (33 lb-ft).





30. Using the Shim Selection Set, adjust gauge until the free play is removed. Turn gauge back together.





31. Insert the Differential Rotator through the transaxle case and engage the differential pinion shaft.





32. Using the Differential Rotator and Shim Selector Set, adjust gauge until the differential rotation is within specification.





33. Measure the gap in the Shim Selector Set.





34. NOTICE: Do not use more than 2 differential shims.

Add 0.15 mm (0.005 in) 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.





35. Remove the transaxle case, Shim Selection Set, differential and bearing cup.

36. Install the differential bearing cup shim(s) into the transaxle case.





37. Using the Differential Bearing Cup Installer and Handle, install the differential bearing cup into the transaxle case.





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





39. Install the spring and the shift detent.





40. Shift the synchronizers into the 2nd and 4th gear positions.

41. Install the main shift control shaft assembly, shift forks.





42. NOTE: Align the reverse idler shaft anchor bolt hole for installation of the bolt through the case.

Install the reverse idler gear and shift fork.





43. Install the shift control shaft and the shift gate.





44. NOTE: Make sure to align the shift gate at the bottom and the shift gate with the main shift control.

Install the shift gate bolt.

- Tighten to 13 Nm (115 lb-in).





45. NOTE: Shift lever shaft uses a solid pin.

Install the shift lever shaft, shift fork selector lever and shift shaft pin.





46. Install the magnet.





47. Position the 2nd and 4th gear synchronizers into neutral, then shift the 1st/2nd gear synchronizer into neutral.

48. Install the oil funnel.





49. NOTE: 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 lb-ft).





50. Install the shift detent ball, spring and bolt.
- Tighten to 18 Nm (159 lb-in).





51. NOTE: Make sure that the shift rail guide bolt is in the groove of the shift rail.

NOTE: Do not shift the transaxle until the reverse idler shaft lock bolt and the shift rail guide bolt are installed.

Install the reverse idler shaft lock bolt and the shift rail guide bolt.

1. Install the reverse idler shaft lock bolt.
- Tighten the reverse idler shaft lock bolt to 22 Nm (16 lb-ft).

2. Install the shift rail guide bolt.
- Tighten the shift rail guide bolt to 12 Nm (106 lb-in).





52. Check the shift function.

53. Install the remaining 13 transaxle case bolts.
- Tighten to 45 Nm (33 lb-ft).

54. Install the primary and secondary 5th gears.





55. Install the spacer and the gear sleeve.





56. Install the 5th/6th shift fork and synchronizer assembly.





57. Install the gear spacer.





58. Install the primary and secondary 6th gears.





59. NOTE: When the locknuts are tightened to specifications they will seat the bearings.

Install the 6th gear bearings onto the primary and secondary shafts.





60. Shift the 5th/6th gear shift fork to 5th.





61. NOTE: Do not reuse locknuts.

Install the new primary and secondary shaft locknuts.

1. Shifting into 5th/6th gears and using the Transmission Turning Torque Socket will keep the primary shaft from turning.

2. Install the new primary and secondary shaft locknuts. Using a punch, stake the locknuts to the shafts.
- Tighten to 160 Nm (118 lb-ft).





62. NOTE: Shift 5th/6th into neutral.

Install a new 5th/6th shift fork roll pin.





63. NOTE: 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 case cover mating surface.

64. Install the case cover and the 9 case cover bolts.
- Tighten to 45 Nm (33 lb-ft).





65. If removed, install the anchor bolt.
- Tighten to 10 Nm (89 lb-in).





66. Install the clutch release fork and bearing.

1. Install the clutch release fork and diaphragm.

2. Install the clutch release bearing.





67. Remove the transaxle from the Holding Fixture.