Step 4

NOTE:
a. Wash all parts.
b. Apply oil to all friction surfaces.
c. Use new roll pins and retaining rings.




Torque Specification

Assembly




1. Install the lever set spring and the reverse shift lever.

Tightening torque: 8-11 N.m (80-110 cm-kg, 69-96 in-lb)

2. Install the differential assembly, the secondary shaft gear assembly and the primary shaft gear assembly.
3. Install the base plate unit, the crank lever assembly and the crank lever shaft.

Tightening torque: 8-11 N.m (80-110 cm-kg, 70-96 in-lb)

4. Install the snap ring.




5. Install the shift rod and the shift fork (1st/2nd).
6. Shift to the 2nd gear.
7. Install the roll pin.




8. Install the interlock pin to shift rod (5th/Rev.)
9. Install the shift rod end the shift rod (5th/Rev.).
10. Install the roll pin.




11. Install the shift rod end, the shift rod and the shift fork (3rd/4th).




12. Set the reverse idle gear and the reverse idle shaft in the direction shown.




13. Install the magnet.
14. Coat both surfaces with sealant and install the transaxle case and the engine mount bracket.

NOTE: Before coating with sealant, clean the contact surfaces.

Tightening torque: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)

15. Install the engine mounting bracket.

Tightening torque: 78-117 N.m (8.0-11.9 m-kg, 58-86 ft-lb)




16. Install the reverse idle shaft set bolt.

Tightening torque: 18-26 N.m (1.8-2.6 m-kg, 13-19 ft-lb)

17. Install the SST.
18. Install the balls, springs and bolts.
19. Install the reverse switch.

Tightening torque (bolts and switch): 20-29 N.m (2.0-3.0 m-kg, 14-22 ft-lb)




20. Install the interlock pins.
21. Install the interlock plate.

Tightening torque: 18-26 N.m (1.8-2.6 m-kg, 13-19 ft-lb)




22. Install the ball, gear sleeve, needle bearing.

NOTE: Apply the transaxle oil to needle bearing.

23. Install the 5th gear and synchronizer ring.
24. Install the secondary 5th gear.
25. Install the clutch hub assembly and shift fork together.




26. Install the synchronizer ring, gear the primary reverse synchronizer gear, sleeve and the secondary reverse synchronizer gear.
27. Shift to the 5th gear and the 1st gear.
28. Tighten the lock nuts and stake it.

Tightening torque: 128-196 N.m (13.0-20.0 m-kg, 94-145 ft-lb)

29. Shift to the neutral.
30. Install the roll pin to the shift fork (5th/Rev.).




31. Coat both surface with sealant.

NOTE: Before coating with sealant, clean the contact surfaces.

32. Install the rear cover.

Tightening torque: 8-11 N.m (80-115 cm-kg, 70-96 in-lb)

33. Install the neutral switch.

Tightening torque: 20-29 N.m (2.0-3.0 m-kg, 14-22 ft-lb)

34. Install the drain plug.

Tightening torque: 39-59 N.m (4.0-6.0 m-kg, 29-43 ft-lb)