Assembly

Part 1 Of 2:

Part 2 Of 2:

Assemble in the order shown in the illustration, referring to the following notes:





Primary shaft gear assembly and secondary shaft gear assembly
^ Install the primary and secondary shaft gear assemblies together.





Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod assembly as shown.





2. Insert the spring seat and spring into the reverse lever shaft. Install the steel ball, and place a scraper so that it contacts the steel ball.
3. With the edge of the control end against the scraper, push the control end in the direction of the arrow so that the ball goes into the shaft. This will line up the rod with the shift rod coupling hole in the clutch housing.





4. Set each clutch hub sleeve to the neutral position, and tap the shift rod from above so that the steel ball goes into the center groove (of the three grooves in the control end).
5. Pull up on the ball part of the control end so that the steel ball goes into the detent in the groove.

Crank lever assembly and crank lever shaft
1. Install a new O-ring to the crank lever shaft.
2. Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank lever.





3. Align the pin holes of the crank lever shaft and the clutch housing, and insert a new pin.





5th/reverse shift rod end and 5th/reverse shift rod
1. Install the shift rod (2) into the shift rod end (1).
2. Align the mark on the shift rod with the mounting bolt hole in the shift rod end as shown in the illustration, and tighten the gate mounting bolt to 11.8 - 13.7 Nm (105 - 121 inch lbs.).

Reverse idler gear and reverse idler shaft
1. Install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.





3. Align the end of the interlock sleeve with the control lever (arrow), and at the same time, face the reverse idler shaft screw hole in the direction shown in the figure.





Transaxle case assembly
1. Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case, and tighten the transaxle case installation bolts to 38 - 51 Nm (28 - 38 ft. lbs.).
2. Insert the SSTs through the drive shaft and joint shaft hole.





Secondary 5th gear
Install the secondary 5th gear as shown.





5th/reverse clutch hub assembly and 5th/reverse shift fork
Install the 5th/reverse clutch hub assembly and the 5th/ reverse shift fork together.

Locknut
1. Shift to 1st gear.





2. Lock the primary shaft by using the SST.
3. Tighten new locknuts onto the primary and secondary shafts to 128 - 196 Nm (95 - 144 ft. lbs.).
4. Stake the locknuts.





5. Measure the 5th gear thrust clearance by using a dial indicator. Standard clearance is 0.100 - 0.220 mm (0.0039 - 0.0087 inch) and maximum is 0.270 mm (0.0106 inch).
6. If not as specified, reassemble the transaxle.