Assembly
ASSEMBLE1. Adjust input shaft bearing preload as follows:
a. Install input shaft, then the transaxle case to clutch housing.
b. Mount dial indicator with bracket tool No. T00L-4201-C, or equivalent, to transaxle case so dial indicator touches end of input shaft.
c. Measure input shaft thrust clearance. Clearance should be 0.0019-0.0039 inch.
Input Shaft Shim Selection Chart:
d. If clearance is not within specification, select proper shim(s).
2. Adjust mainshaft bearing preload as follows:
a. Install funnel and bearing race into clutch housing, then position main shaft into clutch housing.
b. Install mainshaft bearing race into transaxle case, then install case to clutch housing. Tighten bolts to specifications.
c. Mount dial indicator with bracket tool No. T00L-4201-C, or equivalent, to transaxle case and measure mainshaft thrust clearance.
Mainshaft Shim Selection Chart:
d. To determine shim range, add 0.0012 inch to thrust clearance, then add 0.0031 inch to thrust clearance. Select shim within range.
3. Select differential bearing preload as follows:
a. Install bearing race into clutch housing, then set differential assembly into clutch housing.
b. Install transaxle housing side bearing race to selector, part of shim selection tool No. T88C-77000-JF, or equivalent.
Transaxle Case Collar Positions:
c. Position collars from selection tool in specified positions.
d. Position transaxle housing onto collars, then torque selection tool bolts to 14-19 ft lbs.
e. Turn bars until tool can no longer be moved.
f. Seat bearings by mounting bars on parts A and B of selector tool, and turning tool so gap is widened.
g. Turn in reverse direction until gap is eliminated, then install differential rotator tool No. T88C-77000-L, or equivalent, to differential pinion gear through transaxle case.
h. Turn rotator with torque wrench and adjust selector tool with bars until specified preload is obtained. Preload should be 0.3-6.6 in lbs.
i. Remove rotator, then measure clearance of selector circumference.
Differential Shim Selection Chart:
j. Select shim(s) closest to largest measured clearance in selector.
k. Remove bolts, transaxle housing, and collars, then the bearing race from selector.
l. Install selected shim(s) and bearing outer race to transaxle case.
m. Set differential assembly into clutch housing, then instal transaxle housing onto clutch housing. Tighten bolts to specifications.
n. Install rotator into differential side gear through transaxle case.
o. Measure preload by rotating differential with torque wrench. If bearing preload is not within specification, perform procedure again. Preload specification is 0.3-6.6 in lbs.
4. Position differential assembly in clutch housing.
5. Assemble input shaft, main shaft, and shift rail assemblies, then install assembly into clutch housing.
6. Install steel ball and spring into reverse lever shaft, then position shaft through housing, reverse lever set spring, and reverse lever.
7. Compress spring with screwdriver, then align holes and install new roll pin.
8. Install new 0-ring on crank lever shaft, then position crank lever between change arm and control end and connect shaft to lever.
9. Align pin holes of crank lever shaft and clutch housing, then install new roll pin.
10. Tap in blind plug using soft based hammer, then install shift rod end and shift rod.
11. Install reverse idler gear and reverse idler shaft.
12. Instal breather cover and gasket with two bolts. Tighten bolts to specifictions.
13. Install magnet in clutch housing.
Reverse Idler Shaft Screw Hole Alignment:
14. Align interlock sleeve end with control lever while facing reverse idler shaft screw hole in specified direction.
15. Apply thin coat of Gasket Eliminator part No. E1FZ-19562-A, or equivalent, to clutch housing and transaxle case contact surfaces, then install transaxle case to clutch housing. Tighten bolts to specifications.
NOTE: Ensure two longer bolts are installed in original positions as noted during disassembly.
16. Install neutral start switch and back-up lamp switch. Tighten switches to specifications.
17. Install lock bolt and new washer.
18. Install fifth gear onto main shaft, then the gear sleeve, and fifth gear synchronizer ring on input shaft.
19. Install fifth gear synchronizer assembly and fifth gear shift fork and clutch hub together, then install new roll pin.
20. Lock input shaft with input torque adapter tool No. T87C-7025-A, or equivalent.
21. Install new locknuts on input shaft and mainshaft. Tighten locknuts to specifications.
22. Measure fifth gear thrust clearance with dial indicator with bracket tool No. TOOL-4201-C, or equivalent. Clearance should be within 0.0024-0.0120 inch.
23. Install specified sealant to sealing surface or rear cover and install rear cover. Tighten ten bolts to specifications.