Assembly
ASSEMBLE1. Adjust input shaft bearing preload as follows:
a. Using driver handle tool No. T80T-4000-W and bearing cup replacer tool No. T77F-1217-B, or equivalents, install input gear shaft front bearing cup into case. Ensure bearing cup is fully seated.
b. Install input shaft gear assembly into clutch housing, then place rear bearing cup on input shaft bearing.
c. Place case on clutch housing and install washers and bolts.
d. Mount dial indicator with bracket tool No. T00L-420-1C, or equivalent, on case to check input shaft endplay.
e. Rotate input shaft gear assembly several times to seat bearings, then adjust dial indicator to zero at lowest point on end of input shaft.
f. Raise input shaft gear assembly by hand and read endplay, then lower input shaft gear assembly. Lift input shaft gear assembly equally on both sides or it may cause a false reading.
g Select shim equal to or slightly smaller than endplay reading. Shims are available in 0.004, 0.008, 0.012, 0.016, and 0.024 inch sizes.
h. Remove bolts and washers securing case to clutch housing, then the case gauge, rear bearing cup and input shaft gear assembly from clutch housing. Do not remove bearing cups from clutch housing.
2. Adjust output shaft bearing preload as follows:
a. Using driver handle tool No. T80T-4000-W and bearing cup replacer tool No. T77F-1217-B, or equivalents, install output and fifth shaft funnel, then the output shaft front bearing cup into case. Ensure bearing cup is fully seated.
b. Install output shaft gear assembly into clutch housing, then place rear bearing cup on output shaft bearing.
c. Place six collars from shim selection set tool No. T87C-77000-J, or equivalent, on clutch housing.
d. Place case on collars, then install washers and bolts. Torque bolts to 14-19 ft lbs.
e. Mount dial indicator with bracket tool No. T00L-4201-C, or equivalent, on case to check endplay of output shaft.
f. Rotate output shaft gear assembly several times to seat bearings, then adjust dial indicator to zero at lowest point of output shaft end.
g. Raise output shaft gear assembly by hand and read endplay, then lower output shaft gear assembly. Lift output shaft gear assembly equally on both sides or a false reading may result.
h. To determine shim size range, first add 0.0012 inch to endplay reading to establish low end of range. Next, add 0.0031 inch to endplay reading to establish high end of range.
i. Select shim within calculated range. Shims are available in sizes ranging from 0.006 inch-0.028 inch in 0.002 inch increments.
j. Remove bolts and washers securing case to clutch housing, then the case, gauge, rear bearing cup, collars, and output shaft gear assembly from clutch housing.
NOTE: Do not remove bearing cups from clutch housing.
3. Adjust differential bearing preload as follows:
a. Install differential into case, then place rear bearing cup on differential bearing.
b. Position shim selection gauge, part of tool No. T87C-77000-J, or equivalent, with shim gauge adapter ring tool No. T90P-7025-AH, or equivalent, on top of differential.
NOTE: Both gauge halves must be turned to eliminate any gap between them.
Transaxle Case Collar Locations:
c. Place six collars from shim selection gauge on clutch housing as shown in the Transaxle Case Collar Locations image.
d. Place case on collars, then install washers and bolts from selection gauge. Torque bolts to 14-19 ft lbs.
e. Using pins from selection gauge, adjust gauge tool until free play is removed and bearing cup is seated.
f. Thread gauge tool halves back together, then insert differential rotator tool No. T90P-7025-BH, or equivalent, through case and engage differential pinion shaft.
g. Attach torque wrench to adapter, then turn gauge using adjusting rods from gauge until torque wrench reads 0.26-6.6 in lbs.
h. Using feeler gauge, measure gap in selection gauge in four locations at 90° intervals. Use largest measurement for differential bearing shim selection.
i. Select shim(s) equal to or slightly larger than measurement obtained with feeler gauge. Shims are available in sizes ranging from 0.004 inch-0.036 inch in 0.002 inch increments.
j. Remove bolts and washers securing case to clutch housing, then the case, gauge, rear bearing cup, collars, and output shaft gear assembly from the clutch housing.
NOTE: Do not remove bearing cups from clutch housing.
k. Set differential into clutch housing, then install case onto clutch housing.
l. Install transaxle housing-to-clutch housing bolts.
m. Insert differential rotator tool No. T90P-7025-BH, or equivalent, through case and engage it with differential pinion shaft.
n. Attach torque wrench to adapter, then measure bearing preload. Preload should be 0.26-6.6 in lbs. If preload is not within specification, readjust baring preload.
o. Remove torque wrench and rotator from differential pinion shaft, then remove case and differential from clutch housing.
4. Install breather, then use shift lever seal replacer tool No. T74P-77498-A and driver handle tool No. T80T-4000- W, or equivalents, to install shifter shaft seal.
5. Install main shift control shaft and gear control shaft bolt, spring, reverse gate plate, and shift gate selector.
6. Install new selector pin, then the input shift shaft selector plate arm.
7. Install control selector plate. Torque selector plate bolt located above spring to 14-18 ft lbs, then the two remaining bolts to 17-25 ft lbs.
8. Install transaxle drain plug and back-up lamp switch. Tighten both to specifications.
9. Using differential seal replacer tool No. T87C-77000-H, or equivalent, install lefthand differential oil seal into case then the righthand differential oil seal into clutch housing.
10. Install input shaft oil seal to clutch housing using driver or socket.
11. Install adjustment shim and bearing cup for differential bearing to case using bearing cup replacer tool No. T77F-1217-B and driver handle tool No. T80T-4OOO-W, or equivalents.
12. Install adjustment shim(s) for input shaft and output shaft bearing cups to case.
13. Install output shaft diaphragm spring and output and fifth shaft funnel.
14. Using bearing cup replacer tool No. T77F-1217-B and driver handle tool No. T80T-4OOO-W, or equivalents, install input shaft bearing cup into case, then the differential bearing cup into clutch housing and output shaft bearing cup into case.
15. Install reverse lever spring to reverse gearshift lever.
16. Install vehicle speed sensor to clutch housing. Tighten bolt to specifications.
17. Position differential in clutch housing, then the breather cover, new gasket and retaining bolts.
18. Position input shaft to output shaft and connect shift rail to synchronizer sleeves. Install assembly into clutch.
19. Install steel ball and spring into mesh lock plunger, then position mesh lock plunger through housing, reverse lever set spring and reverse gearshift lever.
20. Compress spring with small screwdriver or similar tool, align holes and install new roll pin into mesh lock plunger.
21. Install case plug, then a new 0-ring onto shift lever shaft.
22. Position shift fork selector lever between gearshift selector arm and transmission selector lever arm and support, then connect shift lever shaft to shift fork selector lever.
23. Align shift lever shaft roll pin holes with holes in clutch housing, then install new roll pin.
24. Install shift gate and shift control shaft, then tighten shift relay bolt to specifications.
NOTE: Bolt hole in shift control shaft and in shift gate must be aligned.
25. Install reverse idler gear, bushing and reverse idler gear shaft, then the oil pan magnet in clutch housing.
Reverse Idler Gear Shaft Screw Hole Alignment:
26. Align gear selector interlock sleeve end with gearshift selector arm, while facing reverse idler shaft screw hole in direction shown in the Reverse Idler Gear Shaft Screw Hole Alignment image.
27. Clean clutch housing and case contact surfaces, then apply thin coat of sealant.
28. Position transaxle case on clutch housing, then install bolts in original positions.
29. Install two transaxle plugs tool No. T88C-7025-AH, or equivalent.
30. Install park/neutral position switch and tighten to specifications.
31. Install lock bolt and guide bolt with new washers.
32. Install fifth speed gear onto output shaft, then the fifth gear sleeve, fifth speed cluster gear, and synchronizer blocking ring onto input shaft.
33. Install synchronizer and gear shifter fork together, then install new roll pin.
34. Shift to first gear, then use torque adapter tool No. T87C-7O25-A, or equivalent, to lock up input shaft.
35. Install stop plate onto input shaft, then the new locknuts on input and output shafts. Tighten locknuts to specifications.
36. Crimp locknut tabs, then clean and apply thin coat of sealant to case and case cover contact surfaces.
37. Install case cover and bolts. Tighten bolts to specifications.
38. Fill transaxle with specified fluid.