Assembly
ASSEMBLE1. Adjust input shaft bearing preload as follows:
a. Install input gear shaft with rear bearing race into clutch housing.
b. Position shim selection set tool No. T87C-77000-J or equivalent on top of input gear shaft.
Transaxle Case Collar Locations:
c. Place six collars from selection set between transaxle case and clutch housing.
d. Install transaxle case onto input gear shaft.
e. Install flat washer of appropriate size onto each of bolts from tool kit. Install bolts through transaxle case, collar, and into threaded hole in clutch housing. Torque bolts to 13-14 ft lbs.
f. Mount dial indicator with bracket tool No. TOOL-4201-C, or equivalent, to check endplay of shaft.
g. Rotate input gear shaft several times to help seat bearings, then adjust dial indicator to zero at lowest point on end of in put gear shaft.
h. Raise input gear shaft by hand and read endplay. Do not disturb dial indicator until at least three endplay readings have been taken.
i. Turn input gear shaft several times until dial indicator returns to zero, then raise input gear shaft by hand to take a second endplay measurement. Input gear shaft must be lifted evenly on both sides or readings will be false.
j. Repeat previous step to obtain at least three readings within 0.004 inch of each other.
k. Average at least three measurements to calculate endplay reading. Add 0.003 inch to average endplay reading to obtain final shim size.
Input Shaft Shim Selection Chart:
l. Select shim from the Input Shaft Shim Selection Chart. Do not use more than three shims under a bearing race.
m. Remove bolts and washers securing transaxle case to clutch housing, then remove clutch housing, collars, selector, rear bearing race, and input gear shaft.
2. Adjust main shaft bearing preload as follows:
a. Install differential bearing race into clutch housing using bearing cup installer tool No. T77F-1217-B and drive handle tool No. T80T-4000-W, or equivalents. Inspect bearing race after installation to make sure it is fully seated.
b. Install oil funnel and mainshaft front bearing race into clutch housing.
c. Install input gear shaft front bearing race into clutch housing, then the main shaft with its rear bearing race into clutch housing.
d. Position shim selection set tool No. T87C-77000-J, or equivalent, on top of main shaft.
NOTE: Both halves of selector must be turned to eliminate any gap between them.
Transaxle Case Collar Locations:
e. Place six collars from shim selection set between transaxle case and clutch housing at specified positions.
f. Install transaxle case onto main shaft.
g. Install flat washer onto each of bolts from tool kit, then install bolts through transaxle case, collar, and into clutch housing threaded holes. Torque bolts to 13-14 ft lbs.
h. Mount dial indicator with bracket tool No. T00L-4201-C or equivalent, to check endplay of shaft.
i. Rotate mainshaft several times to help seat bearings, then adjust dial indicator to zero at lowest point on mainshaft.
j. Raise mainshaft by hand and read endplay, then lower mainshaft. Do not disturb dial indicator until at least three end play readings have been taken.
k. Turn main shaft several times until dial indicator returns to zero, then raise main shaft by hand to take second endplay measurement. Main shaft must be lifted equally on both sides or it will cause a false reading.
l. Use previous steps to obtain at least three readings within 0.004 inch of each other.
m. Average three measurements to obtain an average endplay reading. Add 0.003 inch to endplay reading to obtain final shim size.
Mainshaft Shim Selection Chart:
n. Select shim from the Mainshaft Shim Selection Chart. Do not use any more than three shims under a bearing race.
o. Remove bolts and washers securing transaxle case to clutch housing, then the transaxle case, collars, selector, rear bearing race, and mainshaft.
3. Adjust differential bearing preload as follows:
a. Install differential with its rear bearing race into clutch housing.
b. Position shim selection tool on top of differential. Both halves of selector must be turned to eliminate any gap between them.
Transaxle Case Collar Locations:
c. Place six collars from shim selection tool between transaxle case and clutch housing at specified positions. Install transaxle case onto differential.
d. Install flat washer onto each of bolts from tool kit, then install bolts through transaxle case, collar and into threaded holes in clutch housing. Torque bolts to 13-14 ft lbs.
e. Insert differential rotator tool No. T88C-77000-L, or equivalent, through transaxle case and engage differential pinion shaft.
f. Attach torque wrench to tool, then turn selector for differential using adjusting rods until wrench reads 4.3-6.6 in lbs.
g. Use feeler gauge to measure gap in differential selector. Measure gap at four points 90° apart, then average the four readings.
Differential Shim Selection Chart:
h. Select shim from the Differential Shim Selection Chart.
NOTE: Do not use more than three shims under a bearing race.
i. Remove bolts and washers securing transaxle case to clutch housing, then the transaxle case, collars, selector, rear bearing race, and differential.
4. Install transaxle drain plug, then tighten to specifications.
5. Install back-up lamp switch to transaxle case, then tighten to specifications.
6. Install left differential oil seal into transaxle case and right differential oil seal into clutch housing using differential seal replacer tool No. T87C-77000-H, or equivalent.
7. Install input gear shaft seal to clutch housing using driver or socket.
8. Install rear differential bearing adjustment shim and race to transaxle case using bearing cup replacer tool No. T77F-1217-B and drive handle tool No. T80T-4000-W, or equivalents.
9. Install adjustment shims for input gear shaft and mainshaft rear bearing races to transaxle case.
10. Install diaphragm spring for input gear shaft rear bearing race, then the rear bearing race into transaxle case using bearing cup replacer tool No. T77F-1217-B and drive handle tool No. T80T-4000-W, or equivalents.
11. Install differential front bearing race into clutch housing, and the main shaft rear bearing race into transaxle case using bearing cup replacer and drive handle.
12. Install reverse lever set spring to reverse lever, then position in clutch housing.
13. Install reverse lever shaft through its hole in clutch housing (beveled end first), through reverse lever and set spring. Align hole in reverse lever shaft with roll pin hole in clutch housing.
14. Install roll pin through set spring, clutch housing, and into reverse lever shaft using drift.
15. Coat cup sealing reverse lever shaft hole in clutch housing with Gasket Eliminator part No. E1FZ-19562-A, or equivalent, then install cup to hole until flush with housing.
16. Assemble speedometer driven gear assembly as follows:
a. Install new oil seal to top of speedometer gear case.
b. Install speedometer driven gear shaft up through bottom of gear case, then install roll pin through case and into shaft.
c. Install new 0-ring to speedometer case.
17. Install speedometer driven gear assembly to clutch housing.
18. Install breather to clutch housing by tapping in with rubber mallet.
19. Install breather cover to clutch housing.
20. Install change rod oil seal to clutch housing using driver or socket.
21. Install selector spring to clutch housing, then the change rod shift boot to change rod.
22. Feed reverse gate and selector onto rod and change arm, then align roll pin hole in rod with hole in selector.
23. Install roll pin through selector and into hole in change rod, then drive pin flush with selector using drift and hammer.
24. Install change arm bolt through arm and into threaded hole in change rod. Tighten bolt to specifications.
25. Install change arm pin into center slot of guide plate, then the guide plate, hand-tightened bolts and spacer to clutch housing. Adjust guide plate so pin is in center of third/fourth gear slot when control rod is in neutral position.
26. Hold gate in proper position, then tighten bolts to specifications.
27. Check adjustment shims to ensure correct sizes were chosen as follows:
a. Install input gear shaft and differential assembly into clutch housing, then install transaxle case to clutch housing. Tighten bolts to specifications.
CAUTION: Transaxle case and clutch housing are aluminum. To prevent component damage, do not overtighten retaining bolts.
b. Install torque adapter tool No. T87C-7025-K, or equivalent, through oil seal and onto pinion shaft, then use torque wrench to measure preload by turning tool and reading wrench as differential is rotating.
NOTE: Do not use initial torque reading, it will be higher than actual turning torque reading. Preload should be 0.26-6.60 in lbs.
c. Remove turning tool and wrench, then install torque adapter tool No. T87C-7025-A, or equivalent, with input shaft facing up.
d. Install torque wrench to end of shaft holder, then measure turning torque of input shaft by rotating it with wrench. Preload should be 0.26-6.60 in lbs.
e. If bearing preload measurements are not within limits, adjustment shims are incorrect. Follow selection processes at beginning of procedure to select correct shim.
28. Install spring and steel ball to reverse lever shaft, then the crank lever assembly to gear case.
29. Install new 0-ring to crank lever shaft and coat shaft and 0-ring with transaxle fluid.
30. Install crank lever shaft through clutch housing and into lever with roll pin hole positioned up, then the roll pin until it is just below clutch housing surface.
31. Install control end between ball in crank lever and ball in reverse lever shaft.
32. Install differential assembly to clutch housing, then assemble input gear shaft, main shaft, and shift fork assembly.
33. Install gear shaft and shift fork assembly to clutch housing.
NOTE: Install shift fork control rod into control end as unit is lowered into place. Keep assembly as vertical as possible while installing.
34. Align holes in control rod and control end, then install roll pin with drift and hammer.
35. Install shaft rod (fifth and reverse gears).
Shaft Rod Alignment:
NOTE: Ensure alignment mark on rod is in correct position.
36. Install gate-to-shift rod lock bolt and tighten to specifications.
37. Install reverse idler gear onto reverse idler shaft, then the idler gear assembly into clutch housing bore.
38. Install magnet into clutch housing.
39. Ensure control lever is kept flush with surface of end of interlock sleeve. point threaded hole of reverse idler shaft toward alignment mark of clutch housing.
40. Apply continuous 1/16 in beads of Gasket Eliminator part No. E1FZ-19562-A, or equivalent, to mating surfaces of clutch housing and transaxle case. Run bead between bolt holes and inside edge of gasket surface. Do not allow material to get inside transaxle.
41. Install transaxle case to clutch housing. Tighten bolts to specifications, working in a circle until all bolts are tightened.
CAUTION: Transaxle case and clutch housing are aluminum. To prevent component damage, do not overtighten retaining bolts.
42. Install guide bolt to transaxle case, then the lock bolt to transaxle case and into reverse idler shaft threaded hole. Tighten bolts to specifications.
43. Install input gear to end of input gear shaft, then the new locknut. Lock input gear shaft with torque adapter tool No. T87C-7025-A, or equivalent.
44. Tighten input gear locknut to specifications, then stake to groove in input gear shaft.
45. Measure fifth gear endplay by measuring gear and gear sleeve widths. Endplay equals difference between these measurements. Standard endplay is 0.006-0.012 inch.
46. Install fifth gear sleeve on fifth gear, then position synchronizer ring and clutch hub assembly on gear.
47. Install fifth gear shift fork to clutch hub, then install fifth gear assembly on mainshaft while installing shift fork to fifth and reverse shift rod.
48. Install roll pin through fifth gear shift fork and into fifth and reverse shift rod using drift and hammer. Sink pin to just below shift fork surface.
49. Install new lock washer and locknut to end of main shaft.
50. Place transaxle in first/second gear and lock input shaft with torque adapter tool No. T87C-7025-A, or equivalent. Tighten mainshaft locknut to specifications.
51. Using new gasket, install rear cover onto transaxle case. Tighten bolts to specifications.
CAUTION: Do not overtighten.