Assembly
ASSEMBLE1. Install shift relay lever bracket assembly and bolts. Tighten bolts to specifications.
2. Place differential and final drive gear assembly into clutch housing case, then align differential gears for later installation of halfshafts.
3. On five speed models, install fifth gear shaft assembly and fifth fork shaft assembly in case.
Shift Lever Replacement W/Four Speed Transaxle:
4. On all models, position main shaft control assembly so shift forks engage their respective slots in main shaft assembly synchronizer sleeves.
Shaft Assembly Removal And Installation:
5. Position main shaft, input cluster shaft, and main shift control shaft over their respective bores, then install in case as an assembly.
NOTE: Avoid movement of 3-4 synchronizer sleeve which may result in over-travel of the synchronizer sleeve-to-hub, allowing inserts to pop out of position.
6. Position shift lever, 3-4 bias spring, and fifth-reverse kickdown spring (one shift lever ball located in socket of input shift gate selector plate arm assembly and other in socket of main shift control shaft block).
7. Install spring and ball in fifth-reverse inhibitor shift lever hole.
8. Slide shift lever shaft, notch down, through shift lever, then use plastic tipped hammer to tap shift shaft through lever and fifth gear kickout spring into clutch housing bore.
9. Align shift spring pin with case bore, then install pin slightly below case mating surface.
Control Selector Plate Neutral Gate:
10. Verify selector pin is in neutral gate of control selector plate, and finger of fork selector arm is partially engaged with 1-2 and 3-4 forks.
Reverse Relay Lever Engaged In Reverse Idler Gear Groove:
11. Install reverse idler gear on clutch housing, then install reverse shift relay lever in gear slot and slide reverse idler shaft through gear and into its bore.
12. Install magnet in clutch housing pocket.
Fifth Gear Relay Lever Installation:
13. Install fifth gear relay lever onto reverse idler shaft, then align lever with shaft and fork interlock sleeve and reverse gear actuating arm slot. Install retaining C-clip.
14. Ensure case mating surfaces are clean and free of burrs, scratches and nicks. Apply a 1/16 inch wide bead of gasket eliminator part No. E1FZ-19562-A, or equivalent, to clutch housing.
15. Install detent spring and plunger in case bores.
16. Lower transaxle case over clutch housing, then depress spring and plunger using punch and hammer.
17. Gently move transaxle case until shift control shaft, mainshaft, input cluster shaft, and reverse shaft align with respective bores.
18. Install case over dowels and flush onto case. Ensure case does not bind on magnet.
19. Apply Teflon sealant to the threads of interlock sleeve retaining pin in clockwise direction.
20. Using drift punch, align slot in interlock sleeve with hole in transaxle case, then install retaining pin. If hole in case does not align with slot, remove case half and check for proper installation of interlock sleeve. Tighten pin to specifications.
21. Install 15 transaxle-to-clutch housing bolts. Tighten bolts to specifications.
22. Using drift punch, align bore in reverse idler shaft with retaining screw hole in transaxle case.
23. Install reverse idler shaft bolt. Tighten bolt to specifications.
24. Apply Teflon pipe sealant part No. D8AZ-19554-A, or equivalent, to threads of back-up lamp switch in clockwise direction, then install switch. Tighten switch to specifications.
25. On five speed models, apply Teflon pipe sealant part No. D8AZ-19554-A, or equivalent, to threads of detent plunger retaining screw, then install plunger and screw. Tighten screw to specifications.
26. On four speed models, coat detent cartridge spring and plunger threads, then install into case with retaining screw. Tighten screw to specifications.
27. On all models, tap differential seal into transaxle case using differential seal replacer tool No. T81P-1177-A, or equivalent.
28. Place transaxle in upright position, then install drift through hole in input shaft. Ensure proper operation by shifting transaxle through all gears.