Assembly
ASSEMBLENOTE: It is important to clean and inspect all parts carefully prior to assembly. Lubricate contact surfaces with clean multi-purpose automatic transaxle fluid.
1. Using selector shaft bushing replacement tool No. T94P-7025-DH, or equivalent, install outer selector shaft bushing, then use tool No. T94P-7025-HH, or equivalent, to install shift lever shaft oil seal.
2. Using selector shaft bushing replacement tool No. T94P-7025-DH, or equivalent, install inner shift lever shaft bushing, then slide shaft into bore.
3. Install main shift control shaft block or end of shift lever shaft and tighten back socket bolt to specifications.
4. Using Rotunda heat gun tool No. 107-R0300, or equivalent, heat reverse idler gear shaft mounting area of transaxle case to 175° F, then apply a thin coat of silicone rubber part No. D6AZ-19562-AA, or equivalent, to retaining plate mating surface.
5. Using mounting bolt as a guide, position reverse idler gear in case, then drive shaft in until retaining plate contacts transaxle case.
6. Install retaining plate bolts and tighten to specifications, then place outer bearing races in a freezer until they are cooled to 46° F or below, noting the following:
CAUTION: Differential, input shaft and output shaft bearing races require these specific heating and cooling procedures for proper installation In transaxle case. Failure to complete these steps will resuit in premature case wear or inaccurate preload measurements.
a. Shims are used between clutch side of transaxle case and input shaft, output shaft, and differential bearing races to provide correct preload for each component.
NOTE: Service shims must be installed beneath bearing races and heating and cooling procedures must be observed each time a race is installed in clutch side of transaxle case. It is necessary to obtain the correct service shim kit for this purpose.
7. Using Rotunda heat gun tool No. 107-R0300, or equivalent, heat bearing race areas on gear side of transaxle case to 194° F.
8. Using bearing cup replacement tool No. T80T-4000-W, or equivalent, and a suitable soft-faced mallet, install output shaft, input shaft, and differential bearing races in gear side of case.
9. Place clutch side transaxle case bearing races in a freezer until they are cooled to 46° F or below, then heat bearing race recesses of clutch housing to 194° F using Rotunda heat gun tool No. 1O7-R0300, or equivalent.
10. Install service shims from service shim kit in clutch side of transaxle case.
NOTE: Service shim thicknesses for each component are specified in kit; therefore, it Is extremely important that they are mated correctly. Measure thicknesses with a micrometer to ensure accuracy.
11. Install bearing races in clutch side of transaxle case using bearing cup replacement tool No. T94P-7025-BH and driver tool No. T80T-4000-W, or equivalents, and a soft-faced mallet.
12. Engage fourth gear on input shaft, then align input and output shafts as necessary to install them in transaxle case. Do not lubricate tapered roller bearings until preload measurements have been obtained.
13. Lower differential assembly into transaxle case, then position clutch side of case on gear side.
NOTE: Do not use sealer on case a halves at this time.
Input Shaft Endplay Measuring Fixture Installation:
14. Install transaxle to clutch housing bolts and tighten to specifications, then install measuring fixture at control select lever cover opening with cover mounting bolts.
15. Position measuring bar on fourth gear face, then install pinion spline socket tool No. T94P-7025-EH, or equivalent, on input shaft end.
16. Rotate input shaft back and forth approximately 20 times to seat roller bearings, then position transaxle in upright position.
Dial Indicator Installation For Input Shaft Endplay Measurement:
17. Install suitable dial indicator using bracket tools, then position indicator stem on input shaft end and reset indicator to zero.
18. Insert a suitable lever tool through control select lever cover opening, Then use lever to lift input shaft to its full-up position.
19. Record dial indicator reading with input shaft in full-up position, then repeat endplay measurement at least three times and average all measurements.
Output Shaft Endplay Measurement Tool Installation:
20. Install output shaft endplay measurement tools with dial indicator stem resting on measuring fixture and fixture against transaxle fourth gear as shown.
21. Install pinion spline socket tool No. T94P-7025-EH, or equivalent, on end of output shaft, then rotate back and forth approximately 20 times to seat roller bearing.
22. Insert a suitable lever tool through control select lever cover opening, then use lever to lift output shaft to its full-up position.
23. Record dial indicator reading with output shaft in full-up position, then repeat endplay measurement at least three times and average all measurements.
Shim Selection Tool Adapter Installation:
24. Install shim selection tool adapter on transaxle case, then place pinion spline socket tool No. T94P-7025-EH, or equivalent on end of input shaft.
Dial Indicator And Bracket Installation For Differential Endplay Measurement:
25. Rotate input shaft back and forth at least 20 times while applying downward pressure to differential assembly, then install dial indicator and bracket with stem resting on differential. Reset indicator to zero.
Differential Manipulation For Endplay Measurement:
26. Lift differential assembly using measuring fixture tool No. T94P-4451-BH, or equivalent, and a breaker bar.
27. Record dial indicator reading with differential in full-up position, then repeat endplay measurement at least three times and average all measurements.
Preload Shim Selection Chart:
28. Use Preload Shim Selection Chart to calculate required shim thickness for input and output shafts and differential. Add total service shim thickness, average value measured in preceding steps and specified preload.
29. Select required shim for each component, noting the following:
a. Only one shim can be chosen for each component.
b. If required shim value does not match shim range in the Preload Shim Selection Chart, lower required shim value to next lowest value.
CAUTION: Do not raise required shim value; internal transaxle components will be damaged due to incorrect preload.
30. Remove bearing races and service shims from clutch side of transaxle case, then use heating and cooling procedures outlined in preceding steps to install correct preload shims with bearing races.
Input And Output Shaft Alignment:
31. Lubricate input shaft, output shaft, differential gears, and bearings with clean multi-purpose automatic transaxle fluid, then lower input and output shafts into transaxle case aligned as shown in the Input And Output Shaft Alignment image.
32. Rotate input shaft aside and insert reverse idler shaft, then install lower reverse idler gear thrust washer in transaxle case. Ensure tab on washer is mated to recess in bore.
Reverse Idler Gear Assembly Components:
33. Install reverse idler bearing and gear on shaft, then place upper thrust washer on reverse idler gear and secure with petroleum jelly.
34. With input and output shafts moved aside, install reverse idler gear shaft support bracket and tighten bolts to specifications.
35. Ensure fourth gear synchronizer selector ring is in neutral position then install 5-R fork and swivel it aside.
36. Install 3-4 selector fork, then position 1-2 selector fork on long selector fork rail and engage with synchronizer shifter ring while installing long rail through 5-R selector fork and into recess in bottom of case.
37. Install short shift fork rail through 3-4 selector fork and into recess in case bottom. Shift fork rods will be at same height if installed correctly.
38. Lubricate differential gears and bearings with clean multi-purpose automatic transaxle fluid, then install in transaxle case.
39. Install magnet in magnet recess, then ensure transaxle housing sealing surface is clean and dry.
Transaxle Case Sealant Application:
40. Apply a bead of gasket material to transaxle case sealing surface, then install clutch side of transaxle case on gear side, noting the following:
a. Ensure input shaft, output shaft, and differential bearings engage with their respective races in clutch side of transaxle case.
b. Transaxle case bolt must be Installed within 15 minutes of sealant application.
41. Tighten case bolts to specifications, then ensure control select lever cover sealing surface is clean and dry.
42. Apply a 0.008 inch bead of gasket material part No. E1FZ-1956-A, or equivalent, to control select lever cover mating surface then install cover and tighten bolts to specification in an alternating pattern.
43. Install speedometer drive bearing and driven gear in clutch housing. Use a suitable soft drift to install roil pin flush with case.
44. Using differential driveshaft seal replacement tool No. T94P-7025-CH and-driver handle tool No. T80T-4OOO-W, or equivalents, install left and righthand differential oil seals.
45. install a new input shaft guide sleeve 0-ring, then install clutch housing guide shield and tighten screws to specifications
Clutch Slave Cylinder Components:
46. Install clutch slave cylinder on clutch housing by sliding down over input shaft, then install hydraulic pressure line and bleeder pipe. Tighten all fittings and bolts to specifications.