Assemble

1. Assemble input and output shaft gear assemblies (A).

2. Install the following on gear cluster assembly:

a. Install 1-2 shift rail (188), then the lockpin 9194), retaining with petroleum jelly.

b. Install 3rd shift rail (182), then the fifth shift rail (195).

c. Install reverse shift rail (176), then the shift gate (177).

3. Position gear cluster/shift rail assembly on pallet tool No. J-39367, or equivalent, then align shift rail and shaft pilots to fixture.

4. Install bushing installer/adapter tool No. J-36029-2, or equivalent, into reverse shift rail bushing to hold detent ball (126) and spring (125) in position.

5. Install transaxle case assembly (84) on gear cluster and shift rail assembly, noting the following:

a. Align bearing bores in case with shaft pilots, then install transaxle assembly to pallet tool.

b. When installing case assembly (84), bushing installer/adapter tool will be pushed out of case.

6. Install reverse shift rail plug (202) as follows:

a. Install plug flush with case usingplug installer tool No. J-36189 and universal drive handle tool No. J-36190, or equivalents.






b. Push reverse and 3rd shift forks assemblies to hold transaxle in fourth and reverse gear.

7. Select input shaft bearing shim (121) as outlined under "Shim Selection," then install shim. Refer to Shim Selection.

8. Lube input shaft bearing with synchromesh fluid part No. 12345349, or equivalent, and lightly tap bearing into position with plastic hammer.

9. Tighten new input gear bearing retainer (89) to specifications.

10. Install detent pin in 3-4 shift rail, then return transaxle to neutral.






11. Assemble shaft assembly components, onto shift shaft assembly tool No. J-39366, or equivalent.

12. Install shift shaft assembly components and tool into transaxle case.

13. Install shift shaft, pushing shaft tool from components and through shift shaft hole in case, then remove tool.

14. Install roll pins (154 and 158). Ensure pins are even with shift lever and retainer surfaces.

15. Apply gasket maker part No. 1052943, or equivalent, to inside of bolt hole pattern of gear case flange.

16. Install differential (60), then the chip collector magnet (201).

17 Position clutch housing on transaxle case add gear cluster/shift rail assembly.

18. Install transaxle case bolts (83) with washers (82). Tighten transaxle case bolts to 20 lbs. ft.

19. Install spacer (90) and bearing oil delivery tubes (226 and 227).

20. Apply gasket maker part No. 1052943, or equivalent, to inside end plate bolt hole pattern of case.

21. Install input shaft support bearing selective shim as outlined under "Shim Selection." Refer to Shim Selection.






22. Install end cover plate.

23. Install end plate bolts (88) and washers (87): Tighten end plate bolts to specifications.






24. Position all shift rails at same height.

25. Install reverse bushing (166).

26. Assemble interlock pins (167) and springs (169) into bores in detent holder (168) and retain with petroleum jelly.

27. Install detent holder and spring assembly (168) with detent ball (170) for reverse shift rail (222).

28. Install detent balls in the following order, 1-2 shift rail (188), 3-4 shift rail (182) then the fifth gear shift rail (195).

29. Install position holder (168) and bolts (174). Tighten detent holder bolts to 80 lbs. in. Ensure shift rails are in correct detent positions.

30. Apply high temperature grease to inside cover bore, then install new protective cover (140) in bore by tapping until seated and flush with bore.

31. Install shift shaft detent inner spring seat (144), fifth/reverse bias spring (143) and spring outer seat (142).

32. Apply small amount of sealant part No. 1052624, or equivalent, to detent screw (141). Tighten screw to 80 lbs. in.

33. Install new protective cover (140), positioned just deep enough to install snap ring. If the protective cover is installed too deep or top of the cover is caved in, this may cause a hard shift in the 1-2 gate.






34. Install selector lever retainer (131) and bolts (132) using pipe sealant with Teflon. Tighten bolts to 17 lbs. ft.

35. Install shift shaft collar (134) and new pin (138), applying small amount of high temperature grease to slot in collar.

36. Install selector lever pivot (133), new pin (130), retainer (129), lever (135), washer (136) and nut (137). Tighten nut to 17 lbs. ft. Hold lever from turning while tightening nut.

37. Install fluid level indicator assembly (97).

38. Coat new speed sensor seal (212) with synchromesh fluid and install onto speed sensor assembly (171).

39. Install speed sensor assembly (171), retainer (208) and bolt (209). Tighten speed sensor assembly bolt to 80 lbs. in.