Assemble

Attach clutch housing to a holding fixture prior to assembly.

1. Install input shaft seal using input shaft seal installer tool No. J-26540, or equivalent.

2. Install input shaft outer bearing races using shim selector tool No. J-33373 with driver handle tool No. J-8092, or equivalents.

3. Install output race using bearing race installer tool No. J-33371, or equivalent, then the differential race into clutch housing using driver handle tool No. J-8092, or equivalent.

4. Lubricate interlocking pins, then install into clutch housing.

5. Using third and fourth shift bracket for alignment, install reverse shift bracket in clutch housing. Tighten bolts to specifications. Ensure rod operates smoothly after installation.

6. Install differential assembly, then the input and output shafts with 3-4 shift fork and shaft as an assembly into clutch housing. Third/fourth shift fork and shaft is inserted into raised collar of reverse shift lever bracket in clutch housing as an assembly.

7. Install 1-2 shift fork and place shifter shaft in reverse lever bracket. Align hole in fork with shaft and insert new double roll pin, then install reverse lever onto shift bracket.

8. Engage reverse shaft and lever while simultaneously installing reverse and fifth gear shifter shaft. Ensure interlock pin is in fifth gear shifter shaft prior to installation.

9. Install reverse idler shaft and gear into clutch housing and insert reverse lever into collar of gear.




10. Using shim selector tool No. J33373, or equivalent, measure and determine shim size as follows:

a. Place outer bearing races on input, output, and differential bearings, then position shim selection gauges on bearing races.






b. Place seven spacers from shim tool around perimeter of clutch housing, then install bearing and shim retainer on transaxle case. Torque screws to 13 ft. lbs.

c. Place transaxle case over gauges and spacers, then install seven bolts from shim tool and tighten alternately to seat case.

d. Torque shim tool bolts to 1O ft. lbs.

e. Rotate gauges to seat bearings, then rotate differential case three revolutions in each direction.






f. Compress three gauges, then measure outer sleeve and base pad gap with shims from tool. Input shaft shim should be two sizes smaller than largest shim that will fit in gap. Differential shim should be three sizes larger than shim that fits smoothly in gap. Output shaft shim should be largest shim that can be placed into gap without binding.

g. After determining shim size, remove case, spacers and gauges.

11. Install selected shims for input, output and differential bearings into their bearing race bores.

12. Using press rear input shaft bearing race, rear output shaft bearing race, and rear differential case bearing race until seated in their bores.

13. Install magnet in clutch housing.

14. Apply 1/8 inch bead of RTV silicone sealer part No. 1052917, or equivalent, to clutch housing to transaxle mating surface, then install transaxle case to clutch housing.

15. Install reverse idler shaft bolt in transaxle case. Torque to 28 ft. lbs.

16. Install case bolts. Tighten to 11-16 lbs. ft. in diagonal sequence.






17. Install drive axle seals using drive axle seal installer tool No. J-29130, or equivalent.

18. Install thrust washer and collar to output shaft using bearing installation tool No. J-33374, or equivalent, then apply oil to thrust washer and collar and install assembly.

19. Install fifth gear to input shaft, then the needle bearing, fifth gear, blocker ring, hub and sleeve assembly with shift fork in its groove and back plate on output shaft.

20. Align shift fork and drive in roll pin.

21. Install detent ball, springs and bolt for reverse, first, second, third, fourth and fifth speeds. Tighten detent spring bolts to 15-21 lbs. ft.

22. Apply Loctite 262, or equivalent, to threads of input and output shafts, then install and stake new nuts. Tighten nuts to 94 lbs. ft. Ensure material does not flow into splines of fifth gear and input shaft.

23. Assemble control box as follows:

a. Assemble stopper cam and internal lever. Ensure splines on stopper cam and internal lever are aligned.






b. Install stopper cam and internal lever to shift lever assembly, then align cam alignment mark with center on internal lever.

c. Check for proper operation of reverse inhibitor, then use new roll pin to attach internal lever.

24. Install new gasket and control box assembly on transaxle case. Tighten control box to case bolts to 11-16 lbs. ft.

25. Ensure transaxle shifts properly, then install new gasket and rear cover. Tighten rear cover bolts to 11-16 lbs. ft.

26. Install new clutch shaft bearing into clutch housing using inner bearing installer tool No. J-37159 and driver handle tool No. J-36190, or equivalents, then the new oil seal and clutch shaft.

27. Install new clutch shaft outer bushing using outer bushing installer tool No. J-36037, or equivalent. Drive bushing inward until line on tool is flush with housing.

28. Install clutch release bearing.