22. Output Shaft Assemble

- Tools Required
- J 35539 Output Shaft Remover and Installer

1. Inspect the output shaft seal ring for cuts or damage. Replace as necessary.
2. Move the manual shift lever to any position other than Park.





3. Install the output shaft assembly into the transaxle case. Using a J 35539, tap on the output shaft bearing (7074). Excessive hammering will damage the transaxle case.
4. Move the manual shift lever into the Park position in order to lock the output shaft in place.





5. Install the reduction driven gear (7071). Confirm that the reduction driven gear meshes with the reduction drive gear (7073).
6. Install the reduction driven gear nut.
- Tighten the reduction driven gear nut to 150 Nm (108 ft. lbs.).





7. Using a hammer and chisel, stake the reduction driven gear nut (7072) in two places.
8. Inspect the output shaft and the countershaft for smooth operation by rotating both the reduction drive gear (7073) and the reduction driven gear (7071) by hand.





9. Install a new rear case cover gasket (706).
10. Install the rear case cover (705). Confirm that the output shaft bearing on the reduction drive gear enters the rear case cover bore smoothly.
11. Install five of the cover bolts (707). The remaining five bolt positions are currently concealed by the J 35525-A Holding Fixture. You must install these bolts in a later procedure.
- Tighten the rear case cover bolts to 23 Nm (17 ft. lbs.).

12. Install two rear case cover nuts.
- Tighten the rear case cover nuts to 15 Nm (11 ft. lbs.).





13. Position the four tabs of a J 35539 into the four notches inside the transaxle case. These notches are indicated in the illustration by the number 1.





14. Tap on the J 35539 lightly with a hammer in order to seat the output shaft (7077) against the rear case cover (705). Do not tap directly on the output shaft, as this may damage to the output shaft.
15. Rotate the output shaft in order to test the reduction drive gear and the driven gear for any abnormal gear noise.