Part 2 of 3
Transaxle Assemble - Con't
41. Using a feeler gage, measure the thrust clearance for 4th gear of the input shaft.
Thrust Clearance: 0.10 - 0.55 mm (0.0039 - 0.0217 inch).
42. Notice:
Refer to Fastener Notice in Service Precautions.
Install the bolt and the transaxle case receiver to the transaxle case.
Tighten the bolt to 11 Nm (8 ft. lbs.).
43. Install the bearing lock plate and bolt.
Tighten the bolt to 11 Nm (8 ft. lbs.).
44. Using a press, install the output shaft front bearing.
45. If the output shaft front bearing requires replacement, install the bolt and output shaft cover.
46. Using a press, install the input shaft bearing.
47. If the input shaft bearing has been replaced, install a new oil seal.
Oil Seal installation depth should be 15.6 - 16.0 mm (0.614 - 0.630 inch).
48. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.89 mm (0.0350 inch). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.
49. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.75 mm (0.0295 inch). If the clearance is less than the minimum, replace the synchronizer ring.
50. Check the 5th and 6th gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.
51. Assemble the No.3 clutch hub assembly.
52. Install the magnet to the transaxle case
53. Install the differential case assembly to the transaxle case.
54. Install the input and output shafts together into the transaxle case.
55. Install the No.2 gear shift fork to the No.2 hub sleeve groove.
56. Install the No.3 gear shift fork shaft to the reverse shift fork to the transaxle case.
57. Install the reverse shift fork.
58. Install the No.1 gear shift fork to the reverse gear assembly.
59. Install the No.1 gear shift head to the shift shaft.
60. Install the No.1 gear shift fork shaft to the No.1 gear shift fork to the transaxle case.
61. Install the No.2 gear shift fork shaft to the No.2 gear shift fork.
62. Install the No.1 gear shift head, No.1 gear shift fork and the reverse shift fork to the transaxle case.
63. Ensure that the 3 gear shift heads are aligned correctly.
64. Apply Threadlocker 242 G/M P/N 12345382 to the 3 gear shift fork set bolts.
65. Install the 3 gear shift fork set bolts.
Tighten the set bolts to 16 Nm (12 ft. lbs.).
66. Install the 2 snap rings to the No.1 and No.2 gear shift fork shafts.
67. Install the reverse idler gear, thrust washer and shaft.
68. Set the pin on the top of the reverse shift arm into the groove on the reverse idler gear.
69. Fit the claw of the reverse shift arm bracket with the notch of the input shaft front bearing.
70. Install the 2 reverse shift arm bracket, then install the bracket retaining bolts.
Tighten the bolts to 17 Nm (13 ft. lbs.).
71. Install the oil receiver pipes to the transaxle case.
72. Install the oil receiver retaining bolts.
Tighten the bolts to 17 Nm (13 ft. lbs.).
73. Apply RTV Silicone Sealer GM P/N 12346240 (Canadian P/N 10953493) or equivalent to the transaxle case side.
74. Install the 13 transaxle case retaining bolts.
Tighten the 13 bolts to 30 Nm (22 ft. lbs.).
75. Install the 3 transmission case retaining bolts.
Tighten the 3 bolts to 30 Nm (22 ft. lbs.).
76. Using a Allen wrench or equivalent, install the 2 screw plugs to the transaxle case.
^ Tighten screw plug (a) to 13 Nm (9 ft. lbs.).
^ Tighten screw plug (b) to 39 Nm (29 ft. lbs.).
77. Using a Allen wrench or equivalent, Install the 3 screw plug assemblies to the transaxle case.
Tighten the 3 screw plugs to 24.5 Nm (18 ft. lbs.).
78. Install the snap ring to the No.2 shift fork shaft.
79. Install the reverse idler gear shaft lock bolt and gasket to the transaxle case.
Tighten the lock bolt to 29 Nm (22 ft. lbs.).
80. Using snap ring pliers or equivalent, install the 2 snap rings.