Part 3 of 3
Transaxle Assemble - Con't
81. Install the rear bearing retainer to the transaxle case.
82. Coat the 5 rear bearing retainer bolts with Threadlocker 242 G/M P/N 12345382 or the equivalent.
83. Install the bolts.
Tighten the bolts to 27 Nm (20 ft. lbs.).
84. Install the 5th driven gear.
85. Install the 2 spacers and the roller bearing.
86. Install the snap ring to the output shaft.
87. Install 5th gear and the 5th gear synchronizer ring to the input shaft.
88. Before installing the No.3 clutch hub assembly and input shaft rear ball bearing assembly, place a suitable wooden block on the rear side of the input shaft.
89. Install the No.3 clutch hub assembly.
90. Select a snap ring that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.004 inch).
91. Install the 5th gear snap ring to the shaft.
92. Using a dial indicator, measure the radial runout of 6th gear.
Standard radial runout should be between 0.015 - 0.056 mm (0.0006 - 0.0022 inch). Maximum runout should not exceed 0.56 mm (0.0022 inch).
93. If the gear exceeds any of the maximum measurements, replace the gear, roller bearing or shaft.
94. Using a dial indicator, measure the thrust clearance of 5th gear.
Standard thrust clearance should be between 0.10 - 0.62 mm (0.0039 - 0.0244 inch). Maximum clearance should not exceed 0.62 mm (0.0244 inch).
95. Install the No.3 gear shift fork and No.3 hub sleeve.
96. Coat the retaining bolt with Threadlocker 242 G/M P/N 12345382 or the equivalent.
97. Install the bolt.
Tighten the bolt to 16 Nm (12 ft. lbs.).
98. Install the 6th gear synchronizer ring.
99. Install the roller bearing and spacer to the input shaft.
100. Install the 6th drive gear, then the rear bearing to the input shaft.
101. Install the input shaft snap ring.
102. Install the spacer to the output shaft.
103. Install the rear bearing to the output shaft.
104. Install the 6th driven gear to the input shaft.
105. Install the 6th driven gear snap ring to the output shaft.
106. Using a dial indicator, measure the radial runout of 6th gear.
Standard radial runout should be between 0.009 - 0.50 mm (0.0003 - 0.0020 inch). Maximum runout should not exceed 0.50 mm (0.0020 inch).
107. If the gear exceeds any of the maximum measurements, replace the gear, roller bearing or shaft.
108. Using a dial indicator, measure the thrust clearance of 6th gear.
Standard thrust clearance should be between 0.10 - 0.60 mm (0.0039 - 0.0236 inch). Maximum clearance should not exceed 0.60 mm (0.0236 inch).
109. Apply RTV Silicone Sealer GM P/N 12346240 (Canadian P/N 10953493) or equivalent to the transaxle case cover.
110. Install the 9 transmission case cover bolts.
Tighten the 9 bolts to 18 Nm (14 ft. lbs.).
111. Coat the 2 retainer bolts (1) with Threadlocker 242 G/M P/N 12345382 (Canadian P/N 10953489) or the equivalent.
112. Install the 4 bolts and the select lever shaft assembly to the transaxle case.
Tighten the 4 bolts to 18 Nm (14 ft. lbs.).
113. Coat the lock ball threads with Threadlocker 242 G/M P/N 12345382 (Canadian P/N 10953489) or the equivalent.
114. Install the lock ball assembly to the transaxle case.
Tighten the lock ball to 29 Nm (22 ft. lbs.).
115. Install the 2 bolts and the selecting bellcrank assembly.
Tighten the 2 bolts to 25 Nm (15 ft. lbs.).
116. Apply Multi-Purpose grease to the inside surface of the control bellcrank dust cover (1).
117. Install the 3 bolts and the control cable bracket.
Tighten the 3 bolts to 11 Nm (8 ft. lbs.).
118. Install the backup light switch and new gasket to the transaxle case.
Tighten the switch to 40 Nm (29 ft. lbs.).
119. Install the bolt and speedometer drive hole cover.
Tighten the bolt to 11 Nm (8 ft. lbs.).
120. Install the drain plug and gasket.
Tighten the drain plug to 39 Nm (29 ft. lbs.).
121. Install the filler plug and gasket.
Tighten the filler plug to 39 Nm (29 ft. lbs.).