Transaxle Assemble

Transaxle Assemble




1. Install the transmission magnet (31).




2. Install the front differential assembly (42).




3. Install the upper mainshaft assembly (21) and the 3rd/4th and reverse fork assembly (17) together.




4. Together as one assembly, install the input shaft assembly (13), the lower mainshaft assembly (34) and the 1st/2nd and 5th/6th fork assembly (38).




5. Install the manual transmission oil trough (10).





Important: The sealing surfaces must be free of dust and grease.

Important: After applying sealing compound to the sealing surface, the transmission case must be installed within 2 minutes.

6. Clean the case (5) and housing (24) sealing surfaces with acetone or equivalent.
7. Apply sealing compound (1) to the sealing surface over a width of approximately 3 mm (a). Place compound 1-2 mm from chamfer (b).




8. Observing the locations of bolts versus studs, install 17 bolts/screws.

Notice: Refer to Fastener Notice.

9. Install the central release bolt (25) on the opposite side.

Tighten the M8 bolts (48) to 25 N.m (18 lb ft). Tighten the M10 bolts (1) to 50 N.m (37 lb ft).




10. Install the 17 transmission case bolts (30).

Tighten the bolts to 50 N.m (37lb ft).




11. Install the shift control with shift control shaft housing assembly (9).
12. Install the 3 shift control housing bolts/screws (8).

Tighten the bolts to 25 N.m (18 lb ft).




13. Install the backup lamp switch (7).

Tighten the backup lamp switch to 24 N.m (18 lb ft).




14. Install the vehicle speed sensor assembly (46).
15. Install the vehicle speed sensor bolt/screw (45).

Tighten the bolt/screw to 20 N.m (15 lb ft).




16. Install the clutch master cylinder assembly (26).
17. Install the clutch master cylinder screws (27).

Tighten the screws to 10 N.m (89 lb in).




18. Install the drive axle seal (29) using a seal installer.
19. Install the drive axle seal (49) using a seal installer.