Output Shaft

Tools Required
- 87-92-178-Output Shaft Puller Ring
- 87-90-636-Pinion Fixture
- 87-92-103-Output Shaft Assembly Tool

DISASSEMBLY





NOTICE: Do not mix up synchronizer components. All of the parts should be reinstalled in their original locations.

1. Remove output shaft assembly tool 87-92-103 from 1st/2nd driven gear assembly.
2. Remove 2nd driven gear and bushing.
3. Remove 2nd gear synchronizer assembly (blocking ring, inner and outer cones).

IMPORTANT: Mark top of 1st/2nd gear synchronizer hub to orient part correctly during reassembly.

4. Remove 2nd gear synchronizer spring, turn hub and sleeve upside down and remove remaining synchronizer spring and inserts. Remove hub from sleeve.
5. Remove 1st gear synchronizer assembly (blocking ring, inner and outer cones).





6. Remove output shaft bearing using 20 tooth puller ring 87-92-178 and fixture 87-90-636 in a hydraulic press.
7. Check condition of gears and synchronizers.

Tools Required
- 87-92-202-Output Shaft Bearing Race Sleeve
- 87-91-204-Output Shaft Bearing Race Sleeve
- 87-92-103-Output Shaft Assembly Tool

ASSEMBLY





IMPORTANT: Lubricate all rotating parts and bearings with manual transaxle fluid (P/N 21018899) during assembly.

1. Press on output shaft bearing using tools 87-92-202 and 87-91-204.





2. Install 1st gear synchronizer assembly (blocking ring, inner and outer cones) to 1st driven gear.





IMPORTANT: The recesses in the 1st/2nd synchronizer sleeve must align with the gaps in the synchronizer hub.

3. Install 1st/2nd synchronizer hub into synchronizer sleeve. The reference mark on hub made during disassembly faces up (away from 1st gear), and the fork groove on sleeve faces down (towards 1st gear).
4. Install 1st/2nd synchronizer inserts into their positions between the hub and sleeve.

IMPORTANT: The 1st/2nd synchronizer springs on the top and bottom of hub must hook into the same insert.

5. Hook one of the synchronizer springs into a synchronizer insert and route spring in a clockwise direction. Carefully turn over 1st/2nd synchronizer hub and sleeve and install remaining synchronizer spring. The spring should hook into the same insert as the previously installed spring and should also route in a clockwise direction.





6. Install 1st/2nd synchronizer hub and sleeve onto 1st driven gear and blocking ring (fork groove on sleeve faces 1st gear). Align gaps in synchronizer hub with blocking ring lugs.





7. Install 2nd driven gear synchronizer assembly (blocking ring, inner and outer cones) to 1st/2nd synchronizer hub. Align blocking ring lugs with gaps in synchronizer hub.
8. Install 2nd driven gear.
9. Install 2nd driven gear bushing.
10. Hold down 2nd gear and move synchronizer sleeve up and down to check for proper operation.





11. Install output shaft assembly tool 87-92-103 around 1st and 2nd driven gears as shown. This tool holds the 1st and 2nd synchronizer assemblies together during transaxle assembly. Secure tool with plastic tie.