Output Shaft

OUTPUT SHAFT

TOOLS REQUIRED
- 87-90-636 Pinion Fixture
- 87-91 -204 Output Shaft Bearing Race Sleeve
- 87-92-103 Output Shaft Assembly Tool
- 87-92- 178 Output Shaft Puller Ring
- 87-92-202 Output Shaft Puller Ring

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 gear and 1st/2nd gear synchronized sleeve.





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. After marking top of 1st/2nd gear synchronizer hub, turn over the assembly and remove 1st gear.
5. Remove 1st gear synchronizer assembly (blocking ring, inner, and outer cones).
6. Remove 1st gear synchronizer springs turn hub and sleeve over and remove remaining synchronizer spring and inserts. Remove hub from sleeve.





7. Remove output shaft bearing using Output Shaft Puller Ring 87-92-178 and Pinion Fixture 87-90-636 in a hydraulic press.
8. Check condition of gears and synchronizers.

ASSEMBLY

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





1. Press on output shaft bearing using Output Shaft Bearing Race Sleeve 87-92-202 and Output Shaft Bearing Race Sleeve 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 narrow 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 gear and 1st/2nd gear synchronizer sleeve as shown. This tool holds the 1st and 2nd synchronizer assemblies together during transaxle assembly. Secure tool with plastic tie.