Shift Linkage

SHIFT LINKAGE

DISASSEMBLY

IMPORTANT: When disassembling the shift linkage mechanism, all of the shift shafts must be in their neutral positions.





1. Mount shift linkage assembly in a vise with soft jaws.
2. Drive out shift control lever shaft pin. Drive out shift control lever shaft. and remove shift's control lever assembly.

CAUTION: THE SHIFT SHAFT DETENT BALLS ARE UNDER SPRING PRESSURE. THE DETENT BALL OPENINGS IN THE SHIFT LEVER BRACKET MUST BE COVERED DURING DISASSEMBLY OR THE BALLS CAN ACCELERATE OUT OF THE OPENINGS POSSIBLY CAUSING INJURY.





3. Cover reverse shift shaft detent ball opening in shift lever bracket with your thumb and remove reverse shift shaft.

IMPORTANT: There are shift shaft interlock balls and pins between shift shafts that prevent transaxle from being shifted into two different gears at the same time.





4. Remove remaining shift shafts in the same manner. Start with the 5th gear shift shaft, then 3rd/4th, and finally 1st/2nd. Keep all detent balls, springs. and shift shaft interlock pins for reassembly.
5. Inspect all components for signs of excessive wear. Replace any parts which are worn or damaged.

When a manual transaxle with a serial number before T02075 is repaired for a 3rd/4th gear shift fork concern, it must be determined whether the component is a 1st design or a 2nd design.

IMPORTANT: All transaxles built prior to the T02075 serial number will be of the 1st design unless they have been previously repaired for this condition. All service parts are of the 2nd design.





6. Measure the thickness of the 3rd/4th shift fork's sleeve as shown.
1st design: 33.5 mm
2nd design: 37 mm

If the 3rd/4th shift components are a 1st design and need to be replaced, then both blocking rings, the sleeve, and the shift fork must be replaced with the 2nd design parts as a unit. If the blocking rings, sleeve, and shift fork have already been replaced with the 2nd design components, then only replace parts as needed.





7. If the shift forks, shift shafts, or shift shaft blocks need to be replaced, remove the appropriate retaining pins to the component needing replacement. Always discard used retaining pins and install new pins when reassembling.





8. If any components of the shift control lever assembly need to be replaced, compress one of the lever assembly springs and remove spring retainer and discard. The spring on the opposite end is removed in the same manner.

ASSEMBLY





1. If the shift control lever assembly was disassembled, perform following step to reassemble.

IMPORTANT: The springs and spring seats are two different lengths. Refer to illustration for correct spring orientation.

2. Install springs and spring seats. compress spring seats and install new spring seat retainers.





3. It any shift forks, shift shafts, or shift shaft blocks were disassembled, reassemble shift shafts by driving new retaining pins into shift forks or shift shaft blocks.





4. Install 1st/2nd shift shaft.
4.1 Insert detent spring and detent ball through opening in shift lever bracket.
4.2 Compress the ball and spring using a screwdriver and install shift shaft. Place shaft in neutral position.





5. Insert shift shaft interlock ball between 1st/2nd shaft and 3rd/4th shaft. Install interlock pin in 3rd/4th shaft.

IMPORTANT: The 1st/2nd shift shaft inserts into 3rd/4th shift fork.

6. Install 3rd/4th detent spring and ball. Compress ball and spring, and install 3rd/4th shift shaft. Place shaft in neutral position.





7. Insert shift shaft interlock ball between 3rd/4th shaft and 5th shaft. Install interlock pin in 5th shaft.
8. Install 5th detent spring and ball. Compress ball and spring and install 5th shift shaft. Place shaft in neutral position.





9. Insert shift shaft interlock ball between 5th shaft and reverse shaft.
10. Install reverse detent spring and ball. Compress ball and spring and install reverse shift shaft. Place shaft in neutral position.

IMPORTANT: Make sure that shift control lever shaft pin is centered into shift control shaft during installation.





11. Install shift control lever assembly into shift lever bracket. Press in shift control lever shaft and tap in a new shift control lever shaft pin.