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TRANSAXLE ASSEMBLY

TOOLS REQUIRED
- 78-41-067 Sleeve, Inner Drive
- 83-90- 114 Sleeve
- 87-90-867 Input Shaft Bearing Ring
- 87-91-204 Output Shaft Bearing Race Sleeve
- 87-91 -261 Output Shaft Remover
- 87-91 -428 Driver
- 87-92-053 Companion Flange
- 87-92-061 Output Shaft Nut Socket
- 87-92-09510 Kilogram Weight
- 87-92- 103 Output Shaft Assembly Tool
- 87-92-137 Milled Bearing Race
- 87-92-202 Output Shaft Bearing Race Sleeve
- J43707 Transmission Support Fixture
- J44362 Input Shaft Support
- J7754-C Inch Pound Torque Wrench
- SA9179NE Dial Indicator

NOTICE: In all work involving disassembly of transaxle, a new output shaft nut and crush sleeve must be installed during reassembly.

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

1. Mount clutch housing on Transmission Support Fixture J43707 (if necessary).
2. Install differential assembly into clutch housing.





3. Make sure output shaft oil feed tube is staked in place in clutch housing prior to installing output shaft.





4. Install output shaft.
4.1 Install output shaft into clutch housing bore.
4.2 Lubricate bearing.
4.3 Install output shaft bearing race by tapping race with a plastic hammer to start in bore.
4.4 Install bearing retainer.
4.5 Tap down bearing race using retainer and tools Output Shaft Bearing Race Sleeve 87-92-202 and Output Shaft Bearing Race Sleeve 87-91-204 as shown.
5. Apply Loctite 242 Threadlocker (P/N 21485277) to three middle output shaft bearing retainer bolts and install.
Torque:
Output Shaft Bearing Retainer Bolts (Inner): 45 Nm (33 ft. lbs.)
6. Apply Loctite 242 Threadlocker (P/N 21485277) to one outer output shaft bearing retainer bolt and install.
Torque:
Output Shaft Bearing Retainer Bolts (Outer): 24 Nm (18 ft. lbs.)

IMPORTANT: There must be a 15 mm clearance between 1st driven gear and the clutch housing to be able to install the input shaft. This can be done by putting the output shaft nut between clutch housing and 1st driven gear.





7. Install an object on top of main shaft bearing retainer so that there will be a 15 mm clearance between the bearing retainer and the 1st/2nd driven gear assembly when it is installed.
8. Install 1st/2nd driven gear assembly, held together with tool Output Shaft Assembly Tool 87-92-103 on output shaft.

NOTICE: Third driven gear must be reinstalled in the same orientation as it was removed to avoid noise concerns.

9. Install 3rd driven gear and spacer sleeve on output shaft.
10. Lubricate input shaft bearing and install input shaft into clutch housing. Remove the object holding up the 1st/2nd driven gear assembly from under 1st driven gear, and install a plastic tie as shown to hold input and output shafts together.

NOTICE: A new output shaft crush sleeve must be used.

IMPORTANT: 4th driven gear should be installed with machined groove facing down (towards 3rd gear).





11. Carefully tap down output shaft gears to make sure that gears are against surface of clutch housing. This can be done with tools Input Shaft Bearing Ring 87-91-204 and Input Shaft Bearing Ring 87-90-867. Install new crush sleeve and 4th driven gear.

NOTICE: Do not compress the crush sleeve when installing 4th driven gear. Any compression of the sleeve done other than by tightening the output shaft nut will require disassembly of the transaxle and replacement of the crush sleeve.





12. Install Output Shaft Bearing Race Sleeve Tool 87-91-204 on top of 4th driven gear and tap down the 4th driven gear until contact is made with the crush sleeve.
13. Remove plastic ties and Output Shaft Bearing Race Sleeve Tool 87-91-204.

NOTICE: Make sure reverse idler gear shaft lube hole is facing correct way (refer to illustration). If the hole is not facing the correct direction, reposition shaft before installation.





14. Lift input shaft slightly and install reverse idler gear shaft assembly. The shaft lubrication hole should be facing lube passage in clutch housing.





15. Install shift linkage mechanism into clutch housing.
15.1 Put 1st/2nd synchronizer sleeve on output shaft in the 2nd gear position.
15.2 Put 3rd/4th synchronizer sleeve on input shaft in the 4th gear position.
15.3 Insert 1st/2nd and 3rd/4th shift forks into synchronizer sleeves and push mechanism into place.
15.4 Install locating sleeves and loosely install outboard shift linkage bolt.

NOTICE: If thread sealant is not used on short reverse shift lever assembly bolt, a fluid leak could occur.

IMPORTANT: Reverse shift lever assembly oil plate should be under edge of shift linkage mechanism.





16. Install reverse shift lever assembly. Loosely install longer mounting bolt. Apply Loctite 592 thread sealant (P/N 21485278) on shorter bolt and install. Tighten reverse shift lever assembly bolts and shift linkage bolt.
Torque:
Reverse Shift Lever Bolts: 24 Nm (18 ft. lbs.)





17. Install reverse gear fork to reverse gear synchronizer sleeve. Make sure fork is in position on reverse shift lever and install reverse gear fork shaft.
18. Engage reverse gear using shift linkage assembly to check for full engagement of reverse.





19. Lightly lubricate shift control shaft with grease and insert through seal in clutch housing.
20. Insert shift control shaft through shaft block. Put shaft block in position and install bolt.
Torque:
Transaxle Shift Control Shaft Block: 24 Nm (18 ft. lbs.)





21. Shift transaxle into all gear positions with shift control shaft to check for proper operation. Also check shift interlocking feature by trying to engage 1st and reverse gears at the same time. This should be impossible.

NOTICE: Care must be taken when applying gasket material to the clutch housing. If any gasket material gets in the transaxle filter vent (noted by arrow in illustration), it will plug vent and cause transaxle oil leaks.





22. Apply a bead of Loctite 515 Gasket Eliminator (P/N 21005993), or equivalent down the center of the mating flange on clutch housing. The bead should be 1 - 3 mm (0.039 - 0.118 inch) wide.