Major Component ASSY Assembly

Major Component Assy Assembly

Tools Required:
J-36633 Snap Ring Retainer
KM-334 Installer Sleeve
KM-552 Fixture
KM-554 Installer
KM-113-2 Base

Assembly
1. Join the mainshaft and the input shaft.
2. Compress the snap ring at the base of the mainshaft and hold with the snap ring retainer J-36633.
3. Hold the snap ring at the base of the input driveshaft with the snap ring pliers.
4. Install the mainshaft/input shaft assembly onto the bearing plate.





5. Release the mainshaft snap ring and the input shaft snap ring.
6. Position the first-second gearshift fork.





7. Install the fifth gearshift lever into the bearing plate.





8. Install the third-fourth gearshift rod/fork holding pin.





9. Install the support bracket onto the bearing plate.





10. Install the first-second gearshift rod/fork onto the bearing plate.





11. Install the first-second gearshift fork holding pin.





12. Install the support bracket bolts.
^ Tighten the support bracket bolts to 7 Nm (62 inch lbs.).





13. Install the reverse gearshift rod/fork onto the bearing plate.





14. Install the reverse gearshift rod/fork holding pin.





15. Install the rod lock pin and spring into the small plug hole.





16. Install the fourth-gearshift rod plugs.





17. Install the bolts and the fifth-gearshift connector onto the bearing plate, using the pawl.
^ Tighten the fifth-gearshift connector bolts to 7 Nm (62 inch lbs.).





18. Install the input drive fifth gear using the installer KM-554 and the installer sleeve KM-334.





19. Install the snap rings securing the fifth-drive gear.





20. Install the thrust washers, the retaining ring, and the needle bearing into the mainshaft-driven fifth-gear assembly.





21. Install the brass synchronizer ring onto the mainshaft-driven fifth-gear assembly.
22. Install the mainshaft-driven fifth-gear assembly.





23. Install the fifth-drive gear synchronizer gear and the synchronizer sleeve using installer KM554.





24. Install the snap ring holding the fifth speed-driven assembly.





25. Install the bolts and the fifth-gear fork onto the bearing plate.
^ Tighten the fifth-gear fork bolts to 22 Nm (16 ft. lbs.).
26. Remove the bearing plate from the fixture KM-552.
27. Shift the transaxle into second gear.





28. Install the bearing plate, with the shafts attached, into the case.





29. Install the bearing plate bolts.
^ Tighten the bearing plate bolts to 22 Nm (16 ft. lbs.).





30. Install the speedometer-driven gear and the speedometer-housing retaining bolt into the transaxle housing.
^ Tighten the speedometer housing retaining bolt to 4 Nm (35 inch lbs.).
31. Bolt the gearshift lever cover to the fixture KM-552.
32. Position the fixture into the base KM-113-2.





33. Install the gearshift rod, the shift finger lever, and the gearshift lever pin.
34. Install the snap ring, the bushing, the spring, and the intermediate lever.
35. Remove the gearshift lever cover from the base KM-113-2 and the fixture KM-552.





36. Shift the transaxle into NEUTRAL.





37. Install the gearshift lever cover and the gearshift lever cover bolts.
^ Tighten the gearshift lever cover bolts to 22 Nm (16 ft. lbs.).
38. Install the transaxle cover and the transaxle cover bolts.
^ Tighten the transaxle cover bolts to 18 Nm (13 ft. lbs.).





39. Install the transaxle into the vehicle.