Transaxle Reassembly
NOTE:
Whenever transaxle is disassembled, adjust bearing preload. Adjustment is made by selecting shims to insert between rear bearing races and transaxle case.
- Adjust bearing preloads. Install selected shims, bearing races and related parts. See INPUT & OUTPUT SHAFT BEARING PRELOAD and DIFFERENTIAL BEARING PRELOAD under ADJUSTMENTS. Install breather. Using seal replacer, install input shift shaft seal. Install input shift shaft, boot, spring and shift fork selector. Install new selector pin.
- Install shift fork selector plate arm and tighten bolt to specification. See TORQUE SPECIFICATIONS . Install shift fork selector plate. Tighten bolts to specification. Install drain plug and tighten to specification.
- Install differential oil seals. Install input shaft seal. Install park/neutral switch. Install reverse lever and shaft. Install reverse lever roll pin. Install vent tube and 2 vent tube bolts and tighten to specification. Install shift shaft seal. Install shift control shaft assembly with boot drain hole facing down when installed in vehicle.
- Install shift control shaft selector roll pin. Position shift control shaft selector lever in case and install attaching bolt. Tighten bolt to specification. Install shift control shaft selector plate, spacer and 2 attaching bolts. Tighten bolts to specification. Install differential.
- Assemble output shaft, input shaft and shift fork assemblies as a single unit. Install complete assembly into flywheel housing. Keep assembly in vertical position during installation. Install steel ball and spring into shift fork shaft assembly. Shift transmission into 2nd and 4th gears. Install shift fork shaft through flywheel housing. Install roll pin.
- Install shift lever shaft gate and control rod. Install shift lever shaft gate bolt. Tighten to specification. See TORQUE SPECIFICATIONS . Install reverse idler gear and reverse idler shaft.
- Install magnet in clutch housing. Align end of gear selector interlock sleeve with gearshift selector arm. Align reverse idler shaft screw hole with alignment mark (if equipped) or case dowel. See Fig 1 .
- Apply liquid gasket to case contact surface, and bolt case halves together. Install lock bolt into transaxle case. Tighten all bolts to specification. Install 2 Transaxle Plugs (T88C-7025-AH) to prevent side gears from being displaced during installation.
- Install park/neutral switch and back-up light switch. Tighten to specification. Install lock bolt and new washer. Install Guide bolt and new washer. Install 5th gear onto output shaft. Install gear sleeve, 5th gear and synchronize ring onto input shaft.
- Install 5th gear synchronizer assembly, shift fork and synchronizer hub together onto input shaft. Install new roll pin into shift fork. Shift transaxle to 1st gear. Lock input shaft with Input Torque Adapter (T87C-7025-A). Install stop plate on input shaft with flanged side facing away from transaxle case.
- Install new input shaft and output shaft lock nuts. Tighten nuts to specification. See TORQUE SPECIFICATIONS . Stake lock nuts in place. Remove torque adapter. Apply sealant and install rear cover. Tighten bolts to specification. Fill transaxle with specified fluid.