Component Disassembly & Reassembly: MAINSHAFT: Reassembly
- Using press and adapter, press mainshaft 3rd gear on mainshaft. See Fig 1.
- Install thrust needle bearing and needle bearing on mainshaft. Using press and adapter, press mainshaft 4th gear and thrust washer on mainshaft.NOTE: Replace thrust washer if washer can be installed on mainshaft by-hand.
- Remove mainshaft from press. Ensure mainshaft 4th gear rotates freely on mainshaft.
- Install 1st-4th clutch, gear collar, distance collar, thrust washer and snap ring on mainshaft.NOTE: DO NOT install thrust needle bearing, needle bearings, mainshaft 1st gear and thrust needle bearing on mainshaft at this time.
- Remove ball bearing for mainshaft from transaxle housing. Install ball bearing on mainshaft.
- Install gear collar, thrust washer and 2nd clutch on mainshaft. See Figure. DO NOT install thrust needle bearings, needle bearings and mainshaft 2nd gear at this time.
- Install disc spring, distance collar, mainshaft reverse gear, ball bearing, washer and used lock nut on mainshaft. Ensure disc spring is installed with largest side against 2nd clutch. Tighten lock nut to 22 ft. lbs. (30 N.m).
- Move 1st-4th clutch against 4th clutch collar. Using feeler gauge, measure mainshaft 4th gear clearance between gear collar and 1st-4th clutch guide. See Fig 2.
- Measure mainshaft 4th gear clearance in 3 different places. Use average reading as mainshaft 4th gear clearance. Mainshaft 4th gear clearance should be .001-.007" (.03-.18 mm).
- If clearance exceeds .03" (.18 mm), install different thickness thrust washer and recheck clearance. Thrust washer fits between mainshaft 4th gear and the 1st-4th clutch. See MAINSHAFT 4TH GEAR THRUST WASHER SPECIFICATIONS table for available thrust washer sizes.
- Once correct mainshaft 4th gear clearance is obtained, disassemble mainshaft. Lubricate all components with ATF. Wrap splines of mainshaft with tape. Install NEW "O" rings on mainshaft. Reassemble mainshaft. Ensure thrust needle bearings are installed with unrolled edge of bearing retainer facing washer.
MAINSHAFT 4TH GEAR THRUST WASHER SPECIFICATIONS
| Washer No. | Part Number | Thickness - In. (mm) |
|---|---|---|
| 1 | 90431-PY4-020 | .382 (9.70) |
| 2 | 90432-PY4-020 | .384 (9.75) |
| 3 | 90433-PY4-020 | .386 (9.80) |
| 4 | 90434-PY4-020 | .388 (9.85) |
| 5 | 90435-PY4-020 | .390 (9.90) |
| 6 | 90436-PY4-020 | .392 (9.95) |
| 7 | 90437-PY4-020 | .394 (10.00) |