Transaxle Reassembly
- Disassemble transmission case components. Remove bearing retainer and install NEW "O" ring. Reverse disassembly procedure. Install input and output shafts with shift fork assemblies as a single unit.
- Install No. 2 shift fork shaft. Drive in slotted spring pin. Install straight screw plug, tighten to 108 INCH lbs. (12.2 N.m). Install magnet to transaxle case. Install differential case, input and output shaft assemblies. Install No. 1 shift fork shaft, No. 1 shift head, No. 1 and No. 2 shift forks and reverse shift fork with interlock pin. Install reverse shift arm. Tighten bolts to 13 ft. lbs. (18 N.m). Install reverse idler gear, thrust washer and shaft. Apply Three Bond (1281) or equivalent, to transaxle case. Install transmission housing. Tighten bolts to 22 ft. lbs. (30 N.m).NOTE: This transmission uses no gasket between major housings; use Three Bond (1281) sealant. Assemble housing within 10 minutes after applying liquid gasket. Allow 30 minutes curing time before filling with oil.
- Apply Three Bond (1344) or equivalent, to differential side bearing retainer bolt threads. Install differential side bearing retainer and shim. Tighten bolts to 13 ft. lbs. (18 N.m). Install reverse idler gear shaft lock bolt. Tighten to 22 ft. lbs. (30 N.m). Install the 2 bearing snap rings. Install rear bearing retainer. Tighten bolts to 31 ft. lbs. (42 N.m). Install needle bearing and 5th gear. Using a press, install No. 3 clutch assembly with synchronizer. Select and install snap ring that will allow minimum axial play. Measure 5th gear thrust clearance. Standard clearance is .008-.016" (.20-.40 mm). See SNAP RING APPLICATION CHART .SNAP RING APPLICATION CHART
Thickness - In. (mm) Stamped Number .087-.089 (2.20-2.25) 13 .089-.091 (2.25-2.30) 14 .091-.093 (2.30-2.35) 15 .093-.095 (2.35-2.40) 16 .095-.097 (2.40-2.45) 17 .097-.098 (2.45-2.50) 18 .098-.100 (2.50-2.55) 19 .100-.102 (2.55-2.60) 20 .102-.104 (2.60-2.65) 21 .104-.106 (2.65-2.70) 22 .106-.108 (2.70-2.75) 23 .108-.110 (2.75-2.80) 24 .110-.112 (2.80-2.85) 25 .112-.114 (2.85-2.90) 26 .114-.116 (2.90-2.95) 27 - Install 5th driven gear. Install No. 3 hub and No. 3 shift fork. Install set bolt and tighten to specification. Lock transmission in 2 gears. Install and tighten output shaft lock nut to specification. Disengage gears. Stake output shaft lock nut. Install shift and select lever shaft assembly with NEW gasket. Tighten bolts to specification. Apply Three Bond (1281) or equivalent, to lock ball assembly bolt threads. Install lock ball assembly and tighten bolts to specification. See TORQUE SPECIFICATIONS .
- Apply Three Bond (1281) or equivalent sealant to transmission case cover. Install transmission case cover. Apply Three Bond (1344) or equivalent, to transmission case cover bolts, install and tighten to specification. Install engine mount bracket and selecting bellcrank. Install bearing release retainer. Install vehicle speed sensor. Install back-up light switch. Install release fork and bearing. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .