Assemble

1. Apply grease to roller bearings.

2. Place synchronizer ring on gear and align ring slots with shifting keys, then install 3rd gear and hub sleeve No. 2.

Figure 27:

3. Select a snap ring that will allow minimum axial play, then install it on the shaft, Fig. 27.

Figure 9:

4. Measure 3rd gear thrust clearance as shown in Fig. 9. Clearance should be 0.0039-0.0138 inch.

5. Place synchronizer ring on gear and align ring slots with shifting keys, then press in radial ball bearing.

Figure 28:

6. Select a snap ring that wil allow minimum axial play, then install it on the shaft, Fig. 28.

7. Measure 4th gear thrust clearance as shown in Fig. 9. Clearance should be 0.0039-0.0217 inch.

Figure 29:

8. If output shaft was replaced, drive slotted spring pin in the output shaft to a depth of 0.236 inch, Fig. 29.

9. Install locking ball on shaft. Position thrust washer groove over locking ball when installing thrust washer on shaft.

10. Place synchronizer ring on gear and align ring slots with shifting keys, then install 1st gear and hub sleeve No.1 using suitable press.

Figure 30:

11. Select a snap ring that will allow minimum axial play, then install it on the shaft, Fig. 30.

Figure 12:

12. Measure 1st gear thrust clearance as shown in Fig. 12. Clearance should be 0.0039-0.0157 inch.

13. Install spacer, then place synchronizer ring on gear and align ring slots with shifting keys.

14. Install 2nd gear, then the 3rd driven gear using a suitable press.

15. Measure 2nd gear thrust clearance as shown in Fig. 12. Clearance should be 0.0039-0.0177 inch.

16. Install spacer, then the 4th driven gear and bearing using a suitable press.

17. Install magnet, oil receiver and oil receiver attaching bolts, then the differential into transaxle case.

18. Install transaxle case and case attaching bolts. Torque bolts to 22 ft lbs.

Figure 31:

19. Measure preload as shown in Fig. 31. If preload is not 6.9 - 13.9 inch lbs for new bearings or 4.3-8.7 inch lbs for used bearings, remove transmission case side outer race of side bearing, then reselect adjusting shim until preload is as specified. Preload will change approximately 2.6-3.5 inch lbs with each shim thickness.

20. Remove transmission case, then install input and output shaft.

21. Place shift forks Nos. 1 and 2 into groove of hub sleeves Nos. 1 and 2, then install fork shaft No. 1 into shift fork No. 1 hole.

22. Install two interlock balls into the reverse shift fork hole.

23. Install fork shaft No. 3 and reverse shift fork.

24. Install fork shaft No. 2 and shift head, then the three attaching bolts and snap rings.

Figure 33:

25. Position reverse shift fork pivot into the reverse shift arm, then install reverse shift arm in to transaxle case, Fig. 33. Torque shaft attaching bolts to 17 ft lbs.

Figure 34:

26. Install reverse idler gear and shaft, aligning mark on gear with hole in case as shown in Fig. 34.

27. Apply suitable sealant to case mating surfaces, then join case halves and install attaching bolts. Torque attaching bolts to 22 ft lbs.

28. Install balls, springs and seats, then apply suitable sealer to the plugs and lock ball assembly.

29. Install plugs and lock ball assembly, then torque to 18 ft lbs.

30. Install reverse idler gear shaft lock bolt, then torque to 29 ft lbs.

31. Install two bearing snap rings, then the snap ring to fork shaft No. 2.

32. Install rear bearing retainer, then torque five retainer attaching bolts to 14 ft lbs.

33. Install fifth driven gear using suitable tool.

34. Install spacer, needle roller bearing fifth gear and synchronizer ring.

35. Install clutch hub and shifting keys on the hub sleeve, then the shifting key springs under the shifting keys. Ensure the key springs are positioned so that their end gaps are not in line.

36. Install hub sleeve No. 3 on shift fork No. 3 using a suitable tool, then align synchronizer ring slots with shifting keys.

Figure 4:

37. Measure 5th gear thrust clearance as shown in Fig. 4. Clearance should be 0.0039-0.0224 inch.

Figure 35:

38. Select a snap ring that will allow minimum axial play, then install it on the shaft, Fig. 35.

39. Engage gear and install lock nut. Torque lock nut to 87 ft lbs and stake in position.

40. Install shift fork lock washer and attaching bolt, then torque bolt to 13 ft lbs.

41. Place gasket in position on control shaft cover, then install shift and select lever. Torque attaching bolts to 14 ft lbs.

42. Install bellcrank on transmission case, then the lock bolt. Torque lock bolt to 22 ft lbs.

43. Apply suitable sealant to case mating surfaces, then join case halves and install attaching bolts. Torque attaching bolts to 13 ft lbs.

44. Install front bearing retainer, then torque bolts to 13 ft lbs.

45. Apply suitable grease to release bearing hub inside groove, input shaft spline and release fork mating surfaces, then install release for and bearing.

46. Install backup light switch using a suitable tool. Torque switch to 30 ft lbs.

47. Install speedometer drive gear.