11. Transmission Assemble

Transmission Assemble

Tools Required
* J 3289-20 (KM-113-2) Holding Fixture
* J 36633 Snap Ring Retainer
* KM-334 Installer Sleeve
* KM-552 Fixture
* KM-554 Installer




1. Join the mainshaft and the input shaft.
2. Compress the snap ring at the base of the mainshaft and hold with the J 36633 (1).
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 1st-2nd gearshift fork.
7. Install the 5th gearshift lever into the bearing plate.




8. Install the 3rd-4th gearshift rod/fork holding pin.




9. Install the support bracket onto the bearing plate.




10. Install the 1st-2nd gearshift rod/fork onto the bearing plate.




11. Install the 1st-2nd gearshift fork holding pin.





Notice: Refer to Fastener Notice Fastener Notice.

12. Using the KM-552 , install the support bracket bolts.

Tighten the bolts to 7 Nm (62 lb in).




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 4th-gearshift rod plugs.




17. Install the bolts and the 5th-gearshift connector onto the bearing plate, using the pawl.

Tighten the bolts to 7 Nm (62 lb in).




18. Using the KM-554 (2) and the KM-334 (1), install the input drive 5th gear.




19. Install the snap rings securing the 5th drive gear.




20. Install the thrust washers, the retaining ring, and the needle bearing into the mainshaft-driven 5th-gear assembly.




21. Install the brass synchronizer ring onto the mainshaft- driven 5th-gear assembly.




22. Install the mainshaft-driven 5th-gear assembly.
23. Install the 5th-drive gear synchronizer gear and the synchronizer sleeve using the KM-554 (1).




24. Install the snap ring holding the 5th speed-driven assembly.




25. Install the bolts and the 5th-gear fork onto the bearing plate.

Tighten the bolts to 22 Nm (16 lb ft).




26. Remove the bearing plate from the fixture.
27. Shift the transaxle into 2nd gear.
28. Install the bearing plate, with the shafts attached, into the case.




29. Install the bearing plate bolts.

Tighten the bolts to 22 Nm (16 lb ft).




30. Install the speedometer-driven gear and the speedometer-housing retaining bolt into the transaxle housing.

Tighten the bolt to 4 Nm (35 lb in).




31. Bolt the gearshift lever cover to the KM-552 (2).
32. Position the KM-552 (1) into the J 3289-20 (3).
33. Install the gearshift rod (1), the shift finger lever, and the gearshift lever pin.




34. Install the snap ring, the spring, the intermediate lever, and the adjusting pin.
35. Remove the gearshift lever cover from the J 3289-20 and the KM-552 .
36. Shift the transaxle into NEUTRAL.




37. Install the gearshift lever cover and the gearshift lever cover bolts.

Tighten the bolts to 22 Nm (16 lb ft).




38. Install the transaxle cover and the transaxle cover bolts.

* Tighten the bigger transaxle cover bolts to 20 Nm (15 lb ft).
* Tighten the smaller transaxle cover bolts to 15 Nm (11 lb ft).

39. Install the transaxle into the vehicle. Refer to Transmission Replacement D20 - Manual Transaxle.