Intermediate Shaft

DISASSEMBLY

CAUTION: Do not re-use snap rings when servicing the intermediate shaft assembly. Discard upon disassembly and install new ones provided with available snap ring service kit.

NOTE: Depending on date of transaxle manufacture, some intermediate shafts will utilize a needle bearing under the 2nd and 5th Speed Gears.

1. Install intermediate shaft assembly to arbor press table with bearing splitter under the reverse gear.





2. Install 8486-4 button to intermediate shaft. Using arbor press ram, press reverse gear and intermediate roller bearing off of shaft, while holding remaining assembly with hand (Fig. 128).





3. Remove reverse gear blocker ring.
4. Remove reverse gear needle bearing (Fig. 129).





5. Remove 5/R synchro snap ring (Fig. 130).





6. Remove 5/R synchro (Fig. 131).





7. Remove 5th gear blocker ring (Fig. 132).





8. Remove 5th gear and needle bearing (if equipped) (Fig. 133).





9. Remove 3/4 cluster gear snap ring (Fig. 134).








10. Install shaft assembly into fixture 8483, with split collar 8483-3 oriented chamfer side up (Fig. 135). Place 8483-2 into position with chamfer side up (Fig. 136).





11. Using an arbor press, press intermediate shaft out of 3/4 cluster gear (Fig. 137).





12. Remove intermediate shaft from fixture and remove 3/4 cluster gear from shaft (Fig. 138).





13. Remove 2nd gear and needle bearing (if equipped) (Fig. 139).





14. Remove 2nd gear reactor ring (Fig. 140).





15. Remove 2nd gear friction cone (Fig. 141).





16. Remove 2nd Gear outer blocker ring (Fig. 142).





17. Remove 1/2 synchro snap ring (Fig. 143).





18. Remove 1/2 synchro from shaft (Fig. 144).





19. Remove 1st gear blocker ring (Fig. 145).





20. Remove 1st gear friction cone (Fig. 146).





21. Remove 1st gear reactor ring (Fig. 147).





22. Remove 1st gear from shaft (Fig. 148).





23. Remove 1st gear needle bearing (Fig. 149).





24. Remove intermediate shaft roller bearing snap ring (Fig. 150).





25. Press intermediate shaft out of roller bearing supported by bearing splitter (Fig. 151). Roller bearing is not re-usable once removed. It is necessary to install a new roller bearing upon re-assembly.

ASSEMBLY

NOTE: Depending on date of transaxle manufacture, some intermediate shafts will utilize a needle bearing under 2nd and 5th Speed Gears.

NOTE: Do not re-use snap rings when servicing the intermediate shaft assembly. Discard snap rings and install new ones provided with available snap ring service kit.

NOTE: When installing 1/2 & 5/R synchronizers, make sure to align oil slots on synchronizer hub face with oil hold in the shaft splined hub journal.





NOTE: Refer to (Fig. 152) for intermediate shaft assembly reference.





1. Press intermediate shaft into NEW roller bearing with arbor press (Fig. 153).





2. Install intermediate shaft roller bearing snap ring (Fig. 154).





3. Install 1st gear roller bearing to intermediate shaft (Fig. 155).





4. Install 1st gear to intermediate shaft (Fig. 156).





5. Install 1/2 synchro to fixture 8483. Insert 1st gear blocker ring, friction cone, and reactor ring as shown in (Fig. 157).





6. Install intermediate shaft to synchro assembly on fixture (Fig. 158). When installing 1/2 synchronizer, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal. Line up friction cone and reactor ring tabs to gear slots. Remove shaft assembly from fixture.





7. Install NEW 1/2 synchro snap ring (Fig. 159).





8. Install 2nd gear blocker ring (Fig. 160).





9. Install 2nd gear friction cone (Fig. 161).





10. Install 2nd gear reactor ring (Fig. 162).





11. Install 2nd gear and needle bearing (if equipped) to intermediate shaft (Fig. 163).





12. Press 3/4 cluster gear onto intermediate shaft using cup 8481 (Fig. 164).





13. Install NEW 3/4 cluster gear snap ring (Fig. 165).





14. Install 5th gear and needle bearing (if equipped) to intermediate shaft (Fig. 166).





15. Install 5th gear blocker ring to synchronizer (Fig. 167).





16. Install 5th gear synchronizer assembly to intermediate shaft (Fig. 168). When installing 5/R synchronizer, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.





17. Install NEW 5/R synchro snap ring (Fig. 169).





18. Install reverse gear blocker ring (Fig. 170).





19. Install reverse gear needle bearing (Fig. 171).
20. Install reverse gear to intermediate shaft.





21. Install intermediate shaft sealed roller bearing and thrust washer using installer 8482 (Fig. 172).





22. Install NEW intermediate shaft sealed bearing snap ring (Fig. 173).