Part 1

Transmission Overhaul

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)










Material(s)






Exploded View


















Assembly

1. NOTICE: Do not to damage the inner input shaft seal or bearing when installing the hollow input shaft onto the inner input shaft.

Install the hollow input shaft onto the inner input shaft.





2. NOTE: Apply pressure on the synchronizer ring while taking the measurements.

NOTE: If the clearance is less than the minimum measurement stated in the specifications section, install a new output shaft assembly.

Using a suitable feeler gauge, measure the clearance between the synchronizer ring and gear in various places around the circumference.





3. NOTE: Apply pressure on the synchronizer ring while taking the measurements.

NOTE: If the clearance is less than the minimum measurement stated in the specifications section, install a new output shaft assembly.

Using a suitable feeler gauge, measure the clearance between the synchronizer ring and gear in various places around the circumference.





4. NOTE: Make sure the synchronizers are in the neutral position.

Install output shaft 2 assembly on 307-680 /2 and 307-680 /5.





5. Install the input shaft assembly on 307-680 /4.





6. NOTE: Make sure the synchronizers are in the neutral position.

Install output shaft 1 assembly on 307-680 /5.





7. Install 307-680 /1.





8. Flip the gearset assembly over onto 307-680 /1.





9. Remove the 307-680 /2, 307-680 /4 and 307-680 /5.





10. Install the 4th/reverse gear shift fork.





11. Install the 2nd/6th gear shift fork and linkage.





12. NOTE: Make sure shift drum 1 is in the neutral position as shown.

Install shift drum 1.





13. NOTE: Make sure shift drum 2 is in the neutral position as shown.

Install the 3rd gear linkage and shift drum 2.





14. Install the 1st/5th gear shift fork.





15. Install the 3rd gear shift fork.





16. Install the 4 shift fork rods.

1. Install the small shift fork rods.

2. Install the large shift fork rods.






17. Install the oil spout.





18. NOTE: Make sure the output shaft bearing retainer brackets are positioned as shown.

Install 307-680 /3 on the output shaft assemblies.





19. Install the transaxle case onto the gearset assemblies.





20. Install the 6 new output shaft bearing retainer bolts. Tighten in 2 stages.
- Tighten to 10 Nm (89 lb-in).
- Tighten to 32 Nm (24 lb-ft).





21. Install 307-580 on the transaxle case.





22. Turn the transaxle case and gearset assembly over onto 307-580.

23. Remove 307-680.





24. Install the magnet.





25. Install the small clock gears and clock gear pins.





26. Install the large clock gears and clock gear pins.





27. Install the park pawl and park pawl rod.





28. NOTE: Make sure the pin is installed as shown.

Install the park pawl actuation shaft assembly.





29. NOTE: If the differential bearings, differential, clutch housing and/or transaxle case are replaced refer to REFER to Differential Shim Selection .

Install the differential.





30. NOTICE: Make sure the transaxle case and the clutch housing are clean and no old sealant is present or transmission fluid leaks can occur and cause transaxle damage.

Apply a 1 mm (0.0394 in) bead of Gasket Maker around the inside of the bolt holes on the case side and completely around each dowel.





31. NOTICE: Do not overheat the bearing or damage to the bearing may occur.

Using 300-MASHG501AE , heat the input shaft bearing in the clutch housing for approximately 5 minutes.





32. Install the clutch housing onto the transaxle case.





33. Using 307-672 and a hammer, tap the clutch housing down onto the transaxle case.





34. Install the 18 bottom clutch housing-to-case bolts (13 shown).
- Tighten to 18 Nm (159 lb-in).





35. Install the 3 top clutch housing-to-case bolts.
- Tighten to 18 Nm (159 lb-in).





36. Install the park plunger.





37. Install the park plunger plug.
- Tighten to 43 Nm (32 lb-ft).





38. Install the manual control lever and the new manual control lever bolt.
- Tighten to 27 Nm (20 lb-ft).





39. Install a new input shaft snap ring.





40. Using 307-672 /1 and 307-672 /2, install a new input shaft case seal.





41. Using the locating flange on the guide tube, install the guide tube.





42. NOTE: The guide tube bolts must not project beyond the mounting surface of the clutch engagement levers.

Install the 3 guide tube bolts.
- Tighten to 8 Nm (71 lb-in).





43. Inspect the guide tube for wear or damage. Replace as necessary.





44. NOTE: One clutch actuator lever bushing shown, one per clutch actuator lever.

Install the clutch actuator lever bushings.