Assembly

1. Adjust input shaft bearing preload as follows:
a. Mount dial indicator tool No. TOOL-4201-C with brackets No. D78P-4201-F or equivalents, to transaxle case so dial indicator touches end of input shaft.
b. Measure input shaft thrust clearance. Correct clearance is 0.0019-0.0039 inch.
c. If clearance is not as specified, change shim to bring into specifications.
2. Adjust main shaft bearing preload as follows:
a. Install funnel and bearing race into clutch housing. Position main shaft into clutch housing.
b. Install main shaft bearing race into transaxle case. Install transaxle case to clutch housing and torque bolts to 14-19 ft lbs.
c. Mount dial indicator tool No. TOOL-4201-C and brackets No. D78P-4201-F or equivalents, to the transaxle case and measure main shaft thrust clearance.
d. Add 0.0012 inch to measured value to receive lowest range. Add 0.0031 inch to measured value to receive highest range.
e. Select a shim that is between the two ranges resulting from step D.
3. Adjust differential bearing preload as follows:
a. Install bearing race into clutch housing.

Differential Bearing Preload Adjustment:

b. Set differential assembly into clutch housing. Install transaxle housing side bearing race to the selector, part No. T88C-77000-JF or equivalent. Turn A and B until gap shown in example, is eliminated.

Differential Collar Locations:

c. Position collars part No. T88C-77000-JF or equivalent, in positions shown example. Position transaxle housing onto collars and torque bolts to 14-19 ft lbs.
d. Turn bars until selector tool No. T88C-77000-JF or equivalent, can no longer be moved. To seat bearings, mount bars on parts A and B of selector tool so gap is widened.
e. Turn in reverse direction until gap is eliminated. Install differential rotator tool No. T88C-77000-L or equivalent, to differential pinion gear through the transaxle case.
f. Turn differential rotator with a torque wrench and adjust the selector with the bars until the a preload of 0.3-6.6 inch lbs is obtained.
g. Remove differential rotator tool and measure the clearance around the entire circumference of the selector.

Differential Bearing Shim Thickness Chart:

h. Select proper adjustment shim to be used for the differential by referring to the chart in example, and selecting the shim which is nearest to the largest measured clearance in the selector.
i. Remove bolts transaxle housing, collars and the bearing outer race from the selector. Install selected shim and bearing outer race to the transaxle case.
j. Measure backlash by setting the differential assembly into the clutch housing. Install transaxle housing onto the clutch housing and torque bolts to 14-19 ft lbs.
k. Install differential rotator into the differential side gear through the transaxle case. Measure preload by rotating differential with a torque wrench.
4. Position differential assembly in clutch housing.
5. Assemble input shaft, main shaft and shift rail assemblies and install in clutch housing together.
6. Install steel ball and spring into reverse lever shift. Position shaft through housing, reverse lever set spring and reverse lever.
7. Compress spring with a screwdriver, align holes and install new roll pin.
8. Install a new O-ring on crank lever shaft, then position crank lever between change arm and control end and connect crank lever shaft to crank lever.
9. Align pin holes of crank lever shaft and clutch housing. Install new roll pin.
10. Tap in blind plug using a soft hammer, then install shift rod end and shift rod. Torque retaining bolt to 8.7-10 ft lbs. Bolt hole in shift rod and shift rod end must be aligned.
11. Install reverse idler gear and reverse idler shaft, then the breather cover and gasket with two bolts. Torque bolts to 7.2-9.4 ft lbs.

Reverse Idler Shaft Screw Hole:

12. Install magnet in clutch housing, then align end of interlock sleeve with the control lever, at the same time, face the reverse idler shaft screw hole in the direction shown in example.
13. Apply a thin coat of Gasket Eliminator No. E1FZ-19562-A or equivalent, to the contact surfaces of the clutch housing and transaxle case. Torque transaxle case housing to clutch retaining bolt to 27-38 ft lbs.
14. Install neutral start switch and backup lamp switch.
15. Install lock bolt and new washer. Install 5th gear onto main shaft.
16. Install gear sleeve and 5th gear synchronizer ring on input shaft.
17. Install 5th gear synchronizer assembly and 5th gear shift fork and clutch hub together. Install new roll pin.
18. Install stop plate, then lock the input shaft with input torque adapter tool No. T87C-7025-A or equivalent.
19. Install new locknuts on input and main shafts. Torque both locknuts to 94-152 ft lbs.
20. Measure 5th gear thrust clearance with a dial indicator. Correct clearance is 0.0024-0.0122 inch.
21. Install rear cover. Torque 10 bolts to 5.8-8.7 ft lbs.