Assembly
Exploded View Of Transaxle:
1. Install neutral switch and gasket.
2. Install washer and drain plug, then the backup lamp switch.
3. Install differential seals using differential seal installation tool No. T87C-77000-H or equivalent.
4. Install input shaft using bellhousing seal installation tool No. t77J-7025-G or equivalent.
5. Adjust input shaft bearing preload as follows:
a. Install input shaft gear assembly into clutch housing.
b. Place rear bearing cup on input shaft bearing. Position shim selecting gauge tool No. T88C-77000-CH3 or equivalent, on top of input shaft gear assembly.
Installing Collars On Clutch Housing:
c. Place six collars (part No. T87C-77000-J) on clutch housing at positions shown in example.
d. Place transaxle case on collars and install washers and bolts. Torque to 13-14 ft lbs.
e. Mount a dial indicator to check end play of input shaft. Rotate input shaft gear assembly several times to help seat bearings.
f. Adjust dial indicator to zero at lowest point on end of input shaft. Do not disturb dial indicator until at least three end play readings have been taken.
g. Raise input shaft gear assembly by hand and read end play. Lower input shaft gear assembly.
h. Turn input shaft gear assembly several times until dial indicator returns to zero. Raise input shaft gear assembly by hand to take a second measurement.
i. Repeat step H to obtain at least three readings with 0.004 inch of each other. Average at least three measurements to obtain and end play reading. Subtract 0.028 inch from end play reading to account for thickness of diaphragm spring which fits between the shim and the cup. this result is the final shim size.
j. From shim kit No. E92Z-7L172-A or equivalent, select shim that is closest to final shim size determined in step i.
k. Remove bolts and washers securing the transaxle case to the clutch housing. Remove the transaxle case, gauge, rear bearing cup and input shaft gear assembly. Do not remove the bearing cups in the clutch housing.
6. Adjust main shaft bearing preload as follows:
a. Install differential into the clutch housing. Place the rear bearing cup on the differential bearing.
b. Position shim selection gauge tool No. T88C-77000-CH1 or equivalent, on top of the differential.
c. Install six collars (Part No. T88C-77000-J) as shown in step 5c.
d. Turn gauge halves to eliminate any gap between them. Place transaxle case on collars and install bolts and washers. Torque to 13-14 ft lbs.
e. Adjust gauge tool until free play is removed and bearing cup is seated, then thread gauge tool halves back together.
f. Insert torque adapter tool No. T88C-77000-L or equivalent, through transaxle case and engage the differential pinion shaft.
g. Attach a torque wrench to torque adapter tool.
h. use a feeler gauge to measure the gap in the shim section gauge. Measure the gap in four locations at 90° intervals. use the largest measurement.
Main Shaft Shim Selection Chart:
i. Add 0.0059 inch to measured clearance. Refer to chart in example, to select shim that is closest to value obtained in step H.
j. Remove bolts and washers securing transaxle case. Remove transaxle case, collars, gauge, rear bearing cup and differential. Do not remove the bearing cups in the clutch housing.
7. Install adjustment shim and rear differential bearing cup to transaxle case using differential bearing cup replacement tool No. T88C-77000-FH and driver handle tool No. T80T-4000-W or equivalents.
8. Install adjustment shim, diaphragm spring and input shaft bearing cup into transaxle case.
9. Install breather and breather cover. Install shift rod seal using pilot bearing installation tool No. T88C-7025-EH or equivalent.
10. Install shift rod and boot, spring, reverse gate and selector.
11. Install new roll pin, then the change arm.
12. Install guide plate. Torque bolt above spring to 69-100 inch lbs. Torque other two bolts to 16-25 ft lbs.
13. Install reverse lever and reverse lever shaft.
14. Install new roll pin, speedometer driven gear assembly, magnet, differential, input shaft and main shaft.
Positioning Shift Fork & Rod Assembly:
15. Shift to 2nd gear and 4th gear and positions shift fork and shift rod assembly.
16. Insert spring seat and springs into the reverse lever shaft. Install the ball and hold it in position. Push the control end in direction of arrow so ball goes into the shaft.
17. Set each clutch hub sleeve to the neutral position, then tap shift rod from above so the steel ball goes into the center groove. Swivel control end until ball goes into the groove detent.
18. Install crank lever shaft and new O-ring assembly. Insert the pin.
19. Install gate and shift rod. Tighten the gate mounting bolt.
20. Install reverse idler gear and shaft. Ensure shift rod and gate mounting hole are aligned.
Aligning Interlock Sleeve & Control Lever:
21. Align end of interlock sleeve with the control lever as indicated by the arrow in example. Face the reverse idler shaft screw hole in the direction shown.
22. Clean the contact surfaces on the clutch housing and the transaxle case. Apply a thin coat of sealant.
23. Place transaxle case on clutch housing and tighten to specifications.
24. Install tow transaxle plugs No. T88C-7025-AH or equivalent, between differential side gears. Failure to install transaxle plugs may cause differential side gears to become improperly positioned.
25. Install lock bolt and torque to 159-228 inch lbs.
26. Install guide bolt and torque to 78-121 inch lbs.
27. Install ball, springs and lock bolt. Torque bolt to 129-181 inch lbs.
28. Install main 5th gear, gear sleeve, input 5th gear, synchronizer ring, shift fork, clutch hub assembly and synchronizer ring.
29. Install roll pin, then the main reverse synchronizer gear.
30. Install input reverse synchronizer gear, then shift transaxle to 1st gear.
31. Use torque adapter tool No. T88C-7025-GH or equivalent, to lock input shaft. Install locknuts.
32. Clear contact surfaces on transaxle case and rear cover. Install rear cover.