Assembly

1. Assemble clutch hub assembly as follows:
a. Place three synchroizer keys into their slots in the clutch hub. The synchronizer keys for each clutch hub assembly are different.
b. When assembling the 5th gear clutch hub, the larger end of the synchronizer key must face the locknut.

Clutch Hub Assembly:

c. Place the tab on the synchroizer spring into the groove of one of the keys and snap the spring into place.
d. Place tab of other spring into same key (on other side of synchronizer assembly) and rotate the spring in the opposite direction and snap into place.
e. When assembling clutch hub into the sleeve, notice that the sleeve and hub have an extremely close fit and must be held square to prevent jamming. Do not force the sleeve onto the hub.
f. Slide the assembled clutch hub into the clutch hub sleeve.
g. Repeat procedure until all three clutch hubs have been assembled.

Mainshaft Bearing Installation:

2. Press front bearing onto the main shaft using shaft protector tool No. D80L-625-3, bearing cone replacement tool No. T87C-7025-B and axle bearing/seal plate tool No. T75L-1165-B or equivalents.
3. Locate the 1st gear synchronizer ring. Slide 1st gear and synchronizer ring onto the main shaft. Slide the 1st-2nd clutch hub assembly into place, ensuring shift fork groove on the reverse sliding gear faces the 1st gear.
4. Press the main shaft into the assembled components using shaft protector tool No. D80L-625-3 or equivalent. Ensure hub and shaft splines are aligned before applying press pressure. Press to 4,440 lbs. force.
5. Install retaining ring with snap ring pliers. Ensure ring is seated properly in groove.
6. Install 2nd speed synchroizer ring and 2nd speed gear.

Thrust Washer Installation:

7. Coat thrust washer tangs with petroleum jelly. Install them to the holes in the groove. Install retaining ring.
8. Slide 3rd speed gear onto the shaft followed by the 3rd gear synchronizer ring and the 3rd-4th gear clutch hub assembly.
9. Press the gear shaft into the components using shaft protector tool No. D80L-625-3 or equivalent.
10. Install retaining ring using snap ring pliers.
11. Install 4th gear synchronizer ring and 4th speed gear.
12. Press 4th gear components and the main shaft rear bearing onto the main shaft using shaft protector tool No. D80L-625-3, bearing cone replacement tool No. T87C-77000-D and axle bearing/seal plate tool No. T75L-1165-B or equivalents.

1st Gear & Differential Drive Gear Measurement:

13. Measure gear thrust clearance as follows:
a. Measure clearance between 1st gear and differential drive gear as shown in example. Correct clearance is 0.006-0.017 inch.

2nd Gear & Thrust Washer Measurement:

b. Measure clearance between 2nd gear and thrust washer as shown in example. Correct clearance is 0.010-0.025 inch.
c. Measure clearance between 3rd gear and thrust washer. Correct clearance is 0.004-0.017 inch.
d. Measure clearance between 4th gear and bearing inner race. Correct clearance is 0.004-0.018 inch.
14. Assemble input shaft bearing as follows:
a. Press input gear shaft into front bearing using shaft protector tool No. D80L-625-3, bearing cone replacement tool No. T87C-7025-B and axle bearing/seal plate T75L-1165-B or equivalents.
b. Press input gear shaft into rear bearing using shaft protector tool No. D80L-625-3, bearing cone replacement tool No. T87C-77000-D and axle bearing/seal plate T75L-1165-B or equivalents.
15. Install both shift forks and interlock sleeves.
16. Main shaft, input gear shaft and differential bearing preload must be adjusted by selecting shims to insert between the rear bearing races and transaxle case. To determine the correct thickness shim, use shim selection toll set No. T87C-77000-J or equivalent as follows:
a. Install differential bearing race into the clutch housing using bearing cup installation tool No. T77F-1217-B and driver handle tool No. T80T-1217-B and driver hand tool No. T80T-4000-W or equivalents. Inspect bearing race after installation to ensure it is fully seated.
b. Install oil funnel and main shaft front bearing race into clutch housing.
c. Install input gear shaft front bearing race into clutch housing.
d. Install main shaft with rear bearing case into clutch housing. Two halves of selector must be turned to eliminate any gap between them. Position shim selection tool set No. T87C-77000-J1 or equivalent, on top of main shaft.

Transaxle Case Collar Locations:

e. Place six collars (part No. T87C-77000-J) between transaxle case and the clutch housing at the positions shown in example.
f. Install transaxle case onto main shaft. Install a flat washer of appropriate size onto each of the bolts from the tool kit. Install the bolts through the transaxle case, collar and into the threaded holes in the clutch housing. Torque bolts to 13-14 ft lbs.
g. Mount dial indicator tool No. TOOL-4201-A or equivalent to check end play of shaft. Rotate main shaft several times to help seat bearings, then set dial indicator to zero at lowest point on end of main shaft. Do not disturb dial indicator until at least three end play readings have been taken.
h. Raise main shaft by hand and read end play, then lower main shaft.
i. Turn main shaft several times until dial indicator returns to zero. Raise main shaft by hand to take a second end play measurement.
j. Repeat above step to obtain at least three readings within .0004 inch of each other. Average at least three measurements to obtain an end play reading. Add 0.003 inch to end play reading to obtain final shim size.

Main Shaft Shim Size Availability:

k. Refer to chart, for selection of proper shim that is closest to final shims size determined.
l. Remove bolts and washers securing transaxle case to clutch housing. Remove transaxle case, collars, selector, rear bearing race and main shaft.
17. Select input gear shaft shims as follows:
a. Install input gear shaft with its rear bearing race into the clutch housing.
b. Two halves of selector must be turned to eliminate any gap between them. Position selector on top of input gear shaft.

Input Gear Shaft Measurement Collar Positions:

c. Place six collars between transaxle case and clutch housing at positions shown in example.
d. Install transaxle case onto input gear shaft, then install a flat washer of appropriate size onto each of the bolt from the tool kit. Install bolts through transaxle case, collar and into the threaded hole in the clutch housing. Torque bolt to 13-14 ft lbs.

Input Gear Shaft End Play Measurement:

e. Mount dial indicator tool No. TOOL-4201-C or equivalent to check end play of shaft.
f. Rotate input gear shaft several times to help seat bearings. Adjust dial indicator to zero at lowest point on the end of the input gear shaft. Do not disturb dial indicator until at least three end play readings have been taken.
g. Turn input gear shaft several times until dial indicator returns to zero. Raise input gear shaft by hand to take a second measurement.
h. Repeat step G to obtain at least three readings within 0.004 inch of each other. Average at least three measurements to obtain an end play reading. Add 0.003 inch to reading to obtain final shim size.

Input Gear Shaft Shim Availability:

i. Refer to chart, for selection of correct shim that is closest to final shim size determined. No more than three shims may be used below a bearing race.
j. Remove bolts and washers securing transaxle case to clutch housing. Remove clutch housing collars, selector, rear bearing race and input gear shaft.
18. Select differential shims as follows:
a. Install differential with rear bearing race into clutch housing.

Differential Bearing Race Shim Availability:

b. Position selector on top of differential. Place six collars between transaxle case and clutch housing at positions shown in example.
c. Install transaxle case onto differential. Install a flat washer on appropriate size onto each of the bolts from the tool kit. Install bolts through transaxle case, collar, and into the threaded holes in the clutch housing. Torque bolt to 13-14 ft lbs.
d. Insert differential rotator tool No. T88C-77000-L or equivalent, through the transaxle case and engage the differential pinion shaft. Attach a torque wrench to tool.
e. Turn selector for the differential using the adjusting rods, until a reading of 4.3-6.6 ft lbs is obtained on the torque wrench. Use a feeler gauge to measure the gap in the differential selector. Measure the gap at four different locations at 90° intervals. Average the four readings.

Differential Shim Collar Positions:

f. Select an appropriate adjustment shim to be used below the differential bearing race by referring to example. Select a shim that is closest to the measured value of the selector gap. No more than three shims may be used below the differential bearing race.
g. Remove bolt and washers securing transaxle case to clutch housing. Remove transaxle case, collars, selector, rear bearing race and differential.