Assembly
ASSEMBLY1. Install park/neutral position switch and gasket. Tighten to specifications.
2. Install washer and drain plug, then the back-up lamp switch. Tighten to specifications.
3. Install differential seals using differential seal replacer tool No. T87C-77000- H, or equivalent.
Exploded View Of Transaxle:
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. T880-77000- CH3, or equivalent, on top of input shaft gear assembly.
Clutch Housing Collar Locations:
c. Place six collars from tool No. T87C-77000-J, or equivalent, on clutch housing at positions shown in the Clutch Housing Collar Locations image.
d. Place transaxle case on collars and install washers and bolts. Torque to 13-14 ft lbs.
e. Mount dial indicator to check endplay 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 endplay readings have been taken.
g. Raise input shaft gear assembly by hand and read endplay, then 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 second measurement.
i. Repeat previous step to obtain at least three readings within 0.004 inch of each other. Average at least three measurements to obtain endplay reading. Subtract 0.028 inch from endplay reading to account for thickness of diaphragm spring which fits between the shim and the cup. This result is the final shim size.
j. Select shim from shim kit tool No. E92Z-7L172-A, or equivalent, closest to final shim size determined above.
k. Remove bolts and washers securing the transaxle case to the clutch housing, then 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 clutch housing, then place rear bearing cup on differential bearing.
b. Position shim selection gauge tool No. T88C-77000-CH1, or equivalent, on top of differential.
Clutch Housing Collar Locations:
c. Install six collars from tool No. T88C-77000-J, or equivalent, as shown in the Clutch Housing Collar Locations image.
d. Turn gauge halves to eliminate any gap between them, then 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-770O0-L, or equivalent, through transaxle case and engage differential pinion shaft.
g. Attach torque wrench to torque adapter tool.
h. Use feeler gauge to measure gap in shim selection gauge. Measure gap in four locations at 90° intervals. Use largest measurement.
Mainshaft Shim Selection Chart:
i. Add 0.0059 inch to measured clearance. Refer to the Mainshaft Shim Selection Chart to select shim closest to value obtained above.
j. Remove bolts and washers securing transaxle case, then the transaxle case, collars, gauge, rear bearing cup, and differential. Do not remove bearing cups from 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, then the 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 and tighten bolts to specifications.
13. Install reverse lever and reverse lever shaft.
14. Install new roll pin, speedometer driven gear assembly, magnet, differential, input shaft and main shaft.
Shift Fork And Rod Assembly Position:
15. Shift to second gear and fourth gear and position shift fork and shift rod assembly as shown in the Shift Fork And Rod Assembly Position image.
16. Insert spring seat and springs into reverse lever shaft.
17. Install ball and hold in position, then push control end in direction of arrow so ball goes into shaft.
18. Set each clutch hub sleeve to neutral position, then tap shift rod from above so steel ball goes into center groove.
19. Swivel control end until ball goes into groove detent.
20. Install crank lever shaft and new 0-ring assembly, then insert pin.
21. Install gate and shift rod. Tighten gate mounting bolt.
22. Install reverse idler gear and shaft. Ensure shift rod and gate mounting hole are aligned.
Interlock Sleeve And Control Lever Alignment:
23. Align end of interlock sleeve with control lever as indicted by arrow in the Interlock Sleeve And Control Lever Alignment image, then face reverse idler shaft screw hole in direction shown.
24. Clean contact surfaces on clutch housing and transaxle case, then apply thin coat of sealant.
25. Place transaxle case on clutch housing, then install and tighten bolts.
26. Install two transaxle plugs tool No. T88C-7025-AH, or equivalent, between differential side gears.
NOTE: Failure to install transaxle plugs may cause differential side gears to become improperly positioned.
27. Install lock bolt and guide bolt.
28. Install ball, springs, and lock bolt.
29. Install main fifth gear, gear sleeve, input fifth gear, synchronizer ring, shift fork, clutch hub assembly and synchronizer ring.
30. Install roll pin, then the main reverse synchronizer gear.
31. Install input reverse synchronizer gear, then shift transaxle to first gear.
32. Use torque adapter tool No. T88C-7025-GH, or equivalent, to lock input shaft, then install locknuts. Tighten locknuts to specifications.
33. Clean transaxle case and rear cover contact surfaces, then install rear cover. Tighten bolts to specifications.