Steps 1-57

NOTE: Whenever the transaxle has been disassembled, the bearing preload must be adjusted. The input shaft, output shaft and differential bearing preload can be adjusted by selecting shims to insert between the bearing races and the case on the case side.





1. Install the input shaft bearing cup into the flywheel housing.





2. Install the input shaft.





3. Position the bearing cup onto the bearing, then install Shim Selection Gauge T88C-77000-CH3 on the bearing cup.





4. Place the six collars (part of T88C-77000-JF) onto the flywheel housing.





5. Place the transaxle case on the collars and install the six bolts (part of T88C-77000-JF).





6. Mount Dial Indicator with Bracketry TOOL-4201-C on the transaxle case.
7. Rotate the input shaft to seat the bearings.





8. Zero the dial indicator.





9. Rotate the input shaft until the dial indicator returns to zero. Raise the input shaft and read the end play.

CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.

10. Repeat Step 10 to obtain three readings within 0.10 mm (0.004) of each other. Average the three readings. Use the formula below to select the correct shim size.
Example
Reading A = 0.019
Reading B = 0.014
Reading C = 0.021
0.019 + 0.014 + 0.021 = 0.054
0.054/3 = 0.018
Final Shim Size: 0.018
11. From shim kit E92Z-7L172-A or equivalent, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in Step 10.

NOTE: Do not use more than two shims.

12. Remove the transaxle case, gauge, bearing cup, and input shaft.





13. Install the shim.





14. Use (A) Driver Handle T80T-4000-W and (B) Bearing Cup Replacer T77F-1217-B to install the (C) input shaft bearing cup.





15. Install the output and fifth shaft funnel and the output shaft bearing cup into the flywheel housing.





16. Install the output shaft.





17. Position the bearing cup onto the bearing.





18. Position Shim Selection Gauge T88C-77000-CH3 on the bearing cup.





19. Place the six collars (part of T88C-77000-JF) onto the flywheel housing.





20. Place the transaxle case on the collars and install the six bolts (part of T88C-77000-JF).





21. Mount Dial Indicator With Bracketry TOOL-4201-C on the transaxle case.
22. Rotate the output shaft to seat the bearings.





23. Zero the dial indicator.





24. Rotate the output shaft until the dial indicator returns to zero. Raise the output shaft and read the end play.

CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.

25. Repeat step 25 to obtain three readings within 0.10 mm (0.004) of each other. Average the three readings. Use the formula below to select the correct shim size.
Example
Reading A = 0.019
Reading B = 0.014
Reading C = 0.021
0.019 + 0.014 + 0.021 = 0.054
0.054/3 = 0.018
Final Shim Size: 0.018
26. From shim kit E92Z-7L172-A or equivalent, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in Step 25.

NOTE: Do not use more than two shims.

27. Remove the transaxle case, gauge, bearing cup and output shaft.





28. Install the shim.





29. Use (A) Driver Handle T80T-4000-W and (B) Bearing Cup Replacer T77F-1217-B to install the (C) output shaft bearing cup.





30. Use (A) Differential Bearing Cup Replacer T88C-77000-EH and (B) Driver Handle T80T-4000-W to install the (C) differential bearing cup into the flywheel housing.





31. Install the differential.





32. Place the bearing cup on the bearing.





33. Place Shim Selection Gauge T88C-77000-CH1 onto the bearing cup.

NOTE: The gauge halves must be turned to eliminate any gap between them.





34. Position the six collars (part of T88C-77000-JF) on the flywheel housing.





35. Position the transaxle case on the collars and install the six bolts (part of T88C-77000-JF).





36. Use the (A) pins to adjust (B) Shim Selection Gauge T88C-77000-CH1 until the free play is removed. Turn Shim Selection Gauge T88C-77000-CH 1 back together.





37. Insert Differential Rotator T88C-77000-L through the transaxle case and engage the differential pinion shaft.





38. Use the pins to adjust the Shim Selection Gauge T88C-77000-CH1 until the differential rotation is the proper torque.





39. Use a feeler gauge to measure the gap in Shim Selection Gauge T88C-77000-CH1.
40. Add 0.15 mm (0.0059 inch) to the feeler gauge measurement to achieve the final clearance.
41. Use the following chart to select the differential bearing shims that are closest to (or slightly larger-than) the value obtained in Step 41.

NOTE: Do not use more than two differential shims.

Part Number: Shim Thickness
E92Z-4067-A: 0.10 mm (0.004 inch)
E92Z-4067-D: 0.15 mm (0.006 inch)
E92Z-4067-F: 0.20 mm (0.008 inch)
E92Z-4067-G: 0:25 mm (0.010 inch)
E92Z-4067-H: 0.30 mm (0.012 inch)
E92Z-4067-J: 0.35 mm (0.014 inch)
E92Z-4067-K: 0.40 mm (0.016 inch)
E92Z-4067-L: 0.45 mm (0.018 inch)
E92Z-4067-N: 0.50 mm (0.020 inch)
E92Z-4067-P: 0.55 mm (0.022 inch)
E92Z-4067-Q: 0.60 mm (0.024 inch)
E92Z-4067-R: 0.65 mm (0.026 inch)
E92Z-4067-5: 0.70 mm (0.028 inch)
E92Z-4067-T: 0.75 mm (0.030 inch)
E92Z-4067-U: 0.80 mm (0.032 inch)
E92Z-4067-V: 0.85 mm (0.034 inch)
E92Z-4067-W: 0.90 mm (0.036 inch)
E92Z-4067-X: 0.95 mm (0.038 inch)
E92Z-4067-Y: 1.00 mm (0.040 inch)
E92Z-4067-Z: 1.05 mm (0.042 inch)
E92Z-4067-AA: 1.10 mm (0.044 inch)
E92Z-4067-AB: 1.15 mm (0.046 inch)
E92Z-4067-AC: 1.20 mm (0.048 inch)
42. Remove the transaxle case, gauge, bearing cup, and differential.





43. Install the differential shim(s) into the transaxle case.





44. Use (A) Differential Bearing Cup Replacer T88C-77000-EH and (B) Driver Handle T80T-4000-W to install the differential bearing cup into the transaxle case.





45. Use Differential Seal Replacer T87C-77000-H to install the differential seals.





46. Use Bell Housing Seal Replacer T77J-7025-G to install the input shaft oil seal.





47. Install the park/neutral position (PNP) position switch and gasket.





48. Install the reverse shaft lever and rod.





49. Install the roll pin.





50. Install the vehicle speed sensor (VSS).





51. Install the vent tube.
(1) Install the vent tube.
(2) Install the two bolts.





52. Use (A) Shift Lever Seal Replacer T74P-77498-A to install the (B) shift shaft seal.





53. Install the shift shaft and boot.





54. Install the roll pin.





55. Install the shift shaft selector lever.
(1) Install shift shaft selector lever.
(2) Install the shift shaft selector lever bolt.





56. Install the control selector plate and spacer.
(1) Install the control selector plate and spacer.
(2) Install the two bolts.





57. Install the differential.