Manual Transaxle Assembly

ASSEMBLY




1. Install the drive shaft oil seal using the special tool (09431-21200).




2. Install the input shaft front oil seal using the special tool (09431-21000).




3. Install the output shaft bearing outer race and spacer using the special tools (09500-11000, 09532-11500).
4. Install the oil guide.




5. Install the differential gear assembly and output shaft assembly.
6. Install the input and intermediate shafts at the same time.




7. Install the retainer.

8. Reassembly of the shift rail assembly.




1. Place the 1st-2nd gear shift sleeve in the 2nd gear position
2. Place the 3rd-4th gear shift sleeve in the 4th gear position.
3. Install the 1st-2nd shift rail and fork assembly with the select lever pulled toward the 5th-reverse shift rail side.
4. Install the 3rd-4th/5th-reverse shift rail and fork assembly together with the select lever pushed toward the 1st-2nd rail side. (KM2O1 only)




5. Install the 3rd-4th/reverse shift rail and fork assembly with the select lever pushed toward the 1st-2nd rail side (KM200 only).
6. Turn the shift rail to engage the shift lug.

9. Installation of the spring pin.




1. Install the spring pins using the special tool (09414-11100).




2. When installing, make sure that the slit of the spring pin is aligned with the center line of the shift rail.

CAUTION: Do not reuse the spring pins.




10. Install the reverse gear lever assembly.
11. Install the reverse gear shaft and reverse gear in the direction illustrated.




12. Install the reverse shift lever and shoe.




13. Install the input shaft roller bearing outer ring and intermediate shaft bearing race using the special tools (09432-33400, 09500-21000)




14. Install the output shaft bearing outer race and spacer in the transaxle case using the special tools (09500-11000, 09532-11500).




15. Install the drive shaft oil seal in the transaxle case using the special tool (0943121200).

16. Reassembly of spacers (adjustment of end play).




1. Place two pieces of rosin-core solder measuring about 10 mm (0.4 in.) in length and 3 mm (0.12 in.) in diameter on the bearing outer race as shown in the illustration, and install the outer race.
2. Install the transaxle case and tighten the bolts to the specified torque.
3. Remove the transaxle case.
4. Remove the outer races and solder.




5. Measure the thickness of the crushed solder with a micrometer. Select and install the proper spacer.

Standard value:
Intermediate shaft end play: 0.05-0.10 mm (0.002-0.004 in.)
Output shaft end play: 0.05-0.10 mm (0.002-0.004 in.)
Differential case end play: 0.05-0.10 mm (0.002-0.004 in.)




17. Install the oil guide in the transaxle case.




18. Apply the specified sealant to the clutch housing side of the transaxle case.

Specified sealant : THREE BOND 1216




19. Install the transaxle case onto the clutch housing assembly and tighten the bolts (13 EA).




20. Install the restriction ball and gasket.
21. Center the shaft with a phillips screwdriver.
22. Tighten the reverse idler gear shaft bolt to the specified torque.




23. Install the poppet balls, poppet springs and poppet plugs.
24. Install the backup light assembly




25. Install the intermediate gear using the special tool (09432- 33300). (KM2O1 only)
26. Install the 5th gear, the needle roller bearing, synchronizer ring and the synchronizer hub. (KM201 only)
27. Install the 5th gear shift fork and the 5th gear synchronizer sleeve at the same time. (KM201 only)




28. Install the spring pin using the special tool (09414-11100). (KM201 only)




29. When installing, make sure that the slit of the spring pin is aligned with the center line of the shift rail. (KM201 only)

CAUTION: Do not reuse the spring pin.

30. Reassembly of lock nuts. (KM201 only)




1. Install the special tool (09432-21101) onto the input shaft.
2. Screw a 10 mm (0.39 in.) bolt amounting hole into on the clutch housing and attach a breaker bar to the special tool (09432-21101).




3. Shift the transaxle into reverse using the control and select levers.
4. Tighten the lock nut to the specified torque.
5. Stake the lock nut.




31. Apply the specified sealant to the rear cover and install the rear cover.

Specified sealant : THREE BOND 1216




32. Install the mounting bracket.




33. Install the speedometer driven gear assembly.