Part 1 of 2

REASSEMBLY





1. Install both output bearing cups using Bearing Installer MB995004 and wrenches.





2. Install low/reverse clutch retainer gasket.

CAUTION: Be sure to align gasket holes.





3. Install low/reverse clutch piston retainer.





4. Install Torx-loc screws attaching low/reverse clutch piston retainer.





5. Install low/reverse clutch piston.





6. Install pivot shaft and guide bracket.

CAUTION: Be sure that guide bracket and split sleeve touch the rear of the case.





- Guide bracket (disassembled)





- Guide bracket (assembled)





7. Install guide bracket anchor shaft and plug.





8. Install park rod guide bracket anchor shaft with a hammer and drift.





9. Install low/reverse piston return spring.





10. Use center bolt of Spring Compressor MB995005, Spring Compressor MB995006 and Disc MB995010 to assemble low/reverse spring compressor tool.





11. Install compressor tool to transaxle as shown to compress low/reverse piston assembly.





12. Install snap ring with snap ring pliers.

NOTE: Be sure to place the opening between spring levers.





13. Install rear carrier bearing cone, press onto rear carrier using Installer Cap, MD998812, Installer-100, MD998813 and Installer Adapter (44), MD998821.





14. Install rear carrier assembly.





15. Install bearing, press onto output gear using Installer Cap MD998812 and Installer Adapter (48) MD998823.





16. Install a 4.50 mm (0.1772 inch) "test" shim on the rear carrier assembly hub, using grease to hold the shim in place.





17. Install output gear using Gear Installer MB995014 and two wrenches.





18. Tighten output gear bolt to 271 Nm (200 ft. lbs.) while holding output gear with Holder MB995012.

CAUTION: Original retaining bolt must not be re-used. Always use a new retaining bolt when reassembling.





19. Install Dial Indicator Set MB995030 with Fixture MB995045 and Special Bolts MB995013.
20. Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
21. Measure output gear end play.
22. 0nce bearing end play has been determined, refer to the Output Gear Bearing Shim Chart for the required shim.








OUTPUT GEAR BEARING SHIM CHART





23. While holding output gear with Holder MB995012, loosen output gear bolt and washer.





24. Install Gear Puller MB995043 with Bolts MB995044 and Thrust Button MB995009 to output gear. Turn puller center bolt clockwise to remove gear.





25. Remove the "test" shim and install the proper shim.





26. Use grease to hold the shim in place. Install the output gear.





27. Tighten output gear bolt to 271 Nm (200 ft. lbs.) while holding output gear with Holder MB995012.

CAUTION: Original retaining bolt must not be re-used. Always use a new retaining bolt when reassembling.





28. Using torque wrench, check the turning torque. The torque should be between 0.34 to 0.90 Nm (3 to 8 inch lbs.). If the turning torque is too high, install a 0.04 mm (0.0016 inch) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 inch) thinner shim. Repeat until the proper turning torque is obtained.





29. Install output gear and proper shim.





30. Install output gear, using Gear Installer MB995014 and two wrenches.





31. Install output gear bolt and coned lock washer.





32. Tighten output gear bolt to 271 Nm (200 ft. lbs.) while holding output gear with Holder MB995012.

CAUTION: Always use new retaining bolt. Old retaining bolt must not be reused.





33. Install transfer shaft bearing press onto transfer shaft using installer Cap MD998812 Installer-200 MD998814 and Installer Adapter (44) MD998821.





34. Install oil baffle and bearing cup from transfer shaft.





35. Install transfer shaft with Installer/Remover MB995003.





36. Install transfer shaft bearing snap ring with Snap Ring Pliers MB995008.





37. Install transfer shaft gear bearing cup, use Installer Adapter MB990936 and Installer Bar MB990938.





38. Install bearing, press in using Installer Cap MD998812 and Installer Adapter (48) MD998823.





39. Install bearing cup retainer.

NOTE: Align indexing tab with slot.





40. Install a 4.66 mm (0.1835 inch) "test" shim on the transfer shaft.





41. Install transfer shaft gear, using Gear Installer MB995014 and two wrenches as shown.





42. Tighten transfer shaft gear nut to 271 Nm (200 ft. lbs.) while holding transfer shaft gear with Holder MB995012.

CAUTION: Original retaining nut must not be re-used. Always use a new retaining nut when reassembling.





43. Install Dial Indicator Set MB995030 with Fixture MB995045 and Special Bolts MB995013.
44. Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
45. Measure transfer shaft gear end play.
46. 0nce bearing end play has been determined, refer to the Transfer Bearing Shim Chart for the required shim.
47. End play should be between 0.05 to 0.10 mm (0.0020 to 0.0039 inch). If end play is too high, install a 0.04 mm (0.0016 inch) thinner shim. If end play is too low, install a 0.04 mm (0.0016 inch) thicker shim combination. Repeat until 0.05 to 0.10 mm (0.0020 to 0.0039 inch) end play is obtained.








TRANSFER GEAR BEARING SHIM CHART





48. Install transfer shaft gear and proper shim.





49. Install transfer shaft gear, using Gear Installer MB995014 and two wrenches as shown.





50. Install transfer shaft gear nut and lock washer.