Assembly

1. Install neutral switch and gasket, torquing to 14-22 ft lbs.
2. Install washer and drain plug, torquing to 29-43 ft lbs.
3. Install back-up lamp switch, torquing to 14-22 ft lbs.
4. Install differential seals, using differential seal replacer tool No. T87C-77000-H or equivalent.
5. Install input shaft seal, using bell housing seal replacer tool No. T77J-7025-G or equivalent.
6. Adjust input shaft and mainshaft bearing preload as follows:
a. Install differential bearing cup into clutch housing using driver handle T8OT-4OO0-W and differential bearing cup replacer T88C-77000-FH or equivalent.
b. Install oil funnel and mainshaft front bearing cup into clutch housing.
c. Install input gear shaft front bearing cup into clutch housing. Ensure bearing cups are fully seated.
d. Install input shaft gear assembly into clutch housing, then place the rear bearing cup on the input shaft bearing.
e. Position shim selection gauge T88C-77000-CH3 or equivalent on top of input shaft gear assembly.

Shim Selection Adjustment Collar Placement:

f. Install six collars on clutch housing, then install washers and bolts, torquing to 13-14 ft lbs.
g. Mount dial indicator tool No. 4201-C or equivalent, on input shaft.
h. Rotate input shaft gear assembly several times to seat the bearings, then zero dial indicator at lowest point on the end of input shaft.
i. Raise input shaft gear assembly by hand, then read endplay. Turn input shaft gear several times, until dial indicator returns to zero. Raise input shaft gear assembly and obtain a second reading. Average at least three of these readings to obtain endplay reading.
j. Subtract 0.028 inch from endplay reading to obtain final shim size required.
k. Select the shim closest or slightly larger than the final shim reading. Do not use more than two shims.
l. Remove bolts and washers securing transaxle case to clutch housing, then the transaxle case, gauge, rear bearing cup and input shaft assembly. Do not remove the bearing cups.
m. Repeat above procedure for the mainshaft.
7. Install adjustment shim(s), then the rear differential bearing cup using differential bearing cup replacer tool No. T88C-77000-FH or equivalent.

Spring Seat & Spring Installation:

8. Install adjustment shim(s), diaphragm spring and input shaft bearing cup.
9. Install breather and cover, then change the rod seal using pilot bearing installer tool No. T88C-7025-EH and driver handle tool No. T80T-4000-W or equivalents.
10. Install change rod and boot, spring, reverse gate, selector, and a new roll pin.
11. Install change arm and torque to 8.5-10 ft lbs.
12. Install guide plate, torquing bolt above spring to 69-100 inch lbs, then torque remaining two bolts to 16-25 inch lbs.
13. Install reverse lever and lever shaft, then a new roll pin.
14. Install speedometer driven gear or vehicle speed sensor, as equipped.
15. Install magnet, differential, input shaft and mainshaft.

Diaphragm Spring Installation:

16. Shift transaxle into 2nd gear and 4th gear, then position the shift fork and shift rod assembly.

Positioning Shift Fork & Shift Rod Assembly:

17. Install spring seat and springs into reverse lever shaft, then the ball holding it in place with a scraper knife. Push control end, in the direction shown, until ball is in shaft.
18. Place each clutch hub sleeve in the neutral position, then tap shift rod from above so steel ball goes into center groove.
19. Install crank lever shaft and assembly, then insert the pin.
20. Install gate and 5th/reverse shift rod, then tighten gate mounting bolt. Ensure shift rod and gate mounting hole are aligned.
21. Install reverse idler gear and shaft.

Interlock Sleeve & Control Lever Alignment:

22. Align end of interlock sleeve with control lever. Ensure reverse idler shaft screw hole is as shown.
23. Clean clutch housing and transaxle mating surfaces, then apply a thin bead of suitable sealant.
24. Install transaxle case on clutch housing, then torque attaching bolts to 27-38 ft lbs.
25. Install two transaxle plugs No. T88C-7025-AH or equivalent, between the differential side gears. Failure to install plugs may allow side gears to become improperly positioned.
26. Install lock bolt, torquing to 13-19 ft lbs.
27. Install guide bolt, torquing to 6.5-10 ft lbs.
28. Install ball, springs and lock bolt, then torque bolt to 10-15 ft lbs.
29. Install main 5th gear, gear sleeve and input 5th gear.
30. Install synchronizer ring, shift fork, clutch hub assembly and synchronizer ring.
31. Install roll pin, main reverse synchronizer gear and input reverse synchronizer gear.
32. Shift transaxle to 1st gear, then using torque adapter tool No. T88C-7025-GH or equivalent to lock up input shaft, install locknuts and torque to 94-145 ft lbs.
33. Clean transaxle case and rear cover mating surfaces, then apply a thin coat of suitable sealant. Install rear cover and bolts, torquing to 5.5-8 ft lbs.