Assembly

1. Install breather and breather cover, then the oil passage, torquing to 69-100 inch lbs.
2. Install differential oil seals, using differential seal replacer T87C-77000-H or equivalent, then the input shaft seal using bell housing seal replacer T77J-7025-G or equivalent.
3. Adjust bearing preload as follows:
a. Install differential bearing cup into clutch housing using driver handle T80T-4000-W and differential bearing cup replacer T88C-7025-BH 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-CH2 or equivalent on top of input shaft gear assembly.

Shim Selection Adjustment Collar Placement:

f. Place six collars on clutch housing at positions shown in example.
g. Place transaxle case on collars, then install washers and bolts. Torque bolts to 13-14 ft lbs.
h. Mount dial indicator tool No. 4201-C or equivalent, on input shaft.
i. Rotate input shaft gear assembly several times to seat the bearings, then zero dial indicator at the lowest point on the end of input shaft.
j. Raise input shaft gear assembly by hand and read endplay. Turn input shaft gear several times, until dial indicator returns to zero. Raise input shaft gear assembly and take a second reading.
k. Obtain at least three readings within 0.004 inch of each other, then average at least three of the readings to obtain endplay reading.
l. Subtract 0.028 inch from endplay reading to obtain final shim size.
m. Select the shim(s) closest or slightly larger than the final shim reading. Do not use more than two shims.
n. Remove the bolts and washers securing the transaxle case to the clutch housing, Remove the transaxle case, gauge, rear bearing cup and input shaft assembly. Do not remove the bearing cups.
o. Repeat this procedure for the mainshaft. Ensure to remove the sleeve from shim selection gauge T88C-77000-CH2. There should not be any gap between the gauge halves.
4. Install adjustment shim(s) and rear differential bearing cup into transaxle case using differential bearing cup installer T88C-7025-BH and driver handle T80T-4000-W or equivalent.

Spring Seat & Spring Installation:

5. Install adjustment shim(s), diaphragm spring, and the mainshaft bearing cup.
6. Install change arm oil seal using pilot bearing installer T88C-7025-EH and driver handle T80T-4000-W or equivalents, then the change rod and arm.
7. Install baffle plate, torquing bolts to 87-113 inch lbs.
8. Install new roll in into change arm. Roll pin length should measure 1.10 inch.
9. Install differential, then the mainshaft and input shaft gear assemblies.
10. Install 5th-reverse interlock pin to the shift rod, then the shift rod end and shift rod.

1st-2nd Shift Rod, Shift Fork & Roll Pin Installation:

11. Install 1st-2nd shift rod and shift fork, then shift transaxle to 2nd gear and install the roll pin.
12. Install lever set spring, then the reverse shift lever, torquing to 69-95 inch lbs.
13. Install crank lever assembly and crank lever shaft into base plate, then the snap ring,
14. Install base plate assembly, reverse idler gear, reverse idler shaft and magnet.
15. Clean clutch housing-to-transaxle case mating surfaces, then apply a thin coat of sealant. Install transaxle case on clutch housing, torquing attaching bolts to 27-38 ft lbs.
16. Install transaxle plugs T88C-7025-AH or equivalent, between differential side gears. Failure to Install transaxle plugs may allow differential side gears to become improperly positioned.
17. Install righthand transaxle mount, torquing to 58-86 ft lbs.
18. Install reverse idler shaft set bolt, torquing to 13-l9 ft lbs.
19. Install balls, springs and bolts, torquing to 14-22 ft lbs.
20. Install back-up lamp switch, torque to 14-22 ft lbs, then install interlock pins.
21. Install interlock plate, torquing to 13-19 ft lbs.
22. Install neutral switch, torquing to 14-22 ft lbs.
23. Install washer and drain plug, torquing to 29-43 ft lbs.
24. Install speedometer driven gear assembly or vehicle speed sensor, then the main 5th gear and ball.
25. Install sleeve, then lubricate needle bearing with transmission fluid and install.
26. Install input 5th gear and synchronizer ring, shift fork, clutch hub assembly and synchronizer ring.
27. Install main reverse synchronizer gear, then the input reverse synchronizer gear.
28. Install sleeve.
29. Install locknuts, torquing to 94-145 ft lbs, then stake locknuts.
30. Install roll pin, then clean transaxle and rear cover mating surfaces and apply a thin coat of sealant.
31. Install rear cover and bolts, torquing bolts to 68-95 inch lbs.