Assembly
ASSEMBLE1. Install breather and breather cover, then the oil passage. Tighten breather cover bolts to specifications.
2. Install differential oil seals using differential seal replacer tool No. T87C-77000-H, or equivalent, then the input shaft seal using bell housing seal replacer tool No. T77J-7025-G, or equivalent.
3. Adjust bearing preload as follows:
a. Install differential bearing cup into clutch housing using driver handle tool No. T80T-4000-W and differential bearing cup replacer tool No. T88C-7025-BH, or equivalents.
b. Install oil funnel and main shaft front bearing cup into clutch housing.
c. Install input gear shaft front bearing cup into clutch housing.
NOTE: Ensure bearing cups are fully seated.
d. Install input shaft gear assembly into clutch housing, then place rear bearing cup on input shaft bearing.
e. Position shim selection gauge tool No. T88C-77000-CH2, or equivalent, on top of input shaft gear assembly.
Transaxle Case Collar Locations:
f. Place six collars from gauge tool on clutch housing at positions shown in the Transaxle Case Collar Locations image.
g. Place transaxle case on collars, then install washers and bolts.
h. Mount dial indicator tool No. 4201-C, or equivalent, on input shaft.
i. Rotate input shaft gear assembly several times to seat bearings, then zero dial indicator at lowest point on end of input shaft.
j. Raise input shaft gear assembly by hand and read endplay, then turn input shaft gear several times until dial indicator returns to zero.
k. Raise input shaft gear assembly and take second reading. Obtain at least three readings within 0.004 inch of each other, then average at least three readings to obtain endplay reading.
l. Subtract 0.028 inch from endplay reading to obtain final shim size.
m. Select shim(s) closest or slightly larger than final shim reading.
NOTE: Do not use more than two shims.
n. Remove bolts and washers securing transaxle case to clutch housing. Remove transaxle case, gauge, rear bearing cup, and input shaft assembly.
NOTE: Do not remove bearing cups.
o. Repeat this procedure for main shaft. Ensure removal of sleeve from shim selection gauge tool No. T88C-77000-CH2, or equivalent. There should not be any gap between gauge halves.
4. Install adjustment shim(s) and rear differential bearing cup into transaxle case using differential bearing cup installer tool No. T88C-7025-BH and driver handle tool No. T80T-4000-W, or equivalents.
5. Install adjustment shim(s), diaphragm spring, Fig. 122, and main shaft bearing cup.
6. Install change arm oil seal using pilot bearing installer tool No. T88C-7025-EH and driver handle tool No. T80T-4000-W, or equivalents, then the change rod and arm.
7. Install baffle plate.
8. Install new roll pin into change arm.
NOTE: Roll pin length should measure 1.10 inch.
9. Install differential, then the main shaft and input shaft gear assemblies.
10. Install fifth-reverse interlock pin to shift rod, then the shift rod end and shift rod.
Shift Rod, Shift Fork, And Roll Pin Installation:
11. Install 1-2 shift rod and shift fork, then shift transaxle into second gear and install roll pin.
12. Install lever set spring, then reverse shift lever. Tighten to specifications.
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 thin coat of sealant.
16. Install transaxle case on clutch housing.
17. Install transaxle plugs tool No. T88C-7025-AH, or equivalent, between differential side gears.
NOTE: Failure to install transaxle plugs may allow differential side gears to become improperly positioned.
18. Install righthand transaxle mount and reverse idler shaft set bolt. Tighten to specifications.
19. Install balls, springs, and bolts, then torque to 14-22 ft lbs.
20. Install back-up lamp switch. Tighten to specifications.
21. Install interlock pins, then the plate. Tighten to specifications.
22. Install park/neutral position switch, then the drain plug and washer. Tighten to specifications.
23. Install speedometer driven gear assembly or vehicle speed sensor, then the main fifth gear and ball.
24. Install sleeve, then lubricate needle bearing with transaxle fluid and install.
25. Install input fifth gear and synchronizer ring, shift fork, clutch hub assembly, and synchronizer ring.
26. Install main reverse synchronizer gear, then the input reverse synchronizer gear.
27. Install sleeve, then the locknuts.
28. Install roll pin, then clean transaxle and rear cover mating surfaces and apply a thin coat of sealant.
29. Apply thin coat of sealant to mating surfaces, then install rear cover and bolts. Tighten bolts to specifications.