Assembly
NOTE:^ Gears are to be inspected before assembly.
^ Whenever the transaxle is disassembled, the bearing preload must be adjusted. The input shaft, output shaft, and differential bearing preload can be adjusted by selecting shims to insert between the rear bearing cups and the transaxle case.
1. Use Differential Seal Replacer T87C-77000-H and a hammer to install the differential oil seal.
2. Lubricate the differential inner oil seal lip with the specified transmission fluid.
3. Use Bell Housing Seal Replacer T77J-7025-G to install the oil seal.
4. Lubricate the oil seal lip with the specified transmission fluid.
5. Install the adjustment shim(s) and the input shaft bearing race into the transaxle case.
NOTE: Use a soft-faced hammer to install the bearing race. Tap the race lightly around its circumference until the race is fully seated.
6. Install the adjustment shim(s) and the output shaft bearing race into the transaxle case.
7. Use Driver Handle T80T-4000-W and Differential Bearing Cup Replacer T88C-7025-BH to install the differential bearing race into the transaxle case.
8. Use Pilot Bearing Replacer T88C-7025-EH and Driver Handle T80T-4000-W to install the shifter shaft seal.
9. Slide the input shift shaft into the flywheel housing.
NOTE: Ensure that the gear shift control shaft boot drain hole will be facing downward when the transaxle is mounted in the vehicle.
10. Install the shift gate selector and input shift shaft selector plate arm onto the input shift shaft
11. Drive a new roll pin into the shift gate selector.
12. Install the bolt attaching the input shift shaft selector plate arm to the input shift shaft. Tighten the shift rod bolt to 12-13 Nm (105-121 inch lbs.).
13. Install the control selector plate, the two control selector plate bolts and the reverse idler gear spacer.
14. Install the differential into the flywheel housing.
15. Check the input shaft bearing preload as follows:
NOTE: If the input shaft and the differential are to be checked, install the differential and the input shaft at the same time. This will allow you to check both shafts without opening the case again.
a. Set the input shaft into the flywheel housing.
b. Install the transaxle case on the clutch housing. Tighten the transaxle case-to-flywheel housing bolts to 38-51 Nm (28-38 ft. lbs.).
c. Install the previously used shaft locknut onto the input shaft.
d. Place a socket and torque wrench over the shaft locknut and measure the bearing preload (turning torque) of the input shaft.
e. The preload should measure 0.1-0.2 Nm (0.9-2.1 inch lbs.). If the preload is not correct, repeat the input shaft bearing preload procedure.
16. Check the differential bearing preload as follows:
NOTE: If the differential and input shafts are to be checked, install the differential and the input shaft at the same time. This will allow you to check both shafts without opening the case again.
a. Set Differential Rotator T90P-7025-BH into the differential.
b. Use a torque wrench to measure the bearing Reload.
c. The preload should measure 1.4-1.9 Nm (13-17 inch lbs.). If the preload is not correct, repeat the differential bearing preload procedure.
17. Check the output shah bearing preload as follows:
a. Install the output shaft into the flywheel housing.
b. Set the transaxle case on the clutch housing and install the transaxle case-to-flywheel housing bolts. Tighten the transaxle case-to-flywheel housing bolts to 38-51 Nm (28-38 ft lbs.).
c. Place the previously used output shaft locknut on the output shah.
d. Place a socket and a torque wrench over the shaft locknut and measure the bearing preload (turning torque) of the output shah.
e. The preload should measure 0.2-0.4 Nm (1.8-3.4 inch lbs.). If the preload is not correct, repeat the output shah bearing preload procedure.
18. Align the gear shifter forks and shift control shafts with the input shah and output shaft.
NOTE: Lubricate the inner lip of the oil seal with the specified transmission fluid.
19. Install the third/fourth gear shifter fork and main shift control shaft along with the input shaft and output shaft assemblies.
20. Install the shift fork selector lever onto the transmission selector lever arm and support.
21. Install a new shift shaft lever seal on the shift lever shaft. Lubricate the new shift shaft lever seal and the shift lever shaft with the specified transmission fluid.
22. Install the shift lever shaft through the side of the flywheel housing into the shift fork selector lever.
23. Insert a new roll pin through the flywheel housing into the shift lever shaft.
24. Position the fifth/reverse shift gate on the flywheel housing and slide the shift control shaft into the shift gate.
25. Align the shift gate bolt holes and install the shift gate bolt.
26. Place the reverse idler gear and bushing and the reverse idler gear shaft into the flywheel housing.
27. Insert the oil pan magnet into the flywheel housing.
28. Install the reverse lever assembly and partially install the reverse lever shaft.
NOTE: Replace the shift shaft lever seal on the reverse lever shaft and lubricate the new shift shaft lever seal with specified transmission fluid.
29. Insert the ball and spring into the reverse lever shaft.
30. Compress the spring with a punch and insert a new roll pin into the reverse lever shaft.
31. Install the reverse lever shaft plug and stake the plug.
NOTE: Lightly coat the reverse lever shaft plug with sealant.
32. Install the case vent and the two case vent bolts.
33. Install a new vent into the transaxle case.
34. Align the oil passage and install the oil passage bolt. Tighten the oil passage bolt to 8-11 Nm (71-97 inch lbs.).
35. Place the transaxle case onto the flywheel housing.
36. Install the transaxle case-to-flywheel housing bolts. Tighten the transaxle case-to-flywheel housing bolts to 38-51 Nm (28-38 ft. lbs.).
NOTE: Install the transaxle case-to-flywheel housing retainer at the same time as the bolts.
37. Install the backup lamp switch along with a new copper washer. Tighten the backup lamp switch to 20-29 Nm (15-21 ft. lbs.).
NOTE: Always use a new copper washer when installing the backup lamp switch.
38. Install the PNP switch with a new copper washer. Tighten the PNP switch to 20-29 Nm (15-21 ft. lbs.).
NOTE: Always use a new copper washer when installing the park/neutral position switch (PNP switch).
39. Install the shift rail rear pin. Tighten the shift rail rear pin to 12-13 Nm (105-121 inch lbs.).
40. Install the reverse idler shaft detent ball, shifter interlock spring, and reverse idler shaft lock bolt. Tighten the reverse idler she* lock bolt to 15-20 Nm (11-15 ft. lbs.).
41. Install the ball, shifter interlock spring, and detent spring screw into the transaxle case.
42. Install the fifth speed gear onto the output shaft.
43. Install the fifth speed cluster gear sleeve onto the input shaft.
44. Install the fifth speed cluster gear on the input shaft.
45. Install the synchronizer, two synchronizer blocking rings, and the fifth/reverse gear shifter fork onto the input shaft.
CAUTION: Ensure that the grooved side of the synchronizer is facing down toward the fifth gear.
46. Align the fifth/reverse gear shifter fork to the shift control shaft and insert a new roll pin.
47. Install the output reverse synchronizer gear.
48. Install the synchronizer blocking ring.
49. Install the input reverse synchronizer gear.
50. Install the input synchronizer spacer.
51. Loosely install the shaft locknuts.
52. Turn the transaxle and install the Input Shaft Holder T88C-7025-GH.
53. Tighten the shaft locknut on the output shaft to 123-196 (95-144 ft. lbs.).
54. Stake the shaft locknut.
55. Tighten the shaft locknut on the input shaft to 128-196 (95-144 ft. lbs.).
56. Stake the shaft locknut.
57. Remove the Input Shaft Holder.
58. Apply a continuous bead of sealant to the transaxle case.
NOTE: Ensure that the transaxle case and case cover mating surfaces are clean prior to applying sealant.
59. Install the case cover. Tighten the case cover bolts to 8-11 Nm (71-97 inch lbs.).