Assembly

ASSEMBLY

NOTE: When servicing the input shaft assembly, all snap rings MUST be replaced with new ones upon assembly. 5th gear nut must also be replaced.

NOTE: When installing 3/4 synchronizer hub to shaft, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.





NOTE: Refer to (Fig. 215) for input shaft assembly reference.

1. Install input shaft into fixture 8487.
2. Install thrust washer if removed upon disassembly.





3. Install 3rd gear (Fig. 216).





4. Install 3rd gear blocker ring (Fig. 217).





5. Install 3/4 synchronizer (Fig. 218). When installing 3/4 synchronizer hub to shaft, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.





6. Install NEW 3/4 synchronizer snap ring (Fig. 219).





7. Install 4th gear blocker ring (Fig. 220).





8. Install 4th gear (Fig. 221).





9. Install 5th gear and press into position using installer 8481 (Fig. 222).





10. Install NEW 5th gear nut and torque to 200 Nm (148 ft. lbs.) using wrench 8478 (Fig. 223).
11. Stake 5th Gear nut as follows:
a. Install staking tool 8479 to 5th gear nut.





b. Tighten upper thumb screw by hand (Fig. 224).
c. Tighten two (2) side thumb screws by hand.





d. Tighten both staking screws until they bottom on tool body (Fig. 225).





e. Loosen staking screws and thumb screws. Remove tool and visually inspect stake (Fig. 226).

NOTE: The input shaft sealed roller bearing and snap ring do not get installed until transaxle assembly to facilitate installation of the reverse idler gear mechanism.