Assembly

1. Install shift relay lever bracket assembly and retaining bolts. Torque bolts to 6-8 ft lbs.
2. Install differential and final drive gear assembly into clutch housing case.

Shift Lever Assembly Replacement:

3. Position mainshaft control assembly so shift forks engage their respective slots in synchronizer sleeves on mainshaft assembly.

Shaft Assemblies Replacement:

4. Position mainshaft, input cluster shaft and main shift control shaft over their respective bores, then install in case as an assembly. Avoid movement of the 3-4 synchronizer sleeve, which may result in over-travel of the synchronizer sleeve-to-hub, allowing inserts to pop out of position.
5. Position shift lever, 3-4 bias spring and 5th-reverse kickdown spring (one shift lever ball located in socket of the input shift gate selector plate arm assembly an the other in the socket of the main shift control shaft block).
6. Install spring and ball in the 5th-reverse inhibitor shift lever hole.
7. Slide the shift lever shaft, with the notch down, through 3-4 bias spring and shift lever using a small drift punch to depress inhibitor ball and spring.
8. Tap shift shaft through shift lever, then install 5th-reverse gear kickdown spring into bore in clutch housing.
9. Align shift shaft bore with case bore, then install spring slightly below case mating surface.

Selector Pin N Gate Of Control Selector Plate:

10. Verify selector pin is in the N gate of the control selector plate, and finger of the fork selector arm is partially engaged with the 3-4 fork.
11. Install reverse idler gear on clutch housing, then align reverse shift relay lever to the slot in the gear and slide reverse idler shaft through the gear and into its bore.

Reverse Relay Lever Engaged In Reverse Idler Gear Groove:

12. Engage reverse idler gear groove with reverse relay lever.
13. Install magnet in clutch housing pocket.

Install 5th Gear Relay Lever On Reverse Idler Shaft & Align With Fork Interlock Sleeve & Reverse Gear Actuating Arm Slot:

14. Install 5th gear relay lever onto reverse idler shaft, then the shaft and fork interlock sleeve and reverse gear actuating arm slot. Install retaining C-clip.
15. Ensure case mating surfaces are clean and free of burrs, scratches and nicks. Apply a 1/16 inch wide bead of gasket eliminator No. E1FZ-19562-A or equivalent.
16. Install detent spring and plunger in case bores.
17. Lower transaxle case over clutch housing, then depress spring and plunger using a punch and hammer.
18. Gently move transaxle case until shift control shaft, mainshaft, input cluster shaft and reverse shaft align with respective bores.
19. Install case over dowels and flush onto case. Ensure case does not bind on magnet.
20. Apply Teflon sealant to the threads of interlock sleeve retaining pin in a clockwise direction.
21. Using a drift punch align slot in the interlock sleeve with the hole in the transaxle case, then install the retaining pin. Torque retaining pin to 12-15 ft lbs.
22. Install 15 transaxle-to-clutch housing bolts. Torque bolts to 13-17 ft lbs.
23. Using a drift punch align the bore in reverse idler shaft with retaining screw hole in transaxle case.
24. Install reverse idler shaft retaining bolt. Torque bolt to 16-20 ft lbs.
25. Apply Teflon pipe sealant D8AZ-19554-A or equivalent, to threads of back-up lamp switch in a clockwise direction, then install the switch and torque to 12-15 ft lbs.
26. Apply Teflon pipe sealant D8AZ-19554-A or equivalent, to threads of detent plunger retaining screw.
27. Install detent cartridge spring and plunger, if equipped, coating threads with pipe sealant, then the retaining screw, torquing screw to 6-8 ft lbs.
28. Tap differential seal into the transaxle case, using differential seal replacer tool No. T81P-1177-A or equivalent.
29. Place transaxle in an upright position, then install a drift punch through the hole in the input shaft. Ensure proper operation by shifting transaxle through all gears.
30. Fill transaxle with specified fluid.