Transaxle Assembly
Transaxle
All Transmissions
1. NOTE: Apply transmission fluid to all rotating surfaces.
Clean and check all parts carefully before reassembly.
2. Using the special tool, install the output shaft roller bearing and bearing cone.
1. Install the oil thrower.
2. Install the bearing as far as stop.
3. Using the special tool, install the differential bearing cone.
4. Install the shift selector interlock plate and the selector rod.
1. Install the shift selector interlock plate.
2. Install the 5th/reverse gear selector rod.
5. Install the reverse gear idler (as shown), the differential and the magnet.
1. Reverse gear idler.
2. Differential.
3. Magnet.
6. Prepare the input and the output shaft for installation.
1. Position the input shaft and the output shaft together.
2. Position the 1st and 2nd gear selector fork on the shaft assemblies.
3. Position the 3rd and 4th gear selector fork on the shaft assemblies.
7. Install the input shaft, output shaft and selector fork assemblies into the transaxle case.
- Install a rubber band to the selector shaft to aid assembly.
- Insert the input shaft to a depth of approximately 50 mm (1.968 in) and swivel it slightly to the side.
- Insert the output shaft to the level of the input shaft and engage the gears.
- Install the input shaft and the output shaft.
8. Install the selector shaft guide sleeve and new lower snap ring.
1. Push in the selector shaft guide sleeve.
2. Install the new lower snap ring.
9. Install the selector shaft guide sleeve new upper snap ring.
1. Pull up the selector shaft guide sleeve.
2. Install the new upper snap ring.
10. Move the inner gearshift linkage to 5th gear.
- Turn the selector shaft clockwise until the reverse and 5th gear passage is reached, then press downwards.
11. NOTE: The inner diameters of the Belleville washers are touching.
Install the shim and secure it by staking the edge of the housing.
1. Belleville washers.
2. Shim.
3. Install the bearing cone and secure it by staking the edge of the housing.
12. Apply Gasket Maker to the transaxle housing.
13. Install the transaxle housing bolts and evenly tighten.
- Tighten to 33 Nm (24 lb-ft).
14. NOTE: Use a wooden block.
Install the new input shaft and output shaft retaining rings.
15. NOTE: Turn the retaining rings so that they are located in the cut-outs in the gasket.
Install the special tools.
16. Install the new 5th gear housing gasket, 5th gear housing and the 9 new 5th gear housing bolts.
- Tighten to 17 Nm (150 lb-in).
17. NOTE: Remove the transaxle from the special tool and carry out the following step on a press.
NOTE: Install an anti twist stop for the selector rod.
NOTE: The transaxle housing must not rest on the press table. Support the input shaft clutch splines on the press.
Using the special tool and a press, install the 5th gear wheel onto the input shaft.
18. Install the special tool onto the transaxle.
19. Using the special tool, install the new 5th gear snap ring.
1. Install the new snap ring onto the special tool.
2. Install the special tool and push on the new snap ring.
Transmissions with Old Style Synchronizer
20. NOTE: Align the synchronizer with the marks made during disassembly.
Assemble the 5th gear synchronizer assembly:
1. install 5th gear.
2. install the synchronizer ring.
3. install the synchronizer (as shown).
4. install the retention plate.
21. Install the 5th gear synchronizer assembly with selector fork.
- Install the new roll pin.
- Install the new circlip.
Transmissions with New Style Synchronizer and All Replacement Synchronizers
22. Install the mainshaft 5th gear.
23. NOTE: Make sure that the components are installed to the position noted before removal.
Assemble the synchronizer hub and sleeve.
24. NOTE: Make sure that the components are installed to the position noted before removal.
Install the synchronizer actuators.
25. NOTE: Make sure that the components are installed to the position noted before removal.
Install the synchronizer radial spring.
26. NOTE: Make sure that the components are installed to the position noted before removal.
Install the synchronizer ring.
27. Install the synchronizer and selector fork.
1. Align the marks made during removal.
2. Install the new circlip.
3. Install the new roll pin.
All Transmissions
28. Apply Silicone Gasket and Sealant evenly to the end cap.
29. Install the 5th gear cover and the 5th gear cover bolts.
- Tighten to 12 Nm (106 lb-in).
30. NOTE: Install the selector shaft interlock in the neutral position.
Install the selector shaft interlock as shown.
31. NOTE: Make sure the selector shaft interlock in the neutral position.
Apply Threadlock and Sealer to the selector interlock mechanism and install.
- Tighten to 25 Nm (18 lb-ft).
32. Install the shift lever.
33. Using the special tool, install the halfshaft seal until it engages audibly.
34. Engage 5th gear.
- Turn the selector shaft clockwise as far as possible and press it in.
35. Install the gearshift cables bracket and the gearshift cables bracket nuts.
- Tighten to 20 Nm (177 lb-in).
36. Install the selector lever.
1. Install the new snap ring.
2. Install the protective cap.
37. Install the gearshift cables shroud and gearshift cables shroud fasteners.
38. Install the reversing lamp switch.
- Tighten to 14 Nm (124 lb-in).
39. Install the Vehicle Speed Sensor (VSS).
1. Connect the VSS (Vehicle Speed Sensor).
2. Install the retaining pin.
40. NOTICE: Apply adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.
Using the special tools, install the new input shaft seal.
1. Apply a small amount of adhesive tape to the input shaft.
2. Put the input shaft seal on the input shaft.
3. Using the special tool, install the new input shaft seal.
41. Install the clutch slave cylinder and the clutch slave cylinder bolts.
1. Apply a small amount of grease to the input shaft.
2. Install the clutch slave cylinder.
3. Install the 3 clutch slave cylinder bolts.
- Tighten evenly to 11 Nm (97 lb-in).
