Assemble
1. Clean input shaft bearing and apply a small amount of Loctite 620 adhesive part No. 21005996, or equivalent, to bearing outer diameter.
2. Press in input shaft bearing using tool No. SA9118T, or equivalent.
3. Install press fixture tool No. SA9129T, or equivalent, and adjust to housing.
4. Install filter, staking in place with small punch.
5. Install oil baffle plate, then press in output shaft bearing. Ensure plate lies flat in bore and marked bearing surface faces upward.
6. Install output shaft bearing retaining pin.
7. Install the two case to housing dowel pins into clutch housing. A bolt may be used to pull dowels into housing.
8. Tap reverse idler gear shaft roll pin into reverse idler gear assembly on idler shaft. On some transaxies, the reverse idler gear thrust washer is not used. The reverse idler gear used instead has a thicker section. Both styles of reverse idler gears can be used when rebuilding a transaxle as follows:
a. Measure height of reverse idler gear.
b. If height is 1.378 inch, it must be used with reverse idle thrust washer. If height of reverse idler gear is 1.6661 inch, it must not be used with the thrust washer.
9. Install reverse shift lever assembly with reverse idler gear in fork part of lever. Tighten two bolts to specifications.
10. Install transaxle magnet into housing, then the differential assembly into housing.
11. Install input and output shafts as follows:
a. Lift shafts and mesh gears together.
b. Lower shafts together and rotate back and forth to align with differential ring gear and start output shaft in its bearing.
12. Install oil flow tube in pocket of clutch housing next to reverse shift lever.
13. Place 1-2 shift fork into 1-2 synchronizer sleeve, then the 3-4 fork into 3rd synchronizer sleeve.
14. Insert fifth/reverse actuator rod into slot in reverse shift lever.
15. Align shift fork shaft hole in shift forks and fifth/reverse actuator.
16. Install shift fork shaft through forks with shaft retaining ring groove up.
17. Ensure actuator rod is still in reverse shift lever, then hold fifth/reverse actuator in position to expose snap ring groove on each end of actuator.
18. Install new fifth/reverse actuator retainer.
19. Apply thin coat of sealant Loctite 518 part No. 21005993, or equivalent, to both sides of case to clutch housing gasket.
20. Place transaxle case to clutch housing gasket over dowel pins on clutch housing.
21. Lubricate differential and shaft ball bearings, shift fork shaft and reverse idler shaft.
22. Lower transaxle case onto clutch housing, spreading input and output bearing snap rings to let rings slide over bearings. Seat case to clutch housing.
23. Lubricate case to clutch housing bolts with Dexron II ATF, or equivalent, then install and tighten in sequence to specifications. Ensure shafts spin freely as bolts are being tightened.
24. Using differential endplay gauge tool No. SA9112T or equivalent, measure differential endplay on case side differential bearing. Differential endplay is set to zero by using largest endplay gauge that will fit between bearing and case. Use a snap ring of same thickness.
25. Apply light coat of sealer part No. 21005993, or equivalent, to seal area that presses into case, then install axle seal using axle seal installer tool No. SA9113T, or equivalent.
26. Install snap ring if groove is present on case.
27. Install fifth driven gear, then move two shift forks to lock transaxle in two gears simultaneously.
28. Install new output shaft nut. Tighten to 110 lbs. ft.
29. Install fifth gear thrust washer, bearing race, drive gear bearing and drive gear.
30. Install gear synchronizer blocker ring to fifth gear.
31. Install fifth gear synchronizer spring fifth gear synchronizer.
32. Slide fifth/reverse fork over fifth/ reverse synchronizer sleeve, then install sleeve to hub and fork to shift fork shaft at same time.
33. Install fifth/reverse fork retainers. Always use new retainers.
34. Install synchronizer spring to reverse blocker, then install assembly to fifth/ reverse sleeve.
35. Install reverse cone and thrust washer.
36. Move two shift forks to lock transaxle in two gears in tandem.
37. Install input shaft, then tighten nut to specifications.
38. Unlock shafts by lining up shift forks to neutral gate.
39. Rotate reverse cone until one of its slots faces top of transaxle, then align cone to rear cover.
40. Install rear cover gasket, then the rear cover. Torque bolts to 106 in. lbs. in a criss-cross pattern.
41. Install shift housing gasket to case, then the housing to case. Tighten shift housing bolts to 21 lbs. ft.
42. Install vehicle speed sensor. Tighten sensor to 20 lbs. ft.
43. Install oil drain plug to housing. Tighten to 40 lbs. ft.
44. Apply light coat of sealer part No. 21005993, or equivalent, to seal area that presses into case, then install clutch housing axle seal using axle seal installer tool No. SA9113T, or equivalent.
45. Install clutch fork stabilizer and ball stud in clutch housing. Tighten ball stud to 18 lbs. ft.
46. Install clutch fork retainer to clutch fork, then insert clutch release bearing into clutch fork.
47. Lube fork pivot and input shaft spline with high temperature grease part No. 21005995 or equivalent, then install fork and bearing assembly. Excessive amounts of grease on input shaft splines can contaminate clutch disc and cause clutch shudder.