Transaxle Case Assembly

TRANSAXLE CASE ASSEMBLY

^ TOOLS REQUIRED
- J 44375 Assembly Pallet
- J 44376 Bearing Pusher/Puller
- J 44377 Input Shaft Anti-Rotation Tool
- J 44381 Shifter Bearing/Input and Output Bearing Remover
- J 44383 Countershaft Bearing Installer
- J 44387 Output Shaft Bearing Sleeve and Installer Pin
- J 44389 Countershaft Bearing Installer
- J 7079-2 Non-Threaded Driver Handle

ASSEMBLY





1. Install shift rod and bushing.





2. Install counter shaft needle bearing to transaxle case using Countershaft Bearing Installer J44383 (1) and Non-Threaded Driver Handle J7079-2 (2).





3. Install a new shifter shaft bearing flush with the casting in transaxle case, using Shifter Bearing/Input and Output Bearing Remover J44381 and Non-Threaded Driver Handle J7079-2.





IMPORTANT: Do not over-apply threadlocker to bolt threads.

4. Apply P/N 21485277 to the reverse lockout lever bolt threads.

IMPORTANT: The spring fingers must be positioned on either side of lever.

5. Install reverse shift block lever, spring, and bolt to transaxle case, if equipped.
Torque: Reverse Shift Block Bolt: 6 Nm (53 inch lbs.)





6. Install a new differential bearing race to transaxle case using Differential Bearing Race and Sea] Installer J44385 (2) and Threaded Driver Handle J8092 (1).





7. Install a new drive shaft seal to transaxle case using Differential Bearing Race and Seal Installer J44385 (2) and Threaded Driver Handle J8092 (1).





8. Install a new snap ring.
9. Install the countershaft bearing to clutch housing using Shifter Bearing/Input and Output J44381 (1) and Non-Threaded Driver Handle J7079-2 (2).





10. Install input shaft bearing to clutch housing using Shifter Bearing/Input and Output J44381 (1) and Non-Threaded Driver Handle J7079-2 (2).





11. Install output shaft bearing race and bolts using Output Shaft Bearing Sleeve and Installer Pin J44387, and Threaded Driver Handle J8092 (1).
Torque: Output Shaft Bearing Bolts: 10 Nm (89 inch lbs.)





12. Install a new differential bearing race to clutch housing using Differential Bearing Race and Sea] Installer J44385 (2) and Threaded Driver Handle J8092 (1).





13. Install a new drive shaft seal to clutch housing using Differential Bearing Race and Seal Installer J44385 (2) and Threaded Driver Handle J8092 (1).





14. Install snap rings to input shaft and output shaft bearings.
15. Install input shaft and output shaft bearings into transaxle case using Differential Bearing Race and Seat Installer J44385 (2) and Threaded Driver Handle J8092 M.





16. Install shift forks and input shaft and output shaft onto Assembly Pallet J44375.





17. Install countershaft and shift fork onto Assembly Pallet J44375.
18. Rotate shaft to verify all gears are properly meshing.





19. Install case onto shift forks and shafts on to Assembly Pallet J44375. Line up shift forks and shafts with case.





IMPORTANT: Install transaxle case to shafts evenly using Bearing Pusher/Puller J44376.

20. Install transaxle case to shafts using Bearing Pusher/Puller J44376.





21. Shift transaxle into 4th and 5th gear using a screwdriver in an upward direction.
22. Apply P/N 21005994 to input and output shaft bolts.
23. Install NEW input and output bolts while holding transaxle into 4th and 5th gear in an upward direction.
Torque: Shaft Bolts: 95 Nm (68 ft. lbs.)





IMPORTANT: If shimming is required, refer to "Shimming" before installing cover.

24. Apply sealant P/N 21019581 to rear cover.





IMPORTANT: The oil spout only installs in one direction. Ensure the oil spout is completely seated in gear shafts.

25. Install oil spout (funnel).
26. Install rear cover.
27. Install rear cover bolt.
Torque: Rear Cover Bolts: 23 Nm (17 ft. lbs.)





28. Apply sealant P/N 21485278 to backup lamp switch.
29. Install backup lamp switch into transaxle case.
Torque: Backup Lamp Switch: 18 Nm (13 ft. lbs.)





30. Turn transaxle case and Assembly Pallet J44375 over on the table.
31. Remove Assembly Pallet J44375 from gear shafts and shift forks.





32. Install oil trough into transaxle case.





33. Install shift rod to shift fork.





IMPORTANT: Apply a thin bead of sealer and ensure that there is not any excessive sealer around the shift rod bushing.

34. Apply sealer P/N 12378516 to transaxle case to shifter cover mating surface.





IMPORTANT: Install all possible shifter bolts with shifter in neutral position. Install last shifter bolt in gear and shift transaxle back into neutral.

35. Install shifter and shifter retaining bolts.
Torque: Shifter Retaining Bolts: 25 Nm (18 ft. lbs.)





36. Shift transaxle into neutral.
37. Apply P/N 21485278 to shifter guide bolt.

NOTICE: Hand start and tighten shifter guide bolt to avoid damaging shift lever.

38. Install shifter guide bolt.
Torque: Shifter Guide Bolt: 25 Nm (18 ft. lbs.)





39. Install magnet into transaxle case.





40. Install differential into transaxle case.





IMPORTANT: The inner step in the roller bearing faces opposite of the pinion gear.

41. Install roller bearing onto output shaft.





42. Install clutch housing to transaxle case.
43. Apply sealant P/N 12378516 to transaxle case to clutch housing mating surface.





44. Install countershaft into clutch housing bearing using Countershaft Bearing Installer J44389.





45. Install clutch housing to transaxle case bolts.
Torque: Case-to-Clutch Housing Bolts: 27 Nm (20 ft. lbs.)





46. Turn transaxle over.
47. Install transaxle case to clutch housing bolts.
Torque: Case-to-Clutch Housing Bolts: 27 Nm (20 ft. lbs.)





48. Turn transaxle so shifter is on top.
49. Shift transaxle into any gear.





50. Hold input shaft with Input Shaft Anti-Rotation Tool J44377.
51. Apply P/N 21485278 to counter shaft bolt.
52. Install bolt in counter shaft.
Torque: Counter Shaft Bolt: 95 Nm (70 ft. lbs.)





53. Install a new plastic lube funnel into counter shaft.





IMPORTANT: Make sure not to press retainer plug past the bottom of chamfer.

54. Install a new counter shaft retainer plug.





55. Apply P/N 21485277 to vehicle speed sensor bolt.
56. Install vehicle speed sensor, seal, and bolt.
Torque: Vehicle Speed Sensor Bolt: 12 Nm (8 ft. lbs.)





57. Install shift cable bracket (4), isolators (3), spacers (2) and bolt (1).
Torque: Shift Cable Bracket Bolt: 20 Nm (15 ft. lbs.)





58. Install actuator and tube.
59. Install actuator and tube bolts.
Torque: Clutch Actuator Cylinder Bolts: 10 Nm (89 in-lbs)
60. Apply P/N 21485278 to transaxle drain plug.
61. Install transaxle drain plug.
Torque: Transaxle Drain Plug: 38 Nm (28 ft. lbs.)
62. Install transaxle fill cap.