Part 1
Transaxle
Transmission Exploded View
Assembly
1. Install the hollow input shaft onto the inner input shaft.
2. NOTE: If the clearance is less than the minimum measurement stated in specifications, install a new shift fork.
Using a suitable feeler gauge, measure the clearance between the shift fork and synchronizer hub sleeve in various places around the circumference.
3. NOTE: Apply pressure on the synchronizer ring while taking the measurements.
NOTE: If the clearance is less than the minimum measurement stated in specifications, install a new output shaft assembly.
Using a suitable feeler gauge, measure the clearance between the synchronizer ring and gear in various places around the circumference.
4. NOTE: Make sure the synchronizers are in the neutral position.
Install output shaft 2 assembly on the special tool.
5. Install the input shaft assembly on the special tool.
6. NOTE: Make sure the synchronizers are in the neutral position.
Install output shaft 1 assembly on the special tool.
7. Install the special tool.
8. Turn the gearset assembly over onto the special tool.
9. Remove the special tool.
10. Install the 4th/reverse gear shift fork.
11. Install the 2nd/6th gear shift fork and linkage.
12. NOTE: Make sure shift drum 1 is in the neutral position as shown.
Install shift drum 1.
13. NOTE: Make sure shift drum 2 is in the neutral position as shown.
Install the 3rd gear linkage and shift drum 2.
14. Install the 1st/5th gear shift fork.
15. Install the 3rd gear shift fork.
16. Install the 4 shift fork rods.
1. Install the small shift fork rods.
2. Install the large shift fork rods.
17. Install the oil spout.
18. NOTE: Make sure the output shaft bearing retainer brackets are positioned as shown.
Install the special tools on the output shafts assemblies.
19. Install the transmission case onto the gearset assemblies.
20. Install the 6 new output shaft bearing retainer bolts. Tighten in 2 stages.
- Stage 1: tighten to 10 Nm (89 lb-in).
- Stage 2: tighten to 32 Nm (24 lb-ft).
21. Install the special tool on the transmission case.
22. Turn the transmission case and gearset assembly over onto the special tool.
23. Remove the special tool.
24. Install the magnet.
25. Install the small clock gears and clock gear pins.
26. Install the large clock gears and clock gear pins.
27. Install the park pawl and park pawl rod.
28. NOTE: Make sure the pin is installed as shown.
Install the park pawl actuation shaft assembly.
29. NOTE: If the differential bearings, differential, clutch housing and/or transmission case are replaced refer to Differential Shim Selection Differential Shim Selection.
Install the differential.
30. NOTICE: Make sure the transmission case and the clutch housing are clean and no old sealant is present or transmission fluid leaks can occur and cause transmission damage.
NOTICE: Make sure the park plunger and park plunger plug were removed from the the clutch housing or damage to the park pawl actuation shaft assembly (rooster comb) will occur.
Apply a 1 mm (0.039 in) bead of Gasket Maker around the inside of the bolt holes on the case side and completely around each dowel.
31. Using the special tools, install the new clutch housing input shaft bearing.
32. Install the clutch housing input shaft bearing retainer and the new clutch housing input shaft bearing retainer bolts.
- Tighten to 11 Nm (97 lb-in).
33. NOTICE: Do not overheat the bearing or damage to the bearing may occur.
Using a 1500W heat gun, or equivalent, heat the input shaft bearing in the clutch housing for approximately 5 minutes.
34. Install the clutch housing onto the transmission case.
35. Using the special tool and a hammer, tap the clutch housing down onto the transmission case.
36. Install the 18 bottom clutch housing-to-case bolts (13 shown).
- Tighten to 27 Nm (20 lb-ft).
37. Install the 3 top clutch housing-to-case bolts.
- Tighten to 27 Nm (20 lb-ft).
38. Install the park plunger.
39. Install the park plunger plug.
- Tighten to 43 Nm (32 lb-ft).
40. Install the manual control lever and the new manual control lever bolt.
- Tighten to 26 Nm (19 lb-ft).
41. Install a new input shaft snap ring.
42. Using the special tools, install a new input shaft case seal.
43. Using the locating flange on the guide tube, install the guide tube.
44. NOTE: The guide tube bolts must not project beyond the mounting surface of the clutch engagement levers.
Install the 3 guide tube bolts.
- Tighten to 8 Nm (71 lb-in).
45. Inspect the guide tube for wear or damage. Replace as necessary.
46. NOTE: One clutch actuator lever bushing shown, one per clutch actuator lever.
Install the clutch actuator lever bushings.
47. NOTICE: Be sure to properly handle the actuator lever as shown or damage may occur.
Install the clutch actuator lever 2.
48. Install clutch motor 2 without the bolts to aide in the alignment of the clutch actuator lever.
49. Install the 2 clutch actuator lever 2 bolts.
- Tighten to 19 Nm (168 lb-in).
50. NOTICE: Be sure to properly handle the actuator lever as shown or damage may occur.
Install the clutch actuator lever 1.
51. Install clutch motor 1 without the bolts to aide in the alignment of the clutch actuator lever.
52. Install the 2 clutch actuator lever 1 bolts.
- Tighten to 19 Nm (168 lb-in).
53. NOTICE: Tighten the spring retainer bolts by tightening them slightly in an alternating pattern or damage can occur to the clutch actuator levers.
NOTE: Make sure the spring retainer contour aligns with the actuator lever contour as shown.
NOTE: Make sure the serial number on the spring retainer matches the serial number on the actuator lever. If reusing the spring retainers and actuator levers use the marks made during removal for assembly.
Install the spring retainers and spring retainer bolts.
- Tighten to 26 Nm (19 lb-ft).
54. Remove the clutch actuator lever locks if installed.
