Part 2 of 3

10. Clearance between outer gear side and the reaction shaft support should be 0.020 - 0.046 mm (0.008 - 0.0018 inch). Clearance between inner gear side and the reaction shaft support should be 0.020 - 0.046 mm (0.008 - 0.0018 inch).


CAUTION: By-pass valve must be replaced if transmission failure occurs.

Fig. 105:

Fig. 106:

Fig. 107:

Fig. 108:

Fig. 109:

Fig. 110:

Fig. 111:

Fig. 112:

Fig. 113:

Fig. 114:

Fig. 115:

Fig. 116:

Fig. 117:

Fig. 118:

Fig. 119:

Fig. 120:

Fig. 121:

Fig. 122:

The number 7 needle bearing has antireversal tabs and is common with the number 5 and number 2 position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig. 105). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
Stand trans upright on bellhousing
Chain cover must be free of old sealant, dirt and oil before applying new sealant. Apply a 1/8 inch bead of sealant to flange of cover.

CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.

CAUTION: The chain sprockets have a slip fit onto the shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly, removal or installation will be difficult. Overspreading of the chain sprockets will also make sprocket removal difficult.

Fig. 123:

Remove main sump baffle from transaxle case (Fig. 123).

CAUTION: Failure to grind and open stakes of the output shaft nut and transfer shaft nut will result in thread damage to the shafts during nut removal.

WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.

Fig. 124:

Fig. 125:

Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown in (Fig. 124) and (Fig. 125). Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.

Fig. 126:

Using a small chisel, carefully open stakes on nut (Fig. 126).

Fig. 127:

Fig. 128:

Use special tool 6497 and 6498 to remove the transfer shaft nut or the output shaft nut (Fig. 127). Note that your breaker bar will turn clockwise to remove the nut and counter clockwise to install the nut.