Intermediate Shaft: Assembly

NOTE: Depending on date of transaxle manufacture, some intermediate shafts will utilize a needle bearing under 2nd and 5th Speed Gears.

NOTE: Do not re-use snap rings when servicing the intermediate shaft assembly. Discard snap rings and install new ones provided with available snap ring service kit.

NOTE: When installing 1/2 & 5/R synchronizers, make sure to align oil slots on synchronizer hub face with oil hold in the shaft splined hub journal.

NOTE: Refer to (Fig 1 ) for intermediate shaft assembly reference.

Fig 1: Identifying Components Of Intermediate Shaft Assembly

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1. Press intermediate shaft into NEW roller bearing with arbor press (Fig 2 ).
   Fig 2: Installing Intermediate Shaft Bearing

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2. Install intermediate shaft roller bearing snap ring (Fig 3 ).
   Fig 3: Installing Intermediate Shaft Roller Bearing Snap Ring

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3. Install 1st gear roller bearing to intermediate shaft (Fig 4 ).
   Fig 4: Installing 1st Gear Needle Bearing

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4. Install 1st gear to intermediate shaft (Fig 5 ).
   Fig 5: Installing 1st Gear

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5. Install 1/2 synchro to fixture 8483. Insert 1st gear blocker ring, friction cone, and reactor ring as shown in (Fig 6 ).
   Fig 6: Installing 1/2 Synchro On Fixture 8483

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6. Install intermediate shaft to synchro assembly on fixture (Fig 7 ). When installing 1/2 synchronizer, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.  Line up friction cone and reactor ring tabs to gear slots. Remove shaft assembly from fixture.
7. Install NEW  1/2 synchro snap ring (Fig 8 ).
   Fig 7: Installing 1/2 Synchro To Intermediate Shaft

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   Fig 8: Installing 1/2 Synchro Snap Ring

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8. Install 2nd gear blocker ring (Fig 9 ).
   Fig 9: Installing 2nd Gear Blocker Ring

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9. Install 2nd gear friction cone (Fig 10 ).
   Fig 10: Installing 2nd Gear Friction Cone

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10. Install 2nd gear reactor ring (Fig 11 ).
    Fig 11: Installing 2nd Gear Reactor Ring

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11. Install 2nd gear and needle bearing (if equipped) to intermediate shaft (Fig 12 ).
    Fig 12: Installing 2nd Gear

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12. Press 3/4 cluster gear onto intermediate shaft using cup 8481 (Fig 13 ).
    Fig 13: Installing 3/4 Cluster Gear using Tool 8481

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13. Install NEW  3/4 cluster gear snap ring (Fig 14 ).
    Fig 14: Installing 3/4 Cluster Gear Snap Ring

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14. Install 5th gear and needle bearing (if equipped) to intermediate shaft (Fig 15 ).
    Fig 15: Installing 5th Gear Installation

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15. Install 5th gear blocker ring to synchronizer (Fig 16 ).
    Fig 16: Installing 5th Gear Blocker Ring To Synchro

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16. Install 5th gear synchronizer assembly to intermediate shaft (Fig 17 ). When installing 5/R synchronizer, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal. 
    Fig 17: Installing Install 5/R Synchro And 5th Blocker Ring To 5th Gear

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17. Install NEW  5/R synchro snap ring (Fig 18 ).
    Fig 18: Installing 5/R Synchro Snap Ring

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18. Install reverse gear blocker ring (Fig 19 ).
    Fig 19: Installing Reverse Gear Blocker Ring

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19. Install reverse gear needle bearing (Fig 20 ).
    Fig 20: Installing Reverse Gear Needle Bearing

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20. Install reverse gear to intermediate shaft.
21. Install intermediate shaft sealed roller bearing and thrust washer using installer 8482 (Fig 21 ).
    Fig 21: Installing Sealed Roller Bearing Installation

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22. Install NEW  intermediate shaft sealed bearing snap ring (Fig 22 ).
    Fig 22: Installing Intermediate Shaft Bearing Snap Ring

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