Transaxle Reassembly
NOTE:
Lubricate components during reassembly process with ATF.
- Install reverse idler gear shaft roll pin into reverse idler gear shaft and install into bottom case half. Install reverse idler thrust washer and gear onto reverse idler gear shaft.
- Install reverse shift lever assembly. See Fig 1 and Fig 4 . Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install case magnet in bottom case half. Install differential assembly into bottom case half.
- Mesh together and install input and output shafts. Rotate shafts back and forth to start output shaft into its bearing and align ring gear of differential. Install oil flow tube in pocket next to reverse shift lever of bottom case half. See Fig 2 .
- Install 1-2 and 3-4 shift fork on their respective synchronizer sleeves. Install 5th-reverse actuator into slot of reverse shift lever. Align forks and actuator and install shift rail. Ensure shift rail retaining groove is up. Install 5th-reverse actuator retaining clip.
NOTE: Ensure 5th-reverse actuator and shift forks are aligned properly to expose retaining clip grooves. Attempting to install prior to alignment will bend retaining clip, requiring replacement.
- Apply anaerobic sealer to both sides of transaxle case gasket. Place gasket over dowel pins of bottom case half and lower top case half over gear train.
- Spread input and output shaft bearing snap rings to allow snap rings to slide over bearings. Seat top case half and install case half bolts. Tighten bolts in sequence to specification. See Fig 3 . Ensure both shafts rotate freely during tightening process.
- Measure differential end play between side bearing and case using Differential End Play Tool (SA9112T). Install differential selective shim to set end play to zero. Ensure shim is positioned into groove.
- Apply anaerobic sealer to top case half axle seal bore and drive in axle seal. Install snap ring, if equipped. Install 5th driven and 5th gear. Install 5th gear synchronizer ring and spring to 5th gear. See Figure and Fig 5 . Install 5th-reverse shift fork on synchronizer assembly sleeve.
- Install 5th-reverse synchronizer assembly while sliding shift fork over shift rail. Ensure synchronizer ring tabs align with slots in synchronizer hub. Install new 5th-reverse shift fork retaining clip.
- Install synchronizer spring on reverse synchronizer ring to form assembly. Install assembly on 5th-reverse synchronizer sleeve. Install reverse cone and washer. Shift 5th-reverse shift fork into reverse position; transaxle is now in 2 gears.
- Install input and output shaft nuts and tighten to specification. See TORQUE SPECIFICATIONS . Move all shift forks to neutral position. Install rear cover gasket and cover. Install bolts and tighten to specification using crisscross pattern.
- Install shift control housing gasket and shift control housing assembly on case. Install bolts and tighten to specification. Ensure shift control housing is flush with case before tightening bolts.
- Install vehicle speed sensor and tighten to specification. Apply anaerobic sealer to bottom case half axle seal bore and drive in axle seal. Install snap ring, if equipped. Install drain plug and tighten to specification. See TORQUE SPECIFICATIONS .
- Install clutch arm and bearing assembly. Apply light film of grease on input shaft spline.