Assembly (51 - 90)
TRANSAXLE-4X4Assembly
Caution:
^ Whenever the transaxle has been disassembled, the bearing preload must be adjusted. The input shaft, output shaft and differential bearing preload can be adjusted by selecting shims to insert between the bearing races and the case on the case side.
51. Install a new third/fourth gear roll pin.
52. Position the fifth/reverse gear shift rod and install the bolt.
53. Position the reverse detent lever set and install the bolts.
54. Install the reverse detent ball.
55. Install the reverse detent spring and the bolt
56. Install the reverse idler gear and shaft.
1. Position the reverse idler gear.
2. Install reverse idler gear shaft.
57. Install the magnet.
58. Face the reverse idler gear shaft hole in the direction shown.
Caution:
^ The transaxle case must be installed within four minutes after applying silicone gasket and sealant.
59. Apply a small bead of silicone gasket and sealant to the transaxle mating surface.
60. Install the transaxle case.
1. Position the transaxle case.
2. Install the 15 bolts.
61. Install the reverse idler shaft lock bolt.
62. Install the third/fourth gear shift rod interlock pin.
63. Position the two interlock pins.
64. Position the interlock housing and install the bolts.
65. Install the threes detent balls.
66. Install the three detent springs.
Caution:
^ The transaxle shifter must be installed within four minutes after applying silicone gasket and sealant.
67. Apply a small bead of silicone gasket and sealant to the transaxle shifter mating surface.
Caution:
^ Make sure that the shifter fingers engage the shift rod ends correctly or damage to the transaxle may occur.
68. Position the shifter housing and install the bolts.
69. Install the fifth speed gear.
70. Install the fifth gear bushing.
71. Measure the clearance between the fifth/reverse synchronizer sleeve and its shift fork.
72. Install the fifth speed cluster gear.
73. Install the fifth/reverse shift fork and synchronizer hub assembly.
74. Install a new fifth/reverse shift fork roll pin.
75. Install the fifth/reverse synchronizer blocking ring.
76. Shift the transaxle into first gear.
Caution:
^ Do not reuse locknuts.
77. Install the input and output shaft locknuts.
1. Using the special tool or equivalent, keep the input shaft from turning.
2. Install new input and output shaft locknuts.
Caution:
^ The case cover must be installed within four minutes after applying silicone gasket and sealant.
78. Apply a small bead of silicone gasket and sealant to the case and cover mating surface.
79. Install the case cover.
1. Position the case cover.
2. Install the bolts.
80. Position the shift cable bracket and install the bolts.
81. Position the shift cable bracket and install the bolts.
82. Position the clutch slave cylinder line bracket and install the bolts.
83. Rotate the transaxle 180 degrees.
84. Install the vehicle speed sensor (VSS).
85. Install the park/neutral position (PNP)/reversing lamp switch.
86. Install the anchor bolt.
87. Install the clutch release fork and bearing.
1. Install the clutch release fork and bearing.
2. Install the boot.
88. Install a new O-ring seal.
89. Install the power take off unit.
90. Remove the transaxle from the special tool or equivalent.