Special Tools

Note: Lubricate all components in transaxle fluid before installation.

1. Install the thrust washer using the DT-48199 (1) and a hydraulic press.
2. Install the collar using the DT-48199 and a hydraulic press.



3. Install the needle bearings (3).
4. Install the reverse gear (2).
5. Install the reverse gear blocking ring (1).




Note: 

•	The raised center hub of the 5th/Reverse synchronizer assembly faces the 5th gear.

•	Line up the blocking ring tabs and the hub keyways while pressing.

6. Install the 5th/Reverse synchronizer using the DT-48199 (1) and a hydraulic press.



7. Install the bearing collar using the DT-48198 (1) and a hydraulic press.



8. Install the 5th gear blocking ring (3).
9. Install the 2 needle bearings (2).
10. Install the 5th gear (1).




Note: The 3rd gear will install very tight. Ensure that the mating surfaces are clean.

11. Install the 3rd gear using the DT-48196 and a hydraulic press.




Note: The 4th gear will install very tight. Ensure that the mating surfaces are clean.

12. Install the 4th gear using the DT-48196 (1) and a hydraulic press.




Note: 

•	Lubricate all components with transaxle fluid before installation.

•	The machined surface faces the needle thrust bearing.

13. Install the 5th gear using the DT-48197 (1) and a hydraulic press.



14. Install the thrust bearing (2).
15. Install the 2 needle bearings (1).



16. Install the 3rd gear (4).
17. Install the 3rd gear blocking ring (3).
18. Install the thrust bearing (2).
19. Install the thrust washer (1).




Note: 

•	The machined surface of the synchronizer faces the thrust washer.

•	Align the slots in the synchronizer with the gear blocking ring tabs.

20. Install the 3rd/4th synchronizer using the DT-48195 (1) and a hydraulic press.



21. Install the bearing collar using the DT-48195 (1) and a hydraulic press.



22. Install the 4th gear blocking ring (4).
23. Install the needle bearing (3).
24. Install the 4th gear (2).
25. Install the thrust washer (1).




Note: Lubricate all components with transaxle fluid before installation.

26. Install the needle bearing (5).
27. Install the 2nd gear (4).
28. Install the 2nd gear inner cone (3).
29. Install the 2nd gear blocking ring (2).
30. Install the 2nd gear outer cone (1).




Note: 

•	Make sure to properly align the synchronizer to the gear and notches in the blocking ring.

•	Observe the orientation of the synchronizer. The shoulder of the synchronizer faces 1st gear.

31. Install the 1st/2nd synchronizer using the DT-48193 (1) and a hydraulic press.



32. Install the thrust washer (2) and the bearing collar (1) using the DT-48193 and a hydraulic press.



33. Install the 1st gear outer cone (3).
34. Install the 1st gear blocking ring (2).
35. Install the 1st gear inner cone (1).




Note: The steps in both roller bearings must fall into the 1st gear.

36. Install the roller bearing.
37. Install the 1st gear.
38. Install the roller bearing.



39. Install the thrust washer using the DT-48193 (1) and a hydraulic press.



40. Install the angle disc (4) onto the shift rod (5).
41. Install the 1st/2nd pressure spring (3).
42. Install the inner spring seat (2).
43. Install new snap rings (1).



44. Install the shift cover (4).
45. Install the vent cap (3).
46. Install the shift lever (2).
47. Install a new coiled pin (1).



48. Install the 5th/reverse pressure spring (1).
49. Install the outer spring seat (2).

Note: Properly support the shift finger (4) when installing the roll pin. Do not support the shift finger (4) with the shift interlock (3).

50. Install the shift interlock (3) into the shift finger (4).
51. Install a new coiled pin (5).
52. Install a new coiled pin (6).
53. Install a new shaft seal ring to the clutch housing using the DT-48179 and the DT-48187.



54. Install the interm shaft groove ball bearing to the clutch housing using the DT-48179  (1) and the DT-48185 (2).



55. Install the snap ring to the interm shaft groove ball bearing.



56. Install the input shaft roller bearing to the clutch housing using the DT-48179  (1) and the DT-48184 (2).



57. Install a new shaft seal ring to the transaxle housing using DT-48179  (1) and the DT-48187 (2).



58. Install the input shaft and output shaft groove ball bearings into the transaxle housing using DT-48179  (1) and the DT-48181 (2).



59. Install the needle sleeve flush with the casting in the transaxle housing using DT-48179  (2) and the DT-48182  (1).

Caution: Refer to Fastener Caution in the Preface section.




60. Install the reverse shifting blocker (1), the torsion spring (2), and a new thread pin (3) to the transaxle housing and tighten to 6-9 N·m (53-80 lb in).




Note: Check the direction of the roller bearing.

61. Install the output shaft roller bearing to the clutch housing.



62. Install interm (1), input (2), and output (3) shaft assembly with the respective shift forks in the clutch housing.

62.1.

Install the DT-48190 and the input shaft retainer plug.

62.2.

Install the interm (1) and input (2) shaft assembly with the respective shift forks.

Note: Position the interm shaft to the groove ball bearing side.

62.3.

Install the output shaft assembly and the shift fork.

62.4.

After checking the gear engagement, install each shaft assembly completely.

62.5.

Remove the DT-48190 and the input shaft retainer plug.




63. Install the transaxle housing on the clutch housing.

63.1.

Input and output shaft must engage in the groove ball bearings in the transaxle housing.

63.2.

The interm shaft and the shift forks must sit in their opposing bearings in the transaxle housing.

Note: If large forces are necessary when actuating the DT-48187, separate the transaxle housing and the clutch housing again and check positioning of the shaft and shift forks. Repeat operation.

63.3.

Install the DT-48187 on the transaxle housing.

•	Tighten the 4 bolts (1).

•	Screw the spindles into the input and output shaft.

63.4.

Draw the input and output shaft evenly into the groove ball bearings in the transaxle housing.

•	Hold the spindles (2) using a suitable tool.

•	Turn via nuts (3) in direction of the arrow.

63.5.

Remove the DT-48187 from the transaxle housing.

•	Unscrew the spindles into the input and output shaft.

•	Remove the 4 bolts (1).




64. Shift the transaxle into 4th and 5th gear using a screwdriver in an upward direction.
65. Install new input and output shaft bolts while holding the transaxle into 4th and 5th gear in an upward direction and tighten to 90-100 N·m (66-74 lb ft).




Note: Leave area free in order not to block up the oil pipe.

66. Apply Loctite 59000 sealant to the transaxle housing rear cover.




Note: The oil pipe only installs in one direction. Ensure the oil pipe is completely seated in the gear shafts.

67. Install the oil pipe and transaxle housing rear cover.



68. Install transaxle housing rear cover bolts and tighten to 20-25 N·m (15-18 lb ft).




Note: In line with the interm shaft, use suitable tools to assist in the housing separation.

69. Remove the clutch housing from the transaxle housing.



70. Install the idle shift rail (1) into the transaxle housing.
71. Install the idle shift rail bushing (2) to the transaxle housing.
72. Install the drain channel (3) into the transaxle housing.



73. Install the backup lamp switch and the washer to the transaxle housing and tighten to 20 N·m (15 lb ft).



74. Install the shift shaft assembly.

74.1.

Apply Loctite 5203 sealer to the transaxle housing to the gear shift cover mating surface.

74.2.

Position the transaxle into Neutral.

74.3.

Install the shift shaft assembly (3).

74.4.

Install the select control lever (2).

74.5.

Install the shift retaining bolts and tighten to 20-25 N·m (15-18 lb ft).

74.6.

Install the shift guide bolt (1) and tighten to 20-25 N·m (15-18 lb ft).




75. Install the differential bearing race and the shim to the transaxle housing using the DT-48179  (1) and the DT-48187 (2). Refer to Manual Transmission Specifications for shim specifications.



76. Install the differential bearing race and the shim to the clutch housing using the DT-48179  (1) and the DT-48187 (2). Refer to Manual Transmission Specifications for shim specifications.



77. Install the magnet into the transaxle housing.



78. Install the differential into the transaxle housing.



79. Apply Loctite 5203 sealer to the transaxle housing to clutch housing mating surface.

Note: 

•	The input and output shaft must engage in its bearing in the clutch housing.

•	The gear shift forks sit in their opposing bearings in the clutch housing.

80. Install the clutch housing to the transaxle housing.



81. Hold the input shaft with the DT-48180 (1).
82. Draw the interm shaft into the interm shaft groove ball bearing with old retainer plug.

Shift the transaxle into any gear.




83. Install the clutch housing to transaxle housing bolts and tighten to 20-25 N·m (15-18 lb ft).
84. Remove the old retainer plug from the interm shaft, and install a new retainer plug and tighten to 90-100 N·m (66-74 lb ft).
85. Remove the DT-48180.



86. Install the transaxle housing to clutch housing bolts and tighten to 20-25 N·m (15-18 lb ft).



87. Install a new oil pipe into the interm shaft.
88. Install a new interm shaft sealing plug.



89. Coat the thrust bearing guide surface with multi-purpose grease.

Note: Check the thrust bearing guide mounting points.

90. Install the O-ring and the thrust bearing guide.



91. Install the thrust bearing guide bolts and tighten to 8-12 N·m (71-106 lb in).



92. Coat the release lever shaft bushings with multi-purpose grease.
93. Install the release lever shaft bushings in the clutch housing.



94. Coat the thrust clutch bearing bore with multi-purpose grease.
95. Install the thrust clutch bearing and the clutch release fork.



96. Install the clutch release lever.



97. Install the clutch release fork bolt and tighten to 20-25 N·m (15-18 lb ft)



98. Install the speedometer driven gear and the bolt and tighten to 3-5 N·m (27-44 lb in).



99. Install the shift control cable bracket, the washer, and the bolts and tighten to 10-14 N·m (89-124 lb in).
100. Install the transaxle into the vehicle. Refer to Transaxle Assembly in this section.



101. Using a rubber mallet, tap lightly on the transaxle housing mating surface to ensure the bearings are fully seated.



102. Install the DT-48200  (1) to transaxle housing.

Note: Adjust the height of the DT-48200 for the zero point setting.

103. Adjust the zero point setting for each place on the transaxle housing flange surface using the DT-48200 and the height gage.



104. Measure the 3 places on the output shaft gear thrust washer surface using the height gage (average = A).

The height from the transaxle housing flange surface to the thrust washer surface.




105. Place the clutch housing differential bearing race, the differential, the transaxle housing differential bearing race, and the DT-48201 (1) onto the DT-48202 (2).



106. Adjust the zero pint setting for each place on the transaxle housing differential bearing race surface using the height gage.



107. Measure the 3 places on the differential ring gear surface using the height gage (average = B).

The height from the transaxle housing differential bearing race to the differential ring gear surface.




108. Measure the 3 places on the DT-48202 (1) using the height gage (average = C).

The height from the transaxle housing differential bearing race to the clutch housing differential bearing race.




109. To obtain shim size for transaxle housing shim use the following formula:

1 = 37.2mm - A - B

To obtain shim size for clutch housing shim use the following formula:

2 = 134.08mm - C - 1