Special Tools

Note: Lubricate all components in transaxle fluid before installation.

1. Install the thrust washer using the DT-48240 installer and a hydraulic press.
2. Install the collar using the DT-48240 installer 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-48240 installer  (1) and a hydraulic press.



7. Install the bearing collar using the DT-48239 installer  (1) and a hydraulic press.



8. Install the 5th gear blocking ring (3).
9. Install the two 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-48237 installer  (1) and a hydraulic press.



12. Apply sealer-retaining (Permatex 620) to the circumference of the input shaft before installing the 4th gear.

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

13. Install the 4th gear using the DT-48237 installer  (1) and a hydraulic press.




Note: 

•	Lubricate all components with transaxle fluid before installation.

•	The machined surface faces the needle thrust bearing.

14. Apply sealer-retaining (Permatex 620) to the circumference of the input shaft before installing the 5th gear.
15. Install the 5th gear using the DT-48238 installer  (1) and by hydraulic press.



16. Install the thrust bearing (2).
17. Install the two needle bearings (1).



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




Note: 

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

•	Make sure to align the slots in the synchronizer with the gear blocking ring tabs.

22. Install the 3rd/4th synchronizer using the DT-48236 installer  (1) and a hydraulic press.



23. Install the bearing collar using the DT-48236 installer  (1) and a hydraulic press.



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



28. Install the sleeve bearing using an appropriate tool.




Note: Lubricate all components with transaxle fluid before installation.

29. Install the needle bearing (5).
30. Install the 2nd gear (4).
31. Install the 2nd gear inner cone (3).
32. Install the 2nd gear blocking ring (2).
33. 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.

34. Install the 1st/2nd synchronizer using the DT-48235 installer  (1) and a hydraulic press.



35. Install the thrust washer (2) and the bearing collar (1) using the DT-48235 installer and a hydraulic press.



36. Install the 1st gear outer cone (3).
37. Install the 1st gear blocking ring (2).
38. Install the 1st gear inner cone (1).




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

39. Install the roller bearing.
40. Install the 1st gear.
41. Install the roller bearing.



42. Install the thrust washer using the DT-48235 installer  (1) and a hydraulic press.



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



47. Install the shift cover (4).
48. Install the vent cap (3).
49. Install the shift lever (1).
50. Install a new coiled pin (2).



51. Install the 5th/reverse pressure spring (1).
52. Install the outer spring seat (2).

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

53. Install the shift interlock (3) into the shift finger (4).
54. Install a new coiled pin (5, 6).



55. Install a new shaft seal ring to the clutch housing using the DT-48179 handle  (1) and the DT-48230 installer  (2).



56. Install the interm shaft groove ball bearing to the clutch housing using the DT-48179 handle  (1) and the DT-48228 installer  (2).



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



58. Install the input shaft roller bearing to the clutch housing using the DT-48179 handle  (1) and the DT-48227 remover/installer  (2).



59. Install a new shaft seal ring to the transaxle housing using the DT-48179 handle  (1) and DT-48230 installer  (2).



60. Install the input shaft and output shaft groove ball bearings into the transaxle housing using the DT-48179 handle  (1) and the DT-48226 remover/installer  (2).



61. Install the needle sleeve flush with the casting in the transaxle housing using the DT-48179 handle  (1) and the DT-48182 remover/installer  (2).

Caution: Refer to Fastener Caution in the Preface section.




62. 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).



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



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

•	Install the DT-48232 protector and the input shaft retainer plug.

•	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.

•	Install the output shaft assembly and the shift fork.

•	After checking the gears engagement, install each the shaft assembly completely.

•	Remove the DT-48232 protector and the input shaft retainer plug.




65. Install the transaxle housing on the clutch housing.

65.1.

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

65.2.

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

65.3.

Install the DT-48231 pusher/puller on the transaxle housing.

•	Tighten the four bolts (1).

•	Screw the spindles into the input and output shaft.

65.4.

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 arrow.

65.5.

Remove the DT-48231 pusher/puller from the transaxle housing.

•	Unscrew the spindles into the input and output shaft.

•	Remove the four bolts (1).





Note: If large forces are necessary when actuating the DT-48231 pusher/puller separate the transaxle housing and the clutch housing again and check positioning of the shaft and shift forks. Repeat operation.

66. Shift the transaxle into 4th and 5th gear using a screwdriver in an upward direction.
67. Install new input and output shaft retainer plugs while holding the transaxle into 4th and 5th gear in an upward direction and tighten.

•	The input shaft retainer plug to 120-130 N·m (89-96 lb ft).

•	The output shaft retainer plug to 120-130 N·m (89-96 lb ft).





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

68. Apply sealant (LOCTITE 5900) 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.

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



70. Install the 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.

71. Remove the clutch housing from the transaxle housing.



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



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



76. Install the shift shaft assembly.

•	Apply sealer (LOCTITE 5203) to the transaxle housing to the gear shift cover mating surface.

•	Position the transaxle into neutral.

•	Install the shift shaft assembly (3).

•	Install the select control lever (2).

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

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




77. Install the differential bearing race and the shim to the transaxle housing using the DT-48179 handle  (1) and the DT-48230 installer  (2).



78. Install the differential bearing race and the shim to the clutch housing using the DT-48179 handle  (1) and the DT-48230 installer  (2).



79. Install the magnet into the transaxle housing.



80. Install the differential into the transaxle housing.



81. Apply sealer (LOCTITE 5203) 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.

82. Install the clutch housing to the transaxle housing.



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



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

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

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



86. Measure the three 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.




87. Place the clutch housing differential bearing race, the differential, the transaxle housing differential bearing race, and the DT-48241 plate  (1) onto the DT-48242 plate  (2).



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



89. Measure the three places on 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.




90. Measure the three places on the DT-48242 plate  (1) using the height gage. (average=C)

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




91. To obtain shim size (1, 2) for transaxle housing shim use the following formula.

S1 (For Both FWD and AWD)=62.92 mm - A - B

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

•	S2 (For FWD)=156.84 mm - C - S1

•	S2 (For AWD)=158.09 mm - C - S1




93. Hold the input shaft with the DT-48225 holder  (1).
94. Draw the Interm shaft into the Interm shaft groove ball bearing with old retainer plug.

Shift the transaxle into any gear.




95. Install the clutch housing to transaxle housing bolts and tighten to 20-25 N·m (15-18 lb ft).
96. 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).
97. Remove the DT-48225 holder .



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



99. Install a new oil pipe into the interm shaft.
100. Install a new interm shaft sealing plug.



101. Install the O-ring concentric slave cylinder.



102. After installing the pipe screw, tighten the concentric slave cylinder retaining bolts to 8-12 N·m (71-106 lb in).
103. Tighten the pipe screw to 16 N·m (12 lb ft).



104. Install the bushing to the concentric slave cylinder pipe.



105. Install the shift control cable bracket, the washer, and the bolts and tighten to 15-20 N·m (11-15 lb ft).
106. Install the transaxle into the vehicle. Refer to Transmission Replacement.