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21 - 10 TRANSAXLE |
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Fig. 12 A-523/A-543/A-568 Shift Forks and Shift Rail Components
Fig. 13 Interlock Shuttles |
Fig. 14 Interlock Plate |
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CAUTION: Before removing the gearshift housing, reverse the lock pin (so the long end is down) and insert lock pin into the same threaded hole. This procedure will save time when the gearshift housing assembly is reinstalled.
Fig. 15 Gearshift Housing Bolts
Fig. 16 Gearshift Housing Removed
To install gearshift housing, be sure to reverse the lock pin in the housing to lock the selector shaft in the 3-4 neutral position.
CAUTION: Install roller detents so roller and slots are parallel with shift rails.
Remove or install 3-4 lug roll pin, 3-4 fork roll pin, and reverse lug roll pin using the above procedure.
CAUTION: If any roll pin falls out, retrieve roll pin from bottom of case.
TRANSAXLE 21 - 11
Fig. 17 Remove Roller Detents
Fig. 18 Remove 1-2 shift Lug Roll Pin
Fig. 19 Install 1-2 Shift Lug Roll Pin
21 - 12 TRANSAXLE |
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Fig. 20 Remove 1-2 Shift Fork Roll Pin |
Fig. 23 5th Shift Rail and Shift Lug |
Fig. 21 Reverse Pivot Lever
Fig. 24 5th Shift Lug with Interlock Pin
Fig. 22 5th Shift Rail C-Clip
Fig. 25 5th Shift Lug Properly Installed
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TRANSAXLE 21 - 13 |
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Fig. 26 Reverse Shift Rail and Shift Lug |
Fig. 29 Remove or Install Large Snap Ring |
Fig. 27 3-4 Shift Rail and Shift Lug |
Fig. 30 Pry Bearing Retainer Plate to Remove |
CAUTION: Pry only at slot as shown (Fig. 30). |
Fig. 28 1-2 Shift Rail and Shift Lug
Fig. 31 Bearing Support Plate
21 - 14 TRANSAXLE |
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Fig. 32 Remove or Install Reverse Idler Gear |
Fig. 35 Gear Set |
CLUTCH RELEASE BEARING |
Fig. 33 Reverse Idler Gear Assembly
Fig. 1 Remove Retaining E-Clip
Fig. 34 Remove or Install Gear Set
Fig. 2 Remove or Install Clutch Release Shaft
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TRANSAXLE 21 - 15 |
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Fig. 6 Install New Input Shaft Seal
Fig. 3 Clutch Release Shaft Components
REVERSE SHIFT LEVER
INPUT SHAFT OIL SEAL
Fig. 7 Remove or Install Reverse Shift Lever E-Clip
Fig. 4 Remove or Install Input Shaft Seal Retainer
Fig. 5 Input Shaft Seal Retainer |
Fig. 8 Reverse Shift Lever Components |
21 - 16 TRANSAXLE
SUBASSEMBLY-RECONDITION
TRANSAXLE CASE
Fig. 1 Remove Input Shaft Front Bearing Cup
Fig. 2 Install Input Shaft Front Bearing Cup
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Fig. 4 Remove Intermediate Shaft Front Bearing
Use Tool C-4660-2A Screw. The screw has a larger hole in the lower end to fit over the larger oil feeder nipple (Fig. 5).
Fig. 5 Oil Feeder
Fig. 3 Remove or Install Bearing Retaining Strap
Fig. 6 Install Intermediate Shaft Front Bearing
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INTERMEDIATE SHAFT ASSEMBLY
Fig. 1 Intermediate Shaft Bearing Snap Ring
Fig. 2 Remove Intermediate Shaft Rear Bearing
Intermediate shaft ball bearing seal color:
A-525/A-523/A-543 Black, A-568 Blue.
TRANSAXLE 21 - 17
When assembling intermediate shaft, make sure all speed gears turn freely.
Fig. 4 3-4 Synchronizer Hub Snap Ring
Fig. 5 Remove 3-4 Synchronizer Hub and 3rd Speed Gear
Fig. 3 Install Intermediate Shaft Rear Bearing |
Fig. 6 Install 3-4 Synchronizer Hub and 3rd Speed |
Gear |
21 - 18 TRANSAXLE |
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Fig. 7 Snap Ring and Split Thrust Washer
CAUTION: Index snap ring 90 degrees to the split in the thrust washer, as shown above.
1-2 SYNCHRONIZER (DUAL-CONE)
Fig. 1 2nd Speed Gear
Fig. 3 1st Speed Gear and 1-2 Synchronizer Assembly
Fig. 4 Split Thrust Washer
Fig. 2 1-2 Synchronizer Hub Snap Ring
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TRANSAXLE 21 - 19 |
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Fig. 5 Intermediate Shaft Assembly
SYNCHRONIZERS
Fig. 1 1-2 and 3-4 Synchronizer Sleeves and Hubs
21 - 20 TRANSAXLE |
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Fig. 2 5th Speed Synchronizer
Fig. 3 Synchronizer Identification
CAUTION: 1-2 synchronizer assembly components must NOT be interchanged with any other synchronizer assembly, or with previous model years transaxles; they will NOT function correctly.
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TRANSAXLE 21 - 21 |
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Fig. 4 Synchronizers
GEARSHIFT HOUSING
Fig. 1 Gearshift Housing Disassembled
21 - 22 TRANSAXLE |
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Fig. 2 Remove or Install Roll Pin and Lever |
Fig. 5 Install Oil Seal |
Roll pin must be flush with top of lever.
The C-Clip groves in the selector shaft will damage the oil seal. Install oil seal after selector shaft is installed. Always use a new oil seal when selector shaft is removed.
Fig. 3 Dust Boot
Fig. 6 Remove Vent Cap
Fig. 4 Remove Oil Seal
Fig. 7 Crossover Shaft Roll Pin
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TRANSAXLE 21 - 23 |
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Fig. 8 5-R Blocker Attaching Bolts
Proper torque to the 5-R blocker attaching bolts is very important (Fig. 8).
Fig. 9 5-R Blocker Assembly
Fig. 10 Crossover Shaft
Fig. 11 Selector Shaft C-Clip
For Disassembly: Drive roll pin out far enough to clear the selector shaft, but pin must remain in the selector so not to break the housing.
Fig. 12 Selector Shaft C-Clip
Fig. 13 Selector Assembly Roll Pin
21 - 24 TRANSAXLE |
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Fig. 14 Remove or Install Selector Shaft |
Fig. 2 Install Differential Bearing Retainer Seal |
Fig. 15 Disassembled View
Fig. 3 Remove Differential Bearing Retainer Cup
DIFFERENTIAL BEARING RETAINER
Fig. 4 Differential Bearing Retainer
Fig. 1 Remove Differential Bearing Retainer Seal
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TRANSAXLE 21 - 25 |
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Fig. 5 Install Oil Baffle |
Fig. 2 Install New Seal into Extension |
Fig. 6 Insert (Select) Shim and Differential Bearing |
Fig. 3 Remove Extension Bearing Cup |
Retainer Cup |
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EXTENSION HOUSING |
Fig. 4 Extension
Fig. 1 Remove Extension Seal
21 - 26 TRANSAXLE |
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Fig. 5 Install Extension Oil Baffle
Fig. 6 Install Extension Bearing Cup
INPUT SHAFT
Shim thickness need only be determined if any of the following parts are replaced:
²Transaxle case
²Input shaft seal retainer
²Bearing retainer plate
²Rear end cover
²Input shaft
²Input shaft bearings
Refer to Bearing Adjustment Procedure in rear of this section to determine proper shim thickness for correct bearing end play and proper turning torque.
Fig. 1 Remove Input Shaft Rear Bearing Cone
Fig. 2 Install Input Shaft Rear Bearing Cone
Fig. 3 Remove Input Shaft Front Bearing Cone
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TRANSAXLE 21 - 27 |
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A-523, A-543 DIFFERENTIAL |
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Shim thickness need only be determined if any of |
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the following parts are replaced: |
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² Transaxle case |
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² Differential bearing retainer |
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² Extension housing |
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² Differential case |
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² Differential bearings |
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Refer to Bearing Adjustment Procedure in rear |
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of this section to determine proper shim thickness for |
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correct bearing preload and proper bearing turning |
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torque. |
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Fig. 4 Install Input Shaft Front Bearing Cone
Fig. 1 Remove Differential Bearing Cone
Fig. 5 Remove Input Shaft Rear Bearing Cup
CAUTION: Bolt on bearing support plate before installing input shaft rear bearing cup.
Fig. 2 Install Differential Bearing Cone
Fig. 6 Install Input Shaft Rear Bearing Cup