5th Gear and 5th/Reverse Synchronizer Replacement

Tools Required
• SA9211T Shaft Protector
• SA9211T-2 5th Gear Remover

Removal Procedure

1. Remove the end cover. Refer to End Cover Replacement .
2. Place the transaxle in 1st gear.
3. Remove the 5th/Reverse fork retainer and discard.
4. Move the 5th/Reverse fork to lock transaxle in 5th gear.
5. Remove the input shaft nut and discard.
6. If required, remove output shaft nut and discard.
7. Remove the reverse cone, thrust washer, and reverse blocker ring.
8. Remove the 5th/Reverse shift fork.





Important

Synchronizer hub and sleeve must be kept together as a match set. Note spline alignment marks (indicated by the arrows) on hub and sleeve (3rd/4th synchronizer shown, 5th/Reverse synchronizer similar). If alignment marks are not visible, put new marks on hub and sleeve before they are separated.

9. Remove the 5th/Reverse synchronizer, 5th/Reverse blocker ring, and 5th drive gear.

• Important

  If the 5th/Reverse hub is press fit on the input shaft:

  Install the SA9211T on the end of the input shaft with counter bore in the shaft protector going over input shaft.
• Install the SA9211T-2 on the input shaft. Engage legs of puller under clutching teeth ring on 5th drive gear and center the forcing screw on shaft protector.
• Tighten the forcing screw to remove 5th drive gear along with 5th/Reverse hub.
• Remove the 5th driven gear, if required.

• Important

  If the 5th driven gear is press fit on the input shaft:

  Install the Shaft Protector SA9211T-3 on the end of the output shaft with counter bore in shaft protector going over output shaft.
• Install the SA9211T-2 on output shaft. Engage legs of the puller under 5th driven gear and center forcing screw on shaft protector.

• Important

  It may be necessary to release the bearing snap-ring and pull the shaft out to provide access for the puller under the 5th driven gear.

  Tighten the forcing screw on the puller to remove 5th driven gear.

Installation Procedure

1. Install the 5th driven gear, if removed.

• Important

  If the 5th driven gear is press fit on the input shaft:

  Place the 5th driven gear on the output shaft engaging the splines.
• Thread the 5th Gear Installer SA9211T-1 onto the output shaft until it is snug.

• Important

  Before installing the 5th Gear Installer SA9211T-1, make sure that the nut is backed off all the way on the forcing screw.

  Tighten the nut on the forcing screw until the 5th driven gear has been seated.
2. Install the 5th gear thrust washer, if removed.




3. Install the 5th gear bearing race, if removed.
4. Install the 5th gear bearing.
5. Install the 5th gear.
6. Install the 5th gear synchronizer blocker ring to 5th gear.
7. Install the 5th gear synchronizer spring to 5th blocker ring.
8. Install the 5th/Reverse hub onto input shaft.

• Important

  Be sure the tabs on blocker ring are aligned with slots on the hub. 3rd/4th synchronizer shown, 5th/Reverse synchronizer similar.

  Important

  If the 5th/Reverse hub is press fit on the input shaft:

  Place the 5th/Reverse hub on input shaft engaging splines.
• 
  
  
  Thread the SA9211T onto input shaft until it is snug.

• Important

  Before installing 5th driven gear installer SA9211T-1, make sure nut is backed off all the way on forcing screw.

  Tighten the nut on forcing screw until 5th/Reverse hub has been seated.
9. Slide the 5th/Reverse fork over 5th/Reverse synchronizer sleeve and install the sleeve onto hub and fork onto shift fork shaft at the same time.

Important

Be sure to align the mark on the sleeve to the mark on the hub indicated by the arrows 3/4 synchronizer shown, 5th/Reverse synchronizer similar.

10. Install the synchronizer spring to reverse blocker ring and install assembly to 5th/Reverse sleeve.




11. Install reverse cone and thrust washer
12. Lock the transaxle in two gears by shifting into 1st gear, and moving 5th/Reverse shift fork into 5th gear at the same time.

Important

Make sure the threads on the input and output shaft are clean and free of dirt and oil. A wire brush may be used to clean the threads.

13. Install a new input shaft nut.
Tighten

Tighten the input shaft clamp nut to 150 N·m (111 lb ft).

14. If removed, install a new output shaft nut.
Tighten

Tighten the output shaft clamp nut to 150 N·m (111 lb ft).

15. Unlock the transaxle by moving the 5th/Reverse and 1-2 shift forks into neutral position.

Important

Always use new retainer clips.

16. Install the 5th/Reverse fork retainer clip.
17. Install the end cover and wheel. Refer to the End Cover Replacement .