Chapter 11 Manual Transaxle Problems, Troubleshooting, and Service 237 Copyright by Goodheart-Willcox Co., Inc. Input cluster shaft assembly Mainshaft assembly Main shaft control shaft Allen wrench Set screw Shift fork with manual transaxles function as oil pumps, delivering oil to the shafts as they flex during shifts. To function properly, these washers must be installed as specified. In many transaxles, shaft endplay must be checked before the case halves are reassembled. One method of checking endplay involves using a dial indicator, as on a rear-wheel drive transmission. Figure 11-26 shows another method of checking endplay that involves the use of measuring tools. Adjusting the endplay can be done with adjusting nuts or by installing thrust washers of different thicknesses. Once all internal parts have been installed, the case halves can be reassembled. Always use the proper kind of sealer or gas- ket. Do not substitute gasket material for RTV sealer or replace a gasket with a thicker one. Doing so changes the endplay adjust- ments on the transaxle shafts, and it affects the preload on the tapered roller bearings. Figure 11-27 shows assembly of two case halves. After tightening the case halves, make sure the transaxle shafts turn properly. Check shaft endplay once the transaxle is reassembled. If the transaxle uses a separate housing for the internal shift linkage, install it now. Figure 11-28 shows a typical housing. Be careful to align the shift levers and forks before tightening the bolts. Then, check that the linkage operates properly. Install the input shaft, if it was not already installed, and install its bearing housing assembly. Also, install and tighten any outer housings, such as the extension housings sometimes used to hold the seals at the CV axles, Figure 11-29. Make sure the transaxle input and output shafts turn without binding. If the shafts do not turn freely, you must find the problem and correct it. Caution: Do not install a transaxle with binding shafts without correcting the problem. The transaxle will be damaged within the first few minutes of operation. Carefully position each part Double-check part locations Bearing height gauge Depth gauge Figure 11-26. Endplay and other adjustments are critical on manual transaxles. Always take measurements according to the directions given in the service manual and correct conditions that are not to specification. Figure 11-24. Some transaxle shaft components must be reas- sembled with the shaft installed in the case. You should always recheck part positions before completing reassembly. Figure 11-25. The shift forks must be carefully reinstalled to pre- vent shifting difficulties. It is possible to inadvertently install a shift fork upside down. Consult the service manual if you have any doubts. Figure 11-23. Shift forks and rails and input and output shaft gear assemblies are lowered into position as a unit. Be sure to align all parts before installation. (Ford)