For 1990-2009 cars

#### Tools Required

• | J43270 Quill Bearing Seal Protector

• | SA9112T Differential End Play Gage

• | SA9113T Axle Seal Installer

• | SA9118T Quill Bearing Replacer

• | SA9129T Support Fixture

• | SA9172G Ball Detent Handle

• | SA9211T-1Gear Installer

1. Clean the input shaft, quill, bearing and apply a small amount of Loctite 620® Retaining Compound Adhesive (P/N 21005996) or equivalent to the outer diameter of the bearing.

Important: Loctite 620® Retaining Compound Adhesive (P/N 21005996) or equivalent must be applied to the input shaft (quill) bearing prior to pressing it into the clutch housing.

2. Press in the input shaft (quill) bearing using SA9112T .
3. Install the filter and use a small punch to stake filter in place.

Important: Make sure that the anti-rotation slot on the transaxle lubrication funnel, oil baffle plate, lines up with the notch in the clutch housing.

4. Install the transaxle lubrication funnel, oil baffle plate. Make sure it sets flat in the bore.
5. Install the two case-to-housing dowel pins into the clutch housing. A bolt may be used to pull the dowels into the housing.

Notice: The clutch housing must be supported from underneath when pressing out the input shaft roller bearing. If the clutch housing is not supported, the housing may collapse.

6. Install the SA9129T with the Manual Transaxle Adapter Pad 216916 and adjust to housing. After bolting to housing, tighten up the large center screw until adapter pad is snug against the housing.
7. Press in the output shaft (roller) bearing using SA9118T . Bearing surface with marking should face the installer.
8. Install the output shaft bearing retaining ring.
9. Remove the press fixture SA9129T and Manual Transaxle Adapter Pad 216916.
10. Install the transaxle magnet.
11. Install the differential assembly into housing. Lube bearing outer race and lower into housing. If bearing cocks in bore, it may take some working back and forth to seat bearing.
12. Install the Quill Bearing Seal Protector J43270 onto the input shaft end that is inserted into the clutch housing. This is to protect the seal inside the housing from being damaged by the splines of the shaft.
13. Place the housing on wood blocks to allow clearance for the input shaft and Quill Bearing Seal Protector J43270.
14. Install the input and output shafts. Lift shafts and mesh gears together. Lower the shafts together and rotate back and forth to align with differential ring gear and start the output shaft in its bearing. Remove seal protector tool.
15. Tap the reverse idler gear shaft roll pin into reverse idler gear shaft.
16. Install the reverse idler gear assembly on idler shaft and install into clutch housing.
17. Install the reverse shift lever assembly with the reverse idler gear setting in the fork part of the lever.

Important: Clean the bolt threads and holes and apply Loctite 242® Threadlocker P/N 21485277 or equivalent to bolts.

18. Install the two retaining bolts.

Tighten
Tighten the reverse shift lever-to-clutch housing bolts to 14 N·m (10 lb ft).

19. Place the 1st/2nd shift fork into the 1st/2nd synchronizer sleeve and the 3rd/4th fork into the 3rd/4th synchronizer sleeve.
20. Insert the 5th/Reverse actuator rod into the slot in the reverse shift lever.
21. Align the shift fork shaft hole in the shift forks and the 5th/Reverse actuator. Install the shift fork shaft through the forks with shaft retaining ring groove up.

Notice: Carefully align retainer clip to grooves in shift shaft. If the retainer clip is not properly aligned during installation, it will be bent and must be replaced with a new retainer clip. Always use a new retainer clip.

22. Make sure the actuator rod is still in reverse shift lever. Hold 5th/Reverse actuator in position to expose snap ring groove on each end of actuator. Install 5th/Reverse actuator retainer clip.
23. Install the oil trough in pocket of clutch housing next to reverse shift lever.
24. Make sure that the transaxle case and clutch housing surfaces are clean and dry.

Important: The sealant bead path must go completely around the five bolt holes near the differential ring gear.

25. Apply a bead of sealant Loctite 515® Gasket Eliminator Sealant (P/N 21005993) or equivalent, 1 - 3 mm (0.039 - 0.118 in.) wide down the center of the mating flange on the clutch housing as shown.
26. Lubricate the differential and shaft ball bearings, shift fork shaft, and reverse idler shaft.

Important: Before installing the transaxle case, check to make sure the transaxle magnet has been installed, the input and output shaft bearing snap ring grooves are oriented correctly, and the axle seal and axle seal retainer (snap ring) are removed.

27. Lower the transaxle case onto clutch housing. Spread the input and output bearing snap rings to allow the rings to slide over the bearings. Seat the case to the clutch housing.

Important: Clean and lubricate fastener with Saturn Transaxle Fluid. Wipe off excess fluid and install.

28. Install the transaxle case-to-clutch housing bolts and studs. Torque according to sequence shown. Check that shafts spin freely as bolts are being torqued.

Tighten
Tighten the transaxle case-to-clutch housing bolts and studs, in sequence, to 28 N·m (21 lb ft).

29. Install a used shaft nut on input shaft and use a screwdriver to pry the shaft upward to seat the snap rings. Remove nut and repeat the procedure on the output shaft.
30. Using the SA9112T , measure the differential end play on the case side differential bearing. The differential end play is set to zero by using the largest end play gage that will fit between the bearing and the case. Use a selective snap ring of the same thickness.
31. Install the differential selective ring into housing on top of differential ball bearing and make sure it sets into the groove.
32. Apply a light coat of Loctite 515® Gasket Eliminator Sealant (P/N 21005993) or equivalent, to the area of the seal that presses into the case and install left, case side, axle seal using SA9113T and SA9172G .
33. Install the axle seal retainer, snap ring, so retainer opening is easily accessible.
34. Move the two shift forks to lock transaxle in two gears at the same time.
35. Install the 5th driven gear. If 5th driven gear does not easily install onto output shaft, refer to 5th Gear and 5th/Reverse Synchronizer Assembly.

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

• | Place the 5th driven gear on output shaft engaging the splines.

• | Thread the Gear Installer SA9211T-1 onto output shaft until it is snug

| Important: Before installing the SA9211T , make sure nut is backed off all the way on the forcing screw.

• | Tighten the nut on forcing screw until 5th driven gear has been seated.

36. Install the 5th gear thrust washer, if not already installed.
37. Install the 5th gear bearing race, if not already installed.
38. Install the 5th drive gear bearing.
39. Install the 5th drive gear.
40. Install the 5th gear synchronizer blocker ring to 5th gear.
41. Install the 5th gear synchronizer spring to the 5th synchronizer.

Important: When installing the synchronizer hub and sleeve, make sure alignment marks face up.

42. Install the 5th/Reverse hub to input shaft. If the 5th/Reverse hub does easily install onto input shaft refer to the 5th Gear and 5th/Reverse Synchronizer Assembly.

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

• | Place the 5th/Reverse hub on input shaft engaging the splines.

• | Thread the 5th Gear Installer, SA9211T-1 onto input shaft until it is snug.

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

• | Tighten the nut on forcing screw until the 5th/Reverse hub has been seated.

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

43. Slide the 5th/Reverse fork over 5th/Reverse synchronizer sleeve and install sleeve onto hub and fork onto shift fork shaft at the same time.

Important: Be sure tabs on blocker ring are aligned with slots on hub (3rd/4th synchronizer shown, 5th synchronizer similar).

Important: Always use a new retainer clips.

44. Install the 5th/Reverse fork retainer clip.

Important: This may be a one piece or two piece retainer. The manual transaxle service kit contains both. Use the ones that retain the fork the tightest.

45. Install the synchronizer spring to the reverse blocker ring and install the assembly to the 5th/Reverse sleeve.
46. Install the reverse cone and thrust washer.

Important: Always use a new nut.

47. Install the new input shaft nut. Be sure the shaft threads are clean.

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

48. Install new output shaft nut.

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

49. Unlock the shafts by lining up shift forks to neutral gate.
50. Install the shift housing gasket to case.

Tighten
Tighten the shift control housing-to-case bolts to 28 N·m (21 lb ft)

Important: Clean and lubricate the fastener with Saturn Transaxle Fluid. Wipe off excess fluid and install.

51. Before continuing, check to make sure all gears will synchronize.
52. Turn the reverse cone so slots align cone to end cover.
53. Install the end cover gasket.

Important: Clean and lubricate fastener with Saturn Transaxle Fluid. Wipe off excess fluid and install.

54. Install the end cover and bolts using a crisscross pattern.

Tighten
Tighten the end cover-to-case bolts, in crisscross pattern to 12 N·m (9 lb ft)

55. Install the vehicle speed sensor.

Tighten
Tighten the vehicle speed sensor to 26 N·m (19 lb ft)

Important: Clean and lubricate the fastener with Saturn Transaxle Fluid. Wipe off excess fluid and install.

56. Install the transaxle drain plug.

Tighten
Tighten the transaxle drain plug to 30 N·m (22 lb ft).

57. Apply a light coat of Loctite 515® Gasket Eliminator Sealant (P/N 21005993) or equivalent to the area of the seal that presses into the housing and install the right, clutch housing side, axle seal using tool SA9113T .
58. Install the clutch fork stabilizer and ball stud in clutch housing, if removed. The hole for the ball stud is located to the lower left of the output shaft. Torque ball stud.
59. Install the clutch fork retainer to clutch fork.

Tighten
Tighten the clutch fork ball stud to 24 N·m (18 lb ft).

60. Insert the clutch release bearing into clutch fork.

Important: Do not grease the clutch release bearing or bearing quill.

61. Lube the fork pivot with high temperature grease (P/N 21005995) or equivalent and install fork and bearing assembly. Snap the fork retainer over the ball stud.

Notice: Excessive amounts of grease on the input shaft splines can contaminate the clutch disc and cause clutch shudder.

62. Place a light film of high temperature grease P/N 21005995 or equivalent onto input shaft spline.