UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
Component Assembly
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-27
16
2. Install the synchronizer springs (49) (Figure 16-48, Page 16-20) in the sleeve as shown (Figure 16-63,
NOTE: Make sure the ends of the springs are positioned between the synchronizer insert slots (Figure 16-
3. Install the three synchronizer inserts (51) into the slots in the sleeve (Figure 16-48, Page 16-20). Make
sure the notched surfaces of the inserts are facing outward as shown (Figure 16-64, Page 16-27).
4. Install the synchronizer clutch hub (52) (Figure 16-48, Page 16-20) onto the synchronizer sleeve.
Make sure the chamfered end of the hub is oriented toward the long end of the input shaft as shown
(Figure 16-65, Page 16-27).
5. On the long end of the shaft, install the synchronizer ring (48) (Figure 16-48, Page 16-20) with the
smooth collar of the ring towards the clutch hub. Make sure the three notches in the collar mate with
the synchronizer inserts in the synchronizer sleeve as shown (Figure 16-66, Page 16-28).
6. Install the thrust washer (44) and two bearings (46) as shown (Figure 16-48, Page 16-20).
Figure 16-62 Synchro. Gear Assembly
Figure 16-63 Synchro. Springs
Figure 16-64 Synchronizer Inserts
Figure 16-65 Synchronizer Clutch Hub
PRESS
RAM
SYNCHRONIZER
SLEEVE
INPUT
SHAFT
MACHINED
FACE OF
SYNCHRO.
SLEEVE
TOP OF SPLINE
Top of spline pressed
level with machined
face.
Install springs
on top and bottom
of synchronizer
sleeve as shown.
Ends
positioned
between
insert slots.
FRONT VIEW
SYNCHRONIZER
INSERT SLOTS
Synchronizer
inserts overlap
springs.
TOP VIEW
Notched
surfaces
of synchro.
inserts face
out.
SPRINGS TOP AND BOTTOM
SIDE VIEW
CHAMFERED ON END
OF CLUTCH HUB
LONG END
OF SHAFT
SYNCHRONIZER
SLEEVE
SYNCHRONIZER
CLUTCH HUB
