UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
Component Assembly
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-29
16
SHIFTER FORK ASSEMBLY
1. Install the spring (38) and ball (39) into the shifter fork (37) as shown (Figure 16-48, Page 16-20).
2. Use a No. 1 tip phillips screwdriver to depress the ball and spring while inserting shift rod (36) into the
shifter fork (37). Remove screwdriver when the shift rod is inserted far enough for it to depress the ball
and spring, then continue to insert rod until the ball is positioned in the middle groove on the rod (Fig-
DIFFERENTIAL GEAR CASE ASSEMBLY
1. If the bearings (70 or 71) were removed, press new ones onto the differential gear carrier case (75) and
carrier case cover (78) (Figure 16-48, Page 16-20). See following CAUTION.
∆ CAUTION
• Apply pressure against the inner race of the bearing only. Applying pressure anywhere else will
damage the bearing.
2. Install differential gear (82) into carrier case (75) (Figure 16-48, Page 16-20) as shown (Figure 16-67,
3. Start the differential pin (79) into the carrier case by lightly tapping it in with a plastic or rubber hammer.
Before the pin enters the inside of the carrier case, position the thrust plate (76) and idler gear (80) in
the case and continue tapping the pin through the thrust plate and idler gear as shown (Figure 16-68,
Page 16-29).
4. Position the other thrust plate (76) and idler gear (80) in the carrier case. Continue to drive the pin (79)
through them and the wall of the carrier case until the ends of the pin are flush with the sides of the car-
rier case (Figure 16-69, Page 16-30).
Figure 16-67 Differential Gear
Figure 16-68 Idler Gear
DIFFERENTIAL
GEAR CARRIER
CASE
79
80
76
