UNITIZED TRANSAXLE
Component Assembly
Page 16-24 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual
16
Idler Shaft Assembly, Continued:
∆ CAUTION
• Apply pressure against the inner race of the bearing only. Applying pressure anywhere else will
damage the bearing.
INTERMEDIATE GEAR ASSEMBLY
1. If the gear (58) was removed from the shaft, install the key (57) into the slot and then position the gear
on the shaft with keyway properly aligned with key. Press gear into place on the key (Figure 16-41,
Page 16-18).
2. Press the bearing (59) onto the end of the shaft next to the large gear that was installed in step one
(Figure 16-41, Page 16-18). See preceding CAUTION.
3. Press a new bearing (38) onto the other end of the shaft (Figure 16-41, Page 16-18).
SYNCHRONIZER GEAR ASSEMBLY
1. Press the synchronizer sleeve (47) onto the splines of the input shaft (51) (Figure 16-41, Page 16-18).
No particular orientation of the sleeve is necessary, but toward the short end of the shaft, the machined
circular face surrounding the ends of the internal splines in the sleeve must be flush with the machined
lip of the shaft at the ends of the shaft splines (Figure 16-55, Page 16-25).
2. Install the synchronizer springs (46) (Figure 16-41, Page 16-18) in the sleeve as shown (Figure 16-56,
NOTE: Make sure the ends of the springs are positioned between the synchronizer insert slots (Figure 16-
3. Install the three synchronizer inserts (48) into the slots in the sleeve (Figure 16-41, Page 16-18). Make
sure the notched surfaces of the inserts are facing outward as shown (Figure 16-57, Page 16-26).
4. Install the synchronizer clutch hub (49) (Figure 16-41, Page 16-18) 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 16-58, Page 16-26).
Figure 16-53 Synchro. Ring
Figure 16-54 Idler Shaft
Synchro ring must be
replaced when (x)
distance is less than
.02 inch (0.5 mm).
X
Press bearing
onto idler shaft.
Turn idler shaft
over and press
bearing on
other end.
B
A
