UNITIZED TRANSAXLE
Unitized Transaxle Assembly
2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-29
16
GOVERNOR GEAR ASSEMBLY
The governor gear is not assembled before installing it in the unitized transaxle case. The governor gear
shaft is installed into the case and then the rest of the governor gear assembly is installed on the shaft. Pro-
ceed with unitized transaxle assembly.
UNITIZED TRANSAXLE ASSEMBLY
Read DANGER and WARNING on page 16-1.
NOTE: Although the following drawings show the transaxle being assembled in an upright position, laying
the transaxle on its left (driver) side will simplify the assembly process.
1. Make sure both parts of the case are clean and free of any contaminants. Make sure the machined
mating surfaces are free of residue and are not scratched or damaged in any way.
2. Put a light coating of clean transmission oil on the outside edge of the seal to make installation easier.
Press two new oil seals (13 and 22) (Figure 16-34, Page 16-15) into the left (driver) side case. Use an
oil seal installation tool (CCI 1014160) to install a new oil seal (55) (Figure 16-41, Page 16-18) into the
right (passenger side) case. See also Figure 16-66, Page 16-30.
3. Position the governor gear shaft installation tool (CCI 101933101) over the shaft bore in the inside of
the left (driver) side case and insert the governor gear shaft into the tool, long end (from the groove)
first, as shown (Figure 16-67, Page 16-30). Make sure the shaft is started into the bore and then, using
a plastic or rubber hammer, carefully tap the governor gear shaft into the bore until the end being
tapped is flush with the end of the tool. Remove installation tool.
4. Install the washer, governor gear, and sleeve together onto the governor shaft (Figure 16-68, Page 16-
31). Make sure the sleeve is properly positioned within the flyweight brackets of the gear as shown
(Figure 16-69, Page 16-31), and then push them onto the shaft until the gear snaps into the groove on
the shaft.
5. Position the interior washer on the pivot arm, then install the pivot arm and washer into the left (driver
side) case as shown (Figure 16-70, Page 16-31). Install the exterior washer and cotter pin on the pivot
arm outside the case as shown (Figure 16-70, Page 16-31). Bend the legs of the cotter pin.
6. Install the shifter shaft into the left (driver side) case as shown (Figure 16-71, Page 16-31). Then install
the washer and using external snap ring pliers (.070 tip), install retaining ring on the shifter shaft out-
side of the case (Figure 16-71, Page 16-31). Make sure the retaining ring is in the groove of the shaft.
7. Install the gear assemblies into the left (driver side) case.
7.1. Stand the left side case on the mounting plate, then install the differential gear case assembly as
shown (Figure 16-72, Page 16-32). Do not seat the assembly in the bore, but insert it just far
enough that it will not fall out.
7.2. Install the idler gear assembly into case as shown. Do not seat the assembly in the bore, but
insert far enough that it will not fall out. No gears mesh at this time (Figure 16-74, Page 16-32).
7.3. Install the oil guide with the baffle toward the case wall as shown (Figure 16-74, Page 16-32).
Make sure the two tabs on the guide are positioned in the slots in the case.
7.4. Position the shifter fork assembly on the synchronizer gear assembly as shown, and install them
together, bearing end first, into the bore containing the oil guide (Figure 16-75, Page 16-32). Do
not seat the assembly, but make sure the spur gear (40) is meshed with the governor gear (63)
(Figure 16-41, Page 16-18), and the shifter lever (14) (Figure 16-34, Page 16-15) is positioned in
the bracket on the shifter fork. See also Figure 16-76, Page 16-33.
