UNITIZED TRANSAXLE
Unitized Transaxle Assembly
2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 16-33
16
Unitized Transaxle Assembly, Continued:
11.2. Apply a continuous bead of Three Bond No. 1215 (CCI 101928701) around the opening on the
mating surface of the right (passenger) side axle tube as shown (Figure 16-81, Page 16-34).
Then position the axle tube on the right side of the transaxle case as shown and install seven
mounting bolts (77) with lock washers (78) (Figure 16-5, Page 16-4) finger tight. In the sequence
shown, tighten the bolts to 36 ft-lb (48.8 N·m) (Figure 16-82, Page 16-35).
11.3. Duplicate step 11.2 for the left (driver) side axle tube.
11.4. If previously removed, install left and right brake cluster assemblies to the axle tubes. See Sec-
tion 6 – Wheel Brake Assemblies.
11.5. Install the right (passenger side) axle shaft (68) in the right axle tube (76) (Figure 16-5, Page 16-
4). Using 90° angle (.90 tip) snap ring pliers, install the retaining ring as shown (Figure 16-83,
Page 16-35).
11.6. Place a 1/4 to 3/8 inch (6-10 mm) diameter rod against the retaining ring and tap lightly at four to
five locations to ensure it is properly seated. See following WARNING.
∆ WARNING
• Be sure the retaining ring is properly seated in its groove. If the ring is not properly installed,
the axle assembly will separate from the transaxle and damage the axle assembly and other
components. Loss of vehicle control could result in severe personal injury or death.
Figure 16-76 Gear Alignment
Figure 16-77 Gear Alignment
As you insert the synchronizer gear
assembly (complete with shifter fork)
into the casing, several gears
must mesh together.
Large idler
gear and
synchronizer
gear mesh.
Spur gear and
governor gear
mesh.
Shifter arm and the
shifter fork slotted
arm also mesh.
SHIFTER
FORK
The small gear on the
intermediate gear
assembly meshes with
the differential ring gear.
DIFFERENTIAL
RING GEAR
SYNCHRONIZER
INPUT DRIVE GEAR
SMALL IDLER GEAR
Several gears mesh
as you insert the
intermediate gear
assembly.
(These three gears mesh.)
LARGE
INTERMEDIATE
GEAR
