6.1 External Adjustments

External adjustment of the transmission-which includes adjusting the selector shaft detent plunger and the fift gear lockout plunger-may correct shifting problems that are not fully remedied by adjusting the shifting mechanism. These adjustments will also be necessary if the transaxle has been partially or fully disassembled. The selector shaft adjusters are located on the transaxle housing as illustrated in Fig. 6-1. Some later models retain the selector shaft with a bolt; only the 5th gear lockout plunger is adjustable. The adjustments should be made with the transaxle removed, or with the shift linkage removed from the selector shaft.

Fig. 6-1.

Location of selector shaft adjusters. Selector shaft detent plunger 1 with plastic cap, 5th gear lockout plunger 2, and selector shaft lever 3. Inset shows screwdriver being used to remove selector rod.

The selector shaft detent plunger is shown in Fig. 6-2. To adjust, place the transmission in neutral, remove the plastic cap, and loosen the locknut. Turn the adjusting bolt clockwise until the lockring lifts away from the adjusting bolt, then turn the adjusting bolt counterclockwise until the lockring just contacts the adjusting bolt. While holding the adjusting bolt stationary, torque the locknut to 20 Nm (15 ft. lb.). To check the adjustment, hand turn the selector shaft slightly. If the lockring does not lift as soon as the selector shaft is turned, repeat the adjustment. When satisfied with the adjustment, reinstall the plastic cap.

Fig. 6-2.

Cross-section of main selector shaft detent plunger.

The fifth gear lockout plunger is shown in Fig. 6-3. To adjust, place the transmission in neutral, remove the plastic cap, and loosen the locknut. Tighten the adjusting sleeve until the detent just begins to move out. From this position, loosen the adjusting sleeve 1/2 turn, then hold the sleeve stationary and tighten the locknut.

Fig. 6-3.

Cross-section of 5th gear lockout plunger.