Here's the feedback I provided to Calmini after my installation. They seemed receptive to my ideas, but I do not know if they edited their instructions:
"1. Tool list would be helpful. I imagine many customers may need to buy, rent or borrow. Fortunately, I had everything needed, including a bearing press. Although I admit I broke my light-duty retaining ring pliers and had to add to my Snap-on collection to complete the job.
2. The equipment list should include "Factory Shop Manual" since the first step is to remove the transmission using those directions. I would add one comment to the shop manual directions. It says the remove the extension housing and transfer case in one step. It is not clear that the extension housing must be entirely removed first to reveal the one last transfer case bolt, the only one that goes entirely through the front case casting instead of just through the flange. I started to try to separate the case (your step 4) with this one bolt still in. Recognizing there is little or no sealant here led me to realize I had missed a bolt pretty quickly.
3. Mention the friction ring (your step 5 or 34). I was left at step 34 wondering if there was some reason it was omitted with your cluster gear installation. I decided to re-install it (P/N 29133-60A00), which was successful, but I am not absolutely certain I put it back the right way around. A picture would be good here. Speaking of which, it would be helpful to show the orientation of the thrust washers. I understand their function so I properly got the groves facing the cluster gear, but everybody might not know that.
4. Note that the clutch sleeve and three lobe clutch hub DO have a rotational orientation with respect to each other (7D-14). Your step 19 makes no notice of this. Or the fact that the sleeve is not symmetrical and should not be installed wrong way around, although one would soon notice.
5. Consider including the retainer rings in the kit. I slightly twisted the smaller one removing it (those flimsy snap ring pliers). I was able to flatten it out again, but would have preferred to use a new one.
6. The warning in step 36 is appreciated, but the phrase "opposite, not just reverse" confused me. Perhaps a sentence describing that the "larger reduction gear requires that the cluster be positioned first, and the shaft be slid into place (step 33), so the thrust washer detent must be painstakingly inserted..." would have sped up my understanding.
7. Speaking of which, I have great success with a dab of grease on the end of a tube. I used a short piece of brake line rather than a rod. You might include a plastic soda straw or something similar with the kit, or at least mention this idea to help direct the customer's scavenging about their garage
8. By the way, step 46 shows two switches, 4WD and LOW. My X-90 only has 4WD. Don't know if some models of Sidekick are also missing LOW switch, but if so, your directions should make note of it."
