Step 3
NOTEa. Wash all parts.
b. Apply oil to all friction surfaces.
c. Use new roll pins.
Torque Specifications
Bearing Preload
Adjust the bearing preload by selecting adjust shim(s).
1. Install the primary and secondary shaft bearing outer races into the transaxle case (diaphragm springs and shims removed).
2. After mounting the clutch housing onto the transaxle hanger, and set the differential bearing outer race into the clutch housing.
Next, position a piece of pipe against the outer race and tap in with a hammer until it contacts the clutch housing.
3. Assemble the outer races into the SST (selector) as shown in the image.
NOTE: Turn the selector to eliminate the gap indicated by the arrow in the image.
4. Set the differential assembly onto the clutch housing, then mount the bearing outer race and the selector on the differential.
Set the assembled selectors for the primary and secondary shaft in the clutch housing.
Mount the shaft gear assemblies as shown in the image.
5. Set the SST (collars) in the positions shown in the image.
Install the transaxle case then tighten the SST (bolts) to the specified torque.
Tightening torque: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
6. To seat the bearings, mount the SST (bars) on parts (A) and (B) of the selector, and then turn the selector so the gap is widened.
Then turn it in the reverse direction until the gap is eliminated.
7. Manually expand the selector until the selector no longer turns by hand.
NOTE: Check that each shaft turns smoothly.
8. Use a feeler gauge and measure the gap in the selector.
NOTE: Measure the gap around the entire circumference of the selector.
9. Take the maximum reading and determine the shim to be used as follows:
< Primary shaft adjust shim >
- Subtract the diaphragm spring thickness (0.70 mm, 0.0276 in) from the gap determined in the step 8.
- Select the closest thinner shim from the table.
Example 1.22 mm (0.0480 in) - 0.70 mm (0.0276 in) = 0.52 mm (0.0204 in)
Shim: 0.50 mm (0.020 in)
< Secondary shaft adjust shim >
- Subtract the diaphragm spring thickness (0.70 mm, 0.0276 in) from the gap determined in the step 10.
- Select the closest thinner shim from the table.
Example 1.22 mm (0.0480 in) - 0.70 mm (0.0276 in) = 0.52 mm (0.0204 in)
Shim: 0.55 mm (0.022 in)
NOTE: Use a maximum of two shims.
10. Install the SST.
11. Adjust the selector with the SST until the specified preload is obtained.
Preload: 0.5 N.m (5 cm-kg, 4.3 in-lb)
12. Use a feeler gauge to measure the gap in the selector for the differential.
NOTE: Measure the gap around the entire circumference of the selector
13. Add 0.15 mm (0.0059 in) to the measured clearance and select the combination of shims closest in value to that measurement.
See the table for available shim sizes.
Example: 0.32 mm (0.013 in) 0.32 mm (0.013 in) + 0.15 mm (0.006 in) = 0.47 mm (0.019 in).
So the nearest shim (on the thick side) to 0.47 mm (0.019 in) is 0.50 mm (0.020 in).
NOTE: Use a maximum of two shims.
14. Remove the SST and transaxle case.
15. Remove the selectors, the primary shaft assembly and the differential.
16. Remove the bearing outer races.
Assembly
1. Install the neutral switch.
2. Install the drain plug.
3. Install the back-up lamp switch.
4. Install the new oil seals with the SST.
5. Install the differential a just shims() an the bearing outer race with a suitable pipe.
6. Install the adjust shims, diaphragm spring, funnel, and bearing outer races.
NOTE: Install the diaphragm spring as shown in the image.
7. Install the bearing outer races with a suitable pipe.
NOTE: Use the approx. 67 mm (2.638 in) O.D. pipe.
8. Install the new breather.
9. Install the new change rod oil seal.
10. Install the change rod (1), the boot (2), the spring (3), the reverse gate (4), and selector (5), as shown.
11. Install the new roll pin.
12. Install the change arm.
Tightening torque: 12-14 N.m (120-140 cm-kg, 104-122 in-lb)
13. Install the guide plate.
Tightening torque:
(A) 8-11 N.m (80-110 cm-kg, 69-95 in-lb)
(B) 22-35 N.m (2.25-3.35 m-kg, 16-26 ft-lb)
14. Install reverse lever, and reverse lever shaft.
15. Install the new roll pin.
16. Install the speedometer driven gear assembly.
Bearing Preload
Check the shaft gears and the differential bearing preload.
NOTE
a. Check that the correct adjust shims were selected.
b. If the bearing preload is not within specification, adjust again.
1. Set the primary shaft gear and the differential into the clutch housing.
2. Install the transaxle case, and tighten to the specified torque.
Tightening torque: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
3. Connect the SST and install it through the driveshaft hole.
4. Hook a spring scale to the attachment and measure the preload.
Preload: 1.4-2.0 N.m (14-20 cm-kg, 12.1-17.3 in-lb)
5. Remove the SST.
6. With the transaxle facing in the direction shown in the image, install the SST to the primary shaft gear.
7. Measure the preload.
Preload: 0.1-0.25 N.m (1.0-2.5 cm-kg, 0.87-2.17 in-lb)
NOTE: Extend the handle fully and hook the pull scale to the end of the handle.
8. Remove the SST, transaxle case, primary shaft gear and differential.
9. Install the secondary shaft gear and transaxle case then tighten to the specified torque.
Tightening torque: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
10. Check the secondary shaft preload with the SST.
Preload: 0.2-0.4 N.m (2.0-4.0 cm-kg, 1.7-3.4 in-lb)