Case: Adjustments

NOTE: When replacing any of the parts listed in the table illustrated, adjust the bearing preload by selecting and installing the proper adjustment shim(s).









BEARING PRELOAD
1. Install the primary and secondary shaft bearing races into the transaxle case (with the shims removed).
2. Mount the clutch housing onto the transaxle hanger, and set the differential bearing race into the clutch housing. Position a piece of pipe against the bearing race and tap it in until it contacts the clutch housing.





3. Set the bearing races into the Special Service Tools (SSTs) (selector) as shown in the illustration.
4. Turn the selector to eliminate the gap indicated by the arrow.





5. Set the differential assembly into the clutch housing, and set the bearing race and the SST (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 illustration.





6. Set the SST (collars) in the positions shown in the illustration.





7. Install the transaxle case and tighten the SST (bolts) to 38 - 51 Nm (28 - 38 ft. lbs.).





8. To seat the bearings, mount the SST (bars) on parts (A) and (B) of the selectors, and turn the selectors so the gaps are widened. Then turn the SST in the reverse direction until the gaps are eliminated.





9. Manually expand the selector until it no longer turns by hand.
10. Verify that both the primary and secondary shafts turn smoothly.





11. Measure the clearance between the two halves of the SST (selector) around the circumference by using a feeler gauge.





12. Take the maximum reading and determine the shim to be used. Use no more than two shims.

^ Primary shaft adjustment shim select the thinner shim from the table to obtain 0 - 0.05 mm (0 - 0.002 inch). Example: Reading from step 11 = 0.57 mm (0.022 inch). Shim selection range: [0.57 mm (0.022 inch) - 0.05 mm (0.002 inch)] - [0.57 mm (0.022 inch) - 0 mm (0 inch)] = 0.52 mm (0.020 inch) - 0.57 mm (0.022 inch). Shim: 0.55 mm (0.022 inch)

^ Secondary shaft adjustment shim select the thinner shim from the table to obtain 0.03 - 0.08 mm (0.001 - 0.003 inch). Example: Reading from step 11 = 0.57 mm (0.022 inch). Shim selection range: [0.57 mm (0.022 inch) + 0.03 mm (0.001 inch)] - [0.57 mm (0.022 inch) + 0.08 mm (0.003 inch)] = 0.60 mm (0.024 inch) - 0.65 mm (0.026 inch). Shim: 0.60 mm (0.024 inch)





13. Install the SST to the differential.





14. Turn the SST by using a torque wrench. Adjust the SST (selector) with the SST (bars) until 0.5 Nm (4.3 inch lbs.) of preload is obtained.





15. Measure the gap between (A) and (B) around the circumference of the SST (selector) by using a feeler gauge.





16. Add 0.15 mm (0.006 inch) to the measured clearance and select a combination of two shims closest in value to that measurement. Use no more than two shims. Example: 0.32 mm (0.013 inch): 0.32 mm (0.013 inch) + 0.15 mm (0.006 inch) = 0.47 mm (0.019 inch). Nearest shim (on thick side) to 0.47 mm (0.019 inch) is 0.50 mm (0.020 inch).
17. Remove the transaxle case and the SSTs.
18. Remove the selectors, the primary shaft assembly, and the differential.
19. Remove the bearing races.