Assembly

ASSEMBLY
Transaxle








Assembly
1. Clean and check all parts carefully before reassembly.
- Apply Manual transmission fluid to all running surfaces.





2. Using the special tool, install the output shaft roller bearing and bearing cone.
1. Install the oil thrower.
2. Drive in the roller bearing as far as stop.





3. Using the special tool, install the differential bearing cone.





4. Install the selector rod with the locking plate.
1. Install the shift selector interlock plate.
2. Install the fifth and reverse gear selector rod.





5. Install the reverse idle gear.





6. Install the differential and the permanent magnet.





7. Install the fifth and reverse gear selector shaft and shift locking bush.
1. Shift selector interlock plate
2. Fifth and reverse gear selector shaft





8. NOTE: Installation position for the reverse gear idler.

Install the reverse gear idler, the differential and the permanent magnet.
1. Reverse gear idler
2. Differential
3. Permanent magnet





9. Prepare the input and the output shaft for installation.
1. Engage the input shaft and the output shaft.
2. Position the first and second gear selector fork.
3. Position the third and fourth gear selector fork.





10. Install the input shaft and the output shaft.
- Install a rubber band to the selector shaft to aid assembly.
- Insert the input shaft to a depth of approximately 50 mm and swivel it slightly to the side.
- Insert the output shaft to the level of the input shaft and engage the gearwheels.
- Position the input shaft and the output shaft.





11. NOTE: Install a new snap ring.

Install the selector shaft guide sleeve.
1. Push in the guide sleeve.
2. Install the lower snap ring.





12. NOTE: Install a new snap ring.

Install the selector shaft guide sleeve upper snap ring.
1. Pull up the guide sleeve.
2. Install the upper snap ring.





13. Move the inner gearshift linkage to fifth gear. Turn the selector shaft clockwise until the reverse and fifth gear passage is reached, then press downwards.





14. Install the measuring shim and secure with a blow from a punch.
1. Transaxle housing
2. Measuring shim (3.8 mm thick)
3. Bearing cone





15. NOTE: Thoroughly clean the mating face.

Using the special tool, assemble the transaxle housing.





16. Install the special tools.
- Remove the special tool 308-152.





17. Prepare the differential for measuring.
- Turn the differential at least ten times to settle the bearings.
- Install the special tools and"zero" the dial indicator.





18. NOTE: Carry out the previous steps three times and calculate the average measurement.

Measure the differential end float.
1. Using the special tools, raise the differential.
2. Read off the measurement.
- Example:
- 1 measurement: 0.73 mm
- 2 measurement:0.74 mm
- 3 measurement: 0.72 mm
- Average = 0.73 mm + 0.74 mm + 0.72 mm /3 = 0.73 mm.
- The washer thickness to be determined should be rounded down to 0.05 mm and below, and rounded up from 0.06 mm and above.
- The adjusting shims are available from 0.1 mm to 1.1 mm in steps of 0.1 mm.





19. Determine the adjusting shim to be installed (example).
- Thickness of adjusting shim -
- Measuring shims (3.80 mm) +
- Average value (0.73 mm) +
- Bearing preload (0.14 mm)
- Thickness of the Belleville washers (4.42 mm) = 3.80 mm + 0.73 mm + 0.14 mm - 4.42 mm = 0.25 mm.
- The thickness of the adjusting shim should be 0.25 mm, which is rounded down to 0.20 mm.
20. Separate the transmission housing sections.
- Remove the special tools.





21. Remove the bearing cone and measuring shim.





22. NOTE: The inner diameters of the Belleville washers are touching.

Install the adjusting shim determined and secure with a blow from a punch.
1. Belleville washers.
2. Appropriate adjusting shim.
3. Install the bearing cone and secure it with a punch mark on the edge of the housing.





23. Apply Sealant transaxle housing to the transaxle housing evenly.





24. NOTE: Tighten the stud connections to 33 Nm.

Assemble the transaxle housing and tighten the bolts evenly.





25. NOTE: Use a wooden block.

NOTE: Install new snap rings.

Install the input shaft and the output shaft snap rings.





26. NOTE: Turn the snap rings so that they are located in the cut-outs in the gasket. Install the gasket.

Install the special tools.





27. NOTE: Install new retaining bolts.

Install the fifth gear housing.





28. CAUTION: Remove the transaxle from the special tool 307-003 and carry out the following step on a press.

NOTE: Install an anti-twist stop for the selector rod.

NOTE: The transaxle housing must not rest on the press table. Support the input shaft clutch splines on the press.

Using the special tool and a press, install the fifth gear wheel onto the input shaft.
- Install the transaxle to special tool 307-003.





29. CAUTION: Select the new snap ring with a minimum of clearance.

Using the special tool, install the fifth gear wheel snap ring.
1. Install the snap ring onto the special tool.
2. Install the special tool and push on the snap ring.





30. NOTE: Identification of gear synchronizer installation position.

Assemble the fifth gear synchronizer unit.
1. Gear wheel (fifth gear).
2. Synchronizer ring.
3. Gear synchronizer.
4. Retaining plate.





31. NOTE: Install a new retaining bolt.

NOTE: Install a new retaining ring.

Install the fifth gear synchronizer unit with selector fork.
- Install the securing bolt.
- Install a new retaining ring.





32. Apply end cap sealer evenly to the end cap.





33. Install the fifth gear cover.





34. NOTE: Only perform the installation in neutral.

Installation position for selector shaft interlock.





35. NOTE: Only perform the installation in neutral.

Install the selector interlock mechanisms. Apply Universal sealant (Hylomar) to the thread.





36. Install the lever. Install the gaiter.





37. Using the special tool, install the input shaft oil seal until it engages audibly.





38. Engage fifth gear.
- Turn the selector shaft clockwise as far as possible and press it in.





39. Install the special tools.





40. Install the selector cable bracket.





41. NOTE: Install a new snap ring.

Install the selector lever.
1. Install the snap ring.
2. Install the protective cap.





42. Install the shift cable cover.





43. Install the Vehicle Speed Sensor (VSS).
1. Connect the VSS.
2. Install the retaining pin.





44. Install the input shaft oil seal and the clutch slave cylinder.
1. Position the input shaft oil seal.
2. Position the clutch slave cylinder.
3. Tighten the bolts evenly.
45. Remove the transaxle from the stand.