Manual Transaxle-Wagon
Notea. Wash all parts.
b. Apply oil to all friction surfaces.
C. Use new spring pins and retaining rings.
DIFFERENTIAL
Assemble in the numbered order shown in the image.
Side Bearing Inner Race
Install the side bearing inner race by the attachment (49 F401 337A) supplied with bearing installer set (49 F401 330B) and press, as shown in the image.
Note Press to 19,620N (2,000 kg, 4,400 lb)
Side Gear and Pinion Gear
After installing thrust washers on the side gears, place the two side gears into the gear case at the same time, turn them back on the pinion gear and install them into the gear case.
Note The pinion gears and pinion shaft hole must be aligned.
Knock-pin
After installing the knock pin, make a crimp so that the pin can not come out of the gear case.
Backlash of Side Gear and Pinion Gear
Check and adjust by the following procedures:
1. Install the left and right driveshafts on the differential assembly.
2. Support the driveshafts on V-blocks, as shown in the image.
3. Measure the backlash of both pinion gears.
Standard backlash: 0-0.1 mm (0-0.004 in)
4. If the backlash is more than the standard, adjust by selecting a thrust washer from the table to go between the case and side gears.
Note Use thrust washers with the same thickness on each side as much as possible.
ASSEMBLY-STEP 1
Assemble in the numbered order shown in the image.
Clutch Hub Assembly
Install the synchronizer key-spring in the clutch hub by placing the hook in its groove. This holds the three synchronizer keys in place.
Caution
a. The synchronizer keys for the 5th gear are to be installed in one direction.
b. The size of each synchronizer key is different.
Specification are as follows:
c. When assembling the clutch hub for fifth and reverse gear, the larger end of the synchronizer key must face the lock nut.
Bearing Inner Race (drive pinion end of secondary shaft gear)
Install the drive pinion end inner race on the secondary shaft gear with attachment (49 F401 335A) and a press, as shown in the image.
1st Gear Synchronizer Ring
The 1st synchronizer ring is different from the other synchronizer rings
Clutch Hub Assembly (1st - 2nd, 3rd - 4th)
Press the secondary shaft into the clutch hub assemblies (1st - 2nd and 3rd - 4th).
Note Make sure the hub and shaft splines are aligned before applying pressure. Press to 19,620N (2,000 kg, 4,400 lb)
Thrust Washer
Install the thrust washer tangs into the holes in the groove.
Bearing Inner Race (4th gear end of secondary shaft gear)
Press the inner race on the end of the secondary shaft with body (49 F401 331) and attachment (49 F401 336A).
Note Press to 19,620N (2,000 kg, 4,400 lb)
Thrust Clearance of 1st Gear
Measure the clearance between the 1st gear and the differential drive gear on the secondary shaft.
Standard: 0.14-0.37 mm (0.006-0.015 in)
Limit: 0.42 mm (0.017 in)
Thrust Clearance of 2nd Gear
Measure the clearance between the 2nd gear and the thrust washer.
Standard: 0.245-0.580 mm (0.010-0.023 in)
Limit: 0.63 mm (0.025 in)
Thrust Clearance of 3rd Gear
Measure the clearance between the 3rd gear and the thrust washer.
Standard: 0.095-0.38 mm (0.004-0.015 in)
Limit: 0.43 mm (0.017 in)
Thrust Clearance of 4th Gear
Measure the clearance between the 4th gear and the bearing inner race.
Standard: 0.09-0.4 mm (0.004-0.016 in)
Limit: 0.45 mm (0.018 in)
Bearing Inner Race (primary shaft)
Press the inner race on the end of the primary shaft (4th gear end) with body (49 F401 331) and attachment (49 F401 336A).
Press the inner race on the opposite end of the primary shaft (1st gear end) with body (49 F401 331) and attachment (49 F401 335A).
Shift Fork
Install both shift forks and the interlock sleeve, as in the image.
Bearing preload
Adjust the bearing preload by selecting adjustment shim(s).
1. Install the bearing outer race into the transaxle case (shims removed).
2. After mounting the clutch housing onto the transaxle hanger, tap in the differential bearing outer races with a hammer handle until it is flush with the end of 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. As shown in the image, put the outer races into the selectors for primary (49 F401 383), for secondary (49 F401 382A).
Caution Turn the selector to eliminate the gap indicated by the arrow in the image.
4. Set the differential assembly into the clutch housing, and then mount the assembled selector (49 F401 381) and bearing outer race on the differential.
Mount the assembled selectors and bearing outer races for the primary and secondary shaft into the clutch housing.
Mount both shaft gear assemblies as shown in the image.
5. Mount the transaxle case to the shafts and the differential selector, as shown in the image.
6. Set the collars (49 F401 384) between the transaxle case and the clutch housing, and install the bolts (49 F401 386), and tighten to the specified torque.
Tightening torque: 18-20 N.m (1.8-2.0 m-kg, 13-14 ft-lb)
Caution Install the collars at the positions shown in the image.
7. To seat the bearings, mount the bars (49 F401 385) on parts (A) and (B) of the selector, and then turn the selector so the gap shown by the arrow in the image is widened.
Move the bar by hand until the selector can no longer be turned, and then turn it in the reverse direction until the gap (arrow) is eliminated.
8. Manually expand the selector for both shafts until the selector no longer turns.
Caution Make sure that each shaft gear turns smoothly.
9. Use a thickness gauge to measure the gap in the selector for both gears.
Caution Measure the gap around the entire circumference of the selector.
10. Select an appropriate adjustment shim.
1. The shim to be used for the primary shaft gear should be selected by referring to the table and selecting the shim which is nearest (on the large side) to the value obtained, by subtracting the thickness of the diaphragm spring which goes between the shim and the race, from the measured value of the gap in the selector.
Example: 0.94 mm (0.0370 in) 0.94 mm (0.0370 in) - 0.70 mm (0.0276 in) [Diaphragm spring] = 0.24 mm (0.009 in)
So the nearest shim (on the large side) to 0.24 mm (0.009 in) is 0.25 mm (0.010 in).
2. The shim to be used for the secondary shaft gear should be selected by referring to the table and selecting the shim which is nearest (on the large side) to the measured value of the gap in the selector.
Example: 0.39 mm (0.0154 in)
So the nearest shim (on the large side) to 0.39 mm (0.0154 in) is 0.40 mm (0.016 in).
Caution The number of shims to be used must not be more than two.
11. Mount the preload adaptor (49 FT01 515A) onto the differential pinion shaft and then install the preload attachment (49 0180 510B).
12. Hook a spring scale on the preload attachment (49 0180 510B), and pull the scale to turn the attachment. Adjust the selector with the bars (49 F401 385) until the preload specification is obtained.
Preload: 0.5-0.75 N.m (5-7.6 cm-kg, 4.3-6.6 in-lb)
Reading on spring scale: 5-7.5 N (0.5-0.76 kg, 1.1-1.7 lb)
13. Use a thickness gauge to measure the gap in the selector for the differential.
Caution Measure the gap around the entire circumference of the selector
14. Select an appropriate adjustment shim to be used for the differential. It should be selected by referring to the table and selecting the shim which is nearest (on the large side) to the largest measured value of the gap in the selector.
Example: 0.54 mm (0.021 in)
So the nearest shim (on the large side) to 0.54 mm (0.021 in) is 0.55 mm (0.022 in).
Caution The number of shims to be used must not be more than three.
15. Remove the bolts (49 F401 386) and the collars (49 F401 384), and then remove the transaxle case. Remove the shaft gears, selectors, and the differential.
16. Remove the bearing outer races for both shafts from the transaxle case.
0Leave the differential side bearing outer race in the clutch housing.
ASSEMBLY-STEP 2
Assemble in the numbered order shown in the image.
Oil Seal (differential)
Tap the differential oil seals into the transaxle case with the oil seal installer (49 B001 795).
Bearing Outer Race
1. Install the selected adjustment shims and the diaphragm spring into the transaxle case.
Caution Install the diaphragm spring as shown in the image.
2. Install the bearing outer races into the transaxle case and clutch housing.
3. Use a suitable pipe and a hammer to tap the outer races in until they are seated.
ASSEMBLY-STEP 3
Assemble in the numbered order shown in the image.
Bearing Preload
Check the primary shaft gear and the differential bearing preload.
Note
a. Confirm that the correct adjustment shims were selected.
b. If the bearing pre load is not within the standard range, adjust again.
1. Install the primary shaft gear and the differential into the clutch housing.
2. Install the transaxle case, and tighten to the specified torque.
Tightening torque: 19-26 N.m (1.9-2.6 m-kg, 13-19 ft-lb)
3. Connect the preload attachment (49 0180 510B) to the preload adaptor (49 FT01 515A), and install it through the driveshaft hole.
4. Hook a spring scale to the attachment and measure the preload.
Preload: 0.03-0.75 N.m (0.3-7.6 cm-kg, 0.26-6.6 in-lb)
Spring scale reading: 0.3-7.5 N (0.03-0.76 kg, 0.07-1.67 lb)
5. Remove the adaptor and the attachment.
6. With the transaxle facing in the direction shown in the image, install the primary shaft holder (49 F401 440) to the primary shaft gear.
Hook the spring scale to the holder and measure the preload.
Preload: 0.10-0.34 N.m (1.0-3.5 cm-kg, 0.87-3.0 in-lb)
Spring scale reading: 0.54-1.84 N (54-190 g, 0.12-0.41 lb)
Note Extend the handle fully and hook the pull scale to the end of the handle.
Shaft Gear and Shift Fork Assembly
Install the primary shaft gear, secondary shaft gear, and shift fork assembly according to the following procedures:
1. Install the shift fork assembly on the secondary shaft gear assembly.
Note Be careful of the rod direction.
2. Assemble the control end, ball, spring, and crank lever to the clutch housing as shown in the image.
Caution Be careful not to lose the ball and spring.
3. Install the differential assembly.
4. Unite the primary shaft gear, secondary shaft gear and shift fork assembly. Install the control rod into the control end as the unit is lowered into place.
Note Keep the assembly nearly vertical while installing it.
5. Align the holes in the control rod and the control end.
6. Tap the spring pin in with a pin punch and hammer.
Gate (4 speed)
Raise the reverse lever and install the gate in its groove and guide pin.
Shift Rod (5th and reverse)
When installing the shift rod (5th and reverse), make sure that the alignment mark on the rod is in the correct position.
Interlock Sleeve and Reverse Idle Shaft
Before installing the transaxle case, make sure the control lever (arrow) is kept flush with the surface of the end of the interlock sleeve. Point the threaded hole of the reverse idle shaft toward the alignment mark of the clutch housing.
Sealant
Coat sealant sparingly onto the mating surfaces of the case and housing, and the case and rear cover.
Lock Nut (primary gear)
Lock the shaft with the primary shaft holder (49 F401 440) before tightening the locknut. Use a new locknut and tighten it to the specified torque. Stake the locknut to the groove in the primary shaft.
Tightening torque: 128-206 N.m (13-21 m-kg, 94-152 ft-lb)
Shift Fork (5th gear)
Install the shift fork together with the clutch hub assembly.
Lock Nut (5th clutch hub)
Put the transaxle in 1st or 2nd gear and lock the primary shaft with the primary shaft holder (49 F401 440) and tighten the locknut on the secondary shaft to the specified torque. Stake the locknut to the groove in the secondary shaft.
Tightening torque: 128-206 N.m (13-21 m-kg, 94-152 ft-lb)
5th Gear End Play
Measure the width of both the gear sleeve and the 5th gear.
The 5 the gear end play equals the difference between the gear sleeve and the 5th gear.
Standard: 0.15-0.262 mm (0.006-0.010 in)
Limit: 0.31 mm (0.012 in)