Assembly

CAUTION:
a. Clean each part before installing it.
b. Before installation, coat sliding surfaces of the bearings and gears with transaxle oil.
c. Be sure to use new spring pins and retaining rings.

Differential




1. Install the speedometer drive gear into the gear case.
2. Support the ring gear, and press in the side gear inner race using attachment D (49 G030 338) of the bearing installer.

CAUTION: Press in until there is no gap between the bearing inner race and the gear case.




3. After installing the thrust washer onto the pinion gear, install both into the gear case, and install the pinion shaft.
4. Tap the spring pin into the gear case from the speedometer gear side.




5. After installing thrust washers onto 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.

Primary Shaft Gear




1. After supporting 2nd gear, press on the bearing outer race (engine side) using the body (49 F401 331) and attachment A (49 F401 335A) of the bearing installer.

CAUTION: Press on until there is no gap between the primary shaft and the bearing inner race.




2. Install the clutch hub and 3 synchronizer keys into the clutch hub sleeve (3rd and 4th gears).
3. Fit the hook of the synchronizer key spring into the clutch hub groove for the hook, and install the 3 synchronizer keys so that they are held down.
4. Install 3rd gear onto the shaft gear.




5. Install the synchronizer ring onto the clutch hub assembly.
6. Place the clutch hub assembly so that it faces in the direction shown in the image and press on the shaft gear.

CAUTION: Begin pressing only after confirming that the spline of the shaft gear and the clutch hub are properly positioned, and press until the force applied reaches 19.620 N (4,409 lb).




7. Install the retaining ring, the synchronizer ring, and 4th gear onto the shaft gear in that order.
8. Support 2nd gear using the pulley boss puller (49 0636 145), and press the bearing inner race in using attachment B (49 F401 336B) of the bearing installer.

CAUTION: Press on until there is no gap between the shaft and the bearing inner race.

Secondary Shaft Gear




1. Support the drive gear, and press on the bearing inner race using attachment A (49 F401 335A) of the bearing installer.

CAUTION: Press on until there is no gap between the shaft and the bearing inner race.




2. Install the clutch hub and the 3 synchronizer keys into the clutch hub sleeve (1st and 2nd gears).
3. Fit the hook of the synchronizer key spring into the clutch hub groove for the hook, and install the 3 synchronizer keys so that they are held down
4. Install 1st gear onto the shaft gear.




5. Install the synchronizer ring onto the clutch hub assembly.
6. Place the clutch hub assembly so that it faces in the direction shown in the image and press in the shaft gear.
7. Press the clutch hub assembly onto the shaft gear using attachment A (49 F401 335A) of the bearing installer.

CAUTION: Begin pressing only after confirming that the spline of the shaft gear and the clutch hub are properly positioned, and press until the force applied reaches 19,620 N (4,409 lb).




8. Install the retaining ring, the synchronizer ring, and 2nd gear onto the shaft gear in that order.
9. Support the bearing inner race of the shaft gear using attachment A (49 F401 335A) of the bearing installer.
10. Press 3rd gear onto the shaft gear using the body (49 F401 331) and attachment 6(49 F401 336B) of the bearing installer.

CAUTION:
a. Install 3rd gear so that it faces in the direction shown in the image.
b. Press only after confirming that the spline of the shaft gear and 3rd gear are properly positioned, and press until the force applied reaches 29,430 N (6,614 lb).

11. Install the retaining ring onto the shaft gear.




12. Support the bearing inner race of the shaft gear using attachment A (49 F401 335A) of the bearing installer.
13. Install 4th gear and the bearing inner race onto the shaft gear.
14. The body (49 F401 331) and attachment B (49 F401 336B) of the bearing installer in place on the bearing inner race, and press in the bearing inner race and 4th gear at the same time.

CAUTION:
a. Install 4th gear so that it faces in the direction shown in the image.
b. Begin pressing only after confirming that the spline of the shaft gear and 4th gear are properly aligned, and press in until there is no gap between the shaft and the bearing inner race.

Bearing Preload




Adjust the bearing preload by selecting adjustment shim(s).




1. Install the bearing outer race into the transaxle case. (shims removed).
2. Mount the clutch housing onto the transaxle hanger, and tap the bearing outer races alternately with a hammer handle until the outer races are flush with the end of the clutch housing.
3. Position a piece of pipe (outer diameter 68 mm (2.68 in) or less) against the outer race and tap with a hammer until the end of the outer race contacts the clutch housing.




4. Mount the selectors (for primary (49 F401 382A), for secondary (49 G030 382), and for the differential (49 G030 381) to the corresponding bearing outer race.

CAUTION: Turn the selector to eliminate the gap indicated by the arrow.







5. Mount the differential assembly to the clutch housing, and mount the assembled selector and bearing outer race on the differential.
6. Mount the assembled selector and bearing outer race for primary and for secondary shaft into the clutch housing.
7. Mount both shaft gear assemblies as shown.




8. Mount the transaxle case to the shafts and the differential selector, as shown.




9. Set the collars (49 F401 384) between the transaxle case and the clutch housing, and install the bolt set (49 G030 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.




10. To seat the bearings, mount the bars (49 F401 385) on parts (A) and (B) of the selector, and turn the selector so the gap shown by the arrow in the image is widened.
11. Move the bar by hand until the selector can no longer be turned, and turn it in the reverse direction until the gap is eliminated.




12. Manually expand the selector for both shafts until the selector no longer turns,

CAUTION: Make sure that each shaft gear turns smoothly.




13. Use a thickness gauge to measure the gap in the selector at each shaft gear.

CAUTION: Measure the gap around the entire circumference of the selector.




14. Select an appropriate adjustment shim.
1. The shim to be used at the primary shaft gear side 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 (0.70 mm (0.0276 in) from the largest measured value (A).

Example: (A) = 0.94 mm (0.0370 in) 0.94 mm (0.0370 in) - 0.70 mm (0.0276 in) = 0.24 mm (0.0094 in)

So the nearest shim (on the large side) to 0.24 mm (0.0094 in) is 0.25 mm (0.0098 in).

2. The shim to be used at the secondary shaft gear side should be selected by referring to the table and selecting the shim which is nearest (on the large side) to the largest measured value (A).

Example: (A) = 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 (0.0157 in).

CAUTION: The number of shims to be used must not be more than two.




15. Mount the pre-load adaptor (49 FT01 515A) onto the differential pinion shaft then install the pre-load attachment (49 0180 510B).




16. 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 N.m (5 cm-kg, 4.3 in-lb)
Reading on spring scale: 5 N (0.5 kg, 1.1 lb)




17. Measure the clearance between (A) and (B) with a feeler gauge.




18. Add 0.15 mm (0.0059 in) to the measured clearance and select the combination of shims closest in value to that measurement.
See table for available shim sizes.

CAUTION:
a. Measure the gap around the entire circumference of the selector
b. he number of shims to be used must not be more than three.

19. Remove the bolt set (49 G030 386) and the collars (49 F401 384), and remove the transaxle case. Remove the shaft gears, selectors, and the differential.
20. Remove the bearing outer races for both shafts from the transaxle case.
Leave the differential side bearing outer race in the clutch housing.

Preload with the selected shim(s) installed: 0.8-1.8 N.m (8-18 cm-kg, 6.9-15.6 in-lb)

Clutch Housing




1. Install the drain bolt and washer.
2. Install the reverse lever, and secure it with the reverse lever shaft.

NOTE: Align the shaft with the spring pin coupling hole in the clutch housing.

3. Tap in a new spring pin.




4. Tap in the oil seal (differential side) using the oil seal installer (49 G030 795).
5. Install the bleeder.
6. Install the bleeder cover by using the bolts.
7. Install the oil seal (change rod side).




8. Install the change rod (1), the boot (2), the spring (3), the reverse gate (4), and the selector (5) as shown.




9. After aligning the change rod and spring pin coupling hole in the selector, tap in a new spring pin.




10. Install the pipe (1) and the guide plate (2), and temporarily tighten the bolts.

NOTE: Set the spring as shown.

11. Install the change arm onto the change rod, and secure it with the bolt.
Install the shift control rod and detent ball and spring, and select neutral position.
12. Install the crankshaft lever and the crankshaft lever shaft, and secure the shaft to the housing with the pin.




13. Push and pull the change rod and move the guide plate so that the selector moves smoothly in the groove of the guide plate. And tighten the guide plate mounting bolts.
14. Remove the control rod, ball, spring and the pin and remove the crankshaft lever shaft and the crankshaft lever.
15. Install the funnel and the bearing outer race into the secondary shaft gear bearing bore of the clutch housing.
16. Install the oil seal and the bearing inner race into the primary shaft gear bearing bore of the clutch housing.

Transaxle Case




1. Install the oil passage and tighten the bolt.
2. Install the back-up light switch.
3. Install the selected adjustment shim into the differential side bearing bore of the transaxle case.
4. Tap the bearing outer races with a hammer handle until they are flush with the end of the transaxle case.
5. Tap in the outer races until the edges contact the clutch housing using a piece of pipe (outer diameter 68 mm (2.68 in) or less) and a hammer.




6. Tap in the oil seal using the oil seal installer (49 G030 795).
7. Install the previously selected adjustment shim of the secondary shaft gear side into the secondary shaft gear bearing bore of the transaxle case, and install the bearing outer race.




8. Install the previously selected adjustment shim of the primary shaft gear side into the primary shaft gear bearing bore of the transaxle case, install the diaphragm spring in the direction shown in the image, and install the bearing outer race.

Shift Fork and Shift Rod




1. Install the control lever onto the control rod, align each of the spring pin coupling holes, and tap in new spring pins.
2. Install the shift fork (1st and 2nd gears) and the control end onto the control rod so that they face in the direction shown in the image, align the control end and the spring pin hole in the rod, and tap in the new spring pin.




3. After mounting the shift fork (1st and 2nd gears), the interlock sleeve, and the shift forks (3rd and 4th gears), assemble the parts.

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 preload 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: 36-53 N.m (3.7-5.4 m-kg, 27-39 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: 0.8-1.8 N.m (7.9-18.0 cm-kg, 6.9-15.6 in-lb)
Spring scale reading: 7.8-18 N (0.78-1.83 kg, 1.72-4.03 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 G030 440) to the primary shaft gear.
7. Hook the spring scale to the holder and measure the preload.

Preload: 0.05.0.20 N.m (0.5 2.0 cm-kg, 0.43 1.74 in-lb)
Spring scale reading: 2.0-3.9 N (0.20-0.40 kg, 0.44-0.88 lb)

NOTE: Extend the handle fully and hook the pull scale to the end of the handle.

Transaxle




1. After removing the primary shaft gear, install the primary shaft gear and secondary shaft gear at the same time into the clutch housing as shown.




2. Shift the clutch hub sleeve (secondary shaft gear) to 2nd gear and the clutch hub sleeve (primary shaft gear) to 4th gear.
3. Position the shift fork and shift rod assembly as shown and install the shift fork into each hub sleeve.




4. Insert the spring seat and spring into the reverse lever shaft, mount the steel ball, and place a scraper knife so that it contacts the steel ball.
5. With the edge of the control end against the knife, when the control end is pushed in the direction of the arrow in the image so that the ball goes into the shaft, the rod will at the same time line up with the shift rod coupling hole in the clutch housing.




6. Set each clutch hub sleeve to the neutral position, and tap the shift rod from above so that the steel ball goes into the center groove (of the 3 grooves in the control end).
7. Pull the ball part of the control end forward so that the steel ball goes into the detent in the groove.




8. Fit the crank lever in between the change arm and the control end, and connect the crank lever shaft to the crank lever.
9. Align the pin holes of the crank lever shaft and the clutch housing, and insert the pin.

CAUTION: Use a new O-ring for the crank lever shaft.




10. Install the gate (1) and the shift rod (2), and tighten the gate mounting bolt.

NOTE: The mark (indicated by the arrow in the image) and the gate mounting bolt hole must be in the same direction.




11. Install the reverse idle gear and the reverse idle shaft.
12. Connect the magnet to the clutch housing.
13. Align the end of the interlock sleeve with the control lever indicated by the arrow, and, at the same time, face the reverse idle shaft screw hole in the direction shown in the image.




14. After applying a thin coating of sealant to the contact surfaces of the clutch housing and transmission case, tighten the transaxle case installation bolts to the specified torque.

Tightening torque: 36-53 N.m (3.7-5.4 m-kg, 26.8-39.1 ft-lb)

CAUTION:
a. Apply sealant after cleaning the contact surfaces of the clutch housing and transaxle case.
b. Insert the pre-load adaptor (49 G030 455) into the driveshaft coupling hole. If this is not done, the side gear will turn on the pinion gear within the differential gear case, and it might become necessary to disassemble the transaxle again. Leave this adaptor attached until you are ready to install the driveshaft.

5th Gear and Rear Cover




1. Install the lock bolt (1) and the guide bolt (2), and install the ball spring and the lock bolt (3).

CAUTION: After installation, move the change rod to check that the gear change operation is smooth.




2. Position the primary gear (for 5th gear) on the primary shaft gear in the direction shown in the image.




3. Install the clutch hub and the 3 synchronizer keys to the clutch hub sleeve (5th gear).
4. Insert the hook part of the synchronizer key spring into the groove for the hook in the clutch hub.
5. Install the spring so that the 3 synchronizer keys are secured.




6. After installing the gear sleeve (1) onto the secondary shaft gear, connect the 5th gear (2) and synchronizer ring (3).
7. Install the shift fork to the clutch hub assembly, and install them together as shown.

CAUTION: Install the clutch hub assembly and shift fork so that they face in the direction indicated In the image.




8. Align the shift fork and shift rod spring pin holes, tap in the spring pin (1), and install the stopper plate (2) on top of the clutch hub.




9. After locking the shaft gear using the primary shaft holder (49 G030 440), tighten the primary shaft gear and the secondary shaft gear lock nuts to the specified torque.
10. Remove the shaft holder, and align the lock nuts with the shaft gear groove and crimp them

CAUTION: Shift to 1st or 2nd gear.

Tightening torque: 128-206 N.m (13.0-21.0 m-kg, 94-152 ft-lb)




11. After coating the surface of the transaxle case which faces the rear cover with sealant install the rear cover and tighten the bolts to the specified torque.

Tightening torque: 8-11 N.m (0.8-1.1 m-kg, 69-95 in-lb)

CAUTION: Before coating with sealant, clean the contact surfaces of the rear cover and the transaxle case.

12. Install the speedometer driven gear.

CAUTION: Before installing the driven gear onto the transaxle, connect the transaxle to the engine and supply the necessary amount of transaxle oil.

13. Move the change rod to check the shifting operations and remove the transaxle from the transaxle hanger.