Differential

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 on the side bearing inner race using SST.

NOTE: Press on until there is no gap between the bearing and the gear case.




3. Install the thrust washer onto the pinion gear, then 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. Support 2nd gear, then press on the bearing outer race (engine side) using the SST.

NOTE: Press on until there is no gap between the primary shaft and the bearing.




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.

NOTE: Install the clutch hub sleeve as shown.

CAUTION: Begin pressing only after confirming that the splines 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. Install the 2nd gear using the SST.

NOTE: Press on until there is no gap between the shaft and the bearing.




Secondary Shaft Gear
1. Support the drive gear, and press on the bearing inner race using SST.

NOTE: Press on until there is no gap between the shaft and the bearing.




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.

NOTE: The styles and size of the synchronizer rings are different as shown in the illustration.




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 SST.

NOTE: Begin pressing only after confirming that the splines 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 SST.
10. Press 3rd gear onto the shaft gear using the body (49 F401 331) and attachment B (49 F401 336B) of the bearing installer.

NOTE:
a. Install 3rd gear so that it faces in the direction shown in the image.
b. Press only after confirming that the splines 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 SST.
13. Install 4th gear and the bearing inner race onto the shaft gear.
14. Position the SST in place on the bearing inner race, and press on the bearing inner race and 4th gear at the same time.

NOTE:
a. Install 4th gear so that it faces in the direction shown in the image.
b. Begin pressing only after confirming that the splines 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 through the use of adjust shim(s).







1. Install the primary and secondary bearing outer races into the transaxle case (shims removed).
2. Mount the clutch housing on the transaxle hanger, and install the differential bearing outer race with brass drift until it is flush with the clutch housing.
3. Position a piece of pipe [outer diameter 68 mm (2.68 in) or less] against the differential bearing outer race and tap with a hammer until it contacts the clutch housing.







4. Install the outer races into the SST.
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 SST between the transaxle case and the clutch housing, then install the SST and tighten to the specified torque.

Tightening torque: 18-20 N.m (1.8-2.0 m-kg, 13-14 ft-lb)





NOTE: Install the collars at the positions shown in the image.




10. To seat the bearings, mount the SST 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 without the bars for both shafts until the selector no longer turns.

NOTE: Make sure that each shaft gear turns smoothly.




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

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

14. Select an appropriate adjust 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 thin 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 (0.037 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 thin side) to 0.24 mm (0.0094 in) is 0.20 mm (0.0079 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 thin side) to the value obtained by subtracting the thickness of the diaphragm spring [0.70 mm (0.0276 in)] from the largest measured value (B).




Example:
(B) = 0.94 mm (0.037 in)
0.94 mm (0.037 in) - 0.70 mm (0.0276 in) = 0.24 mm (0.0094 in)
So the nearest shim (on the thick side) to 0.24 mm (0.0094 in) is 0.25 mm (0.0098 in).

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

15. Install the SST.




16. Adjust the selector with the SST until the preload specification is obtained.

Preload: 0.5 N.m (5 cm-kg, 4.3 in-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 the table below for available shim sizes.

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




19. Remove the SST, 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.




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 SST.
5. Install the bleeder.
6. Install the bleeder cover.
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. Align the change rod and spring pin coupling hole in the selector, then 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 grooves of the guide plate. Then tighten the guide plate mounting bolts.
14. Remove the control rod, ball, spring and pin. 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 adjust 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 SST.
7. install the previously selected adjust 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 shims and the diaphragm springs in the direction shown in the image, and install the bearing outer races.

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. Assemble the shift fork (1st and 2nd gears), the interlock sleeve and the shift fork (3rd and 4th gears).

NOTE: The dot on the interlock sleeve must face towards the 3rd and the shift fork.

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. Install the SST.
4. Measure the preload.

Preload: 1.4-2.0 N.m (14-20 cm-kg, 12.2-17.5 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, 0.87-2.18 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: 18-26 N.m (1.8-2.7 m-kg, 13.0-18.8 ft-lb)

10. Check the secondary shaft preload with the SST.

Preload: 0.2-0.4 N.m (2.0-4.0 m-kg, 1.7-3.4 in-lb)




1. Remove the transaxle case and shaft gears.
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, install 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. Apply a thin coat 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: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)

CAUTION:
a. Apply sealant after cleaning the contact surfaces of the clutch housing and transaxle case.
b. Insert the preload 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 inserted until installation of 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.

Tightening torque:
1. 18-26 N.m (1.8-2.6 m-kg, 13-19 ft-lb)
2. 9-14 N.m (90-140 cm-kg, 78-162 in-lb)
3. 15-21 N.m (150-210 cm-kg, 173-242 in-lb)




2. Position the secondary 5th gear on the secondary 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. Install the gear sleeve onto the primary shaft gear, then connect the 5th gear and synchronizer ring.
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, and install the synchronizer ring and the reverse synchronizer gears.




9. Lock the shaft gear using the SST, then tighten the primary shaft gear and the secondary shaft gear lock nuts to the specified torque.
10. Remove the shaft holder, then stake the lock nut to the groove.

CAUTION: Shift to 1st or 2nd gear.

Tightening torque: 128-196 N.m (13.0-20.0 m-kg, 94-145 ft-lb)




11. Coat the surface of the transaxle case which faces the rear cover with sealant, then 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. Temporarily install the speedometer driven gear.

CAUTION: Before tightening the driven gear into 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, then remove the transaxle from the transaxle hanger.