Step 4
ASSEMBLY-STEP 4
Assemble in the sequence shown in the image.
Bearing preload
Adjust the bearing preload by selecting and installing the proper adjust shim (s).
1. Install the primary and secondary shaft bearing outer races into the transaxle case (shims removed).
2. After mounting the clutch housing onto the transaxle hanger, tap in the differential bearing outer race with a hammer handle until it is flush with the end of the clutch housing.
Next, position a piece of piece of pipe against the outer race and tap in with a hammer until it contacts the clutch housing.
Primary and Secondary Shaft Gear
1. As shown in the image, put the outer races into the SST.
NOTE: Turn the selector to eliminate the gap indicated by the arrow in the image.
2. Set the SST in place.
3. Mount the primary and secondary shaft gear assemblies to the SST.
4. Set the SST between the transaxle case and the clutch housing, and install the SST, and tighten to the specified torque.
Tightening torque: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
5. To seat the bearings, mount the SST on parts (A) and (B) of the selector, and then turn the selector so the gap 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 is eliminated.
6. Manually expand the selector for both shafts until the selector no longer turns.
NOTE: Make sure that each shaft turns smoothly.
7. Use a thickness gauge to measure the gap of the selector for both gears.
NOTE: Measure the gap around the entire circumference of the selector.
8. Select an appropriate adjustment shim.
1. The shim to be used for the primary shaft gear should be selected by referring to the image and selecting the shim which is nearest (on the thin 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 thin side) to 0.24 mm (0.009 in) is 0.20 mm (0.008 in).
The shim to be used for the secondary shaft gear should be selected by referring to the image and selecting the shim which is nearest (on the thick 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 thick side) to 0.24 mm (0.009 in) is 0.25 mm (0.010 in).
NOTE: The number of shims used must not be more than two.
10. Remove the SST and then remove the transaxle case, shaft gears and selectors.
11. Remove the bearing outer races for both shafts from the transaxle case.
Center Differential
1. Install the center differential and bearing outer race.
2. Set the SST in place.
3. Set the SST between the transaxle case and the clutch housing, and install the SST, and tighten to the specified torque.
Tightening torque: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
4. To seat bearings turn the SST so the gap is widened.
5. Insert the SST.
6. Expand the SST until preload specification is obtained.
Preload: 0.3-1.2 N.m (3-12 kg-cm, 2.6-10.4 in-lb)
7. Use a thickness gauge to measure the gap in the selector for both gears.
NOTE: Measure the gap around the entire circumference of the selector.
8. Select an appropriate adjustment shim to be used for the differential. It should be selected by referring to the image and selecting the shim which is nearest (on thick side) to the largest measured value of the gap in the selector.
Example: 0.54 mm (0.021 in)
So the nearest shim (on thick side) to 0.54 mm (0.021 in) is 0.6 mm (0.014 in).
NOTE: The number of shims to be used must not be more than three.
9. Remove the SST and then remove transaxle case.
10. Remove the selector, bearing outer race and front and center differential.
Oil Seal
Tap the new oil seals into the transaxle case and clutch housing with the SST.
Bearing Outer Race
1. Install the selected adjustment shims and the diaphragm springs into the transaxle case.
NOTE: 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.
Baffle Plate and Oil Passage
1. Install the baffle plate and oil passage.
Tightening torque: 7.9-10.8 N.m (0.8-1.1 m-kg 5.79-7.96 ft-lb)
Base Plate Assembly
1. Install the base plate spring and base plate.
Tightening torque: 18.6-25.5 N.m (1.9-2.6 m-kg 13.74-18.81 ft-lb)
2. Install the crank lever shaft and crank lever.
3. Install the spring pin.
4. Install the inner shift lever to shift lever assembly and then install them to crank lever assembly.
5. Install the spring pin.
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 center differential assembly 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. Connect the SST and install it through the driveshaft hole.
4. Hook a spring scale to the attachment and measure the preload.
NOTE: Extend the handle fully and hook the pull scale to the end of the handle.
Preload: 1.4-2.0 N.m (14-20 cm-kg, 12.2-17.5 in-lb)
5. Remove the SST.
6. Connect the SST to the primary shaft gear.
7. Check the primary shaft preload.
Preload: 0.10-0.25 N.m (1.0-2.5 cm-kg, 0.87-2.18 in-lb)
8. Remove the SST, transaxle case, primary shaft gear and center differential assembly.
9. Install the secondary shaft gear and transaxle case then tighten to the specified torque.
Tightening torque: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
10. Check the secondary shaft preload with the SST.
Preload: 0.2-0.4 N.m (2.0-4.0 cm-kg, 1.7-3.5 in-lb)
11. Remove the SST, transaxle case and secondary shaft gear.