Step 3
NOTE:a. Wash all parts.
b. Apply oil to all friction surfaces.
c. Use new roll pins and retaining rings.
STEP 3
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 pipe against the outer race and tap in with a hammer until it contacts the clutch housing.
3. Put the outer races into the SST as shown in the image.
NOTE: Turn the selector to eliminate the gap indicated by the arrow in the image.
4. Set the differential assembly in the clutch housing, then mount the assembled the SST and bearing outer race on the differential.
Set the assembled selectors and bearing outer races for the primary and secondary shaft in the clutch housing.
Mount the shaft gear assemblies as shown in the image.
NOTE: Install with the collars in the positions shown in the image.
5. Set the SST between the transaxle case and the clutch housing. 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)
6. 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. Move the bar by hand until the selector can no longer be turned, then turn it in the reverse direction until the gap (arrow) is eliminated.
Do this for both selectors.
7. Manually expand both selectors until they no longer turn.
NOTE: Check that each shaft gear still turns smoothly.
8. Use a feeler gauge and measure the gap in the selector for both gears.
NOTE: Measure the gap around the entire circumference of the selector.
9. Select the shim for the shaft gear by referring to the table and selecting the shim which is nearest on the thin or thick side as shown to the value obtained when subtracting the thickness of the diaphragm spring which goes between the shim and the race, from the measurement of the gap in the SST.
Example: 0.94 mm (0.037 in) 0.94 mm (0.037 in) - 0.70 mm (0.028 in) = 0.24 mm (0.009 in) [Diaphragm spring]
Primary shaft (on the thin side): so the nearest shim to 0.24 mm (0.009 in) is 0.20 mm (0.008 in).
Secondary shaft (on the thick side): so the nearest shim to 0.24 mm (0.009 in) is 0.25 mm (0.010 in).
NOTE: Use a maximum of two shims.
10. Mount and install the SST on the differential pinion shaft.
11. Hook a spring scale on the SST and pull the scale to turn the attachment. Adjust the selector with the SST bars until the specified preload is obtained.
Preload: 0.5 N.m (5 cm-kg, 4.3 in-lb)
Reading on spring scale: 5N (0.5 kg, 1.1 lb)
12. Use a feeler gauge to measure the gap in the selector for the differential.
NOTE: Measure the gap around the entire circumference of the selector
13. 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 for available shim sizes.
Example: 0.32 mm (0.013 in) 0.32 mm (0.013 in) + 0.15 mm (0.0059 in) = 0.47 mm (0.019 in).
So the nearest shim (on the thick side) to 0.47 mm (0.019 in) is 0.50 mm (0.020 in).
NOTE: Use a maximum of two shims.
14. Remove the SST and transaxle case.
15. Remove the selectors and the differential.
16. Remove the bearing outer races.
17. Leave the differential side bearing outer race in the clutch housing.
Assembly
1. Install the neutral switch.
2. Install the drain plug.
3. Install the back-up lamp switch.
4. Install the new oil seals with the SST.
5. Install the differential adjust shim(s) and the bearing outer race with a suitable pipe.
6. Install the adjust shims, diaphragm spring, funnel, and bearing outer races.
NOTE: Install the diaphragm spring as shown in the image.
7. Install the bearing outer races with a suitable pipe.
8. Install the new breather.
9. Install the new change rod oil seal.
10. Install the change rod (1), the boot (2), the spring (3), the reverse gate (4), and selector (5), as shown.
11. Install the new roll pin.
12. Install the change arm.
Tightening torque: 12-14 N.m (120-140 cm-kg, 104-122 in-lb)
13. Install the guide plate.
Tightening torque:
(A) 8-11 N.m (80-115 cm-kg, 69-100 in-lb)
(B) 22-33 N.m (2.25-3.35 m-kg, 16-25 ft-lb)
14. Install reverse lever, and reverse lever shaft.
15. Install the new roll pin.
16. Install the speedometer driven gear assembly.
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: 18-26 N.m (1.8-2.7 m-kg, 13.0-18.8 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.
Preload: 1.4-2.0 N.m (14-20 cm-kg, 12.1-17.3 in-lb)
Spring scale reading: 13-20 N (1.3-2.0 kg, 2.9-4.4 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. Hook the spring scale to the holder and 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)