Step 3
NOTE:a. Wash all parts.
b. Apply oil to all friction surfaces.
c. Use new roll pins and retaining rings.
Torque Specifications
Transaxle Case
1. Install the oil passage.
Tightening torque: 8-11 N.m (80-115 cm-kg, 60-100 in-lb)
2. Install the new oil seal with the SST.
3. Tap the primary and secondary shaft bearing outer races in until they are fully seated with a suitable pipe.
NOTE: Install the differential bearing outer race and diaphragm springs and adjust shims after adjusting the bearing preload.
Clutch Housing
1. Install the new oil seal (change rod) to clutch housing.
2. Install the change arm, boot and change rod.
NOTE: The boot should be Installed as shown in the image.
3. Install the new roll pin as shown in the image.
NOTE: Roll pin length is 28 mm (1.10 in)
4. Install the baffle plate.
Tightening torque: 10-13 N.m (100-130 cm-kg, 81-113 in-lb)
5. Tap the new oil seal (differential) with the SST.
6. Tap the new oil seal (primary shaft) with a suitable pipe.
7. Tap the differential bearing outer race in until it is fully seated with a suitable pipe.
NOTE: Install the primary and secondary shaft bearing outer races, after adjusting the bearing pre load.
Bearing Preload Adjustment
When any of following parts are replaced, the bearing preload should be checked and adjusted.
1. As shown in the image, put the outer race into the SST.
2. Mount the secondary shaft gear assembly as shown.
3. Install the transaxle case and set the SST.
Tightening torque: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
4. 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.
5. Manually expand the selector for both shafts until the selector no longer turns.
NOTE: Check that each shaft turns smoothly.
6. 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.
7. Select the shim for the shaft gear by referring to the table and selecting the shim which is nearest (on the thick or thin 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: 1.18 mm (0.046 in) 1.18 mm (0.046 in) - 0.70 mm (0.028 in) = 0.48 mm (0.0919 in) [Diaphragm spring]
So the nearest shim to on the thick side) to 0.48 mm (0.019 in) is 0.50 mm (0.020 in).
NOTE: Use a maximum of two shims.
8. Mount the differential assembly, the primary shaft gear assembly and the SST as shown in the image.
9. Adjust the primary shaft preload in the same manner as that of the secondary shaft.
Example: 1.18 mm (0.046 in) 1.18 mm (0.046 in) - 0.70 mm (0.028 in) = 0.48 mm (0.019 in) [Diaphragm spring]
So the nearest shim (on the thin side) to 0.48 mm (0.019 in) is 0.45 mm (0.018 in)
a. Use a maximum of two shims.
b. With the case of H-type MTX, the secondary shaft selector touches the differential gear, so the secondary shaft bearing preload adjustment should be done separately from for the primary shaft and differential assembly.
10. Move the bars and expand the SST until it can no longer be turned, then turn it in the reverse direction until the gap is eliminated.
11. Set the SST.
12. Expand the selector with the bar until preload specification is obtained.
Preload: 1.2-2.6 N.m (12.0-27.0 cm-kg, 10.4-23.4 in-lb)
Spring scale reading: 6.4-13.9 N (648-1458 g, 1.44-3.24 lb)
13. 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.
14. 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.
Rechecking of Bearing Preload
1. Remove the SST and transaxle.
2. Remove the bearing outer races from the transaxle case.
3. Install the primary and secondary adjust shims, diaphragm springs and bearing outer races to the case as shown in the image.
4. Install the differential adjust shim(s) and bearing outer race to the case.
5. Install the primary and secondary bearing outer races to the clutch housing.
6. Install the primary shaft gear assembly and the differential assembly.
7. Install the transaxle case and tighten the specified torque.
Tightening torque: 16-23 N.m (1.6-2.3 m-kg, 12-17 ft-lb)
8. Connect the SST.
9. Check that the preload is within the specified range.
Primary shaft: 0.1-0.25 N.m (1.0-2.5 cm-kg, 0.87-2.17 in-lb)
Differential: 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)
10. Check secondary shaft preload in the same manner as that of the primary shaft.
Secondary shaft: 0.2-0.4 N.m (2.0-4.0 cm-kg, 1.72-3.46 in-lb)