Assembly (Part 1)
With All Wheel DrivePrecaution
1. All O-rings and gaskets must be replaced with the new ones supplied in the overhaul kit.
2. Verify that all parts are completely clean before assembly.
3. Assemble parts within 10 minutes after applying sealant.
Allow all sealant to cure at least 30 minutes after assembly before filling the transaxle with transaxle oil.
4. Bearing outer races and inner races must be replaced as assemblies.
Clutch hub assembly
NOTE:
- Synchronizer ring diameters are as follows.
- Synchronizer key dimensions are as follows.
1. Install the synchronizer key springs in the clutch hub with the hooks in the grooves to hold the three synchronizer keys in place.
2. Align the synchronizer ring grooves with the synchronizer key during assembly.
Transfer Carrier Assembly
1. Assemble in the reverse order of disassembly, referring to Assembly Note.
Assembly note
Bearing inner race (Side bearing)
1. Install the bearing inner race with the SST.
Bearing outer race (Companion flange and drive pinion)
1. Install the rear bearing outer race with a brass drift.
2. Install the front bearing outer race with the SST.
Adjustment of pinion height
1. Adjust the drive pinion height as follows with the SST.
NOTE: Use the spacer that was removed.
2. Assemble the spacer and bearing inner race (drive pinion) onto the SST.
3. Install the drive pinion model into the transfer carrier.
NOTE: Use the nut which was removed.
4. Install the bearing inner race (companion flange), SST, companion flange, washer, and nut.
5. Tighten the nut to the extent that the companion flange can still be turned by hand.
6. Place the SST on the surface plate and set the dial indicator to "Zero".
7. Set the SST atop the gauge block.
8. Place the feeler of the dial indicator so that it contacts where the side bearing is installed in the carrier, and measure the lowest position on the left and right sides.
9. Add the two (left and right) values obtained by the measurements taken in Step 7, and then divide the total by 2.
Specification: 0 mm (0 in.)
NOTE: The spacer thicknesses are available in increments of 0.03 mm (0.001 in.). Select the spacer thickness that is closest to that necessary.
10. If not within specification, adjust the pinion height by selection of a spacer.
Bearing inner race (Drive pinion)
NOTE: Install the spacer selected for the pinion height adjustment, being careful the direction of installation is correct.
1. Install the spacer onto the drive pinion.
NOTE: Press on until the force suddenly increases.
2. Press the bearing inner race on with the SST.
Adjustment of drive pinion preload
1. Install a new collapsible spacer.
2. Install the drive pinion assembly.
3. Apply a light coat of grease to the end face of the companion flange.
CAUTION: Do not install the oil seal.
4. Install the bearing inner race, companion flange and washer, and tighten the locknut.
Tightening torque: 118 - 180 N-m (12 - 18 m-kg, 87 - 130 ft-lb)
5. Turn the companion flange by hand to seat the bearings.
6. Measure the drive pinion preload.
Adjust the preload by tightening the locknut and record the tightening torque.
Preload: 1.0 - 1.6 N-m (10 - 16 cm-kg, 8.7 - 13.9 in-lb)
7. Remove the nut, washer, and companion flange.
8. Tap a new oil seal into the differential carrier with the SST.
9. Install the washer and companion flange, and tighten the locknut to the tightening torque recorded in Step 6.
Adjustment of backlash
1. Mount the differential gear assembly in the carrier.
2. Install the differential bearing caps making sure that the mark on the cap corresponds with the one on the carrier.
3. Loosely tighten the bearing cap bolts.
4. Mark the ring gear at tour points at approx. 90° intervals. Mount a dial indicator to the carrier so that the feeler comes into contact at a right angle with one of the ring gear teeth.
5. Turn both bearing adjusting screws equally with the SST until the backlash is within specifications.
Standard backlash: 0.09 - 0.11 mm (0.0035 - 0.0043 in.)
NOTE: When adjusting the differential bearing preload, care must be taken not to affect the backlash of the drive pinion gear and ring gear.
6. After adjusting the backlash, tighten the adjusting screws equally until the distance between the pilot sections on the bearing caps is as specified.
Specification: 142.137 - 142.200 mm (5.596 - 5.599 in.)
7. Tighten the bearing cap bolts to the specified torque.
Tightening torque: 37 - 52 N-m (3.8 - 5.3 m-kg, 27 - 38 ft-lb)
8. Install and tighten the lock plates onto the bearing caps.
Tightening torque: 18 - 26 N-m (1.8 - 2.6 m-kg, 13 - 19 ft-lb)
Inspection and adjustment of tooth contact
1. Coat both surfaces of 6-8 teeth of the ring gear with a uniformly thin coat of red lead.
2. While moving the ring gear back and forth by hand, rotate the drive pinion several times and check the tooth contact.
3. If the tooth contact is correct, wipe oft the red lead.
4. If it is not correct, adjust the pinion height, and then adjust the backlash.
1. Toe and flank contact
Replace the spacer with a thinner one to move the drive pinion outward.
2. Heel and face contact
Replace the spacer with a thicker one bring the drive pinion inward.
Idler Gear Assembly
1. Assemble in the reverse order of disassembly, referring to Assembly Note.
Assembly note
Bearing Inner race (Joint sleeve side)
1. Install the bearing with the SST.
Bearing inner race (Idler gear side)
1. Install the bearing with the SST.
Front and Center Differential Assembly
1. Assemble in the reverse order of disassembly, referring to Assembly Note.
Side gears, pinion gears
1. Install the side gears and washers, and fix them with the SST.
2. Install a pinion gear and turn it 180°.
NOTE: Do not install the washer at this time.
3. Install the other pinion gear and washer.
4. Turn the pinion gear and washer 150°.
5. install the washer under the opposite pinion gear.
6. Align the pinion shaft holes of the pinion gears with the differential gear case.
Front differential case sleeve
1. Install the front differential case sleeve with a press as shown in the image.
Adjustment of sun gear clearance
1. install the washer (4.3 mm) onto the gear case with the SST.
2. Set a dial indicator onto the gear case and measure the sun gear thrust clearance.
Clearance: 0.1 - 0.3 mm (0.0003 - 0.0118 in.)
3. If the clearance is not within specification, select and install the appropriate washer from the chart.
Bearing inner race (Sun gear side)
1. Install the bearing inner race with the SST.
Adjustment of front differential gear case radial clearance
1. Install the front differential gear case into the ring gear case.
NOTE: Available gear case needle bearing part numbers.
Small G0D0 27 519
Medium G0D0 27 518
Large G0D0 27 517
2. Verify that the medium size gear case needle bearing can be installed.
3. If it cannot, install the small size gear case needle bearing.
4. If the medium size gear case needle bearing can be installed, measure the clearance between the ring gear case and the needle bearing.
5. If the clearance exceeds 0.06 mm (0.002 in.), install the large size gear case needle bearing.
Adjustment of front ring gear clearance
1. Install the washer and front differential gear case.
2. Install the needle bearing and differential lock hub.
3. Measure the clearance between the front ring gear and needle bearing.
Clearance: 0.15 - 0.30 mm (0.0059 - 0.0118 in.)
4. If the clearance is not within specification, select and install the appropriate washer from the chart below.
Bearing inner race (Gear sleeve side)
1. Install the bearing inner race with the SST.
Top Cover Assembly
1. Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Oil seal (Select lever side)
CAUTION: Apply transaxle oil to outer circumference of the oil seal.
1. Install the new oil seal with a suitable pipe.
Oil seal
CAUTION: Apply transaxle oil to the oil seal lip.
1. Install the new oil seal with a suitable pipe.
Springs
CAUTION: Do not confuse the springs when installing.
Boot
CAUTION: Install the boot with the air bleed downward as shown in the image.
1. Install the boot.
Shift lever
1. Install the shift lever as shown in the image.
Secondary Shaft Assembly
1. Assemble in the order shown in the image, referring to Assembly Note.
Bearing Inner race (Secondary shaft end)
1. Install the new bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
1st gear, synchronizer ring (1st) and clutch hub assembly (1st/2nd)
NOTE: Align the synchronizer ring, grooves and clutch housing hub keys when installing.
1. Assemble the 1st gear, synchronizer ring (1st), and clutch hub assembly (1st/2nd), as shown in the image.
2. Press the clutch hub assembly (1st/2nd) on with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
Synchronizer ring (2nd), 2nd gear and secondary 3rd gear
1. Install the synchronizer ring (2nd) and 2nd gear.
2. Install the secondary 3rd gear with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
Secondary 4th gear and bearing inner race
1. Install the secondary 4th gear and new bearing inner race.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
2. Measure the clearance between the 1st gear and differential drive gear.
Clearance: 0.05 - 0.28 mm (0.002 - 0.011 in.)
Maximum: 0.33 mm (0.013 in.)
3. Measure the clearance between the 2nd gear and secondary 3rd gear.
Clearance: 0.175 - 0.455 mm (0.0069 - 0.0179 in.)
Maximum: 0.505 mm (0.0199 in.)
4. If not as specified, reassemble the secondary shaft assembly.
Primary Shaft Assembly
1. Assemble in the order shown in the image, referring to Assembly Note.
Bearing inner race (Primary shaft end)
1. Install the new bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
3rd gear, synchronizer ring (3rd) and clutch hub assembly (3rd/4th)
NOTE:
- The size of the 1st, 2nd, 3rd, and 4th synchronizer rings are the same. Be careful when Installing them. The 2nd gear ring has the larger cut-out as shown in the illustration.
- Align the synchronizer ring grooves and clutch housing hub keys when installing.
1. Install the 3rd gear, synchronizer ring (3rd), and clutch hub assembly (3rd/4th) with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).