Assembly
Precaution1. All O-rings and gasket must be replaced with the new ones included in the overhaul kit.
2. Before assembly, make sure all parts are completely clean.
3. Assemble the 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. If the clutch housing or transaxle case is replaced, adjust the bearing preload of the shaft gears and the preload of the differential side bearings.
5. If the bearing inner races are replaced, assemble new bearing outer races.
Step 1 (Differential)
1. Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Speedometer drive gear and Side bearing inner race
Install the speedometer drive gear and the new bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
Side bearing Inner race
Install the new bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
Pinion gears and pinion shaft
1. Install the thrust washers and pinion gears.
2. Install the pinion shaft.
Roll pin and aide gears
1. Install the roll pin, then crimp it so that it cannot come out of the gear case.
2. Install the thrust washers and the side gears.
Backlash of aide gear and pinion gear
1. Install the left and right driveshafts in the differential assembly.
2. Support the driveshafts on V-blocks as shown in the image.
3. Measure the backlash of both pinion gears.
4. If not, reassemble the differential assembly.
Backlash: 0-0.1 mm (0-0.004 in)
Step 2
1. Clutch hub
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer spring
5. Primary shaft
6. Bearing inner race
7. Primary 3rd gear
8. Synchronizer ring
9. Clutch hub assembly (3rd and 4th gear)
10. Retaining ring
11. Synchronizer ring
12. Primary 4th gear
13. Bearing inner race
14. Clutch hub
15. Synchronizer key
16. Clutch hub sleeve
17. Synchronizer spring
18. Secondary shaft
19. Bearing inner race
20. Secondary 1st gear
21. Synchronizer ring
22. Clutch hub assembly
23. Retaining ring
24. Synchronizer ring
25. Secondary 2nd gear
26. Secondary 3rd gear
27. Retaining ring
28. Secondary 4th gear
29. Bearing inner race
30. Control rod
31. Control lever
32. Roll pin
33. Shift fork (1st and 2nd gears)
34. Control end
35. Roll pin
36. Interlock sleeve
37. Shift fork (3rd and 4th gears)
1. Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Clutch hub
Install the synchronizer key spring in the clutch hub with the hook in the groove. This holds the three synchronizer keys in place.
NOTE: The sizes of the synchronizer keys are different.
Primary Shaft Gear
Bearing Inner race
Install the new bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
Primary 3rd gear, synchronizer ring and clutch hub assembly
Install the primary 3rd gear, synchronizer ring, and clutch hub assembly with the SST.
NOTE:
- Press to 19,620 N (2,000 kg, 4,400 lb).
- Align the synchronizer ring groove and clutch housing hub key when installing.
Synchronizer ring, primary 4th gear and bearing inner race
1. Install the synchronizer ring, primary 4th gear, and bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
2. Measure the clearance between the primary 3rd gear and primary 2nd gear.
Clearance: 0.05-0.20 mm (0.0020-0.0079 in)
Maximum: 0.25 mm (0.0098 in)
3. Measure the clearance between the primary 4th gear and bearing inner race.
Clearance: 0.165-0.365 mm (0.0065-0.0144 in)
Maximum: 0.415 mm (0.0163 in)
Bearing inner race
Install the new bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
NOTE: The size of the 1st, 2nd, and 3rd/4th synchronizer rings is the same. Be careful when installing them. The 2nd ring has the larger cut-out as shown in the illustration.
Secondary Shaft Gear
Secondary 1st gear, synchronizer ring and clutch hub assembly
1. Assemble the secondary 1st gear, synchronizer ring, and clutch hub assembly (reverse gear), as shown in the image.
NOTE: Align the synchronizer ring, groove and clutch housing hub key when installing.
2. Press on the clutch hub assembly (reverse gear) with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
Synchronizer ring, secondary 2nd gear and secondary 3rd gear
1. Install the synchronizer ring and secondary 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 bearing inner race.
2. Measure the clearance between the secondary 1st gear and differential drive gear.
Clearance: 0.050-0.280 mm (0.0020-0.0110 in)
Maximum: 0.33 mm (0.0130 in)
3. Measure the clearance between the secondary 2nd gear and secondary 3rd gear.
Clearance: 0.175-0.455 mm (0.0069-0.0179 in)
Maximum: 0.505 mm (0.0199 in)
Interlock sleeve
Install both shift forks and the interlock sleeve, as in the image.
Step 3
1. Select the adjust shim(s), referring to Adjustment of Bearing Preload.
2. Assemble in the order shown in the image, referring to Assembly Note.
Bearing Preload Adjustment
Adjust the bearing preload by selecting adjust shim(s).
1. Install the primary and secondary shaft bearing outer races into the transaxle case (diaphragm springs and shims removed).
2. After mounting the clutch housing onto the transaxle hanger, and set the differential bearing outer race into 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. Assemble the outer races into the SST (selector) 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 onto the clutch housing, then mount the bearing outer race and the selector on the differential.
Set the assembled selectors for the primary and secondary shaft in the clutch housing.
Mount the shaft gear assemblies as shown in the image.
5. Set the SST (collars) in the positions shown in the image.
Install the transaxle case then tighten the SST (bolts) to the specified torque.
Tightening torque: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
6. To seat the bearings, mount the SST (bars) on parts (A) and (B) of the selector, and then turn the selector so the gap is widened.
Then turn it in the reverse direction until the gap is eliminated.
7. Manually expand the selector until the selector no longer turns by hand.
NOTE: Check that each shaft turns smoothly.
8. Use a feeler gauge and measure the gap in the selector.
NOTE: Measure the gap around the entire circumference of the selector.
9. Take the maximum reading and determine the shim to be used as follows:
< Primary shaft adjust shim >
- Subtract the diaphragm spring thickness (0.70 mm [0.0276 in]) from the gap determined in Step 8.
- Select the closest thicker shim from the table.
Example 1.2 mm (0.0480 in)-0.70 mm (0.0276 in) = 0.52 mm(0.0205 in)
Shim: 0.50 mm (0.020 in)
< Secondary shaft adjust shim >
- Subtract the diaphragm spring thickness (0.70 mm [0.0276 in]) from the gap determined in Step 10.
- Select the closest thicker shim from the table.
Example 1.22 mm (0.0480 in)-0.70 mm (0.0276 in) = 0.52 mm (0.0205 in)
Shim: 0.55 mm (0.022 in)
NOTE Use a maximum of two shims.
10. Install the SST.
11. Adjust the selector with the SST until the specified preload is obtained.
Preload: 0.5 N.m (5 cm-kg, 4.3 in-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 (0.006 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, the primary shaft assembly and the differential.
16. Remove the bearing outer races.
Assembly note
Oil seals
Install the new oil seals with the SST.
Adjust shims, diaphragm spring, and bearing outer races
Install the adjust shims, diaphragm spring, and bearing outer races.
NOTE: Install the diaphragm spring as shown in the image.
Change rod, boot, spring, reverse gate, and selector
NOTE: install the boot with the air bleed downward as shown in the image.
Install the change rod (1) the boot (2), the spring (3), the reverse gate (4), and selector (5), as shown.
Rechecking of bearing preload
Check the shaft gears and the differential bearing preload.
NOTE
- Check that the correct adjust shims were selected.
- 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. 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, 12.2-17.4 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, 0.87-2.17 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: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)
Step 4
1. Clutch hub
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer spring
5. Ring gear and differential assembly
6. Secondary shaft gear assembly
7. Primary shaft gear assembly
8. Spring
9. Steel ball
10. Shift fork and shift rod assembly
11. Crank lever assembly
12. O-ring
13. Crank lever shaft
14. Pin
16. Shift rod (5th/Rev.) and clip
17. Reverse idler gear
18. Reverse idler shaft
19. Magnet
20. Clutch housing
21. Transaxle case assembly
22. Secondary 5th gear
23. Gear sleeve
24. Primary 5th gear
25. Synchronizer ring
26. Clutch hub assembly
27. Shift fork
28. Roll pin
29. Secondary reverse synchronizer gear
30. Primary reverse synchronizer gear
31. Locknut
32. Locknut
33. Rear cover
1. Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Primary shaft gear assembly and Secondary shaft gear assembly
Install the primary shaft gear assembly and the secondary shaft gear assembly together.
Shift fork and Shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod assembly as shown.
2. 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.
3. 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.
4. 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).
5. Pull the ball part of the control end forward so that the steel ball goes into the detent in the groove.
Crank lever assembly and Crank lever shaft
1. Fit the crank lever in between the change arm and the control end, and connect the crank lever shaft to the crank lever.
2. Align the pin holes of the crank lever shaft and the clutch housing, and insert the pin.
NOTE: Use a new O-ring for the crank lever shaft.
Shift rod end and Shift rod
Install the shift rod end (1) and the shift rod (2), and tighten the shift rod end mounting bolt.
NOTE: The mark (indicated by the arrow in the image) and the shift rod end mounting bolt hole must be in the same direction.
Reverse idle gear and Reverse idle shaft
1. Install the reverse idle gear and the reverse idle shaft.
2. Connect the magnet to the clutch housing.
3. 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.
Clutch housing and Transaxle case
1. Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case, tighten the transaxle case installation bolts to the specified torque.
2. Insert the SST to driveshaft coupling hole.
Secondary 5th gear
Install the secondary 5th gear as shown.
Clutch hub assembly and Shift fork
Install the clutch hub assembly and the shift fork together.
Locknut
1. Shift to 1st gear.
2. Lock the primary shaft with the SST.
3. Tighten new locknuts.
Tightening torque: 128-196 N.m (13.0-20.0 m-kg, 94-145 ft-lb)
4. Stake the locknuts.