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. It the bearing inner races are replaced, assemble new bearing outer races.
Step 1 (Differential)
Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Side bearing inner race
1. Install the speedometer drive gear.
2. Install the new side bearing inner race with the SST.
Side bearing inner race
Install the bearing inner race with the SST.
Roll pin
1. Install the pinion gears and washers.
2. Install the pinion shaft.
3. After installing the roll pin, make a crimp so that the pin cannot come out of the gear case.
Side gears
Install the side gears and washers.
Backlash of side gear and pinion gear
Check and adjust by the following procedure.
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, replace the differential assembly.
Backlash: 0-0.1 mm (0-0.004 in)
Step 2
1. Assemble in the order shown in the image, referring to Assembly Note.
1. Clutch hub Installation
2. Synchronizer key Installation
3. Clutch hub sleeve
4. Synchronizer key spring
5. Primary shaft
6. Bearing inner race Installation
7. Needle bearing
8. Primary 3rd gear Installation
9. Synchronizer ring Installation
10. Clutch hub assembly (3rd/4th)
11. Synchronizer ring
12. Ball
13. Gear sleeve
14. Needle bearing
15. Primary 4th gear
16. Bearing inner race
17. Clutch hub
18. Synchronizer key
19. Clutch hub sleeve
20. Synchronizer key spring
21. Secondary shaft
22. Bearing inner race
23. Thrust washer
24. Needle bearing
25. Secondary 1st gear
26. Synchronizer ring
27. Clutch hub assembly (1st/2nd)
28. Synchronizer ring
29. Ball
30. Gear sleeve
31. Needle bearing
32. Secondary 2nd gear
33. Secondary 3rd gear
34. Gear sleeve
35. Secondary 4th gear
36. Bearing inner race
Standard Dimension:
Assembly note
Synchronizer key
NOTE: There are two (2) types of synchronizer key.
NOTE: The styles and sizes of synchronizer rings are different as shown in the image.
Synchronizer ring and clutch hub assembly
NOTE: Align the synchronizer ring groove and clutch hub key when Installing.
Primary shaft gear
Synchronizer ring, 3rd gear and clutch hub assembly
1. Install the needle bearing and the primary 3rd gear.
NOTE: Apply transaxle oil to the needle bearing.
2. Install the synchronizer ring and clutch hub assembly with the SST.
Standard Dimension::
Synchronizer ring, 4th gear and bearing inner race
1. Install the synchronizer ring.
2. Install the ball and gear sleeve.
3. Install the needle bearing and the primary 4th gear.
NOTE: Apply transaxle oil to the needle bearing.
4. Install the new bearing inner race with the SST.
Bearing inner race
1. Install the new bearing inner race with the SST.
2. Measure the clearance between the primary 3rd gear and primary shaft gear.
If clearance is not within specification, replace any part which is worn or damaged.
Clearance: 0.150-0.262mm (0.0059-0.0103 in)
Maximum: 0.3mm (0.012 in)
3. Measure the clearance between the primary 4th gear and bearing inner race. If clearance is not within specification replace any part which is worn or damaged.
Clearance: 0.150-0.262mm (0.0059-0.0103 in)
Maximum: 0.3mm (0.012 in)
Secondary shaft gear
Secondary 1st gear, synchronizer ring and clutch hub assembly
1. Install the thrust washer.
2. Install the needle bearing and the secondary 1st gear.
NOTE: Apply transaxle oil to the needle bearing.
3. Install the synchronizer ring and clutch hub assembly (reverse gear.)
4. Install the synchronizer ring.
5. Install the ball, gear sleeve and needle bearing.
NOTE: Apply transaxle oil to the needle bearing.
Secondary 3rd gear, 4th gear and bearing inner race
1. Install the secondary 3rd gear, spacer and the secondary 4th gear.
2. Install the bearing inner race with the SST.
NOTE: Check that the spacer does not rotate.
Bearing inner race
1. Install the new bearing inner race with the SST.
2. Measure the clearance between the secondary 1st gear and thrust washer.
Clearance: 0.130-0.354mm (0.0051-0.0139 in)
Maximum: 0.404mm (0.0159 in)
3. Measure the clearance between the secondary 2nd gear and secondary 3rd gear.
If clearance is not within specification, replace any part which is worn or damaged.
Clearance: 0.150-0.262mm (0.0059-0.0103 in)
Maximum: 0.3mm (0.012 in)
Step 3
1. Select the adjust shim(s), referring to Bearing Preload Adjustment.
2. Assemble in the order shown in the image, referring to Assembly Note.
Bearing Preload Adjustment
When any of following parts are replaced, the bearing preload should be checked and adjusted.
1. Put the outer race into the SST.
2. Mount the secondary shaft gear assembly as shown.
NOTE: 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.
NOTE: Install with the SST in the positions in the image.
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 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.
NOTE: Measure the gap around the entire circumference of the selector.
7. Select the shim for the shaft gear by referring to the image 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.
Secondary shaft
Example: 1.18mm (0.047 in) 1.18mm (0.047 in) - [Diaphragm spring] 0.70mm (0.028 in) = 0.48mm (0.019 in)
So the nearest shim (on the thick side) to 0.48mm (0.019 in) is 0.50mm (0.020 in).
NOTE: Use a maximum of two shims.
8. Remove the SST and the transaxle case.
9. Mount the differential assembly, the primary shaft gear assembly and the SST as shown in the image.
10. Adjust the primary shaft preload in the same manner as that of the secondary shaft.
Primary shaft
Example: 1.18mm (0.047 in) 1.18mm (0.047 in) - [Diaphragm spring] 0.70mm (0.028 in) = 0.48mm (0.019 in)
So the nearest shim (on the thin side) to 0.48mm (0.019 in) is 0.45mm (0.018 in).
NOTE: Use a maximum of two shims.
11. 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.
12. Set the SST.
13. Expand the selector with the bar until preload specification is obtained.
Preload: 0.5 N.m (5 cm-kg, 4.3 in-lb)
14. 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.
15. Add 0.15mm (0.0059 in) to the measured clearance and select the combination of shims closest in value to that measurement.
See the image for available shim sizes.
Example: 0.32mm (0.013 in) 0.32mm (0.013 in) + 0.15mm (0.006 in) = 0.47mm (0.019 in).
So the nearest shim (on the thick side) to 0.47mm (0.019 in) is 0.50mm (0.020 in).
NOTE: Use a maximum of two shims.
Assembly note
Oil seal
Install the new oil seal with the SST.
Bearing outer races
Tap the primary and secondary shaft bearing outer races in until they are fully seated with a suitable pipe.
NOTE: Install the primary and secondary shaft bearing outer race and diaphragm springs and adjust shims after adjusting the bearing preload.
Change arm, boot and change rod
Install the change arm boot and change rod.
NOTE: Install the boot with the air bleed downward as shown In the image.
Roll pin
Install the new roll pin as shown in the image.
NOTE: Roll pin length is 28mm (1.10 in).
Oil seals
1. Tap the new oil seal (differential) with the SST.
2. Tap the new oil seal (primary shaft) with a suitable pipe.
Bearing outer race
Tap the differential bearing outer race in until it is fully seated with a suitable pipe.
NOTE: Install the differential bearing outer races, after adjusting the bearing preload.
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: 37-52 N.m (3.8-5.3 m-kg, 27-38 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, 12.2-17.4 in-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, 1.74-3.47 in-lb)
Step 4
1. Assemble in the order shown in the image, referring to Assembly Note.
1. Clutch hub
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer key spring
5. Lever set spring
6. Reverse shift lever
7. Differential assembly
8. Secondary shaft gear assembly
9. Primary shaft gear assembly
10. Base plate unit
11. Crank lever assembly
12. Crank lever shaft and snap ring
13. Shift fork (1st/2nd)
14. Shift rod (1st/2nd)
15. Roll pin
16. Shift rod (5th/Rev.)
17. Interlock pin
18. Shift rod end (5th/Rev.)
19. Roll pin
20. Shift rod end (3rd/4th)
21. Shift fork (3rd/4th)
22. Shift rod (3rd/4th)
23. Roll pin
24. Roll pin
25. Needle bearings
26. Washer
27. Snap ring
28. Reverse idler gear
29. Reverse idler shaft
30. Magnet
31. Clutch housing
32. Transaxle case
33. Bolt(s), spring(s) and ball(s)
34. Reverse switch
35. Interlock pins
36. Interlock plate
37. Ball
38. Gear sleeve
39. Needle bearing
40. Primary 5th gear
41. Synchronizer ring
42. Secondary 5th gear
43. Clutch hub assembly (5th/Rev.)
44. Shift fork (5th/Rev.)
45. Secondary reverse synchronizer gear
46. Synchronizer ring
47. Primary reverse synchronizer gear and gear sleeve
48. Locknut
49. Locknut
50. Roll pin
51. Rear cover
52. Drain plug
53. Neutral switch
Assembly note
Base plate unit, crank lever assembly and crank lever shaft
Install the base plate unit, the crank lever assembly and the crank lever shaft.
Reverse idler gear and reverse Idler shaft
Set the reverse idler gear and the reverse idler shaft in the direction shown.
Clutch housing
Install the SST to driveshaft coupling hole.
Interlock pins and Interlock plate
1. Install the interlock pins.
2. Install the interlock plate.
Tightening torque: 18-26 N.m (1.8-2.6 m-kg, 13-19 ft-lb)
Clutch hub assembly and shift fork
Install the clutch hub assembly and the shift fork together.
Locknuts
1. Shift to the 5th gear and the 1st gear.
2. Tighten the new locknuts and stake them.
Tightening torque: 128-196 N.m (13.0-20.0 m-kg, 94-145 ft-lb)