Assembly
Precaution1. All O-rings and gaskets must be replaced with the new ones included 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 races and bearings must be replaced as sets.
Secondary Shaft Assembly
Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Clutch hub
NOTE: Synchronizer key dimensions are as follows.
Install the synchronizer keys and springs in the clutch hub.
Bearing (secondary shaft end)
Install the new bearing by using the SST.
1st gear, synchronizer ring (1st) and clutch hub assembly (1st/2nd)
NOTE:
- Synchronizer ring diameters are as follows.
- Align the synchronizer ring grooves with the synchronizer key during assembly.
Install the 1st gear, synchronizer ring (1st) and clutch hub assembly (1st/2nd) by using the SST.
Synchronizer ring (2nd), 2nd gear, and secondary 3rd gear
1. Install the synchronizer ring (2nd) and 2nd gear.
2. Install the secondary 3rd gear by using the SST.
Secondary 4th gear
Install the secondary 4th gear by using the SST.
Bearing (secondary shaft)
1. Install the bearing by using the SST.
2. Measure the clearance between 1st gear and the differential drive gear.
Clearance: 0.05-0.28mm (0.002-0.011 in)
Maximum: 0.33mm (0.013 in)
3. Measure the clearance between 2nd gear and the secondary 3rd gear.
Clearance: 0.18-0.51mm (0.007-0.020 in)
Maximum: 0.56mm (0.022 in)
4. It not as specified, reassemble the secondary shaft assembly.
Primary Shaft Assembly
Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Bearing
Install the new bearing by using a press.
3rd gear, synchronizer ring (3rd), and clutch hub assembly (3rd/4th)
CAUTION: Apply transaxle oil to the bore of 3rd gear.
Turn the primary shaft over and install the 3rd gear, synchronizer ring (3rd), and clutch hub assembly (3rd/4th) by using a press.
Synchronizer ring (4th), 4th gear, and bearing
1. Install the retaining ring.
2. Install the synchronizer ring (4th), 4th gear, and bearing by using a press.
3. Measure the clearance between 3rd gear and 2nd gear.
Clearance: 0.06-0.21mm (0.002-0.008 in)
Maximum: 0.26mm (0.010 in)
4. Measure the clearance between 4th gear and the ball bearing.
Clearance: 0.14-0.39mm (0.005-0.015 in)
Maximum: 0.44mm (0.017 in)
5. If not as specified, reassemble the primary shaft assembly.
Clutch Housing and Transaxle Case Components
1. Select the adjustment shim(s), referring to Shim Selection.
2. Assemble in the order shown in the image, referring to Assembly Note.
Shim selection
NOTE: Adjust the preload by selecting and installing the proper shim(s) when replacing any of the following part.
Select the shim(s) as follows.
Primary shaft assembly
1. Set the primary shaft assembly into the clutch housing.
2. Install the transaxle case to the clutch housing and tighten the bolts to the specified torque.
Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14-18 ft.lbf)
3. Mount a dial indicator to the transaxle hanger and measure the primary shaft clearance.
Clearance: 0.005-0.100mm (0.0002-0.0039 in)
4. Select the closest shim (on the thin side) from the image.
Adjustment Shim Thickness:
Adjustment shim thickness:
Secondary shaft bearing preload
1. Install the funnel and bearing race into the clutch housing.
2. Set the secondary shaft into the clutch housing.
3. Install the secondary shaft bearing race into the transaxle case.
4. install the transaxle case to the clutch housing and tighten the bolts to the specified torque.
Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14-18 ft.lbf)
5. Mount a dial indicator to the transaxle case and measure the secondary shaft end play.
6. Select the shim as follows.
a. Add 0.03mm (0.0012 in) to the thrust clearance.
b. Add 0.08mm (0.0031 in) to the thrust clearance.
c. Select the thickest shim in the range from (a) to (b) from the image.
Example: 0.22mm (0.009 in)
0.22mm (0.009 in) + 0.03mm (0.001 in) = 0.25mm (0.010 in)
0.22mm (0.009 in) + 0.08mm (0.003 in) = 0.30mm (0.012 in)
Range: 0.25mm (0.010 in)-0.30mm (0.012 in)
Select the 0.30mm (0.012 in).
Adjustment Shim Thickness:
Adjustment shim thickness
Differential
1. Install the bearing race into the clutch housing.
2. Set the differential assembly into the clutch housing.
NOTE: Turn A and B until the gap indicated (arrow) in the image is eliminated.
3. Set the transaxle case side bearing race into the SST (selector).
4. Set the SST (collars) in the positions shown in the image.
5. Tighten the SST (bolts) to the specified torque.
Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14-18 ft.lbf)
NOTE: Turn the bars until the SST (selector) can no longer be moved.
6. To seat the bearings, mount the bars on parts A and B of the selector, and turn the selector so that the gap is widened.
7. Turn in the reverse direction until the gap is eliminated.
8. Install the SST to the differential pinion shaft through the transaxle case.
9. Turn the SST with a torque wrench. Adjust the SST (selector) with the SST (bars) until the specified preload is obtained.
Preload: 0.03-0.74 N.m (0.3-7.6 kgf.cm, 0.26-8.60 in.lbf)
10. Remove the SST.
11. Measure the clearance around the entire circumference of the SST (selector).
12. Select the proper adjustment shim(s) to be used for the differential by referring to the image and selecting the shim which is nearest (on the thick side) to the largest measured clearance in the selector.
Adjustment Shim Thickness:
Adjustment shim thickness
13. Remove the SST (bolts).
14. Remove the transaxle case and the SST (collars).
15. Remove the bearing race from the SST (selector).
16. Install the selected shim(s) and the bearing race into the transaxle case.
Bearing preload (differential)
Measure the preload as follows.
1. Set the differential assembly into the clutch housing.
2. Install the transaxle case onto the clutch housing.
Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14-18 ft.lbf)
3. Install the SST to the differential pinion shaft through the transaxle case.
4. Measure the bearing preload.
Preload: 0.03-0.74 N.m (0.3-7.6 kgf.cm, 0.2-0.60 in.lbf)
5. If not as specified, readjust the bearing preload.
6. Remove the SST.
7. Remove the transaxle case and differential assembly.
Assembly note
Bearing race (differential)
CAUTION:
- Use adjustment shim(s) selected during bearing preload adjustment.
- Apply transaxle oil to the bearing race.
Install the adjustment shim(s) and install the bearing race by using a suitable pipe.
Bearing race (secondary shaft)
CAUTION:
- Use the adjustment shim(s) selected during bearing preload adjustment.
- Apply transaxle oil to the bearing outer race.
Install the adjustment shim(s) and install the bearing race by using a suitable pipe.
Adjustment shim (primary shaft)
CAUTION:
- Use the adjustment shim(s) selected during bearing preload adjustment.
- Apply transaxle oil to the adjustment shim(s) and install it.
Oil seals (differential)
CAUTION:
- Tap in until the oil seal installer contacts the case.
- Coat the oil seal lip with transaxle oil.
Install the new oil seals by using the SST.
Oil seal (primary shaft)
CAUTION: Apply transaxle oil to outer circumference of the oil seal.
Install the new oil seal by using a suitable pipe.
Oil seal (change rod assembly)
CAUTION:
- Apply the specified oil to the oil seal lip.
- Do not damage the oil seal.
Install a new oil seal by using a suitable pipe.
Outer diameter of pipe: 26mm (1.02 in)
Boot
Install the boot with the drain hole facing downward when mounted on the vehicle.
Oil seal (speedometer gear case)
Install the new oil seal by using a suitable pipe.
Pipe diameter: 15mm (0.591 in)
Roll pin
Install the new roll pin as shown in the image.
5th/Reverse Gear and Housing Parts
Assemble in the order shown in the image, referring to Assembly Note.
1. Control rod
2. Control end
3. 1st/2nd shift fork
4. Control lever
5. Interlock sleeve
6. 3rd/4th shift fork
7. Clutch hub
8. Synchronizer key
9. Clutch hub sleeve
10. Synchronizer key spring
11. Clutch housing
12. Differential assembly
13. Secondary shaft gear assembly
14. Primary shaft gear assembly
15. Spring
16. Steel ball
17. Shift fork and control rod assembly
18. Crank lever assembly
19. Crank lever shaft
20. Pin
21. 5th shift rod end
22. 5th shift rod
23. Reverse idler gear
24. Reverse idler shaft
25. Magnet
26. Transaxle case assembly
27. Neutral switch
28. Back-up light switch
29. Lock bolt
30. Guide bolt
31. Secondary 5th gear
32. Gear sleeve
33. 5th gear
34. Synchronizer ring (5th)
35. Clutch hub assembly (5th)
36. 5th shift fork
37. Stop plate
38. Locknut (secondary shaft)
39. Locknut (primary shaft)
40. Rear cover
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 control rod assembly
1. Shift to 2nd gear and position the shift fork and control rod assembly as shown.
2. Insert the spring seat and spring into the reverse lever shaft, install the steel ball, and place a scraper so that it contacts the steel ball.
3. With the edge of the control end against the scraper, when the control end is pushed the ball goes into the shaft, the rod will at the same time line up with the control rod coupling hole in the clutch housing.
4. Set each clutch hub sleeve to the neutral position, and tap the control rod from above so that the steel ball goes into the center groove (of the three 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
NOTE: Use a new O-ring for the crank lever shaft.
1. Fit the crank lever 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 a new pin.
5th shift rod end and 5th shift rod
NOTE: The mark (indicated by the arrow in the image) and the shift rod end mounting bolt hole must be aligned.
Install the shift rod end 1 and the shift rod 2, and tighten the gate mounting bolt.
Tightening torque: 11.8-13.7 N.m (120-140 kgf.cm, 105-121 ft.lbf)
Reverse idler gear and reverse idler shaft
1. Install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.
3. Align the end of the interlock sleeve with the control lever (arrow), and, at the same time, face the reverse idler shaft screw hole.
Transaxle case assembly
Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case, and tighten the transaxle case installation bolts to the specified torque.
Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14-18 ft.lbf)
Clutch hub assembly (5th) and 5th shift fork
Install the clutch hub assembly (5th) and the 5th shift fork together.
Locknut
1. Shift to 1st gear.
2. Lock the primary shaft with the SST.
3. Tighten new locknuts onto the primary and secondary shafts.
Tightening torque: 128-206 N.m (13-21 kgf.m, 94-152 ft.lbf)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance by using a dial indicator.
Clearance: 0.15-0.26mm (0.006-0.010 in)
Maximum: 0.30mm (0.012 in)
6. If not as specified, reassemble the transaxle.