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 cleaned before assembly.
3. Assemble parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after assembly before tilling 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:
- The size of the 1st, 2nd, 3rd, and 4th synchronizer rings are the same. Be careful when installing them. The 2nd ring has the cut-out as shown in the image.
- Align the synchronizer ring groove and clutch housing hub key 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 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 and bearing
1. Install the secondary 4th gear and the bearing by using the SST.
2. Measure the clearance between the 1st gear and the 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 the secondary 3rd gear.
Clearance: 0.18-0.46 mm (0.007-0.018 in)
Maximum: 0.51 mm (0.020 in)
4. If 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 (primary shaft end)
Install the new bearing by using the SST.
3rd gear, synchronizer ring (3rd) and clutch hub assembly (3rd/4th)
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 synchronizer ring (4th), 4th gear, and a new bearing by using the SSTs.
2. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05-0.20 mm (0.002-0.008 in)
Maximum: 0.25 mm (0.010 in)
3. Measure the clearance between the 4th gear and bearing.
Clearance: 0.17-0.37 mm (0.007-0.015 in)
Maximum: 0.42 mm (0.0017 in)
4. If not as specified, reassemble the primary shaft assembly.
Clutch Housing and Transaxle Case Components
1. Select the adjustment shim(s), referring to Bearing Preload Adjustment.
2. Assemble in the order shown in the image, referring to Assembly Note.
3. Verify that the bearing preload is satisfactory after assembly, referring to Bearing Preload.
Bearing preload adjustment
Adjust the bearing preload by selecting and installing the proper adjustment shim(s).
NOTE: Adjust the preload when replacing any of the following parts.
1. Install the primary and secondary shaft bearing races into the transaxle case (diaphragm springs and shims removed).
2. Mount the clutch housing onto the transaxle hanger, and set the differential bearing race into the clutch housing. Position a piece of pipe against the bearing race and tap it in until it contacts the clutch housing.
3. Set the bearing races into the SSTs (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 into the clutch housing, and set the bearing race and the SST (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.
6. Install the transaxle case and tighten the SST (bolts) to the specified torque.
Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbf)
7. To seal the bearings, mount the SST (bars) on parts A and B of the selectors, and turn the selectors so the gaps are widened.
Then turn the SST in the reverse direction until the gaps are eliminated.
NOTE: Check that each shaft turns smoothly.
8. Manually expand the selector until it no longer turns by hand.
CAUTION: Measure the gap around the entire circumference of the selector.
9. Use a feeler gauge to measure the gap in the SST (selector).
10. Take the maximum reading and determine the shim to be used as follows:
NOTE: Use a maximum of two shims.
- Subtract the diaphragm spring thickness (0.65 mm, (0.026 in) from the gap determined in Step 9.
- Select the thinnest allowable shim from the image to obtain the standard clearance.
Standard clearance: 0 - 0.05 mm (0 - 0.002 in)
Example: 1.22 mm (0.048 in) - 0.65 mm (0.026 in) = 0.57 mm (0.022 in)
Shim selecting range: (0.57 mm (0.022 in) - 0.05 mm (0.002 in)) - (0.57 mm (0.022 in)-0 mm (0 in)) = 0.52 mm (0.020 in) - 0.57 mm (0.022 in)
Shim: 0.55 mm (0.022 in)
- Subtract the diaphragm spring thickness (0.65 mm, (0.026 in)) from the gap determined in Step 9.
- Select the thinnest allowable shim from the image to obtain the standard clearance.
Tightening amount: 0.03 - 0.08 mm (0.001 - 0.003 in)
Example: 1.22 mm (0.048 in) - 0.65 mm (0.026 in) = 0.57 mm (0.022 in)
Shim selecting range: 0.57 mm (0.022 in) + 0.03 mm (0.001 in)) - (0.57 mm (0.022 in) + 0.08 mm (0.003 in)) = 0.60 mm (0.024 in) 0.65 mm (0.026 in)
Shim: 0.60 mm (0.024 in)
11. Install the SST.
12. Turn the SST with a torque wrench. Adjust the SST (selector) with the SST (bars) until the specified preload is obtained.
Preload: 0.5 N.m (5.0 kgf.cm, 4.3 in.lbf)
CAUTION: Measure the gap around the entire circumference of the selector.
13. Use a feeler gauge to measure the gap in the selector for the differential.
14. Add 0.15 mm (0.006 in) to the measured clearance and select the combination of shims closest in value to that measurement.
NOTE: Use a maximum of two shims.
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).
Nearest shim (on thick side) to 0.47 mm (0.019 in) is 0.50 mm (0.020 in).
15. Remove the transaxle case and the SST.
16. Remove the selectors, the primary shaft assembly, and the differential.
17. Remove the bearing races.
Assembly note
Oil seal (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
Bearing race (differential)
CAUTION:
- Use the 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.
Diaphragm spring
Install the diaphragm spring as shown in the image.
Bearing race (transaxle case)
CAUTION:
- Use the 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.
Oil seal (change rod assembly)
CAUTION:
- Apply the specified oil to the oil seal lip.
- Do not damage the oil seal.
Install the new oil seal by using a suitable pipe.
Outer diameter of pipe: 26.0 mm 1.02 in
Boot
Install the boot with the drain hole facing downward when mounted on the vehicle.
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.
Bearing preload
Verify the shaft gears and the differential bearing preloads.
NOTE:
- Verify that the correct adjustment shims were installed.
- If the bearing preload is not within the specification, readjust it.
1. Set the primary shaft gear assembly and the differential into the clutch housing.
2. Install the transaxle case, and tighten to the specified torque.
Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbf)
3. Connect the SST through the drive shaft hole.
4. Connect a torque wrench to the attachment and measure the preload.
Preload: 1.4-1.9 N.m (14-20 kgf.m, 13-17 in.lbf)
5. Remove the SST.
6. With the transaxle facing in the direction shown in the image, install the SST to the primary shaft gear assembly.
7. Measure the preload.
Preload: 0.1-0.2 N.m (1.0-2.5 kgf.cm, 0.9-2.1 in.lbf)
8. Remove the SST, transaxle case, primary shaft gear assembly and differential.
9. Install the secondary shaft gear assembly and transaxle case then tighten to the specified torque.
Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbf)
10. Measure the secondary shaft preload by using the SST.
Preload: 0.2-0.4 N.m (2.0-4.0 kgf.cm, 1.8-3.4 in.lbf)
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. Shift fork (1st/2nd)
4. Control lever
5. Interlock sleeve
6. Shift fork (3rd/4th)
7. Clutch hub
8. Synchronizer keys
9. Clutch hub sleeve
10. Synchronizer key springs
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 shift rod assembly
18. Crank lever assembly
19. Crank lever shaft
20. Pin
21. 5th/reverse shift rod end
22. 5th/reverse shift rod
23. Reverse idler gear
24. Reverse idler shaft
25. Magnet
26. Transaxle case assembly
27. Park/neutral switch
28. Back-up light switch
29. Lock bolt, ball and spring
30. Guide bolt
31. Lock bolt
32. Secondary 5th gear
33. Gear sleeve
34. 5th gear
35. Synchronizer ring (5th)
36. Clutch hub assembly (5th/reverse)
37. Shift fork (5th gear/reverse)
38. Secondary reverse synchronizer gear
39. Synchronizer ring (reverse)
40. Primary reverse synchronizer gear
41. Locknut (secondary shaft)
42. Locknut (primary shaft)
43. 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 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 so that it contacts the steel ball.
3. With the edge of the control end against the scraper, 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 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/reverse shift rod end and 5th/reverse shift rod
NOTE: The mark (indicated by the arrow in the image) and the shift rod end mounting bolt hole must be aligned.
Install 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 in.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 in the direction shown in the image.
Transaxle case assembly
1. 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: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbf)
2. Insert the SSTs through the drive shaft and joint shaft hole.
Secondary 5th gear
Install the secondary 5th gear as shown.
Clutch hub assembly (5th/reverse) and 5th/reverse shift fork
Install the clutch hub assembly (5th/reverse) and the 5th/reverse shift fork together.
Locknut
1. Shift to 1st gear.
2. Lock the primary shaft by using the SST.
3. Tighten new locknuts onto the primary and secondary shafts.
Tightening torque: 128-196 N.m (13-20 kgf.m, 95-144 ft.lbf)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance by using a dial indicator.
Clearance: 0.100-0.220 mm (0.0039-0.0087 in)
Maximum: 0.270 mm (0.0106 in)
6. If not as specified, reassemble the transaxle.