Assembly
Precaution1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit.
2. The bearing outer race and bearing inner race must be replaced as a unit.
3. Before assembly, make sure all parts are completely clean.
4. 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.
Primary Shaft Assembly and Secondary Shaft Assembly
1. Clutch hub
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer springs
5. Clutch hub
6. Synchronizer key
7. Reverse gear clutch hub sleeve
8. Synchronizer springs
9. Primary shaft
10. Bearing (primary shaft end)
11. 3rd gear
12. 3rd synchronizer ring
13. 3rd/4th clutch hub assembly
14. Retaining ring
15. 4th synchronizer ring
16. 4th gear
17. Bearing
18. Secondary shaft
19. Bearing (secondary shaft end)
20. 1st gear
21. 1st synchronizer ring
22. 1st/2nd clutch hub assembly
23. Retaining ring
24. 2nd synchronizer ring
25. 2nd gear
26. Secondary 3rd gear
27. Retaining ring
28. Secondary 4th gear
29. Bearing
30. Control rod
31. Control lever
32. Roll pin
33. 1st/2nd shift fork
34. Control end
35. Roll pin
36. Interlock sleeve
37. 3rd/4th shift fork
Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Clutch hub
Install the synchronizer key springs in the clutch hub with the hooks in the grooves to hold the three synchronizer keys in place.
Bearing (primary shaft end)
Install the new bearing by using the SST.
3rd gear, 3rd synchronizer ring and 3rd/4th clutch hub assembly
NOTE: Refer to the image when assembling the 3rd gear, 3rd synchronizer ring, and the 3rd/4th clutch hub.
1. Install the 3rd gear, 3rd synchronizer ring, and 3rd/4th clutch hub assembly.
2. Align the synchronizer ring grooves and synchronizer keys.
4th synchronizer ring, 4th gear and bearing
1. Install the 4th synchronizer ring, 4th gear, and 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: 0.165 - 0.365 mm (0.0065 - 0.0144 in)
Maximum: 0.415 mm (0.0163 in)
4. If not as specified, reassemble the primary shaft assembly.
Bearing (secondary shaft end)
Install the new bearing by using the SST.
1st gear, 1st synchronizer ring and 1st/2nd clutch hub assembly
1. Assemble the 1st gear, 1st synchronizer ring, and 1st/2nd clutch hub assembly, as shown in the image.
2. Align the synchronizer ring key grooves and synchronizer keys.
3. Install the 1st/2nd clutch hub assembly by using the SST.
2nd synchronizer ring, 2nd gear and secondary 3rd gear
1. Install the 2nd synchronizer ring 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 new bearing by using the SST.
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 (0.0130 in)
3. Measure the clearance between the 2nd gear an 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.
Interlock sleeve
Install both shift forks and the interlock sleeve, as shown in the image.
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 within specification, referring to Bearing Preload.
Bearing preload adjustment
Adjust the bearing preload by selecting adjustment shim(s).
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 in with a hammer until it contacts the clutch housing.
3. Set the races into the SST (selector) as shown in the image.
4. Turn the selector to eliminate the gap indicated by the arrow.
5. 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.
6. Set the SST (collars) in the positions shown in the image.
7. 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)
8. To seat the bearings, mount the SST (bars) on pans (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.
9. Manually expand the selector until it no longer turns by hand.
10. Verify that both the primary and secondary shafts turn smoothly.
11. Measure the clearance between the two halves of the SST (selector) around the circumference by using a feeler gauge.
12. Take the maximum reading and determine the shim to be used. Use no more than two shims.
Primary shaft adjustment shim
- Subtract the diaphragm spring thickness (0.70 mm, 0.0276 in) from the gap determined in Step 11 for the primary shaft.
- Select the closest thinner shim from the image.
Example
1.22 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 adjustment shim
- Subtract the diaphragm spring thickness (0.70 mm, 0.0276 in) from the gap determined in Step 11 for the secondary shaft.
- Select the closest thicker shim from the image.
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)
13. Install the SST to the differential.
14. Turn the SST with a torque wrench. Adjust the SST (selector) by using the SST (bars) until the specified preload is obtained.
Preload: 0.5 N-m (5.0 kgf-cm, 4.3 in-lbf)
15. Measure the gap between A and B around the circumference of the SST (selector) by using a feeler gauge.
16. Add 0.15 mm (0.0059 in) to the measured clearance and select a combination of shims closest in value to that measurement. Use no more than 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).
So the nearest shim (on the thick side) to 0.47 mm (0.019 in) is 0.50 mm (0.020 in).
17. Remove the transaxle case and the SSTs.
18. Remove the selectors, the primary shaft assembly and the differential.
19. Remove the bearing races.
Assembly note
Oil seals
1. Using the SST and a hammer, tap the new oil seal in evenly until the SST contacts the transaxle case.
2. Coat the lip of the oil seal with transaxle oil.
Diaphragm spring
Install the diaphragm spring as shown in the image.
Boot
Install the boot so that the drain hole is facing downward when mounted on the vehicle.
Bearing preload
Verify the bearing preload of the shaft gears and the differential.
Readjust the bearing preloads if they are not within specification.
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. Install the SST to the differential.
4. Connect a torque wrench to the SST and measure the preload.
Preload: 1.4 - 2.0 N-m (14 - 20 kgf-cm, 12 - 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. Connect a torque wrench to the SST and measure the preload.
Preload: 0.1 - 0.25 N-m (1.0 - 2.5 kgf-cm, 0.87 - 2.18 in-lbf)
8. Remove the SST, transaxle case, primary shaft gear assembly and differential.
9. Install the secondary shaft gear assembly and transaxle case, and tighten to the specified torque.
Tightening torque: 38 - 51 N-m (3.8 - 5.3 kgf-m, 28 - 38 ft-lbf)
10. Install the SST to the secondary shaft gear assembly.
11. Connect a torque wrench to the SST and measure the preload.
Preload: 0.2 - 0.4 N-m (2.0 - 4.0 kgf-cm, 1.7 - 3.5 in-lbf)
5th/Reverse Gear and Housing Parts
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 and secondary shaft gear assemblies 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, push the control end in the direction of the arrow so that the ball goes into the shaft. This will line up the rod 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 up on the ball part of the control end in the direction of the arrow so that the steel ball goes into the detent in the groove.
Crank lever assembly and crank lever shaft
1. Install a new O-ring to the crank lever shaft.
2. Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank lever.
3. Align the pin holes of the crank lever shaft and the clutch housing, and insert the new pin.
5th/Reverse shift rod end, 5th/Reverse shift rod and clip
1. Install the shift rod (1) into the shift rod end (2).
2. Align the mark on the shift rod with the mounting bolt hole in the shift rod, and tighten the gate mounting bolt.
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.
Clutch housing and 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 SST through either the drive shaft or joint shaft hole.
Secondary 5th gear
Install the secondary 5th gear as shown.
5th/Reverse clutch hub assembly and 5th/Reverse shift fork
Install the 5th/Reverse clutch hub assembly 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 (13.0 - 20.0 kgf-m, 94 - 145 ft-lbf)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance by using a dial indicator.
Clearance: 0.10 - 0.22 mm (0.0039 - 0.0087 in)
Maximum: 0.27 mm (0.011 in)
6. If not as specified, reassemble the transaxle.