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. The bearing outer race and bearing inner race must be replaced as a unit.
Clutch hub assembly
1. Install the synchronizer key springs in the clutch hub with the hooks in the grooves to hold the three synchronizer keys in place.
2. Align the synchronizer ring grooves and synchronizer keys.
Secondary Shaft Assembly
Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Bearing (secondary shaft end)
Install the new bearing by using the SST.
1st gear, 1st synchronizer ring and 1st/2nd clutch hub assembly
Install the 1st gear, 1st synchronizer ring and 1st/2nd clutch hub assembly by using the SST.
2nd synchronizer ring, 2nd gear, and secondary 3rd gear
Install the 2nd synchronizer ring, 2nd gear, and 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 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 - 0.51 mm (0.007 - 0.020 in)
Maximum: 0.56 mm (0.022 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
Install the new bearing with a press.
3rd gear, 3rd synchronizer ring, and 3rd/4th clutch hub assembly
Install the 3rd gear, 3rd synchronizer ring, and 3rd/4th clutch hub assembly by using a press.
4th synchronizer ring, 4th gear, and bearing
1. Install the 4th synchronizer ring, 4th gear, and bearing by using a press.
2. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.06 - 0.21 mm (0.002 - 0.008 in)
Maximum: 0.26 mm (0.010 in)
3. Measure the clearance between the 4th gear and the bearing.
Clearance: 0.21 - 0.61 mm (0.008 - 0.024 in)
Maximum: 0.66 mm (0.026 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 Shim Selection.
2. Assemble in the order shown in the image, referring to Assembly Note.
Shim selection
Adjust the bearing preload and 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 thrust clearance.
Clearance: 0.000 - 0.100 mm (0.000 - 0.0039 in)
4. Select the thinnest allowable shim from the image to obtain the standard clearance.
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 0.02 mm (0.00 in) to the thrust clearance.
b. Add 0.07 mm (0.003 in) to the thrust clearance.
c. From the image, select the thickest shim within the range of (a) to (b).
Example: 0.23 mm (0.009 in)
0.23 mm (0.009 in) + 0.02 mm (0.001 in) = 0.25 mm (0.010 in)
0.23 mm (0.009 in) + 0.07 mm (0.003 in) = 0.30 mm (0.012 in)
Range: 0.25 mm (0.010 in) - 0.30 mm (0.012 in)
Select the 0.30 mm (0.012 in).
Differential
1. Install the bearing race into the clutch housing.
2. Set the differential assembly into the clutch housing.
3. Install the transaxle case side bearing race to the SST (selector), and turn A and B to eliminate the gap indicated by the arrow.
4. Set the SST (collars) in the positions shown in the image.
5. Install the transaxle case and tighten the SST (bolts) to the specified torque.
Tightening torque: 19 - 25 N-m (1.9 - 2.6 kgf-m, 14 - 18 ft-lbf)
6. To seat the bearings, mount the SST (bars) on parts (A) and (B) of the selector, and turn the selector so the gap is widened.
7. Turn the SST in the reverse direction until the gap is eliminated.
8. Install the SST to the differential.
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 - 6.60 in-lbf)
10. Remove the SST.
11. Measure the clearance between the two halves of the SST (selector) around the circumference.
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.
13. Remove the transaxle case and the SSTs.
14. Remove the bearing race from the SST (selector).
15. Install the selected shim(s) and bearing race to 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.
4. Measure the bearing preload.
Preload: 0.03 - 0.74 N-m (0.3 - 7.6 kgf-cm, 0.26 - 6.60 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
Funnel and bearing race
1. Apply transaxle oil to the outer edge of the bearing race.
2. Install the funnel and the bearing race.
Adjustment shim and bearing race (differential)
1. Apply transaxle oil to the outer edge of the bearing race.
2. Install the selected adjustment shim(s) and the bearing race with a suitable pipe.
Adjustment shim and bearing race (secondary shaft gear)
1. Apply transaxle oil to the outer edge of the bearing race.
2. Install the selected adjustment shim(s) and the bearing race with a suitable pipe.
Adjustment shim (primary shaft gear)
Apply transaxle oil to the selected adjustment shim(s) and install it.
Oil seal (differential)
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.
Oil seal (primary shaft gear)
1. Apply transaxle oil to the outer edge of a new oil seal.
2. Install the oil seal with a suitable pipe.
Oil seal (change rod)
1. Install a new oil seal.
2. Coat the lip of the oil seal with transaxle oil.
Boot and change rod assembly
1. Install the boot onto the change rod assembly so that the drain hole is facing downward when mounted on the vehicle.
2. install the change rod assembly into the clutch housing.
Oil seal (speedometer gear case)
Install the new oil seal with a suitable pipe.
Pipe diameter: 15 mm (0.591 in)
Roll pin (speedometer driven gear assembly)
Install the new roll pin as shown in the image.
5th/Reverse Gear and Housing Parts
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 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 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 and washer
30. Guide bolt
31. Secondary 5th gear
32. Gear sleeve
33. 5th gear
34. 5th synchronizer ring
35. 5th clutch hub assembly
36. 5th shift fork
37. Stop plate
38. Locknut (Secondary shaft)
39. Locknut (Primary shaft
40. Rear cover
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 shift rod end and 5th shift rod
1. Install the shift rod (2) into the shift rod end (1).
2. Align the mark on the shift rod with the mounting bolt hole in the shift rod end as shown in the image, 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
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)
5th clutch hub assembly and 5th shift fork
Install the 5th clutch hub assembly and the 5th 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 - 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: 0.06 - 0.26 mm (0.0024 - 0.0102 in)
Maximum: 0.31 mm (0.0122 in)
6. If not as specified, reassemble the transaxle.