Part II

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 - 26 kgf-m, 14 - 18 ft-lbf)

3. Install the SST to the differential side gear through the transaxle case.

4. Measure the bearing preload.

Preload: 0.03 - 0.74 N-m (0.3 - 7.6 kgf-cm, 0.26 - 6.59 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
Oil seal (differential)
1. Apply transaxle oil to the outer circumference of the oil seal.
2. Install the new oil seal by using the SST.

Adjustment shim and bearing race (secondary shaft gear)

CAUTION: Use adjustment shim(s) selected during bearing preload adjustment.

1. Apply transaxle oil to the bearing race.
2. Install the adjustment shim(s) and the bearing race with a suitable pipe.

Adjustment shim and bearing race (differential)

CAUTION: Use adjustment shim(s) selected during bearing preload adjustment.

1. Apply transaxle oil to the bearing race.
2. Install the adjust shim(s) and the bearing race with a suitable pipe.

Adjustment shim (primary shaft gear)

CAUTION: Use adjustment shim(s) selected during bearing preload adjustment.

Apply transaxle oil to the adjustment shim(s) and install it.

Oil seal (primary shaft gear)
1. Apply transaxle oil to the outer circumference of the oil seal.
2. Install the new oil seal with a suitable pipe.

Oil seal (change rod)

CAUTION: Do not damage the oil seal.

1. Apply transaxle oil to the oil seal lip.
2. Install the new oil seal by using a suitable pipe.

Outer diameter of pipe: 26.0 mm (1.02 in)

Boot and change rod assembly
Install the boot with the air bleeder hole facing downward as shown in the image.

Primary Shaft Assembly
1. Measure the thrust clearance of all gears before disassembly, referring to Preinspection.
2. Disassemble in the order shown in the image, referring to Disassembly Note.
3. Assemble in the reverse order of disassembly, referring to Assembly Note.

Preinspection
3rd gear thrust clearance
1. Measure the clearance between 3rd gear and 2nd gear.

Clearance: 0.06 - 0.21 mm (0.002 - 0.008 in)
Maximum: 0.26 mm (0.010 in)

2. If the clearance exceeds the maximum, check the contact surfaces of the 3rd gear, 2nd gear and 3rd/4th clutch hub. Replace worn or damaged parts.

4th gear thrust clearance
1. Measure the clearance between 4th gear and the ball bearing.

Clearance: 0.14 - 0.39 mm (0.006 - 0.015 in)
Maximum: 0.44 mm (0.017 in)

2. If the clearance exceeds the maximum, check the contact surfaces of the 4th gear, ball bearing, and 3rd/4th clutch hub. Replace worn or damaged parts.

Disassembly note
Bearing and 4th gear

CAUTION: Hold the shaft with one hand so that it does not tall.

Remove the ball bearing and 4th gear by using the SST.

3rd/4th clutch hub assembly, 3rd synchronizer ring and 3rd gear

CAUTION: Hold the shaft with one hand so that it does not fall.

1. Remove the retaining ring.
2. Remove the 3rd/4th clutch hub assembly, 3rd synchronizer ring and 3rd gear by using the SST.

Bearing
Remove the bearing by using the SST.

Assembly note
Bearing
Install the bearing with a press.

3rd gear, 3rd synchronizer ring, and 3rd/4th clutch hub assembly

CAUTION: Apply transaxle oil to the bore of 3rd gear.

Turn the primary shaft over and install the 3rd gear, 3rd synchronizer ring, and 3rd/4th clutch hub assembly with a press.

4th synchronizer ring, primary 4th gear, and bearing
1. Install the retaining ring.
2. Install the 4th synchronizer ring, primary 4th gear, and ball bearing with a press.

3. Measure the clearance between 3rd gear and 2nd gear.

Clearance: 0.06 - 0.21 mm (0.002 - 0.008 in)
Maximum: 0.26 mm (0.010 in)

4. Measure the clearance between 4th gear and the ball bearing.

Clearance : 0.21 - 0.61 mm (0.008 - 0.024 in)
Maximum: 0.66 mm (0.026 in)

5. If not as specified, reassemble the primary shaft assembly.

Secondary Shaft Assembly
1. Measure the thrust clearance of all gears before disassembly, referring to Preinspection.
2. Disassemble in the order shown in the image, referring to Disassembly Note.
3. Assemble in the reverse order of disassembly, referring to Assembly Note.

Preinspection
1st gear thrust clearance
1. Measure the clearance between 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)

2. If the clearance exceeds the maximum, check the contact surfaces of the 1st gear, differential drive gear of the secondary shaft gear, 1st/2nd and clutch hub assembly. Replace worn or damaged parts.

2nd gear thrust clearance
1. Measure the clearance between 2nd gear and secondary 3rd gear.

Clearance: 0.18 - 0.51 mm (0.007 - 0.020 in)
Maximum: 0.56 mm (0.022 in)

2. If the clearance exceeds the maximum, check the contact surfaces of the 2nd gear, secondary 3rd gear, and 1st/2nd clutch hub assembly. Replace worn or damaged parts.

Disassembly note
Bearing (secondary shaft) and secondary 4th gear

CAUTION: Hold the shaft with one hand so that it does not fall.

Remove the bearing and secondary 4th gear by using the SST.

Secondary 3rd gear and 2nd gear

CAUTION: Hold the shaft with one hand so that it does not fall.

1. Remove the retaining ring.
2. Remove the secondary 3rd gear and 2nd gear by using the SST.

1st/2nd clutch hub assembly, 1st synchronizer ring and 1st gear

CAUTION: Hold the shaft with one hand so that it does not fall.

Remove the 1st/2nd clutch hub assembly, 1st synchronizer ring and 1st gear by using the SST.

Bearing (secondary shaft end)

CAUTION: Hold the shaft with one hand so that it does not fall.

Remove the bearing by using the SST.

Assembly note
Clutch hub

NOTE:

- Synchronizer ring dimensions are as follows.

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 with the synchronizer key during assembly.

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 new bearing by using the SST.

2. Measure the clearance between 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.