Manual Transmission/Transaxle: Adjustments

NOTE: 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 19 - 25 Nm (14 - 18 ft. lbs.).





3. Mount a dial indicator to the transaxle hanger and measure the primary shaft thrust clearance. Clearance should be within 0.005 - 0.100 mm (0.0002 - 0.0039 inch).





4. Select the closest shim on the thin side from the table illustrated.





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 19 - 25 Nm (14 - 18 ft. lbs.).





5. Mount a dial indicator to the transaxle case and measure the secondary shaft end play.
6. Select the shim as follows.
a. Add 0.03 mm (0.0012 inch) to the thrust clearance.
b. Add 0.08 mm (0.0031 inch) to the thrust clearance.





c. Select the thickest adjustment shim in the range from (a) to (b) from the table illustrated.

Example: 0.22 mm (0.009 inch)
0.22 mm (0.009 inch) + 0.03 mm (0.001 inch) = 0.25 mm (0.010 inch)
0.22 mm (0.009 inch) + 0.08 mm (0.003 inch) = 0.30 mm (0.012 inch)
Range: 0.25 mm (0.010 inch) - 0.30 mm (0.012 inch)
Select the 0.30 mm (0.012 inch) adjustment shim.

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 shown in the illustration is eliminated.

3. Install the transaxle case side bearing race to the Special Service Tool (SST) (selector).





4. Set the SSTs (collars) in the positions shown in the illustration.





5. Tighten the SSTs (bolts) to 19 - 25 Nm (14 - 18 ft. lbs.).





NOTE: Turn the bars until the SST (selector) can no longer be moved.

6. To seat the bearings, mount the bars on parts ~ and (I) of the selector, and turn the selector so the gap is widened.
7. Turn in the reverse direction until the gap is eliminated.





8. Install the SST to the differential pinion gear through the transaxle case.





9. Turn the SST with a torque wrench. Adjust the SST (selector) with the bars until 0.03 - 0.74 Nm (0.26 - 6.59 inch lbs.) of preload is obtained.
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 table and selecting the shim which is nearest (on the thick side) to the largest measured clearance in the selector.





13. Remove the SSTs (bolts).
14. Remove the transaxle case and the SSTs (collars).





15. Remove the bearing race from the SST (selector).
16. 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. Tighten to 19 - 25 Nm (14 - 18 ft. lbs.).





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





4. Measure the bearing preload. Preload should be within 0.03 - 0.74 Nm (0.26 - 6.59 inch lbs.).
5. If not as specified, readjust the bearing preload.
6. Remove the SST.
7. Remove the transaxle case and differential assembly.