Part 2

SECONDARY SHAFT COMPONENT PREINSPECTION 1ST GEAR THRUST CLEARANCE





1. Measure the clearance between the 1st gear and the differential drive gear.

Clearance: 0.05 - 0.28 mm (0.002 - 0.011 inch)
Maximum: 0.33 mm (0.013 inch)

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

2ND GEAR THRUST CLEARANCE





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

Clearance: 0.1 - 0.46 mm (0.007 - 0.018 inch)
Maximum: 0.51 mm (0.020 inch)

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


SECONDARY SHAFT COMPONENT DISASSEMBLY/ASSEMBLY
1. Preinspect the thrust clearance of 1st gear and 2nd gear before disassembly.








2. Disassemble in the order indicated in the table.
3. Assemble in the reverse order of disassembly.


BEARING, SECONDARY 4TH GEAR DISASSEMBLY NOTE
1. Support the secondary shaft to keep it from falling.





2. Disassemble the bearing and secondary 4th gear by using the SST

SECONDARY 3RD GEAR, 2ND GEAR DISASSEMBLY NOTE
1. Shift the gears to 1st gear.
2. Support the secondary shaft to keep it from failing.





3. Disassemble the secondary 3rd gear and 2nd gear by using the SST

1ST/2ND CLUTCH HUB COMPONENT, 1ST SYNCHRONIZER RING, 1ST GEAR DISASSEMBLY NOTE
1. Support the secondary shaft to keep it from falling.





2. Disassemble the 1st/2nd clutch hub component, 1st synchronizer ring, and 1st gear by using a press.

BEARING (SECONDARY SHAFT END) DISASSEMBLY NOTE
1. Support the secondary shaft to keep it from falling.





2. Disassemble the bearing by using the SSTs.

BEARING (SECONDARY SHAFT END) ASSEMBLY NOTE





- Assemble the new bearing by using the SST

1ST GEAR, 1ST SYNCHRONIZER RING, 1ST/2ND CLUTCH HUB COMPONENT ASSEMBLY NOTE





NOTE
- The 1st synchronizer ring has teeth missing at three places around its outer edge to help distinguish it from the other synchronizer rings.

1. Assemble the 1st gear, 1st synchronizer ring, and 1st/2nd clutch hub component.





2. Align the synchronizer ring grooves and synchronizer keys.





3. Press the 1st/2nd clutch hub component on by using the SST

2ND SYNCHRONIZER RING, 2ND GEAR, SECONDARY 3RD GEAR ASSEMBLY NOTE
1. Assemble the 2nd synchronizer ring and 2nd gear.





2. Assemble the secondary 3rd gear by using the SSTs.

SECONDARY 4TH GEAR, BEARING ASSEMBLY NOTE





1. Assemble the secondary 4th gear and the bearing by using the SSTs.





2. Measure the clearance between the 1st gear and the differential drive gear.

Clearance: 0.05 - 0.28 mm (0.002 - 0.011 inch)





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

Clearance: 0.18 - 0.46 mm (0.007 - 0.018 inch)

4. If not as specified, reassemble the secondary shaft component.

MANUAL TRANSAXLE INSPECTION

- Inspect all parts and repair or replace as necessary.

GEARS INSPECTION
1. Inspect the synchronizer cones for wear.
2. Inspect the gear teeth for damage, wear and cracks.
3. Inspect the synchronizer ring matching teeth for damage and wear.

SYNCHRONIZER RING INSPECTION
1. Inspect the synchronizer ring teeth for damage, wear and cracks.
2. Inspect the tapered surface for wear and cracks.
3. Set the synchronizer ring squarely in the gear.





4. Measure the clearance between the synchronizer ring and the flank surface of the gear all around the circumference.

Standard clearance: 1.50 mm (0.059 inch)
Minimum: 0.80 mm (0.031 inch)

SYNCHRONIZER KEY INSPECTION
1. Inspect the synchronizer key for damage, wear, and cracks.
2. Measure the synchronizer key dimensions.








DIMENSIONS

CLUTCH HUB COMPONENT INSPECTION
1. Inspect the clutch hub sleeve and hub operation.
2. Inspect the gear teeth for damage, wear and cracks.
3. Measure the clearance between the hub sleeve and shift fork.








CLEARANCE

REVERSE IDLER GEAR, REVERSE LEVER INSPECTION
1. Inspect the gear teeth for damage, wear and cracks.





2. Measure the clearance between the reverse idler gear bushing and the reverse lever.

Standard clearance: 0.10 - 0.35 mm (0.004 - 0.014 inch)
Maximum: 0.85 mm (0.033 inch)


BEARING INSPECTION





- Inspect for damage and rough rotation.

PRIMARY SHAFT GEAR, SECONDARY SHAFT GEAR INSPECTION
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear and cracks.
4. Inspect the oil passage for blockage.





5. Measure the shaft gear runout.

Primary shaft gear runout: 0.050 mm (0.0020 inch) max.





Secondary shaft gear runout: 0.015 mm (0.0006 inch) max.





6. Measure the clearance between the shaft and the gears.





CLEARANCE


VEHICLE SPEEDOMETER SENSOR (SPEEDOMETER DRIVEN GEAR) INSPECTION





- Inspect the teeth for damage and wear.

MANUAL TRANSAXLE BEARING PRELOAD ADJUSTMENT





- When replacing any of the parts listed in the table below, adjust the bearing preload by selecting and installing the proper adjustment shims.

BEARING PRELOAD ADJUSTMENT
1. Install the primary and secondary shaft bearing races into the transaxle case (shims removed.)
2. Mount the clutch housing onto the transaxle hanger, and set the differential bearing race into the clutch housing.
3. Position a piece of pipe against the bearing race and tap it in until it contacts the clutch housing.

NOTE:
^ Turn the selector to eliminate the gap indicated by the arrow in the figure.





4. Set the bearing races into the SSTs (49 F401 382A, 49 G030 382A, and 49 G030 381) as shown in the figure.
5. Set the differential component into the clutch housing, and set the bearing race and the SST (49 G030 381) on the differential.
6. Set the SSTs (49 F401 382A and 49 G030 382A) for the primary and secondary shaft in the, clutch housing.





7. Mount the shaft gear components as shown in the figure.





8. Set the SST (49 F401 384) in the positions shown in the figure.





9. Install the transaxle case and tighten the SST (49 G019 021) to the specified torque.

Tightening torque: 38 - 51 Nm (3.8 - 5.3 kgf-m, 28 - 38 ft. lbs.)





10. To seat the bearings, mount the SST (49 F401 385) on parts A and B of the SSTs (49 F401 382A and 49 G030 382A), and turn the SSTs so the gaps are widened. Then turn the SSTs in the reverse direction until the gaps are eliminated.

NOTE:
^ Check that each shaft turns smoothly.





11. Manually expand the SSTs until it no longer turns by hand.





12. Measure the clearance around the entire circumference of the SSTs.

PRIMARY SHAFT ADJUSTMENT SHIM
1. Subtract 0.058 mm (0.002 inch) from the measured clearance to achieve the final clearance.

NOTE
^ Do not use more than one shim.

2. Use the following table to select the primary shaft adjustment shim that are closest to the value obtained in step 1.





ADJUSTMENT SHIM THICKNESS

SECONDARY SHAFT ADJUSTMENT SHIM
1. Add 0.048 mm (0.002 inch) to the measured clearance to achieve the final clearance.

NOTE:
^ Do not use more than one shim.

2. Use the following table to select the secondary shaft adjustment shim that are closest to the value obtained in step 1.





ADJUSTMENT SHIM THICKNESS

DIFFERENTIAL ADJUSTMENT SHIM





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





2. Turn the SST (49 T027 001) with a torque wrench. Adjust the SST (49 G030 381) with the SST (49 F401 385) until the specified preload is obtained.

Preload: 1.4 - 1.9 Nm (14 - 20 kgf-m, 13 - 17 inch lbs.)

3. Remove the SST (49 T027 001).





4. Measure the clearance around the entire circumference of the SST (49 G030 381).

5. Add 0.15 mm (0.006 inch) to the measured clearance to achieve the final clearance.

NOTE:
^ Do not use more than one shim.

6. Use the following table to select the differential adjustment shim that are closest to the value obtained in step 5.





ADJUSTMENT SHIM THICKNESS

BEARING PRELOAD INSPECTION

NOTE:
- Verify that the correct adjustment shims were installed.
- If the bearing preload is not within specification, readjust it.

PRIMARY SHAFT COMPONENT AND DIFFERENTIAL COMPONENT BEARING PRELOAD
1. Install the selected shim, and bearing race to the clutch housing.
2. Set the primary shaft component and differential component to the clutch housing.
3. Install the bearing race into the transaxle case.
4. Install the transaxle case, and tighten to the specified torque.

Tightening torque: 38 - 51 Nm (3.8 - 5.3 kgf-m, 28 - 38 ft. lbs.)





5. Install the SST through the drive shaft hole, and measure the preload.

Differential component bearing preload: 1.4 - 1.9 Nm (14 - 20 kgf-m, 13 - 17 inch lbs.)


6. If not as specified, readjust the bearing preload.
7. Remove the SST





8. Install the SST to the primary shaft component as shown in the figure, and measure the preload.

Primary shaft component bearing preload: 0.11 - 0.2 Nm (1.0 - 2.5 kgf-cm, 0.9 - 2.1 inch lbs.)

9. If not as specified, readjust the bearing preload.
10. Remove the SST

SECONDARY SHAFT COMPONENT BEARING PRELOAD
1. Install the funnel, bearing race and secondary shaft component to the clutch housing.
2. Set the selected shim and bearing race into the transaxle case.
3. Install the transaxle case, and tighten the specified torque.

Tightening torque: 38 - 51 Nm (3.8 - 5.3 kgf-m, 28 - 38 ft. lbs.)





4. Install the SST to the secondary shaft component, and measure the preload.

Secondary shaft component bearing preload: 0.2 - 0.7 Nm (2.0 - 7.5 kgf-cm, 1.8 - 6.5 inch lbs.)

5. If not as specified, readjust the bearing preload.
6. Remove the SST

DIFFERENTIAL DISASSEMBLY/ASSEMBLY

NOTE:
- The bearings do not need to be removed unless you are replacing them.

1. Before disassembly, inspect the backlash of the side gears and pinion gears.





2. Disassemble in the order indicated in the table.
3. Assemble in the reverse order of disassembly.
4. Measure the backlash after assembly.

BEARING (SIDE OPPOSITE RING GEAR) DISASSEMBLY NOTE





- While supporting the gear case, remove the bearing by using the SST

BEARING (RING GEAR SIDE) DISASSEMBLY NOTE





- Remove the bearing by using the SST

BEARING (RING GEAR SIDE) ASSEMBLY NOTE

NOTE:
- When replacing the bearing, replace the bearing and race as a set.





- Install the new bearing by using the SST

BEARING (SIDE OPPOSITE RING GEAR) ASSEMBLY NOTE

NOTE:
- When replacing the bearing, replace the bearing and race as a set.

1. Install the speedometer drive gear.





2. Install the new bearing by using the SST

ROLL PIN ASSEMBLY NOTE





- Install the new roll pin with the split facing as shown.

DIFFERENTIAL INSPECTION

DIFFERENTIAL BACKLASH INSPECTION
- Measure the backlash by the following procedure.
(1) Install the left drive shaft and the joint shaft in the differential component.
(2) Support the drive shaft and the joint shaft on V-blocks.





(3) Measure the backlash of both pinion gears.

Backlash: 0.050 - 0.150 mm (0.0020 - 0.0059 inch)

(4) If not as specified, replace the differential component.

RING GEAR AND GEAR CASE COMPONENT INSPECTION
- Inspect the ring gear for wear and cracks.

BEARING INSPECTION





- Inspect for wear and rough rotation.