Part 1
DISASSEMBLY/ASSEMBLYDisassembly Precaution
1. Clean the transaxle exterior thoroughly with a steam Cleaner or cleaning solvent before disassembly.
Warning: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
3. Clean out all holes and passages with compressed air, and verify that there are no obstructions.
Assembly Precaution
1. Replace all O-rings and gaskets with the new ones included in the overhaul kit.
2. Verify that all parts are completely cleaned before assembly,
3. Assemble parts within 10 minutes after applying sealant. Allow all sealants to cure for at least 30 minutes after assembly before filling the transaxle with transaxle oil.
4. Replace bearing races and bearings as sets.
5TH / Reverse Gear And Housing Parts
1. Disassemble in the order shown in the figure, referring to Preinspection and Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly. Note.
Preinspection
5TH Gear Thrust Clearance
1. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.08 - 0.15 mm (10.0032 - 0.0059 inch)
Maximum: 0.20 mm (0.0079 inch)
2. If the clearance exceeds the the maximum, check the contact surfaces of the 5th gear and the clutch hub. Replace worn or damaged parts.
Disassembly Note
Locknut
1. Mount the transaxle on the SST.
2. Lock the primary shaft by using the SST.
3. Shift to, 1st or 2nd gear to lock the rotation of the primary shaft.
Caution: Do not reuse the removed locknut.
4. Uncrimp the tabs of the locknuts.
5. Remove the locknuts from the primary and secondary shafts.
Shift Fork And Shift Rod Assembly
1. Align the ends of the interlock sleeve and of the control lever (arrow). Turn the shift rod counterclockwise.
2. While holding the 1st/2nd shift fork with one hand and the 3rd/4th shift fork with the other, raise them both at the same time and shift each of the clutch hub sleeves.
3. Lift the control end and remove the steel ball, and, at the same time, remove the shift rod from the clutch housing.
4. Separate the shift rod and shift fork assembly from-each of the clutch hub sleeves.
Assembly Note
Primary Shaft Gear Assembly And Secondary Shaft Gear Assembly
Install the primary shaft gear assembly and the secondary shaft gear assembly together.
Shift Fork And Shift Rod Assembly
1. Shift to 21nd gear and position the shift fork and shift rod assembly as shown.
2. Insert: the spring seat and spring into the reverse lever shaft; then 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 in the figure so that the ball goes into the shaft. The rod will line up 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 the ball part of the control end forward so that the steel ball goes into the detent in the groove.
Crank Lever Assembly And Crank Lever Shaft
Note: Use a new O-ring for the crank lever shaft.
1. Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank lever.
2. Align the pin holes of the crank lever shaft and the clutch housing, and insert the new pin.
5TH/Reverse Shift Rod End And 5Th/reverse Shift Rod
Note: The marks (indicated by the arrows) and the shift rod end mounting bolt hole must face the same direction.
Install the shift rod end (D and the shift rod 0, 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 (indicated by the arrow), and, at the same time, face the reverse idler shaft screw hole in the direction shown in the figure.
Transaxle Case Assembly
Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case; then tighten the transaxle case installation bolts to the specified torque..
Tightening torque: 19 - 25 Nm (1.9 - 2.6 kg-m, 14 - 18 ft. lbs.)
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 on the primary and secondary shafts.
Tightening torque: 128 - 205 Nm (13 - 21 kg-m, 95 - 151 ft. lbs.)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.06 - 0.26 mm (0.0024 - 0.0102 inch)
Maximum : 0.31 mm (10.0122 inch)
6. If not as specified, reassemble the transaxle.
Clutch Housing And Transaxle Case Components
Note: The oil seals do not need to be removed unless you are replacing them.
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Select adjustment shim(s), referring to Bearing Preload Adjustment.
3. Assemble in the reverse order of disassembly, referring to Assemble Note.
Disassembly Note
Blind Plug
Remove the roll pin with pliers.
Reverse Lever Shaft
Protect the reverse lever shaft with a rag and remove the shaft with pliers.
Oil Seal (Change Rod)
Remove the oil seal with a screwdriver.
Funnel And Bearing Race (Secondary Shaft)
Note:
- Remove the bearing race with a screwdriver if necessary.
1) Insert a screwdriver between the clutch housing and bearing race.
2) Pry the bearing race free.
Remove the bearing race by lifting out the funnel and race together.
Oil Seal (Primary Shaft)
Caution: Do not damage the clutch housing.
Remove the oil seal with a screwdriver.
Oil Seal (Differential)
Remove the oil seal with a screwdriver.
Bearing Race And Adjustment Shim (Differential)
1. Install the SST to the bearing race.
2. Remove the bearing race and adjustment shim.
Bearing Preload Adjustment
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 Nm (1.9 - 2.6 kg-m, 14 - 18 ft. lbs.)
3. Mount a dial indicator to the transaxle hanger and measure the primary shaft thrust clearance.
Clearance: 0.005 - 0.100 mm (0.0002 - 0.0039 inch)
4. Select the closest shim on the thin side from the table.
Adjustment Shim Thickness:
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 Nm (1.9 - 2.6 kg-m 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.
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 10.012 inch)
Range: 0.25 mm (0.010 inch) - 0.30 mm (0.012 inch)
Select the 0.30 mm (0.012 inch) adjustment shim.
Adjustment Shim Thickness:
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 figure is eliminated.
3. Install the transaxle case side bearing race to the SST (selector).
4. Set the SSTs (collars) in the positions shown in the figure.
5. Tighten the SSTs (bolts) to the specified torque.
Tightening torque: 19 - 25 Nm (11.9 - 2.6 kg-m 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 (A) and (B) 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 the specified preload is obtained.
Preload: 0.03 - 0.74 Nm (0.3 - 7.6 kg-cm, 0.26 - 6.59 inch lbs.)
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.
Adjustment Shim Thickness:
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.
Tightening torque: 19 - 25 Nm (1.9 - 2.6 kg-m, 14 - 18 ft. lbs.)
3. Install the SST to the differential side gear through the transaxle case.
4. Measure the bearing preload.
Preload: 0.03 - 0.74 Nm (0.3 - 7.6 kg-cm, 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.
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.