Part 2

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 inch)





Boot And Change Rod Assembly
Install the boot with the air bleeder hole facing downward as shown in the figure.





Primary Shaft Assembly
1. Measure the thrust clearance of all gears before disassembly, referring to Preinspection.
2. Disassemble in the order shown in the figure, 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 10.002 - 0.008 inch)
Maximum :0.26 mm (0.010 inch)

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 inch)
Maximum: 0.44 mm (0.017 inch)

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 fall.

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 bear.

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





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

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

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 figure, 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 inch)
Maximum: 0.33 mm (0.013 inch)

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 inch) Maximum: 0.56 mm (0.022 inch)

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.










- 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 inch)
Maximum :0.33mm(0.013 inch)





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

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

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

INSPECTION
Inspect all parts and repair or replace as necessary.

Synchronizer Ring





1. Inspect individual synchronizer ring teeth for damage, wear, and cracks.
2. Inspect tapered surface for wear or cracks.

Note: Set the synchronizer ring squarely in the gear; then measure around the circumference.





3. Measure the clearance between the synchronizer ring and flank surface of the gear.

Standard clearance: 1.12 - 1.88 mm(O.044 - 0.074 inch)
Minimum: 0.8 mm (0.031 inch)

Reverse Idler Gear And Reverse Lever
1. Inspect 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 - 0.32 mm (0.004 - 0.013 inch)
Maximum: 0.37 mm (0.015 inch)

Primary Shaft Gear





Note: If the shaft gear is replaced, adjust the bearing preload.

1. Inspect the shaft gear runout.

Maximum runout: 0.05 mm (0.002 inch)

2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.





3RD Gear, 4TH Gear, 5TH Gear, And Gear Sleeve (5TH Gear)

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









Oil Clearance:





2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.





Bearing
Inspect for damage or rough rotation.

Secondary Shaft Gear





Note: If the shaft gear is replaced, adjust the bearing preload.

1. Inspect the shaft gear runout.

Maximum runout: 0.015 mm (0.0006 inch)

2. Inspect the gear teeth for damage, wear, and cracks.





1ST Gear And 2ND Gear
1. Measure the clearance between the shaft gears and the gears.





Clearance:





2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.

Clutch Hub Assembly
1. Inspect the clutch hub sleeve and hub operation.





2. Inspect the individual gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer key for damage, wear, and cracks.





4. Measure the clearance between the hub sleeve and the shift fork.





Clearance:

Vehicle Speedometer Sensor
(Speedometer Driven Gear)





1. Inspect the teeth for damage and wear.
2. Inspect the O-ring for damage and wear.





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, referring to Inspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
3. Assemble in the reverse order of disassembly, referring to Assembly Note.
4. Measure the backlash after assembly, referring to Inspection.





Disassembly Note
Bearing (Side Opposite Ring Gear)

Caution: Hold the gear case with one hand so that it does not fall.

Remove the bearing by using the SST.





Bearing (Ring Gear Side)

Note: Use pads in the vise.

Remove the bearing by using the SST.


Assembly Note
Speedometer Drive Gear





Install the speedometer drive gear as shown in the figure.

Bearing (Side Opposite Ring Gear)

1. Install the speedometer drive gear.





2. Install the new bearing by using the SST





Bearing (Ring Gear Side)
Install the new bearing by using the SST.





Roll Pin
Install the new roll pin as shown in the figure to hold the pinion shaft.

INSPECTION
Backlash Of Side Gear And Pinion Gear
Measure the backlash by the following procedure.





1. Install the left drive shaft and the joint shaft in the differential assembly.
2. Support the drive shaft and joint shaft on V-blocks.
3. Measure the backlash of both pinion gears.

Backlash: 0 - 0.1 mm (0 - 0.004 inch)

4. If the backlash exceeds specification, adjust by selecting and installing thrust washers between the case and the s e gears.

Caution: Use thrust washers with the same thickness on each side.





Thrust Washer Thickness:





Ring Gear And Gear Case Assembly

Note: If the gear case is replaced, adjust the bearing preload.

Inspect the ring gear for wear and cracks.





Bearing

Note: When replacing the bearing, replace it and the bearing race as a set.
If the bearing is replaced, adjust the bearing preload.

Inspect for wear and rough rotation.