Assembly Procedure
Assembly Procedure
1. Install a new primary shaft oil seal in the clutch housing using the SST.
2. Install a new differential oil seal (clutch housing side) using the SSTs so that the seal is flush with the housing surface.
3. Install a new oil channel in the secondary shaft.
Note: When installing the oil channel, set the rib part of the oil channel to the hollow processing part of the clutch housing.
4. Install a new secondary shaft front bearing using the SSTs as shown in the figure.
5. Install the bearing retainer with the stamp facing up.
Tightening torque:
6.27 - 8.33 N-m (64.0 - 84.9 kgf-cm, 55.5 - 73.7 in-lbf)
6. Measure the differential preload, and install the differential side bearing outer race using the SSTs. (See DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT.)
7. Install the differential to the clutch housing.
Caution:
^ Installing the primary shaft can damage the oil seal, reducing the performance of the transaxle. When installing the primary shaft to the clutch housing, be careful not to damage it.
^ The reverse idler gear will not function properly if the lip of the friction damper comes out of contact with the inner side of the gear. When moving the reverse idler gear component, do not handle the reverse idler gear. Move the component by grasping the ends of the reverse idler shaft.
8. Install the primary shaft component, secondary shaft component, and reverse idler component to the clutch housing at the same time.
9. Install the 1st /2nd bracket to the 1st/2nd fork rod, and install a new retaining pin.
10. Install the 1st/2nd fork rod and 1st/2nd shift fork to the clutch housing, and install a new retaining pin.
11. Install the shift check sleeve.
12. Install the interlock pin to the 3rd/4th fork rod.
13. Install the 3rd/4th bracket, 3rd/4th shift fork, and 3rd/4th fork rod to the clutch housing.
14. Install a new C-ring to the 3rd/4th shift fork.
15. Install a new retaining pin to the 3rd/4th bracket.
16. Install two check balls.
17. Install the 5th/reverse bracket, 5th shift fork, and 5th/reverse fork rod.
18. Install a new C-ring to the 5th/reverse fork rod.
19. Install a new retaining pin to the 5th shift fork.
20. Install the reverse shift fork and reverse fork rod.
21. Install the reverse lever component.
1) Install the cap to the cam part of the reverse lever component, and the reverse lever component to the reverse shift fork.
2) Lift the reverse shift fork, and install the cam part of the reverse lever component to the 5th/reverse bracket.
3) Install a new reverse lever component installation bolt.
Tightening torque:
11.8 - 15.6 N-m (1.2 - 1.5 kgf-m, 8.7 - 11.5 ft-lbf)
Note: When installing the check ball, keep the check ball from dropping into the mold groove of the hole.
22. Install the check ball, the shift check sleeve (5th/reverse), the check spring (5th/reverse), and a new check plug (5th/reverse).
23. Install the magnet to the clutch housing.
24. Install a new differential oil seal to the transaxle case using the SSTs so that the seal is flush with the case surface.
25. Adjust the primary shaft end play. (See PRIMARY SHAFT END PLAY ADJUSTMENT.)
26. Install the primary shaft adjustment shim to the primary shaft.
27. Install the baffle plate and oil pass.
28. Install the transaxle case.
1) Adjust the secondary shaft end play. (See SECONDARY SHAFT END PLAY ADJUSTMENT.)
2) Install the secondary shaft rear bearing adjustment shim to the transaxle case.
3) Install a new snap ring of the secondary shaft rear bearing to the transaxle case.
4) Apply a light coat of silicone sealant to the contact surfaces of the transaxle case and the clutch housing.
Sealant:
Three Bond product: TB1215
5) Place the transaxle case to the clutch housing.
6) Stretch the snap ring at the bore plug hole while lifting the secondary shaft at the control component installation hole.
7) Install the snap ring to the groove of the secondary shaft rear bearing.
8) Install the A bolt and a new B bolt to the transaxle case as shown in the figure.
Tightening torque
A: 50.0 - 53.9 N-m
(5.1 - 5.5 kgf-m, 36.9 - 39.8 ft-lbf)
B: 63.0 - 66.9 N-m
(6.4 - 6.8 kgf-m, 46.5 - 49.3 ft-lbf)
29. Install a new bore plug using the SSTs.
30. Install a new welt plug using the SSTs.
31. Install the check balls, check springs, and a new check ball plugs as shown in the figure.
Tightening torque:
12.7 - 17.0 N-m (1.3 - 1.7 kgf-m, 9.4 - 12.5 ft-lbf)
32. Install a new O-ring to the control component.
33. Install the control component.
Tightening torque:
6.30 - 8.30 N-m (64.3 - 84.6 kgf-cm, 55.8 - 73.4 in-lbf)
34. Install a new shift check bolt.
Tightening torque:
22.5 - 25.5 N-m (2.3 - 2.6 kgf-m, 16.6 - 18.8 ft-lbf)
35. Install a new stopper bolt.
Tightening torque:
26.5 - 30.4 N-m (2.7 - 3.1 kgf-m, 19.5 - 22.4 ft-lbf)
36. Apply a light coat of silicone sealant to the screw of the neutral switch, and install it to the transaxle case.
Sealant:
Three Bond product: TB1215
Tightening torque:
22.5 - 33.3 N-m (2.3 - 3.4 kgf-m, 16.6 - 24.6 ft-lbf)
37. Apply a light coat of silicone sealant to the screw of the reverse switch, and install it to the transaxle case.
Sealant:
Three Bond product: TB1215
Tightening torque:
22.5 - 33.3 N-m (2.3 - 3.4 kgf-m, 16.6 - 24.6 ft-lbf)
38. Install a new drain plug.
Tightening torque:
30.0 - 39.0 N-m (3.1 - 3.9 kgf-m, 22.1 - 28.8 ft-lbf)
39. Install a new gasket to the filler cap, and Install it to the transaxle case.
Tightening torque:
30.0 - 39.0 N-m (3.1 - 3.9 kgf-m, 22.1 - 28.8 ft-lbf)