Assembly

Special Tools:

Assembly

1. CAUTION: Bearing races require a heating and cooling procedure and special tools for installation. This procedure must be followed to provide accurate preload measurements.

Clean and check all parts carefully before assembly.
^ All sliding parts should be lubricated with Merkur manual transmission fluid.

2. NOTE: Heat the transaxle housing to approximately 80°C.

Install the reverse gear idler shaft.
1 Apply Sealer to the reverse gear idler shaft plate mating face.
2 Align the reverse gear idler shaft plate using the longer locating bolt and drive it in.
3 Remove the locating bolt and install the original bolts.

3. CAUTION: The press pressure must not exceed 15 kN.

Install the bearing cups on the transaxle housing side.
^ Heat the housing area to approximately 80°C.
^ Cool down the bearing cups and install them.
^ Install the bearing cups of the:
^ Input shaft using special tools (205-153, 303-420 and 205-267).
^ Output shaft using special tool (205-153).
^ Differential using special tools (205-153 and 308-121).

4. CAUTION: Press the bearing races down again. The press pressure must not exceed 15 kN

Measuring shim to be installed:
^ Input shaft: 1.00 mm
^ Output shaft: 1.00 mm
^ Differential: 1.10 mm

5. CAUTION: The press pressure must not exceed 15 kN.

Install the measuring shims and the bearing cups in the housing section at the clutch end.
^ Heat the housing area to approximately 80°C.
^ Cool down the bearing cups.
1 Install the measuring shims.
2 Install the bearing cups.
^ Install the bearing cups of the:
^ Input shaft using special tools (205-153 and 308-221).
^ Output shaft using special tool (205-153).
^ Differential using special tools (205-153 and 308-121).

6. CAUTION: Do not use the bearing as a support. Support the differential under the gear.

Using the special tools, install the bearing.

7. NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.

Install the fourth gear synchronizer on the input shaft.

8. Assemble the input and output shafts together and insert them in the transaxle case as an assembly.

9. NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.

Install the differential assembly.

10. Position the housing and tighten the sixteen transaxle housing bolts uniformly.

11. Prepare the input shaft for measuring.
^ Using the special tool, turn the input shaft back and forth to settle the bearings.

12. Install the special tool on the transaxle housing and set the indicator to zero.

13. NOTE: Carry out steps, and three times and calculate the average measurement.

Using the special tool, measure the input shaft end float.
1 Lift the input shaft with a lever.
2 Note the resulting measurement.
^ Example: 0.22 mm + 0.23 mm + 0.21 mm divided by three = 0.22 mm.

14. Install the special tool.
^ Turn the output shaft back and forth 20 times to settle the bearings (by means of the input shaft -see step).
1 Install the special tool.
2 Install the bolts.
3 Position the special tool on the fourth gear wheel.

15. NOTE: Carry out steps and three times and calculate the average measurement.

Using the special tool, measure the output shaft end float.
^ Lift the output shaft with a lever and note the resulting measurement, e.g. 0.32 mm.
^ Example: 0.32 m + 0.34 mm + 0.33 mm divided by three = 0.33 mm.

16. Using the special tools, prepare the differential for measuring.
^ Using the special tool 308-224, turn the output shaft back and forth and at the same time press down.
^ Install the special tool 100-002 and set to zero.

17. NOTE: Carry out steps and three times and calculate the average measurement.

Measure the differential end float.
^ Using the special tool lift the differential and note the resulting measurement.

18. Select the correct shim(s) for the differential, input and output shafts. Refer to the Shim Selection Chart.

19. Using the special tools, remove the bearing outer races and shim of the differential, the input shaft and the output shaft again.
^ Install the special tool in the housing recesses.

20. CAUTION: The press pressure must not exceed 15 kN.

Install the selected shims and the bearing cups in the housing section at the clutch end.
^ Heat the housing area to approximately 80 ° C.
^ Cool down the bearing cups.
1 Install the selected shims.
2 Install the bearing cups of the:
^ Input shaft using special tools (250-153 and 308-221).
^ Output shaft using special tool (250-153).
^ Differential using special tools (250-153 and 308-121)

21. CAUTION: Press the bearing races down again. The press pressure must not exceed 15 kN

Installation hook for reverse gear idler (to be fabricated by technician).
^ Diameter of the wire 3 mm.

22. Install the reverse gear idler.
1 Lower thrust washer
2 Needle roller bearing
3 Install the installation hook.
4 Reverse gear idler (the small collar facing downwards)
5 Upper thrust washer
6 Reverse gear idler shaft mounting

23. Install the input and output shafts.
^ Lubricate the taper roller bearings with Merkur manual transmission fluid.
1 Install the input and output shafts together.
2 Remove the installation hook.
3 Press the reverse gear idler shaft mounting down.
4 Apply Gasket maker to the threads of the bolts and tighten them.

24. NOTE: Make sure the fourth gear selector ring is in the neutral position.

Install the fifth/reverse gear selector fork and position it to one side.

25. Install the third/fourth gear selector fork.

26. NOTE: When installed correctly, the selector rods are the same height.

Install the first/second gear selector fork and rods.

27. Install the differential assembly.
1 Differential assembly.
2 Magnetic disk in the recess.

28. Treat the mating face with Gasket maker.
^ The mating face must be dry. Gasket maker must be applied in an even coating to the inside of the mating face. (The even bead of Gasket maker should have a diameter of 2 mm).

29. NOTE: The transaxle housing must not be turned over to tighten the bolts.

Install the transaxle housing (clutch end).
^ Tighten the 16 bolts within 15 minutes, working diagonally.

30. NOTE: Make sure the transaxle is in neutral (the gearshift lever and selector lever must be vertical).

Position the selector mechanism and install the bolts.
^ Coat the mating face with Gasket maker.

31. Using the special tool and the preload gauge, measure the turning torque.

^ Engage fourth gear.
^ Measure the turning torque.
^ If the turning torque is too high, all the measurements (to establish the required shim thickness) must be repeated.

32. Install the vehicle speed sensor(VSS).
1 Install the vehicle speed driven gear (2.5L engine). Install the trigger wheel and VSS (2.0L engine).
2 Install the roll pin.

33. Using the special tools, install the differential oil seals.

34. Install the clutch slave cylinder.
^ Using a new oil seal and Gasket maker, install the clutch slave cylinder