Assembly
ASSEMBLYClutch Housing
1. Hammer the new striking rod oil seal into clutch housing as far as it will go using Tool.
CAUTION: Do not reuse striking rod oil seal.
2. Hammer the differential oil seal into clutch housing with a suit able tool until it becomes flush with clutch housing end face.
CAUTION: Do not reuse differential oil seal.
3. Hammer input shaft oil seal into clutch housing as far as it will go with a suitable tool.
CAUTION: Do not reuse input shaft oil seal.
4. Hammer the dust seal into clutch housing as far as it will go using Tool.
CAUTION: Do not reuse dust seal.
5. Install outer race of differential side bearing using Tool.
6. Install new oil channel (mainshaft).
CAUTION: Pay attention to installation direction of oil channel.
7. Align the notches on mainshaft front bearing and transaxle case. Then, install mainshaft front bearing with a suitable tool.
8. Install mainshaft bearing retainer, tighten bolt to specification.
9. Attach boot, striking rod, and striking lever to clutch housing. Install new retaining pin for striking lever using Tool.
CAUTION:
^ Before installing striking rod, wrap the end with a vinyl tape or similar product to prevent oil seal from being damaged.
^ Do not reuse retaining pin.
10. Hammer the new Welch plug (striking lever side) with a general purpose drift [OD: 12 mm (0.47 inch].
CAUTION: Do not reuse Welch plug.
11. Install selector, selector shaft, and selector shaft pin into clutch housing.
12. Hammer the new Welch plug (selector shaft side) with a general purpose drift [OD: 12 mm (0.47 inch)].
CAUTION: Do not reuse Welch plug.
13. Install select check leaf spring, return spring, steel ball, reverse gate, selector arm, bushing, and return bearing.
14. Tighten the two reamer bolts to specification.
CAUTION: Use correct reamer bolts for each installation point, because each bolt has a different length.
15. Install oil pocket.
16. Install differential assembly, input shaft assembly, and mainshaft assembly into clutch housing.
CAUTION: Be careful not to damage input shaft oil seal during installation of input shaft assembly.
17. Install 5th & reverse shift fork.
18. Install 1st & 2nd shift fork, bracket, and fork rod.
19. Install retaining pin for 1st & 2nd bracket using Tool.
CAUTION: Do not reuse retaining pin.
20. Install two check balls.
21. Install interlock pin into 5th & reverse fork rod using Tool.
22. Install reverse switch bracket, 5th & reverse bracket, and fork rod.
23. Install new retaining pin for 5th & reverse shift fork and reverse switch bracket using Tool.
CAUTION: Do not reuse retaining pin.
24. Install 5th & reverse bracket stopper ring.
CAUTION: Do not reuse stopper pin.
25. Install check ball and interlock plunger.
26. Install 3rd & 4th shift fork, bracket, and fork rod.
27. Install 3rd & 4th bracket retaining pin using Tool.
CAUTION: Do not reuse retaining pin.
28. Install 3rd & 4th shift fork stopper ring.
CAUTION: Do not reuse stopper ring.
29. Install check ball, check pin, and check spring, and apply Anaerobic Liquid Gasket or equivalent onto the check plug. Then, tighten the check plug to specification.
Transaxle Case
1. Insert differential oil seal into differential case with a suitable tool until it becomes flush with case end face.
2. Install Welch plug into transaxle case with a suitable tool.
3. Calculate dimension "N" (thickness of adjusting shim) using the following procedure to satisfy specification of end play for differential side bearing.
End play : 0.15 - 0.21 mm (0.0059 - 0.0083 inch)
Dimension "N" = (N1 - N2) + End play
N: Thickness of adjusting shim
N1: Distance between clutch housing case end face and mounting face of adjusting shim
N2: Distance between differential side bearing and transaxle case
Use the "Available Shims" table for the available shim sizes.
a. Using dial gauge and scale, measure dimension "N1" between clutch housing case end face and mounting face of adjusting shim.
b. Install outer race onto differential side bearing on final gear side. Holding the outer race horizontally by hand, rotate the final gear five times or more (for smooth movement of bearing roller).
c. Using dial gauge and scale as shown, measure dimension "N2" between differential side bearing outer race and transaxle case end face.
4. Install the selected shim and bearing outer race using Tool.
5. Measure the turning torque of the final drive assembly using Tool.
Turning torque of final drive assembly (New bearing): 2.9 - 6.9 Nm (30 - 70 kgf-cm, 26 - 61 inch lbs.)
^ When the old bearing is used again, turning torque will be slightly less than the above.
^ Make sure turning torque is close to the specified range.
^ Changes in turning torque of final drive assembly per revolution should be within 1.0 Nm (10 kgf-cm, 8.7 inch lbs.) without binding.
6. Calculate dimension "O" (thickness of adjusting shim) using the following procedure to satisfy specification of end play for input shaft rear bearing.
End play : 0 - 0.06 mm (0 - 0.0024 inch)
Dimension "O" = (01 - 02) + End play
O : Thickness of adjusting shim
O1: Distance between transaxle case end face and mounting face of adjusting shim
O2: Distance between clutch housing case end face and end face of input shaft rear bearing
Use the "Available Shims" table for the available shim sizes.
a. Using block gauge, scale, and dial gauge, measure dimension "01" between transaxle case end face and mounting face of adjusting shim.
b. Using block gauge, scale, and dial gauge as shown in the figure, measure dimension "02" between clutch housing case end face and end face of input shaft rear bearing.
7. Install selected input shaft rear bearing adjusting shim onto input shaft.
8. Install oil gutter into transaxle case.
9. Clean mating surfaces of clutch housing and transaxle case. Check for cracks and damage, then apply sealant. Use Genuine Anaerobic Liquid Gasket or equivalent.
10. Install transaxle case onto clutch housing, and tighten mounting bolts with specified torque.
Transaxle case mounting bolts: Refer to "CASE COMPONENTS".
11. Apply sealant to threads of back-up lamp switch, PNP switch, and drain plug, then install them. Use Genuine Anaerobic Liquid Gasket or equivalent.
NOTE: Fill the case with oil before installation of filler plug.
12. Install speedometer pinion assembly.
CAUTION: Do not reuse O-ring.
13. Install check springs and check balls. Apply sealant to the thread on the check plug, and install it.
14. Calculate thickness of adjusting shim using the following procedure to satisfy specification of end play for mainshaft rear bearing.
End play : 0 - 0.06 mm (0 - 0.0024 inch)
Dimension "P" = (P1 - P2) + End play
P: Thickness of adjusting shim
P1: Distance between transaxle case end face and mainshaft rear bearing
P2: Distance between adjusting shim end face of rear cover and transaxle mounting face
Use the "Available Shims" table for the available shim sizes.
a. Using dial gauge as shown in the figure, measure dimension "P1" between transaxle case end face and mainshaft rear bearing.
b. Using dial gauge as shown in the figure, measure dimension "P2" between adjusting shim mounting face of rear cover and transaxle mounting face.
15. Using snap ring pliers and flat-head screwdriver as shown, install snap ring.
CAUTION: Do not reuse snap ring.
16. Install selected mainshaft adjusting shim.
17. Install reverse idler gear, O-ring, thrust washers (front and rear), and bearing onto reverse idler shaft.
18. Install snap ring into transaxle case using snap ring pliers.
CAUTION:
^ Do not reuse snap ring.
^ Do not reuse O-ring.
^ Before installation, apply gear oil to O-ring.
19. Using feeler gauge, measure the end play of snap ring, and select a snap ring suitable to satisfy the following specification.
End play : 0.05 - 0.25 mm (0.0020 - 0.0098 inch)
Use the "Available Shims" table for the available shim sizes.
20. Install selected snap ring with a suitable tool.
CAUTION: Do not reuse snap ring.
21. Apply gear oil to rear cover O-ring, and install rear cover, side cover gasket, and side cover. Then tighten mounting bolts with specified torque.
Use the "Available Shims" table for the available shim sizes.
CAUTION: Do not reuse mounting bolts for rear cover and side cover.