Part 2

TRANSAXLE ASSEMBLY


Disassembly and Assembly

ASSEMBLY





1. Install snap rings (1) along transaxle case groove so that notch mates with housing as shown.

CAUTION:
Check snap ring installing direction. Never mis-assemble.





2. Expand snap rings (1) and install input shaft rear bearing and mainshaft rear bearing to transaxle case using Tool (A).






CAUTION:
Check that snap ring is correctly installed within bearing groove.
3. Install check balls (2) to transaxle case.





4. Install bushings (1) until they reach transaxle case using a suitable tool (A).
5. Apply gear oil to O-ring, and then install it to control shaft.





6. Install control shaft (1) to transaxle case, and tighten bolts (Black Arrow) to the specified torque. Exploded View.
CAUTION:
Replace control shaft and selector as a set.





7. Install selector to control shaft, and then install retaining pin (Black Arrow) to selector using a suitable tool.
CAUTION:
- Be careful with the orientation of selector.
- Replace control shaft and selector as a set.
- Never reuse retaining pin.





8. Install gear catch, spring, and bushing to transaxle case, and then tighten bolt (Black Arrow) to the specified torque. Exploded View Removal And Installation, "Exploded View".

CAUTION:
Replace gear catch, spring, and bushing as a set.
9. Install oil gutter to transaxle case.





10. Install air breather inner tube (2) to transaxle case.

CAUTION:
Never damage air breather inner tube.

NOTE:
It is easier to install when air breather inner tube end is wrapped and narrowed by tape. Remove tape after installation.
11. Insert two way connector (1) straight, and then install it to air breather inner tube.

CAUTION:
Check air breather inner tube for twists after installing.





12. Install differential side oil seals (1) to clutch housing and transaxle case, using Tool





- B: Transaxle case side
- C: Clutch housing side
CAUTION:
- Never incline differential side oil seal.
- Never damage clutch housing and transaxle case.





13. Install differential side bearing outer races until they reach clutch housing and transaxle case using the Tool (A).






CAUTION:
Replace differential side bearing outer race and differential side bearing as a set.





14. Install bushings (1) until they reach clutch housing using a suitable tool (A).
15. Install oil channel to clutch housing.

CAUTION:
Never reuse oil channel.





16. Install mainshaft front bearing so that it becomes even to clutch housing surface using Tool (A).










17. Install input shaft front bearing so that it becomes even to clutch housing surface using Tool (A).






18. Install pinion gear and pinion shaft to clutch housing.
19. Install plug to clutch housing (with ABS models).
20. Install vehicle speed sensor to clutch housing (without ABS models).

NOTE:
Apply specific M/T fluid to the vehicle speed sensor O-ring prior to installation.





21. Install final drive assembly (1) to clutch housing.
22. Install dowel pins (2) and magnet to clutch housing.





23. Install reverse gear assembly to clutch housing, and then install retaining pin to clutch housing using a suitable tool.

CAUTION:
Never reuse retaining pin.
24. Install 1st-2nd shift fork to 1st-2nd fork rod, and then install retaining pin to 1st-2nd shift fork.

CAUTION:
- Never reuse retaining pin.
- Replace 1st-2nd fork rod and 1st-2nd shift fork as a set.





25. Set 1st-2nd fork rod assembly (1) onto mainshaft assembly (2), and then install them to clutch housing.





26. Install lock pins (Black Arrow) to clutch housing.
27. Install 3rd-4th shift fork to 3rd-4th fork rod, and then install retaining pin to 3rd-4th shift fork.

CAUTION:
- Never reuse retaining pin.
- Replace 3rd-4th fork rod and 3rd-4th shift fork as a set.





28. Install 3rd-4th fork rod assembly (1), 3rd-4th coupling sleeve (2), and input shaft assembly (3) to clutch housing according to the following procedures.
a. Pull 1st-2nd fork rod (4) up, and then maintain the neutral position.
b. Set 3rd-4th fork rod assembly onto 3rd-4th coupling sleeve, and then install them together with input shaft assembly to clutch housing.

CAUTION:
- Set lock pin (3rd-4th fork rod side) onto 1st-2nd fork rod groove and then install 3rd-4th fork rod assembly.





- Be careful with the orientation of 3rd-4th coupling sleeve.
- A: 4th main gear side
- B: 3rd main gear side
- Install 3rd input gear of input shaft assembly so that it is set under reverse main gear of 3rd-4th coupling sleeve.
- Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer hub as a set.





c. Install springs and insert keys to 3rd-4th synchronizer hub.
d. Apply gear oil to 4th baulk ring.
e. Install 4th baulk ring.





29. Install 5th-reverse fork rod (1) to clutch housing according to the following procedures.

CAUTION:
Replace 5th-reverse fork rod and 5th-reverse shift fork as a set.
a. Pull gear of reverse gear assembly (2) up.
b. Temporarily install 5th-reverse fork rod to clutch housing.





c. Press gear of reverse gear assembly (1) down and then install
5th-reverse fork rod (2) to clutch housing.

CAUTION:
Set levers of 5th-reverse fork rod so as to align with reverse gear assembly groove (Broken circle).





30. Install 4th main gear (2) and spacer (1) to mainshaft.

CAUTION:
Install spacer so that spacer protrusion faces to transaxle rear side.
31. Press 3rd-4th shift fork down and then shift 3rd-4th coupling sleeve to 3rd gear side.





32. Shift control shaft shift lever (1) to the 3rd gear position.

NOTE:
- If it is not shifted to the 3rd gear position, transaxle case cannot be installed to clutch housing.
- The 3rd gear position means that control shaft select lever is fully rotated clockwise and it is returned approximately 10 degrees.
33. Apply recommended sealant to transaxle case mounting surface of clutch housing.
- Use Genuine Silicone RTV or an equivalent. Recommended Chemical Products And Sealants.

CAUTION:
- Never allow old liquid gasket, moisture, oil, or foreign matter to remain on mounting surface.
- Check that mounting surface is not damaged.
- Apply a continuous bead of liquid gasket to the mounting surface.





34. Install transaxle case to clutch housing. If it is difficult to install, slightly rotate control shaft shift lever counterclockwise, and then install.
- 1: Selector
- 2: Shift fork

CAUTION:
- Never disrupt liquid gasket bead with transaxle case or other objects during installation.
- Be careful to align the lever of 5th-reverse fork rod with reverse gear assembly groove.





35. Rotate input shaft so that bearing and shaft fit each other, and then tighten transaxle bolts (Black Arrow) to the specified torque. Exploded View.
36. Apply recommended sealant to the position switch thread and check ball plug thread. tighten them to transaxle case to specified torque.
- Use Genuine Silicon RTV or an equivalent. Recommended Chemical Products And Sealants.

CAUTION:
Never allow old liquid gasket, moisture, oil, or foreign matter to remain on thread.
37. Apply gear oil to mainshaft spline.





38. Install 5th main gear (1) to mainshaft using a suitable bolt (A)
[M10 x 1.0] and a suitable nut (B).





39. Install adapter plate (1), bushing (2), and 5th input gear (3) to input shaft.

CAUTION:
Be careful with the orientation of adapter plate.
Arrow Indicates Transaxle case side
40. Install 5th-reverse synchronizer hub, 5th-reverse coupling sleeve, and 5th-reverse shift fork according to the following procedures.
a. Apply gear oil to 5th-reverse baulk ring.





b. Install 5th-reverse baulk ring (1) to 5th input gear.

CAUTION:
Be careful with the orientation of 5th-reverse baulk ring.
c. Install synchronizer levers (2) to 5th-reverse synchronizer hub (3).

CAUTION:
- Replace 5th-reverse synchronizer hub and 5th-reverse coupling sleeve as a set.
- Be careful with the orientation of synchronizer lever.
Arrow Indicates 5th-reverse synchronizer hub side
d. Install 5th-reverse synchronizer hub assembly and washer to input shaft.

CAUTION:





- Be careful with the orientation of 5th-reverse synchronizer hub.
- : 5th input gear side





- Never allow synchronizer lever (1) to mount on to 5th-reverse baulk ring (2) protrusion (A).
Arrow Indicates 5th-reverse synchronizer hub

e. Set 5th-reverse shift fork (1) to 5th-reverse coupling sleeve, and then install them to 5th-reverse fork rod and input shaft.





- A: Pin punch
- B: Bolt
- C: Nut
CAUTION:





- Be careful with the orientation of 5th-reverse coupling sleeve.
- Arrow Indicates 5th input gear side
- Replace 5th-reverse synchronizer hub and 5th-reverse coupling sleeve as a set.
- Replace 5th-reverse shift fork and 5th-reverse fork rod as a set.
f. Check that the gear position is in the 3rd position. Press 5th-reverse shift fork and shift to 5th gear.
g. Tighten bolt to the specified torque. Exploded View.
h. Tighten nut to the specified torque. Exploded View.

CAUTION:
Never reuse nut.
i. Install retaining pin to 5th-reverse shift fork using a suitable tool.

CAUTION:
Never reuse retaining pin.





41. Shift control shaft shift lever (1) to the neutral position.
42. Install O-ring to rear housing.





43. Install rear housing to transaxle case, and tighten bolts (Black Arrow) to the specified torque. Exploded View.

CAUTION:
Never pinch O-ring when installing rear housing.
44. Install drain plug according to the following procedures.
a. Install gasket to drain plug.

CAUTION:
Never reuse gasket.
b. Install drain plug to clutch housing using a suitable tool.
c. Tighten drain plug to the specified torque. Exploded View Removal And Installation,
"Exploded View".
45. Install filler plug according to the following procedures.
a. Install gasket to filler plug, and then install them to transaxle case.

CAUTION:
Never reuse gasket.
b. Tighten filler plug to the specified torque. Exploded View.

CAUTION:
Fill with gear oil before tightening filler plug to the specified torque.