Assembly

TRANSAXLE ASSEMBLY

Assembly






1.Install pinion gear (1) and pinion shaft (2) to clutch housing.

CAUTION:
Replace transaxle assembly when replacing clutch housing.
2.Install plug to clutch housing.





3.Install 2 way connector (1) to clutch housing.





4.Install bushings (1) so that they becomes even to clutch housing edge surface, using a drift (A) [Commercial service tool].
5.Install oil channel to clutch housing.

CAUTION:
Never reuse oil channel.





6.Install mainshaft front bearing outer race to clutch housing, using the drift (A) [SST: KV-38100200 ( - )].

CAUTION:
Replace mainshaft front bearing outer race and mainshaft front bearing inner race as a set.





7.Install input shaft oil seal (1) to clutch housing, using the drift (A)
[SST: ST-33220000 ( - )].





8.Install snap ring (1) and oil channel (2) to transaxle case.

CAUTION:
- Select and install snap ring that has the same thickness as previous one.
- Replace transaxle assembly when replacing transaxle case.
9.Install mainshaft rear bearing adjusting shim to transaxle case.

CAUTION:
Select mainshaft rear bearing adjusting shim, as per the following procedure when replacing mainshaft adjusting shim, 6th main gear, 5th main gear, or 4th main gear.
- Replace mainshaft adjusting shim.
- If new mainshaft adjusting shim is thinner than previous one, offset the thickness difference by selecting thicker mainshaft rear bearing adjusting shim.
- If new mainshaft adjusting shim is thicker than previous one, offset the thickness difference by selecting thinner mainshaft rear bearing adjusting shim.
- Replace 6th main gear, 5th main gear, or 4th main gear.
- Measure the thickness of the main gear used before and the new main gear
- Increase the thickness of the mainshaft rear bearing adjusting shim, if the difference is smaller than 0.025 mm (0.0010 in).
- Decrease the thickness of the mainshaft rear bearing adjusting shim, if the difference is greater than 0.025 mm (0.0010 in).





10.Install mainshaft rear bearing outer race to transaxle case, using the drift (A) [SST: KV-38100200 ( - )].

CAUTION:
Replace mainshaft rear bearing outer race and mainshaft rear bearing inner race as a set.





11.Install bushings (1) to transaxle case, using a drift (A) [Commercial service tool].





12.Install oil gutter (1) to transaxle case.





13.Install shifter lever B (1) to transaxle case.

CAUTION:
Replace shifter lever A and shifter lever B as a set.
14.Install shifter lever A to transaxle case.

CAUTION:
Replace shifter lever A and shifter lever B as a set.





15.Install retaining pin to shifter lever A (1), using a pin punch.

CAUTION:
Never reuse retaining pin.
16.Install shim to transaxle case.





17.Install differential side bearing outer race (transaxle case side)
to transaxle case, using the drift (A) [SST: ST-33400001 (J26082)].

CAUTION:
Replace differential side bearing outer race (transaxle case side) and differential side bearing inner race (transaxle case side) as a set.





18.Install differential side bearing outer race (clutch housing side) to clutch housing, using the drift (A) [SST: KV-38100200 ( - )].

CAUTION:
Replace differential side bearing outer race (clutch housing side) and differential side bearing inner race (clutch housing side) as a set.





19.Install differential side oil seals (1) to clutch housing and transaxle case, using the drift [Stamping number: B.vi 1666-B] of the drift set [SST: KV-32500QAA ( - )].





Dimension "L1": 1.2 - 1.8 mm (0.047 - 0.071 in)
Dimension "L2": 2.7 - 3.3 mm (0.106 - 0.130 in)

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

20.Install magnet to clutch housing.
21.Install final drive assembly to clutch housing.





22.Set fork rod (1) to input shaft assembly (2), and then install them to clutch housing.





23.Install mainshaft assembly (1), as per the following procedure.
a.Pull up input shaft assembly (2) and fork rod (3).
b.Set 1st-2nd fork rod (4) to mainshaft assembly, and then install them to clutch housing.





24.Install reverse idler shaft assembly (1), as per the following procedure.
a.Install spring washer to clutch housing.
b.Pull up input shaft assembly (2), mainshaft assembly (3), fork rod (4), and 1st-2nd fork rod (5).
NOTE:
It is easier to pull up when shifting each fork rod to each shaft side.
c.Set reverse fork rod (6) to reverse idler shaft assembly, and then install them to clutch housing.





25.Shift 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to the neutral position.
26.Install selector (4) to clutch housing.

CAUTION:
Replace selector lever and selector as a set.





27.Install selector spring (1) to return bushing (A).
28.Apply recommended sealant to mounting surface of transaxle case.
-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 sealant bead continuously.





29.Install transaxle case to clutch housing while rotating shifter lever A (1) in the direction as shown in the figure.





30.Install reverse idler shaft mounting bolt (black arrow), as per the following procedure.
a.Install seal washer to reverse idler shaft mounting bolt, and install reverse idler shaft mounting bolt to transaxle case.

CAUTION:
Never reuse seal washer.
b.Tighten reverse idler shaft mounting bolt to the specified torque.





31.Tighten transaxle case mounting bolts (black arrow) to the specified torque.





32.Install position switch (1), as per the following procedure.
a.Apply recommended sealant to threads of position switch.
-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 thread.
b.Install position switch to transaxle case, and tighten it to the specified torque.
33.Install bracket (2) to transaxle case, and tighten mounting bolt to the specified torque.
34.Install selector lever (3), as per the following procedure.
a.Install selector lever to transaxle case.

CAUTION:
Replace selector lever and selector as a set.
b.Install retaining pin to selector lever, using a pin punch.

CAUTION:
Never reuse retaining pin.
35.Install drain plug, as per the following procedure.
a.Install gasket to drain plug.

CAUTION:
Never reuse gasket.
b.Install drain plug to clutch housing, using a socket [Commercial service tool].
c.Tighten drain plug to the specified torque.
36.Install filler plug, as per the following procedure.
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.

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