Part 1 of 3
Transaxle Assemble
1. Using a dial indicator, check the output shaft journals for runout. Maximum runout is 0.03 mm (0.0012 inch).
2. If the runout exceeds the maximum, replace the output shaft.
3. Using a micrometer, measure the outer diameter of the input shaft journal surfaces.
^ 1: 31.985 mm (1.2592 inch)
^ 2: 37.985 mm (1.4955 inch)
^ 3: 32.985 mm (1.2986 inch)
4. If the out diameter is less than the minimum, replace the output shaft.
5. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.35 mm (0.014 inch). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.
6. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.70 mm (0.0276 inch). If the clearance is less than the minimum, replace the synchronizer ring.
7. Check the 2nd gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.
8. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.75 mm (0.0295 inch). If the clearance is less than the minimum, replace the synchronizer ring.
9. Check the 1st gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.
10. Using a press, install the front bearing inner race.
11. Install the snap ring to the output shaft. Select a snap ring that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.004 inch).
12. Assemble the reverse gear assembly.
13. Install the ball to the output shaft.
14. Install the 1st gear thrust washer to the output shaft.
15. Apply gear oil to the roller bearing, then install the roller bearing to the output shaft.
16. Install the No.1 synchronizer to 1st gear.
17. Place the reverse gear assembly and align the No.1 synchronizer ring slots with the No.1 shifting keys.
18. Using a press, install the reverse gear assembly, 1st gear and the No.1 synchronizer to the output shaft.
19. Select a snap ring that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.004 inch). Install the snap ring to the output shaft.
20. Install the spacer to the output shaft.
21. Install the roller bearing to the output shaft.
22. Place the No.2 synchronizer ring on the 2nd gear.
23. Install the 2nd gear with the No.2 synchronizer rings and align the No.2 synchronizer ring slots with the No.1 shifting keys.
24. Using a press, install the 3rd driven gear to the output shaft.
25. Install the spacer to the output shaft.
26. Using a press, install the radial ball bearing and the 4th driven gear to the output shaft.
27. Assemble the No.2 hub sleeve assembly.
28. Apply gear oil to the roller bearing, then install the roller bearing to the input shaft.
29. Install the 3rd gear on the input shaft.
30. Install the No.2 3rd gear synchronizer ring.
31. Using a press, install the No.2 hub sleeve and 3rd gear to the input shaft.
32. Select a snap ring that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.004 inch).
33. Using a brass bar and hammer, install the No.2 hub sleeve snap ring.
34. Place the No.2 4th gear synchronizer ring on the No.2 Hub sleeve assembly and align the No.2 synchronizer ring slots with the No.2 shifting keys.
35. Install the spacer to the input shaft.
36. Apply gear oil to the roller bearing, then install the roller bearing on the input shaft.
37. Install 4th gear to the input shaft.
38. Using a press, install the center ball bearing.
39. Select a snap ring that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.004 inch).
40. Install the input shaft snap ring.