Assemble
Tools Required- J43707 Transmission Support Fixture
- 87-92-202 Output Shaft Bearing Race Sleeve
- 87-91-204 Output Shaft Bearing Race Sleeve
- 87-92-103 Output Shaft Assembly Tool
- 87-90-867 Input Shaft Bearing Ring
- 87-91-261 Output Shaft Remover
- 78-41-067 Sleeve, Inner Drive
- 87-91-428 Driver
- SA9179NE Dial Indicator
- 87-92-517 Support, Input Shaft
- 87-92-137 Milled Bearing Race
- 87-92-053 Companion Flange
- 87-92-095 10 Kilogram Weight
- 83-90-114 Sleeve
- J7754-C Inch Pound Torque Wrench
- 87-92-061 Millimeter Disc
- 87-91-303 150mm Puller Arms
- 87-91-287 Puller
- 87-91-311 Sleeve, Bearing Driver Shaft
- 87-92-129 Lifting Eye
ASSEMBLY
NOTICE: In all work involving disassembly of transaxle, a new output shaft nut and crush sleeve must be installed during reassembly.
IMPORTANT: Lubricate all rotating parts and bearings with manual transaxle fluid (PIN 21018899) during assembly.
1. Mount clutch housing on holding fixture J43707 (if necessary).
2. Install differential assembly into clutch housing.
3. Make sure output shaft oil trough is in place in clutch housing prior to installing output shaft.
4. Install output shaft into clutch housing bore. Lubricate bearing and install output shaft bearing race. Tap race with a plastic hammer to start in bore. Install bearing retainer and tap down bearing race using retainer and tools 87-92-202 and 87-91-204 as shown.
5. Apply Loctite(R) 242 Threadlocker (P/N 21485277) to three middle output shaft bearing retainer bolts and install.
Torque: 45 Nm (33 ft. lbs.)
6. Apply Loctite(R) 242 Threadlocker (P/N 21485277) to one outer output shaft bearing retainer bolt and install.
Torque: 24 Nm (18 ft. lbs.)
IMPORTANT: There must be a 15 mm clearance between 1st driven gear and the clutch housing to be able to install the input shaft. This can be done by putting the output shaft nut between clutch housing and 1st driven gear.
7. Install 1st/2nd driven gear assembly, held together with tool 87-92-103 on output shaft.
NOTICE: Third driven gear must be reinstalled in the same orientation as it was removed to avoid noise concerns.
8. Install 3rd driven gear and spacer sleeve on output shaft.
9. Lubricate input shaft bearing and install input shaft into clutch housing. Remove output shaft nut from under 1st driven gear, and install a plastic tie as shown to hold input and output shafts together.
NOTICE: A new output shaft crush sleeve must be used.
IMPORTANT: 4th driven gear should be installed with machined groove facing down (towards 3rd gear).
10. Carefully tap down output shaft gears to make sure that gears are against surface of clutch housing. This can be done with tools 87-91-204 and 87-90-867. Install new crush sleeve and 4th driven gear.
11. Install 87-91-261 and tighten until 4th drive gear and 4th driven gear are level with each other.
12. Remove plastic ties and tool 87-92-103.
NOTICE: Make sure reverse idler gear shaft lube hole is facing correct way (refer to illustration). If the hole is not facing the correct direction, reposition shaft before installation.
13. Lift input shaft slightly and install reverse idler gear shaft assembly. The shaft lubrication hole should be facing lube passage in clutch housing.
14. Install shift linkage mechanism into clutch housing.
a. Put 1st/2nd synchronizer sleeve on output shaft in the 2nd gear position.
b. Put 3rd/4th synchronizer sleeve on input shaft in the 4th gear position.
c. Insert 1st/2nd and 3rd/4th shift forks into synchronizer sleeves and push mechanism into place.
d. Install locating sleeves and loosely install outboard shift linkage bolt.
NOTICE: If thread sealant is not used on short reverse shift lever assembly bolt, a fluid leak could occur.
IMPORTANT: Reverse shift lever assembly oil plate should be under edge of shift linkage mechanism.
15. Install reverse shift lever assembly. Loosely install longer mounting bolt. Apply Loctite(R) 592 thread sealant (P/N 21485278) on shorter bolt and install. Tighten reverse shift lever assembly bolts and shift linkage bolt.
Torque: 24 Nm (18 ft. lbs.)
16. Install reverse gear fork to reverse gear synchronizer sleeve. Make sure fork is in position on reverse shift lever and install reverse gear fork shaft.
17. Engage reverse gear using shift linkage assembly to check for full engagement of reverse.
18. Lightly lubricate shift control shaft with grease and insert through seal in clutch housing.
19. Insert shift control shaft through shaft block. Put shaft block in position and install bolt.
Torque: 24 Nm (18 ft. lbs.)
20. Shift transaxle into all gear positions with shift control shaft to check for proper operation. Also check shift interlocking feature by trying to engage 1st and reverse gears at the same time. This should be impossible.
NOTICE: Care must be taken when applying Loctite to the clutch housing. If any Loctite gets in the transaxle filter vent (noted by arrow in illustration), it will plug vent and cause transaxle oil leaks.
21. Apply a bead of Loctite(R) 515 Gasket Eliminator (P/N 21005993) or equivalent down center of the mating flange on clutch housing. The bead should be 1 - 3 mm (0.039 - 0.118 inch) wide.
22. Check for proper alignment of the reverse idler shaft support bracket. The bracket bolt has to be installed after the transaxle case is installed.
23. Shift transaxle into 3rd gear to prevent shift mechanism shafts from moving during case installation.
24. Install transaxle case onto clutch housing and hand start two case to clutch housing bolts. Tap up case to clutch housing alignment sleeves and loosely install reverse idler gear shaft bracket bolt.
25. Install and tighten all case to clutch housing bolts in a crisscross pattern.
Torque: 24 Nm (18 ft. lbs.)
26. Install and tighten reverse idler shaft bolt. Check condition of O-ring and replace if necessary.
Torque: 24 Nm (18 ft. lbs.)
27. Tighten reverse idler gear shaft bracket bolt.
Torque: 24 Nm (18 ft. lbs.)
28. Lubricate and install output shaft bearing using 87-91-261.
29. Install 5th driven gear onto output shaft. Tap down with 78-41-067 far enough to allow installation of tool 87-91-261.
30. Install 87-91-261 and tighten tool until 5th driven gear is against output shaft bearing. Install a new output shaft nut.
IMPORTANT: Carefully tap input shaft with a plastic hammer from engine side so input shaft bearing race is against input shaft bearing retainer.
IMPORTANT: If a dial indicator with a magnetic base is used, it will not work with an aluminum case. Locking C-clamp pliers can be used to hold indicator base to transaxle case.
31. Install 87-91-428 to input shaft and install dial indicator SA9179NE (or equivalent) on input shaft bearing inner race. Attach a drill to 87-91-428 and spin transaxle to seat bearings. Turn transaxle input shaft about 20 revolutions while pushing and pulling on drill. While turning, measure axial play on dial indicator. Axial play should be between 0.09 - 0.15 mm (0.004 - 0.006 inch).
32. Adjust axial play as needed by adding or removing shims under input shaft bearing retainer.
- More shims = decreased preload
- Less shims = increased preload
- Shims are available in 0.10, 0.15, and 0.30 mm thicknesses.
If axial play adjustment is not necessary, tighten input shaft bearing retainer bolts evenly.
Torque: 38 Nm (28 ft. lbs.)
33. Lubricate and install 5th drive gear bearing, 5th drive gear, 5th gear blocking ring, and blocking ring spring.
NOTICE: Installation of 5th gear synchronizer hub with a hammer can cause transaxle bearing damage.
34. Install 5th gear synchronizer hub using puller 87-91-287 with short arms 87-91-303. Lifting eyes 87-92-129 must be installed in case, and sleeve 87-91-311 is used on top of hub as shown. The blocking ring lugs must fit in hub gaps.
IMPORTANT: The 5th gear synchronizer sleeve can only be placed on hub when tall teeth on sleeve are aligned with deep tooth grooves on hub.
35. Install 5th gear synchronizer sleeve. Reference sleeve alignment mark made during disassembly.
NOTICE: Do not pry under gear teeth. Make sure screwdriver is as far past the gear teeth as possible.
36. Install dial indicator SA9179NE (or equivalent) on top of 5th driven gear. Engage 1st gear on transaxle and engage 5th gear by pressing down 5th gear synchronizer sleeve. Install a bolt in case as shown so that you are not prying against the rear cover sealing surface. Measure output shaft end play by prying up on 5th driven gear and watching dial indicator. Tighten output shaft nut until end play is within the following specification.
0.06 ± 0.05 mm (0.002 ± 0.002 inch)
37. Disengage 1st gear and remove 5th gear synchronizer sleeve.
38. Check and adjust preload of differential bearings as follows:
Install ground bearing race 87-92-137 in place of left differential bearing race. Install about 2 mm of shims on top of ground bearing race. Remove O-ring from axle seal retainer and install without any fasteners.
NOTICE: Make sure drill is spinning in clockwise direction. Tool 87-92-053 will unravel if drill is spinning in wrong direction.
39. Place 10 kg weight 87-92-095 on top of axle seal retainer. Install 87-92-053 on output shaft. Use a drill to rotate differential at least 20 revolutions. Use a feeler gauge and measure between transaxle case and axle seal retainer in three different places. Take the average of three readings and adjust shims so that average measurement corresponds to readings in the following table.
- More shims = increased preload
- Less shims = decreased preload
- Shims are available in 0.10, 0.15, 0.30, and 0.50 mm thicknesses.
NOTICE: Do not forget to remove ground bearing race tool 87-92-137. Leaving it in will damage transaxle.
40. Remove 10 kg weight, axle seal retainer, and ground bearing race 87-92-137.
IMPORTANT: The axle seal retainer will not be torqued to specification until the final output shaft preload is set. If the axle seal retainer is torqued down at this point, it will interfere with the final output shaft measurements.
41. Install differential bearing race and tap down using 83-90-114. Install shim pack determined in last step. Install O-ring on axle seal retainer, lubricate O-ring, and install axle seal retainer. Tighten retainer bolts until retainer is 0.15 mm (0.006 inch) from the transaxle case.
42. Turn transaxle to horizontal (in car) position.
IMPORTANT: Make sure that transaxle is in neutral.
43. Remove hose from tool 87-91-428, install a 3/8" - 16 mm deep well socket into one end of hose, and insert other end over input shaft as shown. Install inch pound torque wrench J7754C (or equivalent) to socket and rotate clockwise several rotations at a even speed. Read the average value on torque wrench during rotation. The torque should be between 0.10 - 0.30 Nm (1 - 3 inch lbs.).
If torque is higher or varies greatly while rotating input shaft, there may be contamination in the bearings. The transaxle should be disassembled to determine cause of excessive torque.
NOTICE: Make sure drill is spinning in a clockwise direction. Tool 87-92-053 will unravel if drill is spinning in the wrong direction.
IMPORTANT: Make sure tool 87-92-053 does not damage dial indicator when spinning output shaft.
44. Turn transaxle back to vertical position. Place dial indicator tip on 5th driven gear as shown. Install tool 87-92-053 on output shaft. Turn output shaft several revolutions to seat bearings. Press down on drill and turn output shaft for 20 revolutions and zero dial indicator. Pull up on drill and turn for another 20 revolutions and take a measurement when reading stabilizes. Remove all tools.
45. Engage 1st gear on transaxle and engage 5th gear by pressing down 5th gear synchronizer sleeve.
46. Install output shaft nut socket 87 92 061 on output shaft nut. Calculate the number of mm on socket that the output shaft nut must be tightened. This is done by adding the measured value that was determined in step 44 to the nominal value from the chart below. Set the socket to the number of mm that you have calculated. Mark the tooth at that number on the socket with a marker.
Example: Reading from step 44 is 0.38 + nominal value 0.08 = 46 value on socket 87-92-061.
47. Tighten output shaft nut in 2 - 3 stages until the zero (O) on socket is at marked gear tooth.
48. Before taking a more precise measurement of output shaft bearing preload, make sure the following conditions are true:
- Input shaft bearing end play is 0.09 - 0.15 mm (0.003 - 0.006 inch)
- Axle seal retainer installed but not tight. End play is 0.15 mm (0.006 inch)
49. Turn transaxle to the horizontal (in car) position. Disengage 1st gear and remove 5th gear synchronizer sleeve.
50. Install torque wrench J7754C (or equivalent) on output shaft nut. Transaxle must be in neutral. Rotate wrench clockwise at an even speed. Read average value during rotation.
51. Subtract average value from input shaft (taken in step 43) from average value of output shaft. The calculated preload is a measurement of output shafts turning torque, normally 0.75 ± 0.25 Nm (6.75 ± 2.25 inch lbs.)
Example:
Output Shaft Reading: 1.10 Nm (10 inch lbs.)
Input Shaft Reading: 0.30 Nm (2.7 inch lbs.)
Preload: 1.10 - 0.30 = 0.80 Nm (7.2 inch lbs.)
If the average torque is less than 5 Nm (4.5 inch lbs.):
Cause: Bearings are not sufficiently tight.
Correction: Tighten output shaft nut by two numbers on tool 87-92-061. Take another measurement. Repeat process until correct torque is reached.
If the average torque varies greatly:
Cause: Contamination in bearings or faulty synchronizer blocking rings.
Correction: Disassemble transaxle, inspect components and repair as necessary.
If the average torque is higher than 1.0 Nm (9 inch lbs.):
Cause: Bearings are too tight or contamination in bearings.
Correction: Install a new crush sleeve in transaxle and reset bearing preloads.
52. Lock output shaft nut using a chisel and a hammer.
53. Turn transaxle to vertical position. Put transaxle in 3rd gear.
IMPORTANT: The 5th gear synchronizer sleeve can only be placed on hub when tall teeth on sleeve are aligned with deep tooth grooves on hub.
54. Install 5th gear fork and synchronizer sleeve together. Reference sleeve alignment mark made during disassembly. Install a new hub snap ring.
55. Install a new 5th gear fork retaining pin.
56. Tighten the axle seal retainer bolts.
Torque: 24 Nm (18 ft. lbs.)
57. Clean rear cover gasket surfaces. Surfaces must be clean and dry.
58. Install rear cover gasket.
59. Install rear cover and bolts and torque using a crisscross pattern.
Torque: 24 Nm (18 ft. lbs.)
60. Install back up lamp switch with a new gasket.
Torque: 24 Nm (18 ft. lbs.)
61. Check that magnet is in transaxle drain plug. Clean and apply thread sealant (P/N 21485278) to transaxle drain plug and install.
Torque: 50 Nm (37 ft. lbs.)
62. Put grease (P/N 21005995) between lips of input shaft seal.
NOTICE: Thread sealant must be used on slave cylinder bolts to prevent a transaxle oil leak.
63. Install slave cylinder. Use Loctite(R) 592 (P/N 21485278) thread sealant on screws.
Torque: 10 Nm (7 ft. lbs.)
64. Install clutch actuator cylinder pipe and pipe sleeve.