Assembly
TRANSAXLE ASSEMBLY- TOOLS REQUIRED
- 78-41-067 Sleeve, Inner Drive
- 83-90-114 Sleeve
- 87-90-867 Input Shaft Bearing Ring
- 87-91-204 Output Shaft Bearing Race Sleeve
- 87-91-261 Output Shaft Remover
- 87-91-428 Driver
- 87-92-053 Companion Flange
- 87-92-061 Output Shaft Nut Socket
- 87-92-095 10 Kilogram Weight
- 87-92-103 Output Shaft Assembly Tool
- 87-92-137 Milled Bearing Race
- 87-92-202 Output Shaft Bearing Race Sleeve
- J43707 Transmission Support Fixture
- J44362 Input Shaft Support
- J7754-C Inch Pound Torque Wrench
- SA9179NE Dial Indicator
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 lubricant (P/N 21018899) during assembly.
1. Mount clutch housing on Transmission Support Fixture J43707 (if necessary).
2. Install differential assembly into clutch housing.
3. Make sure output shaft oil feed tube is staked 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 Output Shaft Bearing Race Sleeve 87-92-202 and Output Shaft Bearing Race Sleeve 87-91-204 as shown.
5. Apply Loctite 242@ Thread locker (P/N 21485277) to three middle output shaft bearing retainer bolts and install.
Torque: Output Shaft Bearing Retainer Bolts (Inner): 45 Nm (33 ft. lbs.)
6. Apply Loctite 242(R) Thread locker (P/N 21485277) to one outer output shaft bearing retainer bolt and install.
Torque: Output Shaft Bearing Retainer Bolts (Outer): 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 an object on top of main shaft bearing retainer so that there will be a 15 mm clearance between the bearing retainer and the 1st/2nd driven gear assembly when it is installed.
8. Install 1st/2nd driven gear assembly, held together with tool Output Shaft Assembly 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.
9. Install 3rd driven gear and spacer sleeve on output shaft.
10. Lubricate input shaft bearing and install input shaft into clutch housing. Remove the object holding up the 1st/2nd driven gear assembly 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).
11. Carefully tap down output shaft gears to make sure that gears are against surface of clutch housing. This can be done with tools Input Shaft Bearing Ring 87-91-204 and Input Shaft Bearing Ring 87-90-867. Install new crush sleeve and 4th driven gear.
NOTICE: Do not compress the crush sleeve when installing 4th driven gear. Any compression of the sleeve done other than by tightening the output shaft nut will require disassembly of the transaxle and replacement of the crush sleeve.
12. Install Output Shaft Bearing Race Sleeve Tool 87-91-204 on top of 4th driven gear and tap down the 4th driven gear until contact is made with the crush sleeve.
13. Remove plastic ties and Output Shaft Bearing Race Sleeve Tool 87-91-204.
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.
14. Lift input shaft slightly and install reverse idler gear shaft assembly. The shaft lubrication hole should be facing lube passage in clutch housing.
15. Install shift linkage mechanism into clutch housing.
15.1. Put 1st/2nd synchronizer sleeve on output shaft in the 2nd gear position.
15.2. Put 3rd/4th synchronizer sleeve on input shaft in the 4th gear position.
15.3. Insert 1st/2nd and 3rd/4th shift forks into synchronizer sleeves and push mechanism into place.
15.4. 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.
16. Install reverse shift lever assembly. Loosely install longer mounting bolt. Apply Loctite 592(R) thread sealant (P/N 21485278) on shorter bolt and install. Tighten reverse shift lever assembly bolts and shift linkage bolt.
Torque:
Reverse Shift Lever Bolts: 24 Nm (18 ft. lbs.)
17. 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.
18. Engage reverse gear using shift linkage assembly to check for full engagement of reverse.
19. Lightly lubricate shift control shaft with grease and insert through seal in clutch housing.
20. Insert shift control shaft through shaft block. Put shaft block in position and install bolt.
Torque:
Transaxle Shift Control Shaft Block: 24 Nm (18 ft. lbs.)
21. 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 gasket material to the clutch housing. If any gasket material gets in the transaxle filter vent (noted by arrow in illustration), it will plug vent and cause transaxle oil leaks.
22. Apply a bead of Loctite 515(r) Gasket Eliminator (P/N 21005993), or equivalent down the center of the mating flange on clutch housing. The bead should be 1 - 3 mm (0.039 - 0.118 inch) wide.
23. Check for proper alignment of the reverse idler shaft support bracket. The bracket bolt has to be installed after the transaxle case is installed.
24. Shift transaxle into 3rd gear to prevent shift mechanism shafts from moving during case installation.
25. 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.
26. Install and tighten all case to clutch housing bolts in a criss cross pattern.
Torque: Transaxle Case-to-Clutch Housing Bolts: 24 Nm (18 ft. lbs.)
27. Install and tighten reverse idler shaft bolt. Check condition of O-ring and replace if necessary.
Torque:
Reverse Idler Gear Shaft Bolt: 24 Nm (18 ft. lbs.)
28. Tighten reverse idler gear shaft bracket bolt.
Torque: Reverse Idler Gear Shaft Bracket Bolt: 24 Nm (18 ft. lbs.)
NOTICE: Do not compress the crush sleeve when installing output shaft bearing. Any compression of the sleeve done other than by tightening the output shaft nut will require disassembly of the transaxle and replacement of the crush sleeve.
29. Lubricate and install output shaft bearing using 87-91-261. Tighten 87-91-261 until a solid stop is felt. Do not compress the sleeve.
30. Install 5th driven gear onto output shaft. Tap down with Sleeve, Inner Drive 78-41-067 far enough to allow installation of tool 87-91-261.
31. Install Output Shaft Remover 87-91-261 and tighten tool until 5th driven gear is against output shaft bearing. Install a new output shaft nut but do not tighten.
IMPORTANT:
^ Carefully tap input shaft with a plastic hammer from engine side so input shaft bearing race is against input shaft bearing retainer.
^ 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.
32. Install Driver 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).
33. 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:
Input Shaft Bearing Retainer Bolts: 38 Nm (28 ft. lbs.)
34. Lubricate and install 5th drive gear bearing, 5th drive gear, 5th gear blocking ring, and blocking ring spring.
NOTICE: Make sure that the center wing headed bolt is backed out completely before installing the support tool.
35. Install Input Shaft Support J44362 on the transaxle as shown. Turn the center wing headed bolt until contact is made with the input shaft, then turn an additional quarter to a half turn.
NOTICE: The tangs on the blocking rings must fit in the hub gaps. Care must be taken to ensure that the blocking ring spring is engaged on the blocking ring and does not get pinched between the hub and the blocking ring.
36. Carefully tap down the 5th synchronizer hub onto the input shaft splines using Bearing Driver Shaft Sleeve 87-91-311 and a hammer.
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.
37. 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.
38. 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)
39. Disengage 1st gear and remove 5th gear synchronizer sleeve.
40. Check and adjust preload of differential bearings as follows:
40.1. Install Milled Bearing Race 87-92-137 in place of left differential bearing race.
40.2. Install about 2 mm of shims on top of ground bearing race.
40.3. Remove O-ring from differential bearing 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.
41. Place 10 Kilogram Weight 87-92-095 on top of differential bearing retainer. Install Companion Flange 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 differential bearing 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 X7-92-137. Leaving it in will damage transaxle.
42. Remove 10 kg weight, differential bearing retainer, and ground bearing race 87-92-137.
IMPORTANT: The differential bearing retainer will not be torqued to specification until the final output shaft preload is set. If the differential bearing retainer is torqued down at this point, it will interfere with the final output shaft measurements.
43. Install differential bearing race and tap down using Sleeve 83-90-114. Install shim pack determined in last step. Install O-ring on differential bearing retainer, lubricate O-ring, and install differential bearing retainer. Tighten retainer bolts until retainer is 0.15 mm (0.006 inch) from the transaxle case.
44. Turn transaxle to horizontal (in car) position.
IMPORTANT: Make sure that transaxle is in neutral.
45. 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 J7754-C (or equivalent) to socket and rotate clockwise several rotations at an 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.
^ The measurement taken in this step must be in millimeters. If the measurement is in inches, multiply it by 25.4 to convert to millimeters.
46. 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. This output shaft endplay measurement will be used in tightening the output shaft nut in a later step. Remove all tools. Convert measurement to millimeters if necessary.
47. Engage 1st gear on transaxle and engage 5th gear by pressing down 5th gear synchronizer sleeve.
48. Install Output Shaft Nut Socket 87-92-061 on output shaft nut.
49. Calculate the number of lines that 87-92-061 Millimeter Disc must be turned to tighten the output shaft nut by doing the following:
49.1. Add the output shaft endplay value that was determined in a previous step with the nominal valve from the chart below. Ensure that the output shaft endplay is in millimeters or has been converted to millimeters.
49.2. Multiply the sum found in the previous step by 100.
49.3. With a marker, place a mark on the gear tooth corresponding to the line on the socket that matches the number calculated. This is the number of lines that tool 87-92-061 Millimeter Disc must be turned.
Example: Output shaft endplay reading found previously is 0.38 mm + nominal value 0.08 mm = 0.46 mm.; 0.46 multiplied by 100 = 46. This is the number of lines that tool 87-92-061 Millimeter Disc must be turned.
50. Tighten output shaft nut in 2-3 stages until the zero (0) on socket is at marked gear tooth
51. 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)
- Differential bearing retainer installed but not tight. End play is 0.15 mm (0.006 inch)
52. Turn transaxle to the horizontal (in car) position. Disengage 1st gear and remove 5th gear synchronizer sleeve.
53. Install Inch Pound Torque Wrench J7754-C (or equivalent) on output shaft nut. Transaxle must be in neutral. Rotate wrench clockwise at an even speed. Read average value during rotation.
54. 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 N m (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 lines 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.
55. Lock output shaft nut using a chisel and a hammer.
56. 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.
57. Install 5th gear fork and synchronizer sleeve together. Reference sleeve alignment mark made during disassembly. Install a new hub snap ring.
58. Install a new 5th gear fork retaining pin.
59. Tighten the differential bearing retainer bolts.
Torque:
Differential Bearing Retainer Bolts: 24 Nm (18 ft. lbs.)
60. Clean rear cover gasket surfaces. Surfaces must be clean and dry.
61. Install rear cover gasket.
62. Install rear cover and bolts and torque using a crisscross pattern.
Torque:
Rear Cover-to-Transaxle Bolts: 24 Nm (18 ft. lbs.)
63. Install back-up lamp switch with a new gasket.
Torque:
Back-Up Lamp Switch: 24 Nm (18 ft. lbs.)
64. Check that magnet is in transaxle drain plug. Clean and apply thread sealant (P/N 21485278) to transaxle drain plug and install.
Torque:
Transaxle Drain Plug: 50 Nm (37 ft. lbs.)
65. Put grease (P/N 21005995) between lips of input shaft seek
NOTICE: Thread sealant must be used on slave cylinder bolts to prevent a transaxle oil leak.
66. Install slave cylinder. Use Loctite 592(R) (P/N 21485278) thread sealant on screws.
Torque:
Slave Cylinder Fasteners: 10 Nm (7 ft. lbs.)
67. Install clutch actuator cylinder pipe and pipe sleeve.