23 - 44

TRANSAXLE ASSEMBLY cont.





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 cries-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.

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.





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 wingheaded bolt is backed out completely before installing the support tool.





35. Install Input Shaft Support J44362 on the transaxle as shown. Turn the center wingheaded 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. Measure differential bearing pre-load.
41.1 Place 10 Kilogram Weight 87-92-095 on top of differential bearing retainer.
41.2 Install Companion Flange 87-92-053 on output shaft.
41.3 Use a drill to rotate differential at least 20 revolutions.
41.4 Use a feeler gauge and measure between transaxle case and differential bearing retainer in three different places.
41.5 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.

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 retainer.
43.1 Install differential bearing race and tap down using Sleeve 83-90-114.
43.2 Install shim pack determined in last step.
43.3 Lubricate O-ring and install on differential bearing retainer.
43.4 Install differential bearing retainer.
43.5 Tighten retainer bolts until retainer is 0.15 mm (0.006 inch) from the transaxle case.





44. Turn transaxle to horizontal (in car) position.