45 - 66
TRANSAXLE ASSEMBLY cont.IMPORTANT: Make sure that transaxle is in neutral.
45. Measure input shaft bearing pre-load.
45.1 Remove hose from tool 87-91-428.
45.2 Install a 3/8" drive - 16 mm deep well socket into one end of hose.
45.3 Insert other end over input shaft as shown.
45.4 Install Inch Pound Torque Wrench J7754-C (or equivalent) to socket and rotate clockwise several rotations at an even speed.
45.5 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.
IMPORTANT: 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. Measure output shaft endplay.
46.1 Turn transaxle back to vertical position.
46.2 Place dial indicator tip on 5th driven gear as shown.
46.3 Install tool 87-92-053 on output shaft.
46.4 Turn output shaft several revolutions to seat bearings.
46.5 Press down on drill and turn output shaft for 20 revolutions.
46.6 Zero dial indicator.
46.7 Pull up on drill and turn for another 20 revolutions.
46.8 Take a measurement when reading stabilizes. This output shaft endplay measurement will be used in tightening the output shaft nut in a later step. Convert measurement to millimeters if necessary.
46.9 Remove all tools.
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. Check input shaft and output shaft bearing preload.
53.1 Check that transaxle is in neutral.
53.2 Install Inch Pound Torque Wrench J7754-C (or equivalent) on output shaft nut.
53.3 Rotate wrench clockwise at an even speed.
53.4 Read average value during rotation.
53.5 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 0.5 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.
54. Lock output shaft nut using a chisel and a hammer.
55. 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.
56. Install 5th gear fork and synchronizer sleeve together. Reference sleeve alignment mark made during disassembly. Install a new hub snap ring.
57. Install a new 5th gear fork retaining pin.
58. Tighten the differential bearing retainer bolts.
Torque:
Differential Bearing Retainer Bolts: 24 Nm (18 ft. lbs.)
59. Clean rear cover gasket surfaces. Surfaces must be clean and dry.
60. Install rear cover gasket.
61. Install rear cover and bolts and torque using a crisscross pattern.
Torque:
Rear Cover-to-Transaxle Bolts: 24 Nm (18 ft. lbs.)
62. Install back-up lamp switch with a new gasket.
Torque:
Back-Up Lamp Switch: 24 Nm (18 ft. lbs.)
63. Check that magnet is in transaxle drain plug (1). Clean and apply thread sealant (P/N 21485278) to transaxle drain plug (1) and install.
Torque:
Transaxle Drain Plug: 50 Nm (37 ft. lbs.)
64. 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.
65. Install slave cylinder. Use Loctite 592 (P/N 21485278) thread sealant on screws.
Torque:
Slave Cylinder Fasteners: 10 Nm (7 ft. lbs.)
66. Install clutch actuator cylinder pipe and pipe sleeve.