Manual Transmission/Transaxle: Adjustments
ADJUSTMENT
BEARING ADJUSTMENT PROCEDURE
NOTE: Use onlynewbearings on both output shafts and the differential to ensure correct turning torque. The bearings can loose as much as one half of its turning torque after brake in.
1. Use extreme care when removing and installing bearing cups and cones. Use only an arbor press for installation, as a hammer may not properly align the bearing cup or cone. Burrs or nicks on the bearing seat give a false end-play reading while gauging for proper shims. Improperly seated bearing cups and cones are subject to low-mileage failure.
2. Bearing cups and cones should be replaced if they show signs of pitting or heat distress. If distress is seen on either the cup or bearing rollers, both cup and cone must be replaced.
3. Bearing preload and drag torque specifications must be maintained to avoid premature bearing failures. Used (original) bearings may lose up to 50% of the original drag torque after break-in.
4. Replace bearings as a pair: If one differential bearing is defective, replace both differential bearings, if one input shaft bearing is defective, replace both input shaft bearings.
5. Bearing cones must not be reused if removed unless a ground cone is used to find proper shim size.
6. Turning-torque readings should be obtained while smoothly rotating in either direction.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
NOTE: True bearing turning-torque readings can be obtained only with the gear train removed from the case.
1. Remove bearing cup and existing shim from clutch bellhousing case.
2. Use a cup that has been ground down on the outer edge for ease of measurement.
3. Press in new bearing cup into gear case side.
4. Oil differential bearings with transmission fluid. Install differential assembly (1) into transaxle gear case (2). Install clutch bellhousing over gear case. Install and tighten case bolts to 16 Nm (12 ft. lbs.).
5. Position transaxle with bellhousing facing down on workbench with C-clamps. Position dial indicator.
NOTE: The dial indicator should be parallel to T-Handle to obtain the most accurate reading.
6. Apply a medium load to differential with Torque Tool C-4995A and a T-handle, in the downward direction. Roll differential assembly back and forth a number of times. This will settle the bearings. Zero the dial indicator. To obtain end play readings, apply a medium load in an upward direction while rolling differential assembly back and forth. Record end play.
NOTE: If the original shim is missing or broken always start out with the middle shim size in the new parts package.
7. The shim required for proper bearing preload is the total of end play, plus (constant) preload of 0.18mm (0.007 in.). Never combine shims to obtain the required preload.
8. Remove case bolts. Remove clutch bellhousing differential bearing cup. Install shim(s) selected, then press the bearing cup into clutch bellhousing.
9. Install clutch bellhousing. Install and tighten case bolts to 16 Nm (12 ft. lbs.).
10. Using Torque Tool L-4437-A (3) and an inch-pound torque wrench (1), check turning torque of the differential assembly. The turning torque should be 2 to 3 Nm (18 to 27 in. lbs.) If the turning torque is too high, install as close to 0.02mm (0.0008 inch) thinner shim in shim pack. If the turning torque is too low, install as close to 0.02mm (0.0008 inch) thicker shim in shim pack.
11. Recheck turning torque (1). Repeat until the proper turning torque is obtained.
12. Install the correct shim.
13. Install the new cup.
14. Once proper turning torque has been established for the differential separate case halves, install output shaft 1st through 4th assembly into case with the differential Install clutch bellhousing. Install and tighten case bolts to 16 Nm (12 ft. lbs.) and recheck differential turning torque. The turning torque should be 5 to 8 Nm (44 to 71 in. lbs.) If the turning torque is too high, install as close to 0.02mm (0.0008 inch) thinner shim in shim pack. If the turning torque is too low, install as close to 0.02mm (0.0008 inch) thicker shim in shim pack.
15. Repeat until the proper turning torque is obtained.
16. Once proper turning torque has been established for the differential and the one/four output shaft separate case halves, install output shaft 5th, 6th and reverse assembly into case with the differential, output shaft 1st through 4th assembly and Install clutch bellhousing. Install and tighten case bolts to 16 Nm (12 ft. lbs.) and recheck differential turning torque. Repeat until the proper turning torque is obtained. The turning torque should be 7 to 15 Nm (62 to 133 in. lbs.) If the turning torque is too high, install as close to 0.02 mm (0.0008 inch) thinner shim in shim pack. If the turning torque is too low, install as close to 0.02 mm (0.0008 inch) thicker shim in shim pack.
Once proper turning torque has been established, return to the assembly procedure.