Manual Transaxle Case

MANUAL TRANSAXLE CASE





COMPONENTS

DISASSEMBLY





1. Remove a stopper bolt and a shift check.





2. Loosen 2 bolts, and remove a spring and a ball and a pin with a magnet tool.





3. Take off 4 bolts with shifting any position to loosen bolts.





4. Take off the reverse switch.





5. Remove a control assembly.

NOTE: At this time, it comes to pull out easily if you pull out a control assembly while moving to select direction.





6. Remove a bore plug by a minus driver etc.





7. Take off the snap ring of the output shaft from the hole after removing a bore plug.

NOTE: The output shaft drops with the sound named by expanding the snap ring of the output shaft.





8. Take off all around bolts by the impact wrench.
9. Raise a case while hitting at case corner with plastic hammer.





10. So pull out the case from housing slowly.





11. Remove the oil gutter and baffle plate.





12. Take off the differential side bearing outer race oil seal and the adjusting shim by (-) drive.

REASSEMBLY





1. Install the differential oil seal using special tool (09431 -2COOO).





2. Calculate the thickness N dimension of adjusting shim as it shows, keeping end play of differential side bearing as below dimension.

NOTE: Select one or two pieces of differential side bearing adjusting shim.

End play (mm): 0.15 - 0.21
Shim thickness N = N1 - N2 + end Slav











DIFFERENTIAL SIDE BEARING ADJUSTING SHIM





3. Install the differential side bearing adjusting shim and the differential side bearing outer race using special tool (09431-2C300).





4. Assemble the oil gutter and the baffle plate.
At this time, put a grease on fixing part.





5. Spread the seal on the surface of the case and the housing.
At that time, spread inside the hole of the bolt.
6. Check the output shaft snap ring and shim of transaxle case side. Let that the snap ring gap comes to bore plug hole.
7. Hold a case with your both hands, cover it housing side.





8. If it is inserted excessively, it may damage.





9. There is a about 4mm space of case and hosing if you cab put perfectly.
10. Extend the snap ring of case side, then the case fall down by own weight.





11. So there is no space between case and housing.





12. Tighten the case and the bolt of the hosing.





13. Install the control shaft assembly.
14. Put a select stopper bolt in neutral position.
15. Put in a shift check.





16. Fix a check ball, and a spring by a bolt. (There are 2 places)
17. Shift to the 2nd gear, and keep lift the output shaft, and fix the snap ring of output shaft bearing.





18. Put in a bore plug.