Assembly
Clutch Housing
1. Hammer the striking rod oil seal into clutch housing as far as it will go.
CAUTION: Do not reuse striking rod oil seal.
2. Hammer the differential oil seal into clutch housing until it becomes flush with clutch housing end face.
CAUTION: Do not reuse differential oil seal.
3. Hammer input shaft oil seal into clutch housing as far as it will go.
CAUTION: Do not reuse input shaft oil seal.
4. Hammer the dust seal into clutch housing as far as it will go.
CAUTION: Do not reuse dust seal.
5. Install outer race of differential side bearing.
6. Install new oil channel (mainshaft).
CAUTION: Pay attention to installation direction of oil channel.
7. Align the notches on mainshaft front bearing and transaxle case. Then, install mainshaft front bearing.
8. Install mainshaft bearing retainer, and tighten bolts with specified torque.
9. Attach boot, striking rod, and striking lever to clutch housing. And install retaining pin for selector lever.
CAUTION:
- Before installing striking rod, wrap the end with a vinyl tape or the like to prevent oil seal from being damaged.
- Do not reuse retaining pin.
10. Hammer the welch plug (striking lever side) with a general purpose drift [OD: 12 mm (0.47 inch)].
CAUTION: Do not reuse welch plug.
11. Install selector, selector shaft, and selector shaft pin into clutch housing.
12. Hammer the welch plug (selector shaft side) with a general purpose drift [OD: 12 mm (0.47 inch)].
CAUTION: Do not reuse welch plug.
13. Install select check leaf spring, return spring, steel ball, reverse gate, selector arm, bushing, and return bearing. Then, tighten two reamer bolts with specified torque.
CAUTION: Use correct reamer bolts for each installation point, because each bolt has a different length.
14. Install oil pocket.
15. Install differential assembly, input shaft assembly, and mainshaft assembly into clutch housing.
CAUTION: Be careful not to damage input shaft oil seal during installation of input shaft assembly.
16. Install 5th & reverse shift fork.
17. Install 1st & 2nd shift fork, bracket, and fork rod.
18. Install retaining pin for 1st & 2nd bracket.
CAUTION: Do not reuse retaining pin.
19. Install two check balls.
20. Install interlock pin into 5th & reverse fork rod.
21. Install reverse switch bracket, 5th & reverse bracket, and fork rod.
22. Install retaining pin for 5th & reverse shift fork and reverse switch bracket.
CAUTION: Do not reuse retaining pin.
23. Install 5th & reverse bracket stopper ring.
CAUTION: Do not reuse stopper pin.
24. Install check ball and interlock plunger.
25. Install 3rd & 4th shift fork, bracket, and fork rod.
26. Install 3rd & 4th bracket retaining pin.
CAUTION: Do not reuse retaining pin.
27. Install 3rd & 4th shift fork stopper ring.
CAUTION: Do not reuse stopper ring.
28. Install check ball, check pin, and check spring, and apply Three Bond TB1215, Loctite Part No. 51813 or equivalent onto check plug. Then, tighten it with specified torque.
Tightening torque: Refer to Diagrams; Exploded Views.
Transaxle Case
1. Insert differential oil seal into differential case until it becomes flush with case end face.
2. Install welch plug into transaxle case.
3. Calculate dimension "N" (thickness of adjusting shim) using the following procedure to satisfy specification of end play for differential side bearing.
End play: 0.15 - 0.21 mm (0.0059 - 0.0083 inch)
Dimension "N" = (N1 - N2) + End play
N: Thickness of adjusting shim
N1: Distance between clutch housing case end face and mounting face of adjusting shim
N2: Distance between differential side bearing and transaxle case
Differential side bearing adjusting shims: Refer to Transmission and Drivetrain; Application and ID.
a. Using dial gauge and scale, measure dimension "N1" between clutch housing case end face and mounting face of adjusting shim.
b. Install outer race onto differential side bearing on final gear side. Holding lightly the outer race horizontally by hand, rotate final gear five times or more (for smooth movement of bearing roller).
c. Using dial gauge and scale as shown in the figure, measure dimension "N2" between differential side bearing outer race and transaxle case end face.
4. Install selected shim and bearing outer race.
5. Measure turning torque of final drive assembly.
Turning torque of final drive assembly (New bearing): 2.9 - 6.9 Nm (30 - 70 kg-cm, 26 - 61 inch lbs.)
- When old bearing is used again, turning torque will be slightly less than the above.
- Make sure torque is close to the specified range.
- Changes in turning torque of final drive assembly per revolution should be within 1.0 Nm (10 kg-cm, 8.7 inch lbs.) without binding.
6. Calculate dimension "0" (thickness of adjusting shim) using the following procedure to satisfy specification of end play for input shaft rear bearing.
End play: 0 - 0.06 mm (0 - 0.0024 inch)
Dimension "0" = (01 - 02) + End play
0: Thickness of adjusting shim
01: Distance between transaxle case end face and mounting face of adjusting shim
02: Distance between clutch housing case end face and end face of input shaft rear bearing
Input shaft rear bearing adjusting shims: Refer to Transmission and Drivetrain; Application and ID.
a. Using block gauge, scale, and dial gauge, measure dimension "01" between transaxle case end face and mounting face of adjusting shim.
b. Using gauge block, scale, and dial gauge as shown in the figure, measure dimension "02" between clutch housing case end face and end face of input shaft rear bearing.
7. Install selected input shaft rear bearing adjusting shim onto input shaft.
8. Install oil gutter into transaxle case.
9. Install two magnets.
10. Clean mating surfaces of clutch housing and transaxle case. Check for cracks and damage. Then, apply Three Bond TB1215, Loctite Part No. 51813 or equivalent.
11. Install transaxle case onto clutch housing, and tighten mounting bolts with specified torque.
Tightening torque: Refer to Diagrams; Exploded Views.
12. Apply Three Bond TB1215, Loctite Part No. 51813 or equivalent to threads of reverse switch, PNP switch, and drain plug and install them. (Fill the case with oil before installation of filler plug.)
13. Install speedometer pinion assembly.
CAUTION: Do not reuse O-ring.
14. Install check springs and check balls. Apply sealant to the thread on the check plug, and install it.
15. Calculate thickness of adjusting shim using the following procedure to satisfy specification of end play for mainshaft rear bearing.
End play: 0 - 0.06 mm (0 - 0.0024 inch)
Dimension "P" = (P1 - P2) + End play
P: Thickness of adjusting shim
P1: Distance between transaxle case end face and mainshaft rear bearing
P2: Distance between adjusting shim end face of rear cover and transaxle mounting face
Mainshaft rear bearing adjusting shims: Refer to Transmission and Drivetrain; Application and ID.
a. Using dial gauge as shown in the figure, measure dimension "P1" between transaxle case end face and mainshaft rear bearing.
b. Using dial gauge as shown in the figure, measure dimension "P2" between adjusting shim mounting face of rear cover and transaxle mounting face.
16. Using snap ring pliers as shown in the figure, install snap ring.
CAUTION: Do not reuse snap ring.
17. Install selected mainshaft adjusting shim.
18. Install reverse idler gear, O-ring, thrust washers (front, rear), and bearing onto reverse idler shaft.
19. Install snap ring into transaxle case using snap ring pliers.
CAUTION:
- Do not reuse snap ring.
- Do not reuse O-ring.
- Before installation, apply gear oil to O-ring.
20. Using feeler gauge, measure the end play of snap ring, and select a snap ring suitable to satisfy the following specification.
End play: 0.05 - 0.25 mm (0.0020 - 0.0098 inch)
Available snap ring: Refer to Transmission and Drivetrain; Application and ID.
21. Install selected snap ring.
CAUTION: Do not reuse snap ring.
22. Apply gear oil to rear cover O-ring, and install rear cover, side cover gasket, and side cover. Then tighten mounting bolts with specified torque.
Tightening torque: Refer to Diagrams; Exploded Views..
CAUTION: Do not reuse mounting bolts for rear cover and side cover.