Assembly and Bearing Preload

1. Select the adjust shim(s), Refer to Bearing Preload Adjustment.
2. Assemble in order shown, Refering to the Assembly Notes.

Special Service Tool (SST):

Special Service Tool (SST) Usage:

BEARING PRELOAD ADJUSTMENT

When replacing any of the parts listed in the table, adjust the bearing preload by selecting and installing the proper adjustment shim(s).

Primary Shaft Assembly:
d. Transaxle case
e. Clutch housing
f. Primary shaft gear bearing
g. Primary shaft gear

Secondary Shaft Assembly:
h. Transaxle case
i. Clutch housing
j. Secondary shaft gear bearing
k. Secondary shaft gear
l. Secondary 4th rear

Differential:
m. Transaxle case
n. Clutch housing
o. Differential side bearing
p. Ring gear and gear case

1. Install the primary and secondary shaft bearing races into the transaxle case (diaphragm springs and shims removed).
2. Mount the clutch housing onto the transaxle hanger, and set the differential bearing race into the clutch housing. Position a piece of pipe against the bearing race and tap it in until it contacts the clutch housing.





3. Set the bearing races into the SSTs (selector) as shown.
4. Turn the selector to eliminate the gap indicated by the arrow.





5. Set the differential assembly into the clutch housing, and set the bearing race and the SST (selector) on the differential. Set the assembled selectors for the primary and secondary shaft in the clutch housing. Mount the shaft gear assemblies as shown.





6. Set the SST (collars) in the positions shown.





7. Install the transaxle case and tighten the SST (bolts) to the specified torque.

Tightening torque: 29 - 40 ft. lbs. (39 - 54 Nm)





8. To seat the bearings, mount the SST (bars) on parts A and B of the selectors, and turn the selectors so the gaps are widened. Then turn the SST in the reverse direction until the gaps are eliminated.





9. Manually expand the selector until it no longer turns by hand.
10. Verify that both the primary and secondary shafts turn smoothly.





11. Measure the clearance between the two halves of the SST (selector) around the circumference by using a feeler gauge.
12. Take the maximum reading and determine the shim to be used. Use no more than two shims.





Primary Shaft Adjustment Shim
A. Subtract the diaphragm spring thickness 0.026 inch (0.65 mm) from the gap determined in step 11 for the primary shaft.
B. Make a shim selection range by subtracting the standard clearance parameters from the result in the previous step.
C. Select the thinner shim within the range to obtain the standard clearance.

Standard clearance: 0 - 0.002 inch (0 - 0.05 mm)

Example: 0.048 inch (1.22 mm) - 0.026 inch (0.65 mm)
= 0.022 inch (0.57 mm)

Shim selection range:
(0.022 - 0.002 inch (0.57 - 0.05 mm))
- 0.022 - 0 inch (0.57 - 0 mm))
= 0.020 - 0.022 inch (0.52 - 0.57 mm)

Shim: 0.022 inch (0.55 mm)

Secondary Shaft Adjustment Shim
A. Subtract the diaphragm spring thickness 0.0026 inch (0.65 mm) from the gap determined in step 11 for the secondary shaft.
B. Make a shim selection range by subtracting the standard clearance parameters from the result in the previous step.
C. Select the thinner shim within the range to obtain the standard clearance.

Tightening amount: 0.001 - 0.003 inch (0.03 - 0.08 mm)

Example: 0.048 inch (1.22 mm) - 0.026 inch (0.65 mm)
= 0.022 inch (0.57 mm)

Shim selection range:
0.022 inch (0.57 mm) + 0.001 inch (0.03 mm)
- 0.022 inch (0.57 - 0 mm)
= 0.020 - 0.022 inch (0.57 mm)
+ 0.003 inch (0.08 mm) = 0.024 inch (0.60 mm)
- 0.026 inch (0.65 mm)

Shim: 0.024 inch (0.60 mm)

Differential Side Bearing Adjustment Shim





13. Install the SST (differential rotator) to the differential.





14. Turn the SST (differential rotator) with a torque wrench. Adjust the SST (selector) with the SST (bars) until the specified preload is obtained.

Preload: 4.3 inch lbs. (0.5 Nm)

NOTICE: Measure the differential side bearing preload while the differential is rotating.





15. Measure the gap between A and B around the circumference of the SST (selector) by using a feeler gauge.





16. Add 0.006 inch (0.15 mm) to the measured clearance and select the combination of two shims closest in value to that measurement. Use no more than two shims.

Example: 0.013 inch (0.32 mm)
0.013 inch (0.32 mm) + 0.006 inch (0.15 mm) = 0.019 inch (0.47 mm)

17. Remove the transaxle case and the SSTs.
18. Remove the selectors, the primary shaft assembly, and the differential.
19. Remove the bearing races.


ASSEMBLY NOTES
Oil Seal (Differential)





1. Using the SST (or equivalent) and a hammer, tap the new oil seal in evenly until the SST (or equivalent) contacts the transaxle case.
2. Coat the lip of the oil seal with transaxle oil.

Bearing Race (Differential)

1. Install the differential side bearing adjustment shim(s) into the transaxle case.





2. Apply transaxle oil to the bearing race, and install it to the differential case by using a pipe.

Diaphragm Spring

1. Install the primary shaft adjustment shim(s) into the primary shaft bearing seat in the transaxle case.





2. Install the diaphragm spring as shown.

Bearing Race (Transaxle Case)

1. Install the adjustment shim(s) to the secondary shaft bearing seat in the transaxle case.





2. Apply transaxle oil to each bearing race, and install them to the transaxle case by using a pipe.