Assembly (Part 1)

ASSEMBLY

PRECAUTION
1. Replace all O-rings and gaskets.
2. Verify that all parts are completely clean before assembly.
3. Assemble parts within 10 minutes after applying sealant. Allow all sealant to cure for at least 30 minutes after assembly before filling transaxle with oil.
4. Replace bearing races and bearings as sets.





Secondary Shaft Assembly
Assemble in order shown in figure.

Assembly Note
Clutch Hub











1. Install synchronizer keys and springs in clutch hub.





Bearing (Differential Drive Gear End)
1. Install new bearing by using SST (OK130 175 All).





Secondary 1st Gear, 1st Synchronizer Ring And 1st/2nd Clutch Hub Assembly

NOTICE: The 1st synchronizer ring has teeth missing at three places around its outer edge to help distinguish it from other synchronizer rings.

1. Assemble secondary 1st gear, 1st synchronizer ring, and 1st/2nd clutch hub assembly as shown in figure.





2. Align synchronizer ring grooves and synchronizer keys.





3. Press on 1st/2nd clutch hub assembly by using SST (OK990 175 All 1)

2nd Synchronizer Ring, 2nd Gear And Secondary 3rd Gear
1. Install 2nd synchronizer ring and secondary 2nd gear.





2. Install secondary 3rd gear by using SST (OK130 175 All 3/01<01 1 270 A02/OK1 30 175 Al 1).

Secondary 4th Gear And Bearing





1. Install secondary 4th gear and bearing by using SST (OK130 175 A13/OK011 270 A02/OK130 175 All 1).





2. Measure clearance between 1st gear and differential drive gear.

Clearance: 0.002 - 0.011 inch (0.05 - 0.28 mm)
Maximum: 0.013 inch (0.33 mm)

3. Measure clearance between secondary 2nd gear and secondary 3rd gear.

Clearance: 0.007 - 0.018 inch (0.18 - 0.46 mm)
Maximum: 0.020 inch (0.51 mm)





4. If not as specified, disassemble and reassemble secondary shaft assembly.





Primary Shaft Assembly
Assemble in order shown in figure.





Assembly Note
Bearing (1st Gear End)
Install new bearing by using SST (OK130 175 A13/01(0111 270 A02).





Primary 3rd Gear, 3rd Synchronizer Ring And 3rd/4th Clutch Hub Assembly
Install 3rd gear, 3rd synchronizer ring, and 3rd/4th clutch hub assembly.

4th Synchronizer Ring, Primary 4th Gear And Bearing (4th Gear End)





1. Install 4th synchronizer ring, 4th gear, and new bearing by using SST (OK1 30 175 008/OK01 1 270 A02).





2. Measure clearance between primary 3rd gear and 2nd gear.

Clearance: 0.002 - 0.008 inch (0.05 - 0.20 mm)
Maximum: 0.010 inch (0.25 mm)

3. Measure clearance between primary 4th gear and bearing (4th gear end).

Clearance: 0.007 - 0.015 inch (0.17 - 0.37 mm)
Maximum: 0.017 inch (42 mm)





4. If not as specified, disassemble and reassemble primary shaft assembly.








5th/Reverse Gear And Housing Parts
Assemble in order shown in figure.

Assembly Note
Primary Shaft Assembly And Secondary Shaft Assembly





1. Install primary shaft assembly and secondary shaft assembly into clutch housing as a unit.

Shift Fork And Shift Rod Assembly





1. Shift to 2nd gear and position shift fork and shift rod assembly as shown.
2. Insert spring seat and spring into reverse lever shaft, install detent ball, and place a flat gasket scraper against it.





3. With edge of control end against scraper, push control end in direction of arrow so that detent ball goes into shaft. This will line up rod with shift rod coupling hole in clutch housing.
4. Set each clutch hub sleeve to neutral position, and tap shift rod from above so that detent ball goes into center groove (of three grooves in control end).





5. Pull ball part of control end forward so that detent ball goes into recess in center groove.





Crank Lever Assembly And Crank Lever Shaft
1. Install new O-ring to crank lever shaft.
2. Fit crank lever between change arm and control end, and insert crank lever shaft.
3. Align pin holes of crank lever shaft and clutch housing, and insert pin.





5th/Reverse Shift Rod End And 5th/reverse Shift Rod
1. 1 tall shift rod end (1) and shift rod (2), and tighten the mounting bolt.

Tightening torque: 105 - 121 inch lbs. (11.8 - 13.7 Nm, 120 - 140 kg.cm)





Reverse Idle And Reverse Idle Shaft
1. Install reverse idle gear and reverse idle shaft.
2. Attach magnet to clutch housing.
3. Align end of interlock sleeve with control lever (arrow), and face reverse idle shaft screw hole in direction shown in figure.





TRANSAXLE CASE ASSEMBLY
1. Apply thin coat of sealant to contact surfaces of clutch housing and transaxle case, and tighten transaxle case installation bolts to specified torque.

Tightening torque: 28 - 38 ft. lbs. (38 - 51 Nm, 3.8 - 5.3 kg.m)





Secondary 5th Gear
1. Install secondary 5th gear as shown.





5th/Reverse Clutch Hub Assembly And 5th/reverse Shift Fork
1. Install 5th/reverse clutch hub assembly and 5th/reverse shift fork together.

Locknut
1. Shift to 1st gear.
2. Lock primary shaft using SST (OK201 323 021 / K94A-4205-MT).
3. Tighten new locknuts onto primary and secondary shafts.

Tightening torque: 94 - 145 ft. lbs. (128 - 196 Nm, 13 - 20 kg.m)

4. Stake locknuts.





5. Measure the 5th gear thrust clearance using a dial indicator.

Clearance: 0.004 - 0.009 inch (0.10 - 0.22 mm)
Maximum: 0.011 inch (0.27 mm)





6. If not as specified, disassemble and reassemble 5th and reverse gear assemblies.








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





1. Install primary and secondary shaft bearing races into transaxle case (diaphragm springs and shims removed).
2. Mount clutch housing onto transaxle hanger, and set differential bearing race into clutch housing. Position piece of pipe against bearing race and tap it in until it contacts clutch housing.
3. Set bearing races into SST (OK900 175 AO1/K94A4200-Tl/OK900 175 A02/K94A-4200-T2/OK900 175 A03/K94A-4200-T3) as shown in figure.





4. Turn selector to eliminate gap indicated by arrow.





5. Set differential assembly into clutch housing, and set bearing race and SST (OK900 175 A03/K94A4200-T3) on differential. Set assembled selectors for primary and secondary shaft in clutch housing.
Mount shaft gear assemblies as shown in figure.





6. Set SST (OK130 175 A02/213228) in positions shown in figure.





7. Install transaxle case and tighten SST (OK130 191A07/210590) to specified torque.

Tightening torque: 28 - 38 ft. lbs. (38 - 51 Nm, 3.8 - 5.3 kg.m)





8. To seat bearings, mount SST (OK1 30 175 A03/213229) on parts (& and (D of selectors, and turn selectors so gaps are widened. Then turn SST (OK130 175 A031213229) in reverse direction until gaps are eliminated.
9. Manually expand selector until it no longer turns by hand.





10. Verify that both primary and secondary shafts turn smoothly.
11. Measure clearance between two halves of SST (OK900 175 AOI / K94A-4200-Tl) around circumference by using feeler gauge.





12. Take maximum reading and determine shim to be used. Use no more than two shims.


- Subtract diaphragm spring thickness (0.026 in {0.65 mm)) from gap determined in Step 11 for primary shaft.
- Make shim selection range by subtracting standard clearance parameters from result in previous step.
- Select thinner shim within range to obtain 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 inch (0.57 mm) - 0.002 inch (0.05 mm))
~ (0.022 inch (0.57 mm) - 0 mm (0 inch))
= 0.020 inch (0.52 mm) ~ 0.022 inch (0.57 mm)
Shim: 0.022 inch (0.55 mm)

Shim Selection Chart:

- Make shim selection range by adding standard clearance parameters to result in previous step.
- Select thinner shim within range to obtain standard clearance.

Tightening amount: 9.001 - 0.003 inch (0.03 - 0.08 mm)

Shim selection range: (0.022 inch (0.57 mm) + 0.001 inch (0.03 mm))
~ (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)





13. Install SST (OK130 191 A05 / K94A-4200-T4) to differential.





14. Turn SST (OK130 322 020) with torque wrench.
Adjust SST (OK900 175 A01/K94A-4200-T1) with SST (OK130 175 A03/213229) until specified owl preload is obtained.

Preload: 12.15 - 17.36 inch lbs. (1.37 - 1.96 Nm, 14 - 20 kg.cm)

15. Measure gap between (& and 9 around circumference of SST (OK900 175 A01/K94A-4200T11) by using feeler gauge.





16. Add 0.006 inch (0.15 mm) to measured clearance and select 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).
Nearest shim (on thick side) to 0.019 inch (0.47 mm) is 0.020 inch (0.50 mm).

17. Remove transaxle case and SST (OK900 175 AAO/K94A-4200-T).
18. Remove selectors, primary shaft assembly and the differential.
19. Remove bearing races.