Assembly (Part 2)

Assembly Note
Oil Seal (Differential)





1. Using SST (OK201170AAl/K94U-0001-0) and hammer, tap new oil seal in evenly until 6T(01(2011 170 AA1 /K94U-0001 -0) contacts transaxle case.





2. Coat lip of oil seal with transaxle oil.

Bearing Race (Differential)
1. Install adjustment shim(s) to differential case.





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





Diaphragm Spring On Primary Shaft
Install diaphragm spring as shown in figure.





Bearing Race (Transaxle Case)
1. Install adjustment shim(s) to primary and secondary shaft bearing seats in transaxle case.
2. Apply transaxle oil to each bearing race, and install them to transaxle case by using pipe.

Oil Seal (Change Rod Assembly)
1. stall new oil seal by using pipe.





2. ~oat lip of oil seal with transaxle oil.
Outer diameter of pipe: 1.02 inch (26.0 mm)





Boot
Install boot so that drain hole is facing downward when mounted on vehicle.





Oil Seal (Primary Shaft)
Apply transaxle oil to outer circumference of oil seal, and install it to transaxle case by using pipe.

Bearing Preload
Verify shaft gears and differential bearing preloads.
Readjust bearing preloads if they are not within specification.
1. Set primary shaft gear assembly and differential into clutch housing.





2. Install transaxle case, and tighten to specified torque.

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

3. Install SST (OK130 171 A05/K94A-4200-T4) to differential.





4. Connect torque wrench to SST (OK1 30 171 A05/K94A 4200-T4) and measure preload.

Preload: 13 - 17 inch lbs. (1.4 - 1.9 Nm, 14 - 20 kg.cm)

5. Remove SST (OK1 30 171 A05/K94A-4200-T4).
6. With transaxle facing in direction shown in figure, install SST (OK1 30 171 A05/K94A-4200-T4) to primary shaft gear assembly.





7. Connect torque wrench to SST (OK130 171 A05/K94A 4200-T4) and measure preload.

Preload: 0.9 - 2.1 inch lbs. (0.1 - 0.2 Nm, 1.0 - 2.5 kg.cm)

8. Remove SST (OK1 30 171 A05/K94A-4200-T4), transaxle case, primary shaft gear assembly and differential.
9. Install secondary shaft gear assembly and transaxle case, and tighten to specified torque.

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

10. Install SST (OK1 30 171 A05/K94A-4200-T4) to secondary shaft gear assembly.





11. Connect torque wrench to SST (OK130 171 A05/K94A4200-T4) and measure preload.

Preload: 1.8 - 3.4 inch lbs. (0.2 - 0.4 Nm, 2.0 - 4.0 kg.cm)





DIFFERENTIAL
Disassembly/Inspection/Assembly
1. Before disassembly, inspect backlash of side gears and pinion gears, refer to Preinspection.
2. Disassemble in order shown in figure.
3. Inspect all parts and repair or replace as necessary.
4. Assemble in reverse order of disassembly.
5. Measure backlash after assembly, refer to Backlash of side gear and pinion gear.

Preinspection
Backlash Of Side Gear And Pinion Gear
Measure backlash by following procedure:
1. Install left driveshaft and right joint shaft in differential assembly.
2. Support shafts on V-blocks as shown in figure.
3. Measure backlash of both pinion gears.

Backlash: 0.002 - 0.006 inch (0.05 - 0.15 mm)





4. If not as specified, replace worn and damaged parts.





Disassembly Note
Bearing (Ring Gear Opposite Side)

NOTICE: Do not remove the bearing unless you are replacing it

Remove bearing by using SST (OK1 30 171 013).

Side Bearing Inner Race

Caution: Be careful not to drop differential case.

1. Using SST (OK670 990 AAO), remove side bearing inner race (opposite side of ring gear).





Bearing (Ring Gear Side)
Remove bearing by using SST (OK670 990 AAO).

INSPECTION
1. Inspect all parts and repair or replace as necessary.





Ring, Gear And Gear Case Assembly
1. Inspect ring gear for wear and cracks. If gear case is replaced, adjust bearing preload.





Bearing
1. Inspect for wear and rough rotation. If bearing is removed, then replace it and bearing race together, and adjust bearing preload.





Assembly Note
Bearing (Ring Gear Side)
1. Install new bearing by using SST (OK011 270 A02/11<941.11-00011-0).





Bearing (Ring Gear Opposite Side)
1. Install speedometer drive gear.
2. Install new bearing by using SST (OK011 270 A02/K94U-0001-0).





Roll Pin
1. Install new roll pin as shown in figure to hold pinion shaft.

Backlash Of Side Gear And Pinion Gear
Measure backlash by following procedure:
1. Install left driveshaft and right joint shaft in differential assembly.
2. Support shafts on V-blocks as shown in figure.
3. Measure backlash of both pinion gears.

Backlash: 0.002 - 0.006 inch (0.05 - 0.15 mm)





4. If not as specified, replace worn and damaged parts.








Shift Mechanism
Overhaul
1. Disassemble in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, refer to Assembly note.

Assembly Note
Extension Bar
1. Install the extension bar to the floor, and then onto the transaxle. Tighten the extension bar nut at the transaxle.

Tightening torque: 23 - 34 ft. lbs. (31 - 46 Nm, 3.2 - 4.7 kg.m)





2. Tighten the shifter bracket nuts to the specified torque.

Tightening torque: 86.9 - 130.2 inch lbs. (9.8 - 14.7 Nm, 100 - 150 kg.cm)





Spring
Make sure that the hooked part of the spring is properly seated in the bracket groove, as shown in the figure.