Bearing
Bearing preload adjustmentWhen 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 A01/K94A4200-T1/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 191 A07/210590) to specified torque.
Tightening torque: 28 - 38 ft. lbs. (38 - 51 Nm, 3.8 - 5.3 kg.m)
8. To seat bearings, mount SST (OK130 175 A03/213229) on parts of selectors, and turn selectors so gaps are widened. Then turn SST (OK130 175 A03/213229) 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 A01 / K94A-4200-T1) around circumference by using feeler gauge.
12. Take maximum reading and determine shim to be used. Use no more than two shims.
Primary shaft adjustment shim,
- Subtract diaphragm spring thickness (0.026 inch (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)
Secondary shaft adjustment shims
- 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: 0.001 - 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 preload is obtained.
Preload: 12.15 - 17.36 inch lbs. (1.37 - 1.96 Nm, 14 - 20 kg.cm)
15. Measure gap between (A) and (B) around circumference of SST(OK900 175 A01/K94A-4200T1) 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.
Assembly note
Oil seal (differential)
1. Using SST(OK201 170 AA1/K94U-0001-Q) and hammer, tap new oil seal in evenly until SST(OK201 170 AA1/K94U-0001-Q) 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. Install new oil seal by using pipe.
2. Coat 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(OK130171 A05/K94A-4200-T4) to differential.
4. Connect torque wrench to SST(OK130171AO-K94A4200-T4) and measure preload.
Preload: 13 - 17 inch lbs. (1.4 - 1.9 Nm, 14 - 20 kg.cm)
5. Remove SST(OK130171 A05/K94A-4200-T4).
6. With transaxle facing in direction shown in figure, install SST(OK130171 A05/K94A-4200-T4) to primary shaft gear assembly.
7. Connect torque wrench to SST(OK130171A05/K94A4200-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(OK130 171 A051K94A-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(OK130 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)