Part 1

TRANSAXLE

DISASSEMBLY AND ASSEMBLY

Disassembly Steps 1-15:

Required Special Tool:

DISASSEMBLY SERVICE POINTS





1. Remove the speedometer driven gear assembly.





2. Remove the clamp.





3. Remove the back up lamp switch assembly.





4. Remove the lock ball assembly.
5. Remove the transmission case hanger No. 1.





6. Remove the wiring harness clamp bracket.





7. Remove the control cable bracket.





8. Remove the selecting bell crank assembly and the control bell crank dust cover.





9. Remove the straight screw plug with head.





10. Remove the straight screw plug with head.








11. Remove the straight screw plug with head and the gasket (two places).





12. Remove the lock ball assembly.





13. Remove the straight pin.





14. Remove the shift & select lever shaft assembly.





15. Remove the flange bolt and gasket.





16. Use snap ring pliers to expand the indicated hole snap rings. The hole snap rings will release the radial ball bearings, and the input shaft and output shaft No. 1 will fall under its own weight.





17. Remove the transmission case sub-assembly.





18. Remove the transmission oil separator.





19. Remove the straight screw plug with head, the shift detent ball spring seat No.1, the compression spring and ball (four places).





20. Remove the washer based hexagon bolt.





21. Remove the slotted spring pin (three places).





22. Remove the gear shift fork shaft No.4 and the gear shift fork shaft No.3.





23. Remove the gear shift fork assembly No.3 and the reverse shift fork.





24. After removing the gear shift fork shaft No. 1, remove the slotted spring pin of the gear shift fork shaft No.2 and gear shift head No.2.
25. Remove the gear shift fork shaft No.2.
26. Remove the gear shift head No.2.





27. Remove the gear shift fork assembly No.2.





28. Remove the reverse idler gear shaft, reverse idler thrust washer, needle roller bearing and reverse idler gear.





29. Remove the output shaft No.2 sub-assembly.





30. Remove the input shaft sub-assembly, output shaft No. 1 sub-assembly and gear shift fork assembly No. 1.
31. Remove the differential sub-assembly.





32. Remove the E ring.
33. Remove the shift arm pivot.
34. Remove the gear shift head No.3 and gear shift fork shaft No.5 and shift arm simultaneously.

ADJUSTMENT BEFORE ASSEMBLY
DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT





1. Set the differential assembly to the transaxle case.
2. Push and fit the tapered roller bearing outer race by hand.





3. To fit the tapered roller bearing outer race, rotate the differential assembly by hand about 10 times with the special tool MB992038.





4. Put the transaxle case on the surface table and use a height gauge to measure the dimension "a1", which is from the mating surface of the transaxle case to the end surface of the tapered roller bearing outer race.





5. Put the straight edge on the mating surface of the transmission case and measure the dimension "b1" with a vernier caliper.
6. Select the shim whose dimension is the difference between "b1" and "a1".
7. Install the differential assembly to the transaxle case. Tighten the transmission case bolts to the specified torque of 30 ± 5 Nm (22 ± 4 ft. lbs.).





8. Using special tool MB992038, measure the rotational starting torque of differential case. When it is not within the standard range, reselect the shim.
Standard value: 1.00 - 2.49 Nm (8.85 - 22.04 inch lbs.)

OUTPUT SHAFT No. 2 BEARING PRELOAD ADJUSTMENT
1. Set the output shaft No.2 assembly and differential assembly to the transaxle case.





2. Push and fit the tapered roller bearing outer race by hand.





3. To fit the tapered roller bearing outer race, rotate the output shaft No.2 assembly by hand about 10 times with the special tool MB992038.





4. Put the transaxle case on the surface table and measure the dimension "a2", which is from the mating surface of the transaxle case to the end surface of the bearing outer race, with a height gauge.





5. Put the straight edge on the mating surface of the transmission case and measure the dimension "b2" with a vernier caliper.
6. Select the shim whose dimension is the difference between "b2" and "a2".
7. Install the output shaft No.2 assembly and differential assembly to the transaxle case. Tighten the transmission case bolts to the specified torque of 30 ± 5 Nm (22 ± 4 ft. lbs.).





8. Using special tool MB992038, measure the rotational starting torque on the differential shaft. From this rotational starting torque, subtract the value measured in the adjustment of the bearing preload on the differential side. When this is not within the standard range, reselect the shim.
Standard value: 3.89 - 5.51 Nm (34.43 - 48.77 inch lbs.)