Transaxle Case
Transaxle CaseDisassembly
1. Remove back-up lamp switch, PNP switch, drain plug, and filler plug from transaxle case.
2. Remove snap rings from reverse idler shaft.
3. Remove side cover and rear cover from case.
4. Remove O-ring and mainshaft bearing adjusting shim.
5. Remove reverse idler gear shaft.
a. Attach bolt (M6) to thread of reverse idler gear shaft end.
b. Pull out the attached bolt, and remove reverse idler gear shaft from case.
6. Remove reverse idler gear, thrust washer (front, rear), and bearing from case.
7. Remove snap ring of mainshaft bearing from case.
8. Remove check plugs, springs, and check balls from case.
9. Remove mounting bolts.
10. Remove input shaft rear bearing adjusting shim from transaxle case.
11. Remove oil gutter from case.
12. Remove differential side bearing outer race and adjusting shim from case using Tool.
13. Remove differential oil seal from case using Tool.
14. Remove Welch plugs from case using Tool.
Reassembly
1. Insert differential oil seal into differential case with a suitable tool until it becomes flush with case end face.
2. Install Welch plug into transaxle case with a suitable tool.
3. Calculate dimension "N" (thickness of adjusting shim) using the following procedure to satisfy specification of end play for differential side bearing.
End play: 0.15 - 0.21 mm (0.0059 - 0.0083 inch)
Dimension "N" = (N1 - N2) + End play
N: Thickness of adjusting shim
N1: Distance between clutch housing case end face and mounting face of adjusting shim
N2: Distance between differential side bearing and transaxle case
a. Using dial gauge and scale, measure dimension "N1" between clutch housing case end face and mounting face of adjusting shim.
b. Install outer race onto differential side bearing on final gear side. Holding lightly the outer race horizontally by hand, rotate final gear five times or more (for smooth movement of bearing roller).
c. Using dial gauge and scale as shown in the figure, measure dimension "N2" between differential side bearing outer race and transaxle case end face.
4. Install selected shim and bearing outer race using Tool.
5. Measure turning torque of final drive assembly using Tool.
Turning torque of final drive assembly (New bearing) : 2.9 - 6.9 Nm (30 - 70 kg-cm, 26 - 61 inch lbs.)
- When old bearing is used again, turning torque will be slightly less than the above.
- Make sure torque is close to the specified range.
- Changes in turning torque of final drive assembly per revolution should be within 1.0 Nm (10 kg-cm, 8.7 inch lbs.) without binding.
6. Calculate dimension "O" (thickness of adjusting shim) using the following procedure to satisfy specification of end play for input shaft rear bearing.
End play: 0 - 0.06 mm (0 - 0.0024 inch)
Dimension "O" = (01 - 02) + End play
O: Thickness of adjusting shim
O1: Distance between transaxle case end face and mounting face of adjusting shim
O2: Distance between clutch housing case end face and end face of input shaft rear bearing
a. Using block gauge, scale, and dial gauge, measure dimension "01" between transaxle case end face and mounting face of adjusting shim.
b. Using block gauge, scale, and dial gauge as shown in the figure, measure dimension "02" between clutch housing case end face and end face of input shaft rear bearing.
7. Install selected input shaft rear bearing adjusting shim onto input shaft.
8. Install oil gutter into transaxle case.
9. Clean mating surfaces of clutch housing and transaxle case. Check for cracks and damage, then apply sealant. Use Genuine Anaerobic Liquid Gasket or equivalent.
10. Install transaxle case onto clutch housing, and tighten mounting bolts with specified torque.
11. Apply sealant to threads of back-up lamp switch, PNP switch, and drain plug, then install them. Use Genuine Anaerobic Liquid Gasket or equivalent. (Fill the case with oil before installation of filler plug.)
12. Install speedometer pinion assembly.
CAUTION: Do not reuse O-ring.
13. Install check springs and check balls. Apply sealant to the thread on the check plug, and install it.
14. Calculate thickness of adjusting shim using the following procedure to satisfy specification of end play for mainshaft rear bearing.
End play: 0 - 0.06 mm (0 - 0.0024 inch)
Dimension "P" = (P1 - P2) + End play
P: Thickness of adjusting shim
P1: Distance between transaxle case end face and mainshaft rear bearing
P2: Distance between adjusting shim end face of rear cover and transaxle mounting face
a. Using dial gauge as shown in the figure, measure dimension "P1" between transaxle case end face and mainshaft rear bearing.
b. Using dial gauge as shown in the figure, measure dimension "P2" between adjusting shim mounting face of rear cover and transaxle mounting face.
15. Using snap ring pliers and flat-head screwdriver as shown in the figure, install snap ring.
CAUTION: Do not reuse snap ring.
16. Install selected mainshaft adjusting shim.
17. Install reverse idler gear, O-ring, thrust washers (front, rear), and bearing onto reverse idler shaft.
18. Install snap ring into transaxle case using snap ring pliers.
CAUTION:
- Do not reuse snap ring.
- Do not reuse O-ring.
- Before installation, apply gear oil to O-ring.
19. Using feeler gauge, measure the end play of snap ring, and select a snap ring suitable to satisfy the following specification.
End play: 0.05 - 0.25 mm (0.0020 - 0.0098 inch)
20. Install selected snap ring with a suitable tool.
CAUTION: Do not reuse snap ring.
21. Apply gear oil to rear cover O-ring, and install rear cover, side cover gasket, and side cover. Then tighten mounting bolts with specified torque.
CAUTION: Do not reuse mounting bolts for rear cover and side cover.