Assemble Transaxle

General Measures Before Assembly
- Parts and housing should be thoroughly washed before assembly.
- Check the parts for wear. Change damaged or defective parts.
- If there was a lot of swarf in the gearbox, all bearings should be replaced. Always change both bearings on one shaft, even if only one is damaged.
- Change seals at the drive shafts.
- All bearings and friction surfaces should be oiled before assembly with the same type of oil as used in the gearbox. Refer to Specifications.

Assembly





1. Fit the clutch housing in a work fixture with, Holder, Transmission 87 92 228.
2. Carefully scrape away old remains of sealant from the mating surface, making sure not to damage the surfaces. Make sure the gearcase is scraped clean from the remains of sealant.
3. Fit the differential into the clutch housing and lubricate the bearing.





4. Secure the output shaft in its seat, lubricate the bearing and fit the bearing race. Put on the bearing support and knock it in place. Use Sleeve 87 92 202 and Sleeve, Bearing Race 87 91 204. Use locking compound Loctite 242 on all bolts and then fit them. Tighten the 3 bolts in the middle alternately.
Tightening torque 45 Nm (33 ft. lbs.)
The outer bolts should only be tightened to:
Tightening torque 24 Nm (18 ft. lbs.)





5. Fit 1st and 2nd gearwheels with synchromesh assembly on the output shaft with Assembly fixture, 1st-2nd hub 87 92 103. Then fit the assembled parts on the output shaft. Fit 3rd gear wheel and spacer sleeve on the output shaft. Note that a used gear must be turned the same way as previously. Do not let the fitted gears go too far down on the shaft, save 15 mm. Otherwise, the input shaft cannot be fitted.
6. Place the input shaft in the housing and lubricate the bearing. Fit a cable tie to keep the gears on the input and output shafts meshed.





7. Press down the gears on the output shaft against the surface on the clutch housing. Tap carefully with a hammer and Sleeve, Bearing Race 87 91 204 and Assembly Ring Bearing 87 90 867 until a new retaining sleeve and the 4th gear can be assembled. Mount the 4th gear with turned groove facing downwards.





8. Fit Puller, Pinion 87 91 261 and pull down until the 4th gear pinion and wheel on the in and output shafts are level. Cut the cable ties and remove the Assembly Fixture, 1st-2nd Hub 87 92 103. Check that the 1st and 2nd gear pinions run easily or the output shaft.





9. Lift the input shaft a little and fit the reverse gear wheel with pinion and synchromesh. The hole in the reverse shaft should be facing the channel in the clutch housing.

IMPORTANT: If the lube hole is facing the other way, the reverse gear is incorrectly assembled. If this is the case, correct the fault.





10. Fit the selector mechanism in the clutch housing. The forks should be in the neutral position. Press up the synchromesh sleeve against the 2nd gear position on the output shaft. Press up the synchromesh sleeve in 4th gear position on the input shaft
11. Place the 1st-2nd and 3rd-4th forks in the synchromesh sleeves and turn and push the mechanism into position. The synchromesh sleeves should be in the neutral position. Insert the locating sleeves and align the screws.





12. Fit the selector fork for reverse gear with the two remaining bolts. Use threadlock Loctite 577 for the short bolt (the bolt hole leads into the clutch housing and the thread sealant prevents oil leakage).
Tighten the 3 bolts.
Tightening torque: 24 Nm (18 ft. lbs.)

IMPORTANT: The oil plate for the reverse gear selector fork should be fitted under the edge of the selector mechanism.





13. Fit the fork to the reverse synchromesh sleeve. Check that the reverse gear selector fork enters the groove on the reverse fork. Then push in the shaft. Engage reverse gear using the selector mechanism and check that it is fully engaged.





14. Fit the gear selector rod into position, sparingly lubricated with gearbox oil, refer to Specifications, Fluid Types.
Fit a new seal.
15. Thread in and mount the driver in position. Push in the gear selector rod and fit the screw. Tighten the screw to:
Tightening torque 24 Nm (118 ft. lbs.)





16. Check that all gears can be engaged. Also check the dual interlock feature by engaging 1st and then attempting to engage reverse by pushing in the reverse gear fork using a screwdriver. If reverse can be engaged, the locking pin in the selector mechanism must be checked.





17. Clean the sealing surface well using for example Loctite Super Clean 7063. Coat sparingly with Loctite 518 on both the gearcase and clutch housing contact surfaces. Spread out the Loctite and allow to dry for a few minutes.

IMPORTANT: When assembling the gearbox and applying Loctite, greatest care must be taken. If the sintered plug (at arrow) in the gearbox vent is blocked, oil from the gearbox can be forced out past the shaft seals.





18. Check that the reverse shaft support is correctly positioned so that the screw can be fitted after the gearcase has been fitted. Place the gearcase on the clutch housing.

IMPORTANT: Cover the holes in the gearcase so that nothing can accidentally get into the gearbox.





19. First loosely assemble the clutch housing and gearcase using two screws. Then tap in the locating sleeves. Fit the screw for the reverse shaft loosely. If needed, align the screw hole with the gearcase hole using a narrow screwdriver. Fit the remaining screws.
Tightening torque 24 Nm (18 ft. lbs.)





20. Tighten the screw for the reverse shaft. Note the O-ring!
Tightening torque 24 Nm (18 ft. lbs.)
21. Tighten the screw for the reverse shaft support.
Tightening torque 28 Nm (21 ft. lbs.)





22. Fit the bearing on the output shaft, lubricate the bearing and pull it with Puller, Pinion 87 91 261. Only pull to contact with the retaining sleeve.
23. Fit the gear wheel for 5th gear on the output shaft. Tap down the gear wheel for 5th gear slightly using a hammer and Sleeve, Bearing 78 41 067. Fit puller, Pinion 87 91 261. Pull down the wheel towards the bearing using the tool and then fit a new nut.





24. Fit the Driver 87 191 428 on the input shaft. Position the indicator gauge measuring point on the input shaft bearing. Fit a drill motor on the tool and "run" the gearbox so that the bearings "settle in". First run 20 revolutions and reset the gauge. Lift and run another 20 revolutions and then read off the value (or until the value has stabilized). Measure the axial clearance, which should be 0.09-0.15 mm. (The clearance will decrease to 0.04-0.11 mm when the output shaft bearings are adjusted to the correct pretension). Adjust with shims under the bearing support if needed. Shims are available in dimensions 0.1, 0.15 and 0.30 mm.
- Thicker shims=increase clearance
- Thinner shims=decrease clearance
- Shims are available in dimensions 0.10; 0.15; 0.30 mm.

IMPORTANT: Carefully tap the primary shaft using a plastic hammer so that the bearing race at the 5th pinion is against the bearing support.





25. When adjusting axial play on input shaft:
Undo and remove the 4 screws from the bearing support. Refit the bearing support together with the correct package of shims and tighten alternately.
Tightening torque 38 Nm (28 ft. lbs.)
Check play again. Remove the three tools.
26. Fit Support 87 92 517 as resistance for the input shaft when the 5th gear synchromesh hub is tapped down.
27. Fit the 5th pinion with needle bearing. Lubricate the bearing.





28. Assemble the wire ring, the 3 leaf springs, baulk ring and hub with Assembly Fixture 87 92 582. The hub is tapped down with Sleeve, Bearing 78 41 067 on the input shaft splines.
The synchromesh stops must be directly opposite the deep teeth gaps on the synchromesh hub
29. Remove Assembly Fixture 87 92 582.
30. Fit the 5th synchromesh sleeve with the tip angles down.
31. Remove Support 87 92 517.





32. Mount Dial Indicator 87 92 194 against the gear wheel with Mounting 87 90 727. Engage 1st gear and press down the 5th gear synchromesh sleeve so that the gearbox "locks". Tighten the nut and measure alternately using the dial indicator until an axial play of 0.06 ± 0.05 is attained on the output shaft. Use a short M8 bolt in the sealing surface as a cut-off point. Disengage 1st and 5th gears.

IMPORTANT: Do not lever directly under the gear teeth. Insert the screwdriver well under.





33. Check and adjust the preload of the differential as follows:
Position a Ground Bearing Race 87 92 137 instead of the earlier removed bearing race. Remove the bearing support O-ring. Fit a 2 mm shims package together with the bearing support.





34. Position Weight, Differential Bearing 87 92 095 on the bearing support. Fit Driver 87 92 053 on the output shaft. Use a drill motor and run the differential at least 20 revolutions. Check the clearance with a feeler gauge in three places between the bearing support and the gearcase. Use the average value of the three measured values and adjust the shims package so that the average value agrees with the table:





- Thicker shims=increase preload
- Thinner shims=reduce preload
- Shims for the differential are available in sizes 0. 10, 0. 15, 0.30, 0.50 mm

WARNING: Watch your fingers when the pinions are moving.

35. Remove Weight, Differential Bearing 87 92 095, differential bearing support and Ground Bearing Race 87 92 137.

IMPORTANT: Do not forget to replace the tool Ground Bearing Race 87 92 137 with the correct bearing race. Risk for damaged gearbox.





36. Tap down the bearing race slightly, use Sleeve 83 90 114. Fit and lubricate the O-ring on the bearing support. Fit the bearing support with the calculated shims package. Pull down the bearing support until a "nominal measured value of +0.15 mm" is remaining.

IMPORTANT: The bearing support is torque tightened after checking the preload of the output shaft. There must be a certain amount of axial play so as not to interfere with the measurement of bearing preload on the output shaft.





37. Turn the gearbox so that it is in the same position as it would be in the car, i.e. horizontal.

38. Fit the M8 fuel hose (approx. 100 mm long) between the Driver 87 91 428 and Allen Socket (M8 with 1/2" fitting). Check that no gear is engaged.

IMPORTANT: The torque wrench is extremely sensitive to impacts, overload and careless handling.

39. Connect the torque wrench (graduated in Nm) and rotate the wrench clockwise several revolutions at even speed. Read off the average value while rotating, normally 0.10-0.30 Nm.

Note the value (applies to new bearings) in the table at step 49 under "Read value, input shaft". The value will be used to calculate the correct rolling torque for the output shaft.

If the value is greater than 0.30 Nm or if it varies greatly while rotating, either the baulk rings or dirt and cuttings in the bearing are slowing it down. Dismantle the gearbox and investigate the cause. Rotating the shaft backwards and forwards under axial load may help. The bearings must be oiled in later, however.

40. Turn the gearbox back around.





41. Position the dial indicator measuring tip on the shaft as illustrated. Fit the Driver 87 92 053 on the output shaft and "run" the gearbox with a drill motor so that the bearings "settle in". Press and first run 20 revolutions before resetting the indicator. Lift and run another 20 revolutions and then read off the value (or run until the value has stabilized). Remove the tool Note the recorded value for the axial play and then add on the nominal value. Remove the dial indicator.

WARNING: Watch your fingers when the pinions are moving.

42. Engage 5th gear by pushing down the synchromesh sleeve. Engage 1st gear.





43. Remove the Driver 87 92 053 from the output shaft.





44. Fit the Millimeter Wheel, 27 mm 87 92 061 on the output shaft nut. Set the tool (mm wheel) graduation to the calculated value (recorded + nominal, see example). Mark out a tooth on the gear wheel using a marker pen or the like. Each division corresponds to 0.01 mm.

Value Table:

Check the rolling torque on new bearings only





45. Tighten in 2-3 stages until the zero (0) mark on the tool (mm disc) is aligned with the marked tooth. Measure the end float as described in steps 41-45. Remove the tool and the sleeve. If old bearings are fitted to the output shaft, lock the nut and continue with step 52. If new bearings are fitted, do not lock the nut and continue with the next step.
46. Before taking a more precise measurement of the output shaft bearing preload, the following must be complied with:
Input shaft bearing (axial play 0.09 - 0.15 mm)
Differential, bearing support fitted but not tightened (axial clearance 0.06 ± 0.05 mm)
All bearings oiled
47. Turn the gearbox so that it is in the same position as it would be in the car, i.e. horizontal. Disengage 1st gear and lift off the 5th synchromesh sleeve.





48. Place the torque wrench at the 5th gear nut output shaft. No gear must be engaged. Rotate the torque wrench several turns clockwise at an even speed. Read the average value from the display during rotation.
49. Subtract the read average value for the input shaft from the read average value for the output shaft. The calculated pretension is a value for the output shaft rolling torque, normal 0.75°0.25 Nm.





Tighten the nut on the output shaft two steps at a time on Millimeter Wheel, 27 mm 89 92 061, until the correct rolling torque is achieved.

Average torque varies greatly
Cause: Retarding baulk rings, swarf or dirt in the bearings.
Action: Dismantle the gearbox.

Average torque greater than 1.3 Nm:
Cause: Same as above or bearings too tight
Action: Dismantle the gearbox and change clamping sleeve. The bearings should then be preloaded and checked.

50. Lock the nut
51. Turn the gearbox back around.





52. Lift off the 5th synchromesh sleeve and fit the 5th fork to the 5th synchromesh sleeve. Fit the fork and sleeve to the shaft.

IMPORTANT: The synchromesh sleeve must only be positioned on the synchromesh hub where the high lugs on the synchromesh sleeve a located, aligned with the tooth gaps on the synchromesh hub that are between the deep tooth gaps according to the illustration.

53. Tap the retention pin into the selector shaft.
54. Fit a new circlip.
55. Tighten the screws for the differential bearing support.
Tightening torque 24 Nm (118 ft. lbs.)





56. Remove the cover from the hole in the gearcase and fit a new gasket and the end cover
Tightening torque 24 Nm (18 ft. lbs.)
57. Refit the reversing-light switch with a new gasket.
Tightening torque 24 Nm (118 ft. lbs.)





58. Check that the magnet is in position in the oil drain plug. Fit the plug.
Tightening torque 50 Nm (37 ft. lbs.)





59. Lubricate the sea] rings for input shaft and drive shafts.
60. Fill oil only when the drive shafts have been fitted on the gearbox and the gearbox has been mounted in the car. Oil volume: 1.9 liters.
61. Fit the slave cylinder, use thread sealant Loctite 577 on the screws.
Tightening torque 10 Nm (7 ft. lbs.)
62. Fit delivery pipe in place and fit the bush.
63. Bleed the slave cylinder before the gearbox is mounted. Refer to Clutch M/T, Slave Cylinder.