Part 1
INSTALLATION OF COMPONENT PARTSHINT Coat all of the sliding and rotating surface with gear oil before assembly.
1. ADJUST OUTPUT SHAFT PRELOAD
a. Install the output shaft assembly to the transaxle case.
b. Install the transmission case to the transaxle case.
If necessary, tap on the case with a plastic hammer.
c. Install and torque the seventeen bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N.m)
d. Install the output shaft rear bearing outer race.
e. Install the adjusting shim.
HINT: When re-using the output shaft rear bearing, first install a shim of the same thickness as before. If installing a new bearing, first select and install a shim of lesser thickness than before.
f. Using a torx wrench, install and torque the seven torx screws.
Torx wrench T45 09042-00050
Torque: 430 kg-cm (31 ft-lb, 42 N.m)
g. Install the new lock nut to the output shaft.
h. Turn the output shaft counterclockwise and clockwise several times.
i. Using a torque meter, measure the preload of the output shaft.
Preload (at starting)
New bearing 8.0 - 16.0 kg-cm (6.9 - 13.9 in-lb, 0.8 - 1.6 N.m)
Reused bearing 5.0 - 10.0 kg-cm (4.3 - 8.7 in-lb, 0.5 - 1.0 N.m)
If the preload is not within specification, select the thrust washers.
HINT: The preload will change about 4 5 kg-cm (3.5 - 4.3 in.-lb, 0.4 - 0.5 N.m) with each shim thickness.
j. Remove the lock nut.
k. Using a torx wrench, remove the seven torx screws.
Torx wrench T45 09042-00050
i. Remove the adjust shim.
m. Remove the seventeen bolts and tap off the case with a plastic hammer.
n. Remove the output shaft rear bearing outer race.
o. Remove the output shaft assembly.
2. INSTALL OIL PUMP ASSEMBLY AND OIL PIPE
a. Install the oil pump assembly and temporarily tighten the two bolts.
HINT: Do not drop the oil pump gasket.
b. Install the oil pipe.
c. Torque the four bolts.
Torque: 175 kg-cm (13 ft-lb, 17 N.m)
3. INSTALL MAGNET TO TRANSAXLE CASE
4. INSTALL DIFFERENTIAL CASE ASSEMBLY
5. INSTALL OIL PUMP DRIVE GEAR
6. INSTALL OUTPUT SHAFT ASSEMBLY
Lifting the differential case assembly, install the output shaft assembly.
7. INSTALL INPUT SHAFT ASSEMBLY
Leaning the output shaft assembly to the differential case side, install the input shaft assembly.
HINT: When you install the input shaft assy, be careful not to scratch the oil seal.
8. INSTALL SNAP RING
a. Install the reverse shift fork to the No.3 shift fork.
b. Using a plastic hammer, install the snap ring.
9. INSTALL NO.2 SHIFT FORK AND NO.3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK
a. Place No.2 shift fork into the groove of No.2 hub sleeve.
b. Install the No.3 shift fork shaft with reverse shift fork to the case.
10. INSTALL NO.1 SHIFT FORK, SHIFT HEAD AND NO.2 SHIFT FORK SHAFT.
a. Place No.1 shift fork into the groove of No.1 hub sleeve.
b. Put shift head onto the No.1 shift fork.
c. Install the No.2 shift fork shaft to the case, through the No.2 shift fork, the shift head and the No.1 shift fork.
11. INSTALL NO.1 SHIFT FORK SHAFT
a. Using a magnetic finger, install the interlock roller into the reverse shift fork.
HINT: Align the groove of No.1 fork shaft with the interlock roller hole of reverse shift fork.
b. Install the No.1 shift fork shaft to the case, through the No.1 shift fork and reverse shift fork.
HINT: If it is difficult to put the No.1 shift fork shaft through the reverse shift fork, pull up the No.3 shift fork shaft.
12. INSTALL SET BOLTS
Install and torque the three bolts.
Torque: 240 kg-cm (17 ft-lb, 24 N.m)
13. INSTALL LOCKING BALLS, SPRINGS, SPRING SEATS AND SCREW PLUGS
a. Install the two locking balls, springs and spring seats.
b. Apply sealant to the two screw plugs.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Using SST, torque the two screw plugs.
SST 09313-30021
Torque: 250 kg-cm (18 ft-lb, 25 N.m)
14. INSTALL REVERSE IDLER GEAR SHAFT, THRUST WASHER AND GEAR
a. Install the reverse idler gear shaft with gear and thrust washer to the case.
b. Align the matchmarks, as shown in the illustration.
15. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY AND NO.2 OIL PIPE
a. Put the reverse shift fork pivot into the reverse shift arm and install the reverse shift arm bracket to the transaxle case.
b. Temporarily install the bolt.
c. Install the No.2 oil pipe.
d. Torque the two oil pipe bolts and reverse shift arm bracket bolt.
Torque: 175 kg-cm (13 ft-lb, 17 N.m)
e. Install a new gasket to the oil pipe.
16. INSTALL TRANSMISSION CASE
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transaxle case.
b. Apply seal packing to the transmission case as shown in the figure.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
HINT: Install the transmission case as soon as the seal packing is applied.
c. Install and torque the seventeen bolts.
Transmission case side: Fourteen bolts
Transaxle case side: Three bolts
Torque: 300 kg-cm (22 ft-lb, 29 N.m)