Transaxle Disassembly and Assembly
Disassembly
1. Remove the speedometer by removing a bolt.
2. Remove the release bearing (A) and clutch fork (B).
3. Remove the clutch fork boot.
4. Remove the control shaft complete by removing the bolts (4ea).
5. Remove the back up lamp switch.
6. Remove the shift rail poppet bolts (3ea).
7. Remove the neutral switch.
8. Remove the reverse idler bolt.
9. Remove the mounting bolts (3ea) from the clutch housing inside.
10. Remove the transaxle case by removing the mounting bolts (11ea).
11. Remove the differential outer race(A) by using the special tool (09431-2C200).
12. Remove the output outer race(A) by using the special tool (09431-2C200).
13. Remove the input shaft oil guide(A) in the transalxe case.
14. Remove the oil guide(A).
15. Remove the reverse idle gear assembly.
16. Remove the reverse shift lever assembly by removing a bolt and a special bolt.
17. Remove the shift rail and fork assembly by removing the spring pins.
18. Remove the bearing retainer by removing the special bolts (4ea).
19. Remove the input shaft (A) and output shaft (B) assembly together from the clutch housing.
20. Remove the differential assembly (A).
21. Remove the differential oil seal (A).
22. Remove the clutch release lever fulcrum bolt (A).
23. Remove the differential outer race (A).
24. Remove the output shaft outer race (A).
25. Remove the magnetic (A).
26. Remove the output shaft oil guide (A).
27. Remove the input shaft front oil seal (A).
Reassembly
NOTE:
Before reassembling, clean all parts in slovent, dry them, and apply lubicant to any contact surfaces.
1. Install the input shaft front oil seal (A).
CAUTION:
Do not reuse the old oil seal.
2. Install the output shaft front oil guide (A).
3. Install the magnetic (A).
4. Install the output outer race (A).
5. Install the differential outer race (A).
6. Install the clutch release lever fulcrum bolt (A).
Tightening torque:
55 - 60 Nm(5.5 - 6.0 kgf.m, 39.8 - 43.4 lb-ft)
7. Install the differential oil seal in the transaxle case using the special tool(09452-21200).
8. Install the differential gear assembly (A).
9. Install the input shaft (A) and output shaft (B) in the clutch housing.
10. Install the bearing retainer by installing the special bolts (4ea).
NOTE:
Apply three bond 1303 equivalent around the hex bolt(4ea) before installing the bearing retainer.
Tightening torque:
15 - 22 Nm(1.5 - 2.2 kgf.m, 10.8 - 15.9 lb-ft)
11. Install the shift rail and fork assembly by inserting the spring pins.
CAUTION:
When installing, make sure that the slit of the spring pin is aligned within 15 of the center line of the shift rail.
12. Install the reverse shift lever assembly by installing a bolt and a special bolt.
Tightening torque:
20 - 27 Nm(2.0 - 2.7 kgf.m, 14.5 - 19.5 lb-ft)
13. Install the reverse idle gear assembly.
14. Install the oil guide (A) in the transaxle case.
15. Install the input shaft oil guide (A) in the transalxe case.
16. Measure and choose the proper space as followed.
End play [in(mm)]: 0 - 0.0019T in(0 - 0.05T mm)
Thickness of space [in(mm)] = (Height of housing [in(mm)] + Height of transaxle case [in(mm)]) - lengh of output [in(mm)] + end play [0.0003in(0.075mm)]
NOTE:
Measure the lengh of output shaft with both sides of bearing.
For keeping accuracy, measure at least 3 places and calculate the average value.
17. Install the spacer for output shaft assembly.
Spacer selection
18. Install the output shaft rear outer race.
19. Select the space of the differential assembly to minimize end play.
End paly [in(mm)]: 0.0059T-0.0078T in(0.15T-0.20T mm)
Thickness of space [in(mm)] = (height of housing [in(mm)] + transaxle case [in(mm)]) - the length of differential [in(mm)] + end play [0.0007in(0.175mm)]
NOTE:
Measure the lengh of differential assembly with both sides of bearing.
For keeping accuracy, measure at least 3 places and the calculate average value.
20. Install the spacer for the differential assembly.
Spacer selection
21. Install the differential outer race (A).
22. Apply the specified sealant on the surface of the transaxle housing.
Specified sealant : MS 721-40
23. Install transaxle case onto the transaxle housing by installing the mounting bolts (11ea).
CAUTION:
Use torque lench when tightening bolt.
Tightening torque :
43 - 55 Nm(4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)
24. Install the mounting bolts (3ea) inside of the transaxle housing.
CAUTION:
Use torque lench when tightening bolt.
Tightening torque :
43 - 55 Nm(4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)
25. Install the reverse idler bolt.
Tightening torque :
43 - 55 Nm(4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)
26. Install the neutral switch.
Tightening torque :
30 - 35 Nm(3.0 - 3.5 kgf.m, 21.7 - 25.3 lb-ft)
27. Install the shift rail poppet bolts (3ea).
Tightening torque :
40 - 60 Nm(4.0 - 6.0 kgf.m, 28.9 - 43.4 lb-ft)
28. Install the back up lamp switch.
Tightening torque :
30 - 35 Nm(3.0 - 3.5 kgf.m, 21.7 - 25.3 lb-ft)
29. Install the control shaft complete by installing the bolts (4ea).
CAUTION:
Use torque lench when tightening bolt.
Tightening torque :
20 - 27 Nm(2.0 - 2.7 kgf.m, 14.5 - 19.5 lb-ft)
30. Install the clutch fork boot.
31. Install the release bearing (A) and clutch fork (B).
NOTE:
Spread bearing sliding surface and holes of release fork with Grease.
Standard grease : CASMOLY L9508
32. Install the speedometer by installing a bolt.
Tightening torque :
3 - 5 Nm(0.3 - 0.5 kgf.m, 2.17 - 3.62 lb-ft)