Page 2097 of 2389
12. INSTALL TRANSMISSION CASE
(a) Install the transmission case.
HINT: If necessary, tap on the case with a plastic ham-
mer.
(b) Install and torque the seventeen bolts.
Torque: 300 kg±cm (22 ft±Ib, 29 N±m)
10. INSTALL DIFFERENTIAL NO.2 CASE
(a) Install the conical spring washer and No.2 side gear
thrust washer (Previously selected).
HINT: Be careful not to mistake the direction of conical
spring washer.
(a) Install the differential No.2 case to the No. 1
case.
HINT: Align the matchmarks on the differential No.1
case and connect the N.2 case.
11. INSTALL DIFFERENTIAL CASE ASSEMBLY
Install the differential case assembly ±to the transaxle
case.(c) Install and torque the sixteen bolts.
Torque: 1,260 kg±cm (91 ft±ib, 124 N±m)
± MANUAL TRANSAXLEComponent Parts (Differential Case Assembly E5SF5)MT±167
Page 2098 of 2389
13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Turn the differential case assembly counterclockwise and clock-
wise several time.
(b) Using a spring tension gauge, measure the differential case as-
sembly preload.
Preload (at starting)
New bearing
3.2 ± 6.3 kg
(7.1 ±13.9 lb,31.4±61.8N)
Reused bearing
2.0 ± 4.0 kg
(4.4±8.81b,19.6±39.2N)
If the preload is not within specification, select the thrust
washers.
HINT: The preload will change about 2.4 kg (5.3 Ib, 23.5 N) with
each shim thinness.
14. REMOVE TRANSMISSION CASE
Remove the seventeen bolts and tap off the case with a
plastic hammer.
15. REMOVE DIFFERENTIAL CASE ASSEMBLY
Thickness mm (in.) Thickness mm (in.)
Mark Mark
± MANUAL TRANSAXLEComponent Parts (Differential Case Assembly E5SF5)MT±168
Page 2099 of 2389
INSTALLATION OF COMPONENT
PARTS
(See pages MT±118 to MT±120)
HINT: 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.
(e) Install and torque the seventeen bolts.
Torque: 300 kg±cm (22 ft±lb, 29 N±m)
(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±Ib, 42 N±m)
(d) Install the output shaft rear bearing outer race.
± MANUAL TRANSAXLEInstallation of Component PartsMT±190
Page 2100 of 2389
(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 out-
put shaft.
Preload (at starting)
Now bearing 8.0 ± 16.0 kg±cm
(6.9 ± 13.9 in.±Ib, 0.8 ± 1.6 N±m)
Reused bearing 5.0 ± 10.0 kg±cm
(4.3 ± 8.7 in.±Ib, 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.±Ib, 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.
Thickness mm (in.)
Thickness mm (in.)
Mark Mark
± MANUAL TRANSAXLEInstallation of Component PartsMT±191
Page 2101 of 2389
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.(n) Remove the output shaft rear bearing outer race.
(c)Torque the four bolts.
Torque: 175 kg±cm(13 ft±lb, 17 N±m)
(o) Remove the output shaft assembly.
(b) Install the oil pipe.
± MANUAL TRANSAXLEinstallation of Component PartsMT±192
Page 2102 of 2389
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. B. INSTALL OUTPUT SHAFT ASSEMBLY
Lifting the differential case assembly, install the output
shaft assembly. 4. INSTALL DIFFERENTIAL CASE ASSEMBLY3. INSTALL MAGNET TO TRANSAXLE CASE
S. INSTALL OIL PUMP DRIVE GEAR
± MANUAL TRANSAXLE'.Installation of Component PartsMT±193
Page 2103 of 2389
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.
10. INSTALL NO.1 SHIFT FORK, SHIFT HEAD AND N0.2
SHIFT FORK SHAFT.
(a) Place No±1 shift fork into the groove of No.1 hub
sleeve. 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.
(b) Install the No.3 shift fork shaft with reverse shift
fork to the case.
(b) Put shift head onto the No±1 shift fork.
± MANUAL TRANSAXLEInstallation of Component PartsMT±194
Page 2104 of 2389
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 inter-
lock 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.
13. INSTALL LOCKING BALLS, SPRINGS, SPRING SEATS
AND SCREW PLUGS
(a) Install the two locking balls, springs and spring
seats.(c) Install the No.2 shift fork shaft to the case,
through the No.2 shift fork, the shift head and
the No. t shift fork.
12. INSTALL SET BOLTS
Install and torque the three bolts.
Torque: 240 kg±cm (17 ft±lb, 24 N±m)
± MANUAL TRANSAXLEInstallation of Component PartsMT±195