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TRANSAXLE ASSEMBLY
MT-29
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26. Remove retaining pin of 1st-2nd shift fork using a pin punch.
27. Pull out 1st-2nd fork rod with 1st-2nd bracket.
28. Remove 1st-2nd shift fork.
29. Remove retaining pin of 1st-2nd bracket using a pin punch and
separate 1st-2nd fork rod and 1st-2nd bracket.
30. Remove gear components from clutch housing in the following
procedure.
a. Remove input shaft assembly, mainshaft assembly and reverse
idler gear assembly as a set, tapping input shaft with plastic
hammer.
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.
31. Remove mainshaft bearing retainer and then mainshaft front
bearing from clutch housing using the puller.
32. Remove oil channel from clutch housing.
33. Remove differential side oil seal from clutch housing.
CAUTION:
Be careful not to damage clutch housing.
34. Remove differential side bearing outer race from clutch housing
using the puller.
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MT-30
TRANSAXLE ASSEMBLY
35. Remove input shaft oil seal from clutch housing.
CAUTION:
Be careful not to damage clutch housing.
ASSEMBLY
1. Install input shaft oil seal to clutch housing using the drift.
CAUTION:
Do not reuse input shaft oil seal.
2. Install differential side oil seal until it become flush with end face
of clutch housing using the drift.
CAUTION:
Do not reuse differential side oil seal.
Apply multi-purpose grease onto oil seal lip. (For 4WD
models)
3. Install oil channel on mainshaft side.
CAUTION:
Be careful with the orientation of installation.
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Dimension A: 1.8 - 2.8 mm (0.071 - 0.110 in)
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TRANSAXLE ASSEMBLY
MT-31
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4. Install mainshaft front bearing to clutch housing using the drift.
CAUTION:
Be careful with the orientation of installation.
5. Install mainshaft bearing retainer to clutch housing and tighten
mounting bolt to the specified torque. Refer to MT-23, "
Gear
Components" .
CAUTION:
Install with punched surface facing up.
6. Install differential side bearing outer race to clutch housing using
the drifts.
7. Install final drive assembly into clutch housing.
8. Install input shaft assembly, mainshaft assembly, and reverse
idler gear assembly into clutch housing.
CAUTION:
Be sure not to damage input shaft oil seal.
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MT-32
TRANSAXLE ASSEMBLY
9. Install 1st-2nd bracket onto 1st-2nd fork rod, and then install
retaining pin to 1st-2nd bracket.
CAUTION:
Do not reuse retaining pin.
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install
retaining pin to1st-2nd shift fork.
CAUTION:
Do not reuse retaining pin.
11. Install shift check sleeve to clutch housing.
12. Install interlock pin to 3rd-4th fork rod.
13. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod.
14. Install stopper rings onto 3rd-4th shift fork.
CAUTION:
Do not reuse stopper ring.
15. Install retaining pin onto 3rd-4th bracket.
CAUTION:
Do not reuse retaining pin.
16. Install 2 check balls to clutch housing.
17. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork
rod.
18. Install stopper rings onto 5th-reverse bracket.
CAUTION:
Do not reuse stopper ring.
19. Install retaining pin onto 5th shift fork.
CAUTION:
Do not reuse retaining pin.
20. Install reverse shift fork and reverse fork rod.
21. Install reverse lever assembly following the procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then
install them onto reverse shift fork.
CAUTION:
Do not drop shifter cap.
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TRANSAXLE ASSEMBLY
MT-33
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b. While lifting reverse shift fork, align cam with 5th-reverse
bracket.
c. Install reverse lever assembly to clutch housing, and then
tighten mounting bolts to the specified torque. Refer to MT-25,
"Shift Control Components" .
22. Install check ball, shift check sleeve, check spring and check
plug to clutch housing.
CAUTION:
Do not reuse check plug.
Do not drop check ball.
23. Install the magnet onto clutch housing.
24. Install differential side oil seal until it is flush with end face of
transaxle case using the drift.
CAUTION:
Do not reuse differential side oil seal.
25. Install selected differential side bearing adjusting shim and dif-
ferential side bearing outer race.
For selection of adjusting shim, refer to MT-36, "Differential
Side Bearing Preload" .
26. Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.
For selection of adjusting shims, refer to MT-37, "Reverse
Idler Gear End Play" .
27. Install selected input shaft rear bearing adjusting shim onto input shaft.
For selection of adjusting shims, refer to MT-37, "Input Shaft End Play" .
28. Install baffle plate and oil gutter to transaxle case.
29. Install transaxle case following the procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
For selection of adjusting shims, refer to MT-38, "Mainshaft End Play" .
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse snap ring.
c. Apply recommended sealant to mating surfaces of transaxle
case and clutch housing.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
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MT-34
TRANSAXLE ASSEMBLY
d. With snap ring of mainshaft rear bearing temporarily installed,
place transaxle case over clutch housing.
e. Through bore plug mounting hole, with snap ring stretched, and
lift up mainshaft assembly from the control assembly mounting
hole.
f. Securely install snap ring onto mainshaft rear bearing.
g. Tighten mounting bolts to the specified torque.
CAUTION:
Always replace bolts B as they are self-sealing bolts.
h. Apply gear oil to O-ring and install it to control assembly. Then
install control assembly to transaxle case. Tighten bolts to the
specified torque. Refer to MT-25, "
Shift Control Components" .
CAUTION:
Do not reuse O-ring.
i. Install shift check to transaxle case, and then tighten shift check to the specified torque. Refer to MT-25,
"Shift Control Components" .
CAUTION:
Do not reuse shift check.
j. Install stopper bolt to transaxle case, and then tighten stopper bolt to the specified torque. Refer to MT-25,
"Shift Control Components" .
CAUTION:
Do not reuse stopper bolt.
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Bolt A:
: 52 N·m (5.3 kg-m, 38 ft-lb)
Bolt B:
: 65 N·m (6.6 kg-m, 48 ft-lb)
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TRANSAXLE ASSEMBLY
MT-35
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30. Install bore plug to transaxle case using the drift.
CAUTION:
Do not reuse bore plug.
31. Install welch plug to transaxle case using the drift.
CAUTION:
Do not reuse welch plug.
32. Install 2 check balls, 2 check springs and 2 check plugs to tran-
saxle case, and then tighten check plug to the specified torque.
Refer to MT-25, "
Shift Control Components" .
CAUTION:
Do not reuse check plug.
33. Apply recommended sealant to threads of park/neutral position
switch and back-up lamp switch. Then install them to transaxle
case and tighten to the specified torque. Refer to MT-22, "
Case
and Housing Components" .
34. Install gaskets onto drain plug and plug, and then install them
into transaxle case. Tighten drain plug and plug to the specified
torque. Refer to MT-22, "
Case and Housing Components" .
CAUTION:
Do not reuse gasket.
35. Install O-ring onto plug (for 2WD models) or gasket onto filler
plug (for 4WD models), and then install it into clutch housing.
Tighten plug mounting bolt or filler plug to the specified torque.
Refer to MT-22, "
Case and Housing Components" .
CAUTION:
Do not reuse O-ring or gasket.
After oil is filled, tighten plug mounting bolt or filler plug to specified torque.
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MT-36
TRANSAXLE ASSEMBLY
ADJUSTMENT
Differential Side Bearing Preload
When adjusting differential side bearing preload, select adjust-
ing shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race. Refer to MT-108, "
DIFFERENTIAL
SIDE BEARING ADJUSTING SHIM(S)" .
CAUTION:
Up to 2 adjusting shims can be selected.
Calculate dimension “L” (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differ-
ential side bearing.
1. Using depth micrometer and straightedge, measure dimension
“L
1 ” between transaxle case end face and mounting face of
adjusting shim.
2. Install differential side bearing outer race onto differential side
bearing on final gear side. Holding lightly differential side bear-
ing outer race horizontally by hand, rotate final gear five times or
more (for smooth movement of bearing roller).
3. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension “L
2” between differential side bearing
outer race and clutch housing end face.
4. Install selected differential side bearing adjusting shim, and then
install differential side bearing outer race using the drift.Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L
1 - L2 ) + Preload
L: Thickness of adjusting shim
L
1 : Distance between transaxle case end face and
mounting face of adjusting shim
L
2 : Distance between differential side bearing
outer race and clutch housing end face
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