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TRANSAXLE ASSEMBLY
MT-53
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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-43, "
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-43,
"Shift Control Components" .
CAUTION:
Does not reuse shift check.
j. Install stopper bolt to transaxle case, and then tighten stopper bolt to the specified torque. Refer to MT-43,
"Shift Control Components" .
CAUTION:
Do not reuse stopper bolt.
34. Install bore plug to transaxle case using the drift.
CAUTION:
Do not reuse bore plug.
35. Install welch plug to transaxle case using the drift.
CAUTION:
Do not reuse welch plug.
36. 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-43, "
Shift Control Components" .
CAUTION:
Do not reuse check plug.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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MT-54
TRANSAXLE ASSEMBLY
37. 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-40, "
Case
and Housing Components" .
38. 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-40, "
Case and Housing Components" .
CAUTION:
Do not reuse gasket.
39. 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-40, "
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.
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).
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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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TRANSAXLE ASSEMBLY
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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.
Reverse Idler Gear End Play
When adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear. Refer
to MT-107, "
REVERSE IDLER GEAR ADJUSTING SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.
Calculate dimension “Q” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
1. Using depth micrometer and straightedge, measure dimension
“Q
1 ” between transaxle case end face and mounting face of
adjusting shim.
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End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)
Dimension“Q” = (Q
1 - Q2 ) - End play
Q: Thickness of adjusting shim
Q
1 : Distance between transaxle case end face
and mounting face of adjusting shim
Q
2 : Distance between clutch housing end face
and end face of reverse idler gear (Rear)
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MT-56
TRANSAXLE ASSEMBLY
2. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension “Q
2” between clutch housing end face
and end face of reverse idler gear (Rear).
3. Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.
Input Shaft End Play
When adjusting input shaft end play, select adjusting shim for
input shaft rear bearing. To select adjusting shim, measure
clearance between transaxle case and input shaft rear bearing.
Refer to MT-107, "
INPUT SHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.
Calculate dimension “O” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.
1. Using depth micrometer and straightedge, measure dimension
“O
1 ” between transaxle case end face and mounting face of
adjusting shim.
2. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension “O
2” between clutch housing end face
and end face of input shaft rear bearing.
3. Install selected input shaft rear bearing adjusting shim onto input
shaft.
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End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension“O” = (O
1 - O2 ) - End play
O: Thickness of adjusting shim
O
1 : Distance between transaxle case end face and
mounting face of adjusting shim
O
2 : Distance between clutch housing end face
and end face of input shaft rear bearing
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TRANSAXLE ASSEMBLY
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Mainshaft End Play
When adjusting mainshaft end play, select adjusting shim for
mainshaft rear bearing. To select adjusting shim, measure clear-
ance “M” between transaxle case and mainshaft rear bearing.
Refer to MT-107, "
MAINSHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.
Calculate dimension “P” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for main-
shaft rear bearing.
1. Install mainshaft assembly to clutch housing.
2. Install snap ring to transaxle case.
3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install tempo-
rarily snap ring to mainshaft rear bearing.
4. Install dial indicator to bore plug mounting hole, and expand
snap ring. Lift mainshaft assembly through control assembly
installation hole, and push it against transaxle case. This state
shall be defined as base. Moving distance of mainshaft assem-
bly, with snap ring fit on main rear bearing, becomes “M”.End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension“P” = “M” - End play
P: Thickness of adjusting shim
M: Distance between mainshaft rear bearing end
face and transaxle case end face
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MT-58
INPUT SHAFT AND GEARS
INPUT SHAFT AND GEARSPFP:32200
Disassembly and Assembly (RS5F51A)ECS008C4
DISASSEMBLY
1. Before disassembling, measure end play for 3rd, 4th, and 5th
input gears.
2. Remove oil channel.
3. Press out input shaft rear bearing using the drift and a puller.
4. Remove the snap ring.
5. Press out input shaft bearing spacer and 5th stopper using the
drift and a puller.End play standard value
3rd input gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th input gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th input gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
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INPUT SHAFT AND GEARS
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6. Press out 5th input gear and 5th synchronizer hub assembly
using the drift and a puller.
7. Remove 5th needle bearing.
8. Press out 5th input gear bushing, thrust washer, 4th input gear,
4th needle bearing, 4th input gear bushing, 3rd-4th synchronizer
hub assembly and 3rd input gear using the drift and a puller.
9. Remove 3rd needle bearing.
10. Press out input shaft front bearing using a puller.
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gears
Check items below. If necessary, replace them with new ones.
Damage, peeling, dent, uneven wear, bending, etc. of shaft
Excessive wear, damage, peeling, etc. of gears
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MT-60
INPUT SHAFT AND GEARS
Synchronizer
Check items below. If necessary, replace them with new ones.
Damage and excessive wear of contact surfaces of coupling
sleeve, synchronizer hub and shifting insert
Coupling sleeve and synchronizer hub must move smoothly.
If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
BAULK RING CLEARANCE
Single-cone synchronizer (4th and 5th)
Push baulk ring on the cone, and measure the clearance
between baulk ring and cone. If measurement is below limit,
replace it with a new one.
Double-cone synchronizer (3rd)
Check the clearance between outer baulk ring, synchronizer
cone and inner baulk ring as follows.
CAUTION:
The clearances “A” and “B” are controlled with outer baulk
ring, synchronizer cone and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit
value.
SMT387A
SMT867D
Clearance
Standard value
4th : 0.9 - 1.45 mm (0.035 - 0.057 in)
5th : 0.95 - 1.4 mm (0.037 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
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