TRANSAXLE ASSEMBLY

Assembly

1. Install differential side oil seal (1) to clutch housing using Tool (A).

• Do not reuse differential side oil seal.
• When installing, do not incline differential side oil seal.
• Do not damage clutch housing.

2. Install input shaft oil seal (1) to clutch housing using Tool (A).

• Do not reuse input shaft oil seal.
• When installing, do not incline input shaft oil seal.
• Do not damage clutch housing.

3. Install differential side bearing outer race to clutch housing using Tool.

4. Install oil channel (1) on mainshaft side.

CAUTION:
When installing oil channel, fit the rib (A) of oil channel into the processed area of the spot facing (B).

5. Install mainshaft front bearing to clutch housing using Tool.

Tool number : ST33200000 (J-26082)

CAUTION:
Be careful with the orientation of mainshaft front bearing.

6. Install mainshaft bearing retainer (1) to clutch housing and tighten bolt to the specified torque.

2 : Mainshaft front bearing
3 : Oil channel

CAUTION:
Install with punched surface facing up.

7. Install magnet to clutch housing.
8. Install final drive assembly into clutch housing.

9. Install input shaft assembly, mainshaft assembly, and reverse idler gear assembly into clutch housing.

CAUTION:

• Wrap tape to the spline of input shaft so as not to damage the input shaft oil seal.

• Be careful with the orientation of reverse idler shaft.

10. Install striking rod assembly (1) into clutch housing.

• Check that return spring is securely seated in the groove on return pin.

11. Install 1st-2nd shift fork (1) and 1st-2nd fork rod (2) and then install retaining pin to 1st-2nd shift fork.

• Do not reuse retaining pin.
• Be careful with the orientation of 1st-2nd shift fork and 1st-2nd fork rod.
• Assemble retaining pin from the direction shown until it becomes flush with the end surface of 1st-2nd shift fork.

12. Install 3rd-4th shift fork (1) to 3rd-4th coupling sleeve.

CAUTION:
Be careful with the orientation of 3rd-4th shift fork.

13. Install 5th-6th shift fork (1) and 5th-6th fork rod (2) and then install retaining pin to 5th-6th shift fork.

CAUTION:

• Do not reuse retaining pin.
• Be careful with the orientation of 5th-6th shift fork and 5th-6th fork rod.
• Assemble retaining pin from the direction shown until it becomes flush with the end surface of 5th-6th shift fork.

14. Install 3rd-4th fork rod (2) and then install retaining pin to 3rd-4th shift fork (1).

CAUTION:

• Do not reuse retaining pin.
• Be careful with the orientation of 3rd-4th fork rod.
• Assemble retaining pin from the direction shown until it becomes flush with the end surface of 3rd-4th shift fork.

15. Install reverse shift fork (1) and reverse fork rod (2).

CAUTION:
Be careful with the orientation of reverse shift fork and reverse fork rod.

16. Rotate striking lever of striking rod assembly as shown. Then rotate reverse fork rod to a position where bracket of reverse fork rod does not interfere with striking lever of striking rod assembly.
17. Install retaining pin to reverse shift fork (1).

• Do not reuse retaining pin.
• Assemble retaining pin from the direction shown until it becomes flush with the end surface of reverse shift fork.

18. Install selected differential side bearing adjusting shim(s) and differential side bearing outer race.

• For selection of adjusting shim(s), refer to See: Adjustment.

19. Install selected reverse idler gear adjusting shim onto reverse idler gear assembly.

• For selection of adjusting shim, refer to See: Adjustment.

20. Install selected input shaft rear bearing adjusting shim onto input shaft.

• For selection of adjusting shim, refer to See: Adjustment.

21. Install selected striking rod adjusting shim onto striking rod assembly.

• For selection of adjusting shim, refer to See: Adjustment.

22. Install shifter lever oil seal (1) and striking rod oil seal (2) to transaxle case using suitable tool.

Dimension "H" : 0 - 1.0 mm (0 - 0.039 in)

CAUTION:

• Do not reuse shifter lever oil seal and striking rod oil seal.
• When installing, do not incline shifter lever oil seal and striking rod oil seal.
• Do not damage transaxle case.

23. Install differential side oil seal (1) to transaxle case using Tool (A) [SST: ST30720000 (J-25405)].

• Do not reuse differential side oil seal.
• When installing, do not incline differential side oil seal.
• Do not damage transaxle case.

24. Install shifter lever B (1) and shifter lever A (2) to transaxle case.

CAUTION:
Be careful with the orientation of shifter lever B and shifter lever A.

25. Install retaining pin to shifter lever A.

CAUTION:

• Do not reuse retaining pin.

• Assemble retaining pin from the direction shown until it becomes flush with the end surface of shifter lever A.

26. Install transaxle case according to the following:

1. Install selected mainshaft rear bearing adjusting shim into transaxle case.

• For selection of adjusting shim, refer to See: Adjustment.

2. Install oil gutter A (1) and oil gutter B (2) to transaxle case.

CAUTION:
Insert the tab (A) of oil gutter A and oil gutter B into transaxle case.

3. Temporarily install snap ring of mainshaft rear bearing into transaxle case.

CAUTION:
Do not reuse snap ring.

4. Apply recommended sealant to mating surface of clutch housing as shown.

• Use Genuine Silicone RTV or an equivalent. Refer to See: Specifications\Fluid Types.

CAUTION:

• Remove old sealant adhering to the mounting surfaces. Also remove any moisture, oil, or foreign material adhering to both mounting surfaces.
• Apply sealant so as not to break the bead.
• The width of sealant bead is 1 - 2 mm (0.04 - 0.08 in) .
• The height of sealant bead is 0.4 - 1 mm (0.016 - 0.04 in) .
• The overlap length of both ends of sealant bead is 3 - 5 mm (0.12 - 0.20 in) .

  

5. With shifter lever A (1) held in the position shown, temporarily assemble transaxle case to clutch housing.

CAUTION:
Do not damage striking rod oil seal.

NOTE:
Make sure to hold shifter lever A in the position shown. Otherwise transaxle case cannot be installed to clutch housing.

  

6. While rotating shifter lever A (1) in the direction shown, assemble transaxle case to clutch housing.

2 : Shifter lever B

  

7. Accessing from the bore plug hole, expand snap ring at mainshaft rear bearing so that the ring catches the periphery of mainshaft rear bearing.
8. Temporarily tighten transaxle case bolts.

  

9. Shift the shifter lever A (1) to 2nd gear position.

NOTE:

• The 2nd gear position is attained when shifter lever A is in the position shown.
• When transaxle is shifted to the 2nd gear position, mainshaft assembly is lifted.

10. Seat snap ring in the groove on mainshaft rear bearing. If snap ring is not seated in the groove on mainshaft rear bearing, remove transaxle case and repeat the procedure from step d.

  

11. Tighten transaxle case bolts to the specified torque.
12. Shift the shifter lever A (1) to neutral position.

  

NOTE:
The neutral position is attained when shifter lever A is in the position shown.

27. Install bore plug to transaxle case using Tool.

  

Tool number : ST33061000 (J-8107-2)

CAUTION:
Do not reuse bore plug.

  

28. Install selector lever to transaxle case and then install retaining pin to selector lever.

CAUTION:

• Do not reuse retaining pin.

  

• Assemble retaining pin from the direction shown until it becomes flush with the end surface of selector lever.

29. Install guide bolt (1) according to the following:

1. Shift the shifter lever A and selector lever to neutral position (A).
2. Visually confirm from the guide bolt mounting hole (C) that shift lever A is securely set to neutral position (A). If it is not in the neutral position (B), repeat the procedure from step a.

CAUTION:
The guide groove (D) of striking rod assembly will be damaged when assembling guide bolt (1) if the lever is not in the neutral position (B).

3. Check continuity between terminals of park/neutral position

(PNP) switch to confirm it in the neutral position. If it is not in the neutral position, remove park/neutral position (PNP) switch and repeat the procedure from step a. Refer to See: Gear Sensor/Switch\Testing and Inspection.

  

4. Install guide bolt to transaxle case and then tighten guide bolt to the specified torque.

CAUTION:
Do not reuse guide bolt.

  

30. Apply recommended sealant to threads of park/neutral position (PNP) switch (1). Then install it to transaxle case and tighten to the specified torque.

  

• Use Genuine Silicone RTV or an equivalent. Refer to See: Specifications\Fluid Types.

CAUTION:
Remove old sealant and oil adhering to threads.

31. Install plunger to transaxle case.
32. Apply recommended sealant to threads of back-up lamp switch (2). Then install it to transaxle case and tighten to the specified torque.

• Use Genuine Silicone RTV or an equivalent. Refer to See: Specifications\Fluid Types.

CAUTION:
Remove old sealant and oil adhering to threads.

33. Install air breather tube (3) to transaxle case.

CAUTION:

• Do not reuse air breather tube.
• Assemble air breather tube until its collar element contacts with transaxle case.

  

34. Install gasket onto plug and then install them into transaxle case. Tighten plug to the specified torque.

CAUTION:
Do not reuse gasket.

  

35. Install gasket onto drain plug and then install them into clutch housing. Tighten drain plug to the specified torque.

CAUTION:
Do not reuse gasket.

36. Install O-ring onto plug (with ABS models) or speedometer pinion gear (without ABS models) and then install it into clutch housing. Tighten bolt to the specified torque.

CAUTION:

• Do not reuse O-ring.
• After oil is filled, tighten bolt to specified torque.