When adjusting differential side bearing preload, select adjusting shim for differential side bearing. To select adjusting shim, measure clearance "L" between transaxle case and differential side bearing outer race.
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 differential side bearing.
Using a depth micrometer and straightedge, measure dimension "L1" between transaxle case end face and mounting face of adjusting shim.
Install differential side bearing outer race onto differential side bearing on final gear side. Holding lightly differential side bearing outer race horizontally by hand, rotate final gear five times or more (for smooth movement of bearing roller).
Using a depth micrometer and straightedge as shown, measure dimension "L2" between differential side bearing outer race and clutch housing end face.
CAUTION: "L2": Measure at 4 point by approximately 90 degrees and use the average value.
Install selected differential side bearing adjusting shim and then install differential side bearing outer race using Tool.
Tool number : ST30720000 (J-25405)
CAUTION: Replace differential side bearing and differential side bearing outer race as a set.
REVERSE IDLER GEAR END PLAY
When adjusting reverse idler gear end play, select adjusting shim for reverse idler gear. To select adjusting shim (1), measure clearance between transaxle case (2) and reverse idler gear (Rear) (3).
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.
Using a depth micrometer and straightedge, measure dimension "Q1" between transaxle case end face and mounting face of adjusting shim.
Using a depth micrometer and straightedge as shown, measure dimension "Q2" between clutch housing (1) end face and end face of reverse idler gear (Rear) (2).
CAUTION: "Q2": Measure at 4 point by approximately 90 degrees and use the average value.
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.
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.
Using a depth micrometer and straightedge, measure dimension "O1" between transaxle case end face and mounting face of adjusting shim.
CAUTION: "O1": Measure at 4 point by approximately 90 degrees and use the average value.
Using a depth micrometer and straightedge as shown, measure dimension "O2" between clutch housing end face and end face of input shaft rear bearing.
CAUTION: "O2": Measure at 4 point by approximately 90 degrees and use the average value.
When adjusting striking rod end play, select adjusting shim (1) for striking rod (2). To select adjusting shim, measure clearance between transaxle case (3) and striking rod shim (4).
CAUTION: Only 1 adjusting shim can be selected.
Calculate dimension "R" (thickness of adjusting shim) using the following procedure to satisfy specification of end play for striking rod.
Using a depth micrometer (A) and straightedge (B), measure dimension "R1" between transaxle case (1) end face and mounting face of adjusting shim.
CAUTION: "R1": Measure at 4 point by approximately 90 degrees and use the average value.
Using a depth micrometer (A) and straightedge (B) as shown, measure dimension "R2" between clutch housing (1) end face and end face of striking rod shim (2).
CAUTION:
"R2": Measure at 4 point by approximately 90 degrees and use the average value.
When measuring, be careful for the inclination of striking rod assembly and striking rod shim.
Install selected striking rod adjusting shim onto striking rod assembly.
MAINSHAFT END PLAY
When adjusting mainshaft end play, select adjusting shim (1) for mainshaft rear bearing (2). To select adjusting shim, measure clearance "M" between transaxle case (3) and dummy adjusting shim (4) on mainshaft rear bearing.
5 : Snap ring
6 : Mainshaft
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 mainshaft rear bearing.
*: Refer to the latest parts information to use a dummy adjusting shim of which part number is the thinnest in thickness.
Install transaxle case according to the following:
Temporarily install snap ring of mainshaft rear bearing into transaxle case.
CAUTION: Do not reuse snap ring.
Install dummy adjusting shim (1) to mainshaft assembly.
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.
While rotating shifter lever A (1) in the direction of the arrow shown, assemble transaxle case to clutch housing.
2 : Shifter lever B
Accessing from the bore plug hole, expand snap ring at mainshaft rear bearing so that the ring catches the periphery of mainshaft rear bearing.
Temporarily tighten transaxle case bolts.
Shift the shifter lever A to 2nd gear position.
NOTE:
The 2nd gear position is attained when shifter lever A (1) is in the position shown.
When transaxle is shifted to the 2nd gear position, mainshaft assembly (1) is lifted.
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 1 from step c.
Shift the shifter lever A to 1st gear position, and then shift it to 2nd gear position. Repeat 3 times.
NOTE:
The mainshaft rear bearing position will be stabilized by shifting between 1st gear position and 2nd gear position alternately.
The 1st gear position is attained when shifter lever A (1) is in the position shown.
When transaxle is shifted to the 1st gear position, mainshaft assembly (1) is declined.
Set the dial indicator (A) to dummy adjusting shim (1) through the bore plug mounting hole.
2 : Mainshaft rear bearing
3 : Snap ring
M : Movement between 1st and 2nd gear
Shift the shifter lever A (1) to 2nd gear position (A), and then rotate it in the direction of the arrow (C) until it stops. Using this position as the reference point, measure the amount of movement when shifting shifter lever A to 1st gear position (B) and rotating it in the direction of the arrow (D) until it stops. This measurement is the "M" dimension.
When measurement "M" is 0 - 0.06 mm (0 - 0.0024 in) , adjustment terminates, and the dummy adjusting shim becomes regular adjusting shim. Select adjusting shim from the computed expressions when measurement "M" is over 0.06 mm (0.0024 in) .
