REMOVAL & INSTALLATION
- Disconnect the negative battery cable and the ground strap at the transaxle.
- Remove the clutch cable adjusting nuts, retaining clip from the cable and cable from the bracket.
- Disconnect and tag all the wiring harness clamps and connectors involved with the transaxle removal.
- Remove the speedometer cable boot, speedometer case clip and speedometer cable from the case.
- Remove the transaxle retaining bolts.
- Remove the starter assembly and starter motor plate.
- Remove the vacuum hose from the pressure sensor.
- Install the engine support to prevent the engine from lowering excessively.
- Raise and support the vehicle safely. Drain the transaxle oil.
- Remove the gear shaft control shaft bolt and nut and detach the control shaft from the gear shift shaft.
- Extension rod nut and remove the rod with washers.
- Remove the exhaust pipe front and rear flange bolts.
- Remove the clutch housing lower plate.
- Remove the left front wheel.
- Remove the left tie rod end.
- Remove the left ball joint by removing the joint stud bolt.
- Remove both halfshafts at the transaxle.
- Support the transaxle with a suitable jack and remove the transaxle retaining bolts and nuts.
- Remove the 2 rear engine mounting bolts.
- Remove the 3 bolts and 2 nuts from the transaxle mounting left hand bracket, remove the left hand bracket.
- Lower the transaxle with the engine attached in order to detach it from the stud bolt at the engine rear mounting portion. Pull the transaxle straight out toward the left side to disconnect the input shaft from the clutch cover, lower and remove the transaxle assembly.
- While the transaxle is being raised into its correct position, install the right hand halfshaft into the differential.
- Install the transaxle along with the transaxle to engine nuts and bolts. Install the left hand bracket with its 3 bolts and 2 nuts. Torque them to 37 ft. lbs. (50 Nm).
- Install the 2 rear engine mounting nuts and torque them to 37 ft. lbs. (50 Nm).
- Lower the transaxle supporting jack. Torque the transaxle to engine bolt and nut to 37 ft. lbs. (50 Nm).
- Install the left hand halfshaft to the transaxle. Be sure to push each driveaxle in fully to engage the snaprings with the differential gear.
- Install the left ball joint and ball joint stud bolt. Torque the ball joint bolt and nut to 44 ft. lbs. (60 Nm).
- Install the left tie rod end, castle nut and cotter pin. Torque the castle nut to 32 ft. lbs. (43 Nm).
- Install the left front wheel.
- Install the clutch housing lower plate.
- Install the exhaust pipe front and rear flange nuts.
- Install the extension rod nut and washers. Torque the rod nut to 24 ft. lbs. (33 Nm).
- Install the control shaft to gear shift and install the gear shift control shaft bolt and nut. Torque the gear shift control shaft bolt and nut to 13 ft. lbs. (18 Nm).
- Refill the transaxle with the recommended lubricant.
- Lower the vehicle.
- Remove the engine support fixture.
- Install the vacuum hose to the pressure sensor.
- Install the starter, starter motor plate and 2 bolts.
- Install the transaxle retaining bolts. Torque the retaining bolts to 37 ft. lbs. (50 Nm).
- Install the speedometer cable to case, speedometer case clip and speedometer cable boot.
- Install the clutch cable bracket, retaining clip to cable and clutch cable adjusting nut. Adjust the clutch free-play as necessary.
- Install the negative battery cable and the ground strap to the transaxle.
See Figures 1, 2, 3, 4, 5 and 6
Special tools are required for transaxle overhaul. Without these tools, measurement for bearing shim thickness and transaxle preload can not be made.Transaxle Assembly
- Remove the backup lamp switch.
- Remove the bolts from the side case and remove the side case.
- Remove the snapring and hub plate from the input shaft.
- Remove the shift fork screw and guide ball from the 5th gear shift fork.
- With the transaxle in neutral, remove the roll pin from the 5th gear shift fork.
- Push in on the gear shift shaft to engage transaxle into gear. Slide the 5th gear synchronizer sleeve down to engage 5th gear. This will lock the transaxle in two gears allowing for removal of the 5th gear retaining nut. The retaining nut is staked to the countershaft. Remove the stake mark prior to removing the retaining nut.
- Remove 5th gear shift fork, sleeve, hub, synchronizer ring, spring and keys as an assembly from the input shaft.
- Remove 5th gear, bearing, spacer and washer from the input shaft.
- Remove 5th gear from the countershaft.
- Remove screws retaining the bearing/shim retainer plate to the left case and remove plate and shims. Mark or tag shims for the input shaft and countershaft for reference during assembly.
- Remove bolts retaining left case cap and remove the cap.
- Remove the roll pin retaining the gear shift yoke to the gear shift/selector shaft.
- Install a drift into the roll pin hole in the gear shift/selector shaft and raise the shaft for removal of the yoke and roll pin.
- Remove the bolt retaining the reverse spring and detent ball. Remove the spring and ball from the case.
- Remove the locating bolt for the gear shift/selector shaft.
- Remove the bolts retaining the detent balls and springs for the shift fork shafts.
- Remove the bolts retaining the case halves.
- Insert a prybar into the slots between the case halves, pry or lift to separate case halves.
- Remove the left case. All inner parts such as input shaft, countershaft and differential should remain on the right case.
- Raise 5th and reverse shift shafts to gain clearance for removal of the reverse gear and shaft.
- Remove bolts retaining reverse idler shift lever to the case and remove lever.
- Remove 5th and reverse gear shift shafts together as an assembly.
- Remove the input shaft, countershaft, 1st/2nd and 3rd/4th shift shafts together as an assembly. It may be necessary to raise the differential assembly to gain clearance for removal of the above components.
- Remove the differential assembly from the right case.
- Remove the input shaft and counter shaft bearing cups from the right case using puller tool J29369-2, or equivalent, with a slide hammer.
- Remove the input shaft seal from the right case using the same tool.
- Remove the differential side oil seals from the right and left case.
- Remove the roll pin from the gear shift arm. Position the gear shift arm just above the square recess of the right case by moving the shift shaft. Using a drift, drive the pin out.
- Remove the retaining bolt for the shifter shaft detent ball and spring. Remove ball and spring from case.
- Slide the shifter shaft out and remove the arm, roll pin and shifter shaft from case.
- Remove the shifter shaft boot from the flange of the oil seal.
- Remove the input shaft and countershaft bearing cups from the left case.
Third and fourth gears should not be removed from the input shaft. If the gears are damaged or excessively worn, replace the input shaft.
- Remove the right bearing (small) from the input shaft using a bearing separator and hydraulic press.
- Remove the left bearing (large) from the input shaft using a bearing separator and hydraulic press.
The countershaft right bearing cage protrudes beyond the countershaft end face. Use care not to place the countershaft with the right bearing on a work bench or damage to the bearing cage may occur.
- Remove the right bearing from the countershaft using a bearing separator and hydraulic press.
- Remove the left bearing from the countershaft using a bearing separator and hydraulic press.
- Remove the 4th gear thrust washer, 4th gear, bearing, spacer, 4th gear synchronizer hub and sleeve assembly. Next remove 3rd gear synchronizer ring, 3rd gear and bearing.
- Remove the ring washer from 2nd gear retaining ring halves. Remove the two ring halves, 2nd gear, bearing and 2nd gear synchronizer ring.
- Remove 1st/2nd gear synchronizer assembly retaining ring halves. Remove 1st/2nd synchronizer hub and sleeve assembly, 1st gear synchronizer ring, 1st gear and bearing.
- Remove the side bearings using a gear puller and a plug to protect the gearing bore.
- Remove the speedometer drive gear using a puller.
- Remove the roll pin retaining the pinion shaft.
- Remove the pinion shaft, pinion gears and side gears from the case.
- Remove the ring gear retaining bolts and then remove the ring gear.
Wash all parts thoroughly in clean solvent. Be sure all old lubricant, metallic particles, dirt or foreign material are removed from the surfaces of every part.
Apply compressed air to each oil feed port and channel in each case half to remove any obstructions or cleaning solvent residue. Inspect the case halves for cracks, porosity, damaged mating surfaces, stripped bolt threads or distortion. Replace any part that exhibits these conditions.
Inspect all gear teeth for signs of excessive wear or damage and check all gear splines for burrs, nicks, wear or damage. Remove minor nicks or scratches on an oil stone. Replace any part exhibiting excessive wear or damage.
Inspect all thrust washer for evidence of excessive wear, distortion or damage. Replace any of these parts if they exhibit these conditions.
Inspect the condition of the needle, roller and thrust bearings. Wash bearings thoroughly in a cleaning solvent. Apply compressed air to dry.
Do not allow bearings to spin while applying compressed air. Spinning bearings may damage the rollers.
Lubricate bearings with light oil and check for roughness by slowly turning the race by hand.
Inspect shift forks and shift shafts for evidence of excessive wear, distortion or damage. Replace any of these parts if they exhibit these conditions.
The synchronizer hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled, but the keys, springs and rings may be replaced if worn or broken.
Assemble the low and high speed synchronizer spring to the hubs. Insert one end of the spring in the spring setting hole on the hub, directing the springs on each hub in opposition to each other so that the load is evenly applied to the synchronizer keys.Input Shaft
- Install the right bearing (small) on the input shaft using a bearing driver and hydraulic press.
- Install the left bearing (large) on the input shaft using a bearing driver and hydraulic press.
- Apply clean transaxle fluid to the sliding surfaces of all parts prior to assembly.
- Install the low gear bearing and then the gear on the shaft.
- Install the low gear synchronizer ring and ring spring.
- Install the 1st/2nd gear synchronizer assembly on the shaft. When installing the hub to the countershaft, align the oil groove on the hub with the oil hole onto he shaft.
- Install the low speed synchronizer hub rings. Fit the two rings into the groove on the countershaft.
- Install the 2nd gear bearing and then the gear on the shaft. Install the two rings with the protrusion of the ring into the hole on the countershaft.
- Install the ring washer.
- Install the spring to 2nd gear.
- Install the 3rd gear bearing and then the gear on the shaft.
- Install the 3rd/4th gear synchronizer assembly on the shaft. Install the hub on the countershaft in such a way that oil groove of the hub meets the oil hole of the shaft.
- Install the 4th gear and then the thrust washer. The oil grooves on the washer goes against 4th gear.
- Install the left and right bearings on the shaft.
- Apply clean transaxle oil to the sliding surfaces of all parts prior to assembly.
- Install side washers and then side gears.
- Install the pinion washers and pinion gears.
- Install the pinion gear shaft.
- Measure the backlash of the side pinions and side gears with a feeler gauge. If backlash exceeds 0-0.009 in., adjust it by varying the thickness of the side gear washers.
- Install the pinion shaft roll pin.
- Install the ring gear and retaining bolts. Tighten bolts to 58-72 ft. lbs. (80-100 Nm).
- Install the speedometer gear.
- Install the right and left side bearings. Install the bearing with the seal side facing the differential case.
- Apply grease to the lips of the input shaft seal and differential side oil seals after installation. Apply clean transaxle oil to the sliding surfaces of all parts prior to assembly.
- Install the input shaft seal in the right case.
- Install the input shaft bearing cup in the right case.
- Install the countershaft bearing cup in the right case.
- Install the right and left case differential oil seals.
- Install the reverse gear shift lever. Apply thread locking cement to the bolts prior to installing. Torque bolts to 14-20 ft. lbs. (18-28 Nm).
- Install gear shift shaft oil seal. After installation, apply grease to the lip of the seal.
- Install gear shift shaft boot. Apply grease to the shaft prior to installing.
- Install the shift shaft detent ball, spring, gasket and bolt.
- Install the gear shift arm and roll pin tot he gear shift shaft.
- Install the differential assembly into the right case.
- Install the 5th and reverse gear shift and guide shaft to the right case.
- Install the input shaft, countershaft, 1st/2nd and 3rd/4th gear shift shafts to the right case.
- Install the idler gear, shaft, pin, spacer and washer to the right case.
- Install the case magnet to the right case.
- Apply Loctite® 518 or equivalent, uniformly to the mating surface of the left case.
- Place the left case on the right case and install the retaining bolts. tighten bolts to 14-20 ft. lbs. (18-28 Nm). After tightening bolts, check the input shaft and countershaft for smooth rotation by running them by hand.
- Install the shift fork shaft detent balls, springs, gaskets and bolts. Tighten bolts to 8-11 ft. lbs. (10-16 Nm).
- Install the gear shift yoke on the gear shift arm. Install the gear shift/select shaft assembly, guiding the shaft into the hole in the gear shift yoke. Align the hole in the yoke with the hole in the shaft and install a new roll pin to retain it.
- Install the gearshift locating bolt and washer. Tighten to 30-43 ft. lbs. (40-60 Nm).
- Install the reverse check ball, spring, washer and bolt.
- Install the case cap with a new O-ring to the left case. In stall the retaining bolts.
Measure and determine the bearing shim size for the input shaft and countershaft as follows:
- Install the left bearing cups for the input shaft and countershaft.
- Using finger pressure, press countershaft left bearing cup against the bearing rollers.
- Rotate the countershaft three or four times by hand to seat the bearing. Install the nut from installation tool J34858 on the shaft and then install the countershaft nut and torque to 44-58 ft. lbs. (60-80 Nm).
- Install a dial gauge on J34858 shim selector tool. Place the shim selector on a flat surface and zero the gauge.
- Place the shim selector on the countershaft and left case. Press down on the shim selector and read the dial indicator. The reading on the dial gauge will indicate the size shim required.
- The shim stock is available in twelve selective thickness. Each shim has the thickness stamped on the side. Select the shim required and install it on the back side of the left countershaft bearing cup.
- Repeat the above steps for measuring the input shaft.
- Select the shim required and install it on the back side of the left input shaft bearing cup.
- Install the case . Fit the protrusion of the case plate joint the groove of the gear shift guide shaft. Apply thread locking cement to the threads of the screws and install.
- Check the preload of the transaxle. Install tool J34852 on the input shaft. Connect a spring balance to the wire on the tool and pull the spring balance. Check the preload in N and in 4th gear. If the preload is not 3-15 Nm, the shims will have to be changed on the input shaft or countershaft.
- With the transaxle in 4th gear, install 5th gear on the input shaft and countershaft. Engage the synchronizer so the transaxle will be locked in two gears.
- Install the countershaft nut. After tightening, stake the nut with a chisel. If a crack is found at the staked portion, replace the nut.
- Disengage 5th gear synchronizer and shift the transaxle into N .
- Install the shift guide ball and shift fork screw to the shift fork. After tightening the screw, stake it in place.
- Install a new roll pin to 5th and reverse gear shift shaft.
- Install the synchronizer hub plate and a new snapring.
- Apply Loctite® 518, or equivalent, to the mating surface of the side case. Install the side case. Fit the oil receiver cup in the side case into the hole of the input shaft. Install the bolts 14-20 ft. lbs. (18-28 Nm).
- Install the back-up light switch.