See Figures 1, 2 and 3
Cleanliness is an important factor in the overhaul of the manual transaxle. Before opening up the unit, the entire outside of the transaxle assembly should be cleaned, preferably with a high pressure washer such as a car wash spray unit. Dirt entering the transaxle internal parts will negate all the time and effort spent on the overhaul. During inspection and reassembly all parts should be thoroughly cleaned with solvent then dried with compressed air. Wiping cloths and rags should not be used to dry parts.
Wheel bearing grease, long used to hold thrust washers and lube parts, should not be used. Lube seals with clean transaxle oil and use ordinary unmedicated petroleum jelly to hold the thrust washers and to ease the assembly of seals, since it will not leave a harmful residue as grease often will. Do not use solvent on neoprene seals, if they are to be reused, or thrust washers.
Before installing bolts into aluminum parts, always dip the threads into clean transaxle oil. Antiseize compound can also be used to prevent bolts from galling the aluminum and seizing. Always use a torque wrench to keep from stripping the threads. The internal snaprings should be expanded and the external rings should be compressed, if they are to be reused. This will help ensure proper seating when installed.
See Figures 4, 5, 6 and 7
If the unit is a five-speed, remove the 5th gear housing. Then remove the roll pin from the 5th gear shift fork, the ball bearing, the shift fork and 5th synchro assembly together, 5th gear and the needle bearing from the mainshaft. The rest of the procedure is identical for both the GV and GW transaxles.
- Remove the detent ball retaining bolt, spring and ball.
- Remove the 11 bolts from the housing.
- Loosen the housing by tapping on its edge with a soft face hammer. To separate the transaxle housing from the clutch housing, remove the attachment from the bearing remover 07936-6340000, or equivalent and screw the threaded end into the hole in the transaxle housing. Expand the snapring while operating the bearing remover as a slide hammer.
- Pull out the reverse idler gear shaft and remove the gear.
- Remove the nut and the special spring washer on the reverse shift fork and remove the reverse shift fork.
- Remove the detent ball and spring from the reverse shift fork, if equipped.
- Bend the tabs on the three locking plates down and remove the bolts.
- Remove the reverse shift shaft and inspect for wear or damage.
- Remove the reverse shift guide.
- Remove the 1st/2nd gear shift shaft and inspect for wear or damage.
- Remove the 3rd/4th gear shift shaft and shift fork and inspect for wear or damage. Remove the 3rd gear shift shaft guide from the shaft by removing the roll pin.
- Shift the synchro into 2nd and remove the 1st/2nd gear shift fork.
- Remove the countershaft and mainshaft together as an assembly.
- Remove the special bolts and the flange bolts and remove the shift arm holder. Matchmark the bolts to their locations for accurate assembly later.
- Bend the tab on the locking plate down, remove the special bolt and remove the shift rod.
- Remove the differential assembly.
- Remove the snapring in the transaxle housing. Drive out the axle seals from both housings.
- Remove the bearing retainer plate.
- Insert the bearing remover, or equivalent with attachment 07936-6340101 or 07736-A01000A into the countershaft bearing. Operate the slide hammer to remove the bearing.
- Remove the oil barrier plate, wash thoroughly and reinstall. Unless the countershaft needle bearing is to be replaced, reinstall it using driver 07749-0100000 and attachment 07746-0010300 or 07947-6710100.
- Reinstall the bearing retainer plate, tighten the screw with an impact driver and stake the screw heads.
- Remove the mainshaft bearing seal from the clutch housing. Do not remove the mainshaft bearing unless it rotates roughly and is to be replaced.
- Remove the mainshaft and countershaft bearings from the transaxle housing by expanding each snapring and pushing the bearing out by hand. Do not remove the snaprings unless it is necessary to clean their grooves.
COMPONENT DISASSEMBLY AND ASSEMBLY
See Figure 8CHECKING CLEARANCES
Before disassembling the countershaft assembly, perform the following measurements. If any measurement is not within specifications, disassemble the countershaft assembly and replace spacer collars and/or thrust washers as required.
If all measurements are within specifications, there is no reason to disassemble the countershaft assembly, providing there is no damage to any of its components.
- Measure the clearance between the thrust washer and 1st gear. The specification is 0.001-0.007 in. (0.03-0.180mm).
- Measure the clearance between the 28mm spacer and 2nd gear. The specification is 0.002-0.007 in. (0.05-0.180mm).
- Measure the clearance between the 26mm thrust washer and 3rd gear. The specification is 0.002-0.007 in. (0.05-0.180mm).
- Measure the clearance between 4th gear and its spacer. The specification is 0.002-0.007 in. (0.05-0.180mm).
- If any of the measurements are not within specifications, calculate the thickness needed to bring the measurement back within the serviceable limit before disassembling the unit. 1st gear thrust washers are available in the following thicknesses:
Replacement spacers are available in the following lengths:
See Figure 9
- Temporarily reinstall the mainshaft and countershaft assemblies with 5th gear and spring washer, if equipped in the clutch housing. Install the transaxle housing and install the mainshaft holder 07923-6890101 or 07924-6340300.
- Remove the locknut using a 32mm socket at least 2 1/4 inches deep.
- Remove 5th gear and spring washer, if installed.
- Remove the transaxle housing and pull the gear assemblies out of the clutch housing.
- Remove the ball bearing, flanged spacer, needle bearing and 4th gear.
- Remove the first synchro ring, first spring, sleeve, hub, second spring, second ring and 3rd gear.
- Remove the needle bearing, 28mm spacer, 26mm thrust washer and 2nd gear.
- Remove the needle bearing, 28mm spacer, first synchro ring, first spring, sleeve, hub, second spring, second ring and 1st gear.
- Remove the needle bearing and 32mm thrust washer.
See Figures 10, 11 and 12
- Inspect the needle bearing for wear or damage.
- Check the clearance between each shift fork and its matching synchro sleeve. The specification is 0.018-0.039 in. (0.45-1.00mm). If the clearance exceeds the specification, measure the thickness of the shift fork fingers. The specification is 0.236-0.256 in. (6.00-6.50mm). If any shift forks are replaced, recheck the fork to sleeve clearance. If still out of specifications, replace the synchro sleeve.
- Inspect the gear teeth on all synchro hubs and sleeves for rounded corners, indicating wear.
- Install each hub in its mating sleeve and check for freedom of movement. If replacement is required, replace them as an assembly.
- Inspect the inside of the synchro ring and the synchro ring teeth and matching teeth on the gear for wear in the form of rounding.
- Inspect the gear hub thrust and cone surfaces for wear.
- Inspect the teeth on all gears for uneven wear, scoring, galling or cracks.
- Place the synchro ring on the matching gear cone and rotate it until it stops. The ring to gear clearance specification is 0.016-0.043 in. (0.40-1.10mm). Remove the ring from the gear.
- Measure the outside diameter of the bearing surface behind the countershaft gear. The specification is 1.179-1.182 in. (29.94-30.02mm).
- Measure the outside diameter of the gear surface in front of the countershaft gear. The specification is 1.257-1.260 in. (31.93-32.00mm).
- Inspect the countershaft for runout. The maximum allowable runout is 0.0019 in. (0.05mm). Replace the countershaft if any measurement is not within specification.
Clean all parts thoroughly with solvent and dry with compressed air. Lubricate all parts with oil before assembling.
Each synchro sleeve has three sets of longer teeth 120 degrees apart that must be matched with the three sets of deeper grooves in the hub when assembled.
- Install the 32mm thrust washer and needle bearing.
- Install 1st gear, the first synchro ring, first spring, hub, sleeve, second spring, second ring, 28mm spacer and needle bearing.
- Install 2nd gear, 26mm thrust washer, 28mm spacer and needle bearing.
- Install 3rd gear, the first synchro ring, first spring, hub, sleeve, second spring and second ring.
- Install 4th gear, the needle bearing, flanged spacer and ball bearing.
- Place the countershaft and mainshaft back into the clutch housing. Reinstall the transaxle housing and the mainshaft holder.
- Tighten the countershaft locknut to 65 ft. lbs. (90 Nm). Loosen and retighten to the same torque.
- Disassemble the transaxle and recheck the clearances. If they are right, stake the locknut in place. Do not continue until the clearance specifications are met.
CHECKING 5TH GEAR THRUST CLEARANCE
- Install the thrust washer, needle bearing, 5th gear, synchro ring, spring, hub and bearing onto the mainshaft.
- Place a suitable socket on the outer ace of the ball bearing and press down with approximately 65 lbs. (29kg) of force. Measure the clearance between 5th gear and its thrust washer. The specification is 0.0020-0.0160 in. (0.05-0.040mm).
- Replace the thrust washer if out of specification and recheck the clearance. If still not within serviceable limits, replace 5th gear and recheck.
- Remove all parts for inspection.
- Inspect the needle bearing for wear or damage.
- All checks performed for 1st through 4th gears parts are applicable to 5th gear parts as well; the specifications are identical. Also the synhcro inspection is identical.
- Inspect the oil passages in the mainshaft for clogging.
- Inspect all gear teeth and splines for uneven wear and damage.
- Measure the outer diameter of the 5th gear surface. The specification is 1.100-1.103 in. (27.940-28.010mm).
- Measure the outer diameter of the bearing surface on the opposite side of the mainshaft. The specification is 0.1863-0.866 in. (21.930-22.000mm).
- Measure the runout of the mainshaft. The maximum allowable runout is 0.0019 in. (0.05mm). Replace the mainshaft if any measurement is not within specification.
See Figure 13
- Using an impact driver, remove the retainer plate screws. Then remove the retainer plate.
- Pull out the shift arm shaft and the interlock shaft.
- Remove the detent ball and spring.
- Remove the shift arm, shift springs and spring retainers.
- Inspect the springs and retainers for deformation and rust.
- Inspect the shift arm and holder for wear.
- Inspect the shafts for wear.
- Install the shift arm, shift springs and retainers in the holder.
- Turn the holder upside down and place the detent ball and spring in the shift arm.
- Hold the detent ball in place, aligning the groove in the shift arm shaft with the detent ball. Then insert the shaft through the holder and shift arm.
- Insert the interlock shaft.
- Install the retainer plate. Tighten the retainer plate screws with an impact drive and stake the screws in place.
- Check that the gear shift arm moves freely and smoothly.
See Figures 14 through 20
- Clean all mating surfaces of the transaxle housing and clutch housing.
- Install the mainshaft bearing to the clutch housing if it was removed. Install a new seal.
- Install the mainshaft and countershaft bearings to the transaxle housing.
- Install the shift rod, selector arm, new lock plate and bolt. Bend the lock tab on the lock plate over against the bolt head.
- Install the snapring in the clutch housing and install the differential.
- Align the shift arm with the selector arm and install the shift arm holder. Install the bolts according to the matchmarks made during the disassembly procedure. Tighten the flanged bolts to 9 ft. lbs (12 Nm) and the other bolts to 11 ft. lbs. (15 Nm).
- Install the mainshaft and countershaft together as an assembly.
- Lift the countershaft 1st and 2nd synchro sleeves to shift into 2nd gear.
- Install the 1st/2nd shift fork on the synchro sleeve, then rotate it into place so that the lugs on the back of the fork fit over the shift arm.
- Insert the 3rd/4th shift fork shaft onto the 3rd/4th shift guide and install the roll pin.
- Insert the 3rd/4th shift fork shaft into the 3rd/4th shift fork, then install the shift fork and hook the shift guide to the shift arm.
- Install the 1st/2nd shift shaft.
- Hook the reverse (GV series) or 5th/reverse (GW series) shift guide to the shift arm, then install the shift shaft.
- Install the spring and detent ball into the hole in the clutch housing.
- Install the reverse shift fork with special washer and nut. Make sure that the reverse shift fork is aligned with the detent ball.
- Install the reverse idler gear and shaft.
- Install the three special bolts and lock plates on the shift shafts and bend the tab on each lock plate against the bolt head.
- Apply sealant, (part number 08740-99986 or equivalent) to the mating surface of the clutch housing.
- Install the transaxle housing being careful to line up shafts. Expand the countershaft bearing snapring so that the transaxle housing can drop into place.
- Tighten the bolts to 20 ft. lbs (27 Nm) in the correct sequence.
- Install the detent balls, new washers, springs and retaining bolts. Tighten the bolts to 16 ft. lbs. (22 Nm).
- On four-speed transaxles, install the bearing on the mainshaft.
- On five-speed transaxles, install the thrust washer and needle bearing on the mainshaft. Install the synchro ring and spring. Assemble the synchro hub (raised inner shoulder facing down) and sleeve with the shift fork and install onto the mainshaft. Then install the bearing and install the roll pin into the shift fork.
- Clean the mating surfaces of the case and the end cover or 5th gear housing. Apply sealant, (part number 08740-99986 or equivalent) to the end cover or 5th gear housing and install. Tighten the bolts to 9 ft. lbs. (12 Nm).
- Install the snapring in the axle opening in the transaxle housing aligning the lug on the snapring with the slot in the housing.
- Measure the clearance between the snapring and the bearing outer race. The specification is 0-0.059 in. (0-0.15mm). If the clearance is not within specifications, replace the snapring. They are available in 0.004 in. (0.10mm) increment sizes from 0.096-0.116 in. (2.45-2.95mm).
- Lubricate and install new axle seals using driver 07749-0010000 and attachment 07947-6110500.