Toyota Celica 1986-1993 Repair Guide

Transaxle

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REMOVAL & INSTALLATION




CAUTION
On models with an air bag, wait at least 30 seconds from the time that the ignition switch is turned to the lock position and the battery is disconnected before performing any further work. Do NOT attempt to disassemble the bumper shocks, since they may be under high pressure.


WARNING
The following procedures cover removal and installation of the transaxle without removing the engine. If the transaxle and engine are to removed as an assembly, refer to ""Engine, Removal and Installation" as described in .

2WD Models
  1. Disconnect the negative battery cable. Remove the air cleaner assembly and battery, if necessary for clearance.
  2.  
  3. Remove the clutch tube bracket, if equipped. Disconnect the back-up light switch at the transaxle. Disconnect the speedometer and the engine ground strap.
  4.  
  5. Disconnect the transaxle control cable and position them out of the way.
  6.  
  7. Unbolt the clutch release cylinder. It may be possible to position it out of the way with the hydraulic line still attached.
  8.  
  9. Remove the upper transaxle retaining bolts. Raise and support the vehicle safely. Remove the engine undercover. Drain the transaxle lubricant.
  10.  
  11. Disconnect the exhaust pipe from the manifold. Remove the lower suspension crossmember. Remove the starter (disconnect electrical connections) assembly.
  12.  
  13. Properly support the engine and transaxle assembly. Remove the front and rear transaxle mounts. Remove the center engine mount.
  14.  
  15. Disconnect both halfshafts at the transaxle. Unbolt the steering knuckle from the suspension arm and pull it outward. Remove the left halfshaft.
  16.  
  17. On some vehicles, remove the No. 2 rear engine plate. With the engine properly supported remove the left engine mount.
  18.  
  19. Remove the engine-to-transaxle bolts, lower the left side of the engine and carefully ease the transaxle out of the engine compartment.
  20.  

To install:

  1. Align the input shaft spline with the clutch disc and carefully mate the transaxle to the engine. Tighten the mounting bolts to specifications.
  2.  
  3. Install the left side engine mount and tighten the mounting bolts to specifications.
  4.  
  5. Install the starter.
  6.  
  7. Position the left halfshaft in the steering knuckle, align it with the side gear shaft and tighten the knuckle-to-lower arm bolts to specifications. Torque the left steering knuckle to lower arm to specifications (See ).
  8.  
  9. Connect both halfshafts to the transaxle.
  10.  
  11. Install the center engine mount and tighten the bolts to 29 ft. lbs. (39 Nm). Install the front and rear mounts and tighten them to the same torque. Install the cover on the crossmember.
  12.  
  13. Install the lower suspension crossmember and tighten the bolts to specifications.
  14.  
  15. Connect the exhaust pipe to the manifold and tighten the bolts to 46 ft. lbs. (62 Nm).
  16.  



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Fig. Fig. 1 Removing transaxle1990 S53 and C52 shown



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Fig. Fig. 2 Removing transaxleE50F2 shown

  1. Installation of the remaining components is in the reverse order of removal. Fill the transaxle with the proper type lubricant (See ), then road test the vehicle.
  2.  



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Fig. Fig. 3 Removing transaxleE150F shown



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Fig. Fig. 4 Separating transaxle from engine4wd Celica



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Fig. Fig. 5 Make sure the select lever is kept in the Viscous Mode4wd Celica

4WD Models

WARNING
The Celica 4wd is equipped with the viscous coupling type of center differential lock. Do NOT remove mode select lever bolt. Do NOT move vehicle if this set bolt is removed and lever is in any other mode but viscous (normal) mode.

  1. Remove the engine/transaxle assembly from the vehicle.
  2.  
  3. Install the engine/transaxle assembly into a suitable holding fixture or equivalent.
  4.  
  5. Remove the transaxle assembly from engine. Using the following service procedure since cylinder block rib contacts transfer case.
    1. Pull the transaxle assembly out about 3 in. (76mm) from the engine.
    2.  
    3. Rotate the transaxle assembly in a clockwise manner while pulling out.
    4.  

  6.  
  7. Installation is in the reverse order of removal. Tighten the 12mm engine-to-transaxle bolts to 47 ft. lbs. and the 10mm bolts to 34 ft. lbs. Tighten the left engine mount bolts to 38 ft. lbs. Tighten the center member bolts and the front and rear engine mount bolts to 29 ft. lbs.
  8.  
  9. Fill the transaxle with SAE 75W-90 or API GL5 to the correct level and then road test the vehicle.
  10.  

OVERHAUL



S53 Transaxle
DISASSEMBLE
  1. Remove the release fork, bearing, back-up light switch and speedometer driven gear.
  2.  
  3. Remove the front bearing retainer.
  4.  



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Fig. Fig. 6 S53 manual transaxle componentsCelica



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Fig. Fig. 7 S53 manual transaxle componentsCelica



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Fig. Fig. 8 S53 manual transaxle componentsCelica



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Fig. Fig. 9 Measuring 5th gear thrust clearanceS53 transaxle

  1. Remove the transmission case cover.
  2.  
  3. Remove No. 3 shift fork lockbolt.
  4.  



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Fig. Fig. 1 0Measuring 3rd and 4th gear thrust clearanceS53 transaxle



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Fig. Fig. 1 1Measuring 1st and 2nd gear thrust clearanceS53 transaxle



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Fig. Fig. 1 2Input shaft journal sectionsS53 transaxle



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Fig. Fig. 1 3Checking input shaft runout with a dial indicatorS53 transaxle



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Fig. Fig. 1 4Checking oil clearance of each gearS53 Transaxle

  1. Using a dial indicator, measure the 5th gear thrust clearance. Standard clearance is 0.20-0.40mm with a maximum clearance of 0.45mm.
  2.  
  3. Loosen the locknut and remove the lock ball.
  4.  
  5. Remove the selecting bellcrank.
  6.  



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Fig. Fig. 1 5Measuring clearance of shift forks and hub sleevesS53 transaxle shown



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Fig. Fig. 1 6Measuring clearance between the synchronizer ring back and the gear spline endS53 transaxle shown

  1. Remove the shift and select lever assembly.
  2.  
  3. Unstake the output shaft locknut using a small cold chisel.
  4.  
  5. Engage the gear double meshing.
  6.  
  7. Remove the locknut.
  8.  


WARNING
The locknut has left-hand threads.

  1. Disengage the gear double meshing.
  2.  
  3. Using 2 prybars and a hammer, tap out the No. 3 hub sleeve snapring.
  4.  
  5. Remove the No. 3 shift fork shifting key retainer.
  6.  
  7. Using 3 case cover set bolts, tighten the 3 bolts a little at a time and remove hub sleeve No. 3 and shift fork.
  8.  
  9. Remove 5th gear, synchronizer ring, needle roller bearing and spacer.
  10.  
  11. Remove 5th driven gear using SST No. 09950-20016 or equivalent puller.
  12.  
  13. Remove rear bearing retainer.
  14.  
  15. Remove 2 bearing snaprings by using snapring pliers.
  16.  
  17. Remove reverse idler gear shaft lock bolt.
  18.  
  19. Remove differential side bearing retainer and shim.
  20.  
  21. To remove transmission case, remove the bolts and tap off the case with a plastic hammer.
  22.  
  23. Shift the reverse fork shaft into R.
  24.  
  25. Remove the two bolts and pull off the reverse shift arm.
  26.  
  27. Remove reverse idler gear and shaft by pulling out the shaft.
  28.  
  29. Remove shift fork shaft No. 1, shift head No. 1, shift forks No. 1 and No. 2.
  30.  
  31. Drive out the slotted spring pin from fork shaft No. 1.
  32.  
  33. Drive out the slotted spring pin from shift head and fork shaft No. 1.
  34.  
  35. Pull out fork shaft No. 1 with the shift head and shift forks.
  36.  
  37. Remove reverse shift fork and interlock pin.
  38.  
  39. Remove the No. 2 fork shaft straight screw plug.
  40.  
  41. Using a pin punch and hammer, drive out the No. 2 fork shaft slotted spring pin.
  42.  
  43. Pull out the No. 2 fork shaft.
  44.  
  45. Remove input and output shaft together from transaxle case.
  46.  
  47. Remove differential assembly.
  48.  
  49. Remove the magnet from the transaxle.
  50.  
  51. Using a feeler gauge, measure the 3rd and 4th gear thrust clearance.
  52.  

Standard clearance:



3rd gear-0.10-0.25mm
 
4th gear-0.20-0.45mm Maximum clearance:
 
3rd gear-0.30mm
 
4th gear-0.50mm
 

  1. Remove snapring from input shaft.
  2.  
  3. Using a press, remove the radial ball bearing and 4th gear.
  4.  
  5. Remove the needle roller bearings, synchronizer ring and spacer.
  6.  
  7. Remove the snapring with snapring pliers.
  8.  
  9. Remove hub sleeve No. 2 assembly, 3rd gear, synchronizer ring and needle roller bearing.
  10.  
  11. Measure 1st/2nd gear thrust clearance by using a feeler gauge.
  12.  

Standard Clearance



1st gear-0.10-0.29mm
 
2nd gear-0.20-0.44mm Maximum clearance:
 
1st gear-0.35mm
 
2nd gear-0.50mm
 

  1. Using a press, remove the radial ball bearing, 4th driven gear and spacer.
  2.  
  3. Shift hub sleeve No. 1 into 1st gear.
  4.  
  5. Using a press, remove the 3rd driven gear and 2nd gear.
  6.  
  7. Remove the needle roller bearing, spacer and synchronizer ring.
  8.  
  9. Remove the snapring.
  10.  
  11. Using a press, remove the No. 1 hub sleeve, 1st gear and synchronizer ring.
  12.  
  13. Remove the needle roller bearing and spacer.
  14.  
  15. Remove the shift lever lock pin and nut.
  16.  
  17. Remove the control shift lever.
  18.  
  19. Remove the control shaft cover dust boot.
  20.  
  21. Remove the control shaft cover.
  22.  
  23. Remove the two E-rings from the reverse restrict pin holder.
  24.  
  25. Remove the reverse restrict pin holder, spring and No. 2 shift lever.
  26.  
  27. Remove the shift inner lever No. 2.
  28.  
  29. Using a pin punch and hammer, drive out the slotted spring pin.
  30.  
  31. Remove the shift fork lock plate, shift inner lever No. 1 select spring seat No. 1 and spring.
  32.  

INPUT SHAFT INSPECTION
  1. Using a micrometer, measure the input shaft journal outside diameter sections shown in the accompanying figure.
  2.  

Minimum outer diameters:



Section A-26.97mm
 
Section B-32.42mm
 
Section C-33.09mm
 
Section D-29.97mm
 

  1. Mount the input shaft on V-blocks and measure the runout. Maximum allowable runout is 0.050mm.
  2.  

OUTPUT SHAFT INSPECTION
  1. Using a micrometer, measure the output shaft journal outside diameter sections shown in the accompanying figure.
  2.  

Minimum outside diameters:



Section A-31.97mm
 
Section B-37.97mm
 
Section C-31.97mm
 

  1. Mount the output shaft on V-blocks and measure the runout. Maximum allowable runout is 0.050mm.
  2.  

CHECKING GEAR OIL CLEARANCE

Using a dial indicator, measure the oil clearance between the gear and the input or output shaft with the needle roller bearing installed. Standard clearance:



1st, 2nd, 3rd, 4th gears0.009-0.053mm
 
5th gear0.009-0.050mm Maximum clearance:
 
All gears0.07mm
 

If the clearance exceeds the maximum limit, replace the gear, bearing or shaft.

SYNCHRONIZER RING INSPECTION
  1. Turn the ring and push it in to check the braking action.
  2.  
  3. With a feeler gauge, measure the clearance between the back of the ring and gear spline end. Minimum clearance is 0.6mm.
  4.  
  5. If the clearance is less than the limit, replace the ring.
  6.  

CHECKING SHIFT FORK AND HUB SLEEVE CLEARANCE
  1. With a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance is 1.00mm.
  2.  
  3. If the clearance exceeds the limit, replace the shift fork or hub sleeve.
  4.  

INSPECTING SEALS AND BEARINGS

Inspect all transaxle seals, bearings and races for wear and damage. Replace all damaged or worn seals, bearings and races as required.

REPLACING INPUT SHAFT FRONT BEARING
  1. Unbolt and remove the transaxle case oil receiver.
  2.  
  3. Using SST No. 09308-00010 or equivalent, pull out the old bearing.
  4.  
  5. Using SST No. 09310-35010 or equivalent, press in the new bearing.
  6.  
  7. Install the oil receiver and torque the bolt to 65 inch lbs.
  8.  

REPLACING OUTPUT SHAFT FRONT BEARING
  1. Remove the bolt and bearing locking plate.
  2.  
  3. Using SST No. 09308-00010 or equivalent, pull out the old bearing.
  4.  
  5. Using SST No. 09310-35010 or equivalent, press in the new bearing.
  6.  
  7. Install the lock plate and torque the bolt to 13 ft. lbs.
  8.  

REPLACING INPUT SHAFT FRONT SEAL
  1. Pry out the old oil seal.
  2.  
  3. Using SST No. 09608-20012, drive in the new seal to a depth of 1.00-2.00mm.
  4.  
  5. Once installed, coat the lip of the new seal with multi-purpose grease.
  6.  

REPLACING LEFT HAND SIDE OIL SEAL
  1. Using SST No. 09608-20012 or equivalent, press the old seal from the retainer.
  2.  
  3. Using SST No. 09316-60010 or equivalent, press in the new seal until its surface is flush with the surface of the transaxle case.
  4.  
  5. Coat the lip of the new seal with multi-purpose grease.
  6.  

REPLACING RIGHT HAND SIDE OIL SEAL
  1. Drive the old seal from the retainer with a screwdriver or punch.
  2.  
  3. Using SST No. 09316-60010 or equivalent, press in the new seal until its surface is flush with the surface of the transaxle case.
  4.  
  5. Coat the lip of the new seal with multi-purpose grease.
  6.  

REPLACING LEFT HAND OUTER SIDE BEARING RACE
  1. Using SST No. 09608-20012 or equivalent, press out the outer race.
  2.  
  3. Install the bearing retainer without the O-ring.
  4.  
  5. Install and torque the retainer bolts to 13 ft. lbs.
  6.  
  7. Select the thinnest shim from the chart located in the ""Transaxle Assembly" section below and install it into the case.
  8.  
  9. Using the removal tool, press in a new outer race.
  10.  

REPLACING RIGHT HAND OUTER SIDE BEARING RACE
  1. Using SST No. 09608-20012 or equivalent, press out the outer race with shim.
  2.  
  3. Place the shim into the case.
  4.  
  5. Using the removal tool, press in a new outer race.
  6.  

REPLACING CONTROL SHAFT COVER OIL SEAL
  1. Pry out the old seal.
  2.  
  3. Using SST No. 09608-20012 or equivalent, drive in the new seal until its surface is flush with the surface of the cover.
  4.  
  5. Coat the lip of the seal with multi-purpose grease.
  6.  

REPLACING SPEEDOMETER DRIVEN GEAR OIL SEAL
  1. Using SST No. 09921-00010 or equivalent, pull out the old seal.
  2.  
  3. Using SST No. 09201-60011 or equivalent, drive in the new seal to a depth of 19mm.
  4.  

REPLACING REVERSE RESTRICT PIN
  1. Remove the screw plug.
  2.  
  3. Using a pin punch and hammer, drive out the slotted spring pin.
  4.  
  5. Remove the old reverse restrict pin and replace it with a new one.
  6.  
  7. Using a pin punch and hammer, drive the slotted spring pin back in.
  8.  
  9. Apply Loctite® or similar liquid sealant to the threads of the screw plug.
  10.  
  11. Install the screw plug and torque to 9 ft. lbs.
  12.  

TRANSAXLE REASSEMBLY
  1. Install the No. 2 clutch hub and shifting keys to the hub sleeve.
  2.  
  3. Install the shifting key springs under the shifting keys.
  4.  


WARNING
Install the key springs positioned so that their end gaps are not in line.

  1. Coat the 3rd gear needle roller bearings with ATF.
  2.  
  3. Place the synchronizer ring on the 3rd gear and align the ring slots with the shifting keys.
  4.  
  5. Using a press, install the 3rd gear and No. 2 hub sleeve.
  6.  
  7. Select a snapring that will allow minimum axial play and install it on the shaft.
  8.  
  9. Using a feeler gauge, measure the 3rd gear thrust clearance:

    Standard clearance: 0.10-0.25mm
     
    Maximum clearance: 0.30mm
     

  10.  
  11. Install the synchronizer ring spacer.
  12.  
  13. Coat the needle roller bearing with ATF.
  14.  
  15. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
  16.  
  17. Press in the radial ball bearing.
  18.  
  19. Select a snapring that will allow minimum axial play and install it on the shaft.
  20.  
  21. Measure 4th gear thrust clearance by using a feeler gauge and measure the 4th gear thrust clearance:

    Standard clearance: 0.20-0.45mm
     
    Maximum clearance: 0.50mm
     

  22.  
  23. Install the No. 1 clutch hub and shifting keys to the No. 1 hub sleeve.
  24.  
  25. Install the shifting key springs under the shifting keys.
  26.  


WARNING
Install the key springs positioned so that their end gaps are not in line.

  1. Coat the 1st gear needle roller bearing with ATF.
  2.  
  3. Place the 1st gear synchronizer ring on the gear and align the ring slots with the shifting keys.
  4.  
  5. Using a press, install the 1st gear and hub sleeve No. 1.
  6.  
  7. Select a snapring that will allow minimum axial play and install it on the shaft.
  8.  
  9. Measure 1st gear thrust clearance by using a feeler gauge and measure the 1st gear thrust clearance:

    Standard clearance: 0.10-0.30mm
     
    Maximum clearance: 0.35mm
     

  10.  
  11. Install the 2nd gear spacer.
  12.  
  13. Place the synchronizer ring on the 2nd gear and align the ring slots with the shifting keys.
  14.  
  15. Coat the 2nd gear needle roller bearing with ATF.
  16.  
  17. Install the 2nd gear.
  18.  
  19. Using a press, install the 3rd driven gear.
  20.  
  21. Using a feeler gauge, measure the 2nd gear thrust clearance:

    Standard clearance: 0.20-0.44mm
     
    Maximum clearance: 0.50mm
     

  22.  
  23. Install the output gear spacer.
  24.  
  25. Press in the 4th driven gear and bearing.
  26.  
  27. Install the transaxle magnet.
  28.  
  29. Adjust differential side bearing preload by performing the following:
    1. Install the differential to the transaxle case.
    2.  
    3. Install the transmission case with the used gasket.
    4.  
    5. Install and torque the case bolts. Torque the bolts to 22 ft. lbs.
    6.  
    7. Install the thinnest shim into the transmission case.
    8.  
    9. Install the bearing retainer without an O-ring.
    10.  
    11. Install the retainer bolts. Torque the bolts to 13 ft. lbs.
    12.  
    13. Measure the preload. Preload (starting): 8.7-13.9 inch lbs.
    14.  
    15. If the preload is not within specification, remove the bearing retainer.
    16.  
    17. Reselect an adjusting shim.
    18.  

  30.  


WARNING
The preload will change about 2.6-3.5 inch lbs. with each shim thickness.

  1. If the preload is adjusted within specification, remove the bearing retainer, shim and transmission case with gasket. Be careful not to lose the adjusted shim.
  2.  
  3. Install the input and output shaft together.
  4.  
  5. Insert the No. 2 fork shaft into the transaxle case and align the slotted spring pin.
  6.  
  7. Using a pin punch and hammer drive in the slotted spring pin.
  8.  
  9. Install the straight screw plug and torque it to 9 ft. lbs.
  10.  
  11. Insert the interlock pin to the reverse shift fork hole.
  12.  
  13. Install the reverse shift fork onto fork shaft No. 2.
  14.  
  15. Put the reverse shift arm pivot into the reverse shift fork and install the reverse shift arm to the transaxle case.
  16.  
  17. Shift the reverse shift arm into R.
  18.  
  19. Install and torque the retaining bolts to 13 ft. lbs.
  20.  
  21. Install reverse idler gear and shaft by aligning the transaxle case slot and slotted spring pin.
  22.  
  23. Place shift forks No. 1 and No. 2 into the groove of hub sleeve No. 1 and No. 2.
  24.  
  25. Hold shift head No. 1 and insert fork shaft No. 1 into the transaxle case through shift fork No. 1, No. 2, shift head No. 1 and reverse shift fork.
  26.  
  27. Using a pin punch and hammer, drive the slotted spring pin into shift head No. 1 and fork shaft No. 1.
  28.  
  29. Shift the fork shaft into R.
  30.  
  31. Using a pin punch and hammer, drive the slotted spring pin into fork shaft No. 1.
  32.  
  33. Install the transmission case retaining bolts and torque them 22 ft. lbs.
  34.  
  35. Install the O-ring on the side bearing retainer.
  36.  
  37. Install the shim and side bearing retainer.
  38.  
  39. Install and torque the bearing retainer bolts to 13 ft. lbs.
  40.  
  41. Install and torque reverse idler gear shaft lock bolt to 18 ft. lbs.
  42.  
  43. Install the two bearing snaprings.
  44.  
  45. Install rear bearing retainer and torque the five bolts to 13 ft. lbs. Apply Loctite® or similar thread sealant to the bolt threads before installing them.
  46.  
  47. Using SST No. 09309, install the 5th driven gear.
  48.  
  49. Install the 5th gear spacer.
  50.  
  51. Coat the 5th gear needle roller bearings with ATF.
  52.  
  53. Install the 5th gear with the needle roller bearings and synchronizer ring.
  54.  
  55. Install the No. 3 clutch hub and shifting keys to the No. 3 hub sleeve.
  56.  
  57. Install the shifting key springs under the shifting keys.
  58.  


WARNING
Install the key springs positioned so that their end gaps are not in line.

  1. Support the tip of the input shaft with a spacer to raise the transaxle.
  2.  
  3. Drive in hub sleeve No. 3 with shift fork No. 3.
  4.  


WARNING
Align the synchronizer ring slots with the shifting keys.

  1. Using a dial indicator, measure 5th gear thrust clearance.

    Standard clearance: 0.20-0.40mm
     
    Maximum clearance: 0.45mm
     

  2.  
  3. Install the shifting key retainer.
  4.  
  5. Select a snapring that will allow minimum axial play and install it on the shaft.
  6.  
  7. Engage the gear double meshing and install the locknut. Torque the nut to 90 ft. lbs.
  8.  


WARNING
The locknut has left hand threads.

  1. Disengage the gear double meshing and stake the locknut with a small cold chisel.
  2.  
  3. Coat the shift lever shaft with ATF.
  4.  
  5. Install select spring seat No. 1, spring and E-ring.
  6.  
  7. Install shift inner lever No. 1 with the shift fork lock plate.
  8.  
  9. Align shift inner lever No. 2 with No. 1 and install it.
  10.  
  11. Install select spring seat No. 2 spring and E-ring.
  12.  
  13. Using a pin punch and hammer, drive in the slotted spring pin.
  14.  
  15. Install the control shaft cover and dust boot making sure that the air bleed is facing downward.
  16.  
  17. Install the control shift lever and insert the lever lock pin to the lever. Install the washer and locknut.
  18.  
  19. Apply liquid sealer to the control shaft cover.
  20.  
  21. Install the shift and select lever and torque the control shaft cover to 27 ft. lbs.
  22.  
  23. Apply Loctite® sealant to the lock ball assembly threads. Install and torque the lock ball assembly to 17 ft. lbs.
  24.  
  25. Fully loosen the No. 1 locknut.
  26.  
  27. Screw in the lock ball fully.
  28.  
  29. Turn the lock ball to where the play at the shift outer lever tip is 0.10-0.50mm.
  30.  
  31. Hold the lock ball and torque the locknut to 27 ft. lbs.
  32.  
  33. Check the shift outer level tip play. Acceptable tip play range is 0.10-0.50mm.
  34.  
  35. Install the selecting bellcrank.
  36.  
  37. Install the No. 3 shift fork locking bolt and torque it to 13 ft. lbs.
  38.  
  39. Install the transmission case cover with the eight retaining bolts. Torque the bolts to 13 ft. lbs.
  40.  
  41. Install front bearing retainer and torque to 65 inch lbs.
  42.  
  43. Apply molybdenum disulfide lithium base grease to the following parts: release bearing hub inside groove, input shaft spline and release fork contact surface.
  44.  
  45. Install back-up light switch and torque to 33 ft. lbs.
  46.  
  47. Install speedometer driven gear.
  48.  

C52 Transaxle
DISASSEMBLY
  1. Remove the release fork.
  2.  



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Fig. Fig. 1 7C52 manual transaxle componentsCelica



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Fig. Fig. 1 8C52 manual transaxle componentsCelica



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Fig. Fig. 1 9C52 manual transaxle componentsCelica



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Fig. Fig. 2 0Measuring gear thrust clearanceC52 transaxle

  1. Remove the back-up light switch and speedometer driven gear.
  2.  
  3. Remove the front bearing retainer.
  4.  



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Fig. Fig. 2 1Input shaft journal sectionsC52 transaxle



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Fig. Fig. 2 2Output shaft journal sectionsC52 transaxle



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Fig. Fig. 2 3Aligning the synchronizer ring slots with the shifter keysC52 transaxle shown



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Fig. Fig. 2 4Aligning the reverse idler gear and case matchmarksC52 transaxle

  1. Remove the transmission case cover.
  2.  
  3. Using a dial indicator, measure the 5th gear thrust clearance. Standard clearance is 0.10-0.57mm with a maximum clearance of 0.65mm.
  4.  
  5. Remove the lockbolt.
  6.  
  7. Remove the selecting bellcrank.
  8.  
  9. Remove the shift and select lever assembly.
  10.  
  11. Engage the gear double meshing.
  12.  
  13. Remove the locknut.
  14.  
  15. Disengage the gear double meshing.
  16.  
  17. Using 2 prybars and a hammer, tap out the No. 3 hub sleeve snapring.
  18.  
  19. Remove the No. 3 shift fork bolt.
  20.  
  21. Remove the No. 3 hub sleeve No. 3 and shift fork.
  22.  
  23. Remove 5th gear and No. 3 hub.
  24.  
  25. Remove the synchronizer ring, needle roller bearing and spacer.
  26.  
  27. Remove 5th driven gear using SST No. 09950-20017 or equivalent puller.
  28.  
  29. Remove rear bearing retainer.
  30.  
  31. Remove 2 bearing snaprings by using snapring pliers.
  32.  
  33. Remove reverse idler gear shaft lock bolt.
  34.  
  35. Remove the snapring from the No. 2 shift fork shaft. Remove the plugs, seats, springs, balls and lock ball assembly.
  36.  
  37. To remove transmission case, remove the bolts and tap off the case with a plastic hammer.
  38.  
  39. Remove the reverse shift arm bracket.
  40.  
  41. Remove reverse idler gear, thrust washer and shaft.
  42.  
  43. Remove the shift forks and shift fork shafts.
  44.  
  45. Remove input and output shaft together from transaxle case.
  46.  
  47. Remove differential assembly.
  48.  
  49. Remove the magnet and oil receiver from the transaxle.
  50.  
  51. Using a feeler gauge, measure the 3rd and 4th gear thrust and oil clearance.
  52.  

Standard clearance:



3rd gear0.10-0.35mm
 
4th gear0.10-0.55mm Maximum clearance:
 
3rd gear0.0157 in. (0.40mm)
 
4th gear0.0236 in. (0.60mm)
 

  1. Remove snapring from input shaft.
  2.  
  3. Using a press, remove the radial ball bearing and 4th gear.
  4.  
  5. Remove the needle roller bearings, synchronizer ring and spacer.
  6.  
  7. Remove the snapring with snapring pliers.
  8.  
  9. Remove hub sleeve No. 2 assembly, 3rd gear, synchronizer ring and needle roller bearing.
  10.  
  11. Measure 1st/2nd gear thrust clearance by using a feeler gauge.
  12.  

Standard Clearance:



1st gear0.10-0.40mm
 
2nd gear0.10-0.45mm Maximum clearance:
 
1st gear0.40mm
 
2nd gear0.45mm
 

  1. Using a press, remove the radial ball bearing, 4th driven gear and spacer.
  2.  
  3. Shift hub sleeve No. 1 into 1st gear.
  4.  
  5. Using a press, remove the 3rd driven gear and 2nd gear.
  6.  
  7. Remove the needle roller bearing, spacer and synchronizer ring.
  8.  
  9. Remove the snapring.
  10.  
  11. Using a press, remove the No. 1 hub sleeve, 1st gear and synchronizer ring.
  12.  
  13. Remove the needle roller bearing and spacer.
  14.  
  15. Disassemble the shift and select lever shaft assembly.
  16.  

INPUT SHAFT INSPECTION
  1. Using a micrometer, measure the input shaft journal outside diameter sections shown in the accompanying figure.
  2.  

Minimum outer diameters:



Section A0.9791 in. (24.87mm)
 
Section B1.0421 in. (26.47mm)
 
Section C1.2193 in. (30.97mm)
 
Section D0.9831 in. (24.97mm)
 

  1. Mount the input shaft on V-blocks and measure the runout. Maximum allowable runout is 0.0020 in. (0.050mm).
  2.  

OUTPUT SHAFT INSPECTION
  1. Using a micrometer, measure the output shaft journal outside diameter sections shown in the accompanying figure.
  2.  

Minimum outside diameters:



Section A1.2980 in. (32.97mm)
 
Section B1.4949 in. (37.97mm)
 
Section C1.2587 in. (31.97mm)
 

  1. Mount the output shaft on V-blocks and measure the runout. Maximum allowable runout is 0.0020 in. (0.050mm).
  2.  

SYNCHRONIZER RING INSPECTION
  1. Turn the ring and push it in to check the braking action.
  2.  
  3. With a feeler gauge, measure the clearance between the back of the ring and gear spline end. Minimum clearance is 0.024 in. (0.6mm).
  4.  
  5. If the clearance is less than the limit, replace the ring.
  6.  

CHECKING SHIFT FORK AND HUB SLEEVE CLEARANCE
  1. With a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance is 0.039 in. (1.00mm).
  2.  
  3. If the clearance exceeds the limit, replace the shift fork or hub sleeve.
  4.  

INSPECTING SEALS AND BEARINGS

Inspect all transaxle seals, bearings and races for wear and damage. Replace all damaged or worn seals, bearings and races as required.

REPLACING INPUT SHAFT FRONT BEARING
  1. Unbolt and remove the transaxle case oil receiver.
  2.  
  3. Using SST No. 09308-00010 or equivalent, pull out the old bearing.
  4.  
  5. Using SST No. 09310-35010 or equivalent, press in the new bearing.
  6.  

REPLACING OUTPUT SHAFT FRONT BEARING
  1. Remove the bolt and bearing locking plate.
  2.  
  3. Using SST No. 09308-00010 or equivalent, pull out the old bearing.
  4.  
  5. Using SST No. 09310-35010 or equivalent, press in the new bearing.
  6.  
  7. Install the lock plate and torque the bolt to 8 ft. lbs. (11 Nm).
  8.  

REPLACING INPUT SHAFT FRONT SEAL
  1. Pry out the old oil seal.
  2.  
  3. Using SST No. 09608-12010, drive in the new seal.
  4.  
  5. Once installed, coat the lip of the new seal with multi-purpose grease.
  6.  

REPLACING LEFT OR RIGHT SIDE OIL SEAL
  1. Drive out the old seal.
  2.  
  3. Using SST No. 09350-32014 or equivalent, press in the new seal until its surface is flush with the surface of the transaxle case.
  4.  
  5. Coat the lip of the new seal with multi-purpose grease.
  6.  

REPLACING LEFT OR RIGHT OUTER SIDE BEARING RACE
  1. Using SST No. 09612-65014 or equivalent, pull out the outer race.
  2.  
  3. Place the shim into the case.
  4.  
  5. Using SST No. 09608-20012 or equivalent, drive in a new outer race.
  6.  

REPLACING CONTROL SHAFT COVER OIL SEAL
  1. Pry out the old seal.
  2.  
  3. Using SST No. 09608-20012 or equivalent, drive in the new seal until its surface is flush with the surface of the cover.
  4.  
  5. Coat the lip of the seal with multi-purpose grease.
  6.  

REPLACING SPEEDOMETER DRIVEN GEAR OIL SEAL
  1. Using SST No. 09921-00010 or equivalent, pull out the old seal.
  2.  
  3. Using SST No. 09201-60011 or equivalent, drive in the new seal to a depth of 0.98 in. (25mm). Coat the lip of the oil seal with grease.
  4.  

REPLACING REVERSE RESTRICT PIN
  1. Using SST 09313-30021 or equivalent, remove the reverse restrict holder.
  2.  
  3. Using a pin punch and hammer, drive out the slotted spring pin.
  4.  
  5. Remove the old reverse restrict pin and replace it with a new one.
  6.  
  7. Using a pin punch and hammer, drive the slotted spring pin back in.
  8.  
  9. Using SST 09313-30021 or equivalent, install the reverse restrict holder and torque to 14 ft. lbs. (20 Nm).
  10.  

TRANSAXLE REASSEMBLY
  1. Install the No. 2 clutch hub and shifting keys to the hub sleeve.
  2.  
  3. Install the shifting key springs under the shifting keys.
  4.  


WARNING
Install the key springs positioned so that their end gaps are not in line.

  1. Coat the 3rd gear needle roller bearings with gear oil.
  2.  
  3. Place the synchronizer ring on the 3rd gear and align the ring slots with the shifting keys.
  4.  
  5. Using a press, install the 3rd gear and No. 2 hub sleeve.
  6.  
  7. Select a snapring that will allow minimum axial play and install it on the shaft.
  8.  
  9. Using a feeler gauge, measure the 3rd gear thrust clearance. Standard clearance: 0.0039-0.0138 in. (0.10-0.25mm).
  10.  
  11. Install the synchronizer ring spacer.
  12.  
  13. Coat the needle roller bearing with ATF.
  14.  
  15. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
  16.  
  17. Press in the radial ball bearing.
  18.  
  19. Select a snapring that will allow minimum axial play and install it on the shaft.
  20.  
  21. Measure 4th gear thrust clearance by using a feeler gauge and measure the 4th gear thrust clearance. Standard clearance: 0.0039-0.0217 in. (0.10-0.55mm).
  22.  
  23. Install the No. 1 clutch hub and shifting keys to the No. 1 hub sleeve.
  24.  
  25. Install the shifting key springs under the shifting keys.
  26.  


WARNING
Install the key springs positioned so that their end gaps are not in line.

  1. Coat the 1st gear needle roller bearing with gear oil.
  2.  
  3. Place the 1st gear synchronizer ring on the gear and align the ring slots with the shifting keys.
  4.  
  5. Using a press, install the 1st gear and hub sleeve No. 1.
  6.  
  7. Install snapring and select a snapring that will allow minimum axial play and install it on the shaft.
  8.  
  9. Measure 1st gear thrust clearance by using a feeler gauge and measure the 1st gear thrust clearance. Standard clearance: 0.0039-0.0157 in. (0.10-0.30mm).
  10.  
  11. Install the 2nd gear spacer.
  12.  
  13. Place the synchronizer ring on the 2nd gear and align the ring slots with the shifting keys.
  14.  
  15. Coat the 2nd gear needle roller bearing with gear oil.
  16.  
  17. Install the 2nd gear.
  18.  
  19. Using a press, install the 3rd driven gear.
  20.  
  21. Using a feeler gauge, measure the 2nd gear thrust clearance. Standard clearance: 0.0039-0.0177 in. (0.10-0.45mm).
  22.  
  23. Install the output gear spacer.
  24.  
  25. Press in the 4th driven gear and bearing.
  26.  
  27. Install the transaxle magnet and oil receiver.
  28.  
  29. Adjust differential side bearing preload by performing the following:
    1. Install the thinnest shim into the transaxle case.
    2.  
    3. Using SST 09608-20012, or equivalent, drive in the outer race of the side bearing.
    4.  
    5. Install the differential to the transaxle case and install the case. Torque the bolts to 22 ft. lbs. (29 Nm).
    6.  
    7. Measure the preload. Preload (starting): 6.9-13.9 inch lbs.
    8.  
    9. If the preload is not within specification, remove the transaxle case side outer race of the side bearing with SST.
    10.  
    11. Reselect an adjusting shim.
    12.  

  30.  


WARNING
The preload will change about 2.6-3.5 inch lbs. with each shim thickness.

  1. Remove the transaxle case.
  2.  
  3. Install the input and output shafts together.
  4.  
  5. Install the shift forks and shift fork shafts. Torque the 3 bolts to 12 ft. lbs. (19 Nm).
  6.  
  7. Put the reverse shift arm pivot into the reverse shift fork and install the reverse shift arm to the transaxle case.
  8.  
  9. Install and torque the bolts to 13 ft. lbs. (17 Nm).
  10.  
  11. Install reverse idler gear and shaft by aligning the matchmarks.
  12.  
  13. Apply sealant to the contact surface and install the transaxle case. Torque the bolts to 22 ft. lbs. (29 Nm).
  14.  
  15. Install the balls, springs, seats, plugs and lock ball assembly. Apply sealant to the plugs and lock ball assembly threads. Torque the plug to 18 ft. lbs. (25 Nm).
  16.  
  17. Install and torque reverse idler gear shaft lock bolt to 22 ft. lbs. (29 Nm). Apply sealant to the threads.
  18.  
  19. Install the two bearing snaprings.
  20.  
  21. Install rear bearing retainer and torque the five bolts to 14 ft. lbs. (19 Nm).
  22.  
  23. Using SST No. 09309-12020, install the 5th driven gear.
  24.  
  25. Install the 5th gear spacer.
  26.  
  27. Coat the 5th gear needle roller bearings with gear oil.
  28.  
  29. Install the 5th gear with the needle roller bearings and synchronizer ring.
  30.  
  31. Install the No. 3 clutch hub and shifting keys to the No. 3 hub sleeve.
  32.  
  33. Install the shifting key springs under the shifting keys.
  34.  


WARNING
Install the key springs positioned so that their end gaps are not in line.

  1. Support the tip of the input shaft with a spacer to raise the transaxle.
  2.  
  3. Drive in hub sleeve No. 3 with shift fork No. 3.
  4.  


WARNING
Align the synchronizer ring slots with the shifting keys.

  1. Using a dial indicator, measure 5th gear thrust clearance and compare to the standard clearance of 0.0039-0.0224 in. (0.10-0.57mm).
  2.  
  3. Select a snapring that will allow minimum axial play and install it on the shaft.
  4.  
  5. Engage the gear double meshing and install the locknut. Torque the nut to 87 ft. lbs. (118 Nm).
  6.  
  7. Disengage the gear double meshing and stake the locknut with a small cold chisel. Install the bolt and torque to 12 ft. lbs. (16 Nm).
  8.  
  9. Assemble the shift and select lever shaft assembly. Make sure to install the boot in the correct direction. Position the air bleed of the boot downward.
  10.  
  11. Install the shift and select lever shaft assembly, applying sealant to the bolt threads. Torque the bolts to 14 ft. lbs. (20 Nm).
  12.  
  13. Install the bellcrank and lockbolt. Torque to 22 ft. lbs. (29 Nm).
  14.  
  15. Install the transaxle case cover with sealant. Torque the bolts to 13 ft. lbs. (18 Nm).
  16.  
  17. Install front bearing retainer and torque to 8 ft. lbs. (11 Nm).
  18.  
  19. Install the clutch release fork and bearing. Apply molybdenum disulfide lithium base grease to the following parts: release bearing hub inside groove, input shaft spline and release fork contact surface.
  20.  
  21. Install back-up light switch and torque to 30 ft. lbs. (40 Nm).
  22.  
  23. Install speedometer driven gear.
  24.  

E50F2 Transaxle
TRANSAXLE DISASSEMBLY
  1. Remove the transaxle assembly from the vehicle and position it in a suitable holding fixture.
  2.  



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Fig. Fig. 2 5E50F2 transaxle componentsCelica



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Fig. Fig. 2 6E50F2 transaxle componentsCelica



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Fig. Fig. 2 7E50F2 transaxle componentsCelica



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Fig. Fig. 2 8Measuring fifth gear thrust and oil clearances

  1. Remove the three bolts and five nuts attaching the transfer assembly to the transaxle. Using a rubber mallet, separate the transfer assembly from the transaxle.
  2.  



Click image to see an enlarged view

Fig. Fig. 2 9Measuring 4th gear thrust clearance



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Fig. Fig. 3 0Measuring 3rd gear thrust clearance



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Fig. Fig. 3 1Checking oil clearance of 3rd and 4th gear



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Fig. Fig. 3 2Measuring 2nd gear thrust clearance

  1. Screw in a suitable bolt and washer into the side gear intermediate shaft and remove the shaft using SST No. 09910-00015 or equivalent.
  2.  
  3. Remove the release fork, bearing and boot.
  4.  



Click image to see an enlarged view

Fig. Fig. 3 3Measuring the outside diameter of the input shaft journals



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Fig. Fig. 3 4Checking oil clearance of 1st and 2nd gear



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Fig. Fig. 3 5Measuring 1st gear thrust clearance



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Fig. Fig. 3 6Checking oil pump rotor-to-body and rotor side clearances

  1. Remove the back-up light switch and gasket from the transaxle case.
  2.  



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Fig. Fig. 3 7Input shaft componentsE50F2 transaxle



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Fig. Fig. 3 8Output shaft componentsE50F2 transaxle



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Fig. Fig. 3 9Oil pump componentsE50F2 transaxle



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Fig. Fig. 4 0Shift and select lever shaft componentsE50F2 transaxle

  1. Remove the speedometer driven gear.
  2.  



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Fig. Fig. 4 1Aligning reverse idler gear shaft and gear to caseE50F2 transaxle



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Fig. Fig. 4 2Checking side gear intermediate shaft protrusion lengthE50F2 transaxle

  1. Remove the No. 2 selecting bellcrank and support.
  2.  
  3. Remove the shift and select lever shaft lock bolt. Remove the gasket from the bolt.
  4.  
  5. Unbolt and remove the shift and select lever shaft assembly with the gasket.
  6.  
  7. Unbolt the transmission case cover (ten bolts). Using a rubber mallet, separate the cover from the transaxle.
  8.  
  9. Unstake and remove the output shaft locknut with a small cold chisel. Disengage the double gear meshing.
  10.  
  11. Unbolt and remove the No. 3 hub sleeve and No. 3 shift fork.
  12.  
  13. Using SST. No. 09310-17010 or equivalent, remove the 5th driven gear.
  14.  
  15. Using a dial indicator, measure and record the 5th gear thrust clearance. Standard clearance is 0.0039-0.0224 inch (0.10-0.57mm) and maximum clearance is 0.0256 inch (0.65mm).
  16.  
  17. Using a dial indicator, measure the 5th gear oil clearance. Standard oil clearance is 0.0004-0.0020 inch (0.009-0.050mm) and maximum clearance is 0.0028 inch (0.07mm).
  18.  
  19. Tap out the snapring and using SST No. 09310-17010 or equivalent. Remove the No. 3 clutch hub with synchronizer ring and 5th gear.
  20.  
  21. Remove the needle roller bearing and spacer.
  22.  
  23. Remove the seven Torx® bolts and remove the rear bearing retainer and adjusting shim.
  24.  
  25. Remove the snapring from the input shaft rear bearing and remove the snaprings from the shift fork shafts.
  26.  
  27. Using SST No. 09313-30021 or equivalent, remove the plug, seat, spring and locking ball.
  28.  
  29. Remove the reverse idler gear shaft retaining bolt and bolt gasket.
  30.  
  31. Unbolt and remove the transmission case using a rubber mallet to coax the case loose.
  32.  


WARNING
Fourteen bolts retain the transmission case side and three bolts retain the transaxle case side.

  1. Remove the output shaft rear bearing outer race using a rubber mallet.
  2.  
  3. Remove the No. 2 oil pipe with gasket. Discard the gasket and purchase a new one.
  4.  
  5. Unbolt and remove the reverse shift arm bracket.
  6.  
  7. Remove the reverse idler gear, thrust washer and shaft.
  8.  
  9. Remove the plugs, seats, springs and balls.
  10.  
  11. Remove the three set bolts.
  12.  
  13. Pull up on the No. 3 shift fork shaft and remove the No. 1 shift fork shaft.
  14.  
  15. Remove the interlock roller from the reverse shift fork using a magnetic finger.
  16.  
  17. Remove the No. 2 shift fork shaft, shift head and shift fork.
  18.  
  19. Remove the No. 3 shift fork shaft with reverse shift fork and No. 2 shift fork.
  20.  
  21. Remove the snapring and reverse shift fork from the No. 3 shift fork shaft.
  22.  
  23. Remove the input and output shaft assembly.
  24.  
  25. Remove the differential case assembly with the oil pump drive gear.
  26.  
  27. Remove the magnet from the transaxle case assembly.
  28.  
  29. Unbolt and remove the oil pump assembly with the oil pipe.
  30.  

PRE-DISASSEMBLY TRANSAXLE COMPONENT INSPECTION

WARNING
The pre-disassembly inspection of the transaxle components has been broken down to treat each component separately and for the sake of simplicity. Perform each operation in the order shown. No inspection procedure should be neglected or deleted, as they are all important to ensuring the proper operation of the transaxle. Inspection of the major transaxle components (i.e., input shaft) is included with ""Transaxle Component Disassembly and Assembly".

INSPECT 5TH GEAR SYNCHRONIZER RING
  1. Visually inspect the gear ring for wear or damage.
  2.  
  3. Rotate the ring and push it in to check that the braking action is functioning properly.
  4.  
  5. Measure the clearance between the synchronizer ring back and the gear spline end. Minimum clearance is 0.024 inch (0.6mm).
  6.  
  7. Inspect the clearance of the gears whole circumference. If the clearance is less than the specified limit, replace the ring.
  8.  

CHECK SHIFT FORK AND HUB SLEEVE CLEARANCE
  1. Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. The maximum clearance is 0.039 inch (1.00mm).
  2.  
  3. If the clearance exceeds the limit, replace the shift fork or the hub sleeve.
  4.  

SEAL INSPECTION

Inspect all the oil seals, races and pins for wear and damage. Replace any worn or damaged seals as required.

REPLACEMENT OF INPUT SHAFT AND FRONT BEARING OIL SEAL
  1. Remove the three bolts and the transaxle case receiver.
  2.  
  3. Using SST No. 09612-65014 or equivalent bearing puller, pull the bearing out from the transaxle case.
  4.  
  5. Remove the oil seal with a suitable prying tool. Discard the seal.
  6.  
  7. Using SST No. 09608-12010, drive in the new oil seal and coat the lip of the new seal with multi-purpose grease.
  8.  
  9. Using SST No. 09608-12010 or equivalent, drive in a new bearing.
  10.  

REPLACEMENT OF OUTPUT SHAFT FRONT BEARING OUTER RACE
  1. Using SST No. 09308-00010 or equivalent, pull out the outer race.
  2.  
  3. Remove the output shaft cover.
  4.  
  5. Install the output shaft cover so that the projection is installed into the case side groove.
  6.  
  7. Using SST No. 09316-60010 or equivalent, press in a new outer race.
  8.  
  9. Install the transaxle case receiver and torque the bolts to 65 inch lbs. (7.4 Nm).
  10.  

REPLACEMENT OF SPEEDOMETER DRIVEN GEAR OIL SEAL
  1. Using SST No. 09921-00010 or equivalent, pull out the speedometer driven gear oil seal.
  2.  
  3. Using SST. 09201-60011 or equivalent, drive in a new oil seal to a depth of 1.30 inch (33mm). Coat the lip of the seal with multi-purpose grease.
  4.  

REPLACEMENT OF REVERSE RESTRICT PIN
  1. Remove the screw plug using SST No. 09313-30021 or equivalent.
  2.  
  3. Drive out the slotted spring pin using a pin punch and hammer.
  4.  
  5. Replace the reverse restrict pin.
  6.  
  7. Drive in the slotted spring pin using a pin punch and a hammer.
  8.  
  9. Apply Loctite® or equivalent liquid sealant to the threads of the plug and install and tighten the plug.
  10.  

INPUT SHAFT DISASSEMBLY
  1. Using a feeler gauge, measure the 3rd and 4th gear thrust clearances. Standard clearance for the 3rd gear is 0.0039-0.0138 inch (0.10-0.35mm) and the maximum clearance is 0.0157 inch (0.40mm). Standard forth gear clearance is 0.0039-0.0217 inch (0.10-0.55mm) and the maximum clearance is 0.0236 inch (0.60mm).
  2.  
  3. Using a dial indicator, measure the clearance between the 3rd and forth gear shaft. The 3rd gear standard clearance is 0.0004-0.0020 inch (0.009-0.053mm) with a maximum clearance of 0.003 inch (0.08mm). The 4th gear standard clearance is 0.0004-0.0020 inch (0.009-0.051mm with a maximum clearance of 0.003 inch (0.08mm). If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.
  4.  
  5. Remove the snapring.
  6.  
  7. Remove the input shaft rear bearing and the 4th gear using SST No. 09950-00020 or equivalent and a press.
  8.  
  9. Remove the needle roller bearings, spacer and synchronizer ring.
  10.  
  11. Remove the snapring.
  12.  
  13. Using a press, remove the No. 2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings.
  14.  
  15. Remove the needle roller bearing.
  16.  
  17. Remove the input shaft front bearing inner race using SST No. 09950-00020 and a press.
  18.  

INPUT SHAFT INSPECTION
  1. Check the synchronizer rings for damage or wear.
  2.  
  3. Turn and push in on the synchronizer ring to check the bearing action.
  4.  
  5. Measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance is 0.024 inch (0.6mm). If the clearance is less than specified, replace the ring.
  6.  
  7. Using a feeler gauge, measure the clearance between the No. 2 shift fork and the hub sleeve. Maximum clearance is 0.039 inch (1.00mm). If the clearance exceeds specification, replace the shift fork or the hub sleeve.
  8.  
  9. Check the input shaft for damage or wear.
  10.  
  11. With a micrometer, measure the outer diameter of the input shaft journal surface. The minimum outer diameter for Section A (as shown in the figure) is 1.2964 inch (32.930mm) and Sections B and C is 1.4154 inch (35.950mm).
  12.  
  13. Place the input shaft on V-blocks and check the shaft runout. Maximum runout is 0.0024 inch (0.06mm).
  14.  

INPUT SHAFT REASSEMBLY

WARNING
Before assembling the input shaft, coat all the sliding and rotating surfaces with fresh gear oil.

  1. Install the clutch hub and shifting keys into the No. 2 clutch hub sleeve. Install the shifting key springs under the shifting keys so that the end gaps are staggered (not in line).
  2.  
  3. Coat the 3rd gear needle roller bearing with multi-purpose grease.
  4.  
  5. Install the 3rd gear.
  6.  
  7. Place the 3rd gear synchronizer ring on the gear and align the ring slots with the shifting keys.
  8.  
  9. Using SST No. 09506-3501 or equivalent and a press, install the 3rd gear and the No. 2 hub sleeve.
  10.  
  11. Select a snapring (using the accompanying chart) that will allow minimum axial thrust and install it on the shaft.
  12.  
  13. Using a feeler gauge, measure the 3rd gear thrust clearance. Standard clearance is 0.0039-0.0138 inch (0.10-0.35mm).
  14.  
  15. Install the 4th gear spacer.
  16.  
  17. Coat the 4th gear needle roller bearings with multi-purpose grease.
  18.  
  19. Place the 4th gear synchronizer ring on the gear and align the ring slots with the shifting keys.
  20.  
  21. Using SST No. 09506-35010 or equivalent and a press, install the radial ball bearing.
  22.  
  23. Select a snapring (using the accompanying chart) that will allow minimum axial thrust and install it on the shaft.
  24.  
  25. Using a feeler gauge, measure the 4th gear thrust clearance. Standard thrust clearance is 0.0039-0.0217 inch (0.10-0.55mm).
  26.  
  27. Using SST No. 09316 and a suitable press, install the input shaft front bearing inner race.
  28.  

OUTPUT SHAFT DISASSEMBLY
  1. Using a feeler gauge, measure the 1st and 2nd gear thrust clearance. First gear standard clearance is 0.0039-0.0138 inch (0.10-0.35mm) with a maximum clearance of 0.0157 inch (0.40mm). 2nd gear standard clearance is 0.0039-0.0177 inch (0.010-0.45mm) with a maximum of 0.0197 inch (0.50mm).
  2.  
  3. Using a dial indicator, measure the oil clearance between the 1st and 2nd gear and the shaft. 1st gear standard clearance is 0.0004-0.0020 inch (0.009-0.051mm). 2nd gear standard clearance is 0.0004-0.0020 inch (0.009-0.053mm). Both gears have a maximum oil clearance of 0.003 inch (0.080mm). If the oil clearance exceeds the maximum limit, replace the gear, needle roller bearing or the shaft.
  4.  
  5. Using a suitable press, remove the output shaft rear bearing and 4th driven gear. Remove the spacer.
  6.  
  7. Using SST No. 09950-00020 and a suitable press, remove the 3rd driven gear and 2nd gear.
  8.  
  9. Remove the needle roller bearing, 2nd gear bushing and ball.
  10.  
  11. Remove the synchronizer ring.
  12.  
  13. Using a suitable press, remove the No. 1 hub sleeve and 1st gear.
  14.  
  15. Remove the synchronizer ring and needle roller bearing.
  16.  

OUTPUT SHAFT INSPECTION
  1. Visually inspect the synchronizer rings for wear and damage.
  2.  
  3. Turn and push in on the synchronizer ring to check the bearing action.
  4.  
  5. Measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance is 0.024 inch (0.60mm). If the clearance is less than specified, replace the ring.
  6.  
  7. Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance is 0.039 inch (1.00mm). If the clearance exceeds specification, replace the shift fork or the hub sleeve.
  8.  
  9. Check the input shaft for damage or wear.
  10.  
  11. With a micrometer, measure the outer diameter of the output shaft journal surface and the 2nd gear bushing. The minimum outer diameter 1.5335 inch (38.950mm).
  12.  
  13. Place the input shaft on V-blocks and check the shaft runout. Maximum runout is 0.0024 inch (0.06mm).
  14.  
  15. If necessary, replace the output shaft front bearing. Press the old bearing out using SST Nos. 09307-12101 and 09950-00020 or their equivalents and press in the new bearing using SST No. 09316-00070.
  16.  

OUTPUT SHAFT REASSEMBLY

WARNING
Before assembling the input shaft, coat all the sliding and rotating surfaces with fresh gear oil.

  1. Install the clutch hub and shifting keys into the No. 1 clutch hub sleeve. Install the shifting key springs under the shifting keys so that the end gaps are staggered (not in line).
  2.  
  3. Coat the 1st gear needle roller bearing with multi-purpose grease.
  4.  
  5. Install the 1st gear.
  6.  
  7. Place the 1st gear synchronizer ring on the gear and align the ring slots with the shifting keys.
  8.  
  9. Using SST No. 09316-60010 or equivalent and a press, install the 1st gear and the No. 1 hub sleeve.
  10.  
  11. Using a feeler gauge, measure the 1st gear thrust clearance. Standard clearance is 0.0039-0.0138 inch (0.10-0.35mm).
  12.  
  13. Install the 2nd gear ball and bushing.
  14.  
  15. Coat the 2nd gear needle roller bearing with multi-purpose grease and install the bearing.
  16.  
  17. Place the 2nd gear synchronizer ring on the gear and align the ring slots with the shifting keys.
  18.  
  19. Install the 2nd gear.
  20.  
  21. Using a press, install the 2nd gear.
  22.  
  23. Using a feeler gauge, measure the 2nd gear thrust clearance. Standard clearance is 0.0039-0.0177 inch (0.10-0.45mm).
  24.  
  25. Install the 4th gear spacer and press the 4th driven gear into place.
  26.  
  27. Using SST No. 09506-30012 and a press, install the output shaft rear taper roller bearing.
  28.  

OIL PUMP DISASSEMBLY
  1. Insert the oil pump drive gear into the drive rotor and check that the rotor turns smoothly.
  2.  
  3. Withdraw the gasket from the pump case. Discard the gasket and purchase a new one.
  4.  
  5. Remove the oil strainer retaining bolt. Hold the pump cover stationary, remove the two cover bolts and cover.
  6.  
  7. Withdraw the spring holder, spring, ball and relief valve seat from the oil pump case.
  8.  

OIL PUMP INSPECTION
  1. Mate the oil pump drive gear with the drive rotor.
  2.  
  3. Using a feeler gauge, measure the clearance between the drive rotor and the oil pump case. The standard clearance is 0.004-0.006 inch (0.10-0.16mm) and the maximum oil clearance is 0.012 inch (0.30mm).
  4.  
  5. Using a feeler gauge, measure the clearance between the drive and driven rotors. The standard oil clearance is 0.003-0.006 inch (0.08-0.15mm with a maximum clearance of 0.012 inch (0.30mm).
  6.  
  7. Using a machinists straight edge and a feeler gauge, measure the side clearance of both rotors. Standard side clearance is 0.001-0.003 inch (0.03-0.08mm) with a maximum of 0.006 inch (0.15mm).
  8.  
  9. Remove the oil pump drive and driven rotors.
  10.  
  11. Remove the O-ring from the oil pump case using a machinists scribe or screwdriver. Discard the O-ring and replace with new. Coat the new O-ring with clean gear oil and install the O-ring into the oil pump case.
  12.  

OIL PUMP REASSEMBLY
  1. Install the drive and driven rotors.
  2.  
  3. Wipe the relief valve bore out with a clean lint-free rag.
  4.  
  5. Install the relief valve seat, ball, spring and spring holder into the oil pump case.
  6.  
  7. Place the oil pump cover into place and temporarily install the cover retaining bolts.
  8.  
  9. Install the oil pump strainer and temporarily install the retaining bolt.
  10.  
  11. Torque the bolts evenly to 8 ft. lbs. (10 Nm).
  12.  
  13. Insert the oil pump drive gear into the drive rotor and make sure that the rotor turns freely.
  14.  
  15. Install a new gasket into the oil pump case.
  16.  

SHIFT AND SELECT LEVER SHAFT DISASSEMBLY
  1. Using a pin punch and a hammer, drive the out the No. 2 shift inner lever slotted spring pin and remove the transmission oil baffle.
  2.  
  3. Remove the snapring.
  4.  
  5. Remove the No. 2 select spring seat, No. 2 compression spring and the No. 2 shift inner lever.
  6.  
  7. Using a pin punch and a hammer drive out the No. 1 shift inner lever slotted spring pin.
  8.  
  9. Remove the shift inner plate and the No. 1 shift inner lever from the shaft.
  10.  
  11. Remove the shift interlock plate cover and No. 1 shift inner lever from the shift interlock plate.
  12.  
  13. Using a pin punch and a hammer drive out the select inner lever slotted spring pin.
  14.  
  15. Remove the select inner lever, No. 1 compression spring and No. 1 select spring seat.
  16.  
  17. Remove the remaining snapring.
  18.  
  19. Remove the control shaft cover and dust boot.
  20.  
  21. If necessary, withdraw the oil seal from the control shaft cover. Using SST No. 09620-30010 or equivalent and a hammer, drive the new oil seal into the cover to a depth of 0-0.039 inch (0-1.00mm). After installation coat the new seal with multi-purpose grease.
  22.  

SHIFT AND SELECT LEVER SHAFT REASSEMBLY
  1. Lightly coat all sliding, mating and splined surfaces with multi-purpose grease.
  2.  
  3. Install the dust boot cover onto the control shaft cover.
  4.  
  5. Install the shift select lever onto the control shaft cover.
  6.  
  7. Using a piece of brass stock and a hammer, install the snapring and spring seat.
  8.  
  9. Install the No. 1 spring seat, No. 1 select spring and select inner lever in the proper order.
  10.  
  11. Using a pin punch and a hammer, drive in the select inner lever slotted spring pin.
  12.  
  13. Place the No. 1 shift inner lever into the interlock plate and install the interlock cover.
  14.  
  15. Using a pin punch and a hammer, drive in the No. 1 shift inner lever slotted spring pin.
  16.  
  17. Make sure that the shift interlock plate turns smoothly.
  18.  
  19. Install the No. 2 shift inner lever, No. 2 compression spring, transmission oil baffle and No. 2 select spring seat in the proper order.
  20.  
  21. Install the snapring. Using a pin punch and a hammer, drive in the No. 2 shift inner lever slotted spring pin.
  22.  

TRANSAXLE REASSEMBLY

WARNING
Prior to reassembling the transaxle, coat all the moving and sliding parts with clean lubricant of the same type with which it will be filled.

  1. Install the output shaft assembly to the transaxle case.
  2.  
  3. Install the transaxle case in position. If necessary, use a rubber mallet to coax the transaxle into place.
  4.  
  5. Install the seventeen transaxle case retaining bolts and torque the bolts to 22 ft. lbs. (29 Nm).
  6.  
  7. Install the output shaft rear bearing outer race.
  8.  
  9. Install the adjusting shim.
  10.  


WARNING
If the output shaft rear bearing is being re-used, install a shim of the same thickness as the old shim. If a new bearing is being installed, select a shim of lesser thickness than the old shim.

  1. Install the seven Torx® screws and torque them to 31 ft. lbs. (42 Nm).
  2.  
  3. Install a new locknut onto the output shaft.
  4.  
  5. Rotate the output shaft counterclockwise and clockwise a few times.
  6.  
  7. Using a torque meter, measure the preload of the output shaft. Preload for a new bearing is 6.9-13.9 inch lbs. and 4.3-8.7 inch lbs. for a used bearing. If the preload is not within specification, select the proper thickness shim to adjust the preload.
  8.  


WARNING
The pre-load changes approximately 3.5-4.3 inch lbs. with each shim thickness.

  1. Remove the locknut, seven Torx® screws and the adjusting shim.
  2.  
  3. Remove the seventeen retaining bolts and tap the case off with a rubber mallet.
  4.  
  5. Remove the output shaft rear bearing outer race.
  6.  
  7. Remove the output shaft assembly.
  8.  
  9. Install the oil pump assembly and temporarily install the two retaining bolts. Be careful not to drop the oil pump gasket.
  10.  
  11. Install the oil pipe with the two retaining bolts.
  12.  
  13. Torque the oil pipe and oil pump retaining bolts to 13 ft. lbs. (17 Nm).
  14.  
  15. Install the transaxle case magnet.
  16.  
  17. Install the differential case assembly.
  18.  
  19. Install the oil pump drive gear.
  20.  
  21. Lift the differential case up slightly and install the output shaft assembly.
  22.  
  23. Lean the output shaft assembly towards the differential case side and install the input shaft assembly.
  24.  


WARNING
When installing the input shaft assembly, be careful not to damage the oil seal.

  1. Install the reverse shift fork onto the No. 3 shift fork. Install and seat the snapring with a rubber mallet.
  2.  
  3. Place the No. 2 shift fork into the groove of the No. 2 hub sleeve.
  4.  
  5. Install the No. 3 shift fork shaft with the reverse shift fork into the transaxle case.
  6.  
  7. Place the No. 1 shift fork into the groove of the No. 1 hub sleeve.
  8.  
  9. Place the shift head onto the No. 1 shift fork.
  10.  
  11. Install the No. 2 shift fork shaft into the transaxle case through the No. 2 shift fork, the shift head and the No. 1 shift fork.
  12.  
  13. Using a magnetic finger, install the interlock roller into the reverse shift fork by aligning the groove of the No. 1 shift fork shaft with the interlock roller hole of the reverse shift fork.
  14.  
  15. Install the No. 1 shift fork shaft into the transaxle case through the No. 1 and reverse shift forks. If this is difficult to do, pull up on the No. 3 shift fork shaft and then try to install the No. 1 shift fork again.
  16.  
  17. Install the 3 set bolts and torque them to 17 ft. lbs. (24 Nm).
  18.  
  19. Install the two locking balls, springs and spring seats.
  20.  
  21. Coat the threads of the two screw plugs with Loctite® sealant or equivalent liquid sealant. Install the two plugs and torque them to 18 ft. lbs. (25 Nm).
  22.  
  23. Install the reverse idler gear shaft (with the gear and thrust washer) into the transaxle case.
  24.  
  25. Align the matchmarks on the gear with the matchmarks on the case as shown in the accompanying figure.
  26.  
  27. Place the reverse shift fork into the reverse shift arm. Connect the reverse shift arm bracket to the transaxle case and temporarily install the retaining bolt.
  28.  
  29. Install the No. 2 oil pipe and torque the two retaining bolts and the reverse shift arm bracket bolt to 13 ft. lbs. (17 Nm).
  30.  
  31. Install a new gasket onto the No. 2 oil pipe.
  32.  
  33. Remove any old packing material from the transaxle case contact surfaces and apply a bead of new seal packing No. 08826-00090, Three Bond® 1281 or equivalent to the case.
  34.  
  35. As soon as the sealant is applied, install the transmission case with the seventeen retaining bolts. Torque the bolts to 22 ft. lbs. (29 Nm).
  36.  
  37. Install the reverse idler gear retaining bolt and gasket. Torque the bolt to 22 ft. lbs. (29 Nm).
  38.  
  39. Install the locking ball, spring and spring seat.
  40.  
  41. Coat the threads of the screw plug with Loctite® 242 or equivalent sealer, install and torque the plug to 18 ft. lbs. (25 Nm).
  42.  
  43. Using a rubber mallet, install the two snaprings onto the shift fork shafts.
  44.  
  45. Install the output shaft rear bearing outer race.
  46.  
  47. Install the adjust shim.
  48.  
  49. Using snapring pliers, install the snapring onto the input shaft bearing.
  50.  
  51. Coat the threads of the seven Torx® screws with Loctite® 242 sealant or equivalent. Install the screws and torque them to 31 ft. lbs. (42 Nm).
  52.  
  53. Install the spacer, needle roller bearings and the 5th gear.
  54.  
  55. Install the synchronizer ring and the key spring onto the No. 3 clutch hub.
  56.  
  57. Using SST No. 09310-17010 or equivalent, install the No. 3 clutch hub with synchronizer ring and key spring.
  58.  
  59. Select a snapring that will allow minimum axial play and install onto the shaft using a brass bar and a hammer.
  60.  
  61. Using a dial indicator, measure the 5th gear thrust clearance. The standard thrust clearance is 0.004-0.022 inch (0.10-0.57mm).
  62.  
  63. Using SST No.09310-17010 or equivalent, install the 5th driven gear.
  64.  
  65. Install the No. 3 hub sleeve and the No. 3 shift fork with the set bolt. Torque the set bolt to 17 ft. lbs. (24 Nm).
  66.  
  67. Engage the gear double meshing and install the new locknut. Torque the locknut to 90 ft. lbs. (123 Nm), stake the nut with a small cold chisel and disengage the double meshing.
  68.  
  69. Remove any old packing material from the transmission case cover contact surfaces and apply a bead of new seal packing No. 08826-00090, Three Bond® 1281 or equivalent to the cover.
  70.  
  71. As soon as the sealant is applied, install the cover with the retaining bolts. Torque the retaining bolts to 22 ft. lbs. (29 Nm).
  72.  
  73. Install the shift shaft select lever assembly with new gasket and coat the threads of the bolts with Loctite® 242 or equivalent. Install the bolts and torque them to 14 ft. lbs. (20 Nm). Install the lock bolt with new gasket and torque it to 36 ft. lbs. (36 Nm).
  74.  
  75. Install the No. 2 selecting bellcrank with the support. Coat the threads of the two retaining bolts with Loctite® 242 or equivalent. Install and torque the bolts to 14 ft. lbs. (20 Nm).
  76.  
  77. Install the back-up light switch and torque it to 30 ft. lbs. (40 Nm).
  78.  
  79. Install the speedometer driven gear.
  80.  
  81. Coat the clutch release bearing inside hub, input shaft spline and release fork contact surface with molybdenum disulfide lithium based grease.
  82.  
  83. Coat the front surface of the release bearing with multi-purpose grease.
  84.  
  85. Coat the intermediate shaft with multi-purpose grease.
  86.  
  87. With a rubber mallet, drive the intermediate shaft straight into the top of the shaft touches the differential pinion shaft.
  88.  
  89. Measure the protrusion length of the shaft. The protrusion length should be 255mm.
  90.  
  91. Remove any of the old packing material from the transfer assembly contact surfaces. Apply a bead of new seal packing No. 08826-00090, Three Bond® 1281 or equivalent to the transfer assembly.
  92.  
  93. As soon as the sealant is applied, install the transfer assembly to the transaxle by shifting into 4th gear and installing the transfer assembly while turning the transaxle input shaft.
  94.  
  95. Coat the threads of the transfer case retaining bolts with Loctite® 242 or equivalent sealant. Install the three bolts and two nuts and torque them to 51 ft. lbs. (69 Nm).
  96.  
  97. Move the select lever to the viscous mode position and lock it in place with the lock bolt.
  98.  

E150F Transaxle
TRANSAXLE DISASSEMBLY
  1. Remove the transaxle assembly from the vehicle and position it in a suitable holding fixture.
  2.  



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Fig. Fig. 4 3E150F transaxle componentsCelica



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Fig. Fig. 4 4E150F transaxle componentsCelica



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Fig. Fig. 4 5E150F transaxle componentsCelica



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Fig. Fig. 4 6Input shaft componentsE150F transaxle

  1. Remove the three bolts and five nuts attaching the transfer assembly to the transaxle. Using a rubber mallet, separate the transfer assembly from the transaxle.
  2.  



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Fig. Fig. 4 7Inspecting input shaftE150F transaxle



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Fig. Fig. 4 8Measuring fifth gear thrust clearance



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Fig. Fig. 4 9Measuring 4th gear thrust clearance



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Fig. Fig. 5 0Output shaft componentsE150F transaxle

  1. Screw in a suitable bolt and washer into the side gear intermediate shaft and remove the shaft using SST No. 09910-00015 or equivalent.
  2.  



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Fig. Fig. 5 1Measuring clearance of No. 1 shift fork and hub sleeveE150F transaxle



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Fig. Fig. 5 2Oil pump componentsE150F transaxle



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Fig. Fig. 5 3Shift and select lever shaft componentsE150F transaxle



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Fig. Fig. 5 4Aligning reverse idler gear shaft and gear to caseE150F transaxle



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Fig. Fig. 5 5Checking side gear intermediate shaft protrusion lengthE150F transaxle

  1. Remove the release fork and bearing.
  2.  
  3. Remove the back-up light switch from the transaxle case.
  4.  
  5. Remove the speedometer driven gear.
  6.  
  7. Remove the No. 2 selecting bellcrank and support.
  8.  
  9. Remove the shift and select lever shaft lock bolt. Remove the gasket from the bolt.
  10.  
  11. Unbolt and remove the shift and select lever shaft assembly with the gasket.
  12.  
  13. Unbolt the transmission case cover. Using a rubber mallet, separate the cover from the transaxle.
  14.  
  15. Unstake the locknut, engage the double gear meshing and remove the output shaft locknut with a small cold chisel. Disengage the double gear meshing.
  16.  
  17. Unbolt and remove the No. 3 hub sleeve and No. 3 shift fork.
  18.  
  19. Using SST. No. 09310-17010 or equivalent, remove the 5th driven gear.
  20.  
  21. Using a dial indicator, measure and record the 5th gear thrust clearance. Standard clearance is 0.0039-0.0224 inch (0.10-0.57mm) and maximum clearance is 0.0256 inch (0.65mm).
  22.  
  23. Using a dial indicator, measure the 5th gear oil clearance. Standard oil clearance is 0.0004-0.0020 inch (0.009-0.050mm) and maximum clearance is 0.0028 inch (0.07mm).
  24.  
  25. Tap out the snapring and using SST No. 09310-17010 or equivalent. Remove the No. 3 clutch hub with synchronizer ring and 5th gear.
  26.  
  27. Remove the needle roller bearing and spacer.
  28.  
  29. Remove the seven Torx® bolts and remove the rear bearing retainer and adjusting shim.
  30.  
  31. Remove the snapring from the input shaft rear bearing and remove the snaprings from the shift fork shafts.
  32.  
  33. Using SST No. 09313-30021 or equivalent, remove the plug, seat, spring and locking ball.
  34.  
  35. Remove the reverse idler gear shaft retaining bolt and bolt gasket.
  36.  
  37. Unbolt and remove the transmission case using a rubber mallet.
  38.  
  39. Remove the output shaft rear bearing outer race using a rubber mallet.
  40.  
  41. Remove the No. 2 oil pipe with gasket. Discard the gasket and purchase a new one.
  42.  
  43. Unbolt and remove the reverse shift arm bracket.
  44.  
  45. Remove the reverse idler gear and shaft.
  46.  
  47. Remove the plugs, seats, springs and balls.
  48.  
  49. Remove the set bolts.
  50.  
  51. Pull up on the No. 3 shift fork shaft and remove the No. 1 shift fork shaft.
  52.  
  53. Remove the interlock roller from the reverse shift fork using a magnetic finger.
  54.  
  55. Remove the No. 2 shift fork shaft, shift head and shift fork.
  56.  
  57. Remove the No. 3 shift fork shaft with reverse shift fork and No. 2 shift fork.
  58.  
  59. Remove the snapring and reverse shift fork from the No. 3 shift fork shaft.
  60.  
  61. Remove the input and output shaft assembly.
  62.  
  63. Remove the differential case assembly with the oil pump drive gear.
  64.  
  65. Remove the magnet from the transaxle case assembly.
  66.  
  67. Unbolt and remove the oil pump assembly with the oil pipe.
  68.  

PRE-DISASSEMBLY TRANSAXLE COMPONENT INSPECTION

WARNING
The pre-disassembly inspection of the transaxle components has been broken down to treat each component separately and for the sake of simplicity. Perform each operation in the order shown. No inspection procedure should be neglected or deleted, as they are all important to ensuring the proper operation of the transaxle. Inspection of the major transaxle components (i.e., input shaft) is included with ""Transaxle Component Disassembly and Assembly".

INSPECT 5TH GEAR SYNCHRONIZER RING
  1. Visually inspect the gear ring for wear or damage.
  2.  
  3. Rotate the ring and push it in to check that the braking action id functioning properly.
  4.  
  5. Measure the clearance between the synchronizer ring back and the gear spline end. Minimum clearance is 0.024 inch (0.6mm.
  6.  
  7. Inspect the clearance of the gears whole circumference. if the clearance is less than the specified limit, replace the ring.
  8.  

CHECK SHIFT FORK AND HUB SLEEVE CLEARANCE
  1. Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. The maximum clearance is 0.039 inch (1.00mm).
  2.  
  3. If the clearance exceeds the limit, replace the shift fork or the hub sleeve.
  4.  

SEAL PROTECTION

Inspect all the oil seals, races and pins for wear and damage. Replace any worn or damaged seals as required.

REPLACEMENT OF INPUT SHAFT AND FRONT BEARING OIL SEAL
  1. Remove the three bolts and the transaxle case receiver.
  2.  
  3. Using SST No. 09612-65014 or equivalent bearing puller, pull the bearing out from the transaxle case.
  4.  
  5. Remove the oil seal with a suitable prying tool. Discard the seal.
  6.  
  7. Using SST No. 09608-12010, drive in the new oil seal and coat the lip of the new seal with multi-purpose grease.
  8.  
  9. Using SST No. 09608-12010 or equivalent, drive in a new bearing.
  10.  

REPLACEMENT OF OUTPUT SHAFT FRONT BEARING OUTER RACE
  1. Using SST No. 09308-00010 or equivalent, pull out the outer race.
  2.  
  3. Remove the output shaft cover.
  4.  
  5. Install the output shaft cover so that the projection is installed into the case side groove.
  6.  
  7. Using SST No. 09316-60010 or equivalent, press in a new outer race.
  8.  
  9. Install the transaxle case receiver and torque the bolts to 65 inch lbs. (7.4 Nm).
  10.  

REPLACEMENT OF SPEEDOMETER DRIVEN GEAR SEAL
  1. Using SST No. 09921-00010 or equivalent, pull out the speedometer driven gear oil seal.
  2.  
  3. Using SST. 09201-60011 or equivalent, drive in a new oil seal to a depth of 1.30 inch (33mm). Coat the lip of the seal with multi-purpose grease.
  4.  

REPLACEMENT OF REVERSE RESTRICT PIN
  1. Remove the screw plug using SST No. 09313-30021 or equivalent.
  2.  
  3. Drive out the slotted spring pin using a pin punch and hammer.
  4.  
  5. Replace the reverse restrict pin.
  6.  
  7. Drive in the slotted spring pin using a pin punch and a hammer.
  8.  
  9. Apply Loctite® or equivalent liquid sealant to the threads of the plug and install and tighten the plug.
  10.  

INPUT SHAFT DISASSEMBLY
  1. Using a feeler gauge, measure the 3rd and 4th gear thrust clearances. Standard clearance for the 3rd gear is 0.0039-0.0138 inch (0.10-0.35mm) and the maximum clearance is 0.0157 inch (0.40mm). Standard forth gear clearance is 0.0039-0.0217 inch (0.10-0.55mm) and the maximum clearance is 0.0236 inch (0.60mm).
  2.  
  3. Using a dial indicator, measure the clearance between the 3rd and forth gear shaft. The 3rd gear standard clearance is 0.0004-0.0020 inch (0.009-0.053mm) with a maximum clearance of 0.003 inch (0.08mm). The 4th gear standard clearance is 0.0004-0.0020 inch (0.009-0.051mm with a maximum clearance of 0.003 inch (0.08mm). If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.
  4.  
  5. Remove the snapring.
  6.  
  7. Remove the input shaft rear bearing and the 4th gear using SST No. 09950-00020 or equivalent and a press.
  8.  
  9. Remove the needle roller bearings, spacer and synchronizer ring.
  10.  
  11. Remove the snapring.
  12.  
  13. Using a press, remove the No. 2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings.
  14.  
  15. Remove the needle roller bearing.
  16.  
  17. Remove the input shaft front bearing inner race using SST No. 09950-00020 and a press.
  18.  

INPUT SHAFT INSPECTION
  1. Check the synchronizer rings for damage or wear.
  2.  
  3. Turn and push in on the synchronizer ring to check the bearing action.
  4.  
  5. Measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance is 0.024 inch (0.6mm). If the clearance is less than specified, replace the ring.
  6.  
  7. Using a feeler gauge, measure the clearance between the No. 2 shift fork and the hub sleeve. Maximum clearance is 0.039 inch (1.00mm). If the clearance exceeds specification, replace the shift fork or the hub sleeve.
  8.  
  9. Check the input shaft for damage or wear.
  10.  
  11. With a micrometer, measure the outer diameter of the input shaft journal surface. The minimum outer diameter for Section A (as shown in the figure) is 1.2964 inch (32.930mm) and Sections B and C is 1.4154 inch (35.950mm).
  12.  
  13. Place the input shaft on V-blocks and check the shaft runout. Maximum runout is 0.0024 inch (0.06mm).
  14.  

INPUT SHAFT REASSEMBLY

WARNING
Before assembling the input shaft, coat all the sliding and rotating surfaces with fresh gear oil.

  1. Install the clutch hub and shifting keys into the No. 2 clutch hub sleeve. Install the shifting key springs under the shifting keys so that the end gaps are staggered (not in line).
  2.  
  3. Coat the 3rd gear needle roller bearing with multi-purpose grease.
  4.  
  5. Install the 3rd gear.
  6.  
  7. Place the 3rd gear synchronizer ring on the gear and align the ring slots with the shifting keys.
  8.  
  9. Using SST No. 09506-35010 or equivalent and a press, install the 3rd gear and the No. 2 hub sleeve.
  10.  
  11. Select a snapring that will allow minimum axial thrust and install it on the shaft.
  12.  
  13. Using a feeler gauge, measure the 3rd gear thrust clearance. Standard clearance is 0.0039-0.0138 inch (0.10-0.35mm).
  14.  
  15. Install the 4th gear spacer.
  16.  
  17. Coat the 4th gear needle roller bearings with multi-purpose grease.
  18.  
  19. Place the 4th gear synchronizer ring on the gear and align the ring slots with the shifting keys.
  20.  
  21. Using SST No. 09506-35010 or equivalent and a press, install the radial ball bearing.
  22.  
  23. Select a snapring that will allow minimum axial thrust and install it on the shaft.
  24.  
  25. Using a feeler gauge, measure the 4th gear thrust clearance. Standard thrust clearance is 0.0039-0.0217 inch (0.10-0.55mm).
  26.  
  27. Using SST No. 09316 and a suitable press, install the input shaft front bearing inner race.
  28.  

OUTPUT SHAFT DISASSEMBLY
  1. Using a feeler gauge, measure the 1st and 2nd gear thrust clearance. First gear standard clearance is 0.0039-0.0138 inch (0.10-0.35mm) with a maximum clearance of 0.0157 inch (0.40mm). 2nd gear standard clearance is 0.0039-0.0177 inch (0.010-0.45mm) with a maximum of 0.0197 inch (0.50mm).
  2.  
  3. Using a dial indicator, measure the oil clearance between the 1st and 2nd gear and the shaft. 1st gear standard clearance is 0.0004-0.0020 inch (0.009-0.051mm). 2nd gear standard clearance is 0.0004-0.0020 inch (0.009-0.053mm). Both gears have a maximum oil clearance of 0.003 inch (0.080mm). If the oil clearance exceeds the maximum limit, replace the gear, needle roller bearing or the shaft.
  4.  
  5. Using a suitable press, remove the output shaft rear bearing and 4th driven gear. Remove the spacer.
  6.  
  7. Using SST No. 09950-00020 and a suitable press, remove the 3rd driven gear and 2nd gear.
  8.  
  9. Remove the needle roller bearing, 2nd gear bushing and ball.
  10.  
  11. Remove the synchronizer ring.
  12.  
  13. Using a suitable press, remove the No. 1 hub sleeve and 1st gear.
  14.  
  15. Remove the synchronizer ring and needle roller bearing.
  16.  

OUTPUT SHAFT INSPECTION
  1. Visually inspect the synchronizer rings for wear and damage.
  2.  
  3. Turn and push in on the synchronizer ring to check the bearing action.
  4.  
  5. Measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance is 0.024 inch (0.60mm). If the clearance is less than specified, replace the ring.
  6.  
  7. Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance is 0.039 inch (1.00mm). If the clearance exceeds specification, replace the shift fork or the hub sleeve.
  8.  
  9. Check the input shaft for damage or wear.
  10.  
  11. With a micrometer, measure the outer diameter of the output shaft journal surface and the 2nd gear bushing. The minimum outer diameter 1.5335 inch (38.950mm).
  12.  
  13. Place the input shaft on V-blocks and check the shaft runout. Maximum runout is 0.0024 inch (0.06mm).
  14.  
  15. If necessary, replace the output shaft front bearing. Press the old bearing out using SST Nos. 09307-12101 and 09950-00020 or their equivalents and press in the new bearing using SST No. 09316-00070.
  16.  

OUTPUT SHAFT REASSEMBLY

WARNING
Before assembling the input shaft, coat all the sliding and rotating surfaces with fresh gear oil.

  1. Install the clutch hub and shifting keys into the No. 1 clutch hub sleeve. Install the shifting key springs under the shifting keys so that the end gaps are staggered (not in line).
  2.  
  3. Coat the 1st gear needle roller bearing with multi-purpose grease.
  4.  
  5. Install the 1st gear.
  6.  
  7. Place the 1st gear synchronizer ring on the gear and align the ring slots with the shifting keys.
  8.  
  9. Using SST No. 09316-60010 or equivalent and a press, install the 1st gear and the No. 1 hub sleeve.
  10.  
  11. Using a feeler gauge, measure the 1st gear thrust clearance. Standard clearance is 0.0039-0.0138 inch (0.10-0.35mm). If not, replace the snapring with one that will allow minimum axial play.
  12.  
  13. Install the 2nd gear ball and bushing.
  14.  
  15. Coat the 2nd gear needle roller bearing with multi-purpose grease and install the bearing.
  16.  
  17. Place the 2nd gear synchronizer ring on the gear and align the ring slots with the shifting keys.
  18.  
  19. Install the 2nd gear.
  20.  
  21. Using a press, install the 2nd gear.
  22.  
  23. Using a feeler gauge, measure the 2nd gear thrust clearance. Standard clearance is 0.0039-0.0177 inch (0.10-0.45mm).
  24.  
  25. Install the 4th gear spacer and press the 4th driven gear into place.
  26.  
  27. Using SST No. 09506-30012 and a press, install the output shaft rear taper roller bearing.
  28.  

OIL PUMP DISASSEMBLY
  1. Insert the oil pump drive gear into the drive rotor and check that the rotor turns smoothly.
  2.  
  3. Withdraw the gasket from the pump case. Discard the gasket and purchase a new one.
  4.  
  5. Remove the oil strainer retaining bolt. Remove the oil line case and oil pipe.
  6.  
  7. Remove the oil pump cover, then withdraw the No. 1 relief valve assembly.
  8.  

OIL PUMP INSPECTION
  1. Mate the oil pump drive gear with the drive rotor.
  2.  
  3. Using a feeler gauge, measure the clearance between the drive rotor and the oil pump case. The standard clearance is 0.0039-0.0063 inch (0.10-0.16mm) and the maximum oil clearance is 0.0118 inch (0.30mm).
  4.  
  5. Using a feeler gauge, measure the clearance between the drive and driven rotors. The standard oil clearance is 0.0031-0.0059 inch (0.08-0.15mm with a maximum clearance of 0.0118 inch (0.30mm).
  6.  
  7. Using a machinists straight edge and a feeler gauge, measure the side clearance of both rotors. Standard side clearance is 0.0012-0.0031 inch (0.03-0.08mm) with a maximum of 0.0059 inch (0.15mm).
  8.  
  9. Remove the oil pump drive and driven rotors.
  10.  
  11. Remove the O-ring from the oil pump case using a machinists scribe or screwdriver. Discard the O-ring and replace with new. Coat the new O-ring with clean gear oil and install the O-ring into the oil pump case.
  12.  

OIL PUMP REASSEMBLY
  1. Install a new O-ring. Install the drive and driven rotors.
  2.  
  3. Wipe the relief valve bore out with a clean lint-free rag.
  4.  
  5. Install the relief valve assembly seat, ball, spring and spring holder into the oil pump case.
  6.  
  7. Place the oil pump cover into place and temporarily install the cover retaining bolt. Install the oil line case.
  8.  
  9. Install the oil pump strainer and temporarily install the retaining bolt.
  10.  
  11. Torque the bolts evenly to 8 ft. lbs. (10 Nm).
  12.  
  13. Insert the oil pump drive gear into the drive rotor and make sure that the rotor turns freely.
  14.  
  15. Install a new gasket into the oil pump case.
  16.  

SHIFT AND SELECT LEVER SHAFT DISASSEMBLY
  1. Using a pin punch and a hammer, drive the out the No. 2 shift inner lever slotted spring pin and remove the transmission oil baffle.
  2.  
  3. Remove the snapring.
  4.  
  5. Remove the No. 2 select spring seat, No. 2 compression spring and the No. 2 shift inner lever.
  6.  
  7. Using a pin punch and a hammer drive out the No. 1 shift inner lever slotted spring pin.
  8.  
  9. Remove the shift inner plate and the No. 1 shift inner lever from the shaft.
  10.  
  11. Remove the shift interlock plate cover and No. 1 shift inner lever from the shift interlock plate.
  12.  
  13. Using a pin punch and a hammer drive out the select inner lever slotted spring pin.
  14.  
  15. Remove the select inner lever, No. 1 compression spring and No. 1 select spring seat.
  16.  
  17. Remove the remaining snapring.
  18.  
  19. Remove the control shaft cover and dust boot.
  20.  
  21. If necessary, withdraw the oil seal from the control shaft cover. Using SST No. 09620-30010 or equivalent and a hammer, drive the new oil seal into the cover to a depth of 0-0.039 inch (0-1.00mm). After installation coat the new seal with multi-purpose grease.
  22.  

SHIFT AND SELECT LEVER SHAFT REASSEMBLY
  1. Lightly coat all sliding, mating and splined surfaces with multi-purpose grease.
  2.  
  3. Install the dust boot cover onto the control shaft cover.
  4.  
  5. Install the shift select lever onto the control shaft cover.
  6.  
  7. Using a piece of brass stock and a hammer, install the snapring and spring seat.
  8.  
  9. Install the No. 1 spring seat, No. 1 select spring and select inner lever in the proper order.
  10.  
  11. Using a pin punch and a hammer, drive in the select inner lever slotted spring pin.
  12.  
  13. Place the No. 1 shift inner lever into the interlock plate and install the interlock cover.
  14.  
  15. Using a pin punch and a hammer, drive in the No. 1 shift inner lever slotted spring pin.
  16.  
  17. Make sure that the shift interlock plate turns smoothly.
  18.  
  19. Install the No. 2 shift inner lever, No. 2 compression spring, transmission oil baffle and No. 2 select spring seat in the proper order.
  20.  
  21. Install the snapring. Using a pin punch and a hammer, drive in the No. 2 shift inner lever slotted spring pin.
  22.  

TRANSAXLE REASSEMBLY

WARNING
Prior to reassembling the transaxle, coat all the moving and sliding parts with clean lubricant of the same type with which it will be filled.

  1. Install the output shaft assembly to the transaxle case.
  2.  
  3. Install the transmission case to the transaxle case. If necessary, use a rubber mallet to coax the transaxle into place.
  4.  
  5. Install the seventeen transaxle case retaining bolts and torque the bolts to 22 ft. lbs. (29 Nm).
  6.  
  7. Install the output shaft rear bearing outer race.
  8.  
  9. Install the adjusting shim.
  10.  


WARNING
If the output shaft rear bearing is being re-used, install a shim of the same thickness as the old shim. If a new bearing is being installed, select a shim of lesser thickness than the old shim.

  1. Install the seven Torx® screws and torque them to 31 ft. lbs. (42 Nm).
  2.  
  3. Install a new locknut onto the output shaft.
  4.  
  5. Rotate the output shaft counterclockwise and clockwise a few times.
  6.  
  7. Using a torque meter, measure the preload of the output shaft. Preload for a new bearing is 6.9-13.9 inch lbs. and 4.3-8.7 inch lbs. for a used bearing. If the preload is not within specification, select the proper thickness shim to adjust the preload.
  8.  


WARNING
The pre-load changes approximately 3.5-4.3 inch lbs. with each shim thickness.

  1. Remove the locknut, seven Torx® screws and the adjusting shim.
  2.  
  3. Remove the seventeen retaining bolts and tap the case off with a rubber mallet.
  4.  
  5. Remove the output shaft rear bearing outer race.
  6.  
  7. Remove the output shaft assembly.
  8.  
  9. Install the oil pump assembly and temporarily install the two retaining bolts. Be careful not to drop the oil pump gasket.
  10.  
  11. Install the oil pipe with the two retaining bolts.
  12.  
  13. Torque the oil pipe and oil pump retaining bolts to 13 ft. lbs. (17 Nm).
  14.  
  15. Install the transaxle case magnet.
  16.  
  17. Install the differential case assembly.
  18.  
  19. Install the oil pump drive gear.
  20.  
  21. Lift the differential case up slightly and install the output shaft assembly.
  22.  
  23. Lean the output shaft assembly towards the differential case side and install the input shaft assembly.
  24.  


WARNING
When installing the input shaft assembly, be careful not to damage the oil seal.

  1. Install the reverse shift fork onto the No. 3 shift fork. Install and seat the snapring with a rubber mallet.
  2.  
  3. Place the No. 2 shift fork into the groove of the No. 2 hub sleeve.
  4.  
  5. Install the No. 3 shift fork shaft with the reverse shift fork into the transaxle case.
  6.  
  7. Place the No. 1 shift fork into the groove of the No. 1 hub sleeve.
  8.  
  9. Place the shift head onto the No. 1 shift fork.
  10.  
  11. Install the No. 2 shift fork shaft into the transaxle case through the No. 2 shift fork, the shift head and the No. 1 shift fork.
  12.  
  13. Using a magnetic finger, install the interlock roller into the reverse shift fork by aligning the groove of the No. 1 shift fork shaft with the interlock roller hole of the reverse shift fork.
  14.  
  15. Install the No. 1 shift fork shaft into the transaxle case through the No. 1 and reverse shift forks. If this is difficult to do, pull up on the No. 3 shift fork shaft and then try to install the No. 1 shift fork again.
  16.  
  17. Install the 3 set bolts and torque them to 17 ft. lbs. (24 Nm).
  18.  
  19. Install the two locking balls, springs and spring seats.
  20.  
  21. Coat the threads of the two screw plugs with Loctite® sealant or equivalent liquid sealant. Install the two plugs and torque them to 18 ft. lbs. (25 Nm).
  22.  
  23. Install the reverse idler gear shaft (with the gear and thrust washer) into the transaxle case.
  24.  
  25. Align the matchmarks on the gear with the matchmarks on the case.
  26.  
  27. Place the reverse shift fork into the reverse shift arm. Connect the reverse shift arm bracket to the transaxle case and temporarily install the retaining bolt.
  28.  
  29. Install the No. 2 oil pipe and torque the two retaining bolts and the reverse shift arm bracket bolt to 13 ft. lbs. (17 Nm).
  30.  
  31. Install a new gasket onto the No. 2 oil pipe.
  32.  
  33. Remove any old packing material from the transaxle case contact surfaces and apply a bead of new seal packing No. 08826-00090, Three Bond® 1281 or equivalent to the case.
  34.  
  35. As soon as the sealant is applied, install the transmission case with the seventeen retaining bolts. Torque the bolts to 22 ft. lbs. (29 Nm).
  36.  
  37. Install the reverse idler gear retaining bolt and gasket. Torque the bolt to 22 ft. lbs. (29 Nm).
  38.  
  39. Install the locking ball, spring and spring seat.
  40.  
  41. Coat the threads of the screw plug with Loctite® 242 or equivalent sealer, install and torque the plug to 18 ft. lbs. (25 Nm).
  42.  
  43. Using a rubber mallet, install the two snaprings onto the shift fork shafts.
  44.  
  45. Install the output shaft rear bearing outer race.
  46.  
  47. Install the adjust shim.
  48.  
  49. Using snapring pliers, install the snapring onto the input shaft bearing.
  50.  
  51. Coat the threads of the seven Torx® screws with Loctite® 242 sealant or equivalent. Install the screws and torque them to 31 ft. lbs. (42 Nm).
  52.  
  53. Install the spacer, needle roller bearings and the 5th gear.
  54.  
  55. Install the synchronizer ring and the key spring onto the No. 3 clutch hub.
  56.  
  57. Using SST No. 09310-17010 or equivalent, install the No. 3 clutch hub with synchronizer ring and key spring.
  58.  
  59. Select a snapring that will allow minimum axial play and install onto the shaft using a brass bar and a hammer.
  60.  
  61. Using a dial indicator, measure the 5th gear thrust clearance. The standard thrust clearance is 0.004-0.022 inch (0.10-0.57mm).
  62.  
  63. Using SST No.09310-17010 or equivalent, install the 5th driven gear.
  64.  
  65. Install the No. 3 hub sleeve and the No. 3 shift fork with the set bolt. Torque the set bolt to 17 ft. lbs. (24 Nm).
  66.  
  67. Engage the gear double meshing and install the new locknut. Torque the locknut to 90 ft. lbs. (123 Nm), stake the nut with a small cold chisel and disengage the double meshing.
  68.  
  69. Remove any old packing material from the transmission case cover contact surfaces and apply a bead of new seal packing No. 08826-00090, Three Bond® 1281 or equivalent to the cover.
  70.  
  71. As soon as the sealant is applied, install the cover with the retaining bolts. Torque the retaining bolts to 22 ft. lbs. (29 Nm).
  72.  
  73. Install the shift shaft select lever assembly with new gasket and coat the threads of the bolts with Loctite® 242 or equivalent. Install the bolts and torque them to 14 ft. lbs. (20 Nm). Install the lock bolt with new gasket and torque it to 36 ft. lbs. (36 Nm).
  74.  
  75. Install the No. 2 selecting bellcrank with the support. Coat the threads of the two retaining bolts with Loctite® 242 or equivalent. Install and torque the bolts to 14 ft. lbs. (20 Nm).
  76.  
  77. Install the back-up light switch and torque it to 30 ft. lbs. (40 Nm).
  78.  
  79. Install the speedometer driven gear.
  80.  
  81. Coat the clutch release bearing inside hub, input shaft spline and release fork contact surface with molybdenum disulfide lithium based grease.
  82.  
  83. Coat the front surface of the release bearing with multi-purpose grease.
  84.  
  85. Coat the intermediate shaft with multi-purpose grease.
  86.  
  87. With a rubber mallet, drive the intermediate shaft straight into the top of the shaft touches the differential pinion shaft.
  88.  
  89. Measure the protrusion length of the shaft. The protrusion length should be 255mm.
  90.  
  91. Remove any of the old packing material from the transfer assembly contact surfaces. Apply a bead of new seal packing No. 08826-00090, Three Bond® 1281 or equivalent to the transfer assembly.
  92.  
  93. As soon as the sealant is applied, install the transfer assembly to the transaxle by shifting into 4th gear and installing the transfer assembly while turning the transaxle input shaft.
  94.  
  95. Coat the threads of the transfer case retaining bolts with Loctite® 242 or equivalent sealant. Install the three bolts and two nuts and torque them to 51 ft. lbs. (69 Nm).
  96.  
  97. Move the select lever to the viscous mode position and lock it in place with the lock bolt.
  98.  

 
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