Subassembly-Recondition
Transaxle CaseRemove Input Shaft Front Bearing Cup:
Install Input Shaft Front Bearing Cup:
Remove/Install Bearing Retaining Strap:
Remove Intermediate Shaft Front Bearing:
Bearing And Oil Feeder:
Use Tool C-4660-2A Screw. The screw has a larger hole in the lower end to fit over the larger oil feeder nipple.
Install Intermediate Shaft Front Bearing:
Intermediate Shaft Assembly
Intermediate Shaft Bearing Snap Ring:
Remove Intermediate Shaft Rear Bearing:
Intermediate shaft ball bearing seal color is blue.
Install Intermediate Shaft Rear Bearing:
When assembling intermediate shaft, make sure all speed gears turn freely.
Synchronizer Hub Snap Ring:
Remove 3-4 Synchronizer Hub And 3rd Speed Gear:
Install 3-4 Synchronizer Hub And 3rd Speed Gear:
Snap Ring And Split Thrust Washer Indexing:
CAUTION: Index snap ring 90 degrees to the split in the thrust washer, as shown.
1-2 Synchronizer (Dual Cone)
2nd Speed Gear:
Synchronizer Hub Snap Ring:
1st Speed Gear And 1-2 Synchronizer Assembly:
Split Thrust Washer:
Intermediate Shaft Assembly:
Synchronizers
1-2 And 3-4 Synchronizer Sleeves And Hubs:
5th Speed Synchronizer:
Synchronizer Identification:
Synchronizers:
CAUTION: 1-2 synchronizer assembly components must NOT be interchanged with any other synchronizer assembly, or with previous model years transaxles. They will NOT function correctly.
Selector Shaft housing
Remove/Install Selector Shaft Snap Ring And Boot:
Remove Selector Shaft Seal:
Install Selector Shaft Seal:
Remove/Install Selector Shaft E-Clip:
Remove/Install Selector Shaft:
Selector Shaft Housing Components:
Differential Bearing Reatainer
Remove Differential Bearing Retainer Seal:
Install Differential Bearing Retainer Seal:
Remove Differential Bearing Retainer Cup:
Differential Bearing Retainer:
Install Oil Baffle:
Insert (Select) Shim And Differential Bearing Retainer Cup:
Extension Housing
Remove Extension Seal:
Install New Seal Into Extension:
Remove Extension Bearing Cup:
Extension:
Install Extension Oil Baffle:
Install Extension Bearing Cup:
Input Shaft
Determining Shim Thickness
Shim thickness need only be determined if any of the following parts are replaced:
a. transaxle case
b. input shaft seal retainer
c. bearing retainer plate
d. rear end cover
e. input shaft
f. input shaft bearings
Refer to "Bearing Adjustment Procedure" to determine proper shim thickness for correct bearing end play and proper turning torque.
Remove Input Shaft Rear Bearing Cone:
Install Input Shaft Rear Bearing Cone:
Remove Input Shaft Front Bearing Cone:
Install Input Shaft Front Bearing Cone:
Remove Input Shaft Rear Bearing Cup:
Install Input Shaft Rear Bearing Cup:
CAUTION: Bolt on bearing support plate before installing input shaft rear bearing cup.
Differential
Determining Shim Thickness
Shim thickness need only be determined if any of the following parts are replaced:
a. transaxle case
b. input shaft seal retainer
c. bearing retainer plate
d. rear end cover
e. input shaft
f. input shaft bearings
Refer to "Bearing Adjustment Procedure" to determine proper shim thickness for correct bearing end play and proper turning torque.
Remove Differential Bearing Cone:
Install Differential Bearing Cone:
Remove Differential Bearing Cone:
Install Differential Bearing Cone:
Remove/Install Ring Gear Bolts:
CAUTION: Always install new ring gear bolts. Bolts must be properly torqued to specification.
Remove Ring Gear:
Remove Roll Pin:
Install Roll Pin:
Ring Gear And Side Gear Removed:
CAUTION: Side gear end play must be within 0.001 to 0.013 inch. 4 select thrust washes are available: 0.032, 0.037, 0.042, and 0.047 Inch.
Remove/Install Pinion Shaft:
Differential Gears:
Side gear thrust washers are available in 4 select thickness: 0.032, 0.037, 0.042, and 0.047 inch.
Measure the depth from the differential case to the machined surface in 3 places, as shown, and measure the height of raised "step" on the ring gear. The difference, minus the proper side gear end play (0.001 to 0.013 inch) is the proper thrust washer thickness.
For the other side gear: After assembling the differential side gears, pinion gears, and pinion gears with the pinion gear washers but without the side gear thrust washers, rotate the assemble 2 full revolutions both clockwise and counter clockwise.
Set up dial indicator as shown, and record end play. Rotate side gear 90° and record another end play. Again, rotate side gear 90° and record a final end play.
Using the smallest end play recorded, shim that side gear to within 0.001 to 0.013 inch.
Determine Proper Side Gear Thrust Washer Thickness:
CAUTION: After reassemble of the differential assembly, insert the inner joint housing spline from a driveshaft into the side gear. By hand, turn the side gear with the joint housing spline. If the side gear will NOT turn, or it feels very tight, it will be necessary to remove the ring gear and install a thinner side gear thrust washer.
Checking Side Gear End Play:
Side gear thrust washers are available in 4 select thickness: 0.032, 0.037, 0.042, and 0.047 inch.
Bearing Adjustment procedure
GENERAL RULES ON SERVICING BEARINGS
1. Take extreme care when removing and installing bearing cups and cones. Use only an arbor press for installation, as a hammer may not properly align the bearing cup or cone. Burrs or nicks on the bearing seat will give a false end play reading while gauging for proper shims. Improperly seated bearing cups and cones are subject to low mileage failure.
2. Bearing cups and cones should be replaced if they show signs of pitting or heat distress. If distress is seen on either the cup or bearing rollers, both cup and cone must be replaced.
3. Bearing preload and drag torque specifications must be maintained to avoid premature bearing failures. Used (original) bearing may lose up to 50% of the original drag torque after break-in. All bearing adjustments must be made with no other component interference or gear intermesh.
4. Replace bearings as a pair. For example, if one differential bearing is defective, replace both differential bearings. If one input shaft bearing is defective, replace both input shaft bearings.
5. Bearing cones must not be reused if removed.
6. Turning torque readings should be obtained while smoothly rotating in either direction (breakaway reading is not indicative of the true turning torque).
7. Replace oil baffle, if damaged.
Input Shaft Bearing End Play Adjustment
1. Using Tool L-4656 with Handle C-4171, press input shaft front bearing cup slightly forward in case. Then, using Tool L-4655 with Handle C-4171, press bearing cup back into case, from front, to properly position bearing cup, before checking input shaft end play (see input shaft front bearing cup replace in "Subassembly Recondition"). This step is not necessary if Tool L-4655 was previously used to install input shaft front bearing cup in the case and no input shaft (select) shim has been installed since pressing cup into case.
2. Select a gauging shim which will give 0.025 to 0.254mm (0.001 to 0.010 inch) end play. SUGGESTION: Measure original shim from input shaft seal retainer and select a shim 0.254mm (0.010 inch) thinner than original for the gauging shim.
3. Install gauging shim on bearing cup and install input shaft seal retainer.
CAUTION: The input shaft seal retainer is used to draw the input shaft front bearing cup the proper distance into the case bore during this step. Alternately tighten input shaft seal retainer bolts until input shaft seal retainer is bottomed against case. Tighten bolts to 28 Nm (21 ft. lbs.).
4. Oil input shaft bearings with SAE 5W-30 engine oil and install input shaft in case. Install bearing retainer plate with input shaft rear bearing cup pressed in and bearing support plate installed. Tighten all bolts and nuts to 28 Nm (21 ft. lbs.).
Checking Input Shaft Bearing End Play To Determine Shim Thickness:
5. Position dial indicator to check input shaft end play. Apply moderate load, by hand, to input shaft splines. Push toward rear while rotating input shaft back and forth a number of times to settle out bearings. Zero dial indicator. Pull input shaft toward the front while rotating input shaft back and forth a number of times to settle out bearings. Record end play.
6. The shim required for proper bearing end play is the total of the gauging shim thickness, plus end play, minus (constant) end play of .051mm (0.002 inch). Combine shims, if necessary, to obtain a shim within .O4mm (0.0016 inch) of the required shim (see Shim Chart for proper shim[s]).
7. Remove input shaft seal retainer and gauging shim. Install shim(s) selected in step (6) and reinstall input shaft seal retainer with a 1/16 inch beat of RTV sealant. Record end play. Observe the CAUTION in step (3). Tighten input shaft seal retainer bolts to 28 Nm (21 ft. lbs.).
8. To verify that a preload condition does not exist, use Special Tool L-4508 and an inch-pound torque wrench to check input shaft turning torque. The turning torque should be less than 5 in. lbs.
CAUTION: Step (1) MUST be repeated every time a thinner shim is installed. This will assure that the input shaft bearing cup is pressed the proper distance into the case. If the turning torque is too high, install a .O4mm (0.0016 inch) thinner shim.
Checking Input Shaft Bearing Turning Torque:
9. Recheck input shaft turning torque. Repeat step (8) until the proper bearing turning torque is obtained. Observe "CAUTION" in step (8).
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
1. Remove bearing cup and existing shim from differential bearing retainer. (See Differential Bearing Retainer).
2. Select a gauging shim which will give 0.025 to 0.254mm (0.001 to 0.010 inch) end play. SUGGESTION: Measure original shim from differential bearing retainer and select a shim 0.381mm (0.015 inch) thinner than original for the gauging shim. Install gauging shim in differential bearing retainer and press in bearing cup. Installation of oil baffle is not necessary when checking differential assembly end play.
3. Oil differential bearings with SAE 5W-30 engine oil and install differential assembly in transaxle case. Check extension housing O-ring for damage (replace if necessary) and add a 1/16 inch bead of RTV sealant to extension flange. Install extension housing and differential bearing retainer. Torque bolts to specification.
4. Position transaxle with bell housing facing down on workbench with C-clamps. Position dial indicator.
Checking Differential Bearing End Play To Determine Shim Thickness:
5. Apply a medium load to differential using Tool CA995 with T-Handle in the downward direction while rolling differential assembly back and forth a number of times to settle bearings. Zero dial indicator. To obtain end play readings, apply a medium load in the upward direction while rolling differential assembly back and forth a number of times to settle out the bearings. Record end play.
Differential Bearing Shim Chart:
6. The Shim required for proper bearing preload is the total of the gauging shim thickness, plus end play, plus (constant) preload of 0.254mm (0.010 inch). Combine shims, if necessary, to obtain a shim within .05mm (0.002 inch) of the required shim (see Shim Chart for proper shim[s]).
7. Remove differential bearing retainer. Remove bearing cup and gauging shim. Properly install oil baffle. Be sure oil baffle is not damaged. Install shim(s) selected in step (6) and press in the bearing cup into differential bearing retainer.
8. Using a 1/16 inch bead of RTV sealant for a gasket, install differential bearing retainer. Torque all bolts to specification.
Checking Differential Bearing Turning Torque:
9. Using Special Tool C-4995 and an inch-pound torque wrench, check turning torque of the differential assembly in clockwise and counterclockwise directions. The turning torque should be 9 to 14 in. lbs. for new bearings or a minimum of 6 in. lbs. for used bearings. If the turning torque is too high, install a .05mm (0.002 inch) thinner shim. If the turning torque is too low, install a .05mm,(0.002 inch) thicker shim.
10. Recheck turning torque. Repeat Step (9) until the proper turning torque is obtained.