Step 1

ASSEMBLY-STEP 1
Assemble in the numbered order shown in the image.

NOTE: During assembly, check the thrust clearance of each gear.




Clutch Hub Assembly
Install the synchronizer key-spring in the clutch hub by placing the hook in its groove. This holds the three synchronizer keys in place.

CAUTION:
a. The synchronizer keys for the 5th gear are to be installed in one direction.
b. The size of each synchronizer key is different.







Specification are as follows:
c. When assembling the clutch hub for fifth and reverse gear, the larger end of the synchronizer key must face the lock nut.




Bearing Inner Race (drive pinion end of secondary shaft gear)
Install the drive pinion end inner race on the secondary shaft gear with attachment (49 F401 335A) and a press, as shown in the image.




1st Gear Synchronizer Ring
The 1st synchronizer ring is different from the other synchronizer rings




Clutch Hub Assembly (1st - 2nd, 3rd - 4th)
Press the secondary shaft into the clutch hub assemblies (1st - 2nd and 3rd - 4th).

NOTE: Make sure the hub and shaft splines are aligned before applying pressure. Press to 19,620N (2,000 kg, 4,400 lb)




Thrust Washer
Install the thrust washer tangs into the holes in the groove.




Bearing Inner Race (4th gear end of secondary shaft gear)
Press the inner race on the end of the secondary shaft with body (49 F401 331) and attachment (49 F401 336A).

NOTE: Press to 19,620N (2,000 kg, 4,400 lb)




Thrust Clearance of 1st Gear
Measure the clearance between the 1st gear and the differential drive gear on the secondary shaft.

Standard: 0.14-0.37 mm (0.006-0.015 in)
Limit: 0.42 mm (0.017 in)




Thrust Clearance of 2nd Gear
Measure the clearance between the 2nd gear and the thrust washer.

Standard: 0.245-0.580 mm (0.010-0.023 in)
Limit: 0.63 mm (0.025 in)




Thrust Clearance of 3rd Gear
Measure the clearance between the 3rd gear and the thrust washer.

Standard: 0.095-0.38 mm (0.004-0.015 in)
Limit: 0.43 mm (0.017 in)




Thrust Clearance of 4th Gear
Measure the clearance between the 4th gear and the bearing inner race.

Standard: 0.09-0.4 mm (0.004-0.016 in)
Limit: 0.45 mm (0.018 in)




Bearing Inner Race (primary shaft)
Press the inner race on the end of the primary shaft (4th gear end) with body (49 F401 331) and attachment (49 F401 336A).
Press the inner race on the opposite end of the primary shaft (1st gear end) with body (49 F401 331) and attachment (49 F401 335A).




Shift Fork
Install both shift forks and the interlock sleeve, as in the image.




Bearing preload
Adjust the bearing preload by selecting adjustment shim(s).




1. Install the bearing outer race into the transaxle case (shims removed).
2. After mounting the clutch housing onto the transaxle hanger, tap in the differential bearing outer races with a hammer handle until it is flush with the end of the clutch housing.
Next, position a piece of pipe against the outer race and tap in with a hammer until it contacts the clutch housing.




3. As shown in the image, put the outer races into the selectors for primary (49 F401 383), for secondary (49 F401 382A).

CAUTION: Turn the selector to eliminate the gap indicated by the arrow in image.




4. Set the differential assembly into the clutch housing, and then mount the assembled selector (49 F401 381) and bearing outer race on the differential.
Mount the assembled selectors and bearing outer races for the primary and secondary shaft into the clutch housing.
Mount both shaft gear assemblies as shown in the image.




5. Mount the transaxle case to the shafts and the differential selector, as shown in the image.




6. Set the collars (49 F401 384) between the transaxle case and the clutch housing, and install the bolts (49 F401 386), and tighten to the specified torque.

Tightening torque: 18-20 Nm (1.8-2.0 m-kg, 13-14 ft-lb)




CAUTION: Install the collars at the positions shown in the image.




7. To seat the bearings, mount the bars (49 F401 385) on parts (A) and (B) of the selector, and then turn the selector so the gap shown by the arrow in the image is widened.
Move the bar by hand until the selector can no longer be turned, and then turn it in the reverse direction until the gap (arrow) is eliminated.




8. Manually expand the selector for both shafts until the selector no longer turns.

CAUTION: Make sure that each shaft gear turns smoothly.




9. Use a thickness gauge to measure the gap in the selector for both gears.

CAUTION: Measure the gap around the entire circumference of the selector.

10. Select an appropriate adjustment shim.




1. The shim to be used for the primary shaft gear should be selected by referring to the image and selecting the shim which is nearest (on the large side) to the value obtained, by subtracting the thickness of the diaphragm spring which goes between the shim and the race from the measured value of the gap in the selector.

Example: 0.94 mm (0.0370 in)
0.94 mm (0.0370 in) - 0.10 mm (0.0276 in) [Diaphragm spring] - 0.24 mm (0.009 in)
So the nearest shim (on the large side) to 0.24 mm (0.009 in) is 0.25 mm (0.010 in).




2. The shim to be used for the secondary shaft gear should be selected by referring to the image and selecting the shim which is nearest (on the large side) to the measured value of the gap in the selector.

Example: 0.39 mm (0.0154 in)
So the nearest shim (on the large side) to 0.39 mm (0.0154 in) is 0.40 mm (0.016 in).

CAUTION: The number of shims to be used must not be more than two.




11. Mount the preload adaptor (49 FT01 515A) onto the differential pinion shaft and then install the preload attachment (49 0180 510B).




12. Hook a spring scale on the preload attachment (49 0180 510B), and pull the scale to turn the attachment. Adjust the selector with the bars (49 F401 385) until the preload specification is obtained.

Preload: 0.5-0.75 Nm (5-7.6 cm-kg, 4.3-6.6 in-lb)
Reading on spring scale: 5-7.5 N (0.5-0.76 kg, 1.1-1.1 lb)




13. Use a thickness gauge to measure the gap in the selector for the differential.

CAUTION: Measure the gap around the entire circumference of the selector




14. Select an appropriate adjustment shim to be used for the differential. It should be selected by referring to the image and selecting the shim which is nearest (on the large side) to the largest measured value of the gap in the selector.

Example: 0.54 mm (0.021 in)
So the nearest shim (on the large side) to 0.54 mm (0.021 in) is 0.55 mm (0.022 in).

CAUTION: The number of shims to be used must not be more than three.




15. Remove the bolts (49 F401 386) and the collars (49 F401 384), and then remove the transaxle case. Remove the shaft gears, selectors, and the differential.
16. Remove the bearing outer races for both shafts from the transaxle case.
Leave the differential side bearing outer race in the clutch housing.