CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS ASSEMBLYSM2023747
CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS ASSEMBLY

D6E051517011102


Assembly Components

DPE515BM1014

1
Clutch housing
2
Differential component
3
Primary shaft component
4
Secondary shaft (No.1) component
5
Secondary shaft (No.2) component
6
Needle bearing
7
Reverse idler gear
8
Thrust washer
9
Reverse idler gear shaft
10
1st/2nd shift fork
11
Counter lever
12
3rd/4th control rod end (A)
13
3rd/4th control rod (A)
14
Counter lever pivot
15
Snap ring
16
3rd/4th shift fork
17
1st/2nd control rod
18
3rd/4th control rod end (B)
19
3rd/4th control rod (B)
20
Spring pin
21
Shift fork retaining bolt
22
Spring pin
23
Spring pin
24
Reverse shift fork
25
5th/6th shift fork
26
Reverse control rod
27
5th/6th control rod
28
Shift fork retaining bolt
29
Shift fork retaining bolt
30
Baffle plate
31
Sealing cap, spring seat, detent spring, detent ball
32
Transaxle case
33
Sealing cap
34
Reverse idler shaft retaining bolt
35
Shift component
36
Select lever set

E6U515ZMC0743

1
Clutch housing
2
Magnet
3
Primary shaft oil seal
4
Primary shaft front bearing
5
Oil funnel
6
Secondary shaft (No.1) front bearing
7
Bearing cover
8
Bearing cover
9
Oil funnel
10
Secondary shaft (No.2) front bearing outer race
11
Differential side bearing outer race
12
Differential oil seal
13
Pivot pin
14
Transaxle case
15
Snap ring
16
Snap ring
17
Oil pass
18
Adjust shim
19
Secondary shaft (No.2) rear bearing outer race
20
Adjust shim
21
Differential side bearing outer race
22
Control rod bearing
23
Shift lever shaft bearing
24
Differential oil seal
25
Sealing cap
26
Neutral switch
27
Select push pin
28
Back-up light switch
29
Shift push pin
30
Straight pin
31
Oil level plug
32
Drain plug
33
Knock ring


Assembly Procedure

1.Install a new primary shaft oil seal in the clutch housing using the SST.
E6U515ZMC1085
E6U515ZMC1547
Oil seal press-in depth
4.4-5.0 mm {0.17-0.19 in}

2.Install a new primary shaft front bearing using the SST.
E6U515ZMC1099

3.Install the oil funnel for in the secondary shaft (No.1 and No.2) to the clutch housing.
E6U515ZMC11011
Note
• Align the clutch housing groove and the funnel projection, and insert.
• Lubrication hole can be positioned either on the left or right.

4.Install a new secondary shaft (No.1) front bearing using the SST.
E6U515ZMC11113

5.Install the secondary shaft (No.2) front bearing outer race using the SST.
E6U515ZMC11215

6.Install the primary shaft bearing cover and secondary shaft (No.1) bearing cover.
E6U515ZMC11317
Tightening torque
6.8-15.8 N·m
{69.4-161 kgf·cm, 60.2-139 in·lbf}

7.Install the differential side bearing outer race to the clutch housing using the SST.

(Except L3 Turbo)

DPE515BM101619
(L3 Turbo)
E6U515ZMC15521

8.Install the differential side bearing outer race and adjust shim to the transaxle case using the SST.
E6U515ZMC11423
Note
• Use the adjust shim selected in the differential side bearing preload adjustment.
(See DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT.)

9.Install a new differential oil seal to the clutch housing using the SST.

(4x2)

D6E515ZM420125
(4x4)
E6U515ZMC15827

10.Install the secondary shaft (No. 2) rear bearing outer race and adjust shim to the transaxle case using the SST.

E6U515ZMC11529
Note
• Use the adjust shim selected in the secondary shaft (No. 2) bearing preload adjustment.
(See SECONDARY SHAFT (NO.2) BEARING PRELOAD ADJUSTMENT.)

11.Install a new differential oil seal to the transaxle case using the SST.
E6U515ZMC11731
E6U515ZMC15633
Oil seal press-in depth
-0.5-0.5 mm {-0.019-0.019 in}

12.Install the new control rod bearings to the clutch housing and transaxle case using the SST.
E6U515ZMC16335
Note
• Assembling direction can be either way.
E6U515ZMC16437
Bearing press-in depth
0-0.5 mm {0-0.019 in}

13.Install a new shift lever shaft bearing to the transaxle case using the SST.
E6U515ZMC16838
Note
• Assembling direction can be either way.
E6U515ZMC16939
Bearing press-in depth
0-0.5 mm {0-0.019 in}

14.Install the snap rings to the transaxle case.
E6U515ZMC11640

15.Install each gear component.

(1) Install the differential to the clutch housing.
E6U515ZMC04341
Caution
• Installing the primary shaft can damage the oil seal, reducing the performance of the transaxle. When installing the primary shaft to the clutch housing, be careful not to damage it.
(2) Install the primary shaft component and secondary shaft (No.1) component to the clutch housing at the same time.
E6U515ZMC04442
(3) Install the secondary shaft (No.2) component.
E6U515ZMC04543
(4) Install the reverse idler gear, needle bearing, thrust washer, and reverse idler gear shaft.
E6U515ZMC04644
Caution
• Align the thrust washer rotation lock projection and reverse idle gear shaft groove.
• Position the shaft direction as shown in the figure for the transaxle case assembly.
E6U515ZMC11945

16.Install the 1st/2nd shift fork.

17.Install the counter lever and 3rd/4th control rod (A).
E6U515ZMC04746

18.Install the counter lever pivot and secure it with the snap ring.
E6U515ZMC04847

19.Install the 3rd/4th shift fork and then install the 1st/2nd control rod ball groove in the direction shown in the figure.
E6U515ZMC04948

20.Install 3rd/4th control rod end (B) so that it engages with the counter lever as shown in the figure.
E6U515ZMC05049

21.Install the 3rd/4th control rod (B) ball groove in the direction shown in the figure.
E6U515ZMC05150

22.Tap in 3rd/4th control rod end (A and B) new spring pins shown in the figure.
E6U515ZMC0522

23.Tap in 3rd/4th shift fork spring pin using a pin punch.

24.Install the 1st/2nd shift fork retaining bolt.
E6U515ZMC0144
Tightening torque
15.7-23.5 N·m
{1.7-2.3 kgf·m, 11.6-17.3 ft·lbf}

25.Install the 5th/6th shift fork and reverse shift fork.
E6U515ZMC0546

26.Install the 5th/6th control rod and reverse control rod being careful of the ball groove direction.

27.Install the reverse shift fork retaining bolt and 5th/6th shift fork retaining bolt.
E6U515ZMC0128
Tightening torque
15.7-23.5 N·m
{1.7-2.3 kgf·m, 11.6-17.3 ft·lbf}

28.Install the baffle plate.
E6U515ZMC01010
Tightening torque
6.0-11.0 N·m
{61.2-112.1 kgf·cm, 53.2-97.3 in·lbf}

29.Install the detent ball, detent spring, detent spring seat, and sealing cap to the clutch housing.
E6U515ZMC13712
E6U515ZMC13814

30.Install the magnet to the clutch housing.

31.Install the oil pass to the transaxle case.

32.Install the transaxle case.

(1) Apply a light coat of silicone sealant to the contact surfaces of the transaxle case and the clutch housing.
E6U515ZMC12016
(2) Place the transaxle case on the clutch housing.
(3) Install the bolt (M8 x 1.25) to the secondary shaft (No. 1) through the sealing cap hole.
(4) While pulling up the secondary shaft (No. 1) installation bolt, widen the snap ring, and then fix the snap ring into the secondary shaft bearing groove as shown in the figure.
E6U515ZMC12118
(5) While pushing up the primary shaft from the clutch housing side, widen the snap ring (primary shaft side) and fix it into the primary shaft bearing groove.
E6U515ZMC12220
(6) Measure the center-to-center distance of the respective snap ring holes as shown in the figure and verify that the snap ring is properly installed in the bearing groove.
E6U515ZMC12322
(7) Install the bolts to the transaxle case and clutch housing as shown in the figure.
Front side fixing bolts
DPE515BM100524
Tightening torque
23.6-35.2 N·m
{2.5-3.5 kgf·m, 17.5-25.9 ft·lbf}
Rear side fixing bolts
DPE515BM100626
Tightening torque
23.6-35.2 N·m
{2.5-3.5 kgf·m, 17.5-25.9 ft·lbf}

33.Install the new sealing caps.
E6U515ZMC14928

34.Install the reverse idler shaft retaining bolt with new packing.

Tightening torque
69.6-90.4 N·m
{7.1-9.2 kgf·m, 51.4-66.6 ft·lbf}

35.Apply a coat of silicone sealant to the contact surface of the shift control case and the transaxle case.
E6U515ZMC14830

36.Install the select lever set and the shift component to the transaxle case.

Caution
• Apply grease to the positions shown in the figure.
E6U515ZMC15732
DPE515BM101534
Caution
• Be aware that the stem lengths of bolt A and B shown in the figure are different.
Tightening torque
14.9-22.3 N·m
{1.6-2.2 kgf·m, 11.0-16.4 ft·lbf}

37.Install the neutral switch and back-up light switch with new packing.

Tightening torque
28.2-52.2 N·m
{2.9-5.3 kgf·m, 20.8-38.5 ft·lbf}

38.Install a new straight pin.
E6U515ZMC00236
Tightening torque
21.0-39.0 N·m
{2.2-3.9 kgf·m, 15.5-28.7 ft·lbf}

39.Install a new shift push pin.

Tightening torque
20.6-38.2 N·m
{2.1-3.8 kgf·m, 15.2-28.1 ft·lbf}

40.Install a new select push pin.

Tightening torque
27.5-50.9 N·m
{2.9-5.1 kgf·m, 20.3-37.5 ft·lbf}

41.Install new packing, a drain plug, and a oil level plug.

Tightening torque
27.5-50.9 N·m
{2.9-5.1 kgf·m, 20.3-37.5 ft·lbf}