SECONDARY GEAR AND OUTPUT GEAR END PLAY MEASUREMENT/ADJUSTMENT

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Preparation Before Servicing

1. Print out the measurement/adjustment value input sheet. (See MEASUREMENT/ADJUSTMENT VALUE INPUT SHEET.)

Note

• When performing the measurement/adjustment, input the measured and calculated values into the measurement/adjustment value input sheet.

• If the measurement/adjustment value input sheet has already been printed out for the other measurements/adjustments, use the sheet.

Secondary Gear and Output Gear End Play Measurement/Adjustment

1. Calculate distance A of the converter housing using the following procedure:

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A :Distance A

B :Converter housing end (alignment surface with transaxle case)

(1) Remove any remaining old sealant on the contact surfaces of the transaxle case and converter housing.

(2) Set the transaxle case of the converter housing so that the mating surface side is facing upward.

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(3) Measure the thickness of the straight edge rulers.

Note

• Recommended measuring instrument: Micrometer

(4) Input the straight edge ruler thickness into the measurement/adjustment value input sheet.

(5) Set 2 straight edge rulers and the depth micrometer to the converter housing.

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A :Straight edge ruler

(6) Measure the optional positions (3 locations) shown in the figure with a depth micrometer and subtract the thickness of the straight edge ruler to calculate distance A.

Note

• Recommended measuring instrument: Depth micrometer, straight edge ruler

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A :Measurement location

(7) Input distance A and distance A average value into the measurement/adjustment value input sheet.

(8) Remove the 2 straight edge rulers and depth micrometer from the converter housing.

2. Assemble the thrust needle bearing.

Note

• Thrust needle bearing size: Outer diameter approx. 67 mm {2.6 in}

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3. Assemble the secondary gear and output gear.

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4. Assemble the thrust needle bearing.

Note

• Thrust needle bearing size: Outer diameter approx. 39.4 mm {1.55 in}

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5. Calculate distance B of the secondary gear and output gear using the following procedure.

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A :Distance B

B :Transaxle case end (alignment surface with converter housing)

(1) Measure the thickness of the SST (49 G027 004).

Note

• Recommended measuring instrument: Micrometer

(2) Input the thickness of the SST in the measurement/adjustment value input sheet.

(3) Install the thickness measured SST on to the thrust needle bearing.

Caution

• Install the SST to the center of the thrust needle bearing to reduce measurement differences on the secondary gear and output gear end play measurement.

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(4) Set the 2 straight edge rulers and depth micrometer to the transaxle case.

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A :Straight edge ruler

(5) Measure near the SST center with a depth micrometer.

Caution

• Measure near the center of the SST to reduce measurement differences on the secondary gear and output gear end play measurement.

Note

• Recommended measuring instrument: Depth micrometer, straight edge ruler

(6) Input the depth micrometer measurement value into the measurement/adjustment value input sheet.

(7) Perform the following calculation to calculate distance B.

Distance B = A - D - E

A: Straight edge ruler thickness

D: SST thickness

E: Depth micrometer measurement value

Note

Example

A: Straight edge ruler thickness is 39.76 mm {1.565 in}

D: SST thickness is 15.00 mm {0.5906 in}

E: Depth Micrometer measurement value is 5.82 mm {0.229 in}

Distance B = 39.76 mm {1.565 in} - 15.00 mm {0.5906 in} - 5.82 mm {0.229 in}= 18.94 mm {0.7457 in}

(8) Input distance B into the measurement/adjustment value input sheet.

6. Select the appropriate shim from the following table.

Range^*

Shim thickness

Exceeds 1.644 mm {0.06472 in}, 1.694 mm {0.06669 in} or less

1.45 mm {0.0571 in}

Exceeds 1.594 mm {0.06276 in}, 1.644 mm {0.06472 in} or less

1.40 mm {0.0551 in}

Exceeds 1.544 mm {0.06079 in}, 1.594 mm {0.06276 in} or less

1.35 mm {0.0531 in}

Exceeds 1.494 mm {0.05882 in}, 1.544 mm {0.06079 in} or less

1.30 mm {0.0512 in}

Exceeds 1.444 mm {0.05685 in}, 1.494 mm {0.05882 in} or less

1.25 mm {0.0492 in}

Exceeds 1.394 mm {0.05488 in}, 1.444 mm {0.05685 in} or less

1.20 mm {0.0472 in}

Exceeds 1.344 mm {0.05291 in}, 1.394 mm {0.05488 in} or less

1.15 mm {0.0453 in}

Exceeds 1.294 mm {0.05094 in}, 1.344 mm {0.05291 in} or less

1.10 mm {0.0433 in}

Exceeds 1.244 mm {0.04898 in}, 1.294 mm {0.05094 in} or less

1.05 mm {0.0413 in}

Exceeds 1.194 mm {0.04701 in}, 1.244 mm {0.04898 in} or less

1.00 mm {0.0394 in}

Exceeds 1.144 mm {0.04504 in}, 1.194 mm {0.04701 in} or less

0.95 mm {0.037 in}

Exceeds 1.094 mm {0.04307 in}, 1.144 mm {0.04504 in} or less

0.90 mm {0.035 in}

Exceeds 1.044 mm {0.04110 in}, 1.094 mm {0.04307 in} or less

0.85 mm {0.033 in}

Exceeds 0.994 mm {0.0391 in}, 1.044 mm {0.04110 in} or less

0.80 mm {0.031 in}

Exceeds 0.944 mm {0.0372 in}, 0.994 mm {0.0391 in} or less

0.75 mm {0.030 in}

Exceeds 0.894 mm {0.0352 in}, 0.944 mm {0.0372 in} or less

0.70 mm {0.028 in}

Exceeds 0.844 mm {0.0332 in}, 0.894 mm {0.0352 in} or less

0.65 mm {0.026 in}

Exceeds 0.794 mm {0.0313 in}, 0.844 mm {0.0332 in} or less

0.60 mm {0.024 in}

Exceeds 0.744 mm {0.0293 in}, 0.794 mm {0.0313 in} or less

0.55 mm {0.022 in}

Exceeds 0.694 mm {0.0273 in}, 0.744 mm {0.0293 in} or less

0.50 mm {0.020 in}

Range^*	Shim thickness
Exceeds 1.644 mm {0.06472 in}, 1.694 mm {0.06669 in} or less	1.45 mm {0.0571 in}
Exceeds 1.594 mm {0.06276 in}, 1.644 mm {0.06472 in} or less	1.40 mm {0.0551 in}
Exceeds 1.544 mm {0.06079 in}, 1.594 mm {0.06276 in} or less	1.35 mm {0.0531 in}
Exceeds 1.494 mm {0.05882 in}, 1.544 mm {0.06079 in} or less	1.30 mm {0.0512 in}
Exceeds 1.444 mm {0.05685 in}, 1.494 mm {0.05882 in} or less	1.25 mm {0.0492 in}
Exceeds 1.394 mm {0.05488 in}, 1.444 mm {0.05685 in} or less	1.20 mm {0.0472 in}
Exceeds 1.344 mm {0.05291 in}, 1.394 mm {0.05488 in} or less	1.15 mm {0.0453 in}
Exceeds 1.294 mm {0.05094 in}, 1.344 mm {0.05291 in} or less	1.10 mm {0.0433 in}
Exceeds 1.244 mm {0.04898 in}, 1.294 mm {0.05094 in} or less	1.05 mm {0.0413 in}
Exceeds 1.194 mm {0.04701 in}, 1.244 mm {0.04898 in} or less	1.00 mm {0.0394 in}
Exceeds 1.144 mm {0.04504 in}, 1.194 mm {0.04701 in} or less	0.95 mm {0.037 in}
Exceeds 1.094 mm {0.04307 in}, 1.144 mm {0.04504 in} or less	0.90 mm {0.035 in}
Exceeds 1.044 mm {0.04110 in}, 1.094 mm {0.04307 in} or less	0.85 mm {0.033 in}
Exceeds 0.994 mm {0.0391 in}, 1.044 mm {0.04110 in} or less	0.80 mm {0.031 in}
Exceeds 0.944 mm {0.0372 in}, 0.994 mm {0.0391 in} or less	0.75 mm {0.030 in}
Exceeds 0.894 mm {0.0352 in}, 0.944 mm {0.0372 in} or less	0.70 mm {0.028 in}
Exceeds 0.844 mm {0.0332 in}, 0.894 mm {0.0352 in} or less	0.65 mm {0.026 in}
Exceeds 0.794 mm {0.0313 in}, 0.844 mm {0.0332 in} or less	0.60 mm {0.024 in}
Exceeds 0.744 mm {0.0293 in}, 0.794 mm {0.0313 in} or less	0.55 mm {0.022 in}
Exceeds 0.694 mm {0.0273 in}, 0.744 mm {0.0293 in} or less	0.50 mm {0.020 in}

* :The range is the sum of the average value of distance A subtracted from distance B.

Range = C - F

C: Average value of distance A

F: Distance B

Note

Example

C: Average value of distance A is 20.15 mm {0.7933 in}

F: Distance B is 18.94 mm {0.7457 in}

Range = 20.15 mm {0.7933 in} - 18.94 mm {0.7457 in}= 1.21 mm {0.0476 in}, a shim of 1.00 mm {0.0394 in} thickness should be selected.

7. Remove the 2 straight edge rulers and depth micrometer from the transaxle case.

8. Remove the SSTs.

9. Remove the thrust needle bearing.

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10. Remove the secondary gear and output gear.

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11. Remove the thrust needle bearing.

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