TRANSAXLE ASSEMBLY

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Step 1

1.  Perform the shim adjustment and select a shim of the appropriate thickness. (See SHIM ADJUSTMENT.)

2.  Assemble the SST (49 G019 0A0) to the SST (49 0107 680A).

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Bolt used
Part number: 9YA02 A220 or M12 × 1.75 bolt (length 40 mm {1.6 in})
Tightening torque
88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}

3.  Assemble the clutch housing component to the SST (49 G019 0A0).

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Bolt A
Part number: 99450 1055 or M10 × 1.25 bolt (length 55 mm {2.2 in}) and nut (M10 × 1.25)
Bolt A tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}
Bolt B
SST (component part for 49 G019 0A0: 49 G019 003)
Bolt B tightening torque
88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}
Bolt C
Part number: 9YA02 1080 or M10 × 1.5 bolt (length 55 mm {2.2 in})
Bolt C tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}
Bolt D
Part number: 99450 1030 or M10 × 1.25 bolt (length 30 mm {1.2 in})
Bolt D tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}

4.  Assemble the transaxle in the order shown in the figure.

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1
Clutch housing component
2
Differential
3
Secondary shaft component
(See Secondary shaft component and primary shaft component assembly note.)
4
Primary shaft component
(See Secondary shaft component and primary shaft component assembly note.)
5
Reverse idler gear
6
Reverse idler shaft
(See Reverse idler shaft assembly note.)
7
Reverse gate
(See Shift fork, shift rod end, shift rod, spring, and reverse gate assembly note.)
8
Spring
(See Shift fork, shift rod end, shift rod, spring, and reverse gate assembly note.)
9
Shift fork
(See Shift fork, shift rod end, shift rod, spring, and reverse gate assembly note.)
10
Shift rod end
(See Shift fork, shift rod end, shift rod, spring, and reverse gate assembly note.)
11
Shift rod
(See Shift fork, shift rod end, shift rod, spring, and reverse gate assembly note.)
12
Control set
13
Reverse lever component
14
Magnet
15
Shim
(See Transaxle case component assembly note.)
16
Transaxle case component
(See Transaxle case component assembly note.)
17
Gasket
(See Transaxle case component assembly note.)
18
Shift lever shaft anchor bolt
(See Transaxle case component assembly note.)


Secondary shaft component and primary shaft component assembly note

1.  Assemble the secondary shaft component and primary shaft component to the clutch housing component as a single unit.

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2.  Shake the assembled parts and assemble each one completely.


Reverse idler shaft assembly note

1.  Align the reverse idler shaft anchor bolt installation hole of the reverse idler shaft with the positioning mark of the clutch housing, and assemble the reverse idler shaft as shown in the figure.

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Shift fork, shift rod end, shift rod, spring, and reverse gate assembly note

1.  Assemble the shift fork (5GR/6GR), shift rod end (5GR/6GR), shift rod (5GR/6GR), spring, and reverse gate using the following procedure:

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(1)  Pass the shift rod through the assembly hole of the shift fork.
(2)  Pass the shift rod through the assembly hole of the shift rod end.
(3)  Pass the shift rod through the spring.
(4)  Pass the shift rod through the assembly hole of the reverse gate.
(5)  Assemble the shift fork to the clutch hub sleeve.
(6)  Verify the assembly direction of the shift rod.
Note
•  Assemble the shift rod so that the positioning pits used for verifying the assembly direction are facing the transaxle case side and the exterior side of the manual transaxle.
(7)  Install the spring as shown in the figure.

Shift rod end side

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Reverse gate side

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(8)  Assemble the shift rod to the clutch housing.
(9)  Tighten new bolts and assemble the shift rod end and the shift fork to the shift rod.

2.  Assemble the shift fork (3GR/4GR), shift rod end (3GR/4GR), shift rod end (reverse), and shift rod (3GR/4GR) using the following procedure:

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(1)  Assemble the shift fork to the clutch hub sleeve.
(2)  Verify the assembly direction of the shift rod.
Note
•  Assemble the shift rod so that the positioning pits used for verifying the assembly direction are facing the transaxle case side and the exterior side of the manual transaxle.
(3)  Pass the shift rod through the assembly hole of the shift fork.
(4)  Pass the shift rod through the assembly hole of the shift rod end (3GR/4GR).
(5)  Pass the shift rod through the assembly hole of the shift rod end (reverse).
(6)  Assemble the shift rod to the clutch housing.
(7)  Tighten new bolts and assemble the shift rod end and the shift fork to the shift rod.

3.  Assemble the shift fork (1GR/2GR), shift rod end (1GR/2GR), and shift rod (1GR/2GR) using the following procedure:

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(1)  Assemble the shift fork to the clutch hub sleeve.
(2)  Verify the assembly direction of the shift rod.
Note
•  Assemble the shift rod so that the positioning pits used for verifying the assembly direction are facing the transaxle case side and the exterior side of the manual transaxle.
(3)  Pass the shift rod through the assembly hole of the shift fork.
(4)  Set the shift rod end to the position shown in the figure and pass the shift rod through the assembly hole of the shift rod end.
(5)  Assemble the shift rod to the clutch housing.
(6)  Tighten new bolts and assemble the shift rod end and the shift fork to the shift rod.


Transaxle case component assembly note

1.  Apply silicone sealant TB1216B or equivalent to the clutch housing as shown in the figure.

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2.  Assemble the transaxle case component using the following procedure:

Caution
•  Assemble the transaxle case component before the applied silicone sealant starts to harden.
(1)  Rotate the control rod of the control set as shown in the figure.
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(2)  Hold the reverse idler gear so that the control set is in the reverse condition.
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(3)  Pull the shift lever in the direction shown in the figure.
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(4)  Align the select lever with the positioning mark and set it to the reverse position.
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(5)  Cover the transaxle case component.
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(6)  Rotate the shift lever in the direction shown in the figure.
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(7)  Press the shift lever in the direction shown in the figure.
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(8)  Assemble the shift lever shaft anchor bolt.
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(9)  Widen the clip using snap ring pliers and hold.
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(10)  While pressing the transaxle case so that it does not move, operate the select lever and shift lever to shift to 2nd gear, hold the secondary shaft component, and engage the clip with the groove of the ball bearing assembled to the secondary shaft.
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(11)  Tighten the transaxle case installation bolts and assemble the transaxle case component.
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Step 2

1.  Assemble the parts around the transaxle in the order shown in the figure.

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1
Gasket
2
Drain plug
3
Pin
4
Spring
5
Gasket
6
Plug
7
Oil seal
(See Oil seal assembly note.)
8
Service hole plate
(See Service hole plate assembly note.)
9
Reverse idler shaft anchor bolt
10
Gasket
11
Oil level plug
12
Gasket
13
Back-up light switch
14
Gasket (with i-stop)
15
Neutral switch No.2 (with i-stop)
16
Gasket
17
Neutral switch No.1
18
Detent ball
19
Spring
20
Gasket
21
Plug
22
Stud bolt
(See Stud bolt assembly note.)


Oil seal assembly note

1.   Assemble a new oil seal (LH) to the transaxle case using the SSTs.

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A: 0.3 mm {0.01 in}
B: 0.3 mm {0.01 in}

2.   Assemble a new oil seal (RH) to the clutch housing using the SSTs.

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A: 0.3 mm {0.01 in}
B: 0.3 mm {0.01 in}


Service hole plate assembly note

1.  Verify that there is no damage on the service hole plate installation surface.

2.  Apply silicone sealant TB1216B or equivalent to the service hole plate as shown in the figure.

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3.  Assemble the service hole plate.

Caution
•  Assemble the service hole plate before the applied silicone sealant starts to harden.


Stud bolt assembly note

1.  Assemble the stud bolts.

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2.  Measure the projection of the stud bolts.

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Projection A of stud bolt No.1
70.7—72.7 mm {2.79—2.86 in}
Projection B of stud bolt No.2
40.0—42.0 mm {1.58—1.65 in}
Projection C of stud bolt No.3
70.7—72.7 mm {2.79—2.86 in}
•  If the projection amount is not within the range, adjust the projection amount of the stud bolt.