BEARING PRELOAD ADJUSTMENT

id051500802700

Differential Preload Adjustment

1. Mount the clutch housing onto the transaxle hanger, and set the differential bearing race into the clutch housing. Position a piece of pipe against the bearing race and tap it in until it contacts the clutch housing.

2. Set the bearing race into the SST (selector) as shown in the figure.

Note

• Turn the selector to eliminate the gap indicated by the arrow in the figure.

3. Set the differential component into the clutch housing, and set the bearing race and the SST (selector) on the differential.

4. Set the SST (collars) in the positions shown in the figure.

5. Install the transaxle case and tighten the SST (bolts) to the specified torque.

Tightening torque

37.3-52.0 N·m {3.9-5.3 kgf·m, 28.2-38.3 ft·lbf}

6. To seat the bearing, mount the SST (bars) on parts A and B of the selector, and turn the selector so the gap is widened. Then turn the SST in the reverse direction until the gap is eliminated.

7. Manually expand the selector until it no longer turns by hand.

8. Use a feeler gauge to measure the gap in the SST (selector).

Caution

• Measure the gap around the entire circumference of the selector.

9. Add 0.15 mm {0.006 in} to the measured clearance and select the combination of shims closest in value to that measurement.

Example

0.32 mm {0.013 in}

0.32 mm {0.013 in} + 0.15 mm {0.006 in} = 0.47 mm {0.019 in}

Nearest shim (on thick side) to 0.47 mm {0.019 in} is 0.50 mm {0.020 in}

Differential adjust shim thickness (mm {in})

0.1 {0.004}

0.20 {0.008}

0.25 {0.010}

0.30 {0.012}

0.35 {0.014}

0.40 {0.016}

0.45 {0.018}

0.50 {0.020}

0.55 {0.022}

0.60 {0.024}

0.65 {0.026}

0.70 {0.028}

0.75 {0.030}

0.80 {0.031}

0.85 {0.033}

0.90 {0.035}

0.95 {0.037}

1.0 {0.039}

1.05 {0.041}

1.10 {0.043}

1.15 {0.045}

1.20 {0.047}

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0.1 {0.004}	0.20 {0.008}	0.25 {0.010}	0.30 {0.012}
0.35 {0.014}	0.40 {0.016}	0.45 {0.018}	0.50 {0.020}
0.55 {0.022}	0.60 {0.024}	0.65 {0.026}	0.70 {0.028}
0.75 {0.030}	0.80 {0.031}	0.85 {0.033}	0.90 {0.035}
0.95 {0.037}	1.0 {0.039}	1.05 {0.041}	1.10 {0.043}
1.15 {0.045}	1.20 {0.047}	-	-

10. Remove the transaxle case and the SST.

11. Remove the selector and the differential.

12. Install the adjustment shim(s) and install the bearing race using the SST.

Caution

• Use the adjustment shim(s) selected during bearing preload adjustment.

13. Set the differential into the clutch housing.

14. Install the transaxle case, and tighten to the specified torque.

Tightening torque

37.3-52.0 N·m {3.8-5.3 kgf·m, 27.5-38.3 ft·lbf}

15. Install the SST and a pull scale or torque wrench.

16. Verify that the preload is within the specification.

• If not within the specification, return to Step 1.

Differential preload

1.4-1.9 N·m {14-20 kgf·cm, 13-17 in·lbf}

17. Remove the SST.

Primary Shaft Preload Adjustment

1. Install the primary shaft bearing races into the clutch housing.

2. Set the bearing race into the SST (selector) as shown in the figure.

Note

• Turn the selector to eliminate the gap indicated by the arrow in the figure.

3. Set the SST (selector) for the primary shaft in the clutch housing. Mount the shaft gear assemblies as shown in the figure.

4. Set the SST (collars) in the positions shown in the figure.

5. Install the transaxle case and tighten the SST (bolts) to the specified torque.

Tightening torque

37.3-52.0 N·m {3.9-5.3 kgf·m, 28.2-38.3 ft·lbf}

7. Manually expand the selector until it no longer turns by hand.

8. Use a feeler gauge to measure the gap in the SST (selector).

Caution

• Measure the gap around the entire circumference of the selector.

9. Take the maximum reading and determine the shim to used as follows.

• Select the thinnest allowable shim from the table to obtain standard clearance.

Tightening amount

0-0.05 mm {0-0.002 in}

Example

Reading from step 8: 0.57 mm {0.022 in}

Shim selecting range

(0.57 mm {0.022 in} + 0 mm {0 in})-(0.57 mm {0.022 in} + 0.05 mm {0.002 in}) = 0.57 mm {0.022 in}-0.62 mm {0.024 in}

Shim

0.60 mm {0.024 in}

Primary shaft gear adjust shim size (mm {in})

0.30 {0.012}

0.35 {0.014}

0.40 {0.016}

0.45 {0.018}

0.50 {0.020}

0.55 {0.022}

0.60 {0.024}

0.65 {0.026}

0.70 {0.028}

0.75 {0.030}

0.80 {0.032}

0.85 {0.034}

0.90 {0.036}

0.95 {0.038}

1.00 {0.040}

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0.30 {0.012}	0.35 {0.014}	0.40 {0.016}	0.45 {0.018}
0.50 {0.020}	0.55 {0.022}	0.60 {0.024}	0.65 {0.026}
0.70 {0.028}	0.75 {0.030}	0.80 {0.032}	0.85 {0.034}
0.90 {0.036}	0.95 {0.038}	1.00 {0.040}	-

10. Remove the transaxle case and the SST.

11. Remove the selector and primary shaft component.

12. Remove the bearing race.

13. Install the adjustment shim(s) and install the bearing race using the SST.

Caution

• Use the adjustment shim(s) selected during bearing preload adjustment.

14. Set the primary shaft gear component into the clutch housing.

15. Install the transaxle case, and tighten to the specified torque.

Tightening torque

37.3-52.0 N·m {3.8-5.3 kgf·m, 27.5-38.3 ft·lbf}

16. With the transaxle facing in the direction shown in the figure, install the SST to the primary shaft gear component.

17. Verify that the preload is within the specification.

• If not within the specification, return to Step 1.

Primary shaft gear preload

0.12-0.39 N·m {1.2-4.0 kgf·cm, 1.05-3.47 in·lbf}

18. Remove the SST.

Secondary Shaft Preload Adjustment

1. Install the secondary shaft bearing races into the clutch housing.

2. Set the bearing race into the SST (selector) as shown in the figure.

Note

• Turn the selector to eliminate the gap indicated by the arrow in the figure.

3. Set the SST (selector) for the secondary shaft in the clutch housing. Mount the shaft gear assemblies as shown in the figure.

4. Set the SST (collars) in the positions shown in the figure.

5. Install the transaxle case and tighten the SST (bolts) to the specified torque.

Tightening torque

37.3-52.0 N·m {3.9-5.3 kgf·m, 28.2-38.3 ft·lbf}

7. Manually expand the selector until it no longer turns by hand.

8. Use a feeler gauge to measure the gap in the SST (selector).

Caution

• Measure the gap around the entire circumference of the selector.

9. Take the maximum reading and determine the shim to used as follows.

• Select the thinnest allowable shim from the table to obtain standard clearance.

Tightening amount

0.03-0.08 mm {0.001-0.003 in}

Example

Reading from step 8: 0.57 mm {0.022 in}

Shim selecting range

(0.57 mm {0.022 in} + 0.03 mm {0.001 in})-(0.57 mm {0.022 in} + 0.08 mm {0.003 in}) = 0.60 mm {0.024 in}-0.65 mm {0.026 in}

Shim

0.60 mm {0.024 in}

Secondary shaft gear adjust shim size (mm {in})

0.20 {0.008}

0.25 {0.010}

0.30 {0.012}

0.35 {0.014}

0.40 {0.016}

0.45 {0.018}

0.50 {0.020}

0.55 {0.022}

0.60 {0.024}

0.65 {0.026}

0.70 {0.028}

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0.20 {0.008}	0.25 {0.010}	0.30 {0.012}	0.35 {0.014}
0.40 {0.016}	0.45 {0.018}	0.50 {0.020}	0.55 {0.022}
0.60 {0.024}	0.65 {0.026}	0.70 {0.028}	-

10. Remove the transaxle case and the SST.

11. Remove the selector and the secondary shaft component.

12. Remove the bearing race.

13. Install the adjustment shim(s) and install the bearing race using the SST.

Caution

• Use the adjustment shim(s) selected during bearing preload adjustment.

14. Set the secondary shaft gear component into the clutch housing.

15. Install the transaxle case, and tighten to the specified torque.

Tightening torque

37.3-52.0 N·m {3.8-5.3 kgf·m, 27.5-38.3 ft·lbf}

16. Install the SST and a pull scale or torque wrench.

17. Verify that the preload is within the specification.

• If not within the specification, return to Step 1.

Secondary shaft gear preload

0.2-0.3 N·m {2.0-4.0 kgf·cm, 1.8-3.4 in·lbf}

18. Remove the SST.