Output Shaft Assembly
Tools Required
DT-48240 Output 5th/Reverse Synchronzer Installer
DT-48239 Output 5th Bearing Collar Installer
DT-48237 Output 3rd/4th Gear Installer
Assembly Procedure
Important : Lubricate all components in transaxle fluid before installation.
- Install the thrust washer using the DT-48240 and a hydraulic press.
- Install the collar using the DT-48240 and a hydraulic press.
- Install the needle bearings (3).
- Install the reverse gear (2).
- Install the reverse gear blocking ring (1).
- Install the 5th/Reverse synchronizer using the DT-48240 and a hydraulic press.
Important
- The raised center hub of the 5th/Reverse synchronizer assembly faces the 5th gear.
- Line up the blocking ring tabs and the hub keyways while pressing.
- Install the bearing collar using the DT-48239 and a hydraulic press.
- Install the 5th gear blocking ring (3).
- Install the two needle bearings (2).
- Install the 5th gear (1).
- Install the 3rd gear using the DT-48237 and a hydraulic press.
Important : The 3rd gear will install very tight. Ensure that the mating surfaces are clean.
- Apply Sealer-Retaining (Permatex 620) to the circumference of the input shaft before installing the 4th gear.
- Install the 4th gear using the DT-48237 and a hydraulic press.
Important : The 4th gear will install very tight. Ensure that the mating surfaces are clean.
Input Shaft Assembly
Tools Required
DT-48238 Input 5th Gear Installer
DT-48236 Input 3rd/4th Synchronizer Installer
Assembly Procedure
Important
- Lubricate all components with transaxle fluid before installation.
- The machined surface faces the needle thrust bearing.
- Apply Sealer-Retaining (Permatex 620) to the circumference of the input shaft before installing the 5th gear.
- Install the 5th gear using the DT-48238 and a hydraulic press.
- Install the thrust bearing (2).
- Install the two needle bearings (1).
- Install the 3rd gear (4).
- Install the 3rd gear blocking ring (3).
- Install the thrust bearing (2).
- Install the thrust washer (1).
- Install the 3rd/4th synchronizer using the DT-48236 and a hydraulic press.
Important
- The machined surface of the synchronizer faces the thrust washer.
- Make sure to align the slots in the synchronizer with the gear blocking ring tabs.
- Install the bearing collar using the DT-48236 and a hydraulic press.
- Install the 4th gear blocking ring (4).
- Install the needle bearing (3).
- Install the 4th gear (2).
- Install the thrust washer (1).
- Install the sleeve bearing using an appropriate tool.
Interm Shaft Assembly
Tools Required
DT-48235 Interm 1st/2nd synchronizer installer
Assembly Procedure
Important : Lubricate all components with transaxle fluid before installation.
- Install the needle bearing (5).
- Install the 2nd gear (4).
- Install the 2nd gear inner cone (3).
- Install the 2nd gear blocking ring (2).
- Install the 2nd gear outer cone (1).
- Install the 1st/2nd synchronizer using the DT-48235 and a hydraulic press.
Important
- Make sure to properly align the synchronizer to the gear and notches in the blocking ring.
- Observe the orientation of the synchronizer.The shoulder of the synchronizer faces 1st gear.
- Install the thrust washer (2) and the bearing collar (1) using the DT-48235 and a hydraulic press.
- Install the 1st gear outer cone (3).
- Install the 1st gear blocking ring (2).
- Install the 1st gear inner cone (1).
Important : The steps in both roller bearings must fall into the 1st gear.
- Install the roller bearing.
- Install the 1st gear.
- Install the roller bearing.
- Install the thrust washer using the DT-48235 and a hydraulic press.
Shift Shaft Assembly
Assembly Procedure
- Install the angle disc (4) onto the shift rod (5).
- Install the 1st/2nd pressure spring (3).
- Install the inner spring seat (2).
- Install new snap rings (1).
- Install the shift cover (4).
- Install the vent cap (3).
- Install the shift lever (1).
- Install a new coiled pin (2).
- Install the 5th/reverse pressure spring (1).
- Install the outer spring seat (2).
- Install the shift interlock (3) into the shift finger (4).
Important : Properly support the shift finger (4) when installing the coiled pin. Do not support the shift finger (4) with the shift interlock (3).
- Install a new coiled pin (5).
- Install a new coiled pin (6).
Major Component Assembly
Tools Required
DT-48179 Universal Driver Handle
DT-48182 Needle Sleeve Remover/Installer
DT-48225 Input Shaft Holder
DT-48226 Transaxle Housing Groove Ball Bearing Remover/Installer
DT-48227 Roller Bearing Remover/Installer
DT-48228 Clutch Housing Groove Ball Bearing Remover/Installer
DT-48230 Differential Bearing Race and Shaft Seal Ring Installer
DT-48231 Input and Outupt Shaft Pusher/Puller
DT-48232 Input Shaft Synchro Body Protector
Assembly Procedure
- Install a new shaft seal ring to the clutch housing using the DT-48179 and the DT-48230.
- Install the Interm shaft groove ball bearing to the clutch housing using the DT-48179 and the DT-48228.
- Install the snap ring to the interm shaft groove ball bearing.
- Install the input shaft roller bearing to the clutch housing using the DT-48179 and the DT-48227.
- Install a new shaft seal ring to the transaxle housing using the DT-48179 and DT-48230.
- Install the input shaft and output shaft groove ball bearings into the transaxle housing using the DT-48179 and the DT-48226.
- Install the needle sleeve flush with the casting in the transaxle housing using the DT-48179 and the DT-48182.
- Install the reverse shifting blocker(1), the torsion spring(2), and a new thread pin(3) to the transaxle housing
Tighten
Tighten the thread pin to 6~9 N•m (53~80 lb-in).
- Install the output shaft roller bearing to the clutch housing.
Important : Be careful the direction of roller bearing.
- Install Interm (1), input (2) and output (3) shaft assembly with the respective shift forks in the clutch housing.
- Install the DT-48232 and the input shaft retainer plug.
- Install the Interm (1) and input (2) shaft assembly with the respective shift forks.
Important : Position the Interm shaft to the groove ball bearing side.
- Install the output shaft assembly and the shift fork.
- After checking the gears engagement, install each the shaft assembly completely.
- Remove the DT-48232 and the input shaft retainer plug.
- Install the transaxle housing on the clutch housing.
- Input and output shaft must engage in the groove ball bearings in the transaxle housing.
- The Interm shaft and the shift forks must sit in their opposing bearings in the transaxle housing.
- Install the DT-48231 on the transaxle housing.
- Tighten the four bolts (1).
- Screw the spindles into the input and output shaft.
- Draw the input and output shaft evenly into the groove ball bearings in the transaxle housing.
- Hold the spindles (2) using a suitable tool.
- Turn via nuts (3) in direction of arrow.
- Remove the DT-48231 from the transaxle housing.
- Unscrew the spindles into the input and output shaft.
- Remove the four bolts(1).
Important : If large forces are necessary when actuating the DT-48231,separate the transaxle housing and the clutch housing again and check positioning of the shaft and shift forks. Repeat operation.
- Shift the transaxle into 4th and 5th gear using a screwdriver in an upward direction.
- Install new input and output shaft retainer plugs while holding the transaxle into 4th and 5th gear in an upward direction.
Tighten
Tighten the input shaft retainer plug to 120~130 N•m (89~96 lb-ft).
Tighten the output shaft retainer plug to 120~130 N•m (89~96 lb-ft).
- Apply sealant (Loctite 5900) to the transaxle housing rear cover.
Important : Leave area free in order not to block up the oil pipe.
- Install the oil pipe and transaxle housing rear cover.
Important : The oil pipe only installs in one direction. Ensure the oil pipe is completely seated in the gear shafts.
- Install the transaxle housing rear cover bolts.
Tighten
Tighten the rear cover bolts to 20~25 N•m (15~18 lb-ft).
- Remove the clutch housing from the transaxle housing.
Important : In line with the Interm shaft, use suitable tools to assist in the housing separation.
- Install the idle shift rail (1) into the transaxle housing.
- Install the idle shift rail bushing (2) to the transaxle housing.
- Install the drain channel (3) into the transaxle housing.
- Install the backup lamp switch and the washer to the transaxle housing.
Tighten
Tighten the backup lamp switch to 20 N•m (15 lb-ft).
- Install the shift shaft assembly.
- Apply sealer (Loctite 5203) to the transaxle housing to the gear shift cover mating surface.
- Position the transaxle into neutral.
- Install the shift shaft assembly (3).
- Install the select control lever (2).
- Install the shift retaining bolts.
Tighten
Tighten the shift retaining bolts to 20~25 N•m (15~18l b-ft).
- Install the shift guide bolt (1).
Tighten
Tighten the shift guide bolt to 20~25 N•m (15~18 lb-ft).
- Install the differential bearing race and the shim to the transaxle housing using the DT-48179 and the DT-48230. Refer to "Shimming Procedures" in this section.
- Install the differential bearing race and the shim to the clutch housing using the DT-48230 (For FWD) or the DT-48533 (For AWD) with the DT-48179. Refer to "Shimming Procedures" in this section.
- Install the magnet into the transaxle housing.
- Install the differential into the transaxle housing.
- Apply sealer (Loctite 5203) to the transaxle housing to clutch housing mating surface.
- Install the clutch housing to the transaxle housing.
Important
- The input and output shaft must engage in its bearing in the clutch housing.
- The Gear shift forks sit in their opposing bearings in the clutch housing.
- Hold the input shaft with the DT-48225.
- Draw the Interm shaft into the Interm shaft groove ball bearing with old retainer plug.
- Shift the transaxle into any gear.
- Install the clutch housing to transaxle housing bolts.
Tighten
Tighten the clutch housing to transaxle housing bolts to 20~25 N•m (15~18 lb-ft).
- Remove the old retainer plug from the Interm shaft, and Install a new retainer plug.
Tighten
Tighten the interm shaft retainer plug to 90~100 N•m (66~74 lb-ft).
- Remove the DT-48225.
- Install the transaxle housing to clutch housing bolts.
Tighten
Tighten the transaxle housing to clutch housing bolts to 20~25 N•m (15~18 lb-ft).
- Install a new oil pipe into the interm shaft.
- Install a new interm shaft sealing plug.
- Install the o-ring and concentric slave cylinder.
- After installing the pipe screw provisionally, tighten the concentric slave cylinder retaining bolts.
Tighten
Tighten the concentric slave cylinder retaining bolts to 8~12 N•m (71~106 lb-in).
- Tighten the pipe screw.
Tighten
Tighten the pipe screw to 16 N•m (12 lb-ft).
- Install the bushing to the concentric slave cylinder pipe.
- Install the shift control cable bracket, the washer, and the bolts.
Tighten
Tighten the shift control cable bracket bolts to 15~20 N•m (11~15 lb-ft).
- Install the transaxle into the vehicle. Refer to "Transaxle Assembly" in this section.
Shimming Procedures
Tools Required
DT-48200 transaxle housing fixing
DT-48241 transaxle housing race plate
DT-48242 clutch housing race plate
- Using a rubber mallet, tap lightly on the transaxle housing mating surface to ensure the bearings are fully seated.
- Install the DT-48200 to transaxle housing.
- Adjust the zero point setting for each place on the transaxle housing flange surface Using the DT-48200 and the height gage.
Important : Adjust the height of the DT-48200 for the zero point setting.
- Measure the three places on the output shaft gear thrust washer surface using the height gage.(average=A)
- The height from the transaxle housing flange surface to the thrust washer surface.
- Place the clutch housing differential bearing race, the differential, the transaxle housing differential bearing race, and the DT-48241 onto the DT-48242 (For FWD) or the DT-48534 (For AWD).
- Adjust the zero point setting for each place on the transaxle housing differential bearing race surface using the height gage.
- Measure the three places on differential ring gear surface using the height gage.(average=B)
- The height from the transaxle housing differential bearing race to the differential ring gear surface.
- Measure the three places on the DT-48242 (For FWD) or the DT-48534 (For AWD) using the height gage.(average=C)
- The height from the transaxle housing differential bearing race to clutch housing differential bearing race.
- To obtain shim size for transaxle housing shim use the following formula.
- S1(For Both FWD and AWD) = 62.92mm - A - B
- To obtain shim size for clutch housing shim use the following formula :
- S2 (For FWD) = 156.84mm - C - S1
- S2 (For AWD)= 158.09mm - C - S1
- SHIM SPEC (Tolerance : -0.03)
- - For FWD, shim size of the transaxle housing and the clutch housing.
- - For AWD, shim size of the transaxle housing.
(Unit : mm)
Part Number | Shim Size | Part Number | Shim Size |
96420170 | 0.50 | 96420161 | 0.95 |
96420169 | 0.55 | 96420160 | 1.00 |
96420168 | 0.60 | 96420159 | 1.05 |
96420167 | 0.65 | 96420158 | 1.10 |
96420166 | 0.70 | 96420157 | 1.15 |
96420165 | 0.75 | 96420156 | 1.20 |
96420164 | 0.80 | 96420155 | 1.25 |
96420163 | 0.85 | 96420154 | 1.30 |
96420162 | 0.90 | 96420153 | 1.35 |
- SHIM SPEC (Tolerance : -0.03)
- - For AWD, shim size of the clutch housing.
(Unit : mm)
Part Number | Shim Size | Part Number | Shim Size |
96420188 | 0.50 | 96420179 | 0.95 |
96420187 | 0.55 | 96420178 | 1.00 |
96420186 | 0.60 | 96420177 | 1.05 |
96420185 | 0.65 | 96420176 | 1.10 |
96420184 | 0.70 | 96420175 | 1.15 |
96420183 | 0.75 | 96420174 | 1.20 |
96420182 | 0.80 | 96420173 | 1.25 |
96420181 | 0.85 | 96420172 | 1.30 |
96420180 | 0.90 | 96420171 | 1.35 |
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