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toyota rav4 1994-2000 manual transaxle - hộp số sàn trên xe toyota rav4 đời 1994-2000

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HỘP SỐ SÀN TRÊN XE TOYOTA RAV4 ĐỜI 1994-2000

Trang 1

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem The numbers indicate the priority of the likelycause of the problem Check each part in order If necessary, replace these parts

17.Bearing (Worn or damaged)

MX−3 MX−9 MX−3 MX−9 MX−12 MX−79 MX−12 MX−79

Oil leakage

1 Oil (Level too high) 2WD

4WD

2 Gasket (Damaged)

3 Oil seal (Worn or damaged)

4 O−Ring (Worn or damaged)

MX−3 MX−9 MX−12 MX−79 MX−12 MX−79 MX−12 MX−78 MX−79

Hard to shift or will not shift

1 Control cable (Faulty)

2 Synchronizer ring (Worn or damaged)

3 Shift key spring (Damaged)

MX−77 MX−12 MX−29 MX−36 MX−12 MX−29 MX−36

Jumps out of gear

1 Locking ball spring (Damaged)

2 Shift fork (Worn)

3 Gear (Worn or damaged)

4 Bearing (Worn or damaged)

MX−12 MX−12 MX−79 MX−12 MX−79 MX−12 MX−79

Tight corner braking 1 Differential, Center differential (Faulty) MX−58

MX−72

Trang 2

BackưUp Light SwitchConnector

Control CableClip

Ground Cable

Transaxle Case Protector

Tie Rod End

RH Drive Shaft

Stiffener Plate

No.2 RearEnd Plate

z Snap Ring

z Cotter Pin

LH DriveShaft

PS Gear Assembly

Engine MountingCenter Member

RH Engine Under Cover

LH Engine Under Cover

Front Suspension CrossmemberAssembly with Stabilizer Bar

Clip

Air Cleaner CaseAssemblywith Air Hose

Snap Ring

Engine WireClamp

z Cotter PinLock Cap

Starter

N·m (kgf·cm, ft·lbf) : Specified torque

z Nonưreusable part

zz

ư

MANUAL TRANSAXLE MANUAL TRANSAXLE UNIT (2WD)

MANUAL TRANSAXLE UNIT (2WD)

COMPONENTS

Trang 3

2 REMOVE ENGINE COOLANT RESERVOIR TANK

3 REMOVE ENGINE WIRE CLAMP SET NUT

(b) Remove the 2 bolts, release cylinder and line

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

6 DISCONNECT GROUND CABLE

Remove the set bolt of the ground cable from the transaxle

BACKưUP LIGHT SWITCH CONNECTORS

8 DISCONNECT CONTROL CABLE

(b) Remove the 2 clips from the cables

9 REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING BOLTS

Torque:

Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf) Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)

Trang 4

MANUAL TRANSAXLE MANUAL TRANSAXLE UNIT (2WD)

10 REMOVE ENGINE LEFT MOUNTING INSULATOR SET BOLT AND 2 NUTS

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

11 INSTALL ENGINE SUPPORT FIXTURE

12 TIE PS GEAR ASSEMBLY TO ENGINE SUPPORT TURE BY CORD OR EQUIVALENT

FIX-13 REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

14 RAISE VEHICLE NOTICE:

Make sure that the vehicle is securely supported.

15 REMOVE LH AND RH ENGINE UNDER COVERS

16 DRAIN TRANSAXLE OIL Oil grade: API GL−4 or GL−5 Viscosity: SAE 75W−90 Capacity: 3.9 liters (4.1 US qts, 3.4 Imp qts) Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

17 REMOVE LH AND RH FRONT DRIVE SHAFTS (See page SA−18 )

18 REMOVE FRONT EXHAUST PIPE

(a) Remove the 3 nuts and gasket from the exhaust manifold

Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)

Trang 5

A

BA

B

DE

20 REMOVE ENGINE MOUNTING CENTER MEMBER

Remove the 4 bolts and center member

Torque:

Bolt D: 80 N·m (820 kgf·cm, 59 ft·lbf) Bolt E: 35 N·m (360 kgf·cm, 26 ft·lbf)

21 JACK UP TRANSAXLE SLIGHTLY

Using a trasmission jack, support the transaxle

22 DISCONNECT ENGINE LEFT MOUNTING BRACKET FROM ENGINE LEFT MOUNTING INSULATOR

Remove the set bolt of the engine left mounting bracket

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

23 REMOVE STIFFENER PLATE, NO.2 REAR END PLATE AND TRANSAXLE LOWER SIDE MOUNTING BOLT

(a) Remove the 2 bolts and stiffener plate

24 REMOVE TRANSAXLE

Lower the engine left side and remove the transaxle from theengine

HINT:

At the time of installation, please refer to the following items

S Align the input shaft with the clutch disc and install thetransaxle to the engine

S Temporarily tighten the transaxle mounting bolts

Trang 6

MANUAL TRANSAXLE MANUAL TRANSAXLE UNIT (2WD)

25 REMOVE TRANSAXLE CASE PROTECTOR

Remove the 2 bolts and protector

Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

Trang 7

When working with FIPG material, you must observe the following items.

S Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.

S Thoroughly clean all components to remove all the loose material.

S Clean both sealing surfaces with a non−residue solvent.

S Apply FIPG in an approx 1 mm (0.04 in.) wide bead along the sealing surface.

S Parts must be assembled within 10 minutes of application Otherwise, the FIPG material must be moved and reapplied.

re-HINT:

After installation, check and inspect items as follows

S Front wheel alignment (See page SA−4)

Trang 8

Q09030

Solenoid Hose No.1

Transfer Vacuum ActuatorBracket

Transfer Vacuum Actuator Assembly

Right Transfer Stiffener Plate

Center Transfer Stiffener Plate

Differential Lock Indicator Switch Connector

BackưUp LightSwitch ConnectorVehicle SpeedSensor Connector

Transaxle Case Protector

StarterStiffener Plate

N·m (kgf·cm, ft·lbf) : Specified torque

25 (250, 18)

37 (380, 27) 9.0 (95, 78 in.·lbf)

ư

MANUAL TRANSAXLE MANUAL TRANSAXLE UNIT (4WD)

MANUAL TRANSAXLE UNIT (4WD)

COMPONENTS

Trang 9

2 REMOVE TRANSAXLE CASE PROTECTOR

Remove the 2 bolts and transaxle case protector

5 REMOVE TRANSFER VACUUM ACTUATOR ET

BRACK-Remove the 4 bolts and bracket

(b) Remove the 2 bolts and transfer vacuum actuator bly

assem-Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

7 REMOVE RIGHT TRANSFER STIFFENER PLATE

Remove the 5 bolts and right transfer stiffener plate

Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

8 REMOVE CENTER TRANSFER STIFFENER PLATE

Remove the 3 bolts and center transfer stiffener plate

Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

9 REMOVE STIFFENER PLATE

Remove the 2 bolts and stiffener plate

Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

10 REMOVE TRANSAXLE FROM ENGINE

(a) Remove the 9 transaxle mounting bolts from the engine

Torque:

Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf) Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf) Bolt C: 29 N·m (300 kgf·cm, 22 ft·lbf) Bolt D: 46 N·m (470 kgf·cm, 34 ft·lbf) Bolt E: 25 N·m (250 kgf·cm, 18 ft·lbf) Bolt F: 9.0 N·m (95 kgf·cm, 78 in.·lbf)

Trang 10

Q06188

Q06189

MANUAL TRANSAXLE MANUAL TRANSAXLE UNIT (4WD)

(b) Pull straight until there is a gap of about 60−80 mm(2.4−3.1 in.) between the engine and transaxle case

(c) Move the transmission case cover in the direction, asshown in the illustration

(d) While holding transfer output, gently pull out whole axle

Trang 11

When working with FIPG material, you must observe the following items.

S Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.

S Thoroughly clean all components to remove all the loose material.

S Clean both sealing surfaces with a non−residue solvent.

S Apply FIPG in an approx 1 mm (0.04 in.) wide bead along the sealing surface.

S Parts must be assembled within 10 minutes of application Otherwise, the FIPG material must be moved and reapplied.

re-HINT:

After installation, do the road test

Trang 12

Clutch Release Fork Support

Control Lever HousingSupport Bracket

MagnetTransmissionOil Pipe

z Output Shaft CoverTapered Roller BearingOuter Race

z Front Oil SealInput Shaft FrontBearing

Transmission Oil PumpAssembly

Differential Case Assembly

Oil Pump Drive Gear

MANUAL TRANSAXLE MANUAL TRANSAXLE ASSEMBLY

MANUAL TRANSAXLE ASSEMBLY

COMPONENTS

Trang 13

z Output Shaft Cover

z Tapered Roller Bearing Outer Race

z Front Oil Seal

z Input Shaft Front Oil Seal

Transmission Oil PumpAssembly

Differential Case Assembly

Oil Pump Drive Gear

Differential Side Gear

Intermediate Shaft z Snap Ring

Trang 14

Reverse Restrict

Pin

L Straight Screw Plug

BackưUp Light Switch

No.3 Shift ForkNo.3 Shift Fork Shaft

Interlock Roller

Snap Ring Shift Head

Shift and Select LeverShaft Lock Bolt

No.2 Shift Fork Shaft

L Straight Screw Plug

Reverse Shift Arm Bracket Assembly

Snap RingReverse Shift ForkNo.1 Shift Fork

No.1 Shift Fork Shaft

SeatSpringBall

Slotted SpringPin

Snap Ring

Snap Ring

No.2 Shift Fork

No.2 Oil Receiver Pipe

Drain PlugFiller Plug

x10

x17

LL

Trang 15

N·m (kgf·cm, ft·lbf) : Specified torque

z Non−reusable part

L Precoated part

Output Shaft Assembly

Input Shaft Assembly

z Tapered Roller Bearing Outer Race

Reverse Idler Gear ShaftReverse Idler Gear

Thrust Washer

Rear Bearing Retainer

Needle Roller Bearing5th Driven Gear

Synchronizer Pull Ring

Key Spring

Middle SynchronizerRing

Snap Ring

z Output Shaft Lock Nut

5th Gear

No.3 Clutch HubNo.3 Hub SleeveKey Spring

Outer Synchronizer Ring

Inner Synchronizer Ring

Snap RingSpacerx7

MANUAL TRANSAXLE MANUAL TRANSAXLE ASSEMBLY

MX−15

Trang 16

REMOVE TRANSFER ASSEMBLY

Sealant:

Part No 08833ư00080, THREE BOND 1344, LOCTITE

242 or equivalent Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)

Protrusion length: 255.5 mm (10.06 in.)

3 REMOVE RELEASE FORK AND BEARING

4 REMOVE BACKưUP LIGHT SWITCH WITH GASKET Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)

5 REMOVE BOLT AND VEHICLE SPEED SENSOR Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

6 REMOVE NO.2 SELECTING BELLCRANK WITH LECTING BELLCRANK SUPPORT

SE-Remove the 2 bolts and No.2 selecting bellcrank with the lecting bellcrank support

se-Sealant:

Part No 08833ư00080, THREE BOND 1344, LOCTITE

242 or equivalent Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

Trang 17

9 REMOVE TRANSMISSION CASE COVER

Remove the 10 bolts and transmission case cover

11 REMOVE OUTPUT SHAFT LOCK NUT

(a) Unstake the lock nut

Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf)

12 REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK

(a) Remove the No.3 shift fork set bolt

Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)

(b) Remove the No.3 hub sleeve and No.3 shift fork

13 REMOVE 5TH DRIVEN GEAR

Using SST, remove the 5th driven gear

Trang 18

MANUAL TRANSAXLE MANUAL TRANSAXLE ASSEMBLY

14 MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE

(a) Using a dial indicator, measure the thrust clearance

Standard clearance:

0.10−0.57 mm (0.0039−0.0224 in.) Maximum clearance:

0.65 mm (0.0256 in.)

(b) Using a dial indicator, measure the radial clearance

Standard clearance:

0.009−0.050 mm (0.0004−0.0020 in.) Maximum clearance:

0.070 mm (0.0028 in.)

15 REMOVE NO.3 CLUTCH HUB AND 5TH GEAR

16 REMOVE NEEDLE ROLLER BEARING AND SPACER

17 REMOVE REAR BEARING RETAINER

Using a torx socket wrench (T45), remove the 7 torx screws andrear bearing retainer

Sealant:

Part No 08833−00080, THREE BOND 1344, LOCTITE

242 or equivalent Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)

Trang 19

18 REMOVE SNAP RING

(a) Using a snap ring expander, remove the input shaft rearbearing snap ring

(b) Using 2 screwdrivers and a hammer, remove the 2 snaprings

19 REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING AND LOCKING BALL

(a) Using a hexagon wrench (6 mm), remove the plug

Sealant:

Part No 08833−00080, THREE BOND 1344, LOCTITE

242 or equivalent Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

(b) Using a magnetic finger, remove the seat, spring andlocking ball

20 REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT Sealant:

Part No 08833−00080, THREE BOND 1344, LOCTITE

242 or equivalent Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

21 REMOVE TRANSMISSION CASE

Remove the 17 bolts and tap the case with a plastic hammer

(See page MX−27)

Trang 20

MANUAL TRANSAXLE MANUAL TRANSAXLE ASSEMBLY

23 REMOVE OUTPUT SHAFT REAR TAPER ROLLER BEARING OUTER RACE

Using SST and a hammer, remove the output shaft rear taperroller bearing outer race

24 REMOVE TRANSMISSION OIL PIPE

(a) Remove the gasket from the oil pipe

(b) Remove the 2 bolts and oil pipe

26 REMOVE REVERSE IDLER GEAR AND SHAFT

Pull out the shaft, remove the reverse idler gear and thrustwasher

(b) Using a magnetic finger, remove the 2 seats, springs andballs

28 REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD SET BOLT

Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)

29 REMOVE NO.1 SHIFT FORK SHAFT

Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.HINT:

At the time of reassembly, please refer to the following item.When it is difficult to push the fork shaft through the reverse shiftfork, pull up the No.3 shift fork shaft

Trang 21

30 REMOVE INTERLOCK ROLLER

Using a magnetic finger, remove the interlock roller from the verse shift fork

re-31 REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD AND NO.1 SHIFT FORK

(a) Pull out the No.2 shift fork shaft

(b) Remove the shift head and No.1 shift fork

32 REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO.2 SHIFT FORK

(a) Pull out the No.3 shift fork shaft with the reverse shift fork.(b) Remove the No.2 shift fork

33 REMOVE SNAP RING

ring and reverse shift fork from the No.3 shift fork shaft.(b) Using 2 screwdrivers and a hammer, remove the 3 snaprings from the No.1, No.2 and No.3 shift fork shafts

34 REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY

(a) Leaning the output shaft to the differential side, removethe input shaft assembly

(b) Lift up the differential case assembly, remove the outputshaft assembly

35 REMOVE DIFFERENTIAL CASE ASSEMBLY

(a) Remove the oil pump drive gear

(b) Remove the differential case assembly

36 REMOVE MAGNET FROM TRANSAXLE CASE

37 REMOVE TRANSMISSION OIL PUMP ASSEMBLY AND OIL PIPE

(a) Remove the 2 bolts and oil pipe

Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

(b) Remove the 2 bolts and oil pump assembly

Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

Trang 22

MANUAL TRANSAXLE MANUAL TRANSAXLE ASSEMBLY

38 REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB

(a) Remove the No.5 synchronizer ring with the key springfrom the No.3 clutch hub

(b) Using a screwdriver, remove the snap ring

Trang 23

1 INSPECT NO.5 SYNCHRONIZER RING

(b) Check the braking effect of the synchronizer ring Turn themiddle No.5 synchronizer ring in one direction while push-ing it to the outer No.5 synchronizer ring Check that thering locks

If it does not lock, replace the synchronizer ring

2 MEASURE SHIFT FORK AND HUB SLEEVE ANCE

CLEAR-Using a feeler gauge, measure the clearance between the hubsleeve and shift fork

Maximum clearance: 1.0 mm (0.039 in.)

If the clearance exceeds the maximum, replace the shift fork orhub sleeve

Trang 24

1 REPLACE INPUT SHAFT BEARING AND OIL SEAL

(a) Remove the 3 bolts and transaxle case receiver

(b) Using SST, pull out the bearing

(c) Using a screwdriver, remove the oil seal

(d) Using SST, drive in a new oil seal

(e) Coat the lip of seal with MP grease

(f) Using SST, drive in a new bearing

(09951−07150)(g) Install the transaxle case receiver

(h) Install and torque the 3 bolts

Trang 25

(b) Remove the output shaft cover.

(c) Install a new output shaft cover

Trang 26

Z00201

MANUAL TRANSAXLE MANUAL TRANSAXLE ASSEMBLY

3 REPLACE REVERSE RESTRICT PIN

(a) Using a hexagon wrench (6 mm), remove the screw plug

spring pin

(c) Replace the reverse restrict pin

(d) Using a pin punch and hammer, drive in the slotted springpin

(e) Apply sealant to the screw plug threads

Trang 27

S Clean both sealing surfaces with a non−residue solvent.

S Apply FIPG in an approx 1 mm (0.04 in.) wide bead along the sealing surface.

S Parts must be assembled within 10 minutes of application Otherwise, the FIPG material must be removed and reap- plied.

ADJUST OUTPUT SHAFT PRELOAD

(a) Install the output shaft assembly to the transaxle case.(b) Install the transmission case to the transaxle case.HINT:

If necessary, tap on the case with a plastic hammer

(c) Install and torque the 17 bolts

(f) Install the rear bearing retainer

(g) Using a torx wrench (T45), install and torque the 7 torxscrews

Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)

(h) Install a new lock nut to the output shaft

(i) Turn the output shaft right and left 2 or 3 times to allow thebearing to settle

Trang 28

MANUAL TRANSAXLE MANUAL TRANSAXLE ASSEMBLY

(j) Using a torque wrench, measure the preload

Preload (at starting):

New bearing 0.8−1.6 N·m (8−16 kgf·cm, 6.9−13.9 in.·lbf) Reused bearing

Mark Thickness mm (in.) Mark Thickness mm (in.)

(m) Remove these parts Removal is in the reverse order ofinstallation

S Shim

S Output shaft rear bearing outer race

Trang 29

Snap Ring

Needle Roller Bearing

3rd GearNeedle Roller Bearing

z Input Shaft Front Bearing Inner Race

z Non−reusable part

MANUAL TRANSAXLE INPUT SHAFT

MX−29INPUT SHAFT

COMPONENTS

Trang 30

3rd gear: 0.40 mm (0.0157 in.) 4th gear: 0.60 mm (0.0236 in.)

2 CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance betweenthe gear and shaft

Standard clearance:

3rd gear: 0.009 − 0.053 mm (0.0004 − 0.0021 in.) 4th gear: 0.009 − 0.051 mm (0.0004 − 0.0020 in.) Maximum clearance:

3rd and 4th gears: 0.070 mm (0.0028 in.)

If the clearance exceeds the maximum, replace the gear,needle roller bearing or shaft

3 REMOVE SNAP RING

Using 2 screwdrivers and a hammer, tap out the snap ring

4 REMOVE REAR BALL BEARING AND 4TH GEAR

Using SST and a press, remove the rear bearing

5 REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING

6 REMOVE SNAP RING

Using 2 screwdrivers and a hammer, tap out the snap ring

Trang 32

1 INSPECT 3RD GEAR SYNCHRONIZER RING

(b) Check the braking effect of the synchronizer ring Turn thesynchronizer ring in one direction while pushing it to thegear cone Check that the ring locks

If it does not lock, replace the synchronizer ring

the synchronizer ring back and gear spline end

Minimum clearance: 0.7 mm (0.028 in.)

If the clearance is less than the minimum, replace the nizer ring

synchro-2 INSPECT 4TH GEAR SYNCHRONIZER RING

(b) Check the braking effect of the synchronizer ring Turn thesynchronizer ring in one direction while pushing it to thegear cone Check that the ring locks

If the braking effect is insufficient, apply a small amount of thefine lapping compound between the synchronizer ring and gearcone Lightly rub the synchronizer ring and gear cone together

NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

(c) Check again the braking effect of the synchronizer ring

the synchronizer ring back and spline end

Minimum clearance: 0.8 mm (0.031 in.)

If the clearance is less than the minimum, replace the nizer ring, and apply a small amount of the fine lapping com-pound on gear cone

synchro-NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

Trang 33

Maximum clearance: 1.0 mm (0.039 in.)

If the clearance exceeds the maximum, replace the shift fork orhub sleeve

4 INSPECT INPUT SHAFT

(a) Check the input shaft for wear or damage

(b) Using a micrometer, measure the outer diameter of the put shaft journal surface

in-Minimum outer diameter:

Part A: 27.950 mm (1.1004 in.) Part B: 35.950 mm (1.4154 in.)

(c) Using a dial indicator, check the shaft runout

Maximum runout: 0.05 mm (0.0020 in.)

Trang 34

1 INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE

(a) Install the 3 springs and shifting keys to the clutch hub.(b) Install the hub sleeve to the clutch hub

(a) Apply MP grease to the needle roller bearing

(b) Assemble the needle roller bearings into the 3rd gear.(c) Place the synchronizer rings on the gear and align thering slots with the shifting keys

(d) Using SST and a press, install the 3rd gear and No.2 hubsleeve

3 INSTALL SNAP RING

(a) Select a snap ring that allows the minimum axial play

Mark Thickness mm (in.) Mark Thickness mm (in.)

Trang 35

(a) Install the spacer.

(b) Apply MP grease to the needle roller bearings

(c) Place the synchronizer ring on the gear and align the ringslots with the shifting keys

(d) Install the 4th gear

(e) Using SST and a press, install the rear ball bearing

6 INSTALL SNAP RING

(a) Select a snap ring that allows the minimum axial play

Mark Thickness mm (in.) Mark Thickness mm (in.)

1 2.35 (0.0925) 5 2.55 (0.1004)

2 2.40 (0.0945) 6 2.60 (0.1024)

3 2.45 (0.0965) 7 2.65 (0.1043)

4 2.50 (0.0984) 8 2.70 (0.1063)

(b) Using a screwdriver and hammer, tap in the snap ring

7 MEASURE 4TH GEAR THRUST CLEARANCE (See page MX−30 )

Trang 36

Q06216

4th Driven Gear

3rd Driven Gear

Needle Roller Bearing

1st Gear Bearing Inner Race

SpacerInner Race

2nd GearSpacer

Output Shaft Rear Bearing

Spring

No.1 Hub Sleeve

Needle Roller Bearing

1st GearSynchronizer Ring

Trang 37

1st gear: 0.40 mm (0.0157 in.) 2nd gear: 0.50 mm (0.0197 in.)

2 CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance betweenthe gear and shaft

Standard clearance:

1st gear: 0.009 − 0.051 mm (0.0004 − 0.0020 in.) 2nd gear: 0.009 − 0.053 mm (0.0004 − 0.0021 in.) Maximum clearance:

1st and 2nd gears: 0.070 mm (0.0028 in.)

If the clearance exceeds the maximum, replace the gear,needle roller bearing or shaft

3 REMOVE OUTPUT SHAFT REAR BEARING, 4TH DRIVEN GEAR AND SPACER

(a) Using a press, remove the bearing and 4th driven gear

4 REMOVE 3RD DRIVEN GEAR AND 2ND GEAR

Using a press, remove the 3rd driven gear and 2nd gear

5 REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING

6 REMOVE INNER RACE AND BALL FROM OUTPUT SHAFT

Trang 38

MANUAL TRANSAXLE OUTPUT SHAFT

7 REMOVE NO.1 HUB SLEEVE ASSEMBLY AND 1ST GEAR

Using a press, remove the No.1 hub sleeve and 1st gear

ROLLER BEARING

9 REMOVE 1ST GEAR BEARING INNER RACE

Using SST and a press, remove the 1st gear bearing inner race

10 REMOVE OUTPUT SHAFT FRONT BEARING

Using SST, remove the output shaft front bearing

Trang 39

1 INSPECT 1ST GEAR SYNCHRONIZER RING

(b) Check the braking effect of the synchronizer ring Turn thesynchronizer ring in one direction while pushing it to thegear cone Check that the ring locks

If the braking effect is insufficient, apply a small amount of thefine lapping compound between the synchronizer ring and gearcone Lightly rub the synchronizer ring and gear cone together

NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

(c) Check again the braking effect of the synchronizer ring

the synchronizer ring back and gear spline end

Minimum clearance: 0.8 mm (0.031 in.)

If the clearance is less than the minimum, replace the nizer ring, and apply a small amount of the fine lapping com-pound on gear cone

synchro-NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

2 INSPECT 2ND GEAR SYNCHRONIZER RING

(b) Check the braking effect of the synchronizer ring.(c) Turn the synchronizer ring in one direction while pushing

it to the gear cone Check that the ring locks

If it does not lock, replace the synchronizer ring

the synchronizer ring back and gear spline end

Minimum clearance: 0.7 mm (0.028 in.)

If the clearance is less than the minimum, replace the nizer ring

Trang 40

Q06203

A BA

Q06191

MANUAL TRANSAXLE OUTPUT SHAFT

3 MEASURE NO.1 SHIFT FORK AND HUB SLEEVE CLEARANCE

Using a feeler gauge, measure the clearance between the hubsleeve and shift fork

Maximum clearance: 1.0 mm (0.039 in.)

If the clearance exceeds the maximum, replace the shift fork orhub sleeve

4 INSPECT OUTPUT SHAFT

(a) Check the output shaft for wear or damage

(b) Using a micrometer, measure the outer diameter of theoutput shaft journal surface

Minimum outer diameter:

Part A: 37.526 mm (1.4774 in.) Part B: 34.512 mm (1.3588 in.)

(c) Using a dial indicator, check the shaft runout

Maximum runout: 0.06 mm (0.0024 in.)

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