Necessary equipment
- DT-48179 Universal guide handle
- DT-48182 Needle bearing puller/installer
- DT-48225 Driver for input shaft
- DT-48226 Gearbox housing ball bearing remover/installer assembly
- DT-48227 Roller bearing puller/installer
- DT-48228 Clutch housing ball bearing puller/installer
- DT-48230 Differential Bearing Race and Drive Shaft Seal Installer
- DT-48231 Pusher / puller of the primary and secondary shaft
- DT-48232 Input Shaft Synchronizer Housing Protector
Assembly order
1. Install a new driveshaft oil seal into the clutch housing using DT-48179 and DT-48230.
2. Install the intermediate shaft ball bearing into the clutch housing using DT-48179 and DT-48228.
3. Install the circlip on the intermediate shaft ball bearing.
4. Install the input shaft roller bearing to the clutch housing using DT-48179 and DT-48227.
5. Install a new driveshaft oil seal to the transaxle case assembly using DT-48179 and DT-48230.
6. Install the input and output shaft ball bearings to the transaxle case assembly using DT-48179 and DT-48226.
7. Install the needle bearing in the transaxle case flush with the casting using DT-48179 and DT-48182.
8. Install reverse gear lock (1), torsion spring (2) and a new threaded pin (3) into the gearbox housing with final drive assembly.
Tighten
Tighten grub screw to 6~9 Nm (53~80 lb-in).
9. Install the output shaft roller bearing into the clutch housing.
Important: Make sure the orientation of the roller bearing is correct.
10. Install intermediate (1), primary (2) and secondary (3) shaft assembly together with the corresponding shift forks into the clutch housing.
- Install DT-48232 and input shaft retaining plug.
- Install intermediate (1) and primary (2) shaft assembly along with the corresponding shift forks.
Important: Place the intermediate shaft on the side of the ball bearing.
- Install the output shaft assembly and shift fork.
- After checking the gear engagement, fully install each shaft assembly.
- Remove DT-48232 and input shaft retaining plug.
11. Install the transaxle case assembly to the clutch case.
- The input and output shafts must engage the ball bearings in the transaxle case assembly.
- The intermediate shaft and shift forks must sit in opposing bearings in the transaxle case assembly.
- Install DT-48231 to the transaxle case assembly.
- Tighten four bolts (1).
- Screw the spindles into the input and output shaft.
- Pull the input and output shafts evenly into the ball bearings in the transaxle case assembly.
- Hold spindles (2) with the right tool.
- Turn the nuts (3) in the direction of the arrow.
- Remove DT-48231 from transaxle case assembly.
- Unscrew the spindles from the input and output shafts.
- Remove four screws (1).
Important: If the DT-48231 actuator requires a lot of force, disengage the transaxle case assembly and clutch case again and check the location of the shift shaft and forks. Repeat operation.
12. Shift the gearbox with final drive assembly to 4th and 5th gear by moving the screwdriver upwards.
13. Install new input and output shaft retaining plugs while holding the transaxle and final drive in 4th and 5th gears from bottom to top.
Tighten
Tighten the fixing plug of the input shaft to a torque of 120 ~ 130 Nm (89~96 lb-ft).
Tighten the fixing plug of the secondary shaft to a torque of 120 ~ 130 Nm (89~96 lb-ft).
14. Apply sealant (Loctite 5900) on the rear cover of the transaxle case with final drive assembly.
Important: Leave enough free space so that the oil line does not clog.
15. Install the oil line and rear transaxle case cover assembly.
Important: The oil line can only be installed in one direction. Make sure that the oil line is fully seated in the pinion shafts.
16. Install the transaxle case rear cover bolts.
Tighten
Tighten the rear cover bolts to 20~25 Nm (15~18 lb-ft).
17. Remove the clutch housing from the transaxle housing assembly.
Important: To facilitate the separation of the crankcase, use suitable tools in line with the countershaft.
18. Install the idle gear shift rod (1) into the gearbox housing with final drive assembly.
19. Install the idle gear shift rod bushing (2) into the gearbox housing with final drive assembly.
20. Install drain gutter (3) into the gearbox housing with final drive assembly.
21. Install the reverse light switch and washer to the transaxle case assembly.
Tighten
Tighten the reverse light switch mounting bolt to 20 Nm (15 lb-ft).
22. Install the shift shaft assembly.
- Apply sealant (Loctite 5203) on the mating surface of the gearbox housing with the main gear assembly and the gear shift housing.
- Shift into neutral.
- Install shift shaft assembly (3)..
- Install gear selector lever (2).
- Install the gearshift bolts.
Tighten
Tighten the gearshift mounting bolts to a torque of 20 ~ 25 Nm (15~18 lb-ft).
- install bolt (1) gear shift guide.
Tighten
Tighten the shift guide bolts to 20~25 Nm (15~18 lb-ft).
23. Install the differential bearing race and shim to the transaxle case assembly using DT-48179 and DT-48230. See «Gasket Adjustment Procedures» in this section.
24. Install differential bearing race and gasket to clutch housing using DT-48230 (for four wheel drive) or DT-48533 (for all-wheel drive) with DT-48179. See «Gasket Adjustment Procedures» in this section.
25. Install the magnet to the transaxle case assembly.
26. Install the differential in the gearbox housing.
27. Apply sealant (Loctite 5203) on the mating surface of the gearbox housing with the main gear assembly and the clutch housing.
28. Install the clutch housing to the transaxle housing assembly.
Important:
- The input and output shafts must engage their bearings in the clutch housing.
- The shift forks must sit in opposing bearings in the clutch housing.
29. Hold input shaft with DT-48225.
30. Push the intermediate shaft into the ball bearing of the intermediate shaft using the old retaining plug.
- Shift into any gear.
31. Install the bolts securing the clutch housing to the transaxle housing assembly.
Tighten
Tighten the bolts securing the clutch housing to the gearbox housing with final drive assembly to a torque of 20 ~ 25 Nm (15~18 lb-ft).
32. Remove the old fixing plug from the intermediate shaft and install the new fixing plug.
Tighten
Tighten the fixing plug of the intermediate shaft to a torque of 90 ~ 100 Nm (66~74 lb-ft).
33. Remove DT-48225.
34. Install the transaxle case mounting bolts to the clutch case.
Tighten
Tighten the bolts securing the transaxle housing with final drive assembly to the clutch housing to a torque of 20 ~ 25 Nm (15~18 lb-ft).
35. Install a new oil line to the intermediate shaft.
36. Install a new intermediate shaft sealing plug.
37. Install O-ring and concentric slave cylinder.
38. Fit the hydraulic drive tube fitting and tighten the cylinder mounting bolts.
Tighten
Tighten the clutch release cylinder mounting bolts to a torque of 8 ~ 12 Nm (71~106 lb-in).
39. Tighten the hydraulic hose fitting.
Tighten
Tighten the union to a torque of 16 Nm (12 lb-ft).
40. Install the sleeve on the tube of the concentric slave cylinder.
41. Install shift cable bracket, washer, and bolts.
Tighten
Tighten the shift control cable bracket bolts 15~20 Nm (11~15 lb-ft).
42. Install the gearbox in the car. See «Gearbox with final drive assembly» in this section.