1. Inspect 1st gear thrust clearance
Standard clearance: 0.10 – 0.40 Mm (0.0039 – 0.0157 In.)
2. Inspect 2nd gear thrust clearance
Standard clearance:
0.10 – 0.45 Mm (0.0039 – 0.0177 In.)
3. Inspect 1st gear radial clearance
Standard clearance:
If the clearance is out of specification, replace the 1st gear needle roller bearing.
4. Inspect 2nd gear radial clearance
Standard clearance:
If the clearance is out of specification, replace the 2nd gear needle roller bearing.
5. Remove 4th driven gear
Sst 09950–00020
6. Remove output gear spacer
7. Remove 2nd gear
Sst 09950–00020
8. Remove 2nd gear needle roller bearing
9. Remove synchronizer ring set no.2
10. Remove 1st gear
Hint
: using a waste to prevent the snap ring from being scattered.
Sst 09950–00020
Notice
:
11. Remove synchronizer ring no.1
12. Remove 1st gear needle roller bearing
13. Remove 1st gear thrust washer
14. Remove 1st gear thrust washer pin or ball
15. Remove reverse gear
Notice
: using a waste to prevent the synchromesh shifting key and spring from being scattered.
16. Inspect output shaft
Maximum runout: 0.015 Mm (0.0006 In.)
If the runout exceeds the maximum, replace the output shaft.
Outer diameter:
part a: 31.985 Mm (1.2592 In.)
Part b: 37.985 Mm (1.4955 In)
part c: 32.985 Mm (1.2986 In)
if the outer diameter is below the minimum, replace the output shaft.
17. Inspect 2nd gear
Inside diameter:
If the inside diameter exceeds the maximum, replace the 2nd gear.
18. Inspect 1st gear
Inside diameter:
If the inside diameter exceeds the maximum, replace the 1st gear.
19. Inspect 1st gear thrust washer
Thickness:
If the thickness is below the minimum, replace the 1st gear thrust washer.
20. Inspect synchronizer ring set no.2
Check the braking effect of the synchronizer ring set no.2.
Standard clearance: 0.7 – 1.3 Mm (0.0276 – 0.0512 In.)
If the clearance is out of specification, replace the synchronizer ring set no.2.
21. Inspect synchronizer ring no.1
Check the braking effect of the synchronizer ring no.1.
Standard clearance:
0.75 – 1.65 Mm (0.0295 – 0.065 In.)
If the clearance is out of specification, replace the synchronizer ring no.1.
22. Inspect reverse gear
Standard clearance: 0.15 – 0.35 Mm (0.0059 – 0.0138 In.)
If the clearance is out of specification, replace the reverse gear and reverse shift fork.
23. Inspect transmission clutch hub no.1
24. Install reverse gear
Notice
: be sure to set the reverse gear and transmission clutch hub no.1 In incorrect orientation.
25. Install output shaft front bearing
Sst 09223–50010
Snap ring thickness:
Notice
: take care not to damage the journal surface of the output shaft.
26. Install 1st gear thrust washer pin or ball
27. Install 1st gear thrust washer
28. Install 1st gear needle roller bearing
29. Install 1st gear
30. Install synchronizer ring no.1
31. Install transmission clutch hub no.1
Sst 09316–60011 (09316–00031)
Notice
: the 1st gear can be turned.
Snap ring thickness:
Notice
: take care not to damage the journal surface of the output shaft.
32. Install 2nd gear needle roller bearing
33. Install synchronizer ring set no.2
34. Install 2nd gear
Notice
: fit the synchronizer inner ring claws into the slots in the transmission clutch hub no.1.
35. Install 3rd driven gear
Sst 09309–36100 (09309–03610), 09608–00071, 09950–60010 (09951–00450)
36. Install output gear spacer
37. Install 4th driven gear
Sst 09612–22011
38. Install output shaft rear bearing
Sst 09612–22011
39. Inspect 2nd gear radial clearance
Standard clearance:
If the clearance is out of specification, replace the 2nd gear needle roller bearing.
40. Inspect 1st gear radial clearance
Standard clearance:
If the clearance is out of specification, replace the 1st gear needle roller bearing.
41. Inspect 2nd gear thrust clearance
Standard clearance:
0.10 – 0.45 Mm (0.0039 – 0.0177 In.)
42. Inspect 1st gear thrust clearance
Standard clearance:
0.10 – 0.40 Mm (0.0039 – 0.0157 In.)
Initialization
1. Reset memory
Caution:
perform the reset memory (at initialization) when replacing the automatic
transaxle assy, engine
assy or ecm.
Notice:
hand–held tester only
Turn the ignition switch off.
connect the hand–held tester to the dlc3.
turn the ignition switch to the on ...
Out side moulding
Replacement
Hint:
use the same procedures for the rh side and lh side.
1. Remove outside moulding
Put protective tape around the moulding.
insert a piano wire between the vehicle body and moulding.
tie objects that can serve as handles (for example, wooden
blocks) to all ...
Skid control sensor
Replacement
Hint:
replace the rh side by the same procedure as the lh side.
1. Remove rear wheel
2. Remove rear brake drum sub–assy
3. Disconnect skid control sensor wire
Disconnect the skid control sensor wire connector from
the skid control sensor.
4. Remove rear axle hub & ...