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T3B15B36
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Housing Case

Disassembly Procedure

  1. Remove the transaxle from the vehicle. Refer to "Transaxle Assembly" in this section.
  2. Remove the shift lever cover bolts and the shift lever cover. Do not disassemble the shift lever cover.

    3. T3B15B43
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  3. Remove the transaxle cover bolts and the transaxle cover.

    4. T3B15B45
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  4. Remove the bearing plate bolts and the bearing plate, with the shafts attached. Do not disassemble the shafts.

    5. T3B15B99
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  5. Remove the differential from the transaxle housing. Do not disassemble the differential. Refer to "Differential" in this section.
  6. Remove the backup lamp switch from the transaxle housing.

    7. T3B15B41
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  7. Remove the clutch-release bearing and the clutch-release bearing guide. Refer to Section 5C, Clutch.
  8. Remove the speedometer-driven gear bolt and the speedometer-driven gear from the transaxle housing.

T3B15B41
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Assembly Procedure

  1. Install the speedometer-driven gear bolt and the speedometer-driven gear into the transaxle housing.

    2. Tighten
    Tighten the speedometer-driven gear bolt to 4 N•m (35 lb-in)


    T3B15B99
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  2. Install the clutch-release bearing guide and the clutch-release bearing. Refer to Section 5C, Clutch.
  3. Install the backup lamp switch into the transaxle housing.

    4. Tighten
    Tighten the backup lamp switch to 20 N•m (15 lb-ft).


    T3B15B45
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  4. Install the differential into the transaxle housing. Refer to "Differential" in this section.
  5. Install the bearing plate, with the shafts attached.
  6. Install the bearing plate bolts.

    7. Tighten
    Tighten the bearing plate bolts to 22 N•m (16 lb-ft).


    T3B15B43
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  7. Install the transaxle cover and the transaxle cover bolts.

    8. Tighten
    Tighten the bigger transaxle cover bolts to 20 N•m (15 lb-ft) and the smaller transaxle cover bolts to 15 N•m (11 lb-ft).


    T3B15B36
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  8. Install the gearshift lever cover and the gearshift lever cover bolts.

    9. Tighten
    Tighten the gearshift lever cover bolts to 22 N•m (16 lb-ft).

  9. Install the transaxle into the vehicle. Refer to "Transaxle Assembly" in this section.

T3B15BA1
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Differential

Tools Required

KM-520 Remover/Installer
KM-525 Installer
J-22888-20-A Bearing Puller with J-22888-35 Puller Legs
KM-522 Installer

Disassembly Procedure

  1. Remove the differential cover bolts, the differential cover, and the differential cover gasket.

    2. T3B15BA2
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  2. Remove the bearing-adjusting ring retainer plate bolt and the bearing-adjusting ring retainer plate.

    3. T3B15BA3
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  3. Remove the bearing-adjusting ring using the remover/ installer KM-520.

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  4. Remove the right-side bearing-retainer bolts and the right-side bearing retainer.

    5. T3B15BA5
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  5. Remove the differential assembly from the transaxle case.

    6. T3B15BA6
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  6. Remove the ring gear bolts.

    7. T3B15BA7
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  7. Separate the ring gear from the differential housing.

    8. T3B15BA8
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  8. Drive the pinion gear shaft lock pin from the differential housing and the pinion gear shaft.

    9. T3B15BA9
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  9. Remove the pinion gear shaft.

    10. T3B15BB1
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  10. Remove the pinion gears and the washers.
  11. Remove the side gears and the side thrust washers.

    12. T3B15BB2
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  12. Remove both of the differential bearings using the bearing puller J-22888-20-A with the puller legs J-22888-35.

    13. T3B15BB3
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  13. Remove the speedometer drive gear from the differential gear housing.

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Assembly Procedure

  1. Install the speedometer drive gear onto the differential gear housing using the installer KM-525.

    2. T3B15BB5
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  2. Install both of the differential bearings using the installer KM-522.

    3. T3B15BB1
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  3. Install the side gears and the side thrust washers into the differential housing.
  4. Install the differential pinion gears and the differential pinion gear washers into the differential housing.

    5. T3B15BA9
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  5. Install the pinion gear shaft into the differential housing.

    6. T3B15BB6
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  6. Install the pinion gear shaft lock pin into the differential housing and the pinion gear shaft.

    7. T3B15BA6
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  7. Install the ring gear and the ring-gear bolts.

    8. Tighten
    Tighten the ring-gear bolts to 70 N•m (52 lb-ft).


    T3B15BA5
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  8. Install the differential assembly into the transaxle case.

    9. T3B15BA4
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  9. Install the right-side bearing retainer and the rightside bearing retainer bolts.

    10. Tighten
    Tighten the right-side bearing retainer bolts to 25 N•m (18 lb-ft).


    T3B15BA3
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  10. Install the bearing-adjusting ring.
  11. Tighten the bearing-adjusting ring using the remover/ installer KM-520.

    12. Tighten
    Tighten the bearing adjusting ring until there is no end play with the differential.
    Adjust the preload on the differential bearings.
    Used Bearings:
    1 N•m (9 lb-in) required to rotate the differential one revolution per second.
    New Bearings:
    2 N•m (18 lb-in) required to rotate the differential one revolution per second.
    Tighten or loosen the bearing ring adjuster to get the required preload on the bearings.


    T3B15BA2
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  12. Install the bearing-adjusting ring-retainer plate and the bearing-adjusting ring-retainer plate bolt.

    13. Tighten
    Tighten the bearing-adjusting ring-retainer plate bolt to 25 N•m (18 lb-ft).


    T3B15BA1
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  13. Install the differential cover gasket, the differential cover, and the differential cover bolts.

    14. Tighten
    Tighten the differential cover bolts to 40 N•m (30 lb-ft).


T3B15B68
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Major Component Assembly

Tools Required

J-36633 Snap Ring Retainer
KM-334 Installer Sleeve
KM-552 Fixture
KM-554 Installer
KM-113-2 Base

Assembly Procedure

  1. Join the mainshaft and the input shaft.
  2. Compress the snap ring at the base of the mainshaft and hold with the snap ring retainer J-36633.
  3. Hold the snap ring at the base of the input driveshaft with the snap ring pliers.
  4. Install the mainshaft/input shaft assembly onto the bearing plate.
  5. Release the mainshaft snap ring and the input shaft snap ring.

    6. T3B15B65
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  6. Position the first-second gearshift fork.
  7. Install the fifth gearshift lever into the bearing plate.

    8. T3B15B64
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  8. Install the third-fourth gearshift rod/fork holding pin.

    9. T3B15B63
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  9. Install the support bracket onto the bearing plate.

    10. T3B15BB7
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  10. Install the first-second gearshift rod/fork onto the bearing plate.

    11. T3B15B61
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  11. Install the first-second gearshift fork holding pin.

    12. T3B15B60
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  12. Install the support bracket bolts.

    13. Tighten
    Tighten the support bracket bolts to 7 N•m (62 lb-in).


    T3B15B59
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  13. Install the reverse gearshift rod/fork onto the bearing plate.

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  14. Install the reverse gearshift rod/fork holding pin.

    15. T3B15B57
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  15. Install the rod lock pin and spring into the small plug hole.

    16. T3B15BB8
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  16. Install the fourth-gearshift rod plugs.

    17. T3B15B55
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  17. Install the bolts and the fifth-gearshift connector onto the bearing plate, using the pawl.

    18. Tighten
    Tighten the fifth-gearshift connector bolts to 7 N•m (62 lb-in).


    T3B15BB9
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  18. Install the input drive fifth gear using the installer KM-554 and the installer sleeve KM-334.

    19. T3B15B53
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  19. Install the snap rings securing the fifth-drive gear.

    20. T3B15B52
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  20. Install the thrust washers, the retaining ring, and the needle bearing into the mainshaft-driven fifth-gear assembly.

    21. T3B15B51
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  21. Install the brass synchronizer ring onto the mainshaft- driven fifth-gear assembly.

    22. T3B15BC1
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  22. Install the mainshaft-driven fifth-gear assembly.
  23. Install the fifth-drive gear synchronizer gear and the synchronizer sleeve using installer KM-554.

    24. T3B15B48
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  24. Install the snap ring holding the fifth speed-driven assembly.

    25. T3B15B47
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  25. Install the bolts and the fifth-gear fork onto the bearing plate.

    26. Tighten
    Tighten the fifth-gear fork bolts to 22 N•m (16 lb-ft).


    T3B15B45
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  26. Remove the bearing plate from the fixture KM-552.
  27. Shift the transaxle into second gear.
  28. Install the bearing plate, with the shafts attached, into the case.

    29. T3B15B44
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  29. Install the bearing plate bolts.

    30. Tighten
    Tighten the bearing plate bolts to 22 N•m (16 lb-ft).


    T3B15B41
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  30. Install the speedometer-driven gear and the speedometer-housing retaining bolt into the transaxle housing.

    31. Tighten
    Tighten the speedometer housing retaining bolt to 4 N•m (35 lb-in).


    T3B15B40
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  31. Bolt the gearshift lever cover to the fixture KM-552.
  32. Position the fixture into the base KM-113-2.
  33. Install the gearshift rod, the shift finger lever, and the gearshift lever pin.

    34. T3B15B38
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  34. Install the snap ring, the bushing, the spring, and the intermediate lever.
  35. Remove the gearshift lever cover from the base KM-113-2 and the fixture KM-552.
  36. Shift the transaxle into NEUTRAL.

    37. T3B15B36
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  37. Install the gearshift lever cover and the gearshift lever cover bolts.

    38. Tighten
    Tighten the gearshift lever cover bolts to 22 N•m (16 lb-ft).


    T3B15B42
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  38. Install the transaxle cover and the transaxle cover bolts.

    39. Tighten
    Tighten the bigger transaxle cover bolts to 20 N•m (15 lb-ft) and the smaller transaxle cover bolts to 15 N•m (11 lb-ft).

  39. Install the transaxle into the vehicle. Refer to "Transaxle Assembly" in this section.


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