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Assembly|Installation > < Output Shaft

Transit 2000.5 (01.2000-05.2006)

Manual Transmission/Transaxle - Vehicles With: VXT-75 - Transaxle Transit 2000.5 (01/2000-05/2006)
Assembly

Special Tool(s)

Torque gauge

205-067 (15-041)

Bearing outer race installer

205-075 (15-036)

Installer, differential oil seal

205-115 (15-058)

Socket, Drive Pinion Nut

205-175 (15-073)

Valve spring compressor

303-060 (21-024)

Adapter for 303-060

303-060-02 (21-024-02)

Adapter for 303-060

303-060-07 (21-024-07)

Mounting Plate for 303-435-06

303-435-11 (21-146C)

Holding Fixture, Dial Indicator Gauge

308-216 (16-059A)
General Equipment
Hot air blower
Dial Indicator gauge
Tyre lever
Press
Two M6 x 20 mm locating bolts
Materials
Name
Specification
Manual transmission fluid
WSD-M2C200-C 
Sealer transaxle housing
WSK-M2G348-A5 
High-temperature grease
ESDM-1C220-A 

Assembly

  1. Clean and check all parts carefully before reassembly.

  1. NOTE:
    NOTE:Only if removed.
    NOTE:
    NOTE:Install new bolts.
    Install the reverse gear idler shaft.
    1. Coat the mating face of the reverse gear idler shaft with sealer .
    1. Using two M6 x 20 mm locating bolts, position the reverse gear idler shaft.
    1. Remove the two M6 x 20 mm locating bolts and install the three original bolts.

  1. CAUTION:
    CAUTION:The press force must not exceed 15 kN.
    Using the special tool, install the input shaft bearing cup into the transaxle housing.
    • Using a hot air blower, heat the transaxle housing to approximately 80°C.
    • Using a press, install the bearing cup.

  1. CAUTION:
    CAUTION:The press force must not exceed 15 kN.
    Using the special tool, install the output shaft bearing cup into the transaxle housing.
    • Using a hot air blower, heat the transaxle housing to approximately 80°C.
    • Using a press, install the bearing cup.

  1. CAUTION:
    CAUTION:The press force must not exceed 15 kN.
    Using the special tool, install the differential bearing cup into the transaxle housing.
    • Using a hot air blower, heat the transaxle housing to approximately 80°C.
    • Using a press, install the bearing cup.

  1. CAUTION:
    CAUTION:The press force must not exceed 15 kN.
    Using the special tool, install the input shaft bearing cup into the clutch housing.
    • Install a 1.00 mm measuring shim.
    • Using a hot air blower, heat the transaxle housing to approximately 80°C.
    • Using a press, install the bearing cup.

  1. CAUTION:
    CAUTION:The press force must not exceed 15 kN.
    Using the special tool, install the output shaft bearing cup into the clutch housing.
    • Install a 1.00 mm measuring shim.
    • Using a hot air blower, heat the transaxle housing to approximately 80°C.
    • Using a press, install the bearing cup.

  1. CAUTION:
    CAUTION:The press force must not exceed 15 kN.
    Using the special tool, install the differential bearing cup into the clutch housing.
    • Install a 1.10 mm measuring shim.
    • Using a hot air blower, heat the transaxle housing to approximately 80°C.
    • Using a press, install the bearing cup.
  1. NOTE:
    NOTE:When installing new roller bearings, do not oil the roller bearings before installation.
    When installing the original roller bearings check all parts carefully and lubricate them with transmission fluid.

  1. Engage fourth gear.

  1. Install the input shaft with the output shaft.

  1. Install the differential assembly.

  1. NOTE:
    NOTE:Make sure that the transaxle housing mating surfaces are clean.
    Assemble the transaxle housing.
    • Attach the special tool to the transaxle housing flange.

  1. Install the transaxle housing retaining bolts and studs (19 bolts and 2 studs).

  1. Install the special tool.
    1. Position the special tool.
    1. Install the bolts.
    1. Position the special tool on the fourth gear wheel.

  1. Prepare the input shaft for measuring.
    • Turn the input shaft to and fro approximately 20 times to settle the bearings.

  1. Set up the dial indicator gauge.
    1. Install the special tool to the transaxle.
    1. Set up the magnetic dial indicator gauge base.
    1. Set the dial indicator gauge to "0".

  1. NOTE:
    NOTE:Carry out the preparations and the measurement three times and calculate the average value of the measurements.
    Measure the input shaft end float.
    1. Using a suitable lever, lift the input shaft.
    1. Note the resulting measurement (e.g. 0.22 mm).
    • Example: 0.22 mm + 0.23 mm + 0.24 mm divided by three = 0.23 mm.

  1. Prepare the output shaft for measuring.
    • Turn the output shaft back and forth 20 times to settle the bearings (via input shaft, refer to previous steps).

  1. NOTE:
    NOTE:Carry out previous steps three times and calculate the average measurement.
    Measure the output shaft end float.
    • Lift the output shaft with a lever and note the resulting measurement, e.g. 0.32 mm.
    • Example: 0.32 m + 0.34 mm + 0.33 mm divided by three = 0.33 mm.

  1. Prepare the differential for measuring.
    • Turn the output shaft backwards and forwards 20 times and at the same time press down the differential.

  1. NOTE:
    NOTE:Carry out the following steps three times and calculate the average measurement.
    Using the special tools, measure the differential end float.
    • Lift the differential and note the resulting measurement, e.g. 0.34 mm.
    • Example: 0.34 mm + 0.36 mm + 0.38 mm divided by three = 0.36 mm
  1. NOTE:
    NOTE:The shims are available in steps of 0.01 mm.
    Calculate the required input shaft shim thickness, e.g..
    • Measuring shim thickness: 1.00 mm.
    • Measured input shaft end float: 0.23 mm.
    • Required lash figure for end float: -0.02 mm.
    • Required shim: 0.23 mm - 0.02 mm + 1.00 mm = 1.21 mm.
  1. NOTE:
    NOTE:The shims are available in steps of 0.02 mm.
    Calculate the required output shaft shim thickness, e.g..
    • Measuring shim thickness 1.00 mm.
    • Measured output shaft end float 0.33 mm.
    • Required preload figure for end float: 0.08 mm.
    • Required shim: 1.00 mm + 0.33 mm + 0.08 mm = 1.41 mm.
  1. NOTE:
    NOTE:The shims are available in steps of 0.05 mm.
    Calculate the required differential shim thickness, e.g..
    • Measuring shim thickness: 1.10 mm.
    • Measured differential end float: 0.36 mm.
    • Required preload figure for end float: 0.25 mm
    • Required shim: 1.10 mm + 0.36 mm + 0.25 mm = 1.71 mm.
  1. Remove the bearing cups and measuring shims again.
    • Remove the bearing cups and measuring shims of the:

        • 1. input shaft

        2. output shaft

        3. differential

  1. Install the shims and bearing cups, as calculated in the previous steps.
    1. Install the required shims.
    1. Install the bearing cups of the:

        2. 1. input shaft

        2. output shaft

        3. differential

  1. Fabricate an Installation hook for the reverse gear idler.
    • Diameter of the wire: 3 mm.

  1. Reverse gear idler (installation sequence).
    1. Install the lower thrust washer.
    1. Install the needle roller bearing.
    1. Install the reverse gear idler.
    1. Install the upper thrust washer.
    1. Install the reverse gear idler shaft mounting bracket.

  1. NOTE:
    NOTE:Install the reverse gear idler with the small collar facing downwards.
    Install the installation hook and the reverse gear idler with the mounting bracket.

  1. Install the input shaft with the output shaft.
    1. Move the input shaft and output shaft to the side.
    1. Remove the installation hook.

  1. NOTE:
    NOTE:Make sure that the input shaft is in neutral position.
    Install the selector forks.
    1. Install the fifth and reverse gear selector fork.
    1. Install the third and fourth gear selector fork.
    1. Install the first and second gear selector fork.

  1. NOTE:
    NOTE:If the holes for the reverse gear idler shaft mounting bracket bolts do not line up exactly, check the installation position of the reverse gear idler shaft thrust washers.
    NOTE:
    NOTE:Install new bolts.
    Install the reverse gear idler shaft mounting bracket retaining bolts.
    • Press the mounting down as far as it will go.
    • Coat the bolt threads with sealer and tighten them.

  1. NOTE:
    NOTE:Make sure that the selector rods are installed in the same height.
    Install the selector rods.

  1. Install the differential assembly.
    1. Install the differential assembly.
    1. Install the magnetic disc.

  1. CAUTION:
    CAUTION:Install the transaxle housing within 15 minutes of applying sealer.
    Apply a bed of 2 mm sealer to the inside of the mating surfaces of the transaxle.

  1. Assemble the transaxle housing.

  1. Using the special tools, measure the turning torque.
    • Engage fourth gear.
    • Measure the turning torque.
    • If the turning torque is too high, all the measurements (to establish the required shim thickness) must be repeated.

  1. Install the gearshift cable retaining bracket.

  1. NOTE:
    NOTE:Ensure that no gear is engaged.
    NOTE:
    NOTE:Ensure that the selector mechanism is in the neutral position.
    NOTE:
    NOTE:Ensure that the threaded holes are free of sealer.
    NOTE:
    NOTE:Observe the installation position of the long bolt.
    Install the selector mechanism.
    • Apply sealantsealer centrally to the transmission mating surface and apply outside the line of the threaded holes (bead diameter: 2 mm).
    1. Install the long bolt.
    1. Install the short bolts.

  1. Install the vehicle speed sensor (VSS) (if equipped).

  1. NOTE:
    NOTE:Install new oil seals.
    Using the special tool, install the halfshaft oil seals on both sides (right-hand side shown).

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    CAUTION:
    CAUTION:Using suitable adhesive tape, cover the input shaft splines to prevent damage to the input shaft oil seal.
    CAUTION:
    CAUTION:Do not apply grease on any area of the clutch slave cylinder.
    Install the clutch slave cylinder assembly.
  1. Remove the adhesive tape from the input shaft splines.
  1. Coat the input shaft splines with a thin layer of high-temperature grease.

Assembly|Installation > < Output Shaft