| Assembly Special Tool(s) | | Adapter for 205-044 205-044-01 | | | Dial gauge stand 205-070 | | | Installer, Differential Bearing 205-081A | | | Installer, Drive Pinion Oil Seal 205-115 | | | Remover, Differential Bearing Cone 205-176 | | | Installer, rear wheel hub bearing race/seal 205-217 | | | Installer, rear wheel hub bearing race/seal 205-296 | | | Holding Fixture, Dial Indicator Gauge (Disc Brake) 206-003 | | | Mounting Stand 303-435 | | | Mounting Bracket for 303-435 303-435-04 | | | Mounting Plate for 303-435-04 303-435-12A | | | Depth Gauge, Shim Selection 307-300-02 | | | Adapter for 307-300-02 307-300-03 | | | Spacers, Transmission Housing 307-430 | | | Installer, Output Drive Flange Oil Seal 308-112 | | | Driveshaft remover 308-192 | | | Shim gauge, bearing pre-load 308-603 | General Equipment Magnetic base for dial indicator gauge Dial indicator gauge Hot air gun Materials Name Specification Transmission fluid WSD-M2C200-C Sealant WSK-M2G348-A5 CAUTION:Taper roller bearings must not be oiled prior to measurement of the output shafts and the differential. Only oil the taper roller bearings after successful measurement. NOTE:In order to measure the output shafts, only the output shafts must be installed. NOTE:In order to measure the differential, only the differential must be installed. 1. Assemble the components in the order indicated in the following illustration(s) and table(s). 7 - Output shaft - 1st - 4th gear 11 - Selector fork - 5th / 6th gear 12 - Selector fork - reverse gear 13 - Selector shaft - 5th/6th/reverse gear 14 - Selector fork - 3rd / 4th gear 15 - Selector fork - 1st / 2nd gear 16 - Selector shaft - 1st - 4th gear 18 - Input shaft bearing bolts 21 - Transmission housing retaining bolts Assembly Details Item 1 : 5th/6th/reverse gear output shaft transmission-side bearing outer race | | -
Insert the 5th/6th/reverse gear output shaft transmission-side bearing outer race by hand and after the transmission housing has cooled, install using the special tool. - Heat the transmission housing with a hot air gun to approx. 90°C.
| Item 2 : 1st - 4th gear output shaft transmission-side bearing outer race | | -
Insert the 1st - 4th gear output shaft transmission-side bearing outer race by hand and after the transmission housing has cooled, install using the special tool. - Heat the transmission housing with a hot air gun to approx. 90°C.
| Item 3 : Differential transmission-side bearing outer race | | -
Insert the differential transmission-side bearing outer race by hand and after the transmission housing has cooled, install using the special tool. - Heat the transmission housing with a hot air gun to approx. 90°C.
| Item 4 : Differential clutch-side bearing outer race | | -
Insert the differential clutch-side bearing outer race and measurement shim by hand and after the clutch housing has cooled, install using the special tool. - Heat the clutch housing with a hot air gun to approx. 90°C.
- Install a 1.10 mm measuring shim.
| Item 5 : Clutch housing | | -
Attach the special tool to the clutch housing. | Item 6 : Output shaft - 5th/6th/reverse gear | | -
CAUTION:Insert the 1st - 4th gear output shaft and the 5th/6th/reverse gear output shaft carefully, to avoid damaging the bearings. CAUTION:Degrease and clean the bearings and output shaft bearing outer races. Install the 1st - 4th gear output shaft and the 5th/6th/reverse gear output shaft together in the transmission housing. | | | -
CAUTION:The transmission must cool to room temperature before performing measurements. NOTE:Place the clutch-side bearing outer race on the output shaft clutch-side taper roller bearing. Place the special tool on the 1st-4th gear output shaft and the 5th/6th/reverse gear output shaft. | | | -
NOTE:Repeat this and the following five job steps three times and determine the average values. Prepare the special tool for measuring. - Pull out the measuring rings to approx. 10 mm.
- Hold the clutch-side bearing outer races, turn the output shaft 20 times while pressing down at the same time, so that the bearings settle.
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NOTE:Make certain that the transmission housing mating faces are clean. NOTE:Pay attention that the special tools are in the correct positions. Install the special tools. | | | -
NOTE:Make certain that the clutch housing does not become skewed. NOTE:Make certain that the special tools are inserted correctly in the clutch housing bearing outer race seats. Install the clutch housing on the transmission housing. - Tighten the bolts of the clutch housing to the specified torque.
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NOTE:Make certain that the clutch housing does not become skewed. Detach the clutch housing. | | | -
Set the depth gauge to "0". | | | -
NOTE:While taking the measurements, only press lightly on the special tool, to avoid incorrect readings. Record the measurement results. | | | -
Measure the required thickness of the 1st - 4th gear output shaft adjustment shim. - Add the measured values, divide by three and then add the value for the bearing pre-load.
- 1st - 4th gear output shaft bearing pre-load: 0.17 mm.
- Example: 1.56 mm + 1.57 mm + 1.55 mm, divided by 3 = 1.56 mm. 1.56 mm + 0.17 mm = 1.73 mm.
- Determined adjusting shim thickness: 1.73 mm.
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Determine the required thickness of the output shaft 5th/6th/reverse gear adjusting shim. - Add the measured values, divide by three and then add the value for the bearing pre-load.
- Bearing pre-load - output shaft - 5th/6th/reverse gear 0.15 mm.
- Example: 1.51 mm + 1.52 mm + 1.50 mm, divided by 3 = 1.51 mm. 1.51 mm + 0.15 mm = 1.66 mm.
- Determined adjusting shim thickness: 1.66 mm.
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Remove the special tools. | | | -
Remove the 1st - 4th gear output shaft and the 5th/6th/reverse gear output shaft together from the transmission housing. - Remove the clutch-side bearing outer race from the output shaft clutch-side taper roller bearing.
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Detach the special tool from the clutch housing. | Item 8 : Differential | | -
CAUTION:The transmission housing must have cooled to room temperature before measurements are made. CAUTION:Degrease and clean the bearings and bearing shells of the differential. NOTE:Only the differential must be installed in order to perform measurements. Install the differential. | | | -
NOTE:Make certain that the transmission housing mating faces are clean. NOTE:Working diagonally, tighten the bolts of the transmission housing to the specified torque. Install the clutch housing on the transmission housing. | | | -
Attach the special tools to the transmission. - Clean the clutch-side end face of the differential assembly and mark it at one place.
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NOTE:Repeat this and the following four steps three times and determine the average values. NOTE:To measure the bearing pre-load turn the differential assembly 20 times while pressing down at the same time, so that the bearings settle. Turn the differential assembly 20 times with the special tool. | | | -
NOTE:Preload the dial indicator gauge to 1 mm. Prepare the differential assembly for measurement. - Install the dial gauge on the special tool, align to the mark and zero it.
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Turn the transmission through 180 degrees with the clutch side downwards. | | | -
NOTE:To measure the bearing pre-load turn the differential assembly 20 times while pressing down at the same time, so that the bearings settle. Turn the differential assembly 20 times with the special tool. - Turn the differential assembly until the measuring pin is on the marked spot.
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Measure the differential end float. - Make a note of the measurement, e.g. 0.34 mm.
- Example: 0.34 mm + 0.36 mm + 0.38 mm divided by three = 0.36 mm.
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Determine the required differential adjusting shim thickness. - Installed measurement shim thickness: 1.10 mm.
- Calculated differential end float: 0.36 mm.
- Differential bearing pre-load 0.25 mm.
- Required adjusting shim thickness: 1.10 mm + 0.36 mm + 0.25 mm = 1.71 mm.
- Determined adjusting shim thickness: 1.71 mm.
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Detach the clutch housing from the transmission housing. - Remove the special tools.
- Remove the transmission housing bolts.
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Remove the differential assembly. | Item 9 : Transmission housing | | -
Remove the clutch-side differential bearing outer race. - Remove the measurement shim.
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Insert the differential clutch-side bearing outer race by hand and after the clutch housing has cooled, install using the special tool. - Heat the clutch housing with a hot air gun to approx. 90°C.
- Install adjusting shim of determined thickness.
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NOTE:Install a new 5th/6th/reverse gear output shaft oil thrower. Insert the 5th/6th/reverse gear output shaft clutch-side bearing outer race by hand and after the clutch housing has cooled, install using the special tool. - Heat the clutch housing with a hot air gun to approx. 90°C.
- Install adjusting shim of determined thickness.
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NOTE:Install a new 1st - 4th gear output shaft oil thrower. Insert the 1st - 4th gear output shaft clutch-side bearing outer race by hand and after the clutch housing has cooled, install using the special tool. - Heat the clutch housing with a hot air gun to approx. 90°C.
- Install adjusting shim of determined thickness.
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Insert the input shaft parallel roller bearing by hand and after the clutch housing has cooled, install using the special tool. - Heat the clutch housing with a hot air gun to approx. 90°C.
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Clean all moving parts, check them and before assembly lubricate them with clean transmission fluid. | Item 10 : Input shaft | | -
NOTE:Pay attention to the installation position of the input shaft ball bearing retainer. The retainer of the input shaft ball bearing must be held in place by the 1st - 4th gear selector shaft. Tie together the 1st - 4th gear output shaft, 5th/6th/reverse gear output shaft, input shaft, shift forks and 1st - 4th gear selector shaft using a cable tie. | | | -
CAUTION:Carefully insert the 1st - 4th gear output shaft, 5th/6th/reverse gear output shaft, input shaft, shift forks and the 1st - 4th gear selector shaft, to avoid damage to the bearings. Insert the 1st - 4th gear output shaft, 5th/6th/reverse gear output shaft, input shaft, shift forks and 1st/4th gear selector shaft together into the transmission housing. | | | -
CAUTION:Make certain that the retainer of the input shaft ball bearing is placed in the groove of the transmission housing. Remove the cable tie (shown with the 1st - 4th gear selector shaft removed for clarity). | | | -
Install the 5th/6th/reverse gear selector shaft. | | | -
Install the differential. | Item 17 : Transmission housing retaining bolts | | -
Apply sealant centrally on the transmission mating face and past the threaded holes on the inside (bead diameter: 3 mm). - Install the clutch housing on the transmission housing.
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Tighten the transmission housing retaining bolts to the specified torque in two stages, working diagonally. | Item 19 : Differential transmission-side oil seal | | -
NOTE:Install a new differential oil seal. Install the differential transmission-side oil seal using the special tool. | Item 20 : Gearshift cable abutment bracket | | -
Attach the gearshift cable abutment bracket to the transmission. | Item 22 : Input shaft radial oil seal | | -
CAUTION:Cover the input shaft splines with adhesive tape to avoid damaging the input shaft oil seal. NOTE:Install a new input shaft oil seal. Install the input shaft oil seal with the special tool. | | | -
Remove the adhesive tape from the input shaft splines. | Item 23 : Clutch slave cylinder | | -
NOTE:Check the clutch slave cylinder for brake fluid leaks or damage. Install a new clutch slave cylinder if necessary. Install the clutch slave cylinder. | Item 24 : Differential clutch-side oil seal | | -
NOTE:Install a new differential oil seal. Install the differential clutch-side oil seal using the special tool. | Item 25 : Selector mechanism | | -
Apply sealant centrally on the mating face and past the threaded holes on the outside (bead diameter: 3 mm). | | | -
NOTE:Ensure that the transmission and selector mechanism are in the neutral position. NOTE:Ensure that the threaded holes are free of sealant. Install the selector mechanism. | Item 26 : Transmission | | -
Detach the transmission from the assembly stand. | |
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