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Assembly|Installation > < Differential

Galaxy 2000.75 (04.2000-02.2006)

Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MT350) - Transaxle Galaxy 2000.75 (04/2000-02/2006)
Assembly

Special Tool(s)

Installer, Drive Pinion Oil Seal

204-088 (14-030)

Remover/Installer, Lower Arm Bushing

204-093 (14-032)

Adapter for 205-044

205-044-01 (15-008-01)

Holding Fixture, Dial Indicator Gauge

205-070 (15-022A)

Flange Holding Wrench, Universal

205-072 (15-030A)

Installer, Rear Hub Oil Seal

205-075 (15-036)

Remover, Drive Pinion Oil Seal

205-078 (15-048)

Adapter for 205-078 (Thrust Pad)

205-078-01 (15-048-01)

Installer, Differential Bearing

205-081 (15-032)

Installer, Rear Hub Bearing Cone/Oil Seal

205-216 (15-079)

Installer, Wheel Hub Oil Seal

205-252 (15-083)

Remover, Bearing/Gear

205-310 (15-091)

Remover, Bearing/Gear

205-311 (15-092)

Installer Drive Pinion Oil Seal

205-315 (15-096)

Mounting Bracket, Engine/Differential

205-329 (15-105A)

Compressor, Valve Spring

303-060 (21-024)

Adapter for 303-060

303-060-05 (21-024-05)

Adapter for 303-060

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

Installer/Aligner, Pilot Bearing/Clutch Plate

303-081 (21-044A)

Adapter for 303-171

303-171-01 (21-102-01)

Installer/Aligner, Crankshaft Rear Oil Seal

303-172 (21-102)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-10 (21-139)

Installer, Crankshaft Rear Seal

303-439 (21-190)

Adapter for 303-458

303-458-01 (21-192-01)

Installer, Shift Shaft Oil Seal

307-050 (17-008)

Installer, Halfshaft Oil Seal

308-039 (16-018)

Mounting Bracket for 303-435

308-042A (16-022A)

Installer, Output Drive Flange Oil Seal

308-112 (16-043A)
General Equipment
Dial indicator gauge
Hot Air Gun
Materials
Name
Specification
Sealer, transaxle housing
WSK-M2G348-A5 
M8 x 60 mm locating bolt (vehicles build up to 12/2002)
 
M8 x 100 mm locating bolt (vehicles build from 01/2003 onwards)
 
Manual transmission fluid
N052171VX00 

Assembly

NOTE:
NOTE:Using a suitable press, install the bearing cups.
NOTE:
NOTE:Use vise jaw protectors for all operations in a vise.
NOTE:
NOTE:All the bearings are paired and must not be mixed.
NOTE:
NOTE:Clean the transaxle housing mating faces.
NOTE:
NOTE:If installing new roller bearings, do not lubricate the bearings.
All vehicles
  1. Carefully clean and check all sliding parts and lubricate them with manual transmission fluid before assembly.

  1. Using the special tool, install the selector shaft bearing bushings.
    1. Install the fifth, sixth and reverse gear selector rod bearing bushing.
    1. Install the first and second gear selector rod bearing bushing.
    1. Install the third and fourth gear selector rod bearing bushing.

  1. Using the special tool, install the reverse gear shaft bearing.
Vehicles built up to 12/2002
  1. Using the special tool, install the input shaft bearing cup.
    • Heat the clutch housing with a hot air gun to approx. 80°C.
Vehicles built 01/2003 onwards
  1. NOTE:
    NOTE:Install a new input shaft parallel roller bearing snap ring.
    NOTE:
    NOTE:Ensure that the snap ring stays pressed together during the installing of the input shaft parallel roller bearing, using suitable pliers.
    NOTE:
    NOTE:Remove the pliers before completely installing the input shaft parallel roller bearing to avoid damage.
    Using the special tool, install the input shaft parallel roller bearing.
    1. Press the snap ring.
    1. Install the input shaft parallel roller bearing.
All vehicles
  1. NOTE:
    NOTE:Install the oil splash shield with the large collar facing towards the output shaft.
    Using the special tool, install the first to fourth gear output shaft bearing cup.
    • Install the oil splash shield.
    • Heat the clutch housing with a hot air gun to approx. 80°C.

  1. Using the special tool, install the fifth, sixth and reverse gear output shaft bearing cup.
    • Heat the clutch housing with a hot air gun to approx. 80°C.
  1. CAUTION:
    CAUTION:If installing one or more of the following new parts, adjustment of the first to fourth gear output shaft is required: Transaxle housing, clutch housing, output shaft (first to fourth gear), roller bearings (output shaft first to fourth gear).
    NOTE:
    NOTE:To measure the bearing preload, only install the shaft to be measured.
    Install the first to fourth gear output shaft to the clutch housing.
    • Heat the clutch housing with a hot air gun to approx. 80°C.

  1. Using the special tool, install the first to fourth gear output shaft bearing cup and a 1.70 mm adjusting shim.
    • Heat the transaxle housing with a hot air gun to approx. 80°C.

  1. NOTE:
    NOTE:Tighten the transaxle housing retaining bolts in a diagonal sequence.
    Install the transaxle housing to the clutch housing.
    • Tighten the bolts in two stages.
    • Stage 1: 25 Nm.
    • Stage 2: 90 degrees.

  1. Install the clutch housing retaining bolts.
    • Tighten the bolts in two stages.
    • Stage 1: 25 Nm.
    • Stage 2: 90 degrees.

  1. NOTE:
    NOTE:Preload the dial indicator gauge plunger up to 1 mm.
    Install the special tools, set the dial indicator gauge to ""zero”.
  1. Loosen the transaxle and clutch housing retaining bolts in a diagonal sequence until the housings are released.
  1. NOTE:
    NOTE:If there is no measurable value after the housings are released, install an adjusting shim with a thickness of 1.95 mm or 2.2 mm.
    Calculate the adjusting shims.
    For additional information, refer to: Specifications (308-03B Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MT350), Specifications).
    • To calculate the bearing preload, subtract the measured value (example 0.14 mm) from the adjusting shim (example 1.70 mm), and add a constant compression value (0.20 mm).
    • Example: 1.70 mm - 0.14 mm + 0.20 mm = 1.76 mm.
    • Install adjusting shims with a thickness of 1.75 mm.

  1. Using the special tools, remove the first to fourth gear output shaft bearing cup and the adjusting shim (1.70 mm).

  1. Using the special tool, install the first to fourth gear output shaft bearing cup and a 1.75 mm adjusting shim.
    • Heat the transaxle housing with a hot air gun to approx. 80°C.
  1. Verify the measurement refer to the previous steps.
  1. CAUTION:
    CAUTION:If installing one or more of the following new parts, adjustment of the fifth, sixth and reverse gear output shaft is required: Transaxle housing, clutch housing, output shaft (fifth, sixth and reverse gear), roller bearings (output shaft fifth, sixth and reverse gear).
    NOTE:
    NOTE:To measure the bearing preload, only install the shaft to be measured.
    Install the fifth, sixth and reverse gear output shaft to the clutch housing.
    • Heat the transaxle housing with a hot air gun to approx. 80°C.

  1. Using the special tool, install the fifth and sixth, and reverse gear output shaft bearing cup with a 1.70 mm adjusting shim.
    • Heat the transaxle housing with a hot air gun to approx. 80°C.
  1. NOTE:
    NOTE:Tighten the transaxle housing retaining bolts in a diagonal sequence.
    Assemble the housings refer to previous steps.

  1. NOTE:
    NOTE:Preload the dial indicator gauge plunger up to 1 mm.
    Install the special tools, set the dial indicator gauge to "zero".
  1. Loosen the transaxle and clutch housing retaining bolts in a diagonal sequence until the housings are released.
  1. NOTE:
    NOTE:If there is no measurable value after the housings have been released, install a adjusting shim with a thickness of 1.95 mm or 2.2 mm.
    Calculate the adjusting shims.
    For additional information, refer to: Specifications (308-00 Manual Transmission/Transaxle and Clutch - General Information, Specifications).
    • To calculate the bearing preload, subtract the measured value (example 0.27 mm) from the adjusting shim (example 1.70 mm), and add a constant compression value (0.20 mm).
    • Example: 1.70 mm - 0.27 mm + 0.20 mm = 1.63 mm.
    • Install adjusting shims with a thickness of 1.65 mm.

  1. Using the special tools, remove the fifth, sixth and reverse gear output shaft bearing cup and the adjusting shim (1.70 mm).

  1. Using the special tool, install the fifth, sixth and reverse gear output shaft bearing cup and a 1.65 mm adjusting shim.
    • Heat the transaxle housing with a hot air gun to approx. 80°C.
  1. Verify the measurement refer to previous steps.

  1. CAUTION:
    CAUTION:If installing one or more of the following new parts, adjustment of the differential is required: Transaxle housing, clutch housing, differential, roller bearings (differential).
    NOTE:
    NOTE:To measure the bearing preload, only install the differential.
    NOTE:
    NOTE:Install a new oil splash shield.
    Using the special tool, install the differential bearing cup.
    • Heat the clutch housing with a hot air gun to approx. 80°C.

  1. NOTE:
    NOTE:Do not install an adjustment shim at this stage.
    Using the special tools, install the differential bearing cone.
    • Heat the transaxle housing with a hot air gun to approx. 80°C.
  1. Install the differential to the clutch housing.
  1. NOTE:
    NOTE:Tighten the transaxle housing retaining bolts in a diagonal sequence.
    Assemble the housings refer to previous steps.

  1. Install the special tool.

  1. Attach the special tool to the transmission.
    • Clean the clutch-side end face of the differential assembly and mark it at one place.

  1. NOTE:
    NOTE:Repeat this and the following three steps three times and determine the average values.
    NOTE:
    NOTE:To measure the bearing pre-load turn the differential assembly 10 times while pressing down at the same time, so that the bearings settle.
    Turn the differential assembly 10 times with the retaining bolt.

  1. NOTE:
    NOTE:Preload the dial indicator gauge to 1 mm.
    Prepare the differential assembly for measurement.

  1. Lift the differential using the special tool.
  1. Measure the differential end float.
    • Make a note of the measurement, e.g. 0.70 mm.
    • Example: 0.70 mm + 0.72 mm + 0.71 mm divided by three = 0.71 mm.
  1. Calculate the adjustment shims.
    For additional information, refer to: Specifications (308-03B Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MT350), Specifications).
    • To calculate the bearing preload, add the measured value (example 0.71 mm) a constant compression value (0.30 mm).
    • Example: 0.71 mm + 0.30 mm = 1.01 mm.
    • Install adjusting shims with a thickness of 1.01 mm.

  1. Using the special tools, remove the differential bearing cone.

  1. NOTE:
    NOTE:Install the adjusting shims, thickest shims first.
    Using the special tools, install the differential bearing cone and the adjusting shims.
    • Heat the transaxle housing with a hot air gun to approx. 80°C.
Vehicles built 01/2003 onwards
  1. Adjusting the input shaft is not required.
Vehicles built up to 12/2002
  1. CAUTION:
    CAUTION:If installing one or more of the following new parts, readjustment of the input shaft is required: transaxle housing, clutch housing, input shaft, roller bearings (input shaft).
    NOTE:
    NOTE:To measure the input shaft, both output shafts have to be installed to the housings with their adjusting shims.
    Install the input shaft and both output shafts to the clutch housing.

  1. NOTE:
    NOTE:Do not install an adjusting shim at this stage.
    Using the special tool, install the input shaft bearing cup.
    • Heat the transaxle housing with a hot air gun to approx. 80°C.
  1. NOTE:
    NOTE:Tighten the transaxle housing retaining bolts in a diagonal sequence.
    Assemble the housings refer to previous steps.

  1. NOTE:
    NOTE:To measure the bearing preload, rotate the input shaft several times to seat the bearings.
    NOTE:
    NOTE:Preload the dial indicator gauge plunger up to 1 mm.
    Install the special tools, set the dial indicator gauge to "zero".

  1. NOTE:
    NOTE:Repeat the previous step each time to obtain the "zero" of reading of the dial indicator gauge.
    Move the input shaft towards the dial indicator gauge.
  1. Determine the adjusting shim according to the measured bearing clearance.
    For additional information, refer to: Specifications (308-03B Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MT350), Specifications).

  1. Using the special tools, remove the input shaft bearing cup.

  1. Using the special tool, install the input shaft bearing cup and the appropriate adjusting shim.
    • Heat the transaxle housing with a hot air gun to approx. 80°C.
  1. NOTE:
    NOTE:Verify the measurement refer to previous steps.
    The dial indicator gauge reading should be between 0.015 mm and 0.100 mm. If the bearing clearence cannot be measured but the input shaft play is perceptible and the input shaft turns freely, the adjustment is acceptable.
  1. Loosen the transaxle and clutch housing retaining bolts in a diagonal sequence and remove the input shaft and both output shafts from the transaxle housing.
All vehicles
  1. Discard the transaxle housing bolts.

  1. Using the special tool, install the selector shaft bearing bushings and the reverse gear shaft bearing.
    1. Install the fifth, sixth and reverse gear selector rod bearing bushing.
    1. Install the reverse gear shaft bearing.
    1. Install the first and second gear selector rod bearing bushing.
    1. Install the third and fourth gear selector shaft bearing bushing.
Vehicles built up to 12/2002
  1. NOTE:
    NOTE:Only if removed.
    Using a suitable drift, install the selector shaft locking pin.

  1. NOTE:
    NOTE:Only if removed.
    Using a suitable drift, install the stop sleeves.
All vehicles
  1. NOTE:
    NOTE:Use a rubber band to support the differential.
    Install the differential.
    • Install the magnetic disc.
Vehicles built up to 12/2002
  1. Install the fifth, sixth and reverse gear output shaft with selector rods.

  1. Install the reverse gear shaft.

  1. Install the first to fourth gear output shaft with selector rods.

  1. Install the input shaft.

  1. Install the locking bolt.
    • Remove the rubber band.
Vehicles built 01/2003 onwards
  1. Tie together the input shaft, 5th - 6th and reverse gear output shaft, 5th - 6th and reverse gear reverse gear selector shaft and 5th - 6th and shift forks using a cable tie.

  1. NOTE:
    NOTE:The round edge of the reverse gear shaft thrust washer must face upwards.
    Install the 5th - 6th and reverse gear output shaft together with the reverse gear shaft, input shaft, 5th - 6th and reverse gear selector shaft and shift forks.
    • Install the reverse gear shaft thrust washer.

  1. Install the output shaft.
    1. Lift the 5th - 6th and reverse gear output shaft, reverse gear shaft, input shaft, 5th - 6th and reverse gear selector shaft and shift forks.
    1. Install the output shaft together with the output selector shaft and shift forks.
    • Remove the cable tie and the rubber band.
All vehicles
  1. Apply sealer to the inner edge of the transaxle housing mating face.
Vehicles built 01/2003 onwards
  1. NOTE:
    NOTE:Heat the input shaft roller bearing area of the transaxle housing with a hot air gun to approx. 80°C before assembling.
    Assemble the two halves of the housings.
All vehicles

  1. NOTE:
    NOTE:Tighten the transaxle housing retaining bolts in a diagonal sequence.
    NOTE:
    NOTE:Install new transaxle housing retaining bolts.
    Install the transaxle housing retaining bolts.
    • Tighten the bolts in two stages.
    • Stage 1: 25 Nm.
    • Stage 2: 90 degrees.

  1. NOTE:
    NOTE:Install new clutch housing retaining bolts.
    Install the clutch housing retaining bolts.
    • Tighten the bolts in two stages.
    • Stage 1: 25 Nm.
    • Stage 2: 90 degrees.

  1. CAUTION:
    CAUTION:Wrap the input shaft splines with adhesive tape in order to protect the input shaft oil seal.
    Using the special tools, install the input shaft oil seal.

  1. Install the clutch slave cylinder assembly.
  1. Remove the adhesive tape from the input shaft splines.

  1. NOTE:
    NOTE:Install a new halfshaft oil seal.
    Using the special tool, install the right-hand halfshaft oil seal.

  1. NOTE:
    NOTE:Install a new halfshaft oil seal.
    Using the special tool, install the left-hand halfshaft oil seal.

  1. NOTE:
    NOTE:Move the selector forks, shifting into two gears.
    Push the gear selector forks as indicated.

  1. Using the special tool, install the transaxle left-hand output drive flange.

  1. Using the special tool, install the transaxle right-hand output drive flange.
  1. Shift the gearshift mechanism to neutral position.

  1. NOTE:
    NOTE:Install a new ball sleeve O-ring.
    Using the special tool, install the ball sleeve.
    • Install the O-ring.

  1. Using the special tool, install the selector shaft oil seal.
Vehicles built up to 12/2002
  1. NOTE:
    NOTE:Move the selector rods into the neutral position.
    NOTE:
    NOTE:Make sure the lower selector shaft sleeve is in position.
    Install the selector shaft.

  1. Install a M8 x 60 locating bolt to aid installation.

  1. NOTE:
    NOTE:Remove the M8 x 60 mm locating bolt and install the selector shaft centre retaining bolt.
    Install the shift cover.
    • Install the centre retaining bolt.
    • Install the retaining bolts.

  1. Install the shift cover.
    1. Install the locking bolt.
    1. Install the retaining bolts.

  1. Install the clutch slave cylinder bleed valve.

  1. Install the reversing lamp switch.

  1. NOTE:
    NOTE:Install a new transaxle drain plug.
    Fill the transaxle with manual transmission fluid until the oil level is just below the bottom of the filler hole.
Vehicles built 01/2003 onwards
  1. NOTE:
    NOTE:Move the selector rods into the neutral position.
    NOTE:
    NOTE:Make sure the lower selector shaft sleeve is in position.
    Install the selector shaft.

  1. Install the shift cover.
    1. Install the locking bolt.
    1. Install the retaining bolts.

  1. Install the clutch slave cylinder bleed valve.

  1. Install the reversing lamp switch.

  1. Install the selector interlock mechanism.

  1. NOTE:
    NOTE:Install a new transaxle drain plug.
    Fill the transaxle with manual transmission fluid until the oil level is just below the bottom of the filler hole.

  1. NOTE:
    NOTE:Install a new snap ring.
    NOTE:
    NOTE:Determine the thickest snap ring for installation.
    Install the snap ring.

  1. NOTE:
    NOTE:Install a new transaxle housing plug.
    Install the transaxle housing plug, using the special tool.
All vehicles
  1. Install the selector mechanism bracket and the abutment collar.
    1. Install the circlip.
    1. Install the selector mechanism retaining nut.
    1. Install the abutment collar.

  1. Install the vehicle speed sensor (VSS).

  1. Remove the transaxle from the mounting stand.

Assembly|Installation > < Differential