2WD Models
- Install oil seals into differential side retainers. Place left half of transaxle case on work stand. Screw retainer, without "O" ring, into case. Install outer snap ring and washer onto speedometer shaft. Install assembly into case. Install speedometer driven gear. Install outer snap ring.
- Set interlock plungers between 1st-2nd and 3rd-4th fork rod holes, and between 3rd-4th and reverse fork rod holes. Install reverse arm fork spring, ball and interlock plunger onto reverse shift rod arm. Install reverse fork rod into reverse shift rod arm. Install outer snap ring.
- Install reverse shift lever into left half of case. Install reverse idler gear and reverse idler gear shaft. Install pin. Install reverse shift rod ball, spring, and gasket into case. Install and tighten plug to 13-16 ft. lbs. (18-22 N.m).
- Set reverse shift rod to Reverse position. Measure clearance between reverse idler gear and case. On 2WD turbo, clearance should be .24-.30" (6.0-7.5 mm). On 2WD non-turbo models, clearance should be .06-.12" (1.5-3.0 mm). Different levers are available to adjust specified clearance. See REVERSE SHIFT LEVER SELECTION .REVERSE SHIFT LEVER SELECTION
Part No. (Mark) Result 2WD Non-Turbo 440627101 (1) Farther From Case 440627102 (-) Standard 440627103 (3) Closer To Case Except 2WD Non-Turbo 32820AA000 (0) Farther From Case 32820AA010 (-) Standard 32820AA020 (2) Closer To Case - Install specified reverse shift lever. Shift lever into Neutral position. Measure clearance between reverse idler gear and case. Clearance should be 0-.02" (0-.5 mm). Select and install washer to adjust clearance. Washers are available in thicknesses from .016-.091" (.40-2.30 mm) for 2WD turbo or .024-.094" (.60-2.40 mm) for 2WD non-turbo models.
- Set rod to Neutral position. Ensure interlock plunger, installed in step 2), is on reverse fork rod side. Coat interlock plunger with grease. Install plunger onto 3rd-4th fork rod. Install fork rod into 3rd-4th shift fork through rear of case. Align holes in rod and fork. Install pin.
- Set rod to Neutral position. Ensure interlock plunger is on 3rd-4th fork rod side. Install 1st-2nd fork rod into 1st-2nd fork shift fork through rear of case. Align holes and install pin. Install 5th shift fork onto rear of reverse fork rod. Align holes in rod and fork. Install pin.
- Install check ball plugs, springs and balls. Tighten plugs to 13-16 ft. lbs. (18-22 N.m). Wrap splined areas of axle shafts with tape. Install differential assembly into case. Lubricate and install oil seal. Install needle bearing onto front of mainshaft. Install mainshaft into case. Use care not to damage oil seal. Align pin with hole in needle bearing outer race.
- Install drive pinion and previously selected shims into case. Engage pin on case into hole in bearing outer race. Force mainshaft and pinion shaft toward front of case until no clearance exists between shafts and case.
- Select and install shift fork so driven gears are centered in their synchronizing mechanisms. For 1st-2nd shift fork, measure distance between 1st driven gear and reverse driven gear, and between 2nd driven gear and reverse driven gear. For 3rd-4th shift fork, measure distance between 3rd drive gear and coupling sleeve, and between 4th gear and coupling sleeve. See Fig 1.
- For 5th shift fork, measure clearance between 5th drive gear and coupling sleeve. See SHIFT FORK CLEARANCE SPECIFICATIONS . If clearance is not within specification, select another shift fork. See appropriate SHIFT FORK SELECTION table.SHIFT FORK CLEARANCE SPECIFICATIONS
Shift Fork Application Clearance In. (mm) 1st-2nd .374 (9.50) 3rd-4th 2WD Non-Turbo .374 (9.50) Except 2WD Non-Turbo .367 (9.30) 5th .367 (9.30) 1ST-2ND SHIFT FORK SELECTIONPart No. (Mark) Result 2WD Non-Turbo 32804AA001 (1) .008" (.20 mm) Toward 2nd Gear 32804AA011 (-) Standard 32804AA021 (3) .008" (.20 mm) Toward 1st Gear Except 2WD Non-Turbo 32804AA031 (1) .008" (.20 mm) Toward 1st Gear 32804AA041 (-) Standard 32804AA051 (3) .008" (.20 mm) Toward 2nd Gear 3RD-4TH SHIFT FORK SELECTIONPart No. (Mark) Result 2WD Non-Turbo 442017001 (1) .016" (.40 mm) Toward 4th Gear 442017002 (2) .008" (.20 mm) Toward 4th Gear 442017003 (-) Standard 442017004 (4) .008" (.20 mm) Toward 3rd Gear 442017005 (5) .016" (.40 mm) Toward 3rd Gear Except 2WD Non-Turbo 32810AA031 (1) .008" (.20 mm) Toward 4th Gear 32810AA041 (-) Standard 32810AA051 (3) .008" (.20 mm) Toward 3rd Gear 5TH SHIFT FORK SELECTIONPart No. (Mark) Result 2WD Non-Turbo 32812AA032 (1) .008" (.20 mm) Toward 5th Gear 32812AA042 (-) Standard 32812AA052 (3) .008" (.20 mm) From 5th Gear Except 2WD Non-Turbo 32812AA004 (1) .008" (.20 mm) Toward 5th Gear 32812AA014 (-) Standard 32812AA024 (3) .008" (.20 mm) From 5th Gear - Measure clearance between edges of each shift rail. See SHIFT RAIL CLEARANCE table. See Fig 2. If clearance is not within specification, replace rod or fork.
- Clean mating surfaces of case halves. Apply liquid sealer to cases. Assemble cases. Ensure drive pinion shim(s) are not caught between case halves. Mesh countergear and speedometer gear.
- Tighten in sequence. See Fig 3. Tighten 8-mm case bolts to 17-20 ft. lbs. (23-27 N.m), and 10-mm bolts to 27-31 ft. lbs. (37-42 N.m). Tighten ball bearing bolts at rear of drive pinion to 20-24 ft. lbs. (27-33 N.m).
SHIFT RAIL CLEARANCE (1)
| Application | In. (mm) | ||
|---|---|---|---|
| 2WD Non-Turbo | |||
| "A" & "B" | .012-.063 (.30-1.60) | ||
| Except 2WD Non-Turbo "A" | |||
| 1st-2nd & 3rd-4th "B" | .020-.059 (.50-1.50) | ||
| 3rd-4th & 5th | .024-.055 (.60-1.40) | ||
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