All Except 4WD Dual Range
- With differential bearing preload and ring gear backlash correctly adjusted, remove both axle drive shaft holders. Install "O" ring seal on each holder. Reinstall holders into transaxle case, making sure alignment marks on holders and case are aligned.
- Remove tape from around axle drive shaft splines. On 4WD models, remove pinion shaft lock nut, washer and rear shaft drive gear. Elect a mainshaft collar which will provide 0-.012" (0-.30 mm) clearance between mainshaft bearing and transfer case.
- Install gasket and transfer case (with selected mainshaft collar) on transaxle and install, but DO NOT tighten, transfer case-to-transaxle mounting nuts. Install rear shaft drive gear, washer and lock nut. Tighten lock nut and stake in 4 places. Tighten transfer case-to-transaxle mounting nuts.
- Install new "O" ring in shift arm groove. Install gasket and extension housing on transfer case and tighten bolts. Install rear drive shift fork. Install shift rail spring and ball in transfer case, then install rear drive shift rail. Install roll pin to Secure fork to rail. Install gasket and transfer case cover.
- On all models, use depth gauge to measure the amount of ball bearing protrusion from transmission main case surface and select mainshaft collar according to table. Before measuring, lightly tap the end of the mainshaft with a plastic hammer.MAINSHAFT COLLAR SELECTION
Bearing Protrusion: In. (mm) Collar Thickness: In. (mm) 1600 cc Models .138-.140 (3.50-3.63) .197 (5.0) .133-.138 (3.38-3.50) .202 (5.13) 1800 cc Models .177-.182 (4.50-4.63) .197 (5.0) .172-.177 (4.37-4-50) .202 (5.13) - Install transaxle end cover. Install shifter arm in transmission rear case and install rear case to main case. On 5-speed, adjust 5th gear position. Shift shifter shaft to 5th gear position. Remove drain plug and install dial indicator with stem resting on top of reverse accent shaft. See Fig 1 .
- Measure clearance when shifter shaft is turned to reverse side lightly. Select a reverse accent shaft so that contact clearance is within .002-.015" (.05-.40 mm). On all models, adjust gear selector as follows Insert a rod through hole in shift arm and shift into 3rd gear.
- Arm should move easily toward 1st-2nd gear side, but harder toward reverse side because of return spring action. Next, make adjustment to effort required to move lever to either position. Adjustment is performed by removing plug on cover and changing thickness of aluminum gasket.
- On all except 4WD models, make adjustment so the heavy stroke (reverse side) is a little more than light side. On 4WD models, adjust strokes to take equal effort. On all models, install release bearing guide on case together with 2 release spring brackets.
- Install clutch release fork and release bearing holder. Secure with release bearing holder spring. Install clutch release fork seal ring and spring. Fill internal groove of release bearing holder with grease.