Part 1
BEARING PRELOAD ADJUSTMENTPrimary Shaft Preload Adjustment
1. Measure the thickness of the straight edge which is used for measurements.
2. Measure distance A of the transaxle case using the following procedure.
1. Place two straight edges on the transaxle case as shown in the figure.
2. Set up 3 measurement points of your choosing on the shim assembly area of the transaxle case as shown in the figure.
3. Using a commercially available depth gauge, measure the distance to each measurement point from the straight edge.
CAUTION: When measuring the distance to the measurement point from the straight edge, do not allow the depth gauge head to contact the shim assembly area.
4. Calculate the average value measured in Step 3 using the following formula.
- (Value of first measurement + value of second measurement + value of third measurement) / 3 = Average measured values.
Calculation example
- Value of first measurement = 224.380 mm {8.83386 in}
- Value of second measurement = 224.381 mm {8.83390 in}
- Value of third measurement = 224.379 mm {8.83382 in}
- (224.380 mm {8.83386 in} + 224.381 mm {8.83390 in} + 224.379 mm {8.83382 in}) / 3 = 224.380 mm {8.83386 in}
5. Calculate distance A of the transaxle case using the following formula.
- Average of measured values - straight edge thickness = Distance A
Calculation example
- Straight edge thickness = 5.000 mm {0.1969 in}
- Average of measured values = 224.380 mm {8.83386 in}
- 224.380 mm {8.83386 in} - 5.000 mm {0.1969 in} = 219.380 mm {8.63701 in}
3. Measure distance B of the transaxle case using the following procedure.
1. Set two straight edges on the clutch housing as shown in the figure.
2. Set up 3 measurement points of your choosing on the ball bearing assembly area of the clutch housing as shown in the figure.
3. Using a commercially available depth gauge, measure the distance to each measurement point from the straight edge.
CAUTION: When measuring the distance to the measurement points from the straight edge, do not allow the depth gauge head to contact the ball bearing assembly area.
4. Calculate the average value measured in Step 3 using the following formula.
- (Value of first measurement + value of second measurement + value of third measurement) / 3 = Average measured values.
Calculation example
- Value of first measurement = 30.575 mm {1.2037 in}
- Value of second measurement = 30.577 mm {1.2038 in}
- Value of third measurement = 30.577 mm {1.2038 in}
- (30.575 mm {1.2037 in} + 30.577 mm {1.2038 in} + 30.577 mm {1.2038 in}) / 3 = 30.576 mm {1.2038 in}
5. Calculate distance B of the clutch housing using the following formula.
- Average of measured values - straight edge thickness = Distance B
Calculation example
- Straight edge thickness = 5.000 mm {0.1969 in}
- Average of measured values = 30.576 mm {1.2038 in}
- 30.576 mm {1.2038 in} - 5.000 mm {0.1969 in} = 25.576 mm {1.0069 in}
4. Measure distance C of the primary shaft component using the following procedure.
1. Place two straight edges on the surface plate as shown in the figure and set the primary shaft component on top of them.
2. Set up 3 measurement points of your choosing on the ball bearing as shown in the figure.
3. Using a commercially available height gauge, measure the distance to each measurement point from the straight edge.
4. Calculate the average of the value measured in Step 3 using the following formula, and use the average of the measured value for distance C of the primary shaft component.
- (Value of first measurement + value of second measurement + value of third measurement) / 3 = Distance C
Calculation example
- Value of first measurement = 243.591 mm {9.59020 in}
- Value of second measurement = 243.592 mm {9.59024 in}
- Value of third measurement = 243.593 mm {9.59028 in}
- (243.591 mm {9.59020 in} + 243.592 mm {9.59024 in} + 243.593 mm {9.59028 in}) / 3 = 243.592 mm {9.59024 in}
5. Select the primary shaft shim using the following procedure.
1. Calculate the clearance (clearance D) between the transaxle case and the primary shaft component using the following formula.
- Distance A + Distance B - Distance C = Clearance D
Calculation example
- Distance A = 219.380 mm {8.63701 in}
- Distance B = 25.576 mm {1.0069 in}
- Distance C = 243.592 mm {9.59024 in}
- 219.380 mm {8.63701 in} + 25.576 mm {1.0069 in} - 243.592 mm {9.59024 in} = 1.364 mm {0.05370 in}
2. Based on the calculated clearance D, select a shim of the appropriate thickness from the following table.
Selection example
- Because clearance D 1.364 mm {0.05370 in} applies to 1.320 mm {0.05197 in} or more and less than 1.370 mm {0.05394 in}, a shim of 1.300 {0.05118} thickness is selected.
Secondary Shaft Preload Adjustment
1. Measure the thickness of the straight edge which is used for measurements.
2. Measure distance E of the transaxle case using the following procedure.
1. Place two straight edges on the transaxle case as shown in the figure.
2. Set up 3 measurement points of your choosing on the shim assembly area of the transaxle case as shown in the figure.
3. Using a commercially available depth gauge, measure the distance to each measurement point from the straight edge.
CAUTION: When measuring the distance to the measurement point from the straight edge, do not allow the depth gauge head to contact the shim assembly area.
4. Calculate the average value measured in Step 3 using the following formula.
- (Value of first measurement + value of second measurement + value of third measurement) / 3 = Average measured values.
Calculation example
- Value of first measurement = 223.223 mm {8.78831 in}
- Value of second measurement = 223.219 mm {8.78815 in}
- Value of third measurement = 223.222 mm {8.78827 in}
- (223.223 mm {8.78831 in} + 223.219 mm {8.78815 in} + 223.222 mm {8.78827 in}) / 3 = 223.221 mm {8.78823 in}
5. Calculate distance E of the transaxle case using the following formula.
- Average of measured values - straight edge thickness = Distance E
Calculation example
- Straight edge thickness = 5.000 mm {0.1969 in}
- Average of measured values = 223.221 mm {8.78823 in}
- 223.221 mm {8.78823 in} - 5.000 mm {0.1969 in} = 218.221 mm {8.59138 in}
3. Measure distance F of the transaxle case using the following procedure.
1. Set two straight edges on the clutch housing as shown in the figure.
2. Set up 3 measurement points of your choosing on the ball bearing assembly area of the clutch housing as shown in the figure.
3 Using a commercially available depth gauge, measure the distance to each measurement point from the straight edge.
CAUTION: When measuring the distance to the measurement point from the straight edge, do not allow the depth gauge head to contact the bearing outer race assembly area.
4. Calculate the average value measured in Step 3 using the following formula.
- (Value of first measurement + value of second measurement + value of third measurement) / 3 = Average measured values.
Calculation example
- Value of first measurement = 61.154 mm {2.4076 in}
- Value of second measurement = 61.153 mm {2.4076 in}
- Value of third measurement = 61.153 mm {2.4076 in}
- (61.154 mm {2.4076 in} + 61.153 mm {2.4076 in} + 61.153 mm {2.4076 in}) / 3 = 61.153 mm {2.4076 in}
5. Calculate distance F of the clutch housing using the following formula.
- Average of measured values - straight edge thickness = Distance F
Calculation example
- Straight edge thickness = 5.000 mm {0.1969 in}
- Average of measured values = 61.153 mm {2.4076 in}
- 61.153 mm {2.4076 in} - 5.000 mm {0.1969 in} = 56.153 mm {2.2107 in}
4. Measure distance G of the secondary shaft component using the following procedure.
1. Place two straight edges on the surface plate as shown in the figure and set the bearing outer race and secondary shaft component on top of them.
2. Rotate the secondary shaft component to its rotational direction to engage the taper roller bearing and the bearing outer race assembled to the clutch housing smoothly.
3. Set up 3 measurement points of your choosing on the bearing outer race as shown in the figure.
4. Using a commercially available height gauge, measure the distance to each measurement point from the straight edge.
5. Calculate the average of the value measured in Step 4 using the following formula, and use the average of the measured value for distance G of the secondary shaft component.
- (Value of first measurement + value of second measurement + value of third measurement) / 3 = Distance G
Calculation example
- Value of first measurement = 273.274 mm {10.7588 in}
- Value of second measurement = 273.270 mm {10.7587 in}
- Value of third measurement = 273.273 mm {10.7588 in}
- (273.274 mm {10.7588 in} + 273.270 mm {10.7587 in} + 273.273 mm {10.7588 in}) / 3 = 273.272 mm {10.7587 in}
5. Select the secondary shaft shim using the following procedure.
1. Calculate the clearance (clearance H) between the transaxle case and the primary shaft component using the following formula.
- Distance E + Distance F - Distance G = Clearance H
Calculation example
- Distance E = 218.221 mm {8.59138 in}
- Distance F = 56.153 mm {2.2107 in}
- Distance G = 273.272 mm {10.7587 in}
- 218.221 mm {8.59138 in} + 56.153 mm {2.2107 in} - 273.272 mm {10.7587 in} = 1.102 mm {0.04339 in}
2. Based on the calculated clearance H, select a shim of the appropriate thickness from the following table.
Selection example
- Because clearance H 1.102 mm {0.04339 in} applies to 1.081 {0.04256} or more and less than 1.131 {0.04453}, a shim of 1.250 {0.04921} thickness is selected.