ZEST AND BOLT_VOLUME 1

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DRIVETRAIN C549
CONTENTS
4.1.1 .........................................................................................................................................1
..........................................................................................................................1
4.1.1.2 TECHNICAL SPECIFICATIONS.....................................................................................................3
4.1.1.3 ..............................................................................................................................4
A CLUTCH ASSEMBLY REMOVAL...................................................................................................4
.............................................................................................4
C CLUTCH SLAVE CYLINDER BLEEDING PROCEDURE...............................................................5
D CLUTCH MASTER CYLINDER - REMOVAL..................................................................................7
E CLUTCH PEDAL ASSEMBLY - REMOVAL....................................................................................8
F CLUTCH SWITCH ADJUSTMENT PROCEDURE..........................................................................9
.........................................................................................................................9
4.1.2 TRANSAXLE...............................................................................................................................12
4.1.2.1 GENERAL INFORMATION...........................................................................................................12
A TECHNICAL SPECIFICATIONS...................................................................................................12
B CONSTRUCTION AND SYSTEM DESCRIPTION........................................................................13
B TIGHTENING TORQUES..............................................................................................................15
D SPECIAL TOOLS..........................................................................................................................16
4.1.2.2 MAINTENANCE............................................................................................................................22
...............................................................................................22
4.1.2.3 REMOVAL ANS INSTALLATION OF TRANSAXLE FROM VEHICLE........................................22
4.1.2.4 TRANSAXLE OVERHAUL............................................................................................................26
B FIFTH GEAR - DISMANTLING......................................................................................................27
C REMOVAL OF SHAFTS, CONTROL RODS AND DIFFRENTIAL................................................28
D LAYSHAFT - DISMANTLING........................................................................................................32
E MAINSHAFT - DISMANTLING......................................................................................................33
F MAINSHAFT ASSEMBLY..............................................................................................................34
...............................................................................................................35
................................................................................37
I FIFTH GEAR - ASSEMBLY...........................................................................................................38
J REMOVAL OF SHAFTS, CONTROL RODS, AND DIFFERENTIAL.............................................39
4.1.2.5 DIFFERENTIAL ASSSEMBLY OVERHAUL................................................................................40
4.1.2.6 INPUT SHAFT SEAL REPLACEMENT........................................................................................42