ZEST BOLT Service Manual

DRIVETRAIN C549 CONTENTS 4.1.1 CLUTCH .........................................................................................................................................1 4.1.1.1 SYSTEM LAYOUT ..........................................................................................................................1 4.1.1.2 TECHNICAL SPECIFICATIONS.....................................................................................................3 4.1.1.3 MAINTENANCE ..............................................................................................................................4 A CLUTCH ASSEMBLY REMOVAL...................................................................................................4 B HYDRAULIC ACTUATOR REMOVAL .............................................................................................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 G EXPLODED VIEWS .........................................................................................................................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 A TRANSAXLE OIL REPLACEMENT ...............................................................................................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 G LAYSHAFT ASSEMBLY. ...............................................................................................................35 H TRANSAXLE ASSEMBLY - INSTALLATION ................................................................................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