Part 3

61. INSPECT TRANSMISSION HUB SLEEVE NO.3
a. Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove (A) and the thickness of the claw part on the gear shift fork No.3 (B), and calculate the clearance.
Standard clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 inch) {A-B}
If clearance is out of specification, replace the transmission hub sleeve No.3 and gear shift fork No.3 with new ones.





62. INSPECT 5TH GEAR
a. Using a caliper gauge, measure the inside diameter of the 5th gear.





Inside diameter: mm (inch)

If the inside diameter exceeds the maximum, replace the 5th gear.





63. INSTALL SYNCHRONIZER PULL RING
a. Install the synchronizer ring middle No.5, synchronizer ring outer No.5 and synchronizer pull ring to the synchronizer ring inner No.5. Using a screwdriver, fix them with the synchronizer pull ring snap ring.





64. INSPECT SYNCHRONIZER RING MIDDLE NO.5
a. Check that the synchronizer ring middle No.5 rotates smoothly.





b. Check that the synchronizer ring middle No.5 does not rotate while being pushed against the clutch hub No.3.





65. INSTALL SYNCHROMESH SHIFTING KEY SPRING NO.3
a. Install the synchromesh shifting key spring No.3 to the transmission clutch hub No.3.

NOTICE: Align the projection of the shifting key spring with the hole of the clutch hub No.3 and install.

b. Install the synchronizer ring set and synchromesh shifting key spring No.3 to the transmission clutch hub No.3.

NOTICE:
- Engage the shifting key spring claw to the center of the teeth of the synchronizer ring.
- Align the projection of the shifting key spring with the hole of the clutch hub No.3 and install.





66. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL
a. Using SST and a hammer, install a new front transaxle case cover oil seal.
SST 09316-20011, 09950-60020 (09951-00910), 09950-70010 (09951-07150)
Oil seal drive in depth: -0.5 to 0.5 mm (-0.020 to 0.020 inch)
b. Coat the front transaxle case cover oil seal lip with MP grease.





67. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Using SST and a hammer, install the FR differential case front tapered roller bearing (outer race) to the front transaxle case.
SST 09950-60020 (09951-00910), 09950-70010 (09951-07100, 09951-07150)





b. Using SST and a press, install the FR differential case front tapered roller bearing (inner race) to the front differential case.
SST 09950-70010 (09951-07100, 09951-07150), 09608-10010





68. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Install the front differential case rear shim.
b. Using SST and a hammer, install the FR differential case rear tapered roller bearing (outer race).
SST 09950-60020 (09951-00890), 09950-70010 (09951-07100)





c. Using SST, install the FR differential case rear tapered roller bearing (inner race).
SST 09631-12090, 09950-60010 (09951-00600), 09950-70010 (09951-07100)





69. INSTALL TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, install a new transmission case oil seal to the manual transmission case.
SST 09608-32010, 09950-70010 (09951-07150)
Oil seal drive in depth: 3.0 to 4.0 mm (0.118 to 0.158 inch)
b. Coat the transmission case oil seal lip with MP grease.





70. INSTALL OUTPUT SHAFT REAR BEARING
a. Using SST and a hammer, install the output shaft rear bearing (outer race) to the manual transmission case.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)
Clearance: 3.8 to 4.4 mm (0.150 to 0.173 inch)





71. INSTALL OUTPUT SHAFT (MTM) COVER
a. Coat the output shaft (MTM) cover with MP grease, and install it to the manual transaxle case.

NOTICE: Align the projection of the output shaft with the transmission groove and install.





72. INSTALL OUTPUT SHAFT FRONT BEARING
a. Using SST and a hammer, install the output shaft front bearing (outer race).
SST 09950-60020 (09951-00730), 09950-70010 (09951-07100)





73. ADJUST OUTPUT SHAFT BEARING PRELOAD
a. Install the output shaft to the manual transaxle case.





b. Install the transmission case to the manual transaxle case with the 14 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





c. Install the 3 bolts on the manual transaxle side.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





d. Install the output shaft rear bearing shim to the output shaft.





e. Using a torx socket wrench (T45), install the bearing retainer rear with the 7 screws to the manual transmission case.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)





f. Turn the output shaft in both directions to make sure that it starts to turn smoothly.
g. Temporarily install the output shaft rear set nut.
h. Using a socket wrench and torque wrench, inspect the preload.





Preload: Nm (kgf-cm, inch lbs.)

i. If preload is out of specification, select a proper output shaft rear bearing shim and adjust it.

HINT: The preload of all the output shaft rear bearing shims varies in torque from about 0.04 to 0.06 Nm (0.408 to 0.612 kgf-cm, 0.354 to 0.531 inch lbs.)








Shim: mm (in.)

j. Remove the output shaft rear set nut from the output shaft.





k. Using a torx socket wrench (T45), remove the 7 screws and bearing retainer rear from the manual transmission case.





l. Remove the output shaft rear bearing shim from the output shaft.





m. Remove the 3 bolts.





n. Remove the 14 bolts and manual transmission case from the manual transaxle case.





o. Remove the output shaft assembly from the front manual transaxle case.





74. ADJUST TAPERED ROLLER BEARING PRELOAD
a. Install the differential case assembly to the manual transaxle case.





b. Install the 14 bolts and manual transmission case to the manual transaxle case.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





c. Install the 3 bolts on the front manual transaxle case side.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
d. Turn the differential case in both directions to make sure that it starts to turn smoothly.





e. Using SST and a torque wrench, inspect preload.
SST 09564-32011





Preload: Nm (kgf-cm, inch lbs.)

If preload is out of specification, select a proper front differential case rear shim and adjust it.

HINT: The preload of all the front differential case rear shims varies in torque from about 0.04 to 0.06 Nm (0.408 to 0.612 kgf-cm, 0.354 to 0.531 inch lbs.)





Shim: mm (in.)





f. Remove the 3 bolts.





g. Remove the 14 bolts and manual transmission case from the manual transaxle case.





h. Remove the differential case assembly from the manual transaxle case.





75. INSTALL FRONT TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install a new front transaxle case oil seal to the manual transaxle case.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
Clearance: 1 to 2 mm (0.0394 to 0.0787 inch)
b. Coat the lip of the front transaxle case oil seal with MP grease.





76. INSTALL INPUT SHAFT FRONT BEARING
a. Coat the input shaft front bearing with gear oil, and using SST, install it to the manual transaxle case.
SST 09950-60010 (09951-00570), 09950-70010 (09951-07150)
Clearance: 4.28 to 4.60 mm (0.1685 to 0.1811 inch)





77. INSTALL MANUAL TRANSAXLE CASE RECEIVER
a. Install the 3 bolts and manual transaxle case receiver to the manual transaxle case.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)





78. INSTALL DIFFERENTIAL CASE ASSEMBLY
a. Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the manual transaxle case.





79. INSTALL OUTPUT SHAFT ASSEMBLY
a. Apply gear oil to each sliding part of the output shaft assembly.
b. Slightly lift up on the differential case assembly and, at an angle, install the output shaft assembly to the manual transaxle case.





80. INSTALL INPUT SHAFT ASSEMBLY
a. Apply gear oil to each sliding part of the input shaft assembly.
b. Install the input shaft assembly to the manual transaxle case while tilting the output shaft assembly.





81. INSTALL GEAR SHIFT FORK NO.2
a. Coat the gear shift fork No.2 with gear oil, and install it to the input shaft assembly.





82. INSTALL GEAR SHIFT FORK NO.3
a. Install the reverse shift fork to the gear shift fork shaft No.3.
b. Using a brass bar and hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft No.3.





c. Apply gear oil to each sliding part of the gear shift fork shaft No.3, and install it to the manual transaxle case.





83. INSTALL GEAR SHIFT FORK NO.1
a. Apply gear oil to each sliding part of the gear shift fork No. 1, and install it to the output shaft assembly.





84. INSTALL GEAR SHIFT FORK SHAFT NO.2
a. Apply gear oil to each sliding part of the gear shift fork shaft No.2 and gear shift head No.1, and install them to the manual transaxle case.





b. Install the shift fork set bolt and shift head set bolt to the gear shift head No. 1 and gear shift fork No.2.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)





85. INSTALL REVERSE SHIFT FORK ROLLER
a. Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.





86. INSTALL GEAR SHIFT FORK SHAFT NO.1
a. Using a brass bar and hammer, install the shift fork shaft snap ring to the shift fork shaft No.1.





b. Install the gear shift fork shaft No.1 to the manual transaxle case.





c. Install the shift fork set bolt to the gear shift fork No.1.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)





87. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
a. Install the 2 bolts and reverse shift arm bracket assembly to the manual transaxle case.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)





88. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
a. Coat the reverse idler gear sub-assembly and reverse idler thrust washer with gear oil, and install them to the reverse idler gear shaft.





b. Install the reverse idler gear sub-assembly with the reverse idler gear shaft to the manual transaxle case.

HINT: Align the mark of the reverse idler gear shaft with the hole of the bolt.





89. INSTALL TRANSMISSION MAGNET
a. Clean the transmission magnet, and install it to the manual transaxle case.





90. INSTALL REVERSE RESTRICT PIN ASSEMBLY
a. Install the reverse restrict pin assembly to the manual transaxle case.
b. Using a pin punch ([diameter]5 mm), install the reverse restrict pin slotted spring pin.
Clearance: 12.5 to 13.5 mm (0.492 to 0.531 inch)





c. Coat the reverse restrict pin plug with adhesive 1324, and using a hexagon wrench (6 mm), install it to the manual transmission case.
Torque: 13 Nm (133 kgf-cm, 9.6 ft. lbs.)