Part 2

(Continued from Part 1)





25. INSTALL NO.1 AND NO.2 SHIFT FORKS. NO.1 SHIFT HEAD AND NO.1 FORK SHAFT
a. Place No.1 and No.2 shift forks into the groove of No.1 and No.2 hub sleeves.




b. Hold No.1 shift head and insert No.1 fork shaft into the transaxle case through No.1 and No.2 shift forks, No.1 shift head and reverse shift fork.




c. Using a pin punch and hammer, drive the slotted spring pin into No.1 shift head.




d. Shift the fork shaft into reverse.
e. Using a pin punch and hammer, drive the slotted spring pin into No.1 fork shaft.




26. INSTALL TRANSMISSION CASE
a. Apply seal packing to the transmission case as shown.

Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

b. Install and torque the seventeen bolts.

Torque: 300 kg-cm (22 ft-lb, 29 N-m)




27. INSTALL SHIM AND SIDE BEARING RETAINER WITH O-RING
a. Install a new O-ring on the retainer.
b. Install the shim and retainer.
c. Apply Sealant to the bolt threads.

Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent




d. Install and torque the six bolts.

Torque: 185 kg-cm (13 ft-lb, 18 N-m)




28. INSTALL AND TORQUE REVERSE IDLER GEAR SHAFT LOCK BOLT

Torque: 300 kg-cm (22 ft-lb, 29 N-m)




29. INSTALL BEARING SNAP RINGS




30. INSTALL REAR BEARING RETAINER
a. Apply sealant to the bolt threads.

Sealant: Part No.08833-00070, THREE BOND 1324 or equivalent

b. Install and torque the five bolts.

Torque: 210 kg-cm (15 ft-lb, 21 N-m)




31. INSTALL FIFTH DRIVEN GEAR Using SST, install the 5th driven gear.
SST 09309-32050




32. INSTALL SPACER, NEEDLE ROLLER BEARINGS, FIFTH GEAR AND SYNCHRONIZER RING
a. Install the spacer.
b. Apply ATF to the needle roller bearings.
c. Install the 5th gear with the needle roller bearings and synchronizer ring.




33. INSERT NO.3 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

NOTE: Install the key springs positioned so that their end gaps are not in line.




34. INSTALL NO.3 HUB SLEEVE ASSEMBLY WITH NO.3 SHIFT FORK
a. Support the tip of the input shaft with a spacer or such to raise the transaxle assembly.
b. Using SST, drive in No.3 hub sleeve with shift fork.
SST 09612-22011

NOTE: Align the synchronizer ring slots with the shifting keys.




35. MEASURE FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)







36. INSTALL SHIFTING KEY RETAINER AND SNAP RING
a. Install the retainer.
b. Select a snap ring that will allow minimum axial play and install it on the shaft.




37. INSTALL LOCK NUT
a. Engage the gear double meshing.
b. Install and torque the nut.

Torque: 1.250 kg-cm (90 ft-lb, 123 N-m)

HINT: The lock nut has LH threads.

c. Disengage the gear double meshing.
d. Stake the lock nut.




38. ASSEMBLE SHIFT AND SELECT LEVER ASSEMBLY
a. Apply ATF to the shaft.
b. Install the E-ring.




c. Install shift interlock plate and spring.




d. Install No.1 shift inner lever with the shift fork lock plate.

HINT: One of the spline teeth of the shift and select lever shaft has been eliminated. Therefore, be certain to correctly align this portion to the matching portions on the parts during assembly.




e. Using a pin punch and hammer, drive in the slotted spring pin.




f. Install No.2 shift inner lever spring and reverse restrict pin holder.




g. Install the E-ring.




h. Install the control shaft cover and dust boot.

HINT: Make sure to install the boot in correct direction. Position the air bleed of the boot downward.




i. Install the control shift lever and insert the lever lock pin to the lever. Install the washer and lock nut.




39. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Apply seal packing to the underside of the flanged portion of the control shaft cover.

Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

b. Install the shift and select lever assembly and torque the control shaft cover.

Torque: 375 kg-cm (27 ft-lb, 37 N-m)




40. INSTALL NO.2 LOCK BALL ASSEMBLY
a. Apply sealant to the lock ball assembly threads.

Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

b. Using SST, install and torque the lock ball assembly.
SST 09313-30021

Torque: 230 kg-cm (17 ft-lb, 23 N-m)




41. INSTALL AND ADJUST NO.1 LOCK BALL ASSEMBLY
a. Fully loosen the lock nut.
b. Fully screw in the lock ball.
c. Loosen the lock ball to where the play at the shift outer lever tip is 0.1 - 0.5 mm (0.004 - 0.020 in.).




d. Hold the lock ball and tighten the lock nut.

Torque: 375 kg-cm (27 ft-lb, 37 N-m)

e. Check the shift outer lever tip play.

Lever tip play: 0.1 - 0.5 mm (0.004 - 0.020 in.)

42. INSTALL SELECTING BELLCRANK




43. INSTALL NO.3 SHIFT FORK SECURING BOLT
Install and torque the bolt.

Torque: 185 kg-cm (13 ft-lb, 18 N-m)




44. INSTALL TRANSMISSION CASE COVER
a. Apply seal packing to the transmission case as shown.

Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent.

b. Apply sealant to the bolt threads.

Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

c. Install and torque the eight bolts.

Torque: 300 kg-cm (22 ft-lb, 29 N-m)




45. INSTALL RELEASE BEARING RETAINER

Torque: 75 kg-cm (65 in-lb, 7.4 N-m)




46. INSTALL RELEASE FORK AND BEARING
a. Apply molybdenum disulphide lithium base grease to the following parts.
- Release bearing hub inside groove
- Input shaft spline
- Release fork contact surface
b. Apply MP grease to the front surface of the release bearing.

47. INSTALL BACK-UP LIGHT SWITCH

Torque: 450 kg-cm (33 ft-lb, 44 N-m)

48. INSTALL SPEEDOMETER DRIVEN GEAR