Part 2

OVERHAUL





40. REMOVE GEAR SHIFT FORK NO.1
41. REMOVE GEAR SHIFT FORK SHAFT NO.3





a. Remove the gear shift fork shaft No.3 from the manual transaxle case.





b. Using 2 screwdriver and a hammer, remove the 2 shift fork shaft snap rings from the gear shift fork shaft No. 3.
c. Remove the reverse shift fork from the gear shift fork shaft No.3.





42. REMOVE GEAR SHIFT FORK NO.2
a. Remove the gear shift fork No.2 from the input shaft assy.





43. REMOVE INPUT SHAFT ASSY
a. Incline the output shaft then remove the input shaft from the manual transaxle case.





44. REMOVE OUTPUT SHAFT ASSY
a. Remove the output shaft from the manual transaxle case.





45. REMOVE DIFFERENTIAL CASE ASSY
a. Remove the differential case assy from the manual transaxle case.





46. REMOVE MANUAL TRANSAXLE CASE RECEIVER
a. Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case.





47. REMOVE INPUT SHAFT FRONT BEARING
a. Using SST, remove the input shaft front bearing (outer race) from the manual transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)





48. REMOVE FRONT TRANSAXLE CASE OIL SEAL
a. Using SST, remove the manual transaxle, case oil seal from the manual transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)





49. REMOVE OUTPUT SHAFT FRONT BEARING
a. Using SST, remove the output shaft front bearing (outer race) from the manual transaxle case.
SST 09387-00041 (09387-02020, 09387-02010)





50. REMOVE OUTPUT SHAFT (MTM) COVER
a. Remove the output shaft (MTM) cover from the manual transaxle case.





51. REMOVE OUTPUT SHAFT REAR BEARING
a. Using SST, remove the output shaft rear bearing from the manual transmission case (outer race).
SST 09950-60010 (09951-00680), 09950-70010 (09951-07100)





52. REMOVE TRANSMISSION CASE OIL SEAL
a. Using SST, remove the transmission case oil seal from the manual transmission case.
SST 09308-00010





53. REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL
a. Using a screwdriver, remove the front transaxle case cover oil seal.

HINT: Tape the screwdriver tip before use.

54. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING





a. Using a brass bar and a hammer, remove the FR differential case rear tapered roller bearing (outer race) from the manual transaxle case.





b. Using SST, remove the front differential case rear tapered roller bearing from the front differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00560)
55. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING





a. Using SST and hammer, remove the FR differential case front tapered roller bearing (outer race) and FR differential case rear shim from the manual transmission case.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07100)





b. Using SST, remove the FR differential case front tapered roller bearing (inner race) from front differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00490)





56. REMOVE CONTROL SHAFT COVER BIMETAL FORMED BUSH
a. Using SST, remove the shift & select lever shaft bimetal formed bush.
SST 09319-60020
57. INSPECT REVERSE IDLER GEAR SUB-ASSY





a. Using a calipers gauge, measure the inside diameter of the reverse idler gear.





Inside diameter: mm (in.)

If the inside diameter is exceeds than the maximum, replace the reverse idler gear.





b. Using a micro meter, measure the outer diameter of the reverse idler gear shaft.





Outer diameter: mm (in.)

If the outer diameter is less than the minimum, replace the reverse idler gear shaft.





58. REMOVE TRANSMISSION HUB SLEEVE NO.3
a. Remove the transmission hub sleeve No.3 from the transmission clutch hub No.3.





59. REMOVE SYNCHROMESH SHIFTING KEY SPRING NO.3
a. Push the synchromesh shifting key spring No.3 then remove the 2 synchromesh shifting key spring No.3 from the transmission clutch hub No.3.





60. REMOVE SYNCHRONIZER PULL RING
a. Using a screwdriver, remove the synchronizer pull ring snap ring.
b. Remove the synchronizer pull ring, synchronizer outer ring No.5, synchronizer inner ring No.5 and synchronizer middle ring No.5 from the synchronizer ring No.5.





61. INSPECT TRANSMISSION CLUTCH HUB NO.3
a. Inspect the sliding condition between transmission clutch hub No.3 and transmission hub sleeve No.3.
b. Inspect tip of spline gear on the transmission hub sleeve No.3 for wear.





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





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





Inside diameter: mm (in.)

If the inner diameter is exceeds than the maximum, replace the 5th gear.





64. INSTALL SYNCHRONIZER PULL RING
a. Install the synchronizer middle ring No.5, synchronizer ring outer No.5 and synchronizer pull ring to the synchronizer ring inner No.5 using a screwdriver, fix with snap ring.
65. 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 it is being pushed to the clutch hub No.3.





66. 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 them.

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 them.





67. INSTALL CONTROL SHAFT COVER BIMETAL FORMED BUSH
a. Using SST, install the shift & select lever shaft bimetal formed bush.
SST 09950-60010 (09951-00180), 09950-70010 (09951-07100)
Clearance: 0.081 - 0.149 mm (0.0032 - 0.0059 inch)





68. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL
a. Using SST and a hammer, install the front transaxle case cover oil seal.
SST 09316-20011, 09950-60020 (09951-00910), 09950-70010 (09951-07150)
Oil seal driven in depth: 0 ± 0.5 mm (0 ± 0.020 inch)
b. Coat the lip of front transaxle case cover oil seal with MP grease.
69. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING





a. Using SST and a hammer, install the FR differential case rear tapered roller bearing (outer race) to the front transaxle case.
SST 09950-60020 (09951-00910), 09950-70010 (09951-07100)





b. Using SST and press, install the FR differential case rear tapered roller bearing (inner race) to the front differential case.
SST 09950-70010 (09951-07100, 09951-07150), 09608-10010
70. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Install the front differential case shim rear.





b. Using SST and a hammer, install FR differential case front tapered roller bearing (outer race).
SST 09950-60020 (09951-00890), 09950-70010 (09951-07100)

NOTICE: Install the case shim as thick as the removed one.





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





71. INSTALL TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, install the transmission case oil seal to the manual transmission case.
SST 09608-32010, 09950-70010 (09951-07150) Oil seal driven in depth: 3.5 ± 0.5 mm (0.138 ± 0.020 inch)
b. Coat the lip of transmission case oil seal with MP grease.





72. 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 - 4.4 mm (0.150 - 0.173 inch)





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

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





74. INSTALL OUTPUT SHAFT FRONT BEARING
a. Using SST and a hammer, install the output shaft front bearing (outer race).
SST 019950-60020 (09951-00730), 09950-70010 (09951-07100)
75. ADJUST OUTPUT SHAFT BEARING PRELOAD





a. Install the output shaft to the manual transaxle case.





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





c. Install the 3 bolts to 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.

HINT: Install the same thickness of case shim as the removed one.





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





g. Turn the output shaft in both directions to make it smooth.
h. Using a socket wrench and torque wrench, inspect the preload.





Preload: Nm (kgf-cm, lbs.)

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

HINT: The preload of the output shaft rear bearing shim varies in torque from about 0.04 to 0.06 Nm in one size.





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 RR 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 assy from the front manual transaxle case.
76. ADJUST TAPERED POLLER BEARING PRELOAD





a. Install differential case assy 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 and front manual transaxle case side.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
d. Turn the differential case in both directions to make it smooth.





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





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

If the preload is out of the specification, select the front differential case shim RR and adjust it.

HINT: The preload of the front differential case shim RR varies in torque from about 0.04 to 0.06 Nm is one size.








Shim: mm (In.)





f. Remove the 3 bolts.





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





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





77. INSTALL FRONT TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install the front transaxle case oil seal No.1 to the manual transaxle case.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
b. Coat the lip of front transaxle case oil seal No.1 with MP grease.
Clearance: 1 - 2 mm (0.0394 - 0.0787 inch)