Part 3

OVERHAUL




78. INSTALL INPUT SHAFT FRONT BEARING
a. Coat the input shaft front bearing with gear oil, install it to the manual transaxle case.
SST 09950-60010 (09951-00570), 09950-700101 (09951-07150)
Clearance: 4.28 - 4.60 mm (0.1685 - 0.1811 inch)





79. 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.)





80. INSTALL DIFFERENTIAL CASE ASSY
a. Coat the differential case taper roller bearing with gear oil, install the differential case assy to the manual transaxle case.





81. INSTALL OUTPUT SHAFT ASSY
a. Apply gear oil to each sliding part of the output shaft assy.
b. Lift the differential case assy up with the output shaft assy leaned, and install it to the manual transaxle case.





82. INSTALL INPUT SHAFT ASSY
a. Apply gear oil to each sliding part of the input shaft assy.
b. With the output shaft assy leaned, install the input shaft assy to the manual transaxle case.





83. INSTALL GEAR SHIFT FORK NO.2
a. Coat the gear shift fork No.2 with gear oil, install it to the input shaft assy.
84. INSTALL GEAR SHIFT FORK NO.3





a. Install the gear shift fork No.3 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.





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





85. INSTALL GEAR SHIFT FORK NO.1
a. Apply gear oil to each sliding part of the gear shift fork No.1, install it to the output shaft assy.
86. INSTALL GEAR SHIFT FORK SHAFT NO.2





a. Install the gear shift head No.1 to the gear shift fork shaft No.2.
b. Apply gear oil to each sliding part of the gear shift fork shaft No.2, install it to the manual transaxle case.





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





87. INSTALL REVERSE SHIFT FORK ROLLER
a. Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.
88. 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 bolt to the gear shift fork No.1
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)





89. INSTALL REVERSE SHIFT ARM BRACKET ASSY
a. Install the 2 bolts and reverse shift arm bracket assy to the manual transaxle case.

Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)
90. INSTALL REVERSE IDLER GEAR SUB-ASSY





a. Coat the reverse idler gear and reverse idler thrust washer with MP grease, install them to the reverse idler gear shaft.





b. Install the reverse idler gear to the manual transaxle case.

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





91. INSTALL TRANSMISSION MAGNET
a. Clean the transmission magnet, install it to the manual transaxle case.
92. INSTALL REVERSE RESTRICT PIN ASSY





a. Using a pin punch ([diameter]5mm), install the reverse restrict pin and reverse restrict pin assy.
Clearance: 12.5 - 13.5 mm (0.492 - 0.531 inch)





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





93. INSTALL OIL RECEIVER PIPE NO.1 (MTM)
a. Install the bolt and oil receiver pipe No.1 (MTM) to the manual transmission case.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)

HINT: Tighten the oil receiver pipe No.1 with the bolt.





94. INSTALL OIL RECEIVER PIPE NO.2 (MTM)
a. Install the bolt and oil receiver pipe No.2 (MTM) to the manual transmission case.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)

HINT: Tighten the oil receiver pipe No.2 (MTM) with the bolt while manual transmission case is being put.

95. INSTALL MANUAL TRANSMISSION CASE





a. Apply FIPG bead condition sequentially to the position shown in the diagram of the manual transmission case.

HINT: Install within 10 minutes after applying FIPG.





b. Install the manual transmission case and 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 case side.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
96. INSTALL CLUTCH TUBE BRACKET NO.1
a. Install the clutch tube with 3 bolt brackets.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)





97. INSTALL REVERSE IDLER GEAR SHAFT BOLT
a. Coat the bolt with sealant, install new gasket to the manual transmission case with the bolt.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
98. INSTALL SHIFT FORK SHAFT SNAP RING





a. Using a brass bar and hammer, install the shift fork shaft snap ring to the gear shift fork shaft No.1.





b. Using a brass bar and hammer, install the shift fork shaft snap ring to the gear shift fork shaft No.2.





99. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING
a. Using a snap ring expander, install the input shaft rear bearing hole snap ring.





100. INSTALL OUTPUT SHAFT REAR BEARING SHIM
a. Install the output shaft rear bearing shim to the output shaft.

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





101. INSTALL BEARING RETAINER REAR (MTM)
a. Coat the bearing retainer rear (MTM) with sealant, install it with a torx wrench (T45).
Torque: 42 Nm (428 kgf-cm, 31 ft. lbs.)





102. INSTALL 5TH DRIVEN GEAR
a. Using SST, install the 5th driven gear to the output shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03030, 09955-03011)





103. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
a. Coat the 5th gear needle roller bearing with gear oil, install it to the input shaft.





104. INSTALL 5TH GEAR
a. Coat the 5th gear with gear oil, install it to the input shaft.
105. INSTALL TRANSMISSION CLUTCH HUB NO.3





a. Using SST, install the transmission clutch hub No.3 to the input shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010)

NOTICE: Align the projection of the synchronizer ring with the hole of the 5th gear and install them.





b. Install the transmission hub sleeve No.3 and gear shift fork No.3 to the transmission clutch hub No.3.





c. Coat the shift fork bolt with sealant, install the gear shift fork No. 3.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)





d. Select a snap ring that will allow minimum axial play. Using a brass bar and a hammer, install the shaft snap ring. Clearance: 0.1 mm or less








Snap ring: mm (in.)





106. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, inspect the 5th gear radial clearance.
Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 inch)
If the clearance is out of the specification, replace 1st gear needle roller bearing.





107. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, inspect the 5th gear thrust clearance.
Standard clearance: 0.10 - 0.65 mm (0.0039 - 0.0260 inch)
108. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT





a. Engage the gear double meshing.





b. Install the new manual transmission output shaft rear set nut.
Torque: 123 Nm (1,254 kgf-cm, 91 ft. lbs.)





c. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
109. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSY





a. Apply FIPG to the transaxle case cover sub-assy, as shown in the installation.
FIPG: Part No. 08826-00090, THREE BOND 1281

NOTICE: Install the parts within 10 minutes after applying the packing material (FIPG).





b. Install the transmission case cover sub-assy with 10 bolts to the manual transaxle case.





110. INSTALL DRAIN (MTM) PLUG SUB-ASSY
a. Install the drain plug sub-assy with new gasket to the manual transmission case.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





111. INSTALL MANUAL TRANSMISSION FILLER PLUG
a. Install the manual transmission filler plug with new gasket to the oil seal.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





112. INSTALL SHIFT & SELECT LEVER SHAFT ASSY
a. Coat the shift & select [ever shaft assy with gear oil, install it to the manual transmission case.





113. INSTALL BACK UP LAMP SWITCH ASSY
a. Install back up lamp switch assy to the manual transmission case.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)





114. INSTALL MANUAL TRANSMISSION BREATHER PLUG
a. Install the new gasket with manual transmission breather plug to the manual transmission case.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





115. INSTALL LOCK BALL ASSY NO.1
a. Install the lock ball assy No.1 to the manual transmission case.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





116. INSTALL CONTROL SHAFT COVER
a. Coat the 4 bolts with sealant, install new gasket with control shaft cover with the bolt.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)





117. INSTALL CONTROL SHIFT LEVER
a. Install the control shift lever with shift outer lock pin to the shift & select lever shaft.
b. Install the spring washer with nut.
Torque: 6.4 Nm (65 kgf-cm, 57 inch lbs.)





118. INSTALL SELECTING BELL CRANK ASSY
a. Coat the 2 bolts with sealant, install it with selecting bell crank assy to the manual transmission case.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
119. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY
a. Install the bolt and speedometer driven hole cover sub-assy to the transmission case.
120. INSTALL CLUTCH RELEASE FORK BOOT
a. Install the clutch release fork bolt to the manual transaxle case.





121. INSTALL RELEASE FORK SUPPORT
a. Using a deep socket wrench, install the release fork sup port to the manual transaxle case.
Torque: 47.1 Nm (480 kgf-cm, 35 ft. lbs.)
122. INSTALL CLUTCH RELEASE BEARING ASSY
a. Coat the clutch release bearing assy with release hub grease, install it to the clutch release fork sub assy.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
b. Apply clutch spline grease to the input shaft spline.





123. INSTALL CLUTCH RELEASE FORK SUB-ASSY
a. Install the clutch release fork sub-assy to the input shaft.