Disassembly and Assembly

DISASSEMBLY
1. REMOVE CLUTCH RELEASE FORK AND BEARING

HINT: At the time of reassembly, please refer to the following item. Apply molybdenum disulphide lithium base grease.

2. REMOVE FILLER PLUG AND DRAIN PLUG WITH 2 GASKETS
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
3. REMOVE VEHICLE SPEED SENSOR
a) Remove the bolt and vehicle speed sensor.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
b) Using a small screwdriver, remove the clip from the vehicle speed sensor.
c) Remove the vehicle speed sensor driven gear from the vehicle speed sensor.
d) Using a small screwdriver, remove the O-ring from the vehicle speed sensor.
4. REMOVE BACK-UP LIGHT SWITCH WITH GASKET
Torque: 40 Nm (410 kgf-cm, 30 ft. lbs.)
5. REMOVE CONTROL LEVER HOUSING SUPPORT BRACKET
Remove the 3 bolts and control lever housing support bracket.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
6. REMOVE SELECTING BELLCRANK ASSEMBLY
a) Remove the 2 bolts and selecting bellcrank assembly.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b) Remove the control bellcrank dust cover from the selecting bellcrank assembly.
7. REMOVE TRANSMISSION CASE COVER
a) Remove the 9 bolts.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
b) Carefully tap the projection of the transmission case cover with a brass bar and hammer and remove it.





HINT: At the time of reassembly, please refer to the following item. Apply FIPG to the transmission case cover, as shown in the illustration.

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





8. INSPECT 5TH. GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 inch)
Maximum clearance: 0.57 mm (0.0224 inch)





9. INSPECT 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.
Standard clearance:
KOYO made: 0.015 - 0.058 mm (0.0006 - 0.0023 inch)
NSK made: 0.015 - 0.056 mm (0.0006 - 0.0022 inch)
Maximum clearance:
KOYO made: 0.058 mm (0.0023 inch)
NSK made: 0.056 mm (0.0022 inch)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.





10. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a) Remove the lock bolt and gasket.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
b) Remove the 4 bolts and pull out the shift and select lever shaft assembly with the gasket.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)





11. REMOVE LOCK NUT
a) Engage the gear to the double meshing.
b) Using a chisel and hammer, loosen the staked part of the nut.
c) Remove the lock nut.
Torque: 118 Nm (1,200 kgf-cm, 87 ft. lbs.)
d) Disengage the double meshing of the gear.
12. REMOVE NO. 3 HUB SLEEVE AND NO. 3 SHIFT FORK
a) Remove the bolt from the No. 3 shift fork.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
b) Remove the No. 3 hub sleeve and No. 3 shift fork.
13. REMOVE NO. 3 CLUTCH HUB AND 5TH GEAR
a) Using 2 screwdrivers and a hammer, tap out the snap ring.





HINT: At the time of reassembly, please refer to the following item. Select a snap ring that allows the minimum axial play.





b) Using SST, remove the No. 3 clutch hub assembly, 5th gear and synchronizer ring.
SST 09950-40011

HINT:
^ At the time of reassembly, please refer to the following items. Install the No. 3 clutch hub assembly to the No. 3 hub sleeve.





^ Before driving in the No. 3 clutch hub assembly, place the suitable sized wooden block on the rear side of the input shaft, as shown in the illustration. When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear bearing is overloaded, it might be damaged.





^ Using SST and a hammer, drive in the No. 3 hub sleeve assembly with the No. 3 shift fork.
SST 09612-22011

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

c) Remove the needle roller bearings and spacer.





14. REMOVE 5TH DRIVEN GEAR
Using SST and a socket wrench, remove the 5th driven gear.
SST 09950-40011





HINT: At the time of reassembly, please refer to the following item. Using SST install the 5th driven gear.
SST 09309-12020





15. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and rear bearing retainer.
Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.)
16. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.

HINT: If it is difficult to remove and install the snap rings, pull up the shafts.





17. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
18. REMOVE SNAP RING FROM NO. 2 SHIFT FORK SHAFT
Using 2 screwdrivers and a hammer, tap out the snap ring.





19. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING AND BALL
a) Using a hexagon wrench, remove the 3 straight screw plugs.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b) Using a magnetic finger, remove the 3 seats, springs and balls.





20. REMOVE LOCK BALL ASSEMBLY
Using a hexagon wrench, remove the lock ball assembly.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





21. REMOVE TRANSMISSION CASE
a) Remove the 16 bolts.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
b) Carefully tap the transmission case with a plastic hammer and remove it.





HINT: At the time of reassembly, please refer to the following item. Apply FIPG to the transaxle case, as shown in the illustration.

FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
c) Remove the 2 bolts, No. 1 and No. 2 oil receiver pipes from the transmission case.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)





22. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT
23. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and reverse shift arm bracket.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)

NOTICE: At the time of reassembly, please refer to the following items.
^ Set the pin on the top of the reverse shift arm into a groove on the reverse idler gear.
^ Fit the claw of the reverse shift arm bracket with the notch of the input shaft front bearing.





^ Install the reverse idler gear, thrust washer and shaft, as shown.





24. REMOVE SHIFT FORK AND SHIFT FORK SHAFT
a) Using 2 screwdrivers and a hammer, tap out the 3 snap rings.
b) Remove the 3 set bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
c) Remove the No. 2 shift fork shaft and shift head.





d) Using a magnetic finger, remove the 2 balls from the reverse shift fork.
e) Remove the No. 3 shift fork shaft and reverse shift fork.
f) Pull out the No. 1 shift fork shaft.
g) Remove the No. 1 and No. 2 shift forks.
25. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE
26. REMOVE DIFFERENTIAL CASE ASSEMBLY

NOTICE: At the time of reassembly, please refer to the following item. Before reassembly, inspect the differential side bearing preload.

27. REMOVE MAGNET FROM TRANSAXLE CASE





28. DISASSEMBLE NO. 3 CLUTCH HUB ASSEMBLY
a) Using a screwdriver, remove the 2 shifting key springs from the No. 3 clutch hub.

NOTICE: At the time of reassembly, please refer to the following item. Position the shifting key springs so that their end gaps are not aligned.

b) Remove the 3 shifting keys from the No. 3 clutch hub.

INSPECTION





1. INSPECT 5TH GEAR SYNCHRONIZER RING
a) Check for wear or damage.
b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

c) Check again the braking effect of the synchronizer ring.





d) Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.75 mm (0.0295 inch)
If the clearance is less than the minimum, replace the synchronizer ring and gear cone by applying a small amount of the fine lapping compound.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.





2. INSPECT SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 0.5 mm (0.020 inch)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
3. REMOVE TRANSAXLE CASE RECEIVER
Remove the bolt and transaxle case receiver.





4. IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING AND OIL SEAL
a) Using SST, remove the input shaft front bearing.
SST 09612-65014





b) Using SST, remove the oil seal.
SST 09612-65014





c) Using SST and a hammer, install a new oil seal.
SST 09950-60010 (09951-00360), 09950-70010 (09951-07150)
Drive in depth: 15.8 ± 0.2 mm (0.622 ± 0.008 inch)
d) Coat the lip of the oil seal with MP grease.





e) Using SST and a press, install a new input shaft front bearing.
SST 09950-60010 (09951-00460), 09950-70010 (09951-07150)





5. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING AND OUTPUT SHAFT COVER
a) Remove the bolt and bearing lock plate.





b) Using SST, pull out the output shaft front bearing.
SST 09308-00010





c) Remove the output shaft cover.
d) Install the output shaft cover.

NOTICE: Install the output shaft cover projection into the case side hollow.





e) Using SST and a press, install a new output shaft front bearing.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
f) Install the bearing lock plate with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
6. INSTALL TRANSAXLE CASE RECEIVER
Install the transaxle case receiver with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)





7. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
a) Using a hexagon wrench, remove the straight screw plug.
b) Using a pin punch and hammer, drive out the slotted spring pin.





c) Replace the reverse restrict pin.
d) Using a pin punch and hammer, drive in the slotted spring pin.
e) Apply sealant to the plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f) Using a hexagon wrench, install the straight screw plug.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)

REASSEMBLY
Reassembly is in the reverse order of disassembly.

NOTICE: When working with FIPG material, you must observe the following Items.

^ Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
^ Thoroughly clean all components to remove all the loose material.
^ Clean both sealing surfaces with a non-residue solvent.
^ Apply FIPG in an approximately 1 mm (0.04 inch) wide bead along the sealing surface.
^ Part must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.