Part 2

DISASSEMBLY (Continued)





24. REMOVE OIL RECEIVER PIPE
Remove the 2 bolts and 2 oil receiver pipes from the transmission case.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)

NOTICE: At the time of reassembly, please refer to the following items.
^ Prevent the oil receiver pipes from being deformed.
^ Install the oil receiver pipes while placing it against the transmission case, as shown in the illustration.





25. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT
26. 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 in the illustration.

27. REMOVE GEAR SHIFT FORK AND GEAR SHIFT FORK SHAFT





a. Using 2 screwdrivers and a hammer tap out the 3 snap rings from each gear shift fork shaft.
b. Remove the 3 bolts from the No. 1 gear shift head, No. 1 and No. 2 gear shift forks.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
c. Pull up the No. 3 gear shift fork shaft, remove the No. 2 gear shift fork shaft.





NOTICE: At the time of reassembly, please refer to the following item.
To avoid the interference of the 2 balls, lift up the No. 3 gear shift fork shaft at the position shown in the illustration.





d. Remove the No. 1 gear shift head.





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

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

30. REMOVE MAGNET FROM TRANSAXLE CASE

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 (0.030 inch)
If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.

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





2. INSPECT NO. 3 GEAR SHIFT FORK AND NO. 3 HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and gear shift fork.
Maximum clearance: 0.5 mm (0.020 inch)
If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.
3. REMOVE TRANSAXLE CASE RECEIVER
Remove the bolt and transaxle case receiver from the transaxle case.

REPLACEMENT
1. REPLACE INPUT SHAFT FRONT BEARING AND OIL SEAL





a. Using SST, remove the input shaft front bearing.
SST 09612-65014





b. Using a screwdriver, pry out the oil seal.





c. Using SST and a hammer, tap in a new oil seal.
SST 09950-60010 (09951-00360), 09950-70010 (09951-07150)
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, press in a new input shaft front bearing.
SST 09950-60010 (09951-00400), 09950-70010 (09951-07150)
Depth: 0 - 0.3 mm (0 - 0.012 inch)

NOTICE: Be sure to install a new bearing in the correct direction, as shown in the illustration.

2. REPLACE OUTPUT SHAFT FRONT BEARING AND OUTPUT SHAFT COVER





a. Remove the bolt and bearing lock plate.
b. Using SST, drive out the output shaft front bearing.
SST 0930000010





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, press in a new output shaft front bearing.
SST 09950-60010 (09951-00560), 09950-70010 (09951-7150)

NOTICE:
^ Be sure to install a new bearing in the correct direction, as shown in the illustration.
^ When replacing the output shaft front bearing, replace the output shaft front bearing inner race along with it.

f. Install the bearing lock plate with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
3. INSTALL TRANSAXLE CASE RECEIVER
Install the transaxle case receiver to the transaxle case with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
4. REPLACE REVERSE RESTRICT PIN





a. Using a hexagon wrench, remove the straight screw plug.
b. Using a pin punch and a hammer, tap out the slotted spring pin.





c. Replace the reverse restrict pin.
d. Using a pin punch and a hammer, tap in the slotted spring pin.
e. Apply sealant to the screw 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.)
5. REPLACE CONTROL SHAFT COVER OIL SEAL AND BUSHING





a. Using a screwdriver, pry out the oil seal.





b. Using SST and a press, press out the bushing.
SST 09950-60010 (09951-00200, 09951-00210), 09950-70010 (09951-07150)





c. Using SST and a press, press in a new bushing.
SST 09950-60010 (09951-00200), 09950-70010 (09951-07150)
Depth: 0.65 ± 0.25 mm (0.0256 ± 0.0098 inch)





d. Using SST and a plastic-faced hammer, carefully tap in a new oil seal.
SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)
Depth: 0.70 ± 0.50 mm (0.0276 ± 0.0197 inch)


REASSEMBLY
Reassembly is in the reverse order of disassembly.

NOTICE: When working with FIPG material, you must observe the followings.
^ Using a razor blade and gasket scraper, remove all old FIPG material from the gasket surfaces.
^ Thoroughly clean all components to remove all 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.
^ Parts 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.