Part 2
OVERHAUL41. REMOVE GEAR SHIFT FORK SHAFT No. 3
a. Remove the shift fork shaft No. 3 from the transaxle case.
b. Using 2 screwdrivers and a hammer, remove the shaft snap ring from the shift fork shaft No. 3.
NOTICE: Using a waste to prevent the snap ring from the being scattered.
42. REMOVE GEAR SHIFT FORK SHAFT No. 2
a. Remove the 2 gear shift fork lock bolts from the gear shift fork No. 2 and gear shift head No. 1.
b. Remove the gear shift fork shaft No. 2, gear shift fork No. 2, gear shift fork No. 1, gear shift head No. 1 and reverse shift fork.
43. REMOVE REVERSE IDLER GEAR SUB-ASSY
a. Remove the reverse idler gear shaft, thrust washer and reverse idler gear sub-assy from the transaxle case.
44. REMOVE INPUT SHAFT ASSY
a. Remove the input shaft assy with output shaft assy from the transaxle case.
45. REMOVE REVERSE SHIFT ARM BRACKET ASSY
a. Remove the 2 bolts and reverse shift arm bracket assy from the transaxle case.
46. REMOVE DIFFERENTIAL CASE ASSY
a. Remove the differential case assy from the transaxle case.
47. REMOVE MANUAL TRANSAXLE CASE RECEIVER
a. Remove the bolt and manual transaxle case receiver from the transaxle case.
48. REMOVE BEARING LOCK PLATE
a. Remove the bolt and bearing lock plate from the transaxle case.
49. REMOVE TRANSMISSION MAGNET
a. Remove the transmission magnet from the transaxle case.
50. REMOVE INPUT SHAFT FRONT BEARING
a. Using SST, remove the input shaft front bearing (outer race) from the transaxle case.
SST 09612-24014 (09613-22011)
51. REMOVE FRONT TRANSAXLE CASE OIL SEAL
a. Using SST, remove the front transaxle case oil seal from the transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)
52. REMOVE OUTPUT SHAFT FRONT BEARING
a. Using SST, remove the output shaft front bearing from the transaxle case.
SST 09308-00010
NOTICE: Do not apply unreasonable force to the transaxle case when installing it.
53. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST, remove the front differential case rear tapered roller bearing (outer race) and shim from manual transmission case.
SST 09612-65014 (09612-01040, 09612-01050)
b. Using SST, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.
SST 09612-65014 (09612-01040, 09612-01050), 09950-40011 (09951-00390, 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010
54. REMOVE TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, remove transmission case oil seal from the manual transmission case.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
55. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Using SST, remove the front differential case front tapered roller bearing (outer race) and front differential case washer FR from the transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)
b. Using SST, remove the FR differential case front tapered roller bearing (inner race) from the front differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00390)
56. REMOVE TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, remove transaxle case oil seal from the transaxle case.
SST 09950-60010 (09951-00600), 09950-70010 (09951-07100)
57. REMOVE OUTPUT SHAFT (MTM) COVER
a. Remove the output (MTM) shaft cover from the transaxle case.
58. REMOVE TRANSMISSION HUB SLEEVE No. 3
a. Remove the transmission hub sleeve No. 3, 3 synchromesh shifting key No. 3 and 2 synchromesh shifting key spring No. 3.
NOTICE: Using a waste to prevent the synchromesh shifting key and spring from the being scattered.
59. INSPECT TRANSMISSION HUB SLEEVE No. 3
a. Check the sliding condition between the transmission hub sleeve No. 3 and transmission clutch hub No. 3.
b. Check that spline gears of the transmission hub sleeve No. 3 is not worn down.
c. Using a vernier calipers, inspect the transmission hub sleeve No. 3 and gear shift fork No. 3 as shown in the illustration.
Standard clearance: 0.31 - 0.89 mm (0.0122 - 0.035 inch)
If the clearance out of specification, replace the transmission hub sleeve No. 3 and gear shift fork No. 3
60. INSPECT SYNCHRONIZER RING No. 3 (FOR 6TH GEAR MT)
a. Check for wear of 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.
c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Standard clearance: 0.75 - 1.65 mm (0.0295 - 0.065 inch)
If the clearance is out of specification, replace the synchronizer ring No. 3.
61. INSPECT 6TH GEAR SUB-ASSY
a. Using a caliper gauge, inspect the 6th gear inner diameter.
Inner diameter
If the clearance is exceeds the maximum, replace the 6th gear sub-assy.
62. INSPECT SYNCHRONIZER RING No. 3 (FOR 5TH GEAR MT)
a. 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.
b. Using a feeler gauge, measure the clearance between the synchronizer ring back and 5th gear spline end.
Standard clearance: 0.75 - 1.65 mm (0.0295 - 0.0650 inch)
If the clearance is out of specification, replace the synchronizer ring No. 3.
63. INSPECT 5TH GEAR
a. Using a caliper gauge, inspect the 5th gear inner diameter.
Inner diameter
If the inner diameter is exceeds the maximum, replace the 5th gear.
64. INSPECT REVERSE IDLER GEAR SUB-ASSY
a. Using a caliper gauge, inspect the reverse idler gear sub-assy as shown in the illustration.
Inner diameter
If the inner diameter is exceeds the maximum, replace the reverse idler gear sub-assy.
b. Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.
Outer diameter
If the outer diameter is exceeds the minimum, replace the reverse idler gear shaft.
65. INSTALL TRANSMISSION HUB SLEEVE No. 3
a. Coat the transmission hub sleeve No. 3 with gear oil, install it to the transmission clutch hub No. 3.
NOTICE: Do not set the transmission clutch hub No. 3 in incorrect orientation.
b. Using a screwdriver, install the 2 synchromesh shifting key spring No. 3 and 3 synchromesh shifting key No. 3.
NOTICE: Do not set both openings of the shifting key spring in the same position.
66. INSTALL OUTPUT SHAFT (MTM) COVER
a. Coat the output shaft (MTM) cover with MP grease, install it to the transaxle case.
67. INSTALL TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install the transaxle case oil seal No. 2 to the transaxle case.
SST 09726-27012 (09726-02041), 09950-70010 (09951-07100)
Driven in depth: 1.9 ± 0.3 mm (0.075 ± 0.012 inch)
68. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Using SST and a press, install FR differential case front tapered roller bearing (inner race) to the front differential case.
SST 09350-32014 (09351-32120), 09950-60010 (09951 -00530)
b. Using SST and a press, install the FR differential case front bearing spacer and FR differential case front tapered roller bearing (outer race) to the transaxle case.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
69. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST and a press, install the FR differential case rear tapered roller bearing (inner race) to the front differential case.
SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)
b. Using SST and a press, install the front differential case shim RR and FR differential case rear tapered roller bearing (outer race) to the manual transmission case.
SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)
HINT: Use a front differential case shim RR of the same thickness with the remove one.
70. INSTALL OUTPUT SHAFT FRONT BEARING
a. Coat the new output shaft front bearing with gear oil, using SST and a press, install it to the transaxle case.
SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)
71. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
a. Coat the differential case assy with gear oil, install it to the transaxle case.
b. Install the manual transmission case with 16 bolts.
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)
c. Using SST and a torque wrench, turn the deferential case assy right and left 2 or 3 times to allow the bearings to settle.
SST 09560-32011
d. Using SST and a torque wrench, measure the preload.
SST 09564-32011
Preload
If the preload is out of the specification, select the front differential case shim RR adjust it.
HINT:
Shim thickness
e. Remove the 16 bolts and manual transmission case.
f. Remove the differential case assy from the transaxle case.
72. INSTALL FRONT TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install a new front transaxle case oil seal to the transaxle case.
SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)
Driven in depth: 15.6 - 16.0 mm (0.6142 - 0.6299 inch)
b. Coat the lip of the front transaxle case oil seal with MP grease.
73. INSTALL INPUT SHAFT FRONT BEARING
a. Coat new input shaft front bearing with MP grease, using SST and a press, install it to the transaxle case.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
Driven in depth: 0 - 0.30 mm (0 - 0.0118 inch)
74. INSTALL TRANSMISSION MAGNET
a. Clean the transmission magnet, install it to the transaxle case.
75. INSTALL BEARING LOCK PLATE
a. Install the bearing lock plate with bolt to the transaxle case.
Torque: 11.3 Nm (115 kgf-cm, 8 ft. lbs.)
76. INSTALL MANUAL TRANSAXLE CASE RECEIVER
a. Install the manual transaxle case receiver with bolt to the transaxle case.
Torque: 11.3 Nm (115 kgf-cm, 8 ft. lbs.)
77. INSTALL DIFFERENTIAL CASE ASSY
a. Coat the differential case tapered roller bearing with gear oil, install the differential case assy to the transaxle case.
78. INSTALL REVERSE SHIFT ARM BRACKET ASSY
a. Install the reverse shift arm bracket assy with 2 bolts to the transaxle case.
Torque: 17.2 Nm (175 kgf-cm, 13 ft. lbs.)
79. INSTALL INPUT SHAFT ASSY
a. Coat the sliding and rotating surface of the input and output shafts with gear oil, install them to the transaxle case.
80. INSTALL REVERSE IDLER GEAR SUB-ASSY
a. Coat the reverse idler gear sub-assy, thrust washer and reverse idler gear shaft with gear oil, install them to the transaxle case.
HINT: Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.