Part 3
OVERHAUL81. INSTALL GEAR SHIFT FORK SHAFT No. 2
a. Coat the gear shift fork No. 2 and gear shift fork No. 1 with gear oil, install them to the input and output shafts.
b. Coat the gear shift fork shaft No. 2 with gear oil, install the gear shift head No. 1, reverse shift fork and gear shift fork shaft No. 2.
c. Coat the 2 shift lock bolts with sealant, install them to the gear shift fork No. 2 and gear shift head No. 1.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 15.7 Nm (160 kgf-cm, 12 ft. lbs.)
82. INSTALL GEAR SHIFT FORK SHAFT No. 3
a. Using a brass bar and a hammer, install the shaft snap ring to the gear shift fork shaft No. 3.
b. Coat the gear shift fork shaft No. 3 with gear oil, install it to the transaxle case.
83. INSTALL GEAR SHIFT FORK SHAFT SUB-ASSY No. 1
a. Coat the gear shift fork shaft sub-assy No. 1 with gear oil, install it to the transaxle case.
b. Coat the shift fork lock bolt with sealant, install it to the gear shift fork No. 1.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque 15.7 Nm (160 kgf-cm, 12 ft. lbs.)
c. Using a brass bar and a hammer, install shaft snap ring.
84. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL
a. Install the shift detent ball, shift detent ball compression spring and shift detent ball spring seat to the transaxle case.
b. Coat the shift detent ball plug with sealant, using SST, install it to the transaxle case.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
85. INSTALL OIL RECEIVER PIPE No. 2 (MTM)
a. Install the oil receiver pipe No. 2 (MTM) with bolt to the manual transmission case.
Torque: 17.2 Nm (175 kgf-cm, 13 ft. lbs.)
86. INSTALL OIL RECEIVER PIPE No. 1 (MTM)
a. Install the oil receiver pipe No. 1 (MTM) with bolt to the manual transmission case.
Torque: 17.2 Nm (175 kgf-cm, 13 ft. lbs.)
87. INSTALL MANUAL TRANSMISSION CASE
a. Apply FIPG to the manual transmission case, as shown to the illustration.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
NOTICE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be remove and reapplied.
b. Install the 13 bolts to the manual transmission side.
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)
c. Install the 3 bolts to the transaxle case side.
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)
88. INSTALL REVERSE IDLER GEAR SHAFT BOLT
a. Coat the reverse idler gear shaft bolt with sealant, install it with new gasket to the manual transmission case.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)
89. INSTALL MANUAL TRANSMISSION CASE PLUG
a. Coat the transmission case plug with sealant, using socket hexagon wrench 6, install it to the manual transmission case.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 39.2 Nm (400 kgf-cm, 29 ft. lbs.)
90. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING
a. Using a snap ring expander, install the input shaft rear bearing hole snap ring to the input shaft.
91. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING
a. Using a snap ring expander, install the output shaft rear bearing hole snap ring to the output shaft.
92. INSTALL TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, install the transmission case oil seal to the manual transmission case.
SST 09316-60011 (09316-00011)
Driven in depth: 9.9 ± 0.3 mm (0.390 ± 0.012 inch)
b. Coat the lip of the transmission case oil seal with MP grease.
93. INSTALL SHIFT DETENT BALL
a. Install the 2 shift detent balls, 2 shift detent ball springs and 2 shift detent ball spring seats to the manual transmission case.
b. Coat the 2 shift detent ball plugs with sealant, install it to the manual transmission case.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
94. INSTALL BACK UP LAMP SWITCH ASSY
a. Using SST, install the back up lamp switch assy with a new gasket to the manual transmission case.
SST 09817-16011
Torque: 40.2 Nm (411 kgf-cm, 30 ft. lbs.)
95. INSTALL SHIFT & SELECT LEVER SHAFT ASSY
a. Coat the shift & select lever shaft assy with gear oil.
b. Coat the 4 bolts with sealant, install them with new gasket and shift & select lever shaft assy.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 19.6 Nm (200 kgf-cm, 14 ft. lbs.)
96. INSTALL LOCK BALL ASSY No. 1
a. Coat the lock ball assy No. 1 with sealant, install it to the manual transmission case.
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)
97. INSTALL BEARING RETAINER REAR (MTM)
a. Coat the 5 bolts with sealant, install it with bearing retainer rear to the manual transmission case.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 27.4 Nm (279 kgf-cm, 20 ft. lbs.)
98. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING
a. Using a brass bar and a hammer, install the shift fork shaft snap ring to the shift fork shaft No. 2.
99. 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, 09955-03011, 09956-03080)
100. INSTALL OUTPUT GEAR SPACER
a. Install the output gear spacer to the output shaft.
101. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
a. Coat the 2 5th gear bearing spacers, and 5th gear needle roller bearing with gear oil, install them to the input shaft.
b. Using a brass bar and a hammer, install the transmission clutch hub No. 3 shaft snap ring to the input shaft.
102. INSTALL 5TH GEAR
a. Coat the 5th gear with gear oil, install it to the input shaft.
103. INSTALL SYNCHRONIZER RING No. 3 (FOR 5TH GEAR MT)
a. Coat the synchronizer ring No. 3 with gear oil, install it to the 5th gear.
104. INSTALL TRANSMISSION CLUTCH HUB No. 3
a. Using SST and a hammer, install the transmission clutch hub No. 3 with gear shift fork No. 3 to the input shaft.
SST 09608-04031
NOTICE:
^ Before driving in the transmission clutch hub No. 3, 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 rear bearing is over loaded, it might be damaged.
b. Coat the shift fork lock bolt with sealant, install it to the gear shift fork No. 3.
Torque: 15.7 Nm (160 kgf-cm, 12 ft. lbs.)
c. Select a snap ring that will minimum axial play.
Clearance: 0.1 mm (0.004 inch) or less
Snap ring thickness
d. Using a brass bar and a hammer, install the snap ring to the input shaft.
105. INSTALL COUNTER GEAR 6TH
a. Using SST, install the counter gear to the output shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)
106. INSTALL SYNCHRONIZER RING No. 3 (FOR 6TH GEAR MT)
a. Coat the synchronizer ring No. 3 with gear oil, install it to the transmission clutch hub No. 3.
107. INSTALL 6TH GEAR NEEDLE ROLLER BEARING
a. Coat the 6th gear needle roller bearing with gear oil, install it to the input shaft.
108. INSTALL 6TH GEAR SUB-ASSY
a. Coat the 6th gear sub-assy with gear oil, install it to the input shaft.
109. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING
a. Using SST, steel block and a hammer, install the input shaft rear radial ball bearing to the input shaft.
SST 09608-04031
b. Select a snap ring that will minimum axial play.
Clearance: 0.1 mm (0.004 inch) or less
Snap ring thickness
c. Using a brass bar and hammer, install the snap ring to the input shaft.
110. INSTALL OUTPUT SHAFT REAR BEARING
a. Using SST, install output shaft rear bearing to the output shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)
b. Select a snap ring that will minimum axial play.
Clearance: 0.1 mm (0.004 inch) or less
Snap ring thickness
c. Using a brass bar and hammer, install the snap ring to the output shaft.
111. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance: 0.015 - 0.056 mm (0.0006 - 0.0022 inch)
If the clearance is out of specification, replace the 5th gear needle roller bearing.
112. INSPECT 6TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 6th gear radial clearance.
Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 inch)
If the clearance is out of specification, replace the 6th gear needle roller bearing.
113. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the gear thrust clearance.
Standard clearance: 0.10 - 0.62 mm (0.0039 - 0.0244 inch)
114. INSPECT 6TH GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the 6th gear thrust clearance.
Standard clearance: 0.10 - 0.60 mm (0.0039 - 0.0236 inch)
115. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSY
a. Apply FIPG to the manual transmission case cover sub-assy.
FIPG: Parts No. 08826-00090, THREE BOND 1281 or equivalent
NOTICE: Parts must be assembled within 10 minutes of application. Otherwise, the pack the packing (FIPG) material must be remove and reapplied.
b. Install the manual transmission case cover sub-assy with 9 bolts to the manual transmission case.
Torque: 18.1 Nm (185 kgf-cm, 13 ft. lbs.)
116. INSTALL DRAIN (MTM) PLUG SUB-ASSY
a. Install the drain (MTM) plug sub-assy with a new gasket to the manual transmission case.
Torque: 39.2 Nm (400 kgf-cm, 29 ft. lbs.)
117. INSTALL MANUAL TRANSMISSION FILLER PLUG
a. Install the manual transmission filler plug with a new gasket to the manual transmission case cover.
Torque: 39.2 Nm (400 kgf-cm, 29 ft. lbs.)
118. INSTALL SELECTING BELLCRANK ASSY
a. Install the selecting bellcrank assy with 2 bolts to the manual transmission case.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
119. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
a. Install the floor shift control lever housing support bracket with 3 bolts to the transaxle case.
Torque: 11.3 Nm (115 kgf-cm, 8 ft. lbs.)
120. INSTALL CLUTCH RELEASE FORK BOOT
a. Install clutch release fork boot to the transaxle case.
121. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support to the transaxle case.
Torque: 36.8 Nm (375 kgf-cm, 27 ft. lbs.)
b. Coat the release fork support with release hub grease.
Release hub grease: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
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.
Release hub grease: Part No.08887-01806, RELEASE HUB GREASE or equivalent
123. INSTALL CLUTCH RELEASE FORK SUB-ASSY
a. Apply clutch spline grease to the input shaft spline.
Clutch spline grease: Part No. 08887-01806, CLUTCH SPLINE GREASE or equivalent
b. Install the clutch release fork sub-assy to the input shaft.
124. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY
a. Install a new O-ring to the speedometer driven hole cover sub-assy.
b. Install the speedometer driven hole cover sub-assy with bolt to the transaxle case.
Torque: 11.3 Nm (115 kgf-cm, 8 ft. lbs.)