Part 3 of 4

MANUAL TRANSAXLE ASSY
OVERHAUL
70. INSTALL OUTPUT SHAFT REAR BEARING





a) Using SST and a hammer, install the output shaft rear bearing (outer race) to the manual transmission case.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)
Clearance: 3.8 to 4.4 mm (0.150 to 0.173 inch)
71. INSTALL OUTPUT SHAFT (MTM) COVER





a) Coat the output shaft (MTM) cover with MP grease, and install it to the manual transaxle case.

NOTICE: Align the projection of the output shaft with the transmission groove and install.

72. INSTALL OUTPUT SHAFT FRONT BEARING





a) Using SST and a hammer, install the output shaft front bearing (outer race).
SST 09950-60020 (09951-00730), 09950-70010 (09951-07100)
73. ADJUST OUTPUT SHAFT BEARING PRELOAD





a) Install the output shaft to the manual transaxle case.





b) Install the transmission case to the manual transaxle case with the 14 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





c) Install the 3 bolts on the manual transaxle side.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





d) Install the output shaft rear bearing case shim to the output shaft.





e) Using a torx socket wrench (T45), install the bearing retainer rear with the 7 screws to the manual transmission case.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)





f) Turn the output shaft in both directions to make sure that it starts to turn smoothly.
g) Using a socket wrench and torque wrench, inspect the preload.





Preload

h) If preload is out of specification, select a proper output shaft rear bearing shim and adjust it.

HINT: The preload of all the output shaft rear bearing shims varies in torque from about 0.04 to 0.06 Nm.








Shim

i) Remove the output shaft rear set nut from the output shaft.





f) Using a torx socket wrench (T45), remove the 7 screws and bearing retainer rear from the manual transmission case.





k) Remove the output shaft rear bearing shim from the output shaft.





l) Remove the 3 bolts.





m) Remove the 14 bolts and manual transmission case from the manual transaxle case.





n) Remove the output shaft assy from the front manual transaxle case.
74. ADJUST TAPERED POLLER BEARING PRELOAD





a) Install the differential case assy to the manual transaxle case.





b) Install the 14 bolts and manual transmission case to the manual transaxle case.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





c) Install the 3 bolts on the front manual transaxle case side.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
d) Turn the differential case in both directions to make sure that it starts to turn smoothly.





e) Using SST and a torque wrench, inspect preload.
SST 09564-32011





Preload

If preload is out of specification, select a proper front differential case rear shim and adjust it.

HINT: The preload of all the front differential case rear shims varies in torque from about 0.04 to 0.06 Nm.





Shim: mm (inch)





f) Remove the 3 bolts.





g) Remove the 14 bolts and manual transmission case from the manual transaxle case.





h) Remove the differential case assy from the manual transaxle case.
75. INSTALL FRONT TRANSAXLE CASE OIL SEAL





a) Using SST and a hammer, install the front transaxle case new oil seal No.1 to the manual transaxle case.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
b) Coat the lip of the front transaxle case oil seal No.1 with MP grease.
Clearance: 1 to 2 mm (0.0394 to 0.0787 inch)
76. INSTALL INPUT SHAFT FRONT BEARING





a) Coat the input shaft front bearing with gear oil, and install it to the manual transaxle case.
SST 09950-60010 (09951-00570), 09950-70010 (09951-07150)
Clearance: 4.28 to 4.60 mm (0.1685 to 0.1811 inch)
77. 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.)
78. INSTALL DIFFERENTIAL CASE ASSY





a) Coat the differential case tapered roller bearing with gear oil, and install the differential case assy to the manual transaxle case.
79. 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.
80. INSTALL INPUT SHAFT ASSY





a) Apply gear oil to each sliding part of the input shaft assy.
b) Install the input shaft assy to the manual transaxle case while tilting the output shaft assy.
81. INSTALL GEAR SHIFT FORK NO.2





a) Coat the gear shift fork No.2 with gear oil, and install it to the input shaft assy.
82. 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, and install it to the manual transaxle case.
83. INSTALL GEAR SHIFT FORK NO.1





a) Apply gear oil to each sliding part of the gear shift fork No. 1, and install it to the output shaft assy.
84. 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, and install it to the manual transaxle case.





c) Install the shift fork set bolt and shift head set bolt to the gear shift head No. 1.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
85. INSTALL REVERSE SHIFT FORK ROLLER





a) Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.
86. 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 set bolt to the gear shift fork No. 1.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
87. 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.)
88. INSTALL REVERSE IDLER GEAR SUB-ASSY





a) Coat the reverse idler gear and reverse idler thrust washer with MP grease, and 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.

89. INSTALL TRANSMISSION MAGNET





a) Clean the transmission magnet, and install it to the manual transaxle case.
90. 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 to 13.5 mm (0.492 to 0.531 inch)





b) Coat the reverse restrict pin plug with adhesive 1324, and using a hexagon wrench (6 mm), install the manual transmission case.
Torque: 13 Nm (133 kgf-cm, 9.6 ft. lbs.)
91. 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.

NOTICE: Do not damage the pipe.

92. 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.)

NOTICE: Do not damage the pipe.

93. INSTALL MANUAL TRANSMISSION CASE





a) Apply an unbroken bead of FIPG, as shown in the illustration, to the manual transmission case.

HINT: Install within 10 minutes after applying FIPG.





b) Install the manual transmission case with the 14 bolts to the manual transaxle case.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





c) Install the 3 bolts on the manual transaxle case side.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
94. INSTALL CLUTCH TUBE BRACKET NO.1
a) Install the clutch tube bracket with the bolt.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)
95. INSTALL REVERSE IDLER GEAR SHAFT BOLT





a) Coat the bolt with sealant, and install a 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
96. INSTALL SHIFT FORK SHAFT 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.
97. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING





a) Using a snap ring expander, install the input shaft rear bearing shaft snap ring.
98. INSTALL OUTPUT SHAFT REAR BEARING SHIM





a) Install the output shaft rear bearing shim to the output shaft.
99. INSTALL BEARING RETAINER REAR (MTM)





a) Coat the bearing retainer rear (MTM) with sealant, and install it with a torx wrench (T45).
b) Install a new output rear set nut to the output shaft.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
100. INSTALL 5TH DRIVEN GEAR





a) Using SST, install the 5th driven gear to the output shaft.
SST 09309-12020