Part 4 of 4
MANUAL TRANSAXLE ASSY
OVERHAUL
101. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
a) Coat the 5th gear needle roller bearing with gear oil, and install it to the input shaft.
102. INSTALL 5TH GEAR
a) Coat the 5th gear with gear oil, and install it to the input shaft.
103. INSTALL TRANSMISSION CLUTCH HUB NO.3
a) Using SST, install the transmission clutch hub No.3 to the input shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010)
NOTICE: Align the projection of the synchronizer ring with the hole of the 5th gear and install.
b) Install the transmission hub sleeve No.3 and gear shift fork No.3 to the transmission clutch hub No.3.
c) Coat the shift fork set bolt with sealant, and install it to the gear shift fork No. 3.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
d) Select a snap ring that will allow minimum axial play. Using a brass bar and a hammer, install the shaft snap ring.
Clearance: 0.1 mm or less
Snap ring
104. INSPECT 5TH GEAR RADIAL CLEARANCE
a) Using a dial indicator, inspect the 5th gear radial clearance.
Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 inch)
If clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.
105. INSPECT 5TH GEAR THRUST CLEARANCE
a) Using a dial indicator, inspect the 5th gear thrust clearance.
Standard clearance: 0.10 to 0.65 mm (0.0039 to 0.0260 inch)
If clearance is out of specification, replace the transmission clutch hub No.3, 5th gear or input shaft rear radial ball bearing.
106. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
a) Double mesh the gears. (Engage 1st and 2nd gears simultaneously.)
b) Install a new manual transmission output shaft rear set nut.
Torque: 123 Nm (1,254 kgf-cm, 91 ft. lbs.)
c) Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
d) Disengage the gears.
107. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSY
a) Apply FIPG to the transaxle case cover sub-assy, as shown in the installation.
FIPG: Part No. 08826-00090, THREE BOND 1281
NOTICE: Install the part within 10 minutes after applying the packing material (FIPG).
b) Install the transmission case cover sub-assy with the 10 bolts to the manual transaxle case.
108. INSTALL DRAIN (MTM) PLUG SUB-ASSY
a) Install the drain plug sub-assy with a new gasket to the manual transmission case.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
109. INSTALL MANUAL TRANSMISSION FILLER PLUG
a) Install the manual transmission filler plug with a new gasket to the oil seal.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
110. INSTALL SHIFT & SELECT LEVER SHAFT ASSY
a) Coat the shift & select lever shaft assy with gear oil, and install it to the manual transmission case.
111. INSTALL BACK UP LAMP SWITCH ASSY
a) Install the back up lamp switch assy to the manual transmission case.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
112. INSTALL MANUAL TRANSMISSION BREATHER PLUG
a) Install a new gasket with the manual transmission breather plug to the manual transmission case.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
113. INSTALL LOCK BALL ASSY NO.1
a) Install the lock ball assy No.1 to the manual transmission case.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
114. INSTALL CONTROL SHAFT COVER
a) Coat the 4 bolts with sealant, and install a new gasket and the control shaft cover with the bolts.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
115. INSTALL CONTROL SHIFT LEVER
a) Install the control shift lever with the shift outer lever lever lock pin to the shift & select lever shaft.
b) Install the spring washer with the nut.
Torque: 6.4 Nm (65 kgf-cm, 57 inch lbs.)
116. INSTALL SELECTING BELL CRANK ASSY
a) Coat the 2 bolts with sealant, and install the selecting bell crank assy to the manual transmission case with the bolts.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
117. INSTALL SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSY
a) Install the speedometer driven gear to the speedometer sensor.
b) Install the MTM speedometer shaft sleeve clip to the speedometer driven (MTM) gear sub-assy.
c) Install the speedometer driven (MTM) gear sub-assy to the transmission case with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 48 inch lbs.)
118. INSTALL CLUTCH RELEASE FORK BOOT
a) Install the clutch release fork boot to the manual transaxle case.
119. INSTALL RELEASE FORK SUPPORT
a) Using a deep socket wrench, install the release fork support to the manual transaxle case.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)
120. INSTALL CLUTCH RELEASE BEARING ASSY
a) Coat the clutch release bearing assy with release hub grease, and install it to the clutch release fork sub-assy.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
b) Apply clutch spline grease to the input shaft spline.
121. INSTALL CLUTCH RELEASE FORK SUB-ASSY
a) Install the clutch release fork sub-assy to the input shaft.