Assembly of Transmission

Assembly of Transmission




1. INSERT NO.2 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

CAUTION: Install the key springs positioned so that their end gaps are not in line.




2. INSTALL THIRD GEAR, NEEDLE ROLLER BEARINGS, SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply MP grease to the needle roller bearings.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
c. Using a press, install the 3rd gear and No. 2 hub sleeve.







3. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.




4. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance: 0.10 - 0.35 mm (0.0039 - 0.0138 in.)




5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER BEARING, FOURTH GEAR AND RADIAL BALL BEARING
a. Apply MP grease to the needle roller bearing.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
c. Using SST, press in the radial ball bearing.
SST 0960812010 (09608-00070)







6. INSTALL SNAP RING
Select 8 snap ring that will allow minimum axial play and install it on the shaft.




7. MEASURE FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 4th gear thrust clearance.

Standard clearance: 0.10 - 0.55 mm (0.0039 - 0.0217 in.)




8. IF OUTPUT SHAFT WAS REPLACED, DRIVE IN SLOTTED SPRING
If the output shaft was replaced, drive the slotted spring pin in the output shaft to a depth of 6.0 mm (0.236 in.).




9. INSERT NO.1 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

CAUTION: Install the key springs positioned so that their end gaps are not in line.




10. INSTALL THRUST WASHER, FIRST GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO OUTPUT SHAFT
a. Install the locking ball in the shaft.
b. Fit the thrust washer groove securely over the locking ball when installing the thrust washer on the shaft.
c. Apply MP grease to the needle roller bearing.
d. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.




e. Using a press, install theist gear and No.1 hub sleeve.







11. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play, and install it on the shaft.




12. MEASURE FIRST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st gear thrust clearance.

Standard clearance: 0.10 - 0.40 mm (0.0039 - 0.0157 in.)




13. INSTALL SPACER, SYNCHRONIZER RING, SECOND GEAR, NEEDLE ROLLER BEARING AND THIRD DRIVEN GEAR
a. Install the spacer.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys
c. Apply MP grease to the needle roller bearing.
d. Install the 2nd gear.




e. Using a press, install the 3rd driven gear.




14. MEASURE SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust clearance.

Standard clearance: 0.10 - 0.45 mm (0.0039 - 0.0177 in.)




15. INSTALL OUTPUT GEAR SPACER. FOURTH DRIVEN GEAR AND RADIAL BALL BEARING
a. Install the spacer.
b. Using SST, press in the 4th driven gear and bearing.
SST 09608-12010 (09608-00070)




16. INSTALL MAGNET
17. INSTALL OIL RECEIVER
Install the oil receiver with the two bolts.




18. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
a. Install the thinnest shim into the transmission case.
b. Using SST, drive in the outer race of the side bearing.
SST 09608-20012 (09608-03020, 09608-03090)
c. Install the differential to the transaxle case.




d. Install the transmission case.
e. Install and torque the case bolts.

Torque: 300 kg-cm (22 ft-lb, 29 N.m)







f. Using SST and torque meter, measure the preload.
SST 09564-32011

Preload (starting):
New bearing: 8 - 16 kg-cm (6.9 - 13.9 in.-lb, 0.8 - 1.6 N.m)
Reused bearing: 5 - 10 kg-cm (4.3 - 8.7 in.-lb, 0.5 - 1.0 N.m)

If the preload is not within specification, remove the transmission case side outer race of the side bearing with SST. Reselect an adjusting shim.

NOTE: The preload will change about 3 - 4 kg-cm (2.6 - 3.5 in.-lb, 0.3 - 0.4 N.m) with each shim thickness.




19. REMOVE TRANSMISSION CASE




20. INSTALL INPUT AND OUTPUT SHAFT
Install the input and output shafts together.




21. INSTALL SHIFT FORKS AND SHIFT FORK SHAFTS
a. Place No.1 and No.2 shift forks into the groove of No.1 and No.2 hub sleeves.




b. Insert No.1 fork shaft into No.1 shift fork hole.




c. Insert the two interlock balls into the reverse shift fork hole.




d. Install No.3 fork shaft and the reverse shift fork.




e. Install No.2 fork shaft and the shift head.




f. Install the three bolts.

Torque: 160 kg-cm (12 ft-lb, 16 N.m)




g. Install the three snap rings.




22. INSTALL REVERSE SHIFT ARM
a. Put the reverse shift fork pivot into the reverse shift arm and install the reverse shift arm to the transaxle case.
b. install and torque the bolts.

Torque: 175 kg-cm (13 ft-lb, 17 N.m)




23. INSTALL REVERSE IDLER GEAR AND SHAFT
Install the reverse idler gear and shaft as shown.




24. INSTALL TRANSMISSION CASE
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case or transaxle case.
b. Apply seal packing to the transmission case as shown in the figure.
Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent

NOTE: Install the transmission case as soon as the seal packing is applied.

c. Install and torque the sixteen bolts.

Torque: 300 kg-cm (22 ft-lb, 29 N.m)




25. INSTALL BALL, SPRING, SEAT, PLUG AND LOCK BALL ASSEMBLY

a. Insert the balls, springs and seats into the holes.




b. Apply liquid sealer to the plugs and the lock ball assembly.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Using SST, tighten the three plugs and the lock ball assembly.
SST 09313-30021

Torque: Straight screw plug: 250 kg-cm (18 ft-lb, 25 N.m)
(For shift fork shaft)
Lock ball assembly: 400 kg-cm (29 ft-lb, 39 N.m)




26. INSTALL AND TORQUE REVERSE IDLER GEAR SHAFT LOCK BOLT

Torque: 240 kg-cm (17 ft-lb, 24 N.m)




27. INSTALL BEARING SNAP RINGS
28. INSTALL SNAP RING TO NO.2 FORK SHAFT




29. INSTALL REAR BEARING RETAINER
Install and torque the five bolts.

Torque: 195 kg-cm (14 ft-lb, 19 N.m)




30. INSTALL FIFTH DRIVEN GEAR Using SST, install the 5th driven gear.
SST 0930912020




31. INSTALL SPACER, NEEDLE ROLLER BEARING, FIFTH GEAR AND SYNCHRONIZER RING
a. Install the spacer.
b. Apply MP grease to the needle roller bearings.
c. Install the 5th gear with the needle roller bearing and synchronizer ring.




32. INSERT NO.3 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. install the shifting key springs under the shifting keys.

CAUTION: Install the key springs positioned so that their end gaps are not in line.




33. INSTALL NO.3 HUB SLEEVE ASSEMBLY WITH NO.3 SHIFT FORK
a. Support the tip of the input shaft with a spacer or such to raise the transaxle assembly.
b. Using SST, drive in No.3 hub sleeve with No.3 shift fork.
SST 0961222011

CAUTION: Align the synchronizer ring slots with the shifting keys.




34. MEASURE FIFTH GEAR THRUST CLEARANCE

Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 in.)







35. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.




36. INSTALL LOCK NUT
a. Engage the gear double meshing.
b. Install and torque the nut.

Torque: 1,200 kg-cm (87 ft-lb, 118 N.m)

c. Disengage the gear double meshing.
d. Stake the lock nut.




37. INSTALL BOLT

Torque: 160 kg-cm (12 ft-lb, 16 N.m)




38. ASSEMBLE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Apply MP grease to the shaft.




b. Install the boot and shaft to the control shaft cover.

NOTE: Make sure to install the boot in correct direction. Position the air bleed of the boot downward.




c. Install the snap ring and spring seat.




d. Install the compression spring and select inner lever.




e. Using a pin punch and hammer, drive in the slotted spring pin.




f. Align the interlock plate with No. 1 shift inner lever and install it.
g. Install No.2 shift inner lever.




h. Using a pin punch and hammer, drive in the slotted spring pins.




i. Install the compression spring, seat and E-ring.




39. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Place a new gasket in position on the control shaft cover.
b. Apply liquid sealer to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Install the shift and select lever shaft, and torque the bolts.

Torque: 200 kg-cm (14 ft-lb, 20 N.m)

d. Install the bellcrank to the transmission case.




40. INSTALL LOCK BOLT
Install the lock bolt.

Torque: 300 kg-cm (22 ft-lb, 29 N.m)




41. INSTALL TRANSMISSION CASE COVER
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case or case cover.
b. Apply seal packing to the transmission case as shown in the figure.
Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent

NOTE: Install the transmission case cover as soon as the seal packing is applied.

c. Install and torque the nine bolts.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)




42. INSTALL FRONT BEARING RETAINER

Torque: 110 kg-cm (8 ft-lb, 11 N.m)




43. INSTALL RELEASE FORK AND BEARING
Apply molybdenum disulfide lithium base grease to the following parts:
- Release bearing hub inside groove
- Input shaft spline
- Release fork contact surface




44. INSTALL BACKUP LIGHT SWITCH
Using SST, install the backup light switch.
SST 09817-16011

Torque: 410 kg-cm (30 ft-lb, 40 N.m)

45. INSTALL SPEEDOMETER DRIVEN GEAR