Part 1

1. IF IN PUT SHAFT WAS REPLACED, DRIVE IN SLOTTED SPRING PIN
If the input shaft was replaced, drive the slotted spring pin in the input shaft to a depth of 5.0 mm (0.197 in.).




2. 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.




3. INSTALL THIRD GEAR, NEEDLE ROLLER BEARINGS. SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply ATF 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.







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




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

Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)




6. INSTALL SYNCHRONIZER RING, SPACER, NEEDLE ROLLER BEARINGS, FOURTH GEAR AND RADIAL BALL BEARING
a. Install the spacer.
b. Apply ATF to the needle roller bearings.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.




d. Using SST, press in the 4th gear and radial ball bearing.
SST 09608-20012 (09608-03070)







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




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

Standard clearance: 0.20 - 0.45 mm (0.0079 - 0.0177 in.)




9. IF OUTPUT SHAFT WAS REPLACED, DRIVE IN SLOTTED SPRING PIN
If the output shaft was replaced, drive the slotted spring pin in the output shaft to a depth of 5.0 mm (0.197 in.).




10. 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.




11. INSTALL THRUST WASHER, FIRST GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT SHAFT
a. Apply ATF to the needle roller bearing.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.




c. Using a press, install the 1St gear and No.1 hub sleeve.







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




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

Standard clearance: 0.10 - 0.29 mm (0.0039 - 0.0114 in.)




14. 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 ATF to the needle roller bearing.
d. Install the 2nd gear.




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




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

Standard clearance: 0.20 - 0.44 mm (0.0079 - 0.0173 in.)




16. 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)




17. INSTALL MAGNET




18. MEASURE DIFFERENTIAL SIDE BEARING PRELOAD

NOTE: If the transmission case, transaxle case, differential side bearing, differential case, transaxle case side shim or side bearing retainer was replaced, install the thinnest shim into the transmission case.

(Follow the step 11 on page MT-21)
a. Install the differential to the transaxle case.
b. Install the transmission case.
c. Install and torque the case bolts.

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




d. Install the shim into the transmission case.
e. Install the bearing retainer without an O-ring.
f. Install and torque the retainer bolts.

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




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

Preload (starting): 10 - 16 kg-cm
(8.7 - 13.9 in-lb, 1.0 - 1.6 N-m)

If the preload is not within specification, remove the bearing retainer.
Select another shim.

CAUTION: When selecting the shim begin with one of the thinner shims in the table and work toward thicker one.

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 BEARING RETAINER. SHIM AND TRANSMISSION CASE
It the preload is adjusted within specification, remove the bearing retainer, shim and transmission case.
Be careful not to lose the adjusted shim.




20. INSTALL INPUT AND OUTPUT SHAFTS
Install the input shaft and output shaft together.




21. INSTALL NO.2 FORK SHAFT
a. Insert No.2 fork shaft to the transaxle case and align the slotted spring pin hole.
b. Using a pin punch and hammer, drive in the slotted spring pin.
c. Apply sealant to the plug threads.

Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent




d. Using SST, install the straight screw plug.
SST 09313-30021

Torque: 130 kg-cm (9 ft-lb, 13 N-m)




22. INSTALL REVERSE SHIFT FORK AND INTERLOCK PIN
a. Insert interlock pin into the reverse shift fork hole.




b. Install the reverse shift fork onto No.2 fork shaft.




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




c. Install and torque the bolts.

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

d. Shift the reverse shift arm to neutral position




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