Component Parts Installation
HINT: Coat all of the sliding and rotating surface with gear oil before assembly.1. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD
2. INSTALL NO.2 FORK SHAFT
a. Install the 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.08833-000901 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)
3. INSTALL MAGNET TO TRANSAXLE CASE
4. INSTALL DIFFERENTIAL CASE ASSEMBLY
5. INSTALL INPUT AND OUTPUT SHAFTS
Install the input and output shafts together.
6. INSTALL REVERSE SHIFT FORK AND INTERLOCK PIN
a. Install the reverse shift fork onto No.2 fork shaft.
b. Install the interlock pin into the reverse shift fork hole.
7. INSTALL NO.1 AND NO.2 SHIFT FORKS, NO.1 SHIFT HEAD AND NO.1 FORK SHAFT
a. Place the No.1 and No.2 shift forks into the groove of No.1 and No.2 hub sleeves.
b. Hold the No.1 shift head and insert No.1 fork shaft into the transaxle case through No.1 and No.2 shift forks, No.1 shift head and reverse shift fork.
c. Using a pin punch and hammer, drive in the slotted spring pin into No.1 shift head.
d. Shift the fork shaft into reverse.
e. Using a pin punch and hammer, drive in the slotted spring pin into No.1 fork shaft.
8. 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. 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.
9. INSTALL REVERSE IDLER GEAR AND SHAFT
a. Install the washer and reverse idler gear to the shaft.
b. Install the reverse idler gear and shaft as shown.
10. INSTALL TRANSMISSION CASE
a. Apply seal packing to the transmission case as shown.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
b. Install and torque the seventeen bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N.m)
11. INSTALL SHIM AND SIDE BEARING RETAINER WITH O-RING
a. Install a new O-ring on the retainer.
b. Install the shim and retainer.
c. Apply sealant to the bolt threads.
Sealant: Part No.08833-000801 THREE BOND 1344, LOCTITE 242 or equivalent
d. Install and torque the six bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N.m)
12. INSTALL AND TORQUE REVERSE IDLER GEAR SHAFT LOCK BOLT
Torque: 300 kg-cm (22 ft-lb, 29 N.m)
13. INSTALL BEARING SNAP RINGS
Using a snap ring expander, install the two snap rings.
HINT: If it is difficult to install the snap ring, pull up the shafts.
14. INSTALL NO.1 FORK SHAFT SNAP RING
Using a screwdriver and hammer, drive the snap ring.
15. INSTALL REAR BEARING RETAINER
a. Apply sealant to the bolt threads.
Sealant: Part No.08833-00070, THREE BOND 1324 or equivalent
b. Install and torque the five bolts.
Torque: 430 kg-cm (31 ft-lb, 42 N.m)
16. INSTALL FIFTH DRIVEN GEAR
Using SST, install the 5th driven gear. SST 09309-32050
17. INSTALL SPACER, NEEDLE ROLLER BEARINGS, FIFTH GEAR AND SYNCHRONIZER RING
a. Install the spacer.
b. Apply gear oil to the needle roller bearings.
c. Install the 5th gear with the needle roller bearings and synchronizer ring.
18. 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.
NOTE: Install the key springs positioned so that their end gaps are not in line.
19. INSTALL NO.3 HUB SLEEVE ASSEMBLY WITH SHIFT FORK
a. Support the tip of the input shaft with a spacer or such to raise the transaxle assembly.
b. Using SST and a hammer, drive in No.3 hub sleeve with shift fork.
SST 09612-22011
NOTE: Align the synchronizer ring slots with the shifting keys.
c. Install and torque the bolt to the No.3 shift fork.
Torque: 185 kg-cm (13 ft-lb, 18 N.m)
20. INSPECT FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)
21. INSTALL SHIFTING KEY RETAINER AND SNAP RING
a. Install the retainer.
b. Select a snap ring that will allow minimum axial play and install it on the shaft.
22. INSTALL SHIFT AND SELECT LEVER ASSEMBLY
a. Apply seal packing to the underside of the flanged portion of the control shaft cover.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
b. Install the shift and select lever assembly and torque the control shaft cover.
Torque: 375 kg-cm (27 ft-lb, 37 N.m)
23. INSTALL NO.2 LOCK BALL ASSEMBLY
a. Apply sealant to the lock ball assembly threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST, install and torque the plug.
SST 09313-30021
Torque: 230 kg-cm (17 ft-lb, 23 N.m)
24. INSTALL AND ADJUST NO.1 LOCK BALL ASSEMBLY
a. Fully loosen the lock nut.
b. Fully screw in the lock ball.
c. Loosen the lock ball to where the play at the shift outer lever tip is 0.1 - 0.5 mm (0.004 - 0.020 in.)
d. Hold the lock ball and tighten the lock nut
Torque: 375 kg-cm (27 ft-lb, 37 N.m)
e. Check the shift outer lever tip play.
Lever tip play: 0.1 - 0.5 mm (0.004 - 0.020 in.)
25. INSTALL SELECTING BELLCRANK
26. INSTALL TRANSMISSION CASE COVER
a. Apply seal packing to the transmission case as shown.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
b. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Install and torque the eight bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N.m)
27. INSTALL RELEASE BEARING RETAINER
Torque: 75 kg-cm (65 in.-lb, 7.4 N.m)
28. INSTALL RELEASE FORK AND BEARING
a. Apply molybdenum disulphide lithium base grease to the following parts:
- Release bearing hub inside groove
- Input shaft spline
- Release fork contact surface
b. Apply MP grease to the front surface of the release bearing.
29. INSTALL BACK-UP LIGHT SWITCH
Torque: 450 kg-cm (33 ft-lb, 44 N.m)
30. INSTALL SPEEDOMETER DRIVEN GEAR