Component Parts Installation
HINT: Coat all of the sliding and rotating surface with gear oil before assembly.
1. INSTALL MAGNET TO TRANSAXLE CASE
2. INSTAL OIL PUMP ASSEMBLY AND OIL PIPE
a. Install the oil pump assembly.
b. Install the two bolts.
HINT: Be careful not to drop the oil pump gasket.
c. Install the oil pipe and two bolts.
d. Torque the four bolts.
Torque: 175 kg-cm (13 ft-lb, 17 N-m)
3. ADJUST OUTPUT SHAFT PRELOAD
a. Install the output shaft assembly.
b. Install the transmission case.
HINT: If necessary, tap on the case with a plastic hammer.
c. Install and torque the seventeen bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N-m)
d. Install the output shaft rear taper roller bearing outer race.
e. Install the adjust shim.
HINT: When re-using the output shaft bearing, first install a shim of the same thickness as before. If installing a new tapered roller bearing, first select and install a shim of lesser thickness than before.
f. Install the bearing retainer.
g. Using a torx wrench, install and torque the seven bolts.
Torx wrench T45 09042-00050
Torque: 430 kg-cm (31 ft-lb, 42 N-m)
h. Install the new lock nut to the output shaft.
i. Turn the output shaft right and left two or three times to allow the bearings to settle.
j. Using a torque wrench, measure the preload.
Preload (at 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, 0.1 - 0.2 N-m)
If the preload is not within specification, select the thrust washers.
HINT: The preload will change about 4 - 5 kg-cm (3.5 - 4.3 in.-lb, 0.4 - 0.5 N-m) with each shim thickness.
k. Remove the lock nut.
l. Using a torx wrench, remove the seven torx screws and rear bearing retainer.
Torx wrench T45 09042-00050
m. Remove the shim
n. Remove the seventeen bolts and transmission case.
o. Remove the output shaft assembly.
4. INSTALL DIFFERENTIAL CASE ASSEMBLY
5. INSTALL OIL PUMP DRIVE GEAR
6. INSTALL OUTPUT SHAFT ASSEMBLY
a. Lift up the differential case, install the input shaft assembly.
b. Leaning the output shaft to the differential side, install the input shaft assembly.
7. INSTALL SNAP RINGS
a. Using a plastic hammer, install the snap rings to the No 1, No.2 and No.3 shift fork shafts.
b. Using a plastic hammer, install the reverse shift fork and snap ring to the No.3 shift fork shaft.
8. INSTALL NO.2 SHIFT FORK AND NO.3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK
a. Install the No.2 shift fork to the No.2 hub sleeve.
b. Install the No.3 shift fork shaft with reverse shift fork.
9. INSTALL NO.1 SHIFT FORK, SHIFT HEAD AND NO.2 SHIFT FORK SHAFT
a. Install the No.1 shift fork to the No.1 hub sleeve
b. Put shift head onto the No.1 shift fork.
c. Install the No.2 shift fork shaft to the transaxle case, through the shift head and No.1 shift fork.
10. INSTALL INTERLOCK ROLLER
Using a magnetic finger, install the interlock roller to the reverse shift fork.
11. INSTALL NO.1 SHIFT FORK SHAFT
Install the No.1 shift fork shaft to the case, through the No.1 shift fork and reverse shift fork.
HINT: When it is difficult to install the fork shaft through the reverse shift fork, pull up the No.3 shift fork shaft.
12. INSTALL SET BOLTS
Install and torque the three set bolts.
Torque: 240 kg-cm (17 ft-lb, 24 N-m)
13. INSTALL LOCKING BALLS, SPRINGS, SEATS AND PLUGS
a. Install the two locking balls, springs and seats.
b. Apply liquid sealant to the two plugs.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Using SST, install and torque two plugs.
SST 09313-30021
Torque: 250 kg-cm (18 ft-lb, 25 N-m)
14. INSTALL REVERSE IDLER GEAR AND SHAFT
Install the reverse idler gear and shaft as shown.
15. INSTALL REVERSE SHIFT ARM BRACKET AND NO.2 OIL PIPE
a. Put the reverse shift fork pivot into the reverse shift arm and install the reverse shift arm bracket to the transaxle case.
b. Install the bolt.
c. Install the No.2 oil pipe and two bolts.
d. Torque the reverse shift arm bracket and oil pipe bolts.
Torque: 175 kg-cm (13 ft-lb, 17 N-m)
e. Install the new gasket to the No.2 oil pipe.
16. ALIGN MATCHMARKS
17. 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
HINT: Install the transmission case as shown as the seal packing is applied.
c. Install and torque the seventeen bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N-m)
18. INSTALL AND TORQUE REVERSE IDLER GEAR SHAFT RETAINING BOLT
Torque: 300 kg-cm (22 ft-lb, 29 N-m)
19. INSTALL LOCKING BALL, SPRING, SEAT AND PLUG
a. Install the locking ball, spring and seat.
b. Apply liquid sealant to the plug.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Using SST, install and torque the plug.
SST 09313-30021
Torque: 250 kg-cm (18 ft-lb, 25 N-m)
20. INSTALL SNAP RINGS
Using a plastic hammer, install the three snap rings.
21. INSTALL SHIM
HINT: Install the previously selected shim.
22. INSTALL SNAP RING
Using a snap ring pliers, install the snap ring to the input shaft rear bearing.
23. INSTALL REAR BEARING RETAINER
a. Clean the threads of the torx screws.
b. Apply liquid sealant to the screw threads.
Sealant: Part No.08833-00070, THREE BOND 1324, LOCTITE 242 or equivalent
c. Using a torx wrench, install and torque the seven torx screws.
Torx wrench T45 09042-00050
Torque: 430 kg-cm (31 ft-lb, 42 N-m)
24. INSTALL SPACER, NEEDLE ROLLER BEARING AND FIFTH GEAR
25. INSTALL SYNCHRONIZER RING WITH KEY SPRING TO NO.3 CLUTCH HUB
26. INSTALL NO.3 CLUTCH HUB
Using SST, install the No.3 clutch hub with synchronizer ring and key spring.
SST 09310-17010 (09310-07010, 09310-07020, 09310-07030)
27. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.
28. MEASURE FIFTH GEAR THRUST CLEARANCE
Using a dial indicator measure the 5th gear thrust clearance.
Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 in.)
29. INSTALL FIFTH DRIVEN GEAR
Using SST, install the 5th driven gear.
SST 09310-17010 (09310-07010, 09310-07020, 09310-07040, 09310-07050)
30. INSTALL NO.3 HUB SLEEVE WITH NO.3 SHIFT FORK
31. INSTALL SET BOLT
Install and torque the set bolt.
Torque: 240 kg-cm (17 ft-lb, 24 N-m)
32. INSTALL LOCK NUT
a. Engage the gear double meshing.
b. Install and torque the lock nut.
Torque: 1,250 kg-cm (90 ft-lb, 123 N-m)
c. Disengage the gear double meshing.
d. Stake the lock nut.
33. INSTALL TRANSMISSION CASE COVER
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission 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
HINT: Install the transmission case cover as soon as the seal packing is applied.
c. Install and torque the ten bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N-m)
34. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
35. INSTALL CONTROL SHAFT COVER
a. Place a new gasket in position on the control shaft cover.
b. Install the control shaft cover.
c. Apply liquid sealant to the bolt threads
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Install and torque the bolts.
Torque: 200 kg-cm (14 ft-lb, 20 N-m)
36. INSTALL AND TORQUE LOCK BOLT
Torque: 500 kg-cm (36 ft-lb, 49 N-m)
37. INSTALL SHIFT LEVER
a. Install the boot to the control shaft oil seal.
HINT: Make sure to install the boot in the correct direction. Position the air bleed of the boot downward.
b. Fit the pin's groove into the shaft's notch and tap on with a hammer.
c. Install and torque the nut.
Torque: 120 kg-cm (9 ft-lb, 12 N-m)
38. INSTALL AND TORQUE SELECTING BELLCRANK ASSEMBLY
Torque: 200 kg-cm (14 ft-lb, 20 N-m)
39. INSTALL BACK-UP LIGHT SWITCH WITH GASKET
Torque: 410 kg-cm (30 ft-lb, 40 N-m)
40. INSTALL SPEEDOMETER DRIVEN GEAR
41. INSTALL RELEASE FORK AND BEARING
Apply molybdenum disulphide lithium base grease to the following parts:
- Input shaft spline
- Release fork contact surface