Component Parts Installation

HINT: Coat all of the sliding and rotating surface with ATF before assembly.




1. INSTALL AND TORQUE NO.1 OIL RECEIVER PIPE TO TRANSMISSION CASE

Torque: 75 kg-cm (65 in.-lb. 7.4 N-m)




2. INSTALL TRANSAXLE OIL RECEIVER AND PLATE TO TRANSAXLE CASE
a. Install and torque the oil receiver.

Torque: 75 kg-cm (65 in.-lb, 7.4 N-m)

b. Install and torque the plate.

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




3. INSTALL MAGNET




4. 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 a slotted spring pin.

Drive in depth: 29.5-30.5 mm (1.16-1.20 in.)




c. Apply sealant to the plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Using SST, install and torque the screw plug.
SST 09313-30021

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




5. INSTALL DIFFERENTIAL ASSEMBLY
Install the differential assembly to the transaxle case.




6. INSTALL IN PUT AND OUTPUT SHAFTS ASSEMBLY
Install the input and output shafts together.




7. INSTALL REVERSE SHIFT FORK AND INTER LOCK PIN
a. Insert interlock pin into the reverse shift fork hole.




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




8. INSTALL NO.1 AND NO.2 SHIFT FORKS, NO.1 SHIFT HEAD AND NO.1 FORK SHAFT
a. Place 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 fork, No.1 shift head and reverse shift fork.




c. Using a pin punch and hammer, drive the slotted spring pin into No.1 shift head.

Drive in depth: 2.0 - 3.0 mm (0.08 - 0.12 in.)




d. Shift the shift fork shaft into reverse.
e. Using a pin punch and hammer, drive the slotted spring pin into No.1 fork shaft.

Drive in depth: 3.5 - 4.5 mm (0.14- 0.18 in.)




9. INSTALL REVERSE IDLER GEAR AND SHAFT
a. Install the reverse idler gear shaft to the reverse idler gear.




b. Install the reverse idler gear and shaft to transaxle case.
c. Align the matchmark on the shaft end with the bolt hole in the transaxle case, as shown in the illustration.




10. 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 shift fork shaft into reverse.
c. Install and torque the two bolts.

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

d. Shift the shift fork shaft into neutral position.




11. INSTALL TRANSMISSION CASE
a. Remove any packing material and be careful not to drop oil on the contacting surface 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




c. Install and torque the seventeen bolts.

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




12. INSTALL REVERSE IDLER GEAR SHAFT LOCK BOLT
a. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

b. Install and torque the bolt.

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




13. INSTALL SIDE BEARING RETAINER
a. Install the shim.

HINT: Install the previously selected shim.




b. Install a new O-ring on the side bearing retainer.
c. Install the side bearing retainer.
d. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
e. Install and torque the six bolts.

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




14. INSTALL SNAP RINGS
Using snap ring pliers, install the snap rings to the input and output shaft rear bearing.




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: 210 kg-cm (15 ft-lb, 21 N-m)




16. INSTALL FIFTH DRIVEN GEAR
Using SST, install the fifth driven gear.
SST 09309-32050




17. INSTALL SPACER, NEEDLE ROLLER BEARINGS, FIFTH GEAR AND SYNCHRONIZER RING
a. Install the spacer.
b. Install the needle roller bearings.
c. Install the fifth gear with the 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 NO.3 SHIFT FORK
a. Support the tip of the input shaft with a spacer or such to raise the transaxle assembly.
b. Install the No.3 shift fork set bolt.

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

c. Using SST, drive in No.3 hub sleeve with shift fork.
SST 09612-22011

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




20. INSTALL SHIFTING KEY RETAINER
Install the shifting key retainer as shown in the figure.




21. INSTALL SNAP RING




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




22. MEASURE FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)




23. INSTALL LOCK NUT
a. Engage the gear double meshing.




b. Install and torque the nut.

Torque: 1,250 kg-cm (90 ft-lb, 123 N-m)

HINT: The lock nut has LH threads.




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




24. 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. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Install and torque the eight bolts.

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




25. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY




26. INSTALL CONTROL SHAFT COVER
a. Coat a new O-ring with ATF and install it to the control shaft cover.
b. Install and torque the control shaft cover.

Torque: 335 kg-cm (24 ft-lb, 33 N-m)




27. 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)

d. Install the boot to the shift lever.




28. INSTALL NO.2 LOCK BALL ASSEMBLY
a. Apply liquid sealant to the plug.
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)




29. INSTALL 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.)




30. INSTALL SELECTING BELL CRANK ASSEMBLY AND ENGINE MOUNTING BRACKET
a. Install and torque the selecting bell crank.

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

b. Install and torque the engine mounting bracket.

Torque: 530 kg-cm (38 ft-lb, 52 N-m)




31. INSTALL RELEASE BEARING RETAINER

Torque: 75 kg-cm (65 in.-lb, 7.4 N-m)




32. INSTALL SPEEDOMETER DRIVEN GEAR




33. INSTALL BACK-UP LIGHT SWITCH

Torque: 450 kg-cm (33 ft-lb, 44 N-m)




34. INSTALL RELEASE BEARING FORK AND BEARING
Apply molybdenum disulphide lithium base grease to the following parts:
- Input shaft spline
- Release fork contact surface