Component Parts Installation
BASIC SUBASSEMBLY REASSEMBLYHINT: Coat all of the sliding and rotating surface with gear oil before assembly.
1. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD
2. INSTALL MAGNET TO TRANSAXLE CASE
3. INSTALL DIFFERENTIAL CASE ASSEMBLY
4. ASSEMBLE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS
a. Assemble the No.1 shift fork shaft, No.1 shift head, No.1 and No.2 shift forks.
b. Mount the shift forks to the vise.
c. Using a pin punch and hammer, drive in the slotted spring pin to the No.1 fork shaft as shown in the image.
d. Coat the interlock pin with MP grease.
e. Using a screwdriver, install the interlock pin into the reverse shift fork hole.
f. Install the reverse shift fork to the No.1 shift fork shaft.
HINT: When installing the reverse shift fork with interlock pin to the No.1 shift fork shaft, make sure the interlock pin does not drop out.
NOTE: Be careful not to damage the bushing.
g. Using a pin punch and hammer, drive in the slotted spring pin to the No.1 fork shaft.
5. INSTALL NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1, NO.2 SHIFT FORKS. REVERSE SHIFT FORK WITH INTERLOCK PIN, INPUT AND OUTPUT SHAFT ASSEMBLY
Install the input and output shaft assembly together with the No.1 fork shaft, shift head and shift forks with the interlock pin to the transaxle case.
6. INSTALL NO.2 FORK SHAFT
a. Install the No.2 fork shaft to the transaxle case through the reverse shift fork.
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 a hexagon wrench, install the straight screw plug.
Torque: 13 N.m (130 kgf-cm, 9 ft-lbf)
7. 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 the reverse.
c. Install and torque the 2 bolts.
Torque: 18 N.m (185 kgf-cm, 13 ft-lbf)
d. Shift the reverse shift arm to the neutral position.
8. 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.
9. INSTALL TRANSMISSION CASE
a. Remove any FIPG material and be careful not to drop oil on the contacting surface of the transaxle case or transmission case.
b. Apply FIPG to the transmission case as shown.
FIPG:
Part No.08833-00090, THREE BOND 1281 or equivalent
c. Install and torque the 17 bolts.
Torque: 29 N.m (300 kgf-cm, 22 ft-lbf)
10. 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.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Install and torque the 6 bolts.
Torque: 18 N.m (185 kgf-cm, 13 ft-lbf)
11. INSTALL AND TORQUE REVERSE IDLER GEAR SHAFT LOCK BOLT
Torque: 29 N.m (300 kgf-cm, 22 ft-lbf)
12. INSTALL BEARING SNAP RINGS
Using a snap ring expander, install the 2 snap rings.
HINT: If it is difficult to install the snap ring, pull up the shafts.
13. 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 5 bolts.
Torque: 42 N.m (430 kgf-cm, 31 ft-lbf)
14. INSTALL 5TH DRIVEN GEAR
Using SST, install the 5th driven gear.
SST 09309-12020
15. INSTALL SPACER, NEEDLE ROLLER BEARINGS, 5TH 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.
16. INSTALL NO.5 SYNCHRONIZER RINGS WITH KEY SPRING TO NO.3 CLUTCH HUB
a. Assemble the No.5 synchronizer rings.
b. Using a screwdriver, install the snap ring.
HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.
c. Install the No.5 synchronizer rings with key springs to the No.3 clutch hub.
HINT: Align the holes of the clutch hub with key spring.
17. INSTALL NO.3 CLUTCH HUB
Using SST and a press, install the No.3 clutch hub assembly.
SST 09612-22011
NOTE: Align the holes of the 5th gear and synchronizer ring.
18. INSTALL SHIFTING KEY RETAINER AND SNAP RING
a. Install the retainer.
b. Select a snap ring that will allow minimum axial play.
c. Using a screwdriver and hammer, tap in the snap ring.
19. INSPECT 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)
20. INSTALL NO.3 HUB SLEEVE WITH NO.3 SHIFT FORK
a. Install No.3 hub sleeve with No.3 shift fork to the No.3 clutch hub.
b. Install and torque the set bolt.
Torque: 18 N.m (185 kgf-cm, 13 ft-lbf)
21. INSTALL OUTPUT SHAFT LOCK NUT
a. Engage the gear double meshing.
b. Install and torque the new lock nut.
Torque: 123 N.m (1,250 kgf-cm, 90 ft-lbf)
HINT: The lock nut has LH threads.
c. Stake the lock nut.
d. Disengage the gear double meshing.
22. INSTALL SHIFT AND SELECT LEVER ASSEMBLY
a. Apply FIPG to the underside of the flanged portion of the control shaft cover.
FIPG:
Part No.08826-00090, THREE BOND 1281 or equivalent
b. Install the shift and select lever assembly and torque the control shaft cover.
Torque: 37 N.m (375 kgf-cm, 27 ft-lbf)
23. INSTALL PLUG
a. Apply sealant to plug threads.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a hexagon wrench, install and torque the plug.
Torque: 23 N.m (230 kgf-cm, 17 ft-lbf)
24. INSTALL LOCK BALL
Install and torque the No.1 lock ball.
Torque: 29 N.m (300 kgf-cm, 22 ft-lbf)
25. INSTALL TRANSMISSION CASE COVER
a. Remove the FIPG material and be careful not to drop oil on the contacting surface of the transmission case or transmission case cover.
b. Apply FIPG to the transmission case cover as shown.
FIPG:
Part No.08826-00090, THREE BOND 1281 or equivalent
c. Install the transmission case cover.
d. Apply sealant to the bolt threads.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
e. Install and torque the 8 bolts.
Torque: 29 N.m (300 kgf-cm, 22 ft-lbf)
26. INSTALL SELECTING BELLCRANK AND ENGINE MOUNT BRACKET
a. Install the selecting bellcrank and 2 bolts.
Torque: 37 N.m (380 kgf-cm, 27 ft-lbf)
b. Install the engine mount bracket and torque the 3 bolts.
Torque: 52 N.m (530 kgf-cm, 38 ft-lbf)
27. INSTALL RELEASE BEARING RETAINER
Install the release bearing retainer and torque the 3 bolts.
Torque: 7.4 N.m (75 kgf-cm, 65 in.-lbf)
28. INSTALL BACK-UP LIGHT SWITCH
Torque: 44 N.m (450 kgf-cm, 33 ft-lbf)
29. INSTALL VEHICLE SPEED SENSOR
30. INSTALL RELEASE FORK AND BEARING
a. Apply molybdenum disulphide lithium base grease to the following parts:
- Input shaft spline
- Release fork contact surface
b. Apply MP grease to the front surface of the release bearing.