Basic Subassembly Reassembly

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




1. MEASURE DIFFERENTIAL SIDE BEARING PRELOAD




2. INSTALL MAGNET TO TRANSAXLE CASE
3. INSTALL DIFFERENTIAL CASE ASSEMBLY




4. INSTALL INPUT AND OUTPUT SHAFTS
Install the input and output shafts together.




5. INSTALL SHIFT FORKS AND SHIFT FORK SHAFTS
a. Place the No.1 and No.2 shift forks into the groove of No.1 and No.2 hub sleeves.




b. Install the No.1 fork shaft into the No.1 shift fork hole.




c. C150:
Install the 2 interlock balls into the reverse shift fork hole.




d. Install the No.3 fork shaft and the reverse shift fork.




e. Install the No.2 fork shaft and the shift head.




f. C141:
Using a pin punch and hammer, drive in the slotted spring pin to the reverse shift head.




g. Install the 3 bolts.

Torque: 16 N-m (160 kgf-cm, 12 ft-lbf)




h. C150:
Using a screwdriver and hammer, tap in the 3 snap rings.
C141:
Using a screwdriver and hammer, tap in the 2 snap rings.
i. C141:
Using a pin punch and hammer, drive in the slotted spring pin into the reverse shift fork.




6. INSTALL REVERSE SHIFT ARM BRACKET
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 and torque the bolts.

Torque: 17 N-m (175 kgf-cm, 13 ft-lbf)




7. INSTALL REVERSE IDLER GEAR, THRUST WASHER AND SHAFT
Install the reverse idler gear, thrust washer and shaft, as shown.




8. INSTALL TRANSMISSION CASE
a. Remove any packing material and be careful not to drop oil on the contacting surface of the transaxle case or transmission case.
b. Apply seal packing to the transaxle case, as shown in the figure.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
c. Install and torque the 16 bolts.

Torque: 29 N-m (300 kgf-cm, 22 ft-lbf)




9. C141:
INSTALL PLUG
a. Apply sealant to the plug thread.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a hexagon wrench, tighten the plug.

Torque: 25 N-m (250 kgf-cm, 18 ft-lbf)




10. C150:
INSTALL LOCK BALL ASSEMBLY
a. Apply sealant to the lock ball assembly thread.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a hexagon wrench. tighten the lock ball assembly.




11. C141:
INSTALL STRAIGHT SCREW PLUG
a. Apply sealant to the straight screw plug thread.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a hexagon wrench. tighten the straight screw plug.

Torque: 39 N-m (400 kgf-cm, 29 ft-lbf)




12. INSTALL BALLS, SPRINGS, SEATS AND PLUGS
a. Install the balls, springs and seats into the holes.
b. Apply sealant to the plugs threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent




c. Using a hexagon wrench, tighten the 3 plugs.

Torque: 25 N-m (250 kgf-cm, 18 ft-lbf)




13. INSTALL AND TORQUE REVERSE IDLER GEAR SHAFT LOCK BOLT

Torque: 29 N-m (300 kgf-cm, 22 ft-lbf)




14. INSTALL BEARING SNAP RINGS
Using a snap ring expander, install the 2 snap rings.

HINT: If it is difficult to install the snap rings, pull up the shafts.




15. INSTALL SNAP RING TO NO.2 FORK SHAFT
Using a screwdriver and hammer, tap in the snap ring.




16. INSTALL REAR BEARING RETAINER
Install and torque the 5 bolts.

Torque: 19 N-m (195 kgf-cm, 14 ft-lbf)




17. C150:
INSTALL 5TH DRIVEN GEAR
Using SST, install the 5th driven gear.
SST 09309-12020




18. C150:
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.




19. C150:
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.




20. C150:
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. Using SST and a hammer, drive in No.3 hub sleeve with shift fork.
SST 09812-22011

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




21. C150:
MEASURE 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 in.)




22. C150:
INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and hammer, tap in the snap ring.




23. INSTALL LOCK NUT
a. Engage the gear double meshing.
b. C141:
Install the spacer.
c. Install and torque the nut.

Torque: 118 N-m (1,200 kgf-cm, 87 ft-lbf)

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




24. C150:
INSTALL BOLT

Torque: 16 N-m (160 kgf-cm, 12 ft-lbf)




25. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Place a new gasket in position on the control shaft cover.
b. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Install the shift and select lever shaft and torque the bolts.

Torque: 20 N-m (200 kgf-cm, 14 ft-lbf)




26. INSTALL LOCK BOLT
Install and torque the lock bolt.

Torque: 29 N-m (300 kgf-cm, 22 ft-lbf)




27. INSTALL TRANSMISSION CASE COVER
a. Apply seal packing to the transmission case, as shown in the figure.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
b. Install and torque the 9 bolts.

Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)




28. INSTALL SELECTING BELLCRANK
29. INSTALL CONTROL LEVER HOUSING SUPPORT BRACKET
30. INSTALL BACK-UP LIGHT SWITCH

Torque: 40 N-m (410 kgf-cm, 30 ft-lbf)

31. INSTALL SPEEDOMETER DRIVEN GEAR




32. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO.2) TO FOLLOWING PARTS:
a. Release fork and hub contact point.
b. Release fork and push rod contact point.
c. Release fork pivot point.




33. APPLY SPLINE GREASE TO CLUTCH DISC SPLINE




34. INSTALL RELEASE BEARING AND FORK TO TRANSAXLE