Removal and Installation
COMPONENTSPart 1:
Part 2:
BASIC SUBASSEMBLY SEPARATION
1. REMOVE RELEASE FORK, BEARING, BACK - UP LIGHT SWITCH AND VEHICLE SPEED SENSOR
Torque: 44 N.m (450 kgf.cm, 33 ft-lbf)
2. REMOVE RELEASE BEARING RETAINER
Remove the 3 bolts and retainer.
Torque: 7.4 N.m (75 kgf-cm, 65 in.-lbf)
3. REMOVE ENGINE MOUNT BRACKET AND SELECTING BELLCRANK
a. Remove the 3 bolts and engine mount bracket.
Torque: 52 N.m (530 kgf.cm, 38 ft-lbf)
b. Remove the 2 bolts and selecting bellcrank.
Torque: 37 N.m (380 kgf.cm, 27 ft-lbf)
4. REMOVE TRANSMISSION CASE COVER
a. Remove the 8 bolts.
Sealant: Part No.08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 N.m (300 kgf-cm, 22 ft-lbf)
b. Using a plastic hammer, tap the transmission case cover.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
5. REMOVE LOCK BALL ASSEMBLY
Sealant: Part No.08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 N.m (300 kgf.cm, 22 ft-lbf)
6. REMOVE SHIFT AND SELECT LEVER ASSEMBLY
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
Torque: 37 N.m (375 kgf-cm, 27 ft-lbf)
7. REMOVE OUTPUT SHAFT LOCK NUT
a. Unstake the nut.
b. Engage the gear double meshing.
c. Remove the lock nut clockwise and remove it.
Torque: 123 N.m (1,250 kgf.cm, 90 ft-lbf)
HINT: The lock nut has LH threads.
d. Disengage the gear double meshing.
8. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
a. Remove the No.3 shift fork set bolt.
Torque: 18 N.m (185 kgf.cm, 13 ft-lbf)
b. Remove the No.3 hub sleeve and No.3 shift fork.
9. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-40010
INSTALLATION HINT: Using SST, install the 5th driven gear.
SST 09309-12020
10. MEASURE 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0167 in.)
Maximum clearance: 0.45 mm (0.0177 in.)
11. MEASURE 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.
Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or input shaft.
12. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
a. Using 2 screwdrivers and a hammer, tap out the snap ring.
INSTALLATION HINT: Select a snap ring that will allow minimum axial play.
b. Using SST and a socket wrench, remove the No.3 clutch hub with the synchronizer ring.
SST 09950-30010
INSTALLATION HINT: Using SST and a press, install the No.3 clutch hub assembly.
SST 09612-22011
c. Remove the 5th gear.
13. REMOVE NEEDLE ROLLER BEARING
14. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and retainer.
Sealant: Part No.06833-00080, THREE BOND 1324 or equivalent
Torque: 42 N.m (430 kgf.cm, 31 ft-lbf)
15. REMOVE BEARING SNAP RINGS
Using a snap ring expander, remove the 2 snap rings.
HINT: If it is difficult to remove and install the snap rings, pull up the shafts.
16. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET
Torque: 29 N.m (300 kgf.cm, 22 ft-lbf)
17. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM
Remove the 6 bolts, retainer and shim.
Sealant: Part No.08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 18 N.m (185 kgf.cm, 13 ft-lbf)
18. REMOVE TRANSMISSION CASE
a. Remove the 1 7 bolts.
Torque: 29 N.m (300 kgf.cm, 22 ft-lbf)
b. Using a plastic hammer, tap the transmission case.
FIPG: Part No.08833-00090, THREE BOND 1281 or equivalent
19. REMOVE REVERSE IDLER GEAR AND SHAFT
a. Pull out the shaft.
b. Remove the idler gear and thrust washer.
20. REMOVE REVERSE SHIFT ARM
a. Shift the fork shaft into reverse.
b. Remove the 2 bolts and pull off the reverse shift arm.
Torque: 18 N.m (185 kgf-cm, 13 ft-lbf)
21. REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS, REVERSE SHIFT FORK WITH INTERLOCK PIN, INPUT AND OUTPUT SHAFTS ASSEMBLY
22. REMOVE DIFFERENTIAL CASE ASSEMBLY
23. REMOVE MAGNET FROM TRANSAXLE CASE
24. REMOVE NO.2 FORK SHAFT
a. Using a hexagon wrench, remove the straight screw plug.
Sealant: Part No.08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 13 N.m (130 kgf.cm, 9 ft-lbf)
b. Using a pin punch and hammer. drive out the slotted spring pin.
c. Pull out the shaft.
25. SEPARATE NO.1 FORK SHAFT. NO.1 SHIFT HEAD. NO.1. NO.2 SHIFT FORKS AND REVERSE SHIFT FORK
a. Mount the shift forks to the vise.
b. Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft.
c. Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft, as shown in the illustration.
d. Separate the No.1 shift fork shaft, No.1 shift head, No.1 and No.2 shift forks and reverse shift fork.
26. REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB
a. Remove the No.5 synchronizer ring with the key spring from the No.3 clutch hub.
b. Using a screwdriver, remove the snap ring.
HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.
c. Remove the synchronizer rings.
COMPONENT PARTS INSPECTION
1. INSPECT NO.5 SYNCHRONIZER RINGS
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring.
Turn the middle No.5 synchronizer ring in one direction while pushing it to the outer No.5 synchronizer ring. Check that the ring locks.
If the braking effect is insufficient, replace the synchronizer ring.
2. INSPECT NO.3 SHIFT FORK AND NO.3 HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
3. IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING
a. Remove the 2 bolts and transaxle case receiver.
b. Using SST, pull out the bearing.
SST 09308-00010
c. Using SST, press in a new bearing. SST 09310-35010
d. Install the transaxle case receiver and torque the 2 bolts.
Torque: 7.4 N.m (75 kgf.cm, 65 in.-lbf)
4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING
a. Remove the bolt and bearing lock plate.
b. Using SST, pull out the bearing.
SST 09308-00010
c. Using SST, press in a new bearing.
SST 09310-35010
d. Install the bearing lock plate and torque the bolt.
Torque: 18 N.m (185 kgf-cm, 13 ft-lbf)
5. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL SEAL
a. Using a screwdriver, pry out the oil seal.
b. Using SST, drive in a new oil seal.
SST 09608-00081, 09950-70010, (09951-07150)
Drive in depth: 0 - 0.5 mm (0 - 0.020 in.)
c. Coat the lip of the oil seal with MP grease.
6. IF NECESSARY. REPLACE REVERSE RESTRICT PIN
a. Using a hexagon wrench, remove the straight screw plug.
b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Replace the reverse restrict pin.
d. Using a pin punch and hammer, drive in the slotted spring pin.
Drive in depth: 13.5 ± 0.5 mm (0.531 ± 0.020 in.)
e. Apply sealant to the plug threads.
Sealant: Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using a hexagon wrench, install and torque the straight screw plug.
Torque: 13 N.m (130 kgf.cm, 9 ft-lbf)
BASIC SUBASSEMBLY REASSEMBLY
Assembly is in the reverse order of separation.
HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly.