Basic Subassembly Separation
BASIC SUBASSEMBLY SEPARATION1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH
Torque: 44 N-m (450 kgf-cm, 33 ft-lbf)
3. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
4. REMOVE RELEASE BEARING RETAINER
Remove the 3 bolts and retainer.
Torque: 7.4 N-m (75 kgf-cm, 65 in.-lbf)
5. 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)
6. 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 and remove it.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
7. 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)
8. REMOVE SHIFT AND SELECT LEVER ASSEMBLY
INSTALLATION HINT: Apply FIPG to the underside of the flanged portion of the control shaft cover.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
Torque: 37 N-m (375 kgf-cm, 27 ft-lbf)
9. 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.
10. 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.
11. 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
12. MEASURE 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)
Maximum clearance: 0.45 mm (0.0177 in.)
13. 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.
14. 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.
15. REMOVE NEEDLE ROLLER BEARING
16. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and retainer.
Sealant: Part No.08833-00070, THREE BOND 1324 or equivalent
Torque: 42 N-m (430 kgf-cm, 31 ft-lbf)
17. REMOVE BEARING SNAP RING
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.
18. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET
Torque: 29 N-m (300 kgf-cm, 22 ft-lbf)
19. 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)
20. REMOVE TRANSMISSION CASE
a. Remove the 17 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
21. REMOVE REVERSE IDLER GEAR AND SHAFT
a. Pull out the shaft.
b. Remove the idler gear and thrust washer.
22. 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)
23. 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
24. REMOVE DIFFERENTIAL CASE ASSEMBLY
25. REMOVE MAGNET FROM TRANSAXLE CASE
26. 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.
27. 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.
28. 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.