Removal and Installation of Component Parts
COMPONENTSPart 1:
Part 2:
Part 3:
BASIC SUBASSEMBLY SEPARATION
1. REMOVE RELEASE FORK AND BEARING
INSTALLATION HINT: Apply molybdenum disulphide lithium base grease.
2. REMOVE BOLT AND VEHICLE SPEED SENSOR DRIVEN GEAR
Torque: 11 N.m (115 kgf-cm, 8 ft-lbf)
3. REMOVE BACK-UP LIGHT SWITCH
Torque: 40 N.m (410 kgf-cm, 30 ft-lbf)
4. REMOVE SELECTING BELLCRANK ASSEMBLY
a. Remove the 2 bolts and selecting bellcrank assembly.
Torque: 25 N.m (250 kgf-cm, 18 ft-lbf)
b. Remove the control bellcrank dust cover from the selecting bellcrank assembly.
5. REMOVE CONTROL LEVER HOUSING SUPPORT BRACKET
Remove the 3 bolts and bracket.
Torque: 11 N.m (115 kgf-cm, 8 ft-lbf)
6. REMOVE CLUTCH RELEASE BEARING RETAINER
Using a torx wrench, remove the 3 torx screws and retainer. (Torx wrench T30 09042-00010)
Torque: 11 N.m (110 kgf-cm, 8 ft-lbf)
7. REMOVE TRANSMISSION CASE COVER
a. Remove the 9 bolts.
Torque: 18 N.m (185 kgf-cm, 13 ft-lbf)
b. Carefully tap the projection of the transmission case cover with a brass bar and hammer to remove the transmission case cover from the transmission case, and remove the transmission case cover.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
8. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Remove the lock bolt.
Torque: 29 N.m (300 kgf-cm, 22 ft-lbf)
b. Remove the 4 bolts and pull out the shift and select lever shaft assembly with the gasket.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 N.m (200 kgf-cm, 14 ft-lbf)
9. REMOVE LOCK NUT
a. Engage the gear double meshing.
b. Using a hammer and chisel, loosen the staked part of the nut.
c. Remove the lock nut.
Torque: 118 N.m (1,200 kgf-cm, 87 ft-lbf)
d. Disengage the gear double meshing.
10. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
a. Remove the bolt from the No.3 shift fork.
Torque: 16 N.m (160 kgf-cm, 12 ft-lbf)
b. Remove the No.3 hub sleeve and shift fork.
INSTALLATION HINT: Using SST and a hammer, drive in the No.3 hub sleeve with the shift fork.
SST 09636-20010
INSTALLATION NOTE: Align the synchronizer ring slots with the shifting keys.
11. INSPECT 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 - 0.57 mm (0.0039 - 0.0224 in.)
Maximum clearance:
0.65 mm (0.0256 in.)
12. INSPECT 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.
Standard clearance:
0.015 - 0.058 mm (0.0006 - 0.0023 in.)
Maximum clearance:
0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
13. 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 a screwdriver, remove the key spring.
c. Install a bolt and washer to the tip of the input shaft and using SST, remove the No.3 clutch hub.
SST 09950-30010
NOTE: Select a bolt whose outer diameter is smaller than the screw hole of the Input shaft so that it can be turned easily.
d. Remove the synchronizer ring, 5th gear and needle roller bearing.
14. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09628-62011, 09950-40010 (09957-04010),
09950-60010 (09951-00230)
INSTALLATION HINT: Using SST, install the 5th driven gear.
SST 09309-12020
15. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and retainer.
Torque: 27 N.m (280 kgf-cm, 20 ft-lbf)
16. 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.
17. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
Torque: 29 N.m (300 kgf-cm, 22 ft-lbf)
18. REMOVE SNAP RING FROM NO.2 SHIFT FORK SHAFT
Using 2 screwdrivers and a hammer, tap out the snap ring.
19. REMOVE PLUG, SEAT, SPRING AND BALL
a. Using a hexagon wrench, remove the 3 plugs.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 25 N.m (250 kgf-cm, 18 ft-lbf)
b. Using a magnetic finger, remove the 3 seats, springs and balls.
20. REMOVE LOCK BALL ASSEMBLY
Using a hexagon wrench, remove the lock ball assembly.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 39 N.m (400 kgf-cm, 29 ft-lbf)
21. REMOVE TRANSMISSION CASE
a. Transaxle Case Side:
Remove the 3 bolts.
Torque: 29 N.m (300 kgf-cm, 22 ft-lbf)
b. Transmission Case Side:
Remove the 13 bolts.
Torque: 29 N.m (300 kgf-cm, 22 ft-lbf)
c. Carefully tap the projection of the transmission case with a plastic hammer to remove the transmission case from the transaxle case, and remove the transmission case.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
22. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT
23. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and bracket.
Torque: 17 N.m (175 kgf-cm, 13 ft-lbf)
INSTALLATION HINT: Install the reverse Idler gear, thrust washer and shaft, as shown.
24. REMOVE SHIFT FORK AND SHIFT FORK SHAFT
a. Using 2 screwdrivers and a hammer, tap out the 3 snap rings.
b. Remove the 3 set bolts.
Torque: 16 N.m (160 kgf-cm, 12 ft-lbf)
c. Pull up the No.3 shift fork shaft, remove the No.2 shift fork shaft and shift head.
d. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
e. Remove the No.3 shift fork shaft and reverse shift fork.
f. Pull out the No.1 shift fork shaft.
g. Remove the No.1 and No.2 shift forks.
25. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE
26. REMOVE DIFFERENTIAL CASE ASSEMBLY
INSTALLATION HINT: Before assembly, inspect the differential side bearing preload.
27. REMOVE MAGNET FROM TRANSAXLE CASE
28. REMOVE NO.3 HUB SLEEVE. SHIFTING KEY AND SPRING FROM NO.3 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs from the No.3 clutch hub.
COMPONENT PARTS INSPECTION
1. INSPECT 5TH GEAR SYNCHRONIZER RING
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.
NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
c. Check again the braking effect of the synchronizer ring.
d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchronizer ring and gear cone by applying a small amount of fine lapping compound.
NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
2. INSPECT SHIFT FORK AND 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. REMOVE TRANSAXLE CASE RECEIVER
Remove the bolt and transaxle case receiver.
4. IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING
a. Using SST, pull out the bearing.
SST 09612-65014
b. Using SST and a press, install a new bearing.
SST 09950-60010 (09951-00460),
09950-70010 (09951-07150)
5. 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. Remove the output shaft front cover.
d. Install the output shaft front cover.
HINT: Install the output shaft front cover projection into the case side hollow.
e. Using SST and a press, install a new bearing.
SST 09950-60010 (09951-00620),
09950-70010 (09951-07150)
f. Install the bearing lock plate and torque the bolt.
Torque: 11 N.m (115 kgf-cm, 8 ft-lbf)
6. INSTALL TRANSAXLE CASE RECEIVER
Install the transaxle case receiver and torque the bolt.
Torque: 11 N.m (115 kgf-cm, 8 ft-lbf)
7. 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 until its surface is flush with the transaxle case.
SST 09950-60010 (09951-00400),
09950-70010 (09951-07150)
c. Coat the lip of the oil seal with MP grease.
8. 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.
e. Apply sealant to the screw plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using a hexagon wrench, install 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.