Removal and Installation

DISASSEMBLY
1. Remove release fork and bearing.
2. Remove back-up light switch with gasket.
Torque: 40 N.m (410 kgf/cm, 30 ft. lbs.).
3. Remove bolt and vehicle speed sensor.
Torque: 17 N.m (175 kgf/cm, 13 ft. lbs.).
4. Remove No.2 selecting bellcrank with selecting bellcrank support
- Remove the 2 bolts and No.2 selecting bellcrank with the selecting bellcrank support.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 N.m (200 kgf/cm, 14 ft. lbs.).
5. Remove shift and select lever shaft lock bolt with gasket.
Torque: 49 N.m (500 kgf/cm, 36 ft. lbs.).
6. Remove shift and select lever shaft assembly with gasket.
- Remove the 4 bolts, shift and select lever shaft assembly and gasket.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 N.m (200 kgf/cm, 14 ft. lbs.).





7. Remove transmission case cover.
- Remove the 10 bolts and transmission case cover.
Formed In Place Gasket (FIPG): Part No. 08826-00090, THREE BOND 1281 or equivalent
Torque: 29 N.m (300 kgf/cm, 22 ft. lbs.).
8. Remove breather plug with gasket.
Torque: 49 N.m (500 kgf/cm, 36 ft. lbs.).





9. Remove output shaft lock nut.
a. Unstake the lock nut.
b. Engage the gear double meshing.
c. Remove the lock nut.
Torque: 123 N.m (1,250 kgf/cm, 90 ft. lbs.).
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: 24 N.m (240 kgf/cm, 17 ft. lbs.).
b. Remove the No.3 hub sleeve and No.3 shift fork.





11. Remove 5th driven gear.
- Using Special Service Tool (SST), remove the 5th driven gear.
SST 09950 - 30010





12. Measure 5th gear thrust clearance and radial clearance.
a. Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10-.57 mm (0.0039-.0224 inch).
Maximum clearance: 0.65 mm (0.0256 inch).





b. Using a dial indicator, measure the radial clearance.
Standard clearance: 0.009-0.050 mm (0.0004-0.0020 inch).
Maximum clearance: 0.070 mm (0.0028 inch).
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 SST, remove the No.3 clutch hub with the synchronizer ring and 5th gear.
SST 09950-30010
14. Remove needle roller bearing and spacer.
15. Remove rear bearing retainer.
- Using a torx socket wrench (T45), remove the 7 tore screws and rear bearing retainer.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 42 N.m (430 kgf/cm, 31 ft. lbs.).





16. Remove snap ring.
a. Using a snap ring expander, remove the input shaft rear bearing snap ring.
b. Using 2 screwdrivers and a hammer, remove the 2 snap rings.





17. Remove straight screw plug, seat, spring and locking ball.
a. Using a hexagon wrench (6 mm), remove the plug.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 25 N.m (250 kgf/cm, 18 ft. lbs.).
b. Using a magnetic finger, remove the seat, spring and locking ball.





18. Remove reverse idler gear shaft lock bolt.
- Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 N.m (300 kgf/cm, 22 ft. lbs.).





19. Remove transmission case.
- Remove the 17 bolts and tap the case with a plastic hammer.
Formed In Place Gasket (FIPG): THREE BOND 1281 or equivalent
Torque: 29 N.m (300 kgf/cm, 22 ft. lbs.).





20. Remove shim.

INSTALLATION HINT: Install the previously selected shim by adjusting output shaft preload.





21. Remove output shaft rear taper roller bearing outer race.
- Using SST and a hammer, remove the output shaft rear taper roller bearing outer race.
SST 0931-60011 (09316-00011)
22. Remove transmission oil pipe.
a. Remove the gasket from the oil pipe.
b. Remove the 2 bolts and oil pipe.
Torque: 17 N.m (175 kgf/cm, 13 ft. lbs.).





23. Remove reverse shift arm bracket assembly.
- Remove the bolt and pull off the reverse shift arm and bracket.
Torque: 17 N.m (175 kgf/cm, 13 ft. lbs.).
24. Remove reverse idler gear and shaft.
- Pull out the shaft, remove the reverse idler gear and thrust washer.





INSTALLATION HINT: Align the matchmarks, as shown.





25. Remove straight screw plug, locking ball and spring.
- Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 25 N.m (250 kgf/cm, 18 ft. lbs.).
b. Using a magnetic finger, remove the 2 seats, springs and balls.





26. Remove No.1, No.2 shift forks and shift head set bolt.
Torque: 24 N.m (240 kgf/cm, 17 ft. lbs.).
27. Remove No.1 shift fork shaft
- Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.

INSTALLATION HINT: When it is difficult to push the fork shaft through the reverse shift fork, pull up the No.3 shift fork shaft.





28. Remove interlock roller.
- Using a magnetic finger, remove the interlock roller from the reverse shift fork.





29. Remove No.2 shift fork shaft, shift head and No.1 shift fork
a. Pull out the No.2 shift fork shaft.
b. Remove the shift head and No.1 shift fork.





30. Remove No.3 shift fork shaft with reverse shift fork and No.2 shift fork.
a. Pull out the No.3 shift fork shaft with the reverse shift fork.
b. Remove the No.2 shift fork.
31. Remove snap ring.
a. Using 2 screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No.3 shift fork shaft.
b. Using 2 screwdrivers and a hammer, remove the 3 snap rings from the No.1, No.2 and No.3 shift fork shafts.
32. Remove input and output shafts assembly.
a. Leaning the output shaft to the differential side, remove the input shaft assembly.
b. Lift up the differential case assembly, remove the output shaft assembly.
33. Remove differential case assembly.
a. Remove the oil pump drive gear.
b. Remove the differential case assembly.
34. Remove magnet from transaxle case.
35. Remove transmission oil pump assembly and oil pipe.
a. Remove the 2 bolts and oil pipe.
Torque: 17 N.m (175 kgf/cm, 13 ft. lbs.).
b. Remove the 2 bolts and oil pump assembly.
Torque: 17 N.m (175 kgf/cm, 13 ft. lbs.).





36. 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. H INT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.
c. Remove the synchronizer rings.

INSPECTION





1. Inspect No.5 synchronizer ring.
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 it does not lock, replace the synchronizer ring.





2. Measure 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 inch).
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.





3. If necessary, replace input shaft bearing and oil seal.
a. Remove the 3 bolts and transaxle case receiver.
b. Using Special Service Tool (SST), pull out the bearing.
SST 09612 - 65014
c. Using a screwdriver, remove the oil seal.





d. Using SST, drive in a new oil seal.
SST 09608-00081, 09950-70010 (09951-07150)
e. Coat the lip of seal with UP grease.





f. Using SST, drive in a new bearing.
SST 09950 - 60010 (09951-00580), 09950 - 70010 (09951 - 07150)
g. Install the transaxle case receiver.
h. Install and torque the 3 bolts.
Torque: 7.4 N.m (75 kgf/cm, 65 inch lbs.).





i. Using SST and a press, remove the inner race.
SST 09950-00020





j. Using SST and a press, install a new input shaft front bearing inner race.
SST 09316-60011 (09316-00021)





4. If necessary, replace output shaft front bearing outer race and output shaft front cover.
a. Using SST, pull out the output shaft front bearing outer race. SST 09308-00010
b. Remove the output shaft cover.





c. Install a new output shaft cover.

HINT: Install the output shaft cover projection into the case side groove.





d. Using SST and a hammer, drive in a new output shaft front bearing outer race.
SST 09316 - 60011 (09316-00011, 09316 - 00021)





e. Using SST and a socket wrench, remove the output shaft front bearing.
SST 09950-00020, 09950-00030





f. Using SST and a press, install a new output shaft front bearing.
SST 09316 - 60011 (09316-0071)





5. If necessary, replace reverse restrict pin.
a. Using a hexagon wrench (6 mm), remove the 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: THREE BOND 1344 LOCTITE 242 or equivalent
f. Using a hexagon wrench (6 mm), install and torque the screw plug.
Torque: 13 N.m (130 kgf/cm, 9 ft. lbs.).

REASSEMBLY
- Reassembly is in the reverse order of disassembly.

HINT:
- Before assembly, select a shim by adjusting output shaft preload.
- Coat all of the sliding and rotating surfaces with gear oil before assembly.

ADJUST OUTPUT SHAFT PRELOAD
a. Install the output shaft assembly to the transaxle case.
b. Install the transmission case to the transaxle case.

HINT: If necessary, tap on the case with a plastic hammer.

c. Install and torque the 17 bolts.
Torque: 29 N.m (300 kgf/cm, 22 ft. lbs.).
d. Install the output shaft rear taper roller bearing outer race.
e. Install the adjusting shim.

HINT: When reusing the output shaft bearing, first install a shim of the same thickness as before. If installing a new taper roller bearing, first select and install a shim of lesser thickness than before.

f. Install the rear bearing retainer.
g. Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N.m (430 kgf/cm, 31 ft. lbs.).
h. Install a new lock nut to the output shaft.
i. Turn the output shaft right and left 2 or 3 times to allow the bearing to settle.





j. Using a torque wrench, measure the preload.
Preload (at starting):
- New bearing: 0.8-1.6 N.m (8-16 kgf/cm, 6.9-13.9 inch lbs.).
- Reused bearing: 0.8-1.0 N.m (8-10 kgf/cm, 4.3-8.7 inch lbs.).
If the preload is not within the specification, select an appropriate adjusting shim.





The preload will change about 0.4-0.5 N.m (4-5 kgf/cm, 3.5 - 4.3 inch lbs.). for every 0.05 mm change in adjusting shim thickness.

k. Remove the lock nut.
l. Remove these parts. Removal is in the reverse order of installation.
- Rear bearing retainer
- Shim
- Transmission case
- Output shaft assembly
- Output shaft rear bearing outer race