Manual Transaxle Assembly

DISASSEMBLY
1. REMOVE CLUTCH RELEASE FORK ASSEMBLY WITH BEARING
2. REMOVE BACK-UP LIGHT SWITCH WITH GASKET
3. REMOVE BOLT AND VEHICLE SPEED SENSOR
4. REMOVE NO. 2 SELECTING BELLCRANK WITH SELECTING BELLCRANK SUPPORT
Remove the 2 bolts and No. 2 selecting bellcrank with the selecting bellcrank support.
5. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK BOLT WITH GASKET
6. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY WITH GASKET
Remove the 4 bolts, shift and select lever shaft assembly and gasket.
7. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.
8. REMOVE BREATHER PLUG WITH GASKET





9. REMOVE OUTPUT SHAFT LOCK NUT
a. Unstake the lock nut.
b. Engage the gear double meshing.
c. Remove the lock nut.
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.
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 09950-30012 (09951-03010, 09953-03010, 09950-03010, 09955-03011, 09956-03030)
12. MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE





a. Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 inch)





b. Using a dial indicator, measure the radial clearance.
Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 inch)





13. REMOVE NO. 3 CLUTCH HUB AND 5TH GEAR
a. Using 2 screwdrivers and a hammer, tap out the snap ring.
b. Using SST, remove the No. 3 clutch hub with the synchronizer ring and 5th gear.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010)
14. REMOVE NEEDLE ROLLER BEARING AND SPACER
15. REMOVE REAR BEARING RETAINER
Using a torx socket wrench (T45), remove the 7 torx screws and rear bearing retainer.





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 from No. 1 and No. 2 shift fork shaft.





17. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
18. REMOVE TRANSMISSION CASE
Remove the 17 bolts and tap the case with a plastic hammer.





19. REMOVE SHIM





20. 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 09316-60011 (09316-00011)
21. REMOVE TRANSMISSION OIL PIPE
a. Remove the gasket from the oil pipe.
b. Remove the 2 bolts and oil pipe.





22. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
Remove the bolt and pull off the reverse shift arm and bracket.
23. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, and remove the reverse idler gear and thrust washer.





24. REMOVE NO. 1 AND NO. 2 SHIFT FORKS AND SHIFT HEAD SET BOLT





25. REMOVE NO. 1 SHIFT FORK SHAFT
Pull up the No. 3 shift fork shaft, and remove the No. 1 shift fork shaft.
26. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the reverse shift fork.





27. 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.





28. 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.
29. 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 2 snap rings from the No. 1 and No. 3 shift fork shafts.
30. REMOVE INPUT AND OUTPUT SHAFT 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.
31. REMOVE DIFFERENTIAL CASE ASSEMBLY
a. Remove the oil pump drive gear.
b. Remove the differential case assembly.
32. REMOVE MAGNET FROM TRANSAXLE CASE
33. REMOVE TRANSMISSION OIL PUMP ASSEMBLY AND OIL PIPE
a. Remove the 2 bolts and oil pipe.
b. Remove the 2 bolts and oil pump assembly.





34. REMOVE NO. 5 SYNCHRONIZER RING WITH KEY SPRING FROM N0-3 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. Disassemble 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 FRONT BEARING AND OIL SEAL
a. Remove the 3 bolts and transaxle case receiver.





b. Using 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 09608-0081, 09950-70010 (09951-07150)
e. Coat the lip of seal with MP 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 Nm (75 kgf-cm, 65 inch lbs.)
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 09308-0010
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)
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: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using a hexagon wrench (6 mm), install and torque the screw plug.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)

REASSEMBLY

NOTICE: When working with FIPG material, you must observe the followings.
^ Using a razor blade and a gasket scraper, remove all old FIPG material from the gasket surfaces.
^ Thoroughly clean all components to remove all loose material.
^ Clean both sealing surfaces with a non-residue solvent.
^ Apply FIPG in an approximately 1 mm (0.04 inch) wide bead along the sealing surface.
^ Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.

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

1. INSTALL TRANSMISSION OIL PUMP ASSEMBLY AND OIL PIPE
a. Install the oil pump assembly and 2 bolts.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
b. Install the oil pipe and 2 bolts.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
2. INSTALL MAGNET TO TRANSAXLE CASE
3. 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 Nm (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 Nm (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 0.82 - 1.63 Nm (8 - 16 kgf-cm, 6.9 - 13.9 inch lbs.)
Reused bearing 0.51 - 1.02 Nm (5 - 10 kgf-cm, 4.3 - 8.7 inch lbs.)
If the preload is not within the specification, select an appropriate adjusting shim.





k. The preload will change approximately 0.4 - 0.5 Nm (4 - 5 kgf-cm, 3.5 - 4.3 inch lbs.) for every 0.05 mm change in adjusting shim thickness.
l. Remove the lock nut.
m. Using a torx wrench (T45), remove the 7 torx screws and rear bearing retainer.
n. Remove the shim.
o. Remove the 17 bolts and transmission case.
p. Remove the output shaft assembly.
q. Remove the output shaft rear bearing outer race.
4. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
5. INSTALL DIFFERENTIAL CASE ASSEMBLY
a. Install the differential case assembly.
b. Install the oil pump drive gear.
6. INSTALL INPUT AND OUTPUT SHAFT ASSEMBLY
a. Lift up the differential case assembly, remove the output shaft assembly.
b. Leaning the output shaft to the differential side, install the input shaft assembly.
7. INSTALL SNAP RING
a. Using a plastic hammer, install the 2 snap rings to the No. 1, and No. 3 shift fork shafts.
b. Using a plastic hammer, install the reverse shift fork and snap ring to the No. 3 shift fork shaft.





8. INSTALL NO. 2 SHIFT FORK AND NO. 3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK
a. Install the No. 2 shift fork to the No. 2 hub sleeve.
b. Install the No. 3 shift fork shaft with the reverse shift fork.





9. INSTALL NO. 1 SHIFT FORK, SHIFT HEAD AND NO. 2 SHIFT FORK SHAFT
a. Install the No. 1 shift fork to the No. 1 hub sleeve.
b. Put the shift head onto the No. 1 shift fork.
c. Install the No. 2 shift fork shaft.





10. INSTALL INTERLOCK ROLLER
Using a magnetic finger, install the interlock roller to the reverse shift fork.





11. INSTALL NO. 1 SHIFT FORK SHAFT
Install the No. 1 shift fork shaft to the case, through the No. 1 shift fork and reverse shift fork.

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

12. INSTALL NO. 1, NO. 2 SHIFT FORK AND SHIFT HEAD SET BOLTS
Torque: 24 hem (240 kgf-cm, 17 ft. lbs.)





13. INSTALL STRAIGHT SCREW PLUGS
a. Apply sealant to the plug threads.
b. Using a hexagon wrench (6 mm), install the 2 plugs.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
Sealant: Part No. 08833-00090, THREE BOND 1281 or equivalent





14. INSTALL REVERSE IDLER GEAR AND SHAFT
a. Install the reverse idler gear shaft and thrust washer to the shaft.
b. Install the reverse idler gear shaft into the case hole.
c. Align the matchmarks, as shown.





15. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
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 the bolt.
16. INSTALL TRANSMISSION OIL PIPE
a. Install the oil pipe and 2 bolts.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
b. Install a new gasket to the oil pipe.
17. INSTALL OUTPUT SHAFT REAR TAPER ROLLER BEARING OUTER RACE
Using a plastic hammer, tap in the outer race.





18. INSTALL SHIM
Install the previously selected shim by adjusting output shaft preload (See step 4).
19. INSTALL TRANSMISSION CASE
a. Apply FIPG to the transmission case, as shown in the illustration.
b. Install the transmission case and the 17 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
FIPG: Part No. 08833-00080, THREE BOND 1324 or equivalent





20. INSTALL REVERSE IDLER GEAR SHAFT LOCK BOLT
a. Apply sealant to the bolt threads. Sealant:
Part No. 08833-00080, THREE BOND 1324 or equivalent
b. Install the reverse idler gear shaft lock bolt.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1324 or equivalent
21. INSTALL SNAP RING
a. Using a snap ring expander, install the input shaft rear bearing snap ring.
b. Using a plastic hammer, install the 2 snap rings to the No. 1 and No. 2 shift fork shaft.
22. INSTALL REAR BEARING RETAINER
a. Clean the threads of the torx screws.
b. Apply sealant to the screw threads.
Sealant: Part No. 08833-00080, THREE BOND 1324 or equivalent
c. Using a torx socket wrench (T45), install the rear bearing retainer and 7 torx screws.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
23. INSTALL SPACER AND NEEDLE ROLLER BEARING
24. INSTALL NO. 5 SYNCHRONIZER RING WITH KEY SPRING TO NO. 3 CLUTCH HUB





a. Assemble the NO. 5 synchronizer rings.
b. Using a screwdriver, install the snap ring.

HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.





c. Install the NO. 5 synchronizer rings with the key springs to the No. 3 clutch hub.

HINT: Align the holes of the clutch hub with the key spring.





25. INSTALL NO. 3 CLUTCH HUB AND 5TH GEAR
Using SST, install the No. 3 clutch hub with the synchronizer ring and 5th gear.
SST 0995-30012 (09951-3010, 09953-03010, 09954-03010)








26. INSTALL SNAP RING
a. Select a snap ring that allows the minimum axial play.
b. Using a brass bar and a hammer, install the snap ring.
27. MEASURE 5TH GEAR THRUST AND RADIAL CLEARANCE





28. INSTALL 5TH DRIVEN GEAR
Using SST, install the 5th driven gear.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03030)
29. INSTALL NO. 3 HUB SLEEVE AND NO. 3 SHIFT FORK
a. Install the No. 3 hub sleeve and No. 3 shift fork.
b. Install the No. 3 shift fork set bolt.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)





30. INSTALL OUTPUT SHAFT LOCK NUT
a. Engage the gear double meshing
b. Install the lock nut.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
c. Disengage the gear double meshing.
d. Stake the lock nut.





31. INSTALL TRANSMISSION CASE COVER
a. Apply FIPG to the transmission case, as shown in the illustration.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
b. Install the 10 bolts and transmission case cover.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
32. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY WITH GASKET
a. Apply sealant to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Install the 4 bolts, shift and select lever shaft assembly and a new gasket.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
33. INSTALL SHIFT AND SELECT LEVER SHAFT LOCK BOLT WITH NEW GASKET
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
34. INSTALL BREATHER PLUG WITH NEW GASKET
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
35. INSTALL NO. 2 SELECTING BELLCRANK WITH SELECTING BELLCRANK SUPPORT
a. Apply sealant to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Install the No. 2 selecting bellcrank with the selecting bellcrank support and 2 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
36. INSTALL VEHICLE SPEED SENSOR AND BOLT
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
37. INSTALL BACK-UP LIGHT SWITCH WITH NEW GASKET
Torque: 40 Nm (410 kgf-cm, 30 ft. lbs.)
38. INSTALL CLUTCH RELEASE FORK ASSEMBLY WITH BEARING