Manual Transaxle Assembly

DISASSEMBLY
1. REMOVE RELEASE FORK ASSEMBLY AND RELEASE BEARING
2. REMOVE RELEASE FORK BOOT AND RELEASE FORK SUPPORT
3. REMOVE BOLT AND VEHICLE SPEED SENSOR DRIVEN GEAR
4. REMOVE BACK-UP LIGHT SWITCH
5. REMOVE SELECTING BELLCRANK ASSEMBLY
a. Remove the 2 bolts and selecting bellcrank assembly.
b. Remove the control bellcrank dust cover from the selecting bellcrank assembly
6. REMOVE CONTROL LEVER HOUSING SUPPORT BRACKET
Remove the 3 bolts and bracket.





7. REMOVE TRANSMISSION CASE COVER
a. Remove the 9 bolts.
b. Using a brass bar and hammer, carefully tap the projection of the transmission case cover to remove the transmission case cover from the transmission case.





8. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Remove the lock bolt.
b. Remove the 4 bolts and pull out the shift and select lever shaft assembly with the gasket.





9. REMOVE LOCK NUT
a. Engage the gear double meshing.
b. Using a chisel and hammer, loosen the staked part of the nut.
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 bolt from the No. 3 shift fork.
b. Remove the No. 3 hub sleeve with the shift fork.





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 inch)
Maximum clearance: 0.65 mm (0.0256 inch)





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 inch)
Maximum clearance: 0.070 mm (0.0028 inch)
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.
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 09950-30012

NOTICE: 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, needle roller bearing and spacer.





14. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09628-62011, 09950-40011 (09957-04010), 09950-60010 (09951-00230)





15. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and retainer.
16. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.

HINT: If it is difficult to remove the snap rings, pull up the shafts.





17. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
18. REMOVE SNAP RING FROM NO. 2 SHIFT FORK SHAFT
Using 2 screwdrivers and a hammer, tap out the snap ring.





19. REMOVE STRAIGHT SCREW PLUG, SPRING SEAT, SPRING AND BALL
a. Using a hexagon wrench, remove the 3 plugs.
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.





21. REMOVE TRANSMISSION CASE
a. Remove the 16 bolts.
b. Using a plastic hammer, carefully tap the projection of the transmission case to remove the transmission case from the transaxle case.





22. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT
23. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and bracket.
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.
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
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 spring from the No. 3 clutch hub.

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 the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE: 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 inch)
If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.

NOTICE: 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 inch)
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, remove the bearing.
SST09612-65014





b. Using SST, remove the oil seal.
SST 09612-65014





c. Using SST and a hammer, install a new oil seal.
SST 09950-60010 (09951-00360), 09950-70010 (09951-07150)
Drive in depth: 15.8 ± 0.2 mm (0.622 ± 0.008 inch)
d. Coat the lip of the oil seal with MP grease.





e. 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: Set the projection of the cover 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 Nm (115 kgf-cm, 8 ft. lbs.)
6. INSTALL TRANSAXLE CASE RECEIVER
Install the transaxle case receiver and torque the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
7. 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 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 rear oil before assembly.

1. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD
2. INSTALL NO. 3 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and 3 shifting keys to the hub sleeve.
b. Install the 2 key springs to the hub.

NOTICE: Position the key springs so that their end gaps are not aligned.

c. Install the clutch hub into the hub sleeve.
3. INSTALL MAGNET TO TRANSAXLE CASE
4. INSTALL DIFFERENTIAL CASE ASSEMBLY
5. INSTALL INPUT AND OUTPUT SHAFTS TOGETHER TO TRANSAXLE CASE
6. INSTALL NO. 1 SHIFT FORK, NO. 2 SHIFT FORK AND NO. 1 SHIFT FORK SHAFT
a. Place the No. 1 and No. 2 shift forks into the groove of the No. 1 and No. 2 hub sleeves.
b. Install the No. 1 shift fork shaft into the No. 1 shift fork hole.
c. Install the 2 set bolts of the No. 1 and No. 2 shift forks.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
7. INSTALL REVERSE SHIFT FORK AND NO. 3 SHIFT FORK SHAFT
a. Install the 2 balls to the hole of the reverse shift fork.
b. Install the No. 3 shift fork shaft to the reverse shift fork.
c. Using a screwdriver and hammer, install the snap ring.
d. Install the No. 3 shift fork shaft with the reverse shift fork to the transaxle case.
8. INSTALL SHIFT HEAD AND NO. 2 SHIFT FORK SHAFT





a. Place the shift head, as shown.
b. Install the No. 2 shift fork shaft.





c. To avoid the interference of the 2 balls, lift up the No. 3 shift fork shaft at the position shown in the illustration.
d. Install the No. 2 shift fork shaft until it contacts to the transaxle case.
e. Install the No. 2 shift fork and shift head to the No. 2 shift fork shaft and torque the 2 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
9. INSTALL SNAP RING
Using a screwdriver and hammer, install 2 new snap rings to the No. 1 and No. 3 shift fork shafts.





10. INSTALL REVERSE IDLER GEAR, THRUST WASHER AND SHAFT AS SHOWN





11. INSTALL REVERSE SHIFT ARM BRACKET
Install the bracket and 2 bolts.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
12. INSTALL TRANSMISSION CASE TO TRANSAXLE CASE





a. Apply FIPG to the transaxle case, as shown in the illustration.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent





b. Install the 16 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





13. INSTALL LOCK BALL ASSEMBLY
a. Apply sealant to the lock ball assembly threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a hexagon wrench, install the lock ball assembly.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





14. INSTALL BALL, SPRING, SPRING SEAT AND STRATE SCREW PLUG
a. Install the 3 balls, springs and seats.
b. Apply sealant to kite plugs threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Using a hexagon wrench, install the 3 plugs.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





15. INSTALL SNAP RING TO NO. 2 SHIFT FORK SHAFT
Using a screwdriver and hammer, tap in the snap ring.
16. INSTALL REVERSE IDLER GEAR SHAFT LOCK BOLT
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





17. INSTALL BEARING SNAP RING
Using a snap ring expander, install the 2 snap rings.

HINT: If it is difficult to install the snap rings, pull up the shafts.

18. INSTALL REAR BEARING RETAINER
Apply sealant to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.)





19. INSTALL 5TH DRIVEN GEAR
Using SST, install the 5th driven gear.
SST 09309-12020
20. INSTALL 5TH GEAR
Install the spacer, needle roller bearing, 5th gear and synchronizer ring.





21. INSTALL NO. 3 HUB SLEEVE ASSEMBLY AND NO. 3 SHIFT FORK
a. Using SST and a hammer, drive in the No. 3 hub sleeve assembly with the No. 3 shift fork.
SST 09636-20010

NOTICE: Align the synchronizer ring slots with the shifting keys.

b. Install the bolt to the No. 3 shift fork.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)





22. INSPECT 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 inch)
Maximum clearance: 0.65 mm (0.0256 inch)





23. INSTALL SNAP RING
a. Select a snap ring that allows the minimum axial play.
b. Using a screwdriver and hammer, tap in the snap ring.





24. INSTALL LOCK NUT
a. Engage the gear double meshing.
b. Install a new lock nut.
Torque: 118 Nm (1,200 kgf-cm, 87 ft. lbs.)
c. Disengage the gear double meshing.





25. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Install the shift and select lever assembly with a new gasket.
b. Apply sealant to the "A" bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Install the 4 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
d. Install the lock bolt.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





26. INSTALL TRANSMISSION CASE COVER
a. Apply FIPG to the transmission case cover, as shown in the illustration.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
b. Install the cover and 9 bolts.
Torque: 18 Nm (185 kgf-cm,13 ft. lbs.)
27. INSTALL CONTROL LEVER HOUSING SUPPORT BRACKET
Install the bracket and 3 bolts.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
28. INSTALL SELECTING BELLCRANK ASSEMBLY
a. Install the control bellcrank dust cover to the selecting bellcrank assembly.
b. Install the selecting bellcrank assembly and 2 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
29. INSTALL BACK-UP LIGHT SWITCH
Torque: 40 Nm (410 kgf-cm, 30 ft. lbs.)
30. INSTALL VEHICLE SPEED SENSOR DRIVEN GEAR AND BOLT
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
31. INSTALL RELEASE FORK ASSEMBLY AND RELEASE BEARING
Apply molybdenum disulphide lithium base grease.
32. INSTALL RELEASE FORK SUPPORT
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
33. INSTALL RELEASE FORK BOOT