Part 2

OVERHAUL Continued





46. REMOVE OUTPUT SHAFT FRONT BEARING
a. Using SST, remove the output shaft front bearing from the transaxle case.
SST 09308-00010





47. REMOVE OUTPUT SHAFT (MTM) COVER
a. Remove the output shaft (MTM) cover from the transaxle case.





48. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Using SST, remove the FR differential case front tapered roller bearing (outer race) and shim from the transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)





b. Using SST, remove the FR differential case front tapered roller bearing (inner race) from the front differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00360)

NOTICE: Be careful not to damage the bearing.





49. REMOVE TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, drive out the transaxle case oil seal from the transaxle case.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)





50. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST, remove the FR differential case rear tapered roller bearing (outer race) and shim from the manual transmission case.
SST 09612-65014 (09612-01040, 09612-01050)





b. Using SST and a hammer, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)

NOTICE: Be careful not to damage the bearing.





51. REMOVE TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, remove the transmission case oil seal from the manual transmission case.
SST 09950-60010 (09951-00600), 09950-70010 (09951-07100)





52. INSPECT SYNCHRONIZER RING NO.3
a. Check for wear or damage.
b. Coat the 5th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone. Check that the ring locks.
If the synchronizer ring does not lock, replace the ring or the 5th gear.





c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.75 mm (0.0295 inch)
If the clearance is less than the minimum, replace the synchronizer ring and gear.





53. INSPECT TRANSMISSION HUB SLEEVE NO.3
a. Check the sliding condition between the transmission hub sleeve No.3 and transmission clutch hub No.3.
b. Check that the tip of the spline gear of the transmission hub sleeve No.3 is not worn down.





c. Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove (A) and the thickness of the claw part on the gear shift fork No.3 (B), and calculate the clearance.
Standard clearance (A-B): 0.3 to 0.5 mm (0.012 to 0.0197 inch)
If the clearance is out of specification, replace the transmission hub sleeve No.3 and gear shift fork No.3.





54. INSPECT 5TH GEAR
a. Using a caliper gauge, inspect the 5th gear as shown in the illustration.





5th gear inner diameter

If the inner diameter exceeds the maximum, replace the 5th gear.





55. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
a. Using a caliper gauge, inspect the reverse idler gear sub-assembly as shown in the illustration.





Reverse idler gear sub-assembly inner diameter

If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assembly.
b. Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.





Reverse idler gear shaft outer diameter

If the outer diameter is less than the minimum, replace the reverse idler gear shaft.





56. INSTALL OUTPUT SHAFT (MTM) COVER
a. Coat the output shaft (MTM) cover with MP grease, and install it to the transaxle case.

NOTICE: Fit the output shaft (MTM) cover projection into the case side hollow.





57. INSTALL OUTPUT SHAFT FRONT BEARING
a. Coat a new output shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.
SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)

NOTICE:
^ Be sure to install a new bearing in the correct direction, as shown in the illustration.
^ When replacing the output shaft front bearing, re place the output shaft front bearing inner race along with it.





58. INSTALL FRONT TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install a new front transaxle case oil seal to the transaxle case.
SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)
Drive in depth: 15.6 to 16.0 mm (0.6142 to 0.6299 inch)
b. Coat the lip of the front transaxle case oil seal with MP grease.





59. INSTALL INPUT SHAFT FRONT BEARING
a. Coat a new input shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
Drive in depth: 0 to 0.3 mm (0 to 0.012 inch)





60. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Using SST and a press, install a new FR differential case front tapered roller bearing (inner race) to the front differential case.
SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)





b. Using SST and a press, install a new FR differential case front tapered roller bearing (outer race) with the shim to the transaxle case.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)





61. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST and a press, install a new FR differential case rear tapered roller bearing (inner race) to the front differential case.
SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)





b. Using SST and a press, install a new FR differential case rear tapered roller bearing (outer race) with the shim to the manual transmission case.
SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)





62. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
a. Coat the differential case assembly with gear oil, and install it to the transaxle case.
b. Install the manual transmission case with the 16 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





c. Using SST and a torque wrench, turn the differential case assembly to the right and left 2 or 3 times to allow the bearings to settle. SST 09564-32011





d. Using SST and a torque wrench, measure the preload.
SST 09564-32011
Preload (at starting):
New bearing: 0.78 to 1.57 Nm (8 to 16 kgf-cm, 6.9 to 13.9 inch lbs.)
If the preload is out of specification, select another shim.





Shim thickness

HINT: The preload will change by about 0.3 to 0.4 Nm (3 to 4 kgf-cm, 2.6 to 3.5 inch lbs.) corresponding to a change of 0.05 mm (0.0020 inch) in shim thickness.

e. Remove the 16 bolts and manual transmission case from the transaxle case.
f. Remove the differential case assembly from the transaxle case.





63. INSTALL TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, install a new transmission case oil seal to the manual transmission case.
SST 09316-60011 (09316-00011)
Drive in depth: 9.6 to 10.2 mm (0.378 to 0.402 inch)
b. Coat the lip of the transmission case oil seal with MP grease.





64. INSTALL TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install a new transaxle case oil seal in the transaxle case.
SST 09710-20011 (09710-06071), 09950-70010 (09951-07150)
Drive in depth: 1.6 to 2.2 mm (0.063 to 0.087 inch)
b. Coat the lip of the transaxle case oil seal with MP grease.





65. INSTALL TRANSMISSION MAGNET
a. Clean the transmission magnet, and install it to the transmission case.





66. INSTALL BEARING LOCK PLATE
a. Install the bearing lock plate with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)





67. INSTALL OIL RECEIVER PIPE NO.1 (MTM)
a. Install the oil receiver pipe No.1 (MTM) with the bolt to the manual transmission case.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)

NOTICE:
^ Prevent the oil receiver pipe No.1 (MTM) from being deformed.
^ Install the oil receiver pipe No.1 (MTM) while placing it against the manual transmission case, as shown in the illustration.





68. INSTALL OIL RECEIVER PIPE NO.2 (MTM)
a. Install the oil receiver pipe No.2 (MTM) with the bolt to the manual transmission case.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)

NOTICE:
^ Prevent the oil receiver pipe No.2 (MTM) from being deformed.
^ Install the oil receiver pipe No.2 (MTM) while placing it against the manual transmission case, as shown in the illustration.





69. INSTALL REVERSE RESTRICT PIN ASSEMBLY
a. Install the reverse restrict pin assembly to the manual transmission case.

NOTICE: Do not set the reverse restrict pin assembly in an incorrect orientation.





b. Using a pin punch (diameter 5 mm) and hammer, install the slotted pin to the reverse restrict pin assembly.
Standard clearance (A): 15.5 to 16.5 mm (0.6102 to 0.6496 inch)
c. Apply sealant to the reverse restrict pin plug.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





d. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug to the manual transmission case.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)





70. INSTALL MANUAL TRANSAXLE CASE RECEIVER
a. Install the manual transaxle case receiver with the bolt to the transaxle case.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)





71. INSTALL DIFFERENTIAL CASE ASSEMBLY
a. Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the transaxle case.





72. INSTALL IN PUT SHAFT ASSEMBLY
a. Coat the sliding and rotating surfaces of the input and output shafts with gear oil, and install them to the transaxle case.





73. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
a. Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.

HINT: Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.





74. INSTALL GEAR SHIFT FORK SHAFT SUB-ASSEMBLY NO.1
a. Coat the gear shift fork No.1 and gear shift fork No.2 with gear oil, and install them.





b. Coat the gear shift fork shaft sub-assembly No.1 with gear oil, and install it.
c. Apply sealant to the shift fork lock bolt.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Install the gear shift fork lock bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)





e. Using a brass bar and a hammer, install the snap ring to the gear shift fork shaft No.1.





75. INSTALL GEAR SHIFT FORK SHAFT NO.3
a. Coat the 2 balls with MP grease, and install them to the reverse shift fork.
b. Install the reverse shift fork to the gear shift fork shaft No.3.





c. Using a brass bar and a hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft No.3.





d. Coat the gear shift fork shaft No.3 with gear oil, and install it.





76. INSTALL GEAR SHIFT FORK SHAFT NO.2
a. Coat the gear shift head No.1 and gear shift fork shaft No.2 with gear oil, and install them.





NOTICE: To avoid the interference of the 2 shift fork balls, lift up the gear shift fork shaft No.3 to the position shown in the illustration.





b. Coat the 2 shift lock bolts with sealant, and install them to the gear shift fork No.2 and gear shift head No.1.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)