Part 2
MANUAL TRANSAXLE UNIT ContinuedCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
39. REMOVE REVERSE RESTRICT PIN ASSEMBLY
(a) Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
(b) Using a pin punch (diameter 5 mm) and a hammer, drive out the slotted pin and remove the reverse restrict pin assembly from the manual transmission case.
40. REMOVE OIL RECEIVER PIPE NO. 1 (MTM)
(a) Remove the bolt and oil receiver pipe No. 1 (MTM) from the manual transmission case.
NOTICE: Be careful not to damage the oil receiver pipe No. 1 (MTM).
41. REMOVE OIL RECEIVER PIPE NO. 2 (MTM)
(a) Remove the bolt and oil receiver pipe No. 2 (MTM) from the manual transmission case.
NOTICE: Be careful not to damage the oil receiver pipe No. 2 (MTM).
42. REMOVE BEARING LOCK PLATE
(a) Remove the bolt and bearing lock plate from the transaxle case.
43. REMOVE TRANSMISSION MAGNET
(a) Remove the transmission magnet from the transaxle case.
44. REMOVE INPUT SHAFT FRONT BEARING
(a) Using SST, remove the input shaft front bearing from the transaxle case.
SST 09612-65014 (09612-01050, 09612-01060)
45. REMOVE FRONT TRANSAXLE CASE OIL SEAL
(a) Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
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
53. INSPECT TRANSMISSION HUB SLEEVE NO. 3
54. INSPECT 5TH GEAR
55. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
INSPECTION
1. INSPECT 5TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 5th gear thrust clearance.
5th gear thrust clearance:
2. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 5th gear radial clearance.
5th gear radial clearance:
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
3. 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 in.)
If the clearance is less than the minimum, replace the synchronizer ring and gear.
4. 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 in.)
If the clearance is out of specification, replace the transmission hub sleeve No. 3 and gear shift fork No. 3.
5. 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.
6. 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.
REASSEMBLY
1. INSPECT SYNCHRONIZER RING NO. 3
2. INSPECT TRANSMISSION HUB SLEEVE NO. 3
3. INSPECT 5TH GEAR
4. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
5. 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.
6. 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, replace the output shaft front bearing inner race along with it.
7. 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 in.)
(b) Coat the lip of the front transaxle case oil seal with MP grease.
8. 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 in.)
9. 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)
10. 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)
11. 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
Torque:
New bearing preload (at starting) 0.78 to 1.57 Nm (8 to 16 kgf/cm, 6.9 to 13.9 in. 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 in. lbs.) corresponding to a change of 0.05 mm (0.0020 in.) 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.
12. 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 in.)
(b) Coat the lip of the transmission case oil seal with MP grease.
13. 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 in.)
(b) Coat the lip of the transaxle case oil seal with MP grease.
14. INSTALL TRANSMISSION MAGNET
(a) Clean the transmission magnet, and install it to the transmission case.
15. INSTALL BEARING LOCK PLATE
(a) Install the bearing lock plate with the bolt.
Torque: 11 Nm (115 kgf/cm, 8 ft. lbs.)