Reassembly

REASSEMBLY

1. Install the drive shaft oil seal using the special tool(09431-21200).

NOTE:
Insert the oil seal straightly.

2. Install the input shaft front oil seal using the special tool(09431-21000).

CAUTION:
Do not reuse the oil seal.

3. Install the output shaft oil guide.

4. Install the output shaft bearing outer race using the special tools(09500-11000, 09532-11500).

5. Install the control shaft assembly.

(1) After inserting the rubber boot onto the control shaft, insert the control shaft into the clutch housing.

(2) Insert the neutral return spring (B) onto the control shaft.

NOTE:
Larger diameter of the neutral return spring (B) should be toward the side wall of the clutch housing as shown figure.

(3) Slide the control finger inside the inter lock plate, and then slide the assembly onto the control shaft.

NOTE:
The lug on the control finger should point in the same direction as the control shaft lever.

(4) Insert the stopper plate.
(5) Push the control shaft assembly into the clutch housing support hole.
(6) Push the lock pin through the control finger and control shaft.

6. Install the differential gear assembly.

7. Insert the output shaft, inclining the differential assembly.
And insert the input shaft, inclining the output shaft.

8. Install the input shaft bearing retainer.

CAUTION:
Apply a THREE BOND 1303 on the hex-bolts.

9. Reassembly of the shift rail assemblies.
(1) Place the first and second speed synchronizer sleeve to the second gear position in order to get installing space of 1st-2nd shift rail assembly.
(2) Place the third and fourth speed synchronizer sleeve to neutral position.
(3) Install the shift rail and fork assemblies.

10. Reassembly of spring pin.
(1) Install the spring pins using the special tool(09414-11000) or pin punch.

CAUTION:
Do not reuse the spring pin.

(2) When installing, make sure that the slit of the spring pin is aligned with center line of the shift rail.

11. Install the reverse gear shaft and reverse gear.

12. Install the reverse shift lever.

13. Install the drive shaft oil seal in the transaxle case using the special tool(09431-21200).

CAUTION:
Do not reuse the oil seal.

14. Install the input shaft bearing outer race and spacer using the special tools(09432-22100/09500-11000).
15. Install the output shaft bearing outer race and spacer using the special tools(09432-22100/09500-11000).

16. Installation of spacer.
(1) Place two pieces of rosin-core solder with 3 mm (0.118 in.) in diameter on the bearing outer race as illustrated.

(2) Install the transaxle case temporarily and tighten the bolts to the specified torque, then remove the transaxle case.

(3) Detach the crushed solders.

(4) Measure the thickness of the crushed solder.
(5) Select and install the proper spacers.

Selection example
A. Output shaft
- The thickness of the crushed solder : 1.72mm (0.0677in.)
- Standard value : 0.07T mm (0.0002in.)
1.72mm (0.0677in.) + 0.07mm (0.0027in.) = 1.79mm (0.0704in.)
Therefore, select the spacer of the 1.79mm (0.0704in.) thickness.

17. Install the oil guide in the transaxle case.

18. Apply the specified sealant to the clutch housing side of the transaxle case.

Specified sealant: THREE BOND 1216

19. Install the transaxle case onto the clutch housing assembly and tighten the bolts.

Tightening torque
Transaxle case: 35 - 42Nm (350 - 420kg-cm, 26 - 31lb-ft)

20. Center the reverse idler gear shaft with screw driver.

21. Tighten the reverse idler gear shaft bolt to the specified torque.

Tightening torque
Reverse gear shaft bolt:
43 - 55Nm (430 - 550kg-cm, 32 - 41lb-ft)

22. Install the 5th-reverse shift rail poppet bolt.

23. Install the output shaft gear using the special tool(09432-33300).

24. Install the rear bearing, spacer, snap ring and 5th gear sleeve.

25. Install the fifth speed gear, needle roller bearing, synchronizer ring and synchronizer hub.

CAUTION:
Place the oil groove of synchronizer hub toward the fifth speed gear.

26. Install the stopper plate.

27. Install the race.

28. Install the 5th shift fork and the 5th synchronizer sleeve at the same time.

29. Reassembly of locking nut.
(1) Shift the transaxle into 3rd and 5th gear.
(2) Tighten the locking nut to the specified torque.

Tightening torque :
140 - 160Nm (1400 - 1600kg-cm, 102 - 115lb-ft)