Part 2

Transmission Assemble

50. Coat the new transaxle case oil seal lip with MP grease.




51. Using a suitable driver (1) and a hammer, install a transaxle case oil seal.

Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in)




52. Using a suitable drive (1) and hammer, install the front differential case front tapered roller bearing (outer race) to the manual transaxle case.




53. Using a press (1), install the front differential case front tapered roller bearing (inner race) to the front differential case.




54. Using a suitable drive (1) and hammer, install the front differential case rear shim.
55. Install the front differential case rear tapered roller bearing (2) (outer race).




56.
Using a press (1), install the front differential case rear tapered roller bearing (inner race).




57. Coat the transmission case oil seal lip with MP grease.

Oil seal installation depth - 3.0-4.0 mm (0.1181-0.1575 in)

58. Using a suitable driver (1) and a hammer, install a transmission case oil seal to the manual transmission case.




59. Using a suitable driver (1) and a hammer, install the output shaft rear bearing (outer race) to the manual transmission case.

Clearance - 3.8-4.4 mm (0.150-0.173 in)





Note: Align the projection of the output shaft cover with the transmission groove.

60. Coat the output shaft cover with MP grease, and install it to the manual transaxle case.




61. Using a suitable driver (1) and a hammer, install the new output shaft front bearing (outer race).




62. Install the output shaft to the manual transaxle case.




63. Install the transmission case to the manual transaxle case with the bolts (1-14) and tighten to 29 Nm (21 lb ft).




64. Install the bolts (1) to the manual transaxle case and tighten to 29 Nm (21 lb ft).




65. Install the output shaft rear bearing case shim to the output shaft.




66. Install the rear bearing retainer to the manual transmission case with the bolts and tighten to 43 Nm (32 lb ft).




67. Turn the output shaft in both directions to make sure that it starts to turn smoothly.
68. Using a socket wrench and torque wrench, inspect the preload. Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Output Shaft Preload.
69. If preload is not as specified, select a proper output shaft rear bearing shim and adjust it.
The preload of all the output shaft rear bearing shim varies in torque from about 0.04-0.06 Nm (0.35-0.53 lb in). Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Output Shaft Rear Bearings Thickness.
70. Remove the output shaft rear set nut from the output shaft.




71. Remove the bolts and rear bearing retainer from the manual transmission case.




72. Remove the output shaft rear bearing shim from the output shaft.




73. Remove the bolts (1).




74. Remove the bolts (1-14) and manual transmission case from the manual transaxle case.




75. Remove the output shaft assembly from the front manual transaxle case.




76. Install the differential case assembly to the manual transaxle case.




77. Install the bolts (1-14) and manual transmission case to the manual transaxle case, tighten the bolts to 29 Nm (21 lb ft).




78. Install the bolts (1) to the manual transaxle case and tighten to 29 Nm (21 lb ft).
79. Turn the differential case in both directions to make sure that it starts to turn smoothly.




80. Using J 35405 and a torque wrench (1), inspect preload. Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Preload Specifications.
If preload is not as specified, select a proper front differential case rear shim and adjust it.
The preload of all the front differential case rear shims varies in torque from about 0.04-0.06 Nm (0.35-0.53 lb in). Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Front Differential Case Shim Thickness.




81. Remove the bolts (1).




82. Remove the bolts (1-14) and manual transmission case from the manual transaxle case.




83. Remove the differential case assembly from the manual transaxle case.
84. Coat the lip of the new front transaxle case cover oil seal with MP grease.




85. Using a suitable driver (1) and a hammer, install a new front transaxle case cover oil seal to the manual transaxle case.

Clearance - 1.0-2.0 mm (0.0394-0.0787 in)

86. Coat the new input shaft front bearing with gear oil.




87. Using a suitable driver (1) and a hammer, install the oil seal to the manual transaxle case.

Clearance - 4.28-4.60 mm (0.1685-0.1811 in)




88. Install the manual transaxle case receiver to the manual transaxle case with the bolts (1) and tighten to 7 Nm (62 lb in).




89. Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the manual transaxle case.




90. Apply gear oil to each sliding part of the output shaft assembly.
91. Lift the differential case assembly with the output shaft assembly leaned, and install it to the manual transaxle case.




92. Apply gear oil to each sliding part of the input shaft assembly.
93. Install the input shaft assembly to the manual transaxle case while tilting the output shaft assembly.




94. Coat the No. 2 gear shift fork (1) with gear oil, and install it to the input shaft assembly.




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




97. Apply gear oil to each sliding part of the No. 3 gear shift fork shaft (1), and install it to the manual transaxle case.




98. Apply gear oil to each sliding part of the No. 1 gear shift fork (1), and install it to the output shaft assembly.




99. Install the No. 1 gear shift head to the No. 2 gear shift fork shaft.
100. Apply gear oil to each sliding part of the No. 2 gear shift fork shaft (2), and install it to the manual transaxle case.