Part 1

Transmission Assemble

Special Tools

J 35405 - Differential Preload Wrench




1. Coat the sliding and rotating surfaces of the front differential side gear with gear oil.
2. Install the front No. 1 differential side gear thrust washers onto the front differential side gears.

Note: While rotating the front differential side gear, install the front differential pinions and front differential pinion thrust washers.

3. Install the front differential side gears, front differential pinions, and front differential pinion thrust washers onto the front differential case.




4. Coat the front No. 1 differential pinion shaft with MP grease.
5. Install the front No. 1 differential pinion shaft onto the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.




6. Adjust the front differential side gear backlash.
7. Install the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

Standard Backlash: 0.05-0.20 mm (0.0020-0.0079 in)

8. If the backlash is out of the specification, replace the side gear thrust washers.




9. Using a pin punch (3 mm) and a hammer, install the front differential pinion shaft straight pin onto the front differential case.




10. Using a chisel and a hammer, stake the front differential case hole.




11. Clean the contact surfaces of the front differential case and ring gear.
12. Using a heater, heat the front differential ring gear to 90-100°C (194-230°F).
13. After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.




14. Aligning the matchmarks (1), quickly install the front differential ring gear onto the front differential case.

Caution: Refer to Fastener Caution (Fastener Caution)

15. Install the bolts and tighten to 77 Nm (57 lb ft).




16. Install the speedometer drive gear onto the front differential case.




17. Coat the No. 2 transmission hub sleeve with gear oil.
18. Install the synchromesh shifting key springs and synchromesh shifting keys to the No. 2 transmission clutch hub.





Note: Position the No. 2 transmission hub sleeve and No. 2 transmission clutch hub correctly together.

19. Install the No. 2 transmission clutch hub onto the No. 2 transmission hub sleeve.




20. Coat the 3rd gear needle roller bearing with gear oil and install it onto the input shaft.




21. Coat the 3rd gear with gear oil and install it onto the input shaft.




22. Coat the 3rd gear synchronizer ring with gear oil and install it onto the 3rd gear.





Note: Fit the synchromesh shifting keys into the grooves of the synchronizer ring correctly.

23. Using a press, install the No. 2 transmission clutch hub (1) onto the input shaft.




24. Select a snap ring that will allow minimum axial play. Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Snap Ring Thickness 1.

Standard Clearance: 0.1 mm (0.0039 in) or less

25. Using a brass bar and a hammer, install the snap ring onto the input shaft.




26. Coat the 4th gear synchronizer ring with gear oil and install it onto the No. 2 transmission clutch hub.




27. Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil and install them onto the No. 2 transmission clutch hub.




28. Coat the 4th gear with gear oil and install it onto the input shaft.




29. Using a press (1), install the input shaft rear radial ball bearing onto the input shaft.




30. Select a snap ring that will allow minimum axial play. Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Snap Ring Thickness 2.

Standard Clearance: 0.1 mm (0.0039 in) or less

Note: Do not damage the journal surface of the snap ring.

31. Using a brass bar and a hammer, install the snap ring onto the input shaft.
32. Inspect the 3rd gear radial clearance.




33. Using a dial indicator, measure the 3rd gear radial clearance.

* Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)
* Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)
* Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)
* Maximum clearance, KOYO made bearing - 0.058 mm (0.0022 in)

34. If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.
35. Inspect the 4th gear radial clearance.




36. Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

* Standard clearance, NSK made bearing - 0.009-0.050 mm (0.0003-0.0019 in)
* Standard clearance, KOYO made bearing - 0.009-0.050 mm (0.0003-0.0019 in)
* Maximum clearance, NSK made bearing - 0.050 mm (0.0019 in)
* Maximum clearance, KOYO made bearing - 0.050 mm (0.0019 in)

37. If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.
38. Inspect the 3rd gear thrust clearance.




39. Using a dial indicator, measure the 3rd gear thrust clearance.

* Standard clearance - 0.10-0.35 mm (0.0039-0.0138 in)
* Maximum clearance - 0.35 mm (0.0138 in)

40. If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.




41. Inspect the 4th gear thrust clearance.
42. Using a feeler gauge, measure the 4th gear thrust clearance.

* Standard clearance - 0.10-0.55 mm (0.0039-0.0217 in)
* Maximum clearance - 0.55 mm (0.0217 in)

43. If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.




44. Inspect the reverse gear.
45. Using vernier calipers, measure the width of the reverse gear groove (a) and the thickness of the claw part on the reverse shift fork (b), and calculate the clearance.

Standard Clearance (a-b): 0.15-0.35 mm (0.0059-0.0138 in)

46. If the clearance is out of the specification, replace the reverse gear and reverse shift fork.




47. Inspect that the No. 1 transmission clutch hub and reverse gear slide smoothly.
48. Inspect that the edges of the reverse gear spline gear are not worn down.




49. Coat the reverse gear and No. 1 transmission clutch hub with gear oil.
50. Install the synchromesh shifting key springs and synchromesh keys to the No. 1 transmission clutch hub.





Note: Position the reverse gear and No. 1 transmission clutch hub correctly.

51. Install the reverse gear onto the No. 1 transmission clutch hub assembly.




52. Coat the 1st gear thrust washer pin or ball (1) with MP grease and install it onto the output shaft.




53. Coat the 1st gear thrust washer (1) with gear oil and install it onto the output shaft.




54. Coat the 1st gear needle roller bearing (1) with gear oil and install it onto the output shaft.




55. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
56. Install the inner ring onto the 1st gear.




57. Install the middle ring onto the 1st gear.




58. Install the outer ring onto the 1st gear.




59. Coat the 1st gear with gear oil and install it onto the output shaft.





Note:
* The 1st gear can be turned.
* While checking that the 1st gear thrust washer pin or ball is inserted into the groove of the 1st gear thrust washer, press and fit the No. 1 clutch hub.

60. Using a press, install the No. 1 transmission clutch hub (1) onto the output shaft.




61. Select a snap ring that will allow minimum axial play. Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Snap Ring Thickness 3.

Standard Clearance: 0.1 mm (0.004 in)

62. Using a brass bar and a hammer, install the snap ring onto the output shaft.




63. Coat the 2nd gear needle roller bearing (1) and 2nd gear bearing spacer with gear oil, and install them onto the output shaft.




64. Coat the 2nd gear cone and No. 2 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
65. Install the inner ring onto the 2nd gear.




66. Install the middle ring onto the 2nd gear.




67. Install the outer ring onto the 2nd gear.




68. Coat the 2nd gear with gear oil and install it onto the output shaft.




69. Using a press, install the 3rd driven gear (1) onto the output shaft.




70. Install the output gear spacer (1) onto the output shaft.




71. Using a press (1), install the 4th driven gear onto the output shaft.




72. Using a press (1), install the output shaft rear bearing onto the output shaft.




73. Using a dial indicator, measure the 2nd gear radial clearance.

* Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0006-0.0022 in)
* Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0006-0.0023 in)
* Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)
* Maximum clearance, KOYO made bearing - 0.058 mm (0.0023 in)

74. If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or input shaft.




75. Using a dial indicator, measure the 1st gear radial clearance.

* Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0006-0.0022 in)
* Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0006-0.0023 in)
* Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)
* Maximum clearance, KOYO made bearing - 0.058 mm (0.0023 in)

76. If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or input shaft.




77. Using a dial indicator, measure the 2nd gear thrust clearance.

* Standard Clearance - 0.010-0.55 mm (0.0006-0.0022 in)
* Maximum Clearance - 0.055 mm (0.0217 in)

78. If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.




79. Using a feeler gauge, measure the 1st gear thrust clearance.

* Standard Clearance - 0.010-0.40 mm (0.0039-0.0157 in)
* Maximum Clearance - 0.40 mm (0.0157 in)

80. If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear or No. 1 transmission clutch hub.




81. Using a caliper gauge, inspect the reverse idler gear.

* Standard inside diameter - 18.040-18.058 mm (0.7102-0.7109 in)
* Maximum inside diameter - 18.058 mm (0.7109 in)

82. If the inside diameter exceeds the maximum, replace the reverse idler gear sub-assembly.
83. Using a micrometer, inspect the reverse idler gear shaft.

* Standard outer diameter - 17.966-17.984 mm (0.7073-0.7080 in)
* Minimum outer diameter - 17.966 mm (0.7073 in)

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





Note: Insert the output shaft cover key into the case groove.

85. Coat the output shaft cover with MP grease and install it onto the transaxle case.




86. Coat a new output shaft front bearing with gear oil.

Note:
* Install the new bearing in the correct direction.
* When replacing the output shaft front bearing, replace the output shaft front bearing inner race at the same time.

87. Using a press (1), install it onto the transaxle case.




88. Coat the lip of the front transaxle case oil seal with MP grease.
89. Using a suitable driver (2) and a hammer (1), install a new front transaxle case oil seal onto the transaxle case.

Driven in depth - 15.6-16.0 mm (0.6141-0.6299 in)




90. Coat a new input shaft front bearing with gear oil, and using a press (1), install it onto the transaxle case.

Driven in depth - 0-0.3 mm (0-0.0118 in)




91. Using a suitable driver (1) and a hammer, install a new shift and select lever shaft slide ball bearing onto the manual transmission case.

Driven in depth - 0-0.5 mm (0-0.020 in)




92. Install a new shift and select lever shaft oil seal (1) onto the manual transmission case.

Driven in depth - 9.7-10.3 mm (0.382-0.406 in)




93. Using a press (1), install a new front differential case front tapered roller bearing (inner race) onto the front differential case.




94. Using a press (1), install the front differential case front tapered roller bearing (outer race) together with the plate washer onto the transaxle case.




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





Note: Use a plate washer of the same thickness as the removed one.

96. Using a press (1), install the front differential case rear tapered roller bearing (outer race) with the plate washer onto the manual transmission case.




97. Coat the differential case assembly with gear oil and install it onto the transaxle case.
98. Install the manual transmission case with the bolts and tighten to 29 Nm (22 lb ft).




99. Using J 35405 - wrench (1) , check the preload.

* New bearing: 0.78-1.57 Nm (6.9-13.89 lb in)
* Used bearing: 0.49-0.98 Nm (4.34-8.67 lb in)

100. If the preload is out of the specification, select a different plate washer. Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Plate Washer Thickness.

Note: The preload changes by approximately 0.3-0.4 Nm (2.6-3.5 lb in) per each 0.05 mm (0.0020 in) change in the plate washer thickness.

101. Remove the bolts and the manual transmission case.