Part 2

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 gage, 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 gage, 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.