Part 3

101. Remove the bolts and the manual transmission case.
102. Remove the differential case assembly from the transaxle case.




103. Coat the lip of the front transmission case oil seal with MP grease.
104. Using a suitable driver (1) and a hammer, install a new transmission case oil seal onto the manual transmission case.

Driven in depth: 9.6-10.2 mm (0.378-0.402 in)




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

Driven in depth: 1.6-2.2 mm (0.063-0.087 in)




107. Clean the transmission magnet and install it onto the transaxle case.




108. Install the bearing lock plate onto the transaxle case with the bolt (1) and tighten to 11 Nm (97 lb in).





Note:
* Do not deform the No. 1 oil receiver pipe.
* Install the No. 1 oil receiver pipe while holding it against the manual transmission case.

109. Install the No. 1 oil receiver pipe onto the manual transmission case with the bolt and tighten to 17 Nm (13 lb ft).





Note:
* Do not deform the No. 2 oil receiver pipe.
* Install the No. 2 oil receiver pipe (1) while holding it against the manual transmission case.

110. Install the No. 2 oil receiver pipe onto the manual transmission case with the bolt and tighten to 17 Nm (13 lb ft).





Note: Set the reverse restrict pin assembly in the correct direction.

111. Install the reverse restrict pin assembly onto the manual transmission case.




112. Using a pin punch (5 mm) and a hammer, install the slotted spring pin onto the reverse restrict pin assembly.

Drive in depth: 15.5-16.5 mm (0.6102-0.6496 in)




113. Apply Three Bond 1344 or equivalent sealant to the reverse restrict pin plug.
114. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug onto the manual transmission case and tighten to 13 Nm (115 lb in).




115. Install the manual transaxle case receiver onto the transaxle case with the bolt (1) and tighten to 11 Nm (97 lb in).




116. Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the transaxle case.




117. Coat the sliding and rotating surfaces of the input and output shafts with gear oil and install them onto the transaxle case.





Note: Align the mark (1) on the reverse idler gear shaft with the bolt hole.

118. Coat the reverse idler gear sub-assembly, thrust washer, and reverse idler gear shaft with gear oil, and install them.




119. Coat the No. 1 gear shift fork (1) and No. 2 gear shift fork (2) with gear oil and install them.




120. Coat the No. 1 gear shift fork (2) shaft with gear oil and install it.
121. Apply three bond 1344 sealant, or equivalent, to the shift fork set bolt.
122. Install the shift fork set bolt (2) and tighten to 16 Nm (12 lb ft).




123. Using a brass bar and a hammer, install a new shaft snap ring onto the No. 1 gear shift fork shaft.




124. Coat the shift fork balls (1) with MP grease and install them onto the reverse shift fork.
125. Install the reverse shift fork onto the No. 3 gear shift fork shaft.




126. Using a brass bar and a hammer, install new shift fork shaft snap rings (1, 2) onto the No. 3 shift fork shaft.




127. Coat the No. 3 gear shift fork shaft with gear oil and install it.





Note: To avoid interference by the shift fork balls, lift up the No. 3 gear shift fork shaft to the position.

128. Coat the No. 1 gear shift head and No. 2 gear shift fork shaft with gear oil and install them.




129. Coat the shift lock bolts (1, 2) with three bond 1344 sealant, or equivalent, and install them onto the No. 2 gear shift fork and No. 1 shift head. Tighten the bolts to 16 Nm (12 lb ft).




130. Install the reverse shift arm bracket assembly onto the front transaxle case with the bolts (1, 2) and tighten to 17 Nm (13 lb ft).




131. Apply three bond 1281 sealant (1), or equivalent, to the manual transmission case.




132. Install the bolts (1-13) onto the manual transmission side and tighten to 29 Nm (22 lb ft).




133. Coat the bolts (1-3) with three bond 1344 sealant, or equivalent, and install them onto the manual transaxle side. Tighten the bolts to 29 Nm (22 lb ft).




134. Coat the reverse idler gear shaft bolt (1) with three bond 1344 sealant, or equivalent, and install it with a new gasket. Tighten the bolt to 29 Nm (22 lb ft).




135. Coat the No. 2 lock ball assembly with three bond 1344 sealant, or equivalent, and install it using a hexagon wrench. Tighten the bolts to 29 Nm (22 lb ft).




136. Install the shift detent balls, shift detent ball springs, and shift spring seats onto the manual transmission case.




137. Coat the threads of the shift detent ball plugs with three bond 1344 sealant, or equivalent, and install them using a hexagon wrench. Tighten the bolts to 22 Nm (16 lb ft).




138. Install the shift detent ball, shift detent ball compression spring, and spring seat onto the transaxle case.




139. Coat the threads of the shift detent ball plug with three bond 1344 sealant, or equivalent, and install it using a hexagon wrench. Tighten the bolts to 22 Nm (16 lb ft).




140. Using a snap ring expander, install a new input shaft rear bearing hole snap ring onto the input shaft.




141. Using a snap ring expander, install a new output shaft rear bearing hole snap ring onto the output shaft.




142. Using a brass bar and a hammer, install a new shift fork shaft snap ring onto the No. 2 shift fork shaft.




143. Coat the bolts with three bond 1344 sealant, or equivalent, and install the rear bearing retainer onto the manual transmission case with the bolts. Tighten the bolts to 27 Nm (20 lb ft).




144. Using a suitable tool (1,2), install the 5th driven gear onto the output shaft.




145. Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them onto the input shaft.




146. Coat the 5th gear with gear oil and install it onto the input shaft.




147. Coat the No. 3 synchronizer ring with gear oil and install it onto the 5th gear.





Note: Do not set the shifting key spring openings in the same position.

148. Install the synchromesh shifting keys and synchromesh shifting key springs onto the No. 3 transmission clutch hub.





Note:
* Do not install the No. 3 transmission clutch hub in the wrong direction.
* Install the No. 3 transmission clutch hub with the No. 3 synchronizer ring key groove and the No. 3 synchromesh shifting key aligned.
* Check that the 5th gear can rotate smoothly.
* Place a suitable sized wooden block to support the input shaft.

149. Using a suitable driver (1) and a hammer, install the No. 3 transmission clutch hub onto the input shaft.
150. Select a snap ring that will allow minimum axial play. Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Snap Ring Thickness 4.




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




152. Using a dial indicator, measure the 5th gear thrust clearance.

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

153. If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.




154. Using a dial indicator, measure the 5th gear radial clearance.

* Standard clearance: NSK made bearing: 0.015-0.05 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)

155. If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.





Note: Set the No. 3 transmission clutch hub in the correct direction.

156. Coat the No. 3 transmission clutch hub sleeve with gear oil and install it together with the No. 3 gear shift fork onto the No. 3 transmission clutch hub.




157. Coat the gear shift fork lock bolt with three bond 1344 sealant, or equivalent, and install it onto the No. 3 gear shift fork. Tighten the bolt to 16 Nm (12 lb ft).




158. Engage the gears simultaneously to lock the transmission.
159. Install a new manual transmission output shaft rear nut and tighten to 118 Nm (87 lb ft).




160. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
161. Disengage the gears.





Note: Assemble the parts within 10 minutes of application. Otherwise, the sealant must be removed and reapplied.

162. Apply three bond 1344 sealant (1), or equivalent, to the manual transmission case cover sub-assembly.




163. Install the manual transmission case cover sub-assembly with the bolts onto the manual transmission case and tighten to 21 Nm (15 lb ft).




164. Coat the shift and select lever shaft assembly with gear oil and install it onto the transmission case.




165. Using a suitable driver (1) and a hammer, install a new control shaft cover oil seal onto the control shaft cover.

Driven in depth: 0.2-1.2 mm (0.0079-0.0472 in)

166. Coat the control shaft cover oil seal with MP grease.





Note: Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.

167. Coat the threads of the bolts (1-4) with sealant, three bond 1344 or equivalent.
Install a new gasket and the control shaft cover onto the manual transmission case with the bolts and tighten to 20 Nm (14 lb ft).




168. Coat the threads of the shift guide pin with sealant, three bond 1344 or equivalent.
169. Install the washer and shift guide pin (1) and tighten the bolts to 11 Nm (97 lb in).




170. Coat the threads of the No. 1 lock ball assembly (1) with three bond 1344 sealant, or equivalent, and install it onto the manual transmission case. Tighten the bolts to 29 Nm (22 lb ft).




171. Install the dust boot onto the control shaft cover.
172. Install the shift lever damper with the lock pin onto the shift and select lever shaft assembly.
173. Install the washer with the nut (1) and tighten the bolts to 12 Nm (106 lb in).




174. Install the dust boot onto the shift and select lever shaft oil seal.
175. Install the floor shift control shift lever with the lock pin onto the shift and select lever shaft assembly.
176. Install the washer with the nut (1) and tighten the bolts to 12 Nm (106 lb in).





Note: Apply MP grease to the inside circumferential surface of the control shift lever bush.

177. Install the selecting bellcrank assembly together with the control bellcrank dust cover onto the manual transmission case with the bolts (1, 2) and nut (3).

* Tighten the bolts to 25 Nm (18 lb ft).
* Tighten the nuts to 12 Nm (106 lb in).

178. Install the back-up light switch assembly onto the manual transmission case with a new gasket and tighten to 40 Nm (30 lb ft).
179. Install the back-up light switch wire harness into the clamps.
180. Install a new O-ring onto the speedometer driven hole cover sub-assembly.




181. Install the speedometer driven hole cover sub-assembly onto the manual transaxle case with the bolt and tighten to 11 Nm (97 lb in).




182. Install the manual transmission filler plug onto the manual transmission case with a new gasket and tighten to 39 Nm (29 lb ft).




183. Install the drain plug onto the manual transmission case with a new gasket and tighten to 39 Nm (29 lb ft).