Part 4

91. INSTALL OIL RECEIVER PIPE NO.1 (MTM)
a. Install the bolt and oil receiver pipe No.1 (MTM) to the manual transmission case.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)

NOTICE: Do not damage the pipe.





92. INSTALL OIL RECEIVER PIPE NO.2 (MTM)
a. Install the bolt and oil receiver pipe No.2 (MTM) to the manual transmission case.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)

NOTICE: Do not damage the pipe.





93. INSTALL MANUAL TRANSMISSION CASE
a. Apply FIPG to the manual transmission case in a continuous line, as shown in the illustration.
FIPG: Part No. 08826-00090, THREE BOND 1281

NOTICE: Install the part within 10 minutes after applying the packing material (FIPG).





b. Install the manual transmission case with the 14 bolts to the manual transaxle case.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





c. Coat the 3 bolts with sealant, and install them on the manual transaxle case side.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
94. INSTALL CLUTCH TUBE BRACKET
a. Install the clutch tube bracket with the bolt.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)





95. INSTALL REVERSE IDLER GEAR SHAFT BOLT
a. Coat the reverse idler gear shaft bolt with sealant, and install a new reverse idler gear shaft gasket and the reverse idler gear shaft bolt to the manual transmission case.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





96. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING
a. Using a brass bar and hammer, install the shift fork shaft snap ring to the gear shift fork shaft No.1.





b. Using a brass bar and hammer, install the shift fork shaft snap ring to the gear shift fork shaft No.2.





97. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING
a. Using a snap ring expander, install the input shaft rear bearing shaft snap ring.





98. INSTALL OUTPUT SHAFT REAR BEARING SHIM
a. Install the output shaft rear bearing shim to the output shaft.





99. INSTALL BEARING RETAINER REAR (MTM)
a. Coat the 7 bolts with sealant, and using a torx wrench (T45), install the bearing retainer rear (MTM) with them.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





100. INSTALL 5TH DRIVEN GEAR
a. Using SST, install the 5th driven gear to the output shaft.
SST 09309-12020





101. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
a. Coat the 5th gear needle roller bearing with gear oil, and install it to the input shaft.





102. INSTALL 5TH GEAR
a. Coat the 5th gear with gear oil, and install it to the input shaft.





103. INSTALL TRANSMISSION CLUTCH HUB NO.3
a. Using SST, install the transmission clutch hub No.3 to the input shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010)

NOTICE: Align the projection of the synchronizer ring with the hole of the 5th gear and install.





b. Install the transmission hub sleeve No.3 and gear shift fork No.3 to the transmission clutch hub No.3.





c. Coat the shift fork set bolt with sealant, and install it to the gear shift fork No.3.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





d. Select the transmission clutch hub No.3 shaft snap ring that allows the minimum amount of axial play. Using a brass bar and a hammer, install the transmission clutch hub No.3 shaft snap ring.
Clearance: 0.1 mm or less





Snap ring: mm (in.)





104. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, inspect the 5th gear radial clearance.
Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 inch)
If clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.





105. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, inspect the 5th gear thrust clearance.
Standard clearance: 0.10 to 0.65 mm (0.0039 to 0.0260 inch)
If clearance is out of specification, replace the transmission clutch hub No.3, 5th gear or input shaft rear radial ball bearing.





106. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
a. Engage two gears simultaneously to lock the transmission.





b. Install a new manual transmission output shaft rear set nut.
Torque: 123 Nm (1,254 kgf-cm, 90 ft. lbs.)





c. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
d. Disengage the two gears.





107. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
a. Apply FIPG to the transaxle case cover sub-assembly, as shown in the installation.
FIPG: Part No. 08826-00090, THREE BOND 1281

NOTICE: Install the part within 10 minutes after applying the packing material (FIPG).





b. Install the transmission case cover sub-assembly with the 10 bolts to the manual transaxle case.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





108. INSTALL DRAIN (MTM) PLUG SUB-ASSEMBLY
a. Install the drain (MTM) plug sub-assembly with a new gasket to the manual transmission case.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





109. INSTALL MANUAL TRANSMISSION FILLER PLUG
a. Install the manual transmission filler plug with a new gasket to the manual transaxle case.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





110. INSTALL SHIFT & SELECT LEVER SHAFT ASSEMBLY
a. Coat the shift & select lever shaft assembly with gear oil, and install it to the manual transmission case.





111. INSTALL CONTROL SHAFT COVER
a. Coat the 4 bolts with sealant, and install a new gasket and the control shaft cover with the 4 bolts.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)





112. INSTALL BACK UP LAMP SWITCH ASSEMBLY
a. Install the back up lamp switch assembly and a new gasket to the manual transmission case.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)





113. INSTALL MANUAL TRANSMISSION BREATHER PLUG
a. Install a new gasket and the manual transmission breather plug to the manual transmission case.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





114. INSTALL LOCK BALL ASSEMBLY NO.1
a. Install the lock ball assembly No.1 to the manual transmission case.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





115. INSTALL CONTROL SHIFT LEVER
a. Install the control shift lever with the shift outer lever lever lock pin to the shift & select lever shaft.
b. Install the spring washer with the nut.
Torque: 6.4 Nm (65 kgf-cm, 57 inch lbs.)





116. INSTALL SELECTING BELL CRANK ASSEMBLY
a. Install the shift & select lever bush to the selecting bell crank assembly.
b. Coat the 2 bolts with sealant, and install the selecting bell crank assembly to the manual transmission case with the 2 bolts.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
117. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
a. Install a new O-ring to the speedometer driven hole cover sub-assembly.
b. Install the speedometer driven hole cover sub-assembly to the transmission case with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 48 inch lbs.)
118. INSTALL CLUTCH RELEASE FORK BOOT
a. Install the clutch release fork boot to the manual transaxle case.





119. INSTALL RELEASE FORK SUPPORT
a. Using a deep socket wrench, install the release fork support to the manual transaxle case.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)
120. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
a. Coat the clutch release bearing assembly with release hub grease, and install it to the clutch release fork sub-assembly with the clutch release bearing clip.
Sealant: Part No. 08887-01806, Release Hub Grease or equivalent.





121. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Apply clutch spline grease to the input shaft spline.
b. Install the clutch release fork sub-assembly to the input shaft.