Part 3

MANUAL TRANSAXLE ASSEMBLY (C50) (CONTINUED)

OVERHAUL





51. REMOVE TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, drive out the transmission case oil seal from the manual transmission case.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)





52. REMOVE SHIFT & SELECT LEVER SHAFT BIMETAL FORMED BUSH
a. Using SST remove the shift & select lever shaft bimetal formed bush.
SST 09319-60020

53. INSPECT SYNCHRONIZER RING NO.3
a. Check for any wear or damage.





b. Coat the cone of the 5th gear with gear oil. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone. Check that the ring locks.
If the synchronizer ring does not lock, replace the ring or the 5th gear.





c. Using a feeler gauge, check the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring and gear.

NOTICE: Ensure the fine lapping compound is completely washed of after rubbing.





54. INSPECT TRANSMISSION HUB SLEEVE NO.3
a. Check the sliding condition between the transmission hub sleeve No.3 and transmission clutch hub No.3.
b. Check that the spline gear's edges of the transmission hub sleeve No.3 are not worn down.





c. Using vernier calipers, measure the clearance between the transmission hub sleeve No.3 and gear shift fork No.3.
Standard clearance: 0.3 to 0.5 mm (0.0012 to 0.0020 in.)
If the clearance exceeds the standard clearance, replace the transmission hub sleeve No.3 and gear shift fork No.3.





55. INSPECT 5TH GEAR
a. Using a caliper gauge, inspect the 5th gear as shown in the illustration.
Standard clearance: 29.915 to 29.931 mm (1.1778 to 1.1783 in.)
Maximum clearance: 29.931 mm (1.1783 in.)
If the clearance exceeds the standard clearance, replace the 5th gear.





56. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
a. Using a caliper gauge, inspect the reverse idler gear sub-assembly as shown in the illustration.
Standard clearance: 18.040 to 18.058 mm (0.7102 to 0.7109 in.)
Maximum clearance: 18.058 mm (0.7109 in.)
If the clearance exceeds the maximum, replace the reverse idler gear sub-assembly.
b. Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.
Standard outer diameter: 17.966 to 17.984 mm (0.7073 to 0.7080 in.)
Minimum outer diameter: 17.966 mm (0.7073 in.)
If the outer diameter exceeds the minimum, replace the reverse idler gear shaft.





57. INSTALL OUTPUT SHAFT (MTM) COVER
a. Coat the output shaft cover with MP grease and install it to the front transaxle case.

NOTICE: Install the output shaft (MTM) cover projection into the case side hollow.





58. INSTALL OUTPUT SHAFT FRONT BEARING
a. Coat a new output shaft front bearing with gear oil. Using SST and a press, install it.
SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)

NOTICE:
- Be sure to install a new bearing in the correct direction, as shown in the illustration.
- When replacing the output shaft front bearing, replace the output shaft front bearing inner race along with it.





59. INSTALL FRONT TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install a new front transaxle case oil seal to the front transaxle case.
SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)
Drive in depth: 15.6 to 16.0 mm (0.6141 to 0.6299 in.)
b. Coat the lip of the front transaxle case oil seal with MP grease.





60. INSTALL INPUT SHAFT FRONT BEARING
a. Coat a new input shaft front bearing with MP grease. Using SST and a press, install it to the front transaxle case.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
Drive in depth: 0 to 0.3 mm (0 to 0.0118 in.)





61. INSTALL SHIFT & SELECT LEVER SHAFT BIMETAL FORMED BUSH
a. Using SST, install the shift & select lever shaft bimetal formed bush.
SST 09950-60010 (09951-00220), 09950-70010 (09951-07100)
Drive in depth: 0 to 0.5 mm (0 to 0.0020 in.)





62. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Using SST and a press, install the front differential case front tapered roller bearing (inner race) to the front differential case.
SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)





b. Using SST and a press, install the front differential case front tapered roller bearing (outer race) with plate washer to the front transaxle case.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)





63. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST and a press, install the front differential case rear tapered roller bearing (inner race) to the differential case.
SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)





b. Using SST and a press, install the front differential case rear tapered roller bearing (outer race) with plate washer to the transmission case.
SST 09309-36010, 09950-60020 (09951-00710), 0995-70010 (09951-07150)

HINT: Use a front differential case rear plate washer rear of the same thickness as the one that was removed.





64. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
a. Coat the differential case assembly with gear oil, and install it to the front transaxle case.
b. Install the manual transmission case with the 16 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





c. Using SST and a torque wrench, turn the differential case assembly to the right and left 2 or 3 times to allow the bearings to settle.
SST 09564-32011





d. Using SST and a torque wrench, measure the preload.
SST 09564-32011
Preload (at starting):
New bearing: 0.78 to 1.57 Nm (7.95 to 16.0 kgf-cm, 6.9 to 13.89 inch lbs.)
Reuse bearing: 0.49 to 0.98 Nm (5.0 to 10.0 kgf-cm, 4.34 to 8.67 inch lbs.)

If the preload is out of specification, select another plate washer.

Plate Washer Thickness:

HINT: The preload will change about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2.6 - 3.5 in.lbf) corresponding to a change of 0.05 mm (0.0020 in) in plate washer thickness.

e. Remove the 16 bolts and manual transmission case.
f. Remove the differential case assembly.





65. INSTALL TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, install a new transmission case oil seal to the manual transmission case.
SST 09316-60011 (09316-00011)
Drive in depth: 2.1 to 2.7 mm (0.082677 to 0.106299)
b. Coat the lip of the front transmission case oil seal with MP grease.





66. INSTALL TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install a new transaxle case oil seal to the front transaxle case.
Drive in depth: 1.6 to 2.2 mm (0.0629 to 0.0866 in.)
SST 09710-20011 (09710-06071), 09950-70010 (09951-07150)
b. Coat the lip of the transaxle case oil seal with MP grease.





67. INSTALL TRANSMISSION MAGNET
a. Clean the transmission magnet and install it to the front transaxle case.





68. INSTALL BEARING LOCK PLATE
a. Install the bearing lock plate with the bolt.
Torque: 11 Nm (115 kgf-cm, 8.3 ft. lbs.)





69. INSTALL OIL RECEIVER PIPE NO.1 (MTM)
a. Install the oil receiver pipe No.1 with the bolt to the manual transmission case.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)

NOTICE:
- Prevent the oil receiver pipe no.1 (MTM) from being deformed,
- Install the oil receiver pipe no.1 (MTM) while placing it against the transmission case as shown in the image.





70. INSTALL OIL RECEIVER PIPE NO.2 (MTM)
a. Install the oil receiver pipe No.2 with the bolt to the manual transmission case.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)

NOTICE:
- Prevent the oil receiver pipe no.2 (MTM) from being deformed,
- Install the oil receiver pipe no.2 (MTM) while placing it against the transmission case as shown in the image.





71. INSTALL REVERSE RESTRICT PIN ASSEMBLY
a. Install the reverse restrict pin assembly to the manual transmission case.

HINT: Do set the reverse restrict pin assembly in correct orientation.





b. Using a pin punch (5 mm) and a hammer, install the slotted pin to the restrict pin assembly.
Drive in depth: 16.0 to 17.0 mm (0.6299 to 0.6693 in.)





c. Apply sealant to the reverse restrict pin plug.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug to the manual transmission case.
Torque: 13 Nm (130 kgf-cm, 9.3 ft. lbs.)





72. INSTALL MANUAL TRANSAXLE CASE RECEIVER
a. Install the manual transaxle case receiver with the bolt to the front transaxle case.
Torque: 11 Nm (115 kgf-cm, 8.3 ft. lbs.)





73. INSTALL DIFFERENTIAL CASE ASSEMBLY
a. Coat the differential case tapered roller bearings with gear oil, and install them to the front transaxle case.





74. INSTALL INPUT SHAFT ASSEMBLY
a. Coat the sliding and rotating surface of the input and output shafts with gear oil, install them to the transaxle case.





75. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
a. Coat the reverse idler gear, thrust washer and reverse idler gear shaft with gear oil, install them.

HINT: Align the mark on the reverse idler gear shaft and the bolt hole as shown in the illustration.