Part 4

MANUAL TRANSAXLE ASSEMBLY (C50) (CONTINUED)

OVERHAUL





76. INSTALL GEAR SHIFT FORK SHAFT NO.1
a. Coat the gear shift fork No.1 and gear shift fork No.2 with gear oil, and install them.





b. Coat the gear shift fork shaft No.1 with gear oil, and install it.
c. Apply sealant to the shift fork set bolt.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Install the shift fork set bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)





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





77. INSTALL GEAR SHIFT FORK SHAFT NO.3
a. Coat the 2 shift fork balls with MP grease, and install them to the reverse shift fork.
b. Install the reverse shift fork to the shift fork shaft No.3.





c. Using a brass bar and a hammer, install 2 new shift fork shaft snap rings to the shift fork shaft No.3.





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





78. INSTALL GEAR SHIFT FORK SHAFT NO.2
a. Coat the gear shift head No.1 and gear shift fork shaft No.2 with gear oil, and install them.





b. Coat the 2 shift lock bolts with sealant, and install them to the gear shift fork No.2 and shift head No.1.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)





79. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
a. Install the reverse shift arm bracket assembly with the 2 bolts to the front transaxle case.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)





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

NOTICE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.





b. Coat the 13 bolts with sealant, and install them to the manual transmission case.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





c. Coat the 3 bolts with sealant, and install them to the front transaxle case.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





81. INSTALL REVERSE IDLER GEAR SHAFT BOLT
a. Coat the reverse idler gear shaft bolt with sealant, and install it with a new gasket.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





82. INSTALL LOCK BALL ASSEMBLY NO.2
a. Coat the lock ball assembly No.2 with sealant, and install it with a hexagon wrench.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





83. INSTALL SHIFT DETENT BALL
a. Install the 2 shift detent balls, 2 shift detent ball springs with 2 shift detent ball spring seats No.1 to the manual transmission case.





b. Coat the 2 shift detent ball plugs with sealant, install them using a hexagon wrench.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)





c. Install the shift detent ball, shift detent ball compression spring and shift detent ball spring seat No.1 to the front transaxle case.





d. Coat the shift detent ball plug with sealant, and install it using a hexagon wrench.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)





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





85. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING
a. Using a snap ring expander, install the output shaft rear bearing hole snap ring to the output shaft.





86. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING
a. Using a brass bar and a hammer, install a new shift fork shaft snap ring to the shift fork shaft No.2.





87. INSTALL BEARING RETAINER REAR (MTM)
a. Coat the 5 bolts with sealant, and install the bearing retainer rear with the 5 bolts to the manual transmission case.
Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.)





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





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





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





91. INSTALL SYNCHRONIZER RING NO.3
a. Coat the synchronizer ring No.3 with gear oil, and install it to the 5th gear.





92. INSTALL TRANSMISSION CLUTCH HUB NO.3
a. Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs to the transmission clutch hub No.3 as shown in the illustration.

NOTICE: Do not set both openings of the shifting key springs in the same position.





b. Using SST and a hammer, install the transmission clutch hub No.3 to the input shaft.
SST 09636-20010

NOTICE:
^ Do not install the transmission clutch hub No.3 with it facing wrong direction.
^ Install the transmission clutch hub No.3 checking the positions of the synchronizer ring No.3 key groove and the synchromesh shifting key No.3.
^ Check that the 5th gear is rotating.

NOTICE: Place the suitable sized wooden block to support the input shaft.





c. Select a clutch hub No.3 shaft snap ring that will allow minimum axial play.





Clearance: 0.1 mm or less
d. Using a brass bar and a hammer, install the snap ring to the input shaft.





93. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, inspect the 5th gear thrust clearance.
Standard clearance: 0.1 to 0.57 mm (0.0039 to 0.02244 in.)
Maximum clearance: 0.57 mm (0.02244 in.)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.





94. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, inspect the 5th gear radial clearance.
Standard clearance:
KOYO made: 0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made: 0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:
KOYO made: 0.058 mm (0.0023 in.)
NSK made: 0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.





95. INSTALL GEAR SHIFT FORK NO.3
a. Coat the transmission clutch hub sleeve No.3 with gear oil, and install it and gear shift fork No.3 to the transmission clutch hub No.3.

HINT: Do set the transmission clutch hub No.3 in correct orientation.





b. Coat the gear shift fork lock bolt with sealant, and install it to the gear shift fork No.3.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)





96. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
a. Engage the gears to make them the double meshed.
b. Install a new manual transmission output shaft rear set nut.
Torque: 118 Nm (1200 kgf-cm, 87 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





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





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

NOTICE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.





b. Install the manual transmission case cover to the manual transmission case with the 9 bolts.
Torque: 18 Nm (185 kgf-cm, 14 ft. lbs.)





98. INSTALL SHIFT & SELECT LEVER SHAFT ASSEMBLY
a. Coat the 4 bolts with sealant. Install a new gasket and shift & select lever shaft assembly to the manual transmission case with the 4 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





99. INSTALL LOCK BALL ASSEMBLY NO.1
a. Coat the lock ball assembly No.1 with sealant, install it to the manual transmission case.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





100. INSTALL SELECTING BELL CRANK ASSEMBLY
a. Install the selecting bell crank assembly to the manual transmission case with the 2 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





101. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
a. Install the floor shift control lever housing support bracket to the front transaxle case with the 3 bolts.
Torque: 18 Nm (188 kgf-cm, 14 ft. lbs.)





102. INSTALL BACK UP LAMP SWITCH ASSEMBLY
a. Using SST, install the back-up lamp switch assembly with a new gasket to the manual transmission case.
SST 09817-16011
Torque: 40 Nm (410 kgf-cm, 30 ft. lbs.)





103. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support to the front transaxle case.
Torque: 37 Nm (375 kgf-cm, 25 ft. lbs.)





104. INSTALL CLUTCH RELEASE FORK BOOT
a. Install the clutch release fork boot to the front transaxle case.





105. 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 clip.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent





106. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Install the clutch release fork sub-assembly to the input shaft.
Sealant: Part No. 08887-01806, CLUTCH SPLINE GREASE or equivalent
b. Apply clutch spline grease to the input shaft spline.
107. 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 manual transaxle case with the bolt.
Torque: 11 Nm (115 kgf-cm, 8.3 ft. lbs.)





108. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
a. Install the clutch release cylinder with the 2 bolt.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)





109. INSTALL MANUAL TRANSMISSION FILLER PLUG
a. Install the manual transmission filler plug with a new gasket to the manual transmission case.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





110. INSTALL DRAIN (MTM) PLUG SUB-ASSEMBLY
a. Install the drain plug with a new gasket to the manual transmission case.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)