Part 1

MANUAL TRANSAXLE UNIT

COMPONENTS:

REASSEMBLY (STEPS 1-27)

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

NOTICE: Install the output shaft cover projection into the case hole.

2. INSTALL OUTPUT SHAFT FRONT BEARING
a) Coat a new front bearing with gear oil.
b) Using SST and a press, press it into the front transaxle case.
SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)

NOTICE:
^ Be sure to install the bearing in the correct direction, as shown in the illustration.
^ When replacing the output shaft front bearing, also replace the front bearing inner race.

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

4. INSTALL INPUT SHAFT FRONT BEARING
a) Coat a new input shaft front bearing with gear oil.
b) Using SST and a press, press it into the front transaxle case.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
Standard depth: 0 to 0.3 mm (0 to 0.012 inch)

5. INSTALL SHIFT AND SELECT LEVER SHAFT BIMETAL FORMED BUSH
a) Using SST and a press, press in a new bush to the transmission case.
SST 09950-60010 (09951-00220), 09950-70010 (09951-07100)
Standard depth: 0 to 0.5 mm (0 to 0.020 inch)

6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a) Using SST and a press, press in the front tapered roller bearing (inner race) to the front differential case.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)

b) Using SST and a press, press in the front tapered roller bearing (outer race) with plate washer to the front transaxle case.
SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)

7. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a) Using SST and a press, press in the 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, press in the rear tapered roller bearing (outer race) with plate washer to the transmission case.
SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)

HINT: Use a plate washer with the same thickness as the removed one.

8. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
a) Coat the differential case with gear oil, and install it to the front transaxle case.
b) Install the 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 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.
Standard preload (at starting)

Standard preload (at starting):

If the preload is not within the specification, select another plate washer.
Standard plate washer thickness

Standard plate washer thickness:

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

e) Remove the 16 bolts and transmission case.
f) Remove the differential case from the front transaxle case.

9. INSTALL TRANSMISSION CASE OIL SEAL
a) Using SST and a hammer, tap in a new transmission case oil seal to the transmission case.
SST 09316-60011 (09316-00011)
Standard drive depth: 2.1 to 2.7 mm (0.083 to 0.106 inch)
b) Coat the lip of the front transmission case oil seal with MP grease.

10. INSTALL TRANSAXLE CASE OIL SEAL
a) Using SST and a hammer, tap in a new oil seal to the front transaxle case.
SST 09710-20011 (09710-06071), 09950-70010 (09951-07150)
Standard depth: 1.6 to 2.2 mm (0.063 to 0.087 inch)
b) Coat the lip of the oil seal with MP grease.

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

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

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

NOTICE:
^ Prevent the No. 1 oil receiver pipe from being deformed.
^ Install the No. 1 oil receiver pipe while placing it against the transmission case, as shown in the illustration.

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

NOTICE:
^ Prevent the No. 2 oil receiver pipe from being deformed.
^ Install the No. 2 oil receiver pipe while placing it against the transmission case, as shown in the illustration.

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

NOTICE: Be sure to set the reverse restrict pin in the correct orientation.

b) Using a 5 mm pin punch and hammer, tap in the slotted pin to the reverse restrict pin.
Standard depth: 16.0 to 17.0 mm (0.6299 to 0.6693 inch)

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 torque wrench, install the reverse restrict pin plug to the transmission case.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)

16. INSTALL MANUAL TRANSAXLE CASE RECEIVER
a) Install the transaxle case receiver to the front transaxle case with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)

17. INSTALL DIFFERENTIAL CASE ASSEMBLY
a) Coat the differential case tapered roller bearing with gear oil, and install the differential case to the front transaxle case.

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

19. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
a) Coat the reverse idler gear, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.

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

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

b) Coat the No. 1 gear shift fork shaft 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 hammer, tap in a new shaft snap ring to the No. 1 gear shift fork shaft.

21. INSTALL NO. 3 GEAR SHIFT FORK SHAFT
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 No. 3 gear shift fork shaft.

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

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

22. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

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

NOTICE: To avoid the interference of the 2 shift fork balls, lift up the No. 3 gear shift fork shaft to the position shown in the illustration.

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

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

24. INSTALL MANUAL TRANSMISSION CASE
a) Apply FIPG to the 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 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.)

25. 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.)

26. INSTALL NO. 2 LOCK BALL ASSEMBLY
a) Coat the No. 2 lock ball 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.)

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

b) Coat the 2 shift detent ball plugs with sealant, and install them with 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 No. 1 shift detent ball spring seat to the front transaxle case.

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