Part 2

MANUAL TRANSAXLE UNIT

COMPONENTS:

REASSEMBLY (STEPS 28-54)

28. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING
a) Using a snap ring expander, install a new hole snap ring to the input shaft.

29. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING
a) Using a snap ring expander, install a new hole snap ring to the output shaft.

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

31. INSTALL REAR BEARING RETAINER
a) Coat the 5 bolts with sealant, and install the rear bearing retainer to the transmission case with the 5 bolts.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.)

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

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

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

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

36. INSTALL NO. 3 TRANSMISSION CLUTCH HUB
a) Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs to the No. 3 transmission clutch hub 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, tap in the No. 3 clutch hub to the input shaft.
SST 09636-20010

NOTICE:
^ Do not install the No. 3 transmission clutch hub with it facing in the wrong direction.
^ Install the No. 3 transmission clutch hub, checking the positions of the No. 3 synchronizer ring key groove and the No. 3 synchromesh shifting key.
^ Check that the 5th gear is rotating.
^ Place a suitable sized wooden block to support the input shaft.

c) Select a No. 3 clutch hub shaft snap ring that will allow minimum axial play.
Standard clearance: 0.1 mm (0.004 inch) or less
Standard snap ring thickness

Standard snap ring thickness:

d) Using a brass bar and hammer, tap the snap ring onto the input shaft.

37. INSPECT 5TH GEAR THRUST CLEARANCE
a) Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.1 to 0.57 mm (0.0039 to 0.0224 inch)
Maximum clearance: 0.57 mm (0.0224 inch)
If the clearance is greater than the maximum, replace the gear, needle roller bearing or shaft.

38. INSPECT 5TH GEAR RADIAL CLEARANCE
a) Using a dial indicator, measure the radial clearance.
Standard clearance

Standard clearance:

Maximum clearance

Maximum clearance:

If the clearance is greater than the maximum, replace the gear, needle roller bearing or shaft.

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

HINT: Be sure to set the No. 3 transmission clutch hub in the correct orientation.

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

40. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
a) Engage the 2 gears simultaneously to lock the transmission.
b) Install a new set nut.
Torque: 118 Nm (1200 kgf-cm, 87 ft. lbs.)

c) Using a chisel and hammer, stake the set nut.
d) Disengage the 2 gears.

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

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

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

43. INSTALL NO. 1 LOCK BALL ASSEMBLY
a) Coat the No. 1 lock ball with sealant, and install it 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.)

44. INSTALL SELECTING BELLCRANK ASSEMBLY
a) Install the selecting bellcrank with control shift lever bush to the transmission case with the 2 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

NOTICE: Apply MP grease to the inside circumferential surface of the control shift lever bush (A).

45. 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.)

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

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

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

49. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
a) Coat the clutch release bearing with release hub grease, and install it to the clutch release fork with the clutch release fork bearing hub clip.
Release hub grease: Part No. 08887-01806, RELEASE HUB GREASE or equivalent

50. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
a) Install the clutch release fork to the input shaft.
b) Apply clutch spline grease to the spline of the input shaft.
Clutch spline grease: Part No. 08887-01806, CLUTCH SPLINE GREASE or equivalent
51. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
a) Install a new O-ring to the driven hole cover.
b) Install the driven hole cover to the transaxle case with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)

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

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

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