Part 2
MANUAL TRANSAXLE UNITINSTALLATION (STEPS 31-59)
32. INSTALL CLUTCH TUBE BRACKET
a. Install the clutch tube bracket with the bolt.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)
33. 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 transmission case.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
34. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING
a. Using a brass bar and hammer, tap in the shaft snap ring to the No. 1 gear shift fork shaft.
b. Using a brass bar and hammer, tap in the shaft snap ring to the No. 2 gear shift fork shaft.
35. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING
a. Using a snap ring expander, install the shaft snap ring.
36. INSTALL OUTPUT SHAFT REAR BEARING SHIM
a. Install the output shaft rear bearing shim to the output shaft.
37. INSTALL REAR BEARING RETAINER
a. Coat the 7 bolts with sealant, and using a T45 "Torx" socket, install the bearing retainer with the bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
38. INSTALL 5TH DRIVEN GEAR
a. Using SST, install the 5th driven gear to the output shaft.
SST 09309-12020
39. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
a. Coat the needle roller bearing with gear oil, and install it to the input shaft.
40. INSTALL 5TH GEAR
a. Coat the 5th gear with gear oil, and install it to the input shaft.
41. INSTALL NO. 3 TRANSMISSION CLUTCH HUB
a. Using SST, install the No. 3 transmission clutch hub 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 it.
b. Install the No. 3 transmission hub sleeve and No. 3 gear shift fork to the No. 3 transmission clutch hub.
c. Coat the shift fork set bolt with sealant, and install it to the No. 3 gear shift fork.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Select the No. 3 transmission clutch hub shaft snap ring that allows the minimum amount of axial play.
Using a brass bar and hammer, tap in the No. 3 transmission clutch hub shaft snap ring.
Standard clearance: 0.1 mm (0.004 inch) or less
Standard snap ring:
Standard snap ring
42. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 inch)
If the clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.
43. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the 5th gear thrust clearance.
Standard clearance: 0.10 to 0.65 mm (0.0039 to 0.0260 inch)
If the clearance is out of specification, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.
44. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
a. Engage the 2 gears simultaneously to lock the transmission.
b. Install a new transmission output shaft rear set nut.
Torque: 123 Nm (1,254 kgf-cm, 90 ft. lbs.)
c. Using a chisel and hammer, stake the rear set nut.
d. Disengage the 2 gears.
45. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
a. Apply FIPG to the transaxle case cover, 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 to the transaxle case with the 10 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
46. INSTALL DRAIN PLUG SUB-ASSEMBLY
a. Install a new gasket and the drain plug to the transmission case.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
47. INSTALL MANUAL TRANSMISSION FILLER PLUG
a. Install a new gasket and the filler plug to the transaxle case.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
48. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Coat the shift and select lever shaft with gear oil, and install it to the transmission case.
49. 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.)
50. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
a. Install a new gasket and the back-up light switch to the manual transmission case.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
51. INSTALL MANUAL TRANSMISSION BREATHER PLUG
a. Install a new gasket and the breather plug to the case.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
52. INSTALL NO. 1 LOCK BALL ASSEMBLY
a. Install the No. 1 lock ball to the transmission case.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
53. INSTALL CONTROL SHIFT LEVER
a. Install the control shift lever with the shift outer lever lever lock pin to the shift and select lever shaft.
b. Install the spring washer with the nut.
Torque: 6.4 Nm (65 kgf-cm, 57 inch lbs.)
54. INSTALL SELECTING BELLCRANK ASSEMBLY
a. Install the shift and select lever bush to the selecting bellcrank.
b. Coat the 2 bolts with sealant, and install the selecting bellcrank to the 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.)
55. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
a. Install a new O-ring to the hole cover.
b. Install the hole cover to the transmission case with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 48 ft. lbs.)
56. INSTALL CLUTCH RELEASE FORK BOOT
a. Install the clutch release fork boot to the transaxle case.
57. INSTALL RELEASE FORK SUPPORT
a. Using a deep socket wrench, install the release fork support to the transaxle case.
Torque: 47 Nm (480 kgf-cm, 35 inch lbs.)
58. 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 bearing clip.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
59. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Apply clutch spline grease to the input shaft spline.
b. Install the clutch release fork to the input shaft.