Part 2

17. INSTALL AND TORQUE REVERSE IDLER GEAR RETAINING BOLT WITH GASKET

Torque: 300 kg-cm (22 ft-lb, 29 N.m)




18. INSTALL LOCKING BALL, SPRING, SPRING SEAT AND SCREW PLUG
a. Install the locking ball, spring and spring seat.




b. Apply sealant to the screw plug.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Using SST, torque the screw plug.
SST 09313-30021
Torque: 250 kg-cm (18 ft-lb, 25 N.m)




19. INSTALL SNAP RINGS
Using a plastic hammer, install the two snap rings to the shift fork shafts.




20. INSTALL REAR BEARING RETAINER
a. Install the output shaft rear bearing outer race.




b. Install the adjust shim which is already finished output shaft preload.




c. Using snap ring pliers, install the snap ring to the input shaft rear bearing.




d. Apply sealant to the seven screws.
Sealant: Part No.08833-00070, THREE BOND 1324, LOCTITE 242 or equivalent
e. Using a torx wrench, torque the seven screws.
Torx wrench T45 09042-00050
Torque: 430 kg-cm (31 ft-lb, 42 N.m)




21. INSTALL FIFTH GEAR AND NO.3 CLUTCH HUB
a. Install the spacer, needle roller bearings and 5th gear.




b. Install the synchronizer ring and key spring to the No.3 clutch hub.




c. Using SST, install the No.3 clutch hub with synchronizer ring and key spring.
SST 09310-17010 (09310-07010, 09310-07020, 09310-07030)




d. Select a snap ring that will allow minimum axial play and install it on the shaft.




e. Using a dial indicator, measure the 5th gear thrust clearance.
Standard clearance: 0.10 - 0.57 mm (0.004 - 0.022 in.)




22. INSTALL FIFTH DRIVEN GEAR Using SST, install the 5th driven gear.
SST 09310-17010 (09310-07010, 09310-07020 09310-07040, 09310-07050)




23. INSTALL NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
a. Install the No.3 hub sleeve and No.3 shift fork.




b. Install and torque the set bolt.
Torque: 240 kg-cm (17 ft-lb, 24 N.m)




24. INSTALL LOCK NUT
a. Engage the gear double meshing.




b. Install and torque a new lock nut.
Torque: 1,250 kg-cm (90 ft-lb, 123 N.m)




c. Stake the lock nut.
d. Disengage the gear double meshing.




25. INSTALL TRANSMISSION CASE COVER
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case cover.

b. Apply seal packing to the transmission case as shown in the figure.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

HINT: Install the transmission case cover as soon as the seal packing is applied.




c. Install and torque the ten bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N.m)




26. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Install the shift and select lever shaft assembly and new gasket.
b. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Install and torque the four bolts.
Torque: 200 kg-cm (14 ft-lb, 20 N.m)




d. Install and torque the lock bolt with the new gasket.
Torque: 500 kg-cm (36 ft-lb, 49 N.m)




27. INSTALL NO.2 SELECTING BELLCRANK WITH SELECTING BELLCRANK SUPPORT
a. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Install and torque the two bolts.
Torque: 200 kg-cm (14 ft-lb, 20 N.m)




28. INSTALL BACK-UP LIGHT SWITCH
Install and torque the back-up light switch with the new gasket.

Torque: 410 kg-cm (30 ft-lb, 40 N.m)

29. INSTALL SPEEDOMETER DRIVEN GEAR




30. INSTALL RELEASE FORK AND BEARING
Apply molybdenum disulphide lithium base grease to the following part:
- Input shaft spline
- Release fork contact surface




31. INSTALL DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT
a. Apply MP grease to the intermediate shaft.
b. Using a plastic hammer, correctly drive the intermediate shaft straight until the top of it touches the differential pinion shaft.





HINT: Keeping the intermediate shaft on the pinion shaft of differential, measure the point in the illustration.

Protrusion length: 255.5 mm (10.959 in.)




32. INSTALL TRANSFER ASSEMBLY
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transfer or transaxle.
b. Apply seal packing to the transfer as shown in the figure.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

HINT: Install the transfer as soon as the seal packing is applied.




c. Install the transfer assembly to the transaxle assembly.

HINT: Shift into 4th gear, install the transfer assembly while turning the input shaft of the transaxle.




d. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
e. Install and torque the three bolts and five nuts.
Torque: 700 kg-cm (51 ft-lb, 69 N.m)