Part 1

ASSEMBLY OF TRANSMISSION



1. IF INPUT SHAFT WAS REPLACED, DRIVE IN SLOTTED SPRING PIN
If the input shaft was replaced, drive the slotted spring pin in the input shaft to a depth of 5.0 mm (0.197 in.).




2. INSERT NO.2 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

NOTE: Install the key springs positioned so that their end gaps are not in line.




3. INSTALL THIRD GEAR, NEEDLE ROLLER BEARINGS, SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply ATF to the needle roller bearings.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.




c. Using a press, install the 3rd gear and No.2 hub sleeve.







4. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.




5. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)




6. INSTALL SYNCHRONIZER RING, SPACER, NEEDLE ROLLER BEARINGS, FOURTH GEAR AND RADIAL BALL BEARING
a. Install the spacer.
b. Apply ATF to the needle roller bearings.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.




d. Using SST, press in the 4th gear and radial ball bearing.
SST 09608-20012 (09608-03070)







7. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.




8. MEASURE FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 4th gear thrust clearance.
Standard clearance: 0.20 - 0.45 mm (0.0079 - 0.0177 in.)




9. IF OUTPUT SHAFT WAS REPLACED, DRIVE IN SLOTTED SPRING PIN
If the output shaft was replaced, drive the slotted spring pin in the output shaft to a depth of 5.0 mm (0.197 in.).




10. INSERT NO.1 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

NOTE: Install the key springs positioned so that their end gaps are not in line.




11. INSTALL THRUST WASHER, FIRST GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT SHAFT
a. Apply ATF to the needle roller bearing.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.




c. Using a press, install the 1st gear and No. 1 hub sleeve.







12. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.




13. MEASURE FIRST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance: 0.10 - 0.29 mm (0.0039 - 0.0114 in.)




14. INSTALL SPACER, SYNCHRONIZER RING, SECOND GEAR, NEEDLE ROLLER BEARING AND THIRD DRIVEN GEAR
a. Install the spacer.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
c. Apply ATF to the needle roller bearing.
d. Install the 2nd gear.




e. Using a press, install the 3rd driven gear.




15. MEASURE SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust clearance.
Standard clearance: 0.20 - 0.44 mm (0.0079 - 0.0173 in.)




16. INSTALL OUTPUT GEAR SPACER, FOURTH DRIVEN GEAR AND RADIAL BALL BEARING
a. Install the spacer.
b. Using SST, press in the 4th driven gear and bearing.
SST 09608-12010 (09608-00070)




17. INSTALL MAGNET




18. MEASURE DIFFERENTIAL SIDE BEARING PRELOAD

HINT: If the transmission case, transaxle case, differential side bearing, differential case, transaxle case side shim or side bearing retainer was replaced, install the thinnest shim into the transmission case.

(Follow the step 11 in "Inspection of Transmission Components".)
Inspection of Transmission Components

a. Install the differential to the transaxle case.
b. Install the transmission case.
c. Install and torque the case bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N.m)




d. Install the shim into the transmission case.
e. Install the bearing retainer without an O-ring.
f. Install and torque the retainer bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N.m)




g. Using SST and torque meter, measure the preload.
SST 09564-32011
Preload (starting): 10 - 16 kg-cm (8.7 - 13.9 in.-lb, 1.0 - 1.6 N.m)
If the preload is not within specification, remove the bearing retainer.
Select another shim.





NOTE: When selecting the shim begin with one of the thinner shims in the table below and work toward thicker one.

HINT: The preload will change about 3 - 4 kg-cm (2.6 - 3.5 in.-lb, 0.3 - 0.4 N.m) with each shim thickness.




19. REMOVE BEARING RETAINER, SHIM AND TRANSMISSION CASE
If the preload is adjusted within specification, remove the bearing retainer, shim and transmission case.
Be careful not to lose the adjusted shim.




20. INSTALL INPUT AND OUTPUT SHAFTS
Install the input shaft and output shaft together.




21. INSTALL NO.2 FORK SHAFT
a. Insert No.2 fork shaft to the transaxle case and align the slotted spring pin hole.
b. Using a pin punch and hammer, drive in the slotted spring pin.
c. Apply sealant to the plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent




d. Using SST, install the straight screw plug.
SST 09313-30021
Torque: 130 kg-cm (9 ft-lb, 13 N.m)




22. INSTALL REVERSE SHIFT FORK AND INTERLOCK PIN
a. Insert interlock pin into the reverse shift fork hole.




b. Install the reverse shift fork onto No.2 fork shaft.




23. INSTALL REVERSE SHIFT ARM
a. Put the reverse shift arm pivot into the reverse shift fork and install the reverse shift arm to the transaxle case.
b. Shift the reverse shift arm into reverse.




c. Install and torque the bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N.m)
d. Shift the reverse shift arm to neutral position.




24. INSTALL REVERSE IDLER GEAR AND SHAFT
Install the reverse idler gear and shaft as shown.




25. INSTALL NO.1 AND NO.2 SHIFT FORKS, NO.1 SHIFT HEAD AND NO.1 FORK SHAFT
a. Place No.1 and No.2 shift forks into the groove of No.1 and No.2 hub sleeves.




b. Hold No.1 shift head and insert No.1 fork shaft into the transaxle case through No.1 and No.2 shift forks, No.1 shift head and reverse shift fork.




c. Using a pin punch and hammer, drive the slotted spring pin into No.1 shift head.




d. Shift the fork shaft into reverse.
e. Using a pin punch and hammer, drive the slotted spring pin into No.1 fork shaft.




26. INSTALL TRANSMISSION CASE
a. Apply seal packing to the transmission case as shown in the figure.
Seal packing: Part No. 08826-00090. THREE BOND 1281 or equivalent
b. Install and torque the seventeen bolts.
Torque: 300 kg-cm (22 ft-lb. 29 N.m)




27. INSTALL SHIM AND SIDE BEARING RETAINER WITH O-RING
a. Install a new O-ring on the retainer.
b. Install the shim and retainer.
c. Apply sealant to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent




d. Install and torque the six bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N.m)




28. INSTALL AND TORQUE REVERSE IDLER GEAR SHAFT LOCK BOLT

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




29. INSTALL BEARING SNAP RINGS




30. INSTALL REAR BEARING RETAINER
a. Apply sealant to the bolt threads.
Sealant: Part No. 08833-00070, THREE BOND 1324, or equivalent
b. Install and torque the five bolts.
Torque: 210 kg-cm (15 ft-lb, 21 N.m)




31. INSTALL FIFTH DRIVEN GEAR Using SST, install the 5th driven gear.
SST 09309-32050




32. INSTALL SPACER, NEEDLE ROLLER BEARINGS, FIFTH GEAR AND SYNCHRONIZER RING
a. Install the spacer.
b. Apply ATF to the needle roller bearings.
c. Install the 5th gear with the needle roller bearings and synchronizer ring.




33. INSERT NO.3 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

NOTE: Install the key springs positioned so that their end gaps are not in line.




34. INSTALL NO.3 HUB SLEEVE ASSEMBLY WITH SHIFT FORK
a. Support the tip of the input shaft with a spacer or such to raise the transaxle assembly.
b. Using SST, drive in No.3 hub sleeve with shift fork.
SST 09612-22011

NOTE: Align the synchronizer ring slots with the shifting keys.




35. MEASURE FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)


CONTINUE TO PART 2. Part 2