With C52 Transaxle/2WD

HINT: Coat all of the sliding and rotating surface with gear oil before assembly.




1. MEASURE DIFFERENTIAL SIDE BEARING PRELOAD




2. INSTALL MAGNET TO TRANSAXLE CASE
3. INSTALL DIFFERENTIAL CASE ASSEMBLY




4. INSTALL INPUT AND OUTPUT SHAFTS
Install the input and output shafts together.




5. INSTALL REVERSE IDLER GEAR, THRUST WASHER AND SHAFT
Install the reverse idler gear, thrust washer and shaft as shown.




6. INSTALL REVERSE SHIFT ARM BRACKET
a. Install the reverse shift arm bracket as shown.
b. Install and torque the two bolts.

Torque: 17 N-m (175 kgf-cm, 13 ft-lbf)




7. INSTALL SHIFT FORKS AND SHIFT FORK SHAFTS
a. Place the No.1 and No.2 shift forks into the groove of No.1 and No.2 hub sleeves.




b. Install the No.1 fork shaft into the No.1 shift fork hole.




c. Install the two balls into the reverse shift fork hole.




d. Install the No.3 fork shaft and the reverse shift fork.




e. Install the No.2 fork shaft and the shift head.




f. Install and torque the three bolts.

Torque: 16 N-m (160 kgf-cm, 12 ft-lbf)




g. Using a screwdriver and hammer, tap in the three snap rings.




8. INSTALL TRANSAXLE CASE
a. Remove the any packing material and be careful not to drop oil on the contacting surface of the transaxle case or transaxle case.
b. Apply seal packing to the transaxle case as shown in the figure.

Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent




c. Install and torque the sixteen bolts.

Torque: 29 N-m (300 kgf-cm, 22 ft-lbf)




9. INSTALL LOCK BALL ASSEMBLY
a. Apply sealant to the lock ball assembly thread.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST, tighten the lock ball assembly.
SST 09313-30021




10. INSTALL BALLS, SPRINGS, SEATS AND PLUGS
a. Install the balls, springs and seats into the holes.
b. Apply sealant to the plugs threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent




c. Using SST, tighten the three plugs.
SST 09313-30021

Torque: 25 N-m (250 kgf-cm, 18 ft-lbf)




11. INSTALL AND TORQUE REVERSE IDLER GEAR SHAFT LOCK BOLT

Torque: 29 N-m (300 kgf-cm, 22 ft-lbf)




12. INSTALL BEARING SNAP RINGS
Using a snap ring expander, install the two snap rings.

HINT: If it is difficult to install the snap rings, pull the shafts.




13. INSTALL SNAP RING TO NO.2 FORK SHAFT
Using a screwdriver and hammer, tap in the snap ring.




14. INSTALL REAR BEARING RETAINER
Install and torque the five bolts.

Torque: 19 N-m (195 kgf-cm, 14 ft-lbf)




15. INSTALL FIFTH DRIVEN GEAR
Using SST, install the 5th driven gear. SST 09309-12020




16. INSTALL SPACER, NEEDLE ROLLER BEARING, FIFTH GEAR AND SYNCHRONIZER RING
a. Install the spacer.
b. Apply gear oil to the needle roller bearing.
c. Install the needle roller bearings.




d. Install the 5th gear and synchronizer ring.




17. INSTALL NO.3 CLUTCH HUB INTO HUB SLEEVE
a. Install the three key springs and shifting keys.
b. Install the hub sleeve to the clutch hub.




18. INSTALL NO.3 HUB SLEEVE ASSEMBLY WITH NO.3 SHIFT FORK
a. Using SST and a hammer, drive in No.3 hub sleeve with shift fork.
SST 09636-20010

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




19. MEASURE FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 in.)




20. INSTALL SNAP RING




a. Select a snap ring that will minimum axial play.




b. Using a screwdriver and hammer, tap in the snap ring.




21. INSTALL BOLT

Torque: 16 N-m (160 kgf-cm, 12 ft-lbf)




22. INSTALL LOCK NUT
a. Engage the gear double meshing.
b. Install and torque the nut.

Torque: 118 N-m (1,200 kgf-cm, 87 ft-lbf)

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




23. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Place a new gasket in position on the control shaft cover.
b. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Install the shift and select lever shaft and torque the bolts.

Torque: 20 N-m (200 kgf-cm, 14 ft-lbf)




24. INSTALL LOCK BOLT
Install and torque the lock bolt.

Torque: 29 N-m (300 kgf-cm, 22 ft-lbf)




25. INSTALL TRANSMISSION CASE COVER
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 nine bolts.

Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)




26. INSTALL FRONT BEARING RETAINER
Using a torx wrench, install the three torx screws. Torx wrench T30 09042-00010




27. INSTALL SELECTING BELLCRANK
28. INSTALL CONTROL LEVER HOUSING SUPPORT BRACKET
29. INSTALL BACK-UP LIGHT SWITCH
Install and torque the back-up light switch.

Torque: 40 N-m (410 kgf-cm, 30 ft-lbf)

30. INSTALL SPEEDOMETER DRIVEN GEAR




31. INSTALL RELEASE FORK AND BEARING
a. Apply molybdenum disulphide lithium base grease to the following parts.
Release bearing hub inside groove Install shaft spline Release fork contact surface
b. Apply MP grease to the front surface of the release bearing.
c. Install the release fork and bearing to the transaxle.