With S53 Transaxle/2WD

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

1. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD




2. INSTALL MAGNET TO TRANSAXLE CASE




3. INSTALL DIFFERENTIAL CASE ASSEMBLY




4. ASSEMBLE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS
a. Assemble the No.1 shift fork shaft, No.1 shift head, No.1 and No.2 shift forks.




b. Mount the shift forks to the vise.
c. Using a pin punch and hammer, drive in the slotted spring pin to the No.1 fork shaft as shown in the figure.




d. Coat the interlock pin with MP grease.
e. Using a screwdriver, install the interlock pin into the reverse shift fork hole.
f. Install the reverse shift fork to the No.1 shift fork shaft.

HINT: When installing the reverse shift fork with interlock pin to the No.1 shift fork shaft, make sure the interlock pin does not drop out.




g. Using a pin punch and hammer, drive in the slotted spring pin to the No.1 fork shaft.




5. INSTALL NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1, NO.2 SHIFT FORKS, REVERSE SHIFT FORK WITH INTERLOCK PIN, INPUT SHAFT ASSEMBLY OUTPUT SHAFT ASSEMBLY
Install the input shaft assembly and output shaft assembly together with the No.1 fork shaft, shift head and shift forks with the interlock pin to the transaxle case.




6. INSTALL NO.2 FORK SHAFT
a. Install the No. 2 fork shaft to the transaxle case through the reverse shift fork.




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: 13 N-m (130 kgf-cm, 9 ft-lbf)




7. INSTALL REVERSE SHIFT ARM
a. Put the reverse shift fork pivot into the reverse shift arm and install the reverse shift arm to the transaxle case.
b. Shift the reverse shift arm into the reverse.
c. Install and torque the two bolts.

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

d. Shift the reverse shift arm to the neutral position.




8. INSTALL REVERSE IDLER GEAR AND SHAFT
a. Install the washer and reverse idler gear to the shaft.




b. Install the reverse idler gear and shaft as shown.




9. INSTALL TRANSMISSION CASE
a. Remove the any packing material and be careful not to drop oil on the contacting surface of the transaxle case or transmission case.
b. Apply seal packing to the transmission case as shown.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent




c. Install and torque the seventeen bolts.

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




10. 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: 18 N-m (185 kgf-cm, 13 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 up the shafts.




13. INSTALL NO.1 FORK SHAFT SNAP RING
Using a screwdriver and hammer, tap in the snap ring.




14. 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: 42 N-m (430 kgf-cm, 31 ft-lbf)




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




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




17. INSTALL 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.




18. 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.

c. Install and torque the bolt to the No.3 shift fork.

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




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

Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)




20. INSTALL SHIFTING KEY RETAINER AND SNAP RING
a. Install the retainer.




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




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




21. INSTALL OUTPUT SHAFT LOCK NUT
a. Engage the gear double meshing.




b. Install and torque the new lock nut.

Torque: 123 N-m (1,250 kgf-cm, 90 ft-lbf)




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




22. INSTALL SHIFT AND SELECT LEVER ASSEMBLY
a. Apply seal packing to the underside of the flanged portion of the control shaft cover.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
b. Install the shift and select lever assembly and torque the control shaft cover.

Torque: 37 N-m (375 kgf-cm, 27 ft-lbf)




23. INSTALL NO.2 LOCK BALL ASSEMBLY
a. Apply sealant to the lock ball assembly threads.
Sealant: Part No.08833-00080. THREE BOND 1344. LOCTITE 242 or equivalent
b. Using SST, install and torque the plug.
SST 09313-30021

Torque: 23 N-m (230 kgf-cm, 17 ft-lbf)




24. INSTALL AND ADJUST NO.1 LOCK BALL ASSEMBLY
a. Fully loosen the lock nut.
b. Fully screw in the lock ball.
c. Loosen the lock ball to where the play at the shift outer lever tip is 0.1 - 0.5 mm (0.004 - 0.020 in.).




d. Hold the lock ball and tighten the lock nut.

Torque: 37 N-m (375 kgf-cm, 27 ft-lbf)

e. Check the shift outer lever tip play.

Lever tip play: 0.1 - 0.5 mm (0.004 - 0.020 in.)




25. INSTALL TRANSMISSION CASE COVER
a. Remove the any packing material and be careful not to drop oil on the contacting surface of the transmission case or transmission case cover.
b. Apply seal packing to the transmission case cover as shown.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent




c. Install the transmission case cover.
d. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
e. Install and torque the eight bolts.

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




26. INSTALL ENGINE MOUNT BRACKET AND SELECTING BELLCRANK
a. Install the engine mount bracket and torque the three bolts.

Torque: 52 N-m (530 kgf-cm, 38 ft-lbf)

b. Install the selecting bellcrank and two bolts.




27. INSTALL RELEASE BEARING RETAINER
Install the release bearing retainer and torque the three bolts.

Torque: 7.4 N-m (75 kgf-cm, 65 in-lbf)




28. INSTALL BACK-UP LIGHT SWITCH

Torque: 44 N-m (450 kgf-cm, 33 ft-lbf)

29. INSTALL SPEEDOMETER DRIVEN GEAR




30. INSTALL RELEASE FORK AND BEARING
a. Apply molybdenum disulphide lithium base grease to the following parts:
- Release bearing hub inside groove
- Input shaft spline
- Release fork contact surface
b. Apply MP grease to the front surface of the release bearing.