Part 1

EB62 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY

1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, press in a new front differential case front tapered roller bearing to the differential case.

SST : 09316-20011

SST : 09950-60010

09951-00580

09952-06010

SST : 09950-60020

09951-00910

SST : 09950-40011

09957-04010

SST : 09950-70010

09951-07100

(b) Install the front differential oil baffle to the front transaxle case.

Text in Illustration

NOTICE:
Insert the front differential oil baffle key into the transaxle case groove.

(c) Using SST and a press, press in the front differential case front tapered roller bearing (outer race) to the front transaxle case.

Text in Illustration

SST : 09950-60010

09952-06010

SST : 09950-60020

09951-00780

09951-00890

SST : 09950-70010

09951-07100

2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

(a) Using SST and a press, press in a new front differential case rear tapered roller bearing to the differential case.

SST : 09316-20011

SST : 09950-60010

09951-00580

09952-06010

SST : 09950-60020

09951-00910

SST : 09950-40011

09957-04010

SST : 09950-70010

09951-07100

(b) Using SST, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate shim as shown in the illustration.

Text in Illustration

SST : 09950-60020

09951-00770

09951-00890

3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

(a) Coat the differential case assembly with gear oil and install it to the front transaxle case.

(b) Install the manual transmission case with the 17 bolts.

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

(c) Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

SST : 09564-50010

(d) Using SST and a torque wrench, measure the preload.

SST : 09564-50010

Standard preload (at starting):

New bearing
1.50 to 2.30 N*m (15 to 23 kgf*cm, 13 to 20 in.*lbf)

Used bearing
0.24 to 0.37 N*m (2.4 to 3.8 kgf*cm, 2.1 to 3.3 in.*lbf)

If the preload is not as specified, replace the front differential case rear plate shim with one of a different thickness. Use the table below to select a front differential case rear plate shim which will ensure that the preload is within the specification.

Standard Shim Thickness:

HINT
* Select a thicker plate shim to increase the preload, or a thinner plate shim to decrease the preload.
* Make a memo as the torque values will be needed for the Adjust Output Shaft Bearing Preload procedure.

(e) Remove the 17 bolts and manual transmission case.

(f) Remove the differential case from the front transaxle case.

(g) Replace the installed front differential case rear plate shim with the one selected above.

4. INSTALL FRONT OUTPUT SHAFT BEARING

(a) Install the output shaft cover onto the front transaxle case.

Text in Illustration

NOTICE:
Insert the output shaft cover key into the case groove.

(b) Using SST and a press, press in the front output shaft bearing (outer race) to the front transaxle case.

Text in Illustration

SST : 09950-60010

09951-00620

09952-06010

SST : 09950-60020

09951-00710

SST : 09950-70010

09951-07100

5. INSTALL REAR OUTPUT SHAFT BEARING

(a) Using SST and a press, press in the rear output shaft bearing (outer race) together with the rear output shaft bearing shim to the manual transmission case.

Text in Illustration

SST : 09950-60010

09951-00490

09951-00620

09952-06010

SST : 09950-70010

09951-07150

6. ADJUST OUTPUT SHAFT BEARING PRELOAD

(a) Coat the differential case assembly with gear oil and install it to the front transaxle case.

(b) Coat the output shaft assembly with gear oil and install it to the front transaxle case.

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

(d) Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

SST : 09564-50010

Text in Illustration

(e) Using SST and a torque wrench, measure the preload (value A). Calculate the rear output shaft bearing shim value using the following formula.

SST : 09564-50010

Formula:

Value A - Differential side bearing preload = Output shaft bearing preload

Preload (at starting):

New bearing
2.80 to 5.60 N*m (29 to 57 kgf*cm, 25 to 50 in.*lbf)

Used bearing
2.31 to 4.62 N*m (24 to 47 kgf*cm, 20 to 41 in.*lbf)

If the preload is not as specified, replace the rear output shaft bearing shim with one of a different thickness. Use the table below to select a rear output shaft bearing shim which will ensure that the preload is within the specification.

Standard Bearing Shim Thickness:

HINT
Select a thicker bearing shim to increase the preload, or a thinner bearing shim to decrease the preload.

(f) Remove the 17 bolts and manual transmission case.

(g) Remove the output shaft assembly from the front transaxle case.

(h) Remove the differential case from the front transaxle case.

(i) Replace the installed rear output shaft bearing shim with the one selected above.

7. INSTALL OUTER SHIFT LEVER OIL SEAL

(a) Using SST and a hammer, tap in a new outer shift lever oil seal to the manual transmission case.

Text in Illustration

SST : 09950-60010

09951-00280

SST : 09950-70010

09951-07100

Standard depth:

0.5 to 1.0 mm (0.0197 to 0.0393 in.)

(b) Coat the lip of the outer shift lever oil seal with MP grease.

8. INSTALL OUTER NO. 1 SHIFT LEVER

(a) Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.

(b) Using a (5 mm) pin punch and hammer, tap in the inner shift lever slotted spring pin to the inner No. 1 shift lever.

Standard depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

9. INSTALL NO. 1 OIL RECEIVER PIPE

(a) Install the No. 1 oil receiver pipe to the manual transmission case.

HINT
Make sure that the No. 1 oil receiver pipe fully contacts the manual transmission case.

10. INSTALL STRAIGHT PIN

(a) Using a plastic-faced hammer, tap in 5 new straight pins to the specified protrusion height.

Protrusion height:

10.5 to 11.5 mm (0.413 to 0.452 in.)

Text in Illustration

11. INSTALL BREATHER PLUG

(a) Using SST and a hammer, tap in the breather plug to the front transaxle case.

SST : 09350-30020

09350-07110

12. INSTALL FRONT TRANSAXLE CASE OIL SEAL

(a) Using SST and a hammer, tap in a new front transaxle case oil seal to the front transaxle case.

Text in Illustration

SST : 09612-22011

Standard depth:

1.0 to 2.0 mm (0.0393 to 0.0787 in.)

(b) Coat the lip of the front transaxle case oil seal with MP grease.

13. INSTALL TRANSMISSION MAGNET

(a) Clean the transmission magnet and install it to the front transaxle case.

14. INSTALL INPUT SHAFT COVER

(a) Install the input shaft cover to the manual transmission case.

Text in Illustration

NOTICE:
Insert the input shaft cover key into the manual transmission case groove.

15. INSTALL REAR INPUT SHAFT BEARING SHIM

(a) Install the rear input shaft bearing shim onto the manual transmission case.

NOTICE:
Apply MP grease to the shim to prevent it from falling off the case during assembly.

(b) Measure the distance between the end of the manual transmission case and rear input shaft bearing shim (Dimension A).

Text in Illustration

(c) Measure the distance between the end of the front transaxle case and installation surface of the front input shaft bearing (Dimension B).

(d) Measure the distance between both input shaft bearing outer races (Dimension C).

NOTICE:
Measure Dimension C when both bearings have no clearance.

(e) Calculate the rear input shaft bearing shim clearance using the following formula.

Formula:

(Dimension A + Dimension B) - Dimension C - Rear input shaft bearing shim thickness = Between 0 mm and 0.1 mm (0.00394 in.)

If the clearance is not as specified, replace the rear input shaft bearing shim with one of a different thickness. Use the table below to select a rear input shaft bearing shim which will ensure that the clearance is within the specification.

Standard Rear Input Shaft Bearing Shim Thickness:

(f) Coat the selected rear input shaft bearing shim with MP grease, and then replace the installed rear input shaft bearing shim with the one selected above.

NOTICE:
Do not apply MP grease to the oil grooves.

16. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Coat the differential case with gear oil and install it to the front transaxle case.

17. INSTALL INPUT SHAFT ASSEMBLY

(a) Apply gear oil to all sliding and rotating parts.

(b) Coat the No. 1 gear shift fork shaft with gear oil and install it onto the output shaft assembly.

Text in Illustration

(d) Temporarily install the output shaft with No. 1 gear shift fork shaft to the input shaft assembly, and tie them with a rope or string.

(e) Install the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies to the front transaxle case.