Installation
ImportantInstall the pinion gears and the washers simultaneously.
1. Install the pinion gears and the washers.
Important
Use only a new pin.
2. Install the pinion shaft and the pin. Insert the shaft into the gear pin hole by rotating (1).
3. Install the differential assembly to the right side of the transaxle case. Install the countershaft RH bearing.
Important
Be careful not to damage the teeth of the countershaft pinion and the differential ring gear. Be careful not to damage the input shaft oil seal when inserting the gear unit by using the guide cap (recommended in Steps 2 of Preparation) if possible because the end of the shaft could damage the oil seal.
4. Install the gear unit by matching it with the input and the countershaft hole.
5. Install the fifth-reverse gear shift shaft.
Important
Install the fifth-reverse gear shift shaft spring marked when removing.
6. Install the fifth-reverse gear shift shaft ball and spring.
Tighten
Tighten the bolt to 10-16 Nm (7-12 lb ft).
Important
Match the marking on the reverse idle gear shaft bolt hole with the protrusion of the transaxle case (right side).
7. Install the reverse idler gear shaft assembly (1) and the reverse gear shift lever.
Tighten
Tighten the bolts to 18-28 Nm (13-21 lb ft).
8. Install the gear shift and select shaft assembly.
A. Install the shift and select shaft oil seal.
B. Install the gear select spring assemblies.
C. Install the gear shift interlock plate.
D. Install the gear shift lever.
E. Install the fifth and reverse gear shift cam.
F. Install the return spring.
G. Install the shift and select shaft.
Important
When installing the inner and outer pins, the crevices of the two pins must be symmetrical with each other.
Use only new inner and outer pins.
9. Install the shift and select lever inner and outer pins.
Important
If the bolt could not be inserted, alignment between the interlock plate hole and the bolt could not be matched.
10. Tighten the interlock bolt a little bit.
11. Install the transaxle left side case to the transaxle. Coat the transaxle case with the recommended sealant (Three Bond 1215).
Tighten
Tighten the bolts to 15-22 Nm (11-16 lb ft).
12. Install the first-second gear shaft ball and spring.
Tighten
Tighten the bolt to 10-16 Nm (7-12 lb ft) (1).
13. Install the third-fourth gear shaft ball and spring.
Tighten
Tighten the bolt to 10-16 Nm (7-12 lb ft) (2).
14. Install the reverse idle gear shaft bolt.
Tighten
Tighten the bolt to 18-28 Nm (13-21 lb ft) (3).
15. Install the countershaft bearing shim.
Important
Position the machined boss side toward the side cover plate.
16. Install the left case plate and the countershaft fifth gear.
Important
Use only new screws.
Tighten
Tighten the screws to 6-7 Nm (53-62 lb in).
17. Install the input shaft fifth gear bearing and the fifth/synchronizer ring.
A. Insert the bearing into the input shaft.
B. Install the fifth gear, synchronizer ring and wave spring matching synchronizer's oil groove and input shaft punched mark (1).
18. Install the fifth gear fork to they synchronizer hub assembly.
Important
Position the longer boss side of the hub toward the inner side and match the synchronizer key and the hub groove with the input shaft punched mark.
19. Install the fifth gear fork and the synchronizer hub assembly to the input shaft.
Important
Use only a new shift fork pin.
20. Install the fifth gear shift fork pin.
A. Push the shift fork toward the fifth gear.
B. Install the shift fork pin using a pin punch and a hammer.
Important
Use only new snap rings and fork plug.
21. Install the input shaft fifth gear snap ring, the fifth gear shift fork snap ring and the guide ball.
A. Install the fifth gear synchronizer plate.
B. Install the fifth gear snap ring (3).
C. Install the fifth gear shift fork snap ring (2).
D. Install the guide ball.
E. Install the fifth gear shift fork plug (1). Tighten.
22. Tighten the fifth gear shift fork plug to 10-18 Nm (7-13 lb ft).
23. Install the countershaft fifth gear nut.
A. Push the shift fork toward the fifth gear.
B. Hold the input shaft using the input shaft holder DW220 - 120 (1).
Tighten
Tighten the fifth gear nut to 60-80 Nm (44-59 lb ft)
C. Caulk the nut using a chisel and a hammer.
24. Install the side cover. Coat the side cover with the recommended sealant (Three Bond 1215).
Tighten
Tighten the side cover bolts to 8-12 Nm (71-106 lb in).
25. Install the shift interlock bolt.
Tighten
Tighten the shift interlock bolt to 18-28 Nm (13-21 lb ft).
26. Install the backup light switch and the speedometer driven gear assembly.
Tighten
^ Tighten the backup light switch nut to 15-18 Nm (11-13 lb ft).
^ Tighten the speedometer driven gear assembly bolt to 4-7 Nm (35- 62 lb in).
27. Install the related clutch parts. Refer to Clutch.
28. Install the manual transaxle. Refer to Five-Speed Manual Transaxle.