Assembly

Fig. 13 Exploded view of differential assembly. MR2:

Refer to Fig. 13, during assembly procedure.
1. Adjust differential side bearing preload as follows:
a. Install thinnest shim into transaxle case, then the side bearing outer race.
b. Install differential into transaxle case.
c. Assemble transaxle case, then insert attaching bolts and torque to 22 ft. lbs.
d. Measure side bearing preload. Preload should be 6.9-13.9 inch lbs. for new bearing or 4.3-8.7 inch lbs. on used bearing.

Fig. 15 Side bearing preload shim selective chart. MR2:

e. If preload is not within specifications, select a suitable adjusting shim from chart, Fig. 15, to bring preload to within specifications, then readjust preload as described.
2. Remove transmission case, then install input and output shafts as an assembly.
3. Place No. 1 and 2 shift forks into grooves of their hub sleeves, then insert No. 1 fork shaft into No. 1 shift fork hole. Insert two interlock balls into reverse shift fork hole, then install No. 3 fork shaft and reverse shift fork. Install No. 2 fork shaft and shift head, then insert 3 attaching bolts and torque to 12 ft. lbs. Install 3 snap rings.
4. Place reverse shift fork pivot into reverse shift arm, then install reverse shift arm into transaxle case. Install attaching bolts and torque to 13 ft. lbs.
5. Align mating marks and install reverse idler gear and shaft.
6. Apply a suitable sealant to transaxle case, then assemble case and insert 16 attaching bolts. Torque attaching bolts to 22 ft. lbs.
7. Insert balls, springs and seats into their respective bores, then apply a suitable sealant to plugs and lock ball assembly. Torque straight screw plug to 18 ft. lbs. and the lock ball assembly to 29 ft. lbs.
8. Install reverse idler gear lock bolt, then torque to 29 ft. lbs.
9. Install two bearing snap rings, then the No. 2 shift fork snap ring.
10. Install rear bearing retainer attaching bolts, then torque to 14 ft. lbs.
11. Install 5th driven gear.
12. Install 5th gear spacer, then apply a suitable lubricant to needle roller bearing. Install 5th gear with bearing and synchronizer ring.
13. Install No. 3 clutch hub and shifting keys onto hub sleeve, then insert shifting key springs under shifting keys.
14. Drive in No. 3 hub sleeve with shift fork, then align synchronizer ring slots with shifting keys.

Fig. 16 5th gear snap ring selective chart. MR2:

15. Measure 5th gear thrust clearance. Clearance should be .0039-.0224 inch. If clearance is not as specified, select a suitable snap ring from chart, Fig. 16, that will allow minimum axial play, then install onto shaft.
16. Engage double meshing gear, then install locknut and torque to 87 ft. lbs. Stake lock nut.
17. Install 5th gear synchronizer ring bolt, then torque to 12 ft. lbs.
18. Apply a suitable lubricant to selector lever shaft, then insert snap ring. Install spring seat, compression spring, then the select inner lever. Drive in slotted spring pin using a mallet and suitable drift. Install compression spring, spring seat and E-ring.
19. Install shift and select lever shaft assembly, then the lock bolt.
20. Place control shaft retainer into position, then install control shaft retainer.
21. Install control shaft oil seal boot, positioning air bleed of boot downward. Fit pin groove into shaft notch, then tap with suitable mallet. Install nut, then torque to 9 ft. lbs.
22. Install selecting bellcrank.
23. Apply a suitable sealant to transaxle case, then assemble case. Insert 9 attaching bolts, then torque to 13 ft. lbs.
24. Install front bearing retainer, then torque to 8 ft. lbs.
25. Apply molybdenum disulphide lithium base grease to the release bearing hub inner groove, input shaft spline, then the release fork contact surface. Install back-up lamp switch, then torque to 30 ft. lbs.
26. Install speedometer driven gear.