Manual Transmission/Transaxle Assembly

DISASSEMBLY
1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH
3. REMOVE BOLT AND VEHICLE SPEED SENSOR
4. REMOVE RELEASE BEARING RETAINER
Remove the 3 bolts and retainer.
5. REMOVE SELECTING BELLCRANK
Remove the 2 bolts and selecting bellcrank.
6. REMOVE TRANSMISSION CASE COVER
a. Remove the 8 bolts.
b. Using a plastic hammer, tap the transmission case cover and remove it.
7. REMOVE LOCK BALL ASSEMBLY
8. REMOVE SHIFT AND SELECT LEVER ASSEMBLY
9. REMOVE OUTPUT SHAFT LOCK NUT





a. Unstake the nut.
b. Engage the gear double meshing.





c. Rotate the lock nut clockwise and remove it.

HINT: The lock nut has LH threads.

d. Disengage the gear double meshing.
10. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
a. Remove the No.3 shift fork set bolt.
b. Remove the No.3 hub sleeve and No.3 shift fork.





11. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-40011





12. MEASURE 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 inch)
Maximum clearance: 0.45 mm (0.0177 inch)





13. MEASURE 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.
Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 inch)
Maximum clearance: 0.070 mm (0.0028 inch)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or input shaft.





14. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
a. Using 2 screwdrivers and a hammer, tap out the snap ring.
b. Using SST and a socket wrench, remove the No.3 clutch hub with the synchronizer ring.
SST 09950-30011
c. Remove the 5th gear.
15. REMOVE NEEDLE ROLLER BEARING





16. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and retainer.
17. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.

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

18. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET





19. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM
a. Remove the 6 bolts, retainer and shim.
b. Remove the O-ring from the differential side bearing retainer.
20. REMOVE TRANSMISSION CASE
a. Remove the 17 bolts.
b. Using a plastic hammer, tap the transmission case and remove it.





21. REMOVE REVERSE IDLER GEAR AND SHAFT
a. Pull out the shaft.
b. Remove the idler gear and thrust washer.
22. REMOVE REVERSE SHIFT ARM
a. Shift the fork shaft into reverse.
b. Remove the 2 bolts and pull off the reverse shift arm.
c. Shift the fork shaft into neutral.
23. REMOVE NO.2 SHIFT FORK SHAFT
a. Using a hexagon wrench, remove the straight screw plug.
b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Pull out the shaft.





24. REMOVE INTERLOCK PIN FROM NO. 1 SHIFT FORK SHAFT
Using a magnetic finger, remove the interlock pin from the No. 1 shift fork shaft.
25. REMOVE NO. 1 SHIFT FORK SHAFT, NO. 1 SHIFT HEAD, NO. 1 AND NO. 2 SHIFT FORKS, REVERSE SHIFT FORK AND INPUT AND OUTPUT SHAFTS ASSEMBLY
26. SEPARATE NO. 1 SHIFT FORK SHAFT, NO. 1 SHIFT HEAD, NO. 11, NO. 2 SHIFT FORKS AND REVERSE SHIFT FORK
a. Mount the shift forks to the vise.





b. Using a pin punch and hammer, drive out the 2 slotted spring pins from the No. 1 fork shaft.





c. Separate the No. 1 shift fork shaft, No. 1 shift head, No. 1 and No. 2 shift forks and reverse shift fork.
27. REMOVE DIFFERENTIAL CASE ASSEMBLY
28. REMOVE MAGNET FROM TRANSAXLE CASE





29. REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO. 3 CLUTCH HUB
a. Remove the No.5 synchronizer ring with the key spring from the No. 3 clutch hub.
b. Using a screwdriver, remove the snap ring.

HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.

c. Disassemble the synchronizer rings.

INSPECTION
1. INSPECT NO. 5 SYNCHRONIZER RING
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring. Turn the middle No. 5 synchronizer ring in one direction while pushing it to the outer No. 5 synchronizer ring. Check that the ring locks.
If the braking effect is insufficient, replace the synchronizer ring.





2. INSPECT NO. 3 SHIFT FORK AND NO. 3 HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
3. IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING
a. Remove the 2 bolts and transaxle case receiver.





b. Using SST, pull out the bearing.
SST 09308-00010





c. Using SST, press in a new bearing.
SST 09310-35010
d. Install the transaxle case receiver and torque the 2 bolts.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING
a. Remove the bolt and bearing lock plate.





b. Using SST, pull out the bearing.
SST 09308-00010
c. Remove the output shaft cover.





d. Install the output shaft cover.
e. Using SST, press in a new bearing.
SST 09310-35010
f. Install the bearing lock plate and torque the bolt.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





5. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL SEAL
a. Using a screwdriver, pry out the oil seal.
b. Using SST, drive in a new oil seal.
SST 09608-00081, 09950-70010 (09951-07150)
Drive in depth:
0 - 0.5 mm (0 - 0.020 inch)
c. Coat the lip of the oil seal with MP grease.





6. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
a. Using a hexagon wrench, remove the straight screw plug.
b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Replace the reverse restrict pin.
d. Using a pin punch and hammer, drive in the slotted spring pin.
Drive in depth: 13.5 ± 0.5 mm (0.531 ± 0.020 inch)
e. Apply sealant to the plug threads.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using a hexagon wrench, install and torque the straight screw plug.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)

REASSEMBLY

NOTICE: When working with FIPG material, you must observe the followings.
- Using a razor blade and a gasket scraper, remove all old FIPG material from the gasket surfaces.
- Thoroughly clean all components to remove all loose material.
- Clean both sealing surfaces with a non-residue solvent.
- Apply FIPG in an approximately 1 mm (0.04 inch) wide bead along the sealing surface.
- Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.

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

1. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
2. INSTALL NO. 5 SYNCHRONIZER RING WITH KEY SPRING TO NO. 3 CLUTCH HUB
a. Assemble the No. 5 synchronizer rings.





b. Using a screwdriver, install the snap ring.

HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.





c. Install the No. 5 synchronizer rings with the key springs to the No.3 clutch hub.

HINT: Align the holes of the clutch hub with the key spring.

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





5. ASSEMBLE NO. 1 SHIFT FORK SHAFT, NO. 1 SHIFT HEAD, NO. 1, NO. 2 SHIFT FORKS AND REVERSE SHIFT FORK
a. Assemble the No. 1 shift fork shaft, No. 1 shift head, No. 1 and No. 2 shift forks and reverse shift fork.
b. Mount the shift forks to the vise.
c. Using a pin punch and hammer, drive in the 2 slotted spring pins to the No. 1 fork shaft.
6. INSTALL NO. 1 SHIFT FORK SHAFT, NO. 1 SHIFT HEAD, NO. 1 AND NO. 2 SHIFT FORKS, REVERSE SHIFT FORK AND INPUT AND OUTPUT SHAFTS ASSEMBLY





7. INSTALL INTERLOCK PIN TO NO. 1 SHIFT FORK SHAFT
8. INSTALL NO. 2 SHIFT FORK SHAFT
a. Put in the shaft.
b. Using a pin punch and hammer, drive in the slotted spring pin.
c. Using a hexagon wrench, install the straight screw plug.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
9. INSTALL REVERSE SHIFT ARM
Install the reverse shift arm and 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
10. INSTALL REVERSE IDLER GEAR AND SHAFT
a. Install the idler gear and thrust washer.
b. Put in the shaft.
11. INSTALL TRANSMISSION CASE





a. Using a plastic hammer, tap the transmission case and install it.
FIPG:
Part No.08833-00090, THREE BOND 1281 or equivalent





b. Install the 17 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
12. INSTALL DIFFERENTIAL SIDE BEARING RETAINER AND SHIM
a. Install the O-ring to the differential side bearing retainer.
b. Install the shim, retainer and 6 bolts.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
13. INSTALL GASKET AND REVERSE IDLER GEAR SHAFT LOCK BOLT
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





14. INSTALL BEARING SNAP RING
Using a snap ring expander, install the 2 snap rings.

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

15. INSTALL REAR BEARING RETAINER
Install the retainer and 5 bolts.
Sealant: Part No. 08833-00080, THREE BOND 1324 or equivalent
16. INSTALL NEEDLE ROLLER BEARING





17. INSTALL 5TH DRIVEN GEAR
Using SST, install the 5th driven gear.
SST 09309-12020
18. INSTALL NO. 3 CLUTCH HUB AND 5TH GEAR
a. Install the 5th gear.





b. Using SST and a press, install the No. 3 clutch hub assembly.
SST 09612-22011





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

HINT: Select a snap ring that allows the minimum axial play.

19. MEASURE 5TH GEAR RADIAL CLEARANCE
20. MEASURE 5TH GEAR THRUST CLEARANCE
21. INSTALL NO. 3 HUB SLEEVE AND NO. 3 SHIFT FORK
a. Install the No. 3 hub sleeve and No. 3 shift fork.
b. Install the No. 3 shift fork set bolt.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
22. INSTALL OUTPUT SHAFT LOCK NUT
a. Engine the gear double meshing





b. Install the lock nut and rotate it counterclockwise.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)

HINT: The lock nut has LH threads.





c. Disengage the gear double meshing.
d. Stake the nut.
23. INSTALL SHIFT AND SELECT LEVER ASSEMBLY
Apply FIPG to the underside of the flanged portion of the control shaft cover.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
24. INSTALL LOCK BALL ASSEMBLY
Sealant:
Pad No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





25. INSTALL TRANSMISSION CASE COVER
a. Using a plastic hammer, tap the transmission case cover and install it.
FIPG:
Part No.08826-00090, THREE BOND 1281 or equivalent
b. Install the 8 bolts.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
26. INSTALL SELECTING BELLCRANK
Install the selecting bellcrank and 2 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
27. INSTALL RELEASE BEARING RETAINER
Install the retainer and 3 bolts.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
28. INSTALL BOLT AND VEHICLE SPEED SENSOR
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
29. INSTALL BACK-UP LIGHT SWITCH
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
30. INSTALL RELEASE FORK AND BEARING