Part 1

REASSEMBLY

1. INSTALL SYNCHRONIZER PULL RING
(a) Install the synchronizer middle ring No.5, synchronizer ring outer No.5 and synchronizer pull ring to the synchronizer ring inner No. 5. Using a screwdriver, fix them with the snap ring.

2. INSTALL SYNCHROMESH SHIFTING KEY SPRING NO.3
(a) Install the synchromesh shifting key spring No.3 to the transmission clutch hub No.3.

NOTICE: Align the projection of the shifting key spring with the hole of the clutch hub No.3 and install.

(b) Install the synchronizer ring set and synchromesh shifting key spring No.3 to the transmission clutch hub No.3.

NOTICE:
^ Engage the shifting key spring claw to the center of the teeth of the synchronizer ring.
^ Align the projection of the shifting key spring with the hole of the clutch hub No.3 and install.

3. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL
(a) Using SST and a hammer, install the front transaxle case cover new oil seal.
SST 09316-20011, 09950-60020 (09951-00910), 09950-70010 (09951-07150)
Oil seal driven in depth: -0.5 to 0.5 mm (-0.020 to 0.020 inch)
(b) Coat the front transaxle case cover oil seal lip with MP grease.

4. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using SST and a hammer, install the FR differential case front tapered roller bearing (outer race) to the front transaxle case.
SST 09950-60020 (09951-00910), 09950-70010 (09951-07100)

(b) Using SST and a press, install the FR differential case front tapered roller bearing (inner race) to the front differential case.
SST 09950-70010 (09951-07100, 09951-07150), 09608-10010

5. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Install the front differential case shim rear.
(b) Using SST and a hammer, install the FR differential case rear tapered roller bearing (outer race).
SST 09950-60020 (09951-00890), 09950-70010 (09951-07100)

(c) Using SST, install the FR differential case rear tapered roller bearing (inner race).
SST 09631-12090, 09950-60010 (09951-00600), 09950-70010 (09951-07100)

6. INSTALL TRANSMISSION CASE OIL SEAL
(a) Using SST and a hammer, install the transmission case new oil seal to the manual transmission case.
SST 09608-32010, 09950-70010 (09951-07150)
Oil seal driven in depth: 3.5 ± 0.5 mm (0.138 ± 0.020 inch)
(b) Coat the transmission case oil seal lip with MP grease.

7. INSTALL OUTPUT SHAFT REAR BEARING
(a) Using SST and a hammer, install the output shaft rear bearing (outer race) to the manual transmission case.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)
Clearance: 3.8 to 4.4 mm (0.150 to 0.173 inch)

8. INSTALL OUTPUT SHAFT (MTM) COVER
(a) Coat the output shaft (MTM) cover with MP grease, and install it to the manual transaxle case.

NOTICE: Align the projection of the output shaft with the transmission groove and install.

9. INSTALL OUTPUT SHAFT FRONT BEARING
(a) Using SST and a hammer, install the output shaft front bearing (outer race).
SST 09950-60020 (09951-00730), 09950-70010 (09951-07100)

10. ADJUST OUTPUT SHAFT BEARING PRELOAD
(a) Install the output shaft to the manual transaxle case.

(b) Install the transmission case to the manual transaxle case with the 14 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)

(d) Install the output shaft rear bearing case shim to the output shaft.

(e) Using a "TORX" socket wrench (T45), install the bearing retainer rear with the 7 screws to the manual transmission case.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

(f) Turn the output shaft in both directions to make sure that it starts to turn smoothly.
(g) Using a socket wrench and torque wrench, inspect the preload.

Preload: Nm (kgf-cm, inch lbs.):

(h) If the preload is out of specification, select a proper output shaft rear bearing shim and adjust it.

HINT: The preload of all the output shaft rear bearing shim varies in torque from about 0.04 to 0.06 Nm (0.408 to 0.612 kgf-cm, 0.35 to 0.53 inch lbs.).

Shim: mm (inch):

(i) Remove the output shaft rear set nut from the output shaft.

(j) Using a "TORX" socket wrench (T45), remove the 7 screws and bearing retainer rear from the manual transmission case.

(k) Remove the output shaft rear bearing shim from the output shaft.

(l) Remove the 3 bolts.

(m) Remove the 14 bolts and manual transmission case from the manual transaxle case.

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

11. ADJUST TAPERED ROLLER BEARING PRELOAD
(a) Install the differential case assembly to the manual transaxle case.

(b) Install the 14 bolts and manual transmission case to the manual transaxle case.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)

(c) Install the 3 bolts on the front manual transaxle case side.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
(d) Turn the differential case in both directions to make sure that it starts to turn smoothly.

(e) Using SST and a torque wrench, inspect preload.
SST 09564-32011

Preload: Nm (kgf-cm, inch lbs.):

If the preload is out of specification, select a proper front differential case rear shim and adjust it.

HINT: The preload of all the front differential case rear shims varies in torque from about 0.04 to 0.06 Nm (0.408 to 0.612 kgf-cm, 0.35 to 0.53 inch lbs.).

Shim: mm (inch) (Part 1):

Shim: mm (inch) (Part 2):

(f) Remove the 3 bolts.

(g) Remove the 14 bolts and manual transmission case from the manual transaxle case.

(h) Remove the differential case assembly from the manual transaxle case.

12. INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, install the front transaxle case new oil seal No.1 to the manual transaxle case.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
(b) Coat the lip of the front transaxle case oil seal No.1 with MP grease.
Clearance: 1 to 2 mm (0.0394 to 0.0787 inch)

13. INSTALL INPUT SHAFT FRONT BEARING
(a) Coat the input shaft front bearing with gear oil, and install it to the manual transaxle case.
SST 09950-60010 (09951-00570), 09950-70010 (09951-07150)
Clearance: 4.28 to 4.60 mm (0.1685 to 0.1811 inch)

14. REMOVE MANUAL TRANSAXLE CASE RECEIVER
(a) Install the 3 bolts and manual transaxle case receiver to the manual transaxle case.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)

15. INSTALL DIFFERENTIAL CASE ASSEMBLY
(a) Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the manual transaxle case.

16. INSTALL OUTPUT SHAFT ASSEMBLY
(a) Apply gear oil to each sliding part of the output shaft assembly.
(b) Lift the differential case assembly up with the output shaft assembly leaned, and install it to the manual transaxle case.

17. INSTALL INPUT SHAFT ASSEMBLY
(a) Apply gear oil to each sliding part of the input shaft assembly.
(b) Install the input shaft assembly to the manual transaxle case while tilting the output shaft assembly.

18. INSTALL GEAR SHIFT FORK NO.2
(a) Coat the gear shift fork No.2 with gear oil, and install it to the input shaft assembly.

19. INSTALL GEAR SHIFT FORK NO.3
(a) Install the gear shift fork No.3 to the gear shift fork shaft No.3.
(b) Using a brass bar and hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft.

20. INSTALL GEAR SHIFT FORK NO.1
(a) Apply gear oil to each sliding part of the gear shift fork No. 1, and install it to the output shaft assembly.

21. INSTALL GEAR SHIFT FORK SHAFT NO.2
(a) Install the gear shift head No.1 to the gear shift fork shaft No.2.
(b) Apply gear oil to each sliding part of the gear shift fork shaft No.2, and install it to the manual transaxle case.

(c) Install the shift fork set bolt and shift head set bolt to the gear shift head No. 1.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)

22. INSTALL REVERSE SHIFT FORK ROLLER
(a) Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.

23. INSTALL GEAR SHIFT FORK SHAFT NO.1
(a) Using a brass bar and hammer, install the shift fork shaft snap ring to the shift fork shaft No. 1.

(b) Install the gear shift fork shaft No.1 to the manual transaxle case.

24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
(a) Install the 2 bolts and reverse shift arm bracket assembly to the manual transaxle case.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)

25. INSTALL REVERSE IDLER GEAR SUBASSEMBLY
(a) Coat the reverse idler gear and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft.

(b) Install the reverse idler gear to the manual transaxle case.

HINT: Align the mark of the reverse idler gear shaft with the hole of the bolt.