5TH/REVERSE GEAR AND HOUSING PARTS ASSEMBLY

B3E051501029105

Note
•  Type A and B may differ in the construction of the reverse lockout mechanism.

1.  Assemble in the order indicated in the table.

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1
Control rod
2
Control end
3
1st/2nd shift fork
4
Control lever
5
Interlock sleeve
6
3rd/4th shift fork
7
Clutch hub
8
Synchronizer key
9
Clutch hub sleeve
10
Synchronizer key spring
11
Clutch housing
12
Differential component
13
Secondary shaft gear component
(See Primary Shaft Gear Component and Secondary Shaft Gear Component Assembly Note.)
14
Primary shaft gear component
(See Primary Shaft Gear Component and Secondary Shaft Gear Component Assembly Note.)
15
Shift fork and control rod component
(See Shift Fork and Control Rod Component Assembly Note.)
16
Spring
17
Push pin
18
Crank lever component
(See Crank Lever Component and Crank Lever Shaft Assembly Note.)
19
O-ring
20
Crank lever shaft
(See Crank Lever Component and Crank Lever Shaft Assembly Note.)
21
Pin
22
5th/reverse shift rod end
(See 5th/Reverse Shift Rod End and 5th/Reverse Shift Rod Assembly Note.)
23
5th/reverse shift rod
(See 5th/Reverse Shift Rod End and 5th/Reverse Shift Rod Assembly Note.)
24
Reverse idle gear
(See Reverse Idle Gear and Reverse Idle Shaft Assembly Note.)
25
Reverse idle shaft
(See Reverse Idle Gear and Reverse Idle Shaft Assembly Note.)
26
Magnet
27
Transaxle case component
(See Transaxle Case Component Assembly Note.)
28
Neutral switch
29
Back-up light switch
30
Guide bolt
31
Lock bolt
32
Secondary 5th gear
33
Gear sleeve
34
Primary 5th gear
35
5th synchronizer ring
36
5th/reverse clutch hub component
(See 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note.)
37
5th/reverse shift fork
(See 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note.)
38
Reverse synchronizer ring
39
Reverse synchronizer cone
40
Reverse synchronizer gear sleeve
41
Locknut (secondary shaft)
(See Locknut Assembly Note.)
42
Locknut (primary shaft)
(See Locknut Assembly Note.)
43
Rear cover


Primary Shaft Gear Component and Secondary Shaft Gear Component Assembly Note

1.  Install the primary shaft gear component and the secondary shaft gear component together.

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Shift Fork and Control Rod Component Assembly Note

1.  Shift to 2nd gear and position the shift fork and shift rod component as shown.

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2.  Insert the spring into the reverse lever shaft, install the push pin, and place a scraper so that it contacts the push pin.

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3.  With the edge of the control end against the scraper, when the control end is pushed in the direction of the arrow in the figure so that the push pin goes into the shaft, the rod will at the same time line up with the shift rod coupling hole in the clutch housing.

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4.  Set each clutch hub sleeve to the neutral position, and tap the shift rod from above so that the push pin goes into the center groove (of the three grooves in the control end).

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5.  Pull the ball part of the control end outward so that the push pin goes into the detent in the groove.


Crank Lever Component and Crank Lever Shaft Assembly Note

Note
•  Use a new O-ring for the crank lever shaft.

1.  Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank lever.

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2.  Align the pin holes of the crank lever shaft and the clutch housing, and insert a new pin.

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5th/Reverse Shift Rod End and 5th/Reverse Shift Rod Assembly Note

1.  Put the protrusion of the reverse lever into the slot of the shift rod end.

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2.  Insert the shift rod into the shift rod end.

3.   Place the shift rod end installation bolt in its installation position, and tighten the bolt by rotating the shift rod.

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Tightening torque
12—14 N·m {1.3—1.4 kgf·m, 8.8—10.3 ft·lbf}


Reverse Idle Gear and Reverse Idle Shaft Assembly Note

1.  Align the reverse idler gear lock bolt installation hole and the alignment mark of the clutch housing.

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2.  Apply oil to the surface areas where the reverse idler shaft and the reverse idler gear slide against each other.

3.  Verify that the teeth of the reverse shift lever and the reverse idler gear sleeve are meshed.


Transaxle Case Component Assembly Note

1.  Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case, and tighten the transaxle case installation bolts to the specified torque.

Tightening torque
19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf}


5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note

1.  Verify that the clutch hub, synchronizer key, and clutch hub sleeve are properly assembled.

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Synchronizer key
A: 17.00 mm {0.669 in}
B: 4.25 mm {0.167 in}
C: 5.00 mm {0.197 in}
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2.  Install the 5th/reverse clutch hub component and the 5th/reverse shift fork together.

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Locknut Assembly Note

1.  Shift to 1st gear.

2.  Lock the primary shaft using the SST.

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3.  Tighten new lock nuts onto the primary and secondary shafts.

Tightening torque
130—210 N·m {13.3—21.4 kgf·m, 96—154 ft·lbf}

4.  Stake the locknuts.

5.  Measure the 5th gear thrust clearance using a dial indicator.

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•  If it exceeds the maximum specification, reassemble the transaxle.
Standard clearance
0.06—0.26 mm {0.0024—0.0102 in}
Maximum clearance
0.31 mm {0.0122 in}