Part 1

E351 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY

1. INSTALL SYNCHRONIZER PULL RING





(a) Install the No. 5 synchronizer ring middle, No. 5 synchronizer ring outer and synchronizer pull ring to the No. 5 synchronizer ring inner. Using a screwdriver, fix them in place with the synchronizer pull ring snap ring.

2. INSTALL NO. 5 SYNCHRONIZER RING MIDDLE





(a) Check that the No. 5 synchronizer ring middle rotates smoothly.

(b) Check that the No. 5 synchronizer ring middle does not rotate while being pushed against the No. 3 clutch hub.





3. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY SPRING





(a) Install the No. 3 synchromesh shifting key spring to the No. 3 transaxle clutch hub.

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

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

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 No. 3 clutch hub and install it.

4. INSTALL TRANSAXLE CASE OIL SEAL





(a) Using SST and a hammer, tap in a new front transaxle case cover oil seal.

SST : 09316-20011

SST : 09950-60020

09951-00910

SST : 09950-70010

09951-07150

Standard depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

(b) Coat the lip of the oil seal with MP grease.

5. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING





(a) Using SST and a hammer, tap in the front tapered roller bearing (outer race) to the front differential case.

SST : 09950-60020

09951-00910

SST : 09950-70010

09951-07100

09951-07150

(b) Using SST and a press, press in the front tapered roller bearing (inner race) to the front differential case.





SST : 09950-70010

09951-07100

09951-07150

SST : 09608-10010

6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING





(a) Install the rear shim.

(b) Using SST and a hammer, tap in the rear tapered roller bearing (outer race).

SST : 09950-60020

09951-00890

SST : 09950-70010

09951-07100

(c) Using SST and a press, press in the rear tapered roller bearing (inner race).





SST : 09631-12090

SST : 09950-60010

09951-00600

SST : 09950-70010

09951-07100

7. INSTALL TRANSMISSION CASE OIL SEAL





(a) Using SST and a hammer, tap in a new oil seal to the transaxle case.

SST : 09608-32010

SST : 09950-70010

09951-07150

Standard depth:

3.0 to 4.0 mm (0.118 to 0.158 in.)

(b) Coat the oil seal lip with MP grease.

8. INSTALL OUTPUT SHAFT REAR BEARING





(a) Using SST and a hammer, tap in the rear bearing (outer race) to the transaxle case.

SST : 09950-60020

09951-00680

SST : 09950-70010

09951-07100

Standard clearance:

3.8 to 4.4 mm (0.150 to 0.173 in.)

9. INSTALL OUTPUT SHAFT COVER





(a) Coat the shaft cover with MP grease, and install it to the transaxle case.

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

10. INSTALL OUTPUT SHAFT FRONT BEARING





(a) Using SST and a hammer, tap in the front bearing (outer race).

SST : 09950-60020

09951-00730

SST : 09950-70010

09951-07100

11. ADJUST OUTPUT SHAFT BEARING PRELOAD





(a) Install the output shaft to the transaxle case.

(b) Install the transaxle case to the transaxle case with the 14 bolts.





Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

(c) Install the 3 bolts on the transaxle side.





Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

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





(e) Using a T45 "TORX" socket, install the rear bearing retainer to the transaxle case with the 7 "TORX" screws.

Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)





(f) Turn the output shaft in both directions and check that it turns smoothly.





(g) Temporarily install the output shaft rear set nut.

(h) Using a socket wrench and torque wrench, inspect the preload.

Standard preload:





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

HINT
The preload of all the output shaft rear bearing shims varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.354 to 0.531 in.*lbf).

Standard shim thickness:





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

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





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





(m) Remove the 3 bolts.





(n) Remove the 14 bolts and transaxle case from the transaxle case.





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





12. ADJUST TAPERED ROLLER BEARING PRELOAD

(a) Install the bearing to the transaxle case.





(b) Install the 14 bolts and transaxle case to the transaxle case.





Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

(c) Install the 3 bolts on the front transaxle case side.





Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

(d) Turn the differential case in both directions and check that it turns smoothly.

(e) Using SST and a torque wrench, measure the preload.

SST : 09564-32011





Standard preload:





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

HINT
The preload of all the front differential case rear shims varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.354 to 0.531 in.*lbf).

Standard shim thickness:





(f) Remove the 3 bolts.





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





(h) Remove the bearing from the transaxle case.





13. INSTALL FRONT TRANSAXLE CASE OIL SEAL





(a) Using SST and a hammer, tap in a new oil seal to the transaxle case.

SST : 09950-60010

09951-00420

SST : 09950-70010

09951-07150

Standard distance:

1 to 2 mm (0.039 to 0.079 in.)

(b) Coat the lip of the oil seal with MP grease.

14. INSTALL INPUT SHAFT FRONT BEARING





(a) Coat the input shaft front bearing with gear oil, and using SST, tap in it to the transaxle case.

SST : 09950-60010

09951-00570

SST : 09950-70010

09951-07150

Standard distance:

4.28 to 4.60 mm (0.1685 to 0.1811 in.)

15. INSTALL MANUAL TRANSAXLE CASE RECEIVER





(a) Install the receiver to the transaxle case with the 3 bolts.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

16. INSTALL DIFFERENTIAL CASE ASSEMBLY





(a) Coat the differential case tapered roller bearing with gear oil, and install the differential case to the transaxle case.

17. INSTALL OUTPUT SHAFT ASSEMBLY





(a) Apply gear oil to each sliding part of the output shaft.

(b) Slightly lift up on the differential case at an angle, and install the output shaft to the transaxle case.

18. INSTALL INPUT SHAFT ASSEMBLY





(a) Apply gear oil to each sliding part of the input shaft.

(b) Install the input shaft to the transaxle case while tilting the output shaft.

19. INSTALL NO. 2 GEAR SHIFT FORK





(a) Coat the No. 2 gear shift fork with gear oil, and install it to the input shaft assembly.

20. INSTALL NO. 3 GEAR SHIFT FORK





(a) Install the reverse shift fork to the No. 3 gear shift fork shaft.

(b) Using a brass bar and hammer, tap in the 2 shift fork shaft snap rings to the No. 3 gear shift fork shaft.

(c) Apply gear oil to each sliding part of the No. 3 gear shift fork shaft, and install it to the transaxle case.