Part 1

TL70 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY; 2013 MY FR-S [03/2012 -]

1. INSTALL NO. 3 GEAR SHIFT FORK SHAFT

(a) Install the No. 3 gear shift fork shaft to the No. 3 gear shift fork with a new bolt.

Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)

2. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

(a) Install the No. 1 gear shift fork shaft to the No. 1 gear shift fork with a new bolt.

Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)

(b) Using a brass bar and a hammer, install a new shift fork shaft shaft snap ring.

(c) Install the No. 1 gear shift fork shaft together with the No. 1 gear shift fork to the No. 3 gear shift fork shaft and No. 3 gear shift fork.

(d) Using a brass bar and a hammer, install a new shift fork shaft shaft snap ring.

3. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

(a) Install the No. 2 gear shift fork shaft to the No. 2 gear shift fork with a new bolt.

Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)

(b) Using a brass bar and a hammer, install a new shift fork shaft shaft snap ring.

4. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL

(a) Using SST and a hammer, install a new transmission front bearing retainer oil seal.

SST : 09950-60010

09951-00420

SST : 09950-70010

09951-07100

Installation depth:

11.1 to 11.9 mm (0.437 to 0.469 in.) (from the end surface of the front bearing retainer)

NOTICE:
* Do not damage the lip of the transmission front bearing retainer oil seal.
* Do not damage the front bearing retainer.

(b) Apply MP grease to the lip of the transmission front bearing retainer oil seal.

5. INSTALL REVERSE IDLER GEAR SHAFT

(a) Apply manual transmission gear oil to the reverse idle gear shaft, and then install it to the reverse idler gear sub-assembly.

6. INSTALL INPUT SHAFT

(a) Apply manual transmission gear oil to the input shaft bearing of the input shaft, and then install the input shaft to the output shaft.

7. INSTALL COUNTER SHAFT

(a) Tie the input shaft, output shaft, counter shaft, No. 1 gear shift fork shaft, No. 2 gear shift fork shaft and No. 3 gear shift fork shaft with a rope or belt.

(b) Install the input shaft, output shaft, counter shaft, reverse idler gear sub-assembly, reverse idler gear shaft, No. 1 gear shift fork shaft, No. 2 gear shift fork shaft and No. 3 gear shift fork shaft all together to the clutch housing.

(c) Using a new reverse idler gear shaft gasket and a new reverse idler gear shaft bolt, temporarily install the reverse idler gear shaft (clutch housing side).

(d) Using a snap ring expander, install a new front bearing shaft snap ring and a new No. 1 counter gear front bearing snap ring.

HINT
Install the snap rings to the input shaft and counter shaft.

(e) Remove the rope or belt.

8. INSTALL FRONT BEARING RETAINER

(a) Apply seal packing 1281 continuously to the front bearing retainer as shown in the illustration.

NOTICE:
Install it within 10 minutes of the seal packing application.

(b) Apply adhesive 1344 to the 2nd and 3rd pitches from the tip of new bolt.

Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)

NOTICE:
Install the front bearing retainer ensuring that the transmission front bearing retainer oil seal lip is not damaged.

9. INSTALL NO. 1 OIL RECEIVER PIPE

(a) Install the No. 1 oil receiver pipe.

NOTICE:
Confirm that the protrusions of the No. 1 oil receiver pipe are properly fitted in the grooves.

10. INSTALL MANUAL TRANSMISSION CASE

(a) Apply seal packing 1281 continuously to the manual transmission case as shown in the illustration.

NOTICE:
Install within 10 minutes of the seal packing application.

(b) Check the location of the knock pin, and then using a plastic hammer, install the manual transmission case.

(d) Install the manual transmission case and clamp with the 9 bolts.

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

(e) Install a new reverse idler gear shaft gasket and a new reverse idler gear shaft bolt (manual transmission case side).

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

(f) Securely tighten the reverse idler gear shaft bolt (clutch housing side).

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

(g) Using a snap ring expander, install a new output shaft bearing shaft snap ring.

11. INSTALL OUTPUT SHAFT REAR BEARING RETAINER

(a) Install the shift arm shoe to the output shaft rear bearing retainer.

(b) Apply adhesive 1324 to the 2nd and 3rd pitches from the tip of new bolt.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

12. INSTALL 6TH GEAR THRUST WASHER

(a) Install the gear thrust washer straight pin to the counter shaft.

(b) Apply manual transmission gear oil to the 6th gear thrust washer.

(c) As shown in the illustration, install the 6th gear thrust washer to the counter shaft.

13. INSTALL 6TH GEAR NEEDLE ROLLER BEARING

(a) Apply manual transmission gear oil to the 6th gear needle roller bearing, and then install the 6th gear needle roller bearing to the counter shaft.

14. INSTALL COUNTER 6TH GEAR

(a) Apply manual transmission gear oil to the counter 6th gear, and then install the counter 6th gear to the counter shaft.