Part 2

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

15. INSTALL NO. 4 SYNCHRONIZER RING

(a) Apply manual transmission gear oil to the No. 4 synchronizer ring, and then install the No. 4 synchronizer ring to the counter shaft.





16. INSTALL NO. 4 TRANSMISSION HUB SLEEVE

(a) Apply manual transmission gear oil to the moving parts of the No. 4 transmission clutch hub.









(b) As shown in the illustration, install the No. 4 transmission hub sleeve to the No. 4 transmission clutch hub, and install the 3 No. 1 synchromesh shifting keys and 3 No. 1 synchromesh shifting key springs all together, and then install the 3 synchromesh shifting key balls.

HINT
* Install the synchromesh shifting key ball while holding down the No. 1 synchromesh shifting key spring.
* After the installation, settle the No. 1 synchromesh shifting key spring.

(c) Install a new No. 4 clutch hub snap ring.





17. INSTALL NO. 4 TRANSMISSION CLUTCH HUB

(a) Attach the No. 4 gear shift fork as shown in the illustration and install the No. 4 transmission clutch hub, No. 4 transmission hub sleeve and No. 4 gear shift fork as a unit, using SST and a press.





SST : 09632-36010

HINT
* Align the No. 4 transmission clutch hub and the No. 4 synchronizer ring so that they can fit together.
* Engage the No. 4 gear shift fork with the groove of the No. 4 transmission hub sleeve.

18. INSTALL SHAFT SNAP RING

(a) Select a shaft snap ring that is suitable to retain the specific thrust clearance between the No. 4 transmission clutch hub and shaft snap ring.





Standard clearance:

0 to 0.1 mm (0 to 0.00394 in.)

HINT
Select the thickest shaft snap ring possible for installation.

Shaft Snap Ring Thickness





(b) Using a brass bar and a hammer, install a new shaft snap ring to the counter shaft.





19. INSTALL NO. 2 GEAR SHIFT HEAD

(a) Install the No. 2 gear shift head to the No. 2 gear shift fork shaft.





(b) Using a 5 mm pin punch and a hammer, install a new slotted spring pin to the No. 2 gear shift fork shaft.

NOTICE:
Do not tap the pin too deep.

Standard depth:

0 mm (0 in.) (from the end surface of the No. 2 gear shift head)

20. INSTALL REVERSE AND 5TH SHIFT HEAD

(a) Install the shift detent ball compression spring to the reverse and 5th shift head, and then, while holding down the shaft detent ball with the 5 mm pin punch, install the reverse and 5th shift head to the No. 4 gear shift fork shaft.





(b) Install the washer.





(c) Using a brass bar and a hammer, install a new shift fork shaft shaft snap ring to the No. 4 gear shift fork shaft.





21. INSTALL NO. 4 GEAR SHIFT FORK SHAFT

(a) As shown in the illustration, insert the No. 4 gear shift fork shaft. Using a T40 "TORX" socket wrench, install the shaft detent ball and No. 2 shift detent ball compression spring, and then tighten with a new No. 1 straight screw plug.





Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

22. INSTALL REVERSE SHIFT ARM

(a) Install the reverse shift arm to the shift arm shoe.





NOTICE:
Do not slide the No. 4 gear shift fork shaft up more than necessary as the shaft detent ball may fall into the transmission case.

(b) Using a brass bar and a hammer, install a new shift arm shoe E-ring to the shift arm shoe.





23. INSTALL NO. 5 GEAR SHIFT FORK SHAFT

(a) Using a screwdriver, install the 2 shaft detent balls to the No. 4 gear shift fork shaft.





HINT
Support the shaft detent ball with the screwdriver so that the shaft detent ball does not fall off.

(b) While the identification hole is facing towards the outside, insert the No. 5 gear shift fork shaft. And then, using a T40 "TORX" socket wrench, install the shaft detent ball and No. 2 shift detent ball compression spring, and then tighten 2 new No. 1 straight screw plugs.









Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

(c) Using a 5 mm pin punch and a hammer, install a new slotted spring pin to the No. 5 gear shift fork shaft.





NOTICE:
Do not tap the pin too deep.

Standard depth:

0 mm (0 in.) (from the end surface of the No. 4 gear shift fork)

24. INSTALL NO. 3 GEAR SHIFT HEAD

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





HINT
While rotating, install the No. 3 gear shift head so that the shift arm is engaged with the groove of the No. 3 gear shift head.

(b) Using a 5 mm pin punch and a hammer, install a new slotted spring pin to the No. 3 gear shift fork shaft.

NOTICE:
Do not tap the pin too deep.

Standard depth:

0 mm (0 in.) (from the end surface of the No. 3 gear shift head)

25. INSTALL NO. 1 GEAR SHIFT HEAD

(a) Install the No. 1 gear shift head to the No. 1 gear shift fork shaft.





(b) Using a 5 mm pin punch and a hammer, install a new slotted spring pin to the No. 1 gear shift fork shaft.

NOTICE:
Do not tap the pin too deep.

Standard depth:

0 mm (0 in.) (from the end surface of the No. 1 gear shift head)

26. INSTALL SHIFT AND SELECT LEVER

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









(b) Install the shift and select lever to the No. 1 shift fork shaft with a new bolt.





Torque : 33 Nm (340 kgf-cm, 25 ft-lbf)

27. INSTALL NO. 2 SHIFT INTER LOCK PIN

(a) Install the No. 2 shift inter lock pin to the No. 1 shift fork shaft.





28. INSTALL NO. 1 SHIFT FORK SHAFT

(a) Install the No. 1 shift fork shaft and No. 2 shift inter lock pin by sliding them.