Disassembly and Assembly
Part 1 Of 2:
Part 2 Of 2:
DISASSEMBLY
1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
3. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. REMOVE RELEASE BEARING RETAINER
Remove the 3 bolts and release bearing retainer.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
5. REMOVE SELECTING BELLCRANK
Remove the 2 bolts and selecting bellcrank.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
6. REMOVE TRANSMISSION CASE COVER
a. Remove the 8 bolts.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
b. Using a plastic hammer, tap the transmission case cover and remove it.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent
7. REMOVE LOCK BALL ASSEMBLY
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
8. REMOVE SHIFT AND SELECT LEVER ASSEMBLY
HINT: At the time of reassembly, please refer to the following item.
Apply FIPG to the underside of the flanged portion of the control shaft cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
9. REMOVE OUTPUT SHAFT LOCK NUT
a. Unstake the nut.
b. Engage the gear to the double meshing.
c. Rotate the lock nut clockwise and remove it.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
HINT: The lock nut has LH threads.
d. Disengage the double meshing of the gear.
10. REMOVE NO. 3 HUB SLEEVE AND NO. 3 SHIFT FORK
a. Remove the No. 3 shift fork set bolt.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
b. Remove the No. 3 hub sleeve and No. 3 shift fork.
11. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-40011
HINT: At the time of reassembly, please refer to the following item.
Using SST, install the 5th driven gear.
SST 09309-12020
12. MEASURE 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20-0.40 mm (0.0079-0.0157 inch)
Maximum clearance: 0.45 mm (0.0177 inch)
13. MEASURE 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.
Standard clearance: 0.009-0.050 mm (0.0004-0.0020 inch)
Maximum clearance: 0.070 mm (0.0028 inch)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or input shaft.
14. REMOVE NO. 3 CLUTCH HUB AND 5TH GEAR
a. Using 2 screwdrivers and a hammer, tap out the snap ring.
HINT: At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
b. Using SST and a socket wrench, remove the No. 3 clutch hub with the synchronizer ring.
SST 09950-30011
HINT: At the time of reassembly, please refer to the following item.
Using SST and a press, install the No. 3 clutch hub assembly.
SST 09612-22011
c. Remove the 5th gear.
15. REMOVE NEEDLE ROLLER BEARING
16. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and rear bearing retainer.
Sealant:
Part No.08833-00070, THREE BOND 1324 or equivalent
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
17. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.
HINT: It it is difficult to remove and install the snap rings, pull up the shafts.
18. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
19. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM
Remove the 6 bolts, differential side bearing retainer and shim.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
20. REMOVE TRANSMISSION CASE
a. Remove the 17 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
b. Using a plastic hammer, tap the transmission case and re move it.
FIPG:
Part No. 08833-00090, THREE BOND 1281 or equivalent
21. REMOVE REVERSE IDLER GEAR AND SHAFT
a. Pull out the shaft.
b. Remove the reverse idler gear and thrust washer.
22. REMOVE REVERSE SHIFT ARM
a. Shift the fork shaft into reverse.
b. Remove the 2 bolts and pull off the reverse shift arm.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
23. REMOVE NO. 1 SHIFT FORK SHAFT, NO. 1 SHIFT HEAD, NO. 1 AND NO. 2 SHIFT FORKS, REVERSE SHIFT FORK WITH INTERLOCK PIN, INPUT SHAFT ASSEMBLY AND OUTPUT SHAFT ASSEMBLY
24. REMOVE DIFFERENTIAL CASE ASSEMBLY
25. REMOVE MAGNET FROM TRANSAXLE CASE
26. REMOVE NO. 2 SHIFT FORK SHAFT
a. Using a hexagon wrench, remove the straight screw plug.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Pull out the No. 2 shift fork shaft.
27. SEPARATE NO. 1 SHIFT FORK SHAFT, NO. 1 SHIFT HEAD, NO. 1, NO. 2 SHIFT FORKS AND REVERSE SHIFT FORK
a. Mount the shift forks to the vise.
b. Using a pin punch and hammer, drive out the slotted spring pin from the No. 1 fork shaft.
c. Using a pin punch and hammer, drive out the slotted spring pin from the No. 1 fork shaft, as shown.
d. Separate the No. 1 shift fork shaft, No. 1 shift head, No. 1 and No. 2 shift forks and reverse shift fork.
28. REMOVE NO. 5 SYNCHRONIZER RING WITH KEY SPRING FROM NO. 3 CLUTCH HUB
a. Remove the No. 5 synchronizer ring with the key spring from the No. 3 clutch hub.
b. Using a screwdriver, remove the snap ring.
HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.
c. Remove the synchronizer rings.
INSPECTION
1. INSPECT NO. 5 SYNCHRONIZER RING
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring.
Turn the middle No. 5 synchronizer ring in one direction while pushing it to the outer No. 5 synchronizer ring. Check that the ring locks.
If the braking effect is insufficient, replace the synchronizer ring.
2. INSPECT NO. 3 SHIFT FORK AND NO. 3 HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
3. IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING
a. Remove the 2 bolts and transaxle case receiver.
b. Using SST, pull out the bearing.
SST 09308-00010
c. Using SST, press in a new bearing.
SST 09310-35010
d. Install the transaxle case receiver with the 2 bolts.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING
a. Remove the bolt and bearing lock plate.
b. Using SST, pull out the bearing.
SST 09308-00010
c. Using SST, press in a new bearing.
SST 09310-35010
d. Install the bearing lock plate with bolt.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
5. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL SEAL
a. Using a screwdriver, pry out the oil seal.
b. Using SST, drive in a new oil seal.
SST 09608-00081, 09950-70010 (09951-07150)
Drive in depth: 0-0.5 mm (0-0.020 inch)
c. Coat the lip of the oil seal with MP grease.
6. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
a. Using a hexagon wrench, remove the straight screw plug.
b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Replace the reverse restrict pin.
d. Using a pin punch and hammer, drive in the slotted spring pin.
Drive in depth: 13.5 ± 0.5 mm (0.531 ± 0.020 inch)
e. Apply sealant to the plug threads. Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using a hexagon wrench, install the straight screw plug.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
REASSEMBLY
Reassembly is in the reverse order of disassembly.
NOTICE: When working with FIPG material, you must observe the following items.
^ Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
^ Thoroughly clean all components to remove all the loose material.
^ Clean both sealing surfaces with a non-residue solvent.
^ Apply FIPG in an approx. 1 mm (0.04 inch) wide bead along the sealing surface.
^ Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.
HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.