Part 3

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OVERHAUL





56. INSPECT REVERSE IDLER GEAR SUB-ASSY
a. Using a caliper gauge, inspect the reverse idler gear sub-assy as shown in the illustration.





Reverse idler gear sub-assy inner diameter

If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assy.
b. Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.





Reverse idler gear shaft outer diameter

If the outer diameter is below the minimum, replace the reverse idler gear shaft.





57. INSTALL OUTPUT SHAFT (MTM) COVER
a. Coat the output shaft (MTM) cover with MP grease, install it to the transaxle case.

NOTICE: Install the output shaft (MTM) cover projection into the case side hollow.





58. INSTALL OUTPUT SHAFT FRONT BEARING
a. Coat a new output shaft front bearing with gear oil, using SST and a press, install it to the transaxle case.
SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)

NOTICE:
^ Be sure to install a new bearing in the correct direction, as shown in the illustration.
^ When replacing the output shaft front bearing, replace the output shaft front bearing inner race along with it.





59. INSTALL FRONT TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install a new front transaxle case oil seal to the transaxle case.
SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)
Drive in depth: 15.6 - 16.0 mm (0.6142 - 0.6299 inch)
b. Coat the lip of the front transaxle case oil seal with MP grease.





60. INSTALL INPUT SHAFT FRONT BEARING
a. Coat a new input shaft front bearing with MP grease, using SST and a press, install it to the transaxle case.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
Drive in depth: 0 - 0.3 mm (0 - 0.012 inch)





61. INSTALL FR DIFFERENTIAL CASE: FRONT TAPERED ROLLER BEARING
a. Using SST and a press, install a new FR differential case front tapered roller bearing (inner race) to the front differential case.
SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)





b. Using SST and a press, install a new FR differential case front tapered roller bearing (outer race) with shim to the transaxle case.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)





62. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST and a press, install a new FR differential case rear tapered roller bearing (inner race) to the front differential case.
SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)





b. Using SST and a press, install a new FR differential case rear tapered roller bearing (outer race) with shim to the manual transmission case.
SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)

HINT: Use a shim of the same thickness with the removed one.





63. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
a. Coat the differential case assy with gear oil, install it to the transaxle case.
b. Install the manual transmission case with 16 bolts.
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)





c. Using SST and a torque wrench, turn the differential case assy to the right and left 2 or 3 times to allow the bearings to settle.
SST 09564-32011





d. Using SST and a torque wrench, measure the preload.
SST 09564-32011
Preload (at starting):
New bearing: 0.78 - 1.57 Nm (8 - 16 kgf-cm, 6.9 - 13.9 inch lbs.)
If the preload is out of specification, select another shim.





Shim thickness

HINT: The preload will change by about 0.3 - 0.4 Nm (3 - 4 kgf-cm, 2.6 - 3.5 inch lbs.) corresponding to a change of 0.05 mm (0.0020 inch) in shim thickness.

e. Remove the 16 bolts and manual transmission case from the transaxle case.
f. Remove the differential case assy from the transaxle case.





64. INSTALL TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, install a new transmission case oil seal to the manual transmission case.
SST 09316-60011 (09316-00011)
Drive in depth: 9.9 - 0.3 mm (0.390 - 0.012 inch)
b. Coat the lip of the transmission case oil seal with MP grease.





65. INSTALL TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install a new transaxle case oil seal in the transaxle case.
SST 09710-20011 (09710-06071), 09950-70010 (09951-07150)
Drive in depth: 1.9 - 0.3 mm (0.075 - 0.012 inch)
b. Coat the lip of the transaxle case oil seal with MP grease.





66. INSTALL TRANSMISSION MAGNET
a. Clean the transmission magnet, install it to the transaxle case.





67. INSTALL BEARING LOCK PLATE
a. Install the bearing lock plate with the bolt
Torque: 11.3 Nm (115 kgf-cm, 8 ft. lbs.)





68. INSTALL OIL RECEIVER PIPE NO.1 (MTM)
a. Install the oil receiver pipe No.1 (MTM) with bolt to the manual transmission case.
Torque: 17.2 Nm (175 kgf-cm, 13 ft. lbs.)

NOTICE:
^ Prevent the oil receiver pipe No.1 (MTM) from being deformed.
^ Install the oil receiver pipe No.1 (MTM) while placing it against the manual transmission case, as shown in the illustration.





69. INSTALL OIL RECEIVER PIPE NO.2 (MTM)
a. Install the oil receiver pipe No 2 (MTM) with bolt to the manual transmission case.
Torque: 17.2 Nm (175 kgf-cm, 13 ft. lbs.)

NOTICE:
^ Prevent the oil receiver pipe No.2 (MTM) from being deformed.
^ Install the oil receiver pipe No.2 (MTM) while placing it against the manual transmission case, as shown in the illustration.





70. INSTALL REVERSE RESTRICT PIN ASSY
a. Install the reverse restrict pin assy to the manual transmission case.

NOTICE: Do not set the reverse restrict pin assy in incorrect orientation.





b. Using a pin punch (� 5 mm) and hammer, install the slotted pin to the reverse restrict pin assy.
Drive in depth (A): 15.5 - 16.5 mm (0.6102 - 0.6496 inch)
c. Apply sealant to the reverse restrict pin plug.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





d. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug to the manual transmission case.
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.)





71. INSTALL MANUAL TRANSAXLE CASE RECEIVER
a. Install the manual transaxle case receiver with the bolt to the transaxle case.
Torque: 11.3 Nm (115 kgf-cm, 8 ft. lbs.)





72. INSTALL DIFFERENTIAL CASE ASSY
a. Coat the differential case tapered roller bearing with gear oil, install the differential case assy to the transaxle case.





73. INSTALL INPUT SHAFT ASSY
a. Coat the sliding and rotating surface of the input and out put shafts with gear oil, install them tin the transaxle case.





74. INSTALL REVERSE IDLER GEAR SUB-ASSY
a. Coat the reverse idler gear sub-assy, thrust washer and reverse idler gear shaft with gear oil, install them as shown in the illustration.

HINT: Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.





75. INSTALL GEAR SHIFT FORK SHAFT SUB-ASSY NO.1
a. Coat the gear shift fork No.1 and gear shift fork No.2 with gear oil, install them.





b. Coat the gear shift fork shaft sub-assy No.1 with gear oil, install it.
c. Apply sealant to the shift fork lock bolt.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Install the gear shift fork lock bolt.
Torque: 15.7 Nm (160 kgf-cm, 12 ft. lbs.)





e. Using a brass bar and a hammer, install the shaft snap ring to the gear shift fork shaft No.1.





76. INSTALL GEAR SHIFT FORK SHAFT NO.3
a. Coat the 2 balls with MP grease, install them to the reverse shift fork.
b. Install the reverse shift fork to the gear shift fork shaft No.3.





c. Using a brass bar and a hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft No.3.





d. Coat the gear shift fork shaft No.3 with gear oil, install it.





77. INSTALL GEAR SHIFT FORK SHAFT NO.2
a. Coat the gear shift head No.1 and gear shift fork shaft No.2 with gear oil, install them.





NOTICE: To avoid the interference of the 2 shift fork balls, lift up the gear shift fork shaft NO.3 at the position shown in the illustration.





b. Coat the 2 shift lock bolts with sealant, install then to the gear shift fork No.2 and gear shift head No.1.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 15.7 Nm (160 kgf-cm, 12 ft. lbs.)





78. INSTALL REVERSE SHIFT ARM BRACKET ASSY
a. Install the reverse shift arm bracket assy with 2 bolts to the transaxle case.
Torque: 17.2 Nm (175 kgf-cm, 13 ft. lbs.)





79. INSTALL MANUAL TRANSMISSION CASE
a. Apply FIPG to the manual transmission case, as shown in the illustration.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

NOTICE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.





b. Coat the 13 bolts with sealant, install them to the manual transmission case.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)





c. Coat the 3 bolts with sealant, install them to the transaxle case.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)