Part 4
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OVERHAUL
80. INSTALL REVERSE IDLER GEAR SHAFT BOLT
a. Coat the reverse idler gear shaft bolt with sealant, install it with a new gasket.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)
81. INSTALL LOCK BALL ASSY NO.1
a. Coat the lock ball assy No.1 with sealant, install it with using a hexagon wrench.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 39.2 Nm (400 kgf-cm, 29 ft. lbs.)
82. INSTALL SHIFT DETENT BALL
a. Install the 2 shift detent balls, 2 springs with 2 seats to the manual transmission case.
b. Coat the 2 shift detent ball plugs with sealant, install them with using a hexagon wrench.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
c. Install the shift detent ball, spring and seat to the transaxle case.
d. Coat the shift detent ball plug with sealant, install it with using a hexagon wrench.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
83. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING
a. Using a snap ring expander, install the input shaft rear bearing hole snap ring to the input shaft.
84. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING
a. Using a snap ring expander, install the output shaft rear bearing hole snap ring to the output shaft.
85. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING
a. Using a brass bar and a hammer, install the shift fork shaft shaft snap ring to the shift fork shaft No.2.
86. INSTALL BEARING RETAINER REAR (MTM)
a. Coat the 5 bolts with sealant, install them and bearing retainer rear (MTM) to the manual transmission case.
Torque: 27.4 Nm (279 kgf-cm, 20 ft. lbs.)
87. INSTALL 5TH DRIVEN GEAR
a. Using SST, install the 5th driven gear to the output shaft.
SST 09309-12020
88. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
a. Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, install them to the input shaft.
89. INSTALL 5TH GEAR
a. Coat the 5th gear with gear oil, install it to the input shaft.
90. INSTALL SYNCHRONIZER RING NO.3
a. Coat the synchronizer ring No.3 with gear oil, install it to the 5th gear.
91. INSTALL TRANSMISSION CLUTCH HUB NO.3
a. Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs to the transmission clutch hub No.3.
HINT: Do not set both openings of the shifting key springs in the same position.
b. Using SST and a hammer, install the transmission clutch hub No.3 to the input shaft.
SST 09636-20010
HINT:
^ Before driving in the No.3 clutch hub assy, place the suitable sized wooden block on the rear side of the input shaft, as shown in the illustration.
^ When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear bearing is over loaded, it might be damaged.
c. Select a snap ring from the table that will make the thrust clearance of the transmission clutch hub No.3 below 0.1 mm (0.0039 inch).
Snap ring thickness
d. Using a brass bar and a hammer, install the snap ring to the input shaft.
92. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the 5th gear thrust clearance.
5th gear thrust clearance
93. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 5th gear radial clearance.
5th gear radial clearance
If the clearance exceed the maximum value, replace the gear, needle roller bearing or shaft.
94. INSTALL GEAR SHIFT FORK NO.3
a. Coat the transmission clutch hub sleeve No.3 with gear oil, install it and gear shift fork No.3 to the transmission clutch hub No.3.
HINT: Do not set the transmission clutch hub No.3 in incorrect orientation.
b. Coat the gear shift lock fork ball with sealant, install it to the gear shift fork No.3.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 15.7 Nm (160 kgf-cm, 12 ft. lbs.)
95. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
a. Engage the gear double meshing.
b. Install a new manual transmission output shaft rear set nut.
Torque: 117.6 Nm (1,200 kgf-cm, 87 ft. lbs.)
c. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
d. Disengage the gear double meshing.
96. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSY
a. Apply FIPG to the manual transmission case cover sub-assy as shown in the illustration.
FIPG: Part No. 08826-0009O, 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. Install the manual transmission case cover Embassy with the 9 bolts to the manual transmission case.
Torque: 18.1 Nm (185 kgf-cm, 14 ft. lbs.)
97. INSTALL SHIFT & SELECT LEVER SHAFT ASSY
a. Coat the 4 bolts with sealant, install them, new gasket and shift & select lever shaft assy to the manual transmission case.
Sealant: Part No. 08833-0008O, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 19.6 Nm (200 kgf-cm, 14 ft. lbs.)
NOTICE: Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
98. INSTALL LOCK BALL ASSY NO.1
a. Coat the lock ball assy No.1 with sealant, install it to the manual transmission case.
Sealant: Part No. 08833-0008O, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)
99. INSTALL SELECTING BELL CRANK ASSY
a. Install the selecting bellcrank assy with control shift lever bush with the 2 bolts to the manual transmission case.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
NOTICE: Apply MP grease to the inside circumferential surface of the control shift lever bush (A).
100. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
a. Install the floor shift control lever housing support bracket with the 3 bolts to the transaxle case.
Torque: 11.3 Nm (115 kgf-cm, 8 ft. lbs.)
101. INSTALL BACK UP LAMP SWITCH ASSY
a. Using SST, install the backup lamp switch assy with a new gasket to the manual transmission case.
Torque: 40.2 Nm (410 kgf-cm, 30 ft. lbs.)
SST 09817-16011
102. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY (W/ ABS)
a. Install a new O-ring to the speedometer driver hole cover sub-assy.
b. Install the speedometer driver hole cover sub-assy with the bolt.
Torque: 11.3 Nm (115 kgf-cm, 8 ft. lbs.)
103. INSTALL SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSY (W/O ABS)
a. Install the speedometer driven (MTM) gear sub-assy with clip to the speedometer sensor.
104. INSTALL SPEEDOMETER SENSOR (W/O ABS)
a. Install a new O-ring to the speedometer sensor.
b. Install the speedometer sensor with the bolt.
Torque: 11.3 Nm (115 kgf-cm, 8 ft. lbs.)
105. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support to the transaxle case.
Torque: 36.8 Nm (375 kgf-cm, 25 ft. lbs.)
106. INSTALL CLUTCH RELEASE FORK BOOT
a. Install the clutch release fork boot to the transaxle case.
107. INSTALL CLUTCH RELEASE BEARING ASSY
a. Coat the clutch release bearing assy with the release hub grease, install it to the clutch release fork sub-assy.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
108. INSTALL CLUTCH RELEASE FORK SUB-ASSY
a. Install the clutch release fork sub-assy to the input shaft.
b. Apply clutch spline grease to spline of the input shaft.
Sealant: Part No. 08887-01806, CLUTCH SPLINE GREASE or equivalent
109. INSTALL DRAIN (MTM) PLUG SUB-ASSY
a. Install a new gasket with the drain (MTM) plug sub-assy.
Torque: 39.2 Nm (400 kgf-cm, 29 ft. lbs.)
110. INSTALL MANUAL TRANSMISSION FILLER PLUG
a. Install a new gasket with the manual transmission filler plug.
Torque: 39.2 Nm (400 kgf-cm, 29 ft. lbs.)