Manual Transmission/Transaxle Assembly

MANUAL TRANSAXLE DISASSEMBLY:

DISASSEMBLY
1. REMOVE CLUTCH RELEASE FORK AND BEARING

HINT: At the time of reassembly, please refer to the following item.

Apply molybdenum disulfide lithium base grease.

2. 4WD: REMOVE TRANSFER ASSEMBLY
a. Remove the 2 bolts. Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 78.4 Nm (800 kgf-cm, 58 ft. lbs.)
b. Remove the 6 nuts.
Torque:
78.4 Nm (800 kgf-cm, 58 ft. lbs.) for 17 mm nut
29.4 Nm (300 kgf-cm, 22 ft. lbs.) for 14 mm nut
c. Using a plastic hammer, remove the transfer assembly from the transaxle.

HINT: At the time of reassembly, please refer to the following item.
- Shift into the 4th gear, and install the transfer assembly while turning the input shaft of the transaxle.
- It is possible to apply FIPG either transaxle side or transfer side. In addition, be sure to apply it on the center of the seal.

FIPG:Part No. 08826-00100, THREE BOND 1281 or equivalent
3. 4WD: REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT
4. REMOVE FILLER PLUG AND DRAIN PLUG WITH 2 GASKETS
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
5. REMOVE BACK-UP LIGHT SWITCH WITH GASKET
Torque: 40 Nm (410 kgf-cm, 30 ft. lbs.)
6. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
7. REMOVE CONTROL CABLE BRACKET
Remove the 3 bolts and control cable bracket.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
8. REMOVE CLUTCH TUBE BRACKET
Remove the bolt and tube bracket.
Torque: 17 Nm (175 kgf-cm,13 ft. lbs.)

9. REMOVE SELECTING BELLCRANK ASSEMBLY
Remove the 2 bolts and the selecting bellcrank assembly.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
10. REMOVE CONTROL SHIFT LEVER AND DUST BOOT

a. Remove the nut and wave washer.
Torque: 6.4 Nm (65 kgf-cm, 57 inch lbs.)

b. Using a pin punch and a hammer, tap out the lever lock pin.

NOTICE: At the time of reassembly, please refer to the following item. When fixing the lever lock pin, properly position the shaft groove.

c. Remove the control shift lever and dust boot.

NOTICE: At the time of reassembly, please refer to the following items.
- Install the dust boot into a groove in the control shift lever.
- Be sure to install the dust boot in the correct direction, as shown in the illustration.

11. REMOVE LOCK BALL ASSEMBLY AND SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Remove the lock ball assembly.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
b. Remove the 4 bolts, shift and select lever shaft assembly and gasket.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
12. REMOVE CONTROL SHAFT COVER
Remove the control shaft cover from the shift and select lever shaft assembly.

NOTICE: At the time of reassembly, please refer to the following item. Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.

13. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.
FIPG: Part No. 08826-00100, THREE BOND 1282B or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
14. REMOVE BREATHER PLUG WITH GASKET
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

15. REMOVE OUTPUT SHAFT LOCK NUT
a. Unstake the lock nut.
b. Engage the gear double meshing.
c. Remove the lock nut.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
d. Disengage the gear double meshing.
16. REMOVE NO. 3 HUB SLEEVE AND NO. 3 SHIFT FORK
a. Remove the No. 3 shift fork set bolt.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)
b. Remove the No. 3 hub sleeve and No. 3 shift fork.

17. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03030)
18. MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE

a. Using a dial indicator, measure the thrust clearance.
Maximum clearance: 0.65 mm (0.0256 inch)

b. Using a dial indicator, measure the radial clearance.
Maximum clearance: 0.050 mm (0.0020 inch)
19. 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 the reassembly, please refer to the following item.

Select a snap ring that allows the minimum axial play.

b. Using SST, remove the No. 3 clutch hub with the synchronizer ring and 5th gear.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010)
20. REMOVE NEEDLE ROLLER BEARINGS
21. REMOVE REAR BEARING RETAINER
Using a torx socket wrench (T45), remove the 7 torx screws and rear bearing retainer.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)

22. REMOVE SNAP RING
a. Using a snap ring expander, remove the input shaft rear bearing snap ring.
b. Using 2 screwdrivers and a hammer, remove the 2 snap rings.

23. REMOVE STRAIGHT SCREW PLUG
Using a hexagon wrench (6 mm), remove the plug.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

24. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND WASHER
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
25. REMOVE TRANSMISSION CASE

a. Transaxle case side: Remove the 3 bolts.

b. Transmission case side: Remove the 14 bolts and tap out the case with a plastic hammer.

FIPG: Part No. 08826-00100, THREE BOND 1282B or equivalent
Torque:
29 Nm (300 kgf-cm, 21 ft. lbs.) for transaxle case side
30 Nm (306 kgf-cm, 22 ft. lbs.) for transmission case side

26. REMOVE SHIM

HINT: At the time of reassembly, please refer to the following item. Install the previously selected shim by adjusting output shaft preload.

27. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear bearing outer race.
SST 09316-60011 (09316-00011)

28. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
Remove the 2 bolts and pull off the reverse shift arm and bracket.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)

29. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust washer.

HINT: At the time of reassembly, please refer to the following item. Align the matchmarks, as shown.

30. REMOVE STRAIGHT SCREW PLUGS
Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant: Part No. 08803-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

31. REMOVE 3 SHIFT FORK SET BOLTS
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)
32. REMOVE NO. 1 SHIFT FORK SHAFT
Pull up the No. 3 shift fork shaft, remove the No. 1 shift fork shaft.

HINT: At the time of reassembly, please refer to the following item. When it is difficult to push the fork shaft through the reverse shift fork, pull up the No. 3 shift fork shaft.

33. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the reverse shift fork.

34. REMOVE NO. 2 SHIFT FORK SHAFT, SHIFT HEAD AND NO. 1 SHIFT FORK
a. Pull out the No. 2 shift fork shaft.
b. Remove the shift head and No. 1 shift fork.

35. REMOVE NO. 3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO. 2 SHIFT FORK
a. Pull out the No. 3 shift fork shaft with the reverse shift fork.
b. Remove the No. 2 shift fork.
36. REMOVE SNAP RING
a. Using 2 screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No. 3 shift fork shaft.
b. Using 2 screwdrivers and a hammer, remove the snap rings from the No. 1, No. 2 and No. 3 shift fork shafts.
37. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY
a. Leaning the output shaft to the differential side, remove the input shaft assembly.
b. Lift up the differential case-assembly, remove the output shaft assembly.
38. REMOVE DIFFERENTIAL CASE ASSEMBLY
39. REMOVE MAGNET FROM TRANSAXLE CASE
40. REMOVE 2 BOLTS, NO. 1 AND NO. 2 OIL RECEIVER PIPES
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
41. REMOVE STRAIGHT SCREW PLUG FROM TRANSAXLE CASE
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

42. 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 synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.7 mm (0.028 inch)
If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

2. INSPECT NO. 3 SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 0.35 mm (0.014 inch)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.

REPLACEMENT
1. REPLACE INPUT SHAFT FRONT BEARING AND OIL SEAL
a. Remove the 3 bolts and transaxle case receiver.

b. Using SST, pull out the bearing.
SST 09612-65014 (09612-01040, 09612-01050)

c. Using a screwdriver, remove the oil seal.
d. Using SST, drive in a new oil seal.
SST 09608-00081, 09950-70010 (09951-07150)

e. Coat the lip of seal with MP grease.
f. Using SST, drive in a new bearing.
SST 09950-60010 (09951-00580), 09950-70010 (09951-07150)
g. Install the transaxle case receiver.
h. Install and torque the 3 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
2. REPLACE OUTPUT SHAFT FRONT BEARING OUTER RACE AND OUTPUT SHAFT FRONT COVER

a. Using SST, pull out the output shaft front bearing outer race.
SST 09308-00010
b. Remove the output shaft cover.

c. Install a new output shaft cover.

HINT: Install the output shaft cover projection into the case side groove.

d. Using SST and a hammer, drive in a new output shaft front bearing outer race.
SST 09316-60011 (09316-00011, 09316-00021)
3. REPLACE REVERSE RESTRICT PIN

a. Using a hexagon wrench (6 mm), remove the screw plug.
b. Using a pin punch (5 mm) and hammer, drive out the slotted spring pin.
c. Replace the reverse restrict pin.

d. Using a pin punch (5 mm) and hammer, drive in the slotted spring pin.
d. Apply sealant to the screw plug threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using a hexagon wrench (6 mm), install and torque the screw plug.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
4. REPLACE CONTROL SHAFT COVER OIL SEAL AND BUSHING

a. Using a screwdriver, pry out the oil seal.

b. Using SST and a press, press out the bushing.
SST 09950-60010 (09951-00200, 09951-00210), 09950-70010 (09951-07150)

c. Using SST and a press, press in a new bushing.
SST 09950-60010 (09951-00200), 09950-70010 (09951-07150)
Depth: 0.65 ± 0.25 mm (0.0256 ± 0.0098 inch)

d. Using SST and a plastic-faced hammer, carefully tap in a new oil seal.
SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)
Depth: 0.70 ± 0.50 mm (0.0276 ± 0.0197 inch)

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 approximately 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:
- Before reassembly, select a shim by adjusting output shaft preload.
- Coat all of the sliding and rotating surfaces with gear oil before reassembly.

ADJUST OUTPUT SHAFT PRELOAD
a. Install the output shaft assembly to the transaxle case.
b. Install the transmission case to the transaxle case.

HINT: If necessary, tap on the case with a plastic hammer.

c. Install and torque the 17 bolts.
Torque:
29 Nm (300 kgf-cm, 21 ft. lbs.) for transaxle case side
30 Nm (306 kgf-cm, 22 ft. lbs.) for transmission case side
d. Install the output shaft rear taper roller bearing outer race.
e. Install the adjusting shim.

HINT: When reusing the output shaft bearing, first install a shim of the same thickness as before. If installing a new taper roller bearing, first select and install a shim of lesser thickness than before.

f. Install the rear bearing retainer.

g. Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
h. Install a new lock nut to the output shaft.
i. Turn the output shaft right and left 2 or 3 times to allow the bearing to settle.
j. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing 0.8 - 1.6 Nm (8 - 16 kgf-cm, 6.9 - 13.9 inch lbs.)
Reused bearing 0.5 - 1.0 Nm (5 - 10 kgf-cm, 4.3 - 8.7 inch lbs.)
If the preload is not within the specification, select an appropriate adjusting shim.
k. Remove the lock nut.
l. Remove the 5 parts. Removal is in the reverse order of installation.
1. Remove the rear bearing retainer.
2. Remove the shim.
3. Remove the transmission case.
4. Remove the output shaft assembly.
5. Remove the output shaft rear bearing outer race.