PROCEDURE
INSTALL FRONT OUTPUT SHAFT BEARING
Using SST and a press, install a new front output shaft bearing onto the output shaft.
INSTALL 1ST GEAR BUSH
Coat the 1st gear bush with manual transaxle oil and install it onto the output shaft.
INSTALL 1ST GEAR NEEDLE ROLLER BEARING
Coat the 1st gear needle roller bearing with manual transaxle oil and install it onto the output shaft.
INSTALL 1ST GEAR
Coat the 1st gear with manual transaxle oil and install it onto the output shaft.
Note
Install the 1st gear as shown in the illustration.
INSTALL NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)
Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with manual transaxle oil.
*1 | Inner Ring |
*2 | Middle Ring |
*3 | Outer Ring |
Install the inner ring onto the 1st gear.
Install the middle ring onto the 1st gear.
Note
Engage the claws of the middle ring to the grooves of the 1st gear.
Install the outer ring onto the 1st gear.
Note
Align the claws of the inner ring with the grooves of the outer ring, before installing the outer ring.
INSTALL NO. 1 TRANSMISSION CLUTCH HUB
Install the No. 1 transmission clutch hub onto the output shaft.
Note
Align the cutout of the No. 1 transmission clutch hub with the protrusion of the No. 1 synchronizer ring as shown in the illustration.
INSTALL NO. 1 SYNCHROMESH SHIFTING KEY
Install the 3 No. 1 synchromesh shifting keys to the No. 1 transmission clutch hub.
INSTALL REVERSE GEAR
Coat the reverse gear and No. 1 transmission clutch hub with manual transaxle oil.
Install the reverse gear onto the No. 1 transmission clutch hub assembly.
Note
Install the reverse gear as shown in the illustration.
INSTALL NO. 1 SYNCHRONIZER RING SET (FOR 2ND GEAR)
Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with manual transaxle oil.
Install the outer ring onto the No. 1 transmission clutch hub.
Note
Align the protrusion of the outer ring with the cutout of the No. 1 transmission clutch hub before installing the outer ring.
Install the middle ring onto the outer ring.
*1 | Inner Ring |
*2 | Outer Ring |
*a | Cutout |
Install the inner ring onto the middle ring.
Note
Align the cutout of the outer ring with the protrusion of the inner ring before installing the inner ring.
INSTALL INNER 2ND GEAR BEARING RACE
Coat the inner 2nd gear bearing race with manual transaxle oil and install it onto the output shaft.
INSTALL 2ND GEAR NEEDLE ROLLER BEARING
Coat the 2nd gear needle roller bearing with manual transaxle oil and install it onto the output shaft.
INSTALL 2ND GEAR
*a | Groove |
*b | Claw |
Coat the 2nd gear with manual transaxle oil and install it onto the output shaft.
Note
Align the claw of the middle ring with the groove of the 2nd gear before installing the 2nd gear.
INSTALL 3RD DRIVEN GEAR
Using SST and a press, install the 3rd driven gear onto the output shaft.
INSTALL OUTPUT GEAR SPACER
Install the output gear spacer onto the output shaft.
INSTALL 4TH DRIVEN GEAR
Using SST and a press, install the 4th driven gear onto the output shaft.
INSTALL 5TH DRIVEN GEAR
Using SST and a press, install the 5th driven gear onto the output shaft.
INSTALL OUTPUT GEAR SPACER
Install the output gear spacer onto the output shaft.
INSTALL 6TH DRIVEN GEAR
Using SST and a press, install the 6th driven gear onto the output shaft.
INSTALL REAR OUTPUT SHAFT BEARING
Using SST and a press, install a new rear output shaft bearing onto the output shaft.
INSPECT 2ND GEAR RADIAL CLEARANCE
INSPECT 1ST GEAR RADIAL CLEARANCE
INSPECT 2ND GEAR THRUST CLEARANCE
INSPECT 1ST GEAR THRUST CLEARANCE