OUTPUT SHAFT REASSEMBLY


  1. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A00DSN0E01

      Using SST and a press, install a new front output shaft bearing to the output shaft.

      SST
      09309-14040
      09612-22011

  2. INSTALL 1ST GEAR BUSH


    1. A00DSDE

      Coat the 1st gear bush with gear oil and install it to the output shaft.

  3. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A00DPVR

      Coat the 1st gear needle roller bearing with gear oil and install it to the output shaft.

  4. INSTALL 1ST GEAR


    1. A00DR4XE01

      Coat the 1st gear with gear oil and install it to the output shaft.

      Note

      Install the 1st gear as shown in the illustration.

  5. INSTALL NO. 1 SYNCHRONIZER RING SET (for 1st Gear)


    1. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.

    2. A00DSTY

      Install the inner ring to the 1st gear.

    3. Install the middle ring to the 1st gear.

      Note

      Attach the claws of the middle ring to the grooves of the 1st gear.

    4. Install the outer ring to the 1st gear.

      Note

      Align the claws of the inner ring with the grooves of the outer ring before installing the outer ring.

  6. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    1. A00DTRU

      Install the No. 1 transmission clutch hub to the output shaft.

      Note

      Align the cutout of the No. 1 transmission clutch hub with the protrusion of the outer ring as shown in the illustration.

  7. INSTALL NO. 1 SYNCHROMESH SHIFTING KEY


    1. A00DS36

      Install the 3 No. 1 synchromesh shifting keys to the No. 1 transmission clutch hub.

  8. INSTALL REVERSE GEAR


    1. Coat the reverse gear and No. 1 transmission clutch hub with gear oil.

    2. A00DU8QE01

      Install the reverse gear to the No. 1 transmission clutch hub.

      Note

      Install the reverse gear as shown in the illustration.

  9. INSTALL NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)


    1. Coat the 2nd gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.

    2. A00DPJS

      Install the outer ring to 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.

    3. A00DUG7

      Install the middle ring to the outer ring.

    4. A00DSOIE02
      Text in Illustration
      *1 Cutout
      *2 Middle Ring
      *3 Outer Ring

      Install the inner ring to the middle ring.

      Note

      Align the cutouts of the outer ring with the protrusions of the inner ring before installing the inner ring.

  10. INSTALL INNER 2ND GEAR BEARING RACE


    1. A00DRNSE01

      Coat the inner 2nd gear bearing race with gear oil and install it to the output shaft.

  11. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A00DQR2E01

      Coat the 2nd gear needle roller bearing with gear oil and install it to the output shaft.

  12. INSTALL 2ND GEAR


    1. A00DUKGE02
      Text in Illustration
      *1 Groove
      *2 Claw

      Coat the 2nd gear with gear oil and install it to the output shaft.

      Note

      Align the claw of the middle ring with the groove of the 2nd gear before installing the 2nd gear.

  13. INSTALL 3RD DRIVEN GEAR


    1. A00DQ8AE01

      Using SST and a press, install the 3rd driven gear to the output shaft.

      SST
      09316-60011   ( 09316-00011 )

  14. INSTALL OUTPUT GEAR SPACER


    1. A00DRFVE01

      Install the output gear spacer to the output shaft.

  15. INSTALL 4TH DRIVEN GEAR


    1. A00DSXUE01

      Using SST and a press, install the 4th driven gear to the output shaft.

      SST
      09309-37010
      09502-24010

  16. INSTALL 5TH DRIVEN GEAR


    1. A00DRZGE01

      Using SST and a press, install the 5th driven gear to the output shaft.

      SST
      09316-60011   ( 09316-00011 )

  17. INSTALL OUTPUT GEAR SPACER


    1. A00DSCFE01

      Install the output gear spacer to the output shaft.

  18. INSTALL 6TH DRIVEN GEAR


    1. A00DUHAE01

      Using SST and a press, install the 6th driven gear to the output shaft.

      SST
      09226-10010

  19. INSTALL REAR OUTPUT SHAFT BEARING


    1. A00DTE7E01

      Using SST and a press, install a new rear output shaft bearing to the output shaft.

      SST
      09608-04031

  20. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A005U02

      Using a dial indicator, measure the 2nd gear radial clearance.

      Standard clearance
      for TMC Made
      0.009 to 0.077 mm (0.000355 to 0.00303 in.)
      except TMC Made
      0.009 to 0.075 mm (0.000355 to 0.00295 in.)
      Maximum clearance
      for TMC Made
      0.077 mm (0.00303 in.)
      except TMC Made
      0.075 mm (0.00295 in.)

      Tech Tips

      Two different manual transaxle models produced by different manufacturers are available for this vehicle.

      Referring to the Introduction section, check the serial number. Confirm which manufacturer produced the manual transaxle according to the following table.

      Serial Number Manufacturer
      ##JTR############ for TMC Made
      ##EPP############ except TMC Made

      If the clearance is more than the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  21. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A005VQX

      Using a dial indicator, measure the 1st gear radial clearance.

      Standard clearance
      for TMC Made
      0.009 to 0.077 mm (0.000355 to 0.00303 in.)
      except TMC Made
      0.009 to 0.075 mm (0.000355 to 0.00295 in.)
      Maximum clearance
      for TMC Made
      0.077 mm (0.00303 in.)
      except TMC Made
      0.075 mm (0.00295 in.)

      Tech Tips

      Two different manual transaxle models produced by different manufacturers are available for this vehicle.

      Referring to the Introduction section, check the serial number. Confirm which manufacturer produced the manual transaxle according to the following table.

      Serial Number Manufacturer
      ##JTR############ for TMC Made
      ##EPP############ except TMC Made

      If the clearance is more than the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  22. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A005UQJ

      Using a dial indicator, measure the 2nd gear thrust clearance.

      Standard clearance
      0.15 to 0.33 mm (0.00591 to 0.0129 in.)
      Maximum clearance
      0.33 mm (0.0129 in.)

      If the clearance is more than the maximum, replace the inner 2nd gear bearing race, No. 1 transmission clutch hub, 2nd gear or 3rd driven gear. Replace the part or parts determined to be the most likely cause of the problem.

  23. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A005TYC

      Using a dial indicator, measure the 1st gear thrust clearance.

      Standard clearance
      0.20 to 0.38 mm (0.00788 to 0.0149 in.)
      Maximum clearance
      0.38 mm (0.0149 in.)

      If the clearance is more than the maximum, replace the No. 1 transmission clutch hub, 1st gear bush or 1st gear. Replace the part or parts determined to be the most likely cause of the problem.