MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL NO. 3 GEAR SHIFT FORK SHAFT


    1. A004IVS

      Install the No. 3 gear shift fork shaft to the No. 3 gear shift fork with a new bolt.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

  2. INSTALL NO. 1 GEAR SHIFT FORK SHAFT


    1. A004KST

      Install the No. 1 gear shift fork shaft to the No. 1 gear shift fork with a new bolt.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    2. A004J4A

      Using a brass bar and a hammer, install a new shaft snap ring.

    3. A004IPG

      Install the No. 1 gear shift fork shaft together with the No. 1 gear shift fork to the No. 3 gear shift fork shaft and No. 3 gear shift fork.

    4. A004H1S

      Using a brass bar and a hammer, install a new shaft snap ring.

  3. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A004KA7

      Install the No. 2 gear shift fork shaft to the No. 2 gear shift fork with a new bolt.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    2. A004IU1

      Using a brass bar and a hammer, install a new shaft snap ring.

  4. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A004JL5E02

      Using SST and a hammer, install a new transmission front bearing retainer oil seal.

      SST
      09950-60010   ( 09951-00420 )
      09950-70010   ( 09951-07100 )
      Installation depth
      11.1 to 11.9 mm (0.437 to 0.469 in.) (from the end surface of the front bearing retainer)

      Note


      • Do not damage the lip of the transmission front bearing retainer oil seal.

      • Do not damage the front bearing retainer.

    2. Apply MP grease to the lip of the transmission front bearing retainer oil seal.

  5. INSTALL REVERSE IDLER GEAR SHAFT


    1. A004I2V

      Apply manual transmission gear oil to the reverse idle gear shaft, and then install it to the reverse idler gear.

  6. INSTALL INPUT SHAFT


    1. A004KPF

      Apply manual transmission gear oil to the needle roller bearing of the input shaft, and then install the input shaft to the output shaft.

  7. INSTALL COUNTER SHAFT


    1. Install the input shaft, output shaft, counter shaft, reverse idler gear, reverse idler gear shaft, No. 1 gear shift fork shaft, No. 2 gear shift fork shaft and No. 3 gear shift fork shaft all together to the clutch housing.

      A004H2N
    2. A004IWE

      Using a new gasket and a new bolt, temporarily install the reverse idler gear shaft (clutch housing side).

    3. A004JD1

      Using a snap ring expander, install 2 new shaft snap rings.

      Tech Tips

      Install the shaft snap rings to the input shaft and counter shaft.

  8. INSTALL FRONT BEARING RETAINER


    1. A004H2Z

      Apply seal packing 1281 continuously to the front bearing retainer as shown in the illustration.

      Text in Illustration
      A004HAN Seal Packing 1281

      Note

      Install it within 10 minutes of the seal packing application.

    2. A004HKHE47
      Text in Illustration
      *1 Adhesive 1344

      Apply adhesive 1344 to the 2nd and 3rd pitches from the tip of new bolt.

    3. A004I52

      Install the front bearing retainer with the 7 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      Note

      Install the front bearing retainer ensuring that the transmission front bearing retainer oil seal lip is not damaged.

  9. INSTALL OIL RECEIVER PIPE


    1. A004I89E02
      Text in Illustration
      *a Protrusion

      Install the oil receiver pipe.

      Note

      Confirm that the protrusions of the oil receiver pipe are properly fitted in the grooves.

  10. INSTALL TRANSMISSION CASE


    1. A004IN0

      Apply seal packing 1281 continuously to the transmission case as shown in the illustration.

      Text in Illustration
      A004HAN Seal Packing 1281

      Note

      Install within 10 minutes of the seal packing application.

    2. A004JY5

      Check the location of the knock pin, and then using a plastic hammer, install the transmission case.

      Text in Illustration
      A004HD0 Do not hit hard.
    3. A004HKHE47
      Text in Illustration
      *1 Adhesive 1324

      Apply adhesive 1324 to the 2nd and 3rd pitches.

    4. A004JN7E03
      Text in Illustration
      *1 clamp

      Install the transmission case and clamp with the 9 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
    5. A004H13

      Install a new reverse idler gear shaft fixing bolt and new gasket (transmission case side).

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
    6. A004KI8

      Securely tighten the reverse idler gear shaft fixing bolt (clutch housing side).

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
    7. A004JSY

      Using a snap ring expander, install a new shaft snap ring.

  11. INSTALL REAR BEARING RETAINER


    1. A004J7N

      Install the shift arm pivot to the rear bearing retainer.

    2. A004HKHE47
      Text in Illustration
      *1 Adhesive 1324

      Apply adhesive 1324 to the 2nd and 3rd pitches from the tip of new bolt.

    3. A004IUY

      Using a T45 "TORX" socket wrench, install the rear bearing retainer with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  12. INSTALL 6TH GEAR THRUST WASHER


    1. A004IRI

      Install the straight pin to the counter shaft.

    2. A004JNNE02
      Text in Illustration
      *1 6th Gear Thrust Washer
      A004I9S Front Side

      Apply manual transmission gear oil to the 6th gear thrust washer.

    3. As shown in the illustration, install the 6th gear thrust washer to the counter shaft.

  13. INSTALL NEEDLE ROLLER BEARING


    1. A004IUH

      Apply manual transmission gear oil to the needle roller bearing, and then install the needle roller bearing to the counter shaft.

  14. INSTALL COUNTER SHAFT 6TH GEAR


    1. A004I4U

      Apply manual transmission gear oil to the counter shaft 6th gear, and then install the counter shaft 6th gear to the counter shaft.

  15. INSTALL NO. 2 SYNCHRONIZER RING


    1. A004IY2

      Apply manual transmission gear oil to the No. 2 synchronizer ring, and then install the No. 2 synchronizer ring to the counter shaft.

  16. INSTALL NO. 4 TRANSMISSION HUB SLEEVE


    1. A004HZ4E03
      Text in Illustration
      *1 No. 4 Transmission Clutch Hub
      *2 No. 4 Transmission Hub Sleeve
      *3 Ball
      *4 No. 1 Synchromesh Shifting Key
      *5 No. 1 Synchromesh Shifting Key Spring
      A004I9S Front Side

      Apply manual transmission gear oil to the moving parts of the No. 4 transmission clutch hub.

    2. As shown in the illustration, install the No. 4 transmission hub sleeve to the No. 4 transmission clutch hub, and install the 3 No. 1 synchromesh shifting keys and 3 No. 1 synchromesh shifting key springs all together, and then install the 3 balls.

      Tech Tips


      • Install the ball while holding down the No. 1 synchromesh shifting key spring.

      • After the installation, settle the No. 1 synchromesh shifting key spring.

    3. A004KG4

      Install a new hole snap ring.

  17. INSTALL NO. 4 TRANSMISSION CLUTCH HUB


    1. A004J8XE02

      Using SST and a press, install the No. 4 transmission clutch hub, No. 4 transmission hub sleeve, and No. 4 gear shift fork all together.

      SST
      09632-36010

      Tech Tips


      • Align the No. 4 transmission clutch hub and the No. 2 synchronizer ring so that they can fit together.

      • Engage the No. 4 gear shift fork with the groove of the No. 4 transmission hub sleeve.

  18. INSTALL SHAFT SNAP RING


    1. A004K6X

      Select a shaft snap ring that is suitable to retain the specific thrust clearance between the No. 4 transmission clutch hub and shaft snap ring.

      Standard clearance
      0 to 0.1 mm (0 to 0.00394 in.)

      Tech Tips

      Select the thickest shaft snap ring possible for installation.

      Shaft Snap Ring Thickness
      Part No. Thickness mm (in.) Mark
      SU003-03552 2.80 (0.11023) A
      SU003-03553 2.85 (0.11220) B
      SU003-03554 2.90 (0.11417) C
      SU003-03555 2.95 (0.11614) D
      SU003-03556 3.00 (0.11811) E
      SU003-03557 3.05 (0.12007) F
    2. A004H5L

      Using a brass bar and a hammer, install a new shaft snap ring to the counter shaft.

  19. INSTALL NO. 2 GEAR SHIFT HEAD


    1. A004H93

      Install the No. 2 gear shift head to the No. 2 gear shift fork shaft.

    2. Using a 5 mm pin punch and a hammer, install a new slotted spring pin to the No. 2 gear shift fork shaft.

      Note

      Do not tap the pin too deep.

      Standard depth
      0 mm (0 in.) (from the end surface of the No. 2 gear shift head)

  20. INSTALL 5TH SHIFT HEAD


    1. A004IIF

      Install the compression spring to the 5th shift head, and then, while holding down the ball with the 5 mm pin punch, install the 5th shift head to the No. 3 gear shift fork shaft.

    2. A004KV4

      Install the washer.

    3. A004KNH

      Using a brass bar and a hammer, install a new shaft snap ring to the No. 3 gear shift fork shaft.

  21. INSTALL NO. 3 GEAR SHIFT FORK SHAFT


    1. A004ICF

      As shown in the illustration, insert the No. 3 gear shift fork shaft. Using a T40 "TORX" socket wrench, install the ball and compression spring, and then tighten with a new head straight screw plug.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  22. INSTALL SHIFT ARM


    1. A004K60

      Install the shift arm to the shift arm pivot.

    2. A004J7Q

      Using a brass bar and a hammer, install a new E- ring to the shift arm pivot.

  23. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A004JEY

      Using a screwdriver, install the 2 balls to the No. 3 gear shift fork shaft.

      Tech Tips

      Support the ball with the screwdriver so that the ball does not fall off.

    2. A004H1VE02
      Text in Illustration
      *a Identification Hole

      While the identification hole is facing towards the outside, insert the No. 2 gear shift fork shaft. And then, using a T40 "TORX" socket wrench, install the ball and compression spring, and then tighten 2 new head straight screw plugs.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    3. for Pin:


      1. A004HOM

        Using a 5 mm pin punch and a hammer, install a new slotted spring pin to the No. 2 gear shift fork shaft.

        Note

        Do not tap the pin too deep.

        Standard depth
        0 mm (0 in.) (from the end surface of the No. 4 gear shift fork)

    4. for Bolt:


      1. A004HFB

        Install a new bolt to the No. 2 gear shift fork shaft.

        Torque:
        20 N*m  { 199 kgf*cm, 14 ft.*lbf }

  24. INSTALL NO. 3 GEAR SHIFT HEAD


    1. A004KS1

      Install the No. 3 gear shift head to the No. 3 gear shift fork shaft.

      Tech Tips

      While rotating, install the No. 3 gear shift head so that the shift arm is engaged with the groove of the No. 3 gear shift head.

    2. Using a 5 mm pin punch and a hammer, install a new slotted spring pin to the No. 3 gear shift fork shaft.

      Note

      Do not tap the pin too deep.

      Standard depth
      0 mm (0 in.) (from the end surface of the No. 3 gear shift head)

  25. INSTALL NO. 1 GEAR SHIFT HEAD


    1. A004JFP

      Install the No. 1 gear shift head to the No. 1 gear shift fork shaft.

    2. Using a 5 mm pin punch and a hammer, install a new slotted spring pin to the No. 1 gear shift fork shaft.

      Note

      Do not tap the pin too deep.

      Standard depth
      0 mm (0 in.) (from the end surface of the No. 1 gear shift head)

  26. INSTALL FRONT SHIFT INNER LEVER


    1. A004HKHE47
      Text in Illustration
      *1 Adhesive 1324

      Apply adhesive 1324 to the 2nd and 3rd pitches from the tip of new bolt.

    2. A004HY9

      Install the front shift inner lever to the shift shaft with a new bolt.

      Torque:
      33 N*m  { 340 kgf*cm, 25 ft.*lbf }

  27. INSTALL NO. 1 SHIFT INTER LOCK BLOCK


    1. A004J94

      Install the No. 1 shift inter lock block to the shift shaft.

  28. INSTALL SHIFT SHAFT


    1. A004H4W

      Install the shift shaft and No. 1 shift inter lock block by sliding them.

  29. INSTALL NO. 1 EXTENSION HOUSING OIL RECEIVER PIPE


    1. A004HEJ

      Install the straight pin.

    2. A004KMLE02
      Text in Illustration
      *1 No. 1 Extension Housing Oil Receiver Pipe End

      Install the No. 1 extension housing oil receiver pipe and stopper plate with a new bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note

      Confirm that the end of No. 1 extension housing oil receiver pipe is properly fitted in the groove.

  30. INSTALL NO. 2 EXTENSION HOUSING OIL RECEIVER PIPE


    1. A004JEX

      Install the No. 2 extension housing oil receiver pipe.

  31. INSTALL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A004HPYE02

      Apply MP grease to the lip of the new transmission extension housing oil seal.

    2. Using SST and a hammer, install a new transmission extension housing oil seal.

      SST
      09325-20010
      Installation depth
      0.1 to 1.1 mm (0.00394 to 0.0433 in.) (from the end surface of the transmission extension housing sub-assembly)

      Note

      Do not damage the lip of the transmission extension housing oil seal.

  32. INSTALL EXTENSION HOUSING DUST DEFLECTOR


    1. A004K1JE02

      Using SST and a hammer, install a new extension housing dust deflector.

      SST
      09950-60020   ( 09951-00750 )
      09950-70010   ( 09951-07100 )

      Tech Tips

      Make sure to tap it until it touches the transmission extension housing sub-assembly.

  33. INSTALL EXTENSION HOUSING REAR OIL SEAL


    1. A004KXKE02

      Using SST and a hammer, install a new extension housing rear oil seal.

      SST
      09612-70100   ( 09612-07210 )
      Installation depth
      1.0 to 2.0 mm (0.0394 to 0.0787 in.) (from the end surface of the transmission extension housing sub-assembly)

      Note

      Do not damage the lip of the extension housing rear oil seal.

    2. Apply MP grease to the lip of the extension housing rear oil seal.

  34. INSTALL TRANSMISSION EXTENSION HOUSING SUB-ASSEMBLY


    1. A004KSG

      Apply seal packing 1281 continuously to the transmission extension housing sub-assembly as shown in the illustration.

      Text in Illustration
      A004HAN Seal Packing 1281

      Note

      Install it within 10 minutes of the seal packing application.

    2. A004KX9E02
      Text in Illustration
      *1 clamp

      Install the transmission extension housing sub-assembly and clamp with 8 new bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Note


      • Be sure to install the transmission extension housing sub-assembly while the transmission is in neutral.

      • Make sure to align the knock pin with the hole securely.

    3. A004JSN

      Install a new bolt.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

  35. INSTALL HOLDER


    1. A004IRA

      Using a 27 mm deep socket wrench, install a new holder, compression spring and lock ball pin.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  36. INSTALL LOCK BALL PIN


    1. A004HU6

      Using a 10 mm hexagon socket wrench, install a new head straight screw plug, compression spring and lock ball pin.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  37. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A004IWW

      Install the wire harness clamp bracket with a new bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  38. INSTALL NEUTRAL POSITION SWITCH ASSEMBLY


    1. A004HFE

      Using a 19 mm union nut wrench, install the neutral position switch assembly and a new gasket.

      Torque:
      32 N*m  { 329 kgf*cm, 24 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench Click here.

    2. A004JDT

      Engage the clamp and connect the neutral position switch assembly wire.

  39. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A004KQB

      Using a 19 mm union nut wrench, install the back-up light switch assembly and a new gasket.

      Torque:
      32 N*m  { 329 kgf*cm, 24 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench Click here.

    2. A004IQSE02

      In the order indicated in the illustration, engage the 3 clamps in place, and connect the back-up light switch assembly wire and neutral position switch assembly wire.

      Tech Tips

      Install the wire harness so that there is slack on the connector side.

  40. INSTALL RELEASE FORK SUPPORT


    1. A004IG8

      Using a 19 mm deep socket wrench, install the release fork support to the clutch housing.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  41. INSTALL MANUAL TRANSMISSION DRAIN PLUG


    1. A004KVG

      Install the manual transmission drain plug with a new gasket to the transmission case.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  42. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A004HPK

      Install the manual transmission filler plug with a new gasket to the transmission case.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }