4. Transmission Assemble

Transmission Assemble

Special Tools
* DT 46496 (DW09940-53111) Gear, Bearing Installer
* DT 46497 (DW09943-78210) Bushing, Seal Installer
* DT 46612 (DW09913-76010) Bushing, Seal Installer
* DT 47515 (DW220-100) Needle Bearing Remover
* DT 47516 Needle Bearing Installer
* DT 47517 Input Shaft Holder
* KM-519 Ring Installer





Note: Use a new oil seal.

1. Install a new input shaft oil seal using DT 46497 (1).

Note: Coat the transaxle inner parts with gear fluid when installing.

2. Install a new differential right side oil seal using DT 46612.




3. Install the oil plate with the bolts.
4. Install the oil gutter with the bolt.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the oil level plug, including the steel gasket and tighten to 28 Nm (21 lb ft).
6. Install the differential left side oil seal using KM-519 (2).




7. Install the differential assembly (1) to the right side of the transaxle case. Position the differential ring gear surface lower than the right side of the transaxle case surface.




8. Install the low and the high speed shift shaft assembly to the gear unit.

Note: Do NOT damage the teeth of the counter shaft pinion and the differential ring gear.

9. Push the gear unit by matching the unit with the input and the counter shaft hole (1).




10. Install the 5th reverse gear shift shaft.

Note: Match the marking of the reverse idle gear shaft bolt hole with the protrusion of the transaxle case - right side.

11. Install the reverse idle gear shaft assembly (2).
12. Install the reverse gear shift lever (1).
13. Install the reverse gear shift lever bolt (3) and tighten to 23 Nm (17 lb ft)




14. Install the 3rd-4th gear shift shaft ball and spring (1) and tighten to 13 Nm (10 lb ft).

Note: Install the correct gear shift shaft spring that was marked when removing.

15. Install the 5th reverse gear shift shaft ball, spring (2), and bolt and tighten to 13 Nm (10 lb ft).




16. Install the shift and select shaft needle bearing using DT 47516 (1) with DT 47515 (2).




17. Install the gear shift and select shaft assembly.
18. Install the shift and select shaft oil seal (6).
19. Install the shift and select bellows (5).
20. Install the gear select spring assemblies (2).
21. Install the gear shift interlock plate (9).
22. Install the gear shift lever (8).
23. Install the 5th and reverse gear shift cam (3).
24. Install the return spring (7).
25. Install the shift and select shaft (4).





Note: When installing the inner and outer pins, make the crevices of 2 pins symmetric to each other.

26. Install the shift and the select lever inner and outer pins.




27. Coat the transaxle case with recommended Transaxle Case Sealant-THREE BOND 1215.
28. Install the transaxle left side case to the transaxle right side case bolts (1) and tighten to 19 Nm (14 lb ft).




29. Install the 1st-2nd gear shift shaft ball, spring, and bolt (1) and tighten to 13 Nm (10 lb ft).
30. Install the 3rd-4th gear shift shaft ball, spring, and bolt (2) and tighten to 13 Nm (10 lb ft).
31. Install the reverse idle gear shaft bolt (3) and tighten to 23 Nm (17 lb ft).





Note: Check if the bearing and the outer race are correctly installed by rotating counter shaft.

32. Install the counter shaft bearing outer race (2) using DT 46496 (1).




33. Measure the clearance between the transaxle case surface (3) and the bearing outer race (2) using a straight ruler (1) and a gauge. Refer to Manual Transmission Specifications (Manual Transmission Specifications).
34. Select a shim so that clearance is within standard.





Note: Use only new bolts.

35. Install the side cover plate (1).
36. Install the side cover bolts and tighten to 7 Nm (62 lb in).

Note: Position the machined boss side toward the side cover plate.

37. Install the counter shaft 5th gear (3).




38. Push the shift fork toward the 5th gear.
39. Hold the input shaft using DT 47517 (1).
40. Install the input shaft nut and tighten to 70 Nm (52 lb ft)




41. Insert the input shaft 5th gear bearing into the input shaft.
42. Install the 5th gear wave spring and synchronizer ring, matching the synchronizer's oil groove and input shaft punched mark (1).





Note: When assembling the synchronizer sleeve and hub, ensure distance (a) equals distance (b).

43. Install the synchronizer springs to hub (1).
44. Install the synchronizer key (2).
45. Position the longer boss side of hub toward inner side (3).
46. Position the chamfered spline of sleeve toward inner side and install the hub to the sleeve (4).




47. Install the 5th gear fork to the synchronizer hub assembly.

Note: Position the longer boss side of hub toward inner side and match the synchronizer key and the hub groove with the input shaft punched mark.

48. Install the 5th gear fork and the synchronizer hub assembly to the input shaft.




49. Push the 5th gear shift fork toward the 5th gear.

Note: Use a new shift fork pin.

50. Install the 5th gear shift fork pin using a pin punch and a hammer (1).




51. Install the 5th gear synchronizer plate.
52. Install the 5th gear snap ring (1).

Note: Use only new snap rings.

53. Install the 5th gear fork snap ring (2).
54. Tighten the fork plug after inserting the guide ball into the fork hole.




55. Install the side cover (1) with recommended Side Cover Sealant-THREE BOND 1215.
56. Install the side cover bolts and tighten to 10 Nm (89 lb in).




57. Install the shift interlock bolt and tighten to 23 Nm (17 lb ft).




58. Install the backup light switch (1) and tighten to 17 Nm (13 lb ft).
59. Install the speedometer driven gear assembly (2).
60. Install the speedometer driven gear bolt and tighten to 6 Nm (53 lb in).
61. Install the related clutch parts.




62. Remove the transaxle assembly from DT 46553 (1).
63. Install the transaxle assembly. Refer to Transmission Replacement (Transmission Replacement).