Part 1

Transmission Assemble

Special Tools
* DT-49187 - 5th Driven Gear Replacer
* J 35405 - Differential Preload Wrench




1. Coat the rotating surface of the front differential side gear with gear oil.
2. Install the front differential side gear thrust washers to the front differential side gears.
3. Install the front differential side gears, front differential pinions, and front differential side gear thrust washers to the front differential case.
4. Install the front differential pinions with the front differential washers while turning the front differential pinion.




5. Coat the rotating surface of the No. 1 front differential pinion shaft with gear oil.
6. Install the No. 1 front differential pinion shaft to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.




7. Using a pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.




8. Using a chisel and hammer, stake the front differential case hole.




9. Hold the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

Standard backlash - 0.05-0.20 mm (0.002-0.0079 in)

10. If backlash is out of specification, select another front differential side gear thrust washer and adjust backlash. Refer to Manual Transmission Specifications (MVC 5 Speed - Manual Transmission) for Front Differential Side Gear Thrust Washer.




11. Clean the surface that contacts the differential case.
12. Using a heater, heat the front differential ring gear to 90-110°C (194-230°F).





Caution: Refer to Fastener Caution (Fastener Caution).

13. After moisture on the ring gear has completely evaporated, align the matchmarks, quickly install the front differential ring gear to the front differential case with the bolts and tighten to 106 Nm (78 lb ft).




14. Install the speedometer drive gear to the front differential case.





Note: Assemble the reverse gear and the No. 1 transmission clutch hub in the correct direction.

15. Coat the reverse gear with gear oil.
16. Install the No. 1 synchromesh shifting key springs and No. 1 transmission clutch hub to the reverse gear.
17. Using a screwdriver, install the No. 1 synchromesh shifting keys to the reverse gear.




18. Using a press (1), install the output shaft front bearing (inner race) to the output shaft.





Note: Align the No. 1 synchronizer ring set with the hole of the 1st gear.

19. Coat the No. 1 synchronizer ring set with gear oil and install it to the 1st gear.




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




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





Note:
* Align the No. 1 synchronizer ring with the No. 1 synchromesh shifting key.
* Make sure that the 1st gear rotates.

22. Using a press (1), install the No. 1 transmission clutch hub to the output shaft.




23. Coat the gear bushing ball (1) with MP grease, and install it to the output shaft.




24.
Coat the 2nd gear bushing with gear oil and install it to the output shaft.




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




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





Note: Align the key groove on the No. 2 synchronizer ring set with the No. 1 synchromesh shifting key.

27. Coat the No. 2 synchronizer ring set with gear oil and install it to the No. 1 transmission clutch hub.




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




29. Using a press (1), install the 3rd driven gear to the output shaft.




30. Install the output gear spacer to the output shaft.




31. Using a press (1), install the 4th driven gear to the output shaft.




32. Using a press (1), install the output shaft front bearing (inner race) to the output shaft.




33. Using a press (1), install the input shaft front bearing (inner race).




34. Coat the No. 2 transmission hub sleeve with gear oil.

Note: Install the No. 2 transmission clutch hub sleeve and the No. 2 transmission clutch hub in the correct direction.

35. Using a screwdriver, install the synchromesh shifting key (1) to the input shaft.




36. Coat the 3rd gear bearing with gear oil and install it to the input shaft.




37. Coat the 3rd gear with gear oil and install it to the input shaft.




38. Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear.





Note:
* Align the claw of the clutch hub No. 2 with the notch of the No. 3 synchronizer ring.
* Make sure that the 3rd gear can rotate.

39. Using a press (1), install the No. 2 transmission clutch hub to the input shaft.




40. Select a snap ring so that clearance between the No. 2 transmission clutch hub and the No. 2 clutch hub shaft snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring.

Standard clearance - 0.1 mm (0.0039 in) or less
Refer to Manual Transmission Specifications (MVC 5 Speed - Manual Transmission) for Snap Ring Thickness 1.




41. Coat the 4th gear bearing spacer with gear oil and install it to the input shaft.





Note: Align the claw of the No. 2 clutch hub with the notch of the No. 4 synchronizer ring.

42. Coat the No. 4 synchronizer ring with gear oil and install it to the No. 2 transmission clutch hub.




43. Coat the 4th gear needle roller bearing with gear oil and install it to the input shaft.




44. Coat the 4th gear with gear oil and install it to the input shaft.





Note:
* Install the bearing with its groove facing rearward.
* Make sure that the 3rd gear rotates.

45. Using a press (1), install the input shaft rear radial ball bearing to the input shaft.




46. Select a snap ring so that the clearance between the input shaft radial ball rear bearing and the input shaft rear bearing snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring.

Standard clearance - 0.1 mm (0.004 in) or less
Refer to Manual Transmission Specifications (MVC 5 Speed - Manual Transmission) for Snap Ring Thickness 2.




47. Install the No. 5 synchronizer ring middle, No. 5 synchronizer ring outer, and synchronizer pull ring to the No. 5 synchronizer ring inner. Using a screwdriver, secure them with the snap ring.





Note: Align the projection of the shifting key spring with the hole of the No. 3 clutch hub.

48. Install the No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.

Note:
* Engage the shifting key spring claw to the center of the teeth of the synchronizer ring.
* Align the projection of the shifting key spring with the hole of the No. 3 clutch hub.

49. Install the synchronizer ring set and No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.
50. Coat the new transaxle case oil seal lip with MP grease.




51. Using a suitable driver (1) and a hammer, install a transaxle case oil seal.

Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in)




52. Using a suitable drive (1) and hammer, install the front differential case front tapered roller bearing (outer race) to the manual transaxle case.




53. Using a press (1), install the front differential case front tapered roller bearing (inner race) to the front differential case.




54. Using a suitable drive (1) and hammer, install the front differential case rear shim.
55. Install the front differential case rear tapered roller bearing (2) (outer race).




56.
Using a press (1), install the front differential case rear tapered roller bearing (inner race).




57. Coat the transmission case oil seal lip with MP grease.

Oil seal installation depth - 3.0-4.0 mm (0.1181-0.1575 in)

58. Using a suitable driver (1) and a hammer, install a transmission case oil seal to the manual transmission case.




59. Using a suitable driver (1) and a hammer, install the output shaft rear bearing (outer race) to the manual transmission case.

Clearance - 3.8-4.4 mm (0.150-0.173 in)





Note: Align the projection of the output shaft cover with the transmission groove.

60. Coat the output shaft cover with MP grease, and install it to the manual transaxle case.




61. Using a suitable driver (1) and a hammer, install the new output shaft front bearing (outer race).




62. Install the output shaft to the manual transaxle case.




63. Install the transmission case to the manual transaxle case with the bolts (1-14) and tighten to 29 Nm (21 lb ft).




64. Install the bolts (1) to the manual transaxle case and tighten to 29 Nm (21 lb ft).




65. Install the output shaft rear bearing case shim to the output shaft.




66. Install the rear bearing retainer to the manual transmission case with the bolts and tighten to 43 Nm (32 lb ft).




67. Turn the output shaft in both directions to make sure that it starts to turn smoothly.
68. Using a socket wrench and torque wrench, inspect the preload. Refer to Manual Transmission Specifications (MVC 5 Speed - Manual Transmission) for Output Shaft Preload.
69. If preload is not as specified, select a proper output shaft rear bearing shim and adjust it.
The preload of all the output shaft rear bearing shim varies in torque from about 0.04-0.06 Nm (0.35-0.53 lb in). Refer to Manual Transmission Specifications (MVC 5 Speed - Manual Transmission) for Output Shaft Rear Bearings Thickness.
70. Remove the output shaft rear set nut from the output shaft.




71. Remove the bolts and rear bearing retainer from the manual transmission case.




72. Remove the output shaft rear bearing shim from the output shaft.




73. Remove the bolts (1).




74. Remove the bolts (1-14) and manual transmission case from the manual transaxle case.




75. Remove the output shaft assembly from the front manual transaxle case.




76. Install the differential case assembly to the manual transaxle case.




77. Install the bolts (1-14) and manual transmission case to the manual transaxle case, tighten the bolts to 29 Nm (21 lb ft).




78. Install the bolts (1) to the manual transaxle case and tighten to 29 Nm (21 lb ft).
79. Turn the differential case in both directions to make sure that it starts to turn smoothly.




80. Using J 35405 and a torque wrench (1), inspect preload. Refer to Manual Transmission Specifications (MVC 5 Speed - Manual Transmission) for Preload Specifications.
If preload is not as specified, select a proper front differential case rear shim and adjust it.
The preload of all the front differential case rear shims varies in torque from about 0.04-0.06 Nm (0.35-0.53 lb in). Refer to Manual Transmission Specifications (MVC 5 Speed - Manual Transmission) for Front Differential Case Shim Thickness.