Part 2

Transmission Assemble





81. Remove the bolts (1).




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




83. Remove the differential case assembly from the manual transaxle case.
84. Coat the lip of the new front transaxle case cover oil seal with MP grease.




85. Using a suitable driver (1) and a hammer, install a new front transaxle case cover oil seal to the manual transaxle case.

Clearance - 1.0-2.0 mm (0.0394-0.0787 in)

86. Coat the new input shaft front bearing with gear oil.




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

Clearance - 4.28-4.60 mm (0.1685-0.1811 in)




88. Install the manual transaxle case receiver to the manual transaxle case with the bolts (1) and tighten to 7 Nm (62 lb in).




89. Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the manual transaxle case.




90. Apply gear oil to each sliding part of the output shaft assembly.
91. Lift the differential case assembly with the output shaft assembly leaned, and install it to the manual transaxle case.




92. Apply gear oil to each sliding part of the input shaft assembly.
93. Install the input shaft assembly to the manual transaxle case while tilting the output shaft assembly.




94. Coat the No. 2 gear shift fork (1) with gear oil, and install it to the input shaft assembly.




95. Install the No. 3 gear shift fork to the No. 3 gear shift fork shaft.
96. Using a brass bar and hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft.




97. Apply gear oil to each sliding part of the No. 3 gear shift fork shaft (1), and install it to the manual transaxle case.




98. Apply gear oil to each sliding part of the No. 1 gear shift fork (1), and install it to the output shaft assembly.




99. Install the No. 1 gear shift head to the No. 2 gear shift fork shaft.
100. Apply gear oil to each sliding part of the No. 2 gear shift fork shaft (2), and install it to the manual transaxle case.




101. Install the shift fork set bolt (1) and shift head set bolt to the No. 1 gear shift head and tighten to 24 Nm (18 lb ft).




102. Using a magnetic pick-up tool, install the reverse shift fork roller to the reverse shift fork.




103. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 1 shift fork shaft.




104. Install the No. 1 gear shift fork shaft (1) to the manual transaxle case.




105. Install the shift fork set bolt (1) to the No. 1 gear shift fork and tighten to 24 Nm (18 lb ft).




106. Install the reverse shift arm bracket assembly to the manual transaxle case with the bolts (1) and tighten to 17 Nm (13 lb ft).




107. Using a magnetic pick-up tool, install the reverse shift fork roller to the reverse shift fork.




108. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 1 shift fork shaft.




109. Install the No. 1 gear shift fork shaft (1) to the manual transaxle case.




110. Install the shift fork set bolt (1) to the No. 1 gear shift fork and tighten to 24 Nm (18 lb ft).




111. Install the reverse shift arm bracket assembly to the manual transaxle case with the bolts (1) and tighten to 17 Nm (13 lb ft).




112. Coat the reverse idler gear and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft.





Note: Align the mark of the reverse idler gear shaft with the hole of the bolt (1).

113. Install the reverse idler gear to the manual transaxle case.




114. Clean the transmission magnet and install it to the manual transaxle case.




115. Install the No. 1 oil receiver pipe to the manual transmission case with the bolt (1) and tighten to 17 Nm (13 lb ft).




116. Install the No. 2 oil receiver pipe to the manual transmission case with the bolt (1).




117. Install the transmission oil baffle and reverse restrict pin with the bolt (1) and tighten to 17 Nm (13 lb ft).




118. Using a pin punch, install the slotted pin to the reverse restrict pin assembly.

Clearance (a) - 12.5-13.5 mm (0.492-0.531 in)




119. Coat the reverse restrict pin plug with adhesive. Using a hexagon wrench (6 mm), install the plug (1) in the manual transmission case and tighten to 13 Nm (10 lb ft).




120. Apply a bead of sealant Three Bond 1281, or equivalent, to the manual transmission case as shown.




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




122. Coat the bolts with Three Bond 1281 sealant or equivalent.
123. Install the bolts (1) to the manual transaxle case.




124. Coat the bolt with adhesive. Install a new gasket to the manual transmission case with the bolt (1) and tighten to 30 Nm (22 lb ft).




125. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 1 gear shift fork shaft.




126. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 2 gear shift fork shaft.




127. Using a snap ring expander, install the input shaft rear bearing shaft snap ring.




128. Install the output shaft rear bearing shim to the output shaft.




129. Coat the bolts with Three Bond 1281 sealant or equivalent.
130. Install the rear bearing retainer to the manual transmission case with the bolts and tighten to 43 Nm (32 lb ft).




131. Using DT-49187 - replacer (1), install the 5th driven gear to the output shaft.




132. Coat the 5th gear needle roller bearing with gear oil and install it to the input shaft.




133. Coat the 5th gear with gear oil and install it to the input shaft.

Note: Align the projection of the synchronizer ring with the hole of the 5th gear.

134. Install the No. 3 transmission clutch hub to the input shaft.




135. Install the No. 3 transmission hub sleeve and No. 3 gear shift fork to the No. 3 transmission clutch hub.




136. Coat the shift fork set bolt (1) with Three Bond 1281 sealant, or equivalent, and install it to the No. 3 gear shift fork and tighten to 24 Nm (18 lb ft).




137. Select a snap ring that will allow minimum axial play. Using a brass bar and a hammer, install the shaft snap ring. Refer to Manual Transmission Specifications (MVC 5 Speed - Manual Transmission) for Snap Ring Thickness 3.

Clearance - 0.1 mm (0.004 in) or less




138. Engage the 1st and 2nd gears (1) simultaneously.




139. Install a new manual transmission output shaft rear set nut and tighten to 123 Nm (90 lb ft).




140. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
141. Disengage the gears.




142. Apply Three Bond 1281 sealant, or equivalent, to the manual transmission case cover sub-assembly as shown in the installation.




143. Install the manual transmission case cover subassembly to the manual transaxle case with the bolts (1-10).




144. Install the drain plug (1) to the manual transmission case with a new gasket and tighten to 49 Nm (36 lb ft).




145. Install the manual transmission filler plug (1) to the transaxle case with a new gasket and tighten to 49 Nm (36 lb ft).




146. Coat the shift and select lever shaft assembly with gear oil, and install it to the manual transmission case.




147. Install the back-up light switch assembly (1) to the manual transmission case with a new gasket and tighten to 40 Nm (30 lb ft).




148. Install the manual transmission breather plug (1) to the manual transmission case.




149. Install the shift gate pin (1) to the manual transmission case and tighten to 29 Nm (21 lb ft).




150. Install the No. 1 lock ball assembly (1) to the manual transmission case with the pin and tighten to 29 Nm (21 lb ft).




151. Install the No. 2 clutch tube bracket (1) with the bolt and tighten to 15 Nm (11 lb ft).




152. Coat the bolts (1) with Three Bond 1281 sealant, or equivalent. Install a new gasket and the control shaft cover with the bolts and tighten to 20 Nm (15 lb ft).




153. Install the control shift lever with the shift outer lever lock pin (1) to the shift and select lever shaft.
154. Install the spring washer with the nut and tighten to 12 Nm (9 lb ft).




155. Coat the bolts (1, 2) with Three Bond 1281 sealant, or equivalent. Install the selecting bellcrank assembly to the manual transmission case with the bolts and tighten to 20 Nm (15 lb ft).
156. Install a new O-ring and the speedometer driven hole cover sub-assembly to the transmission case with the bolt and tighten to 6 Nm (53 lb in).
157. Install the clutch release fork boot to the manual transaxle case.




158. Using a deep socket wrench, install the release fork support (1) to the manual transaxle case and tighten to 47 Nm (36 lb ft).
159. Coat the clutch release bearing assembly with release hub grease, and install it to the clutch release fork sub-assembly.
160. Apply clutch spline grease to the input shaft spline.




161. Install the clutch release fork sub-assembly to the input shaft.