Part 1
Assembly
1. Installation of gear shift fork shaft No.3
(1) Install the gear shift fork shaft No.3 to the gear shift fork No.3 with a new bolt.
Standard value:T=19.5Nm {198.8kgf-cm} {14.4ft-lbf}
2. Installation of gear shift fork shaft No.1
(1) Install the gear shift fork shaft No.1 to the gear shift fork No.1 with a new bolt.
Standard value:T=19.5Nm {198.8kgf-cm} {14.4ft-lbf}
(2) Install a new shaft snap ring.
(3) Install the gear shift fork shaft No.1 and the gear shift fork No.1 as a unit to the gear shift fork shaft No.3 and the gear shift fork No.3.
(4) Install a new shaft snap ring.
3. Installation of gear shift fork shaft No.2
(1) Install the gear shift fork shaft No.2 to the gear shift fork No.2 with a new bolt.
Standard value:T=19.5Nm {198.8kgf-cm} {14.4ft-lbf}
(2) Install a new shaft snap ring.
4. Installation of transmission front bearing retainer oil seal
(1) Use the SST to install a new transmission front bearing retainer oil seal.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07100)
Standard value: 11.1 to 11.9 mm {0.437 to 0.469 in} (from end face of bearing retainer FR)
CAUTION:
^ Do not damage the lip of the transmission front bearing retainer oil seal.
^ Do not damage the bearing retainer FR.
(2) Apply MG GEAR OIL SPECIAL-II to the lip of the transmission front bearing retainer oil seal.
5. Installation of reverse idler gear shaft
(1) Apply MG GEAR OIL SPECIAL-II to the reverse idler gear shaft and install the reverse idler gear shaft to the reverse idler gear.
6. Installation of input shaft
(1) Apply MG GEAR OIL SPECIAL-II to the needle roller bearing of the input shaft, and install the input shaft to the output shaft.
7. Installation of counter shaft
(1) Install the input shaft, output shaft, counter shaft, reverse idler gear, reverse idler gear shaft, gear shift fork shaft No.1, gear shift fork shaft No.2, and gear shift fork shaft No.3 as a unit to the clutch housing.
(2) Temporarily tighten the reverse idler gear shaft with a new bolt via a new gasket. (Clutch housing side)
(3) Use the SST to install 2 new shaft snap rings.
SST 499895400
NOTE:
Install the shaft snap rings on the input shaft side and the counter shaft side.
8. Installation of bearing retainer FR
(1) Apply the seal gasket 1281 continuously like beads to the position of the bearing retainer FR shown in the figure.
Captions in illustration
CAUTION:
Install within 10 min. after applying the seal gasket.
(2) Apply Adhesive 1344 to the 2 to 3 pitches from the tip of a new bolt.
Captions in illustration
(3) Install the bearing retainer FR with the 7 bolts.
Standard value:T=17Nm {173kgf-cm} {12.5ft-lbf}
CAUTION:
Do not damage the lip of the bearing retainer FR oil seal.
9. Installation of oil receiver pipe
(1) Install the oil receiver pipe.
CAUTION:
Check that the tip of the oil receiver pipe is not lifted or disconnected.
10. Installation of transmission case
(1) Apply the seal gasket 1281 continuously like beads to the position of the transmission case shown in the figure.
Captions in illustration
CAUTION:
Install within 10 min. after applying the seal gasket.
(2) Check the position of the knock pin and install the transmission case.
(3) Apply Adhesive 1324 to the 2 to 3 pitches from the tip of a new bolt.
Captions in illustration
(4) Install the transmission case and clamp with the 9 bolts.
Captions in illustration
Standard value:T=29Nm {296kgf-cm} {21.4ft-lbf}
(5) Install a new reverse idler gear shaft fixing bolt via a new gasket. (Transmission case side)
Standard value:T=28Nm {286kgf-cm} {20.7ft-lbf}
(6) Tighten the reverse idler gear shaft fixing bolt. (Clutch housing side)
Standard value:T=28Nm {286kgf-cm} {20.7ft-lbf}
(7) Use the SST to install a new shaft snap ring.
SST 499895400
11. Installation of bearing retainer RR
(1) Install the shift arm pivot to the bearing retainer RR.
(2) Apply Adhesive 1324 to the 2 to 3 pitches from the tip of a new bolt.
Captions in illustration
(3) Install the bearing retainer RR with 4 TORX bolts.
Standard value:T=30Nm {306kgf-cm} {22.1ft-lbf}
12. Installation of 6th gear thrust washer
(1) Install the straight pin to the counter shaft.
(2) Apply MG GEAR OIL SPECIAL-II to the 6th gear thrust washer, and install the 6th gear thrust washer to the counter shaft.
13. Installation of needle roller bearing
(1) Apply MG GEAR OIL SPECIAL-II to the needle roller bearing, and install the needle roller bearing to the counter shaft.
14. Installation of counter shaft 6th gear
(1) Apply MG GEAR OIL SPECIAL-II to the counter shaft 6th gear, and install the counter shaft 6th gear to the counter shaft.
15. Installation of synchronizer ring No.2
(1) Apply MG GEAR OIL SPECIAL-II to the synchronizer ring No.2, and install the synchronizer ring No.2 to the counter shaft.
16. Installation of transmission hub sleeve No.4
(1) Apply MG GEAR OIL SPECIAL-II to the sliding area of the transmission clutch hub No.4.
(2) Install the transmission hub sleeve No.4 to the transmission clutch hub No.4, and install the 3 balls after installing the 3 synchromesh shifting keys No.1 and the 3 synchromesh shifting key springs No.1 as a unit.
NOTE:
^ Install the balls while pressing the synchromesh shifting key spring No.1.
^ After the installation, settle the synchromesh shifting key spring No.1.
(3) Install a new hole snap ring.
17. Installation of transmission clutch hub No.4
(1) Use the SST to install the transmission clutch hub No.4, transmission hub sleeve No.4, and gear shift fork No.4 as a unit.
SST 18682AA000
18. Installation of shaft snap ring
(1) Select a shaft snap ring so that the thrust clearance between the transmission clutch hub No.4 and the snap ring is within the standard value.
Standard value: 0 to 0.1 mm {0 to 0.00394 in}
NOTE:
Select a shaft snap ring with the maximum thickness that can be installed.
Shaft snap ring type
(2) Install a new shaft snap ring to the counter shaft.