Manual Transmission Unit Assembly
Manual Transmission Unit AssemblyReference: Manual Transmission Assembly Dismounting and Remounting
Reference: Manual Transmission Unit Disassembly
NOTE:
^ Before assembly, wash and inspect each part and apply specified gear oil to sliding faces of bearing and gear.
^ Use new circlips on shaft for installation. Don't reuse circlips.
1. Set intermediate case (1) to vise (3).
Clean mating surfaces of intermediate case both sides, if intermediate case is reused.
2. Install main shaft assembly (1) to intermediate case.
NOTE: When fitting of intermediate case (1) and bearing is tight, tap rear face of intermediate case (1) with plastic hammer lightly as it will cause main shaft assembly (2) to install.
3. Fix bearing with new C-ring (1) using special tool.
4. Align key slots of high speed synchronizer hub (1) and protrusion of 4th gear synchronizer ring (2) and set input shaft assembly to main shaft assembly.
Check that input shaft assembly turns lightly.
5. Fix with new C-ring to countershaft rear bearing.
6. Install countershaft (1) and rear bearing (2) to intermediate case (3).
NOTE:
^ When installing rear bearing (2), bring it so that its C-ring side is at rear side of intermediate case as shown in the figure.
^ When fitting of intermediate case (3) and rear bearing (2) is tight, tap outer race of rear bearing (2) lightly and evenly with plastic hammer. 7) Install reverse idle gear (1) and shaft (2).
7. Install reverse idle gear (1) and shaft (2).
8. Install main shaft and countershaft bearing plate (1) to intermediate case.
9. Set pin (1) and thrust washer (2) to countershaft.
10. Assemble countershaft 5th gear (1), plate spring (2), circlip (3), 5th & reverse synchronizer sleeve (4), balk levers (5), synchronizer key spring (6) and 5th & reverse synchronizer ring (7) according to the following procedure.
a. Install plate spring (1) to countershaft 5th gear (3) and fix plate spring (1) with new circlip (2) using special tool.
Special Tool
(A): 09900-06107
b. Install 5th & reverse synchronizer sleeve (1) to countershaft 5th gear (2) in specified direction as shown in the figure.
c. Fit balk levers (1) to countershaft 5th gear (2) in specified direction as shown in the figure.
d. Install synchronizer key spring (1).
e. Slide 5th & reverse synchronizer sleeve (1) until sliding surface of balk lever is locked into key location teeth of 5th & reverse synchronizer sleeve (1) with balk lever and synchronizer key spring pushed.
f. Install synchronizer ring (1) to countershaft 5th gear (4).
NOTE: Align protrusions (2) of synchronizer ring (1) with groove (3) of countershaft 5th gear (4).
11. Install needle bearing (1) into countershaft 5th gear assembly (2) which was assembled in Steps a) to f).
12. Install countershaft 5th gear assembly (2) to countershaft (3) facing gear side to intermediate plate (4).
13. Press-fit 5th speed synchronizer dog (1) to countershaft with hydraulic press (2) and special tool.
14. Select circlip (1) that will make clearance in circlip groove 0.1 mm (0.0039 inch) or less.
Circlip thickness specifications
Circlip thickness specifications:
15. Fix with circlip (1) as shown in the figure and check that countershaft 5th gear (2) turns lightly.
16. Check countershaft 5th gear (1) thrust clearance using thickness gauge (2).
If clearance exceeds limit, repeat Step 1) to 15) again or replace defective part(s).
Countershaft 5th gear thrust clearance 0.10 - 0.35 mm (0.0039 - 0.0138 inch)
17. Install reverse gear shift arm bracket (1) to intermediate case (2).
18. Install reverse gear shift arm (1) to reverse gear shift fork (2) fixing it with new circlip (3), if necessary.
19. Fit reverse gear shift arm / fork (1) to reverse idle gear and then install reverse gear shift arm / fork (1) to reverse gear shift arm bracket (2).
20. Insert spring (3) and ball (4) to reverse gear shift fork (5) using magnet.
21. Insert 5th & reverse guide shaft (1) to reverse gear shift fork (3) and intermediate case (4) from front side pushing ball (5) by rod (2).
CAUTION:
Be sure to install 5th & reverse guide shaft as specified direction.
If failure to follow above-mentioned procedure, 5th & reverse guide shaft could result in wrong assembly which ball (5) installed to (6) hole for interlock pin.
22. Insert ball (1) to reverse gear shift fork (2) and interlock pin (3) to intermediate case (4) using magnet.
23. Install 5th gear shaft (2) after fitting 5th gear shift fork (1) to 5th & reverse synchronizer sleeve (3).
24. Drive spring pin (1) into 5th gear shift fork (2) and shaft (3) up to 5th gear shift fork (2) surface using plastic hammer.
25. Install new circlips (1) to groove of 5th gear shift shaft (2) and 5th & reverse guide shaft (3) using lever (4) or the like and hammer.
26. Insert interlock pin (1) to intermediate case (2) using magnet (3).
27. Apply grease to straight pin (1) and install straight pin (1) to low speed gear shift shaft (2).
28. Install low speed gear shift fork (1) and low speed gear shift shaft (2).
29. Insert interlock pin (1) to intermediate case (2) using magnet (3).
30. Install high speed gear shift fork (1) and high speed gear shift shaft (2).
31. Install new circlips (1) to high speed gear shift shaft (2) and low speed gear shift shaft (3) using lever (4) or the like and hammer.
32. Install new low speed gear shift fork bolt (1) and high speed gear shift fork bolt (2) and tighten bolts to specified torque.
33. Install locating balls (1), locating springs (2) and new locating screws (3).
34. Place intermediate case assembly (1) upright as shown in the figure using workbench (2) or the like.
35. Apply sealant evenly to front case side of intermediate case (1) as shown in the figure.
A: Sealant 99000-31110
36. Clean mating surface of front case (1) and install it to intermediate case.
37. Fix new C-rings (1, 2) to bearings as shown in the figure.
38. Clean mating surface of input shaft bearing retainer (1) and apply sealant evenly to input, shaft bearing retainer (1).
B: Sealant 99000-31110
39. Install input shaft bearing retainer (1) tightening new input shaft bearing plate bolt to specified torque.
40. Insert gear shift inner shaft (1) and gear shift inner lever (2) to rear case (4).
41. Drive spring pin (3) into gear shift inner lever (2) using special tool.
Special Tool
(A): 09922-85811
42. Clean mating surface of rear case (1) and apply sealant evenly to rear case side of intermediate case (2).
43. Install rear case (1) to intermediate case (2) with tip end of gear shift shaft inner lever (3) hooked on head of gear shift shaft (4).
Tighten case bolts to specified torque.
44. Tighten return spring low bolt (2) and return spring reverse bolt (black color) (1).
NOTE: Install return spring reverse bolt (black color) (1) to left side of case.
Tightening torque
Return spring reverse bolt (black color) a: 37 Nm (3.7 kg-m, 27.0 ft. lbs.)
Return spring low bolt b: 37 Nm (3.7 kg-m, 27.0 ft. lbs.)
45. Install back-up light switch with new gasket.
46. Install clutch housing (3) and torque its bolts to specification.
NOTE: Use new two mounting bolts (1) as shown in the figure.
Tightening torque
Clutch housing bolt a: 36 Nm (3.6 kg-m, 26.0 ft. lbs.)
47. Install clutch release fork (2) and release bearing (4).
