Transmission Repair Procedure

1. Raise the vehicle on a suitable lift.

2. Remove the left front wheel assembly and front water deflector.





3. Remove the battery from the vehicle.

4. Move the fuse box to allow access to the transmission mount by removing 3 retaining nuts.





5. Support the powertrain assembly using a suitable engine support fixture and remove the transmission mount bolt and nut.





6. Lower the powertrain assembly enough for the transmission side cover to clear the suspension frame in the wheel well.

NOTICE:
Make sure to leave at least 1 mm space between the left inner CV joint and the frame.

It is important to make sure the inner CV joint does not rest on the suspension frame. The weight of the powertrain will bend the CV boot clamp and possibility lead to a CV joint lubricant leak.





7. Place a drain pan under the transmission and remove the transmission side cover and gasket.








8. Inspect the retaining ring on the input shaft. The failure will be indicated by the retaining ring being spread open and the input gear no longer aligned with the main shaft gear.

If the retaining ring is expanded and the gear is misaligned continue to step 9 for repair.

If the retaining ring is ok and the gear has not changed position, continue with diagnosis and inspection.





9. Remove and discard the fifth gear snap ring and drive the gear back into place using 32 mm socket or equivalent and brass hammer.





10. Install the new retaining ring (24078-85Z00) with the rounded side toward the transmission.








11. Remove the sliding fork by first removing the two mounting cap bolts. These bolts are locked in with thread locking compound.

NOTICE
The cap bolt hex can be easily damaged if removed improperly.

It is important to make sure the tool used to remove the bolts is seated completely inside the hex of the cap bolt. If damage occurs to the bolt hex, there will be a risk of getting metal particles in the transmission and additional time will be required to remove the damaged bolt(s).





12. Remove the retaining ring from the fifth speed shift sleeve. Then use the bearing puller J-22888-20-A with puller legs J- 22888-35 or equivalent tool, to remove the fifth gear shift sleeve assembly. Hook the puller under the synchronizer sleeve. Do not disassemble the shift sleeve assembly after removal.





13. Carefully slide the main shaft driven fifth gear assembly off the main shaft and discard. Do not lose the split washer, retaining ring, and split needle bearings.





14. Make sure the split washer, retaining ring, and split needle bearings are installed as shown.





15. Slide the new fifth speed gear assembly (24250-85Z00 for 04-06 or 24250-85Z10 for 07-08) on the main shaft.





16. Be sure to align the new synchronizer ring (24433-85Z00) with the synchronizer hub before re-installing.








17. Drive the synchronizer hub to the main shaft with 32 mm socket or equivalent until it is seated. Install the new retaining ring (24085-85Z00) with the rounded edge facing the transmission, (See step 10 for example).








18. Install the new sliding fork (25251-85Z01) with new bolts (25253-85Z00). Reuse the brass shoes from the old fork. Tighten the 5th-gear fork bolts to 22 N�m (16 lb-ft).





19. Re-install the cover with new cover gasket (24729-85Z00). Tighten the transaxle cover bolts to 18 N�m (13 lb-ft).





20. Lower the vehicle. Raise the powertrain assembly and re-align the transmission with the transmission mount. Tighten the transaxle mounting bracket bolts to 48 N�m (35 lb-ft).





21. Re-install the fuse box and battery.





22. Raise the vehicle and re-install the front water deflector and wheel assembly.

23. Check the transmission fluid level and top off if necessary. Refer to "Checking Fluid Level" found in the manual transmission section of the service manual.

24. Verify transmission shifts properly in all gear positions.