With G52 Transmission

1. INSERT NO. 1 AND NO. 2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
CAUTION: Install the key springs positioned so that their end gaps are not in line.

2. INSTALL THIRD GEAR AND NO. 2 HUB SLEEVE ON OUTPUT SHAFT
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
(c) Install the needle roller bearing in the 3rd gear.

(d) Using a press, install the 3rd gear and No. 2 hub sleeve.

3. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.

(b) Using snap ring pliers, install the snap ring.

4. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)

5. INSTALL SECOND GEAR AND NO. 1 HUB SLEEVE
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
(c) Install the needle roller bearing in the 2nd gear.

(d) Using a press, install the 2nd gear and No. 1 hub sleeve.

6. INSTALL LOCKING BALL AND FIRST GEAR ASSEMBLY
(a) Install the locking ball in the shaft.
(b) Apply gear oil to the needle roller bearing.
(c) Assemble the 1st gear, synchronizer ring, needle roller bearing and bearing inner race.

(d) Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys.
(e) Turn the inner race to align it with the locking ball.

7. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing on the output shaft with the outer race snap ring groove toward the rear.
NOTE: Hold the 1st gear inner race to prevent it from falling.
SST 09506-35010

8. MEASURE FIRST AND SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st and 2nd gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)

9. INSTALL FIFTH GEAR
Using SST and a press, install the 5th gear.
SST 09506-35010

10. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.

(b) Using a screwdriver and hammer, install the snap ring.

11. INSTALL SLEEVE TO OUTPUT SHAFT
Using a plastic hammer, tap the sleeve onto the output shaft.

12. INSTALL OUTPUT SHAFT TO INTERMEDIATE PLATE Install the output shaft into the intermediate plate by pulling on the output shaft and tapping on the intermediate plate.

13. INSTALL INPUT SHAFT
(a) Apply MP grease to the 1 3 needle roller bearings and install them into the input shaft.

(b) Install the input shaft to the output shaft with the synchronizer ring slots aligned with the shifting keys.

14. INSTALL COUNTER GEAR
Install the counter gear into the intermediate plate while holding the counter gear, and install the counter rear bearing with SST.
SST 09316-60010 (0931 6-00010, 09316-00020)

15. INSTALL BEARING SNAP RING
Using snap ring pliers, install the snap ring.
NOTE: Be sure the snap ring is flush with the intermediate plate surface.

16. INSTALL REAR BEARING RETAINER
Using a torx socket wrench, install and torque the screws.
Torque: 185 kg-cm (13 ft-lb, 18 N-m)

17. INSTALL REVERSE SHIFT ARM BRACKET
Install the reverse shift arm bracket and torque the bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N-m)

18. INSTALL BALL AND SPACER

19. INSERT COUNTER FIFTH GEAR INTO NO. 3 HUB SLEEVE
(a) Install the shifting keys and No. 3 hub sleeve onto the counter 5th gear.
(b) Install the shifting key springs under the shifting keys.
CAUTION: Install the key springs positioned so that their end gaps are not in line.

20. INSTALL COUNTER FIFTH GEAR WITH NO. 3 HUB SLEEVE ASSEMBLY AND NEEDLE ROLLER BEARINGS
(a) Apply gear oil to the needle roller bearings.
(b) Install the counter 5th gear with No. 3 hub sleeve and needle roller bearings.

21. INSTALL SYNCHRONIZER RING AND NO. 5 GEAR SPLINE PIECE
(a) Install the synchronizer ring on No. 5 gear spline piece.
(b) Using SST, drive in No. 5 gear spline piece with the synchronizer ring slots aligned with the shifting keys.
SST 09316-60010 (09316-00010)
NOTE: When installing No. 5 gear spline piece, support the counter gear in front with a 3-5 lb hammer or equivalent.

22. INSTALL LOCK NUT
(a) Engage the gear double meshing.

(b) Install and torque the lock nut.
Torque: 1,200 kg-cm (87 ft-lb, 118 N-m)
(c) Stake the lock nut.

(d) Disengage the gear double meshing.

23. MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the counter 5th gear thrust clearance.
Standard clearance:
0.10 - 0.30 mm (0.0039 - 0.0118 in.)

24. INSTALL REVERSE SHIFT ARM TO REVERSE SHIFT ARM BRACKET
Install the reverse shift arm to the pivot of the reverse shift arm bracket.

25. INSTALL REVERSE IDLER GEAR AND SHAFT
(a) Install the reverse idler gear on the shaft.
(b) Align the reverse shift arm shoe to the reverse idler gear groove and insert the reverse idler gear shaft to the intermediate plate.
(c) Install the reverse idler gear shaft stopper and torque the bolt.
Torque: 175 kg-cm (13 ft-lb, 17 N-m)

26. INSTALL NO. 1 AND NO. 2 SHIFT FORK AND NO. 2 SHIFT FORK SHAFT
Place No. 1 and No. 2 shift forks into the groove of No. 1 and No. 2 hub sleeves and install No. 2 fork shaft to No. 1 and No. 2 shift forks through the intermediate plate.

27. INSTALL INTERLOCK PIN
(a) Apply MP grease to the interlock pins.
(b) Using a magnetic finger and screwdriver, install the interlock pin into the intermediate plate.

28. INSTALL NO. 1 SHIFT FORK SHAFT
(a) Install the interlock pin into the shaft hole.

(b) Install No. 1 fork shaft to No. 1 shift fork through the intermediate plate.

29. INSTALL INTERLOCK PIN
Using a magnetic finger and screwdriver, install the interlock pin into the intermediate plate.

30. INSTALL NO. 3 SHIFT FORK SHAFT
(a) Install the interlock pin into the shaft hole.

(b) Install No. 3 fork shaft to the reverse shift arm through the intermediate plate.

31. INSTALL NO. 5 SHIFT FORK SHAFT AND REVERSE SHIFT HEAD
(a) Install the reverse shift head to No. 5 fork shaft.
(b) Insert No. 5 fork shaft to the intermediate plate and put in the reverse shift head to No. 3 shift fork shaft.

32. INSTALL NO. 4 SHIFT FORK SHAFT, NO. 3 SHIFT FORK AND LOCKING BALLS
(a) Using a magnetic finger and screwdriver, install the locking ball into the reverse shift head hole.

(b) Shift No. 3 hub sleeve to the 5th speed position.

(c) Place No. 3 shift fork into the groove of No. 3 hub sleeve and install No. 4 fork shaft to No. 3 shift fork and reverse shift arm.

(d) Using a magnetic finger and screwdriver, install the locking ball into the intermediate plate and insert No. 4 fork shaft to the intermediate plate.

33. CHECK INTERLOCK
(a) Shift No. 1 fork shaft to the 1st speed position.

(b) No. 2, No. 3, No. 4 and No. 5 fork shafts should not move.

34. INSTALL THREE SLOTTED SPRING PINS AND TWO BOLTS
(a) Using a pin punch and hammer, drive the slotted spring pins into shift fork, reverse shift arm and reverse shift head.

(b) Install and torque the two bolts to the shift forks.
Torque: 200 kg-cm (14 ft-lb, 20 N-m)

35. INSTALL E-RINGS
Using a hammer, install the two E-rings.

36. INSTALL LOCKING BALLS, SPRINGS AND SCREW PLUGS
(a) Apply liquid sealer to the plug threads.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(b) Install the locking balls, springs and screw plugs and torque the screw plugs with a torx socket wrench.
Torque: 190 kg-cm (14 ft-lb, 19 N-m)
NOTE: Install the short spring into the bottom of the intermediate plate.

37. DISMOUNT INTERMEDIATE PLATE FROM VISE
(a) Dismount the intermediate plate from the vise.
(b) Remove the bolts, nuts, plate washers and gasket.

38. INSTALL TRANSMISSION CASE WITH NEW GASKET TO INTERMEDIATE PLATE
Align each bearing outer race, each fork shaft end and reverse idler gear shaft end with the case installation holes, and install the case.
If necessary, tap on the case with a plastic hammer.

39. INSTALL BEARING SNAP RINGS
Using snap ring pliers, install the two snap rings.
40. INSTALL FRONT BEARING RETAINER WITH NEW GASKET
(a) Install the bearing retainer with a new gasket.
(b) Apply liquid sealer to the bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

41. INSTALL TRANSFER ADAPTOR, NEW GASKET, SHIFT LEVER SHAFT AND SHIFT LEVER HOUSING
(a) Install a new gasket to the intermediate plate.
(b) Install and torque the transfer adaptor with the eight bolts.
Torque: 380 kg-cm (27 ft-lb, 37 N-m)

(d) Insert the shift lever shaft to the transfer adaptor and shift lever housing.

(e) Install and torque the shift lever housing bolt with a lock washer.
Torque: 390 kg-cm (28 ft-lb, 38 N-m)
(f) Apply liquid sealer to the plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

(g) Using SST, install and torque the plug.
SST 09923-00010
Torque: 380 kg-cm (27 ft-lb, 37 N-m)

42. INSTALL LOCKING BALL, SPRING AND SCREW PLUG
(a) Apply liquid sealer to the plug.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(b) Install the locking ball and spring.

(c) Install and torque the plug.
Torque: 190 kg-cm (14 ft-lb, 19 N-m)

43. AFTER INSTALLING TRANSFER ADAPTOR CHECK FOLLOWING ITEMS
(a) Check to see that the input and output shafts rotate smoothly.
(b) Check to see that shifting can be made smoothly to all positions.

44. INSTALL RESTRICT PINS
(a) Install the black pin on the reverse gear/5th gear side.

(b) Install another pin and torque the pins.
Torque: 280 kg-cm (20 ft-lb, 27 N-m)

45. INSTALL CLUTCH HOUSING
(a) Install the clutch housing.
(b) Install and torque the bolts.
Torque: 380 kg-cm (27 ft-lb, 37 N-m)

46. INSTALL SHIFT LEVER RETAINER WITH NEW GASKET
Torque: 185 kg-cm (13 ft-lb, 18 N-m)
47. INSTALL BACK-UP LIGHT SWITCH
Torque: 380 kg-cm (27 ft-lb, 37 N-m)
48. INSTALL RELEASE FORK AND BEARING
Apply molybdenum disuiphide lithium base grease to the following parts:
^ Release bearing hub inside groove
^ Input shaft spline
^ Release fork contact surface
Apply MP grease to the clutch diaphragm spring contacting surface of the release bearing.