Transmission unit ASSY
Components Removal / installation
MANUAL TRANSMISSION / TRANSAXLE
TRANSMISSION UNIT ASSY
EXPLODED VIEW
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to 
)
)
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)DISASSEMBLY
1. Removal of manual transmission filler plug
(1) Remove the manual transmission filler plug and the gasket.
2. Removal of manual transmission drain plug
(1) Remove the manual transmission drain plug and the gasket.
3. Removal of clutch release fork support
(1) Remove the clutch release fork support from the clutch housing.
4. Removal of back-up light switch ASSY
(1) Release the 3 clamps.
(2) Remove the back-up light switch ASSY and the gasket.
5. Removal of neutral switch
(1) Release the clamp.
(2) Remove the neutral switch and the gasket.
6. Removal of wiring harness clamp bracket
(1) Remove the bolt, and then remove the wiring harness clamp bracket.
7. Removal of lock ball pin
(1) Remove the head straight screw plug, compression spring, and lock ball pin.
8. Removal of holder
(1) Remove the holder, compression spring, and lock ball pin.
9. Removal of transmission extension housing SUB-ASSY (MTM)
(1) Remove the bolt.
(3) Remove the transmission extension housing SUB-ASSY (MTM).
CAUTION:
·Do not damage the transmission extension housing SUB-ASSY (MTM).
·Be sure to remove the transmission extension housing SUB-ASSY (MTM) with the shift position in neutral status.
·Be sure to remove the transmission extension housing SUB-ASSY (MTM) with the shift position in neutral status.
10. Removal of extension housing rear oil seal
11. Removal of extension housing dust deflector
(1) Remove the extension housing dust deflector.
12. Removal of transmission extension housing oil seal
13. Removal of extension housing oil receiver pipe No.2
(1) Remove the extension housing oil receiver pipe No.2.
14. Removal of extension housing oil receiver pipe No.1
(1) Remove the bolt to remove the extension housing oil receiver pipe No.1 and the stopper plate.
(2) Remove the straight pin.
15. Removal of shift shaft
(1) Slide and remove the shift shaft and the shift inner lock block No.1.
16. Removal of shift inner lock block No.1.
(1) Remove the shift inner lock block No.1 from the shift shaft.
17. Removal of shift inner lever FR
(1) Remove bolt, then remove the shift inner lever FR from the shift shaft.
CAUTION:
Verify the direction of the parts.
18. Removal of head straight screw plug
(1) Remove the 3 head straight screw plugs.
(2) Remove the 2 compression springs and the 2 balls.
19. Removal of shift arm
(1) Remove the E-ring.
CAUTION:
Hold the E-ring with a cloth to prevent it from flying out.
(2) Remove the shift arm.
20. Removal of gear shift fork shaft No.3
(1) Remove the gear shift fork shaft No.3.
CAUTION:
·Do not drop the ball of the 5th shift head.
·The ball of the transmission case may fall in the transmission case. If the ball falls, pick the ball up when removing the transmission case.
·The ball of the transmission case may fall in the transmission case. If the ball falls, pick the ball up when removing the transmission case.
(2) Remove the ball of the 5th shift head.
(3) Remove the ball.
21. Removal of 5th shift head
(1) Remove the shaft snap ring.
CAUTION:
Hold the shaft snap ring with a cloth to prevent it from flying out.
(2) Remove the washer.
(3) Remove the 5th shift head, then remove the ball and the compression spring.
CAUTION:
Do not slide the 5th shift head to prevent the ball and the compression spring from falling.
22. Check of counter shaft 6th gear thrust clearance
(1) Use the SST to check the thrust clearance.
SST
09350-20015
09350-06120)
498255400
Standard value
: 0.10 to 0.40mm {0.00394 to 0.0157in}
Limit
: 0.40mm {0.0157in}
NOTE:
If the value exceeds the limit, replace the counter shaft 6th gear, transmission clutch hub No.4, 6th gear thrust washer, needle roller bearing, and counter shaft with new ones.
23. Check of counter shaft 6th gear radial clearance
(1) Check the radial clearance.
Standard value
: 0.015 to 0.068mm {0.000590 to 0.00268in}
Limit
: 0.068mm {0.00268in}
NOTE:
If the value exceeds the limit, replace the counter shaft 6th gear, needle roller bearing, and counter shaft with new ones.
24. Removal of transmission clutch hub No.4
(1) Remove the shaft snap ring.
CAUTION:
Hold the shaft snap ring with a cloth to prevent it from flying out.
(2) Use the SST to remove the transmission clutch hub No.4 together with the transmission hub sleeve No.4, gear shift fork No.4, and gear shift fork shaft No.2 as a unit.
Captions in illustration
| *a |
Hold |
| *b |
Drive |
SST
09950-30012
09951-03010,
09953-03010,
09956-03010)
CAUTION:
Verify the direction of the parts.
25. Removal of gear shift fork No.4
(1) Remove the slotted spring pin.
(2) Remove the gear shift fork No.4 from the gear shift fork shaft No.2.
26. Removal of transmission hub sleeve No.4
(1) Remove the hole snap ring.
(2) Remove the transmission hub sleeve No.4, then remove the 3 synchromesh shifting keys No.1, 3 synchromesh shifting key springs No.1, and 3 balls from the transmission clutch hub No.4.
CAUTION:
·Keep the synchromesh shifting keys No.1, synchromesh shifting key springs No.1, and balls from flying out using a cloth.
·Be careful not to deform the synchromesh shifting key springs No.1.
·Verify the direction of the parts.
·Be careful not to deform the synchromesh shifting key springs No.1.
·Verify the direction of the parts.
NOTE:
Perform the work without displacing the positions of the transmission clutch hub No.4 and synchromesh shifting keys No.1.
27. Removal of synchronizer ring No.2
(1) Remove the synchronizer ring No.2.
28. Removal of counter shaft 6th gear
(1) Remove the counter shaft 6th gear.
29. Removal of needle roller bearing
(1) Remove the needle roller bearing.
30. Removal of 6th gear thrust washer
(1) Remove the 6th gear thrust washer.
CAUTION:
Verify the direction of the parts.
(2) Remove the straight pin.
31. Removal of gear shift head No.2
(1) Remove the slotted spring pin.
(2) Remove the gear shift head No.2 from the gear shift fork shaft No.2.
CAUTION:
·Hold the slotted spring pin with a cloth to prevent it from flying out.
·Do not drop the slotted spring pin from the fork shaft hole into the inside.
·Verify the direction of the parts.
·Do not drop the slotted spring pin from the fork shaft hole into the inside.
·Verify the direction of the parts.
32. Removal of gear shift head No.1.
(1) Remove the slotted spring pin.
(2) Remove the gear shift head No.1 from the gear shift fork shaft No.1.
33. Removal of gear shift head No.3
(1) Remove the slotted spring pin.
(2) Remove the gear shift head No.3 from the gear shift fork shaft No.3.
34. Removal of bearing retainer RR
(1) Remove 4 TORX bolts to remove the bearing retainer RR.
(2) Remove the shift arm pivot.
35. Removal of transmission case
(1) Use the SST to remove the shaft snap ring.
SST
499895400
(2) Remove the reverse idler gear shaft fixing bolt and the gasket. (Transmission case side)
(4) Remove the transmission case.
CAUTION:
Do not damage the transmission case.
36. Removal of oil receiver pipe
(1) Remove the oil receiver pipe.
37. Removal of bearing retainer FR
(1) Remove the 7 bolts, then remove the bearing retainer FR.
38. Removal of transmission front bearing retainer oil seal
39. Removal of counter shaft
(1) Use the SST to remove the 2 shaft snap rings.
SST
499895400
NOTE:
Remove the shaft snap rings on the input shaft side and the counter shaft side.
(2) Remove the bolt and the gasket to free the reverse idler gear and the reverse idler gear shaft. (Clutch housing side)
(3) Remove 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 by hitting them from the clutch housing side with the handle of a hammer.
40. Removal of gear shift fork shaft No.2
(1) Remove the shaft snap ring.
CAUTION:
Hold the shaft snap ring with a cloth to prevent it from flying out.
(2) Remove the bolt, then remove the gear shift fork shaft No.2.
41. Removal of gear shift fork shaft No.1
(1) Remove the shaft snap ring.
CAUTION:
Hold the shaft snap ring with a cloth to prevent it from flying out.
(2) Remove the gear shift fork shaft No.1 and the gear shift fork No.1 as a unit.
(3) Remove the shaft snap ring.
CAUTION:
Hold the shaft snap ring with a cloth to prevent it from flying out.
(4) Remove the bolt, then remove the gear shift fork shaft No.1.
42. Removal of gear shift fork shaft No.3
(1) Remove the bolt, then remove the gear shift fork shaft No.3.
43. Removal of input shaft
(1) Remove the input shaft from the output shaft.
44. Check of reverse idler gear radial clearance
(1) Secure the reverse idler gear shaft with a vise and check the radial clearance.
Standard value
: 0.040 to 0.082mm {0.00157 to 0.00323in}
Limit
: 0.082mm {0.00323in}
NOTE:
If the value exceeds the limit, replace the reverse idler gear and the reverse idler gear shaft with new ones.
45. Removal of reverse idler gear shaft
(1) Remove the reverse idler gear shaft from the reverse idler gear.
INSPECTION
1. Gear shift head No.1 check
(1) Check the dimension of the gear shift head No.1 groove.
Standard value
: 15.2 to 15.4mm {0.59843 to 0.60630in}
Limit
: 15.4mm {0.60630in}
NOTE:
If the value exceeds the limit, replace the gear shift head No.1 with a new one.
2. Gear shift head No.2 check
(1) Check the dimension of the gear shift head No.2 groove.
Standard value
: 15.2 to 15.4mm {0.59843 to 0.60630in}
Limit
: 15.4mm {0.60630in}
NOTE:
If the value exceeds the limit, replace the gear shift head No.2 with a new one.
3. Gear shift head No.3 check
(1) Check the dimension of the gear shift head No.3 groove.
Standard value
: 15.2 to 15.4mm {0.59843 to 0.60630in}
Limit
: 15.4mm {0.60630in}
NOTE:
If the value exceeds the limit, replace the gear shift head No.3 with a new one.
4. Shift shaft check
(1) Check the thickness of the shift shaft claw.
Standard value
: 14.8 to 15.0mm {0.583 to 0.591in}
Limit
: 14.8mm {0.583in}
NOTE:
If the value is smaller than the limit, replace the shift shaft with a new one.
5. Check of shift inner lock block No.1.
(1) Check the thickness of the shift inner lock block No.1 claw.
Standard value
: 14.8 to 15.0mm {0.583 to 0.591in}
Limit
: 14.8mm {0.583in}
NOTE:
If the value is smaller than the limit, replace the shift inner lock block No.1 with a new one.
6. Gear shift fork No.4 check
(1) Check the dimension of the gear shift fork No.4 groove.
Standard value
: 15.2 to 15.4mm {0.59843 to 0.60630in}
Limit
: 15.4mm {0.60630in}
NOTE:
If the value exceeds the limit, replace the gear shift fork No.4 with a new one.
7. Check of 5th shift head
(1) Check the dimension of the 5th shift head groove.
Standard value
: 15.2 to 15.4mm {0.59843 to 0.60630in}
Limit
: 15.4mm {0.60630in}
NOTE:
If the value exceeds the limit, replace the 5th shift head with a new one.
8. Check of synchronizer ring No.2
(1) Apply manual transmission oil to the tapered cone portion of the counter shaft 6th gear. With the synchronizer ring No.2 pressed by hand, check the clearance between the synchronizer ring No.2 and the counter shaft 6th gear.
Standard value
: 0.88 to 1.52mm {0.0346 to 0.0598in}
Limit
: 0.88mm {0.0346in}
CAUTION:
Check the entire circumference of the gear.
NOTE:
·If the value is smaller than the limit, replace the synchronizer ring No.2 and the counter shaft 6th gear with new ones.
·Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to)
·Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to
)
(2) Apply manual transmission oil to the tapered cone portion of the counter shaft 6th gear, and check that the synchronizer ring No.2 does not slip in the circumferential direction while pressing it by hand.
NOTE:
·If it slips, replace the synchronizer ring No.2 and the counter shaft 6th gear with new ones.
·Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to)
·Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to
)
9. Check of counter shaft 6th gear
(1) Check the inner diameter of the counter shaft 6th gear.
Standard value
: 34.015 to 34.040mm {1.33917 to 1.34016in}
Limit
: 34.040mm {1.34016in}
NOTE:
If the value exceeds the limit, replace the counter shaft 6th gear with a new one.
10. Check of transmission hub sleeve No.4
(1) Check that the end of the spline gear of the transmission hub sleeve No.4 is not worn.
NOTE:
If it is worn, replace the transmission hub sleeve No.4 with a new one.
(2) Install the transmission hub sleeve No.4 to the transmission clutch hub No.4 and check that they slide smoothly.
NOTE:
If they do not slide smoothly, replace the transmission hub sleeve No.4 and the transmission clutch hub No.4 with new ones.
11. Check of transmission hub sleeve No.4 clearance
(1) Check the thickness of the gear shift fork No.4 claw.
Standard value
: 7.9 to 8.0mm {0.311 to 0.315in}
Limit
: 7.9mm {0.311in}
NOTE:
If the value is smaller than the limit, replace the gear shift fork No.4 with a new one.
(2) Measure the groove of the transmission hub sleeve No.4 and calculate the clearance between it and the gear shift fork No.4.
Standard value
: 0.15 to 0.35 mm {0.00590 to 0.0138in}
Limit
: 0.35mm {0.0138in}
NOTE:
If the value exceeds the limit, replace the gear shift fork No.4 and the transmission hub sleeve No.4 with new ones as a set.
12. Reverse idler gear check
(1) Check the inner diameter of the reverse idler gear.
Standard value
: 22.04 to 22.061 mm {0.86771 to 0.86854 in}
Limit
: 22.061mm {0.86854in}
NOTE:
If the value exceeds the limit, replace the reverse idler gear with a new one.
13. Reverse idler gear shaft check
(1) Check the outer diameter of the reverse idler gear shaft.
Standard value
: 21.979 to 22.00 mm {0.86531 to 0.86614 in}
Limit
: 21.979mm {0.86531in}
NOTE:
If the value is smaller than the limit, replace the reverse idler gear shaft with a new one.
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:
Standard value:
Tightening torque=19.5N·m
{
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:
Standard value:
Tightening torque=19.5N·m
{
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:
Standard value:
Tightening torque=19.5N·m
{
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.
·Do not damage the bearing retainer FR.
(2) Apply manual transmission oil to the lip of the transmission front bearing retainer oil seal.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)
5. Installation of reverse idler gear shaft
(1) Apply manual transmission oil to the reverse idler gear shaft and install the reverse idler gear shaft to the reverse idler gear.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)
6. Installation of input shaft
(1) Apply manual transmission oil to the needle roller bearing of the input shaft, and install the input shaft to the output shaft.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)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 Three Bond 1281 or equivalent continuously like beads to the position of the bearing retainer FR shown in the figure.
Captions in illustration
 |
Three Bond 1281 or equivalent |
CAUTION:
Install within 10 minutes after applying seal gasket.
(2) Apply Adhesive 1344 or equivalent to the 2 to 3 pitches from the tip of a new bolt.
Captions in illustration
| *1 |
Adhesive 1344 or equivalent |
(3) Install the bearing retainer FR with the 7 bolts.
Standard value:
Standard value:
Tightening torque=17N·m
{
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 Three Bond 1281 or equivalent continuously like beads to the position of the transmission case shown in the figure.
Captions in illustration
|
|
Three Bond 1281 or equivalent |
CAUTION:
Install within 10 minutes after applying seal gasket.
(2) Check the position of the knock pin and install the transmission case.
(3) Apply Adhesive 1324 or equivalent to the 2 to 3 pitches from the tip of a new bolt.
Captions in illustration
| *1 |
Adhesive 1324 or equivalent |
(4) Install the transmission case and clamp with the 9 bolts.
Standard value:
Captions in illustration
| *1 |
Clamp |
Standard value:
Tightening torque=29N·m
{
296kgf·cm}
{21.4ft·lbf}
(5) Install a new reverse idler gear shaft fixing bolt via a new gasket. (Transmission case side)
Standard value:
Standard value:
Tightening torque=28N·m
{
286kgf·cm}
{20.7ft·lbf}
(6) Tighten the reverse idler gear shaft fixing bolt. (Clutch housing side)
Standard value:
Standard value:
Tightening torque=28N·m
{
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 or equivalent to the 2 to 3 pitches from the tip of a new bolt.
Captions in illustration
| *1 |
Adhesive 1324 or equivalent |
(3) Install the bearing retainer RR with 4 TORX bolts.
Standard value:
Standard value:
Tightening torque=30N·m
{
306kgf·cm}
{22.1ft·lbf}
12. Installation of 6th gear thrust washer
(1) Install the straight pin to the counter shaft.
(2) Apply manual transmission oil to the 6th gear thrust washer, and install the 6th gear thrust washer to the counter shaft.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)
13. Installation of needle roller bearing
(1) Apply manual transmission oil to the needle roller bearing and install the needle roller bearing to the counter shaft.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)
14. Installation of counter shaft 6th gear
(1) Apply manual transmission oil to the counter shaft 6th gear, and install the counter shaft 6th gear to the counter shaft.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)
15. Installation of synchronizer ring No.2
(1) Apply manual transmission oil to the synchronizer ring No.2, and install the synchronizer ring No.2 to the counter shaft.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)
16. Installation of transmission hub sleeve No.4
(1) Apply manual transmission oil to the sliding area of the transmission clutch hub No.4.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)(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.
·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 0.1mm {0 to 0.00394in}
NOTE:
Select a shaft snap ring with the maximum thickness that can be installed.
Shaft snap ring type
| Item number |
Thickness mm {in} |
Identification |
|---|---|---|
| 17005AA230 |
2.80 {0.11023} |
A |
| 17005AA240 |
2.85 {0.11220} |
B |
| 17005AA250 |
2.90 {0.11417} |
C |
| 17005AA260 |
2.95 {0.11614} |
D |
| 17005AA270 |
3.00 {0.11811} |
E |
| 17005AA280 |
3.05 {0.12007} |
F |
(2) Install a new shaft snap ring to the counter shaft.
19. Installation of gear shift head No.2
(1) Install the gear shift head No.2 to the gear shift fork shaft No.2.
(2) Install a new slotted spring pin to the gear shift fork shaft No.2.
CAUTION:
Do not drive in the pin excessively.
Standard value
: 0 mm {0 in} (from end face of gear shift head No.2)
20. Installation of 5th shift head
(1) Install the compression spring to the 5th shift head, and install the 5th shift head to the gear shift fork shaft No.3 while pressing the ball with the pin punch 5.
(2) Install the washer.
(3) Install a new shaft snap ring to the gear shift fork shaft No.3.
21. Installation of gear shift fork shaft No.3
(1) Insert the gear shift fork shaft No.3 in the direction shown in the figure, install the ball and the compression spring, and tighten a new head straight screw plug.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
22. Installation of shift arm
(1) Install the shift arm to the shift arm pivot.
(2) Install a new E-ring to the shift arm pivot.
23. Installation of gear shift fork shaft No.2
(1) Install 2 balls to the gear shift fork shaft No.3.
(2) Insert the gear shift fork shaft No.2 in the direction shown in the figure, install the ball and the compression spring, and tighten 2 new head straight screw plugs.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
(3) Install a new slotted spring pin to the gear shift fork shaft No.2.
CAUTION:
Do not drive in the pin excessively.
Standard value
: 0 mm {0 in} (from end face of gear shift fork No.4)
24. Installation of gear shift head No.3
(1) Install the gear shift head No.3 to the gear shift fork shaft No.3.
NOTE:
Install while rotating the gear shift head No.3 so as to insert the shift arm in the groove of the gear shift head No.3.
(2) Install a new slotted spring pin to the gear shift fork shaft No.3.
CAUTION:
Do not drive in the pin excessively.
Standard value
: 0 mm {0 in} (from end face of gear shift head No.3)
25. Installation of gear shift head No.1
(1) Install the gear shift head No.1 to the gear shift fork shaft No.1.
(2) Install a new slotted spring pin to the gear shift fork shaft No.1.
CAUTION:
Do not drive in the pin excessively.
Standard value
: 0 mm {0 in} (from end face of gear shift head No.1)
26. Installation of shift inner lever FR
27. Installation of shift inner lock block No.1
(1) Install the shift inner lock block No.1 to the shift shaft.
28. Installation of shift shaft
(1) Slide and install the shift shaft and the shift inner lock block No.1.
29. Installation of extension housing oil receiver pipe No.1
(1) Install the straight pin.
(2) Install the extension housing oil receiver pipe No.1 and the stopper plate with a new bolt.
Standard value:
Standard value:
Tightening torque=8.5N·m
{
87kgf·cm}
{6.3ft·lbf}
NOTE:
Make sure the end of the oil receiver pipe No.1 is inserted in the groove.
30. Installation of extension housing oil receiver pipe No.2
(1) Install the extension housing oil receiver pipe No.2.
31. Installation of transmission extension housing oil seal
(1) Apply manual transmission oil to the lip of a new transmission extension housing oil seal.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)(2) Use the SST to install a new transmission extension housing oil seal.
SST
09325-20010
Standard value
: 0.1 to 1.1 mm {0.00394 to 0.0433 in} (from end face of transmission extension housing SUB-ASSY (MTM))
CAUTION:
Do not damage the lip of the transmission extension housing oil seal.
32. Installation of extension housing dust deflector
(1) Use the SST to install a new extension housing dust deflector.
SST
09950-60020
09951-00750)
09950-70010
09951-07100)
NOTE:
Drive in the deflector until it contacts the transmission extension housing SUB-ASSY (MTM).
33. Installation of extension housing rear oil seal
(1) Use the SST to install a new extension housing rear oil seal.
SST
18657AA040
Standard value
: 1.0 to 2.0 mm {0.0394 to 0.787 in} (from end face of transmission extension housing SUB-ASSY (MTM))
CAUTION:
Do not damage the lip of the extension housing rear oil seal.
(2) Apply manual transmission oil to the lip of the extension housing rear oil seal.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
)
34. Installation of transmission extension housing SUB-ASSY (MTM)
(1) Apply Three Bond 1281 continuously like beads to the position of the transmission extension housing SUB-ASSY (MTM) shown in the figure.
Captions in illustration
|
|
Three Bond 1281 or equivalent |
CAUTION:
·Install within 10 minutes after applying seal gasket.
·Be sure to install the transmission extension housing SUB-ASSY (MTM) with the shift position in neutral status.
·Be sure to install the transmission extension housing SUB-ASSY (MTM) with the shift position in neutral status.
(2) Install the transmission extension housing SUB-ASSY (MTM) and the clamp with the 8 new bolts.
Standard value:
Captions in illustration
| *1 |
Clamp |
Standard value:
Tightening torque=29N·m
{
296kgf·cm}
{21.4ft·lbf}
CAUTION:
Align the knock pin into the knock pin hole correctly.
(3) Install a new bolt.
Standard value:
Standard value:
Tightening torque=31N·m
{
316kgf·cm}
{22.9ft·lbf}
35. Holder installation
(1) Install a new holder, compression spring, and lock ball pin.
Standard value:
Standard value:
Tightening torque=39.2N·m
{
399.7kgf·cm}
{28.9ft·lbf}
36. Installation of lock ball pin
(1) Install a new head straight screw plug, compression spring, and lock ball pin.
Standard value:
Standard value:
Tightening torque=24.5N·m
{
249.8kgf·cm}
{18.1ft·lbf}
37. Installation of wiring harness clamp bracket
(1) Install the wiring harness clamp bracket with a new bolt.
Standard value:
Standard value:
Tightening torque=7.0N·m
{
71kgf·cm}
{5.2ft·lbf}
38. Installation of neutral switch
(1) Install the neutral switch and a new gasket.
Standard value:
Standard value:
Tightening torque=32.3N·m
{
329.4kgf·cm}
{23.8ft·lbf}
CAUTION:
When tightening by combining a torque wrench and union nut wrench to extend the whole length, the actual torque will be excessive if tightened until the reading of the torque wrench reaches the specified tightening torque. (Refer to )
)
(2) Engage the clamp to connect the neutral switch wire.
39. Installation of back-up light switch ASSY
(1) Install the back-up light switch ASSY and a new gasket.
Standard value:
Standard value:
Tightening torque=32.3N·m
{
329.4kgf·cm}
{23.8ft·lbf}
CAUTION:
When tightening by combining a torque wrench and union nut wrench to extend the whole length, the actual torque will be excessive if tightened until the reading of the torque wrench reaches the specified tightening torque. (Refer to )
)
(2) Engage all of the 3 clamps from the rear side with a slack of the harness positioned only at the forward end, and connect the back-up light switch ASSY wire and the neutral switch wire.
40. Installation of clutch release fork support
(1) Install the clutch release fork support to the clutch housing.
Standard value:
Standard value:
Tightening torque=16N·m
{
163kgf·cm}
{11.8ft·lbf}
41. Installation of manual transmission drain plug
(1) Install the manual transmission drain plug to the transmission case via a new gasket.
Standard value:
Standard value:
Tightening torque=37N·m
{
377kgf·cm}
{27.3ft·lbf}
42. Installation of manual transmission filler plug
(1) Install the manual transmission filler plug to the transmission case via a new gasket.
Standard value:
Standard value:
Tightening torque=37N·m
{
377kgf·cm}
{27.3ft·lbf}