Manual Transmission Unit Assembly

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.

Set intermediate case (1) to vise (3). Clean mating surfaces of intermediate case both sides, if intermediate case is reused.

Fig 1: Setting Intermediate Case To Vise
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Install main shaft assembly (1) to intermediate case.

Fig 2: Installing Main Shaft Assembly To Intermediate Case
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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.

Fig 3: Taping Rear Face Of Intermediate Case Using Plastic Hammer
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Fix with C-ring (1) by using special tool.
Special tool

(A): 09900-06107

Fig 4: Fixing Intermediate Case With C-Ring Using Special Tool
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Align key slots of synchronizer ring and synchronizer keys and set input shaft assembly to main shaft assembly. Check that input shaft assembly turns lightly.

Fig 5: Aligning Key Slots Of Synchronizer Ring And Synchronizer Keys
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Fix with C-ring to counter shaft rear bearing.
Install counter shaft (1) and rear bearing (2) to intermediate case.
NOTE:
- When installing bearing, bring it so that its C-ring side is at rear side of intermediate case as shown.
- When fitting of intermediate case and bearing is tight, tap outer race of bearing lightly and evenly with plastic hammer.
Fig 6: Installing Counter Shaft And Rear Bearing To Intermediate Case
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Install bearing plate (1).
Tightening torque

Bearing plate bolt (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 7: Installing Bearing Plate
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Install reverse idle gear (1) and shaft (2).

Fig 8: Installing Reverse Idle Gear And Shaft
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Tighten reverse gear shift bolt (1) to specification.
Tightening torque

Reverse gear shaft bolt (a): 18 N.m (1.8 kg-m, 13.0 lb-ft)

Fig 9: Tightening Reverse Gear Shift Bolt
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Install reverse link stay (1).
Tightening torque

Reverse link stay bolt (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 10: Installing Reverse Link Stay
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Set ball (1) and thrust washer (2) to counter shaft.

Fig 11: Setting Ball And Thrust Washer To Counter Shaft
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Install needle bearing (1), counter shaft 5th gear (2) and synchronizer ring.
NOTE: When setting synchronizer ring to sleeve of 5th gear, align synchronizer key slot to key.

Fig 12: Installing Synchronizer Ring To Sleeve Of 5Th Gear
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Press-fit 5th speed synchronizer dog (1) to countershaft with press (2) and special tool (B).
Special tool

(B): 09927-08220

Fig 13: Press-Fiting 5Th Speed Synchronizer Dog To Countershaft Using Press And Special Tool
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Select circlip (1) that will make clearance in circlip groove 0.1 mm (0.0039 in.) or less.
Circlip thickness specification

Fig 14: Circlip Thickness Specification Chart
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Fig 15: Checking Circlip Thickness Using Thickness Gauge
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Fix with circlip (1) as shown in the figure and check that counter 5th gear turns lightly.

Fig 16: Fixing Circlip
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Check counter shaft 5th gear (1) thrust clearance by using thickness gauge (2).
Counter shaft 5th gear thrust clearance

0.1 - 0.3 mm (0.0039 - 0.0118 in.)

Fig 17: Checking Counter Shaft 5Th Gear Thrust Clearance Using Thickness Gauge
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Install low speed gear shift fork, high speed gear shift fork and shaft.
Apply thread lock cement to thread of fork bolt and tighten bolt to specification.
"A": Thread lock cement 99000-32020

Tightening torque

Shift fork bolt (a): 20 N.m (2.0 kg-m, 14.5 lb-ft)

Fig 18: Tightening Fork Bolt
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Fix new circlip (1) to high gear shift shaft by using lever or the like and hammer.

Fig 19: Fixing New Circlip To High Gear Shift Shaft Using Lever
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Apply grease "A" to locating roller No. 2 (1) and install roller (1) to low gear shift shaft (2).
"A": Grease 99000-25010

Fig 20: Installing Roller To Low Gear Shift Shaft
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Supporting locating roller No. 3 (1) by magnet (2), insert low gear shift shaft (3) to intermediate case and low speed gear shift fork.

Fig 21: Supporting Roller No. 3 Using Magnet
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Apply thread lock cement "A" to thread of fork bolt and tighten bolt to specification.
"A": Thread lock cement 99000-32020

Tightening torque

Shift fork bolt (a): 20 N.m (2.0 kg-m, 14.5 lb-ft)

Fig 22: Tightening Shift Fork Bolt
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Fix with new circlip (1) to low gear shift shaft (2) by using lever or the like and hammer.

Fig 23: Fixing New Circlip To Low Gear Shift Shaft Using Lever Or Like And Hammer
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Apply grease to locating roller No. 2 (1) and install roller No. 2 (1) to reverse gear shift shaft (2).
"A": Grease 99000-25010

Fig 24: Installing Roller No. 2 To Reverse Gear Shift Shaft
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Assemble reverse gear shift link assembly.
Insert reverse gear shift shaft (2) into reverse gear shift link assembly and intermediate case while holding locating roller No. 1 (1) with magnet (3).
Supporting locating roller No. 1 (1) with magnet (3), insert reverse gear shift shaft (2) into reverse gear shift link and intermediate case.

Fig 25: Inserting Reverse Gear Shift Shaft Into Reverse Gear Shift Link And Intermediate Case
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Fix with new circlip (1) to reverse gear shift shaft by using rod or the like and hammer.

Fig 26: Fixing New Circlip To Reverse Gear Shift Shaft Using Rod Or Like And Hammer
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Drive pin into reverse gear shift link (1) and shaft (2) by using special tool (C).
Special tool

(C): 09922-85811

Fig 27: Installing Pin Into Reverse Gear Shift Link And Shaft Using Special Tool
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Install reverse gear shift yoke (1) and 5th gear shift fork (2) as shown in the figure.

Fig 28: Installing Reverse Gear Shift Yoke And 5th Gear Shift Fork
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Supporting ball (1) with magnet (3) as shown in the figure, insert 5th gear shift shaft (2) to 5th gear shift fork (4) and reverse gear shift yoke (5).

Fig 29: Supporting Ball With Magnet
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Supporting ball (1) with magnet (3) as shown in the figure, insert 5th gear shift shaft (2) into intermediate case (4).

Fig 30: Supporting Ball With Magnet For Inserting 5Th Gear Shift Shaft Into Intermediate Case
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Apply thread lock cement "A" to thread of fork bolt and tighten bolt to specification.
"A": Thread lock cement 99000-32020

Tightening torque

5th gear shift fork bolt (a): 20 N.m (2.0 kg-m, 14.5 lb-ft)

Fig 31: Applying Thread Lock Cement To Thread Of Fork Bolt
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Insert 5th-reverse gear shift shaft (1) to reverse gear shift yoke and drive pin into shaft and yoke.
Special tool

(C): 09922-85811

Fig 32: Driving Pin Into Shaft And Yoke
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Install locating balls, locating springs and locating screw after checking free length of locating springs.
Locating springs free length

Fig 33: Locating Springs Free Length Specification
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NOTE: For 5th gear locating spring, use shorter spring (1).

"A": Thread lock cement 99000-32020

Tightening torque

Locating spring screw (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 34: Installing Locating Balls, Locating Springs And Locating Screw
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Place intermediate case assembly upright as shown in the figure by using workbench or the like.

Fig 35: Placing Intermediate Case Assembly
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Apply sealant evenly to front case side of intermediate case (1) as shwon in the figure.
"A": Sealant 99000-31110

Fig 36: Applying Sealant Evenly To Front Case Side Of Intermediate Case
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Clean mating surface of front case (1) and install it to intermediate case.

Fig 37: Installing Front Case To Intermediate Case
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Fix C-rings (1,2) to bearings as shown in the figure.
Special tool

(A): 09900-06107

Fig 38: Fixing C-Rings To Bearings
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Apply cement "A" to input shaft bearing retainer bolt and install input shaft bearing retainer (1), new gasket and its bolts.
"A": Thread lock cement 99000-32020

Tightening torque

Input shaft bearing retainer bolt (a): 17 N.m (1.7 kg-m, 12.5 lb-ft)

Fig 39: Installing Input Shaft Bearing Retainer
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Clean mating surface of rear case and apply sealant evenly to rear case side of intermediate case.
: Sealant 99000-31110
Install rear case to intermediate case.
Tightening torque

Rear case to intermediate case bolt (a): 35 N.m (3.5 kg-m, 25.5 lb-ft)

Fig 40: Installing Rear Case To Intermediate Case
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With tip end of gear shift shaft inner lever (1) hooked on head of gear shift shaft (2), insert gear shift inner shaft (3) into gear shift shaft inner lever.

Fig 41: Inserting Gear Shift Inner Shaft Into Gear Shift Shaft Inner Lever
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Apply cement "A" to inner gear shift shaft bolt / plug and tighten them to specification.
"A": Thread lock cement 99000-32020

Tightening torque

Gear shift shaft inner bolt (a): 39 N.m (3.9 kg-m, 28.5 lb-ft)

Gear shift shaft inner plug (b): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 42: Tightening Gear Shift Shaft Inner Bolt And Plug
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Tighten return spring low bolt 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): 28 N.m (2.8 kg-m, 20.5 lb-ft)

Fig 43: Tightening Return Spring Low Bolt And Return Spring Reverse Bolt
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Apply cement to locating screw (1) and install locating ball (3), locating spring (2) and screw to rear case.
Locating spring free length "a"

Standard: 22.1 mm (0.87 in.)

Limit: 21.4 mm (0.84 in.)

"A": Thread lock cement 99000-32020

Tightening torque

Locating screw (a): 19 N.m (1.9 kg-m, 14.0 lb-ft)

Fig 44: Installing Locating Ball, Locating Spring And Screw To Rear Case
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Install back-up light switch and new gasket.
Tightening torque

Back-up light switch (a): 45 N.m (4.5 kg-m, 32.5 lb-ft)

Fig 45: Installing Back-Up Light Switch
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Install clutch housing (3) and torque its bolts to specification.
Tightening torque

Clutch housing bolt (a): 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fig 46: Installing Clutch Housing
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