Manual Transmission Unit Assembly

1. 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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2. 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 With Plastic Hammer

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3. Fix with C-ring (1) by using special tool.

   Special tool 

   (A): 09900-06107 

   Fig 4: Fixing With C-Ring By Using Special Tool

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4. 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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5. Install countershaft (1) and rear bearing (2) to intermediate case.
   NOTE: When fitting of intermediate case and bearing is tight, tap outer race of bearing lightly and evenly with plastic hammer.
   Fig 6: Installing Countershaft And Rear Bearing To Intermediate Case

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6. 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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7. Install reverse idle gear (1) and shaft (2).
   Fig 8: Installing Reverse Idle Gear And Shaft

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8. 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 To Specification

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9. 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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10. Set ball (1) and thrust washer (2) to countershaft.
    Fig 11: Setting Ball And Thrust Washer To Countershaft

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11. Install needle bearing (1), countershaft 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 Needle Bearing, Countershaft 5th Gear And Synchronizer Ring

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12. Press-fit 5th speed synchronizer dog (1) to countershaft with hydraulic press (2) and special tool.

    Special tool 

    (B): 09927-08220 

    Fig 13: Pressing-Fit 5th Speed Synchronizer Dog To Countershaft With Hydraulic Press And Special Tool

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13. Select circlip (1) that will make clearance in circlip groove 0.1 mm (0.0039 in.) or less.
    CIRCLIP THICKNESS SPECIFICATIONS
    
    

    ID mark	Circlip thickness	ID mark	Circlip thickness
    A	2.80 - 2.85 mm (0.1102-0.1122 in.)	E	3.00 - 3.05 mm (0.1181-0.1201 in.)
    B	2.85-2.90 mm (0.1122-0.1142 in.)	F	3.05-3.10 mm (0.1201-0.1220 in.)
    C	2.90 - 2.95 mm (0.1142-0.1161 in.)	G	3.10-3.15 mm (0.1220-0.1240 in.)
    D	2.95 - 3.00 mm (0.1162-0.1181 in.)

    Fig 14: Selecting Circlip In Circlip Groove

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14. Fix with circlip (1) as shown in the figure and check that counter 5th gear turns lightly.
    Fig 15: Identifying Circlip

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15. Check countershaft 5th gear (1) thrust clearance by using thickness gauge (2).

    If clearance exceeds limit, repeat Step 1) to 14) again or replace defective part(s). 

    Countershaft 5th gear thrust clearance 

    0.1 - 0.3 mm (0.0039 - 0.0118 in.) 

    Fig 16: Checking Countershaft 5th Gear Thrust Clearance By Using Thickness Gauge

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16. Install low speed gear shift fork, high speed gear shift fork and shaft.
17. 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 17: Installing Low Speed Gear Shift Fork, High Speed Gear Shift Fork And Shaft

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18. Fix new circlip (1) to high gear shift shaft by using lever or the like and hammer.
    Fig 18: Fixing Circlip To High Gear Shift Shaft

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19. Apply grease "A" to locating roller No.2 (1) and install roller (1) to low gear shift shaft (2).

    "A": Grease 99000-25010 

    Fig 19: Installing Roller To Low Gear Shift Shaft

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20. 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 20: Inserting Low Gear Shift Shaft To Intermediate Case And Low Speed Gear Shift Fork

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21. 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 21: Applying Thread Lock Cement To Thread Of Fork Bolt

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22. Fix with new circlip (1) to low gear shift shaft (2) by using lever or the like and hammer.
    Fig 22: Fixing With Circlip To Low Gear Shift Shaft

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23. 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 23: Installing Roller No. 2 To Reverse Gear Shift Shaft

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24. Assemble reverse gear shift link assembly.
25. 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).
26. Supporting locating roller No.1 (1) with magnet (3), insert reverse gear shift shaft (2) into reverse gear shift link and intermediate case.
Fig 24: Inserting Reverse Gear Shift Shaft Into Reverse Gear Shift Link Assembly
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27. Fix with new circlip (1) to reverse gear shift shaft by using rod or the like and hammer.
    Fig 25: Fixing With Circlip To Reverse Gear Shift Shaft

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28. Drive pin into reverse gear shift link (1) and shaft by using special tool (C).

    Special tool 

    (C): 09922-85811 

    Fig 26: Removing Pin Into Reverse Gear Shift Link And Shaft By Using Special Tool

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29. Install reverse gear shift yoke (1) and 5th gear shift fork (2) as shown in the figure.
    Fig 27: Installing Reverse Gear Shift Yoke And 5th Gear Shift Fork

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30. 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 28: Inserting 5th Gear Shift Shaft To 5th Gear Shift Fork And Reverse Gear Shift Yoke

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31. Supporting ball (1) with magnet (3) as shown in the figure, insert 5th gear shift shaft (2) into intermediate case (4).
    Fig 29: Inserting 5th Gear Shift Shaft Into Intermediate Case

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32. 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 30: Applying Thread Lock Cement To Thread Of Fork Bolt

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33. 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 31: Inserting 5th-Reverse Gear Shift Shaft To Reverse Gear Shift Yoke

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34. Install locating balls, locating springs and locating screw after checking free length of locating springs.
    LOCATING SPRINGS FREE LENGTH
    
    

    	Standard	Limit
    "a"	31.0 mm (1.22 in.)	30.1 mm (1.19 in.)
    "b"	20.2 mm (0.80 in.)	19.6 mm (0.77 in.)

    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 32: Installing Locating Balls, Locating Springs And Locating Screw

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35. Place intermediate case assembly upright as shown in the figure by using workbench or the like.
    Fig 33: Placing Intermediate Case Assembly Upright

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36. Apply sealant evenly to front case side of intermediate case (1) as shown in the figure.

    "A": Sealant 99000-31110 

    Fig 34: Applying Sealant Evenly To Front Case Side Of Intermediate Case

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37. Clean mating surface of front case (1) and install it to intermediate case.
    Fig 35: Installing Front Case To Intermediate Case

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38. Fix C-rings (1, 2) to bearings as shown in the figure.

    Special tool 

    (A): 09900-06107 

    Fig 36: Fixing C-Rings To Bearings

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39. 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 37: Applying Cement To Input Shaft Bearing Retainer Bolt

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40. Clean mating surface of rear case and apply sealant evenly to rear case side of intermediate case.

    : Sealant 99000-31110 

41. 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 38: Installing Rear Case To Intermediate Case

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42. 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 39: Inserting Gear Shift Inner Shaft Into Gear Shift Shaft Inner Lever

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43. 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 40: Applying Cement To Inner Gear Shift Shaft Bolt

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44. 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 41: Installing Return Spring Reverse Bolt To Left Side Of Case

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45. 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 42: Installing Locating Ball, Locating Spring And Screw To Rear Case

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46. 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 43: Installing Back-Up Light Switch And Gasket

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47. 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 44: Installing Clutch Housing To Specification

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