Manual Transmission Unit Assembly

Reference: MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING 

Reference: MANUAL TRANSMISSION UNIT DISASSEMBLY 

1. Set intermediate case (1) to vise (3).

   Clean mating surfaces of intermediate case both sides, if intermediate case is reused.

   Fig 1: Identifying Intermediate Case, Aluminum Plate & Vise

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2. Install main shaft assembly (1) to intermediate case.
   Fig 2: Identifying Main Shaft Assembly

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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: Identifying Intermediate Case & Main Shaft Assembly

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

   Special Tool 

   (A): 09900-06107 

   Fig 4: Identifying C-Ring & Special Tool

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4. Align key slots of high speed synchronizer hub (1) and protrusion of 4th gear synchronizer ring (2) and set input shaft assembly to main shaft assembly.

   Check that input shaft assembly turns lightly.

   Fig 5: Identifying High Speed Synchronizer Hub And Protrusion Of 4th Gear Synchronizer Ring

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5. Fix with new C-ring to countershaft rear bearing.
6. Install countershaft (1) and rear bearing (2) to intermediate case (3).
   NOTE:

   • When installing rear bearing (2), bring it so that its C-ring side is at rear side of intermediate case as shown in the figure.
   • When fitting of intermediate case (3) and rear bearing (2) is tight, tap outer race of rear bearing (2) lightly and evenly with plastic hammer.
     Fig 6: Identifying Countershaft, Rear Bearing & Intermediate Case

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

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8. Install main shaft and countershaft bearing plate (1) to intermediate case.

   Tightening torque 

   Main and countershaft bearing plate bolt a: 18 N.m (1.8 kg-m, 13.0 lb-ft) 

   Fig 8: Identifying Countershaft Bearing Plate & Bolt

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9. Set pin (1) and thrust washer (2) to countershaft.
   Fig 9: Identifying Pin And Thrust Washer

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10. Assemble countershaft 5th gear (1), plate spring (2), circlip (3), 5th & reverse synchronizer sleeve (4), balk levers (5), synchronizer key spring (6) and 5th & reverse synchronizer ring (7) according to the following procedure.
    Fig 10: Identifying Countershaft 5th Gear, Plate Spring, Circlip, 5th & Reverse Synchronizer Sleeve, Balk Levers, Synchronizer Key Spring & 5th & Reverse Synchronizer Ring

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    1. Install plate spring (1) to countershaft 5th gear (3) and fix plate spring (1) with new circlip (2) using special tool.

       Special Tool 

       (A): 09900-06107 

       Fig 11: Identifying Plate Spring, Countershaft 5th Gear, Circlip & Special Tool

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    2. Install 5th & reverse synchronizer sleeve (1) to countershaft 5th gear (2) in specified direction as shown in the figure.
       Fig 12: Identifying 5th & Reverse Synchronizer Sleeve & Countershaft 5th Gear

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    3. Fit balk levers (1) to countershaft 5th gear (2) in specified direction as shown in the figure.
       Fig 13: Identifying Balk Levers & Countershaft 5th Gear

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    4. Install synchronizer key spring (1).
       Fig 14: Identifying Synchronizer Key Spring

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    5. Slide 5th & reverse synchronizer sleeve (1) until sliding surface of balk lever is locked into key location teeth of 5th & reverse synchronizer sleeve (1) with balk lever and synchronizer key spring pushed.
       Fig 15: Identifying 5th & Reverse Synchronizer Sleeve

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    6. Install synchronizer ring (1) to countershaft 5th gear (4).
       NOTE: Align protrusions (2) of synchronizer ring (1) with groove (3) of countershaft 5th gear (4).
       Fig 16: Identifying Synchronizer Ring, Countershaft 5th Gear, Protrusions & Groove

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11. Install needle bearing (1) into countershaft 5th gear assembly (2) which was assembled in Steps a) to f).
12. Install countershaft 5th gear assembly (2) to countershaft (3) facing gear side to intermediate plate (4).
    Fig 17: Identifying Countershaft 5th Gear Assembly, Intermediate Plate, Countershaft & Needle Bearing

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

    Special Tool 

    (B): 09913-84510 

    Fig 18: Identifying 5th Speed Synchronizer Dog, Hydraulic Press And Special Tool

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14. 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 19: Identifying Circlip And Thickness Gauge

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15. Fix with circlip (1) as shown in the figure and check that countershaft 5th gear (2) turns lightly.
    Fig 20: Checking Countershaft 5th Gear Turns Lightly

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

    If clearance exceeds limit, repeat Step  1) to  15) again or replace defective part(s).

    Countershaft 5th gear thrust clearance 

    0.10 - 0.35 mm (0.0039 - 0.0138 in.) 

    Fig 21: Identifying Countershaft 5th Gear & Thickness Gauge

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17. Install reverse gear shift arm bracket (1) to intermediate case (2).

    Tightening torque 

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

    Fig 22: Identifying Reverse Gear Shift Arm Bracket & Intermediate Case

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18. Install reverse gear shift arm (1) to reverse gear shift fork (2) fixing it with new circlip (3), if necessary.
    Fig 23: Identifying Reverse Gear Shift Arm, Reverse Gear Shift Fork & Circlip

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19. Fit reverse gear shift arm / fork (1) to reverse idle gear and then install reverse gear shift arm / fork (1) to reverse gear shift arm bracket (2).
20. Insert spring (3) and ball (4) to reverse gear shift fork (5) using magnet.
    Fig 24: Identifying Reverse Gear Shift Arm/Fork, Reverse Gear Shift Arm Bracket, Spring, Ball And Reverse Gear Shift Fork

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21. Insert 5th & reverse guide shaft (1) to reverse gear shift fork (3) and intermediate case (4) from front side pushing ball (5) by rod (2).
    CAUTION: Be sure to install 5th & reverse guide shaft as specified direction.
    If failure to follow above-mentioned procedure, 5th & reverse guide shaft could result in wrong assembly which ball (5) installed to (6) hole for interlock pin.
    Fig 25: Identifying 5th & Reverse Guide Shaft, Reverse Gear Shift Fork, Intermediate Case, Ball, Rod, Hole & Dent

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22. Insert ball (1) to reverse gear shift fork (2) and interlock pin (3) to intermediate case (4) using magnet.
    Fig 26: Identifying Ball, Reverse Gear Shift Fork, Interlock Pin & Intermediate Case

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23. Install 5th gear shaft (2) after fitting 5th gear shift fork (1) to 5th & reverse synchronizer sleeve (3).
    Fig 27: Identifying 5th Gear Shaft, 5th Gear Shift Fork & 5th & Reverse Synchronizer Sleeve

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24. Drive spring pin (1) into 5th gear shift fork (2) and shaft (3) up to 5th gear shift fork (2) surface using plastic hammer.
    Fig 28: Identifying Spring Pin, 5th Gear Shift Fork And Shaft

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25. Install new circlips (1) to groove of 5th gear shift shaft (2) and 5th & reverse guide shaft (3) using lever (4) or the like and hammer.
    Fig 29: Identifying Circlips, Groove Of 5th Gear Shift Shaft, 5th & Reverse Guide Shaft & Lever

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26. Insert interlock pin (1) to intermediate case (2) using magnet (3).
    Fig 30: Identifying Interlock Pin, Intermediate Case & Magnet

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27. Apply grease to straight pin (1) and install straight pin (1) to low speed gear shift shaft (2).

    "A": Grease 99000-25010 

    Fig 31: Identifying Straight Pin And Low Speed Gear Shift Shaft

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28. Install low speed gear shift fork (1) and low speed gear shift shaft (2).
    Fig 32: Identifying Low Speed Gear Shift Fork And Low Speed Gear Shift Shaft

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29. Insert interlock pin (1) to intermediate case (2) using magnet (3).
    Fig 33: Identifying Interlock Pin, Intermediate Case & Magnet

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30. Install high speed gear shift fork (1) and high speed gear shift shaft (2).
    Fig 34: Identifying High Speed Gear Shift Fork And High Speed Gear Shift Shaft

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31. Install new circlips (1) to high speed gear shift shaft (2) and low speed gear shift shaft (3) using lever (4) or the like and hammer.
    Fig 35: Identifying Circlips, High Speed Gear Shift Shaft, Low Speed Gear Shift Shaft & Lever

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32. Install new low speed gear shift fork bolt (1) and high speed gear shift fork bolt (2) and tighten bolts to specified torque.

    Tightening torque 

    Low and high speed gear shift fork bolt a: 20 N.m (2.0 kg-m, 14.5 lb-ft) 

    Fig 36: Identifying Low And High Speed Gear Shift Fork Bolts

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33. Install locating balls (1), locating springs (2) and new locating screws (3).

    Tightening torque 

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

    Fig 37: Identifying Locating Balls, Springs And Screws

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34. Place intermediate case assembly (1) upright as shown in the figure using workbench (2) or the like.
    Fig 38: Identifying Intermediate Case Assembly & Workbench

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

    "A": Sealant 99000-31110 

    Fig 39: Identifying Intermediate Case & Sealant Application Area

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36. Clean mating surface of front case (1) and install it to intermediate case.
    Fig 40: Identifying Mating Surface Of Front Case

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

    Special Tool 

    (A): 09900-06107 

    Fig 41: Identifying C-Rings

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38. Clean mating surface of input shaft bearing retainer (1) and apply sealant evenly to input shaft bearing retainer (1).

    "B": Sealant 99000-31110 

    Fig 42: Identifying Input Shaft Bearing Retainer & Sealant Application Area

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39. Install input shaft bearing retainer (1) tightening new input shaft bearing plate bolt to specified torque.

    Tightening torque 

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

    Fig 43: Identifying Input Shaft Bearing Retainer & Bolt

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40. Insert gear shift inner shaft (1) and gear shift inner lever (2) to rear case (4).
41. Drive spring pin (3) into gear shift inner lever (2) using special tool.

    Special Tool 

    (A): 09922-85811 

    Fig 44: Identifying Gear Shift Inner Shaft, Gear Shift Inner Lever, Rear Case And Spring Pin

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42. Clean mating surface of rear case (1) and apply sealant evenly to rear case side of intermediate case (2).

    "A": Sealant 99000-31110 

    Fig 45: Identifying Rear Case, Intermediate Case & Sealant Application Area

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43. Install rear case (1) to intermediate case (2) with tip end of gear shift shaft inner lever (3) hooked on head of gear shift shaft (4).

    Tighten case bolts to specified torque.

    Tightening torque 

    Rear case to intermediate case bolt a: 37 N.m (3.7 kg-m, 27.0 lb-ft) 

    Fig 46: Identifying Rear Case, Intermediate Case Bolt, Gear Shift Shaft Inner Lever & Gear Shift Shaft

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44. Tighten return spring low bolt (2) 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: 37 N.m (3.7 kg-m, 27.0 lb-ft) 

    Return spring low bolt b: 37 N.m (3.7 kg-m, 27.0 lb-ft) 

    Fig 47: Identifying Return Spring Low Bolt And Return Spring Reverse Bolt

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45. Install back-up light switch with new gasket.

    Tightening torque 

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

    Fig 48: Identifying Back-Up Light Switch

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46. Install clutch housing (3) and torque its bolts to specification.
    NOTE: Use new two mounting bolts (1) as shown in the figure.

    Tightening torque 

    Clutch housing bolt a: 36 N.m (3.6 kg-m, 26.0 lb-ft) 

47. Install clutch release fork (2) and release bearing (4).
    Fig 49: Identifying Clutch Housing, Release Fork, Release Bearing & Bolts

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