Fifth Gear Disassembly and Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.

Install countershaft 5th gear (1) to countershaft facing machined boss "A" inward.

Fig 1: Installing Countershaft 5th Gear To Countershaft
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Apply transaxle oil to needle bearing, and install it to input shaft.
Install input shaft 5th gear (1) to input shaft.
Install special tool in order to stop shaft rotation.
Special Tool
1. 09927-76060
Tighten new countershaft nut (2) to specified torque, and caulk nut (2) securely.
Tightening torque

Countershaft nut a: 100 N.m (10.0 kg-m, 72.5 lb-ft)

Fig 2: Installing Input Shaft 5th Gear To Input Shaft & Tightening Countershaft Nut
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Assemble 5th speed synchronizer sleeve (1), hub (2), 5th speed synchronizer levers (3) and synchronizer ring (4) as follows.

Fig 3: Installing 5th Speed Synchronizer Sleeve, Hub, 5th Speed Synchronizer Levers And Synchronizer Ring
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1. Install hub (1) to 5th speed synchronizer sleeve (2) in specified direction as shown in figure.
  
  Fig 4: Installing Hub To 5th Speed Synchronizer Sleeve
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2. Fit 5th speed synchronizer levers (1) to hub (2) in specified position as shown in figure.
  NOTE: Align protrusion "A" of 5th speed synchronizer levers (1) with groove of hub (2).
  
  Fig 5: Aligning Protrusion "A" Of 5th Speed Synchronizer Levers With Groove Of Hub
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3. Install synchronizer ring (1) to hub (2) in specified direction as shown in figure.
  
  Fig 6: Installing Synchronizer Ring To Hub
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Fit 5th gear shift fork (1) to sleeve (3) and hub (2) assembly, and install them into input shaft and gear shift shaft, aligning punch mark (4) with matching mark (5) on input shaft.

Fig 7: Fitting 5th Gear Shift Fork To Sleeve And Hub Assembly
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Tighten shift fork shaft bolt (2) to which thread lock cement has been applied.
"A": Thread lock cement 99000-32110

Tightening torque

Shift fork shaft bolt a: 10 N.m (1.0 kg-m, 7.5 lb-ft)
Using special tool, install new circlip (1) to input shaft (3) in specified direction as shown in the figure.
Special Tool

: 09900-06107

Fig 8: Installing Circlip To Input Shaft
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Clean mating surface of both left case (2) and side cover (1), apply sealant to side cover (1) as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate it with left case, and then tighten side cover bolts with specified torque.
"B": Sealant 99000-31260

Tightening torque

Side cover bolt a: 10 N.m (1.0 kg-m, 7.5 lb-ft)

Fig 9: Applying Sealant To Side Cover
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