Page 1945 of 2389
(g) Using a pin punch and hammer, drive out the slotted
spring pin.
(h) Remove the shift fork lock plate, No. 1 shift inner
lever, spring and shift interlock plate. (f) Remove the reverse restrict pin holder, spring and
No. 2 shift inner lever.
(i) Remove the E±ring from the shaft.
± MANUAL TRANSAXLES51 TransmissionMT±17
Page 1946 of 2389

3. CHECK OIL CLEARANCE OF EACH GEAR
Using a dial indicator, measure the oil clearance be-
tween the gear and input or output shaft with the needle
roller bearing installed.
Standard clearance:
1 st, 2nd, 3rd and 4th gears
0.009 ± 0.053 mm
(0.0004 ± 0.0021 in.)
5th gear 0.009 ± 0.050 mm
(0.0004 ± 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
if the clearance exceeds the limit, replace the gear,
needle roller bearing or shaft.
INSPECTION OF TRANSMISSION
COMPONENTS
1. INSPECT INPUT SHAFT
(a) Using a micrometer, measure the outer diameter of the
input shaft journal surface.
Minimum outer diameter:
Part A 26.970 mm (1.0618 in.)
B 32.470 mm (1.2783 in.)
C 33.090 mm (7.3028 in.)
D 29.970 mm (1.1799 in.)
(b) Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 in.)
2. INSPECT OUTPUT SHAFT
(a) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Minimum outer diameter:
Part A 31.970 mm (1.2587 in.)
6 37.970 mm (1.4949 in.)
C 31.970 mm (1.2587 in.)
(b) Using a dial indicator, check the shaft run-
out.
Maximum runout: 0.05 mm (0.0020 in.)
± MANUAL TRANSAXLES51 TransmissionMT±18
Page 1947 of 2389
5. MEASURE CLEARANCE OF SHIFT FORKS AND HUB
SLEEVES
Using a feeler gauge, measure the clearance between the
hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the limit, replace the shift fork or
hub sleeve.
(e) Using SST, press in a new bearing.
SST 09310±35010 .
(d) Install the transaxle case oil receiver and torque
the bolt.
Torque: 75 kg±cm (65 in.±Ib, 7.4 11f±m)
6. IF NECESSARY, REPLACE INPUT SHAFT FRONT
BEARING
(a) Remove the bolt and transaxle case oil receiver.
(b) Using SST, pull out the bearing.
SST 09308±00010 (b) Measure the clearance between the synchronizer ring
back and the gear spline end.
Minimum clearance: 0.6 mm 10.024 in.)
If the clearance is less than the limit, replace the synchro-
nizer ring. 4. INSPECT SYNCHRONIZER RINGS
(a) Turn the ring and push it in to check the braking action.
± MANUAL TRANSAXLES51 TransmissionMT±19
Page 1948 of 2389
7. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT
BEARING
(a) Remove the bolt and bearing lock plate.
(b) Using SST, pull out the bearing.
SST 09308±00010
(b) Using SST, drive in a new oil seal.
SST 09608±20012 (09608±00080, 09608±03020)
Drive in depth: 1.0 ± 2.0 mm (0.039 ± 0.079 in.)
(c) Coat the lip of the oil seal with MP grease. (c) Using SST, press in a new bearing.
SST 09310±35010
(d) Install the bearing lock plate and torque the
bolt.
Torque: 185 kg±cm (13 ft±Ib, 18 N±m)
9. IF NECESSARY, REPLACE LH SIDE OIL SEAL
(a) Using SST, press out the oil seal from the retainer.
SST 09608±20012 (09608±00030,09608±03020) 8. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL
SEAL
(a) Using a screwdriver, pry out the oil seal.
± MANUAL TRANSAXLES51 TransmissionMT±20
Page 1949 of 2389
11. IF NECESSARY, REPLACE LH OUTER RACE OF
SIDE BEARING
(a) Using SST, press out the outer race.
SST 09608±20012 (09608±00060,09608±03020)
(b) Install the bearing retainer without an O±ring.
(e) Install and torque the retainer bolts.
Torque: 185 kg±cm(13 ft±Ib, 18 N±m)
(d) Place the thinnest shim into the case.
(See table on page MT±28)
(e) Using SST, press in a new outer race.
SST 09608±20012 (09608±03020,09608±03060) (b) Using SST, drive in a new oil seal until its surface
is flush with the case surface.
SST 09316±60010 (09316±00010)
(e) Coat the lip of the oil seal with MP grease.(b) Using SST, press in a new oil seal until its surface
is flush with the case surface.
SST 09316±60010 (09316±00010)
(c) Coat the lip of the oil seal with IMP grease.
10. IF NECESSARY, REPLACE RH SIDE OIL SEAL
(a) Drive out the oil seal with a screwdriver.
± MANUAL TRANSAXLES51 TransmissionMT±21
Page 1950 of 2389
(b) Using SST, drive in a new oil seal until its surface is
flush with the cover surface.
SST 09608±200 12 (09608±00080, 09608±03020)
(c) Coat the lip of the oil seal with MP grease.
14. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN
GEAR OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09921±00010 12. IF NECESSARY, REPLACE RH OUTER RACE OF
SIDE BEARING
(a) Using SST, press out the outer race and shim.
SST 09608±20012 (09608±00030,09608±03020)
13. IF NECESSARY, REPLACE CONTROL SHAFT COVER
OIL SEAL
(a) Using a screwdriver, pry out the oil seal.(b) Place the shim into the case.
(c) Using SST, press in a new outer race.
SST 09608±20012 (09608±03020,09608±03060)
± MANUAL TRANSAXLES51 TransmissionMT±22
Page 1951 of 2389
(c) Replace the reverse restrict pin.
(d) Drive in the slotted spring pin.
(e) Apply sealant to the plug threads.
Sealant: Part No. 4.8833±00080, THREE6ON D 1344,
LOCTITE 242 or equivalent
(f) Using SST, install the straight screw plug.
SST 09313±30021
Torque: 130 kg±cm (9 ft±lb, 13 N±m)
15. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Using SST, remove the straight screw plug.
SST 09313±30021
(b) Using a pin punch and hammer, drive out the slotted
spring pin. (b) Using SST, drive in a new oil seal.
SST 09201±60011
Drive in depth: 19 mm (0.75 in.)
± MANUAL TRANSAXLES51 TransmissionMT±23
Page 1952 of 2389
INSTALLATION OF TRANSAXLE
1. INSTALL TRANSAXLE TO ENGINE
Align the input shaft spline with the clutch disc, and
install the transaxle to the engine. Torque the bolts.
Torque:
12 mm bolt 650 kg±cm (47 ft±lb, 64 N±m)
10 mm bolt 470 kg±cm (34 ft±Ib, 46 N±m)
2. CONNECT LEFT ENGINE MOUNTING
Connect the left engine mounting with the bolts. Torque
the bolts.
Torque: 530 kg±cm (38 ft±lb, 52 N±rm)
3. INSTALL STABILIZER BAR
(See page FA±35)
4. INSTALL CENTER DRIVE SHAFT
(a) Insert the center drive shaft to the transaxle through the
bearing bracket.
(b) Secure the center drive shaft with the snap ring.
(c) Tighten a new bolt on the bearing bracket.
Torque: 330 kg±cm (24 ft±lb, 32 N±m)
5. CONNECT BOTH DRIVE SHAFTS
Connect the drive shaft and torque the six nuts while de-
pressing the brake pedal.
Torque: 370 kg±cm (27 ft±Ib, 36 N±m)
6. CONNECT LEFT STEERING KNUCKLE TO LOWER
ARM
Torque: 1,150 kg±cm (83 ft±Ib, 113 N±m)
± MANUAL TRANSAXLES51 TransmissionMT±38