Page 1961 of 2389
23. INSTALL REVERSE SHIFT ARM
(a) Put the reverse shift arm pivot into the reverse shift
fork and install the reverse shift arm to the transaxle case.
(b) Shift the reverse shift arm into reverse.
25. INSTALL NO. 1 AND NO. 2 SHIFT FORKS, NO. 1
SHIFT HEAD AND NO. 1 FORK SHAFT
(a) Place No. 1 and No. 2 shift forks into the groove of
No. 1 and No. 2 hub sleeves. (e) Install and torque the bolts.
Torque: 185 kg±cm (13 ft±lb, 18 N±m)
(d) Shift the reverse shift arm to neutral position.
24. INSTALL REVERSE IDLER GEAR AND SHAFT
Install the reverse idler gear and shaft as shown. (b) Install the reverse shift fork onto No. 2 fork shaft.
± MANUAL TRANSAXLES51 TransmissionMT±30
Page 1962 of 2389
27. INSTALL SHIM AND SIDE BEARING RETAINER
WITH O±RING
(a) Install a new 4±ring on the retainer.
(b) Install the shim and retainer.
(c) Apply sealant to the bolt threads.
Sealant: Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent 26. INSTALL TRANSMISSION CASE
(a) Apply seal packing to the transmission case as shown in the
figure.
Seal packing: Part No. O8826±00090, THREE BOND
1281 or equivalent
(b) Install and torque the seventeen bolts.
Torque: 300 kg±cm (22 ft±tb, 29 N±m)
(d) Shift the fork shaft into reverse.
(e) Using a pin punch and hammer, drive the slotted
spring pin into No. 1 fork shaft. (b) Hold No. 1 shift head and insert No. 1 fork shaft
into the transaxle case through No. 1 and No. 2
shift forks, No. 1 shift head and reverse shift fork.
(e) Using a pin punch and hammer, drive the slotted
spring pin into No. 1 shift head.
± MANUAL TRANSAXLES51 TransmissionMT±31
Page 1963 of 2389
30. INSTALL REAR BEARING RETAINER
(a) Apply sealant to the bolt threads.
Sealant: Part No. 08833±00070, THREE BOND
1324, or equivalent
(b) Install and torque the five bolts.
Torque: 210 kg±cm (15 ft±Ib, 21 N± m)
28. INSTALL AND TORQUE REVERSE IDLER GEAR
SHAFT LOCK BOLT
Torque: 300 kg±cm (22 ft±Ib, 29 N±m)
31. INSTALL FIFTH DRIVEN GEAR
Using SST, install the 5th driven gear.
SST 09309±32050(d) Install and torque the six bolts.
Torque: 185 kg±cm (13 ft±lb, 18 N ±m)
29. INSTALL BEARING SNAP RINGS
± MANUAL TRANSAXLES51 TransmissionMT±32
Page 1964 of 2389

34. INSTALL NO. 3 HUB SLEEVE ASSEMBLY WITH SHIFT
FORK
(a) Support the tip of the input shaft with a spacer or such
to raise the transaxle assembly.
(b) Using SST, drive in No. 3 hub sleeve with shift fork.
SST 09612±22011
NOTICE: Align the synchronizer ring slots with the shifting
keys.
33. INSERT NO. 3 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub
sleeve.
(b) install the shifting key springs under the shifting keys.
NOTICE: Install the key springs positioned so that their end
gaps are not in line.
32. INSTALL SPACER, NEEDLE ROLLER BEARINGS,
FIFTH GEAR AND SYNCHRONIZER RING
(a) Install the spacer.
(b) Apply ATF to the needle roller bearings.
(e) Install the 5th gear with the needle roller bearings and
synchronizer ring.
35. MEASURE FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20 ± 0.40 mm
(0.0079 ± 0.0157 in.)
36. INSTALL SHIFTING KEY RETAINER AND SNAP RING
(a) Install the retainer.
(b) Select a snap ring that will allow minimum axial play and
install it on the shaft.
Thickness mm (in.) Thickness mm (in.) Mark
Mark
± MANUAL TRANSAXLES51 TransmissionMT±33
Page 1965 of 2389
37. INSTALL LOCK NUT
(a) Engage the gear double meshing.
(b) Install and torque the nut.
Torque: 1,250 kg±cm (90 ft±lb, 123 N±m)
HINT: The lock nut has LH threads.
(c) Disengage the gear double meshing.
(d) Stake the lock nut.
(d) Install No. 1 shift inner lever with the shift fork lock
plate.
HINT: One of the spline teeth of the shift and select
lever shaft has been eliminated. Therefore, be cer-
tain to correctly align this portion to the matching
portions on the parts during assembly. 38. ASSEMBLE SHIFT AND SELECT LEVER ASSEMBLY
(a) Apply ATF to the shaft.
(b) Install the E±ring.
(e) Using a pin punch and hammer, drive i n the slotted
spring pin. (c) Install shift interlock plate and
spring.
± MANUAL TRANSAXLES51 TransmissionMT±34
Page 1966 of 2389
39. INSTALL SHIFT AND SELECT LEVER ASSEMBLY
(a) Apply seal packing to the underside of the flanged portion of
the control shaft cover.
Seal packing: Part No. 08826±00090, THREE BOND
1281 or equivalent
(b) Install the shift and select lever assembly and torque the con-
trol shaft cover. ._
Torque: 375 kg±cm (27 ft±Ib, 37 N±m)
(h) Install the control shaft cover and dust boot.
HINT: Make sure to install the boot in correct direction.
Position the air bleed of the boot downward. (f) Install No. 2 shift inner lever, spring and reverse
restrict pin holder.
Install the control shift lever and insert the lever lock
pin to the lever. Install the washer and lock nut.(g) Install the E±ring.
± MANUAL TRANSAXLES51 TransmissionMT±35
Page 1967 of 2389

44. INSTALL TRANSMISSION CASE COVER
(a) Apply seal packing to the transmission case as shown in
the figure.
Seal packing: Part No. 08826±00090, THREE BOND
1281 or equivalent
(b) Apply sealant to the bolt threads.
Sealant: Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Install and torque the eight bolts.
Torque: 300 kg±cm (22 ft±Ib, 29 N±m)
40. INSTALL NO. 2 LOCK BALL ASSEMBLY
(a) Apply sealant to the lock ball assembly threads.
Sealant: Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, install and torque the plug.
SST 09313±30021
Torque: 230 kg±cm (117 ft±Ib, 23 N±m)
41. INSTALL AND ADJUST NO. 1 LOCK BALL
ASSEMBLY
(a) Fully loosen the lock nut.
(b) Fully screw in the lock ball.
(e) Loosen the lock ball to where the play at the shift outer
lever tip is 0.1 ± 0.5 mm (0.004 ± 0.020 in.).
(d) Hold the lock ball and tighten the lock nut.
Torque: 375 kg±cm (27 ft±Ib, 37 N±m )
(e) Check the shift outer lever tip play.
Lever tip play: 0.1 ± 0.5 mm (0.004 ± 0.020 in.)
42. INSTALL SELECTING BELLCRANK
43. INSTALL NO. 3 SHIFT FORK SECURING BOLT
Install and torque the bolt.
Torque: 185 kg±cm (13 ft±Ib, 18 N±m)
± MANUAL TRANSAXLES51 TransmissionMT±36
Page 1968 of 2389
46. INSTALL RELEASE FORK AND BEARING
(a) Apply molybdenum disulphide lithium base grease to
the following parts:
wRelease bearing hub inside groove
wInput shaft spline
wRelease fork contact surface
(b) Apply MP grease to the front surface of the release
bearing.
47. INSTALL BACK±UP LIGHT SWITCH
Torque: 450 kg±cm (33 ft±Ib, 44 N±m)
48. INSTALL SPEEDOMETER DRIVEN GEAR45. INSTALL RELEASE BEARING RETAINER
Torque: 75 kg±cm (65 in.±Ib, 7.4 N±m)
± MANUAL TRANSAXLES51 TransmissionMT±37