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3. MEASURE FIRST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance: 0.10 ± 0.35 mm
(0.0039 ± 0.0138 in.)
5. SYNCHRONIZER RING, SECOND GEAR AND THIRD
DRIVEN GEAR
(a) Place the synchronizer ring (for 2nd gear) on the gear
and align the ring slots with the shifting keys.
NOTICE: Do not install the synchronizer ring for 1 st gear.
4. INSTALL BALL, SECOND GEAR BUSHING, NEEDLE
ROLLER BEARING
(a) Install the ball and bushing.
(b) Apply MP grease to the needle roller bearing.
(e) Install the needle roller bearing.(d) Using SST and a press, install the 1 st gear and
No. 1
hub sleeve.
SST 09316±60010¿09316±000401
(b) Install the 2nd gear.
(e) Using a press, install the 3rd driven gear.
± MANUAL TRANSAXLEComponent Parts (Output Shaft Assembly)MT±143
Page 2058 of 2389
6. MEASURE SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust
clearance.
Standard clearance: 0.10 ± 0.45 mm
(0.0039 ± 0.0177 in.)
8. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the output shaft rear ta-
per roller bearing.
SST 09506±30012 7. INSTALL SPACER AND FOURTH DRIVEN GEAR
(a) Install the spacer.
(b) Using a press, install the 4th driven gear.
± MANUAL TRANSAXLEComponent Parts (Output Shaft Assembly)MT±144
Page 2059 of 2389
REMOVAL OF COMPONENT PARTS
COMPONENTS
± MANUAL TRANSAXLERemoval of Component PartsMT±118
Page 2060 of 2389
COMPONENTS (Cont'd)
± MANUAL TRANSAXLERemoval of Component PartsMT±119
Page 2061 of 2389
COMPONENTS (Cont'd)
± MANUAL TRANSAXLERemoval of Component PartsMT±120
Page 2062 of 2389
2. REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE
SHAFT
(a) Screw in a suitable bolt with washer into the side gear
intermediate shaft.
(b) Using SST, remove the side gear intermediate shaft.
SST 09910±00015
REMOVAL OF COMPONENT PARTS
(See pages MT± 118 to MT± 120)
1. REMOVE TRANSFER ASSEMBLY
(a) Remove the three bolts and five nuts.
(b) Using a plastic hammer, remove the transfer assembly
from the transaxle.
B. REMOVE SPEEDOMETER DRIVEN GEAR
6. REMOVE NO.2 SELECTING BELLCRANK WITH
SELECTING BELLCRANK SUPPORT 4. REMOVE BACK±UP LIGHT SWITCH
(a) Remove the back±up light switch.
(b) Remove the gasket from the back±up light switch. 3. REMOVE RELEASE FORK, BEARING AND BOOT
± MANUAL TRANSAXLERemoval of Component PartsMT±121
Page 2063 of 2389
8. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
(a) Remove the four bolts and the shift and select lever
. shaft assembly.
(b) Remove the gasket from the shift and select lever shaft as-
sembly. 7. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK
BOLT
(a) Remove the shift and select lever shaft lock bolt.
(b) Remove the gasket from the bolt.
9. REMOVE TRANSMISSION CASE COVER
(a) Remove the ten bolts.
(b) Using a plastic hammer, remove the case cover.
10. REMOVE OUTPUT SHAFT LOCK NUT
(a) Engage the gear double meshing.
(b) Using a chisel and hammer, unstake the lock nut.
± MANUAL TRANSAXLERemoval of Component PartsMT±122
Page 2064 of 2389
13. MEASURE FIFTH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10 ± 0.57 mm
(0.0039 ± 0.0224 in.)
Maximum clearance: 0.65 mm (0.0256. in.) 11. REMOVE NO.3 HUB SLEEVE AND NO. 3 SHIFT FORK
(a) Remove the No.3 shift fork set bolt.
(b) Remove the No.3 hub sleeve and No.3 shift fork.
12. REMOVE FIFTH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09310±17010 (09310±07010, 09310±07020
09310±07040, 09310±07050)
(b) Using a dial indicator, measure the oil clearance.
Standard clearance: 0.009 ± 0.050 mm
(0.0004 ± 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)(e) Remove the lock nut.
(d) Disengage the gear double meshing.
± MANUAL TRANSAXLERemoval of Component PartsMT±123