Page 2105 of 2389
(b) Apply sealant to the two screw plugs.
Sealant: Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, torque the two screw plugs.
SST 09313±30021
Torque: 250 kg±cm (18 ft±Ib, 25 N±m)
15. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
AND NO.2 OIL PIPE
(a) Put the±reverse shift fork pivot into the reverse shift
arm and install the reverse shift arm bracket to the
transaxle case.
(b) Temporarily install the bolt. 14. INSTALL REVERSE IDLER GEAR SHAFT, THRUST
WASHER AND GEAR
(a) Install the reverse idler gear shaft with gear and thrust
washer to the case.
(b) Align the matchmarks, as shown in the illustration.
(c) Install the No.2 oil pipe.
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16. INSTALL TRANSMISSION CASE
(a) Remove any packing material and be careful not to drop oil on
the contacting surfaces of the transaxle case.
(b) Apply seal packing to the transmission case as shown in the fig-
ure.
Seal packing: Part No.08826±00080, THREE BOND
1281 or equivalent
HINT: Install the transmission case as soon as the seal packing
is applied.
(c) Install and torque the seventeen bolts.
Transmission case side: Fourteen bolts
Transaxle case side: Three bolts
Torque: 300 kg±cm (22 ft±Ib, 29 N±m)
(d) Torque the two oil pipe bolts and reverse shift arm
bracket bolt.
Torque: 175 kg±cm (13 ft±lb, 17 N±m)
17. INSTALL AND TORQUE REVERSE IDLER GEAR
RETAINING BOLT WITH GASKET
Torque: 300 kg±cm (22 ft±Ib, 29 N±m)
(e) Install a new gasket to the oil pipe.
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Page 2107 of 2389
(b) Apply sealant to the screw plug.
Sealant: Part No.08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, torque the screw, plug.
SST 09313±30021
Torque: 250 kg±cm (18 ft±Ib, 25 N±m)
18. INSTALL LOCKING BALL, SPRING, SPRING SEAT
AND SCREW PLUG
(a) Install the locking ball, spring and spring seat.
18. INSTALL SNAP RINGS
Using a plastic hammer, install the two snap rings to
the shift fork shafts.
20. INSTALL REAR BEARING RETAINER
(a) Install the output shaft rear bearing outer race.
(b) Install the adjust shim which is already finished
out put shaft preload.
± MANUAL TRANSAXLEInstallation of Component PartsMT±198
Page 2108 of 2389
(d) Apply sealant to the, seven screws.
Sealant: Part No.08833±00070, THREE BOND 1324,
LOCTITE 242 or equivalent
(e) Using a torx wrench, torque the seven screws.
Tom wrench T45 09042±00050
Torque: 430 kg±cm (31 ft±Ib, 42 N±m)
(c) Using SST, install the No.3 clutch hub with synchronizer
ring and key spring.
SST 09310±17010 I09310±07010, 09310±07020,
09310±070301 21. INSTALL FIFTH GEAR AND NO±3 CLUTCH HUB
(a) Install the spacer, needle roller bearings and 5th gear.
(b) Install the synchronizer ring and key spring to the
No±3 clutch hub.(c) Using snap ring pliers, install the snap ring to the
input shaft rear bearing.
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Page 2109 of 2389
22. INSTALL FIFTH DRIVEN GEAR
Using SST, install the 5th driven gear.
SST 09310±17010 (09310±07010, 09310±07020
09310±07040, 09310±07050)(e) Using a dial indicator, measure the 5th gear thrust clear-
ance.
Standard clearance: 0.10 ± 0.57 mm
(0.004 ± 0.022 in.)
23. INSTALL NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Install the No.3 hub sleeve and No.3 shift fork.(d) Select a snap ring that will allow minimum axial
play and install it on the shaft.
(b) install and torque the set bolt.
Torque: 240 kg±cm (17 ft±Ib, 24 N±m)
± MANUAL TRANSAXLEInstallation of Component PartsMT±200
Page 2110 of 2389
25. INSTALL TRANSMISSION CASE COVER
(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of the transmis-
sion case cover.
(b) Apply seal packing to the transmission case as shown
in the figure.
Seal packing: Part No.08826±00090, THREE
BOND
1281 or equivalent
HINT: Install the transmission case cover as soon as the
seal packing is applied.
Install and torque the ten bolts.
Torque: 300 kg±cm (22 ft±Ib, 29 N±m)
24. INSTALL LOCK NUT
(a) Engage the gear double meshing.
(b) install and torque a new lock nut.
Torque: 1,250 kg±cm (90 ft±Ib, 123 N±m)
(e) Stake the lock nut.
(d) Disengage the gear double meshing.
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Page 2111 of 2389

26. INSTALL SHIFT AND SELECT LEVER SHAFT
ASSEMBLY
(a) Install the shift and select lever shaft assembly and new gasket.
(b) Apply sealant to the bolt threads.
Sealant: Part No.08833±00O80, THREE BOND 1344,
LOCTITE 242 or equivalent
(e) Install and torque the four bolts.
Torque: 200 kg±cm (14 ft±Ib, 20 N±m)
(d) Install and torque the lock bolt with the new gasket.
Torque: 500 kg±cm (36 ft±Ib, 49 N±m)
27. INSTALL NO.2 SELECTING BELLCRANK WITH
SELECTING BELLCRANK SUPPORT
(a) Apply sealant to the bolt threads.
Sealant: Part No.08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install and torque the two bolts.
Torque: 200 kg±cm (14 ft±Ib, 20 N±m)
28. INSTALL BACK±UP LIGHT SWITCH
Instal! and torque the back±up light switch with the
new gasket.
Torque: 410 kg±cm (30 ft±Ib, 40 N±m)
29. INSTALL SPEEDOMETER DRIVEN GEAR
30. INSTALL RELEASE FORK AND BEARING
Apply molybdenum disulphide lithium base grease to
the following part:
wInput shaft spline
wRelease fork contact surface
± MANUAL TRANSAXLEInstallation of Component PartsMT±202
Page 2112 of 2389

32. INSTALL TRANSFER ASSEMBLY
(a) Remove any packing material and be careful not to drop oil on the
contacting surfaces of the transfer or transaxle.
(b) Apply seal packing to the transfer as shown in the figure.
Seal packing: Part No.08826±00090, THREE BOND
1281 or equivalent
HINT: Install the transfer as soon as the seal packing is applied.
(c) Install the transfer assembly to the transaxle assembly
HINT: Shift into 4th gear, install the transfer assembly while turning
the input shaft of the transaxle. 31. INSTALL DIFFERENTIAL SIDE GEAR INTERMEDIATE
SHAFT
(a) Apply MP grease to the intermediate shaft.
(b) Using a plastic hammer, correctly drive the intermedi-
ate shaft straight until the top of it touches the differ-
ential pinion shaft.
(d) Apply sealant to the bolt threads.
Sealant: Part No.08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(e) Install and torque the three bolts and five nuts.
Torque: 700 kg±cm (51 ft±Ib, 69 N±m)
HINT: Keeping the intermediate shaft on the pinion
shaft of differential, measure the point in the il-
lustration.
Protrusion length: 255.5 mm (10.059 in.)
± MANUAL TRANSAXLEInstallation of Component PartsMT±203