Page 3793 of 4770
MT0792
SM0201
SST
Z00431
SM0202
SST MX±34
± MANUAL TRANSAXLE (S51)OUTPUT SHAFT
1884 Author: Date:
4. INSTALL SYNCHRONIZER RING, 2ND GEAR,
NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR
(a) Install the ball.
(b) Fit the 2nd gear bushing groove securely over the ball
when installing the 2nd gear bushing on the shaft.
(c) Place the synchronizer rings on the 2nd gear.
(d) Apply gear oil to the needle roller bearing and install it.
(e) Install the 2nd gear.
NOTICE:
Align the clutch hub grooves with the projections on the
synchronizer ring.
(f) Using SST and a press, install the 3rd driven gear.
SST 09316±60011 (09316±00011)
5. INSPECT 2ND GEAR THRUST CLEARANCE
(See page MX±28)
6. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN
GEAR AND RADIAL BALL BEARING
(a) Install the outer gear spacer.
(b) Using a press, install the 4th driven gear and bearing.
7. INSTALL REAR BEARING
Using SST and a press, install the rear bearing.
SST 09612±22011
Page 3794 of 4770
MX04R±01
Q10277
Shift and Select Lever Shaft
Select Spring Seat
Shift Interlock Plate
Compression Spring
Select Spring Seat No.2Shift Inner Lever No.2Shift Inner Lever No.1Slotted Spring Pin
Control Shaft CoverControl Shaft Lever Lever Lock PinWasher Dust Boot
O±RingOil Seal
N´m (kgf´cm, ft´lbf)
: Specified torque
MP Grease Non±reusable partE±Ring
E±Ring
Compression Spring
6.4 (85, 56 in.´lbf)
± MANUAL TRANSAXLE (S51)SHIFT AND SELECT LEVER SHAFT
MX±35
1885 Author: Date:
SHIFT AND SELECT LEVER SHAFT
COMPONENTS
Page 3795 of 4770
MX04S±01
Z19302
Ring GearOuter Race and Side Bearing
Pinion Thrust Washer
Pinion Gear
Pinion Shaft
Side Gear
Side Gear Thrust Washer Side Bearing and Outer Race
Vehicle Speed Sensor Drive Gear Straight Pin Differential Case
Non±reusable partShim x 8
83 (850, 61)
Shim
N´m (kgf´cm, ft´lbf) : Specified torque MX±36
± MANUAL TRANSAXLE (S51)DIFFERENTIAL CASE
1886 Author: Date:
DIFFERENTIAL CASE
COMPONENTS
Page 3796 of 4770

MX04T±01
Q08148
SST
Q04969
SST
AT2799
± MANUAL TRANSAXLE (S51)DIFFERENTIAL CASE
MX±37
1887 Author: Date:
DISASSEMBLY
1. Vehicle Speed Sensor Drive Gear Side:
REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
(a) Using SST, remove the bearing from the drive gear side
of the case.
SST 09950±00020, 09950±00030
(b) Remove the vehicle speed sensor drive gear.
2. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and case.
(b) Remove the 8 bolts.
(c) Using a copper hammer, tap on the ring gear to remove
it from the case.
3. Ring Gear Side:
REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
Using SST, remove the bearing from the ring gear side of the
case.
SST 09950±00020, 09950±00030
4. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear
while holding one pinion toward the case.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
If the backlash is not within the specification, install the correct
thrust washer to the side gears.
5. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, drive out the straight pin.
(b) Remove the pinion shaft from the case.
(c) Remove the 2 pinions and side gears with the 4 thrust
washers from each gear.
Page 3797 of 4770

Q08145
SST
SM0286
SST
SM0155
SST
Z00442
MT0634
SST MX±38
± MANUAL TRANSAXLE (S51)DIFFERENTIAL CASE
1888 Author: Date:
6. Transaxle Case Side:
IF NECESSARY, REPLACE DIFFERENTIAL SIDE
BEARING RETAINER OIL SEAL
(a) Using SST and a hammer, drive out the oil seal from the
retainer.
SST 09950±60020 (09951±00680), 09950±70010
(09951±07150)
(b) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the case surface.
SST 09350±32014 (09351±32130, 09351±32150)
(c) Coat the lip of the oil seal with MP grease.
7. Transmission Case Side:
IF NECESSARY, REPLACE SIDE OIL SEAL
(a) Using a screwdriver and hammer, drive out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the case surface.
SST 09350±32014 (09351±32130, 09351±32150)
(c) Coat the lip of the oil seal with MP grease.
8. Transaxle Case Side:
IF NECESSARY, REPLACE SIDE BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the bearing out-
er race.
(b) Install the bearing retainer without an O±ring.
(c) Install and torque the 6 bolts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
(d) Place the thinnest shim into the case.
(e) Using SST and a press, install a new bearing outer race.
SST 09950±60020 (09951±00680), 09950±70010
(09951±07150)
(f) Remove the 6 bolts.
(g) Remove the bearing retainer and shim.
Page 3798 of 4770
Q08184
SST
± MANUAL TRANSAXLE (S51)DIFFERENTIAL CASE
MX±39
1889 Author: Date:
9. Transaxle Case Side:
IF NECESSARY, REPLACE SIDE BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the bearing out-
er race and shim.
(b) Place the shim into the case.
(c) Using SST and a press, install a new bearing outer race.
SST 09950±60020 (09951±00680), 09950±70010
(09951±07150)
Page 3799 of 4770

MX04U±01
AT2981
Q08147
MX±40
± MANUAL TRANSAXLE (S51)DIFFERENTIAL CASE
1890 Author: Date:
REASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the correct thrust washers and side gears. Refer to
the table below, select thrust washers which will ensure
that the backlash is within the specification. Try to select
washers of the same size for both sides.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
Thickness mm (in.)Thickness mm (in.)
0.95 (0.0374)1.10 (0.0433)
1.00 (0.0394)1.15 (0.0453)
1.05 (0.0413)1.20 (0.0472)
Install the thrust washers and side gears in the differential
case.
(b) Install the pinion shaft.
(c) Inspect the side gear backlash.
Using a dial indicator, measure the side gear backlash
while holding one pinion gear toward the case.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
If the backlash is not within the specification, install a thrust
washer of different thickness.
(d) Using a pin punch and hammer, drive in the straight pin
through the case and hole in the pinion shaft.
(e) Stake the differential case.
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.
(b) Heat the ring gear in boiling water.
(c) Carefully take the ring gear out of the water.
(d) After moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the differential case and the ring gear.
(e) Temporarily install the 8 bolts.
NOTICE:
The ring gear set bolts should not be torqued until the ring
gear has cooled sufficiently.
(f) After the ring gear has cooled sufficiently, torque the ring
gear set bolts.
Torque: 83 N´m (850 kgf´cm, 61 ft´lbf)
Page 3800 of 4770

SM0287
SST
Q08649
Case Side
SM0289
SST
± MANUAL TRANSAXLE (S51)DIFFERENTIAL CASE
MX±41
1891 Author: Date:
3. INSTALL SIDE BEARING TO DIFFERENTIAL CASE
(a) Using SST and a press, install a new side bearing to the
transmission case side.
SST 09316±60011 (09316±00011), 09350±32014
(09351±32120)
(b) Install the vehicle speed sensor drive gear to the trans-
axle case side.
(c) Using SST and a press, install a new side bearing to the
transaxle case side.
SST 09316±60011 (09316±00011), 09350±32014
(09351±32120)
NOTICE:
Install the black cage bearing on the vehicle speed sensor
drive gear side.
4. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install the differential to the transaxle case.
(b) Install the transmission case.
(c) Install and torque the case bolts.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(d) Install the shim into the transmission case.
(e) Install the bearing retainer without an O±ring.
(f) Install and torque the 6 bolts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)