5L-E CLUTCH UNIT > COMPONENTS

for Preparation Click here

5L-E CLUTCH UNIT > REMOVAL

for Preparation Click here

1. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

(Click here)
2. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

a. Remove the clutch release fork with the clutch release bearing from the
transmission unit.

b. Remove the release bearing and clip from the clutch release fork.

3. REMOVE CLUTCH RELEASE FORK BOOT

a. Remove the clutch release fork boot from the transmission unit.
4. REMOVE RELEASE FORK SUPPORT

a. Remove the release fork support from the transmission unit.

5. REMOVE CLUTCH COVER ASSEMBLY

a. Put matchmarks on the clutch cover assembly and the flywheel sub-assembly.

b. Loosen each set bolt one turn at a time until spring tension is released.

NOTICE:

Do not drop the clutch disc assembly.

c. Remove the set bolts, and pull off the clutch cover assembly.

6. REMOVE CLUTCH DISC ASSEMBLY

NOTICE:

Keep the lining part of the clutch disc assembly, the pressure plate and surface
of the flywheel sub-assembly away from oil and foreign matter.

7. INSPECT INPUT SHAFT BEARING

a. Turn the bearing by hand while applying force in the direction of the rotation.

HINT:

The bearing is permanently lubricated and requires no cleaning or lubrication.

8. REMOVE INPUT SHAFT BEARING

 a. Remove the 2 bolts at symmetrically opposite points.

b. Using SST, remove the input shaft bearing.

SST

09303-35011

L-E CLUTCH UNIT > INSPECTION

for Preparation Click here

1. INSPECT CLUTCH DISC ASSEMBLY

a. Using vernier calipers, measure the rivet head depth.

Minimum rivet depth:

0.3 mm (0.012 in.)

If the result is less than the minimum, replace the clutch disc assembly.

b. Install the clutch disc assembly to the transmission unit.

 NOTICE:
Take care not to insert the clutch disc assembly in the wrong direction.

c. Using a dial indicator, check the clutch disc assembly runout.

Maximum runout:
0.8 mm (0.031 in.)

If the runout exceeds the maximum, replace the clutch disc assembly.

2. INSPECT CLUTCH COVER ASSEMBLY

a. Using vernier calipers, inspect the diaphragm spring for the depth and width of
wear.

Maximum:
A (Depth): B (Width):
0.5 mm (0.020 in.) 6.0 mm (0.236 in.)

If the result exceeds the maximum, replace the clutch cover assembly.

3. INSPECT FLYWHEEL SUB-ASSEMBLY

a. Using a dial indicator, inspect the flywheel sub-assembly runout.

Maximum runout:
0.1 mm (0.004 in.)

If the runout exceeds the maximum, replace the flywheel sub-assembly.

4. INSPECT CLUTCH RELEASE BEARING ASSEMBLY

a. Check that the clutch release bearing assembly moves smoothly without abnormal
resistance by turning the sliding parts of the clutch release bearing assembly
(contact surfaces with the clutch cover) while applying force in the axial direction.

b. Inspect the clutch release bearing assembly for damage or wear.

5L-E CLUTCH UNIT > INSTALLATION

for Preparation Click here

 1. INSTALL INPUT SHAFT BEARING

a. Using SST and a hammer, install a new input shaft bearing.

SST
09304-12012

b. Install the 2 bolts.

Torque:
123 N*m{ 1,250 kgf*cm , 90 ft.*lbf }

2. INSTALL CLUTCH DISC ASSEMBLY

a. Insert SST into the clutch disc assembly, then insert them into the flywheel sub-
assembly.

SST
09301-00110
NOTICE:
Take care not to insert the clutch disc assembly in the wrong direction.

3. INSTALL CLUTCH COVER ASSEMBLY

a. Align the matchmarks on the clutch cover assembly with the one on the flywheel
sub-assembly.

b. Following the procedures shown in the illustration, tighten the 6 bolts starting from
the bolt located near the knock pin on the top.

SST
09301-00110
Torque:
19 N*m{ 195 kgf*cm , 14 ft.*lbf }
HINT:

Evenly tighten the bolts by following the order shown in the

illustration.

Tighten the bolts after checking that the disc is in the center by
lightly moving the SST up and down, left and right.

4. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

a. Using a dial indicator with a roller instrument, check the diaphragm spring tip
alignment.

Maximum non-alignment:
0.9 mm (0.035 in.)

b. If alignment is not as specified, adjust the diaphragm spring tip alignment using
SST.

SST
09333-00013

5. INSTALL CLUTCH RELEASE FORK BOOT

a. Install the clutch release fork boot.

6. INSTALL RELEASE FORK SUPPORT

a. Install the clutch release fork support to the transmission unit.

Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }

7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

a. Apply release hub grease to the release fork, the release bearing assembly, the
push rod contact point and the pivot points as shown in the illustration.

Sealant:
Part No. 08887-01806, RELEASE HUB GREASE or equivalent
b. Apply clutch spline grease to the input shaft spline.

Sealant:
Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent

c. Install the release bearing to the clutch release fork with the clip.

d. Install the clutch release fork assembly to the transmission unit.

NOTICE:
After installation, move the fork back and forth to check that the release
bearing slides smoothly.

8. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL > COMPONENTS

for Preparation Click here

 NUAL TRANSMISSION EXTENSION HOUSING OIL SEAL > REMOVAL

for Preparation Click here

1. DRAIN MANUAL TRANSMISSION OIL

a. Remove the filler plug and gasket.

b. Remove the drain plug and gasket, and drain the oil.

c. Install the drain plug with a new gasket.

Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }

2. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long
Wheelbase)

a. Put matchmarks on both flanges.

b. Remove the 4 nuts, bolts and washers.

HINT:
If the flange connection is hard to separate, temporarily tighten one nut only
and evenly tap the flange with a brass bar and hammer to separate the
propeller with center bearing shaft assembly from the differential companion
flange.
c. Remove the 2 bolts and center support bearing assembly No.1.

d. Remove the propeller with center bearing shaft assembly.

e. Insert SST in the transmission to prevent oil leakage.

NOTICE:
Do not damage the oil seal.

i. Use the following SST for the automatic transmission.

SST
09325-40010

ii. Use the following SST for the manual transmission.

SST
09325-20010
3. REMOVE PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)

a. Put matchmarks on both flanges.

b. Remove the 4 nuts, bolts and washers.

HINT:
If the flange connection is hard to separate, temporarily tighten one nut only
and evenly tap the flange with a brass bar and hammer to separate the
propeller shaft assembly from the differential companion flange.

c. Remove the propeller shaft assembly.

d. Insert SST in the transmission to prevent oil leakage.

NOTICE:
Do not damage the oil seal.
 i. Use the following SST for the automatic transmission

SST
09325-40010

ii. Use the following SST for the manual transmission

SST
09325-20010

4. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

a. Using SST, remove the oil seal.

SST
09308-00010

MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL >

INSTALLATION

for Preparation Click here

1. INSTALL MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

a. Using SST and a hammer, install a new oil seal to the extension housing.

SST
09325-20010
Drive in depth:
- 0.5 to 0.5 mm (-0.020 to 0.020 in.)

b. Coat the lip of the oil seal with MP grease.

2. INSTALL PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)

a. Remove the SST from the extension housing.

b. Install the propeller shaft assembly in the extension housing.

c. Align the matchmarks on the propeller shaft flange and differential flange.
d. Install the propeller shaft assembly with the 4 nuts, 4 bolts and 4 washers.

Torque:
74 N*m{ 755 kgf*cm , 54 ft.*lbf }

3. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long
Wheelbase)

a. Remove the SST from the extension housing.

b. Install the propeller with center bearing shaft assembly in the extension housing.
c. Install the center support bearing assembly No.1, and temporarily tighten the 2
bolts.

d. Align the matchmarks on the propeller shaft flange and differential flange.

e. Install the propeller shaft assy with the 4 nuts, 4 bolts and 4 washers.

Torque:
74 N*m{ 755 kgf*cm , 54 ft.*lbf }
f. Check that the center line of the bracket is at right angles to the shaft axial
direction.

g. Adjust the center support bearing assembly No.1.

HINT:

With the vehicle unladen, adjust the center support bearing No.1
to maintain the angles, as shown.

In the same conditions, check the center line in the axial

direction. Adjust the bearing if necessary.

The center bearing center line and center bearing housing center
line must be adjusted to within -1.0 to 1.0 mm (-0.0394 to 0.0394 in.)
of each other in the vehicle's longitudinal direction with the vehicle
unladen.

h. Tighten the 2 bolts.

Torque:
 36 N*m{ 369 kgf*cm , 27 ft.*lbf }

4. ADD MANUAL TRANSMISSION OIL

a. Park the vehicle in a level place.

b. Remove the transmission filler plug and gasket.

c. Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the
transmission filler plug opening.

Oil grade:
GL-4 or GL-5
Viscosity:
SAE 75W-90
Capacity:
2.2 liters (2.3 US qts, 1.9 lmp. qts)
NOTICE:

Problems may occur when the oil level is too high or too low.

After replacing the oil, drive the vehicle and check the oil level
again.

d. Check for oil leakage if the oil level is low.

e. Install the transmission filler plug and a new gasket.

Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }

HIFT AND SELECT TRANSMISSION CONTROL CABLE > COMPONENTS

for Preparation Click here

1/2
 SHIFT AND SELECT TRANSMISSION CONTROL CABLE > REMOVAL

for Preparation Click here

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

a. Put matchmarks on the control cable assembly and the outer lever.

b. Remove the 2 nuts and separate the transmission control cable assembly from the
outer lever.

c. Using a screwdriver, disengage the claws of the 2 clips.

d. Remove the 2 clips and separate the transmission control cable assembly from the
transmission control cable bracket No.1
e. Remove the bolt and control cable support.

f. Remove the bolt and separate the clamp.

g. Remove the 2 nuts and control cable bracket No.2.

 3. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER

a. Using a clip remover, remove the 2 clips (A).

b. Disengage the 4 clips (B).

c. Disconnect the connector.

d. Push the positions indicated by the arrows in the illustration to separate the fuel lid
lock control cable and bonnet (hood) control cable assembly from the panel.
Remove the instrument panel finish lower.

4. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.1

a. Using a clip remover, remove the 2 clips

b. Disengage the 3 claws and remove the instrument panel No.1 under cover sub-
assembly.

5. REMOVE PARKING BRAKE HOLE COVER

a. Disengage the 6 claws and remove the parking brake hole cover.

6. REMOVE SHIFT LEVER KNOB

a. Turn the shift lever knob in the direction indicated by the arrow and remove it.

7. REMOVE SHIFTING HOLE COVER ASSEMBLY

a. Manual Transmission:
Disengage the 6 claws and remove the shifting hole cover assembly.

b. Automatic Transmission:
Disengage the 8 claws and remove the shifting hole cover assembly.

8. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER

a. Disengage the 8 claws and remove the instrument panel finish panel lower center.

9. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY

a. Separate the control cable assembly from the shift lever.

b. Pull out the control cable assembly locks.

c. Turn the adjust nut clockwise 180. While holding the adjust nut, separate the
control cable assembly.

d. Wide body LHD steering position type:

 i. Remove the 2 nuts and clamp.

e. Remove the 2 nuts and front floor footrest.

HIFT LEVER ASSEMBLY > COMPONENTS

for Preparation Click here

1/2
 IFT LEVER ASSEMBLY > REMOVAL

for Preparation Click here

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER

a. Using a clip remover, remove the 2 clips (A).

b. Disengage the 4 clips (B).

c. Disconnect the connector.

d. Push the positions indicated by the arrows in the illustration to separate the fuel lid
lock control cable and bonnet (hood) control cable assembly from the panel.
Remove the instrument panel finish lower.

3. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.1

a. Using a clip remover, remove the 2 clips

b. Disengage the 3 claws and remove the instrument panel No.1 under cover sub-
assembly.

4. REMOVE PARKING BRAKE HOLE COVER

a. Disengage the 6 claws and remove the parking brake hole cover.
5. REMOVE SHIFT LEVER KNOB

a. Turn the shift lever knob in the direction indicated by the arrow and remove it.

6. REMOVE SHIFTING HOLE COVER ASSEMBLY

a. Manual Transmission:
Disengage the 6 claws and remove the shifting hole cover assembly.

b. Automatic Transmission:
Disengage the 8 claws and remove the shifting hole cover assembly.

7. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER

a. Disengage the 8 claws and remove the instrument panel finish panel lower center.

8. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

a. Separate the shift lever from the control cable assembly.

b. Pull out the control cable assembly locks.

c. Turn the adjust nut clockwise 180. While holding the adjust nut, remove the
control cable assembly.

9. REMOVE SHIFT LEVER ASSEMBLY

 SHIFT LEVER ASSEMBLY > INSTALLATION

for Preparation Click here

1. INSTALL SHIFT LEVER ASSEMBLY

a. Install the shift lever assembly with the 4 bolts.

Torque:
14 N*m{ 140 kgf*cm , 10 ft.*lbf }

2. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

a. Install the transmission control cable assembly to the shift lever.

NOTICE:
Install the transmission control cable assembly so that the end section of the
select cable indicated by the arrow, as shown in the side view, (A in the
illustration) faces upward.
b. Turn the control cable assembly adjust nut clockwise 180. While holding the
adjust nut, push in the locks.

c. Install the control cable assembly to the shift lever.

NOTICE:
Make sure that the control cable assembly is firmly installed to the shift lever.
HINT:
When the cable is installed to the shift lever, the locks are released and the
adjust nut rotates 180. Then, the locks are engaged again.

3. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER

a. Engage the 8 claws and install the instrument panel finish panel lower center.

4. INSTALL SHIFTING HOLE COVER ASSEMBLY

a. Manual Transmission:
Engage the 6 claws and install the shifting hole cover assembly.

b. Automatic Transmission:
Engage the 8 claws and install the sifting hole cover assembly.

5. INSTALL SHIFT LEVER KNOB

6. INSTALL PARKING BRAKE HOLE COVER

a. Engage the 6 claws and install the parking brake hole cover.

7. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.1

a. Engage the 3 claws.

b. Install the instrument panel No.1 under cover sub-assembly with the 2 clips.

8. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER

a. Engage the 4 clips (B).

b. Install the instrument panel finish panel lower with the 2 clips (A).

9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

MANUAL TRANSMISSION ASSEMBLY > COMPONENTS

for Preparation Click here

 MANUAL TRANSMISSION ASSEMBLY > REMOVAL

for Preparation Click here

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2. DRAIN MANUAL TRANSMISSION OIL

a. Remove the filler plug and gasket.

b. Remove the drain plug and gasket, and drain the oil.

c. Install the drain plug with a new gasket.

Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }

3. REMOVE EXHAUST PIPE ASSEMBLY FRONT NO.2 (for Long Wheelbase)

a. Remove the 4 bolts, 2 compression springs.

b. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front
No.2 and 2 gaskets.

4. REMOVE EXHAUST PIPE ASSEMBLY FRONT NO.2 (for Super Long Wheelbase)

a. Remove the 4 bolts, 2 nuts, 2 compression springs.

b. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front
No.2 and 2 gaskets.

5. REMOVE PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)

a. Put matchmarks on both flanges.

b. Remove the 4 nuts, bolts and washers.

HINT:
If the flange connection is hard to separate, temporarily tighten one nut only
and evenly tap the flange with a brass bar and hammer to separate the
propeller shaft assembly from the differential companion flange.

c. Remove the propeller shaft assembly.

d. Insert SST in the transmission to prevent oil leakage.

NOTICE:
Do not damage the oil seal.

i. Use the following SST for the automatic transmission

SST
09325-40010
 ii. Use the following SST for the manual transmission

SST
09325-20010

6. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long
Wheelbase)

a. Put matchmarks on both flanges.

b. Remove the 4 nuts, bolts and washers.

HINT:
If the flange connection is hard to separate, temporarily tighten one nut only
and evenly tap the flange with a brass bar and hammer to separate the
propeller with center bearing shaft assembly from the differential companion
flange.

c. Remove the 2 bolts and center support bearing assembly No.1.

d. Remove the propeller with center bearing shaft assembly.

e. Insert SST in the transmission to prevent oil leakage.

NOTICE:
Do not damage the oil seal.

i. Use the following SST for the automatic transmission.

SST
09325-40010

ii. Use the following SST for the manual transmission.

SST
09325-20010

7. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

a. Put matchmarks on the control cable assembly and the outer lever.
b. Remove the 2 nuts and separate the transmission control cable from the outer
lever.

c. Using a screwdriver, disengage the claws of the 2 clips.

d. Remove the transmission control cable and 2 clips from the transmission control
cable bracket No.1.

8. DISCONNECT WIRE HARNESS

a. Disconnect the 2 connectors and clamp.

9. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY

a. Remove the 2 bolts and separate the clutch release cylinder.

10. REMOVE STARTER ASSEMBLY (for 2.2 kW Type)

a. Disconnect the starter connector.

b. Remove the terminal cap.

c. Remove the nut, and disconnect the 30 terminal.

d. Remove the nut, 2 bolts, and stay.

e. Remove the nut 2 bolts, and starter assembly.

11. REMOVE STARTER ASSEMBLY (for 2.7 kW Type)

a. Disconnect the starter connector.

b. Remove the terminal cap.

c. Remove the nut, and disconnect the 30 terminal.

d. Remove the nut and, 2 bolts, stay and starter assembly.

12. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

a. Support the manual transmission unit with a transmission jack.

b. Remove the bolt, nut, and 2 washers, and separate the transmission unit from the
frame.

c. Remove the 8 bolts and manual transmission unit.

13. REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY

a. Remove the 4 bolts and rear engine mounting insulator assembly.

14. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1

a. Remove the 2 bolts and transmission control cable bracket No.1.

MANUAL TRANSMISSION ASSEMBLY > INSTALLATION

for Preparation Click here

1. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1

a. Install the transmission control cable bracket No.1 with the 2 bolts.

Torque:
28 N*m{ 286 kgf*cm , 21 ft.*lbf }

2. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY

a. Install the engine mounting insulator assembly rear with the 4 bolts.

Torque:
29 N*m{ 296 kgf*cm , 21 ft.*lbf }

3. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

a. Install the transmission unit assembly with the 8 bolts.

Torque:
Bolt A:
72 N*m{ 729 kgf*cm , 53 ft.*lbf }
Bolt B:
69 N*m{ 700 kgf*cm , 51 ft.*lbf }
Bolt C:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }

b. Install the transmission unit assembly with the bolt, nut and 2 washers to the
frame.

Torque:
98 N*m{ 999 kgf*cm , 72 ft.*lbf }
NOTICE:

Insert the bolt from the left side of the vehicle.

Tighten the nut while holding the bolt.

 4. INSTALL STARTER ASSEMBLY (for 2.2 kW Type)

a. Install the starter with the 2 bolts and nut.

Torque:
69 N*m{ 700 kgf*cm , 51 ft.*lbf }

b. Install the stay with the 2 bolts and nut.

Torque:
69 N*m{ 104 kgf*cm , 51 ft.*lbf }

c. Connect the 30 terminal with the nut.

Torque:
9.8 N*m{ 100 kgf*cm , 7 ft.*lbf }

d. Install the terminal cap.

e. Connect the starter connector.

5. INSTALL STARTER ASSEMBLY (for 2.7 kW Type)

a. Install the starter with the 2 bolts, nut and stay.

Torque:
69 N*m{ 700 kgf*cm , 51 ft.*lbf }

b. Install the starter stay with the 2 bolts and nut.

Torque:
Bolt:
37 N*m{ 380 kgf*cm , 27 ft.*lbf }
Nut:
12.5 N*m{ 130 kgf*cm , 9 ft.*lbf }

c. Connect the 30 terminal with the nut.

Torque:
21 N*m{ 215 kgf*cm , 16 ft.*lbf }

d. Install the terminal cap.

e. Connect the starter connector.

 6. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

a. Install the clutch release cylinder with the 2 bolts.

Torque:
12 N*m{ 120 kgf*cm , 9 ft.*lbf }

7. CONNECT WIRE HARNESS

a. Connect the 2 connectors and clamp.

8. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

a. Install 2 new clips to the transmission control cable bracket No.1.

b. Install the transmission control cable assembly to the transmission control cable
bracket No.1.

NOTICE:

Be sure that A claws of the clips are firmly engaged into the
bracket grooves.

Be sure the cable is set in the clip with both B claws erected to
prevent slippage of the cable in the opposite direction.

c. Align the matchmarks on the control cable assembly and the outer lever.

d. Install the transmission control cable assembly to the outer levers with the 2 nuts.

Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }
9. INSTALL PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)

a. Remove the SST from the extension housing.

b. Install the propeller shaft assembly in the extension housing.

c. Align the matchmarks on the propeller shaft flange and differential flange.

d. Install the propeller shaft assembly with the 4 nuts, 4 bolts and 4 washers.

Torque:
74 N*m{ 755 kgf*cm , 54 ft.*lbf }

10. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long
Wheelbase)
a. Remove the SST from the extension housing.

b. Install the propeller with center bearing shaft assembly in the extension housing.

c. Install the center support bearing assembly No.1, and temporarily tighten the 2
bolts.

d. Align the matchmarks on the propeller shaft flange and differential flange.
e. Install the propeller shaft assy with the 4 nuts, 4 bolts and 4 washers.

Torque:
74 N*m{ 755 kgf*cm , 54 ft.*lbf }

f. Check that the center line of the bracket is at right angles to the shaft axial
direction.

g. Adjust the center support bearing assembly No.1.

 HINT:

With the vehicle unladen, adjust the center support bearing No.1
to maintain the angles, as shown.

In the same conditions, check the center line in the axial

direction. Adjust the bearing if necessary.

The center bearing center line and center bearing housing center
line must be adjusted to within -1.0 to 1.0 mm (-0.0394 to 0.0394 in.)
of each other in the vehicle's longitudinal direction with the vehicle
unladen.

h. Tighten the 2 bolts.

Torque:
36 N*m{ 369 kgf*cm , 27 ft.*lbf }

11. INSTALL EXHAUST PIPE ASSEMBLY FRONT NO.2 (for Long Wheelbase)

a. Inspect the compression spring.

i. Using vernier calipers, measure the free length of the compression

springs.

Minimum length:
40.5 mm (1.594 in.)
HINT:
If the free length is less than the minimum, replace the compression spring.
b. Install the gasket.

i. Fully insert a new gasket to the exhaust pipe sub-assembly front No.1
by hand.

ii. Using a wooden block, uniformly strike the gasket so that the gasket and
exhaust pipe sub-assembly front No.1 are properly fit.

NOTICE:

Be careful with the installation direction of the gasket.

Do not damage the outer face.

Do not reuse the gasket.

To ensure a proper seal, do not use the exhaust pipe sub-

assembly front No.2 to force the gasket onto the front exhaust pipe
sub-assembly front No.1.

c. Connect the exhaust pipe support, and install a new gasket and the exhaust pipe
sub-assembly front No.2 with the 4 bolts, 2 nuts, and 2 compression springs.
 Torque:
Exhaust pipe sub-assembly front No.1 side:
43 N*m{ 438 kgf*cm , 32 ft.*lbf }
Exhaust pipe assembly tail side:
48 N*m{ 489 kgf*cm , 35 ft.*lbf }
NOTICE:
After installation, check that the clearance is almost same at any point between
the flanges of the exhaust pipe sub-assembly front No.2 and exhaust pipe sub-
assembly front No.1.

12. INSTALL EXHAUST PIPE ASSEMBLY FRONT NO.2 (for Super Long Wheelbase)

a. Inspect the compression spring.

i. Using vernier calipers, measure the free length of the compression

springs.

Minimum length:
40.5 mm (1.594 in.)
HINT:
If the free length is less than the minimum, replace the compression spring.
b. Install the gasket.

i. Fully insert a new gasket to the exhaust pipe sub-assembly front No.1
by hand.

ii. Using a wooden block, uniformly strike the gasket so that the gasket and
exhaust pipe sub-assembly front No.1 are properly fit.

NOTICE:

Be careful with the installation direction of the gasket.

Do not damage the gasket.

Do not reuse the gasket.

To ensure a proper seal, do not use the exhaust pipe sub-

assembly front No.2 to force the gasket onto the exhaust pipe sub-
assembly front No.1.

c. Connect the exhaust pipe support, and install a new gasket and the exhaust pipe
sub-assembly front No.2 with the 4 bolts, 2 nuts, and 2 compression springs.
 Torque:
Exhaust pipe sub-assembly front No.1 side:
43 N*m{ 438 kgf*cm , 32 ft.*lbf }
Exhaust pipe assembly center side:
48 N*m{ 489 kgf*cm , 35 ft.*lbf }
NOTICE:
After installation, check that the clearance is almost same at any point between
the flanges of the exhaust pipe sub-assembly front No.2 and exhaust pipe sub-
assembly front No.1 .

13. ADD MANUAL TRANSMISSION OIL

a. Park the vehicle in a level place.

b. Remove the transmission filler plug and gasket.

c. Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the
transmission filler plug opening.

Oil grade:
GL-4 or GL-5
Viscosity:
SAE 75W-90
Capacity:
2.2 liters (2.3 US qts, 1.9 lmp. qts)
NOTICE:

Problems may occur when the oil level is too high or too low.

After replacing the oil, drive the vehicle and check the oil level
again.

d. Check for oil leakage if the oil level is low.

e. Install the transmission filler plug and a new gasket.

 Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }

14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

15. CHECK FOR EXHAUST GAS LEAKS

16. PERFORM INITIALIZATION

Some systems need initialization after reconnecting the cable to the negative battery
terminal.

MANUAL TRANSMISSION UNIT > COMPONENTS

for Preparation Click here

1/5
2/5
3/5

4/5
 ANUAL TRANSMISSION UNIT > DISASSEMBLY

for Preparation Click here

1. REMOVE MANUAL TRANSMISSION FILLER PLUG

a. Remove the filler plug and gasket from the manual transmission case.

2. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY

a. Remove the drain plug and gasket from the manual transmission case.

3. REMOVE SPEEDOMETER SENSOR

a. Remove the bolt and speedometer sensor.

b. Using a screwdriver, remove the O-ring from the speedometer sensor.

4. REMOVE BACK UP LIGHT SWITCH ASSEMBLY

a. Using SST, remove the back up light switch assembly and gasket from the manual
transmission case.

SST
09817-16011

5. REMOVE CLUTCH HOUSING

a. Remove the 9 bolts.

b. Using a plastic hammer, remove the clutch housing from the transmission case.

6. REMOVE SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY

a. Remove the 6 bolts, shift lever shaft housing and clamp from the manual
transmission case.

b. Remove the shift lever shaft housing gasket from the manual transmission case.

7. REMOVE EXTENSION HOUSING DUST (MTM) DEFLECTOR

a. Using a brass bar and a hammer, remove the extension housing dust deflector
from the extension housing.

8. REMOVE EXTENSION (MTM) HOUSING SUB-ASSEMBLY

a. Remove 8 bolts.
b. Using a plastic hammer, remove the extension housing from the manual
transmission case.

9. REMOVE TRANSMISSION MAGNET

a. Remove the transmission magnet from the extension housing.

10. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE

a. Remove the bolt and extension housing oil receiver pipe from the extension
housing.

11. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE NO.1

a. Remove the extension housing oil receiver pipe No.1 from the extension housing.

12. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

a. Using SST, remove the manual transmission extension housing oil seal from the
extension housing.

SST
09308-00010

13. REMOVE BEARING RETAINER FRONT (MTM)

a. Remove the 8 bolts.

b. w/o Gasket:

i. Remove the bearing retainer from the transmission case.

c. w/ Gasket:

i. Remove the bearing retainer front and transmission front bearing

retainer gasket from the manual transmission case.
14. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL

a. Using a screwdriver, remove the transmission front bearing retainer oil seal from
the bearing retainer front.

15. REMOVE FRONT BEARING SHAFT SNAP RING

a. Using a snap ring expander, remove the front bearing shaft snap ring from the
manual transmission case.

16. REMOVE COUNTER GEAR FRONT BEARING SNAP RING NO.1

a. Using a snap ring expander, remove the counter gear front bearing snap ring No.1
from the manual transmission case.

17. REMOVE MANUAL TRANSMISSION CASE

a. Stand the manual transmission assembly as shown in the illustration.

b. Using a plastic hammer, carefully tap off the manual transmission case.

c. Remove the manual transmission case from the intermediate plate as shown in the
illustration.

18. FIX INTERMEDIATE PLATE

a. Fix the intermediate plate in a vise.

19. REMOVE SHIFT DETENT BALL

a. Using a "torx" socket wrench T40, remove the 3 shift detent ball spring seats No.1
from the intermediate plate.
b. Using a magnetic finger, remove the 3 compression springs and 3 shift detent balls
from the intermediate plate.

20. REMOVE SHIFT DETENT BALL NO.2

a. Using a "torx" socket wrench T40, remove the shift detent ball spring seat No.2
from the intermediate plate.

b. Using a magnetic finger, remove the compression spring and shift detent ball No.2
from the intermediate plate.

21. REMOVE GEAR SHIFT FORK SHAFT NO.4

a. Remove the shift fork bolt from the gear shift fork No.3.

b. Using a pin punch (5 mm) and a hammer, remove the slotted spring pin from the
reverse shift head.

c. Using 2 screwdrivers and a hammer, remove the shaft snap ring from the gear
shift fork shaft No.4
 NOTICE:
Use a shop rag to prevent the snap ring from flying off.

d. Remove the ball from the intermediate plate.

e. Remove the gear shift fork shaft No.4 and reverse shift fork ball.

22. REMOVE REVERSE SHIFT HEAD

a. Remove the reverse shift head from the reverse shift fork shaft.

23. REMOVE GEAR SHIFT HEAD NO.3

a. Using a pin punch (5 mm) and a hammer, remove the slotted spring pin from the
gear shift head No.3.

b. Remove the gear shift head from the reverse shift fork shaft.

24. REMOVE SHIFT INTER LOCK PIN NO.2

a. Using a magnetic finger, remove shift inter lock pin No.2 from the reverse shift fork
shaft.

25. REMOVE REVERSE SHIFT FORK SHAFT

a. Remove the reverse shift fork shaft, ball and compression spring.

NOTICE:
Cover the hole with a shop rag to prevent the ball from popping out.

26. REMOVE SHIFT INTER LOCK PIN NO.1

a. Using a magnetic finger, remove the shift inter lock pin No.1 from the intermediate
plate.

27. REMOVE SHIFT INTER LOCK PIN NO.2

a. Using a magnetic finger, remove shift inter lock pin No.2 from the gear shift fork
shaft No.2.

28. REMOVE GEAR SHIFT FORK SHAFT NO.2

a. Using a pin punch and a hammer, remove the slotted spring pin from the gear shift
fork No.2.

b. Remove the shift fork shaft snap ring from the gear shift fork shaft No.2.

c. Remove the gear shift fork shaft No.2 from the intermediate plate.
29. REMOVE SHIFT INTER LOCK PIN NO.1

a. Using a magnetic finger, remove shift inter lock pin No.1 from the intermediate
plate.

30. REMOVE GEAR SHIFT FORK SHAFT NO.1

a. Remove the shift fork bolt from the gear shift fork No.1.
b. Remove the gear shift fork shaft No.1 assembly and gear shift fork No.1 from the
intermediate plate.

c. Using a pin punch (5 mm) and a hammer, remove the slotted spring pin from the
gear shift head No.1.

d. Remove the gear shift head No.1 from the gear shift fork shaft No.1.

31. REMOVE GEAR SHIFT FORK NO.2

a. Remove the gear shift fork No.2 from the transmission hub sleeve No.2.

32. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE

a. Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

Standard clearance:
0.125 to 0.325 mm (0.0049 to 0.0128 in.)
Maximum clearance:
0.325 mm (0.0128 in.)

33. REMOVE COUNTER SHAFT 5TH GEAR

a. Using 2 screwdrivers and a hammer, tap out the counter gear rear shaft snap ring
from the counter gear.

b. Using SST, remove the gear spline piece No.5 and synchronizer ring No.3 from the
counter gear.

SST
09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-
05021)
c. Remove the counter shaft 5th gear assembly and counter 5th gear bearing from
the counter gear.

34. REMOVE 5TH GEAR THRUST WASHER

a. Remove the 5th gear thrust washer from the counter gear.

b. Using a magnetic finger, remove the 5th gear bearing inner race lock ball from the
counter gear.

35. REMOVE REVERSE SHIFT ARM BRACKET

a. Remove the 2 bolts and reverse shift arm bracket with the shift arm from the
intermediate plate.

36. REMOVE REVERSE SHIFT ARM

a. Using a screwdriver, remove the E-ring.

b. Remove the shift fork from the shift arm.

37. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

a. Remove the bolt and reverse idler gear shaft stopper from the intermediate plate.

b. Remove the the reverse idler gear shaft and reverse idler gear sub-assembly from
the intermediate plate.

38. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

a. Using a dial indicator, inspect the reverse idler gear radial clearance.

Standard clearance:
0.04 to 0.08 mm (0.0016 to 0.0031 in.)
Maximum clearance:
0.13 mm (0.0051 in.)

If the clearance exceeds the maximum, replace the reverse idler gear.

39. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

a. Using a feeler gauge, measure the clearance between the reverse idler gear and
reverse shift arm.

Standard clearance:
0.05 to 0.35 mm (0.0020 to 0.0138 in.)
Maximum clearance:
0.35 mm (0.0138 in.)
 If the clearance exceeds the maximum, replace the reverse idler gear and reverse
shift arm.

40. REMOVE OUTPUT SHAFT REAR BEARING (MTM) RETAINER

a. Using a "torx" socket wrench T40, remove the 4 screws and output shaft rear
bearing retainer from the intermediate plate.

41. REMOVE COUNTER GEAR

a. Using a snap ring expander, remove the snap ring from the counter shaft center
bearing.
b. Using SST, remove the counter shaft center bearing and the counter gear assembly
from the intermediate plate.

SST
09950-40011 (09951-04010, 09952-04010, 09953-04010, 09954-
04010, 09955-04011, 09958-04011)

42. REMOVE INPUT SHAFT ASSEMBLY

a. Remove the input shaft assembly with the 13 input shaft bearings and synchronizer
ring No.1 from the output shaft.

43. REMOVE OUTPUT SHAFT ASSEMBLY

a. Using a snap ring expander, remove the output shaft bearing snap ring from the
output shaft assembly.

b. Remove the output shaft assembly from the intermediate plate by pulling on the
output shaft assembly and tapping on the intermediate plate with a plastic
hammer.

MANUAL TRANSMISSION UNIT > REASSEMBLY

for Preparation Click here

1. INSTALL OUTPUT SHAFT ASSEMBLY

a. Install the output shaft assembly into the intermediate plate by pulling on the
output shaft assembly and tapping on the intermediate plate with a plastic
hammer.

b. Using a snap ring expander, install the output shaft bearing snap ring to the output
shaft assembly.

HINT:
Be sure the output shaft bearing snap ring is flush with the intermediate plate
surface.

2. INSTALL INPUT SHAFT ASSEMBLY

a. Coat the input shaft assembly and synchronizer ring No.1 with gear oil, and install
them to the output shaft.

3. INSTALL COUNTER GEAR

a. Coat the input shaft and the synchronizer ring No.2 with gear oil.

b. Temporarily install the counter gear assembly and a new counter shaft center
bearing to the intermediate plate.

NOTICE:
Install the bearing (with snap ring) to the counter gear's rear side.
c. Using a plastic hammer, install the counter shaft center bearing to the intermediate
plate by tapping the outer race of the counter shaft center bearing.

HINT:
Hold the front side of the counter gear by hand.

4. INSTALL OUTPUT SHAFT REAR BEARING (MTM) RETAINER

a. Using a "torx" socket wrench T40, install the output shaft rear bearing retainer to
the intermediate plate with the 4 screws.

Torque:
18 N*m{ 185 kgf*cm , 13 ft.*lbf }

5. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

a. Install the reverse idler gear shaft and reverse idler gear sub-assembly to the
intermediate plate.

b. Install the reverse idler gear shaft stopper to the intermediate plate with the bolt.

Torque:
17 N*m{ 175 kgf*cm , 12 ft.*lbf }

6. INSTALL REVERSE SHIFT ARM

a. Install a new E-ring and the shift fork to the shift arm.

7. INSTALL REVERSE SHIFT ARM BRACKET

a. Install the arm bracket with the shift arm to the intermediate plate.

b. Install the 2 bolts.

Torque:
18 N*m{ 185 kgf*cm , 13 ft.*lbf }

8. INSTALL 5TH GEAR BEARING INNER RACE LOCK BALL

a. Install the 5th gear bearing inner race lock ball.

9. INSTALL 5TH GEAR THRUST WASHER

a. Install the 5th gear thrust washer.

10. INSTALL COUNTER SHAFT 5TH GEAR

a. Install the counter shaft 5th gear assembly to the counter gear.

b. Temporarily install the synchronizer ring No.3 on the gear spline piece No.5.

c. Dismount the intermediate plate from the vise.

d. Stand the manual transmission as shown in the illustration.

e. Using a press and 22 mm socket wrench, install the gear spline piece No.5 with the
synchronizer ring No.3 slots aligned with the shifting keys.

f. Mount the intermediate plate in a vise.

g. Select a counter gear rear shaft snap ring that will allow the minimum amount of
axial play.

Standard clearance:
0.1 mm (0.00390in.) or less
Counter gear rear shaft snap ring thickness
Mark Thickness: mm (in.)
A 2.80 to 2.85 (0.110 to 0.112)
B 2.85 to 2.90 (0.112 to 0.114)
C 2.90 to 2.95 (0.114 to 0.116)
D 2.95 to 3.00 (0.116 to 0.118)
E 3.00 to 3.05 (0.118 to 0.120)
F 3.05 to 3.10 (0.120 to 0.122)
G 3.10 to 3.15 (0.122 to 0.124)
h. Using a brass bar and a hammer, install the counter gear rear shaft snap ring to
the counter gear.

11. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE

a. Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

Standard clearance:
0.125 to 0.325 mm (0.0049 to 0.0128 in.)
Maximum clearance:
0.325 mm (0.0128 in.)

12. INSTALL GEAR SHIFT HEAD NO.1

a. Install the gear shift head No.1 to the gear shift fork shaft No.1.

b. Using a pin punch and a hammer, drive in the slotted spring pin to the gear shift
fork shaft No.1.

13. INSTALL GEAR SHIFT FORK NO.2

a. Coat the gear shift fork No.2 with gear oil, and install it to the transmission hub
sleeve No.2.

14. INSTALL GEAR SHIFT FORK SHAFT NO.1

a. Coat the gear shift fork No.1 with gear oil, and install it to the reverse gear.

b. Install the gear shift fork shaft No.1 through the gear shift fork No.2, gear shift
fork No.1 and intermediate plate.

c. Tighten the shift fork bolt..

Torque:
20 N*m{ 204 kgf*cm , 14 ft.*lbf }

15. INSTALL SHIFT INTER LOCK PIN NO.2

a. Coat the shift inter lock pin No.2 with MP grease, and install it into the gear shift
fork shaft No.2.

16. INSTALL GEAR SHIFT FORK SHAFT NO.2

a. Coat the shift inter lock pin No.1 with MP grease.

b. Using a magnetic finger, install the shift inter lock pin No.1 to the intermediate
plate.

c. Install the gear shift fork shaft No.2 through the gear shift fork No.2 and
intermediate plate.
d. Using a pin punch (5 mm) and a hammer, Install the slotted spring pin to the gear
shift fork No.2.

e. Install the shift fork shaft snap ring to the gear shift fork shaft No.2.

17. INSTALL SHIFT INTER LOCK PIN NO.2

a. Coat the shift inter lock pin No.2 with MP grease, and install it into the reverse shift
fork shaft.

18. INSTALL REVERSE SHIFT FORK SHAFT

a. Coat the shift inter lock pin No.1 with MP grease.

b. Using a magnetic finger, install the shift inter lock pin No.1 to the intermediate
plate.

c. Install the ball and compression spring to the reverse shift fork.

d. Using a screwdriver, install the reverse shift fork shaft by pushing the ball gently.
e. Apply gear oil to the gear shift head No.3, and install it to the reverse shift fork
shaft.

f. Using a pin punch (5 mm) and a hammer, install the slotted spring pin to the
reverse shift fork shaft.

19. INSTALL REVERSE SHIFT HEAD

a. Install the reverse shift head to the reverse shift fork shaft.

20. INSTALL GEAR SHIFT FORK SHAFT NO.4

a. Coat the reverse shift fork ball with MP grease.

b. Using a magnetic finger, install the reverse shift fork ball to the reverse shift fork.

c. Install the gear shift fork shaft No.4 through the reverse shift fork.

d. Coat the shift inter lock ball No.1 with MP grease.

e. Using a magnetic finger, install the shift inter lock ball No.1 to the intermediate
plate.

f. Install the gear shift fork shaft No.4 through the gear shift fork No.3 and
intermediate plate.
g. Install the shift fork bolt to the gear shift fork No.3.

Torque:
20 N*m{ 204 kgf*cm , 14 ft.*lbf }

h. Using a brass bar and a hammer, install the snap ring to the gear shift fork shaft
No.4.
i. Using a pin punch (5 mm) and a hammer, install the slotted spring pin to the gear
shift fork shaft No.4.

21. INSTALL SHIFT DETENT BALL NO.2

a. Coat the shift detent ball No.2 with MP grease.

b. Install the shift detent ball No.2 and shift detent ball compression spring to the
intermediate plate.

c. Coat the shift detent ball spring seat No.2 with sealant.

Sealant:
Part No.08833-00080, THREE BOND 1344, LOCITITE 242 or equivalent.

d. Using a "torx" socket wrench T40, install the shift detent ball spring seat No.2 to
the intermediate plate.

Torque:
19 N*m{ 190 kgf*cm , 14 ft.*lbf }
22. INSTALL SHIFT DETENT BALL

a. Coat the 3 shift detent balls with MP grease, and install these balls and 3
compression springs to the intermediate plate.

b. Coat the 3 shift detent ball spring seats No.1 with sealant.

Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

c. Using a "torx" socket wrench T40, install the 3 shift detent ball spring seats No.1 to
the intermediate plate.

Torque:
19 N*m{ 190 kgf*cm , 14 ft.*lbf }

23. INSTALL MANUAL TRANSMISSION CASE

a. Apply seal packing to the manual transmission case as shown in the illustration.

Sealant:
Part No.08833-00090, THREE BOND 1281, LOCITITE 242 or equivalent

b. Stand the intermediate plate as shown in the illustration.

c. Using a plastic hammer, install the manual transmission case to the intermediate
plate as shown in the illustration.

24. INSTALL COUNTER GEAR FRONT BEARING SNAP RING NO.1

a. Using a snap ring expander, install the counter gear front bearing snap ring No.1 to
the counter gear front bearing.

25. INSTALL FRONT BEARING SHAFT SNAP RING

a. Using a snap ring expander, install the front bearing shaft snap ring to the input
shaft front bearing.

26. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL

a. Using SST, press in a new transmission front bearing retainer oil seal to the front
bearing retainer.

SST
09950-60010 (09952-06010, 09951-00440)
Oil seal depth:
12.5 to 13.5 mm (0.492 to 0.531 in.)

27. CHECK BEARING RETAINER FRONT (MTM)

a. Check that "FIPG" is imprinted on the bearing retainer front.

28. INSTALL BEARING RETAINER FRONT (MTM)

a. w/o Gasket:

i. Apply FIPG to the bearing retainer front as shown in the illustration.

FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent

b. w/ Gasket:

i. Install the bearing retainer front with gasket to the transmission case.

c. w/o Gasket:

i. Install the bearing retainer front to the transmission case.

d. Apply sealant to the bolt threads.

Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

e. Install the 8 bolts to the manual transmission case.

 Torque:
17 N*m{ 175 kgf*cm , 12 ft.*lbf }

29. INSTALL MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

a. Using SST, drive in a new manual transmission extension housing oil seal to the
extension housing.

SST
09325-20010

30. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE NO.1

a. Install the extension housing oil receiver pipe No.1 to the the extension housing.

31. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE

a. Install the extension housing oil receiver pipe to the extension housing with the
bolt.

Torque:
11 N*m{ 115 kgf*cm , 8 ft.*lbf }

32. INSTALL TRANSMISSION MAGNET

a. Install the transmission magnet to the extension housing.

33. INSTALL EXTENSION HOUSING DUST (MTM) DEFLECTOR

a. Using a plastic hammer, install the extension housing dust deflector to the
extension housing.

34. INSTALL EXTENSION (MTM) HOUSING SUB-ASSEMBLY

a. Apply seal packing to the extension housing as shown in the illustration.

Sealant:
Part No.08833-00090, THREE BOND 1281, LOCITITE 242 or equivalent
b. Install the extension housing to the manual transmission case with the 8 bolts.

Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }

35. INSTALL SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY

a. Shift the gear shift fork No.2, gear shift head and reverse shift head to the neutral
position.
b. Install a new shift lever shaft housing gasket to the manual transmission case.

c. Apply sealant to the threads of the 4 yellow bolts and 2 bluish-silver bolts.

d. Install the clamp and shift lever shaft housing assembly to the manual transmission
case with the 6 bolts.

Torque:
17 N*m{ 175 kgf*cm , 12 ft.*lbf }

36. INSTALL CLUTCH HOUSING

a. Install the clutch housing.

b. Apply liquid sealer to the bolt threads.

Sealant:
Part No.08833-00080, THREE BOND 1344, LOCITITE 242 or equivalent

c. Install the 9 bolts to the clutch housing.

Torque:
 37 N*m{ 377 kgf*cm , 27 ft.*lbf }

37. INSTALL BACK UP LIGHT SWITCH ASSEMBLY

a. Using SST, install the back up light switch assembly to the manual transmission
case.

SST
09817-16011
Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }

38. INSTALL SPEEDOMETER SENSOR

a. Install a new O-ring to the speedometer sensor.

b. Install the speedometer sensor to the extension housing with the bolt.

Torque:
11 N*m{ 115 kgf*cm , 8 ft.*lbf }
39. INSTALL DRAIN (MTM) PLUG SUB-ASSEMBLY

a. Install a new gasket and the drain plug to the manual transmission case.

Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }

40. INSTALL MANUAL TRANSMISSION FILLER PLUG

a. Install a new gasket and the filler plug to the manual transmission case.

Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }

INPUT SHAFT > COMPONENTS

for Preparation Click here

 INPUT SHAFT > DISASSEMBLY

for Preparation Click here

1. REMOVE SYNCHRONIZER RING NO.2

a. Remove the synchronizer ring No.2.

2. REMOVE INPUT SHAFT BEARING

a. Remove the 13 input shaft bearings from the input shaft assembly.

3. REMOVE INPUT SHAFT FRONT BEARING

a. Using a snap ring expander, remove the snap ring.

b. Using SST and a press, remove the input shaft shim from the input shaft.

SST
09527-10011

INPUT SHAFT > INSPECTION

for Preparation Click here

1. INSPECT SYNCHRONIZER RING NO.2

a. Apply gear oil to the input shaft cone. Press the synchronizer ring against the input
shaft cone and check that the synchronizer ring does not turn in the directions
shown in the illustration.
If it turns, replace the synchronizer ring.
b. Using a feeler gauge, measure the clearance between the synchronizer ring No .2
back and input shaft spline end.

Standard:
1.0 to 2.0 mm (0.0394 to 0.0787 in.)

If the clearance is not as specified, replace the synchronizer ring No.2.

NOTICE:
Ensure the fine lapping compound is completely washed off after rubbing.

INPUT SHAFT > REASSEMBLY

for Preparation Click here

1. INSTALL INPUT SHAFT FRONT BEARING

a. Using SST and a press, press in a new input shaft front bearing.
 SST
09316-60011 (09316-00031)

b. Select a snap ring that will allow minimum amount of axial play.

Standard clearance:
0.1 mm (0.0039 in.) or less
Front bearing shaft snap ring thickness
Mark Thickness: mm (in.)
0 2.05 to 2.10 (0.0807 to 0.0827)
1 2.10 to 2.15 (0.0827 to 0.0847)
2 2.15 to 2.20 (0.0847 to 0.0866)
3 2.20 to 2.25 (0.0866 to 0.0886)
4 2.25 to 2.30 (0.0886 to 0.0906)
5 2.30 to 2.35 (0.0906 to 0.0925)

c. Using a snap ring expander, install the snap ring.

2. INSTALL INPUT SHAFT BEARING

a. Coat the 13 input shaft bearings with MP grease, install them to the input shaft.

3. INSTALL SYNCHRONIZER RING NO.2

a. Coat the synchronizer ring No.2 with gear oil, and install it to the input shaft.

OUTPUT SHAFT > COMPONENTS

for Preparation Click here

 OUTPUT SHAFT > DISASSEMBLY

for Preparation Click here

1. INSPECT 1ST GEAR THRUST CLEARANCE

a. Using a dial indicator, measure the thrust clearance.

Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)

2. INSPECT 2ND GEAR THRUST CLEARANCE

a. Using a dial indicator, measure the thrust clearance.

Standard clearance:
 0.10 to 0.25 mm (0.0039 to 0.0098 in.)

3. INSPECT 3RD GEAR THRUST CLEARANCE

a. Using a feeler gauge, measure the thrust clearance.

Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)

4. INSPECT 1ST GEAR RADIAL CLEARANCE

a. Using a dial indicator, measure the radial clearance.

Standard clearance:
0.009 to 0.056 mm (0.0004 to 0.0022 in.)

If the clearance is not as specified, replace the 1st gear needle roller bearing.
5. INSPECT 2ND GEAR RADIAL CLEARANCE

a. Using a dial indicator, measure the radial clearance.

Standard clearance:
0.008 to 0.0034 mm (0.0003 to 0.00134 in.)

If the clearance is not as specified, replace the 2nd gear needle roller bearing.

6. INSPECT 3RD GEAR RADIAL CLEARANCE

a. Using a dial indicator, measure the radial clearance.

Standard clearance:
0.008 to 0.0034 mm (0.0003 to 0.00134 in.)

If the clearance is not as specified, replace the 3rd gear needle roller bearing.
7. REMOVE SPEEDOMETER DRIVE (MTM) GEAR

a. Using a snap ring expander, remove the snap ring.

b. Remove the drive gear.

c. Using a magnetic finger, remove the ball.

d. Using a snap ring expander, remove the snap ring.

8. REMOVE 1ST GEAR

a. Using 2 screwdrivers and a hammer, tap out the snap ring from the output shaft.
b. Using SST and a press, press out the 5th gear, center bearing, 1st gear, 1st gear
needle roller bearing, and 1st gear bearing inner race from the output shaft.

SST
09527-10011

9. REMOVE SYNCHRONIZER RING NO.1 (for 1st Gear)

a. Remove the synchronizer ring No.1 (for the 1st gear) from the clutch hub No.1.

10. REMOVE 1ST GEAR BEARING INNER RACE LOCK KEY OR BALL
a. Using a magnetic finger, remove the lock ball.

11. REMOVE 2ND GEAR

a. Using SST and a press, press out the clutch hub No.1, reverse gear, synchronizer
ring No.1 and 2nd gear.

SST
09950-00020

12. REMOVE SYNCHRONIZER RING NO.1 (for 2nd Gear)

a. Remove the synchronizer ring No.1 (for the 2nd gear) from the 2nd gear.

13. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

a. Remove the needle roller bearing from the output shaft.

14. REMOVE TRANSMISSION CLUTCH HUB NO.1

a. Remove the 2 synchromesh shifting key springs.

b. Remove the reverse gear and 3 synchromesh shifting keys from the transmission
clutch hub.

15. REMOVE 3RD GEAR

a. Using a snap ring expander, remove the snap ring from the output shaft.
b. Using a press, press out the clutch hub No.2 and 3rd gear.

16. REMOVE SYNCHRONIZER RING NO.2

a. Remove the synchronizer ring from the 3rd gear.

17. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

a. Remove the needle roller bearing form the output shaft.

18. REMOVE TRANSMISSION CLUTCH HUB NO.2

a. Remove the 2 synchromesh shifting key springs.

b. Remove the transmission hub sleeve and 3 synchromesh shifting keys from the
transmission clutch hub.

19. INSPECT OUTPUT SHAFT

a. Using a micrometer, measure the outside diameter of the output shaft journal
surface.

Standard outside diameter:

Part A: 34.984 to 35.000 mm (1.3773 to 1.3780 in.)
Part B: 37.984 to 38.000 mm (1.4954 to 1.4960 in.)
Part C: 30.384 to 30.400 mm (1.1962 to 1.1968 in.)
Part D: 30.002 to 30.018 mm (1.1812 to 1.1818 in.)

If the outside diameter is not as specified, replace the output shaft.

b. Using a micrometer, measure the flange thickness.

Standard thickness:
4.80 to 5.20 mm (0.1890 to 0.2047 in.)
Minimum thickness:
4.80 mm (0.1890 in.)

If the thickness is less than the minimum, replace the output shaft.

20. INSPECT 1ST GEAR BEARING INNER RACE

a. Using a micrometer, measure the inner race thickness.

Standard thickness:
4.00 to 4.20 mm (0.1575 to 0.1654 in.)
Minimum thickness:
4.80 mm (1.0890)

If the thickness is less than the minimum, replace the 1st gear bearing inner
race.
b. Using a micrometer, measure the outside diameter of the inner race.

Standard thickness:
38.985 to 39.000 mm (1.5348 to 1.5354 in.)
Minimum thickness:
38.985 mm (1.5348 in.)

If the outside diameter is not as specified, replace the 1st gear bearing inner
race.

21. INSPECT SYNCHRONIZER RING NO.1 (for 1st Gear)

a. Apply gear oil to the 1st gear cone. Press the synchronizer ring against the 1st gear
cone and check that the synchronizer ring does not turn in the directions shown in
the illustration.
If it turns, replace the synchronizer ring.
b. Using a feeler gauge, measure the clearance between the synchronizer ring No.1
back and 1st gear spline end.

Standard clearance:
1.0 to 2.0 mm (0.0394 to 0.0787 in.)

If the clearance is not as specified, replace the synchronizer ring No.1

22. INSPECT SYNCHRONIZER RING NO.1 (for 2nd Gear)

a. Apply gear oil to the 2nd gear cone. Press the synchronizer ring against the 2nd
gear cone and check that the synchronizer ring does not turn in the directions
shown in the illustration.
If it turns, replace the synchronizer ring.
b. Using a feeler gauge, measure the clearance between the synchronizer ring No.1
back and 2nd gear spline end.

Standard clearance:
1.0 to 2.0 mm (0.0394 to 0.0787 in.)

If the clearance is not as specified, replace the synchronizer ring No.1.

NOTICE:
Ensure the fine lapping compound is completely washed off after rubbing.

23. INSPECT SYNCHRONIZER RING NO.2

a. Apply gear oil to the 3rd gear cone. Press the synchronizer ring against the 3rd
gear cone and check that the synchronizer ring does not turn in the directions
shown in the illustration.
If it turns, replace the synchronizer ring.
b. Using a feeler gauge, measure the clearance between the synchronizer ring No.2
back and 3rd gear spline end.

Standard clearance:
1.0 to 2.0 mm (0.0394 to 0.0787 in.)

If the clearance is not as specified, replace the synchronizer ring No.2.

24. INSPECT REVERSE GEAR

a. Using vernier calipers, measure the clearance between the reverse gear and gear
shift fork No.1.

Standard clearance (A - B):

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

If the clearance is not as specified, replace the gear shift fork No.1 and reverse
gear.
b. Check that the transmission clutch hub No.1 and reverse gear slide smoothly.

c. Check that the spline gear's edges of the reverse gear are not worn down.

25. INSPECT TRANSMISSION HUB SLEEVE NO.2

a. Using vernier calipers, measure the hub sleeve No.2 and gear shift fork No.2 as
shown in the illustration.

Standard clearance (A - B):

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

If the clearance is not as specified, replace the transmission hub sleeve No.2 and
the gear shift fork No.2.
b. Check the sliding condition between the hub sleeve No.2 and clutch hub No.2.

c. Check that the spline gear's edges of the transmission hub sleeve No.2 are not
worn down.

26. INSPECT 1ST GEAR

a. Using a cylinder gauge, measure the inside diameter of the 1st gear.

Standard inside diameter:

44.015 to 44.040 mm (1.7329 to 1.7339 in.)
Maximum inside diameter:
44.040 mm (1.7339 in.)

If the inside diameter exceeds the maximum, replace the 1st gear.

27. INSPECT 2ND GEAR

a. Using a cylinder gauge, measure the inside diameter of the 2nd gear.

Standard inside diameter:

44.015 to 44.040 mm (1.7329 to 1.7339 in.)
Maximum inside diameter:
44.040 mm (1.7339 in.)

If the inside diameter exceeds the maximum, replace the 2nd gear.

28. INSPECT 3RD GEAR

a. Using a cylinder gauge, measure the inside diameter of the 3rd gear.

Standard clearance:
44.015 to 44.040 mm (1.7329 to 1.7339 in.)
Maximum thickness:
44.040 mm (1.7339 in.)

If the inside diameter exceeds the maximum, replace the 3rd gear.
 OUTPUT SHAFT > INSPECTION

for Preparation Click here

1. INSPECT 1ST GEAR THRUST CLEARANCE

a. Using a dial indicator, measure the thrust clearance.

Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)

2. INSPECT 2ND GEAR THRUST CLEARANCE

a. Using a dial indicator, measure the thrust clearance.

Standard clearance:
 0.10 to 0.25 mm (0.0039 to 0.0098 in.)

3. INSPECT 3RD GEAR THRUST CLEARANCE

a. Using a feeler gauge, measure the thrust clearance.

Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)

4. INSPECT 1ST GEAR RADIAL CLEARANCE

a. Using a dial indicator, measure the radial clearance.

Standard clearance:
0.009 to 0.056 mm (0.0004 to 0.0022 in.)

If the clearance is not as specified, replace the 1st gear needle roller bearing.
5. INSPECT 2ND GEAR RADIAL CLEARANCE

a. Using a dial indicator, measure the radial clearance.

Standard clearance:
0.008 to 0.0034 mm (0.0003 to 0.00134 in.)

If the clearance is not as specified, replace the 2nd gear needle roller bearing.

6. INSPECT 3RD GEAR RADIAL CLEARANCE

a. Using a dial indicator, measure the radial clearance.

Standard clearance:
0.008 to 0.0034 mm (0.0003 to 0.00134 in.)

If the clearance is not as specified, replace the 3rd gear needle roller bearing.
7. INSPECT OUTPUT SHAFT

a. Using a micrometer, measure the outside diameter of the output shaft journal
surface.

Standard outside diameter:

Part A: 34.984 to 35.000 mm (1.3773 to 1.3780 in.)
Part B: 37.984 to 38.000 mm (1.4954 to 1.4960 in.)
Part C: 30.384 to 30.400 mm (1.1962 to 1.1968 in.)
Part D: 30.002 to 30.018 mm (1.1812 to 1.1818 in.)

If the outside diameter is not as specified, replace the output shaft.

b. Using a micrometer, measure the flange thickness.

Standard thickness:
4.80 to 5.20 mm (0.1890 to 0.2047 in.)
Minimum thickness:
4.80 mm (0.1890 in.)

If the thickness is less than the minimum, replace the output shaft.

8. INSPECT 1ST GEAR BEARING INNER RACE

a. Using a micrometer, measure the inner race thickness.

Standard thickness:
4.00 to 4.20 mm (0.1575 to 0.1654 in.)
Minimum thickness:
4.80 mm (1.0890)

If the thickness is less than the minimum, replace the 1st gear bearing inner
race.
b. Using a micrometer, measure the outside diameter of the inner race.

Standard thickness:
38.985 to 39.000 mm (1.5348 to 1.5354 in.)
Minimum thickness:
38.985 mm (1.5348 in.)

If the outside diameter is not as specified, replace the 1st gear bearing inner
race.

9. INSPECT SYNCHRONIZER RING NO.1 (for 1st Gear)

a. Apply gear oil to the 1st gear cone. Press the synchronizer ring against the 1st gear
cone and check that the synchronizer ring does not turn in the directions shown in
the illustration.
If it turns, replace the synchronizer ring.
b. Using a feeler gauge, measure the clearance between the synchronizer ring No.1
back and 1st gear spline end.

Standard clearance:
1.0 to 2.0 mm (0.0394 to 0.0787 in.)

If the clearance is not as specified, replace the synchronizer ring No.1

10. REMOVE SYNCHRONIZER RING NO.1 (for 2nd Gear)

a. Apply gear oil to the 2nd gear cone. Press the synchronizer ring against the 2nd
gear cone and check that the synchronizer ring does not turn in the directions
shown in the illustration.
If it turns, replace the synchronizer ring.
b. Using a feeler gauge, measure the clearance between the synchronizer ring No.1
back and 2nd gear spline end.

Standard clearance:
1.0 to 2.0 mm (0.0394 to 0.0787 in.)

If the clearance is not as specified, replace the synchronizer ring No.1.

NOTICE:
Ensure the fine lapping compound is completely washed off after rubbing.

11. INSPECT SYNCHRONIZER RING NO.2

a. Apply gear oil to the 3rd gear cone. Press the synchronizer ring against the 3rd
gear cone and check that the synchronizer ring does not turn in the directions
shown in the illustration.
If it turns, replace the synchronizer ring.
b. Using a feeler gauge, measure the clearance between the synchronizer ring No.2
back and 3rd gear spline end.

Standard clearance:
1.0 to 2.0 mm (0.0394 to 0.0787 in.)

If the clearance is not as specified, replace the synchronizer ring No.2.

12. INSPECT REVERSE GEAR

a. Using vernier calipers, measure the clearance between the reverse gear and gear
shift fork No.1.

Standard clearance (A - B):

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

If the clearance is not as specified, replace the gear shift fork No.1 and reverse
gear.
b. Check that the transmission clutch hub No.1 and reverse gear slide smoothly.

c. Check that the spline gear's edges of the reverse gear are not worn down.

13. INSPECT TRANSMISSION HUB SLEEVE NO.2

a. Using vernier calipers, measure the hub sleeve No.2 and gear shift fork No.2 as
shown in the illustration.

Standard clearance (A - B):

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

If the clearance is not as specified, replace the transmission hub sleeve No.2 and
the gear shift fork No.2.
b. Check the sliding condition between the hub sleeve No.2 and clutch hub No.2.

c. Check that the spline gear's edges of the transmission hub sleeve No.2 are not
worn down.

14. INSPECT 1ST GEAR

a. Using a cylinder gauge, measure the inside diameter of the 1st gear.

Standard inside diameter:

44.015 to 44.040 mm (1.7329 to 1.7339 in.)
Maximum inside diameter:
44.040 mm (1.7339 in.)

If the inside diameter exceeds the maximum, replace the 1st gear.

15. INSPECT 2ND GEAR

a. Using a cylinder gauge, measure the inside diameter of the 2nd gear.

Standard inside diameter:

44.015 to 44.040 mm (1.7329 to 1.7339 in.)
Maximum inside diameter:
44.040 mm (1.7339 in.)

If the inside diameter exceeds the maximum, replace the 2nd gear.

16. INSPECT 3RD GEAR

a. Using a cylinder gauge, measure the inside diameter of the 3rd gear.

Standard clearance:
44.015 to 44.040 mm (1.7329 to 1.7339 in.)
Maximum thickness:
44.040 mm (1.7339 in.)

If the inside diameter exceeds the maximum, replace the 3rd gear.
 OUTPUT SHAFT > REASSEMBLY

for Preparation Click here

1. INSTALL TRANSMISSION CLUTCH HUB NO.2

a. Coat the hub sleeve with gear oil, and install it to the clutch hub.

NOTICE:
Be sure to set the hub sleeve to the clutch hub in the correct direction.

b. Install the 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh
shifting key springs.

HINT:
Do not set the openings of the shifting key springs in the same position.
 2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

a. Coat the needle roller bearing with gear oil, and install it to the output shaft.

3. INSTALL 3RD GEAR

a. Coat the 3rd gear with gear oil, and install it to the output shaft.

4. INSTALL SYNCHRONIZER RING NO.2

a. Coat the synchronizer ring with gear oil, and install it to the 3rd gear.

5. INSTALL TRANSMISSION CLUTCH HUB NO.2

a. Using SST and a press, press in the clutch hub No.2 to the output shaft.

SST
09316-60011 (09316-00021)
b. Select a clutch hub shaft snap ring that will allow the minimum amount of axial
play.

Standard clearance:
0.1 mm (0.039 in.) or less
Clutch hub shaft snap ring thickness:
Mark Thickness: mm (in.)
C-1 1.75 to 1.80 (0.0689 to 0.0709)
D 1.80 to 1.85 (0.0709 to 0.0728)
D-1 1.85 to 1.90 (0.0728 to 0.0748)
E 1.90 to 1.95 (0.0748 to 0.0768)
E-1 1.95 to 2.00 (0.0768 to 0.0787)
F 2.00 to 2.05 (0.0787 to 0.0807)
F-1 2.05 to 2.10 (0.0807 to 0.0827)

c. Using a snap ring expander, install the snap ring.

6. INSPECT 3RD GEAR THRUST CLEARANCE

a. Using a feeler gauge, measure the thrust clearance.

Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)

7. INSTALL TRANSMISSION CLUTCH HUB NO.1

a. Coat the reverse gear with gear oil, and install it to the clutch hub.

NOTICE:
Be sure to set the reverse gear to the clutch hub in the correct direction.

b. Install 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh
shifting key springs.

HINT:
Do not set the openings of the shifting key springs in the same position.

8. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

a. Coat the needle roller bearing with gear oil, and install it to the output shaft.

9. INSTALL 2ND GEAR

a. Coat the 2nd gear with gear oil, and install it to the output shaft.

10. INSTALL SYNCHRONIZER RING NO.1 (for 2nd Gear)

a. Coat the synchronizer ring No.1 with gear oil, and install it to the 2nd gear.

11. INSTALL TRANSMISSION CLUTCH HUB NO.1

a. Using SST and a press, press in the clutch hub to the output shaft.

SST
09316-60011 (09316-00021)

12. INSPECT 2ND GEAR THRUST CLEARANCE

a. Using a dial indicator, measure the thrust clearance.

Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)

13. INSTALL SYNCHRONIZER RING NO.1 (for 1st Gear)

a. Coat the synchronizer ring with gear oil, and install it to the clutch hub No.1.

14. INSTALL 1ST GEAR BEARING INNER RACE LOCK KEY OR BALL
a. Coat the lock ball with gear oil, and install it to the output shaft.

15. INSTALL 1ST GEAR BEARING INNER RACE

a. Coat the needle roller bearing with gear oil.

b. Install the inner lace and the needle roller bearing to the 1st gear.

16. INSTALL 1ST GEAR

a. Coat the 1st gear with gear oil, and install it to the output shaft.

17. INSTALL OUTPUT SHAFT CENTER BEARING

a. Using SST and a press, press in the center bearing to the output shaft.

SST
09316-60011 (09316-00021)

18. INSPECT 1ST GEAR THRUST CLEARANCE

a. Using a dial indicator, measure the thrust clearance.

Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)

19. INSTALL 5TH GEAR

a. Using SST and a press, press in the 5th gear to the output shaft.

SST
09316-60011 (09316-00021)
b. Select a snap ring that will allow minimal axial play.

Standard clearance:
0.1 mm (0.039 in.) or less
Output shaft bearing shaft snap ring
Mark Thickness: mm (in.)
A 2.67 to 2.72 (0.1051 to 0.1071)
B 2.73 to 2.78 (0.1075 to 0.1094)
C 2.79 to 2.84 (0.1098 to 0.1118)
D 2.85 to 2.90 (0.1122 to 0.1141)
E 2.91 to 2.96 (0.1146 to 0.1165)
F 2.97 to 3.02 (0.1169 to 0.1189)
G 3.03 to 3.08 (0.1193 to 0.1213)
H 3.09 to 3.14 (0.1217 to 0.1236)
J 3.15 to 3.20 (0.1240 to 0.1260)
K 3.21 to 3.26 (0.1264 to 0.1283)
L 3.27 to 3.32 (0.1287 to 0.1307)

c. Using a screwdriver and hammer, tap in the snap ring.

 20. INSTALL SPEEDOMETER DRIVE (MTM) GEAR

a. Using a snap ring expander, install the snap ring.

b. Install the ball.

c. Install the drive gear.

d. Using a snap ring expander, install the snap ring.

21. INSPECT 3RD GEAR RADIAL CLEARANCE

a. Using a dial indicator, measure the radial clearance.

Standard clearance:
0.008 to 0.0034 mm (0.0003 to 0.00134 in.)

If the clearance is not as specified, replace the 3rd gear needle roller bearing.
 22. INSPECT 2ND GEAR RADIAL CLEARANCE

a. Using a dial indicator, measure the radial clearance.

Standard clearance:
0.008 to 0.0034 mm (0.0003 to 0.00134 in.)

If the clearance is not as specified, replace the 2nd gear needle roller bearing.

23. INSPECT 1ST GEAR RADIAL CLEARANCE

a. Using a dial indicator, measure the radial clearance.

Standard clearance:
0.009 to 0.056 mm (0.0004 to 0.0022 in.)
If the clearance is not as specified, replace the 1st gear needle roller bearing.
 COUNTER GEAR AND REVERSE IDLER GEAR > COMPONENTS

for Preparation Click here

 COUNTER GEAR AND REVERSE IDLER GEAR > DISASSEMBLY

for Preparation Click here

1. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE

a. Install the 5th gear thrust washer lock ball, the 5th gear thrust washer, and the 5th
gear to the counter gear.

b. Using a dial indicator, measure the counter shaft 5th gear radial clearance.

Standard clearance:
0.008 to 0.034 mm(0.0003 to 0.00134 in.)

If the clearance is not as specified, replace the 5th gear bearing.

2. REMOVE COUNTER 5TH GEAR BEARING

a. Remove the 5th gear bearing from the 5th gear.

3. REMOVE TRANSMISSION HUB SLEEVE NO.3

a. Using a snap ring expander, remove the snap ring from the 5th gear.
b. Remove the hub sleeve No.3, 2 synchromesh shifting keys No.3, key spring (return
spring), and key spring (C spring) from the 5th gear.

4. INSPECT SYNCHRONIZER RING NO.3

a. Apply gear oil to the gear spline piece No.5 cone. Press the synchronizer ring
against the gear spline piece No.5 cone and check that the synchronizer ring does
not turn in the directions shown in the illustration.
If it turns, replace the synchronizer ring.

b. Using a feeler gauge, measure the clearance between the synchronizer ring No.3
back and gear spline piece No.5 spline end.

Standard clearance:
0.65 to 1.35 mm (0.0256 to 0.0531 in.)

If the clearance is not as specified, replace the synchronizer ring No.3.

NOTICE:
Ensure the fine lapping compound is completely washed off after rubbing.
5. INSPECT TRANSMISSION HUB SLEEVE NO.3

a. Check the sliding condition between the transmission hub sleeve No.3 and counter
shaft 5th gear.

b. Check that the spline gear's edges of the transmission hub sleeve No.3 are not
worn down.
c. Using vernier calipers, measure the width of the transmission hub sleeve No.3
groove and the thickness of the claw part on the gear shift fork No.3, and calculate
the clearance.

Standard clearance (A - B):

0.25 to 0.45 mm (0.0098 to 0.0177 in.)

If the clearance is not as specified, replace the transmission hub sleeve No.3 and
gear shift fork No.3.

6. INSPECT COUNTER SHAFT 5TH GEAR

a. Using a cylinder gauge, measure the inside diameter of the 5th gear.

Standard inside diameter:

33.015 to 33.040 mm (1.2998 to 1.3008 in.)
Maximum inside diameter:
33.040 mm (1.3008 in.)

If the inside diameter exceeds the maximum, replace the 5th gear.

7. INSPECT COUNTER GEAR

a. Using a micrometer, measure the outside diameter of the journal surface.

Standard outside diameter:

25.984 to 26.000 mm (1.0230 to 1.0236 in.)
Minimum out side diameter:
25.984 mm (1.0230 in.)

If the outside diameter is less than the minimum, replace the counter gear.
8. INSPECT COUNTER GEAR FRONT BEARING OR ROLLER

a. Make sure the front bearing rotates smoothly.

If the bearing does not rotate smoothly, replace the bearing.

9. REMOVE COUNTER GEAR FRONT BEARING OR ROLLER

a. Using a snap ring expander, remove the counter gear front bearing snap ring No.2
from the counter gear.
b. Using SST, a press, and a socket wrench 14 mm, remove the counter gear front
bearing from the counter gear.

SST
09950-00020

COUNTER GEAR AND REVERSE IDLER GEAR > INSPECTION

for Preparation Click here

1. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE

a. Install the 5th gear thrust washer lock ball, the 5th gear thrust washer, and the 5th
gear to the counter gear.

b. Using a dial indicator, measure the counter shaft 5th gear radial clearance.

Standard clearance:
0.008 to 0.034 mm(0.0003 to 0.00134 in.)
 If the clearance is not as specified, replace the 5th gear bearing.

2. INSPECT SYNCHRONIZER RING NO.3

a. Apply gear oil to the gear spline piece No.5 cone. Press the synchronizer ring
against the gear spline piece No.5 cone and check that the synchronizer ring does
not turn in the directions shown in the illustration.
If it turns, replace the synchronizer ring.

b. Using a feeler gauge, measure the clearance between the synchronizer ring No.3
back and gear spline piece No.5 spline end.

Standard clearance:
0.65 to 1.35 mm (0.0256 to 0.0531 in.)

If the clearance is not as specified, replace the synchronizer ring No.3.

NOTICE:
Ensure the fine lapping compound is completely washed off after rubbing.
3. INSPECT TRANSMISSION HUB SLEEVE NO.3

a. Check the sliding condition between the transmission hub sleeve No.3 and counter
shaft 5th gear.

b. Check that the spline gear's edges of the transmission hub sleeve No.3 are not
worn down.
c. Using vernier calipers, measure the width of the transmission hub sleeve No.3
groove and the thickness of the claw part on the gear shift fork No.3, and calculate
the clearance.

Standard clearance (A - B):

0.25 to 0.45 mm (0.0098 to 0.0177 in.)

If the clearance is not as specified, replace the transmission hub sleeve No.3 and
gear shift fork No.3.

4. INSPECT COUNTER SHAFT 5TH GEAR

a. Using a cylinder gauge, measure the inside diameter of the 5th gear.

Standard inside diameter:

33.015 to 33.040 mm (1.2998 to 1.3008 in.)
Maximum inside diameter:
33.040 mm (1.3008 in.)

If the inside diameter exceeds the maximum, replace the 5th gear.

5. INSPECT COUNTER GEAR

a. Using a micrometer, measure the outside diameter of the journal surface.

Standard outside diameter:

25.984 to 26.000 mm (1.0230 to 1.0236 in.)
Minimum out side diameter:
25.984 mm (1.0230 in.)

If the outside diameter is less than the minimum, replace the counter gear.
6. INSPECT COUNTER GEAR FRONT BEARING OR ROLLER

a. Make sure the front bearing rotates smoothly.

If the bearing does not rotate smoothly, replace the bearing.

COUNTER GEAR AND REVERSE IDLER GEAR > REASSEMBLY

for Preparation Click here

1. INSTALL COUNTER GEAR FRONT BEARING OR ROLLER

a. Using SST and a press, press in a new front bearing to the counter gear.

SST
09515-10010
b. Select a snap ring that will allow the minimum amount of axial play.

Standard clearance:
0.1 mm (0.0039 in.) or less
Counter gear front bearing snap ring No.1
thickness:
Mark Thickness: mm (in.)
1 2.05 to 2.10 (0.0807 to 0.0827)
2 2.10 to 2.15 (0.0827 to 0.0847)
3 2.15 to 2.20 (0.0847 to 0.0866)
4 2.20 to 2.25 (0.0866 to 0.0886)
5 2.25 to 2.30 (0.0886 to 0.0906)
6 2.30 to 2.35 (0.0906 to 0.0925)

c. Using a snap ring expander, install the snap ring.

2. INSTALL TRANSMISSION HUB SLEEVE NO.3

a. Coat the counter shaft 5th gear with gear oil.

b. Install the hub sleeve No.3 and 2 synchromesh shifting keys No.3 to the 5th gear.

HINT:
Be sure to set the hub sleeve No. 3 and synchromesh shifting keys No.3 to the
5th gear in the correct direction.

c. Install the key spring (C spring) and key spring (return spring) to the 5th gear.

d. Using a snap ring expander, install the snap ring to the 5th gear.

3. INSTALL COUNTER 5TH GEAR BEARING

a. Coat the 5th gear bearing with gear oil, and install it to the 5th gear.

4. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE

a. Install the 5th gear thrust washer lock ball, the 5th gear thrust washer, and the 5th
gear to the counter gear.

b. Using a dial indicator, measure the counter shaft 5th gear radial clearance.

Standard clearance:
0.008 to 0.034 mm(0.0003 to 0.00134 in.)
If the clearance is not as specified, replace the 5th gear bearing.

SHIFT LEVER SHAFT HOUSING > COMPONENTS

for Preparation Click here

 HIFT LEVER SHAFT HOUSING > DISASSEMBLY

for Preparation Click here

1. REMOVE LEVER LOCK PIN NO.2

a. Remove the nut from the lever lock pin No.2.

b. Using a brass bar and a hammer, remove the shift lever lock pin No.2.

2. REMOVE SELECT OUTER LEVER

a. Remove the select outer lever and washer from the select lever shaft sub-
assembly.

3. REMOVE SELECT LEVER SHAFT SUB-ASSEMBLY

a. Remove the select lever shaft sub-assembly from the shift lever shaft housing.

4. REMOVE SHIFT OUTER LEVER LOCK PIN

a. Remove the nut from the shift outer lever lock pin.

b. Using a brass bar and a hammer, remove the shift outer lever lock pin.

5. REMOVE SHIFT OUTER LEVER NO.1

a. Remove the shift outer lever No.1 from the shift and select lever shaft.

6. REMOVE SHIFT LEVER BOOT

a. Remove the shift lever boot from the shift lever shaft housing.

7. REMOVE SHIFT AND SELECT LEVER SHAFT

a. Using a pin punch (5 mm) and a hammer, remove the shift lever shaft set slotted
spring pin.

NOTICE:
Be careful not to damage the shift and select lever shaft.
b. Pull out the shift and select lever shaft and remove the shift and select lever.

8. REMOVE SELECT SPRING SEAT NO.1

a. Remove the select spring seat No.1 and spring from the shift lever shaft housing.

9. REMOVE REVERSE RESTRICT PIN NO.1

a. Using a hammer, drive a screw extractor into the reverse restrict pin slotted spring
pin.

b. Pull out the reverse restrict pin slotted spring pin from the shift lever shaft housing.

c. Remove the reverse restrict pin No.1 and spring from the shift lever shaft housing.

10. REMOVE SHIFT LEVER NO.2 SHAFT OIL SEAL

a. Using a screwdriver with its tip taped, remove the shift lever No.2 shaft oil seal
from the shift lever shaft housing.

NOTICE:
Be careful not to damage shift lever shaft housing.

11. REMOVE SHIFT LEVER SHAFT OIL SEAL

a. Using a screwdriver with its tip taped, remove the shift lever shaft oil seal from the
shift lever shaft housing.

NOTICE:
Be careful not to damage shift lever shaft housing.

SHIFT LEVER SHAFT HOUSING > REASSEMBLY

for Preparation Click here

1. INSTALL SHIFT LEVER SHAFT OIL SEAL

a. Using SST and a hammer, install a new oil seal until its surface is flush with the
housing end surface.

SST
09550-10012 (09252-10010)

b. Apply MP grease to the oil seal lip.

2. INSTALL SHIFT LEVER NO.2 SHAFT OIL SEAL

a. Using SST and a hammer, install a new oil seal until its surface is flush with the
housing end surface.

SST
09550-10012 (09252-10010)

b. Apply MP grease to the oil seal lip.

 3. INSTALL REVERSE RESTRICT PIN NO.1

a. Coat the reverse restrict pin No.1 with gear oil.

b. Install the spring to the reverse restrict pin No.1.

c. Install the reverse restrict pin No.1 and spring to the shift lever shaft housing.

4. INSTALL REVERSE RESTRICT PIN SLOTTED SPRING PIN

a. Using a pin punch (5 mm) and a hammer, install the slotted spring pin to the shift
lever shaft housing.

5. INSTALL SELECT SPRING SEAT NO.1

a. Coat the select spring seat No.1 with gear oil.

b. Install the select spring seat No.1 and spring to the shift lever shaft housing.

6. INSTALL SHIFT AND SELECT LEVER SHAFT

a. Coat the shift and select lever shaft with gear oil.

b. Install the shift and select lever and shift and select lever to the shift lever shaft
housing.

7. INSTALL SHIFT LEVER SHAFT SET SLOTTED SPRING PIN

a. Using a pin punch (5 mm) and a hammer, install the shift lever shaft set slotted pin
to the shift and select lever shaft.

8. INSTALL SHIFT LEVER BOOT

a. Install the shift lever boot to the shift lever shaft housing.

9. INSTALL SHIFT OUTER LEVER NO.1

a. Install the shift outer lever No.1 to the shift and select lever shaft.

10. INSTALL SHIFT OUTER LEVER LOCK PIN

a. Install the shift outer lever lock pin to the shift outer lever No.1 with the nut.

Torque:
12 N*m{ 120 kgf*cm , 9 ft.*lbf }

11. INSTALL SELECT LEVER SHAFT SUB-ASSEMBLY

a. Coat the select lever shaft with gear oil, and install it to the shift lever shaft
housing.

12. INSTALL SELECT OUTER LEVER

a. Install the select outer lever and washer to the select lever shaft.

13. INSTALL LEVER LOCK PIN NO.2

a. Install the shift lever lock pin No.2 to the select outer lever with the nut.

Torque:
8.0 N*m{ 80 kgf*cm , 71 in.*lbf }