REPLACEMENT — Part 5 Toyota Corolla IX facelift

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1. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY Remove the bolt and speedometer driven hole cover sub-assy. Remove the O-ring from the speedometer driven hole cover sub-assy.
2. REMOVE CLUTCH RELEASE FORK SUB-ASSY Remove the clutch release fork sub-assy with the clutch release bearing assy from the transaxle case.
3. REMOVE CLUTCH RELEASE BEARING ASSY Remove the clutch release bearing hub clip and clutch release bearing assy from the clutch release fork sub-assy.
4. REMOVE RELEASE FORK SUPPORT Remove the release fork support from the transaxle case.
5. REMOVE CLUTCH RELEASE FORK BOOT Remove the clutch release fork boot from the transaxle case.
6. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET Remove the 3 bolts and floor shift control lever housing support bracket from the transaxle case.
7. REMOVE SELECTING BELL CRANK ASSY Remove the 2 bolts and selecting bell crank assy from the manual transmission case. Remove the control shift lever bush.
8. FIX MANUAL TRANSAXLE ASSY Place the manual transaxle assy on wooden blocks.
9. REMOVE MANUAL TRANSMISSION FILLER PLUG Remove the manual transmission filler plug and gasket from the manual transmission case cover.
10. REMOVE DRAIN (MTM) PLUG SUB-ASSY Remove the drain (MTM) plug sub-assy and gasket from the manual transmission case.
11. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSY Remove the 9 bolts. Using a brass bar and a hammer, remove the manual transmission case cover sub-assy. NOTE: Do not damage the manual transmission case cover sub-assy.
12. INSPECT 6th GEAR THRUST CLEARANCE Using a feeler gauge, measure the 6th gear thrust clearance. Standard clearance: 0.10 to 0.60 mm (0.0039 to 0.0236 in.)
13. INSPECT 5th GEAR THRUST CLEARANCE Using a dial indicator, measure the 5th gear thrust clearance. Standard clearance: 0.10 to 0.62 mm (0.0039 to 0.0244 in.)
14. INSPECT 6th GEAR RADIAL CLEARANCE Using a dial indicator, measure the 6th gear radial clearance. Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 in.) If the clearance is out of specification, replace the 6th gear needle roller bearing.
15. INSPECT 5th GEAR RADIAL CLEARANCE Using a dial indicator, measure the 5th gear radial clearance. Standard clearance: 0.015 to 0.056 mm (0.0006 to 0.0022 in.) If the clearance is out of specification, replace the 5th gear needle roller bearing.
16. REMOVE COUNTER GEAR 6th Using 2 screwdrivers and a hammer, remove the output shaft RR snap ring from the output shaft. HINT: Use a shop rag to keep the snap ring from flying. Using SST, remove the output shaft RR bearing with the counter gear 6th from the output shaft. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011), 09950-60010 (09951-00190)
17. REMOVE OUTPUT GEAR SPACER Remove the output gear spacer from the output shaft.
18. REMOVE 6th GEAR SUB-ASSY Using 2 screwdrivers and a hammer, remove the input shaft snap ring from the input shaft. NOTE: Use a shop rag to keep the snap ring from flying. Using SST, remove the input shaft radial ball bearing RR with the 6th gear sub-assy from the input shaft. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011)
19. REMOVE 6th GEAR NEEDLE ROLLER BEARING Remove the 6th gear needle roller bearing from the input shaft.
20. REMOVE SYNCHRONIZER RING NO.3 (FOR 6th GEAR MT) Remove the synchronizer ring No.3 from the input shaft.
21. REMOVE TRANSMISSION CLUTCH HUB NO.3 Remove the 6th gear spacer. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No.3 shaft snap ring from the input shaft. NOTE: Use a shop rag to keep the snap ring from flying. Remove the shift fork lock bolt from the shift fork No.3. Using SST, remove the transmission clutch hub No.3 with the gear shift fork No.3 from the input shaft. SST 09950-30012 (09951-03010, 09953-03010, 09957-04010), 09950-50013 (09954-05040)
22. REMOVE SYNCHRONIZER RING NO.3 (FOR 5th GEAR MT) Remove the synchronizer ring No.3 from the 5th gear.
23. REMOVE 5th GEAR Remove the 5th gear from the input shaft.
24. REMOVE 5th GEAR NEEDLE ROLLER BEARING Using 2 screwdrivers and a hammer, remove the transmission clutch hub No.3 shaft snap ring from the input shaft. NOTE: Use a shop rag to keep the snap ring from flying. Remove the 5th gear needle roller bearing and two 5th gear bearing spacers from the input shaft.
25. REMOVE 5th DRIVEN GEAR Using SST, remove the 5th driven gear from the output shaft. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09957-04010), 09950-60010 (09951-00190)
26. REMOVE SHIFT FORK SHAFT SNAP RING Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the shift fork shaft No.2. NOTE: Use a shop rag to keep the snap ring from flying.
27. REMOVE BEARING RETAINER REAR (MTM) Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.
28. REMOVE LOCK BALL ASSY NO.1 Remove the lock ball assy No.1 from the manual transmission case.
29. REMOVE SHIFT & SELECT LEVER SHAFT ASSY Remove the 4 bolts and shift & select lever shaft assy and gasket from the manual transmission case.
30. REMOVE BACK UP LAMP SWITCH ASSY Using SST, remove the back up lamp switch assy and gasket from the manual transmission case. SST 09817-16011
31. REMOVE SHIFT DETENT BALL Using a socket hexagon wrench (6 mm), remove the 2 shift detent ball plugs from the manual transmission case. Using a magnetic finger, remove the 2 shift detent ball compression spring seats, 2 shift detent ball compression springs and 2 shift detent balls from the manual transmission case.
32. REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.
33. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING Using a snap ring expander, remove the input shaft rear bearing hole snap ring.
34. REMOVE MANUAL TRANSMISSION CASE PLUG Using a socket hexagon wrench 6 mm, remove the manual transmission case plug from the manual transmission case.
35. REMOVE REVERSE RESTRICT PIN PLUG Using a socket hexagon wrench 6 mm, remove the reverse restrict pin plug from the manual transmission case.
36. REMOVE REVERSE IDLER GEAR SHAFT BOLT Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.
37. REMOVE MANUAL TRANSMISSION CASE Remove the 3 bolts from the transaxle case side. Remove the 13 bolts from the manual transmission case side. Using a brass bar and a hammer, remove the manual transmission case from the transaxle case.
38. REMOVE OIL RECEIVER PIPE NO.1 (MTM) Remove the bolt and oil receiver pipe No.1 from the manual transmission case. NOTE: Be careful not to damage the oil receiver pipe No.1.
39. REMOVE OIL RECEIVER PIPE NO.2 (MTM) Remove the bolt and oil receiver pipe No.2 from the manual transmission case. NOTE: Be careful not to damage the oil receiver pipe No.2.
40. REMOVE SHIFT DETENT BALL Using a socket hexagon wrench (6 mm), remove the shift detent ball plug from the transaxle case. Using a magnetic finger, remove the shift detent ball spring seat, shift detent ball compression spring and shift detent ball from the transaxle case.
41. REMOVE GEAR SHIFT FORK SHAFT SUB-ASSY NO.1 Using 2 screwdrivers and a hammer, remove the shaft snap ring. NOTE: Use a shop rag to keep the snap ring from flying. Remove the gear shift fork lock bolt and gear shift fork shaft sub-assy No.1.
42. REMOVE GEAR SHIFT FORK SHAFT NO.3 Remove the shift fork shaft No.3 from the transaxle case. Using 2 screwdrivers and a hammer, remove the shaft snap ring from the shift fork shaft No.3. NOTE: Use a shop rag to keep the snap ring from flying.
43. REMOVE GEAR SHIFT FORK SHAFT NO.2 Remove the 2 gear shift fork lock bolts from the gear shift fork No.2 and gear shift head No.1. Remove the gear shift fork shaft No.2, gear shift fork No.2, gear shift fork No.1, gear shift head No.1 and reverse shift fork.
44. REMOVE REVERSE IDLER GEAR SUB-ASSY Remove the reverse idler gear shaft, thrust washer and reverse idler gear sub-assy from the transaxle case.
45. REMOVE INPUT SHAFT ASSY Remove the input shaft assy with the output shaft assy from the transaxle case.
46. REMOVE REVERSE SHIFT ARM BRACKET ASSY Remove the 2 bolts and reverse shift arm bracket assy from the transaxle case.
47. REMOVE DIFFERENTIAL CASE ASSY Remove the differential case assy from the transaxle case.
48. REMOVE MANUAL TRANSAXLE CASE RECEIVER Remove the bolt and manual transaxle case receiver from the transaxle case.
49. REMOVE BEARING LOCK PLATE Remove the bolt and bearing lock plate from the transaxle case.
50. REMOVE TRANSMISSION MAGNET Remove the transmission magnet from the transaxle case.
51. REMOVE INPUT SHAFT FRONT BEARING Using SST, remove the input shaft front bearing (outer race) from the transaxle case. SST 09612-24014 (09613-22011)
52. REMOVE FRONT TRANSAXLE CASE OIL SEAL Using SST, remove the front transaxle case oil seal from the transaxle case. SST 09612-65014 (09612-01040, 09612-01050)
53. REMOVE OUTPUT SHAFT FRONT BEARING Using SST, remove the output shaft front bearing from the transaxle case. SST 09308-00010 NOTE: Do not apply excessive force to the transaxle case when installing it.
54. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using SST, remove the front differential case rear tapered roller bearing (outer race) and shim from the manual transmission case. SST 09612-65014 (09612-01040, 09612-01050) Using SST, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case. SST 09612-65014 (09612-01040, 09612-01050), 09950-40011 (09951-00390, 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010
55. REMOVE TRANSMISSION CASE OIL SEAL Using SST and a hammer, remove the transmission case oil seal from the manual transmission case. SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
56. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST, remove the front differential case front tapered roller bearing (outer race) and front differential case front plate washer from the transaxle case. SST 09612-65014 (09612-01040, 09612-01050) Using SST, remove the FR differential case front tapered roller bearing (inner race) from the front differential case. SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00390)
57. REMOVE TRANSAXLE CASE OIL SEAL Using SST and a hammer, remove the transaxle case oil seal from the transaxle case. SST 09950-60010 (09951-00600), 09950-70010 (09951-07100)
58. REMOVE OUTPUT SHAFT (MTM) COVER Remove the output (MTM) shaft cover from the transaxle case.
59. REMOVE TRANSMISSION HUB SLEEVE NO.3 Remove the transmission hub sleeve No.3, 3 synchro-mesh shifting key No.3 and 2 synchromesh shifting key spring No.3. NOTE: Use a shop rag to keep the synchromesh shifting key and spring from flying.
60. INSPECT TRANSMISSION HUB SLEEVE NO.3 Check the sliding condition between the transmission hub sleeve No.3 and transmission clutch hub No.3. Check that the tip of the spline gear of the transmission hub sleeve No.3 is not worn down. Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove (A) and the thickness of the claw part on the gear shift fork No.3 (B), and calculate the clearance. Standard clearance (A - B): 0.31 to 0.89 mm (0.0122 to 0.035 in.) If the clearance is out of specification, replace the transmission hub sleeve No.3 and gear shift fork No.3.
61. INSPECT SYNCHRONIZER RING NO.3 (FOR 6th GEAR MT) Check for wear or damage. Coat the 6th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 6th gear cone. Check that the ring locks. If the synchronizer outer ring does not lock, replace the ring or the 6th gear. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.065 in.) If the clearance is out of specification, replace the synchronizer ring No.3.
62. INSPECT 6th GEAR SUB-ASSY Using a caliper gauge, measure the 6th gear inner diameter. INNER DIAMETER REFERENCE New gear: mm (in.) Maximum inner diameter: mm (in.) 28.015 to 28.031 (1.1030 to 1.1036) 28.031 (1.1036) If the clearance exceeds the maximum, replace the 6th gear sub-assy.
63. INSPECT SYNCHRONIZER RING NO.3 (FOR 5th GEAR MT) Coat the 5th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone. Check that the ring locks. If the synchronizer outer ring does not lock, replace the ring or the 5th gear. Using a feeler gauge, measure the clearance between the synchronizer ring back and 5th gear spline end. Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.0650 in.) If the clearance is out of specification, replace the synchronizer ring No.3.
64. INSPECT 5th GEAR Using a caliper gauge, measure the 5th gear inner diameter. INNER DIAMETER REFERENCE New gear: mm (in.) Maximum inner diameter: mm (in.) 29.915 to 29.931 (1.1778 to 1.1784) 29.931 (1.1784) If the inner diameter exceeds the maximum, replace the 5th gear.
65. INSPECT REVERSE IDLER GEAR SUB-ASSY Using a caliper gauge, inspect the reverse idler gear sub-assy as shown in the illustration. INNER DIAMETER REFERENCE New gear: mm (in.) Maximum inner diameter: mm (in.) 18.040 to 18.058 (0.7102 to 0.7109) 18.058 (0.7109) If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assy Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration. OUTER DIAMETER REFERENCE New idler gear shaft: mm (in.) Minimum outer diameter: mm (in.) 17.966 to 17.984 (0.7073 to 0.7080) 17.966 (0.7073) If the outer diameter is less than the minimum, replace the reverse idler gear shaft.
66. INSTALL TRANSMISSION HUB SLEEVE NO.3 Coat the transmission hub sleeve No.3 with gear oil, and install it to the transmission clutch hub No.3. NOTE: Do not set the transmission clutch hub No.3 in an incorrect orientation. Using a screwdriver, install the 2 synchromesh shifting key spring No.3 and 3 synchromesh shifting key No.3. NOTE: Do not set the openings of the shifting key springs in the same position.
67. INSTALL OUTPUT SHAFT (MTM) COVER Coat the output shaft (MTM) cover with MP grease, and install it to the transaxle case.
68. INSTALL TRANSAXLE CASE OIL SEAL Using SST and a hammer, install the transaxle case oil seal to the transaxle case. SST 09726-27012 (09726-02041), 09950-70010 (09951-07100) Driven in depth: 1.6 to 2.2 mm (0.063 to 0.087 in.)
69. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST and a press, install the FR differential case front tapered roller bearing (inner race) to the front differential case. SST 09350-32014 (09351-32120), 09950-60010 (09951-00530) Using SST and a press, install the front differential case front plate washer and FR differential case front tapered roller bearing (outer race) to the transaxle case. SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
70. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using SST and a press, install the FR differential case rear tapered roller bearing (inner race) to the front differential case. SST 09350-32014 (09351-32120), 09950-60010 (09951-00530) Using SST and a press, install the front differential case rear plate washer and FR differential case rear tapered roller bearing (outer race) to the manual transmission case. SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)
71. INSTALL OUTPUT SHAFT FRONT BEARING Coat a new output shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case. SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)
72. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD Coat the differential case assy with gear oil, and install it to the transaxle case. Install the manual transmission case with the 16 bolts. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Using SST and a torque wrench, turn the differential case assy right and left 2 or 3 times to allow the bearings to settle. SST 09564-32011 Using SST and a torque wrench, measure the preload. SST 09564-32011 PRELOAD REFERENCE Bearing Torque New 0.78 to 1.57 N.m (8 to 16 kgf.cm, 7 to 14 in..lbf) Used 0.49 to 0.98 N.m (5 to 10 kqf.cm, 4 to 9 in..lbf) If the preload is out of specification, select a proper front differential case rear plate washer and adjust it. HINT: WASHER THICKNESS REFERENCE Part No. Thickness: mm (in.) Make 90564-41014 2.10 (0.0827) AA 90564-41015 2.15 (0.0846) BB 90564-41016 2.20 (0.0866) CC 90564-41017 2.25 (0.0886) DD 90564-41018 2.30 (0.0906) EE 90564-41019 2.35 (0.0925) FF 90564-41020 2.40 (0.0945) GG 90564-41021 2.45 (0.0965) HH 90564-41022 2.50 (0.0984) JJ WASHER THICKNESS REFERENCE Part No. Thickness: mm (in.) Make 90564-41023 2.55 (0.1004) KK 90564-41024 2.60 (0.1024) LL 90564-41025 2.65 (0.1043) MM 90564-41026 2.70 (0.1063) NN 90564-11027 2.75 (0.1083) PP 90564-41028 2.80 (0.1102) QQ 90564-41029 2.85 (0.1122) RR 90564-41030 2.90 (0.1142) SS 90564-41031 2.95 (0.1161) TT 90564-41032 3.00 (0.1181) UU Remove the 16 bolts and manual transmission case. Remove the differential case assy from the transaxle case.
73. INSTALL FRONT TRANSAXLE CASE OIL SEAL Using SST and a hammer, install a new front transaxle case oil seal to the transaxle case. SST 09950-60010 (09951-00370), 09950-70010 (09951-07150) Driven in depth: 15.6 to 16.0 mm (0.6142 to 0.6299 in.) Coat the lip of the front transaxle case oil seal with MP grease.
74. INSTALL INPUT SHAFT FRONT BEARING Coat a new input shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case. SST 09950-60010 (09951-00420), 09950-70010 (09951-07150) Driven in depth: 0 to 0.30 mm (0 to 0.0118 in.)
75. INSTALL TRANSMISSION MAGNET Clean the transmission magnet, and install it to the transaxle case.
76. INSTALL BEARING LOCK PLATE Install the bearing lock plate with the bolt to the transaxle case. Torque: 11 N.m (115 kgf.cm, 8 ft.lbf)
77. INSTALL MANUAL TRANSAXLE CASE RECEIVER Install the manual transaxle case receiver with the bolt to the transaxle case. Torque: 11 N.m (115 kgf.cm, 8 ft.lbf)
78. INSTALL DIFFERENTIAL CASE ASSY Coat the differential case tapered roller bearing with gear oil, and install the differential case assy to the transaxle case.
79. INSTALL REVERSE SHIFT ARM BRACKET ASSY Install the reverse shift arm bracket assy with the 2 bolts to the transaxle case. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf)
80. INSTALL INPUT SHAFT ASSY Coat the sliding and rotating surfaces of the input and output shafts with gear oil, and install them to the transaxle case.
81. INSTALL REVERSE IDLER GEAR SUB-ASSY Coat the reverse idler gear sub-assy, thrust washer and reverse idler gear shaft with gear oil, and install them to the transaxle case. HINT: Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.
82. INSTALL GEAR SHIFT FORK SHAFT NO.2 Coat the gear shift fork No.2 and gear shift fork No.1 with gear oil, and install them to the input and output shafts. Coat the gear shift fork shaft No.2 with gear oil, and install the gear shift head No.1, reverse shift fork and gear shift fork shaft No.2. Coat the 2 shift lock bolts with sealant, and install them to the gear shift fork No.2 and gear shift head No.1. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 16 N.m (160 kgf.cm, 12 ft.lbf)
83. INSTALL GEAR SHIFT FORK SHAFT NO.3 Using a brass bar and a hammer, install the shaft snap ring to the gear shift fork shaft No.3. Coat the gear shift fork shaft No.3 with gear oil, and install it to the transaxle case.
84. INSTALL GEAR SHIFT FORK SHAFT SUB-ASSY NO.1 Coat the gear shift fork shaft sub-assy No.1 with gear oil, and install it to the transaxle case. Coat the shift fork lock bolt with sealant, and install it to the gear shift fork No.1. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) Using a brass bar and a hammer, install the shaft snap ring.
85. INSTALL SHIFT DETENT BALL Install the shift detent ball, shift detent ball compression spring and shift detent ball compression spring seat to the transaxle case. Coat the shift detent ball plug with sealant, and using SST, install it to the transaxle case. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 22 N.m (224 kgf.cm, 16 ft.lbf)
86. INSTALL OIL RECEIVER PIPE NO.2 (MTM) Install the oil receiver pipe No.2 (MTM) with the bolt to the manual transmission case. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf)
87. INSTALL OIL RECEIVER PIPE NO.1 (MTM) Install the oil receiver pipe No.1 (MTM) with the bolt to the manual transmission case. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf)
88. INSTALL MANUAL TRANSMISSION CASE Apply FIPG to the manual transmission case, as shown in the illustration. FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied. Install the 13 bolts to the manual transmission side. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Install the 3 bolts to the transaxle case side. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)
89. INSTALL REVERSE IDLER GEAR SHAFT BOLT Coat the reverse idler gear shaft bolt with sealant, and install it with a new gasket to the manual transmission case. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)
90. INSTALL MANUAL TRANSMISSION CASE PLUG Coat the transmission case plug with sealant, and using a socket hexagon wrench (6 mm), install it to the manual transmission case. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
91. INSTALL REVERSE RESTRICT PIN PLUG Coat the reverse restrict pin plug with sealant, and using a socket hexagon wrench (6 mm), install it to the manual transmission case. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 N.m (296 kgf.cm, 21 ft.lbf)
92. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING Using a snap ring expander, install the input shaft rear bearing hole snap ring to the input shaft.
93. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING Using a snap ring expander, install the output shaft rear bearing hole snap ring to the output shaft.
94. INSTALL TRANSMISSION CASE OIL SEAL Using SST and a hammer, install the transmission case oil seal to the manual transmission case. SST 09316-60011 (09316-00011) Driven in depth: 9.6 to 10.2 mm (0.378 to 0.402 in.) Coat the lip of the transmission case oil seal with MP grease.
95. INSTALL SHIFT DETENT BALL Install the 2 shift detent balls, 2 shift detent ball springs and 2 shift detent ball spring seats to the manual transmission case. Coat the 2 shift detent ball plugs with sealant, and install them to the manual transmission case. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 22 N.m (224 kgf.cm, 16 ft.lbf)
96. INSTALL BACK UP LAMP SWITCH ASSY Using SST, install the back up lamp switch assy with a new gasket to the manual transmission case. SST 09817-16011 Torque: 40 N.m (411 kgf.cm, 30 ft.lbf)
97. INSTALL SHIFT & SELECT LEVER SHAFT ASSY Coat the shift & select lever shaft assy with gear oil. Coat the 2 bolts with sealant, and install them and 2 bolts with a new gasket and shift & select lever shaft assy. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)
98. INSTALL LOCK BALL ASSY NO.1 Coat the lock ball assy No.1 with sealant, and install it to the manual transmission case. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)
99. INSTALL BEARING RETAINER REAR (MTM) Coat the 5 bolts with sealant, and install the bearing retainer rear to the manual transmission case with the bolts. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 27 N.m (279 kgf.cm, 20 ft.lbf)
100. INSTALL SHIFT FORK SHAFT SNAP RING Using a brass bar and a hammer, install the shift fork shaft snap ring to the shift fork shaft No.2.
101. INSTALL 5th DRIVEN GEAR Using SST, install the 5th driven gear to the output shaft. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)
102. INSTALL OUTPUT GEAR SPACER Install the output gear spacer to the output shaft.
103. INSTALL 5th GEAR NEEDLE ROLLER BEARING Coat the two 5th gear bearing spacers and 5th gear needle roller bearing with gear oil, and install them to the input shaft. Using a brass bar and a hammer, install the transmission clutch hub No.3 shaft snap ring to the input shaft.
104. INSTALL 5th GEAR Coat the 5th gear with gear oil, and install it to the input shaft.
105. INSTALL SYNCHRONIZER RING NO.3 (FOR 5th GEAR MT) Coat the synchronizer ring No.3 with gear oil, and install it to the 5th gear.
106. INSTALL TRANSMISSION CLUTCH HUB NO.3 Using SST and a hammer, install the transmission clutch hub No.3 with the gear shift fork No.3 to the input shaft. SST 09608-04031 NOTE: Before driving in the transmission clutch hub No.3, place the suitable sized wooden block under the rear side of the input shaft, as shown in the illustration. When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear bearing is over loaded and might be damaged. Coat the shift fork lock bolt with sealant, and install it to the gear shift fork No.3. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) Select the snap ring that allows the minimum amount of axial play. Clearance: 0.1 mm (0.004 in.) or less SNAP RING THICKNESS SPECIFICATION Part No. Thickness: mm (in.) Mark 90520-20074 1.75 (0.0689) A 90520-20075 1.80 (0.0709) B 90520-20076 1.85 (0.0728) C 90520-20077 1.90 (0.0748) D 90520-20078 1.95 (0.0768) E 90520-20079 2.00 (0.0787) F 90520-20080 2.05 (0.0807) G 90520-20081 2.10 (0.0827) H 90520-20082 2.15 (0.0846) J Using a brass bar and a hammer, install the transmission clutch hub No.3 snap ring to the input shaft.
107. INSTALL COUNTER GEAR 6th Using SST, install the counter gear 6th to the output shaft. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)
108. INSTALL SYNCHRONIZER RING NO.3 (FOR 6th GEAR MT) Coat the synchronizer ring No.3 with gear oil, and install it to the transmission clutch hub No.3.
109. INSTALL 6th GEAR NEEDLE ROLLER BEARING Coat the 6th gear needle roller bearing and 6th gear spacer with gear oil, and install them to the input shaft.
110. INSTALL 6th GEAR SUB-ASSY Coat the 6th gear sub-assy with gear oil, and install it to the input shaft.
111. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING Using SST, a steel block and a hammer, install the input shaft rear radial ball bearing to the input shaft. SST 09608-04031 Select the input shaft snap ring that allows the minimum amount of axial play. Clearance: 0.1 mm (0.004 in.) or less SNAP RING THICKNESS SPECIFICATION Part No. Thickness: mm (in.) Mark 90520-17006 1.70 (0.0669) A 90520-17007 1.75 (0.0689) B 90520-17008 1.80 (0.0709) C 90520-17009 1.85 (0.0728) D 90520-17010 1.90 (0.0748) E 90520-17011 1.95 (0.0768) F 90520-17012 2.00 (0.0787) G 90520-17013 2.05 (0.0807) H 90520-17014 2.10 (0.0827) J 90520-17015 2.15 (0.0846) K 90520-17016 2.20 (0.0866) L 90520-17017 2.25 (0.0886) M Using a brass bar and hammer, install the input shaft snap ring to the input shaft.
112. INSTALL OUTPUT SHAFT REAR BEARING Using SST, install the output shaft rear bearing to the output shaft. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080) Select the output shaft RR snap ring that allows the minimum amount of axial play. Clearance: 0.1 mm (0.004 in.) or less SNAP RING THICKNESS SPECIFICATION Part No. Thickness: mm (in.) Mark 90520-18003 2.31 (0.0909) B 90520-18004 2.37 (0.0933) C 90520-18006 2.43 (0.0957) D 90520-18007 2.49 (0.0980) E 90520-18008 2.55 (0.1004) F 90520-18009 2.61 (0.1028) G 90520-18013 2.67 (0.1051) H 90520-18011 2.73 (0.1075) J 90520-18014 2.79 (0.1098) K 90520-18015 2.85 (0.1122) L 90520-18016 2.91 (0.1146) M Using a brass bar and hammer, install the output shaft RR snap ring to the output shaft.
113. INSPECT 5th GEAR RADIAL CLEARANCE Using a dial indicator, measure the 5th gear radial clearance. Standard clearance: 0.015 to 0.056 mm (0.0006 to 0.0022 in.) If the clearance is out of specification, replace the 5th gear needle roller bearing.
114. INSPECT 6th GEAR RADIAL CLEARANCE Using a dial indicator, measure the 6th gear radial clearance. Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 in.) If the clearance is out of specification, replace the 6th gear needle roller bearing.
115. INSPECT 5th GEAR THRUST CLEARANCE Using a dial indicator, measure the 5th gear thrust clearance. Standard clearance: 0.10 to 0.62 mm (0.0039 to 0.0244 in.)
116. INSPECT 6th GEAR THRUST CLEARANCE Using a feeler gauge, measure the 6th gear thrust clearance. Standard clearance: 0.10 to 0.60 mm (0.0039 to 0.0236 in.)
117. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSY Apply FIPG to the manual transmission case cover sub-assy. FIPG: Parts No.08826-00090, THREE BOND 1281 or equivalent NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied. Install the manual transmission case cover sub-assy with the 9 bolts to the manual transmission case. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
118. INSTALL DRAIN (MTM) PLUG SUB-ASSY Install the drain (MTM) plug sub-assy with a new gasket to the manual transmission case. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
119. INSTALL MANUAL TRANSMISSION FILLER PLUG Install the manual transmission filler plug with a new gasket to the manual transmission case cover. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
120. INSTALL SELECTING BELL CRANK ASSY Install the selecting bell crank assy and control shift lever bush with the 2 bolts to the manual transmission case. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) NOTE: Apply MP grease to the inside circumferential surface of the control shift lever bush (A).
121. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET Install the floor shift control lever housing support bracket with the 3 bolts to the transaxle case. Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
122. INSTALL CLUTCH RELEASE FORK BOOT Install the clutch release fork boot to the transaxle case.
123. INSTALL RELEASE FORK SUPPORT Install the release fork support to the transaxle case. Torque: 37 N.m (375 kgf.cm, 27 ft.lbf) Coat the release fork support with release hub grease. Release hub grease: Part No.08887-01806, RELEASE HUB GREASE or equivalent
124. INSTALL CLUTCH RELEASE BEARING ASSY Coat the clutch release bearing assy with release hub grease, and install it to the clutch release fork sub-assy with the bearing clip. Release hub grease: Part No.08887-01806, RELEASE HUB GREASE or equivalent
125. INSTALL CLUTCH RELEASE FORK SUB-ASSY Apply clutch spline grease to the input shaft spline. Clutch spline grease: Part No.08887-01806, CLUTCH SPLINE GREASE or equivalent Install the clutch release fork sub-assy to the input shaft.
126. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY Install a new O-ring to the speedometer driven hole cover sub-assy. Install the speedometer driven hole cover sub-assy with the bolt to the transaxle case. Torque: 11 N.m (115 kgf.cm, 8 ft.lbf)

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1. INSPECT 4th GEAR THRUST CLEARANCE Using a feeler gauge, measure the 4th gear thrust clearance. THRUST CLEARANCE REFERENCE Standard clearance: mm (in.) Maximum clearance: mm (in.) 0.10 to 0.55 (0.0039 to 0.0217) 0.55 (0.0217)
2. INSPECT 3rd GEAR THRUST CLEARANCE Using a dial indicator, measure the 3rd gear thrust clearance. THRUST CLEARANCE REFERENCE Standard clearance: mm (in.) Maximum clearance: mm (in.) 0.10 to 0.35 (0.0039 to 0.0138) 0.35 (0.0138)
3. INSPECT 4th GEAR RADIAL CLEARANCE Using a dial indicator, measure the 4th gear radial clearance. RADIAL CLEARANCE REFERENCE Standard clearance: mm (in.) Maximum clearance: mm (in.) KOYO made 0.015 to 0.058 (0.0006 to 0.0023) 0.058 (0.0023) NSK made 0.015 to 0.056 (0.0006 to 0.0022) 0.056 (0.0022) If the clearance exceeds the maximum replace the gear, needle roller bearing or shaft.
4. INSPECT 3rd GEAR RADIAL CLEARANCE Using a dial indicator, measure the 3rd gear radial clearance. RADIAL CLEARANCE REFERENCE Standard clearance: mm (in.) Maximum clearance: mm (in.) KOYO made 0.015 to 0.058 (0.0006 to 0.0023) 0.058 (0.0023) NSK made 0.015 to 0.056 (0.0006 to 0.0022) 0.0056 (0.0022) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
5. REMOVE 4th GEAR Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: Use a shop rag to keep the snap ring from flying. Using SST and a press, remove the input shaft rear radial ball bearing and 4th gear from the input shaft. SST 09950-00020 NOTE: Do not tighten SST excessively. Support the input shaft assy by hand so that it will not be dropped off.
6. REMOVE 4th GEAR NEEDLE ROLLER BEARING Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.
7. REMOVE 4th GEAR SYNCHRONIZER RING Remove the 4th gear synchronizer ring from the transmission clutch hub No.2.
8. REMOVE 3rd GEAR Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: Use a shop rag to keep the snap ring from flying. Using SST and a press, remove the transmission clutch hub No.2 and 3rd gear from the input shaft. SST 09950-00020 NOTE: Do not tighten SST excessively. Support the input shaft by hand so that it will not be dropped off.
9. REMOVE 3rd GEAR SYNCHRONIZER RING Remove the 3rd gear synchronizer ring from the 3rd gear.
10. REMOVE 3rd GEAR NEEDLE ROLLER BEARING Remove the 3rd gear needle roller bearing from the input shaft.
11. REMOVE TRANSMISSION HUB SLEEVE NO.2 Remove the transmission hub sleeve No.2, 3 shifting key No.2 and 3 shifting key spring No.2 from the transmission clutch hub No.2. HINT: Using a shop rag to prevent the shifting key and shifting key spring from being scattered.
12. INSPECT INPUT SHAFT Using a dial indicator, check the shaft runout. Maximum runout: 0.015 mm (0.0006 in.) If the runout exceeds the maximum, replace the input shaft. Using a micrometer, measure the outer diameter of the input shaft journal surface. OUTER DIAMETER REFERENCE Part Standard outer diameter: mm (in.) Minimum outer diameter: mm (in.) A 24.885 to 24.900 (0.9803) 24.885 (0.9797) B 28.985 to 29.000 (1.1411 to 1.1417) 28.985 (1.1411) C 30.985 to 31.000 (1.2198 to 1.2204) 30.985 (1.2198) D 24.985-25.00 (0.9836 to 0.9842) 24.985 (0.9836) If the outer diameter is below the minimum, replace the input shaft.
13. INSPECT 4th GEAR Using a cylinder gauge, measure the inside diameter of the 4th gear. Standard inside diameter: 34.015 to 34.031 mm (1.3391 to 1.3398 in.) Maximum inside diameter: 34.031 mm (1.3398 in.) If the inside diameter exceeds the maximum, replace the 4th gear.
14. INSPECT 3rd GEAR Using a cylinder gauge, measure the inside diameter of the 3rd gear. Standard inside diameter: 36.015 to 36.031 mm (1.4179 to 1.4185 in.) Maximum inside diameter: 36.031 mm (1.4185 in.) If the inside diameter exceeds the maximum, replace the 3rd gear.
15. INSPECT 4th GEAR SYNCHRONIZER RING Check for wear or damage. Coat the 4th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 4th gear cone. Check that the ring locks. If the synchronizer outer ring does not lock, replace the ring or the 4th gear. Using a feeler gauge, measure the clearance between the 4th gear synchronizer ring back and 4th gear spline end. Minimum clearance: 0.65 mm (0.0256 in.) If the clearance below than the minimum, replace the 4th gear synchronizer ring.
16. INSPECT 3rd GEAR SYNCHRONIZER RING Check for wear or damage. Coat the 3rd gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks. If the synchronizer outer ring does not lock, replace the ring or the 3rd gear. Using a feeler gauge, measure the clearance between 3rd gear synchronizer ring back and 3rd gear spline end. Minimum clearance: 0.75 mm (0.0295 in.) If the clearance below than the minimum, replace the 3rd gear synchronizer ring.
17. INSPECT TRANSMISSION HUB SLEEVE NO.2 Check the sliding condition between the transmission hub sleeve No.2 and transmission clutch hub No.2. Check that the spline gear's edges of the transmission hub sleeve No.2 is not worn down. Using vernier calipers, measure the width of the transmission hub sleeve No.2 groove (B) and the thickness of the claw part on the gear shift fork No.2 (A), and calculate the clearance. Standard clearance (B - A): 0.15 to 0.35 mm (0.0059 to 0.0137 in.) If the clearance is out of specification, replace the transmission hub sleeve No.2 and gear shift fork No.2.
18. INSTALL TRANSMISSION HUB SLEEVE NO.2 Coat the transmission hub sleeve No.2 with gear oil, install it to the transmission clutch hub No.2. NOTE: Do not set the transmission clutch hub sleeve No.2 and the transmission clutch hub No.2 in incorrect orientation. Using a screwdriver, install the 3 synchromesh key springs with 3 synchromesh shifting keys to the transmission clutch hub No.2.
19. INSTALL 3rd GEAR NEEDLE ROLLER BEARING Coat the 3rd gear needle roller bearing with gear oil, install it to the input shaft.
20. INSTALL 3rd GEAR Coat the 3rd gear with gear oil, install it to the input shaft.
21. INSTALL 3rd GEAR SYNCHRONIZER RING Coat the 3rd gear synchronizer ring with gear oil, install it to the 3rd gear.
22. INSTALL TRANSMISSION CLUTCH HUB NO.2 Using SST and a press, install the transmission clutch hub No.2 to the input shaft. SST 09316-60011 (09316-00021) Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No.2 below 0.1 mm (0.004 in.). SNAP RING THICKNESS SPECIFICATION Mark Thickness: mm (in.) Mark Thickness: mm (in.) 0 2.30 (0.0906) 3 2.48 (0.0976) 1 2.36 (0.0929) 4 2.54 (0.1000) 2 2.42 (0.0953) 5 2.60 (0.1024) Using a brass bar and a hammer, tap in the snap ring. NOTE: Take care not to damage the journal surface of the input shaft.
23. INSTALL 4th GEAR SYNCHRONIZER RING Coat the 4th gear synchronizer ring with gear oil, install it to the transmission clutch hub No.2.
24. INSTALL 4th GEAR NEEDLE ROLLER BEARING Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil, install them to the input shaft.
25. INSTALL 4th GEAR Coat the 4th gear with gear oil, install it to the input shaft.
26. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING Using SST and a press, install the input shaft rear radial ball bearing to the input shaft. SST 09636-20010 Select a snap ring from the table below that will make the thrust clearance of the input shaft rear radial ball bearing below 0.1 mm (0.004 in.). SNAP RING THICKNESS SPECIFICATION Mark Thickness: mm (in.) Mark Thickness: mm (in.) 0 2.29 (0.0901) 3 2.47 (0.0972) 1 2.35 (0.0925) 4 2.53 (0.0996) 2 2.41 (0.0948) 5 2.59 (0.1019) Using a brass bar and a hammer, tap in the snap ring. NOTE: Take care not to damage the journal surface of the snap ring.
27. INSPECT 3rd GEAR RADIAL CLEARANCE Using a dial indicator, measure the 3rd gear radial clearance. RADIAL CLEARANCE REFERENCE Standard clearance: mm (in.) Maximum clearance: mm (in.) KOYO made 0.015 to 0.058 (0.0006 to 0.0023) 0.058 (0.0023) NSK madS 0.015 to 0.056 (0.0006 to 0.0022 0.0056 (0.0022) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
28. INSPECT 4th GEAR RADIAL CLEARANCE Using a dial indicator, measure the 4th gear radial clearance. RADIAL CLEARANCE REFERENCE Standard clearance: Maximum clearance: mm (in.) KOYO made 0.015 to 0.058 (0.0006 to 0.0023) 0.058 (0.0023) NSK mad 0.015 to 0.056 (0.0006 to 0.0022) 0.056 (0.0022) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
29. INSPECT 3rd GEAR THRUST CLEARANCE Using a dial indicator, measure the 3rd gear thrust clearance. THRUST CLEARANCE REFERENCE Standard clearance: mm (in.) Maximum clearance: mm (in.) 0.10 to 0.35 (0.0039 to 0.0138) 0.10 (0.0138)
30. INSPECT 4th GEAR THRUST CLEARANCE Using a feeler gauge, measure the 4th gear thrust clearance. THRUST CLEARANCE REFERENCE Standard clearance: mm (in.) Maximum clearance: mm (in.) 0.10 to 0.55 (0.0039 to 0.0217) 0.55 (0.0217)

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1. INSPECT 4th GEAR THRUST CLEARANCE Using a feeler gauge, measure the 4th gear thrust clearance. Standard clearance: 0.10 to 0.55 mm (0.0039 to 0.0217 in.)
2. INSPECT 3rd GEAR THRUST CLEARANCE Using a dial indicator, measure the 3rd gear thrust clearance. Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 in.)
3. INSPECT 4th GEAR RADIAL CLEARANCE Using a dial indicator, measure the 4th gear radial clearance. STANDARD CLEARANCE REFERENCE Bearing Clearance: mm (in.) KOYO made 0.015 to 0.058 (0.0006 to 0.0023) NSK made 0.015 to 0.056 (0.0006 to 0.0022) If the clearance is out of specification, replace the 4th gear needle roller bearing.
4. INSPECT 3rd GEAR RADIAL CLEARANCE Using a dial indicator, measure the 3rd gear radial clearance. STANDARD CLEARANCE REFERENCE Bearing Clearance: mm (in.) KOYO made 0.015 to 0.058 (0.0006 to 0.0023) NSK made 0.015 to 0.056 (0.0006 to 0.0022) If the clearance is out of specification, replace the 3rd gear needle roller bearing.
5. REMOVE 4th GEAR Using 2 screwdrivers and a hammer, remove the input shaft bearing shaft snap ring. HINT: Use a shop rag to keep the snap ring from flying. Using SST and a press, remove the input shaft bearing with 4th gear from the input shaft. SST 09950-00020 NOTE: Do not tighten SST excessively. Support the input shaft assy by hand so that it will not be dropped off.
6. REMOVE 4th GEAR NEEDLE ROLLER BEARING Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.
7. REMOVE 4th GEAR SYNCHRONIZER RING Remove the 4th gear synchronizer ring from the transmission clutch hub No.2.
8. REMOVE 3rd GEAR Using 2 screwdrivers and a hammer, remove the clutch hub No.2 shaft snap ring from the input shaft. HINT: Use a shop rag to keep the snap ring from flying. Using SST and a press, remove the transmission clutch hub No.2 with 3rd gear from the input shaft. SST 09950-00020 NOTE: Do not tighten SST excessively.
9. REMOVE 3rd GEAR SYNCHRONIZER RING Remove the 3rd gear synchronizer ring from the 3rd gear.
10. REMOVE 3rd GEAR NEEDLE ROLLER BEARING Remove the 3rd gear needle roller bearing from the input shaft.
11. REMOVE TRANSMISSION HUB SLEEVE NO.2 Remove the transmission hub sleeve No.2,3 synchronizer shifting keys and 3 synchronizer shifting key springs from the transmission clutch hub No.2. HINT: Use a shop rag to keep the synchromesh shifting key and spring from flying.
12. INSPECT INPUT SHAFT Using a dial indicator and 2 V-blocks, measure the shaft runout. Maximum runout: 0.015 mm (0.0006 in.) If the runout is exceeds the maximum, replace the input shaft. Using a micrometer, measure the outer diameter of the input shaft journal surface. OUTER DIAMETER REFERENCE Part New shaft: mm (in.) Minimum outer diameter: mm (in.) A 21.991 to 21.006 (0.8658 to 0.8270) 21.991 (0.8658) B 24.885 to 24.900 (0.9797 to 0.9803) 24.885 (0.9797) C 28.985 to 29.000 (1.1411 to 1.1417) 28.985 (1.1411) D 30985 to 31.000 (1.2199 to 1.2205) 30.985 (1.2199) If the outer diameter is less than the minimum, replace the input shaft.
13. INSPECT 4th GEAR Using a cylinder gauge, measure the inside diameter of the 4th gear. INSIDE DIAMETER REFERENCE New gear: mm (in.) Maximum inside diameter: mm (in.) 34.015 to 34.031 (1.3390 to 1.33985) 34.031 (1.3398) If the inside diameter is exceeds the maximum, replace the 4th gear.
14. INSPECT 3rd GEAR Using a cylinder gauge, measure the inside diameter of the 3rd gear. INSIDE DIAMETER REFERENCE New gear: mm (in.) Maximum inside diameter: mm (in.) 36.015 to 36.031 (1.4179 to 1.4185) 36.031 (1.4185) If the inside diameter is exceeds the maximum, replace the 3rd gear.
15. INSPECT 4th GEAR SYNCHRONIZER RING Coat the 4th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 4th gear cone. Check that the ring locks. If the synchronizer ring does not lock, replace the ring or 4th gear. Using a feeler gauge, measure the clearance between the 4th gear synchronizer ring back and 4th gear spline end. Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.0650 in.) If the clearance is out of specification, replace the 4th gear synchronizer ring.
16. INSPECT 3rd GEAR SYNCHRONIZER RING Coat the 3rd gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks. If the synchronizer ring does not lock, replace the ring or 3rd gear. Using a feeler gauge, measure the clearance between the 3rd gear synchronizer ring back and 3rd gear spline end. Standard clearance: 0.65 to 1.75 mm (0.0256 to 0.0689 in.) If the clearance is out of specification, replace the 3rd gear synchronizer ring.
17. INSPECT TRANSMISSION HUB SLEEVE NO.2 Check the sliding condition between the transmission hub No.2 and transmission hub sleeve No.2. Check that the spline gear's edges of the transmission hub sleeve No.2 is not worn down. Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove (B) and the thickness of the claw part on the gear shift fork No.1 (A), and calculate the clearance. Standard clearance (B - A): 0.15 to 0.35 mm (0.0059 to 0.0138 in.) If the clearance is out of specification, replace the transmission hub sleeve No.2 and gear shift fork No.2.
18. INSTALL TRANSMISSION HUB SLEEVE NO.2 Coat the transmission hub sleeve No.2 with gear oil, install it to the transmission clutch hub No.2. NOTE: Do not set the transmission hub sleeve No.2 and the transmission clutch hub No.2 in incorrect orientation. Using a screwdriver, install the 3 synchronizer shifting key springs with 3 synchronizer shifting keys.
19. INSTALL 3rd GEAR NEEDLE ROLLER BEARING Coat the 3rd gear needle roller bearing with gear oil, install it to the input shaft.
20. INSTALL 3rd GEAR Coat the 3rd gear with gear oil, install it to the input shaft.
21. INSTALL 3rd GEAR SYNCHRONIZER RING Coat the 3rd gear synchronizer ring with gear oil, install it to the 3rd gear.
22. INSTALL TRANSMISSION CLUTCH HUB NO.2 Using SST and a press, install the transmission clutch hub No.2 to the input shaft. SST 09309-36100 (09309-03610), 09950-60010 (09951-00450) Select a snap ring that will allow minimum axial play. Standard clearance: 0.1 mm (0.004 in.) or less SNAP RING THICKNESS SPECIFICATION Part No. Thickness: mm (in.) Mark 90520-27046 2.30 (0.0906) 0 90520-27047 2.36 (0.0929) 1 90520-27048 2.42 (0.0953) 2 90520-27049 2.48 (0.0976) 3 90520-27050 2.54 (0.1000) 4 90520-27051 2.60 (0.1024) 5 Using a brass bar and a hammer, install the snap ring to the input shaft.
23. INSTALL 4th GEAR SYNCHRONIZER RING Coat the 4th gear synchronizer ring with gear oil, install it to the transmission clutch hub No.2.
24. INSTALL 4th GEAR NEEDLE ROLLER BEARING Coat the 4th gear bearing spacer and 4th gear needle roller bearing with gear oil, install them to the input shaft.
25. INSTALL 4th GEAR Coat the 4th gear with gear oil, install it to the input shaft.
26. INSTALL INPUT SHAFT BEARING Using SST and a press, install the input shaft bearing to the input shaft. SST 09608-04031 Select a snap ring that will allow minimum axial play. Standard clearance: 0.1 mm (0.004 in.) or less SNAP RING THICKNESS SPECIFICATION Part No. Thickness: mm (in.) Mark 90520-22006 2.29 (0.0902) A 90520-22007 2.35 (0.0925) B 90520-22008 2.41 (0.0949) C 90520-22009 2.47 (0.0972) D 90520-22010 2.53 (0.0996) E 90520-22011 2.59 (0.1020) F Using a brass bar and a hammer, install the snap ring to the input shaft.
27. INSPECT 3rd GEAR RADIAL CLEARANCE Using a dial indicator, measure the 3rd gear radial clearance. STANDARD CLEARANCE REFERENCE Bearing Clearance: mm (in.) KOYO made 0.015 to 0.058 (0.0006 to 0.0023) NSK made 0.015 to 0.056 (0.0006 to 0.0022) If the clearance is out of specification, replace the 3rd gear needle roller bearing.
28. INSPECT 4th GEAR RADIAL CLEARANCE Using a dial indicator, measure the 4th gear radial clearance. STANDARD CLEARANCE REFERENCE Bearing Clearance: mm (in.) KOYO made 0.015 to 0.058 (0.0006 to 0.0023) NSK made 0.015 to 0.056 (0.0006 to 0.0022) If the clearance is out of specification, replace the 4th gear needle roller bearing.
29. INSPECT 3rd GEAR THRUST CLEARANCE Using a dial indicator, measure the 3rd gear thrust clearance. Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 in.)
30. INSPECT 4th GEAR THRUST CLEARANCE Using a feeler gauge, measure the 4th gear thrust clearance. Standard clearance: 0.10 to 0.55 mm (0.0039 to 0.0217 in.)

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