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1 MENU

FOREWORD

This workshop manual covers Disassembly, Inspection and Assembly procedures for the following Manual
Transmission:

Manual Transmission: H350

Applicable models: DUTRO

For Onïvehicle Servicing (Inspection, Adjustment, Troubleshooting, Removal and installation) of the Manu-
al transmission, refer to the repair manual for the applicable model.

All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.

© 2001 Hino Motors,Ltd.

All rights reserved. This material may not be reproduced or copied, in whole or in
part, without the written permission of Hino Motors Ltd.
 CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that nonïspecialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.

In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the instruction shown below.

S Must read this manual thoroughly. It is especially important to have a good understanding of
all the contents written in the PRECAUTION of ”IN” section.

S The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using nonïspecified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer’s vehicle before starting the operation.

S If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.

S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
INTRODUCTION 1
PREPARATION 2
SERVICE SPECIFICATIONS 3
MANUAL TRANSMISSION/TRANSAXLE 41
ALPHABETICAL INDEX
INTRODUCTION

HOW TO USE THIS MANUAL

TRANSMISSION WORKSHOP MANUAL . . 01ï1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 01ï1
REPAIR INSTRUCTION FOR MANUAL
TRANSMISSION WORKSHOP MANUAL . . 01ï4
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01ï4
TERMS FOR MANUAL TRANSMISSION
WORKSHOP MANUAL . . . . . . . . . . . . . . . . . . 01ï5
ABBREVIATIONS USED IN THIS MANUAL . . . 01ï5
GLOSSARY OF SAE AND HINO TERMS . . . . . 01ï6
 INTRODUCTION ï HOW TO USE THIS MANUAL TRANSMISSION 01ï1
WORKSHOP MANUAL

HOW TO USE THIS MANUAL TRANSMISSION WORKSHOP

MANUAL
010CWï01

GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains ”Removing and Installing, Replacing, Disassembling, Installing and Checking,
Adjusting”, but ”Final Inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ”disassembled parts drawing” so that it enables you
to understand the fitting condition of the components.
(c) Nonïreusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:
Shift and Select Lever Shaft
EïRing
Select Spring Seat
Compression Spring
Shift Interlock Plate 6.4 (85, 56 in.·lbf)

Compression Spring
Dust Boot Washer
EïRing
Slotted Spring Pin

Shift Inner Lever No.1

Shift Inner Lever No.2 Lever Lock Pin
zOil Seal
Select Spring Seat No.2 Control Shaft Lever
Control Shaft Cover
N·m (kgf·cm, ft·lbf) : Specified torque zOïRing
z Nonïreusable part
MP Grease C91004
01ï2 INTRODUCTION ï HOW TO USE THIS MANUAL TRANSMISSION
WORKSHOP MANUAL

(d) Tightening torque, oil applying position, and nonïreusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a stepïbyïstep format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:

Illustration: Task heading: what to do

what to do and where
87. INSTALL INPUT SHAFT FRONT BEARING

(a) Coat the new input shaft front bearing with MP grease, using
SST and a press, install it to the front transaxle case.
Drive in depth: 0 ï 0.3 mm (0 ï 0.118 in.)
SST 09950ï 60010 (09951ï 00420)
Detailed text:
how to do task
Component part No.
Set part No.

D27381

HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.

5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.

6. TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being repaired.
HINT Provide additional information to help you perform the repair efficiently.
 INTRODUCTION ï HOW TO USE THIS MANUAL TRANSMISSION 01ï3
WORKSHOP MANUAL

7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N˜m (310 kgf˜cm, 22 ft˜lbf)
01ï4 INTRODUCTION ï REPAIR INSTRUCTION FOR MANUAL
TRANSMISSION WORKSHOP MANUAL

REPAIR INSTRUCTION FOR MANUAL TRANSMISSION

WORKSHOP MANUAL
010CXï01

PRECAUTION
1. BASIC REPAIR HINT

(a) PRECOATED PARTS

(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
Seal Lock Adhesive
adhesive and dry with compressed air. Then apply
Z11554 the specified seal lock adhesive to the bolt, nut or
threads.
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) GASKETS
When necessary, use a sealer on gaskets to prevent leaks.
(c) BOLTS, NUTS AND SCREWS
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
 INTRODUCTION ï TERMS FOR MANUAL TRANSMISSION WORKSHOP 01ï5
MANUAL

TERMS FOR MANUAL TRANSMISSION WORKSHOP

MANUAL
010CYï01

ABBREVIATIONS USED IN THIS MANUAL

Abbreviations Meaning
FIPG Formed In Plce Gasket
Max Maximum
Min Minimum
MP Multipurpose
No. Number
RR Rear
SSM Special Service Materials
SST Special service Tools
STD Standard
1st First
2nd Second
3rd Third
5th Fifth
01ï6 INTRODUCTION ï TERMS FOR MANUAL TRANSMISSION WORKSHOP
MANUAL
010CZï01

GLOSSARY OF SAE AND HINO TERMS

This glossary lists all SAEïJ1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their Hino equivalents.
SAE HINO TERMS
SAE TERMS
ABBREVIATIONS ( )ïïABBREVIATIONS
A/C Air Conditioning Air Conditioner
ACL Air Cleaner Air Cleaner
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal ï
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure ï
CAC Charge Air Cooler Inter cooler
CARB Carburettor Carburettor
CFI Continuous Fuel Injection ï
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft position Cam Angle
CPP Clutch Pedal Position ï
CTOX Continuous Trap Oxidizer ï
CTP Closed Throttle Potion ï
DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition ï
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Total Diagnosis Communication Link (TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode ï
ECL Engine Control Level ï
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Control Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only memory
Electrically Erasable Programmable Read Only
EEPROM (EEPROM),
memory
Erasable Programmable Read Only memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition Distributorless Ignition (DI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control ï
Flash Electrically Erasable Programmable
FEEPROM ï
Read Only Memory
FEPROM Flash Erasable Programmable Read Only Memory ï
FF Flexible Fuel ï
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)
IAC Idol Air Control Idol Speed Control (ISC)
IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module ï
IFI Indirect Fuel Injection Indirect Injection
IFS Inertia FuelïShutoff ï
 INTRODUCTION ï TERMS FOR MANUAL TRANSMISSION WORKSHOP 01ï7
MANUAL

ISC Idle Speed Control ï

KS Knock Sensor Knock Sensor
MAF Mass Air Flow Air Flow Meter
Manifold Pressure
MAP Manifold Absolute Pressure
Intake Vacuum
Electric Bleed Air Control Valve (EBCV)
MC Mixture Control Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure ï
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Light
MST Manifold Surface temperature ï
MVZ Manifold Vacuum Zone ï
NVRAM NonïVolatile Random Access Memory ï
O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)
OBD OnïBoard Diagnostic OnïBoard Diagnostic (OBD)
OC Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CC0
OP Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module ï
PNP Park/Neutral Position ï
PROM Programmable Read Only Memory ï
PSP Power Steering Pressure ï
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)
RM Relay Module ï
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass ï
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter ï
SRI Service Reminder Indicator ï
SRT System Readiness Test ï
ST Scan Tool ï
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter
TCM Transmission Control Module Transmission ECU (Electronic Control Unit)
TP Throttle Position Throttle Position
TR Transmission Range ï
Bimetallic Vacuum Switching Valve (BVSV)
TVV Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)
ThreeïWay Catalytic (TWC)
TWC ThreeïWay Catalytic Converter
CCRO
TWC+OC ThreeïWay + Oxidation Catalytic Converter CCR + CCO
VAF Volume Air Flow Air Flow Meter
VR Voltage Regulator Voltage Regulator
VSS Vehicle Speed Sensor Vehicle Speed Sensor (Read Switch Type)
WOT Wide Open Throttle Full Throttle
01ï8 INTRODUCTION ï TERMS FOR MANUAL TRANSMISSION WORKSHOP
MANUAL

WUïOC Warm Up Oxidation Catalytic Converter ï

WUïTWC Warm Up ThreeïWay Catalytic Converter Manifold Converter
3GR Third Gear ï
4GR Fourth Gear ï
PREPARATION

MANUAL TRANSMISSION/TRANSAXLE . . . . 02ï

PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï
 02ï
PREPARATION ï MANUAL TRANSMISSION/TRANSAXLE

MANUAL TRANSMISSION/TRANSAXLE
0219Kï01

PREPARATION
SST
09316ï20011 Transfer Bearing Replacer MANUAL TRANSMISSION ASSY
OUTPUT SHAFT ASSY

09316ï60011 Transmission & Transfer Bearing MANUAL TRANSMISSION ASSY

Replacer OUTPUT SHAFT ASSY
COUNTER GEAR ASSY

(09316ï00011) Replacer Pipe MANUAL TRANSMISSION ASSY

OUTPUT SHAFT ASSY
COUNTER GEAR ASSY

(09316ï00021) Replacer ”A” MANUAL TRANSMISSION ASSY

COUNTER GEAR ASSY

(09316ï00031) Replacer ”B” MANUAL TRANSMISSION ASSY

(09316ï00041) Replacer ”C” MANUAL TRANSMISSION ASSY

09527ï10011 Rear Axle Shaft Bearing Remover MANUAL TRANSMISSION ASSY

09527ï20011 Rear Axle Shaft Bearing Remover OUTPUT SHAFT ASSY

09555ï55010 Differential Drive Pinion OUTPUT SHAFT ASSY

Bearing Replacer

09608ï06041 Front Hub Inner Bearing Cone MANUAL TRANSMISSION ASSY

Replacer

09817ï16011 Backïup Light Switch Tool MANUAL TRANSMISSION ASSY

09950ï00020 Bearing Remover MANUAL TRANSMISSION ASSY

INPUT SHAFT ASSY
COUNTER GEAR ASSY
02ï2
PREPARATION ï MANUAL TRANSMISSION/TRANSAXLE

09950ï00030 Bearing Remover Attachment MANUAL TRANSMISSION ASSY

09950ï40011 Puller B Set MANUAL TRANSMISSION ASSY

(09951ï04020) Hanger 200 MANUAL TRANSMISSION ASSY

(09952ï04010) Slide Arm MANUAL TRANSMISSION ASSY

(09953ï04030) Center Bolt 200 MANUAL TRANSMISSION ASSY

(09954ï04020) Arm 100 MANUAL TRANSMISSION ASSY

(09955ï04031) Claw No.3 MANUAL TRANSMISSION ASSY

(09957ï04010) Attachment MANUAL TRANSMISSION ASSY

(09958ï04011) Holder MANUAL TRANSMISSION ASSY

09950ï50013 Puller C Set MANUAL TRANSMISSION ASSY

(09951ï05010) Hanger 150 MANUAL TRANSMISSION ASSY

(09952ï05010) Slide Arm MANUAL TRANSMISSION ASSY

(09953ï05020) Center Bolt 150 MANUAL TRANSMISSION ASSY

 02ï3
PREPARATION ï MANUAL TRANSMISSION/TRANSAXLE

(09954ï05040) Claw No.4 MANUAL TRANSMISSION ASSY

09950ï60010 Replacer Set MANUAL TRANSMISSION ASSY

INPUT SHAFT ASSY
COUNTER GEAR ASSY
SHIFT LEVER SHAFT HOUSING
ASSY
(09951ï00230) Replacer 23 MANUAL TRANSMISSION ASSY

(09951ï00290) Replacer 29 COUNTER GEAR ASSY

(09951ï00300) Replacer 30 MANUAL TRANSMISSION ASSY

(09951ï00310) Replacer 31 SHIFT LEVER SHAFT HOUSING

ASSY

(09951ï00320) Replacer 32 SHIFT LEVER SHAFT HOUSING

ASSY

(09951ï00330) Replacer 33 MANUAL TRANSMISSION ASSY

(09951ï00480) Replacer 48 MANUAL TRANSMISSION ASSY

(09951ï00570) Replacer 57 INPUT SHAFT ASSY

(09952ï06010) Adapter MANUAL TRANSMISSION ASSY

09950ï60020 Replacer Set No.2 MANUAL TRANSMISSION ASSY

(09951ï00750) Replacer 75 MANUAL TRANSMISSION ASSY

02ï4
PREPARATION ï MANUAL TRANSMISSION/TRANSAXLE

09950ï70010 Handle Set MANUAL TRANSMISSION ASSY

INPUT SHAFT ASSY
COUNTER GEAR ASSY
SHIFT LEVER SHAFT HOUSING
ASSY
(09951ï07100) Handle 100 MANUAL TRANSMISSION ASSY
INPUT SHAFT ASSY
COUNTER GEAR ASSY
SHIFT LEVER SHAFT HOUSING
ASSY

Recomended Tools
09031ï00040 Pin Punch . MANUAL TRANSMISSION ASSY
SHIFT LEVER SHAFT HOUSING
ASSY

09040ï00011 Hexagon Wrench Set SHIFT LEVER SHAFT HOUSING

ASSY

(09043ï20120) Socket Hexagon Wrench 12 SHIFT LEVER SHAFT HOUSING

ASSY

09042ï00010 Torx Socket T30 MANUAL TRANSMISSION ASSY

09042ï00020 Torx Socket T40 MANUAL TRANSMISSION ASSY

09905ï00012 Snap Ring No.1 Expander MANUAL TRANSMISSION ASSY

INPUT SHAFT ASSY
OUTPUT SHAFT ASSY
COUNTER GEAR ASSY

09905ï00013 Snap Ring Pliers INPUT SHAFT ASSY

Equipment
Aluminum plate
Caliper gauge
Cylinder gauge
Dial indicator or dial indicator with magnetic base
Feeler gauge
Magnetic finger
Micrometer
Plastic hammer
Press
Torque wrench
Vernier calipers
Wooden block
 02ï5
PREPARATION ï MANUAL TRANSMISSION/TRANSAXLE

Lubricant
APL GLï4 or GLï5
Manual transmission oil 4.2 liters (4.4 US qts, 3.7 lmp. qts)
SAE 75Wï90

SSM (Special Service Materials)

08826ï00090 ”Seal Packing 1281,”
THREE BOND 1281 or equivalent
(FIPG)

08833ï00080 Adhesive 1344

THREE BOND 1344
LOCTITE 242 or equivalent
SERVICE SPECIFICATIONS

STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . 03ï

HOW TO DETERMINE BOLT STRENGTH . . . . 03ï
SPECIFIED TORQUE
FOR STANDARD BOLTS . . . . . . . . . . . . . . . . . 03ï2
HOW TO DETERMINE NUT STRENGTH . . . . . 03ï3
MANUAL TRANSMISSION /
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï4
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï4
TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . 03ï6
 03ï
SERVICE SPECIFICATIONS ï STANDARD BOLT

STANDARD BOLT
030OQï0

HOW TO DETERMINE BOLT STRENGTH

Bolt Type
Hexagon Head Bolt Class
Stud Bolt Weld Bolt
Normal Recess Bolt Deep Recess Bolt

4 4T

No Mark No Mark No Mark

5 5T

6 6T

w/Washer w/Washer

7 7T

8 8T

9 9T

0 0T

 T

B0643
03ï2
SERVICE SPECIFICATIONS ï STANDARD BOLT
030ORï0

SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Diameter Pitch
Class Hexagon head bolt Hexagon flange bolt
mm mm
N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf
6  5 55 48 in.·lbf 6 60 52 in.·lbf
8 .25 2.5 30 9 4 45 0
0 .25 26 260 9 29 290 2
4T
2 .25 47 480 35 53 540 39
4 .5 74 760 55 84 850 6
6 .5 5 ,50 83 ï ï ï

6  6.5 65 56 in.·lbf 7.5 75 65 in.·lbf

8 .25 5.5 60 2 7.5 75 3
0 .25 32 330 24 36 360 26
5T
2 .25 59 600 43 65 670 48
4 .5 9 930 67 00 ,050 76
6 .5 40 ,400 0 ï ï ï

6  8 80 69 in.·lbf 9 90 78 in.·lbf
8 .25 9 95 4 2 20 5
0 .25 39 400 29 44 440 32
6T
2 .25 7 730 53 80 80 59
4 .5 0 ,00 80 25 ,250 90
6 .5 70 ,750 27 ï ï ï

6  0.5 0 8 2 20 9

8 .25 25 260 9 28 290 2
0 .25 52 530 38 58 590 43
7T
2 .25 95 970 70 05 ,050 76
4 .5 45 ,500 08 65 ,700 23
6 .5 230 2,300 66 ï ï ï

8 .25 29 300 22 33 330 24

8T 0 .25 6 620 45 68 690 50
2 .25 0 ,00 80 20 ,250 90
8 .25 34 340 25 37 380 27
9T 0 .25 70 70 5 78 790 57
2 .25 25 ,300 94 40 ,450 05
8 .25 38 390 28 42 430 3
0T 0 .25 78 800 58 88 890 64
2 .25 40 ,450 05 55 ,600 6
8 .25 42 430 3 47 480 35
T 0 .25 87 890 64 97 990 72
2 .25 55 ,600 6 75 ,800 30
 03ï3
SERVICE SPECIFICATIONS ï STANDARD BOLT
030OSï0

HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard Old Standard Hexagon Nut Class
Hexagon Nut Cold Forging Nut Cutting Processed Nut

4N

No Mark

5N (4T)

No Mark (w/Washer) No Mark (w/Washer) No Mark

6N
6N

7N (5T)

8N
8N

0N (7T)
0N

No Mark

N
N

2N
2N

*: Nut with  or more marks on one side surface of the nut.

B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
03ï4
SERVICE SPECIFICATIONS ï MANUAL TRANSMISSION / TRANSAXLE

MANUAL TRANSMISSION / TRANSAXLE

030OOï0

SERVICE DATA
Oil pump driven rotor to pump cover clearance STD 0.02 ï 0.7 mm (0.0008 ï 0.0067 in.)
Max. 0.7 mm (0.0067 in.)
Oil pump drive to driven rotor tip clearance STD 0.05 ï 0.5 mm (0.0020 ï 0.0059 in.)
Max. 0.5 mm (0.0059 in.)
Reverse gear thrust clearance STD 0.0 ï 0.25 mm (0.0039 ï 0.0098 in.)
Max. 0.25 mm (0.0098 in.)
Reverse gear radial clearance STD 0.05 ï 0.067 mm (0.0006 ï 0.0026 in.)
Max. 0.067 mm (0.0026 in.)
st gear thrust clearance STD 0.0 ï 0.47 mm (0.0039 ï 0.085 in.)
Max. 0.47 mm (0.085 in.)
st gear gear radial clearance STD 0.05 ï 0.068 mm (0.0006 ï 0.0027 in.)
Max. 0.068 mm (0.0027 in.)
Reverse gear inside diameter STD 54.05 ï 54.040 mm (2.266 ï 2.276 in.)
Max. 54.040 mm (2.276 in.)
st gear inside diameter STD 5.55 ï 5.540 mm (2.028 ï 2.029 in.)
Max. 5.540 mm (2.029 in.)
Reverse idler gear inside diameter STD 35.05 ï 35.036 mm (.3785 ï .3793 in.)
Max. 35.036 mm (.3793 in.)
Reverse idler gear shaft outside diameter STD 27.987 ï 28.000 mm (.08 ï ..23 in.)
Min. 27.987 mm (.08 in.)
Reverse idler gear thrust clearance STD 0.0 ï 0.55 mm (0.0039 ï 0.027 in.)
Max. 0.55 mm (0.027 in.)
Reverse idler gear radial clearance STD 0.05 ï 0.059 mm (0.0006 ï 0.0023 in.)
Max. 0.059 mm (0.0023 in.)
Synchronizer ring No.  clearance STD .5 ï 2.05 mm (0.0452 ï 0.0807 in.)
Min. .5 mm (0.0452 in.)
Gear shift fork claw thickness STD .75 ï .85 mm (0.4625 ï 0.4665 in.)
Min. .75 mm (0.4625 in.)
Transmission hub sleeve clearance STD 2.0 ï 2. mm (0.4724 ï 0.4763 in.)
Max. 2. mm (0.4763 in.)
Output shaft center bearing shaft snap ring thickness Mark A 2.40 ï 2.45 mm (0.0945 ï 0.0965 in.)
Mark B 2.45 ï 2.50 mm (0.0965 ï 0.0984 in.)
Mark C 2.50 ï 2.55 mm (0.0984 ï 0.004 in.)
Mark D 2.55 ï 2.60 mm (0.004 ï 0.024 in.)
Mark E 2.60 ï 2.65 mm (0.024 ï 0.044 in.)
Mark F 2.65 ï 2.70 mm (0.044 ï 0.063 in.)
Mark G 2.70 ï 2.75 mm (0.063 ï 0.083 in.)
Mark H 2.75 ï 2.80 mm (0.083 ï 0.02 in.)
Counter gear snap ring thickness Mark A 2.40 ï 2.45 mm (0.0945 ï 0.0965 in.)
Mark B 2.45 ï 2.50 mm (0.0965 ï 0.0984 in.)
Mark C 2.50 ï 2.55 mm (0.0984 ï 0.004 in.)
Mark D 2.55 ï 2.60 mm (0.004 ï 0.024 in.)
Mark E 2.60 ï 2.65 mm (0.024 ï 0.043 in.)
Mark F 2.65 ï 2.70 mm (0.043 ï 0.063 in.)
Mark G 2.70 ï 2.75 mm (0.063 ï 0.083 in.)
Oil seal tap in depth
Output shaft rear bearing retainer 0 Ğ 0.5 mm (0 Ğ 0.020 in.)
Transmission front bearing retainer 5.4 Ğ 6.2 mm (0.606 Ğ 0.638 in.)
Shift lever shaft ï0.2 ï 0.6 mm (ï0.008 ï 0.024 in.)
Shift lever No. 2 shaft 0 ï .0 mm (0 ï 0.039 in.)
5th gear synchronizer ring clearance STD 0.80 ï .60 mm (0.035 ï 0.0630 in.)
Min. 0.80 mm (0.035 in.)
 03ï5
SERVICE SPECIFICATIONS ï MANUAL TRANSMISSION / TRANSAXLE

Input shaft snap ring thickness Mark A 2.50 ï 2.55 mm (0.0984 ï 0.004 in.)
Mark B 2.55 ï 2.60 mm (0.004 ï 0.024 in.)
Mark C 2.60 ï 2.65 mm (0.024 ï 0.044 in.)
Mark D 2.65 ï 2.70 mm (0.044 ï 0.063 in.)
Mark E 2.70 ï 2.75 mm (0.063 ï 0.083 in.)
Mark F 2.75 ï 2.80 mm (0.083 ï 0.02 in.)
Gear thrust clearance
2nd STD 0.0
0 0 ï 0.55
0 55 mm (0.0039
(0 0039 ï 0.027
0 027 in
in.))
3rd and 5th STD 0.0 ï 0.35 mm (0.0039 ï 0.038 in.)
Gear radial clearance
3rd STD 0.05
0 05 ï 0.068
0 068 mm (0.0006
(0 0006 ï 0.0027
0 0027 in.)
in )
2nd and 5th STD 0.020 ï 0.073 mm (0.0008 ï 0.0029 in.)
Output
p shaft gear
g journal
j diameter
st gear Min. 44.484 mm (.753 in.)
2nd gear Min
Min. 49 979 mm (.9677
49.979 ( 9677 in
in.))
3rd gear Min. 57.984 mm (2.2828 in.)
5th gear Min. 37.979 mm (.4952 in.)
Synchronizer ring No. 2 clearance STD .25 ï 2.5 mm (0.0492 ï 0.0846 in.)
Synchronizer ring No. 3 clearance STD .23 ï 2.3 mm (0.0484 ï 0.0839 in.)
2nd gear inside diameter STD 57.05 ï 57.040 mm (2.2447 ï 2.2457 in.)
Max. 57.040 mm (2.2457 in.)
3rd gear inside diameter STD 65.05 ï 65.040 mm (2.5596 ï 2.5606 in.)
Max. 65.040 mm (2.5606 in.)
5th gear inside diameter STD 44.05 ï 44.040 mm (.7329 ï .7339 in.)
Max. 44.040 mm (.7339 in.)
Output shaft snap ring thickness for clutch hub No. 2 Mark 4 .90 ï .95 mm (0.0748 ï 0.0768 in.)
Mark 5 .95 ï 2.00 mm (0.0768 ï 0.0787 in.)
Mark 6 2.00 ï 2.05 mm (0.0787 ï 0.0807 in.)
Mark 7 2.05 ï 2.0 mm (0.0807 ï 0.0827 in.)
Mark 8 2.0 ï 2.5 mm (0.0827 ï 0.0847 in.)
Mark 9 2.5 ï 2.20 mm (0.0847 ï 0.0866 in.)
Output shaft snap ring thickness for clutch hub No.  Mark A 2.90 ï 2.95 mm (0.42 ï 0.6 in.)
Mark B 2.95 ï 3.00 mm (0.6 ï 0.8 in.)
Mark C 3.00 ï 3.05 mm (0.8 ï 0.20 in.)
Mark D 3.05 ï 3.0 mm (0.20 ï 0.220 in.)
Mark E 3.0 ï 3.5 mm (0.220 ï 0.240 in.)
Mark F 3.5 ï 3.20 mm (0.240 ï 0.260 in.)
Output shaft snap ring thickness Mark A 2.40 ï 2.45 mm (0.0945 ï 0.0965 in.)
Mark B 2.45 ï 2.50 mm (0.0965 ï 0.0984 in.)
Mark C 2.50 ï 2.55 mm (0.0984 ï 0.004 in.)
Mark D 2.55 ï 2.60 mm (0.004 ï 0.024 in.)
Mark E 2.60 ï 2.65 mm (0.024 ï 0.044 in.)
Mark F 2.65 ï 2.70 mm (0.044 ï 0.063 in.)
Mark G 2.70 ï 2.75 mm (0.063 ï 0.083 in.)
Mark H 2.75 ï 2.80 mm (0.083 ï 0.02 in.)
Counter gear roller bearing journal diameter STD 35.957 ï 35.970 mm (.456 ï .46 in.)
Min. 35.957 mm (.456 in.)
Counter gear front bearing snap ring thickness Mark A 2.45 ï 2.50 mm (0.0970 ï 0.0984 in.)
Mark B 2.50 ï 2.55 mm (0.0984 ï 0.004 in.)
Mark C 2.55 ï 2.60 mm (0.004 ï 0.024 in.)
Mark D 2.60 ï 2.65 mm (0.024 ï 0.044 in.)
Mark E 2.65 ï 2.70 mm (0.044 ï 0.063 in.)
Mark F 2.70 ï 2.75 mm (0.063 ï 0.083 in.)
Shift lever shaft plug tap in depth .7 ï 2.5 mm (0.067 ï 0.098 in.)
03ï6
SERVICE SPECIFICATIONS ï MANUAL TRANSMISSION / TRANSAXLE
030OPï0

TORQUE SPECIFICATION
Part Tightened N˜˜m kgf˜˜cm ft˜˜lbf
Bearing retainer CTR x Intermediate plate 8 85 3
No. 2 shift fork x No. 3 shift fork shaft 36 370 27
No.  front shift fork x No. 2 shift fork shaft 36 370 27
No.  rear shift fork x No.  shift fork shaft 34 350 25
Inter lock hole plug 8.6 90 4
Case receiver x Transmission 8 85 3
Rear case oil strainer subïassy x Transmission case RR .7 20 9
Oil receiver pipe No.  x Transmission case RR .7 20 9
Transmission oil filter plate x Transmission case (Front) 2 22 8.9
Transmission case RR x Transmission case (Front) 37 380 27
Oil pump cover x Rear bearing retainer 3.9 40 35 in.·lbf
Plug x Rear bearing retainer 9 90 4
Rear bearing retainer x Transmission case RR 37 380 27
Front bearing retainer x Transmission case (Front) 7 70 2
Power takeïoff cover x Transmission case (Front) 4 45 0
Shift lever shaft housing x Transmission case (Front) 7 70 2
Clutch housing x Transmission 37 380 27
Speedometer driven gear x Rear bearing retainer  5 8
Exhaust brake neutral switch assy x Shift lever shaft housing 39 400 29
Shift position switch x Shift lever shaft housing 39 400 29
Backïup light switch x Transmission case (Front) 44 450 33
Clutch release fork support x Transmission case (Front) 39 400 29
Filler, Drain plug x Transmission 37 380 27
Shift outer lever set nut 20 204 5
Select outer lever set nut 7.8 80 69 in.·lbf
MANUAL TRANSMISSION/TRANSAXLE

MANUAL TRANSMISSION SYSTEM . . . . . . . . 41ï1

PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . 41ï1
MANUAL TRANSMISSION ASSY . . . . . . . . . . 41ï2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï2
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï6
INPUT SHAFT ASSY . . . . . . . . . . . . . . . . . . . . . 41ï38
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï38
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï39
OUTPUT SHAFT ASSY . . . . . . . . . . . . . . . . . . . 41ï42
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï42
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï43
COUNTER GEAR ASSY . . . . . . . . . . . . . . . . . . 41ï54
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï54
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï55
SHIFT LEVER SHAFT HOUSING ASSY . . . . . 41ï57
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï57
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï58
 41ï1
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION SYSTEM

MANUAL TRANSMISSION SYSTEM

4106Tï01

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area See page
1. Oil (Level low) L
2. Oil (Wrong) L
3. Gear (Worn or damaged) 41ï6
41ï39
41ï43
Noise
41ï55
4. Bearing (Worn or damaged) 41ï6
41ï39
41ï43
41ï55
1. Oil (Level too high) L
2. Gasket (Damaged) 41ï6
Oil leakage
3. Oil seal (Worn or damaged) 41ï6
4. OïRing (Worn or damaged) L
1. Synchronizer ring (Worn or damaged) 41ï6
Hard to shift or will not shift
2. Shift key spring (Damaged) 41ï6

1. Locking ball spring (Damaged) 41ï6

2. Shift fork (Worn) 41ï6
41ï39
41ï43
3. Gear (Worn or damaged) 41ï6
41ï39
Jumps out of gear
41ï43
41ï55
4. Bearing (Worn or damaged) 41ï6
41ï39
41ï43
41ï55
41ï2
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

MANUAL TRANSMISSION ASSY

4106Uï01

COMPONENTS
L 17 (170, 12)
Neutral Switch
Shift Lever 39 (400, 29)
Shaft Housing
z
Filler Plug z x6
Shift Position Switch
Drain Plug 39 (400, 29)
Clutch Housing z z BackïUp
Light Switch
37 (380, 27) L 17 (170, 12)
44 (450, 33)

Clip z Transmission
Clutch x8 Front Case
Release Bearing
x 10
L 14 (145, 10)
x6
Snap Ring
Front Bearing z Gasket
Retainer Power TakeïOff
Clutch Release Fork Cover
w/PTO
z Spacer Vacuum Tube Hose

Power
Takeïoff
Rear Counter Assy
Gear Bearing
z Gasket L 39 (400, 29)
Transmission
Rear Case

Spacer
Ball Speedometer
z Snap Ring Drive Gear

x 11
L 37 (380, 27)

18 (185, 13)

Oil Receiver x9

12 (120, 9)

Speedometer
Driven Gear L 37 (380, 27)
N·m (kgf·cm, ft·lbf) : Specified torque Rear Bearing
z Nonïreusable part Retainer
L Precoated part D27166
 41ï3
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

z Oil Seal

Front Bearing Retainer

z Nonïreusable part
Apply MP grease D06658
41ï4
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

Rear Bearing Retainer

Clip z Oil Seal

z OïRing
12 (120, 9)

Ball
Spring

19 (190, 14)
Plug

Speedometer 3.9 (40, 35 in.·lbf)

Driven Gear

Driven Rotor
Drive Shaft
Drive Rotor

Oil Pump Cover

N·m (kgf·cm, ft·lbf) : Specified torque

z Nonïreusable part
Apply MP grease D06660
 41ï5
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

No. 3 Shift Fork Shaft

Plug
19 (190, 14)
36 (370, 27)
36 (370, 27)
Spring
Ball
Plug
Spring No. 1 Front Shift Fork
Interlock Roller Ball 34 (350, 25)

Snap Ring
No. 2 Shift Fork Plug
No. 2 Shift Fork Shaft
Interlock Pin

No. 1 Rear Shift Fork

No. 1 Shift Fork Shaft
Plug
Output Shaft Assy Spring
Input Shaft Assy Ball

Shifting Key Spring

No. 1 Synchronizer (Spring)
No. 1 Hub Sleeve
Ring Set
(1st & reverse type)
Needle Roller Bearing
Center Bearing Retainer 1st Gear
Snap Ring
Intermediate Plate
Shifting Key
No. 1 Clutch Hub
(1st & reverse type)

Rear Output
18 (185, 13) Shaft Bearing
Reverse Gear
Counter Gear
Rear Bearing

Needle Roller Inner Race

Bearing
z Snap Ring
Ball

Roller Bearing
Outer Race
Counter Gear Assembly

N·m (kgf·cm, ft·lbf) : Specified torque

zNonïreusable part D07293
41ï6
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY
4106Vï01

OVERHAUL
NOTICE:
When working with FIPG (seal packing) material, you must observe the following items.
S Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-
faces.
S Thoroughly clean all components to remove all the loose material.
S Clean both sealing surfaces with a nonïresidue solvent.
S Apply FIPG in an approx. 1.2 mm (0.05 in.) wide bead along the sealing surface.
S Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.

1. REMOVE FILLER PLUG

C67131

2. REMOVE DRAIN PLUG

C67132

3. REMOVE CLUTCH RELEASE FORK SUBïASSY

4. REMOVE CLUTCH RELEASE BEARING ASSY

D26883
 41ï7
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

5. REMOVE RELEASE FORK SUPPORT

6. REMOVE CLUTCH RELEASE FORK BOOT

D26884

7. REMOVE BACK UP LAMP SWITCH ASSY

(a) Remove the back up lamp switch assy and gasket.

D11339

8. REMOVE SHIFT POSITION SWITCH

(a) Using SST, remove the shift position switch and gasket.
SST 09817ï16011

C67134

9. REMOVE EXHAUST BRAKE NEUTRAL SWITCH

SST
ASSY
(a) Using SST, remove the neutral switch and gasket.
SST 09817ï16011

D11340

10. REMOVE SPEEDOMETER DRIVEN (MTM) GEAR

SUBïASSY
(a) Remove the bolt, lock plate driven gear subïassy and Oï
ring.

D06677
41ï8
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

11. REMOVE CLUTCH HOUSING

(a) Remove the 10 bolts.
(b) Using a plastic hammer, tap out the clutch housing.

D26885

12. REMOVE SHIFT LEVER SHAFT HOUSING ASSY

HINT:
The lever must be removed after shifting it in the neutral posi-
tion.
(a) Remove the 8 bolts and 2 clamps.
(b) Using a plastic hammer, carefully tap out the shift lever
shaft housing.

D11341

13. REMOVE MANUAL TRANSMISSION POWER

TAKEïOFF COVER (W/O POWER TAKE OFF)
(a) Remove the 6 bolts, cover and gasket.
14. REMOVE POWER TAKEïOFF ASSY (W/ POWER
TAKE OFF)
(See pub. No. RM931E on page 87 ï 2)

C67207

15. REMOVE BEARING RETAINER FRONT (MTM)

(a) Remove the 8 bolts.

D07269

(b) Using a brass bar and hammer, carefully tap out the front
bearing retainer.

D07270
 41ï9
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

16. REMOVE TRANSMISSION FRONT BEARING

RETAINER OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
NOTICE:
Protect the bearing retainer with a shop rag to prevent dam-
age.

D06659

17. REMOVE OUTPUT SHAFT REAR BEARING (MTM)

RETAINER
(a) Remove the 9 bolts.

D07271

(b) Using a brass bar and hammer, carefully tap out the bear-
ing retainer.
HINT:
Make the brass bar touched the lib portion of the case.

D27018

18. INSPECT OIL PUMP

(a) Rotate the oil pump drive shaft lightly and check that the
drive rotor turns smoothly.

D27148

19. REMOVE OIL PUMP ASSY

(a) Remove the plug, compression spring and ball.
(1) Fix the rear bearing retainer onto a vise through the
aluminum plate.
(2) Using a torx socket wrench (T40), remove the plug.
(3) Using a magnetic finger, remove the spring and ball.

D27149
41ï10
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

(b) Remove the oil pump cover.

(1) Remove the oil pump drive shaft.
Matchmarks
(2) Place matchmarks on the oil pump cover and rear
bearing retainer.
(3) Using a torx socket wrench (T30), remove the 3
screws.

D27150

(4) Install 3 bolts (normal diameter 8 mm, pitch 1.25

mm, length under the neck 35 mm) on the oil pump
cover and tighten them equally, and then remove
the oil pump cover.
NOTICE:
Do not force in the bolts.

D27019

(c) Remove the drive and driven rotors.

HINT:
If the teeth section of the drive and driven rotors have
scratches, replace them with the new ones.

D27020

20. INSPECT ROTOR

(a) Inspect the driven rotor for body clearance.
Using a feeler gauge, measure the clearance between
the driven rotor and body.
Standard body clearance:
0.02 ï 0.17 mm (0.0008 ï 0.0067 in.)
Maximum body clearance: 0.17 mm (0.0067 in.)

D27021

(b) Inspect the rotors for tip clearance.

Using a feeler gauge, measure the clearance between
the drive rotor and driven rotor.
Standard tip clearance:
0.05 ï 0.15 mm (0.0020 ï 0.0059 in.)
Maximum tip clearance: 0.15 mm (0.0059 in.)

D27022
 41ï11
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

21. REMOVE TYPE T OIL SEAL

(a) Using a screwdriver, pry out the oil seal.
NOTICE:
Protect the bearing retainer with a shop rag not to damage
it.

D27023

22. REMOVE SPEEDOMETER DRIVE (MTM) GEAR

23. REMOVE SPEEDOMETER DRIVE GEAR SPACER
24. REMOVE SPEEDOMETER DRIVE GEAR (MTM) KEY
OR BALL

D27024

25. REMOVE FRONT BEARING SHAFT SNAP RING

(a) Using snap ring pliers (expander), remove the snap ring.

C67146

26. REMOVE COUNTER GEAR FRONT BEARING SNAP

RING NO.2
(a) Using snap ring pliers (expander), remove the snap ring.

C67147

27. REMOVE MANUAL TRANSMISSION CASE

(a) Remove the 11 bolts and 2 clamps.

D27026
41ï12
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

(b) Using a brass bar and hammer, carefully tap out the trans-
mission case.
HINT:
Make the brass bar touched the lib portion of the case.

D27027

28. REMOVE SNAP RING COUNTER GEAR REAR

BEARING
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.

D27028

29. REMOVE COUNTER SHAFT REAR BEARING

(a) Using SST, remove the bearing.
SST SST 09950ï00020, 09950ï00030, 09950ï40011
(09957ï04010), 09950ï60010 (09951ï00300)
HINT:
S Use it after applying the gear oil to the screw of SST cen-
ter bolt and the attachment.

C67149

S Remove the bearing while tapping the tip of the counter

gear with a plastic hammer to prevent the counter gear
from being pushed to the front and attaching to the side
of the gear.

D07278

30. REMOVE TRANSMISSION CASE RR

(a) Using a brass bar and hammer, tap out the transmission
case.
NOTICE:
Attach the brass bar to the rib of the case.

D07279
 41ï13
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

31. REMOVE OIL RECEIVER PIPE NO.1 (MTM)

(a) Remove the 2 bolts and oil receiver pipe from the rear
case.

C67434

32. REMOVE REAR CASE MANUAL TRANSMISSION OIL

STRAINER SUBïASSY
(a) Remove the bolt and oil strainer.
(b) Remove the Oïring from the oil strainer.

C67176

33. REMOVE REVERSE IDLER GEAR

(a) Remove the woodruff key from the reverse idler gear
shaft.
(b) Using a brass bar and hammer, tap out the reverse idler
gear shaft.
(c) Remove the reverse idler gear, 2 thrust washers.

C67177

34. REMOVE REVERSE IDLER GEAR BEARING

(a) Remove the reverse idler gear bearing from the reverse
idler gear.
35. FIX TRANSMISSION INTERMEDIATE PLATE

C67178

36. REMOVE MANUAL TRANSMISSION CASE

RECEIVER
(a) Remove the 3 bolts and case receiver.

C67433
41ï14
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

37. REMOVE TRANSMISSION MAGNET

C67151

38. REMOVE INTER LOCK HOLE PLUG

(a) Using a torx socket wrench (T40), remove the 4 plugs.
39. REMOVE SHIFT DETENT BALL LOW SIDE
COMPRESSION SPRING
(a) Using a magnetic finger, remove the 3 springs.
40. REMOVE SHIFT INTER LOCK BALL
(a) Using a magnetic finger, remove the 3 balls.

C67152

41. REMOVE GEAR SHIFT FORK SHAFT NO.2

(a) Remove the bolt and gear shift fork shaft No. 2.

C67153

42. REMOVE GEAR SHIFT FORK NO.2

(a) Remove the bolt.
(b) Slide the gear shift fork shaft No. 3, and remove the gear
shift fork No.2.

C67154

43. REMOVE GEAR SHIFT FORK SHAFT NO.3

(a) Remove the gear shift fork shaft No. 3 from the intermedi-
ate plate.

C67155
 41ï15
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

44. REMOVE GEAR SHIFT FORK NO.1 (FRONT)

(a) Remove the front gear shift fork.

C67156

45. REMOVE 3RD & 4TH SHIFT FORK SHAFT SHAFT

SNAP RING
(a) Using 2 screwdrivers and a plastic hammer, tap out the
snap ring.

C67157

46. REMOVE GEAR SHIFT FORK SHAFT NO.1

(a) Remove the bolt and gear shift fork shaft No. 1.

C67158

47. REMOVE GEAR SHIFT FORK NO.1 (REAR)

(a) Remove the rear gear shift fork No. 1.

C67159

48. REMOVE SHIFT INTER LOCK PIN NO.2

(a) Using a magnetic finger, remove the inter lock pin No. 2
from the intermediate plate.

C67160
41ï16
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

49. REMOVE SHIFT INTER LOCK NO.1 ROLLER

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

C67161

50. REMOVE SHIFT INTER LOCK PIN

(a) Remove the shift inter lock pin from the shift fork shaft No.
2.

C67162

51. INSPECT REVERSE GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance.
Standard thrust clearance:
0.10 ï 0.25 mm (0.0039 ï 0.0098 in.)
Maximum thrust clearance: 0.25 mm (0.0098 in.)

C67210

52. INSPECT REVERSE GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance.
Standard radial clearance:
0.015 ï 0.067 mm (0.0006 ï 0.0026 in.)
Maximum radial clearance: 0.067 mm (0.0026 in.)

C67211

53. REMOVE OUTPUT SHAFT REAR BEARING

(a) Using SST, remove the bearing.
SST SST 09950ï40011 (09951ï04020, 09952ï04010,
09953ï04030, 09954ï04020, 09955ï04031,
09957ï04010, 09958ï04011), 09950ï60010
(09951ï00230)

D07285
 41ï17
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

HINT:
Use it after applying the gear oil to the screw of SST center bolt
and the attachment.

54. REMOVE REVERSE GEAR

(a) Remove the bearing inner race, reverse gear, and needle
roller bearing.

C67164

55. REMOVE SPEEDOMETER DRIVE GEAR (MTM) KEY

OR BALL

C67165

56. INSPECT 1ST GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance.
Standard thrust clearance:
0.10 ï 0.47 mm (0.0039 ï 0.0185 in.)
Maximum thrust clearance: 0.47 mm (0.0185 in.)

C67208

57. INSPECT 1ST GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance.
Standard radial clearance:
0.015 ï 0.068 mm (0.0006 ï 0.0027 in.)
Maximum radial clearance: 0.068 mm (0.0027 in.)

C67209
41ï18
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

58. REMOVE TRANSMISSION CLUTCH HUB ASSY NO.1

AND 1ST GEAR
SST (a) Using SST, remove the hub sleeve No. 1 assy, synchro-
nizer ring set No. 1 and 1st gear.
SST 09950ï40011 (09957ï04010), 09950ï50013
(09951ï05010, 09952ï05010, 09953ï05020,
09954ï05040), 09950ï60010 (09951ï00230)
(b) Remove the needle roller bearing.
D07327

59. REMOVE BEARING RETAINER CTR

(a) Remove the 4 bolts and bearing retainer from the inter-
mediate plate.

C67171

60. REMOVE OUTPUT SHAFT CENTER BEARING SHAFT

SNAP RING
(a) Using snap ring pliers (expander), remove the snap ring.

D07289

61. REMOVE OUTPUT SHAFT ASSY AND COUNTER

GEAR ASSY
(a) Holding up the input shaft assy, output shaft assy and
counter gear assy, and pull out.
HINT:
For dust prevention, cover your arms with shop rags and the
likes.

C67173

62. REMOVE INPUT SHAFT ASSY

(a) Remove the input shaft assy from the output shaft assy.

C67174
 41ï19
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

63. REMOVE TRANSMISSION OIL FILTER PLATE

(a) Remove the bolt and oil filter plate from the transmission
case.

C67175

64. REMOVE COUNTER GEAR CENTER BEARING

OUTER RACE
(a) Using SST and a press, press out the outer race from the
SST
intermediate plate.
SST 09950ï60020 (09951ï00750), 09950ï70010
(09951ï07100)

D07292

65. INSPECT REVERSE GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the reverse gear.
Standard inside diameter:
54.015 ï 54.040 mm (2.1266 ï 2.1276 in.)
Maximum inside diameter: 54.040 mm (2.1276 in.)

C67180

66. INSPECT 1ST GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the 1st gear.
Standard inside diameter:
51.515 ï 51.540 mm (2.0281 ï 2.0291 in.)
Maximum inside diameter: 51.540 mm (2.0291 in.)

C67181

67. INSPECT REVERSE IDLER GEAR

(a) Using a caliper gauge, measure the inside diameter of the
gear.
Standard inside diameter:
35.015 ï 35.036 mm (1.3785 ï 1.3793 in.)
Maximum inside diameter: 35.036 mm (1.3793 in.)

C67399
41ï20
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

68. INSPECT REVERSE IDLER GEAR SHAFT

(a) Using a micrometer, measure the outside diameter of the
shaft.
Standard outside diameter:
27.987 ï 28.000 mm (1.1018 ï 1.1023 in.)
Minimum outside diameter: 27.987 mm (1.1018 in.)

C67400

69. INSPECT REVERSE IDLER GEAR RADIAL

CLEARANCE
(a) Install the reverse idler gear on the reverse idler gear
shaft, and fix to the vise.
(b) Using a dial indicator, check the radial clearance of the re-
verse idler gear.
Standard radial clearance:
0.015 ï 0.059 mm (0.0006 ï 0.0023 in.)
C67435 Maximum radial clearance: 0.059 mm (0.0023 in.)

70. INSPECT SYNCHRONIZER RING SET NO.1

(a) Using a feeler gauge, measure the clearance between
the synchronizer ring No. 1 and the 1st gear while syn-
chronizer ring No. 1 is pushed to the cone of the 1st gear.
Standard clearance:
1.15 ï 2.05 mm (0.0452 ï 0.0807 in.)
Minimum clearance: 1.15 mm (0.0452 in.)

C67436

(b) Apply gear oil to the taper cone of the 1st gear, and check
that it dose not rotate to the circumference direction while
No. 1 synchronizer ring is pushed.

C67437

71. INSPECT GEAR SHIFT FORK NO.2

(a) Using vernier calipers, measure the claw thickness of the
gear shift fork No. 2.
Standard thickness:
11.75 ï 11.85 mm (0.4625 ï 0.4665 in.)
Minimum thickness: 11.75 mm (0.4625 in.)

C67182
 41ï21
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

72. INSPECT GEAR SHIFT FORK NO.1 (FRONT)

(a) Using vernier calipers, measure the claw thickness of the
gear shift fork front.
Standard thickness:
11.75 ï 11.85 mm (0.4625 ï 0.4665 in.)
Minimum thickness: 11.75 mm (0.4625 in.)

C67183

73. INSPECT GEAR SHIFT FORK NO.1(REAR)

(a) Using vernier calipers, measure the claw thickness of the
gear shift fork rear.
Standard thickness:
11.75 ï 11.85 mm (0.4625 ï 0.4665 in.)
Minimum thickness: 11.75 mm (0.4625 in.)

C67184

74. INSPECT TRANSMISSION HUB SLEEVE NO.1

(a) Using vernier calipers, measure the clearance of the hub
sleeve No. 1.
Standard clearance:
12.0 ï 12.1 mm (0.4724 ï 0.4763 in.)
Maximum clearance: 12.1 mm (0.4763 in.)

C67401

75. INSTALL OUTPUT SHAFT ASSY

(a) Apply gear oil to the sliding part of the output assy.
(b) Using a plastic hammer, install the output shaft assy with
tapping the intermediate plate.

C67187
41ï22
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

76. INSTALL OUTPUT SHAFT CENTER BEARING SHAFT

SNAP RING
(a) Select a snap ring by making the thrust clearance of the
bearing by 0 to 0.1 mm (0.004 in.).
Mark Thickness mm (in.)
A 2.40 ï 2.45 (0.0945 ï 0.0965)
B 2.45 ï 2.50 (0.0965 ï 0.0984)
C 2.50 ï 2.55 (0.0984 ï 0.1004)
C67172
D 2.55 ï 2.60 (0.1004 ï 0.1024)
E 2.60 ï 2.65 (0.1024 ï 0.1043)
F 2.65 ï 2.70 (0.1043 ï 0.1063)
G 2.70 ï 2.75 (0.1063 ï 0.1083)
H 2.75 ï 2.80 (0.1083 ï 0.1102)
(b) Using snap ring pliers (expander), install the snap ring.

77. INSTALL INPUT SHAFT ASSY

(a) Install the input shaft assy to the output shaft assy.
(b) Check that the input shaft assy rotates smoothly.

C67188

78. INSTALL COUNTER SHAFT ASSY

Apply Gear Oil (a) Apply gear oil to the counter shaft center bearing.
(b) Temporarily install the counter gear assy to the intermedi-
ate plate.

C67466

79. INSTALL COUNTER GEAR CENTER BEARING

OUTER RACE
(a) Using a brass bar and hammer, tap in the bearing outer
race.

C67190
 41ï23
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

80. INSTALL BEARING RETAINER CTR

(a) Install the bearing retainer with the 4 bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

C67171

81. INSTALL 1ST GEAR

(a) Apply gear oil to the 1st gear needle roller bearing.
(b) Install the 1st gear needle roller bearing to the output
shaft.

C67170

(c) Apply gear oil to the inside and thrust of the 1st gear.
(d) Install the 1st gear to the output shaft.

C67191

82. INSTALL SYNCHRONIZER RING SET NO.1

(a) Apply gear oil to the taper cone of the synchronizer ring
set No.1.
(b) Install the synchronizer ring set No. 1 to the 1st gear.
NOTICE:
Align the claw of the middle ring with the cutïout of the 1st
gear.
Align the claw of the inner ring with the key groove of the
C67168 outer ring.
41ï24
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

83. INSTALL TRANSMISSION CLUTCH HUB NO.1

b (a) Install the hub sleeve No. 1 to the clutch hub No. 1.
NOTICE:
B The orientation of the clutch hub can be recognized by the
A dimensions (a, b) of the boss part.
The orientation of the hub sleeve can be recognized by the
a shape (A, B) of the outer circumference.
(b) Install the 3 shifting keys.
(c) Using a screwdriver, install the 2 shifting key springs.
Pressïfit NOTICE:
The opening part of the key spring must not be placed in the
same direction.

D27382

(d) Using SST and a press, press in the clutch hub No. 1 assy.
SST 09316ï60011 (09316ï00011, 09316ï00021,
09316ï00031, 09316ï00041)
SST
NOTICE:
Take care not to install the clutch hub No. 1 assembly in the
wrong direction.
Aligning the key groove of the outer ring with synchromesh
SST shifting key, install them.
D27383 (e) Check that the 1st gear rotates smoothly and that the syn-
chronizer ring set No. 1 is not stuck.
84. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a dial indicator,measure the thrust clearance of the
1st gear.
Standard thrust clearance:
0.10 ï 0.47 mm (0.0039 ï 0.0185 in.)
Maximum thrust clearance: 0.47 mm (0.0185 in.)

C67208

85. INSPECT 1ST GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance of the
1st gear.
Standard radial clearance:
0.015 ï 0.068 mm (0.0006 ï 0.0027 in.)
Maximum radial clearance: 0.068 mm (0.0027 in.)

C67209
 41ï25
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

86. INSTALL SPEEDOMETER DRIVE GEAR (MTM) KEY

OR BALL

C67165

87. INSTALL REVERSE GEAR

(a) Apply gear oil to the reverse gear bearing and reverse
gear.
(b) Install the reverse gear bearing and inner race to the re-
verse gear.
(c) Install the reverse gear to the output shaft.

C67194

88. INSTALL OUTPUT SHAFT REAR BEARING

SST (a) Using SST and a press, press in the bearing.
SST 09316ï20011, 09316ï60011 (09316ï00011,
09316ï00041), 09527ï10011
(b) Check that the reverse gear and bearing rotates smooth-
ly.

SST C67195

89. INSPECT REVERSE GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance of the
reverse gear.
Standard thrust clearance:
0.10 ï 0.25 mm (0.0039 ï 0.0098 in.)
Maximum thrust clearance: 0.25 mm (0.0098 in.)

C67210

90. INSPECT REVERSE GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance of the
reverse gear.
Standard radial clearance:
0.015 ï 0.067 mm (0.0006 ï 0.0026 in.)
Maximum radial clearance: 0.067 mm (0.0026 in.)

C67211
41ï26
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

91. INSTALL GEAR SHIFT FORK SHAFT NO.3

(a) Install the shift fork shaft No. 3 and shift fork No. 2.
(b) Install the bolt.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)

C67196

92. INSTALL SHIFT INTER LOCK NO.1 ROLLER

(a) Using a screw driver, push in the inter lock roller.

C67197

93. INSTALL SHIFT INTER LOCK PIN

(a) Apply MP grease to the shift inter lock pin.
(b) Install the shift inter lock pin to the shift fork shaft No. 2.

C67162

94. INSTALL GEAR SHIFT FORK SHAFT NO.2

(a) Install the shift fork shaft No. 2 and front shift fork No. 1.
(b) Install the bolt.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)

C67198

95. INSTALL SHIFT INTER LOCK PIN NO.2

(a) Using a screw driver, install the inter lock pin No. 2 to the
intermediate plate.

C67199
 41ï27
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

96. INSTALL GEAR SHIFT FORK SHAFT NO.1

(a) Install the shift fork shaft No. 1 and rear shift fork No. 1.
(b) Install the bolt.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)

C67403

97. INSTALL 3RD & 4TH SHIFT FORK SHAFT SHAFT

SNAP RING
(a) Using a brass bar and hammer, tap in a new snap ring.

C67200

98. INSTALL SHIFT INTER LOCK BALL

(a) Install the 3 balls.
99. INSTALL SHIFT DETENT BALL LOW SIDE
COMPRESSION SPRING
(a) Install the 3 springs.
100. INSTALL INTER LOCK HOLE PLUG
(a) Using a torx socket wrench (T40), install the 4 plugs.
Torque: 18.6 N·m (190 kgf·cm, 14 ft·lbf)
C67152

101. INSTALL MANUAL TRANSMISSION CASE RECEIVER

(a) Install the case receiver to the intermediate plate with the
3 bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

C67433

102. INSTALL TRANSMISSION MAGNET

(a) Install the transmission magnet to the intermediate plate.

C67151
41ï28
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

103. INSTALL REVERSE IDLER GEAR BEARING

(a) Apply gear oil to the reverse idler gear bearing.
(b) Install the reverse idler gear bearing to the reverse idler
gear.

C67178

104. INSTALL REVERSE IDLER GEAR

(a) Apply MP grease to the 2 thrust washers.
(b) Install the reverse idler gear and 2 thrust washers to the
rear case, and then insert the reverse idler gear shaft into
the rear case.
Rear
NOTICE:
When assembling the washers, the washers must be as-
sembled with dimple facing to the thrust side of the gear.
C67186 (c) Install the reverse idler gear shaft woodruff key with the
rear case.
(d) Check that the reverse idler gear rotates smoothly.

105. INSPECT REVERSE IDLER GEAR THRUST

CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance of the
reverse idler gear.
Standard thrust clearance:
0.10 ï 0.55 mm (0.0039 ï 0.0217 in.)
Maximum thrust clearance: 0.55 mm (0.0217 in.)

C67440

106. INSTALL REAR CASE MANUAL TRANSMISSION OIL

STRAINER SUBïASSY
(a) Install the oil strainer to the rear case with the bolt.
Torque: 11.7 N·m (120 kgf·cm, 9 ft·lbf)

C67176
 41ï29
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

107. INSTALL OIL RECEIVER PIPE NO.1 (MTM)

(a) Install the oil receiver pipe to the rear case with the 2 bolts.
Torque: 11.7 N·m (120 kgf·cm, 9 ft·lbf)

C67434

108. INSTALL TRANSMISSION CASE RR

Seal Packing (a) Apply seal packing to the rear transmission case as
shown.
Seal packing:
Part No. 08826 ï 00090, THREE BOND 1281 or equiva-
lent

C67442

(b) Fix the transmission case onto a vise through a wooden

block.
(c) Using a plastic hammer, lightly tap the intermediate plate
to pressïfit the plate with the case.
NOTICE:
Install the intermediate plate straight so as not to put ex-
cessive force onto the bearing.
(d) Lay down the transmission.
C67443

109. INSTALL COUNTER SHAFT REAR BEARING

(a) Using SST and a hammer, tap in the bearing to the rear
case.
SST 09608ï06041
HINT:
Fit a press to the inner race of the bearing.

SST C67201
41ï30
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

110. INSTALL SNAP RING COUNTER GEAR REAR

BEARING
(a) Select a snap ring by making the thrust clearance of the
bearing by 0 to 0.1mm (0.004 in.).
Mark Thickness mm (in.)
A 2.40 ï 2.45 (0.0945 ï 0.0965)

Mark B 2.45 ï 2.50 (0.0965 ï 0.0984)

C 2.50 ï 2.55 (0.0984 ï 0.1004)
C67444
D 2.55 ï 2.60 (0.1004 ï 0.1024)
E 2.60 ï 2.65 (0.1024 ï 0.1043)
F 2.65 ï 2.70 (0.1043 ï 0.1063)
G 2.70 ï 2.75 (0.1063 ï 0.1083)

(b) Using a screwdriver and a hammer, tap in the snap ring.

C67445

111. INSTALL TRANSMISSION OIL FILTER PLATE

(a) Install the oil filter plate with the bolt.
Torque: 12 N·m (122 kgf·cm, 8.9 ft·lbf)

C67175

112. INSTALL MANUAL TRANSMISSION CASE

Seal Packing (a) Apply adhesive to the 11 bolts.
Adhesive:
Part No. 08833 ï 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Apply seal packing to the transmission case as shown.
Seal packing:
Part No. 08826 ï 00090, THREE BOND 1281 or equiva-
C67446 lent
 41ï31
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

(c) Fix the transmission case onto a vise through a wooden

block.
(d) Using a plastic hammer, pat the transmission case to at-
tach to the intermediate plate.
NOTICE:
Install the transmission case straight so as not to put ex-
cessive force onto the bearing.

C67447

(e) Install the 11 bolts and 2 clamps.

Clamp
Bolt A: 70 mm (2.76 in.)x 8
Bolt B: 100 mm (3.94 in.)x 3
A
A Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

Clamp

B B
C67205

113. INSTALL FRONT BEARING SHAFT SNAP RING

(a) Using snap ring pliers (expander), install the snap ring.

C67147

114. INSTALL COUNTER GEAR FRONT BEARING SNAP

RING NO.1
(a) Using snap ring pliers (expander), install the snap ring.

C67146

115. INSTALL SPEEDOMETER DRIVE GEAR (MTM) KEY

OR BALL

C67398
41ï32
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

116. INSTALL SPEEDOMETER DRIVE GEAR SPACER

(a) Apply gear oil to 2 new oil seal rings and speedometer
drive gear spacer.
(b) Install the 2 oil seal rings to the speedometer drive gear
spacer.
(c) Install the speedometer drive gear spacer to the output
shaft.

C67204

117. INSTALL SPEEDOMETER DRIVE (MTM) GEAR

(a) Install the speedometer drive gear to the output shaft.

C67140

118. INSTALL TYPE T OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal.
SST 09950ï60010 (09951ï00330, 09951ï00480,
SST
09952ï06010), 09950ï70010 (09951ï07100)
Standard protrusion: 0 ï 0.5 mm (0 ï 0.020 in.)
(b) Apply MP grease to the seal lip.

C67203

119. INSTALL OIL PUMP ASSY

(a) Install the drive and driven rotors.
(1) Apply gear oil to the rear bearing retainer, drive and
driven rotors.
(2) Install the drive and driven rotors.

D27020

(b) Install the oil pump cover.

(1) Align the matchmarks and install the oil pump cover.
Matchmarks
(2) Fix the rear bearing retainer onto a vise through the
aluminum plate.
(3) Using a torx socket wrench (T30), install the 3 bolts.
Torque: 3.9 N·m (40 kgf·cm, 35 in.·lbf)
(4) Install the oil pump drive shaft.

D27150
 41ï33
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

(c) Install the ball, compression spring and plug.

(1) Insert the ball and spring into the rear bearing re-
tainer.
(2) Using a torx socket wrench (T40), install the plug.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(3) Rotate the oil pump drive shaft lightly and check that
the drive rotor turns smoothly.

D27149

Seal Packing
120. INSTALL OUTPUT SHAFT REAR BEARING (MTM)
RETAINER
(a) Apply adhesive to the 9 bolts.
Adhesive:
Part No. 08833 ï 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Apply seal packing to the bearing retainer as shown.
Seal packing:
C67404 Part No. 08826 ï 00090, THREE BOND 1281 or equiva-
lent
(c) Install the rear bearing retainer to the rear case.

C67449

(d) Install the 9 bolts.

Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

C67448

121. INSTALL TRANSMISSION FRONT BEARING

RETAINER OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal.
Standard clearance (A ï B):
SST
15.4 ï 16.2 mm (0.606 ï 0.638 in.)
A (b) Apply MP grease to the seal lip.
B
SST 09950ï60010 (09951ï00330, 09951ï00480,
09952ï06010), 09950ï70010 (09951ï07100)
C67202
41ï34
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

122. INSTALL BEARING RETAINER FRONT (MTM)

(a) Apply adhesive to the 8 bolts.
Adhesive:
Part No. 08833ï00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Apply seal packing to the output shaft front bearing retain-
er as shown.
Seal packing:
Part No. 08826ï00090, THREE BOND 1281 or equiva-
lent

Seal Packing
C67450

(c) Install the bearing retainer to the transmission case with

the 8 bolts.
Torque: 17 N·m (170 kgf·cm, 12 ft·lbf)

C67138

123. INSTALL MANUAL TRANSMISSION POWER

TAKEïOFF COVER (W/O POWER TAKE OFF)
(a) Install the 6 bolts, cover and gasket.
Torque: 14 N·m (145 kgf·cm, 10 ft·lbf)
124. INSTALL POWER TAKEïOFF ASSY (W/ POWER TAKE
OFF)
(See pub. No. RM931E on page 87 ï 2)

C67207

125. INSTALL SHIFT LEVER SHAFT HOUSING ASSY

(a) Apply adhesive to the 8 bolts.
Adhesive:
Part No. 08833 ï 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Apply seal packing to the shift lever shaft housing as
shown.
Seal packing:
D27081 Part No. 08826 ï 00090, THREE BOND 1281 or equiva-
lent
 41ï35
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

(c) Install the 2 clamps and housing assy to the transmission

case with the 8 bolts.
Torque: 17 N·m (170 kgf·cm, 12 ft·lbf)

D27082

126. INSTALL CLUTCH HOUSING

B
B (a) Install the clutch housing to the transmission case with
the 10 bolts.
Bolt A: 35 mm (1.38 in.) x 2
Bolt B: 45 mm (1.77 in.) x 8
A Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
B

B
C67213

127. INSTALL SPEEDOMETER DRIVEN (MTM) GEAR

SUBïASSY
(a) Apply gear oil to a new Oïring.
(b) Install the Oïring to the driven gear subïassy.
(c) Install the driven gear subïassy with the lock plate and
bolt.
Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)

D06677

128. INSTALL EXHAUST BRAKE NEUTRAL SWITCH ASSY

SST
(a) Install a new gasket to the neutral switch.
(b) Using SST, install the neutral switch.
SST 09817ï16011
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

D27169

129. INSTALL SHIFT POSITION SWITCH

SST
(a) Install a new gasket to the shift position switch.
(b) Using SST, install the switch.
SST 09817ï16011
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

C67134
41ï36
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

130. INSTALL BACK UP LAMP SWITCH ASSY

(a) Install a new gasket to the back up lamp switch.
(b) Install the back up lamp switch to the transmission case.
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
131. INSTALL CLUTCH RELEASE FORK BOOT

D11339

132. INSTALL RELEASE FORK SUPPORT

(a) Using a socket wrench (19 mm), install the release fork
support.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

D26884

133. INSTALL CLUTCH RELEASE FORK SUBïASSY

(a) Apply release hub grease to the release fork and hub con-
tact, release fork and push rod contact and release fork
pivot points.
Grease:
Part No. 08887ï01806, RELEASE HUB GREASE or
equivalent

D27055

134. INSTALL CLUTCH RELEASE BEARING ASSY

(a) Apply clutch spline grease to the input shaft spline.
Grease:
Part No. 08887ï01706, CLUTCH SPLINE GREASE or
equivalent

D26886

(b) Install the bearing to the release fork, and then install
them to the transmission.

D26883
 41ï37
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY

135. INSTALL DRAIN PLUG

(a) Install the drain plug to the transmission case through a
new gasket.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

C67132

136. INSTALL FILLER PLUG

(a) Install the filler plug to the transmission case through a
new gasket.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

C67131
41ï38
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY

INPUT SHAFT ASSY

4106Wï01

COMPONENTS

Input Shaft

z Input Shaft Bearing

z Snap Ring

Snap Ring

Spacer Spacer
Synchronizer Ring
Roller

z Nonïreusable part D07504

 41ï39
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY
4106Xï01

OVERHAUL
1. REMOVE 5TH GEAR SYNCHRONIZER RING

C67214

2. REMOVE NEEDLE ROLLER HOLE SNAP RING

(a) Using snap ring pliers (expander), remove the snap ring.

C67215

3. REMOVE INPUT SHAFT BEARING

(a) Remove the 12 rollers and 2 spacers.

C67216

4. REMOVE INPUT SHAFT REAR BEARING SHAFT

SNAP RING
(a) Using snap ring pliers (expander), remove the snap ring.

C67452

5. REMOVE INPUT SHAFT FRONT BEARING

(a) Using SST and a press, press out the front bearing.
SST 09950ï00020

SST

C67453
41ï40
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY

6. INSPECT 5TH GEAR SYNCHRONIZER RING

(a) Using a feeler gauge, measure the clearance between
synchronizer ring and input shaft while the synchronizer
ring is pushed to the taper cone of the input shaft.
Standard clearance:
0.80 ï 1.60 mm (0.0315 ï 0.0630 in.)
Minimum clearance: 0.80 mm (0.0315 in.)

C67456

(b) Apply the gear oil to the taper cone of the input shaft, and
check that it dose not rotate to the circumference direction
while synchronizer ring is pushed.

C67457

7. INSTALL INPUT SHAFT FRONT BEARING

(a) Using SST and a press, press in the new bearing to the
SST input shaft.
SST 09950ï60010 (09951ï00570), 09950ï70010
(09951ï07100)
(b) Check that the bearing rotates smoothly.

C67454

8. INSTALL INPUT SHAFT REAR BEARING SHAFT

SNAP RING
(a) Select a snap ring that allows the minimum axial play.
Mark Thickness mm (in.)
A 2.50 ï 2.55 (0.0984 ï 0.1004)
Mark
B 2.55 ï 2.60 (0.1004 ï 0.1024)
C 2.60 ï 2.65 (0.1024 ï 0.1044)
D 2.65 ï 2.70 (0.1044 ï 0.1063)
D27091
E 2.70 ï 2.75 (0.1063 ï 0.1083)
F 2.75 ï 2.80 (0.1083 ï 0.1102)
(b) Using snap ring pliers (expander), install the snap ring.
 41ï41
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY

9. INSTALL INPUT SHAFT BEARING

(a) Install the 12 rollers and 2 spacers.
HINT:
Apply MP grease to the 12 rollers and install it into the input
shaft.

C67216

10. INSTALL NEEDLE ROLLER HOLE SNAP RING

(a) Using snap ring pliers (expander), install the snap ring.
(b) Check that the input shaft needle roller bearing rotates
smoothly and that it is not stuck.

C67215

11. INSTALL 5TH GEAR SYNCHRONIZER RING

(a) Apply gear oil to the taper cone of the input shaft.
(b) Install the 5th gear synchronizer ring to the input shaft.

C67214
41ï42
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

OUTPUT SHAFT ASSY

4106Yï01

COMPONENTS

Ball
Hub Sleeve No. 3

5th Gear
Shifting Key Spring

z Snap Ring
Output Shaft

Needle Roller Bearing

Synchronizer Ring
Shifting Key Spring
Clutch Hub No. 3
Shifting Key Hub Sleeve No. 2
Synchronizer Ring
Set No. 3

Needle Roller Bearing

3rd Gear

Shifting Key
Clutch Hub No. 2
(2nd &3rd type)

Center Bearing
Synchronizer Ring Set No. 2
(2nd &3rd type) 2nd Gear

z Snap Ring
z Snap Ring

Needle Roller Bearing

z Nonïreusable part D07305

 41ï43
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY
4106Zï01

2nd OVERHAUL
3rd 1. INSPECT EACH GEAR THRUST CLEARANCE
5th (a) Using a feeler gauge, measure the thrust clearance of
each gear.
Standard thrust clearance:
Gear Clearance mm (in.)
2nd 0.10 ï 0.55 (0.0039 ï 0.0217)
3rd and 5th 0.10 ï 0.35 (0.0039 ï 0.0138)
D07306

2. INSPECT EACH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance of
5th each gear.
Standard radial clearance:
3rd
Gear Clearance mm (in.)

2nd 3rd 0.015 ï 0.068 (0.0006 ï 0.0027)

2nd and 5th 0.020 ï 0.073 (0.0008 ï 0.0029)
If the clearance exceeds the standard clearance, replace the
D07307
gear, needle roller bearing or shaft.
3. REMOVE OUTPUT SHAFT CENTER BEARING SHAFT
SNAP RING
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.

C67405

4. REMOVE OUTPUT SHAFT CENTER BEARING

(a) Using SST and a press, press out the center bearing.
SST 09555ï55010

C67218

5. REMOVE 2ND GEAR

(a) Remove the 2nd gear from the output shaft.

C67219
41ï44
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

6. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

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

C67220

7. REMOVE SYNCHRONIZER RING SET NO.2

(a) Remove the synchronizer ring set No. 2 from the clutch
hub No. 1 assy.

C67221

8. REMOVE CLUTCH HUB NO.1 SHAFT SNAP RING

(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.

C67222

9. REMOVE 3RD GEAR

(a) Using SST and a press, press out the clutch hub No. 2
SST assy, synchronizer ring set No. 3 and 3rd gear.
SST 09527ï20011

C67406

10. REMOVE TRANSMISSION CLUTCH HUB NO.2

(a) Using a screwdriver, remove the 3 shifting keys, 2 springs
and clutch hub No. 2 from the hub sleeve No. 2.

C67458
 41ï45
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

11. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

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

C67223

12. REMOVE CLUTCH HUB NO.2 SETTING SHAFT SNAP

RING
(a) Using 2 screwdrivers and a hammer, tap the snap ring.

C67224

13. REMOVE 5TH GEAR

(a) Using a press, press out the clutch hub No. 3 assy, 5th
gear synchronizer ring and 5th gear.

C67225

14. REMOVE TRANSMISSION CLUTCH HUB NO.3

(a) Using a screwdriver, remove the 3 shifting keys, 2 springs
and clutch hub No. 3 from the hub sleeve No. 3.

C67407

15. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

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

C67226
41ï46
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

16. INSPECT OUTPUT SHAFT

(a) Using a micrometer, measure the journal diameter.
Minimum journal diameter:
Journal Diameter mm (in.)
1st 44.484 (1.7513)
2nd 49.979 (1.9677)
3rd 57.984 (2.2828)
5th 3rd 2nd 1st
5th 37.979 (1.4952)
D07315
If the journal diameter is less than the minimum, replace the out-
put shaft.

17. INSPECT SYNCHRONIZER RING SET NO.2

(a) Check the synchronizer ring for wear or damage.
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring No. 2 and the 2nd gear.
Standard clearance:
1.25 ï 2.15 mm (0.0492 ï 0.0846 in.)

C67459

(c) Check the braking effect of the synchronizer ring, turn the
synchronizer ring in one direction while pushing it to the
gear cone, and then check that the ring locks.

C67460

18. INSPECT SYNCHRONIZER RING SET NO.3

(a) Check for wear or damage.
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring back and the gear spline end.
Standard clearance:
1.23 ï 2.13 mm (0.0484 ï 0.0839 in.)

C67229
 41ï47
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

(c) Check the braking effect of the synchronizer ring, turn the
synchronizer ring in one direction while pushing it to the
gear cone, and then check that the ring locks.

C67228

19. INSPECT 5TH GEAR SYNCHRONIZER RING

(a) Check for wear or damage.
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring back and the gear spline end.
Standard clearance:
0.8 ï 1.6 mm (0.0315 ï 0.0630 in.)

C67231

(c) Check the braking effect of the synchronizer ring, turn the
synchronizer ring in one direction while pushing it to the
gear cone, and then check that the ring locks.

C67230

20. INSPECT TRANSMISSION HUB SLEEVE NO.2

(a) Using vernier calipers, measure the hub sleeve No. 2.
Standard clearance:
12.0 ï 12.1 mm (0.4724 ï 0.4764 in.)
Maximum clearance: 12.1 mm (0.4764 in.)
(b) Check the tip of the spline gear of the hub sleeve No. 2
for wear.

C67408

(c) Check the sliding condition between the clutch hub No .2

and the hub sleeve No. 2.

C67409
41ï48
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

21. INSPECT TRANSMISSION HUB SLEEVE NO.3

(a) Using vernier calipers, measure the hub sleeve No. 3.
Standard clearance:
12.0 ï 12.1 mm (0.4724 ï 0.4764 in.)
Maximum clearance: 12.1 mm (0.4764 in.)
(b) Check the tip of the spline gear of the hub sleeve No. 3
for wear.

C67408

(c) Check the sliding condition between the clutch hub No. 3
and the hub sleeve No. 3.

C67409

22. INSPECT 2ND GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the 2nd gear.
Standard inside clearance:
57.015 ï 57.040 mm (2.2447 ï 2.2457 in.)
Maximum inside clearance: 57.040 mm (2.2457 in.)

C67232

23. INSPECT 3RD GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the 3rd gear.
Standard inside clearance:
65.015 ï 65.040 mm (2.5596 ï 2.5606 in.)
Maximum inside clearance: 65.040 mm (2.5606 in.)

C67233

24. INSPECT 5TH GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the 3rd gear.
Standard inside clearance:
44.015 ï 44.040 mm (1.7329 ï 1.7339 in.)
Maximum inside clearance: 44.040 mm (1.7339 in.)

C67234
 41ï49
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

25. INSTALL 5TH GEAR NEEDLE ROLLER BEARING

(a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing to the output shaft.

C67226

26. INSTALL 5TH GEAR

(a) Apply gear oil to the 5 th gear.
(b) Install the 5 th gear to the output shaft.

C67235

27. INSTALL 5TH GEAR SYNCHRONIZER RING

(a) Apply gear oil to the synchronizer ring.
(b) Install the synchronizer ring to the 5th gear.

C67236

28. INSTALL TRANSMISSION CLUTCH HUB NO.3

(a) Install the hub sleeve No. 3 to the clutch hub No. 3.
NOTICE:
The orientation of the clutch hub can be recognized by the
a
dimensions (a, b) of the boss part.
The orientation of the hub sleeve can be recognized by the
A
B shape (A, B) of the outer circumference.
(b) Using a screwdriver, install the 3 shifting keys and 2 shift-
b
ing key springs.
Pressïfit
NOTICE:
The opening part of the key spring must not be placed in the
same direction.
(c) Using SST and a press, press in the clutch hub No. 3 assy.
SST
SST 09316ï60011 (09316ï00011)
NOTICE:
Take care not to install the clutch hub No. 3 assembly in the
wrong direction.
Aligning the key groove of the 5th gear synchronizer ring
C67256 with synchromesh shifting key, install them.
41ï50
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

(d) Check that the 5 th gear rotates smoothly and that the 5th
gear synchronizer ring is not stuck.

29. INSTALL CLUTCH HUB NO.2 SETTING SHAFT SNAP

RING
(a) Select a snap ring that allows the minimum axial play.
Mark Thickness mm (in.)
4 1.90 ï 1.95 (0.0748 ï 0.0768)
5 1.95 ï 2.00 (0.0768 ï 0.0787)
6 2.00 ï 2.05 (0.0787 ï 0.0807)

Mark 7 2.05 ï 2.10 (0.0807 ï 0.0827)

C67238
8 2.10 ï 2.15 (0.0827 ï 0.0846)
9 2.15 ï 2.20 (0.0846 ï 0.0866)

(b) Using a brass bar and hammer, tap in a new snap ring.
30. INSPECT 5TH GEAR THRUST CLEARANCE (See step
1)

C67239

31. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

(a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing to the output shaft.

C67240

32. INSTALL SYNCHRONIZER RING SET NO.3

(a) Apply gear oil to the taper cone of the synchronizer ring
set No. 3.
(b) Install the synchronizer ring on the gear and align the ring
slots with the shifting keys.

C67241
 41ï51
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

33. INSTALL 3RD GEAR

(a) Apply gear oil to the 3rd gear.
(b) Install the 3rd gear to the output shaft.

C67242

34. INSTALL TRANSMISSION CLUTCH HUB NO.2

(a) Install the hub sleeve No. 2 to the clutch hub No. 2.
NOTICE:
The orientation of the clutch hub can be recognized by the
dimensions (a, b) of the boss part.
The orientation of the hub sleeve can be recognized by the
Pressïfit
shape (A, B) of the outer circumference.
(b) Using a screwdriver, install the 3 shifting keys and 2 shift-
a
ing key springs.
A NOTICE:
B
The opening part of the key spring must not be placed in the
b same direction.
(c) Using SST and a press, press in the clutch hub No. 2 assy.
SST 09316ï20011
NOTICE:
Take care not to install the clutch hub No. 2 assembly in the
wrong direction.
Aligning the key groove of the synchronizer ring set No. 3
SST outer ring with synchromesh shifting key, install them.
C67255

(d) Check that the 3rd gear rotates smoothly and that the syn-
chronizer ring is not stuck.

35. INSTALL CLUTCH HUB NO.1 SHAFT SNAP RING

(a) Select a snap ring that allows the minimum axial play.
Mark Thickness mm (in.)
A 2.90 ï 2.95 (0.1142 ï 0.1161)
B 2.95 ï 3.00 (0.1161 ï 0.1181)
C 3.00 ï 3.05 (0.1181 ï 0.1201)
D 3.05 ï 3.10 (0.1201 ï 0.1220)
Mark E 3.10 ï 3.15 (0.1220 ï 0.1240)
C67238
F 3.15 ï 3.20 (0.1240 ï 0.1260)
41ï52
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

(b) Using a brass bar and hammer, tap in the snap ring.

C67245

36. INSTALL SYNCHRONIZER RING SET NO.2

(a) Apply gear oil to the taper cone of the synchronizer ring.
(b) Install the synchronizer ring set No. 2 to the clutch hub No.
2 assy and align the ring slots with the shifting keys.

C67221

37. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

(a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing to the output shaft.

C67220

38. INSTALL 2ND GEAR

(a) Apply gear oil to the 2 nd gear.
(b) Install the 2 nd gear to the output shaft.
HINT:
Align the cutïout of the second gear with the claw of the middle
ring of the synchronizer ring set No. 2.

C67246

39. INSTALL OUTPUT SHAFT CENTER BEARING

(a) Using SST and a press, press in a new bearing.
(b) Check that the bearing and 2nd gear rotates smoothly
SST and that the synchronizer ring is not stuck.

C67247
 41ï53
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY

40. INSTALL OUTPUT SHAFT CENTER BEARING SHAFT

SNAP RING
(a) Select a snap ring that allows the minimum axial play.
Mark Thickness mm (in.)
A 2.40 ï 2.45 (0.0945 ï 0.0965)
B 2.45 ï 2.50 (0.0965 ï 0.0984)
C 2.50 ï 2.55 (0.0984 ï 0.1004)

Mark D 2.55 ï 2.60 (0.1004 ï 0.1024)

C67248
E 2.60 ï 2.65 (0.1024 ï 0.1044)
F 2.65 ï 2.70 (0.1044 ï 0.1063)
G 2.70 ï 2.75 (0.1063 ï 0.1083)
H 2.75 ï 2.80 (0.1083 ï 0.1102)

(b) Using a brass bar and hammer, tap in the snap ring.

C67249

41. INSPECT 3RD GEAR THRUST CLEARANCE

(See step 1)
42. INSPECT 2ND GEAR THRUST CLEARANCE
(See step 1)
43. INSPECT 5TH GEAR RADIAL CLEARANCE
(See step 2)
44. INSPECT 3RD GEAR RADIAL CLEARANCE
(See step 2)
45. INSPECT 2ND GEAR RADIAL CLEARANCE
(See step 2)
41ï54
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY

COUNTER GEAR ASSY

41070ï01

COMPONENTS

Counter Gear
Center Bearing
Outer Race

Side Race

Inner Race

Woodruff Key

Reverse Idler Gear

Counter Gear Thrust Washer

Counter Gear
z Snap Ring
Front Bearing

Reverse Idler Gear Shaft

Needle Roller Bearing

Thrust Washer

z Nonïreusable part D07502

 41ï55
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY
41071ï01

OVERHAUL
1. REMOVE COUNTER SHAFT CENTER BEARING
(a) Using a screwdriver, remove the bearing.

C67258

2. REMOVE COUNTER GEAR FRONT BEARING SNAP

RING NO.1
(a) Using snap ring pliers (expander), remove the snap ring.

C67259

3. REMOVE COUNTER GEAR FRONT BEARING OR

SST ROLLER
(a) Using SST and a press, press out the front bearing.
SST 09950ï00020, 09950ï60010 (09951ï00290),
09950ï70010 (09951ï07100)

C67260

4. INSPECT COUNTER GEAR ASSY

(a) Using a micrometer, measure the bearing race outside di-
ameter of the counter gear.
Standard outside diameter:
35.957 ï 35.970 mm (1.4156 ï 1.4161 in.)
Minimum outside diameter: 35.957 mm (1.4156 in.)
If the clearance is less than minimum, replace the gear bearing
or shaft.
C67261

SST 5. INSTALL COUNTER GEAR FRONT BEARING OR

ROLLER
(a) Apply gear oil to the side race and bearing.
(b) Install the inner race and side race to the bearing as
shown.
(c) Using SST and a press, press in the bearing.
SST 09316ï60011 (09316ï00011, 09316ï00021)

C67262
41ï56
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY

6. INSTALL COUNTER GEAR FRONT BEARING SNAP

RING NO.1
(a) Select a snap ring that allows the minimum axial play.
Mark Thickness mm (in.)
A 2.45 ï 2.50 (0.0970 ï 0.0984)
B 2.50 ï 2.55 (0.0984 ï 0.1004)
C 2.55 ï 2.60 (0.1004 ï 0.1024)
D 2.60 ï 2.65 (0.1024 ï 0.1044)
E 2.65 ï 2.70 (0.1044 ï 0.1063)
F 2.70 ï 2.75 (0.1063 ï 0.1083)

(b) Using snap ring pliers (expander), install the snap ring.

C67259

7. INSTALL COUNTER SHAFT CENTER BEARING

(a) Apply gear oil to the counter shaft center bearing.
(b) Engage the center bearing to the counter gear assy.

C67263
 41ï57
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY

SHIFT LEVER SHAFT HOUSING ASSY

41072ï01

COMPONENTS

20 (204, 15) Select Outer Lever

Lever Lock Pin

Washer

Shift Outer Lever No. 1 Washer

Lever Lock Pin

z Oil Seal
7.8 (80, 69 in.·lbf)

Washer
z Oil Seal
Boot Shift Lever
Shaft No. 2
Shift Lever Shaft Housing
Spring

L Plug
EïRing

Lever Shaft
Pin
Shift Lever No. 2 Select Lever Shaft
Spring Seat No. 2

Shift Lever Shaft

Spring Seat

Slotted Lever Spring Pin

Spring

Shift & Select Lever Spring

N·m (kgf·cm, ft·lbf) : Specified torque
z Nonïreusable part
L Precoated part D11343
41ï58
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY
41073ï01

OVERHAUL
1. REMOVE SELECT OUTER LEVER LOCK PIN
(a) Remove the nut and washer.
(b) Using a brass bar and hammer, tap out the lever lock pin.

C67264

2. REMOVE SELECT OUTER LEVER

(a) Remove the select outer lever and washer from the select
lever shaft.

C67265

3. REMOVE SELECT LEVER SHAFT SUBïASSY

(a) Remove the select lever shaft from the housing.

C67266

4. REMOVE SHIFT OUTER LEVER LEVER LOCK PIN

(a) Remove the nut and washer.
(b) Using a brass bar and hammer, tap out the lever lock pin.

C67267

5. REMOVE SHIFT OUTER LEVER NO.1

(a) Remove the shift outer lever No. 1 from the shift lever
shaft.

C67268
 41ï59
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY

6. REMOVE SHIFT & SELECT LEVER SHAFT DUST

BOOT
(a) Remove the dust boot from the housing.

C67269

7. REMOVE SHIFT & SELECT LEVER PIN OR BOLT

(a) Using a pin punch (5 mm) and hammer, tap out the shift
& select lever pin.

D27142

8. REMOVE SHIFT LEVER SHAFT

(a) Remove the shift lever shaft from the housing.

C67270

9. REMOVE SHIFT & SELECT LEVER

(a) Remove the shift & select lever and spring from the hous-
ing.

C67271

10. REMOVE SELECT SPRING SEAT NO.2

(a) Remove the 2 spring seats and spring from the housing.

C67272
41ï60
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY

11. REMOVE SELECT SPRING SEAT

(a) Remove the 2 spring seats and spring from the housing.

C67273

12. REMOVE SHIFT LEVER SHAFT PIN

(a) Remove the shift lever shaft pin from the housing.

C67274

13. REMOVE SHIFT LEVER SHAFT PLUG

(a) Using a plastic hammer, carefully tap the No. 2 shift lever
and remove the plug.

C67275

14. REMOVE SHIFT LEVER SHAFT NO.2

(a) Using a screwdriver, pry out the 2 Eïrings from the shift
lever shaft No. 2.

C67276

(b) Remove the shift lever shaft No. 2 and shift lever No. 2
from the housing.

C67277
 41ï61
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY

15. REMOVE SHIFT LEVER NO.2 SHAFT OIL SEAL

(a) Using a screwdriver, pry out the oil seal.

C67278

16. REMOVE SHIFT LEVER SHAFT OIL SEAL

(a) Using a screwdriver, pry out the oil seal.

C67279

17. INSTALL SHIFT LEVER SHAFT OIL SEAL

(a) Apply MP grease to the lip of a new oil seal.
(b) Using SST and a hammer, tap in the oil seal.
SST SST 09950ï60010 (09951ï00310), 09950ï70010
(09951ï07100)
Drive in depth: ï0.2 ï 0.6 mm (ï0.008 ï 0.024 in.)

C67280

18. INSTALL SHIFT LEVER NO.2 SHAFT OIL SEAL

(a) Apply MP grease to the lip of the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST SST 09950ï60010 (09951ï00320) 09950ï70010
(09951ï07100)
Drive in depth: 0 ï 1.0 mm (0 ï 0.039 in.)
19. INSTALL SHIFT LEVER SHAFT NO.2
(a) Apply MP grease to the shift lever shaft No. 2.
C67281

(b) Install the shift lever No. 2 and shift lever shaft No. 2 to the
housing.

C67277
41ï62
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY

(c) Using a screwdriver and hammer, tap in the 2 Eïrings to

the shift lever shaft No. 2.

C67282

20. INSTALL SHIFT LEVER SHAFT PIN

(a) Apply MP grease to the shift lever shaft pin.
(b) Install the shift lever shaft pin to the housing.

C67274

21. INSTALL SHIFT LEVER SHAFT PLUG

(a) Apply adhesive to a new plug.
Adhesive:
Part No. 08833ï00070, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Using a socket hexagon wrench (12 mm) and hammer,
tap in the plug to the housing.
Drive in depth: 1.7 ï 2.5 mm (0.067 ï 0.098 in.)
C67283

22. INSTALL SELECT SPRING SEAT

(a) Install the 2 spring seats and spring to the housing.

C67273

23. INSTALL SELECT SPRING SEAT NO.2

(a) Install the 2 spring seats No.2 and spring to the housing.

C67272
 41ï63
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY

24. INSTALL SHIFT & SELECT LEVER

(a) Install the shift & select lever and spring to the housing.

C67271

25. INSTALL SHIFT LEVER SHAFT

(a) Apply MP grease to the shift lever shaft.
(b) Install the shift lever shaft to the housing, spring seat and
shift & select lever.

C67270

26. INSTALL SHIFT & SELECT LEVER PIN OR BOLT

(a) Using a pin punch (5 mm) and hammer, tap in the shift &
select lever pin.

D27142

27. INSTALL SHIFT & SELECT LEVER SHAFT DUST

BOOT
(a) Install the dust boot to the housing.

C67269

28. INSTALL SHIFT OUTER LEVER NO.1

(a) Install the shift outer lever No. 1 to the shift lever shaft.

C67268
41ï64
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY

29. INSTALL SHIFT OUTER LEVER LEVER LOCK PIN

(a) Using a brass bar and hammer, tap in the lever lock pin.
(b) Install the nut and washer.
Torque: 20 N·m (204 kgf·cm, 15 ft·lbf)

C67284

30. INSTALL SELECT LEVER SHAFT SUBïASSY

(a) Apply MP grease to the select lever shaft.
(b) Install the select lever shaft to the housing.

C67266

31. INSTALL SELECT OUTER LEVER

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

C67265

32. INSTALL SELECT OUTER LEVER LOCK PIN

(a) Using a brass bar and hammer, tap in the lever lock pin.
(b) Install the nut and washer.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

C67285
 00ï

ALPHABETICAL INDEX
00ï2
ALPHABETICAL INDEX (A ï T)

A R
Page Page
ABBREVIATIONS USED IN THIS MANUAL REPAIR INSTRUCTION FOR MANUAL
(TERMS FOR MANUAL TRANSMISSION REPAIR MANUAL . . . . . . . . . . . . . 01ï4
TRANSMISSION REPAIR MANUAL) . . . . . . . . . . . . 01ï5
S
C
SERVICE DATA
COMPONENTS (COUNTER GEAR ASSY) . . . . . . . . . 41ï54 (MANUAL TRANSMISSION / TRANSAXLE) . . . . . . 03ï4
COMPONENTS (INPUT SHAFT ASSY) . . . . . . . . . . . . 41ï38 SHIFT LEVER SHAFT HOUSING ASSY . . . . . . . . . . . . 41ï57
COMPONENTS SPECIFIED TORQUE FOR STANDARD BOLTS
(MANUAL TRANSMISSION ASSY) . . . . . . . . . . . . . . 41ï2 (STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï2
COMPONENTS (OUTPUT SHAFT ASSY) . . . . . . . . . . 41ï42 STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï1
COMPONENTS
(SHIFT LEVER SHAFT HOUSING ASSY) . . . . . . . . 41ï57
COUNTER GEAR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . 41ï54
T
TERMS FOR MANUAL
G TRANSMISSION WORKSHOP MANUAL . . . . . . . . . 01ï5
TORQUE SPECIFICATION
GENERAL INFORMATION (MANUAL TRANSMISSION / TRANSAXLE) . . . . . . 03ï6
(HOW TO USE THIS MANUAL
TRANSMISSION REPAIR MANUAL) . . . . . . . . . . . . 01ï1
GLOSSARY OF SAE AND TOYOTA TERMS
(TERMS FOR MANUAL
TRANSMISSION REPAIR MANUAL) . . . . . . . . . . . . 01ï6

H
HOW TO DETERMINE BOLT STRENGTH
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï1
HOW TO DETERMINE NUT STRENGTH
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï3
HOW TO USE THIS MANUAL
TRANSMISSION REPAIR MANUAL . . . . . . . . . . . . . 01ï1

I
INPUT SHAFT ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï38

M
MANUAL TRANSMISSION / TRANSAXLE . . . . . . . . . . 03ï4
MANUAL TRANSMISSION ASSY . . . . . . . . . . . . . . . . . 41ï2
MANUAL TRANSMISSION SYSTEM . . . . . . . . . . . . . . . 41ï1
MANUAL TRANSMISSION/TRANSAXLE . . . . . . . . . . . 02ï1

O
OUTPUT SHAFT ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï42
OVERHAUL (COUNTER GEAR ASSY) . . . . . . . . . . . . . 41ï55
OVERHAUL (INPUT SHAFT ASSY) . . . . . . . . . . . . . . . . 41ï39
OVERHAUL (MANUAL TRANSMISSION ASSY) . . . . . 41ï6
OVERHAUL (OUTPUT SHAFT ASSY) . . . . . . . . . . . . . 41ï43
OVERHAUL
(SHIFT LEVER SHAFT HOUSING ASSY) . . . . . . . . 41ï58

P
PRECAUTION (REPAIR INSTRUCTION FOR
MANUAL TRANSMISSION REPAIR MANUAL) . . . . 01ï4
PREPARATION
(MANUAL TRANSMISSION/TRANSAXLE) . . . . . . . 02ï1
PROBLEM SYMPTOMS TABLE
(MANUAL TRANSMISSION SYSTEM) . . . . . . . . . . . 41ï1