Special Tools

J 35405 Differential Preload Wrench

1. Coat the sliding and rotating surfaces of the front differential side gear with gear oil.
2. Install the front No. 1 differential side gear thrust washers onto the front differential side gears.

Note: While rotating the front differential side gear, install the front differential pinions and front differential pinion thrust washers.

3. Install the front differential side gears, front differential pinions, and front differential pinion thrust washers onto the front differential case.



4. Coat the front No. 1 differential pinion shaft with MP grease.
5. Install the front No. 1 differential pinion shaft onto the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.



6. Adjust the front differential side gear backlash.
7. Install the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

Specification
Standard Backlash: 0.05-0.20 mm (0.0020-0.0079 in)

8. If the backlash is out of the specification, replace the side gear thrust washers.



9. Using a pin punch (3 mm) and a hammer, install the front differential pinion shaft straight pin onto the front differential case.



10. Using a chisel and a hammer, stake the front differential case hole.



11. Clean the contact surfaces of the front differential case and ring gear.
12. Using a heater, heat the front differential ring gear to 90-100°C (194-230°F).
13. After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.



14. Aligning the matchmarks (1), quickly install the front differential ring gear onto the front differential case.

Caution: Refer to Fastener Caution in the Preface section.

15. Install the bolts and tighten to 77 N·m (57 lb ft).



16. Install the speedometer drive gear onto the front differential case.



17. Coat the No. 2 transmission hub sleeve with gear oil.
18. Install the synchromesh shifting key springs and synchromesh shifting keys to the No. 2 transmission clutch hub.




Note: Position the No. 2 transmission hub sleeve and No. 2 transmission clutch hub correctly together.

19. Install the No. 2 transmission clutch hub onto the No. 2 transmission hub sleeve.



20. Coat the 3rd gear needle roller bearing with gear oil and install it onto the input shaft.



21. Coat the 3rd gear with gear oil and install it onto the input shaft.



22. Coat the 3rd gear synchronizer ring with gear oil and install it onto the 3rd gear.




Note: Fit the synchromesh shifting keys into the grooves of the synchronizer ring correctly.

23. Using a press, install the No. 2 transmission clutch hub (1) onto the input shaft.



24. Select a snap ring that will allow minimum axial play. Refer to Manual Transmission Specifications for Snap Ring Thickness 1.

Specification
Standard Clearance: 0.1 mm (0.0039 in) or less

25. Using a brass bar and a hammer, install the snap ring onto the input shaft.



26. Coat the 4th gear synchronizer ring with gear oil and install it onto the No. 2 transmission clutch hub.



27. Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil and install them onto the No. 2 transmission clutch hub.



28. Coat the 4th gear with gear oil and install it onto the input shaft.



29. Using a press (1), install the input shaft rear radial ball bearing onto the input shaft.



30. Select a snap ring that will allow minimum axial play. Refer to Manual Transmission Specifications for Snap Ring Thickness 2.

Specification
Standard Clearance: 0.1 mm (0.0039 in) or less

Note: Do not damage the journal surface of the snap ring.

31. Using a brass bar and a hammer, install the snap ring onto the input shaft.
32. Inspect the 3rd gear radial clearance.



33. Using a dial indicator, measure the 3rd gear radial clearance.

Specifications

•	Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)

•	Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)

•	Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)

•	Maximum clearance, KOYO made bearing - 0.058 mm (0.0022 in)

34. If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.
35. Inspect the 4th gear radial clearance.



36. Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

Specifications

•	Standard clearance, NSK made bearing - 0.009-0.050 mm (0.0003-0.0019 in)

•	Standard clearance, KOYO made bearing - 0.009-0.050 mm (0.0003-0.0019 in)

•	Maximum clearance, NSK made bearing - 0.050 mm (0.0019 in)

•	Maximum clearance, KOYO made bearing - 0.050 mm (0.0019 in)

37. If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.
38. Inspect the 3rd gear thrust clearance.



39. Using a dial indicator, measure the 3rd gear thrust clearance.

Specifications

•	Standard clearance - 0.10-0.35 mm (0.0039-0.0138 in)

•	Maximum clearance - 0.35 mm (0.0138 in)

40. If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.



41. Inspect the 4th gear thrust clearance.
42. Using a feeler gage, measure the 4th gear thrust clearance.

Specifications

•	Standard clearance - 0.10-0.55 mm (0.0039-0.0217 in)

•	Maximum clearance - 0.55 mm (0.0217 in)

43. If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.



44. Inspect the reverse gear.
45. Using vernier calipers, measure the width of the reverse gear groove (a) and the thickness of the claw part on the reverse shift fork (b), and calculate the clearance.

Specifications
Standard Clearance (a-b): 0.15-0.35 mm (0.0059-0.0138 in)

46. If the clearance is out of the specification, replace the reverse gear and reverse shift fork.



47. Inspect that the No. 1 transmission clutch hub and reverse gear slide smoothly.
48. Inspect that the edges of the reverse gear spline gear are not worn down.



49. Coat the reverse gear and No. 1 transmission clutch hub with gear oil.
50. Install the synchromesh shifting key springs and synchromesh keys to the No. 1 transmission clutch hub.




Note: Position the reverse gear and No. 1 transmission clutch hub correctly.

51. Install the reverse gear onto the No. 1 transmission clutch hub assembly.



52. Coat the 1st gear thrust washer pin or ball (1) with MP grease and install it onto the output shaft.



53. Coat the 1st gear thrust washer (1) with gear oil and install it onto the output shaft.



54. Coat the 1st gear needle roller bearing (1) with gear oil and install it onto the output shaft.



55. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
56. Install the inner ring onto the 1st gear.



57. Install the middle ring onto the 1st gear.



58. Install the outer ring onto the 1st gear.



59. Coat the 1st gear with gear oil and install it onto the output shaft.




Note: 

•	The 1st gear can be turned.

•	While checking that the 1st gear thrust washer pin or ball is inserted into the groove of the 1st gear thrust washer, press and fit the No. 1 clutch hub.

60. Using a press, install the No. 1 transmission clutch hub (1) onto the output shaft.



61. Select a snap ring that will allow minimum axial play. Refer to Manual Transmission Specifications for Snap Ring Thickness 3.

Specification
Standard Clearance: 0.1 mm (0.004 in)

62. Using a brass bar and a hammer, install the snap ring onto the output shaft.



63. Coat the 2nd gear needle roller bearing (1) and 2nd gear bearing spacer with gear oil, and install them onto the output shaft.



64. Coat the 2nd gear cone and No. 2 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
65. Install the inner ring onto the 2nd gear.



66. Install the middle ring onto the 2nd gear.



67. Install the outer ring onto the 2nd gear.



68. Coat the 2nd gear with gear oil and install it onto the output shaft.



69. Using a press, install the 3rd driven gear (1) onto the output shaft.



70. Install the output gear spacer (1) onto the output shaft.



71. Using a press (1), install the 4th driven gear onto the output shaft.



72. Using a press (1), install the output shaft rear bearing onto the output shaft.



73. Using a dial indicator, measure the 2nd gear radial clearance.

Specifications

•	Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0006-0.0022 in)

•	Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0006-0.0023 in)

•	Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)

•	Maximum clearance, KOYO made bearing - 0.058 mm (0.0023 in)

74. If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or input shaft.



75. Using a dial indicator, measure the 1st gear radial clearance.

Specifications

•	Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0006-0.0022 in)

•	Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0006-0.0023 in)

•	Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)

•	Maximum clearance, KOYO made bearing - 0.058 mm (0.0023 in)

76. If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or input shaft.



77. Using a dial indicator, measure the 2nd gear thrust clearance.

Specifications

•	Standard Clearance - 0.010-0.55 mm (0.0006-0.0022 in)

•	Maximum Clearance - 0.055 mm (0.0217 in)

78. If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.



79. Using a feeler gage, measure the 1st gear thrust clearance.

Specifications

•	Standard Clearance - 0.010-0.40 mm (0.0039-0.0157 in)

•	Maximum Clearance - 0.40 mm (0.0157 in)

80. If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear or No. 1 transmission clutch hub.



81. Using a caliper gage, inspect the reverse idler gear.

Specifications

•	Standard inside diameter - 18.040-18.058 mm (0.7102-0.7109 in)

•	Maximum inside diameter - 18.058 mm (0.7109 in)

82. If the inside diameter exceeds the maximum, replace the reverse idler gear sub-assembly.
83. Using a micrometer, inspect the reverse idler gear shaft.

Specifications

•	Standard outer diameter - 17.966-17.984 mm (0.7073-0.7080 in)

•	Minimum outer diameter - 17.966 mm (0.7073 in)

84. If the outer diameter is less than the minimum, replace the reverse idler gear shaft.




Note: Insert the output shaft cover key into the case groove.

85. Coat the output shaft cover with MP grease and install it onto the transaxle case.



86. Coat a new output shaft front bearing with gear oil.

Note: 

•	Install the new bearing in the correct direction.

•	When replacing the output shaft front bearing, replace the output shaft front bearing inner race at the same time.

87. Using a press (1), install it onto the transaxle case.



88. Coat the lip of the front transaxle case oil seal with MP grease.
89. Using a suitable driver (2) and a hammer (1), install a new front transaxle case oil seal onto the transaxle case.

Specification
Driven in depth - 15.6-16.0 mm (0.6141-0.6299 in)




90. Coat a new input shaft front bearing with gear oil, and using a press (1), install it onto the transaxle case.

Specification
Driven in depth - 0-0.3 mm (0-0.0118 in)




91. Using a suitable driver (1) and a hammer, install a new shift and select lever shaft slide ball bearing onto the manual transmission case.

Specification
Driven in depth - 0-0.5 mm (0-0.020 in)




92. Install a new shift and select lever shaft oil seal (1) onto the manual transmission case.

Specification
Driven in depth - 9.7-10.3 mm (0.382-0.406 in)




93. Using a press (1), install a new front differential case front tapered roller bearing (inner race) onto the front differential case.



94. Using a press (1), install the front differential case front tapered roller bearing (outer race) together with the plate washer onto the transaxle case.



95. Using a press (1), install a new front differential case rear tapered roller bearing (inner race) to the differential case.




Note: Use a plate washer of the same thickness as the removed one.

96. Using a press (1), install the front differential case rear tapered roller bearing (outer race) with the plate washer onto the manual transmission case.



97. Coat the differential case assembly with gear oil and install it onto the transaxle case.
98. Install the manual transmission case with the bolts and tighten to 29 N·m (22 lb ft).





99. Using J 35405 wrench , check the preload.

Preload

•	New bearing: 0.78-1.57 N·m (6.9-13.89 lb in)

•	Used bearing: 0.49-0.98 N·m (4.34-8.67 lb in)

100. If the preload is out of the specification, select a different plate washer. Refer to Manual Transmission Specifications for Plate Washer Thickness.

Note: The preload changes by approximately 0.3-0.4 N·m (2.6-3.5 lb in) per each 0.05 mm (0.0020 in) change in the plate washer thickness.

101. Remove the bolts and the manual transmission case.
102. Remove the differential case assembly from the transaxle case.



103. Coat the lip of the front transmission case oil seal with MP grease.
104. Using a suitable driver (1) and a hammer, install a new transmission case oil seal onto the manual transmission case.

Specification
Driven in depth: 9.6-10.2 mm (0.378-0.402 in)




105. Coat the lip of the transaxle case oil seal with MP grease.
106. Using a suitable driver (1) and a hammer, install a new transaxle case oil seal onto the transaxle case.

Specification
Driven in depth: 1.6-2.2 mm (0.063-0.087 in)




107. Clean the transmission magnet and install it onto the transaxle case.



108. Install the bearing lock plate onto the transaxle case with the bolt (1) and tighten to 11 N·m (97 lb in).




Note: 

•	Do not deform the No. 1 oil receiver pipe.

•	Install the No. 1 oil receiver pipe while holding it against the manual transmission case.

109. Install the No. 1 oil receiver pipe onto the manual transmission case with the bolt and tighten to 17 N·m (13 lb ft).




Note: 

•	Do not deform the No. 2 oil receiver pipe.

•	Install the No. 2 oil receiver pipe (1) while holding it against the manual transmission case.

110. Install the No. 2 oil receiver pipe onto the manual transmission case with the bolt and tighten to 17 N·m (13 lb ft).




Note: Set the reverse restrict pin assembly in the correct direction.

111. Install the reverse restrict pin assembly onto the manual transmission case.



112. Using a pin punch (5 mm) and a hammer, install the slotted spring pin onto the reverse restrict pin assembly.

Specification
Drive in depth: 15.5-16.5 mm (0.6102-0.6496 in)




113. Apply Three Bond 1344 or equivalent sealant to the reverse restrict pin plug.
114. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug onto the manual transmission case and tighten to 13 N·m (115 lb in).



115. Install the manual transaxle case receiver onto the transaxle case with the bolt (1) and tighten to 11 N·m (97 lb in).



116. Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the transaxle case.



117. Coat the sliding and rotating surfaces of the input and output shafts with gear oil and install them onto the transaxle case.




Note: Align the mark (1) on the reverse idler gear shaft with the bolt hole.

118. Coat the reverse idler gear sub-assembly, thrust washer, and reverse idler gear shaft with gear oil, and install them.



119. Coat the No. 1 gear shift fork (1) and No. 2 gear shift fork (2) with gear oil and install them.



120. Coat the No. 1 gear shift fork (2) shaft with gear oil and install it.
121. Apply three bond 1344 sealant, or equivalent, to the shift fork set bolt.
122. Install the shift fork set bolt (2) and tighten to 16 N·m (12 lb ft).



123. Using a brass bar and a hammer, install a new shaft snap ring onto the No. 1 gear shift fork shaft.



124. Coat the shift fork balls (1) with MP grease and install them onto the reverse shift fork.
125. Install the reverse shift fork onto the No. 3 gear shift fork shaft.



126. Using a brass bar and a hammer, install new shift fork shaft snap rings (1, 2) onto the No. 3 shift fork shaft.



127. Coat the No. 3 gear shift fork shaft with gear oil and install it.




Note: To avoid interference by the shift fork balls, lift up the No. 3 gear shift fork shaft to the position.

128. Coat the No. 1 gear shift head and No. 2 gear shift fork shaft with gear oil and install them.



129. Coat the shift lock bolts (1, 2) with three bond 1344 sealant, or equivalent, and install them onto the No. 2 gear shift fork and No. 1 shift head. Tighten the bolts to 16 N·m (12 lb ft).



130. Install the reverse shift arm bracket assembly onto the front transaxle case with the bolts (1, 2) and tighten to 17 N·m (13 lb ft).



131. Apply three bond 1281 sealant (1), or equivalent, to the manual transmission case.



132. Install the bolts (1-13) onto the manual transmission side and tighten to 29 N·m (22 lb ft).



133. Coat the bolts (1-3) with three bond 1344 sealant, or equivalent, and install them onto the manual transaxle side. Tighten the bolts to 29 N·m (22 lb ft).



134. Coat the reverse idler gear shaft bolt (1) with three bond 1344 sealant, or equivalent, and install it with a new gasket. Tighten the bolt to 29 N·m (22 lb ft).



135. Coat the No. 2 lock ball assembly with three bond 1344 sealant, or equivalent, and install it using a hexagon wrench. Tighten the bolts to 29 N·m (22 lb ft).



136. Install the shift detent balls, shift detent ball springs, and shift spring seats onto the manual transmission case.



137. Coat the threads of the shift detent ball plugs with three bond 1344 sealant, or equivalent, and install them using a hexagon wrench. Tighten the bolts to 22 N·m (16 lb ft).



138. Install the shift detent ball, shift detent ball compression spring, and spring seat onto the transaxle case.



139. Coat the threads of the shift detent ball plug with three bond 1344 sealant, or equivalent, and install it using a hexagon wrench. Tighten the bolts to 22 N·m (16 lb ft).



140. Using a snap ring expander, install a new input shaft rear bearing hole snap ring onto the input shaft.



141. Using a snap ring expander, install a new output shaft rear bearing hole snap ring onto the output shaft.



142. Using a brass bar and a hammer, install a new shift fork shaft snap ring onto the No. 2 shift fork shaft.



143. Coat the bolts with three bond 1344 sealant, or equivalent, and install the rear bearing retainer onto the manual transmission case with the bolts. Tighten the bolts to 27 N·m (20 lb ft).



144. Using a suitable tool (1,2), install the 5th driven gear onto the output shaft.



145. Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them onto the input shaft.



146. Coat the 5th gear with gear oil and install it onto the input shaft.



147. Coat the No. 3 synchronizer ring with gear oil and install it onto the 5th gear.




Note: Do not set the shifting key spring openings in the same position.

148. Install the synchromesh shifting keys and synchromesh shifting key springs onto the No. 3 transmission clutch hub.




Note: 

•	Do not install the No. 3 transmission clutch hub in the wrong direction.

•	Install the No. 3 transmission clutch hub with the No. 3 synchronizer ring key groove and the No. 3 synchromesh shifting key aligned.

•	Check that the 5th gear can rotate smoothly.

•	Place a suitable sized wooden block to support the input shaft.

149. Using a suitable driver (1) and a hammer, install the No. 3 transmission clutch hub onto the input shaft.
150. Select a snap ring that will allow minimum axial play. Refer to Manual Transmission Specifications for Snap Ring Thickness 4.



151. Using a brass bar and a hammer, install a new snap ring onto the input shaft.



152. Using a dial indicator, measure the 5th gear thrust clearance.

Specification

•	Standard clearance: 0.10-0.55 mm (0.0039-0.0217 in)

•	Maximum clearance: 0.55 mm (0.0217 in)

153. If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.



154. Using a dial indicator, measure the 5th gear radial clearance.

Specification

•	Standard clearance: NSK made bearing: 0.015-0.05  mm (0.0006-0.0022 in)

•	Standard clearance: KOYO made bearing: 0.015-0.058 mm (0.0006-0.0023 in)

•	Maximum clearance: NSK made bearing: 0.056 mm (0.0022 in)

•	Maximum clearance: KOYO made bearing: 0.058 mm (0.0023 in)

155. If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.




Note: Set the No. 3 transmission clutch hub in the correct direction.

156. Coat the No. 3 transmission clutch hub sleeve with gear oil and install it together with the No. 3 gear shift fork onto the No. 3 transmission clutch hub.



157. Coat the gear shift fork lock bolt with three bond 1344 sealant, or equivalent, and install it onto the No. 3 gear shift fork. Tighten the bolt to 16 N·m (12 lb ft).



158. Engage the gears simultaneously to lock the transmission.
159. Install a new manual transmission output shaft rear nut and tighten to 118 N·m (87 lb ft).



160. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
161. Disengage the gears.




Note: Assemble the parts within 10 minutes of application. Otherwise, the sealant must be removed and reapplied.

162. Apply three bond 1344 sealant (1), or equivalent, to the manual transmission case cover sub-assembly.



163. Install the manual transmission case cover sub-assembly with the bolts onto the manual transmission case and tighten to 21 N·m (15 lb ft).



164. Coat the shift and select lever shaft assembly with gear oil and install it onto the transmission case.



165. Using a suitable driver (1) and a hammer, install a new control shaft cover oil seal onto the control shaft cover.

Specification
Driven in depth: 0.2-1.2 mm (0.0079-0.0472 in)

166. Coat the control shaft cover oil seal with MP grease.




Note: Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.

167. Coat the threads of the bolts (1-4) with sealant, three bond 1344 or equivalent.

Install a new gasket and the control shaft cover onto the manual transmission case with the bolts and tighten to 20 N·m (14 lb ft).




168. Coat the threads of the shift guide pin with sealant, three bond 1344 or equivalent.
169. Install the washer and shift guide pin (1) and tighten the bolts to 11 N·m (97 lb in).



170. Coat the threads of the No. 1 lock ball assembly (1) with three bond 1344 sealant, or equivalent, and install it onto the manual transmission case. Tighten the bolts to 29 N·m (22 lb ft).



171. Install the dust boot onto the control shaft cover.
172. Install the shift lever damper with the lock pin onto the shift and select lever shaft assembly.
173. Install the washer with the nut (1) and tighten the bolts to 12 N·m (106 lb in).



174. Install the dust boot onto the shift and select lever shaft oil seal.
175. Install the floor shift control shift lever with the lock pin onto the shift and select lever shaft assembly.
176. Install the washer with the nut (1) and tighten the bolts to 12 N·m (106 lb in).




Note: Apply MP grease to the inside circumferential surface of the control shift lever bush.

177. Install the selecting bellcrank assembly together with the control bellcrank dust cover onto the manual transmission case with the bolts (1, 2) and nut (3).

•	Tighten the bolts to 25 N·m (18 lb ft).

•	Tighten the nuts to 12 N·m (106 lb in).

178. Install the back-up light switch assembly onto the manual transmission case with a new gasket and tighten to 40 N·m (30 lb ft).
179. Install the back-up light switch wire harness into the clamps.
180. Install a new O-ring onto the speedometer driven hole cover sub-assembly.



181. Install the speedometer driven hole cover sub-assembly onto the manual transaxle case with the bolt and tighten to 11 N·m (97 lb in).



182. Install the manual transmission filler plug onto the manual transmission case with a new gasket and tighten to 39 N·m (29 lb ft).



183. Install the drain plug onto the manual transmission case with a new gasket and tighten to 39 N·m (29 lb ft).