Tools Required

1. Install the input shaft oil seal using the bushing seal installer DT 46497  (1).

Important:  Use only a new oil seal.

Important:  Coat the transaxle inner parts with gear fluid when installing.

2. Install the differential right side oil seal using the bushing, seal installer DT 46612 .

Notice: Refer to Fastener Notice in the Preface section.




3. Install the oil gutter with the bolt.
4. Install the oil level plug, including the steel gasket.

Tighten
Tighten the oil level plug to 25-30 N·m (18-22 lb ft).

5. Install the differential left side oil seal using the oil seal installer KM-519  (2).



6. Install the counter shaft RH bearing.
7. Install the differential assembly to the right side of the transaxle case.



8. Install the low and the high speed shift shaft assembly to the gear unit.

Important:  Be careful not to damage teeth of the counter shaft pinion and the differential ring gear.

9. Push the gear unit by matching it with the input and the counter shaft hole (1).



10. Install the 5th reverse gear shift shaft.

Important:  Install the 5th reverse gear shift shaft spring marked when removing.

11. Install the 5th reverse gear shift shaft ball and spring.

Tighten
Tighten the 5th reverse gear shift shaft ball and spring bolt to 10-16 N·m (7-12 lb ft).





Important:  Match the marking of the reverse idle gear shaft bolt hole with the protrusion of the transaxle case, right side.

12. Install the reverse idle gear shaft assembly (2).
13. Install the reverse gear shift lever (1).

Tighten
Tighten the bolts to 18-28 N·m (13-21 lb ft).

14. Install the left side case cap with the bolts, including O-ring (1).

Tighten
Tighten the bolt to 8-12 N·m (71-106 lb in).




15. Install the shift and select, and shaft needle bearings using needle bearing installer DT 47516  (1) with a needle remover DT 47515  (2).



16. Install the shift and select shaft oil seal.
17. Install the shift and select bellows.
18. Install the gear select spring assembles.
19. Install the gear shift interlock plate.
20. Install the gear shift lever.
21. Install the 5th reverse gear shift cam.
22. Install the return spring.
23. Install the shift and select shaft.




Important:  When installing inner and outer pins, make the crevices of 2 pins be symmetric to each other.

24. Install the shift and select lever inner and outer pins.



25. Coat the transaxle case with recommended Transaxle Case Sealant - THREE BOND 1215.
26. Install the transaxle left side case to the transaxle right side case.

Tighten
Tighten the bolts to 15-22 N·m (11-16 lb ft).




27. Install the 1st-2nd gear shift shaft ball, spring, and bolt (1).

Tighten
Tighten the bolt to 10-16 N·m (7-12 lb ft).

28. Install the 3rd-4th gear shift shaft ball, spring, and bolt (2).

Tighten
Tighten the bolt to 10-16 N·m (7-12 lb ft).

29. Install the reverse idle gear shaft bolt (3).

Tighten
Tighten the bolt to 18-28 N·m (13-21 lb ft).





Important:  Check if the bearing and the outer race are correctly installed by rotating the counter shaft.

30. Install the counter shaft bearing outer race (2) using the gear, bearing installer DT 46496 .



31. Measure clearance between the transaxle case surface and the bearing outer race using a straight ruler and gage.
32. Select shim in order that clearance is within standard. Refer to Manual Transmission Specifications .

•	Straight ruler (1)

•	Bearing outer race (2)

•	Case surface (3)





Important: Use only new screws.

33. Install the left case plate (2).

Tighten
Tighten the screws to 6-7 N·m (53-62 lb in).

34. Install the counter shaft 5th gear (3).

Important:  Position the machined boss side toward the side cover plate.

35. Insert the 5th gear bearing into the input shaft.
36. Install the 5th gear bearing, synchronizer ring, and wave spring, matching the synchronizer oil groove, and input shaft punched mark (1).



37. Install the synchronizer springs to hub (1).

Important: When assembling the synchronizer sleeve and hub, let distance (a) equal distance (b).

38. Install the synchronizer key (4).
39. Position the longer boss side of hub toward inner side (3).
40. Position the chamfered spline of sleeve toward inner side and install the hub to the sleeve (2).



41. Install the 5th gear fork to the synchronizer hub assembly.

Important:  Position the longer boss side of hub toward inner side and match the synchronizer key and the hub groove with the input shaft punched mark.

42. Install the 5th gear fork and the synchronizer hub assembly to the input shaft.



43. Push the 5th gear shift fork toward the 5th gear.

Important:  Use only new shift fork pin.

44. Install the 5th gear shift fork pin using a pin punch and a hammer (1).



45. Install the 5th gear synchronizer plate.
46. Install the 5th gear snap ring (1).

Important:  Use only new snap ring.

47. Install the 5th gear fork snap ring (2).
48. Tighten the fork plug after inserting the guide ball into the fork hole.



49. Push the fork toward the 5th gear.
50. Hold the input shaft using the input shaft holder DT 47517  (1).

Tighten
Tighten the 5th gear nut to 60-80 N·m (44-59 lb ft).

51. Caulk the nut using a chisel and a hammer.



52. Install the side cover (2) with recommended Side Cover Sealant - THREE BOND 1215 and side cover bolts (1).

Tighten
Tighten the side cover bolts to 8-12 N·m (71-106 lb in).

53. Install the shift interlock bolt.

Tighten
Tighten the shift interlock bolt to 18-28 N·m (13-21 lb ft).




54. Install the backup light switch (4).

Tighten
Tighten the nut to 15-18 N·m (11-13 lb ft).

55. Install the speedometer driven gear assembly (2).

Tighten
Tighten the bolt to 4-7 N·m (35-62 lb in).




56. Install the transaxle mount with bolts (2).

Tighten

•	Tighten the bolts to 50-60 N·m (37-44 lb ft).

•	Tighten the transaxle mount nut and bolts to 55-67 N·m (41-48 lb ft).

57. Install the related clutch parts. Refer to Clutch, Pressure Plate, and Pilot Bearing Replacement .
58. Install the transaxle assembly. Refer to Transmission Replacement .