MANUAL TRANSMISSION

• HEADINGS
  • Special Tools
  • Service Precautions
  • Reverse Lockout System
    • General Troubleshooting Information
      • How to Troubleshoot Circuits at the ECM
    • Component Location Index
    • System Description
    • Circuit Diagram
    • Circuit Troubleshooting
    • Reverse Lockout Solenoid Test
    • Reverse Lockout Solenoid Disassembly/Reassembly
  • Manual Transmission
    • Transmission Fluid Inspection and Replacement
    • Back-up Light Switch Test
    • Transmission Removal
    • Transmission Installation
    • Transmission Disassembly
      • Exploded View - Clutch Housing
      • Exploded View - Transmission Housing
    • Reverse Shift Fork Clearance Inspection
    • Change Lever Clearance Inspection
    • Change Lever Assembly Disassembly/Reassembly
    • Shift Fork Clearance Inspection
    • Shift Fork Disassembly/Reassembly
    • Mainshaft Assembly Clearance Inspection
    • Mainshaft Disassembly
    • Mainshaft Inspection
    • Mainshaft Reassembly
      • Exploded View
    • Countershaft Assembly Clearance Inspection
    • Countershaft Disassembly
    • Countershaft Inspection
    • Countershaft Reassembly
      • Exploded View
    • Synchro Sleeve and Hub Inspection and Reassembly
    • Synchro Ring and Gear Inspection
    • Mainshaft Bearing and Oil Seal Replacement
    • Countershaft Bearing Replacement
    • Mainshaft Thrust Clearance Adjustment
    • Transmission Reassembly
    • Gearshift Mechanism Replacement
  • M/T Differential
    • Component Location Index
    • Backlash Inspection
    • Differential Carrier, Final Driven Gear Replacement
    • Carrier Bearing Replacement
    • Oil Seal Replacement
    • Differential Thrust Clearance Adjustment
• FIGURES
  • Fig. 1: Identifying Manual Transmission Special Tools
  • Fig. 2: Connecting Backprobe Adapters To Stacking Patch Cords And Connect Cords To Digital Multimeter
  • Fig. 3: Disconnecting Connector And Probe Terminals From Terminal Side
  • Fig. 4: Component Location Index
  • Fig. 5: Identifying Reverse Lockout Mechanism
  • Fig. 6: Manual Transmission Circuit Diagram
  • Fig. 7: Measuring Voltage Between Reverse Lockout Solenoid 2P Connector Terminal No. 2 And Body Ground
  • Fig. 8: Connecting 2P Connector Terminal No. 2 To Battery Positive Terminal And Terminal No. 1 To Battery Negative Terminal
  • Fig. 9: Measuring Voltage Between ECM Connector E2 And Body Ground
  • Fig. 10: Connecting Battery Positive Terminal To Reverse Lockout Solenoid 2P Connector No. 2 Terminal And Battery Negative Terminal To No. 1 Terminal
  • Fig. 11: Identifying Bolts And Reverse Lockout Solenoid
  • Fig. 12: Identifying Roller, Select Lock Return Spring And Select Lock Cam
  • Fig. 13: Identifying Reverse Lockout Solenoid, Bolts & w/Torque Spec.
  • Fig. 14: Identifying Filler Plug, Washer And Fluid Proper Level
  • Fig. 15: Identifying Drain Plug w/Torque Specs.
  • Fig. 16: Identifying Back-Up Light Switch Connector w/Torque Spec.
  • Fig. 17: Identifying Liquid Gasket, P/N 08718-0001 And 2 mm Bead Around Mating Surface Of Transmission Housing
  • Fig. 18: Securing Hood In Its Vertical Position (Support Rod In Lower Hole)
  • Fig. 19: Identifying Slave Cylinder And Clutch Line
  • Fig. 20: Identifying Cable Bracket And Shift Cables
  • Fig. 21: Identifying Output Shaft (Countershaft) Speed Sensor Connector, Back-Up Light Switch Connector And Reverse Lockout Solenoid Connector
  • Fig. 22: Identifying Secondary Heated Oxygen Sensor Connector And Bracket
  • Fig. 23: Identifying Front Engine Mount Stop And Front Mount Bolt
  • Fig. 24: Identifying Rear Engine Mount Stop
  • Fig. 25: Identifying Upper Transmission Mounting Bolts
  • Fig. 26: Identifying Return Hose And Power Steering Fluid Reservoir
  • Fig. 27: Identifying Engine Hanger Adapter
  • Fig. 28: Identifying Engine Support Hanger, Hook, Engine Hanger Adapter And Wingnut
  • Fig. 29: Identifying Transmission Mount Bracket And Ground Cable
  • Fig. 30: Identifying Reference Mark Across Steering Joint And Steering Gearbox Pinion Shaft
  • Fig. 31: Identifying Splash Shield
  • Fig. 32: Identifying Power Steering Pressure Switch Connector
  • Fig. 33: Identifying Exhaust Pipe A
  • Fig. 34: Identifying Rear Engine Mount Lower Bracket Mounting Bolts
  • Fig. 35: Identifying Lower Transmission Mount Mounting Nuts
  • Fig. 36: Identifying Middle Subframe Mounting Bracket
  • Fig. 37: Identifying Mark At Both Ends Of Subframe
  • Fig. 38: Attaching Subframe Adapter To Subframe
  • Fig. 39: Identifying Front Suspension Subframe Stiffeners And Front Suspension Subframe
  • Fig. 40: Identifying Front Engine Mount Upper Bracket
  • Fig. 41: Identifying Shift Cable Bracket And Rear Engine Mount Upper Mounting Bolt
  • Fig. 42: Identifying Rear Engine Mount Upper Bracket
  • Fig. 43: Identifying Clutch Cover
  • Fig. 44: Identifying Lower Transmission Mounting Bolts
  • Fig. 45: Identifying Transmission Lower Mounts And Mount Bracket Collars
  • Fig. 46: Identifying Release Fork Boot, Release Fork, Release Bearing And Clutch Housing
  • Fig. 47: Identifying Dowel Pins
  • Fig. 48: Identifying Mount Bracket Collars And Transmission Lower Mounts w/Torque Specs.
  • Fig. 49: Identifying Lower Transmission Mounting Bolts w/Torque Specs.
  • Fig. 50: Identifying Clutch Cover w/Torque Specs.
  • Fig. 51: Identifying Rear Engine Mount Upper Bracket w/Torque Specs.
  • Fig. 52: Identifying Rear Engine Mount Upper Mounting Bolt And Shift Cable Bracket w/Torque Specs.
  • Fig. 53: Identifying Front Engine Mount Upper Bracket w/Torque Spec.
  • Fig. 54: Supporting Subframe With Subframe Adapter And Jack
  • Fig. 55: Identifying Front Suspension Subframe And Front Suspension Subframe Stiffeners w/Torque Specs.
  • Fig. 56: Identifying Reference Mark At Both Ends Of Subframe
  • Fig. 57: Identifying Middle Subframe Mounting Bracket w/Torque Specs.
  • Fig. 58: Identifying Lower Transmission Mount Mounting Nuts w/Torque Spec.
  • Fig. 59: Identifying Rear Engine Mount Lower Bracket Mounting Bolts w/Torque Spec.
  • Fig. 60: Identifying Exhaust Pipe And Gaskets w/Torque Specs.
  • Fig. 61: Identifying Power Steering Pressure Switch Connector
  • Fig. 62: Identifying Splash Shield
  • Fig. 63: Identifying Steering Gearbox Pinion Shaft, Wire, Joint Yoke & Torque Spec.
  • Fig. 64: Identifying Mount Bracket Collars, Transmission Mount Bracket, Ground Cable & Torque Specs.
  • Fig. 65: Identifying Power Steering Pump, Hose Clamp, Return Hose, Power Steering Fluid Reservoir& Torque Specs.
  • Fig. 66: Identifying Upper Transmission Mounting Bolts w/Torque Spec.
  • Fig. 67: Identifying Rear Engine Mount Stop w/Torque Spec.
  • Fig. 68: Identifying Engine Mount Mounting Bolt, Front Engine Mount Stop & Torque Specs.
  • Fig. 69: Identifying Bracket And Secondary Heated Oxygen Sensor Connector w/Torque Spec.
  • Fig. 70: Identifying Reverse Lockout Solenoid Connector And Back-Up Light Switch Connector
  • Fig. 71: Identifying Cable Bracket, Cables & Torque Spec.
  • Fig. 72: Identifying Grease Applying Area & Torque Specs.
  • Fig. 73: Exploded View Of Clutch Housing
  • Fig. 74: Exploded View Of Transmission Housing
  • Fig. 75: Identifying Detent Bolts, Back-Up Light Switch And Transmission Hanger
  • Fig. 76: Identifying Harness Bracket, Interlock Bolt, Change Lever Assembly And Dowel Pins
  • Fig. 77: Identifying Filler Plug, Output Shaft (Countershaft) Speed Sensor, And Mount Bracket Collars
  • Fig. 78: Identifying Transmission Hangers, Harness Bracket And Mount Bracket Collars
  • Fig. 79: Identifying Sealing Cap, Snap Ring, Transmission Housing And Dowel Pins
  • Fig. 80: Identifying Reverse Idler Gear, Reverse Gear Shaft And Thrust Washer
  • Fig. 81: Identifying Reverse Shift Fork
  • Fig. 82: Identifying Mainshaft Assembly, Countershaft Assembly, Shift Forks And Clutch Housing
  • Fig. 83: Identifying Differential Assembly And Magnet
  • Fig. 84: Identifying Oil Gutter Plate, Shim And Oil Guide Plate
  • Fig. 85: Identifying Drain Plug, Drain Plug Washer And Release Bearing Guide
  • Fig. 86: Measuring Clearance Between Reverse Idler Gear And Reverse Shift Fork
  • Fig. 87: Identifying Width Of Reverse Shift Fork
  • Fig. 88: Measuring Clearance Between Change Lever And Select Lever
  • Fig. 89: Identifying Groove Of Change Lever
  • Fig. 90: Exploded View Of Change Lever Assembly w/Torque Spec.
  • Fig. 91: Measuring Clearance Between Shift Fork And Synchro Sleeve
  • Fig. 92: Identifying Thickness Of Shift Fork Fingers
  • Fig. 93: Measuring Clearance Between Shift Fork And Shift Arm
  • Fig. 94: Identifying Width Of Shift Arm
  • Fig. 95: Identifying Shift Forks
  • Fig. 96: Pushing Down On Mainshaft
  • Fig. 97: Identifying Thickness Of 3rd Gear
  • Fig. 98: Measuring Clearance Between 4th Gear And Distance Collar
  • Fig. 99: Identifying Length Of Distance Collar
  • Fig. 100: Identifying Thickness Of 4th Gear
  • Fig. 101: Measuring Clearance Between Distance Collar And 5th Gear
  • Fig. 102: Identifying Length Of Distance Collar
  • Fig. 103: Identifying Thickness Of 5th Gear
  • Fig. 104: Measuring Clearance Between 6th Gear And Angular Ball Bearing
  • Fig. 105: Identifying Length Of Distance Collar
  • Fig. 106: Identifying Thickness Of 6th Gear
  • Fig. 107: Removing Angular Ball Bearing And Tapered Cone Ring
  • Fig. 108: Pressing Mainshaft Out Of 5th/6th Synchro Hub
  • Fig. 109: Pressing Mainshaft Out Of 3rd/4th Synchro Hub
  • Fig. 110: Identifying Mainshaft Inspection Points
  • Fig. 111: Measuring Mainshaft Runout
  • Fig. 112: Exploded View Of Mainshaft Reassembly
  • Fig. 113: Installing Double Cone Synchro Assembly
  • Fig. 114: Installing 3rd/4th Synchro Hub
  • Fig. 115: Installing 3rd/4th Synchro Hub
  • Fig. 116: Identifying 3rd/4th Synchro Sleeve
  • Fig. 117: Identifying Synchro Spring And Double Cone Synchro Assembly
  • Fig. 118: Installing 4th Gear
  • Fig. 119: Installing Double Cone Synchro Assembly
  • Fig. 120: Installing 5th/6th Synchro Hub
  • Fig. 121: Installing 5th/6th Synchro Hub
  • Fig. 122: Identifying Synchro Spring And Double Cone Synchro Assembly
  • Fig. 123: Installing 6th Gear
  • Fig. 124: Installing Angular Ball Bearing
  • Fig. 125: Measuring Clearance Between 1st Gear And Distance Collar
  • Fig. 126: Identifying Length Of Distance Collar
  • Fig. 127: Identifying Thickness Of 1st Gear
  • Fig. 128: Measuring Clearance Between 2nd Gear And 3rd Gear
  • Fig. 129: Identifying Length Of Distance Collar
  • Fig. 130: Identifying Thickness Of 2nd Gear
  • Fig. 131: Removing Special Bolt
  • Fig. 132: Pressing Countershaft Out Of Ball Bearing
  • Fig. 133: Pressing Countershaft Out Of 5th Gear
  • Fig. 134: Pressing Countershaft Out Of 3rd Gear
  • Fig. 135: Identifying Countershaft Inspection Points
  • Fig. 136: Measuring Countershaft Runout
  • Fig. 137: Exploded View Of Countershaft Assembly w/Torque Spec.
  • Fig. 138: Installing Triple Cone Synchro Assembly And Synchro Spring
  • Fig. 139: Installing 1st/2nd Synchro Hub
  • Fig. 140: Installing Synchro Spring And Triple Cone Synchro Assembly
  • Fig. 141: Installing Distance Collar And Friction Damper
  • Fig. 142: Installing 2nd Gear
  • Fig. 143: Installing 3rd Gear
  • Fig. 144: Installing 4th Gear
  • Fig. 145: Installing 5th Gear
  • Fig. 146: Installing 6th Gear
  • Fig. 147: Installing Ball Bearing
  • Fig. 148: Measuring Clearance Between Bearing And Shim
  • Fig. 149: Pressing Countershaft Out Of Ball Bearing
  • Fig. 150: Installing 6th Gear
  • Fig. 151: Installing Ball Bearing
  • Fig. 152: Tightening Special Bolt w/Torque Spec.
  • Fig. 153: Installing Synchro Hub In Synchro Sleeve
  • Fig. 154: Identifying Synchro Ring And Synchro Ring Teeth
  • Fig. 155: Identifying Synchro Sleeve Teeth
  • Fig. 156: Identifying Thrust Surface On Gear Hub
  • Fig. 157: Measuring Clearance Between Gear And Synchro Ring
  • Fig. 158: Removing Ball Bearing
  • Fig. 159: Removing Oil Seal
  • Fig. 160: Installing Oil Seal
  • Fig. 161: Installing Ball Bearing
  • Fig. 162: Identifying Bearing Set Plate And Clutch Housing
  • Fig. 163: Removing Needle Bearing
  • Fig. 164: Installing Needle Bearing
  • Fig. 165: Identifying Bearing Set Plate Bolts w/Torque Spec.
  • Fig. 166: Identifying Shim And Transmission Housing
  • Fig. 167: Identifying 3rd/4th Synchro Hub, 5th/6th Synchro Hub, Distance Collar And Ball Bearing
  • Fig. 168: Identifying Distance Between End Of Clutch Housing And Bearing Inner Race
  • Fig. 169: Identifying Shim, And Oil Guide Plate M And Transmission Housing
  • Fig. 170: Identifying Spring Washer And Clutch Housing Side Ball Bearing
  • Fig. 171: Identifying Mainshaft Base, Mainshaft Holder And Mainshaft Holder Bolt
  • Fig. 172: Measuring Mainshaft End Play
  • Fig. 173: Identifying Release Bearing Guide, Drain Plug Washer And Drain Plug
  • Fig. 174: Identifying Magnet And Differential Assembly
  • Fig. 175: Identifying Spring Washer, Countershaft, Shift Forks And Ball Bearing
  • Fig. 176: Identifying Reverse Shift Fork
  • Fig. 177: Identifying Shim, Thrust Washer, Reverse Idler Gear And Reverse Gear Shaft
  • Fig. 178: Identifying Shim, Oil Gutter Plate And Transmission Housing
  • Fig. 179: Identifying Transmission Housing Sealing Surface Of Clutch Housing
  • Fig. 180: Expanding Snap Ring
  • Fig. 181: Identifying Countershaft Bearing Groove Dimension
  • Fig. 182: Identifying Bead Dimension Around Mating Surface Of Transmission Housing
  • Fig. 183: Identifying Transmission Hangers, Harness Bracket And Mount Bracket Collars
  • Fig. 184: Identifying Tightening Sequence Of Special Bolts
  • Fig. 185: Identifying Mating Surface Of Transmission Housing
  • Fig. 186: Identifying Dowel Pins, Change Lever Assembly And Harness Bracket
  • Fig. 187: Identifying Bead Dimension Around Mating Surface Of Transmission Housing
  • Fig. 188: Identifying Mount Bracket Collars, Washer, Flange Bolt, Filler Plug Washer And Filler Plug
  • Fig. 189: Identifying Bead Dimension Around Mating Surface Of Transmission Housing
  • Fig. 190: Identifying Back-Up Light Switch, Steel Balls And Washers
  • Fig. 191: Identifying Gearshift Mechanism Components
  • Fig. 192: Identifying M/T Differential Components Location
  • Fig. 193: Measuring Backlash Of Both Pinion Gears
  • Fig. 194: Identifying Final Driven Gear And Differential Carrier
  • Fig. 195: Removing Carrier Bearings
  • Fig. 196: Installing Bearings
  • Fig. 197: Removing Oil Seal From Transmission Housing
  • Fig. 198: Removing Oil Seal From Clutch Housing
  • Fig. 199: Installing Oil Seal In Transmission Housing
  • Fig. 200: Installing Oil Seal In Clutch Housing
  • Fig. 201: Identifying Shim And Transmission Housing
  • Fig. 202: Identifying Differential Assembly And Clutch Housing
  • Fig. 203: Installing Differential Assembly In Clutch Housing
  • Fig. 204: Measuring Clearance Between Shim And Bearing Outer Race In Transmission Housing
• TABLES
  • VEHICLE SPEED AND INHIBITOR POSITION REFERENCE
  • SHIM THICKNESS SPECIFICATION
  • SHIM THICKNESS SPECIFICATION
  • SHIM THICKNESS SPECIFICATION

2004-08 TRANSMISSION

Manual Transmission - TSX

Special Tools

Fig. 1: Identifying Manual Transmission Special Tools

Service Precautions

Clutch Housing and Transmission Housing:

• The clutch housing and transmission housing are made of magnesium. When steel and magnesium are in contact with one another, there is a possibility of galvanic corrosion (a corrosion that happens between different types of metals). To prevent this from happening, special bolts and washers are used. Make sure you use only these special bolts and washers in the areas indicated, do not substitute them with regular bolts and washers.
• Replace the clutch housing, transmission housing, and the special bolts and washers if galvanic corrosion has occurred on these parts.
• Transmission 8 mm housing bolts have left-hand threads.

Reverse Lockout System

General Troubleshooting Information

How to Troubleshoot Circuits at the ECM

Special Tools Required

• Digital multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter
• Backprobe set 07SAZ-001000A (2)

1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C).

   Fig. 2: Connecting Backprobe Adapters To Stacking Patch Cords And Connect Cords To Digital Multimeter

2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal.
3. If you can not get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector.

   NOTE:

   Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections.

   Fig. 3: Disconnecting Connector And Probe Terminals From Terminal Side

Component Location Index

Fig. 4: Component Location Index

System Description

At a vehicle speed of 12 mph (20 km/h) or more, the ECM receives a signal from the output shaft (countershaft) speed sensor and activates the reverse lockout solenoid, which pushes select lock cam B into the locked position. As a result, the select lever can not rotate to the reverse select position, making it impossible to engage reverse gear. At a vehicle speed of 9 mph (15 km/h) or less, the signal from the output shaft (countershaft) speed sensor is interrupted, the ECM turns off the reverse lockout solenoid. The select lock return spring pulls back select lock cam B, enabling the select lever to move freely so reverse gear can be selected.

VEHICLE SPEED AND INHIBITOR POSITION REFERENCE

Vehicle speed	Inhibitor	Reverse selection
Above 12 mph (20 km/h)	ON	Not allowed
Below 9 mph (15 km/h)	OFF	OK
Ignition switch OFF	OFF	OK

Fig. 5: Identifying Reverse Lockout Mechanism

Circuit Diagram

Fig. 6: Manual Transmission Circuit Diagram

Circuit Troubleshooting

1. Check the No. 18(15 A) fuse in the under-dash fuse/ relay box.

   Is the fuse OK?

   YES -Go to step 2.

   NO -Replace the fuse, and recheck.

2. Start the engine, and check the malfunction indicator lamp (MIL).

   Does the MIL come on?

   YES -Troubleshoot the DTC (see GENERAL TROUBLESHOOTING INFORMATION ), and recheck.

   NO -Go to step 3.

3. Turn the ignition switch OFF.
4. Shift into reverse gear.

   Can you shift the transmission into reverse gear?

   YES -Go to step 5.

   NO -Repair the transmission, and recheck.

5. Raise the vehicle on a lift, make sure it is securely supported, and allow the front wheels to rotate freely.
6. Start the engine. With the vehicle moving slowly (vehicle speed below 9 mph (15 km/h)), shift the transmission into reverse gear, but do not release the clutch pedal.

   Can you shift the transmission into reverse gear?

   YES -Go to step 7.

   NO -Turn the ignition switch OFF, then go to step 16.

7. Disable the VSA by pressing VSA OFF switch. Shift the transmission into low gear and drive the vehicle until the speedometer reads above 12 mph (20 km/h).

   Can you shift the transmission into reverse gear?

   YES -Go to step 8.

   NO -Intermittent failure, the system is OK at this time. :

8. Turn the ignition switch OFF.
9. Disconnect the reverse lockout solenoid 2P connector.
10. Turn the ignition switch ON (II).
11. Measure the voltage between the reverse lockout solenoid 2P connector terminal No. 2 and body ground.

    Fig. 7: Measuring Voltage Between Reverse Lockout Solenoid 2P Connector Terminal No. 2 And Body Ground

    Is there battery voltage?

    YES -Go to step 12.

    NO -Check for poor connections or loose terminals between the under-dash fuse/relay box and the reverse lockout solenoid. If the connections are OK, repair open or short in the wire between the No. 18 (15 A) fuse in the under-dash fuse/relay box and the reverse lockout solenoid.

12. Turn the ignition switch OFF.
13. Remove the reverse lockout solenoid (see REVERSE LOCKOUT SOLENOID DISASSEMBLY/REASSEMBLY ).
14. At the reverse lockout solenoid side, connect the reverse lockout solenoid 2P connector terminal No. 2 to the battery positive terminal, and connect the terminal No. 1 to the battery negative terminal. Make sure the reverse lockout solenoid operates.

    Fig. 8: Connecting 2P Connector Terminal No. 2 To Battery Positive Terminal And Terminal No. 1 To Battery Negative Terminal

    Does the reverse lockout solenoid operate properly?

    YES -Go to step 15.

    NO -Replace the reverse lockout solenoid (see REVERSE LOCKOUT SOLENOID DISASSEMBLY/REASSEMBLY ).

15. Reinstall the reverse lockout solenoid, and reconnect the reverse lockout solenoid 2P connector.
16. Turn the ignition switch ON (II).
17. Measure the voltage between ECM connector E2 and body ground.

    Fig. 9: Measuring Voltage Between ECM Connector E2 And Body Ground

    Is there battery voltage?

    YES -Check for poor connections or loose terminals between the reverse lockout solenoid and ECM connector E (31P). If necessary, update the ECM if it does not have the latest software (see UPDATING THE ECM/PCM ), or substitute a known-good ECM (see SUBSTITUTING THE ECM/PCM ), then recheck. If the symptom/ indication goes away with a known-good ECM, replace the original ECM, '04-05 models (see ECM/PCM REPLACEMENT ), '06-08 models (see '06-08 MODELS ).

    NO -Repair open in the wire between the reverse lockout solenoid and the ECM (E2).

Reverse Lockout Solenoid Test

1. Remove the reverse lockout solenoid (see REVERSE LOCKOUT SOLENOID DISASSEMBLY/REASSEMBLY ).
2. Connect the battery positive terminal to the reverse lockout solenoid 2P connector No. 2 terminal, and connect the battery negative terminal to the No. 1 terminal.

   Fig. 10: Connecting Battery Positive Terminal To Reverse Lockout Solenoid 2P Connector No. 2 Terminal And Battery Negative Terminal To No. 1 Terminal

3. Make sure the reverse lockout solenoid operates. If the reverse lockout solenoid does not work, replace it.

Reverse Lockout Solenoid Disassembly/Reassembly

1. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets.
2. Disconnect the negative cable from the battery, then disconnect the positive cable.
3. Remove the battery.
4. Remove the air cleaner assembly (see AIR CLEANER REMOVAL/INSTALLATION ).
5. Remove the battery base (see step 8 on ENGINE REMOVAL ).
6. Carefully remove the shift cable, select cable, and cable bracket together to avoid bending the cables (see step 8 ).
7. Disconnect the output shaft (countershaft) speed sensor connector, back-up light switch connector, and reverse lockout solenoid connector (see step 9 ).
8. Remove the bolts (A) and reverse lockout solenoid (B).

   Fig. 11: Identifying Bolts And Reverse Lockout Solenoid

9. Remove the roller (A), the select lock return spring (C), and select lock cam B.

   Fig. 12: Identifying Roller, Select Lock Return Spring And Select Lock Cam

10. Install in the reverse order of removal.
11. Clean any the dirt and oil from the sealing surface.
12. Apply liquid gasket, P/N 08718-0001 evenly to the transmission housing mating surface of the reverse lockout solenoid. Install the component within 5 minutes of applying the liquid gasket.

    NOTE:

    If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

13. Install the reverse lockout solenoid.

    Fig. 13: Identifying Reverse Lockout Solenoid, Bolts & w/Torque Spec.

14. Connect the reverse lockout solenoid connector, back-up light switch connector, and output shaft (countershaft) speed sensor connector (see step 40 ).
15. Install the cable bracket (see step 41 ).
16. Install the battery base (see step 44 on ENGINE INSTALLATION ).
17. Install the air cleaner assembly (see AIR CLEANER REMOVAL/INSTALLATION ).
18. Install the battery. Clean the battery posts and cable terminals. Connect the positive cable to the battery first, then connect the negative cable, and apply multipurpose grease to prevent corrosion.
19. Enter the anti-theft codes for the radio system and the navigation system (if equipped), then enter the audio presets.
20. Set the clock (on vehicles without navigation).

Manual Transmission

Transmission Fluid Inspection and Replacement

1. Raise the vehicle on a lift.
2. Remove the splash shield (see step 26 ).
3. Remove the filler plug (A) and washer (B), check the condition of the fluid, and make sure it is at the proper level (C).

   Fig. 14: Identifying Filler Plug, Washer And Fluid Proper Level

4. If the fluid is dirty, remove the drain plug (A), and drain it.

   Fig. 15: Identifying Drain Plug w/Torque Specs.

5. Install the drain plug with a new washer, and refill the transmission fluid to the proper level.

   Fluid Capacity

   2.0 L (2.1 US qt) at fluid change

   2.2 L (2.3 US qt) at overhaul

   Always use Acura Manual Transmission Fluid (MTF). Using engine oil can cause suffer shifting because it does not contain the proper additives.

6. Install the filler plug (B) with a new washer.
7. Install the splash shield (see step 25 ).

Back-up Light Switch Test

1. Disconnect the back-up light switch connector (A).

   Fig. 16: Identifying Back-Up Light Switch Connector w/Torque Spec.

2. Check for continuity between the back-up light switch 2P connector terminals No. 1 and No. 2. There should be continuity when the shift lever is only in reverse.
3. If necessary, replace the back-up light switch. Apply liquid gasket, P/N 08718-0001 (A) evenly to the threads of the back-up light switch, and a 2 mm (0.079 in.) bead around the mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

   NOTE:

   If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 17: Identifying Liquid Gasket, P/N 08718-0001 And 2 mm Bead Around Mating Surface Of Transmission Housing

Transmission Removal

Special Tools Required

• Engine support hanger, A & Reds AAR-T-12566
• Engine hanger/adapter VSB02C000015
• Front subframe adapter VSB02C000016

  *These special tools are available through the Acura Tool and Equipment Program 1-888-424-6857.

NOTE:

Use fender covers to avoid damaging painted surfaces.

1. Secure the hood in its vertical position (support rod in the lower hole).

   Fig. 18: Securing Hood In Its Vertical Position (Support Rod In Lower Hole)

2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets.
3. Disconnect the negative cable from the battery, then disconnect the positive cable.
4. Remove the battery.
5. Remove the air cleaner assembly (see AIR CLEANER REMOVAL/INSTALLATION ).
6. Remove the battery base (see step 8 on ENGINE REMOVAL ).
7. Carefully remove the slave cylinder to avoid bending the clutch line.

   NOTE:

   Do not operate the clutch pedal after the slave cylinder has been removed.

   Fig. 19: Identifying Slave Cylinder And Clutch Line

8. Remove the cable bracket (A), then disconnect the shift cables (B) from the top of the transmission housing. Carefully remove both cables and the bracket together to avoid bending the cables.

   Fig. 20: Identifying Cable Bracket And Shift Cables

9. Disconnect the output shaft (countershaft) speed sensor connector (A), back-up light switch connector (B), and reverse lockout solenoid connector (C).

   Fig. 21: Identifying Output Shaft (Countershaft) Speed Sensor Connector, Back-Up Light Switch Connector And Reverse Lockout Solenoid Connector

10. Disconnect the secondary heated oxygen sensor (secondary HO2S) connector (A), then remove the bracket (B).

    Fig. 22: Identifying Secondary Heated Oxygen Sensor Connector And Bracket

11. Remove the front engine mount stop (A) then remove the front mount bolt (B).

    Fig. 23: Identifying Front Engine Mount Stop And Front Mount Bolt

12. Remove the rear engine mount stop.

    Fig. 24: Identifying Rear Engine Mount Stop

13. Remove the two upper transmission mounting bolts.

    Fig. 25: Identifying Upper Transmission Mounting Bolts

14. Remove and plug the return hose (A) from the power steering fluid reservoir (B). Immediately wipe off any spilled fluid.

    Fig. 26: Identifying Return Hose And Power Steering Fluid Reservoir

15. Remove the power steering pump outlet line (C) from the power steering pump (D).
16. Remove the power steering pump outlet line bracket (E).
17. Attach the engine hanger adapter to the threaded holes in the cylinder head.

    Fig. 27: Identifying Engine Hanger Adapter

18. Install the engine support hanger (A) to the vehicle, and attach the hook (B) to the engine hanger adapter (C). Tighten the wingnut (D) by hand, to lift and support the engine.

    Fig. 28: Identifying Engine Support Hanger, Hook, Engine Hanger Adapter And Wingnut

19. Remove the transmission mount bracket (A) and ground cable (B).

    NOTE:

    Be careful not to drop the mount bracket collars (C).

    Fig. 29: Identifying Transmission Mount Bracket And Ground Cable

20. Remove the steering wheel (see STEERING WHEEL REMOVAL ).
21. Remove the steering joint cover (A).

    Fig. 30: Identifying Reference Mark Across Steering Joint And Steering Gearbox Pinion Shaft

22. Make a reference mark (B) across the steering joint and steering gearbox pinion shaft. Remove the steering joint bolt (C), and disconnect the steering joint (D) by removing the steering joint toward the steering column. Hold the slider shaft (E) on the column with a piece of wire (F) between the joint yoke (G) on the slider shaft to the joint yoke on the upper shaft (see STEERING COLUMN REMOVAL AND INSTALLATION ).
23. Raise the vehicle on the lift, and make sure it is securely supported.
24. Remove the front wheels.
25. Drain the transmission fluid. Reinstall the drain plug using a new washer (see TRANSMISSION FLUID INSPECTION AND REPLACEMENT ).
26. Remove the splash shield.

    Fig. 31: Identifying Splash Shield

27. Separate the tie-rod ball joint (see step 19 on STEERING GEARBOX REMOVAL ).
28. Separate the front stabilizer link (see step 5 on DRIVESHAFT REMOVAL ).
29. Remove the damper fork (see step 6 on DRIVESHAFT REMOVAL ).
30. Separate the knuckle from the lower arm (see step 11 on KNUCKLE/HUB REPLACEMENT ).
31. Disconnect the power steering pressure switch connector.

    Fig. 32: Identifying Power Steering Pressure Switch Connector

32. Remove exhaust pipe A.

    Fig. 33: Identifying Exhaust Pipe A

33. Remove the driveshaft inboard joints (see step 9 on DRIVESHAFT REMOVAL ).
34. Remove the intermediate shaft (see INTERMEDIATE SHAFT REMOVAL ).
35. Remove the rear engine mount lower bracket mounting bolts.

    Fig. 34: Identifying Rear Engine Mount Lower Bracket Mounting Bolts

36. Remove the lower transmission mount mounting nuts.

    Fig. 35: Identifying Lower Transmission Mount Mounting Nuts

37. Remove the middle subframe mounting bracket.

    Fig. 36: Identifying Middle Subframe Mounting Bracket

38. Make to mark (A) at both ends of the subframe (B) that lines up with the edge (C) of the stiffeners (D).

    Fig. 37: Identifying Mark At Both Ends Of Subframe

39. Attach the subframe adapter to the subframe by wrapping the band over the subframe and attaching the end of the band to the subframe adapter with the pin (A).

    Fig. 38: Attaching Subframe Adapter To Subframe

40. Raise the jack, and line up the slots in the arms with the bolt holes on the corner of the jack base (B), then attach them securely.
41. Remove the front suspension subframe stiffeners (A), and front suspension subframe (B).

    Fig. 39: Identifying Front Suspension Subframe Stiffeners And Front Suspension Subframe

42. Remove the front engine mount upper bracket.

    Fig. 40: Identifying Front Engine Mount Upper Bracket

43. Remove the shift cable bracket (A), rear engine mount upper mounting bolt (B), and rear engine mount (C).

    Fig. 41: Identifying Shift Cable Bracket And Rear Engine Mount Upper Mounting Bolt

44. Remove the rear engine mount upper bracket.

    Fig. 42: Identifying Rear Engine Mount Upper Bracket

45. Remove the clutch cover.

    Fig. 43: Identifying Clutch Cover

46. Support the transmission with a transmission jack.
47. Remove the four lower transmission mounting bolts.

    Fig. 44: Identifying Lower Transmission Mounting Bolts

48. Pull the transmission away from the engine until the transmission mainshaft clears the clutch pressure plate.
49. Slowly lower the transmission about 150 mm (6 in.) Check once again that all hoses and electrical wiring are disconnected and free from the transmission, then lower it all the way.
50. Remove the front transmission lower mount (A) and rear transmission lower mount (B).

    NOTE:

    Be careful not to drop the mount bracket collars (C).

    Fig. 45: Identifying Transmission Lower Mounts And Mount Bracket Collars

51. Remove the release fork boot (A) from the clutch housing (B).

    Fig. 46: Identifying Release Fork Boot, Release Fork, Release Bearing And Clutch Housing

52. Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E).

Transmission Installation

Special Tools Required

• Engine support hanger, A & Reds AAR-T-12566
• Engine hanger/adapter VSB02C000015
• Front subframe adapter VSB02C000016

  * These special tools are available through the Acura Tool and Equipment Program 1-888-424-6857.

NOTE:

Use fender covers to avoid damaging painted surfaces.

1. Make sure the two dowel pins (A) are installed in the clutch housing.

   Fig. 47: Identifying Dowel Pins

2. Install the release fork, the release bearing, and the boot (see step 4 on RELEASE BEARING REPLACEMENT ).
3. Check that the mount bracket collars (A) are installed in the transmission, then install the front transmission lower mount (B) and rear transmission lower mount (C).

   Fig. 48: Identifying Mount Bracket Collars And Transmission Lower Mounts w/Torque Specs.

4. Place the transmission on the transmission jack, and raise it to the engine level.
5. Install the four lower transmission mounting bolts.

   Fig. 49: Identifying Lower Transmission Mounting Bolts w/Torque Specs.

6. Install the clutch cover.

   Fig. 50: Identifying Clutch Cover w/Torque Specs.

7. Install the rear engine mount upper bracket.

   Fig. 51: Identifying Rear Engine Mount Upper Bracket w/Torque Specs.

8. Install the rear engine mount (A), rear engine mount upper mounting bolt (B), and shift cable bracket (C).

   Fig. 52: Identifying Rear Engine Mount Upper Mounting Bolt And Shift Cable Bracket w/Torque Specs.

9. Install the front engine mount upper bracket.

   Fig. 53: Identifying Front Engine Mount Upper Bracket w/Torque Spec.

10. Support the subframe with the subframe adapter and a jack.

    Fig. 54: Supporting Subframe With Subframe Adapter And Jack

11. Install the front suspension subframe (A) and front suspension subframe stiffeners (B).

    Fig. 55: Identifying Front Suspension Subframe And Front Suspension Subframe Stiffeners w/Torque Specs.

12. Align the reference mark (A) you made with edge (B) of both rear stiffeners (C), and tighten the rear subframe mounting bolts, then the front bolts, and tighten the stiffener bolts to the specified torque.

    Fig. 56: Identifying Reference Mark At Both Ends Of Subframe

13. Install the middle subframe mounting bracket.

    Fig. 57: Identifying Middle Subframe Mounting Bracket w/Torque Specs.

14. Install the lower transmission mount mounting nuts.

    Fig. 58: Identifying Lower Transmission Mount Mounting Nuts w/Torque Spec.

15. Install the rear engine mount lower bracket mounting bolts.

    Fig. 59: Identifying Rear Engine Mount Lower Bracket Mounting Bolts w/Torque Spec.

16. Install the intermediate shaft (see INTERMEDIATE SHAFT INSTALLATION ).
17. Install the driveshaft inboard joint (see DRIVESHAFT INSTALLATION ).
18. Connect the knuckle onto the lower arm (see step 7 on DRIVESHAFT INSTALLATION ).
19. Install the damper fork (see step 9 on DRIVESHAFT INSTALLATION ).
20. Connect the front stabilizer (see step 11 on DRIVESHAFT INSTALLATION ).
21. Install exhaust pipe A with new gaskets (B).

    Fig. 60: Identifying Exhaust Pipe And Gaskets w/Torque Specs.

22. Connect the power steering pressure switch connector.

    Fig. 61: Identifying Power Steering Pressure Switch Connector

23. Connect the return line to the power steering fluid reservoir.
24. Connect the tie-rod ball joint (see step 24 on STEERING GEARBOX INSTALLATION ).
25. Install the splash shield.

    Fig. 62: Identifying Splash Shield

26. Refill the transmission with the recommended transmission fluid (see TRANSMISSION FLUID INSPECTION AND REPLACEMENT ).
27. Install the front wheels, and set them in the straight ahead position.
28. Lower the vehicle on the lift.
29. Connect the steering joint to the steering gearbox pinion shaft (A) by aligning the reference mark (B) you made, and remove the wire (C) from the joint yoke (D).

    Fig. 63: Identifying Steering Gearbox Pinion Shaft, Wire, Joint Yoke & Torque Spec.

30. Install the steering joint cover (E).
31. Install the steering wheel (see STEERING WHEEL INSTALLATION ).
32. Check that the mount bracket collars (A) are installed in the transmission, then install the transmission mount bracket (B) and ground cable (C).

    Fig. 64: Identifying Mount Bracket Collars, Transmission Mount Bracket, Ground Cable & Torque Specs.

33. Remove the engine support hanger and engine hanger adapter from the engine.
34. Install the power steering pump outlet line (A) with a new O-ring (B) to the power steering pump (C), and secure the hose clamp (D) with the bolt.

    Fig. 65: Identifying Power Steering Pump, Hose Clamp, Return Hose, Power Steering Fluid Reservoir& Torque Specs.

35. Connect the return hose (E) to the power steering fluid reservoir (F), then secure the hose with the clamp (G).
36. Install the two upper transmission mounting bolts.

    Fig. 66: Identifying Upper Transmission Mounting Bolts w/Torque Spec.

37. Install the rear engine mount stop.

    Fig. 67: Identifying Rear Engine Mount Stop w/Torque Spec.

38. Install the front engine mount mounting bolt (A) and front engine mount stop (B).

    Fig. 68: Identifying Engine Mount Mounting Bolt, Front Engine Mount Stop & Torque Specs.

39. Install the bracket (A), then connect the secondary heated oxygen sensor (secondary HO2S) connector (B).

    Fig. 69: Identifying Bracket And Secondary Heated Oxygen Sensor Connector w/Torque Spec.

40. Connect the reverse lockout solenoid connector (A), back-up light switch connector (B), and output shaft (countershaft) speed sensor connector (C).

    Fig. 70: Identifying Reverse Lockout Solenoid Connector And Back-Up Light Switch Connector

41. Install the cable bracket (A) and cables (B).

    Fig. 71: Identifying Cable Bracket, Cables & Torque Spec.

42. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the cable ends, and install new cotter pins (C)
43. Apply super high temp urea grease (P/N 08798-9002) to the end of the slave cylinder rod. Install the slave cylinder. Be careful not to bend the clutch line.

    Fig. 72: Identifying Grease Applying Area & Torque Specs.

44. Install the battery base (see step 44 on ENGINE INSTALLATION ).
45. Install the air cleaner assembly (see AIR CLEANER REMOVAL/INSTALLATION ).
46. Remove the steering wheel (see STEERING WHEEL REMOVAL ).
47. Center the cable reel and reinstall the steering wheel (see STEERING WHEEL INSTALLATION ).
48. Install the battery. Clean the battery posts and cable terminals, connect the positive cable to the battery, then connect the negative cable, and apply multipurpose grease to prevent corrosion.
49. Fill the power steering fluid reservoir with fluid to the upper level line.
50. Start the engine, turn the steering wheel from lock-to-lock several times to bleed air from the power steering system.
51. Recheck the fluid level, and refill if necessary.
52. Check the front wheel alignment (see WHEEL ALIGNMENT ).
53. Test-drive the vehicle.
54. Check the shift lever and the clutch operation.
55. Enter the anti-theft codes for the audio system and the navigation system (if equipped), then enter the audio presets.
56. Set the clock (on vehicles without navigation).

Transmission Disassembly

Exploded View - Clutch Housing

Fig. 73: Exploded View Of Clutch Housing

Exploded View - Transmission Housing

Fig. 74: Exploded View Of Transmission Housing

NOTE:

Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

1. Remove the detent bolts (A), washers, springs, steel balls, and back-up light switch (B).

   Fig. 75: Identifying Detent Bolts, Back-Up Light Switch And Transmission Hanger

2. Remove the transmission hanger (C), 20 mm bolt (D), and 20 mm washer (E).
3. Remove the harness bracket A, interlock bolt (B), change lever assembly (C), and two 8x14 mm dowel pins (D).

   Fig. 76: Identifying Harness Bracket, Interlock Bolt, Change Lever Assembly And Dowel Pins

4. Remove the filler plug (A), 10 mm flange bolt (B), and mount bracket collars (C).

   Fig. 77: Identifying Filler Plug, Output Shaft (Countershaft) Speed Sensor, And Mount Bracket Collars

5. Remove the output shaft (countershaft) speed sensor (D), plain washer (E), and O-ring (F).
6. Remove the 8 mm special bolts (left-hand threads and black color) in a crisscross pattern in several steps.
7. Remove transmission hanger A, transmission hanger B, harness bracket B (C), and mount bracket collars (D).

   Fig. 78: Identifying Transmission Hangers, Harness Bracket And Mount Bracket Collars

   Service Precaution: All 8 mm transmission housing bolts have left-hand threads.

8. Remove the 32 mm sealing cap (A).

   Fig. 79: Identifying Sealing Cap, Snap Ring, Transmission Housing And Dowel Pins

9. Expand the 72 mm snap ring (B) on the countershaft ball bearing, and remove it from the groove with snap ring pliers.
10. Remove the transmission housing (C) and three 14 x 20 mm dowel pins (D).
11. Remove the reverse idler gear (A), reverse gear shaft (B), and 20 x 36 x 2 mm thrust washer (C).

    Fig. 80: Identifying Reverse Idler Gear, Reverse Gear Shaft And Thrust Washer

12. Remove the reverse shift fork.

    Fig. 81: Identifying Reverse Shift Fork

13. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and countershaft assembly (B) with the shift forks (C) from the clutch housing (D).

    Fig. 82: Identifying Mainshaft Assembly, Countershaft Assembly, Shift Forks And Clutch Housing

14. Remove the 28 mm spring washer (E) and 28 mm washer (F).
15. Remove the differential assembly (A) and magnet (B).

    Fig. 83: Identifying Differential Assembly And Magnet

16. Remove the oil gutter plate (A), 72 mm shim (B), and oil guide plate M.

    Fig. 84: Identifying Oil Gutter Plate, Shim And Oil Guide Plate

17. Remove the drain plug (A), drain plug washer (B), and release bearing guide (C).

    Fig. 85: Identifying Drain Plug, Drain Plug Washer And Release Bearing Guide

Reverse Shift Fork Clearance Inspection

1. Measure the clearance between the reverse idler gear (A) and the reverse shift fork (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2.

   Standard: 0.20-0.59 mm (0.007-0.024 in.)

   Service Limit: 1.3 mm (0.051 in.)

   Fig. 86: Measuring Clearance Between Reverse Idler Gear And Reverse Shift Fork

2. Measure the width of the reverse shift fork.
   • If the width is not within the standard, replace the reverse shift fork.
   • If the width is within the standard, replace the reverse gear.

     Standard: 13.4-13.7 mm (0.527-0.539 in.)

     Fig. 87: Identifying Width Of Reverse Shift Fork

Change Lever Clearance Inspection

1. Measure the clearance between the change lever (A) and the select lever (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2.

   Standard: 0.05-0.25 mm (0.002-0.010 in.)

   Service Limit: 0.5 mm (0.020 in.)

   Fig. 88: Measuring Clearance Between Change Lever And Select Lever

2. Measure the groove of the change lever.
   • If the groove is not within the standard, replace the change lever.
   • If the groove is within the standard, replace the select lever.

     Standard: 15.00-15.10 mm (0.591-0.594 in.)

     Fig. 89: Identifying Groove Of Change Lever

Change Lever Assembly Disassembly/Reassembly

NOTE:

If 5 minutes have passed after applying liquid gasket, reapply it, and assemble the shift arm cover. Prior to reassembling, clean all parts in solvent, dry them, and apply grease to the contact surfaces as shown. Fig. 90: Exploded View Of Change Lever Assembly w/Torque Spec.

Shift Fork Clearance Inspection

NOTE:

The synchro sleeve and synchro hub should be replaced as a set.

1. Measure the clearance between each shift fork (A) and its matching synchro sleeve (B). If the clearance exceeds the service limit, go to step 2.

   Standard: 0.35-0.65 mm (0.014-0.026 in.)

   Service Limit: 1.0 mm (0.039 in.)

   Fig. 91: Measuring Clearance Between Shift Fork And Synchro Sleeve

2. Measure the thickness of the shift fork fingers.
   • If the thickness is not within the standard, replace the shift fork.
   • If the thickness is within the standard, replace the synchro sleeve and synchro hub as a set.
   • If one arm of the shift fork shows more wear than others, the fork may be bent and needs to be replaced.

     Standard: 7.4-7.6 mm (0.29-0.30 in.)

     Fig. 92: Identifying Thickness Of Shift Fork Fingers

3. Measure the clearance between the shift fork (A) and the shift arm (B). If the clearance exceeds the service limit, go to step 4.

   Standard: 0.2-0.5 mm (0.008-0.020 in.)

   Service Limit: 0.62 mm (0.024 in.)

   Fig. 93: Measuring Clearance Between Shift Fork And Shift Arm

4. Measure the width of the shift arm.
   • If the width is not within the standard, replace the shift arm.
   • If the width is within the standard, replace the shift fork or reverse shift piece.

     Standard: 16.9-17.0 mm (0.665-0.669 in.)

     Fig. 94: Identifying Width Of Shift Arm

Shift Fork Disassembly/Reassembly

NOTE:

Prior to reassembling, clean all the parts in solvent, dry them, and apply manual transmission fluid (MTF) to all contact surfaces.

Fig. 95: Identifying Shift Forks

Mainshaft Assembly Clearance Inspection

NOTE:

If replacement is required, always replace the synchro sleeve and synchro hub as a set.

1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B).

   Fig. 96: Pushing Down On Mainshaft

2. Measure the clearance between 2nd gear (C) and 3rd gear (D) with a feeler gauge (E).
   • If the clearance is more than the service limit, go to step 3.
   • If the clearance is within the service limit, go to step 4.

     Standard: 0.06-0.16 mm (0.002-0.006 in.)

     Service Limit: 0.25 mm (0.010 in.)

3. Measure the thickness of 3rd gear.
   • If the thickness is less than the service limit, replace 3rd gear.
   • If the thickness is within the service limit, replace the 3rd/4th synchro hub and 3rd/4th synchro sleeve as a set.

     Standard: 23.92-23.97 mm (0.941-0.944 in.)

     Service Limit: 23.80 mm (0.937 in.)

     Fig. 97: Identifying Thickness Of 3rd Gear

4. Measure the clearance between 4th gear (A) and the distance collar (B) with a dial indicator (C).
   • If the clearance is more than the service limit, go to step 5.
   • If the clearance is within the service limit, go to step 7.

     Standard: 0.06-0.16 mm (0.002-0.006 in.)

     Service Limit: 0.25 mm (0.010 in.)

     Fig. 98: Measuring Clearance Between 4th Gear And Distance Collar

5. Measure the length (1) of the distance collar as shown.
   • If the length (1) is not within the standard, replace the distance collar.
   • If the length (1) is within the standard, go to step 6.

     Standard: 24.03-24.08 mm (0.946-0.948 in.)

     Fig. 99: Identifying Length Of Distance Collar

6. Measure the thickness of 4th gear.
   • If the thickness is less than the service limit, replace 4th gear.
   • If the thickness is within the service limit, replace the 3rd/4th synchro hub and 3rd/4th synchro sleeve as a set.

     Standard: 23.92-23.97 mm (0.941-0.944 in.)

     Service Limit: 23.80 mm (0.937 in.)

     Fig. 100: Identifying Thickness Of 4th Gear

7. Measure the clearance between the distance collar (A) and 5th gear (B) with a dial indicator (C).
   • If the clearance is more than the service limit, go to step 8.
   • If the clearance is within the service limit, go to step 10.

     Standard: 0.06-0.16 mm (0.002-0.006 in.)

     Service Limit: 0.25 mm (0.010 in.)

     Fig. 101: Measuring Clearance Between Distance Collar And 5th Gear

8. Measure the length (2) of the distance collar as a set.
   • If the length (2) is not within the standard, replace the distance collar.
   • If the length (2) is within the standard, go to step 9.

     Standard: 24.03-24.08 mm (0.946-0.948 in.)

     Fig. 102: Identifying Length Of Distance Collar

9. Measure the thickness of 5th gear.
   • If the thickness is less than the service limit, replace 5th gear.
   • If the thickness is within the service limit, replace the 5th/6th synchro hub and 5th/6th synchro sleeve as a set.

     Standard: 23.92-23.97 mm (0.941-0.944 in.)

     Service Limit: 23.80 mm (0.937 in.)

     Fig. 103: Identifying Thickness Of 5th Gear

10. Measure the clearance between 6th gear (A) and the angular ball bearing (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 11.

    Standard: 0.06-0.16 mm (0.002-0.006 in.)

    Service Limit: 0.25 mm (0.010 in.)

    Fig. 104: Measuring Clearance Between 6th Gear And Angular Ball Bearing

11. Measure the length of the distance collar.
    • If the length is not within the standard, replace the distance collar.
    • If the length is within the standard, go to step 12.

      Standard: 24.03-24.08 mm (0.946-0.948 in.)

      Fig. 105: Identifying Length Of Distance Collar

12. Measure the thickness of 6th gear.
    • If the thickness is less than the service limit, replace 6th gear.
    • If the thickness is within the service limit, replace the 5th/6th synchro hub and 5th/6th synchro sleeve as a set.

      Standard: 23.92-23.97 mm (0.941-0.944 in.)

      Service Limit: 23.80 mm (0.937 in.)

      Fig. 106: Identifying Thickness Of 6th Gear

Mainshaft Disassembly

1. Remove the angular ball bearing (A) and the tapered cone ring using a commercially available bearing separator (B) and a commercially available bearing puller (C). Make sure the bearing separator is under the tapered cone ring.

   Fig. 107: Removing Angular Ball Bearing And Tapered Cone Ring

2. Support 5th gear (A) on steel blocks, and press the mainshaft out of the 5th/6th synchro hub (B).

   NOTE:

   Do not use a jaw-type puller, it can damage the gear teeth.

   Fig. 108: Pressing Mainshaft Out Of 5th/6th Synchro Hub

3. Support 3rd gear (A) on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub (B).

   NOTE:

   Do not use a jaw-type puller, it can damage the gear teeth.

   Fig. 109: Pressing Mainshaft Out Of 3rd/4th Synchro Hub

Mainshaft Inspection

1. Inspect the gear and bearing contact areas for wear and damage, then measure the mainshaft at points A, B, C, D, and E. If any part of the mainshaft is less than the service limit, replace it.

   Standard:

   A Ball Bearing Contact Area (Transmission Housing Side): 27.987-28.000 mm (1.1019-1.1024 in.)

   B Distance Collar Contact Area: 31.984-32.000 mm (1.2594-1.2598 in.)

   C Needle Bearing Contact Area: 38.984-39.000 mm (1.5348-1.5354 in.)

   D Ball Bearing Contact Area (Clutch Housing Side): 27.977-27.990 mm (1.1015-1.1020 in.)

   E Bushing Surface: 20.800-20.850 mm (0.819-0.821 in.)

   Service Limit:

   A: 27.93 mm (1.100 in.)

   B: 31.93 mm (1.257 in.)

   C: 38.93 mm (1.533 in.)

   D: 27.92 mm (1.099 in.)

   E: 20.75 mm (0.817 in.)

   Fig. 110: Identifying Mainshaft Inspection Points

2. Inspect the runout by supporting both ends of the mainshaft. Then rotate the mainshaft two complete turns while measuring with a dial gauge. If the runout is more than the service limit, replace the mainshaft.

   Standard: 0.02 mm (0.001 in.) max.

   Service Limit: 0.05 mm (0.002 in.)

   Fig. 111: Measuring Mainshaft Runout

Mainshaft Reassembly

Exploded View

Fig. 112: Exploded View Of Mainshaft Reassembly

Special Tools Required

• Driver, 40 mm I.D. 07746-0030100
• Attachment, 30 mm I.D. 07746-0030300

NOTE:

Refer to the EXPLODED VIEW, as needed, during this procedure.

1. Clean all the parts in solvent, dry them, and apply manual transmission fluid (MTF) to all contact surfaces except the 3rd/4th and 5th/6th synchro hubs.
2. Install the needle bearing and 3rd gear on the mainshaft.
3. Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 3rd gear (C), then install the synchro spring (D).

   Fig. 113: Installing Double Cone Synchro Assembly

4. Install the 3rd/4th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves in the 3rd/4th synchro hub (C).

   Fig. 114: Installing 3rd/4th Synchro Hub

5. Install the 3rd/4th synchro hub (A) using the 40 mm I.D. driver (B).

   Fig. 115: Installing 3rd/4th Synchro Hub

6. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) of the 3rd/4th synchro sleeve and 3rd/4th synchro hub. After installing, check the operation of the 3rd/4th synchro hub set.

   Fig. 116: Identifying 3rd/4th Synchro Sleeve

7. Install the synchro spring (A).

   Fig. 117: Identifying Synchro Spring And Double Cone Synchro Assembly

8. Install the double cone synchro assembly (B) by aligning the synchro ring fingers (C) with the grooves in the 3rd/4th synchro hub (D).
9. Install 4th gear (A) by aligning the synchro cone fingers (B) with the holes in 4th gear (C).

   Fig. 118: Installing 4th Gear

10. Install the needle bearings, 4th/5th distance collar, and 5th gear.
11. Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 5th gear (C), then install the synchro spring (D).

    Fig. 119: Installing Double Cone Synchro Assembly

12. Install the 5th/6th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves in the 5th/6th synchro hub (C).

    Fig. 120: Installing 5th/6th Synchro Hub

13. Install the 5th/6th synchro hub (A) using the 40 mm I.D. driver (B) and 30 mm I.D. attachment (C).

    Fig. 121: Installing 5th/6th Synchro Hub

14. Install the 5th/6th synchro sleeve.
15. Install the synchro spring (A).

    Fig. 122: Identifying Synchro Spring And Double Cone Synchro Assembly

16. Install the double cone synchro assembly (B) by aligning the synchro ring fingers (C) with the grooves in the 5th/6th synchro hub (D).
17. Install the distance collar and the needle bearing.
18. Install 6th gear (A) by aligning the synchro cone fingers (B) with the holes in 6th gear (C).

    Fig. 123: Installing 6th Gear

19. Install the new angular ball bearing (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment, and press (D).

    Fig. 124: Installing Angular Ball Bearing

Countershaft Assembly Clearance Inspection

1. Measure the clearance between 1st gear (A) and the distance collar (B) with a feeler gauge (C).
   • If the clearance is more than the service limit, go to step 2.
   • If the clearance is within the service limit, go to step 4.

     Standard: 0.06-0.16 mm (0.002-0.006 in.)

     Service Limit: 0.25 mm (0.010 in.)

     Fig. 125: Measuring Clearance Between 1st Gear And Distance Collar

2. Measure the length of the distance collar as shown.
   • If the length is not within the standard, replace the distance collar.
   • If the length is within the standard, go to step 3.

     Standard: 23.03-23.08 mm (0.907-0.909 in.)

     Fig. 126: Identifying Length Of Distance Collar

3. Measure the thickness of 1st gear.
   • If the thickness is less than the service limit, replace 1st gear.
   • If the thickness is within the service limit, replace the 1st/2nd synchro hub and reverse gear as a set.

     Standard: 22.92-22.97 mm (0.902-0.904 in.)

     Service Limit: 22.87 mm (0.900 in.)

     Fig. 127: Identifying Thickness Of 1st Gear

4. Measure the clearance between 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 5.

   Standard: 0.06-0.16 mm (0.002-0.006 in.)

   Service Limit: 0.25 mm (0.010 in.)

   Fig. 128: Measuring Clearance Between 2nd Gear And 3rd Gear

5. Measure the length of the distance collar.
   • If the length is not within the standard, replace the distance collar.
   • If the length is within the standard, go to step 6.

     Standard: 28.03-28.08 mm (1.104-1.106 in.)

     Fig. 129: Identifying Length Of Distance Collar

6. Measure the thickness of 2nd gear.
   • If the thickness is less than the service limit, replace 2nd gear.
   • If the thickness is within the service limit, replace the 1st/2nd synchro hub and reverse gear as a set.

     Standard: 27.92-27.97 mm (1.099-1.101 in.)

     Service Limit: 27.87 mm (1.097 in.)

     Fig. 130: Identifying Thickness Of 2nd Gear

Countershaft Disassembly

1. Securely clamp the countershaft assembly in a bench vise with wood blocks.

   Fig. 131: Removing Special Bolt

2. Remove the special bolt (left-hand threads).
3. Support 6th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft out of the ball bearing (E).

   Fig. 132: Pressing Countershaft Out Of Ball Bearing

4. Remove the 35 mm shim.
5. Support 4th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of 5th gear (F).

   Fig. 133: Pressing Countershaft Out Of 5th Gear

6. Support 2nd gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of 3rd gear (F).

   Fig. 134: Pressing Countershaft Out Of 3rd Gear

Countershaft Inspection

1. Inspect the gear and bearing contact areas for wear and damage, then measure the countershaft at points A, B, and C. If any part of the countershaft is less than the service limit, replace it.

   Standard:

   A: Ball Bearing Contact Area (Transmission Housing Side): 30.020-30.033 mm (1.1819-1.1824 in.)

   B: Distance Collar Contact Area: 39.937-39.950 mm (1.5723-1.5728 in.)

   C: Needle Bearing Contact Area (Clutch Housing Side): 35.000-35.015 mm (1.3779-1.3785 in.)

   Service Limit:

   A: 29.97 mm (1.180 in.)

   B: 39.883 mm (1.5702 in.)

   C: 34.95 mm (1.376 in.)

   Fig. 135: Identifying Countershaft Inspection Points

2. Inspect the runout by supporting both ends of the countershaft. Then rotate the countershaft two complete turns while measuring with a dial gauge. If the runout is more than the service limit, replace the countershaft.

   Standard: 0.02 mm (0.001 in.) max.

   Service Limit: 0.05 mm (0.002 in.)

   Fig. 136: Measuring Countershaft Runout

Countershaft Reassembly

Exploded View

Fig. 137: Exploded View Of Countershaft Assembly w/Torque Spec.

Special Tools Required

• Driver, 40 mm I.D. 07746-0030100
• Attachment, 30 mm I.D. 07746-0030300

NOTE:

Refer to the EXPLODED VIEW, as needed, during this procedure.

1. Clean all parts in solvent, dry them, and apply manual transmission fluid (MTF) to all contact surfaces.
2. Install the distance collar and needle bearing onto the countershaft.
3. Install the 1st gear.
4. Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the grooves in 1st gear (C), then install the synchro spring (D).

   Fig. 138: Installing Triple Cone Synchro Assembly And Synchro Spring

5. Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves in the 1st/2nd synchro hub (C).

   Fig. 139: Installing 1st/2nd Synchro Hub

6. Install reverse gear.
7. Install the synchro spring (A).

   Fig. 140: Installing Synchro Spring And Triple Cone Synchro Assembly

8. Install the triple cone synchro assembly (B) by aligning the synchro ring fingers (C) with the grooves in the 1st/2nd synchro hub (D).
9. Install the distance collar (A) and friction damper (B) by aligning the friction damper fingers (C) with the grooves in the 1st/2nd synchro hub (D).

   Fig. 141: Installing Distance Collar And Friction Damper

10. Install the needle bearing.
11. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the grooves (C) in 2nd gear.

    Fig. 142: Installing 2nd Gear

12. Support the countershaft (A) on steel blocks, then install 3rd gear (B) using the 40 mm I.D. driver (C) and a press (D).

    NOTE:

    Do not exceed the maximum pressure.

    Fig. 143: Installing 3rd Gear

13. Install 4th gear (A) using the 40 mm I.D. driver (B) and a press (C).

    NOTE:

    Do not exceed the maximum pressure.

    Fig. 144: Installing 4th Gear

14. Install 5th gear (A) using the 40 mm I.D. driver (B) and a press (C).

    NOTE:

    Do not exceed the maximum pressure.

    Fig. 145: Installing 5th Gear

15. Install 6th gear (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press (D).

    NOTE:

    Do not exceed the maximum pressure.

    Fig. 146: Installing 6th Gear

16. Install the 35 mm shim and the old ball bearing (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press (D).

    Fig. 147: Installing Ball Bearing

17. Measure the clearance between the old bearing (A) and the 35 mm shim (B) with a feeler gauge (C).

    Standard: 0.04-0.10 mm (0.0016-0.0039 in.)

    Fig. 148: Measuring Clearance Between Bearing And Shim

18. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 16 is within the standard, replace only the ball bearing.

    35 mm Shim

    SHIM THICKNESS SPECIFICATION
    

    	Part Number	Thickness
    A	23981-PPP-000	0.87 mm (0.034 in.)
    AA	23981-PPP-900	0.91 mm (0.036 in.)
    B	23982-PPP-000	0.95 mm (0.037 in.)
    AB	23982-PPP-900	0.99 mm (0.039 in.)
    C	23983-PPP-000	1.03 mm (0.041 in.)
    AC	23983-PPP-900	1.07 mm (0.042 in.)
    D	23984-PPP-000	1.11 mm (0.044 in.)
    AD	23984-PPP-900	1.15 mm (0.045 in.)
    E	23985-PPP-000	1.19 mm (0.047 in.)
    AE	23985-PPP-900	1.23 mm (0.048 in.)
    F	23986-PPP-000	1.27 mm (0.050 in.)
    AF	23986-PPP-900	1.31 mm (0.052 in.)
    G	23987-PPP-000	1.35 mm (0.053 in.)
    AG	23987-PPP-900	1.39 mm (0.055 in.)
    H	23988-PPP-000	1.43 mm (0.056 in.)
    AH	23988-PPP-900	1.47 mm (0.058 in.)
    J	23989-PPP-000	1.51 mm (0.060 in.)
    AJ	23989-PPP-900	1.55 mm (0.061 in.)
    K	23990-PPP-000	1.59 mm (0.063 in.)
    AK	23990-PPP-900	1.63 mm (0.064 in.)
    L	23991-PPP-000	1.67 mm (0.066 in.)
    AL	23991-PPP-900	1.71 mm (0.067 in.)
    M	23992-PPP-000	1.75 mm (0.069 in.)
    AM	23992-PPP-900	1.79 mm (0.070 in.)
    N	23993-PPP-000	1.83 mm (0.072 in.)
    AN	23993-PPP-900	1.87 mm (0.074 in.)
    P	23994-PPP-000	1.91 mm (0.075 in.)
    AP	23994-PPP-900	1.95 mm (0.077 in.)
    Q	23995-PPP-000	1.99 mm (0.078 in.)

19. Support 6th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft out of the ball bearing (E).

    Fig. 149: Pressing Countershaft Out Of Ball Bearing

20. If necessary, install the 35 mm shim selected in step 18.
21. Install 6th gear (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press (D).

    NOTE:

    Do not exceed the maximum pressure.

    Fig. 150: Installing 6th Gear

22. Install the new ball bearing (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press (D), then recheck the clearance.

    Fig. 151: Installing Ball Bearing

23. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

    Fig. 152: Tightening Special Bolt w/Torque Spec.

24. Apply MTF to the new special bolt (B), then tighten it (left-hand threads).

Synchro Sleeve and Hub Inspection and Reassembly

1. Inspect gear teeth on all synchro hubs and synchro sleeves for wear (rounded off corners).
2. Install each synchro hub (A) in its mating synchro sleeve (B), and check for free movement. Make sure to match the three sets of longer teeth (C) (120 degrees apart) on the synchro sleeve with the three sets of deeper grooves (D) in the synchro hub.

   NOTE:

   Do not install the synchro sleeve with its longer teeth in the slots of the synchro hub (E) because it will damage the spring ring. If replacement is required, always replace the synchro sleeve and synchro hub as a set. Fig. 153: Installing Synchro Hub In Synchro Sleeve

Synchro Ring and Gear Inspection

1. Inspect the inside of each synchro ring (A) for wear. Inspect the teeth (B) on each synchro ring for wear (rounded off).

   Fig. 154: Identifying Synchro Ring And Synchro Ring Teeth

2. Inspect the teeth (A) on each synchro sleeve and matching teeth on each gear for wear (rounded off).

   Fig. 155: Identifying Synchro Sleeve Teeth

3. Inspect the thrust surface (A) on each gear hub for wear.

   Fig. 156: Identifying Thrust Surface On Gear Hub

4. Inspect the cone surface (B) on each gear hub for wear and roughness.
5. Inspect the teeth on all gears (C) for uneven wear, scoring, and cracks.
6. Coat the cone surface of each gear with manual transmission fluid (MTF), and place its synchro ring on it. Rotate the synchro ring, making sure that it does not slip.
7. Measure the clearance between each gear (A) and its synchro ring (B) all around the gear. Hold the synchro ring against the gear evenly while measuring clearance. If the clearance is less than the service limit, replace the synchro ring and gear.

   Double Cone Synchro and Triple Cone Synchro-to-Gear Clearance

   Standard:

   (1): Outer Synchro Ring. (B) to Synchro Cone (C) 0.70-1.19 mm (0.028-0.047 in.)

   (2): Synchro Cone (C) to Gear (A) 0.50-1.04 mm (0.020-0.041 in.)

   (3): Outer Synchro Ring (B) to Gear (A) 0.95-1.68 mm (0.037-0.066 in.)

   Service Limit:

   (1): 0.3 mm (0.012 in.)

   (2): 0.3 mm (0.012 in.)

   (3): 0.6 mm (0.024 in.)

   Fig. 157: Measuring Clearance Between Gear And Synchro Ring

Mainshaft Bearing and Oil Seal Replacement

Special Tools Required

• Oil seal driver 07JAD-PL90100
• Adjustable bearing puller, 20-40 mm 07736-A01000B
• Attachment, 42 x 47 mm 07746-0010300
• Driver 07749-0010000
• Slide hammer, 3/8"-16 UNF commercially available

1. Remove the ball bearing (A) from the clutch housing (B) using the 20-40 mm adjustable bearing puller (C) and a commercially available 3/8"-16 UNF slide hammer (D).

   Fig. 158: Removing Ball Bearing

2. Remove the oil seal (A) from the transmission side. Be careful when removing the oil seal so the clutch housing is not damaged.

   Fig. 159: Removing Oil Seal

3. Drive in the new oil seal from the transmission side using the driver (A) and 42 x 47 mm attachment (B).

   Fig. 160: Installing Oil Seal

4. Drive in the new ball bearing (A) from the transmission side using the oil seal driver (B).

   Fig. 161: Installing Ball Bearing

Countershaft Bearing Replacement

Special Tools Required

• Oil seal driver 07JAD-PL90100
• Adjustable bearing puller, 20-40 mm 07736-A01000B
• Slide hammer, 3/8"-16 UNF commercially available

1. Remove the bearing set plate (A) from the clutch housing (B).

   Fig. 162: Identifying Bearing Set Plate And Clutch Housing

2. Remove the needle bearing (A) using the 20-40 mm adjustable bearing puller (B) and a commercially available 3/8"-16 UNF slide hammer (D), then remove oil guide plate C.

   Fig. 163: Removing Needle Bearing

3. Position oil guide plate C and new needle bearing (A) in the bore of the clutch housing (B).

   Fig. 164: Installing Needle Bearing

4. Install the needle bearing using the oil seal driver (D).
5. Install the bearing set plate (A) with bolts (B).

   Fig. 165: Identifying Bearing Set Plate Bolts w/Torque Spec.

Mainshaft Thrust Clearance Adjustment

Special Tools Required

• Mainshaft holder 07GAJ-PG20110
• Mainshaft base 07GAJ-PG20130

1. Remove the 72 mm shim (A) and oil guide plate M from the transmission housing (B).

   Fig. 166: Identifying Shim And Transmission Housing

2. Install the 3rd/4th synchro hub (A), the distance collar (B), the 5th/6th synchro hub (C), distance collar (D), and ball bearing (E) on the mainshaft (F), then install the assembled mainshaft in the transmission housing (G).

   Fig. 167: Identifying 3rd/4th Synchro Hub, 5th/6th Synchro Hub, Distance Collar And Ball Bearing

3. Install the 28 mm washer (H) on the mainshaft.
4. Measure the distance (1) between the end of the transmission housing and 28 mm washer with a straight edge and vernier caliper. Measure at three locations, and average the reading.
5. Measure the distance (2) between the end of the clutch housing (A) and bearing inner race (B) with a straight edge and depth gauge. Measure at three locations, and average the readings.

   Fig. 168: Identifying Distance Between End Of Clutch Housing And Bearing Inner Race

   Shim Selection Formula:

6. Select the proper 72 mm shim from the chart. Follow the example below, and use the measurements you made in steps 4 and 5:

   (Basic Formula)

   (1) + (2) - (0.8 + 0.11) = shim thickness (maximum)

   (1) + (2) - (0.8 + 0.17) = shim thickness (minimum)

   • Add distance (2) (step 5) to distance (1) (step 4).
   • 0.8 mm (0.031 in.): Spring washer, a dimension in the installation.
   • 0.11 mm (0.004 in.): Minimum thrust clearance.
   • 0.17 mm (0.007 in.): Maximum thrust clearance.

   (For example)

   2.32 + 0.15 - (0.8 + 0.11) = 1.56 mm (0.061 in.)

   2.32 + 0.15 - (0.8 + 0.17) = 1.50 mm (0.059 in.)

   Take the middle value of the minimum value and the maximum value, and select the 1.53 mm (0.060 in.) shim.

   72 mm Shim

   SHIM THICKNESS SPECIFICATION
   

   	Part Number	Thickness
   A	23931-P21-000	0.60 mm (0.024 in.)
   B	23932-P21-000	0.63 mm (0.025 in.)
   C	23933-P21-000	0.66 mm (0.026 in.)
   D	23934-P21-000	0.69 mm (0.027 in.)
   E	23935-P21-000	0.72 mm (0.028 in.)
   F	23936-P21-000	0.75 mm (0.030 in.)
   G	23937-P21-000	0.78 mm (0.031 in.)
   H	23938-P21-000	0.81 mm (0.032 in.)
   I	23939-P21-000	0.84 mm (0.033 in.)
   J	23940-P21-000	0.87 mm (0.034 in.)
   K	23941-P21-000	0.90 mm (0.035 in.)
   L	23942-P21-000	0.93 mm (0.037 in.)
   M	23943-P21-000	0.96 mm (0.038 in.)
   N	23944-P21-000	0.99 mm (0.039 in.)
   O	23945-P21-000	1.02 mm (0.040 in.)
   P	23946-P21-000	1.05 mm (0.041 in.)
   Q	23947-P21-000	1.08 mm (0.043 in.)
   R	23948-P21-000	1.11 mm (0.044 in.)
   S	23949-P21-000	1.14 mm (0.045 in.)
   T	23950-P21-000	1.17 mm (0.046 in.)
   U	23951-P21-000	1.20 mm (0.047 in.)
   V	23952-P21-000	1.23 mm (0.048 in.)
   W	23953-P21-000	1.26 mm (0.050 in.)
   X	23954-P21-000	1.29 mm (0.051 in.)
   Y	23955-P21-000	1.32 mm (0.052 in.)
   Z	23956-P21-000	1.35 mm (0.053 in.)
   AA	23957-P21-000	1.38 mm (0.054 in.)
   AB	23958-P21-000	1.41 mm (0.056 in.)
   AC	23959-P21-000	1.44 mm (0.057 in.)
   AD	23960-P21-000	1.47 mm (0.058 in.)
   AE	23961-P21-000	1.50 mm (0.059 in.)
   AF	23962-P21-000	1.53 mm (0.060 in.)
   AG	23963-P21-000	1.56 mm (0.061 in.)
   AH	23964-P21-000	1.59 mm (0.063 in.)
   AI	23965-P21-000	1.62 mm (0.064 in.)
   AJ	23966-P21-000	1.65 mm (0.065 in.)
   AK	23967-P21-000	1.68 mm (0.066 in.)
   AL	23968-P21-000	1.71 mm (0.067 in.)
   AM	23969-P21-000	1.74 mm (0.069 in.)
   AN	23970-P21-000	1.77 mm (0.070 in.)
   AO	23971-P21-000	1.80 mm (0.071 in.)
   AP	23972-PPP-J000	1.83 mm (0.072 in.)
   AQ	23973-PPP-J000	1.86 mm (0.073 in.)
   AR	23974-PPP-J000	1.89 mm (0.074 in.)
   AS	23975-PPP-J000	1.92 mm (0.075 in.)
   AT	23976-PPP-J000	1.95 mm (0.076 in.)
   AV	23977-PPP-J000	1.98 mm (0.077 in.)
   AW	23978-PPP-J000	2.01 mm (0.079 in.)
   AX	23979-PPP-J000	2.04 mm (0.080 in.)
   AY	23980-PPP-J000	2.07 mm (0.081 in.)
   AZ	23981-PPP-J000	2.10 mm (0.082 in.)
   BA	23982-PPP-J000	2.13 mm (0.083 in.)
   BB	23983-PPP-J000	2.16 mm (0.085 in.)
   BC	23984-PPP-J000	2.19 mm (0.086 in.)
   BD	23985-PPP-J000	2.22 mm (0.087 in.)
   BE	23986-PPP-J000	2.25 mm (0.088 in.)

7. Install the 72 mm shim (A) selected and oil guide plate M in the transmission housing (B).

   Fig. 169: Identifying Shim, And Oil Guide Plate M And Transmission Housing

8. Thoroughly clean the 28 mm spring washer (A) and 28 mm washer (B) before installing them on the clutch housing side ball bearing (C).

   NOTE:

   Install the spring washer in the direction shown.

   Fig. 170: Identifying Spring Washer And Clutch Housing Side Ball Bearing

9. Install the assembled mainshaft in the clutch housing.
10. Place the transmission housing over the mainshaft and onto the clutch housing.
11. Tighten the clutch and transmission housings with several 8 mm special bolts (left-hand threads).

    NOTE:

    It is not necessary to use sealing agent between the housings. The 8 mm special bolts have left-hand threads.

12. Lightly tap on the mainshaft with a plastic hammer.
13. Attach the mainshaft base (A) and mainshaft holder (B) to the mainshaft as follows:
    • Back-out the mainshaft holder bolt (C), and loosen the two hex bolts (D).
    • Fit the holder over the mainshaft so its lip is towards the transmission.
    • Align the mainshaft holder lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.

      Fig. 171: Identifying Mainshaft Base, Mainshaft Holder And Mainshaft Holder Bolt

14. Fully seat the mainshaft by tapping its end with a plastic hammer.
15. Thread in the mainshaft holder bolt until it just contacts the wide surface of the mainshaft base.
16. Zero a dial gauge (A) on the end of the mainshaft.

    Fig. 172: Measuring Mainshaft End Play

17. Turn the mainshaft holder bolt (B) clockwise, and stop turning when the dial gauge (A) has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft end play.

    NOTE:

    Do not turn the mainshaft holder bolt more than 60 degrees after the needle of the dial gauge stops moving. Applying more pressure with the mainshaft holder bolt may damage the transmission.

18. If the reading is within the standard, the clearance is correct. If the reading is not within the standard, recheck the shim thickness.

    Standard: 0.11-0.17 mm (0.004-0.007 in.)

Transmission Reassembly

NOTE:

Prior to reassembling, clean all the parts in solvent, dry them, and apply manual transmission fluid (MTF) to any contact surfaces.

1. Install the release bearing guide (A), new drain plug washer (B), and drain plug (C).

   Fig. 173: Identifying Release Bearing Guide, Drain Plug Washer And Drain Plug

2. Install the magnet (A) and differential assembly (B).

   Fig. 174: Identifying Magnet And Differential Assembly

3. Install the 28 mm spring washer (A) and 28 mm washer (B) over the ball bearing (C).

   NOTE:

   Install the spring washer in the direction shown.

   Fig. 175: Identifying Spring Washer, Countershaft, Shift Forks And Ball Bearing

4. Apply vinyl tape the mainshaft spline (D) to protect the seal. Install the mainshaft and countershaft (E) into the shift forks (F), and install them as an assembly.
5. Install the reverse shift fork.

   Fig. 176: Identifying Reverse Shift Fork

6. Install the 20 x 36 x 2 mm thrust washer (A), reverse idler gear (B), and reverse gear shaft (C) by aligning the mark (D) with reverse gear shaft hole (E).

   Fig. 177: Identifying Shim, Thrust Washer, Reverse Idler Gear And Reverse Gear Shaft

7. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment (see MAINSHAFT THRUST CLEARANCE ADJUSTMENT ). Install the oil gutter plate (B), oil guide plate M, and 72 mm shim into the transmission housing (C).

   Fig. 178: Identifying Shim, Oil Gutter Plate And Transmission Housing

8. Clean any dirt or oil from the transmission housing sealing surface.
9. Apply liquid gasket, P/N 08718-0001, evenly to the transmission housing sealing surface of the clutch housing. Install the component within 5 minutes of applying the liquid gasket.

   NOTE:

   If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 179: Identifying Transmission Housing Sealing Surface Of Clutch Housing

10. Install the three 14 x 20 mm dowel pins (A).

    Fig. 180: Expanding Snap Ring

11. Place the transmission housing over the clutch housing, being careful to line up the shafts.
12. Lower the transmission housing the rest of the way as you expand the 72 mm snap ring (B). Release the snap ring so it seats in the groove of the countershaft bearing.
13. Make sure the 72 mm snap ring is securely seated in the groove of the countershaft bearing.

    Dimension (1) as installed: 3.3-6.0 mm (0.13-0.24 in.)

    Fig. 181: Identifying Countershaft Bearing Groove Dimension

14. Apply liquid gasket, P/N 08718-0001 (A) evenly to the threads of the 32 mm searing cap, and a 2 mm (0.079 in.) bead around the mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

    NOTE:

    If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 182: Identifying Bead Dimension Around Mating Surface Of Transmission Housing

15. Install the transmission hangers A and B, harness bracket B (C), mount bracket collars (D), and 8 mm special bolts (left-hand threads) finger-tight.

    NOTE:

    The 8 mm special bolts have left-hand threads.

    Fig. 183: Identifying Transmission Hangers, Harness Bracket And Mount Bracket Collars

16. Tighten the 8 mm special bolts (left-hand threads) in a crisscross pattern in several steps.

    Fig. 184: Identifying Tightening Sequence Of Special Bolts

17. Clean any dirt or oil from the shift arm cover sealing surface.
18. Apply liquid gasket, P/N 08718-0001, evenly to the change lever assembly mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

    NOTE:

    If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 185: Identifying Mating Surface Of Transmission Housing

19. Install the two 8 x 14 mm dowel pins (B), change lever assembly (C), and harness bracket A.

    Fig. 186: Identifying Dowel Pins, Change Lever Assembly And Harness Bracket

20. Apply liquid gasket, P/N 08718-0001 (A) evenly to the threads of the interlock bolt, and a 2 mm (0.079 in.) bead around the mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

    NOTE:

    If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 187: Identifying Bead Dimension Around Mating Surface Of Transmission Housing

21. Install the interlock bolt (D) on the transmission housing.
22. Install the mount bracket collars (A), new 10 mm washer (B), and 10 mm flange bolt (C). Install the new filler plug washer (D) and filler plug (E) finger-tight.

    Fig. 188: Identifying Mount Bracket Collars, Washer, Flange Bolt, Filler Plug Washer And Filler Plug

23. Apply MTF to the new O-ring (F), then install the new O-ring, plain washer (G), and the output shaft (countershaft) speed sensor (H).
24. Apply liquid gasket, P/N 08718-0001 (A) evenly to the threads of the back-up light switch, and a 2 mm (0.079 in.) bead around the mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

    NOTE:

    If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 189: Identifying Bead Dimension Around Mating Surface Of Transmission Housing

25. Install the back-up light switch (A) on the transmission housing.

    Fig. 190: Identifying Back-Up Light Switch, Steel Balls And Washers

26. Install the detent bolts, spring, and steel balls (6) with new 12 mm washers (C).
27. Install the new 20 mm washer (D), 20 mm bolt (E), and transmission hanger (F).

Gearshift Mechanism Replacement

Fig. 191: Identifying Gearshift Mechanism Components

M/T Differential

Component Location Index

Fig. 192: Identifying M/T Differential Components Location

Backlash Inspection

1. Place the differential assembly on V-blocks (A), and install the intermediate shaft (B) and the left driveshaft (C).

   Fig. 193: Measuring Backlash Of Both Pinion Gears

2. Measure the backlash of both pinion gears (D) with a dial indicator (E). If the backlash is not within the standard, replace the differential carrier.

   Standard: 0.05-0.15 mm (0.002-0.006 in.)

Differential Carrier, Final Driven Gear Replacement

1. Remove the bolts (left-hand threads) in a crisscross pattern in several steps, then remove the final driven gear (A) from the differential carrier (B).

   Fig. 194: Identifying Final Driven Gear And Differential Carrier

2. Install the final driven gear with the chamfer on the inside diameter facing the carrier. Align the marks on the driven gear and the carrier. Tighten the bolts in a crisscross pattern in several steps.

Carrier Bearing Replacement

Special Tools Required

Driver, 40 mm I.D. 07746-0030100

1. Check the carrier bearings for wear and rough rotation. If they rotate smoothly and their rollers show no signs of wear, the bearings are OK.
2. Remove the carrier bearings (A) with a commercially available bearing puller (B).

   Fig. 195: Removing Carrier Bearings

3. Install the new bearings (A) with the 40 mm I.D. driver (B) and a press. Press on each bearing until it bottoms. There should be no clearance between the bearings and the carrier.

   NOTE:

   Place the seal (C) part of the bearing towards the outside of the differential, then install it.

   Fig. 196: Installing Bearings

Oil Seal Replacement

Special Tools Required

• Driver 07749-0010000
• Oil seal driver attachment 07NAD-P20A100

1. Remove the oil seal (A) from the transmission housing (B).

   Fig. 197: Removing Oil Seal From Transmission Housing

2. Remove the oil seal (A) from the clutch housing (B).

   Fig. 198: Removing Oil Seal From Clutch Housing

3. Install the new oil seal in the transmission housing with the driver (A) and oil seal driver attachment (B).

   Fig. 199: Installing Oil Seal In Transmission Housing

4. Install the new oil seal in the clutch housing with the driver (A) and oil seal driver attachment (B).

   Fig. 200: Installing Oil Seal In Clutch Housing

Differential Thrust Clearance Adjustment

Special Tools Required

Driver, 40 mm I.D. 07746-0030100

1. If you removed the 80 mm shim (A) from the transmission housing (6), reinstall the same sized shim.

   Fig. 201: Identifying Shim And Transmission Housing

2. Install the differential assembly (A) into the clutch housing (B).

   Fig. 202: Identifying Differential Assembly And Clutch Housing

3. Install the transmission housing onto the clutch housing, then tighten the 8 mm special bolts (left-hand threads) in a crisscross pattern in several steps (see step 16 ).

   8 x 1.25 mm Special Bolt (Left-hand Threads) 24 N.m (2.4 kgf.m, 17.4 lbf.ft)

4. Use the 40 mm I.D. driver (A) to bottom the differential assembly in the clutch housing (B).

   Fig. 203: Installing Differential Assembly In Clutch Housing

5. Measure the clearance between the 80 mm shim and the bearing outer race in the transmission housing.

   Standard: 0-0.10 mm (0-0.0039 in.)

   Fig. 204: Measuring Clearance Between Shim And Bearing Outer Race In Transmission Housing

6. If the clearance is more than the standard, select a new 80 mm shim from the following table. If the clearance measured in step 5 is within the standard, go to step 9.

   80 mm Shim

   SHIM THICKNESS SPECIFICATION
   

   	Part Number	Thickness
   A	41441-PL3-B00	1.00 mm (0.039 in.)
   B	41442-PL3-B00	1.10 mm (0.043 in.)
   C	41443-PL3-B00	1.20 mm (0.047 in.)
   D	41444-PL3-B00	1.30 mm (0.051 in.)
   E	41445-PL3-B00	1.40 mm (0.055 in.)
   F	41446-PL3-B00	1.50 mm (0.059 in.)
   G	41447-PL3-B00	1.60 mm (0.063 in.)
   H	41448-PL3-B00	1.70 mm (0.067 in.)
   J	41449-PL3-B00	1.80 mm (0.071 in.)
   K	41450-PL3-B00	1.05 mm (0.041 in.)
   L	41451-PL3-B00	1.15 mm (0.045 in.)
   M	41452-PL3-B00	1.25 mm (0.049 in.)
   N	41453-PL3-B00	1.35 mm (0.053 in.)
   P	41454-PL3-B00	1.45 mm (0.057 in.)
   Q	41455-PL3-B00	1.55 mm (0.061 in.)
   R	41456-PL3-B00	1.65 mm (0.065 in.)
   S	41457-PL3-B00	1.75 mm (0.069 in.)

7. Remove the bolts and transmission housing.
8. Replace the thrust shim selected in step 6, then recheck the clearance.
9. Reinstall the transmission housing.

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