Assembly Special Tool(s) | 204-087 Installer, Front Wheel Hub Bearing Cup/Seal | | 204-160 Installer, Front Wheel Bearing | | 205-067 Preload Gauge | | 205-072 Universal Flange Holding Wrench | | 205-175 Socket, Drive Pinion Nut | | 205-215 Installer, Rear Wheel Hub Seal | | 205-310 Remover, Bearing/Gear | | 205-329 Mounting Bracket, Engine/Differential | | 205-332 Protector, Axle Shaft | | 303-318 Aligner/Installer, Crankshaft Front Seal | | 303-435 Mounting Stand | | 303-435-06 Mounting Bracket for 303-435 | | 308-095 Installer, Input Shaft Bearing | | 308-604 Installer, Output Drive Flange Seal | | 308-605 Installer, Input Shaft Seal | Materials Name Specification Adhesive - Loctite 243 WSK-M2G349-A7 Grease SA-M1C9107-A High-Temperature Grease ESD-M1C220-A Sealant - Loctite 518 WSK-M2G348-A5 Transmission Fluid WSD-M2C200-C General Equipment Cable ties Flat-bladed screwdriver Hot air gun Hydraulic press | -
All synchronizer rings and needle bearings should be lubricated with clean transmission fluid prior to assembly. | | -
Gear wheel - 4th gear and synchronizer assembly - 3rd/4th gear | | -
Snap ring, synchronizer assembly - 3rd/4th gear | | -
Synchronizer hub – 5th/6th gear | | -
NOTE:Make sure that these components are installed to the noted removal position. | | -
NOTE:Make sure that these components are installed to the noted removal position. Install the following items: | | -
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Secure the shaft pack with cable ties. -
Secure the input shaft to protect it against falling down. | | - Install the following items:
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Secure the bearing with grease. -
Install the main shift shaft. | | -
Heat the reverse gear bearing sleeve with a hot air blower to around 100 °C and use a suitable length of tube or pipe to fully install it once the reverse gear bearing sleeve has cooled down. | | -
Heat up the special tool with a hot air blower to around 100 °C and then transfer it to the bearing. | | -
NOTE:Only tighten the bolts finger tight at this stage. | | -
Align the swinging shift fork using a flat-blade screwdriver. Torque: 37 Nm | | -
Tap the locating pins back into installation position. | | -
Tighten the transmission housing bolts, working diagonally. Torque: 24 Nm | | -
Move the gearshift shaft to neutral. | | -
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Tighten the bolt. Torque: 210 Nm -
Tighten the bolt. Torque: 180 Nm | | - Install the following items:
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Attach the layshaft bolt. Torque: 95 Nm -
Detach the input shaft snap ring. | | - Install the following items:
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Install the oil seal flush. | | -
NOTE:Only tighten the bolts finger tight at this stage. | | -
Move the gearshift shaft to neutral. | | -
X = 154 mm (gearshift shaft in neutral) Torque: 25 Nm | | -
Refer to: Specifications (308-03C Manual Transmission/Transaxle - Vehicles With: MT82, Specifications). Torque: 35 Nm | | |