G52 MANUAL TRANSMISSION PRECAUTION: ‘TROUBLESHOOTING ASSEMBLY REMOVAL AND INSTALLATION = - COMPONENT PARTS REMOVAL AND INSTALLATION neUT SHAFT ‘COUNTER GEAR AND REVERSE IDLER GEAR FRONT BEARING RETAINER SERVICE SPECIFICATIONS wrt Mr 2 mr 2 Mt 4 MT 5 MI 9 wT 18 oo MT= 20 Mt 21 M120 Mr 0 t= 32ue G52 MANUAL TRANSMISSION ~ PRECAUTION, PREPARATION PRECAUTION When working with FIPG rial. you must obs nd geskot scraper, remove all the old FIPG materal from the gasket surf componente to remove al the loose material soaling surtecos with a non—residue solvent. Apply FIPG in an approx. 1 mm (0.04 in} wide bead along the sasling aur Parts must be assembled within 10 minutes of application. Otherwise, the FIPG mater removed end respplied. must be ur PREPARATION SST (SPECIAL SERVICE TOOLS) ‘GV BGTT —enenaon 8 Fans Bor | (oss16-a0011) nasser Poe Coun oar rebar ea ‘Sapa er bing a Cr TTT Far I -FOOTS Fats Ce “Gonrsinn pace ot ERB Rear be (69651-20440) aaa ontop inner SQ (esi 20510} Row 87 “tra oe(G52 MANUAL TRANS! M3 RECOMMENDED TOOLS ‘ORATOR Pom RES To esr Fe ‘BETTS gt ae a 54875 ‘SSM (SPECIAL SERVICE MATERIALS) | tears atx Frei ‘Siro sew aeMES (G52 MANUAL TRANSMISSION — TROUBLESHOOTING TROUBLESHOOTING low to help you find the eaueo of the problem. The numbers indicate the parity iy cout ofthe prob. Check each pat In oda It racecar, replace these por lls eee El Sis} T'/S/5/5/ 5/5) § J SISIPLE oT aT |] lglg] iB lalehe } peas ibalee \ i Hagel a 2| elgleis/alesl2lile | m \E REE GISELE | no 1 Ele [3 [it (icles AGE i Coo cco ; ALL | [ores | | jv]? 3 | | | | | = a Hee Pee | PET PTT(G52 MANUAL TRANSM \SSEMBLY REMOVAL AND INSTALLATION ASSEMBLY REMOVAL AND INSTALLATION COMPONENTS ‘Tansmission Shit Lever Knob ———§) 0-——Tranaler Shit Lever Knob one pgs ae Snap Ring “Tar Prepatir Shalt Back-Up Light Switch Connector wo Peston Bwiteh Connector ee. FH Stitener Pate Engine Rear ee ‘Mounting aa eit @ sachet Front Exhaust Pipe 20.) | 7]: Specied torque No an No Eni Under ovr Mrs.wit G52 MANUAL TRANSMISSION — ASSEMBLY REMOVAL AND INSTALLATION 1 (a) 6) @ a) ©) SEs spi ST aon Lenn Drain Plug TRANSMISSION REMOVAL REMOVE TRANSMISSION SHIFT LEVER, Remove the upper console panel Romove the 4 screws, shift lover boot and retain Cover the shift lever cap with a cloth Prassing down on the shift lever cap and rotate it counterclockwise to remove, Pull out the hift lever INSTALLATION HINT: Apply MP grease to the tip of the shift lover. REMOVE TRANSFER SHIFT LEVER Using pliets. remove the snap ring and pull out the hit lover, HINT: Shift the transfer shit lever to the “H4” posi: INSTALLATION HINT: Apply MP or the shift love. to the tip of RAISE VEHICLE AND DRAIN TRANSMISSION Oi ‘APIGL—4 of GL-S ity: 2.2 itera (2-3 US ate. 1 Torque: 37 Nm (380 koticm, 27 tbs) REMOVE NO.1 AND NO.2 ENGINE UNDER COVERS. REMOVE FRONT AND REAR PROPELLER SHAFTS (See page PR—3) REMOVE CLUTCH RELEASE CYLINDER Remove the 2 bolts and release cylinder Torque: 12 Nim (120 katiem, 9 fib) DISCONNECT THESE CONNECTORS: ‘© Baok—up light switch connector ‘+ Spoed sensor connector '* 4W0 position switch connector REMOVE FRONT EXHAUST PIPE 3 Door: Remove the 3 nuts and gasket from the exhaust manifold ‘Torque: 62 Nom (630 kat cm, 48 feibt) Remove the 2 bolt, springs. gach “Torqua: 43 Nim (440 ktm, 32 fbf), and pipe.G52 MANUAL TRANSMISSION — ASSEMBLY REMOVAL AND INSTALLATION _MT-7 5 Door {2} Remove the 2 bolts trom the eluteh housing, Toraue: Bolt A: 71 Nem (720 kat-em, 62 Fb) Bol 8: 60 Nm (700 haf em, BY FES (0) Remove the 3 nuts and gackot from tho exhaust manitols Torque: 62 Nom (620 kat em, 46 feb) (6) Remove the 2 bolts. springs. gasket and pipe Torque 42 Nim (40 kgf-em, 32 fel) ie 9, REMOVE LH AND RH STIFFENER PLATES (2) Remove the 4 bolts and LH stiffener plate Toraue: 17 en head: 69 Nem (700 kgt-em, 51 FIBA) 14 mm head: 37 Nan (380 kotem, 27 feb) (b} Remove the 3 (6 door) or 4 (3 doer) bolts and RH stiffener plate Toraue 17 mum head: 89 Nm (700 kgtom, 51 fl) 14 mm heed: 37 Nem (380 kgtem, 27 feb) 10. REMOVE NO.3 CROSSMEMBER (a). Support the transmission rear side. (b} Remove the 4 set bolts of the engine rear mounting. Torque: 18 Nm (185 kgf em, 13 #8164) [e)_ Remove the 4 bolts, nuts and crossmamber. Torque: 65 Nim (660 kaf-cm, 48 fe1bf) 11, REMOVE ENGINE REAR MOUNTING Remove the 4 bolts and engine rear mounting from the transmission Torque: 85 Nm (650 katem, 48 felt) 12. JACK UP TRANSMISSION SLIGHTLY Using a transmission jack, support the transmission 13. REMOVE STARTER (a) Remove the nut and digeonnet the wire from the (b) Remove the 2 bolts, nut and starter. Torque: 69 Nim (200 ket-em, 61 fbf) 14. REMOVE TRANSMISSION WITH TRANSFER Us) Disconnect the wire harness tem the tanamisson, \\_|_ 8) emove tw 4 uaremioson mounting ble fom he | ua = engine onli } a ae 2 Wey (730 katem, 63 feb) tf (e} Pullout the transmission with the transfer doven and Je 8 toward the roar.Mr-8 (G52 MANUAL TRANSMISSION — ASSEMBLY REMOVAL AND INSTALLATION. 15. REMOVE TRANSFER FROM TRANSMISSION @ Cy) Disconnect the braather hose and remove the 8 trans for adaptor rear mounting bots Torque: 24 Nim (240 kaf-em, 17 feb) Pull the transfer straight up and remove it from the HINT: Take care not to damage the transfer adaptor oil seal with the transfer input gear spline. INSTALLATION HINT: Apply MP grease to the trans: tor adaptor oll seal, TRANSMISSION INSTALLATION Installation isin the reverse order of removal HINT: Attar installation, do the road test652 MANUAL TRANSMISSION — COMPONENT PARTS REMOVAL AND ure INSTALLATION, COMPONENT PARTS REMOVAL AND INSTALLATION COMPONENTS Back-Up Liat Switch [am.2 Pcasker ] * he elas fen easter Imormecinte Plate Transmission Case +(e0T | ‘cuteh Housing ty Ve et ‘contol Sit Lever : Retainer ae Restrict Fi —— eo vetcctor (Cavcno.3 — Transtar Adaptor Aestit in “9 f'iete, 2 01 Receiver Ppe Magn [Nim aghem, Wat): Spectod torque @ Ner-rousatie part 4% Procoated parthwr.1o_@52 MANUAL TRANSMISSION ~ COMPONENT PARTS REMOVAL AND INSTALLATION Output Shaft Assembiy Fear Boaring Retainer ar st ing Synehronlzer ing oa Syehorze Reg @ Bearing a Peg er Ow Ioler Gear Shatt, Toes, else Intermediate Plate counter Gear Feverse olor Goat Pug—@ Serine Bearing Coste. snap Rieg—@ Shit Lever Housing shit Fon Shana omar He imetdck in —Shitand Set Lover tro ia ‘Shift Fork No.2— f — Shit Fork Shalt Not «(ta a « zemof® a Z2evinton st os a vag Shot ewe = toed Sng Pn ~, Reverse Shit Head | x(a an Ring Feces) Slated Seen Pin Lon lo srattneg ¢— [BERIT] ecoaaaaeee shi arm sno Bal eaeeieee Fost tntorock Bae, Reverse Shitt Arm Shit Fore Nos ing ares, a . ‘Shift Fork Shatt No.é rove sit A ve fe (0 iim igh em, Wb] Speoied Aare @ Non-reusable part 4 Precoatod partG52 MANUAL TRANSMISSION — COMPONENT PARTS REMOVAL AND INSTALLATION writ BASIC SUBASSEMBLY SEPARATION @ © cc) © REMOVE BACK-UP LIGHT SWITCH AND GASKET Torque: 37 Nm (380 kofem, 27 felbt) REMOVE CLUTCH HOUSING Remove the @ bolts and clutch housing. forque: 37 Nm (880 kafem. 27 febt) INSTALLATION HINT: Apply liquid sealer to the“ bolt threads. Sealant: Pert Mo.08833 ~ 00080, THREE BOND 1344, LOCTITE 262 or equlvelont REMOVE CONTROL SHIFT LEVER RETAINER Remove the 4 bolts, retainer and oll deflector. Torque: 18 Nim (185 kgtcm, 13 felt) REMOVE 2 RESTRICT PINS Toraue: 28 Nm (280 katcm. 21 felbf) REMOVE TRANSFER ADAPTOR Remove the shift lever housing set bolt. Torque: 38 Nim (300 kgtem, 28 feb), Romove the 8 bolts. Torque: 37 Nm (380 kat-em, 27 feb) Using a plastic hammer, tap the transfer adaptor and remove it. FIPG: Part No. 0862600090, THREE BOND 1281 or ‘equivalont REMOVE FRONT BEARING RETAINER Remove the 8 bolts, gasket and retainer. Sealant: Part No.08833 ~ 00080, THREE BOND 1344, LOCTITE 242 or equlvslont ‘Torque: 17 Nom (170 kgfer, 12 feb") SEPARATE INTERMEDIATE PLATE FROM TRANS- MISSION CASE Using a snap ring expander, remove the 2 snap-rings from the input shaft and eounter gear Stand the transmission, as shove, Using a plastic hammer, carefully tap the ate and romove it. FiPG: Part No, 08826-00090, THREE BOND 1201 or ‘equivalent MOUNT INTERMEDIATE PLATE IN VISE Using the 2 clutch housing bolts, plate washers and suitable ruts, as shown. INSTALLATION NOTICE: Increase or decrease plate was: here 20 that the bolt tip dove not prot ‘Mount the intermediate plate in a vise,raz G52 MANUAL TRANSMISSION — COMPONENT PARTS REMOVAL AND @ ro) 10. Ww ® w 12, INSTALLATION REMOVE STRAIGHT SCREW PLUG, SPRING AND BALL Using a torx socket wrench (T40},ramove tho 4 screw ‘plugs fram tha intermediate plate, Sealant: Pert No. 08833 ~ 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 19 Nem (100 kgtiem, 14 ff) Using a magnetic finger, remove the 4 springs and bats. REMOVE SHIFT FORK SHAFT SNAP RING Using 2 screwdrivers and a hammer, drive out the 3 snap rings. REMOVE SHIFT FORK NO.3, SHIFT FORK SHAFT 1NO.4 AND REVERSE SHIFT HEAD Remove the shift fork No.3 set bolt, Torque: 20 Nm (200 kptcm, 14 felt) Remove the shift fork No.3, shift fork shaft Nod, averse shift haad and 2 balls REMOVE REVERSE SHIFT ARM, REVERSE SHIFT FORK AND SHIFT FORK SHAFT NO.3 Using @ magnetic finger, remove the interlock trom the shift fork shaft No.3G52 MANUAL TRANSMISSION — COMPONENT PARTS REMOVAL AND ap.ag INSTALLATION (©) Using 2 pin punch and hammer spring pin (6) Remove the shift fork shaft No.3. (4) Using manetic finger. remove the interlock pin. (0) Remove the reverse chift arm end fork. (f) Using a screwdriver, remove the 2 rings. (a). Separate the shift arm, fork and shoo. 13. REMOVE SHIFT FORK SHAFTS NO.1, NO.2 AND SHIFT FORKS NO.1, NO.2 (2) Using @ magnetic finger. remove the interlock pin from the shift fork shaft No.2. (6) Remove the shift fork No.1 set bott. Torque: 20 Nem (200 katem. 14 feist)wr wre (G52 MANUAL TRANSMISSION — COMPONENT PARTS REMOVAL AND @ @ « 16. @ 4, INSTALLATION Romove the shift fork shaft No.1 Using a magnatic finger, romove the interlock pin Remove the shift fork No.2 sot bolt. “Torque: 20 Nem (200 gem, 14 fest) Romove the shift forks No.1, No.2 and shitt fork shaft No.2 MEASURE COUNTER 5TH GEAR THRUST CLEAR- ANCE Using a feoler gauge, measure the eounter Sth gear thrust clearance. ‘Standard elastance: 0.10~0.30 mm (0.0039-0.0118 in) Moximum elesrancet 0.36 mm (0.0138 in) REMOVE GEAR SPLINE PIECE NO.5, SYNCHRON!- ZER RING, NEEDLE ROLLER BEARING AND COUNT. ER STH GEAR WITH HUB SLEEVE NO.3 Using 2 serewdrivers and a hammer, top out the snap ring INSTALLATION HINT: Select @ snap ring that will low minimum axial py. ro Thera na Nos. Using SST, remove the goar epline pie SST 09950-80010 Remove the synchronizer ring, n ‘and counter Sth gear, le roller bearing(G52 MANUAL TRANSMISSION ~ COMPONENT PARTS REMOVAL AND aig Socket Wrench \ 16. @ © "7. 18. (a) INSTALLATION INSTALLATION HINT: Using 9 press and socket wrench, install the goar spline piece No.5 with the synchronizer ring slots aligned withthe shifting keys. REMOVE SPACER AND BALL Remove the spacer Using a magnetic finger. remove the bal, REMOVE REVERSE SHIFT ARM BRACKET Remove the 2 bolts and raverse shift atm bracket, Torque: 18 Nm (185 kgtcm, 13 felbf) REMOVE REVERSE IDLER GEAR AND SHAFT Romove the reverse idler gear shaft stopper set bolt and stopper Torque: 17 Nim (178 kgt.em, 13 feb)hwT.1g G52 MANUAL TRANSMISSION ~ COMPONENT PARTS REMOVAL AND. 19 20. @) 0) co) 21. INSTALLATION REMOVE REAR BEARING RETAINER Using a torx socket wranch (740). remove the 4 serow plugs and retainer Torque: 18 Wm (185 kaf-em, 13 fe1bf) REMOVE COUNTER GEAR Using a snap ting expander, ramove the counter gear rear bearing snap ring Using SST and a socket wrench, remove the counter 03" rear bearing SST 09950-40010 Remove the counter gear. INSTALLATION HINT: Install the counter the intermadiate plate whil holding the counter gear, and installing the counter rear bearing with SST. SST 09316-6001 1 (08316-0001 1) REMOVE INPUT SHAFT ASSEMBLY Remove the inout shaft with the 13 needle roller boarings and synchronizer ring from the output shaft. INSTALLATION HINT: Install tho input shaft to the output shaft with the synehronizer ring slots aligned with the shifting keys.G52 MANUAL TRANSMISSION ~ COMPONENT PARTS REMOVAL AND yqy.4 INSTALLATION, 22, REMOVE OUTPUT SHAFT ASSEMBLY (a) Using 2 snap ring expander, remove the output shaft center bearing snap ring INSTALLATION HINT: Be eure the enap ring is flush With the intermediate plate surface. (0) Remove the output shaft from the intermediate plate by pulling on the output shaft and tapping on the intermediate plate with a plastic hammer. BASIC SUBASSEMBLY REASSEMBLY Roassombly is in the reverse order of separation. HINT: Coat all of the sliding and rotating surfaces with 900 oil before assembly. aEMT-18 652 MANUAL TRANSMISSION — INPUT SHAFT INPUT SHAFT COMPONENTS [wr j Synehonize ing INPUT SHAFT INSPECTION INSPECT SYNCHRONIZER RING (9) Cheek for wear or damage. {b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while push- ing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small om = amount of fine lapping compound between the syn Cchronizer ring and gear cone. Lightly rub the syn: cchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound Is completely wash [@) Check again the br ring. (@) Using a arance between the synchronizer ring back ‘spline end. Minimum elearanes: 0.8 mm (0.031 in) wie If the clearance is ls then the minimum, replace the ‘synchronizer ring and gear cone by applying a smal ‘amount of fine lapping compound. NOTICE: Ensure the fine lapping compound is completly washed off after rubbing.(G52 MANUAL TRANSMISSION — INPUT SHAFT Bre BEARING REPLACEMENT IF NECESSARY, REPLACE INPUT SHAFT BEARING (2) Using 2 snap ring expander. remove the snap ring. [b) Using @ prass, ramove the bearing {c)_ Using SST and a press, install a new bearing SST 09508-35010 (@)_ Solect a snap ring that will allow imu ail py co Tren one | Tis-n16 woos)-see7y 210-218 Rowx=aos6 | 315-230 wowto=coww 236-22 eons-aobo 225-230 om -oo009 | ‘220-735 (00s0s—a0078) (6). Using a snap ring expander. install the snap ringrae G52 MANUAL TRANSMISSION — OUTPUT SHAFT OUTPUT SHAFT COMPONENTS: Teeter ing fikt’ | —snaina ke spina! i ‘3 cut Hb no vu hat | | ening SF Fno shit Key | | e Shiting Key Spring 2nd peur Noedie Rotor Bearing Reverse Gear | | Sypehronzer Ring | Synchronizer Ring Needle Roller Bearing Clutch Hub No.t @ tion reusable pat OUTPUT SHAFT DISASSEMBLY 1. MEASURE EACH GEAR THRUST CLEARANCE Using a feelor gauge, measure the thrust clearance of gee arance: 0.10 0.28 mm (0.0039 0.0098 in.) ‘Maximum clearance: 0.30 mm (0.0118 in.)(G52 MANUAL TRANSMISSION — OUTPUT SHAFT ret 2. MEASURE EACH GEAR RADIAL CLEARANCE Using a cal indicator, measure the racial clearance of Seee= et nn Woote~aar1a md npernee same Rate STEN Moar ied sete lan sla Tasanbeston pauitho ea gout node ralorbetng or st. 3, RENOVE STH GEAR, REAR BEARING, 1ST GEAR, INNER RAGE AND NEEDLE ROLLER SEARING Fe ee enntontineninronpeirn (©) Using 2 prass, remove the 5th gear, raar bearing, 1st 900" and inner race, (6) Remove the needle roar bearing. 4, REMOVE SYNCHRONIZER RING 5. REMOVE LOCKING BALL Using a magnatic finger, remove the locking bal. 6. REMOVE REVERSE GEAR ASSEMBLY. SYNCHRO- NIZER RING, 2ND GEAR AND NEEDLE ROLLER BEARING (@) Using 2 press, remove the reverss gear assombly, synchronizer ring and 2nd gear (0) Remove the needle roller bearing,Mt wr-22 G52 MANUAL TRANSMISSION — OUTPUT SHAFT 7 ®) w cy REMOVE REVERSE GEAR, SHIFTING KEY AND ‘SPRING FROM CLUTCH HUB NO.1. Using a screwdriver. remove the 3 shifting keys and 2 springs from the clutch hub No.1 REMOVE HUB SLEEVE NO.2 ASSEMBLY, SYNCH. RONIZER RING, 3RD GEAR AND NEEDLE ROLLER BEARING Using a snap ring expander, remove the snap ring, Using a press, remove the hub sleeve No.2 aczembiy, synchronizer ring and Sed gear. Remove the noodle roller bearing REMOVE HUB SLEEVE NO.2, SHIFTING KEY AND ‘SPRING FROM CLUTCH HUB NO.2 Using a screwdriver, remove the 3 shifting keys and ‘springs from the clutch hub No.2. OUTPUT SHAFT COMPONENT PARTS INSPECTION 1 a) INSPECT OUTPUT SHAFT AND INNER RACE Using calipers. measure the output shaft flange thick: Minimum thickness: 4.70 mm (0-1860 In.) 1 the thickness ig lass than the minimum, replace the output shaft.(G52 MANUAL. TRANSMISSION — OUTPUT SHAFT rea » meaaure the inner race flange thick 9 ram (0.1574 In.) lass than the minimum, replace the (€) Using a micrometer, measure the outer diametor of the output shaft journal Minimum dieters 2nd goar: 37.88 mm (1.4905 in) 23rd goer: 34.86 mm (1.3724 in) It the outer diameter lees than the minimum, replace ‘the output shaft (2) Using a micrometer, measure the outer diameter of the inner ra Minimum diameter: 38.085 mm (1.5348 In) If the outer diameter is les than the minimum, replace the inner race, (@) Using a dial indieator, check the shaft runout ‘Maximum runout 0.06 mm (0.0024 in.) If the runout exceeds the maximum, replace the ‘output shart, 2, INSPECT SYNCHRONIZER RING (a) Check for woar or damage. (b) Chock the braking o*fect of the eynehronizer ring, ‘Turn the synchronizer ring in one direction while push ing it to the gear eons, Chack that the ring locks. If the braking effect is insufficient, apply a smal ‘smount of fine lapping compound between the syn- Cchronizer ring and gear cone. Lightly rub tho sym chronizer ring and gear cone together.r-24 Hub Sleeve No.2 Reverse Gear ©) @ (052 MANUAL TRANSMISSION — OUTPUT SHAFT. Check again the braking affect of the synchronizer 3F gauge, moacure the clearance botw the synchronizer ring back and gear spline end Minimum clearance: 0.8 mm (0.031 in) If the clearance is less than the minimum, replace the synehronizer ring and gear cone by applying a small ‘amount of fin lapping compound. NOTICE: Ensure the fine lapping compound is completely wathed off after rubbing. MEASURE SHIFT FORK AND HUB SLEEVE CLEAR. ANCE: Using @ fosler gauge, measure theo! ‘tha hub slaave and shift fork Maximum elesrance: 1.0 mm (0.039 in.) HH the clearance exceods the maximum, replace the shift fork oF hub sleeve. ance betwoen OUTPUT SHAFT ASSEMBLY a CS) Cy) @ 0) © HINT: Coat all of the sliging and rotating surfaces with ‘90ar oil before assembly. INSTALL CLUTCH HUBS NO.1 AND NO.2 INTO RE- VERSE GEAR AND HUB SLEEVE NO.2 Inctall the eluteh hub No.2 end shifting keys to the hub sleeve No.2. Install tha cluteh hub No.1 and shifting keys to the reverse gear Install the shifting key springs under the shifting keys. NOTICE: Inetall the key springs eo that thei ond gape notin fine. INSTALL 3RD GEAR AND HUB SLEEVE NO.2 ON OUTPUT SHAFT Apply gear oil to the shaft and needle roller bearing Place the synchronizer ring on the gear and align the ring slots with the shifting keys Install the needle rolier bearing in the 3rd gear.(G52 MANUAL TRANSMISSION — OUTPUT SHAFT bras) (4) Using » press, install the 3rd goar and hub sleave No.2, 3. INSTALL SNAP RING {@). Select @ snap ring that will allow minimum axial play. Triste wT 135-190 (00728-00748) 718-135 ore 00766) 200-295 (00787-00807 (©) Using a snap ring expander, install the snap ring. 4, MEASURE SRD GEAR THRUST CLEARANCE (See page MT~20) 5, INSTALL 2ND GEAR AND REVERSE GEAR ASSEM- BLy (2) Apoly goar oil to the sheft and ne (©) Place the synchronizer ring on the @ ring slots with the shifting keys. (2) Install she noodle roller bearing in the 2nd ges (@)_ Using a press, install the 2nd gear and reverse gear ascombly. 6. MEASURE 2ND GEAR THRUST CLEARANCE (See page MT~20) lo roller bearing ‘and align the 7. INSTALL LOCKING BALL AND 1ST GEAR ASSEM- BLY (2) Install the locking ballin the shaft, (©) Apply gear oil to the needle roller bearing. 1 (6) Assomble the 1st gear, synchronizer rina, needle roller bearing and bearing inner race, ()_ Insta the assembly on the output shaft with the synehronizar ring slots aligned with the shifting keys (€) Turn the inner race to align it with the locking ballwr MT-26 (G52 MANUAL TRANSMISSION ~ OUTPUT SHAFT 8. INSTALL OUTPUT SHAFT REAR BEARING Using SST and @ press, instal the bearing on the output shaft with the outer race snap ring groove toward the rear. HINT: Holé the Tet goar inner race to pravent it from falling, as shown. SST 09508-35010 8. INSTALL 5TH GEAR Using SST and a press, install the Sth gear ‘3ST 09506-35010 10. INSTALL SNAP RING (a) Select a snap ring that will allow minimum axial play. re a | 3 279-278 01075-01000) ae —as7-a02 93109-01109 - 303-200 @.199-01219) me 200 K-32 1-330 @rzee-arsor [a2 3i2 eze7-ers07 (0) Using 2 serowdriver and haramar, tap in the enap ting 11, MEASURE 1ST GEAR THRUST CLEARANCE (See page MT~20)(G52 MANUAL TRANSMISSION ~ COUNTER GEAR ANO REVERSE IOLER ayy. GEAR COUNTER GEAR AND REVERSE IDLER GEAR COMPONENTS @ Bearing Roverse Inier Gear Stat en OY (QE | ‘Reenter canes Reverse idler Gear COUNTER GEAR COMPONENT PARTS ~~ DISASSEMBLY REMOVE HUB SLEEVE NO.3, SHIFTING KEY AND SPRING {@) Remove the hub sleeve No.3. (©) Using a screwdriver remove the 3 shifting keys and 2 springs. COUNTER GEAR AND REVERSE IDLER ~~ GEAR COMPONENT PARTS INSPECTION 1. MEASURE COUNTER 5TH GEAR RADIAL CLEAR- ANCE. (2) Install the spac Sth gear to the needle roller bearing and counter ®wr-28 (G52 MANUAL TRANSMISSION ~ COUNTER GEAR AND REVERSE IDLER GEAR Standerd clearance 0.009 ~0.032 mm (0.0004-0.0013 In} Mexiou claaranee: 0.032 mm (0.0013 in) 2. INSPECT COUNTER GEAR Using a micrometer, measure the outer diameter of needle rolier besring race, Standard outer diamatar: 25,98 ~26.00 mm (1.0228~ 1.0236 in) Minimum outer dlameter: 25.86 mm (1.0181 in.) |. INSPECT SYNCHRONIZER RING (@) Chock for woor or damag (©) Chock the braking effect of the synchronizer ring. Turn the synchronizer ring in ons draetion while push ing it to the gear cons. Chack that the ring locks. IH the braking effect is insufficient, apply @ small amount of fine lspping compound between the syn chronizer ring and gear cone. Lightly rub the syn chronizer ring and gear cone together. NOTICE: Ensure the fine lapping compcund is comletely washed off efter rubbing. (€) Check again the braking effect of the synchronizer ring. (@)_ Using 2 feeier gauge, measure the clearance betwean the synchronizer ring back and gear spline end, ‘Minimum cloerance: 0.8 mm (0.031 in.) Ifthe clearance is lass than the minimum, replace the ‘synchronizer ting and gear cone by applying @ small ‘amount of fine lapping compound. NOTICE: Enaure the fine lping compound is completely washed off efter rubbing. 4. MEASURE SHIFT FORK AND HUB SLEEVE CLEAR. ANCE Using 2 fooler gauge. measure the clearance between the hub sleeve and shift fork. 9: 1.0 mm (0.039 in} .d¢ the maximum, replace the ‘5. MEASURE REVERSE IDLER GEAR RADIAL CLEAR- ANCE Using a dial indicator, measure the reverse idler gear radial clearance, Standord clearance: 0.04~0.08 mm (0.0016~0.0031 in Maximum clearance: 0.13 mm (0.0061 in.) It the clearance exceeds the maximum, replace the(G52 MANUAL TRANSMISSION — COUNTER GEAR AND REVERSE IDLER 47.29 GEAR 6. MEASURE REVERSE IDLER GEAR AND SHIFT ARM SHOE CLEARANCE ler gauge, measure the clearance between and shift arm shos. 9.05 0.28 mm (0.0020~0.0110 in) ‘Maximum eloorance: 0.50 mm (0.0197 in) ifthe fads the maximum, replace the shift arm or reverse idlar gear BEARING REPLACEMENT IF NECESSARY. REPLACE COUNTER GEAR FRONT BEARING la) Using a snap ring expander, remove the snap ring. (b) Using SST and a press, remove the boaring. SST 09950-00020 [e) Replace the side race. {d) Using a pross and socket wrench, install the bearing, side race and innerrace. {e). Select 9 nap ring that will allow minimum axial pay: 265-210 (0907-00837 1 20 (909480086 COUNTER GEAR COMPONENT PARTS ASSEMBLY INSTALL HUB SLEEVE NO.3, SHIFTING KEY AND ‘SPRING (2) Install the hub si counter Sth gear. (b)_ Install the shifting key springs under the shifting keys. NOTICE: Postion the key ‘are nat in line. ve No.3 and shifting keys to theMT-20 (G52 MANUAL TRANSMISSION ~ FRONT BEARING RETAINER, TRANSFER ADAPTOR, FRONT BEARING RETAINER COMPONENTS: casket OIL SEAL REPLACEMENT IF NECESSARY, REPLACE FRONT BEARING RE- TAINER O1L SEAL (2) Using a screwdriver, remove the of seal (0). Using SST and a press installa naw oll seal ‘SST 09960-60010 (09951-00440), 09950-70010 (09951-07150) Drive In dapth: 12.7 # 08 mm (0800 + 0.020 in) ‘rom atainer ond TRANSFER ADAPTOR COMPONENTSG52 MANUAL TRANSMISSION ~ TRANSFER ADAPTOR, Mrat REVERSE RESTRICT PIN REPLACEMENT 1. REMOVE REVERSE RESTRICT PIN (@) Using # torx socket wrench (T40), remove the screw plug (©) Using a pin punch and hammer, drive out the slotted spring pin (2) Remove the reverse restrict pn. 2. INSPECT REVERSE RESTRICT PIN Turn and push the reverse restrict pin by hand. Check for smooth operation. INSTALL REVERSE RESTRICT PIN (a) Install the roverse restrict pin to the transfer adaptor. (©) Using a pin punch and hammer, drive in the slotted spring pin, as shown, (6) Apply sealant to the plug threads. ‘Sealant: Part No, 08833 ~ 00080, THREE BOND 1344, LOCTITE 242 or equivalent (d)_ Using 2 tore socket wrench (T40}, install and torquo the sorow plug ‘Torque: 19 Nm (190 kat-em, 14 feibt) OIL SEAL REPLACEMENT IF NECESSARY, REPLACE TRANSFER ADAPTOR OWL SEAL (2) Using a screwdriver, remove the oll seal (©) Using SST and a hammer, instal « new oil seal ‘SST 09960-60010 (09951-00570), (09950-70010 (09951-07150) Drive in depth: 45.5 + 0.6 mm (1.791 + 0.020 in)alt (G52 MANUAL TRANSMISSION ~ SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA Hee Tin at rang > ti 3400 em (13724) tn 270M 0.0) Ti ‘8 nm 824m) wi 309 am @7F HD ii nt 5348 mn) a ‘76-025 mn 0090-0.0008 oe 020mm @or1eh) rr 8082 rn 0.00080 5GTTIT | (2032 mo ©0013 63 ——r0 ‘3809-0039 mm (90004—0.0013 2089 rn ©0030) TO mm (0038 ny a8 mm (0031) weno 205-210 mm (20607-00027 ns ot 2210-216 nm (20627-00949 in} an 2 215-220 mm (20846-00988 im} mena 220-225 nm @oeee- 00006 my mama 1220-230 mm (nceb6-0.0908 Mas | 220-236 mm (20006-00026 in) ae nea = a = ern fn Ete eres tol oot foc aeseemnel eee Rear Mare (267-2.72 mm (0.1051-0.1071 inj | wane 2207-302 mm (21160-01180 in} | wane 303-308 mn 1183-01213 m) Mar 308-314 nm (21217-0.200 i | Ms 315-320 mm @1240-0.200'n) rk 2221-226 mm (01264-01289 nt ‘oun hor see oir Barna ace Sar ‘510 7358-2800 rm (0228-10235 mi cero ee 2586 nm (1.08 nd | | emer siar ‘TD 670=030 mm (90090-20778 R) i ee Omnmaciem |(G52 MANUAL TRANSMISSION ~ SERVICE SPECIFICATIONS. 0032 wen 0013 ny 005-028 qm (Or0-O0iT0m) 050 mm (00197 205-2 10 mm (20807-00827 in) 210-218 mm (00827-00846 in) | 215-270 mn (0048-00066 0) | 220-225 mm (00866-00088 225-230 mm (00086-00008 Ges sine en No mae 280-288 nm (2110-0112 9) | as 8 285-290 mm 112-€114in) | mone | 1290-208 mm 0114-8:118in) | mao | 1295-200 wm 0. | woe | 300-208 mm :118-2120in) | en 2410-218 mm 0128-81249) | ‘i wiv woe 127 + 05 mm asco + 0020.) TORQUE SPECIFICATIONS ~ [ ahaa Trt erp ace Gach wna Gn BA (ses noe T=) a ‘Sear seen 9MT