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SECTION 5B

FIVE-SPEED MANUAL TRANSAXLE

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted.

DESCRIPTION AND OPERATION

FIVE-SPEED MANUAL TRANSAXLE

This five-speed transaxle assembly adopts the synchronized mesh type of 5 forward speed. The reverse speed gear is driven by sliding idle gear without synchronizer.

REVERSE GEAR MISSHIFT PREVENTING MECHANISM

It prevents the gear from directly being shifted from 5th to reverse when shifting to reverse from 5th. Shift to the reverse in neutral position to prevent the shift cam from being interfered to the shift guide bolt.

D103B001
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In case of shifting to 5th gear, shift and select shaft rotates to right that shift cam aparts from guide bolt and moves upwards by returning spring. Therefore, shifting to reverse in this condition is impossible because of interference of guide bolt.

D103B002
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When shifting to reverse from neutral position between 5th and reverse, shift cam rotates to left and shifting is possible.

D103B003
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DIFFERENTIAL

Differential is integrated with transmission case and installed on chassis together with engine. It changes the direction of power and increase torque by reducing speed.
Reduction gear is installed parallel to counter shaft and is helical gear type. Differential gear is bevel gear type and is integrated with reduction gear.

COMPONENT LOCATORS

GEAR SHIFT CONTROL


D13B4011
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  1. Gear Shift Control Lever Knob
  2. Gear Shift Cable Bracket
  3. Select Cable
  4. Shift Cable
  5. Select Arm
  6. Gear Shift Control Lever
  7. Gear Shift Control Lever Guide

INPUT SHAFT AND COUNTER SHAFT GEAR


D13B4031
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  1. Input Shaft Circlip
  2. 5th Gear Synchronizer Plate
  3. 5th Gear Synchronizer Sleeve
  4. 5th Gear Synchronizer Spring
  5. 5th Gear Synchronizer Key
  6. 5th Gear Synchronizer Hub
  7. 5th Gear Synchronizer Ring
    1. Wave Spring
  8. Input Shaft 5th Gear
  9. Input Shaft 5th Gear Bearing
  10. Input Shaft 5th Gear Spacer
  11. Input Shaft Bearing(Left)
  12. Input Shaft 4th Gear
  13. 4th Gear Synchronizer Ring
    1. Wave Spring
  14. Input Shaft 4th Gear Bearing
  15. 3rd-4th Gear Synchronizer Sleeve
  16. 3rd-4th Gear Synchronizer Spring
  17. 3rd-4th Gear Synchronizer Key
  18. 3rd-4th Gear Synchronizer Hub
  19. 3rd Gear Synchronizer Ring
  20. Input Shaft 3rd Gear
  21. Input Shaft 3rd Gear Bearing
  22. Input Shaft
  23. Input Shaft Bearing(Right)
  24. Input Shaft Oil Seal
  25. Reverse Gear Shaft Bolt
  26. Reverse Gear Shaft
  27. Reverse idle Gear
  28. Counter Shaft Nut
  29. Counter Shaft 5th Gear
  30. Counter Shaft Bearing Shim
  31. Counter Shaft Bearing(Left)
  32. Counter Shaft 4th Gear
  33. Counter Shaft 3rd-4th Gear Spacer
  34. Counter Shaft 3rd Gear
  35. Counter Shaft 2nd Gear
  36. 2nd Gear Synchronizer Ring
  37. Counter Shaft 2nd Gear Bearing
  38. 1st-2nd Gear Synchronizer Circlip
  39. 1st-2nd Gear Synchronizer Sleeve
  40. 1st-2nd Gear Synchronizer Spring
  41. 1st-2nd Gear Synchronizer Key
  42. 1st-2nd Gear Synchronizer Hub
  43. 1st Gear Synchronizer Ring
  44. Counter Shaft 1st Gear
  45. Counter Shaft 1st Gear Bearing
  46. Counter Shaft
  47. Counter Shaft Bearing(Right)

GEAR SHIFT FORK


D13B4021
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  1. Shift and Select Shaft
  2. Shift Interlock Bolt
  3. Shift Lever
  4. Select Lever
  5. Shift and Select Shaft Boot
  6. Gearshift Control Case
  7. Shift Guide Bolt
  8. Gearshift Control Case Guide Plate
  9. Gearshift Control Case Gasket
  10. Low Speed Shift Fork
  11. Low Speed Shift Shaft
  12. Low Speed Shift Shaft Spring/Ball
  13. Low Speed Shift York
  14. High Speed Shift York
  15. High Speed Shaft Spring/Ball
  16. High Speed Shift Shaft
  17. High Speed Shift Fork
  18. Reverse Shift Arm
  19. 5th/Reverse Shift Ball
  20. 5th/Reverse Shift Shaft Spring/Ball
  21. Reverse Shift Shaft Guide Spring/Ball
  22. 5th/Reverse Shift Shaft
  23. 5th/Reverse Shift York
  24. 5th/Shift Fork Guide Ball
  25. 5th/Shift Fork
  26. Reverse Shift Lever

DIFFERENTIAL AND CASE


D13B4041
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  1. Speedometer Driven Gear
  2. Oil Level Plug
  3. Case Cap O-ring(Left)
  4. Case Cap(Left)
  5. Back Up Light Switch
  6. Transaxle Case(Right)
  7. Oil Plate
  8. Transaxle Case(Left)
  9. Oil Drain Plug
  10. Oil Gutter
  11. Side Cover Plate
  12. Side Cover
  13. Differential Ring Gear
  14. Differential Oil Seal(Left)
  15. Differential Bearing(Left)
  16. Differential Case
  17. Speedometer Drive Gear
  18. Differential Bearing(Right)
  19. Differential Oil Seal(Right)
  20. Differential Pinion Gear Shaft Pin
  21. Differential Side Gear Adjust Shim
  22. Differential Side Gear
  23. Differential Pinion Gear Shaft
  24. Differential Pinion Gear
  25. Differential Pinion Gear Washer

DIAGNOSTIC INFORMATION AND PROCEDURE

GENERAL DIAGNOSIS

Condition
Probable Cause
Correction
Gear Slipping Out of Mesh
  • Worn shift fork.
  • Replace shift fork.
  • Worn synchronizer sleeve or gear.
  • Replace sleeve or gear.
  • Worn bearings on input shaft or counter shaft.
  • Replace bearing.
  • Weakened or damaged location spring.
  • Replace spring.
  • Loose or damaged synchronizer spring.
  • Replace synchronizer spring.
  • Excessive back-lash of gear.
  • Adjust back-lash of gear.
Gear Catching
  • Bent or distorted shift shaft or shift fork.
  • Replace shift shaft or shift fork.
  • Weakened or damaged synchronizer spring.
  • Replace spring.
Hard Shifting
  • Worn synchronizer ring.
  • Replace synchronizer ring.
  • Worn synchronizer sleeve or gear.
  • Replace sleeve or gear.
  • Bent or distorted shift shaft.
  • Replace shift shaft.
  • Excessive free travel of all gears in axial direction.
  • Replace gear.
  • Worn bearings on input shaft or counter shaft.
  • Replace bearing.
  • Poor adjustment of clutch cable.
  • Adjust clutch cable.
  • Distorted or broken clutch disc.
  • Replace clutch disc.
  • Damaged pressure plate.
  • Replace pressure plate.
Noise in the Neutral Gear
  • Insufficient lubricant.
  • Supply lubricant.
  • Worn input shaft gear.
  • Replace gear.
  • Worn bearings on the input shaft gears.
  • Replace bearing.
  • Worn clutch release bearing.
  • Replace clutch release bearing.
Noise in the All Gears
  • Insufficient lubricant.
  • Supply lubricant.
  • Worn bearings on input shaft or counter shaft.
  • Replace bearing.
  • Worn input shaft or counter shaft gear.
  • Replace gear.
  • Worn or damaged synchronizer ring.
  • Replace synchronizer ring.
  • Worn or damaged synchronizer sleeve.
  • Replace synchronizer sleeve.
  • Worn differential gear or bearing.
  • Replace gear or bearing.
Noise in the Peculiar Gear
  • Worn or damaged synchronizer ring in the peculiar gear.
  • Replace synchronizer ring.
  • Worn or damaged gear in the peculiar gear.
  • Replace gear.
  • Worn or damaged bearing in the peculiar gear.
  • Replace bearing.
Leak of Lubricant
  • Damaged gasket, oil seal or O-ring.
  • Replace gasket, oil seal or O-ing.

CHECKING FLUID LEVEL

Check for a leak in the area of transaxle case and sealing and then check fluid level and condition after removing oil level plug.
  1. Operate the engine until it comes to normal operating temperature(Coolant temperature : 80~90°C (176~194°F)).
  2. Stall the engine and raise the vehicle.
  3. Remove the oil level plug and check the fluid level.
  4. The fluid should slightly flow out from the oil level plug hole.
  5. If the level is low, add the recommended fluid through the oil level plug hole until the fluid begins to run out.
  6. If the fluid is contaminated or discolored, replace it with the recommended fluid.
  7. Reinstall the oil level plug and tighten it securely.

D103B301
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CHANGING FLUID

  1. Operate the engine until it comes to normal operating temperature(Coolant temperature : 80~90°C (176~194°F)).
  2. Stall the engine and raise the vehicle.
  3. Drain the fluid after removing the drain plug.
  4. Reinstall the drain plug and tighten it securely after coating sealant.
  5. Remove the oil level plug and replenish the fluid until it begins to run out.
  6. a. Oil drain plug.
    b. Oil level plug.
  7. Reinstall the oil level plug and tighten it securely.
Fluid Specification
75W-85(GL-4)
Fluid Capacity
2.1L(2.21qt)
Service interval
Refer to Owner's Manual

CHECKING TRANSAXLE NOISE

Many noises that appear to come from the transaxle may actually originate with other sources such as tires, road surfaces, wheel bearings, or engine and exhaust system.
Identify the cause of any noise before attempting to repair the clutch, the transaxle, or their related linkages.
To verify suspected transaxle noises,
  1. Select a smooth, level asphalt road to reduce tyre and resonant body noise.
  2. Drive the vehicle far enough to warm up all the lubricants thoroughly.
  3. Record the speed and the gear range of the transaxle when the noise occurs.
  4. Check for noises with the vehicle stopped, but with the engine running.
  5. Determine if the noise occurs while the vehicle operates in.

CHECKING BEARING NOISE

Differential Side Bearing Noise

Differential side bearing noise and wheel bearing noise can be confused easily. Since side bearings are preloaded, a differential side bearing noise should not diminish much when the differential/transaxle is run with the wheels off the ground.

Wheel Bearing Noise

Wheel bearings produce a rough growl or grating sound that will continue when the vehicle is coasting and the transaxle is in NEUTRAL. Since wheel bearings are not pre-loaded, a wheel bearing noise should diminish considerably when the wheels are off the ground.

REPAIR INSTRUCTION

ON-VEHICLE SERVICE



D103B501
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MANUAL TRANSAXLE ASSEMBLY

Tools Required

DW110-021 Engine Support Fixture
DW220-031 Transaxle Remove/Install Support

Removal Procedure

  1. Remove the air cleaner assembly. Refer to Section 1B, SOHC Engine Mechanical.
  2. Remove the battery and battery tray. Refer to Section 1E, Engine Electrical.
  3. Disconnect the select and the shift cable.


  4. D103B502
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  5. Remove the engine wiring harness bending strap.
  6. Disconnect the ground wire and the backup lamp switch connector.


  7. D13B5031
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  8. Disconnect the radiator lower hose.
  9. Remove crankshaft position (CKP) sensor.


  10. D103B507
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  11. Disconnect the speedometer cable.
  12. Remove the vehicle speed sensor (VSS) if equipped.


  13. D102E502
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  14. Remove the starter motor.


  15. D13B5041
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  16. Fix the engine assembly.


  17. D103B510
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  18. Remove the transaxle upper bolts.
  19. a. Exhaust manifold side bolt.
    b. Thermostat housing side bolt.


    D103B505
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  20. Remove the transaxle under cover.
  21. Remove the front tires and wheels.


  22. D103B506
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  23. Drain the transaxle fluid.
  24. Disconnect the clutch cable.


  25. D103B509
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  26. Remove the front under longitudinal frames and stabilizer. Refer to Section 2C, Front Suspension.
  27. Remove the drive axle (only transaxle side). Refer to Section 3B, Manual Transaxle Drive Axle.
  28. Remove the clutch housing lower plate.


  29. D12B5731
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  30. Remove the front exhaust pipe.


  31. D13B5111
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  32. Support the transaxle with the transaxle remove/ install support DW220-030N.


  33. D103B512
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  34. Remove the transaxle lower bolt and nut.
  35. a. Lower bolt.
    b. Lower nut.


    D13B5131
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  36. Remove the transaxle mount bolts.


  37. D10B5141
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  38. Position the manual transaxle assembly in tilting.


  39. D13B5151
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  40. Remove the manual transaxle assembly.
  41. a. Jack.
    b. Transaxle assembly.


    D103B516
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  42. Support the engine to normal position using the engine support fixture DW110-021.
  43. Notice : The abnormal position of the engine may damage to the related parts or interfere with them. You have to support the engine to normal position when removing the transaxle.

    Important : If it is impossible to use the special tool, support the engine to normal position with the auto jack.



D13B5171
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the transaxle mounting bolts.
  3. Tighten
    Tighten the transaxle mounting bolts (body side) to 45-55 N•m (33-41 lb-ft).



    D13B518A
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  4. Install the transaxle lower bolt, nut.
  5. Tighten
    Tighten the bolt and nut to 55-65 N•m (41-48 lb-ft).

    a. Lower bolt.
    b. Lower nut.


    D13B5572
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  6. Tighten the front exhaust pipe nuts.
  7. Tighten
    • Tighten the front exhaust pipe nuts (exhaust manifold side) to 25-35 N•m (18-25 lb-ft).



    D13B519A
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  8. Install the transaxle upper bolts.
  9. Tighten
    Tighten the bolts to 55-65 N•m (41-48 lb-ft).

    a. Exhaust manifold side bolt.
    b. Thermostat housing side bolt.


    D13B548A
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  10. Install the starter motor.
  11. Tighten
    Tighten the starter motor bolts to 18-28 N•m (13-21 lb-ft).

  12. Connect all electric connectors.


  13. D13B5032
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  14. Install the radiator lower hose and crank position (CKP) sensor.
  15. Tighten
    Tighten the radiator lower hose bolt to 8-15 N•m (70-132 lb-in).
    Tighten the CKP sensor bolt to 5-8 N•m (44-70 lb-in).



    D13B520A
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  16. Refill the transaxle fluid.
  17. Classification
    75W - 85 (GL-4)
    Capacity
    2.1L (2.21 qt)


    D13B521A
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  18. Adjust the clutch cable. Refer to Section 5C, Clutch.
  19. Install the transaxle under cover.
  20. Tighten
    Tighten the transaxle under cover bolts to 35-55 N•m (25-41 lb-ft).



D103B501A
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GEAR SHIFT CONTROL CASE ASSEMBLY

Removal Procedure

  1. Remove the air hose (air cleaner to throttle body). Refer to Section 1B, SOHC Engine Mechanical.
  2. Remove the battery.
  3. Disconnect the select and the shift control cable.


  4. D103B522
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  5. Remove the select lever.


  6. D103B523
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  7. Remove the shift interlock bolt.
  8. Important : Certainly remove the shift interlock bolt. Otherwise, the gear shift control case can not be removed.



    D103B524
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  9. Remove the gear shift control case assembly.
  10. Important : Make sure the gear shift lever is in NEUTRAL.



    D103B525
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  11. Remove the shift lever.


  12. D103B526
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  13. Remove the select/shift shaft.


  14. D103B527
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  15. Remove the gear shift control case plate.


D103B528
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Inspection Procedure

  1. Inspect for worn or damaged the fifth/reverse shift cam (1).
  2. Inspect for worn or damaged shift interlock plate (2).
  3. Inspect for worn or damaged select/shift lever (3).
  4. Inspect for bent or damaged select/shift shaft (4).


D13B529A
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the shift guide bolt.
  3. Tighten
    Tighten the shift guide bolt to 18-28 N•m (13-21 lb-ft).



    D13B530A
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  4. Install the gear shift control case and the select lever.
  5. Tighten
    • Tighten the gear shift control case bolts to 18-28 N•m (13-21 lb-ft).
    • a. Gear shift control case bolt.
    • Tighten the select lever bolts to 18-28 N3m (13-21 lb-ft).
    • b. Select lever bolt.

    Important : Make sure a correct bolt. There is length difference between select lever bolts.



    D13B531A
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  6. Install the shift interlock bolt.
  7. Tighten
    Tighten the shift interlock bolt to 18-28 N•m (13-21 lb-ft).



D103B532
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SPEEDOMETER DRIVEN GEAR AND CABLE

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Remove the speedometer driven gear assembly.


  2. D103B533
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    a. Vehicle speed sensor connector.
    b. Vehicle speed sensor.

    Caution : Be careful to prevent personal injury while the exhaust pipe is hot.



    D103B534
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  3. Remove the battery. Refer to Section 1E, Engine Electrical.
  4. Disconnect the instrument cluster side cable. Refer to Section 9E, Instrumentation/Driver Information.
  5. Remove the speedometer cable.


D103B535
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Inspection Procedure

  1. Remove the O-ring from the speedometer driven gear housing.
  2. Remove the driven gear pin and disconnect the driven gear.
  3. a. O-ring.
    b. Driven gear pin.
    c. Driven gear.


D103B536
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Important : Install the speedometer driven gear assembly after connecting the speedometer cable with the speedometer driven gear assembly completely.



    D13B537A
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  3. Install the speedometer driven gear assembly to transaxle housing.
  4. Tighten
    Tighten the speedometer driven gear assembly bolt to 4-7 N•m (35-62 lb-in).



D13B539A
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GEAR SHIFT CONTROL CABLE

Removal Procedure

  1. Remove the air hose (air cleaner to throttle body). Refer to Section 1B, SOHC Engine Mechanical.
  2. Remove the battery.
  3. Disconnect the transaxle side select and shift control cable.


  4. D13B5381
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  5. Remove the floor console. Refer to Section 9G, Interior Trim.


  6. D13B5381
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  7. Disconnect the gear shift lever side select and shift control cable.


  8. D13B539A
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  9. Remove the select and shift control cable.


D103B540
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Push the cables toward the engine compartment through dash panel's hole slightly.
  3. Position the cables on the select and the shift lever.


  4. D13B5411
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  5. Connect the transaxle side select and shift control cable.
  6. Connect the gear shift lever side shift control cable.
  7. Connect the gear shift lever side select control cable.
  8. Tighten the adjust nuts.
  9. Tighten
    Tighten the select cable adjust nut to 8-12 N•m (71-106 lb-in).



D13B544A
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GEAR SHIFT CONTROL LEVER

Removal Procedure

  1. Remove the floor console. Refer to Section 9G, Interior Trim.
  2. Disconnect the select and shift control cable. Refer to "Gear Shift control cable" in this section.
  3. Remove the gear shift control lever assembly.
  4. (If equipped with auto clutch).


D13B544A
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the gear shift control lever assembly.
  3. Tighten
    Tighten the bolts to 4-7 N•m (35-62 lb-in).

  4. Adjust the select cables. Refer to "Gear Shift Control Cable" in this section.

UNIT REPAIR



D103B502
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GEAR UNIT

Tools Required

09913-76010 Bushing, Seal Installer
DW09940-53111 Gear, Bearing Installer
DW09943-78210 Bushing, Seal Installer
DW220-010A Transaxle Fixture
KM519 Oil Seal Installer

Disassembly Procedure

  1. Remove the manual transaxle. Refer to "Manual Transaxle Assembly" in this section.
  2. Position the manual transaxle to a transaxle stand using the transaxle fixture DW220-010.


  3. D103B502
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  4. Remove the related clutch parts. Refer to Section 5C, Clutch.
  5. Remove the manual transaxle mounting bracket.


  6. D103B502
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  7. Disconnect the backup light switch and speedometer driven gear assembly.


  8. D103B704
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  9. Remove the select lever.


  10. D103B705
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  11. Remove the gear shift control case assembly.
  12. Important : Certainly remove the shift interlock bolt. Otherwise, gear shift control case can not be removed.



    D103B706
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  13. Remove the side cover.


  14. D103B707
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  15. Remove the fifth-gear shift fork guide ball, the snap ring and the input shaft fifth-gear snap ring.


  16. D103B708
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  17. Remove the fifth-gear shift fork pin.


  18. D103B709
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  19. Remove the input shaft fifth-gear fork and synchronizer hub assembly.


  20. D103B710
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  21. Remove the input shaft fifth-gear, the synchronizer ring and the fifth-gear bearing.


  22. D103B711
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  23. Remove the countershaft fifth-gear.


  24. D103B712
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    D103B713
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  25. Remove the side cover plate and the counter shaft bearing shim.


  26. D103B714
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  27. Remove the shift shaft spring and ball.
  28. Important : There is difference between the fifth-reverse gear shift shaft spring and the others. Mark it to distinguish easily when installing.



    D103B715
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  29. Remove the reverse idle gear shaft bolt.
  30. Important : The case (Left) can not be removed without removing the reverse idle gear shaft bolt.



    D103B716
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  31. Remove the transaxle case (Left).


  32. D103B717
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  33. Remove the reverse gear shift lever.


  34. D103B718
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  35. Remove the reverse idle gear shaft assembly.


  36. D103B719
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  37. Remove the fifth-reverse gear shift shaft.
  38. a. Fifth-reverse gear shift shaft.


    D103B720
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  39. Remove the gear unit.
  40. Notice : Be careful not to damage teeth of the counter shaft pinion and the differential ring gear.



    D103B721
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  41. Remove the differential assembly.


  42. D103B722
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  43. Remove the related parts of the transaxle case (Left Side).


  44. D103B723
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    D103B724
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  45. Remove the related parts of the transaxle case (Right Side).


D103B725
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Synchronizer Sleeve and Shift Fork Inspection

  1. Measure the clearance between synchronizer sleeve and shift fork and if the clearance exceeds the limit, replace the shift fork.
  2. Unit : mm (in.)
    Clearance Between Sleeve and Shift Fork
    Standard
    Limit
    0.2~0.6
    (0.008~0.024)
    1.0
    (0.039)


D103B726
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Assembly Procedure

  1. Install the related parts of the transaxle case (Right Side).
  2. Important : Use only a new oil seal.

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



    D13B727A
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  3. Install the related parts of the transaxle case (Left Side).
  4. a. Oil level plug.

    Tighten
    Tighten the oil level plug to 36-54 N•m (26-40 lb-ft).



    D13B727A
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    Tighten
    Tighten the bolt to 8-12 N•m (71-106 lb-in).

    b. Case cap retaining bolt.


    D103B728
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  5. Install the differential assembly to the right side of transaxle case.
  6. a. Differential assembly.


    D103B729
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  7. Install the low and the high speed shift shaft assembly to the gear unit.
  8. Install the gear unit.
  9. Notice : Be careful not to damage teeth of the counter shaft pinion and the differential ring gear.



    D13B730A
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  10. Install the fifth-reverse gear shift shaft.
  11. Install the reverse idle gear shaft assembly and the reverse gear shift lever.
  12. Important : Match the marking of the reverse idle gear shaft bolt hole with the protrusion of the transaxle case (Right Side).

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



    D13B731A
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  13. Install the shift shaft ball and spring.
  14. Tighten
    Tighten the bolt to 10-16 N•m (7-12 lb-ft) (a).

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

    Important : Install the fifth-reverse gear shift shaft spring marked when removing.



    D13B732A
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  15. Install the transaxle left side case.
  16. Transaxle Case Sealant
    THREE BOND 1215

    Tighten
    Tighten the bolts to 15-22 N•m (11-16 lb-ft) (a).
    • Tighten the bolts (8), stud bolts (3) if equipped with auto clutch.
    Tighten the bolts to 15-22 N•m (11-16 lb-ft) (b).



    D13B733A
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  17. Install the first-second gear shift shaft ball and spring.
  18. Tighten
    Tighten the bolt to10-16 N•m (7-12 lb-ft) (a).

  19. Install the reverse idle gear shaft bolt.
  20. Tighten
    Tighten the bolt to 18-28 N•m (13-21 lb-ft) (b).



    D103B734
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  21. Install the counter shaft bearing outer race.
  22. a. Bearing outer race.

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



    D13B735A
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  23. Install the counter shaft bearing shim.
  24. Unit : mm (in.)
    Measured value (A)
    Shim thickness
    0.33-0.37(0.0130-0.0146)
    0.45 (0.0177)
    0.38-0.42 (0.0147-0.0165)
    0.50 (0.0197)
    0.43-0.47 (0.0169-0.0185)
    0.55 (0.0217)
    0.48-0.52 (0.0189-0.0205)
    0.60 (0.0236)
    0.53-0.57 (0.0209-0.0224)
    0.65 (0.0256)
    0.58-0.62 (0.0228-0.0244)
    0.70 (0.0276)
    0.63-0.67 (0.0248-0.0264)
    0.75 (0.0295)
    0.68-0.72 (0.0268-0.0283)
    0.80 (0.0315)
    0.73-0.77 (0.0287-0.0303)
    0.85 (0.0335)
    0.78-0.82 (0.0307-0.0323)
    0.90 (0.0354)
    0.83-0.87 (0.0327-0.0343)
    0.95 (0.0374)
    0.88-0.92 (0.0346-0.0362)
    1.00 (0.0394)
    0.93-0.97 (0.0366-0.0382)
    1.05 (0.0413)
    0.98-1.02 (0.0386-0.0402)
    1.10 (0.0433)
    1.03-1.07 (0.0406-0.0421)
    1.15 (0.0453)
    a. Straight ruler
    b. Bearing outer race
    c. Case surface


    D13B736A
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  25. Install the side cover plate and the counter shaft fifth gear.
  26. Tighten
    Tighten the screws to 6-7 N.m (53-62 lb-in).

    Important : Use only new screws.

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



    D13B737A
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  27. Install the counter shaft fifth gear nut.
  28. Tighten
    Tighten the fifth gear nut to 60-80 N•m (44-59 lb-ft).
    • Caulk the nut using a chisel and a hammer (2).



    D103B710
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  29. Install the input shaft fifth gear bearing and the fifth gear / synchronizer ring.


  30. D103B738
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  31. Install the fifth gear synchronizer hub assembly.
  32. Important : In case of assembling synchronizer sleeve and hub, let A=B.



    D103B739
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  33. Install the fifth gear fork to the synchronizer hub assembly.
  34. Install the fifth gear fork and the synchronizer hub assembly to the input shaft.
  35. Important : Position the longer boss side of hub toward inner side and match the synchronizer key and the hub groove with the input shaft punched mark.



    D103B740
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  36. Install the fifth gear shift fork pin.
  37. Important : Use only new shift fork pin.



    D103B741
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  38. Install the input shaft fifth gear snap ring, the fifth gear shift fork snap ring and guide ball.
  39. Important : Use only new snap ring.



    D13B742A
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  40. Install the side cover(1).
  41. Side Cover Sealant
    THREE BOND 1215

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



    D13B743A
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  42. Install the gear shift control case assembly.
  43. Tighten
    • Tighten the bolts to 18-28 N•m (13-21 lb-ft) (a).
    • Tighten the shift interlock bolt to 18-28 N•m (13-21 lb-ft) (b).
    • Install the select lever.

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



    D13B744A
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  44. Install the backup light switch and the speedometer driven gear assembly.
  45. Tighten
    Tighten the nut to 15-18 N•m (11-13 lb-ft) (a).
    • Install the speedometer driven gear assembly (2).

    Tighten
    Tighten the bolt to 4-7 N•m (35-62 lb-in) (b).
    • Install the hydraulic pump assembly (If equipped with auto clutch). Refer to Section 5D, Auto Clutch.



    D13B7452
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  46. Install the transaxle mount.
  47. Tighten
    • Tighten the bolts to 55-65 N•m (41-48 lb-ft) (a).
    • Tighten the nut to 55-65 N•m (41-48 lb-ft) (b).



    D13B701A
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  48. Install the related clutch parts. Refer to Section 5C, Clutch.
  49. Remove the transaxle assembly from transaxle stand.
  50. Install the transaxle assembly. Refer to "Manual Transaxle Assembly" in this section.


D103B746
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INPUT SHAFT

Tools Required

DW09921-57810 Gear, Bearing Remover
DW09925-98221 Gear, Bearing Installer
DW09940-53111 Gear, Bearing Installer

Disassembly Procedure

  1. Remove the gear unit. Refer to "Gear Unit" in this section.
  2. Remove the input shaft right side bearing.


  3. D103B747
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  4. Remove the input shaft fifth gear spacer, the left side bearing and the fourth gear.
  5. a. Fifth gear spacer.
    b. Left side bearing.
    c. Fourth gear


    D103B748
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  6. Remove the fourth gear bearing.
  7. Remove the fourth gear synchronizer ring and wave spring.


  8. D103B749
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  9. Remove the third-fourth synchronizer circlip.


  10. D103B750
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  11. Remove the third-fourth synchronizer hub assembly, the third gear 1 synchronizer ring.
  12. a. Third-fourth synchronizer hub assembly.
    b. Third gear and synchronizer ring.


    D103B751
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  13. Disassemble the third-fourth synchronizer hub assembly.


  14. D103B752
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  15. Remove the input shaft third gear bearing (1).


D103B753
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Synchronizer Assembly Inspection

  1. Inspecting wear of cone area.
  2. Unit : mm (in.)
    Clearance Between Gear and Ring
    Standard
    Limit
    1.0 (0.039)
    0.5 (0.020)


    D103B754
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  3. Inspecting cone contact condition.


  4. D103B755
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  5. Inspecting key slot width of synchronizer ring.
  6. Unit : mm (in.)
    Key Slot Width
    Standard
    Limit
    1st gear
    8.2 (0.323)
    8.6 (0.339)
    2nd, 3rd, 4th gear
    9.6 (0.378)
    10.0 (0.394)
    5th gear
    9.4 (0.370)
    9.8 (0.386)


    D103B756
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  7. Inspecting wear of synchronizer ring.


  8. D103B757
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  9. Inspecting synchronizer key and spring.


D103B758
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Assembly Procedure

  1. Install the third gear bearing, the third gear / synchronizer ring.
  2. a. Third gear / synchronizer ring.
    b. Third gear bearing.

    Important : Coat the inner parts; gear, bearing, oil seal etc. with gear fluid.



    D103B759
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  3. Assemble the third-fourth synchronizer hub assembly.
  4. Important : In case of assembling the synchronizer sleeve and the hub, let A=B.

    a. Sleeve.
    b. Hub.


    D103B760
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  5. Install the third-fourth synchronizer hub assembly.
  6. Important : Position the longer flange of hub toward the third gear and match the key and the ring groove.



    D13B761A
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    Notice : When installing gear, bearing and hub assembly, install them slowly using the gear, bearing installer DW09940-53111 and a hammer. If overpressed, the gear teeth may be damaged.



    D103B749
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  7. Install the third-fourth synchronizer circlip.
  8. Install the fourth synchronizer ring and wave spring.
  9. Important : Match the ring groove to the key of hub.



    D103B762
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  10. Install the input shaft fourth gear bearing and the fourth gear.
  11. a. Fourth gear.
    b. Fourth gear bearing.


    D103B763
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  12. Install the input shaft left side bearing and the fifth gear spacer.
  13. a. Fifth gear spacer.
    b. Input shaft left side bearing.


    D103B764
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  14. Install the input shaft right side bearing.
  15. Install the gear unit. Refer to "Gear Unit" in this section.


D103B765
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COUNTER SHAFT

Tools Required

09913-76010 Bushing, Seal Installer
DW09913-80112 Gear, Bearing Installer
DW09921-57810 Gear, Bearing Remover
DW09925-98221 Gear, Bearing Installer
DW09940-53111 Gear,Bearing Installer
DW220-020-01 Differential Bearing Puller
DW220-020-02 Differential Bearing Plate Adapter
DW220-020-03 Differential Bearing Plate Adapter
KM466-A Gear, Bearing Remover/Installer

Disassembly Procedure

  1. Remove the gear unit. Refer to "Gear Unit" in this section.
  2. Remove the counter shaft right side bearing.


  3. D103B747
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  4. Remove the counter shaft left side bearing and the fourth gear.
  5. a. Counter shaft left side bearing.
    b. Fourth gear.


    D103B767
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  6. Remove the counter shaft third-fourth gear spacer.
  7. Remove the counter shaft third gear and second gear.
  8. a. Third gear.
    b. Second gear.


    D103B768
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  9. Remove the counter shaft second gear bearing.
  10. Remove the second gear synchronizer ring.
  11. Remove the first-second gear synchronizer circlip.


  12. D103B769
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  13. Remove the counter shaft first-second gear synchronizer hub assembly, the first gear / the first gear synchronizer ring.
  14. a. Synchronizer hub assembly.
    b. First gear / First gear synchronizer ring.


    D103B770
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  15. Disassemble the first-second gear synchronizer hub assembly.


  16. D103B771
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  17. Remove the counter shaft first gear bearing.


D103B772
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Synchronizer Hub and Sleeve Inspection



D103B773
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Assembly Procedure

  1. Install the related counter shaft first gear.
  2. Important : Coat the inner parts; gear, bearing and oil seal etc. with gear fluid.

    Important : Be careful there is the difference of key groove width between the first synchronizer ring and the second synchronizer ring.



    D103B774A
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    Unit : mm (in.)
    Key Groove Width
    First synchronizer ring (A) : 8.2 (0.323)
    Second synchronizer ring (B) : 9.6 (0.378)


    D103B775
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  3. Assemble the first-second synchronizer hub assembly.
  4. Important : Let (A)=(B) when installing the keys.

    a. Sleeve.
    b. Hub.


    D103B776
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  5. Install the first-second synchronizer hub assembly.
  6. Important : Position the synchronizer key to the first gear synchronizer ring groove.



    D103B768
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  7. Install the second synchronizer ring.
  8. Important : Position the second synchronizer ring groove to the synchronizer hub key.

  9. Install the first-second gear synchronizer circlip.


  10. D103B777
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  11. Install the related counter shaft second gear.


  12. D103B778
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  13. Install the counter shaft third gear and the third-fourth gear spacer.
  14. a. Third-fourth gear spacer.
    b. Third gear.


    D103B779
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  15. Install the counter shaft fourth gear.


  16. D103B780
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  17. Install the counter shaft left side bearing.


  18. D103B765
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  19. Install the counter shaft right side bearing.
  20. Install the gear unit. Refer to "Gear Unit" in this section.


D103B781
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GEAR SHIFT FORK

Disassembly Procedure

  1. Remove the gear unit. Refer to "Gear Unit" in this section.
  2. Remove the each shift shaft assembly from the gear unit.
  3. Remove the first-second gear shift shaft assembly.


  4. D103B783
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    Important : Mark the place and direction of shift fork and yoke to install easily before removing them.



    D103B782
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  5. Disassemble the third-fourth gear shift shaft assembly.


  6. D103B784
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  7. Disassemble the fifth-reverse gear shift shaft assembly.
  8. a. Fifth-reverse gear ball.
    b. Reverse shift guide ball and spring.


    D103B785
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D103B786
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Inspection Procedure-Shift Shaft

  1. Check for bent, deformed or damaged shift shaft.
  2. Replace shift shaft if necessary.


D103B787
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Inspection Procedure-Shift Fork

  1. Measure the end thickness of shift fork and replace if below limit.
  2. Unit : mm (in.)
    Shift fork end thickness (mm)
    Standard
    Limit
    Low Speed Shift Fork
    8.7 (0.343)
    8.1 (0.319)
    High Speed Shift Fork
    7.8 (0.307)
    7.2 (0.283)
    Fifth Gear Shift Fork
    7.8 (0.307)
    7.2 (0.283)


D103B788
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Assembly Procedure

  1. Install in the reverse order of removal.
  2. Important : Use only new fork fin and yoke pin.



D103B789
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DIFFERENTIAL

Disassembly Procedure

  1. Remove the differential assembly. Refer to "Gear Unit" in this section.
  2. Remove the differential ring gear.


  3. D103B790
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  4. Remove the pinion gear pin.


  5. D103B791
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  6. Remove the pinion gear shaft.


  7. D103B792
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  8. Remove the pinion gears and the side gears.
  9. Important : Remove the pinion gear and the washer by rotating the side gear.



    D13B793A
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  10. Remove the differential right side bearing and speedometer drive gear.


  11. D13B794A
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  12. Remove the differential left side bearing.


D103B795
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Side Gear Play Inspection

  1. Measure the axle direction play of side gear and replace a side gear washer if it exceeds limit.
  2. UNIT : mm (in.)
    Thrust Free Play of Differential Side
    0.05-0.33 (0.0020-0.0130)
    UNIT : mm (in.)
    Thrust Adjusting Shim
    0.90 (0.0354) 0.95 (0.0374)
    1.00 (0.0394) 1.05 (0.0413)
    1.10 (0.0433) 1.15 (0.0453)
    1.20 (0.0472)


    D103B796
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  3. After checking for worn or scratched thrust adjusting shim, replace it if necessary.
  4. a. Side gear.
    b. Driver.


D103B797
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Assembly Procedure

  1. Install the differential left side bearing.
  2. Important : Coat the inner parts; bearing, washer, shim etc. with gear fluid.



    D103B798
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  3. Install the speedometer drive gear and differential right side bearing.


  4. D103B799
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  5. Install the side gears and the pinion gears.
  6. Important : Install the pinion gears and washers simultaneously.



    D103B800
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  7. Install the pinion gear shaft and pin.
  8. Important : Use only new pin.



    D13B801A
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  9. Install the differential ring gear.
  10. Tighten
    Tighten the bolts to 80-100 N•m (59-74 lb-ft).

  11. Install the differential assembly. Refer to "Gear Unit" in this section.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Application
Description
Unit
Standard
Limit
General
Type
Forward gear
-
Synchronized mesh type
-
Reverse gear
-
Sliding mesh type
-
Gear ratio
1st
-
3.818
-
2nd
-
2.210
-
3rd
-
1.423
-
4th
-
1.029
-
5th
-
0.837
-
Reverse
-
3.583
-
Final drive ratio
-
4.444
-
Fluid capacity
L(qt)
2.1 (2.21)
-
Fluid classification
-
75W-85 (GL-4)
-
Service
Key groove width of synchronizer ring
1st gear
mm(in.)
8.2 (0.323)
8.6 (0.339)
2nd, 3rd, 4th gear
mm(in.)
9.6 (0.378)
10.0 (0.394)
5th gear
mm(in.)
9.4 (0.370)
9.8 (0.386)
Shift fork end thickness
Low speed shift fork (1st~2nd)
mm(in.)
8.7 (0.343)
8.1 (0.319)
High speed shift fork (3rd~4th)
mm(in.)
7.8 (0.307)
7.2 (0.283)
5th gear shift fork
mm(in.)
7.8 (0.307)
7.2 (0.283)
Clearance between gear and synchronizer ring
mm(in.)
1.0 (0.039)
0.5 (0.020)
Clearance between sleeve and shift fork
mm(in.)
0.2 - 0.6 (0.008 - 0.024)
1.0 (0.039)
Thrust free play of differential side gear
mm(in.)
0.05 - 0.33 (0.002 - 0.013)
-
Speedometer gear ratio(Driven/Drive)
-
17/18 (0.944)
-

FASTENER TIGHTENING SPECIFICATIONS

Application
N•m
Lb-Ft
Lb-In
5th/Reverse Gear Shift Shaft Bolt
10 - 16
7 - 12
-
Back Up Light Switch Nut
15 - 18
11 - 13
-
Counter Shaft 5th Gear Nut
60 - 80
44 - 59
-
Crankshaft Position Sensor Bolt
5 - 8
-
44 - 70
Differential Ring Gear Bolt
80 - 100
59 - 74
-
Engine Mounting Front Bracket Bolt (Cylinder Block Side)
35 - 41
25 - 30
-
Engine Mounting Front Damping Bush Bolt (Crossmember Side)
35 - 41
25 - 30
-
Engine Mounting Front Damping Bush Bolts (Crossmember Side)
45 - 55
33 - 41
-
Engine Mounting Front Damping Bush Bolt/Nut (Bracket Side)
68 - 83
51 - 61
-
Front Exhaust Pipe Nut (Exhaust Manifold Side/Muffler Side)
25 - 35
18 - 25
-
Gear Shift Control Case Bolt
18 - 28
13 - 21
-
Gear Shift Lever Bolt
4 - 7
-
35 - 62
High Speed Shift Shaft Bolt
10 - 16
7 - 12
-
Low Speed Shift Shaft Bolt
10 - 16
7 - 12
-
Oil Drain Plug
25 - 30
18 - 22
-
Oil Level Plug
36 - 54
26 - 40
-
Radiator Lower Hose Bracket Bolts
8 - 15
-
70 - 132
Reverse idle Gear Shaft Bolt
18 - 28
13 - 21
-
Reverse Shift Lever Bolt
18 - 28
13 - 21
-
Select Cable Nut(Shift Lever Side)
8 - 12
-
71 - 106
Select Lever Bolt
18 - 28
13 - 21
-
Side Cover Plate Screw
6 - 7
-
53 - 62
Shift Guide Bolt
18 - 28
13 - 21
-
Shift Interlock Bolt
18 - 28
13 - 21
-
Side Cover Bolt
8 - 12
-
71 - 106
Speedometer Driven Gear Bolt
4 - 7
-
35 - 62
Starter Motor Bolt
18 - 28
13 - 21
-
Transaxle Case Bolt
15 - 22
11 - 16
-
Transaxle Case(left) Cap Bolt
8 - 12
-
71 - 106
Transaxle Lower Bolt and Nut(Engine Side)
55 - 65
41 - 48
-
Transaxle Mounting Bolt(Body Side)
45 - 55
33 - 41
-
Transaxle Mounting Bolt and Nut(Transaxle Side)
55 - 65
41 - 48
-
Transaxle Upper Bolt(Engine Side)
55 - 65
41 - 48
-
Transaxle Under Cover Bolt
35 - 55
25 - 41
-

SPECIAL TOOLS

SPECIAL TOOLS TABLE


D103B110
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09913-76010 Bushing, Seal Installer

D103B106
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DW09913-80112 Gear, Bearing Installer

D103B104
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DW09921-57810 Gear, Bearing Remover

D103B107
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DW09925-98221 Gear, Bearing Installer

D103B105
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DW09940-53111 Gear, Bearing Installer

D103B109
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DW09943-78210 Bushing, Seal Installer

D103B103
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DW110-021 Engine Assembly Support Fixture

D13B101A
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DW220-010A Transaxle Fixture

D13B112A
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DW220-020A-01 Differential Bearing Puller

D13B113A
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DW220-020A-02 Differential Bearing Plate Adapter

D13B114A
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DW0220-020A-03 Differential Bearing Plate Adapter

D103B102
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DW220-031 Transaxle Remove/Install Support

D103B108
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KM466-A Gear, Bearing Remover/Installer

D103B111
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KM519 Oil Seal Installer


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