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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

5th and reverse gear cam prevents the gear from directly being shifted from 5th to reverse when shifting to reverse from 5th. So, when shifting to reverse, be sure to shift to reverse from neutral position.

M3C15B02
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In case of shifting to 5th gear, shift and select shaft rotates to right that shift and select lever arm fixs on the groove of 5th and reverse gear shift cam.
When shifting to reverse from 5th gear, shifting to reverse is impossible because 5th and reverse gear shift cam fixs on cam stopper' case.
When shifting to reverse from neutral position between 5th and reverse, gear shift and select lever arm rotates to left and shifting is possible.

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


M3C15B94
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  1. Gear Shift Control Lever Knob
  2. Select and Shift Cable
  3. Gear Shift Select Lever
  4. Gear Shift Control Lever
  5. Gear Shift Bracket
  6. Gear Shift Housing Cover

Input Shaft and Counter Shaft Gear


M3C15B95
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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
7-1 Wave Spring
  1. Input Shaft 5th Gear
  2. Input Shaft 5th Gear Bearing
  3. Input Shaft 5th Gear Spacer
  4. Input Shaft Bearing(Left)
  5. Input Shaft 4th Gear
  6. 4th Gear Synchronizer Ring
13-1 Circlip
  1. Input Shaft 4th Gear Bearing
  2. 3rd-4th Gear Synchronizer Sleeve
  3. 3rd-4th Gear Synchronizer Spring
  4. 3rd-4th Gear Synchronizer Key
  5. 3rd-4th Gear Synchronizer Hub
  6. 3rd Gear Synchronizer Ring
  7. Input Shaft 3rd Gear
  8. Input Shaft 3rd Gear Bearing
  9. Input Shaft
  10. Input Shaft Bearing(Right)
  11. Input Shaft Oil Seal
  12. Reverse Gear Shaft Bolt
  13. Reverse Gear Shaft
  14. Reverse Idle Gear
  15. Counter Shaft Nut
  16. Counter Shaft 5th Gear
  17. Counter Shaft Bearing Shim
  18. Counter Shaft Bearing(Left)
  19. Counter Shaft 4th Gear
  20. Counter Shaft 3rd-4th Gear Spacer
  21. Counter Shaft 3rd Gear
  22. Counter Shaft 2nd Gear
  23. 2nd Gear Synchronizer Ring
  24. Counter Shaft 2nd Gear Bearing
  25. 1st-2nd Gear Synchronizer Circlip
  26. 1st-2nd Gear Synchronizer Sleeve
  27. 1st-2nd Gear Synchronizer Spring
  28. 1st-2nd Gear Synchronizer Key
  29. 1st-2nd Gear Synchronizer Hub
  30. 1st Gear Synchronizer Ring
  31. Counter Shaft 1st Gear
  32. Counter Shaft 1st Gear Bearing
  33. Counter Shaft
  34. Counter Shaft Bearing(Right)

Gear Shift Fork


M3C15B96
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  1. Shift and Select Shaft
  2. Shift Interlock Bolt
  3. Shift Lever
  4. Bracket
  5. Low Speed Shift Fork
  6. Low Speed Shift Shaft
  7. Low Speed Shift Shaft Spring/Ball
  8. Low Speed Shift York
  9. High Speed Shift York
  10. High Speed Shaft Spring/Ball
  11. High Speed Shift Shaft
  12. High Speed Shift Fork
  13. Reverse Shift Arm
  14. 5th/Reverse Shift Ball
  15. 5th/Reverse Shift Shaft Spring/Ball
  16. Reverse Shift Shaft Guide Spring/Ball
  17. 5th/Reverse Shift Shaft
  18. 5th/Reverse Shift York
  19. 5th/Shift Fork Guide Ball
  20. 5th/Shift Fork
  21. Reverse Shift Lever

Differential and Case


M3C15B97
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  1. Speedometer Driven Gear
  2. Oil Level Plug
  3. Back Up Light Switch
  4. Transaxle Case(Right)
  5. Transaxle Case(Left)
  6. Oil Drain Plug
  7. Oil Gutter
  8. Left Case Plate
  9. Side Cover
  10. Differential Ring Gear
  11. Differential Oil Seal(Left)
  12. Differential Bearing(Left)
  13. Differential Case
  14. Speedometer Drive Gear
  15. Differential Bearing(Right)
  16. Differential Oil Seal(Right)
  17. Differential Pinion Gear Shaft Pin
  18. Differential Side Gear Adjust Shim
  19. Differential Side Gear
  20. Differential Pinion Gear Shaft
  21. Differential Pinion Gear
  22. 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 clutch cover.
  • Replace clutch cover.
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 oil seal.
  • Replace oil seal.

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.

M3C15B98
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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 pre-loaded, 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.


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