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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 LOCK unless otherwise noted.

SPECIFICATIONS

Fastener Tightening Specifications

Application
N•m
Lb-Ft
Lb-In
Backup Lamp Switch
20
15
-
Bearing Plate Bolts
22
16
-
Bearing-Adjusting Ring-Retainer Plate Bolt
25
18
-
Bearing Retainer Bolts, Right Side
25
18
-
Clutch-Release Cylinder Bracket Bolts
75
55
-
Differential Cover Bolts
40
30
-
Fifth-Gear Fork Bolts
22
16
-
Fifth-Gearshift Connector Bolts
7
-
62
Gearshift Housing Bolts
8
-
71
Gearshift Lever Cover Bolts
22
16
-
Input Driveshaft Detent Screw
15
11
-
Front Transaxle Mounting Bracket Bolts and Nut
90
66
-
Rear Transaxle Mounting Bracket Bolts (a)
90
66
-
Rear Transaxle Mounting Bracket Bolts (b)
65
48
-
Left Front Transaxle Mounting Bracket Nut
155
114
-
Lower Transaxle-to-Engine Bolts (a)
75
55
-
Lower Transaxle-to-Engine Bolts (b)
21
15
-
Lower Transaxle-to-Engine Bolts (c)
31
23
-
Ring-Gear Bolts
70
52
-
Rod Clamp Bolt
14
-
124
Speedometer-Driven Gear Bolt
4
-
35
Speedometer Housing Retaining Bolt
4
-
35
Support Bracket Bolt
7
-
62
Transaxle Cover Bolts, Bigger
20
15
-
Transaxle Cover Bolts, Smaller
15
11
-
Transaxle-to-Engine Upper Bolts
75
55
-

SPECIAL TOOLS

Special Tools Table


J6125B
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J-6125-B
Slide Hammer

J22888
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J-22888-20-A
Bearing Puller with
J-22888-35
Puller Legs

J22912
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J-22912-01
Universal Bearing
Puller

J28467B
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J-28467-B
Engine-Support Fixture

KM553A
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KM-553-A
Fifth-Gear Puller

J36633
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J-36633
Snap Ring Retainer

KM1132
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KM-113-2
Base

KM334
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KM-334
Installer Sleeve

J42469
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J-42469
Shift Rod Remover

KM519
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KM-519
Ring Installer

KM520
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KM-520
Remover/Installer

KM522
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KM-522
Installer

KM525
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KM-525
Installer

KM552
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KM-552
Fixture

KM554
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KM-554
Installer

DIAGNOSIS

Isolate Noise

Identify the cause of any noise before attempting to repair the clutch, the transaxle, or their related linkages.
Symptoms of trouble with the clutch or the manual transaxle include
Any of these conditions requires a careful analysis. Make the following checks before disassembling the clutch or the transaxle for repairs.

Road Travel Noise

Many noises that appear to come from the transaxle may actually originate with other sources, such as the
These noises may vary according to the

Transaxle Noise

Transaxle gears, like any mechanical device, are not absolutely quiet and will make some noise during normal operation.
To verify suspected transaxle noises,
  1. Select a smooth, level asphalt road to reduce tire 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

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.

Other Noise

Brinelling

A brinelled bearing causes a "knock" or "click" approximately every second revolution of the wheel because the bearing rollers do not travel at the same speed as the wheel. In operation, the effect is characterized by a low-pitched noise.
A brinelled bearing is caused by excessive thrust which pushes the balls up on the pathway and creates a triangular- shaped spot in the bearing race. A brinelled bearing can also be caused from pressing one race into position by applying pressure on the other race.
A false indication of a brinelled bearing occurs as a result of vibration near the area where the bearing is mounted. Brinelling is identified by slight indentations, resulting in a washboard effect in the bearing race.

Lapping

Lapped bearing noise occurs when fine particles of abrasive materials such as scale, sand, or emery circulate through the oil in the vehicle, causing the surfaces of the roller and the race to wear away. Bearings that wear loose but remain smooth, without spalling or pitting, are the result of dirty oil.

Locking

Large particles of foreign material wedged between the roller and the race usually cause one of the races to turn, creating noise from a locked bearing. Pre-loading regular taper roller bearings to a value higher than that specified also can result in locked bearings.

Pitting

Pitting on the rolling surface comes from normal wear and the introduction of foreign materials.

Spalling

Spalled bearings have flaked or pitted rollers or races caused by an overload or an incorrect assembly that results in a misalignment, a cocking of bearings, or adjustments that are too tight.
After completing these checks, refer to the "Diagnosis Chart" in this section.

Symptom Diagnosis

Checks
Action
Check for a knock at low speeds.
  • Replace any worn drive axle CV joints.
  • Replace any worn side gear hub.
Check for a noise most pronounced on turns.
  • Correct any abnormalities in the differential gear.
Check for a clunk upon acceleration or deceleration.
  • Tighten any loose engine mounts.
  • Replace any worn drive axle inboard joints.
  • Replace any worn differential pinion shaft in the case.
  • Replace any worn side gear hub in the case.
Check for a clunking noise in turns.
  • Replace any worn outboard CV joint.
Check for a vibration.
  • Replace any rough wheel bearing.
  • Replace any bent drive axle shaft.
  • Replace any out-of-round tires.
  • Balance any unbalanced tire.
  • Replace any worn CV joint in the drive axle shaft.
  • Correct an excessive drive axle angle by adjusting the trim height.
Check for a noise in the NEUTRAL gear with the engine running.
  • Replace any worn cluster bearing shaft.
  • Replace any worn clutch-release bearing.
  • Replace any worn input shaft cluster gears.
  • Replace any worn first-gear/bearing.
  • Replace any worn second-gear/bearing.
  • Replace any worn third-gear/bearing.
  • Replace any worn fourth-gear/bearing.
  • Replace any worn fifth-gear/bearing.
  • Replace any worn mainshaft bearings.
Check for a noise in the first gear (1) only.
  • Replace any chipped, scored, or worn first-gear constant mesh gears.
  • Replace any worn first-second gear synchronizer.
  • Replace any worn first-gear/bearing.
  • Replace any worn differential gear/bearing.
  • Replace any worn ring gear.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the second gear (2) only.
  • Replace any chipped, scored, or worn second-gear constant mesh gears.
  • Replace any worn first-second gear synchronizer.
  • Replace any worn second-gear/bearing.
  • Replace any worn differential gear/bearing.
  • Replace any worn ring gear.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the third gear (3) only.
  • Replace any chipped, scored, or worn third-gear constant mesh gears.
  • Replace any worn third-fourth gear synchronizer.
  • Replace any worn third-gear/bearing.
  • Replace any worn differential gear/bearing.
  • Replace any worn ring gear.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the fourth gear (4) only.
  • Replace any chipped, scored, or worn fourth gear or output gear.
  • Replace any worn third-fourth gear synchronizer.
  • Replace any worn fourth-gear/bearing.
  • Replace any worn differential gear/bearing.
  • Replace any worn ring gear.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the fifth gear (5) only.
  • Replace any chipped, scored, or worn fifth gear or output gear.
  • Repair any worn fifth-gear synchronizer.
  • Replace any worn fifth-gear/bearing.
  • Replace any worn differential gear/bearing.
  • Replace any worn ring gear.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the reverse (R) gear only.
  • Replace any chipped, scored, or worn reverse idler gear, idler-gear bushing, input gear, or output gear.
  • Replace any worn first-second gear synchronizer.
  • Replace any worn output gear.
  • Replace any worn differential gear/bearings.
  • Replace any worn ring gear.
Check for a noise in all gears.
  • Add sufficient lubricant.
  • Replace any worn bearings.
  • Replace any chipped, scored, or worn input-gear shaft or output-gear shaft.
Check for the transaxle slipping out of gear.
  • Adjust or replace the linkage as needed.
  • Adjust, repair, or replace any binding shift linkage.
  • Tighten or replace the input-gear bearing retainer as needed.
  • Repair or replace any worn or bent shift fork.
Check for a leak in the area of the clutch.
  • Repair the transaxle casing.
  • Replace any damaged release bearing guide.
Check for a leak at the center of the transaxle.
  • Repair the transaxle casing.
  • Repair the shift mechanism.
  • Replace the damaged backup lamp switch.
Check for a leak at the differential.
  • Adjust or replace the bearing retainers.
  • Tighten or replace the differential cover.
  • Adjust or replace the drive axle shaft seals.
Check for a hard shift.
  • Replace any damaged release-bearing guide.
  • Adjust, repair, or replace the shift mechanism.
  • Adjust, repair, or replace the clutch-release system.
  • Replace any chipped, scored, or worn fifth-gear synchronizer.
  • Replace any chipped, scored, or worn first-second gear synchronizer.
  • Replace any worn third-fourth gear synchronizer.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a clashing of gears.
  • Replace any damaged release-bearing guide.
  • Adjust, repair, or replace the clutch-release system.
  • Replace the chipped, scored, or worn input shaft/gear-cluster gears.
  • Replace any worn fifth-gear synchronizer.
  • Replace any worn fifth-gear/bearing.
  • Replace any worn first-gear/bearing.
  • Replace any worn first-second gear synchronizer.
  • Replace any worn second-gear/bearing.
  • Replace any worn third-gear/bearing.
  • Replace any worn third-fourth synchronizer.
  • Replace any worn fourth-gear/bearing.
  • Replace any worn reverse-idler gear.

COMPONENT LOCATORS

Gears and Case


V3B15B01
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  1. Case
  2. Mainshaft Bearing
  3. Fourth Gear
  4. Synchronizer Blocking Ring
  5. Synchronizer Sleeve
  6. Pin
  7. Third-Fourth Gearshift Fork
  8. Third-Fourth Gearshift Shaft
  9. Spring
  10. Key
  11. Third-Fourth Synchronizer Gear
  12. Synchronizer Blocking Ring
  13. Third Gear
  14. Second Gear
  15. First-Second Gear Blocking Ring
  16. First-Second Gearshift Fork
  17. First-Second Gearshift Shaft
  18. Synchronizer Hub Sleeve
  19. Synchronizer Spring
  20. Key
  21. First-Second Synchronizer Gear
  22. Snap Ring
  23. Outer Blocking Ring
  24. First Gear
  25. First Gear Needle Bearing
  26. Mainshaft Wear Plate
  27. Snap Ring
  28. Mainshaft Bearing
  29. Shift Rod Plug (21.5 mm)
  30. Spring
  31. Shift Rod Lock Pin
  32. Bearing Plate
  33. Shift Rod Plug (50.4 mm)
  34. Detent Rod Bolt
  35. Bolt
  36. Bolt
  37. Support
  38. Fifth Gearshift Fork
  39. Pin
  40. Fifth Gear Connector
  41. Shoe
  42. Key
  43. Snap Ring
  44. Gasket
  45. Cover
  46. Bolt
  47. Plug
  48. Bolt
  49. Screw
  50. Synchronizer Gear
  51. Spring
  52. Synchronizer Sleeve
  53. Synchronizer Blocking Ring
  54. Mainshaft Driven Fifth Gear
  55. Ring
  56. Thrust Washer
  57. Ring
  58. Input Drive Fifth Gear
  59. Bolt
  60. Cluster Gear Snap Ring
  61. Screw
  62. Cluster Shaft Bearing
  63. Ring
  64. Input Shaft Cluster Gear
  65. Ball
  66. Reverse Idler Gear Shaft
  67. Reverse Idler Gear
  68. Washer
  69. Washer Reverse Gear Fork Shaft
  70. Reverse Gearshift Fork
  71. Input Drive Shaft
  72. Bolt
  73. Fifth-Gear Pawl
  74. Fifth-Gear Needle Bearing
  75. First-Gear Needle Bearing
  76. Main Driven Shaft
  77. Fifth Gearshift Lever
  78. Hex Plug
  79. Gasket
  80. Reverse Lamp Switch
  81. Input Shaft Bearing
  82. Second-Gear Needle Bearing
  83. Third-Gear Needle Bearing
  84. Fourth-Gear Needle Bearing
  85. Washer

Differential and Case


V3B15B02
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  1. Speedometer-Driven Gear
  2. Seal
  3. Hex Bolt
  4. Bearing Plate
  5. Washer
  6. Bolt
  7. Seal
  8. Seal
  9. Bearing Adjusting Ring
  10. Side Bearing Race
  11. Housing Cover Gasket
  12. Differential Cover
  13. Bolt
  14. Differential Bearing
  15. Pinion Gear Shaft
  16. Differential Housing
  17. Thrust Washer
  18. Side Gear
  19. Washer
  20. Pinion Gear
  21. Ring Gear
  22. Speedometer Drive Gear
  23. Bolt
  24. Pinion Shaft Lock Pin
  25. Right Side Bearing Retainer
  26. Seal
  27. Retainer Bolt

Shift Linkage


V3B15B03
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  1. Gearshift Control
  2. Bolt
  3. Bolt
  4. Gearshift Bellows Tube
  5. Clamp
  6. Gearshift Guide Control
  7. Gearshift Control Rod
  8. Clip
  9. Front Gearshift Bracket
  10. Bolt
  11. Rear Gearshift Bracket
  12. Bolt
  13. Clip
  14. Pin


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