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.
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION
FIVE-SPEED MANUAL TRANSAXLE
This five-speed transaxle assembly is a transmission of constant-mesh design.
Combined in the assembly are:
- All forward gears.
- The reverse gear.
- The differential output.
The basic components of the five-speed transaxle assembly units are the:
- Transaxle case.
- Input shaft.
- Input shaft gears.
- Output shaft.
- Output shaft gears.
- Ring gear and differential assembly.
Forward Gear
Shifting to a forward gear is accomplished through a combination of synchronizers with blocker rings controlled by sliding shift forks.
Reverse Gear
Reverse gear is not synchronized and uses a sliding idler gear arrangement.
Differential Assembly
The differential is a conventional arrangement of gears that is supported by tapered roller bearings. The final output gear turns the ring gear and differential assembly which turns the drive axle shafts.
COMPONENT LOCATORS
GEARS AND CASE
- Case
- Mainshaft Bearing-outer Race
- Fourth Gear
- Synchronizer Ring
- Synchronizer Sleeve
- Pin
- Third-Fourth Gearshift Fork
- Third-Fourth Gearshift Rod
- Spring
- Key
- Third-Fourth Synchronizer Hub
- Synchronizer Ring
- Third Gear
- Second Gear
- Synchronizer Ring
- First-Second Gearshift Fork
- First-Second Gearshift Rod
- Sliding Gear-Rev. Gear
- Synchronizer Spring
- Key
- 1/2nd Hub
- Snap Ring
- Synchronizer
- First Gear
- Thrust Needle Bearing
- Mainshaft Disk
- Snap Ring
- Mainshaft Bearing
- Detent Sleeve
- Spring
- Detent Ball
- Bearing Plate
- Detent Sleeve
- Rod Bolt
- Bolt
- Bolt
- Support
- Fifth Gearshift Fork
- Pin
- Bridge-strain Bolt
- Shoe
- Key
- Snap Ring
- Gasket
- Cover
- Bolt
- Bolt
- Screw
- Fifth Gear Hub
- Spring
- Synchronizer Sleeve
- Synchronizer Blocking Ring
- Mainshaft Driven Fifth Gear
- Retaining Ring
- Thrust Washer
- Circlip
- Input Drive Fifth Gear
- Bolt
- Cluster Gear Snap Ring
- Screw
- Input Shaft Ball Bearing
- Ring
- Input Shaft Cluster Gear
- Ball
- Reverse Idler Gear Shaft
- Reverse Idler Gear
- Washer
- Reverse Gear Rod
- Reverse Gearshift Fork
- Input Shaft
- Bolt
- Fifth-Gear Pawl
- Fifth-Gear Needle Bearing
- First-Gear Needle Bearing
- Main Shaft
- Fifth Gearshift Lever
- Hex Plug
- Gasket-Bearing Plate
- Reverse Lamp Switch
- Input Shaft Bearing
- Second-Gear Needle Bearing
- Third-Gear Needle Bearing
- Fourth-Gear Needle Bearing
- Retaining Ring
DIFFERENTIAL AND CASE
- Speedometer-Driven Gear
- Seal
- Hex Bolt
- Plate-Lock
- Washer
- Bolt
- Seal
- O-Ring
- Ring Bearing
- Side Bearing Race
- Differential Cover Gasket
- Differential Cover
- Bolt
- Differential Bearing
- Differential Gear Shaft
- Differential Housing
- Thrust Washer
- Side Bevel Gear
- Washer
- Pinion Bevel Gear
- Ring Gear
- Speedometer Drive Gear
- Bolt
- Differential Gear Shaft Lock Pin
- Flange Bearing
- O-Ring
- Bolt
SHIFT LINKAGE
- Gearshift Lever Knob
- Gearshift Lever Boot
- Gearshift Lever
- Gearshift Lever Stop Clamp
- Gearshift Lever Shaft
- Gearshift Lever Stop Bushing
- Gearshift Lever Stop Bushing
- Bolt
- Gearshift Housing
- Shift Rod Clamp Bolt
- Washer
- Clamp
- Linkage Adjuster Bolt
- Gearshift Control Rod
- Linkage Ball Socket
- Circlip Ring
- Linkage Reverse Lever
- Gearshift Boot
- Bushing
- Bushing
- Rod U-Joint Bushing
- Clip
- Gearshift Rod
- Shift Finger Lever
- Cover Bolt
- Intermediate Lever
- Shift Lever Thrust Spring
- Bushing
- Snap Ring
- Oil Filler Plug
- Oil Plug Cap
- Gearshift Lever Cover
- Pin
- Bolt
- Gearshift Adjuster Linkage
- Shift Reverse Pivot Bolt
- Boot
- Gearshift Tube
- Bushing
- Gearshift Tube Bearing
DIAGNOSTIC INFORMATION AND PROCEDURES
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:
- A great effort required to shift gears.
- The sound of gears clashing and grinding.
- Gear blockout.
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:
- Tires.
- Road surfaces.
- Wheel bearings.
- Engine.
- Exhaust system.
These noises may vary according to the:
- Size of the vehicle.
- Type of the vehicle.
- Amount of insulation used in the body of the vehicle.
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:
- Select a smooth, level asphalt road to reduce tire and resonant body noise.
- Drive the vehicle far enough to warm up all the lubricants thoroughly.
- Record the speed and the gear range of the transaxle when the noise occurs.
- Check for noises with the vehicle stopped, but with the engine running.
- Determine if the noise occurs while the vehicle operates in:
- Drive - under a light acceleration or a heavy pull.
- Float - maintaining a constant speed with a light throttle on a level road.
- Coast - with the transaxle in gear and the throttle partly or fully closed.
- All of the above.
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 causes 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.
SYMPTOM DIAGNOSIS
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Checks
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Action
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Check for a knock at low speeds.
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- Replace any worn drive axle CV joints.
- Replace any worn side gear hub.
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Check for a noise most pronounced on turns.
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- Correct any abnormalities in the differential gear.
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Check for a clunk upon acceleration or deceleration.
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- 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.
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Check for a clunking noise in turns.
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- Replace any worn outboard CV joint.
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Check for a vibration.
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- 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.
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Check for a noise in the NEUTRAL gear with the engine running.
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- 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.
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Check for a noise in the first gear (1) only.
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- 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.
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Check for a noise in the second gear (2) only.
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- 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.
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Check for a noise in the third gear (3) only.
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- 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.
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Check for a noise in the fourth gear (4) only.
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- 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.
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Check for a noise in the fifth gear (5) only.
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- 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.
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Check for a noise in the reverse (R) gear only.
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- 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.
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Check for a noise in all gears.
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- Add sufficient lubricant.
- Replace any worn bearings.
- Replace any chipped, scored, or worn input-gear shaft or output-gear shaft.
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Check for the transaxle slipping out of gear.
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- 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.
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Check for a leak in the area of the clutch.
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- Repair the transaxle casing.
- Replace any damaged release bearing guide.
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Check for a leak at the center of the transaxle.
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- Repair the transaxle casing.
- Repair the shift mechanism.
- Replace the damaged backup lamp switch.
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Check for a leak at the differential.
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- Adjust or replace the bearing retainers.
- Tighten or replace the differential cover.
- Adjust or replace the drive axle shaft seals.
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Check for a hard shift.
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- 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.
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Check for a clashing of gears.
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- 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.
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REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
CHECKING FLUID LEVEL
- With the vehicle on a level surface and the fluid in the transaxle cold, Remove the filter plug and check the fluid level. the fluid should come to the bottom edge of the plughole.
- If the level is low, add SAE 80 manual transaxle fluid through the filter plughole until the fluid begins to run out.
- Reinstall the filter plug and tighten it securely.
The speed gears and the synchronizer parts on this vehicle receive lubrication through specific passages in the mainshaft.
It takes 1.9 liters (2.01 quarts) to fill the transaxle completely.
SHIFT LINKAGE ADJUSTMENT
- Disconnect the negative battery cable.
- Position the gearshift lever into NEUTRAL.
Important : All the gears must be easy to engage when the vehicle is stationary, the engine is running, and the clutch is disengaged.
- Loosen the rod clamp bolt.
Installation Notice
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Tightening Torque
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14 N•m (124 lb-in)
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- Remove the adjustment hole plug from the shift lever cover.
- Turn the gearshift rod and fully insert a 5 mm (0.2 inch) gauge pin into the adjustment hole.
- Remove the boot from the console.
- Pull the boot upward to expose the shift control lever mechanism.
- Position the gearshift lever close to the left side of the NEUTRAL position.
- Insert a 5 mm (0.2 inch) gauge pin into the holes to align the gearshift lever with the gearshift lever housing.
- Remove the 5 mm (0.2 inch) gauge pin from the adjustment hole.
- Install the adjustment hole plug.
- Remove the 5 mm (0.2 inch) gauge pin from the gearshift lever.
- Install the boot to the console.
- Connect the negative battery cable.
GEARSHIFT LEVER
Removal and Installation Procedure
- Disconnect the negative battery cable.
- Position the gearshift lever into NEUTRAL.
- Disconnect the boot from the console cover.
- Lift the console cover upward to expose the shift control lever mechanism.
- Rotate the gearshift lever stop clamp and remove it.
- Remove the gearshift lever from the gearshift lever shaft.
- Installation should follow the removal procedure in the reverse order.
GEARSHIFT TUBE, BOOT, BUSHING AND/OR BEARING RING
(Left-Hand Drive Shown, Right-Hand Drive Similar)
Removal and Installation Procedure
- Disconnect the negative battery cable.
- Remove the rod clamp bolt.
- Separate the linkage bolt from the gearshift tube.
- Remove the rod clamp from the gearshift tube.
- Remove the center console. Refer to Section 9G, Interior Trim.
Installation Notice
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Tightening Torque
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14 N•m (124 lb-in)
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- Position the shift lever into NEUTRAL.
- Disconnect the gearshift boot from the front portion of the floor console and lift upward to expose the shift control lever mechanism.
- Rotate the gearshift lever stop clamp and remove it.
- Remove the gearshift lever and the boot.
- Remove the gearshift housing bolts.
Installation Notice
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Tightening Torque
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6 N•m (53 lb-in)
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- Remove the gearshift tube with the gearshift housing from the vehicle.
- Remove the gearshift tube from the gearshift housing.
- Remove the bushing and the gearshift tube bearing from the gearshift housing.
Installation Notice
- Press the bearing ring into the gearshift housing from the inside.
- Remove the bushing from the gearshift tube bearing.
- Installation should follow the removal procedure in the reverse order.
CONTROL SHIFT ROD
Removal and Installation Procedure
- Disconnect the negative battery cable.
- Separate the plastic clip from the end of each ball socket.
- Separate the ball sockets from the ball studs on the linkage bolts using a pry bar.
Installation Notice
- Press the ball sockets from the ball studs on the linkage bolts using a pry bar.
- Remove the control shift rod from the vehicle.
- Installation should follow the removal procedure in the reverse order.
LINKAGE LEVER AND/OR BUSHINGS
Removal and Installation Procedure
- Disconnect the negative battery cable.
- Separate the plastic clip from the end of each ball socket.
- Separate the ball sockets from the ball studs on the linkage bolts using a pry bar.
- Remove the control shift rod.
- Remove the clip and the bolt from the universal joint.
- Remove the rod clamp bolt.
Installation Notice
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Tightening Torque
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14 N•m (124 lb-in)
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- Separate the linkage bolt from the shift tube.
- Remove the linkage lever assembly from the vehicle.
- Remove both linkage lever bushings from the linkage lever assembly.
Installation Notice
- Coat the linkage lever bushing with silicone grease.
- Remove the snap rings retaining the linkage bolts to the linkage lever assembly.
- Disconnect the linkage bolts from the linkage lever.
- Installation should follow the removal procedure in the reverse order.
SPEEDOMETER DRIVEN GEAR
Removal and Installation Procedure
- Disconnect the speedometer speed sensor electrical connector.
- Remove the speedometer housing retaining bolt.
Installation Notice
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Tightening Torque
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4 N•m (35 lb-in)
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- Remove the speedometer-driven gear and the speedometer housing.
- Installation should follow the removal procedure in the reverse order.
SHIFT LEVER COVER
Removal and Installation Procedure
- Remove the clip and the bolt at the universal joint.
Adjustment Notice:
- Remove the gearshift lever cover bolts.
Installation Notice
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Tightening Torque
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22 N•m (16 lb-ft)
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- Separate the gearshift lever cover and the gasket from the case.
- Installation should follow the removal procedure in the reverse order.
DRIVE AXLE SEAL
Tools Required
Removal and Installation Procedure
- Remove the drive axle from the transaxle. Refer to Section 3B, Manual Transaxle Drive Axle.
- Remove the drive axle seal by lifting the outer lip of the seal with a pry bar.
Removal Notice
- Do not damage the bearing adjusting ring with the pry bar.
- Install the new drive axle seal using the ring installer KM-519 and a hammer.
- Coat the seal lip with the transaxle fluid.
- Install the drive axle. Refer to Section 3B, Manual Transaxle Drive Axle.
TRANSAXLE ASSEMBLY
Tools Required
DW 110-060 Engine Support Fixture
Removal and Installation Procedure
- Disconnect the backup lamp switch electrical connector.
- Disconnect the speedometer speed sensor electrical connector.
- Remove the clip and the bolt from the universal joint.
- Remove the clutch release cylinder bracket bolts and the clutch release cylinder bracket.
Installation Notice
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Tightening Torque
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70 N•m (52 lb-ft)
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- Install the engine support fixture DW 110-060.
- Remove the upper transaxle-to-engine bolts.
Installation Notice
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Tightening Torque
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70 N•m (52 lb-ft)
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- Remove both of the drive axle shafts. Refer to Section 3B, Manual Transaxle Drive Axle.
- Remove the left front transaxle support bracket bolts and nut.
Installation Notice
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Tightening Torque
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60 N•m (44 lb-ft)
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- Remove the left front transaxle support bracket cage.
- Remove the left front transaxle support bracket bolts and the left front transaxle support bracket.
Installation Notice
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Tightening Torque
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50 N•m (37 lb-ft)
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- Support the transaxle with a transaxle support jack.
- Remove the shift linkage bolt and the shift linkage.
Installation Notice
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Tightening Torque
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14 N•m (124 lb-in)
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- Remove the lower transaxle-to-engine bolts.
Installation Notice
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Tightening Torque
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19mm bolts
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75 N•m (55lb-ft)
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14mm bolts
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30 N•m (22lb-ft)
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- Remove the left shift linkage bracket bolts and the left shift linkage bracket.
Installation Notice
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Tightening Torque
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75 N•m (55 lb-ft)
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- Remove the transaxle.
Removal Notice
- Rest the transaxle only in an upright position.
- Slide the transaxle sideways away from the engine block.
- Lower the transaxle
- Installation should follow the removal procedure in the reverse order.
UNIT REPAIR
MAJOR COMPONENT
Tools Required
J-6125-B Slide Hammer
J-22888-20-A Bearing Puller with J-22888-35 Puller Legs
KM-553-A Fifth Gear Puller
J-36633 Snap Ring Retainer
KM-113-2 Base
J-42469 Shift Rod Remover
KM-552 Fixture
Disassembly and Assembly Procedure
- Remove the transaxle from the vehicle. Refer to "Transaxle Assembly" in this section.
- Remove the filler plug at the cover.
- Remove the bolts from the gearshift lever cover.
- Remove the gearshift lever cover.
Installation Notice
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Tightening Torque
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22 N•m (16 lb-ft)
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- Bolt the gearshift lever cover to the fixture KM-552.
- Position the fixture KM-552 into the base KM-113-2.
- Remove the snap ring, the bushing, the spring, and the intermediate lever.
- Remove the shift finger lever pin.
- Remove the gearshift rod and the shift finger lever.
- Remove the bolt and the speedometer-driven gear from the transaxle housing.
Installation Notice
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Tightening Torque
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4 N•m (35 lb-in)
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- Remove the transaxle cover bolts.
Installation Notice
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Tightening Torque
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18 N•m (13 lb-ft)
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- Remove the transaxle cover.
- Shift the transaxle into second gear.
- Remove the bearing plate bolts.
Installation Notice
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Tightening Torque
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22 N•m (16 lb-ft)
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- Remove the bearing plate from the case with the shafts attached.
- Shift the transaxle into reverse (R).
- Bolt the bearing plate to the fixture KM-552 and install the fixture KM-552 into the base KM-113-2.
- Remove the bolts and the fifth-gear fork from the bearing plate.
Installation Notice
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Tightening Torque
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22 N•m (16 lb-ft)
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- Remove the mainshaft-driven fifth-speed assembly snap ring.
- Remove the fifth driven gear synchronizer sleeve and the synchronizer gear using the bearing puller J-22888-20-A with the puller legs J-22888-35.
- Remove the mainshaft-driven fifth-gear assembly.
- Remove the brass synchronizer ring.
- Remove the needle bearing, the retaining ring, and the thrust washers.
- Remove the input drive fifth-gear snap ring.
- Remove the input drive fifth gear using the fifth-gear puller KM-553-A.
- Remove the bolts and the fifth-gearshift connector from the bearing plate using the pawl.
Installation Notice
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Tightening Torque
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7 N•m (62 lb-in)
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- Remove the four shift-rod plugs using the shift rod remover J-42469 and the slide hammer J-6125-B.
- Remove the spring and the rod lock pin from the small plughole.
- Remove the pin from the reverse gearshift rod/fork assembly.
- Remove the reverse gearshift rod/fork assembly from the bearing plate.
- Remove the bolts from the support bracket.
Installation Notice
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Tightening Torque
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7 N•m (62 lb-in)
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- Remove the first-second gearshift fork holding pin.
- Drive the first-second gearshift rod out until it is just free of the bearing plate.
- Remove the support bracket from the bearing plate.
- Remove the third-fourth gearshift fork holding pin and the third-fourth gearshift rod.
- Remove the fifth gearshift lever from the bearing plate.
- Remove the first-second gearshift rod.
- Compress the snap ring holding the mainshaft and secure it with the snap ring retainer J-36633.
- Hold the snap ring open at the base of the input shaft using the snap ring pliers.
- Remove the mainshaft assembly and the input shaft assembly from the bearing plate.
- Assembly should follow the disassembly procedure in the reverse order.
INPUT SHAFT AND CLUSTER GEAR
Tools Required
J-22912-01 Universal Bearing Puller
Disassembly and Assembly Procedure
- Remove the detent screw at the end of the input driveshaft.
Installation Notice
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Tightening Torque
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15 N•m (11 lb-ft)
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- Remove the snap ring at the base of the gear cluster.
Installation Notice
- Install the snap ring at the base of the gear cluster.
- Press the input driveshaft from the input shaft cluster gear using the universal bearing puller J-22912-01.
- Remove the cluster shaft bearing from the input shaft gear cluster using universal bearing puller J-22912-01.
- Press the cluster shaft bearing onto the input shaft gear cluster.
- Press the input driveshaft into the input shaft gear cluster assembly.
MAINSHAFT
Tools Required
J-22912-01 Universal Bearing Puller
Disassembly and Assembly Procedure
- Remove the mainshaft bearing using the universal bearing puller J-22912-01.
- Remove the snap ring.
- Remove the first gear, the thrust needle bearing, and the mainshaft disk.
- Remove the synchronizer hub sleeve that contains the synchronizer spring.
- Remove the outer blocking ring.
- Remove the keys from the first-second synchronizer gear.
- Remove the barrel-type first-gear needle bearing.
- Remove the retaining ring and the thruster washer.
- Remove the first-second synchronizer hurb from the mainshaft.
- Remove the first-second gear syncronizer ring.
- Remove the second gear using the universal bearing puller J-22912-01.
- Remove the second-gear needle bearing.
- Remove the retaining ring and the thrust washer.
- Remove the third gear and the synchronizer blocking ring.
- Separate the synchronizer blocking ring from the third gear.
- Remove the third-gear needle bearing from the mainshaft.
- Remove the synchronizer sleeve containing the keys and the spring.
- Remove the retaining ring and the thruster washer from the mainshaft.
- Remove the third-fourth synchronizer hub containing the synchronizer spring.
- Remove the fourth-gear assembly.
- Separate the synchronizer blocking ring from the fourth gear.
- Remove the fourth-gear needle bearing, the retaining ring, and the thrust washer.
- Remove the mainshaft bearing.
- Installation should follow the removal procedure in the reverse order.
HOUSING CASE
Disassembly and Assembly Procedure
- Remove the transaxle from the vehicle. Refer to "Transaxle Assembly" in this section.
- Remove the shift lever cover bolts and the shift lever cover. Do not disassemble the shift lever cover.
Installation Notice
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Tightening Torque
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22 N•m (16 lb-ft)
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- Remove the transaxle cover bolts and the transaxle cover.
Installation Notice
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Tightening Torque
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18 N•m (13 lb-ft)
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- Remove the bearing plate bolts and the bearing plate, with the shafts attached. Do not disassemble the shafts.
Installation Notice
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Tightening Torque
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22 N•m (16 lb-ft)
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- Remove the differential from the transaxle housing. Do not disassemble the differential. Refer to "Differential" in this section.
- Remove the backup lamp switch from the transaxle housing.
Installation Notice
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Tightening Torque
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20 N•m (15 lb-ft)
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- Remove the clutch-release bearing and the clutch-release bearing guide. Refer to Section 5C, Clutch.
- Remove the speedometer-driven gear bolt and the speedometer-driven gear from the transaxle housing.
Installation Notice
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Tightening Torque
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5 N•m (44 lb-in)
|
- Assembly should follow the disassembly procedure in the reverse order.
DIFFERENTIAL
Tools Required
KM-520 Remover/Installer
KM-525 Installer
J-22888-20-A Bearing Puller with J-22888-35 Puller Legs
KM-522 Installer
Disassembly and Assembly Procedure
- Remove the differential cover bolts, the differential cover, and the differential cover gasket.
Installation Notice
|
Tightening Torque
|
40 N•m (30 lb-ft)
|
- Remove the bearing-adjusting ring retainer plate bolt and the bearing-adjusting ring retainer plate.
Installation Notice
|
Tightening Torque
|
5 N•m (44 lb-in)
|
- Remove the bearing-adjusting ring using the remover/installer KM-520.
Installation Notice
|
Tightening Torque
|
Used Bearing
|
1 N•m (9 lb-in)
|
|
New Bearing
|
2 N•m (18 lb-in)
|
- Tighten or loosen the bearing ring adjuster to get the required preload on the bearings.
- Used Bearings:
-
- 1 N•m (9 lb-in) required to rotate the differential one revolution per second.
-
- 2 N•m (18 lb-in) required to rotate the differential one revolution per second.
- Remove the right-side bearing-retainer bolts and the right-side bearing retainer.
Installation Notice
|
Tightening Torque
|
25 N•m (18 lb-ft)
|
- Remove the differential assembly from the transaxle case.
- Remove the ring gear bolts.
Installation Notice
|
Tightening Torque
|
90 N•m (66 lb-ft)
|
- Separate the ring gear from the differential housing.
- Drive the pinion gear shaft lock pin from the differential housing and the pinion gear shaft.
- Remove the pinion gear shaft.
- Remove the pinion gears and the washers.
- Remove the side gears and the side thrust washers.
- Remove both of the differential bearings using the bearing puller J-22888-20-A with the puller legs J-22888-35.
- Remove the speedometer drive gear from the differential gear housing.
- Installation should follow the removal procedure in the reverse order.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
|
Application
|
N•m
|
Lb-Ft
|
Lb-In
|
|
Backup Lamp Switch
|
20
|
15
|
-
|
|
Bearing Plate Bolts
|
22
|
16
|
-
|
|
Bearing Retainer Bolts, Right Side
|
25
|
18
|
-
|
|
Bearing-Adjusting Ring-Retainer Plate Bolt
|
5
|
-
|
44
|
|
Center Rear Transaxle Support Bracket Bolts
|
90
|
66
|
-
|
|
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
|
6
|
-
|
53
|
|
Gearshift Lever Cover Bolts
|
22
|
16
|
-
|
|
Input Driveshaft Detent Screw
|
15
|
11
|
-
|
|
Left Front Transaxle Support Bracket Bolts
|
60
|
44
|
-
|
|
Left Rear Transaxle Support Bracket Bolts
|
60
|
44
|
-
|
|
Lower Transaxle-to-Engine Bolts
|
75
|
55
|
-
|
|
Ring-Gear Bolts
|
70
|
52
|
-
|
|
Rod Clamp Bolt
|
14
|
-
|
124
|
|
Speedometer Housing Retaining Bolt
|
4
|
-
|
35
|
|
Speedometer-Driven Gear Bolt
|
5
|
-
|
44
|
|
Support Bracket Bolt
|
7
|
-
|
62
|
|
Transaxle Cover Bolts
|
18
|
13
|
-
|
|
Upper Transaxle-to-Engine Bolts
|
75
|
55
|
-
|
SPECIAL TOOLS
SPECIAL TOOLS TABLE
