MANUAL

TRANSAXLE

SPECIAL SERVICE TOOLS MT-2

SYMPTOM-RELATED DIAGNOSTIC PROCEDURE MT-4

SPECIFICATIONS MT-5

DESCRIPTION AND OPERATION MT-6

SERVICE ADJUSTMENT PROCEDURE MT-7

REMOVAL AND REPLACEMENT PROCEDURE MT-10

DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURE MT-15

МТ-2 MANUAL TRANSAXLE
SPECIAL SERVICE TOOLS MT-3
МТ-4 MANUAL TRANSAXLE

SYMPTOM RELATED DIAGNOSTIC PROCEDURES

SPECIFICATIONS MT-5

SPECIFICATIONS
Manual transaxle
— — ______^^ Engine / Transaxle Diesel (KJ 2.9TCI) Gasoline (GV 2.5D)
Item ~~ . HTX
Transmission control Floor shift
Synchromesh system Forward: Synchromesh
Reverse: Selective sliding, Synchromesh
Gear ratio 1st 3.753
2rd 1.950
3rd 1.30
4th 0.941
5th 0.750
Reverse 3.167
Final gear ratio 3.88 4.313
Oil Grade API Service GL-4
Viscosity SAE 75W-90
Capacity US qt (liters, Imp qt) 2.43(2.3,2.1)
МТ-6 MANUAL TRANSAXLE

DESCRIPTION AND Guide plate unit

Because FIFTH and REVERSE are on straight line in
OPERATION the shift pattern, a shift interlock is installed to prevent a
direct shift from FIFTH gear into REVERSE.
The reverse lock out cam is mounted on the interlock
Manual transaxle plate where crank lever engages the shift pattern.
Manual transaxle assembly The reverse lock out cam is spring - loaded to block the
The five-speed manual transaxle has a split case path of the crank lever to REVERSE gear from FIFTH
design one half of the case is the clutch housing and gear.
the other half is the transaxle case. When the crank lever moves from the FIFTH gear
The clutch housing includes the following components; position, the contour of the reverse lock out cam directs
the crank lever into the NEUTRAL position.
• Clutch release components The crank lever can enter the REVERSE gear position
• Speedometer gear only from the NEUTRAL position.
Change rod unit

The transaxle case includes the following components; Shin rods

When the crank lever selector rotates, its motion is
First / Second detent transferred to the synchronizers through shift rod ends,
• Third / Fourth detent shift rods and fork shifts.
Fifth / Reverse detent The transaxle contains three shift rods.
Backup lamp switch
Shift first / Second rod
• Shift third / Fourth rod
The transaxle assembly is installed transversely in the • Shift fifth / Reverse rod
engine compartment with the clutch housing facing the
LH side of the vehicle.
The transaxle assembly is held in position by the front Detent plug, spring and ball
and rear transaxle mounting rubbers which are Once the transaxle is shifted into a gear, movement of
attached to the subframe and another transaxle the remaining shift rods is prevented by the detent plug,
mounting rubber which is attached into the LH side of spring and ball.
the vehicle. The shift rods are locked in position to eliminate the
These mounting rubbers also serve as mounts for the simultaneous engagement of the transaxle in two
engine. gears.
The transverse installation of the transaxle assembly
requires the left front wheel driveshaft and joint and When the transaxle is shifted into a gear, the positive
right front wheel driveshaft and joint to transfer torque feeling of engagement is provided by the detents.
from the differential to the front wheels. The front wheel The detents are spring - loaded balls that ride against
driveshaft and joints engage the differential side gears notches cut in the shift rods.
at the transaxle end and wheel hubs at the wheel end. Each shift rod has three notches. The center notch on
all shift rod is the NEUTRAL detent. The notches on
either side of the center notch represent a gear
Synchromesh position.
The disadvantages of the sliding-mesh and the
constant-mesh are because the speeds of the meshing
clutch and the sliding gear do not coincide, noise is
produced, tooth wear is hastened, breakage occurs
easily, and shifting becomes difficult.
To overcome these, the synchromesh system is used to
quickly equalize speeds of meshing teeth. This system
can generally be called a synchro mechanism.
The main advantage of this type is that double-clutching
is not necessary during shifting, resulting in a smoother
meshing of gears. Overall shifting is rapid and good,
and acceleration performance is found to be much
better than in the other systems described.
SERVICE ADJUSTMENT PROCEDURE MT-7

3. Install new washer on drain plug and reinstall plug in case.

SERVICE ADJUSTMENT
PROCEDURE Tightening torque:
29-43 Ib-ft (40-58 N-m, 4.0-6.0 kg-m)

Manual transaxle
Oil inspection
1. Raise vehicle and support it with safety stands.

Jje Notice
a) Keep vehicle level when checking oil level.
b) The transaxle speed driven gear is installed in
the clutch housing of transaxle.

2. Remove the speed driven gear from the clutch

housing of transaxle.

4. Remove the speed driven gear from the clutch

housing of transaxle.
5. Add specified amount and type of oil into the speed
driven gear hole until level reaches 'F' on the speed
driven gear.

AV2A41182

3. Verify that oil level is between 'F and 'L' on the

speed driven gear.
4. If oil level is 'L', fill specified amount and type of oil
untill level reaches 'F'.
5. Install the speed driven gear on the clutch housing
of transaxle.
6. Lower vehicle.

BSX041004

Oil change
1. Raise vehicle and support it with safety stands. Specified oil:
Grade: API Service GL-4
% Notice Viscosity: SAE 75W-90
a) Keep vehicle level when checking oil level. Capacity: 2.43 US qt (2.3 1, 2.1 Imp qt)
b) The transaxle speed driven gear is installed in
the clutch housing of transaxle. 6. Verify that oil level is between 'F' and 'L' on the
speed driven gear.
2. Remove drain plug and washer at bottom of transaxle 7. Install the speed driven gear on the clutch housing
case and drain fluid into suitable container. of transaxle.
8. Warm up vehicle until transaxle oil reaches its
T normal temperature, then check for leakage of
J. Caution
transaxle oil.
Avoid spilling the transmission fluid. The fluid
9. Lower vehicle.
may be hot.
МТ-8 MANUALTRANSAXLE

Oil seal change 7. Insert pry bar between outer ring and transaxle and
1. Jack up vehicle and support it with safety stands. pry driveshaft from transaxle.
2. Remove drain plug at bottom of transaxle case and
drain fluid into a container.

AV2050010

AS2A41013
Notice
After removing the front wheel driveshaft, support
3. Remove front wheels and tires. the front wheel driveshaft with wire to prevent the
4. Separate front stabilizer from lower arm. driveshaft from damaging the tripod joint bearing
and boot.
Caution
Do not damage dust boots.

5. Remove pinch bolt and pull lower arm downward to

separate knuckle from lower control arm ball joint.
6. Loosen cotter pin and nut and disconnect tie-rod
end with SST(OK130 283 021).

BSX041010

8. Remove oil seal with screwdriver.

OK130283021

AV2050004

Caution
Do not subject CV Joint to shock when removing
driveshaft.

AS2A41016
SERVICE ADJUSTMENT PROCEDURE MT-9

ф Notice
a) Tap in until oil seal is flush with case.
b) Coat oil seal lip with transaxle oil.

9. Tap new oil seal into transaxle case with

SST(OK201 170AA1).

AS2A41017

10. Replace driveshaft end clip and install driveshaft

into transaxle with end-gap of clip facing upward.

AS2A41018
МТ-10 MANUAL TRANSAXLE

REMOVAL AND 12. Remove the crankshaft position sensor.

13. Disconnect back-up lamp switch connector and
REPLACEMENT PROCEDURE earth cables from transaxle.

Manual transaxle
Removal and replacement procedure of Manual
transaxle (Refer to section EM Gr. Engine).

Removal
1. Disconnect negative battery cable(first) and positive
battery cable(sec.).
2. Raise and support the vehicle.
3. Remove the front wheels and tires.
4. Remove the drain plug and drain the transaxle fluid
from the transaxle into suitable container.
5. Drain the coolant into suitable container.
6. Remove the fresh airduct.
BSX041018

Fresh airduct
14. Remove the release cylinder after removing two
release cylinder bolts.
15. Remove the starter motor.
16. Disconnect the shift cable and the select cable.

AV2041001

7. Disconnect the water hose and the heater hose.

8. Disconnect the fuel hose.
9. Disconnect the accel cable.
10. Remove the battery and battery bracket. Select cable
11. Disconnect the speed sensor connector from
transaxle after removing speed sensor connector
bolt.
17. Remove the front stabilizer bar (Refer to section SS
Gr. Suspension system).
Crank angle 18. Use the engine hanger or equivalent to support the
sensor
engine.
19. Remove the fixed bracket after removing the power
steering rack and pinion.

Select cable
AV2041002
REMOVAL AND REPLACEMENT PROCEDURE
20. Remove the tie rod end cotter pin and tie rod end
nut and disconnect the tie rod end from the front
wheel knuckle with SST(OK130 283 021). Discard
the used tie rod end cotter pin.
AV2050004
21. Remove the clamp bolts and nuts. Pull the front
suspension lower arm down ward, seperating the front
suspension lower arm from the front wheel knuckle.
AV2041004
Caution
Be careful not to damage the ball Joint dust boot.
AV2041005
MT-11
22. Remove the lower arm from the side of the
subframe after removing the tension rod which is
installed to lower arm.
23. Use a pry bar to seperate the front wheel driveshaft
and joint from the transaxle.
Caution
Seperate the front wheel driveshaft and joint
from the transaxle gradually. If it is suddenly
yanked out of transaxle, the differential oil seal
may be damaged.
AV2050010
Caution
After removing the front wheel driveshaft,
support the front wheel driveshaft with wire to
prevent the driveshaft from damaging the tripod
Joint bearing and boot
BSX041010
МТ-12 MANUALTRANSAXLE

24. Remove the exhaust pipe. Replacement

25. Remove the engine mounting No.1 and 2 from the 1. Install the engine - to - transaxle and tighten the
subframe. engine - to- the transaxle with bolts.
26. Remove the subframe.
Tightening torque:
Engine mounting No. ф М12 bolt: 50-66 Ib-ft (69~89 N>m, 7.0-9.1 kg-m)
(2) M10 bolt: 27-38 Ib-ft (37-52 N-m, 3.8-5.3 kg-m)

AV2A42127

2. Lift the engine and the transaxle slowly and position

the engine and the transaxle in the vehicle.
3. Tighten lightly the engine mounting No.3, 4 in the
vehicle (refer to section EM Gr.-Engine).
4. Tighten the subframe with bolts (refer to section SS
Gr.-Suspension system).

Tightening torque:
AV2A10025 88-101 Ib-ft (120-137 N-m, 12.2-14 kg-m)

5. Install the engine mounting No.1,2 to the subframe

27. Remove the engine mounting bracket which is installed
and tighten bolts and nuts.
to the transaxle after loosening the engine mounting
No.3 and 4 nuts and removing the engine mount.
Tightening torque:
® 49-69 Ib-ft (67-93 N-m, 6.8-9.5 kg-m)
® 63-86 Ib-ft (85-117 N-m, 8.7-11.9 kg-m)

AV2041006

28. Gently lower the engine and the transaxle with jack.
29. Loosen the transaxle bolts from the engine. AV2A10025
REMOVAL AND REPLACEMENT PROCEDURE MT-13

6. Install the power steering rack and pinion to the subframe. 12. Install the stabilizer to the lower arm and tighten the stabilizer
bolts (refer to section SS (^.-Suspension system).
% Notice
When installing oil seal, be careful not to damage Tightening torque:
oil seal. 1&-19 Ib-ft (21-26 N-m, 2.2-2.7 kg-m)

7. Install the exhaust pipe. 13. Attach the tie rod end to the front wheel knuckle.
8. Put lower arm into the side of the subframe and then Tighten the tie rod nut and then install a new tie rod
tighten lower arm and subframe with bolts and nuts. end cotter pin.

Tightening torque:
88-101 Ib-ft (120-137 N-m, 12.2-14 kg-m)

9. Install new clip onto driveshaft and push driveshaft

and joint shaft into transaxle with opening of clip
pointing upward.

AV2A50001

14. Install the starter motor (Refer to section ЕЕ Gr.-

Starter system).
15. Install the shift cable and the select cable to the
transaxle and tighten the shift cable bolt and the
select cable bolt.
AS2A41032
Tightening torque:
11-17 Ib-ft (15-22 N-m, 1.6-2.3 kg-m)
10. Attach the lower arm ball joint to the front wheel knuckle.

Tightening torque:
69~85 Ib-ft (93~115 N*m, 9.5~11.7 kg-m)

Select cable

AV2041004

11. Install tension rod to the lower arm and then tighten bolts.

Tightening torque:
69-85 Ib-ft (93-115 N-m, 9.5-11.7 kg-m)
МТ-14 MANUAL TRANSAXLE

16. Install the clutch release cylinder and tighten the

release cylinder bolts (Refer to section CH Gr.
Clutch).

Tightening torque:
14-19 Ib-ft (19-25 N*m, 1.9-2.6 kg-m)

17. Reconnect back-up switch connector and earth

cables to the transaxle.
18. Reconnect the vehicle crank angle sensor
connector.

Crank angle
sensor

Select cable AV2041002

19. Reconnect the crankshaft position sensor

connector.
20. Position the battery and install it after installing the
battery support.
21. Reconnect the axle cable.
22. Reconnect the fuel hose.
23. Reconnect the water hose and heater hose.
24. Reinstall frash air duct.
25. Reconnect the battery ground cable.
26. Add the specified transaxle fluid to the transaxle.
(Refer to the procedure in this section)
27. Install the wheel and tire and tighten the nuts.

Tightening torque:
65-79 ib-ft (88-108 N-m, 9.0-11.0 kg-m)

28. Check the front wheel alignment. (Refer to SS Gr -

Suspension system/on-vehicle service)
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-15

DISASSEMBLY, INSPECTION AND RE-ASSEMBLY

PROCEDURES
Manual transaxle
Disassembly

AV2A41002

(1) Rear cover (9) Reverse lever spring (16) 1/2 shitt fork (25) 5/R shift rod end
(2) Lock nut set (17) 1/2 shift rod end (26) Secondary gear train
(3) Retainer ring (10) Reverse shift lever (18) Roll pins (27) Primary gear train
(4) Transaxle case (11) Change rod (19) 3/4 shift rod (28) Bearing cover
(5) Detent plug & Spring, (12) Back lamp switch (20) 3/4 shift fork (29) Defferential assembly
steel ball (13) Speedometer driven (21) 3/4 shift rod end (30) Magnet
(6) Reverse idle shaft gear (22) Roll pins (31) Oil seal
(7) Reverse idle gear (14) Roll pins (23) 5/R shift rod (32) Clutch housing
(8) Control case assembly (15) 1/2 shift rod (24) 5/R shift fork
МТ-16 MANUALTRANSAXLE

Caution 3. Shift to 1 st gear to lock the rotation of the primary

a) Clean transaxle exterior thoroughly with shaft.
steam cleaner or cleaning solvent before 4. Remove the screws that secure the rear cover to
disassembly. the case. Tap the rear cover with a fiber or plastic
b) Clean removed parts (except sealed mallet to loosen the seal. Remove the rear cover.
bearings) and all sealing surfaces with
cleaning solvent, and dry with compressed
air. Rear cover
c) Clean out all holes and passages with
compressed air and verify that there are no
obstructions.

A WARNING
USING COMPRESSED AIR CAN CAUSE DIRT
AND OTHER PARTICLES TO FLY OUT,
CAUSING INJURY TO EYES.
WEAR PROTECTIVE EYE WEAR WHENEVER
USING COMPRESSED AIR.

^ Caution AV2A41159
Do not remove an oil seal If not necessary.
5. Uncrimp the tabs of the locknuts.
1 . Mount the transaxle on the SST(OK1 30 990/OK1 30 6. Remove the locknut and retainer ring from
175 011 A). secondary shaft.

4s Notice
Do not reuse the removed locknut.
OK130 990007

7. Remove the detent plugs, springs and steel balls in

the side of case.
8. Remove the back lamp switch.

OK130175011A

BSX041030

2. Lock the primary shaft by using the SST(OK201 323

021).

Detend plug Back lamp

switch AV2A41158

BSX041034
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-17

9. Remove the bolts installed to case. 14. Carefully remove the roll pins from the rod/fork
Tap the case lightly with a plastic hammer to loosen assembly with a pin punch.
the seal. Remove the case.
10. Remove the reverse idle shaft and gear. 3/4 shift rod
11. Remove the reverse lever spring set after loosening 1/2 shift rod
bolt. 5/R shift rod
12. Remove the reverse shift lever after loosening two
bolts.

Primary shaft Secondary shaft

gear assembly gear assembly

Reverse shift AV2A41003

lever
15. Refer to removing order on the figure. Discard the
used roll pin.

Reverse lever
spring set AV2A41160

13. Remove the control case assembly after removing

the change rod.

Change rod

AV2A41001

16. Remove the 5/R shift rod, 5/R shift fork and 5/R
shift rod end.

Control case assembly AV2A41161

5/R shirt
fork

5/R shift rod

5/R shift
rod end

AV2A41001
МТ-18 MANUAL TRANSAXLE

17. Remove the 3/4 shitt rod, 3/4 shift fork and 3/4 shift 20. Loosen the three bearing cover screws after
rod end. removing rings, bearings, and clutch hub
assemblies put into secondary shaft and then
remove the secondary shaft.

3/4 shitt rod Secondary shaft

3/4 shift fork

shift rod end Bearing cover

AV2A41163

AV2A41166
18. Remove the 1/2 shift rod, 1/2 shift fork and 1/2 shift
rod end. 21. Remove the differential assembly.

1/2 shift rod

1/2 shift fork

1/2 shift rod end

BSX041129
AV2A41164
22. Remove the speedometer driven gear after
19. Remove gears and clutch hub assemblies into the loosening the bolt.
primary and secondary shaft in order and then 23. Remove the primary shaft oil seal with a
remove the primary shaft. screwdriver or suitable tool.
(Refer to primary shaft assembly - MT-28page)

Primary shaft
gear assembly Secondary shaft
gear assembly

BSX041058
AV2A41165
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-19
24. Remove the sealing cap. 30. Remove the oil seal of the differential side of
25. Remove the change rod oil seal with a screwdriver transaxle case with a screwdriver or suitable tool.
or suitable tool.
26. Remove the differential oil seal with a screwdriver
or suitable tool.
27. Install a SST(OK130170 012) on the differential
bearing outer race.
28. Remove the bearing outer race with a suitable pipe.

BSX041059

r
J. Caution
Do not damage the transaxle case.

31. Remove the secondary bearing outer race of the

BSX041060 transaxle case with a screwdriver or suitable tool.

29. After installing a SST(OK130 170 012) to the

bearing outer race of the differential side, remove
the bearing outer race and the adjust shim from the
transaxle case.

OK130170012

BSX041062

BSX041061
МТ-20 MANUALTRANSAXLE

Selection of shim Secondary shaft assembly

Adjust the preload and select the shim as follows. 1. Set the secondary shaft into the clutch housing.
2. Install the secondary shaft bearing outer race into
Primary shaft assembly the transaxle case.
3. Install the transaxle case to the clutch housing and
1. Set the primary shaft assembly into the clutch
tighten bolts to the specified torque.
housing.
2. Install the transaxle case to the clutch housing and
Tightening torque:
tighten bolts to the specified torque.
32-40 Ib-ft (43-54 N-m, 4.4-5.5 kg-m)
Tightening torque:
32-40 Ib-ft (43-54 N-m, 4.4-5.5 kg-m)

BSX041127

4. Mount a dial indicator to the transaxle case and

AV2A41167
measure the secondary shaft end play.

Clearance:
3. Mount the dial indicator to the transaxle hanger and
0.0012-0.0039 In (0.03-0.1 mm)
measure the primary shaft thrust clearance.

Clearance: 0~0.004 in (0~0.10 mm)

4. Select the closest shim on the thin side from the

table.

Thickness of adjustment shim:

0.012 in (0.3 mm), 0.016 In (0.4 mm),
0.02 in (0.5 mm)

Primary
shaft

BSX041125
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-21

5. Select the shim as follows. Differential

(a) Add the 0.001 in (0.03 mm) to the thrust 1. Install the bearing outer race into the clutch
clearance. housing.
(b) Add the 0.003 in (0.08 mm) to the thrust 2. Set the differential assembly into the clutch
clearance. housing.
(c) Select the thickest shim in the range between
(a) and (b).

BSX041129

AV2A41168

Notice
Example: 0.0087 in (0.22 mm) Turn A and В until the gap shown in figure is
0.0087 in (0.22 mm) + 0.012 in (0.03 mm) eliminated.
= 0.0098 in (0.25 mm)
0.0087 in (0.22 mm) + 0.003 in (0.08 mm) 3. Install the transaxle case side bearing outer race to
= 0.012 in (0.30 mm) a SST(OK900 175 AAO).
Range: 0.0098 in (0.25 mm) - 0.001 in (0.30 mm)
Select the 0.012 in (0.30 mm) one

Thickness of adjustment shim in (mm)

0.0079 (0.20) 0.0098 (0.25) 0.012 (0.30) 0.014 (0.35)
0.016(0.40) 0.018(0.45) 0.020 (0.50) 0.027 (0.70)

Selector
МТ-22 MANUAL TRANSAXLE

4. Set the SST(OK900175 AAO) in the positions

shown in figure.

OK900 175 AAO AV2A41181

AV2A41169 6. To set the bearings, mount the bars on parts and of

5. Tighten the SST(OK900 175 AAO) to the specified
torque.
Tightening torque:
32-40 Ib-ft (43-54 N-m, 4.4-5.5 kg-m)
the selector, and turn the selector so the gap is
widened.
7. Turn in the reverse direction until the gap is
eliminated.
8. Install SST(OK900 175 AAO/OK130 322 020) to the
differential pinion gear, through the transaxle case.

OK900175 AAO
OK900175 AAO

OK130322020

AV2A41170 BSX041133

9. Turn the SST(OK130 322 020) with a spring

Notice
balance. Until the specified preload can be
Turn the bars until SST(OK900 175 А АО) can no
obtained, adjust the SST(OK900 175 AAO) with a
longer be moved.
bar.

Preload:
10-14 Ib-in (1.4-2.0 N-m, 14-20 kg-cm)
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-23

10. Remove the SST(OK130 322 020). 14. Remove the transaxle case and SST(OK900175
AAO).

OK900 175 A A O
OK130322020

BSX041134 OK900 175 AAO AV2A41172

11. Measure the clearance around the entire

circumference of the SST(OK900175 AAO). 15. Remove the bearing outer race from the
SST(OK900 175 AAO).
16. Install the selected shim and the bearing outer race
to the transaxle case.

Bearing
outer race

AV2A41171

12. Select the proper adjust shim(s) to be used for the

BSX041136
differential by referring to the table and selecting the
shim which is nearest (on the thick side) to the
largest measured clearance in the selector.

Thickness of adjust shim in (mm)

0.004(0.10) 0.0079 (0.20) 0.0098 (0.25) 0.012 (0.30)
0.014 (0.35) 0.016(0.40) 0.018(0.45) 0.020 (0.50)
0.022 (0.55) 0.024 (0.60) 0.026 (0.65) 0.028 (0.70)
0.030 (0.75) 0.032 (0.80) 0.034 (0.85) 0.036 (0.90)

13. Remove the SST(OK900 175 AAO).

МТ-24 MANUAL TRANSAXLE

Bearing preload (Differential) 3. Install a SST(OK900 175 AAO) to the differential

Measure the preload as follows. side gear, through the transaxle case.
1. Set the differential assembly into the clutch
housing.
OK900 175 A A O

AV2A41174

BSX041129
4. Measure the bearing preload.

2. Install the transaxle case onto the clutch housing. Preload:

13-17 Ib-in (1.4-1.9 N*m, 14-20 kg-cm)
Tightening torque:
32~40 Ib-ft (43~54 N-m, 4.4-5.5 kg-m) 5. If not as specified, readjust the bearing preload.
6. Remove the SST(OK130 322 020).

AV2A41167
BSX041138

7. Remove the transaxle case and the differential

assembly.
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES
Assembly
1. Using SST(OK201 170 AA1) and hammer, tap new
oil seal in evenly until SST(OK201170 AA1)
contacts transaxle case.
2. Coat lip of oil seal with transaxle case.
AV2A41175
3. Install adjustment shim(s) to differential case.
4. Apply transaxle oil to bearing, and install it to
differential case by using suitable tool.
AS2A41137
5. Install adjustment shim(s) to primary and secondary
shaft bearing seats in transaxle case.
MT-25
6. Apply transaxle oil to each bearing race, and install
them to transaxle case by using suitable tool.
AS2A41139
7. Install new oil seal by using suitable tool.
8. Coat lip of oil seal with transaxle oil.
9. Install the speedometer driven gear.
10. Apply transaxle oil to primary shaft oil seal, and
install it to transaxle case by using suitable tool.
AV2A41176
11. Set differential into clutch housing.
Differential gear
Clutch housing
AV2A41177
МТ-26 MANUAL TRANSAXLE

12. Install transaxle case, and tighten to specified 19. Connect torque wrench to SST(OK130171 A05)
torque. and measure preload (Neutral condition).

Tightening torque: Preload:

32~40 Ib-ft (43-54 N*m, 4.4~5.5 kg-m) 0.9-2.1 Ib-in (0.1-0.2 N-m, 1.0-2.5 kg-cm)

13. Install SST(OK130171 A05) to differential.

14. Connect torque wrench to SST(OK130 171 A05)
and measure preload.

Preload:
13-17 Ib-in (1.4-1.9 N-m, 14-20 Kg-cm)

AS2A41145

20. If not as specified, readjust the bearing preload.

21. Remove SST(OK130171 A05), transaxle case,
OK130171 A05 primary shaft gear assembly and secondary shaft
gear assembly.
22. Install the secondary shaft in the clutch housing
AV2A41178 after removing rings, bearings and clutch hub
assemblies, then install the secondary bearing
15. If not as specified, readjust the bearing preload. cover.
16. Remove SST(OK130171 A05) and transaxle case.
17. Install secondary shaft gear assembly and transaxle
case and tighten to specified torque.
Primary shaft Secondary shaft
Tightening torque: gear assembly gear assembly
32~40 Ib-ft (43-54 N*m, 4.4~5.5 kg-m)

18. With transaxle facing in direction shown in figure.

Install SST(OK130171 A05) to primary shaft gear
assembly.

AV2A41179

23. Install the primary shaft in the clutch housing and

install gears and clutch hub assemblies into the
primary and secondary shaft in order.
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-27

24. Install the 1/2 shift rod, 1/2 shift fork and 1/2 shift 27. Install the roll pins to the rod/fork assembly with a
rod end. pin punch in reverse order shown on the figure.

1/2 shift fork

1/2 shift rod end AV2A41164 AV2A41001

25. Install the 3/4 shift rod, 3/4 shift fork and 3/4 shift 28. Install the control case assembly and the change
rod end. rod and then tighten the two control case assembly
bolts.
29. Install the reverse shift lever and tighten the two
reverse shift lever bolts.
30. Install the reverse lever spring set.
31. Install the reverse idle shaft and gear.
3/4 shift rod

3/4 shift fork

Reverse idle
shaft & gear

Reverse
shift lever

3/4 shift rod end

AV2A41163

26. Install the 5/R shift rod, 5/R shift fork and 5/R shift
rod end.
Reverse lever
spring set AV2A41160

5/R shift fork

5/R shift rod

5/R shift rod end

AV2A41001
МТ-28 MANUAL TRANSAXLE

32. Attach magnet to clutch housing. 38. Tighten the locknut and retainer ring onto
33. Apply thin coat of sealant to contact surfaces of secondary shaft.
clutch housing and transaxle case, and tighten
transaxle installation bolts to specified torque. Tightening torque:
108-159 Ib-ft (147-216 N-m, 15-22 kg-m)
Total weight of sealer coated: 1.5~2.3 g
(TB:1216Tor1216TB)

Tightening torque: OK201 323 021

32~40 Ib-ft (43-54 N*m, 4.4~5.5 kg-m)

BSX041034

39. Apply thin coat of sealant to contact surface of

transaxle case and rear cover and tighten rear
AV2A41180 cover installation screws to specified torque.

34. Install the back lamp switch. Tightening torque:

35. Install the detent plugs, springs and steel balls in 12-17 Ib-ft (16-23 N-m, 1.6-2.3 kg-m)
the side of case.

Detent plugs

Back lamp switch AV2A41159

36. Shift to 1 st gear to lock the rotation of the primary

shaft.
37. Lock the primary shaft by using SST(OK201 323 021).
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-29

Primary shaft assembly

1. Measure thrust clearance of all gears before disassembly (Refer to preinspection).
2. Disassemble in order shown on the figure (Refer to disassembly note).
3. Assembly will be performed in the reverse order (Refer to assembly note).

r
J. Caution
Check thrust clearance of all gears before disassembly and after assembly.

Notice
a) Can not check thrust clearance of all gears under the primary shaft assembly which is removed from the clutch
housing.
b) Check thrust clearance of all gears under the primary shaft assembly installed on the clutch housing.

AV2A41007

(1) Retainer ring (13) Gear sleeve

(2) Shim (14) Needle bearing
(3) Bearing (15) 4th gear
(4) Reverse cone sleeve (16) Synchronizer ring
(5) Reverse cone (17) Retainer ring
(6) Synchronizer ring (18) Clutch hub sleeve
(7) Clutch hub sleeve (19) Synchronizer ring
(8) Synchronizer key (20) 3rd gear
(9) Clutch hub (21) Needle bearing
(10) Synchronizer ring (22) Primary shaft
(11) 5th gear (23) Bearing
(12) Needle bearing
мт-зо MANUAL TRANSAXLE

Preinspection Disassembly note

3rd gear thrust clearance Bearing (5th clutch hub end)
1. Measure clearance between 3rd gear and 2nd gear. Remove bearing by using SST(OK130171 013).

Clearance: 0.002~0.008 in (0.05~0.20 mm) OK130 171 013

Maximum: 0.010 in (0.25 mm)

2. If clearance exceeds maximum, check contact

surface of 3rd gear, 2nd gear and clutch hub
(3rd/4th). Replace worn and damaged parts.

OK130171013

3rd/4th clutch hub assembly, 3rd synchronizer

ring, 3rd gear, 5th clutch hub assembly, 5th
synchronizer ring, and 5th gear
1. Remove retaining ring.
2. Remove 5th clutch hub assembly, 5th synchronizer
ring, and 5th gear by using SST(OK130 175 008).
3. Remove 3rd/4th clutch hub assembly, 3rd synchronizer
ring, and 3rd gear by using SST(OK130175 008).
AS2A41051

4th/5th gear thrust clearance

1. Measure clearance between 4th gear and 5th gear.

4th: Clearance: 0.005~0.012 in (0.135-0.30 mm)

Maximum: 0.013 in (0.335 mm) OK130175008
5th: Clearance: 0.002~0.007 in (0.07~0.20 mm)
Maximum: 0.01 in (0.25 mm)

2. If clearance exceeds maximum, check contact

surfaces of 4th gear, 5th gear, clutch hub (3rd/4th),
and clutch hub(5th). Replace worn and damaged
parts. AS2A41054

Bearing (reverse gear end)

Remove bearing by using SST(OK670 990 AAO).

OK670 990 AAO

AV2A41004

AS2A41055
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-31

Assembly note
Bearing (reverse gear end)
Install new bearing by using SST(OK130 175 A13
/OK011 270A02).

v
Л "=HA

OK130 175 A13

OK011 270 A02 AS2A41090

3. Measure clearance between primary 4th gear and

AS2A41087
5th gear.

Clearance: 0.005~0.012 in (0.135~0.30 mm)

Maximum: 0.013 in (0.335 mm)
5th synchronizer ring, primary 5th gear and
bearing (5th clutch hub end)
1. Install 5th synchronizer ring, 5th gear, and new
bearing by using SST(OK011 270 A02/OK130 175
008).

OK011 270 A02

AV2A41004

4. If not as specified, disassemble and reassemble

primary shaft assembly.
AS2A41089

2. Measure clearance between primary 3rd gear and

2nd gear.

Clearance: 0.002~0.008 In (0.05~0.20 mm)

Maximum: 0.010 in (0.25 mm)
МТ-32 MANUAL TRANSAXLE

Secondary shaft assembly

1. Measure thrust clearance of 1 st gear and 2nd gear before disassembly (Refer to Preinspection).
2. Disassemble in order shown on the figure (Refer to Disassembly note).
3. Assembly will be performed in the reverse order (Refer to assembly note).

T
J>. Caution
Check thrust clearance of all gears before disassembly and after assembly.

Sfc Notice
a) Can not check thrust clearance of all gears under the secondary shaft assembly which is removed from the
clutch housing.
b) Check thrust clearance of all gears under the secondary shaft assembly installed on the clutch housing.

AV2041009

(1) Spacer (9) Synchronizer inner ring (17) Double cone

(2) Retainer ring (10) Double cone (18) Synchronizer inner ring
(3) Secondary 5th gear (11) Synchronizer ring (19) Secondary 1st gear
(4) Secondary 4th gear (12) Synchronizer key spring (20) Needle bearing
(5) Secondary 3rd gear (13) Reverse gear (21) Cap bearing
(6) Secondary 2nd gear (14) Clutch hub sleeve (22) Cone bearing
(7) Needle bearing (15) Synchronizer key spring (23) Secondary shaft
(8) Sleeve (16) Synchronizer ring
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-33

Preinspection Disassembly note

Secondary 1st gear thrust clearance Bearing and secondary 5th gear
1. Measure clearance between secondary 1 st gear Remove bearing and secondary 5th gear by using
and bearing. SST(OK201 172 008).

Clearance: 0.003~0.012 in (0.07~0.30 mm)

Maximum: 0.014 in (0.36 mm)

2. If clearance exceeds maximum, check contact

surfaces of secondary 1 st gear, bearing of
secondary shaft, and 1st/2nd clutch hub assembly.
Replace worn and damaged parts.
OK201 172008

AS2A41059

1st/2nd clutch hub assembly, 1st synchronizer

ring, and secondary 1st gear
1. Remove retaining ring.
2. Remove 1 sV2nd clutch hub assembly, 1 st synchronizer
ring, and secondary 1st gear using press.

AV2A41005

Secondary 2nd gear thrust clearance

1. Measure clearance between secondary 2nd gear
and secondary 3rd gear.

Clearance: 0.003-0.01 In (0.07~0.25 mm)

Maximum: 0.011 in (0.29 mm)

2. If clearance exceeds maximum, check contact AS2A41061

surfaces secondary of 2nd gear, secondary 3rd
gear, and 1st/2nd clutch hub assembly. Replace
worn and damaged parts. Bearing (differential drive gear end)
1. Remove bearing by using SST(OK130171 013).

OK130171 013

AV2A41006 OK130 171 013

МТ-34 MANUAL TRANSAXLE

Assembly note 3. Press on 1st/2nd clutch hub assembly on by using

1. Replace all O-rings and gaskets. SST(OK990175A11).
2. Verify that all parts are completely clean before
assembly.
3. Assemble parts within 10 minutes after applying
sealant. Allow all sealant to cure for at least 30
minutes after assembly before filling transaxle with
oil.
4. Replace bearing races and bearings as sets.

Bearing (differential drive gear end)

1. Install new bearing by using SST(OK130175 A11).

Secondary 5th gear and bearing

1. Install secondary 5th gear and bearing by using
SST(OK130 175 A13 / OK011 270 A02 / OK130175 A11).

AV2A41008

Secondary 1st gear, 1st synchronizer ring and

1st/2nd clutch hub assembly
1. Assemble secondary 1 st gear, 1 st synchronizer
ring, and 1st/2nd clutch hub assembly, as shown in
figure.
2. Align synchronizer ring grooves and synchronizer AV2A41010
keys.
2. Measure clearance between 1 st gear and
differential drive gear.

Clearance: 0.003~0.012 in (0.07~0.30 mm)

Oil groove
(three places) Maximum: 0.014 in (0.36 mm)

AS2A41080

AV2A41005
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-35

3. Measure clearance between secondary 2nd gear

and secondary 3rd gear.

Clearance: 0.003~0.01 in (0.07~0.25 mm)

Maximum: 0.011 in (0.29 mm)

AV2A41006

4. If not as specified, disassemble and reassemble

secondary shaft assembly.
МТ-36 MANUAL TRANSAXLE

Differential
Disassembly/Inspection/Assembly
1. Before disassembly, inspection backlash of side gears and pinion gears (Refer to preinspection).
2. Disassemble in order shown on the figure (Refer to disassembly note).
3. Inspect all parts and repair or replace as necessary.
4. Assemble in reverse order of disassembly (Refer to assembly note).
5. Measure backlash after assembly.

Replace

Replace

Apply specified oil to the parts

AS2A41147

(1) Roll pin (6) Thrust washer

(2) Pinion shaft (7) Bearing (side opposite ring gear)
(3) Pinion gear (8) Speedometer drive gear
(4) Thrust washer (9) Bearing (ring gear side)
(5) Side gear (10) Ring gear and differential case assembly
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-37

Preinspection Side bearing inner race

Backlash of side gear and pinion gear
Measure backlash by following procedure;
1. Install left driveshaft and right joint shaft in
differential assembly.
2. Support shafts on V-blocks as shown in figure.
3. Measure backlash of both pinion gears.
Caution
Be careful not to drop differential case.
1 . With using SST, remove side bearing inner race
(opposite side of ring gear).

Backlash: 0-0.004 in (0-0.1 mm) Bearing (ring gear side)

Remove bearing by using SST(OK670 990 AAO).
4. If not as specified, replace worn and damage parts.

AS2A41151
AS2A41148

Disassembly note
Bearing (side opposite ring gear)

$ Notice
Do not remove the bearing unless you are replacing
it.

Remove bearing by using SST(OK130 171 013).

OK130 171 013

AS2A42119
МТ-38 MANUAL TRANSAXLE

Assembly note Backlash of side gear and pinion gear

Bearing (ring gear side)
1. Install new bearing by using SST(OK011 270 A02).
Measure backlash by following procedure:
1. Install left driveshaft and right joint shaft in
differential assembly.
2. Support shafts on v-blocks as shown in figure.
3. Measure backlash of both pinion gears.

OK011 270 A02 Backlash: 0~0.004 in (0~0.1 mm)

4. If not as specified, replace worn and damage parts.

AS2A41154

Bearing (side opposite ring gear)

1. Install vehicle speed sensor.
2. Install new bearing by using SST(OK011 270 A02).

AS2A41157

AS2A41155
DISASSEMBLY, INSPECTION AND RE-ASSEMBLY PROCEDURES MT-39

Shift mechanism
Overhaul
1. Disassemble in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly.

1-17(15-22,1.6-2.3)
~--v.
14-20(18-27, 1.8-2.7)

Ib-ft (N-m, kg-m)

AV2041011

(1) Knob change (6) Clip

(2) Boot (7) Snap pin
(3) Change lever assembly (8) Washer
(4) Nut (9) Shift cable
(5) Bolt (10) Select cable