Manual
CONTENTS
Transaxle
Workshop
Manual
A65M–R
FOREWORD
This manual explains the structure,
operation, and service points for
the above-indicated manual transaxle.
In order to do these procedures safely,
quickly, and correctly, you must first read
this manual and any other relevant service
materials carefully.
The information in this manual is current
up to April, 2002. Any changes that
occur after that time will not be reflected in
this particular manual. Therefore,
the contents of this manual may not exactly
match the mechanism that you are
currently servicing.
Title Section
General Information GI
Overhaul J
Technical Data TD
Special Tools ST
© 2002 Mazda Motor Corporation
PRINTED IN THE NETHERLANDS, APRIL 2002
1739–1E–02D
Mazda Motor Corporation
HIROSHIMA, JAPAN
WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing procedures
for the vehicle in this workshop manual were developed with
Mazda-trained technicians in mind. This manual may be useful to
non-Mazda trained technicians, but a technician with our
service-related training and experience will be at less risk when
performing service operations. However, all users of this manual are
expected to at least know general safety procedures.
This manual contains "Warnings" and "Cautions" applicable to risks
not normally encountered in a general technician's experience.
They should be followed to reduce the risk of injury and the risk that
improper service or repair may damage the vehicle or render it unsafe.
It is also important to understand that the "Warnings" and "Cautions"
are not exhaustive. It is impossible to warn of all the hazardous
consequences that might result from failure to follow the procedures.
The procedures recommended and described in this manual are
effective methods of performing service and repair. Some require tools
specifically designed for a specific purpose. Persons using procedures
and tools which are not recommended by Mazda Motor Corporation
must satisfy themselves thoroughly that neither personal safety nor
safety of the vehicle will be jeopardized.
The contents of this manual, including drawings and specifications, are
the latest available at the time of printing, and
reserves the right to change the vehicle designs and alter the contents
of this manual without notice and without incurring obligation.
Parts should be replaced with genuine Mazda replacement parts or
with parts which match the quality of genuine Mazda replacement
parts. Persons using replacement parts of lesser quality than that of
genuine Mazda replacement parts must satisfy themselves thoroughly
that neither personal safety nor safety of the vehicle will be
jeopardized.
Mazda Motor Corporation is not responsible for any problems which
may arise from the use of this manual. The cause of such problems
includes but is not limited to insufficient service-related training, use of
improper tools, use of replacement parts of lesser quality than that of
genuine Mazda replacement parts, or not being aware of any revision
of this manual.
Mazda Motor Corporation
GI
GENERAL INFORMATION
GI
HOW TO USE THIS MANUAL
RANGE OF TOPICS.......................................... GI-2
SERVICING PROCEDURE ............................... GI-2
SYMBOLS.......................................................... GI-3
ADVISORY MESSAGES ................................... GI-4
UNITS
FUNDAMENTAL PROCEDURES
ELECTRICAL SYSTEM
NEW STANDARDS
ABBREVIATIONS
................................................................... GI-5
UNITS TABLE.................................................... GI-5
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT................................................... GI-6
SPECIAL SERVICE TOOLS.............................. GI-6
DISASSEMBLY.................................................. GI-6
INSPECTION DURING REMOVAL,
DISASSEMBLY............................................... GI-6
ARRANGEMENT OF PARTS ............................ GI-7
CLEANING OF PARTS...................................... GI-7
REASSEMBLY................................................... GI-7
ADJUSTMENT................................................... GI-8
RUBBER PARTS AND TUBING........................ GI-8
HOSE CLAMPS ................................................. GI-8
TORQUE FORMULAS....................................... GI-8
VISE................................................................... GI-9
........................................ GI-9
CONNECTORS.................................................. GI-9
............................................ GI-12
NEW STANDARDS TABLE ............................. GI-12
.............................................. GI-14
ABBREVIATIONS TABLE................................ GI-14
............................. GI-2
........................ GI-6
GI–1
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
RANGE OF TOPICS
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts and visual inspe ct ion) have been omitted.
AME201000001M01
End Of Sie
SERVICING PROCEDURE
Inspection, Adjustment
• Inspection and adjustment procedures are divided into steps. Important points regarding the location and
contents of the procedures are explained in detail and shown in the illustrations.
AME201000001M02
XME2010001
Repair Procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torque s, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
GI–2
HOW TO USE THIS MANUAL
3. Procedure steps are numbered and the par t that is the main point of the procedure is shown in the illustration
with the corresponding number. Occasiona lly, there ar e important p oints or addit ional informat ion concerning a
procedure. Refer to this information when servicing the related part.
GI
End Of Sie
SYMBOLS
• There are eight symbols indicating oil, grease, fluids, sealan t, and the use of
show application points or use of these materia l s du rin g service.
Symbol Meaning Kind
Apply oil New appropriate engine oil or gear oil
Apply brake fluid New appropriate brake fluid
Apply automatic transaxle/transmission fluid
New appropriate automatic transaxle/transmission
fluid
or equivalent. These symbols
SST
AME201000001M03
XME2010010
GI–3
HOW TO USE THIS MANUAL
Symbol Meaning Kind
Apply grease Appropriate grease
Apply sealant Appropriate sealant
Apply petroleum jelly Appropriate petroleum jelly
Replace part O-ring, gasket, etc.
Use SST or equivalent Appropriate tools
End Of Sie
ADVISORY MESSAGES
• You will find several
manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
Specifications
• The values indicate the allowable range when performing inspections or adjustments.
Upper and Lower Limits
• The values indicate the upper and lower limits that must not be exceeded when perfor ming inspections or
adjustments.
Warnings, Cautions, Notes, Specifications
and
Upper and Lower Limits
AME201000001M04
in this
End Of Sie
GI–4
UNITS
UNITS
UNITS TABLE
Electrical current A (ampere)
Electric power W (watt)
Electric resistance ohm
Electric voltage V (volt)
Length
Negative pressure
Number of
revolutions
Positive pressure
Torque
Volume
Weight
mm (millimeter)
in (inch)
kPa (kilo pascal)
mmHg (millimeters of mercury)
inHg (inches of mercury)
rpm (revolutions per minute)
kPa (kilo pascal)
2
kgf/cm
centimeter)
psi (pounds per square inch)
N·m (Newton meter)
kgf·m (kilogram force meter)
kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
imp qt (Imperial quart)
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
N (Newton)
g (gram)
oz (ounce)
(kilogram force per square
GI
AME201200002M01
Conversion to SI Units (Système International d'Unités)
• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.
Rounding Off
• Converted values are rounded off to the same number of p laces as the SI unit value. For example, if the SI u nit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
Upper and Lower Limits
• When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. Fo r ex am p l e, co ns ide r 2. 7 kgf /cm
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}
270—310 kPa {2.7—3.2 kgf/cm
• The actual converted values for 2.7 kgf/cm
2
, 39—45 psi}
2
are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as
2
in the following specifications:
an upper limit, so the converted values are roun ded down to 260 and 38. In the second specification, 2. 7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
GI–5
FUNDAMENTAL PROCEDURES
FUNDAMENTAL PROCEDURES
PREPARATION OF TOOLS AND MEASURING EQUIPMENT
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
End Of Sie
SPECIAL SERVICE TOOLS
• Use special service tools or equivalent when they
are required.
AME201400004M01
WGIWXX0023E
AME201400004M02
End Of Sie
DISASSEMBLY
• If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.
End Of Sie
INSPECTION DURING REMOVAL, DISASSEMBLY
• When removed, each part should be carefully
inspected for malfunction, deformatio n, dam a ge ,
and other problems.
WGIWXX0024E
AME201400004M03
WGIWXX0027E
AME201400004M04
End Of Sie
GI–6
WGIWXX0028E
FUNDAMENTAL PROCEDURES
ARRANGEMENT OF PARTS
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the par ts
to be replaced from those that will be reused.
End Of Sie
CLEANING OF PARTS
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
••••
Using compressed air can cause dirt and
other particles to fly out cau sing injury t o
the eyes. Wear protective eye wear
whenever using compressed air.
AME201400004M05
GI
WGIWXX0029E
AME201400004M06
End Of Sie
REASSEMBLY
•
Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
•
If removed, these parts should be replaced with
new ones:
— Oil seals
— Gaskets
— O-rings
— Lockwashers
— Cotter pins
— Nylon nuts
•
Depending on location:
— Sealant and gaskets, or both, sho u ld be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
— Oil should be applied to the moving
components of parts.
— Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
WGIWXX0030E
AME201400004M07
WGIWXX0031E
End Of Sie
WGIWXX0032E
GI–7
FUNDAMENTAL PROCEDURES
ADJUSTMENT
•
Use suitable gauges and/or testers when making
adjustments.
End Of Sie
RUBBER PARTS AND TUBING
•
Prevent gasoline or oil from getting on rubber
parts or tubing.
AME201400004M08
WGIWXX0033E
AME201400004M09
End Of Sie
HOSE CLAMPS
•
When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
End Of Sie
TORQUE FORMULAS
•
When using a torque wrench-SST or equivalent
combination, the written torque must be
recalculated due to the extra length that the SST
or equivalent adds to the torque wrench.
Recalculate the torque using the following
formulas. Choose the formula that applies to you.
Torque Unit Formula
N·mN·m × [L/(L+A)]
kgf·mkgf·m × [L/(L+A)]
kgf·cm kgf·cm × [L/(L+A)]
ft·lbf ft·lbf × [L/(L+A)]
in·lbf in·lbf × [L/(L+A)]
WGIWXX0034E
AME201400004M10
WGIWXX0035E
AME201400004M11
WGIWXX0036E
A : The length of the SST past the torque wrench drive
L : The length of the torque wrench
End Of Sie
GI–8
FUNDAMENTAL PROCEDURES, ELECTRICAL SYSTEM
VISE
•
When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
ELECTRICAL SYSTEM
CONNECTORS
Data Link Connector
•
Insert the probe into the service hole when
connecting a jumper wire to the data link
connector.
Caution
•
• Inserting a jumper wire probe into the
••
data link connector terminal may damage
the terminal.
AME201400004M12
GI
WGIWXX0037E
AME201700006M01
Disconnecting Connectors
•
When disconnecting connector, grasp the
connectors, not the wires.
•
Connectors can be disconnected by pressing or
pulling the lock lever as shown.
X3U000WAY
WGIWXX0041E
WGIWXX0042E
GI–9
ELECTRICAL SYSTEM
Locking Connector
•
When locking connectors, listen for a click
indicating they are securely locked.
Inspection
•
When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from
the wiring harness side.
X3U000WB1
•
Inspect the terminals of waterproof conne c to r s
from the connector side since they cannot be
accessed from the wiring harness side.
Caution
•
• To prevent damage to the terminal, wrap
••
a thin wire around the tester probe before
inserting into terminal.
Terminals
Inspection
•
Pull lightly on individual wires to verify that they
are secured in the terminal.
WGIWXX0044E
WGIWXX0045E
GI–10
WGIWXX0064E
ELECTRICAL SYSTEM
Replacement
•
Use the appropriate tools to remove a terminal as
shown. When installing a terminal, be sure to
insert it until it locks securely.
•
Insert a thin piece of metal from the terminal side
of the connector and with the terminal locking t ab
pressed down, pull the terminal out from the
connector.
Sensors, Switches, and Relays
•
Handle sensors, switches, and relays carefully.
Do not drop them or strike them against other
objects.
GI
WGIWXX0046E
Wiring Harness
Wiring color codes
•
Two-color wires are indicated by a two-color code symbol.
•
The first letter indicates the base color of the wire
and the second the color of the stripe.
CODE COLOR CODE COLOR
B Black O Orange
BR Brown P Pink
GGreenR Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow
LG Light Green
End Of Sie
WGIWXX0047E
X3U000WB7
GI–11
NEW STANDARDS
NEW STANDARDS
NEW STANDARDS TABLE
•
Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Abbrevi-
ation
AP Accelerator Pedal — Accelerator Pedal
ACL Air Cleaner — Air Cleaner
A/C Air Conditioning — Air Conditioning
BARO Barometric Pressure — Atmospheric Pressure
B+ Battery Positive Voltage
— Brake Switch — Stoplight Switch
— Calibration Resistor — Corrected Resistance #6
CMP sensor Camshaft Position Sensor — Crank Angle Sensor
CAC Charge Air Cooler — Intercooler
CLS Closed Loop System — Feedback System
CTP Closed Throttle Position — Fully Closed
CPP Clutch Pedal Position — Idle Switch
CIS Continuous Fuel Injection System — Clutch Position
CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6
CKP sensor Crankshaft Position Sensor — Crank Angl e Sensor 2
DLC Data Link Connector — Diagnosis Connector
DTM Diagnostic Test Mode — Test Mode #1
DTC Diagnostic Trouble Code(s) — Service Code(s)
DI Distributor Ignition — Spark Ignition
DLI Distributorle ss Ignition — Direct Ignition
EI Electronic Ignition — Electronic Spark Ignition #2
ECT Engine Coolant Temperature — Water Thermo
EM Engine Modification — Engine Modification
— Engine Speed Input Signal — Engine RPM Signal
EVAP Evaporative Emission — Evaporative Emission
EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation
FC Fan Control — Fan Control
FF Flexible Fuel — Flexible Fuel
4GR Fourth Gear — Overdrive
— Fuel Pump Relay — Circuit Opening Relay #3
FSO
solenoid
GEN Generator — Alternator
GND Ground — Ground/Earth
HO2S Heated Oxygen Sensor — Oxygen Sensor With heater
IAC Idle Air Control — Idle Speed Control
— IDM Relay — Spill Valve Relay #6
— Incorrect Gear Ratio ——
— Injection Pump FIP Fuel Injection Pump #6
— Input/Turbine Speed Sensor — Pulse Generator
IAT Intake Air Temperature — Intake Air Thermo
KS Knock Sensor — Knock Sensor
MIL Malfunction Indicator Lamp — Malfunction Indicator Light
MAP Manifold Absolute Pressure — Intake Air Pressure
MAF sensor Mass Air Flow Sensor — Airflow Sensor
MFL Multiport Fuel Injection — Multiport Fuel Injection
OBD On-Board Diagnostic — Diagnosis/Self Diagnosis
OL Open Loop — Open Loop
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
Name
Abbrevi-
ation
V
B
Name
Battery Voltage
AME202800020M01
Remark
GI–12
NEW STANDARDS
New Standard Previous Standard
Abbrevi-
ation
— Output Speed Sensor — Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter — Catalytic Converter
O2S Oxygen Sensor — Oxygen Sensor
PNP Park/Neutral Position — Park/Neutral Range
— PCM Control Relay — Main Relay #6
PSP Power Steering Pressure — Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
— Pressure Control Solenoid — Line Pressure Sole noid Valve
PAIR Pulsed Secondary Air Injection — Secondary Air Injection System
— Pump Speed Sensor — NE Sensor #6
AIR Secondary Air Injection — Secondary Air Injection System
SAPV Secondary Air Pulse Valve — Reed Valve
SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— Shift Solenoid A
— Shift Solenoid B
— Shift Solenoid C — 3-4 Shift Solenoid Valve
3GR Third Gear — 3rd Gear
TWC Three Way Catalytic Converter — Catalytic Converter
TB Throttle Body — Throttle Body
TP sensor Throttle Position Sensor — Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch — Lockup Position
TCM
—
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger
VSS Vehicle Speed Sensor — Vehicle Speed Sensor
VR Voltage Regulator — IC Regulator
VAF sensor Volume Air Flow Sensor — Air flow Sensor
WUTWC
WOT Wide Open Throttle — Fully Open
Transmission (Transaxle) Control
Module
Transmission (Transaxle) Fluid
Temperature Sensor
Warm Up Three Way Catalytic
Converter
Name
Abbrevi-
ation
— 1-2 Shift Solenoid Valve
— Shift A Solenoid Valve
— 2-3 Shift Solenoid Valve
— Shift B Solenoid Valve
— ECAT Control Unit
— ATF Thermosensor
— Catalytic Converter #5
Name
Remark
GI
Pulsed
injection
Injection
with air
pump
#1 : Diagnostic trouble codes depend on the diagnostic test mode
#2 : Controlled by the PCM
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhau st ma n ifold
#6 : Part name of diesel engine
End Of Sie
GI–13
ABBREVIATIONS
ABBREVIATIONS
ABBREVIATIONS TABLE
SST Special service tool
End Of Sie
AME203000011M01
GI–14
J
OVERHAUL
MANUAL TRANSAXLE.......................................... J-2
PRECAUTION...................................................... J-2
CLUTCH HOUSING AND TRANSAXLE CASE
COMPONENTS DISASSEMBLY...................... J-3
PRIMARY SHAFT COMPONENTS
PREINSPECTION............................................. J-8
PRIMARY SHAFT COMPONENTS
DISASSEMBLY................................................. J-9
PRIMARY SHAFT COMPONENTS
INSPECTION.................................................. J-11
PRIMARY SHAFT COMPONENTS
ASSEMBLY..................................................... J-13
SECONDARY SHAFT COMPONENTS
PREINSPECTION........................................... J-18
SECONDARY SHAFT COMPONENTS
DISASSEMBLY............................................... J-19
SECONDARY SHAFT COMPONENTS
INSPECTION.................................................. J-20
SECONDARY SHAFT COMPONENTS
ASSEMBLY..................................................... J-24
REVERSE IDLER SHAFT COMPONENTS
DISASSEMBLY/ASSEMBLY .......................... J-30
REVERSE IDLER SHAFT COMPONENTS
INSPECTION.................................................. J-31
DIFFERENTIAL PREINSPECTION ................... J-32
DIFFERENTIAL DISASSEMBLY....................... J-32
DIFFERENTIAL ASSEMBLY............................. J-33
PRIMARY SHAFT END PLAY ADJUSTMENT.. J-35
SECONDARY SHAFT END PLAY
ADJUSTMENT................................................ J-36
REVERSE IDLER GEAR END PLAY
ADJUSTMENT................................................ J-37
DIFFERENTIAL SIDE BEARING PRELOAD
ADJUSTMENT................................................ J-38
CLUTCH HOUSING AND TRANSAXLE CASE
COMPONENTS ASSEMBLY.......................... J-40
J
J–1
MANUAL TRANSAXLE
MANUAL TRANSAXLE
PRECAUTION
1. Clean the transaxle exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.
Warning
•
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
••
Wear protective eye wear whenever using compressed air.
Caution
•
• Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the
••
bearing.
2. Clean the removed parts using cleaning solvent, and dry the m using compressed air.
3. Clean out all holes and passages using compressed air, and check that there are no obstructions.
4. Use a plastic hammer when disassembling the transaxle case and other light alloy metal parts.
5. Make sure each part is cleaned before assembling.
6. Coat all movable parts with the specified oil.
7. Replace parts whenever required.
8. Remove old sealant from contact surfaces before applying new sealant.
9. Assemble the parts within 10 minutes after app lying sealant. Allow all sealant to cure at least 30 minutes after
assembly before filling the transaxle with transaxle oil.
Warning
•
• Although the stand has a self-locking brake system, there is a possibility that the bra ke may not
••
hold when the transaxle is he ld in a lopsi ded position on the stand. Th is would cause the transaxle
to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold
the rotating handle firmly when turning the transaxle.
AME511201029M09
End Of Sie
J–2
MANUAL TRANSAXLE
CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS DISASSEMBLY
Disassembly Components
AME511217010M01
J
.
1Drain plug
2 Filler cap
3 Neutral switch
4 Reverse switch
5 Air-bleed plug
6 Bore plug
7 Welt plug
8 Baffle plate
9 Oil pass
10 Transaxle case
AME5112M004
11 Pivot pin
12 Magnet
13 Differential oil seal
14 Knock pin
15 Dowel pin
16 Secondary shaft bearing retainer
17 Secondary shaft front bearing
18 Oil channel
19 Primary shaft oil seal
20 Clutch housing
J–3
MANUAL TRANSAXLE
.
1 Stopper bolt
2 Shift check bolt
3 Shift control component
4O ring
5 Rod bushing
6 Reverse lever component
7 Reverse fork rod
8Cap
9 Reverse shift fork
10 Retaining pin
11 C ring
12 5th/Reverse fork rod
13 5th shift fork
14 5th/reverse bracket
15 Check plug (5th/reverse)
16 Check spring (5th/reverse)
J–4
AME5112M097
17 Shift check sleeve (5th/reverse)
18 Check ball
19 Inter lock pin
20 3rd/4th fork rod
21 3rd/4th shift fork
22 3rd/4th bracket
23 Shift check sleeve (1st/2nd)
24 1st/2nd fork rod
25 1st/2nd bracket
26 1st/2nd shift fork
27 Clutch housing
28 Transaxle case
29 Check plug (1st/2nd, 3rd/4th)
30 Check spring (1st/2nd)
31 Check spring (3rd/4th)
MANUAL TRANSAXLE
Disassembly Procedure
1. Remove the drain plug and the filler cap.
2. Remove the neutral switch and reverse switch.
3. Remove the shift check bolt and stopper bolt.
4. Remove the shift control component.
5. Remove the check plugs, check springs, check
balls, and shift check sleeve as shown in the
figure.
J
AME5112M098
6. Remove the transaxle case installation bolt.
7. Remove the bore plug using screwdriver.
8. Stretch the snap ring of the secondary shaf t rear
bearing at the bore plug hole, and remove the
transaxle case.
9. Remove the baffle plate and the oil pass.
10. Remove the snap ring, secondary shaft adjust
shim, primary shaft rear bearing adjust shim from
the transaxle case.
11. Remove the differential side bearing outer race
(transaxle case side) using the SST, and remove
the adjust shim.
AME5112M142
AME5112M007
AME5112M101
J–5
MANUAL TRANSAXLE
12. Remove the welt plug using a fit stick.
13. Remove the differential oil seal (transaxle case
side) using a screwdriver.
14. Remove the magnet from clutch housing.
15. Shift to 5th gear.
16. Remove the reverse lever component bracket
bolt.
17. Lift the reverse lever component, and remove it.
18. Remove the reverse fork rod.
19. Remove the reverse shift fork.
AME5112M008
20. Shift 3rd/4th fork rod to the 3rd gear, and remove
the retaining pin of 5th shift fork using a pin
punch.
21. Remove the C ring of the 5th/reverse bracket.
22. Remove the 5th/reverse fork rod, and remove the
5th shift fork and 5th/reverse bracket.
23. Remove the check balls and the interlock pin from
the clutch housing.
24. Remove the retaining pin of 3rd/4th fo rk ro d
bracket using a pin punch.
25. Remove the two C rings of the 3rd/4th shift fork.
26. Remove the 3rd/4th fork rod, and remove the 3rd/
4th shift fork and 3rd/4th bracket.
27. Remove the shift check sleeve from the clutch
housing.
AME5112M009
AME5112M010
AME5112M011
J–6
AME5112M012
MANUAL TRANSAXLE
28. Remove the retaining pin of 1st/2nd shift fork
using a pin punch.
29. Remove the 1st/2nd fork rod and 1st/2nd bracket
at a time.
30. Remove the 1st/2nd shift fork.
31. Remove the retaining pin of the 1st/2nd bracket
using a pin punch, and remove the 1st/2nd
bracket from the 1st/2nd fork rod.
32. Remove each gear component.
(1) Tap the primary shaft using a plastic hammer.
Caution
•
• The oil channel in the clutch housing can
••
be damaged when removing the
secondary shaft component. Remove the
secondary shaft component to right
above.
(2) Remove the primary shaft component,
secondary shaft component, and rever se idler
gear component at the same time.
(3) Remove the differential.
33. Remove the secondary shaft bearing retainer.
J
AME5112M013
AME5112M014
Warning
•
• Using a heat gun can will cause the
••
clutch housing to heat up greatly. To
prevent burns wear gloves whenever
using a heat gun.
Caution
•
• The clutch housing will be damaged if
••
heated above 120 °°°°C. Heat the clutch
housing below 120 °°°°C.
Note
• If the secondary shaft front bearing can’t be removed easily, heat the clutch housing to about 100 °C using
a heat gun and remove it.
34. Remove the secondary shaft front bearing using a
screwdriver.
35. Remove the oil channel of the secondary shaft.
36. Remove the differential oil seal (clutch housing
side) using a screwdriver.
Warning
•
• Using a heat gun will cause the clutch
••
housing to heat up greatly. To prevent
burns wear gloves whenever using a heat
gun.
Caution
•
• The clutch housing will be damaged if
••
heated above 120 °°°°C. Heat the clutch housing below 120 °°°°C.
AME5112M015
AME5112M074
Note
• If the differential side bearing oute r race can ’t be r emoved easily, heat t he clutch ho using to ab out 1 00 °C
using a heat gun and remove it.
J–7
MANUAL TRANSAXLE
37. Remove the differential side bearing outer race
using the SST.
38. Remove the primary shaft oil seal using a
screwdriver.
AME5112M102
End Of Sie
PRIMARY SHAFT COMPONENTS PREINSPECTION
3rd Gear Thrust Clearance
1. Measure the clearance between the 3rd gear and 2nd gear.
• If not as specified, assemble the primary shaft component again.
Clearance
0.18—0.31 mm {0.0071—0.0122 in}
5th Gear Thrust Clearance
1. Measure the clearance between 4th thrust washer and the 5th gear.
• If not as specified, assemble the primary shaft component again.
AME5112M016
AME511217201M01
AME5112M093
Clearance
0.06—0.16 mm {0.0024—0.0063 in}
4th Gear End Play
1. Remove the primary shaft rear bearing.
2. Set up the primary shaft component, and fix it.
3. Slide the 4th gear up and down, and measure the length of the movement.
• If not as specified, assemble the primary shaft component again.
Length of the movement
0.20—0.30 mm {0.0078—0.0118 in}
J–8
MANUAL TRANSAXLE
End Of Sie
PRIMARY SHAFT COMPONENTS DISASSEMBLY
1. Disassemble in the order shown in the figure.
.
AME511217201M02
J
1 Primary shaft rear bearing adjust shim
2 Oil channel
3 Primary shaft rear bearing
(See J–10 Primary Shaft Rear Bearing Disassembly
Note)
4 Snap ring
5 Primary shaft bearing spacer
(See J–10 Primary Shaft Bearing Spacer and 5th
Gear Stopper Disassembly Note)
6 5th gear stopper
7 5th clutch hub set
(See J–10 5th Clutch Hub Set, 5th Synchronizer
Ring and 5th Gear Disassembly Note)
8 5th synchronizer ring
9 5th gear
10 5th needle bearing
11 5th bushing
(See J–10 5th Bushing, Thrust Washer, 4th Gear,
4th Needle Bearing, 4th Bushing, 4th Synchronizer
Ring, 3rd/4th Clutch Hub Set, 3rd Synchronizer Ring
and 3rd Gear Disassembly Note)
12 Thrust washer
13 4th gear
AME5112M095
14 4th needle bearing
15 4th bushing
16 4th synchronizer ring
17 3rd/4th clutch hub set
18 3rd synchronizer ring
19 3rd gear
20 3rd needle bearing
21 Primary shaft
22 Primary shaft front bearing
(See J–11 Primary Shaft Front Bearing Disassembly
Note)
23 Synchronizer key spring (5th)
24 5th synchronizer key
25 5th clutch hub and sleeve
26 3rd/4th synchronizer key
27 3rd/4th clutch hub and sleeve
28 Synchronizer key spring (3rd/4th)
J–9
MANUAL TRANSAXLE
Primary Shaft Rear Bearing Disassembly Note
1. Remove the bearing using the SSTs.
Primary Shaft Bearing Spacer and 5th Gear Stopper Disassembly Note
1. Remove the primary shaft bearing spacer and 5th
gear stopper at the same time using the SSTs.
AME5112M103
AME5112M106
5th Clutch Hub Set, 5th Synchronizer Ring and 5th Gear Disassembly Note
1. Remove the 5th clutch hub set, 5th synchronizer
ring and 5th gear at the same time using the
SSTs.
AME5112M108
5th Bushing, Thrust Washer, 4th Gear, 4th Needle Bearing, 4th Bushing, 4th Sync hronizer Ring, 3rd/4th
Clutch Hub Set, 3rd Synchronizer Ring and 3rd Gear Disassembly Note
1. Remove the 5th bushing, thrust wa sher, 4th gear,
4th needle bearing, 4th bushing, 4th synchro nizer
ring, 3rd/4th clutch hub set, 3rd synchronizer ring
and 3rd gear at the same time using the SSTs.
J–10
AME5112M109
MANUAL TRANSAXLE
Primary Shaft Front Bearing Disassembly Note
1. Remove the primary shaft front bearing using the
SST.
End Of Sie
PRIMARY SHAFT COMPONENTS INSPECTION
Primary Shaft and Gear Inspection
1. Inspect the shaft for damage, abnormal wear, dents, flaking, or bending.
• If there is malfunction, replace the shaft.
2. Inspect the gears for damage, abnormal wear,
dents, flaking, or bending.
• If there is malfunction, replace the gear.
3. Inspect the oil passage for clogging.
• If there is malfunction, replace the shaft.
J
AME5112M107
AME511217201M03
Synchronizer Ring and Clutch Hub Component Inspection
1. Inspect the clutch hub sleeve, clutch hub, and
synchronizer key contact surface for damage and
abnormal wear.
• If there is malfunction, replace the part where
necessary.
2. Verify that the clutch hub sleeve and clutch hub
for move smoothly.
• If there is malfunction, replace parts as
necessary.
3. Inspect the synchronizer ring teeth and grooves
for damage, abnormal wear, and cracks.
• If there is malfunction, replace the
synchronizer ring.
4. Inspect the tapered surface for abnormal wear
and cracks.
• If there is malfunction, replace parts as
necessary.
AME5112M044
AME5112M045
AME5112M046
J–11
MANUAL TRANSAXLE
5. Measure the clearance between the synchronizer
ring and the flank surface of the gear.
• If not as specified, replace the synchronizer
ring.
Note
• Set the synchronizer ring squarely in the
gear; then measure around the
circumference.
Standard clearance
3rd: 0.90—1.45 mm {0.035—0.057 in}
4th: 0.90—1.45 mm {0.035—0.057 in}
5th: 0.95—1.40 mm {0.037—0.055 in}
Minimum clearance
0.70 mm {0.028 in}
Bearing Inspection
1. Inspect the ball and the ball contact surface for damage and abnormal wear.
• If there is malfunction, replace the bearing.
2. Verify that the bearing to rotates smoothly.
• If there is malfunction, replace the bearing.
AME5112M070
End Of Sie
AME5112M072
J–12
MANUAL TRANSAXLE
PRIMARY SHAFT COMPONENTS ASSEMBLY
1. Assemble in the order shown in the figure.
.
AME511217201M04
J
1 Primary shaft
2 3rd needle bearing
3 3rd gear
4 3rd synchronizer ring
5 3rd/4th synchronizer key spring
(See J–14 3rd/4th Synchronizer Key Spring, 3rd/4th
Synchronizer Key and 3rd/4th Clutch Hub and
Sleeve Assembly Note)
6 3rd/4th synchronizer key
7 3rd/4th clutch hub and sleeve
8 3rd/4th clutch hub set
(See J–14 3rd/4th Clutch Hub Set Assembly Note)
9 4th synchronizer ring
10 4th bushing
(See J–15 4th Bushing Assembly Note)
11 4th needle bearing
12 4th gear
13 Primary shaft thrust washer
(See J–15 Primary Shaft Thrust Washer Assembly
Note)
14 5th bushing
(See J–16 5th Bushing Assembly Note)
15 5th needle bearing
AME5112M135
16 5th gear
17 5th synchronizer ring
18 5th synchronizer key spring
(See J–16 5th Synchronizer Key Spring, 5th
Synchronizer Key and 5th Clutch Hub and Sleeve
Assembly Note)
19 5th synchronizer key
20 5th clutch hub and sleeve
21 5th clutch hub set
(See J–17 5th Clutch Hub Set Assembly Note)
22 5th gear stopper
23 Primary shaft bearing spacer
(See J–17 Primary Shaft Bearing Spacer Assembly
Note)
24 Snap ring
(See J–17 Snap Ring Assembly Note)
25 Primary shaft rear bearing
(See J–18 Primary Shaft Rear Bearing Assembly
Note)
26 Primary shaft front bearing
(See J–18 Primary Shaft Front Bearing Assembly
Note)
27 Oil channel
28 Primary shaft rear bearing adjust shim
J–13
MANUAL TRANSAXLE
3rd/4th Synchronizer Key Spring, 3rd/4th Synchronizer Key and 3rd/4th Clutch Hub and Sleeve Assembly
Note
1. Install the 3rd/4th synchronizer key spring, 3rd/4th synchr onizer key and 3r d/4th clutch hub to th e 3rd/4th clutch
sleeve.
(1) Install a new 3rd/4th clutch hub in the
direction as shown in the figure.
AME5112M047
(2) Install a new 3rd/4th clutch sleeve in the
direction as shown in the figure.
(3) Install center projection parts of 3rd/4th
synchronizer key springs to different
synchronizer keys on each side.
3rd/4th Clutch Hub Set Assembly Note
Note
• Align the synchronizer ring grooves with the synchronizer key during assembly.
1. Install the 3rd/4th clutch hub set using the SSTs.
AME5112M048
AME5112M049
J–14
AME5112M110
MANUAL TRANSAXLE
4th Bushing Assembly Note
1. Install the 4th bushing using the SSTs.
Primary Shaft Thrust Washer Assembly Note
1. Install the primary shaft thrust washer using the
SSTs.
J
AME5112M114
2. Measure length C1 as shown in the figure.
• If it is not within the specification, adjust it by
selecting a proper thrust washer from below.
• Select only one thrust washer.
Specification C1
154.7—154.8 mm {6.091—6.094 in}
Primary shaft thrust washer size
Thickness (mm {in})
3.84 {0.151} 4.02 {0.158}
3.90 {0.154} 4.08 {0.161}
3.96 {0.156} 4.14 {0.163}
AME5112M115
AME5112M050
J–15
MANUAL TRANSAXLE
5th Bushing Assembly Note
1. Install a new 5th bushing using the SSTs.
AME5112M116
5th Synchronizer Key Spring, 5th Synchronizer Key and 5th Clutch Hub and Sleeve Assembly Note
1. Assembly the 5th synchronizer key springs, 5th synchronizer key and 5th clutch hub to the 5th clutch sleeve.
(1) Install a new 5th clutch hub in the direction as
shown in the figure.
(2) Install a new 5th clutch sleeve in the direction
as shown in the figure.
(3) Install center projection parts of 5th
synchronizer key springs to different
synchronizer keys on each side.
AME5112M051
AME5112M052
AME5112M049
J–16
MANUAL TRANSAXLE
5th Clutch Hub Set Assembly Note
Note
• Align the synchronizer ring grooves with the synchronizer key during assembly.
1. Install the 5th clutch hub set using the SSTs.
Primary Shaft Bearing Spacer Assembly Note
1. Install the primary shaft bearing spacer using the
SSTs.
J
AME5112M117
Snap Ring Assembly Note
1. Install a new snap ring to the primary shaft.
2. Measure the clearance between the snap ring
and the primary shaft bearing spacer.
• If it is not within the specification, adjust it by
selecting a proper snap ring from below.
Clearance
0.0—0.1 mm {0.0000—0.0039 in}
Snap ring size
Thickness (mm {in})
1.71 {0.067} 2.01 {0.079}
1.76 {0.069} 2.06 {0.081}
1.81 {0.071} 2.11 {0.083}
1.86 {0.073} 2.16 {0.085}
1.91 {0.075} 2.21 {0.087}
1.96 {0.077} 2.26 {0.089}
AME5112M118
AME5112M053
J–17
MANUAL TRANSAXLE
Primary Shaft Rear Bearing Assembly Note
1. Place the primary shaft rear bearing with the brown side facing toward the 5th gear.
2. Install the primary shaft rear bearing using the
SSTs.
Primary Shaft Front Bearing Assembly Note
1. Install the primary shaft front bearing using the
SSTs.
2. Inspect the 3rd gear and 5th gear thrust
clearance and 4th gear end play. (See J–8
PRIMARY SHAFT COMPONENTS
PREINSPECTION.)
AME5112M119
End Of Sie
SECONDARY SHAFT COMPONENTS PREINSPECTION
1st Gear End Play
1. Set up the secondary shaft component, and fix it.
2. Slide the 1st gear up and down, and measure the length of the movement.
• If not as specified, assemble the secondary shaft component again.
Length of the movement
0.20—0.30 mm {0.0078—0.0118 in}
2nd Gear End Play
1. Set up the secondary shaft component, and fix it.
2. Slide the 2nd gear up and down, and measure the length of the movement.
• If not as specified, assemble the secondary shaft component again.
AME5112M120
AME511217301M01
AME5112M094
Length of the movement
0.06—0.16 mm {0.0024—0.0063 in}
End Of Sie
J–18
MANUAL TRANSAXLE
SECONDARY SHAFT COMPONENTS DISASSEMBLY
1. Disassemble in the order shown in the figure.
.
AME511217301M02
J
1 Secondary shaft rear bearing adjust shim
2 Snap ring
3 Snap ring
4 C ring holder
5 Secondary shaft C ring
6 Secondary shaft rear bearing
(See J–20 Secondary Shaft Rear Bearing
Disassembly Note)
7 Snap ring
8 5th gear
(See J–20 4th Gear and 5th Gear Disassembly
Note)
9 4th gear
10 4th gear adjustment shim
11 3rd/4th secondary shaft spacer
12 3rd gear
(See J–20 3rd Gear, 2nd Gear, 2nd Needle Bearing,
2nd Bushing, 2nd Inner Synchronizer Component,
1st/2nd Clutch Hub Set, 1st Inner Synchronizer
Component, 1st Needle Bearing, 1st Bushing, 1st
Gear and Reverse Main Gear Disassembly Note)
AME5112M096
13 2nd gear
14 2nd needle bearing
15 2nd bushing
16 2nd inner synchronizer component
17 1st/2nd clutch hub set
18 1st inner synchronizer component
19 1st needle bearing
20 1st bushing
21 1st gear
22 Reverse main gear
23 Secondary shaft
24 Synchronizer key spring
25 1st/2nd synchronizer key
26 1st/2nd clutch hub and sleeve
J–19
MANUAL TRANSAXLE
Secondary Shaft Rear Bearing Disassembly Note
1. Remove the secondary shaft rear bearing using
the SSTs.
4th Gear and 5th Gear Disassembly Note
1. Remove the 4th gear and 5th gear at the same
time using the SSTs.
AME5112M113
AME5112M111
3rd Gear, 2nd Gear, 2nd Needle Bearing, 2nd Bushing, 2nd Inner Synchronizer Component, 1st/2nd Clutch
Hub Set, 1st Inner Synchronizer Component, 1st Needle Bearing, 1st Bushing, 1st Gear and Reverse
Main Gear Disassembly Note
1. Remove the 3rd gear, 2nd gear, 2nd needle
bearing, 2nd bushing, 2nd inner synchro nizer
component, 1st/2nd clutch hub set, 1st inner
synchronizer component, 1st needle bearing, 1st
bushing, 1st gear and reverse main gear at the
same time using the SST.
AME5112M112
End Of Sie
SECONDARY SHAFT COMPONENTS INSPECTION
Secondary Shaft and Gear Inspection
1. Inspect the shaft for damage, abnormal wear, dents, flaking, or bending.
• If there is malfunction, replace the shaft.
2. Inspect the gears for damage, abnormal wear,
dents, flaking, or bending.
• If there is malfunction, replace the gear.
3. Inspect the oil passage for clogging.
• If there is malfunction, replace the shaft.
AME511217301M03
J–20
AME5112M058
MANUAL TRANSAXLE
Synchronizer Ring and Clutch Hub Component Inspection
1. Inspect the clutch hub sleeve, clutch hub, and
synchronizer key contact surface for damage and
abnormal wear.
• If there is malfunction, replace the part where
necessary.
2. Verify that the clutch hub sleeve and clutch hub
move smoothly.
• If there is malfunction, replace parts as
necessary.
3. Inspect the synchronizer ring teeth and grooves
for damage, abnormal wear, and cracks.
• If there is malfunction, replace the
synchronizer ring.
4. Inspect the tapered surface for abnormal wear
and cracks.
• If there is malfunction, replace parts as
necessary.
J
AME5112M045
Synchronizer Ring Clearance Inspection
Synchronizer component (1st gear)
1. Measure the clearance of synchronizer
component outer, middle and inner synchronizer
rings.
• If clearances A and B exceed the maximum,
replace as a set.
(1) Measure clearance A in two places or more
and on opposite sides using a dial gauge, and
calculate the average value.
Clearance A
Standard: 0.60—0.80 mm
{0.0236—0.0315 in}
Maximum: 0.20 mm {0.0079 in} or less
AME5112M046
AME5112M059
AME5112M129
J–21
MANUAL TRANSAXLE
(2) Measure clearance B in two places or more
and on opposite sides using a feeler gauge,
and calculate the average value.
Clearance B
Standard: 0.60—1.10 mm
{0.0236—0.0433 in}
Maximum: 0.20 mm {0.0079 in} or less
Synchronizer componen t (2 nd ge a r)
1. Inspect clearance of the synchronizer compone nt
outer, middle, and inner synchronizer rings.
• If the clearance A, B and C exceed the
maximum, replace as a set.
AME5112M060
(1) Measure clearance A in two places or more
and on opposite sides using a feeler gauge
while the synchronizer ring is manually press
fit to the taper surface of the clutch gear, and
calculate the average value.
Clearance A
Standard: 0.60—1.20 mm
{0.0236—0.0472 in}
Maximum: 0.30 mm {0.0118 in} or less
(2) Measure clearance B in two places or more
and on opposite sides with a feeler gauge,
and calculate the average value.
Clearance B
Standard: 0.60—1.10 mm
{0.0236—0.0433 in}
Maximum: 0.20 mm {0.0079 in} or less
AME5112M092
AME5112M090
AME5112M060
J–22
MANUAL TRANSAXLE
(3) Measure clearance C in two places or more
and on opposite sides with a feeler gauge
while the synchronizer ring is manually press
fit to the taper surface of the clutch gear, and
calculate the average value.
Clearance C
Standard: 0.70—1.10 mm
{0.0276—0.0433 in}
Maximum: 0.30 mm {0.0118 in} or less
Bearing Inspection
1. Inspect the ball and the ball contact surface for damage and abnormal wear.
• If there is malfunction, replace the bearing.
2. Verify that the bearing rotates smoot hly.
• If there is malfunction, replace the bearing.
J
AME5112M091
End Of Sie
AME5112M072
J–23
MANUAL TRANSAXLE
SECONDARY SHAFT COMPONENTS ASSEMBLY
1. Assemble in the order shown in the figure.
.
AME511217301M04
1 Secondary shaft
2 Reverse main gear
(See J–25 Reverse Main Gear Assembly Note)
3 1st bushing
(See J–25 1st Bushing Assembly Note)
4 1st needle bearing
5 1st gear
6 1st inner synchronizer component
7 Synchronizer key spring
(See J–26 Synchronizer Key Spring, 1st/2nd
Synchronizer Key and 1st/2nd Clutch Hub and
Sleeve Assembly Note)
8 1st/2nd synchronizer key
9 1st/2nd clutch hub and sleeve
10 1st/2nd clutch hub set
(See J–26 1st/2nd Clutch Hub Set Assembly Note)
11 2nd inner synchronizer component
12 2nd bushing
(See J–27 2nd Bushing Assembly Note)
13 2nd needle bearing
14 2nd gear
AME5112M136
15 3rd gear
(See J–27 3rd Gear Assembly Note)
16 3rd/4th secondary shaft spacer
17 4th gear adjustment shim
(See J–27 4th Gear Adjustment Shim Assembly
Note)
18 4th gear
(See J–28 4th Gear Assembly Note)
19 5th gear
(See J–28 5th Gear Assembly Note)
20 5th gear Snap ring
(See J–28 5th Gear Snap Ring Assembly Note)
21 Secondary shaft rear bearing
(See J–28 Secondary Shaft Rear Bearing Assembly
Note)
22 Secondary shaft C ring
(See J–29 Secondary Shaft C Ring Assembly Note)
23 C ring holder
24 Snap ring
25 Snap ring
26 Secondary shaft rear bearing adjust shim
J–24
MANUAL TRANSAXLE
Reverse Main Gear Assembly Note
1. Place a new reverse main gear with the bevel
edge facing toward the engine.
2. Install the reverse main gear using the SST.
J
AME5112M062
1st Bushing Assembly Note
Caution
•
• The shaft can be damaged when
••
installing the 1st bushing if the SST
touchedes the secondary shaft. Install
the SST to the shaft without touching the
shaft.
1. Place the 1st bushing, and assemble the SST as
shown in the figure.
2. Install the 1st bushing using the SSTs.
AME5112M133
AME5112M122
AME5112M121
J–25
MANUAL TRANSAXLE
Synchronizer Key Spring, 1st/2nd Synchronizer Key and 1st/2nd Clutch Hub and Sleeve Assembly Note
1. Install the synchronizer key spring, 1st/2nd synchronizer key and 1st/2nd clutch hub to the 1st/2nd clutch
sleeve.
(1) Install a new 1st/2nd clutch hub in the
direction as shown in the figure.
AME5112M047
(2) Install the 1st/2nd clutch sleeve in the
direction as shown in the figure.
(3) Install center projection parts of synchronizer
key springs to different synchronizer keys at
each side.
1st/2nd Clutch Hub Set Assembly Note
Note
• Align the synchronizer ring grooves with the synchronizer key during assembly.
1. Install the 1st/2nd clutch hub set using the SSTs.
AME5112M063
AME5112M049
J–26
AME5112M123
MANUAL TRANSAXLE
2nd Bushing Assembly Note
1. Install the 2nd bushing using the SSTs.
3rd Gear Assembly Note
1. Place a new 3rd gear in the direction as shown in
the figure.
2. Install the 3rd gear using the SST.
J
AME5112M124
4th Gear Adjustment Shim Assembly Note
1. Install the 4th gear adjustment shim washer.
2. Measure length C2 as shown in the figure.
• If it is not within the specification, adjust it by
selecting a proper 4th gear adjustment shim
from below.
• Select only one 4th gear adjustment shim.
Specification C2
173.85—173.95 mm {6.844—6.848 in}
4th gear adjustment shim size
Thickness (mm {in})
0.52 {0.021} 0.84 {0.033}
0.60 {0.024} 0.92 {0.036}
0.68 {0.027} 1.00 {0.039}
0.76 {0.030} 1.08 {0.043}
AME5112M125
AME5112M064
J–27
MANUAL TRANSAXLE
4th Gear Assembly Note
1. Place a new 4th gear in the direction as shown in
the figure.
2. Install the 4th gear using the SST.
5th Gear Assembly Note
1. Place a new 5th gear in the direction as shown in
the figure.
2. Install the 5th gear using the SSTs.
AME5112M126
5th Gear Snap Ring Assembly Note
1. Install a new 5th gear snap ring to the secondary shaft.
2. Measure the clearance between the 5th gear
snap ring and the 5th gear.
• If it is not within the specification, adjust it by
selecting a proper snap ring from below.
Clearance
0.0—0.1 mm {0.0000—0.0039 in}
5th gear snap ring size
Thickness (mm {in})
1.85 {0.073} 2.05 {0.081}
1.90 {0.075} 2.10 {0.083}
1.95 {0.077} 2.15 {0.085}
2.00 {0.079} 2.20 {0.087}
Secondary Shaft Rear Bearing Assembly Note
1. Install the secondary shaft rear bearing using the
SSTs.
AME5112M127
AME5112M065
J–28
AME5112M128
MANUAL TRANSAXLE
Secondary Shaft C Ring Assembly Note
1. Install the secondary shaft C ring to the secondary shaft.
2. Measure the clearance between the secondary
shaft C ring and the secondary shaft rear b ear ing.
• If it is not within the specification, adjust it by
selecting a proper C ring from below.
Clearance
0.00—0.06 mm {0.0000—0.0024 in}
Secondary shaft C ring size
Thickness (mm {in})
2.535 {0.0998} 2.835 {0.1116}
2.565 {0.1010} 2.865 {0.1128}
2.595 {0.1022} 2.895 {0.1140}
2.625 {0.1033} 2.925 {0.1152}
2.655 {0.1045} 2.955 {0.1163}
2.685 {0.1057} 2.985 {0.1175}
2.715 {0.1069} 3.015 {0.1187}
2.745 {0.1081} 3.045 {0.1199}
2.775 {0.1093} 3.075 {0.1211}
2.805 {0.1104} —
J
AME5112M066
3. Inspect the 1st gear and 2nd gear end play. (S ee J–18 SECONDARY SHAFT COMPONENTS
PREINSPECTION.)
End Of Sie
J–29
MANUAL TRANSAXLE
REVERSE IDLER SHAFT COMPONENTS DISASSEMBLY/ASSEMBLY
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
.
AME511217315M01
1 Reverse idler adjust shim
2 Reverse idler rear gear and reverse coupling sleeve
3 Insert spring
(See J–30 Insert Spring Assembly Note)
4 Reverse idler needle bearing
5 Thrust needle bearing
Insert Spring Assembly Note
1. Install the insert spring in the direction as shown
in the figure.
End Of Sie
AME5112M005
6 Reverse synchronizer ring
7 Reverse idler front gear
8 Reverse idler needle bearing
9 Thrust needle bearing
10 Reverse idler shaft
11 Spring pin
AME5112M071
J–30
MANUAL TRANSAXLE
REVERSE IDLER SHAFT COMPONENTS INSPECTION
Reverse idler shaft and gears Inspection
1. Inspect the shaft for damage, abnormal wear, dents, flaking, or bending.
• If there is malfunction, replace the shaft.
2. Inspect the gears for damage, abnormal wear,
dents, flaking, or bending.
• If there is malfunction, replace the gear.
Synchronizer Ring and Clutch Hub Component Inspection
1. Inspect the clutch hub sleeve, clutch hub, and
insert spring contact surface for damage,
abnormal wear, or bending.
• If there is malfunction, replace the part where
necessary.
2. Verify that the clutch hub sleeve and clutch hub
move smoothly.
• If there is malfunction, replace parts as
necessary.
AME511217315M02
J
AME5112M068
3. Inspect the synchronizer ring teeth and grooves
for damage, abnormal wear, and cracks.
• If there is malfunction, replace the
synchronizer ring.
4. Inspect the tapered surface for abnormal wear
and cracks.
• If there is malfunction, replace parts as
necessary.
5. Measure the clearance between the synchro nizer
ring and the flank surface of the gear.
• If not as specified, replace the synchronizer
ring.
Note
• Set the synchronizer ring squarely in the
gear; then measure around the
circumference.
Standard clearance
0.95—1.40 mm {0.037—0.055 in}
Minimum clearance
0.70 mm {0.028 in}
AME5112M139
AME5112M046
AME5112M070
J–31
MANUAL TRANSAXLE
Bearing Inspection
1. Inspect the ball and the ball contact surface for damage and abnormal wear.
• If there is malfunction, replace the bearing.
2. Verify that the bearing rotates smoot hly.
• If there is malfunction, replace the bearing.
End Of Sie
DIFFERENTIAL PREINSPECTION
Backlash Inspection
1. Measure the backlash of the side gear.
• If not as specified, replace parts as
necessary.
Standard
0.10—0.20 mm {0.0039—0.0079 in}
AME5112M072
AME511227100M01
End Of Sie
DIFFERENTIAL DISASSEMBLY
1. Disassemble in the order shown in the figure.
AME5112M140
AME511227100M02
.
1 Ring gear
2 Bearing (ring gear-opposite side)
(See J–33 Bearing (Ring Gear-Opposite Side)
Disassembly Note)
3 Spacer
J–32
AME5112M006
4 Bearing (ring gear side)
(See J–33 Bearing (Ring Gear Side) Disassembly
Note)
5 Gear case component
MANUAL TRANSAXLE
Bearing (Ring Gear-Opposite Side) Disassembly Note
1. Remove the bearing using the SST.
Bearing (Ring Gear Side) Disassembly Note
1. Remove the bearing using the SSTs.
J
AME5112M130
End Of Sie
DIFFERENTIAL ASSEMBLY
1. Assemble in the order shown in the figure.
AME5112M134
AME511227100M03
.
1 Ring gear
(See J–34 Ring Gear Assembly Note)
2 Gear case component
3 Bearing (ring gear side)
(See J–34 Bearing (Ring Gear Side) Assembly
Note)
AME5112M141
4 Spacer
(See J–34 Spacer Assembly Note)
5 Bearing (ring gear-opposite side)
(See J–34 Bearing (Ring Gear-Opposite Side)
Assembly Note)
J–33
MANUAL TRANSAXLE
Ring Gear Assembly Note
1. Install the gear case component, and tighten a
bolt in the order shown in the figure.
Tightening torque
112.7—127.4 N·m
{11.5—13.0 kgf·m, 83—94 ft·lbf}
Bearing (Ring Gear Side) Assembly Note
1. Install a new bearing using the SSTs.
AME5112M075
Spacer Assembly Note
1. Install the spacer using the SST.
Bearing (Ring Gear-Opposite Side) Assembly Note
1. Install a new bearing using the SSTs.
AME5112M073
AME5112M131
End Of Sie
J–34
AME5112M132
MANUAL TRANSAXLE
PRIMARY SHAFT END PLAY ADJUSTMENT
Note
• Adjust the primary shaft end play by measuring the clearance between the transaxle case and the primary
shaft rear bearing, and selecting a primary shaft bearing adjustment shim.
• Calculate adjustment shim thickness O as
defined below to adjust the primary shaft
bearing end play to standard value.
Standard value: 0.00—0.06 mm
{0.0000—0.0024 in}
Dimension O = (O1 - O2) + end play
O: adjustment shim thickness
O1: transaxle case contact face and
adjustment shim installation surface
dimension
O2: clutch housing contact face and
primary shaft rear bearing contact face
dimension
Adjustment shim thickness
0.40 {0.016} 0.76 {0.030} 1.12 {0.044} 1.48 {0.058}
0.44 {0.017} 0.80 {0.031} 1.16 {0.046} 1.52 {0.060}
0.48 {0.019} 0.84 {0.033} 1.20 {0.047} 1.56 {0.061}
0.52 {0.020} 0.88 {0.035} 1.24 {0.049} 1.60 {0.063}
0.56 {0.022} 0.92 {0.036} 1.28 {0.050} 1.64 {0.065}
0.60 {0.024} 0.96 {0.038} 1.32 {0.052} 1.68 {0.066}
0.64 {0.025} 1.00 {0.039} 1.36 {0.054} 1.72 {0.068}
0.68 {0.027} 1.04 {0.041} 1.40 {0.055} —
0.72 {0.028} 1.08 {0.043} 1.44 {0.057} —
AME511201029M07
J
AME5112M030
(mm {in})
1. Measure dimension O1 for the clutch housing
installation surface of the transaxle case and the
adjustment shim installation surface using a
depth gauge and straight edge.
2. Measure dimension O2 for the transaxle case
installation surface of the clutch housing and the
primary shaft rear bearing contact face using a
depth gauge and straight edge.
Note
• Select only one adjustment shim.
3. Install the selected primary shaft rear bearing
adjustment shim in the primary shaft component.
End Of Sie
AME5112M031
AME5112M032
J–35
MANUAL TRANSAXLE
SECONDARY SHAFT END PLAY ADJUSTMENT
Note
• Adjust the secondary shaft end play by measuring clearance M between the transaxle case and the
secondary shaft rear bearing, and selecting a secondary shaft bearing adjustment shim.
• Calculate adjustment shim thickness P as
defined below to adjust the secondary shaft
bearing end play to standard value.
Standard value: 0.00—0.06 mm
{0.0000—0.0024 in}
Dimension P = M + end play
P: adjustment shim thickness
M: transaxle case contact face and
secondary shaft rear bearing contact
Adjustment shim thickness
0.40 {0.016} 0.64 {0.025} 0.84 {0.033} 1.04 {0.041}
0.48 {0.019} 0.68 {0.027} 0.88 {0.035} 1.08 {0.043}
0.52 {0.020} 0.72 {0.028} 0.92 {0.036} —
0.56 {0.022} 0.76 {0.030} 0.96 {0.038} —
0.60 {0.024} 0.80 {0.031} 1.00 {0.039} —
AME511201029M08
AME5112M033
(mm {in})
1. Install the secondary shaft component to the clutch housing.
2. Install the snap ring to the transaxle case.
3. Attach the transaxle case to the clutch housing, and temporarily install installation b olts. Temporarily at tach the
snap ring to the secondary shaft rear bearing.
4. Set a dial gauge to the secondary shaft rear bearing through the snap ring installa tion hole.
5. While expanding the snap ring, lift the secondary shaft component through the control component installation
hole until it contacts the transaxle case.
6. Release the secondary shaft component so that
it moves back down and the snap ring resets to
the secondary shaft rear bearing. Dimension M is
the measured distance that the secondary shaft
component moves.
Note
• Select only one adjustment shim.
7. Install the selected primary shaft rear bearing
adjustment shim in the primary shaft component.
AME5112M034
End Of Sie
J–36
MANUAL TRANSAXLE
REVERSE IDLER GEAR END PLAY ADJUSTMENT
Note
• Adjust the reverse idler gear end play by measuring the clearance between the transaxle case and a
reverse idler gear (rear), and selecting a reverse idler gear adjustment shim.
• Calculate dimension Q for the adjustment
shim thickness as defined below to adjust
the reverse idler gear end play to standard
value.
Standard value: 0.04—0.10 mm
{0.0016—0.0039 in}
Dimension Q = (Q1 + Q2) + end play
Q: adjustment shim thickness
Q1: transaxle case contact face and
adjustment shim installation surface
dimension
Q2: clutch housing contact face and
reverse idler gear (rear) contact face
dimension
Adjustment shim thickness
1.76 {0.069} 2.00 {0.007} 2.24 {0.088} 2.48 {0.098}
1.80 {0.070} 2.04 {0.080} 2.28 {0.090} 2.52 {0.099}
1.84 {0.072} 2.08 {0.082} 2.32 {0.091} 2.56 {0.101}
1.88 {0.074} 2.12 {0.083} 2.36 {0.093} 2.60 {0.102}
1.92 {0.076} 2.16 {0.085} 2.40 {0.094} 2.64 {0.104}
1.96 {0.077} 2.20 {0.087} 2.44 {0.096} —
AME511201029M06
J
AME5112M039
(mm {in})
1. Measure dimension Q1 between clutch housing
installation surface of the transaxle case and
adjustment shim installation surface using a
depth gauge and straight edge.
2. Measure dimension Q2 between the transaxle
case installation surface of the clutch hou sing and
the reverse idler gear (rear) contact face using a
depth gauge and straight edge.
Note
• Select only one adjustment shim.
3. Install the selected reverse idler gear adjustment
shim in the reverse idler gear component.
End Of Sie
AME5112M040
AME5112M041
J–37
MANUAL TRANSAXLE
DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT
Note
• Adjust the differential side bearing preload by measuring clearan ce L be tween the tr ansaxle case and t he
differential side bearing outer race, and selecting a differential side bearing adjustment shim.
• Calculate dimension L for the adjustment
shim thickness as defined below to adjust
the differential side bearing preload to
standard value.
Standard value: 0.15—0.21 mm
{0.0059—0.0083 in}
Dimension L = (L1 + L2) + preload
L: adjustment shim thickness
L1: transaxle case contact face and
adjustment shim installation surface
dimension
L2: clutch housing contact face and
differential side bearing contact face
dimension
Adjustment shim thickness
0.48 {0.019} 0.60 {0.024} 0.72 {0.028} 0.84 {0.033}
0.52 {0.020} 0.64 {0.025} 0.76 {0.030} 0.88 {0.035}
0.56 {0.022} 0.68 {0.027} 0.80 {0.031} 0.92 {0.036}
AME511201029M05
AME5112M035
(mm {in})
1. Measure dimension L1 betwee n th e clut ch
housing installation surface of the transaxle case
and the adjustment shim installation surface
using a depth gauge and straight edge.
2. Install the outer race to the ring gear side of the
differential side bearing and, keeping the outer
race level, lightly push it in and rotate the final
gear 5 times or more.
3. Verify dimension L2 between the differential side
bearing outer race and the transaxle case
installation surface of the clutch housing using a
depth gauge and straight edge.
Note
• Select up to 2 adjustment shims.
AME5112M036
AME5112M037
J–38
MANUAL TRANSAXLE
4. Install selected adjustment shim, and install the
differential side bearing outer race using the
SSTs.
End Of Sie
J
AME5112M038
J–39
MANUAL TRANSAXLE
CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS ASSEMBLY
Assembly Components
AME511217010M05
.
1 Clutch housing
2 Primary shaft oil seal
3 Oil channel
4 Secondary shaft front bearing
5 Secondary shaft bearing retainer
6 Dowel pin
7 Knock pin
8 Differential oil seal
9 Magnet
10 Pivot pin
J–40
AME5112M137
11 Transaxle case
12 Oil pass
13 Baffle plate
14 Welt plug
15 Bore plug
16 Air-bleed plug
17 Reverse switch
18 Neutral switch
19 Filler cap
20 Drain plug
MANUAL TRANSAXLE
J
.
1 Transaxle case
2 Clutch housing
3 1st/2nd shift fork
4 1st/2nd bracket
5 1st/2nd fork rod
6 Shift check sleeve (1st/2nd)
7 3rd/4th bracket
8 3rd/4th shift fork
9 3rd/4th fork rod
10 Inter lock pin
11 Check ball
12 Shift check sleeve (5th/reverse)
13 Check spring (5th/reverse)
14 Check plug (5th/reverse)
15 5th/reverse bracket
16 5th shift fork
AME5112M138
17 5th/Reverse fork rod
18 C ring
19 Retaining pin
20 Reverse shift fork
21 Cap
22 Reverse fork rod
23 Reverse lever component
24 Rod bushing
25 O ring
26 Shift control component
27 Shift check bolt
28 Stopper bolt
29 Check spring (3rd/4th)
30 Check spring (1st/2nd)
31 Check plug (1st/2nd, 3rd/4th)
J–41
MANUAL TRANSAXLE
Assembly Procedure
1. Install a new primary shaft oil seal in the clutch
housing using the SST.
2. Install a new differential oil seal (clutch housing
side) using the SSTs so that the seal is flush with
the housing surface.
AME5112M017
3. Install a new oil channel in the secondary shaft.
Note
• When installing the oil channel, set the rib
part of the oil channel to the hollow
processing part of the clutch housing.
4. Install a new secondary shaft front bearing using
the SSTs as shown in the figure.
AME5112M105
AME5112M018
AME5112M019
J–42
MANUAL TRANSAXLE
5. Install the bearing retainer with the stamp facing
up.
Tightening torque
6.27—8.33 N·m
{0.64—0.85 kgf·m, 4.62—6.14 ft·lbf}
6. Measure the differential preload, and install the
differential side bearing outer race using the
SSTs. (See J–38 DIFFERENTIAL SIDE
BEARING PRELOAD ADJUSTMENT.)
J
AME5112M020
7. Install the differential to the clutch housing.
Caution
•
• Installing the primary shaft can damage
••
the oil seal, reducing the performance of
the transaxle. When installing the
primary shaft to the clutch housing, be
careful not to damage it.
8. Install the primary shaft component, secondary
shaft component, and reverse idler component to
the clutch housing at the same time.
AME5112M021
AME5112M038
AME5112M022
AME5112M014
J–43
MANUAL TRANSAXLE
9. Install the 1st /2nd bracket to the 1st/2n d fork rod,
and install a new retaining pin.
10. Install the 1st/2nd fork rod and 1st/2nd shift fork to
the clutch housing, and install a new retaining pi n.
11. I ns ta ll the sh ift che ck sleev e.
12. Install the interlock pin to the 3rd/4th fork rod.
13. Install the 3rd/4th bracket, 3rd/4th shift fork, and
3rd/4th fork rod to the clutch housing.
AME5112M023
14. Install a new C ring to the 3rd/4th shift fork.
15. Install a new retaining pin to the 3rd/4th bracket.
16. Install two check balls.
17. Install the 5th/reverse bracket, 5th shift fork, and
5th/reverse fork rod.
18. Install a new C ring to the 5th/reverse fork rod.
19. Install a new retaining pin to the 5th shift fork.
20. Install the reverse shift fork and reverse fork rod.
21. Install the reverse lever component.
(1) Install the cap to the cam part of the reverse
lever component, and the reverse lever
component to the reverse shift fork.
AME5112M013
AME5112M012
AME5112M011
J–44
AME5112M010
MANUAL TRANSAXLE
(2) Lift the reverse shift fork, and install the cam
part of the reverse lever component to the
5th/reverse bracket.
(3) I ns ta ll a ne w re ve rse leve r com p on e nt
installation bolt.
Tightening torque
11.8—15.6 N·m
{1.20—1.59 kgf·m, 8.7—11.5 ft·lbf}
Note
• When install the check ball, keep the check
ball from dropping into the mold groove of
the hole.
22. Install the check ball, the shift check sleeve (5th/
reverse), the check spring (5th/reverse), and a
new check plug (5th/reverse).
23. Install the magnet to the clutch housing.
24. Install a new differential oil seal to the transaxle
case using the SSTs so that the seal is flush with
the case surface.
25. Adjust the primary shaft end play. (See J–35
PRIMARY SHAFT END PLAY ADJUSTMENT.)
26. Install the primary shaft adjustment shim to the
primary shaft.
27. Install the baffle plate and oil pass.
28. Install the transaxle case.
(1) Adjust the secondary shaft end play. (See J–
36 SECONDARY SHAFT END PLAY
ADJUSTMENT.)
(2) Install the secondary shaft rear bearing
adjustment shim to the transaxle case.
(3) Install a new snap ring of the secondary shaft rear bearing to the transaxle case.
(4) Apply a light coat of silicone sealant to the
contact surfaces of the transa xle case and the
clutch housing.
J
AME5112M024
AME5112M009
AME5112M104
Sealant
Three Bond product: TB1215
AME5112M025
J–45
MANUAL TRANSAXLE
(5) Place the transaxle case to the clutch
housing.
(6) Stretch the snap ring at the bore plug hole
while lifting the secondary shaft at the control
component installation hole.
(7) Install the snap ring to the groove of the
secondary shaft rear bearing.
AME5112M026
(8) Install the A bolt and a ne w B bolt to the
transaxle case as shown in the figure.
Tightening torque
A: 50.0—53.9 N·m
{5.1—5.5 kgf·m, 36.9—39.8 ft·lbf}
B: 63.0—66.9 N·m
{6.4—6.8 kgf·m, 46.5—49.3 ft·lbf}
29. Install a new bore plug using the SSTs.
AME5112M100
AME5112M027
AME5112M028
J–46
MANUAL TRANSAXLE
30. Install a new welt plug using the SSTs.
31. Install the shift check sleeve, the check balls,
check springs, and a new check ball plugs as
shown in the figure.
Tightening torque
12.7—17.0 N·m
{1.30—1.73 kgf·m, 9.4—12.5 ft·lbf}
32. Install a new O ring to the control component.
J
AME5112M029
AME5112M099
33. Install the control component.
Tightening torque
6.30—8.30 N·m
{0.64—0.85 kgf·m, 4.65—6.12 ft·lbf}
34. Install a new shift check bolt.
Tightening torque
22.5—25.5 N·m
{2.29—2.60 kgf·m, 16.6—18.8 ft·lbf}
35. Install a new stopper bolt.
Tightening torque
AME5112M098
26.5—30.4 N·m
{2.70—3.10 kgf·m, 19.5—22.4 ft·lbf}
36. Apply a light coat of silicone sealant to the screw of the neutral switch, and install it to the transaxle case.
Sealant
Three Bond product: TB1215
Tightening torque
22.5—33.3 N·m {2.29—3.40 kgf·m, 16.6—24.6 ft·lbf}
37. Apply a light coat of silicone sealant to the screw of the reverse switch, and install it to the transaxle case.
Sealant
Three Bond product: TB1215
Tightening torque
22.5—33.3 N·m {2.29—3.40 kgf·m, 16.6—24.6 ft·lbf}
38. Install a new drain plug.
Tightening torque
30.0—39.0 N·m {3.06—3.98 kgf·m, 22.1—28.8 ft·lbf}
39. Install a new gasket to the filler cap, and Install it to the transaxle case.
Tightening torque
30.0—39.0 N·m {3.06—3.98 kgf·m, 22.1—28.8 ft·lbf}
End Of Sie
J–47
TD
TECHNICAL DATA
TECHNICAL DATA ............................................. TD-2
MANUAL TRANSAXLE..................................... TD-2
TD
TD–1
TECHNICAL DATA
TECHNICAL DATA
MANUAL TRANSAXLE
Item Specification
Transaxle type A65M-R
1st gear End play (mm {in}) 0.20—0.30 {0.0078—0.0118}
2nd gear End play (mm {in}) 0.06—0.16 {0.0024—0.0063}
Gear clearance
Synchronizer ring
Primary shaft
Secondary shaft
Reverse idler gear
Primary shaft thrust
washer
Primary shaft snap
ring
4th gear adjustment
shim
3rd gear
4th gear End play (mm {in}) 0.20—0.30 {0.0078—0.0118}
5th gear
1st gear
2nd gear
3rd gear Clearance (mm {in}) 0.90—1.45 {0.035—0.057}
4th gear Clearance (mm {in}) 0.90—1.45 {0.035—0.057}
5th gear Clearance (mm {in}) 0.95—1.40 {0.037—0.055}
Reverse idler gear Clearance (mm {in}) 0.95—1.40 {0.037—0.055}
End play (mm {in}) 0.00—0.06 {0.0000—0.0024}
Adjustment shim thickness (mm {in})
End play (mm {in}) 0.00—0.06 {0.0000—0.0024}
Adjustment shim thickness (mm {in})
End play (mm {in}) 0.04—0.10 {0.0016—0.0039}
Adjustment shim thickness (mm {in})
Thickness (mm {in})
Thickness (mm {in})
Thickness (mm {in})
Thrust
clearance
Thrust
clearance
Clearance B*
Clearance C*
Clearance A*
Clearance B*
Clearance C*
(mm {in}) 0.18—0.31 {0.0071—0.0122}
(mm {in}) 0.06—0.16 {0.0024—0.0063}
1
1
1
1
1
(mm {in}) 0.60—1.10 {0.0236—0.0433}
(mm {in}) 0.60—0.80 {0.0236—0.0315}
(mm {in}) 0.60—1.20 {0.0236—0.0472}
(mm {in}) 0.60—1.10 {0.0236—0.0433}
(mm {in}) 0.70—1.10 {0.0276—0.0433}
0.40 {0.016}, 0.44 {0.017}, 0.48 {0.019},
0.52 {0.020}, 0.56 {0.022}, 0.60 {0.024},
0.64 {0.025}, 0.68 {0.027}, 0.72 {0.028},
0.76 {0.030}, 0.80 {0.031}, 0.84{0.033},
0.88 {0.035}, 0.92 {0.036}, 0.96 {0.038},
1.00 {0.039}, 1.04 {0.041}, 1.08 {0.043},
1.12 {0.044}, 1.16 {0.046}, 1.20 {0.047},
1.24 {0.049}, 1.28 {0.050}, 1.32 {0.052},
1.36 {0.054}, 1.40 {0.055}, 1.44 {0.057},
1.48 {0.058}, 1.52 {0.060}, 1.56 {0.061},
1.60 {0.063}, 1.64 {0.065}, 1.68 {0.66},
1.72 {0.68}
0.40 {0.016}, 0.48 {0.019}, 0.52 {0.020},
0.56 {0.022}, 0.60 {0.024}, 0.64 {0.025},
0.68 {0.027}, 0.72 {0.028}, 0.76 {0.030},
0.80 {0.031}, 0.84 {0.033}, 0.88 {0.035},
0.92 {0.036}, 0.96 {0.038}, 1.00 {0.039},
1.04 {0.041}, 1.08 {0.043}
1.76 {0.069}, 1.80 {0.070}, 1.84 {0.072},
1.88 {0.074}, 1.92 {0.076}, 1.96 {0.077},
2.00 {0.007}, 2.04 {0.080}, 2.08 {0.082},
2.12 {0.083}, 2.16 {0.085}, 2.20 {0.087},
2.24 {0.088}, 2.28 {0.090}, 2.32 {0.091},
2.36 {0.093}, 2.40 {0.094}, 2.44 {0.096},
2.48 {0.098}, 2.52 {0.099}, 2.56 {0.101},
2.60 {0.102}, 2.64 {0.104}
3.84 {0.151}, 3.90 {0.154}, 3.96 {0.156},
4.02 {0.158}, 4.08 {0.161}, 4.14 {0.163}
1.71 {0.067}, 1.76 {0.069}, 1.81 {0.071},
1.86 {0.073}, 1.91 {0.075}, 1.96 {0.077},
2.01 {0.079}, 2.06 {0.081}, 2.11 {0.083},
2.16 {0.085}, 2.21 {0.087}, 2.26 {0.089}
0.52 {0.021}, 0.60 {0.024}, 0.68 {0.027},
0.76 {0.030}, 0.84 {0.033}, 0.92 {0.036},
1.00 {0.039}, 1.08 {0.043}
AME931001029M01
TD–2
TECHNICAL DATA
Item Specification
5th gear snap ring Thickness (mm {in})
Secondary shaft C
ring
Differential
*1 : Measure the clearance A, B or C as shown in the figure.
Thickness (mm {in})
Preload (mm {in}) 0.15—0.21 {0.0059—0.0083}
Adjustment shim thickness (mm {in})
Backlash of side gear and pinion gear (mm {in}) 0.10—0.20 {0.0039—0.0079}
1.85 {0.073}, 1.90 {0.075}, 1.95 {0.077},
2.00 {0.079}, 2.05 {0.081}, 2.10 {0.083},
2.15 {0.085}, 2.20 {0.087}
2.535 {0.0998}, 2.565 {0.1010},
2.595 {0.1022}, 2.625 {0.1033},
2.655 {0.1045}, 2.685 {0.1057},
2.715 {0.1069}, 2.745 {0.1081},
2.775 {0.1093}, 2.805 {0.1104},
2.835 {0.1116}, 2.865 {0.1128},
2.895 {0.1140}, 2.925 {0.1152},
2.955 {0.1163}, 2.985 {0.1175},
3.015 {0.1187}, 3.045 {0.1199},
3.075 {0.1211}
0.48 {0.019}, 0.52 {0.020}, 0.56 {0.022},
0.60 {0.024}, 0.64 {0.025}, 0.68 {0.027},
0.72 {0.028}, 0.76 {0.030}, 0.80 {0.031},
0.84 {0.033}, 0.88 {0.035}, 0.92 {0.036}
TD
End Of Sie
AME5112M092
TD–3
ST
SPECIAL TOOLS
SPECIAL TOOLS .................................................ST-2
MANUAL TRANSAXLE......................................ST-2
ST
ST–1
SPECIAL TOOLS
SPECIAL TOOLS
MANUAL TRANSAXLE
49 0710 520
Bearing puller
498 B019 014
Removing plate
49 F401 336B
Attachment B
49 G030 797
49 0727 415
Bearing installer
49 F026 103
Wheel hub
puller
49 F401 337A
Attachment C
49 G033 102
AME941001029M01
49 0839 425C
Bearing puller
set
49 F401 331
Body
49 G027 002
Bearing
remover
49 G033 105
Handle
49 H010 401
Oil seal installer
49 S231 506
Body
49 W032 2A0
Bearing
remover set
Handle
49 H027 002
Bearing
remover
49 T017 002
Bearing installer
49 G030 796
Body
Attachment
49 P005 205
Oil seal installer
49 U027 003
Oil seal installer
—
End Of Sie
ST–2
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