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C TRANSMISSION/TRANSAXLE
SECTION
MANUAL TRANSAXLE
CONTENTS
A
B
MT
D
E
PRECAUTIONS ......................................................... |
3 |
Caution .................................................................... |
3 |
PREPARATION .......................................................... |
4 |
Special Service Tools .............................................. |
4 |
Commercial Service Tools ....................................... |
6 |
NOISE, VIBRATION AND HARSHNESS (NVH) |
|
TROUBLESHOOTING ............................................... |
8 |
NVH Troubleshooting Chart .................................... |
8 |
MANUAL TRANSAXLE ........................................ |
8 |
DESCRIPTION ........................................................... |
9 |
Cross-Sectional View .............................................. |
9 |
DOUBLE-CONE SYNCHRONIZER ................... |
10 |
TRIPLE-CONE SYNCHRONIZER ..................... |
10 |
REVERSE GEAR NOISE PREVENTION FUNC- |
|
TION (SYNCHRONIZING METHOD) ................ |
10 |
M/T OIL ..................................................................... |
11 |
Changing M/T Oil ................................................... |
11 |
DRAINING ........................................................... |
11 |
FILLING ............................................................... |
11 |
Checking M/T Oil .................................................... |
11 |
OIL LEAKAGE AND OIL LEVEL ......................... |
11 |
SIDE OIL SEAL ....................................................... |
12 |
Removal and Installation ....................................... |
12 |
REMOVAL .......................................................... |
12 |
INSTALLATION .................................................. |
12 |
POSITION SWITCH ................................................. |
13 |
Checking ............................................................... |
13 |
BACK-UP LAMP SWITCH ................................. |
13 |
PARK/NEUTRAL POSITION SWITCH .............. |
13 |
CONTROL LINKAGE .............................................. |
14 |
Components of Control Device and Cable ............ |
14 |
Removal and Installation ....................................... |
15 |
AIR BREATHER HOSE ........................................... |
16 |
Removal and Installation ....................................... |
16 |
TRANSAXLE ASSEMBLY ....................................... |
17 |
Removal and Installation ....................................... |
17 |
REMOVAL .......................................................... |
17 |
INSTALLATION .................................................. |
18 |
Component Parts (RS5F51A) ............................... |
19 |
CASE AND HOUSING COMPONENTS ............. |
19 |
GEAR COMPONENTS ...................................... |
20 |
SHIFT CONTROL COMPONENTS .................... |
22 |
FINAL DRIVE COMPONENTS .......................... |
23 |
Component Parts (RS6F51A) ................................ |
24 |
CASE AND HOUSING COMPONENTS ............. |
24 |
GEAR COMPONENTS ...................................... |
25 |
SHIFT CONTROL COMPONENTS .................... |
27 |
FINAL DRIVE COMPONENTS .......................... |
28 |
Disassembly and Assembly (RS5F51A) ................ |
28 |
DISASSEMBLY .................................................. |
28 |
ASSEMBLY ........................................................ |
32 |
Disassembly and Assembly (RS6F51A) ................ |
37 |
DISASSEMBLY .................................................. |
37 |
ASSEMBLY ........................................................ |
41 |
Adjustment (RS5F51A) .......................................... |
47 |
INPUT SHAFT END PLAY ................................. |
47 |
MAINSHAFT END PLAY .................................... |
48 |
DIFFERENTIAL SIDE BEARING PRELOAD ..... |
48 |
REVERSE IDLER GEAR END PLAY ................. |
49 |
Adjustment (RS6F51A) .......................................... |
50 |
INPUT SHAFT END PLAY ................................. |
50 |
MAINSHAFT END PLAY .................................... |
51 |
DIFFERENTIAL SIDE BEARING PRELOAD ..... |
52 |
REVERSE IDLER GEAR END PLAY ................. |
53 |
INPUT SHAFT AND GEARS ................................... |
54 |
Assembly and Disassembly (RS5F51A) ................ |
54 |
DISASSEMBLY .................................................. |
54 |
INSPECTION AFTER DISASSEMBLY ............... |
55 |
ASSEMBLY ........................................................ |
57 |
Assembly and Disassembly (RS6F51A) ................ |
61 |
DISASSEMBLY .................................................. |
61 |
INSPECTION AFTER DISASSEMBLY ............... |
62 |
ASSEMBLY ........................................................ |
64 |
MAINSHAFT AND GEARS ...................................... |
68 |
Assembly and Disassembly (RS5F51A) ................ |
68 |
DISASSEMBLY .................................................. |
68 |
INSPECTION AFTER DISASSEMBLY ............... |
69 |
F
G
H
I
J
K
L
M
MT-1
ASSEMBLY ......................................................... |
72 |
Assembly and Disassembly (RS6F51A) ................ |
76 |
DISASSEMBLY .................................................. |
76 |
INSPECTION AFTER DISASSEMBLY ............... |
77 |
ASSEMBLY ......................................................... |
80 |
REVERSE IDLER SHAFT AND GEARS ................. |
85 |
Assembly and Disassembly (RS5F51A) ................ |
85 |
DISASSEMBLY .................................................. |
85 |
INSPECTION AFTER DISASSEMBLY ............... |
85 |
ASSEMBLY ......................................................... |
86 |
Assembly and Disassembly (RS6F51A) ................ |
86 |
DISASSEMBLY .................................................. |
86 |
INSPECTION AFTER DISASSEMBLY ............... |
87 |
ASSEMBLY ......................................................... |
87 |
FINAL DRIVE ........................................................... |
89 |
Assembly and Disassembly (RS5F51A) ................ |
89 |
PRE-INSPECTION ............................................. |
89 |
DISASSEMBLY .................................................. |
89 |
INSPECTION AFTER DISASSEMBLY ............... |
90 |
ASSEMBLY ......................................................... |
90 |
Assembly and Disassembly (RS6F51A) ................ |
92 |
PRE-INSPECTION ............................................. |
92 |
DISASSEMBLY .................................................. |
92 |
INSPECTION AFTER DISASSEMBLY ............... |
93 |
ASSEMBLY ......................................................... |
94 |
SHIFT CONTROL ..................................................... |
96 |
Inspection (RS5F51A) ........................................... |
96 |
SHIFT FORK ...................................................... |
96 |
Inspection (RS6F51A) ........................................... |
97 |
SHIFT FORK ...................................................... |
97 |
SERVICE DATA AND SPECIFICATIONS (SDS) .....98 |
|
General Specifications ........................................... |
98 |
TRANSAXLE ....................................................... |
98 |
FINAL GEAR ....................................................... |
99 |
End Play ................................................................. |
99 |
Baulk Ring Clearance ............................................. |
99 |
Available Snap Rings ........................................... |
100 |
INPUT SHAFT BEARING SPACER .................. |
100 |
6TH INPUT GEAR BUSHING ........................... |
100 |
5TH MAIN GEAR .............................................. |
100 |
Available C-Rings ................................................ |
100 |
MAINSHAFT C-RING ....................................... |
100 |
Available Thrust Washer ...................................... |
101 |
INPUT SHAFT THRUST WASHER .................. |
101 |
DIFFERENTIALSIDEGEARTHRUSTWASHER |
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|
.101 |
Available Adjusting Shims .................................... |
101 |
4TH MAIN GEAR ADJUSTING SHIM ............... |
101 |
INPUT SHAFT REAR BEARING ADJUSTING |
|
SHIM ................................................................. |
102 |
MAINSHAFT REAR BEARING ADJUSTING |
|
SHIM ................................................................. |
102 |
REVERSE IDLER GEAR ADJUSTING SHIM ... |
102 |
6TH MAIN GEAR ADJUSTING SHIM ............... |
102 |
Available Shims ................................................... |
103 |
BEARING PRELOAD ........................................ |
103 |
DIFFERENTIAL SIDE BEARING ADJUSTING |
|
SHIM(S) ............................................................ |
103 |
MT-2
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PRECAUTIONS |
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PRECAUTIONS |
PFP:00001 |
Caution |
ECS008BM |
● Do not reuse transaxle oil, once it has been drained.
● Check oil level or replace oil with vehicle on level ground.
● During removal or installation, keep inside of transaxle clear of dust or dirt.
● Check for the correct installation status prior to removal or disassembly. If mating marks are required, be certain they do not interfere with the function of the parts they are applied to.
● In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tightening sequence is specified, observe it.
● Be careful not to damage sliding surfaces and mating surfaces.
A
B
MT
D
E
F
G
H
I
J
K
L
M
MT-3
PREPARATION
PREPARATION
Special Service Tools
PFP:00002
ECS008BN
Tool number |
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Description |
Tool name |
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KV381054S0 |
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● Differential side bearing outer race removal |
Puller |
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● Mainshaft front bearing removal |
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ZZA0601D |
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ST35321000 |
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● Input shaft oil seal installation |
Drift |
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● Reverse main gear installation |
a: 49 mm (1.93 in) dia. |
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● 1st main gear bushing installation |
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b: 41 mm (1.61 in) dia. |
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● 1st-2nd synchronizer hub assembly |
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installation |
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● 2nd main gear bushing installation |
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● 3rd main gear installation |
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ZZA1000D |
● Differential side bearing (clutch housing |
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side) removal |
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ST30720000 |
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● Differential oil seal installation |
Drift |
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● Differential side bearing outer race |
a: 77 mm (3.03 in) dia. |
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installation |
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b: 55.5 mm (2.185 in) dia. |
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● Mainshaft rear bearing installation |
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● Differential side bearing installation |
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ZZA0811D |
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ST33200000 |
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● Mainshaft front bearing installation |
Drift |
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● 6th input gear bushing installation |
a: 60 mm (2.36 in) dia. |
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(RS6F51A) |
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b: 44.5 mm (1.752 in) dia. |
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● 4th main gear installation |
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● 5th main gear installation |
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ZZA1002D |
● 6th main gear installation (RS6F51A) |
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KV40105320 |
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Differential side bearing outer race installation |
Drift |
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a: 88 mm (3.46 in) dia. |
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ZZA0898D |
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ST33061000 |
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● Bore plug installation |
Drift |
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● Differential side bearing (transaxle case |
a: 38 mm (1.50 in) dia. |
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side) removal |
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b: 28.5 mm (1.122 in) dia. |
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ZZA1000D |
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MT-4
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PREPARATION |
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Tool number |
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Description |
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Tool name |
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ST33052000 |
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● Welch plug installation |
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Drift |
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● Input shaft rear bearing removal |
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a: 22 mm (0.87 in) dia. |
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● Input shaft bearing spacer and 5th stopper |
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b: 28 mm (1.10 in) dia. |
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removal (RS5F51A) |
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● 5th input gear bushing, thrust washer, 4th |
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input gear, 4th gear bushing, 3rd-4th |
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synchronizer hub assembly and 3rd input |
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gear removal |
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● Input shaft front bearing installation |
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ZZA1023D |
● 6th input gear and 6th input gear bushing |
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removal (RS6F51A) |
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● Mainshaft rear bearing removal |
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● 4th main gear and 5th main gear removal |
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● 6th main gear removal (RS6F51A) |
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KV40105020 |
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● 5th input gear and 5th synchronizer hub |
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Drift |
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assembly removal |
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a: 39.7 mm (1.563 in) dia. |
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● 3rd main gear, 2nd main gear, 2nd main |
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b: 35 mm (1.38 in) dia. |
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gear bushing, 1st-2nd synchronizer hub |
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c: 15 mm (0.59 in) |
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assembly, 1st main gear, reverse main gear |
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and 1st main gear bushing removal |
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ZZA1133D |
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KV40105710 |
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● 3rd-4th synchronizer hub assembly |
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Press stand |
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installation |
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a: 46 mm (1.81 in) dia. |
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● 4th input gear bushing installation |
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b: 41 mm (1.61 in) |
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● 5th input gear bushing installation |
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● 5th synchronizer hub assembly installation |
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(RS5F51A) |
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● 5th-6th synchronizer hub assembly |
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ZZA1058D |
installation (RS6F51A) |
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● 2nd main gear bushing installation |
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● 3rd main gear installation |
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ST38220000 |
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● Reverse main gear installation |
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Press stand |
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● 1st main gear bushing installation |
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a: 63 mm (2.48 in) dia. |
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● 1st-2nd synchronizer hub assembly |
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b: 65 mm (2.56 in) |
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installation |
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ZZA1058D |
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ST30032000 |
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● 5th stopper and input shaft bearing spacer |
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Drift |
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installation (RS5F51A) |
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a: 80 mm (3.15 in) dia. |
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● Input shaft front bearing installation |
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b: 38 mm (1.50 in) dia. |
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c: 31 mm (1.22 in) dia. |
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ZZA0978D |
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ST30901000 |
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● Input shaft rear bearing installation |
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Drift |
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● 4th main gear installation |
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a: 79 mm (3.11 in) dia. |
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● 5th main gear installation |
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b: 45 mm (1.77 in) dia. |
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c: 35.2 mm (1.386 in) dia. |
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● 6th main gear installation (RS6F51A) |
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● Mainshaft rear bearing installation |
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ZZA0978D |
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A
B
MT
D
E
F
G
H
I
J
K
L
M
MT-5
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PREPARATION |
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Tool number |
Description |
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Tool name |
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ST30031000 |
Measuring wear of inner baulk ring |
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Puller |
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ZZA0537D |
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KV40101630 |
Reverse main gear installation |
Drift |
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a:68 mm (2.68 in) dia.
b:60 mm (2.36 in) dia.
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ZZA1003D |
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KV38102510 |
● 1st main gear bushing installation |
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Drift |
● 1st-2nd synchronizer hub assembly |
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a: 71 mm (2.80 in) dia. |
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installation |
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b: 65 mm (2.56 in) dia. |
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● Differential side bearing (transaxle case |
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side) installation |
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ZZA0838D |
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KV40104830 |
Differential side bearing (clutch housing side) |
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Drift |
installation |
a:70 mm (2.76 in) dia.
b:63.5 mm (2.500 in) dia.
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ZZA0936D |
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ST15243000 |
Measuring end play of side gear |
Drift |
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a: φ 30mm |
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SCIA1088J |
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Commercial Service Tools |
ECS008BO |
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Tool name |
Description |
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Puller |
Each bearing, gear and bushing removal |
ZZA0537D
MT-6
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PREPARATION |
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Tool name |
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Description |
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A |
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Puller |
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Each bearing, gear and bushing removal |
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B |
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NT077 |
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MT |
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Pin punch |
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Each retaining pin removal and installation |
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Tip diameter: 4.5 mm (0.177 in) dia. |
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D |
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E |
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ZZA0815D |
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F |
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G |
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K |
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L |
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M |
MT-7
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
PFP:00003
ECS008BP
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.
MANUAL TRANSAXLE
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(RS6F51A) |
(RS6F51A) |
(RS6F51A) |
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(RS6F51A) |
(RS6F51A) |
(RS6F51A) |
(RS6F51A) |
(RS6F51A) |
(RS6F51A) |
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-MA37 |
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(RS5F51A),MT-24 |
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(RS5F51A),MT-24 |
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(RS5F51A),MT-24 |
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(RS5F51A),MT-27 |
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(RS5F51A),MT-27 |
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(RS5F51A),MT-25 |
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(RS5F51A),MT-25 |
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(RS5F51A),MT-25 |
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(RS5F51A),MT-25 |
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Reference page |
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-MT14 |
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MT-19 |
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MT-19 |
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MT-19 |
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MT-22 |
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MT-22 |
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MT-20 |
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MT-20 |
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MT-20 |
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MT-20 |
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CHECK BALL (Worn or damaged) |
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SUSPECTED PARTS |
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CHECK PLUG RETURN SPRING AND |
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(Possible cause) |
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SHIFT CONTROL LINKAGE (Worn) |
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OIL (Oil level is low.) |
OIL (Wrong oil.) |
OIL (Oil level is high.) |
GASKET (Damaged) |
OIL SEAL (Worn or damaged) |
O-RING (Worn or damaged) |
SHIFT FORK (Worn) |
GEAR (Worn or damaged) |
BEARING (Worn or damaged) |
BAULK RING (Worn or damaged) |
INSERT SPRING (Damaged) |
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Noise |
1 |
2 |
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3 |
3 |
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Symptoms |
Oil leakage |
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3 |
1 |
2 |
2 |
2 |
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Hard to shift or will not shift |
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1 |
1 |
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2 |
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3 |
3 |
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Jumps out of gear |
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MT-8
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DESCRIPTION |
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DESCRIPTION |
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PFP:00000 |
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A |
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Cross-Sectional View |
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ECS008BQ |
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B |
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MT |
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D |
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E |
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F |
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I |
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K |
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L |
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PCIB0773E |
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M |
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1. |
3rd input gear |
2. |
3rd-4th synchronizer hub |
3. |
3rd-4th coupling sleeve |
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4. |
4th input gear |
5. |
5th input gear |
6. |
5th synchronizer hub |
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7. |
5th coupling sleeve |
8. |
Input shaft rear bearing |
9. |
Mainshaft rear bearing |
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10. |
5th main gear |
11. |
4th main gear |
12. |
3rd main gear |
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13. |
2nd main gear |
14. |
1st-2nd coupling sleeve |
15. |
1st-2nd synchronizer hub |
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16. |
1st main gear |
17. |
Reverse main gear |
18. |
Differential side bearing |
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19. |
Differential case |
20. |
Final gear |
21. |
Differential side bearing |
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22. |
Mainshaft front bearing |
23. |
Mainshaft |
24. |
Input shaft |
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25. |
Input shaft front bearing |
26. |
Clutch housing |
27. |
Reverse idler shaft |
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28. |
Reverse idler gear (Front) |
29. |
Reverse coupling sleeve |
30. |
Reverse synchronizer hub |
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31. |
Reverse idler gear (Rear) |
32. |
5th input gear |
33. |
5th-6th synchronizer hub |
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34. |
5th-6th coupling sleeve |
35. |
6th input gear |
36. |
Input shaft rear bearing |
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37. |
Mainshaft rear bearing |
38. |
5th main gear |
39. |
6th main gear |
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MT-9
DESCRIPTION
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 1st gear to reduce operating force of the shift lever.
TRIPLE-CONE SYNCHRONIZER
Triple-cone synchronizer is adopted for 2nd gear to reduce operating force of the shift lever.
PCIB0774E
REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)
Reverse gear can be matched smoothly in a structure by setting synchronizer hub, coupling sleeve, baulk ring and insert spring to reverse gear, and letting reverse gear be synchronized.
PCIB0775E
MT-10
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M/T OIL |
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M/T OIL |
PFP:KLD20 |
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Changing M/T Oil |
ECS008BR |
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DRAINING |
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1. |
Start engine and let it run to warm up transaxle. |
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2. |
Stop engine. Remove drain plug and drain oil. |
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3. |
Set a new gasket on drain plug and install it to transaxle. Refer to MT-19, "CASE AND HOUSING COM- |
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PONENTS" , MT-24, "CASE AND HOUSING COMPONENTS" . |
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CAUTION:
Do not reuse gasket.
FILLING
1.Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole.
Oil grade |
: API GL-4 |
Oil capacity (reference) |
: Approx. 2.3 (4 lmp pt) |
2.After refilling oil, check oil level. Assemble a new gasket to filler plug, then install it to transaxle. Refer to
MT-19, "CASE AND HOUSING COMPONENTS" , MT-24, "CASE AND HOUSING COMPONENTS" .
CAUTION:
Do not reuse gasket.
Checking M/T Oil |
ECS008BS |
OIL LEAKAGE AND OIL LEVEL
●Check that oil is not leaking from transaxle or around it.
●Check oil level from filler plug mounting hole as shown in the figure.
CAUTION:
Never start engine while checking oil level.
●Set a new gasket on filler plug and install it on transaxle. Refer to MT-19, "CASE AND HOUSING COMPONENTS" , MT-24, "CASE AND HOUSING COMPONENTS" .
CAUTION:
Do not reuse gasket.
SCIA0361E
A
B
MT
D
E
F
G
H
I
J
K
L
M
MT-11
SIDE OIL SEAL
SIDE OIL SEAL
Removal and Installation
REMOVAL
PFP:32113
ECS008BT
●Clutch housing side oil seal used on 4WD vehicles is attached to transfer. Be sure to replace it when transfer is removed.
1.Remove drive shaft from transaxle. Refer to FAX-11, "Removal and Installation" .
2.Remove oil seal with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage the case surface when removing oil seal.
SCIA0824E
INSTALLATION
1.Using a drift, drive the oil seal straight until it protrudes from the case end equal to dimension A shown in the figure.
Dimension "A":
Within 0.5 mm (0.020 in) of flush with the case.
Drift to be used: |
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Transaxle case side: |
ST30720000 |
Clutch housing side: |
ST30720000 |
CAUTION:
● When installing oil seals, apply multi-purpose grease to SCIA0352E oil seal lips.
● Oil seals are not reusable. Never reuse them.
2.Install all parts in reverse order of removal and check oil level after installation. Refer to MT-11, "Checking M/T Oil" .
MT-12
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POSITION SWITCH |
POSITION SWITCH |
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Checking |
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BACK-UP LAMP SWITCH |
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● Check continuity. |
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Gear position |
Continuity |
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Reverse |
Yes |
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Except reverse |
No |
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PARK/NEUTRAL POSITION SWITCH
● Check continuity.
Gear position |
Continuity |
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Neutral |
Yes |
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Except neutral |
No |
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PFP:32005
A
ECS008BU
B
MT
D
SCIA0708E E
F
G
H
I
J
K
L
M
MT-13
CONTROL LINKAGE
CONTROL LINKAGE
Components of Control Device and Cable
PFP:34103
ECS008BV
PCIB0777E
1. |
Control lever knob |
2. |
Select cable |
3. |
Shift cable |
4. |
Lock plate |
5. |
Lock plate |
6. |
Clutch housing |
7. |
Cable mounting bracket |
8. |
Control device assembly |
9. |
Control lever |
10. |
Lock plate |
11. |
Washer |
12. |
Snap pin |
13. |
Washer |
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MT-14
CONTROL LINKAGE
Removal and Installation |
ECS00CY6 |
CAUTION:
●Keep in mind that the select side lock plate for securing control cable is different from the one on the shift side.
●After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st, 2nd, or Reverse.
●Shift control lever to the neutral position for removal.
Install select cable according to the following procedure.
1.Install select cable of transaxle side to control assembly.
2.Install select cable to pin on select lever part of control device assembly.
PCIB0815E
3.Push lock part (A) of select cable all the way to the direction of the arrow. (6 M/T model only)
4.Slide stopper part (B) all the way to lock part (A) as shown by the arrow. (6 M/T model only)
CAUTION:
Make sure that select cable and select lever are installed securely.
PCIB0817E
A
B
MT
D
E
F
G
H
I
J
K
L
M
MT-15
AIR BREATHER HOSE |
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AIR BREATHER HOSE |
PFP:31098 |
Removal and Installation |
ECS008BW |
Refer to the figure for air breather hose removal and installation information. |
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QR engine model |
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PCIB0778E
1. |
Air cleaner case |
2. |
Transaxle |
3. |
Clip |
4. |
Air breather hose |
5. |
Clip |
6. |
PCV hose |
7.Resonator
YD engine model
PCIB0779E
1. |
Air cleaner case |
2. |
Transaxle |
3. |
Clip |
4. |
Clip |
5. |
Air breather hose |
6. |
Clip |
7. |
Bracket |
8. |
Mass air flow sensor |
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CAUTION:
●Make sure there are no pinched or restricted areas on air breather hose caused by bending or winding when installing it.
●Be sure to insert hose into transaxle tube until overlap area reaches the spool.
MT-16
TRANSAXLE ASSEMBLY
TRANSAXLE ASSEMBLY
Removal and Installation
PFP:32010
A
ECS008BX
B
MT
D
E
F
G
H
I
PCIB0780E
1. |
Center member |
2. |
Insulator assembly |
3. |
Grommet |
J |
4. |
Transaxle |
5. |
Rear engine mounting bracket |
6. |
Rear engine mounting insulator |
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7. |
Stopper rubber (YD engine model) |
8. |
Stopper |
9. |
LH engine mounting insulator |
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10. |
LH engine mounting bracket |
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K |
REMOVAL
1.Remove air cleaner, air duct, and battery. Refer to EM-15, "Removal and Installation" ,EM-133, "Removal
and Installation"
2.Remove air breather hose. Refer to MT-16, "Removal and Installation" .
3.Remove clutch operating cylinder. Refer to CL-10, "Removal and Installation" .
CAUTION:
Do not depress clutch pedal during removal procedure.
4.Disconnect control cable from transaxle. Refer to MT-15, "Removal and Installation" .
5.Drain gear oil from transaxle. Refer to MT-11, "DRAINING" .
6.Disconnect park/neutral position switch, back-up lamp switch, and ground harness connectors.
7.Remove exhaust front tube and the drive shaft. Refer to EX-2, "Removal and Installation" .
8.Remove transfer. Refer to TF-55, "Removal and Installation" .
9.Remove starter motor. Refer to SC-25, "Removal and Installation" .
10.Place a jack onto transaxle.
CAUTION:
When setting jack, be careful not to bring it into contact with switch.
11.Remove center member, engine insulator and engine mount bracket. Refer to EM-78, "ENGINE ASSEMBLY" (QR engine model) or EM-208, "ENGINE ASSEMBLY" (YD engine model).
12.Remove suspension members. Refer to FSU-12, "FRONT SUSPENSION MEMBER" .
13.Support engine by placing a jack under oil pan.
L
M
MT-17
TRANSAXLE ASSEMBLY
14.Remove bolts securing transaxle to engine.
15.Remove transaxle from vehicle.
MTD0062D
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
●When installing transaxle to engine, tighten bolts to the specified torque.
CAUTION:
When installing transaxle, be careful not to bring transaxle input shaft into contact with clutch cover.
QR engine model:
Bolt No. |
1 |
2 |
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3 |
4 |
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5 |
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6 |
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Quantity |
2 |
1 |
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1 |
2 |
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2 |
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2 |
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“ |
” mm (in) |
40 |
75 |
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45 |
40 |
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30 |
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40 |
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(1.57) |
(2.95) |
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(1.77) |
(1.57) |
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(1.18) |
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(1.57) |
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Tightening torque |
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74.5 |
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42.7 |
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35.3 |
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N·m (kg - m, ftlb) |
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(7.6, 55) |
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(4.4, 31) |
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(3.6, 26 ) |
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SCIA0353E |
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YD engine model: |
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Bolt No. |
1 |
2 |
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3 |
4 |
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5 |
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6 |
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Quantity |
2 |
2 |
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1 |
1 |
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3 |
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1 |
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“ |
” mm (in) |
55 |
50 |
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120 |
45 |
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40 |
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35 |
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(2.17) |
(2.76) |
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(4.72) |
(1.77) |
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(1.57) |
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(1.38) |
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Tightening torque |
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44 |
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33.5 |
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N·m (kg - m, ftlb) |
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(4.5, 32) |
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(3.4, 25) |
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● After installation, check oil level, and check for leaks and loose |
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mechanisms. Refer to MT-11, "Checking M/T Oil" . |
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SCIA0748E |
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MT-18
TRANSAXLE ASSEMBLY
Component Parts (RS5F51A) |
ECS008BY |
CASE AND HOUSING COMPONENTS |
A |
B
MT
D
E
F
G
H
I
J
K
L
M
PCIB0781E
1. |
Clutch housing |
2. |
Differential oil seal |
3. |
Ball pin |
4. |
Washer |
5. |
Input shaft oil seal |
6. |
Oil channel |
7. |
Magnet |
8. |
Back-up lamp switch |
9. |
Oil gutter |
10. |
Baffle plate |
11. |
Transaxle case |
12. |
Filler plug |
13. |
Gasket |
14. |
Welch plug |
15. |
Bore plug |
16. |
Drain plug |
17. |
Differential oil seal |
18. |
Park/Neutral position switch |
19. |
Air breather tube |
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MT-19
TRANSAXLE ASSEMBLY
GEAR COMPONENTS
PCIB0782E
1. |
Input shaft front bearing |
2. |
Input shaft |
3. |
3rd needle bearing |
4. |
3rd input gear |
5. |
3rd baulk ring |
6. |
3rd-4th spread spring |
7. |
3rd-4th shifting insert |
8. |
3rd-4th synchronizer hub |
9. |
4th baulk ring |
10. |
3rd-4th coupling sleeve |
11. |
4th input gear bushing |
12. |
4th needle bearing |
13. |
4th input gear |
14. |
Thrust washer |
15. |
5th input gear bushing |
16. |
5th needle bearing |
17. |
5th input gear |
18. |
5th baulk ring |
19. |
5th spread spring |
20. |
5th shifting insert |
21. |
5th synchronizer hub |
22. |
5th coupling sleeve |
23. |
5th stopper |
24. |
Input shaft bearing spacer |
25. |
Snap ring |
26. |
Input shaft rear bearing |
27. |
Oil channel |
28. |
Input shaft rear bearing adjusting |
29. |
Retaining pin |
30. |
Reverse idler shaft |
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shim |
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31. |
Thrust needle bearing |
32. |
Reverse idler gear needle bearing |
33. |
Reverse insert spring |
34. |
Reverse idler gear (Front) |
35. |
Reverse baulk ring |
36. |
Reverse coupling sleeve |
37. |
Reverse idler gear (Rear) |
38. |
Reverse idler gear adjusting shim |
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MT-20
TRANSAXLE ASSEMBLY
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A |
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B |
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MT |
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D |
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E |
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F |
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G |
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H |
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I |
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PCIB0783E |
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J |
1. |
Mainshaft front bearing |
2. |
Mainshaft bearing retainer |
3. |
Mainshaft |
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4. |
Reverse main gear |
5. |
1st main gear |
6. |
1st main gear bushing |
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7. |
1st needle bearing |
8. |
1st inner baulk ring |
9. |
1st gear synchronizer cone |
K |
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10. |
1st outer baulk ring |
11. |
1st-2nd spread spring |
12. |
1st-2nd shifting insert |
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13. |
1st-2nd synchronizer hub |
14. |
2nd outer baulk ring |
15. |
2nd gear synchronizer cone |
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16. |
2nd inner baulk ring |
17. |
1st-2nd coupling sleeve |
18. |
2nd main gear bushing |
L |
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19. |
2nd needle bearing |
20. |
2nd main gear |
21. |
3rd main gear |
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22. |
3rd-4th mainshaft spacer |
23. |
4th main gear adjusting shim |
24. |
4th main gear |
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25. |
5th main gear |
26. |
Snap ring |
27. |
Mainshaft rear bearing |
M |
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28. |
Mainshaft C-ring |
29. |
C-ring holder |
30. |
Snap ring |
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31. |
Snap ring |
32. |
Mainshaft rear bearing adjusting shim |
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MT-21
TRANSAXLE ASSEMBLY
SHIFT CONTROL COMPONENTS
PCIB0784E
1. |
3rd-4th bracket |
2. |
Retaining pin |
3. |
Stopper ring |
4. |
5th-reverse bracket |
5. |
Reverse lever assembly |
6. |
Shifter cap |
7. |
Reverse shift fork |
8. |
Reverse fork rod |
9. |
Check plug |
10. |
Check spring |
11. |
Shift check sleeve |
12. |
Check ball |
13. |
5th-reverse fork rod |
14. |
5th shift fork |
15. |
Check spring |
16. |
3rd-4th fork rod |
17. |
Interlock pin |
18. |
Shift check sleeve |
19. |
1st-2nd fork rod |
20. |
1st-2nd bracket |
21. |
1st-2nd shift fork |
22. |
3rd-4th shift fork |
23. |
Control assembly |
24. |
Stopper bolt |
25. |
Shift check |
26. |
O-ring |
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MT-22
TRANSAXLE ASSEMBLY
FINAL DRIVE COMPONENTS
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PCIB0785E |
1. |
Differential side bearing outer race |
2. |
Differential side bearing (clutch |
3. |
Differential case |
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housing side) |
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4. |
Final gear |
5. |
Differential side bearing (transaxle |
6. |
Differential side bearing outer race |
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case side) |
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7. |
Differential side bearing adjusting |
8. |
Side gear |
9. |
Side gear thrust washer |
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shim |
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10. |
Retaining pin |
11. |
Pinion mate thrust washer |
12. |
Pinion mate gear |
13. |
Pinion mate shaft |
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A
B
MT
D
E
F
G
H
I
J
K
L
M
MT-23
TRANSAXLE ASSEMBLY
Component Parts (RS6F51A) |
ECS008BZ |
CASE AND HOUSING COMPONENTS
PCIB0781E
1. |
Clutch housing |
2. |
Differential oil seal |
3. |
Ball pin |
4. |
Washer |
5. |
Input shaft oil seal |
6. |
Oil channel |
7. |
Magnet |
8. |
Back-up lamp switch |
9. |
Oil gutter |
10. |
Baffle plate |
11. |
Transaxle case |
12. |
Filler plug |
13. |
Gasket |
14. |
Welch plug |
15. |
Bore plug |
16. |
Drain plug |
17. |
Differential oil seal |
18. |
Park/Neutral position switch |
19. |
Air breather tube |
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MT-24
TRANSAXLE ASSEMBLY
GEAR COMPONENTS
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B |
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MT |
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D |
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E |
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F |
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G |
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H |
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I |
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J |
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PCIB0786E |
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1. |
Input shaft front bearing |
2. |
Input shaft |
3. |
3rd needle bearing |
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4. |
3rd input gear |
5. |
3rd baulk ring |
6. |
3rd-4th spread spring |
K |
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7. |
3rd-4th shifting insert |
8. |
3rd-4th synchronizer hub |
9. |
4th baulk ring |
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10. |
3rd-4th coupling sleeve |
11. |
4th input gear bushing |
12. |
4th needle bearing |
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13. |
4th input gear |
14. |
Thrust washer |
15. |
5th input gear bushing |
L |
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16. |
5th needle bearing |
17. |
5th input gear |
18. |
5th baulk ring |
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19. |
5th-6th spread spring |
20. |
5th-6th shifting insert |
21. |
5th-6th synchronizer hub |
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22. |
5th-6th coupling sleeve |
23. |
6th baulk ring |
24. |
6th input gear |
M |
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25. |
6th needle bearing |
26. |
6th input gear bushing |
27. |
Snap ring |
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28. |
Input shaft rear bearing |
29. |
Oil channel |
30. |
Input shaft rear bearing adjusting |
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shim |
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31. |
Retaining pin |
32. |
Reverse idler shaft |
33. |
Thrust needle bearing |
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34. |
Reverse idler gear needle bearing |
35. |
Reverse insert spring |
36. |
Reverse idler gear (Front) |
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37. |
Reverse balk ring |
38. |
Reverse coupling sleeve |
39. |
Reverse idler gear (Rear) |
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40. |
Reverse idler gear adjusting shim |
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MT-25
TRANSAXLE ASSEMBLY
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PCIB0787E |
1. |
Mainshaft front bearing |
2. |
Mainshaft bearing retainer |
3. |
Mainshaft |
4. |
Reverse main gear |
5. |
1st main gear |
6. |
1st main gear bushing |
7. |
1st needle bearing |
8. |
1st inner baulk ring |
9. |
1st gear synchronizer cone |
10. |
1st outer baulk ring |
11. |
1st-2nd spread spring |
12. |
1st-2nd shifting insert |
13. |
1st-2nd synchronizer hub |
14. |
2nd outer baulk ring |
15. |
2nd gear synchronizer cone |
16. |
2nd inner baulk ring |
17. |
1st-2nd coupling sleeve |
18. |
2nd main gear bushing |
19. |
2nd needle bearing |
20. |
2nd main gear |
21. |
3rd main gear |
22. |
3rd-4th mainshaft spacer |
23. |
4th main adjusting shim |
24. |
4th main gear |
25. |
5th main gear |
26. |
6th main gear |
27. |
Mainshaft rear bearing |
28. |
Mainshaft C-ring |
29. |
C-ring holder |
30. |
Snap ring |
31. |
Snap ring |
32. |
Mainshaft rear bearing adjusting shim |
33. |
5th-6th mainshaft spacer |
34. |
6th main adjusting shim |
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MT-26
TRANSAXLE ASSEMBLY
SHIFT CONTROL COMPONENTS
A
B
MT
D
E
F
G
H
I
J
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PCIB0788E |
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1. |
3rd-4th bracket |
2. |
Retaining pin |
3. |
Check plug |
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4. |
5th-6th bracket |
5. |
Stopper ring |
6. |
Reverse bracket |
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K |
7. |
Reverse lever assembly |
8. |
Shifter cap |
9. |
Reverse shift fork |
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10. |
Reverse fork rod |
11. |
Check spring |
12. |
Shift check sleeve |
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13. |
Check ball |
14. |
Reverse bracket fork rod |
15. |
5th-6th shift fork |
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L |
16. |
5th-6th fork rod |
17. |
Interlock pin |
18. |
Shift check sleeve |
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19. |
Check spring |
20. |
Check spring |
21. |
3rd-4th fork rod |
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22. |
3rd-4th shift fork |
23. |
1st-2nd fork rod |
24. |
1st-2nd fork rod bracket |
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M |
25. |
1st-2nd shift fork |
26. |
Stopper bolt |
27. |
Shift check |
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28. |
O-ring |
29. |
Control assembly |
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MT-27
TRANSAXLE ASSEMBLY
FINAL DRIVE COMPONENTS
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PCIB0785E |
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1. |
Differential side bearing outer race |
2. |
Differential side bearing (clutch |
3. |
Differential case |
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housing side) |
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4. |
Final gear |
5. |
Differential side bearing (transaxle |
6. |
Differential side bearing outer race |
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case side) |
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7. |
Differential side bearing adjusting shim |
8. |
Side gear |
9. |
Side gear thrust washer |
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10. |
Retaining pin |
11. |
Pinion mate thrust washer |
12. |
Pinion mate gear |
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13. |
Pinion mate shaft |
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Disassembly and Assembly (RS5F51A) |
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ECS008C0 |
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DISASSEMBLY
1.Remove drain plug and filler plug from transaxle case.
2.Remove park/neutral position switch and back-up lamp switch from transaxle case.
3.Remove shift check and stopper bolt from transaxle case, and then remove control assembly from transaxle case.
SCIA0389E
MT-28
TRANSAXLE ASSEMBLY
4.Remove check plugs (3 pieces), check springs (3 pieces), check balls (3 pieces) and shift check sleeve (1 piece) from transaxle case.
5.Remove transaxle case mounting bolts.
6.Remove bore plug from transaxle case.
CAUTION:
Be careful not to damage transaxle case.
7.While spreading the snap ring of mainshaft rear bearing located at bore plug hole, remove transaxle case from clutch housing.
8.Remove oil gutter, baffle plate from transaxle case.
9.Remove snap ring, mainshaft rear bearing adjusting shim and input shaft rear bearing adjusting shim from transaxle case.
10.Remove differential side bearing outer race (transaxle case side) from transaxle case using the puller, and then remove differential side bearing adjusting shim from transaxle case.
11. Remove welch plug from transaxle case.
12.Remove differential oil seal (tansaxle case side) from transaxle case.
13.Remove magnet from clutch housing.
SCIA0396E
SCIA0983E
SCIA0897E
SCIA0402E
SCIA0397E
A
B
MT
D
E
F
G
H
I
J
K
L
M
MT-29
TRANSAXLE ASSEMBLY
14.With shift lever in 5th position, remove mounting bolts from reverse lever assembly. Lift reverse lever assembly to remove.
CAUTION:
Be careful not to lose shifter cap.
15.Pull out reverse fork rod then remove reverse shift fork.
SCIA0390E
16.Shift 3rd-4th fork rod to 3rd position. Remove retaining pin of 5th shift fork using a pin punch.
SCIA0391E
17.Remove stopper rings for 5th-reverse bracket.
18.Pull out 5th-reverse fork rod and remove 5th shift fork and 5threverse bracket.
19.Remove check balls (2 pieces) from clutch housing.
SCIA0392E
20.Remove retaining pin of 3rd-4th bracket using a pin punch.
21.Remove stopper rings for 3rd-4th shift fork.
22.Pull out 3rd-4th fork rod and remove 3rd-4th shift fork and 3rd4th bracket.
23.Remove interlock pin and shift check sleeve from clutch housing.
SCIA0393E
24.Remove retaining pin of 1st-2nd shift fork using a pin punch.
25.Pull out 1st-2nd fork rod with 1st-2nd bracket.
26.Remove 1st-2nd shift fork.
27.Remove retaining pin of 1st-2nd bracket using a pin punch and separate 1st-2nd fork rod and 1st-2nd bracket.
SCIA0394E
MT-30
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