MANUAL TRANSAXLE a) section MT 7 ea Lg CONTENTS 2 DISASSEMBLY... .2 REPAIR FOR COMPONENT PARTS. Input Shatt and Gears ... PREPARATION..... ‘Special Service Tools. Commercial Service Tools NOISE, VIBRATION AND HARSHNESS. wwe Mainshatt and Gears... ‘TROUBLESHOOTING. sens Final Drive NVH Troubleshooting Char... eee 5 Shift Control Components... ON-VEHICLE SERVICE .....osssnnnnnse 6 Case Components... Replacing Oil Seal 6 ADJUSTMENT. : Position Switch Che sou? Differential Side Bearing Prelcad .. REMOVAL AND INSTALLATION .8 ASSEMBLY. “9 SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications... TRANSAXLE GEAR CONTROL. MAJOR OVERHAUL. Case Components. Inspection and Adjustment. 38 Gear Components. BA Shift Control Components, RA BR T 5S BT a, a DKPREPARATION Special Service Tools ‘Tho actual shapes of Kent-Moore tools may difer from those of special service too's ilutrated here, Tool number (Kent Moore No) Deserpton Teo! name v20107700 = Measuring turing brave of tral dive 39027) si assembly Preload adapter 3B Soiecng afore side bearing auusting shim (Use with X¥V38106000) ror v98108000 Solocting aiforonta side boating saa) wD) ging shim (Us th KV38107700) Hoight gauge adaptor (corenal sido beeing) see xKvae101000 im Removing and netling retaining pin (025680.A) a Pin punch 4 rm (0.18 ‘sT22790000 Removing Sth man gear (28631) Puler 621mm 3.23) da 80m (1.18) a ‘730081000 Removing rd and ah syrctronizer (22912-01) ‘Measuring wear of znd & 3rd baulk ring Pater 0 mm (2.54 I) ca 0 mm (1.97 i) ela ‘sT30021000 . Removing 6th eynelonizor (G22912.01) . Puler 110mm (433 ny sia wan 8. (2.68 tn) ‘sT33290001 Removing diferent of sea! (434280) Remewng diferent side Dearing out Puter race i | ro] sa 250 mem (9.8410) Tata ms MT-2PREPARATION Special Service Tools (Cont'd) Tool number {Kenettoore No.) Deseraton Teo! name a Kvar100000 eam Tnstaling diferent of sea c-) 7 (Use wth $735325000 7 Dt z 2 A\ tie s = \a\\ 7 en sri08 Unit: mm Gr) '$795825000 Inetaling aferentl of see Le cy «5 (Use with k¥31103000.) Drit handle ae wrt me Kva8102100 ting ipa a ew Bwaing (02860201) Dat a: 4mm (1.79 In a, Towa ‘b: 24.5 mm (0.965 in) dia. We ‘sraez00000 Insaling manshaft front beaing io (26082) a rit 30 mm (2.96 in) dia. eR 0 bi: 445 mm (1,752 na, 's122950000 - Installing input shaft front bearing BA (J25678-01) a Drift = as 5 2: 34.mm (1-24 tn a, roe 2: 28 mim (110 in ai. aa x ‘sT20452000 ) Inetating 16 & and synetrenzer 1 oe—ae8 | a Installing 3rd & 4th synchronizer ett h- RS ve 5 65 mm (1.77 in) in T0668 (b: 36 mm (1.42 in) dia. a 137750000 oo Inetaling Sth main goar oe = pre xa ett aie Instating Sth synetron et ae Installing mainshaft rear bearing 1: 40 mm (1.57 In) da, a oes 31 mm (1.22 in) dia, ix MT-3PREPARATION Special Service Tools (Cont’d) Teo number (Kent Moore No} Description Teel name ‘STa0821000 : Trtaling cient! side bearing outer ce (as742-5) (Use wn ST20641000 ) bt a 79mm (241i) roa by: 58mm 92 ry a To0811000 (Use wit $720621000) (12574244) Daft anata 15 mm (059i) Teal raro Descrion Poter = Femoing inp shat ont bearing Removing manshat ear bestng srr at 7) Intling eiferena de baring nner race Oo w 56 mm (2.20 in) oa sees 505m (968i) et = Ttaling Sig 0d of eal wv 238 mm (180 9 aa. 6s 321mm (1.26) MT-4NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart Use the chart below to help you find the cause of the problem. The numbers indicate the order of the inspection. If necessary, repair or replace these parts. a MANUAL TRANSAXLE ¥ | a8, é & 2 Sle |s|Slele Retorenco page i z EVElE/EIElE 26 223 | a 3 5 5 5 a 2 3 | eee 3 (Possible cause) ae 2 -lf ra z 3 e/ 8 aT : 2} |e/8lele i | jelelele Blals/2lgle|elajelgya ™ z slels s]2/E)sl/els i al e/alé aisle : z F Eom 5/2/8/)3|% sl2/elzjalé 2/2/3)9)2 eye/8/3)3/2 5/55 |8ls |4/8|8|8)2 ap Nose ft Om ympiom |USaa0 ata] af af 2 ee Hard ooh or wil nt hit 1 2 a3 ums out of gear fa] 3[_ 3 imps out o gar a ST Ix MT-5ON-VEHICLE SERVICE Replacing Oil Seal DIFFERENTIAL OIL SEAL 1. Drain gear oil from transaxle. 2. Remove drive shafts. Refer to FA section (“Removal", “FRONT AXLE — Drive Shaft”). 3. Remove differential oil seal with Tool. ar sr sa290001 [| ss«zs0) s Install differential oil seal. Apply multi-purpose grease to seal lip of oil seal before installing. Install drive shafts. Refer to FA section (“Installation”, “FRONT AXLE — Drive Shaft"). ait at t0a000 ¢ — 9 o mm @2t ny Ps vg Leese Flight sie auariag STRIKING ROD OIL SEAL 1, Remove transaxle control rod from yoke. 2. Remove retaining pin. * Be careful not to damage boot. Kvaziorood 3, Remove striking rod oil seal. surraa] MT-6ON-VEHICLE SERVICE Replacing Oil Seal (Cont'd) 4. install striking rod ol! seal © Apply multi-purpose grease to seat tip of olf seal before Installing. al (aa, ad Position Switch Check ‘€) @ Check conti Et ‘i Seek cori lckeu amp ‘wich ‘Gear postion Gontnty wich hoes — - Backup lamp owtch - aus ‘xcept overee No ie Nesta ves Nout positon swtch . Excopt aout No MT?REMOVAL AND INSTALLATION Removal CAUTION: Before separating transaxle from engine, remove the crank- shaft position sensor (OBD) from transaxle. Be careful not to damage sensor edge or ring gear teeth. 1. Remove battery negative terminal. 2. Remove air cleaner housing. ae vehicle speed sensor and ground harness connectors. Remove starter motor from transaxle, Remove crankshaft position sensor (OBD) from transaxle. Be careful not to damage sensor tip. son 7. Remove shift control rod trom transaxle. 8 Drain gear oil from transaxle. 9. Remove drive shafts from transaxle. Refer to FA section (’Removal”, “FRONT AXLE — Drive Shatt’) 10. Support the transaxle with a jack 11. Remove LH and rear mounts. 12, Remove bolts securing transaxle. 13, Lower transaxle. Installation © Tighten starter motor to transaxle. (): 41 - 52 Nem (4.2 - 5.3 kg-m, 30 - 38 ft-lb) ‘* Tighfen LH and rear mounts to the specified torque. Refer to EM section (“ENGINE REMOVAL"). ‘* Install transaxle and any part removed. * Check olutch cable adjustment. Refer to CL section (“Adjusting Clutch Pedal”, “INSPECTION AND ADJUST- MENT"). Bot No, aierieg “mm Ge) @ 70-79 (7.1 -8.1, 51-59) 35217) © 70-70 (74-81, 51-59) 85 (256) ® Ba22-43.2-oy | 35113) @ 31-42 (92-43, 23-31) 45 (1.7) MT-8TRANSAXLE GEAR CONTROL SEC. 341 BB) 14-19 (045-000 29-50 e-11@9-11,00-23) /P2s-37(30-38,22-29 a Baars a4-13,10- 13) ® shite tever kncb ® Boot @® Shit lover socket @ shit iever ® Bearing seat spring ® Seat ® Bushing © Ong @ Hand lever socket @ Piate bot @ Teansaxle hole cover ® Suppor ros @ Piate @ Collar @ Busting © Support rod bracket MT-9 Bv-mgam, ny D-mtm et) EB shouste reac @ Collar @ Bushing @ Shit contr! roa @ Retum soning ‘Return spring rubber @ Holder bracket co a FaMAJOR OVERHAUL Case Components SEC. 320 FA Watiog surtace 10 (6) 10-20 (10-20, 07-176) Tivead of bot wy 6 Mating surtace to anamassion cave by aden ~ AD (STAB S00 tp BEAmsing surtace to ‘ransmsoon cao Bw om nsty * on GPovem ogo ee on fly recommended seat (WEAvateg \ {Genuine anacrotic tuk gas transmission —— an a oee nee (ONY \ Q haa RRM eto oregaary eg SS) - ©: Repy oou season ] 2 | Select proper hikes x oO 2 Pay atone Grecton omen’ — | |" Gamer avacan (jos oo (20-30, 14-22) (oer-o8s, Gasveisctoo | WE os. a6 esa 18-25 56-74) \ EB thread of or {Ap Seal awa? ® itch housing @® oxing ® Bearing retainer @® Reverse iter shatt Case cover @ Stiking 10d ol sead nur shat oi sal @ Back-up lamp switch Boot ® Oilpocket @ Dierental ot seal € Neutral position smith Boning tier & Orn nn & Sierra ol ea ier plug ranamission case o-ing ® Ar breather @ Oi guiter @ Vehicle speed sensor © Welch pig @ Git channel MT-10SEC. 322 18 Soe en EK BF sep gear ot. Q Reverse iter gear @ Reverse ide bushing @® Reverse idler spacer @ Snap ring ® Spacer © Input shatt front bearing ® Input shatt © 5th goar noode bearing © 5th input goar Bauik ring ® Coupling sleove ® Spread spring ® shiting inson @ st synchronizer hub ® Spread spring @ sh stopper ® Snap ving @ Input shat ear beating @ Mainshet front bearing @9) Steel ball @ Mainshatt He ae MAJOR OVERHAUL Gear Components @ 1st main gear @ Bauk ring @ 1st gear needle bearing @ Reverse main gear (Coupling sleeve) @ Insert spring @ 1908 2nd synchronizer hub @ 2nd outer baulk ring @ 2nd synchronizer cone @ 2nd inner baulk ring @ 2nd main gear @ 2nd & 5rd bushing @ 30 main gear @ 3a inner Baul ring @ ska synchronizer cone @ sr outer tauk ng ® Couping sieeve @ 31d & 4th synchronizer hud @ Insert spring Baulk ing 4m man gear @ 4mm bushing MT-11 aurise @® Sth main gear Spacer @ Mainshatt rear bearing © Mainshatt C-ring ® Cxing holder @ Snap ring @ Snap ring @ Diterential side bearing @ Speedometer stopper © Speedometer drive gear © Diferenial caso @ Diferential side bearing adjusting stim @ Diferontial side bearing @ Final gear @ Look pin @ Pinion mate trust washer @ Pinion mate gear @ ‘Side gear thrust washer Sige gear Pion mate shaft B & & a = 8 @84 8 @MAJOR OVERHAUL Shift Control Components SEC. 328 je.3- 0.3 (0.64 - 0.85, 56-74) B+Da-w 2-16 a8 8 hag? BD wm gn) FD am fern 1 FLD Aopy toting sean. % Select wan proper lent 4 Slot proper por. Acjtment fs requred saree D check plunger sit check bat @ tmterock pn Select tun spring Sit check spring @ Retaining pn @ O-ring Fork shaft support spring @ Stiking rod @ Check sleeve Fork shat @ Retaining pin ® Striking lever Sth shift fork @ Yoke @© Striking interiock ‘Shifter cap @ Reverse check plug @ Exing 3rd & 4th shift fork @ Check ball (Large) @® Reverse brake cam ‘Shifter cap @ Check ball (Small) @® Reverse brake cam spring @® 1st & 2nd shift fork @9 Stopper pin @ Check bal plug @ Conta bracket © Reverse check spring MT-12DISASSEMBLY 1. Remove case cover. a fe aN 2. Remove mainshait bearing snap ring. be Co re eo 3. Remove transmission case while slightly titing it to prevent [ill Sth shift fork from interfering with transmission case. at Ba Ba BR 4. Draw out reverse idler spacer and fork shaft. sr BS BT BA 5. Remove Sth and 3rd & 4th shift forks. © Be careful not to lose shifter caps. a BK MT-13,DISASSEMBLY ‘Shit cheek spring ononcin § me | KES 6. Remove control bracket with 1st & 2nd shift fork. 7. Remove gear components from clutch housing. a. Remove input shaft front bearing retainer securing bolts. b. Remove input shaft with bearing retainer, mainshaft assem- bly and reverse idler gear. © Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side. © Do not draw out reverse idler shaft from clutch housing because these fittings will be loose. When removing input shaft, be careful not to scratch oil seal lip with shaft spline. c. Remove final drive assembly. 8. Remove oil pocket, shift check ball, shift check spring and check ball plug. 9. Drive retaining pin out of striking lever. Remove striking rod, striking lever and striking interlock. '* Select a position where retaining pin does not interfere with clutch housing when removing retaining MT-14coneck \ soe \asseniy a neck pig Reverse West tse Reverse | check val DISASSEMBLY © Be careful not to damage oll seal lip when removing striking red. If necessary, tape edges of striking rod. 10. Remove reverse check plug, then detach reverse check spring and check balls. © Ifthe smaller ball does not come out, remove it together with check sleeve assembly. 11, Remove check sleeve assembly, MT-15 a, Le a Cu aT Fa RR BRREPAIR Newdtebearing ourraal | ‘Set Too! betow 5th input gear. 5th synchronzar hu ‘sTa0ae10%9 (oan) FOR COMPONENT PARTS Input Shaft and Gears DISASSEMBLY 1. Before disassembly, check Sth input gear end play. Gear end play: 18 - 0.31 mm (0.0074 - 0.0122 in) If not within specification, disassemble and check contact surface of gear, shaft and hub. Check clearance of snap ting groove. Refer to “ASSEMBLY”, MT-17. Remove snap ring and 5th stopper. 3. Remove Sth synchronizer, 5th input gear and Sth gear needle bearing. 4. Remove snap ring of input shaft front bearing and spacer. 5. Remove input shaft front bearing. 8. Remove bearing retainer. MT-16REPAIR FOR COMPONENT PARTS: Input Shaft and Gears (Cont'd) far clearance 1 INSPECTION Gear and shaft Check sheft for cracks, wear or bending. Check gears for excessive wear, chips or cracks. Sth synchronizer Check spline portion of coupling sleeves, hubs and gears for wear of cracks. Check baulk rings for cracks or deformation. ‘Check insert springs for wear or deformation. Measure clearance between baulk ring and gear. Clearance between baulk ring and gear: ‘Standard 0.9 - 1.5 mm (0.035 - 0.059 in) Wear limit 0.7 mm (0.028 in) Bearing Make sure bearings roll freely and are free from noise, cracks, pitting or wear. ASSEMBLY Assemble Sth synchronizer. MT-17 as, EuREPAIR FOR COMPONENT PARTS: hp Inert ourze10, ‘2670-01 Bearing retainer 137750000 325805-90) Sh stopper uso Input Shaft and Gears (Cont'd) © Be careful not to hook front and rear ends of spread spring to the same insert. 2. Install bearing retainer. 3. Press on input shaft front bearing. 4. Install spacer. 5. Select and install snap ring that gives proper clearance of input shaft groove. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) ‘Snap tings of input shaft front bearing: Refer to SDS, MT-38. © Be sure to replace Sth gear synchronizer hub with new ‘one when it is removed. 6. Install 5th gear needie bearing, 5th input gear, 5th synchro- nizer and 5th stopper. ‘Input shaft must be vertical to press on synchronizer hub. 7. Measure gear end play as a final check. Refer to “DISASSEMBLY”, MT-16. 8. Select and install snap ring that gives proper clearance of input shaft groove. Allowable clearance of groove: 0 = 0.1 mm (0 - 0.004 in) ‘Snap ring of 5th synchronizer: Refer to SDS, MT-38. MT-18REPAIR FOR COMPONENT PARTS. Mainshaft and Gears DISASSEMBLY 1. Before disassembly, measure gear end play. Gear end play: ‘st main gear MA 0.18 - 0.31 mm (0.0071 - 0.0122 in) 2nd, 3rd, 4th main gear 0.20 - 0.30 mm (0.0079 - 0.0118 in) ea ‘* fend play is not within the specified limit, disassemble and check the parts. Refer to “ASSEMBLY”, MT-22, 2. Remove mainshatt rear bearing snap ring, C-ring holder and mainshaft C-rings. End play Feeler gouge k joale bearing Sy rushing sur7ose] Sw me a eora roe i: SO — — Maina o-ring anna rar FR tearing RA : BR 3, Remove mainshaft rear bearing and spacer. 8? sutable RS iosbar a ‘oar oar a "e aT 4, Remove 5th main gear. ct a 1 MT-19REPAIR FOR COMPONENT PARTS. wi p=, At bushing + Stoo bal edo srs0021000— qzeizon — busting 2nd gear surased] avers Mainshaft and Gears (Cont'd) 5. Remove 4th main gear, 4th bushing and steel ball ‘* Be careful not to lose steel ball. 6. Remove 8rd & 4th synchronizer and 3rd main gear. 7. Remove 2nd & 3rd bushing and 2nd main gear. ‘© Be careful not to lose the steel ball. 8. Remove ist & 2nd synchronizer hub and 1st main gear. INSPECTION Gear and shaft '® Check shaft for cracks, wear or bending. '* Check gears for excessive wear, chips or cracks. MT-20REPAIR FOR COMPONENT PARTS. Mainshait and Gears (Cont'd) Synchronizer ‘* Check spline portion of coupling sleeves, hubs and gears for wear or cracks. © Check baulk rings for cracks or deformation. © Check insert springs for deformation. Measure clearance between baulk ring and gear. ‘ear clearance | Clearance between baulk rings and gears, for 1st and 4th gear only: Standard 1st 0.95 - 1.45 mm (0.0374 - 0.0571 in) 4th 0.9 - 1.45 mm (0.0354 - 0.0571 in) Wear limit 0.7 mm (0.028 in) . © 2nd and 3rd gears have inner and outer baulk rings and : so have different measurements. sure syncheonaoe pinner bauk ring Se" ap © Measure wear of 2nd and 3rd baulk rings. a. Place inner baulk ring in position on synchronizer cone. b. Hold baulk ring evenly against synchronizer cone and mea- sure distance “A”. c. Place outer baulk ing in position on synchronizer cone. d. Hold baulk ring evenly against synchronizer core and mea- sure distance *B". Standard: Inner-A 0.7 - 0.9 mm (0.028 - 0.035 in) Outer-B 0.6 - 1.1 mm (0.024 - 0.043 in) Wear limit: 0.2 mm (0.008 in) e. If distance “A” or “B” is smaller than the wear limit, replace baulk ring, MT-21 FA ox1st man gear « eo REPAIR FOR COMPONENT PARTS saris surzo = 2nd & ard C9} sate Aah Z@ oN ‘Stee! ball CDN swrezic| Mainshaft and Gears (Cont'd) Bearing Make sure bearings roll freely and are free from noise, cracks, pitting or wear. The mainshaft front bearing cannot be reused. It must be replaced once removed. ASSEMBLY 1. Install 1st gear needle bearing, 1st main gear and baulk fing. 2. Press on 1st & 2nd synchronizer hub. * Ensure correct fitting of 1st & 2nd synchronizer hub. 3. Install 2nd synchronizer cone, outer & inner baulk ring and. reverse main gear (coupling sleeve). 4. Install steel ball, 2nd main gear, 2nd & 3rd bushing. Apply gear oil to 2nd & 3rd bushing before installing it. © Apply multi-purpose grease to stee! ball before install- ing it. © 2nd & 3rd bushing has a groove in which steel ball fits. MT-22REPAIR FOR COMPONENT PARTS somraeac) —srarisoon0 (25658.01) suroos0| Mainshaft and Gears (Cont'd) 5. Install Srd main gear, synchronizer cone, outer & inner baulk ting. 6. Press on 3rd & 4th synchronizer hub. ‘* Ensure correct fitting of 3rd & 4th synchronizer hub. 7. Install 8rd & 4th coupling sieeve and 4th baulk ring 8. Install steel ball, 4th bushing and 4th main gear. * Apply multi-purpose grease to steel ball before install- ing it. 4th bushing has a groove in which steel ball fits. 9. Press on Sth main gear. MT-23 @ Wa aT Fa RR Bw ORREPAIR FOR COMPONENT PARTS: ana spacer em7isc) at austing = ST37780000) |i2sees.o arr erin note SB Meinsnate cwing beanng —Mainshat roar sur0829) autor surri29 Mainshaft and Gears (Cont'd) 10. Select proper mainshaft bearing spacer to give correct bear- ing distance. ‘Bearing distance “C”: 230.15 - 230.25 mm (9.0610 - 9.0649 in) Spacers available: Refer to SDS, MT-39. 11, Press on mainshaft rear bearing. 12, Select and install mainshaft C-ring that gives proper clear- ance of groove in mainshatt. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Mainshaft C-rings: Refer to SDS, MT-38. 13. Install C-ring holder and snap ring. 14, Measure gear end play as the final check. Refer to “DISASSEMBLY”, MT-19. MT-24REPAIR FOR COMPONENT PARTS: Final Drive DISASSEMBLY 4. Remove final gear. 2. Remove speedometer drive gear by cutting it. 3. Press out differential side bearings. 4. Drive out retaining pin and draw out pinion mate shaft 5. Remove pinion mate gears and side gears. | sures) INSPECTION Gear, washer, shaft and case Check mating surfaces of differential case, side gears and pinion mate gears. | @ Check washers for wear. aarri99 Bearing Make sure bearings roll freely and are tree from noise, cracks, pitting or wear. © When replacing tapered roller bearing, replace outer and inner race as a set. sears] ASSEMBLY 1. Attach side gear thrust washer to side gear and install both of them in differential case. 2. install pinion mate washers and pinion mate gears in place. MT-25, @ wa, Et BR BS BT a @ IDKREPAIR FOR COMPONENT PARTS: Final Drive (Cont'd) ~S kvaa107700 / 30027; sur7728, 3. Insert pinion mate shaft. When inserting, be careful not to damage pinion mate thrust washers. Measure clearance between side gear and differential case with washers following the procedure below: Set Too! and dial indicator on side gear. Move side gear up and down to measure dial indicator deflection. Clearance between side gear and differential case with washers: 0.1 - 0.2 mm (0.004 - 0.008 In) If not within specification, adjust clearance by changing thickness of side gear thrust washers, Side gear thrust washers for differential case side: Refer to SDS, MT-39. Install retaining pin. Make sure that ret Install final gear. Apply locking sealant to final gear fixing bolts before installing them. Install speedometer drive gear. MT-26REPAIR FOR COMPONENT PARTS: Final Drive (Cont'd) 8. Press on differential side bearings. sw7008 Striking rod Controf bracket Shift Control Components INSPECTION Check contact surface and sliding surface for wear, scratches, projections or other damage. 5 Shift fork and shifter cap ty suroanc [— aiiing ter | sR | Fa eee Sorenereseseeratace en ADJUSTMENT OF INPUT SHAFT BRAKING - MECHANISM 4. Install striking lever and rod, striking interlock assembly and control bracket on clutch housing as shown. ‘© When installing contro! bracket on clutch housing, assure protrusion beneath bracket is correctly seated. 3 Conre rackot BS F cauten mousing surrzao} oe MT-27REPAIR FOR COMPONENT PARTS. Shift Control Components (Cont’d) 2, Measure maximum height “H” while shifting from neutral to reverse position. Maximum height “H”: 67.16 - 67.64 mm (2.6441 - 2.6630 in) Sonat racket OO fing surtece Reverse bake cam sur7ee9 3. Measure clearance “C” between reverse brake cam and striking lever while shifting to reverse position. Clearance “C”: 0.125 mm (0.0020 - 0.0049 in) Js not within specification, replace the follow- as a set. ing lever assembly ‘© Striking interlock assembly (This includes reverse brake cam.) ‘© Control bracket assembly Striking ver cll MT-28REPAIR FOR COMPONENT PARTS Case Components REMOVAL AND INSTALLATION Input shaft oil seal 1. Drive out input shaft oi! seal, 2. Install input shaft oil seal. ¢ Apply multi-purpose grease to seal lip of oil seal before installing. SMT7510) Input shaft rear bearing 1, Remove welch plug from transmission case. 2, Remove input shaft rear bearing by tapping it from welch plug hole. 3. Install welch plug. © Apply recommended sealant to mating surface of trans- mission case. sures] MT-29FOR COMPONENT PARTS: Case Components (Cot 4. Install input shaft rear bearing, evss1a2100, (a2s203-01) Mainshaft front bearing and oil channel 1. Remove mainshatt front bearing retainer. eur7e79| Remove mainshaff front bearing. Remove oil channel. ex 4. Install oil channel. an aeak © Ensure that the oil groove faces the oil pocket. ol pocket 08 groove urs . Install mainshaft front bearing. . Install mainshaft front bearing retainer. * Apply locking sealant to thread of screw before instal- lation, on MT-30ADJUSTMENT Differential Side Bearing Preload If any of the following parts are replaced, adjust differential side bearing preload. a © Differential case ‘© Differential side bearing Me Clutch housing : © Transmission case eg 1. Remove differential side bearing outer race (transmission “” case side) and shim. & 3. Install final drive assembly on clutch housing 4. Install transmission case on clutch housing. a * Tighten transmission case fixing bolts to the specified torque. Refer to MT-10, PA aeaiteone 5. Set dial indicator on front end of differential case. ft Pritt 6. insert Tool all the way into differential side gear. wa 7. Move Tool up and down and measure dial indicator deflec- ep tion. 8 Select shim considering bearing preload. | © Suitable shim thickness = dial indicator deflection + specitied bearing preload Differential side bearing adjusting shims: Refer to SDS, MT-40. aT Bearing preload: | vaasor700 0.25 - 0.30 mm (0.0098 - 0.0118 in) ; (user) 9, Install selected shim and differential side bearing outer race Hi ‘on transmission case. 10. Check differential side bearing turning torque. a. Install final drive assembly on clutch housing. EB b. Install transmission case on clutch housing. © Tighten transmission case fixing bolts to the specified j,,. torque. Refer to MT-10. nero MT-31ADJUSTMENT Differential Side Bearing Preload (Cont'd) c. Measure tuming torque of final drive assembly. ‘Turning torque of final drive assembly (New bearing): 2.9 - 6.9 Nem (30 - 70 kg-om, 26 - 61 in-Ib) * When old bearing Is reused, turning torque will be slightly less than the above. Make sure torque Is close to the specified range. ‘© Changes in turning torque of final drive assembly per revolution should be within 1.0 N-m (10 kg-em, 8.7 in-Ib) without binding. MT-32~calephane tape Sh ‘UO sea! T g Shi chock sping Shite cheek bat tare a RE a Fh ran Reverse check plug Reverse ‘hele epting Check eat po ASSEMBLY Install striking rod, lever and interlock. Tape edges of striking rod to avoid damaging oil seal lip during installation. When taped edges of striking rod. are past the oil seal, remove tape. Install reverse check sleeve assembly. Install check balls, reverse check spring and reverse check plug. Check reverse turning torque (at striking rod). Reverse check turning torque (at striking rod): 4.9 - 7.4 Nem (50 - 75 kg-cm, 43 - 65 in-Ib) {f not within specification, select another check plug having a different length and reinstall it. Reverse check plugs: Refer to SDS, MT-38. Install selected reverse check plug. Apply locking sealant to thread of plug before installing it Install check ball plug, shift check ball and shift check spring. Install oil pocket. Install gear components onto clutch housing. Install final drive assembly. MT-33sur sus} ASSEMBLY b. Install input shaft assembly with bearing retainer, mainshaft assembly and reverse idler gear. © Be careful not to damage oil seal lip with splines of input shaft. © Be careful not to damage oil channel when inserting mainshatt into clutch housing. . Install input shaft front bearing retainer. 8. Apply grease to shifter caps and install to control bracket. Install control bracket with 1st & 2nd shift fork. ‘© When installing control bracket on clutch housing, ensure bracket is correctly seated, 10. Install 3rd & 4th and 5th shift forks. 11. Insert fork shaft. ‘© Apply multi-purpose grease to support spring before Installing. 12. Install reverse idler spacer.ASSEMBLY 18. Apply recommended sealant to mating surface of clutch housing. Refer to MT-10, 14, install transmission case on clutch housing. 16. Install mainshaft front bearing snap ring. 16. Tap mainshaft with a soft hammer to ensure mainshatt is properly seated, MT-35, a “ ieASSEMBLY 17. Check mainshatt bearing end play. Mainshaft bearing end play: 0 - 0.1 mm (0 - 0,004 in) ‘© If not within specification, select another case cover having a different thickness. Available case covers: Refer to SDS, MT-38. 18. Install O-ring and case cover on transmission case. © Apply recommended sealant to mating surface of trans- mission case. MT-36SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications TRANSAXLE a Era Tansae del ie Snavoneeh Ye Shit pater ee w Gear ate a 2nd ge ra jen & Rovees i Ae Narberareot [rout oe Y 76 2 a 3 20 MT s 8 Pex im Main cow + ° 2 42 FA a 2 pi 29 Ba s at ox “ eo Reveee Wer gear a et mn Wo 57-7 i ‘Oil capacity: (0) (US pi imp pt) 36-38 i {etree (rsi8-4,638-6.98) ener ean Soul Bs a ps rN Rs “Feta WA salon POneng WT OP -“GHAGBTS AND BODY WANTENANGE) a FINAL GEAR A Engine ‘SR200E Ba Fal ie rao a6 Fal gear Pinon zr Number of teeth < e Sion gurPeon wate pat 110 10k MT-37SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment GEAR END PLAY Case cover coo Ed play oy ain sa aig on Bay Tat mm (0 -on08im Teta ar o78-081 (o007t -O6te Thickness mm ti) Pai nanter and min gear 20-030 (@0078- 0011) 7.78 (24248) S81 5000 Sd main gear 120-089 (00078 - 0118 10.89 (04284) serstsaiot ‘th main gar 220-090 00070 - 001 10.9 (0408 verona Sn put oer 0:8-031 60071 -00122) 1059 (04300) serosa eee 10.98 (0.4923) 32181-50404 CLEARANCE BETWEEN BAULK RING 1.9 0.494) erarsauos AND GEAR 4st, 4th, 5th baulk ring AVAILABLE SNAP RINGS UntimmM —_Input shaft front bearing Standard Wear nt Allowable clearance - 0.1 mm (0 - 0.004 in) a [oa 148 wars dsm a weemay pT premee cam | 08 44s 0.054 00570 07 029) —, a wn [08-15 005-005 papa Sedans 2nd and 3rd baulk ring eee Sere 1.45 0571) eave woo07 Unt: mm (np Input shaft 5th synchronizer hub ete [aaa Fa maa TTT ai nome 8 nimi ot N ft Tasca nee ; y r f 0 CTE errs 7 205 (0.0807), 2511-88019 2.10 (00827) sesttaeni4 == “Inner bau ring 2.15 0.0846) esti E85 XS ™ symetnonizer cone 2.20 (0.0886) wart ear 2.25 (0.0888), ean e917 pee aura 2.0 (0.0808) sest-Mani8 Diversion Sandra Wear iit Tot tert oomastmms tee i i ipa 001) rasan eae Cainme oO) “Teaness rm 09 Per numer AVAILABLE REVERSE CHECK PLUGS —=xzn oe AND CASE COVERS eee | 4.52 0.1780) 208-001 Reverse check plug Ldsesiactt Eaedde: Reverse check beng trie a8. 74Nm apes) an (at cing 0) (90-79 4am, 4965 ie) itn aE a SL 479 (0.1982) seaesei08 Length en Gh Pat rater 480 0.1600) 2208.50105 73 (6280) wee MEnCE ar (o.97) 52548-50106 77 0319) cvieevenes 49601845) 2s4e.s0l07 830327) s2t08.ma0or 89 250) seiee1an08 Gandad ore creck pug MT-38SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd) MAINSHAFT BEARING ADJUSTING DIFFERENTIAL SIDE GEAR THRUST SPACER WASHER Abe Gare teen Os ad a Str as ih ser be © “Tricknate mi Ge) 7 SS a — 78-000 i ( Mo ni} (0.0285 - 0.0315) Pee Mm Ly a sweroene / wares ons 020 Axrananatt adjust a seieeo2na ital = (0.0995 - 0.0954) we 090-008 (0.0858 - 0.0574) ere sure 98-100 _ [tore tate (009740009 certs Bearing distance * (9.0610 - 9.0649 in) Tian ma Petr "891 0748) 2347 0) ‘308,070 court 1305 07509 cesar sie ‘92,0700 sesso 181907059 verano 1998 07589) cousaies 19.99 (0.7610) ‘92047-50J08 ay 1940 (07809 eeu snior oo) eevanse a RA GR ae RS. BT Ha 7 1X MT-39SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd) INPUT SHAFT BRAKING MECHANISM AVAILABLE SHIMS — DIFFERENTIAL SIDE BEARING piLanasndlaskoi cn BERSSREEEEEEEESEEEEEES PRELOAD AND ADJUSTING SHIM Bearing preload (Reused bearing) Unt) iia oe Cer 025030 (00% -corey Turning torque (New bearing) Unt: en are.) ree Revorve brake cam Final drive 2.8 - 6.9 (30 - 70, 26 - 61) iasEsESEAESERESRSSEGEEESSIERREREGSI1:.__2 Dace! Minguace nv oer 57.18 67.04 eee mm (mp | (26447-26800) Differential side bearing adjusting shims Revers bate cam Tess) Pas ombe sing ter 04 0173) 009 048 0.0188 sessa0% ass oczet sesse46003 je 000 (002% serset00 r 0.64 (0.0252) |38454.MBO05. 0.08 0026) ses nas 072 (00285 sesee007 Letitia! 0.76 (0.0299) 96454-M0000 005-0105 0.80 (00516 sess eee 9.84 (0.0931) (98454-ME010, 08 0.346 senses MT-40