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Mazda 6 2003-2007 Transaxle Workshop Manual G35M-R
Citation preview
CONTENTSManualTransaxleWorkshopManualG35MR
FOREWORD
This manual explains the mechanism, operation, and service points for the above-indicated manual transaxle. In order to do these procedures safety, 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 March, 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 serving.
Mazda Motor CorporationHIROSHIMA, JAPAN
2002 Mazda Motor CorporationPRINTED IN The Netherlands, MARCH 2002 17321E02C
Title Section
General Information GI
Manual Transaxle J
Technical Data TD
Special Tools ST
1732-1E-02C(INDEX).fm 1
WARNINGServicing 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 Mazda Motor Corporation 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.
1732-1E-02C(WARNING).fm 1
GIGIGENERAL INFORMATION
HOW TO USE THIS MANUAL ............................. GI-2RANGE OF TOPICS .......................................... GI-2SERVICING PROCEDURE ............................... GI-2SYMBOLS.......................................................... GI-4ADVISORY MESSAGES ................................... GI-4
UNITS ................................................................... GI-5UNITS TABLE .................................................... GI-5
FUNDAMENTAL PROCEDURES ........................ GI-6PREPARATION OF TOOLS AND MEASURING
EQUIPMENT................................................... GI-6SPECIAL SERVICE TOOLS .............................. GI-6DISASSEMBLY.................................................. GI-6INSPECTION DURING REMOVAL,
DISASSEMBLY............................................... GI-6ARRANGEMENT OF PARTS ............................ GI-7CLEANING OF PARTS...................................... GI-7REASSEMBLY................................................... GI-7ADJUSTMENT ................................................... GI-8RUBBER PARTS AND TUBING ........................ GI-8HOSE CLAMPS ................................................. GI-8TORQUE FORMULAS....................................... GI-8VISE ................................................................... GI-9
ELECTRICAL SYSTEM........................................ GI-9CONNECTORS.................................................. GI-9
NEW STANDARDS ............................................ GI-12NEW STANDARDS TABLE ............................. GI-12
ABBREVIATIONS .............................................. GI-14ABBREVIATIONS TABLE................................ GI-14
1732-1E-02C.book 1 GI1
GI2
HOW TO USE THIS MANUAL
RANGE OF TOPICSA6E201000001M01
This manuinto the fo Remo Disas Repla Inspe Adjus
Simple opparts, jack
End Of SieSERVICING PInspection, A Inspection
divided inlocation aexplained
HOW TO USE THIS MANUAL
1732-1E-02C.book 2 al contains procedures for performing all required service operations. The procedures are divided llowing five basic operations:val/Installationsembly/Assemblycementctiontmenterations which can be performed easily just by looking at the vehicle (i.e., removal/installation of ing, vehicle lifting, cleaning of parts and visual inspection) have been omitted.ROCEDURE
A6E201000001M02djustment and adjustment procedures are
to steps. Important points regarding the nd contents of the procedures are in detail and shown in the illustrations.
XME2010001
HOW TO USE THIS MANUAL
GI
Repair Procedure1. 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 torques, and symbols for oil, grease, and sealant are shown in the overview illustrationshown.
3. Procedurewith the cprocedure
End Of Sie
1732-1E-02C.book 3 GI3
. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
steps are numbered and the part that is the main point of the procedure is shown in the illustration orresponding number. Occasionally, there are important points or additional information concerning a . Refer to this information when servicing the related part.
XME2010010
GI4
HOW TO USE THIS MANUAL SYMBOLS
A6E201000001M03 There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
End Of SieADVISORY M You will fi
manual.
Warning A Warning
Caution A Caution
Note A Note pr
Specification The value
Upper and L The value
adjustmenEnd Of Sie
Symbol Meaning Kind
1732-1E-02C.book 4 ESSAGESA6E201000001M04
nd several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
indicates a situation in which serious injury or death could result if the warning is ignored.
indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
ovides added information that will help you to complete a particular procedure.
ss indicate the allowable range when performing inspections or adjustments.ower Limitss indicate the upper and lower limits that must not be exceeded when performing inspections or ts.
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
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
UNITS
GIUNITS TABLEA6E201200002M01
Conversion t All numer
from thes
Rounding Of Converted
value is 1
Upper and L When the
an upper unit value
2102627031
The actuaan upper used as a
End Of Sie
UNITS
Electrical curreElectric powerElectric resistaElectric voltag
Length
Negative pres
Number of revolutions
Positive press
Torque
1732-1E-02C.book 5 GI5
o SI Units (Systme International d'Units)ical values in this manual are based on SI units. Numbers shown in conventional units are converted e values.
f values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
7.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
ower Limits data indicates upper and lower limits, the converted values are rounded down if the SI unit value is limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:
0 kPa {2.12.7 kgf/cm2, 3038 psi}0 kPa {2.73.2 kgf/cm2, 3945 psi}l converted values for 2.7 kgf/cm2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is lower limit, so the converted values are rounded up to 270 and 39.
nt A (ampere)W (watt)
nce ohme V (volt)
mm (millimeter)in (inch)
sure
kPa (kilo pascal)mmHg (millimeters of mercury)inHg (inches of mercury)rpm (revolutions per minute)
ure
kPa (kilo pascal)kgf/cm2 (kilogram force per square centimeter)psi (pounds per square inch)Nm (Newton meter)kgfm (kilogram force meter)kgfcm (kilogram force centimeter)ftlbf (foot pound force)inlbf (inch pound force)
Volume
L (liter)US qt (U.S. quart)imp qt (Imperial quart)ml (milliliter)cc (cubic centimeter)cu in (cubic inch)fl oz (fluid ounce)
WeightN (Newton)g (gram)oz (ounce)
GI6
FUNDAMENTAL PROCEDURES
PREPARATION OF TOOLS AND MEASURING EQUIPMENTA6E201400004M01
Be sure thequipmen
End Of SieSPECIAL SE Use spec
are requir
End Of SieDISASSEMB If the disa
requiring mshould betheir perfoidentified easily and
End Of SieINSPECTION When rem
inspectedand other
End Of Sie
FUNDAMENTAL PROCEDURES
1732-1E-02C.book 6 at all necessary tools and measuring t are available before starting any work.
RVICE TOOLSA6E201400004M02
ial service tools or equivalent when they ed.
LYA6E201400004M03
ssembly procedure is complex, any parts to be disassembled, all parts
marked in a place that will not affect rmance or external appearance and so that reassembly can be performed efficiently.
DURING REMOVAL, DISASSEMBLYA6E201400004M04
oved, each part should be carefully for malfunction, deformation, damage, problems.
WGIWXX0023E
WGIWXX0024E
WGIWXX0027E
WGIWXX0028E
FUNDAMENTAL PROCEDURES
GI
ARRANGEMENT OF PARTSA6E201400004M05
All disassembled parts should be carefully arranged for reassembly.
Be sure to separate or otherwise identify the parts to be repl
End Of SieCLEANING O All parts t
thoroughl
Warning Usin
othethe ewhe
End Of SieREASSEMBL Standard
adjustmenreassemb
If removenew ones Oil se Gaske O-ring Lockw Cotter Nylon
Dependin Seala
applieis appsealan
Oil shcomp
Specithe prbefore
End Of Sie
1732-1E-02C.book 7 GI7
aced from those that will be reused.
F PARTSA6E201400004M06
o be reused should be carefully and y cleaned in the appropriate method.
g compressed air can cause dirt and r particles to fly out causing injury to yes. Wear protective eye wear
never using compressed air.
YA6E201400004M07
values, such as torques and certain ts, must be strictly observed in the ly of all parts.d, these parts should be replaced with :alstssashers pins nuts
g on location:nt and gaskets, or both, should be d to specified locations. When sealant lied, parts should be installed before t hardens to prevent leakage.
ould be applied to the moving onents of parts.fied oil or grease should be applied at escribed locations (such as oil seals) reassembly.
WGIWXX0029E
WGIWXX0030E
WGIWXX0031E
WGIWXX0032E
GI8
FUNDAMENTAL PROCEDURES ADJUSTMENT
A6E201400004M08 Use suitable gauges and/or testers when making
adjustments.
End Of SieRUBBER PA Prevent g
parts or tu
End Of SieHOSE CLAM When rein
original loclamp ligh
End Of SieTORQUE FO When usi
combinatirecalculator equivaRecalculaformulas.
A : The lengL : The leng
TorquN
kgkgfftin
1732-1E-02C.book 8 RTS AND TUBINGA6E201400004M09
asoline or oil from getting on rubber bing.
PSA6E201400004M10
stalling, position the hose clamp in the cation on the hose and squeeze the tly with large pliers to ensure a good fit.
RMULASA6E201400004M11
ng a torque wrench-SST or equivalent on, the written torque must be ed due to the extra length that the SST lent adds to the torque wrench. te the torque using the following Choose the formula that applies to you.
th of the SST past the torque wrench driveth of the torque wrench
WGIWXX0033E
WGIWXX0034E
WGIWXX0035E
e Unit Formulam Nm [L/(L+A)]fm kgfm [L/(L+A)]cm kgfcm [L/(L+A)]lbf ftlbf [L/(L+A)]lbf inlbf [L/(L+A)] WGIWXX0036E
FUNDAMENTAL PROCEDURES, ELECTRICAL SYSTEM
GI
End Of SieVISEA6E201400004M12
When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
End Of Sie
CONNECTORData Link Co Insert the
connectinconnector
Caution Inse
datathe t
Disconnectin When dis
connector
Connectopulling the
1732-1E-02C.book 9 GI9
SA6E201700006M01
nnector probe into the service hole when g a jumper wire to the data link .
rting a jumper wire probe into the link connector terminal may damage erminal.
g Connectorsconnecting connector, grasp the s, not the wires.
rs can be disconnected by pressing or lock lever as shown.
WGIWXX0037E
ELECTRICAL SYSTEM
X3U000WAY
WGIWXX0041E
WGIWXX0042E
GI10
ELECTRICAL SYSTEM Locking Connector When locking connectors, listen for a click
indicating they are securely locked.
Inspection When a te
measuringthe wiring
Inspect thfrom the caccessed
Caution To p
a thiinse
TerminalsInspection Pull lightly
are secur
1732-1E-02C.book 10 ster is used to inspect for continuity or voltage, insert the tester probe from
harness side.
e terminals of waterproof connectors onnector side since they cannot be from the wiring harness side.
revent damage to the terminal, wrap n wire around the tester probe before rting into terminal.
on individual wires to verify that they ed in the terminal.
X3U000WB1
WGIWXX0044E
WGIWXX0045E
WGIWXX0064E
ELECTRICAL SYSTEM
GI
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 conpressed dconnector
Sensors, Sw Handle se
Do not droobjects.
Wiring HarneWiring color Two-color
symbol. The first le
and the se
End Of Sie
CODEB
BRG
GYL
LBLG
1732-1E-02C.book 11 GI11
nector and with the terminal locking tab own, pull the terminal out from the .
itches, and Relaysnsors, switches, and relays carefully. p them or strike them against other
ss codes wires are indicated by a two-color code
tter indicates the base color of the wire cond the color of the stripe.
WGIWXX0046E
WGIWXX0047E
COLOR CODE COLORBlack O OrangeBrown P PinkGreen R RedGray V VioletBlue W White
Light Blue Y YellowLight Green
X3U000WB7
GI12
NEW STANDARDS
NEW STANDARDS TABLEA6E202800020M01
Following
NEW STANDARDS
Abbrevi-ationAP
ACLA/C
BAROB+
CMP sensorCACCLSCTPCPPCIS
CS sensorCKP sensor
DLCDTMDTCDI
DLIEI
ECTEM
EVAPEGRFCFF
4GR
FSO solenoid
GENGNDHO2SIAC
IATKSMILMAP
MAF sensorMFLOBDOL
1732-1E-02C.book 12 is a comparison of the previous standard and the new standard.New Standard Previous Standard
RemarkName Abbrevi-ation Name
Accelerator Pedal Accelerator PedalAir Cleaner Air CleanerAir Conditioning Air ConditioningBarometric Pressure Atmospheric PressureBattery Positive Voltage VB Battery VoltageBrake Switch Stoplight SwitchCalibration Resistor Corrected Resistance #6Camshaft Position Sensor Crank Angle SensorCharge Air Cooler IntercoolerClosed Loop System Feedback SystemClosed Throttle Position Fully ClosedClutch Pedal Position Idle SwitchContinuous Fuel Injection System Clutch PositionControl Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6Crankshaft Position Sensor Crank Angle Sensor 2Data Link Connector Diagnosis ConnectorDiagnostic Test Mode Test Mode #1Diagnostic Trouble Code(s) Service Code(s)Distributor Ignition Spark IgnitionDistributorless Ignition Direct IgnitionElectronic Ignition Electronic Spark Ignition #2Engine Coolant Temperature Water ThermoEngine Modification Engine ModificationEngine Speed Input Signal Engine RPM SignalEvaporative Emission Evaporative EmissionExhaust Gas Recirculation Exhaust Gas RecirculationFan Control Fan ControlFlexible Fuel Flexible FuelFourth Gear OverdriveFuel Pump Relay Circuit Opening Relay #3
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
Generator AlternatorGround Ground/EarthHeated Oxygen Sensor Oxygen Sensor With heaterIdle Air Control Idle Speed ControlIDM Relay Spill Valve Relay #6Incorrect Gear Ratio Injection Pump FIP Fuel Injection Pump #6Input/Turbine Speed Sensor Pulse GeneratorIntake Air Temperature Intake Air ThermoKnock Sensor Knock SensorMalfunction Indicator Lamp Malfunction Indicator LightManifold Absolute Pressure Intake Air PressureMass Air Flow Sensor Airflow SensorMultiport Fuel Injection Multiport Fuel InjectionOn-Board Diagnostic Diagnosis/Self DiagnosisOpen Loop Open Loop
NEW STANDARDS
GI
#1 : Diagnost#2 : Controlle#3 : In some m
relay (sp#4 : Device th#5 : Directly c#6 : Part nam
End Of Sie
Output Speed Sensor Vehicle Speed Sensor 1OCO2SPNP
PSPPCM
PAIR
AIR
SAPVSFI
3GRTWCTB
TP sensorTCVTCC
TCM
TRTC
VSSVR
VAF sensor
WUTWC
WOT
New Standard Previous StandardRemarkAbbrevi-
ation NameAbbrevi-
ation Name
1732-1E-02C.book 13 GI13
ic trouble codes depend on the diagnostic test moded by the PCM
odels, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump eed).at controls engine and powertrainonnected to exhaust manifolde of diesel engine
Oxidation Catalytic Converter Catalytic ConverterOxygen Sensor Oxygen SensorPark/Neutral Position Park/Neutral RangePCM Control Relay Main Relay #6Power Steering Pressure Power Steering PressurePowertrain Control Module ECU Engine Control Unit #4Pressure Control Solenoid Line Pressure Solenoid Valve
Pulsed Secondary Air Injection Secondary Air Injection System Pulsed injectionPump Speed Sensor NE Sensor #6
Secondary Air Injection Secondary Air Injection SystemInjection with air pump
Secondary Air Pulse Valve Reed ValveSequential Multipoint Fuel Injection Sequential Fuel InjectionShift Solenoid A 1-2 Shift Solenoid Valve
Shift A Solenoid Valve
Shift Solenoid B 2-3 Shift Solenoid Valve Shift B Solenoid Valve
Shift Solenoid C 3-4 Shift Solenoid ValveThird Gear 3rd GearThree Way Catalytic Converter Catalytic ConverterThrottle Body Throttle BodyThrottle Position Sensor Throttle SensorTimer Control Valve TCV Timing Control Valve #6Torque Converter Clutch Lockup PositionTransmission (Transaxle) Control Module ECAT Control Unit
Transmission (Transaxle) Fluid Temperature Sensor ATF Thermosensor
Transmission (Transaxle) Range Inhibitor PositionTurbocharger TurbochargerVehicle Speed Sensor Vehicle Speed Sensor Voltage Regulator IC RegulatorVolume Air Flow Sensor Air flow SensorWarm Up Three Way Catalytic Converter Catalytic Converter #5
Wide Open Throttle Fully Open
GI14
ABBREVIATIONS
ABBREVIATIONS TABLEA6E203000011M01
End Of Sie
ABBREVIATIONS
SST1st GR2nd GR3rd GR4th GR5th GR
1732-1E-02C.book 14 Special service toolFirst gearSecond gearThird gearForth gearFifith gear
JJMANUAL TRANSAXLE
MANUAL TRANSAXLE.......................................... J-2PRECAUTION...................................................... J-25TH GEAR THRUST CLEARANCE
PREINSPECTION............................................. J-25TH/REVERSE GEAR AND HOUSING PARTS
DISASSEMBLY................................................. J-35TH/REVERSE GEAR AND HOUSING PARTS
INSPECTION .................................................... J-6CLUTCH HOUSING AND TRANSAXLE CASE
COMPONENTS DISASSEMBLY...................... J-8PRIMARY SHAFT COMPONENTS
PREINSPECTION........................................... J-12PRIMARY SHAFT COMPONENTS
DISASSEMBLY............................................... J-13PRIMARY SHAFT COMPONENTS
INSPECTION .................................................. J-14PRIMARY SHAFT COMPONENTS
ASSEMBLY..................................................... J-16SECONDARY SHAFT COMPONENTS
PREINSPECTION........................................... J-18SECONDARY SHAFT COMPONENTS
DISASSEMBLY............................................... J-20SECONDARY SHAFT COMPONENTS
INSPECTION .................................................. J-21SECONDARY SHAFT COMPONENTS
ASSEMBLY..................................................... J-24DIFFERENTIAL PREINSPECTION ................... J-27DIFFERENTIAL DISASSEMBLY ....................... J-28DIFFERENTIAL ASSEMBLY ............................. J-29BEARING PRELOAD ADJUSTMENT................ J-30CLUTCH HOUSING AND TRANSAXLE CASE
COMPONENTS ASSEMBLY.......................... J-365TH/REVERSE GEAR AND HOUSING PARTS
ASSEMBLY..................................................... J-38
1732-1E-02C.book 1 J1
J2
MANUAL TRANSAXLE
PRECAUTIONA6E511201029M01
1. Clean the
Warning Usin
Wea
Caution Clea
bear
2. Clean the3. Clean out4. Use a pla5. Make sure6. Coat all m7. Replace p8. Remove o9. Assemble
assembly
Warning Alth
holdto tuthe r
End Of Sie5TH GEAR T1. Remove t2. Measure
dial indica If the c
the coclutch
Clearanc0.100
Maximum0.270 m
End Of Sie
MANUAL TRANSAXLE
1732-1E-02C.book 2 transaxle exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.
g compressed air can cause dirt and other particles to fly out, causing injury to the eyes. r protective eye wear whenever using compressed air.
ning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the ing.
removed parts using cleaning solvent, and dry them using compressed air. all holes and passages using compressed air, and check that there are no obstructions.stic hammer when disassembling the transaxle case and other light alloy metal parts. each part is cleaned before assembling.ovable parts with the specified oil.arts whenever required.ld sealant from contact surfaces before applying new sealant. the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after before filling the transaxle with transaxle oil.
ough the stand has a self-locking brake system, there is a possibility that the brake may not when the transaxle is held in a lopsided position on the stand. This would cause the transaxle rn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold otating handle firmly when turning the transaxle.
HRUST CLEARANCE PREINSPECTIONA6E511201029M02
he rear cover.the 5th gear thrust clearance using a tor.learance exceeds the maximum, check ntact surfaces of 5th gear and the hub. Replace worn or damaged parts.
e0.220 mm {0.00400.0086 in}m {0.0106 in}
Z4F5112M001
MANUAL TRANSAXLE 5TH/REVERSE GEAR AND HOUSING PARTS DISASSEMBLY
A6E511201029M031. Disassemble in the order shown in the figure.
Caution If an
occuwith
1732-1E-02C.book 3 J3
Jy old sealant gets into the transaxle during installation of the transaxle case, trouble may r in the transaxle. Remove any old sealant from the transaxle case and clutch housing, and cleaning fluids.
J4
MANUAL TRANSAXLE
.
1 Rear co
2 Locknu(See J3 Locknu(See J4 5th/rev5 5th/rev6 5th syn7 5th gea
1732-1E-02C.book 4 A6E5112M117
ver
t (primary shaft)5 Locknut Disassembly Note)t (secondary shaft)5 Locknut Disassembly Note)
erse shift forkerse clutch hub componentchronizer ringr
8 Gear sleeve9 Secondary 5th gear
10 Lock bolt11 Guide bolt12 Lock bolt, ball, and spring13 Back-up light switch14 Neutral switch15 Transaxle case component16 Magnet
MANUAL TRANSAXLE
Locknut Disa1. Assemble2. Lift the tra
3. Lock the p4. Shift to 1s
shaft.5. Bend bac6. Remove t
secondary
Shift Fork an1. Aligh the
control levcounterclo
2. While holdand the 3them bothclutch hub
17 Reverse idler shaft18 Reverse idler gear19 5th/reverse shift rod20 5th/reverse shift rod end21 Pin22 Crank l23 Crank l
24Shift fo(See JDisass
25 Push p26 Primary
27 Secondary shaft gear component28 Differential component29 Clutch housing30 Synchronizer key springs
1732-1E-02C.book 5 J5
J
ssembly Note the SST.nsaxle and mount it on the SST.
rimary shaft with the SST.t gear to lock the rotation of the primary
k the caulking of locknuts using a chisel.he locknuts from the primary and shafts.
d Shift Rod Component Disassembly Noteends of the interlock sleeve and of the er (arrow). Turn the shift rod ckwise.ing the 1st/2nd shift fork with one hand
rd/4th shift fork with the other, raise at the same time and shift each of the sleeves.
ever shaftever componentrk and shift rod component5 Shift Fork and Shift Rod Component
embly Note)in shaft gear component
31 Clutch hub sleeve32 Clutch hub33 3rd/4th shift fork34 Interlock sleeve35 Control lever36 1st/2nd shift fork37 Control end38 Control rod
A6E5112M108
Z4F5112M004
Z4F5112M005
J6
MANUAL TRANSAXLE 3. Lift the control end and remove the steel, and at
the same time, remove the control rod from the clutch housing.
4. Separate the shift rod and shift fork component from each of the clutch hub sleeves.
End Of Sie5TH/REVERS5th and Reve1. Inspect th
If ther2. Inspect th
If ther3. Inspect th
If ther
Synchronize1. Inspect th
If ther2. Inspect th
If ther3. Measure
ring and t If not
ring.
Note Set t
gearcircu
Standard1.50 mm
Minimum0.80 mm
Clutch Hub C1. Inspect th
If ther2. Inspect th
If ther3. Inspect th
If ther4. Measure
and shift f If the
replac
Standard0.100
Maximum0.86 mm
1732-1E-02C.book 6 E GEAR AND HOUSING PARTS INSPECTIONA6E511201029M04
rse Gear Inspectione synchronizer cones for wear.e is malfunction, replace parts as necessary.e gear teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e synchronizer ring matching teeth for damage and wear.e is malfunction, replace the synchronizer ring.
r Ring Inspectione synchronizer ring teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e tapered surface for wear and cracks.e is malfunction, replace parts as necessary.the clearance between the synchronizer he flank surface of the gear.as specified, replace the synchronizer
he synchronizer ring squarely in the ; then measure around the mference.
clearance {0.059 in} {0.031 in}omponent Inspection
e clutch hub sleeve and hub operation.e is malfunction, replace parts as necessary.e gear teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e synchronizer keys for damage, wear, and cracks.e is malfunction, replace parts as necessary.the clearance between the hub sleeve ork.clearance exceeds the maximum, e the hub sleeve and shift fork as a set.
clearance.36 mm {0.0040.014 in} clearance {0.034 in}
A6E5112M006
A6E5112M118
A6E5112M008
MANUAL TRANSAXLE Reverse Idle Gear and Reverse Lever Inspection1. Inspect the gear teeth for damage, wear, and cracks.
If there is malfunction, replace the reverse idle gear.2. Measure the clearance between the reverse idle
gear bushing and the reverse lever. If not
Standard0.100
Maximum0.85 mm
5th Gear and1. Measure
the Sleev If not
neces
5th gear 34.000
Sleeve ou33.945
Clearanc0.030
End Of Sie
1732-1E-02C.book 7 J7
Jas specified, replace as necessary.
clearance.35 mm {0.0040.013 in} Clearance {0.033 in}
Sleeve Inspectionthe clearance between the 5th gear and e.as specified, replace parts as sary.
inner diameter34.025 mm {1.33861.3395 in}ter diameter33.970 mm {1.33651.3373 in}
e0.080 mm {0.00120.0031 in}
A6E5112M009
Z4F5112M010
J8
MANUAL TRANSAXLE CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS DISASSEMBLY
A6E511217010M011. Disassemble in the order shown in the figure..
1 Bearing2 Oil sea
(See JNote)
3 Bearing(See JDisasse
4 Funnel5 Guide p6 Sealing7 Roll pin
(See J8 Control
(See J9 Selecto
10 Change11 Bleathe12 Bleathe13 Hole co14 Oil sea
(See J15 Bearing
(See JNote)
1732-1E-02C.book 8 A6E5112M113
race (primary shaft)l (primary shaft)9 Oil Seal (Primary Shaft) Disassembly
race (secondary shaft)9 Bearing Race (Secondary Shaft) mbly Note)
late component cap
9 Roll Pin Disassembly Note) rod9 Control Rod Disassembly Note)r
arm
r cover componentr
ver
l (differential)10 Oil Seal (Differential) Disassembly Note) race (differential)11 Bearing Race (Differential) Disassembly
16 Reverse lever shaft17 Reverse lever18 Drain plug and washer19 Bearing race (transaxle case)
(See J11 Bearing Race (Transaxle Case) Disassembly Note)
20 Adjustment shim(s)21 Bearing race (differential)
(See J11 Bearing Race (Differential) Disassembly Note)
22 Adjustment shim(s)23 Oil seal (differential)
(See J10 Oil Seal (Differential) Disassembly Note)24 Dowel pin25 O-ring26 Crank lever shaft27 Clank component lever28 Roll pin29 Shift lever component30 Key31 Control end 32 Spring and washer33 shift lever shaft
MANUAL TRANSAXLE
Oil Seal (Primary Shaft) Disassembly Note1. Remove t
Bearing Rac1. Remove t
funnel out
Roll Pin Disa1. Align the g
pin with thout using
Control Rod 1. Move the
34 Boots 35 Oil passage
1732-1E-02C.book 9 J9
Jhe oil seal using screwdriver.
e (Secondary Shaft) Disassembly Notehe bearing race by lifting it and the together.
ssembly Noteroove for removal of the clutch housing e position of the roll pin, then tap the pin a pin punch.
Disassembly Notecontrol rod in the direction of arrow.
A6E5112M012
A6E5112M013
Z4F5112M014
A6E5112M005
J10
MANUAL TRANSAXLE 2. Using a flathead screwdriver and hammer, make
a hole on the cap.
3. Pthe sealinto the hothe transm
Oil Seal (Cha1. Remove t
Oil Seal (Diff1. Remove t
1732-1E-02C.book 10 cap off, putting the flathead screwdriver le, made in Step 2, from the inside of ission.
nge Rod Component) Disassembly Notehe oil seal using the screwdriver.
erential) Disassembly Notehe oil seal using the screwdriver.
A6E5112M106
A6E5112M107
A6E5112M015
A6E5112M016
MANUAL TRANSAXLE Bearing Race (Differential) Disassembly Note1. Remove the bearing outer race using the SST.
Reverse Lev1. Remove t
2. Protect thpliers to re
Bearing Rac1. Remove t
End Of Sie
1732-1E-02C.book 11 J11
J
er Shaft Disassembly Notehe roll pin using pliers.
e reverse lever shaft with a rag and use move the shaft.
e (Transaxle Case) Disassembly Notehe bearing race using the SST.
Z4F5112M017
A6E5112M018
A6E5112M019
Z4F5112M020
J12
MANUAL TRANSAXLE PRIMARY SHAFT COMPONENTS PREINSPECTION
A6E511217201M013rd Gear Thrust Clearance1. Measure the clearance between 3rd gear and 2nd
gear. If the c
the coand 3dama
Clearanc0.050
Maximum0.25 mm
4th Gear Thr1. Measure
bearing. If the c
the coand 3dama
Clearanc0.170
Maximum0.42 mm
End Of Sie
1732-1E-02C.book 12 learance exceeds the maximum, check ntact surfaces of the 3rd gear, 2nd gear rd/4th clutch hub. Replace worn and ged parts.
e.20 mm {0.0020.007 in} {0.010 in}
ust Clearancethe clearance between 4th gear and the
learance exceeds the maximum, check ntact surfaces of the 4th gear, bearing, rd/4th clutch hub. Replace worn and ged parts.
e.37 mm {0.0070.014 in} {0.017 in}
A6E5112M021
A6E5112M022
MANUAL TRANSAXLE PRIMARY SHAFT COMPONENTS DISASSEMBLY
A6E511217201M021. Disassemble in the order shown in the figure..
Bearing (4th1. Remove t
1 Bearing(See JNote)
2 4th gea3 4th syn4 Retaini5 3rd/4th
(See JSynchr
6 3rd syn(See JSynchr
1732-1E-02C.book 13 J13
J
Gear End) Disassembly Notehe bearing using the SST.
Z4F5112M023
(4th gear end)13 Bearing (4th Gear End) Disassembly
r
chronizer ringng ring clutch hub component14 3rd/4th Clutch Hub Component, 3rd
onizer Ring and 3rd Gear Disassembly Note)chronizer ring14 3rd/4th Clutch Hub Component, 3rd
onizer Ring and 3rd Gear Disassembly Note)
7 3rd gear(See J14 3rd/4th Clutch Hub Component, 3rd Synchronizer Ring and 3rd Gear Disassembly Note)
8 Bearing (primary shaft end)(See J14 Bearing (Primary Shaft End) Disassembly Note)
9 Primary shaft gear10 Synchronizer key springs11 3rd/4th clutch hub sleeve12 Synchronizer keys13 3rd/4th clutch hub
Z4F5112M024
J14
MANUAL TRANSAXLE 3rd/4th Clutch Hub Component, 3rd Synchronizer Ring and 3rd Gear Disassembly Note1. Remove the retaining ring.2. Remove the 3rd/4th clutch hub component, 3rd
synchronizer ring, and 3rd gear using the SST.
Bearing (Prim1. Remove t
Caution Use
prevgear
End Of SiePRIMARY SH4th Gear, 3rd1. Inspect th
If ther2. Inspect th
If ther3. Inspect th
If ther
4th Synchron1. Inspect th
If ther2. Inspect th
If ther3. Measure
ring and t If not
ring.
Note Set t
gearcircu
Standard1.50 mm
Minimum0.80 mm
1732-1E-02C.book 14 ary Shaft End) Disassembly Notehe bearing using the SST.
protective plates in the vise to ent damage to the primary shaft .
AFT COMPONENTS INSPECTIONA6E511217201M03
Gear Inspectione synchronizer cones for wear.e is malfunction, replace parts as necessary.e gear teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e synchronizer ring matching teeth for damage and wear.e is malfunction, replace the synchronizer ring.
izer Ring, 3rd Synchronizer Ring Inspectione synchronizer ring teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e tapered surface for wear and cracks.e is malfunction, replace parts as necessary.the clearance between the synchronizer he flank surface of the gear.as specified, replace the synchronizer
he synchronizer ring squarely in the ; then measure around the mference.
clearance {0.059 in} {0.031 in}
Z4F5112M025
Z4F5112M026
A6E5112M027
MANUAL TRANSAXLE 3rd/4th Clutch Hub Component Inspection1. Inspect the clutch hub sleeve and hub operation.
If there is malfunction, replace parts as necessary.2. Inspect the gear teeth for damage, wear, and cracks.
If there is malfunction, replace parts as necessary.3. Inspect th
If ther4. Measure
and shift f If the
replac
Standard0.100
Maximum0.90 mm
Primary Sha1. Inspect th
If ther2. Inspect th
If ther3. Inspect th
If ther4. Inspect th
If ther5. Measure
If not
Primary s0.050 m
6. Measure and the g If not
neces
End Of Sie
Gear Sh(Oute3rd 35.945{1.4154th 30.945{1.218
1732-1E-02C.book 15 J15
Je synchronizer keys for damage, wear, and cracks.e is malfunction, replace parts as necessary.the clearance between the hub sleeve orks.clearance exceeds the maximum, e the hub sleeve and shift fork as a set.
.40 mm {0.0040.015 in} {0.035 in}
ft Gear Inspectione gear contact surface for damage and wear.e is malfunction, replace the primary shaft.e splines for damage and wear.e is malfunction, replace the primary shaft.e gear teeth for damage, wear, and cracks.e is malfunction, replace the primary shaft.e oil passage for clogging.e is malfunction, replace the primary shaft.the shaft gear runout.as specified, replace the primary shaft.
haft runoutm {0.0020 in} max.
the clearance between the shaft gears ears.as specified, replace parts as sary.
A6E5112M028
aftr dia.)
Gear(Inner dia.) Clearance
35.970 1.416}
36.00036.025 {1.4171.418} 0.0300.080
{0.0010.003}30.970 1.219}
31.00031.025 {1.2201.221}
Z4F5112M029
Z4F5112M030
J16
MANUAL TRANSAXLE PRIMARY SHAFT COMPONENTS ASSEMBLY
A6E511217201M041. Assemble in the order shown in the figure..
1 3rd/4th(See J
2 Synchr3 3rd/4th4 Synchr5 Primary6 Bearing
(See JNote)
7 3rd gea(See J3rd/4th
8 3rd syn(See J3rd/4th
1732-1E-02C.book 16 Z4F5112M031
clutch hub17 3rd/4th Clutch Hub Assembly Note)
onizer keys clutch hub sleeveonizer key springs shaft gear (primary shaft end)17 Bearing (Primary Shaft End) Assembly
r17 3rd Gear, 3rd Synchronizer Ring, and
Clutch Hub Component Assembly Note)chronizer ring17 3rd Gear, 3rd Synchronizer Ring, and
Clutch Hub Component Assembly Note)
9 3rd/4th clutch hub component(See J17 3rd Gear, 3rd Synchronizer Ring, and 3rd/4th Clutch Hub Component Assembly Note)
10 Retaining ring11 4th synchronizer ring
(See J18 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note)
12 4th gear(See J18 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note)
13 Bearing (4th gear end)(See J18 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note)
MANUAL TRANSAXLE 3rd/4th Clutch Hub Assembly Note1. Install the synchronizer key springs in the clutch
hub with the hooks in the grooves to hold the three synchronizer key in place.
SynchronA: 17.0B: 4.3 mC: 5.0 m
2. Align the synchroni
Bearing (Prim1. Install the
3rd Gear, 3rd1. Install the
3rd/4th clu
1732-1E-02C.book 17 J17
Jizer key size mm {0.669 in}
m {0.17 in}m {0.20 in}
synchronizer ring grooves with the zer key during assembly.
ary Shaft End) Assembly Note new bearing using the SST.
Synchronizer Ring, and 3rd/4th Clutch Hub Component Assembly Note 3rd gear, 3rd synchronizer ring, and tch hub component using a press.
A6E5110M131
Z4F5112M032
Z4F5112M033
Z4F5112M034
J18
MANUAL TRANSAXLE 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note1. Install the 4th synchronizer ring, 4th gear, and a
new bearing using the SST.
2. Measure 2nd gear. If not
shaft
Clearanc0.050
Maximum0.25 mm
3. Measure bearing. If not
shaft
Clearanc0.170
Maximum0.42 mm
End Of SieSECONDARY1st Gear Thr1. Measure
differentia If the c
the codifferegear, Repla
Clearanc0.050
Maximum0.33 mm
1732-1E-02C.book 18 the clearance between the 3rd gear and
as specified, reassemble the primary component.
e.20 mm {0.0020.007 in} {0.010 in}
the clearance between the 4th gear and
as specified, reassemble the primary component.
e.37 mm {0.0070.014 in} {0.017 in}
SHAFT COMPONENTS PREINSPECTIONA6E511217301M01
ust Clearance Inspectionthe clearance between 1st gear and the l drive gear.learance exceeds the maximum, check ntact surfaces of the 1st gear, ntial drive gear of the secondary shaft and 1st/2nd clutch hub component. ce worn and damaged parts.
e.28 mm {0.0020.011 in} {0.013 in}
Z4F5112M035
A6E5112M036
A6E5112M037
A6E5112M038
MANUAL TRANSAXLE 2nd Gear Thrust Clearance Inspection1. Measure the clearance between 2nd gear and
secondary 3rd gear. If the clearance exceeds the maximum, check
the contact surfaces of the 2nd gear, seconcompparts.
Clearanc0.180
Maximum0.51 mm
End Of Sie
1732-1E-02C.book 19 J19
Jdary 3rd gear, and 1st/2nd clutch hub onent. Replace worn and damaged
e.46 mm {0.0070.018 in} {0.020 in}
A6E5112M039
J20
MANUAL TRANSAXLE SECONDARY SHAFT COMPONENTS DISASSEMBLY
A6E511217301M021. Disassemble in the order shown in the figure..
1 Bearing(See JDisasse
2 Second3 Retaini4 Second
(See JDisasse
5 Friction6 Inner c7 Double8 2nd ge9 Synchr
10 Retaini
1732-1E-02C.book 20 A6E5112M111
21 Bearing and Secondary 4th Gear mbly Note)ary 4th gear
ng ringary 3rd gear21 Secondary 3rd Gear and 2nd Gear mbly Note) damperone
cone
ar
onizer ringng ring
11 1st/2nd clutch hub component(See J21 1st/2nd Clutch Hub Component, 1st Synchronizer Ring, and 1st Gear Disassembly Note)
12 1st gear13 Synchronizer ring14 Inner cone15 Double cone16 Bearing
(See J21 Bearing (Secondary Shaft End) Disassembly Note)
17 Secondary shaft gear18 Synchronizer key springs19 Clutch hub sleeve (reverse gear)20 Synchronizer keys21 1st/2nd clutch hub
MANUAL TRANSAXLE Bearing and Secondary 4th Gear Disassembly Note1. Remove the bearing and secondary 4th gear
using the SST.
Secondary 31. Remove t2. Shift the g3. Remove t
using the
1st/2nd Clutc1. Remove t2. Remove t
synchroni
Bearing (Sec1. Remove t
End Of Sie
1732-1E-02C.book 21 J21
J
rd Gear and 2nd Gear Disassembly Notehe retaining ring.ears to 1st gear.he secondary 3rd gear and 2nd gear SST.
h Hub Component, 1st Synchronizer Ring, and 1st Gear Disassembly Notehe retaining ring.he 1st/2nd clutch hub component, 1st zer ring, and 1st gear using a press.
ondary Shaft End) Disassembly Notehe bearing using the SST.
Z4F5112M041
Z4F5112M042
A6E5112M043
Z4F5112M044
J22
MANUAL TRANSAXLE SECONDARY SHAFT COMPONENTS INSPECTION
A6E511217301M03Gears Inspection1. Inspect the synchronizer cones for wear.
If there is malfunction, replace parts as necessary.2. Inspect th
If ther3. Inspect th
If ther
Synchronize1. Inspect th
If ther2. Inspect th
If ther3. Measure
ring and tfeeler gau If the
replac
Standard1.50 mm
Minimum0.80 mm
Clutch Hub C1. Inspect th
If ther2. Inspect th
If ther3. Inspect th
If ther4. Measure
and shift f If the
replac
Standard0.100
Maximum0.95 mm
Secondary S1. Inspect th
If ther2. Inspect th
If ther3. Inspect th
If ther4. Inspect th
If ther
1732-1E-02C.book 22 e gear teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e synchronizer ring matching teeth for damage and wear.e is malfunction, replace the synchronizer ring.
r Ring Inspectione synchronizer ring teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e tapered surface for wear and cracks.e is malfunction, replace parts as necessary.the clearance between the synchronizer he side of gear circumferentially using a ge.clearance is exceed the minimum, e the synchronizer ring.
clearance {0.059 in} {0.031 in}
omponent Inspectione clutch hub sleeve and hub operation.e is malfunction, replace parts as necessary.e gear teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e synchronizer keys for damage, wear, and cracks.e is malfunction, replace parts as necessary.the clearance between the hub sleeve ork.clearance exceeds the maximum, e the hub sleeve and shift fork as a set.
clearance.45 mm {0.0040.017 in} clearance {0.037 in}
haft Gear Inspectione gear contact surface for damage and wear.e is malfunction, replace the secondary shaft.e splines for damage and wear.e is malfunction, replace the secondary shaft.e gear teeth for damage, wear, and cracks.e is malfunction, replace the secondary shaft.e oil passage for clogging.e is malfunction, replace the secondary shaft.
A6E5112M047
A6E5112M049
MANUAL TRANSAXLE 5. Measure the shaft gear runout.
If not as specified, replace the secondary shaft.
Secondary shaft gear runout0.015 m
6. Measure and the g If not
neces
End Of Sie
Gear Sh(oute1st 39.445{1.5532nd 34.945{1.376
1732-1E-02C.book 23 J23
Jm {0.0006 in} max.
the clearance between the shaft gears ears.as specified, replace parts as sary.
mm{in}aftr dia.)
Gear(inner dia.) Clearance
39.470 1.554}
39.50039.525 {1.5551.556}
0.0300.080 {0.0020.003}
34.905 1.374}
35.01535.035 {1.3781.379}
0.050.09 {0.0020.003}
A6E5112M050
Z4F5112M102
J24
MANUAL TRANSAXLE SECONDARY SHAFT COMPONENTS ASSEMBLY
A6E511217301M041. Assemble in the order shown in the figure..
1 1st/2nd(See J
2 Synchr3 Clutch 4 Synchr5 Second6 Bearing
(See JAssem
7 1st gea(See J2nd Clu
8 Synchr9 Inner c
1732-1E-02C.book 24 A6E5112M110
clutch hub25 1st/2nd Clutch Hub Assembly Note)
onizer keyshub sleeve (reverse gear)onizer key springary shaft gear (secondary shaft end)25 Bearing (Secondary Shaft End)
bly Note)r25 1st Gear, 1st Synchronizer Ring, and 1st/tch Hub Component Assembly Note)
onizer ringone
10 Double cone11 1st/2nd clutch hub component12 Retaining ring13 Synchronizer ring14 2nd gear15 Double cone16 Inner cone17 Friction damper18 Secondary 3rd gear19 Retaining ring20 Secondary 4th gear
(See J26 Secondary 4th Gear and Bearing Assembly Note)
21 Bearing
MANUAL TRANSAXLE 1st/2nd Clutch Hub Assembly Note1. Install the synchronizer key springs in the clutch
hub with the hooks in the grooves to hold the three synchronizer keys in place.
SynchronA: 19.0B: 4.3 mC: 5.0 m
Bearing (Sec1. Install the
1st Gear, 1st
Note The
sync
1. Assemble1st/2nd clfigure.
1732-1E-02C.book 25 J25
Jizer key mm {0.748 in}
m {0.17 in}m {0.20 in}
ondary Shaft End) Assembly Note new bearing using the SST.
Synchronizer Ring, and 1st/2nd Clutch Hub Component Assembly Note
size of the 1st, 2nd, 3rd, and 4th hronizer rings are the same.
the 1st gear, 1st synchronizer ring, and utch hub component, as shown in the
A6E5110M131
Z4F5112M052
A6E5112M114
Z4F5112M054
J26
MANUAL TRANSAXLE 2. Press the 1st/2nd clutch hub component on using
the SST.
2nd Synchro1. Install the2. Install the
Secondary 41. Install the
using the
2. Measure the differe
Clearanc0.050
Maximum0.33 mm
1732-1E-02C.book 26 nizer Ring, 2nd Gear, and Secondary 3rd Gear Assembly Note 2nd synchronizer ring and 2nd gear. secondary 3rd gear using the SST.
th Gear and Bearing Assembly Note secondary 4th gear and the bearing SST.
the clearance between the 1st gear and ntial drive gear.
e.28 mm {0.0020.011 in} {0.013 in}
Z4F5112M055
A6E5112M115
Z4F5112M057
A6E5112M058
MANUAL TRANSAXLE 3. Measure the clearance between the 2nd gear and
the secondary 3rd gear. If not as specified, reassemble the secondary
shaft component.
Clearanc0.180
Maximum0.51 mm
End Of SieDIFFERENTIBacklash Ins1. Measure
If not neces
Standard0.050
End Of Sie
1732-1E-02C.book 27 J27
Je.46 mm {0.0070.018 in} {0.020 in}
AL PREINSPECTIONA6E511227100M01
pectionthe backlash of the side gear.as specified, replace parts as sary.
0.150 mm{0.00200.059 in}
A6E5112M059
A6E5112M060
J28
MANUAL TRANSAXLE DIFFERENTIAL DISASSEMBLY
A6E511227100M021. Disassemble in the order shown in the figure..
Bearing (Sid1. Remove t
1 Roll pin2 Pinion 3 Pinion 4 Thrust 5 Side ge6 Thrust
1732-1E-02C.book 28 e Opposite Ring Gear) Disassembly Notehe bearing using the SSTs.
Z4F5112M061
shaftgearwasherar
washer
7 Bearing (side opposite ring gear)(See J28 Bearing (Side Opposite Ring Gear) Disassembly Note)
8 Speedometer drive gear9 Bearing (ring gear side)
(See J29 Bearing (Ring Gear Side) Disassembly Note)
10 Ring gear and gear case component
Z4F5112M062
MANUAL TRANSAXLE Bearing (Ring Gear Side) Disassembly Note1. Remove the bearing using the SST.
End Of SieDIFFERENTI1. Assemble
1 Ring ge2 Bearing
(See JNote)
3 Speedo4 Bearing
(See JAssem
5 Thrust
1732-1E-02C.book 29 J29
J
AL ASSEMBLYA6E511227100M03
in the order shown in the figure..
Z4F5112M063
Z4F5112M064
ar and gear case component (ring gear side)30 Bearing (Ring Gear Side) Assembly
meter drive gear (side opposite ring gear)30 Bearing (Side Opposite Ring Gear)
bly Note)washer
6 Side gear7 Thrust washer8 Pinion gear9 Pinion shaft
10 Roll pin(See J30 Roll Pin Assembly Note)
J30
MANUAL TRANSAXLE Bearing (Ring Gear Side) Assembly Note1. Install the new bearing using the SST.
Bearing (Sid1. Install the2. Install the
Roll Pin Ass1. Install the
hold the p
2. Measure (1) Install
differe(2) Suppo
in the(3) Meas
If da
Backlash0.050
End Of Sie
BEARING PR1. Install the2. Mount the
housing. P
1732-1E-02C.book 30 e Opposite Ring Gear) Assembly Note speedometer drive gear. new bearing using the SST.
embly Note new roll pin as shown in the figure to inion shaft.
the backlash by the following procedure. the left and right drive shafts in the ntial component.rt the drive shaft on V-blocks as shown
figure.ure the backlash of both pinion gears.not as specified, replace worn and mage parts.
0.150 mm {0.00200.059 in}
ELOAD ADJUSTMENTA6E511201029M05
primary and secondary shaft bearing races into the transaxle case (shims removed). clutch housing onto the transaxle hanger, and set the differential bearing race into the clutch osition a piece of pipe against the bearing race and tap it in until it contacts the clutch housing.
Z4F5112M065
Z4F5112M066
A6E5112M067
A6E5112M068
MANUAL TRANSAXLE 3. Set the bearing races into the SSTs (selector) as
shown in the figure.
Note Turn the selector to eliminate the gap
indic
4. Set the dihousing, a(selector)(selector)the clutchMount thefigure.
5. Set the SSthe figure
6. Install the(bolts) toTightenin
37.35ftlbf}
7. To seat thparts A anselectors Then turnthe gaps a
1732-1E-02C.book 31 J31
Jated by the arrow in the figure.
fferential component into the clutch nd set the bearing race and the SST
on the differential. Set the SSTs for the primary and secondary shaft in housing. shaft gear assemblies as shown in the
T (collars) in the positions shown in .
transaxle case and tighten the SST the specified torque.
g torque2.0 Nm {3.95.3 kgfm, 28.238.3
e bearings, mount the SST (bars) on d B of the selectors, and turn the so the gaps are widened. the SST in the reverse direction until re eliminated.
Z4F5112M069
Z4F5112M070
Z4F5112M071
Z4F5112M072
Z4F5112M073
J32
MANUAL TRANSAXLE 8. Manually expand the selector until it no longer
turns by hand.
9. Use a feeSST (sele
Caution Mea
circu
10. Take the shim to usPrimary s Selec
table
Standard00.05
ExampleReadin
Shim sele(0.57 m
mm {Shim
0.55 mm
Seconda Selec
Tightenin0.030
ExampleReadin
Shim sele(0.57 m
in}0Shim
0.60 mm
Thickness of
0.20 {0.008}0.40 {0.016}0.60 {0.024}
1732-1E-02C.book 32 ler gauge to measure the gap in the ctor).
sure the gap around the entire mference of the selector.
maximum reading and determine the ed as follows.haft adjustment shim
t the thinnest allowable shim from the to obtain standard clearance.
clearance mm {00.002 in}g from step 9: 0.57 mm {0.022 in}cting range
m {0.022 in}0.05 mm {0.002 in})(0.57 mm {0.022 in}0 mm {0 in})=0.52 mm {0.020 in}0.57 0.022 in}
{0.022 in}ry shaft adjustment shimt the thinnest allowable shim from the table to obtain standard clearance.
g amount.08 mm {0.0010.003 in}g from step 9: 0.57 mm {0.022 in}cting range
m {0.022 in}+0.03 mm {0.001 in})(0.57 mm {0.022 in}+0.08 mm {0.003 in})=0.60 mm {0.024 .65 mm {0.026 in} {0.024 in}
shimmm{in}
0.25 {0.010} 0.30 {0.012} 0.35 {0.014}0.45 {0.018} 0.50 {0.020} 0.55 {0.022}0.65 {0.026} 0.70 {0.028}
A6E5112M074
Z4F5112M075
MANUAL TRANSAXLE 11. Install the SST and a pull scale or torque wrench.
12. Adjust theobtain the
Note Read
to tu Mea
aver
Preload0.5 Nm
Reading 5 N {0.5
13. Use a feeselector fo
14. Add 0.15 clearanceclosest in
Example0.32 mm
0.32in}=0
Nea{0.019
Thickness of
15. Remove t16. Remove t17. Remove t
0.1 {0.004}0.35 {0.014}0.55 {0.022}0.75 {0.030}0.95 {0.037}1.15 {0.045}
1732-1E-02C.book 33 J33
J
clearance of the SST (selector) to specified preload/pull scale reading.
the preload when the differential starts rn.sure several times and calculate the age value.
{5.0 kgfcm, 4.3 inlbf}on pull scale kgf, 1.1 lbf}ler gauge to measure the gap in the r the differential.
mm{0.006 in} to the measured and select the combination of shims value to that measurement.
{0.013 in} mm {0.013 in}+0.15 mm {0.006
.47 mm {0.019 in}rest shim (on thick side) to 0.47 mm in} is 0.50 mm {0.020 in} shim
mm{in}
he transaxle case and the SST.he selectors, the primary shaft component, and the differential.he bearing races.
0.20 {0.008} 0.25 {0.010} 0.30 {0.012}0.40 {0.016} 0.45 {0.018} 0.50 {0.020}0.60 {0.024} 0.65 {0.026} 0.70 {0.028}0.80 {0.031} 0.85 {0.033} 0.90 {0.035}1.0 {0.039} 1.05 {0.041} 1.10 {0.043}
1.20 {0.047}
Z4F5112M076
Z4F5112M077
Z4F5112M078
J34
MANUAL TRANSAXLE 18. Install the adjustment shim(s) and install the
bearing race using a suitable pipe.
Caution Use the adjustment shim(s) selected
duri
19. Install thebearing ra
Caution Use
duri
20. Set the prdifferentia
21. Install thespecified
Tightenin37.35
ftlbf}
22. Install the23. Verify tha
If not
Preload1.41.9
Reading 1419
24. Remove t
25. With the tthe figuregear com
26. Verify tha If not
Preload0.120
inlbf}Reading
1.23.9
27. Remove tgear com
1732-1E-02C.book 34 ng bearing preload adjustment.
adjustment shim(s) and install the ce using a suitable pipe.
the adjustment shim(s) selected ng bearing preload adjustment.
imary shaft gear component and the l into the clutch housing. transaxle case, and tighten to the torque.
g torque2.0 Nm {3.85.3 kgfm, 27.538.3
SST and a pull scale or torque wrench.t the preload is within the specification.as specified, return to Step 1.
Nm {1420 kgfcm, 1317 inlbf}on pull scaleN {1.42.0 kgf, 3.14.4 lbf}he SST.
ransaxle facing in the direction shown in , install the SST to the primary shaft ponent.t the preload is within the specification.as specified, return to Step 1.
.39 Nm {1.24.0 kgfcm, 1.053.47 on pull scale N {0.120.40 kgf, 0.270.88 lbf}
he SST, transaxle case, primary shaft ponent and differential.
A6E5112M079
A6E5112M103
A6E5112M080
A6E5112M081
A6E5112M082
MANUAL TRANSAXLE 28. Install the secondary shaft gear component and transaxle case, then tighten to the specified torque.
Tightening torque37.352.0 Nm {3.85.3 kgfm, 27.538.3 ftlbf}
29. Install the30. Verify tha
If not
Preload0.20.3
inlbf}Reading
23 N
31. Remove t
End Of Sie
1732-1E-02C.book 35 J35
J SST and a pull scale or torque wrench.t the preload is within the specification.as specification, return to Step 1.
Nm {2.04.0 kgfcm, 1.83.4 on pull scale{0.20.4 kgf, 0.50.8 lbf}he SST and transaxle case.
Z4F5112M083
J36
MANUAL TRANSAXLE CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS ASSEMBLY
A6E511217010M021. Assemble in the order shown in the figure..
1 Oil pas2 Oil sea
(See J3 Adjustm4 Bearing
(See JNote)
5 Adjustm6 Bearing
(See JAssem
7 Drain p8 Revers9 Revers
10 Bearing(See JNote)
11 Oil sea(See J
12 Hole co13 Bleathe
1732-1E-02C.book 36 A6E5112M112
sagel (differential)37 Oil Seal (Differential) Assembly Note)ent shim(s) race (differential)37 Bearing Race (Differential) Assembly
ent shim(s) race (transaxle case)37 Bearing Race (Transaxle Case)
bly Note)lug and washere levere lever shaft race (differential)37 Bearing Race (Differential) Assembly
l (differential)37 Oil Seal (Differential) Assembly Note)ver
r
14 Bleather cover component15 Control rod16 Selector17 Roll pin18 Change arm19 Sealing cap20 Guide plate component21 Funnel22 Bearing race (secondary shaft)23 Oil seal (primary shaft)
(See J38 Oil Seal (Primary Shaft)Assembly Note)24 Bearing race (primary shaft)25 Boots 26 Shift lever component27 shift lever shaft28 Key29 Control end 30 Spring and washer31 Clank component lever
MANUAL TRANSAXLE
Oil Seal (Differential) Assembly Note1. Apply transaxle oil to the new oil seal lip.2. Install the
Bearing Rac1. Install the
bearing ra
Bearing Rac1. Install the
bearing ra
Oil Seal (Cha1. Apply tran2. Install the
Outer dia26.0 mm
32 O-ring33 Crank lever shaft
1732-1E-02C.book 37 J37
J oil seal using the SST.
e (Differential) Assembly Note adjustment shim(s) and install the ce using a suitable pipe.
e (Transaxle Case) Assembly Note adjustment shim(s) and install the ce using a suitable pipe.
nge Rod Component) Assembly Notesaxle oil to the new oil seal lip. oil seal using a suitable pipe.
meter of pipe {1.02 in}
Z4F5112M085
A6E5112M079
A6E5112M103
A6E5112M086
J38
MANUAL TRANSAXLE Oil Seal (Primary Shaft)Assembly Note1. Apply transaxle oil to outer circumference of the oil seal.2. Install the new oil seal using a suitable pipe.
End Of Sie5TH/REVERS1. Assemble
1732-1E-02C.book 38 E GEAR AND HOUSING PARTS ASSEMBLYA6E511201029M06
in the order shown in the figure..
A6E5112M088
A6E5112M119
MANUAL TRANSAXLE
Clutch Hous1. Assemble2. Assembly
1 Clutch housing(See J39 Clutch Housing Assembly Note)
2 Control rod3 Control end4 1st/2nd5 Contro6 Interloc7 3rd/4th8 Clutch 9 Clutch
10 Synchr11 Differen12 Second
(See JSecond
13 Primary(See JSecond
14 Push p15 Shift fo
(See JAssem
16 Crank l(See JLever S
17 Crank l(See JLever S
18 Pin19 5th/rev
(See JRevers
20 5th/reverse shift rod(See J41 5th/Reverse Shift Rod End and 5th/Reverse Shift Rod Assembly Note)
21 Reverse idle gear(See J41 Reverse Idle Gear and Reverse Idle
1732-1E-02C.book 39 J39
J
ing Assembly Note the SST. clutch housing on the SST.
shift forkl leverk lever shift forkhubhub sleeveonizer key springstial componentary shaft gear component40 Primary Shaft Gear Component and ary Shaft Gear Component Assembly Note) shaft gear component40 Primary Shaft Gear Component and ary Shaft Gear Component Assembly Note)
inrk and shift rod component40 Shift Fork and Shift Rod Component
bly Note)ever component40 Crank Lever Component and Crank haft Assembly Note)
ever shaft40 Crank Lever Component and Crank haft Assembly Note)
erse shift rod end41 5th/Reverse Shift Rod End and 5th/e Shift Rod Assembly Note)
Shaft Assembly Note)22 Reverse idle shaft
(See J41 Reverse Idle Gear and Reverse Idle Shaft Assembly Note)
23 Magnet24 Transaxle case component
(See J41 Transaxle Case Component Assembly Note)
25 Neutral switch26 Back-up light switch27 Lock bolt, ball and spring28 Guide bolt29 Lock bolt30 Secondary 5th gear
(See J42 Secondary 5th Gear Assembly Note)31 Gear sleeve32 5th gear33 5th synchronizer ring34 5th/reverse clutch hub component
(See J42 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note)
35 5th/reverse shift fork(See J42 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note)
36 Locknut (secondary shaft)(See J42 Locknut Assembly Note)
37 Locknut (primary shaft)(See J42 Locknut Assembly Note)
38 Rear cover
A6E5112M108
J40
MANUAL TRANSAXLE Primary Shaft Gear Component and Secondary Shaft Gear Component Assembly Note1. Install the primary shaft gear component and the secondary shaft gear component together.
Shift Fork and Shift Rod Component Assembly Note1. Shift to 2nd gear and position the shift fork and
shift rod c
2. Insert thelever shafscraper so
3. With the escraper, wdirection ogoes into line up wiclutch hou
4. Set each and tap thball goes grooves in
5. Pull the bathe steel b
Crank Lever 1. Fit the cra
lever.2. Aligh the p
clutch hou
1732-1E-02C.book 40 omponent as shown.
spring seat and spring into the reverse t, install the steel ball, and place a that it contacts the steel ball.dge of the control end against the hen the control end is pushed in the f the arrow in the figure so that the ball
the shaft, the rod will at the same time th the shift rod coupling hole in the sing.
clutch hub sleeve to the neutral position, e shift rod from above so that the steel into the center groove (of the three the control end).ll part of the control end forward so that all goes into the detent in the groove.
Component and Crank Lever Shaft Assembly Notenk lever between the change arm and the control end, and connect the crank lever shaft to the crank
in holes of the crank lever shaft and the sing, and insert a new pin.
A6E5112M091
Z4F5112M092
A6E5112M093
A6E5112M094
MANUAL TRANSAXLE 5th/Reverse Shift Rod End and 5th/Reverse Shift Rod Assembly Note
Note The mark (indicated by the arrow in the
figure) and the shift rod end mounting bolt hole
1. Install shitighten the
Tightenin11.81
inlbf}
Reverse Idle1. Install the2. Attach the3. Aligh the
control levthe reversshown in
Transaxle Ca1. Apply a th
transaxle
Tightenin37.35
2. Install theshaft hole
1732-1E-02C.book 41 J41
J must be aligned.ft rod end 1 and the shift rod 2, and gate mounting bolt.
g torque3.7 Nm {120140 kgfcm,105121
Gear and Reverse Idle Shaft Assembly Note reverse idle gear and the reverse idler shaft. magnet to the clutch housing.
end of the interlock sleeve with the er (arrow), and at the same time, face e idle shaft screw hole in the direction the figure.
se Component Assembly Notein coat of sealant to the contact surfaces of the clutch housing and transaxle case, and tighten the case installation bolts to the specified torque.
g torque2.0 Nm {3.85.3 kgfm, 2838 ftlbf} SSTs through the drive shaft and joint .
Z4F5112M095
Z4F5112M096
Z4F5112M097
J42
MANUAL TRANSAXLE Secondary 5th Gear Assembly Note1. Install the secondary 5th gear as shown.
5th/Reverse 1. Install the
the 5th/re
Locknut Ass1. Shift to 1s2. Lock the p3. Tighten n
secondary
Tightenin127.5
ftlbf}4. Stake the
5. Measure dial indica If not
Clearanc0.100
Maximum0.270 m
End Of Sie
1732-1E-02C.book 42 Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note 5th/reverse clutch hub component and verse shift fork together.
embly Notet gear.rimary shaft using the SST.
ew lock nuts onto the primary and shafts.
g torque205.8 Nm {13.020.0 kgfm, 95144
locknuts.
the 5th gear thrust clearance using a tor.as specified, reassemble the transaxle.
e0.220 mm {0.00390.0087 in}m {0.0106 in}
A6E5112M098
A6E5112M099
A6E5112M100
A6E5112M101
TD
TDTECHNICAL DATA
TECHNICAL DATA ............................................. TD-2MANUAL TRANSAXLE..................................... TD-2
1732-1E-02C.book 1 TD1
TD2
TECHNICAL DATA
MANUAL TRANSAXLEA6E931001029M01
TECHNICAL DATA
Transaxle type
Thrust clearan
Oil clearance
Shift fork and sleeve
Synchronizer r
Reverse idle greverse lever
1732-1E-02C.book 2 Item SpecificationG35M-R
ce
1st gear Clearance (mm {in}) 0.050.28 {0.0020.011}Maximum (mm {in}) 0.33 {0.013}2nd gear Clearance (mm {in}) 0.180.46 {0.0070.018}Maximum (mm {in}) 0.51 {0.020}3rd gear Clearance (mm {in}) 0.050.20 {0.0020.007}Maximum (mm {in}) 0.25 {0.010}4th gear Clearance (mm {in}) 0.170.37 {0.0070.014}Maximum (mm {in}) 0.42 {0.017}5th gear Clearance (mm {in}) 0.1000.220 {0.00400.0086}Maximum (mm {in}) 0.270 {0.0106}
1st gear
1st gear inner diameter (mm {in}) 39.50039.525 {1.5551.556}Secondary shaft outer diameter
(mm {in}) 39.44539.470 {1.5531.554}
Clearance (mm {in}) 0.0300.080 {0.0020.003}
2nd gear
2nd gear inner diameter (mm {in}) 35.01535.035 {1.3781.379}Secondary shaft outer diameter
(mm {in}) 34.94534.905 {1.3761.374}
Clearance (mm {in}) 0.050.09 {0.0020.003}
3rd gear
3rd gear inner diameter (mm {in}) 36.00036.025 {1.4171.418}Primary shaft outer diameter
(mm {in}) 35.94535.970 {1.4151.416}
Clearance (mm {in}) 0.0300.080 {0.0010.003}
4th gear
4th gear inner diameter (mm {in}) 31.00031.025 {1.2201.221}Primary shaft outer diameter
(mm {in}) 30.94530.970 {1.2181.219}
Clearance (mm {in}) 0.0300.080 {0.0010.003}
5th gear
5th gear inner diameter (mm {in}) 34.00034.025 {1.33861.3395}Sleeve outer diameter (mm {in}) 33.94533.970 {1.33651.3373}Clearance (mm {in}) 0.0300.080 {0.00120.0031}
hub
Clearance between 1st/2nd shift fork and hub sleeve
Standard (mm {in}) 0.100.45 {0.0040.017}Maximum (mm {in}) 0.95 {0.037}
Clearance between 3rd/4th shift fork and hub sleeve
Standard (mm {in}) 0.100.40 {0.0040.015}Maximum (mm {in}) 0.90 {0.035}
Clearance between 5th shift fork and hub sleeve
Standard (mm {in}) 0.100.36 {0.0040.014}Maximum (mm {in}) 0.86 {0.034}
ingClearance between synchronizer ring and flank surface of gear
Standard (mm {in}) 1.50 {0.059}Maximum (mm {in}) 0.80 {0.031}
ear and Clearance between reverse idle gear bushing and reverse lever
Standard (mm {in}) 0.100.35 {0.0040.013}
maximum (mm {in}) 0.85 {0.033}
TECHNICAL DATA
End Of Sie
Primary shaft gear
Runout (mm {in}) 0.050 {0.0020}max.Bearing preload (Nm {kgfcm, inlbf}) 0.120.39 {1.24.0, 1.053.47}
0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012},
Secondary sha
Differential
Item Specification
1732-1E-02C.book 3 TD3
TD
Preload adjust shims (mm {in}) 0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018}, 0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024}, 0.65 {0.026}, 0.70 {0.028}
ft gear
Runout (mm {in}) 0.015 {0.0006}max.Bearing preload (Nm {kgfcm, inlbf}) 0.20.3 {2.04.0, 1.83.4}
Preload adjust shims (mm {in})0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012}, 0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018}, 0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024},
0.65 {0.026}, 0.70 {0.028}Differential bearing preload (Nm {kgfcm, inlbf}) 1.41.9 {1420, 1317}
Preload adjust shims (mm {in})
0.1 {0.004}, 0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012}, 0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018}, 0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024}, 0.65 {0.026}, 0.70 {0.028}, 0.75 {0.030}, 0.80 {0.031}, 0.85 {0.033}, 0.90 {0.035}, 0.95 {0.037}, 1.0 {0.039}, 1.05 {0.041}, 1.10 {0.043}, 1.15 {0.045},
1.20 {0.047}Backlash of side gear and pinion gear Standard (mm {in}) 0.0500.150 {0.00200.059}
ST
STSPECIAL TOOLS
SPECIAL TOOLS .................................................ST-2MANUAL TRANSAXLE......................................ST-2
1732-1E-02C.book 1 ST1
ST2
SPECIAL TOOLS
MANUAL TRANSAXLEA6E941001029M01
End Of Sie
SPECIAL TOOLS
49 0107 680A
Engine stand
49 FT01 361
Bearing remover
49 F401 366A
Plate
49 B017 207
Attachment G
49 F401 331
Body
49 G030 338
Attachment E
49 B017 102
Preload adapt
1732-1E-02C.book 2 49 G019 0A0
Transaxle hanger set
49 0839 425C
Bearing puller set
46 0636 145
Fan pulley boss puller
498 G030 370
Removing plate
49 G030 795
Oil seal installer
49 G030 440
Primary shaft holder
49 B017 208
Attachment H
49 B017 209
Attachment J
49 F401 335A
Attachment A
49 F401 336B
Attachment B
49 G030 380D
Shim selector set
49 G017 202
Preload adapter
er
49 G030 455
Diff. side gear holder
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