MX1

MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE SYSTEM

MANUAL TRANSAXLE SYSTEM

MX04X01

PRECAUTION
When working with FIPG material, you must observe the following items. L Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces. L Thoroughly clean all components to remove all the loose material. L Clean both sealing surfaces with a nonresidue solvent. L Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface. L Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.

Author :

Date :

1802

MX2
MANUAL TRANSAXLE (E153) TROUBLESHOOTING

TROUBLESHOOTING
MX04Y01

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace parts.
Symptom Suspect Area 1. Oil (Level low) 2. Oil (Wrong) 3. Gear (Worn or damaged) 4. Bearing (Worn or damaged) 1. Oil (Level too high) 2. Gasket (Damaged) 3. Oil seal (Worn or damaged) 4. ORing (Worn or damaged) 1. Control cable (Faulty) 2. Synchronizer ring (Worn or damaged) y g( g ) Hard to shift or will not shift 3. Shift key spring (Damaged) 3 See page MX4 MX4 MX 10 MX10 MX10 MX4 MX10 MX 10 MX10 MX10 MX49 MX10 MX24 MX31 MX10 MX24 MX31 MX10 MX10 MX 10 MX10 MX10

Noise N i

Oil l k leakage

Jumps out of gear J t f

1. Locking ball spring (Damaged) 2. Shift fork (Worn) 3. Gear (Worn or damaged) 4. Bearing (Worn or damaged)

Author :

Date :

1803

MX3
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE UNIT

MANUAL TRANSAXLE UNIT

MX04Z01

COMPONENTS
Hood
14 (150, 10)

w/ Cruise Control : Cruise Control Actuator Control Cable Clip

13 (130, 9)

12 (120, 9)

Clutch Line Bracket

21 (210, 15) 12 (120, 9)

Clutch Release Cylinder

26 (270, 20)

21 (210, 15)

Clip Washer Starter

Air Cleaner Case Assembly with Air Hose

RH Fender Apron Seal RH Drive Shaft

L 32 (330, 24) 7.8 (80, 69 in.lbf)

Clutch Accumulator Vehicle Speed Sensor 39 (400, 29) Connector 64 (650, 47) Ground Cable Transaxle BackUp Light Switch Connector x5 L Snap Ring Engine Wire
20 (200, 14)

HoldDown Clamp Battery

Flywheel Housing Under Cover

46 (470, 34) 37 (380, 27)

RH Exhaust Manifold Stay LH Drive Shaft

LSnap

Engine LH Mounting 64 (650, 47) Insulator with Bracket Rear RH Suspension Member Brace
36 (370, 27) 10 (100, 7) 19 (195, 14)

Ring

64 (650, 47) 181 (1,850, 134)

LH Fender Apron Seal PS Gear Assembly No.1 Fuel Tube Protector

Steering Return Pipe

32 (330, 24) 181 (1,850, 134) Silver Bolt : 44 (450, 33) Green Bolt : 66 (670, 48) 66 (670, 48)

49 (500, 36) 294 (3,000, 217)

Lock Cap Pin Pin Rear LH Suspension Member Brace Stabilizer Bar Link
L Cotter L Cotter

Suspension Member with Lower Suspension Arm Front RH Suspension Member Brace
Silver Bolt : 44 (450, 33) Green Bolt : 66 (670, 48) 36 (370, 27) 181 (1,850, 134) 48 (490, 35)

Hole Plug
80 (820, 59)

127 (1,300, 94) 39 (400, 29) L Gasket L Gasket 56 (570, 41)

RH Fender Liner

Front LH Suspension Member Brace L Gasket

L 62 (630, 46) L

Front Exhaust Pipe No.1 Exhaust Pipe Support Bracket

33 (330, 24)

L 62 (630, 46)

Engine Rear Side Shutter Plate Nm (kgfcm, ftlbf) : Specified torque L Nonreusable part LH Fender Liner
33 (330, 24)

Exhaust Pipe Support Stay

Q09981

Author :

Date :

1804

MX4
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE UNIT
MX05001

REMOVAL
1. REMOVE HOOD HINT: At the time of installation, please refer to the following item. Adjust the hood. (See page BO10) 2. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE

3. (a) (b)

Q09982

4. (a) (b) 5. (a) (b)

(c)
Q09983

w/ Cruise Control: REMOVE CRUISE CONTROL ACTUATOR Disconnect the cruise control actuator connector. Remove the 3 bolts and cruise control actuator with the bracket. Torque: 13 Nm (130 kgfcm, 9 ftlbf) REMOVE STARTER Disconnect the connector and wire from the starter. Remove the 2 bolts and starter. Torque: 39 Nm (400 kgfcm, 29 ftlbf) DISCONNECT CLUTCH RELEASE CYLINDER Remove the 2 bolts and disconnect the release cylinder. Torque: 12 Nm (120 kgfcm, 9 ftlbf) Remove the 2 set bolts and nut of the clutch accumulator. Torque: Bolt: 21 Nm (210 kgfcm, 15 ftlbf) Nut: 26 Nm (270 kgfcm, 20 ftlbf) Remove the set bolt of the clutch line bracket. Torque: 12 Nm (120 kgfcm, 9 ftlbf)

6. DISCONNECT GROUND CABLE Remove the set bolt of the ground cable from the transaxle.

Q09984

7. 8. 9. (a) (b)

DISCONNECT ENGINE WIRE FROM CLAMP DISCONNECT VEHICLE SPEED SENSOR AND BACKUP LIGHT SWITCH CONNECTORS DISCONNECT CONTROL CABLE Remove the 2 clips and washers. Remove the 2 clips from the cables.

Q09985

Author :

Date :

1805

MX5
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE UNIT

10.

Q09986

REMOVE 5 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque: 17 mm head: 64 Nm (650 kgfcm, 47 ftlbf) 11. REMOVE FRONT WHEEL Torque: 103 Nm (1,050 kgfcm, 76 ftlbf) 12. RAISE VEHICLE NOTICE: Make sure that the vehicle is securely supported. 13. REMOVE ENGINE REAR SIDE SHUTTER PLATE AND LH AND RH FENDER APRON SEALS

Filler Plug Oil Level 0 5 mm

14.

15.
Drain Plug
Q09987

DRAIN TRANSAXLE OIL Oil grade: API GL4 or GL5 Viscosity: SAE 75W90 Capacity: 4.2 liters (4.4 US qts, 3.7 Imp. qts) Torque: 49 Nm (500 kgfcm, 36 ftlbf) REMOVE LH AND RH DRIVE SHAFTS (See page SA25)

16. (a) (b)

(c)
Q09988

(d)

(e)

REMOVE FRONT EXHAUST PIPE Remove the 2 bolts and exhaust pipe support stay. Torque: 33 Nm (330 kgfcm, 24 ftlbf) Remove the 4 nuts and 2 gaskets from the exhaust manifold. Torque: 62 Nm (630 kgfcm, 46 ftlbf) Remove the 2 bolts, nuts and gasket. Torque: 56 Nm (570 kgfcm, 41 ftlbf) Remove the 2 set bolts of the No.1 exhaust pipe support bracket. Torque: 33 Nm (330 kgfcm, 24 ftlbf) Remove the front exhaust pipe.

Author :

Date :

1806

MX6
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE UNIT

17. (a)

(b) (c)
Q09989

DISCONNECT PS GEAR ASSEMBLY FROM FRONT SUSPENSION MEMBER Remove the 2 nuts and disconnect the stabilizer bar link from the stabilizer bar. Torque: 39 Nm (400 kgfcm, 29 ftlbf) Remove the 4 set bolts of the stabilizer bar bracket. Torque: 19 Nm (195 kgfcm, 14 ftlbf) Remove the 2 bolts, nut and No.1 fuel tube protector.

(d) (e)

Tie the PS gear assembly to the proper position with a code or an equivalent to suspend the assembly securely. Remove the 2 set bolts and nuts of the PS gear assembly. Torque: 181 Nm (1,850 kgfcm, 134 ftlbf)

Q09990

18.

DISCONNECT FRONT ENGINE ABSORBER FROM TRANSAXLE Remove the 2 bolts. Torque: 48 Nm (490 kgfcm, 35 ftlbf)

Q09991

19. REMOVE RH EXHAUST MANIFOLD STAY Remove the bolt, nut and stay. Torque: 20 Nm (200 kgfcm, 14 ftlbf)

Q09992

20.

REMOVE 3 ENGINE FRONT SIDE MOUNTING BOLTS Torque: Silver bolt: 44 Nm (450 kgfcm, 33 ftlbf) Green bolt: 66 Nm (670 kgfcm, 48 ftlbf)

Q09993

Author :

Date :

1807

MX7
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE UNIT

21. (a)

(b)
Q09994

REMOVE LH ENGINE MOUNTING INSULATOR WITH BRACKET Remove the 2 hole plugs, nuts and 3 bolts. Torque: Bolt: 64 Nm (650 kgfcm, 47 ftlbf) Nut: 80 Nm (820 kgfcm, 59 ftlbf) Lift up the transaxle and remove the left engine mounting insulator with the bracket.

22.

Q09995

C A

C C A A B B
Q09996

REMOVE HOLE PLUG AND 4 ENGINE REAR SIDE MOUNTING NUTS Torque: 66 Nm (670 kgfcm, 48 ftlbf) 23. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER (See page EM69) 24. DISCONNECT STEERING RETURN PIPE FROM FRONT SUSPENSION MEMBER Remove the 2 bolts. Torque: 10 Nm (100 kgfcm, 7 ftlbf) 25. REMOVE FRONT SUSPENSION MEMBER WITH LOWER SUSPENSION ARM (a) Remove the LH and RH fender liner set screws. (b) Remove the 6 bolts, 4 nuts, front LH and RH suspension member braces, rear LH and RH suspension member braces and front suspension member with the lower suspension arm. Torque: Bolt A: 181 Nm (1,850 kgfcm, 134 ftlbf) Bolt B: 32 Nm (330 kgfcm, 24 ftlbf) Nut C: 36 Nm (370 kgfcm, 27 ftlbf) 26. JACK UP TRANSAXLE SLIGHTLY Using a transmission jack, support the transaxle.

14 mm Head B

27.
14 mm Head B

(a) (b)
14 mm Head A

REMOVE FLYWHEEL HOUSING UNDER COVER AND TRANSAXLE LOWER SIDE MOUNTING BOLT Remove the 2 bolts and cover. Torque: 7.8 Nm (80 kgfcm, 69 in.lbf) Remove the 3 bolts of the transaxle lower side. Torque: 14 mm head A: 46 Nm (470 kgfcm, 34 ftlbf) 14 mm head B: 37 Nm (380 kgfcm, 27 ftlbf)

Q09997

Author :

Date :

1808

MX8
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE UNIT

28. REMOVE TRANSAXLE Lower the engine left side and remove the transaxle from the engine. HINT: At the time of installation, please refer to the following items. L Align the input shaft with the clutch disc and install the transaxle to the engine. L Temporarily tighten the transaxle mounting bolts.

Author :

Date :

1809

MX9
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE UNIT
MX05101

INSTALLATION
Installation is in the reverse order of removal (See page MX4). HINT: After installation, check and inspect items as follows. L Front wheel alignment (See page SA4). L Do the road test.

Author :

Date :

1810

MX10
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

MANUAL TRANSAXLE ASSEMBLY

MX05202

COMPONENTS
Clutch Release Fork Assembly with Bearing Clutch Release Fork Support
47 (480, 35) 17 (175, 13)

Control Level Housing Support Bracket

Oring Boot
17 (175, 13)

Vehicle Speed Sensor Clutch Release Line Bracket Cover Transaxle Case Receiver
7.4 (75, 65 in.lbf) 17 (175, 13)

Transaxle Case Transmission Oil Cooler SubAssembly

34 (350, 25)

17 (175, 13)

Transmission Oil Pipe Transmission Oil Pipe Magnet

17 (175, 13)

Elbow
27 (275, 20)

Oring

Output Shaft Cover Tapered Roller Bearing Outer Race Front Oil Seal Input Shaft Front Bearing

17 (175, 13)

17 (175, 13)

Transmission Oil Pump Assembly

Differential Case Assembly Oil Pump Drive Gear

Nm (kgfcm, ftlbf) : Specified torque Nonreusable part

Z19124

Author :

Date :

1811

MX11
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

Reverse Shift Arm Bracket Assembly Snap Ring Reverse Shift Fork No.1 Shift Fork
24 (240, 17)

Straight Screw Plug L 25 (250, 18) Seat Spring No.1 Shift Fork Shaft
17 (175, 13)

Ball

Snap Ring No.2 Shift Fork Shaft Snap Ring Snap Ring L
25 (250, 18)

25 (250, 18)

Interlock Roller

No.3 Shift Fork Shaft No.3 Shift Fork BackUp Light Switch
40 (410, 30)

Shift Head
24 (240, 17)

24 (240, 17)

No.2 Shift Fork L

Straight Screw Plug L 13 (130, 9)

Gasket Slotted Spring Pin

Shift and Select Lever Shaft Lock Bolt

49 (500, 36)

20 (200, 14)

Gasket Breather Plug

49 (500, 36)

L Gasket L

Reverse Restrict Gasket Pin No.2 Oil Receiver Pipe

x 17
17 (175, 13)

20 (200, 14)

No.1 Oil Receiver Pipe

Shift and Select Lever Shaft Assembly

29 (300, 22)

No.2 Selecting Bellcrank with Selecting Bellcrank Support

Gasket Gasket Filler Plug

49 (500, 36) 29 (300, 22)

Drain Plug
49 (500, 36)

Transmission Case Transmission Case Cover Nm (kgfcm, ftlbf) : Specified torque Nonreusable part LPrecoated part

x 10

Q10278

Author :

Date :

1812

MX12
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

Input Shaft Assembly Output Shaft Assembly Tapered Roller Bearing Outer Race

Reverse Idler Gear Reverse Idler Gear Shaft Lock Bolt L 29 (300, 22) Thrust Washer Shim

42 (430, 31)

x7 Rear Bearing Retainer Snap Ring 5th Driven Gear Key Spring Inner Synchronizer Ring Middle Synchronizer Ring Outer Synchronizer Ring Synchronizer Pull Ring Key Spring No.3 Clutch Hub No.3 Hub Sleeve Snap Ring Output Shaft Lock Nut
123 (1,250, 90)

Spacer Needle Roller Bearing 5th Gear

Snap Ring

Nm (kgfcm, ftlbf) : Specified torque Nonreusable part LPrecoated part

Z17555

Author :

Date :

1813

MX13
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY
MX05302

DISASSEMBLY
1. 2. REMOVE RELEASE FORK AND BEARING REMOVE BACKUP LIGHT SWITCH WITH GASKET Torque: 40 Nm (410 kgfcm, 30 ftlbf) 3. REMOVE BOLT AND VEHICLE SPEED SENSOR Torque: 17 Nm (175 kgfcm, 13 ftlbf) 4. REMOVE NO.2 SELECTING BELLCRANK WITH SELECTING BELLCRANK SUPPORT Remove the 2 bolts and No.2 selecting bellcrank with the selecting bellcrank support. Sealant: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 20 Nm (200 kgfcm, 14 ftlbf) 5. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK BOLT WITH GASKET Torque: 49 Nm (500 kgfcm, 36 ftlbf) 6. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY WITH GASKET Remove the 4 bolts, shift and select lever shaft assembly and gasket. Sealant: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 20 Nm (200 kgfcm, 14 ftlbf)

FIPG

7. REMOVE TRANSMISSION CASE COVER Remove the 10 bolts and transmission case cover. FIPG: Part No. 08826 00090, THREE BOND 1281 or equivalent Torque: 29 Nm (300 kgfcm, 22 ftlbf) 8. REMOVE BREATHER PLUG WITH GASKET Torque: 49 Nm (500 kgfcm, 36 ftlbf)
Q05816

9. (a) (b) (c) (d) 10. (a)

Q00449

(b)

REMOVE OUTPUT SHAFT LOCK NUT Unstake the lock nut. Engage the gear double meshing. Remove the lock nut. Torque: 123 Nm (1,250 kgfcm, 90 ftlbf) Disengage the gear double meshing. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK Remove the No.3 shift fork set bolt. Torque: 24 Nm (240 kgfcm, 17 ftlbf) Remove the No.3 hub sleeve and No.3 shift fork.
Author : Date : 1814

MX14
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

11. REMOVE 5TH DRIVEN GEAR Using SST, remove the 5th driven gear. SST 0995030010
SST

Q05849

12. (a)

MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE Using a dial indicator, measure the thrust clearance. Standard clearance: 0.10 0.57 mm (0.0039 0.0224 in.) Maximum clearance: 0.65 mm (0.0256 in.)

Z01304

(b)

13. (a)
Z01306

Using a dial indicator, measure the radial clearance. Standard clearance: 0.009 0.050 mm (0.0004 0.0020 in.) Maximum clearance: 0.070 mm (0.0028 in.) REMOVE NO.3 CLUTCH HUB AND 5TH GEAR Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT: At the time of reassembly, please refer to the following item. Select a snap ring that allows the minimum axial play.
Mark a b c d
Q00299

Thickness mm (in.) 1.75 (0.0689) 1.80 (0.0709) 1.85 (0.0729) 1.90 (0.0748) 1.95 (0.0768)

Mark f g h j

Thickness mm (in.) 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 2.15 (0.0847)

Author :

Date :

1815

MX15
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

(b)
SST

Z01308

Using SST, remove the No.3 clutch hub with the synchronizer ring and 5th gear. SST 0995030010 14. REMOVE NEEDLE ROLLER BEARING AND SPACER 15. REMOVE REAR BEARING RETAINER Using a torx socket wrench (T45), remove the 7 torx screws and rear bearing retainer. Sealant: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 42 Nm (430 kgfcm, 31 ftlbf)

16. (a) (b)

REMOVE SNAP RING Using a snap ring expander, remove the input shaft rear bearing snap ring. Using 2 screwdrivers and a hammer, remove the 2 snap rings.

Q06190

17. (a)

(b)
Q01615

REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING AND LOCKING BALL Using a hexagon wrench (6 mm), remove the plug. Sealant: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 25 Nm (250 kgfcm, 18 ftlbf) Using a magnetic finger, remove the seat, spring and locking ball. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT Sealant: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 Nm (300 kgfcm, 22 ftlbf)

18.

Q00056

Author :

Date :

1816

MX16
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

FIPG

19. REMOVE TRANSMISSION CASE Remove the 17 bolts and tap the case with a plastic hammer. FIPG: Part No. 08826 00090, THREE BOND 1281 or equivalent Torque: 29 Nm (300 kgfcm, 22 ftlbf)

Q05815

20. REMOVE SHIM HINT: At the time of reassembly, please refer to the following item. Install the previously selected shim by adjusting output shaft preload. (See page MX22)

MT0669

21.

SST

MT0693

REMOVE OUTPUT SHAFT REAR TAPER ROLLER BEARING OUTER RACE Using SST and a hammer, remove the output shaft rear taper roller bearing outer race. SST 0931660011 (0931600011) 22. REMOVE TRANSMISSION OIL PIPE (a) Remove the gasket from the oil pipe. (b) Remove the 2 bolts and oil pipe. Torque: 17 Nm (175 kgfcm, 13 ftlbf) 23. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY Remove the bolt and pull off the reverse shift arm and bracket. Torque: 17 Nm (175 kgfcm, 13 ftlbf) 24. REMOVE REVERSE IDLER GEAR AND SHAFT Pull out the shaft, and remove the reverse idler gear and thrust washer.

Q06375

Matchmarks

HINT: At the time of reassembly, please refer to the following item. Align the matchmarks, as shown.

Z17557

Author :

Date :

1817

MX17
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

25. (a)

(b)
Q01614

REMOVE STRAIGHT SCREW PLUG, LOCKING BALL AND SPRING Using a hexagon wrench (6 mm), remove the 2 plugs. Sealant: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 25 Nm (250 kgfcm, 18 ftlbf) Using a magnetic finger, remove the 2 seats, springs and balls.

26.

Q08124

REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD SET BOLT Torque: 24 Nm (240 kgfcm, 17 ftlbf) 27. REMOVE NO.1 SHIFT FORK SHAFT Pull up the No.3 shift fork shaft, and remove the No.1 shift fork shaft. HINT: At the time of reassembly, please refer to the following item. When it is difficult to push the fork shaft through the reverse shift fork, pull up the No.3 shift fork shaft. 28. REMOVE INTERLOCK ROLLER Using a magnetic finger, remove the interlock roller from the reverse shift fork.

Q08125

29. (a) (b)

REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD AND NO.1 SHIFT FORK Pull out the No.2 shift fork shaft. Remove the shift head and No.1 shift fork.

Q08126

30. (a) (b) 31. (a) (b)

Z00182

REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO.2 SHIFT FORK Pull out the No.3 shift fork shaft with the reverse shift fork. Remove the No.2 shift fork. REMOVE SNAP RING Using 2 screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No.3 shift fork shaft. Using 2 screwdrivers and a hammer, remove the 3 snap rings from the No.1, No.2 and No.3 shift fork shafts.

Author :

Date :

1818

MX18
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

32. (a) (b) 33. (a) (b) 34. 35. (a) (b)

REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY Leaning the output shaft to the differential side, remove the input shaft assembly. Lift up the differential case assembly, remove the output shaft assembly. REMOVE DIFFERENTIAL CASE ASSEMBLY Remove the oil pump drive gear. Remove the differential case assembly. REMOVE MAGNET FROM TRANSAXLE CASE REMOVE TRANSMISSION OIL PUMP ASSEMBLY AND OIL PIPE Remove the 2 bolts and oil pipe. Torque: 17 Nm (175 kgfcm, 13 ftlbf) Remove the 2 bolts and oil pump assembly. Torque: 17 Nm (175 kgfcm, 13 ftlbf)

36. (a)

MT0781

(b) HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring. (c) Remove the synchronizer rings.

REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB Remove the No.5 synchronizer ring with the key spring from the No.3 clutch hub. Using a screwdriver, remove the snap ring.

Author :

Date :

1819

MX19
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY
MX05401

INSPECTION
1. (a) (b) INSPECT NO.5 SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the middle No.5 synchronizer ring in one direction while pushing it to the outer No.5 synchronizer ring. Check that the ring locks. If it does not lock, replace the synchronizer ring.
MT0782

2.

MEASURE SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
WM0066

3.
SST

(a) (b) (c)

IF NECESSARY, REPLACE INPUT SHAFT BEARING AND OIL SEAL Remove the 3 bolts and transaxle case receiver. Using SST, pull out the bearing. SST 0961265014 Using a screwdriver, remove the oil seal.

Z00192

SST

(d) (e)

Using SST, drive in a new oil seal. SST 0960800081, 0995070010 (0995107150) Coat the lip of seal with MP grease.

Z00194

(f)
SST

(g) (h)

Using SST, drive in a new bearing. SST 0995060010 (0995100580), 0995070010 (0995107150) Install the transaxle case receiver. Install and torque the 3 bolts. Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)

Q08014

Author :

Date :

1820

MX20
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

(i)
SST

Using SST and a press, remove the inner race. SST 0995000020

Q05164

(j)

Using SST and a press, install a new input shaft front bearing inner race. SST 0931660011 (0931600021)

SST

Q00141

4.
SST

(a)

(b)
Q00338

IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING OUTER RACE AND OUTPUT SHAFT FRONT COVER Using SST, pull out the output shaft front bearing outer race. SST 0930800010 Remove the output shaft cover.

(c) Install a new output shaft cover. HINT: Install the output shaft cover projection into the case side groove.

Z00197

(d)
SST

Using SST and a hammer, drive in a new output shaft front bearing outer race. SST 0931660011 (0931600011, 0931600021)

SST

Q06368

Author :

Date :

1821

MX21
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

(e)

Using SST and a socket wrench, remove the output shaft front bearing. SST 0995000020, 0995000030

SST

Socket Wrench

Q00245

(f)

Using SST and a press, install a new output shaft front bearing. SST 0931660011 (0931600071)

SST
Z00199

5. (a) (b) (c)

IF NECESSARY, REPLACE REVERSE RESTRICT PIN Using a hexagon wrench (6 mm), remove the screw plug. Using a pin punch and hammer, drive out the slotted spring pin. Replace the reverse restrict pin.

Q01611

(d) (e)

(f)
Z00201

Using a pin punch and hammer, drive in the slotted spring pin. Apply sealant to the screw plug threads. Sealant: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a hexagon wrench (6 mm), install and torque the screw plug. Torque: 13 Nm (130 kgfcm, 9 ftlbf)

Author :

Date :

1822

MX22
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY
MX05501

REASSEMBLY
Reassembly is in the reverse order of disassembly. HINT: L Before reassembly, select a shim by adjusting output shaft preload. L Coat all of the sliding and rotating surfaces with gear oil before reassembly. ADJUST OUTPUT SHAFT PRELOAD (a) Install the output shaft assembly to the transaxle case. (b) Install the transmission case to the transaxle case. HINT: If necessary, tap on the case with a plastic hammer. (c) Install and torque the 17 bolts. Torque: 29 Nm (300 kgfcm, 22 ftlbf) (d) Install the output shaft rear taper roller bearing outer race. (e) Install the adjusting shim. HINT: When reusing the output shaft bearing, first install a shim of the same thickness as before. If installing a new taper roller bearing, first select and install a shim of lesser thickness than before. (f) Install the rear bearing retainer. (g) Using a torx wrench (T45), install and torque the 7 torx screws. Torque: 42 Nm (430 kgfcm, 31 ftlbf) (h) Install a new lock nut to the output shaft. (i) Turn the output shaft right and left 2 or 3 times to allow the bearing to settle.

Author :

Date :

1823

MX23
MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE ASSEMBLY

(j)

Z12593

Using a torque wrench, measure the preload. Preload (at starting): New bearing 0.8 1.6 Nm (8 16 kgfcm, 6.9 13.9 in.lbf) Reused bearing 0.5 1.0 Nm (5 10 kgfcm, 4.3 8.7 in.lbf) If the preload is not within the specification, select an appropriate adjusting shim. The preload will change approx. 0.4 0.5 Nm (4 5 kgfcm, 3.5 4.3 in.lbf) for every 0.05 mm change in adjusting shim thickness.
Mark 0 1 2 3 4 5 6 7 8 9 A B C Thickness mm (in.) 1.30 (0.0512) 1.35 (0.0531) 1.40 (0.0551) 1.45 (0.0571) 1.50 (0.0591) 1.55 (0.0610) 1.60 (0.0630) 1.65 (0.0650) 1.70 (0.0669) 1.75 (0.0689) 1.80 (0.0709) 1.85 (0.0728) 1.90 (0.0748) Mark D E F G H J K L M N P Q Thickness mm (in.) 1.95 (0.0768) 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 2.15 (0.0846) 2.20 (0.0866) 2.25 (0.0886) 2.30 (0.0906) 2.35 (0.0925) 2.40 (0.0945) 2.45 (0.0965) 2.50 (0.0984)

(k) (l)

Remove the lock nut. Remove these parts. Removal is in the reverse order of installation. L Rear bearing retainer L Shim L Transmission case L Output shaft assembly L Output shaft rear bearing outer race

Author :

Date :

1824

MX24
MANUAL TRANSAXLE (E153) INPUT SHAFT

INPUT SHAFT
MX05601

COMPONENTS
Spacer Synchronizer Ring 4th Gear Snap Ring Needle Roller Bearing 3rd Gear Needle Roller Bearing Rear Bearing Spring Snap Ring LInput Shaft Front Bearing Inner Race Synchronizer Ring No.2 Hub Sleeve No.2 Clutch Hub Shifting Key LNonreusable part Input Shaft

MT0791

Author :

Date :

1825

MX25
MANUAL TRANSAXLE (E153) INPUT SHAFT
MX05701

DISASSEMBLY
1. MEASURE 3RD AND 4TH GEARS THRUST CLEARANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 3rd gear: 0.10 0.35 mm (0.0039 0.0138 in.) 4th gear: 0.10 0.55 mm (0.0039 0.0217 in.) Maximum clearance: 3rd gear: 0.40 mm (0.0157 in.) 4th gear: 0.60 mm (0.0236 in.)

3rd Gear 4th Gear

Q06369

Q00111

2. CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE Using a dial indicator, measure the radial clearance between the gear and shaft. Standard clearance: 3rd gear: 0.009 0.053 mm (0.0004 0.0021 in.) 4th gear: 0.009 0.051 mm (0.0004 0.0020 in.) Maximum clearance: 3rd and 4th gears: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring.

SST

4. REMOVE REAR BALL BEARING AND 4TH GEAR Using SST and a press, remove the rear bearing. SST 0995000020 5. REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING 6. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring.
Q05165

Author :

Date :

1826

MX26
MANUAL TRANSAXLE (E153) INPUT SHAFT

7.

REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRONIZER RING AND 3RD GEAR Using a press, remove the No.2 hub sleeve, 3rd gear and synchronizer rings. 8. REMOVE NEEDLE ROLLER BEARING

Q00115

Author :

Date :

1827

MX27
MANUAL TRANSAXLE (E153) INPUT SHAFT
MX05801

INSPECTION
1. (a) (b) INSPECT 3RD GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If it does not lock, replace the synchronizer ring.
MT0780

(c)

Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.7 mm (0.028 in.) If the clearance is less than the minimum, replace the synchronizer ring.

MT0786

2. (a) (b)

WM0064

INSPECT 4TH GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ring.

(d)

WM0064

Using a feeler gauge, measure the clearance between the synchronizer ring back and spline end. Minimum clearance: 0.8 mm (0.031 in.) If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.
Author : Date : 1828

MX28
MANUAL TRANSAXLE (E153) INPUT SHAFT

3.

MEASURE NO.2 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
WM0066

4. (a) (b)

INSPECT INPUT SHAFT Check the input shaft for wear or damage. Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum outer diameter: Part A: 27.950 mm (1.1004 in.) Part B and C: 35.950 mm (1.4154 in.)

Q00172

(c)

Using a dial indicator, check the shaft runout. Maximum runout: 0.05 mm (0.0020 in.)

Q00173

Author :

Date :

1829

MX29
MANUAL TRANSAXLE (E153) INPUT SHAFT
MX05902

REASSEMBLY
HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE (a) Install the 3 springs and shifting keys to the clutch hub. (b) Install the hub sleeve to the clutch hub. HINT: Direct identification groove of the hub sleeve to front of the transmission.

Front

Q00383

2.

(a) (b) (c)

INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT Apply MP grease to the needle roller bearing. Assemble the needle roller bearings into the 3rd gear. Place the synchronizer rings on the gear and align the ring slots with the shifting keys.

MT0790

(d)

Using SST and a press, install the 3rd gear and No.2 hub sleeve. SST 0950635010

SST

Q00183

3. (a)
H J K L
Q00116

INSTALL SNAP RING Select a snap ring that allows the minimum axial play.
Thickness mm (in.) 2.30 (0.0906) 2.35 (0.0925) 2.40 (0.0945) 2.45 (0.0965) Mark M N P Thickness mm (in.) 2.50 (0.0984) 2.55 (0.1004) 2.60 (0.1024)

Mark

(b)

Using a screwdriver and hammer, tap in the snap ring.

Author :

Date :

1830

MX30
MANUAL TRANSAXLE (E153) INPUT SHAFT

4.

MEASURE 3RD GEAR THRUST CLEARANCE (See page MX24)

5.

(a) (b) (c)

SST
N00494

(d) (e) 6. (a)

1 2 3 4

INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, 4TH GEAR AND REAR BALL BEARING Install the spacer. Apply MP grease to the needle roller bearings. Place the synchronizer ring on the gear and align the ring slots with the shifting keys. Install the 4th gear. Using SST and a press, install the rear ball bearing. SST 0950635010 INSTALL SNAP RING Select a snap ring that allows the minimum axial play.
Thickness mm (in.) 2.35 (0.0925) 2.40 (0.0945) 2.45 (0.0965) 2.50 (0.0984) Mark 5 6 7 8 Thickness mm (in.) 2.55 (0.1004) 2.60 (0.1024) 2.65 (0.1043) 2.70 (0.1063)

Mark

Q00116

(b) 7.

Using a screwdriver and hammer, tap in the snap ring. MEASURE 4TH GEAR THRUST CLEARANCE (See page MX24)

Author :

Date :

1831

MX31
MANUAL TRANSAXLE (E153) OUTPUT SHAFT

OUTPUT SHAFT
MX05A01

COMPONENTS
Needle Roller Bearing 3rd Driven Gear 4th Driven Gear Spacer Needle Roller Bearing No.1 Hub Sleeve

2nd Gear Spacer Shifting Key LOutput Shaft Rear Bearing Shifting Key Spring

Spacer

1st Gear Synchronizer Ring No.1 Clutch Hub S Synchronizer Ring LOutput Shaft Front Bearing Output Shaft
N00785

LNonreusable part

Author :

Date :

1832

MX32
MANUAL TRANSAXLE (E153) OUTPUT SHAFT
MX05B01

DISASSEMBLY
1. MEASURE 1ST AND 2ND GEARS THRUST CLEARANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 1st gear: 0.10 0.35 mm (0.0039 0.0138 in.) 2nd gear: 0.10 0.45 mm (0.0039 0.0177 in.) Maximum clearance: 1st gear: 0.40 mm (0.0157 in.) 2nd gear: 0.50 mm (0.0197 in.)

1st Gear 2nd Gear

Q06370

Z00218

2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE Using a dial indicator, measure the radial clearance between the gear and shaft. Standard clearance: 1st gear: 0.009 0.051 mm (0.0004 0.0020 in.) 2nd gear: 0.009 0.053 mm (0.0004 0.0021 in.) Maximum clearance: 1st and 2nd gears: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH DRIVEN GEAR AND SPACER (a) Using a press, remove the bearing and 4th driven gear. (b) Remove the spacer.

Z00219

4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR Using a press, remove the 3rd driven gear and 2nd gear. 5. REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING 6. REMOVE SNAP RING Using a snap ring expander, remove the snap ring.

Z00220

Author :

Date :

1833

MX33
MANUAL TRANSAXLE (E153) OUTPUT SHAFT

7.

REMOVE NO.1 HUB SLEEVE ASSEMBLY AND 1ST GEAR Using a press, remove the No.1 hub sleeve and 1st gear. 8. REMOVE SYNCHRONIZER RING AND NEEDLE ROLLER BEARING

Z00222

9. REMOVE OUTPUT SHAFT FRONT BEARING Using SST, remove the output shaft front bearing. SST 0995000020, 0995000030

SST

Q00296

Author :

Date :

1834

MX34
MANUAL TRANSAXLE (E153) OUTPUT SHAFT
MX05C02

INSPECTION
1. (a) (b) INSPECT 1ST GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ring.

WM0064

(d)

WM0065

Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.8 mm (0.031 in.) If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. 2. INSPECT 2ND GEAR SYNCHRONIZER RING (a) Check for wear or damage. (b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If it does not lock, replace the synchronizer ring.

MT0780

(c)

Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.7 mm (0.028 in.) If the clearance is less than the minimum, replace the synchronizer ring.

MT0787

Author :

Date :

1835

MX35
MANUAL TRANSAXLE (E153) OUTPUT SHAFT

3.

MEASURE NO.1 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
WM0066

4. (a) (b)

INSPECT OUTPUT SHAFT Check the output shaft for wear or damage. Using a micrometer, measure the outer diameter of the output shaft journal surface. Minimum outer diameter: 38.950 mm (1.5335 in.)

Z00223

(c)

Using a dial indicator, check the shaft runout. Maximum runout: 0.06 mm (0.0024 in.)

Z00224

Author :

Date :

1836

MX36
MANUAL TRANSAXLE (E153) OUTPUT SHAFT
MX05D01

REASSEMBLY
HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE (a) Install the clutch hub and shifting keys to the hub sleeve. (b) Install the shifting key springs under the shifting keys. NOTICE: Position the key springs so that their end gaps are not aligned.

Front

Q00384

2.

(a) (b) (c)

INSTALL NEEDLE ROLLER BEARING, 1ST GEAR, SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO OUTPUT SHAFT Apply MP grease to the needle roller bearing. Install the 1st gear. Place the synchronizer ring (for the 1st gear) on the gear and align the ring slots with the shifting keys.

Z00225

(d)
SST

Using SST and a press, install the 1st gear and No.1 hub sleeve. SST 0931660011 (0931600041)

Z00385

3. (a)
A B C D
Z00386

INSTALL SNAP RING Select a snap ring that allows the minimum axial play.
Thickness mm (in.) 2.80 (0.1102) 2.85 (0.1122) 2.90 (0.1142) 2.95 (0.1161) Mark E F G Thickness mm (in.) 3.00 (0.1181) 3.05 (0.1201) 3.10 (0.1220)

Mark

(b)

Using a snap ring expander, install the snap ring.

Author :

Date :

1837

MX37
MANUAL TRANSAXLE (E153) OUTPUT SHAFT

4.

MEASURE 1ST GEAR THRUST CLEARANCE (See page MX31)

5.

MT0792

INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RING, 2ND GEAR AND 3RD DRIVEN GEAR (a) Install the spacer. (b) Apply MP grease to the needle roller bearing. (c) Place the synchronizer rings (for the 2nd gear) on the gear. NOTICE: Do not install the synchronizer ring for the 1st gear. (d) Install the 2nd gear. (e) Using a press, install the 3rd driven gear. NOTICE: Align the clutch hub grooves with the projections on the synchronizer ring. 6. MEASURE 2ND GEAR THRUST CLEARANCE (See page MX31)

N00495

7. (a) (b)

INSTALL SPACER AND 4TH DRIVEN GEAR Install the spacer. Using a press, install the 4th driven gear.

Z00390

8. INSTALL OUTPUT SHAFT REAR BEARING Using SST and a press, install the bearing. SST 0950630012
SST

Z00391

Author :

Date :

1838

MX38
MANUAL TRANSAXLE (E153) OUTPUT SHAFT

9. INSTALL OUTPUT SHAFT FRONT BEARING Using SST and a press, install a new output shaft front bearing. SST 0931660011 (0931600071)

SST
Z00392

Author :

Date :

1839

MX39
MANUAL TRANSAXLE (E153) OIL PUMP

OIL PUMP
MX05E01

COMPONENTS
LORing LGasket Oil Strainer

Oil Pump Driven Rotor

10 (105, 8)

Transmission Oil Pump Case

Oil Pump Drive Rotor Oil Pump Drive Gear Relief Valve Ball Spring Spring Holder Oil Pump Cover
10 (105, 8)

Nm (kgfcm, ftlbf) : Specified torque LNonreusable part

Z17558

Author :

Date :

1840

MX40
MANUAL TRANSAXLE (E153) OIL PUMP
MX05F01

INSPECTION
1. (a) (b) CHECK ROTOR BODY CLEARANCE Install the oil pump drive gear to the drive rotor. Using a feeler gauge, measure the body clearance between the drive rotor and oil pump case. Standard clearance: 0.10 0.16 mm (0.0039 0.0063 in.) Maximum clearance: 0.30 mm (0.0118 in.) CHECK ROTOR TIP CLEARANCE Install the oil pump drive gear to the drive rotor. Using a feeler gauge, measure the tip clearance between the drive and driven rotors. Standard clearance: 0.08 0.15 mm (0.0031 0.0059 in.) Maximum clearance: 0.30 mm (0.0118 in.)

Z00242

2. (a) (b)

Z00243

3. CHECK SIDE CLEARANCE Using a precision straight edge and feeler gauge, measure the side clearance of both rotors. Standard clearance: 0.03 0.08 mm (0.0012 0.0031 in.) Maximum clearance: 0.15 mm (0.0059 in.)
Z00244

Author :

Date :

1841

MX41
MANUAL TRANSAXLE (E153) SHIFT AND SELECT LEVER SHAFT

SHIFT AND SELECT LEVER SHAFT

MX05G02

COMPONENTS
Dust Boot LOil Seal Control Shaft Cover Snap Ring No.1 Compression Spring Shift Interlock Plate No.2 Shift Inner Lever No.2 Select Spring Seat No.1 Select Spring Seat

Slotted Spring Pin No.2 Compression Spring Snap Ring No.1 Shift Inner Lever

Slotted Spring Pin

Shift and Select Lever Shaft LNonreusable part MP Grease

Q10276

Author :

Date :

1842

MX42
MANUAL TRANSAXLE (E153) DIFFERENTIAL CASE

DIFFERENTIAL CASE
MX05H01

COMPONENTS
Transaxle Case Cover L L Stud Bolt
54 (550, 40)

L Oil Seal L

54 (550, 40)

Differential Spider Differential Pinion

Differential Side Gear Side Gear Thrust Washer Pinion Thrust Washer Tapered Roller Bearing and Outer Race
63 (640, 46)

Differential Right Case Vehicle Speed Sensor Drive Gear Differential Left Case x 16

Ring Gear Tapered Roller Bearing and Outer Race

x 16 Shim

124 (1,260, 91)

Oil Baffle

Oil Seal

Z17560

Author :

Date :

1843

MX43
MANUAL TRANSAXLE (E153) DIFFERENTIAL CASE
MX05I03

DISASSEMBLY
SST

Q05166

1. REMOVE TAPERED ROLLER BEARING Using SST, remove the left and right bearings. SST 0995040011 2. REMOVE RING GEAR (a) Place matchmarks on both the differential case and ring gear. (b) Remove the 16 bolts. (c) Using a plastic hammer, tap the ring gear and remove it. 3. (a) (b) (c) (d) DISASSEMBLE DIFFERENTIAL CASE Place matchmarks on the differential right and left cases. Using a torx wrench (T50), remove the 16 torx screws. Using a plastic hammer, tap the differential left case. Remove the vehicle speed sensor drive gear from the differential right case.

Matchmarks

Z00281

(e)

Remove the 2 differential side gears, side gear thrust washers, 4 differential pinions and pinion thrust washers from the differential left case.

Z00284

4.

(a) (b) (c)

Z00286

(d) (e) HINT: First select and install a shim of less thickness than before.

Transmission Case Side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Using a screwdriver, remove the oil seal. Remove the oil baffle. Using a brass bar and hammer, drive out the bearing outer race lightly and evenly. Remove the shim. Install the shim. (See page MX42)

Author :

Date :

1844

MX44
MANUAL TRANSAXLE (E153) DIFFERENTIAL CASE

(f)
SST

Using SST and a press, install a new tapered roller bearing outer race. SST 0931660011 (0931600011, 0931600041)

Z00288

(g) Install the oil baffle. HINT: Install the oil baffle projection into the case side cutout.

Z00289

SST

(h) (i)

Using SST and a hammer, drive in a new oil seal. SST 0922315020, 0995070010 (0995107150) Coat the lip of oil seal with MP grease.

Q06288

5.

(a) (b) (c)

MT0659

Transaxle Case Side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Remove the 4 bolts and 3 nuts. Using a plastic hammer, tap the stud bolt and remove the transaxle case cover. Using a screwdriver and hammer, drive out the oil seal from the transaxle case cover.

SST

(d)

Using SST, a brass bar and hammer, remove the tapered roller bearing outer race. SST 0961265014

Z01427

Author :

Date :

1845

MX45
MANUAL TRANSAXLE (E153) DIFFERENTIAL CASE

SST

(e)

Using SST and a press, install a new tapered roller bearing outer race. SST 0931660011 (0931600011, 0931600041)

Z00292

(f) (g)

Using SST and a hammer, drive in a new oil seal. SST 0931660011 (0931600011) Coat the oil seal lip with MP grease.

SST

Z00293

(h)

FIPG

(i)
F

Z19038

(j) (k)

Apply FIPG to the transaxle case cover, as shown. FIPG: Part No. 08826 00090, THREE BOND 1281 or equivalent Apply sealant to the bolt threads. Sealant: Part No.08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the stud bolt and cover to the transaxle case. Install and torque the 4 bolts and 3 nuts. Torque: 54 Nm (550 kgfcm, 40 ftlbf)

Author :

Date :

1846

MX46
MANUAL TRANSAXLE (E153) DIFFERENTIAL CASE
MX05J01

REASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. (a) Install the thrust washer to the side gear. (b) Install the 4 pinions and thrust washers to the spider. (c) Install the side gear and spider with the 4 pinions to the differential left case. (d) Using a dial indicator, measure the backlash of the pinion gear while holding the differential left case. Standard backlash: 0.05 0.20 mm (0.0020 0.0079 in.) HINT: Push the pinion gear and spider with the 4 pinions to the differential left case.

Z00295

(e)

Install the side gear and spider with the 4 pinions to the right side of the differential case. Check the side gear backlash.

Z00296

(f)

Refer to the table below, and select the thrust washer which will ensure that the backlash is within the specification. Try to select a washer of the same size.
Thickness mm (in.) 0.80 (0.0315) 0.90 (0.0354) 1.00 (0.0394) 1.10 (0.0433) Thickness mm (in.) 1.20 (0.0472) 1.30 (0.0512) 1.40 (0.0551)

Z00297

(g)

Install the vehicle speed sensor drive gear.

Z00298

Author :

Date :

1847

MX47
MANUAL TRANSAXLE (E153) DIFFERENTIAL CASE

(h) (i)
Matchmarks

(j)

2. (a)
Z00299

(b) (c) (d)

Align the matchmarks on the differential cases. Using a plastic hammer, carefully tap the differential case to install it. Using a torx wrench (T50), install and torque the 16 torx screws. Torque: 63 Nm (640 kgfcm, 46 ftlbf) INSTALL RING GEAR Clean the contact surface of the differential case and the threads of the ring gear and differential case. Heat the ring gear in boiling water. Carefully remove the ring gear from the water. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

Driven Gear Side

Z00303

HINT: Align the matchmarks on the differential left case. (e) Temporarily install the 16 bolts. NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently. (f) After the ring gear has cooled sufficiently, torque the ring gear set bolts. Torque: 124 Nm (1,260 kgfcm, 91 ftlbf) 3. INSTALL TAPERED ROLLER BEARING Using SST and a press, install new left and right bearings onto the differential case. SST 0931620011, 0931660011 (0931600011) HINT: Press the bearing on the ring side first. 4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD (See pages MX22) 5. INSTALL DIFFERENTIAL CASE ASSEMBLY TO TRANSAXLE CASE 6. INSTALL OUTPUT SHAFT ASSEMBLY Lift up the differential case and install the output shaft assembly. 7. INSTALL TRANSMISSION CASE (a) Install the transmission case. HINT: If necessary, tap on the case with a plastic hammer. (b) Install and torque the 17 bolts. Torque: 29 Nm (300 kgfcm 22 ftlbf)

SST

SST
Q06410

Author :

Date :

1848

MX48
MANUAL TRANSAXLE (E153) DIFFERENTIAL CASE

8.

INSTALL OUTPUT SHAFT REAR TAPERED ROLLER BEARING OUTER RACE Using a plastic hammer, drive in the outer race. 9. INSTALL SHIM (See pages MX22) HINT: Install the previously selected shim. 10. INSTALL REAR BEARING RETAINER Using a torx wrench (T45), install and torque the 7 torx screws. Torque: 42 Nm (430 kgfcm, 31 ftlbf) 11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD (a) Install a new lock nut to the output shaft. (b) Turn the output shaft right and left 2 or 3 times to allow the bearings to settle. (c) Using a torque wrench, measure the preload. Preload (at starting): New bearing (Output shaft preload plus) 0.2 0.3 Nm (1.8 3.5 kgfcm, 1.6 3.0 in.lbf) Reused bearing (Output shaft preload plus) 0.1 0.2 Nm (1.1 2.2 kgfcm, 1.0 1.9 in.lbf) If the preload is not within the specification, select an appropriate adjusting shim. HINT: The total preload will change by about 0.1 0.2 Nm (1 2 kgfcm, 0.9 1.7 in.lbf) with each 0.05 mm change in adjusting shim thickness.
Mark
Z00309

Q00036

Thickness mm (in.) 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 2.15 (0.0846) 2.20 (0.0866) 2.25 (0.0886) 2.30 (0.0906) 2.35 (0.0925) 2.40 (0.0945)

Mark 9 A B C D E F G H

Thickness mm (in.) 2.45 (0.0965) 2.50 (0.0984) 2.55 (0.1004) 2.60 (0.1024) 2.65 (0.1043) 2.70 (0.1063) 2.75 (0.1083) 2.80 (0.1102) 2.85 (0.1122)

0 1 2 3 4 5 6 7 8

12. REMOVE REAR BEARING RETAINER Using a torx wrench (T45), remove the 7 torx screws and rear bearing retainer. 13. REMOVE SHIM 14. REMOVE TRANSMISSION CASE (a) Remove the 17 bolts. (b) Using a plastic hammer, tap the transmission case. 15. REMOVE OUTPUT SHAFT ASSEMBLY 16. REMOVE DIFFERENTIAL CASE ASSEMBLY

Author :

Date :

1849

MX49
MANUAL TRANSAXLE (E153) SHIFT LEVER AND CONTROL CABLE

SHIFT LEVER AND CONTROL CABLE

MX05K01

COMPONENTS
Shift Lever Knob

Center Console Upper Panel Heater Control Assembly

Center Cluster Finish Panel Rear Console Box Front Console Box

Shift Cable Grommet Retainer

Shift Cable Grommet Retainer Grommet

4.9 (50, 43 in.lbf)

Shift Cable Grommet Clip

4.9 (50, 43 in.lbf)

12 (120, 9)

Clip

Clip

Shift Lever Assembly Clip

Clip Clip Clip Washer Washer Clip

Shift Control Cable Washer Select Control Cable

Nm (kgfcm, ftlbf) : Specified torque

Q10281

Author :

Date :

1850

MX1
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE SYSTEM

MANUAL TRANSAXLE SYSTEM

MX04A01

PRECAUTION
When working with FIPG material, you must observe the following items. L Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces. L Thoroughly clean all components to remove all the loose material. L Clean both sealing surfaces with a nonresidue solvent. L Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface. L Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.

Author :

Date :

1851

MX2
MANUAL TRANSAXLE (S51) TROUBLESHOOTING

TROUBLESHOOTING
MX04B04

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area 1. Oil (Level low) 2. Oil (Wrong) 3. Gear (Worn or damaged) 4. Bearing (Worn or damaged) 1. Oil (Level too high) 2. Gasket (Damaged) 3. Oil seal (Worn or damaged) 4. Oring (Worn or damaged) 1. Control cable (Faulty) 2. Synchronizer ring (Worn or damaged) y g( g ) Hard to shift or will not shift 3. Shift key spring (Damaged) 3 See page MX4 MX4 MX 9 MX9 MX9 MX4 MX9 MX 9 MX9 MX9 MX43 MX9 MX20 MX28 MX9 MX20 MX28 MX9 MX9 MX 9 MX9 MX9

Noise N i

Oil l k leakage

Jumps out of gear J t f

1. Locking ball spring (Damaged) 2. Shift fork (Worn) 3. Gear (Worn or damaged) 4. Bearing (Worn or damaged)

Author :

Date :

1852

MX3
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE UNIT

MANUAL TRANSAXLE UNIT

MX04C01

COMPONENTS
Hood
14 (145, 10)

Control Cable Clip

Clutch Line 12 (120, 9) Bracket

w/ Cruise Control: Cruise Control Actuator

13 (130, 9)

Clip Washer

12 (120, 9) 6.9 (70, 61 in.lbf)

Clutch Release Cylinder

Air Cleaner Case Assembly with Air Hose

RH Drive Shaft L Snap Ring

L 32 (330, 24)

39 (400, 29)

Manifold Stay
39 (400, 29) RH Stiffener Plate

Vehicle Speed Sensor 46 (470, 34) Connector Ground Cable Starter

39 (400, 29)

RH Fender Apron Seal

37 (380, 27)

BackUp Light Switch Connector

64 (650, 47)

HoldDown Clamp Battery

LH Stiffener Plate
37 (380, 27) 9.3 (95, 82 in.lbf)

Transaxle
64 (650, 47)

L Snap

Ring LH Drive Shaft LH Fender Apron Seal

Manifold Stay Rear End Plate with Oil Pan 42 (425, 31) Insulator Rear RH Suspension Member Brace
36 (370, 27) 32 (330, 24) 10 (100, 7)

64 (650, 47) 19 (195, 14) L

Engine LH Mounting Insulator with Bracket

181 (1,850, 134)

PS Gear Assembly No.1 Fuel Tube Protector

49 (500, 36) 294 (3,000, 217)

Steering Return Pipe

181 (1,850, 134) Silver Bolt: 44 (450, 33) Green Bolt: 66 (670, 48)

Suspension Member with Lower Suspension Arm Front RH Suspension Member Brace
36 (370, 27) 181 (1,850, 134) Silver Bolt: 44 (450, 33) Green Bolt: 66 (670, 48)

Hole Plug
66 (670, 48)

Front LH Suspension Member Brace

Hole Plug
80 (820, 59) L Gasket

Lock Cap L Cotter Pin L Cotter Pin Rear LH Suspension Member Brace Stabilizer Bar Link
127 (1,300, 94) 39 (400, 29) 33 (330, 24) L L Gasket 56 (570, 41)

RH Fender Liner Engine Rear Side Shutter Plate LH Fender Liner

L 62 (630, 46)

Front Exhaust Pipe No.1 Exhaust Pipe Support Bracket

33 (330, 24) 19 (195, 14)

Exhaust Pipe Bracket Nm (kgfcm, ftlbf) : Specified torque L Nonreusable part

Q09998

Author :

Date :

1853

MX4
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE UNIT
MX04D01

REMOVAL
1. REMOVE HOOD HINT: At the time of installation, please refer to the following item. Adjust the hood. (See page BO10) 2. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE

3. (a) (b)

Q09982

4. (a) (b) 5. (a) (b)

A B
Q09999

w/ Cruise Control: REMOVE CRUISE CONTROL ACTUATOR Disconnect the cruise control actuator connector. Remove the 3 bolts and cruise control actuator with the bracket. Torque: 13 Nm (130 kgfcm, 9 ftlbf) REMOVE STARTER Disconnect the connector and wire from the starter. Remove the 2 bolts and starter. Torque: 39 Nm (400 kgfcm, 29 ftlbf) DISCONNECT CLUTCH RELEASE CYLINDER Remove the 2 bolts and disconnect the release cylinder. Torque: 12 Nm (120 kgfcm, 9 ftlbf) Remove the 2 set bolts of the clutch line bracket. Torque: Bolt A: 12 Nm (120 kgfcm, 9 ftlbf) Bolt B: 6.9 Nm (70 kgfcm, 61 in.lbf)

6. DISCONNECT GROUND CABLE Remove the set bolt of the ground cable from the transaxle.

Q10000

7. REMOVE MANIFOLD STAY Remove the 2 bolts and stay. Torque: 42 Nm (425 kgfcm, 31 ftlbf) 8. DISCONNECT VEHICLE SPEED SENSOR AND BACKUP LIGHT SWITCH CONNECTORS 9. DISCONNECT CONTROL CABLE (a) Remove the 2 clips and washers. (b) Remove the 2 clips from the cables.
Q10001

Author :

Date :

1854

MX5
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE UNIT

14 mm Head

10.

17 mm Head
Q10002

REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque: 17 mm head: 64 Nm (650 kgfcm, 47 ftlbf) 14 mm head: 46 Nm (470 kgfcm, 34 ftlbf) 11. REMOVE FRONT WHEEL Torque: 103 Nm (1,050 kgfcm, 76 ftlbf) 12. RAISE VEHICLE NOTICE: Make sure that the vehicle is securely supported. 13. REMOVE ENGINE REAR SIDE SHUTTER PLATE AND LH AND RH FENDER APRON SEALS

14.
Oil Level 0 5 mm Filler Plug

15.

DRAIN TRANSAXLE OIL Oil grade: API GL4 or GL5 Viscosity: SAE 75W90 Capacity: 2.6 liters (2.7 US qts, 2.3 Imp. qts) Torque: 49 Nm (500 kgfcm, 36 ftlbf) REMOVE LH AND RH DRIVE SHAFTS (See page SA16)

Drain Plug

Q10003

16. (a)

REMOVE FRONT EXHAUST PIPE Remove the 2 bolts, nut and exhaust pipe bracket. Torque: Bolt: 19 Nm (195 kgfcm, 14 ftlbf) Nut: 33 Nm (330 kgfcm, 24 ftlbf)

Q10010

(b) (c) (d)

(e)
Q10004

Remove the 3 nuts and gasket from the exhaust manifold. Torque: 62 Nm (630 kgfcm, 46 ftlbf) Remove the 2 bolts, nuts and gasket. Torque: 56 Nm (570 kgfcm, 41 ftlbf) Remove the 2 set bolts of the No.1 exhaust pipe support bracket. Torque: 33 Nm (330 kgfcm, 24 ftlbf) Remove the front exhaust pipe.

Author :

Date :

1855

MX6
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE UNIT

17. (a)

(b) (c) (d) (e)

Q09989

DISCONNECT PS GEAR ASSEMBLY FROM FRONT SUSPENSION MEMBER Remove the 2 nuts and disconnect the stabilizer bar link from the stabilizer bar. Torque: 39 Nm (400 kgfcm, 29 ftlbf) Remove the 4 set bolts of the stabilizer bar bracket. Torque: 19 Nm (195 kgfcm, 14 ftlbf) Remove the 2 bolts, nut and No.1 fuel tube protector. Tie the PS gear assembly to the proper position with a code or an equivalent to suspend the assembly securely. Remove the 2 set bolts and nuts of the PS gear assembly. Torque: 181 Nm (1,850 kgfcm, 134 ftlbf)

Q09990

18.

REMOVE 3 ENGINE FRONT SIDE MOUNTING BOLTS Torque: Silver bolt: 44 Nm (450 kgfcm, 33 ftlbf) Green bolt: 66 Nm (670 kgfcm, 48 ftlbf)

Q10005

19. (a)

(b)
Q10006

REMOVE LH ENGINE MOUNTING INSULATOR WITH BRACKET Remove the 2 hole plugs, nuts and 3 bolts. Torque: Bolt: 64 Nm (650 kgfcm, 47 ftlbf) Nut: 80 Nm (820 kgfcm, 59 ftlbf) Lift up the transaxle and remove the left engine mounting insulator with the bracket.

20.

Q10007

REMOVE HOLE PLUG AND 3 ENGINE REAR SIDE MOUNTING NUTS Torque: 66 Nm (670 kgfcm, 48 ftlbf) 21. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER (See page EM69) 22. DISCONNECT STEERING RETURN PIPE FROM FRONT SUSPENSION MEMBER Remove the 2 bolts. Torque: 10 Nm (100 kgfcm, 7 ftlbf)
Author : Date : 1856

MX7
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE UNIT

23.
A

C A

C C B A A B
Q10008

REMOVE FRONT SUSPENSION MEMBER WITH LOWER SUSPENSION ARM (a) Remove the LH and RH fender liner set screws. (b) Remove the 6 bolts, 4 nuts, front LH and RH suspension member braces, rear LH and RH suspension member braces and front suspension member with the lower suspension arm. Torque: Bolt A: 181 Nm (1,850 kgfcm, 134 ftlbf) Bolt B: 32 Nm (330 kgfcm, 24 ftlbf) Nut C: 36 Nm (370 kgfcm, 27 ftlbf) 24. JACK UP TRANSAXLE SLIGHTLY Using a transmission jack, support the transaxle.

25. REMOVE LH STIFFENER PLATE Remove the 3 bolts and LH stiffener plate. Torque: 37 Nm (380 kgfcm, 27 ftlbf)

Q10011

26.

Q10009

REMOVE REAR END PLATE WITH OIL PAN INSULATOR AND RH STIFFENER PLATE (a) Remove the 2 bolts and rear end plate with the oil pan insulator. Torque: 9.3 Nm (95 kgfcm, 82 in.lbf) (b) Remove the 2 bolts and manifold stay. Torque: 39 Nm (400 kgfcm, 29 ftlbf) (c) Remove the 4 bolts and RH stiffener plate. Torque: 39 Nm (400 kgfcm, 29 ftlbf) 27. REMOVE TRANSAXLE Lower the engine left side and remove the transaxle from the engine. HINT: At the time of installation, please refer to the following items. L Align the input shaft with the clutch disc and install the transaxle to the engine. L Temporarily tighten the transaxle mounting bolts.

Author :

Date :

1857

MX8
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE UNIT
MX04E01

INSTALLATION
Installation is in the reverse order of removal (See page MX4). HINT: L Front wheel alignment (See page SA4). L Do the road test.

Author :

Date :

1858

MX9
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY

MANUAL TRANSAXLE ASSEMBLY

MX04F02

COMPONENTS
Release Bearing Retainer
5.4 (55, 48 in.lbf)

Vehicle Speed Sensor

Straight Screw Plug L 13 (130, 9) Lock Ball Assembly

7.4 (75, 65 in.lbf)

Reverse Restrict Pin L 29 (300, 22) BackUP Light Switch

44 (450, 33)

Shift and Select Lever Assembly

37 (375, 27)

37 (380, 27)

Slotted Spring Pin Shim

Selecting Bellcrank

Release Bearing Boot

Differential Side Bearing Retainer Transmission x6 Case Protector Transmission Case Gasket ORing L
18 (185, 13) 18 (185, 13)

Drain Plug Clutch Release Fork Release Fork Support

39 (400, 29)

Gasket L 42 (430, 31) x5 Rear Bearing Retainer Lock Nut

29 (300, 22) 123 (1,250, 90)

Filler Plug
49 (500, 36)

x 17

Lock Bolt Spacer Needle Roller Bearing 5th Gear No.3 Clutch Hub Assembly N0.3 Hub Sleeve No.3 Shift Fork
18 (185, 13) 29 (300, 22)

Gasket

Snap Ring

5th Driven Gear

Snap Ring x8 Nm (kgfcm, ftlbf) : Specified torque Nonreusable part L Precoated part L
29 (300, 22)

Transmission Case Cover

Z19123

Author :

Date :

1859

MX10
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY

Reverse Shift Fork Interlock Pin Transaxle Case Oil Seal No.2 Shift Fork Shaft No.2 Shift Fork Transaxle Case Receiver
7.4 (75, 65 in.lbf)

No.1 Shift Fork

No.1 Shift Head No.1 Shift Fork Shaft Differential Case Assembly Input Shaft Front Bearing Bearing Lock Plate

Input Shaft Assembly Reverse Shift Arm Output Shaft Assembly

18 (185, 13)

Reverse Idler Gear and Shaft Nm (kgfcm, ftlbf) : Specified torque Nonreusable part

Output Shaft Front Bearing Output Shaft Cover

Z18962

Author :

Date :

1860

MX11
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY
MX04G02

DISASSEMBLY
1. 2. REMOVE RELEASE FORK AND BEARING REMOVE BACKUP LIGHT SWITCH Torque: 44 Nm (450 kgfcm, 33 ftlbf) 3. REMOVE BOLT AND VEHICLE SPEED SENSOR Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) 4. REMOVE RELEASE BEARING RETAINER Remove the 3 bolts and retainer. Torque: 7.4 Nm (75 kgfcm, 65 in.lbf) 5. REMOVE SELECTING BELLCRANK Remove the 2 bolts and selecting bellcrank. Torque: 37 Nm (380 kgfcm, 27 ftlbf)

6. (a)

(b)
FIPG
Z18142

7.

8. HINT: At the time of installation, please refer to the following item. Apply FIPG to the underside of the flanged portion of the control shaft cover. FIPG: Part No. 08826 00090, THREE BOND 1281 or equivalent Torque: 37 Nm (375 kgfcm, 27 ftlbf)

REMOVE TRANSMISSION CASE COVER Remove the 8 bolts. Sealant: Part No.08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 Nm (300 kgfcm, 22 ftlbf) Using a plastic hammer, tap the transmission case cover and remove it. FIPG: Part No. 08826 00090, THREE BOND 1281 or equivalent REMOVE LOCK BALL ASSEMBLY Sealant: Part No.08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 Nm (300 kgfcm, 22 ftlbf) REMOVE SHIFT AND SELECT LEVER ASSEMBLY

Author :

Date :

1861

MX12
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY

9. (a) (b)

REMOVE OUTPUT SHAFT LOCK NUT Unstake the nut. Engage the gear double meshing.

Q02530

(c)
Install

Rotate the lock nut clockwise and remove it. Torque: 123 Nm (1,250 kgfcm, 90 ftlbf)

Remove
Q05696

HINT: The lock nut has LH threads. (d) Disengage the gear double meshing. 10. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK (a) Remove the No.3 shift fork set bolt. Torque: 18 Nm (185 kgfcm, 13 ftlbf) (b) Remove the No.3 hub sleeve and No.3 shift fork. 11. REMOVE 5TH DRIVEN GEAR Using SST, remove the 5th driven gear. SST 0995040011

SST

Q05200

HINT: At the time of installation, please refer to the following item. Using SST, install the 5th driven gear. SST 0930912020
SST SST

Z00455

12. MEASURE 5TH GEAR THRUST CLEARANCE Using a dial indicator, measure the thrust clearance. Standard clearance: 0.20 0.40 mm (0.0079 0.0157 in.) Maximum clearance: 0.45 mm (0.0177 in.)

Q02695

Author :

Date :

1862

MX13
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY

Q02696

13. MEASURE 5TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the radial clearance. Standard clearance: 0.009 0.050 mm (0.0004 0.0020 in.) Maximum clearance: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or input shaft. 14. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR (a) Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: At the time of installation, please refer to the following item. Select a snap ring that allows the minimum axial play.
Mark 13 Thickness mm (in.) 2.202.25 (0.08660.0886) 2.252.30 (0.08860.0906) 2.302.35 (0.09060.0925) 2.352.40 (0.09250.0945) 2.402.45 (0.09450.0965) 2.452.50 (0.09650.0984) 2.502.55 (0.09840.1004) 2.552.60 (0.10040.1024) Mark 21 Thickness mm (in.) 2.602.65 (0.10240.1043) 2.652.70 (0.10430.1063) 2.702.75 (0.10630.1083) 2.752.80 (0.10830.1102) 2.802.85 (0.11020.1122) 2.852.90 (0.11220.1142) 2.902.95 (0.11420.1161)

14

22

15

23

16

24

17

25

18

26

19

27

20

(b)

Using SST and a socket wrench, remove the No.3 clutch hub with the synchronizer ring. SST 0995030010

SST Socket Wrench

Q02726

Author :

Date :

1863

MX14
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY

SST

HINT: At the time of installation, please refer to the following item. Using SST and a press, install the No.3 clutch hub assembly. SST 0961222011 (c) Remove the 5th gear. 15. REMOVE NEEDLE ROLLER BEARING

Q02682

x5

Q05785

16. REMOVE REAR BEARING RETAINER Remove the 5 bolts and retainer. Sealant: Part No.08833 00070, THREE BOND 1324 or equivalent Torque: 42 Nm (430 kgfcm, 31 ftlbf) 17. REMOVE BEARING SNAP RING Using a snap ring expander, remove the 2 snap rings. HINT: If it is difficult to remove and install the snap rings, pull up the shafts.

x6

x 17

18.

Q05826

FIPG
Q09474

REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET Torque: 29 Nm (300 kgfcm, 22 ftlbf) 19. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM Remove the 6 bolts, retainer and shim. Sealant: Part No.08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 18 Nm (185 kgfcm, 13 ftlbf) 20. REMOVE TRANSMISSION CASE (a) Remove the 17 bolts. Torque: 29 Nm (300 kgfcm, 22 ftlbf) (b) Using a plastic hammer, tap the transmission case and remove it. FIPG: Part No. 08833 00090, THREE BOND 1281 or equivalent

Author :

Date :

1864

MX15
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY

21. (a) (b) 22. (a) (b) 23.

Q05827

24. 25. 26. (a)

(b) (c)

REMOVE REVERSE IDLER GEAR AND SHAFT Pull out the shaft. Remove the idler gear and thrust washer. REMOVE REVERSE SHIFT ARM Shift the fork shaft into reverse. Remove the 2 bolts and pull off the reverse shift arm. Torque: 18 Nm (185 kgfcm, 13 ftlbf) REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS, REVERSE SHIFT FORK WITH INTERLOCK PIN, INPUT AND OUTPUT SHAFTS ASSEMBLY REMOVE DIFFERENTIAL CASE ASSEMBLY REMOVE MAGNET FROM TRANSAXLE CASE REMOVE NO.2 SHIFT FORK SHAFT Using a hexagon wrench, remove the straight screw plug. Sealant: Part No.08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 13 Nm (130 kgfcm, 9 ftlbf) Using a pin punch and hammer, drive out the slotted spring pin. Pull out the shaft.

27.

(a) (b) (c)

Q03065

(d)

SEPARATE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1, NO.2 SHIFT FORKS AND REVERSE SHIFT FORK Mount the shift forks to the vise. Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft. Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft, as shown. Separate the No.1 shift fork shaft, No.1 shift head, No.1 and No.2 shift forks and reverse shift fork.

Author :

Date :

1865

MX16
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY

28. (a)

MT0781

(b) HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring. (c) Remove the synchronizer rings.

REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB Remove the No.5 synchronizer ring with the key spring from the No.3 clutch hub. Using a screwdriver, remove the snap ring.

Author :

Date :

1866

MX17
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY
MX05M01

INSPECTION
1. INSPECT NO.5 SYNCHRONIZER RING (a) Check for wear or damage. (b) Check the braking effect of the synchronizer ring. Turn the middle No.5 synchronizer ring in one direction while pushing it to the outer No.5 synchronizer ring. Check that the ring locks. If the braking effect is insufficient, replace the synchronizer ring.

2.

INSPECT NO.3 SHIFT FORK AND NO.3 HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
WM0066

3.
SST

SST

(a) (b)

IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING Remove the 2 bolts and transaxle case receiver. Using SST, pull out the bearing. SST 0930800010

Z00409

(c)
SST SST

(d)

Using SST, press in a new bearing. SST 0931035010 Install the transaxle case receiver and torque the 2 bolts. Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)

Z00410

4.
SST SST

(a) (b)

IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING Remove the bolt and bearing lock plate. Using SST, pull out the bearing. SST 0930800010

Z00411

Author :

Date :

1867

MX18
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY

(c)
SST SST

(d)

Using SST, press in a new bearing. SST 0931035010 Install the bearing lock plate and torque the bolt. Torque: 18 Nm (185 kgfcm, 13 ftlbf)

Front
Z00593

5.
0 0.5mm SST

(a) (b)

(c)
Z00413

IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL SEAL Using a screwdriver, pry out the oil seal. Using SST, drive in a new oil seal. SST 0960800081, 0995070010 (0995107150) Drive in depth: 0 0.5 mm (0 0.020 in.) Coat the lip of the oil seal with MP grease.

6. (a) (b)
13.5 0.5mm

(c) (d)

Z00596

(e)

(f)

IF NECESSARY, REPLACE REVERSE RESTRICT PIN Using a hexagon wrench, remove the straight screw plug. Using a pin punch and hammer, drive out the slotted spring pin. Replace the reverse restrict pin. Using a pin punch and hammer, drive in the slotted spring pin. Drive in depth: 13.5 0.5 mm (0.531 0.020 in.) Apply sealant to the plug threads. Sealant: Part No.08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a hexagon wrench, install and torque the straight screw plug. Torque: 13 Nm (130 kgfcm, 9 ftlbf)

Author :

Date :

1868

MX19
MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE ASSEMBLY
MX04I01

REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MX11). HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

Author :

Date :

1869

MX20
MANUAL TRANSAXLE (S51) INPUT SHAFT

INPUT SHAFT
MX04J01

COMPONENTS
Spacer Needle Roller Bearing 4th Gear Rear Bearing Snap Ring Synchronizer Ring

Synchronizer Ring

Input Shaft

Shifting Key No.2 Clutch Hub Snap Ring 3rd Gear Needle Roller Bearing No.2 Hub Sleeve Key Spring
Q02560

Author :

Date :

1870

MX21
MANUAL TRANSAXLE (S51) INPUT SHAFT
MX04K01

DISASSEMBLY
1. INSPECT 3RD AND 4TH GEARS THRUST CLEARANCE Using a feeler gauge, measure the clearance. Standard clearance: 3rd gear: 0.10 0.25 mm (0.0039 0.0098 in.) 4th gear: 0.20 0.45 mm (0.0079 0.0177 in.) Maximum clearance: 3rd gear: 0.30 mm (0.0118 in.) 4th gear: 0.50 mm (0.0197 in.)

3rd Gear 4th Gear

Q05793

2.

Z00417

INSPECT 3RD AND 4TH GEARS RADIAL CLEARANCES Using a dial indicator, measure the radial clearance between the gear and shaft. Standard clearance: 0.009 0.053 mm (0.0004 0.0021 in.) Maximum clearance: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring.

4.
SST

Q05201

REMOVE REAR BEARING, 4TH GEAR, NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING FROM INPUT SHAFT (a) Using SST and a press, remove the 4th gear and rear bearing. SST 0995000020 (b) Remove the needle roller bearings, spacer and synchronizer ring. 5. REMOVE SNAP RING Using a snap ring expander, remove the snap ring.
Author : Date : 1871

MX22
MANUAL TRANSAXLE (S51) INPUT SHAFT

6.
SST

CM0064

REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR SYNCHRONIZER RING AND NEEDLE ROLLER BEARING Using SST and a press, remove the No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings. SST 0995000020 NOTICE: Be careful not to mistake the 3rd gear synchronizer ring for the 4th gear synchronizer ring. 7. REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND SPRING FROM NO.2 CLUTCH HUB Using a screwdriver, remove the 3 shifting keys and 2 springs from the No.2 clutch hub.

SM0269

Author :

Date :

1872

MX23
MANUAL TRANSAXLE (S51) INPUT SHAFT
MX04L01

INSPECTION
1. (a) (b) INSPECT SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ring.

WM0064

(d)

WM0065

Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.6 mm (0.024 in.) If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. 2. INSPECT NO.2 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace shift fork or hub sleeve.

WM0066

Author :

Date :

1873

MX24
MANUAL TRANSAXLE (S51) INPUT SHAFT

SM0182

INSPECT INPUT SHAFT Check the input shaft for wear or damage. Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum outer diameter: Part A: 26.970 mm (1.0618 in.) Part B: 32.470 mm (1.2783 in.) Part C: 33.090 mm (1.3028 in.) Part D: 29.970 mm (1.1799 in.) If the outer diameter is less than the minimum, replace the input shaft.

3. (a) (b)

(c)

Using a dial indicator, check the shaft runout. Maximum runout: 0.05 mm (0.0020 in.) If the runout exceeds the maximum, replace the input shaft.

CM0013

Author :

Date :

1874

MX25
MANUAL TRANSAXLE (S51) INPUT SHAFT
MX04M01

REASSEMBLY
Engine Side

SM0282

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE (a) Install the clutch hub and shifting keys to the hub sleeve. (b) Install the shifting key springs under the shifting keys. NOTICE: Position the key springs so that their end gaps are not aligned.

2.

INSTALL 3RD GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT (a) Apply gear oil to the needle roller bearings. (b) Place the synchronizer ring (for the 3rd gear) on the gear and align the ring slots with the shifting keys. NOTICE: Do not install the synchronizer ring for 4th gear.
SM0193

(c)

Using a press, install the 3rd gear and No.2 hub sleeve.

Z00419

3. (a)

INSTALL SNAP RING Select a snap ring that allows the minimum axial play.
Mark 1 2 3 4 5 Thickness mm (in.) 1.952.00 (0.07680.0787) 2.002.05 (0.07870.0807) 2.052.10 (0.08070.0827) 2.102.15 (0.08270.0846) 2.152.20 (0.08460.0866) 2.202.25 (0.08660.0886)

Z00604

Author :

Date :

1875

MX26
MANUAL TRANSAXLE (S51) INPUT SHAFT

(b) 4.

Using a snap ring expander, install the snap ring. INSPECT 3RD GEAR THRUST CLEARANCE (See page MX20)

5.

(a) (b)

INSTALL SYNCHRONIZER RING, NEEDLE ROLLER BEARING, SPACER, 4TH GEAR AND REAR BALL BEARING Apply gear oil to the needle roller bearings. Install the spacer and needle roller bearings.

SM0189

(c) Place the synchronizer ring on the gear. HINT: Align the ring slots with the shifting keys and the ring projections with the hub slots.

SM0190

(d)

Using SST and a press, install the rear ball bearing. SST 0960800071

SST

SM0049

6. (a)

INSTALL SNAP RING Select a snap ring that allows the minimum axial play.
Mark A B C D E Thickness mm (in.) 2.152.20 (0.08460.0866) 2.202.25 (0.08660.0886) 2.252.30 (0.08860.0906) 2.302.35 (0.09060.0925) 2.352.40 (0.09250.0945)

SM0050

(b)

Using a screwdriver and hammer, tap in the snap ring.

Author : Date : 1876

MX27
MANUAL TRANSAXLE (S51) INPUT SHAFT

7.

INSPECT 4TH GEAR THRUST CLEARANCE (See page MX20)

Author :

Date :

1877

MX28
MANUAL TRANSAXLE (S51) OUTPUT SHAFT

OUTPUT SHAFT
MX04N01

COMPONENTS
Output Shaft Spacer 1st Gear Needle Roller Bearing Synchronizer Ring No.1 Hub Sleeve Shifting Key

Shifting Key Spring No.1 Clutch Hub Needle Roller Bearing Ball Spacer Rear Bearing

Synchronizer Ring 2nd Gear 2nd Gear Bushing

3rd Driven Gear 4th Driven Gear

Q02544

Author :

Date :

1878

MX29
MANUAL TRANSAXLE (S51) OUTPUT SHAFT
MX04O01

DISASSEMBLY
1.
2nd Gear

1st Gear
Q05794

INSPECT 1ST AND 2ND GEARS THRUST CLEARANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 1st gear: 0.10 0.29 mm (0.0039 0.0114 in.) 2nd gear: 0.20 0.44 mm (0.0079 0.0173 in.) Maximum clearance: 1st gear: 0.35 mm (0.0138 in.) 2nd gear: 0.50 mm (0.0197 in.)

2.

SM0137

SST

INSPECT 1ST AND 2ND GEARS RADIAL CLEARANCE Using a dial indicator, measure the radial clearance between the gear and shaft. Standard clearance: 0.009 0.053 mm (0.0004 0.0021 in.) Maximum clearance: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR AND OUTPUT GEAR SPACER (a) Using SST and a press, remove the rear ball bearing and 4th driven gear. SST 0995000020 (b) Remove the output gear spacer and ball.

CM0065

4.
SST

(a) (b)

(c)
MT0063

REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING AND SYNCHRONIZER RING Shift the No.1 hub sleeve into the 1st gear. Using SST and a press, remove the 3rd driven gear and 2nd gear. SST 0995000020 Remove the needle roller bearing and synchronizer rings.

Author :

Date :

1879

MX30
MANUAL TRANSAXLE (S51) OUTPUT SHAFT

5.

(a) (b) (c)

Z00427

REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, THRUST WASHER AND LOCKING BALL Using a press, remove the No.1 hub sleeve, 1st gear and synchronizer ring. Remove the needle roller bearing and locking ball. Using a screwdriver and hammer, drive out the thrust washer.

6.

REMOVE NO.1 HUB SLEEVE, 3 SHIFTING KEYS AND SPRINGS FROM NO.1 CLUTCH HUB

Q02948

Author :

Date :

1880

MX31
MANUAL TRANSAXLE (S51) OUTPUT SHAFT
MX04P01

INSPECTION
1. (a) (b) INSPECT 1ST GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ring.

WM0064

(d)

WM0065

Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end. Minimum clearance: 0.6 mm (0.024 in.) If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. 2. INSPECT 2ND GEAR SYNCHRONIZER RING (a) Check for wear or damage. (b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, replace the synchronizer ring.

MT0780

(c)

Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.7 mm (0.028 in.) If the clearance is less than the minimum, replace the synchronizer ring.

MT0787

Author :

Date :

1881

MX32
MANUAL TRANSAXLE (S51) OUTPUT SHAFT

3.

INSPECT SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
WM0066

4. (a)
A B C

CM0014

INSPECT OUTPUT SHAFT Using a micrometer, measure the outer diameter of the output shaft journal surface. Minimum outer diameter: Part A: 31.970 mm (1.2587 in.) Part B: 37.970 mm (1.4949 in.) Part C: 31.990 mm (1.2594 in.) If the outer diameter is less than the minimum, replace the output shaft. (b) Using a dial indicator, check the shaft runout. Maximum runout: 0.05 mm (0.0020 in.) If the runout exceeds the maximum, replace the output shaft.

CM0015

Author :

Date :

1882

MX33
MANUAL TRANSAXLE (S51) OUTPUT SHAFT
MX04Q01

REASSEMBLY
HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE (a) Install the 3 springs and shifting keys to the clutch hub. (b) Install the hub sleeve to the clutch hub. HINT: Position the identification groove of the hub sleeve to the front of the transmission.

Front

Q02949

2.

(a)
SST

(b)

INSTALL THRUST WASHER, 1ST GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO OUTPUT SHAFT Using SST and a press, install the thrust washer. SST 0931660011 (0931600041) Apply gear oil to the needle roller bearing.

SM0199

(c)

Place the synchronizer ring on the gear and align the ring slots with the shifting keys.

Z00428

(d) 3.

Using a press, install the 1st gear and No.1 hub sleeve. INSPECT 1ST GEAR THRUST CLEARANCE (See page MX28)

Z00429

Author :

Date :

1883

MX34
MANUAL TRANSAXLE (S51) OUTPUT SHAFT

MT0792

INSTALL SYNCHRONIZER RING, 2ND GEAR, NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR (a) Install the ball. (b) Fit the 2nd gear bushing groove securely over the ball when installing the 2nd gear bushing on the shaft. (c) Place the synchronizer rings on the 2nd gear. (d) Apply gear oil to the needle roller bearing and install it. (e) Install the 2nd gear. NOTICE: Align the clutch hub grooves with the projections on the synchronizer ring.

4.

(f)
SST

5.

Using SST and a press, install the 3rd driven gear. SST 0931660011 (0931600011) INSPECT 2ND GEAR THRUST CLEARANCE (See page MX28)

SM0201

6. (a) (b)

INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND RADIAL BALL BEARING Install the outer gear spacer. Using a press, install the 4th driven gear and bearing.

Z00431

SST

7. INSTALL REAR BEARING Using SST and a press, install the rear bearing. SST 0961222011

SM0202

Author :

Date :

1884

MX35
MANUAL TRANSAXLE (S51) SHIFT AND SELECT LEVER SHAFT

SHIFT AND SELECT LEVER SHAFT

MX04R01

COMPONENTS

Shift and Select Lever Shaft ERing Select Spring Seat Compression Spring Shift Interlock Plate Compression Spring ERing Slotted Spring Pin
6.4 (85, 56 in.lbf)

Dust Boot

Washer

Shift Inner Lever No.1 Shift Inner Lever No.2 Select Spring Seat No.2

LOil Seal Control Shaft Cover L ORing

Lever Lock Pin Control Shaft Lever

Nm (kgfcm, ftlbf) : Specified torque L Nonreusable part MP Grease

Q10277

Author :

Date :

1885

MX36
MANUAL TRANSAXLE (S51) DIFFERENTIAL CASE

DIFFERENTIAL CASE
MX04S01

COMPONENTS
Shim LOuter Race and Side Bearing Pinion Thrust Washer Ring Gear Pinion Gear Pinion Shaft
83 (850, 61)

x8 L Side Bearing and Outer Race Side Gear Side Gear Thrust Washer

Shim Differential Case Straight Pin Vehicle Speed Sensor Drive Gear Nm (kgfcm, ftlbf) : Specified torque LNonreusable part

Z19302

Author :

Date :

1886

MX37
MANUAL TRANSAXLE (S51) DIFFERENTIAL CASE
MX04T01

SST

DISASSEMBLY
1. Vehicle Speed Sensor Drive Gear Side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE Using SST, remove the bearing from the drive gear side of the case. SST 0995000020, 0995000030 Remove the vehicle speed sensor drive gear. REMOVE RING GEAR Place matchmarks on the ring gear and case. Remove the 8 bolts. Using a copper hammer, tap on the ring gear to remove it from the case.

(a)

Q08148

(b) 2. (a) (b) (c)

3.

SST

Ring Gear Side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE Using SST, remove the bearing from the ring gear side of the case. SST 0995000020, 0995000030

Q04969

AT2799

4. INSPECT SIDE GEAR BACKLASH Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the case. Standard backlash: 0.05 0.20 mm (0.0020 0.0079 in.) If the backlash is not within the specification, install the correct thrust washer to the side gears. 5. DISASSEMBLE DIFFERENTIAL CASE (a) Using a pin punch and hammer, drive out the straight pin. (b) Remove the pinion shaft from the case. (c) Remove the 2 pinions and side gears with the 4 thrust washers from each gear.

Author :

Date :

1887

MX38
MANUAL TRANSAXLE (S51) DIFFERENTIAL CASE

6.

(a)
SST

Transaxle Case Side: IF NECESSARY, REPLACE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, drive out the oil seal from the retainer. SST 0995060020 (0995100680), 0995070010 (0995107150)

Q08145

(b)

(c)

Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface. SST 0935032014 (0935132130, 0935132150) Coat the lip of the oil seal with MP grease.

SST

SM0286

7.
SST

(a) (b)

(c)
SM0155

Transmission Case Side: IF NECESSARY, REPLACE SIDE OIL SEAL Using a screwdriver and hammer, drive out the oil seal. Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface. SST 0935032014 (0935132130, 0935132150) Coat the lip of the oil seal with MP grease.

8.

(a) (b) (c)

Z00442

Transaxle Case Side: IF NECESSARY, REPLACE SIDE BEARING OUTER RACE Using a brass bar and hammer, drive out the bearing outer race. Install the bearing retainer without an Oring. Install and torque the 6 bolts. Torque: 18 Nm (185 kgfcm, 13 ftlbf)

(d) (e)
SST

(f) (g)

Place the thinnest shim into the case. Using SST and a press, install a new bearing outer race. SST 0995060020 (0995100680), 0995070010 (0995107150) Remove the 6 bolts. Remove the bearing retainer and shim.

MT0634

Author :

Date :

1888

MX39
MANUAL TRANSAXLE (S51) DIFFERENTIAL CASE

9.

(a)
SST

(b) (c)
Q08184

Transaxle Case Side: IF NECESSARY, REPLACE SIDE BEARING OUTER RACE Using a brass bar and hammer, drive out the bearing outer race and shim. Place the shim into the case. Using SST and a press, install a new bearing outer race. SST 0995060020 (0995100680), 0995070010 (0995107150)

Author :

Date :

1889

MX40
MANUAL TRANSAXLE (S51) DIFFERENTIAL CASE
MX04U01

REASSEMBLY
1. (a) ASSEMBLE DIFFERENTIAL CASE Install the correct thrust washers and side gears. Refer to the table below, select thrust washers which will ensure that the backlash is within the specification. Try to select washers of the same size for both sides. Standard backlash: 0.05 0.20 mm (0.0020 0.0079 in.)
Thickness mm (in.) 0.95 (0.0374) 1.00 (0.0394) 1.05 (0.0413) Thickness mm (in.) 1.10 (0.0433) 1.15 (0.0453) 1.20 (0.0472)

(b)

Install the thrust washers and side gears in the differential case. Install the pinion shaft.

(c)

AT2981

Inspect the side gear backlash. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the case. Standard backlash: 0.05 0.20 mm (0.0020 0.0079 in.) If the backlash is not within the specification, install a thrust washer of different thickness. (d) Using a pin punch and hammer, drive in the straight pin through the case and hole in the pinion shaft. (e) Stake the differential case. 2. INSTALL RING GEAR ON DIFFERENTIAL CASE (a) Clean the contact surface of the differential case and the threads of the ring gear and differential case. (b) Heat the ring gear in boiling water. (c) Carefully take the ring gear out of the water. (d) After moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. HINT: Align the matchmarks on the differential case and the ring gear. (e) Temporarily install the 8 bolts. NOTICE: The ring gear set bolts should not be torqued until the ring gear has cooled sufficiently. (f) After the ring gear has cooled sufficiently, torque the ring gear set bolts. Torque: 83 Nm (850 kgfcm, 61 ftlbf)

Q08147

Author :

Date :

1890

MX41
MANUAL TRANSAXLE (S51) DIFFERENTIAL CASE

3. (a)

SST

INSTALL SIDE BEARING TO DIFFERENTIAL CASE Using SST and a press, install a new side bearing to the transmission case side. SST 0931660011 (0931600011), 0935032014 (0935132120)

SM0287

(b)

Install the vehicle speed sensor drive gear to the transaxle case side.

Case Side

Q08649

(c)

SST

SM0289

Using SST and a press, install a new side bearing to the transaxle case side. SST 0931660011 (0931600011), 0935032014 (0935132120) NOTICE: Install the black cage bearing on the vehicle speed sensor drive gear side. 4. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD (a) Install the differential to the transaxle case. (b) Install the transmission case. (c) Install and torque the case bolts. Torque: 29 Nm (300 kgfcm, 22 ftlbf) (d) Install the shim into the transmission case. (e) Install the bearing retainer without an Oring. (f) Install and torque the 6 bolts. Torque: 18 Nm (185 kgfcm, 13 ftlbf)

Author :

Date :

1891

MX42
MANUAL TRANSAXLE (S51) DIFFERENTIAL CASE

(g)

SST

Z00620

Using SST and a torque wrench, measure the preload. SST 0956432011 Preload (at starting): 0.8 1.6 Nm (8 16 kgfcm, 6.9 13.9 in.lbf) If the preload is not within the specification, remove the transmission case side bearing retainer. Select another shim. HINT: The preload will change about 0.3 0.4 Nm (3 4 kgfcm, 2.6 3.5 in.lbf) with each 0.05 mm (0.0019 in.) change in shim thickness.
Mark 1 2 3 4 5 6 7 8 9 10 Thickness mm (in.) 1.90 (0.0748) 1.95 (0.0768) 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 2.15 (0.0846) 2.20 (0.0866) 2.25 (0.0886) 2.30 (0.0906) 2.35 (0.0925) Mark 11 12 13 14 15 16 17 18 19 Thickness mm (in.) 2.40 (0.0945) 2.45 (0.0965) 2.50 (0.0984) 2.55 (0.1004) 2.60 (0.1024) 2.65 (0.1043) 2.70 (0.1063) 2.75 (0.1083) 2.80 (0.1102)

(h) (i) (j) (k)

Remove Remove Remove Remove

the the the the

6 bolts. bearing retainer and shim. 17 bolts. transmission case.

Author :

Date :

1892

MX43
MANUAL TRANSAXLE (S51) SHIFT LEVER AND CONTROL CABLE

SHIFT LEVER AND CONTROL CABLE

MX04V02

COMPONENTS
Shift Lever Knob

Center Console Upper Panel Heater Control Assembly

Center Cluster Finish Panel

Front Console Box

Rear Console Box

Shift Cable Grommet Retainer

Shift Cable Grommet Retainer

Shift Cable Grommet Clip

4.9 (50, 43 in.lbf)

12 (120, 9)

Grommet
4.9 (50, 43 in.lbf)

Clip

Clip

Shift Lever Assembly Clip

Clip Clip Clip Washer Clip

Shift Control Cable Washer Select Control Cable

Washer

Nm (kgfcm, ftlbf) : Specified torque

Q10340

Author :

Date :

1893