MT–1

MANUAL TRANSAXLE

MANUAL TRANSAXLE
MT–2
MANUAL TRANSAXLE – Description

DESCRIPTION
• Transaxle types S51 are constant mesh synchronizers for forward gears, and a sliding mesh
reverse gear.
• The input shaft is composed of the 1st and 2nd speed gears and the reverse drive gear, and
the output shaft is composed of the drive gear (for use with the ring gear).
• The oil used in transaxle is as follows:
S51 ................................ ATF type DEXRON ll
• The illustrations below show the engagements– of transaxle gears.
 MT–3
MANUAL TRANSAXLE – Precautions

PRECAUTIONS
When working with FIPG material, you must be observe the following.
• Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces.
• Thoroughly clean all components to remove all the loose material.
• Clean both seating surfaces with a non–residue solvent.
• Apply the seal packing in approx.1 mm (0.04 in.) bead along the sealing surface.
• Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG)
material must be removed and reapplied.
TROUBLESHOOTING
Problem Possible cause Remedy Page

Noise Transmission or differential faulty Disassemble and inspect transmission or MT–7,42

differential
Wrong oil grade Replace oil
Oil level low Add oil .

Oil leakage Oil level too high Drain oil

Oil seal, 4–ring or gasket worn or Replace oil seal, O–ring or gasket MT–7
damaged

Hard to shift or will not Control cable faulty Replace control cable
shift Transmission faulty Disassemble and inspect transmission MT–7

Jumps out of gear Transmission faulty Disassemble and inspect transmission MT–7
 MT–3
MANUAL TRANSAXLE – Troubleshooting

PRECAUTIONS
When working with FIPG material, you must be observe the following.
• Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces.
• Thoroughly clean all components to remove all the loose material.
• Clean both seating surfaces with a non–residue solvent.
• Apply the seal packing in approx.1 mm (0.04 in.) bead along the sealing surface.
• Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG)
material must be removed and reapplied.

TROUBLESHOOTING
Problem Possible cause Remedy Page

Noise Transmission or differential faulty Disassemble and inspect transmission or MT–7,42

differential
Wrong oil grade Replace oil
Oil level low Add oil .

Oil leakage Oil level too high Drain oil

Oil seal, 4–ring or gasket worn or Replace oil seal, O–ring or gasket MT–7
damaged

Hard to shift or will not Control cable faulty Replace control cable
shift Transmission faulty Disassemble and inspect transmission MT–7

Jumps out of gear Transmission faulty Disassemble and inspect transmission MT–7
MT–4
MANUAL TRANSAXLE – S51 Transmission

S51 TRANSMISSION
REMOVAL OF TRANSAXLE
1. REMOVE NEGATIVE BATTERY CABLE
2. REMOVE CLUTCH RELEASE CYLINDER AND TUBE
CLAMP

3. REMOVE–.CLUTCH TUBE BRACKET

(a) Remove the retainer from the bracket.
(b) Remove the bolt and bracket.

4. DISCONNECT CONTROL CABLES

(a) Remove the clips and washers.
(b) Remove the retainer from the cables.

5. REMOVE STARTER
(a) Disconnect the cable and connector.
(b) Remove the starter with the two bolts.
6. DISCONNECT BACK–UP LIGHT SWITCH
CONNECTOR AND GROUND STRAP

7. REMOVE TRANSAXLE MOUNTING BOLTS OF

TRANSAXLE UPPER
8. RAISE VEHICLE
NOTICE: Be sure the vehicle is securely supported.
9. REMOVE UNDER COVERS
10. DRAIN OUT FLUID
11. DISCONNECT SPEEDOMETER CABLE
 MT–5
MANUAL TRANSAXLE – S51 Transmission.

12. REMOVE SUSPENSION LOWER CROSSMEMBER

13. REMOVE ENGINE MOUNTING CENTER MEMBER

(a) Remove the front and rear engine mounting bolts.
(b) Remove the engine mounting center member.

14. DISCONNECT BOTH DRIVE SHAFTS

Loosen the six nuts while depressing the brake pedal.

15. REMOVE CENTER DRIVE SHAFT

(a) Using pliers, remove the snap ring from the bearing
bracket.
(b) Remove the bolt on the bearing bracket.
(c) Pull out the center drive shaft.

16. DISCONNECT LEFT STEERING KNUCKLE FROM

LOWER ARM
(a) Disconnect the steering knuckle from the tower arm.
(b) Pull the steering knuckle toward the outside and remove
the drive shaft.
17. REMOVE STABILIZER BAR
(See page FA–34)
MT–6
MANUAL TRANSAXLE – S51 Transmission
18. DISCONNECT LEFT ENGINE MOUNTING
(a) Raise the transaxle and engine slightly with a jack
and wooden block in between.
(b) Disconnect the left engine mounting.

19. REMOVE TRANSAXLE

(a) Remove the transaxle mounting bolts from the engine.
(b) Lower the engine left side and remove the transaxle
from the engine.
 MT–7
MANUAL TRANSAXLE – S51 Transmission

COMPONENTS
MT–8
MANUAL TRANSAXLE – S51 Transmission

COMPONENTS (Cont’d)
 MT–9
MANUAL TRANSAXLE – S51 Transmission

COMPONENTS (Cont’d)
MT–10
MANUAL TRANSAXLE – S51 Transmission

DISASSEMBLY OF TRANSMISSION
(See pages MT–7 to 9)
1. REMOVE RELEASE FORK, BEARING, BACK–UP
LIGHT SWITCH AND SPEEDOMETER DRIVEN
GEAR
2. REMOVE RELEASE BEARING RETAINER
3. REMOVE TRANSMISSION CASE COVER
4. REMOVE NO. 3 SHIFT FORK SECURING BOTH

5. MEASURE FIFTH GEAR THRUST CLEARANCE

Using a dial indicator, measure the thrust clear-
ance.
Standard clearance: 0.20 – 0.40 mm
(0.0079 – 0.0157 in.)
Maximum clearance: 0.45 mm (0.0177 in.)

6. REMOVE NO. 1 AND NO.2 LOCK BALL ASSEMBLIES

(a) Loosen the lock nut and remove the No. 1 lock ball.

(b) Using SST and remove the No. 2 lock ball.

SST 09313–30021
7. REMOVE SELECTING BELLCRANK

8. REMOVE SHIFT AND SELECT LEVER ASSEMBLY

 MT–11
MANUAL TRANSAXLE – S51 Transmission
9. REMOVE. OUTPUT SHAFT LOCK NUT
(a) Unstake the nut.
(b) Engage the gear double meshing.

(c) Remove the lock nut.

HINT: The lock nut has LH threads.
(d) Disengage the gear double meshing.

10. REMOVE NO. 3 HUB SLEEVE ASSEMBLY AND

SHIFT FORK
(a) Using two screwdrivers and a hammer, tap out the
snap ring.
(b) Remove the shifting key retainer.

(e) Using the three case cover set bolts, tighten the three
bolts a little at a time and remove No. 3 hub sleeve
assembly and shift fork.
11. REMOVE FIFTH GEAR, SYNCHRONIZER RING,
NEEDLE ROLLER BEARINGS AND SPACER

12. REMOVE FIFTH DRIVEN GEAR

Using SST, remove the 5th driven gear.
SST 09950–20017
MT–12
MANUAL TRANSAXLE – S51 Transmission

13. REMOVE REAR BEARING RETAINER

14. REMOVE BEARING SNAP RINGS
Using snap ring pliers, remove the two snap rings.

15. REMOVE REVERSE IDLER GEAR SHAFT¿¿ LOCK

BOLT

16. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

AND SHIM

17. REMOVE TRANSMISSION CASE

Remove the seventeen bolts and tap off the case with
a plastic hammer.

18. REMOVE REVERSE SHIFT ARM

(a) Shift the fork shaft into reverse.
(b) Remove the two bolts and pull off the reverse shift arm.
19. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft.
 MT–13
MANUAL TRANSAXLE – S51 Transmission

20. REMOVE NO. 1 SHIFT FORK SHAFT, NO. 1 SHIFT

HEAD, NO. 1 AND NO. 2 SHIFT FORKS, INPUT
SHAFT AND OUTPUT SHAFT.
(a) Drive out the slotted spring pin from No. 1 fork shaft.

(b) Remove the input shaft and output shaft together with
No. 1 fork shaft and shift head and shift forks from the
transaxle case.

21. SEPARATE THE NO. 1 FORK SHAFT, NO. 1 SHIFT HEAD,

No. 1 AND NO. 2 SHIFT FORKS
(a) Mount the shift forks to the vise.
(b) Drive out the slotted spring pin from No. 1 fork shaft as
shown in the figure.

(c) Separate the No. 1 shift fork, shaft, No. 1 shift head,
No. 1 and No. 2 shift fork.

22. REMOVE REVERSE SHIFT FORK AND INTERLOCK

PIN
MT–14
MANUAL TRANSAXLE – S51 Transmission

23. REMOVE NO. 2 FORK SHAFT

(a) Using SST, remove the straight screw plug.
SST 09312–30021

(b) Using a pin punch and hammer, drive out the slotted
spring pin.
(e) Pull out the shaft.
24. REMOVE DIFFERENTIAL ASSEMBLY
25. REMOVE MAGNET

26. MEASURE THIRD AND FOURTH GEAR THRUST

CLEARANCE
Using a feeler gauge, measure the thrust 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.)
27. REMOVE SNAP RING FROM INPUT SHAFT
Using two screwdrivers and a hammer, tap out the
snap ring.

28. REMOVE RADIAL BALL BEARING, FOURTH GEAR,

NEEDLE ROLLER BEARINGS, SYNCHRONIZER
RING AND SPACER FROM INPUT SHAFT
(a) Using a press, remove the radial ball bearing and 4th gear.
(b) Remove the needle roller bearings, synchronizer ring and
spacer.
 MT–15
MANUAL TRANSAXLE – S51 Transmission

29. REMOVE SNAP RING

Using snap ring pliers, remove the snap ring.

30. REMOVE NO. 2 HUB SLEEVE ASSEMBLY, THIRD

GEAR, SYNCHRONIZER RING AND NEEDLE ROLLER
BEARINGS
Using a press, remove No. 2 hub sleeve, 3rd gear, syn-
chronizer ring and needle roller bearings.

31. MEASURE FIRST AND SECOND GEAR THRUST

CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1 st 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:
1 st gear 0.35 mm (0.0138 in.)
2nd gear 0.50 mm (0.0197 in.)
32. REMOVE RADIAL BALL BEARING, FOURTH DRIVEN
GEAR AND OUTPUT GEAR SPACER FROM OUTPUT
SHAFT
(a) Using a press, remove the radial ball bearing and 4th
driven gear.
(b) Remove the spacer.

33. REMOVE THIRD DRIVEN GEAR, SECOND GEAR,

NEEDLE ROLLER BEARING, SPACER AND
SYNCHRONIZER RING
(a) Shift No. 1 hub sleeve into the 1st gear.
MT–16
MANUAL TRANSAXLE – S51 Transmission

(b) Using a press, remove the 3rd driven gear and

2nd gear.
(c) Remove the needle roller bearing, spacer and
synchronizer ring.

34. REMOVE SNAP RING

Using two screwdrivers and a hammer, tap out the snap
ring.

35. REMOVE NO. 1 HUB SLEEVE ASSEMBLY, FIRST

GEAR, SYNCHRONIZER RING, NEEDLE ROLLER
BEARING AND THRUST WASHER
(a) Using a press, remove No. 1 hub sleeve, 1 st gear and
synchronizer ring.
(b) Remove the needle roller bearing and thrust washer.

36. DISASSEMBLE SHIFT AND SELECT LEVER

ASSEMBLY
(a) Remove the lever lock pin and nut.
(b) Remove the control shift lever.
(c) Remove the dust boot.
(d) Remove the control shaft cover.

(e) Remove the E–ring.

 MT–17
MANUAL TRANSAXLE – S51 Transmission

(f) Remove the reverse restrict pin holder, spring and

No. 2 shift inner lever.

(g) Using a pin punch and hammer, drive out the slotted
spring pin.

(h) Remove the shift fork lock plate, No. 1 shift inner
lever, spring and shift interlock plate.

(i) Remove the E–ring from the shaft.

MT–18
MANUAL TRANSAXLE – S51 Transmission

INSPECTION OF TRANSMISSION
COMPONENTS
1. INSPECT INPUT SHAFT
(a) Using a micrometer, measure the outer diameter of the
input shaft journal surface.
Minimum outer diameter:
Part A 26.970 mm (1.0618 in.)
B 32.470 mm (1.2783 in.)
C 33.090 mm (7.3028 in.)
D 29.970 mm (1.1799 in.)
(b) Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 in.)

2. INSPECT OUTPUT SHAFT

(a) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Minimum outer diameter:
Part A 31.970 mm (1.2587 in.)
6 37.970 mm (1.4949 in.)
C 31.970 mm (1.2587 in.)

(b) Using a dial indicator, check the shaft run-

out.
Maximum runout: 0.05 mm (0.0020 in.)

3. CHECK OIL CLEARANCE OF EACH GEAR

Using a dial indicator, measure the oil clearance be-
tween the gear and input or output shaft with the needle
roller bearing installed.
Standard clearance:
1 st, 2nd, 3rd and 4th gears
0.009 – 0.053 mm
(0.0004 – 0.0021 in.)
5th gear 0.009 – 0.050 mm
(0.0004 – 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
if the clearance exceeds the limit, replace the gear,
needle roller bearing or shaft.
 MT–19
MANUAL TRANSAXLE – S51 Transmission

4. INSPECT SYNCHRONIZER RINGS

(a) Turn the ring and push it in to check the braking action.

(b) Measure the clearance between the synchronizer ring

back and the gear spline end.
Minimum clearance: 0.6 mm 10.024 in.)
If the clearance is less than the limit, replace the synchro-
nizer ring.

5. MEASURE CLEARANCE OF SHIFT FORKS AND HUB

SLEEVES
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 limit, replace the shift fork or
hub sleeve.

6. IF NECESSARY, REPLACE INPUT SHAFT FRONT

BEARING
(a) Remove the bolt and transaxle case oil receiver.
(b) Using SST, pull out the bearing.
SST 09308–00010

(e) Using SST, press in a new bearing.

SST 09310–35010 .
(d) Install the transaxle case oil receiver and torque
the bolt.
Torque: 75 kg–cm (65 in.–Ib, 7.4 11f–m)
MT–20
MANUAL TRANSAXLE – S51 Transmission

7. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT

BEARING
(a) Remove the bolt and bearing lock plate.
(b) Using SST, pull out the bearing.
SST 09308–00010

(c) Using SST, press in a new bearing.

SST 09310–35010
(d) Install the bearing lock plate and torque the
bolt.
Torque: 185 kg–cm (13 ft–Ib, 18 N–m)

8. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL

SEAL
(a) Using a screwdriver, pry out the oil seal.

(b) Using SST, drive in a new oil seal.

SST 09608–20012 (09608–00080, 09608–03020)
Drive in depth: 1.0 – 2.0 mm (0.039 – 0.079 in.)
(c) Coat the lip of the oil seal with MP grease.

9. IF NECESSARY, REPLACE LH SIDE OIL SEAL

(a) Using SST, press out the oil seal from the retainer.
SST 09608–20012 (09608–00030,09608–03020)
 MT–21
MANUAL TRANSAXLE – S51 Transmission

(b) Using SST, press in a new oil seal until its surface
is flush with the case surface.
SST 09316–60010 (09316–00010)
(c) Coat the lip of the oil seal with IMP grease.

10. IF NECESSARY, REPLACE RH SIDE OIL SEAL

(a) Drive out the oil seal with a screwdriver.

(b) Using SST, drive in a new oil seal until its surface
is flush with the case surface.
SST 09316–60010 (09316–00010)
(e) Coat the lip of the oil seal with MP grease.

11. IF NECESSARY, REPLACE LH OUTER RACE OF

SIDE BEARING
(a) Using SST, press out the outer race.
SST 09608–20012 (09608–00060,09608–03020)
(b) Install the bearing retainer without an O–ring.
(e) Install and torque the retainer bolts.
Torque: 185 kg–cm(13 ft–Ib, 18 N–m)
(d) Place the thinnest shim into the case.
(See table on page MT–28)
(e) Using SST, press in a new outer race.
SST 09608–20012 (09608–03020,09608–03060)
MT–22
MANUAL TRANSAXLE – S51 Transmission

12. IF NECESSARY, REPLACE RH OUTER RACE OF

SIDE BEARING
(a) Using SST, press out the outer race and shim.
SST 09608–20012 (09608–00030,09608–03020)

(b) Place the shim into the case.

(c) Using SST, press in a new outer race.
SST 09608–20012 (09608–03020,09608–03060)

13. IF NECESSARY, REPLACE CONTROL SHAFT COVER

OIL SEAL
(a) Using a screwdriver, pry out the oil seal.

(b) Using SST, drive in a new oil seal until its surface is
flush with the cover surface.
SST 09608–200 12 (09608–00080, 09608–03020)
(c) Coat the lip of the oil seal with MP grease.

14. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN

GEAR OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09921–00010
 MT–23
MANUAL TRANSAXLE – S51 Transmission

(b) Using SST, drive in a new oil seal.

SST 09201–60011
Drive in depth: 19 mm (0.75 in.)

15. IF NECESSARY, REPLACE REVERSE RESTRICT PIN

(a) Using SST, remove the straight screw plug.
SST 09313–30021
(b) Using a pin punch and hammer, drive out the slotted
spring pin.

(c) Replace the reverse restrict pin.

(d) Drive in the slotted spring pin.
(e) Apply sealant to the plug threads.
Sealant: Part No. 4.8833–00080, THREE6ON D 1344,
LOCTITE 242 or equivalent
(f) Using SST, install the straight screw plug.
SST 09313–30021
Torque: 130 kg–cm (9 ft–lb, 13 N–m)
MT–38
MANUAL TRANSAXLE – S51 Transmission

INSTALLATION OF TRANSAXLE
1. INSTALL TRANSAXLE TO ENGINE
Align the input shaft spline with the clutch disc, and
install the transaxle to the engine. Torque the bolts.
Torque:
12 mm bolt 650 kg–cm (47 ft–lb, 64 N–m)
10 mm bolt 470 kg–cm (34 ft–Ib, 46 N–m)

2. CONNECT LEFT ENGINE MOUNTING

Connect the left engine mounting with the bolts. Torque
the bolts.
Torque: 530 kg–cm (38 ft–lb, 52 N–rm)
3. INSTALL STABILIZER BAR
(See page FA–35)

4. INSTALL CENTER DRIVE SHAFT

(a) Insert the center drive shaft to the transaxle through the
bearing bracket.
(b) Secure the center drive shaft with the snap ring.
(c) Tighten a new bolt on the bearing bracket.
Torque: 330 kg–cm (24 ft–lb, 32 N–m)

5. CONNECT BOTH DRIVE SHAFTS

Connect the drive shaft and torque the six nuts while de-
pressing the brake pedal.
Torque: 370 kg–cm (27 ft–Ib, 36 N–m)

6. CONNECT LEFT STEERING KNUCKLE TO LOWER

ARM
Torque: 1,150 kg–cm (83 ft–Ib, 113 N–m)
 MT–39
MANUAL TRANSAXLE – S51 Transmission

7. INSTALL ENGINE MOUNTING CENTER MEMBER

(a) Install the engine mounting center member with the
four bolts. Torque the bolts.
Torque: 400 kg–cm (29 ft–lb, 39 N–m)
(b) Install the front and rear engine mounting bolts.
Torque the bolts.
Torque: 440 kg–cm (32 ft–lb, 43 N–m)

8. INSTALL SUSPENSION LOWER CROSSMEMBER

Torque: A 2,110 kg–cm (153 ft–Ib, 207 N–m)
8400 kg–cm (29 ft–Ib, 39 N–m))
9. CONNECT SPEEDOMETER CABLE
10. FILL TRANSAXLE WITH ATF DEXRON II
Capacity: 2.6 liters (2.7 U S qts, 2.3Imp. qts)
11. INSTALL UNDER COVERS

12. INSTALL TRANSAXLE MOUNTING BOLTS OF

TRANSAXLE UPPER
Torque: 650 kg–cm (47 ft–Ib, 64 N–m)
13. CONNECT BACK–UP LIGHT SWITCH CONNECTOR
AND GROUND STRAP

14. INSTALL STARTER

(a) Install the starter with the two bolts.
(b) Connect the connector and cable.

15. CONNECT CONTROL CABLES

(a) Install the retainers.
(b) Connect the cables to the linkage with the washer and
clip.
MT–40
MANUAL TRANSAXLE – S51 Transmission

16. INSTALL CLUTCH TUBE BRACKET

(a) Install the bracket with a bolt.
(b) Install the retainer to the bracket.

17. INSTALL CLUTCH RELEASE CYLINDER AND TUBE

CLAMP
18. INSTALL NEGATIVE BATTERY CABLE
19. CHECK FRONT WHEEL ALIGNMENT
(See page FA–3)
20. PERFORM ROAD TEST
Check for any abnormal noise or operation.
MT–24
MANUAL TRANSAXLE – S51 Transmission

ASSEMBLY OF TRANSMISSION
(See pages MT–7 to 9)
1. IF INPUT SHAFT WAS REPLACED, DRIVE IN
SLOTTED SPRING PIN
If the input shaft was replaced, drive the slotted spring pin
in the input shaft to a depth of 5.0 mm (O.197 in.).

2. INSERT 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: Install the key springs positioned so that their end
gaps are not in line.

3. INSTALL THIRD GEAR, NEEDLE ROLLER

BEARINGS, SYNCHRONIZER RING AND NO. 2
HUB SLEEVE ASSEMBLY TO INPUT SHAFT
(a) Apply ATF to the needle roller bearings.
(b) Place the synchronizer ring on the gear and align the
ring slots with the shifting keys.

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

4. INSTALL SNAP RING

Select a snap ring that will allow minimum –axial play
and install it on the shaft.

Mark Thickness mm (in.)

 MT–25
MANUAL TRANSAXLE – S51 Transmission

5. MEASURE THIRD GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 3rd gear thrust
clearance.
Standard clearance: 0.10 – 0.25 mm
(0.0039 – 0.0098 in.)

6. INSTALL SYNCHRONIZER RING, SPACER, NEEDLE

ROLLER BEARINGS, FOURTH GEAR AND RADIAL
BALL BEARING
(a) Install the spacer.
(b) Apply ATF to the needle roller bearings.
(c) Place the synchronizer ring on the gear and align the
ring slots with the shifting keys.

(d) Using SST, press in the 4th gear and radial ball
bearing.
SST 09608–20012 (09608–03070)

7. INSTALL SNAP RING

Select a snap ring that will allow minimum axial play and
install it on the shaft.

Mark Thickness mm
(in.)

8. MEASURE FOURTH GEAR THRUST CLEARANCE

Using a feeler, gauge, measure the 4th gear thrust clearance.
Standard clearance: 0.20 – 0.45 mm (0.0079 .– 0.0177 in.)
MT–26
MANUAL TRANSAXLE – S51Transmission
9. IF OUTPUT SHAFT WAS REPLACED, DRIVE IN
SLOTTED SPRING PIN
If the output shaft was replaced, drive the slotted spring
pin in the output shaft to a depth of 5.0 mm (0.197 in.).

10. INSERT 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: Install the key springs positioned so that their end
gaps are not in line.

11. INSTALL THRUST WASHER, FIRST GEAR, NEEDLE

ROLLER BEARING, SYNCHRONIZER RING AND
NO. 1 HUB SLEEVE ASSEMBLY TO OUTPUT SHAFT
(a) Apply ATF to the needle roller bearing.
(b) Place the synchronizer ring on the gear and align the
ring slots with the shifting keys.

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

12. INSTALL SNAP RING

Select a snap ring that will allow minimum axial play
and install it on the shaft.

Mark Thickness mm (in.)

 MT–27
MANUAL TRANSAXLE – S51 Transmission

13. MEASURE FIRST GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 1 st gear thrust
clearance.
Standard clearance: 0.10 – 0.29 mm
(0.0039 – 0.0114 in.)

14. INSTALL SPACER, SYNCHRONIZER RING, SECOND

GEAR, NEEDLE ROLLER BEARING AND THIRD
DRIVEN GEAR
(a) Install the spacer.
!by Place the synchronizer ring on the gear and align
the ring slots with the shifting keys.
(c) Apply ATF to the needle roller bearing.
(d) Install the 2nd gear.

(e) Using a press, install the 3rd driven gear.

15. MEASURE SECOND GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 2nd gear thrust
clearance.
Standard clearance: 0.20 – 0.44 mm (0.0079 – 0.0173 in.)

16. INSTALL OUTPUT GEAR SPACER, FOURTH DRIVEN

GEAR AND RADIAL BALL BEARING
(a) Install the spacer.
(b) Using SST, press in the 4th driven gear and bearing.
SST 09608–12010 (09608–00070)
MT–28
MANUAL TRANSAXLE – S51 Transmission

17. INSTALL MAGNET

18. MEASURE DIFFERENTIAL SIDE BEARING PRELOAD

HINT: If the transmission case, transaxle case, differen-

tial
side bearing, differential case, transaxle case side shim
or side bearing retainer was replaced, install the thinnest
shim into the transmission case.
(Follow the step 11 on page MT–21)
(a) Install the differential to the transaxle case.
(b) Install the transmission case.
(c) Install and torque the case bolts.
Torque: 300 kg–cm (22 ft–Ib, 29 N–m))
(d) Install the shim into the transmission case.
(e) Install the bearing retainer without an O–ring.
(f) Install and torque the retainer bolts.
Torque: 185 kg–cm (13 ft–Ib, 18 N–m)

(g) Using SST and torque meter, measure the preload.

SST 09564–32011
Preload (starting): 10 – 16 kg–cm
(8.7 – 13.9 in.–Ib, 1.0 – 1.6 N–m)
If the preload is not within specification, remove the bearing
retainer. Select another shim.
NOTICE: When selecting the shim begin with one of the thinner
shims in the table below and work toward thicker one.
HINT: The preload will change about 3 4 kg–cm (2.6 –
3.5 in.–Ib, 0.3 – 0.4 N–m) with each shim thickness.

Mark Thickness mm (in.) Mark Thickness mm (in.)

 MT–29
MANUAL TRANSAXLE – S51 Transmission

19. REMOVE BEARING RETAINER, SHIM AND

TRANSMISSION CASE
If the preload is adjusted within specification, remove the
bearing retainer, shim and transmission case.
Be careful not to lose the adjusted shim.

20. INSTALL INPUT AND OUTPUT SHAFTS

Install the input shaft and output shaft together.

21. INSTALL NO. 2 FORK SHAFT

(a) Insert No. 2 fork shaft to the transaxle case and align the
slotted spring pin hole.
(b) Using a pin punch and hammer, drive in the slotted spring
pin.
(c) Apply sealant to the plug threads.
Sealant: Part No. 08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent

(d) Using SST, install the straight screw

plug.
SST 09313–30021
Torque: 130 kg–cm (9 ft–Ib, 13 N–m)

22. INSTALL REVERSE SHIFT FORK AND INTERLOCK

PIN
(a) Insert interlock pin into the reverse shift fork hole.
MT–30
MANUAL TRANSAXLE – S51 Transmission

(b) Install the reverse shift fork onto No. 2 fork shaft.

23. INSTALL REVERSE SHIFT ARM

(a) Put the reverse shift arm pivot into the reverse shift
fork and install the reverse shift arm to the transaxle case.
(b) Shift the reverse shift arm into reverse.

(e) Install and torque the bolts.

Torque: 185 kg–cm (13 ft–lb, 18 N–m)
(d) Shift the reverse shift arm to neutral position.

24. INSTALL REVERSE IDLER GEAR AND SHAFT

Install the reverse idler gear and shaft as shown.

25. INSTALL NO. 1 AND NO. 2 SHIFT FORKS, NO. 1

SHIFT HEAD AND NO. 1 FORK SHAFT
(a) Place No. 1 and No. 2 shift forks into the groove of
No. 1 and No. 2 hub sleeves.
 MT–31
MANUAL TRANSAXLE – S51 Transmission

(b) Hold No. 1 shift head and insert No. 1 fork shaft
into the transaxle case through No. 1 and No. 2
shift forks, No. 1 shift head and reverse shift fork.

(e) Using a pin punch and hammer, drive the slotted

spring pin into No. 1 shift head.

(d) Shift the fork shaft into reverse.

(e) Using a pin punch and hammer, drive the slotted
spring pin into No. 1 fork shaft.

26. INSTALL TRANSMISSION CASE

(a) Apply seal packing to the transmission case as shown in the
figure.
Seal packing: Part No. O8826–00090, THREE BOND
1281 or equivalent
(b) Install and torque the seventeen bolts.
Torque: 300 kg–cm (22 ft–tb, 29 N–m)

27. INSTALL SHIM AND SIDE BEARING RETAINER

WITH O–RING
(a) Install a new 4–ring on the retainer.
(b) Install the shim and retainer.
(c) Apply sealant to the bolt threads.
Sealant: Part No. 08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
MT–32
MANUAL TRANSAXLE – S51 Transmission

(d) Install and torque the six bolts.

Torque: 185 kg–cm (13 ft–lb, 18 N –m)

28. INSTALL AND TORQUE REVERSE IDLER GEAR

SHAFT LOCK BOLT
Torque: 300 kg–cm (22 ft–Ib, 29 N–m)

29. INSTALL BEARING SNAP RINGS

30. INSTALL REAR BEARING RETAINER

(a) Apply sealant to the bolt threads.
Sealant: Part No. 08833–00070, THREE BOND
1324, or equivalent
(b) Install and torque the five bolts.
Torque: 210 kg–cm (15 ft–Ib, 21 N– m)

31. INSTALL FIFTH DRIVEN GEAR

Using SST, install the 5th driven gear.
SST 09309–32050
 MT–33
MANUAL TRANSAXLE – S51 Transmission

32. INSTALL SPACER, NEEDLE ROLLER BEARINGS,

FIFTH GEAR AND SYNCHRONIZER RING
(a) Install the spacer.
(b) Apply ATF to the needle roller bearings.
(e) Install the 5th gear with the needle roller bearings and
synchronizer ring.

33. INSERT NO. 3 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: Install the key springs positioned so that their end
gaps are not in line.

34. INSTALL NO. 3 HUB SLEEVE ASSEMBLY WITH SHIFT

FORK
(a) Support the tip of the input shaft with a spacer or such
to raise the transaxle assembly.
(b) Using SST, drive in No. 3 hub sleeve with shift fork.
SST 09612–22011
NOTICE: Align the synchronizer ring slots with the shifting
keys.

35. MEASURE FIFTH GEAR THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20 – 0.40 mm
(0.0079 – 0.0157 in.)

36. INSTALL SHIFTING KEY RETAINER AND SNAP RING

(a) Install the retainer.
(b) Select a snap ring that will allow minimum axial play and
install it on the shaft.

Mark Thickness mm (in.) Mark Thickness mm (in.)

MT–34
MANUAL TRANSAXLE – S51 Transmission

37. INSTALL LOCK NUT

(a) Engage the gear double meshing.
(b) Install and torque the nut.
Torque: 1,250 kg–cm (90 ft–lb, 123 N–m)
HINT: The lock nut has LH threads.
(c) Disengage the gear double meshing.
(d) Stake the lock nut.

38. ASSEMBLE SHIFT AND SELECT LEVER ASSEMBLY

(a) Apply ATF to the shaft.
(b) Install the E–ring.

(c) Install shift interlock plate and

spring.

(d) Install No. 1 shift inner lever with the shift fork lock
plate.
HINT: One of the spline teeth of the shift and select
lever shaft has been eliminated. Therefore, be cer-
tain to correctly align this portion to the matching
portions on the parts during assembly.

(e) Using a pin punch and hammer, drive i n the slotted

spring pin.
 MT–35
MANUAL TRANSAXLE – S51 Transmission

(f) Install No. 2 shift inner lever, spring and reverse

restrict pin holder.

(g) Install the E–ring.

(h) Install the control shaft cover and dust boot.

HINT: Make sure to install the boot in correct direction.
Position the air bleed of the boot downward.

Install the control shift lever and insert the lever lock
pin to the lever. Install the washer and lock nut.

39. INSTALL SHIFT AND SELECT LEVER ASSEMBLY

(a) Apply seal packing to the underside of the flanged portion of
the control shaft cover.
Seal packing: Part No. 08826–00090, THREE BOND
1281 or equivalent
(b) Install the shift and select lever assembly and torque the con-
trol shaft cover. ._
Torque: 375 kg–cm (27 ft–Ib, 37 N–m)
MT–36
MANUAL TRANSAXLE – S51 Transmission
40. INSTALL NO. 2 LOCK BALL ASSEMBLY
(a) Apply sealant to the lock ball assembly threads.
Sealant: Part No. 08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, install and torque the plug.
SST 09313–30021
Torque: 230 kg–cm (117 ft–Ib, 23 N–m)

41. INSTALL AND ADJUST NO. 1 LOCK BALL

ASSEMBLY
(a) Fully loosen the lock nut.
(b) Fully screw in the lock ball.
(e) Loosen the lock ball to where the play at the shift outer
lever tip is 0.1 – 0.5 mm (0.004 – 0.020 in.).

(d) Hold the lock ball and tighten the lock nut.
Torque: 375 kg–cm (27 ft–Ib, 37 N–m )
(e) Check the shift outer lever tip play.
Lever tip play: 0.1 – 0.5 mm (0.004 – 0.020 in.)
42. INSTALL SELECTING BELLCRANK

43. INSTALL NO. 3 SHIFT FORK SECURING BOLT

Install and torque the bolt.
Torque: 185 kg–cm (13 ft–Ib, 18 N–m)

44. INSTALL TRANSMISSION CASE COVER

(a) Apply seal packing to the transmission case as shown in
the figure.
Seal packing: Part No. 08826–00090, THREE BOND
1281 or equivalent
(b) Apply sealant to the bolt threads.
Sealant: Part No. 08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Install and torque the eight bolts.
Torque: 300 kg–cm (22 ft–Ib, 29 N–m)
 MT–37
MANUAL TRANSAXLE – S51 Transmission

45. INSTALL RELEASE BEARING RETAINER

Torque: 75 kg–cm (65 in.–Ib, 7.4 N–m)

46. INSTALL RELEASE FORK AND BEARING

(a) Apply molybdenum disulphide lithium base grease to
the following parts:
• Release bearing hub inside groove
• Input shaft spline
• Release fork contact surface
(b) Apply MP grease to the front surface of the release
bearing.

47. INSTALL BACK–UP LIGHT SWITCH

Torque: 450 kg–cm (33 ft–Ib, 44 N–m)
48. INSTALL SPEEDOMETER DRIVEN GEAR
 MT–41
MANUAL TRANSAXLE – Shift Lever and Control Cable

SHIFT LEVER AND CONTROL CABLE

COMPONENTS
MT–42
MANUAL TRANSAXLE – Differential

DIFFERENTIAL
REMOVAL OF DIFFERENTIAL
1. REMOVE TRANSAXLE
(See pages MT–4 to 6)
2. REMOVE DIFFERENTIAL ASSEMBLY
(See steps 1 to 24 on pages MT–10 to 14)
REPLACEMENT OF DIFFERENTIAL
(See pages AT–158 to 160)
ADJUSTMENT OF DIFFERENTIAL CASE
(See pages AT–161, 162)
INSTALLATION OF DIFFERENTIAL
1. INSTALL DIFFERENTIAL ASSEMBLY TO TRANSAXLE
(See steps 18 to 37 and 39 to 48 on pages MT–28 to 37)
2. INSTALL TRANSAXLE
(See pages MT–38 to 40)
 MT–43
MANUAL TRANSAXLE – Description

DESCRIPTION
• Transaxle types E52 are constant mesh synchronizers for forward gears, and a sliding mesh reverse
gear.
• The input shaft is composed of the 1 st and 2nd speed gears and the reverse drive gear, and the out-
put shaft is composed of the drive gear (for use with the ring gear).
• The oil used in transaxle is as follows:
E52 . . . . . . . . . . . . . . . : . . . ... . . . . . . . . . . . SAE75W–90 or 80W–90
• The illustrations below show the engagements of transaxle gears.
MT–44
MANUAL TRANSAXLE – Precautions

PRECAUTIONS
When working with FIPG material, you must be observe the following.
• Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces.
• Thoroughly clean all components to remove all the loose material.
• Clean both sealing surfaces with a non–residue solvent.
• Apply the seal packing in approx.1 mm (0.04 in.) bead along the sealing surface.
• Parts must be assembled within 10 minutes of apptication. Otherwise, the packing (FIPG)
material must be removed and reapplied.
TROUBLESHOOTING
Problem Possible cause Remedy Page

Noise Transmission or differential faulty Disassemble and inspect transmission MT–47,85

or differential
Wrong oil grade Replace oil
Oil level low Add oil

Oil leakage Oil level too high Drain oil

Oil seal, O–ring or gasket worn or Replace oil seal, O–ring or gasket MT–47
damaged

Hard to shift or will not Control cable faulty Replace control cable
shift Transmission faulty Disassemble and inspect transmission MT–47

Jumps out of gear Transmission faulty Disassemble and inspect transmission MT–47
MT–44
MANUAL TRANSAXLE – Troubleshooting

PRECAUTIONS
When working with FIPG material, you must be observe the following.
• Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces.
• Thoroughly clean all components to remove all the loose material.
• Clean both sealing surfaces with a non–residue solvent.
• Apply the seal packing in approx.1 mm (0.04 in.) bead along the sealing surface.
• Parts must be assembled within 10 minutes of apptication. Otherwise, the packing (FIPG)
material must be removed and reapplied.

TROUBLESHOOTING
Problem Possible cause Remedy Page

Noise Transmission or differential faulty Disassemble and inspect transmission MT–47,85

or differential
Wrong oil grade Replace oil
Oil level low Add oil

Oil leakage Oil level too high Drain oil

Oil seal, O–ring or gasket worn or Replace oil seal, O–ring or gasket MT–47
damaged

Hard to shift or will not Control cable faulty Replace control cable
shift Transmission faulty Disassemble and inspect transmission MT–47

Jumps out of gear Transmission faulty Disassemble and inspect transmission MT–47
 MT–45
MANUAL TRANSAXLE – Removal and Installation of Transaxle

REMOVAL AND INSTALLATION OF

TRANSAXLE
Remove and install the parts as shown.
HINT: Oil grade: API GL–4 or GL–5
Viscosity: SAE 75W–90 or 80W–90
Capacity: 4.2 litter (4.4 US qts, 3.7 Imp. qts)
MT–46
MANUAL TRANSAXLE – Removal and installation of Transaxle

REMOVAL AND INSTALLATION OF

TRANSAXLE Cont’d
Remove and install the parts as shown.
MT–62
MANUAL TRANSAXLE – Component Parts.

COMPONENT PARTS
Input Shaft Assembly

DISASSEMBLY OF INPUT SHAFT ASSEMBLY

1. MEASURE THIRD AND FOURTH GEAR 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.)
 MT–63
MANUAL TRANSAXLE – Component Parts

2. CHECK OIL CLEARANCE OF THIRD AND FOURTH

GEAR
Using dial indicator, measure the oil 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 gear 0.070 mm (0.0028 in.)
If clearance exceeds the limit, replace the gear, needle
roller bearing or shaft.
3. REMOVE SNAP RING
Using two screwdrivers and a hammer, tap out the snap
ring.

4. REMOVE RADIAL BALL BEARING AND FOURTH GEAR

Using SST and a press, remove the radial ball bearing.
SST 09950–00020
5.REMOVE NEEDLE ROLLER BEARINGS, SPACER AND
SYNCHRONIZER RING

6. REMOVE SNAP RING

Using two screwdrivers and a hammer, tap out the snap ring.

7. REMOVE NO.2 CLUTCH HUB ASSEMBLY,

SYNCHRONIZER RING AND THIRD GEAR
Using a press, remove No.2 hub sleeve, 3rd gear, syn-
chronizer ring and needle roller bearings.
8. REMOVE NEEDLE ROLLER BEARING
MT–64
MANUAL TRANSAXLE – Component Parts
9. REMOVE INPUT SHAFT FRONT BEARING INNER
RACE
Using SST and a press, remove the inner race.
SST 09950–00020
 MT–65
MANUAL TRANSAXLE – Component Parts

INSPECTION OF INPUT SHAFT COMPONENT

PARTS
1. INSPECT SYNCHRONIZER RINGS
(a) Check for wear or damage.
(b) Turn the ring and push it in to check the braking action.

(c) 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 limit, replace the
synchronizer ring.

2. MEASURE CLEARANCE OF NO.2 SHIFT FORK AND

HUB SLEEVE
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 limit, replace the shift fork
or hub sleeve.

3. INSPECT INPUT SHAFT

(a) Check the input shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of
the input shaft journal surface.
Minimum outer diameter:
Part A 32.930 mm (1.2965 in.)
Part B and C 35.950 mm (1.4154 in.)

(c) Using a dial indicator, check the shaft runout.

Maximum runout: 0.05 mm (0.0020 in.)
MT–66
MANUAL TRANSAXLE – Component Parts

ASSEMBLY OF INPUT SHAFT ASSEMBLY

(See page MT–62)
HINT: Coat all of the sliding and rotating surface with
gear oil before assembly.
1. INSERT 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: Install the shifting key springs positioned so that their
end gaps are not in line.
2. INSTALL NEEDLE ROLLER BEARING, THIRD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE
ASSEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearings.
(b) Assemble the needle roller bearings into the 3rd gear.
(c) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(d) Using SST and a press, install the 3rd gear and No–2
hub sleeve.
SST 09506–35010
3. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and
install it on the shaft.

Mark Thickness mm (in.) Mark Thickness mm (in.)

4. MEASURE THIRD GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 3rd gear thrust
clearance.
Standard clearance: 0.10 – 0.35 mm
(0.0039 – 0.0138 in.)

5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE

ROLLER BEARINGS, FOURTH GEAR AND RADIAL
BALL BEARING
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearings.
(c) Place the synchronizer ring on the gear and align the
ring slots with the shifting keys.
(d) Install the 4th gear.
(e) Using SST and a press, install the radial ball bearing.
SST 09506–35010
 MT–67
MANUAL TRANSAXLE – Component Parts

6. INSTALL SNAP RING

Select a snap ring that will allow minimum axial play and
install it on the shaft.

Mark Thickness mm (in.) Mark Thickness mm (in.)

7. MEASURE FOURTH GEAR TH . RUST CLEARANCE

Using a feeler gauge, measure the 4th gear thrust clearance.
Standard clearance: 0.10 – 0.55 mm
(0.0039 – 0.0217 in:)

8. INSTALL INPUT SHAFT FRONT BEARING INNER RACE

Using SST and a press, install the input shaft front bearing in-
ner race.
SST 09316–60010 (09316–00020)
 MT–47
MANUAL TRANSAXLE – Removal of Component Parts

REMOVAL OF COMPONENT PARTS

COMPONENTS
MT–48
MANUAL TRANSAXLE – Removal of Component Parts

COMPONENTS (Cont’d)
 MT–49
MANUAL TRANSAXLE – Removal of Component Parts

COMPONENTS (Cont’d)
MT–50
MANUAL TRANSAXLE – Removal of Component Parts

REMOVAL OF COMPONENT PARTS

(See pages MT–47 to 49)
1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK–UP LIGHT SWITCH
Using SST, remove the back–up light switch.
SST 09817–16011

3. REMOVE SPEEDOMETER DRIVEN GEAR

(a) Remove the set bolt and speedometer adaptor.
(b) Remove the speedometer driven gear.

4. REMOVE SELECTING BELLCRANK ASSEMBLY

5. REMOVE SHIFT AND SELECT LEVER

(a) Remove the lock bolt.

(b) Remove the four bolts and pull out the shift and
select lever.
 MT–51
MANUAL TRANSAXLE – Removal of Component Parts

6. REMOVE TRANSMISSION CASE COVER

7. REMOVE LOCK NUT

(a) Unstake the lock nut.
(b) Engage the gear double meshing.

(c) Remove the lock nut.

(d) Disengage the gear double meshing.

8. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK

(a) Remove the No.3 shift fork set bolt.
(b) Remove the No.3 hub sleeve and No–3 shift fork.

9. REMOVE FIFTH DRIVEN GEAR

Using SST, remove the 5th driven gear.
SST 09310–17010 (09310–07010, 09310–07020,
09310–07040, 09310–07050)
MT–52
MANUAL TRANSAXLE – Removal of Component Parts

10. MEASURE FIFTH GEAR THRUST CLEARANCE AND

OIL CLEARANCE
(a) 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.)

(b) Using a dial indicator, measure the oil clearance.

Standard clearance: 0.009 – 0.050 mm
(0.0004 – 0.0020 in.)
Maximum clearance: 0.070 mm t0:0028 in.)

11. REMOVE NO–3 CLUTCH HUB AND FIFTH GEAR

(a) Using two screwdrivers and a hammer, tap out the
snap ring.

(b) Using SST, remove the No.3 clutch hub with synchro-
nizer ring and 5th gear.
SST 09310–17010 (09310–07010, 09310–07020,
09310–07040, 09310–07050)
12. REMOVE NEEDLE ROLLER BEARING AND SPACER

13. REMOVE REAR BEARING RETAINER

(a) Using a torx socket wrench, remove the seven torx
screws and bearing retainer.
Torx wrench T45 09042–00050
(b) Remove the adjust shim.
 MT–53
MANUAL TRANSAXLE – Removal of Component Parts

14. REMOVE SNAP RING

(a) Using snap ring pliers, remove the snap ring.

(b) Using two screwdrivers and a hammer, remove

the three snap rings.

15. REMOVE PLUG, SEAT, SPRING AND LOCKING BALL

(a) Using SST, remove the plug.
SST 09313–30021
(b) Using a magnetic finger, remove the seat, spring and
locking ball.

16. REMOVE REVERSE IDLER GEAR SHAFT RETAINING

BOLT

17. REMOVE TRANSMISSION CASE

(a) Remove the fourteen bolts from the transmission case
side.
MT–54
MANUAL TRANSAXLE – Removal of Component Parts

(b) Remove the three bolts from the transaxle case

side and tap off the case with a plastic hammer.

18. REMOVE OUTPUT SHAFT REAR TAPERED ROLLER

BEARING OUTER RACE
Using a plastic hammer, drive out the outer race.

19. REMOVE NO.2 OIL PIPE

(a) Remove the gasket.
(b) Remove the two bolts and oil pipe.

20. REMOVE REVERSE SHIFT ARM BRACKET

Remove the two bolts and pull off the bracket.

21. REMOVE REVERSE IDLER GEAR AND SHIFT

Pull out the shift, remove the reverse idler gear and
thrust washer.
 MT–55
MANUAL TRANSAXLE – Removal of Component Parts

22. REMOVE STRAIGHT SCREW, LOCKING BALLS AND

SPRINGS
(a) Using SST, remove the two plugs.
SST 09313–30021
(b) Using a magnetic finger, remove the two spring seats,
springs and balls.

23. REMOVE SET BOLT

24. REMOVE NO.1 SHIFT FORK SHAFT

Pull up No.3 shift fork shaft, remove the No.1 shift fork
shaft.

25. REMOVE INTERLOCK ROLLER

Using a magnetic finger, remove the interlock roller from
the reverse shift fork.

26. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD AND

NO.1 SHIFT FORK
(a) Pull out the No.2shift fork shaft.
(b) Remove the shift head and No.1 shift fork.
MT–56
MANUAL TRANSAXLE – Removal of Component Parts
27. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE
SHIFT FORK AND NO.2 SHIFT FORK
(a) Pull out the No.3 shift fork shaft with reverse shift fork.
(b) Remove the No–2 shift fork.

28. REMOVE SNAP RINGS

(a) Using two screwdrivers and a hammer, remove the
snap ring and reverse shift fork from the No.3 shift
fork shaft.
(b) Using two screwdrivers and a hammer, remove the
snap rings from the No.1, No.2 and No.3 shift fork
shafts.

29. REMOVE INPUT AND OUTPUT SHAFT ASSEMBLY

(a) Leaning the output shaft to the differential side,
remove the input shaft assembly.

(b) Lift up the differential case assembly, remove the

output shaft.

30. REMOVE DIFFERENTIAL ASSEMBLY

(a) Remove the oil pump drive gear.
 MT–57
MANUAL TRANSAXLE – Removal of Component Parts

(b) Remove the differential case assembly.

31. REMOVE MAGNET FROM TRANSAXLE CASE

32. REMOVE OIL PUMP ASSEMBLY

(a) Remove the two bolts and oil pipe.

(b) Remove the two bolts and oil pump.

MT–58
MANUAL TRANSAXLE – Removal of Component Parts

INSPECTION OF COMPONENT PARTS

1. INSPECT SYNCHRONIZER RING FOR FIFTH GEAR
(a) Check for wear or damage.
(b) Turn the ring and push it in to check the braking action.

(e) 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 limit, replace the
synchronizer ring.

2. MEASURE CLEARANCE OF SHIFT FORKS AND HUB

SLEEVE
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 limit, replace the shift fork
or hub sleeve.

3. REMOVE TRANSAXLE CASE RECEIVER

4. IF NECESSARY, REPLACE INPUT SHAFT BEARING

AND OIL SEAL
(a) Using SST, pull out the bearing.
SST 09812–65014
 MT–59
MANUAL TRANSAXLE – Removal of Component Parts

(b) Using a screwdriver; remove the oil seal.

(c) Using SST, drive in a new oil seal.

SST 09608–12010 (09608–00020, 09608–00080)
(d) Coat the lip of seal with NIP grease.

(e) Using SST, drive in a new bearing.

SST 09608–12010 (09608–00020, 09608–00060)

5. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT

OUTER RACE AND OUTPUT SHAFT COVER
(a) Using SST, pull out the outer race.
SST 09308–000 10
(b) Remove the output shaft cover.

(e) Install the output shaft front cover.

HINT: Install the shaft cover projection into the case
side groove.
MT–60
MANUAL TRANSAXLE – Removal of Component Parts

(d) Using SST, press in a new outer race.

SST 09316–60010 (09316–00010,
09316–00020)

6. INSTALL AND TORQUE TRANSAXLE CASE RECEIVER

Torque: 75 kg–cm (65 in.–lb, 7.4 N–m)

7. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN

GEAR OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09921–00010

(b) Using SST, drive in a new oil seal.

SST 09201–60011
Drive in depth: 33 mm (1.30 in.)
(c) Coat the lip of oil seal with MP grease.

8. IF NECESSARY, REPLACE REVERSE RESTRICT PIN

(a) Using SST, remove the screw plug.
SST 09313–30021
(b) Using a pin punch and hammer, drive out the slotted
spring pin.
 MT–61
MANUAL TRANSAXLE – Removal of Component Parts

(c) Replace the reverse restrict pin.

(d) Using a pin punch and hammer, drive in the slotted spring pin.
(e) Apply sealant to the plug threads.
Sealant: Part No.08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(f) Using SST, install the screw plug.
SST 09313–30021
MT–68
MANUAL TRANSAXLE – Component Parts

Output Shaft Assembly

DISASSEMBLY OF OUTPUT SHAFT

ASSEMBLY
1. MEASURE FIRST AND SECOND GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1 st 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:
1 st gear 0.40 mm (0.0157 in.)
2nd gear 0.50 mm (0.0197 in.)
 MT–69
MANUAL TRANSAXLE – Component Parts

2.CHECK– OIL CLEARANCE OF FIRST AND SECOND

GEAR
Using dial indicator, measure the oil 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:
1 st and 2nd gear 0.070 mm’(0.0028 in.)
If the clearance exceeds the limit, replace the gear,
needle roller bearing or shaft.
3. REMOVE OUTPUT SHAFT REAR– BEARING, FOURTH
DRIVEN GEAR AND SPACER
(a) Using a press, remove the bearing and 4th driven gear.
(b) Remove the spacer.

4. REMOVE THIRD DRIVEN GEAR AND SECOND GEAR

Using a press, remove the 3rd driven gear and 2nd
gear.
5. REMOVE NEEDLE ROLLER BEARINGS, SPACER AND
SYNCHRONIZER RING

6. REMOVE SNAP RING

Using snap ring pliers, remove the snap ring.

7. REMOVE NO.1 HUB SLEEVE ASSEMBLY AND FIRST

GEAR
Using a press, remove No. 1 hub sleeve and 1 st gear.
8. REMOVE SYNCHRONIZER RING AND NEEDLE
ROLLER’ BEARING
MT–70
MANUAL TRANSAXLE – Component Parts

INSPECTION OF OUTPUT SHAFT

COMPONENT PARTS
1. INSPECT SYNCHRONIZER RINGS
(a) Check for wear or damage.
(b) Turn the ring and push it in to check the braking action.

(c) Measure the clearance between the synchronizer

ring back and the gear spline end.
Maximum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the limit, replace the
synchronizer ring.

2. MEASURE CLEARANCE OF NO–1 SHIFT FORK AND

HUB SLEEVE
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 limit, replace the shift fork
or hub sleeve.

3. INSPECT OUTPUT SHAFT

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

(c) Using a dial indicator, check the shaft runout.

Maximum runout: 0.06 mm (0.0024 in.)
 MT–71
MANUAL TRANSAXLE – Component Parts

4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT

BEARING
(a) Using SST and a press, remove the bearing.
SST 09307–12010, 09950–00020

(b) Using SST and a press, install the new bearing.

SST 09316–60010 (09316–00070)
MT–72
MANUAL TRANSAXLE – Component Parts

ASSEMBLY OF OUTPUT SHAFT

ASSEMBLY
(See page MT–68)
HINT: Coat all of the sliding and rotating surface with
gear oil before assembly.
1. INSERT NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub
sleeve.
Install the shifting key springs under the shifting
keys.
NOTICE: Install the key springs positioned so that their
end gaps are not in line.
2. INSTALL NEEDLE ROLLER BEARING, FIRST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearings.
(b) Install the 1st gear.
(e) Place the synchronizer ring (for 1st gear) on the gear
and align the ring slots with the shifting keys.
NOTICE: Do not install the synchronizer ring for 2nd
gear.
(d) Using SST and a press, install the 1 st gear and No. 1
hub sleeve.
SST 09316–60010 (09316–00040)

3. INSTALL SNAP RING

Select a snap ring that will allow minimum axial play
and install it on the shaft.

Mark Thickness mm (in.) Mark Thickness mm (in.)

4. MEASURE FIRST GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 1st gear thrust
clearance.
Standard clearance: 0.10 – 0.35 mm
(0.0039 – 0.0138 in.)
 MT–73
MANUAL TRANSAXLE – Component Parts

5. INSTALL SPACER, NEEDLE ROLLER BEARING,

SYNCHRONIZER RING, SECOND GEAR AND
THIRD DRIVEN GEAR
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearing.
(c) Place the synchronizer ring (for 2nd gear) on the gear
and align the ring slots with the shifting keys.
NOTICE: Do not install the synchronizer ring for 1st
gear.

(d) Install the 2nd gear.

(e) Using a press, install the 3rd driven gear.

6. MEASURE SECOND GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 2nd gear thrust
clearance.
Standard clearance: 0.10 – 0.45 mm
(0.0039 – 0.0177 in.)

7. INSTALL SPACER AND FOURTH DRIVEN GEAR

(a) Install the spacer.
(b) Using a press, install the 4th driven gear.

8. INSTALL OUTPUT SHAFT REAR BEARING

Using SST and a press, instal! the bearing.
SST 09506–30012
MT–74
MANUAL TRANSAXLE – Component Parts

Oil Pump Assembly

DISASSEMBLY OF OIL PUMP

1. CHECK OPERATION OF OIL PUMP
Install the oil pump drive gear to the drive rotor, check
that the drive rotor turn smoothly.

2. REMOVE GASKET TO OIL PUMP CASE

 MT–75
MANUAL TRANSAXLE – Component Parts

3. REMOVE BOLT AND OIL STRAINER

4. REMOVE OIL PUMP COVER

(a) Hold the oil pump cover, remove the two bolts and a
cover.

(b) Remove the spring holder, spring, ball and relief

valve seat.

5. CHECK ROTOR BODY CLEARANCE

(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the body clearance be-
tween the drive rotor and oil pump case.
Standard clearance: 0.10 – 0.16 mm
(0.004 – 0.006 in.)
Maximum clearance: 0.30 mm (0.012 in.)

6. CHECK ROTOR TIP CLEARANCE

(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the tip clearance be-
tween the drive and driven rotors.
Standard clearance: 0.08 – 0.15 mm
(0.003 – 0.006 in.)
Maximum clearance: 0.30 mm (0.012 in.)
MT–76
MANUAL TRANSAXLE – Component Parts

7. CHECK SIDE CLEARANCE

Using a precision straight edge and feeler gauge, mea-
sure the side clearance of both rotors.
Standard clearance: 0.03 – 0.08 mm
(0.001 – 0.003 in.)
Maximum clearance: 0.15 mm (0.006 in.)

8. REMOVE OIL PUMP DRIVE ROTOR AND DRIVEN

ROTOR

9. IF NECESSARY, REPLACE O–RING

(a) Using a screwdriver, remove the O–ring.

(b) Apply gear oil to the O–ring.

(c) Install the O–ring.
 MT–77
MANUAL TRANSAXLE – Component Parts

1. INSTALL DRIVEN ROTOR AND DRIVE ROTOR

2: INSTALL OIL PUMP COVER

(a) Install the relief valve, ball, spring and spring holder to
the oil pump case.

(b) Hold the oil pump cover, temporarily install the two
bolts.

3. INSTALL OIL STRAINER

Install the oil strainer to the oil pump case, temporarily
install the bolt.

4. TORQUE OIL PUMP COVER BOLTS

Torque the three bolts evenly.
Torque: 105 kg–cm (8 ft–Ib, 10 N–m)
MT–78
MANUAL TRANSAXLE – Component Parts

5. CHECK OPERATION OF OIL PUMP

Insert the oil pump drive gear to the drive rotor, check
that the drive rotor turn smoothly.

6. INSTALL GASKET
Install the new gasket to the oil pump case.
 MT–79
MANUAL TRANSAXLE – Component Parts

Shift and Select Lever Assembly

DISASSEMBLY OF SHIFT AND SELECT LEVER

ASSEMBLY
1. REMOVE NO.2 SHIFT INNER LEVER
(a) Using a pin punch and hammer, drive out the slotted spring pin.

(b) Using two screwdrivers and a hammer, remove the

snap ring.
MT–80
MANUAL TRANSAXLE – Component Parts

(c) Remove the No.2 select spring seat, No–2 com-

pression spring and No.2 shift inner lever.

2. REMOVE SHIFT INTERLOCK PLATE AND NO.1 SHIFT

INNER LEVER
(a) Using a pin punch and hammer, drive out the slotted
spring pin.

(b) Remove the shift interlock plate and No.1 shift inner lever.

3. REMOVE SELECT INNER LEVER

(a) Using a pin punch and hammer, drive out the slotted
spring pin.

(b) Remove the select inner lever–, No. 1 compression spring and
No. 1 select spring seat.
 MT–81
MANUAL TRANSAXLE – Component Parts

4. REMOVE SNAP RING

Using two screwdrivers and a hammer, remove the
snap ring.

5. REMOVE CONTROL SHAFT COVER AND DUST BOOT

(a) Remove the control shaft cover with dust boot from the
shaft.
(b) Remove the dust boot from the control shaft cover.

INSPECTION AND REPLACEMENT OF SHIFT

AND SELECT LEVER ASSEMBLY
IF NECESSARY, REPLACE CONTROL SHAFT COVER OIL
SEAL
(a) Using a screwdriver, pry out the oil seal.

(b) Using SST, drive in a new oil seal.

SST 09620–30010 (09627–30010, 09631–00020)
Drive in depth: 0.5 ± 0.5 mm (0.020 ± 0.020 in.)
(c) Coat the oil seal lip with MP grease.
MT–82
MANUAL TRANSAXLE – Component Parts

ASSEMBLY OF SHIFT AND SELECT

LEVER ASSEMBLY
(See page MT–79)
1. COAT SHAFT WITH MP GREASE, AS SHOWN

2. INSTALL DUST BOOT AND CONTROL SHAFT COVER

(a) Install the dust boot to the control shaft cover as
shown.

(b) Install the control shaft to the control shaft cover.

3. INSTALL SNAP RING

Using a brass bar and hammer, instal! the snap ring.
 MT–83
MANUAL TRANSAXLE – Component Parts

4. INSTALL SELECT INNER LEVER

(a) Install the No.1 select spring seat, No.1 compression
spring and select inner lever.

(b) Using a pin punch and hammer, drive in the slotted spring
pin.
(c) Check that the No. 1 select spring seat slide smoothly.

5. INSTALL SHIFT INTERLOCK PLATE AND No.1 SHIFT

INNER LEVER
(a) Install the shift interlock plate and No.1 shift inner lever
as shown.

(b) Using a pin punch and hammer, drive in the

slotted spring pin.

6. INSTALL NO.2 SHIFT INNER LEVER

(a) Install the No.2 shift inner lever, No–2 compression
spring and No.2 select spring seat.
MT–84
MANUAL TRANSAXLE – Component Parts

(b) Compress the spring and install the snap ring

with pliers.

(c) Using a pin punch and hammer, drive in the slotted spring
pin.
(d) Check that the No.2 select spring seat slide smoothly.
MT–108
MANUAL TRANSAXLE – Shift Lever and Control Cable

SHIFT LEVER AND CONTROL CABLE

COMPONENTS
 MT–109
MANUAL TRANSAXLE – Description

DESCRIPTION
GENERAL
• The E56F5 transaxle has been made compact by arranging the transmission, the center differen-
tial, the front differential and the transfer on the same quadruple case axle.
• The center differential, which compensates for the difference between the rotation speed of the
front and rear wheels, provide¿durability and reliability by utilizing bevel gear to distributing the
engine power from the transmission to both the front and rear propeller shafts in a 50I50 split.–
This center differential has been equipped with a lock mechanism which enables the vehicle to
get out of the trouble spot more easily when one of the four wheels spins in the deep snow or
muddy roads, etc.

E56F5 Transaxle
MT–110
MANUAL TRANSAXLE – Description

Transaxle type E56 F5

Floor shift vehicles are provided will

Operation method
push–pull type remote control
Transmission
Forward: Constant mesh
Transmission type
Reverse: Sliding mesh

Reduction side (Gear type) . Helical gear

Center differential Differential side (Gear type) Bevel gear

Type of differential control mechanism Differential lock

Transfer Gear type Hypoid Gear

• The oil used in each transaxle is as follows:

Transaxle oil E50 (08885–80206)
Recommended oil
Oil grade: AN GL–5
Viscosity: SAE 75W–90 or 80W–90
Above –18°C (0°F) SAE 90
Above – 1 8°C (0°F) SAE 84W
• Oil capacity: 5.0 Liters (s.3 Us qts, 4.4 Imp. qts)
OIL PUMP
The oil pump is of the trochoid type, and is driven by
the differential ring gear and the pump drive gear. It is
located at the bottom of the transaxle case.

KEY–LESS TYPE SYNCHROMESH

FUNCTION
* HUB SLEEVE
There are three protrusions on the inside of the hub sleeve to
push the key spring.
* CLUTCH HUB
Three apertures are located around the clutch hub to secure the
synchronizer ring and key spring in place.
* KEY SPRING
The key spring has four claws. One claw is to secure the key spring
in place. Three claws also act as shifting keys as well as key
springs.
SYNCHRONIZER RING
A chamfered ledge is provided at three points along the outer pe-
riphery and a bolt is provided in each to secure a key spring.
 MT–85
MANUAL TRANSAXLE – Component Parts

Differential
MT–86
MANUAL TRANSAXLE – Component Parts

DISASSEMBLY OF DIFFERENTIAL
CASE
1. REMOVE SIDE BEARING
Using SST, remove the two side bearings.
SST 09950–20017

2. REMOVE RING GEAR

(a) Place the matchmarks on both the differential case and
ring gear.

(b) Remove the sixteen bolts.

(c) Using a plastic hammer, tap out the ring gear.

3. DISASSEMBLE OF DIFFERENTIAL CASE

(a) Place the matchmarks on the differential right and
left case.
(b) Using a torx socket wrench, remove the sixteen torx
screws.
 MT–87
MANUAL TRANSAXLE – Component Parts

(b) Using a torx wrench, remove the sixteen torx

screws.
Torx wrench T50 09042–00040

(c) Using a plastic hammer, tap out the differential left

case.
(d) Remove the speedometer drive gear from the differ-
ential right case.

(e) Remove the two differential side gears, two side

gear thrust washers, differential spider, four dif-
ferential pinions and four pinion washers from
the differential left case.
MT–88
MANUAL TRANSAXLE – Component Parts

INSPECTION OF DIFFERENTIAL CASE

1 . (Transmission Case Side)
IF NECESSARY. REPLACE OIL SEAL AND TAPER
ROLLER BEARING OUTER RACE
(a) Using screwdriver, remove the oil seal.
(b) Remove the transmission oil baffle.

(c) Using a brass bar and hammer, drive out the bear-
ing outer race lightly and evenly.
(d) Remove the shim.

(e) Install the shim.

(See page MT–96, 97)
HINT: First select and install a shim of leaser thick-
ness than before.

(f) Using SST and a press, install the taper roller bearing outer
race.
SST 09316–60010 (09316–00010, 09316–00040)

(g) Install the transmission oil baffle.

HINT: Install the transmission oil baffle projection
into the case side cutout.
 MT–89
MANUAL TRANSAXLE – Component .Parts

(h) Using SST and a hammer, drive in a new oil seal.

SST 09223–15010
(i) Coat the tip of oil seal with MP grease.

2. (Transaxle Case Side)

IF NECESSARY, REPLACE OIL SEAL AND TAPER
ROLLER BEARING OUTER RACE
(a) Remove the four bolts and three nuts.

(b) Using a plastic hammer, tap the stud bolt and re-
move the transaxle case cover.

(c) Using a screwdriver and hammer, drive out the oil

seal.

(d) Using SST, brass bar and hammer, remove the ta-
per roller bearing outer race.
SST 09612–65014
MT–90
MANUAL TRANSAXLE – Component Parts

(e) Using SST and a press, install the taper roller bearing.
SST 09316–60010 (09316–00010, 09316–00040)

(f) Using SST and a hammer, drive in a new oil seal.

SST 09316–60010 (09316–00010)
(g) Coat the lip of oil seal with MP grease.

(h) Remove any packing material and be careful not to drop oil
on the contacting surfaces of the transaxle case or case
cover.
Apply seal packing to the transaxle case cover as shown.
Seal packing: Part No. 08826–00090, THREE BOND
1281 or equivalent
HINT: Install the transaxle case cover as soon as the seal
packing is applied.

Q) Apply sealant to the bolt threads.

Sealant: Part No.08833–00080, THREE BOND
1344, LOCTITE 242 or equivalent
(k) Install and torque the four bolts and three nuts.
Torque: 550 kg–cm (40 ft–lb, 54 N–m)
 MT–91
MANUAL TRANSAXLE – Component Parts

ASSEMBLY OF DIFFERENTIAL CASE

1. ASSEMBLE DIFFERENTIAL CASE
HINT: Coat all of the sliding and rotating surface with
gear oil before assembly.
(a) Install the thrust washer to the side gear.

(b) Install the four pinions and thrust washers to

the spider.
(c) Install the side gear and spider with four pinions
to the differential left case.

(d) Using a dial indicator, measure the backlash of one pinion

gear while holding the No–2 differential case.
Standard backlash: 0.05 – 0.20 mm
(0.0020 – 0.0079 in.)
HINT: Push the pinion gear of the left side of the differential
case.
(e) Install the side gear and spider with four pinions to the right
side of the differential case.
Check the side gear backlash.
(f) Referring to the table below, select the thrust washer which will
ensure that the backlash is within specification. Try to select
a washer of the same size.

Thickness mm (in.) Thickness mm (in.)

Install the speedometer driven gear.

MT–92
MANUAL TRANSAXLE – Component Parts

(h) Align the matchmarks on the differential cases.

Using a plastic hammer, carefully tap the differen-

tial case.

(j) Using a torx wrench, install and ,torque the sixteen

torx screws.
Torx wrench T50 09042–00040
Torque: 640 k9–cm (46 ft–Ib, 63 N–m)

2. INSTALL RING GEAR

(a) Clean the contact surface of the differential case.
(b) Heat the ring gear to about 100°C (212°F) in an oil bath.
NOTICE: Do not heat the ring gear above 110°C (230°F).
(c) Clean the contact surface of the ring gear with cleaning
solvent.

(d) Quickly install the ring gear on the differential case.

Install the sixteen bolts.
HINT: Align the matchmarks on the differential left case
and contact the ring gear.
(e) Tighten the set bolts uniformly and a little at a time.
Torque the bolts.
Torque: 1,260 kg–cm (91 ft–Ib, 124 N–m)
 MT–93
MANUAL TRANSAXLE – Component Parts

3. INSTALL SIDE BEARING ’

Using SST and a press, install the side bearings onto
the differential case.
SST 09316–20011, 09506–35010
HINT: Press the bearing on the ring gear side first.

4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD

(See pages MT–96 to 98)

5. INSTALL DIFFERENTIAL CASE ASSEMBLY

Install the differential case assembly to the transaxle
case.

6. INSTALL OUTPUT SHAFT ASSEMBLY

Lift up the differential case, install the output shaft as-
sembly.

7. INSTALL TRANSMISSION CASE

(a) Install the transmission case.
HINT: If necessary, tap on the case with a plastic ham-
mer.
(b) Install and torque the seventeen bolts.
Torque: 300 kg–cm (22 ft–lb, 29 N–m)
MT–94
MANUAL TRANSAXLE – Component Parts

8. INSTALL OUTPUT SHAFT REAR TAPER ROLLER

BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.

9. INSTALL SHIM
(See pages MT–96, 97)
HINT: Install the previously selected shim.

10. INSTALL REAR BEARING RETAINER

Using a torx wrench, install and torque the seven torx
screws.
Torx wrench T45 09042–00050
Torque: 430 kg–cm (31 ft–lb, 42 N–m)
11. ADJUST DIFFERENTIAL CASE PRELOAD
(a) Install the new lock nut to the output shaft.
(b) Turn the output shaft right and left two or three times to
allow the bearings to settle
(c) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Add output shaft preload)
2.0 – 4.1 kg–cm
(1.7 – 3.6 in.–Ib, 0.2 – 0.4 N–m)
Reused bearing (Add output shaft preload)
1.3 – 2.5 kg–cm
(1.1 – 2.2 in.–Ib, 0.1 – 0.2 N–m)
If the preload is not within specification, select the thrust
washers.
HINT: The total preload will change about 12 kg–cm
(0.9 1.7 in.–lb, 0.1 – 0.2 N–m) with each shim thickness.

Mark Thickness mm (in.) Mark Thickness mm (in.)

 MT–95
MANUAL TRANSAXLE – Component Parts

12. REMOVE REAR BEARING RETAINER

Using torx wrench, remove the seven torx screws and
rear bearing retainer.
Torx wrench T45 09042–00050
13. REMOVE SHIM

14. REMOVE TRANSMISSION CASE

Remove the seventeen bolts and tap off the case with a
plastic hammer.

15. REMOVE OUTPUT SHAFT ASSEMBLY

16. REMOVE DIFFERENTIAL CASE ASSEMBLY
MT–96
MANUAL TRANSAXLE – Component Parts

INSTALLATION OF COMPONENT
PARTS
(See pages MT–47 to 49)
HINT: Coat all of the sliding and rotating surface with
gear oil before assembly.
1. INSTALL MAGNET TO TRANSAXLE£ CASE

2. INSTALL OIL PUMP ASSEMBLY AND OIL PIPE

(a) Install the oil pump assembly.
(b) Install the two bolts.
HINT: Be careful not to drop the oil pump gasket.

(c) Install the oil pipe and two bolts.

(d) Torque the four bolts.

Torque: 175 kg–cm (13 ft–Ib, 17 N–m)

3. ADJUST OUTPUT SHAFT PRELOAD

(a) Install the output shaft assembly.
 MT–97
MANUAL TRANSAXLE – Component Parts

(b) Install the transmission case.

HINT: If necessary, tap on the case with a plastic
hammer.
Install and torque the seventeen bolts.
Torque: 300 kg–cm (22 ft–lb, 29 N–m)
(d) Install the output shaft rear taper roller bearing outer
race.

(e) Install the adjust shim.

HINT: When re–using the output shaft bearing, first
install a shim of the same thickness as before. If
installing a new tapered roller bearing, first select
and install a shim of lesser thickness than before.

(f) Install the bearing retainer.

(g) Using a torx wrench, install and torque the seven
bolts.
Torx wrench T45 09042–00050
Torque: 430 kg–cm (31 ft–Ib, 42 N–m)
(h) Install the new lock nut to the output shaft.
(i) Turn the output shaft right and left ’two or three
times to allow the bearings to settle.
(j) Using a torque meter, measure the preload.
Preload (at starting) :
New bearing 8 – 16 kg–cm
(6.9 – 13.9 in.–Ib,
0.8 – 1.6 N–m)
Reused bearing 5 –, 10 kg–cm
(4.3 – 8.7 in.–lb, 0.5 – 1.0 N–m)
If the preload is not within specification, select the
thrust washers.
HINT: The preload will change about 4 5 kg–cm
(3.5 4.3 in.–lb, 0.4 0.5 N–m) with each shim thick-
ness.

Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.)
MT–98
MANUAL TRANSAXLE – Component Parts
(k) Remove the lock nut.
(I) Using a torx wrench, remove the seven torx screws
and rear bearing retainer.
Torx wrench T45 09042–00050

(m)) Remove the shim.

(n) Remove the seventeen bolts and transmission
case.
(o) Remove the output shaft assembly.

4. INSTALL DIFFERENTIAL CASE ASSEMBLY

5. INSTALL OIL PUMP DRIVE GEAR

6. INSTALL OUTPUT SHAFT ASSEMBLY

(a) Lift up the differential case, install the output shaft as-
sembly.
 MT–99
MANUAL TRANSAXLE – Component Parts

(b) Leaning the output shaft to the differential side, install

the input shaft assembly.

7. INSTALL SNAP RINGS

(a) Using a plastic hammer, install the snap rings to the
No–1, No–2 and No–3 shift fork shafts.

(b) Using a plastic hammer, install the reverse shift

fork and snap ring to the No.3 shift fork shaft.

8. INSTALL NO.2 SHIFT FORK AND NO.3 SHIFT FORK

SHAFT WITH REVERSE SHIFT FORK
(a) Install the No.2 shift fork to the No.2 hub sleeve.

(b) Install the No.3 shift fork shaft with reverse shift
fork.
MT–100
MANUAL TRANSAXLE – Component Parts

9. INSTALL NO.1 SHIFT FORK, SHIFT HEAD AND NO.2

SHIFT FORK SHAFT
(a) Install the No.1 shift fork to the No.1 hub sleeve.

(b) Put shift head onto the NO–1 shift fork.

(c) Install the No.2 shift fork shaft to the transaxle

case, through the shift head and No–1 shift fork.

10. INSTALL INTERLOCK ROLLER

Using a magnetic finger, install the interlock roller to the
reverse shift fork.

1 1. INSTALL NO.1 SHIFT FORK SHAFT

Install the No.1 shift fork shaft to the case, through the
No.1 shift fork and reverse shift fork.
HINT: When it is difficult to install the fork shaft through
the reverse shift fork, pull up the No.3 shift fork shaft.
 MT–101
MANUAL TRANSAXLE – Component Parts

12. INSTALL SET BOLTS

Install and torque the three set bolts.
Torque: 240 kg–cm I17 ft–Ib, 24 N–m)
o

13. INSTALL LOCKING BALLS, SPRINGS, SEATS AND

PLUGS
(a) Install the two locking balls, springs and seats.

(b)Apply sealant to the two plugs.

Sealant: Part No.08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, install and torque two plugs.
SST 09313–30021
Torque: 250 kg–cm (18 ft–lb, 25 N–m)

14. INSTALL REVERSE IDLER GEAR AND SHAFT

Install the reverse idler gear and shaft as shown.

15. INSTALL REVERSE SHIFT ARM BRACKET AND NO.2

OIL PIPE
(a) Put the reverse shift fork pivot into the reverse shift arm
and install the reverse shift arm bracket to the trans-
axle case.
(b) Install the bolt.
MT–102
MANUAL TRANSAXLE – Component Parts

(c) Install the No.2 oil pipe and two bolts.

(d) Torque the reverse shift arm and oil pump bolts.
Torque: 175 kg–cm (13 ft–lb, 17 N–m)

(e) Install the new gasket to the No.2 oil pipe.

16. INSTALL TRANSMISSION CASE

(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of the transmis-
sion case or transaxle case.
(b) Apply seal packing to the transmission case as shown
in the figure.
Seal packing: Part No.08826–00090, THREE
BOND
1281 or equivalent
HINT: Install the transmission case as shown as the seal
packing is applied.
(c) Install and torque the seventeen bolts.
Torque: 300 kg–cm (22 ft–Ib, 29 N–m)
17. INSTALL AND TORQUE REVERSE IDLER GEAR SHAFT
RETAINING BOLT
Torque: 300 kg–cm (22 ft–lb, 29 N–m)

18. INSTALL LOCKING BALL, SPRING, SEAT AND PLUG

(a) Install the locking ball, spring and seat.
 MT–103
MANUAL TRANSAXLE – Component Parts

(b) Apply sealant to the plug.

Sealant: Part No.08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, install and torque the plug.
SST 09313–30021
Torque: 250 kg–cm (18 ft–Ib, 25 N–m)

19. INSTALL SNAP .RINGS

Using a plastic hammer, install the three snap rings.

20. INSTALL OUTPUT SHAFT REAR TAPER ROLLER

BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.

21. INSTALL SHIM

HINT: Install the previously selected.

22. INSTALL SNAP RING

Using a snap ring pliers, install the snap ring to the input
shaft rear bearing.
MT–104
MANUAL TRANSAXLE – Component Parts

23. INSTALL REAR BEARING RETAINER

(a) Clean the threads of the torx screws.
(b) Using a torx wrench, install and torque the seven torx
screws.
Torx wrench T45 09042–00050
Torque: 430 kg–cm (31 ft–Ib, 42 N–m)

24. INSTALL SPACER, NEEDLE ROLLER BEARING AND

FIFTH GEAR

25. INSTALL SYNCHRONIZER RING WITH 1 KEY SPRING

TO NO.3 CLUTCH HUB

26. INSTALL NO.3 CLUTCH HUB

Using SST, install the No.3 clutch hub with synchroniz-
er ring and key spring.
SST 09310–17010 (09310–07010, 09310–07020,
09310–07030)

27. INSTALL SNAP RING

Select a snap ring that will allow minimum axial play
and install it on the shaft.

Mark Thickness mm (in.) Mark Thickness mm (in.)

 MT–105
MANUAL TRANSAXLE – Component Parts

28. MEASURE FIFTH GEAR THRUST CLEARANCE

Using a dial indicator measure the 5th gear thrust clearance.
Standard clearance: 0.10 – 0.57 mm
(0.0039 – 0.0224 in.)

29. INSTALL FIFTH DRIVEN GEAR

Using SST, install the 5th driven gear.
SST 09310–17010 (09310–07010, 09310–07020,
09310–07040, 09310–07050)

30. INSTALL NO.3 HUB SLEEVE WITH NO.3 SHIFT FORK

31. INSTALL SET BOLT

Install and torque the set bolt.
Torque: 240 kg–cm (17 ft–Ib, 24 N–m)

32. INSTALL LOCK NUT

(a) Engage the gear double meshing.
(b) Install and torque the lock nut.
Torque: 1,250 kg–cm (90 ft–Ib, 123 N–n)
(c) Disengage the gear double meshing.
(d) Stake the lock nut.
MT–106
MANUAL TRANSAXLE – Component Parts

33. INSTALL TRANSMISSION CASE COVER

(a) Remove any packing material and be careful not to drop oil on
the contacting surfaces of the transmission case cover.
(b) Apply seal packing to the transmission case as shown in the
figure. .
Seal packing: Part No.08826–00090, THREE BOND
1281 or equivalent
HINT: Install the transmission case cover as soon as the seal
packing is applied.
(c) Install and torque the ten bolts.
Torque: 300 kg–cm (22 ft–Ib, 29 N–m)
34. INSTALL SHIFT AND SELECT LEVER SHAFT
ASSEMBLY
(a) Place a new gasket in position on the control shaft cover.
(b) Install the control shaft cover.
(c) Apply sealant to the bolt threads.
Sealant: Part
No.08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(d) install and torque the bolts.
Torque: 200 kg–cm (14 ft–Ib, 20 N–m)
35. INSTALL AND TORQUE LOCK BOLT
Torque: 500 kg–cm (36 ft–Ib, 49 N–m)

36. INSTALL AND. TORQUE SELECTING BELLCRANK

ASSEMBLY
Torque: 200 kg–cm (14 ft–Ib, 20 N–m)

37. INSTALL BACK–UP LIGHT SWITCH

Using SST, install and torque the back–up light switch.
SST 09817–16011
Torque: 410 kg–cm (30 ft–Ib, 40 N–m)
 MT–107
MANUAL TRANSAXLE – Component Parts

38. INSTALL SPEEDOMETER DRIVEN GEAR

39. INSTALL RELEASE FORK AND BEARING

Apply molybdenum disulphide lithium base grease to
the following parts:
• Input shaft spline
• Release fork contact surface
 MT–111
MANUAL TRANSAXLE – Precautions

PRECAUTIONS
When working with FIPG material, you must –be observe the following.
• Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces.
• Thoroughly clean all components to remove all the loose material.
• Clean both sealing surfaces with a non–residue solvent.
e Apply the seal packing in 1.2 mm (0.04) in.) bead along the sealing surface.
• Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG)
material must be removed and reapplied. ,

TROUBLESHOOTING
Problem Possible cause Remedy Page

Noise Transmission, differential! Disassemble and inspect transmission,

or transfer faulty differential or transfer MT–118
Wrong oil grade Replace oil
Oil lever low Add oil MT– 117

Oil leakage Oil lever too high Drain oil

Oil seal, O–ring or gasket worn or Replace oil seal, O–ring or gasket FA–5
damaged MT–118

Hard to shift or will Control cable faulty Replace control cable MT–205
not shift Transmission faulty Disassemble and inspect transmission MT– 118
 MT–111
MANUAL TRANSAXLE – Troubleshooting

PRECAUTIONS
When working with FIPG material, you must –be observe the following.
• Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces.
• Thoroughly clean all components to remove all the loose material.
• Clean both sealing surfaces with a non–residue solvent.
• Apply the seal packing in 1.2 mm (0.047 in.) bead along the sealing surface.
• Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG)
material must be removed and reapplied. ,

TROUBLESHOOTING
Problem Possible cause Remedy Page

Noise Transmission, differential! Disassemble and inspect transmission,

or transfer faulty differential or transfer MT–118
Wrong oil grade Replace oil
Oil lever low Add oil MT–117

Oil leakage Oil lever too high Drain oil

Oil seal, O–ring or gasket worn or Replace oil seal, O–ring or gasket FA–5
damaged MT–118

Hard to shift or will Control cable faulty Replace control cable MT–205
not shift Transmission faulty Disassemble and inspect transmission MT– 118
MT–112
MANUAL TRANSAXLE – On–Vehicle Repair

ON–VEHICLE REPAIR
REPLACEMENT OF OUTPUT SHAFT
OIL SEAL
1. DRAIN TRANSAXLE OIL
2. REMOVE PROPELLER SHAFT
(See page PR–4)

3. REMOVE OUTPUT SHAFT OIL SEAL

Using SST, drive out the oil seal.
SST 09308–00010

4. INSTALL OUTPUT SHAFT OIL SEAL

Using SST, drive in a new oil seal.
SST 09325–20010
Oil seal depth: 1.1 – 1.9 mm (0.043 – 0.075)
5. INSTALL PROPELLER SHAFT
(See page PR–13)
6. FILL TRANSAXLE WITH GEAR OIL
(See page MT–117)
 MT–113
MANUAL TRANSAXLE – Center Differential Lock Control (E56F5)

CENTER DIFFERENTIAL LOCK

CONTROL (E56F5)
SYSTEM DIAGRAM AND WIRING DIAGRAM
MT–114
MANUAL TRANSAXLE – Center Differential Lock Control (E56F5)

Function Inspection
DIFFERENTIAL LOCK CONTROL
INSPECT DIFFERENTIAL LOCK OPERATION
Start the engine. Check that the differential lock indica-
tor light comes on when the differential lock control
switch is turned to ON. Check that the light goes off
when the switch is turned to OFF.
HINT: After checking the system, turn the control switch
to OFF and check that the differential lock function is
released.
Reference: If the indicator light does not come on and
go out when the control switch is operated, move the
vehicle
slightly forward. when the system is operated it should
be normal.

Single Unit Inspection

DIFFERENTIAL LOCK SWITCH
1. INSPECT CONTINUITY OF DIFFERENTIAL LOCK
SWITCH
(a) Disconnect the differential lock switch connector.
(b) Check continuity between terminals 1 to 4.
Switch ON: Continuity
Switch OFF: No continuity
4WD CONTROL SOLENOID
1. INSPECT OPERATION OF 4WD CONTROL SOLENOID
Check air flow of each port when the battery voltage is
applied and is not applied to terminals No.1, No.2 of
the solenoid.

Port
Voltage

Apply battery voltage

Non voltage

TRANSFER VACUUM ACTUATOR

1. INSPECT ACTUATOR HOSE CONNECTION
Check that the actuator hoses are connected to the
solenoids and actuator tightly and properly.
 MT–115
MANUAL TRANSAXLE – Center Differential Lock Control (E56F5)

2. INSPECT ACTUATOR AIRTIGHTNESS

(Vacuum Tank)
(a) Disconnect the No. 1, No. 3 and No. 4 hoses from the sole-
noids.
(b) Plug the No. 3 hose.
W Connect the mighty vac to the No. 1 hose.
(d) Check the the indicator remains stable when a vacuum of
500 mmHg 0 9.69 in.Hg. 66.7 kPa) is applied.

(No. 1 Vacuum Chamber Side)

(a) Disconnect the No. 2 and No. 4 hoses form the sole-
noids.
(b) Connect the mighty vac to the No. 2 hose.
(c) Check that the indicator remains stable when a vacu-
um of 504 mmHg (19.69 in.Hg, 66.7 kPa) is applied.

(No. 2 Vacuum Chamber Side

(a) Disconnect the all hoses from the solenoids.
(b) Plug the No. 3 hoses.
W Connect the mighty vac to the No. 1 and No. 4 hoses.
(d) Check that the indicator remains stable when a vacuum of
500 mmHg (19.69 in.Hg, 66.7 kPa) is applied.

TRANSFER INDICATOR SWITCH

INSPECT TRANSFER INDICATOR SWITCH FOR
CONTINUITY
(a) Disconnect the indicator switch from the transfer.
(b) Check continuity between the terminals when the
switch is turned ON and when turned OFF.
Switch *ON position: Continuity
Switch OFF position: No continuity
If not, replace the indicator switch.
MT–116
MANUAL TRANSAXLE – Removal and Installation of Transaxle

REMOVAL AND INSTALLATION OF TRANSAXLE

REMOVAL AND INSTALLATION OF ENGINE
REMOVE ENGINE WITH TRANSAXLE
(See page EM–3)
INSTALL ENGINE WITH TRANSAXLE
(See page EM–7)
REMOVAL AND INSTALLATION OF
TRANSAXLE
REMOVE AND INSTALL TRANSAXLE AS SHOWN
 MT–117
MANUAL TRANSAXLE – Removal and Installation of Transaxle

(MAIN POINT OF REMOVAL AND

INSTALLATION)
1. REMOVE TRANSAXLE ASSEMBLY
HINT: When removing transaxle from engine, remove as the
following procedure since cylinder block rib contacts
transfer case.
(a) Pull straight until there are space of 60 – 80mm (2 –3 in.)
between engine and transaxle case.

(b) Move the transmission case cover to the arrow in the

illustration.

(e) While holding the transfer output slightly, pull out

whole transaxle.
2. INSTALL TRANSAXLE ASSEMBLY FOLLOWING
REMOVAL SEQUENCE IN REVERSE

REPLACEMENT OF TRANSAXLE GEAR OIL

1. DRAIN TRANSAXLE OIL
2. FILL TRANSAXLE OIL WITH GEAR OIL
Oil: Transaxle oil E50 (08885–80206) or equivalent
Recommended oil
Oil grade: API G!–5
Viscosity: SAE 75W–90 or 80W–90
Above –18°C (0°F) SAE 90
Below –18°C (0°F) SAE 80W
Capacity: 5.0 liters (5.3 US qts, 4.4 Imp qts)
MT–134
MANUAL TRANSAXLE – Component Parts (Input Shaft Assembly)

COMPONENT PARTS
Input Shaft Assembly

DISASSEMBLY OF INPUT SHAFT

ASSEMBLY
1. MEASURE THIRD AND FOURTH GEAR 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.)
 MT–135
MANUAL TRANSAXLE – Component Parts (Input Shaft Assembly)

2. CHECK OIL CLEARANCE OF THIRD AND FOURTH

GEAR
Using dial indicator, measure the oil clearance between
the gear and shaft.
Standard clearance:
3rd gear 0.009 – 0.053 mm
(0.0004 – 0.0020 in.)
4th gear 0.009 – 0.051 mm(0.0004 – 0.0020 in.)
Maximum clearance: 0.080 mm (0–0031 in.)
If clearance exceeds the limit, replace the gear, needle
roller bearing or shaft.
3. REMOVE SNAP RING
Using two screwdrivers and a hammer, tap out the snap
ring.

4. REMOVE INPUT SHAFT REAR BEARING AND FOURTH

GEAR
Using SST and a press, remove the input shaft rear
bearing.
SST 09950–00020
5. REMOVE NEEDLE ROLLER BEARINGS, SPACER AND
SYNCHRONIZER RING

6. REMOVE SNAP RING

Using two screwdrivers and a hammer, tap out the snap
ring.

7. REMOVE NO.2 CLUTCH HUB ASSEMBLY,

SYNCHRONIZER RING AND THIRD GEAR
Using a press, remove No.2 hub sleeve, 3rd gear, syn-
chronizer ring and needle roller bearings.
8. REMOVE NEEDLE ROLLER BEARING
MT–136
MANUAL TRANSAXLE – Component Parts (Input Shaft Assembly)

9. REMOVE INPUT SHAFT FRONT BEARING INNER

RACE
Using SST and a press, remove the inner race.
SST 09950–00020

INSPECTION OF INPUT SHAFT COMPONENT

PARTS
1. INSPECT SYNCHRONIZER RINGS
(a) Check for wear or damage.
(b) Turn the ring and push it in to check the bearing action.

(c) Measure the clearance between the synchro-

nizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the limit, replace the
synchronizer ring.

2. MEASURE CLEARANCE OF NO.2 SHIFT FORK AND

HUB SLEEVE
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 limit, replace the shift fork
or hub sleeve.

3. INSPECT INPUT SHAFT

(a) Check the input shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of
the input shaft journal surface.
Minimum outer diameter:
Part A 32.930 mm (1.2964 in.)
B and C 35.950 mm (1.4154 in.)
 MT–137
MANUAL TRANSAXLE – Component Parts (Input Shaft Assembly

(c) Using a dial indicator, check the shaft runout.

Maximum runout: 0.060 mm (0.0024 in.)

ASSEMBLY OF INPUT SHAFT ASSEMBLY

(See page MT–134)
HINT: Coat all the sliding and rotating surface with gear oil b¿¿ore
assembly.
1. INSERT NO.2 CLUTCH 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: install the key springs positioned so that their end gaps are
not in line.
2. INSTALL NEEDLE ROLLER BEARING. THIRD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE
ASSEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearings.
(b) Install the 3rd gear.
(e) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(d) Using SST and a press, install the 3rd gear and No.2
hub sleeve.
SST 09506–35010
3. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and
install it on the shaft.
Snap ring thickness:

Mark Thickness mm (in.)

4. MEASURE THIRD GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 3rd gear thrust clear-
ance.
Standard clearance: 0.10 – 0.35 mm
(0.0039 – 0.0138 in.)
MT–138
MANUAL TRANSAXLE – Component Parts (Input. Shaft Assembly)

5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE

ROLLER BEARINGS, FOURTH GEAR AND RADIAL
BALL BEARING
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearings.
(c) Place the synchronizer ring on the gear and align the
the ring slots with the shifting keys.
(d) Install the 4th gear.
(e) Using SST and a press, install the radial ball bearing.
SST 09506–35010
6. INSTALL –SNAP RING
Select a snap ring that will allow minimum axial play and
install it on the shaft.
Snap ring thickness:

Mark Thickness mm (in.)

7. MEASURE FOURTH GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 4th gear thrust
clearance.
Standard clearance: 0.10 – 0.55 mm
(0.0039 – 0.0217 in.)
8. INSTALL INPUT SHAFT FRONT BEARING INNER
RACE
Using SST and a press, install the input shaft front
bearing inner race.
SST 09316–60010 (09316–00020)
 MT–139
MANUAL TRANSAXLE – Component Parts (Output Shaft Assembly)

Output Shaft Assembly

DISASSEMBLY OF OUTPUT SHAFT

ASSEMBLY
1. MEASURE FIRST AND SECOND GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1 st gear 0.10 – 0.35 mm
(0.0039 – 0.0138 in.)2nd gear 0.10 – 0.45 mm
(0.0038 – 0.0177 in.)
Maximum clearance:
1 st gear 0.40 mm (0.0157 in.)
2nd gear 0.50 mm (0.0197 in.)
MT–140
MANUAL TRANSAXLE – Component Parts (Output Shaft Assembly

2. CHECK OIL CLEARANCE OF FIRST AND SECOND

GEAR
Using dial indicator, measure the oil 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 – 0.0020 in.)
Maximum clearance: 0.080 mm (0.0031 in.)
If the clearance exceeds the limit, replace the gear,
needle roller bearing or shaft.
3. REMOVE OUTPUT SHAFT REAR BEARING, FOURTH
DRIVEN GEAR AND SPACER
(a) Using a press, remove the bearing and 4th driven
gear.
(b) Remove the spacer.

4. REMOVE THIRD DRIVEN GEAR AND SECOND GEAR

Using SST and a press, remove the 3rd driven gear and
2nd gear.
SST 09950–00020

5. REMOVE NEEDLE ROLLER BEARING. SECOND GEAR

BUSHING AND BALL
6. REMOVE SYNCHRONIZER RING

7. REMOVE NO.1 HUB SLEEVE ASSEMBLY AND FIRST

GEAR
Using a press, remove No. 1 hub sleeve and 1st gear.
8. REMOVE SYNCHRONIZER RING AND NEEDLE
ROLLER BEARING
 MT–141
MANUAL TRANSAXLE – Component Parts (Output Shaft Assembly

INSPECTION OF OUTPUT SHAFT

COMPONENT PARTS
1. INSPECT SYNCHRONIZER RINGS
(a) Check for wear or damage.
(b) Turn the ring and push it in to check the braking action.

(e) 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 limit, replace the
synchronizer ring.

2. MEASURE CLEARANCE OF NO.1 SHIFT FORK AND

HUB SLEEVE
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 limit, replace the shift fork
or hub sleeve.

3. INSPECT OUTPUT SHAFT

(a) Check the output shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the
second gear bushing and output shaft journal sur-
face.
Minimum outer diameter:
Part A: 44.950 mm (1.7697 in.)
Part B: 43.950 mm (1.7303 in.)

(c) Using a dial indicator, check the shaft runout.

Maximum runout: 0.060 mm (0.0024 in.)
MT–142
MANUAL TRANSAXLE – Component Parts (Output Shaft Assembly)

4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT

BEARING
(a) Using SST and a press, remove the bearing.
SST 09307–12010, 09950–00020

(b) Using SST and a press, install a new bearing.

SST 09316–60010 (09316–00070)

ASSEMBLY OF OUTPUT SHAFT ASSEMBLY

(See page MT–139)
HINT: Coat all the sliding and rotating surface with gear oil before
assembly.
1. INSERT 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: Install the key springs positioned so that their end gaps are
not in line.
2. INSTALL NEEDLE ROLLER BEARINGS, FIRST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearings.
(b) Install the 1st gear.
(c) Place the synchronizer ring (for 1st gear) on the gear
and align the ring slots with the shifting keys.
NOTICE: Do not install the synchronizer ring for 2nd gear.
 MT–143
MANUAL TRANSAXLE – Component Parts (Output Shaft Assembly)
(d) Using SST and a press, install the 1 st gear and
No. 1
hub sleeve.
SST 09316–60010¿09316–000401

3. MEASURE FIRST GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance: 0.10 – 0.35 mm
(0.0039 – 0.0138 in.)

4. INSTALL BALL, SECOND GEAR BUSHING, NEEDLE

ROLLER BEARING
(a) Install the ball and bushing.
(b) Apply MP grease to the needle roller bearing.
(e) Install the needle roller bearing.

5. SYNCHRONIZER RING, SECOND GEAR AND THIRD

DRIVEN GEAR
(a) Place the synchronizer ring (for 2nd gear) on the gear
and align the ring slots with the shifting keys.
NOTICE: Do not install the synchronizer ring for 1 st gear.

(b) Install the 2nd gear.

(e) Using a press, install the 3rd driven gear.
MT–144
MANUAL TRANSAXLE – Component Parts (Output Shaft Assembly)
6. MEASURE SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust
clearance.
Standard clearance: 0.10 – 0.45 mm
(0.0039 – 0.0177 in.)

7. INSTALL SPACER AND FOURTH DRIVEN GEAR

(a) Install the spacer.
(b) Using a press, install the 4th driven gear.

8. INSTALL OUTPUT SHAFT REAR BEARING

Using SST and a press, install the output shaft rear ta-
per roller bearing.
SST 09506–30012
MT–118
MANUAL TRANSAXLE – Removal of Component Parts

REMOVAL OF COMPONENT PARTS

COMPONENTS
 MT–119
MANUAL TRANSAXLE – Removal of Component Parts

COMPONENTS (Cont’d)
MT–120
MANUAL TRANSAXLE – Removal of Component Parts

COMPONENTS (Cont’d)
 MT–121
MANUAL TRANSAXLE – Removal of Component Parts

REMOVAL OF COMPONENT PARTS

(See pages MT– 118 to MT– 120)
1. REMOVE TRANSFER ASSEMBLY
(a) Remove the three bolts and five nuts.
(b) Using a plastic hammer, remove the transfer assembly
from the transaxle.

2. REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE

SHAFT
(a) Screw in a suitable bolt with washer into the side gear
intermediate shaft.
(b) Using SST, remove the side gear intermediate shaft.
SST 09910–00015

3. REMOVE RELEASE FORK, BEARING AND BOOT

4. REMOVE BACK–UP LIGHT SWITCH

(a) Remove the back–up light switch.
(b) Remove the gasket from the back–up light switch.

B. REMOVE SPEEDOMETER DRIVEN GEAR

6. REMOVE NO.2 SELECTING BELLCRANK WITH
SELECTING BELLCRANK SUPPORT
MT–122
MANUAL TRANSAXLE – Removal of Component Parts
7. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK
BOLT
(a) Remove the shift and select lever shaft lock bolt.
(b) Remove the gasket from the bolt.

8. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

(a) Remove the four bolts and the shift and select lever
. shaft assembly.
(b) Remove the gasket from the shift and select lever shaft as-
sembly.

9. REMOVE TRANSMISSION CASE COVER

(a) Remove the ten bolts.
(b) Using a plastic hammer, remove the case cover.

10. REMOVE OUTPUT SHAFT LOCK NUT

(a) Engage the gear double meshing.

(b) Using a chisel and hammer, unstake the lock nut.

 MT–123
MANUAL TRANSAXLE – Removal of Component Parts

(e) Remove the lock nut.

(d) Disengage the gear double meshing.

11. REMOVE NO.3 HUB SLEEVE AND NO. 3 SHIFT FORK

(a) Remove the No.3 shift fork set bolt.
(b) Remove the No.3 hub sleeve and No.3 shift fork.

12. REMOVE FIFTH DRIVEN GEAR

Using SST, remove the 5th driven gear.
SST 09310–17010 (09310–07010, 09310–07020
09310–07040, 09310–07050)

13. MEASURE FIFTH GEAR THRUST CLEARANCE

(a) 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.)

(b) Using a dial indicator, measure the oil clearance.

Standard clearance: 0.009 – 0.050 mm
(0.0004 – 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
MT–124
MANUAL TRANSAXLE – Removal of Component Parts

14. REMOVE NO.3 CLUTCH HUB AND FIFTH GEAR

(a) Using two screwdrivers and a hammer, tap out the
snap ring.

(b) Using SST, remove the No.3 clutch hub with syn-
chronizer ring and 5th gear.
SST 09310–17010
(09310–07010, 09310–07020, 09310–07030)

15. REMOVE NEEDLE ROLLER BEARING AND SPACER

16. REMOVE REAR BEARING RETAINER

(a) Using a torx wrench, remove the seven torx screws and
bearing retainer.
Torx wrench T45 09042–00050

(b) Remove the adjusting shim.

 MT–125
MANUAL TRANSAXLE – Removal of Component Parts

17. REMOVE SNAP RING

(a) Using snap ring pliers, remove the snap ring of the in-
put shaft rear bearing.

(b) Using two screwdrivers and a hammer, remove

the two snap rings of the shift fork shafts.

18. REMOVE PLUG, SEAT, SPRING AND LOCKING BALL

(a) Using SST, remove the plug.
SST 09313–30021

(b) Using a magnetic finger, remove the seat, spring

and ball.

19. REMOVE REVERSE IDLER GEAR SHAFT RETAINING

BOLT
(a) Remove the reverse idler gear shaft retaining bolt.
(b) Remove the gasket from the bolt.
MT–126
MANUAL TRANSAXLE – Removal of Component Parts

24. REMOVE TRANSMISSION CASE

Remove the seventeen bolts and tap off the case with a
plastic hammer.
• Transmission case side: Fourteen bolts
• Transaxle case side: Three bolts

21. REMOVE OUTPUT SHAFT REAR BEARING OUTER

RACE
Using a plastic hammer, remove the output shaft rear
bearing outer race.

22. REMOVE NO.2 OIL PIPE

(a) Remove the gasket.

(b) Remove the two bolts and oil pipe.

23. REMOVE REVERSE SHIFT ARM BRACKET

Remove the bolt and pull off the bracket.
 MT–127
MANUAL TRANSAXLE – Removal of Component Parts

24. REMOVE REVERSE IDLER GEAR, THRUST WASHER

AND SHAFT
Pull out the shaft, remove the reverse idler gear and
thrust washer.

25. REMOVE PLUGS, SEATS, SPRINGS AND BALLS

(a) Using SST, remove the two plugs.
SST 09313–30021

(b) Using a magnetic finger, remove the two seats,

springs and balls.

26. REMOVE SET BOLTS

Remove the three set bolts.

27. REMOVE NO–1 SHIFT FORK SHAFT

Pull up No.3 shift fork shaft, remove the No.1 shift fork
shaft.
MT–128
MANUAL TRANSAXLE – Removal of Component Parts
28. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from
the reverse shift fork.

29. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD AND

NO.1 SHIFT FORK
(a) Full out the No.2 shift fork shaft.

(b) Remove the shift head and No. 1 shift

fork.

30. REMOVE N0.3 SHIFT FORK SHAFT WITH REVERSE

SHIFT FORK AND NO.2 SHIFT FORK
(a) Pull out the No.3 shift fork shaft with reverse shift fork.
(b) Remove the No.2 shift fork.

31. REMOVE SNAP RING

Using two screwdrivers and a hammer, remove the
snap ring and reverse shift fork from the No.3 shift fork
shaft
 MT–129
MANUAL TRANSAXLE – Removal of Component Parts

32. REMOVE INPUT AND OUTPUT SHAFT ASSEMBLY

(a) Leaning the output shaft to the differential side,
remove the input shaft assembly.

(b) Lift up the differential case assembly, remove the output

shaft assembly.

33. REMOVE DIFFERENTIAL CASE ASSEMBLY

(a) Remove the oil pump drive gear.

(b) Remove the differential case assembly.

34. REMOVE MAGNET FROM TRANSAXLE CASE

MT–130
MANUAL TRANSAXLE – of Component Parts

35. REMOVE OIL PUMP ASSEMBLY

(a) Remove the two bolts and oil pipe.

(b) Remove the two bolts and oil pump.

INSPECTION OF COMPONENT PARTS

1. INSPECT SYNCHRONIZER RING OF FIFTH GEAR
(a) Check for wear or damage.
(b) Turn the ring and push it in to check the braking ac-
tion.

(e) Measure the clearance between the synchronizer ring back

and the gear spline end.
Standard clearance: 0.75 – 1.65 mm
(0.0295 – 0.0650 in.)
Minimum clearance: 0.6 mm (0.024 in.)
NOTE: Inspect the clearance of the gear’s whole circumfer-
ence.
If the clearance is less than the limit, replace the synchronizer
ring.

2. MEASURE CLEARANCE OF SHIFT FORK AND HUB

SLEEVE
Using a feeler gauge, measure the clearance between
the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (a.039 in.)
If the clearance exceeds the limit, replace the shift fork
or hub sleeve.
 MT–131
MANUAL TRANSAXLE – Removal of Component Parts

3. REMOVE TRANSAXLE CASE RECEIVER

Remove the three bolts and the transaxle case receiver.

4. IF NECESSARY, REPLACE INPUT SHAFT FRONT

BEARING AND OIL SEAL
(a) Using SST, pull out the bearing from the transaxle
case.
SST 09612–65014

(b) Using a screwdriver, remove the oil seal.

(c) Using SST, drive in a new oil seal.

SST 09608–12010 (09608–00020, 09608–00080)
(d) Coat the lip of oil seal with MP grease.

(e) Using SST, drive in a new bearing.

SST 09608–12010 (09608–00020,
09608–00060)
MT–132
MANUAL TRANSAXLE – Removal of Component Parts
5. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT
BEARING OUTER RACE AND OUTPUT SHAFT COVER
(a) Using SST, pull out the outer race.
SST 09308–00010 .
(b) Remove the output shaft cover.

(c) Install the output shaft cover.

NOTE: Install the output shaft cover projection
into the case side groove.

(d) Using SST, press in a new outer race.

SST 09316–60010 (09316–00010, 09316–00020)

6. INSTALL AND TORQUE TRANSAXLE CASE RECEIVER

Torque: 75 kg–cm (65 in.–Ib, 7.4 N–m)

7. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN

GEAR OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09921–00010
 MT–133
MANUAL TRANSAXLE – Removal of Component Parts

(b) Using SST, drive in a new oil seal.

SST 09201–60011
Drive in depth: 33 mm 0 .30 in.)
(c) Coat the lip of oil seal with MP grease.

8. IF NECESSARY, REPLACE REVERSE RESTRICT PIN

(a) Using SST, remove the screw plug.
SST 09313–30021

(b) Using a pin punch and hammer, drive out the

slotted spring pin.

(e) Replace the reverse restrict pin.

(d) Using a pin punch, drive in the slotted spring pin.

(f) Apply liquid sealant to the plug threads.

Sealant: Part No.08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(f) Using SST, install the screw plug.
SST 09313–30021
 MT–145
MANUAL TRANSAXLE – Component Parts (Oil Pump)

OIL PUMP

DISASSEMBLY OF OIL PUMP

1. CHECK OPERATION OF OIL PUMP
Install the oil pump drive gear to the drive rotor, check
that the drive rotor turns smoothly.

2. REMOVE GASKET FROM OIL PUMP CASE

MT–146
MANUAL TRANSAXLE – Component Parts (Oil Pump)

3. REMOVE BOLT AND OIL STRAINER

4. REMOVE OIL PUMP COVER

(a) Hold the oil pump cover, remove the two bolts and the
cover.

(b) Remove the spring holder, spring, ball and relief

valve seat.

5. CHECK ROTOR BODY CLEARANCE

(a) Install the oil pump drive gear to the drive rotor.
(b) 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.)

6. CHECK ROTOR TIP CLEARANCE

(a) Install the oil pump drive gear to the drive rotor.
(b) 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.)
 MT–147
MANUAL TRANSAXLE – Component Parts (oil Pump)

7. CHECK. SIDE CLEARANCE

Using a precision straight edge and feeler gauge, mea-
sure 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.)

8. REMOVE OIL PUMP DRIVE ROTOR AND DRIVEN

ROTOR

9. IF NECESSARY, REPLACE O–RING

(a) Using a screwdriver, remove the O–ring.

(b) Apply the gear oil to a new O–ring.

(c) Install a new O–ring.
MT–148
MANUAL TRANSAXLE – Component Parts (Oil Pump)

ASSEMBLY OF OIL PUMP

1. INSTALL DRIVEN ROTOR AND DRIVE ROTOR

2. INSTALL OIL PUMP COVER

(a) Install the relief valve seat, ball, spring and spring hold-
er to the oil pump case.

(b) Hold the oil pump cover, temporarily install the

two bolts.

3. INSTALL OIL STRAINER

Install the oil strainer to the oil pump case, temporarily
install the bolt.

4. TORQUE OIL PUMP COVER BOLTS

Torque the three bolts evenly.
Torque: 105 kg–cm (8 ft–lb, 10 N–m)
 MT–149
MANUAL TRANSAXLE – Component Parts (Oil Pump)

5. CHECK OPERATION OF OIL PUMP

Insert the oil pump drive gear to the drive rotor, check
that the drive rotor turns smoothly.

6. INSTALL GASKET
Install a new gasket to the oil pump case.
MT–150
MANUAL TRANSAXLE – Component Parts (Shift and Select Lever Shaft

Shift and Select Lever Shaft

DISASSEMBLY OF SHIFT AND SELECT LEVER

SHAFT ASSEMBLY
1. REMOVE N0.2 SHIFT INNER LEVER
(a) Using a pin punch and a hammer, drive out the slatted spring pin
and remove the transmission oil baffle.

(b) Using two screwdrivers and a hammer, remove

the snap ring.
(c) Remove No.2 select spring seat, No.2 compres-
sor spring and No.2 shift inner lever.
 MT–151
MANUAL TRANSAXLE – Component Parts (Shift and Select Lever Shaft

2. REMOVE SHIFT INTERLOCK PLATE AND NO.1 SHIFT

INNER LEVER
(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the shift inter plate and No. 1 shift inner lever
from the shaft.
(e) Remove the shift interlock plate cover and No. 1 shift
inner lever from the shift interlock plate.

3. REMOVE SELECT INNER LEVER

(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the select inner lever, No.1 compression
spring and No.1 select spring seat.

4. REMOVE SNAP RING

Using two screwdrivers and a hammer, remove the
snap ring.

5. REMOVE CONTROL SHAFT COVER AND DUST BOOT

6. 1F NECESSARY, REPLACE CONTROL SHAFT COVER

OIL SEAL
(a) Using a screwdriver, remove oil seal.
MT–152
MANUAL TRANSAXLE – Component Parts (Shift and Select Lever Shaft

(b) Using SST and a hammer, drive in the new oil seal.
SST 09620–30010 (09631–00020, 09627–30010)
Oil seal depth: 0 – 1.0 mm (0 – 0.039 in.)
(c) Apply MP grease to the oil seal.

ASSEMBLY OF SHIFT AND SELECT LEVER

SHAFT ASSEMBLY
7. APPLY SHAFT WITH MP GREASE. AS SHOWN

2. INSTALL SHIFT AND SELECT LEVER SHAFT

(a) Install the boot to the control shaft cover, as shown.

(b) Install the shift and select lever shaft to the

control shaft cover.
 MT–153
MANUAL TRANSAXLE – Component Parts (Shift and Select Lever Shaft)

3. INSTALL SNAP RING

Using a brass bar and hammer, install the snap ring
and spring seat.

4. INSTALL SELECT INNER LEVER

(a) Install the No.1 spring seat, No–1 select spring and select in-
ner lever, as shown.

(b) Using a pin punch and hammer, drive in the

slotted spring pin.

5. INSTALL SHIFT INTERLOCK PLATE AND NO.1 SHIFT

INNER LEVER
(a) Place the No–1 shift inner lever into the interlock plate.
(b) Install the shift interlock plate cover to the interlock
plate.

(c) Using a pin punch and hammer, drive in the slotted

spring pin.
(d) Check that the shift interlock plate turns smoothly.
MT–154
MANUAL TRANSAXLE – Component Parts (Shift and Select Lever Shaft)

6. INSTALL NO.2 SHIFT INNER LEVER

(a) Install the No.2 shift inner lever, No.2 compression
spring, transmission oil baffle and No.2 select spring
seat, as shown.

(b) Install the snap ring.

(c) Using a pin punch and hammer, drive in the

slotted spring pin.
 MT–155
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E56F5)

Differential Case Assembly

(E56F5)
MT–156
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E56F5)

DISASSEMBLY OF DIFFERENTIAL CASE

1. REMOVE DIFFERENTIAL CASE
(a) Remove the sixteen bolts.

(b) Remove the differential No.2 case up

ward.

2. REMOVE RING GEAR

(a) Place the matchmarks on both the differential No.2
case and ring gear.

(b) Using a plastic hammer, tap out the ring gear.

3. REMOVE NO.2 DIFFERENTIAL SIDE GEAR THRUST

WASHER AND CONICAL SPRING WASHER
 MT–157
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E56F5)

4. REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY

5. DISASSEMBLE FRONT DIFFERENTIAL CASE

ASSEMBLY
(a) Remove the front differential side gear together with
thrust washer.
(b) Remove the front differential side gear thrust washer
from the side gear.

(c) Using snap ring pliers, remove the snap ring.

HINT: Before removing the shaft snap ring, wrap
vinyl tape around the case prevent the it from dam-
age.
(d) Remove the spacer.

(e) Remove the No.2 pinion shaft, two pinion shafts,

pinion holder, four differential pinions, four thrust
washers, front differential side gear and thrust
washer from the front differential case.
MT–158
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E56F5)
6. REMOVE SPEEDOMETER DRIVE GEAR AND SPACER
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the spacer.

(c) Remove the speedometer drive gear.

7. DISASSEMBLE DIFFERENTIAL NO.1 CASE

Remove the four pinion shafts, pinion holder, four dif-
ferential pinions, four thrust washers, side gear sub as-
sembly, conical spring washer and No.2 thrust washer.

8. REMOVE SIDE BEARING

(a) Using a pin punch and hammer, drive out the side
bearing evenly through two holes in the differential
No. 1 case.
 MT–159
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E5SF5)

(b) Using a pin punch and hammer, drive out the side bear-
ing evenly through two holes in the differential
No–2 case.

INSPECTION OF DIFFERENTIAL CASE

1. MEASURE DIFFERENTIAL NO.1 AND NO.2 CASE
Using a cylinder gauge, measure the inner diameter of
the differential No.1 and No.2 case.
Standard diameter:
No–1 case 104.000 – 104.035 mm
(4.0945 – 4.0959 in.)
No.2 case 97.000 – 97.035 mm
(3.8189 – 3.8203 in.)
Maximum diameter:
No.1 case 104.060 mm (4.0968 in.)
No.2 case 97.060 mm (3.8213 in.)
2. MEASURE FRONT DIFFERENTIAL CASE
Using a micrometer, measure the outer diameter of front
differential case.
Standard diameter: A 103.929 – 103.964 mm
(4.0917 – 4.0931 in.)
B 96.929 – 96.964 mm
(3.8161 – 3.8175 in.)
Minimum diameter: A 103.850 mm (4.0886 in.)
B 96.850 mm (3.8130 in.)
3. MEASURE CONICAL SPRING WASHER
Using a caliper, measure the height of the conical spring
washer.
Standard height:
No.1 case conical spring washer
1.85 – 2.05 mm (0.073 – 0.081 in.)
No.2 case conical spring washer
2.60 – 2.80 mm (0.102 – 0.110 in.)
Minimum height:
No–1 case conical spring washer
1.75 mm (0.069 in.)
No.2 case conical spring washer
2.50 mm (0.098 in.)
4. (TRANSMISSION CASE SIDE)
IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
(a) Using a screwdriver, remove the oil seal.
MT–160
MANUAL TRANSAXLE – Components Parts (Differential Case Assembly)

(b) Using a screw driver and hammer, drive out the

transmission oil baffle.

(c) Using a brass bar and hammer, drive out the bearing
outer race lightly and evenly.
(d) Remove the adjusting shim.

(e) Install the new transmission oil baffle.

HINT:
• Install the transmission oil baffle projection into
the case side cutout.
• Do not install the oil baffle when adjusting the dif-
ferential side bearing preload.

(f) Install the adjusting shim.

(See page MT– 168)
HINT: First select and install a shirr of lesser thick-
ness than before.

Using SST and a press, install the taper roller bear-

ing outer race.
SST 09316–60010 (09316–00010,09316–00040)
 MT–161
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E5SF5)

(h) Using SST, drive in a new oil seal.

SST 09223–15010
Drive in depth: 6.0 – 7.0 mm
(0.4–0.5ft–lb,0.6–0.7N–m)
(I) Coat the lip of the oil seal with MP grease.

5. (TRANSAXLE CASE SIDE)

IF NECESSARY, REPLACE TAPERED ROLLER BEAR–
ING OUTER RACE
(a) Using a brass bar and hammer, drive out the bearing
outer race lightly and evenly through the cut–out
position on the transaxle case.

(b) Using SST and a press, install the tapered roller bearing outer
race.
SST 09316–60010 (09316–00010, 09316–00040)

ASSEMBLY OF DIFFERENTIAL CASE

HINT: Coat all of the sliding surface with gear oil before assem-
bly.
1. INSTALL SIDE BEARING
(a) Using SST and a press, install the side bearing to the differential
No.1 case.
SST 09316–60010 (06316–00010, 09316–00020),
09316–20011

(b) Using SST and a press, install the side bearing to the differen-
tial No.2 case.
SST 09309–36010, 09316–60010 (09316–00010)
MT–162
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E56F5)

2. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE

GEAR BACKLASH
(Differential Side Gear Sub Assembly)

(a) Install the No.2 side gear thrust washer, (temporarily install)
1.0 mm (0.039 in.) size thrust washer, differential side
gear sub assembly, four pinions, four thrust washers, pin-
ion shaft holder and four shafts to the differential No. 1
case.
HINT: Trust washer 1.0 mm (0.039 in.) size is for check of
backlash.

(b) Using a dial indicator, measure the backlash of

one pinion gear while holding the differential
side gear sub assembly toward the case.
Standard clearance: 0.05 – 0.20 mm
(0.0020 – 0.0079 in.)
HINT: Referring to the table below, select the No.2
thrust washer which will ensure that the backlash
is within specification. Try to select a washer of the
same size.

Thickness mm(in.) Thickness mm (in.)

(e) Remove the differential No. 1 case.

3. ASSEMBLE DIFFERENTIAL NO–1 CASE

(a) Install the No.2 side gear thrust washer (Previously selected),
conical spring washer and differential side gear sub assem-
bly to the No–1 case.
HINT: Be carful not to mistake the direction of conical spring
washer.
 MT–163
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E5SF5)

(b) Install the four pinion thrust washers, four differential pin-
ions, shaft holder and four shafts to the No. 1
case.

4. INSTALL SPEEDOMETER DRIVE GEAR

(a) Install the speedometer drive gear as shown in the figure.

(b) Install the spacer.

(c) Using snap ring pliers, install the snap ring.

5. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE

GEAR BACKLASH
(a) Install the front differential side gear thrust washer, side gear,
shaft holder, four pinions, four thrust washers, No–2 shaft
and two shafts to the front differential case.
MT–164
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E56F5)

(d) Using a dial indicator, measure the backlash of one pinion

gear while holding the front differential side.
gear toward the case.
Standard backlash: 0.05 – 0.20 mm
I0.0020 – 0.0079 in.)
HINT: Do not mount the surface of No.2 differential case
which contacts with bushing in a vise.
Referring to the table below, select the thrust washer which
will ensure that the backlash is within specification.
Try to select a washer of the same size.
Mark Thickness mm (in.)

6. INSTALL SNAP RING

Using snap ring pliers, install the shaft snap ring toward
to as shown.
HINT: Before installing the shaft snap ring, wrap vinyl
tape around the case prevent the it from damage.

7. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE

GEAR THRUST CLEARANCE
(Differential No.2 Case)
(a) Install the No.2 side gear thrust washer, front dif-
ferential side gear thrust washer, side gear and front
differential case assembly to the differential
No–2 case.
HINT: Engage the front differential side gear and pinion
gear of No.2 case.
 MT–165
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E5SF5)

(b) Using a dial indicator, measure the thrust clearance of front dif-
ferential side gear while holding the No.2
case on the left side.
Standard clearance: 0.14 – 0.21 mm
(0.006 – 0.008 in.)
HINT: Turning the side gear a bit, check the maximum value of
thrust clearance.
Referring to the table below, select the thrust washer which. will
ensure that the thrust clearance within specification. Try to select
a washer of the same size. . .
Mark Thickness mm (in.) Mark Thickness mm(in.)

(c) Remove the differential No.2

case.

8. INSTALL RING GEAR

(a) Clean the contact surface of the differential No.2
case.
(b) Heat the ring gear to about 100°C (212°F) in an oil bath.
NOTICE: Do not heat the ring gear above 110°C (230°F).
(c) Clean the contact surface of the ring gear with cleaning solvent.
(d) Then quickly install the ring gear on the differential
No.2 case. .
HINT: Align the matchmarks on the differential No.2 case and
connect the ring gear.
9. SELECT CENTER DIFFERENTIAL SIDE GEAR THRUST
WASHER
(a) Install the front differential case assembly, side gear, thrust
washer, (Temporarily install) 1.0 mm (0.039 in.) size No.2
thrust washer and No.2 thrust washer to the differential No. 1
case assembly.
HINT: Thrust washer 1.0 mm (0.039 in.) size is for check of back-
lash.
Engage the front differential side gear and pinion gear of
No. 1 case.
MT–166
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E.56175)

(b) Clean the No.2 side gear thrust washer and No.2case.
(c) Place the Plastigauge onto the No.2 thrust washer as shown in the
figure.
HINT: Place the Platigauge in four positions on top of the side gear
thrust washer so that they are above the axes of the three pinion
shafts inside the differential No–1 case.

Place the Plastigauge so that is as close as possible to the

outer side of the No.2 thrust washer.
(d) Install the No.2 case.
HINT: Align the matchmarks on the differential No. 1 case
and connect the No.2 case.
Do not turn the No.2 case.

(e) Install and torque the sixteen bolts.

Torque: 1,260 kg–cm (91 ft–Ib, 124 N–m)

(f) Remove the sixteen bolts and differential No.2

case up ward.
(g) Measure the Plastigauge at its widest point.
Standard clearance: 0.155 – 0.250 mm
(0.0061 – 0.0098 in.)
HINT: Referring to the table below, select the thrust
washer which will ensure that the backlash is within
specification. Try to select a washer of the same
size.

Thickness mm(in.) Thickness mm(in.)

(h) Remove the differential No.2 case, No.2 thrust washer

and (Temporarily install) 1.0 mm (0.039 in.)
thrust washer.
 MT–167
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E5SF5)

10. INSTALL DIFFERENTIAL NO.2 CASE

(a) Install the conical spring washer and No.2 side gear
thrust washer (Previously selected).
HINT: Be careful not to mistake the direction of conical
spring washer.

(a) Install the differential No.2 case to the No. 1

case.
HINT: Align the matchmarks on the differential No.1
case and connect the N.2 case.

(c) Install and torque the sixteen bolts.

Torque: 1,260 kg–cm (91 ft–ib, 124 N–m)

11. INSTALL DIFFERENTIAL CASE ASSEMBLY

Install the differential case assembly –to the transaxle
case.

12. INSTALL TRANSMISSION CASE

(a) Install the transmission case.
HINT: If necessary, tap on the case with a plastic ham-
mer.
(b) Install and torque the seventeen bolts.
Torque: 300 kg–cm (22 ft–Ib, 29 N–m)
MT–168
MANUAL TRANSAXLE – Component Parts (Differential Case Assembly E5SF5)

13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

(a) Turn the differential case assembly counterclockwise and clock-
wise several time.
(b) Using a spring tension gauge, measure the differential case as-
sembly preload.
Preload (at starting)
New bearing
3.2 – 6.3 kg
(7.1 –13.9 lb,31.4–61.8N)
Reused bearing
2.0 – 4.0 kg
(4.4–8.81b,19.6–39.2N)
If the preload is not within specification, select the thrust
washers.
HINT: The preload will change about 2.4 kg (5.3 Ib, 23.5 N) with
each shim thinness.

Mark Thickness mm (in.) Mark Thickness mm (in.)

14. REMOVE TRANSMISSION CASE

Remove the seventeen bolts and tap off the case with a
plastic hammer.

15. REMOVE DIFFERENTIAL CASE ASSEMBLY

MT–190
MANUAL TRANSAXLE – Installation of Component Parts

INSTALLATION OF COMPONENT
PARTS
(See pages MT–118 to MT–120)
HINT: Coat all of the sliding and rotating surface with
gear oil before assembly.
1. ADJUST OUTPUT SHAFT PRELOAD
(a) Install the output shaft assembly to the transaxle
case.
(b) Install the transmission case to the transaxle case.
If necessary, tap on the case with a plastic hammer.
(e) Install and torque the seventeen bolts.
Torque: 300 kg–cm (22 ft–lb, 29 N–m)

(d) Install the output shaft rear bearing outer race.

(e) Install the adjusting shim.

HINT: When re–using the output shaft rear bearing,
first install a shim of the same thickness as before.
If installing a new bearing, first select and install a
shim of lesser thickness than before.

(f) Using a torx wrench, install and torque the

seven torx screws.
Torx wrench T45 09042–00050
Torque: 430 kg–cm (31 ft–Ib, 42 N–m)
 MT–191
MANUAL TRANSAXLE – Installation of Component Parts
(g) Install the new lock nut to the output shaft.
(h) Turn the output shaft counterclockwise and clockwise
several times.
(i) Using a torque meter, measure the preload of the out-
put shaft.
Preload (at starting)
Now bearing 8.0 – 16.0 kg–cm
(6.9 – 13.9 in.–Ib, 0.8 – 1.6 N–m)
Reused bearing 5.0 – 10.0 kg–cm
(4.3 – 8.7 in.–Ib, 0.5 – 1.0 N–m)
If the preload is not within specification, select the
thrust washers.
HINT: The preload will change about 4 5 kg–cm (3.5
4.3 in.–Ib, 0.4 – 0.5 N–m) with each shim thickness.
Mark Thickness mm (in.) Mark Thickness mm (in.)

(j) Remove the lock nut.

(k) Using a torx wrench, remove the seven torx
screws.
Torx wrench T45 09042–00050
(I) Remove the adjust shim.

(m) Remove the seventeen bolts and tap off the case
with a plastic hammer.
MT–192
MANUAL TRANSAXLE – installation of Component Parts

(n) Remove the output shaft rear bearing outer race.

(o) Remove the output shaft assembly.

2. INSTALL OIL PUMP ASSEMBLY AND OIL PIPE

(a) Install the oil pump assembly and temporarily tighten
the two bolts.
HINT: Do not drop the oil pump gasket.

(b) Install the oil pipe.

(c)Torque the four bolts.

Torque: 175 kg–cm(13 ft–lb, 17 N–m)
 MT–193
MANUAL TRANSAXLE – ’.Installation of Component Parts

3. INSTALL MAGNET TO TRANSAXLE CASE

4. INSTALL DIFFERENTIAL CASE ASSEMBLY

S. INSTALL OIL PUMP DRIVE GEAR

B. INSTALL OUTPUT SHAFT ASSEMBLY

Lifting the differential case assembly, install the output
shaft assembly.

7. INSTALL INPUT SHAFT ASSEMBLY

Leaning the output shaft assembly to the differential
case side, install the input shaft assembly.
HINT: When you install the input shaft assy, be careful
not to scratch the oil seal.
MT–194
MANUAL TRANSAXLE – Installation of Component Parts

8. INSTALL SNAP RING

(a) Install the reverse shift fork to the No.3 shift fork.
(b) Using a plastic hammer, install the snap ring.

9. INSTALL NO.2 SHIFT FORK AND NO–3 SHIFT FORK

SHAFT WITH REVERSE SHIFT FORK
(a) Place No.2 shift fork into the groove of No.2 hub
sleeve.

(b) Install the No.3 shift fork shaft with reverse shift
fork to the case.

10. INSTALL NO.1 SHIFT FORK, SHIFT HEAD AND N0.2

SHIFT FORK SHAFT.
(a) Place No–1 shift fork into the groove of No.1 hub
sleeve.

(b) Put shift head onto the No–1 shift fork.

 MT–195
MANUAL TRANSAXLE – Installation of Component Parts

(c) Install the No.2 shift fork shaft to the case,

through the No.2 shift fork, the shift head and
the No. t shift fork.

11. INSTALL NO.1 SHIFT FORK SHAFT

(a) Using a magnetic finger, install the interlock roller into
the reverse shift fork.
HINT: Align the groove of No.1 fork shaft with the inter-
lock roller hole of reverse shift fork.

(b) Install the No–1 shift fork shaft to the case,

through the No. 1 shift fork and reverse shift
fork.
HINT: If it is difficult to put the No.1 shift fork shaft
through the reverse shift fork, pull up the No.3 shift
fork shaft.

12. INSTALL SET BOLTS

Install and torque the three bolts.
Torque: 240 kg–cm (17 ft–lb, 24 N–m)

13. INSTALL LOCKING BALLS, SPRINGS, SPRING SEATS

AND SCREW PLUGS
(a) Install the two locking balls, springs and spring
seats.
MT–196
MANUAL TRANSAXLE – Installation of Component Parts

(b) Apply sealant to the two screw plugs.

Sealant: Part No. 08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, torque the two screw plugs.
SST 09313–30021
Torque: 250 kg–cm (18 ft–Ib, 25 N–m)

14. INSTALL REVERSE IDLER GEAR SHAFT, THRUST

WASHER AND GEAR
(a) Install the reverse idler gear shaft with gear and thrust
washer to the case.

(b) Align the matchmarks, as shown in the illustration.

15. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

AND NO.2 OIL PIPE
(a) Put the–reverse shift fork pivot into the reverse shift
arm and install the reverse shift arm bracket to the
transaxle case.
(b) Temporarily install the bolt.

(c) Install the No.2 oil pipe.

 MT–197
MANUAL TRANSAXLE – Installation of Component Parts

(d) Torque the two oil pipe bolts and reverse shift arm
bracket bolt.
Torque: 175 kg–cm (13 ft–lb, 17 N–m)

(e) Install a new gasket to the oil pipe.

16. INSTALL TRANSMISSION CASE

(a) Remove any packing material and be careful not to drop oil on
the contacting surfaces of the transaxle case.
(b) Apply seal packing to the transmission case as shown in the fig-
ure.
Seal packing: Part No.08826–00080, THREE BOND
1281 or equivalent
HINT: Install the transmission case as soon as the seal packing
is applied.
(c) Install and torque the seventeen bolts.
Transmission case side: Fourteen bolts
Transaxle case side: Three bolts
Torque: 300 kg–cm (22 ft–Ib, 29 N–m)

17. INSTALL AND TORQUE REVERSE IDLER GEAR

RETAINING BOLT WITH GASKET
Torque: 300 kg–cm (22 ft–Ib, 29 N–m)
MT–198
MANUAL TRANSAXLE – Installation of Component Parts

18. INSTALL LOCKING BALL, SPRING, SPRING SEAT

AND SCREW PLUG
(a) Install the locking ball, spring and spring seat.

(b) Apply sealant to the screw plug.

Sealant: Part No.08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, torque the screw, plug.
SST 09313–30021
Torque: 250 kg–cm (18 ft–Ib, 25 N–m)

18. INSTALL SNAP RINGS

Using a plastic hammer, install the two snap rings to
the shift fork shafts.

20. INSTALL REAR BEARING RETAINER

(a) Install the output shaft rear bearing outer race.

(b) Install the adjust shim which is already finished

out put shaft preload.
 MT–199
MANUAL TRANSAXLE – Installation of Component Parts

(c) Using snap ring pliers, install the snap ring to the
input shaft rear bearing.

(d) Apply sealant to the, seven screws.

Sealant: Part No.08833–00070, THREE BOND 1324,
LOCTITE 242 or equivalent
(e) Using a torx wrench, torque the seven screws.
Tom wrench T45 09042–00050
Torque: 430 kg–cm (31 ft–Ib, 42 N–m)

21. INSTALL FIFTH GEAR AND NO–3 CLUTCH HUB

(a) Install the spacer, needle roller bearings and 5th gear.

(b) Install the synchronizer ring and key spring to the

No–3 clutch hub.

(c) Using SST, install the No.3 clutch hub with synchronizer
ring and key spring.
SST 09310–17010 I09310–07010, 09310–07020,
09310–070301
MT–200
MANUAL TRANSAXLE – Installation of Component Parts

(d) Select a snap ring that will allow minimum axial

play and install it on the shaft.

(e) Using a dial indicator, measure the 5th gear thrust clear-
ance.
Standard clearance: 0.10 – 0.57 mm
(0.004 – 0.022 in.)

22. INSTALL FIFTH DRIVEN GEAR

Using SST, install the 5th driven gear.
SST 09310–17010 (09310–07010, 09310–07020
09310–07040, 09310–07050)

23. INSTALL NO.3 HUB SLEEVE AND NO.3 SHIFT FORK

(a) Install the No.3 hub sleeve and No.3 shift fork.

(b) install and torque the set bolt.

Torque: 240 kg–cm (17 ft–Ib, 24 N–m)
 MT–201
MANUAL TRANSAXLE – Installation of Component Parts
24. INSTALL LOCK NUT
(a) Engage the gear double meshing.

(b) install and torque a new lock nut.

Torque: 1,250 kg–cm (90 ft–Ib, 123 N–m)

(e) Stake the lock nut.

(d) Disengage the gear double meshing.

25. INSTALL TRANSMISSION CASE COVER

(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of the transmis-
sion case cover.
(b) Apply seal packing to the transmission case as shown
in the figure.
Seal packing: Part No.08826–00090, THREE
BOND
1281 or equivalent
HINT: Install the transmission case cover as soon as the
seal packing is applied.
Install and torque the ten bolts.
Torque: 300 kg–cm (22 ft–Ib, 29 N–m)
MT–202
MANUAL TRANSAXLE – Installation of Component Parts

26. INSTALL SHIFT AND SELECT LEVER SHAFT

ASSEMBLY
(a) Install the shift and select lever shaft assembly and new gasket.
(b) Apply sealant to the bolt threads.
Sealant: Part No.08833–00O80, THREE BOND 1344,
LOCTITE 242 or equivalent
(e) Install and torque the four bolts.
Torque: 200 kg–cm (14 ft–Ib, 20 N–m)
(d) Install and torque the lock bolt with the new gasket.
Torque: 500 kg–cm (36 ft–Ib, 49 N–m)

27. INSTALL NO.2 SELECTING BELLCRANK WITH

SELECTING BELLCRANK SUPPORT
(a) Apply sealant to the bolt threads.
Sealant: Part No.08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install and torque the two bolts.
Torque: 200 kg–cm (14 ft–Ib, 20 N–m)

28. INSTALL BACK–UP LIGHT SWITCH

Instal! and torque the back–up light switch with the
new gasket.
Torque: 410 kg–cm (30 ft–Ib, 40 N–m)
29. INSTALL SPEEDOMETER DRIVEN GEAR

30. INSTALL RELEASE FORK AND BEARING

Apply molybdenum disulphide lithium base grease to
the following part:
• Input shaft spline
• Release fork contact surface
 MT–203
MANUAL TRANSAXLE – Installation of Component Parts
31. INSTALL DIFFERENTIAL SIDE GEAR INTERMEDIATE
SHAFT
(a) Apply MP grease to the intermediate shaft.
(b) Using a plastic hammer, correctly drive the intermedi-
ate shaft straight until the top of it touches the differ-
ential pinion shaft.

HINT: Keeping the intermediate shaft on the pinion

shaft of differential, measure the point in the il-
lustration.
Protrusion length: 255.5 mm (10.059 in.)

32. INSTALL TRANSFER ASSEMBLY

(a) Remove any packing material and be careful not to drop oil on the
contacting surfaces of the transfer or transaxle.
(b) Apply seal packing to the transfer as shown in the figure.
Seal packing: Part No.08826–00090, THREE BOND
1281 or equivalent
HINT: Install the transfer as soon as the seal packing is applied.
(c) Install the transfer assembly to the transaxle assembly
HINT: Shift into 4th gear, install the transfer assembly while turning
the input shaft of the transaxle.

(d) Apply sealant to the bolt threads.

Sealant: Part No.08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(e) Install and torque the three bolts and five nuts.
Torque: 700 kg–cm (51 ft–Ib, 69 N–m)
MT–204
MANUAL TRANSAXLE – Shift Lever and Control Cable

SHIFT LEVER AND CONTROL CABLE

COMPONENTS
 MT–169
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

Transfer Assembly (E56F5)

COMPONENT
MT–170
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

DISASSEMBLY OF TRANSFER COMPONENT

PARTS
1. REMOVE TRANSFER VACUUM ACTUATOR
(a) Remove the four bolts.
(b) Remove the actuator bracket and stiffener center plate.

(c) Remove the three bolts.

(d) Remove the vacuum actuator.

2. REMOVE DUST BOOT

3. REMOVE DIFFERENTIAL LOCK SHIFT FORK SHAFT

(a) Remove transfer indicator switch.
(b) Using SST, remove the plug.
SST 09313–30021

(c) Using SST, remove the plug.

SST 09043–38100
 MT–171
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

(d) Remove the set bolt.

(e) Remove the shift fork shaft, shift fork and sleeve.

4. REMOVE DYNAMIC DAMPER

Remove the four bolts and dynamic damper.

5. REMOVE EXTENSION HOUSING

(a) Remove the four bolts and tap off the housing with a
plastic hammer.
(b) Remove the O–ring and the dust deflector from the ex-
tension housing.

6. REMOVE SIDE GEAR SHAFT HOLDER

(a) Using a screwdriver and hammer, remove the oil seal.

(b) Using snap ring pliers, remove the snap ring.

MT–172
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

(c) Remove the shaft holder.

7. CHECK PRELOAD
(a) Using SST and a spring tension gauge, measure the
driven pinion preload of the backlash between the
driven pinion and ring gear.
SST 09326–20011
Preload (at starting): 0.9 – 1.4 kg
(2–3 lb, 9– 14 N)
(a) Using SST and a spring tension gauge, measure the
total preload.
SST 09326–20011
Preload (at starting):
Add driven pinion preload
0.5–0.90 (1–2 lb,5–9 N)
8. REMOVE TRANSFER INSPECTION HOLE COVER
Remove the three bolts and a cover.

9. CHECK RING GEAR BACKLASH

Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 – 0.18 mm (0.0051 – 0.0071 in.)
10. CHECK TOOTH CONTACT (Seepage MT–183)

11. REMOVE DRIVEN PINION BEARING CAGE

ASSEMBLY
(a) Remove the six bolts and tap off a plastic hammer.
(b) Remove the 4–ring and shim from the driven pinion
bearing cage.
 MT–173
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

12. REMOVE TRANSFER RIGHT CASE

Remove the ten bolts and tap off the case with a plastic
hammer.

13. REMOVE RING GEAR MOUNTING CASE ASSEMBLY

14. REMOVE ADJUSTING NUT LOCK PLATE

Using snap ring pliers, remove the lock plate from the
transfer right case.

15. IF NECESSARY, REPLACE EXTENSION HOUSING OIL

SEAL
(a) Using a screwdriver, remove the oil seal.

(b) Using SST and a hammer, drive in a new oil seal.

SST 09325–20010
Oil seal depth: 1.1 – 1.9 mm (0.043 – 0.075 in.)
(c) Coat the lip of oil seal with MP grease.
MT–174
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

16. IF NECESSARY, REPLACE SHIFT FORK

SHAFT OIL SEAL
(a) Using a screwdriver and hammer, remove the oil seal.

(b) Coat the lip of oil seal with MP grease.

(c) Using a socket wrench and hammer, drive in a
new oil seal as shown.
Oil seal height: 7.5 – 8.5 mm (0.295 – 0.335
in.)

17. IF NECESSARY, REPLACE SIDE GEAR SHAFT HOLDER

BEARING
(a) Using snap ring pliers, remove the snap ring.

(b) Using a press, remove the bearing from the

side gear shaft holder.

(c) Using SST and a press, install a new bearing as

shown.
SST 09316–60010 (09316–00010)
 MT–175
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

(d) Using snap ring pliers, install the snap ring.

18. IF NECESSARY, REPLACE TRANSFER OIL TUBE

(a) Remove the bolt and oil tube.

(b) Using a screwdriver, remove the cushion.

(c) Install anew cushion.

(d) Install the oil tube.

(e) Install and torque the bolt.
Torque: 130 kg–cm (9 ft–Ib, 13 N–m)
MT–176
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E5.6F5)

19. IF NECESSARY, REPLACE RING GEAR MOUNTING

CASE SIDE BEARING OUTER RACE
(Transfer Right Case)
(a) Using SST, turn the bearing adjusting nut, remove the
outer race and bearing adjusting nut.
SST 09318–20010

(b) Install the bearing adjusting nut until it touches the

lip of the case.
HINT: If the nut is difficult to turn, use SST (09318–
20010).

(c) Using SST and a press, install the press until it is

almost touching the bearing adjusting nut.
SST 09608–35014 (09608–06020,
09608–06160)

(Transfer Left Case)

(a) Using a brass bar and hammer, drive out the bear-
ing outer race lightly and evenly.
Remove the plate washer.

(c) Install the plate washer.

HINT: First install a washer of the same thickness
as before.
 MT–177
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

(d) Using. SST and a press, install the outer race.

SST 09316–60010 (09316–00010, 09316–00060)

20. MEASURE CLEARANCE OF DIFFERENTIAL LOCK

SHIFT FORK AND SLEEVE
Measure the clearance between the shift fork and
sleeve.
Maximum clearance: 1.0 mm (0.039 in.)

21. INSPECT TRANSFER VACUUM ACTUATOR

(a) the push rod.
(b) Apply a vacuum of 500 mmHg to port Y1 and Y2.
Move in the push rod and measure the push rod strake.
Push rod strake: 16.5 mm (0.650 in.) or more
(c) Apply a vacuum of 500 mmHg to port Y3. Check that no remain
the vacuum in actuator.
If not, replace the actuator.
(d) After the check, apply a vacuum of 500 mmHg to port Y of the ac-
tuator (Put the differential lock on the free side).
MT–178
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

DRIVEN PINION. BEARING CAGE ASSEMBLY

DISASSEMBLY OF DRIVEN PINION BEARING

CAGE
1. REMOVE LOCK NUT
(a) Unstake the lock nut.
(b) Using SST, remove the luck nut.
SST 09326–20011

2. REMOVE DRIVEN PINION

Using a press, remove the driven pinion, rear bearing
and spacer.
 MT–179
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

3. IF NECESSARY, REPLACE DRIVEN PINION FRONT

BEARING
(a) Using SST and a press, remove the front bearing.
SST 09950–00020

(b) Using SST and a press, install the front bearing.

SST 09506–35010

4. IF NECESSARY, REPLACE FRONT AND REAR

BEARING OUTER RACE
(a) Using a brass bar and hammer, drive out the bearing
outer race race lightly and evenly.
HINT: Be careful not to damage the drive pinion bearing
cage and earing outer race.

(b) Using SST and a press, install the front bearing outer race.
SST 09608–35014 (09608–06020, 09608–06210)
(c) Using SST and a press, install the rear bearing outer race.
SST 09550–10012 (09252–10010, 09555–10010)

ASSEMBLY OF DRIVEN PINION BEARING

CAGE
(See page MT– 178)
HINT: Coat all of the sliding and rotating surface with gear oil be-
fore assembly.
1. INSTALL DRIVEN PINION BEARING CAGE
(a) Install a new bearing spacer.
HINT: Insert the spacer with the smaller facing upwards.
MT–180
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

(b) Using SST and a press, install the rear bearing.

HINT: Press down until the pinion can just move slightly up
and down.
SST 09316–60010 (09316–00020)

2. ADJUST DRIVEN PINION PRELOAD

(a) Using SST, install and torque the new lock nut.
SST 09326–20011
Torque: 1,000 kg–cm (72 ft–Ib, 90 N–m)
HINT: Use a torque wrench with a fulcrum length of 50
cm (19.69 in.).

(b) Using SST and a spring tension gauge, measure

the driven pinion preload.
HINT: Turn the driven pinion right and left two or three
times to allow the bearings to settle.
Preload (at starting) :
Now bearing
1.8–2.9kg(4.0–6.41b,17.6–28.4N)
Reused bearing
0.9–1.4kg(2.0–3.11b,8.8–13.7N)
* If preload is greater than specification, replace the
bearing spacer.
* If preload is less than specification, retighten the
nut 5 – 10° at a time until the specified preload is
reached.
If the maximum torque is exceed while retightening the
nut, replace the bearing spacer and repeat the preload
procedure. Do not back off the pinion nut to reduce the
preload.
Maximum torque: 2,200 kg–cm (159 ft–Ib, 216 N–m)
3. STAKE LOCK NUT
 MT–181
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

RING GEAR MOUNTING CASE

ASSEMBLY

DISASSEMBLY OF RING GEAR MOUNTING

CASE
1. REMOVE MOUNTING CASE SIDE BEARING
Using SST, remove the side bearing.
SST 09950–20017

2. CHECK RING GEAR RUNOUT

Using a dial indicator, check the ring gear runout.
Maximum runout: 0.1 mm (0.004 in.)
MT–182
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

3. REMOVE RING GEAR

(a) Place the matchrmarks on both the mounting case and
ring gear.
(b) Remove the twelve bolts.

(c) Using a plastic hammer, tap out the ring gear.

INSPECTION OF RING GEAR MOUNTING

CASE
1. CHECK RING GEAR MOUNTING CASE RUNOUT
HINT: Perform only when the limit is exceeded in the ring gear
runout inspection.
(a) Using a dial indicator, check the mounting case
Maximum runout: 0.1 mm (0.004 in.)

ASSEMBLY OF RING GEAR

MOUNTING CASE
1. INSTALL RING GEAR
(a) Clean the contact surface of the differential case.
(b) Heat the ring gear to about 100°C (21 20F) in an oil bath.
(e) Clean the contact surface of the ring gear with clean-
ing solvent.
(d) Then quickly install the ring gear on the differential
case.
(e) Align the marks on the ring gear and differential case
NOTICE: Do not heat the ring gear more than 11O°C
(230°F).
(f) Coat the ring gear set bolts with gear oil.
(g) Install and torque the set bolts uniformly, a little at a
time.
Torque: 985 kg–cm (71 ft–Ib, 97 N–m)
2. CHECK RING GEAR RUNOUT
(See page MT– 181)
 MT–183
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

3. INSTALL MOUNTING CASE SIDE BEARING

Using SST and a press, install the two side bearing.
SST 09316–20011
NOTE: Bearing inner diameter
Ring gear tooth side 55 mm (2.2 in.)
Ring gear back side 54 mm (2.1 in.)

ASSEMBLY OF TRANSFER COMPONENT

PARTS
(See page MT–169)
HINT: Coat all of the sliding and rotating surface with gear oil before
assembly.
1. ADJUST RING GEAR BACKLASH
(a) Install the adjust shim to the driven pinion bearing
cage assembly.
HINT: First install a shim of the same thickness as before.
(b) Install the driven pinion bearing cage assembly to the
transfer left case.
(e) Install and torque the six bolts.
Torque: 400 kg–cm (29 ft–Ib, 39 N–m)
HINT: Do not install the O–ring.

(d) Install the ring gear mounting case assembly to

the transfer left case.

(e) Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 – 0.18 mm (0.0051 – 0.0071 in.)
(f) Referring to the table below, select the plate washer which will
ensure that the backlash is within specification. Try to select
a washer of the same size.
MT–184
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

HINT: The backlash will change about 0.02 mm (0.0008

in.) with each shim thickness.

Mark Thickness mm (in.) Mark Thickness mm (in.)

2. ADJUST TOTAL PRELOAD

(a) Install the transfer right case.
(b) Install and torque the twelve bolts.
Torque: 450 kg–cm (33 ft–lb, 44 N–m)

(c) Adjust the total preload by tightening the bearing adjusting

nut.
Using SST, tightening the adjusting nut.
SST 09318–20010
HINT: Measure the preload while tightening the adjusting nut
a little at a time.
(d) Using SST and a spring tension gauge, measure the total
preload.
SST 09326–20011
(Preload at starting):
New bearing
Add driven pinion preload
1.3– 1.4 kg (2.9–3.1 Ib, 12.7– 13.7 N)
Reused bearing
Add driven pinion preload
0.5–0.9kg (1.1 –2.0Ib,4.9–8.8 N)
HINT: Turn the output shaft counterclockwise and clockwise
several times.
(e) When the standard value for total preload is exceeded, re-
move the transfer right case, push in the adjusting nut and
outer race.
Again adjust the total preload.
3. CHECK RING GEAR BACKLASH
(a) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 – 0.18 mm (0.0051 – 0.0071 in.)
(b) When the backlash is outside the standard value, select a
different plate washer to the one selected step 2. Again
adjust the backlash and total preload.
 MT–185
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

4. CHECK TOOTH CONTACT

(a) Coat 3 or 4 teeth at four different position on the ring
gear with red lead.
(b) Rotate the ring gear, inspect the teeth pattern.

(e) If the teeth are not contacting properly, again se-

lect the proper shim and plate.
Mark Thickness mm (in.) Mark Thickness mm (in.)

5. REMOVE RING GEAR MOUNTING CASE ASSEMBLY

(a) Remove the twelve bolts and transfer right case.
MT–186
MANUAL TRANSAXLE – Component Parts (Transfer Assembly F56 F5)

(b) Remove the ring gear mounting case assembly.

6. REMOVE DRIVEN PINION BEARING CAGE

ASSEMBLY
(a) Remove the six bolts and bearing cage assembly.

7. INSTALL DRIVEN PINION BEARING CAGE

ASSEMBLY
(a) Coat the O–ring with gear oil.
(b) Install the O–ring to the driven pinion bearing cage.
(c) Install the driven pinion bearing cage with adjust shim
(Previously selected) to the transfer left case.
(d) Install and torque the six bolts.
Torque: 400 kg–cm (29 ft–Ib. 39 N–m)

8. INSTALL RING GEAR MOUNTING CASE ASSEMBLY

9. INSTALL TRANSFER RIGHT CASE

(a) Remove any packing material and be careful not to drop oil
on the contacting surfaces of the transfer left case or right
case.
(b) Apply seal packing to the transfer left case as shown in the
figure.
Seal packing: Part No.08826–00090, THREE BOND
1281 or equivalent
HINT: Install the transfer right case as soon as the seal pack-
ing is applied.
 MT–187
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

(c) Apply sealant to the bolt threads.

Sealant: Part No.08833–00080, THREE BOND 1344,
LOCTITE 242 OR EQUIVALENT
(d) Install and torque the twelve bolts.
Torque: 450 kg–cm (33 ft–lb, 44 N–m)
10. CHECK TOTAL PRELOAD
(See page MT– 184)

11. INSTALL ADJUSTING NUT LOCK PLATE

Using snap ring pliers, install the lock plate so that the
projection from the lock plate fits properly into the
groove of the adjusting nut.
HINT: Choose one of the two types of lock plate can be
installed, tighten the adjusting nut to the minimum limit.

12. INSTALL SIDE GEAR SHAFT SIDE GEAR SHAFT

HOLDER
(a) Install the side gear shaft holder to the transfer right
case.
(b) Using snap ring pliers, install the snap ring.

13. INSTALL OIL SEAL

(a) Coat the lip of the oil seal with MP grease.
(b) Using a brass bar and hammer, drive in a new oil seal.

14. INSTALL TRANSFER INSPECTION HOLE COVER

(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of transfer left
case or transfer inspection hole cover.
(b) Apply seal packing to the transfer left case as shown
in the figure.
Seal packing: Part No.08826–00090, THREE
BOND
1281 or equivalent
HINT: Install the transfer inspection hole cover as soon
as the seal packing is applied.
MT–188
MANUAL TRANSAXLE – Component Parts (Transfer Assembly E56F5)

(c) Install and torque the three bolts.

Torque: 160 kg–cm (12 ft–Ib, 16 N–M)

15. INSTALL EXTENSION HOUSING

(a) Coat the O–ring with gear oil.
(b) Install the O–ring to the extension housing.
(c) Install the extension housing to the driven pinion bear-
ing cage.
(e) Install and torque the four bolts.
Torque: 260kg–cm (19 ft–Ib, 25 N–m)

16. INSTALL DYNAMIC DANPER

Install and torque the four bolts.
Torque: 260 kg–cm (19 ft–Ib, 25 N–m)

17. INSTALL DIFFERENTIAL LOCK SHIFT FORK

SHAFT
(a) Install the differential lock sleeve with shift fork.
(b) Install and torque the set bolt.
Torque: 160 kg–cm (12 ft–Ib, 16 N–m)

(c) Using SST, install and torque the plug.

SST 09043–36100
Torque: 400 kg–cm (29 ft–Ib, 39 N–m)
 MT–189
MANUAL TRANSAXLE – Component Parts (Transfer Assembly)

(d) Install and torque the indicator switch.

Torque: 400 kg–cm (29 ft–Ib, 39 N–m)
(e) Using SST, install and torque the plug.
SST 09313–30021
Torque: 250 kg–cm (18 ft–Ib, 25 N–m)

(e) Set the shift fork shaft at the as shown in the figure.

1s. INSTALL DUST BOOT

19. INSTALL TRANSFER VACUUM ACTUATOR

(a) Install the vacuum actuator.
(b) Install and torque the three bolts.

(c) Install the stiffener center plate and actuator

bracket.
(d) Install and torque the four bolts.
Torque: 380 kg–cm (27 ft–lb, 37 N–m)