MANUAL TRANSMISSION (TYPE M5H Series) SECTIONAL VIEW wna TRANSMISSION ASSEMBLY .. COMPONENTS (PART 1) COMPONENTS (PART 2) COMPONENTS (PART 3) COMPONENTS (PART 4) CONTROL LINKAGE-RELATED PARTS .. COMPONENTS DISASSEMBLY .. INSPECTION REPLACEMENT ASSEMBLY .... APPLICATION POINTS OF GREASE & BOND AND APPLICATION PROCEDURE INPUT SHAFT COMPONENTS DISASSEMBLY INSPECTION ASSEMBLY DISCRIMINATION OUTPUT SHAFT COMPONENTS sss DISASSEMBLY INSPECTION .. ASSEMBLY DISCRIMINATION DIFFERENTIAL GEAR COMPONENTS BEARING .. DIFFERENTIAL GEAR .. DIFFERENTIAL CASE .. ‘SHIFT LEVER & SELECTING PROD wssssscserensee COMPONENTS FEMOVAL svn MT-46 INSTALLATION MT-47 DISASSEMBLY .. MT-48 INSPECTION MT-48 ASSEMBLY MT-49 APPENDIX 6. an MT-50 SSTs (Special Service TOOIS) sre MT-50 SERVICE SPECIFICATIONS MT-51 TIGHTENING TORQUE ...MT-2 SECTIONAL VIEW 4th gear Output shaft Sub-gears Reverse idler gear shaft Input shatt 1st gear TaMT-3 SPECIFICATIONS Item ‘Specifications TRANEWISSION TYPE Maree wanes [HA Vehicle mode! Cuore Move: | ‘Sirion Engine ype ENE iz = = Forward goa Consiatomesh ype Reverse gear Selective sing vee Tstgeer ai = = na gear 3a = = Geer ratio a em = = ahoeer O54 on6 = Sih ose 0707 0750 = averse gear ara © E Fnalredveton gear ato 2286 = 450 ‘Number of ferent’ side gear ooh 6 = = umber of ferential pion weeth 70 Ee € Speedometer gear rato (@rwervenv@) 25 = ia Type SAE TONERS 0 TEW-90, APIGL oF GLA Ot used Capacity Ter 25-225 Seon INSTRUCTIONS . Keep your job site always clean. As for disassembled parts, first clean them before you proceed to the next operation. 2. During the disassembly, make sure not to lose any parts, such as balls, springs, keys and rollers. 3. Since some parts resemble in shape, identify each part by referring to parts catalogs. Furthermore, take precautionary measures, such 2s putting tags on the parts during disassembly so that no wrong assembly may ocour. 4. Be very careful not to damage the lip section of an oil seal during operation, 5. Never reuse oil seals, slotted pins and bearings removed. 6. Care must be exercised to ensure that no pressing force is applied to the balls during the press-fiting of a ball bearing. 7. During the assembly, apply the designated gear oil to the rotating and sliding sections of gears and cil seals, Designated Oil: SAE 75W-85 or 75W-90, API GL-3 or GL-4 8. After completion of assembling, make sure that all the following movements are smooth; the rotation of the input shaft; the shift & select operation in each gear, the movement of the clutch release lever, the movement of the clutch release hub. 9. After completion of assembling, make sure that no cil leakage or oozing is present at each of the mating surfaces and plug sections. 40. After mounting the transmission on the vehicle, fil the transmission with the specified amount of the designated oil Designated Oil: SAE 76W-85 or 75W-80, API GL-3 or GL-4 Specified Amount: 2.1 ~ 2.25 liter NOTE: «Refer to the MA section.MT-4 TRANSMISSION ASSEMBLY COMPONENTS (PART 1) (© Wmead siraignt screw plug & Gasket (filer side) @ Winead straight screw plug & Gasket (Grain si¢9) @ Cuitch cable bracket @ Breather plug Backup lamp switch assembly & Gasket Lock plate @ Speedometer shat sleeve subassembly LL oar 69-08 an +: Non-reusable parts ‘Transmission case cover subassembly ‘Case cover ol pipe ( Gasket & Lock ball plate Ball & Compression spring ‘Transmission case Hola snap ring @ Clamp G Lett mount bracketMT-5 COMPONENTS (PART 2) £2: Tatoning torque 5 Nor-ruabie pata iomin Boot G trou sat hearing ook plate Ol seat Wes a eer 8 gata ll seal Biota on case assemblyMT-6 COMPONENTS (PART 3) r Transmission hub sleeve stopper ‘Transmission clutch No. 8 hub assembly Q Lock i Conical spring washer ‘Synchronizer ring @ (1-373) *MT-7 COMPONENTS (PART 4) * : Non-rousable parts Reverse idler shaft 181 & 2nd shit fork shaft Reverse idler gear 181 & 2nd shift head Q Compression spring ‘Sed & ath shift fork ‘Slotted spring pin x5 4st & 2nd shit fork ‘Sth & reverse shift fork shaft 5 shift fork Reverse shift arm head Shift interlock plate rd & 4th shift fork shatMT-3 CONTROL LINKAGE-RELATED PARTS COMPONENTS Unit: Nem © Select support assembly & shiting bell @ Wave washer, bolt and nut set rank Shih & selector shaft ‘a. Compression sprin ‘Shit inner lever . Reverse restict cam Control shatt boot Reverse restrict shaft Magnet . ® Shift inter lock plateDISASSEMBLY H Remove the screw plugs (at the drain and filler sides). NOTE: + Never reuse the removed gaskets. Remove the clutch cable bracket. Remove the backup lamp switch assembly and breather plug. NOTE: ‘+ Never reuse the removed gasket, Remove the lock plate and speedometer shatt sleeve sub- assembly. Remove the oil seal, using the SST given below. SST: 09921-00010-000 NOTE: + Never reuse the removed oil seal. |. Remove the transmission case cover subassembly as fol- lows: (1) To drive out the case cover subassembly, tap the flange section lightly in the axial direction, using a plastic hammer. NOTE: «Never tap the case cover at its side. TaoMT-10 7. Remove the case cover il pipe. 8. Measure the end play of the 5th gear. Specified Value: 0.1 - 0.23 mm Limit: 0.4 mm 9. Removal of lock nut (1) Operate the shift & selector shaft so that the gear may be inthe 5th position. (2) Remove the slotted spring, using a knock pin punch. (3) With the 5th shift fork held, place the shift & selector shaft in the neutral position once. Then, place the shaft in the reverse position so as to set the gear to an inter- locked state, NOTE: * Never reuse the removed slotted spring pin. (4) Release the staked condition at the input shaft side and the output shaft side, respectively, using a chisel and.@ hammer. Then, remove the nut. NOTE: + Never reuse the removed nuts.Remove the conical spring washer and transmission hub sleeve stopper at the input shaft side. Remove the Sth shift fork and transmission clutch hub as- sembly No. 3 at the same time. Remove the synchronizer ring, Sth gear and Sth gear bush at input shaft side. Remove the conical spring washer and remove the output Sth gear at the output shaft side. . Remove the lock ball plate and gasket. Take out the com- pression springs and balls. NOTE: + Never reuse the removed gasket. Remove the transmission case attaching bolts,MT-12 15. ig Transmission case removal (1) Expand the snap ring, using the following SST and drop the shaft. SST: 09905-00012-000 (2) To drive out the transmission case, tap the case rib with a plastic hammer. Detach the hole snap ring. Pull out the reverse idler gear shaft. Remove the reverse idler gear together with the compression spring. Slotted spring pin removal (1) Working from the arrow-headed direction in the figure, drive out the slotted spring pins by means of a punch pin. (Four points) NOTE: «Never reuse the removed slotted spring pins. Pull out the 5th & reverse shift fork shaft. Remove the re- verse shift arm head.20. 21. 22. 23. 24. Remove the 3rd & 4th shift fork shaft and the 3rd & 4th shift fork. Pull out the 1st & 2nd shift fork shaft. Remove the ist & 2nd shift head. Remove the input shaft bearing lock plate. Remove the input shaft assembly and output shaft assem- bly including the 1st and 2nd shift fork at the same time. Remove the selecting & shifting bell crank support assem- bly and magnet. NOTE: * Be sure not to release the staked section of the bell crank. * Replacement parts are supplied only as those with the bell crank support assembly. (The reverse restricting cam is excluded.) Furthermore, it should be noted that the reverse re- stricting cam can not be disassembled. TRSMT-14 25. Disassemble the bell crank support assembly, as re- quired. 26. Remove the shift interlock plates. 27. Differential case removal (1) With a brass bar placed on the inner race of the side bearing, lightly tap the bar so that the differential case may be driven out from the transaxle case. 28. Removal of wave washer, nut and set bolt (1) After the nut has been loosened, proceed to loosen’ the set bolt: 29. Remove the shift & select shaft, shift inner lever and con- trol shaft boot. Control shaft oot Shift inner lever ‘Shift select shaft Se, & TaeMT-15 INSPECTION 1. Check the needle roller bearing for wear or damage under the assembled state. 2. Check each oil seal for wear or damage. Pant Inspection criteria ‘Visually inspect to see if the lip Lip section of oil seat section exhibits excessive damage ‘or wear. wear or damage. 3. Check the speedometer shaft sieeve subassembly for 0 & Input 2. if | ‘select shaft section ‘section Bearing section at differential side aa Spestedvane | __Umt _| Driven gear shaft diameter |_7.972-7.987 7.98 Shalt sleeve bore D | 8.029- 8085 810 Oil seal ip section @ Visually inspect the section for One ® | excessive wear or camage. Diven geartwotheurlace __@ 4. Check the shift fork shafts, balls and springs for damage or wear. ® Par Inspection enteria o Bal jock section © and interiock | Visually inspect the section for © section of fork shaft @) excessive damage or wear. ee : 3 é i 5. Check the 1st shift fork, the 2nd shift fork and the reverse: DaraoTeson shift head for damage or weer. a a Spectedvane | Ut © Thickness at ip-section of a @| 88-70 63 i Groove width of shitinner lever contact-seetion oy aeagee ee Groove wicth of reverse shitarmpin-contact-section _@| _159- 15049 = JET ‘Groove width of shitinner levercontact-section oy ares aMT-16 6. Check the interlock plate for damage or wear. Pant Boediiachvaie! tm o © | @| 16.15- 16.45 16.0 c Cc =| cepataoan OL BS [to a he ae ak — “= 4 ‘Two lock plates must bs replaced al the same time. 7. Check the control shaft and inner lever for damage or wear. Part Inspection criteria Sexiest © | Visaly inspect the following ems Inner lever recessed given below. section and shaft inserting Shaft for bend section @ | + Recessed section of inner lever Slain section of dust boot ae eee send wear or and breakage ‘+ Dust boot for cracks or wear Tip-end of lock bolt @ | + Te-end at lock bolt for wear wear. Pant 8. Check the reverse restricting cam and shaft for damage or Inspection cnteria ‘Operation of restricting cam ‘> Ensure thatthe miss operation preventing mechanism functions at the support assembly. © The cam should be raised at the sama time when the section @ is lited. ® When tumed tothe lt, ensure thatthe cam drops and the section @ is locked. TOTES Each part of reverse restricting cam and shaft ® Visually inspect each part tor damage or wear, 9. Check the reverse idler gear and shaff for wear or damage. = Spaced vas | —_Umt Bush iver diameter | tro00- 170e7 | __17.060 Shaft outer ameter @ | 16981-16066 | 16900 Groove width @I s0co-aoss | 82 Wear or damage of Visually inspect ine spring fr spring @ | flattened condition DATOREPLACEMENT Replace any parts that exhibit abnormality, following the pro- cedure given below. 1. Oil seal for control shaft use Disassembly: Remove the oil seal by pinching its flange section with pli- ers. NOTE: ‘+ Never reuse the removed oil seal. ‘Assembly: Drive the oil seal into position, until it comes into contact with the axle case. SST: 09515-87201-000 2. Oil seal for input shaft use Disassembly: Remove the oil seal with a common screwdriver. NOTE: * Never reuse the removed oil seal. Assembly: Drive the oil seat into position, until it be-comes flush with the edge surface of the transaxle case, SST; 09606-87201-000 3. Needle Roller Bearing, Disassembly: After the output shaft bearing lock plate has been re- moved, remove the roller bearing, using the following SST. SST: 08908-00010-000 NOTE: + Naver reuse the removed needle roller bearing. Assembly: (1) Assemble the roller bearing, using the following SST. SST: 09309-87201-000 NOTE: + Visually check to see if the output shaft cover exhibits severe distortion or clogging. (2) install the bearing lock plate. Tightening Torque: 6.9-9.8 Nm iT TBSTMT-18 4, Oil seal for differential use Disassembly: Remove the oil seal with a common screwdriver. NOTE: = Never reuse the removed oil seal. Assembly: Drive the oll seal into position, until it comes into contact with the rib of the transaxle case (case side) contact with the differential side bearing (housing side). SST: 09517-87705-000 (Case side) (09517-87706-000 (Housing side) 5. Oll seal for speedometer shaft sleeve Disassembly: Remove the oil seal, using the SST given below. SST: 09921-00010-000 NOTE: + Never reuse the removed oil seal. Assembly: Assembly the oil seal, using the SST given below. SST: 08201-60011-000 ASSEMBLY NOTE: + Apply gear oil to the entire surfaces of the rotary or sliding sections. 1. Assemble the boot on the case. NOTE: * Be very careful not to scratch the boot ‘+ Install the water drain hole in such a direction that the hole faces toward the lower side of the vehicle. 2. Assemble the shift & selector shaft in the case. 3. Assemble the shift inner lever on the control shaft. 4. Assemble of wave washer, nut and setting bolt. (1) Align the hole of the shift inner lever with the cut-out section of the shift & selector shaft. Proceed to tighten the set bolt to the specified torque. Tightening Torque: 39.2 - 49.0 Nm (2) Tighten the nut to the specified torque. Tightening Torque: 18.6 - 29.4 Nm 5. Assemble the differential case Assy. (09201-60017-0006. Assemble the shift interlock plate in the neutral position 7. Install the magnet into position, 8. Assembly of selecting & shifting bell crank support as- sembly (1) Assemble the restricting cam. Assemble the restricting cam in such a way that the slotted spring pin may be inserted into the hole ©) NOTE: * Be sure not to forget to attach the spring in place. * Assemble the restricting cam in such a way that the forward end of the restricting cam may be fitted into the bracket hole. (2) Assemble the magnet and selecting & shifting bell crank support assembly. Tightening Torque: 6.9-9.8Nm 9. Assemble the input shaft assembly and output shaft as- sembly, including the 1st and 2nd shift fork at the same time. (1) Assemble the 1st & 2nd shift fork onto the synchroniz- er sleeve for the 1st & 2nd gear use provided at the output shaft side. 40. Assemble the input shaft bearing lock plate. Tightening Torque: 14.7-21.6N-mMT-20 i; Assembly of the rd & th shift fork. NOTE: «Prior to the assembling, apply gear oil to the sliding section of each shift fork. (1) Assemble the Srd & 4th shift fork onto the synchronizer ‘sleeve for the Srd & 4th gear use provided at the input shaft side. Assemble the 1st & 2nd shift head, the 1st & 2nd shift fork shaft and the rd & 4th shift fork shaft. |. Assemble the reverse shift arm head Assemble the 5th & reverse shift fork shaft. Working from the direction as indicated in the figure, drive the slotted spring pin into position, until it becomes flush with the edge surface of the shift fork. . Assemble the compression spring, reverse idler gear and reverse idler gear shaft.Install the hole snap ring in the transmission case, . Transmission case assembly (1) Apply the Three Bond sealer 1216 or 1217 to the mat- ing surface of the housing. While the hole snap ring of the bearing is held in an expanded state, assemble the transmission case in the transaxle case, SST: 09905-00012-000 NOTE: ‘+ Make sure that the snap ring is fitted positively in the bearing, by raising the output shaft by your hand. (2) Tighten the housing attaching bolts. Tightening Torque: 14.7 -21.6Nm . Assemble the balls and compression springs. Assemble the lock ball plate and gasket. Tightening Torque: 6.9- 9.8 N-mMT-22 20. Assemble the output Sth gear and the conical spring washer for the output shaft. NOTE: + Tighten a new lock nut temporarily. 21, Assemble the 5th gear bush. 22. Assemble the 5th gear. 23. Assembly of transmission clutch hub (1) Assemble the clutch hub, aligning the spline-missing section of the clutch with the key installing section (in which teeth are missing at both sides) of the hub. (2) Assemble the synchronizer ring at one side of the clutch hub. Place the clutch hub on a level bench in such a way that the side where synchronizer ring has been assembled may come at the lower side. (3) Assemble the three shifting keys and spring in place. (4) Install the synchronizer ring. Turn over the hub assem- bly. (6) Detach the synchronizer ring that has been installed in the step (2). Install the other spring. NOTE: * Make sure that this spring does not come at the same position as the spring at the opposite side. ‘Conical spring Gear, Nut side | || > sice Daa24, (6) Install the synchronizer ring in place. Push the syn- chronizer ring in both directions by your both hands. Check to see if the synchronizing action takes place smoothly. NOTE: * The hub assembly for the 3rd and 4th gear use differs from the hub assembly for the Sth gear use only in the Inner diameter of the clutch hub. Other parts are shared in common. * The sleeve and cluteh do not have any installing direc- tion to be observed during their assembly. Assemble the transmission clutch hub assembly and the 5th gear shift fork and the synchronizer ring at the same time. Assemble the transmission hub sleeve stopper. Assemble the conical spring washer in such a way that its expanded side may face toward the transmission side. New lock nut installation (1) Make the gears in an interlocked state. (See page MT-10,) (2) Tighten the lock nut at the input shaft to the specified torque, using a socket whose width across flats is 32mm. Tightening Torque: 98.1 - 137.3 N-m (3) Tighten the lock nut at the output shaft to the specified torque. Tightening Torque: 96.1 - 137.3N-m Inetall the conical spring with its expanded side facing toward the tranemission sideMT-24 (4) Before the lock nut is staked, measure the end play of the 5th gear. Specified Value: 0.1 - 0.23 mm Limit: 0.4mm (6) Stake the lock nut, using a punch and a hammer. NOTE: * When staking the lock nut, point a suitable staking tool toward the output shaft axis center and stake the lock nut securely, as shown in the figure below. (Poor staking may cause abnormal noise.) (1) Suitable staking tool a (2) New nut - (@) Shatt (Conect) }s) 28. Drive the slotted spring pin into position, until it becomes flush with the edge surface of the shift fork. 29. Install the case cover oil pipe until its rib section comes into contact with the case. 30. Assembly of transmission case cover (1) Apply the liquid gasket sealer (Three Bond 1216 or 1217) to the mating surfaces of the case, except for those hole areas. (2) Tighten the transmission case installing bolts. (M6 bolts) Tightening Torque: 6.9 - 9.8 Nem ... 7 M6 bolts (#) (8) Tighten the transmission installing bolts together with the left mounting. (M8 bolts) Tightening Torque: 14.7 - 21.6 N-m....3 M8 bolts (<=)31 33, 34 Assemble the speedometer shaft sleeve subassembly and lock plate. (1) Insert the lock plate into the speedometer shaft sleeve subassembly. Then, insert the subassembly into the transmission case by hand. (2) Tighten the bolts. Tightening Torque: 6.9-9.8N-m Install the backup lamp switch wigasket and breather plug. Tightening Torques: 28.4-49.0Nm (Back up Lamp Switch) 9.8-12.7Nm (Breather Plug) NOTE: + Never reuse the removed gasket. Install the clutch cable bracket, Tightening Torque: 14.7-21.6 Nem Install the serew plugs (at the drain and filer sides). Tightening Torque: 28.4 - 49.0 Nm NOTE: + Never reuse the removed gaskets,MT-26 OEE APPLICATION POINTS OF GREASE & BOND AND APPLICATION PROCEDURE © NOTE: As for each gear clustered ‘on the input and output shafts ‘and the rotary and sliding sections of the oll seals, apply gear oll tothe entire ‘surtace of each part. SSSApplication Procedure for Liquid Gasket Sealer (Three Bond 1216 Or 1217) 1 Cut the first stage of the nozzle of the sealer (Three Bond 1216 or 1217) that is furnished in accessories. . Ba asim 2. Remove any remaining trace of the liquid gasket that may. be found on the housing or the case with thinner or a scraper. Care must be exercised not to scratch the sur- faces during the cleaning. Apply the liquid sealer to the entire periphery of the cover subassembly transmission case and the case without any unapplied spot, as indicated in the illustration af the right. NOTE: ‘+ Apply the liquid sealer to the inside of each hole, ex- cluding those bots holes. + Be sure to perform the assembling within five minutes after the application of the liquid sealer. * Make sure to dry the thinner completely. NOTE: ‘+ The liquid gasket starts to cure when it reacts with the moisture in the atmosphere. Hence, upon completion of the work, be sure to expel any air trapped in the tube and tighten the tube cap securely. + As regards the storage place for this liquid gasket, avoid such places where high temperature or high hu- midity prevails or those exposed to direct sunrays. Make sure to store it in a dry, cold and dark place. (The allowable limit for use is approximately six months.)MT-28 INPUT SHAFT COMPONENTS 2: Tightening torque Unit: Nom * i Non-reusabie parts: Lock nut ‘Synchronizer hub assembly No, 2 Conical washer Synchronizer ring Bearing Srd gear 4h gear bushing ® Shaft snap ring 4th ge Bearing Synereorizer ing Input shaft DTTOperation Prior to Disassembly 1. Pull out the input shaft and the output shaft at the same time from the transmission case. 2. Measure the end play of the ard gear and 4th gear. Part ‘Specified value mm Limit ram 3rd gear 01-037 05 ‘ath gear 01-023 04 DISASSEMBLY 1. Remove the bearing, using the following SST. SST: 08602-87301-000 2. Remove the 4th gear and 4th gear bush. 3. Remove the synchronizer ring. Then, remove the synchro- nizer hub assembly No. 2. Detach the two synchromesh shifting springs and three synchromesh shifting keys. 4, Remove the synchronizer ring and 3rd gear. ESMT-30 5. Detach the shaft snap ring, using two screwdrivers. NOTE: © Special care must be exercised as to the snap ring which may be lost during the disassembly. + Never reuse the shaft snap ring. 6. Remove the bearing, using the following SST. SST: 09602-87301-000 INSPECTION 1. Check the 4th and 5th gear bush for wear or damage. Part ‘Specified value mm Limit_mm Bore ®D (25,027 - 25.042 25,050 Outer diameter @ 36.940 - 36.960 36.890, Overall length ® 28.97 - 29.03 28.97 “Tienes ot Taamess ofange | 204-308 208 2. Check each gear for Wear or damage. Specifed vake om | __Umit mn Pant Bore | weam@ | BoeO | wiah® Sed geartinwa) rim srs] 723-2140] a725 | 272 sth gear (npui) —__frmocar | 25a0-2587| —a725 | 257 Selina section Gear section __ | visuaty inspect the section for excessive Tapered sacl 7B [ceerace or wos Both edge surfaces of gear Fiting section with | Wapect the section for excess pay, ick or hub sieeve @ | rounded edge.MT-31 8, Check the clutch hub and sleeve for the Grd & 4th gear use for wear or damage. Clutch Hub Part Limit Splined section ©. Sreciroresh sing, | cage or wer key fitting groove: Visually ingpect the section for excessive up-&-down direction and slant of ihe hub and sieeve. ‘With the hub fitted into the sleeve, check for excessive looseness in Sleeve Part | Specitied value mm Limit mm Shittiork groove a one @| 708-712 73 Fitting section with | Visually inspect the section for excessive ‘gear @ | damage, wear, nick or rounded edge. 4. Check the input shaft for wear or damage. Pan ‘Specified value mm Urrit mm ‘user diameter of bush Cae ae cien @ |. 25:002+25017 24.99 Tooth surfaces of Visually inspect the suriace lor excessive gearand spline __@ | damage, wear, nick or rounded edge. wear or damage. 5. Check the synchromesh shifting key and key spring for THE Part Specified value mm | __Limit mm Key for Sid & ath gear (dimension H) enna eo Song © | Visually inspect the spring for damage or 6. Check the synchronizer ring for wear or damage. mi Specie value Gap when dain synchronizer ring is 0.85 - 1.45 pressed to gear poe os ‘Damage atinner tapered section | vieuaily inspect the section for Cankggateeiine excessive damage,MT-32 7. Check the bearing for wear or damage. Part Inspection eriteria ‘When the inner race is tumed by Bearing \your fingers, it should tum ‘Smoothly without any binding. ASSEMBLY 43 Apply gear oil to the entire surface of the rotary or sliding section of each gear of the input shatt. 2. Assemble the bearing, using the following SST. SST: 09309-87201-000 3. Drive anew snap ring into position, using a screwdriver. For easier installation, hold the snap ring with the following SST. SST: 09909-87201-000 CAUTION: + Bevery careful not to scratch the shaft. 4, Assemble the 3rd gear. 5. Assemble the synchronizer ring and synchronizer hub as- sembly No. 2. (1) Assembie the clutch and sleeve. Ensure that both parts can slide smoothly. (2) Assemble the shifting keys and springs. NOTE: * Hook the key springs to the synchromesh shifting keys during the assembly, as shown in the right figure. TTS 09809-87201-000 TASTES Tae TOTSTTS DAT6. Assemble the synchronizer ring and 4th gear. 7. Assemble the 4th gear bushing. 8. Assemble the bearing, using the following SST. SST: 09309-87201-000 TSS ‘09008-87201-000 Dra 9. Upon completion of the assembly, measure the end play of each part of the input shaft. Part ‘Specified value mm Limit ram ‘rd gear 04-037 Os ‘ath gear 01-023 Oa NOTE: «Ifthe end play does not comply with the specification, ‘check the gear, bushing and clutch hub sliding section. Replace any parts which exhibit abnormality. DISCRIMINATION 1. Discrimination of synchronizer ring ‘Synchronizer ring No. 1 (For Grd, 4th and Sth gear)MT-34 OUTPUT SHAFT COMPONENTS 69-98 se iliaal @ 6 tf Unit: Nem * :Non-rousable parts ® 960-137 Q Lock nut {Q Bushing Conical spring washer ‘Synchronizer ring No. 3 Quan ser ‘Synchronizer hud assembly Synchronizer ring No. 2 Sua sh ons ‘st gear assembly drive gear vasher Sto 3rd gear Spring plats @ scissors gear issors gear Spring plate Output snatt ® 2nd gear assemblyOperation Prior to Disassembly 4, Pull out input and output shaft at the same time trom trans- mission case. 2. Measure the end play of the 1st and 2nd gear of the out- put shaft. Pant Specified vaue am Tint rom isi gear 01-04 05 2nd gear 04-028 04 DISASSEMBLY 1. Remove bearing, using following SST. SST: 09602-87301-000 2. Remove output 4th gear, speedometer drive gear, output 3rd gear, snap ring, scissors gear and spring plate. 3. Remove 2nd gear. 4, Remove 2nd gear bush and synchronizer ring No. 3. .09602-87801-000 ‘Scissors gear rd gear 4th gear 0 sprrifpate £0¢ ‘Snap ritig ‘Speedometer gearMT-36 5, Removal of synchronizer hub assembly. (1) Remove the two synchromesh shifting key springs and three synchromesh shifting keys. 6. Remove the synchronizer ring No. 2 and the 1st gear. 7. Remove the washer. wuras6room INSPECTION paar re re 1. Check the 2nd gear bushing for wear or damage. @ Part Speciiod valve com iit ram j E Bore @|_2887 28.885 2596 Outer diameler _@ | _ 98540-96:960 3689 ® ® Overall length 2 92.47 -32.53 92.47, 2. Check each gear for wear or damage. Specified value mm Grit mm a BoreO | wah® | Bore | wiaih® ‘st gear (output) {52.025 -32,050) 30.23-3030| 32.075 02 2nd gear (output) proov-aroas|saa0-22a7| 3705 | 322 3rd gear amn-a70es| 2728-270| 3705 | 272 “th gear ro0n- 3700s) 25@0-2587 | 97.058_| 257 ‘Sth gear 37.000 - 37.028) 25.80- 25.87 | 37.05 25.7 Splined section Tapered section @ Gaarsacien >] Vu nsec ne section fr excessive Boh edge surfaces gear @ Fiting section with | Inspect he section lor excessive pay, nick or hub sieeve ® | rounded edge.MT-37 3. Check the clutch hub for the ‘st & 2nd gears and reverse gear for wear or damage. Clutch Hub Part Limit rt Seinedeion —D] ay remine ro cee ee erianggean Ties as a dope, SOE a SF Stoneman tyeoasSonadiane Reverse Gear Part ‘Speciied value mmm init am ws 706-718 13 Fitting section with gear | Visualy inspect he section for excessive Reverse gear tooth | damage, wear, nick or rounded edge. surtace ® 4. Check the output shaft for wear or damage. Specified value Umit Fa mm. mm. Oat da led oer barge! sec | © | 29:979-30.000 | 20.96 Outer oi. of 1s pr-contact sc. @ | 31.971-31.991 31.96 Visually inspect the surface for Tooth surfaces of gear and spline | excessive damage, wear, nick or rounded edge. 5. Check the synchromesh shifting key and key spring for wear or damage. Par Specttied value rm mit em ‘Shing yor tt & and (rs (mansion) sae a © | Visually inspect te spring for damage or istorton, Spring ai 6. Check the synchronizer ring for wear or damage. | Spootegvane | __ unt Gap wen = Sewanee | IME,| oasis | os ote ‘Damage at inner tapered section Visually inspect the section for Damage at spline excessive damage. iE 1st& 2nd gear Reverse gear ® ® ® 1 a eee), Or 5mmMT-38 7. Check the bearing for wear or damage. Part Inspection crite Bearing ‘When the inner race is turned by your fingers, it should tum ‘smoothly without any binding, ASSEMBLY NOTE: ‘* Apply gear oil to the entire surface of the rotary or slid- ing section of each gear of the output shaft. 1. Assemble spring plate, scissors gear and snap ring. 2. Installation of the 1st gear 3. Assemble the washer. 4. Assembly of synchronizer hub assembly. (1) Assemble hub clutch and reverse gear. Ensure that both parts can slide smoothly. (2) Assemble the shifting keys and springs. NOTE: ‘+ Hook the key springs to the synchromesh shitting keys during the assembly, as shown in the right figure. (3) Assemble the synchronizer ring No. 2. 5. Assemble spring plate, scissors gear and snap ring to 2nd gear. Then, assemble synchronizer ring No. 3, bushing and 2nd gear,6. Assemble the output 3rd gear, speedometer drive gear and output 4th gear. NOTE: ‘© Apply gear oll to the entire surface of the rotary or slid- ing section of each gear. ® a g 1) 7. Assemble the bearing, using the following SST. SST: 09309-87201-000 NOTE: * The bearing should be assembled in such a way that the groove in the bearing outer race may come at the upper side. DISCRIMINATION 1. Discrimination of synchronizer ring Chip of tooth ‘Synchronizer ring No, 2 ‘Synchronizer ring No. 3 (For 1st gear) (For 2nd gear)MT-40 DIFFERENTIAL GEAR COMPONENTS : Tightening torque Unit: Nm + :Non-rousable parts, Radial ba bearing Ditferential side gear Radial ball bearing Differential side gear washer Q Ditlerential ring gear Gil seal ‘Slotted spring pin Ditferential case Differential pinion shatt © Diferential pinion washer Differential pinionBEARING NOTE: © Check bearings for wear and rough rotation. if bearings are normal condition, removal is not necessary. REMOVAL, 1. Remove the bearing at the engine side, using the follow- ing SST. SST: 09602-87301-000 2. Remove the bearing at the transmission side, using the following SST. SST: 09306-87302-000 NOTE: '* Grinding off the interfering section of the SST will make the operation easier. INSTALLATION 1. Assemble a new radial ball bearings, using the following SST. SST: 09618-87301-000 NOTE: + Install the racial ball bearings with the bearing having a larger outer diameter assembled at the ring gear side. DIFFERENTIAL GEAR INSPECTION 1. Check the differential ring geer for wear or damage. Pan Inspection onteria ‘Visually inspect the surface for Gear tooth surface ‘wear, Gamage, nick or rounded REMOVAL 1. Clamp the differential case in a vise. Remove the attach- ing bolts. /09618-87301-000MT-42 2. Remove the differential ring gear. if any difficulty in removing the ring gear is encountered, evenly tap the peripheral section of the ring gear, using a plastic hammer. INSTALLATION 1. Install the ring gear in such a way that the side having large chamfer at its inner diameter comes at the case side. 2. Tighten the ring gear attaching botts. Tightening Torque: 93.2- 105 Nm NOTE: «Be sure to attach the lock plate to the two bolts provid- ed in the pinion shaft direction. DIFFERENTIAL CASE DISASSEMBLY NOTE: * As for the side gears, pinions and pinion shaft, their disassembling and assembling operations can be car- ried out without removing both bearings or ring gear. . Disassemble the radial ball bearings. 2. Disassemble the ring gear. 3. Drive out the slotted spring pin, using a punch pin. NOTE: ‘+ Never reuse the slotted spring pin. Daa4. Pull out the differential pinion shatt. 5. Remove the pinions, pinion washers, side gears and side gear washers. INSPECTION 1. Check the side gears, pinions and pinion shaft for wear or damage. Past ‘Speciied value rom Lit rm Pinion shaft iting Pre saeE et) |" 1808-15.08 15.10 ‘Outer ciameter of oer 14944-14962 1496 ‘Check the gear tooth sulace and the enined section fhe side gear for wear or damage, 2. Check the side gear thrust washers and pinion washers for wear or damage. Pan ‘Speciiod value rom iit mm Thickness of trust ee 095-085 070 cata pine ‘Vaually nepect the section for excessive wear or damage. 3. Check the differential case for wear or damage. Pant Spectied valve mm Cit mim Dive shaft fitting hole >), eaPza, rae TRIE Pinion gear contact section _@ ‘Side gear thrust washer ‘Visually Inspect the section for excessive wear ‘or damage. Contact sectionMT-44 ASSEMBLY 1, Assemble the differential washers and differential side gears into the differential case. 2. Assembly of differential pinions and washers (1) Make the two pinions mesh with the side gears, work- ing from the case side. Rotate the side gear so that the pinion’s hole may align with the pinion shaft hole pro- vided in the case. 8. Assemble the differential pinion shaft. 4, Side gear backlash measurement (1) Fix the side gear at one side. (2) Measure the backlash of each side gear at the right and left sides at several points, using a dial gauge. Specified Backlash: 0.02 - 0.21 mm 5. New slotted spring pin installation (1) Align the pin hole of the pinion shaft with the corre- sponding pin hole in the case. (2) Working from the backside of the case (ring gear side), drive a new slotted spring pin into position, until it becomes flush with the case edge Surface. CSTEInstall the ring gear onto the differential case. Tighten the ring gear attaching bolts. Tightening Torque: 93.2 105 N-m NOTE: ‘Be sure to attach the lock plate to the two bolts provid- ed in the pinion shaft direction. Assemble the radial ball bearings. TSSMT-46 SHIFT LEVER & SELECTING ROD COMPONENTS 38-157 © Bott, ® Nut ‘only spare parts (Gasser & 8 Cezaz}-} REMOVAL 1. Jack up the vehicle. 2. Remove the lower arm bracket connecting rod. Remove the shift lever knob. Disconnect the shift & select shaft subassembly and the extension rod subassembly from the transaxle. NOTE: * Never reuse the removed attaching bolts of the shift & select shaft subassembly and the extension rod sub- assembly. po 5. Disconnect the floor shift support No. 2 of the extension rod subassembly from the boc6. Pull out the shift & select shaft subassembly together with the extension rod subassembly. INSTALLATION 1. Install the shift & select shaft subassembly together with the extension rod subassembly. 2. Connect the floor shift support No. 2 of the extension rod subassembly to the body. Tightening Torque: 9.8 - 15.7 Nem (Floor side) 3. Connect the shift & select shaft subassembly and the ex- tension rod subassembly to the transaxle. Tightening Torque: 16.7 - 30.4 Nm (Transaxle side) NOTE: ‘+ Be sure to use a new attaching bolts for both the shift & select shaft subassembly and extension rod sub- assembly. 4, Install the shift lever knob, 5. Install the front exhaust pipe. Tightening Torque: 41.2 - 62.7 Nm (Front side) 15.2 - 22.8 N-m (Rear side) NOTE: + Be sure to use a new exhaust pipe gasket and a new nut for rear side. 6. Install the lower arm bracket connecting rod. Tightening Torque: 39.2 - 92.1 Nm 7. Jack down the vehicle.MT-48 DISASSEMBLY 4. Detach the shift & select shaft subassembly from the body. Remove the snap ring by using a snap ring pliers. Remove the collar and bush for the shift knob. Remove the floor shift support No. 1. Remove the nut, washer, collar and the bush for the floor shift support No. 1. pep Remove the extension rod subassembly by using a grinder. Remove the shift & select shaft subassembly by using a grinder. Remove the control rod joint. Remove the bush and O-ring. ep ND INSPECTION Check each component for wear, damage, deformation or flattened condition. aaMT-49 ASSEMBLY 1 2 3. 4, Install a new O-ring. . Apply MP grease to both the inner and outer surfaces of the bush and install it. Install the control joint. . Assemble the shift & select shaft subassembly. NOTE: ‘+ In-case of the spare part, as the connecting method of the shift & select shaft and shift lever is bolt connect- ing, be sure not to mistake the connecting method. Install the extension rod subassembly. Install the nut, washer, collar and the bush for the floor shift support No. 1. Install the floor shift support No. 1. Tightening Torque: 15.7 - 20.6 N-m (Floor side) Install the collar and bush for the shift knob. Install a new snap ring by using a snap ring pliers. Install the shift & select shaft subassembly to the body.MT-50 APPENDIX SSTs (Special Service Tools) Part No. and name Purpose (09201-60011-000 \Valve guide bush remover & replacer ‘Assembling oll seal (08806-87302-000 ‘Counter gear front bearing puller Removal of bearing (99808-00010-000 Oil seal puller Removal of oll seal '99809-87201-000 Transmission bearing replacer ‘Assembling bearing (09515-87201-000 ear axle shatt bearing replacer Cip-end 616.5) ‘Assembling ol seal (09517-67705-000 il seal replacer (Transmission case side) ‘Assembling cl seal (09517-87706-000 Oil seal replacer (Clutch housing side) ‘Assembling ol seal '09602-8730-000, Counter gear bearing puller Removal of bearing (08606-87201-000 Front hub bearing remover & replacer (Tip-ena 924) Assembling ol seal LN Gites eyy (09618-87301-000 ‘Assembling bearing ‘Transmission bearing replacer (09005-00012-000 Removal of snap ring ‘Snap ring expander (09821-00010-000 Removal of ol seal Spring tension too!MT-51 SERVICE SPECIFICATIONS Unt Item Specitied value Allowatble limit Remarks inne ameter 28870-28888 2898 and gear bush Outer carter 36940-36060 26800 vera ength 32470-32590 war Taner meter 25027-25082 25.080 Outer diameter 36.940 - 36.960 36.890 sth and Sn gear bush vera engin 2s.870-29020 2e70 Teknets of fange : Tiel 294-908 aoe tstgear 10-040 as 2nd gear 00-028 aa End play re gear 0-037 08 ah gear ax0-028 oa ah gear 910-028 a tet gear 3023-2030 302 an gear 3220-2237 m2 Gear wan ara gear 2728-2730 22 an gear 2580-2587 237 gear 2580-2587 287 Bushinner damatr | 17000-1707 17.050 Revers idergoarand | Shak over dameter | 16947-16908 16200 Bush sat cieerance 3 s.000-8.058 82 Input shal outer meter 25002-25017 28 Bush insaing poston Fret 22879-90000 2098 utput shat outer caretr Pear sian -3198 a1g6 ‘Synchronizer ring-to-gear clearance 0.85 - 1.45 OsMT-52 Le hem ‘Specified value ‘Allowable limit | Remarks oe ie aa nats 1630 Differential pinion and _| iting hoe of pinion side gear Outer diameter of er sane ccc a Teresi iim a0 Caneel ang iad vaciaaR aaa See ee = Siasarials gous pa basa omen : Driven gear thalt 7.972-7.987 7.96 ‘Speedometer: ae giameter z a a ‘Shaft sleeve bore: 8.029 - 8.065 810 Thickness of tip-section of fork oh-75 eS y oases See accel al soto ‘Shitt fork Groove width of shift inner ase aad ee ze [SRR iee cpanel eae arm pin-contact-section 18.000- 15.043. = Sienna Sen Hi ech cane oa eho ee 10 = Maat as ones Tip end width 7.884 - 7.920 78 gai tak yore won! Seaton 708-732 = ee = —— on = Thickness of for 1st & 2nd 5.0-5.2 47 ey siting key for Sed & 4th, Sth 46-48 43. roodMT-53 TIGHTENING TORQUE Tightening component neia eee Nm aim Clutch cable bracket Traneanto 147-248 15-22 Surge tak stay No. x Transat 147-218 15-22 eer mount bracket x Tansaxe 290-685 50-70 Transaxle x Engine 490-686 50-70 Engine mount oackat ex Transaxle 290-686 50-70 E/G mt insulator left x Transaxle (Nut) 720-134 74-137 E/G mt. insulator left x Transaxle (Bolt) 48.0 -89.2 49-91 ‘Serge tank stay No. intake manifold 147-216 45-22 Staner x Transaxle 74-44 30-45 Stay» Traneaxto (510 244A 30-45 Engine mount insulator rearx Stay Nut 720-134 74-197 ‘Shit control sha x Transaxde 167-004 47-84 ‘Deve shal asserbiy x Allemator bracket 343-400 35-50 Lower arn x Fr. euspension cree member 167-265 170-250 Shock absorber (upper support) x Flame 28.4 -42.1 29-43 Power ran siffener x Transat 794-441 30-45 Power tain stiflener x Cynder lock 147-218 15-22 Engine mount ont brackel x Tense 294-441 30-45 Engine lower mounting subassembly x Flame 460-092 49-91 E/G mit nelator fe xE/G lower mi. mem. 720-136 74-197 E/G mt. rmuator xE/G ower mt mem 250-485 27-60 ‘Cuch ease cable x Clamp 39-69 04-07 Tieod end Knvcle Baan 30-45 Breather pg x Transaxle 98-127 40-13 Witead sraight screw plug (er ide) 294-490 30-50 Wihead straight screw plug (drain side) 29.4 - 49.0 30-50 ‘Speedometer sieve (Lock nat) x Tenses 60-98 07-10 Backup lamp switch assembly x Transaxle 294-490 30-50 Bearing ick pate x Bell crank 09-98 07-10 ‘Shift inner lever (Bolt) 30.2 -49.0 40-50 ‘Shift inner lever (Nut) 19.6 - 29.4 20-30 Lock rut nut shat 1-079) 100-140 Lock mtx Output shalt 981-1973 100-140 ier! case xing gear 35.1 105 95-107 Front exheust pipe (rent sie, bat) 12-627 42-64 Front exhaust pipe rear Sr) 152-228 16-23 Shi & select shal subassembly x Tansee 167-204 17-34 Exaension rod subassembly x Tranean 167-204 17-81 Foor shit suppor Ne, 2x Foot 167-004 17-88 Lower ai lt. Con rod x Lower arm 392-921 20-04 Foor shit suppor No. 1x Extension rod 157-206 16-2: Taro