You are on page 1of 92

MX–1

MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE SYSTEM

MANUAL TRANSAXLE SYSTEM
MX04X–01

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

Author :

Date :

1802

MX–2
MANUAL TRANSAXLE (E153) – TROUBLESHOOTING

TROUBLESHOOTING
MX04Y–01

PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace parts.
Symptom Suspect Area 1. Oil (Level low) 2. Oil (Wrong) 3. Gear (Worn or damaged) 4. Bearing (Worn or damaged) 1. Oil (Level too high) 2. Gasket (Damaged) 3. Oil seal (Worn or damaged) 4. O–Ring (Worn or damaged) 1. Control cable (Faulty) 2. Synchronizer ring (Worn or damaged) y g( g ) Hard to shift or will not shift 3. Shift key spring (Damaged) 3 See page MX–4 MX–4 MX 10 MX–10 MX–10 MX–4 MX–10 MX 10 MX–10 MX–10 MX–49 MX–10 MX–24 MX–31 MX–10 MX–24 MX–31 MX–10 MX–10 MX 10 MX–10 MX–10

Noise N i

Oil l k leakage

Jumps out of gear J t f

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

Author :

Date :

1803

MX–3
MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT

MANUAL TRANSAXLE UNIT
MX04Z–01

COMPONENTS
Hood
14 (150, 10)

w/ Cruise Control : Cruise Control Actuator Control Cable Clip
13 (130, 9)

12 (120, 9)

Clutch Line Bracket
21 (210, 15) 12 (120, 9)

Clutch Release Cylinder
26 (270, 20)

21 (210, 15)

Clip Washer Starter

Air Cleaner Case Assembly with Air Hose

RH Fender Apron Seal RH Drive Shaft
L 32 (330, 24) 7.8 (80, 69 in.·lbf)

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

Hold–Down Clamp Battery

Flywheel Housing Under Cover
46 (470, 34) 37 (380, 27)

RH Exhaust Manifold Stay LH Drive Shaft
LSnap

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

Ring

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

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

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

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

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

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

Hole Plug
80 (820, 59)

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

RH Fender Liner

Front LH Suspension Member Brace L Gasket

L 62 (630, 46) L

L

Front Exhaust Pipe No.1 Exhaust Pipe Support Bracket
33 (330, 24)

L 62 (630, 46)

Engine Rear Side Shutter Plate N·m (kgf·cm, ft·lbf) : Specified torque L Non–reusable part LH Fender Liner
33 (330, 24)

Exhaust Pipe Support Stay

Q09981

Author :

Date :

1804

Torque: 39 N·m (400 kgf·cm. Torque: 12 N·m (120 kgf·cm. 29 ft·lbf) DISCONNECT CLUTCH RELEASE CYLINDER Remove the 2 bolts and disconnect the release cylinder. Torque: Bolt: 21 N·m (210 kgf·cm. 9. (a) (b) 5. 15 ft·lbf) Nut: 26 N·m (270 kgf·cm. (a) (b) DISCONNECT ENGINE WIRE FROM CLAMP DISCONNECT VEHICLE SPEED SENSOR AND BACK–UP LIGHT SWITCH CONNECTORS DISCONNECT CONTROL CABLE Remove the 2 clips and washers. 8. Q09985 Author : Date : 1805 . 9 ft·lbf) 6. REMOVE HOOD HINT: At the time of installation. Q09984 7. Remove the 3 bolts and cruise control actuator with the bracket. Torque: 12 N·m (120 kgf·cm. (a) (b) Q09982 4. 9 ft·lbf) Remove the 2 set bolts and nut of the clutch accumulator. please refer to the following item. (See page BO–10) 2. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE 3. Remove the 2 clips from the cables. 20 ft·lbf) Remove the set bolt of the clutch line bracket. Remove the 2 bolts and starter. Adjust the hood.MX–4 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT MX050–01 REMOVAL 1. Torque: 13 N·m (130 kgf·cm. (a) (b) (c) Q09983 w/ Cruise Control: REMOVE CRUISE CONTROL ACTUATOR Disconnect the cruise control actuator connector. 9 ft·lbf) REMOVE STARTER Disconnect the connector and wire from the starter. DISCONNECT GROUND CABLE Remove the set bolt of the ground cable from the transaxle.

36 ft·lbf) REMOVE LH AND RH DRIVE SHAFTS (See page SA–25) 16.1 exhaust pipe support bracket.4 US qts. 41 ft·lbf) Remove the 2 set bolts of the No. 3.050 kgf·cm. 46 ft·lbf) Remove the 2 bolts. RAISE VEHICLE NOTICE: Make sure that the vehicle is securely supported. nuts and gasket. (a) (b) (c) Q09988 (d) (e) REMOVE FRONT EXHAUST PIPE Remove the 2 bolts and exhaust pipe support stay. 15. Torque: 62 N·m (630 kgf·cm. 76 ft·lbf) 12. Author : Date : 1806 . Torque: 33 N·m (330 kgf·cm. Torque: 33 N·m (330 kgf·cm. Drain Plug Q09987 DRAIN TRANSAXLE OIL Oil grade: API GL–4 or GL–5 Viscosity: SAE 75W–90 Capacity: 4. Q09986 REMOVE 5 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque: 17 mm head: 64 N·m (650 kgf·cm. REMOVE FRONT WHEEL Torque: 103 N·m (1.MX–5 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT 10. 47 ft·lbf) 11. 24 ft·lbf) Remove the front exhaust pipe. 13. qts) Torque: 49 N·m (500 kgf·cm. REMOVE ENGINE REAR SIDE SHUTTER PLATE AND LH AND RH FENDER APRON SEALS Filler Plug Oil Level 0 – 5 mm 14.2 liters (4.7 Imp. Torque: 56 N·m (570 kgf·cm. 24 ft·lbf) Remove the 4 nuts and 2 gaskets from the exhaust manifold.

(d) (e) Tie the PS gear assembly to the proper position with a code or an equivalent to suspend the assembly securely. REMOVE 3 ENGINE FRONT SIDE MOUNTING BOLTS Torque: Silver bolt: 44 N·m (450 kgf·cm. 14 ft·lbf) Remove the 2 bolts. Torque: 181 N·m (1. 35 ft·lbf) Q09991 19. 29 ft·lbf) Remove the 4 set bolts of the stabilizer bar bracket. DISCONNECT FRONT ENGINE ABSORBER FROM TRANSAXLE Remove the 2 bolts. Torque: 48 N·m (490 kgf·cm. 14 ft·lbf) Q09992 20. 48 ft·lbf) Q09993 Author : Date : 1807 . nut and stay. 134 ft·lbf) Q09990 18. (a) (b) (c) Q09989 DISCONNECT PS GEAR ASSEMBLY FROM FRONT SUSPENSION MEMBER Remove the 2 nuts and disconnect the stabilizer bar link from the stabilizer bar.MX–6 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT 17. Torque: 39 N·m (400 kgf·cm. Torque: 19 N·m (195 kgf·cm. Torque: 20 N·m (200 kgf·cm.850 kgf·cm. REMOVE RH EXHAUST MANIFOLD STAY Remove the bolt. 33 ft·lbf) Green bolt: 66 N·m (670 kgf·cm.1 fuel tube protector. nut and No. Remove the 2 set bolts and nuts of the PS gear assembly.

Torque: 7. 14 mm Head B (a) (b) 14 mm Head A REMOVE FLYWHEEL HOUSING UNDER COVER AND TRANSAXLE LOWER SIDE MOUNTING BOLT Remove the 2 bolts and cover. nuts and 3 bolts. 48 ft·lbf) 23. JACK UP TRANSAXLE SLIGHTLY Using a transmission jack. 14 mm Head B 27. (a) (b) Q09994 REMOVE LH ENGINE MOUNTING INSULATOR WITH BRACKET Remove the 2 hole plugs. 69 in. (b) Remove the 6 bolts. 47 ft·lbf) Nut: 80 N·m (820 kgf·cm. Q09995 C A C A C C A A B B Q09996 REMOVE HOLE PLUG AND 4 ENGINE REAR SIDE MOUNTING NUTS Torque: 66 N·m (670 kgf·cm. 59 ft·lbf) Lift up the transaxle and remove the left engine mounting insulator with the bracket. Torque: Bolt A: 181 N·m (1. 22. Torque: Bolt: 64 N·m (650 kgf·cm.MX–7 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT 21. 24 ft·lbf) Nut C: 36 N·m (370 kgf·cm. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER (See page EM–69) 24. DISCONNECT STEERING RETURN PIPE FROM FRONT SUSPENSION MEMBER Remove the 2 bolts. 27 ft·lbf) 26. rear LH and RH suspension member braces and front suspension member with the lower suspension arm. 34 ft·lbf) 14 mm head B: 37 N·m (380 kgf·cm. Torque: 14 mm head A: 46 N·m (470 kgf·cm. 27 ft·lbf) Q09997 Author : Date : 1808 .8 N·m (80 kgf·cm. Torque: 10 N·m (100 kgf·cm.850 kgf·cm. REMOVE FRONT SUSPENSION MEMBER WITH LOWER SUSPENSION ARM (a) Remove the LH and RH fender liner set screws. front LH and RH suspension member braces.·lbf) Remove the 3 bolts of the transaxle lower side. support the transaxle. 7 ft·lbf) 25. 134 ft·lbf) Bolt B: 32 N·m (330 kgf·cm. 4 nuts.

MX–8 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT 28. please refer to the following items. Author : Date : 1809 . L Align the input shaft with the clutch disc and install the transaxle to the engine. L Temporarily tighten the transaxle mounting bolts. REMOVE TRANSAXLE Lower the engine left side and remove the transaxle from the engine. HINT: At the time of installation.

check and inspect items as follows. Author : Date : 1810 . HINT: After installation. L Do the road test.MX–9 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT MX051–01 INSTALLATION Installation is in the reverse order of removal (See page MX–4). L Front wheel alignment (See page SA–4).

ft·lbf) : Specified torque Non–reusable part Z19124 Author : Date : 1811 . 65 in. 13) Transmission Oil Pipe Transmission Oil Pipe Magnet 17 (175. 13) Vehicle Speed Sensor Clutch Release Line Bracket Cover Transaxle Case Receiver 7. 13) 17 (175. 13) Transmission Oil Pump Assembly Differential Case Assembly Oil Pump Drive Gear N·m (kgf·cm.4 (75. 13) Control Level Housing Support Bracket O–ring Boot 17 (175. 13) Elbow 27 (275.·lbf) 17 (175. 35) 17 (175. 13) Transaxle Case Transmission Oil Cooler Sub–Assembly 34 (350. 20) O–ring Output Shaft Cover Tapered Roller Bearing Outer Race Front Oil Seal Input Shaft Front Bearing 17 (175. 25) 17 (175.MX–10 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE ASSEMBLY MX052–02 COMPONENTS Clutch Release Fork Assembly with Bearing Clutch Release Fork Support 47 (480.

3 Shift Fork Shaft No. 17) Straight Screw Plug L 25 (250. 13) Ball Snap Ring No. ft·lbf) : Specified torque Non–reusable part LPrecoated part x 10 Q10278 Author : Date : 1812 . 14) No.2 Shift Fork L Straight Screw Plug L 13 (130. 14) Gasket Breather Plug 49 (500. 17) No. 13) L 20 (200.2 Oil Receiver Pipe x 17 17 (175.1 Oil Receiver Pipe Shift and Select Lever Shaft Assembly 29 (300. 9) Gasket Slotted Spring Pin Shift and Select Lever Shaft Lock Bolt 49 (500. 36) Transmission Case Transmission Case Cover N·m (kgf·cm. 36) 29 (300. 18) Interlock Roller No. 17) 24 (240. 36) 20 (200.2 Shift Fork Shaft Snap Ring Snap Ring L 25 (250.3 Shift Fork Back–Up Light Switch 40 (410. 22) No.1 Shift Fork 24 (240. 18) L 25 (250.MX–11 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY Reverse Shift Arm Bracket Assembly Snap Ring Reverse Shift Fork No. 18) Seat Spring No. 30) Shift Head 24 (240. 22) Drain Plug 49 (500.1 Shift Fork Shaft 17 (175.2 Selecting Bellcrank with Selecting Bellcrank Support Gasket Gasket Filler Plug 49 (500. 36) L Gasket L L Reverse Restrict Gasket Pin No.

31) x7 Rear Bearing Retainer Snap Ring 5th Driven Gear Key Spring Inner Synchronizer Ring Middle Synchronizer Ring Outer Synchronizer Ring Synchronizer Pull Ring Key Spring No. 22) Thrust Washer Shim L 42 (430.3 Clutch Hub No.250.3 Hub Sleeve Snap Ring Output Shaft Lock Nut 123 (1. 90) Spacer Needle Roller Bearing 5th Gear Snap Ring N·m (kgf·cm. ft·lbf) : Specified torque Non–reusable part LPrecoated part Z17555 Author : Date : 1813 .MX–12 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY Input Shaft Assembly Output Shaft Assembly Tapered Roller Bearing Outer Race Reverse Idler Gear Reverse Idler Gear Shaft Lock Bolt L 29 (300.

3 hub sleeve and No. REMOVE RELEASE FORK AND BEARING REMOVE BACK–UP LIGHT SWITCH WITH GASKET Torque: 40 N·m (410 kgf·cm. Sealant: Part No.3 shift fork set bolt.3 shift fork. THREE BOND 1344.2 SELECTING BELLCRANK WITH SELECTING BELLCRANK SUPPORT Remove the 2 bolts and No. 2. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK BOLT WITH GASKET Torque: 49 N·m (500 kgf·cm. (a) Q00449 (b) REMOVE OUTPUT SHAFT LOCK NUT Unstake the lock nut.3 HUB SLEEVE AND NO. Remove the lock nut. REMOVE NO. THREE BOND 1344. 08833 – 00080. Torque: 123 N·m (1. 14 ft·lbf) 5. Author : Date : 1814 . Sealant: Part No.2 selecting bellcrank with the selecting bellcrank support. FIPG: Part No. 36 ft·lbf) Q05816 9. 08826 – 00090. shift and select lever shaft assembly and gasket.3 SHIFT FORK Remove the No. LOCTITE 242 or equivalent Torque: 20 N·m (200 kgf·cm. (a) (b) (c) (d) 10. Torque: 24 N·m (240 kgf·cm.MX–13 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY MX053–02 DISASSEMBLY 1. Engage the gear double meshing. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY WITH GASKET Remove the 4 bolts. 14 ft·lbf) FIPG 7. 36 ft·lbf) 6. 22 ft·lbf) 8. 08833 – 00080. LOCTITE 242 or equivalent Torque: 20 N·m (200 kgf·cm. REMOVE NO. THREE BOND 1281 or equivalent Torque: 29 N·m (300 kgf·cm. REMOVE BOLT AND VEHICLE SPEED SENSOR Torque: 17 N·m (175 kgf·cm. 90 ft·lbf) Disengage the gear double meshing. 30 ft·lbf) 3. REMOVE TRANSMISSION CASE COVER Remove the 10 bolts and transmission case cover. 17 ft·lbf) Remove the No.250 kgf·cm. 13 ft·lbf) 4. REMOVE BREATHER PLUG WITH GASKET Torque: 49 N·m (500 kgf·cm.

0028 in. measure the thrust clearance. measure the radial clearance.10 – 0.75 (0.80 (0.0039 – 0.85 (0.90 (0.0807) 2.009 – 0.0787) 2.0709) 1. Mark a b c d Q00299 Thickness mm (in.10 (0. HINT: At the time of reassembly.0729) 1.0748) 1.MX–14 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY 11. (a) Z01306 Using a dial indicator.05 (0.0256 in.0827) 2. please refer to the following item.) Maximum clearance: 0.) 1. tap out the snap ring. remove the 5th driven gear.65 mm (0. (a) MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE Using a dial indicator.) REMOVE NO. Standard clearance: 0.) 2.57 mm (0.0847) – e Author : Date : 1815 .) Maximum clearance: 0. Standard clearance: 0.0224 in.070 mm (0.0004 – 0.95 (0.0689) 1. SST 09950–30010 SST Q05849 12.00 (0.3 CLUTCH HUB AND 5TH GEAR Using 2 screwdrivers and a hammer.) Z01304 (b) 13.0768) Mark f g h j – Thickness mm (in. Select a snap ring that allows the minimum axial play. REMOVE 5TH DRIVEN GEAR Using SST.0020 in.15 (0.050 mm (0.

THREE BOND 1344. 08833 – 00080. remove the No. remove the input shaft rear bearing snap ring. SPRING AND LOCKING BALL Using a hexagon wrench (6 mm). remove the plug. (a) (b) Q01615 REMOVE STRAIGHT SCREW PLUG. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT Sealant: Part No. SST 09950–30010 14. REMOVE NEEDLE ROLLER BEARING AND SPACER 15. 18 ft·lbf) Using a magnetic finger. Q06190 17. LOCTITE 242 or equivalent Torque: 42 N·m (430 kgf·cm. (a) (b) REMOVE SNAP RING Using a snap ring expander. THREE BOND 1344. Q00056 Author : Date : 1816 . 22 ft·lbf) 18. THREE BOND 1344. 31 ft·lbf) 16. Sealant: Part No. 08833 – 00080. Sealant: Part No. spring and locking ball. remove the 7 torx screws and rear bearing retainer.3 clutch hub with the synchronizer ring and 5th gear. 08833 – 00080. LOCTITE 242 or equivalent Torque: 25 N·m (250 kgf·cm. LOCTITE 242 or equivalent Torque: 29 N·m (300 kgf·cm. Using 2 screwdrivers and a hammer.MX–15 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY (b) SST Z01308 Using SST. remove the seat. REMOVE REAR BEARING RETAINER Using a torx socket wrench (T45). remove the 2 snap rings. SEAT.

(b) Remove the 2 bolts and oil pipe. REMOVE REVERSE IDLER GEAR AND SHAFT Pull out the shaft. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY Remove the bolt and pull off the reverse shift arm and bracket. REMOVE SHIM HINT: At the time of reassembly. FIPG: Part No. REMOVE TRANSMISSION OIL PIPE (a) Remove the gasket from the oil pipe. as shown. please refer to the following item. Install the previously selected shim by adjusting output shaft preload. 13 ft·lbf) 23. 13 ft·lbf) 24. Q06375 Matchmarks HINT: At the time of reassembly. remove the output shaft rear taper roller bearing outer race. REMOVE TRANSMISSION CASE Remove the 17 bolts and tap the case with a plastic hammer. Align the matchmarks. SST 09316–60011 (09316–00011) 22. 22 ft·lbf) Q05815 20. (See page MX–22) MT0669 21. Torque: 17 N·m (175 kgf·cm. SST MT0693 REMOVE OUTPUT SHAFT REAR TAPER ROLLER BEARING OUTER RACE Using SST and a hammer.MX–16 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY FIPG 19. THREE BOND 1281 or equivalent Torque: 29 N·m (300 kgf·cm. and remove the reverse idler gear and thrust washer. 08826 – 00090. Torque: 17 N·m (175 kgf·cm. Z17557 Author : Date : 1817 . please refer to the following item.

REMOVE NO.2 SHIFT FORK SHAFT. 08833 – 00080.2 shift fork shaft.2 SHIFT FORKS AND SHIFT HEAD SET BOLT Torque: 24 N·m (240 kgf·cm. HINT: At the time of reassembly. remove the interlock roller from the reverse shift fork.3 shift fork shaft with the reverse shift fork. and remove the No.3 shift fork shaft. Sealant: Part No. NO. (a) (b) Q01614 REMOVE STRAIGHT SCREW PLUG.2 and No.2 SHIFT FORK Pull out the No. pull up the No.MX–17 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY 25.3 shift fork shaft. REMOVE SNAP RING Using 2 screwdrivers and a hammer. LOCKING BALL AND SPRING Using a hexagon wrench (6 mm). SHIFT HEAD AND NO. Q08125 29. REMOVE INTERLOCK ROLLER Using a magnetic finger. Author : Date : 1818 . remove the 3 snap rings from the No. remove the 2 seats. Using 2 screwdrivers and a hammer. remove the snap ring and reverse shift fork from the No.2 shift fork.1 shift fork shaft. Remove the shift head and No. (a) (b) Z00182 REMOVE NO. THREE BOND 1344.3 shift fork shaft. 26. (a) (b) REMOVE NO. please refer to the following item.1.1 SHIFT FORK SHAFT Pull up the No.1. When it is difficult to push the fork shaft through the reverse shift fork. No. Remove the No. Q08124 REMOVE NO. 18 ft·lbf) Using a magnetic finger.3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO.1 SHIFT FORK Pull out the No. 28. remove the 2 plugs. 17 ft·lbf) 27. LOCTITE 242 or equivalent Torque: 25 N·m (250 kgf·cm.3 shift fork shafts. (a) (b) 31. Q08126 30. springs and balls.1 shift fork.

remove the input shaft assembly. 13 ft·lbf) 36. (a) MT0781 (b) HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring. Author : Date : 1819 . (a) (b) 34.5 synchronizer ring with the key spring from the No.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO. (a) (b) 33. REMOVE DIFFERENTIAL CASE ASSEMBLY Remove the oil pump drive gear. remove the output shaft assembly. REMOVE NO. (c) Remove the synchronizer rings. REMOVE MAGNET FROM TRANSAXLE CASE REMOVE TRANSMISSION OIL PUMP ASSEMBLY AND OIL PIPE Remove the 2 bolts and oil pipe. Torque: 17 N·m (175 kgf·cm. Torque: 17 N·m (175 kgf·cm. Remove the differential case assembly. (a) (b) REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY Leaning the output shaft to the differential side. 13 ft·lbf) Remove the 2 bolts and oil pump assembly.MX–18 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY 32. remove the snap ring. Using a screwdriver. 35.3 CLUTCH HUB Remove the No.3 clutch hub. Lift up the differential case assembly.

pull out the bearing. Using SST. Check that the ring locks.5 synchronizer ring in one direction while pushing it to the outer No.MX–19 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY MX054–01 INSPECTION 1.0 mm (0. 65 in. 09950–70010 (09951–07150) Install the transaxle case receiver. measure the clearance between the hub sleeve and shift fork. replace the shift fork or hub sleeve. remove the oil seal. SST 09612–65014 Using a screwdriver. Torque: 7.·lbf) Q08014 Author : Date : 1820 .) If the clearance exceeds the maximum. drive in a new bearing.039 in. If it does not lock. 09950–70010 (09951–07150) Coat the lip of seal with MP grease. Check the braking effect of the synchronizer ring. WM0066 3.5 SYNCHRONIZER RING Check for wear or damage. MT0782 2. (a) (b) INSPECT NO. MEASURE SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge. Install and torque the 3 bolts. Maximum clearance: 1. SST (a) (b) (c) IF NECESSARY. SST 09950–60010 (09951–00580).5 synchronizer ring. SST 09608–00081. REPLACE INPUT SHAFT BEARING AND OIL SEAL Remove the 3 bolts and transaxle case receiver. drive in a new oil seal. Turn the middle No. Z00192 SST (d) (e) Using SST. replace the synchronizer ring.4 N·m (75 kgf·cm. Z00194 (f) SST (g) (h) Using SST.

pull out the output shaft front bearing outer race. REPLACE OUTPUT SHAFT FRONT BEARING OUTER RACE AND OUTPUT SHAFT FRONT COVER Using SST. drive in a new output shaft front bearing outer race. remove the inner race. install a new input shaft front bearing inner race. HINT: Install the output shaft cover projection into the case side groove. SST 09316–60011 (09316–00021) SST Q00141 4.MX–20 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY (i) SST Using SST and a press. SST 09316–60011 (09316–00011. (c) Install a new output shaft cover. 09316–00021) SST Q06368 Author : Date : 1821 . Z00197 (d) SST Using SST and a hammer. SST (a) (b) Q00338 IF NECESSARY. SST 09308–00010 Remove the output shaft cover. SST 09950–00020 Q05164 (j) Using SST and a press.

Apply sealant to the screw plug threads. REPLACE REVERSE RESTRICT PIN Using a hexagon wrench (6 mm). Using a pin punch and hammer. Torque: 13 N·m (130 kgf·cm.MX–21 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY (e) Using SST and a socket wrench. install a new output shaft front bearing. 08833 – 00080. drive in the slotted spring pin. drive out the slotted spring pin. 9 ft·lbf) Author : Date : 1822 . 09950–00030 SST Socket Wrench Q00245 (f) Using SST and a press. Replace the reverse restrict pin. SST 09316–60011 (09316–00071) SST Z00199 5. remove the screw plug. THREE BOND 1344. SST 09950–00020. install and torque the screw plug. remove the output shaft front bearing. (a) (b) (c) IF NECESSARY. Sealant: Part No. LOCTITE 242 or equivalent Using a hexagon wrench (6 mm). Q01611 (d) (e) (f) Z00201 Using a pin punch and hammer.

Torque: 29 N·m (300 kgf·cm. If installing a new taper roller bearing. HINT: L Before reassembly. HINT: If necessary. first select and install a shim of lesser thickness than before. Torque: 42 N·m (430 kgf·cm. first install a shim of the same thickness as before. (e) Install the adjusting shim. install and torque the 7 torx screws. 31 ft·lbf) (h) Install a new lock nut to the output shaft. 22 ft·lbf) (d) Install the output shaft rear taper roller bearing outer race.MX–22 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY MX055–01 REASSEMBLY Reassembly is in the reverse order of disassembly. L Coat all of the sliding and rotating surfaces with gear oil before reassembly. tap on the case with a plastic hammer. HINT: When reusing the output shaft bearing. (b) Install the transmission case to the transaxle case. ADJUST OUTPUT SHAFT PRELOAD (a) Install the output shaft assembly to the transaxle case. (g) Using a torx wrench (T45). select a shim by adjusting output shaft preload. Author : Date : 1823 . (i) Turn the output shaft right and left 2 or 3 times to allow the bearing to settle. (f) Install the rear bearing retainer. (c) Install and torque the 17 bolts.

0925) 2.0689) 1.0807) 2.05 mm change in adjusting shim thickness.45 (0.0630) 1. Removal is in the reverse order of installation.3 – 8.65 (0.0945) 2.·lbf) If the preload is not within the specification.5 N·m (4 – 5 kgf·cm.35 (0.MX–23 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY (j) Z12593 Using a torque wrench.·lbf) for every 0.3 in.40 (0.0728) 1.0906) 2.7 in.50 (0.0886) 2.40 (0.95 (0.0610) 1. L Rear bearing retainer L Shim L Transmission case L Output shaft assembly L Output shaft rear bearing outer race Author : Date : 1824 .20 (0.55 (0.8 – 1.0551) 1.9 in.0768) 2.0591) 1.9 – 13. 6.6 N·m (8 – 16 kgf·cm.15 (0. select an appropriate adjusting shim.0512) 1.0748) Mark D E F G H J K L M N P Q – Thickness mm (in. 0.0984) – (k) (l) Remove the lock nut.05 (0.0787) 2.0 N·m (5 – 10 kgf·cm.·lbf) Reused bearing 0. 3. Mark 0 1 2 3 4 5 6 7 8 9 A B C Thickness mm (in.30 (0.5 – 4. The preload will change approx.60 (0.0669) 1.50 (0.0531) 1.0866) 2.35 (0.00 (0.0827) 2.4 – 0.0965) 2. 4.45 (0.85 (0.0571) 1.75 (0. Preload (at starting): New bearing 0.0846) 2.0709) 1.90 (0.30 (0.5 – 1.) 1. Remove these parts. measure the preload.) 1.80 (0.25 (0.10 (0.0650) 1.70 (0.

2 Clutch Hub Shifting Key LNon–reusable part Input Shaft MT0791 Author : Date : 1825 .2 Hub Sleeve No.MX–24 MANUAL TRANSAXLE (E153) – INPUT SHAFT INPUT SHAFT MX056–01 COMPONENTS Spacer Synchronizer Ring 4th Gear Snap Ring Needle Roller Bearing 3rd Gear Needle Roller Bearing Rear Bearing Spring Snap Ring LInput Shaft Front Bearing Inner Race Synchronizer Ring No.

) Maximum clearance: 3rd and 4th gears: 0.60 mm (0.) 4th gear: 0. needle roller bearing or shaft.0021 in. replace the gear.35 mm (0. SST 4. tap out the snap ring.10 – 0. CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE Using a dial indicator.0028 in.10 – 0.) 4th gear: 0.55 mm (0.009 – 0.40 mm (0. REMOVE NEEDLE ROLLER BEARING. Q05165 Author : Date : 1826 . tap out the snap ring. Standard clearance: 3rd gear: 0. 3. REMOVE SNAP RING Using 2 screwdrivers and a hammer. REMOVE REAR BALL BEARING AND 4TH GEAR Using SST and a press.051 mm (0. measure the thrust clearance.0004 – 0. SPACER AND SYNCHRONIZER RING 6.0236 in.0039 – 0. Standard clearance: 3rd gear: 0.0039 – 0.) 4th gear: 0.070 mm (0.MX–25 MANUAL TRANSAXLE (E153) – INPUT SHAFT MX057–01 DISASSEMBLY 1.0138 in.0217 in.0004 – 0. remove the rear bearing. measure the radial clearance between the gear and shaft.0157 in.) If the clearance exceeds the maximum.) Maximum clearance: 3rd gear: 0.0020 in. SST 09950–00020 5.009 – 0. REMOVE SNAP RING Using 2 screwdrivers and a hammer.053 mm (0. MEASURE 3RD AND 4TH GEARS THRUST CLEARANCE Using a feeler gauge.) 3rd Gear 4th Gear Q06369 Q00111 2.

3rd gear and synchronizer rings. REMOVE NEEDLE ROLLER BEARING Q00115 Author : Date : 1827 .2 hub sleeve. remove the No. SYNCHRONIZER RING AND 3RD GEAR Using a press.2 CLUTCH HUB ASSEMBLY. 8.MX–26 MANUAL TRANSAXLE (E153) – INPUT SHAFT 7. REMOVE NO.

(d) WM0064 Using a feeler gauge. Check the braking effect of the synchronizer ring. measure the clearance between the synchronizer ring back and gear spline end.8 mm (0. Minimum clearance: 0. Minimum clearance: 0.7 mm (0. MT0780 (c) Using a feeler gauge. Lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.) If the clearance is less than the minimum. Check that the ring locks. MT0786 2. Check that the ring locks. replace the synchronizer ring. measure the clearance between the synchronizer ring back and spline end. If the braking effect is insufficient.028 in.MX–27 MANUAL TRANSAXLE (E153) – INPUT SHAFT MX058–01 INSPECTION 1. (a) (b) INSPECT 3RD GEAR SYNCHRONIZER RING Check for wear or damage. and apply a small amount of the fine lapping compound on gear cone. apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. (a) (b) WM0064 INSPECT 4TH GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. replace the synchronizer ring. (c) Check again the braking effect of the synchronizer ring.) If the clearance is less than the minimum. Author : Date : 1828 . replace the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. If it does not lock. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.031 in.

Maximum clearance: 1.039 in. measure the clearance between the hub sleeve and shift fork.0 mm (0.950 mm (1. Maximum runout: 0. MEASURE NO.) If the clearance exceeds the maximum.2 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge. replace the shift fork or hub sleeve.) Q00172 (c) Using a dial indicator. Using a micrometer.05 mm (0. (a) (b) INSPECT INPUT SHAFT Check the input shaft for wear or damage.) Q00173 Author : Date : 1829 . Minimum outer diameter: Part A: 27.950 mm (1.1004 in.MX–28 MANUAL TRANSAXLE (E153) – INPUT SHAFT 3.4154 in.) Part B and C: 35. WM0066 C B A 4.0020 in. measure the outer diameter of the input shaft journal surface. check the shaft runout.

SST 09506–35010 SST Q00183 3. SYNCHRONIZER RING AND NO.1004) 2.0984) 2.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT Apply MP grease to the needle roller bearing. Author : Date : 1830 . Front Q00383 2.55 (0.45 (0. HINT: Direct identification groove of the hub sleeve to front of the transmission. Thickness mm (in.50 (0. Place the synchronizer rings on the gear and align the ring slots with the shifting keys. MT0790 (d) Using SST and a press.2 CLUTCH HUB INTO HUB SLEEVE (a) Install the 3 springs and shifting keys to the clutch hub. (b) Install the hub sleeve to the clutch hub. (a) (b) (c) INSTALL NEEDLE ROLLER BEARING.0906) 2. (a) H J K L Q00116 INSTALL SNAP RING Select a snap ring that allows the minimum axial play.) 2.1024) – Mark (b) Using a screwdriver and hammer. 3RD GEAR.0945) 2.60 (0. INSTALL NO.MX–29 MANUAL TRANSAXLE (E153) – INPUT SHAFT MX059–02 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.) 2. tap in the snap ring. install the 3rd gear and No.30 (0.0925) 2. 1.2 hub sleeve. Assemble the needle roller bearings into the 3rd gear.0965) Mark M N P – Thickness mm (in.35 (0.40 (0.

install the rear ball bearing. Thickness mm (in.50 (0.70 (0.MX–30 MANUAL TRANSAXLE (E153) – INPUT SHAFT 4.1043) 2. MEASURE 3RD GEAR THRUST CLEARANCE (See page MX–24) 5. MEASURE 4TH GEAR THRUST CLEARANCE (See page MX–24) Author : Date : 1831 . Using SST and a press.65 (0. tap in the snap ring.35 (0.1063) Mark Q00116 (b) 7. (a) (b) (c) SST N00494 (d) (e) 6.45 (0.1024) 2.0965) 2.1004) 2.0984) Mark 5 6 7 8 Thickness mm (in. Place the synchronizer ring on the gear and align the ring slots with the shifting keys. (a) 1 2 3 4 INSTALL SPACER. Using a screwdriver and hammer.0945) 2. Install the 4th gear.0925) 2. 4TH GEAR AND REAR BALL BEARING Install the spacer.) 2.60 (0.40 (0. SYNCHRONIZER RING.) 2. NEEDLE ROLLER BEARING. SST 09506–35010 INSTALL SNAP RING Select a snap ring that allows the minimum axial play.55 (0. Apply MP grease to the needle roller bearings.

1 Hub Sleeve 2nd Gear Spacer Shifting Key LOutput Shaft Rear Bearing Shifting Key Spring Spacer 1st Gear Synchronizer Ring No.1 Clutch Hub S Synchronizer Ring LOutput Shaft Front Bearing Output Shaft N00785 LNon–reusable part Author : Date : 1832 .MX–31 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT OUTPUT SHAFT MX05A–01 COMPONENTS Needle Roller Bearing 3rd Driven Gear 4th Driven Gear Spacer Needle Roller Bearing No.

REMOVE 3RD DRIVEN GEAR AND 2ND GEAR Using a press.070 mm (0.10 – 0.50 mm (0.) 2nd gear: 0.) 1st Gear 2nd Gear Q06370 Z00218 2.0039 – 0. REMOVE NEEDLE ROLLER BEARING. 3. measure the radial clearance between the gear and shaft. REMOVE SNAP RING Using a snap ring expander.10 – 0.0028 in.0157 in. Z00220 Author : Date : 1833 .35 mm (0. Z00219 4. measure the thrust clearance.40 mm (0.) Maximum clearance: 1st and 2nd gears: 0. SPACER AND SYNCHRONIZER RING 6. replace the gear.) If the clearance exceeds the maximum. remove the snap ring.0039 – 0. Standard clearance: 1st gear: 0.0020 in. (b) Remove the spacer.) Maximum clearance: 1st gear: 0. Standard clearance: 1st gear: 0. needle roller bearing or shaft.009 – 0.0021 in. REMOVE OUTPUT SHAFT REAR BEARING.) 2nd gear: 0. remove the bearing and 4th driven gear.0004 – 0. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE Using a dial indicator.053 mm (0.009 – 0.0138 in.0177 in.) 2nd gear: 0.0197 in.0004 – 0.MX–32 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT MX05B–01 DISASSEMBLY 1. 5. remove the 3rd driven gear and 2nd gear. 4TH DRIVEN GEAR AND SPACER (a) Using a press.051 mm (0. MEASURE 1ST AND 2ND GEARS THRUST CLEARANCE Using a feeler gauge.45 mm (0.

1 HUB SLEEVE ASSEMBLY AND 1ST GEAR Using a press. REMOVE NO.1 hub sleeve and 1st gear. 09950–00030 SST Q00296 Author : Date : 1834 . remove the No.MX–33 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT 7. remove the output shaft front bearing. REMOVE SYNCHRONIZER RING AND NEEDLE ROLLER BEARING Z00222 9. 8. SST 09950–00020. REMOVE OUTPUT SHAFT FRONT BEARING Using SST.

028 in. Minimum clearance: 0.) If the clearance is less than the minimum. measure the clearance between the synchronizer ring back and gear spline end. INSPECT 2ND GEAR SYNCHRONIZER RING (a) Check for wear or damage. Turn the synchronizer ring in one direction while pushing it to the gear cone. Turn the synchronizer ring in one direction while pushing it to the gear cone. replace the synchronizer ring.7 mm (0. (b) Check the braking effect of the synchronizer ring. WM0064 (d) WM0065 Using a feeler gauge.8 mm (0. and apply a small amount of the fine lapping compound on gear cone. Check the braking effect of the synchronizer ring. (a) (b) INSPECT 1ST GEAR SYNCHRONIZER RING Check for wear or damage. measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.) If the clearance is less than the minimum.MX–34 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT MX05C–02 INSPECTION 1. replace the synchronizer ring. apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. MT0787 Author : Date : 1835 . NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. replace the synchronizer ring. (c) Check again the braking effect of the synchronizer ring. Check that the ring locks.031 in. Check that the ring locks. 2. Lightly rub the synchronizer ring and gear cone together. If the braking effect is insufficient. If it does not lock. MT0780 (c) Using a feeler gauge. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

Maximum clearance: 1.06 mm (0.) Z00223 (c) Using a dial indicator. (a) (b) INSPECT OUTPUT SHAFT Check the output shaft for wear or damage. check the shaft runout. measure the outer diameter of the output shaft journal surface.1 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge. WM0066 4.MX–35 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT 3. Using a micrometer.039 in.5335 in. measure the clearance between the hub sleeve and shift fork.) If the clearance exceeds the maximum. Minimum outer diameter: 38. Maximum runout: 0.) Z00224 Author : Date : 1836 .0 mm (0.950 mm (1. MEASURE NO.0024 in. replace the shift fork or hub sleeve.

Place the synchronizer ring (for the 1st gear) on the gear and align the ring slots with the shifting keys.1 hub sleeve. Z00225 (d) SST Using SST and a press.1102) 2.1181) 3.90 (0. Front Q00384 2. NOTICE: Position the key springs so that their end gaps are not aligned. install the 1st gear and No.80 (0.1220) – Mark (b) Using a snap ring expander.1142) 2.05 (0. Author : Date : 1837 . SST 09316–60011 (09316–00041) Z00385 3. (a) (b) (c) INSTALL NEEDLE ROLLER BEARING.95 (0.1201) 3.MX–36 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT MX05D–01 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.1 CLUTCH HUB INTO HUB SLEEVE (a) Install the clutch hub and shifting keys to the hub sleeve. Install the 1st gear.1161) Mark E F G – Thickness mm (in. (a) A B C D Z00386 INSTALL SNAP RING Select a snap ring that allows the minimum axial play.1122) 2. INSTALL NO. Thickness mm (in.00 (0. 1.10 (0.) 3. (b) Install the shifting key springs under the shifting keys. 1ST GEAR.) 2. SYNCHRONIZER RING AND NO.85 (0.1 HUB SLEEVE TO OUTPUT SHAFT Apply MP grease to the needle roller bearing. install the snap ring.

NOTICE: Align the clutch hub grooves with the projections on the synchronizer ring. INSTALL OUTPUT SHAFT REAR BEARING Using SST and a press. MEASURE 1ST GEAR THRUST CLEARANCE (See page MX–31) 5. SYNCHRONIZER RING. SST 09506–30012 SST Z00391 Author : Date : 1838 . (b) Apply MP grease to the needle roller bearing. install the 4th driven gear. (a) (b) INSTALL SPACER AND 4TH DRIVEN GEAR Install the spacer. (c) Place the synchronizer rings (for the 2nd gear) on the gear. MT0792 INSTALL SPACER. install the bearing. NEEDLE ROLLER BEARING. 2ND GEAR AND 3RD DRIVEN GEAR (a) Install the spacer. Using a press. NOTICE: Do not install the synchronizer ring for the 1st gear. 6. MEASURE 2ND GEAR THRUST CLEARANCE (See page MX–31) N00495 7. (d) Install the 2nd gear. install the 3rd driven gear.MX–37 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT 4. Z00390 8. (e) Using a press.

MX–38 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT 9. SST 09316–60011 (09316–00071) SST Z00392 Author : Date : 1839 . INSTALL OUTPUT SHAFT FRONT BEARING Using SST and a press. install a new output shaft front bearing.

ft·lbf) : Specified torque LNon–reusable part Z17558 Author : Date : 1840 .MX–39 MANUAL TRANSAXLE (E153) – OIL PUMP OIL PUMP MX05E–01 COMPONENTS LO–Ring LGasket Oil Strainer Oil Pump Driven Rotor 10 (105. 8) N·m (kgf·cm. 8) Transmission Oil Pump Case Oil Pump Drive Rotor Oil Pump Drive Gear Relief Valve Ball Spring Spring Holder Oil Pump Cover 10 (105.

(a) (b) CHECK ROTOR BODY CLEARANCE Install the oil pump drive gear to the drive rotor.0063 in.30 mm (0.10 – 0.08 – 0. Standard clearance: 0. measure the body clearance between the drive rotor and oil pump case.0118 in.08 mm (0.0059 in.0039 – 0. CHECK SIDE CLEARANCE Using a precision straight edge and feeler gauge.0012 – 0.15 mm (0. Using a feeler gauge.) Maximum clearance: 0.0031 in. (a) (b) Z00243 3. Standard clearance: 0.) Maximum clearance: 0.0118 in.) Maximum clearance: 0.MX–40 MANUAL TRANSAXLE (E153) – OIL PUMP MX05F–01 INSPECTION 1. Using a feeler gauge.30 mm (0.15 mm (0.) Z00242 2. Standard clearance: 0.) Z00244 Author : Date : 1841 .0031 – 0.03 – 0. measure the tip clearance between the drive and driven rotors. measure the side clearance of both rotors.) CHECK ROTOR TIP CLEARANCE Install the oil pump drive gear to the drive rotor.16 mm (0.0059 in.

2 Shift Inner Lever No.MX–41 MANUAL TRANSAXLE (E153) – SHIFT AND SELECT LEVER SHAFT SHIFT AND SELECT LEVER SHAFT MX05G–02 COMPONENTS Dust Boot LOil Seal Control Shaft Cover Snap Ring No.1 Select Spring Seat Slotted Spring Pin No.2 Compression Spring Snap Ring No.1 Compression Spring Shift Interlock Plate No.1 Shift Inner Lever Slotted Spring Pin Shift and Select Lever Shaft LNon–reusable part MP Grease Q10276 Author : Date : 1842 .2 Select Spring Seat No.

40) Differential Spider Differential Pinion Differential Side Gear Side Gear Thrust Washer Pinion Thrust Washer Tapered Roller Bearing and Outer Race 63 (640.MX–42 MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE DIFFERENTIAL CASE MX05H–01 COMPONENTS Transaxle Case Cover L L Stud Bolt 54 (550.260. 40) L Oil Seal L 54 (550. 91) Oil Baffle Oil Seal Z17560 Author : Date : 1843 . 46) Differential Right Case Vehicle Speed Sensor Drive Gear Differential Left Case x 16 Ring Gear Tapered Roller Bearing and Outer Race x 16 Shim 124 (1.

REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Using a screwdriver. Remove the oil baffle. Using a brass bar and hammer. (b) Remove the 16 bolts. remove the left and right bearings. Remove the vehicle speed sensor drive gear from the differential right case. remove the 16 torx screws. tap the differential left case. 4 differential pinions and pinion thrust washers from the differential left case. drive out the bearing outer race lightly and evenly. REMOVE RING GEAR (a) Place matchmarks on both the differential case and ring gear. tap the ring gear and remove it.MX–43 MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE MX05I–03 DISASSEMBLY SST Q05166 1. SST 09950–40011 2. Install the shim. Remove the shim. (a) (b) (c) (d) DISASSEMBLE DIFFERENTIAL CASE Place matchmarks on the differential right and left cases. Z00284 4. Using a plastic hammer. (a) (b) (c) Z00286 (d) (e) HINT: First select and install a shim of less thickness than before. 3. (See page MX–42) Author : Date : 1844 . remove the oil seal. Matchmarks Z00281 (e) Remove the 2 differential side gears. (c) Using a plastic hammer. side gear thrust washers. Using a torx wrench (T50). REMOVE TAPERED ROLLER BEARING Using SST. Transmission Case Side: IF NECESSARY.

REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Remove the 4 bolts and 3 nuts. 09316–00041) Z00288 (g) Install the oil baffle. Z00289 SST (h) (i) Using SST and a hammer. Using a plastic hammer. install a new tapered roller bearing outer race. (a) (b) (c) MT0659 Transaxle Case Side: IF NECESSARY. drive in a new oil seal. Using a screwdriver and hammer.MX–44 MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE (f) SST Using SST and a press. HINT: Install the oil baffle projection into the case side cutout. a brass bar and hammer. remove the tapered roller bearing outer race. drive out the oil seal from the transaxle case cover. SST (d) Using SST. SST 09612–65014 Z01427 Author : Date : 1845 . 09950–70010 (09951–07150) Coat the lip of oil seal with MP grease. tap the stud bolt and remove the transaxle case cover. SST 09223–15020. Q06288 5. SST 09316–60011 (09316–00011.

install a new tapered roller bearing outer race. LOCTITE 242 or equivalent Install the stud bolt and cover to the transaxle case. Sealant: Part No. 09316–00041) Z00292 (f) (g) Using SST and a hammer. 40 ft·lbf) Author : Date : 1846 . Install and torque the 4 bolts and 3 nuts. FIPG: Part No. 08826 – 00090. THREE BOND 1344. SST Z00293 (h) FIPG (i) F Z19038 (j) (k) Apply FIPG to the transaxle case cover. as shown. THREE BOND 1281 or equivalent Apply sealant to the bolt threads.MX–45 MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE SST (e) Using SST and a press. SST 09316–60011 (09316–00011) Coat the oil seal lip with MP grease. drive in a new oil seal. Torque: 54 N·m (550 kgf·cm. SST 09316–60011 (09316–00011.08833 – 00080.

MX–46
MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE
MX05J–01

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

Z00295

(e)

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

Z00296

(f)

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

Z00297

(g)

Install the vehicle speed sensor drive gear.

Z00298

Author :

Date :

1847

MX–47
MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE

(h) (i)
Matchmarks

(j)

2. (a)
Z00299

(b) (c) (d)

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

Driven Gear Side

Z00303

HINT: Align the matchmarks on the differential left case. (e) Temporarily install the 16 bolts. NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently. (f) After the ring gear has cooled sufficiently, torque the ring gear set bolts. Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf) 3. INSTALL TAPERED ROLLER BEARING Using SST and a press, install new left and right bearings onto the differential case. SST 09316–20011, 09316–60011 (09316–00011) HINT: Press the bearing on the ring side first. 4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD (See pages MX–22) 5. INSTALL DIFFERENTIAL CASE ASSEMBLY TO TRANSAXLE CASE 6. INSTALL OUTPUT SHAFT ASSEMBLY Lift up the differential case and install the output shaft assembly. 7. INSTALL TRANSMISSION CASE (a) Install the transmission case. HINT: If necessary, tap on the case with a plastic hammer. (b) Install and torque the 17 bolts. Torque: 29 N·m (300 kgf·cm 22 ft·lbf)

SST

SST
Q06410

Author :

Date :

1848

MX–48
MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE

8.

INSTALL OUTPUT SHAFT REAR TAPERED ROLLER BEARING OUTER RACE Using a plastic hammer, drive in the outer race. 9. INSTALL SHIM (See pages MX–22) HINT: Install the previously selected shim. 10. INSTALL REAR BEARING RETAINER Using a torx wrench (T45), install and torque the 7 torx screws. Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) 11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD (a) Install a new lock nut to the output shaft. (b) Turn the output shaft right and left 2 or 3 times to allow the bearings to settle. (c) Using a torque wrench, measure the preload. Preload (at starting): New bearing (Output shaft preload plus) 0.2 – 0.3 N·m (1.8 – 3.5 kgf·cm, 1.6 – 3.0 in.·lbf) Reused bearing (Output shaft preload plus) 0.1 – 0.2 N·m (1.1 – 2.2 kgf·cm, 1.0 – 1.9 in.·lbf) If the preload is not within the specification, select an appropriate adjusting shim. HINT: The total preload will change by about 0.1 – 0.2 N·m (1 – 2 kgf·cm, 0.9 – 1.7 in.·lbf) with each 0.05 mm change in adjusting shim thickness.
Mark
Z00309

Q00036

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

Mark 9 A B C D E F G H

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

0 1 2 3 4 5 6 7 8

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

Author :

Date :

1849

9 (50. 9) Clip Clip Shift Lever Assembly Clip Clip Clip Clip Washer Washer Clip Shift Control Cable Washer Select Control Cable N·m (kgf·cm.·lbf) Shift Cable Grommet Clip 4.·lbf) 12 (120.MX–49 MANUAL TRANSAXLE (E153) – SHIFT LEVER AND CONTROL CABLE SHIFT LEVER AND CONTROL CABLE MX05K–01 COMPONENTS Shift Lever Knob Center Console Upper Panel Heater Control Assembly Center Cluster Finish Panel Rear Console Box Front Console Box Shift Cable Grommet Retainer Shift Cable Grommet Retainer Grommet 4. 43 in.9 (50. 43 in. ft·lbf) : Specified torque Q10281 Author : Date : 1850 .

L Clean both sealing surfaces with a non–residue solvent. remove all the old FIPG material from the gasket surfaces.) wide bead along the sealing surface. the FIPG material must be removed and reapplied.MX–1 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE SYSTEM MANUAL TRANSAXLE SYSTEM MX04A–01 PRECAUTION When working with FIPG material. L Thoroughly clean all components to remove all the loose material. Otherwise. Author : Date : 1851 .04 in. L Apply FIPG in an approx. L Using a razor blade and gasket scraper. L Parts must be assembled within 10 minutes of application. 1 mm (0. you must observe the following items.

O–ring (Worn or damaged) 1. Oil (Wrong) 3. Locking ball spring (Damaged) 2. Control cable (Faulty) 2.MX–2 MANUAL TRANSAXLE (S51) – TROUBLESHOOTING TROUBLESHOOTING MX04B–04 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. Gasket (Damaged) 3. Shift fork (Worn) 3. Oil (Level too high) 2. Gear (Worn or damaged) 4. The numbers indicate the priority of the likely cause of the problem. If necessary. Synchronizer ring (Worn or damaged) y g( g ) Hard to shift or will not shift 3. Gear (Worn or damaged) 4. Symptom Suspect Area 1. Shift key spring (Damaged) 3 See page MX–4 MX–4 MX 9 MX–9 MX–9 MX–4 MX–9 MX 9 MX–9 MX–9 MX–43 MX–9 MX–20 MX–28 MX–9 MX–20 MX–28 MX–9 MX–9 MX 9 MX–9 MX–9 Noise N i Oil l k leakage Jumps out of gear J t f 1. Bearing (Worn or damaged) Author : Date : 1852 . replace these parts. Bearing (Worn or damaged) 1. Oil seal (Worn or damaged) 4. Oil (Level low) 2. Check each part in order.

61 in. 134) Silver Bolt: 44 (450.850. 9) Clip Washer 12 (120. 134) Silver Bolt: 44 (450. 94) 39 (400. 47) 19 (195.·lbf) Clutch Release Cylinder Air Cleaner Case Assembly with Air Hose RH Drive Shaft L Snap Ring L 32 (330. 9) Bracket w/ Cruise Control: Cruise Control Actuator 13 (130.MX–3 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE UNIT MX04C–01 COMPONENTS Hood 14 (145.1 Exhaust Pipe Support Bracket 33 (330. 217) Steering Return Pipe 181 (1.9 (70. 7) 64 (650. 47) L Snap Ring LH Drive Shaft LH Fender Apron Seal Manifold Stay Rear End Plate with Oil Pan 42 (425. 27) Back–Up Light Switch Connector 64 (650.850. 48) Front LH Suspension Member Brace Hole Plug 80 (820. 14) Exhaust Pipe Bracket N·m (kgf·cm. 47) Hold–Down Clamp Battery LH Stiffener Plate 37 (380. 46) Front Exhaust Pipe No. 24) L L Gasket 56 (570. 31) Insulator Rear RH Suspension Member Brace 36 (370. 24) 10 (100. 29) 33 (330. 29) RH Fender Apron Seal 37 (380. 27) 9. 27) 32 (330.300. 9) 6. 33) Green Bolt: 66 (670. 14) L Engine LH Mounting Insulator with Bracket 181 (1. 41) RH Fender Liner Engine Rear Side Shutter Plate LH Fender Liner L 62 (630. ft·lbf) : Specified torque L Non–reusable part Q09998 Author : Date : 1853 .000. 33) Green Bolt: 66 (670.3 (95. 134) PS Gear Assembly No. 48) Hole Plug 66 (670. 59) L Gasket Lock Cap L Cotter Pin L Cotter Pin Rear LH Suspension Member Brace Stabilizer Bar Link 127 (1.850. 29) RH Stiffener Plate Vehicle Speed Sensor 46 (470. 82 in.·lbf) Transaxle 64 (650. 27) 181 (1. 10) Control Cable Clip Clutch Line 12 (120. 36) 294 (3. 24) 19 (195. 48) Suspension Member with Lower Suspension Arm Front RH Suspension Member Brace 36 (370. 34) Connector Ground Cable Starter 39 (400. 29) Manifold Stay 39 (400. 24) 39 (400.1 Fuel Tube Protector 49 (500.

(a) (b) 5. 9 ft·lbf) Remove the 2 set bolts of the clutch line bracket. Torque: 13 N·m (130 kgf·cm. Q10001 Author : Date : 1854 . Remove the 2 bolts and starter. REMOVE HOOD HINT: At the time of installation. (a) (b) A B Q09999 w/ Cruise Control: REMOVE CRUISE CONTROL ACTUATOR Disconnect the cruise control actuator connector. DISCONNECT VEHICLE SPEED SENSOR AND BACK–UP LIGHT SWITCH CONNECTORS 9. 9 ft·lbf) Bolt B: 6. DISCONNECT GROUND CABLE Remove the set bolt of the ground cable from the transaxle. please refer to the following item. (a) (b) Q09982 4. 29 ft·lbf) DISCONNECT CLUTCH RELEASE CYLINDER Remove the 2 bolts and disconnect the release cylinder. Torque: 39 N·m (400 kgf·cm. Q10000 7. (b) Remove the 2 clips from the cables. DISCONNECT CONTROL CABLE (a) Remove the 2 clips and washers.9 N·m (70 kgf·cm. 9 ft·lbf) REMOVE STARTER Disconnect the connector and wire from the starter. Torque: 12 N·m (120 kgf·cm.MX–4 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE UNIT MX04D–01 REMOVAL 1.·lbf) 6. (See page BO–10) 2. REMOVE MANIFOLD STAY Remove the 2 bolts and stay. 31 ft·lbf) 8. 61 in. Torque: Bolt A: 12 N·m (120 kgf·cm. Torque: 42 N·m (425 kgf·cm. Remove the 3 bolts and cruise control actuator with the bracket. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE 3. Adjust the hood.

MX–5 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE UNIT 14 mm Head 10. 46 ft·lbf) Remove the 2 bolts. RAISE VEHICLE NOTICE: Make sure that the vehicle is securely supported. (a) REMOVE FRONT EXHAUST PIPE Remove the 2 bolts. Torque: 62 N·m (630 kgf·cm. Torque: 56 N·m (570 kgf·cm. 47 ft·lbf) 14 mm head: 46 N·m (470 kgf·cm. 34 ft·lbf) 11. Oil Level 0 – 5 mm Filler Plug 15. Torque: Bolt: 19 N·m (195 kgf·cm. REMOVE ENGINE REAR SIDE SHUTTER PLATE AND LH AND RH FENDER APRON SEALS 14. nuts and gasket.6 liters (2. 17 mm Head Q10002 REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque: 17 mm head: 64 N·m (650 kgf·cm. 24 ft·lbf) Remove the front exhaust pipe. 13. qts) Torque: 49 N·m (500 kgf·cm. 24 ft·lbf) Q10010 (b) (c) (d) (e) Q10004 Remove the 3 nuts and gasket from the exhaust manifold. REMOVE FRONT WHEEL Torque: 103 N·m (1. 14 ft·lbf) Nut: 33 N·m (330 kgf·cm. DRAIN TRANSAXLE OIL Oil grade: API GL–4 or GL–5 Viscosity: SAE 75W–90 Capacity: 2.3 Imp. Torque: 33 N·m (330 kgf·cm. nut and exhaust pipe bracket. 41 ft·lbf) Remove the 2 set bolts of the No. 76 ft·lbf) 12. 2.7 US qts.1 exhaust pipe support bracket. Author : Date : 1855 .050 kgf·cm. 36 ft·lbf) REMOVE LH AND RH DRIVE SHAFTS (See page SA–16) Drain Plug Q10003 16.

1 fuel tube protector. 29 ft·lbf) Remove the 4 set bolts of the stabilizer bar bracket. Torque: 10 N·m (100 kgf·cm. Torque: 181 N·m (1. Tie the PS gear assembly to the proper position with a code or an equivalent to suspend the assembly securely. nuts and 3 bolts. Torque: 39 N·m (400 kgf·cm. REMOVE 3 ENGINE FRONT SIDE MOUNTING BOLTS Torque: Silver bolt: 44 N·m (450 kgf·cm. 33 ft·lbf) Green bolt: 66 N·m (670 kgf·cm. 14 ft·lbf) Remove the 2 bolts.850 kgf·cm. Remove the 2 set bolts and nuts of the PS gear assembly. 48 ft·lbf) Q10005 19. DISCONNECT STEERING RETURN PIPE FROM FRONT SUSPENSION MEMBER Remove the 2 bolts. (a) (b) (c) (d) (e) Q09989 DISCONNECT PS GEAR ASSEMBLY FROM FRONT SUSPENSION MEMBER Remove the 2 nuts and disconnect the stabilizer bar link from the stabilizer bar. 59 ft·lbf) Lift up the transaxle and remove the left engine mounting insulator with the bracket. Q10007 REMOVE HOLE PLUG AND 3 ENGINE REAR SIDE MOUNTING NUTS Torque: 66 N·m (670 kgf·cm. Torque: 19 N·m (195 kgf·cm. 47 ft·lbf) Nut: 80 N·m (820 kgf·cm. nut and No. (a) (b) Q10006 REMOVE LH ENGINE MOUNTING INSULATOR WITH BRACKET Remove the 2 hole plugs. Torque: Bolt: 64 N·m (650 kgf·cm. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER (See page EM–69) 22. 20.MX–6 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE UNIT 17. 48 ft·lbf) 21. 7 ft·lbf) Author : Date : 1856 . 134 ft·lbf) Q09990 18.

(b) Remove the 6 bolts. Author : Date : 1857 . Torque: 39 N·m (400 kgf·cm. JACK UP TRANSAXLE SLIGHTLY Using a transmission jack. Q10009 REMOVE REAR END PLATE WITH OIL PAN INSULATOR AND RH STIFFENER PLATE (a) Remove the 2 bolts and rear end plate with the oil pan insulator. HINT: At the time of installation. 4 nuts. L Temporarily tighten the transaxle mounting bolts.3 N·m (95 kgf·cm. 29 ft·lbf) 27.·lbf) (b) Remove the 2 bolts and manifold stay. Torque: 37 N·m (380 kgf·cm. 82 in. 24 ft·lbf) Nut C: 36 N·m (370 kgf·cm. 27 ft·lbf) Q10011 26. support the transaxle. 134 ft·lbf) Bolt B: 32 N·m (330 kgf·cm. 25. 27 ft·lbf) 24. L Align the input shaft with the clutch disc and install the transaxle to the engine. rear LH and RH suspension member braces and front suspension member with the lower suspension arm. front LH and RH suspension member braces. Torque: 39 N·m (400 kgf·cm. Torque: Bolt A: 181 N·m (1. 29 ft·lbf) (c) Remove the 4 bolts and RH stiffener plate.850 kgf·cm. REMOVE LH STIFFENER PLATE Remove the 3 bolts and LH stiffener plate. please refer to the following items. A C A C C B A A B Q10008 REMOVE FRONT SUSPENSION MEMBER WITH LOWER SUSPENSION ARM (a) Remove the LH and RH fender liner set screws. REMOVE TRANSAXLE Lower the engine left side and remove the transaxle from the engine. Torque: 9.MX–7 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE UNIT C 23.

Author : Date : 1858 . HINT: L Front wheel alignment (See page SA–4).MX–8 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE UNIT MX04E–01 INSTALLATION Installation is in the reverse order of removal (See page MX–4). L Do the road test.

36) x 17 Lock Bolt Spacer Needle Roller Bearing 5th Gear No. ft·lbf) : Specified torque Non–reusable part L Precoated part L 29 (300. 29) Gasket L 42 (430. 27) Slotted Spring Pin Shim Selecting Bellcrank Release Bearing Boot Differential Side Bearing Retainer Transmission x6 Case Protector Transmission Case Gasket O–Ring L 18 (185.·lbf) Vehicle Speed Sensor Straight Screw Plug L 13 (130. 65 in.3 Clutch Hub Assembly N0.3 Shift Fork 18 (185. 31) x5 Rear Bearing Retainer Lock Nut 29 (300. 13) 29 (300. 22) Gasket Snap Ring 5th Driven Gear Snap Ring x8 N·m (kgf·cm.4 (75.250. 33) Shift and Select Lever Assembly 37 (375. 22) 123 (1.·lbf) Reverse Restrict Pin L 29 (300.3 Hub Sleeve No.4 (55. 9) Lock Ball Assembly 7. 22) Back–UP Light Switch 44 (450. 27) 37 (380. 90) Filler Plug 49 (500. 48 in.MX–9 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE ASSEMBLY MX04F–02 COMPONENTS Release Bearing Retainer 5. 22) Transmission Case Cover Z19123 Author : Date : 1859 . 13) Drain Plug Clutch Release Fork Release Fork Support 39 (400. 13) 18 (185.

1 Shift Head No. 13) Reverse Idler Gear and Shaft N·m (kgf·cm.MX–10 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY Reverse Shift Fork Interlock Pin Transaxle Case Oil Seal No. ft·lbf) : Specified torque Non–reusable part Output Shaft Front Bearing Output Shaft Cover Z18962 Author : Date : 1860 .2 Shift Fork Transaxle Case Receiver 7.1 Shift Fork Shaft Differential Case Assembly Input Shaft Front Bearing Bearing Lock Plate Input Shaft Assembly Reverse Shift Arm Output Shaft Assembly 18 (185.4 (75.·lbf) No. 65 in.2 Shift Fork Shaft No.1 Shift Fork No.

22 ft·lbf) REMOVE SHIFT AND SELECT LEVER ASSEMBLY Author : Date : 1861 . 08826 – 00090.08833 – 00080.4 N·m (75 kgf·cm. (a) (b) FIPG Z18142 7. THREE BOND 1344.MX–11 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY MX04G–02 DISASSEMBLY 1. 8.·lbf) 5. 27 ft·lbf) 6. 27 ft·lbf) REMOVE TRANSMISSION CASE COVER Remove the 8 bolts. 08826 – 00090.4 N·m (55 kgf·cm. REMOVE RELEASE FORK AND BEARING REMOVE BACK–UP LIGHT SWITCH Torque: 44 N·m (450 kgf·cm.08833 – 00080. THREE BOND 1281 or equivalent Torque: 37 N·m (375 kgf·cm. HINT: At the time of installation. REMOVE SELECTING BELLCRANK Remove the 2 bolts and selecting bellcrank. tap the transmission case cover and remove it. FIPG: Part No. LOCTITE 242 or equivalent Torque: 29 N·m (300 kgf·cm. 48 in.·lbf) 4. please refer to the following item. 22 ft·lbf) Using a plastic hammer. 2. Torque: 37 N·m (380 kgf·cm. THREE BOND 1281 or equivalent REMOVE LOCK BALL ASSEMBLY Sealant: Part No. FIPG: Part No. Apply FIPG to the underside of the flanged portion of the control shaft cover. LOCTITE 242 or equivalent Torque: 29 N·m (300 kgf·cm. THREE BOND 1344. 65 in. REMOVE RELEASE BEARING RETAINER Remove the 3 bolts and retainer. REMOVE BOLT AND VEHICLE SPEED SENSOR Torque: 5. 33 ft·lbf) 3. Sealant: Part No. Torque: 7.

11. (a) (b) REMOVE OUTPUT SHAFT LOCK NUT Unstake the nut.0157 in. Q02530 (c) Install Rotate the lock nut clockwise and remove it.0079 – 0. 10. 90 ft·lbf) Remove Q05696 HINT: The lock nut has LH threads.45 mm (0.3 shift fork. Standard clearance: 0.0177 in.) Q02695 Author : Date : 1862 . (d) Disengage the gear double meshing.3 shift fork set bolt.3 hub sleeve and No.MX–12 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY 9.250 kgf·cm. REMOVE 5TH DRIVEN GEAR Using SST. remove the 5th driven gear. install the 5th driven gear. please refer to the following item.20 – 0.40 mm (0. REMOVE NO. MEASURE 5TH GEAR THRUST CLEARANCE Using a dial indicator. Torque: 123 N·m (1.) Maximum clearance: 0. SST 09950–40011 SST Q05200 HINT: At the time of installation. Torque: 18 N·m (185 kgf·cm. 13 ft·lbf) (b) Remove the No. Engage the gear double meshing. Using SST. measure the thrust clearance.3 HUB SLEEVE AND NO.3 SHIFT FORK (a) Remove the No. SST 09309–12020 SST SST Z00455 12.

0866–0. REMOVE NO.60 (0.0925–0.65–2.1063) 2.55–2.1122–0. replace the gear.70 (0. tap out the snap ring.25–2.1142–0.1083) 2.1063–0.0945–0.45 (0.1142) 2.65 (0.30–2.25 (0.80–2.80 (0.75–2.1161) – 14 22 15 23 16 24 17 25 18 26 19 27 20 – (b) Using SST and a socket wrench.90 (0.85–2.1043–0.1102–0.90–2.35 (0.85 (0.1083–0. 14.0020 in.0965–0.MX–13 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY Q02696 13.) 2.30 (0.1004) 2. please refer to the following item.40–2.75 (0.0906–0.20–2.50–2.40 (0.) Maximum clearance: 0.55 (0.070 mm (0. SST 09950–30010 SST Socket Wrench Q02726 Author : Date : 1863 .1024–0. remove the No.45–2.1102) 2.60–2.0945) 2.0925) 2. Mark 13 Thickness mm (in.0984) 2.0004 – 0.50 (0.1043) 2.35–2.0886–0.0028 in.0906) 2.0984–0. HINT: At the time of installation.95 (0.) 2.1024) Mark 21 Thickness mm (in.3 CLUTCH HUB AND 5TH GEAR (a) Using 2 screwdrivers and a hammer. Standard clearance: 0.050 mm (0.3 clutch hub with the synchronizer ring. MEASURE 5TH GEAR RADIAL CLEARANCE Using a dial indicator.0965) 2.009 – 0. measure the radial clearance.70–2. Select a snap ring that allows the minimum axial play.1004–0.0886) 2.) If the clearance exceeds the maximum. needle roller bearing or input shaft.1122) 2.

HINT: If it is difficult to remove and install the snap rings. x6 x 17 18. install the No. 31 ft·lbf) 17. REMOVE NEEDLE ROLLER BEARING Q02682 x5 Q05785 16. THREE BOND 1324 or equivalent Torque: 42 N·m (430 kgf·cm. pull up the shafts. THREE BOND 1344. REMOVE REAR BEARING RETAINER Remove the 5 bolts and retainer. tap the transmission case and remove it. 15. FIPG: Part No. Using SST and a press. Torque: 29 N·m (300 kgf·cm. 22 ft·lbf) (b) Using a plastic hammer. THREE BOND 1281 or equivalent Author : Date : 1864 . 08833 – 00090. Sealant: Part No. SST 09612–22011 (c) Remove the 5th gear. Q05826 FIPG Q09474 REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET Torque: 29 N·m (300 kgf·cm. Sealant: Part No. please refer to the following item.08833 – 00080. remove the 2 snap rings.MX–14 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY SST HINT: At the time of installation. LOCTITE 242 or equivalent Torque: 18 N·m (185 kgf·cm. retainer and shim. REMOVE TRANSMISSION CASE (a) Remove the 17 bolts. REMOVE BEARING SNAP RING Using a snap ring expander. 13 ft·lbf) 20. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM Remove the 6 bolts.3 clutch hub assembly.08833 – 00070. 22 ft·lbf) 19.

Sealant: Part No.1 SHIFT HEAD. Author : Date : 1865 .1 SHIFT FORK SHAFT.2 SHIFT FORKS AND REVERSE SHIFT FORK Mount the shift forks to the vise. REMOVE REVERSE SHIFT ARM Shift the fork shaft into reverse. 25. No. Separate the No.2 SHIFT FORK SHAFT Using a hexagon wrench. THREE BOND 1344. Q05827 24. NO. (a) (b) 23. NO. Using a pin punch and hammer.1 shift fork shaft. NO.1 SHIFT HEAD.2 SHIFT FORKS.2 shift forks and reverse shift fork. Remove the 2 bolts and pull off the reverse shift arm. NO. drive out the slotted spring pin.1 fork shaft.1 and No.1 AND NO.1 fork shaft.1 SHIFT FORK SHAFT. No. Remove the idler gear and thrust washer. INPUT AND OUTPUT SHAFTS ASSEMBLY REMOVE DIFFERENTIAL CASE ASSEMBLY REMOVE MAGNET FROM TRANSAXLE CASE REMOVE NO. drive out the slotted spring pin from the No. REVERSE SHIFT FORK WITH INTERLOCK PIN. 26.08833 – 00080.1. (a) (b) (c) Q03065 (d) SEPARATE NO. Pull out the shaft.1 shift head. Torque: 18 N·m (185 kgf·cm. 27. 13 ft·lbf) REMOVE NO. (a) (b) (c) REMOVE REVERSE IDLER GEAR AND SHAFT Pull out the shaft. Using a pin punch and hammer. remove the straight screw plug. LOCTITE 242 or equivalent Torque: 13 N·m (130 kgf·cm. 9 ft·lbf) Using a pin punch and hammer. NO.MX–15 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY 21. as shown. (a) (b) 22. drive out the slotted spring pin from the No.

3 CLUTCH HUB Remove the No. REMOVE NO.MX–16 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY 28. remove the snap ring. (c) Remove the synchronizer rings. Author : Date : 1866 .3 clutch hub.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO. Using a screwdriver. (a) MT0781 (b) HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.5 synchronizer ring with the key spring from the No.

·lbf) Z00410 4. Using SST.5 SYNCHRONIZER RING (a) Check for wear or damage. INSPECT NO. SST SST (a) (b) IF NECESSARY.5 synchronizer ring in one direction while pushing it to the outer No. Using SST. WM0066 3. 65 in. 2. pull out the bearing.039 in. SST 09308–00010 Z00409 (c) SST SST (d) Using SST. replace the shift fork or hub sleeve. SST 09308–00010 Z00411 Author : Date : 1867 . SST SST (a) (b) IF NECESSARY. Check that the ring locks. REPLACE INPUT SHAFT FRONT BEARING Remove the 2 bolts and transaxle case receiver. Torque: 7.) If the clearance exceeds the maximum. REPLACE OUTPUT SHAFT FRONT BEARING Remove the bolt and bearing lock plate. Maximum clearance: 1. (b) Check the braking effect of the synchronizer ring. INSPECT NO. replace the synchronizer ring.5 synchronizer ring.0 mm (0. press in a new bearing. Turn the middle No.4 N·m (75 kgf·cm. If the braking effect is insufficient. SST 09310–35010 Install the transaxle case receiver and torque the 2 bolts.3 SHIFT FORK AND NO. pull out the bearing.MX–17 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY MX05M–01 INSPECTION 1. measure the clearance between the hub sleeve and shift fork.3 HUB SLEEVE CLEARANCE Using a feeler gauge.

9 ft·lbf) Author : Date : 1868 .) Apply sealant to the plug threads. Torque: 18 N·m (185 kgf·cm.020 in. LOCTITE 242 or equivalent Using a hexagon wrench. press in a new bearing. drive in the slotted spring pin.5mm SST (a) (b) (c) Z00413 IF NECESSARY. Torque: 13 N·m (130 kgf·cm. Sealant: Part No. 13 ft·lbf) Front Z00593 5. REPLACE REVERSE RESTRICT PIN Using a hexagon wrench.5 ± 0.08833 – 00080. Replace the reverse restrict pin. REPLACE INPUT SHAFT FRONT OIL SEAL Using a screwdriver.5mm (c) (d) Z00596 (e) (f) IF NECESSARY.5 ± 0. remove the straight screw plug. Drive in depth: 13.) Coat the lip of the oil seal with MP grease. Using SST. drive in a new oil seal.MX–18 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY (c) SST SST (d) Using SST. THREE BOND 1344. Using a pin punch and hammer. (a) (b) 13. 6.5 mm (0 – 0.531 ± 0. 0 – 0. drive out the slotted spring pin. SST 09608–00081.020 in. install and torque the straight screw plug.5 mm (0. Using a pin punch and hammer. 09950–70010 (09951–07150) Drive in depth: 0 – 0. pry out the oil seal. SST 09310–35010 Install the bearing lock plate and torque the bolt.

MX–19 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY MX04I–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page MX–11). Author : Date : 1869 . HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

2 Clutch Hub Snap Ring 3rd Gear Needle Roller Bearing No.MX–20 MANUAL TRANSAXLE (S51) – INPUT SHAFT INPUT SHAFT MX04J–01 COMPONENTS Spacer Needle Roller Bearing 4th Gear Rear Bearing Snap Ring Synchronizer Ring Synchronizer Ring Input Shaft Shifting Key No.2 Hub Sleeve Key Spring Q02560 Author : Date : 1870 .

remove the 4th gear and rear bearing.0177 in.) 4th gear: 0. Standard clearance: 0. measure the radial clearance between the gear and shaft. SST Q05201 REMOVE REAR BEARING.0079 – 0. 3. Z00417 INSPECT 3RD AND 4TH GEARS RADIAL CLEARANCES Using a dial indicator.50 mm (0.10 – 0.) 3rd Gear 4th Gear Q05793 2.070 mm (0. tap out the snap ring. NEEDLE ROLLER BEARING. measure the clearance.30 mm (0. needle roller bearing or shaft.0021 in. spacer and synchronizer ring.25 mm (0.45 mm (0.0039 – 0. REMOVE SNAP RING Using a snap ring expander.) Maximum clearance: 0.) 4th gear: 0. 4. 4TH GEAR.053 mm (0.) If the clearance exceeds the maximum.0004 – 0. Standard clearance: 3rd gear: 0. 5. remove the snap ring.0098 in.MX–21 MANUAL TRANSAXLE (S51) – INPUT SHAFT MX04K–01 DISASSEMBLY 1.0028 in. INSPECT 3RD AND 4TH GEARS THRUST CLEARANCE Using a feeler gauge. SST 09950–00020 (b) Remove the needle roller bearings. SPACER AND SYNCHRONIZER RING FROM INPUT SHAFT (a) Using SST and a press. Author : Date : 1871 . replace the gear.0197 in. REMOVE SNAP RING Using 2 screwdrivers and a hammer.0118 in.20 – 0.) Maximum clearance: 3rd gear: 0.009 – 0.

MX–22
MANUAL TRANSAXLE (S51) – INPUT SHAFT

6.
SST

CM0064

REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR SYNCHRONIZER RING AND NEEDLE ROLLER BEARING Using SST and a press, remove the No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings. SST 09950–00020 NOTICE: Be careful not to mistake the 3rd gear synchronizer ring for the 4th gear synchronizer ring. 7. REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND SPRING FROM NO.2 CLUTCH HUB Using a screwdriver, remove the 3 shifting keys and 2 springs from the No.2 clutch hub.

SM0269

Author :

Date :

1872

MX–23
MANUAL TRANSAXLE (S51) – INPUT SHAFT
MX04L–01

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

WM0064

(d)

WM0065

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

WM0066

Author :

Date :

1873

MX–24
MANUAL TRANSAXLE (S51) – INPUT SHAFT

A

B

C

D

SM0182

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

3. (a) (b)

(c)

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

CM0013

Author :

Date :

1874

0807–0.0827–0. SM0193 (c) Using a press.0768–0. NOTICE: Position the key springs so that their end gaps are not aligned. Z00419 3.0846) 2. INSTALL NO.05–2.15 (0.2 CLUTCH HUB INTO HUB SLEEVE (a) Install the clutch hub and shifting keys to the hub sleeve.95–2. NEEDLE ROLLER BEARING.MX–25 MANUAL TRANSAXLE (S51) – INPUT SHAFT MX04M–01 REASSEMBLY Engine Side SM0282 HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.0787–0. Mark 1 2 3 4 5 Thickness mm (in.0787) 2.2 hub sleeve.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT (a) Apply gear oil to the needle roller bearings.00–2.0866–0.0846–0. 2. (b) Place the synchronizer ring (for the 3rd gear) on the gear and align the ring slots with the shifting keys. (b) Install the shifting key springs under the shifting keys.20 (0.15–2.10 (0.0886) Z00604 6 Author : Date : 1875 .00 (0. 1.) 1. install the 3rd gear and No.0866) 2.10–2.25 (0. SYNCHRONIZER RING AND NO. (a) INSTALL SNAP RING Select a snap ring that allows the minimum axial play.20–2. NOTICE: Do not install the synchronizer ring for 4th gear.05 (0. INSTALL 3RD GEAR.0827) 2.0807) 2.

25–2.35 (0.0866) 2.40 (0.25 (0. install the rear ball bearing.MX–26 MANUAL TRANSAXLE (S51) – INPUT SHAFT (b) 4. (a) (b) INSTALL SYNCHRONIZER RING.0866–0.20–2.0846–0.0886–0.0945) SM0050 (b) Using a screwdriver and hammer.20 (0.30–2. Install the spacer and needle roller bearings. Author : Date : 1876 . SM0189 (c) Place the synchronizer ring on the gear.0886) 2. SST 09608–00071 SST SM0049 6.0906) 2. Mark A B C D E Thickness mm (in.15–2. SM0190 (d) Using SST and a press.0925) 2.0906–0.35–2. 4TH GEAR AND REAR BALL BEARING Apply gear oil to the needle roller bearings. (a) INSTALL SNAP RING Select a snap ring that allows the minimum axial play. tap in the snap ring.30 (0. NEEDLE ROLLER BEARING. HINT: Align the ring slots with the shifting keys and the ring projections with the hub slots. INSPECT 3RD GEAR THRUST CLEARANCE (See page MX–20) 5.) 2. Using a snap ring expander. install the snap ring. SPACER.0925–0.

INSPECT 4TH GEAR THRUST CLEARANCE (See page MX–20) Author : Date : 1877 .MX–27 MANUAL TRANSAXLE (S51) – INPUT SHAFT 7.

1 Clutch Hub Needle Roller Bearing Ball Spacer Rear Bearing Synchronizer Ring 2nd Gear 2nd Gear Bushing 3rd Driven Gear 4th Driven Gear Q02544 Author : Date : 1878 .1 Hub Sleeve Shifting Key Shifting Key Spring No.MX–28 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT OUTPUT SHAFT MX04N–01 COMPONENTS Output Shaft Spacer 1st Gear Needle Roller Bearing Synchronizer Ring No.

SST (a) (b) (c) MT0063 REMOVE 3RD DRIVEN GEAR. SM0137 SST INSPECT 1ST AND 2ND GEARS RADIAL CLEARANCE Using a dial indicator. 2nd Gear 1st Gear Q05794 INSPECT 1ST AND 2ND GEARS THRUST CLEARANCE Using a feeler gauge.) If the clearance exceeds the maximum. Standard clearance: 1st gear: 0. 2ND GEAR. REMOVE REAR BALL BEARING. SST 09950–00020 (b) Remove the output gear spacer and ball. CM0065 4. 4TH DRIVEN GEAR AND OUTPUT GEAR SPACER (a) Using SST and a press.053 mm (0. Standard clearance: 0.009 – 0. remove the rear ball bearing and 4th driven gear.0197 in. 3.MX–29 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT MX04O–01 DISASSEMBLY 1.0173 in.29 mm (0.0039 – 0.) Maximum clearance: 1st gear: 0.0114 in. SST 09950–00020 Remove the needle roller bearing and synchronizer rings. measure the thrust clearance.0028 in.0079 – 0.35 mm (0.) Maximum clearance: 0. Using SST and a press.0138 in. NEEDLE ROLLER BEARING AND SYNCHRONIZER RING Shift the No.50 mm (0.0021 in.44 mm (0.) 2nd gear: 0.10 – 0.070 mm (0. measure the radial clearance between the gear and shaft. remove the 3rd driven gear and 2nd gear.) 2. replace the gear.1 hub sleeve into the 1st gear.20 – 0. needle roller bearing or shaft. Author : Date : 1879 .0004 – 0.) 2nd gear: 0.

1 hub sleeve.MX–30 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT 5. (a) (b) (c) Z00427 REMOVE NO. SYNCHRONIZER RING. NEEDLE ROLLER BEARING. REMOVE NO. 1ST GEAR. Using a screwdriver and hammer.1 HUB SLEEVE. 3 SHIFTING KEYS AND SPRINGS FROM NO. Remove the needle roller bearing and locking ball. drive out the thrust washer. 6. 1st gear and synchronizer ring. remove the No.1 HUB SLEEVE ASSEMBLY.1 CLUTCH HUB Q02948 Author : Date : 1880 . THRUST WASHER AND LOCKING BALL Using a press.

Turn the synchronizer ring in one direction while pushing it to the gear cone. Minimum clearance: 0. MT0787 Author : Date : 1881 . Minimum clearance: 0. Check that the ring locks.028 in. replace the synchronizer ring. and apply a small amount of the fine lapping compound on gear cone. MT0780 (c) Using a feeler gauge. measure the clearance between the synchronizer ring back and gear spline end. Turn the synchronizer ring in one direction while pushing it to the gear cone. apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. (a) (b) INSPECT 1ST GEAR SYNCHRONIZER RING Check for wear or damage. replace the synchronizer ring. Check the braking effect of the synchronizer ring. replace the synchronizer ring.) If the clearance is less than the minimum. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.7 mm (0. Lightly rub the synchronizer ring and gear cone together. 2. If the braking effect is insufficient. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.6 mm (0. Check that the ring locks.) If the clearance is less than the minimum. If the braking effect is insufficient. WM0064 (d) WM0065 Using a feeler gauge.024 in. measure the clearance between the synchronizer ring back and the gear spline end. (b) Check the braking effect of the synchronizer ring. (c) Check again the braking effect of the synchronizer ring. INSPECT 2ND GEAR SYNCHRONIZER RING (a) Check for wear or damage.MX–31 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT MX04P–01 INSPECTION 1.

) If the clearance exceeds the maximum.) Part C: 31.970 mm (1. check the shaft runout.0020 in. measure the clearance between the hub sleeve and shift fork.039 in. replace the shift fork or hub sleeve. WM0066 4.970 mm (1.) If the runout exceeds the maximum. Maximum clearance: 1. (b) Using a dial indicator.4949 in. replace the output shaft. (a) A B C CM0014 INSPECT OUTPUT SHAFT Using a micrometer. measure the outer diameter of the output shaft journal surface.2587 in.) If the outer diameter is less than the minimum.990 mm (1. Maximum runout: 0.) Part B: 37.MX–32 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT 3.2594 in. replace the output shaft. Minimum outer diameter: Part A: 31.0 mm (0. INSPECT SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge.05 mm (0. CM0015 Author : Date : 1882 .

(a) SST (b) INSTALL THRUST WASHER. Front Q02949 2. SYNCHRONIZER RING AND NO. Z00428 (d) 3. SST 09316–60011 (09316–00041) Apply gear oil to the needle roller bearing. SM0199 (c) Place the synchronizer ring on the gear and align the ring slots with the shifting keys.1 CLUTCH HUB INTO HUB SLEEVE (a) Install the 3 springs and shifting keys to the clutch hub. Using a press. 1ST GEAR. (b) Install the hub sleeve to the clutch hub.1 HUB SLEEVE TO OUTPUT SHAFT Using SST and a press.1 hub sleeve. HINT: Position the identification groove of the hub sleeve to the front of the transmission. 1. install the thrust washer.MX–33 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT MX04Q–01 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. install the 1st gear and No. NEEDLE ROLLER BEARING. INSTALL NO. INSPECT 1ST GEAR THRUST CLEARANCE (See page MX–28) Z00429 Author : Date : 1883 .

(f) SST 5. SST 09316–60011 (09316–00011) INSPECT 2ND GEAR THRUST CLEARANCE (See page MX–28) SM0201 6. (c) Place the synchronizer rings on the 2nd gear. Using SST and a press. INSTALL REAR BEARING Using SST and a press. NOTICE: Align the clutch hub grooves with the projections on the synchronizer ring. 4TH DRIVEN GEAR AND RADIAL BALL BEARING Install the outer gear spacer. NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR (a) Install the ball. Using a press. (b) Fit the 2nd gear bushing groove securely over the ball when installing the 2nd gear bushing on the shaft.MX–34 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT MT0792 INSTALL SYNCHRONIZER RING. (d) Apply gear oil to the needle roller bearing and install it. Z00431 SST 7. SST 09612–22011 SM0202 Author : Date : 1884 . install the 4th driven gear and bearing. 4. install the 3rd driven gear. 2ND GEAR. (a) (b) INSTALL OUTPUT GEAR SPACER. install the rear bearing. (e) Install the 2nd gear.

2 Select Spring Seat No.1 Shift Inner Lever No. 56 in.MX–35 MANUAL TRANSAXLE (S51) – SHIFT AND SELECT LEVER SHAFT SHIFT AND SELECT LEVER SHAFT MX04R–01 COMPONENTS Shift and Select Lever Shaft E–Ring Select Spring Seat Compression Spring Shift Interlock Plate Compression Spring E–Ring Slotted Spring Pin 6.2 LOil Seal Control Shaft Cover L O–Ring Lever Lock Pin Control Shaft Lever N·m (kgf·cm.4 (85.·lbf) Dust Boot Washer Shift Inner Lever No. ft·lbf) : Specified torque L Non–reusable part MP Grease Q10277 Author : Date : 1885 .

MX–36 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE DIFFERENTIAL CASE MX04S–01 COMPONENTS Shim LOuter Race and Side Bearing Pinion Thrust Washer Ring Gear Pinion Gear Pinion Shaft 83 (850. ft·lbf) : Specified torque LNon–reusable part Z19302 Author : Date : 1886 . 61) x8 L Side Bearing and Outer Race Side Gear Side Gear Thrust Washer Shim Differential Case Straight Pin Vehicle Speed Sensor Drive Gear N·m (kgf·cm.

MX–37 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE MX04T–01 SST DISASSEMBLY 1. 09950–00030 Q04969 AT2799 4. 09950–00030 Remove the vehicle speed sensor drive gear. Vehicle Speed Sensor Drive Gear Side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE Using SST. (a) Q08148 (b) 2. remove the bearing from the ring gear side of the case. tap on the ring gear to remove it from the case. (a) (b) (c) 3. (c) Remove the 2 pinions and side gears with the 4 thrust washers from each gear. SST 09950–00020. install the correct thrust washer to the side gears. DISASSEMBLE DIFFERENTIAL CASE (a) Using a pin punch and hammer. Remove the 8 bolts. 5. Standard backlash: 0. REMOVE RING GEAR Place matchmarks on the ring gear and case.20 mm (0. Using a copper hammer.05 – 0. measure the backlash of one side gear while holding one pinion toward the case. remove the bearing from the drive gear side of the case. SST 09950–00020.) If the backlash is not within the specification. (b) Remove the pinion shaft from the case.0079 in. drive out the straight pin. SST Ring Gear Side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE Using SST.0020 – 0. INSPECT SIDE GEAR BACKLASH Using a dial indicator. Author : Date : 1887 .

REPLACE SIDE BEARING OUTER RACE Using a brass bar and hammer. (a) (b) (c) Z00442 Transaxle Case Side: IF NECESSARY. drive out the oil seal from the retainer. 8. Install and torque the 6 bolts. Using SST and a hammer. REPLACE SIDE OIL SEAL Using a screwdriver and hammer.MX–38 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE 6. drive out the bearing outer race. SST 09950–60020 (09951–00680). install a new bearing outer race. 09351–32150) Coat the lip of the oil seal with MP grease. 09351–32150) Coat the lip of the oil seal with MP grease. REPLACE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer. drive out the oil seal. 09950–70010 (09951–07150) Remove the 6 bolts. SST 09350–32014 (09351–32130. Torque: 18 N·m (185 kgf·cm. drive in a new oil seal until its surface is flush with the case surface. Using SST and a press. 09950–70010 (09951–07150) Q08145 (b) (c) Using SST and a hammer. drive in a new oil seal until its surface is flush with the case surface. Remove the bearing retainer and shim. Install the bearing retainer without an O–ring. 13 ft·lbf) (d) (e) SST (f) (g) Place the thinnest shim into the case. (a) SST Transaxle Case Side: IF NECESSARY. SST (a) (b) (c) SM0155 Transmission Case Side: IF NECESSARY. SST 09350–32014 (09351–32130. SST SM0286 7. MT0634 Author : Date : 1888 . SST 09950–60020 (09951–00680).

MX–39 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE 9. 09950–70010 (09951–07150) Author : Date : 1889 . drive out the bearing outer race and shim. install a new bearing outer race. (a) SST (b) (c) Q08184 Transaxle Case Side: IF NECESSARY. Place the shim into the case. REPLACE SIDE BEARING OUTER RACE Using a brass bar and hammer. SST 09950–60020 (09951–00680). Using SST and a press.

(a) ASSEMBLE DIFFERENTIAL CASE Install the correct thrust washers and side gears.20 mm (0.) 0. HINT: Align the matchmarks on the differential case and the ring gear.0413) Thickness mm (in. torque the ring gear set bolts.15 (0.) If the backlash is not within the specification.05 – 0. 61 ft·lbf) Q08147 Author : Date : 1890 . Using a dial indicator. (e) Temporarily install the 8 bolts.0020 – 0. quickly install the ring gear to the differential case. NOTICE: The ring gear set bolts should not be torqued until the ring gear has cooled sufficiently. 2. Install the pinion shaft.MX–40 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE MX04U–01 REASSEMBLY 1. Torque: 83 N·m (850 kgf·cm. (b) Heat the ring gear in boiling water.0079 in. (c) AT2981 Inspect the side gear backlash. Standard backlash: 0. Try to select washers of the same size for both sides.0394) 1.0472) (b) Install the thrust washers and side gears in the differential case.10 (0.0453) 1. (c) Carefully take the ring gear out of the water.20 (0. select thrust washers which will ensure that the backlash is within the specification.0079 in.95 (0.0374) 1.05 – 0. install a thrust washer of different thickness. (e) Stake the differential case. (d) After moisture on the ring gear has completely evaporated. (f) After the ring gear has cooled sufficiently.) Thickness mm (in.05 (0. Standard backlash: 0. drive in the straight pin through the case and hole in the pinion shaft.0020 – 0.00 (0. (d) Using a pin punch and hammer.0433) 1.20 mm (0. INSTALL RING GEAR ON DIFFERENTIAL CASE (a) Clean the contact surface of the differential case and the threads of the ring gear and differential case. measure the side gear backlash while holding one pinion gear toward the case. Refer to the table below.) 1.

SST 09316–60011 (09316–00011). 4. (b) Install the transmission case. 22 ft·lbf) (d) Install the shim into the transmission case.MX–41 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE 3. 09350–32014 (09351–32120) NOTICE: Install the black cage bearing on the vehicle speed sensor drive gear side. Case Side Q08649 (c) SST SM0289 Using SST and a press. Torque: 29 N·m (300 kgf·cm. 13 ft·lbf) Author : Date : 1891 . (e) Install the bearing retainer without an O–ring. install a new side bearing to the transaxle case side. (a) SST INSTALL SIDE BEARING TO DIFFERENTIAL CASE Using SST and a press. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD (a) Install the differential to the transaxle case. SST 09316–60011 (09316–00011). (c) Install and torque the case bolts. Torque: 18 N·m (185 kgf·cm. install a new side bearing to the transmission case side. 09350–32014 (09351–32120) SM0287 (b) Install the vehicle speed sensor drive gear to the transaxle case side. (f) Install and torque the 6 bolts.

6 – 3.1102) – (h) (i) (j) (k) Remove Remove Remove Remove the the the the 6 bolts.55 (0. bearing retainer and shim.0925) Mark 11 12 13 14 15 16 17 18 19 – Thickness mm (in.9 in.·lbf) with each 0.9 – 13.) 2.1083) 2.4 N·m (3 – 4 kgf·cm. SST 09564–32011 Preload (at starting): 0. remove the transmission case side bearing retainer.) change in shim thickness.30 (0.8 – 1.0846) 2.90 (0.0945) 2.0906) 2.95 (0.0807) 2.1024) 2.1004) 2.MX–42 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE (g) SST Z00620 Using SST and a torque wrench.0019 in.0984) 2. 2.20 (0.0965) 2.60 (0.45 (0.35 (0. 6.1063) 2.65 (0.00 (0. transmission case.70 (0.80 (0.0768) 2. measure the preload.0886) 2.0827) 2.1043) 2.) 1.5 in.·lbf) If the preload is not within the specification.05 (0. HINT: The preload will change about 0. Select another shim.40 (0. 17 bolts. Mark 1 2 3 4 5 6 7 8 9 10 Thickness mm (in.3 – 0.25 (0.15 (0.50 (0.0866) 2.0787) 2.05 mm (0.75 (0.10 (0.6 N·m (8 – 16 kgf·cm. Author : Date : 1892 .0748) 1.

43 in.MX–43 MANUAL TRANSAXLE (S51) – SHIFT LEVER AND CONTROL CABLE SHIFT LEVER AND CONTROL CABLE MX04V–02 COMPONENTS Shift Lever Knob Center Console Upper Panel Heater Control Assembly Center Cluster Finish Panel Front Console Box Rear Console Box Shift Cable Grommet Retainer Shift Cable Grommet Retainer Shift Cable Grommet Clip 4.·lbf) Clip Clip Shift Lever Assembly Clip Clip Clip Clip Washer Clip Shift Control Cable Washer Select Control Cable Washer N·m (kgf·cm.9 (50. 43 in. 9) Grommet 4. ft·lbf) : Specified torque Q10340 Author : Date : 1893 .·lbf) 12 (120.9 (50.