Professional Documents
Culture Documents
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
PRECAUTION
1.IGNITION SWITCH EXPRESSIONS
1. The type of ignition switch used on this model differs according to the
specifications of the vehicle. The expressions listed in the table below are used in
this section.
1. When revving the engine, make sure that the gear is in neutral.
1. When removing or installing parts related to the multi-mode manual transmission
system, perform [Clamp Position Adjustment], [Initialization and Learning]
and/or [Synchronization Position Calibration]. In addition, the required operations
differ according to the parts to be removed and installed. Proceed with the
operation in the order shown in the table below.
Before removal
Parts to be removed Operation order See
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 1/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
procedure
• Clutch actuator
• Transmission
assembly
• Transmission parts
(inside gear box)
• Clutch disc and clutch
cover • CLAMP
• Clutch release bearing POSITION
• Clutch release fork ADJUSTMENT
• Clutch release lever
• Flywheel
• End plate (2SZ-FE
only)
• Crankshaft
• Shift and select
actuator (with clutch actuator)
2.
Before installation
See
Parts to be installed Operation order
procedure
• CLAMP POSITION
• New clutch
ADJUSTMENT
actuator
3. NOTICE:
4. Push rods of brand new clutch actuators (service supply parts) are not set in the
clutch clamp position. Therefore, adjust the clamp positions before installing new
clutch actuators.
5.
After installation
See
Parts installed Operation order
procedure
• Transmission 1. INITIALIZATION OF MULTI-
assembly MODE MANUAL
• Transmission parts TRANSMISSION SYSTEM
(inside gear box) [Initialization of ECU]
• Shift and select
actuator (with clutch
actuator) 2. LEARNING OF MULTI-
MODE MANUAL
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 2/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
6. NOTICE:
Replace the clutch disc and clutch cover together. If only one is replaced,
•
the adjustment system of the clutch cover does not function properly. This
may cause clutch drag or clutch slippage, which may result in
deterioration of drivability or malfunctions of the system parts.
After replacing any system components, perform initialization and
•
system, clear (initialize) the previously stored learning values. Since the
multi-mode manual transmission system does not have an overwrite
function, clearing (initializing) stored data is necessary before the new
data can be stored.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 3/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
START)
HINT:
If any malfunctions are suspected in the transmission control system after
reassembling or repairing transmission system components, perform
troubleshooting in accordance with the following chart.
Result:
Result Proceed To
No DTC output A
DTC output B
B . Go to DTC Chart
1. Check that the clutch position learning has been completed.
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data
List.
4. Read the Learn-Clutch Stopper Point result.
Result:
Result Proceed To
Exec (Executed) A
Notexec (Not executed) B
Fail (Failure) C
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 4/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Check that the T/M gear position learning has been completed.
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data
List.
4. Read the Learn-T/M results.
Result:
Result Proceed To
Exec (Executed) A
Notexec (Not executed) B
Fail (Failure) C
C . Go to step 6
1. Referring to the shift slit position of the shift and select actuator, check whether
the actual transmission gear position is in neutral.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 5/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Result:
Result Proceed To
Neutral A
Other than Neutral B
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 6/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Result:
Result Proceed To
ON A
OFF B
6.Check whether T/M up-lock has occurred during gear position learning
1. Check whether T/M up-lock has occurred during gear position learning.
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data
List.
4. Read the Possibility of T/M Uplock results.
HINT:
T/M up-lock: The transmission gear momentarily cannot be engaged due to
mechanical reasons during gear position learning.
Result:
Result Proceed To
No (Not occurred) A
Yes (Occurred) B
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 7/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Result:
Result Proceed To
No DTC output A
DTC output B
B . Go to DTC Chart
1. Check that the clutch position learning has been completed.
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data
List.
4. Read the Learn-Clutch Stopper Point results.
Result:
Result Proceed To
Exec (Executed) A
Notexec (Not executed) B
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 8/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Fail (Failure) C
1. Check that the T/M gear position learning has been completed.
1. Connect the intelligent tester to the DLC3.
2.
3. Turn
Selectthe
theignition switch
following menuonitems:
(IG) and the tester/ Multi-Mode
Powertrain ON. M/T / Data
List.
4. Read the Learning-T/M results.
Result:
Result Proceed To
Exec (Executed) A
Notexec (Not executed) B
Fail (Failure) C
C . Go to step 8
1. Check that the clutch position learning has been completed.
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data
List.
4. Read the Learn-Clutch Standby Point results.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 9/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Result:
Result Proceed To
Exec (Executed) A
Notexec (Not executed) B
Fail (Failure) C
5.Confirm that gear position in [1st] or [R] when shift lever in [E], [M] or [R]
2. Referring to the shift slit position of the shift and select actuator, check that the
actual transmission
position is changed gear
fromposition is in
N to E, M or the
R. 1st or R position when the shift lever
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 10/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
NG . Go to step 9
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 11/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Check that value of the Accelerator Pedal Angle changes in accordance
with the accelerator pedal operation ().
Standard (1KR-FE):
Accelerator Pedal Tester
Operation Display
Fully depressed 60 to 100 %
Fully released 0 to 25 %
Standard (2SZ-FE):
Accelerator Pedal Tester
Operation Display
Fully depressed 52 to 100 %
Fully released 0 to 22 %
OK
1. Check that the engine can be revved up when the transmission gear is in neutral.
Result:
Result Proceed To
Possible A
Impossible B
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 12/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
8.Check whether T/M up-lock has occurred during gear position learning
1. Check whether T/M up-lock has occurred during gear position learning.
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data
List.
4. Read the Possibility of T/M Uplock result.
HINT:
T/M up-lock: The transmission gear momentarily cannot be engaged due to
mechanical reasons during gear position learning.
Result:
Result Proceed To
No (Not occurred) A
Yes (Occurred) B
A
9.Check whether clutch disengaged when shift lever in [E], [M] or [R]
1. Check the actual clutch state when the shift lever is in the E, M or R position.
Result:
Result Proceed To
Disengaged A
Not disengaged B
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 13/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. When the vehicle is parked with the shift lever in any position other than N:
•
The engine cannot be started if the shift lever is moved to any position
other than N by operating the shift lock release button.
The shift lever should be moved back to the N position to start the engine.
The engine cannot be started if the shift lever is in the position it was in
•
lock release button, the gear is shifted to neutral when the ignition switch
is turned on (IG) so that the engine can be started.
2. When the vehicle is parked with the shift lever in the N position:
The engine can be started even if the shift lever is moved to any position
•
other than N by operating the shift lock release button. In this case, the
gear is shifted to the position in accordance with the shift lever position
after the engine starts.
N (Same
in whenposition
vehicle Possible -
parked)
*: The shift lever was moved with the shift lock release button operation.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 14/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
• Set the gear to the neutral position before removing the shift and select actuator. If
the gear cannot be shifted to the neutral position due to malfunctions of the
actuator and/or transaxle gear, remove the plug from the shift and select actuator
and observe the position of the shift slit within. If the slit is in any position other
than neutral, use a screwdriver to set it to neutral.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 15/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Perform the electronic throttle learning when the following operations are done ().
ECM replacement
•
•
Throttle body assembly replacement
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 16/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > PARTS
LOCATION
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 17/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/5
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 18/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 19/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 20/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 21/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2/5
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 22/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 23/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 24/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3/5
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 25/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 26/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 27/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4/5
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 28/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 29/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 30/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
5/5
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > SYSTEM
DIAGRAM
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 31/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 32/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 33/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 34/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 35/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 36/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 37/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 38/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 39/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 40/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 41/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
1. The multi-mode manual transmission has been developed from the conventional
manual transmission by adding actuators that are directly controlled by electric
motors. The transmission control system consists of an electronic throttle control
system, clutch actuator, shift and select actuator, sensors, a shift lever, and a
transmission control ECU. The system offers automatic clutch operation and two
driving modes: automatic shifting E mode and manual shifting M mode.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 42/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. The stroke sensors, which are mounted on each actuator and detect the actuator
operating position, are double non-contact type.
3. The multi-mode manual transmission is equipped with a clutch actuator, which
has a motor for clutch engagement, and a shift and select actuator, which has two
motors for shifting and selecting gear shafts that have been used on the
conventional manual
signals from the transmission.
transmission Each
control actuator
ECU. operates in accordance
The transmission control ECUwith
receives information from the ECM and sensors, and controls the engine and
multi-mode manual transmission.
4. The shift lever features a Shift-by-Wire System that electrically detects the shift
lever position chosen by the driver and sends a shift lever position signal to the
transmission control ECU to control the transmission.
5. The shift lever has an electrical shift lock mechanism. When the ignition switch is
turned off, or the shift lever is in the N position with the engine running and the
brake pedal released, the shift lever is locked in the current shift position.
6. The multi-mode manual transmission system has fail-safe functions. When the
transmission control
illuminates the ECU detects
Multi-mode Manual a malfunction
TransmissioninWarning
the system, the(MMT
Light ECU Warning
Light) to inform the driver that a malfunction has occurred. If necessary, the ECU
illuminates the Malfunction Indicator Lamp (MIL) and MMT Warning Light
simultaneously. Under such conditions, the fail-safe function allows the vehicle to
be operated in order to avoid emergency situations.
Components Outlines
Combination Controls the operation of the indicator lights, warning light, and
meter (meter ECU) buzzer.
Multi-mode
manual
transmission
Illuminates to alert the driver when a malfunction occurs in the
warning light
multi-mode manual transmission system.
(built into
combination
meter)
Gear position
indicator
Indicates the present gear position. The indicator flashes if the
(built into
actual gear position and the shift lever position do not match.
combination
meter)
Mode indicator Indicates E-mode or M-mode.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 43/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
(built into
combination
meter)
Es indicator light
Illuminates when the sporty [Es] pattern is selected during normal
(built into
combination [E] pattern
normal [E] driving in selected.
pattern is E-mode. Does not illuminate while the
meter)
Buzzer Sounds if the following conditions met simultaneously:
(built into Engine is running
combination Shift lever is in E, M or R position
meter) Driver's door is open
Shift lever position
sensor Outputs the shift lever position and shift request (+ or -) through
(built into shift the ON/OFF combination of 6-contact switch and 2-contact switch.
lever assembly)
Transmission shift
main switch
Outputs the shift mode signal (E-mode or M-mode).
(built into shift
lever assembly)
Shift lock solenoid
Actuated by the transmission control ECU. Restricts the movement
(built into shift
of the shift lever.
lever assembly)
Shift motor
Actuated by the transmission control ECU. Effects the shift
(built into shift and *
operation of the shift and select lever shaft.
select actuator)
Shift stroke sensor Detects the shift and select actuator operation position (shift
(built into shift and *
direction).
select actuator)
Select motor
Actuated by the transmission control ECU. Effects the select
(built into shift and *
operation of the shift and select lever shaft.
select actuator)
Select stroke
sensor Detects the shift and select actuator operation position (select
*
(built into shift and direction).
select actuator)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 44/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 45/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
HINT:
HINT:
When attempting to shift to reverse at a vehicle speed of 6 km/h (3.7 mph) or
more, the reverse warning buzzer sounds, and the gear does not shift to reverse.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 46/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
ECU.
[Automatic shift control (E and Es modes)]
When the shift lever is in the E position, the most appropriate gear is
automatically selected in accordance with the accelerator pedal opening angle and
the vehicle speed. In addition to this automatic shift control, LHD (Left Hand
Drive) vehicles
depressed until ahave
clickkick down
is felt, thecontrol.
ECM for When
LHDthe accelerator
vehicles pedalthis
interprets is fully
as the
kick down signal being received. Kick down signals affects the transmission shift
control.
Shift control can be switched between normal [E] mode and sporty [Es] mode by
pressing the pattern select switch.
Normal [E] mode: Economical automatic shift control with emphasis on fuel
economy
Sporty [Es] mode: Automatic shift control with emphasis on driving performance
[Sequential shift control (M-mode)]
Moving the shift lever to the M position enables the driver to select the gear. The
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 47/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
HINT:
If the shift lever is kept in the N position for 2 seconds with the brake pedal
released at a specified vehicle speed or less, the transmission control ECU locks
the shift lever to prevent improper shift lever operation. When depressing the
brake pedal, the shift lever is unlocked.
HINT:
The multi-mode manual transmission system does not have a park position. The
vehicle can be parked with the shift lever in any position (N, E, M or R). When
the vehicle is parked with the shift lever in a position other than N, the vehicle is
parked with the gear engaged. The vehicle may not be parked with the gear
engaged if the ignition switch is turned off before the gearshift is complete.
Clamp position adjustment is necessary to position the push rod when the
•
•
For details of replacement, refer to CLAMP POSITION ADJUSTMENT
().
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 48/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 49/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. REPLACEMENT
and the clutch
ORisREMOVAL/INSTALLATION
not engaged. OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM PARTS
Refer to the respective pages for each part.
3. INITIALIZATION AND LEARNING
LEARNING ().
2. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM:
This operation is performed to store the individual specification
•
LEARNING ().
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 50/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 51/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
TROUBLESHOOTING
for Preparation
NEXT
NEXT
NEXT
HINT:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 52/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Result:
PROCEED TO CAN
A
COMMUNICATION SYSTEM
.
B . Go to step 5
NEXT
NEXT
7.VISUAL INSPECTION
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 53/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
NEXT
Result:
Result Proceed To
Symptom does not occur A
Symptom occurs B
A . Go to step 9
B . Go to step 10
9.SYMPTOM SIMULATION
HINT:
NEXT
10.DTC CHECK
HINT:
Refer to the relevant pages ().
Result:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 54/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
No output B
A . Go to step 11
B . Go to step 12
11.DTC CHART
HINT:
Refer to the relevant pages ().
NEXT
Go to step 13
NEXT
13.CIRCUIT INSPECTION
HINT:
Refer to the relevant pages ().
NEXT
14.IDENTIFICATION OF PROBLEM
NEXT
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 55/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
15.ADJUSTMENT, REPAIR
NEXT
16.CONFIRMATION TEST
NEXT
END
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 56/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
HINT:
• By using an intelligent tester, initialization and learning of the multi-mode manual
transmission system can be performed sequentially. Under manual operation (not
using intelligent tester), initialization and learning must be performed
individually.
• The learning values and the DTC history of the multi-mode manual transmission
system are stored in the EEPROM in the transmission control ECU. The stored
information is not cleared even when the negative terminal of the battery is
disconnected. To clear all the stored information, initialize the transmission
control ECU.
• Perform the procedure below to ensure that the initialized transmission control
ECU stores the adjusted clutch position (stopper position, clamp position, and
standby position) or gear position (shift position and select position).
• If the initialization cannot be performed normally, there may be a malfunction in
the shift lever position sensor, NE signals, or CAN communication.
• When replacing the following parts, proceed with the operation in the order listed
in the table below.
See
Parts installed Operation order
procedure
• Transmission assembly 1. INITIALIZATION OF MULTI-MODE
• Transmission parts MANUAL TRANSMISSION SYSTEM See below
(inside gear box) [Initialization of ECU]
Shift and select actuator
• 2. LEARNING OF MULTI-MODE
See below
(with clutch actuator) MANUAL TRANSMISSION SYSTEM
Transmission control
•
3. SYNCHRONIZATION POSITION
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 57/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
ECU CALIBRATION
1. INITIALIZATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM See below
• Shift stroke sensor [Initialization of transmission]
• Select stroke sensor 2. LEARNING OF MULTI-MODE
See below
MANUAL TRANSMISSION SYSTEM
3. SYNCHRONIZATION POSITION
CALIBRATION
• Clutch actuator 1. INITIALIZATION OF MULTI-MODE
• Clutch stroke sensor MANUAL TRANSMISSION SYSTEM See below
• Clutch disc and clutch [Initialization of clutch]
cover
• Clutch release bearing
• Clutch release fork
•
Clutch release lever
2. LEARNING OF MULTI-MODE
• Flywheel See below
• End plate (2SZ-FE MANUAL TRANSMISSION SYSTEM
only)
• Crankshaft
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 58/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 59/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 60/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
14. On the Multi-Mode M/T / Utility screen, select Step 3 Initial Learning.
15. Press the Next key.
HINT:
transmission.
17. Press the Next key.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 61/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
20. Wait 10 seconds.
HINT:
Count down the seconds from 10 to 0.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 62/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
23. Wait 40 seconds.
HINT:
Count down the seconds from 40 to 0.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 63/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
HINT:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 64/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
• The learning values and the DTC history of the multi-mode manual transmission
system are stored in the EEP ROM in the transmission control ECU. The stored
information is not cleared even when the negative terminal of the battery is
disconnected. To clear all the stored information, initialize the transmission
control ECU.
• If the initialization of the multi-mode manual transmission system fails, perform
the operation again from step (a) more than 15 seconds after turning the ignition
switch off.
• If the initialization cannot be performed normally, there may be a malfunction in
the shift lever position sensor, NE signals, or CAN communication.
• When replacing the following parts, proceed with the operations in the order
listed in the table below.
See
Parts installed Operation order
procedure
• Transmission assembly 1. INITIALIZATION OF MULTI-MODE
• Transmission parts MANUAL TRANSMISSION SYSTEM See below
(inside gear box) [Initialization of ECU]
• Shift and select actuator 2. LEARNING OF MULTI-MODE
(with clutch actuator) See below
MANUAL TRANSMISSION SYSTEM
• Transmission control
ECU 3. SYNCHRONIZATION POSITION
CALIBRATION
1. INITIALIZATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM See below
• Shift stroke sensor [Initialization of transmission]
• Select stroke sensor 2. LEARNING OF MULTI-MODE
See below
MANUAL TRANSMISSION SYSTEM
3. SYNCHRONIZATION POSITION
CALIBRATION
• Clutch actuator 1. INITIALIZATION OF MULTI-MODE
•
• Clutch
Clutch stroke sensor
disc and clutch MANUAL TRANSMISSION
[Initialization of clutch] SYSTEM See below
cover
• Clutch release bearing
• Clutch release fork 2. LEARNING OF MULTI-MODE
Clutch release lever See below
•
MANUAL TRANSMISSION SYSTEM
• Flywheel
• End plate (2SZ-FE
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 65/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
only)
• Crankshaft
2. Using SST, connect terminals TC (13) and CG (4) of the DLC3.
SST
09843-18040
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 66/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 67/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
0. The buzzer sounds at intervals of 0.5 seconds as follows (an interval of 2.5
seconds exists between each cycle).
Twice when initializing the ECU (one cycle)
•
HINT:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 68/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
• Perform the procedure below to ensure that the initialized transmission control
ECU stores the adjusted clutch position or gear position.
• If the learning of the multi-mode manual transmission system fails, perform the
operation again from step (a) more than 15 seconds after turning the ignition
switch off.
HINT:
The shift N position indicator blinks when the engine starts.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 69/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
CALIBRATION
for Preparation
See
Parts installed Operation order
procedure
• Transmission assembly 1. INITIALIZATION OF MULTI-MODE
• Transmission parts MANUAL TRANSMISSION SYSTEM
(inside gear box) [Initialization of ECU]
•
Shift and select actuator 2. LEARNING OF MULTI-MODE
(with clutch actuator) MANUAL TRANSMISSION SYSTEM
Transmission control
•
• Shift stroke sensor
1. INITIALIZATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 70/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
[Initialization of transmission]
Crankshaft
1. While driving the vehicle in M-mode, shift up and down between 1st and 5th at
the vehicle speeds specified below.
2. Check that the gears shift smoothly.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 71/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
HINT:
• When a malfunction cannot be confirmed by conducting a DTC check and the
cause of the problem cannot be identified through a basic inspection, troubleshoot
in accordance with the priority order indicated in the table below.
Inspect the fuse and relay before confirming the suspected areas as shown in the
•
chart below.
NOTICE:
When removing the following parts, perform the operations correctly by
following the precautions on the relevant pages.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 72/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 73/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 74/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 75/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
TERMINALS OF ECU
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 76/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Symbols
Wiring Specified
(Terminal Terminal Description Condition
Color Condition
No.)
+B - GND
Battery (ECU power
(D79-1 - B - W-B Always 10 to 14 V
source)
D79-6)
IG - GND
Ignition switch off → Below 1 V →
(D79-3 - O - W-B Ignition switch
on (IG) 10 to 14 V
D79-6)
Ignition switch on
(IG),
PKB - GND
Parking brake switch 10 to 14 V →
(D79-4 - P - W-B Parking brake switch
OFF → ON Below 1 V
D79-6) (Parking brake lever
released → pulled)
Ignition switch on
SLS - GND
LG - W- (IG), 10 to 14 V →
(D79-5 - Shift lock solenoid
B Brake pedal depressed Below 1 V
D79-6)
→ Released
GND - Body
ground W-B -
(D79-6 - Body Ground Always Below 1 Ω
Body ground
ground)
MDSW - Ignition switch on
GND Transmission shift (IG), 10 to 14 V →
L - W-B
(D79-10 - main switch Shift lever position E Below 1 V
D79-6) → M
LS4C - Shift lever position Ignition switch on 10 to 14 V →
B - W-B
GND sensor (IG), Below 1 V
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 77/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
DG - GND
(D79-25 - P - W-B Terminal TC of DLC3 Ignition switch
→ Connect on (IG) 10 to 14 V →
terminals
Below 1 V
D79-6) TC and CG of DLC3
INDC -
Communication line
GND
R - W-B with combination Always Below 1.44 V
(D79-29 -
meter
D79-6)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 78/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
INDA - Pulse
Communication line
GND generation
Y - W-B with combination Ignition switch on (IG)
(D79-31 - (See waveform
meter
D79-6) 1)
STP - GND
(D79-34 - G - W-B Stop light switch Brake→pedal to 14 1VV→
depressed 10Below
Released
D79-6)
Ignition switch on
ST1- - GND
(IG), 10 to 14 V →
(D79-35 - Y - W-B Stop light switch
Brake pedal released Below 1 V
D79-6)
→ depressed
CAN+ - Pulse
CAN- generation
W-B CAN communication Ignition switch on (IG)
(A38-1 - (See waveform
A38-2) 2)
MREL -
GND LG - W- AMT relay (motor Ignition switch off → Below 1 V →
(A38-5 - B power source) on (IG) 10 to 14 V
D79-6)
Ignition switch off,
STA - GND Starter relay operation
Brake pedal depressed, Below 1 V →
(A38-6 - SB - W-B signal
Shift lever position N 10 to 14 V
D79-6) (input)
→ Starter operates
Ignition switch on
RSW - GND
(IG), Below 1 V →
(A38-9 - R - W-B Back-up light switch
D79-6) Shift leverRposition
except → R 10 to 14 V
Pulse
NE - GND
Engine speed signal generation
(A38-10 - L - W-B Idling
from ECM (See waveform
D79-6)
3)
Pulse
NIP- - NIP+ Engine running,
Transmission generation
(A38-15 - V-P Clutch engaged
revolution sensor (See waveform
A38-16) (during driving)
4)
E2S1 - GND
(A38-17 - P - W-B Shift stroke
groundsensor Always Below 1Ω
D79-6) (main)
VSS1 -
Shift stroke sensor
GND
B - W-B voltage monitor Ignition switch on (IG) 0.5 V to 4.5 V
(A38-18 -
(main)
D79-6)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 79/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
VCS1 -
GND Shift stroke sensor
W - W-B Ignition switch on (IG) 4.5 V to 5.5 V
(A38-19 - power source (main)
D79-6)
VCL1 -
GND O - W-B Select stroke sensor Ignition switch on (IG) 4.5 V to 5.5 V
(A38-20 - power source (main)
D79-6)
VSL1 -
Select stroke sensor
GND
V - W-B voltage monitor Ignition switch on (IG) 0.5 V to 4.5 V
(A38-21 -
(main)
D79-6)
E2L1 -
GND Select stroke sensor
Y - W-B Always Below 1 Ω
(A38-22 - ground (main)
D79-6)
Pulse
SPD - GND Ignition switch on
generation
(A38-23 - V - W-B Vehicle speed signal (IG),
(See waveform
D79-6) during driving
5)
E2L2 -
GND GR - W- Select stroke sensor
Always Below 1 Ω
(A38-24 - B ground (sub)
D79-6)
E2R1 -
GND -
(A38-25 LG B
- W- Clutch stroke
ground sensor
(main) Always Below 1 Ω
D79-6)
VSR1 -
Clutch stroke sensor
GND
B - W-B voltage monitor Ignition switch on (IG) 0.5 V to 4.5 V
(A38-26 -
(main)
D79-6)
VCR1 -
GND Clutch stroke sensor
W - W-B Ignition switch on (IG) 4.5 V to 5.5 V
(A38-27 - power source (main)
D79-6)
E2S2 - GND
GR - W- Shift stroke sensor
(A38-28 - Always Below 1 Ω
B ground (sub)
D79-6)
VSS2 -
GND BR - W- Shift stroke sensor
Ignition switch on (IG) 0.5 V to 4.5 V
(A38-29 - B voltage monitor (sub)
D79-6)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 80/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
VCS2 -
GND Shift stroke sensor
R - W-B Ignition switch on (IG) 4.5 V to 5.5 V
(A38-30 - power source (sub)
D79-6)
VCL2 -
GND L - W-B Select stroke sensor Ignition switch on (IG) 4.5 V to 5.5 V
(A38-31 - power source (sub)
D79-6)
VSL2 -
GND LG - W- Select stroke sensor
Ignition switch on (IG) 0.5 V to 4.5 V
(A38-32 - B voltage monitor (sub)
D79-6)
E2R2 -
GND GR - W- Clutch stroke sensor
Always Below 1 Ω
(A38-33 - B ground (sub)
D79-6)
VSR2 -
GND BR - W- Clutch stroke sensor
Ignition switch on (IG) 0.5 V to 4.5 V
(A38-34 - B voltage monitor (sub)
D79-6)
VCR2 -
GND Clutch stroke sensor
G - W-B Ignition switch on (IG) 4.5 V to 5.5 V
(A38-35 - power source (sub)
D79-6)
MSF+ - Ignition switch on
Pulse
GND -
(A37-1 B - W-B Shift motor motor not(IG),
operating → generation
()
D79-6) operating
+BM - GND
Ignition switch off → Below 1 V →
(A37-2 - B - W-B Motor power source
on (IG) 10 to 14 V
D79-6)
MSF- - Ignition switch on Below 1 V →
GND (IG), Pulse
W - W-B Shift motor
(A37-3 - motor not operating → generation
D79-6) operating ()
MSL-
GND - Ignition switch on
(IG), Below 1 V →
Pulse
L - W-B Select motor
(A37-4 - motor not operating → generation
D79-6) operating ()
MSL+ - Ignition switch on Below 1 V →
GND (IG), Pulse
B - W-B Select motor
(A37-5 - motor not operating → generation
D79-6) operating ()
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 81/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Waveform 1:
Communication with Combination Meter
2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 82/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Waveform 2:
CAN Communication Terminal
4.
5. Waveform 3:
Engine speed signal from ECM
Terminal NE - GND
Gauge set 5 V/DIV, 5 ms/DIV
Condition Engine idling
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 83/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
6.
7. Waveform 4:
Transmission Revolution Sensor Terminal
8.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 84/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
9. Waveform 5:
Vehicle Speed Signal Terminal
ECM:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 85/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Waveform 1:
CAN Communication Terminal
2.
3. Waveform 2:
Engine speed signal
Terminal NEO - E1
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 86/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
DIAGNOSIS SYSTEM
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 87/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
DESCRIPTION
• The transmission control ECU has a self-diagnosis system. If the ECU, the multi-
mode manual transmission system or any components fail to operate correctly, the
•
• When troubleshooting Euro-OBD vehicles, the only difference from the usual
troubleshooting procedure is that an OBD scan tool (complying with ISO 15765-
4) or an intelligent tester is connected to the vehicle, and various data output from
the vehicle ECU is read.
• Euro-OBD regulations require that the vehicle's on board computer illuminates
the MIL (Malfunction Indicator Lamp) on the combination meter when the ECM
(Engine Control Module) detects a malfunction in: 1) the emission control
systems and components, or 2) the powertrain control components (which affect
vehicle emissions), or 3) the ECM. Therefore, the transmission control ECU
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 88/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
illuminates the MIL and multi-mode manual transmission warning light together
if malfunctions related to these systems or components are detected.
• If the malfunction does not recur on 3 consecutive trips, the MIL goes out
automatically. However, the DTCs remain recorded in the transmission control
ECU memory.
•
• To check DTCs, connect the OBD scan tool or intelligent tester to the DLC3
(Data Link Connector 3) on the vehicle. The OBD scan tool or intelligent tester
also enables the DTCs to be erased and the freeze frame data and various forms of
engine data to be checked. See the instruction manual of the OBD scan tool or
intelligent tester for details.
• The DTCs include ISO controlled codes and manufacturer controlled codes. ISO
controlled codes must be set as prescribed by the ISO, while manufacturer
controlled codes can be set by the manufacturer within prescribed limits ().
• Freeze frame data record the vehicle conditions (engine speed, vehicle speed,
transmission gear position, shift position, etc.) when malfunctions are detected.
When troubleshooting, the freeze frame data can help determine if the vehicle was
moving or stationary, if the engine was warmed up or not, the transmission gear
was in neutral or not, and other data, from the time the malfunction occurred.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 89/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. The ECU uses ISO 15765-4 for communication. The terminal arrangement of the
DLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format.
Terminal Reference
Symbol Name Result Condition
No. terminal
5-Signal Pulse During
SIL 7 Bus "+" line
ground generation transmission
Chassis
CG 4 Body ground 1 Ω or less Always
ground
Signal
SG 5 Body ground 1 Ω or less Always
ground
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 90/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
5. The DLC3 is the interface prepared for reading various data from the vehicle's
ECU. After connecting the cable of an intelligent tester or OBD scan tool, turn the
ignition switch on (IG) and turn the tester or scan tool ON.
6. If a communication failure message is displayed on the tester or scan tool screen
(on the tester: no information available), a problem exists in either the vehicle or
tester.
anotherInvehicle.
order to identify the location of the problem, connect the tester to
If communication is normal: Inspect the DLC3 on the original vehicle.
If communication is impossible: The problem is probably with the tester itself.
Consult the service department listed in the instruction manual.
BATTERY VOLTAGE
Standard voltage:
11 to 14 V
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 91/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Inspect the battery, fuses, fusible links, wiring harness, connectors and ground.
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > DTC
CHECK / CLEAR
for Preparation
HINT:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 92/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
DTCs which are stored in the transmission control ECU can be displayed on the
intelligent tester.
HINT:
Intelligent testers can display current DTC data, pending DTC data and historical
DTC data. Touch the [Current], [Pending] or [History] button on the DTC display
screen.
[Current]: Displays the current DTC data.
[Pending]: Displays the pending DTC data
[History]: Displays the historical DTC data (past codes).
HINT:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 93/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
• A "!" displayed to the left of DTC data shown in red indicates that freeze
frame data has been recorded for that parameter.
• For further information about using the intelligent tester, refer to the
instruction manual.
HINT:
For further information about using the intelligent tester, refer to the instruction
manual.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 94/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE
SAFE CHARTSYSTEM > FAIL-
for Preparation
FAIL-SAFE CHART
1. If any of the following codes is recorded, the transmission control ECU enters the
fail-safe mode.
10.
cond
•
• Gear does
• P0806 • Clutch stroke •
not change
• P0807 sensor or its circuit
• Vehicle does
• P0808 • Clutch •
not start moving
• P0810 actuator assembly or
again after stopping
• P0900 its circuit •
11.
dete
off
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 95/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
23.
dete
off
Either (a) or
40.
• P0905 • Shift stroke
cond
•
• P0906
P0907 • sensor or its circuit
Shift • Gear does
•
Either (a) or
46.
cond
• Convert •
engine revolution
signals into CAN •
• Engine speed
• P0725 communication
input circuit
signals
• No effect •
47.
dete
off
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 96/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
55.
dete
off
• Gear does
• Transmission not change
control ECU •
Engine
• Clutch cannot be started
• P0603 Pass conditi
actuator, shift • Transmission
• P0885 ignition swi
actuator, select control ECU stops
actuator power engine when vehicle
source circuit stops
• Impossible
• Shift lever
to enter M-mode
position sensor or its
• Gear does
circuit Pass conditi
• P0820 not shift to 1st or
•
Transmission reverse (and forward ignition swi
shift main switch or
or backward gears)
its circuit
76.
• Gear does
cond
not change
•
• CAN • Only
• U0100 communication possible to drive in
•
signal circuit 1st or reverse gears
after vehicle stops
•
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 97/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
77.
dete
off
HINT:
*
• : Transmission gear: Actual transmission gear position
• The transmission control ECU identifies the actual transmission gear
position through the signals from the shift stroke sensor and select stroke
sensor.
• The transmission control ECU identifies the shift lever position through
the signal from the shift lever position sensor.
MULTI-MODE MANUAL
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 98/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
DATA LIST
HINT:
By reading the Data List displayed on an intelligent tester, you can check values,
including those of the switches, sensors, and actuators, without removing any
parts. Reading the Data List as the first step of troubleshooting is one method of
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 99/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
10.3 to 17.9 %:
Running
without load
(2,500 rpm)
1KR-FE:
75 to 95°C (167 • If value -40 °C
to 203°F):
Engine (-40 °F): sensor circuit
Coolant After engine
Coolant open
temperature: warmed up
Temperature • If value 140 °C
Min.: -40°C, 2SZ-FE:
[Coolant (284 °F): sensor circuit
Max.: 140°C 80 to 100°C
Temp] shorted
(176 to 212°F):
After engine
warmed up
Engine Run
Engine run time:
Time Time since
[Eng Run Min.: 0 s, Max.: engine start -
65535 s
Time]
Engine 1KR-FE:
revolutions per 730 to 830 rpm: If NE signal circuit has a short
Engine
minute: Idling or open circuit, back-up engine
Revolution
Min.: 0 rpm, 2SZ-FE: speed data from CAN
[Engine Rev]
Max.: 16,383.75 600 to 700 rpm: communication displayed
rpm Idling
0 km/h (0 mph):
Vehicle
Vehicle Speed Vehicle speed: stationary When vehicle speed
malfunctions, speed value
signal
Min.: 0 km/h, Approximately
[Vehicle Spd] calculated from input
Max.: 255 km/h same value as
revolution signal displayed
combination
meter display
Battery Battery voltage:
10 to 15 V:
Voltage Min.: 0 V, Max.: -
Idling
[Batt] 65.535 V
Accumulated
driving mileage
Drive Mile
after since
malfunction 0 km/h (0 mph): Distance driven since
Malfunction occurrence of diagnosis
detection: System normal
[Driving malfunction displayed
Min.: 0 km/h,
Mileage]
Max.: 65,535
km/h
Running Time Running time Equivalent to
-
from MIL ON from MIL ON: running time
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 100/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 101/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 102/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Sig4]
Shift Lever
ON: Shift lever
Switch Shift lever
position in (-) LSW5 (LSW-) terminal signal
Signal5 switch signal (-):
OFF: Other of transmission control ECU
[Shift SW OFF or ON
Sig5] than above
LS2C (LSRC) terminal signal
Shift Lever Check signal of OFF: Shift lever
of transmission ECU
Check Signal1 shift lever switch position in (R)
Reversal signal of LSW2
[Shift Chek signal 2: ON: Other than
(LSWR) (ON and OFF
Sig1] OFF or ON above
reversed)
OFF: Shift lever
LS3C (LSSC) terminal signal
Shift Lever Check signal of position in (E),
of transmission control ECU
Check Signal2 shift lever switch (M), (+) or (-)
Reversal signal of LSW3
[Shift Chek signal 3: ON: Shift lever
(LSWS) (ON and OFF
Sig2] OFF or ON position in (R) reversed)
or (N)
LS4C (LSNC) terminal signal
Shift Lever Check signal of OFF: Shift lever
of transmission ECU
Check Signal3 shift lever switch position in (N)
Reversal signal of LSW4
[Shift Chek signal 4: ON: Other than
(LSWN) (ON and OFF
Sig3] OFF or ON above
reversed)
ON:
T/M Reverse Transmission During malfunctions, indicator
Transmission
Switch Signal reverse switch shows either OFF or ON
gear in reverse
[T/M R SW signal: continuously, regardless of
OFF: Other
Sig] OFF or ON than above gear position
Ignition switch
Ignition Signal ON: Ignition
signal: -
[Ignition Sig] switch on (IG)
OFF or ON
Mode Switch Transmission ON: Sequential
Signal shift main switch shift control
-
[Mode SW signal: (M-mode)
Sig] OFF or ON selected
ON: Sporty [Es]
Es Mode Es Mode Switch
mode selected
Switch Signal Signal: (Automatic -
[Es SW Sig] OFF or ON
shift control)
ON: Parking
Parking Brake Parking brake
brake applied
Signal switch signal: -
OFF: Parking
[Pkb Sig] OFF or ON
brake released
Brake Switch Brake switch OFF: Brake ST1- terminal signal of
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 103/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Target shift
Shift Position position: positions:
Maximum of 15
(Target) Min.: 0 mm, mm during gear -
[Shift Pos-Tar] Max.: 127.998 change control
mm operation
(varies with
vehicle
condition)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 104/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Difference
between actual
and target select
Target select positions:
Select Position
position: Maximum of 15
(Target)
[Select Pos- Min.: 0 mm, mm during gear -
Max.: 127.998 change control
Tar]
mm operation
(varies with
vehicle
condition)
Requested clutch
Clutch Motor
motor current
Current Req Instruction (calculated) current
from CPU: -20 to 20 A
[Clutch Motor value from CPU
Min.: -50 A,
Req]
Max.: 50 A
Clutch Motor Actual clutch
Current MMT motor current: 0 A: When clutch motor not in
-20 to 20 A
[Clutch Min.: -50 A, operation
Motor] Max.: 50 A
Requested shift
Shift Motor
motor current
Current Req Instruction (calculated) current
from CPU: -40 to 40A
[Shift Motor value from CPU
Min.: -50 A,
Req]
Max.: 50 A
Actual shift
Shift Motor
Current MMT motor current: -40 to 40A 0 A: When shift motor not in
Min.: -50 A, operation
[Shift Motor]
Max.: 50 A
Requested select
Select Motor
motor current
Current Req Instruction (calculated) current
from CPU: -25 to 25 A
[Select Motor value from CPU
Min.: -50 A,
Req]
Max.: 50 A
Actual select
Select Motor
motor current: 0 A: When select motor not in
Current MMT -25 to 25 A
[Select Motor] Min.:
Max.: -50 A,
50 A operation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 105/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Reference value
(varies with
Current clutch load:
vehicle
Calculated from average clutch
condition)
motor current
39.33 to 45.29:
Current clutch Difference between Base
Current Clutch load (calculated Stopper Clutch Load and Current
Load position
value): Clutch Load increases as clutch
[Current 37.07 to 43.03:
Min.: -1000 N, disks wear away
Clutch Load] Complete
Max.: 1000 N After performing LCC
engagement
adjustment, difference
position
decreases (Almost same as
24.5 to 35.25:
Base Clutch Load value)
Standby
position
Number of LCC
(Load Controlled
Clutch
Count Adjust Clutch cover) When clutch motor stroke
adjustment - amount reaches certain value,
[Clutch Adj
performed: the count increases by 1
Cnt]
Min.: 0 , Max.:
255
Number of LCC
(Load Controlled
Clutch Adjust Clutch cover) When difference between Base
Fail Count adjustment Clutch Load and Current
-
[Clutch Adj judged Clutch Load exceeds threshold,
Fail] unnecessary: the count increases by 1
Min.: 0 , Max.:
255
Number of LCC
(Load Controlled
Clutch Adjust When difference between Base
Clutch cover)
Detection Clutch Load and Current
adjustment -
[Clutch Adj Clutch Load exceeds threshold,
required:
Detect] the count increases by 1
Min.: 0 , Max.:
255
11: System wake-up control
mode
12: Vehicle driving control
System control
Mode Changes mode
mode:
[Mode - 13: System end control mode
Min.: 0, Max.:
Changes] 14: System initialization mode
255
17: Engine starting control
mode
20: Fixed gear shift control
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 106/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
mode
21: Gear shift control mode
22: Shift lever lock control
mode
25: Shut-down control mode
26: Vehicle stationary control
mode
27: Vehicle start off control
mode
Gear change
Gear Mode
mode indication:
Changes - -
Min.: 0, Max.:
[Gear Mode]
255
1st Uplock
1st gear up-lock
Signal
signal:
[1st Uplock
Sig] OFF or ON
2nd Uplock
2nd gear up-lock
Signal
signal:
[2nd Uplock
OFF or ON
Sig]
3rd Uplock If gear shift fails, uplock signal
3rd gear up-lock
Signal indicates whether transmission
signal:
[3rd Uplock up-lock has occurred or not
OFF or ON
Sig] Up-lock:
-
4th Uplock Transmission gear momentarily
Signal 4th gear up-lock cannot be engaged due to
signal: mechanical reasons (not
[4th Uplock
OFF or ON malfunction)
Sig]
5th Uplock
5th gear up-lock
Signal
signal:
[5th Uplock
OFF or ON
Sig]
Rev Uplock
Reverse gear up-
Signal
lock signal:
[Rev Uplock
OFF or ON
Sig]
Vehicle Speed Vehicle speed
ON: When momentarily
Signal Open signal circuit OFF: During
interruption in vehicle speed
[Vehicle Spd open judgement: vehicle running
signal
Open] OFF or ON
Input Rev Input revolution OFF: During ON: When abnormal pulse
Signal Open signal circuit engine running interval detected
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 107/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
•
Engine running
• Transmission
ON: Clutch
gear in 1st, 2nd or
Vehicle creep partial
Creep Control Reverse
control mode: engagement
[Creep Ctrl] • Brake pedal not
OFF or ON continues for
depressed
long time
• Parking brake
released
• Accelerator
pedal released
+B terminal low
Low Voltage OFF: +B
voltage
Signal terminal voltage -
judgement:
[Low Volt] 8 V or more
OFF or ON
ON: High differential spin
occurred sharply at differential
gear
When following conditions
met, transmission control ECU
detects run-off in vehicle and
restricts gear shift:
Run Off Vehicle run-off
OFF: While
Signal judgement • Accelerator
vehicle running
[Run Off Sig] OFF or ON pedal angle exceeds
threshold
• SPD signal
change rate above
threshold
• Shift position in
1st, 2nd or 3rd
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 108/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
ON: Ignition
Motor Relay switch on (IG)
AMT relay drive
Signal OFF: Ignition
signal: -
[Mot Relay switch off and
OFF or ON
Sig] after system
shut-down
Shift lever lock
Shift Lever
solenoid OFF: Shift lever
Lock Solenoid -
operation: locked
[SLS]
OFF or ON
Clutch touch
Clutch Touch position: Difference between Clutch
Position Learning value Touch position and Clutch
Min.: 0 mm,
[Clt Touch shown Clamp Position within 4.0 mm
Max.: 127.998
Pos] (0.16 in.) to 16.0 mm (0.63 in.)
mm
Clutch clamp
Clutch Clamp Difference between Clutch
position:
Position Learning value Touch position and Clutch
Min.: 0 mm,
[Clt Clamp shown Clamp Position within 4.0 mm
Max.: 127.998
Pos] (0.16 in.) to 16.0 mm (0.63 in.)
mm
Neutral position
Neutral
Position (shift position): Learning value Median value between [3rd Pos
Min.: 0 mm, (Shift)] and [4th Pos (Shift)]
(Shift) shown
Max.: 127.998 displayed
[N Pos (Shift)]
mm
Neutral Neutral position Median value between [1st Pos
Learning value
Position (select position): (Sel)] and [5th Pos (Sel)]
shown
(Select) Min.: 0 mm, displayed
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 109/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 110/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 111/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Reverse gear
Reverse Gear position (select Difference between [R Pos
position): Learning value (Sel)] and [4th Pos (Sel)]
Pos (Select)
Min.: 0 mm, shown within 5.5 mm (0.22 in.) to 8.5
[R Pos (Sel)]
Max.: 127.998 mm (0.33 in.)
mm
Yes: Transmission gear
Possibility of No:
Possibility of temporarily could not be
transmission up- Initialization
T/M Uplock engaged due to mechanical
lock: and learning
[T/M Uplock] reasons during gear position
No or Yes complete
learning
ACTIVE TEST
HINT:
Performing an Active Test enables components including the relays, VSV
(Vacuum Switching Valve), and actuators, to be operated without removing any
parts. The Active Test can be performed with an intelligent tester. Performing an
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 112/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Test Details/Vehicle
Items Diagnosis Notes
conditions
If shift and select actuator does not
[Test Details]
shift to the gear indicated, there
Target gear position control
could be some malfunctions in the
Target Gear (Gear
N, 1st,position)
2nd, 3rd, 4th, 5th, R following parts:
Shift stroke sensor
Position [Vehicle Conditions]
Select stroke sensor
Control Ignition switch on (IG),
Shift and select actuator assembly
Engine stopped, Vehicle
AMT relay
stationary, Shift lever N
Transmission assembly
position
Transmission control ECU
If clutch actuator does not operate to
[Test Details]
the position indicated, there could be
Target clutch control
some malfunctions in the following
Standby position: Standby
parts:
Target Clamp position: Clamp Clutch stroke sensor
Clutch [Vehicle Conditions]
Clutch actuator assembly
Control Ignition switch on (IG),
AMT relay
Engine stopped, Vehicle
Clutch release bearing
stationary, Shift lever N
Clutch release fork
position
Transmission control ECU
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 113/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
ADJUSTMENT
for Preparation
• The multi-mode manual transmission system has a load controlled clutch cover
(adjustment system). The pressure plate moves depending on the wear condition
of the clutch disc lining.
When removing or installing any parts related to the multi-mode manual
•
transmission system, move the clutch actuator to the clutch clamp position. This is
for normal operation of the load controlled clutch cover (adjustment system).
If the clutch position adjustment operation input fails, perform the operation again
•
from step (a) more than 15 seconds after turning the ignition switch off.
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 114/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Do not depress the brake pedal while performing the clamp position adjustment
using an intelligent tester.
•
• Shift the ignition
Turn the lever intoswitch
the Noff.
position.
• Apply the parking brake.
5. Select the following menu items: Powertrain / Multi-Mode M/T / Utility / Parts
Exchange.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 115/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
9. After checking the vehicle condition, press the Next key.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 116/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 117/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
14. On the Multi-Mode M/T / Utility screen, select Step 1 Clutch Position Adjustment
(Clamp Position Adjustment).
15. Press the Next key.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 118/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
HINT:
Perform [Initialization and Learning] after repairing the multi-mode manual
transmission control system ().
• The multi-mode manual transmission system has a load controlled clutch cover
(adjustment system). The pressure plate moves depending on the wear condition
of the clutch disc lining.
• When removing or installing any parts related to the multi-mode manual
transmission system, move the clutch actuator to the clutch clamp position. This is
for normal operation of the load controlled clutch cover (adjustment system).
•
If the clutch position adjustment operation input fails, perform the operation again
from step (a) more than 15 seconds after turning the ignition switch off.
2. Using SST, connect terminals TC (13) and CG (4) of the DLC3
SST
09843-18040
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 119/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Turn the ignition switch on (IG) with the brake pedal released.
6. Shift the shift lever in the following sequence with the brake pedal depressed:
N→E→M→+→M→+→M→+→M→+→M→E→ N.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 120/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
HINT:
If the buzzer does not sound at this time, wait at least 15 seconds after turning the
ignition switch off. Then, perform the procedure from step (a) again.
11. Shift the shift lever to the [-] position with the brake pedal depressed.
HINT:
Perform [Initialization and Learning] after repairing the multi-mode manual
transmission control system ().
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 121/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
for Preparation
DESCRIPTION
In this vehicle, since the starter motor control depends on the ECM due to cranking
holding function, the ST relay that supplies power to the starter motor is operated by the
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 122/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
ECM. When the appropriate vehicle conditions are satisfied (the brake pedal is depressed
and the transmission gear is in neutral) the engine can be cranked. If the brake pedal is
not depressed or the transmission gear is not in neutral, the engine cannot be cranked.
During cranking, the ST relay operation signal (STA signal) is input into the STA
terminal of the transmission control ECU, and is used to control the multi-mode manual
transmission system.
WIRING DIAGRAM
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 123/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 124/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 125/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 126/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
INSPECTION PROCEDURE
1.READ VALUE USING INTELLIGENT TESTER
2. Turn the ignition switch on (IG) and turn the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data List / STA
Switch Signal.
4. Check
and thethe valuestarts.
engine displayed on the tester when the ignition switch is turned on (IG)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 127/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
NG
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 128/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Remove the ST relay from the engine room relay block.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 129/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard resistance:
Specified
Tester Connections
Conditions
1KR-FE:
STA (A32-27) -
STA (A38-6) Below 1 Ω
2SZ-FE:
STA (A21-48) -
STA (A38-6)
STA (A38-6) - Body
10 k Ωor higher
ground
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 130/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 131/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
for Preparation
DESCRIPTION
While the vehicle is driven with the shift lever in the E position, the most appropriate
gear is automatically selected in accordance with the accelerator pedal opening angle and
vehicle speed. In this time, shift control can be switched between normal mode (E) and
sports mode (Es) by pressing the pattern select switch.
WIRING DIAGRAM
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 132/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
INSPECTION PROCEDURE
1.INSPECT PATTERN SELECT SWITCH ASSEMBLY
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 133/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard resistance:
Tester Switch Specified
Connections Conditions Conditions
1-4 ON Below 1 Ω
10 k Ω or
1-4 OFF higher
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 134/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
Standard resistance:
Tester Switch Specified
Connections Conditions Conditions
PWR (D79-
10 k Ω or
23) - Body OFF
higher
ground
PWR (D79-
23) - Body ON Below 1 Ω
ground
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 135/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 136/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Measure the voltage between the terminal of the transmission control ECU
connector and the body ground when the pattern select switch is ON and OFF.
Standard voltage:
Tester Switch Specified
Connections Conditions Conditions
Pattern
PWR (D79-
select
23) - Body 10 to 14 V
switch
ground
OFF
PWR (D79- Pattern
23) - Body select Below 1 V
ground switch ON
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 137/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
REPLACE TRANSMISSION
NG CONTROL ECU ASSEMBLY
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 138/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 139/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
INSPECTION PROCEDURE
1.READ VALUE USING INTELLIGENT TESTER
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 140/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Turn the ignition switch on (IG) and turn the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data List /
Ignition Signal.
4. Read the value.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 141/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 142/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Measure the voltage between the terminal of the transmission control ECU
connector and the body ground.
Standard voltage:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 143/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
REPLACE TRANSMISSION
OK CONTROL ECU ASSEMBLY
NG
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 144/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the integration relay from the engine room relay block.
2. Measure the voltage between the terminal of the integration relay and the body
ground.
Standard voltage:
Specified
Tester Connections
Conditions
Integration relay (1C-
10 to 14 V
1) - Body ground
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 145/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
NG CONNECTOR (INTEGRATION
RELAY - BATTERY)
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 146/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard resistance:
Below 1 Ω
Standard resistance:
Tester Specified
Connections Conditions
1C-1 - 1B-4 10 k Ω or higher
Below 1 Ω
(When battery
1C-1 - 1B-4 voltage applied to
terminals 1B-2 and
1B-3)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 147/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 148/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the IGN fuse from the main body ECU.
Standard resistance:
Below 1 Ω
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 149/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 150/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 151/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Specified
Tester Connections
Conditions
Integration relay (1B-
Below 1 Ω
4) - IG (D79-3)
Standard resistance (Check for short):
Specified
Tester Connections
Conditions
IG (D79-3) - Body
10 k Ω or higher
ground
Result:
Proceed
Result
To
Outside normal range A
Within normal range (with
B
Entry and Start System)
Within normal range
(without Entry and Start C
System)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 152/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
B Go to step 7
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 153/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
C Go to step 8
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 154/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 155/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 156/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 157/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 158/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 159/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 160/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 161/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 162/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
for Preparation
DESCRIPTION
The shift lock solenoid is built into the shift lever assembly. When the ignition switch is
turned off, or when the shift lever is in the N position without depressing the brake pedal
although the ignition switch is turned on (IG), the shift lock solenoid restricts the shift
lever movement.
The transmission control ECU sends the shift lock cancellation signal to the shift lock
solenoid to cancel the shift lock when the multi-mode manual transmission system
conditions are satisfied.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 163/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
WIRING DIAGRAM
INSPECTION PROCEDURE
1.INSPECT SHIFT LOCK SOLENOID
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 164/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard resistance:
Tester Specified
Connections Conditions
IG (D81-2) - E 30 to 35 Ω at 20°C
(D81-6) (68°F)
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 165/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 166/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
E (D81-6) - Body
Below 1 Ω
ground
SLS (D79-5) - Body
10 k Ω or higher
ground
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 167/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
2. Measure the voltage between the terminal of the transmission control ECU and
the body ground when the brake pedal is operated.
Standard voltage:
Pedal Tester Specified
Conditions Connections Conditions
Brake SLS (D79-5)
pedal - Body 10 to 14 V
depressed ground
Brake
SLS (D79-5)
pedal Below 1 V
Body ground
released
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 168/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
REPLACE TRANSMISSION
NG CONTROL ECU ASSEMBLY
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 169/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
for Preparation
DESCRIPTION
The combination meter interprets the multi-mode manual transmission system condition
through information from the INDC and INDA circuits, and if necessary, illuminates
(blinks) the multi-mode manual transmission warning light and sounds the buzzer.
• INDC Terminal Circuit:
The battery voltage is constantly supplied to the INDC circuit. If the INDC circuit
is open, the combination meter detects a malfunction in the circuit and illuminates
the multi-mode manual transmission warning light. The INDC circuit is used to
send the multi-mode manual transmission warning light signal to the combination
meter when the ignition switch is off.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 170/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 171/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
meter)
Shift ON ON
position depends on depends on
OFF OFF OFF OFF
indicator communication communication
*
1 signal signal
Multi-mode
ON ON
manual
depends on depends on
transmission ON ON OFF ON
communication communication
warning
signal signal
light
*
1: when shift position indicator ON, the number or letter segments are illuminated.
WIRING DIAGRAM
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 172/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
INSPECTION PROCEDURE
HINT:
• Check that the multi-mode manual transmission warning light and shift position
indicator light come on.
Under normal conditions, the shift position indicator indicates the current gear
position while the ignition switch is turned on (IG), and the multi-mode manual
transmission warning light comes on for a bulb check for approximately 5
seconds when the ignition switch is turned from off to on (IG).
If the shift position indicator light does not come on, the INDA circuit may be
malfunctioning. If the multi-mode manual transmission warning light does not
come on, the INDA and/or INDC circuits may be malfunctioning.
• The buzzer built into the combination meter sounds when the following
conditions are met:
The shift lever is in any position except N.
•
•
The driver's door is open.
• Vehicle speed is 10 km/h (6.21 mph) or less.
• Engine speed is 400 rpm or more.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 173/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard resistance:
Specified
Tester Connections
Conditions
INDC (D79-29) -
Below 1 Ω
BRQ (D1-13)
INDA (D79-31) -
Below 1 Ω
TX+ (D1-8)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 174/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 175/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 176/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 177/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 178/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 179/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 180/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 181/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 182/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 183/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Measure the voltage between the terminal of the transmission control ECU
connector and the body ground when the parking brake switch is ON and OFF.
Standard voltage:
Tester Switch Specified
Connections Conditions Conditions
Parking
PKB (D79-
brake
4) - Body 10 to 14 V
switch
ground
OFF
Parking
PKB (D79-
brake
4) - Body switch Below 1 V
ground
ON
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 184/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 185/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
for Preparation
DESCRIPTION
Terminal TC and CG are located in the DLC3. When performing [Clamp Position
Adjustment] and [Initialization and Learning] without using an intelligent tester,
connecting terminals TC and CG is necessary. If the TC terminal circuit is open, these
calibration procedures cannot be performed without using an intelligent tester.
WIRING DIAGRAM
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 186/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
INSPECTION PROCEDURE
1.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU -
DLC3)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 187/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard resistance:
Specified
Tester Connections Conditions
DG (D79-25) - TC
Below 1 Ω
(D15-13)
DG (D79-25) -
10 k Ωor higher
Body ground
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 188/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 189/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard resistance:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 190/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
OK
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 191/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE OIL > ON-VEHICLE
INSPECTION
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 192/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the
filler plug opening.
NOTICE:
4. When the oil level is low, check for oil leakage.
Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 193/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 194/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 195/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 196/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 197/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 198/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 199/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 200/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Remove the drain plug and gasket, and drain the oil.
Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
1. Using SST and a hammer, release the staked part of the axle hub nut.
SST
09930-00010
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 201/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
NOTICE:
• Insert SST into the groove with the flat surface facing up.
• Do not damage the tip of SST using grinders.
• Completely unstake the staked part before removing the axle hub nut.
•
Do not damage the threads of the drive shaft.
2. Using a 30 mm socket wrench, remove the axle hub nut.
1. Remove the bolt and separate the speed sensor and flexible hose.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 202/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Remove the bolt and separate the speed sensor from the steering knuckle.
NOTICE:
• Keep the speed sensor tip and installation portion free of foreign matter.
• Remove the speed sensor without turning it from its original installation
angle.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 203/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
SST
09628-00011
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 204/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Using SST, separate the tie rod end from the steering knuckle.
SST
09628-62011
NOTICE:
Do not damage the tie rod end dust cover.
1. Remove the nut and separate the stabilizer link from the shock absorber.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 205/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
HINT:
If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold
the stud.
1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting
between the drive shaft and front axle.
HINT:
If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass
bar and hammer.
2. Push the front axle out of the vehicle to remove the drive shaft from the front
axle.
NOTICE:
• Do not push the front axle further out of the vehicle than is necessary.
•
Do not damage the outboard joint boot.
• Do not damage the speed sensor rotor.
• Suspend the drive shaft with a piece of string or the equivalent.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 206/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
SST
09520-01010
09520-24010 (09520-32040)
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 207/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 208/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 209/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
INSTALLATION
for Preparation
SST
09636-20010
Drive in depth:
1.7 to 2.7mm (0.067 to 0.106 in.)
NOTICE:
Do not damage the oil seal lip.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 210/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
SST
09316-60011 (09316-00011)
Drive in depth:
2.1 to 3.1mm (0.083 to 0.122 in.)
NOTICE:
Do not damage the oil seal lip.
1. Coat the spline of the inboard joint with gear oil.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 211/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 212/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
74 N*m{ 755 kgf*cm , 55 ft.*lbf }
HINT:
If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold
the stud.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 213/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install the tie rod end onto the steering knuckle with a new castle nut.
Torque:
49 N*m{ 500 kgf*cm , 36 ft.*lbf }
NOTICE:
If the holes for the clip are not aligned, tighten the nut by a further turn of up to
60°.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 214/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install the lower arm onto the steering knuckle with a new castle nut.
Torque:
98 N*m{ 1,000 kgf*cm , 72 ft.*lbf }
NOTICE:
If the holes for the clip are not aligned, tighten the nut by a further turn of up to
60°.
HINT: The installation procedure for the RH side is the same as that for the LH side.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 215/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install the speed sensor onto the steering knuckle with the bolt.
Torque:
• Check that the speed sensor tip and installation portion are free of foreign
matter.
• Install the speed sensor without turning it from its original installation
angle.
2. Install the flexible hose and speed sensor with the bolt.
Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
NOTICE:
Install the flexible hose and speed sensor without twisting them.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 216/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
216 N*m{ 2,203 kgf*cm , 160 ft.*lbf }
2. Using a chisel and hammer, caulk the axle hub nut.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 217/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the
filler plug opening.
NOTICE:
4. When the oil level is low, check for oil leakage.
Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 218/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 219/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 220/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 221/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 222/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/2
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 223/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 224/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 225/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 226/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard Resistance:
30 to 35 Ω at 20°C (68°F)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 227/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 228/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
5. Using an ohmmeter, measure the resistance according to the value in the table
below.
Standard Resistance:
Shift Specified
Terminals
position condition
10 k Ω or
E 4-8
higher
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 229/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 230/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 231/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 232/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 233/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 234/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Disengage the 4 claws and remove the position indicator light guide from the shift
lever assembly.
3. Disengage the 4 claws and remove the position indicator housing from the
position indicator light guide.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 235/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 236/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Using a screwdriver with its tip wrapped in protective tape, release the secondary
lock.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 237/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 238/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Connect marked wire harnesses 2 and 4 to the indicator light wire connector as
shown in the illustration.
2. Connect wire harnesses 6 and 8 to the indicator light wire connector as shown in
the illustration.
5. Connect the indicator light wire connector onto the shift lever assembly.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 239/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Apply MP grease to the shift lock release button and spring.
2. Install the shift lock release button and spring onto the shift lever.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 240/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 241/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Connect the indicator light wire onto the shift lever assembly.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 242/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
12 N*m{ 122 kgf*cm , 8.9 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 243/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 244/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE ASSEMBLY >
COMPONENTS
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 245/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 246/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 247/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1 / 10
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 248/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 249/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 250/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2 / 10
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 251/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 252/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 253/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3 / 10
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 254/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 255/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 256/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 257/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 258/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 259/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 260/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 261/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 262/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
6 / 10
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 263/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 264/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 265/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
7 / 10
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 266/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 267/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 268/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
8 / 10
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 269/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 270/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 271/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
9 / 10
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 272/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 273/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 274/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
10 / 10
MULTI-MODE MANUAL
TRANSAXLE ASSEMBLY >
REMOVAL
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 275/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the floor carpet and 2 clips and remove the column hole cover silencer.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 276/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Use a seat belt to fix the steering wheel assembly, in order to avoid breakage of
the spiral cable.
2. Place matchmarks on the sliding yoke of the steering intermediate shaft assembly
and the power steering.
3. Loosen bolt A, remove bolt B and separate the steering intermediate shaft
assembly.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 277/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 278/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Disengage the 7 clips and remove the hood to cowl top seal.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 279/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Disengage the 2 hooks and remove cowl top ventilator louver center No. 1.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 280/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Disconnect the washer hose and remove the cowl top ventilator louver sub-
assembly.
2. Disengage the 4 claws and remove the cowl top ventilator louver LH.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 281/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Disengage the 10 claws and clip and remove the cowl top ventilator louver sub-
assembly.
2. Disengage the 4 claws and remove the cowl top ventilator louver LH.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 282/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Slide the wiper link. Disengage the meshing of the rubber pin, then disconnect the
connector and remove the front wiper motor and link.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 283/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Disengage the claws and remove cowl to resister duct No. 2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 284/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Disengage the clamp and separate the wiper motor connector.
2. Remove the 9 bolts and the cowl top panel outer.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 285/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 286/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 287/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the bolt and separate the wire harness bracket.
2. Disconnect the clutch stroke sensor connector and motor connector.
NOTICE:
Do not forcibly pull the connector as this may damage the wire harness.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 288/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
NOTICE:
• Loosen the bolts slowly, and be careful not to get your fingers caught as
the clutch actuator assembly moves due to the reaction force from the
clutch cover.
• Do not drop the removed clutch actuator assembly or subject it to any
impacts.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 289/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 290/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Remove exhaust pipe support No. 4 and the exhaust front pipe assembly.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 291/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 292/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Remove the 3 No. 4 exhaust pipe supports and remove the exhaust pipe assembly
front.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 293/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a hammer, release the staked part of the axle hub nut.
SST
09930-00010
NOTICE:
• Insert SST into the groove with the flat surface facing up.
• Do not damage the tip of SST using grinders.
• Completely unstake the staked part before removing the axle hub nut.
• Do not damage the threads of the drive shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 294/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the bolt and separate the speed sensor and flexible hose.
2. Remove the bolt and separate the speed sensor from the steering knuckle.
NOTICE:
• Keep the speed sensor tip and installation portion free of foreign matter.
• Remove the speed sensor without turning it from its original installation
angle.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 295/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
SST
09628-00011
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 296/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Using SST, separate the tie rod end from the steering knuckle.
SST
09628-62011
NOTICE:
Do not damage the tie rod end dust cover.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 297/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the nut and separate the stabilizer link from the shock absorber.
HINT:
If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold
the stud.
1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting
between the drive shaft and front axle.
HINT:
If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass
bar and hammer.
2. Push the front axle out of the vehicle to remove the drive shaft from the front
axle.
NOTICE:
• Do not push the front axle further out of the vehicle than is necessary.
• Do not damage the outboard joint boot.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 298/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
SST
09520-01010
09520-24010 (09520-32040)
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 299/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a screwdriver and hammer, remove the drive shaft.
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 300/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Parts No.:
No. 1 engine hanger 12281-40030
No. 2 engine hanger 12282-40010
Bolt 91671-80820
Torque:
NOTICE:
Do not attempt to hang the engine by hooking the chain to any other part.
Parts No.:
No. 1 engine hanger 12281-23021
No. 2 engine hanger 12282-23010
Bolt 91671-80820
Torque:
NOTICE:
Do not attempt to hang the engine by hooking the chain to any other part.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 301/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the bolt and separate the engine moving control rod.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 302/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 3 bolts and the engine moving control rod bracket.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 303/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the bolt and nut, then separate the engine mounting insulator LH.
2. Remove the 4 bolts and the engine mounting insulator LH.
1. Remove the bolt and nut, then separate the engine mounting insulator LH.
2. Remove the 5 bolts and the engine mounting insulator LH.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 304/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
FE)
1. Remove the 4 bolts and the engine mounting bracket LH.
1. Remove the 4 bolts and the engine mounting bracket LH.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 305/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 9 bolts and multi-mode manual transaxle from the engine.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 306/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE ASSEMBLY >
INSTALLATION
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 307/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Align the input shaft with the clutch disc and install the manual transaxle onto the
engine.
Torque:
64 N*m{ 653 kgf*cm , 47 ft.*lbf } for bolt A
39 N*m{ 398 kgf*cm , 29 ft.*lbf } for bolt B
NOTICE:
• Insert dowel pins into dowel holes securely so that the end face of
transaxle assembly fits close against engine assembly before tightening the
bolts between the engine and transaxle.
• Make sure that the dowel pins are not loose, bent, damaged or scratched
and then install the transaxle onto the engine with the contact surfaces of
the engine and transaxle flat against each other.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 308/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
64 N*m{ 653 kgf*cm , 47 ft.*lbf }
Torque:
64 N*m{ 653 kgf*cm , 47 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 309/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf } for bolt A
64 N*m{ 653 kgf*cm , 47 ft.*lbf } for bolt B
2. Install the engine mounting bracket LH and engine mounting insulator LH with
the bolt and nut.
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf } for nut C
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 310/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf }
2. Install the engine mounting bracket LH and engine mounting insulator LH with
the bolt and nut.
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf }
1. Install the engine mounting control bracket with the 3 bolts.
Torque:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 311/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Provisionally install the front suspension crossmember onto the body with the 6
bolts.
3. By inserting SST into the datum holes in the front suspension crossmembers RH
and LH alternately, tighten bolts A, B and C on both sides to the specified torque,
in several steps.
SST
09670-00011
Torque:
70 N*m{ 714 kgf*cm , 52 ft.*lbf } for Bolt A
160 N*m{ 1,631 kgf*cm , 118 ft.*lbf } for Bolt B
95 N*m{ 969 kgf*cm , 70 ft.*lbf } for Bolt C
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 312/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 313/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Install the engine moving control rod with the bolt.
Torque:
120 N*m{ 1,224 kgf*cm , 89 ft.*lbf }
1. Coat the spline of the inboard joint with gear oil.
2. Align the inboard joint splines and install the drive shaft with a screwdriver and
hammer.
NOTICE:
• Face the cut area of the front drive inboard joint hole snap ring downward.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 314/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
HINT:
Confirm whether the drive shaft is securely driven in by checking the reaction
1. Push the front axle out of the vehicle to align the spline of the drive shaft with the
front axle and insert the front axle.
NOTICE:
• Do not push the front axle further out of the vehicle than is necessary.
• Do not damage the outboard joint boot.
• Check for any foreign matter on the speed sensor rotor and insertion part.
• Do not damage the speed sensor rotor.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 315/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
74 N*m{ 755 kgf*cm , 55 ft.*lbf }
HINT:
If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold
the stud.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 316/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install the tie rod end onto the steering knuckle with a new castle nut.
Torque:
49 N*m{ 500 kgf*cm , 36 ft.*lbf }
NOTICE:
If the holes for the clip are not aligned, tighten the nut by a further turn of up to
60°.
1. Install the lower arm onto the steering knuckle with a new castle nut.
Torque:
98 N*m{ 1,000 kgf*cm , 72 ft.*lbf }
NOTICE:
If the holes for the clip are not aligned, tighten the nut by a further turn of up to
60°.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 317/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install the speed sensor onto the steering knuckle with the bolt.
Torque:
8.5 N*m{ 87 kgf*cm , 75 in.*lbf }
NOTICE:
• Check that the speed sensor tip and installation portion are free of foreign
matter.
• Install the speed sensor without turning it from its original installation
angle.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 318/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Install the flexible hose and speed sensor with the bolt.
Torque:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 319/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
216 N*m{ 2,203 kgf*cm , 160 ft.*lbf }
2. Using a chisel and hammer, caulk the axle hub nut.
1. Using vernier calipers, measure the free length of the compression spring.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 320/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket
until its surface is flush with the exhaust manifold.
NOTICE:
4. Install the exhaust front pipe assembly and a new exhaust pipe gasket with the 4
compression springs and 4 bolts.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 321/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
43 N*m{ 439 kgf*cm , 32 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 322/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using vernier calipers, measure the free length of the compression spring.
Minimum length:
40.5 mm (1.594 in.)
2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket
until its surface is flush with the exhaust manifold.
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 323/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Install the exhaust pipe assembly front with the 2 compression springs and 2 bolts.
Torque:
43 N*m{ 439 kgf*cm , 32 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 324/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
Torque:
9.8 N*m{ 100 kgf*cm , 87 in.*lbf }
5. Install the harness clamp.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 325/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
Torque:
9.8 N*m{ 100 kgf*cm , 87 in.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 326/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
26 N*m{ 260 kgf*cm , 19 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 327/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Sealant:
Toyota Genuine Release Hub Grease or Equivalent
2. Set the clutch actuator to the transaxle and provisionally tighten the 3 bolts.
NOTICE:
Keep the clearance between the bolt head and actuator flange.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 328/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Gently hold down the clutch actuator assembly toward flat surface of transmission
assembly and slide it so that the convex portion of the clutch actuator rod comes
into contact with the concave portion of the release lever.
NOTICE:
4. Tighten the 3 bolts by hand while holding the clutch actuator assembly.
NOTICE:
Support the clutch actuator assembly until all the 3 bolts are tightened.
5. Tighten the 3 bolts to the specified torque in the order A, B, and C, as shown.
Torque:
17 N*m{ 173 kgf*cm , 13 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 329/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
6. Connect the clutch stroke sensor connector and motor connector.
7. Install the wire harness bracket onto the transaxle with the bolt.
Torque:
13 N*m{ 131 kgf*cm , 9.5 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 330/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 331/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 332/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 333/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Engage the 2 claws and install cowl to register duct No. 2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 334/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Slide the wiper link as shown in the illustration and engage the rubber pin with
the body.
3. Install the front wiper motor and link with the 2 bolts.
Torque:
5.5 N*m{ 56 kgf*cm , 49 in.*lbf }
1. Engage the 4 claws and install the cowl top ventilator louver LH.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 335/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Engage the 11 claws and install the cowl top ventilator louver sub-assembly.
3. Install the clip.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 336/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
5. Engage the 2 hooks and install cowl top ventilator louver center No. 1.
1. Engage the 4 claws and install the cowl top ventilator louver LH.
2. Install the clip.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 337/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Engage the 10 claws and install the cowl top ventilator louver sub-assembly.
1. Engage the 7 clips and install the hood to cowl top seal.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 338/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Scrape any metal powder off the serrated part of the wiper arm with a round file
or the equivalent (when reinstalling).
3. Operate the wiper, then stop the windshield wiper motor in the automatic stop
position.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 339/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Align the blade tip with the mark on the windshield glass, as shown in the
illustration.
Torque:
26 N*m{ 265 kgf*cm , 19 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 340/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Scrape any metal powder off the serrated part of the wiper arm with a round file
or the equivalent (when reinstalling).
3. Operate the wiper, then stop the windshield wiper motor in the automatic stop
position.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 341/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Align the blade tip with the mark on the windshield glass, as shown in the
illustration.
Torque:
26 N*m{ 265 kgf*cm , 19 ft.*lbf }
1. Check that the clearance measurements are within the standard ranges.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 342/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 343/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Move the hood to adjust the clearance to within the standard range.
3. Tighten the hood side hinge bolts after the adjustment.
Torque:
13 N*m{ 133 kgf*cm , 10 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 344/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Adjust the height of the hood front end by turning the cushion rubber.
HINT:
The cushion rubber can be raised and lowered by turning it.
Torque:
7.5 N*m{ 76 kgf*cm , 66 in.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 345/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Align the matchmarks and install the sliding yoke onto the intermediate shaft.
Torque:
28 N*m{ 290 kgf*cm , 21 ft.*lbf }
2. Tighten bolt A.
Torque:
28 N*m{ 290 kgf*cm , 21 ft.*lbf }
1. Install the column hole cover silencer sheet with the 2 clips.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 346/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the
filler plug opening.
NOTICE:
4. When the oil level is low, check for oil leakage.
Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 347/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 348/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE
COMPONENTSUNIT >
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 349/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 350/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 351/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/3
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 352/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 353/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 354/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2/3
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 355/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 356/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 357/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3/3
MULTI-MODE MANUAL
TRANSAXLE UNIT >
DISASSEMBLY
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 358/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the plug from the shift and select actuator.
2. Look through the plug and check that the slit of the shift and select shaft is in the
position shown in the illustration.
If not, turn it with a screwdriver.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 359/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using an 18 mm socket wrench, remove the lock ball assembly from the transaxle
case.
1. Using SST, remove the park/neutral position switch with the gasket from the
transaxle case.
SST
09817-16011
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 360/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 6 bolts.
2. Tap the actuator flange with a plastic hammer to remove it.
1. Using SST, remove the back-up light switch with the gasket from the transaxle
case.
SST
09817-16011
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 361/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Using a small screwdriver, remove the O-ring from the transmission revolution
sensor.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 362/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 363/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 364/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Remove gear shift head No.1 and gear shift fork No. 1.
4. Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork
shaft No. 1.
1. Using a magnetic finger, remove the straight pin from gear shift fork No. 3.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 365/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Using 2 screwdrivers and a hammer, remove the 2 snap rings from gear shift fork
shaft No. 3.
3. Cover gear shift fork shaft No.3 with a piece of cloth gear shift fork shaft No. 3 at
the upper edge with pliers as shown in the illustration, and pull gear shift fork
shaft No. 3 out of the transaxle case to remove gear shift fork No. 3, compression
spring and gear shift head No. 3.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 366/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the reverse idler gear shaft from the transaxle case.
1. Remove the 2 bolts and reverse shift arm bracket from the transaxle case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 367/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a magnetic finger, remove the straight pin from the reverse shift fork.
2. Shift hub sleeve No. 2 into the 3rd gear, as shown.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 368/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Remove the set bolt from gear shift fork No. 2.
4. Pull out gear shift fork snap rings, gear shift fork and the reverse shift fork from
5. Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork
shaft No. 2.
6. Remove the reverse shift fork from gear shift fork shaft No. 2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 369/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
7. Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork
shaft No. 2.
8. Remove gear shift fork No. 2 from gear shift fork shaft No. 2.
1. Remove the input shaft assembly from the manual transaxle case.
1. Remove the output shaft assembly from the manual transaxle case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 370/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the differential case assembly from the front transaxle case.
1. Remove the oil receiver pipe No. 2 from the manual transmission case.
NOTICE:
Do not damage oil receiver pipe No. 2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 371/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the transmission magnet from the front transaxle case.
1. Using a screwdriver, remove the front transaxle case oil seal.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 372/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST, remove the output shaft front bearing (outer race) from the front
transaxle case.
SST
09308-00010
1. Remove the output shaft cover from the front transaxle case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 373/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST, remove the front differential case rear tapered roller bearing and the
shim.
SST
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 374/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
09950-60010 (09951-00560)
09950-70010 (09951-07200)
1. Using a screwdriver, remove the transaxle case oil seal from the front transaxle
case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 375/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a brass bar and hammer, remove the front differential case front tapered
roller bearing.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 376/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
SST
09527-30010
09612-65014 (09612-01030, 09612-01050)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 377/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE UNIT > INSPECTION
for Preparation
1. Using a micrometer, measure the outer diameter of the reverse idler gear shaft.
If the outer diameter is less than the minimum, replace the reverse idler gear shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 378/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Using a caliper gauge, measure the inside diameter of the reverse idler gear.
1. Using a caliper gauge, measure the inside diameter of the reverse shift fork.
If the inside diameter exceeds the maximum, replace the reverse shift fork.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 379/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a micrometer, measure the outer diameter of gear shift fork shaft No. 1.
If the outer diameter is less than the minimum, replace gear shift fork shaft No. 1.
1. Using a micrometer, measure the outer diameter of gear shift fork shaft No. 2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 380/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the outer diameter is less than the minimum, replace gear shift fork shaft No. 2.
1. Using a micrometer, measure the outer diameter of gear shift fork shaft No. 3.
If the outer diameter is less than the minimum, replace gear shift fork shaft No. 3.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 381/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using vernier calipers, measure the inside diameter of gear shift fork No. 1.
If the inside diameter and thickness are outside the specifications, replace gear
shift fork No. 1.
1. Using vernier calipers, measure the inside diameter of gear shift fork No. 2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 382/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the inside diameter and thickness are outside the specifications, replace gear
shift fork No. 2.
1. Using vernier calipers, measure the inside diameter of gear shift fork No. 3.
If the inside diameter and thickness are outside the specifications, replace gear
shift fork No. 3.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 383/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using vernier calipers, measure the inside diameter of gear shift head No. 1.
If the inside diameter exceeds the maximum, replace gear shift head No. 1.
1. Using vernier calipers, measure the inside diameter of gear shift head No. 3.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 384/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the inside diameter exceeds the maximum, replace gear shift head No. 3.
MULTI-MODE MANUAL
TRANSAXLE UNIT >
REASSEMBLY
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 385/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard depth:
10.5 to 11.5 mm (0.4134 to 0.4528 in.)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 386/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a press, press in the output shaft front bearing (outer race).
SST
09950-60010 (09951-00510)
09950-70010 (09951-07150)
1. Using SST and a press, press in the front differential case front tapered roller
bearing (outer race).
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 387/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
SST
09350-32014 (09351-32111, 09351-32130)
HINT:
When re-using the output shaft rear tapered roller bearing, first install a shim of
the same thickness as before. If installing a new output shaft rear tapered roller
bearing, first select and install a shim which is thinner than the original.
2. Using SST and a press, press in the FR differential case rear tapered roller bearing
(outer race).
SST
09950-60010 (09951-00620)
09950-70010 (09951-07100)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 388/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the differential case assembly with gear oil, and install it onto the front
transaxle case.
Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
HINT:
Manual transmission case side: 8 bolts
Front transaxle case side: 5 bolts
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 389/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Using SST and a torque wrench, turn the differential case assembly right and left
2 or 3 times to allow the bearings to settle.
SST
09564-32011
SST
09564-32011
Preload (at starting):
New bearing:
0.78 to 1.57 N*m (7.95 to 16.00 kgf*cm, 6.9 to 13.89 in.*lbf)
Used bearing:
0.49 to 0.98 N*m (5.00 to 9.99 kgf*cm, 4.3 to 8.67 in.*lbf)
6. Remove the 13 bolts and the manual transmission case from the front transaxle
case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 390/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
7. Remove the differential case assembly from the front transaxle case.
1. Install the output shaft rear bearing shim onto the manual transmission case.
HINT:
When re-using the output shaft rear tapered roller bearing, first install a shim of
the same thickness as before. If installing a new output shaft rear tapered roller
bearing, first select and install a shim which is thinner than the original.
2. Using SST and a press, press in the output shaft rear bearing (outer race).
SST
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 391/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
09950-60010 (09951-00570)
09950-70010 (09951-07200)
1. Install the output shaft assembly and the differential case assembly onto the front
transaxle case.
2. Install the manual transmission case onto the front transaxle case with the 13
bolts.
Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 392/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Using SST and a torque wrench, turn the output shaft assembly and differential
case assembly right and left 2 or 3 times to allow the bearings to settle.
SST
09564-32011
SST
09564-32011
Preload (at starting):
New bearing:
3.46 to 6.91 N*m (35.3 to 70.5 kgf*cm, 30.6 to 61.2 in.*lbf) for 1KR-FE
3.18 to 6.35 N*m (32.4 to 64.7 kgf*cm, 28.1 to 56.2 in.*lbf) for 2SZ-FE
Used bearing:
2.16 to 4.32 N*m (22.0 to 44.1 kgf*cm, 19.1 to 38.2 in.*lbf) for 1KR-FE
1.98 to 3.97 N*m (20.2 to 40.5 kgf*cm, 17.5 to 35.1 in.*lbf) for 2SZ-FE
Thickness Thickness
Mark Mark
mm (in.) mm (in.)
A 1.55
(0.0610) J 1.95
(0.0768)
1.60 2.00
B K
(0.0630) (0.0787)
1.65 2.05
C L
(0.0650) (0.0807)
D 1.70 M 2.10
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 393/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
(0.0669) (0.0827)
1.75 2.15
E N
(0.0689) (0.0846)
1.80 2.20
F P
(0.0709) (0.0866)
1.85 2.25
G Q
(0.0728) (0.0886)
1.90
H
(0.0748)
6. Remove the 13 bolts and the manual transmission case from the front transaxle
case.
7. Remove the output shaft assembly from the front transaxle case.
8. Remove the differential case assembly from the front transaxle case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 394/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Select an input shaft rear bearing shim that brings the value within the
specifications.
Shim thickness:
Shim thickness (B - A) should be more than 0 mm (0 in.) and less than 0.1 mm
(0.0039 in.)
Thickness Thickness
Mark Mark
mm (in.) mm (in.)
1.80 2.15
F N
(0.0709) (0.0846)
G 1.85 P 2.20
(0.0728) (0.0866)
1.90 2.25
H Q
(0.0748) (0.0886)
1.95 2.30
J R
(0.0768) (0.0906)
K 2.00 S 2.35
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 395/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
(0.0787) (0.0925)
2.05 2.40
L T
(0.0807) (0.0945)
2.10
M - -
(0.0827)
1. Using SST and a hammer, install a new transmission case oil seal into the manual
transmission case.
SST
09950-60010 (09951-00370)
09950-70010 (09951-07150)
Drive in depth:
2.1 to 3.1 mm (0.083 to 0.122 in.)
2. Coat the tip of the transmission oil seal with MP grease.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 396/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a hammer, install the transaxle case oil seal to the front transaxle
case.
SST
09316-60011 (09316-00011)
Drive in depth:
1.7 to 2.7 mm (0.067 to 0.106 in.)
2. Coat the tip of the transmission case oil seal with MP grease.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 397/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a hammer, install the front transaxle case oil seal into the front
transaxle case.
SST
09710-20011 (09710-06071)
09950-70010
Drive in depth: (09951-07150)
14.4 to 15.4 mm (0.567 to 0.606 in.)
2. Coat the tip of the front transaxle case oil seal with MP grease.
1. Clean the transmission magnet and then install it onto the front transaxle case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 398/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install oil receiver pipe No. 2 onto the manual transmission case.
NOTICE:
Do not damage oil receiver pipe No. 2.
1. Coat the differential case tapered roller bearings with gear oil, and install them
onto the front transaxle case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 399/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install the output shaft assembly onto the front transaxle case.
1. Coat the sliding and rotating surfaces of the input and output shafts assembly with
gear oil, and install them onto the front transaxle case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 400/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install gear shift fork No. 2 onto gear shift fork shaft No. 2.
2. Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft
No. 2.
3. Install the reverse shift fork onto gear shift fork shaft No. 2.
4. Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft
No. 2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 401/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
5. Shift hub sleeve No. 2 into the 3rd gear, as shown.
6. Install gear shift fork shaft No. 2 with the 2 snap rings.
7. Install gear shift fork No.2 and reverse shift fork onto the transaxle case.
8. Set gear shift fork No. 2 onto hub sleeve No. 2.
9. Install the set bolt onto gear shift fork No. 2.
Torque:
16 N*m{ 160 kgf*cm , 12 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 402/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
10. Using a magnetic finger, install the straight pin into the reverse shift fork.
NOTICE:
Insert the straight pin along the groove on gear shift fork shaft No. 2, as shown in
the illustration.
1. Install the reverse shift arm bracket onto the transaxle case with the 2 bolts.
Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
NOTICE:
Fit the edge of the reverse shift fork into the hole in the reverse shift arm bracket.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 403/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the reverse idler gear shaft with gear oil, and install it onto the transmission
case.
NOTICE:
Set the top of the reverse shift arm bracket into the groove on the reverse idler
gear, as shown in the illustration.
2. Align the mark on the reverse idler gear shaft with the bolt hole, as shown in the
illustration.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 404/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install gear shift fork No. 3, the compression spring and gear shift head No. 3 onto
gear shift fork shaft No. 3.
2. Install gear shift fork shaft No. 3 onto the transaxle case together with gear shift
fork No. 3, the compression spring and shift head No. 3.
3. Set gear shift fork No. 3 onto hub sleeve No. 3.
4. Using a screwdriver and hammer, tap 2 new snap rings onto gear shift fork shaft
No. 3.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 405/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
5. Using a magnetic finger, install the straight pin onto gear shift fork No. 3.
1. Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft
No. 1.
2. Set gear shift fork No. 1 onto the reverse gear.
3. Set gear shift head No. 1 onto gear shift fork No. 1.
4. Install gear shift fork shaft No. 1 onto the transaxle case with the snap ring.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 406/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 407/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 408/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Sealant:
Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
1. Apply sealant to the reverse idler gear shaft lock bolt threads.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 409/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Install the reverse idler gear shaft lock bolt with a new gasket.
Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
Torque:
7.8 N*m{ 80 kgf*cm , 69 in.*lbf }
Torque:
18 N*m{ 185 kgf*cm , 13 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 410/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
FIPG:
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
3. Install the shift and select actuator with the 6 bolts and wire harness clamp.
Torque:
18 N*m{ 184 kgf*cm , 13 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 411/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST, install the park/neutral position switch with a new gasket onto the
transaxle case.
Torque:
40 N*m{ 410 kgf*cm , 30 ft.*lbf }
SST
09817-16011
Sealant:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 412/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Using an 18 mm socket wrench, install the lock ball assembly onto the
transmission case.
Torque:
37 N*m{ 375 kgf*cm , 27 ft.*lbf }
1. Using SST, install the back-up light switch with a new gasket onto the transaxle
case.
SST
09817-16011
Torque:
40 N*m{ 410 kgf*cm , 30 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 413/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 414/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 415/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 416/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/2
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 417/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 418/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 419/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2/2
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 420/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum clearance:
0.35 mm (0.0138 in.)
If the clearance exceeds the maximum, replace the 3rd gear synchronizer ring.
1. Using a dial indicator, measure the 5th gear thrust clearance.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 421/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard clearance:
0.10 to 0.50 mm (0.0039 to 0.0197 in.)
Maximum clearance:
0.50 mm (0.0197 in.)
If the clearance exceeds the maximum, replace the 5th gear synchronizer ring.
1. Using a dial indicator, measure the 3rd gear radial clearance.
Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing
or the shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 422/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 423/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the clearance exceeds the maximum, replace the 5th gear needle roller bearing
or the shaft.
1. Using SST and a press, remove the input shaft rear radial ball bearing, hub sleeve
No. 3, 5th gear synchronizer ring and 5th gear from the input shaft.
SST
09950-00020
09612-24014 (09612-10061)
HINT:
NOTICE:
Do not excessively tighten SST.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 424/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 2 shifting key springs No. 1 from the transmission clutch hub No. 3.
2. Remove the transmission hub sleeve No. 3 from the transmission clutch hub No.
3.
3. Remove the 3 shifting keys No. 3 from the transmission clutch hub No. 3.
1. Remove the 5th gear needle roller bearing from the input shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 425/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 5th gear bearing spacer from the input shaft.
1. Using a dial indicator, measure the 4th gear thrust clearance.
Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 426/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the clearance exceeds the maximum, replace the 4th gear synchronizer ring.
1. Using a snap ring expander, remove the 5th gear shaft snap ring from the input
shaft.
HINT:
Do not damage the journal surface of the input shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 427/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 428/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 4th gear needle roller bearing from the input shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 429/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 4th gear bearing spacer from the input shaft.
1. Remove the 4th gear synchronizer ring from the clutch hub No. 2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 430/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a snap ring expander, remove the clutch hub No. 2 setting shaft snap ring
from the input shaft.
HINT:
Do not damage the journal surface of the input shaft.
1. Using SST and a press, remove the hub sleeve No. 2, 3rd gear synchronizer ring
and 3rd gear from the input shaft.
SST
09950-00020
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 431/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 2 shifting key springs No. 1 from the transmission clutch hub No. 2.
2. Remove the transmission hub sleeve No. 2 from the transmission clutch hub No.
2.
3. Remove the 3 shifting keys No. 2 from the transmission clutch hub No. 2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 432/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 3rd gear needle roller bearing from the input shaft.
1. Using a press, remove the input shaft front bearing from the input shaft.
SST
09950-00020
HINT:
Support the input shaft by hand to prevent it from dropping off.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 433/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Maximum runout:
0.03 mm (0.0012 in.)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 434/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Using a micrometer, measure the outer diameter of the input shaft journal surface.
Standard:
Measured Outer Diameter mm
Part (in.)
25.502 to 25.515
A
(1.0040 to 1.00453)
30.985 to 31.000
B
(1.2199 to 1.2205)
33.985 to 34.000
C, D
(1.3380 to 1.3386)
23.002 to 23.015
E
(0.9056 to 0.9091)
22.967 to 23.000
F
(0.9042 to 0.9055)
If the outer diameters are below the minimum, replace the input shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 435/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.
If the inside diameter exceeds the maximum, replace the 3rd gear.
1. Using a cylinder gauge, measure the inside diameter of the 4th gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 436/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the inside diameter exceeds the maximum, replace the 4th gear.
1. Using a cylinder gauge, measure the inside diameter of the 5th gear.
If the inside diameter exceeds the maximum, replace the 5th gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 437/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Turn the 3rd gear synchronizer ring in one direction while pushing it against the
3rd gear cone.
5. Using a feeler gauge, measure the clearance between the synchronizer ring back
and the gear spline end.
Standard clearance:
0.75 to 1.65 mm (0.0295 to 0.0650 in.)
Minimum clearance:
0.75 mm (0.0295 in.)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 438/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the clearance is less than the minimum, replace the synchronizer ring or the 3rd
gear.
3. Turn the synchronizer ring in one direction while pushing it against the 4th gear
cone.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 439/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 440/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Turn the synchronizer ring in one direction while pushing it against the 5th gear
cone.
4. Check that the ring ring
If the synchronizer locks.
does not lock, replace the synchronizer ring or the 5th
gear.
5. Using a feeler gauge, measure the clearance between the synchronizer ring back
and the gear spline end.
Standard clearance:
0.75 to 1.65 mm (0.0295 to 0.0650 in.)
Minimum clearance:
0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 5th
gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 441/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 442/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the clearance is outside the specifications, replace the transmission hub sleeve
No. 3 and gear shift fork No. 3.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 443/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a press, install a new input shaft front bearing onto the input shaft.
SST
09515-10010
1. Coat the 3rd gear needle roller bearing with gear oil, and install it onto the input
shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 444/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the 3rd gear with gear oil, and install it onto the input shaft.
1. Coat the 3rd gear synchronizer ring with gear oil, and install it onto the 3rd gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 445/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install the 3 shifting keys No. 2, 2 shifting key springs and transmission hub
sleeve No. 2 onto the clutch hub No. 2.
NOTICE:
Assemble the transmission hub sleeve No. 2 and transmission clutch hub No. 2 in
the correct orientations, as shown in the illustration.
2. Using SST and a press, install the transmission clutch hub sleeve No. 2 onto the
input shaft.
SST
09506-35010
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 446/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Select a snap ring that allows the minimum axial play.
Standard clearance:
0.1 mm (0.0039 in.) or less.
Thickness Thickness
Mark Mark
mm (in.) mm (in.)
2.28 2.46
A D
(0.0898) (0.0969)
2.34 2.52
B E
(0.0921) (0.0992)
2.40 2.58
C (0.0945) F (0.1016)
2. Using a snap ring expander, install the new snap ring onto the input shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 447/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
HINT:
Do not damage the journal surface of the input shaft.
1. Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum clearance:
0.35 mm (0.0138 in.)
If the clearance exceeds the maximum, replace the 3rd gear synchronizer ring.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 448/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a dial indicator, measure the 3rd gear radial clearance.
Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing
or the shaft.
1. Coat the 4th gear synchronizer ring with gear oil, and install it onto transmission
clutch hub No. 2.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 449/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 450/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the 4th gear with gear oil, and install it onto the input shaft.
1. Install the 5th gear thrust washer ball onto the input shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 451/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the 5th gear thrust washer with gear oil, and install it onto the input shaft.
1. Select a snap ring, using the table below, that makes the thrust clearance of the
5th gear thrust washer less than 0.1 mm (0.0039 in.).
Thickness Thickness
Mark Mark
mm (in.) mm (in.)
2.28 2.46
1 4
(0.0898) (0.0969)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 452/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2.34 2.52
2 5
(0.0921) (0.0992)
2.40 2.58
3 6
(0.0945) (0.1016)
2. Using a snap ring expander, install a new snap ring onto the input shaft.
HINT:
Do not damage the journal surface of the input shaft.
1. Using a dial indicator, measure the 4th gear thrust clearance.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 453/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard clearance:
0.1 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance :
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace the 4th gear synchronizer ring.
1. Using a dial indicator, measure the 4th gear radial clearance.
Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 4th gear needle roller bearing
or the shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 454/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the 5th gear bearing spacer with gear oil, and install it onto the input shaft.
1. Coat the 5th gear needle roller bearing with gear oil, and install it onto the input
shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 455/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the 5th gear with gear oil, and install it onto the input shaft.
1. Coat the 5th gear synchronizer ring with gear oil, and install it onto the 5th gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 456/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install the 3 shifting keys No. 3, 2 shifting key springs No. 1 and transmission hub
sleeve No. 3 onto the transmission clutch hub No. 3.
NOTICE:
Assemble the transmission hub sleeve No. 3 and the transmission clutch hub No.
3 in the correct orientations, as shown in the illustration.
2. Place the 5th gear synchronizer ring on the 5th gear, and align the synchronizer
ring slots with the shifting keys No. 3.
3. Using SST and a press, press the No. 3 hub sleeve into the input shaft.
SST
09515-10010
NOTICE:
Install the transmission hub sleeve No. 3 in the correct orientation, as shown in
the illustration.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 457/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a press, install a new input shaft rear radial ball bearing onto the
input shaft.
SST
09515-10010
1. Using a dial indicator, measure the 5th gear thrust clearance.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 458/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard clearance:
0.10 to 0.50 mm (0.0039 to 0.0197 in.)
Maximum clearance:
0.50 mm (0.0197 in.)
If the clearance exceeds the maximum, replace the 5th gear synchronizer ring.
1. Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 5th gear needle roller bearing
or the shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 459/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 460/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 461/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 462/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/2
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 463/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 464/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 465/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2/2
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 466/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a press, remove the output shaft rear bearing.
SST
09950-60010 (09951-00220)
09950-70010 (09951-07100)
1. Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:
0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 467/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the clearance exceeds the maximum, replace the 1st gear synchronizer ring.
1. Using a feeler gauge, measure the 2nd gear thrust clearance.
Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance:
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace the 2nd gear synchronizer ring.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 468/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a dial indicator, measure the 1st gear radial clearance.
Standard clearance:
0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:
0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the 1st gear needle roller bearing
or the shaft.
1. Using a dial indicator, measure the 2nd gear radial clearance.
Standard clearance:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 469/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the clearance exceeds the maximum, replace the 2nd gear needle roller bearing
or the shaft.
1. Using 2 screwdrivers and a hammer, remove the counter 5th gear shaft snap ring
from the output shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 470/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 471/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a press, remove the 3rd driven gear and 2nd gear from the output
shaft.
SST
09950-00020
1. Remove the 2nd gear needle roller bearing from the output shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 472/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 2nd gear bearing spacer from the output shaft.
1. Remove the 2nd gear synchronizer ring from the reverse gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 473/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using 2 screwdrivers, remove the clutch hub No. 1 shaft snap ring from the output
shaft.
HINT:
Do not damage the journal surface of the output shaft.
1. Using a press, remove the transmission clutch hub No. 1 and 1st gear from the
output shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 474/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 1st gear needle roller bearing from the output shaft.
1. Using SST and a press, remove the output shaft front bearing from the output
shaft.
SST
09950-00020
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 475/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 2 shifting key springs No. 1, 3 shifting keys No. 1 and reverse gear
from the transmission clutch hub No. 1.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 476/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Maximum runout:
0.03 mm (0.0012 in.)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 477/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Using a micrometer, measure the outer diameter of the output shaft journal
surface.
Standard:
Measured Outer Diameter mm
Part (in.)
23.002 to 23.015
A
(0.9056 to 0.9061)
B, C 28.3 (1.1142)
33.985 to 34.000
D, E
(1.3380 to 1.3386)
25.002 to 25.015
F
(0.9843 to 0.9847)
If the outer diameters are below the minimum, replace the input shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 478/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a cylinder gauge, measure the inside diameter of the 1st gear.
If the inside diameter exceeds the maximum, replace the 1st gear.
1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 479/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the inside diameter exceeds the maximum, replace the 2nd gear.
3. Turn the synchronizer ring in one direction while pushing it against the 1st gear
cone.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 480/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
5. Using a feeler gauge, measure the clearance between the synchronizer ring back
and the gear spline end.
Standard clearance:
0.8 to 1.6 mm (0.031 to 0.063 in.)
Minimum clearance:
0.80 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 1st
gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 481/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Turn the synchronizer ring in one direction while pushing it against the 2nd gear
cone.
4. Check that the ring ring
If the synchronizer locks.
does not lock, replace the synchronizer ring or the 2nd
gear.
5. Using a feeler gauge, measure the clearance between the synchronizer ring back
and the gear spline end.
Standard clearance:
0.8 to 1.6 mm (0.031 to 0.063 in.)
Minimum clearance:
0.80 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 2nd
gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 482/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using vernier calipers, measure the clearance between the reverse gear and the
reveres gear fork.
If the clearance is outside the specifications, replace the reverse gear fork and
reverse gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 483/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a press, install the output shaft front bearing onto the output shaft.
SST
09710-22021 (09710-01051)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 484/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the 1st gear needle roller bearing with gear oil, and install it onto the output
shaft.
1. Coat the 1st gear with gear oil, and install it onto the output shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 485/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the 1st gear synchronizer ring with gear oil, and install it onto the 1st gear.
1. Install 2 shifting key springs No. 1, 3 shifting keys No. 1 and the reverse gear
onto the transmission clutch hub No. 1.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 486/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Using SST and a press, install the transmission clutch hub No. 1 onto the output
shaft.
SST
09316-60011 (09316-00011, 09316-00071)
NOTICE:
Install the reverse gear assembly in the correct orientation, as shown in the
illustration.
1. Select a snap ring that allows the minimum axial play.
Standard clearance:
0 to 0.1 mm (0 to 0.0039 in.)
Mark Thickness Mark Thickness
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 487/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
mm (in.) mm (in.)
2.28 2.46
A D
(0.0898) (0.0969)
2.34 2.52
B E
(0.0921) (0.0992)
2.40 2.58
C F
(0.0945) (0.1016)
2. Using a snap ring expander, install the new snap ring onto the output shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 488/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:
0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance:
1. Using a dial indicator, measure the 1st gear radial clearance.
Standard clearance:
0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:
0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the 1st gear needle roller bearing
or the shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 489/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the 2nd gear bearing spacer with gear oil and install it onto the output shaft.
1. Coat the 2nd gear needle roller bearing with gear oil, and install it onto the output
shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 490/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Coat the 2nd synchronizer ring with gear oil, and install it onto the reverse gear.
1. Coat the 2nd gear with gear oil, and install it onto the output shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 491/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a press, install the 3rd driven gear onto the output shaft.
SST
09316-60011 (09316-00041)
1. Using a feeler gauge, measure the 2nd gear thrust clearance.
Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance :
0.55 mm (0.0217 in.)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 492/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
If the clearance exceeds the maximum, replace the 2nd gear synchronizer ring.
1. Using a dial indicator, measure the 2nd gear radial clearance between the gear and
shaft.
Standard clearance:
0.015 to 0.056 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.056 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 2nd gear needle roller bearing
or the shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 493/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Install the output shaft spacer onto the output shaft.
1. Using SST and a press, install the 4th driven gear onto the output shaft.
SST
09223-00010
09316-60011 (09316-00021)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 494/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a press, install the 5th driven gear onto the output shaft.
SST
09223-00010
09316-60011 (09316-00021)
1. Select a snap ring, using the table below, that makes the thrust clearance of the
5th driven gear less than 0.1 mm (0.0039 in.).
Thickness Thickness
Mark Mark
mm (in.) mm (in.)
2.22 2.52
A F
(0.0874) (0.0992)
B 2.28 G 2.58
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 495/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
(0.0898) (0.1016)
2.34 2.64
C H
(0.0921) (0.1039)
2.40 2.70
D J
(0.0945) (0.1063)
2.46
E - -
(0.0969)
2. Using a brass bar and hammer, tap the new snap ring onto the output shaft.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 496/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a press, install the output shaft rear bearing onto the output shaft.
SST
09612-22011
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 497/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 498/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 499/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/1
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 500/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST, remove the front differential case front tapered roller bearing.
SST
09950-00020
09950-00030
HINT:
Set the claw of SST to the bearing inner race at the indented part of the
differential case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 501/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST, remove the front differential case rear tapered roller bearing.
SST
09950-00020
09950-00030
1. Place matchmarks on the front differential ring gear and the front differential
case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 502/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Remove the 6 bolts. Using a hammer, remove the front differential ring gear from
the front differential case.
1. Using a pin punch and hammer, remove the pinion shaft slotted spring pin.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 503/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Remove the 2 pinion gears, 2 side gears and the 4 thrust washers from each gear.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 504/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
REASSEMBLY
for Preparation
1. Install the appropriate thrust washers and side gears. Refer to the table below and
select thrust washers that bring the backlash to within the specifications. Select
washers of the same size for both sides.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
Thickness mm (in.) Thickness mm (in.)
0.50 (0.0197) 0.75 (0.0295)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 505/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Install the thrust washers and the side gears into the differential case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 506/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Using a dial indicator, check the side gear backlash. Measure the side gear
backlash while holding one pinion gear toward the differential case.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
If the backlash is not within the specification, install a thrust washer of a different
thickness.
5. Using a pin punch and a hammer, install the pinion shaft slotted spring pin
through the front differential case and the hole in the pinion shaft.
6. Using a chisel and hammer, caulk the pin holes around the circumference of the
front differential case.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 507/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).
3. Aligning the matchmarks, quickly install the front differential ring gear onto the
front differential case with the 6 bolts.
Torque:
124 N*m{ 1,260 kgf*cm , 91 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 508/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST and a press, install the front differential case rear tapered roller
bearing.
SST
09350-32014 (09351-32120, 09351-32140)
1. Using SST and a press, install the front differential case front tapered roller
bearing.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 509/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
SST
09350-32014 (09351-32120, 09351-32140)
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 510/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 511/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 512/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/2
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 513/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 514/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 515/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2/2
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 516/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. REMOVE BATTERY
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 517/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 518/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the bolt and separate the wire harness bracket.
3. Remove the 2 screws and the shift stroke sensor from the shift and select actuator.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 519/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 520/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Connect the battery positive (+) lead to terminal A and the negative (-) lead to
terminal B.
3. Turn the sensor arm and check the voltage between terminals B and C.
angle voltage
55° 4.05 V
0° 2.25 V
-55° 0.45 V
Voltage (Power source voltage at 4.7 to 5.3 V):
Sensor Terminal (B - C) output
angle voltage
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 521/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
55° 4.5 V
0° 2.5 V
-55° 0.5 V
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 522/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
INSTALLATION
for Preparation
3. Set the stroke senor so that the sensor side and the actuator side sensor arms are in
the positions shown in the illustration.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 523/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Turn the stroke sensor clockwise and fix it with the 2 screws.
Torque:
2.0 N*m{ 20 kgf*cm , 18 in.*lbf }
6. Install the wire harness bracket onto the transaxle with the bolt.
Torque:
13 N*m{ 131 kgf*cm , 9.5 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 524/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 525/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
5. INSTALL BATTERY
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 526/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 527/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 528/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 529/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 530/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/2
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 531/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 532/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 533/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2/2
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 534/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. REMOVE BATTERY
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 535/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 536/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the bolt and separate the wire harness bracket.
3. Remove the 2 screws and select stroke sensor from the shift and select actuator.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 537/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 538/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Connect the battery positive (+) lead to terminal A and the negative (-) lead to
terminal B.
3. Turn the sensor arm and check the voltage between terminals B and C.
angle voltage
55 ° 4.05 V
0° 2.25 V
-55° 0.45 V
Voltage (Power source voltage at 4.7 to 5.3V):
Sensor Terminal (B - C) output
angle voltage
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 539/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
55 ° 4.5 V
0° 2.5 V
-55° 0.5 V
NOTICE:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 540/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
INSTALLATION
for Preparation
3. Set the stroke sensor so that the sensor side and the actuator side sensor arms are
in the positions shown in the illustration.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 541/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Turn the stroke sensor clockwise and fix it with the 2 screws.
Torque:
2.0 N*m{ 20 kgf*cm , 18 in.*lbf }
6. Install the wire harness bracket onto the transaxle with the bolt
Torque:
13 N*m{ 131 kgf*cm , 9.5 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 542/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 543/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
5. INSTALL BATTERY
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 544/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
TRANSMISSION REVOLUTION
SENSOR > COMPONENTS
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 545/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 546/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 547/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 548/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/1
TRANSMISSION REVOLUTION
SENSOR > REMOVAL
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 549/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Remove the drain plug and gasket and drain the transaxle oil.
Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 550/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. Using a screwdriver, remove the O-ring from the transmission revolution sensor.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 551/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
TRANSMISSION REVOLUTION
SENSOR > INSPECTION
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 552/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard Resistance:
560 to 680 Ω at 20 °C(68°F)
TRANSMISSION REVOLUTION
SENSOR > INSTALLATION
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 553/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
7.8 N*m{ 80 kgf*cm , 69 in.*lbf }
Torque:
18 N*m{ 185 kgf*cm , 13 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 554/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 555/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the
filler plug opening.
NOTICE:
•
•
An excessively
After replacing large ordrive
the oil, smallthe
amount of and
vehicle oil may cause
check problems.
the oil level again.
4. When the oil level is low, check for oil leakage.
Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 556/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 557/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 558/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 559/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/4
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 560/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 561/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 562/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2/4
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 563/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 564/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 565/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3/4
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 566/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 567/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 568/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 569/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
4. REMOVE BATTERY
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 570/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 571/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the bolt and nut, then separate the engine mounting insulator LH.
2. Remove the 4 bolts and the engine mounting insulator LH.
1. Remove the bolt and nut, then separate the engine mounting insulator LH.
2. Remove the 5 bolts and the engine mounting insulator LH.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 572/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Remove the 4 bolts and the engine mounting bracket LH.
1. Remove the 4 bolts and the engine mounting bracket LH.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 573/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Separate the back-up light switch wire harness from the 2 clamps.
3. Using SST, remove the back-up light switch and gasket from the transaxle case.
SST
09817-16011
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 574/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 575/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard Resistance:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 576/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Using SST, install the back-up light switch with a new gasket onto the transaxle
case.
SST
09817-16011
Torque:
40 N*m{ 410 kgf*cm , 30 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 577/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Install the back-up light switch wire harness into the 2 clamps.
1. Install the engine mounting bracket LH with the 4 bolts.
Torque:
64 N*m{ 653 kgf*cm , 47 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 578/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
64 N*m{ 653 kgf*cm , 47 ft.*lbf }
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf } for bolt A
64 N*m{ 653 kgf*cm , 47 ft.*lbf } for bolt B
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 579/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Install the engine mounting bracket LH and engine mounting insulator LH with
the bolt and nut.
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf } for nut C
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf }
2. Install the engine mounting bracket LH and engine mounting insulator LH with
the bolt and nut.
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 580/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 581/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
9. INSTALL BATTERY
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 582/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 583/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 584/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 585/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/1
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 586/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Using SST,
transaxle remove the park/neutral position switch with the gasket from the
case.
SST
09817-16011
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 587/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 588/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard Resistance:
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 589/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
SST
09817-16011
1. Using SST, install the park/neutral position switch with a new gasket onto the
transaxle case.
Torque:
40 N*m{ 410 kgf*cm , 30 ft.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 590/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 591/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/1
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 592/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 593/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 594/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Check the resistance between the terminals of the shift motor.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 595/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
Standard Resistance:
Tester Specified
connection condition
1-2 0.1 to 100 Ω
If the resistance is not as specified, replace the shift and select actuator.
2. Check the resistance between the terminals of the select motor.
Standard Resistance:
Tester Specified
connection condition
1-2 0.1 to 100 Ω
If the resistance is not as specified, replace the shift and select actuator.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 596/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 597/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Install the new O-ring onto the select stroke sensor.
3. Set the stroke sensor so that the sensor side and the actuator side sensor arms are
in the positions shown in the illustration.
4. Turn the select stroke sensor clockwise and fix it with the 2 screws.
Torque:
2.0 N*m{ 20 kgf*cm , 18 in.*lbf }
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 598/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE ECU >
COMPONENTS
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 599/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 600/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 601/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1/2
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 602/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 603/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 604/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2/2
MULTI-MODE MANUAL
TRANSAXLE ECU > REMOVAL
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 605/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Slightly deform the upper part of the glove compartment door assembly to release
the 2 stoppers and open the glove compartment door assembly until it becomes
horizontal.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 606/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Pull the glove compartment door assembly out horizontally to disengage the hinge
portion and remove the glove compartment door assembly.
NOTICE:
Pull the glove compartment door out horizontally, otherwise, installation failure
caused by excessive play around the hinge portion will result.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 607/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Disengage the clip and remove the transmission control ECU.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 608/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Remove the bolt and screw, then remove the transmission control ECU.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 609/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
MULTI-MODE MANUAL
TRANSAXLE ECU > REMOVAL
for Preparation
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 610/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
1. Slightly deform the upper part of the glove compartment door assembly to release
the 2 stoppers and open the glove compartment door assembly until it becomes
horizontal.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 611/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
2. Pull the glove compartment door assembly out horizontally to disengage the hinge
portion and remove the glove compartment door assembly.
NOTICE:
Pull the glove compartment door out horizontally, otherwise, installation failure
caused by excessive play around the hinge portion will result.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 612/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
3. Disengage the clip and remove the transmission control ECU.
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 613/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 614/614