Introduction Preparation Service specifications Manual transaxle Alphabetical indexINTRODUCTION How to use this manual transaxle repair manual General information. Repair instruction for manual transaxle repair manual Precauton... se Terms for manual transaxle repair manual ‘Abbreviations used in this manual Glossary of SAE and FAW terms.Introduction-How to use this manval transavlerepa manuel o1-1 How to use this manual transaxle repair manual 4.General information {a)Generally repair operations can be separated in the following 3 main processes: (()Diagnosis (2)Removing and installing, Replacing Disassembling, instaling and Checking, Adjusting (3)Final Inspection (b)This manual explains “Removing and Installing, Replacing, Disassembling, Installing and Checking, “Adjusting” , but “Final, Inspection” is omitted. ie (c)The following essential operations are not written in this manuel, however done in the practical situation. (1)Operation with a jack or lt (2)Cleaning of a removed part if necessary (3)Vfsual check Index ‘An alphabetical INDEX is provided as @ section on the end of the book to guide you to the item to be repaired 3.Preparation {a)Use of special service tools (SST) and special service materials (SSM) may be required, depending ‘on the repairing conditon. Be sure to use SST and SSM when they are required and follow the work- ing procedure property. Alist of SST and SSM isin the preparation section in this manual 4.Repair procedures {a)Component drawing is placed as the section or tie if necesary (b)llustrations of the parts catalog are placed as the “d'sassembled parts drawing” so that it enables ‘you to understand the fing coneition of the components, (c)Nor-reusable parts, grease applied parts, precoated parts and torque are specified in the components drawing Example: ‘Shit and selec lever shat Ering Selective sping, ‘ute, Compression sping + ‘Shitinterlock guard pares The 1st shit inner lever or ‘Tho 2nd shit inner lover Lever lock pin © Ol seal ‘The 2nd selective Shi contol over ee ent ‘Shift control piece [N= mvoF=m R=) ‘eon @ Non-eusable pats se MP grease01-2 Introduction-How touse this manual tansanle repair manual (¢)Torque, oll applying position, and non-reusable parts are described as important points in the procedure. cases where such information can only be i lustration. In those cases, all the information such as torque, ol, etc. is described in the illustration. {@)instaling procedure of operation item is performed in the reverse order ofthe removal, and only the important points are described. (f}Only items with points are described in the procedure, and the operational portion and content are HM "tocar esng anaustoton nthe evsanstonsetaisot te pectin meta, sandavlve and notice are placed, (g)There may be cases where the illustrations of similar models are used. In those cases, the detalls may (h)The procedures are presented in a step-by-step format (1)The illustration shows what to do and where to do. (2)The task heading tells what to do, (3)The detailed text tells how to perform the task and gives other information such as specifications ‘and wamings. Example: Iustration What to do and where HINT: Task heading: what to do 4 87.Install the front bearing of output shaft. (@)Coat on the new front bearing of output shaft with MP grease, and instal the bearing on the clutch case by Sst Press depth: 0-.0:3mm (o0.118in).—\ ‘SST 09905-60010 (09991-00420) i A / \ Set part Component part Detaled text No No how todo task This format provides an experienced technician with a FAST TRACK to the necessary information. ‘The task heading can be read at a glance when necessary, and the text below provides detailed information. Important specifications and warnings always stand out in bold type. 5 Service specifications (a)Specifcetions are presented in bold type throughout the manual. You never have to leave the proced- tre to look up your specifications. The specifications are also found in the service specifications section for a quick reference. 6 Terms definition ‘Component part No. CAUTION Indicate the posstilty of injury to you or other people, NOTICE Indicate the possibilty of damage to the components being repaired HINT Provide aditional information to held you perform the repair efficientlyIntroduction-How to use this manval transavlerepa manual 01-3 7.S1 unit The UNITS used in this manual are primarily expressed according to the SI UNIT (Intemational System Of Unit), and alternately expressed in the metric system and in the English System. Example: Torque:30N + m (340kgf « cm, 22ft + tbf)01-4 Introduction-Repai instruction for manual transaxle repait manual Repair instruction for manual transaxle repair manual Precaution 1 Basic repair HINT ‘Seal lock adhesive 211854 NOTICE: (a)Precoated Parts (1)Precoated parts are bolts, nuts, ect. That are coated with a seal lock adhesive at the factory. (2)if a precoated partis retightened, loosened or caused to moveiin any way, it must be recoated with the specified adhesive. (3)Wvhen reusing precoated pads, clean off the old adhesive and dry with compressed air. Then apply the ‘specified seal lock adhesive to the bolt, nut or threads. Do the torque checking with the lower limit value of the torque tolerance. (4)Depending on the seal lock agent to apply, there may be a case where it is necessary to leave it for 2 specified ime unti it hardens. BOLTS, NUTS AND THREAD Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.Intvoduction-Terms for manual transaxle repair manual 01-5 Terms for manual transaxle repair manual Abbreviations used in this manual ‘Abbreviated Meaning FIG engine FIPG formed in place gasket MAX. ‘maximum MIN ‘minimum MP ‘multipurpose wt ‘manual transmission N neutral No. umber RH righthand ssM ‘special service materials ssT ‘special service tools sto standard TA transaxle ™ transmission TMC TOYOTA Motor Corporation wi with wio without ast First 2ND ‘Second01-6 Introduction-Glossery of SAE and FAW terms, Glossary of SAE and FAW terms This glossary lists all SAE-V1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their FAW equivalents. Aeaton sae tome ae AC air conditioner air conditioner ACL air Geaner air cleaner AIR ‘secondary air injection airinjection (Al) AP ‘accelerator pedal = Be battery postive voltage +B, battery voltage BARO barometric pressure = CAC ‘charge air cooler Inter cooler: ‘CARB carburetor carburettor CFI continuous fuel injection = cKP ‘crankshaft position crank angle cL VAF volume air fow air flow meter vR voltage regulator voltage regulator vss vehicle speed sensor vericie speed sensor (Read switch type) wor wide open throttle |Full throttle WU-OC | warm up oxidation catalytic converter | — WU-TWG | warm-up three-way cataiyic converter | — BRD third gear = 4TH fourth gear =PREPARATION Manual Transaxle, 02-1 PHEDATE WOTK nr svn . sisiPreparation —manval transaxle 02-1 Manual transaxle Prepare work ‘Special Service Tools “ (09223-00010 rear cover and il sealreplacer Output sat assy(ST085) (09002.00010 oil seal puler oD IES Nr? Ze cee (09316-60011 tansmissicn andtransfer bearing replacer Mancal transaxle 9ssy(6T085) Manval ransaxle as5y(6T085) Output shaft assy(ST005) Mancal transaxle asey(STO65) 09950-92041 transmission too set OP (00816-00011) replace pipe =F (08816-00021) “A” placer Out shat 286/(57085) (0816-00061) ~C” replacer ‘uy shat 355)(57085) (08816-00071) “F*replacer uit shat 266/(57085) Diferental assy(5T065) Mancal transaxle assyiSTO55) (06951-32111) overdive bearing race replacer Mancal transaxle aseyiSTOSS) (08851-32120) bearing replacer (09861-32190) handle Diferental asey(ST085) Manca! transaxle assyi6T055) (06351-32140) oil seal replacor ¢ |e 8G oe Diferental 9¢8y(6T065)02-2 Preparation—manual ransaxle (08387-00041 beating puller assy Manual tensaxie assy(ST085) (09387-02010) ol seal replacer Manual wansaxle assy(5T085) (09687-02020) onesway dutch complete tool sat (09506-35010 _cliferenial pinion beering replacer Manval tansaxleassy(5T085) Input shat assy(5T085) (08515-10010 Input shaft assy(57085) (09527-30010 resraxo bearing remover Manual tansaxie assy(5T085) (08554-52011 ferential preload adopter Manual wansaxle assy(ST035) (08612-86014 steering worm bearing puller (09612-01030). “C” stripper Manual vancavieassy(5T085) Manual tensaxieassy(5T055) (09612-01050) nuthanger pin Manual wansaxle assy(5T035) (09710-20011 front suspension bushing tool st (08710-08071) replacer Manval tancaxleassy(5T085) Manual wensaxle a8sy(6T096) (09710-22021) front suspension bushing tool setPreparation —manval transaxle 02-3 (0971001051) Tomer arm bush romove ‘Output shat assy(ST065) (9817-16011 reverae lamp awitch took Manval anes aesy(STOSS) ‘08960-00020 (09612-10061) beaing remove steering smal gear bearing Diserontal assy(ST086) Input shat assy(67085) Output sha® aesy(STO8S) Input shat assy(57065) *ffse ‘08950-00080 beeing stipper spare parts Digerontal assy(S 068) 6250-60010 replace st Manva tance as ST055) Ishak ary) See das ro08) ‘Sess (coe -00220) apace 22 put sat as (1086 © ‘Shift lever shaft assy(5T065) (C6 0080) alas 24 pu chat anny(TO88) (co -0080) velecer 28 hit ver sat a85(5088) (Coe -0870) velaes 37 Manual tance asySt085) © Output shat oasyiT065) © (C65'-00510) rehaer 51 Manva tance a(ST08) (coe -0880) epacer 8 Manva vance ayST08) (Co'-00570) placer 7 Manval tance osfST08)02-4 Preparation—manual ransaxle © (09951-00620) replacer 62 Manual wansaxle assy(ST085) Manual aneaxie assy(STO5S) uiput shaft assy(STO65) Shiftlover shat assyi5T065) om) (09951-07100) hanele 100, aa (09951-07150) hande 150 Manval tansaxleassy(5T085) Output shat ae5y(6T068) ‘Shitlever shat assy(STOSS) Manual tansaxie a5sy(5T085) ay sion sn Manual teneaxla assy(ST035) Recommend tool a (06081-00080. pin punch Manual vansanle assy(ST035) Equipment Dal indicator Feeler gauge: Magnetic bar Micrometer Torque wrench CalipersSERVICE SPECIFICATIONS Standard bolt = How to determine bolt strength ‘Specified torque for standard bolt How to determine nut strength = Manual transmission/transaxle Service date--+-- Torque specificationService specifications- Standard bolt 09-4 Standard bolt How to determine bolt strength The bot ype Hexagon heed bot Gress }—_Snae Sudbt Wieldedbot Nomairecessbot | Dep recess bot O 4 a \ No Ware No Mare q 5T we © a Wich " ey * (8) SS) © @ a Oo @ KS 7 A | ) @ : @ (s2]] nT |03-2 Service specifications- Standard bolt Specified torque for standard bolt ‘Specified torque Class | Diameter Pitch Hexagon head bolt Hexagon flange bolt mm mm Nem kgfem — fteibf [Nem kgfem ftetbt 6 1 5 55 48in-ibt| 6 60 82 bf 8 1.25 125 130 9 14 1510 aT 10 1.25 ee. a ee 12 1.28 47 4803583 14 15 T 70 55 BA 85D 16 15 15 115083 ZS = 6 1 65 85 sen-ibt | 7.5 75 65iN If 8 1.28 5 16 t2 17517513 st 10 1.25 32 802k HD 28 12 1.25 so 603 | 5B 14 15 si 930 G7 100108078 16 15 1a 1400 tot | 5 6 1 8 80 6an-ibt| 9 90 78in of 8 1.25 19195 4 | 2 208 er 10 1.25 394003 aC 28 12 1.25 71 7303s) BIB 14 15 01100 go | 125128076 16 15 17 61780 t27_ | - - 6 1 105 110 8 2 120 «9 8 1.28 2 20019, | eat 7 10 1.28 52 50038 BAB 12 1.25 95 970-70 | 105 105076 14 15 145 1500108 | 165 1700123 16 15 20 00 tes | - “ 8 1.25 a ae a a aT 10 1.25 616058 50 12 1.28 0 10080 120-1280 9 8 1.25 34 05) 8D sv 10 1.28 7 710 8t 7 7900 87 12 1.28 1251300 94_—| 1401480108 8 1.25 388 | aH sor 10 1.25 73 «800 58) 8D 12 1.25 140 © 1450105 | 155 1600116 8 1.28 2 #0 at | 47 ABO 88 “Tt 10 1.28 a7 890 GAT D7 12 1.25 16 © 1600116 175 1800130Service specifications- Standard bolt 03-3 How to determine nut strength Nutiype: Present standard 46 standard hex nut cass Dereon nat Cold forging nut Cutting processed nut aN Fy | awn No Mark (Selt-gasket) | No Mark (sel-gasket) No Mark 00 Oo HAl~ 8N oo “” No Wark 11N ao - 4: Mark sid face on nut to for may mark, HINT: The nut strength class and bolt strength class similar or bigger, then bolt strength class when used firm parts.03-4 Manual transmission/transaxle Service date Service specifications- Manual transmission [Manual wansmission reverse idler gear shat outside diameter ‘Standard | 18.941-16 968men(0.6276 06287 in) Minimurs | 18.884mm40.6278in) reverse idler gear clearence ‘Standard | 16.09-16,025mm(0.6250-0 6309 in) Maximum | 16.025-mny0.6309 in.) reverse gear dt with ‘Standerd | 13.1-13.17mm(051S7 05186) Maximum | 13.17me0.5186 in) reverse suing arm outside diameter ‘Standard | 12.962-19,006men(0.5103-06120 in) Minimurs | 13.962mm40.5103 in) 1st, nd shit fork sha outside dametor ‘Standard | 13.057-13.884nmy(0,5495-0.5808 in) Minimum | 13.987mm40.5486 in) et nd shi fork bore ‘Standerd | 14.00-14.043mm(0.8612-0 6528 in) Maximum | 14.043mm0 6525 in) 51d, shit fork shaft ouside ameter ‘Standard | 13.967-18.964mn0,5496-0.5608 in) Minimum | 13.957mm40.5496in.) 3tc, ath shit fork bore ‘Standard | 14.00-14,049mm(0.5512-0 5529 in) Maximum | 14.048mm(.8528 in) 5th, reverse shi fork outside diameter ‘Standard | 13.957-13 9eémen(0 549505506 in) Mininurn | 18.987 mmd0.5485 in) 5th, reverse shit fork bore ‘Standard | 14.00-14.083mm(0.8512-0 5529 in) Maximum | 14.048m(.6529 in) 3rd Ath eeur sit eek sot width ‘Standaed | 10.05-10,Somr(0_3967-0,5608 in) Maximum | 10.15mn(0.3996 in) Src, th shit fork depth Standard | 8 89-9.srn(0.3870-0 3897 in.) Minimurs | 9 83mm(0°3870 in) ts bum SR fork Sow ‘Standsed | 10.05-10.t5mm(0.3967-0.5998 in) Maximum | 10. 15me(03096 in) 5th kum sti fork depth Standard | 9.89-9.9mm(0.3870-0:3897 in.) Minimums | 9.8%nm(0:3870 in) citferentsl conical bearing preloade use SST) new bearing (0.781 S7N + (796-16 00Kgf «em, 6.9-13.89 in + Ib old bearing (048.0.98N + mi6.00-889Kgf + em-.3-8.67 in +b) outout shat conical beating praloade (use Sst) new bearing 3.0866.18N + m(3t.6.63.0kaf + em27.8-64,7 in bf old beating 41.99:,08N + m1 7-98 4kaf= em.17.1-94.2in «Io Diterential tapered raller bearing ajustng shim hickness = zerncronmoow>d 120mm(0.0472 in) 1 26mmn(0.0482 in) 4 30nm(00512 in) 13enm(0.0581 in) 4 4omm(00551 in) 1.4Senm(0.0571 in) 1.50mm(0.0581 in) 1 58mm(0.0810 in) 1.80mm(0.0800 in) 1.8Smm(0.0860 in) 1 70mr(0.0869 in) 175mmn(0.0869 in) 180mm(0.0703 in) [Cutpatsat tapered aller bearing adustng shim thiciness WarkService specifications- Manual transmission 03-5 Input shat acjustng shim thicknaes = ZErnezommoOR> 4omovzernezone jovze ° 1 5mm(0.0610 in) 4.60rm(0.0630 in ) 1.65mny0.0650 in) 1.70mmy0.0868 in) 41:75mmy0.0868 in ) 1. 80mn0.0708 in) 4.85rnm4(0.0728 in ) 1.90mn0.0748 in.) 1.95rmm(0.0768 in) 200mm99.0787 in) 205mm40.0807 in ) 2.40mm0.0827 in) 2.15mmy.0846 in) 2:20mm(0.0866 in ) 2.25mm0.0888 in ) 1.80mn0,0708 in) 1.85mm0.0728 in) 4.80rm(0.0748 in) 1.85mn0.0768 in) 2.00mm.0787 in) 2.05mm.0807 in) 2.40rmm(0.0827 in) 2.15mmy.0848 in) 2.20mnmy(0.0866 in) 2.25mm0.0888 in ) 2:30mmy0.0808 in) 2:36mmy(0.0825 in ) 2.40mmy0.0945 in.) (Od sealinstalag depth Fiont tance cil ses) Transmission ol seal 2.040 Smmn(0s1142:+0.086 in) 005mm(0:+0,020in) Transaxle ol seal 0: 03mm(0 0.012%) Input shen “ed gear trust clearance Standard | 0:100.30mn(0.0038-00118in.) Maximum | 030mm¥0.0118 in) “th goer trust cl ‘Standard | 0:10-0.47mm(0.0036-0.0188 in) Maximum | 047mn¥0.0185 in ‘Bh goer trust cl ‘Standard | 0:10-0.38mn(0.006-0.0130 in) Maximum | 033mm0.0130 in.) ‘Synchronizer ing and gear clearance Standard | 1.05~1.95(0.0813.0.05318in) Minimum | 1.05(0.0613 in) abrasion fmt 0.6(0.0236 in.) Input shal staighiness Maximum | 0.03(0.0012 in) ‘el gear bore Standard | 39,00-39.025(1.6354-1.5964 in) Maximum | 39,025(1.53¢4 in) ‘31d gear ofinput shat damster ‘Standard | 34,975.340991(1.377-13776in) Minimum | 34.975(1.377i) “th gear boxe ‘Standard | $8.00-36.026(1.£854-1.5964 in) Maximum | 39,026(1.5364 in) “4h gear ofinput shai dlametor ‘Standard | 94.975-34991(1.377-1776in) Minimum | 34.975(1.377in) “Bh goer bore ‘Standard | 96.00-36.025(1 4173-14183 in) Maximum | _36,026(1.6183 in) ‘8h gear of input shat diameter ‘Standard | 30.975-30.991(1.2185-1 220% in) Minimum | 30:975(1.2195in) Input shat snap rng thickness Mark03-6 Service specifications- Manual transmission No.2 ehteh hub 5th gear shalt snap ring nmoomy 2.28ren(0.0888 in) 2.34ren(0.0924 in) 2.40ren(0.0848 in) 2.461m(0.0969 in ) 252mm(0.0982 in) 258m(0.1016 in) 2.281n(0.0898 in ) 2.34men(0.0824 in) 2.40rnn(0.0845 in) 2.46rm(0.0969 n ) 252mm(0.0882 in) 258rn(0.1016 in) Output shat ‘st goar shatthrust clearance ‘Standard Maxims (0.15.0 32r(0.0068-0.0728in) 0.32mm(0.0128 in.) ‘nd gear shaft thrust clearance ‘Standard Maxim 0.15-0:35ram(0,0058-0.0738in) 0.36m(0.0138 in.) Tet gear bore ‘Standard Maxims 30.00.36, 025(1.5354-1.5954 in) 38,025(1.5368 in) ‘Oukput shat Tat shit shat outside dametor ‘Standard Miimam 34.975-34.991(1.371.3776in) 34.975(137Ta,) No.2 gear bore ‘Standard Maxirurn $38.00-38.025(1 5954-1.5954 in.) 39,028(1.5364 in) (Output shat 2nd shi shaft outside diameter 34.975-34.891(1.877-1.9776in) 34.975(137Ta) 15k 2nd drum shi fork slot with ‘Standard Maxinurs 10,05-10.15irm0.9967-0:3896 in) 410.450.9898 in) 1st Dna shit fork thickness ‘Standard Micimum {9.83.9 Smn0.9870-0.3857 in) 8.82r(0:3870 in) ‘Synchronizer ring and gear clearance ‘Standard Miimam 1,05-1.96(00413.0.05316in) 1.05(0.0413 in) abrasion it 0.5(0.0236 in) Cutt aiak sighs Outat hat snp ring ikness Perera (Output Sth shit enap ting Diferential Maxinurs Mark -rosmooe>E>mooe> .03rn(0.0012 in.) 2.201(0.0898 in) 2.34rnn(0.0898 in ) 2.ACren(0.0888 in ) 2.46rn(0.0888 in) 252nn(0.0898 in ) 2.58rmm(0.0838 in ) 2.227m(0.0874 in.) 2.28rn(0.0838 in) 2.34ren(0.0824 in) 2,40rnm(0.0945 in.) 2.46rn(0.0989 in) 2.521(0.0882'n ) 258mm(0.1016 in) 2.84men(0-1038 in) 2.7omen(0-1088 in) Diferential gear clearance (.05.0:20nm(0,0020-0.0079 in.) Diforential gear thrust washer thickness 0.50rr(0.0197 in)Service specifications- Manual transmission 03-7 0.56m(0.0217 in) 0.80rm(0.0238 in.) 0.85rm(0.0258 in.) 0,70rm(0.0276 in.) 0,76r(0.0295 in ) .80rmn(0.0915 in) 0.86rm(0.0935 in) 0.90rm(0.0954 in.) 0.36m(0.0874 In.) ‘Sh fork shat (Od seal installed depth ‘shift shat cover seal 2.0-2.5mm(.078-0.088 in) {hi fork shat ol sea 0: 0,mm(0-+0.020 in)03-8 Service specifications- Manual transmission Torque specification Parttightened Nem | Kof-on | Ft-lbf ‘ist and 2nd engine hanger 20 204 16 Transaxie x Engine oy 650 a7 Reinforced back panel 39 400 Ey Engine rear bracket x Rubber insulator 64 650 a7 Engine rear bracket x Transaxle 49 500 6 Engine left bracket x Rubber insulator 49 500 36 Front exhaust pipe x Tall pipe 45 459 3 Front exhaust pipe x Exhaust manifold 62 632 46 Starter x transaxle 39 400 29 Clutch release cylinder x Transaxle 2 120. 9 2nd shift fork x 2nd shift fork shaft 16 160 2 Reverse shift arm bracket x Transaxle case 7 475 13 ‘st shift fork x 1st shift fork shart 16 160 2 | Transmission case x Transaxle case 2 | 20 2 Reverse idler locking bolt 29 300 2 Locking ball assy x Transmission case 7 375 a7 Transmission speed sensor TFT) 78 80 6sin.bit Transmission case caver(TFT) 18 2 ‘st, 2nd and neutral switch 40 40 | 30 Backing up lamp switch 40 410 30 Cushion block 29 300 2 Shift shaft assy x Transmission case 12 120 9 Control cable x Transaxle case 1 115 8 Speed sensor a 115 8 Cluteh release fork support a7 375 2 Oil flier plug and drain plug 39 ‘400 2 Shift Shift shaft 16 160 2 Differential case x Gearing ring 124 1260 1 Shift assy x Case 12 120 9 Control cable x Case 49 50 43in.bitMANUAL TRANSAXLE Manual transaxle assembly(5TO65) - ‘Components =~ Overhaul Input shaft assembly(ST065) ‘Components ~~ Overhaul ~ Output shaft assembly(5T065): Components --- " Overhaul ~ Shift and select lever shaft assembly(5T065) 41-54 ‘Components ~ ese 4154 Overhaul Differential assembly(5T085) ‘Components --~- Overhaul ~Manual transaxle- Manual transaxle assembly(5T065) at Manual Transaxle Assembly(STO6S) Components Casas] teh release bosrng ¢ CCutch release fork soa y a | se ea asserty HEHE ‘Speed senser Differential case ascembly (Output shalt font besving —t Conical beating (Output shatt assembly Input shat assembly Roller bearing + Speciied torque © Non-raveatle part N 2070841-2 Manual transaxle- Manual transaxle assembly (5T065) Front transaxle caso ‘st goar shit fork shat. © Shap ing i, Compression spr ‘gh gear sit ey, it ne oie Sih gear sit head Sth goar sit fork : (eo) snap ring Sra th shi fork Eas oP casket Input shat assombiy Ti mikgh= om 8B] : Specifiedtorave © Nomreusable part N de Procosted pert 620708Manual transaxle- Manual transaxle assembly(5T065) aa \winghamess ean bracket . Compression sping — g i eceivetit) utp sha rear Boeing utr acor omg Output sha aah. bearing shim Transave case Shing ok assenty —- QP” ont sas @ % cnr pu A >) xB N= milgf= em. R-1bi] + Specitedtorque Non rousable part N_ 4 Pracosted patt 20708a4 Manual transaxle- Manual transaxle assembly (STO65) Overhaul 1.Remove the oil filler plug, {a)Remove the oil filer plug and gasket from the transaxle case. 2.Remove the oil drain plug subassembly. (a)Remove the ail drain plug and gasket from the transaxle case. 3.Remove clutch release bearing assembly. 4. Remove clutch release fork assembly, 5 Remove the clutch release fork boot, (a)Remove clutch release fork boot from the clutch case, 6.Remove the clutch release fork locating bolt. (a)Remove the clutch release fork locating bolt from the clutch case, 7.Remove the speed sensor. (a)Remove the balt and the speed sensor. (b)Remove the fixing clip from the odoometer with, a screw driver. &. Remove the speed sensor driver gear assembly. (a)Remove the speed sensor driver from the speed ‘sensor. (b)Remove the “0” ring from the speed sensor using a screw driver. 9 Remove back-up lamp switch, (a)Remove back-up lamp switch and gasket from the transaxle case using the SST. ‘SST 09817-16011Manual transaxle- Manual transaxle assembly(5T065) as 10.Remove the control cable, (a)Remove 4 bolts and 2 brackets from the clutch case. N 20710 11, Remove the lock assembly. (a)Remove the lock assembly from the ‘transaxle case. 520709 12Remove the shift & selector lever shaft assembly (@)Remove 4 bots. the shit & selector lever shaft assembly, the hamess bracket and the com- pression spring from transaxle. 13 Remove the reverse idler gear bolt (a)Remove the reverse idler gear bolt and the wash- ‘er from the transaxle case 14. Remove the transaxle case. (a)Remove 13 bots. ce NOTE: a My The side of transaxle case: 8 bolts JAM A The side of clutch case 8 bolts o (&)Remove the transaxle case with copper bar ff iy and hand hammer top on the projection SASS N os7i441-6 Manual transaxle- Manual transaxle assembly (5T065) GBS 15 Remove reverse idler gear shaft. (a)Remove the reverse Idler gear shart 16. Remove reverse idler gear subassembly. 17 Remove reverse shaft arm bracket assembly (a)Remove two bolts and the reverse shaft arm bracket assembly from transaxle case. 418 Remove the ‘st-2nd gear shift fork shaft. (a)Remove the 1st2nd gear shift fork shaft (b)Drive out the spring pin trom the firstsecond ‘gear guide block with the pin punch and hand hammer.Manual transaxle- Manual transaxle assembly(5T065) ac (c)Remove the tst-2nd gear shift fork shaft. The ‘ist:2nd gear guide block and the 1st-2nd gear shift fork (d)Tap out the snap rings from the 1st-2nd gear shift fork shaft with two screw drivers and hand hammer. 19.Remove the shift fork shaft on the left (a)Remove the cylincrical pin from the fifth gear shift fork. (b)Tap out the spring pin from the Sth gear guide block with pin punch and hand hammer. (c)Tap out the gripping ring from the 5th gear shift fork shaft with two screw drivers and hand hammer.41-8 Manual transaxle- Manual transaxle assembly (5T065) (a)Remove the 6th gear shift fork shaft, the com- pression spring, the 5th gear guide block and the 5th gear shift fork from the clutch case. (e)Tap out the gripping ring from the 5th gear shift fork shaft with two screw drivers and hand hammer, NOTE: Prevent the snap ring from flying out with duster cloth. 20.Remove the 2nd shift fork shaft. (a)Remove the fixing pin from the reverse gear shift fork block with the magnetic bar. (b)Tap out the snap ring from the 3ré-4th gear shift fork shaft with two screw drivers and hammer. NOTE: Prevent the snap ring from flying out with duster cloth. (c)Remove the bolt from the 3rd-4th gear shift fork.Manual transaxle- Manual transaxle assembly(57085) 41-9 (@)Convert the 3ré-ath gear shit fork and make i mesh with the 4th gear (e)Remove the 3rd-dtn gear shit fork shat the a Srd-ath gear shift fork and the reverse gear t shit fork (fJTap out the snap ring from the 3rd-4th gear shift fork shaft with two screw drivers and hammer, NOTE: Prevent the snap ring from flying out with duster cloth, 7 ‘20815 21.Remove the input shaft assembly. (a)Remove the input shaft assembly from the clutch case. 22Remove the output shaft assembly. (@)Remove the output shaft assembly from the clutch case, ‘Shake it several tes and elevate output shaft ‘assembly, input shaft assembly, three shift forks and fork shaft assembly together from the dutch case, then repair them separately 23.Remove the differential assembly. ==5 (a)Remove the differential assembly from the ~ P clutch case,41-10 Manual transaxle- Manual transaxle assembly (5T065) 24. Remove the oil receiver pipe.(MTM) (@)Remove the oll recetver pipe from the transaxle case, NOTICE: Be careful not to damage the 2nd oil receiver pipe. 25.Remove the transaxle magnet. (a)Remove the transaxle magnet from the clutch case. 26.Remove the input shaft oil seal (a)Remove the input shaft oil seal with the screw- driver. 27 Remove the output shaft front bearing (a)Remove the output shaft front bearing from the transaxle case with SST. ‘SST 09608-00010 28 Remove the oil-guide grommet (a)Remove the cil-guide grommet from the clutch case,Manual transaxle- Manual transaxle assembly(5T065) aon 29.Remove the transaxle case differential oil seal {a)Remove the transaxle case differential ol ‘seal with the screw driver, 20.Remove the transaxle housing rear tapered bearing outer race with SST as below (@Remove the transaxle case back rolling ‘cone bearing outer race and gasket with SST Ei SST 09950-80010(09951-00560), 08980-70010(09961-07200) 31 Remove the transaxle housing oil seal (a)Remove the axle shatt oil seal from the clutch housing with the screw driver. ‘32,.Remove the clutch housing front tapered roller bearing with SST as below. (@)Remove the clutch case front rolling cone bearing with SST. SST 09387-00041 (09387-02010,09387-02020) c20881 33. Remove the input shaft rear bearing gasket (a)Remove the input shaft rear bearing gasketai-12 Manual transaxle- Manual transaxle assembly (5T065) sey 20904 G20005 20908 34.Remove the output shaft rear bearing outer race. (a)Remove the output shaft rear bearing outer race SST 09527-30010. 09612-65014 (09612-01030, 08612-01050) 35.Remove the output shaft rear bearing gasket. (a)Remove the output shaft rear bearing gasket, 36.Inspect the reverse idler gear subassembly. (a)Check the reverse idler gear shaft with the dial gouge, Standard outside diameter. 15,941~15,968(0.6276-0.6287 in.) (b)Check the reverse idler gear subassembly, ‘Standard diameter of bore, 1.6,00-16.027mm (0.6299-0.6310 in.) Maximum diameter of bore. 16.04mm (0.6315 in.) Ifthe dearence exceed the maximum, replace the reverse idler gear 37 Inspect the reverse shift fork. (a)Check the reverse shift fork with the caliper. ‘Standard diameter of bore. 14.4mm(0.5669 in.) 4.0-14,043mm(0.9512-1.5529 in.) :6.00-6.03mmManual transaxle- Manual transaxle assembly(5T065) aa 38 Inspect the 1st-2nd gear shift fork shaft. (a)Measure the 1st-2nd gear shift fork shaft with the micrometer, Standard outside diameter: —— 13,957-13.984 mm(0.5495-05506 in.) canny 39.Inspect the 3rd-4th gear shift fork shaft (a)Measure the 3vd-th gear shift fork shaft with ‘the micrometer. Standard outside diameté 13.957-13.984 mm(0.5495-0.5506 in.) 7 cane 40.Inspect the 5th reverse shift fork shaft. (a)Measure the 5th reverse shift fork shaft with the ‘micrometer. Standard outside diam 13,987-13.984 mm(0.5495-0.5506 in.) carts 41.Inspect the 1st-2nd gear shift fork 1 (a)Measure the 1st-2nd gear shift fork with the I ‘vemier caliper. Standard inner diameter and thickne: $3-9,9 mm(0.3870-0.3888 in.) 83-9.9 mm(0.3870-0.9898 in.) .00-14.043 mmn(0.5512-0.5529 in.) 8 c2it20 42. Inspect the 3rd-4th gear shift fork. {a)Measure the 3rd-ath gear shift fork with the (ei 8 vemier caliper. Standard inner diameter and thickness: .83-8,9 mm(0.3870-0.3898 in.) :14,00-14,043 mm(0.5512-0.5529 in) 21124atta Manual transaxle- Manual transaxle assembly (5T065) a ati atts G2r124 105-115 mm (0413¢04828in) o2n1se 43.Inspect the Sth reverse shift fork. (a)Measure the 5th reverse shift fork with the vernier caliper. Standard inner diameter and thickne: 49.83.9.9 mm(0.3870-0.3898 in.) B:14,00-14,043 mm(0.5512-0.5529 in.) 44.Inspect the 1st-3rd gear shift fork head. (a)Measure the 1st-3rd gear shit fork head with the vernier caliper. Standard inside diameter: 14,00-14,043 mm(0.5512-0.5529 in.) 45.Inspect the Sth reverse shift fork head. (a)Measure the 5th reverse shift fork head with the vernier gauge. Standard inner diameter: ‘A:14,00-14,043 mm(0.5512-0.5529 in ) B:14.3 mm(0.5630 in) 46 Install the case stright pin. (a)install the case stright pin. Standard dept 10.5-11.5 mmn(0.4134-0.4528 in.) 47 Install the output shaft oil guide gasket (@)install the ouput shaft oll guide gasket as shown in the illustration.Manual transaxle- Manual transaxle assembly(5T065) as 48 Install the output shaft front bearing outer race. (a)Press heavily down the SST to press the output ‘shaft front Dearing outer race into the case. SST 09950-60010(09951-00510) (09950-70010(09951-07180) 49 Install the right-front differential front tapered roller bearing outer race, (a)Press heavily down the SST to press the right- {ront differential front tapered roller bearing ‘outer race into the case, SEF cost atta 00510 cE (09350-32014(09361-32111,0351-32130) 50.Install the right-front differential rear tapered roller bearing outer race. (a)install the gasket into the transaxle case. NOTE: Reuse the output shaft rear tapered roller bear- ing again, install a gasket whose thickness is as ‘same as the original one. If you use a new out- put shaft rear bearing, select and install a thinn- er gasket, (b)Press heavily down the SST, to press the right- front ferential rear tapered roller bearing into the housing (outer race). SST 09950-60010(0991-00620) (08950-70010(09861-07100) 51 Adjust the preload force of the differential (@)Apply gear oil on the differential, and then instal it on the clutch case,41-16 Manual transaxle- Manual transaxle assembly (5T065) pos7i4 2r162 (©)Instal the 13 bolts ofthe transaxle case. ‘Torque: 29.4N.m(300kgf.cm.22ft.Ibf) NOTE: transaxle case side:8 bolts (Tur the differential right and left two or three times to alow the bearings to settle, with the SST and the torque wrench, SST 09564-32011 (@)Measure the preload with the SST and torque wrench SST 09564-32011 Proload (original ono); Now bearing: 0.781.57N.m(7.95-16.00kgf.cm, 6.9-13.88i Used bearin 0.49-0.98N.1m(5.00-9.99kgf.cm,4.9-8.67in.Ibf) (@)Select other gaskets, Mark [Thickness mm(n)| Mark | Thickness min) A | 1.200.0472)| | 1.85(0.0610) | 1.250.049) | J 1.6010.0680) | 1.30(0.0512)/_K | 1.65(0.0850) D_| 1.95(0.0831) | _L_|_1.70(0.0889) | 1.40(0.0551) | M_|_1.76(0.0689) | F | 1.45(0.0571) | _N__| 4.80(0.0709) G | 1.60(0.0591) | (Remove 13 bolts and the transaxle case from the clutch case. (g)Remove the differential assembly from the clutch case. 52.Install the output shaft rear bearing, (a)instal the output shart rear bearing gasket into the transaxle. NOTE: Reuse the output shaft rear tapered roller bear- ing, install a gasket whose thickness as same as the original one firstly. if you use a new out- put shaft rear bearing, select and install a thin- ner gasket firstly.Manual transaxle- Manual transaxle assembly (5T065) eait6s bosri4 Sst, caits2 (b)Press heavily down the SST, to press the output, ‘shaft rear bearing into the housing (outer rece) SST 09980-60010(09951.00620), (08950-70010(08951-07 100) aid 53 Adjust the preload of the output shaft bearing, (a)install the output shaft assembly and the differen tial assembly on the clutch case. (b)Install the transaxle case on the clutch case with 13 bolts, Torque:28.4N.m(300kgf.cm, 22ft bf) (c)Tum the output shatt assembly and the differen tial allow right and left hvo or three times to allow the bearing install to settle with SST and a torque wrench (d)Measure the preload with SST and a torque ‘spanner. ‘SST.09564-32011 Preload(Original on}: New bearing: 3.09-6.18Nm(31.5-63.0kgf.cm,37.9-54.7 in. bf) Use bearing: 1,96-3.96Nm(19,7-29.4kgf.cm.17.1-34.2 in. bf)arte Manual transaxle- Manual transaxle assembly (5T065) (e)Select other output shaft back bearing gaskets. ‘Mark [Thickness mmin)[ Mark [Thickness mmvin) A__| 1.55(0.0610) | J | 1.95(0.0768) B__| 1.60(0.0630) |__| 2.00(0.0787) © 7.66(0.0660) | L| 2.06(0.0807) D_ | 4.700.066) | Mm | 2.10(0.0827) E | 4.750.0689) | N | 2.16(0.0846) F | 1.800.070) | P| 2.20(0.0866) G | 1.85(0.0728) |G | 2.25(0.0886) H_| 4:90(0.0748) | (fRemove the 13 bolts and the transaxle case from the transaxle case (g)Remove the output shaft assembly from the clutch ‘case. (h)Remove the differential assembly from the clutch, case. '54 Adjust the input shaft rear bearing gasket (a)Measure correctly the size ofthe “A” and "B” with the vernier caliper. (0)Select the input shaft rear bearing gasket and make its value within the specification, The thickness of the gasket: 0= B.A(tho thicknoss of the gasket) <0.1mm(0.0038in,) ‘Mark [Thickness mm(n)] “Mark [Thickness mmtn ) F | 1.800.070) | N | 2.16(0.0846) 1.85(0.0728) | P| 2.20(0.0868) 1.90(0.0748) | Q | 2.25(0.0886) 4,95(0.0768) | R_ | 2.30(0.0906) 2.000.0767) |S | 2.35(0.0025) 2.05(0.0807) | T | 2.400.945) M_| 2.10(0.0827) (c)Install the input shatt rear bearing gasket. elxielzlo 56 Install the left half-shaft oil seal {@)install a new left haif-shaft oil seal on the trans- ‘axie case, using SST and hammer. SST 09950-60010(09951-00620). 09950-70010(09957-07 100) Depth: 0-0.3mm(0-0.0448 in.) (b)Apply the front of the lefthalt-shaft oil seal with MP grease.Manual transaxle- Manual transaxle assembly (5T065) at-19 FAA c2n7e 05736 56 Install the oil seal of right half-shaft. {a)install the oil seal of right half-shaft to the dutch ‘case with SST and hand hammer. (b)Coat the front of the oil seal of right haif-shatt with MP grease, 57 Install the oil seal of input shaft {a)install the oil seal of input shaft to the clutch ‘case with SST and hand hammer. SST 09710-20011(09710-08071), 09950-70010(09951-07150) Depth:0 + 0.3 mm(0-0.0118 in.) (b)With the front of the oil seal of clutch case with MP grease. '58 Install the magnet of transaxle, {(a)Ciean and install the magnet of transaxle in dutch case. 5 Install the 2nd gear oil receive pipe of the 2nd gear oil (a)Install ol guide in the transaxie case. ATTATION: Be careful don't damage the oil guide, 60.Install differential assembly. (a)Apply gear oll to the tapered roller bearing of the cifferential, and install it to the clutch case.41-20 Manual transaxle- Manual transaxle assembly (5T065) 2tt80 ai 61 Install output shaft assembly. (a)install the output shaft to the clutch case. 62 Install input shaft assembly. (2)Apply gear oil to the smooth turning surface of Input shaft then instal itto the clutch case. 63 Install the 3rd-4th shift fork shaft. (@)install te 3rc-ath gear fork shaft to the gear shift fork spindle. (o)Install new snap ring in the 3rd-4th gear shift fork shaft with hand hammer. (c)Instal the reverse shift fork block to the Srdeath gear shift fork spindle, (@)Convert the 3rd-4th gear fork shaft to 4th, (e)Instal the 3rd-ath gear shift fork shaft and the reverse shift fork block. (Apply sealant to the bolt thread of Src-ath shift fork shaft. Sealant: Part No.:08833-00080,THREE BOND1344, LOCTITE oF equivalent. (g)install the bolt of 3rd-4th gear fork shaft “Torque:16N.m(160kgf.cm,12ft.Ibf)Manual transaxle- Manual transaxle assembly(5T065) ey) (h)install new snap ring to the 3rd-sth gear shift fork spindle with cupper bar and hammer. (instal cylindrical lock to the reverse shift head with magnetic bar. 64 Install the Sth reverse gear shift fork shaft. (a)install the 6th gear shift fork shaft to the 5th Seow (nt re rp gio te tev ge Lo Si ta e2it8s (o)Install Sth reverse gear shift fork shaft, compre- ‘ssion spring, Sth-reverse head and Sth-reverse shift fork shaft to the clutch case. 62086041-22 Manual transaxle- Manual transaxle assembly (5T065) 620867 2119s (d)install slotted spring pin to the Sth-reverse shift block with hand hammer and pin punch. (e)install new snap ring to the 5th-reverse gear shift fork shaft with screw driver and hand hammer. (finstall straight pin to the 5th-reverse shift fork. shaft. 65 Install the 1st-2nd gear shift fork shat. (a)install the 1st-2nd shift fork shaft to the 1st-2nd ‘synchronizer ring (b)install new snap ring to the 1st-2nd gear shift fork shaftManual transaxle- Manual transaxle assembly(5T065) A129 (c)Install the tst-2nd gear shift fork shaft, 1st-2nd shift fork shaft and ‘st-2nd shift head by ae 520885 {(D)install slotted spring pin to the ‘1st-2nd shifthead with pin punch and hand hammer. (e)Apply sealant to the bolt of the 1st-2nd shit fork shaft Sealant Part No.:08833-00080, THREE BOND 1244, LOCTITE 242 (install the bolt ofthe first-second shit fork shaft Torque: 16N.m(160kgf.cm,12ft. Ibf) 61-65 Assemble input. shaft assembly, output shaft assembly three forks and fork shafts assembly together, and shake some times in order to align each hole, then install each assembly correctly. 66 Install reverse idle gear assembly, 67 Install reverse idle gear shaft. (a)Apply gear oll to the reverse ide gear shaft then install it as show in the illustration. (b)Align the sign of the reverse idle gear shatt and the bolt as show in the illustration,at-24 Manual transaxle- Manual transaxle assembly (5T065) zits e2it89 N 621190 68 Install reverse shift arm bracket assembly. (a)install the reverse shift arm, bracket assembly to the clutch case with two boits. Torque:t7.2N.n(175kaf.cm. 12.7ftbf) 69 Install transaxle case (a)Apply sealant to the transaxle case es show in ‘he illustration. Sealant: Code:08826-00090, THREE BOND 1281, Attontion: partly assembly must be finished in 10 mins after daubing seal glue. (b)Apply sealant to 13 bolts. Part No.:08833-00080,THREE BOND 1344, LOCTITE 242 or equivalent. (c)install hand transaxle case with 13 bolts, ‘Torque:29.4N.m(300kgf.cm,21.7tIbf) 70.|nstall the bolt of the reverse idle gear shaft. {@)Apply sealant to the bot ofthe reverse ale gear shaft Part No.:08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. (b)Instal the bolt of reverse ide gear shaft and new ‘washer to the transaxle case, Torque:29.4N.m(300kgf.cm,21.7fuibf) 71 Install shifter shaft assembly. (a)Apply sealant to the transaxle case as show in the illustration, Sealar Part No.:08826-00090,THREE BOND 1281, or equivalent.Manual transaxle- Manual transaxle assembly(5T065) 41-25 (c)install wire hamess clamping bracket the shift ‘and shaft assembly and compression spring to the transaxle case with 4 bots, Torque: 15N.m(150kgf.cm,11 fbf) N 20708 72.Install shifting lock ball assembly (a)Apply sealant tothe shitting lock ball assembly. Seala Part No.:08833-00080, THREE BOND 1344, Loctite 242 | (b)Install the shifting lock ball assembly to the trans- axle case, eau. Torque:39,2N.m(400kat.cm,29Ft bf) 73.install the shifting control cable bracket {a)Install two brackets to the clutch case with four bolts, Torque: 15N.m(150kaf.cm,11ft1bf) 74,install back-up lamp switch assembly. {@)install back-up lamp switch and new washer to the transaxle case with SST. ‘Torque:40.2N.m(410kgf.cm,30ft bf) 75.install the speed sensor. {a)install the speed sensor with bolt Torque:12N.m(120kgf.cm,9ft.Ibf) 76 install speed sensor driven gear. {a)install new O ring of the speed sensor. (b)Install the speed sensor driven gear assembly ‘and speed sensor together with clamp,41-26 Manual transaxle- Manual transaxle assembly (5T065) e218 77 Install the clutch release fork support. (a)instal the clutch release fork support to cuutch case. ‘Torque:36.8N.m(375kgf.cm, 25ftIbf) 78.nstall the clutch release fork assembly. (a)install the clutch release fork assembly and the ‘clutch release bearing assembly together to the Input shat Sealant: Part No.:08887-01806,CLUTH SPLINE GREASE (b)Coat spline of input shaft with grease, 79 Install oil drain plug subassembly, (@)install ol drain plug and new washer together to the transaxle case. Torque:38.2N.m(400kgt.cm,28ft.Ibf) 80 Install the oil filer plug of the manual trans- axle. (a)install the ol filer plug of the transaxle and new washer together to the transaxle case. Torque:39.2N.m(400kaf.cm,29ft bf)Manual transaxle- Input shaft assembly(5T065) A237 Input Shaft assembly(5T065) Components ‘td gear needle becring sd gear ‘nd clutch hub locking snap ring (Oe, Sth gear ssynchroner cing N © Nonreussbie parts 81d gear synchronizer ting tate Koy spring 2nd transaxle chech anes. 9 € ) 2nd shit key in ‘umbush ‘separate ‘th gear symenronize ing 5th gear shah whet es @G, chert anke - Sra shin key 4 Output shalt ron bearing Sth tnust gasket bal S. ®@ ‘th gear 4 th goar sha snap ring (( vesshtrad ; vata kkey spring. tstenin 2121841-28 Manual transaxle- Input shaft assembly(5T065) Overhaul 4 Inspect 3rd gear thrust clearance (a)Measure 3rd gear thrust clearance with feeler guage. Standard clearanc 0.10-0.30mm(0,0039-0.0118in.) Max clearance: 0.30mnm(0.0418in, (b)Measure 6th gear thrust clearance with dial Indicator. Standard clearance: 0.10-0.33mm(0.0039-0.0130in.) Max clearance: 0.33mi(0.0130in.) 2.Inspect 3rd gear radial clearance. (a)Measure 3rd gear radial clearance with dial indicator. Standard clearanc 10.008-0.050mm(0.0004-0.0020in.) Max clearance: 0.050mm(0.0020in.) Ifthe clearance exceed the max numerical value, sziz2t replace 3rd gear, needle bearing or shaft (b)Measure 4th gear radial clearance with dial indicator. Standard clearance: 0,009-0,050mm(0.0004-0.0020in.) Max clearance: 0,050mm(0.0020in.) If the clearance exceed the max numerical value, replace 3rd gear, needle bearing or shaft e21222Manual transaxle- Input shaft assembly(5T065) 41-29 621223 621204 621226 621226 (c)Measure gear and shatt 5th gear radial clearance with dial indicator, Standard clearance: 0.009-0.50mm(0,0004-0.0020in.) Max clearan« 0.050mm(0.0020in.) Ifthe clearance is exceeds the max clearance, replace 3rd gear, needle bearing or shaft. 3.Remove Sth gear. (a)Press heavily down the SST. remove input shaft radial ball bearing 3rd clutch hub, 5th gear ‘synchronizer ring and Sth gear from input shart. HINT: + Protect input shaft drop off. Please hold it. + Sot the SST fixed claw between 4th gear and Sth gear, as shown in the illustration. NOTICE: Don't excessive fitm SST. 4.Remove 3rd transaxle clutch hub, (a)Remove two 3rd, 4th, 5th, synchronizer spring from Sth clutch hub. (b)Remove &th clutch hub sleeve from Sth clutch hub, (c)Remove three shifting key from 3rd transaxle clutch hub. 5 Remove Sth gear needle beating41-20 Manual transaxle- Input shaft assembly(ST065) 21227 e21228 o21228 621280 o21281 6 Remove Sth gear bearing spacer. T.Inspect thrust clearance. (a)Measure 4th gear thrust clearance with dial indicator ‘Standard clearanc 0,010-0.47mm(0,0039-0.0185in.) Max clearance: 0.47mm(0.0185in.) Ifthe clearance exceed the max clearance, replace 4th gear or shaft 8,Remove Sth gear shaft snap ring (a)Remove 4th shift gear thrust gasket snap ring with snap ring expander. HINT: Be careful Don't damage input shaft journal surf 9.Remove 4th gear thrust gasket 10. Remove 4th gear thrust gasket ball (a)Remove steel ball from input shaft with magnet bar.Manual transaxle- Input shaft assembly(5T065) aa 621232 621234 11. Remove 4th gear. 12Remove 4th gear needle bearing. 13Remove 4th gear synchronizer ring 14Remove 4th gear bearing spacer. 15.Remove 3rd, 4th clutch hub snap ring with snap ring expander. Be careful: Don't damage input shaft journal surface. 16 Remove Sid gear. (a)Press heaviling down SST, remove 3rd, 4th ‘synchronizer assembly, 3rd gear synchronizer ring and 3rd gear. SST 09950-00020 NOTICE: Don't excessive firm SST. Be careful: Protect input shaft assembly fall, pl 47. Remove 31d, 4th clutch hub. (a)Remove two 3rd, 4th, 5th synchronizer spring from 3rd, 4th clutch hub, (b)Remove 2rd, 4th hub sleeve from 3rd, 4th clutch hub, (c)Remove three slide block from rd, 4th clutch hub.41-92 Manual transaxle- Input shaft assembly(5T065) 621237 621238 621236 18Remove 3rd gear needle bearing. 419.Remove input shaft front bearing (a)Press heaviling down SST, remove input shaft front bearing from input shaft, SST 09950-00020 Be careful: Protect input shaft fall, please hold it. 20.Inspect 3rd gear synchronizer ring, {(a)Check for wear and damage. (b)Check the braking effect of the synchronizer ring Tum the synchronizer ring in one direction while pushing itto the gear cone, check that the ring locks. It the braking etfectis insufficient, apply a small ‘amount of the fine lapping compound between the synchronizer ring and the gear cone, lightly rub them together: NOTICE: Ensure the fine lapping compound is completely washed off. (©)Measure the clearance between the 4th gear ‘synchronizer ring back and gear spline end with feeler gauge, Standard clearance: 1.05-1.35mm(0.0413-0.053tin.) I< 0.6mm replace the synchronizer ringManual transaxle- Input shaft assembly(5T065) aaa 21.Inspect 4th gear synchronizer ring, (a)Check nommal wear and outdent damage. (b)Check 3rd synchronizer ring braking. Push the ‘4th synchronizer ring where is near the circular come side then turn the 4th synchronizer ring single side to check the ring’s braking If the brak- ing effect doesn't work. Printa litte grinding paste between the synchronizer ring and the circular come of year and rub them at the same time o21238 lightly NOTE: Be sure to clean the grinding poste after rubbing them. (c)Measure 4th gear synchronizer ring back side ‘and 4th gear key way clearance, Standard clearance: 1.05-4.35mm(0.0413-0.0534in.) If <0.6 replace synchronizer ring. e21239 22 Inspect Sth gear synchronizer ring (a)Check for wear and damage. (b)Check 5th synchronizer ring braking. Push the ‘th synchronizer ring where is near the circular ‘cone side then turn the Sth synchronizer ring ‘single side to check the ring's braking, Ifthe braking effect doesn't work. Printa lite grinding paste between the synchronizer ring and the reular cone of gear and rub them at the same time lightly, NOTE: Be sure to clean the grinding paste after rubbing them. (c)Measure clearance between &th gear synchron- izer ring back side and 5th gear key way. Standard clearance: 1.05-1.35mm(0.0413-0.1534in.) 1106 replace synchronizer ring, 621236at-aa Manual transaxle- Input shaft assembly(5T065) et o21264 23.Check 2nd transaxle clutch hub sleeve. (a)Check 2nd transaxle clutch hub sleeve and 2nd shift fork thickness with vemier caliper. Standard thickness: (0.15-0.32mm(0,0059-0.0126in) 24,Check 3rd transaxle hub sleeve, (a)Check 3rd transaxle hub sleeve and 3rd shitt fork. thickness with vemier caliper. Standard thickness: 0.15-0.32mm(0.0059-0.0126in) 25.Check input shat. (a)Check input shart wearing and damage. (b)Check input shaft straightness with dial quage. Standard straightliness:0.03mm(0,0012in) (c)Measure input shaft journal surface outside diameter. Standard outside diameter: Measure the part ‘Outside dametermmin.) ‘A 26802-25516 1,0040-10.0488) | 8 | 30975-90801(1.2185-42201) D 33,975-33,991(1.3376-1.3382) E 23.002-23.015(0.9056-0.9091) Fr 22.967-23.000(0.9042-0.9055) 26.Check 3rd gear. (a)Measure 3rd gear inner diameter. Standard inside the path: 39,00-39,025mm (1.5354-1.5364in)Manual transaxle- Input shaft assembly(ST065) 41-35 s21246 e21246 621247 \ 621286 21248 27 Check 4th gear. (a)Measure 4th gear inner diameter with cylinder bore gauge. ‘Standard inside: 39,00-39.025mm(1.5354-1.5364in.) 28.Check 5th gear. (a)Measure Sth gear inner diameter with cylinder bore gauge. ‘Standar 36.00-36.025mm(1.4173-1.4183in.) 29.Check input shaft front bearing (a)Press the SST bearing, then install input shaft front bearing on the input shaft SST 09518-10010 30.Check 3rd gear shaft needle bearing. (a)Apply gear oil on the Std need bearing, then install it on the input shaft 31.Check 3rd gear. (a)Print gear oil on the 2rd gear, then install it on the input shaft41-96 Manual transaxle- Input shaft assembly(5T065) 32Install 3rd gear synchronizer ring, (a)Print gear oil on the 3rd gear synchronizer ring then install in on the input shaft 21268 3 Install 3rd, 4th gear synchronizer assembly. (@)instal three rd-dth gear synchronizing sliding keys, two 3rd-4th-Sth gear synchronizing springs and a 3rd-Ath-Sth gear synchronizing hub sleeve to 3rd-ath gear clutch hub. NOTICE: ‘As showing in the illustration, install 3rd-4th gear synchronizing hub sleeve and Srd-4th Gear clutch hub. 621236 (b)Press SST, install Srd-ath gear synchronizer ‘assembly to output shaft 34 Install locating bearing snap ring or 2nd cluteh hub. (a)Select a new snap ring to reach the smallest axial clearance. Standard Clearanco:0.4mm(0.0038in.) Mark [Thickness mm(n)] Mark [Thickness min} A | 2.28(0.0898) | _D_ | 2.46(0.969) _B | 23400921) | _E | 2.62(0.992) [.2.40(0.0945) | _F | 2.56(0.1016) (b)Install a new snap ring to output shaft by snap ring expander. NOTICE: Be carefully don't damage the surface of output shaft neck.Manual transaxle- Input shaft assembly(5T065) aa 36.Inspect the 3rd gear thrust clearance, (a)Use the feeler gauge to measure the thrust clearance. Standard Clearance: 0.10-0.30mm(0.0039-0.0118in.) 36 Inspect 3rd gear radial clearance. (a)Measure the 3 gear position gear racial clearance with dial indicator Standard clearance: 0.009-0.050mm(0.0004-0.0020in.) a1 | Maximum clearance: 0.050mm(0,0020in.) Ifthe dearance is exceed the stendard,replace 3rd gear position gear needle bearing or shart 621283 37.Inspect range 4th gear synchronizer ring. (a)Apply the gear oll on synchronizer ring and instal them on 3rd and 4th gear synchronizer locking ring, 621264 38 Install range 4th gear bearing spacer. 1621256 39 Install 4th gear needle roller bearing (a)Apply the gear oll on 4th gear needle roller bearing and install them on input bearing.41-98 Manual transaxle- Input shaft assembly(ST065) 821287 621230 621228 40.Install 4th gear (a)Paint gear oll on 4th gear and install them on input bearing, 41 Install 4th gear thrust washer steel ball, 42 install 4th gear thrust washer. 43.Install 4th gear thrust washer ring. (a)choose a ring be and make sth gear thrust washer clearance less than 0.1mm. Mark [Thickness ‘mm(n.)| Mark | Thickness mmiin.) 1 | 2.28(0.0898) | 4 | 2.46(0.969) I 6210,992) | 58(0.1016) (b)Use ring expander and fix @ new ring on the input bearing, INDICATION: Don't damage input shaft journal surface.