SECTION 4 MANUAL TRANSMISSION

AND MANUAL TRANSMISSION

CONTROL MECHANISM
SECTION 1 MECHANISM AND SPECIFICATIONS 55
MANUAL TRANSMISSION 55
SHIFT AND SELECT MECHANISM 59
MANUAL TRANSMISSION CONTROL MECHANISM 61
SECTION 2 MAINTAINCE PROCEDURE 62
MANUAL TRANSMISSION CONTRAL MECHANISM 62
MANUAL TRANSMISSION ASSEMBLY 70
 SECTION 1 MECHANISM AND SPECIFICATIONS
MANUAL TRANSMISSION
Either four-speed or five-speed manual transmission is equipped on the sedan, and five-speed
is used on most of the models.

Manual Transmission

Manual Transmission Specifications

Type
4-speed 5-speed
Item
Transmission type Forward gears: Constant mesh, Reverse gears: Selective sliding
1st gear 3.090 (34/11 ) 3.090 (34/11)
2nd gear 1.842 (35/19) 1.842 (35/19)
Gear ratio
3rd gear 1.250 (35/28) 1.250 (35/28)
(Tooth
4th gear 0.864 (32/37) 0.864 (32/37)
number)
5th gear — 0.707 (29/41)
Reverse gear 3.142 (44/30/14) 3.142 (44/30/14)
Final reduction gear ratio 4.500 (72/16) 4.714
Speedo-meter Gear ratio
16/4 17/4
(driven/drive)
Kind GL-4 80W/90 GL-4 80W/90
Capacity l 1.9 - 2.0 2.1 - 2.2
Oil
(lmp. qts (1.67- 1.76, (1.85- 1.94,
U.S. qts) 2.0 - 2.1) 2.2 - 2.3)
POWER TRANSMITTING MECHANISM
The following indicates the power flow route for each shift positions.

①1st gear
②2nd gear

③3rd gear ④4th gear

⑤5the gear ⑥Reverse gear

Power Transmitting Mechanism

TRANSAXLE CASE
Casting aluminum alloy is employed to produce the transaxle case and transmission case.
The mating surface between the transaxle case and the transmission case and the mating
surface between the transmission case and the cover are sealed with Three Bond 1216 which
features superior oil-resistant ability.

Transaxle case

Lubrication
In line with higher running speeds, a shaft center lubricating mechanism having higher
lubricating effects is adopted. A guide pipe is provided at the end of the output shaft so as to
lubricate those parts around the output shaft.

Shaft Center Lubricating Mechanism

Input Shaft
The number of spline teeth provided on the input shaft to accommodate the clutch disc has
been increased from 18 to 20 and the outer diameter of the input shaft has been increased
from19mm to 21mm with the engine output power increased.
The pressure angle of the second gear is 17°.
 Input Shaft

REVERSE GEAR & SLEEVE

Three key grooves of the reverse gear and sleeve
are used to meet the requirement of the engine output
torque. The reverse gear sleeves also activate while
engaging1st gear or 2nd gear.

Reverse gear

OUTPUT SHAFT
Peening treatment has been applied to the output shaft to meet the increased engine output.

Output Shaft
DIFFERENTIAL
The planetary type differential
composed of the side gear, the pinion,
the pinion shaft, the ring gear and the
differential case, are used on the
vehicles.

Differential Specifications
Final reduction gear ratio 4.500
Number of tooth 72
Tooth width (mm) 23
Differential ring gear
Outer diameter (mm) 184.0
Gear type Helical gear
Number of tooth 16
Tooth width (mm) 26
Final reduction gear
Outer diameter (mm) 47.3
Gear type Helical gear
Number of tooth 16
Differential side gear
Number of inner spline teeth 23
Number of differential pinion tooth 10
Pinion shaft outer diameter (mm) 15
SHIFT & SELECT MECHANISM
A shift & select mechanism which features compact design and excellent operating feeling and
which is best suited for the vertical-split type transmission case is employed.

Shift & Select Mechanism

INTERLOCK MECHANISM
The interlock mechanism is a device which
prevents two gears from being engaged
simultaneously. This mechanism is composed of
two interlock plates.
When the 1st & 2nd shift fork shaft moves
axially from the neutral position, the interlock
plate engaged in the cut-out section of the shaft is
paused out, thereby pushing the cut-out section of
the 3rd & 4th fork shaft.
Furthermore, the other plate also pushes the
cutout section of the reverse shift fork shaft. As a
result, both the 3rd and 4th shift fork shaft and
the reverse shift fork shaft are locked, thus INTERLOCK MECHANISM
preventing two gears from being engaged
simultaneously.

Interlock Mechanism
TRANSMISSION CONTROL DEVICE
This control device is single-manipulation device with hinge linked.

The extension rod

The control rod

 SECTION 2 MAINTENANCE OPERATION
TRANSMISSION CONTROL DEVICE
COMPONENTS

REMOVAL
1. Detach the shift lever knob and the
shift & select lever boot.

2. Detach the dust seal retainer and dust

boot.

3. Disconnect the shift & select shaft

subassembly at the transmission side.
Remove the pin and the bush.

4. Remove the extension rod

subassembly and floor shift support
No.2.

INSPECTION
Check to see if each joint section under an assembled condition rotates smoothly without
any binding. (See below.)

DISASSEMBLY
1. working from the case side, pull out
the hole snap ring by means of the
SST.
SST: 09905-87001-000

2. Disassemble the plate washer, bush and shift lever seat.

3. Remove the extension rod

subassembly from the shift lever
subassembly.
4. Disassemble the plate washer and shift lever retainer dust boot.

5. Disassemble the bush, nut, plate

washer and floor shift support No. 1.

6. Grind off the staked section of the

extension rod sub- assembly and the
shift & select sub- assembly using a
grinder.

INSPECTION
Inspect the following parts. Replace the disabled ones.

Grease Application Points

ASSEMBLY
1. Assemble the extension rod.
NOTE: On replacement parts, the
connecting method with the support
 employs a bolt. Hence, care must be
exercised to ensure that the assembling
is carried out in the correct direction.

2. Insert the bush into position.

NOTE: If any difficulty is encountered
in inserting the bush, apply soap water
to the case side for easier installation.

3. Assemble the floor shift support No.1.

Install the nut and washer.

4. Assemble the bush into the shift lever

subassembly.

5. Assemble the shift & select shaft.

NOTE: On replacement parts, the
connecting method with the shift lever
employs a bolt. Hence, care must be
exercised to ensure that the
assembling is carried out in the correct
direction.
Tightening Torque: 9.8- 15.68N·m
(1.0- 1.6 kgf·m)

T: 1.0 ~ 1.6 kgf·m

6. Assemble the shift lever retainer dust
boot and plate washer onto the
extension rod.

7. After the shift lever subassembly has

been installed, assemble the shift
lever seat, bush and plate washer.

8. Assemble the hole snap ring, using the

SST given below.
SST: 09905-87001-000

INSTALLATION
1. Install the floor shift support No.2,
shift lever and extension rod as a set on
the vehicle.
2. Install the extension rod subassembly
onto the transmission.
Tightening Torque: 9.8- 15.68N·m
(1.0- 1.6 kgf·m)

3. Assemble the bush in the shift & select

shaft. Install the transmission side of
the shift & select shaft subassembly.

4. Install the dust boot and dust seal retainer.

5. Install the shift & select lever boot and the shift lever knob.
MANUAL TRANSMISSION ASSEMBLY
REMOVAL
1. Remove the engine hood assembly.
2. Remove the hold-down clamps and battery.
3. Remove the battery carrier stay.

4. Disconnect the following harnesses:

① Harness to the starter
② Transmission ground cable
③ Backup lamp harness
④ Cables for Speedometer harshness

5. Remove the starter assembly.

6. Disconnect the speedometer connector.

7. Detach the three harness clamps.

8. Disconnect the clutch cable.

9. Remove the two bolts that directly attach the

transmission assembly to the engine.
 10. Jack up the vehicle. Remove the
front tires at the right and left sides of the
vehicle.
NOTE: Be sure to support the
vehicle securely by means of safety
stands

11. Drain the transmission oil.

12. Disconnect the front exhaust pipe at the
bracket support No.1 and manifold sides.

13. Disconnect the following control linkage-

related parts from the transmission housing.
(1) Shift & select shaft S/A
(2) Extension rod S/A

14. Remove the stabilizer bar.

(1) Remove the stabilizer bar, end nut and
retainer.
(2) Remove the stabilizer bar installing nuts.
15 Disconnect the lower arm at the bracket side.

16. Remove the drive shafts at the right

and left sides, using the following SST.
SST: 09648-87201-000
NOTE:
1. No stopper is provided at the
inboard side of the drive shaft. Hence, be
sure to support the inboard joint section
during the removal.
2. Be very careful not to damage the lip section of the
oil seal during the removal.

17. Remove the transmission assembly attaching

bolts.
NOTE:
Be sure to leave the one bolt located at the front
central part.

18. Lightly support the lower part of the

transmission, using a jack. Then, remove
the engine mounting lower/left bracket
attaching bolts.
Turn the engine mounting lower left insulator
90 degrees so that it may point upward.
19. Remove the one bolt located at the front central part
of the transmission assembly. Slowly jack down the
transmission assembly and take it out from below the
vehicle.

INSTALLATION
(1). Install the transmission assembly to
the engine assembly as follows:
① Ensure that the clutch disc is
centered in position, using the SST
given below
SST: 09301-87702-000
②Install the transmission, making sure
that the clutch disc may not be pried.
Temporarily tighten the attaching bolts.

(2). Tighten the transmission assembly

attaching bolts securely.
Tightening Torque: 5.0 – 7.0 kg·m (49 – 68.6N·m)

(3). Install the engine mounting lower/left insulator

and engine mounting lower/left bracket.
Bracket Tightening Torque:
3.0 - 4.5 kg·m (29.4 – 44.1 N·m)
Insulator Tightening Torque:
7.5 - 10.5 kg·m (73.5 – 102.9 N·m)
(4). Install the drive shafts at the right and left sides.
NOTE:
Slowly install the drive shaft to the differential case,
making sure that no damage is made to the lip section of
the oil seal.

(5). Install the lower arm (at the bracket side).

Temporarily tighten the attaching bolts.

（6）Install the stabilizer bar.

①Temporarily tighten the stabilizer, bar end nut.
②Tighten the cushion and stabilizer bar bracket.
Tightening Torque: 4.0 – 6.0 kg·m (58.8 – 83.3 N·m)

(7). Install the following control linkage-related parts:

①Shift & select shaft S/A
Tightening Torque: 1.0 – 1.6 kg·m (9.8 –
15.68N·m)
② Extension rod S/A
Tightening Torque: 1.0 – 1.6 kg·m (9.8 – 15.6N·m)
(8). Install the manifold side of the front exhaust pipe.
Install the bracket support No.1,
①Manifold side
Tightening Torque: 3.0 – 5.0 kg·m (29.4 –
49N·m)
②Bracket support NO.1
Tightening Torque: 2.0 – 3.0kg·m (19.6 – 29.4N·m)

(9). Install the front wheels at the right and left wheels.
Jack down the vehicle.
(10). Rock the vehicle in an up-and-down direction a
few times so as to settle the suspension.
With the vehicle in an unloaded, tighten the nuts.
① Stabilizer bar installing nuts
Tightening Torque: 7.5 – 10.5kg·m (73.5 –
102.9N·m)
② Lower arm (bracket side)
Tightening Torque: 7.5 – 10.5 kg·m (73.5 –
102.9N·m)

(11). Fill the transmission oil.

Oil capacity:
4-speed transmission: 1.9 – 2.05 l
(1.7 – 1.8 Imp qts, 2.0 – 2.1 U.S. qts.)
5-speed transmission: 2.1 – 2.25 l
(1.8 – 1.9 Imp qts, 2.2 – 2.3 U.S. qts.)
 (12). Install the clutch cable.
(13). Attach the three harness clamps.

(14). Install the speedometer connector.

(15). Install the starter assembly.

Tightening Torque: 3.0 – 6.0kg·m (29.4 –
58.8 N·m)
(16). Install the following harnesses:
①Harness to starter
②Transmission ground
③Backup lamp harness
④Speedometer cable

（ 17 ） Install the battery carrier stay, battery,

hold-down clamp and engine hood assembly.