100 - Manual Transmission - F40 (MR6)

TRANSMISSION
Manual Transmission - F40 (MR6)
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications

Specification
Application Metric English
Backup Lamp Switch 28 21 lb ft
Shift Control Housing Bolt 26 N.m 19 lb ft
Transmission Control Bolt 8 N.m 71 lb in
Transmission Drain Plug 30 N.m 22 lb ft
Transmission Fasteners M10 40 N.m 30 lb ft
Transmission Fasteners M12 60 N.m 44 lb ft
Transmission Filler Plug 30 N.m 22 lb ft
Transmission Front Mount through Bolt 100 N.m 74 lb ft
Transmission Front Mount to Transmission Bolt 100 N.m 74 lb ft
Transmission Mount - Left Side to Body Bolt 22 N.m 16 lb ft
Transmission Mount - Left Side to Bracket Bolt
 First Pass 50 N.m (1) 37 lb ft (1)
 Second Pass 60 degrees
 Final Pass 15 degrees
Transmission Mount - Left Side to Transmission Bolt 100 N.m 74 lb ft
Transmission Rear Mount Bracket through Bolt 100 N.m 74 lb ft
Transmission Rear Mount Bracket to Transmission Bolt 100 N.m 74 lb ft
Transmission Rear Mount to Suspension Frame Bolt
 First Pass 100 N.m (1) 74 lb ft (1)
 Final Pass 120 degrees - 120 degrees
1 = Use NEW Fastener
MANUAL TRANSMISSION SPECIFICATIONS
Manual Transmission Specifications

Name Specification
Transmission Type F40-6
Fully synchronized with final drive gear and
Transmission Content
differential
1st Gear Ratio 3.917
2nd Gear Ratio 2.040
3rd Gear Ratio 1.321
4th Gear Ratio 0.954
Reverse 3.750
Transmission Weight Dry (Approximate) 53.5-55.5 kg
ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS
Adhesives, Fluids, Lubricants, and Sealers

GM Part Number
Application Type of Material United States Canada
Refer to Electronic Refer to Electronic
Input Shaft Lubrication GNY 202
Parts Catalog Parts Catalog
Manual Transmission Fluid Castrol BOT 303 19259104 19259105
Transmission Control Lever
Silicone Grease Refer to Electronic Parts Catalog
Lubricant
SCHEMATIC WIRING DIAGRAMS

MANUAL TRANSMISSION WIRING SCHEMATICS
MR6
Fig. 1: MR6
Courtesy of GENERAL MOTORS COMPANY
COMPONENT LOCATOR
MANUAL TRANSMISSION COMPONENT VIEWS
Shift Control and Shift Lever/Selector Lever Cable Components

Fig. 2: Shift Control and Shift Lever/Selector Lever Cable Components
Callout Component Name

1 Manual Transmission Shift Lever and Selector Lever Cable
2 Shift Control Housing
3 Manual Transmission Selector and Shift Lever Cable Bracket Nut (Qty: 2)
4 Manual Transmission Selector and Shift Lever Cable Bracket Nut Washer (Qty: 2)
5 Manual Transmission Selector and Shift Lever Cable Bracket
Shift Shaft Components

Fig. 3: Shift Shaft Components

1 Shift Shaft Bolts (Qty: 2)
2 Shift Shaft
3 Shift Shaft O-Ring
Clutch Housing Components

Fig. 4: Clutch Housing Components

1 Clutch Actuator Cylinder Pipe Sleeve
2 Clutch Actuator Cylinder O-Ring
3 Clutch Actuator Cylinder
4 Clutch Actuator Cylinder Bolts (Qty: 3)
5 Front Wheel Drive Shaft Oil Seal
Transmission Housing Components

Fig. 5: Transmission Housing Components

1 Transmission Oil Filler Plug
2 Front Wheel Drive Shaft Oil Seal
3 Transmission Oil Drain Plug
4 Backup Lamp Switch Washer
5 Backup Lamp Switch
DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC CODE INDEX
DIAGNOSTIC CODE INDEX

DTC Description
DTC P0502 or P0503 DTC P0502 Vehicle Speed Sensor Circuit Low Voltage
DTC P0503 Vehicle Speed Sensor Circuit Intermittent
DTC P0806-P0808 DTC P0806 Clutch Pedal Position (CPP) Sensor Performance
DTC P0807 Clutch Pedal Position (CPP) Sensor Circuit Low
Voltage
DTC P0808 Clutch Pedal Position (CPP) Sensor Circuit High
Voltage
DTC P080A DTC P080A Clutch Pedal Position (CPP) Not Learned
DTC P0502 OR P0503: VEHICLE SPEED SENSOR
Diagnostic Instructions
 Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
 Review Strategy Based Diagnosis for an overview of the diagnostic approach.
 Diagnostic Procedure Instructions provides an overview of each diagnostic category.
DTC Descriptors
DTC P0502
Vehicle Speed Sensor Circuit Low Voltage
DTC P0503
Vehicle Speed Sensor Circuit Intermittent
Diagnostic Fault Information
Short to Open/High Short to Signal

Circuit Ground Resistance Voltage Performance
Operating Conditions: Engine Running, drive wheels turning.
5 V Reference P0502, P0503 P0502, P0503 P0502, P0503 P0503
VSS Signal P0502, P0503 P0502, P0503 P0502, P0503 P0503
Low Reference - P0502, P0503 - -

Operating Conditions: Engine Running, drive wheels turning.
0 km/h (0 0 km/h (0
5 V Reference 0 km/h (0 MPH) -
MPH) MPH)
0 km/h (0 0 km/h (0
VSS Signal 0 km/h (0 MPH) -
MPH) MPH)
Low Reference - 0 km/h (0 MPH) - -
Circuit/System Description
The vehicle speed sensor (VSS) is a 3 wire sensor. The engine control module (ECM) provides a 5 volt
reference circuit, low reference circuit and a signal circuit to the VSS. The VSS is a Hall Effect type sensor that
produces a square wave output signal to the ECM. As vehicle speed increases, the output frequency of the VSS
signal increases. The ECM converts the square wave output signal into vehicle speed shown as km/h (MPH).
The ECM supplies the VSS signal to other control modules on the vehicle through the serial data
communications line.
Conditions for Running the DTC
P0502
 DTC P0101, P0102, P0103, P0106, P0107, P0108, P0300, P0301, P0302, P0303, P0304, P0305, P0306,
or P0503 is not set.
 Ignition voltage is between 11-32 V.
 Throttle position is 8 % or greater.
 Engine speed is between 1,500-6,500 RPM.
P0503
 Ignition voltage is between 11-32 V.

 Engine speed is between 200-7,500 RPM for 5 s or greater.
 VSS signal is 200 RPM or greater for 2 s or greater.
 Change in VSS signal is 150 RPM or less for 2 s or greater.
Conditions for Setting the DTC
P0502
VSS signal is less than 60 RPM for 4.5 s.
P0503
Change in VSS signal is 350 RPM or greater for 3.3 s.
Action Taken When the DTC Sets
P0502 and P0503 are Type B DTCs.
Conditions for Clearing the DTC
P0502 and P0503 are Type B DTCs.
Diagnostic Aids
The battery must be fully charged. Refer to Battery Inspection/Test .
Reference Information
Schematic Reference
Manual Transmission Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Transmission System Description and Operation
Electrical Information Reference
 Circuit Testing
 Connector Repairs
 Testing for Intermittent Conditions and Poor Connections
 Wiring Repairs
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
K20 Engine Control Module: Scan Tool Information
Special Tools
J-38522-A Vehicle Signal Generator
For equivalent regional tools, refer to Special Tools.
Circuit/System Verification
CAUTION: Support the lower control arms in the normal horizontal position in
order to avoid damage to the drive axles. Do not operate the vehicle
in gear with the wheels hanging down at full travel.
1. Raise and support the drive wheels in a horizontal position.

2. Start and idle the engine.
3. Place the transmission in second gear and release the clutch pedal.
4. Verify the scan tool Vehicle Speed Sensor parameter increases as the drive wheel speed increases.
 If the Vehicle Speed Sensor parameter does not increase
Refer to Circuit/System Testing.
If the Vehicle Speed Sensor parameter does increase

5. Operate the vehicle within the conditions for running the DTC to verify the DTC does not set. You may
also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records.
 If the DTC sets
If the DTC does not set


6. All OK.
Circuit/System Testing
1. Ignition OFF and all vehicle systems OFF. Disconnect the harness connector at the B115 Vehicle Speed
Sensor. It may take up to 2 minutes for all vehicle systems to power down.
2. Test for less than 10 ohms between the low reference circuit terminal 2 and ground.
 If 10 ohms or greater
1. Disconnect the X2 harness connector at the K20 Engine Control Module.

2. Test for less than 2 ohms in the circuit end to end.
 If 2 ohms or greater, repair the open/high resistance in the circuit.
 If less than 2 ohms, replace the K20 Engine Control Module.
 If less than 10 ohms
3. Ignition ON.
4. Test for 4.8-5.2 V between the 5 V reference circuit terminal 1 and ground.
 If less than 4.8 V
1. Ignition OFF, disconnect the X2 harness connector at the K20 Engine Control Module.
2. Test for infinite resistance between the 5 V reference circuit and ground.
 If less than infinite resistance, repair the short to ground on the circuit.
 If infinite resistance
3. Test for less than 2 ohms in the 5 V reference circuit end to end.
 If greater than 5.2 V
1. Ignition OFF, disconnect the X2 harness connector at the K20 Engine Control Module, Ignition
ON.
2. Test for less than 1 V between the 5 V reference circuit and ground.
 If 1 V or greater, repair the short to voltage on the circuit.
 If less than 1 V, replace the K20 Engine Control Module.
 If between 4.8-5.2 V
5. Ignition OFF, connect the test leads of the J-38522-A vehicle signal generator as follows:
 Red test lead to the signal circuit terminal 3 at the B115 Vehicle Speed Sensor wire harness
connector.
 Black test lead to ground at the transmission case.
 Double black power and ground lead wire to B+ and ground.
6. Set and adjust the J-38522-A vehicle signal generator to the following switch positions:
 Signal switch to 5 V.
 Frequency switch to 600 Hz.
 Duty cycle switch to 50% or normal position.
7. Ignition ON.
8. Verify the scan tool Vehicle Speed Sensor parameter displays between 41-51 km/h (25-32 mph).
 If the vehicle speed sensor parameter is not within the specified range
2. Test for infinite resistance between the signal circuit terminal 3 and ground.
3. Test for less than 2 ohms in the signal circuit end to end.
 If the vehicle speed sensor parameter is within the specified range
9. Replace the B115 Vehicle Speed Sensor.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
 Vehicle Speed Sensor Replacement

 Control Module References for ECM replacement, programming and setup.
DTC P0806-P0808: CLUTCH PEDAL POSITION (CPP) SENSOR
DTC Descriptors
DTC P0806
Clutch Pedal Position (CPP) Sensor Performance
DTC P0807
Clutch Pedal Position (CPP) Sensor Circuit Low Voltage
DTC P0808
Clutch Pedal Position (CPP) Sensor Circuit High Voltage

5 V Reference P0651, P0807 P0807 P0651, P0808 -
Signal P0807 P0807 P0808 P0806
Low Reference - P0808 P0808 -
Typical Scan Tool Data
CPP Sensor Voltage

Short to
Circuit Ground Open Short to Voltage
Operating Conditions: Ignition ON.
CPP Sensor Voltage Parameter Normal Range: 1 V with clutch pedal applied to 4 V when clutch
pedal is released.
5 V Reference 0V 0V 5V
Signal 0V 0V 5V
Low Reference - 5V -
CPP Sensor Percentage

Short to
Circuit Ground Open Short to Voltage
Operating Conditions: Ignition ON.
CPP Sensor Percent Parameter Normal Range: 0% with clutch pedal released to 100% when clutch
pedal is applied.
5 V Reference 100% 100% 0-100%
Signal 100% 100% 100%
Low Reference - 0% -
The clutch pedal position (CPP) sensor is a three wire sensor, connected to a 5 V reference circuit, a low
reference circuit, and a signal circuit. The engine control module supplies 5 V to the CPP sensor, and also
provides a sensor ground path on the low reference circuit. The CPP sensor sends a voltage signal to the ECM
on the signal circuit. The voltage on the signal circuit will vary from a voltage near 4 V when the clutch pedal is
released, to a voltage near 1 V when the clutch pedal is applied.
P0806
 DTC P0335, P0336, P0502, P0503, P0807, or P0808 is not set.

 The vehicle speed is greater than 8 kmh (5 mph).
 The ignition is ON.
P0807 and P0808
 DTC P0651 is not set.

 The system voltage is more than 9 V.
 The ignition is ON.
P0806
The CPP sensor is stuck in range.
P0807
The CPP sensor voltage is less than 0.1 V for more than 1 s.
P0808
The CPP sensor voltage is more than 5.2 V for more than 1 s.
DTC P0806 - P0808 are Type A DTCs.
DTC P0806 - P0808 are Type A DTCs.
Schematic Reference

 Circuit Testing
 Wiring Repairs
DTC Type Reference
Scan Tool Reference
K20 Engine Control Module: Scan Tool Information for scan tool information
1. If DTC P0651 or P080A is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle .
2. Ignition ON.
3. Verify the scan tool CPP Sensor percent parameter varies from 0% when the clutch pedal is released, to
100% when the clutch pedal is in the apply position.
 If the percentage does not vary from 0% to 100%
If the percentage varies from 0% to 100%

4. Operate the vehicle within the conditions for running the DTC to verify the DTC does not set. You may
also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records
data.
 If the DTC sets
If the DTC does not set


5. All OK.
Circuit/System Testing
1. Ignition OFF, disconnect the harness connector of the B25B Clutch Pedal Position Sensor.
2. Test for less than 5 ohms between the low reference circuit terminal C and ground:
 If 5 ohms or greater
1. Disconnect the X1 harness connector at the K20 Engine Control Module.

2. Test for less than 2 ohms in the circuit end to end.
 If less than 5 ohms
3. Ignition ON.
4. Test for 4.8-5.2 V between the 5 V reference circuit terminal A and ground:
2. Test for infinite resistance between the 5 V reference circuit and ground.
3. Test for less than 2 ohms in the 5 V reference circuit end to end.
2. Test for less than 1 V between the 5 V reference circuit and ground.
 If between 4.8-5.2 V
5. Verify the scan tool CPP Sensor voltage parameter is less than 0.1 V.
 If 0.1 V or greater
1. Ignition OFF, disconnect the X1 harness connector at the K20 Engine Control Module, Ignition
ON.
2. Test for less than 1 V between the signal circuit terminal B and ground.
6. Install a 3 A fused jumper wire between the signal circuit terminal B and the 5 V reference circuit
terminal C.
7. Verify the scan tool CPP Sensor voltage parameter is greater than 4.9 V.
 If 4.9 V or less
1. Ignition OFF, remove the jumper wire, disconnect the X1 harness connector at the K20 Engine
Control Module.
2. Test for infinite resistance between the signal circuit terminal B and ground.
3. Test for less than 2 ohms in the signal circuit end to end.
 If less than 2 ohms , replace the K20 Engine Control Module.
8. Test or replace the B25B Clutch Pedal Position Sensor.
Component Testing
Static Test
1. Ignition OFF, disconnect the harness connector of the B25B Clutch Pedal Position Sensor.
2. Measure the resistance between the signal terminal B and the low reference terminal C at the B25B
Clutch Pedal Position Sensor. Depress the clutch pedal through the entire range. The resistance should
vary from low to high and vice versa without any spikes or dropouts.
 If the resistance is erratic with spikes or dropouts
Replace the B25B Clutch Pedal Position Sensor.
If the resistance is not erratic without spikes or dropouts


3. All OK.
Repair Instructions
 Clutch Pedal Position Sensor Replacement

 Control Module References for ECM replacement, programming and setup.
DTC P080A: CLUTCH PEDAL POSITION (CPP) NOT LEARNED
DTC Descriptor
DTC P080A
Clutch Pedal Position (CPP) Not Learned

The clutch pedal position (CPP) is a 3-wire sensor, connected to a 5 V reference circuit, a low reference circuit,
and a signal circuit. The engine control module supplies 5 V to the CPP sensor, and also provides a sensor
ground path on the low reference circuit. The CPP sensor sends a voltage signal to the ECM on the signal
circuit. The voltage on the signal circuit will vary from a voltage near 5 V when the clutch pedal is released to a
voltage less than or equal to 1.5 V when the clutch pedal is applied.
Clutch pedal fully applied.
Clutch pedal position not learned.
P080A is a Type A DTC.
P080A is a Type A DTC.
Schematic Reference
 Circuit Testing
 Wiring Repairs
DTC Type Reference

Scan Tool Reference
K20 Engine Control Module: Scan Tool Information
Perform the clutch pedal position sensor learn procedure.
Repair Instructions
 Clutch Pedal Position Sensor Learn

 Control Module References for replacement, programming and setup.
CLUTCH PEDAL POSITION SENSOR LEARN
NOTE: The clutch pedal position (CPP) sensor learn procedure is required when the
following service procedures have been performed regardless of whether DTC
P080A is set:
 An engine control module (ECM) replacement

 A CPP sensor replacement
 Any repairs which affect the CPP sensor relationship
1. Install a scan tool.

2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to
Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set.
3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and
perform the following instructions displayed on the scan tool screen.
NOTE: The CPP sensor learn procedure cannot be performed more than once per
ignition cycle. The clutch pedal needs to be fully depressed and held
steady throughout this procedure in order to perform a correct learning.
4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail - Low Volt,
Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the
process was successful.
5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is
complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A, .
If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC.
6. Turn OFF the ignition for 30 s after the learn procedure has successfully completed in order to store the
CPP sensor variation values in ECM history.
SYMPTOMS - MANUAL TRANSMISSION
Symptoms - Manual Transmission

Complaint/Condition Possible Cause correction
 Inspect drive axle joint and
 Worn drive axle joint
replace if necessary.
Knock at Low Speeds  Worn side gear or pinion
 Inspect differential case
gear bores
and replace if necessary.
Inspect differential gears and
Noisy Around Turns Worn differential gears
 Inspect engine mounts and
tighten if necessary.
 Loose engine mounts  Inspect inboard drive axle
 Worn inboard drive axle joint and replace if
joint necessary.
Clunk or Acceleration or
Deceleration  Worn differential pinion  Inspect differential pinion
shaft shaft and replace if
 Worn side gear hub necessary.
counterbore  Inspect side gear hub
counterbore and replace if
necessary.
Worn outboard drive axle C/V Inspect C/V joint and replace if
Click Noise On Turns
joint necessary.
 lnspect bearing and replace
if necessary.
 Worn input gear bearing
Noisy in Neutral With Engine  lnspect bearing and replace
Running  Worn speed gear bearing
if necessary.
 Worn bearing races
 lnspect bearing race and
 Worn, chipped, or scored
 lnspect gears and replace if
1st speed constant-mesh
necessary.
Noisy in First Gear Only gears
 lnspect synchronizer and
 Worn, shipped, or scored
1st/2nd synchronizer
2nd speed constant-mesh
necessary.
Noisy in Second Gear Only gears
1st/2nd synchronizer
 Worn, chipped, or scored  lnspect gears and replace if

Noisy in Third Gear Only necessary.
3rd speed constant-mesh
gears  lnspect synchronizer and
 Worn, chipped, or scored replace if necessary.
3rd/4th synchronizer
4th speed constant-mesh
necessary.
gears
Noisy in Fourth Gear Only 3rd/4th synchronizer
 lnspect gear and replace if
necessary.
output gear
necessary.
output gear
5th speed constant-mesh
necessary.
gears
Noisy in Fifth Gear Only  lnspect synchronizer and
5th synchronizer
necessary.
output gear
reverse speed constant-
necessary.
Noisy in Reverse Only mesh gears
 Worn or damaged output
necessary.
gear
 Add fluid to proper level.
 Fluid level low
 Inspect wheel bearing and
 Worn or damaged wheel
bearings
 Inspect gear and replace if
necessary.
input/output shaft gear
Noisy in All Gears  Inspect output gear bearing
 Worn output gear bearing
and replace if necessary.
 Loose shift rail guide bolt
 Tighten shift rail guide
 Worn, chipped, or scored bolt.
1st, 2nd, 3rd, 4rd, 5th, or
 Inspect components and
Reverse gears.
replace as necessary.
 Tighten or replace mounts.

 Loose transaxle mounts
 Inspect cables and replace
 Bent or worn cables if necessary.
Slips Out of Gear
 Broken or loose input gear  Inspect shift fork and
bearing retainer replace if necessary.
 Worn or bent shift fork  Inspect shift fork and
 Dirty clutch housing and replace if necessary.
engine  Clean clutch housing and
 Stiff shift lever seal engine.
 Manual transaxle internal  Inspect seal and replace if
shift mechanism necessary.
malfunction  Disassemble transaxle,
repair as necessary.
 Missing or misadjusted
first gear thrust bearing or
washer
 Worn or damaged fist gear
spline lock on 1st/2nd  Inspect bearing and washer
synchronizer and replace if necessary.
 Worn of damaged second  Inspect spline lock and
gear spline lock on 1st/2nd replace if necessary.
synchronizer
 Inspect spline lock and
 Worn or damaged third replace if necessary.
gear spline lock on 3rd/4th
synchronizer
Slips Out of Gear While  Worn or damaged fourth
Accelerating gear spline lock on 3rd/4th
synchronizer
 Worn or damaged 5th gear
spline lock on the
5th/Reverse synchronizer  Inspect spline lock and
 Worn or damaged Reverse
gear spline lock on the  Inspect spline lock and
5th/Reverse synchronizer replace if necessary.
 Worn or damaged 1st, 2nd,  Disassemble transaxle,
3rd, 4th, 5th or reverse gear repair as necessary.
spline lock
 Manual transaxle internal
shift mechanism
malfunction
 Damaged, worn, or missing
 Inspect shift rails and
shift rails
Slips Out of Gear While Coasting  Manual transaxle internal
 Disassemble transaxle,
shift mechanism
repair as necessary.
malfunction
 Drain excess fluid.

 Fluid level high  Inspect axle shaft seals and
 Damaged axle shaft seals replace if necessary.
 Vent cap plugged  Clear or replace vent cap.
 Poor sealing on shift cover  Replace sealer on shift
 Poor sealing between case cover.
and clutch housing  Replace sealer between
 Poor sealing on rear cover case and clutch housing
and tighten.
 Poor sealing or loose back-
Fluid Leakage up lamp switch  Replace sealant on rear
cover and tighten.
 Poor sealing or loose
vehicle speed sensor  Tighten switch or replace
sealant as needed.
 Tighten sensor or replace
sealant as needed.
REPAIR INSTRUCTIONS - ON VEHICLE

TRANSMISSION FLUID DRAIN AND FILL
Fig. 6: Transmission Fluid Drain and Fill Components

Transmission Fluid Drain and Fill

Preliminary Procedure
Remove the battery tray. Refer to Battery Tray Replacement .
Transmission Filler Plug
CAUTION:
Refer to Fastener Caution .
1 NOTE:
A NEW filler plug must be installed.
Tighten
30 (22 lb ft)
Transmission Drain Plug
WARNING:
When the transmission is at operating temperatures, take necessary precautions when
removing the check/fill plug, to avoid being burned by draining fluid.
Procedure
2 1. Place pan under transmission to collect fluid.

2. Allow transmission fluid to drain out for approximately 10 minutes.
NOTE:
A NEW drain plug must be installed.
Tighten
30 (22 lb ft)
Transmission Fluid
Procedure
1. On FWD vehicles, fill the transmission with 2.2 liters of transmission fluid, a residue
of approximately 0.2 liters remains in the transmission. For recommended fluid, refer
to Adhesives, Fluids, Lubricants, and Sealers.
3 2. On AWD vehicles, fill the transmission with 1,6 liters of transmission fluid, a residue
of approximately 0.2 liters remains in the transmission. For recommended fluid, refer
to Adhesives, Fluids, Lubricants, and Sealers
NOTE:
If a new transmission is installed during servicing, this must be filled with 1.8
liters of transmission fluid because the new transmissions are already filled with
0.68 liters of transmission fluid from the factory.
TRANSMISSION CONTROL LEVER BOOT REPLACEMENT

The transmission control lever boot and shift knob are replaced as an assembly. To remove the assembly refer
to Transmission Control Lever Knob Replacement.
TRANSMISSION CONTROL LEVER KNOB REPLACEMENT
Removal Procedure
NOTE: The control lever knob and boot are replaced as an assembly.
1. Remove transmission control lever boot from front floor console, gently pulling boot frame on front side
upwards.
Fig. 7: Transmission Control Lever Retainer Ring

2. Slide transmission control lever boot upwards.

3. Press in on the 2 tabs shown by the arrows.
4. Slide the blue lock ring (1) upward to release the retainers on the knurled shaft.
5. Remove the knob from the shifter by pulling up to release the knob from the knurled shaft.
6. Pull trigger (2) upwards.
7. Remove the reverse block out boot assembly from the shifter.
Fig. 8: Pull Latch
8. Press pull latch (1) in direction of arrows.

9. Remove reverse gear block (2) from transmission shifter boot assembly.
Installation Procedure
Fig. 9: Reverse Gear Block & Hook
1. Install reverse gear block (2) to transmission control lever knob.

2. Let the hook (1) engage hearable (arrow).
Fig. 10: Transmission Control Lever Retainer Ring & Trigger
3. Install transmission control lever knob.

4. Push trigger (2) upwards.
5. Press the transmission control lever knob during installation completely down.
6. Clip transmission control lever boot into front floor console.
SHIFT CONTROL LEVER REPLACEMENT
Removal Procedure
1. Remove the front floor console. Refer to Front Floor Console Replacement .
Fig. 11: Selector Lever Cable, Adjust Locks And Transmission Control Lever Housing
2. Unlock shift lever and selector lever cable adjust locks (2).
3. Clip shift lever and selector lever cable (3) out of transmission control lever housing (1).
Fig. 12: Transmission Control Lever And Bolts
4. Remove the four transmission control lever fasteners (1).

5. Remove transmission control lever (2).
1. Install NEW transmission control lever (2).
CAUTION: Refer to Fastener Caution in the Preface section.
2. Install the four transmission control lever fasteners (1) and tighten to 8 N.m (71 lb in).
NOTE: Do not lock yet.
3. Slide shift lever and selector lever cable into shift lever and selector lever cable adjust locks (2).
4. Clip shift lever and selector lever cable (3) into transmission control lever housing (1).
5. Adjust shift lever and selector lever cable. Refer to Manual Transmission Shift Lever Cable
Adjustment.
6. Install the front floor console. Refer to Front Floor Console Replacement .
MANUAL TRANSMISSION SHIFT LEVER AND SELECTOR LEVER CABLE ADJUSTMENT
Special Tools
DT-527-A Adjuster or 5mm drill bit
NOTE: Not using the specified tools may lead to shift system mis-adjustment.
1. Shift transmission into NEUTRAL.
2. Remove the front floor console cover. Refer to Front Floor Console Replacement .
Fig. 15: Cable Lock Adjusters & Sliding Ring

3. Unlock the cable lock adjusters (2), by pushing back the spring force loaded black sliding ring (1) until
self-locking. One for each cable.
NOTE: The driver side slider ring can be accessed through side panel of console
using a suitable tool.
4. Slide transmission control lever boot upwards.

Fig. 16: Control Lever Retaining Ring & Latches
5. Disengage control lever retaining ring by pressing both latches (3) while sliding up retaining ring (1) until
loose.
6. Lock the position of the shift control lever by rotating the reverse lockout device with the following
instructions:
Fig. 17: Transmission Control Lever Knob
1. Slide up shift control lever until almost removed.

2. Rotate complete shift control lever assembly 180 degrees so the reverse inhibitor button on lever is
facing toward the rear.
3. Secure integral pins (2) on reverse lockout device in holes located on shifter base (3) by pushing
downward on device until seated.
7. Remove engine control module from battery tray and lay aside.
Fig. 18: Transmission Control Housing
NOTE: The hole of the transmission gear control (2) must be aligned to the hole in
the base so the pin (1) can pass thru both. The transmission gear control
will be locked in the 1-2 neutral position.
8. Lock the transmission gear control (2) with DT-527-A pin (1) or 5mm drill bit.
Fig. 19: Cable Lock Adjusters & Sliding Ring
NOTE:  During this procedure DO NOT touch or preload the fixed shift lever
as this may cause mis-adjustment to the shift system.
 The lock adjuster on the driver side is accessed through the hole (3)
at top of shift housing using an adequate tool.
 When locking the adjuster locks (1) a defined snap noise should be
audible, a snap effect should be felt.
9. Secure lock adjusters (2), by pushing down the lock tab. One lock adjuster for each cable.
Fig. 20: Transmission Control Lever Retainer Ring & Trigger
10. Reposition the reverse lockout device with the following instructions:
1. Push down on tab (2) and pull up on device to release from installed position.
2. Slide up shift control lever until almost removed.
3. Rotate complete shift control lever assembly 180 degrees so the reverse inhibitor button on lever is
facing toward the front.
4. Push down on reverse lock out device until fully seated.
5. Push down retaining ring (1) until it snaps into position until fully seated.
11. Remove the DT-527-A adjuster or 5mm drill bit from the transmission gear control.
12. Check correct shifting function.
13. If necessary repeat adjusting procedure.
14. Install the front floor console cover. Refer to Front Floor Console Replacement .
15. Install the engine control module.
TRANSMISSION CONTROL (TRANSMISSION SHIFT LEVER) REPLACEMENT
Removal Procedure
4. Remove the four transmission control lever fasteners (1).

5. Remove the transmission control (2).
1. Install the NEW transmission control (2).
CAUTION: Refer to Fastener Caution .
2. Install the four transmission control lever fasteners (1) and tighten to 8 N.m (71 lb in).
5. Adjust shift lever and selector lever cable.
MANUAL TRANSMISSION SHIFT LEVER CABLE REPLACEMENT
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .

Fig. 25: Selector Lever Cable, Bracket And Transmission Control Housing
2. Remove shift lever and selector lever cable (2) from transmission control housing (3).
3. Remove shift lever and selector lever cable from shift lever and selector lever cable bracket (1) by
pushing back locking rings in counterclockwise direction.
Fig. 26: Shift Lever And Selector Lever Cable
4. Remove shift lever and selector lever cable (3) from bulkhead.
3. Install shift lever and selector lever cable from inside the vehicle.
NOTE: Install the guide with the white marking upwards to the bulkhead. Do not
cross the cables.
4. Install shift lever and selector lever cable (3) to bulkhead.

5. Check for correct fit.
Fig. 30: Selector Lever Cable, Bracket And Transmission Control Housing
6. Install shift lever and selector lever cable (2) to shift lever and selector lever cable bracket (1).
7. Install shift lever and selector lever cable to transmission control housing (3).
8. Install the battery tray. Refer to Battery Tray Replacement .
9. Adjust shift lever and selector lever cable. Refer to Manual Transmission Shift Lever Cable
Adjustment.
MANUAL TRANSMISSION SHIFT LEVER AND SELECTOR LEVER CABLE REPLACEMENT
Removal Procedure

2. Remove the shift lever and selector lever cable (2) from the transmission control housing (3).
3. Remove the shift lever and selector lever cable from the shift lever and selector lever cable bracket (1) by
pushing back locking rings in counter driving direction.
Fig. 32: Selector Lever Cable
4. Remove the shift lever and selector lever cable grommet (1) from the bulkhead.
6. Unlock the shift lever and selector lever cable adjust locks (2).
7. Clip the shift lever and selector lever cable (3) out of the transmission control lever housing (1).
1. Slide the shift lever and selector lever cable into the shift lever and selector lever cable adjust locks (2).
2. Clip the shift lever and selector lever cable (3) into the transmission control lever housing (1).
3. Install shift lever and selector lever cable from inside the vehicle.
Fig. 35: Selector Lever Cable
NOTE: Install the guide with the white marking upwards to the bulkhead. Do not
cross the cables.
4. Install the shift lever and selector lever cable grommet (1) to the bulkhead.
5. Check for correct fit.
6. Install the shift lever and selector lever cable (2) to the shift lever and selector lever cable bracket (1).
7. Install the shift lever and selector lever cable to the transmission control housing (3).
9. Adjust the shift lever and selector lever cable. Refer to Manual Transmission Shift Lever and Selector
Lever Cable Adjustment.
MANUAL TRANSMISSION SHIFT LEVER CABLE ADJUSTMENT
Special Tools
DT-527-A Adjuster
Removal Procedure
1. Shift transmission into NEUTRAL.

Fig. 37: Shift Lever And Selector Lever Cable Adjust Locks
3. Unlock shift lever and selector lever cable adjust locks (1), by pushing back the spring force loaded black
sliding ring until self-locking.
4. Unlock the left cable trough the opening at the housing (arrow) using a suitable tool.
5. Remove transmission control lever boot. Refer to Transmission Control Lever Boot Replacement.
Fig. 38: Reverse Blocker Assembly, Pins & Holes
6. Turn transmission reverse blocker assembly (1) 180 degrees and install to transmission control lever.
7. Push the 2 pins (2) into the 2 holes (3).
8. Remove engine control module from battery tray and lay aside.
Fig. 39: Transmission Control Housing
9. Block transmission control housing (2) using DT-527-A adjuster (1) or equivalent.
Fig. 40: Shift Lever And Selector Lever Cable Adjust Locks
NOTE: When locking the adjuster locks (1) a defined snap noise should be
audible / a snap effect should be felt.
1. Lock shift lever and selector lever cable adjust locks.

2. Lock shift lever and selector lever cable adjust locks (1), by pushing down the two blue locking pieces
WITHOUT touching/preloading the fixed shift lever.
3. Install transmission control lever knob.
Turn the transmission control lever knob back 180 degrees.
4. Remove DT-527-A adjuster from transmission control housing.

5. Check correct shifting function.
6. If necessary repeat adjusting procedure.
VEHICLE SPEED SENSOR REPLACEMENT

Fig. 41: Vehicle Speed Sensor & Bolt
Vehicle Speed Sensor Replacement

Preliminary Procedures
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation .
3. Disconnect the vehicle speed sensor electrical connector.
Vehicle Speed Sensor Bolt
CAUTION:
1
Tighten
8 (71 lb in)
2 Vehicle Speed Sensor
BACKUP LAMP SWITCH REPLACEMENT

Fig. 42: Backup Lamp Switch & Seal Ring
Backup Lamp Switch Replacement

Backup Lamp Switch
Procedure
1. Remove the electrical connector.

1
2. Install NEW seal ring.
Tighten
25 (18 lb ft)
2 Seal Ring
SHIFT CONTROL HOUSING REPLACEMENT

Fig. 43: Shift Control Housing & Fasteners
Shift Control Housing Replacement

1. Remove the battery and battery tray. Refer to Battery Tray Replacement .
2. Remove the brake pressure modulator. Refer to Electronic Brake and Traction Control Module
with Brake Pressure Modulator Valve Replacement .
3. Remove the manual transmission shift lever and selector lever cable from the shift control housing.
Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement.
4. Lock the transmission control housing with DT-527-A adjuster or equivalent.
Special Tools DT-527-A AdjusterFor equivalent regional tools, refer to Special Tools.
Shift Control Housing Fastener (Qty: 2)
CAUTION:
1
Tighten
26 (19 lb ft)
Shift Control Housing
Procedure
1. Detach the cables from the shift linkage lever.

2. Remove the shift cables.
3. Install a NEW seal.
2
4. After installation, adjust the manual transmission shift lever cable. Refer to Manual
Transmission Shift Lever and Selector Lever Cable Adjustment.
NOTE:
Shift transmission into NEUTRAL.
TRANSMISSION FRONT MOUNT REPLACEMENT
Fig. 44: Transmission Front Mount & Fasteners

Transmission Front Mount Replacement

WARNING:
To avoid any vehicle damage, serious personal injury or death when major components are removed
from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the
opposite end from which the components are being removed and strap the vehicle to the hoist.
WARNING:
Refer to Safety Glasses Warning .
CAUTION:
In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the
width of the oil pan bottom between the oil pan and the jack support.
Preliminary Procedure
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
Transmission Mount to Frame Through Bolt
CAUTION:
1
Tighten
100 N.m (74 lb ft)
Transmission Front Mount Fastener (Qty: 2)
2 Tighten
100 N.m (74 lb ft)
Transmission Front Mount
3 Procedure
Support the transmission.
TRANSMISSION REAR MOUNT REPLACEMENT

Fig. 45: Transmission Rear Mount & Fasteners
Transmission Rear Mount Replacement

WARNING:
WARNING:
CAUTION:
2. Remove the transmission rear mount bracket. Refer to Transmission Mount Bracket
Replacement - Rear.
3. Reposition the steering gear if equipped with electric power steering, NJ0 or NJ1. Refer to
STEERING GEAR REPLACEMENT .
Transmission Rear Mount Fastener (Qty: 2)
CAUTION:
1 NOTE:
Use NEW bolts only.
Tighten
100 (74 lb ft) plus 120-130 degrees
Transmission Rear Mount
2 Procedure
Support the transmission before removing the transmission rear mount.
TRANSMISSION MOUNT REPLACEMENT - LEFT SIDE
Fig. 46: Transmission Mount & Fasteners - Left Side

Transmission Mount Replacement - Left Side

WARNING:
Preliminary Procedure Remove the transmission mount bracket. Refer to Transmission Mount
Bracket Replacement - Left Side.
Transmission Mount Fastener (Qty: 4)
CAUTION:
1
Tighten
22 N.m (16 lb ft)
2 Transmission Mount
TRANSMISSION REAR MOUNT BRACKET REPLACEMENT
Fig. 47: Transmission Rear Mount Bracket & Fasteners

Transmission Rear Mount Bracket Replacement

WARNING:
WARNING:
CAUTION:
Preliminary Procedure Raise and suitably support the vehicle. Refer to Lifting and Jacking the
Vehicle .
Transmission Rear Mount Bracket Fastener (Qty: 4)
CAUTION:
1
Procedure
Tighten
100 (74 lb ft)
2 Transmission Rear Mount Bracket
TRANSMISSION MOUNT BRACKET REPLACEMENT - REAR
Fig. 48: Transmission Mount Bracket - Rear

Transmission Mount Bracket Replacement - Rear
WARNING:
WARNING:
Preliminary Procedure Raise and suitably support the vehicle. Refer to Lifting and Jacking the
Vehicle .
Transmission Rear Mount Bracket Fastener (Qty: 4)
CAUTION:
1
Procedure
Tighten
100 N.m (74 lb ft)
2 Transmission Rear Mount Bracket
TRANSMISSION MOUNT BRACKET REPLACEMENT - LEFT SIDE

Fig. 49: Transmission Mount Bracket - Left Side
Transmission Mount Bracket Replacement - Left Side

WARNING:
1. Install the engine support fixture. Refer to ENGINE SUPPORT FIXTURE , for the 2.0L engine.
Transmission Mount Bracket to Mount Fastener (Qty: 3)
CAUTION:
1
Procedure
Install NEW bolts.
Tighten
50 (37 lb ft) + 60 degrees + 15 degrees
2 Transmission Mount Bracket Fastener (Qty: 3)

Tighten
100 (74 lb ft)
Transmission Mount Bracket
3 NOTE:
Adjust support fixture as necessary to allow bracket removal.
FRONT WHEEL DRIVE SHAFT SEAL REPLACEMENT - LEFT SIDE
Fig. 50: Front Wheel Drive Shaft Seal - Left Side

Front Wheel Drive Shaft Seal Replacement - Left Side

WARNING:
WARNING:
2. Remove the front wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft
Replacement - Left Side .
3. Place a drain pan underneath to collect transmission fluid.
Front Wheel Drive Shaft Seal
Procedure
1. Remove drive axle shaft seal ring with DT-586 hammer and DT-7004 hook.
2. Coat new axle shaft seal ring with transmission fluid.
3. Install the drive axle shaft seal ring flush into transmission with DT-519 installer.
4. Check transmission fluid level. Refer to Transmission Fluid Drain and Fill.
1
Special Tools
 DT-519 Seal Installer

 DT-586 Slide Hammer
 DT-7004 Remover Hook
FRONT WHEEL DRIVE SHAFT SEAL REPLACEMENT - RIGHT SIDE
Fig. 51: Front Wheel Drive Shaft Seal - Right Side

Front Wheel Drive Shaft Seal Replacement - Right Side

WARNING:
WARNING:
2. Remove the intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement
(with MR6) , Front Wheel Drive Intermediate Shaft Replacement (with MHH, MHK or
MDK) .
3. Place a drain pan underneath to collect transmission fluid.
Front Wheel Drive Shaft Seal
Procedure
1. Remove drive axle shaft seal ring with DT-7004 hook and DT-586 hammer.
2. Coat new axle shaft seal ring with transmission fluid.
3. Install the drive axle shaft seal ring flush into transmission with DT-519 installer.
4. Check transmission fluid level. Refer to Transmission Fluid Drain and Fill.
1
Special Tools
 DT-519 Seal Installer

 DT-586 Slide Hammer
 DT-7004 Remover Hook
TRANSMISSION REPLACEMENT
Special Tools
DT-48783 Special Socket

Removal Procedure

2. Remove the shift lever cable from the selector on the transmission. Refer to Manual Transmission Shift
Lever Cable Replacement.
3. Remove the clutch actuator cylinder hose. Refer to Clutch Actuator Cylinder Pipe Replacement .
4. Remove the fasteners and brackets for the wiring harness on the transmission.
5. Remove the connector to the reverse light switch. Refer to Backup Lamp Switch Replacement.
Fig. 52: Upper Transmission Fasteners

6. Remove upper transmission fasteners (1) using the DT-48783 special socket or equivalent E-Torx socket.
7. Remove the starter motor. Refer to Starter Replacement (LUK) , Starter Replacement (LTG) .
8. Install the engine support fixture. Refer to ENGINE SUPPORT FIXTURE for the 2.0L engine.
9. Remove the subframe. Refer to Drivetrain and Front Suspension Frame Replacement .
10. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LTG) .
11. Remove the rear transmission bracket. Refer to Transmission Rear Mount Bracket Replacement.
12. Remove the transmission front mount. Refer to Transmission Front Mount Replacement.
13. Drain the transmission fluid. Refer to Transmission Fluid Drain and Fill.
14. Pull out the left drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement -
Left Side .
15. Pull out the right drive shaft from the intermediate shaft and remove the intermediate shaft. Refer to
Front Wheel Drive Intermediate Shaft Replacement (with MR6) , Front Wheel Drive Intermediate
Shaft Replacement (with MHH, MHK or MDK) .
16. Lower the vehicle.
17. Remove the fasteners to the transmission bracket left side. Refer to Transmission Mount Bracket
Replacement - Left Side.
18. Lower the engine enough with support fixture to access the transmission.
19. Raise the vehicle.
20. Place an appropriate transmission jack under the vehicle and support the transmission.
Fig. 53: Lower Transmission Fasteners

21. Remove the lower transmission fasteners (1).

Fig. 54: View Of Lower Transmission Fasteners
22. Remove lower transmission fasteners (1).

23. Separate the transmission from the engine.
24. Lower the transmission away from the vehicle. With assistance, place transmission in suitable work area.
1. Lubricate input shaft splines and the two guiding sleeves.

2. Place the transmission to the engine support fixture.
3. Attach transmission to the engine.
Fig. 55: Lower Transmission Fasteners
CAUTION: Refer to Fastener Caution .
4. Install the transmission fasteners.

 Tighten the fastener (1) to 60 (44 lb ft).

Fig. 56: View Of Lower Transmission Fasteners
5. Install the transmission fasteners.

6. Install the starter motor. Refer to Starter Replacement (LTG) .

7. Lower the vehicle.
8. Raise the engine to the correct level with the engine support fixture.
9. Install the fasteners to the transmission bracket left side. Refer to Transmission Mount Bracket
Replacement - Left Side.
10. Remove the engine support fixture.
11. Install the ground cable and the upper fasteners to the starter motor. Refer to Starter Replacement
(LTG) .
12. Raise the vehicle.
13. Install the rear transmission bracket. Refer to Transmission Rear Mount Bracket Replacement.
14. Install the transmission front mount. Refer to Transmission Front Mount Replacement.
15. Install the intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement (with
MR6) , Front Wheel Drive Intermediate Shaft Replacement (with MHH, MHK or MDK) .
16. Install the left drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left
Side .
17. Install the catalytic converter. Refer to Catalytic Converter Replacement (LTG) .
18. Install the subframe. Refer to Drivetrain and Front Suspension Frame Replacement .
19. Fill up the transmission fluid. Refer to Transmission Fluid Drain and Fill.
20. Install the clutch actuator cylinder hose. Refer to Clutch Actuator Cylinder Pipe Replacement .
Fig. 57: Upper Transmission Fasteners

21. Install the upper transmission fasteners (1) using the DT-48783 special socket. Tighten the fasteners to 60
(44 lb ft).
22. Install the shift lever cable to the selector on the transmission. Refer to Manual Transmission Shift
Lever Cable Replacement.
23. Install the fasteners and brackets for the wiring harness to the transmission.
24. Install the connector to the reverse light switch.
DESCRIPTION AND OPERATION

TRANSMISSION SYSTEM DESCRIPTION AND OPERATION
The F40-6 is a 6-speed manual transmission. This manual transmission is an all-synchromesh 3-shaft
transmission.
Fig. 58: Manual Transmission

This 3-shaft transmission has the following advantages:
 Compact construction
 Improved smooth-running performance
 Better shift quality
 High torque transmission
Location of the Shafts and the Differential in the Transmission Housing

Fig. 59: Transmission Housing Components

1 Input shaft
2 Upper main shaft
3 Differential gear
4 Lower main shaft
In this transmission angular cone bearings are used for all shafts. These bearings require a certain amount of
play and pretension. The required amount of bearing play and pretension is achieved at the production stage by
using shims under the angular cone bearing in the transmission housing.
Location of the Shafts and the Differential
This diagram shows the location of the respective shafts and differential gear.
Fig. 60: Location Of Shafts & Differential

1 Input shaft
2 Upper main shaft
3 Lower main shaft
4 Differential gear
Location of the Gear Wheels
This diagram shows the location of the gear wheels on the respective shaft.
Fig. 61: Location Of Gear Wheels

1 Reverse gear wheel - Upper Main Shaft
2 3rd gear wheel - Upper Main Shaft
3 4th gear wheel - Upper Main Shaft
4 6th gear wheel - Input Shaft with 1st/Reverse Gear and 2nd Gear
5 4th gear wheel - Input Shaft with 1st/Reverse Gear and 2nd Gear
6 3rd/5th gear wheel - Input Shaft with 1st/Reverse Gear and 2nd Gear
7 6th gear wheel - Lower Main Shaft
8 5th gear wheel - Lower Main Shaft
9 2nd gear wheel - Lower Main Shaft
10 1st gear wheel - Lower Main Shaft
Particular benefits of this 3-shaft transmission are that gear wheel for 3rd gear is also used for 5th gear and that
1st gear wheel is used for reversal of the rotating direction for reverse gear.
Power Flow in the Individual Gears
The following diagrams show the flow of power in the individual gears.
1st Gear
Fig. 62: 1st Gear


1 1st gear power flow
2nd Gear
Fig. 63: 2nd Gear

1 2nd gear power flow
3rd Gear
Fig. 64: 3rd Gear

1 3rd gear power flow
4th Gear
Fig. 65: 4th Gear

1 4th gear power flow
5th Gear
Fig. 66: 5th Gear

6th Gear
Fig. 67: 6th Gear

Reverse Gear
Fig. 68: Reverse Gear

1 Reverse gear power flow
Transmission Shift Linkage

Fig. 69: Reverse Gear
The gears of the F40-6 transmission will be shifted via a cable linkage system.
TRANSMISSION IDENTIFICATION INFORMATION

Fig. 70: Transmission Identification
The code for the F40-6 transmission is located at the front of the transmission housing.
 Manufacturing plant (1)

 Last two digits of year (example 02 = 2002) (2)
 Serial number (3)
 Alpha code (4)
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS
Tool
Illustration Number/Descrip
DT-519
KM-519
Seal Installer
DT-527-A
KM-527-A
Adjusting Too
DT-586
KM-586
Remover Hook
DT-7004
KM-J-7004
J-6125-1B
Remover Hook
DT-48793
Special Socket

100 - Manual Transmission - F40 (MR6)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

100 - Manual Transmission - F40 (MR6)

Uploaded by

Copyright:

Available Formats

TRANSMISSION

Manual Transmission - F40 (MR6)

Fastener Tightening Specifications

MANUAL TRANSMISSION SPECIFICATIONS

Manual Transmission Specifications

ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS

Adhesives, Fluids, Lubricants, and Sealers

SCHEMATIC WIRING DIAGRAMS

Shift Control and Shift Lever/Selector Lever Cable Components

Callout Component Name

Shift Shaft Components

Callout Component Name

Clutch Housing Components

Callout Component Name

Transmission Housing Components

Callout Component Name

DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC CODE INDEX

DTC P0502 OR P0503: VEHICLE SPEED SENSOR

Vehicle Speed Sensor Circuit Low Voltage

Vehicle Speed Sensor Circuit Intermittent

Diagnostic Fault Information

Short to Open/High Short to Signal

Diagnostic Fault Information

Short to Open/High Short to Signal

Conditions for Running the DTC

 Ignition voltage is between 11-32 V.

Conditions for Setting the DTC

VSS signal is less than 60 RPM for 4.5 s.

Change in VSS signal is 350 RPM or greater for 3.3 s.

Action Taken When the DTC Sets

P0502 and P0503 are Type B DTCs.

Conditions for Clearing the DTC

P0502 and P0503 are Type B DTCs.

Manual Transmission Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Transmission System Description and Operation

Electrical Information Reference

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

K20 Engine Control Module: Scan Tool Information

J-38522-A Vehicle Signal Generator

For equivalent regional tools, refer to Special Tools.

1. Raise and support the drive wheels in a horizontal position.

Refer to Circuit/System Testing.

If the Vehicle Speed Sensor parameter does increase

Refer to Circuit/System Testing.

If the DTC does not set

1. Disconnect the X2 harness connector at the K20 Engine Control Module.

 If less than 2 ohms, replace the K20 Engine Control Module.

 If less than 10 ohms

 If less than 2 ohms, replace the K20 Engine Control Module.

 If greater than 5.2 V

 Double black power and ground lead wire to B+ and ground.

 Frequency switch to 600 Hz.

 Duty cycle switch to 50% or normal position.

 If less than 2 ohms, replace the K20 Engine Control Module.

 If the vehicle speed sensor parameter is within the specified range

9. Replace the B115 Vehicle Speed Sensor.

Perform the Diagnostic Repair Verification after completing the repair.