MANUAL TRANSAXLE

C TRANSMISSION/TRANSAXLE

SECTION
MANUAL TRANSAXLE
MT B

MT

CONTENTS
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
DESCRIPTION ............................................................ 3
Cross-Sectional View ............................................... 3
CONTROL LINKAGE ................................................. 4
Components ............................................................. 4
Removal and Installation .......................................... 4
INSTALLATION ..................................................... 4
AIR BREATHER HOSE .............................................. 5
Components ............................................................. 5
E
TRANSAXLE ASSEMBLY .......................................... 6 F
Removal and Installation .......................................... 6
COMPONENTS ..................................................... 6
INSTALLATION ..................................................... 7 G
Disassembly and Assembly ...................................... 8
COMPONENTS ..................................................... 8
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 13
H
General Specifications ............................................ 13
I

Revision: 2005 September MT-1 C11

 PRECAUTIONS

PRECAUTIONS PFP:00001

Service Notice or Precautions GCS0015Z

● If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts may
damage CSC seal and may cause clutch fluid leakage.

Revision: 2005 September MT-2 C11

 DESCRIPTION

DESCRIPTION PFP:00000
A
Cross-Sectional View GCS00160

MT

PCIB1614E

1. Clutch housing 2. CSC (Concentric Slave Cylinder) 3. 1st-2nd synchronizer assembly

4. 3rd-4th synchronizer assembly 5. 5th input gear 6. 5th-reverse synchronizer assembly
7. Reverse synchronizer cone 8. 5th main gear 9. 4th main gear
10. 3rd main gear 11. 2nd main gear 12. 2nd double cone synchronizer
13. 1st double cone synchronizer 14. 1st main gear 15. Differential side bearing
16. Differential assembly 17. Final gear 18. Mainshaft
19. Input shaft

Revision: 2005 September MT-3 C11

 CONTROL LINKAGE

CONTROL LINKAGE PFP:34103

Components GCS00161

PCIB1685E

1. Control lever knob 2. Control lever 3. Control device assembly

4. Select cable 5. Shift cable 6. Clutch housing
7. Tapping bolt 8. Cable mounting bracket 9. Bracket
A: Black color
B: White color

Removal and Installation GCS00162

INSTALLATION
Note the following, and install in the reverse order of removal.
NOTE:
Tapping work for tapping bolt is not applied to new clutch housing. Do not perform tapping by other than
screwing tapping bolt because tapping is formed by screwing tapping bolt into clutch housing.

Revision: 2005 September MT-4 C11

 AIR BREATHER HOSE

AIR BREATHER HOSE PFP:31098

A
Components GCS000AG

MT

PCIB1511E

1. Air cleaner case 2. Air breather hose 3. Air duct J

4. Clip 5. Transaxle assembly 6. 2 way connector

Revision: 2005 September MT-5 C11

 TRANSAXLE ASSEMBLY

TRANSAXLE ASSEMBLY PFP:32010

Removal and Installation GCS000AI

CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage CSC seal and may cause clutch fluid leakage.
COMPONENTS

PCIB1514E

1. LH engine mount bracket (transaxle 2. Transaxle assembly 3. Rear engine mount bracket
side)
4. Washer 5. Rear torque rod
: Refer to MT-7, "INSTALLATION" for the tightening torque.
Refer to GI-11, "Components" , for the symbols in the figure.

Revision: 2005 September MT-6 C11

 TRANSAXLE ASSEMBLY

INSTALLATION
● If transaxle is removed from the vehicle, always replace CSC. A
● When installing the transaxle assembly to the engine, install the
mounting bolts following the standard below.
CAUTION: B
When installing transaxle assembly, be careful not to bring
transaxle input shaft into contact with clutch cover.
MT
Bolt No. 1 2 3 4
Quantity 2 2 1 3

Bolt length “ ” 55 49 69 55 D
mm (in) (2.17) (1.93) (2.72) (2.17)
PCIB1517E
Tightening torque 48.0
N·m (kg-m, ft-lb) (4.9, 35) E
A: M/T to engine
B: Engine to M/T
F

Revision: 2005 September MT-7 C11

 TRANSAXLE ASSEMBLY

Disassembly and Assembly GCS00163

COMPONENTS
Case and Housing Components

PCIB1518E

1. Differential side oil seal 2. CSC (Concentric Slave Cylinder) 3. Input shaft oil seal
4. Clutch housing 5. Dowel pin 6. Magnet
7. Drain plug 8. Gasket 9. Oil channel
10. 2 way connector 11. Oil gutter 12. Air breather inner tube
13. Filler plug 14. Transaxle case 15. O-ring
16. Rear housing 17. Position switch

Refer to GI-11, "Components" and the followings for the symbols in the figure.

: Apply Genuine Liquid Gasket, Three Bond 1215 or the equivalent.

Revision: 2005 September MT-8 C11

 TRANSAXLE ASSEMBLY

Gear Components
A

MT

L
PCIB1519E

1. Input shaft front bearing 2. Input shaft 3. Snap ring

4. Input shaft rear bearing 5. Adapter plate 6. Bushing M
7. 5th input gear 8. 5th baulk ring 9. Spread spring
10. 5th-reverse synchronizer hub 11. 5th-reverse coupling sleeve 12. Lock washer
13. Reverse synchronizer cone 14. Reverse baulk ring 15. Input shaft nut
16. Retaining pin 17. Reverse gear assembly

Refer toGI-11, "Components" and the followings for the symbols in the figure.

: Apply gear oil.

: Replace the parts as a set.

Revision: 2005 September MT-9 C11

 TRANSAXLE ASSEMBLY

PCIB1520E

1. Mainshaft front bearing 2. Mainshaft 3. 1st main gear

4. 1st inner baulk ring 5. 1st synchronizer cone 6. 1st outer baulk ring
7. 1st-2nd synchronizer hub 8. 1st-2nd coupling sleeve 9. Spring
10. Insert key 11. 2nd outer baulk ring 12. 2nd synchronizer cone
13. 2nd inner baulk ring 14. Snap ring 15. Thrust washer
16. 2nd main gear 17. 3rd main gear 18. 3rd baulk ring
19. 3rd-4th synchronizer hub 20. 3rd-4th coupling sleeve 21. 4th baulk ring
22. 4th main gear 23. Washer 24. Snap ring
25. Mainshaft rear bearing 26. 5th main gear 27. Mainshaft bolt

Refer to GI-11, "Components" and the followings for the symbols in the figure.

: Apply gear oil.

: Replace the parts as a set.

Revision: 2005 September MT-10 C11

 TRANSAXLE ASSEMBLY

Shift Control Components

A

MT

J
PCIB1521E

1. Retaining pin 2. 1st-2nd shift fork 3. Bushing

4. 1st-2nd fork rod 5. Lock pin 6. 5th-reverse fork rod K
7. Bracket 8. Reverse gear gate 9. 5th-reverse shift fork
10. Check ball 11. 3rd-4th shift fork 12. 3rd-4th fork rod
13. Control shaft 14. O-ring 15. Selector L
16. Check ball plug 17. Interlock bolt 18. Bushing
19. Spring 20. Striking interlock
M
Refer to GI-11, "Components" and the followings for the symbols in the figure.

: Apply gear oil.

: Replace the parts as a set.

: Apply Genuine Liquid Gasket, Three Bond 1215 or the equivalent.

Revision: 2005 September MT-11 C11

 TRANSAXLE ASSEMBLY

Final Drive Components

PCIB1522E

1. Side gear 2. Pinion mate shaft 3. Pinion mate gear

4. Thrust washer 5. Lock ring 6. Differential side bearing outer race
7. Differential side bearing 8. Differential case

Refer to GI-11, "Components" and the followings for the symbols in the figure.
: Replace the parts as a set.

Revision: 2005 September MT-12 C11

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
General Specifications GCS000AO

Engine type HR16DE

Transaxle model RS5F91R B
Number of speed 5
Synchromesh type Warner
MT
Shift pattern

SCIA0821E
E
Gear ratio 1st 3.7272
2nd 2.0476
F
3rd 1.3928
4th 1.0294
5th 0.8205 G
Reverse 3.5454
Final gear 4.0666
H
Number of teeth Input gear 1st 11
2nd 21
3rd 28 I
4th 34
5th 39
J
Reverse 11
Main gear 1st 41
2nd 43 K
3rd 39
4th 35
L
5th 32
Reverse 39
Reverse idler gear 26 M
Final gear Final gear/Pinion 61/15
Side gear/Pinion
13/9
mate gear
Oil capacity (Reference) (Imp pt) 2.6 (4-5/8)
Remarks Reverse synchronizer Installed
Double-cone synchronizer 1st and 2nd

Revision: 2005 September MT-13 C11

 SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: 2005 September MT-14 C11