Mazda 6 2003-2007 Transaxle Workshop Manual G35M-R

CONTENTSManualTransaxleWorkshopManualG35MR

FOREWORD

This manual explains the mechanism, operation, and service points for the above-indicated manual transaxle. In order to do these procedures safety, quickly, and correctly, you must first read this manual and any other relevant service materials carefully.

The information in this manual is current up to March, 2002. Any changes that occur after that time will not be reflected in this particular manual. Therefore, the contents of this manual may not exactly match the mechanism that you are currently serving.

Mazda Motor CorporationHIROSHIMA, JAPAN

2002 Mazda Motor CorporationPRINTED IN The Netherlands, MARCH 2002 17321E02C

Title Section

General Information GI

Manual Transaxle J

Technical Data TD

Special Tools ST

1732-1E-02C(INDEX).fm 1

WARNINGServicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda-trained technicians in mind. This manual may be useful to non-Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are expected to at least know general safety procedures.

This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures.

The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools which are not recommended by Mazda Motor Corporation must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.

Parts should be replaced with genuine Mazda replacement parts or with parts which match the quality of genuine Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.Mazda Motor Corporation is not responsible for any problems which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service-related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Mazda replacement parts, or not being aware of any revision of this manual.

1732-1E-02C(WARNING).fm 1

GIGIGENERAL INFORMATION

HOW TO USE THIS MANUAL ............................. GI-2RANGE OF TOPICS .......................................... GI-2SERVICING PROCEDURE ............................... GI-2SYMBOLS.......................................................... GI-4ADVISORY MESSAGES ................................... GI-4

UNITS ................................................................... GI-5UNITS TABLE .................................................... GI-5

FUNDAMENTAL PROCEDURES ........................ GI-6PREPARATION OF TOOLS AND MEASURING

EQUIPMENT................................................... GI-6SPECIAL SERVICE TOOLS .............................. GI-6DISASSEMBLY.................................................. GI-6INSPECTION DURING REMOVAL,

DISASSEMBLY............................................... GI-6ARRANGEMENT OF PARTS ............................ GI-7CLEANING OF PARTS...................................... GI-7REASSEMBLY................................................... GI-7ADJUSTMENT ................................................... GI-8RUBBER PARTS AND TUBING ........................ GI-8HOSE CLAMPS ................................................. GI-8TORQUE FORMULAS....................................... GI-8VISE ................................................................... GI-9

ELECTRICAL SYSTEM........................................ GI-9CONNECTORS.................................................. GI-9

NEW STANDARDS ............................................ GI-12NEW STANDARDS TABLE ............................. GI-12

ABBREVIATIONS .............................................. GI-14ABBREVIATIONS TABLE................................ GI-14

1732-1E-02C.book 1 GI1

GI2

HOW TO USE THIS MANUAL

RANGE OF TOPICSA6E201000001M01

This manuinto the fo Remo Disas Repla Inspe Adjus

Simple opparts, jack

End Of SieSERVICING PInspection, A Inspection

divided inlocation aexplained


1732-1E-02C.book 2 al contains procedures for performing all required service operations. The procedures are divided llowing five basic operations:val/Installationsembly/Assemblycementctiontmenterations which can be performed easily just by looking at the vehicle (i.e., removal/installation of ing, vehicle lifting, cleaning of parts and visual inspection) have been omitted.ROCEDURE

A6E201000001M02djustment and adjustment procedures are

to steps. Important points regarding the nd contents of the procedures are in detail and shown in the illustrations.

XME2010001


GI

Repair Procedure1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit

together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions.

2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustrationshown.

3. Procedurewith the cprocedure

End Of Sie

1732-1E-02C.book 3 GI3

. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also

steps are numbered and the part that is the main point of the procedure is shown in the illustration orresponding number. Occasionally, there are important points or additional information concerning a . Refer to this information when servicing the related part.

XME2010010

GI4

HOW TO USE THIS MANUAL SYMBOLS

A6E201000001M03 There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols

show application points or use of these materials during service.

End Of SieADVISORY M You will fi

manual.

Warning A Warning

Caution A Caution

Note A Note pr

Specification The value

Upper and L The value

adjustmenEnd Of Sie

Symbol Meaning Kind

1732-1E-02C.book 4 ESSAGESA6E201000001M04

nd several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this

indicates a situation in which serious injury or death could result if the warning is ignored.

indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.

ovides added information that will help you to complete a particular procedure.

ss indicate the allowable range when performing inspections or adjustments.ower Limitss indicate the upper and lower limits that must not be exceeded when performing inspections or ts.

Apply oil New appropriate engine oil or gear oil

Apply brake fluid New appropriate brake fluid

Apply automatic transaxle/transmission fluid New appropriate automatic transaxle/transmission fluid

Apply grease Appropriate grease

Apply sealant Appropriate sealant

Apply petroleum jelly Appropriate petroleum jelly

Replace part O-ring, gasket, etc.

Use SST or equivalent Appropriate tools

UNITS

GIUNITS TABLEA6E201200002M01

Conversion t All numer

from thes

Rounding Of Converted

value is 1

Upper and L When the

an upper unit value

2102627031

The actuaan upper used as a

End Of Sie

UNITS

Electrical curreElectric powerElectric resistaElectric voltag

Length

Negative pres

Number of revolutions

Positive press

Torque

1732-1E-02C.book 5 GI5

o SI Units (Systme International d'Units)ical values in this manual are based on SI units. Numbers shown in conventional units are converted e values.

f values are rounded off to the same number of places as the SI unit value. For example, if the SI unit

7.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

ower Limits data indicates upper and lower limits, the converted values are rounded down if the SI unit value is limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:

0 kPa {2.12.7 kgf/cm2, 3038 psi}0 kPa {2.73.2 kgf/cm2, 3945 psi}l converted values for 2.7 kgf/cm2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is lower limit, so the converted values are rounded up to 270 and 39.

nt A (ampere)W (watt)

nce ohme V (volt)

mm (millimeter)in (inch)

sure

kPa (kilo pascal)mmHg (millimeters of mercury)inHg (inches of mercury)rpm (revolutions per minute)

ure

kPa (kilo pascal)kgf/cm2 (kilogram force per square centimeter)psi (pounds per square inch)Nm (Newton meter)kgfm (kilogram force meter)kgfcm (kilogram force centimeter)ftlbf (foot pound force)inlbf (inch pound force)

Volume

L (liter)US qt (U.S. quart)imp qt (Imperial quart)ml (milliliter)cc (cubic centimeter)cu in (cubic inch)fl oz (fluid ounce)

WeightN (Newton)g (gram)oz (ounce)

GI6

FUNDAMENTAL PROCEDURES

PREPARATION OF TOOLS AND MEASURING EQUIPMENTA6E201400004M01

Be sure thequipmen

End Of SieSPECIAL SE Use spec

are requir

End Of SieDISASSEMB If the disa

requiring mshould betheir perfoidentified easily and

End Of SieINSPECTION When rem

inspectedand other

End Of Sie


1732-1E-02C.book 6 at all necessary tools and measuring t are available before starting any work.

RVICE TOOLSA6E201400004M02

ial service tools or equivalent when they ed.

LYA6E201400004M03

ssembly procedure is complex, any parts to be disassembled, all parts

marked in a place that will not affect rmance or external appearance and so that reassembly can be performed efficiently.

DURING REMOVAL, DISASSEMBLYA6E201400004M04

oved, each part should be carefully for malfunction, deformation, damage, problems.

WGIWXX0023E

WGIWXX0024E

WGIWXX0027E

WGIWXX0028E


GI

ARRANGEMENT OF PARTSA6E201400004M05

All disassembled parts should be carefully arranged for reassembly.

Be sure to separate or otherwise identify the parts to be repl

End Of SieCLEANING O All parts t

thoroughl

Warning Usin

othethe ewhe

End Of SieREASSEMBL Standard

adjustmenreassemb

If removenew ones Oil se Gaske O-ring Lockw Cotter Nylon

Dependin Seala

applieis appsealan

Oil shcomp

Specithe prbefore

End Of Sie

1732-1E-02C.book 7 GI7

aced from those that will be reused.

F PARTSA6E201400004M06

o be reused should be carefully and y cleaned in the appropriate method.

g compressed air can cause dirt and r particles to fly out causing injury to yes. Wear protective eye wear

never using compressed air.

YA6E201400004M07

values, such as torques and certain ts, must be strictly observed in the ly of all parts.d, these parts should be replaced with :alstssashers pins nuts

g on location:nt and gaskets, or both, should be d to specified locations. When sealant lied, parts should be installed before t hardens to prevent leakage.

ould be applied to the moving onents of parts.fied oil or grease should be applied at escribed locations (such as oil seals) reassembly.

WGIWXX0029E

WGIWXX0030E

WGIWXX0031E

WGIWXX0032E

GI8

FUNDAMENTAL PROCEDURES ADJUSTMENT

A6E201400004M08 Use suitable gauges and/or testers when making

adjustments.

End Of SieRUBBER PA Prevent g

parts or tu

End Of SieHOSE CLAM When rein

original loclamp ligh

End Of SieTORQUE FO When usi

combinatirecalculator equivaRecalculaformulas.

A : The lengL : The leng

TorquN

kgkgfftin

1732-1E-02C.book 8 RTS AND TUBINGA6E201400004M09

asoline or oil from getting on rubber bing.

PSA6E201400004M10

stalling, position the hose clamp in the cation on the hose and squeeze the tly with large pliers to ensure a good fit.

RMULASA6E201400004M11

ng a torque wrench-SST or equivalent on, the written torque must be ed due to the extra length that the SST lent adds to the torque wrench. te the torque using the following Choose the formula that applies to you.

th of the SST past the torque wrench driveth of the torque wrench

WGIWXX0033E

WGIWXX0034E

WGIWXX0035E

e Unit Formulam Nm [L/(L+A)]fm kgfm [L/(L+A)]cm kgfcm [L/(L+A)]lbf ftlbf [L/(L+A)]lbf inlbf [L/(L+A)] WGIWXX0036E

FUNDAMENTAL PROCEDURES, ELECTRICAL SYSTEM

GI

End Of SieVISEA6E201400004M12

When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.

End Of Sie

CONNECTORData Link Co Insert the

connectinconnector

Caution Inse

datathe t

Disconnectin When dis

connector

Connectopulling the

1732-1E-02C.book 9 GI9

SA6E201700006M01

nnector probe into the service hole when g a jumper wire to the data link .

rting a jumper wire probe into the link connector terminal may damage erminal.

g Connectorsconnecting connector, grasp the s, not the wires.

rs can be disconnected by pressing or lock lever as shown.

WGIWXX0037E

ELECTRICAL SYSTEM

X3U000WAY

WGIWXX0041E

WGIWXX0042E

GI10

ELECTRICAL SYSTEM Locking Connector When locking connectors, listen for a click

indicating they are securely locked.

Inspection When a te

measuringthe wiring

Inspect thfrom the caccessed

Caution To p

a thiinse

TerminalsInspection Pull lightly

are secur

1732-1E-02C.book 10 ster is used to inspect for continuity or voltage, insert the tester probe from

harness side.

e terminals of waterproof connectors onnector side since they cannot be from the wiring harness side.

revent damage to the terminal, wrap n wire around the tester probe before rting into terminal.

on individual wires to verify that they ed in the terminal.

X3U000WB1

WGIWXX0044E

WGIWXX0045E

WGIWXX0064E

ELECTRICAL SYSTEM

GI

Replacement Use the appropriate tools to remove a terminal as

shown. When installing a terminal, be sure to insert it until it locks securely.

Insert a thin piece of metal from the terminal side of the conpressed dconnector

Sensors, Sw Handle se

Do not droobjects.

Wiring HarneWiring color Two-color

symbol. The first le

and the se

End Of Sie

CODEB

BRG

GYL

LBLG

1732-1E-02C.book 11 GI11

nector and with the terminal locking tab own, pull the terminal out from the .

itches, and Relaysnsors, switches, and relays carefully. p them or strike them against other

ss codes wires are indicated by a two-color code

tter indicates the base color of the wire cond the color of the stripe.

WGIWXX0046E

WGIWXX0047E

COLOR CODE COLORBlack O OrangeBrown P PinkGreen R RedGray V VioletBlue W White

Light Blue Y YellowLight Green

X3U000WB7

GI12

NEW STANDARDS

NEW STANDARDS TABLEA6E202800020M01

Following

NEW STANDARDS

Abbrevi-ationAP

ACLA/C

BAROB+

CMP sensorCACCLSCTPCPPCIS

CS sensorCKP sensor

DLCDTMDTCDI

DLIEI

ECTEM

EVAPEGRFCFF

4GR

FSO solenoid

GENGNDHO2SIAC

IATKSMILMAP

MAF sensorMFLOBDOL

1732-1E-02C.book 12 is a comparison of the previous standard and the new standard.New Standard Previous Standard

RemarkName Abbrevi-ation Name

Accelerator Pedal Accelerator PedalAir Cleaner Air CleanerAir Conditioning Air ConditioningBarometric Pressure Atmospheric PressureBattery Positive Voltage VB Battery VoltageBrake Switch Stoplight SwitchCalibration Resistor Corrected Resistance #6Camshaft Position Sensor Crank Angle SensorCharge Air Cooler IntercoolerClosed Loop System Feedback SystemClosed Throttle Position Fully ClosedClutch Pedal Position Idle SwitchContinuous Fuel Injection System Clutch PositionControl Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6Crankshaft Position Sensor Crank Angle Sensor 2Data Link Connector Diagnosis ConnectorDiagnostic Test Mode Test Mode #1Diagnostic Trouble Code(s) Service Code(s)Distributor Ignition Spark IgnitionDistributorless Ignition Direct IgnitionElectronic Ignition Electronic Spark Ignition #2Engine Coolant Temperature Water ThermoEngine Modification Engine ModificationEngine Speed Input Signal Engine RPM SignalEvaporative Emission Evaporative EmissionExhaust Gas Recirculation Exhaust Gas RecirculationFan Control Fan ControlFlexible Fuel Flexible FuelFourth Gear OverdriveFuel Pump Relay Circuit Opening Relay #3

Fuel Shut Off Solenoid FCV Fuel Cut Valve #6

Generator AlternatorGround Ground/EarthHeated Oxygen Sensor Oxygen Sensor With heaterIdle Air Control Idle Speed ControlIDM Relay Spill Valve Relay #6Incorrect Gear Ratio Injection Pump FIP Fuel Injection Pump #6Input/Turbine Speed Sensor Pulse GeneratorIntake Air Temperature Intake Air ThermoKnock Sensor Knock SensorMalfunction Indicator Lamp Malfunction Indicator LightManifold Absolute Pressure Intake Air PressureMass Air Flow Sensor Airflow SensorMultiport Fuel Injection Multiport Fuel InjectionOn-Board Diagnostic Diagnosis/Self DiagnosisOpen Loop Open Loop

NEW STANDARDS

GI

#1 : Diagnost#2 : Controlle#3 : In some m

relay (sp#4 : Device th#5 : Directly c#6 : Part nam

End Of Sie

Output Speed Sensor Vehicle Speed Sensor 1OCO2SPNP

PSPPCM

PAIR

AIR

SAPVSFI

3GRTWCTB

TP sensorTCVTCC

TCM

TRTC

VSSVR

VAF sensor

WUTWC

WOT

New Standard Previous StandardRemarkAbbrevi-

ation NameAbbrevi-

ation Name

1732-1E-02C.book 13 GI13

ic trouble codes depend on the diagnostic test moded by the PCM

odels, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump eed).at controls engine and powertrainonnected to exhaust manifolde of diesel engine

Oxidation Catalytic Converter Catalytic ConverterOxygen Sensor Oxygen SensorPark/Neutral Position Park/Neutral RangePCM Control Relay Main Relay #6Power Steering Pressure Power Steering PressurePowertrain Control Module ECU Engine Control Unit #4Pressure Control Solenoid Line Pressure Solenoid Valve

Pulsed Secondary Air Injection Secondary Air Injection System Pulsed injectionPump Speed Sensor NE Sensor #6

Secondary Air Injection Secondary Air Injection SystemInjection with air pump

Secondary Air Pulse Valve Reed ValveSequential Multipoint Fuel Injection Sequential Fuel InjectionShift Solenoid A 1-2 Shift Solenoid Valve

Shift A Solenoid Valve

Shift Solenoid B 2-3 Shift Solenoid Valve Shift B Solenoid Valve

Shift Solenoid C 3-4 Shift Solenoid ValveThird Gear 3rd GearThree Way Catalytic Converter Catalytic ConverterThrottle Body Throttle BodyThrottle Position Sensor Throttle SensorTimer Control Valve TCV Timing Control Valve #6Torque Converter Clutch Lockup PositionTransmission (Transaxle) Control Module ECAT Control Unit

Transmission (Transaxle) Fluid Temperature Sensor ATF Thermosensor

Transmission (Transaxle) Range Inhibitor PositionTurbocharger TurbochargerVehicle Speed Sensor Vehicle Speed Sensor Voltage Regulator IC RegulatorVolume Air Flow Sensor Air flow SensorWarm Up Three Way Catalytic Converter Catalytic Converter #5

Wide Open Throttle Fully Open

GI14

ABBREVIATIONS

ABBREVIATIONS TABLEA6E203000011M01

End Of Sie

ABBREVIATIONS

SST1st GR2nd GR3rd GR4th GR5th GR

1732-1E-02C.book 14 Special service toolFirst gearSecond gearThird gearForth gearFifith gear

JJMANUAL TRANSAXLE

MANUAL TRANSAXLE.......................................... J-2PRECAUTION...................................................... J-25TH GEAR THRUST CLEARANCE

PREINSPECTION............................................. J-25TH/REVERSE GEAR AND HOUSING PARTS

DISASSEMBLY................................................. J-35TH/REVERSE GEAR AND HOUSING PARTS

INSPECTION .................................................... J-6CLUTCH HOUSING AND TRANSAXLE CASE

COMPONENTS DISASSEMBLY...................... J-8PRIMARY SHAFT COMPONENTS

PREINSPECTION........................................... J-12PRIMARY SHAFT COMPONENTS

DISASSEMBLY............................................... J-13PRIMARY SHAFT COMPONENTS

INSPECTION .................................................. J-14PRIMARY SHAFT COMPONENTS

ASSEMBLY..................................................... J-16SECONDARY SHAFT COMPONENTS

PREINSPECTION........................................... J-18SECONDARY SHAFT COMPONENTS

DISASSEMBLY............................................... J-20SECONDARY SHAFT COMPONENTS

INSPECTION .................................................. J-21SECONDARY SHAFT COMPONENTS

ASSEMBLY..................................................... J-24DIFFERENTIAL PREINSPECTION ................... J-27DIFFERENTIAL DISASSEMBLY ....................... J-28DIFFERENTIAL ASSEMBLY ............................. J-29BEARING PRELOAD ADJUSTMENT................ J-30CLUTCH HOUSING AND TRANSAXLE CASE

COMPONENTS ASSEMBLY.......................... J-365TH/REVERSE GEAR AND HOUSING PARTS

ASSEMBLY..................................................... J-38

1732-1E-02C.book 1 J1

J2

MANUAL TRANSAXLE

PRECAUTIONA6E511201029M01

1. Clean the

Warning Usin

Wea

Caution Clea

bear

2. Clean the3. Clean out4. Use a pla5. Make sure6. Coat all m7. Replace p8. Remove o9. Assemble

assembly

Warning Alth

holdto tuthe r

End Of Sie5TH GEAR T1. Remove t2. Measure

dial indica If the c

the coclutch

Clearanc0.100

Maximum0.270 m

End Of Sie

MANUAL TRANSAXLE

1732-1E-02C.book 2 transaxle exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.

g compressed air can cause dirt and other particles to fly out, causing injury to the eyes. r protective eye wear whenever using compressed air.

ning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the ing.

removed parts using cleaning solvent, and dry them using compressed air. all holes and passages using compressed air, and check that there are no obstructions.stic hammer when disassembling the transaxle case and other light alloy metal parts. each part is cleaned before assembling.ovable parts with the specified oil.arts whenever required.ld sealant from contact surfaces before applying new sealant. the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after before filling the transaxle with transaxle oil.

ough the stand has a self-locking brake system, there is a possibility that the brake may not when the transaxle is held in a lopsided position on the stand. This would cause the transaxle rn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold otating handle firmly when turning the transaxle.

HRUST CLEARANCE PREINSPECTIONA6E511201029M02

he rear cover.the 5th gear thrust clearance using a tor.learance exceeds the maximum, check ntact surfaces of 5th gear and the hub. Replace worn or damaged parts.

e0.220 mm {0.00400.0086 in}m {0.0106 in}

Z4F5112M001

MANUAL TRANSAXLE 5TH/REVERSE GEAR AND HOUSING PARTS DISASSEMBLY

A6E511201029M031. Disassemble in the order shown in the figure.

Caution If an

occuwith

1732-1E-02C.book 3 J3

Jy old sealant gets into the transaxle during installation of the transaxle case, trouble may r in the transaxle. Remove any old sealant from the transaxle case and clutch housing, and cleaning fluids.

J4

MANUAL TRANSAXLE

.

1 Rear co

2 Locknu(See J3 Locknu(See J4 5th/rev5 5th/rev6 5th syn7 5th gea

1732-1E-02C.book 4 A6E5112M117

ver

t (primary shaft)5 Locknut Disassembly Note)t (secondary shaft)5 Locknut Disassembly Note)

erse shift forkerse clutch hub componentchronizer ringr

8 Gear sleeve9 Secondary 5th gear

10 Lock bolt11 Guide bolt12 Lock bolt, ball, and spring13 Back-up light switch14 Neutral switch15 Transaxle case component16 Magnet

MANUAL TRANSAXLE

Locknut Disa1. Assemble2. Lift the tra

3. Lock the p4. Shift to 1s

shaft.5. Bend bac6. Remove t

secondary

Shift Fork an1. Aligh the

control levcounterclo

2. While holdand the 3them bothclutch hub

17 Reverse idler shaft18 Reverse idler gear19 5th/reverse shift rod20 5th/reverse shift rod end21 Pin22 Crank l23 Crank l

24Shift fo(See JDisass

25 Push p26 Primary

27 Secondary shaft gear component28 Differential component29 Clutch housing30 Synchronizer key springs

1732-1E-02C.book 5 J5

J

ssembly Note the SST.nsaxle and mount it on the SST.

rimary shaft with the SST.t gear to lock the rotation of the primary

k the caulking of locknuts using a chisel.he locknuts from the primary and shafts.

d Shift Rod Component Disassembly Noteends of the interlock sleeve and of the er (arrow). Turn the shift rod ckwise.ing the 1st/2nd shift fork with one hand

rd/4th shift fork with the other, raise at the same time and shift each of the sleeves.

ever shaftever componentrk and shift rod component5 Shift Fork and Shift Rod Component

embly Note)in shaft gear component

31 Clutch hub sleeve32 Clutch hub33 3rd/4th shift fork34 Interlock sleeve35 Control lever36 1st/2nd shift fork37 Control end38 Control rod

A6E5112M108

Z4F5112M004

Z4F5112M005

J6

MANUAL TRANSAXLE 3. Lift the control end and remove the steel, and at

the same time, remove the control rod from the clutch housing.

4. Separate the shift rod and shift fork component from each of the clutch hub sleeves.

End Of Sie5TH/REVERS5th and Reve1. Inspect th

If ther2. Inspect th


If ther

Synchronize1. Inspect th


If ther3. Measure

ring and t If not

ring.

Note Set t

gearcircu

Standard1.50 mm

Minimum0.80 mm

Clutch Hub C1. Inspect th



If ther4. Measure

and shift f If the

replac

Standard0.100

Maximum0.86 mm

1732-1E-02C.book 6 E GEAR AND HOUSING PARTS INSPECTIONA6E511201029M04

rse Gear Inspectione synchronizer cones for wear.e is malfunction, replace parts as necessary.e gear teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e synchronizer ring matching teeth for damage and wear.e is malfunction, replace the synchronizer ring.

r Ring Inspectione synchronizer ring teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e tapered surface for wear and cracks.e is malfunction, replace parts as necessary.the clearance between the synchronizer he flank surface of the gear.as specified, replace the synchronizer

he synchronizer ring squarely in the ; then measure around the mference.

clearance {0.059 in} {0.031 in}omponent Inspection

e clutch hub sleeve and hub operation.e is malfunction, replace parts as necessary.e gear teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e synchronizer keys for damage, wear, and cracks.e is malfunction, replace parts as necessary.the clearance between the hub sleeve ork.clearance exceeds the maximum, e the hub sleeve and shift fork as a set.

clearance.36 mm {0.0040.014 in} clearance {0.034 in}

A6E5112M006

A6E5112M118

A6E5112M008

MANUAL TRANSAXLE Reverse Idle Gear and Reverse Lever Inspection1. Inspect the gear teeth for damage, wear, and cracks.

If there is malfunction, replace the reverse idle gear.2. Measure the clearance between the reverse idle

gear bushing and the reverse lever. If not

Standard0.100

Maximum0.85 mm

5th Gear and1. Measure

the Sleev If not

neces

5th gear 34.000

Sleeve ou33.945

Clearanc0.030

End Of Sie

1732-1E-02C.book 7 J7

Jas specified, replace as necessary.

clearance.35 mm {0.0040.013 in} Clearance {0.033 in}

Sleeve Inspectionthe clearance between the 5th gear and e.as specified, replace parts as sary.

inner diameter34.025 mm {1.33861.3395 in}ter diameter33.970 mm {1.33651.3373 in}

e0.080 mm {0.00120.0031 in}

A6E5112M009

Z4F5112M010

J8

MANUAL TRANSAXLE CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS DISASSEMBLY

A6E511217010M011. Disassemble in the order shown in the figure..

1 Bearing2 Oil sea

(See JNote)

3 Bearing(See JDisasse

4 Funnel5 Guide p6 Sealing7 Roll pin

(See J8 Control

(See J9 Selecto

10 Change11 Bleathe12 Bleathe13 Hole co14 Oil sea

(See J15 Bearing

(See JNote)

1732-1E-02C.book 8 A6E5112M113

race (primary shaft)l (primary shaft)9 Oil Seal (Primary Shaft) Disassembly

race (secondary shaft)9 Bearing Race (Secondary Shaft) mbly Note)

late component cap

9 Roll Pin Disassembly Note) rod9 Control Rod Disassembly Note)r

arm

r cover componentr

ver

l (differential)10 Oil Seal (Differential) Disassembly Note) race (differential)11 Bearing Race (Differential) Disassembly

16 Reverse lever shaft17 Reverse lever18 Drain plug and washer19 Bearing race (transaxle case)

(See J11 Bearing Race (Transaxle Case) Disassembly Note)

20 Adjustment shim(s)21 Bearing race (differential)

(See J11 Bearing Race (Differential) Disassembly Note)

22 Adjustment shim(s)23 Oil seal (differential)

(See J10 Oil Seal (Differential) Disassembly Note)24 Dowel pin25 O-ring26 Crank lever shaft27 Clank component lever28 Roll pin29 Shift lever component30 Key31 Control end 32 Spring and washer33 shift lever shaft

MANUAL TRANSAXLE

Oil Seal (Primary Shaft) Disassembly Note1. Remove t

Bearing Rac1. Remove t

funnel out

Roll Pin Disa1. Align the g

pin with thout using

Control Rod 1. Move the

34 Boots 35 Oil passage

1732-1E-02C.book 9 J9

Jhe oil seal using screwdriver.

e (Secondary Shaft) Disassembly Notehe bearing race by lifting it and the together.

ssembly Noteroove for removal of the clutch housing e position of the roll pin, then tap the pin a pin punch.

Disassembly Notecontrol rod in the direction of arrow.

A6E5112M012

A6E5112M013

Z4F5112M014

A6E5112M005

J10

MANUAL TRANSAXLE 2. Using a flathead screwdriver and hammer, make

a hole on the cap.

3. Pthe sealinto the hothe transm

Oil Seal (Cha1. Remove t

Oil Seal (Diff1. Remove t

1732-1E-02C.book 10 cap off, putting the flathead screwdriver le, made in Step 2, from the inside of ission.

nge Rod Component) Disassembly Notehe oil seal using the screwdriver.

erential) Disassembly Notehe oil seal using the screwdriver.

A6E5112M106

A6E5112M107

A6E5112M015

A6E5112M016

MANUAL TRANSAXLE Bearing Race (Differential) Disassembly Note1. Remove the bearing outer race using the SST.

Reverse Lev1. Remove t

2. Protect thpliers to re

Bearing Rac1. Remove t

End Of Sie

1732-1E-02C.book 11 J11

J

er Shaft Disassembly Notehe roll pin using pliers.

e reverse lever shaft with a rag and use move the shaft.

e (Transaxle Case) Disassembly Notehe bearing race using the SST.

Z4F5112M017

A6E5112M018

A6E5112M019

Z4F5112M020

J12

MANUAL TRANSAXLE PRIMARY SHAFT COMPONENTS PREINSPECTION

A6E511217201M013rd Gear Thrust Clearance1. Measure the clearance between 3rd gear and 2nd

gear. If the c

the coand 3dama

Clearanc0.050

Maximum0.25 mm

4th Gear Thr1. Measure

bearing. If the c

the coand 3dama

Clearanc0.170

Maximum0.42 mm

End Of Sie

1732-1E-02C.book 12 learance exceeds the maximum, check ntact surfaces of the 3rd gear, 2nd gear rd/4th clutch hub. Replace worn and ged parts.

e.20 mm {0.0020.007 in} {0.010 in}

ust Clearancethe clearance between 4th gear and the

learance exceeds the maximum, check ntact surfaces of the 4th gear, bearing, rd/4th clutch hub. Replace worn and ged parts.

e.37 mm {0.0070.014 in} {0.017 in}

A6E5112M021

A6E5112M022

MANUAL TRANSAXLE PRIMARY SHAFT COMPONENTS DISASSEMBLY


Bearing (4th1. Remove t

1 Bearing(See JNote)

2 4th gea3 4th syn4 Retaini5 3rd/4th

(See JSynchr

6 3rd syn(See JSynchr

1732-1E-02C.book 13 J13

J

Gear End) Disassembly Notehe bearing using the SST.

Z4F5112M023

(4th gear end)13 Bearing (4th Gear End) Disassembly

r

chronizer ringng ring clutch hub component14 3rd/4th Clutch Hub Component, 3rd

onizer Ring and 3rd Gear Disassembly Note)chronizer ring14 3rd/4th Clutch Hub Component, 3rd

onizer Ring and 3rd Gear Disassembly Note)

7 3rd gear(See J14 3rd/4th Clutch Hub Component, 3rd Synchronizer Ring and 3rd Gear Disassembly Note)

8 Bearing (primary shaft end)(See J14 Bearing (Primary Shaft End) Disassembly Note)

9 Primary shaft gear10 Synchronizer key springs11 3rd/4th clutch hub sleeve12 Synchronizer keys13 3rd/4th clutch hub

Z4F5112M024

J14

MANUAL TRANSAXLE 3rd/4th Clutch Hub Component, 3rd Synchronizer Ring and 3rd Gear Disassembly Note1. Remove the retaining ring.2. Remove the 3rd/4th clutch hub component, 3rd

synchronizer ring, and 3rd gear using the SST.

Bearing (Prim1. Remove t

Caution Use

prevgear

End Of SiePRIMARY SH4th Gear, 3rd1. Inspect th



If ther

4th Synchron1. Inspect th


If ther3. Measure

ring and t If not

ring.

Note Set t

gearcircu

Standard1.50 mm

Minimum0.80 mm

1732-1E-02C.book 14 ary Shaft End) Disassembly Notehe bearing using the SST.

protective plates in the vise to ent damage to the primary shaft .

AFT COMPONENTS INSPECTIONA6E511217201M03

Gear Inspectione synchronizer cones for wear.e is malfunction, replace parts as necessary.e gear teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e synchronizer ring matching teeth for damage and wear.e is malfunction, replace the synchronizer ring.

izer Ring, 3rd Synchronizer Ring Inspectione synchronizer ring teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e tapered surface for wear and cracks.e is malfunction, replace parts as necessary.the clearance between the synchronizer he flank surface of the gear.as specified, replace the synchronizer

he synchronizer ring squarely in the ; then measure around the mference.

clearance {0.059 in} {0.031 in}

Z4F5112M025

Z4F5112M026

A6E5112M027

MANUAL TRANSAXLE 3rd/4th Clutch Hub Component Inspection1. Inspect the clutch hub sleeve and hub operation.

If there is malfunction, replace parts as necessary.2. Inspect the gear teeth for damage, wear, and cracks.

If there is malfunction, replace parts as necessary.3. Inspect th

If ther4. Measure

and shift f If the

replac

Standard0.100

Maximum0.90 mm

Primary Sha1. Inspect th




If ther5. Measure

If not

Primary s0.050 m

6. Measure and the g If not

neces

End Of Sie

Gear Sh(Oute3rd 35.945{1.4154th 30.945{1.218

1732-1E-02C.book 15 J15

Je synchronizer keys for damage, wear, and cracks.e is malfunction, replace parts as necessary.the clearance between the hub sleeve orks.clearance exceeds the maximum, e the hub sleeve and shift fork as a set.

.40 mm {0.0040.015 in} {0.035 in}

ft Gear Inspectione gear contact surface for damage and wear.e is malfunction, replace the primary shaft.e splines for damage and wear.e is malfunction, replace the primary shaft.e gear teeth for damage, wear, and cracks.e is malfunction, replace the primary shaft.e oil passage for clogging.e is malfunction, replace the primary shaft.the shaft gear runout.as specified, replace the primary shaft.

haft runoutm {0.0020 in} max.

the clearance between the shaft gears ears.as specified, replace parts as sary.

A6E5112M028

aftr dia.)

Gear(Inner dia.) Clearance

35.970 1.416}

36.00036.025 {1.4171.418} 0.0300.080

{0.0010.003}30.970 1.219}

31.00031.025 {1.2201.221}

Z4F5112M029

Z4F5112M030

J16

MANUAL TRANSAXLE PRIMARY SHAFT COMPONENTS ASSEMBLY

A6E511217201M041. Assemble in the order shown in the figure..

1 3rd/4th(See J

2 Synchr3 3rd/4th4 Synchr5 Primary6 Bearing

(See JNote)

7 3rd gea(See J3rd/4th

8 3rd syn(See J3rd/4th

1732-1E-02C.book 16 Z4F5112M031

clutch hub17 3rd/4th Clutch Hub Assembly Note)

onizer keys clutch hub sleeveonizer key springs shaft gear (primary shaft end)17 Bearing (Primary Shaft End) Assembly

r17 3rd Gear, 3rd Synchronizer Ring, and

Clutch Hub Component Assembly Note)chronizer ring17 3rd Gear, 3rd Synchronizer Ring, and

Clutch Hub Component Assembly Note)

9 3rd/4th clutch hub component(See J17 3rd Gear, 3rd Synchronizer Ring, and 3rd/4th Clutch Hub Component Assembly Note)

10 Retaining ring11 4th synchronizer ring

(See J18 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note)

12 4th gear(See J18 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note)

13 Bearing (4th gear end)(See J18 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note)

MANUAL TRANSAXLE 3rd/4th Clutch Hub Assembly Note1. Install the synchronizer key springs in the clutch

hub with the hooks in the grooves to hold the three synchronizer key in place.

SynchronA: 17.0B: 4.3 mC: 5.0 m

2. Align the synchroni

Bearing (Prim1. Install the

3rd Gear, 3rd1. Install the

3rd/4th clu

1732-1E-02C.book 17 J17

Jizer key size mm {0.669 in}

m {0.17 in}m {0.20 in}

synchronizer ring grooves with the zer key during assembly.

ary Shaft End) Assembly Note new bearing using the SST.

Synchronizer Ring, and 3rd/4th Clutch Hub Component Assembly Note 3rd gear, 3rd synchronizer ring, and tch hub component using a press.

A6E5110M131

Z4F5112M032

Z4F5112M033

Z4F5112M034

J18

MANUAL TRANSAXLE 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note1. Install the 4th synchronizer ring, 4th gear, and a

new bearing using the SST.

2. Measure 2nd gear. If not

shaft

Clearanc0.050

Maximum0.25 mm

3. Measure bearing. If not

shaft

Clearanc0.170

Maximum0.42 mm

End Of SieSECONDARY1st Gear Thr1. Measure

differentia If the c

the codifferegear, Repla

Clearanc0.050

Maximum0.33 mm

1732-1E-02C.book 18 the clearance between the 3rd gear and

as specified, reassemble the primary component.

e.20 mm {0.0020.007 in} {0.010 in}

the clearance between the 4th gear and

as specified, reassemble the primary component.

e.37 mm {0.0070.014 in} {0.017 in}

SHAFT COMPONENTS PREINSPECTIONA6E511217301M01

ust Clearance Inspectionthe clearance between 1st gear and the l drive gear.learance exceeds the maximum, check ntact surfaces of the 1st gear, ntial drive gear of the secondary shaft and 1st/2nd clutch hub component. ce worn and damaged parts.

e.28 mm {0.0020.011 in} {0.013 in}

Z4F5112M035

A6E5112M036

A6E5112M037

A6E5112M038

MANUAL TRANSAXLE 2nd Gear Thrust Clearance Inspection1. Measure the clearance between 2nd gear and

secondary 3rd gear. If the clearance exceeds the maximum, check

the contact surfaces of the 2nd gear, seconcompparts.

Clearanc0.180

Maximum0.51 mm

End Of Sie

1732-1E-02C.book 19 J19

Jdary 3rd gear, and 1st/2nd clutch hub onent. Replace worn and damaged

e.46 mm {0.0070.018 in} {0.020 in}

A6E5112M039

J20

MANUAL TRANSAXLE SECONDARY SHAFT COMPONENTS DISASSEMBLY


1 Bearing(See JDisasse

2 Second3 Retaini4 Second

(See JDisasse

5 Friction6 Inner c7 Double8 2nd ge9 Synchr

10 Retaini

1732-1E-02C.book 20 A6E5112M111

21 Bearing and Secondary 4th Gear mbly Note)ary 4th gear

ng ringary 3rd gear21 Secondary 3rd Gear and 2nd Gear mbly Note) damperone

cone

ar

onizer ringng ring

11 1st/2nd clutch hub component(See J21 1st/2nd Clutch Hub Component, 1st Synchronizer Ring, and 1st Gear Disassembly Note)

12 1st gear13 Synchronizer ring14 Inner cone15 Double cone16 Bearing

(See J21 Bearing (Secondary Shaft End) Disassembly Note)

17 Secondary shaft gear18 Synchronizer key springs19 Clutch hub sleeve (reverse gear)20 Synchronizer keys21 1st/2nd clutch hub

MANUAL TRANSAXLE Bearing and Secondary 4th Gear Disassembly Note1. Remove the bearing and secondary 4th gear

using the SST.

Secondary 31. Remove t2. Shift the g3. Remove t

using the

1st/2nd Clutc1. Remove t2. Remove t

synchroni

Bearing (Sec1. Remove t

End Of Sie

1732-1E-02C.book 21 J21

J

rd Gear and 2nd Gear Disassembly Notehe retaining ring.ears to 1st gear.he secondary 3rd gear and 2nd gear SST.

h Hub Component, 1st Synchronizer Ring, and 1st Gear Disassembly Notehe retaining ring.he 1st/2nd clutch hub component, 1st zer ring, and 1st gear using a press.

ondary Shaft End) Disassembly Notehe bearing using the SST.

Z4F5112M041

Z4F5112M042

A6E5112M043

Z4F5112M044

J22

MANUAL TRANSAXLE SECONDARY SHAFT COMPONENTS INSPECTION

A6E511217301M03Gears Inspection1. Inspect the synchronizer cones for wear.

If there is malfunction, replace parts as necessary.2. Inspect th


If ther

Synchronize1. Inspect th


If ther3. Measure

ring and tfeeler gau If the

replac

Standard1.50 mm

Minimum0.80 mm

Clutch Hub C1. Inspect th



If ther4. Measure

and shift f If the

replac

Standard0.100

Maximum0.95 mm

Secondary S1. Inspect th




If ther

1732-1E-02C.book 22 e gear teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e synchronizer ring matching teeth for damage and wear.e is malfunction, replace the synchronizer ring.

r Ring Inspectione synchronizer ring teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e tapered surface for wear and cracks.e is malfunction, replace parts as necessary.the clearance between the synchronizer he side of gear circumferentially using a ge.clearance is exceed the minimum, e the synchronizer ring.

clearance {0.059 in} {0.031 in}

omponent Inspectione clutch hub sleeve and hub operation.e is malfunction, replace parts as necessary.e gear teeth for damage, wear, and cracks.e is malfunction, replace parts as necessary.e synchronizer keys for damage, wear, and cracks.e is malfunction, replace parts as necessary.the clearance between the hub sleeve ork.clearance exceeds the maximum, e the hub sleeve and shift fork as a set.

clearance.45 mm {0.0040.017 in} clearance {0.037 in}

haft Gear Inspectione gear contact surface for damage and wear.e is malfunction, replace the secondary shaft.e splines for damage and wear.e is malfunction, replace the secondary shaft.e gear teeth for damage, wear, and cracks.e is malfunction, replace the secondary shaft.e oil passage for clogging.e is malfunction, replace the secondary shaft.

A6E5112M047

A6E5112M049

MANUAL TRANSAXLE 5. Measure the shaft gear runout.

If not as specified, replace the secondary shaft.

Secondary shaft gear runout0.015 m

6. Measure and the g If not

neces

End Of Sie

Gear Sh(oute1st 39.445{1.5532nd 34.945{1.376

1732-1E-02C.book 23 J23

Jm {0.0006 in} max.

the clearance between the shaft gears ears.as specified, replace parts as sary.

mm{in}aftr dia.)

Gear(inner dia.) Clearance

39.470 1.554}

39.50039.525 {1.5551.556}

0.0300.080 {0.0020.003}

34.905 1.374}

35.01535.035 {1.3781.379}

0.050.09 {0.0020.003}

A6E5112M050

Z4F5112M102

J24

MANUAL TRANSAXLE SECONDARY SHAFT COMPONENTS ASSEMBLY


1 1st/2nd(See J

2 Synchr3 Clutch 4 Synchr5 Second6 Bearing

(See JAssem

7 1st gea(See J2nd Clu

8 Synchr9 Inner c

1732-1E-02C.book 24 A6E5112M110

clutch hub25 1st/2nd Clutch Hub Assembly Note)

onizer keyshub sleeve (reverse gear)onizer key springary shaft gear (secondary shaft end)25 Bearing (Secondary Shaft End)

bly Note)r25 1st Gear, 1st Synchronizer Ring, and 1st/tch Hub Component Assembly Note)

onizer ringone

10 Double cone11 1st/2nd clutch hub component12 Retaining ring13 Synchronizer ring14 2nd gear15 Double cone16 Inner cone17 Friction damper18 Secondary 3rd gear19 Retaining ring20 Secondary 4th gear

(See J26 Secondary 4th Gear and Bearing Assembly Note)

21 Bearing

MANUAL TRANSAXLE 1st/2nd Clutch Hub Assembly Note1. Install the synchronizer key springs in the clutch

hub with the hooks in the grooves to hold the three synchronizer keys in place.

SynchronA: 19.0B: 4.3 mC: 5.0 m

Bearing (Sec1. Install the

1st Gear, 1st

Note The

sync

1. Assemble1st/2nd clfigure.

1732-1E-02C.book 25 J25

Jizer key mm {0.748 in}

m {0.17 in}m {0.20 in}

ondary Shaft End) Assembly Note new bearing using the SST.

Synchronizer Ring, and 1st/2nd Clutch Hub Component Assembly Note

size of the 1st, 2nd, 3rd, and 4th hronizer rings are the same.

the 1st gear, 1st synchronizer ring, and utch hub component, as shown in the

A6E5110M131

Z4F5112M052

A6E5112M114

Z4F5112M054

J26

MANUAL TRANSAXLE 2. Press the 1st/2nd clutch hub component on using

the SST.

2nd Synchro1. Install the2. Install the

Secondary 41. Install the

using the

2. Measure the differe

Clearanc0.050

Maximum0.33 mm

1732-1E-02C.book 26 nizer Ring, 2nd Gear, and Secondary 3rd Gear Assembly Note 2nd synchronizer ring and 2nd gear. secondary 3rd gear using the SST.

th Gear and Bearing Assembly Note secondary 4th gear and the bearing SST.

the clearance between the 1st gear and ntial drive gear.

e.28 mm {0.0020.011 in} {0.013 in}

Z4F5112M055

A6E5112M115

Z4F5112M057

A6E5112M058

MANUAL TRANSAXLE 3. Measure the clearance between the 2nd gear and

the secondary 3rd gear. If not as specified, reassemble the secondary

shaft component.

Clearanc0.180

Maximum0.51 mm

End Of SieDIFFERENTIBacklash Ins1. Measure

If not neces

Standard0.050

End Of Sie

1732-1E-02C.book 27 J27

Je.46 mm {0.0070.018 in} {0.020 in}

AL PREINSPECTIONA6E511227100M01

pectionthe backlash of the side gear.as specified, replace parts as sary.

0.150 mm{0.00200.059 in}

A6E5112M059

A6E5112M060

J28

MANUAL TRANSAXLE DIFFERENTIAL DISASSEMBLY


Bearing (Sid1. Remove t

1 Roll pin2 Pinion 3 Pinion 4 Thrust 5 Side ge6 Thrust

1732-1E-02C.book 28 e Opposite Ring Gear) Disassembly Notehe bearing using the SSTs.

Z4F5112M061

shaftgearwasherar

washer

7 Bearing (side opposite ring gear)(See J28 Bearing (Side Opposite Ring Gear) Disassembly Note)

8 Speedometer drive gear9 Bearing (ring gear side)

(See J29 Bearing (Ring Gear Side) Disassembly Note)

10 Ring gear and gear case component

Z4F5112M062

MANUAL TRANSAXLE Bearing (Ring Gear Side) Disassembly Note1. Remove the bearing using the SST.

End Of SieDIFFERENTI1. Assemble

1 Ring ge2 Bearing

(See JNote)

3 Speedo4 Bearing

(See JAssem

5 Thrust

1732-1E-02C.book 29 J29

J

AL ASSEMBLYA6E511227100M03

in the order shown in the figure..

Z4F5112M063

Z4F5112M064

ar and gear case component (ring gear side)30 Bearing (Ring Gear Side) Assembly

meter drive gear (side opposite ring gear)30 Bearing (Side Opposite Ring Gear)

bly Note)washer

6 Side gear7 Thrust washer8 Pinion gear9 Pinion shaft

10 Roll pin(See J30 Roll Pin Assembly Note)

J30

MANUAL TRANSAXLE Bearing (Ring Gear Side) Assembly Note1. Install the new bearing using the SST.

Bearing (Sid1. Install the2. Install the

Roll Pin Ass1. Install the

hold the p

2. Measure (1) Install

differe(2) Suppo

in the(3) Meas

If da

Backlash0.050

End Of Sie

BEARING PR1. Install the2. Mount the

housing. P

1732-1E-02C.book 30 e Opposite Ring Gear) Assembly Note speedometer drive gear. new bearing using the SST.

embly Note new roll pin as shown in the figure to inion shaft.

the backlash by the following procedure. the left and right drive shafts in the ntial component.rt the drive shaft on V-blocks as shown

figure.ure the backlash of both pinion gears.not as specified, replace worn and mage parts.

0.150 mm {0.00200.059 in}

ELOAD ADJUSTMENTA6E511201029M05

primary and secondary shaft bearing races into the transaxle case (shims removed). clutch housing onto the transaxle hanger, and set the differential bearing race into the clutch osition a piece of pipe against the bearing race and tap it in until it contacts the clutch housing.

Z4F5112M065

Z4F5112M066

A6E5112M067

A6E5112M068

MANUAL TRANSAXLE 3. Set the bearing races into the SSTs (selector) as

shown in the figure.

Note Turn the selector to eliminate the gap

indic

4. Set the dihousing, a(selector)(selector)the clutchMount thefigure.

5. Set the SSthe figure

6. Install the(bolts) toTightenin

37.35ftlbf}

7. To seat thparts A anselectors Then turnthe gaps a

1732-1E-02C.book 31 J31

Jated by the arrow in the figure.

fferential component into the clutch nd set the bearing race and the SST

on the differential. Set the SSTs for the primary and secondary shaft in housing. shaft gear assemblies as shown in the

T (collars) in the positions shown in .

transaxle case and tighten the SST the specified torque.

g torque2.0 Nm {3.95.3 kgfm, 28.238.3

e bearings, mount the SST (bars) on d B of the selectors, and turn the so the gaps are widened. the SST in the reverse direction until re eliminated.

Z4F5112M069

Z4F5112M070

Z4F5112M071

Z4F5112M072

Z4F5112M073

J32

MANUAL TRANSAXLE 8. Manually expand the selector until it no longer

turns by hand.

9. Use a feeSST (sele

Caution Mea

circu

10. Take the shim to usPrimary s Selec

table

Standard00.05

ExampleReadin

Shim sele(0.57 m

mm {Shim

0.55 mm

Seconda Selec

Tightenin0.030

ExampleReadin

Shim sele(0.57 m

in}0Shim

0.60 mm

Thickness of

0.20 {0.008}0.40 {0.016}0.60 {0.024}

1732-1E-02C.book 32 ler gauge to measure the gap in the ctor).

sure the gap around the entire mference of the selector.

maximum reading and determine the ed as follows.haft adjustment shim

t the thinnest allowable shim from the to obtain standard clearance.

clearance mm {00.002 in}g from step 9: 0.57 mm {0.022 in}cting range

m {0.022 in}0.05 mm {0.002 in})(0.57 mm {0.022 in}0 mm {0 in})=0.52 mm {0.020 in}0.57 0.022 in}

{0.022 in}ry shaft adjustment shimt the thinnest allowable shim from the table to obtain standard clearance.

g amount.08 mm {0.0010.003 in}g from step 9: 0.57 mm {0.022 in}cting range

m {0.022 in}+0.03 mm {0.001 in})(0.57 mm {0.022 in}+0.08 mm {0.003 in})=0.60 mm {0.024 .65 mm {0.026 in} {0.024 in}

shimmm{in}

0.25 {0.010} 0.30 {0.012} 0.35 {0.014}0.45 {0.018} 0.50 {0.020} 0.55 {0.022}0.65 {0.026} 0.70 {0.028}

A6E5112M074

Z4F5112M075

MANUAL TRANSAXLE 11. Install the SST and a pull scale or torque wrench.

12. Adjust theobtain the

Note Read

to tu Mea

aver

Preload0.5 Nm

Reading 5 N {0.5

13. Use a feeselector fo

14. Add 0.15 clearanceclosest in

Example0.32 mm

0.32in}=0

Nea{0.019

Thickness of

15. Remove t16. Remove t17. Remove t

0.1 {0.004}0.35 {0.014}0.55 {0.022}0.75 {0.030}0.95 {0.037}1.15 {0.045}

1732-1E-02C.book 33 J33

J

clearance of the SST (selector) to specified preload/pull scale reading.

the preload when the differential starts rn.sure several times and calculate the age value.

{5.0 kgfcm, 4.3 inlbf}on pull scale kgf, 1.1 lbf}ler gauge to measure the gap in the r the differential.

mm{0.006 in} to the measured and select the combination of shims value to that measurement.

{0.013 in} mm {0.013 in}+0.15 mm {0.006

.47 mm {0.019 in}rest shim (on thick side) to 0.47 mm in} is 0.50 mm {0.020 in} shim

mm{in}

he transaxle case and the SST.he selectors, the primary shaft component, and the differential.he bearing races.

0.20 {0.008} 0.25 {0.010} 0.30 {0.012}0.40 {0.016} 0.45 {0.018} 0.50 {0.020}0.60 {0.024} 0.65 {0.026} 0.70 {0.028}0.80 {0.031} 0.85 {0.033} 0.90 {0.035}1.0 {0.039} 1.05 {0.041} 1.10 {0.043}

1.20 {0.047}

Z4F5112M076

Z4F5112M077

Z4F5112M078

J34

MANUAL TRANSAXLE 18. Install the adjustment shim(s) and install the

bearing race using a suitable pipe.

Caution Use the adjustment shim(s) selected

duri

19. Install thebearing ra

Caution Use

duri

20. Set the prdifferentia

21. Install thespecified

Tightenin37.35

ftlbf}

22. Install the23. Verify tha

If not

Preload1.41.9

Reading 1419

24. Remove t

25. With the tthe figuregear com

26. Verify tha If not

Preload0.120

inlbf}Reading

1.23.9

27. Remove tgear com

1732-1E-02C.book 34 ng bearing preload adjustment.

adjustment shim(s) and install the ce using a suitable pipe.

the adjustment shim(s) selected ng bearing preload adjustment.

imary shaft gear component and the l into the clutch housing. transaxle case, and tighten to the torque.

g torque2.0 Nm {3.85.3 kgfm, 27.538.3

SST and a pull scale or torque wrench.t the preload is within the specification.as specified, return to Step 1.

Nm {1420 kgfcm, 1317 inlbf}on pull scaleN {1.42.0 kgf, 3.14.4 lbf}he SST.

ransaxle facing in the direction shown in , install the SST to the primary shaft ponent.t the preload is within the specification.as specified, return to Step 1.

.39 Nm {1.24.0 kgfcm, 1.053.47 on pull scale N {0.120.40 kgf, 0.270.88 lbf}

he SST, transaxle case, primary shaft ponent and differential.

A6E5112M079

A6E5112M103

A6E5112M080

A6E5112M081

A6E5112M082

MANUAL TRANSAXLE 28. Install the secondary shaft gear component and transaxle case, then tighten to the specified torque.

Tightening torque37.352.0 Nm {3.85.3 kgfm, 27.538.3 ftlbf}

29. Install the30. Verify tha

If not

Preload0.20.3

inlbf}Reading

23 N

31. Remove t

End Of Sie

1732-1E-02C.book 35 J35

J SST and a pull scale or torque wrench.t the preload is within the specification.as specification, return to Step 1.

Nm {2.04.0 kgfcm, 1.83.4 on pull scale{0.20.4 kgf, 0.50.8 lbf}he SST and transaxle case.

Z4F5112M083

J36

MANUAL TRANSAXLE CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS ASSEMBLY


1 Oil pas2 Oil sea

(See J3 Adjustm4 Bearing

(See JNote)

5 Adjustm6 Bearing

(See JAssem

7 Drain p8 Revers9 Revers

10 Bearing(See JNote)

11 Oil sea(See J

12 Hole co13 Bleathe

1732-1E-02C.book 36 A6E5112M112

sagel (differential)37 Oil Seal (Differential) Assembly Note)ent shim(s) race (differential)37 Bearing Race (Differential) Assembly

ent shim(s) race (transaxle case)37 Bearing Race (Transaxle Case)

bly Note)lug and washere levere lever shaft race (differential)37 Bearing Race (Differential) Assembly

l (differential)37 Oil Seal (Differential) Assembly Note)ver

r

14 Bleather cover component15 Control rod16 Selector17 Roll pin18 Change arm19 Sealing cap20 Guide plate component21 Funnel22 Bearing race (secondary shaft)23 Oil seal (primary shaft)

(See J38 Oil Seal (Primary Shaft)Assembly Note)24 Bearing race (primary shaft)25 Boots 26 Shift lever component27 shift lever shaft28 Key29 Control end 30 Spring and washer31 Clank component lever

MANUAL TRANSAXLE

Oil Seal (Differential) Assembly Note1. Apply transaxle oil to the new oil seal lip.2. Install the

Bearing Rac1. Install the

bearing ra

Bearing Rac1. Install the

bearing ra

Oil Seal (Cha1. Apply tran2. Install the

Outer dia26.0 mm

32 O-ring33 Crank lever shaft

1732-1E-02C.book 37 J37

J oil seal using the SST.

e (Differential) Assembly Note adjustment shim(s) and install the ce using a suitable pipe.

e (Transaxle Case) Assembly Note adjustment shim(s) and install the ce using a suitable pipe.

nge Rod Component) Assembly Notesaxle oil to the new oil seal lip. oil seal using a suitable pipe.

meter of pipe {1.02 in}

Z4F5112M085

A6E5112M079

A6E5112M103

A6E5112M086

J38

MANUAL TRANSAXLE Oil Seal (Primary Shaft)Assembly Note1. Apply transaxle oil to outer circumference of the oil seal.2. Install the new oil seal using a suitable pipe.

End Of Sie5TH/REVERS1. Assemble

1732-1E-02C.book 38 E GEAR AND HOUSING PARTS ASSEMBLYA6E511201029M06

in the order shown in the figure..

A6E5112M088

A6E5112M119

MANUAL TRANSAXLE

Clutch Hous1. Assemble2. Assembly

1 Clutch housing(See J39 Clutch Housing Assembly Note)

2 Control rod3 Control end4 1st/2nd5 Contro6 Interloc7 3rd/4th8 Clutch 9 Clutch

10 Synchr11 Differen12 Second

(See JSecond

13 Primary(See JSecond

14 Push p15 Shift fo

(See JAssem

16 Crank l(See JLever S

17 Crank l(See JLever S

18 Pin19 5th/rev

(See JRevers

20 5th/reverse shift rod(See J41 5th/Reverse Shift Rod End and 5th/Reverse Shift Rod Assembly Note)

21 Reverse idle gear(See J41 Reverse Idle Gear and Reverse Idle

1732-1E-02C.book 39 J39

J

ing Assembly Note the SST. clutch housing on the SST.

shift forkl leverk lever shift forkhubhub sleeveonizer key springstial componentary shaft gear component40 Primary Shaft Gear Component and ary Shaft Gear Component Assembly Note) shaft gear component40 Primary Shaft Gear Component and ary Shaft Gear Component Assembly Note)

inrk and shift rod component40 Shift Fork and Shift Rod Component

bly Note)ever component40 Crank Lever Component and Crank haft Assembly Note)

ever shaft40 Crank Lever Component and Crank haft Assembly Note)

erse shift rod end41 5th/Reverse Shift Rod End and 5th/e Shift Rod Assembly Note)

Shaft Assembly Note)22 Reverse idle shaft

(See J41 Reverse Idle Gear and Reverse Idle Shaft Assembly Note)

23 Magnet24 Transaxle case component

(See J41 Transaxle Case Component Assembly Note)

25 Neutral switch26 Back-up light switch27 Lock bolt, ball and spring28 Guide bolt29 Lock bolt30 Secondary 5th gear

(See J42 Secondary 5th Gear Assembly Note)31 Gear sleeve32 5th gear33 5th synchronizer ring34 5th/reverse clutch hub component

(See J42 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note)

35 5th/reverse shift fork(See J42 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note)

36 Locknut (secondary shaft)(See J42 Locknut Assembly Note)

37 Locknut (primary shaft)(See J42 Locknut Assembly Note)

38 Rear cover

A6E5112M108

J40

MANUAL TRANSAXLE Primary Shaft Gear Component and Secondary Shaft Gear Component Assembly Note1. Install the primary shaft gear component and the secondary shaft gear component together.

Shift Fork and Shift Rod Component Assembly Note1. Shift to 2nd gear and position the shift fork and

shift rod c

2. Insert thelever shafscraper so

3. With the escraper, wdirection ogoes into line up wiclutch hou

4. Set each and tap thball goes grooves in

5. Pull the bathe steel b

Crank Lever 1. Fit the cra

lever.2. Aligh the p

clutch hou

1732-1E-02C.book 40 omponent as shown.

spring seat and spring into the reverse t, install the steel ball, and place a that it contacts the steel ball.dge of the control end against the hen the control end is pushed in the f the arrow in the figure so that the ball

the shaft, the rod will at the same time th the shift rod coupling hole in the sing.

clutch hub sleeve to the neutral position, e shift rod from above so that the steel into the center groove (of the three the control end).ll part of the control end forward so that all goes into the detent in the groove.

Component and Crank Lever Shaft Assembly Notenk lever between the change arm and the control end, and connect the crank lever shaft to the crank

in holes of the crank lever shaft and the sing, and insert a new pin.

A6E5112M091

Z4F5112M092

A6E5112M093

A6E5112M094

MANUAL TRANSAXLE 5th/Reverse Shift Rod End and 5th/Reverse Shift Rod Assembly Note

Note The mark (indicated by the arrow in the

figure) and the shift rod end mounting bolt hole

1. Install shitighten the

Tightenin11.81

inlbf}

Reverse Idle1. Install the2. Attach the3. Aligh the

control levthe reversshown in

Transaxle Ca1. Apply a th

transaxle

Tightenin37.35

2. Install theshaft hole

1732-1E-02C.book 41 J41

J must be aligned.ft rod end 1 and the shift rod 2, and gate mounting bolt.

g torque3.7 Nm {120140 kgfcm,105121

Gear and Reverse Idle Shaft Assembly Note reverse idle gear and the reverse idler shaft. magnet to the clutch housing.

end of the interlock sleeve with the er (arrow), and at the same time, face e idle shaft screw hole in the direction the figure.

se Component Assembly Notein coat of sealant to the contact surfaces of the clutch housing and transaxle case, and tighten the case installation bolts to the specified torque.

g torque2.0 Nm {3.85.3 kgfm, 2838 ftlbf} SSTs through the drive shaft and joint .

Z4F5112M095

Z4F5112M096

Z4F5112M097

J42

MANUAL TRANSAXLE Secondary 5th Gear Assembly Note1. Install the secondary 5th gear as shown.

5th/Reverse 1. Install the

the 5th/re

Locknut Ass1. Shift to 1s2. Lock the p3. Tighten n

secondary

Tightenin127.5

ftlbf}4. Stake the

5. Measure dial indica If not

Clearanc0.100

Maximum0.270 m

End Of Sie

1732-1E-02C.book 42 Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note 5th/reverse clutch hub component and verse shift fork together.

embly Notet gear.rimary shaft using the SST.

ew lock nuts onto the primary and shafts.

g torque205.8 Nm {13.020.0 kgfm, 95144

locknuts.

the 5th gear thrust clearance using a tor.as specified, reassemble the transaxle.

e0.220 mm {0.00390.0087 in}m {0.0106 in}

A6E5112M098

A6E5112M099

A6E5112M100

A6E5112M101

TD

TDTECHNICAL DATA

TECHNICAL DATA ............................................. TD-2MANUAL TRANSAXLE..................................... TD-2

1732-1E-02C.book 1 TD1

TD2

TECHNICAL DATA

MANUAL TRANSAXLEA6E931001029M01

TECHNICAL DATA

Transaxle type

Thrust clearan

Oil clearance

Shift fork and sleeve

Synchronizer r

Reverse idle greverse lever

1732-1E-02C.book 2 Item SpecificationG35M-R

ce

1st gear Clearance (mm {in}) 0.050.28 {0.0020.011}Maximum (mm {in}) 0.33 {0.013}2nd gear Clearance (mm {in}) 0.180.46 {0.0070.018}Maximum (mm {in}) 0.51 {0.020}3rd gear Clearance (mm {in}) 0.050.20 {0.0020.007}Maximum (mm {in}) 0.25 {0.010}4th gear Clearance (mm {in}) 0.170.37 {0.0070.014}Maximum (mm {in}) 0.42 {0.017}5th gear Clearance (mm {in}) 0.1000.220 {0.00400.0086}Maximum (mm {in}) 0.270 {0.0106}

1st gear

1st gear inner diameter (mm {in}) 39.50039.525 {1.5551.556}Secondary shaft outer diameter

(mm {in}) 39.44539.470 {1.5531.554}

Clearance (mm {in}) 0.0300.080 {0.0020.003}

2nd gear

2nd gear inner diameter (mm {in}) 35.01535.035 {1.3781.379}Secondary shaft outer diameter

(mm {in}) 34.94534.905 {1.3761.374}

Clearance (mm {in}) 0.050.09 {0.0020.003}

3rd gear

3rd gear inner diameter (mm {in}) 36.00036.025 {1.4171.418}Primary shaft outer diameter

(mm {in}) 35.94535.970 {1.4151.416}

Clearance (mm {in}) 0.0300.080 {0.0010.003}

4th gear

4th gear inner diameter (mm {in}) 31.00031.025 {1.2201.221}Primary shaft outer diameter

(mm {in}) 30.94530.970 {1.2181.219}

Clearance (mm {in}) 0.0300.080 {0.0010.003}

5th gear

5th gear inner diameter (mm {in}) 34.00034.025 {1.33861.3395}Sleeve outer diameter (mm {in}) 33.94533.970 {1.33651.3373}Clearance (mm {in}) 0.0300.080 {0.00120.0031}

hub

Clearance between 1st/2nd shift fork and hub sleeve

Standard (mm {in}) 0.100.45 {0.0040.017}Maximum (mm {in}) 0.95 {0.037}

Clearance between 3rd/4th shift fork and hub sleeve


Clearance between 5th shift fork and hub sleeve


ingClearance between synchronizer ring and flank surface of gear

Standard (mm {in}) 1.50 {0.059}Maximum (mm {in}) 0.80 {0.031}

ear and Clearance between reverse idle gear bushing and reverse lever

Standard (mm {in}) 0.100.35 {0.0040.013}

maximum (mm {in}) 0.85 {0.033}

TECHNICAL DATA

End Of Sie

Primary shaft gear

Runout (mm {in}) 0.050 {0.0020}max.Bearing preload (Nm {kgfcm, inlbf}) 0.120.39 {1.24.0, 1.053.47}

0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012},

Secondary sha

Differential

Item Specification

1732-1E-02C.book 3 TD3

TD

Preload adjust shims (mm {in}) 0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018}, 0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024}, 0.65 {0.026}, 0.70 {0.028}

ft gear

Runout (mm {in}) 0.015 {0.0006}max.Bearing preload (Nm {kgfcm, inlbf}) 0.20.3 {2.04.0, 1.83.4}

Preload adjust shims (mm {in})0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012}, 0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018}, 0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024},

0.65 {0.026}, 0.70 {0.028}Differential bearing preload (Nm {kgfcm, inlbf}) 1.41.9 {1420, 1317}

Preload adjust shims (mm {in})

0.1 {0.004}, 0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012}, 0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018}, 0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024}, 0.65 {0.026}, 0.70 {0.028}, 0.75 {0.030}, 0.80 {0.031}, 0.85 {0.033}, 0.90 {0.035}, 0.95 {0.037}, 1.0 {0.039}, 1.05 {0.041}, 1.10 {0.043}, 1.15 {0.045},

1.20 {0.047}Backlash of side gear and pinion gear Standard (mm {in}) 0.0500.150 {0.00200.059}

ST

STSPECIAL TOOLS

SPECIAL TOOLS .................................................ST-2MANUAL TRANSAXLE......................................ST-2

1732-1E-02C.book 1 ST1

ST2

SPECIAL TOOLS

MANUAL TRANSAXLEA6E941001029M01

End Of Sie

SPECIAL TOOLS

49 0107 680A

Engine stand

49 FT01 361

Bearing remover

49 F401 366A

Plate

49 B017 207

Attachment G

49 F401 331

Body

49 G030 338

Attachment E

49 B017 102

Preload adapt

1732-1E-02C.book 2 49 G019 0A0

Transaxle hanger set

49 0839 425C

Bearing puller set

46 0636 145

Fan pulley boss puller

498 G030 370

Removing plate

49 G030 795

Oil seal installer

49 G030 440

Primary shaft holder

49 B017 208

Attachment H

49 B017 209

Attachment J

49 F401 335A

Attachment A

49 F401 336B

Attachment B

49 G030 380D

Shim selector set

49 G017 202

Preload adapter

er

49 G030 455

Diff. side gear holder

Retun to main menuGI General InformationJ Manual TransaxleTD Technical DataST Special Tools

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