• MANUAL TRANSMISSION


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  • FileName: MT.pdf [preview-online]
    • Abstract: main shaft using a press and the inserter. CAUTION: Do not reuse 3rd main gear. 10. Install 3rd-4th main ... 3rd gear bushing onto counter shaft using a press and the. inserter. 14. Install 3rd-4th coupling sleeve and ...

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MANUAL TRANSMISSION
C TRANSMISSION/TRANSAXLE
A
SECTION
MANUAL TRANSMISSION
MT B
MT
D
E
CONTENTS
PRECAUTIONS ......................................................... 2 . SHIFT CONTROL .................................................... 13 . F
Caution .................................................................... 2
. Removal and Installation ....................................... 13 .
Precautions for Battery Service ............................... 2 . REMOVAL .......................................................... 13
.
PREPARATION .......................................................... 3 . INSTALLATION .................................................. 15 . G
Special Service Tools .............................................. 3 . INSPECTION AFTER INSTALLATION ............... 17 .
Commercial Service Tool ........................................ 6 . AIR BREATHER HOSE ........................................... 18 .
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ....................................... 18 .
H
TROUBLESHOOTING ............................................... 7 . TRANSMISSION ASSEMBLY ................................. 19 .
NVH Troubleshooting Chart .................................... 7 . Removal and Installation from Vehicle .................. 19 .
MANUAL TRANSMISSION .................................. 7 . REMOVAL .......................................................... 19
.
DESCRIPTION ........................................................... 8. INSTALLATION .................................................. 21 . I
Cross-Sectional View .............................................. 8 . Component Parts Drawing .................................... 22 .
DOUBLE-CONE SYNCHRONIZER ..................... 8 . CASE COMPONENTS ....................................... 22 .
TRIPLE-CONE SYNCHRONIZER ....................... 9 . GEAR COMPONENTS ...................................... 23 . J
M/T OIL .................................................................... 10
. SHIFT CONTROL COMPONENTS .................... 25 .
Replacement ......................................................... 10. Disassembly and Assembly ................................... 27 .
DRAINING .......................................................... 10. DISASSEMBLY .................................................. 27 .
K
FILLING .............................................................. 10
. INSPECTION AFTER DISASSEMBLY ............... 38 .
Checking ............................................................... 10
. ASSEMBLY ........................................................ 43.
OIL LEAKAGE AND OIL LEVEL ........................ 10 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 61 .
REAR OIL SEAL ......................................................11 . General Specifications ........................................... 61 . L
Removal and Installation ........................................11 . End Play ................................................................ 61
.
REMOVAL ...........................................................11 . Snap Rings ............................................................ 62
.
INSTALLATION ...................................................11 . Baulk Ring Clearance ............................................ 63 . M
POSITION SWITCH ................................................. 12 .
Checking ............................................................... 12
.
COMPONENT LOCATION ................................. 12 .
BACK-UP LAMP SWITCH ................................. 12 .
NEUTRAL POSITION SWITCH ......................... 12 .
MT-1
PRECAUTIONS
PRECAUTIONS PFP:00001
Caution ACS004YE
q Do not reuse transmission oil, once it has been drained.
q Check oil level or replace oil with vehicle on level ground.
q During removal or installation, keep inside of transmission clear of dust or dirt.
q Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
q In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
q Be careful not to damage sliding surfaces and mating surfaces.
Precautions for Battery Service ACS006DA
Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
MT-2
PREPARATION
PREPARATION PFP:00002
A
Special Service Tools ACS004YF
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
B
(Kent-Moore No.)
Tool name
ST30911000 q Main shaft bearing installation MT
( — ) q 5th-6th synchronizer assembly installation
Inserter
a: 98 mm (3.86 in) dia. q Reverse main gear bushing installation
D
b: 40 mm (1.57 in) dia. q 3rd gear bushing installation
q 3rd-4th synchronizer assembly installation
ZZA0920D
E
ST30022000 q 3rd main gear installation
( — ) q 4th main gear installation
Inserter
a: 110 mm (4.33 in) dia. F
b: 46 mm (1.81 in) dia.
G
ZZA0920D
ST27861000 q 1st-2nd synchronizer assembly installation
( — ) q 1st gear bushing installation
Support ring H
a: 62 mm (2.44 in) dia.
b: 52 mm (2.05 in) dia.
I
ZZA0832D
ST33400001 Rear oil seal installation
(J26082) J
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
K
ZZA0814D
KV381054S0 Remove rear oil seal L
( — )
Oil seal puller
M
ZZA0601D
ST30032000 Counter rear bearing inner race installation
(J26010-01)
Inserter
a: 80 mm (3.15 in) dia.
b: 31 mm (1.22 in) dia.
ZZA0920D
MT-3
PREPARATION
Tool number Description
(Kent-Moore No.)
Tool name
KV32102700 Main drive gear bearing installation
( — )
Drift
a: 48 mm (1.89 in) dia.
b: 41 mm (1.61 in) dia.
ZZA0534D
ST23860000 Reverse counter gear installation
( — )
Drift
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
ZZA0534D
ST01530000 Reverse synchronizer assembly installation
( — )
Drift
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
ZZA0534D
ST35291000 Striking rod oil seal installation
( — )
Drift
a: 40 mm (1.57 in) dia.
b: 29.5 mm (1.161 in) dia.
c: 22.5 mm (0.886 in) dia.
SCIA1575E
KV40100630 4th counter gear thrust washer installation
(J26092)
Inserter
a: 67 mm (2.64 in) dia.
b: 38 mm (1.50 in) dia.
ZZA0920D
KV38102100 Front cover oil seal installation
(J25803-01)
Drift
a: 44 mm (2.36 in) dia.
b: 28 mm (1.10 in) dia.
NT084
KV32103300 Reverse synchronizer assembly installation
(J46529)
Press plate
PCIB0165J
MT-4
PREPARATION
Tool number Description
(Kent-Moore No.) A
Tool name
ST30031000 Inner baulk ring support
(J22912-01) B
Puller
MT
ZZC0499D
ST224490000 Hold adapter plate D
( — )
Adapter setting plate
E
ZZC0465D
F
G
H
I
J
K
L
M
MT-5
PREPARATION
Commercial Service Tool ACS004YG
Tool name Description
Puller Each bearing, gear and bushing removal
ZZB0823D
Pin punch Each retaining pin removaland installation
Tip diameter: 6.0 mm (0.24 in) dia.
ZZA0815D
Power tool Loosening bolts and nuts
PBIC0190E
Puller q Reverse synchronizer assembly removal
q Reverse counter gear removal
q Reverse main gear removal
NT077
MT-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
A
NVH Troubleshooting Chart ACS004YH
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts. B
MANUAL TRANSMISSION
MT-10
MT-10
MT-10
MT-22
MT-22
MT-13
MT-25
MT-25
MT-23
MT-23
MT-23
MT-23
Reference page MT
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
D
E
F
SUSPECTED PARTS G
(Possible cause)
SHIFT CONTROL LINKAGE (Worn)
BAULK RING (Worn or damaged)
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
INSERT SPRING (Damaged)
H
GEAR (Worn or damaged)
OIL (Oil level is high.)
GASKET (Damaged)
SHIFT FORK (Worn)
OIL (Oil level is low.)
I
OIL (Wrong oil.)
J
Noise 1 2 3 3
K
Oil leakage 3 1 2 2
Symptoms
Hard to shift or will not shift 1 1 2 2 2
Jumps out of gear 1 1 2 2 L
M
MT-7
DESCRIPTION
DESCRIPTION PFP:00000
Cross-Sectional View ACS004YI
PCIB0672E
1. Front cover 2. Main drive gear 3. 5th-6th synchronizer hub
4. 5th-6th coupling sleeve 5. Transmission case 6. 6th main gear
7. 2nd main gear 8. 1st-2nd synchronizer hub 9. 1st-2nd coupling sleeve
10. 1st main gear 11. 3rd main gear 12. 4th main gear
13. Reverse main gear 14. Reverse coupling sleeve 15. Reverse synchronizer hub
16. Striking rod 17. Counter shaft 18. Filler plug
19. 6th counter gear 20. 2nd counter gear 21. 1st counter gear
22. 3rd counter gear 23. 3rd-4th synchronizer hub 24. 3rd-4th coupling sleeve
25. Drain plug 26. 4th counter gear 27. Reverse idler gear
28. Reverse idler shaft 29. Reverse counter gear 30. Main shaft
31. Rear extension
DOUBLE-CONE SYNCHRONIZER
The 1st, 3rd and 4th gears are equipped with a double-cone synchronizer to reduce the operating force of the
shift lever as shown.
MT-8
DESCRIPTION
TRIPLE-CONE SYNCHRONIZER
The 2nd gear is equipped with a triple-cone synchronizer to reduce the operating force of the shift lever as A
shown.
B
MT
D
PCIB0594E
E
F
G
H
I
J
K
L
M
MT-9
M/T OIL
M/T OIL PFP:KLD20
Replacement ACS004YJ
DRAINING
1. Start the engine and warm up the transmission unit sufficiently.
2. After stopping engine, remove filler plug and drain plug to drain oil.
3. Replace gasket on drain plug with new one. Screw drain plug into transmission case, and tighten to the
specified torque. Refer to MT-22, "CASE COMPONENTS" .
CAUTION:
Do not reuse gasket.
FILLING
1. Fill new oil into the transmission to the level of the filler plug mounting hole.
Oil grade: API GL-4
Viscosity: Refer to MA-9, "Fluids and Lubricants" .
Oil capacity: Approx. 2.9 (3-1/8 US qt, 2-1/2 lmp qt)
2. Replace gasket on filler plug with new one. Screw filler plug into transmission case, and tighten to the
specified torque. Refer to MT-22, "CASE COMPONENTS" .
CAUTION:
Do not reuse gasket.
Checking ACS004YK
OIL LEAKAGE AND OIL LEVEL
q Check if oil is leaking from transmission or around it.
q Check oil level from filler hole as shown in the figure.
CAUTION:
Never start engine while checking oil level.
q When screwing in filler plug with a new gasket, first screw into
the transmission by hand, then tighten to the specified torque.
Refer to MT-22, "CASE COMPONENTS" .
CAUTION:
Do not reuse gasket.
PCIB0268E
MT-10
REAR OIL SEAL
REAR OIL SEAL PFP:33140
A
Removal and Installation ACS004YL
REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
B
2. Remove rear oil seal using oil seal puller.
Tool number : KV381054S0 ( — )
MT
D
E
PCIB0194E
INSTALLATION
1. Apply multi-purpose grease to rear oil seal lip. Drive in rear oil F
seal until the edge is approximately 1.2 - 2.2 mm (0.047 - 0.087
in) above the boss edge using drift.
Tool number : ST33400001 (J26082) G
CAUTION:
q Do not reuse rear oil seal.
q When installing, do not tilt oil seal.
H
I
J
K
L
PCIB0267E
2. Install propeller shaft. Refer to PR-4, "Removal and Installation" . M
CAUTION:
q If lubricant leak has occurred during the repair work, check oil level after finishing work. Refer
to MT-10, "Checking" .
MT-11
POSITION SWITCH
POSITION SWITCH PFP:32005
Checking ACS004YM
COMPONENT LOCATION
PCIB0622E
BACK-UP LAMP SWITCH
q Check continuity.
Gear position Continuity
Reverse Yes
Except reverse No
SCIA0645E
NEUTRAL POSITION SWITCH
q Check continuity.
Gear position Continuity
Neutral Yes
Except neutral No
SCIA0645E
MT-12
SHIFT CONTROL
SHIFT CONTROL PFP:34103
A
Removal and Installation ACS004YN
B
MT
D
E
F
G
H
I
PCIB0689E
1. Insulator 2. Seat 3. Control lever J
4. Control lever spring 5. Guide plate 6. Control lever boot
7. Hole cover 8. Shift knob
K
REMOVAL
1. Remove shift knob with the following procedure.
a. Release metal clips on console boots from center console. Refer L
to IP-11, "Removal and Installation" .
M
PCIB0435E
MT-13
SHIFT CONTROL
b. Lift console boot, and push down hole cover. Set water pump
plier or a suitable tool to control lever.
CAUTION:
Put waste cloth between water pump plier and control lever
assembly to avoid damaging control lever


Use: 0.247