SECTION 7A - MANUAL TRANSAXLE

1. GENERAL DESCRIPTION

1.1 CONSTRUCTION AND SERVICING

2. DIAGNOSIS

3. ON-VEHICLE SERVICE

3.1 OIL CHANGE

3.2 DIFFERENTIAL SIDE OIL SEAL

Replacement

3.3 GEAR SHIFT CONTROL LEVER AND

CABLE

Removal

Installation

3.4 VEHICLE SPEED SENSOR (VSS)

Removal

Installation

4. UNIT REPAIR OVERHAUL

4.1 TRANSAXLE UNIT COMPONENT

IDENTIFICATION

4.2 TRANSAXLE CASE COMPONENT

IDENTIFICATION

4.3 INPUT AND COUNTER SHAFT

COMPONENT IDENTIFICATION

4.4 GEAR SHIFTER COMPONENT

IDENTIFICATIO

4.5 DIFFERENTIAL COMPONENT

IDENTIFICATION

4.6 TRANSAXLE UNIT

Removal

Installation

4.7 UNIT DISASSEMBLY

Fifth Gears

Gear Shifter, Input Shaft and

Counter Shaft

Right Case

4.8 SUB ASSEMBLY SERVICE

Right Case

Left Case

Input Shaft Assembly

Counter Shaft Assembly

Gear Shifter

Differential Assembly

4.10 UNIT ASSEMBLY

Differential to Left Case

Fifth Gears

Gear Shift and Select Shaft

Assembly

5. REQUIRED SERVICE MATERIAL

6. SPECIAL TOOLS

WARNING:

For vehicles equipped with Supplement Restraint (Airbag) System

• Service on and around the airbag system components or wiring must be performed only by

an authorised HOLDEN retailer. Refer to Section 10B AIRBAG SYSTEM-COMPONENTS AND

WIRING LOCATION VIEW in GENERAL DESCRIPTION in order to confirm whether you are

performing service on or near the airbag system components or wiring. Please observe all

WARNINGS and SERVICE PRECAUTIONS, refer to Section 10B ON-VEHICLE SERVICE before

performing service on or around the airbag system components or wiring. Failure to follow

WARNINGS could result in unintentional activation of the system or could render the system

inoperative. Either or these two conditions may result in severe injury.

• Technical service work must not be started for at least 90 seconds after the ignition switch is

turned to the “LOCK” position and the negative cable is disconnected from the battery. Oth-

erwise, the system may be activated by reserve energy in the Sensing and Diagnostic Module

(SDM).

Techline

1. GENERAL DESCRIPTION

1.1 CONSTRUCTION AND SERVICING

The transaxle provides five forward speeds and on e reverse speed by means of three synchronisers and the

input shaft, the countershaft and the reverse gear shaft. All forward gears are in constant mesh, and the

re v e rs e uses a sliding idler gear arrangement.

The low spee d s ync hroniser i s mo unt ed on the count er shaf t and engages with th e count er shaf t first ge ar or

second gear, while the high speed synchron iser is done on the input shaft and engages with the input shaft

third gear or fourt h gear.

The fifth speed synchroniser on the input shaft is engaged with the fifth gear mounted on the input shaft.

The double cone synchronizing mechanism is provided to the second gear synchrome sh device for high per-

form ance of shifting to second gear.

The countershaft turns the final gear and the differential assembly, thereby turning the front drive shafts which

are attached to the front wheels.

The transf er assembly is attached to the right side of the transaxle differential output.

For servicing, it is necess ary t o use genui ne s eala nt or its equivalent on the mating surfaces of the aluminum

transaxle case. The case fastening bolts must be tightened to the specified torque by means of a torque

wrench. It is also imp or t ant that al l p arts are thoroughl y cleane d wi th cleani ng f luid and ai r dried befo re reas-

sembling.

Further c are must be t aken to adjust t he preload of t he co unter s haft taper roll er bearings. New sy nchroniser

rings are prohibited from being lapped with respectiv e gear cones by using lapping compound bef ore they are

assembled.

Legend

1. 5th speed sleeve & hub 9. I nput shaft 17. Low speed sleeve & hub

2. Input shaft 5th gear 10. Right case 18. Count ers haft 1st gear

3. Input sh aft 4th gear 11. Side cover 19. Fina l gear

4. H igh speed sleeve & hub 12. Countershaft 5th gear 20. Differential case

5. Input shaft 3rd gear 13. Countershaft 4th gear 21. Vehi cle spe ed sensor

6. Left case 14. Countershaft 22. Transf er assembly

7. R everse gear shaft 15. Countershaft 3rd gear

8. R everse idler gear 16. Countershaft 2nd gear

2. DIAGNOSIS

Condition Possible Cause Correction

Gears slipping out of

mesh

Incor rectly adjusted gear shift select control

cables. Adjust

Worn shift fork shaft. Replace

Worn shift fork or synchronis er sleeve. Replace

Weak or damaged locating springs. Replace

Worn bearings on input shaft or countershaft. Replace

Worn chamfered teeth on sleeve and gear. Replace sleeve and gear.

Hard shifting Incorrectly adjusted gear shift select control

cables. Adjust

Inadequate or insuffi cient lubricant. Replenish

Improper clutch pedal free travel. Adjust

Distorted or broken clutch disc . Repl ace

Damaged clutch pressure plate. Replace clutch cover

Worn synchroniser ring. Replace

Worn chamfered tooth on sleeve or gear. Replace sleeve or gear.

Worn gear shift select control cables joint. Replace

Distorted shift sha ft. Repl ace

Noise Inadequate or insufficient lubricant. Replenish

Damaged or worn bearing(s). Replace

Damaged or worn gear(s). Replace

Damaged or worn synchroniser parts. R eplace

3. ON-VEHICLE SERVICE

CAUTION: Do not reuse circlip, spring pin, E-ring, oil

seal, gasket, self locking nut and specified parts.

3.1 OIL CHANGE

1. Before changing or inspecting the oil, raise the vehicle

on a hoist.

2. Check the oil level and the transaxle for leakage.

If a leakage exists, repair it.

3. Remove the drain plug (2) and drain the old oil.

4. Remove the oil level filler plug (3) located near the left

hand drive shaft (1). This will assist in the drainage.

5. Refill the transaxle with the new specified oil up to the

level of the oil level filler plug.

6. Apply sealant to the thread of the drain plug and the oil

level filler plug. Torque them as specified below.

“A”: Sealant - Three Bond No. 1215

NOTE:

• It is highly recommended to use API GL-4 75W-90

gear oil.

• Whenever a vehicle is hoisted for any service work

other than an oil change, be sure to check for oil leak-

age.

3.2 DIFFERENTIAL SIDE OIL SEAL

REPLACEMENT

1. Raise the vehicle and drain the transaxle and the

transfer oil, refer to 3.1 OIL CHANGE.

2. Remove the wheel, then to remove the tie-rod end (1)

remove the split pin (4) and the castle nut (3).

3. Disconnect the tie-rod end from the knuckle (2) using

special tool 09913-65210 (A).

4. Remove the two stabiliser mounting brackets from the

vehicle body refer to Section 3D, 3.2 STABILISER BAR

AND/OR BUSHINGS.

TRANSAXLE OIL LEVEL FILLER PLUG

AND DRAIN PLUG

TO RQUE SPECIFICATION a: 21.0 Nm

TRANSAXLE OIL API GL-4

TRANSAXLE OIL CAPACI TY 2.2 l it res

5. Remove the ball joint bolt and then separate the sus-

pension arm from the knuckle.

6. Separate the transfer from the transaxle assembly,

refer to Section 7D, 4.1 TRANSFER UNIT.

7. Remove the drive shaft joint (1) using two large size

screwdrivers (2), to release the snap ring fitting of the

joint spline at the differential side. Pushing the knuckle

portion outward, detach the drive shaft at the differen-

tial side.

8. Remove the oil seal (1).

9. Using special tool 09913-75510 (A) for left or right

hand and a hammer, install a new oil seal until it

becomes flush with the case surface.

NOTE: When installing the oil seal, face the spring side

inward.

10. Apply grease “A” to the oil seal lip. Check the drive

shaft for smoothness where the oil seal contacts.

“A”: Lithium grease

11. Insert the transfer into the transaxle, refer to

Section 7D, 4.6 TRANSFER UNIT.

12. Insert the drive shaft joint into the differential gear.

CAUTION:

• Be careful not to scratch the oil seal lip while inserting

the drive shaft joint.

• Make sure to seat the snap ring when inserting the

drive shaft joint fully.

• Only use your hands when inserting the joint boot as a

hammer will cause damage.

13. Connect the ball joint with the knuckle and fasten with a

bolt, to specification, refer to Section 3D, 3.3 WHEEL

HUB AND STEERING KNUCKLE.

14. Connect the tie-rod end with the knuckle and fasten

with a new nut, to the specified torque, refer to Section

3D, 3.3 WHEEL HUB AND STEERING KNUCKLE.

15. Install the stab iliser mounti ng brackets, an d fasten the

bolts to the specified torque, refer to Section 3D,

3.2 STABILISER BAR AND/OR BUSHINGS.

16. Replenish the transaxle oil and transfer oil as specified,

refer to 3.1 OIL CHANGE in this Section, then check

the oil seal for leakage.

3.3 GEAR SHIFT CONTROL LEVER AND CABLE

Legend

1. Gear shift control le v er knob 5. Gear select control cable 9. Cab l e brack et bolt

2. Lever boot holder 6. Gear shift control cable

guide nut 10. Cable grommet

3. Gear shift le ver boot 11. E-ring

4. Gear shift control cable

: Apply Lithium grease to connecting

portion of gear shift control cable

7. Gear shift control le ver

assembly Tightening torque

8. Cable mou nting bolt

REMOVAL

1. Remov e the console.

2. Disconn ect the gear shift and the select cont rol cables

from the gear shift control lever assembly.

3. Remove the gear sh ift control cable guide nuts and the

gear shift lever assembly from the body.

4. Disconnect the shift and the select cables from the

transaxle.

5. Remove the E-rings, the cable grommet and the cable

clamp.

6. Remove the shift and the select cables from the body.

INSTALLATION

Reinstallation is the reverse of the removal noting the fol-

lowing:

• Appl y grease to the turning or sliding port ions.

• Tighten all retaining bolts and nuts to the correct t orque

specifications.

3.4 VEHICLE SPEED SENSOR (VSS)

REMOVAL

1. Disconnect the negative cable at the battery.

2. Discon nect the VSS connector (1).

3. Remove the VSS.

CABLE MOUNTING BOLT

TORQUE SPECIFICATION 5.5 Nm

GEAR SHIFT CONTR O L

CABLE GUIDE NUT

TORQUE SPECIFICATION 13.0 Nm

CABLE BRACKET BOLT

TORQUE SPECIFICATION 50.0 Nm

INSTALLATION

1. Check the O-ring (1) and the VSS surface for any

flaws. Apply Lithium grease to the O-ring and install the

VSS into the transaxle and tighten securely. For

inspection and testing refer to Section 6, 2.22 DTC

PO500 (DTC No16) VEHICAL SPEED SENSOR (VSS

MALFUNCTION)

2. Connec t the negative cable at th e batter y.

3. Co nne ct the VSS connector (1).

4. UNIT REPAIR OVERHAUL

4.1 TRANSAXLE UNIT COMPONENT IDENTIFICATION

Legend

1. Eng ine 7. B ackup light switch connec-

tor 13. Clutch housing lower plate

2. Transaxle 14. Transaxle to engine bolts

3. Eng ine left mount ing 8. V S S connect or 15. Transaxle to engine nut

4. Eng ine left mount ing

bracket 9. Transaxle to engine bolts 16. Ground c able

10. Engine left mounting bracket

bolts 17. Clutch housing lower plate bolts

5. Shift & select control

cables 18. Starting motor nut

11. S ta rting mo tor Tightening torque

6. C lutch cable 12. S ta rting mo tor bolt

4.2 TRANSAXLE CASE COMPONENT IDENTIFICATION

Legend

1. Transaxle right case 9. Oil level/filler plug

: Apply sealant Three Bond No. 1 215 to all

around thread par t of plug

2. Transaxle left case

: Apply sealant Three Bond No . 1216B to

mating surface of l eft case and right case. 10. Oil gutter bolt

: Apply sealant Three Bond No. 1216B to

all around thread part of plug

3. Gear shifter assembly

4. Transaxle left case plate

5. Transaxle side cov er

: Apply sealant Three Bond No . 1216B to

mating surface of side cover and left case

11. VSS

12. Oil gutter bolt

: Apply thread lock 1322 to all

around thread par t of bolt

6. Backup light switch

7. O-ring

: Apply Lithium grease to O-ring 13. Left case plate screw

Tightening torque

8. Differential assembly Do not reuse.

4.3 INPUT AND COUNTER SHAFT COMPONENT IDENTIFICATION

Legend

1. Input sha ft 27. Countershaft 1st gear

2. Oil seal

: Apply Lithium grease to oil seal lip 28. 1st gear synchroniser ring

29. Low speed sync hroniser spring

3. Input sha ft right bearing 30. Low speed sleeve & hub

4. Input shaft 3rd gear 31. Low speed synchroniser ke y

5. Needle bearing (resin cage type) 32. Circlip

5-1. Needle bearing (resin cage type) 33. 2nd gear synchroniser outer ring

6. High speed synchroniser ring 34. Needle bearing

(separated steel cage type)

7. High speed synchroniser spring

8. High speed sleeve & hub 34-1. Needle bearing (steel cage type)

Countershaft 2nd gear

9. High speed synchroniser key 35.

10. Circlip 36. Countershaft 3rd gear

11. Input shaft 4th gear 37. 3rd & 4th gear spacer

12. Input shaft left bearing 38. Countershaft 4th gear

13. Input sha ft 5th gear 39. Countershaft left bearing

14. 5th gear spac er 40. Bearin g set shim

15. 5th gear needle bearing

(separated steel cage type) 41. Countershaft 5th gear

42. Countershaft nut

: After tightening nut to specified

torque, stake nut securely

16. 5th speed synchroniser ring

17. 5th synchroniser spring

18. 5th speed sleeve & hub 43. Reverse s haft bolt

: Apply thread lock cem ent 1322 to

thread of bolt.

19. 5th synchroniser key

20. 5th synchroniser hub plate

21. Circlip 44. Washer

22. Reverse gear shaft 45. Centre cone

23. Reverse idler gear 46. 2nd gear synchroniser inner ring

24. Reverse shaft washer Tightening torque

25. Countershaft right bearing Do not reuse

26. Countershaft Apply transaxle oil

4.4 GEAR SHIFTER COMPONENT IDENTIFICATION

Legend

1. Gear shift & se lect shaft 15. Gear s hift interlock bolt

: Apply sealant Three Bond No. 12 15 to bolt

2. 5t h & reverse gear shift cam

3. Gear shift interloc k plate t hread.

4. Gear shift & select lever 16. Reverse gear shift lever bolt

5. S hift cable lever : Apply thread lock 1322 to all around

6. Select cable le v er thread part of bolt

7. Low speed gear shift shaft 17. Guide case

8. High speed gear shift shaft 18. Select le v er shaft bush

9. 5t h & reverse gear shift shaft : Apply Lithium grease to whole area of

10. 5t h & reverse gear shift shaft bush

11. 5th & re v erse gear shift guide shaft 19. Select le ver boss

12. Re verse gear shift arm : Apply Lithium grease to internal and

13. 5t h gear shift fork external diameter

14. 5t h to reverse interlock guide bolt

: Apply sealant Three bond 1215

to bolt th r e a d

Tightening torque

Do not reuse

4.5 DIFFERENTIAL COMPONENT IDENTIFICATION

Legend

1. S ide gea r washer 9. Final gear

2. Differential side pinion gear 10. Final gear bolt

: Apply thread lo ck 1322 all around

thread part of bolt

3. Differential side g ear

4. S ide gea r washer

5. Differential side o il seal

: Apply Lithium grease to oil

seal lip

11. Differential pinion shaft

12. Differential pinion shaft pin

Tightening torque

6. Differential side b eari ng Do not reuse

7. Speed sensor ring Apply transaxle oil

8. Differential case

4.6 TRANSAXLE UNIT

REMOVAL

Under Hood

1. Disconnect the negative cable at the battery.

2. Undo the wiring harness clamps.

3. Disconnect the backup light switch connector, the VSS

connector and the ground transaxle cable.

4. Disconnect the clutch cable from the clutch release

lever and the bracket.

5. Disconnect the gear shift and the select control cables.

6. Remove the water pipe bracket bolts from the tran-

saxle.

7. Remove the transaxle bolts (1).

8. Remove the starter motor.

9. Support the engine by using a lifting device.

On Lift

10. Drain the transaxle oil, refer to 3.1 OIL CHANGE.

11. Drain the transfer oil, refer to Section 7D, 3.1 OIL

CHANGE.

12. Remove the left and the right drive shafts, refer to

Section 4A, 3.1 DRIVE SHAFT ASSEMBLY.

13. Remove the left side of the engine under cover, refer to

Section 6A1, 4.1 ENGINE ASSEMBLY.

14. Remove the clutch housing lower plate, refer to Section

7C, 4.1 CLUTCH COVER, CLUTCH DISC AND

FLYWHEEL.

15. Remove the transfer, refer to Section 7D,

4.1 TRANSFER UNIT.

16. Remove the transaxle to the engine bolt and nut.

17. Lower the vehicle and support the transaxle with a

transaxle jack.

18. Remove the engine left mounting (1) with the bracket

(2).

19. Remove the other attached parts from the transaxle.

20. Move the transaxle out to disconnect the input shaft

from the clutch disc then lower it.

INSTALLATION

CAUTION:

• Care should be taken not to scratch the oil seal lip

with the drive shaft while raising the transaxle.

• Do not hit the drive shaft joint with a hammer when

installing it into the differential gear.

Install the transaxle in the reverse order of removal proce-

dure noting the following:

• For installing the transfer, refer to Section 7D,

4.6 TRANSFER UNIT.

• For the fastener specified torque, refer to

4.1 TRANSAXLE UNIT COMPONENT

IDENTIFICATION in this Section.

•Push in the right and left hand drive shaft joints fully, so

as to engag e the snap rin g on th e shaft with th e differ-

ential gear .

•Fit the wiring harness securely in clamps.

•After connect ing the clutch cable, be sure to adjust the

play correctly, refer to Section 7C, 3.1 CLUTCH

CABLE.

•Fill the transaxle a nd the transfer with oil as specified,

refer to 3.1 OIL CHANGE in this Section.

•Connect the battery and check the function of the

engine, clutch and the transaxle.

4.7 UNIT DISASSEMBLY

FIFTH GEARS

1. Remove the side cover bolts and take off the trans axle

side cov e r.

CAUTION: Care should be taken not to distort the side

cover when removing from the left case.

2. Using s pecial too l 09900-06107 (A), remove the circlip

(1) and then the hub plate (2).

3. Using special tool 09922-85811 (B), drive out the 5th

gear shift fork spring pin (3).

4. Remove the gear shift fork (2), sleeve and hub

assembly (3), synchroniser ring spring, synchroniser

r ing and the 5th gear together. Use a gear puller (1) for

removal if the spline fitting of the hub is tight.

5. Unstake the countershaft nut.

6. Install the input shaft 5th gear (1) and special tool

09927-76010 (C) t o stop the rotation of the shaf ts, and

then remove the countershaf t nut (2).

7. Remove the special tool, the input shaft 5th gear, the

needle bearing of the separated steel cage type and

then the count er shaft 5t h gear. A gear puller (4) would

be necessary if the s pline fitting of the counter shaft 5th

gear (3) is tight.

8. Remove the plate screws (1), take off the left case

plate (2), and the bearing set shim.

GEAR SHIFTER, INPUT SHAFT AND COUNTER

SHAFT

1. Remove the gear shift interlock bolt (1) and the 5th

reverse interlock guide bolt (2) from the transaxle case.

2. Remov e the gear shifter assemb ly (3).

3. Remove the gear shift locating bolts (1) with the

washers, then take out the locating springs and the

steel balls.

4. Remov e the back up light switc h (2).

5. Remove the reverse shaft bolt (1) with the washe r.

6. Remove the case bolts (2) from outside and another

bolt from the clutch housing side.

7. Remove t he left case (3) by tapping the flanges with a

plastic hammer.

8. Remove the reverse gear shaft (1) with the washer (2),

take off the reverse idler gear (3).

9. Remove the reverse gear shift lever bolts (4), and the

re verse gear shift lever (5).

10. Remove the 5th and reverse gear shift guide shaft (6)

together with the 5th and rev erse gear shift shaft (7).

11. Tap the input shaft end with a plastic hammer and

part ially push out as an assembly from the case.

12. Remove the input shaft assembly (1), the counter shaft

assembly (2), the high speed gear shift shaft (3) and

the low speed gear shift shaft (4) as one unit.

13. Remove the count er shaf t left beari ng c up from the l eft

case.

14. Remove the differential side left oil seal also from the

left case .

RIGHT CASE

1. Remove the differential gear assembly (1) from the

right case (2).

2. Remov e the bolt and then pull out the VSS (3).

3. Remove the input shaft right bearing, if fitted in the

r ight case and remove the input shaft oil seal (1) using

specia l tools 09930-30104 (A) and 09923-74510 (B ).

4. Remove the countershaft right bearing cup (2) using

specia l tools 09941-64511 and 09923-30104.

4.8 SUB ASSEMBLY SERVICE

NOTE: B efore instal lation, was h ea ch part and ap pl y the

sp ecified ge ar oil to th e slidi ng faces of the b earin g and

the gear.

RIGHT CASE

1. Install the input shaft oil seal (1) facing its spring side

upward. Use special tool 09951-76010 (A) and a

hammer f or installation and apply grease “B” to oil seal

lip.

“B”: Lithium grease

2. Install the countershaft right bearing cup (2) by using

specia l tools 09924-74510 (B ), 099 25- 68 210 (C) and

a hamm er.

LEFT CASE

1. If the input oil gutter has been removed, install it with

the bolt to which thread lock cement “A” has been

applied.

“A”: Thread lock cement 1322

2. Install the differential side left oil seal (1) by using

special tool 09913-75510 (A) with a hammer . F ace the

spring side inward and insert, until it becomes flush

with the case surface.

3. Appl y grease “B” to the oil seal.

4. Install the counter shaft left bearing cup into the case

bore, by lightly ta pping it with a plastic hammer.

“B”: Lithium grease

INPUT SHAFT ASSEMBLY

Disassembly

1. Remove the input shaft right be aring (2) from the input

shaft (1) by using a bearing puller (3) and a press.

2. Drive out the 5th gear spacer (2), left bearing (3) and

the 4th gear (4) together from the input shaft (1) u sing

a puller (5) and a press.

CAUTION: To avoid the gear tooth from being dam-

aged, support the flat side of the bearing puller.

3. Take out the 4th gear needle bearing and the high

speed synchroniser ring.

OIL GUTTER BOLT (a)

TORQUE SPECIFICATION 10.0 Nm

4. Using circli p pliers, remo ve the circlip (1).

5. Using a puller (4) and a press, drive out the high speed

synchroniser sleeve and the hub assembly (2) together

with the 3rd gear (3), from the input shaft (1).

CAUTION: Make sure to use the flat side of the puller

to avoid causing damage to the 3rd gear tooth.

6. Take out the 3rd gear needle bearing from the shaft.

7. Disassemble the synchroniser sleeve and the hub

assembly.

Inspection and Reassembly

1. Clean a ll the components thoroughly, inspect them for

any abnormality and replace if necessary.

2. If the synchroniser needs to be repaired, check

clearance “a” between the ring (2) and the gear (1).

3. Check each chamfered tooth of the gear, the ring and

the sleeve to determin e the parts to replace.

4. To ensure lubrication, air blow oil holes (1) and make

sure that they are free from any obstruction.

SYNCHRONISER RING AND GEAR

CLEARANCE STANDARD “a”:

SERVICE LIMIT “a”:1. 0 - 1. 4 mm

0.5 mm

5. Fit the high speed synchroniser sleeve (4) to the hub

(3), insert the 3 keys (2) and then the set springs (1).

NOTE:

•No specific direction is assigned to each key, but it is

assigned as the sleeve & hub assembly.

•The size of the high speed synchroniser sleeve, hub,

keys and springs, is between those of the low speed

and the 5th speed ones.

•Synchroniser key installation position: A = B

6. Driv e in the right bearing (1), to the input shaft (2) using

special tool 09913-80113 (A) and a hammer.

7. Install the 3rd gear needle bearing of the resin cage

type, apply oil, then install the 3rd gear (1) and the syn-

chroniser ring (2).

8. Drive in the high speed sleeve and the hub assembly

(3) by using special tool 09913-84510 (C) and a

hammer, facing the long flange side (B) of the hub

towards the 3rd gear [A].

NOTE:

•While press-fitting the sleeve and the hub, make sure

the synchroniser rin g key slots (A) are aligned with the

keys in the sleeve and the hub assembly.

•Check the free rotation of the 3rd gear after press-fit-

ting the sleeve and the hub assembly.

•Synchroniser rings for 3rd and 4th are identical.

[A]: 3RD GEAR SIDE

C: LONG F LAN GE

D: KEY WAY

E: PROJECT END

9. Install the circlip (1) confirming that the circlip is

installed in the groove securely.

10. Install the needle bearing (2) of the steel cage type,

and apply oil.

11. Install the synchroniser ring (3) and the 4th gear (4 ).

12. Press-fit the left bearing (2) using the special tool

09925-9822 1 (C) and a ham me r.

13. Using the same special tool, drive in the 5th gear

spacer (1).

CAUTION: To prevent the 5th gear spacer from being

distorted because of excessive compression, do not

press-fit together with the left bearing.

COUNTER SHAFT ASSEMBLY

Disassembly

1. Drive out the left bea ring cone (2) with the 4t h ge ar (3)

from the counter shaft (1) using a puller (4) and a

press.

CAUTION:

•Use a puller and a press that will bear at least 5 ton

safely.

•To avoid tooth damage, support the 4th gear on the flat

side of the puller .

2. Apply the puller (5) to the 2nd gear (4).

3. Driv e out the 3rd & 4th gear spacer (2), the 3rd gear (3)

together with the 2nd gear from the counter shaft (1) by

using a press.

4. Remove the needle bearing of the separated steel

cage type from the counter shaft.

CAUTION:

•If the compression exceeds 5 ton, release the com-

pression once, reset the puller support and then

continue to press the work again.

•To avoid the gear tooth from being damaged, sup-

port the flat side of the bearing puller.

5. Remove the 2nd synchroniser outer ring, the centre

cone and the inner ring.

6. Using circli p pliers, remo ve the circlip (1).

7. Apply a puller (3) to the 1st gear (2).

8. Drive out the low speed synchroniser sleeve and the

hub assembly (1) with the gear using a press.

CAUTION: To avoid gear teeth from being damaged,

support the flat side of the bearing puller.

9. Disassemble the synchroniser sleeve and the hub

assembly.

10. Remove the needle bearing from the shaft.

11. Remove the right bearing cone (2) using a puller (3),

metal stick (1) and a press.

Inspection and reassembly

1. Clean a ll the components thoroughly, inspect them for

any abnormality and replace if necessary.

2. If the synchroniser needs to be repaired, check

clearance “a” between the ring (2) and the gear (1).

3. Check each chamfered tooth of the gear, the ring and

the sleeve to determin e the parts to replace.

SYNCHRONISER RING AND GEAR

CLEARANCE STANDARD “a”:

SERVICE LIMIT “a”:1. 0 - 1. 4 mm

0.5 mm

4. Assemble the synchroniser outer ring (1), the inner ring

(3) and the cone (2) together then measure the step

difference between the outer ring and the inner ring.

5. Check the gear teeth and the synchroniser ring and

replace if worn or damaged.

6. To ensure lubrication, blow air blow through the oil

holes (1) and make sure that they are free from any

obstruction.

7. Fit the low speed synchroniser sleeve (4) to the hub

(3), inser t 3 keys (2) and then the set springs (1).

NOTE:

•No specific direction is assigned to each key but it is

assigned as a slee ve and hub assembly.

•The size of the low speed synchroniser keys and

springs are larger, than those of the high speed and

the 5th speed synchroniser keys .

•Synchroniser key installation position: A = B

8. Install the right bearing cone (1) to the counter shaft (2)

using special tool 09923-78210 (A) and a hammer.

9. Install the needle bea ring of t he resin c age type. Apply

oil, then install the 1st gear and the 1st gear synchro-

niser ring.

SYNCHRONISER RING AND GEAR

CLEARANCE STANDARD “a”:

SERVICE LIMIT “a”:1. 0 - 1. 4 mm

0.5 mm

[A]: 1ST GEAR SIDE

C: KEY WAY

D: SHORT FLANGE

10. Driv e in the low speed sleev e and t he hub assembly (1)

by using special tools 09923-78210 (A), 09925-18011

(B), 09940-53111 (C) and a hammer. Face the “B”

side of the sleeve towards the 1st gear.

NOTE:

•Suppo rt the shaf t with the special tool, shown in figure,

so that the retainer of the bearing cone (4) will be free

from compression.

•Make sure that the synchroniser ring (2) and the key

slots are aligned with the keys while press-fitting the

sleeve and the hub assembly.

•Check free rotation of the 1st gear (3) after press-fitting

the sleeve and hub assembly.

•A: Align key slots with the keys.

11. Install the circlip (1) confirming that the circlip is

installed in the groove securely.

12. Install the needle bearing (2) of the separated steel

cage type and apply oil.

13. Assemble the synchroniser outer ring (3), the centre

cone (4) and the inner ring (5), and install to the 2nd

gear (6), refer [A]: Section A-A.

14. Press-fit the 3rd gear (2) and the spacer (1) by using

specia l tools 09923-78210 (A ), 099 13- 80 113 (D) and

a press.

CAUTION: Press-fit the 3rd gear and the spacer first,

and then the 4th gear separately so that the counter

shaft will not be compressed excessively.

15. Press-fit the 4th gear (2) using t he same procedure as

the above.

16. Install the left bearing cone (1) using special tools

09923-7821 0 (A), 099 25-982 21 (E) and a hammer.

NOTE: For the protection of the right bearing cone (3),

always support the shaft with special tools as shown in

the figure.

GEAR SHIFTER

Gear Shift and Select Shaft Assembly

1. Push the spring pins out using specified spring pin

removers 09922-85811 (A) 4.5 mm, 09925-78210

(B) 6.0 mm, Commercially available spring pin

remover (C) 2.8 - 3.0 mm.

2. Inspect component parts for wear, distortion or

damage. If required, replace any defective parts.

NOTE:

•When dr iving in t he spring pin s, prevent the shaft from

being bent by supporting it with a wood block.

•Assemble the 5th and the reverse gear shift cam with

the pit and the spring pin aligned.

•Make sure to select an appropriate spring by identify-

ing the painted c olours to keep the gear shifting perfor-

mance as designed.

•Low speed select spring - No paint

•Reverse select spring - Pink

Legend

1. E-ring 10. Spr ing pin

2. Washer 11. Ball

3. Reverse select spring 12. Gear shift & select shaft

4. Blank 13. 5th & rev erse gear shift cam

5. Gear sh ift inte rlo ck plate 14. Spr ing pin

6. Ball 15. C am guide retur n sprin g

7. Gear shift interlock spring 16. 5th & reverse gear shift cam guide

8. Gear sh ift & select lever 17. Spr ing pin

9. Spr ing pin 18. Low speed select spr ing

High Speed and Low Speed Gear Shift Shafts

Inspection

1. Using a feeler gauge, check the clearance between the

fork (1) and the sleeve (2) and replace those par ts if it

exceeds the limit below.

NOTE:

For correct judgement of parts replacement, carefully

inspec t the contact port ion of the fork and the sleeve.

2. Insert each gear shift shaft into the case and check

that it moves smoothly. If it doesn’t, correct using an

oilstone, reamer or the like.

5th & Reverse Gear Shifter

1. Disassemble component parts using special tool

09922-85811 (A) and a hammer.

2. Replace or c orrect the part s as requi red and as semble

the shafts makin g sure that the component parts are in

the correct order as shown in the fi gure.

NOTE:

•Distinguish the reverse gear shift ar m spring (Blue) (2)

from the low speed locating spri ng (Yellow).

•Install the 2 s teel b alls (3) in the reverse gear shi ft ar m

(1) without fail.

•Drive in the spring pin for the reverse shift ar m, facing

the slit (A) toward the front.

Legend

FORK AND SLEEVE CLEARANCE

SERVICE LIMIT “a”: 1.0 mm

1. 5th & rev erse gear shift yoke 5. Snap ring

2. Bal l 6. P in

3. 5th & rev erse gear shift guide shaft 7. Ball

4. Reverse gear sh ift arm 8. R everse gear shift ar m spring

DIFFERENTIAL ASSEMBLY

Disassembly

1. Using special tools 09913-60910 (A), 09925-88210

(B) remove the right bearing (1) and the sensor rotor

(2).

2. Remove the left bearing in the same manner.

3. Support the differential case (1) with a soft jawed vise

and remov e the final gear bolts.

4. Take out the final gear (2).

5. Drive out the differential pinion shaft (3) pin using

special tool 09922-85811 (C) and a hammer, then dis-

assembl e the component parts.

Adjustment and reassembly

Judging from any abnormalities noted before disassembly

and what is found through a visual i nspection of the compo-

nent parts after disassembly, prepare to replace the parts

and proceed to reassembly. Ensure that all parts are clean.

1. Assemble the differential gear and measure the thrust

play of the differential gear as follows.

Left side

•Hold the differential assembly with a soft jawed vise

and apply the measuring tip of the dial gauge 09900-

20607 (A) and stand 09900-20701 (B) to the top sur-

face of the gear.

•Using two screwdrivers (1), move the gear (2) up and

down and read the movement of the dial gauge pointer.

DIFFERENTIAL GEAR THRUST PLAY 0.03-0.31 mm

Right side

•As in the previous procedure, set the dial gauge tip

09900-20607 (A) and the stand 09900-20701 (B) to

the gear (1) shoulder.

•Move the gea r up and down by hand and read the di al

gauge.

2. If the thrust play is out of specification, select a suitable

thru st washer from the fo llowing available size.

3. Install the t hrust washer and rec heck that the spec ified

gear play is obtained.

4. Drive in a new differential pinion shaft pin (2) until the

depth from the differential case (3) surface, is about 1

mm.

5. Press-fit the new sensor rotor (1) with the groove (4)

side downward as shown, using special tools 09913-

75510 (A), 09940-54910 (B) and a copper hammer.

6. Press-fit the left bearing using special tools 09951-

76010 (C), 09951-16060 (D) and a co pper ham mer.

7. Support the differential assembly (1) as illustrated, so

the left bearing (2) is floating, then press-fit the right

bearin g (3) like the left bearing in Step 6.

THRUST WASHER THICKNESS

0.90 mm, 0.95 mm , 1. 00 mm, 1.05 mm , 1. 10 mm, 1.15 mm

1.20 mm .

8. Hold the differential assembly with a soft jawed vise

(3), install the final gear (2) as shown in figure, then

tighten the bolts (1) with the thread lock cement “A”

applied to specified torque.

NOTE: Make sure to install the final gear in the correct

installing direction.

“A”: Lock thread cement 1322

CAUTION: Use of any bolts other than those speci-

fied is prohibited.

4.10 UNIT ASSEMBLY

DIFFERENTIAL TO LEFT CASE

Assembly

1. Install the differential assembly (1) into the right case

(2).

2. Insert t he VSS (3) with Lithiu m grease applied to its O-

r ing, then tighten it with bolt.

3. Assemble the input shaft (5), the countershaft (4), the

low speed gear s hift sha ft (2) and the high speed gear

shift shaft (3) together, then install them into the right

case (1).

CAUTION: Take care not to damage the oil seal lip

when installing the input shaft, or oil leakage may

take place.

NOTE:

•The input shaft right bearing on the shaft can be

installed into the right case by tapping the shaft with a

plastic hammer.

•Check to make sure that the counter shaft is engaged

with the final gear when installing.

FINAL GEAR BOLT (a)

TORQUE SPECIFICATION 90 Nm

4. Install the 5th and the reverse gear shift shaft (1) with

the 5th and reverse gear shift guide shaft (2) into the

r ight case (5). The reverse gear shift arm (4) has to be

joined with the reverse gear shift lever (3) at the same

time.

5. Install the reverse gear shift lever, fasten it with bolts

after applying thread lock cement “A”

“A”: Lock thread cement 1322.

NOTE: When installing the reverse gear s hift lever, set it

as the following specification.

NOTE:

•Distance (b) can be measured by provisionally install-

ing the reverse gear shaft.

•When (b) is 5 mm, clearance between the reverse idler

gear groove and the shift lev er end will be 1 mm.

6. Make the reverse idler gear (1) with the reverse gear

shift lever (2), inser t the reverse gear shaf t (3) i nto the

case through the idler gear and then align the “A” in the

sh a ft w i t h th e “B” in the case.

NOTE:

•Make sure that the washer (4) has been installed in the

shaft above the gear.

•Check to confirm the reverse gear shift lever end has

clearance 1 mm (0.04 in.) to th e idler g ear groove.

7. Clean the mating surfaces of both the right case (2)

and the left case (1).

8. Using a 1.5mm in diameter bead of sealant “B” apply to

the right case and attach to the lef t case .

“B”: Sealant - Three Bond No. 1215

9. Tighten t he cas e bol ts (3) from the le ft case s ide to the

specified torque.

10. Install the reverse shaft bolt (4), to which thread lock

cement “A” have been applied with aluminum washer

and tighten it.

“A”: Thread lock cement 1322

11. Install another case bolts from the clutch housing side

and tighten them to specification.

REVERSE GEAR SHIFT LEVER BOLT (a)

TO RQUE SPECIF ICATION 23 Nm

DISTANCE BETWEEN LEVER END &

SHAFT BORE (b) 5 mm

TRANSAXLE CASE BOLT (b)

TORQUE SPECIFICATION 19 Nm

REVERSE SHAFT BOLT (c)

TORQUE SPECIFICATION 23 Nm

12. Che ck the locating spr ing for deterioration and rep lace

with a new one as necessar y.

13. Install the steel ball (4) and the locating spring for the

respective gear shift shaft. Fit the washer (2) and

tighten the bolt (1) to which sealant has to be applied to

its thread part

Sealant - Three Bond No. 1215.

FIFTH GEARS

1. To seat the countershaft left bearing cup (1) to the

bearing cone, tap the cup using special tool 09913-

84510 (A) and a plastic hammer.

2. Provisionally place a shim (2) on the bearing cup (3),

place a straight edge (1) over it and compress it by

hand throu gh the straight edge, and then mea sure “a”.

(Clearance between the case surface (4) and the

straight edge) by using a feeler gauge (5).

3. By repeating the above step, select a suitable shim

which adjusts the clearance “a” to the specification and

place on the bearing cup.

NOTE: Insert a 0.15 mm feeler gauge, to know whether

or not a shim fulfills the specification quickly.

LOCATING SPRING FREE LENGTH

LO W SPEED (3) AND

5th & REVERSE (6) STANDARD

SERVICE LIMIT 26.1 mm

25.0 mm

HIGH SPEED (5) STANDARD

SERVICE LIMIT 40.1 mm

39.0 mm

LOCATING SPRING BOLT (d)

TORQUE SPECIFICATION 13.0 Nm

CLEARANCE BETWEEN CASE SUR-

FACE & STRAIGHT EDGE (SHIM PRO-

TRUSION) “a”0.13 - 0.17 m m

AVAILABLE SHIM THICKNESS

0.40 mm, 0.45 mm , 0. 50 mm, 0.55 mm , 0. 60 mm, 0.65 mm

0.70 mm, 0.75 mm, 0.80 mm, 0.85 mm, 0.90 mm, 0.95 mm,

1.00 mm , 1.05 mm, 1.10 mm, 1.15 mm.

4. Inserting the end of the left case plate (4) in the groove

of the shift gui de shaft (6). Tighten with a new s crew (1)

and bolts (2) with adhesive, pre-coated temporarily

with less than specified torque.

CAUTION: Do not reuse the left plate screw and bolts.

Be sure to use new screws and bolts with adhesive

pre-coated. Otherwise, screw may loosen.

5. Finally, tighten the new screw and the bolts to the

specified torque in the order of the circled numbers

shown in figure.

NOTE: After tightening the screw, and the bolts, make

sure that the countershaft (3) can be rotated by hand

feeling some load.

6. Assemble the 5th speed synchroniser sleeve (4) and

the hub (3) with the keys (2) and the springs (1).

NOTE: The short side (C) [A] in the keys, the long flange

(D) in the hub and the chamfered spline (E) in the sleeve

should face inward (5th gear side).

7. Install the 5th gear (1) to the counter shaft, facing the

machined boss (A) inward.

8. Install the needle bearing of the separated steel cage

type to the input shaft, apply oil then install the 5th gear

(1) and special tool 09927-76010 (B) to stop the shaft

rotation.

9. Install the new countershaft nut (2) and tighten to the

specification.

LEFT CASE PLATE SCREW & BOLT (a)

TORQUE SPECIFICATION 11.0 Nm

SYNCHRONISER KEY INSTALLATION

POSITION A = B

COUNTERSHAFT NUT (b)

TORQUE SPECIFICATION 60.0 Nm

10. Remove the special tool, then stake the nut at (C) with

a staking tool and a hammer.

11. Install the synchroniser ring (2).

12. Fit th e 5th gear s hift fork (1) t o the s leeve an d the hub

assem bly (3) and install them into the input shaft. Shift

the shaft and the shift guide shaft at one aligning the

hub oil groove (A) with the shaft mark (B).

NOTE: The long flange of the hub faces inward (gear

side).

13. Using special tool 09922-85811 (B), dr ive the new pin

(3) into the 5th gear shift f ork.

14. Using special tool 09900-06107 (A), fit the hub plate

(2) and fix with a circlip (1).

15. Clean the mating surface of both the left case (2) and

the side cover (1).

16. Using a 1.5mm in diameter bead of sealant 9 “B” apply

to the side cover and attach to the left case.

“B”: Sealant - Three Bond No. 1216B

17. Tighten the case bolt.

SIDE COVER No. 1 BOLTS (a)

TORQUE SPECIFICATION 10.0 Nm

SIDE COVER No. 2 BOLTS (b)

TORQUE SPECIFICATION 23.0 Nm

GEAR SHIFT AND SELECT SHAFT ASSEMBLY

1. Clean the mating surface of the guide case.

2. Appl y grease “A” to the s ele ct lever shaft bush and the

select lever boss. Install the gear shift and the select

shaft assem bly with a new gasket into the transaxle.

“A”: Lithium grease

3. Apply sealant to the gear shift guide case No. 2 bolt

(5). Tighten the gear shift guide case No. 1 bolts (1)

and the No. 2 bolt (5) to the specified torque at the

position that clearance “a” is within 1 - 1.5 mm.

4. Install the washe r and the gear shift inter lock bo lt (2) to

which sealant “B” has been appl ied and then tighten it

to the specified torque.

“B”: Sealant - Three Bond No. 1215

5. Install the washer and the 5th t o reverse interlock guide

bolt (3), to which sealant “B” has been applied and

then tighten it to the specified torque

“B”: Sealant - Three Bond No. 1215

6. Tighten the backup light switch (1) to the specified

torque.

7. Check the input shaft f or rotation in each gear position.

8. Also confirm the function of the back up light switch in

reverse position using the ohmmeter.

GUIDE CASE BOLT (a)

TORQUE SPECIFICATION 23.0 Nm

GEAR SHIFT INTERLOCK BOLT (a)

TORQUE SPECIFICATION 23.0 Nm

5th TO REVERSE INTERLOCK BOLT (a)

TORQUE SPECIFICATION 23.0 Nm

BACKUP LIGHT SWITCH (b)

TORQUE SPECIFICATION 19.0 Nm

5. REQUIRED SERVICE MATERIAL

6. SPECIAL TOOLS

NOTE: Refer to Section 0A GENERAL INFORMATION – 7. CONSOLIDATED TOOLS for a detailed list of

special tools and the local equivalent if one is available.

Material Recommended product Use

Lithium grease Lithium grease •Oil seal lips

•O-rings

•Select lever boss

•Select lever shaft bush

•Gear shift contro l cable end

Sea lant Three Bon d No. 1216B •Oil drain plug and filler/level plug

•M ating surface of transa xle case

•M ating surface of side cover

•Gear shift interlock bolt

Sea lant Three Bon d No. 1215 •Locating spring bolts

•Gear shift interlock bolt

•5th to revers e gear interlock guide

bolt

Thread lock cement THRE AD LOCK 1322 •Reverse gear shift lever bolts

•Oil gutter bolt

•Shift fork bolt

•Reverse shaft bolt

•Final gear bolts

09900-06107 09900-20607 09900-20701 09913-60910

Snap ring pliers

(Opening type) Dial gauge Magneti c stand Bearing puller

09913-75510 09913-80113 09913-84510 09922-85811

Bearing installer Bearing installer Bearing installer Spring pin remover

4.5 mm

09923-74510 09923-78210 09924-74510 09925-18011

Bea ring remover Beari ng installer I nsta ller attachment Bearing installer

09925-68210 09925-78210 09925-88210 09925-98221

Bear ing outer ra ce

installer Spring pin remover 6 mm Bearing puller attachment Bearing installer

09927-76010 09930-30104 09940-53111 09940-54910

Gear holder Sliding shaft Bearing installer Sensor rotor installer

09941-64511 09951-16060 09951-76010

Bearing remover Bush remover Bearing installer