WARNING(US).

fm 1 ページ ２０１０年３月１１日 木曜日 午後１時２８分

WARNING
Servicing 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.
1A09-1U-12A(INDEX).fm 1 ページ ２０１２年１月１３日 金曜日 午前１０時５４分

Manual CONTENTS
Transaxle Title Section

Workshop GENERAL INFORMATION 00

Manual TRANSMISSION/TRANSAXLE 05

C66M-R © 2012 Mazda Motor Corporation

PRINTED IN U.S.A., JANUARY 2012
FOREWORD Form No. 1A09–1U–12A
Part No. 9999–95–C66M–12
This manual explains the service points for
the above-indicated automotive system.
This manual covers all models with the
above-indicated automotive system, not any
one specific model.

In order to do these procedures safely,

quickly, and correctly, you must first read
this manual and any other relevant service
materials carefully.

All the contents of this manual, including

drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.

Mazda Motor Corporation reserves the right

to alter the specifications and contents of
this manual without obligation or advance
notice.

All rights reserved. No part of this book may

be reproduced or used in any form or by any
means, electronic or mechanical—including
photocopying and recording and the use of
any kind of information storage and retrieval
system—without permission in writing.

Mazda Motor Corporation

HIROSHIMA, JAPAN
1A09-1U-12A(INDEX).fm 2 ページ ２０１２年１月１３日 金曜日 午前１０時５４分
1A09-1U-12A.book 1 ページ ２０１２年１月６日 金曜日 午後４時４６分

GENERAL INFORMATION 00SECTION

00-00

Toc of SCT INFORMATION . . . . 00-00

GENERAL
Toc of SCT
00-00 GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00-00–2 Preparation of Tools and
Range of Topics . . . . . . . . . . . . . . . . . . 00-00–2 Measuring Equipment . . . . . . . . . . . . 00-00–6
Service Procedure . . . . . . . . . . . . . . . . 00-00–2 Special Service Tools . . . . . . . . . . . . . . 00-00–6
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–4 Disassembly . . . . . . . . . . . . . . . . . . . . . 00-00–6
Advisory Messages. . . . . . . . . . . . . . . . 00-00–4 Inspection During
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–5 Removal, Disassembly . . . . . . . . . . . . 00-00–6
Conversion From SI Units Arrangement of Parts . . . . . . . . . . . . . . 00-00–7
(Système International d'Unités) . . . . . 00-00–5 Cleaning of Parts . . . . . . . . . . . . . . . . . 00-00–7
Number Of Digits For Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–7
Converted Values . . . . . . . . . . . . . . . . 00-00–5 Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–8
Converted Value Rounding Rubber Parts and Tubing . . . . . . . . . . . 00-00–8
Off And Rounding Up/down . . . . . . . . 00-00–5 Torque Formulas . . . . . . . . . . . . . . . . . 00-00–8
ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00-00–5 Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–8
FUNDAMENTAL PROCEDURES. . . . . . . 00-00–6

End of Toc
WM: GENERAL INFORMATION

00-00–1
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GENERAL INFORMATION
HOW TO USE THIS MANUAL
id000000000100
Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following basic operations:
— Removal/Installation
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
• Simple operations which can be performed easily just by looking at the actual unit (i.e., removal/installation of
parts, cleaning of parts, and visual inspection) have been omitted.

Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
divided into steps. Important points regarding the SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SERVICE
explained in detail and shown in the illustrations.
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}

49 1232 670A

49 H002 671 SHOWS TIGHTENING

TORQUE
49 H032 322 SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.

bpe2ue00000101

00-00–2
1A09-1U-12A.book 3 ページ ２０１２年１月６日 金曜日 午後４時４６分

GENERAL INFORMATION
Repair procedure
1. 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
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also 00-00
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
Procedure ITEM (S)
INDICATES ANY RELEVANT
1
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION REFERENCES WHICH NEED
1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING
"Removal/Installation" 2. Remove the undercover. (See 01-10-4 Undercover Removal)
Portion 3. Remove in the order indicated in the table. INSTALLATION
4. Install in the reverse order of removal.
2 5. Inspect the rear wheel alignment and adjust it if necessary.
"Inspection After SHOWS SPECIAL
Installation" Portion 11 SERVICE TOOL (SST)
9 SST
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION

GREASE
FOR SERVICE 12 SST R

INSTALL THE PARTS BY SHOWS APPLICATION

PERFORMING STEPS 8 43—56 {4.3—5.8, 32—41}
POINTS OF GREASE, ETC.
10
— IN REVERSE ORDER
1—3 44—60 {4.4—6.2, 32—44} 7 R

SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS NON-REUSEABLE PARTS

SST
3
5
6 SHOWS DETAILS
SST
GREASE

4 R
94—116 {9.5—11.9, 69—86}
2 118—156 {12.0—16.0, 87—115} SHOWS TIGHTENING
SHOWS THERE 1 R TORQUE UNITS
ARE REFERRAL
N·m {kgf·m, ft·lbf}
NOTES FOR SERVICE
1 Split pin 7 Split pin
2 Nut 8 Nut
3 Lower trailing link ball joint 9 Upper trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) (See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
4 Bolt 10 Nut
5 Lower trailing link 11 Upper trailing link
6 Dust boot (lower trailing link) 12 Dust boot (upper trailing link)

Lower Trailing Link Ball Joint, Upper Trailing Link 49 T028 304 UPPER TRAILING LINK
Ball Joint Removal Note 49 T028 305 LOWER TRAILING LINK
Remove the ball joint using the SSTs.

SHOWS SPECIAL
SERVICE TOOL (SST)
NO. KNUCKLE

49 T028 303

SHOWS REFERRAL
NOTES FOR
SERVICE
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00-00–3
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GENERAL INFORMATION
Symbols
• 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.
Symbol Meaning Kind

OIL Apply oil New appropriate engine oil or gear oil

BRAKE Apply brake fluid New appropriate brake fluid

FLUID

New appropriate automatic

Apply automatic transaxle/
transaxle/
ATF
transmission fluid
transmission fluid

Apply grease Appropriate grease

GREASE

Appropriate
SEALANT Apply sealant
sealant

Appropriate
P Apply petroleum jelly
petroleum jelly

R Replace part O-ring, gasket, etc.

Use SST or
SST Appropriate tools
equivalent

Advisory Messages
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.

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

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

Note
• A Note provides added information that will help you to complete a particular procedure.

Specification
• The values indicate the allowable range when performing inspections or adjustments.

Upper and lower limits

• The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
End Of Sie

00-00–4
1A09-1U-12A.book 5 ページ ２０１２年１月６日 金曜日 午後４時４６分

GENERAL INFORMATION
UNITS
id000000100400

Electric current A (ampere)

Electric power W (watt)
Electric resistance ohm 00-00
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
Positive pressure kgf/cm2 (kilogram force per square centimeter)
psi (pounds per square inch)
Number of revolutions rpm (revolutions per minute)
N·m (Newton meter)
kgf·m (kilogram force meter)
Torque kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)

Conversion From SI Units (Système International d'Unités)

• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.

Number Of Digits For Converted Values

• The number digits for converted values is the same as the number of significant figures*1 of the SI unit.
• For the torque value, the number of significant figures is, in principle, is 2 digits, in consideration of market
practicalities. However, if the number of decimal places at the upper and lower limits of the converted value
differs, the one with least number of decimal places is used. In addition, if the integer part is 3 digits or more,
the integer part becomes the significant number of figures.
*1 : The number of significant figures is the number of digits from the left-most non-zero digit to the right-most digit
including 0. (Example: 0.12 is 2 digits, 41.0 is 3 digits)

Converted Value Rounding Off And Rounding Up/down

• If there is no tolerance in the SI unit value, after conversion, rounding off is to within the number of significant
digits.
• If there is tolerance in the SI unit value and the figure after conversion indicates the upper limit, the number of
digits is rounded down to within the number of significant figures. If it indicates the lower limit, they are rounded
up to within the number of significant figures.
• Even if the SI unit value is the same, the converted value may differ based on whether that value is the upper or
lower limit.
End Of Sie
ABBREVIATIONS
id000000010100

MTX Manual Transaxle

SST Special Service Tool

End Of Sie
GAIHAN: -

00-00–5
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GENERAL INFORMATION
FUNDAMENTAL PROCEDURES
id000000750100
Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.

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Special Service Tools

• Use special service tools or equivalent when they
are required.
49 SE01 310

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Disassembly
• If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.

bpe2ue00000112

Inspection During Removal, Disassembly

• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.

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00-00–6
1A09-1U-12A.book 7 ページ ２０１２年１月６日 金曜日 午後４時４６分

GENERAL INFORMATION
Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
00-00

bpe2ue00000114

Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.

Warning
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.

bpe2ue00000002

Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, the following parts should be replaced
with new ones:
— Oil seals
— Gaskets
— O-rings
— Lockwashers
— Cotter pins
— Nylon nuts
bpe2ue00000115

• Depending on location:
— Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
— Oil should be applied to the moving
components of parts.
— Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.

bpe2ue00000116

00-00–7
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GENERAL INFORMATION
Adjustment
• Use suitable gauges and testers when making
adjustments.

bpe2ue00000117

Rubber Parts and Tubing

• Prevent gasoline or oil from getting on rubber
parts or tubing.

bpe2ue00000118

Torque Formulas
• When using a torque wrench-SST or equivalent
combination, the written torque must be SST
3
recalculated due to the extra length that the SST 2

or equivalent adds to the torque wrench.

1 0

Recalculate the torque by using the following

1

formulas. Choose the formula that applies to you.

2
3

Torque Unit Formula

N·m N·m × [L/(L+A)]
kgf·m kgf·m × [L/(L+A)]
A L
kgf·cm kgf·cm × [L/(L+A)]
ft·lbf ft·lbf × [L/(L+A)] bpe2ue00000119

in·lbf in·lbf × [L/(L+A)]

A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.

Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie

PROTECTIVE PLATES
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00-00–8
1A09-1U-12A(05-15).fm 1 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

TRANSMISSION/TRANSAXLE 05SECTION

05-15
Toc of SCT TRANSAXLE . . . . . . 05-15
MANUAL SERVICE TOOLS . . . . . . . . . . . 05-60
TECHNICAL DATA . . . . . . . . . . 05-50
Toc of SCT
05-15 MANUAL TRANSAXLE
PRECAUTION. . . . . . . . . . . . . . . . . . . . . . 05-15–2 Clutch Hub (5GR/6GR)
Service Caution. . . . . . . . . . . . . . . . . . . 05-15–2 Removal Note. . . . . . . . . . . . . . . . . . . 05-15–21
TRANSAXLE DISASSEMBLY . . . . . . . . . 05-15–3 Ball Bearing (Clutch Housing Side)
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 05-15–3 Removal Note. . . . . . . . . . . . . . . . . . . 05-15–22
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 05-15–5 PRIMARY SHAFT
TRANSAXLE CASE AND CLUTCH COMPONENT INSPECTION . . . . . . . . . 05-15–22
HOUSING DISASSEMBLY. . . . . . . . . . . 05-15–6 Gear Inspection . . . . . . . . . . . . . . . . . . 05-15–22
Oil Path Removal Note . . . . . . . . . . . . . 05-15–7 Primary Shaft Inspection . . . . . . . . . . . 05-15–22
Oil Seal Removal Note . . . . . . . . . . . . . 05-15–7 Synchronizer Ring Inspection. . . . . . . . 05-15–23
Bearing Outer Race Clutch Hub Component Inspection. . . . 05-15–23
(Differential) Removal Note . . . . . . . . . 05-15–7 PRIMARY SHAFT
SHIFT CONTROL MODULE COMPONENT ASSEMBLY . . . . . . . . . . 05-15–24
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-15–8 Ball Bearing (Clutch Housing Side)
Pin Removal Note . . . . . . . . . . . . . . . . . 05-15–9 Assembly Note . . . . . . . . . . . . . . . . . . 05-15–25
Clip Removal Note . . . . . . . . . . . . . . . . 05-15–10 Clutch Hub (5GR/6GR)
SHIFT CONTROL Assembly Note . . . . . . . . . . . . . . . . . . 05-15–25
MODULE ASSEMBLY . . . . . . . . . . . . . . 05-15–11 Clutch Hub Sleeve Assembly Note. . . . 05-15–25
Oil Seal Assembly Note . . . . . . . . . . . . 05-15–12 Synchronizer Key Assembly Note . . . . 05-15–26
Clip Assembly Note. . . . . . . . . . . . . . . . 05-15–12 Synchronizer Ring Assembly Note . . . . 05-15–26
Pin Assembly Note . . . . . . . . . . . . . . . . 05-15–12 Clutch Hub (3GR/4GR)
REVERSE IDLER GEAR COMPONENT Assembly Note . . . . . . . . . . . . . . . . . . 05-15–27
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 05-15–14 Ball Bearing (Transaxle Case Side)
REVERSE IDLER GEAR COMPONENT Assembly Note . . . . . . . . . . . . . . . . . . 05-15–27
INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-15–15 SECONDARY SHAFT COMPONENT
Reverse idler gear inspection . . . . . . . . 05-15–15 PREINSPECTION . . . . . . . . . . . . . . . . . 05-15–27
Synchronizer ring inspection . . . . . . . . . 05-15–15 Secondary 1st Gear Thrust
Clutch hub component inspection . . . . . 05-15–15 Clearance Inspection . . . . . . . . . . . . . 05-15–27
REVERSE IDLER GEAR Secondary 2nd Gear Thrust
COMPONENT ASSEMBLY . . . . . . . . . . 05-15–16 Clearance Inspection . . . . . . . . . . . . . 05-15–27
Clutch Hub Sleeve Assembly Note . . . . 05-15–17 SECONDARY SHAFT COMPONENT DISASSEMBLY
Shim Assembly Note. . . . . . . . . . . . . . . 05-15–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-15–28
PRIMARY SHAFT COMPONENT Tapered Roller Bearing
PREINSPECTION. . . . . . . . . . . . . . . . . . 05-15–18 (Transaxle Case Side), Secondary
3rd Gear Thrust 4th Gear Removal Note . . . . . . . . . . . 05-15–29
Clearance Inspection . . . . . . . . . . . . . 05-15–18 Secondary 3rd Gear, Secondary
4th Gear Thrust 6th Gear Removal Note . . . . . . . . . . . 05-15–29
Clearance Inspection . . . . . . . . . . . . . 05-15–18 Secondary 5th Gear Removal Note . . . 05-15–29
5th Gear Thrust Tapered Roller Bearing
Clearance Inspection . . . . . . . . . . . . . 05-15–18 (Clutch Housing Side)
6th Gear Thrust Removal Note. . . . . . . . . . . . . . . . . . . 05-15–30
Clearance Inspection . . . . . . . . . . . . . 05-15–19 SECONDARY SHAFT
PRIMARY SHAFT COMPONENT INSPECTION . . . . . . . . . 05-15–30
COMPONENT DISASSEMBLY . . . . . . . 05-15–20 Gear Inspection . . . . . . . . . . . . . . . . . . 05-15–30
Ball Bearing (Transaxle Case Side) Gear sleeve inspection . . . . . . . . . . . . . 05-15–30
Removal Note . . . . . . . . . . . . . . . . . . . 05-15–21 Secondary Shaft Inspection . . . . . . . . . 05-15–31
Clutch Hub (3GR/4GR) Synchronizer Ring Inspection. . . . . . . . 05-15–31
Removal Note . . . . . . . . . . . . . . . . . . . 05-15–21 Clutch Hub Component Inspection. . . . 05-15–32

05-15–1
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MANUAL TRANSAXLE
SECONDARY SHAFT Thrust Washer
COMPONENT ASSEMBLY . . . . . . . . . . 05-15–32 Selection Calculation . . . . . . . . . . . . . 05-15–42
Middle Cone Ring Assembly Note . . . . 05-15–33 DIFFERENTIAL DISASSEMBLY. . . . . . . 05-15–43
Synchronizer Ring Tapered Roller Bearing
(Secondary 1st Gear) Removal Note. . . . . . . . . . . . . . . . . . . 05-15–44
Assembly Note . . . . . . . . . . . . . . . . . . 05-15–34 Ring Gear Removal Note . . . . . . . . . . . 05-15–44
Clutch Hub Assembly Note . . . . . . . . . . 05-15–34 Pin Removal Note . . . . . . . . . . . . . . . . 05-15–45
Gear Sleeve Assembly Note . . . . . . . . . 05-15–35 DIFFERENTIAL ASSEMBLY. . . . . . . . . . 05-15–45
Secondary Shaft Assembly Note . . . . . 05-15–35 Pin Assembly Note . . . . . . . . . . . . . . . . 05-15–46
Clutch Hub Sleeve Assembly Note . . . . 05-15–36 Ring Gear Assembly Note . . . . . . . . . . 05-15–46
Synchronizer Key Assembly Note . . . . . 05-15–37 Tapered Roller Bearing
Synchronizer Ring Installation Note . . . . . . . . . . . . . . . . . 05-15–47
(Secondary 2nd Gear) BEARING PRELOAD ADJUSTMENT. . . 05-15–47
Assembly Note . . . . . . . . . . . . . . . . . . 05-15–37 Primary Shaft Preload Adjustment . . . . 05-15–47
Secondary 2nd Gear Secondary Shaft
Assembly Note . . . . . . . . . . . . . . . . . . 05-15–37 Preload Adjustment . . . . . . . . . . . . . . 05-15–51
Friction Damper (Secondary 2nd Gear) Differential Preload Adjustment . . . . . . 05-15–55
Assembly Note . . . . . . . . . . . . . . . . . . 05-15–38 TRANSAXLE CASE AND
Secondary 5th Gear Assembly Note. . . 05-15–38 CLUTCH HOUSING ASSEMBLY . . . . . 05-15–59
Secondary 6th Gear and Secondary Bearing Outer Race
3rd Gear Assembly Note. . . . . . . . . . . 05-15–39 (Differential) Assembly Note. . . . . . . . 05-15–59
Secondary 4th Gear Assembly Note. . . 05-15–39 Oil Seal Assembly Note . . . . . . . . . . . . 05-15–60
Tapered Roller Bearing TRANSAXLE ASSEMBLY. . . . . . . . . . . . 05-15–60
Assembly Note . . . . . . . . . . . . . . . . . . 05-15–39 Step 1. . . . . . . . . . . . . . . . . . . . . . . . . . 05-15–60
DIFFERENTIAL BACKLASH Step 2. . . . . . . . . . . . . . . . . . . . . . . . . . 05-15–66
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 05-15–40

End of Toc
PRECAUTION
OHM: C66 MANUAL TRANSAXLE

id051500168000

Warning
• Always wear protective eye wear when using compressed air. Otherwise, dirt particles blown off
by compressed air could get into the eyes.

Service Caution
Disassembly
1. Clean the outside of the transaxle using steam and/or degreaser before disassembly.
2. To prevent dust penetration into the transaxle, perform the disassembly in a dust free environment.
3. Clean the disassembled parts using degreaser and dry them using compressed air.
4. Clean the oil holes and oil grooves using compressed air and verify that they are not plugged.
5. Always wear protective eye wear when using compressed air.
6. When disassembling a connecting part of a light-alloy part for the transaxle case, use a plastic hammer.
7. Organize and store the disassembled parts to protect them from dirt.
8. If using a vise, always secure the component using an aluminum plate to prevent component damage.
9. Disassemble while verifying damage, cracks, deformation, scratches, and the assembly condition of each part.

Cleaning
1. Thoroughly wash the exterior of the transaxle using steam or degreaser before disassembly.
2. Clean the removed parts using degreaser and dry them using compressed air. Clean the oil holes and oil
passages using compressed air.

Assembly
1. Before assembly, verify that each part is clean and dried.
2. Apply a sufficient amount of the specified oil (SAE 75W-80, API service GL-4) to moving parts and sliding
surfaces when performing assembly.
3. For parts such as gaskets, springs, or pins which are designated for replacement with every disassembly,
always use a new part.
4. Clean off remaining silicone sealant before applying new silicone sealant.
5. After applying silicone sealant, install the transaxle case before the applied silicone sealant starts to harden,
and wait for 30 min or more before adding oil.
6. When using a vise, always secure the component using an aluminum plate to prevent component damage.
End Of Sie

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MANUAL TRANSAXLE
TRANSAXLE DISASSEMBLY
id051500168100
Step 1
1. Assemble the SST (49 G019 0A0) to the SST (49
0107 680A).

Bolt used
Part No.: 9YA02 A220 or M12×1.75 length 40
mm {1.6 in} 05-15
Tightening torque 49 G019 0A0
88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}

49 0107 680A

bc61um00000001

2. Assemble the MTX to the SST. B

Bolt A
Part No.: 99450 1055 or M10×1.25 length 55
mm {2.2 in}, and nut (M10×1.25)
49 G019 0A0
Bolt A tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}
Bolt B
SST (49 G019 033 part of 49 G019 0A0) A
C
Bolt B tightening torque A
88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}
Bolt C
Part No.: 9YA02 1080 or M10×1.5 length 55
mm {2.2 in}
Bolt C tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf} D
Bolt D
Part No.: 99450 1030 or M10×1.25 length 30 bc61um00000126
mm {2.2 in}
Bolt D tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}

05-15–3
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MANUAL TRANSAXLE
3. Remove the parts around the MTX using the procedure shown in the figure. .

10

17 R
R
11

18
R 18
3 18
2

R
5 R 17

6 7

4 9 R
8

12 13
R

14
R R 16
15

bc61um00000127

1 Breather 10 Shift control module

2 Neutral switch 11 O-ring
3 Gasket 12 Oil level plug
4 Plug 13 Gasket
5 Gasket 14 Reverse gear shaft anchor bolt
6 Spring 15 Drain plug
7 Detent ball pin 16 Gasket
8 Back-up light switch 17 Oil seal
9 Gasket 18 Stud bolt

05-15–4
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MANUAL TRANSAXLE
Step 2
1. Disassemble the MTX in the order shown in the figure. .

13
C

B D 05-15
12

D
A 4 5
R
C
R R
5
B 7
5
8
6 R
5 R
6
A
R 10
SELECTIVE
9 2
3
6
11
7
2 6
SELECTIVE
7
7 1

bc61um00000004

Transaxle case component 8 Oil path

1 (See 05-15-6 Transaxle case component removal 9 Reverse idler gear component
note.)
Primary shaft component
2 Shim 10 (See 05-15-6 Primary shaft component, secondary
3 Bearing outer race shaft component removal note.)
4 Magnet 11 Secondary shaft component
5 Shift rod (See 05-15-6 Primary shaft component, secondary
shaft component removal note.)
6 Shift rod end
12 Differential
7 Shift fork
13 Clutch housing component

2. Remove the silicone sealant of the transaxle case component and clutch housing component, and clean all the
parts.

05-15–5
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MANUAL TRANSAXLE
Transaxle case component removal note
1. Tap the locations shown in the figure using a
plastic hammer to remove the transaxle case
component.

bc61um00000005

Primary shaft component, secondary shaft component removal note

1. Remove the primary shaft component and
secondary shaft component as a single unit.
End Of Sie PRIMARY SHAFT SECONDARY SHAFT
COMPONENT COMPONENT

bc61um00000006

TRANSAXLE CASE AND CLUTCH HOUSING DISASSEMBLY

id051500168200
1. Disassemble the transaxle case component and clutch housing component in the order shown in the figure.

SST
7
SELECTIVE 2
5 8

SST
4
7

6
3
10 R
A

1
bc61um00000161

05-15–6
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MANUAL TRANSAXLE
Oil path 6 Dowel pin
1
(See 05-15-7 Oil Path Removal Note.) Bearing outer race (differential)
2 Funnel 7 (See 05-15-7 Bearing Outer Race (Differential)
Oil seal Removal Note.)
3
(See 05-15-7 Oil Seal Removal Note.) 8 Shim
4 Bearing outer race 9 Transaxle case
5 Funnel 10 Clutch housing
05-15

Oil Path Removal Note

1. Remove the oil path.
2. As shown in the figure, verify that the oil path
OIL PATH
connection area is not broken.
• If the oil path connection area is broken,
replace the oil path.

bc61um00000167

Oil Seal Removal Note

1. Remove the oil seal using a flathead screwdriver. OIL SEAL

FLATHEAD
SCREWDRIVER
bc61um00000168

Bearing Outer Race (Differential) Removal Note

1. Remove the bearing outer race (differential) from
the transaxle case using the SST. TRANSAXLE CASE

BEARING
OUTER RACE 49 W032 2A0
bc61um00000008

05-15–7
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MANUAL TRANSAXLE
2. Remove the bearing outer race (differential) from
the clutch housing using the SST.
End Of Sie 49 W032 2A0

BEARING
OUTER RACE

CLUTCH HOUSING

bc61um00000011

SHIFT CONTROL MODULE DISASSEMBLY

id051500170100
1. Disassemble the shift control module in the order shown in the figure.

R
2 10 A

11

9
R
13 1
R
7

2
6 R
14

4 12

R 3

A
bc61um00000102

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MANUAL TRANSAXLE
1 Select lever 7 Switch pin
Pin 8 Shift lever
2
(See 05-15-9 Pin Removal Note.) 9 Interlock sleeve
Clip 10 Control lever component
3
(See 05-15-10 Clip Removal Note.)
11 Holder plate
4 Spring seat
12 Guide plate
5 Spring
13 Oil seal 05-15
6 Washer
14 Control case

Pin Removal Note

1. Secure the shift control module in a vise.

SHIFT CONTROL MODULE

VISE

bc61um00000103

2. Mark the switch pin and interlock sleeve.

SWITCH PIN
Note MARK
• The switch pin has a particular installation
direction.

INTERLOCK
SLEEVE

bc61um00000125

3. Remove the pin (switch pin) using a punch.

SWITCH PIN

PUNCH

PIN
VISE

bc61um00000105

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MANUAL TRANSAXLE
4. Move the shift lever to set the guide pin to the
5GR position of the guide plate.
5GR
POSITION

GUIDE PIN

GUIDE PLATE

SHIFT LEVER

bc61um00000106

5. Remove the pin (control lever component) using a CONTROL LEVER

punch. COMPONENT PUNCH

PIN
VISE

bc61um00000107

Clip Removal Note

1. Move the guide pin to the position shown in the
SPRING SEAT CLIP
figure for the guide plate.
2. Push down the spring seat by hand. GUIDE PLATE
3. Detach the clip.
End Of Sie

GUIDE PIN

bc61um00000108

05-15–10
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MANUAL TRANSAXLE
SHIFT CONTROL MODULE ASSEMBLY
id051500170200
1. Assemble the shift control module using the procedure shown in the figure.

OIL
: APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

7
05-15

R
13 5 A

GREASE
4

GREASE
6 R
SST
2 14
R
8

13
9 R
1

10

11 3

R 12

19—25 {2.0—2.5, 15—18}

A

N·m {kgf·m, ft·lbf}

bc61um00000109

1 Control case 8 Switch pin

Oil seal 9 Washer
2
(See 05-15-12 Oil Seal Assembly Note.) 10 Spring
3 Guide plate 11 Spring seat
4 Holder plate Clip
12
5 Control lever component (See 05-15-12 Clip Assembly Note.)
6 Interlock sleeve Pin
13
7 Shift lever (See 05-15-12 Pin Assembly Note.)

05-15–11
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MANUAL TRANSAXLE
14 Selector lever

Oil Seal Assembly Note

1. Assemble a new oil seal to the control case using
the SST.

49 T032 302

OIL SEAL R

CONTROL CASE

bc61um00000110

Clip Assembly Note

1. Move the guide pin to the position shown in the
SPRING SET CLIP
figure for the guide plate.
2. Push down the spring seat by hand. GUIDE PLATE
3. Assemble the clip.

GUIDE PIN

bc61um00000111

Pin Assembly Note

1. Secure the shift control module in a vise.

SHIFT CONTROL MODULE

VISE

bc61um00000112

05-15–12
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MANUAL TRANSAXLE
2. Align the switch pin and interlock sleeve
markings. SWITCH PIN
MARKING

INTERLOCK
SLEEVE 05-15

bc61um00000142

3. Assemble a new pin (switch pin) using a punch.

SWITCH PIN

PUNCH
PIN

VISE

bc61um00000143

4. Move the control lever component to set the guide

pin to the 5GR position of the guide plate. CONTROL LEVER
COMPONENT

5GR
POSITION

GUIDE PIN

GUIDE PLATE

bc61um00000144

5. Assemble a new pin (control lever component)

using a punch. CONTROL LEVER
COMPONENT PUNCH
End Of Sie

PIN VISE

bc61um00000145

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MANUAL TRANSAXLE
REVERSE IDLER GEAR COMPONENT DISASSEMBLY
id051500168300
1. Disassemble the reverse idler gear component in the order shown in the figure.

R SELECTIVE
1 2 3 4 5 6 7

8 9 10 11 12
bc61um00000012

1 Clip 7 Reverse synchronizer key spring

2 Shim 8 Thrust washer
3 Needle bearing 9 Clutch hub sleeve
4 Friction damper 10 Reverse idler gear
5 Reverse idler gear 11 Thrust washer
6 Synchronizer ring 12 Reverse gear shaft

End Of Sie

05-15–14
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MANUAL TRANSAXLE
REVERSE IDLER GEAR COMPONENT INSPECTION
id051500168400
Reverse idler gear inspection
1. Inspect the gears for damage, wear, or loss.
• If there is any malfunction, replace the reverse idler gear.
2. Inspect for damage and wear on the contact surface of the synchronizer ring.
• If there is any malfunction, replace the reverse idler gear.

Synchronizer ring inspection 05-15

1. Inspect the teeth of the synchronizer ring for damage, wear, or loss.
• If there is any malfunction, replace the synchronizer ring.
2. Inspect the taper surface for wear or loss.
• If there is any malfunction, replace the synchronizer ring.
3. While holding the synchronizer ring and reverse
idler gear with your fingers as shown in the figure,
measure the clearance of the synchronizer ring
REVERSE IDLER
and gear side surface around the entire GEAR
circumference using a thickness gauge.
• If it is less than the minimum specification,
replace the synchronizer ring.
SYNCHRONIZER
Clearance between synchronizer ring and RING
reverse idler gear side THICKNESS GAUGE
Specification: 0.95 mm {0.037 in}
Minimum: 0.49 mm {0.019 in}
bc61um00000013

Clutch hub component inspection

1. Inspect the clutch hub sleeve and clutch hub operation.
• If there is any malfunction, replace the malfunctioning part.
2. Inspect the spline for damage, wear or loss.
• If there is any malfunction, replace the malfunctioning part.
3. While holding the clutch hub sleeve and shift fork
together with your hand as shown in the figure, SHIFT FORK
measure the clearance between the shift fork and CLUTCH HUB
clutch hub sleeve groove using a thickness SLEEVE
gauge.
• If it exceeds the maximum, replace the clutch THICKNESS GAUGE
hub sleeve and shift fork as a set.

Clearance between shift fork and clutch hub

sleeve groove
Specification: 0.225 mm {0.00886 in}
Maximum: 0.40 mm {0.016 in}
bc61um00000014

End Of Sie

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MANUAL TRANSAXLE
REVERSE IDLER GEAR COMPONENT ASSEMBLY
id051500168500
1. Assemble the reverse idler gear component in the order shown in the figure.

OIL
: APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

R SELECTIVE
12 11 10 9 8 7 6

5 4 3 2 1
bc61um00000015

1 Reverse gear shaft 7 Synchronizer ring

2 Thrust washer 8 Reverse idler gear
3 Reverse idler gear 9 Friction damper
Clutch hub sleeve 10 Needle bearing
4
(See 05-15-17 Clutch Hub Sleeve Assembly Note.) Shim
11
5 Thrust washer (See 05-15-17 Shim Assembly Note.)
6 Reverse synchronizer key spring 12 Clip

05-15–16
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MANUAL TRANSAXLE
Clutch Hub Sleeve Assembly Note
1. Assemble the clutch hub sleeve to the reverse REVERSE IDLER GEAR CLUTCH HUB SLEEVE
idler gear.

Note
• The clutch hub sleeve can be assembled to
only the specified position due to the shape
of its spline. Therefore, it is necessary to find 05-15
the position where the clutch hub sleeve can
be assembled smoothly while gradually
rotating the clutch hub sleeve in the rotation
direction.
bc61um00000016

Shim Assembly Note

1. Measure distance A shown in the figure from the A
thrust washer to the needle bearing.
2. Select a shim of the appropriate thickness NEEDLE
referring to the measured values in the table. BEARING
Distance A measured value Appropriate
Equal to or Less than (mm shim thickness
more (mm {in}) {in}) (mm {in})
56.495 {2.2242} 56.525 {2.2254} 3.150 {0.1240}
56.525 {2.2254} 56.575 {2.2274} 3.100 {0.1220} THRUST
WASHER
56.575 {2.2274} 56.625 {2.2293} 3.050 {0.1201}
56.625 {2.2293} 56.675 {2.2313} 3.000 {0.1181}
bc61um00000017
56.675 {2.2313} 56.725 {2.2333} 2.950 {0.1161}
56.725 {2.2333} 56.775 {2.2352} 2.900 {0.1142}
56.775 {2.2352} 56.800 {2.2362} 2.850 {0.1122}

3. Assemble the selected shim.

(1) Align the notch of the shim with the projection
of the friction damper, and assemble the
shim.
End Of Sie SHIM
NOTCH

PROJECTION OF
FRICTION DAMPER

bc61um00000018

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MANUAL TRANSAXLE
PRIMARY SHAFT COMPONENT PREINSPECTION
id051500168600
3rd Gear Thrust Clearance Inspection
1. Adjust the SST (49 0107 680A), point the transaxle case assembly surface of the clutch housing upward, and
then level it.
2. Assemble the primary shaft component to the
clutch housing.
3. Set the dial gauge to the position of the arrow
shown in the figure.
4. Hold the primary shaft component by hand. 3RD GEAR

Note
• To prevent error during the thrust clearance
PRIMARY
measurement, hold the primary shaft SHAFT
component by hand so that the primary shaft CLUTCH HOUSING COMPONENT
component does not move.

5. Move the 3rd gear in the axial direction and

measure the 3rd gear thrust clearance.
• If it exceeds the maximum specification,
inspect the 3rd gear and surrounding parts for
damage and wear and replace the
malfunctioning part. bc61um00000118

3rd gear thrust clearance

Specification: 0.257 mm {0.0101 in}
Maximum: 0.417 mm {0.0164 in}

4th Gear Thrust Clearance Inspection

1. Insert a thickness gauge into the clearance
between the 4th gear and the ball bearing.
2. Rotate the thickness gauge one full rotation along
the primary shaft and measure the 4th gear thrust
clearance.
• If it exceeds the maximum specification,
inspect the 4th gear and surrounding parts for 4TH GEAR
damage and wear and replace the THICKNESS
malfunctioning part. GAUGE

4th gear thrust clearance BALL BEARING

Specification: 0.325 mm {0.0128 in}
bc61um00000119
Maximum: 0.489 mm {0.0193 in}

5th Gear Thrust Clearance Inspection

1. Adjust the SST (49 0107 680A), point the transaxle case assembly surface of the clutch housing upward, and
then level it.
2. Assemble the primary shaft component to the
clutch housing.
3. Set the dial gauge to the position of the arrow PRIMARY
shown in the figure. SHAFT
4. Hold the primary shaft component by hand. COMPONENT

Note
• To prevent error during the thrust clearance 5TH GEAR
measurement, hold the primary shaft
component by hand so that the primary shaft CLUTCH HOUSING
component does not move.

bc61um00000120

05-15–18
1A09-1U-12A(05-15).fm 19 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
5. Move the 5th gear in the axial direction and measure the 5th gear thrust clearance.
• If it exceeds the maximum specification, inspect the 5th gear and surrounding parts for damage and wear
and replace the malfunctioning part.

5th gear thrust clearance

Specification: 0.192 mm {0.00756 in}
Maximum: 0.324 mm {0.0128 in}
05-15
6th Gear Thrust Clearance Inspection
1. Adjust the SST (49 0107 680A), point the transaxle case assembly surface of the clutch housing upward, and
then level it.
2. Assemble the primary shaft component to the
clutch housing.
3. Set the dial gauge to the position of the arrow
shown in the figure.
4. Hold the primary shaft component by hand.
6TH GEAR
Note
• To prevent error during the thrust clearance
PRIMARY
measurement, hold the primary shaft
SHAFT
component by hand so that the primary shaft CLUTCH HOUSING COMPONENT
component does not move.

5. Move the 6th gear in the axial direction and

measure the 6th gear thrust clearance.
• If it exceeds the maximum specification,
inspect the 6th gear and surrounding parts for
damage and wear and replace the
malfunctioning part. bc61um00000121

6th gear thrust clearance

Specification: 0.262 mm {0.0103 in}
Maximum: 0.398 mm {0.0157 in}

End Of Sie

05-15–19
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MANUAL TRANSAXLE
PRIMARY SHAFT COMPONENT DISASSEMBLY
id051500168700
1. Disassemble the primary shaft component as shown in the figure.

R
21

22

20
19
18
16 R
17
15
14
13
12
12
11

16 16

10
9
SST
8 6 R
7 5
4
3 R
SST R
2 1

bc61um00000019

1 Clip 9 Synchronizer ring

Ball bearing 10 3rd gear
2 (See 05-15-21 Ball Bearing (Transaxle Case Side) 11 Holder
Removal Note.)
12 Retaining ring
3 4th gear
13 6th gear
4 Synchronizer ring
14 Synchronizer ring
5 Clutch hub sleeve
15 Clutch hub sleeve
6 Synchronizer key
16 Synchronizer key
7 Clip
17 Clip
Clutch hub (3GR/4GR)
8 (See 05-15-21 Clutch Hub (3GR/4GR) Removal
Note.)

05-15–20
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MANUAL TRANSAXLE
18 Clutch hub (5GR/6GR) 20 5th gear
(See 05-15-21 Clutch Hub (5GR/6GR) Removal Ball bearing
Note.) 21 (See 05-15-22 Ball Bearing (Clutch Housing Side)
19 Synchronizer ring Removal Note.)
22 Primary shaft

Ball Bearing (Transaxle Case Side) Removal Note

1. Set the primary shaft component and SSTs in a 05-15
press as shown in the figure.
2. Disassemble the ball bearing using the press.
49 B032 317
49 0710 520

BALL BEARING R
bc61um00000128

Clutch Hub (3GR/4GR) Removal Note

1. Set the primary shaft component and SST in a 3RD
press as shown in the figure. GEAR CLUTCH HUB
2. Remove from the clutch hub to the 3rd gear as a (3GR/4GR)
single unit using the press.

49 F026 103
bc61um00000129

Clutch Hub (5GR/6GR) Removal Note

1. Set the primary shaft component in a press as
shown in the figure.
2. Remove from the clutch hub to the 5th gear as a
single unit using the press.
CLUTCH HUB
(5GR/6GR)

5TH GEAR

bc61um00000022

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MANUAL TRANSAXLE
Ball Bearing (Clutch Housing Side) Removal Note
1. Set the primary shaft component in a press as
shown in the figure.
2. Remove the ball bearing using the press.
End Of Sie

BALL BEARING R

bc61um00000023

PRIMARY SHAFT COMPONENT INSPECTION

id051500168800
Gear Inspection
1. Inspect the gears for damage, wear, or loss.
• If there is any malfunction, replace the gear.
2. Inspect the gears and synchronizer rings for damage and wear on contact surfaces.
• If there is any malfunction, replace the gear.
3. Measure the inner diameter of the gear using a
cylinder gauge in X and Y directions as shown in
the figure.
• If it exceeds the maximum specification,
replace the gear. X
CYLINDER GAUGE
Inner diameter of gear
Measurement Specification (mm Maximum (mm Y
location {in}) {in})
3rd gear 37.01 {1.4571} 37.02 {1.4575}
GEAR
4th gear 32.81 {1.2917} 32.82 {1.2921}
5th gear 42.01 {1.6539} 42.02 {1.6543} bc61um00000024

6th gear 37.01 {1.4571} 37.02 {1.4575}

Primary Shaft Inspection

1. Inspect the spline for damage and wear.
• If there is any malfunction, replace the primary shaft.
2. Inspect the gear area for damage, wear, and loss.
• If there is any malfunction, replace the primary shaft.
3. Measure the lateral runout of the primary shaft.
(1) Set the primary shaft on V-blocks so that the
V-blocks support the primary shaft journal as
shown in the figure.
(2) Measure the lateral runout of the position V-BLOCK DIAL GAUGE
shown in the figure for the primary shaft using
a dial gauge.
• If it exceeds the maximum specification,
replace the primary shaft.

Lateral runout of primary shaft PRIMARY SHAFT

Maximum: 0.05 mm {0.002 in}
bc61um00000025

05-15–22
1A09-1U-12A(05-15).fm 23 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
4. Measure the outer diameter of the primary shaft
X
using a micrometer. Measurement positions total
eight and are in the X and Y directions, at four
points (A, B, C, and D) as shown in the figure. Y
• If it is less than the minimum specification, D C B A
replace the primary shaft.

Outer diameter of primary shaft 05-15

Measurement Specification Minimum (mm
PRIMARY SHAFT
location (mm {in}) {in})
A: 4th gear MICROMETER
32.77 {1.2902} 32.76 {1.2898}
assembly part
bc61um00000026
B: 3rd gear
36.97 {1.4555} 36.96 {1.4551}
assembly part
C: 6th gear
36.97 {1.4555} 36.96 {1.4551}
assembly part
D: 5th gear
41.97 {1.6524} 41.96 {1.652}
assembly part

Synchronizer Ring Inspection

1. Inspect the teeth of the synchronizer ring for damage, wear, or loss.
• If there is any malfunction, replace the synchronizer ring.
2. Inspect the taper surface for wear or loss.
• If there is any malfunction, replace the synchronizer ring.
3. While holding the synchronizer ring and gear with
your fingers as shown in the figure, measure the THICKNESS GAUGE
clearance of the synchronizer ring and gear side
surface around the entire circumference using a
thickness gauge.
• If it is less than the minimum specification,
replace the synchronizer ring.

Clearance between synchronizer ring and gear SYNCHRONIZER RING

Measurement Specification (mm Minimum (mm
location {in}) {in}) GEAR
Synchronizer ring
0.97 {0.038} 0.32 {0.013} bc61um00000027
(3GR)
Synchronizer ring
1.05 {0.0413} 0.40 {0.016}
(4GR)
Synchronizer ring
1.15 {0.0453} 0.50 {0.020}
(5GR)
Synchronizer ring
1.15 {0.0453} 0.50 {0.020}
(6GR)

Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve and clutch hub operation.
• If there is any malfunction, replace the malfunctioning part.
2. Inspect the spline for damage, wear or loss.
• If there is any malfunction, replace the malfunctioning part.
3. While holding the clutch hub sleeve and shift fork
together with your hand as shown in the figure,
measure the clearance between the shift fork and
clutch hub sleeve groove using a thickness
gauge.
• If it exceeds the maximum, replace the clutch
hub sleeve and shift fork as a set. SHIFT FORK

CLUTCH HUB SLEEVE

THICKNESS GAUGE

bc61um00000028

05-15–23
1A09-1U-12A(05-15).fm 24 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Clearance between shift fork and clutch hub sleeve groove
Measurement location Specification (mm {in}) Maximum (mm {in})
Shift fork (3GR/4GR) 0.225 {0.00886} 0.40 {0.016}
Shift fork (5GR/6GR) 0.225 {0.00886} 0.40 {0.016}

End Of Sie
PRIMARY SHAFT COMPONENT ASSEMBLY
id051500168900
1. Assemble the primary shaft component using the procedure shown in the figure.

R
SST OIL
: APPLY SPECIFIED OIL TO INDIVIDUAL PARTS
2

3
4
SST
5 8 R
6
7
9
10
11
11
12

8 8

13
14
SST
15 18 R
16
17
19
20 R
SST
R
21 22
18

18

bc61um00000029

1 Primary shaft Clutch hub (5GR/6GR)

Ball bearing 5 (See 05-15-25 Clutch Hub (5GR/6GR) Assembly
2 (See 05-15-25 Ball Bearing (Clutch Housing Side) Note.)
Assembly Note.) 6 Clip
3 5th gear Clutch hub sleeve
7
4 Synchronizer ring (See 05-15-25 Clutch Hub Sleeve Assembly Note.)

05-15–24
1A09-1U-12A(05-15).fm 25 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Synchronizer key 16 Clip
8
(See 05-15-26 Synchronizer Key Assembly Note.) Clutch hub sleeve
17
Synchronizer ring (See 05-15-25 Clutch Hub Sleeve Assembly Note.)
9
(See 05-15-26 Synchronizer Ring Assembly Note.) 18 Synchronizer key
10 6th gear (See 05-15-26 Synchronizer Key Assembly Note.)
11 Retaining ring Synchronizer ring
19
12 Holder (See 05-15-26 Synchronizer Ring Assembly Note.)
20 4th gear 05-15
13 3rd gear
14 Synchronizer ring Ball bearing
21 (See 05-15-27 Ball Bearing (Transaxle Case Side)
Clutch hub (3GR/4GR) Assembly Note.)
15 (See 05-15-27 Clutch Hub (3GR/4GR) Assembly
Note.) 22 Clip

Ball Bearing (Clutch Housing Side) Assembly Note

1. Set the primary shaft and new ball bearing, and
the SSTs in a press as shown in the figure.
2. Assemble the ball bearing using the press.
49 F401 331

49 F401 336B
R BALL BEARING

PRIMARY SHAFT
(2ND GEAR)
bc61um00000030

Clutch Hub (5GR/6GR) Assembly Note

1. Set the primary shaft component and SST in a
press as shown in the figure.
KEY GROOVE
2. Align the projection of the synchronizer ring with
the key groove of the clutch hub.
3. Assemble the clutch hub using the press. 49 F401 331

CLUTCH HUB

PROJECTION OF
SYNCHRONIZER RING
PRIMARY SHAFT (2ND GEAR)
bc61um00000031

Clutch Hub Sleeve Assembly Note

1. Align the positioning groove of the clutch hub
sleeve so that it is lined up with the center of the POSITIONING
key groove of the clutch hub, and assemble the GROOVE
clutch hub sleeve. CLUTCH HUB
SLEEVE

CLUTCH HUB
KEY GROOVE

bc61um00000032

05-15–25
1A09-1U-12A(05-15).fm 26 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Synchronizer Key Assembly Note
1. Align with the direction of the synchronizer key as SYNCHRONIZER KEY (3GR/4GR)
shown in the figure, and assemble the clutch hub.

LONG

SHORT

SYNCHRONIZER KEY (5GR/6GR)

LONG

SHORT
bc61um00000033

2. After the synchronizer key is assembled, verify

DETENT BALL
that the detent ball of the synchronizer key is
engaged with the positioning groove of the clutch
hub sleeve.

SYNCHRONIZER
POSITIONING KEY
GROOVE
CLUTCH HUB

CLUTCH HUB SLEEVE

bc61um00000130

Synchronizer Ring Assembly Note

1. Align the projection of the synchronizer ring with SYNCHRONIZER RING (4GR)
the key groove of the clutch hub as shown in the
figure, and assemble the synchronizer ring. PROJECTION

SYNCHRONIZER
RING (6GR)

PROJECTION
KEY GROOVE KEY GROOVE
bc61um00000034

05-15–26
1A09-1U-12A(05-15).fm 27 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Clutch Hub (3GR/4GR) Assembly Note
1. Set the primary shaft component and SST in a
press as shown in the figure. KEY GROOVE
2. Align the projection of the synchronizer ring with
the positioning groove of the clutch hub key. 49 F401 331
3. Assemble the clutch hub using the press.

CLUTCH HUB 05-15

PRIMARY SHAFT
PROJECTION OF (2ND GEAR)
SYNCHRONIZER RING

bc61um00000035

Ball Bearing (Transaxle Case Side) Assembly Note

1. Set the primary shaft component, new ball
bearing, SST, and an appropriate steel plate in a STEEL PLATE
press as shown in the figure. 49 F401 336B
2. Assemble the ball bearing using the press. R BALL BEARING
End Of Sie
PRIMARY SHAFT
(2ND GEAR)

bc61um00000036

SECONDARY SHAFT COMPONENT PREINSPECTION

id051500169000
Secondary 1st Gear Thrust Clearance Inspection
1. Insert a thickness gauge into the clearance
between the secondary 1st gear and the
secondary shaft differential drive gear.
2. Route the thickness gauge one full rotation along
the secondary shaft and measure the secondary
1st gear thrust clearance. SECONDARY 1ST GEAR
• If it exceeds the maximum specification,
inspect the secondary 1st gear and THICKNESS GAUGE
surrounding parts for damage and wear and
replace the malfunctioning part. SECONDARY SHAFT
(DIFFERENTIAL DRIVE GEAR)
Secondary 1st gear thrust clearance
bc61um00000122
Specification: 0.174 mm {0.00685 in}
Maximum: 0.291 mm {0.0115 in}

Secondary 2nd Gear Thrust Clearance Inspection

1. Insert the thickness gauge into the clearance
between the secondary 2nd gear and the
secondary 5th gear.
SECONDARY
2. Route the thickness gauge one full rotation along 5TH GEAR
the secondary shaft and measure the secondary
2nd gear thrust clearance. THICKNESS GAUGE
• If it exceeds the maximum specification,
inspect the secondary 2nd gear and
surrounding parts for damage and wear and SECONDARY
replace the malfunctioning part. 2ND GEAR

Secondary 2nd gear thrust clearance

bc61um00000123
Specification: 0.174 mm {0.00685 in}
Maximum: 0.294 mm {0.0116 in}

End Of Sie

05-15–27
1A09-1U-12A(05-15).fm 28 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
SECONDARY SHAFT COMPONENT DISASSEMBLY
id051500169100
1. Disassemble the secondary shaft component in the order shown in the figure.

R
SST 24
23
22
21
20
19
18

16
17
16
15
14
13
12
11
10

16

9
8 R
7 SST
6 SST
5 R
4 SST
R
3
SST
R
2 1

bc61um00000037

1 Clip Secondary 6th gear

Tapered roller bearing 6 (See 05-15-29 Secondary 3rd Gear, Secondary 6th
2 (See 05-15-29 Tapered Roller Bearing (Transaxle Gear Removal Note.)
Case Side), Secondary 4th Gear Removal Note.) 7 Clip
Secondary 4th gear Secondary 5th gear
8
3 (See 05-15-29 Tapered Roller Bearing (Transaxle (See 05-15-29 Secondary 5th Gear Removal Note.)
Case Side), Secondary 4th Gear Removal Note.) 9 Friction damper
4 Clip 10 Secondary 2nd gear
Secondary 3rd gear 11 Gear sleeve
5 (See 05-15-29 Secondary 3rd Gear, Secondary 6th
Gear Removal Note.) 12 Inner cone ring
13 Middle cone ring
14 Synchronizer ring

05-15–28
1A09-1U-12A(05-15).fm 29 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
15 Clutch hub sleeve 21 Friction damper
16 Synchronizer key 22 Secondary 1st gear
17 Clutch hub Tapered roller bearing
18 Synchronizer ring 23 (See 05-15-30 Tapered Roller Bearing (Clutch
Housing Side) Removal Note.)
19 Middle cone ring
24 Secondary shaft
20 Inner cone ring
05-15

Tapered Roller Bearing (Transaxle Case Side), Secondary 4th Gear Removal Note
1. Set the SSTs and secondary shaft component in
R
a press. TAPERED ROLLER
2. Remove the tapered roller bearing and secondary BEARING
4th gear simultaneously using the press.
SECONDARY 4TH 49 B032 317
GEAR
49 F026 103

bc61um00000038

Secondary 3rd Gear, Secondary 6th Gear Removal Note

1. Set the SST and secondary shaft component in a SECONDARY
press as shown in the figure. 3RD GEAR
2. Remove the secondary 3rd gear and secondary
6th gear using the press.
49 F026 103
SECONDARY
6TH GEAR

bc61um00000039

Secondary 5th Gear Removal Note

1. Set the secondary shaft component in a press as
SECONDARY
shown in the figure. 5TH GEAR
2. Remove all parts from the secondary 5th gear to
the secondary 1st gear simultaneously using the SECONDARY
press. 2ND GEAR

CLUTCH HUB
SLEEVE

SECONDARY
1ST GEAR

bc61um00000040

05-15–29
1A09-1U-12A(05-15).fm 30 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Tapered Roller Bearing (Clutch Housing Side) Removal Note
1. Set the SSTs and secondary shaft component in
a press as shown in the figure. 49 B032 317 R
TAPERED ROLLER
2. Remove the tapered roller bearing using the 49 B017 206 BEARING
press.
End Of Sie

49 F401 366A
bc61um00000041

SECONDARY SHAFT COMPONENT INSPECTION

id051500169200
Gear Inspection
1. Inspect the gears for damage, wear, or loss.
• If there is any malfunction, replace the gear.
2. Inspect the gears and synchronizer rings for damage and wear on contact surfaces.
• If there is any malfunction, replace the gear.
3. Measure the inner diameter of the gear using a
cylinder gauge in X and Y directions as shown in
the figure.
• If it exceeds the maximum specification,
replace the gear. X
CYLINDER GAUGE
Inner diameter of gear
Measurement Specification (mm Maximum (mm Y
location {in}) {in})
Secondary 1st gear 41.512 {1.6343} 41.525 {1.6348}
GEAR
Secondary 2nd
46.534 {1.8320} 46.544 {1.8324}
gear bc61um00000024

Gear sleeve inspection

1. Measure the outer diameter of the gear sleeve
using the micrometer in X and Y directions as MICROMETER
shown in the figure.
• If is less than the minimum specification,
replace the gear sleeve. X

Outer diameter of gear sleeve

Y
Specification: 46.444 mm {1.8285 in}
Minimum: 46.434 mm {1.8281 in}

GEAR SLEEVE

bc61um00000043

05-15–30
1A09-1U-12A(05-15).fm 31 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Secondary Shaft Inspection
1. Inspect the spline for damage and wear.
• If there is any malfunction, replace the secondary shaft.
2. Inspect the gear area for damage, wear, and loss.
• If there is any malfunction, replace the secondary shaft.
3. Measure the lateral runout of the secondary shaft.
(1) Set the secondary shaft on V-blocks so that
the V-blocks support the secondary shaft 05-15
journal as shown in the figure. DIAL GAUGE
V-BLOCK
(2) Measure the lateral runout of the secondary
shaft at the position shown in the figure using
a dial gauge.
• If it exceeds the maximum specification,
replace the secondary shaft.

Lateral runout of secondary shaft SECONDARY SHAFT

Maximum: 0.05 mm {0.002 in}
bc61um00000044

4. Measure the outer diameter of the secondary SECONDARY SHAFT

shaft at the position shown in the figure using a
micrometer. Measurement positions total four and
are in the X and Y directions, at two points (A and A B
B) as shown in the figure.
• If is less than the minimum specification,
replace the secondary shaft. X

Outer diameter of secondary shaft

Y
Specification Minimum
Measurement location
(mm {in}) (mm {in}) MICROMETER
A: Secondary 1st gear 41.445
41.457 {1.6322} bc61um00000045
assembly part {1.6317}
B: Secondary 2nd gear 39.266
39.276 {1.5463}
assembly part {1.5459}

Synchronizer Ring Inspection

1. Inspect the teeth of the synchronizer ring for damage, wear, or loss.
• If there is any malfunction, replace the synchronizer ring.
2. Inspect the taper surface for wear or loss.
• If there is any malfunction, replace the synchronizer ring.
3. While holding the synchronizer ring and gear with
your fingers as shown in the figure, measure the THICKNESS GAUGE
clearance of the synchronizer ring and gear side
surface around the entire circumference using a
thickness gauge.
• If it is less than the minimum specification,
replace the synchronizer ring.

Clearance between synchronizer ring and gear SYNCHRONIZER RING

Measurement Specification (mm Minimum (mm
location {in}) {in}) GEAR
Synchronizer ring
0.94 {0.037} 0.55 {0.022} bc61um00000027
(1GR)
Synchronizer ring
0.94 {0.037} 0.55 {0.022}
(2GR)

05-15–31
1A09-1U-12A(05-15).fm 32 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Clutch Hub Component Inspection
1. Inspect the clutch hub sleeve and clutch hub operation.
• If there is any malfunction, replace the malfunctioning part.
2. Inspect the spline for damage, wear or loss.
• If there is any malfunction, replace the malfunctioning part.
3. While holding the clutch hub sleeve and shift fork
together with your hand as shown in the figure,
measure the clearance between the shift fork and
clutch hub sleeve groove using a thickness
gauge.
• If it exceeds the maximum specification,
replace the clutch hub sleeve and shift fork as SHIFT FORK
a set.
CLUTCH HUB SLEEVE
Clearance between shift fork and clutch hub THICKNESS GAUGE
sleeve groove
Specification: 0.225 mm {0.00886 in}
bc61um00000028
Maximum: 0.40 mm {0.016 in}

End Of Sie
SECONDARY SHAFT COMPONENT ASSEMBLY
id051500169300
1. Assemble the secondary shaft component in the order shown in the figure.
R
SST 8 OIL
: APPLY SPECIFIED OIL TO INDIVIDUAL PARTS
24
1
2
3
4
5

10
6
10
7
9
11
12
13
14

10

15 SST
R
16
17
18
19 R
20 SST
R
21 SST
22 R
23

bc61um00000048

05-15–32
1A09-1U-12A(05-15).fm 33 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
1 Secondary 1st gear Friction damper
2 Friction damper 15 (See 05-15-38 Friction Damper (Secondary 2nd
Gear) Assembly Note.)
3 Inner cone ring
Secondary 5th gear
Middle cone ring 16 (See 05-15-38 Secondary 5th Gear Assembly
4
(See 05-15-33 Middle Cone Ring Assembly Note.) Note.)
Synchronizer ring 17 Clip
5 (See 05-15-34 Synchronizer Ring (Secondary 1st
Gear) Assembly Note.) 18 Secondary 6th gear 05-15
(See 05-15-39 Secondary 6th Gear and Secondary
Clutch hub 3rd Gear Assembly Note.)
6
(See 05-15-34 Clutch Hub Assembly Note.)
Secondary 3rd gear
Gear sleeve 19 (See 05-15-39 Secondary 6th Gear and Secondary
7
(See 05-15-35 Gear Sleeve Assembly Note.) 3rd Gear Assembly Note.)
Secondary shaft 20 Clip
8
(See 05-15-35 Secondary Shaft Assembly Note.)
Secondary 4th gear
Clutch hub sleeve 21 (See 05-15-39 Secondary 4th Gear Assembly
9
(See 05-15-36 Clutch Hub Sleeve Assembly Note.) Note.)
Synchronizer key Tapered roller bearing
10
(See 05-15-37 Synchronizer Key Assembly Note.) 22 (See 05-15-39 Tapered Roller Bearing Assembly
11 Synchronizer ring Note.)
(See 05-15-37 Synchronizer Ring (Secondary 2nd 23 Clip
Gear) Assembly Note.)
Tapered roller bearing
12 Middle cone ring 24 (See 05-15-39 Tapered Roller Bearing Assembly
13 Inner cone ring Note.)
Secondary 2nd gear
14 (See 05-15-37 Secondary 2nd Gear Assembly
Note.)

Middle Cone Ring Assembly Note

1. Assemble the middle cone ring so that the middle
cone ring projection and the groove of the
secondary 1st gear are engaged as shown in the MIDDLE CONE RING
figure. GROOVE OF
SECONDARY
1ST GEAR PROJECTION

bc61um00000169

05-15–33
1A09-1U-12A(05-15).fm 34 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Synchronizer Ring (Secondary 1st Gear) Assembly Note
1. Assemble the synchronizer ring so that the
synchronizer ring projection and the cavity of the PROJECTION
inner cone ring are engaged as shown in the
figure.
2. Verify that the ends of the inner cone ring, middle
cone ring, and synchronizer ring are arranged in a SYNCHRONIZER
RING SYNCHRONIZER RING
flat plane.
PROJECTION

INNER CONE
RING

CAVITY

INNER CONE RING

bc61um00000170

Clutch Hub Assembly Note

1. Assemble the clutch hub to the position shown in
the figure while rotating the clutch hub in the
rotation direction. CLUTCH HUB

bc61um00000051

05-15–34
1A09-1U-12A(05-15).fm 35 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Caution
• When assembling the clutch hub, it is SYNCHRONIZER
necessary to engage the synchronizer A
RING CLUTCH HUB
ring projection, round groove of the
clutch hub, and grooves of the friction
damper and clutch hub. Therefore, rotate
the clutch hub and engage it with each
part. PROJECTION 05-15

ROUND
GROOVE
GROOVE

FRICTION
DAMPER B

PROJECTION
A B

bc61um00000171

Gear Sleeve Assembly Note

1. Assemble the gear sleeve so that the gear sleeve
projection and clutch hub groove are engaged as
GEAR SLEEVE
shown in the figure.

CLUTCH HUB
GROOVE

PROJECTION

bc61um00000172

Secondary Shaft Assembly Note

1. Set the secondary shaft in a press as shown in
the figure.

SECONDARY SHAFT

bc61um00000173

05-15–35
1A09-1U-12A(05-15).fm 36 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
2. Set the secondary shaft with the parts from the
secondary 1st gear to the gear sleeve as a single GEAR
unit. SLEEVE

Caution SECONDARY
• If you take your hand off the secondary 1ST GEAR
1st gear, it will fall off and the assembled
parts will come apart. Therefore, until the
assembled parts are press-fit to the
secondary shaft, lift up and hold the
secondary 1st gear so that each part
does not come apart.

SECONDARY SHAFT

bc61um00000174

3. Set the gear sleeve to the SST.

4. Using a press, press-fit the parts from the
secondary 1st gear to the gear sleeve to the
secondary shaft.

49 F401 331

GEAR SLEEVE

bc61um00000175

Clutch Hub Sleeve Assembly Note

1. Align the positioning groove of the clutch hub
sleeve with the center of the clutch hub key
groove as shown in the figure, and assemble the
clutch hub sleeve. POSITIONING
GROOVE

CLUTCH HUB
SLEEVE

KEY GROOVE

bc61um00000176

05-15–36
1A09-1U-12A(05-15).fm 37 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Synchronizer Key Assembly Note
1. Align with the direction of the synchronizer key as
shown in the figure, and assemble the clutch hub. SYNCHRONIZER
KEY

LONG
05-15

SHORT

bc61um00000177

2. After the synchronizer key is assembled, verify

DETENT BALL
that the detent ball of the synchronizer key is
engaged with the positioning groove of the clutch
hub sleeve.

SYNCHRONIZER
POSITIONING KEY
GROOVE
CLUTCH HUB

CLUTCH HUB SLEEVE

bc61um00000131

Synchronizer Ring (Secondary 2nd Gear) Assembly Note

1. Assemble the synchronizer ring so that the
CLUTCH HUB
synchronizer ring projection and round groove of
the clutch hub are engaged as shown in the
SYNCHRONIZER
figure.
RING
ROUND GROOVE

PROJECTION

bc61um00000178

Secondary 2nd Gear Assembly Note

1. Verify that the ends of the inner cone ring, middle
cone ring, and synchronizer ring are arranged in a GOOD
flat plane.

NO GOOD MIDDLE CONE RING

ARE NOT ENGAGED

bc61um00000056

05-15–37
1A09-1U-12A(05-15).fm 38 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
2. Assemble the secondary 2nd gear so that the
groove of the secondary 2nd gear and middle SECONDARY
cone ring projection are engaged as shown in the 2ND GEAR
figure.

GROOVE

MIDDLE CONE RING PROJECTION

bc61um00000057

Friction Damper (Secondary 2nd Gear) Assembly Note

1. Assemble the friction damper so that the friction
damper projection and the groove of the gear
sleeve are engaged as shown in the figure. GEAR SLEEVE

FRICTION
DAMPER

GROOVE PROJECTION
bc61um00000058

Secondary 5th Gear Assembly Note

1. Set the secondary shaft component, secondary
5th gear, and the SST in a press as shown in the
DIFFERENTIAL
figure.
DRIVE GEAR
49 F401 331

SECONDARY
V-BLOCK 5TH GEAR

bc61um00000059

2. Move the clutch hub sleeve in the axial direction

while pressing the secondary 2nd gear by hand
so that it does not move, and verify that the SECONDARY
synchronizer key is assembled correctly. 2ND GEAR
3. Assemble the secondary 5th gear using the
press.
SYNCHRONIZER
KEY

CLUTCH HUB
SLEEVE

bc61um00000060

05-15–38
1A09-1U-12A(05-15).fm 39 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Secondary 6th Gear and Secondary 3rd Gear Assembly Note
1. Set the secondary shaft component, secondary
6th gear, and secondary 3rd gear in a press as
shown in the figure.
2. Assemble the secondary 6th gear and secondary
3rd gear using the press.

05-15
SECONDARY
6TH GEAR
SECONDARY
3RD GEAR

bc61um00000061

Secondary 4th Gear Assembly Note

1. Set the secondary shaft component and
secondary 4th gear in a press as shown in the
figure.
2. Assemble the secondary 4th gear using the
press.

SECONDARY
4TH GEAR

bc61um00000062

Tapered Roller Bearing Assembly Note

1. Set the secondary shaft component, new tapered
roller bearing (transaxle case side), SST, and an STEELE PLATE
appropriate steel plate in a press as shown in the 49 H027 001
TAPERED ROLLER
figure. BEARING
2. Assemble the tapered roller bearing (transaxle R
case side) using the press.
3. Assemble a new clip.
SECONDARY SHAFT
(DIFFERENTIAL
DRIVE GEAR)

bc61um00000063

4. Set the secondary shaft component, new tapered

roller bearing (clutch housing side), SST, and an STEEL PLATE
appropriate steel plate in a press as shown in the 49 F401 336B
TAPERED ROLLER
figure. BEARING
5. Assemble the tapered roller bearing (clutch R
housing side) using the press.
End Of Sie

bc61um00000064

05-15–39
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MANUAL TRANSAXLE
DIFFERENTIAL BACKLASH ADJUSTMENT
id051500169400
1. Secure the differential in a vice.
DIFFERENTIAL

VISE

bc61um00000067

2. Assemble the drive shaft and the joint shaft to the JOINT SHAFT
differential.

DRIVE SHAFT

DIFFERENTIAL

bc61um00000196

3. Set the dial gauge with the measuring probe

attached perpendicularly to the area shown in the
figure for the pinion gear. PINION GEAR
DIAL GAUGE

DIAL GAUGE

AREA IN WHICH DIAL

GAUGE END IS SET
bc61um00000195

05-15–40
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MANUAL TRANSAXLE
4. Measure the side gear on the joint shaft side and PINION GEAR
the pinion gear backlash using the following
procedure:
(1) Affix the side gear on the joint shaft side by
hand.

05-15

PINION GEAR SIDE GEAR

(JOINT SHAFT SIDE)
bc61um00000197

(2) Measure the backlash by moving the pinion PINION GEAR

gear with the dial gauge that has been set
and determine measured value A.

Caution
• Because a difference occurs in the
backlash measurement value if the
secured side gear moves, move the
pinion gear by hand so that the secured
side gear does not move.
SIDE GEAR
(JOINT SHAFT SIDE)
bc61um00000198

(3) Measure the opposite of the pinion gear SIDE GEAR

backlash in the same way as procedure 2 in (JOINT SHAFT SIDE)
Step 4 and determine measured value B.
(4) Calculate the average value of measured
values A and B using the following formula
and determine the backlash measurement
value on the joint shaft side of the pinion gear.
• (Measured value A + measured value B)/2
= backlash measurement value on joint
shaft side
PINION GEAR
bc61um00000199

5. Measure the side gear on the drive shaft side and PINION GEAR
the pinion gear backlash using the following
procedure:
(1) Affix the side gear on the drive shaft side by
hand.

SIDE GEAR
PINION GEAR
(DRIVE SHAFT SIDE)
bc61um00000200

(2) Measure the backlash by moving the pinion PINION GEAR

gear that the dial gauge has been set and
determine measured value C.

Caution
• Because a difference occurs in the
backlash measurement value if the
secured side gear moves, move the
pinion gear by hand so that the secured
side gear does not move.
SIDE GEAR
(DRIVE SHAFT SIDE)
bc61um00000201

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MANUAL TRANSAXLE
(3) Measure the opposite of the pinion gear SIDE GEAR
backlash in the same way as procedure 2 in (DRIVE SHAFT SIDE)
Step 5 and determine measured value D.
(4) Calculate the average value of measured
values C and D using the following formula
and determine the backlash measurement
value on the drive shaft side of the pinion
gear.
• (Measured value C + measured value D)/
2 = backlash measurement value on drive
shaft side
PINION GEAR
6. Verify that the backlash on the joint shaft and
bc61um00000202
drive shaft sides is within the specification.

Differential pinion gear backlash

Specification: 0.05—0.15 mm {0.002—0.005 in}

• If the measured backlash for each is within the specification, the thrust washer thickness is the same as the
removed one and there is no problem, therefore the "DIFFERENTIAL BACKLASH ADJUSUTMENT"
procedure is finished.
• If not within the specification, perform "Thrust Washer Selection Calculation". (See 05-15-42 Thrust Washer
Selection Calculation.)
• If it exceeds the specification even when a 0.95 mm {0.037 in} thick thrust washer is used, replace the
differential case.

Thrust Washer Selection Calculation

Note
• Perform the thrust washer selection calculation for each on the drive shaft and joint shaft sides.

1. Calculate the backlash gap by subtracting constant number A from backlash measurement value.
• Constant number A = 0.090 mm {0.0035 in}
• Backlash measurement value - 0.090 mm {0.0035 in} = backlash gap
Calculation example
• Backlash measurement value = 0.165 mm {0.00650 in}
• 0.165 mm {0.00650 in} - 0.090 mm {0.0035 in} = 0.075 mm {0.0030 in}
2. Calculate the thrust washer thickness gap by multiplying the backlash gap by constant number B.
• Constant number B = 1.25 mm/mm {1.333 in/in}
• Backlash gap × 1.25 mm/mm {1.333 in/in} = thrust washer thickness gap
Calculation example
• Backlash gap = 0.075 mm {0.0030 in}
• 0.075 mm {0.0030 in} × 1.25 mm/mm {1.333 in/in} = 0.094 mm {0.0037 in}
3. Calculate the thrust washer thickness calculated value by adding the thrust washer thickness gap to the
thickness of the thrust washer used in the measurement.
• Thickness of thrust washer used in measurement + thrust washer thickness gap = thrust washer thickness
calculated value
Calculation example
• Thickness of thrust washer used in measurement = 0.810 mm {0.8103 mm}
• Thrust washer thickness gap = 0.094 mm {0.0037 in}
• 0.810 mm {0.0319 in} + 0.094 mm {0.0037 in} = 0.904 mm {0.0356 in}
4. Calculate the thrust washer thickness on the opposite side in the same way.
5. Based on each thrust washer thickness calculated value, select each thrust washer of the appropriate
thickness.

Caution
• Select the same thickness of the thrust washers on the drive shaft and joint shaft sides.However, if
the measurement value cannot be adjusted within the specification, select the different thickness
of the thrust washer.

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MANUAL TRANSAXLE
Thrust washer thickness calculated value
Appropriate thrust washer thickness (mm {in})
Equal to or more (mm {in}) Less than (mm {in})
0.925 {0.0364} 1.025 {0.04035} 0.95 {0.037}
0.875 {0.0344} 0.925 {0.0364} 0.90 {0.035}
0.825 {0.0325} 0.875 {0.0344} 0.85 {0.033}
0.775 {0.0305} 0.825 {0.0325} 0.80 {0.031}
0.675 {0.0266} 0.775 {0.0305} 0.75 {0.030} 05-15

Selection example
• Because shim thickness calculated value 0.904 mm {0.0356 in} applies to 0.875 mm {0.0344 in} or more and
less than 0.925 mm {0.0364 in}, a shim of 0.90 mm {0.035 in} thickness is selected.

Note
• Constant number A, 0.090 mm {0.0035 in} is the backlash median value of the specification.
• The backlash gap is the difference between the backlash median value of the specification and the
backlash measurement value.
• Constant number B is the thrust washer thickness which varies each time the backlash changes by 1.0
mm {0.039 in}.Because the thrust washer thickness changes 0.1 mm {0.004 in} when the backlash
changes 0.08 mm {0.003 in}, the quotient is 1.25 mm/mm {1.333 in/in}.
• The thrust washer thickness gap is the difference between the thickness of the thrust washer used in the
measurement and the thickness of an appropriate thrust washer.In the formula to calculate the thrust
washer thickness gap, the thrust washer thickness gap is calculated by multiplying the backlash gap with
constant number B.

End Of Sie
DIFFERENTIAL DISASSEMBLY
id051500169500
1. Perform the “DIFFERENTIAL BACKLASH ADJUSTMENT”.(See 05-15-40 DIFFERENTIAL BACKLASH
ADJUSTMENT.)
2. Disassemble the differential in the order shown in the figure.

2 4

SST
1

3 R

1
9 SST
5 6

8 7 6 5 7 8
SELECTIVE SELECTIVE

bc61um00000132

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MANUAL TRANSAXLE
Tapered roller bearing 4 Pinion gear shaft
1 (See 05-15-44 Tapered Roller Bearing Removal 5 Pinion gear
Note.)
6 Pinion gear shaft
Ring gear
2 7 Side gear
(See 05-15-44 Ring Gear Removal Note.)
Pin 8 Thrust washer
3 9 Differential case
(See 05-15-45 Pin Removal Note.)

Tapered Roller Bearing Removal Note

1. Secure the differential in a vice.
DIFFERENTIAL

VISE

bc61um00000067

2. Remove the tapered roller bearing (clutch

housing side) using the SST. TAPERED ROLLER
BEARING
Note GROOVE
• There is a groove in the differential case
component for attaching the SST tab.

49 0839 425C
bc61um00000068

3. Using the SST, remove the tapered roller bearing

(transaxle case side). TAPERED ROLLER GROOVE
BEARING
Note
• There is a groove in the differential case
component for attaching the SST tab.

49 0839 425C
bc61um00000069

Ring Gear Removal Note

1. Secure the differential in a vice as shown in the
RING GEAR
figure.
2. Remove the ring gear bolts.
3. Tap the ring gear using a plastic hammer and
remove the ring gear.

BOLT

VISE

bc61um00000070

05-15–44
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MANUAL TRANSAXLE
Pin Removal Note
1. Remove the pin using a punch.
End Of Sie
PUNCH

05-15
PIN

bc61um00000133

DIFFERENTIAL ASSEMBLY
id051500169600
1. Assemble the differential in the order shown in the figure.
2. Perform the “DIFFERENTIAL BACKLASH ADJUSTMENT”.(See 05-15-40 DIFFERENTIAL BACKLASH
ADJUSTMENT.)

OIL
: APPLY SPECIFIED OIL TO INDIVIDUAL PARTS
8 6

SST
9
152—176 N·m {16—17 kgf·m, 113—129 ft·lbf}

7 R

9
1 SST
5 4

2 3 4 5 3 2
SELECTIVE SELECTIVE
bc61um00000134

1 Differential case 6 Pinion gear shaft

2 Thrust washer Pin
7
3 Side gear (See 05-15-46 Pin Assembly Note.)
4 Thrust washer Ring gear
8
(See 05-15-46 Ring Gear Assembly Note.)
5 Pinion gear

05-15–45
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MANUAL TRANSAXLE
Tapered roller bearing
9
(See 05-15-46 Ring Gear Assembly Note.)

Pin Assembly Note

1. Install a new pin as shown in the figure to hold the
pinion gear shaft. PIN R PUNCH
45°

PIN R
45°
OR
45°

45°
R PIN

bc61um00000135

Ring Gear Assembly Note

1. Assemble the ring gear so that the differential
holes and ring gear holes shown in the figure are
aligned.

azzjjw00001001

2. Secure the differential in a vice.

RING GEAR
3. Install the ring gear by tightening the ring gear
installation bolts in several passes.

Tightening torque
152—176 N·m {16—17 kgf·m, 113—129 ft·lbf}

BOLT

VISE

bc61um00000070

05-15–46
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MANUAL TRANSAXLE
Tapered Roller Bearing Installation Note
1. Set the differential, the tapered roller bearing
(clutch housing side), SST, and an appropriate
STEEL PLATE
steel plate in a press as shown in the figure.
2. Assemble the tapered roller bearing (clutch
housing side) using the press. TAPERED ROLLER
49 UB71 525 BEARING

05-15

bc61um00000074

3. Set the differential, the tapered roller bearing

(transaxle case side), SST, and an appropriate
steel plate to the press as shown in the figure.
4. Assemble the tapered roller bearing (transaxle STEEL PLATE
case side) using the press. TAPERED ROLLER
End Of Sie 49 UB71 525 BEARING

bc61um00000075

BEARING PRELOAD ADJUSTMENT

id051500169700
Primary Shaft Preload Adjustment
1. Measure the thickness of the straight edge which is used for measurements.
2. Measure distance A of the transaxle case using TRANSAXLE CASE
the following procedure.
A A

bc61um00000083

(1) Place two straight edges on the transaxle

case as shown in the figure.
TRANSAXLE
CASE

STRAIGHT EDGE

bc61um00000179

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MANUAL TRANSAXLE
(2) Set up 3 measurement points of your
choosing on the shim assembly area of the MEASUREMENT POINT
transaxle case as shown in the figure.
(3) Using a commercially available depth gauge,
measure the distance to each measurement
point from the straight edge.

Caution
• When measuring the distance to the
measurement point from the straight
edge, do not allow the depth gauge head
to contact the shim assembly area.
bc61um00000180

(4) Calculate the average value measured in

Step 3 using the following formula.
• (Value of first measurement + value of second measurement + value of third measurement) / 3 =
Average measured values.
Calculation example
• Value of first measurement = 224.380 mm {8.83386 in}
• Value of second measurement = 224.381 mm {8.83390 in}
• Value of third measurement = 224.379 mm {8.83382 in}
• (224.380 mm {8.83386 in} + 224.381 mm {8.83390 in} + 224.379 mm {8.83382 in}) / 3 = 224.380 mm
{8.83386 in}
(5) Calculate distance A of the transaxle case using the following formula.
• Average of measured values - straight edge thickness = Distance A
Calculation example
• Straight edge thickness = 5.000 mm {0.1969 in}
• Average of measured values = 224.380 mm {8.83386 in}
• 224.380 mm {8.83386 in} - 5.000 mm {0.1969 in} = 219.380 mm {8.63701 in}
3. Measure distance B of the transaxle case using CLUTCH HOUSING
the following procedure.

bc61um00000181

(1) Set two straight edges on the clutch housing

as shown in the figure.
CLUTCH HOUSING

STRAIGHT EDGE

bc61um00000182

05-15–48
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MANUAL TRANSAXLE
(2) Set up 3 measurement points of your
choosing on the ball bearing assembly area of
the clutch housing as shown in the figure.
(3) Using a commercially available depth gauge,
measure the distance to each measurement
point from the straight edge.

Caution 05-15
• When measuring the distance to the
measurement points from the straight
edge, do not allow the depth gauge head MEASUREMENT POINT
to contact the ball bearing assembly
bc61um00000183
area.

(4) Calculate the average value measured in Step 3 using the following formula.
• (Value of first measurement + value of second measurement + value of third measurement) / 3 =
Average measured values.
Calculation example
• Value of first measurement = 30.575 mm {1.2037 in}
• Value of second measurement = 30.577 mm {1.2038 in}
• Value of third measurement = 30.577 mm {1.2038 in}
• (30.575 mm {1.2037 in} + 30.577 mm {1.2038 in} + 30.577 mm {1.2038 in}) / 3 = 30.576 mm {1.2038
in}
(5) Calculate distance B of the clutch housing using the following formula.
• Average of measured values - straight edge thickness = Distance B
Calculation example
• Straight edge thickness = 5.000 mm {0.1969 in}
• Average of measured values = 30.576 mm {1.2038 in}
• 30.576 mm {1.2038 in} - 5.000 mm {0.1969 in} = 25.576 mm {1.0069 in}
4. Measure distance C of the primary shaft
component using the following procedure.

PRIMARY SHAFT
COMPONENT
c

bc61um00000184

05-15–49
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MANUAL TRANSAXLE
(1) Place two straight edges on the surface plate
as shown in the figure and set the primary
shaft component on top of them.

PRIMARY SHAFT
COMPONENT

STRAIGHT EDGE

SURFACE PLATE
bc61um00000185

(2) Set up 3 measurement points of your

choosing on the ball bearing as shown in the
figure.
(3) Using a commercially available height gauge,
measure the distance to each measurement
point from the straight edge.
(4) Calculate the average of the value measured MEASUREMENT
in Step 3 using the following formula, and use BALL BEARING
POINT
the average of the measured value for
distance C of the primary shaft component.
• (Value of first measurement + value of
second measurement + value of third
bc61um00000186
measurement) / 3 = Distance C
Calculation example
• Value of first measurement = 243.591 mm {9.59020 in}
• Value of second measurement = 243.592 mm {9.59024 in}
• Value of third measurement = 243.593 mm {9.59028 in}
• (243.591 mm {9.59020 in} + 243.592 mm {9.59024 in} + 243.593 mm {9.59028 in}) / 3 = 243.592 mm
{9.59024 in}
5. Select the primary shaft shim using the following procedure.
(1) Calculate the clearance (clearance D) between the transaxle case and the primary shaft component using
the following formula.
• Distance A + Distance B - Distance C = Clearance D
Calculation example
• Distance A = 219.380 mm {8.63701 in}
• Distance B = 25.576 mm {1.0069 in}
• Distance C = 243.592 mm {9.59024 in}
• 219.380 mm {8.63701 in} + 25.576 mm {1.0069 in} - 243.592 mm {9.59024 in} = 1.364 mm {0.05370
in}

05-15–50
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MANUAL TRANSAXLE
(2) Based on the calculated clearance D, select a shim of the appropriate thickness from the following table.
Clearance D measured value Appropriate
Equal to or Less than (mm shim thickness
more (mm {in}) {in}) (mm {in})
1.570 {0.06181} 1.610 {0.06339} 1.550 {0.06102}
1.520 {0.05984} 1.570 {0.06181} 1.500 {0.05906}
1.470 {0.05787} 1.520 {0.05984} 1.450 {0.05709} 05-15
1.420 {0.05591} 1.470 {0.05787} 1.400 {0.05512}
1.370 {0.05394} 1.420 {0.05591} 1.350 {0.05315}
1.320 {0.05197} 1.370 {0.05394} 1.300 {0.05118}
1.270 {0.050} 1.320 {0.05197} 1.250 {0.04921}
1.220 {0.04803} 1.270 {0.050} 1.200 {0.04724}
1.170 {0.04606} 1.220 {0.04803} 1.150 {0.04528}
1.120 {0.04409} 1.170 {0.04606} 1.100 {0.04331}
1.070 {0.04213} 1.120 {0.04409} 1.050 {0.04134}
1.020 {0.04016} 1.070 {0.04213} 1.000 {0.03937}
0.970 {0.0382} 1.020 {0.04016} 0.950 {0.0374}
0.920 {0.0362} 0.970 {0.0382} 0.900 {0.0354}
0.870 {0.0343} 0.920 {0.0362} 0.850 {0.0335}
0.820 {0.0323} 0.870 {0.0343} 0.800 {0.0315}
0.770 {0.0303} 0.820 {0.0323} 0.750 {0.0295}
0.720 {0.0283} 0.770 {0.0303} 0.700 {0.0276}
0.680 {0.0268} 0.720 {0.0283} 0.650 {0.0256}

Selection example
• Because clearance D 1.364 mm {0.05370 in} applies to 1.320 mm {0.05197 in} or more and less than 1.370
mm {0.05394 in}, a shim of 1.300 {0.05118} thickness is selected.

Secondary Shaft Preload Adjustment

1. Measure the thickness of the straight edge which is used for measurements.
2. Measure distance E of the transaxle case using TRANSAXLE CASE
the following procedure.

bc61um00000085

(1) Place two straight edges on the transaxle

case as shown in the figure.
TRANSAXLE
CASE

STRAIGHT EDGE

bc61um00000187

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MANUAL TRANSAXLE
(2) Set up 3 measurement points of your
choosing on the shim assembly area of the MEASUREMENT POINT
transaxle case as shown in the figure.
(3) Using a commercially available depth gauge,
measure the distance to each measurement
point from the straight edge.

Caution
• When measuring the distance to the
measurement point from the straight
edge, do not allow the depth gauge head
to contact the shim assembly area.
bc61um00000188

(4) Calculate the average value measured in

Step 3 using the following formula.
• (Value of first measurement + value of second measurement + value of third measurement) / 3 =
Average measured values.
Calculation example
• Value of first measurement = 223.223 mm {8.78831 in}
• Value of second measurement = 223.219 mm {8.78815 in}
• Value of third measurement = 223.222 mm {8.78827 in}
• (223.223 mm {8.78831 in} + 223.219 mm {8.78815 in} + 223.222 mm {8.78827 in}) / 3 = 223.221 mm
{8.78823 in}
(5) Calculate distance E of the transaxle case using the following formula.
• Average of measured values - straight edge thickness = Distance E
Calculation example
• Straight edge thickness = 5.000 mm {0.1969 in}
• Average of measured values = 223.221 mm {8.78823 in}
• 223.221 mm {8.78823 in} - 5.000 mm {0.1969 in} = 218.221 mm {8.59138 in}
3. Measure distance F of the transaxle case using CLUTCH HOUSING
the following procedure.

bc61um00000189

(1) Set two straight edges on the clutch housing

as shown in the figure.
CLUTCH HOUSING

STRAIGHT EDGE
bc61um00000190

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MANUAL TRANSAXLE
(2) Set up 3 measurement points of your
choosing on the ball bearing assembly area of
the clutch housing as shown in the figure.
(3) Using a commercially available depth gauge,
measure the distance to each measurement
point from the straight edge.

Caution 05-15
• When measuring the distance to the
measurement point from the straight
edge, do not allow the depth gauge head MEASUREMENT POINT
to contact the bearing outer race
bc61um00000191
assembly area.

(4) Calculate the average value measured in Step 3 using the following formula.
• (Value of first measurement + value of second measurement + value of third measurement) / 3 =
Average measured values.
Calculation example
• Value of first measurement = 61.154 mm {2.4076 in}
• Value of second measurement = 61.153 mm {2.4076 in}
• Value of third measurement = 61.153 mm {2.4076 in}
• (61.154 mm {2.4076 in} + 61.153 mm {2.4076 in} + 61.153 mm {2.4076 in}) / 3 = 61.153 mm {2.4076
in}
(5) Calculate distance F of the clutch housing using the following formula.
• Average of measured values - straight edge thickness = Distance F
Calculation example
• Straight edge thickness = 5.000 mm {0.1969 in}
• Average of measured values = 61.153 mm {2.4076 in}
• 61.153 mm {2.4076 in} - 5.000 mm {0.1969 in} = 56.153 mm {2.2107 in}
4. Measure distance G of the secondary shaft
component using the following procedure.

SECONDARY SHAFT
COMPONENT G

bc61um00000192

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MANUAL TRANSAXLE
(1) Place two straight edges on the surface plate
as shown in the figure and set the bearing BEARING OUTER RACE
outer race and secondary shaft component
on top of them.
(2) Rotate the secondary shaft component to its
rotational direction to engage the taper roller
bearing and the bearing outer race SECONDARY SHAFT
assembled to the clutch housing smoothly. COMPONENT

BEARING OUTER RACE

STRAIGHT EDGE
SURFACE PLATE
bc61um00000148

(3) Set up 3 measurement points of your MEASUREMENT POINT

choosing on the bearing outer race as shown
in the figure.
(4) Using a commercially available height gauge, BEARING OUTER RACE
measure the distance to each measurement
point from the straight edge.
(5) Calculate the average of the value measured
in Step 4 using the following formula, and use
the average of the measured value for
distance G of the secondary shaft
component.
• (Value of first measurement + value of
bc61um00000193
second measurement + value of third
measurement) / 3 = Distance G
Calculation example
• Value of first measurement = 273.274 mm {10.7588 in}
• Value of second measurement = 273.270 mm {10.7587 in}
• Value of third measurement = 273.273 mm {10.7588 in}
• (273.274 mm {10.7588 in} + 273.270 mm {10.7587 in} + 273.273 mm {10.7588 in}) / 3 = 273.272 mm
{10.7587 in}
5. Select the secondary shaft shim using the following procedure.
(1) Calculate the clearance (clearance H) between the transaxle case and the primary shaft component using
the following formula.
• Distance E + Distance F - Distance G = Clearance H
Calculation example
• Distance E = 218.221 mm {8.59138 in}
• Distance F = 56.153 mm {2.2107 in}
• Distance G = 273.272 mm {10.7587 in}
• 218.221 mm {8.59138 in} + 56.153 mm {2.2107 in} - 273.272 mm {10.7587 in} = 1.102 mm {0.04339
in}

05-15–54
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MANUAL TRANSAXLE
(2) Based on the calculated clearance H, select a shim of the appropriate thickness from the following table.
Clearance H measured value Appropriate
Equal to or Less than (mm shim thickness
more (mm {in}) {in}) (mm {in})
1.331 {0.05240} 1.355 {0.05335} 1.500 {0.05906}
1.281 {0.05043} 1.331 {0.05240} 1.450 {0.05709}
1.231 {0.04846} 1.281 {0.05043} 1.400 {0.05512} 05-15
1.181 {0.04650} 1.231 {0.04846} 1.350 {0.05315}
1.131 {0.04453} 1.181 {0.04650} 1.300 {0.05118}
1.081 {0.04256} 1.131 {0.04453} 1.250 {0.04921}
1.031 {0.04059} 1.081 {0.04256} 1.200 {0.04724}
0.981 {0.0386} 1.031 {0.04059} 1.150 {0.04528}
0.931 {0.0367} 0.981 {0.0386} 1.100 {0.04331}
0.881 {0.0347} 0.931 {0.0367} 1.050 {0.04134}
0.831 {0.0327} 0.881 {0.0347} 1.000 {0.03937}
0.781 {0.0307} 0.831 {0.0327} 0.950 {0.0374}
0.731 {0.0288} 0.781 {0.0307} 0.900 {0.0354}
0.681 {0.0268} 0.731 {0.0288} 0.850 {0.0335}
0.631 {0.0248} 0.681 {0.0268} 0.800 {0.0315}
0.581 {0.0229} 0.631 {0.0248} 0.750 {0.0295}
0.531 {0.0209} 0.581 {0.0229} 0.700 {0.0276}
0.495 {0.0195} 0.531 {0.0209} 0.650 {0.0256}

Selection example
• Because clearance H 1.102 mm {0.04339 in} applies to 1.081 {0.04256} or more and less than 1.131
{0.04453}, a shim of 1.250 {0.04921} thickness is selected.

Differential Preload Adjustment

1. Assemble a new shim of the same thickness as
the removed shim.

Caution
• Preload cannot be measured accurately if
the shim is reused. An used shim is
deformed by the pressure applied during
assembly.

SHIM

bc61um00000150

2. Assemble the bearing outer race to the transaxle

case using the SSTs.
49 G030 797

49 V001 795

BEARING
OUTER RACE

bc61um00000149

05-15–55
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MANUAL TRANSAXLE
3. Assemble the bearing outer race to the clutch
49 G030 797
housing using the SSTs.

49 V001 795

BEARING
OUTER RACE

bc61um00000151

4. Assemble the SST to the clutch housing. B

Bolt A
Part No.: 99450 1055 or M10×1.25 length 55
mm {2.2 in}, and nut (M10×1.25)
49 G019 0A0
Bolt A tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}
Bolt B
SST (49 G019 033 part of 49 G019 0A0) A
C
Bolt B tightening torque A
88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}
Bolt C
Part No.: 9YA02 1080 or M10×1.5 length 55
mm {2.2 in}
Bolt C tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf} D
Bolt D
Part No.: 99450 1030 or M10×1.25 length 30 bc61um00000126
mm {2.2 in}
Bolt D tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}

5. Apply transaxle oil to the roller area of the taper

roller bearing on the differential.

APPLY
TRANSAXLE
OIL

bc61um00000153

6. Assemble the differential to the clutch housing. DIFFERENTIAL CLUTCH HOUSING

bc61um00000154

05-15–56
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MANUAL TRANSAXLE
7. Assemble the transaxle case to the clutch
housing. 22—30 {2.3—3.0, 17—22}

05-15

38—52 {3.9—5.3, 29—38}

22—30 {2.3—3.0, 17—22} N·m {kgf·m, ft·lbf}

bc61um00000101

8. Set the SST so that its end engages the pinion

shaft of the differential.
49 B019 025 49 B019 025

PINION SHAFT

bc61um00000155

9. Rotate the differential ten times using the SST to

ROTATE DIFFERENTIAL
engage the taper roller bearing and the bearing TEN TIMES
outer race smoothly.
49 B019 025

bc61um00000156

10. Measure the differential preload.

TORQUE WRENCH 49 B019 025
Standard preload
0.7—1.7 N·m {7.2—17 kgf·cm, 6.2—15 ft·lbf}

• If the measured preload is within the

specification, the shim thickness is the same
as the removed one and there is no problem,
therefore the "Differential Preload
Adjustment" procedure is finished.
• If not within the specification, perform "Shim
selection calculation". (See 05-15-58 Shim
bc61um00000157
selection calculation.)

05-15–57
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MANUAL TRANSAXLE
Shim selection calculation
1. Calculate the preload gap by subtracting the measured preload value from constant number A.
• Constant number A = 1.2 N·m {12 kgf·cm, 11 in·lbf}
• 1.2 N·m {12 kgf·cm, 11 in·lbf} - measured preload value = preload gap
Calculation example
• Measured preload value = 2.5 N·m {25 kgf·cm, 22 in·lbf}
• 1.2 N·m {12 kgf·cm, 11 in·lbf} - 2.5 N·m {25 kgf·cm, 22 in·lbf} = -1.3 N·m {13 kgf·cm, 12 in·lbf}
2. Calculate the shim thickness gap by multiplying the preload gap by constant number B.
• Constant number B = 0.083 mm/N·m {0.008 mm/kgf·cm, 0.0004 in/in·lbf}
• Preload gap x 0.083 mm/N·m {0.008 mm/kgf·cm, 0.0004 in/in·lbf} = shim thickness gap
Calculation example
• Preload gap = -1.3 N·m {-13 kgf·cm, -12 in·lbf}
• -1.3 N·m {-13 kgf·cm, -12 in·lbf} x 0.083 mm/N·m {0.008 mm/kgf·cm, 0.0004 in/in·lbf} = -0.108 mm {-
0.00425 in}
3. Calculate the shim thickness calculated value by adding the shim thickness gap to the thickness of the shim
used in the measurement.
• Shim thickness gap + thickness of shim used in measurement = shim thickness calculated value
Calculation example
• Shim thickness gap = -0.108 mm {-0.00425 in}
• Thickness of shim used in measurement = 0.9000 mm {0.03543 in}
• -0.108 mm {-0.00425 in} + 0.9000 mm {0.03543 in} = 0.792 mm {0.0312 in}
4. Based on the shim thickness calculated value, select a shim of the appropriate thickness.
Shim thickness calculated
value Appropriate
shim thickness
Equal to or Less than (mm (mm {in})
more (mm {in}) {in})
1.220 {0.04803} 1.260 {0.04961} 1.350 {0.05315}
1.170 {0.04606} 1.220 {0.04803} 1.300 {0.05118}
1.120 {0.04409} 1.170 {0.04606} 1.250 {0.04921}
1.070 {0.04213} 1.120 {0.04409} 1.200 {0.04724}
1.020 {0.04016} 1.070 {0.04213} 1.150 {0.04528}
0.970 {0.0382} 1.020 {0.04016} 1.100 {0.04331}
0.920 {0.0362} 0.970 {0.0382} 1.050 {0.04134}
0.870 {0.0343} 0.920 {0.0362} 1.000 {0.03937}
0.820 {0.0323} 0.870 {0.0343} 0.950 {0.0374}
0.770 {0.0303} 0.820 {0.0323} 0.900 {0.0354}
0.720 {0.0283} 0.770 {0.0303} 0.850 {0.0335}
0.670 {0.0264} 0.720 {0.0283} 0.800 {0.0315}
0.620 {0.0244} 0.670 {0.0264} 0.750 {0.0295}
0.570 {0.0224} 0.620 {0.0244} 0.700 {0.0276}
0.520 {0.0205} 0.570 {0.0224} 0.650 {0.0256}
0.470 {0.0185} 0.520 {0.0205} 0.600 {0.0236}
0.420 {0.0165} 0.470 {0.0185} 0.550 {0.0217}
0.390 {0.0154} 0.420 {0.0165} 0.50 {0.0197}

Selection example
• Because shim thickness calculated value 0.792 mm {0.0312 in} applies to 0.775 mm {0.0305 in} or more
and less than 0.825 mm {0.0325 in}, a shim of 0.800 mm {0.0315 in} thickness is selected.

Note
• The preload gap is the difference between the central value of the standard preload value and the
measured preload value.
• Constant number A, 1.2 N·m {12 kgf·cm, 11 in·lbf} is the central value of the standard preload value.
• The shim thickness gap is the difference between the thickness of the removed shim and the thickness of
an appropriate shim. In the formula to calculate the shim thickness gap, the shim thickness gap is
calculated by multiplying the preload gap with constant number B.
• Constant number B is the shim thickness which varies each time the preload changes by 1.0 N·m {10
kgf·cm, 8.9 in·lbf}. Because the shim thickness changes 0.1 mm {0.004 in} when the preload changes
1.2 N·m {12 kgf·cm, 11 in·lbf}, the quotient is 0.083 mm/N·m {0.008 mm/kgf·cm 0.0004 in/in·lbf}.

End Of Sie

05-15–58
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MANUAL TRANSAXLE
TRANSAXLE CASE AND CLUTCH HOUSING ASSEMBLY
id051500169900
1. Perform the differential preload adjustment and select a shim of the appropriate thickness. (See BEARING
PRELOAD ADJUSTMENT.)
2. Assemble the transaxle case component and clutch housing component in the order shown in the figure.

OIL
: APPLY SPECIFIED OIL TO INDIVIDUAL PARTS
05-15
2

5 A

SELECTIVE 9
SST 3
4
SST
6 4

5 A
8
1 R
SST

10
bc61um00000163

1 Clutch housing 6 Funnel

2 Transaxle case 7 Bearing outer race
3 Shim Oil seal
8
4 Bearing outer race (differential) (See 05-15-60 Oil Seal Assembly Note.)
(See 05-15-59 Bearing Outer Race (Differential) 9 Funnel
Assembly Note.) 10 Oil path
5 Dowel pin

Bearing Outer Race (Differential) Assembly Note

1. Assemble the bearing outer race (differential) to
49 G030 797
the clutch housing using the SSTs.

49 V001 795

BEARING
OUTER RACE

CLUTCH
HOUSING

bc61um00000137

05-15–59
1A09-1U-12A(05-15).fm 60 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
2. Assemble the bearing outer race (differential) to
the transaxle case using the SSTs.
49 G030 797

49 V001 795

BEARING
OUTER RACE

TRANSAXLE CASE

bc61um00000078

Oil Seal Assembly Note

1. Assemble the oil seal using the SST.
End Of Sie

OIL SEAL

49 B032 335A
bc61um00000164

TRANSAXLE ASSEMBLY
id051500170000
Step 1
1. Perform the primary shaft and secondary shaft preload adjustment and select a shim of the appropriate
thickness. (See BEARING PRELOAD ADJUSTMENT.)
2. Assemble the SST (49 G019 0A0) to the SST (49
0107 680A).

Bolt used
Part No.: 9YA02 A220 or M12×1.75 length 40
mm {1.6 in}
Tightening torque 49 G019 0A0
88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}

49 0107 680A

bc61um00000090

3. Assemble the clutch housing component to the B

SST.

Bolt A
Part No.: 99450 1055 or M10×1.25 length 55
49 G019 0A0
mm {2.2 in}, and nut (M10×1.25)
Bolt A tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}
Bolt B A
C
SST (49 G019 033 part of 49 G019 0A0) A
Bolt B tightening torque
88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}
Bolt C
Part No.: 9YA02 1080 or M10×1.5 length 55
mm {2.2 in}
Bolt C tightening torque D
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}
bc61um00000126

05-15–60
1A09-1U-12A(05-15).fm 61 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Bolt D
Part No.: 99450 1030 or M10×1.25 length 30 mm {2.2 in}
Bolt D tightening torque
38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}

4. Assemble the MTX in the order shown in the figure. .

OIL
: APPLY SPECIFIED OIL TO INDIVIDUAL PARTS 05-15
1 SEALANT

C *1 : R 12—15 N·m {123—152 kgf·cm, 107—132 in·lbf}

B D
2

D
A 10 8

C *1

8
B *1 *1
8
9
7 6
8 *1
A
*1 3 7 SELECTIVE
5 *1 12
11
4 7
6
12 7
SELECTIVE
6
6 13
22—30 {2.3—3.0, 17—22}

22—30 {2.3—3.0, 17—22}

38—52 {3.9—5.3, 29—38}
N·m {kgf·m, ft·lbf}

bc61um00000092

1 Clutch housing component Shift fork

2 Differential 6 (See 05-15-63 Shift fork, shift rod end, and shift rod
assembly note.)
Secondary shaft component
3 (See 05-15-62 Secondary shaft component and Shift rod end
primary shaft component assembly note.) 7 (See 05-15-63 Shift fork, shift rod end, and shift rod
assembly note.)
Primary shaft component
4 (See 05-15-62 Secondary shaft component and Shift rod
primary shaft component assembly note.) 8 (See 05-15-63 Shift fork, shift rod end, and shift rod
assembly note.)
Reverse idler gear component
5 (See 05-15-62 Reverse idler gear component 9 Oil path
assembly note.) 10 Magnet

05-15–61
1A09-1U-12A(05-15).fm 62 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
11 bearing outer race 13 Transaxle case component
(See 05-15-65 Bearing outer race, shim, Transaxle (See 05-15-65 Bearing outer race, shim, Transaxle
case component assembly note.) case component assembly note.)
shim
12 (See 05-15-65 Bearing outer race, shim, Transaxle
case component assembly note.)

Secondary shaft component and primary shaft component assembly note

1. Assemble the secondary shaft component and
primary shaft component to the clutch housing
component as a single unit. PRIMARY SHAFT SECONDARY SHAFT
2. Shake the assembled parts and assemble each COMPONENT COMPONENT
one completely.

bc61um00000094

Reverse idler gear component assembly note

1. Pull the reverse idler gear shaft and position it to
the location shown in the figure.
2. Engage each gear while aligning the shim notch
with the ball bearing of the primary shaft
REVERSE IDLER
component. GEAR SHAFT
3. Push the reverse idler gear shaft and assemble
the reverse idler gear component.

BALL BEARING

NOTCH SHIM
bc61um00000139

05-15–62
1A09-1U-12A(05-15).fm 63 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Shift fork, shift rod end, and shift rod assembly note
1. Assemble the shift fork (1GR/2GR), shift rod end
(1GR/2GR), and shift rod (1GR/2GR) using the SHIFT ROD (1GR/2GR)
following procedure:
(1) Assemble the shift fork to the clutch hub ASSEMBLY
sleeve. DIRECTION
SHIFT ROD END
(2) Verify the assembly direction of the shift rod. (1GR/2GR)
05-15
Note
• Assemble the shift rod so that the pits used 12—15 N·m
for verifying the assembly direction are {123—152 kgf·cm,
facing the transaxle case side and the 107—132 in·lbf}

exterior side of the MTX. R

(3) Pass the shift rod through the assembly hole

of the shift rod end.
(4) Pass the shift rod through the assembly hole
of the shift fork.
(5) Assemble the shift rod to the clutch housing.
(6) Tighten the assembly bolt and assemble the
shift fork, shift rod end, and shift rod.

SHIFT FORK (1GR/2GR)

bc61um00000096

2. Assemble the shift fork (5GR/6GR), shift rod end

(5GR/6GR), and shift rod (5GR/6GR) using the SHIFT ROD (5GR/6GR)
following procedure:
ASSEMBLY
(1) Assemble the shift fork to the clutch hub
DIRECTION
sleeve. SHIFT ROD END
(2) Verify the assembly direction of the shift rod. (5GR/6GR)

Note
12—15 N·m
• Assemble the shift rod so that the pits used {123—152 kgf·cm,
for verifying the assembly direction are 107—132 in·lbf}
facing the transaxle case side and the R
exterior side of the MTX.

(3) Pass the shift rod through the assembly hole

of the shift fork.
(4) Set the shift rod end to the position shown in
the figure and pass the shift rod through the
assembly hole of the shift rod end.
(5) Assemble the shift rod to the clutch housing.
(6) Tighten the assembly bolt and assemble the
shift fork, shift rod end, and shift rod.
SHIFT FORK (5GR/6GR)

bc61um00000097

05-15–63
1A09-1U-12A(05-15).fm 64 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
3. Assemble the shift fork (reverse) and shift rod
SHIFT ROD
(reverse) using the following procedure:
(REVERSE)
(1) Assemble the shift fork to the clutch hub
sleeve.
(2) Assemble the shift rod.

SHIFT FORK (REVERSE)

bc61um00000098

4. Assemble the shift fork (3GR/4GR), shift rod end

(3GR/4GR), shift rod end (reverse), and shift rod
ASSEMBLY SHIFT ROD (3GR/4GR)
(3GR/4GR) using the following procedure:
(1) Assemble the shift fork to the clutch hub DIRECTION
sleeve. SHIFT FORK
(2) Verify the assembly direction of the shift rod. (3GR/4GR)
12—15 N·m
{123—152 kgf·cm,
Note 107—132 in·lbf}
• Assemble the shift rod so that the pits used R
for verifying the assembly direction are
facing the transaxle case side and the
exterior side of the MTX.
SHIFT ROD END
(3GR/4GR)
(3) Pass the shift rod through the assembly hole
of the shift fork.
(4) Set the shift rod end (3GR/4GR) to the
position shown in the figure and pass the shift
rod through the assembly hole of the shift rod
end (3GR/4GR).
(5) Set the shift rod end (reverse) to the position
shown in the figure and pass the shift rod
through the assembly hole of the shift rod end
(reverse). SHIFT ROD END (REVERSE)
(6) Assemble the shift rod to the clutch housing. bc61um00000099
(7) Tighten the assembly bolt and assemble the
shift fork, shift rod end, and shift rod.

05-15–64
1A09-1U-12A(05-15).fm 65 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Bearing outer race, shim, Transaxle case component assembly note
1. Assemble the bearing outer race to the secondary
shaft component. BEARING OUTER
RACE

05-15

bc61um00000165

2. Assemble the shims.

SHIM P
P SHIM
bc61um00000166

3. Apply silicone sealant to the transaxle case

component as shown in the figure.
1—2 mm
{0.04—0.07 in}

TRANSAXLE CASE

bc61um00000100

4. Assemble the transaxle case component.

22—30 {2.3—3.0, 17—22}
Caution
• Assemble the transaxle case component
before the applied silicone sealant starts
to harden.

38—52 {3.9—5.3, 29—38}

22—30 {2.3—3.0, 17—22} N·m {kgf·m, ft·lbf}

bc61um00000101

05-15–65
1A09-1U-12A(05-15).fm 66 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
Step 2
1. Assemble the parts around the MTX in the order shown in the figure. .

19—25 {2.0—2.5, 15—18}

17
15—25 {1.6—2.5, 12—18}
18
8

B
SST
C 1 R
A R
7

20—29 B
{2.1—2.9, R
15—21}
A C
15
16

SST
R
13 R 1

12 11

14 9 R
32—47 10 20—29 {2.1—2.9, 15—21}
{3.3—4.7,
24—34}
6 5
39—59 R 19—25
{4.0—6.0, {2.0—2.5,
29—43} 15—18}

R
4

R 2
39—59
3 {4.0—6.0,
29—43}
N·m {kgf·m, ft·lbf}

bc61um00000093

Oil seal 7 O-ring

1 (See 05-15-65 Bearing outer race, shim, Transaxle 8 Shift control module
case component assembly note.)
9 Gasket
2 Gasket
10 Back-up light switch
3 Drain plug
11 Detent ball pin
4 Reverse gear shaft anchor bolt
12 Spring
5 Gasket
13 Gasket
6 Oil level plug
14 Plug

05-15–66
1A09-1U-12A(05-15).fm 67 ページ ２０１２年１月１２日 木曜日 午前１１時１５分

MANUAL TRANSAXLE
15 Gasket 17 Breather
16 Neutral switch 18 Stud bolt

Oil seal assembly note

1. Assemble a new oil seal to the clutch housing
using the SSTs.
05-15

OIL SEAL R

49 U027 003
49 G030 797

bc61um00000140

2. Assemble a new oil seal to the transaxle case

using the SSTs.
End Of Sie

R OIL SEAL

49 U027 003
49 G030 797

bc61um00000141

05-15–67
1A09-1U-12A(05-15).fm 68 ページ ２０１２年１月１２日 木曜日 午前１１時１５分
1A09-1U-12A.book 1 ページ ２０１２年１月６日 金曜日 午後４時４６分

TECHNICAL DATA
05-50 TECHNICAL DATA
TRANSMISSION/TRANSAXLE Gear Shaft Outer Diameter . . . . . . . . . . 05-50–2
TECHNICAL DATA . . . . . . . . . . . . . . . . 05-50–1 Synchronizer Clearance . . . . . . . . . . . . 05-50–2
Manual Transaxle . . . . . . . . . . . . . . . . . 05-50–1 Shift Fork and Clutch
Gear Thrust Clearance . . . . . . . . . . . . 05-50–1 Hub Sleeve Clearance . . . . . . . . . . . . 05-50–2
Gear Inner Diameter . . . . . . . . . . . . . . 05-50–1 Bearing Preload . . . . . . . . . . . . . . . . . . 05-50–2
Gear Sleeve Outer Diameter . . . . . . . . 05-50–1 Differential Gear Backlash. . . . . . . . . . . 05-50–2 05-50
Gear Shaft Runout . . . . . . . . . . . . . . . . 05-50–1 Adjust Shim Size . . . . . . . . . . . . . . . . . . 05-50–3

End of Toc
TRANSMISSION/TRANSAXLE TECHNICAL DATA
WM: TRANSMISSION/TRANSAXLE

id055000800100
Manual Transaxle
Item Specification
Grade API service GL-4
Manual transaxle oil Viscosity SAE 75W-80
Capacity (approx. quantity) 1.65 L {1.74 US qt, 1.45 lmp qt}

Gear Thrust Clearance

Measurement location Specification (mm {in}) Maximum (mm {in})

3rd gear 0.257 {0.0101} 0.417 {0.0164}
4th gear 0.325 {0.0128} 0.489 {0.0193}
5th gear 0.192 {0.00756} 0.324 {0.0128}
6th gear 0.262 {0.0103} 0.398 {0.0157}
Secondary 1st gear 0.174 {0.00685} 0.291 {0.0115}
Secondary 2nd gear 0.174 {0.00685} 0.294 {0.0116}

Gear Inner Diameter

Measurement location Specification (mm {in}) Maximum (mm {in})

3rd gear 37.01 {1.4571} 37.02 {1.4575}
4th gear 32.81 {1.2917} 32.82 {1.2921}
5th gear 42.01 {1.6539} 42.02 {1.6543}
6th gear 37.01 {1.4571} 37.02 {1.4575}
Secondary 1st gear 41.512 {1.6343} 41.525 {1.6348}
Secondary 2nd gear 46.534 {1.8320} 46.544 {1.8324}

Gear Sleeve Outer Diameter

Specification (mm {in}) Minimum (mm {in})

46.444 {1.8285} 46.434 {1.8281}

Gear Shaft Runout

Measurement location Maximum (mm {in})

Primary shaft 0.05 {0.002}
Secondary shaft 0.05 {0.002}

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TECHNICAL DATA
Gear Shaft Outer Diameter

Measurement location Specification (mm {in}) Minimum (mm {in})

3rd gear assembly part 36.97 {1.4555} 36.96 {1.4551}
4th gear assembly part 32.77 {1.2902} 32.76 {1.2898}
Primary shaft
5th gear assembly part 41.97 {1.6524} 41.96 {1.652}
6th gear assembly part 36.97 {1.4555} 36.96 {1.4551}
Secondary Secondary 1st gear assembly part 41.457 {1.6322} 41.445 {1.6317}
shaft Secondary 2nd gear assembly part 39.276 {1.5463} 39.266 {1.5459}

Synchronizer Clearance

Measurement location Specification (mm {in}) Minimum (mm {in})

Synchronizer ring (1GR) 0.94 {0.037} 0.55 {0.022}
Synchronizer ring (2GR) 0.94 {0.037} 0.55 {0.022}
Synchronizer ring (3GR) 0.97 {0.038} 0.32 {0.013}
Synchronizer ring (4GR) 1.05 {0.0413} 0.40 {0.016}
Synchronizer ring (5GR) 1.15 {0.0453} 0.50 {0.020}
Synchronizer ring (6GR) 1.15 {0.0453} 0.50 {0.020}
Synchronizer ring (reverse) 0.95 {0.037} 0.49 {0.019}

Shift Fork and Clutch Hub Sleeve Clearance

Specification (mm {in}) Maximum (mm {in})

0.225 {0.00886} 0.40 {0.016}

Bearing Preload

Item Specification (N·m {kgf·cm, in·lbf})

differential preload 0.7—1.7 {7.2—17, 6.2—15}

Differential Gear Backlash

Item Specification (mm {in})

pinion gear backlash 0.05—0.15 {0.002—0.005}

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TECHNICAL DATA
Adjust Shim Size
Reverse idler gear (mm {in})
3.150 {0.1240} 3.100 {0.1220} 3.050 {0.1201} 2.950 {0.1161}
2.900 {0.1142} 2.850 {0.1122} - -

Primary shaft (mm {in})

1.550 {0.06102} 1.500 {0.05906} 1.450 {0.05709} 1.400 {0.05512}
1.350 {0.05315} 1.300 {0.05118} 1.250 {0.04921} 1.200 {0.04724} 05-50
1.150 {0.04528} 1.100 {0.04331} 1.050 {0.04134} 1.000 {0.03937}
0.950 {0.0374} 0.900 {0.0354} 0.850 {0.0335} 0.800 {0.0315}
0.750 {0.0295} 0.700 {0.0276} 0.650 {0.0256} -

Secondary shaft (mm {in})

1.500 {0.05906} 1.450 {0.05709} 1.400 {0.05512} 1.350 {0.05315}
1.300 {0.05118} 1.250 {0.04921} 1.200 {0.04724} 1.150 {0.04528}
1.100 {0.04331} 1.050 {0.04134} 1.000 {0.03937} 0.950 {0.0374}
0.900 {0.0354} 0.850 {0.0335} 0.800 {0.0315} 0.750 {0.0295}
0.700 {0.0276} - - -

Differential (mm {in})

1.350 {0.05315} 1.300 {0.05118} 1.250 {0.04921} 1.200 {0.04724}
1.150 {0.04528} 1.100 {0.04331} 1.050 {0.04134} 1.000 {0.03937}
0.950 {0.0374} 0.900 {0.0354} 0.850 {0.0335} 0.800 {0.0315}
0.750 {0.0295} 0.700 {0.0276} 0.650 {0.0256} 0.600 {0.0236}
0.550 {0.0217} 0.50 {0.0197} - -

Differential thrust washer size (mm {in})

0.95 {0.037} 0.90 {0.035} 0.85 {0.033} 0.80 {0.031}
0.75 {0.030} - - -

End Of Sie

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1A09-1U-12A.book 1 ページ ２０１２年１月６日 金曜日 午後４時４６分

SERVICE TOOLS
05-60 SERVICE TOOLS
TRANSMISSION/TRANSAXLE SST. . . . 05-60–1 Manual Transaxle [C66M-R] . . . . . . . . . 05-60–1
Example . . . . . . . . . . . . . . . . . . . . . . . . 05-60–1

End of Toc
TRANSMISSION/TRANSAXLE SST
WM: TRANSMISSION/TRANSAXLE

id056000804200 05-60
1: Mazda SST number
2: Global SST number

Example
1:49 UN30 3009
2:303-009

Crankshaft
damper
remover

Manual Transaxle [C66M-R]

1:49 0107 680A 1:49 G019 0A0 1:49 W032 2A0
2: – 2: – 2: –

Engine stand Transaxle Bearing remver

hanger set set

1:49 T032 302 1:49 0710 520 1:49 F401 331

2: – 2: – 2: –

Bearing installer Bearing puller Bearing installer

body

1:49 F401 336B 1:49 B032 317 1:49 F026 103

2: – 2: – 2: –

Attachment Bearing & oil Wheel hub

seal remover puller

1:49 B017 206 1:49 F401 366A 1:49 H027 001

2: – 2: – 2: –

Attachment F Plate Collar

1:49 0839 425C 1:49 UB71 525 1:49 V001 795

2: – 2: – 2: –

Bearing puller Bearing Installer Oil seal installer

set

1:49 G030 797 1:49 F027 005 1:49 F027 003

2: – 2: – 2: –

Handle Attachmentφ62 Handle

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SERVICE TOOLS
1:49 U027 003 1:49 B032 335A
2: – 2: –

Oil seal installer Oil seal installer –

End Of Sie

05-60–2