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CHAPTER 7:

Manual Transaxle

2004 > 1.6L DOHC >

STRUCTURAL VIEW

2004 > 1.6L DOHC >

Structural view

Cross-sectional view

Power flow

Manual Transaxle

2004 > 1.6L DOHC >

Removal and replacement procedure


Components

COMPONENTS

COMPONENTS

MANUAL TRANSAXLE DIAGRAM

COMPONENT

COMPONENT

5th/reverse gear and housing parts


components

a. Clean transaxle exterior thoroughly with steam cleaner or cleaning solvent before disassembly. b. Clean removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent and dry with compressed air. c. Clean out all holes and passages with compressed air and verify that there are no obstructions.

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

2004 > 1.6L DOHC >

Removal
1. Disconnect negative battery cable (first) and positive battery cable (second).

2. Remove two nuts and remove fresh air duct. 3. To remove air cleaner assembly, disconnect hose from intake manifold, MAF sensor connector, air temperature sensor connector and two bolts, one nut and then remove air cleaner assembly. 4. Disconnect back-up switch connector from connector bracket in case. 5. Disconnect vehicle speed sensor connector from right side of transaxle.

6. Disconnect ground strap (one bolt). 7. Disconnect crankshaft position sensor connector. 8. Remove two upper starter bolts.

9. Remove two upper clutch housing bolts.

10. Support engine with engine support bar SST(0K201 170 AA0).

11. Remove No. 4 engine mounting bolts (three to transaxle) and remove No. 4 engine mount. 12. Loosen four lug nuts from both front wheels (LH, RH). 13. Raise and properly support vehicle. 14. Remove both front wheels. 15. Remove splash shield under the left side of vehicle. (three bolts and three fasteners). 16. Remove engine mounting member (two bolts, four nuts).

17. Place drain pan under transaxle drain plug. 18. Remove transaxle drain plug and drain transaxle oil.

19. Disconnect retainer clip, set aside clutch hydraulic line and remove clutch release cylinder (two bolts).

20. Remove the left stabilizer control link from bracket attached to shock absorber after loosening the control link nut.

21. Remove left tie rod ends from steering knuckle by removing one cotter pin and one nut with SST(0K130 283 021).

22. Remove pinch bolt and front left ball joints and disconnect ball joints from steering knuckles.

23. Gently pry left driveshaft from transaxle.

24. Slide driveshaft assembly out of transaxle and install SST (0K201 270 014).

25. Remove four No. 2 engine mounting bolts and remove No. 2 engine mount. 26. Remove four catalytic converter bolts (two front, two rear) and remove catalytic converter. 27. Remove three No. 1 engine mount bracket bolts and loosen No. 1 engine mount nut. 28. Disconnect extension bar (two washers, one nut). 29. Disconnect control rod (one nut, one bolt, one clip). 30. Remove one lower starter bolt and set aside starter. 31. Remove four lower clutch housing bolts and support transaxle with jack or suitable floor jack and then remove remaining two bolts. 32. Gently separate transaxle assembly from engine and lower.

INSTALLATION

1. Raise and suitably support vehicle. 2. Set transaxle on jack or floorjack and position transaxle under vehicle. 3. Raise transaxle and align transaxle with engine.

4. Connect transaxle to engine using six mounting bolts through clutch housing. Tightening torque: A : 28~38 lb-ft (37~52 Nm, 3.8~5.3 kg-m) B : 66~86 lb-ft (89~116Nm,9.1~11.9kg-m)

5. Remove floorjack from transaxle. 6. Remove SST (0K201 270 014). 7. Install starter using lower starter bolt. 8. Install new clip onto driveshaft.

9. Push left driveshaft into transaxle with opening of clip pointing upward. 10. Install left lower ball joints into steering knuckle then install pinch bolt. Tightening torque: 32~45 lb-ft (43~61 Nm, 4.4~6.2 kg-m) 11. Install left stabilizer control links to bracket attached to shock absorber. Tightening torque: 32~45 lb-ft (43~61 Nm, 4.4~6.2 kg-m)

12. Install left tie rod end to steering knuckle then install tie rod end nuts. Tightening torque: 22~33 lb-ft (30~44 Nm, 3.0~4.5 kg-m) 13. Insert cotter pins.

14. Connect control rod with one nut and two bolts. 15. Connect extension bar with two washers and one nut. 16. Install No. 1 engine mount then install three mounting bolts. Tightening torque: 49~69 lb-ft (67~93 Nm, 6.8~9.5 kg-m) 17. Install catalytic converter and four bolts (two front, two rear). Tightening torque: Front : 27~38 lb-ft (37~52 Nm, 3.8~5.3 kg-m) Rear : 31~45 lb-ft (42~61 Nm, 4.3~6.2 kg-m) 18. Install No. 2 engine mount, then install four mounting bolts. Tightening torque: 28~38 lb-ft (38~51 Nm, 3.8~5.3 kg-m) 19. Install clutch release cylinder with two bolts and attach hydraulic line to retainer clip. Tightening torque: 13~19 lb-ft (18~26 Nm, 1.9~2.6 kg-m)

20. Install drain plug. 21. Install engine mounting member-to-chassis bolts (two front) and nuts (two rear). Tightening torque: A : 48~65 lb-ft (64~89 Nm,6.5~9.1kg-m) 22. Install two No. 2 engine mount-to-mounting member nuts. Tightening torque: B : 23~38 lb-ft (38~51 Nm,3.8~5.3kg-m)

23. Install left splash shield (three bolts and three fasteners). 24. Install both right and left wheels, then tighten both right and left lug nuts (four lug nuts each). Tightening torque: 65~87 lb-ft (88~118 Nm, 9~12 kg-m) 25. Install No. 4 engine mount then install mounting nuts (three to transaxle). Tightening torque: 49~68 lb-ft (68~93 Nm, 6.8~9.5kg-m)

26. Lower vehicle. 27. Remove engine support bar SST(0K201 170 AA0).

28. Install two upper clutch housing bolts. Tightening torque: 66-86 lb-ft (89-116 Nm, 9.1-11.9 kg-m)

29. Install two upper starter bolts. Tightening torque: 27~38 lb-ft (37~52 Nm, 3.8~5.3 kg-m)

30. Reconnect crankshaft position sensor connector. 31. Reconnect ground strap with one bolt. 32. Reconnect vehicle speed sensor connector. 33. Reconnect back-up switch connector. 34. Reinstall air cleaner assembly. 35. Reconnect air temperature sensor connector. 36. Reconnect MAF sensor connector. 37. Reinsert data link connector. 38. Reinstall fresh air duct with two nut.

39. Reconnect positive (first) then negative (last) battery cables. 40. Add gear oil, refer to Oil inspection, page 41-10. 41. Test vehicle and check fluid levels.

Disassembly, inspection and re-assembly procedures Disassembly

a. Clean transaxle exterior thoroughly with steam cleaner or cleaning solvent before disassembly. b. Clean removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air. c. Clean out all holes and passages with compressed air and verify that there are no obstructions.

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

5th/Reverse gear and housing parts Locknut


1. Mount transaxle on SST(0K130 990 007).

2. Lock primary shaft using SST (0K201 323 021). 3. Shift to 1st gear to lock rotation of secondary shaft. 4. Uncramp tabs of locknuts. 5. Remove locknuts from primary and secondary shafts.

Shift fork and shift rod assembly


1. Align ends of interlock sleeve and control lever (arrow). Turn shift rod counterclockwise. 2. While holding 1st/2nd shift fork with one hand and 3rd/4th shift fork with other, raise them both at same time and shift both clutch hub sleeves.

3. Lift shift rod end and remove detent ball and, at same time, remove shift rod from clutch housing. 4. Separate shift rod and shift fork assemblies from both clutch hub sleeves.

Preinspection
5th gear thrust clearance 1. Measure 5th gear thrust clearance by using dial indicator. Clearance: 0.004~0.009 in (0.10~0.22 mm) Maximum: 0.011 in (0.27 mm) 2. If clearance exceeds maximum, check contact surfaces of 5th gear and clutch hub. Replace worn or damaged parts.

5th/Reverse gear and housing parts


Assemble in order shown in figure, refer to Assembly note.

Assembly note
Primary shaft assembly and secondary shaft assembly 1. Install primary shaft assembly and secondary shaft assembly into clutch housing as a unit.

Shift fork and shift rod assembly


1. Shift to 2nd gear and position shift fork and shift rod assembly as shown.

2. Insert spring seat and spring into reverse lever shaft, install detent ball, and place a flat gasket scraper against it. 3. With edge of control end against scraper, push control end in direction of arrow so that detent ball goes into shaft. This will line up rod with shift rod coupling hole in clutch housing.

4. Set each clutch hub sleeve to neutral position, and tap shift rod from above so that detent ball goes into center groove (of three grooves in control end). 5. Pull ball part of control end forward so that detent ball goes into recess in center groove.

Crank lever assembly and crank lever shaft


1. Install new O-ring to crank lever shaft. 2. Fit crank lever between change arm and control end, and insert crank lever shaft. 3. Align pin holes of crank lever shaft and clutch housing, and insert pin.

5th/reverse shift rod end and 5th/reverse shift rod


1. Install shift rod end (1) and shift rod (2), and tighten gate mounting bolt. Tightening torque: 105~121 lb-in (11.8~13.7 Nm, 120~140 kg-cm)

Reverse idle and reverse idle shaft


1. Install reverse idle gear and reverse idle shaft. 2. Attach magnet to clutch housing. 3. Align end of interlock sleeve with control lever (arrow), and face reverse idle shaft screw hole in direction shown in figure.

Transaxle case assembly


1. Apply thin coat of sealant to contact surfaces of clutch housing and transaxle case, and tighten transaxle case installation bolts to specified torque. Tightening torque: 28~38 lb-ft (38~51 Nm, 3.8~5.3 kg-m)

Secondary 5th gear


1. Install secondary 5th gear as shown.

5th/reverse clutch hub assembly and 5th/reverse shift fork


1. Install 5th/reverse clutch hub assembly and 5th/reverse shift fork together.

Locknut
1. Shift to 1st gear. 2. Lock primary shaft using SST (0K201 323 021). 3. Tighten new locknuts onto primary and secondary shafts. Tightening torque: 94~145 lb-ft (128~196 Nm, 13~20 kg-m) 4. Stake locknuts.

5. Measure the 5th gear thrust clearance using a dial indicator. Clearance: 0.004~0.009 in (0.10~0.22 mm) Maximum: 0.011 in (0.27 mm) 6. If not as specified, disassemble and reassemble 5th and reverse gear assemblies.

Bearing
Bearing preload adjustment When replacing any of parts listed in table below, adjust bearing preload by selecting and installing proper adjustment shim(s). Primary shaft assembly a. b. c. d. Transaxle case Clutch housing Primary shaft gear bearing Primary shaft gear a. b. c. d. e. Secondary shaft assembly Transaxle case Clutch housing Secondary shaft gear bearing Secondary shaft gear Secondary 4th gear a. b. c. d. Differential Transaxle case Clutch housing Differential side bearing Ring gear and gear case assembly

1. Install primary and secondary shaft bearing races into transaxle case (diaphragm springs and shims removed). 2. Mount clutch housing onto transaxle hanger, and set differential bearing race into clutch housing. Position piece of pipe against bearing race and tap it in until it contacts clutch housing. 3. Set bearing races into SST (0K900 175 A01/0K900 175 A02/0K900 175 A03) as shown in figure. 4. Turn selector to eliminate gap indicated by arrow.

5. Set differential assembly into clutch housing, and set bearing race and SST (0K900 175 A03) on differential. Set assembled selectors for primary and secondary shaft in clutch housing. Mount shaft gear assemblies as shown in figure.

6. Set SST (0K130 175 A02) in positions shown in figure.

7. Install transaxle case and tighten SST (0K130 191 A07) to specified torque. Tightening torque: 28~38 lb-ft (38~51 Nm, 3.8~5.3 kg-m)

8. To seat bearings, mount SST (0K130 175 A03) on parts A and B of selectors, and turn selectors so gaps are widened. Then turn SST (0K130 175 A03) in reverse direction until gaps are eliminated.

9. Manually expand selector until it no longer turns by hand. 10. Verify that both primary and secondary shafts turn smoothly.

11. Measure clearance between two halves of SST (0K900 175 A01) around circumference by using feeler gauge. 12. Take maximum reading and determine shim to be used. Use no more than two shims.

Primary shaft adjustment shim


a. Subtract diaphragm spring thickness (0.026 in {0.65 mm}) from gap determined in Step 11 for primary shaft. b. Make shim selection range by subtracting standard clearance parameters from result in previous step. c. Select thinner shim within range to obtain standard clearance. Standard clearance: 0~0.002 in (0~0.05 mm) Example: 0.048 in (1.22 mm) - 0.026 in (0.65 mm) = 0.022 in (0.57 mm) Shim selection range: (0.022 in (0.57 mm) - 0.002 in (0.05 mm)) ~ (0.022 in (0.57 mm) - 0 mm (0 in)) = 0.020 in (0.52 mm) ~ 0.022 in (0.57 mm) Shim: 0.022 in (0.55 mm) Thickness (Shaft gears) 0.008 0.010 0.012 0.014 0.016 0.018 (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) in (mm) 0.020 0.022 0.024 0.026 0.028 (0.50) (0.55) (0.60) (0.65) (0.70)

Secondary shaft adjustment shim


a. Make shim selection range by adding standard clearance parameters to result in previous step. b. Select thinner shim within range to obtain standard clearance. Tightening amount: 0.001~0.003 in (0.03~0.08 mm) Shim selection range: (0.022 in (0.57 mm) + 0.001 in (0.03 mm)) ~ (0.022 in (0.57 mm) + 0.003 in (0.08 mm)) = 0.024 in (0.60 mm) ~ 0.026 in (0.65 mm) Shim: 0.024 in (0.60 mm) 1. Install SST (0K130 191 A05) to differential

2. Turn SST (0K130 322 020) with torque wrench. Adjust SST (0K900 175 A01) with SST (0K130 175 A03) until specified preload is obtained. Preload: 12.15~17.36 lb-in (1.37~1.96 Nm, 14~20 kg-cm)

3. Measure gap between A and B around circumference of SST (0K900 175 A01) by using feeler gauge. 4. Add 0.006 in (0.15 mm) to measured clearance and select combination of two shims closest in value to that measurement. Use no more than two shims.

Example: 0.013 in (0.32 mm) 0.013 in (0.32 mm) + 0.006 in (0.15 mm) = 0.019 in (0.47 mm). Nearest shim (on thick side) to 0.019 in (0.47 mm) is 0.020 in (0.50 mm). 5. Remove transaxle case and SST (0K900 175 AA0). 6. Remove selectors, primary shaft assembly and the differential. 7. Remove bearing races.

Assembly note
Oil seal (differential) 1. Using SST (0K201 170 AA1) and hammer, tap new oil seal in evenly until SST (0K201 170 AA1) contacts transaxle case. 2. Coat lip of oil seal with transaxle oil.

Thickness 0.004 0.008 0.010 0.012 0.014 0.016 0.018 0.020 0.022 0.024 0.026 (0.10) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65)

in (mm) 0.004 0.008 0.010 0.012 0.014 0.016 0.018 0.020 0.022 0.024 0.026 (0.10) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65)

Bearing race (differential)


1. Install adjustment shim(s) to differential case. 2. Apply transaxle oil to bearing race, and install it to differential case by using pipe.

Diaphragm spring on primary shaft


1. Install diaphragm spring as shown in figure.

Bearing race (transaxle case)


1. Install adjustment shim(s) to primary and secondary shaft bearing seats in transaxle case. 2. Apply transaxle oil to each bearing race, and install them to transaxle case by using pipe.

Oil seal (change rod assembly)


1. Install new oil seal by using pipe. 2. Coat lip of oil seal with transaxle oil. Outer diameter of pipe: 1.02 in (26.0 mm)

Boot
1. Install boot so that drain hole is facing downward when mounted on vehicle.

Oil seal (primary shaft)


1. Apply transaxle oil to outer circumference of oil seal, and install it to transaxle case by using pipe.

Bearing preload
Verify shaft gears and differential bearing preloads.Readjust bearing preloads if they are not within specification. 1. Set primary shaft gear assembly and differential into clutch housing.

2. Install transaxle case, and tighten to specified torque. Tightening torque: 28~38 lb-ft (38~51 Nm, 3.8~5.3 kg-m)

3. Install SST (0K130 171 A05) to differential. 4. Connect torque wrench to SST (0K130 171 A05) and measure preload. Preload: 13~17 lb-in (1.4~1.9 Nm, 14~20 kg-cm)

5. Remove SST (0K130 171 A05). 6. With transaxle facing in direction shown in figure, install SST (0K130 171 A05) to primary shaft gear assembly. 7. Connect torque wrench to SST (0K130 171 A05) and measure preload. Preload: 0.9~2.1 lb-in (0.1~0.2 Nm, 1.0~2.5 kg-cm)

8. Remove SST (0K130 171 A05), transaxle case, primary shaft gear assembly and differential. 9. Install secondary shaft gear assembly and transaxle case, and tighten to specified torque. Tightening torque: 28~38 lb-ft (38~51 Nm, 3.8~5.3 kg-m) 10. Install SST (0K130 171 A05) to secondary shaft gear assembly.

11. Connect torque wrench to SST (0K130 171 A05) and measure preload. Preload: 1.8~3.4 lb-in (0.2~0.4 Nm, 2.0~4.0 kg-cm)

REMOVAL
1. Remove the battery (-) cable.

2. Remove the air duct. 3. Remove the air cleaner and air flow hose assembly. 4. Disconnect the backup light switch connector.

5. Disconnect the clutch tube and clip. 6. Remove the clutch release cylinder (Refer to "CH" Group).

7. Remove the speedometer cable.

8. Remove the select cable and shift cable (Refer to "MT" Group). 9. Remove the starter motor mounting bolts. Remove the transaxle assembly upper connecting bolts. 10. Attach to the engine hooks using special tool (09200-38001).

11. Remove the transaxle mounting bracket and insulator. 12. Lift up the vehicle. 13. Remove the front tire. 14. Remove the drain plug and drain the transaxle gear oil. 15. Disconnect the tie rod end, lower arm ball joint and drive shaft. (Refer to "DS" Group). 16. Remove the gear box u-joint bolt and the return tube mounting bolts. 17. Remove the front muffler. 18. Remove the sub-frame mounting bolts and the sub-frame.

19. Remove the transaxle front and rear mounting bracket. 20. Remove the transaxle side mounting bolts. 21. Remove the transaxle assembly supporting by a jack.

When supporting the transaxle assembly, make sure that the lifting force is applied to a wide area, not to a small localized area.

a. Engine and transmission mounting insulators should be installed the specified them.

b. a. b. c. d. c.

Mounting bracket installation procedures. Engine mounting bracket. T/M mounting bracket. Rear roll stopper mounting bracket. Front roll stopper mounting bracket. Especially, when installing front roll stopper mounting bracket, be careful not to be crushed the insulator, if being crushed, idle vibration is high.

INSTALLATION
1. Installation is the reverse of removal.

DISASSEMBLY
1. Remove the T/M mounting bracket.

2. Remove the shift control cable bracket.

3. Remove the clutch release cylinder.

4. Remove the backup lamp switch.

5. Remove the speedometer driven gear.

6. Remove the clutch release fork shaft and the release bearing sleeve.

7. Remove the reamer bolt.

8. Remove the poppet ball assembly.

9. Remove the side cover and the reverse idler gear assembly.

10. Remove the select lever, the shift lever and sealing cap.

11. Remove the clutch housing from the transmission case with the snap ring extended.

12. Remove the interlock body and the control shaft.

13. Remove the shift rail.

14. Remove the fork shift (5th & Rev).

15. Remove the fork shift (3rd & 4th).

16. Remove the fork shift (1st & 2nd).

17. Remove the bearing retainer.

18. Remove the output shaft assembly and the input shaft assembly.

19. Remove the differential assembly.

20. Remove the detent body cover and the roller bearing.

21. Remove the differential bearing outer spacer using special tool (09455-33200) and the drive shaft oil seal.

22. Remove the shift arm and the select arm from the transmission case.

REASSEMBLY
1. Install the drive shaft oil seal using the special tool (09431-39000).

Insert the oil seal straightly.

2. Install the shift arm and the select arm in the transmission case.

3. Install the detent body cover and the roller bearing.

4. Install the differential assembly.

5. Install the output shaft assembly and the input shaft assembly.

6. Install the retainer bearing.

7. Install the fork shift (1st & 2nd).

8. Install the fork shift (3rd & 4th).

9. Install the fork shift (5th & Rev).

10. Install the shift rail.

11. Install the interlock body and the control shaft.

12. Assemble the clutch housing and the transmission case with the snap ring extended.

13. Install the select lever, the shift lever and the sealing cap.

14. Install the side cover and the reverse idler gear assembly. 15. Install the poppet ball assembly.

16. Install the reamer bolt.

17. Install the clutch release fork shaft and the release bearing sleeve.

18. Install the speedometer driven gear.

19. Install the backup lamp.

20. Install the clutch release cylinder mounting bracket.

21. Install the shift control mounting bracket.

22. Install the mounting bracket.

REMOVAL
1. Disconnect negative battery cable (first) and positive battery cable (second).

2. Remove two nuts and remove fresh air duct. 3. To remove air cleaner assembly, disconnect hose from intake manifold, MAF sensor connector, air temperature sensor connector and two bolts, one nut and then remove air cleaner assembly. 4. Disconnect back-up switch connector from connector bracket in case. 5. Disconnect vehicle speed sensor connector from right side of transaxle.

6. Disconnect ground strap (one bolt). 7. Disconnect crankshaft position sensor connector. 8. Remove two upper starter bolts.

9. Remove two upper clutch housing bolts.

10. Support engine with engine support bar SST (0K201 170 AA0).

11. Remove No. 4 engine mounting bolts (three to transaxle) and remove No. 4 engine mount. 12. Loosen four lug nuts from both front wheels (LH, RH). 13. Raise and properly support vehicle. 14. Remove both front wheels. 15. Remove splash shield under the left side of vehicle. (three bolts and three fasteners). 16. Remove engine mounting member (two bolts, four nuts).

17. Place drain pan under transaxle drain plug. 18. Remove transaxle drain plug and drain transaxle oil.

19. Disconnect retainer clip, set aside clutch hydraulic line and remove clutch release cylinder (two bolts).

20. Remove the left stabilizer control link from bracket attached to shock absorber after loosening the control link nut.

21. Remove left tie rod ends from steering knuckle by removing one cotter pin and one nut with SST (0K130 283 021).

22. Remove pinch bolt and front left ball joints and disconnect ball joints from steering knuckles.

23. Gently pry left drive shaft from transaxle.

24. Remove the joint shaft installed at the RH side. 25. Slide drive shaft assembly out of transaxle and install SST (0K201 270 014).

26. Remove four No. 2 engine mounting bolts and remove No. 2 engine mount. 27. Remove four catalytic converter bolts (two front, two rear) and remove catalytic converter. 28. Remove three No. 1 engine mount bracket bolts and loosen No. 1 engine mount nut. 29. Disconnect extension bar (two washers, one nut). 30. Disconnect control rod (one nut, one bolt, one clip). 31. Remove one lower starter bolts and set aside starter. 32. Remove four lower clutch housing bolts and support transaxle with jack or suitable floor jack and then remove remaining two bolts. 33. Gently separate transaxle assembly from engine and lower.

REPLACEMENT
1. Raise and suitably support vehicle. 2. Set transaxle on jack or floor jack and position transaxle under vehicle. 3. Raise transaxle and align transaxle with engine.

4. Connect transaxle to engine using six mounting bolts through clutch housing. Tightening torque: A : 28~38 lb-ft (37~52 Nm, 3.8~5.3 kg-m) B : 66~86 lb-ft (89~116Nm, 9.1~11.9kg-m)

1. Remove floor jack from transaxle. 2. Remove SST (0K201 270 014 ). 3. Install joint shaft and tighten the three bolts.(Refer to section DS) Tightening torque: 31~46 lb-ft (42~62 Nm, 4.3~6.3 kg-m)

4. Install starter using lower starter bolt. 5. Install new clip onto drive shaft.

6. Push left drive shaft into transaxle with opening of clip pointing upward. 7. Install left lower ball joints into steering knuckle then install pinch bolt. Tightening torque: 32~45 lb-ft (43~61 Nm, 4.4~6.2 kg-m) 8. Install left stabilizer control links to bracket attached to shock absorber. Tightening torque: 32~45 lb-ft (43~61 Nm, 4.4~6.2 kg-m)

9. Install left tie rod end to steering knuckle then install tie rod end nuts. Tightening torque: 22~33 lb-ft (30~44 Nm, 3.0~4.5 kg-m)

10. Insert cotter pins. 11. Connect control rod with one nut and two bolts. 12. Connect extension bar with two washers and one nut. 13. Install No. 1 engine mount then install three mounting bolts. Tightening torque: 49~69 lb-ft (67~93 Nm, 6.8~9.5 kg-m) 14. Install catalytic converter and four bolts (two front, two rear). Tightening torque: Front : 27~38 lb-ft (37~52 Nm, 3.8~5.3 kg-m) Rear : 31~45 lb-ft (42~61 Nm, 4.3~6.2 kg-m) 15. Install No. 2 engine mount, then install four mounting bolts. Tightening torque: 28~38 lb-ft (38~51 Nm, 3.8~5.3 kg-m) 16. Install clutch release cylinder with two bolts and attach hydraulic line to retainer clip.

Tightening torque: 13~19 lb-ft (18~26 Nm, 1.9~2.6 kg-m)

17. Install drain plug. 18. Install engine mounting member-to-chassis bolts (two front) and nuts (two rear). Tightening torque: A : 48~65 lb-ft (64~89 Nm, 6.5~9.1kg-m) 19. Install two No. 2 engine mount-to-mounting member nuts. Tightening torque: B : 23~38 lb-ft (38~51 Nm, 3.8~5.3kg-m)

20. Install left splash shield (three bolts and three fasteners) 21. Install both right and left wheels, then tighten both right and left lug nuts (four lug nuts each). Tightening torque: 65~87 lb-ft (88~118 Nm, 9~12 kg-m) 22. Install No. 4 engine mount then install mounting nuts (three to transaxle). Tightening torque: 49~68 lb-ft (68~93 Nm, 6.8~9.5kg-m)

23. Lower vehicle. 24. Remove engine support bar SST(0K201 170 AA0A).

25. Install two upper clutch housing bolts. Tightening torque: 66-86 lb-ft (89-116 Nm, 9.1-11.9 kg-m)

26. Install two upper starter bolts. Tightening torque: 27~38 lb-ft (37~52 Nm, 3.8~5.3 kg-m)

27. Reconnect crankshaft position sensor connector. 28. Reconnect ground strap with one bolt. 29. Reconnect vehicle speed sensor connector.

30. Reconnect back-up switch connector. 31. Reinstall air cleaner assembly. 32. Reconnect air temperature sensor connector. 33. Reconnect MAF sensor connector. 34. Reinsert data link connector. 35. Reinstall fresh air duct with two nut.

36. Reconnect positive (first) then negative (last) battery cables. 37. Add gear oil, refer to Oil inspection. 38. Test vehicle and check fluid levels.

DISASSEMBLY
1. Mount the transaxle on the SST(0K130 990 007/0K130 175 011A).

2. Remove the release bearing and the release fork. 3. Remove the oil level gauge. 4. Remove the speed sensor.

5. Remove the backup lamp switch. 6. Remove the rear cover.

To remove the rear cover, lightly tap the rear cover using a plastic hammer.

Do not reuse the removed lock nut. 7. Lock the primary shaft with the SST(0K201 323 021).

8. Shift to 1st or 2nd gear to lock the rotation of primary shaft. 9. Uncrimp the tabs of the lock nuts. 10. Remove the lock nut from the primary and secondary shaft and remove the reverse clutch cone and the reverse synchronizer sleeve from the primary shaft.

Do not reuse the removed roll pin. 11. Remove the roll pin from the 5th shift fork with a pin punch.

12. Remove the synchronizer ring and 5th shift fork, the 5th clutch hub assembly, 5th gear synchronizer ring, 5th gear sleeve at the same time. 13. Remove the secondary 5th gear.

14. After loosening the detent plug, remove the spring and the steel ball by using a magnetic stick.

15. Remove the reverse idle shaft lock bolt from the transaxle case assembly. 16. Remove the transaxle assembly.

To remove the transaxle case, lightly tap the transaxle case using a plastic hammer. 17. Remove the magnet. 18. Remove the reverse idle shaft and the reverse idle gear.

19. Remove the control case assembly after loosening 3 bolts.

20. Remove the lever spring set. 21. After putting shift lever in neutral, remove the roll pin from the 1/2 shift fork using a pin punch.

Do not reuse the removed roll pin.

22. Remove the 1/2 shift rod and the 1/2 shift fork. 23. After removing the roll pin from the 3/4 shift fork and the 3/4 shift rod end by using a pin punch, remove the 3/4 shift fork and shift rod end.

24. Remove E-Ring from the 5/R shift rod. 25. After removing the roll pin from the 5/R shift rod end by using a pin punch, remove the 5/R shift rod and 5/R shift rod end.

26. Remove the primary shaft geartrain and secondary shaft geartrain as an assembly.

27. Remove the differential assembly.

ASSEMBLY

Apply the transaxle oil to the differential bearing outer race. 1. Install the differential assembly in the clutch housing.

a. Be sure not to damage the oil seal of the clutch housing side during installing the primary shaft. b. Apply the transaxle oil to the lips of the primary oil seal. c. Apply the transaxle oil to the secondary bearing outer race. 2. Install the primary shaft and the secondary shaft assembly in the clutch housing.

3. Assemble the 3rd/4th shift fork to the 3rd/4th clutch hub sleeve, insert the 5th/Rev shift rod into the shift fork and insert the 5th/Rev shift rod pin.

Use a new roll pin. 4. Align the 5th/Rev shift rod end with the 5th/Rev shift rod and insert the roll pin. 5. After inserting the 3rd/4th shift rod into the 3rd/4th shift fork, insert the 3rd/4th shift fork into the 3rd/4th shift rod end.

Use a new roll pin.

6. Align the 3rd/4th shift rod end with the 3rd/4th shift rod and insert the roll pin. 7. Align the 3rd/4th shift rod with 3rd/4th shift fork and insert the roll pin. 8. Assemble the 1st/2nd shift fork to the 1st/2nd clutch hub sleeve, install the 1st/2nd shift rod.

Use a new roll pin.

9. Align the 1st/2nd shift rod with the 1st/2nd shift fork and insert the roll pin.

Use a new E-ring.

10. Insert the E-Ring into 5th/Rev shift rod. 11. Align the projection of the reverse shift lever with the 5th/Reverse shift rod end groove, and set the reverse shift lever to the clutch housing. 12. Install a new O-Ring to the reverse shift lever shaft.

Install the O-Ring so that it is on the outside. 13. Insert the reverse lever shaft into the reverse lever.

14. Insert the pin. 15. After assembling the lever spring set, tighten bolts. Tightening torque: 5.8~8.3 lb-ft (7.8~11.3 Nm, 80~115 kg-cm) 16. After installing the control case assembly, tighten bolts. Tightening torque: 5.8~8.3 lb-ft (7.8~11.3 Nm, 80~115 kg-cm)

When assembling the control case assembly, make sure to use the correct length bolt. Bolt "A" is longer than bolt "B"

17. Install the reverse idle shaft and the reverse idle gear.

18. Install the magnet.

Thoroughly clean sealants from clutch housing and the transaxle case. 19. Apply a thin coat of sealant (Threebond#1216T or 1216TB) on the contacting surface of the clutch housing and the transaxle case.

20. Tighten the transaxle case mounting bolts. Tightening torque: 13.7~18.8 lb-ft (18.6~25.5 Nm, 1.9~2.6 kg-m)

21. Tighten the reverse idle shaft locking bolt to the transaxle case assembly. Tightening torque: 13.7~18.8 lb-ft (18.6~25.5 Nm, 1.9~2.6 kg-m)

a. Since the length of detent springs are different, be sure to select the correct spring. b. The length of detent spring: 5th/Rev is longer than 1st/2nd, 3rd/4th. c. Apply sealant to the detent plug. 22. Insert the steel ball, spring and tighten the detent plug. Tightening torque: 10.8~15 lb-ft (15~20 Nm, 1.5~2.1 kg-m)

23. Assemble the secondary 5th gear.

a. Since the shape of synchronizer ring are different, be sure to install correctly b. There is missing synchronizer teeth in 3 places on the synchronizer ring of the reverse clutch hub assembly side.

Pay attention for the assembling direction of 5th gear sleeve. 24. Install the 5th gear sleeve, 5th gear and the synchronizer ring.

Assemble the oil groove of 5th clutch hub assembly to the 5th gear side.

25. After installing the 5th shift fork to the 5th clutch hub assembly, assemble the 5th clutch hub assembly and the 5th shift fork. 26. Assemble the synchronizer ring. 27. Assemble the reverse clutch cone and the reverse synchronizer sleeve at first, install it to the primary shaft.

Use a new roll pin. 28. Insert the roll pin to the 5th shift fork. 29. To prevent the primary shaft from rotating, shift to 1st and 2nd gear.

30. Install SST(0K201 171 010) on the primary shaft.

Use a new lock nut.

31. To prevent the lock nut from loosening after tightening it on to the primary shaft and secondary shaft, use caulking. Tightening torque: 94~151 lb-ft (127~206 Nm, 13~21 kg-m) 32. Measure thrust clearance of the 5th gear and the reverse clutch cone with a dial indicator. Clearance 5th gear: 0.0029~0.0156 in (0.075~0.395 mm) Reverse clutch cone: 0.004~0.01 in (0.1~0.25 mm)

If not within the specification, reassemble the transaxle.

Thoroughly clean sealants from the transaxle case and the rear cover. 33. Apply a thin coat of sealant (Threebond#1216 or 1216TB) to the contacting surface of the transaxle case and the rear cover.

34. Install the rear cover, making sure to align the stopper groove position of the reverse clutch cone. Tighten bolts. Tightening torque: 5.8~8.3 lb-ft (7.8~11.3 Nm, 80~115 kg-cm)

35. Insert a washer onto the backup lamp switch and install the switch. Tightening torque: 14~21.7 lb-ft (20~29.4 Nm, 2.0~3.0 kg-m) 36. Assemble the speed sensor to the speedometer driven gear. Tightening torque: 5.8~8.3 lb-ft (7.8~11.3 Nm, 80~115 kg-cm) 37. Insert a bush to the change rod.

38. Assemble the release bearing and the release fork. 39. Remove the transaxle from the SST(0K130 175 011A).

Do not damage the transaxle case. 40. Remove the secondary bearing outer race of the transaxle case with a screw driver.

Manual Transaxle Case

2004 > 1.6L DOHC >

Clutch housing and transaxle case components

Do not remove an oil seal if not necessary. 1. Disassemble in order on figure, refer to Disassembly note. 2. Assembly will be in reverse order of disassembly.

2004 > 1.6L DOHC >

Disassembly note
Bearing outer race (primary shaft side) 1. Remove bearing outer race by using SST(0K130 170 012).

Reverse lever shaft


1. Remove roll pin using pliers. 2. Protect reverse lever shaft with rag and remove shaft with pliers.

Oil seal (Change rod)


1. Remove oil seal with screwdriver.

Funnel and bearing outer race (Secondary shaft)


1. Remove bearing outer race by lifting out funnel and race together.

Remove bearing outer race with screwdriver if necessary. a. Insert screwdriver between clutch housing and bearing outer race. b. Pry bearing outer race free.

Oil seal (Primary shaft)

Do not damage clutch housing. 1. Remove oil seal with screwdriver.

Oil seal (Differential)


1. Remove oil seal with screwdriver.

Bearing outer race (Differential)


1. Install SST(0K130 170 012) to bearing outer race. 2. Remove bearing outer race.

Bearing outer race and adjust shim (Differential)


1. Install SST(0K130 170 012) to bearing outer race. 2. Remove bearing outer race and adjust shim.

Oil seal (Speedometer gear case)


1. Remove oil seal.

Assembly note
Transaxle case oil seal (Differential side) 1. Assemble oil seal using SST (0K201 170 AA1).

Shift Lever

2004 > 1.6L DOHC >

Shift mechanism
Components

Overhaul
1. Disassemble in the order shown in the figure. 2. Inspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, refer to Assembly note.

COMPONENT

1. Disassemble in the order shown in the figure. 2. Inspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of disassembly.

2004 > 1.6L DOHC >

Assembly note
Extension bar 1. Install the extension bar to the floor, and then onto the transaxle.Tighten the extension bar nut at the transaxle. Tightening torque: 23~34 lb-ft (31~46Nm, 3.2~4.7 kg-m) 2. Tighten the shifter bracket nuts to the specified torque. Tightening torque: 86.9~130.2 lb-in(9.8~14.7 Nm, 100~150 kg-cm)

Spring
Make sure that the hooked part of the spring is properly seated in the bracket groove, as shown in the figure.

The Other Manual Transaxle System

2004 > 1.6L DOHC >

COMPONENTS

Do not remove an oil seal if not necessary. 1. Disassemble in order on figure. 2. Assembly will be in reverse order of disassembly.

2004 > 1.6L DOHC >

DISASSEMBLY
1. Remove the speedometer driven gear.

2. Remove the pin with long-nosed pliers. 3. After removing the reverse lever shaft from the reverse shift lever, remove the reverse shift lever.

4. After loosening bolt, remove the change arm and the change rod.

5. After loosening two bolts, remove the baffle plate.

Remove the secondary bearing outer race with a screwdriver if necessary. 6. Insert a screwdriver into the secondary bearing outer race of the clutch housing shaft. 7. Lift up the bearing outer race. 8. While lifting up the funnel and the bearing outer race, lift up the bearing outer race.

9. Remove the change rod oil seal with a screwdriver.

Do not damage the clutch housing.

10. Remove the primary oil seal with a screwdriver.

11. Remove the differential oil seal with a screwdriver. 12. Install SST(0K130 170 012) on the differential bearing outer race. 13. Remove the bearing outer race with a suitable pipe. 14. After installing SST(0K130 170 012) on the bearing outer race of the differential side, remove the bearing outer race and the adjust shim from the transaxle case.

15. Remove the oil seal of the transaxle case of the differential side with a screw driver.

ASSEMBLY
PRECAUTION a. Before installing the clutch housing and the transaxle case, adjust the following bearing preload and assemble the suitable adjust shim. b. The primary shaft preload. c. The secondary shaft preload. d. The adjust shim in the differential side.

a. After measuring the secondary preload use a selected shim as a adjust shim. b. Apply the transaxle oil to the adjust shim and the bearing outer race. 1. After inserting the adjust shim into the transaxle case, assemble the secondary bearing outer race.

Apply the transaxle oil to outer surface of the oil seal. 2. Assemble the differential oil seal of the transaxle case with a SST(0K201 170 AA1).

3. Assemble the differential oil seal of the clutch housing with a SST(0K201 170 AA1).

a. Use an adjust shim which is selected for adjusting the differential. b. Apply the transaxle oil on the adjust shim and the bearing outer race.

4. After inserting the adjust shim into the transaxle case, assemble the differential bearing outer race. 5. Assemble the differential bearing outer race of the clutch housing with a SST(0K201 170 AA1).

Apply the transaxle oil to outer surface of the change rod oil seal. 6. Install the oil seal.

Apply the transaxle oil to the secondary bearing outer race. 7. Install the funnel and the secondary bearing outer race to the clutch housing.

8. Install the baffle plate and tighten bolts.

Tightening torque: 5~7.2 lb-ft (6.8~9.8 Nm, 70~100 kg-cm)

Assemble the boot with facing air bleed downward, as shown in figure.

9. Push the boot into the change rod assembly.

10. Install the change rod assembly to the clutch housing. 11. After inserting the change arm into the change rod, tighten bolts. Tightening torque: 8.7~10 lb-ft (11.7~13.7 Nm, 1.2~1.4 kg-m)

12. Install the speedometer shaft and gear assembly to the sleeve. 13. Install a new O-ring to the speedometer sleeve.

14. After installing the speedometer driven gear to the clutch housing, tighten bolts. Tightening torque: 5.0~7.2 lb-ft (6.8~9.8 Nm, 80~115 kg-cm)

2004 > 1.6L DOHC >

Symptom related diagnostic procedures


Diagnostic chart Problem Shift lever does not shift smoothly or is hard to shift Possible cause Seized shift lever ball seat Seized control rod joint Bent control rod Replace Replace Replace Replace Replace Replace Replace Lubricate with grease Add oil Replace with oil of specified quality Replace Replace Replace Replace Replace Replace Replace Adjust Adjust Replace Replace Replace Tighten Replace Replace Replace Replace Replace Replace Replace Replace Replace Tighten Add oil Replace with oil of specified quality Replace Replace Replace Replace Replace Replace Action

Worn control rod bushing Too much play in shift Weak shift lever ball spring lever Worn shift lever ball bushing Bent control rod No grease in shifter Insufficient oil Deterioration of oil quality Wear or play of shift fork or shift rod Worn synchronizer ring Worn synchronizer cone area of gear Bad contact of synchronizer ring and cone area of gear Excessive gear side clearance Worn bearing Worn synchronizer key spring Excessive primary shaft bearing preload Improperly adjusted change guide plate

Difficult to shift

Bent control rod Worn control rod bushing Weak shift lever ball spring Improperly installed extension bar Worn shift fork Worn clutch hub Worn clutch hub sleeve Does not stay in gear Worn sliding surface of shaft gears Worn sliding surface of gear Worn sliding groove of control rod end Weak detent spring Excessive thrust clearance Worn bearing Improperly installed or loose engine mount Insufficient oil Deterioration of oil quality Worn bearing Worn sliding surfaces of gears or shafts Excessive gear backlash Damaged gear teeth Foreign material in gears Damaged differential gear or excessive backlash

Abnormal noise

2004 > 1.6L DOHC >

Oil inspection
1. Raise vehicle and support it with safety stands.

Keep vehicle level when checking oil level. 2. Remove oil level plug and washer.

3. Verify that oil level is near bottom of plug hole.

4. If oil level is low, fill specified amount and type of oil until level reaches bottom of hole. 5. Install new washer on oil level plug and reinstall plug in case. Tightening torque: 29~43 lb-ft (40~58 Nm , 4.0~6.0 kg-m) 6. Lower vehicle.

REPLACEMENT
Oil change 1. Raise vehicle and support it with safety stands.

Keep vehicle level when checking oil level. 2. Remove drain plug at bottom of transaxle case and drain fluid into suitable container.

3. Install new washer on drain plug and reinstall plug in case. Tightening torque: 29~43 lb-ft (40~58 Nm, 4.0~6.0 kg-m) 4. Remove oil level plug from transaxle case. 5. Add specified amount and type of oil into oil level plug hole until level reaches bottom of hole.

Specified oil: Grade : API Service GL-4 Viscosity : SAE 75W-90 (Fill-for-Life) Capacity : 2.9 US qt (2.7 l, 2.4 lmp qt) 6. Install new washer on plug and reinstall plug in case. Tightening torque: 29~43 lb-ft (40~58 Nm, 4.0~6.0 kg-m) 7. Warm up vehicle until transaxle oil reaches its normal temperature, then check for leakage of transaxle oil. 8. Lower vehicle.

Oil seal change


1. Jack up vehicle and support it with safety stands. 2. Remove drain plug at bottom of transaxle case and drain fluid into a container.

3. Remove front wheel. 4. Remove splash shield under the left side of vehicle. 5. Remove the stabilizer control link from bracket attached to shock absorber after loosening the control link nut.

Do not damage dust boots. 6. Remove pinch bolt and pull lower arm downward to separate knuckle from lower control arm ball joint.

7. Loosen nut and disconnect tie-rod end with SST(0K130 283 021).

Do not subject cv joint to shock when removing driveshaft. 8. Insert pry bar between outer ring and transaxle and pry driveshaft from transaxle. 9. Suspend driveshaft with rope.

10. Remove oil seal with screwdriver.

a. Tap in until oil sear is flush with case. b. Coat oil seal lip with transaxle oil. 11. Tap new oil seal into transaxle case with SST (0K201 170 AA1).

12. Replace driveshaft end clip and install driveshaft into transaxle with end-gap of clip facing upward.

SERVICE ADJUSTMENT PROCEDURES


OIL INSPECTION 1. Raise vehicle and support it with safety stands. 2. Remove the oil level gauge.

3. Verify that oil level is within the specification.

Keep vehicle level when checking oil level.

4. If oil level is low, fill specified amount and type of oil through the oil level gauge hole.

5. Reinstall the oil level gauge in case. 6. Lower vehicle.

OIL CHANGE
1. Raise vehicle and support it with safety stands.

Keep vehicle level when checking oil level. 2. Remove drain plug at bottom of transaxle case and drain fluid into suitable container.

3. Install new washer on drain plug and reinstall plug in case. Tightening torque: 29~43 lb-ft (40~58 Nm, 4.0~6.0 kg-m) 4. Add specified amount and type of oil into the oil level gauge hole.

Specified oil Grade: API Service GL-4 Viscosity: SAE 75W-90 (Fill-for-life) Capacity: 2.80 US qt(2.65L, 2.32 lmp qt)

5. Warm up vehicle until transaxle oil reaches its normal temperature, then check for leakage of transaxle oil. 6. Lower vehicle.

OIL SEAL CHANGE


1. Jack up vehicle and support it with safety stands. 2. Remove drain plug at bottom of transaxle case and drain fluid into a container.

3. Remove front wheel. 4. Remove splash shield under the left side of vehicle. 5. Remove the stabilizer control link from bracket attached to shock absorber after loosening the control link nut.

Do not damage dust boots. 6. Remove pinch bolt and pull lower arm downward to separate knuckle from lower control arm ball joint.

7. Loosen nut and disconnect tie rod end with SST(0K130 283 021).

Do not subject cv joint to shock when removing drive shaft. 8. Insert pry bar between outer ring and transaxle and pry drive shaft from transaxle.

9. Suspend drive shaft with rope. 10. Remove oil seal with screwdriver.

a. Tap in until oil seal is flush with case. b. Coat oil seal lip with transaxle oil.

11. Tap new oil seal into transaxle case with SST (0K201 170 AA1 ).

12. Replace drive shaft end clip and install drive shaft into transaxle with end-gap of clip facing upward.

Manual Transaxle Gear System

Main Shaft

2004 > 1.6L DOHC >

COMPONENT
1. Measure thrust clearance of all gears before disassembly, refer to preinspection. 2. Assemble in order shown in figure. 3. Assembly will be in reverse order of disassembly.

Check thrust clearance of all gears before disassembly and after assembly.

2004 > 1.6L DOHC >

DISASSEMBLY

Hold the shaft with one hand so that it does not fall. 1. Remove the ball bearing with a SST(0K130 175 008).

2. Remove 4th gear. 3. Remove the retaining ring.

4. Remove the clutch hub assembly (3rd/4th), the synchronizer ring (3rd) and the 3rd gear. 5. Remove the bearing with a SST(0K670 990 AA0).

PRE INSPECTION
3RD GEAR THRUST CLEARANCE 1. Measure the clearance between 3rd gear and 2nd gear. Clearance: 0.0024~0.0083 in (0.06~0.21 mm)

2. If the clearance exceeds the maximum, check the contact surface of 3rd gear, 2nd gear and the clutch hub (2nd/3rd), replace worn or damaged parts.

4TH GEAR SIDE CLEARANCE


1. Measure the clearance between 4th gear and the ball bearing. Clearance: 0~0.015 in (0~0.37 mm)

2. If the clearance exceeds the maximum, check the contact surface of 4th gear, the ball bearing and the clutch hub (3rd/4th), replace worn or damaged parts.

INSPECTION
SYNCHRONIZER RING 1. Inspect individual synchronizer ring teeth for damage, wear or cracks. 2. Inspect the taper surface for wear or cracks.

Set the synchronizer ring squarely in the gear then measure around the circumference. 3. Measure the clearance between the synchronizer ring and the flank surface of the gear. Standard clearance: 0.0433~0.0551 in (1.1~1.4 mm) Minimum: 0.03 in (0.8 mm)

PRIMARY SHAFT

If the shaft gear is replaced, adjust the bearing preload. 1. Inspect the shaft gear runout Maximum runout: 0.004 in (0.10 mm)

2. Inspect the splines for damage or wear. 3. Inspect the gear teeth surface for damage, wear or cracks. 3rd gear, 4th gear, 5th gear and gear sleeve (5th gear) a. Measure the clearance between the shaft gears and gears.

Oil clearance Items 3rd gear 4th gear 5th gear Shaft (A) (outer diameter) 1.377 - 1.378 (34.987 34.998) 1.218 - 1.219 (30.94 30.97) Gear(B) (inner diameter) 1.220 - 1.221 (31.00 - 31.02) 1.339 - 1.340 (34.00 - 34.02) Sleeve(C) (outer diameter) 1.336 - 1.337 (33.94 - 33.97)

b. Inspect the 5th gear sleeve for damage. c. Inspect the gear teeth surface for damage, wear or cracks.

Bearing a. Inspect for damage or rough rotation.

INSPECTION
If installation of the primary shaft is completely done, measure the thrust clearance. Thrust clearance of 3rd gear a. Measure the thrust clearance between 3rd gear and 2nd gear. Clearance: 0.0024~0.0083 in (0.06~0.21 mm)

Thrust clearance of 4th gear a. Measure the thrust clearance between 4th gear and the ball bearing.

Clearance: 0.0039~0.146 in (0.1~0.37 mm) Maximum: 0.022 in (0.57 mm)

If not as specified, reassemble the primary shaft assembly.

ASSEMBLY
1. Assemble 3rd gear, the synchronizer ring and the clutch hub assembly. 2. Assemble the new retaining ring.

3. Assemble 4th gear. 4. Assemble the new ball bearing with press.

SELECTION OF SHIM
Adjust the preload and select the shim as follows. 1. Set the primary shaft assembly into the clutch housing. 2. Install the transaxle case to the clutch housing and tighten bolts to the specified torque. Tightening torque: 14~19 lb-ft (19~26 Nm, 1.9~2.6 kg-m)

3. Mount the dial indicator to the transaxle hanger and measure the primary shaft thrust clearance. Clearance: 0~0.004 in (0~0.10 mm)

4. Select the closest shim on the thin side from the table. Thickness of adjustment shim: 0.012 in (0.3 mm), 0.016 in (0.4 mm), 0.02 in (0.5 mm)

Intermediate Shaft

2004 > 1.6L DOHC >

Secondary shaft assembly


1. Measure thrust clearance of 1st gear and 2nd gear before disassembly, refer to Preinspection. 2. Disassemble in order shown in figure, refer to Disassembly note.

2004 > 1.6L DOHC >

Preinspection
Secondary 1st gear thrust clearance 1. Measure clearance between secondary 1st gear and differential drive gear. Clearance: 0.002~0.011 in (0.05~0.28 mm) Maximum: 0.013 in (0.33 mm) 2. If clearance exceeds maximum, check contact surfaces of secondary 1st gear, differential drive gear of secondary shaft, and 1st/2nd clutch hub assembly. Replace worn and damaged parts.

Secondary 2nd gear thrust clearance


1. Measure clearance between secondary 2nd gear and secondary 3rd gear. Clearance: 0.007~0.018 in (0.18~0.46 mm) Maximum: 0.020 in (0.51 mm) 2. If dlearance exceed masimum, check contact surfaces of secondary 2nd gear, secondary 3rd gear, and 1st/2nd clutch hub assembly. Replace worn and damaged parts.

Disassembly note
Bearing and secondary 4th gear 1. Remove bearing and secondary 4th gear by using SST (0K201 172 008).

Secondary 3rd gear and Secondary 2nd gear


1. Remove retaining ring. 2. Shift gears to 1st gear. 3. Remove secondary 3rd gear and secondary 2nd gear by using SST (0K201 172 008).

1st/2nd clutch hub assembly, 1st synchronizer ring, and secondary 1st gear
1. Remove retaining ring. 2. Remove 1st/2nd clutch hub assembly, 1st gear synchronizer ring, and secondary 1st gear using press.

Bearing (differential drive gear end)


1. Remove bearing by using SSTs.

Inspection

Inspect all parts and repair or replace as necessary.

Gears
1. Inspaect synchronizer cones for wear. 2. Inspaect gear teeth for damage, wear and cracks. 3. Inspaect synchronizer ring matching teeth for damage and wear.

Synchronizer ring
1. Inspect synchronizer ring teeth for damage, wear and cracks. 2. Inspect tapered surface for wear and cracks.

3. Set synchronizer ring squarely in gear. 4. Measure clearance between synchronizer ring and flank surface of gear. Standard clearance : 0.059 in (1.5 mm) Minimum : 0.031 in (0.8 mm)

Clutch hub assembly


1. Inspect clutch hub sleeve and hub operation. 2. Inspect gear teeth for damage, wear, and cracks. 3. Inspect synchronizer keys for damage, wear and cracks.

4. Measure clearance between clutch hub sleeves and shift forks.

Clearance

Reverse idle gear and reverse lever


1. Inspect gear teeth for damage, wear and cracks. 2. Measure clearance between reverse idle gear bushing and reverse lever. Standard c learance : 0.011~0.013 in (0.28~0.3 mm) Maximum : 0.020 in (0.5 mm)

Bearing
1. Inspect for damage and rough rotation.

Primary shaft and secondary shaft


1. Inspect gear contact surface for damage and wear. 2. Inspect splines for damage and wear.

3. Inspect gear teeth for damage, wear and cracks. 4. Inspect oil passage for clogging. 5. Measure primary and secondary shaft runout. Primary shaft runout : 0.002 in (0.05 mm) max.

Secondary shaft runout : 0.0006 in (0.015 mm) max.

If shaft is replaced, adjust bearing preload.

6. Determine clearance between shafts and gears.

Clearance

Vehicle speed sensor (speedometer driven gear)


1. Inspect teeth for damage and wear. 2. Inspect O-ring for damage and wear.

Assembly
Precaution 1. Replace all O-rings and gaskets. 2. Verify that all parts are completely clean before assembly. 3. Assemble parts within 10 minutes after applying sealant. Allow all sealant to cure for at least 30 minutes after assembly before filling transaxle with oil. 4. Replace bearing races and bearings as sets.

Secondary shaft assembly


Assemble in order shown in figure, refer to Assembly note.

Assembly note
Clutch hub

Synchronizer key dimensions

1. Install synchronizer keys and springs in clutch hub.

Bearing (differential drive gear end)


1. Install new bearing by using SST (0K130 175 A11).

Secondary 1st gear, 1st synchronizer ring and 1st/2nd clutch hub assembly

The 1st synchronizer ring has teeth missing at three places around its outer edhe to help distinguish it from other synchronizer rings.

1. Assemble secondary 1st gear, 1st synchronizer ring, and 1st/2nd clutch hub assembly as shown in figure. 2. Align synchronizer ring grooves and synchronizer keys.

3. Press on 1st/2nd clutch hub assembly by using SST (0K990 175 A11).

2nd synchronizer ring, 2nd gear and secondary 3rd gear


1. Install 2nd synchronizer ring and secondary 2nd gear. 2. Install secondary 3rd gear by using SST (0K130 175 A13/0K011 270 A02/0K130 175 A11).

Secondary 4th gear and bearing


1. Install secondary 4th gear and bearing by using SST (0K130 175 A13/0K011 270 A02/0K130 175 A11).

2. Measure clearance between 1st gear and differential drive gear. Clearance: 0.002~0.011 in (0.05~0.28 mm) Maximum: 0.013 in (0.33 mm)

3. Measure clearance between secondary 2nd gear and secondary 3rd gear. Clearance: 0.007~0.018 in (0.18~0.46 mm) Maximum: 0.020 in (0.51 mm) 4. If not as specified, disassemble and reassemble secondary shaft assembly.

Count Shaft

2004 > 1.6L DOHC >

COMPONENT
1. Measure thrust clearance of 1st gear and 2nd gear before disassembly. 2. Disassemble in order shown in figure. 3. Assembly will be in reverse order of disassembly.

2004 > 1.6L DOHC >

DISASSEMBLY NOTE
BEARING AND SECONDARY 4TH GEAR Remove bearing and secondary 4th gear by using SST(0K201 172 008).

SECONDARY 3RD GEAR AND SECONDARY 2ND GEAR


1. Shift gears to 1st gear. 2. Remove secondary 3rd gear and secondary 2nd gear by using SST(0K201 172 008).

PREINSPECTION
SECONDARY 1ST GEAR THRUST CLEARANCE 1. Measure clearance between secondary 1st gear and differential drive gear. Clearance: 0.002~0.011 in (0.05~0.28 mm)

2. If clearance exceeds maximum, check contact surfaces of secondary 1st gear, differential drive gear of secondary shaft, and 1st/2nd clutch hub assembly. Replace worn and damaged parts.

SECONDARY 2ND GEAR THRUST CLEARANCE


1. Measure clearance between secondary 2nd gear and secondary 3rd gear. Clearance: 0.002~0.0067 in (0.05~0.17 mm)

2. If clearance exceeds maximum, check contact surfaces of secondary 2nd gear, secondary 3rd gear, and 1st/2nd clutch hub assembly. Replace worn and damaged parts.

INSPECTION

Inspect all parts and repair or replace as necessary.

GEARS
1. Inspect synchronizer cones for wear. 2. Inspect gear teeth for damage, wear, and cracks. 3. Inspect synchronizer ring matching teeth for damage and wear.

SYNCHRONIZER RING
1. Inspect synchronizer ring teeth for damage, wear, and cracks. 2. Inspect tapered surface for wear and cracks.

3. Set synchronizer ring squarely in gear. 4. Measure clearance between synchronizer ring and flank surface of gear. Standard clearance: 0.055~0.067 in (1.4~1.7 mm) Minimum: 0.031in (0.8 mm)

CLUTCH HUB ASSEMBLY


1. Inspect clutch hub sleeve and hub operation. 2. Inspect gear teeth for damage, wear, and cracks. 3. Inspect synchronizer keys for damage, wear, and cracks.

4. Measure clearance between clutch hub sleeves and shift forks. Clearance Standard 1st/2nd 3rd/4th 0.004~0.014 (0.1~0.35) 0.011~0.02 (0.27~0.50) Maximum 0.029 (0.75) 0.070 (1.80)

REVERSE IDLE GEAR AND REVERSE LEVER


1. Inspect gear teeth for damage, wear, and cracks. 2. Measure clearance between reverse idle gear bushing and reverse lever. Standard clearance: 0.0037~0.013 in (0.095~0.33 mm) Maximum: 0.012 in (0.31 mm)

BEARING
1. Inspect for damage and rough rotation.

PRIMARY SHAFT AND SECONDARY SHAFT


1. Inspect gear contact surface for damage and wear. 2. Inspect splines for damage and wear. 3. Inspect gear teeth for damage, wear, and cracks. 4. Inspect oil passage for clogging. 5. Measure primary and secondary shaft runout. Secondary shaft runout: 0.0006 in (0.015 mm) max.

If shaft is replaced, adjust bearing preload. Oil clearance Shaft (Outer dia.) 1st 1.553 - 1.554 (39.445 - 39.47) Gear (inner dia) 1.555 - 1.556 (39.5 - 39.525) Sleeve (Outer dia) Clearance 0.001 - 0.003

2nd

1.384 - 1.385 (35.145 - 35.17)

1.850 - 1.851 (47.009 - 47.025)

(0.03 - 0.08)

ASSEMBLY NOTE
CLUTCH HUB Synchronizer key dimensions 1 1st/2nd 3rd/4th 5th/Rev 0.7087(18) 0.669(17) 0.669(17.0) 2 0.167(4.25) 0.167(4.25) 0.167(4.25) 3 0.197(5.0) 0.197(5.0) 0.197(5.0)

1. Install synchronizer keys and springs in clutch hub.

BEARING (DIFFERENTIAL DRIVE GEAR END)

Secondary 1st gear, 1st synchronizer ring and 1st/2nd clutch hub assembly
1. Assemble secondary 1st gear, 1st synchronizer ring, and 1st/2nd clutch hub assembly, as shown in figure. 2. Align synchronizer ring grooves and synchronizer keys.

3. Press on 1st/2nd clutch hub assembly by using SST(0K900 175 AA1).

2nd synchronizer ring, 2nd gear and secondary 3rd gear


1. Install 2nd synchronizer ring and secondary 2nd gear. 2. Install secondary 3rd gear by using SST(0K900 175 AA1).

Secondary 4th gear and bearing inner race


1. Install secondary 4th gear and bearing inner race by using SST(0K900 175 AA1).

2. Measure clearance between 1st gear and differential drive gear. Clearance: 0.002~0.011 in (0.05~0.28 mm)

3. Measure clearance between secondary 2nd gear and secondary 3rd gear. Clearance: 0.002~0.0067 in (0.05~0.17 mm)

4. If not as specified, disassemble and reassemble secondary shaft assembly.

SELECTION OF SHIM
1. Install the funnel and bearing outer race into the clutch housing.

2. Set the secondary shaft into the clutch housing. 3. Install the secondary shaft bearing outer race into the transaxle case. 4. Install the transaxle case to the clutch housing and tighten bolts to the specified torque. Tightening torque: 14~19 lb-ft (19~26 Nm, 1.9~2.6 kg-m)

5. Mount a dial indicator to the transaxle case and measure the secondary shaft end play. Clearance: 0.002~0.004 in (0.05~0.10 mm)

6. Select the shim as follows. a. Add the 0.001 in (0.03 mm) to the thrust clearance. b. Add the 0.003 in (0.08 mm) to the thrust clearance. c. Select the thickest shim in the range between (a) and (b). Example: 0.0087 in (0.22 mm) + 0.001 in (0.03 mm) = 0.0098 in (0.25 mm) 0.0087 in (0.22 mm) + 0.003 in (0.08 mm) = 0.012 in (0.30 mm) Range: 0.0098 in (0.25 mm) - 0.001 in (0.30 mm) Select the 0.012 in (0.30 mm) one Thickness of adjustmemt shim 0.0079(0.20) 0.016(0.40) 0.0098(0.25) 0.018(0.45) 0.012(0.30) 0.020(0.50) 0.014(0.35) 0.027(0.70)

Differential

2004 > 1.6L DOHC >

Components
1. Before disassembly, inspect backlash of side gears and pinion gears, refer to Preinspection. 2. Disassemble in order shown in figure, refer to Disassembly note. 3. Inspect all parts and repair or replace as necessary. 4. Assemble in reverse order of disassembly, refer to Assembly note. 5. Measure backlash after assembly, refer to Backlash of side gear and pinion gear.

components

COMPONENT

Do not remove side bearings unless necessary.

COMPONENT
1. Before disassembly, inspect backlash of side gears and pinion gears, refer to Preinspection. 2. Disassemble in order shown in figure, refer to Disassembly Note. 3. Inspect all parts and repair or replace as necessary. 4. Assemble in reverse order of disassembly, refer to Assembly Note. 5. Measure backlash after assembly, refer to Backlash of Side Gear and Pinion Gear.

2004 > 1.6L DOHC >

Preinspection
Backlash of side gear and pinion gear Measure backlash by following procedure: 1. Install left driveshaft and right joint shaft in differential assembly. 2. Support shafts on V-blocks as shown in figure. 3. Measure backlash of both pinion gears. Backlash : 0.002~0.006 in (0.05~0.15 mm) 4. If not as specified, replace worn and damaged parts.

Disassembly note
Bearing (ring gear opposite side)

Do not remove the bearing unless you are replacing it. 1. Remove bearing by using SST (0K130 171 013).

Side bearing inner race

Be careful not to drop differential case. 1. Using SST (0K670 990 AA0), remove side bearing inner race (opposite side of ring gear).

Bearing (ring gear side)


1. Remove bearing by using SST (0K670 990 AA0).

Inspection
1. Inspect all parts and repair or replace as necessary.

Ring gear and gear case assembly


1. Inspect ring gear for wear and cracks. If gear case is replaced, adjust bearing preload.

Bearing
1. Inspect for wear and rough rotation. If bearing is removed, then replace it and bearing race together, and adjust bearing preload.

Assembly note
Bearing (ring gear side) 1. Install new bearing by using SST (0K011 270 A02).

Bearing (ring gear opposite side)


1. Install speedometer drive gear. 2. Install new bearing by using SST (0K011 270 A02).

Roll pin
1. Install new roll pin as shown in figure to hold pinion shaft.

Backlash of side gear and pinion gear


Measure backlash by following procedure: 1. Install left driveshaft and right joint shaft in differential assembly. 2. Support shafts on V-blocks as shown in figure. 3. Measure backlash of both pinion gears. Backlash: 0.002~0.006 in (0.05~0.15 mm) 4. If not as specified, replace worn and damaged parts.

DISASSEMBLY
1. Clamp the differential case in a vise. 2. Remove the differential drive retaining bolts and remove the differential drive gea from the case.

3. Remove the taper bearing using the special tool (09433-21000).

Do not reuse the bearing removed from the shaft.

4. Drive out the lock pin from the hole A using a punch..

5. Drive out the pinion shaft.

REASSEMBLY
1. Install the spacer on the back of the side gear and then install the gear in the differential case.

a. When installing a new side gear, use a spacer of medium thickness [0.83-0.92 mm (0.33-0.036 in.)].

b. Do not reuse the lock pin. c. The lock pin head must be sunk below the flange surface of the differential case. 2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears by turning them. 3. Insert the pinion shaft.

4. Measure the backlash between the side gears and pinions. Standard value : 0.025-0.0150 mm (0.001-0.006 in.)

5. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.

Adjust the backlash of both side gears to the same specification. 6. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.

a. Do not reuse the lock pin. b. The lock pin head must not protrude more than 3 mm (0.0118 in.) gear in the differential case.

7. Install the tapered roller bearing on both sides of the differential case using the special tool (09455-21100).

When press-fitting the bearing, press on the inner race only.

8. Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the illustration. Specified sealant : BM stud locking No.2471

If a bolt is reused, remove the old sealant from the threads.

DISASSEMBLY
1. Remove two side gears and two thrust washers.

a. Use protective plates in vise to prevent damage to differential. b. Insert punch into spring pin hole from ring gear side. 2. Place gear case on a vise and knock pin out with suitable pin punch and hammer. Then remove two thrust washers, two pinion gears and pinion shaft.

3. Remove side bearing inner race (side opposite ring gear) from gear case with SST(0K130 171 013).

4. Remove speedometer drive gear. 5. Remove side bearing (ring gear side) from gearcase with SST(0K670 990 AA0).

RE-ASSEMBLY
1. Set speedometer drive gear onto ring gear and case assembly.

Do not reuse side bearings if they were removed.

2. Press side bearing (side opposite ring gear) into ring gear and case assembly with SST(0K990 175 AA1).

3. Press on other side bearing (ring gear side) in same manner. 4. Install pinion gears and thrust washers into case. 5. Install pinion shaft.

6. Install spring pin, and stake hole to prevent spring pin from coming out of gear case.

7. Install thrust washers and side gears into gear case at same time, then rotate them around pinion gears and align them with driveshaft holes.

Be certain that both side gears are centered in their respective driveshaft holes. If not, remove both side gears and re-install them again.

8. Measure backlash of side gears and pinion gears as follows: a. Install left and right driveshafts in differential assembly. b. Support driveshafts on V-blocks. c. Measure backlash of both pinion gears. Backlash Standard: 0.001~0.004 in (0.025-0.1 mm) Maximum: 0.020 in (0.5 mm)

9. If backlash is not within specification, replace differential assembly.

PRE-INSPECTION
Backlash of side gear and pinion gear 1. Before disassembly, measure backlash of side gears and pinion gears. If not within specification, replace differential assembly. Backlash Standard: 0.001-0.004 in (0.025-0.1 mm) Maximum: 0.020 in (0.5 mm)

PRE-INSPECTION
Backlash of side gear and pinion gear 1. Before disassembly, measure backlash of side gears and pinion gears. If not within specification, replace differential assembly. Backlash Standard: 0.001-0.004 in (0.025-0.1 mm) Maximum: 0.020 in (0.5 mm)

PREINSPECTION
Backlash of side gear and pinion gear Measure backlash by following procedure:

1. Install left driveshaft and right joint shaft in differential assembly. 2. Support shafts on V-blocks as shown in figure. 3. Measure backlash of both pinion gears. Backlash: 0~0.004 in (0~0.1 mm)

4. If not as specified, replace worn and damage parts.

INSPECTION
1. Inspect all parts and repair or replace as necessary.

RING GEAR AND GEAR CASE ASSEMBLY


1. Inspect ring gear for wear and cracks. If gear case is replaced, adjust bearing preload.

BEARING
1. Inspect for wear and rough rotation. If bearing is removed, then replace it and bearing race together, and adjust bearing preload.

DISASSEMBLY NOTE
Bearing (side opposite ring gear)

Do not remove the bearing unless you are replacing it.

1. Remove bearing by using SST(0K130 171 013).

Side bearing inner race

Be careful not to drop differential case. 1. With using SST(0K670 990 AA0), remove side bearing inner race (opposite side of ring gear).

Bearing (ring gear side)


Remove bearing by using SST(0K670 990 AA0).

ASSEMBLY NOTE
BEARING (RING GEAR SIDE) 1. Install new bearing by using SST(0K900 175 AA1).

BEARING (SIDE OPPOSITE RING GEAR)


1. Install speedometer drive gear. 2. Install new bearing by using SST(0K900 175 AA1).

Roll pin
1. Install new roll pin as shown in figure to hold pinion shaft.

Backlash of side gear and pinion gear


Measure backlash by following procedure: 1. Install left driveshaft and right joint shaft in differential assembly. 2. Support shafts on v-blocks as shown in figure. 3. Measure backlash of both pinion gears. Backlash: 0~0.004 in (0~0.1 mm) 4. If not as specified, replace worn and damage parts.

SELECTION OF SHIM
1. Install the bearing outer race into the clutch housing. 2. Set the differential assembly into the clutch housing.

Turn A and B until the gap shown in figure is eliminated. 3. Install the transaxle case side bearing outer race to a SST(0K900 175 AA0).

4. Set the SST(0K900 175 AA0) in the positions shown in figure.

5. Tighten the SST(0K900 175 AA0) to the specified torque. Tightening torque: 14~19 lb-ft (19~26 Nm, 1.9~2.6 kg-m)

Turn the bars until SST(0K900 175 AA0) can no longer be moved.

6. To set the bearings, mount the bars on parts "A" and "B" of the selector, and turn the selector so the gap is widened. 7. Turn in the reverse direction until the gap is eliminated. 8. Install SST(0K900 175 AA0/0K130 322 020) to the differential pinion gear, through the transaxle case.

9. Turn the SST (0K130 322 020) with a spring balance. Until the specified preload can be obtained, adjust the SST (Selector) with a bar. Preload: 10~14 lb-in (1.4~2.0 Nm, 14~20 kg-cm)

10. Remove the SST(0K130 322 020). 11. Measure the clearance around the entire circumference of the SST(0K900 175 AA0).

12. Select the proper adjust shim(s) to be used for the differential by referring to the table and selecting the shim which is nearest (on the thick side) to the largest measured clearance in the selector.

Thickness of adjust shim 0.004(0.10) 0.14(0.35) 0.022(0.55) 0.030(0.75) 13. Remove the SST(0K900 175 AA0). 14. Remove the transaxle case and SST(0K900 175 AA0). 15. Remove the bearing outer race from the SST(0K900 175 AA0). 16. Install the selected shim and the bearing outer race to the transaxle case. 0.0079(0.20) 0.016(0.40) 0.024(0.60) 0.032(0.80) 0.0098(0.25) 0.018(0.45) 0.026(0.65) 0.034(0.85) 0.012(0.30) 0.020(0.50) 0.028(0.70) 0.036(0.90)

BEARING PRELOAD (DIFFERENTIAL)


Measure the preload as follows. 1. Set the differential assembly into the clutch housing.

2. Install the transaxle case onto the clutch housing. Tightening torque: 14~19 lb-ft (19~26 Nm, 1.9~2.6 kg-m)

3. Install a SST(0K900 175 AA0) to the differential side gear, through the transaxle case.

4. Measure the bearing preload. Preload: 1.04~1.44 lb-ft (137~196 Nm, 14~20 kg-cm)

5. If not as specified, readjust the bearing preload. 6. Remove the SST(0K130 322 020). 7. Remove the transaxle case and the differential assembly.

Manual Transaxle Control System

Shift Fork

2004 > 1.6L DOHC >

COMPONENTS

Manual Transaxle Shift Control

2004 > 1.6L DOHC >

ASSEMBLY NOTE
EXTENSION BAR 1. Install the extension bar to the floor, and then onto the transaxle. Tighten the extension bar nut at the transaxle. Tightening torque: 23~34 lb-ft (31~46 Nm, 3.2~4.7 kg-m) 2. Tighten the shifter bracket nuts to the specified torque. Tightening torque: 86.9~130.2 lb-in (9.8~14.7 Nm, 100~150 kg-cm)

SPRING
Make sure that the hooked part of the spring is properly seated in the bracket groove, as shown in the figure.