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MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
A
SECTION
MANUAL TRANSAXLE
MT B
MT
D
E
CONTENTS
RS6F51R GEAR COMPONENTS ...................................... 18 . F
SHIFT CONTROL COMPONENTS .................... 20 .
PRECAUTIONS ......................................................... 3 . FINAL DRIVE COMPONENTS .......................... 21 .
Caution .................................................................... 3
. Disassembly and Assembly ................................... 21 . G
PREPARATION .......................................................... 4 . DISASSEMBLY .................................................. 21 .
Special Service Tools .............................................. 4 . ASSEMBLY ........................................................ 25.
Commercial Service Tools ....................................... 6 . Adjustment ............................................................. 32
.
NOISE, VIBRATION AND HARSHNESS (NVH) H
INPUTSHAFT END PLAY .................................. 32 .
TROUBLESHOOTING ............................................... 7 . DIFFERENTIAL SIDE BEARING PRELOAD ..... 33 .
NVH Troubleshooting Chart .................................... 7 . MAINSHAFT END PLAY .................................... 34 .
MANUAL TRANSAXLE ........................................ 7 . REVERSE IDLER GEAR END PLAY ................. 35 . I
DESCRIPTION ........................................................... 8 . INPUT SHAFT AND GEARS ................................... 37 .
Cross-Sectional View .............................................. 8 . Assembly and Disassembly ................................... 37 .
DOUBLE-CONE SYNCHRONIZER ..................... 9 . DISASSEMBLY .................................................. 37 . J
REVERSE GEAR NOISE PREVENTION FUNC- INSPECTION AFTER DISASSEMBLY ............... 38 .
TION (SYNCHRONIZING METHOD) .................. 9 . ASSEMBLY ........................................................ 39.
M/T OIL .................................................................... 10
. MAINSHAFT AND GEARS ...................................... 44 .
Changing M/T Oil .................................................. 10 . K
Assembly and Disassembly ................................... 44 .
DRAINING .......................................................... 10 . DISASSEMBLY .................................................. 44 .
FILLING .............................................................. 10
. INSPECTION AFTER DISASSEMBLY ............... 45 .
Checking M/T Oil ................................................... 10 . ASSEMBLY ........................................................ 47. L
OIL LEAKAGE AND OIL LEVEL ........................ 10 . REVERSE IDLER SHAFT AND GEARS ................. 53 .
SIDE OIL SEAL ........................................................11 . Assembly and Disassembly ................................... 53 .
Removal and Installation ........................................11 . DISASSEMBLY .................................................. 53 . M
REMOVAL ...........................................................11 . INSPECTION AFTER DISASSEMBLY ............... 53 .
INSTALLATION ...................................................11 . ASSEMBLY ........................................................ 54.
POSITION SWITCH ................................................. 12 . FINAL DRIVE ........................................................... 55
.
Checking ............................................................... 12
. Assembly and Disassembly ................................... 55 .
BACK-UP LAMP SWITCH ................................. 12 . PRE-INSPECTION ............................................. 55 .
NEUTRAL POSITION SWITCH ......................... 12 . DISASSEMBLY .................................................. 55 .
CONTROL LINKAGE .............................................. 13 . INSPECTION AFTER DISASSEMBLY ............... 56 .
Removal and Installation of Control Device and ASSEMBLY ........................................................ 56.
Cable ..................................................................... 13
. SHIFT CONTROL .................................................... 59 .
AIR BREATHER HOSE ........................................... 14 . Inspection .............................................................. 59
.
Removal and Installation ....................................... 14 . SHIFT FORK ...................................................... 59.
TRANSAXLE ASSEMBLY ....................................... 15 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 60 .
Removal and Installation ....................................... 15 . General Specifications ........................................... 60 .
REMOVAL .......................................................... 15 . TRANSAXLE ...................................................... 60 .
INSTALLATION .................................................. 16 . FINAL GEAR ...................................................... 60.
Component Parts .................................................. 17 . Gear End Play ....................................................... 61
.
CASE AND HOUSING COMPONENTS ............ 17 .
MT-1
Clearance Between Baulk Ring and Gear ............. 61 . MAINSHAFT ADJUSTING SHIM ........................63 .
3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING 61 ... INPUT SHAFT REAR BEARING ADJUSTING
1ST AND 2ND DOUBLE BAULK RING .............. 61 . SHIM ...................................................................63
.
Available Snap Rings ............................................. 61
. MAINSHAFT REAR BEARING ADJUSTING
6TH BUSHING ................................................... 61
. SHIM ...................................................................63
.
Available C-rings .................................................... 62
. REVERSE IDLER GEAR ADJUSTING SHIM .....63 .
MAINSHAFT C-RING ......................................... 62 . 6TH MAIN GEAR ADJUSTING SHIM .................64 .
Available Thrust Washer ........................................ 62. Available Shims .....................................................64
.
INPUT SHAFT THRUST WASHER .................... 62 . BEARING PRELOAD ..........................................64 .
DIFFERENTIALSIDEGEARTHRUSTWASHER DIFFERENTIAL SIDE BEARING ADJUSTING
... 62 SHIM (S) .............................................................64
.
Available Adjusting Shims ..................................... 63 .
MT-2
PRECAUTIONS
[RS6F51R]
PRECAUTIONS
[RS6F51R] PFP:00001
A
Caution ECS0095I
q If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder). CSC
insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts may damage B
CSC seal and may cause clutch fluid leak.
q Do not reuse transaxle oil, once it has been drained.
q Check oil level or replace oil with vehicle on level ground. MT
q During removal or installation, keep inside of transaxle clear of dust or dirt.
q Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to. D
q In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
q Be careful not to damage sliding surfaces and mating surfaces. E
F
G
H
I
J
K
L
M
MT-3
PREPARATION
[RS6F51R]
PREPARATION PFP:00002
Special Service Tools ECS0095J
Tool number
Description
Tool name
KV381054S0 q Side bearing outer race removal
Puller q Mainshaft front bearing removal
ZZA0601D
ST35321000 q Input shaft oil seal installation
Drift q Reverse main gear installation
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia. q 1st bushing installation
q 1st-2nd synchronizer hub installation
q 2nd bushing installation
ZZA1000D
q 3rd main gear installation
ST30720000 q Differential oil seal installation
Drift q Differential side bearing outer race
a: 77 mm (3.03 in) dia. installation
b: 55.5 mm (2.185 in) dia.
q Mainshaft rear bearing installation
q Differential side bearing installation
ZZA0811D
ST33200000 q Mainshaft front bearing installation
Drift q 6th bushing installation
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia. q 4th main gear installation
q 5th main gear installation
q 6th main gear installation
ZZA1002D
ST33061000 q Bore plug installation
Drift q Differential side bearing removal
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
ZZA1000D
ST33052000 q Welch plug installation
Drift q Input shaft rear bearing removal
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia. q 5th bushing, thrust washer, 4th input gear,
4th gear bushing, 3rd-4th synchronizer hub
and 3rd input gear removal
q Input shaft front bearing installation
q 6th input gear and 6th bushing removal
q Mainshaft rear bearing removal
ZZA1023D
q 4th main gear and 5th main gear removal
q 6th main gear removal
MT-4
PREPARATION
[RS6F51R]
Tool number
Description A
Tool name
KV40105020 q 5th input gear and synchronizer hub
Drift removal
a: 39.7 mm (1.563 in) dia. B
q 3rd main gear, 2nd main gear, 2nd bushing,
b: 35 mm (1.38 in) dia.
1st-2nd synchronizer hub, 1st main gear,
c: 15 mm (0.59 in)
reverse main gear and 1st bushing removal
MT
ZZA1133D
KV40105710 q 3rd-4th synchronizer hub installation
Press stand q 4th bushing installation D
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in) q 5th busing installation
q 5th-6th synchronizer hub installation
E
q 2nd bushing installation
ZZA1058D
q 3rd main gear installation
ST38220000 q Reverse main gear installation F
Press stand q 1st bushing installation
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in) q 1st-2nd synchronizer hub installation
G
ZZA1058D
H
ST30032000 q Input shaft front bearing installation
Drift
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia. I
c: 31 mm (1.22 in) dia.
ZZA0978D J
ST30901000 q Input shaft rear bearing installation
Drift q 4th main gear installation
a: 79 mm (3.11 in) dia. K
b: 45 mm (1.77 in) dia. q 5th main gear installation
c: 35.2 mm (1.386 in) dia. q 6th main gear installation
q Mainshaft rear bearing installation
L
ZZA0978D
ST30031000 q Measuring wear of 1st and 2nd baulk ring
Puller M
ZZA0537D
KV40101630 q Reverse main gear installation
Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.
ZZA1003D
MT-5
PREPARATION
[RS6F51R]
Tool number
Description
Tool name
KV38102510 q 1st bushing installation
Drift q 1st-2nd synchronizer hub installation
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia. q Differential side bearing installation
ZZA0838D
KV38105900 q Checking differential side gear end play
Preload adapter
NT087
Commercial Service Tools ECS0095K
Tool name Description
Puller q Each bearing gear and bushing removal
ZZB0823D
Puller q Each bearing gear and bushing removal
NT077
Pin punch q Each retaining pin removal and installation
Tip diameter: 4.5 mm (0.177 in) dia.
ZZA0815D
Power tool q Loosening bolts and nuts
PBIC0190E
MT-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[RS6F51R]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
A
NVH Troubleshooting Chart ECS0095L
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts. B
MANUAL TRANSAXLE
MT-10
MT-17
MT-17
MT-17
MT-13
MT-20
MT-20
MT-18
MT-18
MT-18
MT-18
Reference page MT
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
D
E
F
SUSPECTED PARTS G
(Possible cause)
SHIFT CONTROL LINKAGE (Worn)
BAULK RING (Worn or damaged)
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
INSERT SPRING (Damaged)
H
O-RING (Worn or damaged)
GEAR (Worn or damaged)
OIL (Oil level is high.)
GASKET (Damaged)
SHIFT FORK (Worn)
OIL (Oil level is low.)
I
OIL (Wrong oil.)
J
Noise 1 2 3 3
K
Oil leakage 3 1 2 2 2
Symptoms
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3 L
M
MT-7
DESCRIPTION
[RS6F51R]
DESCRIPTION PFP:00000
Cross-Sectional View ECS0095M
MCIA0009E
MT-8
DESCRIPTION
[RS6F51R]
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 1st and 2nd gears to A
reduce operating force of the shift lever.
B
MT
SCIA0750E
D
REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)
The gear can be matched smoothly in a structure by setting synchro- E
nizer hub, coupling sleeve, baulk ring and insert spring to reverse
gear, and letting gear be synchronized.
F
G
SCIA0751E H
I
J
K
L
M
MT-9
M/T OIL
[RS6F51R]
M/T OIL PFP:KLD20
Changing M/T Oil ECS0095N
DRAINING
1. Start the engine and let it run to warm up the transaxle.
2. Stop the engine. Remove drain plug and drain oil.
3. Set a gasket on the drain plug and install it to the transaxle.
Drain plug:
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