Page 137 of 349
D06621
N·m (kgf·cm, ft·lbf): Specified torque
Non–reusable part
Precoated partTransmission Case Cover Transmission CaseNo.2 Selecting Bellcrank with
Selecting Bellcrank Support Shift and Select Lever
Shaft Assembly
No.1 Oil Receiver Pipe Reverse
Restrict Pin Straight Screw PlugBack–Up Light SwitchNo.3 Shift Fork No.3 Shift Fork ShaftInterlock Roller
Shift Head
Shift and Select Lever
Shaft Lock BoltNo.2 Shift Fork Shaft Straight Screw Plug Reverse Shift Arm Bracket Assembly
Snap Ring
Reverse Shift Fork
No.1 Shift Fork
No.1 Shift Fork Shaft Seat
Spring
Ball
Slotted
Spring PinSnap RingSnap Ring
No.2 Shift Fork
No.2 Oil Receiver Pipe
Drain Plug Filler Plug
x 10 x 17
24 (240, 17)
25 (250, 18)
25 (250, 18)
24 (240, 17)
24 (240, 17)
25 (250, 18)
17 (175, 13)
40 (410, 30)
13 (130, 9)49 (500, 36)20 (200, 14)
17 (175, 13)
29 (300, 22)
49 (500, 36)
20 (200, 14)
49 (500, 36)
49 (500, 36)29 (300, 22)
Breather Plug Gasket
Gasket Gasket Gasket Gasket
Snap Ring
MX–10
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
Page 138 of 349
D06653
N·m (kgf·cm, ft·lbf): Specified torque
Non–reusable part
Precoated partOutput Shaft AssemblyInput Shaft Assembly
Tapered Roller Bearing
Outer Race
Reverse Idler Gear ShaftReverse Idler Gear
Thrust Washer
Rear Bearing Retainer
Needle Roller Bearing 5th Driven Gear
Synchronizer Pull RingKey Spring
Middle Synchronizer
Ring
Snap Ring Output Shaft
Lock Nut5th Gear
No.3 Clutch Hub
No.3 Hub Sleeve Key Spring Outer Synchronizer RingInner Synchronizer RingSnap Ring
Spacer x 7Shim
Lock Bolt
29 (300, 22)
42 (430, 31)
123 (1,250, 90)
Snap Ring
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–11
Page 139 of 349
MX099–01
Q05816
FIPG
Q00449
MX–12
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
DISASSEMBLY
1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK–UP LIGHT SWITCH WITH GASKET
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
3. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
4. REMOVE NO.2 SELECTING BELLCRANK WITH SE-
LECTING BELLCRANK SUPPORT
Remove the 2 bolts and No.2 selecting bellcrank with the se-
lecting bellcrank support.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
5. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK
BOLT WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
6. REMOVE SHIFT AND SELECT LEVER SHAFT AS-
SEMBLY WITH GASKET
Remove the 4 bolts, the shift, select lever shaft assembly and
gasket.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
7. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.
FIPG:
Part No. 08826–00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
8. REMOVE BREATHER PLUG WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
9. REMOVE OUTPUT SHAFT LOCK NUT
(a) Remove the lock nut.
(b) Engage the gear double meshing.
(c) Remove the lock nut.
Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf)
(d) Disengage the gear double meshing.
10. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the No.3 shift fork set bolt.
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(b) Remove the No.3 hub sleeve and No.3 shift fork.
Page 141 of 349
Q06190
Q01615
Q00056
Q05815
FIPG MX–14
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
16. REMOVE SNAP RING
(a) Using a snap ring expander, remove the input shaft rear
bearing snap ring.
(b) Using 2 screwdrivers and a hammer, remove the 2 snap
rings.
17. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING
AND LOCKING BALL
(a) Using a hexagon wrench (6 mm), remove the plug.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the seat, spring and
locking ball.
18. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
19. REMOVE TRANSMISSION CASE
Remove the 17 bolts and tap the case with a plastic hammer.
FIPG:
Part No. 08826–00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
Page 142 of 349
MT0669
MT0693
SST
Q06375
Z17557
Matchmarks
Q01614
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–15
20. REMOVE SHIM
HINT:
At the time of reassembly, please refer to the following item.
Install the previously selected shim by adjusting output shaft
preload.
(See page MX–21)
21. REMOVE OUTPUT SHAFT REAR TAPER ROLLER
BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear taper
roller bearing outer race.
SST 09316–60011 (09316–00011)
22. REMOVE TRANSMISSION OIL PIPE
(a) Remove the gasket from the oil pipe.
(b) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
23. REMOVE REVERSE SHIFT ARM BRACKET AS-
SEMBLY
Remove the bolt and pull off the reverse shift arm and bracket.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
24. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust
washer.
HINT:
At the time of reassembly, please refer to the following item.
Align the matchmarks, as shown.
25. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the 2 seats, springs and
balls.
Page 143 of 349
Q08124
Q08125
Q08126
Z00182
MX–16
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
26. REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD
SET BOLT
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
27. REMOVE NO.1 SHIFT FORK SHAFT
Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.
HINT:
At the time of reassembly, please refer to the following item.
When it is difficult to push the fork shaft through the reverse shift
fork, pull up the No.3 shift fork shaft.
28. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the re-
verse shift fork.
29. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD
AND NO.1 SHIFT FORK
(a) Pull out the No.2 shift fork shaft.
(b) Remove the shift head and No.1 shift fork.
30. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE
SHIFT FORK AND NO.2 SHIFT FORK
(a) Pull out the No.3 shift fork shaft with the reverse shift fork.
(b) Remove the No.2 shift fork.
31. REMOVE SNAP RING
(a) Using 2 screwdrivers and a hammer, remove the snap
ring and reverse shift fork from the No.3 shift fork shaft.
(b) Using 2 screwdrivers and a hammer, remove the 3 snap
rings from the No.1, No.2 and No.3 shift fork shafts.
32. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY
(a) Leaning the output shaft to the differential side, remove
the input shaft assembly.
(b) Lift up the differential case assembly, remove the output
shaft assembly.
33. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the oil pump drive gear.
(b) Remove the differential case assembly.
34. REMOVE MAGNET FROM TRANSAXLE CASE
35. REMOVE TRANSMISSION OIL PUMP ASSEMBLY
AND OIL PIPE
Page 145 of 349
MX05W–02
MT0782
WM0066
Z00192
SST
Z00194
SST
Q08014
SST MX–18
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
INSPECTION
1. INSPECT NO.5 SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
middle No.5 synchronizer ring in one direction while push-
ing it to the outer No.5 synchronizer ring. Check that the
ring locks.
If it does not lock, replace the synchronizer ring.
2. MEASURE SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
3. IF NECESSARY, REPLACE INPUT SHAFT BEARING
AND OIL SEAL
(a) Remove the 3 bolts and transaxle case receiver.
(b) Using SST, pull out the bearing.
SST 09612–65014
(c) Using a screwdriver, remove the oil seal.
(d) Using SST, drive in a new oil seal.
SST 09608–00081, 09950–70010 (09951–07150)
(e) Coat the lip of seal with MP grease.
(f) Using SST, drive in a new bearing.
SST 09950–60010 (09951–00580), 09950–70010
(09951–07150)
(g) Install the transaxle case receiver.
(h) Install and torque the 3 bolts.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)
Page 148 of 349
MX05X–02
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–21
REASSEMBLY
Reassembly is in the reverse order of disassembly.
(See page MX–12)
NOTICE:
When working with FIPG material, you must observe the follow-
ing items.
Using a razor blade and gasket scraper, remove all the old
FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose
material.
Clean both sealing surfaces with a non–residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along
the sealing surface.
Parts must be assembled within 10 minutes of application.
Otherwise, the FIPG material must be removed and reap-
plied.
HINT:
Before reassembly, select a shim by adjusting output
shaft preload.
Coat all of the sliding and rotating surfaces with gear oil
before reassembly.
ADJUST OUTPUT SHAFT PRELOAD
(a) Install the output shaft assembly to the transaxle case.
(b) Install the transmission case to the transaxle case.
HINT:
If necessary, tap on the case with a plastic hammer.
(c) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(d) Install the output shaft rear taper roller bearing outer race.
(e) Install the adjusting shim.
HINT:
When reusing the output shaft bearing, first install a shim of the
same thickness as before. If installing a new taper roller bear-
ing, first select and install a shim of lesser thickness than be-
fore.
(f) Install the rear bearing retainer.
(g) Using a torx wrench (T45), install and torque the 7 torx
screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
(h) Install a new lock nut to the output shaft.
(i) Turn the output shaft right and left 2 or 3 times to allow the
bearing to settle.
