Page 2969 of 4592

MX05D±01
Q00384
Front
Z00225
Z00385
SST
Z00386
MX±36
± MANUAL TRANSAXLE (E153)OUTPUT SHAFT
1837 Author: Date:
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not
aligned.
2. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Install the 1st gear.
(c) Place the synchronizer ring (for the 1st gear) on the gear
and align the ring slots with the shifting keys.
(d) Using SST and a press, install the 1st gear and No.1 hub
sleeve.
SST 09316±60011 (09316±00041)
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.80 (0.1102)E3.00 (0.1181)
B2.85 (0.1122)F3.05 (0.1201)
C2.90 (0.1142)G3.10 (0.1220)
D2.95 (0.1161)±±
(b) Using a snap ring expander, install the snap ring.
Page 2970 of 4592
MT0792
N00495
Z00390
Z00391
SST
± MANUAL TRANSAXLE (E153)OUTPUT SHAFT
MX±37
1838 Author: Date:
4. MEASURE 1ST GEAR THRUST CLEARANCE
(See page MX±31)
5. INSTALL SPACER, NEEDLE ROLLER BEARING, SYN-
CHRONIZER RING, 2ND GEAR AND 3RD DRIVEN
GEAR
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearing.
(c) Place the synchronizer rings (for the 2nd gear) on the
gear.
NOTICE:
Do not install the synchronizer ring for the 1st gear.
(d) Install the 2nd gear.
(e) Using a press, install the 3rd driven gear.
NOTICE:
Align the clutch hub grooves with the projections on the
synchronizer ring.
6. MEASURE 2ND GEAR THRUST CLEARANCE
(See page MX±31)
7. INSTALL SPACER AND 4TH DRIVEN GEAR
(a) Install the spacer.
(b) Using a press, install the 4th driven gear.
8. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing.
SST 09506±30012
Page 2971 of 4592
Z00392SST MX±38
± MANUAL TRANSAXLE (E153)OUTPUT SHAFT
1839 Author: Date:
9. INSTALL OUTPUT SHAFT FRONT BEARING
Using SST and a press, install a new output shaft front bearing.
SST 09316±60011 (09316±00071)
Page 2972 of 4592
MX05E±01
Z17558
GasketO±Ring
Transmission Oil
Pump Case
Relief Valve
Ball
Spring
Spring Holder
Oil Pump CoverOil Pump Drive Gear Oil Strainer
Oil Pump Driven Rotor
Oil Pump Drive Rotor
10 (105, 8)
10 (105, 8)N´m (kgf´cm, ft´lbf) : Specified torque
Non±reusable part
± MANUAL TRANSAXLE (E153)OIL PUMP
MX±39
1840 Author: Date:
OIL PUMP
COMPONENTS
Page 2973 of 4592
MX05F±01
Z00242
Z00243
Z00244
MX±40
± MANUAL TRANSAXLE (E153)OIL PUMP
1841 Author: Date:
INSPECTION
1. CHECK ROTOR BODY CLEARANCE
(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the body clearance be-
tween the drive rotor and oil pump case.
Standard clearance:
0.10 ± 0.16 mm (0.0039 ± 0.0063 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
2. CHECK ROTOR TIP CLEARANCE
(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the tip clearance between
the drive and driven rotors.
Standard clearance:
0.08 ± 0.15 mm (0.0031 ± 0.0059 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
3. CHECK SIDE CLEARANCE
Using a precision straight edge and feeler gauge, measure the
side clearance of both rotors.
Standard clearance:
0.03 ± 0.08 mm (0.0012 ± 0.0031 in.)
Maximum clearance:
0.15 mm (0.0059 in.)
Page 2974 of 4592
MX05G±02
Q10276
Dust Boot
Oil Seal
Control Shaft Cover
Snap Ring
No.1 Compression Spring
Shift Interlock Plate
No.2 Shift Inner Lever
No.2 Select Spring Seat
Snap RingNo.2 Compression SpringSlotted Spring Pin
No.1 Shift Inner LeverNo.1 Select Spring Seat
Slotted Spring Pin
Shift and Select Lever Shaft
Non±reusable part
MP Grease
± MANUAL TRANSAXLE (E153)SHIFT AND SELECT LEVER SHAFT
MX±41
1842 Author: Date:
SHIFT AND SELECT LEVER SHAFT
COMPONENTS
Page 2975 of 4592
MX05H±01
Z17560
Transaxle Case Cover
Stud Bolt
54 (550, 40)
54 (550, 40)
Oil Seal
Differential Spider
Differential Pinion
Differential Side Gear
Side Gear Thrust
Washer
Pinion Thrust Washer
Tapered Roller Bearing
and Outer Race
63 (640, 46)
x 16 Differential Right Case
Vehicle Speed Sensor Drive Gear
Differential Left Case
Ring Gear
x 16Tapered Roller Bearing and Outer Race
Shim
124 (1,260, 91)
Oil Baffle
Oil Seal MX±42
± MANUAL TRANSAXLE (E153)DIFFERENTIAL CASE
1843 Author: Date:
DIFFERENTIAL CASE
COMPONENTS
Page 2976 of 4592

MX05I±03
Q05166
SST
Z00281
Matchmarks
Z00284
Z00286
± MANUAL TRANSAXLE (E153)DIFFERENTIAL CASE
MX±43
1844 Author: Date:
DISASSEMBLY
1. REMOVE TAPERED ROLLER BEARING
Using SST, remove the left and right bearings.
SST 09950±40011
2. REMOVE RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap the ring gear and remove it.
3. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the differential right and left cases.
(b) Using a torx wrench (T50), remove the 16 torx screws.
(c) Using a plastic hammer, tap the differential left case.
(d) Remove the vehicle speed sensor drive gear from the dif-
ferential right case.
(e) Remove the 2 differential side gears, side gear thrust
washers, 4 differential pinions and pinion thrust washers
from the differential left case.
4. Transmission Case Side:
IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
(a) Using a screwdriver, remove the oil seal.
(b) Remove the oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the shim.
(e) Install the shim. (See page MX±42)
HINT:
First select and install a shim of less thickness than before.