Page 2977 of 4592
Z00288
SST
Z00289
Q06288
SST
MT0659
Z01427
SST MX±44
± MANUAL TRANSAXLE (E153)DIFFERENTIAL CASE
1845 Author: Date:
(f) Using SST and a press, install a new tapered roller bear-
ing outer race.
SST 09316±60011 (09316±00011, 09316±00041)
(g) Install the oil baffle.
HINT:
Install the oil baffle projection into the case side cutout.
(h) Using SST and a hammer, drive in a new oil seal.
SST 09223±15020, 09950±70010 (09951±07150)
(i) Coat the lip of oil seal with MP grease.
5. Transaxle Case Side:
IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
(a) Remove the 4 bolts and 3 nuts.
(b) Using a plastic hammer, tap the stud bolt and remove the
transaxle case cover.
(c) Using a screwdriver and hammer, drive out the oil seal
from the transaxle case cover.
(d) Using SST, a brass bar and hammer, remove the tapered
roller bearing outer race.
SST 09612±65014
Page 2978 of 4592
Z00292
SST
Z00293
SST
Z19038
FIPGF
± MANUAL TRANSAXLE (E153)DIFFERENTIAL CASE
MX±45
1846 Author: Date:
(e) Using SST and a press, install a new tapered roller bear-
ing outer race.
SST 09316±60011 (09316±00011, 09316±00041)
(f) Using SST and a hammer, drive in a new oil seal.
SST 09316±60011 (09316±00011)
(g) Coat the oil seal lip with MP grease.
(h) Apply FIPG to the transaxle case cover, as shown.
FIPG:
Part No. 08826 ± 00090, THREE BOND 1281 or
equivalent
(i) Apply sealant to the bolt threads.
Sealant:
Part No.08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(j) Install the stud bolt and cover to the transaxle case.
(k) Install and torque the 4 bolts and 3 nuts.
Torque: 54 N´m (550 kgf´cm, 40 ft´lbf)
Page 2979 of 4592

MX05J±01
Z00295
Z00296
Z00297
Z00298
MX±46
± MANUAL TRANSAXLE (E153)DIFFERENTIAL CASE
1847 Author: Date:
REASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
(a) Install the thrust washer to the side gear.
(b) Install the 4 pinions and thrust washers to the spider.
(c) Install the side gear and spider with the 4 pinions to the
differential left case.
(d) Using a dial indicator, measure the backlash of the pinion
gear while holding the differential left case.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
HINT:
Push the pinion gear and spider with the 4 pinions to the differ-
ential left case.
(e) Install the side gear and spider with the 4 pinions to the
right side of the differential case. Check the side gear
backlash.
(f) Refer to the table below, and select the thrust washer
which will ensure that the backlash is within the specifica-
tion. Try to select a washer of the same size.
Thickness mm (in.)Thickness mm (in.)
0.80 (0.0315)1.20 (0.0472)
0.90 (0.0354)1.30 (0.0512)
1.00 (0.0394)1.40 (0.0551)
1.10 (0.0433)±
(g) Install the vehicle speed sensor drive gear.
Page 2980 of 4592

Z00299
Matchmarks
Z00303
Driven Gear
Side
Q06410
SST
SST
± MANUAL TRANSAXLE (E153)DIFFERENTIAL CASE
MX±47
1848 Author: Date:
(h) Align the matchmarks on the differential cases.
(i) Using a plastic hammer, carefully tap the differential case
to install it.
(j) Using a torx wrench (T50), install and torque the 16 torx
screws.
Torque: 63 N´m (640 kgf´cm, 46 ft´lbf)
2. INSTALL RING GEAR
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.
(b) Heat the ring gear in boiling water.
(c) Carefully remove the ring gear from the water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the differential left case.
(e) Temporarily install the 16 bolts.
NOTICE:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
(f) After the ring gear has cooled sufficiently, torque the ring
gear set bolts.
Torque: 124 N´m (1,260 kgf´cm, 91 ft´lbf)
3. INSTALL TAPERED ROLLER BEARING
Using SST and a press, install new left and right bearings onto
the differential case.
SST 09316±20011, 09316±60011 (09316±00011)
HINT:
Press the bearing on the ring side first.
4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
(See pages MX±22)
5. INSTALL DIFFERENTIAL CASE ASSEMBLY TO
TRANSAXLE CASE
6. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case and install the output shaft assem-
bly.
7. INSTALL TRANSMISSION CASE
(a) Install the transmission case.
HINT:
If necessary, tap on the case with a plastic hammer.
(b) Install and torque the 17 bolts.
Torque: 29 N´m (300 kgf´cm 22 ft´lbf)
Page 2981 of 4592

Q00036
Z00309
MX±48
± MANUAL TRANSAXLE (E153)DIFFERENTIAL CASE
1849 Author: Date:
8. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER
BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.
9. INSTALL SHIM (See pages MX±22)
HINT:
Install the previously selected shim.
10. INSTALL REAR BEARING RETAINER
Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N´m (430 kgf´cm, 31 ft´lbf)
11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install a new lock nut to the output shaft.
(b) Turn the output shaft right and left 2 or 3 times to allow the
bearings to settle.
(c) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
0.2 ± 0.3 N´m (1.8 ± 3.5 kgf´cm, 1.6 ± 3.0 in.´lbf)
Reused bearing (Output shaft preload plus)
0.1 ± 0.2 N´m (1.1 ± 2.2 kgf´cm, 1.0 ± 1.9 in.´lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
HINT:
The total preload will change by about 0.1 ± 0.2 N´m (1 ± 2
kgf´cm, 0.9 ± 1.7 in.´lbf) with each 0.05 mm change in adjusting
shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
12. REMOVE REAR BEARING RETAINER
Using a torx wrench (T45), remove the 7 torx screws and rear
bearing retainer.
13. REMOVE SHIM
14. REMOVE TRANSMISSION CASE
(a) Remove the 17 bolts.
(b) Using a plastic hammer, tap the transmission case.
15. REMOVE OUTPUT SHAFT ASSEMBLY
16. REMOVE DIFFERENTIAL CASE ASSEMBLY
Page 2982 of 4592
MX05K±01
Q10281
Shift Lever Knob
Center Console Upper Panel
Heater Control Assembly
Center Cluster
Finish Panel
Front Console Box
12 (120, 9)
Shift Lever Assembly
Clip
Washer Shift Control Cable
Select Control Cable Clip
Clip ClipClip
Clip
Clip Shift Cable Grommet Retainer
4.9 (50, 43 in.´lbf)Shift Cable
Grommet
Grommet Shift Cable Grommet
Retainer
4.9 (50, 43 in.´lbf)
Washer
Clip
N´m (kgf´cm, ft´lbf): Specified torqueRear Console Box
Washer
± MANUAL TRANSAXLE (E153)SHIFT LEVER AND CONTROL CABLE
MX±49
1850 Author: Date:
SHIFT LEVER AND CONTROL CABLE
COMPONENTS
Page 2983 of 4592
MX04A±01
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE SYSTEM
MX±1
1851 Author: Date:
MANUAL TRANSAXLE SYSTEM
PRECAUTION
When working with FIPG material, you must observe the following items.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-
faces.
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 reapplied.
Page 2984 of 4592

MX04B±04
MX±2
± MANUAL TRANSAXLE (S51)TROUBLESHOOTING
1852 Author: Date:
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
1. Oil (Level low)MX±4
Ni
1. Oil (Level low)
2. Oil (Wrong)
MX±4
MX±4Noise2. Oil (Wrong)
3. Gear (Worn or damaged)
MX±4
MX±93. Gear (Worn or damaged)
4. Bearing (Worn or damaged)
MX 9
MX±9
1. Oil (Level too high)MX±4
Oil l k
1. Oil (Level too high)
2. Gasket (Damaged)
MX±4
MX±9Oil leakage2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
MX±9
MX±93. Oil seal (Worn or damaged)
4. O±ring (Worn or damaged)
MX 9
MX±9
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)MX±43
MX±9
Hard to shift or will not shift
yg( g)
3 Shift key s
pring (Damaged)
MX±20
MX±28
MX±93. Shift key spring (Damaged)MX±9
MX±20
MX±28
1. Locking ball spring (Damaged)MX±9
Jtf
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
MX±9
MX±9Jumps out of gear2. Shift fork (Worn)
3. Gear (Worn or damaged)
MX±9
MX±93. Gear (Worn or damaged)
4. Bearing (Worn or damaged)
MX 9
MX±9