Page 3809 of 4770

Q09994
Q09995
Q09996
CA
C
A
CB
AAB
C
Q09997
14 mm Head B14 mm Head B
14 mm Head A
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE UNIT
MX±7
1808 Author: Date:
21. REMOVE LH ENGINE MOUNTING INSULATOR WITH
BRACKET
(a) Remove the 2 hole plugs, nuts and 3 bolts.
Torque:
Bolt: 64 N´m (650 kgf´cm, 47 ft´lbf)
Nut: 80 N´m (820 kgf´cm, 59 ft´lbf)
(b) Lift up the transaxle and remove the left engine mounting
insulator with the bracket.
22. REMOVE HOLE PLUG AND 4 ENGINE REAR SIDE
MOUNTING NUTS
Torque: 66 N´m (670 kgf´cm, 48 ft´lbf)
23. ATTACH ENGINE SLING DEVICE TO ENGINE HANG-
ER
(See page EM±69)
24. DISCONNECT STEERING RETURN PIPE FROM
FRONT SUSPENSION MEMBER
Remove the 2 bolts.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
25. REMOVE FRONT SUSPENSION MEMBER WITH LOW-
ER SUSPENSION ARM
(a) Remove the LH and RH fender liner set screws.
(b) Remove the 6 bolts, 4 nuts, front LH and RH suspension
member braces, rear LH and RH suspension member
braces and front suspension member with the lower sus-
pension arm.
Torque:
Bolt A: 181 N´m (1,850 kgf´cm, 134 ft´lbf)
Bolt B: 32 N´m (330 kgf´cm, 24 ft´lbf)
Nut C: 36 N´m (370 kgf´cm, 27 ft´lbf)
26. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
27. REMOVE FLYWHEEL HOUSING UNDER COVER AND
TRANSAXLE LOWER SIDE MOUNTING BOLT
(a) Remove the 2 bolts and cover.
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
(b) Remove the 3 bolts of the transaxle lower side.
Torque:
14 mm head A: 46 N´m (470 kgf´cm, 34 ft´lbf)
14 mm head B: 37 N´m (380 kgf´cm, 27 ft´lbf)
Page 3810 of 4770
MX±8
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE UNIT
1809 Author: Date:
28. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:
At the time of installation, please refer to the following items.
Align the input shaft with the clutch disc and install the
transaxle to the engine.
Temporarily tighten the transaxle mounting bolts.
Page 3811 of 4770
MX051±01
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE UNIT
MX±9
1810 Author: Date:
INSTALLATION
Installation is in the reverse order of removal (See page MX±4).
HINT:
After installation, check and inspect items as follows.
Front wheel alignment (See page SA±4).
Do the road test.
Page 3812 of 4770
MX052±02
Z19124
Clutch Release Fork Assembly
with Bearing
Clutch Release Fork SupportControl Level Housing
Support Bracket
BootO±ring
Vehicle Speed Sensor
Transaxle Case Receiver Clutch Release
Line BracketCover
Transaxle Case
Transmission Oil
Pipe Transmission
Oil Cooler
Sub±Assembly
ElbowO±ring
Magnet
Transmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive GearOutput Shaft Cover
Tapered Roller Bearing
Outer Race
Front Oil Seal
Input Shaft Front
Bearing
N´m (kgf´cm, ft´lbf): Specified torque
Non±reusable part
47 (480, 35)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
7.4 (75, 65 in.´lbf)
17 (175, 13)
27 (275, 20)
34 (350, 25)
17 (175, 13)
Transmission Oil Pipe MX±10
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
1811 Author: Date:
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS
Page 3813 of 4770

Q10278
Reverse Shift Arm Bracket Assembly
Snap Ring
Reverse Shift Fork
No.1 Shift Fork
Straight Screw Plug
Seat
Spring
Ball
No.1 Shift Fork Shaft
Snap Ring
24 (240, 17)
25 (250, 18)
25 (250, 18)
Interlock Roller
No.2 Shift Fork Shaft
Snap Ring
Shift Head25 (250, 18)
No.3 Shift Fork Shaft
Snap Ring
No.3 Shift Fork
24 (240, 17)
24 (240, 17)
No.2 Shift Fork
Back±Up Light Switch
40 (410, 30)
Straight Screw Plug
13 (130, 9)Slotted Spring
Pin
Reverse Restrict
Pin
No.2 Oil Receiver PipeShift and Select Lever
Shaft Lock Bolt
Breather Plug
49 (500, 36)
20 (200, 14)
29 (300, 22)
20 (200, 14)x 17
Shift and Select Lever
Shaft Assembly
No.2 Selecting Bellcrank with
Selecting Bellcrank Support
29 (300, 22)
x 10
Transmission Case Cover
Drain Plug49 (500, 36)
Transmission Case Filler Plug
49 (500, 36)
No.1 Oil Receiver Pipe
17 (175, 13)
N´m (kgf´cm, ft´lbf) : Specified torque
Non±reusable part
Precoated partGasket Gasket
Gasket
Gasket
Gasket
49 (500, 36)
Gasket
17 (175, 13)
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
MX±11
1812 Author: Date:
Page 3814 of 4770
Z17555
Input Shaft Assembly
Output Shaft Assembly
Tapered Roller Bearing
Outer Race
Shim
Thrust Washer Reverse Idler Gear
Reverse Idler Gear Shaft
Lock Bolt
29 (300, 22)
42 (430, 31)
Rear Bearing Retainer
Snap Ring
Spacer
Needle Roller Bearing
5th Gear 5th Driven Gear
Key Spring
Inner Synchronizer Ring
Synchronizer Pull Ring
Key Spring Outer Synchronizer Ring
Middle Synchronizer Ring
Snap Ring
Snap Ring
Output Shaft Lock Nut
123 (1,250, 90)
No.3 Clutch Hub
No.3 Hub Sleeve
N´m (kgf´cm, ft´lbf) : Specified torque
Non±reusable part
Precoated part
x 7 MX±12
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
1813 Author: Date:
Page 3815 of 4770

MX053±02
Q05816
FIPG
Q00449
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
MX±13
1814 Author: Date:
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, shift and 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) Unstake 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 3816 of 4770
Q05849
SST
Z01304
Z01306
Q00299
MX±14
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
1815 Author: Date:
11. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950±30010
12. MEASURE 5TH GEAR THRUST CLEARANCE AND
RADIAL CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 ± 0.57 mm (0.0039 ± 0.0224 in.)
Maximum clearance:
0.65 mm (0.0256 in.)
(b) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.009 ± 0.050 mm (0.0004 ± 0.0020 in.)
Maximum clearance:
0.070 mm (0.0028 in.)
13. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
a1.75 (0.0689)f2.00 (0.0787)
b1.80 (0.0709)g2.05 (0.0807)
c1.85 (0.0729)h2.10 (0.0827)
d1.90 (0.0748)j2.15 (0.0847)
e1.95 (0.0768)±±