Page 3825 of 4770

Z12593
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
MX±23
1824 Author: Date:
(j) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing
0.8 ± 1.6 N´m (8 ± 16 kgf´cm, 6.9 ± 13.9 in.´lbf)
Reused bearing
0.5 ± 1.0 N´m (5 ± 10 kgf´cm, 4.3 ± 8.7 in.´lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
The preload will change approx. 0.4 ± 0.5 N´m (4 ± 5 kgf´cm, 3.5
± 4.3 in.´lbf) for every 0.05 mm change in adjusting shim thick-
ness.
MarkThickness mm (in.)MarkThickness mm (in.)
01.30 (0.0512)D1.95 (0.0768)
11.35 (0.0531)E2.00 (0.0787)
21.40 (0.0551)F2.05 (0.0807)
31.45 (0.0571)G2.10 (0.0827)
41.50 (0.0591)H2.15 (0.0846)
51.55 (0.0610)J2.20 (0.0866)
61.60 (0.0630)K2.25 (0.0886)
71.65 (0.0650)L2.30 (0.0906)
81.70 (0.0669)M2.35 (0.0925)
91.75 (0.0689)N2.40 (0.0945)
A1.80 (0.0709)P2.45 (0.0965)
B1.85 (0.0728)Q2.50 (0.0984)
C1.90 (0.0748)±±
(k) Remove the lock nut.
(l) Remove these parts. Removal is in the reverse order of
installation.
Rear bearing retainer
Shim
Transmission case
Output shaft assembly
Output shaft rear bearing outer race
Page 3826 of 4770
MX056±01
MT0791
Synchronizer Ring Spacer
4th Gear
Snap Ring
Rear BearingNeedle Roller Bearing
Snap RingSpring
Shifting KeyNo.2 Clutch HubNo.2 Hub SleeveSynchronizer Ring3rd GearNeedle Roller Bearing
Input Shaft Front Bearing Inner Race
Input Shaft
Non±reusable part MX±24
± MANUAL TRANSAXLE (E153)INPUT SHAFT
1825 Author: Date:
INPUT SHAFT
COMPONENTS
Page 3827 of 4770

MX057±01
Q06369
3rd Gear
4th Gear
Q00111
Q05165
SST
± MANUAL TRANSAXLE (E153)INPUT SHAFT
MX±25
1826 Author: Date:
DISASSEMBLY
1. MEASURE 3RD AND 4TH GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
3rd gear: 0.10 ± 0.35 mm (0.0039 ± 0.0138 in.)
4th gear: 0.10 ± 0.55 mm (0.0039 ± 0.0217 in.)
Maximum clearance:
3rd gear: 0.40 mm (0.0157 in.)
4th gear: 0.60 mm (0.0236 in.)
2. CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between
the gear and shaft.
Standard clearance:
3rd gear: 0.009 ± 0.053 mm (0.0004 ± 0.0021 in.)
4th gear: 0.009 ± 0.051 mm (0.0004 ± 0.0020 in.)
Maximum clearance:
3rd and 4th gears: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
4. REMOVE REAR BALL BEARING AND 4TH GEAR
Using SST and a press, remove the rear bearing.
SST 09950±00020
5. REMOVE NEEDLE ROLLER BEARING, SPACER AND
SYNCHRONIZER RING
6. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
Page 3828 of 4770
Q00115
MX±26
± MANUAL TRANSAXLE (E153)INPUT SHAFT
1827 Author: Date:
7. REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRO-
NIZER RING AND 3RD GEAR
Using a press, remove the No.2 hub sleeve, 3rd gear and syn-
chronizer rings.
8. REMOVE NEEDLE ROLLER BEARING
Page 3829 of 4770

MX058±01
MT0780
MT0786
WM0064
WM0064
± MANUAL TRANSAXLE (E153)INPUT SHAFT
MX±27
1828 Author: Date:
INSPECTION
1. INSPECT 3RD GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
(c) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance:
0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
2. INSPECT 4TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and spline end.
Minimum clearance:
0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
Page 3830 of 4770
WM0066
Q00172
CBA
Q00173
MX±28
± MANUAL TRANSAXLE (E153)INPUT SHAFT
1829 Author: Date:
3. MEASURE NO.2 SHIFT FORK AND HUB SLEEVE
CLEARANCE
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.
4. INSPECT INPUT SHAFT
(a) Check the input shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the in-
put shaft journal surface.
Minimum outer diameter:
Part A: 27.950 mm (1.1004 in.)
Part B and C: 35.950 mm (1.4154 in.)
(c) Using a dial indicator, check the shaft runout.
Maximum runout:
0.05 mm (0.0020 in.)
Page 3831 of 4770

MX059±02
Q00383
Front
MT0790
Q00183SST
Q00116
± MANUAL TRANSAXLE (E153)INPUT SHAFT
MX±29
1830 Author: Date:
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to front of the
transmission.
2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Assemble the needle roller bearings into the 3rd gear.
(c) Place the synchronizer rings on the gear and align the
ring slots with the shifting keys.
(d) Using SST and a press, install the 3rd gear and No.2 hub
sleeve.
SST 09506±35010
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
H2.30 (0.0906)M2.50 (0.0984)
J2.35 (0.0925)N2.55 (0.1004)
K2.40 (0.0945)P2.60 (0.1024)
L2.45 (0.0965)±±
(b) Using a screwdriver and hammer, tap in the snap ring.
Page 3832 of 4770
N00494
SST
Q00116
MX±30
± MANUAL TRANSAXLE (E153)INPUT SHAFT
1831 Author: Date:
4. MEASURE 3RD GEAR THRUST CLEARANCE
(See page MX±24)
5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE
ROLLER BEARING, 4TH GEAR AND REAR BALL
BEARING
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearings.
(c) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(d) Install the 4th gear.
(e) Using SST and a press, install the rear ball bearing.
SST 09506±35010
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
12.35 (0.0925)52.55 (0.1004)
22.40 (0.0945)62.60 (0.1024)
32.45 (0.0965)72.65 (0.1043)
42.50 (0.0984)82.70 (0.1063)
(b) Using a screwdriver and hammer, tap in the snap ring.
7. MEASURE 4TH GEAR THRUST CLEARANCE
(See page MX±24)