Page 1979 of 3833
PRECAUTIONS
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PRECAUTIONSPFP:00001
CautionECS008BM
●Do not reuse transaxle oil, once it has been drained.
●Check oil level or replace oil with vehicle on level ground.
●During removal or installation, keep inside of transaxle clear of dust or dirt.
●Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
●In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
●Be careful not to damage sliding surfaces and mating surfaces.
Page 1980 of 3833

MT-4
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsECS008BN
Tool name
Tool numberDescription
Puller
KV381054S0
●Side bearing outer race removal
●Mainshaft front bearing removal
Drift
ST35321000
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
●Input shaft oil seal installation
●Reverse main gear installation
●1st bushing installation
●1st-2nd synchronizer hub installation
●2nd bushing installation
●3rd main gear installation
●Differential side bearing removal
Drift
ST30720000
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
●Differential oil seal installation
●Differential side bearing outer race
installation
●Mainshaft rear bearing installation
●Differential side bearing installation
Drift
ST33200000
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
●Mainshaft front bearing installation
●6th bushing installation (RS6F51A)
●4th main gear installation
●5th main gear installation
●6th main gear installation (RS6F51A)
Drift
KV40105320
a: 88 mm (3.46 in) dia.
●Differential side bearing outer race
installation
Drift
ST33061000
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
●Bore plug installation
●Differential side bearing removal
ZZA0601D
ZZA1000D
ZZA0811D
ZZA1002D
ZZA0898D
ZZA1000D
Page 1983 of 3833

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
MT-7
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NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartECS008BP
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
MANUAL TRANSAXLE
Reference pageMA-35
MT-17
(RS5F51A), MT-22
(RS6F51A)
MT-17
(RS5F51A), MT-22
(RS6F51A)
MT-17
(RS5F51A), MT-22
(RS6F51A)
MT-13
MT-20
(RS5F51A), MT-25
(RS6F51A)
MT-20
(RS5F51A), MT-25
(RS6F51A)
MT-18
(RS5F51A), MT-23
(RS6F51A)
MT-18
(RS5F51A), MT-23
(RS6F51A)
MT-18
(RS5F51A), MT-23
(RS6F51A)
MT-18
(RS5F51A), MT-23
(RS6F51A)
SUSPECTED PARTS
(Possible cause)
OIL (Oil level is low.)
OIL (Wrong oil.)
OIL (Oil level is high.)
GASKET (Damaged)
OIL SEAL (Worn or damaged)
O-RING (Worn or damaged)
SHIFT CONTROL LINKAGE (Worn)
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
SHIFT FORK (Worn)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
BAULK RING (Worn or damaged)
INSERT SPRING (Damaged)
SymptomsNoise 1 2 3 3
Oil leakage 3 1 2 2 2
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3
Page 1986 of 3833

MT-10
M/T OIL
M/T OIL
PFP:KLD20
Changing M/T OilECS008BR
DRAINING
1. Start the engine and let it run to warm up the transaxle.
2. Stop the engine. Remove drain plug and drain oil.
3. Set a gasket on the drain plug and install it to the transaxle.
CAUTION:
Do not reuse gasket.
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole.
2. After refilling oil, check oil level. Assemble gasket to filler plug, then install it to transaxle body.
CAUTION:
Do not reuse gasket.
Checking M/T OilECS008BS
OIL LEAKAGE AND OIL LEVEL
●Check that oil is not leaking from transaxle or around it.
●Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Never start engine while checking oil level.
●Set a new gasket on the filler plug and install it on the transaxle.
CAUTION:
Do not reuse gasket.Drain plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
Oil grade : API GL-4
Capacity (reference)
: Approx. 2.3 (4 lmp pt)
Filler plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
Filler plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
SCIA0361E
Page 1987 of 3833
SIDE OIL SEAL
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SIDE OIL SEALPFP:32113
Removal and InstallationECS008BT
REMOVAL
●Clutch housing side oil seal used on 4WD vehicles is attached to the transfer. Be sure to replace it
when transfer is removed.
1. Remove the drive shaft from the transaxle.
2. Remove oil seal with flat tip screwdriver.
CAUTION:
Be careful not to damage the case surface when removing
the oil seal.
INSTALLATION
1. Using a drift (special service tool), drive the oil seal straight until
it protrudes from the case end equal to dimension A shown in
the figure.
CAUTION:
●When installing oil seals, apply multi-purpose grease to oil seal lips.
●Oil seals are not reusable. Never reuse them.
2. Install all parts in reverse order of removal and check oil level after installation.
SCIA0824E
Dimension "A":
Within 0.5 mm (0.020 in) of flush with the case.
Drift to be used:
Transaxle case side: ST30720000
Clutch housing side: ST30720000
SCIA0352E
Page 1991 of 3833

TRANSAXLE ASSEMBLY
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TRANSAXLE ASSEMBLYPFP:32010
Removal and InstallationECS008BX
REMOVAL
1. Remove air cleaner, air duct, and battery.
2. Remove the air breather hose.
3. Remove clutch operating cylinder.
CAUTION:
Do not depress clutch pedal during removal procedure.
4. Disconnect control cable from transaxle.
5. Drain gear oil from transaxle.
6. Disconnect PNP switch, back-up lamp switch, and ground harness connectors.
7. Remove exhaust front tube and the drive shaft.
8. Remove transfer.
●Refer to TF-11, "Removal and Installation from Vehicle" .
9. Remove starter motor.
10. Place a jack onto the transaxle.
CAUTION:
When setting jack, be careful not to bring it into contact with the switch.
11. Remove center member, engine insulator and engine mount bracket.
●Refer to EM-69, "ENGINE ASSEMBLY" (QR engine models) or EM-193, "ENGINE ASSEMBLY" (YD
engine models).
12. Remove suspension members.
●Refer to FSU-12, "FRONT SUSPENSION MEMBER" .
13. Support engine by placing a jack under oil pan.
14. Remove bolts securing transaxle to engine.
SCIA0845E
Page 1992 of 3833
MT-16
TRANSAXLE ASSEMBLY
15. Remove transaxle from vehicle.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
●When installing the transaxle to the engine, tighten to the specified torque.
CAUTION:
When installing transaxle, be careful not to bring transaxle input shaft into contact with the clutch
cover.
QR engine models:
*: Tightening the bolt for 4WD models.
YD engine models:
●After installation, check oil level, and look for leaks and loose
mechanisms.
MTD0062D
Bolt No. 1 2 3* 4 5 6
Quantity 2 1 1 2 2 2
“ ” mm (in)40
(1.57)75
(2.95)45
(1.77)40
(1.57)30
(1.18)40
(1.57)
Tightening torque
N·m (kg - m, ft- lb)69.6 - 79.4
(7.1 - 8.1, 52 - 58)39.2 - 46.1
(4.0 - 4.7, 29 - 34)30.4 - 40.2
(3.1 - 4.1,
23 - 29)
Bolt No. 1 2 3 4 5 6
Quantity 2 2 1 1 3 1
“ ” mm (in)55
(2.17)70
(2.76)120
(4.72)45
(1.77)40
(1.57)35
(1.38)
Tightening torque
N·m (kg - m, ft- lb)40 - 49
(4.0 - 5.0, 29 - 36)31 - 36
(3.1 - 3.7, 23 - 26)
SCIA0353E
SCIA0748E
Page 1993 of 3833
TRANSAXLE ASSEMBLY
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Component Parts (RS5F51A)ECS008BY
CASE AND HOUSING COMPONENTS
1. Clutch housing 2. Input shaft oil seal 3. Oil channel
4. Magnet 5. Differential oil seal 6. Ball pin
7. Washer 8. Transaxle case 9. Welch plug
10. Bore plug 11. Differential oil seal 12. Park/Neutral position switch
13. Oil gutter 14. Back-up lamp switch 15. Air breather tube
16. Baffle plate 17. Filler plug 18. Gasket
19. Drain plug 20. Gasket
SCIA1112E