Page 2545 of 3066
DESCRIPTION
MT-9
D
E
F
G
H
I
J
K
L
MA
B
MT
DESCRIPTIONPFP:00000
Cross-sectional ViewECS0044O
SCIA0749E
Page 2546 of 3066
MT-10
DESCRIPTION
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.
REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)
The gear can be matched smoothly in a structure by setting synchro-
nizer hub, coupling sleeve, baulk ring and insert ring to reverse gear,
and letting gear be synchronized.
SCIA0750E
SCIA0751E
Page 2547 of 3066

M/T OIL
MT-11
D
E
F
G
H
I
J
K
L
MA
B
MT
M/T OILPFP:KLD20
Changing M/T OilECS001WQ
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 OilECS001WR
OIL LEAKAGE AND OIL LEVEL
lCheck that oil is not leaking from transaxle or around it.
lCheck oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Never start engine while checking oil level.
lSet 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 - 4.0 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 - 4.0 kg-m, 23 - 28 ft-lb)
Filler plug:
: 30 - 39 N·m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
SCIA0361E
Page 2548 of 3066
MT-12
SIDE OIL SEAL
SIDE OIL SEAL
PFP:32113
Removal and InstallationECS001WS
REMOVAL
lClutch 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 driveshaft from the transaxle.
2. Remove oil seal with a slotted 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.
Drift to be used:
CAUTION:
lWhen installing oil seals, apply multi-purpose grease to oil seal lips.
lOil 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 of flush with the case.
SCIA0352E
Transaxle case side ST3340 0001
Clutch housing side KV401 00620
Page 2549 of 3066
POSITION SWITCH
MT-13
D
E
F
G
H
I
J
K
L
MA
B
MT
POSITION SWITCHPFP:32005
CheckingECS001WT
BACK-UP LAMP SWITCH
lCheck continuity.
PARK/NEUTRAL POSITION SWITCH
lCheck continuity.
Gear position Continuity
Reverse Yes
Except reverse No
SCIA0708E
Gear position Continuity
Neutral Yes
Except neutral No
Page 2550 of 3066
MT-14
CONTROL LINKAGE
CONTROL LINKAGE
PFP:34103
Removal and Installation of Control Device and CableECS001WU
Refer to the figure for removal and installation procedure.
CAUTION:
lKeep in mind that the select side lock plate for securing the control cable is different from the one
on the shift side.
lAfter assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st,
2nd, or Reverse.
SCIA0711E
Page 2551 of 3066
AIR BREATHER HOSE
MT-15
D
E
F
G
H
I
J
K
L
MA
B
MT
AIR BREATHER HOSEPFP:31098
Removal and InstallationECS0 01 W V
Refer to the figure for air breather hose removal and installation information.
QR engine models
YD engine models
CAUTION:
lMake sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
lBe sure to insert hose into the transaxle tube until overlap area reaches the spool.
SCIA0354E
SCIA0747E
Page 2552 of 3066

MT-16
TRANSAXLE ASSEMBLY
TRANSAXLE ASSEMBLY
PFP:32010
Removal and InstallationECS001WW
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 driveshaft.
8. Remove transfer.
lRefer toTF-12, "Removal and Installation from Vehicle"in "TF TRANSFER."
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.
12. Remove suspension members.
lRefer toFSU-12, "FRONT SUSPENSION MEMBER"in "FSU FRONT SUSPENSION."
13. Support engine by placing a jack under oil pan.
14. Remove bolts securing transaxle to engine.
SCIA0845E