Page 3513 of 5135

± INTRODUCTIONTERMS FOR MANUAL TRANSAXLE REPAIR MANUAL
01±7
C250 M/T REPAIR MANUAL (RM1020E) ISC
Idle Speed Control±
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure±
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface temperature±
MVZManifold Vacuum Zone±
NVRAMNon±Volatile Random Access Memory±
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn±Board DiagnosticOn±Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CC0
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module±
PNPPark/Neutral Position±
PROMProgrammable Read Only Memory±
PSPPower Steering Pressure±
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module±
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass±
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter±
SRIService Reminder Indicator±
SRTSystem Readiness Test±
STScan Tool±
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
TCMTransmission Control ModuleTransmission ECU (Electronic Control Unit)
TPThrottle PositionThrottle Position
TRTransmission Range±
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree±Way Catalytic ConverterThree±Way Catalytic (TWC)
CC
RO
TWC+OCThree±Way + Oxidation Catalytic ConverterCCR + CCO
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor (Read Switch Type)
WOTWide Open ThrottleFull Throttle
Page 3514 of 5135
01±8
± INTRODUCTIONTERMS FOR MANUAL TRANSAXLE REPAIR MANUAL
C250 M/T REPAIR MANUAL (RM1020E) WU±OC
Warm Up Oxidation Catalytic Converter±
WU±TWCWarm Up Three±Way Catalytic ConverterManifold Converter
3GRThird Gear±
4GRFourth Gear±
Page 3515 of 5135

410DH±01
C80538
C68312
C68309
C68254
41±48
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
OVERHAUL
1. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 1st gear thrust clear-
ance.
Standard clearance:
0.10 ± 0.40 mm (0.0039 ± 0.0157 in.)
Maximum clearance:
0.40 mm (0.0157 in.)
2. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 2nd gear thrust clear-
ance.
Standard clearance:
0.1 ± 0.45 mm (0.0039 ± 0.0177 in.)
Maximum clearance:
0.45 mm (0.0177 in.)
3. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 1st gear radial clear-
ance between the gear and shaft.
Standard clearance:
0.015 ± 0.058 mm (0.0006 ± 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 1st gear
needle roller bearing.
4. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 2nd gear radial clear-
ance between the gear and shaft.
Standard clearance:
0.015 ± 0.058 mm (0.0006 ± 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 2nd gear
needle roller bearing.
Page 3516 of 5135
C80539
SST
C68005
C80431
C80541
D30552
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±49
C250 M/T REPAIR MANUAL (RM1020E)
5. REMOVE 4TH DRIVEN GEAR
(a) Using SST and a press, remove the output shaft bearing
rear and 4th driven gear from the output shaft.
SST 09950±00020
6. REMOVE OUTPUT GEAR SPACER
(a) Remove the output gear spacer from the output shaft.
7. REMOVE 2ND GEAR
(a) Using SST, remove the 3rd driven gear and 2nd gear from
the out put shaft.
SST 09950±00020
8. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
(a) Remove the 2nd gear needle roller bearing and 2nd gear
bearing spacer from the output shaft.
9. REMOVE SYNCHRONIZER RING NO.1 (FOR SECOND
SYNCHRONIZER RING)
(a) Remove the synchronizer ring No.1 from the output shaft.
Page 3517 of 5135
C80543
C80544
SST
C68516
C68012
C68013
41±50
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
10. REMOVE 1ST GEAR
(a) Using 2 screwdrivers and a hammer, remove the clutch
hub No.1 shaft snap ring from the output shaft.
HINT:
Using a shop rug to prevent the shaft snap ring from being
scatted.
(b) Using SST and a press, remove the clutch hub No.1 assy
and 1st gear from the output shaft.
SST 09950±00020
11. REMOVE SYNCHRONIZER RING NO.1 (FOR FIRST
SYNCHRONIZER RING)
(a) Remove the synchronizer ring No.1 from the 1st gear.
12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output
shaft.
13. REMOVE 1ST GEAR THRUST WASHER
(a) Remove the 1st gear thrust washer from the output shaft.
Page 3518 of 5135
C68014
C68015
C80545
AB C
C80439
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±51
C250 M/T REPAIR MANUAL (RM1020E)
14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
(a) Remove the 1st gear thrust washer pin or ball from the
output shaft.
15. REMOVE REVERSE GEAR
(a) Remove the reverse gear, 3 synchromesh shifting keys
and 3 synchromesh keys springs.
HINT:
Using a waste to prevent the shifting key and shifting key spring
from being scatted.
16. INSPECT OUTPUT SHAFT
(a) Using a dial indicator, check the shaft runout.
Minimum runout: 0.015 mm (0.0006 in.)
If the runout exceeds the maximum, replace the output shaft.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Standard outer diameter:
Part A: 31.985 ±32.000 mm (1.2592 ± 1.2598 in.)
Part B: 37.985 ±38.000 mm (1.4955 ± 1.2598 in.)
Part C: 32.985 ±33.000 mm (1.2986 ± 1.2992 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.
SST 99999±60009
Page 3519 of 5135

C68017
C68017
C68514
C68023
C68239
41±52
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
17. INSPECT 2ND GEAR
(a) Using a cylinder gauge, measure the clearance of the 2nd
gear.
Standard clearance:
38.015 ± 38.031 mm (1.4966 ± 1.4972 in.)
Maximum clearance:
38.031 mm (1.4972 in.)
If the clearance exceeds the maximum, replace the 1st gear.
18. INSPECT 1ST GEAR
(a) Using a cylinder gauge, measure the clearance of the 1st
gear.
Standard clearance:
44.015 ± 44.031 mm (1.7328 ± 1.7335 in.)
Maximum clearance:
44.031 mm (1.7335 in.)
If the clearance exceeds the maximum, replace the 1st gear.
19. INSPECT 1ST GEAR THRUST WASHER
(a) Using a micrometer, measure the 1st gear thrust washer.
Standard thickness:
5.975 ± 6.025 mm (0.2352 ± 0.2372 in.)
Minimum thickness:
5.975 mm (0.2352 in.)
If the clearance exceeds the minimum, replace the 1st gear.
20. INSPECT SYNCHRONIZER RING NO.1 (FOR SECOND
SYNCHRONIZER RING)
(a) Coat the 2nd gear cone with gear oil. 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.
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Standard clearance:
0.70 ± 1.30 mm (0.0276 ± 0.0512 in.)
Minimum clearance:
0.70 mm (0.0276in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
Page 3520 of 5135

C68021
C68022
C68409
C68240
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±53
C250 M/T REPAIR MANUAL (RM1020E)
21. INSPECT SYNCHRONIZER RING NO.1 (FOR FIRST
SYNCHRONIZER RING)
(a) Coat the 1st gear cone with gear oil. 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.
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Standard clearance:
0.75 ± 1.65 mm (0.0295 ± 0.0650 in.)
Minimum clearance:
0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
22. INSPECT REVERSE GEAR
(a) Using a vernier caliper, measure the clearance between
the reverse gear and shift fork.
Maximum clearance: 0.35 mm (0.014 in.)
If the clearance exceeds the maximum, replace the shift form
or reverse gear.
23. INSPECT TRANSMISSION CLUTCH HUB NO.1
(a) Check that the transmission clutch hub No.1 and reverse
gear slides smoothly.
(b) Check that the spline gear's edges of the reverse gear is
not worn down.