Page 3569 of 5135
4101E±02
C67982
C80408
Match
marks
C67984
C67989
41±66
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
OVERHAUL
1. REMOVE SPEEDOMETER DRIVE (MTM) GEAR
(a) Remove the speedometer drive gear from the front differ-
ential case.
2. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place match marks on the from the front differential ring
gear and from the front differential case.
(b) Remove the 8 bolts. Using a hammer, remove the front
differential ring gear from the front differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR
BACKLASH
(a) Fixing the front differential pinion to the from the front dif-
ferential case side. Using a dial indicator, measure the
front differential side gear back lash.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
Page 3570 of 5135

C67985
C67986
C67987
C67988
C68517
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
41±67
C250 M/T REPAIR MANUAL (RM1020E)
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a chisel and hammer, loosen the staked part of the
front differential case.
(b) Using a pin punch (3 mm) and a hammer, remove the
front differential pinion shaft straight pin from the front dif-
ferential case.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Remove the front differential pinion shaft No.1 from the
front differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions , front differential
pinion thrust washers and front differential side gear
thrust washers No.1 from the front differential case.
HINT:
Revolving the front differential pinion, remove the 2 pinions, pin-
ion thrust washers and side gear thrust washers.
7. INSPECT FRONT DIFFERENTIAL PINION THRUST
WASHER
(a) Using a micrometer, measure the thickness of the front
differential pinion thrust washer.
Minimum thickness: 0.94 mm (0.03701 in.)
If the thickness exceed the minimum, replace the front differen-
tial pinion thrust washer.
Page 3571 of 5135

C68518
C67988
C67987
41±68
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
8. INSPECT FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Using a micrometer, measure the outer diameter of the
front differential pinion shaft No.1.
Minimum outer diameter: 16.982 mm (0.6685 in.)
If the outer diameter exceed the minimum, replace the front dif-
ferential pinion shaft No.1.
9. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the sliding and rotating surface of the front differen-
tial side gear with MP grease.
(b) Install the 2 front differential side gear thrust washers to
the 2 front differential side gear.
(c) Install the 2 front differential pinions with front differential
washers to the front differential case.
HINT:
Revolving the front differential pinion, install the 2 front differen-
tial pinions with front differential washers.
10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
(a) Coat the front differential pinion shaft No.1 with MP
grease.
(b) Install the front differential pinion shaft No.1 to the front
differential case so that the hole for the front differential
pinion shaft straight pin is aligned with the hole in the front
differential case.
Page 3572 of 5135

C67989
C67990
C67991
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
41±69
C250 M/T REPAIR MANUAL (RM1020E)
11. ADJUST FRONT DIFFERENTIAL SIDE GEAR
BACKLASH
(a) Fixing the front differential pinion to the front differential
case side. Using a dial indicator, measure the front differ-
ential side gear backlash.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
HINT:
Because the thrust washer does not have any mark for
distinction, measure the thickness with a micrometer to
select a proper thrust washer.
Select washers of the same thickness for both the right
and left.
Thrust washer thickness
Parts No.Thickness mm (in.)
41361 ± 221400.95 (0.0374 in.)
41361 ± 220201.00 (0.0394 in.)
41361 ± 221501.05 (0.0413 in.)
41361 ± 220301.10 (0.0433 in.)
41361 ± 221601.15 (0.0452 in.)
41361 ± 220401.20 (0.0472 in.)
12. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch ( 3mm) and hammer, install the front
differential pinion shaft straight pin to the front differential
case.
(b) Using a chisel and hammer, stake the front differential
case hole.
Page 3573 of 5135
9011 0
C58905
C80408
Match
marks
C67982
41±70
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
13. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using a heater, heat the front differential ring gear to 90
± 110 C (194.0 ± 230.0 F. )
(b) Clean the contact surface of the front differential case.
(c) Aligning the both match marks, quickly install the front dif-
ferential ring gear to the front differential case.
(d) Install the 8 bolts.
Torque: 77 Nm (790 kgfcm, 57 ftlbf)
14. INSTALL SPEEDOMETER DRIVE (MTM) GEAR
(a) install the speedometer drive gear to the front differential
case.
Page 3574 of 5135
410DK±01
D30564
Front Differential Pinion Front Differential Pinion Thrust Washer
Nm (kgfcm, ftlbf): Specified torque
77 (790, 57)
Front Differential Ring Gear Set Bolt Front Differential CaseFront Differential Side Gear
Front Differential Side Gear
Thrust Washer No.1
Front Differential Pinion
Front Differential Pinion Thrust Washer
Front Differential Pinion Shaft
Straight Pin Front Differential Side GearFront Differential Side Gear Thrust Washer No.1
Speedometer Drive (MTM)
Gear Front Differential Ring GearFront Differential Pinion Shaft No.1
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
41±65
C250 M/T REPAIR MANUAL (RM1020E)
DIFFERENTIAL CASE ASSY (C250)
COMPONENTS
Page 3575 of 5135
410DJ±01
C80760
C80761
C80762
C80763
41±60
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
OVERHAUL
1. REMOVE SHIFT & SELECT LEVER BUSH
(a) Remove the shift & select lever bush from the selecting
bell crank assy.
2. REMOVE SELECTING BELLCRANK DUST COVER
NO.1
(a) Remove the selecting bellcrank dust cover No.1 from the
selecting bellcrank assy.
3. REMOVE SELECTING BELL CRANK NO.2
(a) Remove the nut, spring washer and selecting bellcrank
No.2 plate washer.
(b) Remove selecting bellcrank No.2 from the selecting bell-
crank support.
4. REMOVE SELECTING BELLCRANK DUST COVER
NO.2
(a) Remove the selecting bellcrank dust cover No.2 from the
selecting bellcrank No.2.
Page 3576 of 5135

C80764
Bush
C80572
D30553
D30554
D30555
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (C250)
41±61
C250 M/T REPAIR MANUAL (RM1020E)
5. REMOVE SELECTING BELLCRANK NO.2 BUSH
(a) Remove the 2 selecting bellcrank No.2 bushes from the
selecting bellcrank.
6. REMOVE SELECT SPRING SEAT NO.2
(a) Using a screwdriver, remove the select spring seat No.2
E±ring, select spring seat No.2 and select return spring
No.2 from the shift & select lever shaft.
7. REMOVE SHIFT LEVER INNER NO.2
(a) Using a pin punch (5mm) and hammer, remove the shift
inner lever slotted pin and shift lever inner No.2 from the
shift & select lever shaft.
HINT:
Make sure of the orientation of the shift lever inner No.2.
8. REMOVE SHIFT LEVER INNER NO.1
(a) Using a pin punch (5mm) and hammer, remove the shift
inner lever slotted pin, shift lever inner No.1 and shift inter
lock plate from the shift & select lever shaft.
HINT:
Make sure of the orientation of the shift lever inner No.1.
9. REMOVE SELECT INNER LEVER
(a) Using a pin punch (5mm) and hammer, remove the se-
lect inner lever slotted pin, select inner lever select return
spring No.1 and select return spring No.1 seat from shift
& select lever shaft.
HINT:
Make sure of the orientation of the select inner lever.