en_4j2_5b.pdf part of Daewoo Nubira/Lacetti Service Manual - Daewoo Lacetti.part01.rar, Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno Covers the 1.4L, 1.6L and 1.8L engine. Year 2004 text manual preview

Text preview for : en_4j2_5b.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno Covers the 1.4L, 1.6L and 1.8L engine. Year 2004

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SECTION : 5B

FIVESPEED MANUAL TRANSAXLE
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5B2 Fastener Tightening Specifications . . . . . . . . . . . 5B2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 5B3 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B5 Isolate Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B5 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 5B6 COMPONENT LOCATORS . . . . . . . . . . . . . . . . . . 5B9 Gears and Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B9 Bearing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B11 Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 5B12 Shift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B13 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . ONVEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . Checking Fluid Level . . . . . . . . . . . . . . . . . . . . . . Shift Linkage Adjustment . . . . . . . . . . . . . . . . . . 5B15 5B15 5B15 5B15 Gearshift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B17 Gearshift Lever Housing . . . . . . . . . . . . . . . . . . . 5B18 Speedometer Driven Gear . . . . . . . . . . . . . . . . . 5B18 Shift Linkage Assembly . . . . . . . . . . . . . . . . . . . . 5B19 Drive Axle Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B20 Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . . . 5B21 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B26 Major Component Disassembly . . . . . . . . . . . . . 5B26 Input Shaft and Cluster Gear . . . . . . . . . . . . . . . 5B35 Mainshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B37 Housing Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B48 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B50 Major Component Assembly . . . . . . . . . . . . . . . 5B56 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B63 FiveSpeed Manual Transaxle . . . . . . . . . . . . . . 5B63

5B 2IFIVESPEED MANUAL TRANSAXLE

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application Backup Lamp Switch Bearing Plate Bolts Bearing Retainer Bolts, Right Side BearingAdjusting RingRetainer Plate Bolt ClutchRelease Cylinder Retaining Bolts Damping Block Connection Nut and Bolt Differential Cover Bolts FifthGear Fork Bolts FifthGearshift Connector Bolts Flywheel Inspection Cover Bolts Gearshift Housing Bolts Gearshift Lever Cover Bolts Input Driveshaft Detent Screw Rear Damping Block Retaining Bolts Rear Mounting Bracket Bolts RingGear Bolts Rod Clamp Bolt Speedometer Housing Retaining Bolt SpeedometerDriven Gear Bolt Transaxle Cover Bolts Transaxle Lower Retaining Bolts(a) Transaxle Lower Retaining Bolt(b) Transaxle Lower Retaining Bolts(c) Transaxle Upper Retaining Bolts Transaxle Upper Mounting Bracket Bolts NSm 20 22 25 5 20 68 40 22 7 7 7 22 15 68 90 70 14 4 5 18 73 31 21 73 48 LbFt 15 16 18 15 50 30 16 16 11 50 66 52 13 54 23 15 54 35 LbIn 44 62 62 62 124 35 44

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FIVESPEED MANUAL TRANSAXLE 5B 3

SPECIAL TOOLS
SPECIAL TOOLS TABLE

J6125B Slide Hammer

KM553A FifthGear Puller

J2288820A Bearing Puller with J2288835 Puller Legs

J36633 Snap Ring Retainer

J2291201 Universal Bearing Puller

KM1132 Base

J28467B Engine Support Fixture

KM334 Installer Sleeve

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J42469 Shift Rod Remover

KM525 Installer

KM519 Ring Installer

KM552 Fixture

KM520 Remover/Installer

KM554 Installer

KM522 Installer

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FIVESPEED MANUAL TRANSAXLE 5B 5

DIAGNOSIS
ISOLATE NOISE
Identify the cause of any noise before attempting to repair the clutch, the transaxle, or their related linkages. Symptoms of trouble with the clutch or the manual transaxle include: S S S A great effort required to shift gears. The sound of gears clashing and grinding. Gear blockout.

Bearing Noise
Differential Side Bearing Noise Differential side bearing noise and wheel bearing noise can be confused easily. Since side bearings are pre loaded, a differential side bearing noise should not diminish much when the differential/transaxle is run with the wheels off the ground. Wheel Bearing Noise Wheel bearings produce a rough growl or grating sound that will continue when the vehicle is coasting and the transaxle is in NEUTRAL. Since wheel bearings are not preloaded, a wheel bearing noise should diminish considerably when the wheels are off the ground.

Any of these conditions requires a careful analysis. Make the following checks before disassembling the clutch or the transaxle for repairs.

Road Travel Noise
Many noises that appear to come from the transaxle may actually originate with other sources such as the: S S S S S Tires. Road surfaces. Wheel bearings. Engine. Exhaust system.

Other Noise
Brinelling A brinelled bearing causes a "knock" or "click" approximately every second revolution of the wheel because the bearing rollers do not travel at the same speed as the wheel. In operation, the effect is characterized by a low pitched noise. A brinelled bearing is caused by excessive thrust which pushes the balls up on the pathway and creates a triangularshaped spot in the bearing race. A brinelled bearing can also be caused from pressing one race into position by applying pressure on the other race. A false indication of a brinelled bearing occurs as a result of vibration near the area where the bearing is mounted. Brinelling is identified by slight indentations, resulting in a washboard effect in the bearing race. Lapping Lapped bearing noise occurs when fine particles of abrasive materials such as scale, sand, or emery circulate through the oil in the vehicle, causing the surfaces of the roller and the race to wear away. Bearings that wear loose but remain smooth, without spalling or pitting, are the result of dirty oil. Locking Large particles of foreign material wedged between the roller and the race usually causes one of the races to turn, creating noise from a locked bearing. Preloading regular taper roller bearings to a value higher than that specified also can result in locked bearings Pitting Pitting on the rolling surface comes from normal wear and the introduction of foreign materials. Spalling Spalled bearings have flaked or pitted rollers or races caused by an overload or an incorrect assembly that results in a misalignment, a cocking of bearings, or adjustments that are too tight. After completing these checks, refer to the "Diagnosis Chart" in this section.

These noises may vary according to the: S S S Size of the vehicle. Type of the vehicle. Amount of insulation used in the body of the vehicle.

Transaxle Noise
Transaxle gears, like any mechanical device, are not absolutely quiet and will make some noise during normal operation. To verify suspected transaxle noises: 1. 2. 3. 4. 5. Select a smooth, level asphalt road to reduce tire and resonant body noise. Drive the vehicle far enough to warm up all the lubricants thoroughly. Record the speed and the gear range of the transaxle when the noise occurs. Check for noises with the vehicle stopped, but with the engine running. Determine if the noise occurs while the vehicle operates in: S S S S Drive under a light acceleration or a heavy pull. Float maintaining a constant speed with a light throttle on a level road. Coast with the transaxle in gear and the throttle partly or fully closed. All of the above.

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SYMPTOM DIAGNOSIS
Checks Check for a knock at low speeds. Check for a noise most pronounced on turns. Check for a clunk upon acceleration or deceleration. S S S S S S S Check for a clunking noise in turns. Check for a vibration. S S S S S S S S S S S S S S S S S S S S S S Check for a noise in the second gear (2) only. S S S S S S Check for a noise in the third gear (3) only. S S S S S S Action Replace any worn drive axle CV joints. Replace any worn side gear hub. Correct any abnormalities in the differential gear. Tighten any loose engine mounts. Replace any worn drive axle inboard joints. Replace any worn differential pinion shaft in the case. Replace any worn side gear hub in the case. Replace any worn outboard CV joint. Replace any rough wheel bearing. Replace any bent drive axle shaft. Replace any outofround tires. Balance any unbalanced tire. Replace any worn CV joint in the drive axle shaft. Correct an excessive drive axle angle by adjusting the trim height. Replace any worn cluster bearing shaft. Replace any worn clutchrelease bearing. Replace any worn input shaft cluster gears. Replace any worn firstgear/bearing. Replace any worn secondgear/bearing. Replace any worn thirdgear/bearing. Replace any worn fourthgear/bearing. Replace any worn fifthgear/bearing. Replace any worn mainshaft bearings. Replace any chipped, scored, or worn firstgear constant mesh gears. Replace any worn firstsecond gear synchronizer. Replace any worn firstgear/bearing. Replace any worn differentialgear/bearing. Replace any wornring gear. Adjust, repair, or replace the shift lever and the rods. Replace any chipped, scored, or worn secondgear constant mesh gears. Replace any worn firstsecond gear synchronizer. Replace any worn secondgear/bearing. Replace any worn differentialgear/bearing. Replace any wornring gear. Adjust, repair, or replace the shift lever and the rods. Replace any chipped, scored, or worn thirdgear constant mesh gears. Replace any worn thirdfourth gear synchronizer. Replace any worn thirdgear/bearing. Replace any worn differentialgear/bearing. Replace any wornring gear. Adjust, repair, or replace the shift lever and the rods.

Check for a noise in the NEUTRAL gear with the engine running.

Check for a noise in the first gear (1) only.

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Checks Check for a noise in the fourth gear (4) only. S S S S S S Check for a noise in the fifth gear (5) only. S S S S S S Check for a noise in the reverse (R) gear only. S S S S S Check for a noise in all gears. S S S S S S S Check for a leak in the area of the clutch. Check for a leak at the center of the transaxle. S S S S S S S S Action Replace any chipped, scored, or worn fourth gear or output gear. Replace any worn thirdfourth gear synchronizer. Replace any worn fourthgear/bearing. Replace any worn differentialgear/bearing. Replace any wornring gear. Adjust, repair, or replace the shift lever and the rods. Replace any chipped, scored, or worn fifth gear or output gear. Repair any worn fifthgear synchronizer. Replace any worn fifthgear/bearing. Replace any worn differentialgear/bearing. Replace any wornring gear. Adjust, repair, or replace the shift lever and the rods. Replace any chipped, scored, or worn reverse idler gear, idlergear bushing, input gear, or output gear. Replace any worn firstsecond gear synchronizer. Replace any worn output gear. Replace any worn differentialgear/bearing. Replace any wornring gear. Add sufficient lubricant. Replace any worn bearings. Replace any chipped, scored, or worn inputgear shaft or outputgear shaft. Adjust or replace the linkage, as needed. Adjust, repair, or replace any binding shift linkage. Tighten or replace the inputgear bearing retainer, as needed. Repair or replace any worn or bent shift fork. Repair the transaxle casing. Replace any damaged release bearing guide. Repair the transaxle casing. Repair the shift mechanism. Replace the damaged backup lamp switch. Adjust or replace the bearing retainers. Tighten or replace the differential cover. Adjust or replace the drive axle shaft seals.

Check for the transaxle slipping out of gear.

Check for a leak at the differential.

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Checks Check for a hard shift. S S S S S S S Check for a clashing of gears. S S S S S S S S S S S S Action Replace any damaged releasebearing guide. Adjust, repair, or replace the shift mechanism. Adjust, repair, or replace the clutchrelease system. Replace any chipped, scored, or worn fifthgear synchronizer. Replace any chipped, scored, or worn firstsecond gear synchronizer. Replace any worn thirdfourth gear synchronizer. Adjust, repair, or replace the shift lever and the rods. Replace any damaged releasebearing guide. Adjust, repair, or replace the clutchrelease system. Replace the chipped, scored, or worn input shaft/ gearcluster gears. Replace any worn fifthgear synchronizer. Replace any worn fifthgear/bearing. Replace any worn firstgear/bearing. Replace any worn firstsecond gear synchronizer. Replace any worn secondgear/bearing. Replace any worn thirdgear/bearing. Replace any worn thirdfourth synchronizer. Replace any worn fourthgear/bearing. Replace any worn reverseidler gear.

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COMPONENT LOCATORS
GEARS AND CASE

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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. Roller Bearing Transaxle Main Shaft Washer Washer Retaining Ring 4th Speed Gear Needle Cage Synchronizer Ring Shift Sleeve Synchronizer Key 3rd & 4th Synchronizer Spring Washer Circlip 3rd Speed Gear Washer Washer Retaining Ring 2nd Speed Gear Needle Cage Inside Synchronizer Ring Intermediate Ring Outside Synchronizer Ring Sliding Gear 1st & 2nd Synchronizer Key 1st & 2nd Synchronizer Spring Washer Circlip 1st Speed Gear Needle Cage 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. Needle Cage Main Shaft Disc Retaining Ring Groove Ball Bearing Washer Retaining Ring 5th Speed Gear Needle Cage Synchronizer Ring 5th Shift Sleeve 5th Synchronizer Spring 5th Synchronizer Key Retaining Ring Needle Sleeve Input Drive Shift Input Shaft Cluster Gear Bolt Retaining Ring Cluster Bearing Ring Groove Ball Bearing Cluster 5th Speed Gear Retaining Ring Washer Reverse Idler Gear Reverse Idler Gear Shaft Ball

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BEARING PLATE

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Strain Bolt Bridge Bolt Bolt Bolt Bearing Plate Bolt Pin Blocking Pin Compression Spring Plug Gear Shift Sliding Fork

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

GearShift Shoe Screw Transaxle Cover Transaxle Cover Gasket Magnet Bearing Plate Gasket Bolt Bolt Bolt Screw Detent Sleeve

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DIFFERENTIAL GEAR

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Differential Gear Housing Differential Gear Speedometer Drive Gear Washer Side Gear Bevel Differential Gear Bevel Gear Disc Differential Gear Shaft Differential Spring Pin Bolt

11. 12. 13. 14. 15. 16. 17. 18. 19.

Taper Roller Bearing Differential Bearing Ring Shaft Seal Ring ORing Differential Gear Bearing Flange ORing Locking Plate Bolt Bolt

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SHIFT LINKAGE

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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Gear Shift Control Bolt Gear Shift Tube Bellows Clamp Bolt Gear Shift Control Mode Gear Shift Guide Control Pin Clip Bolt 1st & 2nd Gear Shift Fork 1st & 2nd Gear Shift Rod Pin 3rd & 4th Gear Shift Fork 3rd & 4th Gear Shift Rod Pin 5th Speed Engaging Piece Gear Shift Rod Pawl Reverse Gear Shift Fork Reverse Gear Shift Rod Pin Gear Shift Rod Shift Finger 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. Gear Shift Lever Cover Gear Shift Inter Lever Plate Compression Spring Bush Retaining Ring Gear Shift Cover Gasket Bolt Plug Plug Speedometer Driven Gear Bolt Differential Gear Cover Gasket Differential Gear Cover Screw Backup Lamp Switch Oring Pin Pin Sleeve Bush

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MAINTENANCE AND REPAIR
ONVEHICLE SERVICE CHECKING FLUID LEVEL
1. With the vehicle on a level surface and the fluid in the transaxle cold, remove the filler plug and check the fluid level. The fluid should come to the bottom edge of the plug hole.

2.

3. 4.

If the level is low, add SAE 80 manual transaxle fluid through the filler plug hole until the fluid begins to run out. Reinstall the filler plug and tighten it securely. If the fluid is contaminated, drain the oil after removing the differential gear cover.

SHIFT LINKAGE ADJUSTMENT (LEFTHAND DRIVE SHOWN, RIGHTHAND DRIVE SIMILAR)
1. 2. Disconnect the negative battery cable. Position the gearshift lever into NEUTRAL.

Important : All the gears must be easy to engage when the vehicle is stationary, the engine is running, and the clutch is disengaged. 3. Loosen the rod clamp bolt.

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4. 5. Remove the adjustment hole plug from the shift lever cover. Turn the gearshift rod and fully insert a 5 mm (0.2 inch) gauge pin into the adjustment hole.

6. 7. 8. 9.

Remove the boot from the console. Pull the boot upward to expose the shift control lever mechanism. Position the gearshift lever close to left side of the NEUTRAL position. Insert a 5 mm (0.2 inch) gauge pin into the holes to align the gearshift lever with the gearshift lever housing.

10. Tighten the rod clamp bolt.

Tighten
Tighten the rod clamp bolt to 14 NSm (124 lbin).

11. Remove .the 5 mm (0.2 inch) gauge pin from the adjustment hole. 12. Install the adjustment hole plug. 13. Remove the 5 mm (0.2 inch) gauge pin from the gearshift lever. 14. Install the boot to the console. 15. Connect the negative battery cable.

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GEARSHIFT LEVER (LEFTHAND DRIVE SHOWN, RIGHTHAND DRIVE SIMILAR)
Removal Procedure
1. 2. 3. 4. Disconnect the negative battery cable. Position the gearshift lever into NEUTRAL. Disconnect the boot from the console cover. Lift the console cover upward to expose the shift control lever mechanism. Rotate the gearshift lever stop clamp and remove it. Remove the gearshift lever from the gearshift lever shaft.

5. 6.

Installation Procedure
1. 2. 3. Install the gearshift lever into the gearshift lever shaft. Install the gearshift lever stop clamp. Rotate the gearshift lever stop clamp to secure it.

4. 5.

Lower the boot and connect it to the console cover. Connect the negative battery cable.

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GEARSHIFT LEVER HOUSING (LEFTHAND DRIVE SHOWN, RIGHTHAND DRIVE SIMILAR)
Removal Procedure
1. 2. 3. 4. Disconnect the negative battery cable. Remove the rod clamp. Refer to "Shift Linkage Adjustment" in this section. Remove the console. Remove the gearshift lever housing bolts and the gearshift lever housing.

Installation Procedure
1. Install the gearshift lever housing and the gearshift lever housing bolts.

Tighten
2. 3. 4. Tighten the gearshift housing bolts to 7 NSm ( 62 lb in). Adjust the shift linkage. Install the console. Connect the negative battery cable.

SPEEDOMETER DRIVEN GEAR
Removal Procedure
1. Disconnect the speedometer speed sensor electrical connector.

2. 3.

Remove the speedometer housing retaining bolt. Remove the speedometerdriven gear and the speedometer housing.

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1. 2. 3. Coat the Oring with petroleum jelly. Install the speedometerdriven gear and the speedometer housing. Install the speedometer housing retaining bolt.

Tighten
Tighten the speedometer housing retaining bolt to 4 NSm (35 lbin).

4.

Connect the speedometer speed sensor electrical connector.

SHIFT LINKAGE ASSEMBLY
Removal Procedure
1. 2. 3. 4. Disconnect the negative battery cable. Remove the rod clamp. Refer to "Shift Linkage Adjustment" in this section. Remove the clip and the bolt from universal joint. Separate the universal joint from the transaxle.

5.

6.

Remove the fixing shaft pin and separate the linkage connection part from the transaxle rear mounting bracket. Remove the shift linkage assembly.

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1. 2. Install the shift linkage assembly. Install the fixing shaft pin and connect the linkage connection part to the transaxle rear mounting bracket.

3. 4. 5. 6. 7.

Install the universal joint to the transaxle. Install the clip and the bolt from universal joint. Install the rod clamp. Refer to "Shift Linkage Adjustment" in this section. Adjust the shift linkage. Refer to "Shift Linkage Adjustment" in this section. Connect the negative battery cable.

DRIVE AXLE SEAL
Tools Required KM519 Ring Installer

Removal Procedure
Notice : Do not damage the bearing adjusting ring with the pry bar. 1. 2. Remove the drive axle from the transaxle. Refer to Section 3B, Manual Transaxle Drive Axle. Remove the drive axle seal by lifting the outer lip of the seal with a pry bar.

Installation Procedure
1. 2. 3. Install the new drive axle seal using the ring installer KM519 and a hammer. Coat the seal lip with the transaxle fluid. Install the drive. Refer to Section 3B, Manual Transaxle Drive Axle.

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TRANSAXLE ASSEMBLY
Tools Required J28467B Engine Support Fixture

Removal Procedure
1. 2. 3. 4. Install the engine support fixture J28467B. Remove the battery and battery tray. Refer to Section 1E, ENGINE ELETRICAL. Remove the shift linkage assembly. Refer to "Shift Linkage Adjustment" in this section. Remove the drive axle shaft. Refer to Section 3B, Manual Transaxle Drive Axle. Disconnect the backup lamp switch electrical connector. Disconnect the speedometer speed sensor electrical connector.

5. 6.

7.

Remove the pin and the clutch release cylinder pipe.

Remove the damping block connection nut and bolt. 9. Remove the three rear mounting bracket bolts. 10. Remove the rear mounting bracket from the transaxle.

8.

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11. Remove the two rear damping block retaining bolts. 12. Remove the rear damping block from the front cross member.

13. Remove the two cage retaining bolts. 14. Remove the three transaxle upper mounting bracket bolts. 15. Remove the upper mounting bracket and cage.

16. Remove the three transaxle upper retaining bolts.

17. Support the transaxle with a transaxle support jack.

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18. Remove the seven transaxle lower retaining bolts.

19. Remove the transaxle. Notice : Rest the transaxle only in an upright position. 20. Slide the transaxle sideways away from the engine block. 21. Lower the transaxle.

Installation Procedure
1. 2. Support the transaxle with a transaxle support jack. Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block.

3.

Install the seven transaxle lower retaining bolts.

Tighten
Tighten the transaxle lower retaining bolts(a) to 73 NSm ( 54 lbft ). Tighten the transaxle lower retaining bolt(b) to 31 NSm ( 23 lbft ). Tighten the transaxle lower retaining bolts(c) to 21 NSm ( 15 lbft ).

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4. Install the three transaxle upper retaining bolts.

Tighten
Tighten the transaxle upper retaining bolts to 73 NSm (54 lbft ).

5. 6.

Install the cage retaining bolt and cage. Install the three transaxle upper mounting bracket bolts and bracket.

Tighten
Tighten the transaxle upper mounting bracket bolts to 48 NSm (35 lbft ).

7.

Install the two rear damping block retaining bolts.

Tighten
8. Tighten the rear damping block retaining bolts to 68 NSm (50 lbft ). Install the rear damping block from the front cross member.

9.

Install the three rear mounting bracket bolts and the bracket.

Tighten
Tighten the rear mounting bracket bolts to 90 NSm (66 lbft ). 10. Install the damping block connection nut and bolt.

Tighten
Tighten the damping block connection nut and bolt to 68 NSm (50 lbft ).

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11. Connect the clutch release cylinder pipe.

12. Connect the speedometer speed sensor electrical connector. 13. Connect the backup lamp switch electrical connector.

14. Remove the engine support fixture J28467B. 15. Install the drive axle shaft. Refer to Section 3B, Manual Transaxle Drive Axle. 16. Install the shift linkage assembly. Refer to "Shift Linkage Assembly" in this section. 17. Install the battery and battery tray. Refer to Section 1E, ENGINE ELETRICAL. 18. Inspect the fluid level. Refer to "Checking Fluid Level" in this section.

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UNIT REPAIR MAJOR COMPONENT DISASSEMBLY
Tools Required J6125B Slide Hammer J2288820A BearingPuller with J2288835 Puller Legs KM553A Fifth Gear Puller J36633 Snap Ring Retainer KM1132 Base J42469 Shift Rod Remover KM552 Fixture

Disassembly Procedure
1. 2. 3. Remove the transaxle from the vehicle. Refer to "Transaxle Assembly" in this section. Remove the filler plug at the cover. Remove the bolts from the gearshift lever cover.

4.

Remove the gearshift lever cover.

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5. 6. Bolt the gearshift lever cover to the fixture KM552. Position the fixture KM552 into the base KM1132.

7.

Remove the snap ring, the bushing, the spring, and the intermediate lever.

8.

Remove the shift finger lever pin.

9.

Remove the gearshift rod and the shift finger lever.

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10. Remove the bolt and the speedometerdriven gear from the transaxle housing.

11. Remove the transaxle cover bolts.

12. Remove the transaxle cover.

13. Shift the transaxle into second gear. 14. Remove the bearing plate bolts.

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15. Remove the bearing plate from the case with the shafts attached.

16. Shift the transaxle into reverse (R). 17. Bolt the bearing plate to the fixture KM552 and install the fixture KM552 into the base KM1132.

18. Remove the bolts and the fifthgear fork from the bearing plate.

19. Remove the mainshaftdriven fifthspeed assembly snap ring.

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20. Remove the fifth driven gear synchronizer sleeve and the synchronizer gear using the bearing puller J2288820A with the puller legs J2288835.

21. Remove the mainshaftdriven fifthgear assembly.

22. Remove the brass synchronizer ring.

23. Remove the needle bearing, the retaining ring, and the thrust washers.

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24. Remove the input drive fifthgear snap ring.

25. Remove the input drive fifth gear using the fifth gear puller KM553A.

26. Remove the bolts and the fifthgearshift connector from the bearing plate using the pawl.

27. Remove the four shiftrod plugs using the shift rod remover J42469 and the slide hammer J6125B.

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28. Remove the spring and the rod lock pin from the small plug hole.

29. Remove the pin from the reverse gearshift rod/fork assembly.

30. Remove the reverse gearshift rod/fork assembly from the bearing plate.

31. Remove the bolts from the support bracket.

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32. Remove the firstsecond gearshift fork holding pin.

33. Drive the firstsecond gearshift rod out until it is just free of the bearing plate.

34. Remove the support bracket from the bearing plate.

35. Remove the thirdfourth gearshift fork holding pin and the thirdfourth gearshift rod.

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5B 34IFIVESPEED MANUAL TRANSAXLE
36. Remove the fifth gearshift lever from the bearing plate.

37. Remove the firstsecond gearshift rod.

38. Compress the snap ring holding the mainshaft and secure it with the snap ring retainer J36633.

39. Hold the snap ring open at the base of the input shaft using the snap ring pliers. 40. Remove the mainshaft assembly and the input shaft assembly from the bearing plate.

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INPUT SHAFT AND CLUSTER GEAR
Tools Required J2291201 Universal Bearing Puller

Disassembly Procedure
1. Remove the detent screw at the end of the input driveshaft.

2.

Remove the snap ring at the base of the gear cluster.

3.

Press the input driveshaft from the input shaft cluster gear using the universal bearing puller J2291201.

4.

Remove the cluster shaft bearing from the input shaft gear cluster using universal bearing puller J2291201.

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5B 36IFIVESPEED MANUAL TRANSAXLE Assembly Procedure
1. Press the cluster shaft bearing onto the input shaft gear cluster.

2.

Press the input driveshaft into the input shaft gear cluster assembly.

3.

Install the snap ring at the base of the gear cluster.

4.

Install the detent screw at the end of the input driveshaft.

Tighten
Tighten the input driveshaft detent screw to 15 NSm (11 lbft).

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MAINSHAFT
Tools Required J2291201 Universal Bearing Puller

Disassembly Procedure
1. Remove the mainshaft bearing using the universal bearing puller J2291201.

2.

Remove the snap ring.

3.

Remove the first gear, the flattype firstgear needle bearing, and the mainshaft wear plate.

4. 5.

Remove the synchronizer hub sleeve that contains the synchronizer spring. Remove the outer blocking ring.

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5B 38IFIVESPEED MANUAL TRANSAXLE
6. Remove the keys from the firstsecond synchronizer gear.

7.

Remove the barreltype firstgear needle bearing.

8.

Remove the snap ring and the washer.

9.

Remove the firstsecond synchronizer gear from the mainshaft.

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10. Remove the firstsecond gear blocking ring.

11. Remove the second gear using the universal bearing puller J2291201.

12. Remove the secondgear needle bearing.

13. Remove the ring and the thrust washer.

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5B 40IFIVESPEED MANUAL TRANSAXLE
14. Remove the third gear and the synchronizer blocking ring.

15. Separate the synchronizer blocking ring from the third gear.

16. Remove the thirdgear needle bearing from the mainshaft.

17. Remove the synchronizer sleeve containing the keys and the spring.

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18. Remove the snap ring and the washer from the mainshaft.

19. Remove the thirdfourth synchronizer gear containing the synchronizer spring.

20. Remove the fourthgear assembly.

21. Separate the synchronizer blocking ring from the fourth gear.

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5B 42IFIVESPEED MANUAL TRANSAXLE
22. Remove the fourthgear needle bearing, the ring, and the thrust washer.

23. Remove the mainshaft bearing.

Assembly Procedure
1. Install the mainshaft bearing.

2.

Install the ring, the thrust washer, and the fourth gear needle bearing.

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3. Attach the synchronizer blocking ring to the fourth gear.

4.

Install the fourthgear assembly.

5.

Install the thirdfourth gear synchronizer containing the synchronizer spring.

6.

Install the snap ring and the washer around the mainshaft.

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5B 44IFIVESPEED MANUAL TRANSAXLE
7. Install the synchronizer sleeve containing the keys and the spring.

8.

Install the thirdgear needle bearing.

9.

Attach the synchronizer blocking ring to the third gear.

10. Install the thirdgear assembly.

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11. Install the thrust washer and the ring.

12. Install the secondgear needle bearing.

13. Install the second gear.

14. Install the firstsecond gear blocking ring.

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5B 46IFIVESPEED MANUAL TRANSAXLE
15. Install the firstsecond synchronizer gear.

16. Install the washer and the snap ring.

17. Install the firstgear needle bearing.

18. Install the keys onto the firstsecond synchronizer gear.

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19. Install the synchronizer hub sleeve containing the synchronizer spring.

20. Install the outer blocking ring. 21. Install the mainshaft wear plate, the flattype firstgear needle bearing, and the first gear.

22. Install the snap ring.

23. Press on the mainshaft bearing.

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5B 48IFIVESPEED MANUAL TRANSAXLE

HOUSING CASE
Disassembly Procedure
1. 2. Remove the transaxle from the vehicle. Refer to "Transaxle Assembly" in this section. Remove the shift lever cover bolts and the shift lever cover. Do not disassemble the shift lever cover.

3.

Remove the transaxle cover bolts and the transaxle cover.

4.

Remove the bearing plate bolts and the bearing plate, with the shafts attached. Do not disassemble the shafts.

5.

6.

Remove the differential from the transaxle housing. Do not disassemble the differential. Refer to "Differential" in this section. Remove the backup lamp switch from the transaxle housing.

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7. 8. Remove the clutchrelease bearing and the clutch release bearing guide. Refer to Section 5C, Clutch. Remove the speedometerdriven gear bolt and the speedometerdriven gear from the transaxle housing.

Assembly Procedure
1. Install the speedometerdriven gear bolt and the speedometerdriven gear into the transaxle housing.

Tighten
Tighten the speedometerdriven gear bolt to 5 NSm (44 lbin)

2.

3.

Install the clutchrelease bearing guide and the clutchrelease bearing. Refer to Section 5C, Clutch. Install the backup lamp switch into the transaxle housing.

Tighten
Tighten the backup lamp switch to 20 NSm (15 lbft).

4. 5. 6.

Install the differential into the transaxle housing. Refer to "Differential" in this section. Install the bearing plate, with the shafts attached. Install the bearing plate bolts.

Tighten
Tighten the bearing plate bolts to 22 NSm (16 lbft).

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5B 50IFIVESPEED MANUAL TRANSAXLE
7. Install the transaxle cover and the transaxle cover bolts.

Tighten
Tighten the transaxle cover bolts to 18 NSm (13 lbft).

8.

Install the gearshift lever cover and the gearshift lever cover bolts.

Tighten
9. Tighten the gearshift lever cover bolts to 22 NSm (16 lbft). Install the transaxle into the vehicle. Refer to "Transaxle Assembly" in this section.

DIFFERENTIAL
Tools Required KM520 Remover/Installer KM525 Installer J2288820A Bearing Puller with J2288835 Puller Legs KM522 Installer

Disassembly Procedure
1. Remove the differential cover bolts, the differential cover, and the differential cover gasket. Remove the bearingadjusting ring retainer plate bolt and the bearingadjusting ring retainer plate.

2.

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3. Remove the bearingadjusting ring using the remover/ installer KM520.

4.

Remove the rightside bearingretainer bolts and the rightside bearing retainer.

5.

Remove the differential assembly from the transaxle case.

6.

Remove the ring gear bolts.

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5B 52IFIVESPEED MANUAL TRANSAXLE
7. Separate the ring gear from the differential housing.

8.

Drive the pinion gear shaft lock pin from the differential housing and the pinion gear shaft.

9.

Remove the pinion gear shaft.

10. Remove the pinion gears and the washers. 11. Remove the side gears and the side thrust washers.

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12. Remove both of the differential bearings using the bearing puller J2288820A with the puller legs J2288835.

13. Remove the speedometer drive gear from the differential gear housing.

Assembly Procedure
1. Install the speedometer drive gear onto the differential gear housing using the installer KM525.

2.

Install both of the differential bearings using the installer KM522.

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5B 54IFIVESPEED MANUAL TRANSAXLE
3. 4. Install the side gears and the side thrust washers into the differential housing. Install the differential pinion gears and the differential pinion gear washers into the differential housing.

5.

Install the pinion gear shaft into the differential housing.

6.

Install the pinion gear shaft lock pin into the differential housing and the pinion gear shaft.

7.

Install the ring gear and the ringgear bolts.

Tighten
Tighten the ringgear bolts to 70 NSm (52 lbft).

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8. Install the differential assembly into the transaxle case.

9.

Install the rightside bearing retainer and the rightside bearing retainer bolts.

Tighten
Tighten the rightside bearing retainer bolts to 25 NSm (18 lbft).

10. Install the bearingadjusting ring. 11. Tighten the bearingadjusting ring using the remover/ installer KM520.

Tighten
Tighten the bearing adjusting ring until there is no end play with the differential. Adjust the preload on the differential bearings. Used Bearings: 1 NSm (9 lbin) required to rotate the differential one revolution per second. New Bearings: 2 NSm (18 lbin) required to rotate the differential one revolution per second. Tighten or loosen the bearing ring adjuster to get the required preload on the bearings. 12. Install the bearingadjusting ringretainer plate and the bearingadjusting ringretainer plate bolt.

Tighten
Tighten the bearingadjusting ringretainer plate bolt to 5 NSm (44 lbin).

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5B 56IFIVESPEED MANUAL TRANSAXLE
13. Install the differential cover gasket, the differential cover, and the differential cover bolts.

Tighten
Tighten the differential cover bolts to 40 NSm (30 lb ft).

MAJOR COMPONENT ASSEMBLY
Tools Required J36633 Snap Ring Retainer KM334 Installer Sleeve KM552 Fixture KM554 Installer KM1132 Base

Assembly Procedure
1. 2. 3. 4. 5. 6. 7. Join the mainshaft and the input shaft. Compress the snap ring at the base of the mainshaft and hold with the snap ring retainer J36633. Hold the snap ring at the base of the input driveshaft with the snap ring pliers. Install the mainshaft/input shaft assembly onto the bearing plate. Release the mainshaft snap ring and the input shaft snap ring. Position the firstsecond gearshift fork. Install the fifth gearshift lever into the bearing plate.

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8. Install the thirdfourth gearshift rod/fork holding pin.

9.

Install the support bracket onto the bearing plate.

10. Install the firstsecond gearshift rod/fork onto the bearing plate.

11. Install the firstsecond gearshift fork holding pin.

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5B 58IFIVESPEED MANUAL TRANSAXLE
12. Install the support bracket bolts.

Tighten
Tighten the support bracket bolts to 7 NSm (62 lbin).

13. Install the reverse gearshift rod/fork onto the bearing plate.

14. Install the reverse gearshift rod/fork holding pin.

15. Install the rod lock pin and spring into the small plug hole.

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16. Install the fourthgearshift rod plugs.

17. Install the bolts and the fifthgearshift connector onto the bearing plate, using the pawl.

Tighten
Tighten the fifthgearshift connector bolts to 7 NSm (62 lbin).

18. Install the input drive fifth gear using the installer KM554 and the installer sleeve KM334.

19. Install the snap rings securing the fifthdrive gear.

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5B 60IFIVESPEED MANUAL TRANSAXLE
20. Install the thrust washers, the retaining ring, and the needle bearing into the mainshaftdriven fifth gear assembly.

21. Install the brass synchronizer ring onto the mainshaft driven fifthgear assembly.

22. Install the mainshaftdriven fifthgear assembly. 23. Install the fifthdrive gear synchronizer gear and the synchronizer sleeve using installer KM554.

24. Install the snap ring holding the fifth speeddriven assembly.

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25. Install the bolts and the fifthgear fork onto the bearing plate.

Tighten
Tighten the fifthgear fork bolts to 22 NSm (16 lbft).

26. Remove the bearing plate from the fixture KM552. 27. Shift the transaxle into second gear. 28. Install the bearing plate, with the shafts attached, into the case.

29. Install the bearing plate bolts.

Tighten
Tighten the bearing plate bolts to 22 NSm (16 lbft).

30. Install the speedometerdriven gear and the speedometerhousing retaining bolt into the transaxle housing.

Tighten
Tighten the speedometer housing retaining bolt to 4 NSm (35 lbin).

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5B 62IFIVESPEED MANUAL TRANSAXLE
31. Bolt the gearshift lever cover to the fixture KM552. 32. Position the fixture into the base KM1132. 33. Install the gearshift rod, the shift finger lever, and the gearshift lever pin.

34. Install the snap ring, the bushing, the spring, and the intermediate lever. 35. Remove the gearshift lever cover from the base KM1132 and the fixture KM552. 36. Shift the transaxle into NEUTRAL.

37. Install the gearshift lever cover and the gearshift lever cover bolts.

Tighten
Tighten the gearshift lever cover bolts to 22 NSm (16 lbft).

38. Install the transaxle cover and the transaxle cover bolts.

Tighten
Tighten the transaxle cover bolts to 18 NSm (13 lbft). 39. Install the transaxle into the vehicle. Refer to "Transaxle Assembly" in this section.

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GENERAL DESCRIPTION AND SYSTEM OPERATION
FIVESPEED MANUAL TRANSAXLE
This fivespeed transaxle assembly is a transmission of constantmesh design. Combined in the assembly are: S S S All forward gears. The reverse gear. The differential output.

S S S

Output shaft. Output shaft gears. Ring gear and differential assembly.

Forward Gear Shifting to a forward gear is accomplished through a combination of synchronizers with blocker rings controlled by sliding shift forks. Reverse Gear Reverse gear is not synchronized and uses a sliding idler gear arrangement. Differential Assembly The differential is a conventional arrangement of gears that is supported by tapered roller bearings. The final output gear turns the ring gear and differential assembly which turns the drive axle shafts.

The basic components of the fivespeed transaxle assembly units are the: S S S Transaxle case. Input shaft. Input shaft gears.

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