Service Manual2008 Captiva FIVE-SPEED MANUAL TRANSAXLE (D33)

SECTION 5B

FIVE-SPEED MANUAL TRANSAXLE (D33)

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.

SPECIFICATIONS

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Thread Pin	6~9	-	53~80
Input Shaft Retainer Plug	120~130	89~96	-
Output Shaft Retainer Plug	120~130	89~96	-
Transaxle Housing Rear Cover Bolts	20~25	15~18	-
Backup Lamp Switch	20	15	-
Shift Retaining Bolts	20~25	15~18	-
Shift Guide Bolt	20~25	15~18	-
Clutch Housing-to-Transaxle Housing Bolts	20~25	15~18	-
Transaxle Housing-to-Clutch Housing Bolts	20~25	15~18	-
Interm Shaft Retainer Plug	90~100	66~74	-
Concentric Slave Cylinder Retaining Bolts	8~12	-	71~106
Concentric Slave Cylinder to Clutch Oil Pipe Screw	16	12	-
Shift Control Cable Bracket Bolts	15~20	11~15	-
Fluid Level Check Plug	6 N•m + 45°~180°	-	53 Lb-In + 45°~180°
Fluid Drain Plug	6 N•m + 45°~180°	-	53 Lb-In + 45°~180°
Shift Control Lever Housing Bolt	8	-	71
Upper Transaxle-to-Engine Bolts (FAM II 2.4D or 2.0S DIESEL)	75	55	-
Front Damper Bush Mounting Bolts	50	37	-
Rear Transaxle Mounting Bracket Bolts	90	66	-
Oil Pan Flange-to-Transaxle Botls	50	37	-
Right Lower Engine-to-Transaxle Botls (FAM II 2.4D or 2.0S DIESEL)	75	55	-
Left Lower Engine-to-Transaxle Bolts (2.0S DIESEL)	75	55	-
Left Upper Transaxle Mounting Bracket Bolts	50	37	-

SPECIAL TOOLS

Special Tools Table

	DT-48179 Universal Driver Handle
	DT-48225 Input Shaft Holder
	DT-48226 Transaxle Housing Groove Ball Bearing Remover/Installer
	DT-48182 Needle Sleeve Remover/Installer
	DT-48183 Removal Bridge
	DT-48189 Differential Bearing Race Remover
	DT-48227 Roller Bearing Remover/Installer
	DT-48228 Clutch Housing Groove Ball Bearing Remover/Installer
	DT-48229 Interm Shaft Remover
	DT-48230 Differential Bearing Race and Shaft Seal Ring Installer
	DT-48231 Input and Output Shaft Pusher/Puller
	DT-48236 Input 3rd/4th Synchronizer Installer
	DT-48232 Input Shaft Synchro Body Protector
	DT-48233 Interm Shaft Press Adapter
	DT-48234 Input/Output Shaft Press Adapter
	DT-48235 Interm 1st/2nd Synchronizer Installer
	DT-48200 Transaxle Housing Fixing
	DT-48241 Transaxle Housing Race Plate
	DT-48237 Output 3rd/4th Gear Installer
	DT-48238 Input 5th Gear Installer
	DT-48239 Output 5th Bearing Collar Installer
	DT-48533 Clutch Housing Differential Bearing Race Installer (AWD)
	DW110-060 Engine Assembly Support Fixuture
	DT-48240 Output 5th/Reverse Synchronzer Installer
	DT-48242 Clutch Housing Race Plate
	DT-48532 Clutch Housing Differential Bearing Race Remover (AWD)
	DT-48534 Clutch Housing Race Plate (AWD)

DIAGNOSIS

Isolate Noise

Identify the cause of any noise before attempting to repair the clutch or the transaxle.

Symptoms of trouble with the clutch or the manual transaxle include

A great effort required to shift gears.
The sound of gears clashing and grinding.
Gear blockout.

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

Tires.
Road surfaces.
Wheel bearings.
Engine.
Exhaust system.

These noises may vary according to the

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,

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

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.

Bearing Noise

Differential Side Bearing Noise

Differential side bearing noise and wheel bearing noise can be confused easily. Since side bearings are preloaded, 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 pre-loaded, a wheel bearing noise should diminish considerably when the wheels are off the ground.

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 triangular- shaped 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 cause one of the races to turn, creating noise from a locked bearing. Pre-loading 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.

Symptom Diagnosis

Complaint/Condition	Possible Cause	Correction
Knock at Low Speeds	Worn drive axle joint.	Inspect drive axle joint and replace if necessary.
Knock at Low Speeds	Worn side gear or pinion gear bores.	Inspect differential case and replace if necessary.
Noisy Around Turns	Worn differential gears.	Inspect differential gears and replace if necessary.
Clunk on Acceleration or Deceleration	Loose engine mounts.	Inspect engine mounts and tighten if necessary.
	Worn inboard drive axle joint.	lnspect inboard drive axle joint and replace if necessary.
	Worn differential pinion shaft.	lnspect differential pinion shaft and replace if necessary.
	Worn side gear hub counterbore.	lnspect side gear hub counterbore and replace if necessary.
Click Noise ON Turns	Worn outboard drive axle C/V joint.	lnspect C/V joint and replace if necessary.
Noisy in Neutral With Engine Running	Worn input gear bearing.	lnspect bearing and replace if necessary.
	Worn speed gear bearing.	lnspect bearing and replace if necessary.
	Worn bearing races.	lnspect bearing race and replace if necessary.
Noisy in First Gear Only	Worn, chipped, or scored 1st speed constant-mesh gears.	lnspect gears and replace if necessary.
Noisy in First Gear Only	Worn, chipped, or scored 1st/2nd synchronizer.	lnspect synchronizer and replace if necessary.
Noisy in Second Gear Only	Worn, chipped, or scored 2nd speed constant-mesh gears.	lnspect gears and replace if necessary.
Noisy in Second Gear Only	Worn, chipped, or scored 1st/2nd synchronizer.	lnspect synchronizer and replace if necessary.
Noisy in Third Gear Only	Worn, chipped, or scored 3rd speed constant-mesh gears.	lnspect gears and replace if necessary.
Noisy in Third Gear Only	Worn, chipped, or scored 3rd/4th synchronizer.	lnspect synchronizer and replace if necessary.
Noisy in Fourth Gear Only	Worn, chipped, or scored 4th speed constant-mesh gears.	lnspect gears and replace if necessary.
	Worn, chipped, or scored 3rd/4th synchronizer.	lnspect synchronizer and replace if necessary.
	Worn, chipped, or scored output gear.	lnspect gear and replace if necessary.
Noisy in Fifth Gear Only	Worn, chipped, or scored 5th speed constant-mesh gears.	lnspect gears and replace if necessary.
	Worn, chipped, or scored 5th/Reverse synchronizer.	lnspect synchronizer and replace if necessary.
	Worn, chipped, or scored output gear.	lnspect gear and replace if necessary.
Noisy in Reverse Only	Worn, chipped, or scored reverse speed constant-mesh gears.	lnspect gear and replace if necessary.
	Worn or damaged output gear.	lnspect gear and replace if necessary.
	Worn or damaged input gear.	lnspect gear and replace if necessary.
Noisy in All Gears	Fluid level low.	Add fluid to proper level.
	Worn or damaged wheel bearings.	Inspect wheel bearing and replace if necessary.
	Worn, chipped, or scored input/output shaft gear.	Inspect gear and replace if necessary.
	Worn output gear bearing.	Inspect output gear bearing and replace if necessary.
	Loose shift rail guide bolt.	Tighten shift rail guide bolt.
	Worn, chipped, or scored 1st, 2nd, 3rd, 4rd, 5th, or Reverse gears.	Inspect components and replace as necessary.
Slips Out of Gear	Loose transaxle mounts.	Tighten or replace mounts.
	Bent or worn cables.	Inspect cables and replace if necessary.
	Broken or loose input gear bearing retainer.	Inspect shift fork and replace if necessary.
	Worn or bent shift fork.	Inspect shift fork and replace if necessary.
	Dirty clutch housing and engine.	Clean clutch housing and engine.
	Stiff shift lever seal.	Inspect seal and replace if necessary.
	Manual transaxle internal shift mechanism malfunction.	Disassemble transaxle, repair as necessary.
Slips Out of Gear While Accelerating	Missing or misadjusted first gear thrust bearing or washer.	Inspect bearing and washer and replace if necessary.
	Worn or damaged first gear spline lock on 1st/2nd synchronizer.	Inspect spline lock and replace if necessary.
	Worn or damaged second gear spline lock on 1st/2nd synchronizer.	Inspect spline lock and replace if necessary.
	Worn or damaged third gear spline lock on 3rd/4th synchronizer.	Inspect spline lock and replace if necessary.
	Worn or damaged fourth gear spline lock on 3rd/4th synchronizer.	Inspect spline lock and replace if necessary.
	Worn or damaged 5th gear spline lock on the 5th/Reverse synchronizer.	Inspect spline lock and replace if necessary.
	Worn or damaged Reverse gear spline lock on the 5th/Reverse synchronizer.	Inspect spline lock and replace if necessary.
	Worn or damaged 1st, 2nd, 3rd, 4th, 5th or reverse gear spline lock.	Inspect spline lock and replace if necessary.
	Manual transaxle internal shift mechanism malfunction.	Disassemble transaxle, repair as necessary.
Slips Out of Gear While Coasting	Damaged, worn, or missing shift rails.	Inspect shift rails and replace if necessary.
Slips Out of Gear While Coasting	Manual transaxle internal shift mechanism malfunction.	Disassemble transaxle, repair as necessary.
Fluid Leakage	Fluid level high.	Drain excess fluid.
	Damaged axle shaft seals.	Inspect axle shaft seals and replace if necessary.
	Vent cap plugged.	Clear or replace vent cap.
	Poor sealing on shift cover.	Replace sealer on shift cover.
	Poor sealing between transaxle housing and clutch housing.	Replace sealer between transaxle housing and clutch housing and tighten.
	Poor sealing on rear cover.	Replace sealant on rear cover and tighten.
	Poor sealing or loose back-up lamp switch.	Tighten switch or replace sealant as needed.