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SECTION 5B1

FIVE-SPEED MANUAL TRANSAXLE - D16 -

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
Backup Lamp Switch
20
15
-
Bearing Plate Bolts
22
16
-
Bearing Retainer Bolts, Right Side
25
18
-
Bearing-Adjusting Ring-Retainer Plate Bolt
5
-
44
Clutch-Release Cylinder Retaining Bolts
20
15
-
Damping Block Connection Nut and Bolt
85
63
-
Differential Cover Bolts
40
30
-
Fifth-Gear Fork Bolts
22
16
-
Fifth-Gearshift Connector Bolts
7
-
62
Flywheel Inspection Cover Bolts
7
-
62
Gearshift Housing Bolts
7
-
62
Gearshift Lever Cover Bolts
22
16
-
Input Driveshaft Detent Screw
15
11
-
Rear Damping Block Retaining Bolts
55
41
-
Rear Mounting Bracket Bolts
75
55
-
Ring-Gear Bolts
70
52
-
Rod Clamp Bolt
16
12
-
Speedometer Housing Retaining Bolt
4
-
35
Speedometer-Driven Gear Bolt
5
-
44
Transaxle Cover Bolts
18
13
-
Transaxle Lower Retaining Bolts(a)
75
55
-
Transaxle Lower Retaining Bolt(b)
20
15
-
Transaxle Lower Retaining Bolts(c)
30
22
-
Transaxle Upper Retaining Bolts
75
55
-
Transaxle Upper Mounting Bracket Bolts
60
44
-

SPECIAL TOOLS

Special Tools Table


J6125B
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J-6125-B
Slide Hammer

J22888
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J-22888-20-A
Bearing Puller with
J-22888-35
Puller Legs

J22912
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J-22912-01
Universal Bearing Puller

EN-48356
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EN-48356
Engine Fixture

KM553A
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KM-553-A
Fifth-Gear Puller

J36633
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J-36633
Snap Ring Retainer

KM1132
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KM-113-2
Base

KM334
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KM-334
Installer Sleeve

J42469
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J-42469
Shift Rod Remover

KM519
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KM-519
Ring Installer

KM520
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KM-520
Remover/Installer

KM522
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KM-522
Installer

KM525
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KM-525
Installer

KM552
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KM-552
Fixture

KM554
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KM-554
Installer

DIAGNOSIS

Isolate Noise

Identify the cause of any noise before attempting to repair the clutch, the transaxle, or their related link-ages.
Symptoms of trouble with the clutch or the manual transaxle include:
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:
These noises may vary according to the:

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. Select a smooth, level asphalt road to reduce tire and resonant body noise.
  2. Drive the vehicle far enough to warm up all the lubricants thoroughly.
  3. Record the speed and the gear range of the transaxle when the noise occurs.
  4. Check for noises with the vehicle stopped, but with the engine running.
  5. Determine if the noise occurs while the vehicle operates in:

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 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 causes 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

Checks
Action
Check for a knock at low speeds.
  • Replace any worn drive axle CV joints.
  • Replace any worn side gear hub.
Check for a noise most pronounced on turns.
  • Correct any abnormalities in the differential gear.
Check for a clunk upon acceleration or deceleration.
  • 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.
Check for a clunking noise in turns.
  • Replace any worn outboard CV joint.
Check for a vibration.
  • Replace any rough wheel bearing.
  • Replace any bent drive axle shaft.
  • Replace any out-of-round 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.
Check for a noise in the NEUTRAL gear with the engine running.
  • Replace any worn cluster bearing shaft.
  • Replace any worn clutch-release bearing.
  • Replace any worn input shaft cluster gears.
  • Replace any worn first-gear/bearing.
  • Replace any worn second-gear/bearing.
  • Replace any worn third-gear/bearing.
  • Replace any worn fourth-gear/bearing.
  • Replace any worn fifth-gear/bearing.
  • Replace any worn mainshaft bearings.
Check for a noise in the first gear (1) only.
  • Replace any chipped, scored, or worn first-gear constant mesh gears.
  • Replace any worn first-second gear synchronizer.
  • Replace any worn first-gear/bearing.
  • Replace any worn differential-gear/bearing.
  • Replace any worn-ring gear.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the second gear (2) only.
  • Replace any chipped, scored, or worn second-gear constant mesh gears.
  • Replace any worn first-second gear synchronizer.
  • Replace any worn second-gear/bearing.
  • Replace any worn differential-gear/bearing.
  • Replace any worn-ring gear.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the third gear (3) only.
  • Replace any chipped, scored, or worn third-gear constant mesh gears.
  • Replace any worn third-fourth gear synchronizer.
  • Replace any worn third-gear/bearing.
  • Replace any worn differential-gear/bearing.
  • Replace any worn-ring gear.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the fourth gear (4) only.
  • Replace any chipped, scored, or worn fourth gear or output gear.
  • Replace any worn third-fourth gear synchronizer.
  • Replace any worn fourth-gear/bearing.
  • Replace any worn differential-gear/bearing.
  • Replace any worn-ring gear.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the fifth gear (5) only.
  • Replace any chipped, scored, or worn fifth gear or output gear.
  • Repair any worn fifth-gear synchronizer.
  • Replace any worn fifth-gear/bearing.
  • Replace any worn differential-gear/bearing.
  • Replace any worn-ring gear.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the reverse (R) gear only.
  • Replace any chipped, scored, or worn reverse idler gear, idler-gear bushing, input gear, or output gear.
  • Replace any worn first-second gear synchronizer.
  • Replace any worn output gear.
  • Replace any worn differential-gear/bearing.
  • Replace any worn-ring gear.
Check for a noise in all gears.
  • Add sufficient lubricant.
  • Replace any worn bearings.
  • Replace any chipped, scored, or worn input-gear shaft or output-gear shaft.
Check for the transaxle slipping out of gear.
  • Adjust or replace the linkage, as needed.
  • Adjust, repair, or replace any binding shift linkage.
  • Tighten or replace the input-gear bearing retainer, as needed.
  • Repair or replace any worn or bent shift fork.
Check for a leak in the area of the clutch.
  • Repair the transaxle casing.
  • Replace any damaged release bearing guide.
Check for a leak at the center of the transaxle.
  • Repair the transaxle casing.
  • Repair the shift mechanism.
  • Replace the damaged backup lamp switch.
Check for a leak at the differential.
  • Adjust or replace the bearing retainers.
  • Tighten or replace the differential cover.
  • Adjust or replace the drive axle shaft seals.
Check for a hard shift.
  • Replace any damaged release-bearing guide.
  • Adjust, repair, or replace the shift mechanism.
  • Adjust, repair, or replace the clutch-release system.
  • Replace any chipped, scored, or worn fifth-gear synchronizer.
  • Replace any chipped, scored, or worn first-second gear synchronizer.
  • Replace any worn third-fourth gear synchronizer.
  • Adjust, repair, or replace the shift lever and the rods.
Check for a clashing of gears.
  • Replace any damaged release-bearing guide.
  • Adjust, repair, or replace the clutch-release system.
  • Replace the chipped, scored, or worn input shaft/gear-cluster gears.
  • Replace any worn fifth-gear synchronizer.
  • Replace any worn fifth-gear/bearing.
  • Replace any worn first-gear/bearing.
  • Replace any worn first-second gear synchronizer.
  • Replace any worn second-gear/bearing.
  • Replace any worn third-gear/bearing.
  • Replace any worn third-fourth synchronizer.
  • Replace any worn fourth-gear/bearing.
  • Replace any worn reverse-idler gear.
  • Replace any worn part in reverse semi synchro system.

COMPONENT LOCATORS

Gears and Case


T3B15BC2
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  1. Roller Bearing
  2. Transaxle Main Shaft
  3. Washer
  4. Washer Retaining Ring
  5. 4th Speed Gear
  6. Needle Cage
  7. Synchronizer Ring
  8. Shift Sleeve
  9. Synchronizer Key
  10. 3rd & 4th Synchronizer Spring
  11. Washer
  12. Circlip
  13. 3rd Speed Gear
  14. Washer
  15. Washer Retaining Ring
  16. 2nd Speed Gear
  17. Needle Cage
  18. Inside Synchronizer Ring
  19. Intermediate Ring
  20. Outside Synchronizer Ring
  21. Sliding Gear
  22. 1st & 2nd Synchronizer Key
  23. 1st & 2nd Synchronizer Spring
  24. Washer
  25. Circlip
  26. 1st Speed Gear
  27. Needle Cage
  28. Needle Cage
  29. Main Shaft Disc
  30. Retaining Ring
  31. Groove Ball Bearing
  32. Washer
  33. Retaining Ring
  34. 5th Speed Gear
  35. Needle Cage
  36. Synchronizer Ring
  37. 5th Shift Sleeve
  38. 5th Synchronizer Spring
  39. 5th Synchronizer Key
  40. Retaining Ring
  41. Needle Sleeve
  42. Input Drive Shift
  43. Input Shaft Cluster Gear
  44. Bolt
  45. Retaining Ring
  46. Cluster Bearing Ring
  47. Groove Ball Bearing
  48. Cluster 5th Speed Gear
  49. Retaining Ring
  50. Washer
  51. Reverse Idler Gear
  52. Reverse Idler Gear Shaft
  53. Ball

Bearing Plate


T3B15BC3
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  1. Strain Bolt Bridge
  2. Bolt
  3. Bolt
  4. Bolt
  5. Bearing Plate
  6. Bolt
  7. Pin
  8. Blocking Pin
  9. Compression Spring
  10. Plug
  11. Gear Shift Sliding Fork
  12. GearShift Shoe
  13. Screw
  14. Transaxle Cover
  15. Transaxle Cover Gasket
  16. Magnet
  17. Bearing Plate Gasket
  18. Bolt
  19. Bolt
  20. Bolt
  21. Screw
  22. Detent Sleeve

Differential Gear


T3B15BC4
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  1. Differential Gear Housing
  2. Differential Gear
  3. Speedometer Drive Gear
  4. Washer
  5. Side Gear
  6. Bevel Differential Gear
  7. Bevel Gear Disc
  8. Differential Gear Shaft
  9. Differential Spring Pin
  10. Bolt
  11. Taper Roller Bearing
  12. Differential Bearing Ring
  13. Shaft Seal Ring
  14. O-Ring
  15. Differential Gear Bearing Flange
  16. O-Ring
  17. Locking Plate
  18. Bolt
  19. Bolt

Shift Linkage


S7C35B01
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  1. Gear Shift Control
  2. Bolt
  3. Gear Shift Tube Bellows
  4. Clamp
  5. Bolt
  6. Gear Shift Control Mode
  7. Gear Shift Guide Control
  8. Pin
  9. Clip
  10. Bolt
  11. 1st & 2nd Gear Shift Fork
  12. 1st & 2nd Gear Shift Rod
  13. Pin
  14. 3rd & 4th Gear Shift Fork
  15. 3rd & 4th Gear Shift Rod
  16. Pin
  17. 5th Speed Engaging Piece
  18. Gear Shift Rod Pawl
  19. Reverse Gear Shift Fork
  20. Reverse Gear Shift Rod
  21. Pin
  22. Gear Shift Rod
  23. Shift Finger
  24. Gear Shift Lever Cover
  25. Gear Shift Interm Lever
  26. Plate
  27. Compression Spring
  28. Bush
  29. Retaining Ring
  30. Gear Shift Cover Gasket
  31. Bolt
  32. Plug
  33. Adjusting Pin
  34. Speedometer Driven Gear
  35. Bolt
  36. Differential Gear Cover Gasket
  37. Differential Gear Cover
  38. Screw
  39. Backup Lamp Switch
  40. O-ring
  41. Pin
  42. Pin
  43. Sleeve
  44. Bush
  45. Pin
  46. Clip
  47. Assist Lever
  48. Detent


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