07 Manual Transaxle System

Chapter 7 :
Manual transaxle
system
General information
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2005 > 1.5L DIESEL >
SPECIAL TOOL
TOOL
Illustration Use
(Number and Name)
09455-33200 Installation of input shaft hub and sleeve
Bearing installer
09455-21100 Installation of differential taper roller

Bearing installer bearing
09432-33300 Installation of input shaft ball bearing

Bearing installer
09432-22000 Installation of output shaft taper roller

Bearing installer bearing
09432-2C100 Installation of output shaft synchronizer

Bearing installer hub and sleeve
09452-21200 Installation of differential oil seal

Oil seal installer
09200-38001 Removal and installation of the transaxle

Engine support fixture
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2005 > 1.5L DIESEL >
TROUBLESHOOTING
Symptom Probable cause Remedy

Vibration, noise Loose or damaged transaxle and engine mounts Tighten or replace mounts
Inadequate shaft end play Correct end play
Worn or damaged gears Replace gears
Inadequate grade of oil Replace with specified oil
Low oil level Replenish
Inadequate engine idle speed Adjust idle speed
Replace control cable oil seal or
Oil leakage Broken or damaged, oil seal or O-ring
O-ring
Hard shift Faulty control cable Replace control cable
Poor contact or wear of synchronizer ring and
Correct or replace
gear cone
Weakened synchronizer spring Replace synchronizer spring
Inadequate grade of oil Replace with specified oil
Jumps out of gear Worn gear shift fork or broken poppet spring Replace shift fork or poppet spring
Synchronizer hub-to-sleeve spline clearance too Replace synchronizer hub and
large sleeve
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2005 > 1.5L DIESEL >
SPECIFICATIONS
Engine type U1.5 Diesel

Transaxle type M5CF2
Gear ratio 1st 3.615
2nd 1.962
3rd 1.257
4th 0.905
5th 0.702
Reverse 3.583
Final gear ratio 3.941
Service Standard
Items Standard value [in(mm)]
Input shaft rear bearing end play 0.00-0.0019L(0.00-0.05L)
Output shaft bearing end play (At 70kgf load) 0.0019T-0.0039T(0.05T-0.10T)
Input shaft front bearing end play (At 70kgf load) 0.00-0.0019L(0.00-0.05L)
Differential bearing end play 0.0059T-0.0078T(0.15T-0.20T)
Differential pinion backlash 0.001L-0.006L(0.025L-0.150L)
T: Indicate tightening of -(minus) direction of end play

L: Indicate loosening of +(plus) direction of end play
SNAP RING AND SPACER FOR ADJUSTMENT

Part name Thickness [in(mm)] Part number
Spacer 0.028 (0.71) 43331-23071
(For adjustment of differential
0.029 (0.74) 43331-23074
bearing end play)
0.030 (0.77) 43331-23077
0.031 (0.8) 43331-23080
0.033 (0.83) 43331-23083
0.034 (0.86) 43331-23086
0.035 (0.89) 43331-23089
0.036 (0.93) 43331-23092
0.037 (0.95) 43331-23095
0.039 (0.98) 43331-23098
0.040 (1.01) 43331-23101
0.041 (1.04) 43331-23104
0.042 (1.07) 43331-23107
0.043 (1.1) 43331-23110
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0.044 (1.13) 43331-23113

0.046 (1.16) 43331-23116
0.047 (1.19) 43331-23119
0.048 (1.22) 43331-23122
0.049 (1.25) 43331-23125
0.050 (1.28) 43331-23128
Spacer 0.0295-0.0323 (0.75-0.82) 53526-39082
(For adjustment of differential
0.0327-0.0362 (0.83-0.92) 53526-39092
pinion backlash)
0.0366-0.0425 (0.93-1.00) 53526-39100
0.0398-0.0425 (1.01-1.08) 53526-39108
0.0429-0.0457 (1.09-1.16) 53526-39116
0.0461-0.0492 (1.17-1.25) 53526-39125
0.0496-0.0528 (1.26-1.34) 53526-39134
Spacer 0.056 (1.43) 43227-28430
(For adjustment of output shaft
0.057 (1.46) 43227-28460
bearing end play)
0.059 (1.49) 43227-28490
0.060 (1.52) 43227-28520
0.061 (1.55) 43227-28550
0.062 (1.58) 43227-28580
0.063 (1.61) 43227-28610
0.065 (1.64) 43227-28640
0.066 (1.67) 43227-28670
0.067 (1.70) 43227-28700
0.068 (1.73) 43227-28730
0.069 (1.76) 43227-28760
0.070 (1.79) 43227-28790
0.072 (1.82) 43227-28820
0.073 (1.85) 43227-28850
0.074 (1.88) 43227-28880
0.075 (1.91) 43227-28910
Snap ring 0.078 (1.98) 43278-23298
(For adjustment of input shaft
0.080 (2.02) 43278-23302
rear bearing end play)
0.081 (2.06) 43278-23306
0.083 (2.10) 43278-23310
0.084 (2.14) 43278-23314
0.086 (2.18) 43278-23318
Snap ring 0.098 (2.50) 43245-23350
0.100 (2.54) 43245-23354
5th gear end play)
0.102 (2.58) 43245-23358
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0.103 (2.62) 43245-23362

0.105 (2.66) 43245-23366
Snap ring 0.088 (2.24) 43224-21240
0.091 (2.31) 43224-21310
front bearing end play)
0.094 (2.38) 43224-21380
0.096 (2.45) 43224-23450
TIGHTENING TORQUE
Standard value N·m kg·cm lb·ft
Release cylinder tube nut 13-17 130-170 9-12
Release cylinder tube bracket 15-22 150-220 10-16
Release cylinder bolt 15-22 150-220 10-16
Control shift complete bolt 30-35 300-350 21-25
Oil drain plug 60-80 600-800 43-58
Oil filler plug 60-80 600-800 43-58
Poppet ball 30-35 300-350 21-25
Clutch housing to transmission case 43-55 430-550 32-40
Speedometer driven gear 3-5 30-50 2-4
Reverse idler bolt 43-55 430-550 32-40
Reverse shift lever assembly bolt 15-22 150-220 10-16
Input shaft bearing retainer 15-22 150-220 10-16
Shift control cable bracket on transaxle side 15-22 150-220 10-16
Rear roll support bracket bolt 60-80 600-800 43-58
Rear roll stopper insulator bolt and nut 50-65 500-650 36-47
Front roll stopper insulator bolt and nut 50-65 500-650 36-47
Front roll support bracket bolt 60-80 600-800 43-58
Transaxle mounting sub bracket nut 60-80 600-800 43-58
Transaxle mounting bracket bolts 60-80 600-800 43-58
Differential drive gear seal bolt 130-140 1300-1400 94-101
Clutch release lever fulcrum bolt 55-60 550-600 40-43
Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if
over-tightened or loosening if under-tightened. In either case, serious personal injury or death could result
to vehicle occupants.
LUBRICATIONS
Items Recommnend lubricant Quantity
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SAE 75W/85
API GL-4
Transaxle gear oil TGO-7(MS517-14) 2.0L(2.1US qt, 1.76lmp qt)
ZIC G-F TOP 75W/85
HD GEAR OIL XLS 75W/85
Air bleeder MS721-38 As requried
Transaxle housing MS721-40 or MS721-38 As requried
Surface of release fork and bearing Grease (CASMOLY L9508) As requried
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Manual transaxle system
2005 > 1.5L DIESEL >
SERVICE ADJUSTMENT PROCEDURE

TRANSAXLE GEAR OIL LEVEL
INSPECTION
Inspect each component for evidence of leakage.
Check the gear oil level by removing the filler plug.
If the oil is contaminated, it is necessary to replace it with new oil.
1. Remove oil filler plug(A).
2. Check level with finger.

Oil level must be up to fill the hole, add oil until it runs over.
3. Install filler plug.
Filler plug tightening torque :

60-80 Nm (600-800 kg·cm, 43-58 lb·ft)
REPLACEMENT
1. With the vehicle parked on a level surface, remove the drain plug.
2. Drain the transaxle oil.
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3. Install the drain plug with new washer.
Drain plug tightening torque:

60-80 Nm (600-800 kg·cm, 43-58 lb·ft)
4. Add new oil through the fille plug hole and, fill it ot just below the plug opening.
Standard oil SAE 75W/85, API GL-4
Oil capacity: 2.0 liter (2.1 US qt, 1.76 lmp qt)
BACKUP LAMP SWITCH

INSPECTION
1. Disconnect the backup lamp switch(A).
2. Check the continuity between no. 1 and 2 terminals of backup lamp switch.
When the shift lever is in reverse, there should be contunuity.
3. If necessary, repair or replace the backup lamp switch.
DRIVE SHAFT OIL SEAL

REPLACE
1. Disconnect the drive shaft from the transaxle. (see "DS" group)
2. Using a flat-tip screwdriver, remove the oil seal.
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3. Using the special tool(09452-21200), tap the drive shaft oil seal into the transaxle.
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2005 > 1.5L DIESEL >
COMPONENTS (1)
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COMPONENTS (2)
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2005 > 1.5L DIESEL >
DISASSEMBLY
1. Remove the vehicle speed sensor(A). (Bolt: 1EA)
2. Remove the release cylinder tube bracket(A). (Bolt: 1EA)
3. Remove the release cylinder(A) tube from the release cylinder.

4. Remove the release cylinder from the transaxle. (Bolt: 2EA)
5. Remove the release bearing(A) and shift fork(B).
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6. Remove the shift fork boot(A).
7. Remove the shift cable bracket(A). (Bolt:2EA)
8. Remove the control shift complete(A) from the transaxle case. (Bolt:6EA)
9. Remove the shift rail poppet bolt(A) (3EA).
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10. Remove the drain plug(A).
11. Remove the filler plug(A).
12. Remove the reverse idle bolt(A) from the transaxle case.
13. Remove the housing bolt(3EA) from the clutch housing inside.
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14. Remove the transaxle case(A) from the housing(B). (Bolt: 11EA)
15. Remove the differential outer race(A).
16. Remove the output outer race(A).
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17. Remove the input shaft oil guide(A) in the transalxe case.
18. Remove the oil guide(A).
19. Remove the bushing(A) (3EA).
20. Remove the drive shaft oil seal(A).
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21. Remove the reverse idle gear assembly(A).
22. Remove the reverse shaft lever assembly(A). (Bolt: 2EA)
23. Remove the spring pin.
Be careful not to damage it when removing spring pin.
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24. Remove the shift rail and fork assembly.
25. Remove the bearing retainer(A). (Bolt: 4EA)
26. Remove the input shaft(A) and output shaft(B) assembly together from the clutch housing.
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27. Remove the differential assembly(A).
28. Remove the differential oil seal(A).
29. Remove the reamer bolt(A).
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30. Remove the differential outer race(A).
31. Remove the output shaft outer race(A).
32. Remove the magnetic(A).
33. Remove the output shaft oil guide(A).
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34. Remove the dowel pin(3EA).
35. Remove the input shaft front oil seal(A).
36. Remove the bushing(3EA) from the clutch housing.
REASSEMBLY
Before reassembling, clean all parts in slovent, dry them, and apply lubicant to any contact surfaces.
1. Install the bushing(3EA) in the housing using the special tool.
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2. Install the input shaft front oil seal(A).
Do not reuse the old oil seal.
3. Install the dowel pin(3EA) into the groove of the housing surface.
4. Install the output shaft front oil guide(A).
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5. Install the magnetic(A).
6. Install the output outer race(A).
7. Install the differential outer race(A).
8. Install the reamer bolt(A).
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9. Install the differential oil seal(A) in the transaxle case using the special tool(09452-21200).
10. Install the differential gear assembly(A).
11. Install the input shaft(A) and output shaft(B) in the clutch housing.
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12. Install the bearing retainer.(Bolt: 4EA)
Apply three bond 1303 equivalent around the hex bolt(4EA) before installing the bearing retainer(A).
TORQUE :
15-22 Nm(150-220 kg·cm, 10-16 lb·ft)
13. Install the 1&2 shift rail and fork assembly.

14. Install the 3&4, 5th shift rail and fork assembly.
15. Install the spring pin.
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When installing, make sure that the slit of the spring pin is aligned within 15° of the center line of the
shift rail.
16. Install the reverse shift lever(A). (Bolt:2EA)
TORQUE :
15-22 Nm(150-220 kg·cm, 10-16 lb·ft)
17. Install the reverse idle gear assembly(A).
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18. Install the drive shaft oil seal(A) in the transaxle case using the special tool(09452-21200).
19. Install the bushing(A) (3EA) in the transaxle case.
20. Install the oil guide(A) in the transaxle case.
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21. Install the input shaft oil guide(A).
22. Measure and choose the proper space as followed.
End play [in(mm)]: 0.0019T-0.0039T in(0.05T-0.10T mm)

Thickness of space [in(mm)] = (Height of housing [in(mm)] + Height of transaxle case [in(mm)]) - lengh of
output [in(mm)] + end play [0.0003in(0.075mm)] + tolerance [0.0018in(0.045mm)]
Measure the lengh of output shaft with both sides of bearing.

For keeping accuracy, measure at least 3 places and calculate the average value.
23. Install the output shaft space.

INPUT SIDE BEARING ADJUSTING SPACE
Parts Number Thickness [in(mm)]

43227-28430 0.056 (1.43)
43227-28460 0.057 (1.46)
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43227-28490 0.059 (1.49)

43227-28520 0.060 (1.52)
43227-28550 0.061 (1.55)
43227-28580 0.062 (1.58)
43227-28610 0.063 (1.61)
43227-28640 0.065 (1.64)
43227-28670 0.066 (1.67)
43227-28700 0.067 (1.70)
43227-28730 0.068 (1.73)
43227-28760 0.069 (1.76)
43227-28790 0.070 (1.79)
43227-28820 0.072 (1.82)
43227-28850 0.073 (1.85)
43227-28880 0.074 (1.88)
43227-28910 0.075 (1.91)
24. Install the output shaft rear outer race(A).
25. Select the space of the differential assembly to minimize end play.
End paly [in(mm)]: 0.0059T-0.0078T in(0.15T-0.20T mm)

Thickness of space [in(mm)] = (height of housing [in(mm)] + transaxle case [in(mm)]) - the length of
differential [in(mm)] + end play [0.0007in(0.175mm)] + tolerance [0.0022in(0.055mm)]
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Measure the lengh of differential assembly with both sides of bearing.

For keeping accuracy, measure at least 3 places and the calculate average value.
26. Install the space of the differential assembly.

INPUT SIDE BEARING ADJUSTING SPACE
Parts Number Thickness [in(mm)]

53526-39082 0.0295-0.0323(0.75-0.82)
53526-39092 0.0327-0.0362 (0.83-0.92)
53526-39100 0.0366-0.0425 (0.93-1.00)
53526-39108 0.0398-0.0425 (1.01-1.08)
53526-39116 0.0429-0.0457 (1.09-1.16)
53526-39125 0.0461-0.0492 (1.17-1.25)
53526-39134 0.0496-0.0528 (1.26-1.34)
27. Install the differential outer race(A).
28. Apply the specified sealant on the surface of the transaxle housing.
Specified sealant: MS 721-40
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29. Install transaxle case onto the transaxle housing. (Bolt:11EA)
Use torque lench when tightening bolt.
TORQUE :
43-55 Nm(430-550 kg·cm, 32-40 lb·ft)
30. Install bolt insides of the transaxle housing.(Bolt:3EA)
TORQUE :
43-55 Nm(430-550 kg·cm, 32-40 lb·ft)
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31. Install the reverse idle bolt(A) to housing side.
TORQUE :
43-55 Nm(430-550 kg·cm, 32-40 lb·ft)
32. Install filler plug(A).
TORQUE :
60-80 Nm(600-800 kg·cm, 43-58 lb·ft)
33. Install drain plug(A).
TORQUE :
60-80 Nm(600-800 kg·cm, 43-58 lb·ft)
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34. Install 1&2, 3&4, 5th shift rail poppet bolt(A).
TORQUE :
30-35 Nm(300-350 kg·cm, 21-25 lb·ft)
35. Install the control shift complete onto the transaxle case. (Bolt:6EA)
TORQUE :
30-35 Nm(300-350 kg·cm, 21-25 lb·ft)
36. Install the shift cable bracket(A). (Bolt:2EA)
TORQUE :
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15-22 Nm(150-220 kg·cm, 10-16 lb·ft)
37. Install the shift lever boot(A).
38. Install the release bearing(A) and release fork(B).
Spread bearing sliding surface and holes of release fork with Grease.
Standard grease : CASMOLY L9508
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39. Install the release cylinder. (Bolt:2EA)
TORQUE :
15-22 Nm(150-220 kg·cm, 10-16 lb·ft)
40. Install the release cylinder tube bracket(A). (Bolt:1EA)
TORQUE :
15-22 Nm(150-220 kg·cm, 10-16 lb·ft)
41. Install the vehicle speed sensor(A). (Bolt 1EA)
TORQUE :
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3-5 Nm(30-50 kg·cm, 2-4 lb·ft)
REMOVAL
• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
• Mark all wiring and hoses to avoid misconnection.
1. Disconnect the battery terminals(A).
2. Remove the battery and battery tray.
3. Remove the air duct(A).
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4. Remove the intake hose(A).
5. Remove the air cleaner assembly.

(1) Disconnect the AFS(Air Flow Sensor) connector (A).
(2) Remove the air cleaner upper cover (B).

(3) Remove the air hose (C).
(4) Remove the air cleaner element.
(5) Remove the bolts(B) and air cleaner lower cover(A).
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6. Remove the ground cable from transaxle(A).
7. Remove the transaxle wire harness connectors and control cable from transaxle(M/T).
(1) Remove the clutch release cylinder (A).
(2) Remove the transaxle control cable (A).
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(3) Disconnect the vehicle speed sensor connector (A).

(4) Disconnect the back lamp switch connector (B).
(5) Disconnect the neutral switch connector (C).
8. Install the SST(09200-38001, 09200-1C000), the engine support fixture and the adapter, on the engine and
transaxle assembly.
9. Remove the transaxle mounting bracket(A).
TORQUE :
Bolt(B): 88.3 ~ 107.9Nm (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lbf.ft)
10. Remove the front tires.

11. Remove the ABS wheel speed sensor(A).
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12. Remove the caliper and hang caliper assembly(A) with wire.
13. Remove the knuckle mounting bolts(A).
14. Remove the steering u-joint mounting bolt(A).
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15. Remove the front muffler(A).
16. Remove the front roll stopper bolt(A).
17. Remove the rear roll stopper bolt(A).
18. Using a floor jack, support the transaxle assembly.
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After removing the sub frame mounting bolt , the transaxle assembly may fall downward, and so
support them securely with floor jack.
Verify that the hoses and connectors are disconnected before removing the transaxle assembly.
19. Remove the sub frame(D).
TORQUE :
Bolt(A) :
39.2 ~ 53.9Nm (4.0 ~ 5.5kgf.m, 28.9 ~ 39.8lbf.ft)
Nut(B), Bolt(C) :
156.9 ~ 176.5Nm (16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lbf.ft)
20. Remove the transaxle rower mounting bolts(A).
21. Remove the engine support fixture and the adapter.

22. Remove the engine and transaxle assembly by lifting vehicle.
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When remove the transaxle assembly, be careful not to damage any surrounding parts or body
components.
INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
• Adjust the shift cable.
• Refill the transaxle with fluid.
• Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
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Manual transaxle gear
system
Input Shaft
2005 > 1.5L DIESEL >
COMPONENTS
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2005 > 1.5L DIESEL >
DISASSEMBLY
1. Remove the snap ring(A) and remove the front ball bearing(B) and the rear ball bearing(C) using press.
2. Remove the snap ring(A) and spacer(B).
3. Remove the snap ring(A).
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4. Remove the 5th sleeve, 5th gear, 4th gear, 3&4th sleeve and 3rd gear all together using press.
REASSEMBLY
1. Install the 3rd needle bearing(A) on the input shaft(B).
2. Apply MT oil to the needle bearing.

3. Install the 3rd gear(A).
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4. Install the 3rd inner synchronizer ring(A). (Double cone type)
5. Install the 3rd synchronizer cone(B).

6. Install the 3rd outer synchronizer ring(C).
Pay attention the direction of protrusion of a synchronizer ring.
7. Assemble the 3rd&4th synchronizer hub(A) using press.
• When installing the synchronizer hub, make sure that the fingers of synchronizer ring are seated
correctly in its groove on the synchronizer hub.
• After installation of the synchronizer hub, check that sychronizer hub rotates smoothly.
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8. Install the synchronizer keys(A).
9. Install the 3rd&4th synchronizer sleeve.
• Put down the 3rd slope face of sleeve with the identification mark.
• Make sure that the groove of sleeve inside is seated correctly in the groove of synchronizer hub.
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10. Install the 4th outer synchronizer ring(A). (Double cone type)
When installing the synchronizer ring, make sure that the fingers of synchronizer ring are seated
correctly in the grooves of the 3rd&4th synchronizer hub.
11. Install the 4th synchronizer cone(B).

12. Install the 4tr inner synchronizer ring(C).
13. Install the 4th gear sleeve(A) using press.
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14. Install the 4th needle bearing(A).
15. Apply MT oil to the needle bearing.

16. Install the 4th gear(A).
17. Install the 5th sleeve(A) using press and special tool(09455-33200).
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18. Install the 5th needle bearing(A).
19. Install the 5th gear(A).
20. Install the 5th inner synchronizer ring(A).
21. Install the 5th synchronizer cone(B).

22. Install the 5th outer synchronizer ring(C).
23. Install the 5th synchronizer hub(A) using the press and special tool(09455-33200).
• When installling hub, make sure the direction as shown in the picture.
• When pressing the hub, make sure that the fingers of the 5th synchronizer ring(double cone) are
seated correctly in the grooves of the hub.
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24. Install the synchronizer key(A).
25. Install the 5th synchronizer sleeve.
• Put down the 5th slope face of sleeve with the identification mark.
• Make sure that the groove of sleeve inside is seated correctly in the groove of synchronizer hub.
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26. Install the snap ring(A).
27. Install the spacer(A).
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When installing the spacer, make sure that three fingers of spacer are seated correctly in three
grooves of 5th synchronizer hub.
28. Install the thrust washer.

29. Install the ball bearing(A) by press.
30. Install the snap ring.

31. Install the oil guide ring(A).
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32. Install the front input shaft ball bearing by press.

33. Install the snap ring(A).
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Output Shaft
2005 > 1.5L DIESEL >
COMPONENTS
1 of 1 16/06/09 11:17
2005 > 1.5L DIESEL >
DISASSEMBLY
1. Remove the taper ball bearing.
Do not reuse the removed bearing.
INSPECTION
Output shaft
1. Check the outer surface of where the needle bearing is mounted for damage or abnormal wear.
2. Check the splines for damage or wear.
Needle bearing
1. Install the needle bearing on the shaft with the bearing sleeve and gear.
Check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for distortion.
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Synchronizer ring
1. Check the clutch gear teeth for damage.
2. Check internal surface for damage, wear or broken grooves.
3. Push the synchronizer ring toward the clutch gear and check clearance "A".
Replace if it is not within specifications.
Limit : 0.02 in(0.5 mm)
SYNCHRONIZER SLEEVE AND HUB

1. Install the synchronizer sleeve on the hub and check that it slides smoothly.
2. Check that the sleeve is free from damage.
3. Check for wear of the hub end surfaces (in contact with each gear).
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Replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY
1. Check for wear of the synchronizer key center protrusion.
2. Replace the synchronizer key assembly.
GEARS
1. Check the bevel gear and clutch gear teeth for damage or wear.
2. Check the gear bore for damage or wear.
REASSEMBLY
1. Install the needle bearing(A).
3 of 8 16/06/09 11:18
2. Apply the MT oil to the needle bearing.

3. Install the 1st gear(A).
4. Install the 1st inner synchronizer ring(A). (Trifle cone)
5. Install the 1st synchronizer cone(B).

6. Install the 1st outer synchronizer ring(C).
7. Install the 1st&2nd synchronizer hub using press and special tool(09432-2C100).
When installing hub, make sure that the the fingers of 1st synchronizer ring are seated correctly in the
grooves of synchronizer hub.
4 of 8 16/06/09 11:18
When installling hub, make sure the direction as shown in the picture.
8. Install the synchronizer key(A).
9. Install the 1st&2nd sleeve(A).
10. Install the 2nd sleeve using press and special tool(09432-2C100).
5 of 8 16/06/09 11:18
11. Install the 2nd outer synchronizer ring(A). (Trifle cone)
12. Install the 2nd synchronizer cone(B).

13. Install the 2nd inner synchronizer rin(C).
14. Install the 2nd needle bearing(A).
15. Install the 2nd gear(A).
6 of 8 16/06/09 11:18
16. Install the 3rd(A), 4th(B) and 5th(C) gear using press.
Heat the 3rd gear with electrical heater before using press.
17. Install the spacer using press and special tool(09455-21100).

18. Install the rear taper roller bearing using press and special tool(09432-22000).
7 of 8 16/06/09 11:18
19. Install the opposite side taper roller bearing using press and special tool(09432-22000).
8 of 8 16/06/09 11:18
Differential
2005 > 1.5L DIESEL >
COMPONENTS
1 of 1 16/06/09 11:19
2005 > 1.5L DIESEL >
DISASSEMBLY
1. Clamp the differential case in a vise.
2. Remove the differential drive gear retaining bolts and remove the differential drive gear from the case.
3. Remove the taper roller bearing using the special tool.
Do not reuse the bearing removed from the shaft.
4. Drive out the lock pin from the hole A using a punch.
5. Drive out the pinion shaft.
6. Remove the pinion gears, washers, side gears and spacers.
REASSEMBLY
1 of 4 16/06/09 11:19
1. Install the spacer on the back of the side gear and then install the gear in the differential case.
When installing a new side gear, use a spacer of medium thickness [0.0366~0.0394 in(0.93~1.00 mm)].
2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging
them with the side gears by turning them.
3. Insert the pinion shaft.
4. Measure the backlash between the side gears and pinions.
Standard value :
0.001~0.006in (0.025~0.150mm)
5. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and
remeasure.
Adjust the backlash of both side gears to the same specification.
2 of 4 16/06/09 11:19
6. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.
• Do not reuse the lock pin.

• The lock pin head must be sunk below the flange surface of the differential case.
7. Install the taper roller bearings on both sides of the differential case.
When press-fitting the bearing, press on the inner race only.
8. Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence
shown in the illustration.
Specified sealant : BM Stud Locking No. 2471.
TORQE
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Differential drive gear bolt:

130~140Nm (1300~1400kg·cm, 94~101lb·ft)
If a bolt is reused, remove the old sealant from the threads.
4 of 4 16/06/09 11:19
Speedometer Driven gear
Assembly
2005 > 1.5L DIESEL >
COMPONENTS
1 of 1 16/06/09 11:19
2005 > 1.5L DIESEL >
REASSEMBLY
Apply gear oil sparingly to the speedometer driven gear shaft and insert the shaft.
Insert carefully the speedometer driven gear into the clutch housing not to disassemble the speedometer
driven gear shaft
1 of 1 16/06/09 11:19

07 Manual Transaxle System

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Chapter 7 :

2005 > 1.5L DIESEL >

09455-21100 Installation of differential taper roller

09432-33300 Installation of input shaft ball bearing

09432-22000 Installation of output shaft taper roller

09432-2C100 Installation of output shaft synchronizer

09452-21200 Installation of differential oil seal

09200-38001 Removal and installation of the transaxle

2005 > 1.5L DIESEL >

Symptom Probable cause Remedy

2005 > 1.5L DIESEL >

Engine type U1.5 Diesel

T: Indicate tightening of -(minus) direction of end play

SNAP RING AND SPACER FOR ADJUSTMENT

0.044 (1.13) 43331-23113

0.103 (2.62) 43245-23362

2005 > 1.5L DIESEL >

SERVICE ADJUSTMENT PROCEDURE

2. Check level with finger.

3. Install filler plug.

Filler plug tightening torque :

3. Install the drain plug with new washer.

Drain plug tightening torque:

BACKUP LAMP SWITCH

DRIVE SHAFT OIL SEAL

2005 > 1.5L DIESEL >

2005 > 1.5L DIESEL >

2. Remove the release cylinder tube bracket(A). (Bolt: 1EA)

3. Remove the release cylinder(A) tube from the release cylinder.

5. Remove the release bearing(A) and shift fork(B).

6. Remove the shift fork boot(A).

7. Remove the shift cable bracket(A). (Bolt:2EA)

9. Remove the shift rail poppet bolt(A) (3EA).

10. Remove the drain plug(A).

11. Remove the filler plug(A).

15. Remove the differential outer race(A).

16. Remove the output outer race(A).

18. Remove the oil guide(A).

19. Remove the bushing(A) (3EA).

20. Remove the drive shaft oil seal(A).

21. Remove the reverse idle gear assembly(A).

22. Remove the reverse shaft lever assembly(A). (Bolt: 2EA)

23. Remove the spring pin.

Be careful not to damage it when removing spring pin.

24. Remove the shift rail and fork assembly.

25. Remove the bearing retainer(A). (Bolt: 4EA)

27. Remove the differential assembly(A).

28. Remove the differential oil seal(A).

29. Remove the reamer bolt(A).

30. Remove the differential outer race(A).

31. Remove the output shaft outer race(A).

32. Remove the magnetic(A).

33. Remove the output shaft oil guide(A).

34. Remove the dowel pin(3EA).

35. Remove the input shaft front oil seal(A).

36. Remove the bushing(3EA) from the clutch housing.

1. Install the bushing(3EA) in the housing using the special tool.

2. Install the input shaft front oil seal(A).

Do not reuse the old oil seal.