MANUAL
TRANSAXLE
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MANUAL TRANSAXLE CONTROL . . . . . . . . . . . . . . . . . . . . .
SHIFT LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . 1 7
5TH SPEED SYNCHRONIZER ASSEMBLY . . . . . . . . . . . . 2 5
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 7
INTERMEDIATE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SHIFT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SPEEDOMETER DRIVEN GEAR ASSEMBLY . . . . . . . . . . 49
MANUAL TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . . . . . .
GENERAL
G E N E R A L
SPECIFICATIONS
Model
KM 200
KM 201
Type
4-speed floor shift
5-speed floor shift
Gear ratio 1st
3.363
3.363
2nd
1.947
1.947
3rd
1.285
1.285
4th
0.939
0.939
5th
-
0.777
Reverse
3.083
3.083
Final gear ratio
4.021 (EC. GEN. AUS. NAS)
4.021 (EC. GEN. AUS. NAS)
4.322 (EC. GEN. W/G)
4.322 (EC. GEN. W/G)
Speedometer gear ratio (driven/drive)
3 2 / 3 6
3 2 / 3 6
SERVICE STANDARD
mm (in.)
Standard value
Input shaft bearing end play
0.01-0.12 (0.0004-0.0041)
Intermediate gear bearing end play
0.01-0.14 (0.0004-0.0055)
Intermediate shaft end play
0.05-0.10 (0.002-0.004)
Output shaft end play
0.05-0.10 (0.002-0.004)
Differential case end play
0.05-0.10 (0.002-0.004)
Differential pinion. backlash
0.025-0.150 (0.001-0.006)
LUBRICANTS AND GREASE
Recommended lubricant
Quantity
Transaxle gear oil lit
Hypoid gear oil,
1.8 (1.9, 1.6,) (KM 201)
(U.S. qts., Imp. qts.)
SAE 75W/85W,
1.7 (1.8, 1.5) (KM 200)
API-GL4
Transaxle input shaft spline
MOLYWHITE TA NO.2
As required
Transaxle oil seal lip
RETINAX AM, MOLYTEX GREASE EP 2
As required
SEALANTS AND ADHESIVES
Recommended sealants and adhesives
Quantity
Transaxle case and clutch housing
THREE BOND 1216
As required
alignment surface
Transaxle case and rear cover
THREE BOND 1216
As required
alignment surface
Differential drive gear bolt
THREE BOND 1303 or LOCTITE 648
As required
Bearing retainer bolt (flush bolt only)
THREE BOND 1303
As required
4 3 - 2
GENERAL
SNAP RING FOR ADJUSTMENT AND SPACER
Part name
Thickness mm (in.)
Identification symbol
Snap ring
2.24 (0.0882)
None
(For adjustment of input shaft bearing end play)
2.31 (0.0909)
Blue
2.38 (0.0937)
Brown
Snap ring
1.4 (0.0551)
Brown
(For adjustment of intermediate gear bearing end play)
1.5 (0.0591)
None
1.6 (0.0630)
Blue
Spacer
0.56 (0.0220)
56
(For adjustment of intermediate gear end play)
0.65 (0.0256)
65
0.74 (0.0291)
74
0.83 (0.0327)
83
0.92 (0.0362)
92
1.01 (0.0398)
01
1.10 (0.0433)
10
Spacer
0.83 (0.0327)
83
(For adjustment of output shaft preload)
0.86 (0.0339)
86
0.89 (0.0350)
89
0.92 (0.0362)
92
0.95 (0.0374)
95
0.98 (0.0386)
98
1.01 (0.0398)
01
1.04 (0.0409)
0 4
1.07 (0.0421)
07
1.10 (0.0433)
10
1.13 (0.0445)
13
1.16 (0.0457)
16
1.19 (0.0469)
19
1.22 (0.0480)
22
1.25 (0.0492)
25
1.28 (0.0504)
28
1.31 (0.0516)
31
1.34 (0.0528)
34
Spacer
0.56 (0.0220)
56
(For adjustment of differential case end play)
0.65 (0.0256)
65
0.74 (0.0291)
74
0.83 (0.0327)
83
0.92 (0.0362)
92
1.01 (0.0398)
01
Spacer
0.75-0.82 (0.0295-0.0323)
-
(For adjustment of differential pinion backlash)
0.83-0.92 (0.0327-0.0362)
-
0.93-1.00 (0.0366-0.0394)
-
1.01-1.08 (0.0398-0.0425)
-
1.09-1.16 (0.0429-0.0457)
-
4 3 - 3
GENERAL
TIGHTENING TORQUE
Nm
kg.cm
Ib.ft
Shift cable and select cable to body
Shift lever assembly to body
Lever (A) to bracket assembly
Clutch release cylinder mounting bolts
Clutch line to transaxle assembly
Shift cable and select cable to transaxle
Starter motor mounting bolts
Transaxle mount bracket to transaxle
Transaxle mount bracket to body
Transaxle mount bracket to tension rod
Tension rod to tension rod bracket
Tie rod end to knuckle
Lower arm ball joint to knuckle
Bell housing cover mounting bolts
Drive shaft and inner shaft assembly to body
Transaxle mounting bolts [12 mm (0.47 in.) diameter bolt]
Transaxle mounting bolts [10 mm (0.39 in.) diameter bolt]
Transaxle mounting bolts [8 mm (0.31 in.) diameter bolt]
Rear cover bolt
Backup ight switch
Poppet spring plug
Speedometer sleeve bolt
Input shaft lock nut
Intermediate gear lock nut
Reverse idler gear shaft bolt
Transaxle case tightening bolt
Stopper bracket bolt
Restrict ball assembly
Reverse shift lever assembly attaching bolt
Bearing retainer bolt
Differential drive gear bolt
Interlock plate bolt
9 - 1 4
9 0 - 1 4 0
7 - 1 0
9 - 1 4
9 0 - 1 4 0
7 - 1 0
1 9 - 2 8
1 9 0 - 2 8 0
1 3 - 2 0
1 5 - 2 2
1 5 0 - 2 2 0
1 1 - 1 6
1 5 - 2 2
1 5 0 - 2 2 0
1 1 - 1 6
1 5 - 2 2
1 5 0 - 2 2 0
1 1 - 1 6
2 7 - 3 4
2 7 0 - 3 4 0
2 0 - 2 5
6 0 - 8 0
6 0 0 - 8 0 0
4 3 - 5 8
9 0 - 1 1 0
9 0 0 - 1 1 0 0
6 5 - 8 0
7 5 - 9 5
7 5 0 - 9 5 0
5 4 - 6 9
3 5 - 5 5
3 5 0 - 5 5 0
2 5 - 4 0
1 5 - 3 4
1 5 0 - 3 4 0
1 1 - 2 5
6 0 - 7 2
6 0 0 - 7 2 0
4 3 - 5 2
1 0 - 1 2
1 0 0 - 1 2 0
7 - 9
4 0 - 5 0
4 0 0 - 5 0 0
2 9 - 3 6
4 3 - 5 5
4 3 0 - 5 5 0
3 2 - 3 9
3 0 - 3 5
3 0 0 - 3 5 0
2 2 - 2 5
1 0 - 1 2
1 0 0 - 1 2 0
7 - 9
1 5 - 2 2
1 5 0 - 2 2 0
1 1 - 1 5
3 0 - 3 5
3 0 0 - 3 5 0
2 2 - 2 5
3 0 - 4 2
3 0 0 - 4 2 0
2 2 - 3 0
3 - 5
3 0 - 5 0
2 - 4
1 4 0 - 1 6 0
1 4 0 0 - 1 6 0 0
1 0 2 - 1 1 5
1 4 0 - 1 6 0
1 4 0 0 - 1 6 0 0
1 0 2 - 1 1 5
4 3 - 5 5
4 3 0 - 5 5 0
3 2 - 3 9
3 5 - 4 2
3 5 0 - 4 2 0
2 6 - 3 0
1 5 - 2 2
1 5 0 - 2 2 0
1 1 - 1 5
3 0 - 3 5
3 0 0 - 3 5 0
2 2 - 2 5
1 5 - 2 2
1 5 0 - 2 2 0
1 1 - 1 5
1 5 - 2 2
1 5 0 - 2 2 0
1 1 - 1 5
1 3 0 - 1 4 0
1 3 0 0 - 1 4 0 0
9 4 - 1 0 1
2 0 - 2 7
2 0 0 - 2 7 0
1 5 - 1 9
4 3 - 4
GENERAL
SPECIAL TOOLS
Tool
(Number and Name)
0 9 4 1 4 - 1 1 0 0 0
Lock pin extractor
0 9 4 1 4 - 1 1 1 0 0
Lock pin installer
0 9 4 3 1 - 2 1 0 0 0
Front oil seal installer
0 9 4 3 1 - 2 1 2 0 0
Oil seal installer
0 9 4 3 2 - 2 1 1 0 1
Input shaft holder
0 9 4 3 2 - 2 1 2 0 1
Snap ring remover
0 9 4 3 2 - 2 1 3 0 0
Removing plate
0 9 4 3 2 - 2 4 0 0 0
Removing plate
Illustration
Use
Driving out the spring pin of the shift fork
Driving in the spring pin of the shift fork
Installation of the input shaft front oil seal
Installation of differential oil seal
Holding the input shaft when loosening
input shaft nut
Removal of input shaft snap ring
Removal of input shaft front
Removal of 1st-2nd speed synchronizer
assembly and 2nd speed gear
4 3 - 5
GENERAL
4 3 - 6
GENERAL
Tool
(Number and Name)
0 9 5 0 0 - 1 1 0 0 0
Bar
Illustration
Use
Installation of output shaft bearing outer
race (use with 09532-11500)
0 9 5 0 0 - 2 1 0 0 0
Bar
Installation of input shaft bearing outer
ring (use with 09432-33400)
0 9 5 3 2 - 1 1 5 0 0
Pinion bearing outer race
installer
Installation of output shaft bearing outer
race (use with 09500-11000)
4 3 - 7
GENERAL
TROUBLESHOOTING
Symptom
Vibration, noise
Oil leakage
Hard shift
Jumps out of gear
Probable cause
Remedy
Loose or damaged transaxle and engine mounts
Tighten or replace mounts
Inadequate shaft end play
Correct end play
Worn of damaged gears
Replace gears
Use of inferior grade of gear oil
Replace with specified gear oil
Low oil level
Replenish
Inadequate engine idle speed
Adjust idle speed
Broken or damaged oil seal or O-ring
Replace oil seal or O-ring
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
Use of inferior grade of gear oil
Replace with specified gear oil
Worn gear shift fork or broken poppet spring
Replace shift fork or poppet spring
Synchronizer hub to sleeve spline clearance
excessive
Replace synchronizer hub and sleeve
4 3 - 8
GENERAL
SERVICE ADJUSTMENT PROCEDURES
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.
With the vehicle parked on a level surface, remove the drain
plug and make sure that there is oil 5-9 mm (0.2-0.4 in.)
below the plug opening.
2.
Check that the transaxle gear oil is not noticeably dirty, and
that it is of a suitable viscosity.
REPLACEMENT OF TRANSAXLE GEAR OIL
1.
With the vehicle parked on a level surface, remove the drain
plug to drain the transaxle gear oil.
2.
Replace the gasket with a new one and install the drain plug.
3. Add new oil through the drain plug, filling to a level 5-9
mm (0.2-0.4 in.) below the plug opening.
Transaxle oil total capacity:
1.8 liters (1.9 u.s.qts., 1.6 Imp.qts.) (KM201 only)
1.7 liters (1.8 u.s.qts., 1.5 Imp.qts.) (KM200 only)
DRIVE SHAFT OIL SEAL REPLACEMENT
1. Disconnect the drive shaft from the transaxle.
(Refer to Drive Shaft.)
2. Using a flat-tip screwdriver, remove the oil seal.
4 3 - 9
GENERAL
3. Using the special tool, (09431-21200) tap the drive shaft
oil seal into the transaxle.
4. Apply a coating of gear oil to the lip of the oil seal.
Transaxle gear oil: Hypoid gear oil, SAE 75W-85W
conforming to API GL-4 or higher
SPEEDOMETER CABLE REPLACEMENT
1. Correctly insert the adapter into the instrument panel, and
fasten the new speedometer cable.
2. Install the grommet so the cable attachment part and the
projecting part are horizontal, as shown in the illustration.
Caution
The cable should be installed so that the radius of the
cable bend is 150 mm (5.9 in.) or more.
3. At the transaxle, the cable should be inserted into the
transaxle, and the nut should be securely tightened.
Caution:
If the cable is not correctly and securely connected, it may
cause the speedometer to read incorrectly or it may
produce abnormal noise.
4 3 - 1 0
MANUAL TRANSAXLE CONTROL
M A N U A L T R A N S A X L E C O N T R O L
COMPONENTS
TORQUE : Nm (kg.cm, Ib.ft)
REMOVAL
1. Remove the console assembly (Refer to CONSOLE).
2. Remove the cotter pins and clips (shift lever side).
3. Remove the shift lever assembly.
4 3 - 1 1
MANUAL TRANSAXLE CONTROL
4. Remove the retainer and bolts.
5. Remove the cotter pins and clips (Transaxle side).
6. Remove the shift cable and select cable.
INSPECTION
1.
Check the select cable for proper operation and for damage.
2.
Check the shift cable for proper operation and for damage.
3. Check the boot for damage.
4. Check each bushing for wear, abrasion, sticking, restricted
movement or damage.
5. Check for a weak or damaged spring.
INSTALLATION
1. install the shift lever assembly.
2. Installation of shift lever and select cable.
1) Move the transaxle select lever and shift lever to the
neutral position.
2)
When connecting the select cable to lever (B), adjust the
select cable’s length so that lever (B) is at the neutral
position.
3) The flange side of the resin bushing at the select cable
end should be at the lever (B) end surface.
4) The flange side of the resin bushing at the shift cable
end should be at the shift lever’s cotter pin hole.
5) After connecting the shift cable, check that the
dimensions (A) and (B) shown in the illustration are
equal.
6)
Move the shift lever to each position and verify that the
shifting is smooth.
3. install the retainer and bolts.
4 3 - 1 2
SHIFT LEVER ASSEMBLY
S H I F T L E V E R A S S E M B L Y
INSPECTION
1. Check the bushing for wear or damage.
2. Check the return spring for damage or deterioration.
ASSEMBLY
1. Apply multi-purpose grease to the sliding part of the
bushings.
2. Assembly is the reverse of disassembly.
4 3 - 1 3
MANUAL TRANSAXLE
MANUAL TRANSAXLE
C O M P O N E N T S
TORQUE : Nm (kg.cm, Ib.ft)
4 3 - 1 4
MANUAL TRANSAXLE
REMOVAL
1. Remove the drain plug and drain the transaxle gear oil.
2. Remove the clutch release cylinder (Refer to the CLUTCH
SECTION)
3. Remove the air cleaner assembly.
4.
Remove the select cable and shift cable (Refer to MANUAL
TRANSAXLE CONTROL SECTION)
5. Disconnect the backup light switch connector.
6. Remove the speedometer cable.
7. Remove the starter motor mounting bolts.
Remove the transaxle assembly upper connecting bolts and
transaxle mounting bracket bolt.
8. Remove the splash shield.
9.
Disconnect the tie rod end, lower the arm ball joint and drive
shaft (Refer to DRIVE SHAFT AND FRONT AXLE SECTION)
10. Remove the bell housing cover.
4 3 - 1 5
MANUAL TRANSAXLE
11. Remove the transaxle assembly lower mounting bolts with
the transaxle assembly supported by a jack.
12. Remove the transaxle assembly.
NOTE
When supporting the transaxle assembly, make sure that
the lifting force is applied to a wide area, not to a small
localized area.
INSTALLATION
1. Installation is the reverse of removal.
4 3 - 1 6
MANUAL TRANSAXLE ASSEMBLY
MANUAL TRANSAXLE ASSEMBLY
4 3 - 1 7
MANUAL TRANSAXLE ASSEMBLY
DISASSEMBLY
1. Remove the rear cover bolts and rear cover.
2. Remove the backup light switch, gasket and mounting
bracket.
3. Remove the poppet plugs, poppet springs and poppet balls.
4. Remove the speedometer drive gear assembly.
4 3 - 1 8
MANUAL TRANSAXLE ASSEMBLY
5. Remove the spring pin using the special tool (09414-
11000). (KM 201 only)
6. Removal of the lock nuts. (KM 201 only)
1) Unstake the lock nuts on the input and intermediate
shafts.
2) Shift the transaxle into reverse using the control and
select levers.
3) Install the special tool (09432-21101) onto the input
shaft.
4) Screw a 10 mm (0.39 in.) bolt into a mounting hole on
the clutch housing and attach a breaker bar to the special
tool.
5) Remove the lock nut, while bracing the breaker bar
against the bolt.
4 3 - 1 9
MANUAL TRANSAXLE ASSEMBLY
7. Remove the 5th speed synchronizer sleeve and 5th speed
shift fork. (KM 201 only)
8.
Remove the 5th speed synchronizer hub, synchronizer ring,
5th speed gear, needle bearing, bearing sleeve and roller
bearing. (KM 201 only)
9. After removing the snap ring, remove the spacer and the
roller bearing (KM200 only).
10. Remove the intermediate gear using the special tool
(09455-21000). (KM 201 only)
11. Remove the reverse idler gear shaft bolt and restriction ball
assembly.
(13 EA) and the transaxle
12. Remove the transaxle cover bolts
cover.
4 3 - 2 0
MANUAL TRANSAXLE ASSEMBLY
13. Remove the differential oil seal and oil guide.
14. Remove the output shaft bearing outer race and spacer
using the special tool (09455-32200).
15. Remove the input shaft roller bearing outer ring using the
special tool (09432-21000).
16. Remove the reverse shift lever and the reverse shift shoe.
17. Remove the reverse gear shaft and the reverse gear.
4 3 - 2 1
MANUAL TRANSAXLE ASSEMBLY
18. Remove the spring pins using the special tool (09414-
11000).
19. Disassembly of the shift rail and fork assembly.
1) Shift the 1st-2nd gear shift fork into 2nd gear.
2) Shift the 3rd-4th gear shift fork into 4th gear.
3)
Pull out the 1st-2nd shift rail and fork assembly with the
select lever pushed to 5th-reverse shift rail side.
4) Pull out the 3rd-4th/5th-reverse shift rail and fork
assembly together with the select lever fully pushed into
the 1st-2nd rail side.
5)
After pulling out the 1st-2nd shift rail and fork assembly
in the shift rail hole located in the clutch housing,
remove the reverse rail assembly and then the 1st-2nd
shift rail and fork assembly (KM200 only)
20. Remove the bearing retainer.
4 3 - 2 2
MANUAL TRANSAXLE ASSEMBLY
21. Lift up the input shaft assembly and remove the intermediate
shaft assembly.
22. Remove the output shaft assembly and differential gear
assembly.
23. Remove the output shaft bearing outer race and spacer
using the special tool (09455-32200).
24. Remove the differential bearing oil seal.
MANUAL TRANSAXLE ASSEMBLY
25. Remove the input shaft oil seal.
4 3 - 2 4
5TH SPEED SYNCHRONIZER ASSEMBLY
5 T H S P E E D S Y N C H R O N I Z E R A S S E M B L Y
COMPONENTS
INSPECTION
SYNCHRONIZER SLEEVE AND HUB
1. Install the synchronizer sleeve on the hub and check that
they slide smoothly.
2. Check that the sleeve is free from damage.
3.
Check for wear of the hub front end (surface in contact with
the 5th speed gear).
Caution
Replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, distortion and breakage.
4 3 - 2 5
5TH SPEED SYNCHRONIZER ASSEMBLY
ASSEMBLY
1.
Assemble the synchronizer hub, sleeve and key noting their
direction.
2. The synchronizer sleeve has teeth missing at six places.
Assemble the hub to the sleeve so that the center tooth
between the two missing teeth will touch the synchronizer
key.
3.
Install the synchronizer spring so that the stepped portions
will rest on the synchronizer keys.
Caution
When installing the synchronizer springs, make sure they
are not facing the same direction.
4 3 - 2 6
INPUT SHAFT
I N P U T S H A F T
COMPONENTS
4 3 - 2 7
INPUT SHAFT
DISASSEMBLY
1. Remove the snap ring using the special tool (09432-
21201).
2. Remove the front bearing using the special tool (09432-
21300).
3. Remove the inner ring, spacer, 4th gear, needle bearing,
bearing sleeve,
synchronizer rings, 3rd and 4th gear
synchronizer hub and sleeve and 3rd gear all together using
the special tool (09432-33200)
4 3 - 2 8
INPUT SHAFT
INSPECTION
INPUT SHAFT
1.
Check the outer surface of the input shaft where the needle
bearing is mounted for damage or abnormal wear [portion
(A)].
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.
SYNCHRONIZER RING
1. Check the clutch gear teeth for damage.
2. Check the 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 : 0.5 mm (0.02 in.)
4 3 - 2 9
INPUT SHAFT
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).
Caution:
Replace the synchromizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, distortion or damage.
GEARS
1. Check the bevel gear and clutch gear teeth for damage or
wear.
2. Check the gear cone for rough surfaces, damage or wear.
3. Check the gear bore for damage or wear.
4 3 - 3 0
INPUT SHAFT
ASSEMBLY
1. Install the synchronizer hub and sleeve so that they are
positioned as shown in the figure.
2. The synchronizer sleeve has teeth missing at six places.
Assemble the hub to the sleeve so that the center tooth
between the two missing teeth will touch synchronizer key.
3.
Install the synchronizer spring so that the spepped portions
will rest on the synchronizer keys.
Caution
When installing the synchronizer springs, make sure they
are not facing the same direction.
4 3 - 3 1
INPUT SHAFT
4. Install the needle roller bearing and 3rd gear on the input
shaft.
5.
Install the 3rd-4th gear synchronizer assembly on the input
shaft using the special tool (09432-33300).
Caution
1. When installing the synchronizer assembly, make sure
that the three synchronizer keys are seated correctly
in their respective grooves of the synchronizer ring.
2. After installing the synchronizer assembly, check that
3rd gear rotates smoothly.
6.
Install the needle roller bearing sleeve using the special tool
(09432-33300).
7.
Install the synchronizer ring, needle roller bearing, 4th gear,
the spacer and the inner ring using the special tool (09432-
33300).
4 3 - 3 2
INPUT SHAFT
8. Install the front bearing using the special tool (09432-
33300).
9. Install the snap ring.
Caution
Be careful not to damage the input shaft oil seal surface
on the input shaft.
4 3 - 3 3
INTERMEDIATE SHAFT
I N T E R M E D I A T E S H A F T
COMPONENTS
4 3 - 3 4
INTERMEDIATE SHAFT
DISASSEMBLY
1. Remove the snap ring.
2.
Remove the ball bearing, 1st gear, bearing sleeve and needle
roller bearing.
CAUTION
Do not reuse the bearing removed from the shaft.
3. Remove the 1st-2nd gear synchronizer assembly, 2nd gear
and the needle roller bearing together, using the special tool
(09432-24000).
4. Remove the ball bearing using the special tool (09433-
21000).
CAUTION
Do not reuse the bearing removed from the shaft.
4 3 - 3 5
INTERMEDIATE SHAFT
INSPECTION
INTERMEDIATE SHAFT
1.
Check the outer surface of the intermediate shaft where the
needle bearing is mounted for damage or abnormal wear
[portion (A)].
2. Check the splines for damage and wear.
NEEDLE BEARING
1. Install the needle bearing on the shaft with the bearing
sleeve and gear and check that it rotates smoothly without
abnormal noise or play.
2. Check the needle bearing cage for distortion.
SYNCHRONIZER RING
1. Check the clutch gear teeth for damage.
2. Check the 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 : 0.5 mm (0.02 in.)
4 3 - 3 6
INTERMEDIATE SHAFT
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 that are in contact
with each speed gear.
Caution
Replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, distortion or damage.
GEARS
1. Check the bevel gear and clutch gear teeth for damage or
wear.
2.
Check the gear cone for a rough surfaces, damage or wear.
3. Check the gear bore for damage or wear.
4 3 - 3 7
INTERMEDIATE SHAFT
ASSEMBLY
1.
Install the ball bearing over the intermediate shaft using the
special tool (09432-33300).
CAUTION
When installing the bearing, push on the inner race only.
2.
Install the 1st gear synchronizer ring noting its identification
mark.
3. Combine the 1st-2nd gear synchronizer hub and sleeve.
4. The synchronizer sleeve has teeth missing at six places.
Assemble the hub to the sleeve so that the center tooth
between the two missing teeth will touch the synchronizer
key.
5.
Install the synchronizer spring so that the stepped portions
will rest on the synchronizer keys.
Caution
When installing the synchronizer springs, make sure they
are not facing the same direction.
4 3 - 3 8
INTERMEDIATE SHAFT
6. Install the needle roller bearing, 2nc gear, 1st-2nd gear
synchronizer assembly over the intermediate shaft using the
special tool (09432-33300).
Caution:
1. When installing the synchronizer assembly, make sure
that the three synchronizer keys are seated correctly
in their respective grooves on the synchronizer ring.
2. After installation of the synchronizer assembly, check
that 3rd gear rotates smoothly.
7.
Install the needle roller bearing, 1st gear and bearing sleeve
together using the special tool (09432-33300).
8. Install the ball bearing using the special tool (09432-
33300).
Caution:
When installing the bearing, push on the inner race only.
9. Install the snap ring.
4 3 - 3 9
OUTPUT SHAFT
OUTPUT SHAFT
COMPONENTS
DISASSEMBLY
1. Remove the tapered roller bearing using the special tool
(09432-33200).
CAUTION:
Do not reuse the bearing removed from the shaft.
ASSEMBLY
1. Install the tapered roller bearing using the special tool
(09432-33300).
CAUTION:
When installing the bearing, push on the inner race only.
4 3 - 4 0
SHIFT FORK
S H I F T F O R K
ASSEMBLY
1.
Insert the interlock plunger as illustrated on the 3rd-4th gear
shift rail. (KM201 only)
4 3 - 4 1
DIFFERENTIAL
D I F F E R E N T I A L
COMPONENTS
TORQUE : Nm (kg.cm, Ib.ft)
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.
4 3 - 4 2
DIFFERENTIAL
3.
Remove the ball bearings using the special (09432-21000).
CAUTION
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.
ASSEMBLY
1. Install the spacer on the back of the side gear and then
install the gear in the differential case.
CAUTION
1. When installing a new side gear, use a spacer of
medium thickness [0.93-1.00 mm (0.036-0.04 in)].
2. Do not reuse the lock pin.
3. The lock pin head must be sunk below the flange
surface of the differential case.
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 3 - 4 3
DIFFERENTIAL
4. Measure the backlash between the side gears and pinions.
Standard value : 0.025-0.150 mm
(0.001-0.006 in.)
5.
If the backlash is out of specification, disassemble and install
the correct spacer, reassemble and remeasure.
Caution:
Adjust the backlash of both side gears to the same
specification.
6. Align the pinion shaft lock pin hole with the case lock pin
hole and insert the lock pin.
Caution
1. Do not reuse the lock pin.
2. The lock pin head must not protrude more than 3 mm
(0.118 in.).
7. Install the tapered roller bearings on both sides of the
differential case using the special tool (09455-21100).
Caution
When press-fitting the bearings, 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 : 3M Stud Locking No.4170
Caution
If a bolt is reused, remove the old sealant from the
threads.
4 3 - 4 4
CLUTCH HOUSING
C L U T C H H O U S I N G
4 3 - 4 5
CLUTCH HOUSING
DISASSEMBLY
1.
Remove the select lever assembly and the select lever shoe.
2. Remove the interlock plate bolt and gasket.
3.
Drive out the spring pin from the control finger using the
special tool (09414-11000).
4. Drive out the spring pin from the stopper body using the
special tool (09414-11000).
5.
Pull out the control shaft and remove the control shaft boots
and oil seal.
6. Remove the neutral return spring assembly, control finger,
interlock plate, stopper body and the neutral return spring.
7.
Remove the control shaft oil seal and the needle bearings.
NOTE
The stopper body, stopper plate, return spring and pin are
used in the KM201 only.
4 3 - 4 6
CLUTCH HOUSING
ASSEMBLY
1. Install the needle bearing flush with surface “A” of the
clutch housing.
2. Install the control shaft oil seal using a socket wrench.
3. Install the neutral return spring assembly, control finger,
interlock plate, stopper body and neutral return spring with
the control shaft.
NOTE
The stopper body, stopper plate, return spring and pin are
used in the to KM201 only.
4. Install new spring pins using the special tool (09414-
11100).
Caution:
1. Do not reuse the spring pins.
2. Install the spring pins with their slits at right angle to
the center of the control shaft.
4 3 - 4 7
CLUTCH HOUSING
5. Install the interlock plate bolt and gasket.
6. Install the select lever assembly and select shoe.
4 3 - 4 8
SPEEDOMETER DRIVEN GEAR ASSEMBLY
S P E E D O M E T E R D R I V E N G E A R A S S E M B L Y
COMPONENTS
ASSEMBLY
1. Apply gear oil sparingly to the speedometer driven gear shaft
and insert the shaft.
2. Install the spring pin in such a way that the slit does not
face the gear shaft.
4 3 - 4 9
MANUAL TRANSAXLE ASSEMBLY
INSTALLATION
1. Install the drive shaft oil seal using the special tool
(09434-21200).
2. Install the input shaft front oil seal using the special tool
(09431-21000).
3.
4.
5.
6.
Install the output shaft bearing outer race and spacer using
the special tools (09500-11000, 09532-11500).
Install the oil guide.
Install the differential gear assembly and output shaft
assembly.
Install the input and intermediate shafts at the same time.
4 3 - 5 0
MANUAL TRANSAXLE ASSEMBLY
7. Install the retainer.
8. Reassembly of the shift rail assembly.
1) Place the 1st-2nd gear shift sleeve in the 2nd gear
position.
2) Place the 3rd-4th gear shift sleeve in the 4th gear
position.
3) Install the 1st-2nd shift rail and fork assembly with the
select lever pulled toward the 5th-reverese shift rail side.
4) Install the 3rd-4th/5th-reverse shift rail and fork
assembly together with the select lever pushed toward
the 1st-2nd rail side. (KM201 only)
5) Install the 3rd-4th/reverse shift rail and fork assembly
with the select lever pushed toward the 1st-2nd rail side
(KM200 only).
6) Turn the shift rail to engage the shift lug.
9. Installation of the spring pin.
1) Install the spring pins using the special tool (09414-
11100).
4 3 - 5 1
MANUAL TRANSAXLE ASSEMBLY
2)
When installing, make sure that the slit of the spring pin
is aligned with the center line of the shift rail.
CAUTION
Do not reuse the spring pins.
10. Install the reverse gear lever assembly.
11. Install the reverse gear shaft and reverse gear in the
direction illustrated.
12. Install the reverse shift lever and shoe.
13. Install the input shaft roller bearing outer ring and
intermediate shaft bearing race using the special tools
(09432-33400, 09500-21000)
4 3 - 5 2
MANUAL TRANSAXLE ASSEMBLY
14. Install the output shaft bearing outer race and spacer in the
transaxle case using the special tools (09500-11000,
09532-11500).
15. Install the drive shaft oil seal in the transaxle case using the
special tool (09431-21200).
16. Reassembly of spacers (adjustment of end play).
1 )
2 )
3)
4)
5)
Place two pieces of rosin-core solder measuring about
10 mm (0.4 in.) in length and 3 mm (0.12 in.) in diameter
on the bearing outer race as shown in the illustration, and
install the outer race.
Install the transaxle case and tighten the bolts to the
specified torque.
Remove the transaxle case.
Remove the outer races and solder.
Measure the thickness of the crushed solder with a
micrometer. Select and install the proper spacer.
Standard value:
Intermediate shaft end play:
0.05-0.10 mm (0.002-0.004 in.)
Output shaft end play:
0.05-0.10 mm (0.002-0.004 in.)
Differential case end play:
0.05-0.10 mm )(0.002-0.004 in.)
4 3 - 5 3
MANUAL TRANSAXLE ASSEMBLY
17. Install the oil guide in the transaxle case.
18. Apply the specified sealant to the clutch housing side of the
transaxle case.
Specified sealant : THREE BOND 1216
19. Install the transaxle case onto the clutch housing assembly
and tighten the bolts (13 EA).
20. Install the restriction ball and gasket.
21. Center the shaft with a phillips screwdriver.
22. Tighten the reverse idler gear shaft bolt to the specified
torque.
4 3 - 5 4
MANUAL TRANSAXLE ASSEMBLY
23. Install the poppet balls, poppet springs and poppet plugs.
24. Install the backup light assembly
25. Install the intermediate gear using the special tool (09432-
33300). (KM201 only)
26. Install the 5th gear, the needle roller bearing, synchronizer
ring and the synchronizer hub. (KM201 only)
27. Install the 5th gear shift fork and the 5th gear synchronizer
sleeve at the same time. (KM201 only)
28. Install the spring pin using the special tool (09414-11100).
(KM201 only)
29. When installing, make sure that the slit of the spring pin
is aligned with the center line of the shift rail. (KM201 only)
Caution
Do not reuse the spring pin.
MANUAL TRANSAXLE ASSEMBLY
30. Reassembly of lock nuts. (KM201 only)
1) Install the special tool (09432-21101) onto the input
shaft.
2) Screw a 10 mm (0.39 in.) bolt amounting hole into on
the clutch housing and attach a breaker bar to the special
tool (09432-21101).
3) Shift the transaxle into reverse using the control and
select levers.
4) Tighten the lock nut to the specified torque.
5) Stake the lock nut.
31. Apply the specified sealant to the rear cover and install the
rear cover.
Specified sealant : THREE BOND 1216
32. Install the mounting bracket.
4 3 - 5 6
MANUAL TRANSAXLE ASSEMBLY
33. Install the speedometer driven gear assembly.
4 3 - 5 7
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