PREPARATION MATERIALS PREPARATION MATERIALS PP

DRIVE TRAIN MANUAL TRANSMISSION/TRANSAXLE MT

PREPARATION MATERIALS

PREPARATION MATERIALS
MANUAL TRANSMISSION/TRANSAXLE
PP
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-2
GENERAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-8
GREASE ⋅ OTHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-8
 PP–2 Preparation materials - MANUAL TRANSMISSION/TRANSAXLE

MANUAL TRANSMISSION/TRANSAXLE
Preparation materials

SST
Illustration Tool number Description Remarks
39852770 Puller ASSY Used for removing the transmission extension
housing oil seal.

PP

ST-398527700
499277100 Bushing 1-2 installer • Used for installing the transmission clutch hub
No. 3.
• Used for installing the transmission clutch hub
No. 1.
• Used for installing the output shaft bearing RR.
• Used for installing the sixth gear.

ST-499277100
899714110 Remover • Used for removing the input shaft bearing FR.
• Used for removing the counter drive gear.
• Used for removing the counter shaft third gear.
• Used for removing and installing the
transmission clutch hub No. 3.
• Used for installing the transmission clutch hub
No. 1.
• Used for installing the output shaft bearing RR.
• Used for installing the sixth gear.

ST-899714110
398477703 Drift 2 • Used for installing the input shaft bearing FR.
• Used for installing the transmission clutch hub
No. 3.
• Used for installing the transmission clutch hub
No. 1.
• Used for installing the output shaft bearing RR.
• Used for installing the sixth gear.
• Used for installing the transmission clutch hub
No. 2.
• Used for installing the counter drive gear.

ST-398477703
 Preparation materials - MANUAL TRANSMISSION/TRANSAXLE
PP–3

Illustration Tool number Description Remarks

499277000 Installer • Used for installing the input shaft bearing FR.
• Used for installing the transmission clutch hub
No. 1.
• Used for installing the output shaft bearing RR.
• Used for installing the sixth gear.
• Used for installing the counter drive gear.

PP

ST-499277000
18654AA000 Installer Used for installing the transmission clutch hub No. 2.

ST18654AA000
09325-20010 Transmission oil plug • Used for installing the transmission extension
housing oil seal (MTM).
• Used for installing the transmission extension
housing oil seal.

ST0932520010
498057300 Installer Used for installing the counter gear front bearing.

ST-498057300
 PP–4 Preparation materials - MANUAL TRANSMISSION/TRANSAXLE

Illustration Tool number Description Remarks

09350-20015 TOYOTA automatic transmission tool Used for inspecting the counter shaft 6th gear thrust
set clearance.

PP

ST0935020015
(09350-06120) Terminal No. 2 measure Used for inspecting the counter shaft 6th gear thrust
clearance.

ST0935006120
18657AA040 Installer Used for installing the extension housing rear oil seal.

ST18657AA040
18682AA000 Installer Used for installing the transmission clutch hub No. 4.

ST18682AA000
 Preparation materials - MANUAL TRANSMISSION/TRANSAXLE
PP–5

Illustration Tool number Description Remarks

499895400 Expander Used for removing and installing the shaft snap ring.

PP

ST-499895400
899864100 Remover • Used for removing the transmission clutch hub
No. 3.
• Used for removing the counter gear front
bearing.
• Used for removing the counter drive gear.

ST-899864100
09950-00020 Remover • Used for removing the sixth gear.
• Used for removing the counter gear front
bearing.

ST0995000020
18722AA000 Remover Used for removing the first gear.

ST18722AA000
 PP–6 Preparation materials - MANUAL TRANSMISSION/TRANSAXLE

Illustration Tool number Description Remarks

09950-30012 Puller A set Used for removing the transmission clutch hub No. 4.

PP

ST0995030012
(09951-03010) Upper plate Used for removing the transmission clutch hub No. 4.

ST0995103010
(09953-03010) Center bolt Used for removing the transmission clutch hub No. 4.

ST0995303010
(09956-03010) Adapter 16 Used for removing the transmission clutch hub No. 4.

ST0995603010
 Preparation materials - MANUAL TRANSMISSION/TRANSAXLE
PP–7

Illustration Tool number Description Remarks

09950-60010 Replacer set Used for installing the transmission front bearing
retainer oil seal.

PP

ST0995060010
(09951-00420) Replacer 42 Used for installing the transmission front bearing
retainer oil seal.

ST0995100420
09950-60020 Replacer set No. 2 Used for installing the extension housing dust
deflector.

ST0995060020
(09951-00750) Replacer 75 Used for installing the extension housing dust
deflector.

ST0995100750
 PP–8 Preparation materials - MANUAL TRANSMISSION/TRANSAXLE

Illustration Tool number Description Remarks

09950-70010 Handle set • Used for installing the transmission front bearing
retainer oil seal.
• Used for installing the extension housing dust
deflector.

PP

ST0995070010
09951-07100 Handle 100 • Used for installing the transmission front bearing
retainer oil seal.
• Used for installing the extension housing dust
deflector.

ST0995107100

GENERAL TOOL
Tool name Remarks
Socket hexagon Used for removing and installing the lock ball pin.
TORX® socket wrench T40 Used for removing and installing the head straight screw plug.
TORX® socket wrench T45 Used for removing and installing the TORX bolt.
Brass bar 16φ • Used for disassembling and assembling the manual transmission ASSY.
• Used for disassembling and assembling the input shaft ASSY.
• Used for disassembling and assembling the output shaft ASSY.
Thickness gauge Used for measuring clearance.
Caliper Used for measuring clearance.
Dial gauge (10 mm) Used for measuring clearance.
Micrometer Used for measuring outer diameter.
V-block • Used for inspecting the output shaft runout.
• Used for inspecting the counter shaft runout.
Cylinder gauge Used for measuring inner diameter.
Magnetic base Used for measuring clearance.

GREASE⋅OTHER
Description Part number Used location
MG Gear Oil Special II – • Manual transmission ASSY GL-3 or more (75W-90)
• Input shaft ASSY <Caution>
• Output shaft ASSY • The function or the
• Counter gear ASSY
performance of the substitute
oil might be inferior to the
genuine transmission gear oil.
• Do not mix different types of oil.
Nichimoly N-130 or equivalent – Input shaft —
Permalub ECN-9 or equivalent – • Floor shift control shaft —
• Control shaft
Nigtight LYW No. 2 or equivalent – • Shift lever cap —
• Shift lever pin
• Control shift lever retainer
DRIVE TRAIN

MANUAL TRANSMISSION/TRANSAXLE
MANUAL TRANSMISSION ASSY
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MT-23
MT-26 MT
INPUT SHAFT ASSY
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-44
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-44
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-46
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-46
OUTPUT SHAFT ASSY
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-48
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-52
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-57
COUNTER GEAR ASSY
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-61
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-62
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-65
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-68
 MT–2 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

MANUAL TRANSMISSION ASSY

Drive train
Manual transmission/transaxle

EXPLODED VIEW

Wiring harness clamp bracket

7.0 {71}{5.2}

MT Clutch housing

Reverse idler gear

Reverse idler
gear shaft

16 {163}{11.8} Gasket
x7
Clutch release fork support
17 {173}{12.5}

Transmission front bearing

retainer oil seal
28 {286}{20.7}
Bearing retainer FR

Nm {kgfcm}{ftlbf} : Tightening torque

Non-reusable parts Locking part

Manual transmission oil

MT-03050
<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–3

Shaft snap ring

Gear shift fork No. 1

Gear shift fork No. 3

Gear shift fork shaft No. 3

MT

19.5 {198.8}{14.4}
19.5 {198.8}{14.4}

Shaft snap ring

Gear shift fork shaft No. 1

Shaft snap ring

Output shaft

Input shaft Counter shaft

Straight pin

19.5 {198.8}{14.4}

Gear shift fork No. 2

Shaft snap ring

Shaft snap ring

Gear shift fork shaft No. 2

Nm {kgfcm}{ftlbf} : Tightening torque

Non-reusable parts

Oil receiver pipe

Manual transmission oil
NICHIMOLY N-130 or equivalent MT-03005
 MT–4 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)

MT
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–5

Shift shaft

Gear shift head No. 2

Slotted spring pin Shift inner lock

block No. 1
Gear shift head No. 1
MT
Slotted spring pin
33.3 {339.5}{24.6}

Gear shift head No. 3

Slotted spring pin

Transmission case

Compression spring
Shift inner lever FR

Shaft snap ring

29 {296}{21.4} Gear shift fork shaft No. 3

Clamp x9 Washer

5th shift head

Compression
x2 spring
x2
x2 x2 Ball
Ball
Gear shift fork shaft No. 2
19 {194}{14}
Head straight Gasket
screw plug

37 {377}{27.3}

Gasket Manual transmission

Ball 28 {286}{20.7} drain plug
Gasket
19 {194}{14}
Head straight screw plug
37 {377}{27.3}
Manual transmission filler plug
Manual transmission oil
Nm {kgfcm}{ftlbf} : Tightening torque Locking part Non-reusable parts MT-03006
 MT–6 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)

Shift arm pivot Shift arm

Shaft snap ring

MT
Bearing retainer RR x4

30 {306}{22.1}

E-ring

Gear shift fork No. 4

6th gear thrust washer

Needle roller bearing

Counter shaft 6th gear

19.5 {198.8}{14.4} Transmission hub

sleeve No. 4

Ball

Synchromesh shifting key spring No. 1

Synchromesh shifting key No. 1

x3 x3 x3

Hole snap ring

Shaft snap ring

Synchronizer ring No. 2

Transmission clutch hub No.4

Nm {kgfcm}{ftlbf} : Tightening torque Non-reusable parts Locking part
Manual transmission oil MT-03043
<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–7

Transmission extension housing oil seal

Extension housing dust deflector

Extension housing rear oil seal

32.3 {329.4}{23.8} MT
Clamp
Back-up light switch ASSY

x8

Gasket 29 {296}{21.4}
39.2 {399.7}{28.9}
Holder

Compression spring

Lock ball pin

Lock ball pin

Compression
spring

Extension housing oil

receiver pipe No. 2 24.5 {249.8}{18.1}
Head straight
screw plug
Transmission extension
housing SUB-ASSY (MTM)

Straight pin Gasket

8.5 {87}{6.3}

Stopper plate
32.3 {329.4}{23.8}

Extension housing oil Neutral switch

receiver pipe No. 1

Nm {kgfcm}{ftlbf} : Tightening torque

Non-reusable parts
31 {316}{22.9}
Manual transmission oil
MT-03008
 MT–8 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)

DISASSEMBLY
1. Remove the manual transmission filler plug.
(1) Remove the manual transmission filler plug and gasket.

MT

C257296

2. Remove the manual transmission drain plug.

(1) Remove the manual transmission drain plug and gasket.

C257297

3. Remove the clutch release fork support.

(1) Remove the clutch release fork support from the clutch housing.

C258508

4. Remove the back-up light switch ASSY.

(1) Release the engagement of the three clamps.

MT-02923
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–9

(2) Remove the back-up light switch ASSY and gasket.

MT
C257023

5. Remove the neutral switch.

(1) Release the engagement of the clamp.

C257024

(2) Remove the neutral switch and gasket.

C257025

6. Remove the wiring harness clamp bracket.

(1) Remove the bolt, and remove the wiring harness clamp bracket.

C257298

7. Remove the lock ball pin.

(1) Remove the head straight screw plug, compression spring and
lock ball pin.

C257027
 MT–10 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

8. Remove the holder.

(1) Remove the holder, compression spring and lock ball pin.

MT
C257028

9. Remove the transmission extension housing SUB-ASSY (MTM).

(1) Remove the bolt.

C257029

(2) Remove the eight bolts and clamp.

Captions in illustration
*1 Clamp

C257030J01

(3) Remove the transmission extension housing SUB-ASSY (MTM).

<Caution>
• Be careful not to damage the transmission extension housing
SUB-ASSY (MTM).
• Make sure to remove the transmission extension housing SUB-
ASSY (MTM) with the shift position in neutral.

C257031

10. Remove the extension housing rear oil seal.

(1) Remove the extension housing rear oil seal.
Captions in illustration
 *1 Protective tape

<Caution>
Be careful not to damage the transmission extension housing SUB-
ASSY (MTM).
<Reference>
When removing the part, apply a cloth to avoid damaging the
C257033J01 transmission extension housing SUB-ASSY (MTM).
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–11

11. Remove the extension housing dust deflector.

(1) Remove the extension housing dust deflector.

MT
C257039

12. Remove the transmission extension housing oil seal.


(1) Remove the transmission extension housing oil seal.
Captions in illustration
*1 Protective tape

<Caution>
Be careful not to damage the transmission extension housing SUB-
ASSY (MTM).
<Reference>
When removing the part, apply a cloth to avoid damaging the
C257299J01 transmission extension housing SUB-ASSY (MTM).

13. Remove the extension housing oil receiver pipe No. 2.

(1) Remove the extension housing oil receiver pipe No. 2.

C257034

14. Remove the extension housing oil receiver pipe No. 1.

(1) Remove the bolt, and remove the extension housing oil receiver
pipe No. 1 and stopper plate.

C257036
 MT–12 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

(2) Remove the straight pin.

MT
C257037

15. Remove the shift shaft.

(1) Slide the shift shaft and shift inner lock block No. 1 to remove.

C257328

16. Remove the shift inner lock block No. 1.

(1) Remove the shift inner lock block No. 1 from the shift shaft.

C262543

17. Remove the shift inner lever FR.

(1) Remove the bolt, and remove the shift inner lever FR from the shift
shaft.
<Caution>
Check the direction of the part.

C257329

18. Remove the head straight screw plug.

(1) Remove the three head straight screw plugs.

C257294
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–13

(2) Remove the two compression springs and two balls.

MT
C257295

19. Remove the shift arm.

(1) Remove the E-ring.
<Caution>
Hold with a cloth to prevent the E-ring from flying out.

C257330

(2) Remove the shift arm.

C257331

20. Remove the gear shift fork shaft No. 3.

(1) Remove the gear shift fork shaft No. 3.
<Caution>
• Be careful that the ball may fall off from the 5th shift head portion.
• The ball in the transmission case portion may fall into the
transmission case. In this case, remove the ball when the
transmission case is detached.
(2) Remove the ball from the 5th shift head portion.

MT-02895

(3) Remove the ball.

C257335
 MT–14 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

21. Remove the 5th shift head.

(1) Remove the shaft snap ring.
<Caution>
Hold with a cloth to prevent the shaft snap ring from flying out.

MT
C257332

(2) Remove the washer.

C257333

(3) Remove the 5th shift head, and remove the ball and compression
spring.
<Caution>
Be careful that sliding the 5th shift head may cause fall of the ball and
compression spring.

C257336

22. Check the counter shaft 6th gear thrust clearance.

(1) Using the SST, check the thrust clearance.
SST 09350-20015 (09350-06120), 498255400
556 Standard value: 0.10 to 0.40 mm {0.00394 to 0.0157 in}
Limit: 0.40 mm {0.0157 in}
<Reference>
When the result exceeds the limit, replace the counter shaft 6th
gear, transmission clutch hub No. 4, 6th gear thrust washer, needle
roller bearing, and counter shaft.
C257300J01
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–15

23. Check the counter shaft 6th gear radial clearance.

(1) Check the radial clearance.
Standard value: 0.015 to 0.068 mm {0.000590 to 0.00268 in}
Limit: 0.068 mm {0.00268 in}
<Reference>
When the result exceeds the limit, replace the counter shaft 6th
gear, needle roller bearing, and counter shaft.

MT
C257301

24. Remove the transmission clutch hub No. 4.

(1) Remove the shaft snap ring.
<Caution>
Hold with a cloth to prevent the shaft snap ring from flying out.

C257337

(2) Using the SST, remove the transmission clutch hub No. 4 with the
transmission hub sleeve No. 4, gear shift fork No. 4 and gear shift
fork shaft No. 2 as a unit.
Captions in illustration
D *a Hold
*b Rotate
556
SST 09950-30012 (09951-03010, 09953-03010,
C 09956-03010)
<Caution>
C257338J01 Check the direction of the part.

25. Remove the gear shift fork No. 4.

(1) Remove a bolt, and remove the gear shift fork No.4 from the gear
shift fork shaft No.2.

MT-03025

26. Remove the transmission hub sleeve No. 4.

(1) Remove the hole snap ring.

C257340
 MT–16 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

(2) Remove the transmission hub sleeve No. 4, and remove the three
synchromesh shifting key No. 1s, three synchromesh shifting key
spring No. 1s, and three balls from the transmission clutch hub No.
4.
<Caution>
• Use a cloth to prevent the synchromesh shifting key No. 1s,
synchromesh shifting key spring No. 1s, and balls from flying out.
• Do not deform the synchromesh shifting key spring No. 1s.

MT • Check the direction of the part.

<Reference>
C257070
Perform the procedure without moving the positions of the
transmission clutch hub No. 4 and synchromesh shifting key
No. 1s.
27. Remove the synchronizer ring No. 2.
(1) Remove the synchronizer ring No. 2.

C257341

28. Remove the counter shaft 6th gear.

(1) Remove the counter shaft 6th gear.

C257342

29. Remove the needle roller bearing.

(1) Remove the needle roller bearing.

C258418
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–17

30. Remove the 6th gear thrust washer.

(1) Remove the 6th gear thrust washer.
<Caution>
Check the direction of the part.

MT
C258419

(2) Remove the straight pin.

C258420

31. Remove the gear shift head No. 2.

(1) Remove the slotted spring pin.
(2) Remove the gear shift head No. 2 from the gear shift fork shaft No.
2.
<Caution>
• Hold with a cloth to prevent the slotted spring pin from flying out.
• Be careful not to let the slotted spring pin fall inside from the fork
shaft hole.
• Check the direction of the part.

C258421

32. Remove the gear shift head No. 1.

(1) Remove the slotted spring pin.
(2) Remove the gear shift head No. 1 from the gear shift fork shaft
No. 1.

C258422

33. Remove the gear shift head No. 3.

(1) Remove the slotted spring pin.
(2) Remove the gear shift head No. 3 from the gear shift fork shaft
No. 3.

C258423
 MT–18 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

34. Remove the bearing retainer RR.

(1) Remove the four TORX bolts, and remove the bearing retainer RR.

MT
C258424

(2) Remove the shift arm pivot.

C258425

35. Remove the transmission case.

(1) Using the SST, remove the shaft snap ring.
SST 499895400
556

MT-02860

(2) Remove the reverse idler gear shaft mounting bolt and gasket.
(The transmission case side)

C258427
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–19

(3) Remove the nine bolts and clamp.

Captions in illustration
*1 Clamp


MT
C258428J01

(4) Remove the transmission case.

<Caution>
Be careful not to damage the transmission case.

C258429

36. Remove the oil receiver pipe.

(1) Remove the oil receiver pipe.

C258430

37. Remove the bearing retainer FR.

(1) Remove the seven bolts, and remove the bearing retainer FR.

C258431

38. Remove the transmission front bearing retainer oil seal.

(1) Remove the transmission front bearing retainer oil seal.

Captions in illustration
*1 Protective tape

<Caution>
Be careful not to damage the bearing retainer FR.
<Reference>
When removing the part, apply a cloth to avoid damaging the
bearing retainer FR.
C257040J01
 MT–20 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

39. Remove the counter shaft.

(1) Using the SST, remove the two shaft snap rings.
SST 499895400
<Reference>
Remove the shaft snap rings on the input shaft side and counter
556 shaft side both.

MT

556

MT-02861

(2) Remove the bolt and gasket to free the reverse idler gear and
reverse idler gear shaft. (The clutch housing side)

C258433

(3) While tapping with a hammer handle from the clutch housing side,
remove the input shaft, output shaft, counter shaft, reverse idler
gear, reverse idler gear shaft, gear shift fork shaft No. 1, gear shift
fork shaft No. 2, and gear shift fork shaft No. 3 as a unit.

C258434
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–21

40. Remove the gear shift fork shaft No. 2.

(1) Remove the shaft snap ring.
<Caution>
Hold with a cloth to prevent the shaft snap ring from flying out.

MT
C258435

(2) Remove the bolt, and remove the gear shift fork shaft No. 2.

C258436

41. Remove the gear shift fork shaft No. 1.

(1) Remove the shaft snap ring.
<Caution>
Hold with a cloth to prevent the shaft snap ring from flying out.

C258437

(2) Remove the gear shift fork shaft No. 1 and gear shift fork No. 1 as
a unit.

C258438
 MT–22 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

(3) Remove the shaft snap ring.

<Caution>
Hold with a cloth to prevent the shaft snap ring from flying out.

MT
C258439

(4) Remove the bolt, and remove the gear shift fork shaft No. 1.

C258440

42. Remove the gear shift fork shaft No. 3.

(1) Remove the bolt, and remove the gear shift fork shaft No. 3.

C260035

43. Remove the input shaft.

(1) Remove the input shaft from the output shaft.

C258452

44. Check the reverse idler gear radial clearance.

(1) Fix the reverse idler gear shaft on a vise, and then check the radial
clearance.
Standard value: 0.040 to 0.082 mm {0.00157 to 0.00323 in}
Limit: 0.082 mm {0.00323 in}
<Reference>
When the result exceeds the limit, replace the reverse idler gear
and reverse idler gear shaft.

C257110
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–23

45. Remove the reverse idler gear shaft.

(1) Remove the reverse idler gear shaft from the reverse idler gear.

MT
C257111

INSPECTION
1. Check the gear shift head No. 1.
(1) Measure the groove of the gear shift head No. 1.
Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
Limit: 15.4 mm {0.60630 in}
<Reference>
When the result exceeds the limit, replace the gear shift head
No. 1.

C257302

2. Check the gear shift head No. 2.

(1) Measure the groove of the gear shift head No. 2.
Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
Limit: 15.4 mm {0.60630 in}
<Reference>
When the result exceeds the limit, replace the gear shift head
No. 2.

C257303

3. Check the gear shift head No. 3.

(1) Measure the groove of the gear shift head No. 3.
Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
Limit: 15.4 mm {0.60630 in}
<Reference>
When the result exceeds the limit, replace the gear shift head
No. 3.

C257304
 MT–24 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

4. Check the shift shaft.

(1) Measure the thickness of the claw of shift shaft.
Standard value: 14.8 to 15.0 mm {0.583 to 0.591 in}
Limit: 14.8 mm {0.583 in}
<Reference>
When the result is below the limit, replace the shift shaft.

MT
C257305

5. Check the shift inner lock block No. 1.

(1) Measure the thickness of the claw of shift inner lock block No. 1.
Standard value: 14.8 to 15.0 mm {0.583 to 0.591 in}
Limit: 14.8 mm {0.583 in}
<Reference>
When the result is below the limit, replace the shift inner lock block
No. 1.

C258815

6. Check the gear shift fork No. 4.

(1) Measure the groove of the gear shift fork No. 4.
Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
Limit: 15.4 mm {0.60630 in}
<Reference>
When the result exceeds the limit, replace the gear shift fork No. 4.

C257307

7. Check the 5th shift head.

(1) Measure the groove of the 5th shift head.
Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
Limit: 15.4 mm {0.60630 in}
<Reference>
When the result exceeds the limit, replace the 5th shift head.

C259359

8. Check the synchronizer ring No. 2.

(1) Apply manual transmission oil to the taper cone portion of the
counter shaft 6th gear, and with the synchronizer ring No. 2 tightly
fit by pressing by hand, check the clearance between the
synchronizer ring No. 2 and counter shaft 6th gear.
Standard value: 0.88 to 1.52 mm {0.0346 to 0.0598 in}
Limit: 0.88 mm {0.0346 in}
<Caution>
Check for the entire circumference of the gear.
C257043
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–25

<Reference>
• When the result is below the limit, replace the synchronizer ring
No. 2 and counter shaft 6th gear.
• Use recommended or substitute products for manual
transmission oil. (Refer to PP-8)
(2) Apply manual transmission oil to the taper cone portion of the
counter shaft 6th gear, and with the synchronizer ring No. 2 tightly
fit by pressing by hand, check there is no slippage in the
circumferential direction. MT
<Reference>
• When slippage occurs, replace the synchronizer ring No. 2 and
counter shaft 6th gear.
• Use recommended or substitute products for manual
transmission oil. (Refer to PP-8)
C257044

9. Check the counter shaft 6th gear.

(1) Measure the inner diameter of counter shaft 6th gear.
Standard value: 34.015 to 34.040 mm {1.33917 to 1.34016 in}
Limit: 34.040 mm {1.34016 in}
<Reference>
When the result exceeds the limit, replace the counter shaft 6th
gear.

C257045

10. Check the transmission hub sleeve No. 4.

(1) Check the spline gear edge of the transmission hub sleeve No. 4
for wear.
<Reference>
When wear is present, replace the transmission hub sleeve No. 4.
(2) Install the transmission hub sleeve No. 4 to the transmission clutch
hub No. 4, and check for smooth sliding.
<Reference>
When sliding is not smooth, replace the transmission hub sleeve
C257046 No. 4 and transmission clutch hub No. 4.

11. Check the transmission hub sleeve No. 4 clearance.

(1) Measure the thickness of the claw of gear shift fork No. 4.
Standard value: 7.9 to 8.0 mm {0.311 to 0.315 in}
Limit: 7.9 mm {0.311 in}
<Reference>
When the result is below the limit, replace the gear shift fork No. 4.
(2) Measure the groove of transmission hub sleeve No. 4, and
calculate the clearance between the gear shift fork No. 4.
Standard value: 0.15 to 0.35 mm {0.00590 to 0.0138 in}
C257047 Limit: 0.35 mm {0.0138 in}
<Reference>
When the result exceeds the limit, replace the gear shift fork No. 4
and transmission hub sleeve No. 4 as a set.
 MT–26 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

12. Check the reverse idler gear.

(1) Measure the inner diameter of reverse idler gear.
Standard value: 22.04 to 22.061 mm {0.86771 to 0.86854 in}
Limit: 22.061 mm {0.86854 in}
<Reference>
When the result exceeds the limit, replace the reverse idler gear.

MT
C257112

13. Check the reverse idler gear shaft.

(1) Check the outer diameter of reverse idler gear shaft.
Standard value: 21.979 to 22.000 mm {0.86531 to 0.86614 in}
Limit: 21.979 mm {0.86531 in}
<Reference>
When the result is below the limit, replace the reverse idler gear
shaft.

C257113

ASSEMBLY
1. Install the gear shift fork shaft No. 3.
(1) Install the gear shift fork shaft No. 3 to the gear shift fork No. 3,
using a new bolt.
Standard value: T=19.5N•m {198.8kgf•cm} {14.4ft•lbf}

C260035

2. Install the gear shift fork shaft No. 1.

(1) Install the gear shift fork shaft No. 1 to the gear shift fork No. 1,
using a new bolt.
Standard value: T=19.5N•m {198.8kgf•cm} {14.4ft•lbf}

C258440
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–27

(2) Install a new shaft snap ring.

MT
C258441

(3) Install the gear shift fork shaft No. 1 and gear shift fork No. 1 as a
unit to the gear shift fork shaft No. 3 and gear shift fork No. 3.

C258442

(4) Install a new shaft snap ring.

C260036

3. Install the gear shift fork shaft No. 2.

(1) Install the gear shift fork shaft No. 2 to the gear shift fork No. 2,
using a new bolt.
Standard value: T=19.5N•m {198.8kgf•cm} {14.4ft•lbf}

C258436
 MT–28 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

(2) Install a new shaft snap ring.

MT
C258443

4. Install the transmission front bearing retainer oil seal.

(1) Using the SST, install a new transmission front bearing retainer oil
seal.
SST 09950-60010 (09951-00420), 09950-70010
556 (09951-07100)
Standard value: 11.1 to 11.9 mm {0.437 to 0.469 in}
(From the bearing retainer FR end face)
<Caution>
• Be careful not to damage the lip face of the transmission front
bearing retainer oil seal.
C257041J01
• Be careful not to damage the bearing retainer FR.
(2) Apply manual transmission oil to the lip face of the transmission
front bearing retainer oil seal.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
5. Install the reverse idler gear shaft.
(1) Apply manual transmission oil to the reverse idler gear shaft, and
install it to the reverse idler gear.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)

C257111

6. Install the input shaft.

(1) Apply manual transmission oil to the needle roller bearing of input
shaft, and install the input shaft to the output shaft.
<Reference>
Use recommended or substitute products for manual transmission oil.
(Refer to PP-8)

C258452

7. Install the counter shaft.

(1) Install the input shaft, output shaft, counter shaft, reverse idler gear, reverse idler gear shaft, gear shift fork shaft No. 1,
gear shift fork shaft No. 2, and gear shift fork shaft No. 3 as a unit to the clutch housing.
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–29

Output shaft ASSY Gear shift fork shaft No. 1 & No. 3

Gear shift fork shaft No. 2

Input shaft ASSY

Counter gear ASSY

MT

Reverse idler gear

MT-02862

(2) Using a new gasket, temporarily tighten a new bolt for the reverse
idler gear shaft. (The clutch housing side)

C258433
 MT–30 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

(3) Using the SST, install two new shaft snap rings.
SST 499895400
<Reference>
Install the shaft snap rings on the input shaft side and counter
shaft side both.
556

MT

556

MT-02861

8. Install the bearing retainer FR.

(1) Apply three bond 1281 or equivalent to the bearing retainer FR
continuously in a bead form as shown in the figure.
Captions in illustration

Three bond 1281 or equivalent

<Caution>
Install within 10 min. after applying the seal gasket.
C257042

(2) Apply ADHESIVE 1344 or equivalent to two to three pitches from

the end of a new bolt.
Captions in illustration
*1 ADHESIVE 1344 or equivalent


P000601J03

(3) Install the bearing retainer FR using the seven bolts.

Standard value: T=17N•m {173kgf•cm} {12.5ft•lbf}
<Caution>
Be careful not to damage the lip face of the bearing retainer FR oil
seal.

C258431
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–31

9. Install the oil receiver pipe.

(1) Install the oil receiver pipe.
<Caution>
Make sure that the oil receiver pipe end is not loosely fitted, or coming
off.

MT
C258430

10. Install the transmission case.

(1) Apply three bond 1281 or equivalent to the transmission case
continuously in a bead form as shown in the figure.
Captions in illustration

Three bond 1281 or equivalent

<Caution>
Install within 10 min. after applying the seal gasket.
C257309

(2) Check the position of knock pin, and install the transmission case.

C258447

(3) Apply ADHESIVE 1324 or equivalent to two to three pitches from

the end of a new bolt.
Captions in illustration
*1 ADHESIVE 1324 or equivalent


P000601J03
 MT–32 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

(4) Install the transmission case and clamp using the nine bolts.
Captions in illustration
*1 Clamp

Standard value: T=29N•m {296kgf•cm} {21.4ft•lbf}


MT
C258428J01

(5) Using a new gasket, tighten a new securing bolt for the reverse
idler gear shaft. (The transmission case side)
Standard value: T=28N•m {286kgf•cm} {20.7ft•lbf}

C258427

(6) Fully tighten the securing bolt for the reverse idler gear shaft. (The
clutch housing side)
Standard value: T=28N•m {286kgf•cm} {20.7ft•lbf}

C258444

(7) Using the SST, install a new shaft snap ring.

SST 499895400

556

MT-02860
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–33

11. Install the bearing retainer RR.

(1) Install the shift arm pivot to the bearing retainer RR.

MT
C258425

(2) Apply ADHESIVE 1324 or equivalent to two to three pitches from

the end of a new bolt.
Captions in illustration
*1 ADHESIVE 1324 or equivalent


P000601J03

(3) Install the bearing retainer RR using the four TORX bolts.
Standard value: T=30N•m {306kgf•cm} {22.1ft•lbf}

C258424

12. Install the 6th gear thrust washer.

(1) Install the straight pin to the counter shaft.

C258420
 MT–34 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

(2) Apply manual transmission oil to the 6th gear thrust washer, and
install it to the counter shaft.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)

MT
C258419

13. Install the needle roller bearing.

(1) Apply manual transmission oil to the needle roller bearing, and
install it to the counter shaft.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)

C258418

14. Install the counter shaft 6th gear.

(1) Apply manual transmission oil to the counter shaft 6th gear, and
install it to the counter shaft.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)

C257342

15. Install the synchronizer ring No. 2.

(1) Apply manual transmission oil to the synchronizer ring No. 2, and
install it to the counter shaft.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)

C257341

16. Install the transmission hub sleeve No. 4.

(1) Apply manual transmission oil to the sliding surface of
transmission clutch hub No. 4.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
(2) First install the transmission hub sleeve No. 4 to the transmission
clutch hub No. 4, then install the three synchromesh shifting key
No. 1s and the three synchromesh shifting key spring No. 1s as a
C257048 unit, and lastly install the three balls.
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–35

<Reference>
• Install the balls, while compressing the synchromesh shifting
key spring No. 1s.
• After finishing the installation, let the synchromesh shifting key
spring No. 1s sit for a while.
(3) Install a new hole snap ring.

MT

C259267

17. Install the transmission clutch hub No. 4.

(1) Using the SST, install the transmission clutch hub No. 4,
transmission hub sleeve No. 4, and gear shift fork No. 4 as a unit.
SST 18682AA000

556

MT-02863

18. Install the shaft snap ring.

(1) Select a shaft snap ring so that the thrust gap between the
transmission clutch hub No. 4 and snap ring is within the standard
value.
Standard value: 0 to 0.1 mm {0 to 0.00394 in}
<Reference>
Select a shaft snap ring with the maximum thickness possible.
Shaft snap ring type
Item number Thickness (mm {in}) Identification

C257312
17005AA230 2.80 {0.110} A
17005AA240 2.85 {0.11220} B
17005AA250 2.90 {0.11417} C
17005AA260 2.95 {0.11614} D
17005AA270 3.00 {0.11811} E
17005AA280 3.05 {0.12007} F

(2) Install a new shaft snap ring to the counter shaft.

C257313
 MT–36 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

19. Install the gear shift head No. 2.

(1) Install the gear shift head No. 2 to the gear shift fork shaft No. 2.
(2) Install a new slotted spring pin to the gear shift fork shaft No. 2.
<Caution>
Be careful not to hammer in the pin excessively.
Standard value: 0 mm {0 in}
(From the gear shift head No. 2 end face)

MT
C258421

20. Install the 5th shift head.

(1) Install the compression spring to the 5th shift head, and while
pushing the ball with a pin punch 5, install the 5th shift head to the
gear shift fork shaft No. 3.

C257314

(2) Install the washer.

C258644

(3) Install a new shaft snap ring to the gear shift fork shaft No. 3.

C258645
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–37

21. Install the gear shift fork shaft No. 3.

(1) Insert the gear shift fork shaft No. 3 in the direction shown in the
figure, install the ball and compression spring, and then tighten a
new head straight screw plug.
Standard value: T=19N•m {194kgf•cm} {14ft•lbf}

MT
C258816

22. Install the shift arm.

(1) Install the shift arm to the shift arm pivot.

C257331

(2) Install a new E-ring to the shift arm pivot.

C258445

23. Install the gear shift fork shaft No. 2.

(1) Install the two balls to the gear shift fork shaft No. 3.

C258451
 MT–38 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

(2) Insert the gear shift fork shaft No. 2 in the direction shown in the
figure, install the ball and compression spring, and then tighten two
new head straight screw plugs.
Standard value: T=19N•m {194kgf•cm} {14ft•lbf}

MT

C257316

(3) Install a new bolt to the gear shift fork shaft No. 2.
Standard value: T=19.5N•m {198.8kgf•cm} {14.4ft•lbf}

MT-03024

24. Install the gear shift head No. 3.

(1) Install the gear shift head No. 3 to the gear shift fork shaft No. 3.
<Reference>
Install the gear shift head No. 3 while rotating so that the shift arm
fits in the groove.
(2) Install a new slotted spring pin to the gear shift fork shaft No. 3.
<Caution>
Be careful not to hammer in the pin excessively.
Standard value: 0 mm {0 in}
(From the gear shift head No. 3 end face)
C258423

25. Install the gear shift head No. 1.

(1) Install the gear shift head No. 1 to the gear shift fork shaft No. 1.
(2) Install a new slotted spring pin to the gear shift fork shaft No. 1.
<Caution>
Be careful not to hammer in the pin excessively.
Standard value: 0 mm {0 in}
(From the gear shift head No. 1 end face)

C258422
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–39

26. Install the shift inner lever FR.

(1) Apply ADHESIVE 1324 or equivalent to two to three pitches from
the end of a new bolt.
Captions in illustration
*1 ADHESIVE 1324 or equivalent

 MT
P000601J03

(2) Install the shift inner lever FR to the shift shaft, using a new bolt.
Standard value: T=33.3N•m {339.5kgf•cm} {24.6ft•lbf}

C257329

27. Install the shift inner lock block No. 1.

(1) Install the shift inner lock block No. 1 to the shift shaft.

C262544

28. Install the shift shaft.

(1) Slide the shift shaft and shift inner lock block No. 1 to install.

C258446

29. Install the extension housing oil receiver pipe No. 1.

(1) Install the straight pin.

C257037
 MT–40 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

(2) Install the extension housing oil receiver pipe No. 1 and stopper
plate, using a new bolt.
Standard value: T=8.5N•m {87kgf•cm} {6.3ft•lbf}
<Reference>
Check that the end of oil receiver pipe No. 1 is inserted into the
groove.

MT
C257036

30. Install the extension housing oil receiver pipe No. 2.

(1) Install the extension housing oil receiver pipe No. 2.

C257034

31. Install the transmission extension housing oil seal.

(1) Apply manual transmission oil to the lip face of a new transmission
556 extension housing oil seal.
<Reference>
556 Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
(2) Using the SST, install a new transmission extension housing oil
seal.
SST 09325-20010
C257319J01 Standard value: 0.1 to 1.1 mm {0.00394 to 0.0433 in}
(From the transmission extension housing
SUB-ASSY (MTM) end face)
<Caution>
Be careful not to damage the lip face of the transmission extension
housing oil seal.
32. Install the extension housing dust deflector.
(1) Using the SST, install a new extension housing dust deflector.
SST 09950-60020 (09951-00750), 09950-70010
(09951-07100)
556 <Reference>
Make sure to hammer in until the end contacts the transmission
extension housing SUB-ASSY (MTM).

C257320J01
 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–41

33. Install the extension housing rear oil seal.

(1) Using the SST, install a new extension housing rear oil seal.
SST 18657AA040
Standard value: 1.0 to 2.0 mm {0.0394 to 0.0787 in}
(From the transmission extension housing
556 556 SUB-ASSY (MTM) end face)
<Caution>
Be careful not to damage the lip face of the extension housing rear oil
seal.
(2) Apply manual transmission oil to the lip face of the extension
MT
MT-02864 housing rear oil seal.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
34. Install the transmission extension housing SUB-ASSY (MTM).
(1) Apply three bond 1281 or equivalent to the transmission extension
housing SUB-ASSY (MTM) continuously in a bead form as shown
in the figure.
Captions in illustration

Three bond 1281 or equivalent

<Caution>
C257322 • Install within 10 min. after applying the seal gasket.
• Make sure to install the transmission extension housing SUB-
ASSY (MTM) with the shift position in neutral.
(2) Install the transmission extension housing SUB-ASSY (MTM) and
clamp, using eight new bolts.
Captions in illustration
*1 Clamp

Standard value: T=29N•m {296kgf•cm} {21.4ft•lbf}

<Caution>
Make sure to align the knock pin with the knock pin hole.


C257030J01

(3) Install a new bolt.

Standard value: T=31N•m {316kgf•cm} {22.9ft•lbf}

C257029
 MT–42 Manual transmission/transaxle - MANUAL TRANSMISSION ASSY

35. Install the holder.

(1) Install a new holder, compression spring and lock ball pin.
Standard value: T=39.2N•m {399.7kgf•cm} {28.9ft•lbf}

MT
C257028

36. Install the lock ball pin.

(1) Install a new head straight screw plug, compression spring and
lock ball pin.
Standard value: T=24.5N•m {249.8kgf•cm} {18.1ft•lbf}

C257027

37. Install the wiring harness clamp bracket.

(1) Install the wiring harness clamp bracket using a new bolt.
Standard value: T=7.0N•m {71kgf•cm} {5.2ft•lbf}

C257298

38. Install the neutral switch.

(1) Install the neutral switch and a new gasket.
Standard value: T=32.3N•m {329.4kgf•cm} {23.8ft•lbf}
<Caution>
When a torque wrench extended with a union nut wrench is used, the
actual tightening torque becomes over-torque if the part is tightened
until the torque wrench reading reaches the specified tightening
torque.

C257025

(2) Engage the clamp and connect the neutral switch wire.

C257024
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT–43

39. Install the back-up light switch ASSY.

(1) Install the back-up light switch ASSY and a new gasket.
Standard value: T=32.3N•m {329.4kgf•cm} {23.8ft•lbf}
<Caution>
When a torque wrench extended with a union nut wrench is used, the
actual tightening torque becomes over-torque if the part is tightened
until the torque wrench reading reaches the specified tightening
torque.

MT
C257023

(2) With the slack of the harness kept only in the front, engage the
three clamps in order from the rearmost, and connect the back-up
light switch ASSY wire and neutral switch wire.

MT-02926

40. Install the clutch release fork support.

(1) Install the clutch release fork support to the clutch housing.
Standard value: T=16N•m {163kgf•cm} {11.8ft•lbf}

C258508

41. Install the manual transmission drain plug.

(1) Install the manual transmission drain plug to the transmission
case, using a new gasket.
Standard value: T=37N•m {377kgf•cm} {27.3ft•lbf}

C257297

42. Install the manual transmission filler plug.

(1) Install the manual transmission filler plug to the transmission case,
using a new gasket.
Standard value: T=37N•m {377kgf•cm} {27.3ft•lbf}

C257296
 MT–44 Manual transmission/transaxle - INPUT SHAFT ASSY

INPUT SHAFT ASSY

Drive train
Manual transmission/transaxle

EXPLODED VIEW

Needle roller bearing

MT
Synchronizer ring No. 2

Input shaft bearing FR

Input shaft

Shaft snap ring

Non-reusable parts

Manual transmission oil

NICHIMOLY N-130 or equivalent

MT-03009

<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)

DISASSEMBLY
1. Check the needle roller bearing.
(1) Install the input shaft to the output shaft, and check the needle
roller bearing.
Specification: There is no abnormal feel in the part movement,
binds, abnormal noise or loose fit.
<Reference>
If defective, replace the needle roller bearing.

C257051
Manual transmission/transaxle - INPUT SHAFT ASSY
MT–45

2. Check the radial clearance.

(1) Install the input shaft to the output shaft, and check the radial
clearance.
Standard value: 0.029 to 0.072 mm {0.00114 to 0.00283 in}
Limit: 0.072 mm {0.00283 in}
<Reference>
When the result exceeds the limit, replace the input shaft, needle
roller bearing, and output shaft.
MT
C257052

3. Check the input shaft bearing FR.

(1) Check the input shaft bearing FR.
Specification: There is no abnormal feel in the part movement,
binds, abnormal noise or loose fit.
<Reference>
If defective, replace the input shaft bearing FR.

C257050

4. Remove the needle roller bearing.

(1) Remove the needle roller bearing from the input shaft.

C258448

5. Remove the synchronizer ring No. 2.

(1) Remove the synchronizer ring No. 2 from the input shaft.

C258449

6. Remove the input shaft bearing FR.

(1) Remove the shaft snap ring from the input shaft.
<Caution>
• Use a cloth to prevent the shaft snap ring from flying out.
• Check the direction of the part.

C257053
 MT–46 Manual transmission/transaxle - INPUT SHAFT ASSY

(2) Using the SST, remove the input shaft bearing FR from the input
shaft.
SST 899714110
<Caution>
556
Apply press pressure to the inner race of input shaft bearing FR to
remove the input shaft and bearing FR.

MT
MT-02866

INSPECTION
1. Check the synchronizer ring No. 2.
(1) Apply manual transmission oil to the cone portion of the third gear,
and with the synchronizer ring No. 2 tightly fit by pressing by hand,
check the clearance between the synchronizer ring No. 2 and third
gear.
Standard value: 0.8 to 1.6 mm {0.0314 to 0.0629 in}
Limit: 0.8 mm {0.0314 in}
<Caution>
Check for the entire circumference of the gear.
<Reference>
C257058
• When the result is below the limit, replace the synchronizer ring
No. 2.
• Use recommended or substitute products for manual
transmission oil. (Refer to PP-8)
(2) Apply manual transmission oil to the cone portion of the third gear,
and with the synchronizer ring No. 2 tightly fit by pressing by hand,
check there is no slippage in the circumferential direction.
<Reference>
• When slippage occurs, replace the synchronizer ring No. 2.
• Use recommended or substitute products for manual
transmission oil. (Refer to PP-8)

C257057

ASSEMBLY
1. Install the input shaft bearing FR.
(1) Using the SST, install the input shaft bearing FR to the input shaft.
SST 499277000, 398477703
556 <Caution>
Hold and press-fit the inner race of the input shaft bearing FR.

MT-02867
Manual transmission/transaxle - INPUT SHAFT ASSY
MT–47

(2) Select a shaft snap ring so that the thrust gap between the input
shaft bearing FR and shaft snap ring is within the standard value.
Standard value: 0 mm {0 in}
Limit: 0.1 mm {0.00394 in}
Shaft snap ring type
Item number Thickness (mm {in}) Identification mark
17005AA460 1.95 {0.07677} 0
17005AA470 2.00 {0.07874} 1
17005AA480 2.05 {0.08070} 2 MT
17005AA490 2.10 {0.08267} 3
17005AA500 2.15 {0.08464} 4
17005AA510 2.20 {0.08661} 5

(3) Install a new shaft snap ring to the input shaft.

C257056

2. Install the synchronizer ring No. 2.

(1) Apply manual transmission oil to the synchronizer ring No. 2, and
install it to the input shaft.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)

C258449

3. Install the needle roller bearing.

(1) Apply manual transmission oil to the needle roller bearing, and
install it to the input shaft.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)

C258448
 MT–48 Manual transmission/transaxle - OUTPUT SHAFT ASSY

OUTPUT SHAFT ASSY

Drive train
Manual transmission/transaxle

EXPLODED VIEW

Ball

Reverse gear bearing

MT Synchromesh shifting key spring No. 1

Synchromesh shifting key No. 1

[ [ [
Reverse gear

Synchronizer ring No. 3

Transmission hub sleeve No. 3

Transmission clutch hub No. 3

Shaft snap ring

Output shaft

Non-reusable parts

Manual transmission oil

MT-03010
<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
 Manual transmission/transaxle - OUTPUT SHAFT ASSY
MT–49

Synchromesh shifting key No. 1

Synchromesh shifting key spring No. 1

Ball
MT
Synchronizer ring set No. 1

[ [ [

Transmission clutch hub No. 1

Transmission hub sleeve No. 1

Second gear

Second gear needle roller bearing

Output shaft bearing RR

First gear bearing inner race

First gear

Sixth gear

Shaft snap ring

First gear needle roller bearing

First shift restrict ball

Synchronizer ring set No. 1

Non-reusable parts

Manual transmission oil

MT-03011
 MT–50 Manual transmission/transaxle - OUTPUT SHAFT ASSY

<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)

DISASSEMBLY
1. Check the thrust clearance.
(1) Check the thrust clearance of the first gear, second gear and
reverse gear.
Captions in illustration
MT *a Reverse gear thrust clearance
*b Second gear thrust clearance
*c First gear thrust clearance

Standard value
C D E Gear Standard value (mm {in}) Limit (mm {in})
C257060J01
0.15 to 0.40
First gear 0.40 {0.0157}
{0.00590 to 0.0157}
0.10 to 0.45
Second gear 0.45 {0.0177}
{0.00394 to 0.0177}
0.10 to 0.45
Reverse gear 0.45 {0.0177}
{0.00394 to 0.0177}

<Reference>
When the result exceeds the limit, replace the respective gear,
transmission clutch hub, needle roller bearing, and output shaft.
2. Check the radial clearance.
(1) Check the radial clearance of the first gear, second gear and
reverse gear.
Captions in illustration
*a Reverse gear radial clearance
*b Second gear radial clearance
*c First gear radial clearance

Standard value
C D E Gear Standard value (mm {in}) Limit (mm {in})
C257061J01
0.015 to 0.066
First gear 0.066 {0.00260}
{0.000590 to 0.00260}
0.015 to 0.066
Second gear 0.066 {0.00260}
{0.000590 to 0.00260}
0.015 to 0.066
Reverse gear 0.066 {0.00260}
{0.000590 to 0.00260}

<Reference>
When the result exceeds the limit, replace the respective gear,
needle roller bearing, and output shaft.
3. Remove the reverse gear.
(1) Using the SST, remove the shaft snap ring.
SST 499895400

556

MT-02870
 Manual transmission/transaxle - OUTPUT SHAFT ASSY
MT–51

(2) Using the SST, remove the transmission clutch hub No. 3,
transmission hub sleeve No. 3, reverse gear, synchronizer ring No.
3, and reverse gear bearing from the output shaft.
SST 899714110, 899864100
556 <Caution>
Check the direction of the part.

MT
MT-02871

4. Remove the transmission hub sleeve No. 3.

(1) Remove the transmission hub sleeve No. 3, and remove the three
synchromesh shifting key No. 1s, three synchromesh shifting key
spring No. 1s, and three balls from the transmission clutch hub
No. 3.
<Caution>
• Use a cloth to prevent the synchromesh shifting key No. 1s,
synchromesh shifting key spring No. 1s, and balls from flying out.
• Do not deform the synchromesh shifting key spring No. 1s.
<Reference>
C257064
Perform the procedure without moving the positions of the
transmission clutch hub No. 3 and synchromesh shifting key
No. 1s.
5. Remove the sixth gear.
(1) Remove the shaft snap ring.
<Caution>
Use a cloth to prevent the shaft snap ring from flying out.

C257065

(2) Using the SST, remove the sixth gear.

SST 09950-00020

556

C257066J01
 MT–52 Manual transmission/transaxle - OUTPUT SHAFT ASSY

6. Remove the first gear.

(1) Using the SST, remove the output shaft bearing RR, first gear, first
bearing inner race, first gear needle roller bearing, and first shift
restrict ball.
556 SST 18722AA000
<Caution>
Check the direction of the part.

MT
MT-02873

7. Remove the second gear.

(1) Using the SST, remove the second gear, transmission clutch hub
No. 1, transmission hub sleeve No. 1, and second gear needle
roller bearing from the output shaft.
SST 18722AA000
<Caution>
556 Check the direction of the part.

MT-02874

8. Remove the synchronizer ring set No. 1.

(1) Remove the two sets of the synchronizer ring set No. 1.
9. Remove the transmission hub sleeve No. 1.
(1) Remove the transmission hub sleeve No. 1, and remove the three
synchromesh shifting key No. 1s, three synchromesh shifting key
spring No. 1s, and three balls from the transmission clutch hub
No. 1.
<Caution>
• Use a cloth to prevent the synchromesh shifting key No. 1s,
synchromesh shifting key spring No. 1s, and balls from flying out.
• Do not deform the synchromesh shifting key spring No. 1s.
<Reference>
C257070
Perform the procedure without moving the positions of the
transmission clutch hub No. 1 and synchromesh shifting key
No. 1s.

INSPECTION
1. Check the output shaft bearing RR.
(1) Check the output shaft bearing RR.
Specification: There is no abnormal feel in the part movement,
binds, abnormal noise or loose fit.
<Reference>
If defective, replace the output shaft bearing RR.

C257071
 Manual transmission/transaxle - OUTPUT SHAFT ASSY
MT–53

2. Check the output shaft.

(1) Check the outer diameter of each portion.
Standard value
Check position Standard value (mm {in}) Limit (mm {in})
31.984 to 32.000
A 31.984 {1.25921}
{1.25921 to 1.25984}
42.984 to 43.000
B 42.984 {1.69228}
# {1.69228 to 1.69291}
$ %
C
40.984 to 41.000
{1.61354 to 1.61417}
40.984 {1.61354} MT
C257074J01

<Reference>
When the result is below the limit, replace the output shaft.
(2) Check the runout at the positions shown in the figure.
Standard value: 0.03 mm {0.00118 in} or less
<Reference>
When the result is not within the standard value, replace the output
shaft.

C257075

3. Check the reverse gear.

(1) Measure the inner diameter of reverse gear.
Standard value: 47.015 to 47.040 mm {1.85098 to 1.85197 in}
Limit: 47.040 mm {1.85197 in}
<Reference>
When the result exceeds the limit, replace the reverse gear.

C257077

4. Check the first gear.

(1) Measure the inner diameter of first gear.
Standard value: 46.315 to 46.340 mm {1.82425 to 1.82441 in}
Limit: 46.340 mm {1.82441 in}
<Reference>
When the result exceeds the limit, replace the first gear.

C257077
 MT–54 Manual transmission/transaxle - OUTPUT SHAFT ASSY

5. Check the second gear.

(1) Measure the inner diameter of second gear.
Standard value: 49.015 to 49.040 mm {1.92972 to 1.93071 in}
Limit: 49.040 mm {1.93071 in}
<Reference>
When the result exceeds the limit, replace the second gear.

MT
C257077

6. Check the first gear bearing inner race.

(1) Check the outer diameter of first gear bearing inner race.
Standard value: 40.284 to 40.300 mm {1.58598 to 1.58661 in}
Limit: 40.284 mm {1.58598 in}
<Reference>
When the result is below the limit, replace the first gear bearing
inner race.

C257076

7. Check the transmission hub sleeve No. 1 clearance.

(1) Measure the thickness of the claw of gear shift fork No. 1.
Standard value: 7.9 to 8.0 mm {0.311 to 0.315 in}
Limit: 7.9 mm {0.311 in}
<Reference>
When the result is below the limit, replace the gear shift fork No. 1.
(2) Measure the groove of transmission hub sleeve No. 1, and
calculate the clearance between the gear shift fork No. 1.
Standard value: 0.15 to 0.35 mm {0.00590 to 0.0138 in}
C257047 Limit: 0.35 mm {0.0138 in}
<Reference>
When the result exceeds the limit, replace the gear shift fork No. 1
and transmission hub sleeve No. 1 as a set.
8. Check the transmission hub sleeve No. 3 clearance.
(1) Measure the thickness of the claw of gear shift fork No. 3.
Standard value: 7.9 to 8.0 mm {0.311 to 0.315 in}
Limit: 7.9 mm {0.311 in}
<Reference>
When the result is below the limit, replace the gear shift fork No. 3.
(2) Measure the groove of transmission hub sleeve No. 3, and
calculate the clearance between the gear shift fork No. 3.
Standard value: 0.15 to 0.35 mm {0.00590 to 0.0138 in}
C257047 Limit: 0.35 mm {0.0138 in}
<Reference>
When the result exceeds the limit, replace the gear shift fork No. 3
and transmission hub sleeve No. 3 as a set.
 Manual transmission/transaxle - OUTPUT SHAFT ASSY
MT–55

9. Check the transmission hub sleeve No. 1.

(1) Check the spline gear edge of the transmission hub sleeve No. 1
for wear.
<Reference>
When wear is present, replace the transmission hub sleeve No. 1.
(2) Install the transmission hub sleeve No. 1 to the transmission clutch
hub No. 1, and check for smooth sliding.
<Reference>
When sliding is not smooth, replace the transmission hub sleeve MT
C257079 No. 1 and transmission clutch hub No. 1.

10. Check the transmission hub sleeve No. 3.

(1) Check the spline gear edge of the transmission hub sleeve No. 3
for wear.
<Reference>
When wear is present, replace the transmission hub sleeve No. 3.
(2) Install the transmission hub sleeve No. 3 to the transmission clutch
hub No. 3, and check for smooth sliding.
<Reference>
When sliding is not smooth, replace the transmission hub sleeve
C257080 No. 3 and transmission clutch hub No. 3.

11. Check the synchronizer ring set No. 1. (For the first gear)
(1) Apply manual transmission oil to the taper cone portion of the first gear and synchronizer ring set No. 1, and with the
synchronizer ring set No. 1 tightly fit by pressing by hand, check the clearance between the synchronizer ring set No. 1
and first gear.

C D E

C257073J01

Captions in illustration
*a Inner *b Middle
*c Outer - -

Standard value
Measurement position Standard value (mm {in})
Inner 0.48 to 1.12 {0.0189 to 0.0441}
Middle 0.38 to 1.22 {0.0150 to 0.0480}
Outer 0.8 to 1.8 {0.0315 to 0.0709}

<Caution>
Check for the entire circumference of the gear.
<Reference>
• When the result is not within the standard value, replace the synchronizer ring set No. 1.
• Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
 MT–56 Manual transmission/transaxle - OUTPUT SHAFT ASSY

(2) Apply manual transmission oil to the taper cone portion of the first
gear, and with the synchronizer ring set No. 1 tightly fit by pressing
by hand, check there is no slippage in the circumferential direction.
<Reference>
• When slippage occurs, replace the synchronizer ring set No. 1.
• Use recommended or substitute products for manual
transmission oil. (Refer to PP-8)

MT
C257072

12. Check the synchronizer ring set No. 1. (For the second gear)
(1) Apply manual transmission oil to the taper cone portion of the second gear and synchronizer ring set No. 1, and with the
synchronizer ring set No. 1 tightly fit by pressing by hand, check the clearance between the synchronizer ring set No. 1
and second gear.

C D E

C257073J01

Captions in illustration
*a Inner *b Middle
*c Outer - -

Standard value
Measurement position Standard value (mm {in})
Inner 0.48 to 1.12 {0.0189 to 0.0441}
Middle 0.38 to 1.22 {0.0150 to 0.0480}
Outer 0.8 to 1.8 {0.0315 to 0.0709}

<Caution>
Check for the entire circumference of the gear.
<Reference>
• When the result is not within the standard value, replace the synchronizer ring set No. 1.
• Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
(2) Apply manual transmission oil to the taper cone portion of the
second gear, and with the synchronizer ring set No. 1 tightly fit by
pressing by hand, check there is no slippage in the circumferential
direction.
<Reference>
• When slippage occurs, replace the synchronizer ring set No. 1.
• Use recommended or substitute products for manual
transmission oil. (Refer to PP-8)

C257072
 Manual transmission/transaxle - OUTPUT SHAFT ASSY
MT–57

ASSEMBLY
1. Install the transmission hub sleeve No. 1.
(1) Apply manual transmission oil to the sliding surface of
transmission clutch hub No. 1.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
(2) First install the transmission hub sleeve No. 1 to the transmission
clutch hub No. 1, then install the three synchromesh shifting key MT
No. 1s and the three synchromesh shifting key spring No. 1s as a
C257081 unit, and lastly install the three balls.
<Reference>
• Install the balls, while compressing the synchromesh shifting
key spring No. 1s.
• After finishing the installation, let the synchromesh shifting key
spring No. 1s sit for a while.
2. Install the transmission hub sleeve No. 3.
(1) Apply manual transmission oil to the sliding surface of
transmission clutch hub No. 3.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
(2) First install the transmission hub sleeve No. 3 to the transmission
clutch hub No. 3, then install the three synchromesh shifting key
No. 1s and the three synchromesh shifting key spring No. 1s as a
C257081 unit, and lastly install the three balls.
<Reference>
• Install the balls, while compressing the synchromesh shifting
key spring No. 1s.
• After finishing the installation, let the synchromesh shifting key
spring No. 1s sit for a while.
3. Install the reverse gear.
(1) Apply manual transmission oil to the installation portion of the
output shaft, reverse gear bearing, and inner surface and taper
cone portion of reverse gear.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
(2) Install the reverse gear bearing and reverse gear to the output
shaft.
C257082

4. Install the transmission clutch hub No. 3.

(1) Install the synchronizer ring No. 3 to the reverse gear.
(2) Using the SST, install the transmission clutch hub No. 3.
556 SST 499277100, 398477703, 899714110
<Reference>
• After installing the transmission clutch hub No. 3, make sure
that the synchronizer ring moves in the thrust direction.
• Press the transmission clutch hub No. 3 until it contacts the
output shaft.
• Align the transmission clutch hub No. 3 and synchronizer ring
MT-02875
No. 3.
 MT–58 Manual transmission/transaxle - OUTPUT SHAFT ASSY

5. Install the shaft snap ring. (Transmission clutch hub No. 3)

(1) Select a shaft snap ring so that the thrust gap between the
transmission clutch hub No. 3 and shaft snap ring is within the
standard value.
Standard value: 0 to 0.1 mm {0 to 0.00394 in}
<Reference>
Select a shaft snap ring with the maximum thickness possible.
Shaft snap ring type
MT Item number Thickness (mm {in}) Identification mark
17005AA520 1.80 {0.07086} A
556 17005AA530 1.85 {0.07283} B
17005AA540 1.90 {0.07480} C
17005AA550 1.95 {0.07677} D
17005AA560 2.00 {0.07874} E
17005AA570 2.05 {0.08070} F

(2) Using the SST, install a new shaft snap ring to the output shaft.
SST 499895400

MT-02876

6. Install the second gear.

(1) Apply manual transmission oil to the installation portion of the
output shaft, second gear needle roller bearing, and inner surface
and taper cone portion of second gear.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
(2) Install the second gear needle roller bearing and second gear to
the output shaft.
C257085

7. Install the transmission clutch hub No. 1.

(1) Install the synchronizer ring set No. 1 (for the second gear) in the
position shown in the figure.
<Caution>
• Align the claw of middle ring with the gear groove.
• Align the claw of inner ring with the outer ring groove.

C257086
 Manual transmission/transaxle - OUTPUT SHAFT ASSY
MT–59

(2) Using the SST, install the transmission clutch hub No. 1.
SST 499277100, 899714110, 398477703,
499277000
<Reference>
556 • After installing the transmission clutch hub No. 1, make sure
that the synchronizer ring set No. 1 (for the second gear)
moves in the thrust direction.
• Press the transmission clutch hub No. 1 until it contacts the
output shaft. MT
MT-02877

(3) Install the synchronizer ring set No. 1 (for the first gear) in the
position shown in the figure.
<Caution>
• Align the protruded section of outer ring with the hub groove.
• Align the claw of inner ring with the outer ring groove.

C257088

8. Install the first gear.

(1) Apply manual transmission oil to the installation portion of the
output shaft, needle roller bearing, bearing inner race, and inner

surface and taper cone portion of first gear.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
(2) Install the first shift restrict ball, first gear, first gear needle roller
bearing, and first gear bearing inner race to the output shaft.
C257089J01 <Caution>
Align the claw of middle ring with the gear groove.
Captions in illustration
*1 First shift restrict ball

9. Install the output shaft bearing RR.

(1) Using the SST, install the output shaft bearing RR.
SST 499277100, 899714110, 398477703,
499277000
556 <Reference>
Press the output shaft bearing RR until it contacts the first gear
bearing inner race.

MT-02878
 MT–60 Manual transmission/transaxle - OUTPUT SHAFT ASSY

10. Install the sixth gear.

(1) Using the SST, install the sixth gear.
SST 499277100, 899714110, 398477703,
499277000
<Reference>
Press the sixth gear until it contacts the output shaft bearing RR.
556

MT
MT-02879

11. Install the shaft snap ring. (Sixth gear)

(1) Select a shaft snap ring so that the thrust gap between the sixth
gear and shaft snap ring is within the standard value.
Standard value: 0.1 to 0.11 mm {0.00394 to 0.00433 in}
<Reference>
Select a shaft snap ring with the maximum thickness possible.
Shaft snap ring type
Item number Thickness (mm {in}) Identification mark
17005AA350 2.67 {0.10511} A
17005AA360 2.73 {0.10748} B
17005AA370 2.79 {0.10984} C
17005AA380 2.85 {0.11220} D
17005AA390 2.91 {0.11456} E
17005AA400 2.97 {0.11692} F
17005AA410 3.03 {0.11929} G
17005AA420 3.09 {0.12165} H
17005AA430 3.15 {0.12401} J
17005AA440 3.21 {0.12638} K
17005AA450 3.27 {0.12874} L

(2) Using a brass bar, install a new shaft snap ring to the output shaft.
C257092
 Manual transmission/transaxle - COUNTER GEAR ASSY
MT–61

COUNTER GEAR ASSY

Drive train
Manual transmission/transaxle

EXPLODED VIEW

Shaft snap ring

Counter shaft fourth gear

Fourth gear bearing inner race MT

Fourth washer retaining ring

Counter drive gear

Fourth inner race thrust washer

Shaft snap ring

Shaft snap ring

Counter gear front bearing

Synchronizer ring set No. 3

Ball

Synchromesh shifting key spring No. 1

Synchromesh shifting key No. 1

[ [ [

Transmission clutch hub No. 2

Transmission hub sleeve No. 2

Synchronizer ring No. 1

Non-reusable parts

Manual transmission oil

MT-03012
<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
 MT–62 Manual transmission/transaxle - COUNTER GEAR ASSY

Needle roller bearing

MT

Counter shaft

Counter shaft third gear

Manual transmission oil

MT-03013

<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)

DISASSEMBLY
1. Check the thrust clearance.
(1) Check the thrust clearance of the counter shaft third gear and
C D
counter shaft fourth gear.
Captions in illustration
*a Counter shaft fourth gear thrust clearance
*b Counter shaft third gear thrust clearance

Standard value
Gear Standard value (mm {in}) Limit (mm {in})
0.10 to 0.35
Counter shaft third gear 0.35 {0.0138}
C257094J01 {0.00394 to 0.0138}
0.10 to 0.35
Counter shaft fourth gear 0.35 {0.0138}
{0.00394 to 0.0138}

<Reference>
When the result exceeds the limit, adjust with the fourth inner race
thrust washer.
 Manual transmission/transaxle - COUNTER GEAR ASSY
MT–63

2. Check the radial clearance.

(1) Check the radial clearance of the counter shaft third gear and
C D counter shaft fourth gear.
Captions in illustration
*a Counter shaft fourth gear radial clearance
*b Counter shaft third gear radial clearance

Standard value
Gear Standard value (mm {in}) Limit (mm {in})

Counter shaft third gear

0.015 to 0.068
0.068 {0.00268}
MT
C257095J01 {0.000590 to 0.00268}
0.065 to 0.115
Counter shaft fourth gear 0.115 {0.00453}
{0.002559 to 0.00453}

<Reference>
When the result exceeds the limit, replace the respective gear and
needle roller bearing or fourth gear bearing inner race as a set.
3. Remove the counter gear front bearing.
(1) Using the SST, remove the shaft snap ring.
SST 499895400
<Caution>
Check the direction of the part.

556
MT-02882
(2) Using the SST, remove the counter gear front bearing.
SST 09950-00020, 899864100

556

MT-03059

4. Remove the counter drive gear.

(1) Using the SST, remove the shaft snap ring.
SST 499895400

556
MT-02884
 MT–64 Manual transmission/transaxle - COUNTER GEAR ASSY

(2) Using the SST, remove the counter drive gear.

SST 899714110, 899864100

556

MT
MT-02885

5. Remove the counter shaft fourth gear.

(1) Using the SST, remove the shaft snap ring, then the fourth washer
retaining ring, and lastly fourth inner race thrust washer.
556 SST 499895400
<Caution>
Check the direction of the part.

MT-02886
(2) Remove the fourth gear bearing inner race, while prying with a flat
tip screwdriver and rotating counterclockwise along the gear.

C257101

(3) Remove the counter shaft fourth gear and synchronizer ring No. 1.

C257102
 Manual transmission/transaxle - COUNTER GEAR ASSY
MT–65

6. Remove the counter shaft third gear.

(1) Using the SST, remove the transmission clutch hub No. 2, counter
shaft third gear, synchronizer ring set No. 3, and needle roller
bearing.
556 SST 899714110
<Caution>
Check the direction of the part.

MT
MT-02887

7. Remove the transmission hub sleeve No. 2.

(1) Remove the transmission hub sleeve No. 2, and remove the three
synchromesh shifting key No. 1s, three synchromesh shifting key
spring No. 1s, and three balls from the transmission clutch hub
No. 2.
<Caution>
• Use a cloth to prevent the synchromesh shifting key No. 1s,
synchromesh shifting key spring No. 1s, and balls from flying out.
• Do not deform the synchromesh shifting key spring No. 1s.
• Check the direction of the part.
C257070
<Reference>
Perform the procedure without moving the positions of the
transmission clutch hub No. 2 and synchromesh shifting key
No. 1s.

INSPECTION
1. Check the transmission hub sleeve No. 2.
(1) Check the spline gear edge of the transmission hub sleeve No. 2
for wear.
<Reference>
When wear is present, replace the transmission hub sleeve No. 2.
(2) Install the transmission hub sleeve No. 2 to the transmission clutch
hub No. 2, and check for smooth sliding.
<Reference>
When sliding is not smooth, replace the transmission hub sleeve
C257080 No. 2 and transmission clutch hub No. 2.

2. Check the transmission hub sleeve No. 2 clearance.

(1) Measure the thickness of the claw of gear shift fork No. 2.
Standard value: 7.9 to 8.0 mm {0.311 to 0.315 in}
Limit: 7.9 mm {0.311 in}
<Reference>
When the result is below the limit, replace the gear shift fork No. 2.
(2) Measure the groove of transmission hub sleeve No. 2, and
calculate the clearance between the gear shift fork No. 2.
Standard value: 0.15 to 0.35 mm {0.00590 to 0.0138 in}
C257047 Limit: 0.35 mm {0.0138 in}
<Reference>
When the result exceeds the limit, replace the gear shift fork No. 2
and transmission hub sleeve No. 2 as a set.
 MT–66 Manual transmission/transaxle - COUNTER GEAR ASSY

3. Check the synchronizer ring No. 1.

(1) Apply manual transmission oil to the taper cone portion of the
counter shaft fourth gear, and with the synchronizer ring No. 1
tightly fit by pressing by hand, check the clearance between the
synchronizer ring No. 1 and counter shaft fourth gear.
Standard value: 0.8 to 1.6 mm {0.0314 to 0.0629 in}
Limit: 0.8 mm {0.0314 in}
<Caution>
MT Check for the entire circumference of the gear.
<Reference>
C257104
• When the result is below the limit, replace the synchronizer ring
No. 1 and counter shaft fourth gear.
• Use recommended or substitute products for manual
transmission oil. (Refer to PP-8)
(2) Apply manual transmission oil to the taper cone portion of the
counter shaft fourth gear, and with the synchronizer ring No. 1
tightly fit by pressing by hand, check there is no slippage in the
circumferential direction.
<Reference>
• When slippage occurs, replace the synchronizer ring No. 1 and
counter shaft fourth gear.
• Use recommended or substitute products for manual
transmission oil. (Refer to PP-8)
C257105

4. Check the synchronizer ring set No. 3.

(1) Apply manual transmission oil to the taper cone portion of the counter shaft third gear and synchronizer ring set No. 3,
and with the synchronizer ring set No. 3 tightly fit by pressing by hand, check the clearance between the synchronizer
ring set No. 3 and counter shaft third gear.

C D E

C257073J01

Captions in illustration
*a Inner *b Middle
*c Outer - -

Standard value
Measurement position Standard value (mm {in})
Inner 0.4 to 1.2 {0.0157 to 0.0472}
Middle 0.3 to 1.3 {0.0118 to 0.0512}
Outer 0.8 to 1.8 {0.0315 to 0.0709}

<Caution>
Check for the entire circumference of the gear.
<Reference>
• When the result exceeds the limit, replace the synchronizer ring set No. 3.
• Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
 Manual transmission/transaxle - COUNTER GEAR ASSY
MT–67

(2) Apply manual transmission oil to the taper cone portion of the
counter shaft third gear, and with the synchronizer ring set No. 3
tightly fit by pressing by hand, check there is no slippage in the
circumferential direction.
<Reference>
• When slippage occurs, replace the synchronizer ring set No. 3.
• Use recommended or substitute products for manual
transmission oil. (Refer to PP-8)
MT
C257072

5. Check the counter shaft.

(1) Check the outer diameter of each portion.
# $ %
Standard value
Check position Standard value (mm {in}) Limit (mm {in})
39.284 to 39.300
A 39.284 {1.54661}
{1.54661 to 1.54721}
37.984 to 38.000
B 37.984 {1.49543}
{1.49543 to 1.49606}
24.987 to 25.000
C 24.987 {0.98374}
{0.98374 to 0.98425}
C257106J01

<Reference>
When the result is below the limit, replace the counter shaft.
(2) Check the runout at the positions shown in the figure.
Standard value: 0.03 mm {0.00118 in} or less
<Reference>
When the result is not within the standard value, replace the
counter shaft.

C257107

6. Check the counter shaft third gear.

(1) Measure the inner diameter of counter shaft third gear.
Standard value: 43.015 to 43.040 mm {1.69350 to 1.69448 in}
Limit: 43.040 mm {1.69448 in}
<Reference>
When the result exceeds the limit, replace the counter shaft third
gear.

C257108
 MT–68 Manual transmission/transaxle - COUNTER GEAR ASSY

7. Check the counter shaft fourth gear.

(1) Measure the inner diameter of counter shaft fourth gear.
Standard value: 46.315 to 46.340 mm {1.82425 to 1.82441 in}
Limit: 46.340 mm {1.82441 in}
<Reference>
When the result exceeds the limit, replace the counter shaft fourth
gear.

MT
C257108

8. Check the fourth gear bearing inner race.

(1) Check the outer diameter of fourth gear bearing inner race.
Standard value: 46.225 to 46.250 mm {1.81988 to 1.82087 in}
Limit: 46.225 mm {1.81988 in}
<Caution>
Do not measure the oil groove.
<Reference>
When the result is below the limit, replace the fourth gear bearing
inner race.
C257109

ASSEMBLY
1. Install the transmission hub sleeve No. 2.
(1) Apply manual transmission oil to the sliding surface of
transmission clutch hub No. 2.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
(2) First install the transmission hub sleeve No. 2 to the transmission
clutch hub No. 2, then install the three synchromesh shifting key
No. 1s and the three synchromesh shifting key spring No. 1s as a
C257081 unit, and lastly install the three balls.
<Reference>
• Install the shifting key pole, while compressing the shifting key
spring. Install the balls, while compressing the synchromesh
shifting key spring No. 1s.
• After finishing the installation, let the synchromesh shifting key
spring No. 1s sit for a while.
2. Install the counter shaft third gear.
(1) Apply manual transmission oil to the installation portion of the
counter shaft, needle roller bearing, and inner surface and taper
cone portion of counter shaft third gear.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
(2) Install the needle roller bearing and counter shaft third gear.

C257114
 Manual transmission/transaxle - COUNTER GEAR ASSY
MT–69

3. Install the transmission clutch hub No. 2.

(1) Install the synchronizer ring set No. 3 to the counter shaft third
gear.
• Align the claw of middle ring with the gear groove.
556 • Align the claw of inner ring with the outer ring groove.
(2) Using the SST, install the transmission clutch hub No. 2.
SST 18654AA000, 398477703
<Caution>
Check the position of the synchronizer ring set No. 3.
<Reference>
MT
MT-02888 • Press-fit the transmission clutch hub No. 2 until it contacts the
counter shaft.
• After press-fitting, make sure that the synchronizer ring set No.
3 moves in the thrust direction.
4. Install the counter shaft fourth gear.
(1) Install the synchronizer ring No. 1 to the transmission clutch hub
No. 2.
(2) Apply manual transmission oil to the fourth gear bearing inner
race, and inner surface and taper cone portion of counter shaft
fourth gear.
<Reference>
Use recommended or substitute products for manual transmission
oil. (Refer to PP-8)
(3) Install the counter shaft fourth gear and fourth gear bearing inner
race.
<Reference>
Install the fourth gear bearing inner race, while rotating clockwise
along the gear.

C257116
 MT–70 Manual transmission/transaxle - COUNTER GEAR ASSY

5. Install the fourth inner race thrust washer.

(1) Select a fourth inner race thrust washer so that the thrust gap
between the fourth gear bearing inner race and fourth inner race
thrust washer is within the standard value.
556
Standard value: 0 to 0.1 mm {0 to 0.00394 in}
<Reference>
Select a fourth inner race thrust washer with the maximum
thickness possible.
MT Type of fourth inner race thrust washer
Item number Thickness (mm {in}) Identification mark
17002AA090 3.75 {0.14763} A
17002AA100 3.80 {0.14960} B
17002AA110 3.85 {0.15157} C
17002AA120 3.90 {0.15354} D
17002AA130 3.95 {0.15551} E
17002AA140 4.00 {0.15748} F
17002AA150 4.05 {0.15944} G
17002AA160 4.10 {0.16141} H

(2) Using the SST, install a new fourth inner race thrust washer, a new
fourth washer retaining ring, and a new shaft snap ring to the
MT-02889
counter shaft.
SST 499895400
6. Install the counter drive gear.
(1) Using the SST, install the counter drive gear.
556 SST 499277000, 398477703

MT-02890
 Manual transmission/transaxle - COUNTER GEAR ASSY
MT–71

7. Install the shaft snap ring. (Transmission clutch hub No. 3)

(1) Select a shaft snap ring so that the thrust gap between the counter
drive gear and shaft snap ring is within the standard value.
Standard value: 0 to 0.1 mm {0 to 0.00394 in}
<Reference>
Select a shaft snap ring with the maximum thickness possible.
Shaft snap ring type
Item number Thickness (mm {in}) Identification mark
17005AA520 1.80 {0.07086} A MT
17005AA530 1.85 {0.07283} B

556 17005AA540 1.90 {0.07480} C

17005AA550 1.95 {0.07677} D
17005AA560 2.00 {0.07874} E
17005AA570 2.05 {0.08070} F

(2) Using the SST, install a new shaft snap ring to the counter shaft.
SST 499895400

MT-02891

8. Install the counter gear front bearing.

(1) Using the SST, install a new counter gear front bearing while
556 holding down by hand.
SST 498057300

MT-02892

9. Install the shaft snap ring. (Counter gear front bearing)

(1) Select a shaft snap ring so that the thrust gap between the counter
gear front bearing and shaft snap ring is within the standard value.
Standard value: 0 to 0.1 mm {0 to 0.00394 in}
<Reference>
Select a shaft snap ring with the maximum thickness possible.
Shaft snap ring type
Item number Thickness (mm {in}) Identification mark
17005AA310 2.05 {0.08070} 1
17005AA290 2.10 {0.08267} 2
17005AA320 2.15 {0.08464} 3
556 17005AA300 2.20 {0.08661} 4
17005AA330 2.25 {0.08858} 5
17005AA340 2.30 {0.09055} 6

(2) Using the SST, install a new shaft snap ring to the counter shaft.
SST 499895400

MT-02893