Manual Transaxle

(M5CF1)
GENERAL OUTPUT SHAFT
SHIFT FORK
MANUAL TRANSAXLE SYSTEM DIFFERENTIAL
MANUAL TRANSAXLE SPEEDOMETER DRIVEN GEAR ASSEMBLY
INPUT SHAFT
MT -2 MANUAL TRANSAXLE (M5CF1)

GENERAL
SPECIFICATIONS EFEAC1DF

Transaxle type M5CF1

Gear ratio 1st 3.615
2nd 2.053
3rd 1.370
4th 1.031
5th 0.837
Reverse 3.583
Final gear ratio 4.056

SERVICE STANDARD

Items Standard value [in(mm)]

Input shaft rear bearing end play 0.00-0.0019L(0.00-0.05L)
Output shaft bearing end play (At 70kgf load) 0.0019T-0.0039T(0.05T-0.10T)
Input shaft front bearing end play (At 70kgf load) 0.00-0.0019L(0.00-0.05L)
Differential bearing end play 0.0059T-0.0078T(0.15T-0.20T)
Differential pinion backlash 0.001L-0.0039L(0.025L-0.10L)

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

L: Indicate loosening of +(plus) direction of end play
GENERAL MT -3

SNAP RING AND SPACER FOR ADJUSTMENT

Part name Thickness [in(mm)] Part number

Spacer 0.028 (0.71) 43331-23071
(For adjustment of differential bearing end play)
0.029 (0.74) 43331-23074
0.030 (0.77) 43331-23077
0.031 (0.8) 43331-23080
0.033 (0.83) 43331-23083
0.034 (0.86) 43331-23086
0.035 (0.89) 43331-23089
0.036 (0.93) 43331-23092
0.037 (0.95) 43331-23095
0.039 (0.98) 43331-23098
0.040 (1.01) 43331-23101
0.041 (1.04) 43331-23104
0.042 (1.07) 43331-23107
0.043 (1.1) 43331-23110
0.044 (1.13) 43331-23113
0.046 (1.16) 43331-23116
0.047 (1.19) 43331-23119
0.048 (1.22) 43331-23122
0.049 (1.25) 43331-23125
0.050 (1.28) 43331-23128
Spacer 0.0295-0.0323 (0.75-0.82) 45835-22782
(For adjustment of differential pinion backlash)
0.0327-0.0362 (0.83-0.92) 45835-22792
0.0366-0.0425 (0.93-1.00) 45835-22700
0.0398-0.0425 (1.01-1.08) 45835-22708
0.0429-0.0457 (1.09-1.16) 45835-22716
MT -4 MANUAL TRANSAXLE (M5CF1)

Part name Thickness [in(mm)] Part number

Spacer 0.056 (1.43) 43227-28430
(For adjustment of output shaft bearing end play)
0.057 (1.46) 43227-28460
0.059 (1.49) 43227-28490
0.060 (1.52) 43227-28520
0.061 (1.55) 43227-28550
0.062 (1.58) 43227-28580
0.063 (1.61) 43227-28610
0.065 (1.64) 43227-28640
0.066 (1.67) 43227-28670
0.067 (1.70) 43227-28700
0.068 (1.73) 43227-28730
0.069 (1.76) 43227-28760
0.070 (1.79) 43227-28790
0.072 (1.82) 43227-28820
0.073 (1.85) 43227-28850
0.074 (1.88) 43227-28880
0.075 (1.91) 43227-28910
Snap ring 0.078 (1.98) 43278-23198
(For adjustment of input shaft rear bearing end play)
0.080 (2.02) 43278-23202
0.081 (2.06) 43278-23206
0.083 (2.10) 43278-23210
0.084 (2.14) 43278-23214
0.086 (2.18) 43278-23218
Snap ring 0.098 (2.50) 43239-23050
(For adjustment of input shaft 5th gear end play)
0.100 (2.54) 43239-23054
0.102 (2.58) 43239-23058
0.103 (2.62) 43239-23062
0.105 (2.66) 43239-23066
Snap ring 0.088 (2.24) 43224-21240
(For adjustment of input shaft front bearing end play)
0.091 (2.31) 43224-21310
0.094 (2.38) 43224-21380
0.096 (2.45) 43224-23450
GENERAL MT -5

TIGHTENING TORQUE

Standard value Nm kgf.cm lb-ft

Clutch tube flare nut 13-17 130-170 9-12
Release cylinder bolt 15-22 150-220 10-16
Control shift complete bolt 20-27 200-270 15-20
Oil drain plug 60-80 600-800 43-58
Oil filler plug 60-80 600-800 43-58
Poppet ball 30-35 300-350 21-25
Clutch housing to transmission case 43-55 430-550 32-40
Speedometer driven gear 3-5 30-50 2-4
Reverse idler bolt 43-55 430-550 32-40
Reverse shift lever assembly bolt 15-22 150-220 10-16
Input shaft bearing retainer 15-22 150-220 10-16
Shift control cable bracket on
20-27 200-270 15-20
transaxle side
Rear roll support bracket bolt 60-80 600-800 43-58
Rear roll stopper insulator bolt and nut 50-65 500-650 36-47
Front roll stopper insulator bolt and nut 50-65 500-650 36-47
Front roll support bracket bolt 60-80 600-800 43-58
Transaxle support bracket bolts 60-80 600-800 43-58
Transaxle mounting bracket bolts 70-95 700-950 50-69
Differential drive gear seal bolt 130-140 1300-1400 94-101
Clutch release lever fulcrum bolt 55-60 550-600 40-43
Shift lever mounting bolts 9-14 90-140 6-9.5

WARNING In either case, serious personal injury or death

could result to vehicle occupants.
Always follow torque tightening levels. Failure
to follow such levels can result in parts breaking
if over-tightened or loosening if under-tightened.

LUBRICATIONS

Items Recommnend lubricant Quantity

SAE 75W/85
API GL-4
Transaxle gear oil TGO-7(MS517-14) 1.9L(2.0US qt, 1.67lmp qt)
ZIC G-F TOP 75W/85
HD GEAR OIL XLS 75W/85
Air bleeder MS721-38 As requried
Transaxle housing MS721-40 or MS721-38 As requried
Surface of release fork and bearing Grease (CASMOLY L9508) As requried
MT -6 MANUAL TRANSAXLE (M5CF1)

SPECIAL TOOL E6B9B1F4

TOOL
Illustration Use
(Number and Name)
09455-21100 Installation of differential taper
Bearing installer roller bearing

LKGF001E

09452-21200 Installation of differential oil seal

Oil seal installer

Y45006B

09432-33300
Bearing installer

Installer of ball bearing and

taper roller bearing

LKGF001F

09432-22000 Installer of output shaft taper

Output shaft Bearing installer roller bearing

LKGF001F

09432-21500 Installatoin of output shaft

Bearing installer gears and sleeve

LKGF001E
MANUAL TRANSAXLE SYSTEM MT -7

MANUAL TRANSAXLE
SYSTEM
MANUAL TRANSAXLE

COMPONENTS (1) EE8CE91E

69

AMJF003A
MT -8 MANUAL TRANSAXLE (M5CF1)

1. 5th synchronizer key assembly 36. Pinion shaft

2. 5th synchronizer hub 37. Washer
3. 5th synchronizer sleeve 38. Differential drive gear
4. 5th synchronizer ring 39. Differential gear seal bolt
5. Needle roller bearing 40. Gasket
6. 5th speed gear 41. Drain plug
7. 5th speed gear sleeve 42. Differential taper roller bearing
8. 4th speed gear 43. Spacer
9. Needle roller bearing 44. 1st tripple cone assembly
10. 4th speed gear sleeve 45. 1st synchronizer key
11. 4th synchronizer ring 46. 1st & 2nd synchronizer sleeve
12. 4th synchronizer key assembly 47. 1st & 2nd synchronizer hub
13. 3rd & 4th synchronizer sleeve 48. 2nd tripple cone assembly
14. 3rd & 4th synchronizer hub 49. 2nd speed gear
15. 3rd double cone assembly 50. Needle roller bearing
16. 3rd speed gear 51. 2nd speed gear sleeve
17. Needle roller bearing 52. 3rd speed output gear
18. Input shaft bearing retainer 53. 4th speed output gear
19. Clutch housing 54. 5th speed output gear
20. Needle roller bearing 55. Spacer
21. 1st speed gear 56. Output bearing spacer
22. Input shaft front ball bearing 57. Output shaft
23. Input shaft front snap ring 58. Output shaft rear taper roller bearing
24. Input shaft front oil seal 59. Oil guide ring
25. Input shaft 60. Input shaft rear snap ring
26. Output shaft front taper roller bearing 61. Input shaft rear ball bearing
27. Differential oil seal 62. Input shaft oil guide
28. Output shaft oil guide 63. Thrust washer
29. Lock pin 64. Input shaft 5th spacer
30. Differential spacer 65. Spacer
31. Differential taper roller bearing 66. Transaxle case
32. Speedometer drive gear 67. Transaxle support bracket bolt
33. Differential side gear 68. Transaxle support bracket
34. Differential side gear 69. Ring
35. Differential pinion gear

LMJF003A
MANUAL TRANSAXLE SYSTEM MT -9

COMPONENTS (2)

30-35 (300-350, 21-25)

12-22 (120-220, 10-16)

TORQUE:Nm(kgf.cm, lbf.ft)
1. Control shift complete 9. 3rd & 4th shift lug and fork 17. Output shaft rear outer racer
2. Oil seal 10. 1st & 2nd shift rail 18. Output shaft assembly
3. Transaxle case 11. 1st & 2nd shift fork 19. Output shaft front outer racer
4. 5th shift fork 12. Input shaft oil guide 20. Output shaft oil guide
5. 5th shift rail 13. Snap ring 21. Oil guide
6. Reverse shift lug 14. Input shaft assembly 22. Differential assembly
7. Pin 15. Input shaft bearing retainer 23. Oil seal
8. 3rd & 4th shift rail 16. Spacer 24. Clutch housing
LKGF003C
MT -10 MANUAL TRANSAXLE (M5CF1)

DISASSEMBLY E8CAFE82 5. Remove the clutch fork boot(A).

1. Remove the vehicle speed sensor(A). (Bolt: 1EA)

A
A

LKGF004E

LKGF004A 6. Remove the shift cable bracket(A). (Bolt:2EA)

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

cylinder.

3. Remove the release cylinder from the transaxle. (Bolt:

2EA)

LKGF004F

7. Remove the control shift complete(A) from the

transaxle case. (Bolt:6EA)

LMJF019I

4. Remove the release bearing(A) and clutch fork(B).

LKGF004G

A
B

LKGF004D
MANUAL TRANSAXLE SYSTEM MT -11

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

LKGF004K

LKGF004H 12. Remove the housing bolt(3EA) from the clutch hous-
ing inside.
9. Remove the drain plug(A).

LKGF004L
LKGF004I

10. Remove the filler plug(A). 13. Remove the transaxle case(A) from the housing(B).
(Bolt: 11EA)

LKGF004J

B
11. Remove the reverse idle bolt(A) from the transaxle
case.

LKGF004M
MT -12 MANUAL TRANSAXLE (M5CF1)

14. Remove the differential outer race(A). 17. Remove the oil guide(A).

A
A

LKGF004N LKGF004Q

15. Remove the output outer race(A). 18. Remove the bushing(A) (3EA).

LKGF004O
LKGF004R

16. Remove the input shaft oil guide(A) in the transalxe

case. 19. Remove the drive shaft oil seal(A).

LKGF004P LKGF004S
MANUAL TRANSAXLE SYSTEM MT -13

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

LKGF004V

LKGF004T 23. Remove the shift rail and fork assembly.

21. Remove the reverse shaft lever assembly(A). (Bolt:

2EA)

LKGF004W

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

LKGF004U

22. Remove the spring pin.

NOTE
Be careful not to damage it when removing spring pin. A

LKGF004X
MT -14 MANUAL TRANSAXLE (M5CF1)

25. Remove the input shaft(A) and output shaft(B) assem- 28. Remove the clutch release lever fulcrum bolt(A).
bly together from the clutch housing.

LKGF005B

29. Remove the differential outer race(A).

LKGF004Y

26. Remove the differential assembly(A).

A

LKGF005C

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

LKGF004Z

A
27. Remove the differential oil seal(A).

LKGF005D

LKGF005A
MANUAL TRANSAXLE SYSTEM MT -15

31. Remove the magnetic(A). 34. Remove the input shaft front oil seal(A).

A
A

LKGF005E LKGF005H

32. Remove the output shaft oil guide(A). 35. Remove the bushing(3EA) from the clutch housing.

LKGF005F LKGF005I

33. Remove the dowel pin(3EA).

LKGF005G
MT -16 MANUAL TRANSAXLE (M5CF1)

REASSEMBLY E70B65AD 3. Install the dowel pin(3EA) into the groove of the hous-
ing surface.
NOTE
Before reassembling, clean all parts in slovent, dry
them, and apply lubicant to any contact surfaces.

1. Install the bushing(3EA) in the housing using the spe-

cial tool.

LKGF005G

4. Install the output shaft front oil guide(A).

LKGF005I

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

NOTE
Do not reuse the old oil seal.

LKGF005F

5. Install the magnetic(A).

LKGF005H

LKGF005E
MANUAL TRANSAXLE SYSTEM MT -17

6. Install the output outer race(A). 9. Install the differential oil seal(A) in the transaxle case
using the special tool(09452-21200).

09452-21200

LKGF005D

LMJF002A
7. Install the differential outer race(A).

A
A

LKGF005A
LKGF005C

8. Install the clutch release lever fulcrum bolt(A). 10. Install the differential gear assembly(A).

LKGF005B LKGF004Z
MT -18 MANUAL TRANSAXLE (M5CF1)

11. Install the input shaft(A) and output shaft(B) in the 14. Install the 3＆4, 5th shift rail and fork assembly.
clutch housing.

LKGF004W

15. Install the spring pin.

LKGF004Y

12. Install the bearing retainer.(Bolt: 4EA)

NOTE
Apply three bond 1303 equivalent around the hex
bolt(4EA) before installing the bearing retainer(A).

TORQUE :
15-22 Nm(150-220 kgf.cm, 10-16 lbf.ft)

LKGF004V

NOTE

A When installing, make sure that the slit of the spring

pin is aligned within 15 of the center line of the shift
rail.

Slit
15 15 Spring pin

LKGF004X

13. Install the 1＆2 shift rail and fork assembly.

Shift rall

LKGF006B
MANUAL TRANSAXLE SYSTEM MT -19

16. Install the reverse shift lever(A). (Bolt:2EA) 18. Install the drive shaft oil seal(A) in the transaxle case
using the special tool(09452-21200).
TORQUE :
15-22 Nm(150-220 kgf.cm, 10-16 lbf.ft)

LKGF004S

LKGF004U

17. Install the reverse idle gear assembly(A).

09452-21200

LMJF004A

19. Install the bushing(A) (3EA) in the transaxle case.

A
A

LKGF004T

LKGF004R
MT -20 MANUAL TRANSAXLE (M5CF1)

20. Install the oil guide(A) in the transaxle case. End play [in(mm)]: 0.0019T-0.0039T in(0.05T-0.10T
mm)
Thickness of space [in(mm)] = (Height of housing
A
[in(mm)] + Height of transaxle case [in(mm)]) - lengh
of output [in(mm)] + end play [0.0003in(0.075mm)] +
tolerance [0.0018in(0.045mm)]

NOTE
Measure the lengh of output shaft with both sides of
bearing.
For keeping accuracy, measure at least 3 places and
calculate the average value.

23. Install the output shaft space.

INPUT SIDE BEARING ADJUSTING SPACE

LKGF004Q
Parts Number Thickness [in(mm)]
21. Install the input shaft oil guide(A).
43227-28430 0.056 (1.43)
43227-28460 0.057 (1.46)
43227-28490 0.059 (1.49)
A 43227-28520 0.060 (1.52)
43227-28550 0.061 (1.55)
43227-28580 0.062 (1.58)
43227-28610 0.063 (1.61)
43227-28640 0.065 (1.64)
43227-28670 0.066 (1.67)
43227-28700 0.067 (1.70)
43227-28730 0.068 (1.73)
LKGF004P
43227-28760 0.069 (1.76)
22. Measure and choose the proper space as followed. 43227-28790 0.070 (1.79)
43227-28820 0.072 (1.82)
43227-28850 0.073 (1.85)
43227-28880 0.074 (1.88)
43227-28910 0.075 (1.91)

LKGF006D
MANUAL TRANSAXLE SYSTEM MT -21

24. Install the output shaft rear outer race(A). 26. Install the space of the differential assembly.

INPUT SIDE BEARING ADJUSTING SPACE

Parts Number Thickness [in(mm)]

45835-22782 0.0295-0.0323(0.75-0.82)
A
45835-22792 0.0327-0.0362 (0.83-0.92)
45835-22700 0.0366-0.0425 (0.93-1.00)
45835-22708 0.0398-0.0425 (1.01-1.08)
45835-22716 0.0429-0.0457 (1.09-1.16)

LKGF004O

25. Select the space of the differential assembly to mini-

mize end play.

LKGF006F

27. Install the differential outer race(A).

LKGF006E

End paly [in(mm)]: 0.0059T-0.0078T in(0.15T-0.20T

mm)
Thickness of space [in(mm)] = (height of housing
[in(mm)] + transaxle case [in(mm)]) - the length of
differential [in(mm)] + end play [0.0007in(0.175mm)]
+ tolerance [0.0022in(0.055mm)]
LKGF004N

NOTE
Measure the lengh of differential assembly with both
sides of bearing.
For keeping accuracy, measure at least 3 places and
the calculate average value.
MT -22 MANUAL TRANSAXLE (M5CF1)

28. Apply the specified sealant on the surface of the

transaxle housing.

Specified sealant: MS 721-40

LKGF006I

31. Install the reverse idle bolt(A) to housing side.

TORQUE :
LKGF006G
43-55 Nm(430-550 kgf.cm, 32-40 lbf.ft)

29. Install transaxle case onto the transaxle housing.

(Bolt:11EA)

NOTE
Use torque lench when tightening bolt.

TORQUE :
43-55 Nm(430-550 kgf.cm, 32-40 lbf.ft)

LKGF004K

32. Install filler plug(A).

TORQUE :
60-80 Nm(600-800 kgf.cm, 43-58 lbf.ft)

LKGF006H

A
30. Install bolt insides of the transaxle housing.(Bolt:3EA)

NOTE
Use torque lench when tightening bolt.

TORQUE :
43-55 Nm(430-550 kgf.cm, 32-40 lbf.ft)

LKGF004J
MANUAL TRANSAXLE SYSTEM MT -23

33. Install drain plug(A). 35. Install the control shift complete onto the transaxle
case. (Bolt:6EA)
TORQUE :
60-80 Nm(600-800 kgf.cm, 43-58 lbf.ft) TORQUE :
30-35 Nm(300-350 kg·cm, 21-25 lb·ft)

A NOTE
Use torque lench when tightening bolt.

LKGF004I

34. Install 1＆2, 3＆4, 5th shift rail poppet bolt(A).

TORQUE :
30-35 Nm(300-350 kg·cm, 21-25 lb·ft) LKGF006J

36. Install the shift cable bracket(A). (Bolt:2EA)

A TORQUE :
20-27 Nm(200-270 kgf.cm, 15-20 lbf.ft)

LKGF004H

LKGF004F
MT -24 MANUAL TRANSAXLE (M5CF1)

37. Install the clutch fork boot(A).

LKGF004E
LKGF006K

38. Install the release bearing(A) and clutch fork(B).

39. Install the release cylinder(A). (Bolt:2EA)

TORQUE :
15-22 Nm(150-220 kgf.cm, 10-16 lbf.ft)

A
B

LKGF004D

NOTE
Spread bearing sliding surface and holes of release
LMJF019I
fork with Grease.

Standard grease : CASMOLY L9508

MANUAL TRANSAXLE SYSTEM MT -25

40. Install the vehicle speed sensor(A). (Bolt 1EA)

TORQUE :
3-5 Nm(30-50 kg·cm, 2-4 lb·ft)

LKGF004A
MT -26 MANUAL TRANSAXLE (M5CF1)

INPUT SHAFT

COMPONENTS E46DF4DF

27 28
26
25

24

23
22
21

19
20
18
17
16
15

14

13
12
11

29

1. Snap ring 10. 3rd &4th synchronizer sleeve 20. Synchronizer key
2. Front ball bearing 11. 4th gear sleeve 21. Spacer
3. Needle bearing 12. Needle bearing 22. ring
4. 3rd speed gear 13. 4th synchronizer ring 23. 5th synchronizer sleeve
5. 3rd inner synchronizer ring 14. 4th speed gear 24. Spacer
6. 3rd synchronizer cone 15. 5th gear sleeve 25. Thrust washer
7. 3rd outer synchronizer ring 16. Needle bearing 26. Rear ball bearing
8. 3rd &4th synchronizer hub 17. 5th speed gear 27. Snap ring
9. Synchronizer key 18. 5th synchronizer ring 28. Oil guide
19. 5th synchronizer hub 29. Input shaft
LMJF005A
MANUAL TRANSAXLE SYSTEM MT -27

DISASSEMBLY E26BB9DF 2. Remove the thrust washer(A) and spacer(B).

1. Remove the snap ring(A) and washer(D) and remove

the front ball bearing(B) and the rear ball bearing(C) A
using press.

B
A

LKGF009A
LKGF009C

3. Remove the ring(A) and specer(B).

LKGF009B

LMJF019B
MT -28 MANUAL TRANSAXLE (M5CF1)

4. Remove the 5th sleeve, 5th gear, 4th gear, 3 ＆4th NEEDLE ROLLER BEARING
sleeve and 3rd gear all together using press.
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.

LKGF009E

INSPECTION E2E5B004

INPUT SHAFT
LKGF009G
1. Check the outer surface of the input shaft where the
needle bearing is mounting for damage or abnormal SYNCHRONIZER RING
wear.
1. Check the clutch gear teeth for damage.
2. Check the input shaft gear teeth for damage.
2. Check the internal surface for damage, wear or bro-
ken grooves.

Damage and wear

Damage and wear

LKGF009F

LKGF009H
MANUAL TRANSAXLE SYSTEM MT -29

3. Push the synchronizer ring toward the clutch gear and SYNCHRONIZER KEY
check clearance "A".
Replace if it is not within specifications. 1. Check for wear of the synchronizer key center protru-
sion.
Limit"A" : 0.02in (0.5mm)
2. Replace the synchronizer key assembly.

A GEARS

1. Check the bevel gear and clutch gear teeth for danage
or wear.

2. Check the gear bore for damage or wear.

LKGF009I

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. LKGF009L

3. Check for wear of the hub end surfaces (in contact

with each gear).

CAUTION
Replace the synchronizer hub and sleeve as a set.

LKGF009J
MT -30 MANUAL TRANSAXLE (M5CF1)

REASSEMBLY EAD7E2AA 4. Install the 3rd inner synchronizer ring(A). (Double

cone type)
1. Install the 3rd needle bearing(A) on the input shaft(B).
C

A
B

LKGF010A

AMJF557A
2. Apply transaxle oil to the needle bearing.
5. Install the 3rd synchronizer cone(B).
3. Install the 3rd gear(A).
6. Install the 3rd outer synchronizer ring(C).
A
NOTE
Pay attention the direction of protrusion of a synchro-
nizer ring.

3rd 4th

LKGF010B

LMJF006A
MANUAL TRANSAXLE SYSTEM MT -31

7. Assemble the 3rd ＆ 4th synchronizer hub(A) using 9. Install the 3rd＆4th synchronizer sleeve.
press.
NOTE
NOTE
• Put down the 3rd slope face of sleeve with the
• When installing the synchronizer hub, make sure identification mark.
that the fingers of synchronizer ring are seated • Make sure that the groove of sleeve inside is
correctly in its groove on the synchronizer hub. seated correctly in the groove of synchronizer
• After installation of the synchronizer hub, check hub.
that sychronizer hub rotates smoothly.

LKGF010G

LMJF007A

8. Install the synchronizer keys(A).

4th 3rd

a
A
a a
a

LMJF008A

LKGF010F
MT -32 MANUAL TRANSAXLE (M5CF1)

10. Install the 4th outer synchronizer ring(A). 12. Install the 4th needle bearing(A).

NOTE
A
When installing the synchronizer ring, make sure that
the fingers of synchronizer ring are seated correctly
in the grooves of the 3rd＆4th synchronizer hub.

LKGF010M

13. Apply transaxle oil to the needle bearing.

14. Install the 4th gear(A).

LKGF010I

A
A

LKGF010N
LMJF009A

11. Install the 4th gear sleeve(A) using press. 15. Install the 5th sleeve(A) using press.

LMJF010A LMJF011A
MANUAL TRANSAXLE SYSTEM MT -33

16. Install the 5th needle bearing(A). 19. Install the 5th synchronizer hub(A) using the press.

A NOTE
• When installling hub, make sure the direction as
shown in the picture.
• When pressing the hub, make sure that the fin-
gers of the 5th synchronizer ring(double cone)
are seated correctly in the grooves of the hub.

5th Spacer

LKGF010P

17. Install the 5th gear(A).

LKGF010S

LKGF010Q

18. Install the 5th synchronizer ring(A).

LMJF013A

LMJF012A
MT -34 MANUAL TRANSAXLE (M5CF1)

20. Install the synchronizer key(A). 22. Install the spacer(A) and ring(B).

A
B
A

LKGF010F

21. Install the 5th synchronizer sleeve.

LMJF019F

NOTE
23. Install the spacer(A).
• Put down the 5th slope face of sleeve with the
identification mark.
• Make sure that the groove of sleeve inside is
seated correctly in the groove of synchronizer A
hub.

LKGF010U

LKGF010G

4th 5th

a a
a

LKGF010Z
MANUAL TRANSAXLE SYSTEM MT -35

NOTE 26. Install the snap ring.

When installing the spacer, make sure that three fin- 27. Install the front input shaft ball bearing by press and
gers of spacer are seated correctly in three grooves special tool(09432-33300).
of 5th synchronizer hub.
28. Install the snap ring(A).

A
A
A

B C B C

LKGF009K
LKGF010Y
24. Install the thrust washer.

25. Install the ball bearing(A) by press and special

tool(09432-33300).

09432-33300

LMJF019D
MT -36 MANUAL TRANSAXLE (M5CF1)

OUTPUT SHAFT

COMPONENTS E30AFAD9

1. 1st speed gear 9. 2nd outer synchronizer ring 17. 5th speed gear
2. Needle bearing 10. 2nd synchronizer cone 18. Sleeve
3. 1st inner synchronizer ring 11. 2nd inner synchronizer ring 19. Rear taper roller bearing
4. 1st synchronizer cone 12. 2nd sleeve 20. Outer race
5. 1st outer synchronizer ring 13. Needle bearing 21. Output shaft
6. 1st & 2nd speed sleeve 14. 2nd speed gear 22. Front taper roller bearing
7. 1st &2nd synchronizer hub 15. 3rd speed gear 23. Outer race
8. Synchronizer key 16. 4th speed gear
LKGF012A
MANUAL TRANSAXLE SYSTEM MT -37

DISASSEMBLY E8DFDF9F 3. Remove the 1st＆2nd synchronizer hub, 2nd sleeve,

3rd gear, 4th gear and 5th gear all together using
1. Remove the taper ball bearing. press.

NOTE
Do not reuse the removed bearing.

LKGF013C

INSPECTION E2CCC11D

LKGF013A
OUTPUT SHAFT
2. Heat the 3rd, 4th and 5th gear with electrical heater
as shown picture below. 1. Check the outer surface of where the needle bearing
is mounted for damage or abnormal wear.

2. Check the splines for damage or wear.

LKGF013B

LKGF013D
MT -38 MANUAL TRANSAXLE (M5CF1)

NEEDLE BEARING 3. Push the synchronizer ring toward the clutch gear and
check clearance "A".
1. Install the needle bearing on the shaft with the bearing Replace if it is not within specifications.
sleeve and gear.
Check that it rotates smoothly without abnormal noise Limit : 0.02 in(0.5 mm)
or play.

2. Check the needle bearing cage for distortion. A

LKGF009I

SYNCHRONIZER SLEEVE AND HUB

LKGF009G

1. Install the synchronizer sleeve on the hub and check

SYNCHRONIZER RING
that it slides smoothly.
1. Check the clutch gear teeth for damage.
2. Check that the sleeve is free from damage.
2. Check internal surface for damage, wear or broken
3. Check for wear of the hub end surfaces (in contact
grooves.
with each gear).

NOTE
Replace the synchronizer hub and sleeve as a set.
Damage and wear

Damage and wear

LKGF009H

LKGF009J
MANUAL TRANSAXLE SYSTEM MT -39

SYNCHRONIZER KEY REASSEMBLY E1A25AEF

1. Check for wear of the synchronizer key center protru- 1. Install the needle bearing(A).
sion.

2. Replace the synchronizer key assembly.

A
GEARS

1. Check the bevel gear and clutch gear teeth for dam-
age or wear.

2. Check the gear bore for damage or wear.

LKGF014A

2. Apply the MT oil to the needle bearing.

3. Install the 1st gear(A).

LKGF009L

LKGF014B
MT -40 MANUAL TRANSAXLE (M5CF1)

4. Install the 1st inner synchronizer ring(A). NOTE

When installling hub, make sure the direction as
A
shown in the picture.
B

2nd 1st
C

LKGF014C
LKGF014E

5. Install the 1st synchronizer cone(B).

8. Install the synchronizer key(A).
6. Install the 1st outer synchronizer ring(C).

7. Install the 1st＆2nd synchronizer hub using press.

NOTE
When installing hub, make sure that the the fingers
of 1st synchronizer ring are seated correctly in the
grooves of synchronizer hub.

LKGF014F

9. Install the 1st＆2nd sleeve(A).

LMJF014A

LKGF014G
MANUAL TRANSAXLE SYSTEM MT -41

10. Install the 2nd sleeve using press. 14. Install the 2nd needle bearing(A).

LMJF015A LKGF014J

11. Install the 2nd outer synchronizer ring(A). (Trifle cone) 15. Install the 2nd gear(A).

A
A
B

LKGF014K

LKGF014I

12. Install the 2nd synchronizer cone(B).

13. Install the 2nd inner synchronizer rin(C).

MT -42 MANUAL TRANSAXLE (M5CF1)

16. Install the 3rd(A), 4th(B) and 5th(C) gear using 17. Install the spacer using press and special tool(09455-
press.(09432-21500) 21100).

18. Install the rear taper roller bearing using press and
NOTE
special tool(09432-22000).
Heat the 3rd gear with electrical heater before using
press.
NOTE
Do not reuse the removed bearing.

09432-22000

LKGF014L

LMJF001B
09432-21500
19. Install the opposite side taper roller bearing using
press and special tool(09432-22000).
C

B
NOTE
Do not reuse the removed bearing.
A

09432-22000

LMJF019G

LMJF002B
MANUAL TRANSAXLE SYSTEM MT -43

SHIFT FORK

COMPONENTS ED5FA5BA

1. 5th shift fork 5. 3rd & 4th shift rail

2. 5th shift rail 6. 3rd & 4th shift lug and fork
3. Reverse shift lug 7. 1st & 2nd shift rail
4. Pin 8. 1st & 2nd shift fork
LKGF015A
MT -44 MANUAL TRANSAXLE (M5CF1)

DIFFERENTIAL

COMPONENTS EADF7D60

130-140(1300-1400, 94-101)

TORQUE : Nm (kg·cm, lb·ft)

1. Pinion shaft 8. Pinion gear

2. Lock pin 9. Washer
3. Washer 10. Spacer
4. Taper roller bearing 11. Differential drive gear
5. Spacer 12. Taper roller bearing
6. Differential case 13. Spacer
7. Side gear 14. Outer race
LKGF016A
MANUAL TRANSAXLE SYSTEM MT -45

DISASSEMBLY EE6CFA41 4. Drive out the lock pin from the hole A using a punch.

1. Clamp the differential case in a vise. 5. Drive out the pinion shaft.

2. Remove the differential drive gear retaining bolts and 6. Remove the pinion gears, washers, side gears and
remove the differential drive gear from the case. spacers.

Pinion shaft

Lock pin

Differential case

LKGF016B LMJF017A

3. Remove the taper roller bearing using press.

CAUTION
Do not reuse the bearing removed from the shaft.

Press

Bearing

Differential case

LMJF016A
MT -46 MANUAL TRANSAXLE (M5CF1)

REASSEMBLY E4921CE7 4. Measure the backlash between the side gears and
pinions.
1. Install the spacer on the back of the side gear and
then install the gear in the differential case. Standard value :
0.001~0.006in (0.025~0.150mm)
CAUTION
When installing a new side gear, use a spacer 5. If the backlash is out of specification, disassemble and
of medium thickness [0.0366~0.0394 in(0.93~1.00 install the correct spacer, reassemble and remeasure.
mm)].
CAUTION
Adjust the backlash of both side gears to the same
specification.

LKGF016E

2. Set the washer on the back of each pinion and insert

the two pinions to specified position while engaging
LKGF016G
them with the side gears by turning them.

3. Insert the pinion shaft. 6. Align the pinion shaft lock pin hole with the case lock
pin hole and insert the lock pin.

CAUTION
Pinion shaft
• Do not reuse the lock pin.
Pinion gear • The lock pin head must be sunk below the
flange surface of the differential case.

Pinion shaft
Differential case
Lock pin

A
Lock pin hole Side gear
Installation
direction
LKGF016F

Lock pin enlarger Projection at three

chamtering places on pin outside

LKGF016H
MANUAL TRANSAXLE SYSTEM MT -47

7. Install the taper roller bearings on both sides of the

differential case.

CAUTION
When press-fitting the bearing, press on the inner
race only.

AMJF016I

8. Apply specified sealant to the entire threads of the

bolts. Tighten to specifications using the sequence
shown in the illustration.

Specified sealant : BM Stud Locking No. 2471.

TORQE
Differential drive gear bolt:
130~140Nm (1300~1400kg·cm, 94~101lb·ft)

CAUTION
If a bolt is reused, remove the old sealant from the
threads.

3
5 1

7 8

2 6
4

AMJF016J
MT -48 MANUAL TRANSAXLE (M5CF1)

SPEEDOMETER DRIVEN GEAR

ASSEMBLY

COMPONENTS E5C04DA3

2 5

4
1 3

1. Oil seal 3. O-ring

2. Sleeve 4. Speedometer driven gear
5. Spring pin
LMJF018B

REASSEMBLY E4CDE2EC

Apply gear oil sparingly to the speedometer driven gear

shaft and insert the shaft.

AMJF017B