TRANSAXLE & TRANSMISSION

Transcription

1 TRSSS & DRV ST T TRSX & TRSSS T TTS 6T: RS652 nspection...19 UT DSS... 9 /T SYST... 9 System Diagram...9 System Description...10 SYT DSS...11 S, VRT D RSSS (V) TRUST...11 V Troubleshooting hart...11 RUT...12 RUTS...12 recaution for Supplemental Restraint System (SRS) "R " and "ST T R-T- SR"...12 recaution for rocedure without owl Top over...12 Service otice or recautions...12 RRT...13 RRT...13 Special Service Tools...13 ommercial Service Tools V T...17 /T...17 Draining...17 Refilling...17 nspection V RR...18 SD S...18 Removal and nstallation U SWT...19 Removal and nstallation...19 R/UTR ST SWT...20 Removal and nstallation...20 nspection...20 TR...21 xploded View...21 Removal and nstallation...21 djustment...22 R RTR S...24 xploded View...24 Removal and nstallation...24 RV D STT...26 TRSX SSY...26 xploded View...26 Removal and nstallation...26 DSSSY D SSY...28 TRSX SSY...28 xploded View...28 Disassembly...32 ssembly...39 djustment...49 UT ST D R...56 xploded View...56 Disassembly...56 ssembly...57 nspection...61 ST D R...63 xploded View...63 Disassembly...63 ssembly...64 nspection...69 RVRS DR ST D R...72 xploded View...72 T-1

2 Disassembly ssembly nspection DRV xploded View Disassembly ssembly nspection ST R D R RD xploded View Disassembly ssembly nspection SRV DT D STS (SDS) SRV DT D STS (SDS) eneral Specifications nd lay aulk Ring learance Dimension Differential Side earing reload Differential Side ear learance VT: R009 S ST DSS D RR WRW Work low Diagnostic Work Sheet ST D DUSTT DDT SRV W R TR UT DDT SRV W R TR UT : recaution for T and VT ssembly Replacement UT DSS VT SYST System Diagram omponent arts ocation - oupe omponent arts ocation - Sedan SYST ross-sectional View System Diagram System Description omponent arts ocation - oupe omponent arts ocation - Sedan omponent Description YDRU TR SYST System Diagram System Description omponent arts ocation - oupe omponent arts ocation - Sedan omponent Description TR SYST System Diagram System Description omponent arts ocation - oupe omponent arts ocation - Sedan omponent Description U D ST TR SYST..107 System Diagram System Description omponent arts ocation - oupe omponent arts ocation - Sedan omponent Description ST S System Diagram System Description omponent arts ocation - oupe omponent arts ocation - Sedan omponent Description ST SYST System Diagram System Description omponent arts ocation omponent Description RD DST (D) SYST Diagnosis Description DSS SYST (T) SUT- unction (TRSSS) Diagnostic Tool unction T DSS U1000 RUT Description DT ogic Diagnosis rocedure STRT S Description DT ogic Diagnosis rocedure ST SWT Description DT ogic Diagnosis rocedure omponent nspection (Stop amp Switch) R/UTR ST SWT..129 Description DT ogic Diagnosis rocedure T-2

3 omponent nspection VT UD TRTUR SSR Description DT ogic Diagnosis rocedure omponent nspection (VT luid Temperature Sensor) UT SD SSR (R SD SSR) Description DT ogic Diagnosis rocedure V SD SSR VT (S- DRY SD SSR) Description DT ogic Diagnosis rocedure SD S Description DT ogic Diagnosis rocedure T D Description DT ogic Diagnosis rocedure TRQU VRTR UT S- D VV Description DT ogic Diagnosis rocedure omponent nspection (Torque onverter lutch Solenoid Valve) /T T S/V UT ( -U) Description DT ogic Diagnosis rocedure omponent nspection (Torque onverter lutch Solenoid Valve) omponent nspection (ock-up Select Solenoid Valve) RSSUR SD VV Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)] RSSUR TR SD RR ( RSSUR S- D VV) Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)] RSSUR TR SD RR (S RSSUR S- D VV) Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)] omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)] RSSUR TR SD TR (S RSSUR SD VV) Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)] U D SWT Description DT ogic Diagnosis rocedure omponent nspection (anual ode Switch) TRSSS UD RSSUR SSR (S RSSUR SSR) Description DT ogic Diagnosis rocedure RSSUR SSR UT Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)] omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)] TRSSS UD RSSUR SSR (R RSSUR SSR) Description DT ogic Diagnosis rocedure SDRY RSSUR DW Description DT ogic Diagnosis rocedure T T-3

4 omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)] omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)] TRSSS TR DU (WR SUY) Description DT ogic Diagnosis rocedure TRTT ST SSR Description DT ogic Diagnosis rocedure ST V SD S Description DT ogic Diagnosis rocedure VT SD SSR UT Description DT ogic Diagnosis rocedure TR TRTT TR SYST Description DT ogic Diagnosis rocedure U ST SD VV Description DT ogic Diagnosis rocedure omponent nspection (ock-up Select Solenoid Valve) RSSUR TR Description DT ogic Diagnosis rocedure Wiring Diagram - VT ST SYST - Sedan Diagnosis rocedure U DSS T Reference Value Wiring Diagram VT TR SYST oupe Wiring Diagram VT TR SYST Sedan ail-safe DT nspection riority hart DT ndex SYT DSS SYST SYT Symptom Table RUT RUTS recaution for Supplemental Restraint System (SRS) "R " and "ST T R-T- SR" recaution for rocedure without owl Top over. 228 recaution ecessary for Steering Wheel Rotation fter attery Disconnect recaution for n oard Diagnosis (D) System of VT and ngine recaution for T and VT ssembly Replacement Removal and nstallation rocedure for VT Unit onnector recaution Service otice or recaution TT UT onversion Table RRT RRT Special Service Tool ommercial Service Tool ST TR Description DT ogic Diagnosis rocedure omponent nspection (Step otor) ST TR - UT Description DT ogic Diagnosis rocedure ST SYST Description Wiring Diagram - VT ST SYST - oupe T-4 -V T VT UD nspection hanging UD R leaning ST TST nspection and udgment RSSUR TST nspection and udgment RD TST...244

5 Description heck before ngine s Started heck at dle ruise Test VT ST nspection and djustment V RR TRSSS TR DU xploded View Removal and nstallation TR DV xploded View Removal and nstallation TR xploded View Removal and nstallation R RTR S xploded View Removal and nstallation DRT SD S xploded View Removal and nstallation RV D STT TRSX SSY xploded View Removal and nstallation nspection SRV DT D STS (SDS) SRV DT D STS (SDS) eneral Specification Vehicle Speed When Shifting ears Stall Speed ine ressure Solenoid Valves VT luid Temperature Sensor rimary Speed Sensor Secondary Speed Sensor Removal and nstallation VT: R010 S ST DSS D RR WRW Work low Diagnostic Work Sheet ST D DUSTT DDT SRV W R TR UT DDT SRV W R TR UT : Service fter Replacing T and Transaxle ssembly UT DSS VT SYST System Diagram omponent arts ocation - oupe omponent arts ocation - Sedan SYST ross-sectional View System Diagram System Description omponent arts ocation - oupe omponent arts ocation - Sedan omponent Description YDRU TR SYST System Diagram System Description omponent arts ocation - oupe omponent arts ocation - Sedan omponent Description TR SYST System Diagram System Description omponent arts ocation - oupe omponent arts ocation - Sedan omponent Description U D ST TR SYST. 281 System Diagram System Description omponent arts ocation - oupe omponent arts ocation - Sedan omponent Description ST S System Diagram System Description omponent arts ocation - oupe omponent arts ocation - Sedan omponent Description ST SYST System Diagram System Description omponent arts ocation omponent Description RD DST (D) SYST Diagnosis Description DSS SYST (T) SUT- unction (TRSSS) T T-5

6 Diagnostic Tool unction T DSS U1000 RUT Description DT ogic Diagnosis rocedure U1010 TR UT () Description DT ogic Diagnosis rocedure ST SWT Description DT ogic Diagnosis rocedure omponent nspection (Stop amp Switch) R/UTR ST SWT. 302 Description DT ogic Diagnosis rocedure omponent nspection (ark/eutral osition Switch) VT UD TRTUR SSR. 305 Description DT ogic Diagnosis rocedure omponent nspection (VT luid Temperature Sensor) UT SD SSR (R SD SSR) Description DT ogic Diagnosis rocedure V SD SSR VT (S- DRY SD SSR) Description DT ogic Diagnosis rocedure SD S Description DT ogic Diagnosis rocedure Diagnosis rocedure omponent nspection (Torque onverter lutch Solenoid Valve) /T T S/V UT ( -U)..320 Description DT ogic Diagnosis rocedure omponent nspection (Torque onverter lutch Solenoid Valve) omponent nspection (ock-up Select Solenoid Valve) RSSUR SD VV..322 Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)] RSSUR TR SD RR ( RSSUR S- D VV) Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)] RSSUR TR SD RR (S RSSUR S- D VV) Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)] omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)] RSSUR TR SD TR (S RSSUR SD VV) Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)] T D Description DT ogic Diagnosis rocedure TRQU VRTR UT S- D VV Description DT ogic T U D SWT Description DT ogic Diagnosis rocedure omponent nspection (anual ode Switch) TRSSS UD RSSUR SSR (S RSSUR SSR) Description

7 DT ogic Diagnosis rocedure omponent nspection (ock-up Select Solenoid Valve) RSSUR SSR UT Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)] omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)] TRSSS UD RSSUR SSR (R RSSUR SSR) Description DT ogic Diagnosis rocedure SDRY RSSUR DW Description DT ogic Diagnosis rocedure omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)] omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)] TRSSS TR DU (WR SUY) Description DT ogic Diagnosis rocedure TRTT ST SSR Description DT ogic Diagnosis rocedure ST V SD S Description DT ogic Diagnosis rocedure VT SD SSR UT Description DT ogic Diagnosis rocedure TR TRTT TR SYST Description DT ogic Diagnosis rocedure U ST SD VV Description DT ogic Diagnosis rocedure T RSSUR TR Description DT ogic Diagnosis rocedure ST TR Description DT ogic Diagnosis rocedure omponent nspection (Step otor) ST TR - UT Description DT ogic Diagnosis rocedure ST ST DTR RUT Description omponent unction heck Diagnosis rocedure ST SYST Description Wiring Diagram - VT ST SYST - oupe Wiring Diagram - VT ST SYST - Sedan Diagnosis rocedure U DSS T Reference Value Wiring Diagram - VT TR SYST - oupe Wiring Diagram - VT TR SYST - Sedan ail-safe DT nspection riority hart DT ndex SYT DSS SYST SYT Symptom Table RUT RUTS recaution for Supplemental Restraint System (SRS) "R " and "ST T R-T- SR" recaution for rocedure without owl Top over..405 recaution ecessary for Steering Wheel Rotation fter attery Disconnect recaution for n oard Diagnosis (D) System of VT and ngine T

8 recaution for T and VT ssembly Replacement Removal and nstallation rocedure for VT Unit onnector recaution Service otice or recaution TT UT onversion Table RRT RRT Special Service Tool ommercial Service Tool V T VT UD nspection hanging VT UD R SYST leaning ST TST nspection and udgment RSSUR TST nspection and udgment RD TST Description heck before ngine s Started heck at dle ruise Test VT ST nspection and djustment V RR TRSSS TR DU xploded View Removal and nstallation TR DV xploded View Removal and nstallation nspection and djustment TR xploded View Removal and nstallation DRT SD S xploded View Removal and nstallation R RTR S xploded View Removal and nstallation xploded View Removal and nstallation R/UTR ST () SWT..432 xploded View Removal and nstallation RRY SD SSR xploded View Removal and nstallation SDRY SD SSR xploded View Removal and nstallation U TT T xploded View Removal and nstallation RV D STT TRSX SSY xploded View Removal and nstallation nspection DSSSY D SSY TRQU VRTR D VRTR US S xploded View Disassembly ssembly SRV DT D STS (SDS) SRV DT D STS (SDS) eneral Specification Vehicle Speed When Shifting ears Stall Speed ine ressure Solenoid Valves VT luid Temperature Sensor rimary Speed Sensor Secondary Speed Sensor Removal and nstallation T-8

9 /T SYST < UT DSS > [6T: RS652] UT DSS /T SYST System Diagram RSS-ST VW D: T 1. Transaxle case 2. 3rd input gear 3. 3rd-4th synchronizer hub 4. 3rd-4th coupling sleeve 5. 4th input gear 6. 5th input gear 7. 5th-6th synchronizer hub 8. 5th-6th coupling sleeve 9. 6th input gear 10. nput shaft rear bearing 11. ainshaft rear bearing 12. 6th main gear 13. 5th main gear 14. 4th main gear 15. 3rd main gear 16. 2nd main gear 17. 1st-2nd synchronizer hub 18. 1st-2nd coupling sleeve 19. 1st main gear 20. Reverse main gear 21. Differential side bearing 22. Differential case assembly 23. inal gear 24. Speedometer drive gear 25. ainshaft front bearing 26. ainshaft 27. nput shaft 1877 T-9

10 /T SYST < UT DSS > [6T: RS652] 28. nput shaft front bearing 29. lutch housing 30. Reverse idler shaft 31. Reverse idler gear (ront) 32. Reverse coupling sleeve 33. Reverse idler gear (Rear) System Description DU- SYRZR Double-cone synchronizer is adopted for 3rd gear to reduce operating force of the shift lever. TR- SYRZR Triple-cone synchronizer are adopted for 1st and 2nd gears to reduce operating force of the shift lever. D: RVRS R S RVT UT (SYRZ TD) Reverse gear can be matched smoothly in a structure by setting synchronizer hub (1) of reverse idler gear (Rear), reverse coupling sleeve (2), reverse baulk ring (3), and reverse insert spring (4) to reverse idler gears, and letting reverse gear be synchronized. 5 : Reverse idler gear (Rear) 6 : Reverse idler gear (ront) 1909 T-10

11 S, VRT D RSSS (V) TRUST < SYT DSS > [6T: RS652] SYT DSS S, VRT D RSSS (V) TRUST V Troubleshooting hart D: Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. f necessary, repair or replace these parts. Reference page -12 T-28 T-21 T-32 T-28 T SUSTD RTS (ossible cause) (il level is low.) (Wrong oil.) (il level is high.) ST (Damaged) S (Worn or damaged) ST TR (Worn) STR RD SSY ST R (Worn) R (Worn or damaged) R (Worn or damaged) U R (Worn or damaged) SRT SR (Damaged) Symptoms oise il leakage ard to shift or will not shift umps out of gear T-11

12 < RUT > RUT RUTS RUTS [6T: RS652] recaution for Supplemental Restraint System (SRS) "R " and "ST T R-TSR" D: The Supplemental Restraint System such as R and ST T R-TSR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. nformation necessary to service the system safely is included in the SR and S section of this Service anual. WR: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized SS/T dealer. mproper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. or removal of Spiral able and ir ag odule, see the SR section. Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service anual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. recaution for rocedure without owl Top over When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. D: Service otice or recautions 3706 D: Do not reuse transaxle oil, once it has been drained. heck oil level or replace oil with vehicle on level surface. During removal or installation, keep inside of transaxle clear of dust or dirt. heck for the correct installation status prior to removal or disassembly. f matching marks are required, be certain they do not interfere with the function of the parts they are applied. n principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. f tightening sequence is specified, use it. e careful not to damage sliding surfaces and mating surfaces. T-12

13 < RRT > RRT RRT RRT [6T: RS652] Special Service Tools D: The actual shapes of ent-oore tools may differ from those of special service tools illustrated here. Tool number (ent-oore o.) Tool name V381054S0 (-34286) uller Description Removing differential side bearing outer race Removing mainshaft front bearing T ST (-26082) Drift ZZ0601D nstalling differential side oil seal (clutch housing side) a: 60 mm (2.36 in) dia. b:47 mm (1.85 in) dia. ZZ0814D ST ( ) Drift ST (-26082) Drift ZZ1000D nstalling input shaft oil seal nstalling reverse main gear nstalling 1st main gear bushing nstalling 1st-2nd synchronizer hub assembly nstalling 2nd main gear bushing nstalling 3rd main gear a: 49 mm (1.93 in) dia. b: 41 mm (1.61 in) dia. nstalling mainshaft front bearing nstalling 6th input gear bushing nstalling 4th main gear nstalling 5th main gear nstalling 6th main gear a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia. ZZ1002D ST (-25405) Drift ZZ0811D nstalling differential side oil seal (transaxle case side) nstalling differential side bearing outer race (transaxle case side) nstalling mainshaft rear bearing nstalling differential side bearing a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia. ST ( ) Drift nstalling bore plug Removing differential side bearing (transaxle case side) Removing differential side bearing (clutch housing side) a: 38 mm (1.50 in) dia. b: 28.5 mm (1.122 in) dia. ZZ1000D T-13

14 < RRT > Tool number (ent-oore o.) Tool name ST ( ) Drift V ( ) Drift ST ( ) uller RRT ZZ1023D ZZ1133D Description [6T: RS652] Removing input shaft rear bearing Removing 5th input gear bushing, 4th input gear, 4th input gear bushing, 3rd-4th synchronizer hub assembly, and 3rd input gear nstalling input shaft front bearing Removing mainshaft rear bearing Removing 6th main gear Removing 4th main gear and 5th main gear a: 22 mm (0.87 in) dia. b: 28 mm (1.10 in) dia. Removing 5th input gear and 5th-6th synchronizer hub assembly Removing 3rd main gear, 2nd main gear, 2nd main gear bushing, 1st-2nd synchronizer hub assembly, 1st main gear, 1st main gear bushing, and reverse main gear a: 39.7 mm (1.563 in) dia. b: 35 mm (1.38 in) dia. c: 15 mm (0.59 in) easuring wear of inner baulk ring V ( ) ress stand ST ( ) Drift ST ( ) Drift ZZ0537D ZZ1058D ZZ0978D nstalling 3rd-4th synchronizer hub assembly nstalling 4th input gear bushing nstalling 5th input gear bushing nstalling 5th-6th synchronizer hub assembly nstalling 2nd main gear bushing nstalling 3rd main gear a: 46 mm (1.81 in) dia. b: 41 mm (1.61 in) nstalling input shaft rear bearing nstalling 4th main gear nstalling 5th main gear nstalling 6th main gear nstalling mainshaft rear bearing a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35.2 mm (1.386 in) dia. nstalling input shaft front bearing a: 80 mm (3.15 in) dia. b: 38 mm (1.50 in) dia. c: 31 mm (1.22 in) dia. ZZ0978D T-14

15 < RRT > RRT [6T: RS652] Tool number (ent-oore o.) Tool name Description ST ( ) ress stand nstalling reverse main gear nstalling 1st main gear bushing nstalling 1st-2nd synchronizer hub assembly a: 63 mm (2.48 in) dia. b: 65 mm (2.56 in) V (-35870) Drift ZZ1058D nstalling reverse main gear a: 68 mm (2.68 in) dia. b: 60 mm (2.36 in) dia. T ZZ1003D V ( ) Drift ZZ0838D nstalling 1st main gear bushing nstalling 1st-2nd synchronizer hub assembly nstalling differential side bearing (transaxle case side) nstalling differential side bearing (clutch housing side) a: 71 mm (2.80 in) dia. b: 65 mm (2.56 in) dia. ( ) (-39713) reload adapter easuring end play of side gear T087 ommercial Service Tools D: Tool name Description in punch Removing and installing retaining pin a: 4.5 mm (0.177 in) dia. in punch T410 Removing and installing retaining pin of selector lever a: 5.5 mm (0.217 in) dia. T410 T-15

16 < RRT > Tool name in punch RRT Description [6T: RS652] Removing and installing retaining pin of each shifter lever a: 7.5 mm (0.295 in) dia. Drift T410 nstalling striking rod oil seal and shifter lever oil seal a: 24.5 mm (0.965 in) dia. uller S-T063 Removing each bearing, gear, and bushing uller ZZ0537D Removing each bearing, gear, and bushing ower tool T077 oosening bolts and nuts 0190 T-16

17 /T < -V T > [6T: RS652] -V T /T Draining D: Start engine and let it run to warm up transaxle oil. 2. Stop engine and remove the drain plug to drain the oil. 3. nstall the drain plug with a new gasket to the transaxle case. Tighten the drain plug to the specified torque. Refer to T-28, "xploded View". UT: Do not reuse gasket. Refilling 1. Remove the filler plug (1) and fill transaxle with new oil. D: T 2. fter refilling oil, measure oil level to check if it is within the specification using suitable gauge () as shown. UT: Do not start engine while checking oil level. nsert the suitable gauge straight and against the wall of the filler plug hole, then measure the gauge from the top of the filler plug hole to the oil level as shown. 3. nstall the filler plug with a new -ring to the clutch housing. UT: Do not reuse -ring. 4. Tighten filler plug bolt to the specified torque. Refer to T-28, "xploded View". nspection ake sure that oil is not leaking from transaxle or around it. V il grade il level 1. Remove the filler plug (1). 2. easure oil level to check if it is within the specification using a suitable gauge () as shown. UT: Do not start engine while checking oil level. nsert the suitable gauge straight and against the wall of the filler plug hole, then measure the gauge from the top of the filler plug hole to the oil level as shown. il level : Refer to -12, "luids and ubricants". : Refer to T-82, "eneral Specifications". : Refer to T-82, "eneral Specifications". 3. nstall the filler plug with a new -ring to the clutch housing. UT: Do not reuse -ring. 4. Tighten the filler plug bolt to the specified torque. Refer to T-28, "xploded View". D0138ZZ D: D0138ZZ T-17

18 SD S < -V RR > [6T: RS652] -V RR SD S Removal and nstallation D: RV 1. Remove the drive shaft. Refer to X-9, "Removal and nstallation (eft Side)", X-10, "Removal and nstallation (Right Side)". 2. Remove oil seal using suitable tool. UT: Do not damage the transaxle case surface when removing oil seal. STT 1. Drive the oil seal straight into the transaxle case and clutch housing to the specified dimension "" using Tools. S0824 Dimension : 0 ±± 0.5 mm (0 ± in) Tool numbers : ST ( 25405) : ST (-26082) UT: Do not reuse oil seal. 2. nstall the drive shaft. Refer to X-9, "Removal and nstallation (eft Side)", X-10, "Removal and nstallation (Right Side)". 3. heck the transaxle fluid level. Refer to T-17, "nspection". S1010 T-18

19 -U SWT < -V RR > [6T: RS652] -U SWT Removal and nstallation D: or removal and installation of back-up lamp switch, refer to T-28, "xploded View". nspection heck continuity. D: ear position Reverse xcept reverse ontinuity Yes o T S0708 T-19

20 R/UTR ST SWT < -V RR > [6T: RS652] R/UTR ST SWT Removal and nstallation or removal and installation of park/neutral position switch, refer to T-28, "xploded View". nspection D: D: heck continuity. ear position eutral xcept neutral ontinuity Yes o S0708 T-20

21 TR < -V RR > [6T: RS652] TR xploded View D: T D ontrol lever knob 2. ontrol lever 3. ontrol device assembly 4. Retainer grommet 5. Select cable 6. Shift cable 7. ock plate 8. able bracket Removal and nstallation RV D: Shift control lever to the neutral position. 2. Remove the air filter assembly. Refer to -25, "Removal and nstallation" (QR25D), -129, "Removal and nstallation" (VQ35D). 3. Remove the shift cable from the shift lever and cable bracket. 4. Remove the select cable from the select lever and cable bracket. 5. Remove the center console. Refer to -17, "Disassembly and ssembly". 6. Remove the shift cable from the control device assembly. 7. Remove the select cable from the control device assembly. 8. Remove the bracket covering the retainer grommet. T-21

22 TR < -V RR > [6T: RS652] 9. Remove the retainer grommet bolts and retainer grommet. 10. Remove the shift cable and select cable from the vehicle. 11. Remove the control device assembly bolts and the control device assembly. STT nstallation is in the reverse order of removal. fter assembly, make sure control lever automatically returns to eutral when it is moved to 1st, 2nd, or Reverse. When control lever is shifted to each position, make sure there is no binding or disconnection at each connection. djustment ST DUSTT 1. Remove the select cable eye end (1) from the select lever (2) of the control device. 2. Slide the lock () on the select cable eye end (1) away from the cable end. 3. Turn the select cable eye end (1) over and push the stopper () to release the adjustment. D: D0051ZZ 4. nstall the select cable eye end (1) to the select lever (2) of the control device D0052ZZ 5. old the shift lever with the gap between the reverse gate stopper and the shifter base at the specified distance (). Distance "" : mm ( in) D0053ZZ T-22

23 TR < -V RR > [6T: RS652] 6. ush the stopper () into the cable eye end housing (1). 7. Slide the lock () over the stopper (). 8. heck for smooth gear select operation. D0054ZZ T T-23

24 R RTR S < -V RR > [6T: RS652] R RTR S xploded View QR25D engine models D: D0041ZZ 1. lip 2. ir cleaner case 3. Transaxle assembly 4. lip 5. ir breather hose. Set paint mark and clip at front side : ront VQ35D engine models D0042ZZ 1. ir cleaner case 2. Transaxle assembly 3. lip 4. ir breather hose 5. lip. Set paint mark and clip at front side : ront Removal and nstallation Refer to the figure for air breather hose removal and installation information. UT: nstall air breather hose with paint mark and clip facing front. nstall air breather hose onto air breather tube until overlap area reaches the spool. nstall air breather hose to air cleaner case by fully inserting the clip. D: T-24

25 R RTR S < -V RR > [6T: RS652] ake sure there are no pinched or restricted areas on air breather hose caused by bending or winding when installing it. T T-25

26 TRSX SSY < RV D STT > [6T: RS652] RV D STT TRSX SSY xploded View D: D Transaxle assembly 2. engine mounting bracket. Refer to T-26, "Removal and nstallation" Removal and nstallation D: UT: f transaxle assembly is removed from the vehicle, always replace S (oncentric Slave ylinder). nserted S returns to the original position when removing transaxle assembly. Dust on clutch disc sliding parts may damage S seal and may cause clutch fluid leakage. RV 1. Remove the engine and transaxle as an assembly. Refer to -72, "Removal and nstallation" (QR25D), -198, "Removal and nstallation" (VQ35D). UT: Do not depress clutch pedal during removal procedure. 2. Disconnect the electrical connectors from the following: ack-up lamp switch ark/neutral position switch 3. Remove the harness from the transaxle. 4. Remove the starter motor. Refer to STR-25, "Removal and nstallation" (QR25D), STR-49, "Removal and nstallation" (VQ35D). 5. Remove the transaxle to engine and engine to transaxle bolts. T-26

27 TRSX SSY < RV D STT > [6T: RS652] 6. Separate the transaxle from the engine. 7. f necessary remove the following: ir breather hose Switches engine mount rackets STT nstallation is in the reverse order of removal. f transaxle is removed from the vehicle, always replace S. Refer to -12, "Removal and nstallation". When installing the transaxle assembly to the engine, install the bolts following the standard below. UT: When installing transaxle assembly do not bring transaxle input shaft into contact with clutch cover. - QR25D engine models : Transaxle to engine T : ngine to transaxle olt symbol D Quantity olt length mm (in) Tightening torque m (kg - m, ft- lb) 35.3 (3.6, 26) 45 (1.77) 74.5 (7.6, 55) 80 (3.15) 45 (1.77) 42.6 (4.3, 31) 35 (1.38) 45 (1.77) 48.0 (4.9, 35) VQ35D engine models : Transaxle to engine : ngine to transaxle olt o. Quantity olt length mm (in) Tightening torque m (kg - m, ft- lb) 55 (2.17) 74.5 (7.6, 55) (4.59) 45 (1.77) 50.0 (5.1, 37) WD0188ZZ leed the air from the clutch hydraulic system. Refer to -6, "ir leeding rocedure". fter installation, check oil level, and check for leaks and loose mechanisms. Refer to T-17, "nspection". T-27

28 TRSX SSY < DSSSY D SSY > [6T: RS652] DSSSY D SSY TRSX SSY xploded View S D US D: Differential side oil seal 2. lutch housing 3. nput shaft oil seal 4. il channel 5. il gutter 6. ack-up lamp switch 7. lunger 8. asket 9. lug 10. ore plug 11. Striking rod oil seal 12. Transaxle case 13. il gutter 14. ir breather tube 15. ark/eutral position () switch 16. Shifter lever oil seal 17. Drain plug 18. agnet 19. -ring 20. iller plug (With S models) 21. Speedometer pinion gear (Without S models) : pply enuine Silicone RTV or an equivalent. Refer to -15, "Recommended hemical roducts and Sealants". ST D R T-28

29 TRSX SSY < DSSSY D SSY > [6T: RS652] T 1. nput shaft front bearing 2. nput shaft 3. 3rd needle bearing 4. 3rd input gear 5. 3rd inner baulk ring 6. 3rd synchronizer cone 7. 3rd outer baulk ring 8. 3rd-4th spread spring 9. 3rd-4th shifting insert 10. 3rd-4th synchronizer hub 11. 4th baulk ring 12. 3rd-4th coupling sleeve 13. 4th input gear bushing 14. 4th needle bearing 15. 4th input gear 16. Thrust washer 17. 5th input gear bushing 18. 5th needle bearing 19. 5th input gear 20. 5th baulk ring 21. 5th-6th spread spring 22. 5th-6th shifting insert 23. 5th-6th synchronizer hub 24. 5th-6th coupling sleeve 25. 6th baulk ring 26. 6th input gear 27. 6th needle bearing 28. 6th input gear bushing 29. Snap ring 30. nput shaft rear bearing 31. il channel 32. nput shaft rear bearing adjusting 33. Retaining pin shim 34. Reverse idler shaft 35. Thrust needle bearing 36. Reverse idler gear needle bearing 37. Reverse insert spring 38. Reverse idler gear (ront) 39. Reverse baulk ring 40. Reverse coupling sleeve 41. Reverse idler gear (Rear) 42. Reverse idler gear adjusting shim : Replace the parts as a set. Refer to -4, "omponents" for symbols not described on the above. pply gear oil to gears, shafts, synchronizers, and bearings when assembly T-29

30 TRSX SSY < DSSSY D SSY > [6T: RS652] ainshaft front bearing 2. ainshaft bearing retainer 3. ainshaft 4. Reverse main gear 5. 1st main gear 6. 1st main gear bushing 7. 1st needle bearing 8. 1st inner baulk ring 9. 1st synchronizer cone 10. 1st outer baulk ring 11. 1st-2nd spread spring 12. 1st-2nd shifting insert 13. 1st-2nd synchronizer hub 14. 2nd outer baulk ring 15. 2nd synchronizer cone 16. 2nd inner baulk ring 17. 1st-2nd coupling sleeve 18. 2nd main gear bushing 19. 2nd needle bearing 20. 2nd main gear 21. 3rd main gear 22. 3rd-4th mainshaft spacer 23. 4th main adjusting shim 24. 4th main gear 25. 5th main gear 26. 5th-6th mainshaft spacer 27. 6th main gear 28. 6th main gear adjusting shim 29. ainshaft rear bearing 30. ainshaft -ring 31. -ring holder 32. Snap ring 33. ainshaft rear bearing adjusting shim : Replace the parts as a set. Refer to -4, "omponents" for symbols not described on the above. pply gear oil to gears, shafts, synchronizers, and bearings when assembly. ST R D R RD T-30

31 TRSX SSY < DSSSY D SSY > [6T: RS652] T 1. lutch housing 2. Retaining pin 3. Reverse shift fork 4. Reverse fork rod 5. Return spring 6. Striking rod assembly 7. Striking rod shim 8. Striking rod adjusting shim 9. Shifter lever 10. Shifter lever 11. uide bolt 12. Selector lever 13. Transaxle case 14. 3rd-4th shift fork 15. 3rd-4th fork rod 16. 1st-2nd shift fork 17. 1st-2nd fork rod 18. 5th-6th shift fork 19. 5th-6th fork rod DRV 1806 T-31

32 TRSX SSY < DSSSY D SSY > [6T: RS652] Differential side bearing outer race (clutch housing side) Disassembly 2. Differential side bearing (clutch housing side) 1. Remove drain plug and gasket from clutch housing. 2. Remove plug bolt and then plug (with S models) or speedometer pinion gear (without S models) and -ring from clutch housing. 3. Speedometer drive gear 4. Differential case 5. inal gear 6. Differential side bearing (transaxle case side) 7. Differential side bearing outer race (transaxle case side) 8. Differential side bearing adjusting shim 9. inion mate shaft 10. Side gear 11. Side gear thrust washer 12. inion mate gear 13. inion mate thrust washer 14. Retaining pin Replace parts as a set D: T-32

33 TRSX SSY < DSSSY D SSY > [6T: RS652] 3. Remove plug and gasket from transaxle case. 4. Remove park/neutral position () switch (1) from transaxle case. 5. Remove back-up lamp switch (2) and plunger from transaxle case. UT: Do not lose plunger. 6. Remove air breather tube (3) from transaxle case T Remove guide bolt from transaxle case. 8. Remove retaining pin using suitable tool and then remove selector lever from transaxle case Remove transaxle case bolts T-33

34 TRSX SSY < DSSSY D SSY > [6T: RS652] 10. Remove bore plug from transaxle case. UT: Do not damage transaxle case. ccess bore plug from cutout () of transaxle case when removing Remove transaxle case following the procedures below. a. xpand snap ring at mainshaft rear bearing accessing from the bore plug hole. Then pull up transaxle case from clutch housing until snap ring comes off b. With shifter lever (1) held in the position shown, remove transaxle case from clutch housing. UT: Do not drop each adjusting shim. T: ake sure to hold shifter lever in the position shown. therwise transaxle case cannot be removed from clutch housing Remove oil gutter (1) and oil gutter (2) from transaxle case. : Tab of oil gutter 1841 T-34

35 TRSX SSY < DSSSY D SSY > [6T: RS652] 13. Remove snap ring from transaxle case. 14. Remove retaining pin using suitable tool and then remove shifter lever and shifter lever from transaxle case T Remove differential side bearing outer race from transaxle case using Tool, then remove differential side bearing adjusting shim from transaxle case. Tool number UT: Do not damage transaxle case. :V381054S (-34286) 16. Remove differential side oil seal from transaxle case using suitable tool. UT: Do not damage transaxle case S Remove shifter lever oil seal (1) and striking rod oil seal (2) from transaxle case. UT: Do not damage transaxle case T-35

36 TRSX SSY < DSSSY D SSY > [6T: RS652] 18. Remove striking rod shim (1), striking rod adjusting shim (2), mainshaft rear bearing adjusting shim (3), input shaft rear bearing adjusting shim (4), and reverse idler gear adjusting shim (5) Remove retaining pin of reverse shift fork (1) using suitable tool. 2 : Reverse fork rod Rotate striking lever of striking rod assembly as shown. Then rotate reverse fork rod to a position where bracket of reverse fork rod does not interfere with striking lever of striking rod assembly. 21. ull out reverse shift fork and reverse fork rod Remove retaining pin of 5th-6th shift fork (1) using suitable tool. 2 : 5th-6th fork rod Remove retaining pin of 3rd-4th shift fork (1) using suitable tool. 24. ull out 3rd-4th fork rod (2). T

37 TRSX SSY < DSSSY D SSY > [6T: RS652] 25. ull out 5th-6th shift fork (1) and 5th-6th fork rod (2). 26. ull out 3rd-4th shift fork (1) T Remove retaining pin of 1st-2nd shift fork (1) using suitable tool. 28. ull out 1st-2nd shift fork and 1st-2nd fork rod (2). 29. Remove striking rod assembly (1) Remove gear components from clutch housing in the following procedure. a. Remove a set of input shaft assembly, mainshaft assembly, and reverse idler gear assembly by tapping the tip of input shaft from the back of the clutch housing with a plastic hammer. UT: lways withdraw mainshaft straight out. ailure to do so can damage resin oil channel on clutch housing side. b. Remove final drive assembly T-37 S0964

38 TRSX SSY < DSSSY D SSY > [6T: RS652] 31. Remove magnet from clutch housing Remove mainshaft bearing retainer and then mainshaft front bearing from clutch housing using Tool. Tool number :V381054S (-34286) UT: Do not damage clutch housing, mainshaft front bearing, and oil channel. 33. Remove oil channel from clutch housing Remove differential side bearing outer race from clutch housing using Tool. Tool number :V381054S (-34286) UT: Do not damage clutch housing and differential side bearing outer race Remove input shaft oil seal from clutch housing using suitable tool. UT: Do not damage clutch housing. S Remove differential side oil seal from clutch housing using suitable tool. UT: Do not damage clutch housing. T

39 TRSX SSY < DSSSY D SSY > [6T: RS652] ssembly 1. nstall differential side oil seal (1) to clutch housing using Tool (). Dimension Tool number : mm ( in) : ST (-26082) UT: Do not reuse differential side oil seal. When installing, do not incline differential side oil seal. Do not damage clutch housing. D: T 2. nstall input shaft oil seal (1) to clutch housing using Tool () Dimension : mm ( in) Tool number : ST ( ) UT: Do not reuse input shaft oil seal. When installing, do not incline input shaft oil seal. Do not damage clutch housing T-39

40 TRSX SSY < DSSSY D SSY > [6T: RS652] 3. nstall differential side bearing outer race to clutch housing using Tool. Tool number : ST (-25405) UT: Replace differential side bearing and differential side bearing outer race as a set. W nstall oil channel (1) on mainshaft side. UT: When installing oil channel, fit the rib () of oil channel into the processed area of the spot facing () nstall mainshaft front bearing to clutch housing using Tool. Tool number : ST (-26082) UT: e careful with the orientation of mainshaft front bearing nstall mainshaft bearing retainer (1) to clutch housing and tighten bolt to the specified torque. 2 : ainshaft front bearing 3 : il channel UT: nstall with punched surface facing up nstall magnet to clutch housing T-40

41 TRSX SSY < DSSSY D SSY > [6T: RS652] 8. nstall final drive assembly into clutch housing. 9. nstall input shaft assembly, mainshaft assembly, and reverse idler gear assembly into clutch housing. UT: Wrap tape to the spline of input shaft so as not to damage the input shaft oil seal. e careful with the orientation of reverse idler shaft. S0888 T S nstall striking rod assembly (1) into clutch housing. UT: heck that return spring is securely seated in the groove on return pin T-41

42 TRSX SSY < DSSSY D SSY > [6T: RS652] 11. nstall 1st-2nd shift fork (1) and 1st-2nd fork rod (2) and then install retaining pin to 1st-2nd shift fork. UT: Do not reuse retaining pin. e careful with the orientation of 1st-2nd shift fork and 1st-2nd fork rod. ssemble retaining pin from the direction shown until it becomes flush with the end surface of 1st-2nd shift fork nstall 3rd-4th shift fork (1) to 3rd-4th coupling sleeve. UT: e careful with the orientation of 3rd-4th shift fork nstall 5th-6th shift fork (1) and 5th-6th fork rod (2) and then install retaining pin to 5th-6th shift fork. UT: Do not reuse retaining pin. e careful with the orientation of 5th-6th shift fork and 5th-6th fork rod. ssemble retaining pin from the direction shown until it becomes flush with the end surface of 5th-6th shift fork nstall 3rd-4th fork rod (2) and then install retaining pin to 3rd-4th shift fork (1). UT: Do not reuse retaining pin. e careful with the orientation of 3rd-4th fork rod. ssemble retaining pin from the direction shown until it becomes flush with the end surface of 3rd-4th shift fork nstall reverse shift fork (1) and reverse fork rod (2). UT: e careful with the orientation of reverse shift fork and reverse fork rod T-42

43 TRSX SSY < DSSSY D SSY > [6T: RS652] 16. Rotate striking lever of striking rod assembly as shown. Then rotate reverse fork rod to a position where bracket of reverse fork rod does not interfere with striking lever of striking rod assembly. 17. nstall retaining pin to reverse shift fork (1). 2 : Reverse fork rod UT: Do not reuse retaining pin. ssemble retaining pin from the direction shown until it becomes flush with the end surface of reverse shift fork T nstall selected differential side bearing adjusting shim(s) and differential side bearing outer race. or selection of adjusting shim(s), refer to T-49, "djustment". 19. nstall selected reverse idler gear adjusting shim onto reverse idler gear assembly. or selection of adjusting shim, refer to T-49, "djustment". 20. nstall selected input shaft rear bearing adjusting shim onto input shaft. or selection of adjusting shim, refer to T-49, "djustment". 21. nstall selected striking rod adjusting shim onto striking rod assembly. or selection of adjusting shim, refer to T-49, "djustment". 22. nstall shifter lever oil seal (1) and striking rod oil seal (2) to transaxle case using suitable tool. Dimension : mm ( in) UT: Do not reuse shifter lever oil seal and striking rod oil seal. When installing, do not incline shifter lever oil seal and striking rod oil seal. Do not damage transaxle case T-43

44 TRSX SSY < DSSSY D SSY > [6T: RS652] 23. nstall differential side oil seal (1) to transaxle case using Tool () [SST: ST (-25405)]. Dimension : mm ( in) Tool number : ST (-25405) UT: Do not reuse differential side oil seal. When installing, do not incline differential side oil seal. Do not damage transaxle case nstall shifter lever (1) and shifter lever (2) to transaxle case. UT: e careful with the orientation of shifter lever and shifter lever nstall retaining pin to shifter lever. UT: Do not reuse retaining pin. ssemble retaining pin from the direction shown until it becomes flush with the end surface of shifter lever nstall transaxle case according to the following: a. nstall selected mainshaft rear bearing adjusting shim into transaxle case. or selection of adjusting shim, refer to T-49, "djustment". T-44

45 TRSX SSY < DSSSY D SSY > [6T: RS652] b. nstall oil gutter (1) and oil gutter (2) to transaxle case. UT: nsert the tab () of oil gutter and oil gutter into transaxle case. c. Temporarily install snap ring of mainshaft rear bearing into transaxle case. UT: Do not reuse snap ring T 1842 d. pply recommended sealant to mating surface of clutch housing as shown. Use enuine Silicone RTV or an equivalent. Refer to - 15, "Recommended hemical roducts and Sealants". UT: Remove old sealant adhering to the mounting surfaces. lso remove any moisture, oil, or foreign material adhering to both mounting surfaces. pply sealant so as not to break the bead. The width of sealant bead is 1-2 mm ( in). The height of sealant bead is mm ( in). The overlap length of both ends of sealant bead is 3-5 mm ( in). e. With shifter lever (1) held in the position shown, temporarily assemble transaxle case to clutch housing. UT: Do not damage striking rod oil seal. T: ake sure to hold shifter lever in the position shown. therwise transaxle case cannot be installed to clutch housing T-45

46 TRSX SSY < DSSSY D SSY > [6T: RS652] f. While rotating shifter lever (1) in the direction shown, assemble transaxle case to clutch housing. 2 : Shifter lever 1929 g. ccessing from the bore plug hole, expand snap ring at mainshaft rear bearing so that the ring catches the periphery of mainshaft rear bearing. h. Temporarily tighten transaxle case bolts i. Shift the shifter lever (1) to 2nd gear position. T: The 2nd gear position is attained when shifter lever is in the position shown When transaxle is shifted to the 2nd gear position, mainshaft assembly is lifted. j. Seat snap ring in the groove on mainshaft rear bearing. f snap ring is not seated in the groove on mainshaft rear bearing, remove transaxle case and repeat the procedure from step d. S0893 T-46

47 TRSX SSY < DSSSY D SSY > [6T: RS652] k. Tighten transaxle case bolts to the specified torque. l. Shift the shifter lever (1) to neutral position. T: The neutral position is attained when shifter lever is in the position shown T nstall bore plug to transaxle case using Tool. Tool number UT: Do not reuse bore plug. : ST ( ) 28. nstall selector lever to transaxle case and then install retaining pin to selector lever. UT: Do not reuse retaining pin. ssemble retaining pin from the direction shown until it becomes flush with the end surface of selector lever T-47

48 TRSX SSY < DSSSY D SSY > [6T: RS652] 29. nstall guide bolt (1) according to the following: a. Shift the shifter lever and selector lever to neutral position (). b. Visually confirm from the guide bolt mounting hole () that shift lever is securely set to neutral position (). f it is not in the neutral position (), repeat the procedure from step a. UT: The guide groove (D) of striking rod assembly will be damaged when assembling guide bolt (1) if the lever is not in the neutral position (). c. heck continuity between terminals of park/neutral position () switch to confirm it in the neutral position. f it is not in the neutral position, remove park/neutral position () switch and repeat the procedure from step a. Refer to T-20, "nspection" d. nstall guide bolt to transaxle case and then tighten guide bolt to the specified torque. UT: Do not reuse guide bolt pply recommended sealant to threads of park/neutral position () switch (1). Then install it to transaxle case and tighten to the specified torque. Use enuine Silicone RTV or an equivalent. Refer to - 15, "Recommended hemical roducts and Sealants". UT: Remove old sealant and oil adhering to threads. 31. nstall plunger to transaxle case. 32. pply recommended sealant to threads of back-up lamp switch (2). Then install it to transaxle case and tighten to the specified torque. Use enuine Silicone RTV or an equivalent. Refer to - 15, "Recommended hemical roducts and Sealants". UT: Remove old sealant and oil adhering to threads. 33. nstall air breather tube (3) to transaxle case. UT: Do not reuse air breather tube. ssemble air breather tube until its collar element contacts with transaxle case T-48