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...15 -V T...17 /T...17 Draining...17 Refilling...17 nspection...17 -V RR...18 SD S...18 Removal and nstallation...18 -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
Disassembly... 72 ssembly... 72 nspection... 72 DRV... 74 xploded View... 74 Disassembly... 74 ssembly... 74 nspection... 77 ST R D R RD... 79 xploded View... 79 Disassembly... 79 ssembly... 79 nspection... 80 SRV DT D STS (SDS)... 82 SRV DT D STS (SDS)... 82 eneral Specifications... 82 nd lay... 83 aulk Ring learance... 83 Dimension... 84 Differential Side earing reload... 84 Differential Side ear learance... 84 VT: R009 S ST... 85 DSS D RR WRW... 85 Work low... 85 Diagnostic Work Sheet... 86 ST D DUSTT... 88 DDT SRV W R TR UT... 88 DDT SRV W R TR UT : recaution for T and VT ssembly Replacement... 88 UT DSS... 89 VT SYST... 89 System Diagram... 89 omponent arts ocation - oupe... 90 omponent arts ocation - Sedan... 91 SYST... 92 ross-sectional View... 92 System Diagram... 93 System Description... 93 omponent arts ocation - oupe... 94 omponent arts ocation - Sedan... 95 omponent Description... 95 YDRU TR SYST... 97 System Diagram... 97 System Description... 97 omponent arts ocation - oupe... 99 omponent arts ocation - Sedan... 100 omponent Description... 101 TR SYST...102 System Diagram... 102 System Description... 102 omponent arts ocation - oupe... 104 omponent arts ocation - Sedan... 105 omponent Description... 106 -U D ST TR SYST..107 System Diagram... 107 System Description... 107 omponent arts ocation - oupe... 108 omponent arts ocation - Sedan... 109 omponent Description... 110 ST S...111 System Diagram... 111 System Description... 111 omponent arts ocation - oupe... 112 omponent arts ocation - Sedan... 113 omponent Description... 114 ST SYST...115 System Diagram... 115 System Description... 115 omponent arts ocation... 115 omponent Description... 115 RD DST (D) SYST...117 Diagnosis Description... 117 DSS SYST (T)...119 SUT- unction (TRSSS)... 119 Diagnostic Tool unction... 122 T DSS...123 U1000 RUT...123 Description... 123 DT ogic... 123 Diagnosis rocedure... 123 0615 STRT S...124 Description... 124 DT ogic... 124 Diagnosis rocedure... 124 0703 ST SWT...126 Description... 126 DT ogic... 126 Diagnosis rocedure... 126 omponent nspection (Stop amp Switch)... 127 0705 R/UTR ST SWT..129 Description... 129 DT ogic... 129 Diagnosis rocedure... 129 T-2
omponent nspection... 130 0710 VT UD TRTUR SSR.. 132 Description... 132 DT ogic... 132 Diagnosis rocedure... 132 omponent nspection (VT luid Temperature Sensor)... 133 0715 UT SD SSR (R SD SSR)... 134 Description... 134 DT ogic... 134 Diagnosis rocedure... 134 0720 V SD SSR VT (S- DRY SD SSR)... 137 Description... 137 DT ogic... 137 Diagnosis rocedure... 137 0725 SD S... 141 Description... 141 DT ogic... 141 Diagnosis rocedure... 141 0730 T D... 142 Description... 142 DT ogic... 142 Diagnosis rocedure... 142 0740 TRQU VRTR UT S- D VV... 143 Description... 143 DT ogic... 143 Diagnosis rocedure... 143 omponent nspection (Torque onverter lutch Solenoid Valve)... 144 0744 /T T S/V UT ( -U).. 145 Description... 145 DT ogic... 145 Diagnosis rocedure... 145 omponent nspection (Torque onverter lutch Solenoid Valve)... 146 omponent nspection (ock-up Select Solenoid Valve)... 146 0745 RSSUR SD VV.. 147 Description... 147 DT ogic... 147 Diagnosis rocedure... 147 omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)]... 148 0746 RSSUR TR SD RR ( RSSUR S- D VV)... 149 Description... 149 DT ogic...149 Diagnosis rocedure...149 omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)]...150 0776 RSSUR TR SD RR (S RSSUR S- D VV)... 151 Description...151 DT ogic...151 Diagnosis rocedure...151 omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)]...152 omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)]...152 0778 RSSUR TR SD TR (S RSSUR SD VV)... 154 Description...154 DT ogic...154 Diagnosis rocedure...154 omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)]...155 0826 U D SWT... 156 Description...156 DT ogic...156 Diagnosis rocedure...156 omponent nspection (anual ode Switch)...158 0840 TRSSS UD RSSUR SSR (S RSSUR SSR)... 159 Description...159 DT ogic...159 Diagnosis rocedure...159 0841 RSSUR SSR UT... 162 Description...162 DT ogic...162 Diagnosis rocedure...162 omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)]...163 omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)]...163 0845 TRSSS UD RSSUR SSR (R RSSUR SSR)... 165 Description...165 DT ogic...165 Diagnosis rocedure...165 0868 SDRY RSSUR DW... 168 Description...168 DT ogic...168 Diagnosis rocedure...168 T T-3
omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)]...169 omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)]...169 1701 TRSSS TR DU (WR SUY)... 171 Description...171 DT ogic...171 Diagnosis rocedure...171 1705 TRTT ST SSR... 174 Description...174 DT ogic...174 Diagnosis rocedure...174 1722 ST V SD S... 175 Description...175 DT ogic...175 Diagnosis rocedure...175 1723 VT SD SSR UT... 177 Description...177 DT ogic...177 Diagnosis rocedure...177 1726 TR TRTT TR SYST... 179 Description...179 DT ogic...179 Diagnosis rocedure...179 1740 -U ST SD VV... 180 Description...180 DT ogic...180 Diagnosis rocedure...180 omponent nspection (ock-up Select Solenoid Valve)...181 1745 RSSUR TR... 182 Description...182 DT ogic...182 Diagnosis rocedure...182 Wiring Diagram - VT ST SYST - Sedan... 190 Diagnosis rocedure... 191 U DSS...194 T...194 Reference Value... 194 Wiring Diagram VT TR SYST oupe... 199 Wiring Diagram VT TR SYST Sedan... 207 ail-safe... 214 DT nspection riority hart... 215 DT ndex... 216 SYT DSS...217 SYST SYT...217 Symptom Table... 217 RUT...228 RUTS...228 recaution for Supplemental Restraint System (SRS) "R " and "ST T R-T- SR"... 228 recaution for rocedure without owl Top over. 228 recaution ecessary for Steering Wheel Rotation fter attery Disconnect... 228 recaution for n oard Diagnosis (D) System of VT and ngine... 229 recaution for T and VT ssembly Replacement... 229 Removal and nstallation rocedure for VT Unit onnector... 229 recaution... 230 Service otice or recaution... 231 TT UT onversion Table... 232 RRT...233 RRT...233 Special Service Tool... 233 ommercial Service Tool... 233 1777 ST TR... 183 Description...183 DT ogic...183 Diagnosis rocedure...183 omponent nspection (Step otor)...185 1778 ST TR - UT... 186 Description...186 DT ogic...186 Diagnosis rocedure...186 ST SYST... 188 Description...188 Wiring Diagram - VT ST SYST - oupe...188 T-4 -V T...235 VT UD...235 nspection... 235 hanging... 236 UD R...237 leaning... 237 ST TST...240 nspection and udgment... 240 RSSUR TST...242 nspection and udgment... 242 RD TST...244
Description... 244 heck before ngine s Started... 244 heck at dle... 245 ruise Test... 246 VT ST... 248 nspection and djustment... 248 -V RR... 249 TRSSS TR DU... 249 xploded View... 249 Removal and nstallation... 249 TR DV... 250 xploded View... 250 Removal and nstallation... 250 TR... 251 xploded View... 251 Removal and nstallation... 251 R RTR S... 252 xploded View... 252 Removal and nstallation... 252 DRT SD S... 253 xploded View... 253 Removal and nstallation... 253 RV D STT... 254 TRSX SSY... 254 xploded View... 254 Removal and nstallation... 254 nspection... 255 SRV DT D STS (SDS)... 256 SRV DT D STS (SDS)... 256 eneral Specification... 256 Vehicle Speed When Shifting ears... 256 Stall Speed... 256 ine ressure... 256 Solenoid Valves... 257 VT luid Temperature Sensor... 257 rimary Speed Sensor... 257 Secondary Speed Sensor... 257 Removal and nstallation... 257 VT: R010 S ST... 258 DSS D RR WRW... 258 Work low... 258 Diagnostic Work Sheet... 259 ST D DUSTT... 261 DDT SRV W R TR UT...261 DDT SRV W R TR UT : Service fter Replacing T and Transaxle ssembly...261 UT DSS... 263 VT SYST... 263 System Diagram...263 omponent arts ocation - oupe...264 omponent arts ocation - Sedan...265 SYST... 266 ross-sectional View...266 System Diagram...267 System Description...267 omponent arts ocation - oupe...268 omponent arts ocation - Sedan...269 omponent Description...270 YDRU TR SYST... 271 System Diagram...271 System Description...271 omponent arts ocation - oupe...273 omponent arts ocation - Sedan...274 omponent Description...274 TR SYST... 276 System Diagram...276 System Description...276 omponent arts ocation - oupe...278 omponent arts ocation - Sedan...279 omponent Description...279 -U D ST TR SYST. 281 System Diagram...281 System Description...281 omponent arts ocation - oupe...282 omponent arts ocation - Sedan...283 omponent Description...283 ST S... 285 System Diagram...285 System Description...285 omponent arts ocation - oupe...286 omponent arts ocation - Sedan...287 omponent Description...287 ST SYST... 289 System Diagram...289 System Description...289 omponent arts ocation...289 omponent Description...289 RD DST (D) SYST.. 291 Diagnosis Description...291 DSS SYST (T)... 293 SUT- unction (TRSSS)...293 T T-5
Diagnostic Tool unction...296 T DSS...297 U1000 RUT... 297 Description...297 DT ogic...297 Diagnosis rocedure...297 U1010 TR UT ()... 298 Description...298 DT ogic...298 Diagnosis rocedure...298 0703 ST SWT... 299 Description...299 DT ogic...299 Diagnosis rocedure...299 omponent nspection (Stop amp Switch)...300 0705 R/UTR ST SWT. 302 Description...302 DT ogic...302 Diagnosis rocedure...302 omponent nspection (ark/eutral osition Switch)...303 0710 VT UD TRTUR SSR. 305 Description...305 DT ogic...305 Diagnosis rocedure...305 omponent nspection (VT luid Temperature Sensor)...306 0715 UT SD SSR (R SD SSR)... 307 Description...307 DT ogic...307 Diagnosis rocedure...307 0720 V SD SSR VT (S- DRY SD SSR)... 312 Description...312 DT ogic...312 Diagnosis rocedure...312 0725 SD S... 316 Description...316 DT ogic...316 Diagnosis rocedure...316 Diagnosis rocedure... 318 omponent nspection (Torque onverter lutch Solenoid Valve)... 319 0744 /T T S/V UT ( -U)..320 Description... 320 DT ogic... 320 Diagnosis rocedure... 320 omponent nspection (Torque onverter lutch Solenoid Valve)... 321 omponent nspection (ock-up Select Solenoid Valve)... 321 0745 RSSUR SD VV..322 Description... 322 DT ogic... 322 Diagnosis rocedure... 322 omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)]... 323 0746 RSSUR TR SD RR ( RSSUR S- D VV)...324 Description... 324 DT ogic... 324 Diagnosis rocedure... 324 omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)]... 325 0776 RSSUR TR SD RR (S RSSUR S- D VV)...326 Description... 326 DT ogic... 326 Diagnosis rocedure... 326 omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)]... 327 omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)]... 327 0778 RSSUR TR SD TR (S RSSUR SD VV)...329 Description... 329 DT ogic... 329 Diagnosis rocedure... 329 omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)]... 330 0730 T D... 317 Description...317 DT ogic...317 Diagnosis rocedure...317 0740 TRQU VRTR UT S- D VV... 318 Description...318 DT ogic...318 T-6 0826 U D SWT...331 Description... 331 DT ogic... 331 Diagnosis rocedure... 331 omponent nspection (anual ode Switch)... 333 0840 TRSSS UD RSSUR SSR (S RSSUR SSR)...334 Description... 334
DT ogic... 334 Diagnosis rocedure... 334 omponent nspection (ock-up Select Solenoid Valve)...356 0841 RSSUR SSR UT... 337 Description... 337 DT ogic... 337 Diagnosis rocedure... 337 omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)]... 338 omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)]... 338 0845 TRSSS UD RSSUR SSR (R RSSUR SSR)... 340 Description... 340 DT ogic... 340 Diagnosis rocedure... 340 0868 SDRY RSSUR DW... 343 Description... 343 DT ogic... 343 Diagnosis rocedure... 343 omponent nspection [ressure ontrol Solenoid Valve (ine ressure Solenoid Valve)]... 344 omponent nspection [ressure ontrol Solenoid Valve (Secondary ressure Solenoid Valve)]... 344 1701 TRSSS TR DU (WR SUY)... 346 Description... 346 DT ogic... 346 Diagnosis rocedure... 346 1705 TRTT ST SSR... 349 Description... 349 DT ogic... 349 Diagnosis rocedure... 349 1722 ST V SD S... 350 Description... 350 DT ogic... 350 Diagnosis rocedure... 350 1723 VT SD SSR UT... 352 Description... 352 DT ogic... 352 Diagnosis rocedure... 352 1726 TR TRTT TR SYST... 354 Description... 354 DT ogic... 354 Diagnosis rocedure... 354 1740 -U ST SD VV... 355 Description... 355 DT ogic... 355 Diagnosis rocedure... 355 T-7 1745 RSSUR TR... 357 Description...357 DT ogic...357 Diagnosis rocedure...357 1777 ST TR... 358 Description...358 DT ogic...358 Diagnosis rocedure...358 omponent nspection (Step otor)...360 1778 ST TR - UT... 361 Description...361 DT ogic...361 Diagnosis rocedure...361 ST ST DTR RUT... 363 Description...363 omponent unction heck...363 Diagnosis rocedure...363 ST SYST... 364 Description...364 Wiring Diagram - VT ST SYST - oupe...364 Wiring Diagram - VT ST SYST - Sedan...366 Diagnosis rocedure...367 U DSS... 370 T... 370 Reference Value...370 Wiring Diagram - VT TR SYST - oupe...375 Wiring Diagram - VT TR SYST - Sedan...384 ail-safe...392 DT nspection riority hart...393 DT ndex...394 SYT DSS... 395 SYST SYT... 395 Symptom Table...395 RUT... 405 RUTS... 405 recaution for Supplemental Restraint System (SRS) "R " and "ST T R-T- SR"...405 recaution for rocedure without owl Top over..405 recaution ecessary for Steering Wheel Rotation fter attery Disconnect...405 recaution for n oard Diagnosis (D) System of VT and ngine...406 T
recaution for T and VT ssembly Replacement...406 Removal and nstallation rocedure for VT Unit onnector...406 recaution...407 Service otice or recaution...408 TT UT onversion Table...409 RRT...410 RRT... 410 Special Service Tool...410 ommercial Service Tool...410 -V T...411 VT UD... 411 nspection...411 hanging...412 VT UD R SYST... 413 leaning...413 ST TST... 416 nspection and udgment...416 RSSUR TST... 418 nspection and udgment...418 RD TST... 420 Description...420 heck before ngine s Started...420 heck at dle...421 ruise Test...422 VT ST... 424 nspection and djustment...424 -V RR...425 TRSSS TR DU... 425 xploded View...425 Removal and nstallation...425 TR DV... 426 xploded View...426 Removal and nstallation...426 nspection and djustment...427 TR... 428 xploded View...428 Removal and nstallation...428 DRT SD S... 429 xploded View...429 Removal and nstallation...429 R RTR S...430 xploded View... 430 Removal and nstallation... 430...431 xploded View... 431 Removal and nstallation... 431 R/UTR ST () SWT..432 xploded View... 432 Removal and nstallation... 432 RRY SD SSR...433 xploded View... 433 Removal and nstallation... 433 SDRY SD SSR...434 xploded View... 434 Removal and nstallation... 434 U TT T...435 xploded View... 435 Removal and nstallation... 435 RV D STT...436 TRSX SSY...436 xploded View... 436 Removal and nstallation... 436 nspection... 438 DSSSY D SSY...439 TRQU VRTR D VRTR US S...439 xploded View... 439 Disassembly... 439 ssembly... 439 SRV DT D STS (SDS)...440 SRV DT D STS (SDS)...440 eneral Specification... 440 Vehicle Speed When Shifting ears... 440 Stall Speed... 440 ine ressure... 440 Solenoid Valves... 441 VT luid Temperature Sensor... 441 rimary Speed Sensor... 441 Secondary Speed Sensor... 441 Removal and nstallation... 441 T-8
/T SYST < UT DSS > [6T: RS652] UT DSS /T SYST System Diagram RSS-ST VW D:0000000001344686 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
/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:0000000001344687 1454 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
S, VRT D RSSS (V) TRUST < SYT DSS > [6T: RS652] SYT DSS S, VRT D RSSS (V) TRUST V Troubleshooting hart D:0000000001344688 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 1 2 3 3 il leakage 3 1 2 2 ard to shift or will not shift 1 1 2 3 3 umps out of gear 1 2 3 3 T-11
< RUT > RUT RUTS RUTS [6T: RS652] recaution for Supplemental Restraint System (SRS) "R " and "ST T R-TSR" D:0000000001836944 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:0000000001836946 Service otice or recautions 3706 D:0000000001344689 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
< RRT > RRT RRT RRT [6T: RS652] Special Service Tools D:0000000001344690 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 ST33400001 (-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 ST35321000 ( ) Drift ST33200000 (-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 ST30720000 (-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. ST33061000 (-8107-2) 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
< RRT > Tool number (ent-oore o.) Tool name ST33052000 ( ) Drift V40105020 ( ) Drift ST30031000 (-22912-01) 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 V40105710 ( ) ress stand ST30901000 (-26010-01) Drift ST30032000 (-26010-01) 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
< RRT > RRT [6T: RS652] Tool number (ent-oore o.) Tool name Description ST38220000 ( ) 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) V40101630 (-35870) Drift ZZ1058D nstalling reverse main gear a: 68 mm (2.68 in) dia. b: 60 mm (2.36 in) dia. T ZZ1003D V38102510 ( ) 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:0000000001344691 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
< 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
/T < -V T > [6T: RS652] -V T /T Draining D:0000000001344692 1. 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:0000000001344693 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:0000000001344694 D0138ZZ T-17
SD S < -V RR > [6T: RS652] -V RR SD S Removal and nstallation D:0000000001344695 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 ± 0.020 in) Tool numbers : ST30720000 ( 25405) : ST33400001 (-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
-U SWT < -V RR > [6T: RS652] -U SWT Removal and nstallation D:0000000001344696 or removal and installation of back-up lamp switch, refer to T-28, "xploded View". nspection heck continuity. D:0000000001344697 ear position Reverse xcept reverse ontinuity Yes o T S0708 T-19
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:0000000001344698 D:0000000001344699 heck continuity. ear position eutral xcept neutral ontinuity Yes o S0708 T-20
TR < -V RR > [6T: RS652] TR xploded View D:0000000001344700 T D0025 1. 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:0000000001344701 1. 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
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:0000000001344702 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 "" : 6.3 7.0 mm (0.25 0.28 in) D0053ZZ T-22
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
R RTR S < -V RR > [6T: RS652] R RTR S xploded View QR25D engine models D:0000000001344703 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:0000000001344704 T-24
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
TRSX SSY < RV D STT > [6T: RS652] RV D STT TRSX SSY xploded View D:0000000001344705 D0049 1. Transaxle assembly 2. engine mounting bracket. Refer to T-26, "Removal and nstallation" Removal and nstallation D:0000000001344706 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
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 1 3 1 2 2 1 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) 1972 - VQ35D engine models : Transaxle to engine : ngine to transaxle olt o. Quantity 4 2 4 olt length mm (in) Tightening torque m (kg - m, ft- lb) 55 (2.17) 74.5 (7.6, 55) 116.5 (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
TRSX SSY < DSSSY D SSY > [6T: RS652] DSSSY D SSY TRSX SSY xploded View S D US D:0000000001344707 1805 1. 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
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. 1888 T-29
TRSX SSY < DSSSY D SSY > [6T: RS652] 1889 1. 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
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
TRSX SSY < DSSSY D SSY > [6T: RS652] 1964 1. 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:0000000001344708 1834 T-32
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. 1865 T 1835 7. Remove guide bolt from transaxle case. 8. Remove retaining pin using suitable tool and then remove selector lever from transaxle case. 1836 1837 9. Remove transaxle case bolts. 1838 T-33
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. 1839 11. 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. 1840 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. 1808 12. Remove oil gutter (1) and oil gutter (2) from transaxle case. : Tab of oil gutter 1841 T-34
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. 1842 T 1844 15. 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. 0936 S0397 17. Remove shifter lever oil seal (1) and striking rod oil seal (2) from transaxle case. UT: Do not damage transaxle case. 1846 T-35
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). 1858 19. Remove retaining pin of reverse shift fork (1) using suitable tool. 2 : Reverse fork rod 1850 20. 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. 1851 22. Remove retaining pin of 5th-6th shift fork (1) using suitable tool. 2 : 5th-6th fork rod 1852 23. Remove retaining pin of 3rd-4th shift fork (1) using suitable tool. 24. ull out 3rd-4th fork rod (2). T-36 1853
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). 1854 T 1855 27. 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). 1856 30. 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. 1857 T-37 S0964
TRSX SSY < DSSSY D SSY > [6T: RS652] 31. Remove magnet from clutch housing. 1859 32. 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. 0937 34. 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. 0938 35. Remove input shaft oil seal from clutch housing using suitable tool. UT: Do not damage clutch housing. S0398 36. Remove differential side oil seal from clutch housing using suitable tool. UT: Do not damage clutch housing. T-38 1874
TRSX SSY < DSSSY D SSY > [6T: RS652] ssembly 1. nstall differential side oil seal (1) to clutch housing using Tool (). Dimension Tool number : -0.5-0.5 mm (-0.020-0.020 in) : ST33400001 (-26082) UT: Do not reuse differential side oil seal. When installing, do not incline differential side oil seal. Do not damage clutch housing. D:0000000001344709 T 2. nstall input shaft oil seal (1) to clutch housing using Tool (). 1864 Dimension : 1.1-2.1 mm (0.043-0.083 in) Tool number : ST35321000 ( ) UT: Do not reuse input shaft oil seal. When installing, do not incline input shaft oil seal. Do not damage clutch housing. 1814 T-39
TRSX SSY < DSSSY D SSY > [6T: RS652] 3. nstall differential side bearing outer race to clutch housing using Tool. Tool number : ST30720000 (-25405) UT: Replace differential side bearing and differential side bearing outer race as a set. W0275 4. 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 (). 1921 5. nstall mainshaft front bearing to clutch housing using Tool. Tool number : ST33200000 (-26082) UT: e careful with the orientation of mainshaft front bearing. 0939 6. 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. 1938 7. nstall magnet to clutch housing. 1859 T-40
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 S0964 10. nstall striking rod assembly (1) into clutch housing. UT: heck that return spring is securely seated in the groove on return pin. 1857 1866 T-41
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. 1856 12. nstall 3rd-4th shift fork (1) to 3rd-4th coupling sleeve. UT: e careful with the orientation of 3rd-4th shift fork. 1855 13. 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. 1852 14. 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. 1853 15. nstall reverse shift fork (1) and reverse fork rod (2). UT: e careful with the orientation of reverse shift fork and reverse fork rod. 1875 T-42
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. 1851 T 1850 18. 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 : 0-1.0 mm (0-0.039 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. 1818 T-43
TRSX SSY < DSSSY D SSY > [6T: RS652] 23. nstall differential side oil seal (1) to transaxle case using Tool () [SST: ST30720000 (-25405)]. Dimension : -0.5-0.5 mm (-0.020-0.020 in) Tool number : ST30720000 (-25405) UT: Do not reuse differential side oil seal. When installing, do not incline differential side oil seal. Do not damage transaxle case. 1878 24. nstall shifter lever (1) and shifter lever (2) to transaxle case. UT: e careful with the orientation of shifter lever and shifter lever. 1843 25. 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. 1844 26. 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
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. 1841 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 (0.04-0.08 in). The height of sealant bead is 0.4-1 mm (0.016-0.04 in). The overlap length of both ends of sealant bead is 3-5 mm (0.12-0.20 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. 1807 1808 T-45
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. 1840 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. 1809 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
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. 1838 T 1930 27. nstall bore plug to transaxle case using Tool. Tool number UT: Do not reuse bore plug. : ST33061000 (-8107-2) 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. 0941 1837 T-47
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". 1890 d. nstall guide bolt to transaxle case and then tighten guide bolt to the specified torque. UT: Do not reuse guide bolt. 1836 30. 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. 1835 T-48