SECTION 5B2
FIVE-SPEED MANUAL TRANSAXLE (Y4M)
Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted.
SPECIFICATIONS
General Specifications
Application | Description | Unit | Standard | Limit |
General | Type | Forward gear | - | Synchronized mesh type | - |
. | Reverse gear | - | Sliding mesh type | - |
Gear ratio | 1st | - | 3.416 | - |
. | 2nd | - | 1.950 | - |
. | 3rd | - | 1.280 | - |
. | 4th | - | 0.971 | - |
. | 5th | - | 0.757 | - |
. | Reverse | - | 3.272 | - |
Final drive ratio | - | 4.105 | - |
Fluid capacity | L(qt) | 2.1 (2.21) | - |
Fluid classification | - | SAE 75W85W | - |
Service | Key groove width of synchronizer ring | 1st, 2nd, 3rd, 4th gear | mm (in.) | 9.6 (0.378) | 10.0 (0.394) |
. | 5th gear | mm (in.) | 9.4 (0.370) | 9.8 (0.386) |
Shift fork end thickness | Low speed shift fork (1st~2nd) | mm (in.) | 8.7 (0.343) | 8.1 (0.319) |
. | High speed shift fork (3rd~4th) | mm (in.) | 7.8 (0.307) | 7.2 (0.283) |
. | 5th gear shift fork | mm (in.) | 7.8 (0.307) | 7.2 (0.283) |
Clearance between gear and synchronizer ring | mm (in.) | 1.0 (0.039) | 0.5 (0.020) |
Clearance between sleeve and shift fork | mm (in.) | 0.2-0.6 (0.008-0.024) | 1.0 (0.039) |
Thrust free play of differential side gear | mm (in.) | 0.05-0.33 (0.002-0.013) | - |
Speedometer gear ratio(Driven/Drive) | - | 17/18 (0.944) | - |
Fastener Tightening Specifications
Application | N•m | Lb-Ft | Lb-In |
5th/Reverse Gear Shift Shaft Bolt | 10-16 | 7-12 | - |
Back Up Light Switch Nut | 15-18 | 11-13 | - |
Counter Shaft 5th Gear Nut | 60-80 | 44-59 | - |
Crankshaft Position Sensor Bolt | 5-8 | - | 44-70 |
Differential Ring Gear Bolt | 80-100 | 59-74 | - |
High Speed Shift Shaft Bolt | 10-16 | 7-12 | - |
Low Speed Shift Shaft Bolt | 10-16 | 7-12 | - |
Oil Drain Plug | 25-30 | 18-22 | - |
Oil Level Plug | 25-30 | 18-22 | - |
Radiator Lower Hose Bracket Bolts | 8-15 | - | 70-132 |
Reverse Idle Gear Shaft Bolt | 18-28 | 13-21 | - |
Reverse Shift Lever Bolt | 18-28 | 13-21 | - |
Cable Bracket Bolt | 18-28 | 13-21 | - |
Left Case Plate Screw | 6-7 | - | 53-62 |
Shift Interlock Bolt | 18-28 | 13-21 | - |
Side Cover Bolt | 8-12 | - | 71-106 |
Speedometer Driven Gear Bolt | 5-8 | - | 44-71 |
Transaxle Case Bolt | 15-22 | 11-16 | - |
Transaxle Lower Bolt (Engine Side) | 55-65 | 41-48 | - |
Transaxle Mounting Bracket Bolts | 55-65 | 41-48 | - |
Transaxle Upper Bolt (Engine Side) | 55-65 | 41-48 | - |
Rear Damping Block Retaining Bolts | 50-60 | 37-44 | - |
Rear Mounting Bracket Bolts | 55-65 | 41-48 | - |
Damping Block Connection Nut and Bolt | 75-85 | 55-63 | - |
SPECIAL TOOLS
Special Tools Table
 
| 09913-76010 Bushing, Seal Installer |
| DW09913-80112 Gear, Bearing Installer |
| DW09921-57810 Gear, Bearing Remover |
| DW09925-98221 Gear, Bearing Installer |
| DW09940-53111 Gear, Bearing Installer |
| DW09943-78210 Bushing, Seal Installer |
| DW110-060 Engine Assembly Support Fixture |
| DW220-020A-01 Differential Bearing Puller |
| DW220-020A-02 Differential Bearing Plate Adapter |
| DW220-020A-03 Differential Bearing Plate Adapter |
| DW220-100 Needle Bearing Remover |
| DW220-120 Input Shaft Holder |
| KM466-A Gear, Bearing Remover / Installer |
| KM519 Oil Seal Installer |
| DW220-110 Needle Bearing Installer |
DIAGNOSIS
General Diagnosis
Condition | Probable Cause | Correction |
Gear Slipping Out of Mesh | | |
- Worn synchronizer sleeve or gear.
| |
- Worn bearings on input shaft or counter shaft.
| |
- Weakened or damaged location spring.
| |
- Loose or damaged synchronizer spring.
| - Replace synchronizer spring.
|
- Excessive back-lash of gear.
| - Adjust back-lash of gear.
|
Gear Catching | - Bent or distorted shift shaft or shift fork.
| - Replace shift shaft or shift fork.
|
- Weakened or damaged synchronizer spring.
| |
Hard Shifting | | - Replace synchronizer ring.
|
- Worn synchronizer sleeve or gear.
| |
- Bent or distorted shift shaft.
| |
- Excessive free travel of all gears in axial direction.
| |
- Worn bearings on input shaft or counter shaft.
| |
- Poor adjustment of clutch cable.
| |
- Distorted or broken clutch disc.
| |
| |
Noise in the Neutral Gear | | |
| |
- Worn bearings on the input shaft gears.
| |
- Worn clutch release bearing.
| - Replace clutch release bearing.
|
Noise in the All Gears | | |
- Worn bearings on input shaft or counter shaft.
| |
- Worn input shaft or counter shaft gear.
| |
- Worn or damaged synchronizer ring.
| - Replace synchronizer ring.
|
- Worn or damaged synchronizer sleeve.
| - Replace synchronizer sleeve.
|
- Worn differential gear or bearing.
| |
Noise in the Peculiar Gear | - Worn or damaged synchronizer ring in the peculiar gear.
| - Replace synchronizer ring.
|
- Worn or damaged gear in the peculiar gear.
| |
- Worn or damaged bearing in the peculiar gear.
| |
Leak of Lubricant | | |
Checking Fluid Level
Check for a leak in the area of transaxle case and sealing and then check fluid level and condition after removing oil level plug.
- Operate the engine until it comes to normal operating temperature(Coolant temperature : 80~90°C (176~ 194°F)).
- Stall the engine and raise the vehicle.
- Remove the oil level plug and check the fluid level.
- The fluid should slightly flow out from the oil level plug hole.
- If the level is low, add the recommended fluid through the oil level plug hole until the fluid begins to run out.
- If the fluid is contaminated or discolored, replace it with the recommended fluid.
- Reinstall the oil level plug and tighten it securely.
Changing Fluid
- Operate the engine until it comes to normal operating temperature(Coolant temperature : 80~90°C (176~ 194°F)).
- Stall the engine and raise the vehicle.
- Drain the fluid after removing the drain plug.
- Reinstall the drain plug and tighten it securely after coating sealant.
- Remove the oil level plug and replenish the fluid until it begins to run out.
- a. Oil drain plug.
- b. Oil level plug.
- Reinstall the oil level plug and tighten it securely.
Fluid Specification | SAE 75W85W |
Fluid Capacity | 2.1L (2.21qt) |
Service interval | Refer to Owner's Manual |
Checking Transaxle Noise
Many noises that appear to come from the transaxle may actually originate with other sources such as tires, road surfaces, wheel bearings, or engine and exhaust system.
Identify the cause of any noise before attempting to repair the clutch, the transaxle, or their related linkages.
To verify suspected transaxle noises,
- Select a smooth, level asphalt road to reduce tyre and resonant body noise.
- Drive the vehicle far enough to warm up all the lubricants thoroughly.
- Record the speed and the gear range of the transaxle when the noise occurs.
- Check for noises with the vehicle stopped, but with the engine running.
- Determine if the noise occurs while the vehicle operates in.
- Drive - Under a light acceleration or a heavy pull.
- Float - Maintaining a constant speed with a light throttle on a level road.
- Coast - With the transaxle in gear and the throttle partly or fully closed.
- All of the above.
Checking Bearing Noise
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise can be confused easily. Since side bearings are pre-loaded, a differential side bearing noise should not diminish much when the differential/transaxle is run with the wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound that will continue when the vehicle is coasting and the transaxle is in NEUTRAL. Since wheel bearings are not pre-loaded, a wheel bearing noise should diminish considerably when the wheels are off the ground.
COMPONENT LOCATORS
Gear Shift Control
- Gear Shift Control Lever Knob
- Gear Shift Control Lever Assembly
- Select and Shift Cable
Input Shaft and Counter Shaft Gear
- Input Shaft Circlip
- 5th Gear Synchronizer Plate
- 5th Gear Synchronizer Sleeve
- 5th Gear Synchronizer Spring
- 5th Gear Synchronizer Key
- 5th Gear Synchronizer Hub
- 5th Gear Synchronizer Ring
7-1 Wave Spring
- Input Shaft 5th Gear
- Input Shaft 5th Gear Bearing
- Input Shaft 5th Gear Spacer
- Input Shaft Bearing(Left)
- Input Shaft 4th Gear
- 4th Gear Synchronizer Ring
13-1 Circlip
- Input Shaft 4th Gear Bearing
- 3rd-4th Gear Synchronizer Sleeve
- 3rd-4th Gear Synchronizer Spring
- 3rd-4th Gear Synchronizer Key
- 3rd-4th Gear Synchronizer Hub
- 3rd Gear Synchronizer Ring
- Input Shaft 3rd Gear
- Input Shaft 3rd Gear Bearing
- Input Shaft
- Input Shaft Bearing(Right)
- Input Shaft Oil Seal
- Reverse Gear Shaft Bolt
- Reverse Gear Shaft
- Reverse Idle Gear
- Counter Shaft Nut
- Counter Shaft 5th Gear
- Counter Shaft Bearing Shim
- Counter Shaft Bearing(Left)
- Counter Shaft 4th Gear
- Counter Shaft 3rd-4th Gear Spacer
- Counter Shaft 3rd Gear
- Counter Shaft 2nd Gear
- 2nd Gear Synchronizer Ring
- Counter Shaft 2nd Gear Bearing
- 1st-2nd Gear Synchronizer Circlip
- 1st-2nd Gear Synchronizer Sleeve
- 1st-2nd Gear Synchronizer Spring
- 1st-2nd Gear Synchronizer Key
- 1st-2nd Gear Synchronizer Hub
- 1st Gear Synchronizer Ring
- Counter Shaft 1st Gear
- Counter Shaft 1st Gear Bearing
- Counter Shaft
- Counter Shaft Bearing(Right)
Gear Shift Fork
- Shift and Select Shaft
- Shift Interlock Bolt
- Shift Lever
- Bracket
- Low Speed Shift Fork
- Low Speed Shift Shaft
- Low Speed Shift Shaft Spring/Ball
- Low Speed Shift York
- High Speed Shift York
- High Speed Shaft Spring/Ball
- High Speed Shift Shaft
- High Speed Shift Fork
- Reverse Shift Arm
- 5th/Reverse Shift Ball
- 5th/Reverse Shift Shaft Spring/Ball
- Reverse Shift Shaft Guide Spring/Ball
- 5th/Reverse Shift Shaft
- 5th/Reverse Shift York
- 5th/Shift Fork Guide Ball
- 5th/Shift Fork
- Reverse Shift Lever
Differential and Case
- Speedometer Driven Gear
- Back Up Light Switch
- Transaxle Case(Right)
- Transaxle Case(Left)
- Oil Gutter
- Left Case Plate
- Side Cover
- Differential Ring Gear
- Differential Oil Seal(Left)
- Differential Bearing(Left)
- Differential Case
- Speedometer Drive Gear
- Differential Bearing(Right)
- Differential Oil Seal(Right)
- Differential Pinion Gear Shaft Pin
- Differential Side Gear Adjust Shim
- Differential Side Gear
- Differential Pinion Gear Shaft
- Differential Pinion Gear
- Differential Pinion Gear Washer
