Service Manual2006 Kalos MAINTENANCE AND REPAIR

Kalos/Aveo

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

Manual Transaxle Assembly

Tools Required

DW110-060 Engine Support Fixture

Removal Procedure

Remove the battery and battery tray. Refer to Section 1E, Engine Electrical.
Disconnect the select and the shift cable.

Remove the cable pins (1).
Remove the washers (2).
Disconnect the select and the shift cable (3).
Remove the cable E-rings (4).
Disconnect the cables from the cable bracket.

Remove the engine wiring harness bending strap.
Disconnect the backup lamp switch connector.

Disconnect the radiator upper hose.

Remove the bolt (1).
Disconnect the radiator upper hose (2).

Remove crankshaft position (CKP) sensor.

Remove the bolt (3).
Disconnect the CKP sensor connector.
Remove the CKP sensor.

Disconnect the vehicle speed sensor connector.
Remove the vehicle speed sensor (VSS).
Remove the starter motor. Refer to Section 1E, Engine Electrical.

Install engine support fixture DW110-060.

Remove the transaxle upper bolts.

a. Exhaust manifold side bolt.

b. Thermostat housing side bolt.

Remove the front tires and wheels.

Drain the transaxle fluid.

Remove the drain plug and drain the fluid.

Disconnect the clutch cable.

Remove the cable adjust nut (1).
Remove the rear clutch release plate, the washer and the front clutch release plate(2).
Disconnect the cable from the transaxle mount hole (3).

Remove the front under longitudinal frames and stabilizer. Refer to Section 2C, Front Suspension.
Remove the drive axle (only transaxle side). Refer to Section 3B, Manual Transaxle Drive Axle.
Remove the clutch housing lower plate.

Remove the bolts (1).
Remove the lower plate (2).

Remove the front exhaust pipe. Refer to Section 1G, Engine Exhaust.

Remove the three transaxle mounting bracket bolts.

Support the transaxle with a transaxle support jack.

Remove the damping block connection nut and bolt (b).
Remove the three rear mounting bracket bolts (a).
Remove the rear mounting bracket from the transaxle.

Remove the two rear damping block retaining bolts.
Remove the rear damping block.

Remove the transaxle lower bolts.

Remove the transaxle.
Slide the transaxle sideways away from the engine block.
Lower the transaxle.

Installation Procedure

Support the transaxle with a transaxle support jack.
Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideaways into the engine block.

Install the transaxle lower bolts.

Tighten

Tighten the bolts to 55-65 N•m (41-48 lb-ft).

Install the two rear damping block retaining bolts.

Tighten

Tighten the rear damping block retaining bolts to 50-60 N•m (37-44 lb-ft).

Install the three rear mounting bracket bolts and the bracket.

Tighten

Tighten the rear mounting bracket bolts (a) to 55-65 N•m (41-48 lb-ft).
Tighten the damping block connection nut and bolt (b) to 75-85 N•m (55-63 lb-ft).

Install the three rear transaxle mounting bracket bolts.

Tighten

Tighten the transaxle mounting bracket bolts to 55-65 N•m (41-48 lb-ft).

Install the front exhaust pipe nuts. Refer to Section 1G, Engine Exhaust.

Install the clutch housing lower plate.
Install the drive axle. Refer to Section 3B, Manual Transaxle Drive Axle.
Install the front under longitudinal frames and stabilizer. Refer to Section 2C, Front Suspension.

Connect the clutch cable.

Connect the cable to the transaxle mount hole.
Install the rear clutch release plate, the washer and the front clutch release plate.
Install the cable adjust nut.

Install the transaxle upper bolts.

Tighten

Tighten the bolts to 55-65 N•m (41-48 lb-ft).

Install the starter motor. Refer to Section 1E, Engine Electrical.
Remove engine support fixture DW110-060.

Install the vehicle speed sensor.
Connect the VSS connector.

Install the radiator upper hose and crankshaft position (CKP) sensor.

Tighten

Tighten the radiator upper hose bolt to 8-15 N•m (70-132 lb-in).
Tighten the CKP sensor bolt to 5-8 N•m (44-70 lb-in).

Connect the backup lamp switch connector.
Install the engine wiring harness bending strap.

Connect the select and shift cable.

Connect the cable from the cable bracket.
Install the cable E-rings.
Connect the select and the shift cable.
Install the washers.
Install the cable pins.

Refill the transaxle fluid.

Tighten the drain plug to 25-30 N•m (18-22 lb-ft) (a).
Remove the oil level plug (b).
Refill recommended fluid to the proper level.

Classification	SAE 75W85W
Capacity	2.1L (2.21qt)

Tighten

Tighten the oil level plug to 25-30 N•m (18-22 lb-ft) (b).

Adjust the clutch cable. Refer to Section 5C2, Clutch (Cable Type).

Adjust the clutch cable by the clutch cable adjust nut.

Speedometer Driven Gear

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

Disconnect the vehicle speed sensor connector.
Remove the bolt and the speedometer driven gear assembly.

Remove the vehicle speed sensor from the speedometer driven gear.

a. Vehicle speed sensor.

b. Speedometer driven gear.

Caution : Be careful to prevent personal injury while the exhaust pipe is hot.

Inspection Procedure

Remove the O-ring from the speedometer driven gear housing.
Remove the driven gear pin and disconnect the driven gear.

Check for a damaged or torn O-ring.
Check for a worn or damaged tooth of driven gear.

a. O-ring.

b. Driven gear pin.

c. Driven gear.

Installation Procedure

Install the speedometer driven gear assembly to transaxle housing.

Tighten

Tighten the speedometer driven gear assembly bolt to 5-8 N•m (44-71 lb-in).

Install the vehicle speed sensor.
Connect the vehicle speed sensor connector.

Gear Shift Control Cable

Removal Procedure

Remove the air hose (air cleaner to throttle body). Refer to Section 1B, SOHC Engine Mechanical.
Remove the battery.
Disconnect the transaxle side select and shift control cable.

Remove the cable pins (1).
Remove the washers (2).
Disconnect the select and shift control cable (3).
Remove the cable E-rings (4).
Disconnect the cables from the cable bracket.

Remove the floor console. Refer to Section 9G, Interior Trim.

Remove the clip, cable pin and E-rings and disconnect the gear shift lever side select and shift control cable.

Remove the select and shift control cable.

Remove the nuts.
Pull the cables out in the passenger room.

Installation Procedure

Install in the reverse order of removal.
Push the cables toward the engine compartment through dash panel's hole slightly.
Position the cables on the select and the shift lever.

Connect the transaxle side select and shift control cable.
Connect the gear shift lever side shift control cable.
Connect the gear shift lever side select control cable.

Insert the select control cable eye ring to the select arm pin.
Install the selector lever control cable clip.
Install the select control cable to gear shift lever bracket with E-ring.
Insert a driver to the select arm adjustment hole to prevent the movement of gear shift lever in NEUTRAL.

Tighten the adjust nuts.

Tighten

Tighten the select cable adjust nut to 8-12 N•m (71-106 lb-in).

Gear Shift Control Lever

Removal Procedure

Remove the floor console. Refer to Section 9G, Interior Trim.
Disconnect the select and shift control cable. Refer to "Gear Shift Control Cable" in this section.
Remove the gear shift control lever assembly.

Remove the bolts.
Remove the gear shift control lever assembly.

Installation Procedure

Install in the reverse order of removal.
Install the gear shift control lever assembly.

Tighten

Tighten the bolts to 4-7 N•m (35-62 lb-in).

Adjust the select cables. Refer to "Gear Shift Control Cable" in this section.

UNIT REPAIR

Gear Unit

Tools Required

09913-76010 Bushing, Seal Installer

DW09940-53111 Gear, Bearing Installer

DW09943-78210 Bushing, Seal Installer

DW220-100 Needle Bearing Remover

DW220-110 Needle Bearing Installer

DW220-120 Input Shaft Holder

KM519 Oil Seal Installer

Disassembley Procedure

Remove the manual transaxle. Refer to "Manual Transaxle Assembly" in this section.
Remove the related clutch parts. Refer to Section 5C2, Clutch (Cable Type).

Disconnect the backup light switch and speedometer driven gear assembly.

Remove the nut and backup light switch.
Remove the bolt and the speedometer driven gear assembly.

Remove the shift interlock bolt.

Important : Certainly remove the shift interlock bolt. Otherwise, gear shift and shaft assembly can not be removed.

Remove the side cover.

Remove the bolts.
Remove the side cover using a rubber hammer.
Remove the sealant on the side cover and the transaxle case.

Remove the fifth-gear shift fork guide ball, the snap ring and the input shaft fifth-gear snap ring.

Remove the fifth-gear shift fork plug (1).
Remove the guide ball using a magnet.
Remove the fifth-gear shift fork snap ring (2).
Remove the fifth-gear snap ring (3).
Remove the fifth-gear synchronizer plate.

Remove the fifth-gear shift fork pin.

Shift the shift fork to the fifth-gear.
Remove the fork pin using a punch and a hammer.

Remove the input shaft fifth-gear fork and synchronizer hub assembly.

Pull and remove the fork and the hub assembly together (1).
Remove the sleeve, key and spring from the synchronizer hub assembly.

Remove the input shaft fifth-gear, the synchronizer ring and the fifth-gear bearing.

Pull and remove the fifth-gear, wave spring and synchronizer ring together (1).
Remove the fifth-gear bearing.

Remove the countershaft fifth-gear.

Remove the caulking and the nut.

Remove the left case plate and the counter shaft bearing shim.

Remove the screws.
Remove the left case plate.
Remove the counter shaft bearing shim.

Remove the shift shaft spring and ball.

Remove the bolt and remove the fifth-reverse gear shift shaft spring and ball (1).
Remove the bolt and remove the third-fourth gear shift shaft spring and ball (2).
Remove the bolt and remove the first-second gear shift shaft spring and ball (3).

Important : There is difference between the fifth-reverse gear shift shaft spring and the others. Mark it to distinguish easily when installing.

Remove the reverse idle gear shaft bolt.

Important : The case (Left) can not be removed without removing the reverse idle gear shaft bolt.

Remove the transaxle case (Left).

Remove the bolts from the left side case.
Remove the bolts from the right side case.
Remove the left side case by hitting with a rubber hammer lightly.
Remove the sealant on the case.

Remove the reverse gear shift lever.

Remove the bolts.
Remove the reverse gear shift lever.

Remove the reverse idle gear shaft assembly.

Push the reverse idle gear toward inner case.
Pull the shaft and remove the reverse idle gear and shaft.
Remove the reverse idle gear from the shaft.

Remove the fifth-reverse gear shift shaft.

Remove the shift & select lever inner and outer pins.

Remove the gear shift & select shaft assembly.

Remove the shift and select shaft (1).
Remove the gear select spring assembles (2).
Remove the gear shift interlock plate (3).
Remove the gear shift lever (4).
Remove the fifth & reverse gear shift cam (5).
Remove the return spring (6).
Remove the shift and select bellows (8).
Remove the shift and select shaft oil seal (7).

Remove the shift and select shaft needle bearings using needle bearing remover DW220-100.

Remove the gear unit.

Remove the gear unit and the shift shaft assembly together.

Notice : Be careful not to damage teeth of the counter shaft pinion and the differential ring gear.

Remove the high and the low speed shift shaft assembly from the gear unit.

Remove the differential assembly.

Insert a wooden stick into the lower side of differential.
Remove the differential assembly by moving it right and left.
Remove the counter shaft RH bearing.

Remove the related parts of the transaxle case (Left side).

Remove the oil gutter.
Remove the differential left side oil seal using a hammer and a copper chisel.

Remove the oil level plug.
Remove counter shaft bearing outer race using a hammer and the gear, bearing installer DW09940-53111.

Remove the related parts of the transaxle case (Right side).

Remove the input side oil seal using a screwdriver (1).
Remove the differential right side oil seal using a hammer and a copper chisel (2).

Synchronizer Sleeve and Shift Fork Inspection

Measure the clearance between synchronizer sleeve and shift fork and if the clearance exceeds the limit, replace the shift fork.

Unit : mm(in.)

Clearance Between Sleeve and Shift Fork	Standard	Limit
Clearance Between Sleeve and Shift Fork	0.2~0.6 (0.008~0.024)	1.0 (0.039)

Assembly Procedure

Install the related parts of the transaxle case (Right Side).

Install the input shaft oil seal using the bushing seal installer DW09943-78210.
Install the differential right side oil seal using the bushing, seal installer 09913-76010.

Important : Use only a new oil seal.

Important : Coat the transaxle inner parts with gear fluid when installing.

Install the related parts of the transaxle case (Left side).

Install the oil gutter.
Install the oil level plug.

Tighten

Tighten the oil level plug to 25-30 N•m (18-22 lb-ft).

Install the differential left side oil seal using the oil, seal installer KM519.

Install the differential assembly to the right side of the transaxle case.

Install the counter shaft RH bearing.

Install the low and the high speed shift shaft assembly to the gear unit.
Install the gear unit.

Push the gear unit by matching it with the input and the count shaft hole.

Notice : Be careful not to damage teeth of the counter shaft pinion and the differential ring gear.

Install the fifth-reverse gear shift shaft.
Install the fifth-reverse gear shift shaft ball and spring.

Tighten

Tighten the bolt to 10-16 N•m (7-12 lb-ft).

Important : Install the fifth-reverse gear shift shaft spring marked when removing.

Install the reverse idle gear shaft assembly and the reverse gear shift lever.

Install the reverse idle gear shaft assembly (1).

Important : Match the marking of the reverse idle gear shaft bolt hole with the protrusion of the transaxle case (Right side).

Install the reverse gear shift lever.

Tighten

Tighten the bolts to 18-28 N•m (13-21 lb-ft).

Install the shift and select and shaft needle bearings using needle bearing installer DW220-110 with needle bearing remover DW220-100.

Install the gear shift and select shaft assembly.

Install the shift & select shaft oil seal.
Install the shift & select bellows.
Install the gear select spring assembles.
Install the gear shift interlock plate.
Install the gear shift lever.
Install the fifth & reverse gear shift cam.
Install the return spring.
Install the shift & select shaft.

Install the shift & select lever inner and outer pins.

Important : When installing inner and outer pins, make the crevices of two pins be symmetric each other.

Install the transaxle left side case.

Coat the transaxle case with recommended sealant.

Transaxle Case Sealant

THREE BOND 1215

Install the transaxle left side case to the transaxle right side case.

Tighten

Tighten the bolts to 15-22 N•m (11-16 lb-ft).

Install the first-second gear shift shaft ball and spring.

Tighten

Tighten the bolt to 10-16 N•m (7-12 lb-ft) (a).

Install the third-fourth gear shift shaft ball and spring.

Tighten

Tighten the bolt to 10-16 N•m (7-12 lb-ft) (b).

Install the reverse idle gear shaft bolt.

Tighten

Tighten the bolt to 18-28 N•m (13-21 lb-ft) (c).

Install the counter shaft bearing outer race.

Install the counter shaft bearing outer race using the gear, bearing installer DW09940-53111.

a. Bearing outer race.

Important : Check if the bearing and the outer race are correctly installed by rotating counter shaft.

Install the counter shaft bearing shim.

Measure clearance between the transaxle case surface and the bearing outer race using a straight ruler and gauge.
Select shim in order that clearance is within standard.

Unit : mm (in.)

Measured value (A)		Shim thickness
0.33-0.37 (0.0130-0.0146)		0.55 (0.0217)
0.38-0.42 (0.0147-0.0165)		0.60 (0.0236)
0.43-0.47 (0.0169-0.0185)		0.65 (0.0256)
0.48-0.52 (0.0189-0.0205)		0.70 (0.0276)
0.53-0.57 (0.0209-0.0224)		0.75 (0.0295)
0.58-0.62 (0.0228-0.0244)		0.80 (0.0315)
0.63-0.67 (0.0248-0.0264)		0.85 (0.0335)
0.68-0.72 (0.0268-0.0283)		0.90 (0.0354)
0.73-0.77 (0.0287-0.0303)		0.95 (0.0374)
0.78-0.82 (0.0307-0.0323)		1.00 (0.0394)
0.83-0.87 (0.0327-0.0343)		1.05 (0.0413)
0.88-0.92 (0.0346-0.0362)		1.10 (0.0433)
0.93-0.97 (0.0366-0.0382)		1.15 (0.0453)
0.98-1.02 (0.0386-0.0402)		1.20 (0.0472)
1.03-1.07 (0.0406-0.0421)		1.25 (0.0492)

a. Straight ruler

b. Bearing outer race

c. Case surface

Install the left case plate and the counter shaft fifth gear.

Install the left case plate.

Tighten

Tighten the screws to 6-7 N•m (53-62 lb-in).

Important : Use only new screws.

Install the counter shaft fifth gear.

Important : Position the machined boss side toward the side cover plate.

Install the input shaft fifth gear bearing and the fifth/synchronizer ring.

Insert the bearing into the input shaft.
Install the fifth gear, synchronizer ring and wave spring matching synchronizer's oil groove and input shaft punched mark (1).

Install the fifth gear synchronizer hub assembly.

Install the synchronizer springs to hub (1).
Install the synchronizer key (2).

Important : In case of assembling synchronizer sleeve and hub, let A=B.

Position the longer boss side of hub toward inner side (3).
Position the chamfered spline of sleeve toward inner side and install the hub to the sleeve (4).

Install the fifth gear fork to the synchronizer hub assembly.
Install the fifth gear fork and the synchronizer hub assembly to the input shaft.

Important : Position the longer boss side of hub toward inner side and match the synchronizer key and the hub groove with the input shaft punched mark.

Install the fifth gear shift fork pin.

Push the shift fork toward the fifth gear.
Install the shift fork pin using a pin punch and a hammer.

Important : Use only new shift fork pin.

Install the input shaft fifth gear snap ring, the fifth gear shift fork snap ring and guide ball.

Install the fifth gear synchronizer plate.
Install the fifth gear snap ring (3).
Install the fork snap ring (2).

Important : Use Only new snap ring.

Tighten the fork plug after inserting the guide ball into the fork hole.

Install the counter shaft fifth gear nut.

Push the shift fork toward the fifth gear.
Hold the input shaft using the input shaft holder DW220-120.

Tighten

Tighten the fifth gear nut to 60-80 N•m (44-59 lb-ft).

Caulk the nut using a chisel and a hammer.

Install the side cover.

Coat the side cover with recommended sealant.

Side Cover Sealant

THREE BOND 1215

Tighten

Tighten the side cover bolts to 8-12 N•m (71-106 lb-in).

Install the shift interlock bolt.

Tighten

Tighten the shift interlock bolt to 18-28 N•m (13-21 lb-ft).

Install the backup light switch and the speedometer driven gear assembly.

Install the backup light switch.

Tighten

Tighten the nut to 15-18 N•m (11-13 lb-ft).

Install the speedometer driven gear assembly.

Tighten

Tighten the bolt to 4-7 N•m (35-62 lb-in).

Install the related clutch parts. Refer to Section 5C2, Clutch (Cable Type).
Install the transaxle assembly. Refer to "Manual Transaxle Assembly" in this section.

Input Shaft

Tools Required

DW09921-57810 Gear, Bearing Remover

DW09925-98221 Gear, Bearing Installer

DW09940-53111 Gear, Bearing Installer

Disaasemly Procedure

Remove the gear unit. Refer to "Gear Unit" in this section.
Remove the input shaft right side bearing.

Position the bearing to the gear, bearing remover DW09921-57810.
Remove the bearing by pressing (1).

Remove the input shaft fifth gear spacer, the left side bearing and the fourth gear.

Position the fourth gear to the gear, bearing remover DW09921-57810.
Remove the following parts.

a. Fifth gear spacer.

b. Left side bearing.

c. Fourth gear

Remove the fourth gear bearing.
Remove the fourth gear synchronizer ring and wave spring.

Remove the third-fourth synchronizer circlip.

Remove the third-fourth synchronizer hub assembly, the third gear 1 synchronizer ring.

Position the third gear to the gear, bearing remover DW09921-57810.
Remove the following parts.

a. Third-fourth synchronizer hub assembly.

b. Third gear and synchronizer ring.

Disassemble the third-fourth synchronizer hub assembly.

Remove the hub (1).
Remove the synchronizer sleeve and the key (2).
Remove the synchronizer springs (3).

Remove the input shaft third gear bearing (1).

Synchronizer Assembly Inspection

Inspection wear of cone area.

After matching synchronizer ring to gear, measure as shown in figure. Replace if it is below limit.

Unit : mm (in.)

Clearance Between Gear and Ring		Standard	Limit
Clearance Between Gear and Ring		1.0 (0.039)	0.5 (0.020)

Inspecting cone contact condition.

When synchronizer mechanism is abnormal in operation, connection between ring inner surface and gear cone area is considered to be partially defective in spite of correct clearance between gear and ring. Therefore, cone area and ring inner surface shall be inspected. In this case, ring inner surface shall be glossy. Black area is abnormal and if inspection is difficult, check after applying red lead. Cone area can be worn in wave form.

Inspecting key slot width of synchronizer ring.

Measure key slot width of synchronizer ring. Replace if it exceeds limit.

Unit : mm (in.)

Key Slot Width	Standard	Limit
1st, 2nd, 3rd, 4th gear	9.6 (0.378)	10.0 (0.394)
5th gear	9.4 (0.370)	9.8 (0.386)

Inspecting wear of synchronizer ring.

Check for worn or damaged synchronizer ring teeth. Replace it if necessary.

Inspecting synchronizer key and spring.

Check for worn synchronizer key (1).
Check for weak, damaged or broken spring (2).

Assembly Procedure

Install the third gear bearing, the third gear / synchronizer ring.

a. Third gear / synchronizer ring.

b. Third gear bearing.

Important : Coat the inner parts; gear, bearing, oil seal etc. with gear fluid.

Assemble the third-fourth synchronizer hub assembly.

Install the synchronizer springs to the hub.
Install the synchronizer key to the hub.

Important : In case of assembling the synchronizer sleeve and the hub, let A=B.

Install the hub to the sleeve.

a. Sleeve.

b. Hub.

Install the third-fourth synchronizer hub assembly.

Insert the hub assembly into the input shaft (1).

Important : Position the longer flange of hub toward the third gear and match the key and the ring groove.

Install the hub assembly using a hammer and the gear, bearing installer DW09940-53111.

Notice : When installing gear, bearing and hub assembly, install them slowly using the gear, bearing installer DW09940-53111 and a hammer. If overpressed, the gear teeth may be damaged.

Install the third-fourth synchronizer circlip.
Install the fourth synchronizer ring.

Important : Match the ring groove to the key of hub.

Install the input shaft fourth gear bearing and the fourth gear.

a. Fourth gear.

b. Fourth gear bearing.

Install the input shaft left side bearing and the fifth gear spacer.

Install the following parts using the gear, bearing installer DW09925-98221 and a hammer.

a. Fifth gear spacer.

b. Input shaft left side bearing.

Install the input shaft right side bearing.

Install the bearing to the input shaft using the gear, bearing installer DW09925-98221 and a hammer (1).

Install the gear unit. Refer to "Gear Unit" in this section.

Counter Shaft

Tools Required

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

DW220-020-01 Differential Bearing Puller

DW220-020-02 Differential Bearing Plate Adapter

DW220-020-03 Differential Bearing Plate Adapter

KM466-A Gear, Bearing Remover/Installer

Disassembly Procedure

Remove the gear unit. Refer to "Gear Unit" in this section.
Remove the counter shaft right side bearing.

Remove the counter shaft left side bearing and the fourth gear.

Position the fourth gear to the gear, bearing remover DW09921-57810.
Remove the following parts by pressing.

a. Counter shaft left side bearing.

b. Fourth gear.

Remove the counter shaft third-fourth gear spacer.
Remove the counter shaft third gear and second gear.

Position the second gear to the gear, bearing remover DW09921-57810.
Remove the following parts by pressing.

a. Third gear.

b. Second gear.

Remove the counter shaft second gear bearing.
Remove the second gear synchronizer ring.
Remove the first-second gear synchronizer circlip.

Remove the counter shaft first-second gear synchronizer hub assembly, the first gear / the first gear synchronizer ring.

Position the first gear to the gear, bearing remover DW09921-57810.
Remove the following parts by pressing.

a. Synchronizer hub assembly.

b. First gear / First gear synchronizer ring.

Remove the first gear synchronizer ring from the first gear.

Disassemble the first-second gear synchronizer hub assembly.

Push the hub from the hub assembly (1).
Disassemble the synchronizer sleeve and key (2).
Disassemble the synchronizer springs (3).

Remove the counter shaft first gear bearing.

Synchronizer Hub and Sleeve Inspection

Check the sleeve for improper operation after assembling the hub and the sleeve.
Check the wear of hub and sleeve.
Replace synchronizer hub or sleeve if necessary.

Assembly Procedure

Install the related counter shaft first gear.

Install the first gear bearing (1).
Install the first gear (2).
Install the first gear synchronizer ring (3).

Important : Coat the inner parts; gear, bearing and oil seal etc. with gear fluid.

Important : Be careful there is the difference of teeth numbers between the first synchronizer ring and the second synchronizer ring.

Unit : mm (in.)

Key Groove Width	First synchronizer ring (A) : 9.6 (0.378)
	Second synchronizer ring (B) : 9.6 (0.378)

Assemble the first-second synchronizer hub assembly.

Install the synchronizer springs to hub.
Install the synchronizer keys to hub.

Important : Let (A)=(B) when installing the keys.

Install the hub to the sleeve.

a. Sleeve.

b. Hub.

Install the first-second synchronizer hub assembly.

Insert the hub assembly into the counter shaft using the gear, bearing installer DW09925-98221, the gear bearing remover/installer KM466-A and a hammer (1).

Important : Position the synchronizer key to the first gear synchronizer ring groove.

Install the first-second gear synchronizer circlip.
Install the second synchronizer ring.

Important : Position the second synchronizer ring groove to the synchronizer hub key.

Install the related counter shaft second gear.

Install the second gear bearing (1).
Install the second gear (2).

Install the counter shaft third gear and the third-fourth gear spacer.

Insert the third gear and the third-fourth gear spacer into the counter shaft.
Install the following parts using the gear, bearing installer DW09913-80112 and a hammer.

a. Third-fourth gear spacer.

b. Third gear.

Install the counter shaft fourth gear.

Install the fourth gear to the counter shaft using the gear, bearing installer DW09925-98221 and a hammer (1).

Install the counter shaft left side bearing.

Install the left side bearing to the counter shaft using the gear, bearing installer DW09925-98221 and a hammer (1).

Install the counter shaft right side bearing.
Install the gear unit. Refer to "Gear Unit"in this section.

Gear Shift Fork

Disassembly Procedure

Remove the gear unit. Refer to "Gear Unit"in this section.
Remove the each shift shaft assembly from the gear unit.
Remove the first-second gear shift shaft assembly.

Fix the shift shaft assembly to a vise with protector.
Remove the first-second gear shift yoke pin using a pin punch and a hammer (1).
Remove the first-second gear shift yoke (2).
Remove the first-second gear fork pin using a pin punch and a hammer (3).
Remove the first-second gear shift fork (4).

Important : Mark the place and direction of shift fork and yoke to install easily before removing them.

Disassemble the third-fourth gear shift shaft assembly.

Fix the third-fourth gear shift shaft assembly to a vise with protector.
Remove the third-fourth gear fork pin using a pin punch and a hammer (1).
Remove the third-fourth gear fork (2).
Remove the third-fourth gear shift yoke pin using a pin punch and a hammer (3).
Remove the third-fourth gear shift yoke (4).

Disassemble the fifth-reverse gear shift shaft assembly.

Remove the shift shaft not installed with yoke by pushing (1).
Remove the following parts from the reverse shift arm.

a. Fifth-reverse gear ball.

b. Reverse shift guide ball and spring.

Fix the shift shaft assembly to a vise with protector.
Remove the reverse gear shift arm pin using a pin punch and a hammer (2).
Remove the reverse gear shift arm (3).

Remove the fifth gear shift yoke pin using a pin punch and a hammer (4).
Remove the fifth gear shift yoke (5).

Inspection Procedure - Shift Shaft

Check for bent, deformed or damaged shift shaft.
Replace shift shaft if necessary.

Inspection Procedure - Shift Fork

Measure the end thickness of shift fork and replace if below limit.

Unit : mm (in.)

Shift fork end thickness (mm)	Standard	Limit
Low Speed Shift Fork	8.7 (0.343)	8.1 (0.319)
High Speed Shift Fork	7.8 (0.307)	7.2 (0.283)
Fifth Gear Shift Fork	7.8 (0.307)	7.2 (0.283)

Assembly Procedure

Install in the reverse order of removal.

Important : Use only new fork fin and yoke pin.

Differential

Disassembly Procedure

Remove the differential assembly. Refer to "Gear Unit"in this section.
Remove the differential ring gear.

Fix the differential assembly to a vise with protector.
Remove the bolts (1).
Remove the ring gear (2).

Remove the pinion gear pin.

Remove the pin using a pin punch and a hammer (1).

Remove the pinion gear shaft.

Remove the shaft from the case (1).

Remove the pinion gears and the side gears.

Remove the pinion gears and the washers (1).

Important : Remove the pinion gear and the washer by rotating the side gear.

Remove the side gears (2).
Remove the adjust shims from the side gears (3).

Remove the differential right side bearing and speedometer drive gear.

Remove the right side bearing using the differential bearing puller DW220-020A-01 and the differential bearing plate adapter DW220-020A-02.
Remove the speedometer drive gear (1).

Remove the differential left side bearing.

Remove the left side bearing using the differential bearing puller DW220-020A-01 and the differential bearing plate adapter DW220-020A-03.

Side Gear Play Inspection

Measure the axle direction play of side gear and replace a side gear washer if it exceeds limit.

Unit : mm (in.)

Thrust Free Play of

Differential Side

0.05-0.33

(0.0020-0.0130)

Unit : mm (in.)

Thrust Adjusting Shim	0.90(0.0354)-0.95(0.0374)
	1.00(0.0394)-1.05(0.0413)
	1.10(0.0433)-1.15(0.0453)
	1.20(0.0472)

After checking for worn or scratched thrust adjusting shim, replace it if necessary.

a. Side gear.

b. Driver.

Assembly Procedure

Install the differential left side bearing.

Insert the left side bearing (1).
Install the left side bearing using the bushing, seal installer 09913-76010 and a hammer.

Important : Coat the inner parts; bearing, washer, shim etc. with gear fluid.

Install the speedometer drive gear and differential right side bearing.

Insert the speedometer drive gear(1).
Insert the differential right side bearing (2).
Install the right side bearing using the bushing, seal installer 09913-76010 and a hammer.

Install the side gears and the pinion gears.

Insert the trust adjusting shims to the side gears.
Install the side gears (1).
Install the pinion gears and washers (2).

Important : Install the pinion gears and washers simultaneously.

Install the pinion gear shaft and pin.

Insert the shaft into the gear pin hole by rotating (1).
Press the pin using a pin punch and a hammer (2).

Important : Use only new pin.

Install the differential ring gear.

Fix the differential assembly to a vise.
Install the ring gear with the bolts (1).

Tighten

Tighten the bolts to 80-100 N•m (59-74 lb-ft).

Install the differential assembly. Refer to "Gear Unit"in this section.