Table of Contents 5-iii
Gear Shift Control Lever and Cable
Components...................................................... 5B-5
Gear Shift Control Lever and Cable Removal
and Installation.................................................. 5B-6
Gear Select Control Cable Adjustment ............... 5B-6
Back Up Light Switch Removal and
Installation......................................................... 5B-7
Back Up Light Switch Inspection......................... 5B-7
Manual Transaxle Unit Components................... 5B-8
Manual Transaxle Unit Dismounting and
Remounting....................................................... 5B-9
Gear Shift and Select Shaft Assembly
Components.................................................... 5B-11
Gear Shift and Select Shaft Assembly
Removal and Installation................................. 5B-11
Gear Shift and Select Shaft Disassembly and
Assembly ........................................................ 5B-12
Manual Transaxle Assembly Components........5B-13
Fifth Gear Disassembly and Assembly ............. 5B-14
Manual Transaxle Assembly Disassembly
and Reassembly ............................................. 5B-16
Transaxle Right Case Disassembly and
Assembly ........................................................ 5B-23
Transaxle Left Case Disassembly and
Assembly ........................................................ 5B-24
Input Shaft and Countershaft Components.......5B-25
Input Shaft Assembly Disassembly and
Reassembly .................................................... 5B-26
Countershaft Assembly Disassembly and
Reassembly .................................................... 5B-28
Synchronizer Parts Inspection ..........................5B-31
Gear Shift Shaft Components ...........................5B-31
5th and Reverse Gear Shift Shafts
Disassembly and Assembly ............................ 5B-32
Gear Shift Shaft and Fork Inspection................ 5B-32
Differential Components ...................................5B-33
Differential Disassembly and Assembly ............5B-33
Specifications.....................................................5B-35
Tightening Torque Specifications...................... 5B-35
Special Tools and Equipment ...........................5B-36
Recommended Service Material ....................... 5B-36
Special Tool ......................................................5B-36
Clutch ....................................................... 5C-1
General Description .............................................5C-1
Clutch Construction.............................................5C-1
Diagnostic Information and Procedures............5C-2
Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ..............................................5C-2
Clutch Pedal Inspection ......................................5C-2
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-3
Clutch Pedal Position (CPP) Switch Removal
and Installation ..................................................5C-4
Clutch Pedal Position (CPP) Switch
Inspection and Adjustment................................5C-5
Clutch Fluid Pipe and Hose Components ...........5C-5
Clutch Fluid Pipe Removal and Installation.........5C-6
Clutch Fluid Pipe Inspection................................5C-6
Clutch Master Cylinder Removal and
Installation .........................................................5C-6
Clutch Operating Cylinder Removal and
Installation .........................................................5C-7
Clutch Operating Cylinder Inspection..................5C-7
Clutch Pedal and Clutch Pedal Bracket
Components......................................................5C-7
Clutch Cover, Clutch Disc and Flywheel
Components......................................................5C-8
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation...................................5C-8
Clutch Cover, Clutch Disc and Flywheel
Inspection........................................................5C-10
Clutch Release System Removal and
Installation .......................................................5C-11
Clutch Release System Inspection ...................5C-13
Specifications.....................................................5C-13
Tightening Torque Specifications......................5C-13
Special Tools and Equipment ...........................5C-14
Recommended Service Material .......................5C-14
Special Tool ......................................................5C-14