Manual Transmission/Transaxle: Testing and Inspection

1. Check input shaft for wear or damage, then measure outer diameter of the input shaft journal surface. Diameter (A) should be 0.9791 inch, diameter (B) should be 1.0421 inch, diameter (C) should be 1.2193 inch and diameter (D) should be 0.9831 inch. If not within specifications, replace input shaft.




2. Check input shaft runout as shown in above image. If runout is greater than 0.0020 inch, replace input shaft.




3. Check output shaft for wear or damage, then measure outer diameter of the output shaft journal surface. Diameter (A) should be 1.2980 inch, diameter (B) should be 1.4949 inch and diameter (C) should be 1.2587 inch. If not within specifications, replace output shaft.




4. Check output shaft runout as shown in above image. If runout is greater than 0.0020 inch, replace output shaft.




5. Measure oil clearance between gear and input or output shaft with needle roller bearing installed. Clearance should be between 0.0008-0.0020 inch.

6. Inspect synchronizer rings for wear or damage, then turn ring and push it in to ensure proper breaking action.




7. Measure clearance between synchronizer ring back and gear spline end. Clearance should be 0.024 inch.




8. Measure clearance between hub sleeve and shift fork. Clearance should be 0.039 inch.

9. Remove bolt and oil receiver, then the input shaft front bearing. Replace as required.

10. Remove bolt and bearing lock plate, then the output shaft front bearing. Replace as required.

11. Remove input shaft front oil seal using a suitable screwdriver, then install new seal using suitable tool. Replacement of input shaft front oil seal does not require transaxle disassembly.

12. Remove left and right differential oil seals, then coat lip of new oil seals with grease and install using suitable tool.

13. If necessary, remove reverse restrict holder, then using a punch and hammer, drive out the slotted spring pin. Replace reverse restrict holder and slotted spring pin.