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    3维修手册 Chapter 4

    Uploaded by

    Frank Ch Ccaico
    The document discusses the manual transmission and manual transmission control mechanism used in a vehicle. It provides specifications for the 4-speed and 5-speed manual transmissions. It describes the power flow routes for each gear position. It details components of the transmission like the transaxle case, lubrication system, input shaft, reverse gear, output shaft, and differential. It also describes the shift and select mechanism and interlock mechanism. Finally, it provides maintenance and removal/installation procedures for the transmission control device and manual transmission assembly.

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    © All Rights Reserved
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    3维修手册 Chapter 4

    Uploaded by

    Frank Ch Ccaico
    66 views25 pages
    The document discusses the manual transmission and manual transmission control mechanism used in a vehicle. It provides specifications for the 4-speed and 5-speed manual transmissions. It describes the power flow routes for each gear position. It details components of the transmission like the transaxle case, lubrication system, input shaft, reverse gear, output shaft, and differential. It also describes the shift and select mechanism and interlock mechanism. Finally, it provides maintenance and removal/installation procedures for the transmission control device and manual transmission assembly.

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    REPARACION DE MOTOR

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    The document discusses the manual transmission and manual transmission control mechanism used in a vehicle. It provides specifications for the 4-speed and 5-speed manual transmissions. It describes the power flow routes for each gear position. It details components of the transmission like the transaxle case, lubrication system, input shaft, reverse gear, output shaft, and differential. It also describes the shift and select mechanism and interlock mechanism. Finally, it provides maintenance and removal/installation procedures for the transmission control device and manual transmission assembly.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    66 views25 pages

    3维修手册 Chapter 4

    Uploaded by

    Frank Ch Ccaico
    The document discusses the manual transmission and manual transmission control mechanism used in a vehicle. It provides specifications for the 4-speed and 5-speed manual transmissions. It describes the power flow routes for each gear position. It details components of the transmission like the transaxle case, lubrication system, input shaft, reverse gear, output shaft, and differential. It also describes the shift and select mechanism and interlock mechanism. Finally, it provides maintenance and removal/installation procedures for the transmission control device and manual transmission assembly.

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    © All Rights Reserved
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    of 25

    SECTION 4 MANUAL TRANSMISSION

    AND MANUAL TRANSMISSION


    CONTROL MECHANISM
    SECTION 1 MECHANISM AND SPECIFICATIONS 55
    MANUAL TRANSMISSION 55
    SHIFT AND SELECT MECHANISM 59
    MANUAL TRANSMISSION CONTROL MECHANISM 61
    SECTION 2 MAINTAINCE PROCEDURE 62
    MANUAL TRANSMISSION CONTRAL MECHANISM 62
    MANUAL TRANSMISSION ASSEMBLY 70
    SECTION 1 MECHANISM AND SPECIFICATIONS
    MANUAL TRANSMISSION
    Either four-speed or five-speed manual transmission is equipped on the sedan, and five-speed
    is used on most of the models.

    Manual Transmission

    Manual Transmission Specifications


    Type
    4-speed 5-speed
    Item
    Transmission type Forward gears: Constant mesh, Reverse gears: Selective sliding
    1st gear 3.090 (34/11 ) 3.090 (34/11)
    2nd gear 1.842 (35/19) 1.842 (35/19)
    Gear ratio
    3rd gear 1.250 (35/28) 1.250 (35/28)
    (Tooth
    4th gear 0.864 (32/37) 0.864 (32/37)
    number)
    5th gear — 0.707 (29/41)
    Reverse gear 3.142 (44/30/14) 3.142 (44/30/14)
    Final reduction gear ratio 4.500 (72/16) 4.714
    Speedo-meter Gear ratio
    16/4 17/4
    (driven/drive)
    Kind GL-4 80W/90 GL-4 80W/90
    Capacity l 1.9 - 2.0 2.1 - 2.2
    Oil
    (lmp. qts (1.67- 1.76, (1.85- 1.94,
    U.S. qts) 2.0 - 2.1) 2.2 - 2.3)
    POWER TRANSMITTING MECHANISM
    The following indicates the power flow route for each shift positions.

    ①1st gear
    ②2nd gear

    ③3rd gear ④4th gear

    ⑤5the gear ⑥Reverse gear

    Power Transmitting Mechanism


    TRANSAXLE CASE
    Casting aluminum alloy is employed to produce the transaxle case and transmission case.
    The mating surface between the transaxle case and the transmission case and the mating
    surface between the transmission case and the cover are sealed with Three Bond 1216 which
    features superior oil-resistant ability.

    Transaxle case

    Lubrication
    In line with higher running speeds, a shaft center lubricating mechanism having higher
    lubricating effects is adopted. A guide pipe is provided at the end of the output shaft so as to
    lubricate those parts around the output shaft.

    Shaft Center Lubricating Mechanism


    Input Shaft
    The number of spline teeth provided on the input shaft to accommodate the clutch disc has
    been increased from 18 to 20 and the outer diameter of the input shaft has been increased
    from19mm to 21mm with the engine output power increased.
    The pressure angle of the second gear is 17°.
    Input Shaft

    REVERSE GEAR & SLEEVE


    Three key grooves of the reverse gear and sleeve
    are used to meet the requirement of the engine output
    torque. The reverse gear sleeves also activate while
    engaging1st gear or 2nd gear.

    Reverse gear

    OUTPUT SHAFT
    Peening treatment has been applied to the output shaft to meet the increased engine output.

    Output Shaft
    DIFFERENTIAL
    The planetary type differential
    composed of the side gear, the pinion,
    the pinion shaft, the ring gear and the
    differential case, are used on the
    vehicles.

    Differential Specifications
    Final reduction gear ratio 4.500
    Number of tooth 72
    Tooth width (mm) 23
    Differential ring gear
    Outer diameter (mm) 184.0
    Gear type Helical gear
    Number of tooth 16
    Tooth width (mm) 26
    Final reduction gear
    Outer diameter (mm) 47.3
    Gear type Helical gear
    Number of tooth 16
    Differential side gear
    Number of inner spline teeth 23
    Number of differential pinion tooth 10
    Pinion shaft outer diameter (mm) 15
    SHIFT & SELECT MECHANISM
    A shift & select mechanism which features compact design and excellent operating feeling and
    which is best suited for the vertical-split type transmission case is employed.

    Shift & Select Mechanism

    INTERLOCK MECHANISM
    The interlock mechanism is a device which
    prevents two gears from being engaged
    simultaneously. This mechanism is composed of
    two interlock plates.
    When the 1st & 2nd shift fork shaft moves
    axially from the neutral position, the interlock
    plate engaged in the cut-out section of the shaft is
    paused out, thereby pushing the cut-out section of
    the 3rd & 4th fork shaft.
    Furthermore, the other plate also pushes the
    cutout section of the reverse shift fork shaft. As a
    result, both the 3rd and 4th shift fork shaft and
    the reverse shift fork shaft are locked, thus INTERLOCK MECHANISM
    preventing two gears from being engaged
    simultaneously.

    Interlock Mechanism
    TRANSMISSION CONTROL DEVICE
    This control device is single-manipulation device with hinge linked.

    The extension rod

    The control rod


    SECTION 2 MAINTENANCE OPERATION
    TRANSMISSION CONTROL DEVICE
    COMPONENTS

    REMOVAL
    1. Detach the shift lever knob and the
    shift & select lever boot.

    2. Detach the dust seal retainer and dust


    boot.

    3. Disconnect the shift & select shaft


    subassembly at the transmission side.
    Remove the pin and the bush.

    4. Remove the extension rod


    subassembly and floor shift support
    No.2.

    INSPECTION
    Check to see if each joint section under an assembled condition rotates smoothly without
    any binding. (See below.)

    DISASSEMBLY
    1. working from the case side, pull out
    the hole snap ring by means of the
    SST.
    SST: 09905-87001-000

    2. Disassemble the plate washer, bush and shift lever seat.

    3. Remove the extension rod


    subassembly from the shift lever
    subassembly.
    4. Disassemble the plate washer and shift lever retainer dust boot.

    5. Disassemble the bush, nut, plate


    washer and floor shift support No. 1.

    6. Grind off the staked section of the


    extension rod sub- assembly and the
    shift & select sub- assembly using a
    grinder.

    INSPECTION
    Inspect the following parts. Replace the disabled ones.

    Grease Application Points

    ASSEMBLY
    1. Assemble the extension rod.
    NOTE: On replacement parts, the
    connecting method with the support
    employs a bolt. Hence, care must be
    exercised to ensure that the assembling
    is carried out in the correct direction.

    2. Insert the bush into position.


    NOTE: If any difficulty is encountered
    in inserting the bush, apply soap water
    to the case side for easier installation.

    3. Assemble the floor shift support No.1.


    Install the nut and washer.

    4. Assemble the bush into the shift lever


    subassembly.

    5. Assemble the shift & select shaft.


    NOTE: On replacement parts, the
    connecting method with the shift lever
    employs a bolt. Hence, care must be
    exercised to ensure that the
    assembling is carried out in the correct
    direction.
    Tightening Torque: 9.8- 15.68N·m
    (1.0- 1.6 kgf·m)

    T: 1.0 ~ 1.6 kgf·m


    6. Assemble the shift lever retainer dust
    boot and plate washer onto the
    extension rod.

    7. After the shift lever subassembly has


    been installed, assemble the shift
    lever seat, bush and plate washer.

    8. Assemble the hole snap ring, using the


    SST given below.
    SST: 09905-87001-000

    INSTALLATION
    1. Install the floor shift support No.2,
    shift lever and extension rod as a set on
    the vehicle.
    2. Install the extension rod subassembly
    onto the transmission.
    Tightening Torque: 9.8- 15.68N·m
    (1.0- 1.6 kgf·m)

    3. Assemble the bush in the shift & select


    shaft. Install the transmission side of
    the shift & select shaft subassembly.

    4. Install the dust boot and dust seal retainer.

    5. Install the shift & select lever boot and the shift lever knob.
    MANUAL TRANSMISSION ASSEMBLY
    REMOVAL
    1. Remove the engine hood assembly.
    2. Remove the hold-down clamps and battery.
    3. Remove the battery carrier stay.

    4. Disconnect the following harnesses:


    ① Harness to the starter
    ② Transmission ground cable
    ③ Backup lamp harness
    ④ Cables for Speedometer harshness

    5. Remove the starter assembly.


    6. Disconnect the speedometer connector.

    7. Detach the three harness clamps.

    8. Disconnect the clutch cable.

    9. Remove the two bolts that directly attach the


    transmission assembly to the engine.
    10. Jack up the vehicle. Remove the
    front tires at the right and left sides of the
    vehicle.
    NOTE: Be sure to support the
    vehicle securely by means of safety
    stands

    11. Drain the transmission oil.


    12. Disconnect the front exhaust pipe at the
    bracket support No.1 and manifold sides.

    13. Disconnect the following control linkage-


    related parts from the transmission housing.
    (1) Shift & select shaft S/A
    (2) Extension rod S/A

    14. Remove the stabilizer bar.


    (1) Remove the stabilizer bar, end nut and
    retainer.
    (2) Remove the stabilizer bar installing nuts.
    15 Disconnect the lower arm at the bracket side.

    16. Remove the drive shafts at the right


    and left sides, using the following SST.
    SST: 09648-87201-000
    NOTE:
    1. No stopper is provided at the
    inboard side of the drive shaft. Hence, be
    sure to support the inboard joint section
    during the removal.
    2. Be very careful not to damage the lip section of the
    oil seal during the removal.

    17. Remove the transmission assembly attaching


    bolts.
    NOTE:
    Be sure to leave the one bolt located at the front
    central part.

    18. Lightly support the lower part of the


    transmission, using a jack. Then, remove
    the engine mounting lower/left bracket
    attaching bolts.
    Turn the engine mounting lower left insulator
    90 degrees so that it may point upward.
    19. Remove the one bolt located at the front central part
    of the transmission assembly. Slowly jack down the
    transmission assembly and take it out from below the
    vehicle.

    INSTALLATION
    (1). Install the transmission assembly to
    the engine assembly as follows:
    ① Ensure that the clutch disc is
    centered in position, using the SST
    given below
    SST: 09301-87702-000
    ②Install the transmission, making sure
    that the clutch disc may not be pried.
    Temporarily tighten the attaching bolts.

    (2). Tighten the transmission assembly


    attaching bolts securely.
    Tightening Torque: 5.0 – 7.0 kg·m (49 – 68.6N·m)

    (3). Install the engine mounting lower/left insulator


    and engine mounting lower/left bracket.
    Bracket Tightening Torque:
    3.0 - 4.5 kg·m (29.4 – 44.1 N·m)
    Insulator Tightening Torque:
    7.5 - 10.5 kg·m (73.5 – 102.9 N·m)
    (4). Install the drive shafts at the right and left sides.
    NOTE:
    Slowly install the drive shaft to the differential case,
    making sure that no damage is made to the lip section of
    the oil seal.

    (5). Install the lower arm (at the bracket side).


    Temporarily tighten the attaching bolts.

    （6）Install the stabilizer bar.


    ①Temporarily tighten the stabilizer, bar end nut.
    ②Tighten the cushion and stabilizer bar bracket.
    Tightening Torque: 4.0 – 6.0 kg·m (58.8 – 83.3 N·m)

    (7). Install the following control linkage-related parts:


    ①Shift & select shaft S/A
    Tightening Torque: 1.0 – 1.6 kg·m (9.8 –
    15.68N·m)
    ② Extension rod S/A
    Tightening Torque: 1.0 – 1.6 kg·m (9.8 – 15.6N·m)
    (8). Install the manifold side of the front exhaust pipe.
    Install the bracket support No.1,
    ①Manifold side
    Tightening Torque: 3.0 – 5.0 kg·m (29.4 –
    49N·m)
    ②Bracket support NO.1
    Tightening Torque: 2.0 – 3.0kg·m (19.6 – 29.4N·m)

    (9). Install the front wheels at the right and left wheels.
    Jack down the vehicle.
    (10). Rock the vehicle in an up-and-down direction a
    few times so as to settle the suspension.
    With the vehicle in an unloaded, tighten the nuts.
    ① Stabilizer bar installing nuts
    Tightening Torque: 7.5 – 10.5kg·m (73.5 –
    102.9N·m)
    ② Lower arm (bracket side)
    Tightening Torque: 7.5 – 10.5 kg·m (73.5 –
    102.9N·m)

    (11). Fill the transmission oil.


    Oil capacity:
    4-speed transmission: 1.9 – 2.05 l
    (1.7 – 1.8 Imp qts, 2.0 – 2.1 U.S. qts.)
    5-speed transmission: 2.1 – 2.25 l
    (1.8 – 1.9 Imp qts, 2.2 – 2.3 U.S. qts.)
    (12). Install the clutch cable.
    (13). Attach the three harness clamps.

    (14). Install the speedometer connector.

    (15). Install the starter assembly.


    Tightening Torque: 3.0 – 6.0kg·m (29.4 –
    58.8 N·m)
    (16). Install the following harnesses:
    ①Harness to starter
    ②Transmission ground
    ③Backup lamp harness
    ④Speedometer cable

    （ 17 ） Install the battery carrier stay, battery,


    hold-down clamp and engine hood assembly.

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