Manual Transaxle 4WD

Check the following parts, replace if necessary.

1st, 2nd, 3rd, 4th, and 5th gears
1. Worn or damaged synchronizer cone.
2. Worn or damaged hub sleeve coupling.
3. Worn or damaged teeth.
4. Worn or damaged inner surface or end surface of gears.

Synchronizer Ring
1. Engagement with gear
2. Worn or damaged teeth
3. Worn or damaged tapered surface
4. Clearance from side of gear
Clearance: 1.5 mm (0.059 in)
Minimum: 0.8 mm (0.031 in)

NOTE:
a. Press the synchronizer ring uniformly against the gear and measure around the circumference.
b. If the clearance is less than specified, replace the synchronizer ring or gear.

Clutch Hub
1. Worn or damaged splines.
2. Worn or damaged synchronizer key groove.
3. Worn end surface.
4. Operation of the hub sleeve when it is installed.

Primary Shaft Gear and Secondary Shaft Gear
1. Worn or damaged gear contact surface.
2. Worn or damaged splines.
3. Worn teeth.
4. Clogged oil passage.
5. Shaft gears runout.
Primary shaft gear runout: 0.05 mm (0.002 in) max.

Secondary shaft gear runout: 0.015 mm (0.0006 in) max.

NOTE: If the shaft gear is replaced, adjust the bearing preload.

6. Oil clearance between shaft gears and gears.

Clutch Hub Sleeve
1. Worn or damaged hub splines.
2. Worn or damaged sleeve fork groove.
3. Clearance between sleeve and shift fork.

Synchronizer Key and Key Spring
1. Worn key.
2. Fatigued or damaged spring.

Bearing
1. Roughness or noise while turning.
2. Damaged bearing
3. Worn bearing.

Reverse Idle Gear and Shaft
1. Worn or damaged gear.
2. Worn shaft.
Standard clearance: 0.1-0.32 mm (0.004-0.013 in)
Maximum: 0.5 mm (0.02 in)

Clutch Housing and Transaxle Case
Cracks or damage.

NOTE: If the clutch housing or transaxle case is replaced, adjust the bearing preload of the shaft gears and the preload of the differential side bearings.