Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Manual Transaxle Construction: Notes
The transaxle provides six forward speeds and one reverse speed by means of four synchromesh device and three shafts-input shaft, countershaft and reverse gear shaft.
The low speed sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd gear, while the high speed sleeve & hub is done on input shaft and engaged with input shaft 3rd gear or 4th gear. The 5th & 6th speed sleeve & hub is mounted on input shaft and engaged with input shaft 5th gear or 6th gear. The reverse gear sleeve & hub mounted on reverse gear shaft and engaged with reverse idler left gear or reverse idler right gear.
The triple cone synchronizing mechanism is provided to 1st and 2nd gear synchromesh devices for high performance of shifting to 2nd gear.
The double cone synchronizing mechanism is provided to 3rd gear synchromesh device for high performance of shifting.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transaxle case. It is also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reassembling.
Further, care must be taken to adjust between case and shaft to thrust clearance of input shaft and countershaft. Synchronizer rings are prohibited from being lapped with respective gear cones using lapping compound before they are assembled.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.