Manual Transaxle Construction

The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three shafts: input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.

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 mounted on input shaft and engaged with input shaft 3rd gear or 4th gear. The 5th speed sleeve & hub on input shaft is engaged with input shaft 5th gear mounted on the input shaft.

To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse shift braking device is used. This device utilizes the 5th synchromesh, which is the lever synchro type, to apply the brake on the input shaft rotation.

The double cone synchronizing mechanism is provided to 1st and 2nd gear synchromesh devices to improve shift feeling of 1st and 2nd gears.

For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque wrench. 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 preload of countershaft taper roller bearings. New synchronizer rings are inhibited from being lapped with respective gear cones using lapping compound before they are assembled.