Service Workbook

Powertrain

2012Year
 WARNING

Warning: To reduce the possibility of personal injury and property damage, the following

instructions must be observed:

All six service workbooks provided by SMCV are dedicated for professional technicians. Trying to

do service or repair work without appropriate trainings, tools or equipments may cause injury to

yourself or others. It can also result in vehicle damage or abnormal operation.

正 Correct service and repair work is essential to personal safety of service technicians, as

well as safe and reliable operation of vehicles. If any part needs to be replaced, use the same part

number or other part number(s) specified by SMCV only. Never use any replacement part which is not

approved by SMCV.

The repair instructions suggested and introduced in this workbook are beneficial for correct

service and repair. And sometimes special tools are required.

In this case, any use of the replacement parts, repair instructions or tools which are not

suggested or approved by SMCV should not be allowed until it is proved that this has no threat to

the personal safety or safe operation.

The technical parameters and maintenance instructions of power train provided in this workbook

are intended for all Datong PV, MPV and VAN models of model year - 2012 in general rather than any

particular vehicle model. For the specification of any particular vehicle, purchasers should consult

their SMCV Distributor or Dealer.

Throughout this workbook, WARNINGS and CAUTIONS are included which should be strictly observed

for reducing personal injuries at the service and repair work. Any incorrect service or repair will

cause damage to the vehicle, leaving hidden dangers. However, these WARNINGS and CAUTIONS are not

complete. And it is impossible for SMCV to give warnings for all potential dangers resulting from

violation of these instructions.

 In order to avoid accidental airbag deployment and relevant potential injury, it is recommended

to service the airbag first when both the airbag and other systems need to be repaired.

No part of this publication may be reproduced, stored in a retrieval system or transmitted, in

any form, whether electronic or mechanical, or by photocopying, recording or other means without

prior permission in writing of SMCV.

 Error and Advice Reporting

If any error is found in this service workbook, or any advice, you are encouraged to tell us.

You can send any advice via letter or fax to SMCV After Sales at

After Sales, SAIC Commercial Vehicle Co., Ltd

#2500, Jungong Road,

Shanghai City, China Postcode: 200438

The following information should be provided:

· Your name

·Authorized repair center

·Tel. and fax of the authorized repair center

·Model year and model

·VIN

·Description of your concern(s)

·Necessary relevant information (e.g. sample or marked page)

·Any applicable electronic information part identification number

SMCV will give relevant response in the following ways:

·Submitting your concern to relevant service engineer

·Consulting relevant service engineer

·Satisfying your concern within 10 working days.

Datong users are encouraged to send your concerns to SMCV Customer Support Center at: 400-081-2011.
 Content
General Information ........................................................................................ 1-1
Introduction .......................................................................................................................... 1-1

General Precautions ............................................................................................................ 1-2

Manual transmission ....................................................................................... 2-1

Technical data...................................................................................................................... 2-1
Parameters ........................................................................................................................................................ 2-1
End play ............................................................................................................................................................. 2-1
Torque................................................................................................................................................................ 2-2

Layout .................................................................................................................................. 2-3

Layout of transmission ....................................................................................................................................... 2-3
Exploded diagram of transmission housing ...................................................................................................... 2-4
Exploded diagram of transmission control mechanism..................................................................................... 2-5
Exploded diagram of gear transmission mechanism ........................................................................................ 2-7
Disassembly / assembly of differential assembly............................................................................................... 2-9
Layout of transmission accessories ................................................................................................................. 2-10
Layout of transmission lever and cable............................................................................................................ 2-11

Fault diagnosis information and procedure ........................................................................ 2-12

SPECIAL TOOLS ............................................................................................................... 2-14

Repair instructions ............................................................................................................. 2-15

Replacement of manual transmission assembly.............................................................................................. 2-15
Disassembly of manual transmission assembly .............................................................................................. 2-19
Disassembly of differential assembly............................................................................................................... 2-51
Disassembly of differential assembly............................................................................................................... 2-51
Replace, check and adjust gear lever cable .................................................................................................... 2-52
Replace shift mechanism knob ........................................................................................................................ 2-53

CLUTCH.......................................................................................................... 3-1
Technical Data ..................................................................................................................... 3-1
Parameters ........................................................................................................................................................ 3-1
Torque................................................................................................................................................................ 3-1

Layout .................................................................................................................................. 3-2

Layout of clutch system ..................................................................................................................................... 3-2

Diagnosis information and procedure .................................................................................. 3-3

SPECIAL TOOLS ................................................................................................................. 3-5

Repair instructions ............................................................................................................... 3-6

Replace driven plate and disc............................................................................................................................ 3-6
 Content
Replace master cylinder..................................................................................................................................... 3-7
Replace slave cylinder ....................................................................................................................................... 3-9
Hydraulic clutch air expelling............................................................................................................................ 3-10

Drive Shaft .................................................................................................... 4-11

Technical data..................................................................................................................... 4-11
Parameters....................................................................................................................................................... 4-11
Torque .............................................................................................................................................................. 4-11

Layout ................................................................................................................................. 4-12

Layout of drive shaft ......................................................................................................................................... 4-12

Fault diagnosis information and procedure ........................................................................ 4-13

SPECIAL TOOLS................................................................................................................ 4-13

Repair instructions .............................................................................................................. 4-14

Replace left drive shaft..................................................................................................................................... 4-14
Replace right drive shaft................................................................................................................................... 4-17
Replace CV joint gaiter..................................................................................................................................... 4-19
Replace CV joint............................................................................................................................................... 4-20
Replace tripod universal joint / gaiter ............................................................................................................... 4-21
Replace drive shaft oil seal .............................................................................................................................. 4-22
 General Information
General Information

Introduction

WARNINGS and CAUTIONS are given throughout this Service Workbook in the following form:

Warning: procedures which must be followed precisely to avoid the possibility of personal
injury.

CAUTION: This calls attention to procedures which must be followed to avoid damage to components
or methods which make a job easier to be performed.

References to the left or right hand side in this Service Workbook are made when viewing the
vehicle from the rear, unless instructed otherwise.

To reduce repetition, operations covered in this service workbook do not always include
reference to testing the vehicle after repair. It is essential that work is inspected and tested
after the assembly. And if necessary, road test can be performed to test the safety performance of
the vehicle.

The drawing number of the illustration inset lies in the left bottom of the figure.

The illustration insets in the repair instructions are laid out parallel to the described
contents; Parts pointed by a bold straight arrow are those to be removed or installed; parts
numbered with 1, 2, ... correspond to the descriptions of the same number; In illustrations, numbers
1, 2, etc. indicates the relevant parts in the text contents.

1-1
General Information

General Precautions

When disconnecting the vehicle battery, always disconnect the earth return (negative) cable
firstly, and then the positive cable. For double batteries installation, disconnect both earth
return (negative) cables firstly, and then the positive cables. When connecting battery, connect the
positive cable(s) firstly, then the negative cable(s).

Prior to overhauling transmission or driveshaft joints, ensure the work area and tools are clean
to avoid dirt ingress to gears, bearings, joint surfaces etc.

When removing transmission, do not allow it to 'hang' on its input shaft as damage may be caused.

If carrying out work which involves the drive shafts, do not allow gaiters to become trapped
which could cause damage, splits, etc.

When carrying out transmission overhaul, always take care not to chip gear teeth when meshing
them.

Care must be taken when working under bonnet to avoid rotating pulleys and drive belts.

Do not work under the vehicle when supported only by a jack. Always use safety stands.

Transmission is heavy. While removing or fitting, it is recommended the weight of transmission

is taken on a suitable cradle jack.

Before using special tools to fit oil seals, ensure there are no burrs on the tool diameters
which could cause damage.

Many securing bolts on this transmission use micro-encapsulation (patch-lock) for locking
purposes. The threads of these bolts should be cleaned and Loctite 270 applied before re-use.

Only oil approved by SAIC Motor - Technology center of Commercial Vehicle can be used.

Always wear safety glasses for eye protection.

Always wear gloves when handling oil or grease.

Ensure the ignition switch is 'OFF', unless the procedure requires otherwise.

Always apply the handbrake when working on the vehicle, and place blocks against the front and
rear of the tyres to prevent movement.

Only run the engine in a well-ventilated area to avoid the danger of carbon monoxide poisoning.

To prevent burns, avoid contacting with hot parts such as the cooling and exhaust systems.

Do not eat or smoke while working on a vehicle.

To avoid injury, always remove rings, watches, loose jewellery, loose clothing etc. before
starting work on a vehicle.

If using compressed air to clean or dry components, ensure all precautions are taken to protect
yourself and other personnel in the area.

1-2
 Manual transmission
Manual transmission

Technical data
Parameters

Model Driving mode of transmission

Manufacturer WIA

Driving mode of transmission Transversal arrangement and front wheel drive

Gear ratios
- 1st 3.769
- 2nd 2.105
- 3rd 1.300
- 4th 0.941
- 5th 0.750
- Reverse 3.167
- Final drive 4.188

Oil capacity 2.30L

End play

Items Standard Value(mm)

1st gear end play 0.07-0.29 毫米 （Loosen）

2st gear end play
3st gear end play
4st gear end play
REV gear end play
Input shaft rear bearing end play
Output shaft rear bearing end play
Diferential side bearing end play
0.06-0.21 毫米 （Loosen）
0.06-0.21 毫米 （Loosen）
0.135-0.335 毫米 （Loosen）
0.07-0.25 毫米 （Loosen）
0.00-0.10 毫米 （Loosen）
0.03-0.10 毫米 （Loosen）
0.05-0.10 毫米 （Tighten）

2-1
Manual transmission

Torque

Application Torque value (Nm)

Engine assembly to transmission bolt 47 ~ 53

Transmission to engine assembly bolt 47 ~ 53

Transmission to block bolt 89 ~ 98

Vehicle speed sensor screw 7 ~ 9

Clutch release guide sleeve bolt 6 ~ 8

Output shaft bearing cap screw 45 ~ 55

Selector lever unit bolt 19 ~ 26

Drain plug 40 ~ 60

Filler plug 65

Transmission housing and clutch housing bolts 44 ~ 55

Reverse idler gear shaft bolt 6 ~ 8

Reverse idler bolt 45 ~ 55

Transmission housing rear cover bolt 20 ~ 25

Reverse lever assembly bolt 8 ~ 11

Differential sealing bolt 130 ~ 140

5 gear/Reverse interlock device bolt 8 ~ 11

Locking spring locknut 15 ~ 21

Output shaft locknut 150 ~ 220

Reverse lever supporting spring bolt 8 ~ 11

Balancing block bolt 23 ~ 29

Transmission cable mounting bolt 13 ~ 17

Transmission lever to instrument desk framework bolt 16 ~ 18

Transmission shift lever fitting reinforced plate nut 18 ~ 22

Transmission suspension nut 95 ~ 105

2-2
 Manual transmission

Layout
Layout of transmission

CS120001

2-3
 Manual transmission

Exploded diagram of transmission housing

6
24
7 13
7
8
12

27
4 6
5 10
26 1 6
9
3 14

21 15 16
11
19 18
17
23
20 22
2 2

25
CE121C-001

1 Transmission assembly 15 Reverse cone stop pin support bolt

2 Transmission housing to clutch housing bolts 16 Bush

3 Wiring harness carrier 17 Drain plug

4 Ventilation plug assembly 18 Gasket

5 Oil feed gutter 19 Pin

6 Flanged bolt 20 Transmission housing rear cover bolt

7 Needle roller bearing 21 Rear cover assembly

8 Clutch release guide sleeve 22 Filler plug

9 Oil feed gutter 23 Gasket

10 Bush 24 Spring clip

11 Reverse cone stop pin support 25 Reverse light switch assembly

12 Clutch housing 26 Transmission housing to clutch housing bolt

13 Clutch release guide sleeve bolt 27 Plug

14 Magnet

2-4
 Manual transmission

Exploded diagram of transmission control mechanism

2 3
1
5
6
10 8
9
7
11

13
15
12
17
16
21
1 20
19 22
14 18
25 21
20
23 22
24
19
18
29 21
20
28 22
27 26
18
32

30 31

CE121E-001

1 Flanged bolt 10 Spring pin

2 5th/Reverse interlock device 11 Return spring
3 Oil seal 12 Selector lever unit
4 Shift lever unit 13 Reamed bolt
5 Spring seat 14 Selector lever unit bolt
6 Interlock plate 15 Reverse lever supporting spring
7 Shift finger 16 Reverse lever assembly
8 Bolt 17 Reverse lever supporting spring bolt
9 Spring pin 18 Spring pin

2-5
Manual transmission

19 Spring pin 26 Pin

20 Locking spring 27 3rd/4th shift guide block

21 Setting screw 28 3rd/4th shift fork

22 Steel ball 29 3rd/4th shift transverse lever

23 1st/2nd shift guide block 30 5th/Reverse shift guide block

24 1st/2nd shift fork 31 5th/Reverse shift fork

25 1st/2nd shift transverse lever 32 5th/Reverse shift transverse lever

2-6
 Manual transmission

Exploded diagram of gear transmission mechanism

2
45 5
4
1
14
13
3 12
10
11 25
9 24
8 23
7 22
6
21
11 32
20
19 31
18
17
16
15 30
46 29 38
28
39
26
27 37
26
36
35 44
34
33 43
42
41
40

CE121D-001

1 Reverse idler gear shaft 8 Retaining ring

2 Reverse idler gear 9 4th synchromesh ring
3 Input shaft 10 3rd/4th synchro unit
4 Ball bearing 11 Synchromesh guide block
5 Oil seal 12 Needle roller bearing
6 Needle roller bearing 13 3rd synchromesh ring
7 4th gear assembly 14 3rd gear assembly

2-7
Manual transmission

15 Retaining ring 31 Output shaft

16 Adjusting shim 32 Sealing cap

17 Ball bearing 33 4th output gear

18 Reverse cone shaft sleeve 34 3rd output gear

19 Clutch reverse cone stop pin 35 2nd gear shaft sleeve

20 Reverse synchromesh ring 36 Needle roller bearing

21 5th/Reverse synchro unit 37 2nd gear assembly

22 5th synchromesh ring 38 1st/2nd synchro unit

23 Needle roller bearing 39 Synchromesh guide block

24 5th gear assembly 40 Output shaft locknut

25 5th gear shaft sleeve 41 Tapered roller bearing

26 Twin cone synchromesh ring 42 Adjusting shim

27 Needle roller bearing 43 Spacer

28 1st gear assembly 44 5th output gear

29 Bearing cap 45 Reverse idler gear shaft bolt

30 Tapered roller bearing 46 Bearing cap screw

2-8
 Manual transmission

Disassembly / assembly of differential assembly

2
1
6 4
5

14

13
8
4

3
2

7
11 9
7 10

12

10
9

7
11
7

CE121F-001

1 Differential assembly 8 Differential assembly

2 Oil seal 9 Oil seal
3 Adjusting shim 10 Adjusting shim
4 Tapered roller bearing 11 Tapered roller bearing
5 Differential driven gear 12 Differential driven gear
6 Differential sealing bolt 13 Differential sealing bolt
7 Gasket 14 Gasket

2-9
Manual transmission

Layout of transmission accessories

6
3

9
1
CE121B-001

1 Clutch release fork assembly 6 Transmission to block bolt

2 Clutch release fork to transmission stud 7 Clutch release fork cover
3 Balancing block nut 8 Transmission to engine assembly bolt
4 Balancing block 9 Engine assembly to transmission bolt
5 Balancing block to transmission bolt

2-10
 Manual transmission

Layout of transmission lever and cable

5 3
6

9
8

11

10

13
12

9
8
CE152A-001

1 Shift mechanism handle assembly 7 E ring

2 Shift handle leather sheath 8 Lock pin
3 Leather sheath retaining ring 9 Gasket
4 Manual transmission lever assembly 10 Selection cable assembly
5 Manual transmission lever to instrument desk 11 Shift cable assembly
framework bolt
12 Cable mounting assembly
6 Transmission shift lever fitting reinforced plate
13 Cable mounting assembly to transmission bolt
nut

2-11
Manual transmission

Fault diagnosis information and

procedure

Fault Possible cause Solution

Gear lever cannot shift gears Gear lever ball cup seized Replace
flexibly or is difficult to shift
gears Control rod joint seized Replace

Control rod bent Replace

Excessive gear lever Gear lever ball bush worn Replace

clearance
Needle roller bearing of control shaft worn Replace

Difficult to shift gears No grease in gear lever Replace

Inadequate lubrication Apply lubricant

Lubricant unqualified Replace with qualified lubricant

Shift fork or shift fork rail worn or excessive Replace

clearance

Synchromesh gear ring worn Replace

Inner ring of synchromesh gear worn Replace

Excessive gear side clearance Replace

Bearing worn Replace

Synchromesh strut spring worn Replace

Excessive main shaft bearing pre- Adjust

tightening force

Poor contact between synchromesh gear Replace

ring and inner gear ring

Fail to mesh with gears Control rod bush worn Replace

Poor gear lever ball spring Replace

Improperly fitted extension rod Tighten

Shift fork worn Replace

Clutch hub worn Replace

Clutch hub socket worn Replace

Shaft gear sliding surface worn Replace

Gear sliding surface worn Replace

Gear lever end gate worn Replace

Poor setting spring Replace

Excessive thrust clearance Replace

Bearing worn Replace

Engine carrier improperly fitted or loose Tighten

2-12
 Manual transmission

Abnormal sound Inadequate lubrication Apply lubricant

Lubricant unqualified Replace with qualified lubricant

Bearing worn Replace

Synchromesh gear ring worn Replace

Gear sliding surface or shaft worn Replace

Excessive gear lateral clearance Replace

Gear damaged Replace

Foreign objects in gear Replace

Differential gear damaged or excessive Replace

lateral clearance

2-13
Manual transmission

SPECIAL TOOLS
Maintenance special tooling table (same tooling number
on each tool) Name Illustration

Name Illustration

Housing separator

Ball joint separator C00017044

C00017036

Universal driven handle

Universal puller C00017045

C00017040

Gear lever mounting pin

Input shaft retainer C00017046

C00017041

Engine supporting carrier

Thrust journal C00017050

C00017042

Power set installation tool

Bearing installer C00017051

C00017043

2-14
 Manual transmission

assembly
Repair instructions
Replacement of manual transmission Tools required：C00017051,C00017050

Removal
1 Disconnect battery.

2 Remove trim cover of front left wheel and

transmission shaft nuts, and slacken front left
wheel bolts.

3 Separate air intake pipe.

4 Separate gear lever cable at transmission end.

5 Slacken 6 bolts fitted in left power train

(arrowed).

6 Slacken all removable housing bolts from above.

7 Remove front left wheel after the vehicle

supported by lifting jack.

CS123094

8 Separate clutch slave cylinder. Make hard pipe

upward to prevent brake fluid leakage when
removing.

9 Drain brake fluid to proper container.

CS123086

10 Remove left drive shaft and pull right drive shaft

out of transmission (see "Replace drive shaft").

11 Remove starter motor (see "Replace starter

motor").

2-15
Manual transmission

12 Disconnect reverse light harness ① and remove

cable from housing harness buckle.

CS123087

13 Separate engine rear carrier.

CS123088

14 Remove 2 bolts of clutch housing and fit engine

bracket C00017050 and preset screw length of
90 - 100 mm.

15 Support transmission with proper bracket.

CS123089

2-16
 Manual transmission

16 Remove bolt arrowed and remove left power

train mounting.

CS123090

17 Pull engine / transmission toward the front part of

vehicle until the rear part of engine aligns and
contacts with screw on tool C00017050 bracket.

C00017050

CS123091

18 Remove remaining bolts and lower transmission

to detach it. (Engine left side shall be supported
by tool C00017050).

CAUTION: 如 If refit the original transmission, oil

seal of transmission shaft shall be replaced.

2-17
Manual transmission

Fitting

1 Fitting is reverse of removal procedure, but the

following must be noted:

— Slightly lubricate input shaft spline.

— Don't "hang" transmission on input shaft before fitting
bolts.
— When fitting left support of power train, tool
C00017051 must be used to check equal 5 mm clearance
of support on both sides (as shown in the figure)

CS123087

5MM 1P 5MM

1P

1P

CS123092

— Fill 2.30 litres specified oil through filler plug hole

after fitting transmission shaft. Remove oil level plug and
allow excess oil to run out. Refit plug.
— Check all shifts right after connecting gear change
cable. If necessary, adjust cable (see "Replace, check and
adjust gear lever cable mechanism").
— As a self-locking nut, transmission suspension nut
shall be used only once at most so as to provide strong
fastening performance.

2-18
 Manual transmission

C00017041,C00017042,C00017043,
Disassembly of manual transmission
assembly C00017044,C00017046
Removal
Tools required： 1 Remove 7 securing screws.

2 Carefully tap rear cover to open it with straight

screwdriver and hammer.

CS123000

3 Engage the gear with shift lever.

CS123001

4 Secure input shaft with C00017041.

C00017041

CS123002

2-19
Manual transmission

5 Remove output shaft locknut.

CS123003

6 Remove setting screw ①, locking spring ②, steel

ball ③ and reverse light switch ④ .

3
2
1

CS123004

7 Remove reverse idler gear shaft screw.

CS123005

2-20
 Manual transmission

8 Remove 17 transmission housing screws.

CS123006

9 Remove transmission housing with C00017044.

C00017044

CS123007

10 Remove magnet ① , output shaft adjusting shim

② , output shaft spacer ③ and output shaft
2 4
adjusting shim ④ .
3

CS123008

2-21
Manual transmission

11 Remove reverse idler gear ① and gear shaft ② .

CS123009

12 Remove reverse lever ① and reverse lever

supporting spring ② .

2
1

CS123010

13 Remove 5th / reverse fork, 5th / reverse shift

transverse lever and shift guide block.

CS123011

2-22
 Manual transmission

14 Remove 3rd /4th shift transverse lever, 3rd /4th

and 5th / reverse shift fork, 3rd /4th shift guide
block.

CS123012

15 Reverse 1st /2nd shift transverse lever, 1st / 2nd

shift fork and 1st /2nd shift guide block.

CS123013

16 Check gear clearance and compare obtained

clearance with the information provided in
"Technical Data". If outside tolerance, adjust
again.

CS123014

2-23
Manual transmission

17 Remove steel cable retaining ring of input shaft.

CS123015

18 Remove input shaft bearing ① and 5th gear

assembly ② with gear puller C00017040 at the
same time.

CS123016

19 Remove 5th gear shaft sleeve.

CS123017

2-24
 Manual transmission

20 Remove output shaft 4th / 5th gear with gear

puller C00017040.

CS123018

21 Remove 5th gear shaft sleeve, 4th gear, 4th gear

bearing and 4th synchromesh ring with gear
puller C00017040.

CS123020

22 Remove 3rd / 4th steel cable retaining ring of

synchro unit.

CS123021

2-25
Manual transmission

23 Remove 3rd /4th gear synchro unit, 3rd

synchromesh ring and 3rd gear with gear puller
C00017040 and take out 3rd needle roller
bearing.

CS123022

24 Remove output shaft 2nd / 3rd gear with gear

puller C00017040.

CS123023

25 Remove output shaft needle roller bearing and

2nd gear shaft sleeve.

CS123024

2-26
 Manual transmission

26 Remove twin cone synchro ring on output shaft.

CS123025

27 Lift 1st /2nd synchro unit, 1st synchro, 1st gear,

needle roller bearing from output shaft and
remove input shaft ① at the same
time.(arrowed).
1

CS123026

28 Remove output shaft bearing cap screws with

hex wrench to remove bearing cap.

CAUTION:Engage removal tool with screw slot

securely with hammer or similar tools and then
remove bearing cap.

CS123027

2-27
Manual transmission

29 Remove output shaft.

CAUTION:Fit transmission housing temporarily

with stop shim and tighten output shaft locknut,
and then pry output shaft assembly out with
proper tools as shown in the figure. Remove
transmission housing.

CS123028

30 Remove differential after removing odometer

transmission gear.

CAUTION:Position clutch housing inclined and

remove differential. Differential assembly is
heavy and may fall out after output shaft has
been removed.

CS123029

31 Remove input shaft oil seal with screwdriver or

proper tools and then remove sealing cover.

CS123030

2-28
 Manual transmission

32 Remove differential oil seal with screwdriver or

proper tools. (Oil seal must be replaced every
time / gently separated when replacing).

CS123031

33 Remove outer ring of taper roller bearing with

proper tools (replace only when bearing
replacement required).

CS123032

34 Remove output bearing with proper tools.

CS123033

2-29
Manual transmission

35 Remove two spring pins and pull out shift lever

unit.

CS123034

36 Remove oil feed gutters ① and reverse cone

stop pin ② .
1

2
CS123035

Inspection

1 Check input and output shafts.

Press bearing clear of input shaft and if the bearing or
output shaft placement is required, press to remove
bearing.
CAUTION:Input shaft bearing is pre-packed
sealed unit and must not be washed.

CS123078

2-30
 Manual transmission

Check that all oil ways are clear.

Inspect for wear, damage signs of overheating as
appropriate:
– All splined areas.
– All bearing running surfaces.
– Thread.
– Retaining ring grooves.

CS123079

2 Check gear / bearing / bush

– Gear teeth for blueing, chips, wear etc., including dog

teeth。
– Wear on shaft bearings, needle roller bearings and
bushes.

Pay particular attention to gears / bushes etc., which

show excessive end-float when measurements are taken
during removal.
Check 1st gear end-float as follows
- Assemble 1st gear and its bearing to output shaft.
- Press 1st / 2nd synchro unit to hub.
- Pull off hub.
CS123080
Replace components as necessary.

Fitting

1 Fit oil feed gutters ① and reverse cone stop pin

②
1

2
CS123035

2-31
Manual transmission

2 Fit shift lever assembly.

CS123034

3 Fit new oil seal on transmission housing with

special tool C00017047.

CS123036

4 Select and fit differential bearing shim.

a. After fitting differential assembly, measure distance

(A) between sealing surface of clutch housing and
outer ring of differential.

CS123037

2-32
 Manual transmission

b. Measure distance (B) between sealing surface of

transmission housing and mounting surface of outer
ring of transmission housing bearing with height
indicator. Standard value B: 16.3 - 16

CS123038

c. Selection of shim
Shim thickness: B-A- Differential end clearance
Standard differential end clearance:-0.1 - -0.2 mm

Part No. Shim thickness (mm)

C00013929 0.10

C00013930 0.20

C00013931 0.30

C00013932 0.15

C00013933 0.25

C00013934 0.35

5 Fit differential into clutch housing and fit

odometer transmission gear.

CAUTION: Lubricate components before fitting.

CS123029

2-33
Manual transmission

6 Apply transmission oil to input shaft oil seal and

fit it on clutch housing with proper tools.

CS123039

7 Fit output shaft taper roller bearing and fit output

shaft to clutch housing.

CS123040

8 Apply Loctite on screw and tighten it

progressively and fit output shaft bearing cap.
Screw tightening torques: 45 ~ 55Nm.

CS123027

2-34
 Manual transmission

9 Fit needle roller bearing ① to output shaft and

assemble 1st gear ② and twin cone synchro ring
③ before fitting to output shaft. Fit input shaft ④
at the same time. 4

3
2
1

CS123041

10 Fit 1st /2nd synchro unit after aligning with

correlation marks made earlier.

CS123042

11 Fit twin cone synchro ring.

CS123043

2-35
Manual transmission

12 Fit 2nd gear shaft sleeve.

CS123044

13 Fit output shaft 2nd gear needle roller bearing.

CS123045

14 Fit output shaft 2nd gear (engage gears of input

shaft).

CS123046

2-36
 Manual transmission

15 Fit output shaft 3rd gear.

CS123047

16 Fit input shaft 3rd gear needle roller bearing.

CS123048

17 Fit input shaft 3rd gear.

CS123049

2-37
Manual transmission

18 Fit input shaft 3rd synchromesh ring.

CS123050

19 Fit input 3rd /4th synchro unit.

CS123051

20 Fit new retaining ring.

CS123052

2-38
 Manual transmission

21 Fit input shaft 4th synchromesh ring.

CS123053

22 Fit input shaft 4th gear needle roller bearing.

CS123054

23 Fit input shaft 4th gear.

CS123055

2-39
Manual transmission

24 Fit output shaft 4th gear (engage with gears of

input shaft).

CS123056

25 Fit input shaft 5th gear shaft sleeve.

CS123057

26 Fit input shaft 5th gear needle roller bearing.

CS123058

2-40
 Manual transmission

27 Fit input shaft 5th gear.

CS123059

28 Fit output shaft 5th gear to engage with input

shaft.

CS123060

29 Fit 5th synchromesh ring and 5th / reverse

synchro unit. (3 grooves turn upward)

CS123062

2-41
Manual transmission

30 Fit reverse synchromesh ring.

CS123063

31 Fit clutch reverse cone stop pin.

CS123064

32 Fit reverse cone shaft sleeve.

CS123065

2-42
 Manual transmission

33 Press input shaft bearing ② and secure with

retaining ring ① .

CS123066

34 Position 1st /2nd shift guide block ③ to interlock

plate and assemble 1st /2nd shift fork ① and
shift transverse lever ② before engaging with 1st
/ 2nd shift guide block ③ . 2

CAUTION:Do not secure spring pin at this step. 1

CS123067

35 Fit 3rd / 4th shift fork ② and 5th / reverse shift

fork ① .Position 3rd /4th shift guide block ④ on
shift lever unit and fit 3rd /4th shift transverse
lever ③ . 1

CAUTION:Do not fit and secure spring pin. 2

CS123068

2-43
Manual transmission

36 Position 5th / reverse shift guide block ② to

interlock plate and then fit 5th / reverse
transverse lever ① and fit fixed spring pin ③ .

3
1

CS123069

37 Fit reverse lever ① and reverse supporting

spring ② . Bolt tightening torque: 8 ~ 11Nm.

2
1

CS123010

38 Fit reverse idler gear and gear shaft.

CS123009

2-44
 Manual transmission

39 Fit magnet ① , output shaft spacer ③ , output

shaft adjusting shim ② and input shaft adjusting
4
shim ④ . 2

CS123008
40 Selection of input shaft shim

a. Measure C dimension (C = C' - C")

·"Use height indicator to measure C' dimension of

transmission housing.

C’

< Measure > C’

CS123070

·"Measure C" dimension with microcallipers.

C’’

< Measure > C’

CS123071

2-45
Manual transmission

·"Calculate C dimension (C = C' - C")

Standard value of C dimension: 243.87 mm ~ 244.0 mm.

C’’

C’ C
Transaxle casing

CS123072

b. Measure distance (D) between sealing surface of

clutch housing and input shaft ball bearing with height
indicator.

CS123074

c. Selection of shim
Shim thickness: (D-C) - (end clearance of input shaft)
Standard end clearance of input shaft: 0 ~ 0.10 mm
Input shaft shim table.。

Part No. Shim thickness (mm)

C00013855 0.20

C00013856 0.15

C00013857 0.30

C00013858 0.10

C00013859 0.25

2-46
 Manual transmission

41 Selection of output shaft shim

a. Temporarily fit original shim and transmission housing.

CS123006

b. Temporarily fit output shaft taper roller bearing and

tighten output shaft locknut and fit dial gauge.

CS123075

c. Place two screwdrivers under nut to measure end-float

of output shaft. Note reading.

Standard end clearance of output shaft: 0.03 ~ 0.1 mm

If measured end-float is incorrect, thickness of shim pack

must be adjusted after removing housing.

CS123076

2-47
Manual transmission

Output shaft shim table.。

Part No. Shim thickness (mm)

C00013885 0.10

C00013886 0.15

C00013887 0.20

C00013888 0.30

C00013889 0.50

C00013890 0.25

42 Remove transmission housing and fit new

adjusting shim to bearing seats of input and
output shafts in transmission housing.

CS123077

43 Fit transmission housing. Bolt tightening .

torque: 44 ~ 55Nm

CS123006

2-48
 Manual transmission

44 Fit reverse idler gear shaft bolt.

Bolt tightening torque: 45 ~ 55Nm

CS123005

45 Fit setting screw ① , locking spring ② , steel ball

③ and reverse light switch ④ .
Screw tightening torques: 15 ~ 21Nm.

3
2
1

CS123004

46 Turn shift lever to engage gear and secure input

shaft with C00017041.
C00017041

CS123002

2-49
Manual transmission

47 Fit output shaft taper roller bearing and tighten

output shaft locknut.

Nut tightening torques: 150 ~ 220Nm

CS123003

48 Fit rear cover and tighten securing screw.

Screw tightening torques: 20 ~ 25Nm

CS123000

2-50
 Manual transmission

Disassembly of differential assembly

Tools required: C00017042, C00017043 proper bearing
puller.
Removal

1 Remove transmission assembly (see "Replace

manual transmission assembly").

2 Disassemble transmission assembly (see

"Disassembly of manual transmission
assembly").。

3 Use C00017042 to remove differential bearing

after withdrawing differential assembly.

1 Disassembly
differential

Tools require
C00017043 p
puller.
Removal
CS123082

3 Remove taper roller bearing ① .

4 Remove differential sealing bolts and differential
gear housing and driven gear.
1
5 Remove differential spider, side gear, differential
planet gear and thrust washer.

CS123084

Inspect:
– Gear teeth for blueing, chips, wear etc.
– Wear on bearing and thrust washer surfaces.
– Wear on transmission shaft splines.
Fitting
Fitting is the reverse of removal, but note the following:
1 Wash can not be used again after removal.
2 Clean and apply slight smear of oil to bearing
location in casing.

2-51
Manual transmission

Replace, check and adjust gear lever cable

Removal

1 Disconnect battery (negative cable first).

2 Disconnect cable at gear lever of transmission.

3 Remove E ring ② from cable mounting to

release cable ① .

CS123093
4 Remove lower central panel assembly (see
"Replace upper and lower central panel".

5 从 Remove E ring from manual transmission

lever assembly.

6 Pry cable joint off manual transmission lever

assembly with proper lever.

CS153004
7 Withdraw gear lever cable.

Check and adjust:

If poor gear changing is experienced, and before
attempting to adjust the cables.
It is recommended to proceed as follows to eliminate
possible faults in the gear lever mechanism.

Check gear lever:

1 Select neutral.

2 Disconnect both cables of transmission.

3 Move the gear lever in all directions and check for

indications of seizure.

4 This plastic joint shall be replaced during any repair that

may lead to cable joint disconnection

2-52
 Manual transmission

If gear lever mechanism is normal, proceed as the

following to adjust cable:
1 Check cable has been disconnected.

2 Install gear lever setting pin C00017046 to lock

gear lever in neutral position.
C00017046
3 Adjust cable lengths until positioned correctly.
Secure cable eyes and tighten locknuts.

4 Remove setting pin C00017046.

5 Select all gear positions to check for right

adjustment. Gears should be engaged smoothly
and fully. Re-adjust if necessary.

CS153005
Fitting

1 Fitting is reverse of removal procedure. Note the

following:

– The cable must be checked / adjusted for length.

Do the following after connecting cable to the gear
lever mechanism.
– Check correct engagement of all gears.
– Check that lower central panel controls all
operations correctly after reconnection.

Replace shift mechanism knob

Removal
1 Disconnect the negative cable of battery.

2 Place shift knob in neutral position.

3 Disconnect shift knob leather sheath buckle from

console.

4 Upturn shift knob leather sheath.

5 Turn retaining ring of shift leather sheath to

remove it

6 Remove shift knob

CS123095

2-53
Manual transmission

Fitting
1 Fitting is reverse of removal procedure.

2-54
 CLUTCH
CLUTCH

Technical Data
Parameters

Model Hydraulic power-assisted clutch

Oil capacity Share: brake fluid

Inner diameter of driven plate 175mm

Outer diameter of disc 259mm

Inner diameter of disc 174mm

Material of friction disk Raybestos B-8805

Thickness of driven plate when newly fitted and 7.2 ± 0.3mm

compressed

Limit wearing capacity of driven plate Single face 1mm

Torque

Application Torque value (Newton metres)

Master and slave cylinders and clutch fuel pipe joint 16 ± 2Nm
Clutch disc to flywheel bolt 36Nm

3-1
CLUTCH

Layout
Layout of clutch system

1 Clutch disc 5 Slave cylinder and release mechanism

2 Driven plate 6 Clutch pedal
3 Release bearing 7 Clutch to flywheel bolt
4 Master cylinder

3-2

Diagnosis information and procedure
Faul
When pressing clutch
pedal down to the end,
shift lever fails to engage
gears and disengage the
reverse easily
Clutch slipping
Clutch shaking
Clutch clattering
Release bearing makes
noise when clutch
engaged.
Possible
Link mechanism loose.
Clutch disk damaged.
Fork shaft improperly fitted..
Clutch disk hub seized on input shaft
splines.
Clutch disk warped or bent..
Driver incorrectly operates the vehicle.
Clutch disk wet..
Friction surface of clutch worn or spit.
Disc or flywheel warped.
Diaphragm spring weakened.
Driven plate not in position.
Driven plate overheated
Friction surface burnt or burnished due to
oil on it.
Wear on input shaft splines.
Disc or flywheel warped.
Burnt or smeared resins on disc or
flywheel.
Retractable spring weakened.
Release fork loose.
Oil in driven plate bump stop.
Driven plate damping spring damaged.
Driver incorrectly operates vehicle.
Release bearing seized.
Check release lever improperly installed.
Return spring of connection rod weakened.
CLUTCH
Solution
If necessary, repair or replace loose link
mechanism.
Replace damaged clutch disk.
Remove fork shaft and properly fit it again.
Apply slight wheel bearing grease to fork ends
at release bearing.
Repair or replace clutch disk hub.
Replace warped or bent clutch disk.
Correct driver's operation to vehicle when
necessary.
Clear leakage faults at oil leakage points and fit
new clutch disk.
Replace worn clutch disk with new disk.
Replace warped disc or flywheel.
Replace diaphragm spring.
Start engine 30-40 times. Don't over heat
engine.
Cool driven plate.
Clear leakage faults at oil leakage points and fit
new clutch disk.
Replace worn input shaft.
Replace warped disc or flywheel.
Remove burnt or smeared resins on surface
clearly. Replace any burnt or heat cracked
parts.
Replace disc.
Remove and refit release fork properly.
Clear oil leakage fault and replace driven plate.
Replace driven plate.
Correct driver's operation to vehicle when
necessary.
Clean and lubricate release bearing again.
Check burrs or breaches on release bearing.
Remove and refit release lever properly.
Replace weakened return spring of connection
rod.
3-3
CLUTCH

Clutch makes noise Release bearing worn. Replace worn release bearing.

Release lever improperly installed. Remove fork shaft and properly fit it again.
Apply slight wheel bearing grease to fork ends
at release bearing.

Pedal fails to return when Connection rod or release bearing seized. Lubricate and move seized connection rod or
stopping on floor. release bearing.

Disc spring weakened. Replace disc.

3-4
 CLUTCH

SPECIAL TOOLS
Maintenance special tooling table (same tooling number
on each tool）

Name Illustration

Clutch aligner

C00016994

3-5
CLUTCH

Repair instructions
Replace driven plate and disc
Tools required: C00016994
Removal

1 Remove vehicle transmission. (See

"Replacement of manual transmission
assembly")
2 Support clutch driven plate with C00016994 and
progressively remove securing bolts.

3 Remove disc and driven plate.

CS123083
4 Remove release fork ① , release bearing ② and
guide sleeve ③ . 1

CS123081
Fitting

1 Fit driven plate and disc and align driven plate

with C00016994. Progressively tighten securing
bolts. Tightening torques: 36Nm
2 Fit transmission release fork ① , release bearing ②
and guide sleeve ③ and refit transmission. ③
Tightening torques: 6~8Nm

CAUTION: Check driven plate thickness and

replace it when beyond or approaching limit
wearing capacity. Clutch disc must be
replaced if it drops accidentally. If driven
plate is replaced for wearing, it is
recommended to replace disc.

3-6
 CLUTCH

Replace master cylinder

Removal

1 Disconnect negative cable of the battery. (Refer

to battery chapter for safety cautions)

2 Empty brake fluid reservoir.

CAUTION: Be careful: Cool water must be used to

wash paint surface where brake fluid splashed on
immediately.

FRT

CS153001

3 Disconnect spring clamp and remove oil supply

hose of clutch master cylinder with both ends
capped tightly to prevent dirt ingress.

4 Disconnect clutch high pressure hard pipe from

master cylinder.

5 Remove bolt and clutch master cylinder from pedal.

3
5
4

CS153003
6 When separating the main pump and pedal, press
the inside of the fastener and pull out lightly along
the axial direction together with the metal pole so
that the fastener is not damaged. Be sure not to hold
the metal pole and shake it fiercely or pull it out too
quickly.

CS153006

3-7
CLUTCH

Fitting

1 Fitting is reverse of removal procedure.

Tightening torque of master cylinder fitting bolt: 15 ±
2Nm
Tightening torque of master cylinder and clutch hard
pipe: 16 ± 2Nm

2 Expel air. See "hydraulic clutch air expelling".

3 Fill brake fluid to MAX (maximum) mark on reservoir

and connect negative cable of battery.

3-8
 CLUTCH

Replace slave cylinder

Removal

1 Empty brake fluid.

2 Disconnect clutch hard pipe from slave cylinder.

3 Remove bolts and clutch slave cylinder from

transmission.

4 Disconnect hard pipe form master cylinder.

5 Remove hose and hard pipe assembly from each

pipe clip (arrowed).

2 3
CS153000
Fitting

1 Fitting is reverse of removal procedure.

Tightening torque of master cylinder and hard pipe:
16 ± 2Nm

Tightening torque of slave cylinder fitting bolt: 15 ±

2Nm

Tightening torque of slave cylinder and clutch hard

pipe: 16 ± 2Nm

2 Expel air. See "hydraulic clutch air expelling".

3 Fill brake fluid to MAX (maximum) mark on reservoir

and connect negative cable of battery.

3-9
CLUTCH

Hydraulic clutch air expelling

1 Expel air coming into hydraulic system when

disconnecting pipeline for repair. When expelling
air, brake fluid in clutch reservoir shall stay in
minimum (MIN) or slightly higher position.
2 Connect vinyl plastic hose to exhaust plug of clutch
slave cylinder. Insert the other end of vinyl plastic
hose into glass container that contains half brake
fluid.

3 Press clutch pedal slowly.

CS153002
4 When pressing clutch pedal, release exhaust screw
until oil starts to flow out, and then tighten exhaust
screw and release pedal.

5 Repeat step 3 and 4 until no bubbles in oil.

6 Fill brake fluid to maximum (MAX) mark position.

CAUTION:Electrical joint and paint surface will be

damaged by brake fluid, which shall be protected
from contacting with brake fluid by using cotton
cloth, proper container and wing cover.
CAUTION:System discharged oil is inhibited to
fill into reservoir of clutch master cylinder again.
Reasons are as below:

1 Possible air in oil

2 Possible contaminated oil

3 Possible too much water in oil

3-10
 Drive Shaft
Drive Shaft

Technical data

Parameters

Max oscillation angle of tripod universal joint (movable joint) >45°

Max oscillation angle of constant velocity joint (fixed joint) >23°
Press-in force between internal transfer wheel and solid 500-15000 （N）
shaft

Press-in force between tripod and solid shafts 500-20000 （N）

Torque

Application Torque value (Newton metres)

Anti-roll bar link nut 50 ± 5

Hub locknut ① 100 ± 10，② 300 ± 30，③ 450 ± 16
Knuckle ball pin to knuckle screw 90 ± 9
Track rod ball joint to knuckle nut 85-95
Bearing plate to bearing carrier bolt 8-10

Wheel bolt 180 ± 13

4-11
Drive Shaft

Layout
Layout of drive shaft

10 9 3 4
1

8
6 7

14

11
5
2
3

9 10
14
13
12 7
6

1 Drive shaft (LH) 8 Spring retaining ring

2 Drive shaft (RH) 9 Hub washer
3 CV joint 10 Locknut
4 Tripod universal joint (LH) 11 Bearing plate
5 Tripod universal joint (RH) 12 Bolt
6 CV joint gaiter 13 Bearing seat carrier
7 Tripod universal joint gaiter 14 Transmission box

4-12
 Drive Shaft

Fault diagnosis information and

procedure

Fault Possible cause Solution

Drive shaft noise Drive shaft unbalanced Calibrate to clear fault or

replace

Universal joint's ball, steel ball, retainer or outer Replace the universal joint
housing worn

Knocking when start and abnormal Universal joint worn or damaged Replace the universal joint
sliding noise Transmission output shaft splines worn Replace parts

SPECIAL TOOLS
Maintenance special tooling table (same tooling number
on each tool)）

Name Illustration

Ball joint separator

C00017036

4-13
Drive Shaft

Repair instructions
Replace left drive shaft
Tools required: C00017036
Removal

1 Remove wheel with vehicle supported by lift (see

"Replace wheel").

2 Remove nuts connecting track rod ball joint and

knuckle and separate track rod ball joint with
C00017038.

3 Remove nuts connecting anti-roll bar link and

control arm.

4 Disconnect the front ABS speed sensor harness.

5 Loosen the front brake hose on front strut carrier.

6 Remove locknut and hub washer on drive shaft. 3 2

CS173008
7 Remove 4 screws securing knuckle ball pin.

CS223005
8 Use suitable pry bar to pry knuckle clear of ball
joint.

CAUTION:Do not damage gaiter.

9 Pry spring retaining ring of left drive shaft out as
shown in the figure for it is secured in differential.
If difficult, turn the shaft 1/3 turn and another 1/3
turn if necessary.

CAUTION:Pull out left drive shaft horizontally to

prevent damaging differential oil seal.
10 Pull front hub outward to separate front hub and
left drive shaft. CS173004
11 Place proper drain tray under differential
connector and remove left drive shaft.

4-14
 Drive Shaft

12 After removing left drive shaft, cap the differential

connector with a plug to prevent dirt ingress.

CS173007
Fitting

1 Clean left drive shaft ends, mounting areas in

front hub and connection areas of differential.

2 Position spring retaining ring on the topmost of

left drive shaft and fit left drive shaft in differential
and push into position.

CS173003

3 Fit left drive shaft in knuckle. Fit 4 screws

securing knuckle ball pin and tighten with a
torque of:90 ± 9Nm.

4 Fit anti-roll bar link nut and tighten with a torque

of: 50 ± 5Nm.

5 Fit track rod ball joint to knuckle and secure with

nuts tightened with a torque of: (85-95) Nm.

6 Fasten the front brake hose to front strut carrier.

7 Connect the front ABS speed sensor harness.

4-15
Drive Shaft

8 Fit hub washer and locknut and tighten the

torque in accordance with 3 steps below. Fit
wheel and lower lift to ground firstly.

– Pre-tightening torques: 100 ± 10Nm.

– Turn drive shaft 10 turns and fit hub bearing into

position and tighten with a torque of: 300 ± 30 Nm.

– Turn drive shaft again and tighten with a torque of: 450
± 16Nm.

9 Stake locknuts of left drive shaft to make them

caught in the groove of half rear axle.

10 Fit the wheel (see "Replace wheel").

CS173012

4-16
 Drive Shaft

Replace right drive shaft

Tools required: C00017036

Removal
1 Remove the wheel with vehicle supported by lift
(see "Replace wheel").

2 Remove securing bolts of bearing seat plate and

bearing carrier to remove bearing carrier.

CS173006

3 Remove nut connecting track rod ball joint and

knuckle and separate track rod ball joint with
C00017036.

4 Remove nuts connecting anti-roll bar link and

control arm.

5 Disconnect the front ABS speed sensor harness.

6 Loosen the front brake hose on front strut carrier.

7 Remove locknut and hub washer on drive shaft. 4 3

CS173014

8 Remove 4 screws securing knuckle ball pin.

9 Use suitable pry bar to pry knuckle clear of ball

joint.

CAUTION: 不 Do not damage gaiter.

10 Pull front hub outward to separate front hub and
right drive axle.

11 Loosen right drive shaft from differential.

12 Place proper drain tray under differential

connector and remove right drive shaft.

13 After removing right drive shaft, cap the CS223005

differential connector with a plug to prevent dirt
ingress.

4-17
Drive Shaft

Fitting
1 Clean right drive shaft ends, mounting areas in
front hub and connection areas of differential.

2 Fit bearing carrier in bearing seat plate and

secure bolts by tightening a torque of: 8-10 Nm.

3 Fit right drive shaft in knuckle. Fit 4 screws of

knuckle ball pin and tighten with a torque of:90
± 9 Nm.

4 Fit anti-roll bar link nut and tighten with a torque

of: 50 ± 5 Nm.

5 Secure knuckle and knuckle with nuts and

tighten a torque of: 85-95 Nm.

6 Fasten the front brake hose to front strut carrier.

7 Connect the front ABS speed sensor harness.

8 Fit hub washer and locknut and tighten the

torque in accordance with 3 steps below. Fit
wheel and lower lift to ground firstly.

– Pre-tightening torques: 100 ± 10Nm.

– Turn drive shaft 10 turns and fit hub bearing into

position and tighten with a torque of: 300 ± 30 Nm.

– Turn drive shaft again and tighten with a torque of: 450
± 16Nm.
9 Stake locknuts of right drive shaft to make them
caught in the groove of half rear axle.
CS173012
10 Fit the wheel (see "Replace wheel").

4-18
 Drive Shaft

Replace CV joint gaiter

Removal

1 Remove drive shaft from vehicle (see "Replace

left drive shaft" and "Replace right drive shaft")
2 Clamp drive shaft with a vise.

3 Remove 2 gaiter clamps and discard. 3

6
3
5

CS173009

4 Hold CV shaft in alignment with drive shaft and

slightly tap CV housing with a copper hammer to
detach it.

5 Remove snap ring from drive shaft and discard.

6 Remove gaiter.

CS173005

Fitting

1 Fit new gaiter to drive shaft, positioning its end to

the outboard of the two grooves (arrowed).
2 Fit new snap ring on drive shaft.

3 Fill CV joint with grease supplied and apply any

remaining grease into the gaiter.

4 Press drive shaft fully home into CV joint.

5 Clean the connection area of gaiter and CV joint

gaiter and secure gaiter clamp.

6 CV joint is sure to turn in all directions freely

without disturbing gaiter.
CS173000
7 Fit drive shaft (see "Replace left drive shaft" and
"Replace right drive shaft").

4-19
Drive Shaft

Replace CV joint
Removal

1 Remove drive shaft (see "Replace left drive

shaft" and "Replace right drive shaft").

2 Clamp drive shaft with a vise.

3 Loosen 1 large clamp securing the gaiter and

push the gaiter back.

4 Hold CV shaft in alignment with drive shaft and

slightly tap CV housing with a copper hammer to
detach it.
5 Remove snap ring from drive shaft and discard.

6 Remove CV joint.

CS173005

Fitting

1 Fit 1 large clamp securing the gaiter to drive

shaft.

2 Fit new snap ring on drive shaft.

3 Fill CV joint with grease supplied and apply any

remaining grease into the gaiter.

4 Press drive shaft fully home into CV joint.

5 Clean the connection area of gaiter and CV joint

and secure 1 gaiter clamp.

6 Fit drive shaft assembly (see "Replace left drive

shaft" and "Replace right drive shaft").

4-20
 Drive Shaft

Replace tripod universal joint / gaiter

Removal

1 Remove drive shaft (see "Replace left drive

shaft" and "Replace right drive shaft").

2 Clamp drive shaft with a vise.

3 Loosen 2 clamps and discard and make

correlation marks on tripod universal joint and
housing temporarily.

4 Pull tripod universal joint out of the gaiter.

3
7
3
CS173010

5 Remove intermediate drive shaft snap spring

with nippers and discard.

6 Remove tripod universal shaft from intermediate

drive shaft.

7 Remove gaiter.

CS173002

Fitting

1 Clean drive shaft and tripod universal joint gaiter

2 Fit 2 new clamps and gaiter to intermediate drive

shaft.

3 Position tripod universal joint on intermediate

drive shaft.

4-21
Drive Shaft

4 Fit new spring snap to intermediate drive shaft.

When fitting tripod universal joint, note that its flat
face is fitted outward (arrowed), towards spring
snap.

5 Fill tripod universal joint with grease supplied

and apply any remaining grease into the gaiter.

6 To ensure joint is fitted in its original position,

align correlation marks and fit into housing.

7 Secure tripod universal joint gaiter on drive shaft.

CS173001

Replace drive shaft oil seal

Removal

1 Remove drive shaft that needs to replace oil seal

(see "Replace left drive shaft" and "Replace right
drive shaft").
2 Pry out drive shaft oil seal with wrench.

CS173011

Fitting

1 Lubricate oil seal lip with clean transaxle oil and

press oil seal into position with proper sleeve.
2 Fit drive shaft (see "Replace left drive shaft" and
"Replace right drive shaft").

CS173013

4-22