Manual Transaxle echo 2002 Guide

7/28/2019 Manual Transaxle echo 2002 Guide

1/44

MX078-04

Q06511

Oil Seal

Plate WasherOuter Race and Side Bearing

Vehicle Speed Sensor Drive Gear

Straight Pin

Side Bearing and Outer Race

Oil Seal

Ring Gear

Shim

Differential Case

Pinion Shaft

Pinion Gear

Thrust Washer

Side Gear

Thrust Washer

z Non-reusable part

x 6

Nm (kgfcm, ftlbf) : Specified torque

124 (1,260, 91)

z

z

z

z

MX-38-MANUAL TRANSAXLE DIFFERENTIAL CASE

919Author: Date:

2002 ECHO (RM884U)

DIFFERENTIAL CASE

COMPONENTS


2/44

MX079-04

Z16129

SST

MT0081

Matchmarks

MT0083

MT0084

N00098

SST

-MANUAL TRANSAXLE DIFFERENTIAL CASE

MX-39

920Author: Date:

2002 ECHO (RM884U)

DISASSEMBLY1. REMOVE SIDE BEARING FROM DIFFERENTIAL

CASE

(a) Using SST, remove the bearings from both sides of the

differential case.

SST 09950- 00020, 09950- 00030, 09950- 60010

(09951-00360)

(b) Remove the vehicle speed sensor drive gear from the RH

side.

2. REMOVE RING GEAR

(a) Place matchmarks on the ring gear and differential case.

(b) Remove the 6 bolts.

(c) Using a plastic hammer, tap on the ring gear to remove it

from the differential case.

3. INSPECT SIDE GEAR BACKLASH

Using a dial indicator, measure the backlash of one side gear

while holding one pinion toward the differential case.

Standard backlash:

0.05 - 0.20 mm (0.0020 - 0.0079 in.)

If the backlash is not within the specification, install the correct

thrust washer to the side gears.

4. DISASSEMBLE DIFFERENTIAL CASE

(a) Using a pin punch and hammer, drive out the straight pin.

(b) Remove the pinion shaft from the differential case.

(c) Remove the 2 pinion gears and side gears with the 4

thrust washers from each gear.

5. Transmission case side:

IF NECESSARY, REPLACE OIL SEAL AND SIDE

BEARING OUTER RACE

(a) Using a screwdriver and hammer, drive out the oil seal.

(b) Using SST, pull out the outer race and shim.

SST 09612-65014

(c) Place the shim into the differential case.


3/44

Q08120

SST

Q08121

SST

2.4 0.3 mm

N00100

SST

Z16127

SST

Q06517

1.9 0.3 mm

SST


921Author: Date:

2002 ECHO (RM884U)

(d) Using SST and a hammer, drive in a new outer race.

SST 09950- 60020 (09951- 00710), 09950- 70010

(09951-07150)

NOTICE:

When replacing the side bearing outer race, replace the

side bearing along with it.

(e) Using SST and a hammer, drive in a new oil seal.

SST 09350- 32014 (09351- 32111), 09950- 70010

(09951-07150)

Drive in depth: 2.4 0.3 mm (0.094 0.012 in.)

(f) Coat the lip of the oil seal with MP grease.

6. Transaxle case side:

IF NECESSARY, REPLACE OIL SEAL AND SIDE

BEARING OUTER RACE

(a) Using a screwdriver and hammer, drive out the oil seal.

(b) Using SST, pull out the outer race and plate washer.

SST 09612-65014

(c) Place the plate washer into the differential case.

(d) Using SST and a hammer, drive in a new outer race.

SST 09950- 60020 (09951- 00680), 09950- 70010

(09951-07150)

NOTICE:

When replacing the side bearing outer race, replace the


(e) Using SST and a hammer, drive in a new oil seal.

SST 09350-32014 (09351-32130, 09351-32150)


(f) Coat the lip of the oil seal with MP grease.


4/44

N00102

MX07A-05

MT0083

N00172

Matchmarks CaseSide


MX-41

922Author: Date:

2002 ECHO (RM884U)

REASSEMBLY1. ASSEMBLE DIFFERENTIAL CASE

(a) Install the correct thrust washers and side gears.

Refer to the table below, select thrust washers which will

ensure that the backlash is within the specification. Try to

select washers of the same size for both sides.

Standard backlash:

0.05 - 0.20 mm (0.0020 - 0.0079 in.)

Thickness mm (in.) Thickness mm (in.)

1.50 (0.0591) 1.65 (0.0650)

1.55 (0.0610) 1.70 (0.0669)

1.60 (0.0630) 1.75 (0.0689)

(b) Install the thrust washers and side gears in the differential

case.

(c) Install the pinion shaft.

(d) Using a dial indicator, check the side gear backlash.

Measure the side gear backlash while holding one pinion

gear toward the differential case.

Standard backlash:

0.05 - 0.20 mm (0.0020 - 0.0079 in.)

If the backlash is not within the specification, install a thrust

washer of different thickness.

(e) Using a pin punch and hammer, drive in the straight pin

through the differential case and hole in the pinion shaft.

(f) Using a chisel and hammer, caulk the pin holes around

the circumference of the differential case.

2. INSTALL RING GEAR ON DIFFERENTIAL CASE

(a) Clean the contact surface of the differential case.

(b) Heat the ring gear in boiling water.

(c) Carefully remove the ring gear from the water.

(d) After the moisture on the ring gear has completely evapo-

rated, quickly install the ring gear to the differential case.

HINT:

Align the matchmarks on the differential case and contact the

ring gear.

(e) Install the 6 set bolts. Tighten each set bolt uniformly, a

little at a time in succession. Torque the bolts.

Torque: 124 Nm (1,260 kgfcm, 91 ftlbf)


5/44

D08261

SSTSST

CM0061

D08262

SST


923Author: Date:

2002 ECHO (RM884U)

3. INSTALL SIDE BEARING

(a) Install the vehicle speed sensor drive gear to the RH side.

(b) Using SST and a press, install new side bearings to the

both sides of the differential case.

SST 09350-32014 (09351-32090, 09351-32120)

NOTICE:When replacing the side bearing outer race, replace the


4. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD

NOTICE:

Perform this only when replacing the side bearing and out-

er race of the differential case.

(a) Install the differential case assembly to the transaxle

case.(b) Install the transmission case.

(c) Install and torque the case bolts.

Torque: 29 Nm (300 kgfcm, 22 ftlbf)

(d) Using SST and a torque wrench, turn the differential case

assembly right and left 2 or 3 times to allow the bearings

to settle.

SST 09564-3201 1

(e) Using SST and a torque wrench, measure the preload.

SST 09564-3201 1

Preload (at starting):

New bearing

0.8 - 1.6 Nm (8 - 16 kgfcm, 6.9 - 13.9 in.lbf)

Reused bearing

0.5 - 1.0 Nm (5 - 10 kgfcm, 4.3 - 8.7 in.lbf)

If the preload is not within the specification, remove the trans-

mission case side outer race of the side bearing with SST (See

page MX-39 ).

(f) Select an appropriate shim.
http://disa.pdf/http://disa.pdf/


6/44


MX-43

924Author: Date:

2002 ECHO (RM884U)

HINT:

The preload will change by about 0.3 - 0.4 Nm (3 - 4 kgfcm,

2.6 - 3.5 in.lbf) corresponding to a change of 0.05 mm (0.0020

in.) in shim thickness.

Mark Thickness mm (in.) Mark Thickness mm (in.)

AA 2.10 (0.0827) LL 2.60 (0.1024)

BB 2.15 (0.0846) MM 2.65 (0.1043)

CC 2.20 (0.0866) NN 2.70 (0.1063)

DD 2.25 (0.0886) PP 2.75 (0.1083)

EE 2.30 (0.0906) QQ 2.80 (0.1102)

FF 2.35 (0.0925) RR 2.85 (0.1122)

GG 2.40 (0.0945) SS 2.90 (0.1142)

HH 2.45 (0.0965) TT 2.95 (0.1161)

JJ 2.50 (0.0984) UU 3.00 (0.1181)

KK 2.55 (0.1004) - -


7/44

MX06Z-03

D07738

Needle Roller Bearing

3rd Gear

Synchronizer Ring

No. 2 Hub Sleeve

Shifting Key Spring

No. 2 Clutch Hub

Spacer

Synchronizer Ring

Snap Ring


4th Gear

Rear Ball BearingSnap Ring

Input Shaft

Shifting Key

-MANUAL TRANSAXLE INPUT SHAFT

MX-23

904Author: Date:

2002 ECHO (RM884U)

INPUT SHAFT

COMPONENTS


8/44

MX070-03

Q05793

3rd Gear

4th Gear

N00065

Q04983

SST

MX-24-MANUAL TRANSAXLE INPUT SHAFT

905Author: Date:

2002 ECHO (RM884U)

DISASSEMBLY1. INSPECT 3RD AND 4TH GEARS THRUST CLEAR-

ANCE

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

3rd gear: 0.10 - 0.35 mm (0.0039 - 0.0138 in.)

4th gear: 0.10 - 0.55 mm (0.0039 - 0.0217 in.)

Maximum clearance:

3rd gear: 0.35 mm (0.0138 in.)

4th gear: 0.55 mm (0.0217 in.)

2. INSPECT 3RD AND 4TH GEARS RADIAL CLEAR-

ANCE

Using a dial indicator, measure the radial clearance between

the gear and shaft.

Standard clearance:

KOYO made:

0.015 - 0.058 mm (0.0006 - 0.0023 in.)

NSK made:

0.015 - 0.056 mm (0.0006 - 0.0022 in.)

Maximum clearance:

KOYO made: 0.058 mm (0.0023 in.)

NSK made: 0.056 mm (0.0022 in.)

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or shaft.

3. REMOVE SNAP RING

Using 2 screwdrivers and a hammer, tap out the snap ring.

4. REMOVE REAR BALL BEARING, 4TH GEAR, NEEDLE

ROLLER BEARING, SPACER AND SYNCHRONIZER

RING FROM INPUT SHAFT

(a) Using SST and a press, remove the rear ball bearing and

4th gear.

SST 09950-00020

(b) Remove the needle roller bearings, spacer and synchro-nizer ring.

5. REMOVE SNAP RING



9/44

CM0064

SST

CM0141


MX-25

906Author: Date:

2002 ECHO (RM884U)

6. REMOVE NO. 2 HUB SLEEVE ASSEMBLY, 3RD GEAR,

SYNCHRONIZER RING AND NEEDLE ROLLER BEAR-

ING

(a) Using SST and a press, remove the No. 2 hub sleeve as-

sembly, 3rd gear and synchronizer ring.

SST 09950-00020(b) Remove the needle roller bearings.

7. DISASSEMBLE NO. 2 HUB SLEEVE ASSEMBLY

(a) Using a screwdriver, remove the 2 shifting key springs

and 3 shifting keys from the No. 2 clutch hub.

(b) Remove the No. 2 hub sleeve from the No. 2 clutch hub.


10/44

MX071-03

WM0064

WM0065

WM0066


907Author: Date:

2002 ECHO (RM884U)

INSPECTION1. INSPECT SYNCHRONIZER RING

(a) Check for wear or damage.

(b) Check the braking effect of the synchronizer ring. Turn the

synchronizer ring in one direction while pushing it to the

gear cone. Check that the ring locks.

If the braking effect is insufficient, apply a small amount of the

fine lapping compound between the synchronizer ring and gear

cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE:

Ensure the fine lapping compound is completely washed

off after rubbing.

(c) Check again the braking effect of the synchronizer ring.

(d) Using a feeler gauge, measure the clearance between

the synchronizer ring back and gear spline end.

Minimum clearance: 0.75 mm (0.0295 in.)

If the clearance is less than the minimum, replace the synchro-

nizer ring and apply a small amount of the fine lapping com-

pound on gear cone.

NOTICE:


off after rubbing.

2. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-

ANCE

Using a feeler gauge, measure the clearance between the hub

sleeve and shift fork.

Maximum clearance: 0.35 mm (0.014 in.)

If the clearance exceeds the maximum, replace the shift fork or

hub sleeve.


11/44

CM0066

AB C D

CM0013


MX-27

908Author: Date:

2002 ECHO (RM884U)

3. INSPECT INPUT SHAFT

(a) Check the input shaft for wear or damage.

(b) Using a micrometer, measure the outer diameter of the in-

put shaft journal surface.

Minimum outer diameter:

Part A: 24.885 mm (0.9797 in.)Part B: 28.985 mm (1.1411 in.)

Part C: 30.985 mm (1.2199 in.)

Part D: 24.967 mm (0.9830 in.)

If the outer diameter is less than the minimum, replace the input

shaft.

(c) Using a dial indicator, check the shaft runout.

Maximum runout: 0.03 mm (0.0012 in.)

If the runout exceeds the maximum, replace the input shaft.


12/44

MX072-03

D02999

EngineSide

Z08629

N00067

N00068


909Author: Date:

2002 ECHO (RM884U)

REASSEMBLYHINT:

Coat all of the sliding and rotating surfaces with gear oil before

reassembly.

1. ASSEMBLE NO. 2 HUB SLEEVE ASSEMBLY

(a) Install the 3 shifting keys and No. 2 hub sleeve to the

No. 2 clutch hub.

(b) Install the 2 shifting key springs under the shifting keys.

NOTICE:

Position the shifting key springs so that their end gaps are

not in line.

2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,

SYNCHRONIZER RING AND NO. 2 HUB SLEEVE AS-

SEMBLY TO INPUT SHAFT

(a) Apply gear oil to the needle roller bearings and install it.

(b) Install the 3rd gear and synchronizer ring.

(c) Install the No. 2 hub sleeve assembly so that the synchro-

nizer ring slots and shifting keys are aligned.

(d) Using a press, install the No. 2 hub sleeve assembly.

3. INSTALL SNAP RING

(a) Select a snap ring that allows the minimum axial play.


0 2.30 (0.0906) 3 2.48 (0.0976)

1 2.36 (0.0929) 4 2.54 (0.1000)

2 2.42 (0.0953) 5 2.60 (0.1024)

(b) Using a screwdriver and hammer, tap in the snap ring.

4. INSPECT 3RD GEAR THRUST CLEARANCE

(See page MX-24 )


13/44

N00070

SM0049

SST

SM0050


MX-29

910Author: Date:

2002 ECHO (RM884U)

5. INSTALL SPACER, NEEDLE ROLLER BEARING, SYN-

CHRONIZER RING, 4TH GEAR AND REAR BALL

BEARING

(a) Install the spacer.

(b) Apply gear oil to the needle roller bearings and install it.

(c) Place the synchronizer ring on the No. 2 hub sleeve as-sembly and align the synchronizer ring slots with the shift-

ing keys.

(d) Install the 4th gear.

(e) Using SST and a press, install the rear ball bearing.

SST 09608-00071




A 2.29 (0.0902) D 2.47 (0.0972)

B 2.35 (0.0925) E 2.53 (0.0996)

C 2.41 (0.0949) F 2.59 (0.1020)


7. INSPECT 4TH GEAR THRUST CLEARANCE

(See page MX-24 )


14/44

MX06V-04

D07730

Clutch Release Fork

Clutch Release Fork Boot

Clutch Release Bearing

z Oil Seal

z O-Ring

z

ClipVehicle Speed Sensor

Vehicle Speed Sensor Driven Gear

Control Lever HousingSupport Bracket

Transaxle Case Receiver

Transaxle Case

Plate Washer

Differential Case Assembly

Magnet Side BearingOuter Race

z Oil Seal

Input Shaft Front Bearingz

z

Output Shaft Cover

Output Shaft Front Bearing

Bearing Lock Plate


Non-reusable part

Precoated partL

z

11 (115, 8)

29 (300, 22)L 11 (115, 8)

11 (115, 8)

11 (115, 8)

Clutch Release Fork Support37 (375, 27)

-MANUAL TRANSAXLE MANUAL TRANSAXLE ASSEMBLY

MX-9

890Author: Date:

2002 ECHO (RM884U)

MANUAL TRANSAXLE ASSEMBLY

COMPONENTS


15/44

Z18919

Reverse Shift Arm Bracket

Reverse Shift Fork

Snap Ring No. 3 Shift Fork Shaft

Snap Ring

17 (175, 13)

Thrust Washer

ReverseIdler Gear

Idler Gear Shaft

29 (300, 22)

Ball

L Straight Screw Plug

25 (250, 18)

Ball

Spring

Seat

L 25 (250, 18)

No.3 Shift Fork

L 25 (250, 18)

No. 2 Shift Fork Shaft

Output Shaft Assembly

Input Shaft Assembly

Snap Ring

Shift Head

16 (160, 12)

16 (160, 12)

No. 1 Shift Fork Shaft

No. 1 Shift Fork

16 (160, 12)

16 (160, 12)

No. 2 Shift Fork

z Lock Nut118 (1,200, 87)

5th Driven Gear

27 (280, 20)

x 5Spacer

Snap Ring

Rear Bearing Retainer


5th Gear

Synchronizer Ring

No. 3 Hub Sleeve

Shifting Key

z Non-reusable part

L Precoated part


No. 3 Clutch Hub

Snap Ring

Shifting Key Spring

z Gasket

MX-10-MANUAL TRANSAXLE MANUAL TRANSAXLE ASSEMBLY

891Author: Date:

2002 ECHO (RM884U)


16/44

D07731

No. 2 Oil Receiver Pipe

Lock Ball Assembly

L

Straight Screw PlugL

Slotted Spring Pin

Reverse Restrict Pin

No. 1 Oil Receiver Pipe

z Gasket

Filler Plug

L

x 13

Transmission Case

Drain Plug

TransmissionCase Cover

L

x 9

Oil Seal

Selecting Bellcrank Assembly

Control BellcrankDust Cover

L

Shift and Select LeverShaft Assembly

Gasket

Lock Bolt

Breather Plug

Non-reusable part

Precoated part

Nm (kgfcm, ftlbf): Specified torque

Back-Up Light Switch

z

Gasketz

GasketzSide BearingOuter Race

z

Shim

Gasketz

z

z

L

17 (175, 13)

39 (400, 22)

13 (130, 9)

17 (175, 13)

39 (400, 29)

29 (300, 22)

39 (400, 29)18 (185, 13)

25 (250, 18)

20 (200, 14)

29 (300, 22)

40 (410, 30)


MX-11

892Author: Date:

2002 ECHO (RM884U)


17/44

MX0AA-02

Q07828

FIPG


893Author: Date:

2002 ECHO (RM884U)

DISASSEMBLY1. REMOVE CLUTCH RELEASE FORK AND BEARING

HINT:

At the time of reassembly, please refer to the following item.

Apply molybdenum disulphide lithium base grease (See page

CL-17 ).

2. REMOVE FILLER PLUG AND DRAIN PLUG WITH 2

GASKETS


3. REMOVE VEHICLE SPEED SENSOR

(a) Remove the bolt and vehicle speed sensor.


(b) Using a small screwdriver, remove the clip from the ve-

hicle speed sensor.

(c) Remove the vehicle speed sensor driven gear from the

vehicle speed sensor.(d) Using a small screwdriver, remove the O-ring from the ve-

hicle speed sensor.

4. REMOVE BACK-UP LIGHT SWITCH WITH GASKET


5. REMOVE CONTROL LEVER HOUSING SUPPORT

BRACKET

Remove the 3 bolts and control lever housing support bracket.


6. REMOVE SELECTING BELLCRANK ASSEMBLY

(a) Remove the 2 bolts and selecting bellcrank assembly.Torque: 25 Nm (250 kgfcm, 18 ftlbf)

(b) Remove the control bellcrank dust cover from the select-

ing bellcrank assembly.

7. REMOVE TRANSMISSION CASE COVER

(a) Remove the 9 bolts.

Sealant:

Part No. 08833-00080, THREE BOND 1344, LOCTITE

242 or equivalent


(b) Carefully tap the projection of the transmission case cov-er with a brass bar and hammer and remove it.

HINT:


Apply FIPG to the transmission case cover, as shown in the il-

lustration.

FIPG:

Part No. 08826-00090, THREE BOND 1281 or equiva-

lent
http://../cl/cluuni/inst.pdfhttp://../cl/cluuni/inst.pdf


18/44

N00038

N00039

Q06523

Lock Bolt

Q06512


MX-13

894Author: Date:

2002 ECHO (RM884U)

8. INSPECT 5TH GEAR THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 - 0.57 mm (0.0039 - 0.0224 in.)

Maximum clearance:

0.57 mm (0.0224 in.)

9. INSPECT 5TH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance.

Standard clearance:

KOYO made:

0.015 - 0.058 mm (0.0006 - 0.0023 in.)

NSK made:0.015 - 0.056 mm (0.0006 - 0.0022 in.)

Maximum clearance:

KOYO made: 0.058 mm (0.0023 in.)

NSK made: 0.056 mm (0.0022 in.)



10. REMOVE SHIFT AND SELECT LEVER SHAFT AS-

SEMBLY

(a) Remove the lock bolt and gasket.


(b) Remove the 4 bolts and pull out the shift and select lever

shaft assembly with the gasket.

Sealant:Part No. 08833-00080, THREE BOND 1344, LOCTITE

242 or equivalent


11. REMOVE LOCK NUT

(a) Engage the gear to the double meshing.

(b) Using a chisel and hammer, loosen the staked part of the

nut.

(c) Remove the lock nut.

Torque: 118 Nm (1,200 kgfcm, 87 ftlbf)

(d) Disengage the double meshing of the gear.


19/44

Q06531

SST

D08260

Wooden Block


895Author: Date:

2002 ECHO (RM884U)

12. REMOVE NO. 3 HUB SLEEVE AND NO. 3 SHIFT FORK

(a) Remove the bolt from the No. 3 shift fork.


(b) Remove the No. 3 hub sleeve and No. 3 shift fork.

13. REMOVE NO. 3 CLUTCH HUB AND 5TH GEAR

(a) Using 2 screwdrivers and a hammer, tap out the snapring.

HINT:


Select a snap ring that allows the minimum axial play.


A 2.25 (0.0886) E 2.49 (0.0980)

B 2.31 (0.0909) F 2.55 (0.1004)

C 2.37 (0.0933) G 2.61 (0.1028)

D 2.43 (0.0957) - -

(b) Using SST, remove the No. 3 clutch hub assembly, 5th

gear and synchronizer ring.

SST 09950-4001 1

HINT:

At the time of reassembly, please refer to the following items.

S Install the No. 3 clutch hub assembly to the No. 3 hub

sleeve.

S Before driving in the No. 3 clutch hub assembly, place the

suitable sized wooden block on the rear side of the input

shaft, as shown in the illustration. When driving it in, fix the

input shaft firmly so that it is not pushed downward. Other-

wise the input shaft rear bearing is overloaded, it might be

damaged.


20/44

D07736

SST

Engine Side

Q06533

SST Socket Wrench

N00174

SST

SST

Q06514

x 5

MT0057


MX-15

896Author: Date:

2002 ECHO (RM884U)

S Using SST and a hammer, drive in the No. 3 hub sleeve

assembly with the No. 3 shift fork.

SST 09612-2201 1

NOTICE:

Align the synchronizer ring slots with the shifting keys.

(c) Remove the needle roller bearings and spacer.

14. REMOVE 5TH DRIVEN GEAR

Using SST and a socket wrench, remove the 5th driven gear.

SST 09950-4001 1

HINT:


Using SST, install the 5th driven gear.

SST 09309-12020

15. REMOVE REAR BEARING RETAINER

Remove the 5 bolts and rear bearing retainer.


16. REMOVE BEARING SNAP RING

Using a snap ring expander, remove the 2 snap rings.

HINT:

If it is difficult to remove and install the snap rings, pull up theshafts.

17. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT

AND GASKET


18. REMOVE SNAP RING FROM NO. 2 SHIFT FORK

SHAFT



21/44

D02998

Q06524

Z00668

MT0094

FIPG

Q08151


897Author: Date:

2002 ECHO (RM884U)

19. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING

AND BALL

(a) Using a hexagon wrench, remove the 3 straight screw

plugs.

Sealant:

Part No. 08833-00080, THREE BOND 1344, LOCTITE242 or equivalent


(b) Using a magnetic finger, remove the 3 seats, springs and

balls.

20. REMOVE LOCK BALL ASSEMBLY

Using a hexagon wrench, remove the lock ball assembly.

Sealant:


242 or equivalent


21. REMOVE TRANSMISSION CASE

(a) Remove the 16 bolts.

Sealant:


242 or equivalent


(b) Carefully tap the transmission case with a plastic hammer

and remove it.

HINT:


Apply FIPG to the transaxle case, as shown in the illustration.

FIPG:

Part No. 08826-00090, THREE BOND 1281 or equiva-

lent

(c) Remove the 2 bolts, No. 1 and No. 2 oil receiver pipesfrom the transmission case.


22. REMOVE REVERSE IDLER GEAR, THRUST WASHER

AND SHAFT

23. REMOVE REVERSE SHIFT ARM BRACKET

Remove the 2 bolts and reverse shift arm bracket.


NOTICE:

At the time of reassembly, please refer to the followingitems.

S Set the pin on the top of the reverse shift arm into a

groove on the reverse idler gear.


22/44

MT0093Align Alignment Mark

Z15124

N00047


MX-17

898Author: Date:

2002 ECHO (RM884U)

S Fit the claw of the reverse shift arm bracket with the

notch of the input shaft front bearing.

S Install the reverse idler gear, thrust washer and shaft,

as shown.

24. REMOVE SHIFT FORK AND SHIFT FORK SHAFT

(a) Using 2 screwdrivers and a hammer, tap out the 3 snap

rings.

(b) Remove the 3 set bolts.


(c) Remove the No. 2 shift fork shaft and shift head.

(d) Using a magnetic finger, remove the 2 balls from the re-

verse shift fork.

(e) Remove the No. 3 shift fork shaft and reverse shift fork.

(f) Pull out the No. 1 shift fork shaft.

(g) Remove the No. 1 and No. 2 shift forks.

25. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER

FROM TRANSAXLE CASE26. REMOVE DIFFERENTIAL CASE ASSEMBLY

NOTICE:

At the time of reassembly, please refer to the following

item.

Before reassembly, inspect the differential side bearing

preload (See page MX-41 ).

27. REMOVE MAGNET FROM TRANSAXLE CASE
http://../difcas/reas.pdfhttp://../difcas/reas.pdf


23/44

D07737


899Author: Date:

2002 ECHO (RM884U)

28. DISASSEMBLE NO. 3 CLUTCH HUB ASSEMBLY


from the No. 3 clutch hub.

NOTICE:

At the time of reassembly, please refer to the following

item.Position the shifting key springs so that their end gaps are

not aligned.

(b) Remove the 3 shifting keys from the No. 3 clutch hub.


24/44

MX0AB-01

WM0064

WM0065

WM0066

N00053

SST


MX-19

900Author: Date:

2002 ECHO (RM884U)

INSPECTION1. INSPECT 5TH GEAR SYNCHRONIZER RING








NOTICE:


off after rubbing.






nizer ring and gear cone by applying a small amount of the fine

lapping compound.

NOTICE:


off after rubbing.

2. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-

ANCE

Using a feeler gauge, measure the clearance between the hub

sleeve and shift fork.



hub sleeve.3. REMOVE TRANSAXLE CASE RECEIVER

Remove the bolt and transaxle case receiver.

4. IF NECESSARY, REPLACE INPUT SHAFT FRONT

BEARING AND OIL SEAL

(a) Using SST, remove the input shaft front bearing.

SST 09612-65014


25/44

N00160

SST

SST

Z16126

SST

15.8 0.2 mm

Q07845

SST

Q10216

N00162

SST

SST


901Author: Date:

2002 ECHO (RM884U)

(b) Using SST, remove the oil seal.

SST 09612-65014

(c) Using SST and a hammer, install a new oil seal.

SST 09950- 60010 (09951- 00360), 09950- 70010

(09951-07150)


(d) Coat the lip of the oil seal with MP grease.

(e) Using SST and a press, install a new input shaft front

bearing.

SST 09950- 60010 (09951- 00460), 09950- 70010

(09951-07150)

5. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT

BEARING AND OUTPUT SHAFT COVER

(a) Remove the bolt and bearing lock plate.

(b) Using SST, pull out the output shaft front bearing.

SST 09308-00010


26/44

N00056

Case Cover

Q07846

SST

SST

N00060

N00061


MX-21

902Author: Date:

2002 ECHO (RM884U)

(c) Remove the output shaft cover.

(d) Install the output shaft cover.

NOTICE:

Install the output shaft cover projection into the case side

hollow.

(e) Using SST and a press, install a new output shaft front

bearing.

SST 09950- 60010 (09951- 00620), 09950- 70010

(09951-07150)

(f) Install the bearing lock plate with the bolt.

Torque: 11 Nm (115 kgfcm, 8 ftlbf)6. INSTALL TRANSAXLE CASE RECEIVER

Install the transaxle case receiver with the bolt.


7. IF NECESSARY, REPLACE REVERSE RESTRICT PIN

(a) Using a hexagon wrench, remove the straight screw plug.

(b) Using a pin punch and hammer, drive out the slotted

spring pin.

(c) Replace the reverse restrict pin.

(d) Using a pin punch and hammer, drive in the slotted spring

pin.

(e) Apply sealant to the plug threads.

Sealant:


242 or equivalent(f) Using a hexagon wrench, install the straight screw plug.



27/44

MX06Y-02


903Author: Date:

2002 ECHO (RM884U)

REASSEMBLYReassembly is in the reverse order of disassembly (See page MX-12 ).

NOTICE:

When working with FIPG material, you must observe the following items.

S Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-

faces.

S Thoroughly clean all components to remove all the loose material.

S Clean both sealing surfaces with a non-residue solvent.

S Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.

S Part must be assembled within 10 minutes of application. Otherwise, the FIPG material must

be removed and reapplied.

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.


28/44

MX0A8-02

D08265

Wiper Arm

Wiper Arm Head Cap

20 (205, 15)

RH CowlTop Ventilator

Hood

11 (115, 8)

No. 2 CylinderHead Cover

7.0 (71, 62 in.lbf)

33 (340, 25)

x 5

Wire HarnessClamp

Air Cleaner CaseAssembly with AirHose

Hold-DownClamp

Battery

Tray

Back-Up LightSwitch Connector

Ground Cable

Clip

ClipWasher

Control Cable

z

4.9 (50, 43 in.lbf)

Vehicle Speed Sensor Connector

33 (340, 25)

Starter Connector

Starter Wire

Starter

Clutch Release Cylinder

12 (120, 9)Nm (kgfcm, ftlbf) : Specified torque

zNon-reusable part

Transaxle

49 (500, 36)

LH Cowl Top Ventilator

Starter Cover

z

39 (400, 29)

39 (400, 29)

MX-2-MANUAL TRANSAXLE MANUAL TRANSAXLE UNIT

883Author: Date:

2002 ECHO (RM884U)

MANUAL TRANSAXLE UNIT

COMPONENTS


29/44

D08267

RH Front Drive Shaft

Snap Ringz

LH Front Drive Shaft

Snap Ringz

Engine RearMounting Insulator

Engine RearMounting Bracket

49 (500, 36)

z

Suspension Member

80 (820, 59)

116 (1,185, 86)

LH Engine Under Cover

z Non-reusable part


z Lock Nut216 (2,200, 159)

98 (1,000, 72)

Clipz

49 (500, 36)

z Cotter Pin

70 (715, 52)

z

7.8 (80, 69 in.lbf)

25 (250, 18)*32 (325, 24)

Pressure Feed and Return Tube

64 (650, 47)

Power steering:

* For use with SST

-MANUAL TRANSAXLE MANUAL TRANSAXLE UNIT

MX-3

884Author: Date:

2002 ECHO (RM884U)


30/44

MX06U-03


889Author: Date:

2002 ECHO (RM884U)

INSTALLATIONInstallation is in the reverse order of removal (See page MX-4 ).

HINT:

After installation, check and inspect items as follows.

S Front wheel alignment (See page SA-5 ).

S Do the road test.
http://remo.pdf/http://../sa/fwa/insp.pdfhttp://../sa/fwa/insp.pdfhttp://remo.pdf/


31/44

MX0A9-02

D08226

D08225

D08227


885Author: Date:

2002 ECHO (RM884U)

REMOVAL1. REMOVE HOOD

HINT:

At the time of installation, please refer to the following item.

Adjust the hood (See page BO-6 ).

2. REMOVE WIPER ARM (See page BO-32 )

HINT:

At the time of installation, please refer to the following item.

Adjust the installation position of the wiper arms (See page

BO-34 ).

3. REMOVE RH AND LH COWL TOP VENTILATOR LOU-

VERS (See page BO-32 )

4. REMOVE NO. 2 CYLINDER HEAD COVER

Remove the 4 nuts and No. 2 cylinder head cover.

Torque: 7.0 Nm (71 kgfcm, 62 in.lbf)

5. REMOVE BATTERY AND AIR CLEANER CASE AS-SEMBLY WITH AIR HOSE

6. DISCONNECT WIRE HARNESS FROM TRANSAXLE

Remove the set bolt of the wire harness clamp.

7. DISCONNECT CONTROL CABLE

(a) Remove the 2 clips and washers.

(b) Remove the 2 clips and disconnect the control cables

from the transaxle.

8. DISCONNECT CLUTCH RELEASE CYLINDER

(a) Remove the set bolt of the clutch line.

Torque: 4.9 Nm (50 kgfcm, 43 in.lbf)

(b) Remove the 2 set bolts of the clutch release cylinder.


9. DISCONNECT GROUND CABLE

Remove the set bolt of the ground cable from the engine left

mounting bracket.

10. DISCONNECT BACK-UP LIGHT SWITCH AND VE-

HICLE SPEED SENSOR CONNECTORS
http://../bo/hood/adju.pdfhttp://../bo/fwaw/remo.pdfhttp://../bo/fwaw/adju.pdfhttp://../bo/fwaw/remo.pdfhttp://../bo/fwaw/remo.pdfhttp://../bo/fwaw/adju.pdfhttp://../bo/fwaw/remo.pdfhttp://../bo/hood/adju.pdf


32/44

D08228

Starter Set Bolt

D07978

D07983

Q09187

Filler Plug

Drain Plug

Oil Level0 - 5 mm(0 - 0.02 in.)


MX-5

886Author: Date:

2002 ECHO (RM884U)

11. REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING

BOLTS


12. REMOVE STARTER SET BOLT


13. ATTACH ENGINE SLING DEVICE TO ENGINE HANG-

ER

(a) Remove the bolt.

(b) Install the 2 No. 1 engine hangers with the bolts in the cor-

rect direction.

Parts No.:

No. 1 engine hanger: 12281-21010

Bolt: 91642-81025


(c) Attach the engine chain hoist to the engine hangers.

CAUTION:

Do not attempt to hang the engine by hooking the chain to

any other part.

14. RAISE VEHICLE

CAUTION:

Make sure that the vehicle is securely supported.

15. REMOVE LH ENGINE UNDER COVER

16. DRAIN TRANSAXLE OIL

Oil grade: API GL-4 or GL-5

Viscosity: SAE 75 W-90

Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts)


17. REMOVE RH AND LH FRONT DRIVE SHAFTS (See

page SA-18 )
http://../sa/fds/remo.pdfhttp://../sa/fds/remo.pdf


33/44

Q06446

D08231

D08232


887Author: Date:

2002 ECHO (RM884U)

18. REMOVE SUSPENSION MEMBER

(a) Remove the 2 set nuts and bolt of the engine rear mount-

ing insulator from the suspension member (See page

SA-37 ).

(b) Disconnect the sliding yoke (See page SR-13 ).

(c) Power steering:Disconnect the pressure feed and return tubes (See page

SR-48 ).

(d) Power steering:

Disconnect the tube clamp (See page SR-48 ).

(e) Remove the suspension member (See page SA-37 ).

19. JACK UP TRANSAXLE SLIGHTLY

Using a transmission jack, support the transaxle.

20. DISCONNECT ENGINE LEFT MOUNTING BRACKET

FROM ENGINE LEFT MOUNTING INSULATOR

Remove the 2 bolts.


21. REMOVE ENGINE REAR MOUNTING INSULATOR

AND BRACKET

(a) Remove the bolt, nut and engine rear mounting insulator.


(b) Remove the 3 bolts and engine rear mounting bracket.


22. REMOVE STARTER

(a) Remove the bolt, starter cover and starter.


(b) Disconnect the starter connector.

(c) Remove the nut and starter wire.
http://../sa/fsb/remo.pdfhttp://../sr/tsc/remo.pdfhttp://../sr/psg/remo.pdfhttp://../sr/psg/remo.pdfhttp://../sa/fsb/remo.pdfhttp://../sa/fsb/remo.pdfhttp://../sr/psg/remo.pdfhttp://../sr/psg/remo.pdfhttp://../sr/tsc/remo.pdfhttp://../sa/fsb/remo.pdf


34/44

D08230


MX-7

888Author: Date:

2002 ECHO (RM884U)

23. REMOVE 5 TRANSAXLE LOWER SIDE MOUNTING

BOLTS


24. REMOVE TRANSAXLE

Lower the engine left side and remove the transaxle from the

engine.HINT:

At the time of installation, please refer to the following items.

S Align the input shaft with the clutch disc and install the

transaxle to the engine.

S Temporarily tighten the transaxle mounting bolts.


35/44

MX073-03

Q06509


1st Gear

Reverse Gear

Shifting Key

No. 1 Clutch Hub

Synchronizer Ring

Output Shaft Assembly

Ball

Thrust Washer

Synchronizer Ring


2nd GearShifting Key Spring

Snap Ring3rd Driven Gear

Output Gear Spacer4th Driven Gear

Rear Ball Bearing

MX-30

-MANUAL TRANSAXLE OUTPUT SHAFT

911Author: Date:

2002 ECHO (RM884U)

OUTPUT SHAFT

COMPONENTS


36/44

MX074-03

Q05794

2nd Gear

1st Gear

SM0137

CM0065

SST


MX-31

912Author: Date:

2002 ECHO (RM884U)

DISASSEMBLY1. INSPECT 1ST AND 2ND GEARS THRUST CLEAR-

ANCE

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

1st gear: 0.10 - 0.40 mm (0.0039 - 0.0157 in.)

2nd gear: 0.10 - 0.55 mm (0.0039 - 0.0217 in.)

Maximum clearance:

1st gear: 0.40 mm (0.0157 in.)

2nd gear: 0.55 mm (0.0217 in.)

2. INSPECT 1ST AND 2ND GEARS RADIAL CLEAR-

ANCE

Using a dial indicator, measure the radial clearance between

the gear and shaft.

Standard clearance:

KOYO made

0.015 - 0.058 mm (0.0006 - 0.0023 in.)

NSK made:

0.015 - 0.056 mm (0.0006 - 0.0022 in.)

KOYO made: 0.058 mm (0.0023 in.)

NSK made: 0.056 mm (0.0022 in.)



3. REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR

AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT

(a) Using SST and a press, remove the rear ball bearing and

4th driven gear.

SST 09950-00020

(b) Remove the output gear spacer.


37/44

N00074

MT0063

SST

N00076

CM0142

MX-32-MANUAL TRANSAXLE OUTPUT SHAFT

913Author: Date:

2002 ECHO (RM884U)

4. REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE

ROLLER BEARING AND SYNCHRONIZER RING

(a) Shift the reverse gear into the 1st gear.

(b) Using SST and a press, remove the 3rd driven gear and

2nd gear.

SST 09950-00020

(c) Remove the needle roller bearing and synchronizer ring.

5. REMOVE SNAP RING


6. REMOVE REVERSE GEAR ASSEMBLY, 1ST GEAR,

SYNCHRONIZER RING, NEEDLE ROLLER BEARING,

THRUST WASHER AND BALL

(a) Using a press, remove the reverse gear assembly, 1st

gear and synchronizer ring.

(b) Remove the needle roller bearing, thrust washer and ball.

7. DISASSEMBLE REVERSE GEAR ASSEMBLY


and 3 shifting keys from the No. 1 clutch hub.

(b) Remove the reverse gear from the No. 1 clutch hub.


38/44

MX075-04

WM0064

WM0065

WM0066

MT0071

A B C


MX-33

914Author: Date:

2002 ECHO (RM884U)

INSPECTION1. INSPECT SYNCHRONIZER RING








NOTICE:


off after rubbing.






nizer ring and apply a small amount of the fine lapping com-

pound on gear cone.

NOTICE:


off after rubbing.

2. INSPECT SHIFT FORK AND REVERSE GEAR CLEAR-

ANCE

Using a feeler gauge, measure the clearance between the re-

verse gear and shift fork.



reverse gear.

3. INSPECT OUTPUT SHAFT

(a) Check the output shaft for wear or damage.

(b) Using a micrometer, measure the outer diameter of the

output shaft journal surface.

Minimum outer diameter:

Part A: 32.985 mm (1.2986 in.)

Part B: 37.985 mm (1.4955 in.)Part C: 31.985 mm (1.2592 in.)

If the outer diameter is less than the minimum, replace the out-

put shaft.


39/44

CM0015


915Author: Date:

2002 ECHO (RM884U)

(c) Using a dial indicator, check the shaft runout.

Maximum runout: 0.03 mm (0.0012 in.)

If the runout exceeds the maximum, replace the output shaft.


40/44

MX076-03

CM0009

Engine

Side

N00077

N00078

N00079


MX-35

916Author: Date:

2002 ECHO (RM884U)

REASSEMBLYHINT:

Coat all of the sliding and rotating surfaces with gear oil before

reassembly.

1. ASSEMBLE REVERSE GEAR ASSEMBLY

(a) Install the 3 shifting keys and reverse gear to the No. 1

clutch hub.

(b) Install the 2 shifting key springs under the shifting keys.

NOTICE:

Position the shifting key springs so that their end gaps are

not in line.

2. INSTALL BALL, THRUST WASHER, NEEDLE ROLLER

BEARING, 1ST GEAR, SYNCHRONIZER RING AND

REVERSE GEAR ASSEMBLY TO OUTPUT SHAFT

(a) Install the ball to the output shaft.

(b) Fit the thrust washer groove securely over the locking ball

when installing the thrust on the output shaft.

(c) Apply gear oil to the needle roller bearing and install it.

(d) Install the 1st gear and synchronizer ring.

(e) Place the reverse gear assembly and align the synchro-

nizer ring slots with the shifting keys.

(f) Using a press, install the reverse gear assembly.


41/44

N00080

N00083

N00084

N00086

SST


917Author: Date:

2002 ECHO (RM884U)




A 2.50 (0.0984) D 2.68 (0.1055)

B 2.56 (0.1008) E 2.74 (0.1079)

C 2.62 (0.1031) F 2.80 (0.1102)


4. INSPECT 1ST GEAR THRUST CLEARANCE

(See page MX-31 )

5. INSTALL NEEDLE ROLLER BEARING, SYNCHRONIZ-

ER RING, 2ND GEAR AND 3RD DRIVEN GEAR

(a) Apply gear oil to the needle roller bearing and install it.

(b) Place the synchronizer ring on the reverse gear assembly

and align the ring slots with the shifting keys.

(c) Install the 2nd gear.

(d) Using a press, install the 3rd driven gear.

6. INSPECT 2ND GEAR THRUST CLEARANCE

(See page MX-31 )

7. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN

GEAR AND REAR BALL BEARING

(a) Install the output gear spacer.

(b) Using SST and a press, install the 4th driven gear and

rear ball bearing.

SST 09608-00071
http://disa.pdf/http://disa.pdf/http://disa.pdf/http://disa.pdf/


42/44

MX077-03

Q05961

Boot

Shift and Select LeverShaft

Control Shaft CoverSnap Ring

Oil Seal

Gasket

Spring

No. 2 SelectSpring Seat

Spring

E-Ring

z Non-reusable part

Apply MP grease

Slotted Spring Pin

No. 1 Shift Inner Lever

Slotted Spring Pin

No. 1 Select Spring Seat

No. 2 Shift Inner Lever

Select Inner Lever

Shift InterlockPlate

z

z

-MANUAL TRANSAXLE SHIFT AND SELECT LEVER SHAFT

MX-37

918Author: Date:

2002 ECHO (RM884U)

SHIFT AND SELECT LEVER SHAFT

COMPONENTS


43/44

MX07B-03

D07753

Floor Shift Lever Knob

Shifting Hole Cover

Panel

Rear Console Box

Console Mat

12 (120, 9)

Shift Lever Assembly

Heat Insulator

Select Control Cable

Clip

Clip

Washer


z Non-reusable part

Clipz

Clipz

ClipWasher

4.9 (50, 43 in.lbf)

Clip

Shift ControlCable

MX-44-MANUAL TRANSAXLE SHIFT LEVER AND CONTROL CABLE

925Author: Date:

2002 ECHO (RM884U)

SHIFT LEVER AND CONTROL CABLE

COMPONENTS


44/44

MX06R-03

-MANUAL TRANSAXLE TROUBLESHOOTING

MX-1

TROUBLESHOOTING

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely

cause of the problem. Check each part in order. If necessary, replace these parts.

Symptom Suspect Area See page

Noise

14.Oil (Level low)

15.Oil (Wrong)

16.Gear (Worn or damaged)

17.Bearing (Worn or damaged)

MX-4

MX-4

MX-9

MX-9

Oil leakage

1. Oil (Level too high)

2. Gasket (Damaged)

3. Oil seal (Worn or damaged)

4. O-Ring (Worn or damaged)

MX-4

MX-9

MX-9

MX-9

Hard to shift or will not shift

1. Control cable (Faulty)

2. Synchronizer ring (Worn or damaged)

3. Shift key spring (Damaged)

MX-44

MX-23

MX-30

MX-23

MX-30

Jumps out of gear

1. Locking ball spring (Damaged)

2. Shift fork (Worn)

3. Gear (Worn or damaged)

4. Bearing (Worn or damaged)

MX-9

MX-9

MX-9

MX-9
http://../mxu/remo.pdfhttp://../mxu/remo.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxu/remo.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../slacc/comp.pdfhttp://../inpsha/comp.pdfhttp://../outsha/comp.pdfhttp://../inpsha/comp.pdfhttp://../outsha/comp.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../outsha/comp.pdfhttp://../inpsha/comp.pdfhttp://../outsha/comp.pdfhttp://../inpsha/comp.pdfhttp://../slacc/comp.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxu/remo.pdfhttp://../mxa/comp.pdfhttp://../mxa/comp.pdfhttp://../mxu/remo.pdfhttp://../mxu/remo.pdf

Manual Transaxle echo 2002 Guide

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Transcript of Manual Transaxle echo 2002 Guide