8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 1/614
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
PRECAUTION
1.IGNITION SWITCH EXPRESSIONS
1. The type of ignition switch used on this model differs according to thespecifications of the vehicle. The expressions listed in the table below are used in
this section.
ExpressionIgnition Switch
(position)
Engine Switch
(condition)
Ignition Switch off LOCK Off
Ignition Switch on (IG) ON On (IG)
Ignition Switch on (ACC) ACC On (ACC)
Engine Start START Start
2.PRECAUTION REGARDING ON-VEHICLE INSPECTION
1. When revving the engine, make sure that the gear is in neutral.
3.PRECAUTION REGARDING PARTS REMOVAL AND INSTALLATION
1. When removing or installing parts related to the multi-mode manual transmissionsystem, perform [Clamp Position Adjustment], [Initialization and Learning]
and/or [Synchronization Position Calibration]. In addition, the required operations
differ according to the parts to be removed and installed. Proceed with theoperation in the order shown in the table below.
Before removal
Parts to be removed Operation order See
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 2/614
procedure
• Clutch actuator
• Transmissionassembly
• Transmission parts
(inside gear box)• Clutch disc and clutch
cover
• Clutch release bearing
• Clutch release fork
• Clutch release lever
• Flywheel
• End plate (2SZ-FEonly)
• Crankshaft
• Shift and select
actuator (with clutch actuator)
• CLAMP
POSITION
ADJUSTMENT
2.
Before installation
Parts to be installed Operation orderSee
procedure
• New clutch
actuator
• CLAMP POSITION
ADJUSTMENT
3. NOTICE:
4. Push rods of brand new clutch actuators (service supply parts) are not set in theclutch clamp position. Therefore, adjust the clamp positions before installing new
clutch actuators.5.
After installation
Parts installed Operation orderSee
procedure1. INITIALIZATION OF MULTI-MODE MANUAL
TRANSMISSION SYSTEM
[Initialization of ECU]
• Transmissionassembly
• Transmission parts
(inside gear box)
• Shift and selectactuator (with clutch
actuator) 2. LEARNING OF MULTI-
MODE MANUAL
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 3/614
TRANSMISSION SYSTEM• Transmission
control ECU 3. SYNCHRONIZATION
POSITION CALIBRATION
1. INITIALIZATION OF MULTI-MODE MANUAL
TRANSMISSION SYSTEM
[Initialization of transmission]
2. LEARNING OF MULTI-
MODE MANUAL
TRANSMISSION SYSTEM
• Shift stroke sensor
• Select stroke sensor
3. SYNCHRONIZATIONPOSITION CALIBRATION
1. INITIALIZATION OF MULTI-
MODE MANUAL
TRANSMISSION SYSTEM[Initialization of clutch]
• Clutch actuator
• Clutch stroke
sensor
• Clutch disc and
clutch cover
• Clutch release bearing
• Clutch release fork
• Clutch release lever
• Flywheel
• End plate (2SZ-FE
only)
• Crankshaft
2. LEARNING OF MULTI-
MODE MANUAL
TRANSMISSION SYSTEM
6. NOTICE:
• Replace the clutch disc and clutch cover together. If only one is replaced,
the adjustment system of the clutch cover does not function properly. This
may cause clutch drag or clutch slippage, which may result indeterioration of drivability or malfunctions of the system parts.
• After replacing any system components, perform initialization and
learning of related components (refer to the operations listed above). Ifinitialization and learning are not performed, the transmission system will
not function properly.
• Before proceeding with learning of the multi-mode manual transmissionsystem, clear (initialize) the previously stored learning values. Since the
multi-mode manual transmission system does not have an overwrite
function, clearing (initializing) stored data is necessary before the new
data can be stored.
4.TROUBLESHOOTING INITIALIZATION AND LEARNING (ENGINE DOES NOT
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 4/614
START)
HINT:
If any malfunctions are suspected in the transmission control system afterreassembling or repairing transmission system components, perform
troubleshooting in accordance with the following chart.
1.Check for DTC output
1. Using an intelligent tester, check for output DTCs.1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / DTC.
4. Read any DTCs.
Result:
Result Proceed To
No DTC output A
DTC output B
B. Go to DTC Chart
A
2.Check clutch position learning condition
1. Check that the clutch position learning has been completed.
1. Connect the intelligent tester to the DLC3.2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data
List.
4. Read the Learn-Clutch Stopper Point result.
Result:
Result Proceed To
Exec (Executed) A
Notexec (Not executed) B
Fail (Failure) C
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 5/614
B. Execute learning again ()
C. Check clutch system
A
3.Check T/M gear position learning condition
1. Check that the T/M gear position learning has been completed.1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data
List.4. Read the Learn-T/M results.
Result:
Result Proceed To
Exec (Executed) A
Notexec (Not executed) B
Fail (Failure) C
B. Execute learning again ()
C. Go to step 6
A
4.Check whether gear is in neutral
1. Referring to the shift slit position of the shift and select actuator, check whether
the actual transmission gear position is in neutral.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 6/614
Result:
Result Proceed To
Neutral A
Other than Neutral B
B. Check transmission assembly
A
5.Check whether park/neutral position switch is ON
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 7/614
1. Check whether the park/neutral position switch is ON ().
Result:
Result Proceed To
ON A
OFF B
B. Check park/neutral position switch
A
Check starter system and brake system
6.Check whether T/M up-lock has occurred during gear position learning
1. Check whether T/M up-lock has occurred during gear position learning.1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / DataList.
4. Read the Possibility of T/M Uplock results.
HINT:
T/M up-lock: The transmission gear momentarily cannot be engaged due tomechanical reasons during gear position learning.Result:
Result Proceed To
No (Not occurred) A
Yes (Occurred) B
B. Perform initialization and learning ag
learning fails twice or more, check tr
A
Check transmission assembly
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 8/614
5.TROUBLESHOOTING INITIALIZATION AND LEARNING (VEHICLE DOES NOT START OFF)
HINT:If any malfunctions are suspected in the transmission control system after
reassembling or repairing transmission system components, perform
troubleshooting in accordance with the following chart.
1.Check for DTC output
1. Using an intelligent tester, check for output DTCs.1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.3. Select the following menu items: Powertrain / Multi-Mode M/T / DTC.
4. Read any DTCs.
Result:
Result Proceed To
No DTC output A
DTC output B
B. Go to DTC Chart
A
2.Check clutch position learning condition
1. Check that the clutch position learning has been completed.1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / DataList.
4.
Read the Learn-Clutch Stopper Point results.
Result:
Result Proceed To
Exec (Executed) A
Notexec (Not executed) B
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 9/614
Fail (Failure) C
B. Execute learning again ()
C. Check clutch system
A
3.Check T/M gear position learning condition
1. Check that the T/M gear position learning has been completed.1. Connect the intelligent tester to the DLC3.
2.
Turn the ignition switch on (IG) and the tester ON.3. Select the following menu items: Powertrain / Multi-Mode M/T / DataList.
4. Read the Learning-T/M results.
Result:
Result Proceed To
Exec (Executed) A
Notexec (Not executed) B
Fail (Failure) C
B. Execute learning again ()
C. Go to step 8
A
4.Check clutch standby point learning condition
1. Check that the clutch position learning has been completed.1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / DataList.
4. Read the Learn-Clutch Standby Point results.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 10/614
Result:
Result Proceed To
Exec (Executed) A
Notexec (Not executed) B
Fail (Failure) C
B. Execute learning again (Ignition switstart engine)
C. Check clutch system
A
5.Confirm that gear position in [1st] or [R] when shift lever in [E], [M] or [R]
1. Start the engine.
2. Referring to the shift slit position of the shift and select actuator, check that the
actual transmission gear position is in the 1st or R position when the shift lever position is changed from N to E, M or R.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 11/614
NG. Go to step 9
OK
6.Inspect accelerator pedal position sensor signal
1. Check the accelerator pedal position sensor signal circuit.1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data
List.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 12/614
4. Check that value of the Accelerator Pedal Angle changes in accordance
with the accelerator pedal operation ().
2. Check the CAN communication circuit ().
Standard (1KR-FE):Accelerator Pedal
Operation
Tester
Display
Fully depressed 60 to 100 %
Fully released 0 to 25 %
Standard (2SZ-FE):
Accelerator Pedal
Operation
Tester
Display
Fully depressed 52 to 100 %
Fully released 0 to 22 %
NG. Check engine control system and CAsystem
OK
7.Rev up engine with transmission in neutral
1. Check that the engine can be revved up when the transmission gear is in neutral.
Result:
Result Proceed To
Possible A
Impossible B
B.
Check engine control system
A
Check clutch system and transmission control ECU
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 13/614
8.Check whether T/M up-lock has occurred during gear position learning
1. Check whether T/M up-lock has occurred during gear position learning.
1. Connect the intelligent tester to the DLC3.2. Turn the ignition switch on (IG) and the tester ON.
3.
Select the following menu items: Powertrain / Multi-Mode M/T / DataList.
4. Read the Possibility of T/M Uplock result.
HINT:T/M up-lock: The transmission gear momentarily cannot be engaged due to
mechanical reasons during gear position learning.Result:
Result Proceed To
No (Not occurred) A
Yes (Occurred) B
B. Perform initialization and learning ag
learning fails twice or more, check tr
A
Check transmission assembly
9.Check whether clutch disengaged when shift lever in [E], [M] or [R]
1. Check the actual clutch state when the shift lever is in the E, M or R position.
Result:
Result Proceed To
Disengaged A
Not disengaged B
B. Check clutch system
A
Check transmission assembly
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 14/614
6.PRECAUTIONS REGARDING USE OF SHIFT LOCK RELEASE BUTTON
1. When the vehicle is parked with the shift lever in any position other than N:
•
The engine cannot be started if the shift lever is moved to any positionother than N by operating the shift lock release button.The shift lever should be moved back to the N position to start the engine.
• The engine cannot be started if the shift lever is in the position it was in
when the vehicle was parked.The shift lever should be moved back to the N position to start the engine.
• When the shift lever is returned to the N position by operating the shift
lock release button, the gear is shifted to neutral when the ignition switch
is turned on (IG) so that the engine can be started.2. When the vehicle is parked with the shift lever in the N position:
• The engine can be started even if the shift lever is moved to any position
other than N by operating the shift lock release button. In this case, thegear is shifted to the position in accordance with the shift lever position
after the engine starts.
Shift lever position when
vehicle parked
Current shiftlever position
Enginecranking
operation
Note
Other than N Other than N* Impossible -
Other than NSame position in
when vehicle parked
Impossible -
Other than N N* PossibleGear shifted to neutral when
ignition switch on (IG)
N Other than N* PossibleGear shifted to position inaccordance with shift lever
position after engine start
N
N
(Same positionin when vehicle
parked)
Possible -
*: The shift lever was moved with the shift lock release button operation.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 15/614
7.OTHER PRECAUTIONS REGARDING MULTI-MODE MANUALTRANSMISSION SYSTEM
• Set the gear in neutral when revving the engine.
• Set the gear to the neutral position before removing the shift and select actuator. Ifthe gear cannot be shifted to the neutral position due to malfunctions of the
actuator and/or transaxle gear, remove the plug from the shift and select actuator
and observe the position of the shift slit within. If the slit is in any position otherthan neutral, use a screwdriver to set it to neutral.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 16/614
8.PRECAUTION REGARDING ELECTRONIC THROTTLE CONTROL SYSTEM(FOR 1KR-FE)
1. Perform the electronic throttle learning when the following operations are done ().
• ECM replacement
•
Throttle body assembly replacement
9.PRECAUTION REGARDING USE OF INTELLIGENT TESTER
NOTICE:
Observe the following items for safety reasons:
• Read its instruction books before using the tester.
• Prevent the tester cable from being caught on the pedals, shift lever and steering
wheel when driving with the tester connected to the vehicle.
•
When driving the vehicle for testing purposes using the tester, two people arerequired. One drives the vehicle, and the other operates the tester.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 17/614
MULTI-MODE MANUALTRANSAXLE SYSTEM > PARTS
LOCATION
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 18/614
1 / 5
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 19/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 20/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 21/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 22/614
2 / 5
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 23/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 24/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 25/614
3 / 5
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 26/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 27/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 28/614
4 / 5
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 29/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 30/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 31/614
5 / 5
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > SYSTEM
DIAGRAM
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 32/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 33/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 34/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 35/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 36/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 37/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 38/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 39/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 40/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 41/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 42/614
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > SYSTEMDESCRIPTION
for Preparation
MULTI-MODE MANUAL TRANSMISSION SYSTEM OUTLINE
1.
The multi-mode manual transmission has been developed from the conventionalmanual transmission by adding actuators that are directly controlled by electric
motors. The transmission control system consists of an electronic throttle control
system, clutch actuator, shift and select actuator, sensors, a shift lever, and atransmission control ECU. The system offers automatic clutch operation and two
driving modes: automatic shifting E mode and manual shifting M mode.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 43/614
2. The stroke sensors, which are mounted on each actuator and detect the actuator
operating position, are double non-contact type.3. The multi-mode manual transmission is equipped with a clutch actuator, which
has a motor for clutch engagement, and a shift and select actuator, which has two
motors for shifting and selecting gear shafts that have been used on the
conventional manual transmission. Each actuator operates in accordance withsignals from the transmission control ECU. The transmission control ECU
receives information from the ECM and sensors, and controls the engine and
multi-mode manual transmission.4. The shift lever features a Shift-by-Wire System that electrically detects the shift
lever position chosen by the driver and sends a shift lever position signal to the
transmission control ECU to control the transmission.5. The shift lever has an electrical shift lock mechanism. When the ignition switch is
turned off, or the shift lever is in the N position with the engine running and the
brake pedal released, the shift lever is locked in the current shift position.6. The multi-mode manual transmission system has fail-safe functions. When the
transmission control ECU detects a malfunction in the system, the ECUilluminates the Multi-mode Manual Transmission Warning Light (MMT Warning
Light) to inform the driver that a malfunction has occurred. If necessary, the ECUilluminates the Malfunction Indicator Lamp (MIL) and MMT Warning Light
simultaneously. Under such conditions, the fail-safe function allows the vehicle to
be operated in order to avoid emergency situations.
FUNCTIONS OF MAIN COMPONENTS
Components Outlines
Combination
meter (meter ECU)
Controls the operation of the indicator lights, warning light, and
buzzer.
Multi-mode
manual
transmission
warning light(built into
combination
meter)
Illuminates to alert the driver when a malfunction occurs in the
multi-mode manual transmission system.
Gear positionindicator
(built into
combinationmeter)
Indicates the present gear position. The indicator flashes if theactual gear position and the shift lever position do not match.
Mode indicator Indicates E-mode or M-mode.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 44/614
(built into
combination
meter)
Es indicator light
(built into
combinationmeter)
Illuminates when the sporty [Es] pattern is selected during normal
[E] pattern driving in E-mode. Does not illuminate while thenormal [E] pattern is selected.
Buzzer
(built into
combinationmeter)
Sounds if the following conditions met simultaneously:
Engine is running
Shift lever is in E, M or R positionDriver's door is open
Shift lever position
sensor
(built into shiftlever assembly)
Outputs the shift lever position and shift request (+ or -) throughthe ON/OFF combination of 6-contact switch and 2-contact switch.
Transmission shiftmain switch
(built into shiftlever assembly)
Outputs the shift mode signal (E-mode or M-mode).
Shift lock solenoid
(built into shift
lever assembly)
Actuated by the transmission control ECU. Restricts the movementof the shift lever.
Shift motor
(built into shift and
select actuator)
Actuated by the transmission control ECU. Effects the shiftoperation of the shift and select lever shaft.
*
Shift stroke sensor(built into shift and
select actuator)
Detects the shift and select actuator operation position (shift
direction).*
Select motor
(built into shift andselect actuator)
Actuated by the transmission control ECU. Effects the select
operation of the shift and select lever shaft.*
Select stroke
sensor
(built into shift andselect actuator)
Detects the shift and select actuator operation position (select
direction).*
Clutch motor(built into clutchactuator)
Actuated by the transmission control ECU. Engages and
disengages the clutch.
Clutch stroke
sensor
(built into clutchactuator)
Detects the push rod position of the clutch actuator from therotational angle of the worm wheel in the clutch actuator, and sends
the signal to the transmission control ECU.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 45/614
LCC (Load
Controlled Clutch
cover)
The diaphragm spring height of the LCC is adjusted to a
predetermined position automatically, in order to apply a constant
load to the clutch motor.
Transmission
revolution sensor
Detects the input shaft speed of the transaxle and transmits it to the
transmission control ECU.
Park/neutral
position switch(built into
transmission
assembly)
Detects whether the transmission gear is in neutral.
Back-up lightswitch
(built into
transmissionassembly)
Detects whether the transmission gear is in reverse, and illuminatesthe back-up lights.
Stop light switch Detects whether the brake pedal is depressed or released.
Parking brake
switchDetects whether the parking brake lever is applied.
Pattern select [Es]
switch
Outputs the driving pattern (Normal [E] pattern or Sporty [Es] pattern) in E-mode in accordance with the ON/OFF condition to the
transmission control ECU.
Transmission
control ECU
Controls the multi-mode manual transmission system and signals
the ECM to effect engine control during upshifting or downshiftingvia CAN (Controller Area Network) communication.
When the multi-mode manual transmission system malfunctions,
the transmission control ECU diagnoses the malfunctioning areasand stores the data. Furthermore, the multi-mode manual
transmission warning light and malfunction indicator lamp are
illuminated to inform the driver of malfunctions in the system.
Buzzer(built into
transmission
control ECU)
Sounds during system warning.When performing the initialization and learning or the clamp
position adjustment without using intelligent tester, the buzzer
sounds to inform that the ECU mode is changed.
ECM
Outputs sensor information via CAN communication to thetransmission control ECU.
Affects engine control in accordance with signals from thetransmission control ECU.
Accelerator pedal
position sensor
Detects the accelerator pedal position and transmits signals to the
ECM.
Crankshaft
position sensor
Detects the engine speed and transmits signals to the transmission
control ECU via the ECM.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 46/614
HINT:
*: Shift and select directions are as shown in the illustration.
MULTI-MODE MANUAL TRANSMISSION SYSTEM CONTROL
1. System start:
The multi-mode manual transmission system starts when the ignition switch isturned on (IG). The shift lever can be operated when the ignition switch is on and
the brake pedal is depressed. The engine starts when the ignition switch is turnedto the ST position (the engine switch is operated) with the brake pedal depressed
and the gear in neutral.
2. Take off/reverse assist control:When the brake pedal is not depressed with the gear in 1st, 2nd or reverse, the
clutch is half-engaged, even if the accelerator pedal is not depressed. As a result,
the vehicle can creep slowly like an automatic transmission vehicle. This will
assist the vehicle in preparing to move. The take off assist control is cancelled
while the parking brake switch is ON.
HINT:
When attempting to shift to reverse at a vehicle speed of 6 km/h (3.7 mph) ormore, the reverse warning buzzer sounds, and the gear does not shift to reverse.
3. Shift control:When upshifting with the accelerator pedal depressed, the ECM restrains theengine rev up in accordance with the request signal from the transmission control
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 47/614
ECU.
[Automatic shift control (E and Es modes)]When the shift lever is in the E position, the most appropriate gear is
automatically selected in accordance with the accelerator pedal opening angle and
the vehicle speed. In addition to this automatic shift control, LHD (Left Hand
Drive) vehicles have kick down control. When the accelerator pedal is fullydepressed until a click is felt, the ECM for LHD vehicles interprets this as the
kick down signal being received. Kick down signals affects the transmission shift
control.Shift control can be switched between normal [E] mode and sporty [Es] mode by
pressing the pattern select switch.
Normal [E] mode: Economical automatic shift control with emphasis on fueleconomy
Sporty [Es] mode: Automatic shift control with emphasis on driving performance
[Sequential shift control (M-mode)]Moving the shift lever to the M position enables the driver to select the gear. The
driver can select gears optionally by shifting the lever to the [+] or [-] position.4. Ascent/descent shift control:
While driving in E-mode or Es-mode, the system operates to prevent excessshifting and obtain the proper driving force and engine brake power by estimating
the road inclination based on the vehicle conditions.
[Ascent shift control]On an ascent, upshifting to the 3rd, 4th or 5th gear is prohibited, depending on the
degree of road inclination.
[Descent shift control]On a descent, the current gear position is maintained, depending on the degree of
road inclination, to obtain engine brake power. When the brake pedal isdepressed, the transmission control ECU automatically downshifts to improve the
vehicle (driving force) control performance.
5. AI (Artificial Intelligence) shift control:The AI shift control enables the transmission control ECU to estimate the road
conditions and the driver's intention in order to automatically select the optimal
shift pattern. This improves the ride comfort.
[Accelerator pedal rapid open control]When the accelerator pedal is rapidly depressed, the system interprets it as an
acceleration demand and advances the downshift timing.
[Accelerator pedal sudden close control]When the accelerator pedal is suddenly released, the system interprets it as a
deceleration demand and ensures the engine brake power without changing gear.
This also ensures there is sufficient driving force for the next acceleration stage.6. Control when the vehicle stops (stopping control):
The transmission control ECU automatically disengages the clutch when the input
speed of the transmission revolution sensor falls below a specified speed. Thisenables the vehicle to stop without stalling. If the shift lever is in the E or M
positions, the transmission control ECU shifts the gear to the most appropriate
position when the vehicle speed decreases to less than a specified speed.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 48/614
HINT:
If the shift lever is kept in the N position for 2 seconds with the brake pedalreleased at a specified vehicle speed or less, the transmission control ECU locks
the shift lever to prevent improper shift lever operation. When depressing the
brake pedal, the shift lever is unlocked.
7. Control when the vehicle is parked (parking control):When the ignition switch is turned off, the transmission control ECU locks the
shift lever in the current position, and 1 second later engages the clutch to park the
vehicle with the gear engaged.
HINT:
The multi-mode manual transmission system does not have a park position. The
vehicle can be parked with the shift lever in any position (N, E, M or R). Whenthe vehicle is parked with the shift lever in a position other than N, the vehicle is
parked with the gear engaged. The vehicle may not be parked with the gear
engaged if the ignition switch is turned off before the gearshift is complete.
MULTI-MODE MANUAL TRANSMISSION SYSTEM REMOVAL ANDINSTALLATION PROCEDURES
The multi-mode manual transmission differs from the conventional manual transmission.
The following operations are necessary when removing and installing the component
parts.
1. CLAMP POSITION ADJUSTMENT
• Preload is applied to the clutch actuator push rod installed on the vehicle.
• Clamp position adjustment is necessary to position the push rod when the
clutch actuator is reinstalled.
• The push rod position of a new clutch actuator is not suitable for clutch
actuator installation. When installing a new clutch actuator, Clamp
Position Adjustment must be performed before the installation.
• The push rod position of a clutch actuator that has been installed on thevehicle is not suitable for clutch actuator reinstallation. Clamp Position
Adjustment must be performed when removing the clutch actuator.
•
For details of replacement, refer to CLAMP POSITION ADJUSTMENT().
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 49/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 50/614
• Push rod position A (Stopper position):
The stopper position is where the clutch actuator push rod is fullyretracted. Clearance exists between the release bearing and the diaphragm
spring.
• Push rod position B (Clutch clamp position):
The clutch clamp position is where 0 N [newton] of preload is applied tothe diaphragm spring. Removal or installation of the clutch actuator is
possible at this point. No clearance exists between the release bearing and
the diaphragm spring.
• Push rod position C (Complete engagement position):
During normal clutch operation, the push rod alternates between this
position and the standby position (between C and D). When the system isstopped (while the ignition switch is off), the push rod maintains this
position.
• Push rod position D (Standby position):The standby position is where the clutch actuator push rod is protruded
and the clutch is not engaged.2. REPLACEMENT OR REMOVAL/INSTALLATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM PARTSRefer to the respective pages for each part.
3. INITIALIZATION AND LEARNING
1. INITIALIZATION OF TRANSMISSION SYSTEM:
• The transmission control ECU stores information from eachcomponent, such as sensors and motors, to control the system.
• Sensors and motors that comprise the multi-mode manual
transmission system have individual specification values. Thetransmission control ECU learns and stores these values, and
controls the multi-mode manual transmission system. Therefore,the values stored in the transmission control ECU must be cleared
when the sensor or actuator is replaced.
• Learning of the multi-mode manual transmission system can be
performed when there is no learning value in the ECU. It istherefore necessary to perform initialization of the transmission
control ECU before performing learning of the multi-mode manual
transmission system.
• For details of replacement, refer to INITIALIZATION AND
LEARNING ().
2. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM:
•
This operation is performed to store the individual specificationvalues of components, such as sensors and actuators, in the
transmission control ECU.
• For details of replacement, refer to INITIALIZATION AND
LEARNING ().
NOTICE:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 51/614
Perform this operation after initialization of the multi-mode manual transmission
system.
4. SYNCHRONIZATION POSITION CALIBRATION
• The transmission components have individual specification values. The
transmission control ECU learns and stores those values, and controls thegearshift accurately. Synchronization position calibration corrects andadjusts the shift points appropriately in accordance with the individual
specification values of the components.
• For details of replacement, refer to SYNCHRONIZATION POSITION
CALIBRATION ().
MULTI-MODE MANUAL
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 52/614
TRANSAXLE SYSTEM > HOW TO
PROCEED WITH
TROUBLESHOOTINGfor Preparation
1.VEHICLE BROUGHT TO WORKSHOP
NEXT
2.CUSTOMER PROBLEM ANALYSIS
NEXT
3.CONNECT INTELLIGENT TESTER TO DLC3
HINT:
If the display indicates a communication fault in the tool, inspect the DLC3.
NEXT
4.CHECK CAN COMMUNICATION SYSTEM
1. Check for output DTCs.
HINT:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 53/614
The ECM of this system is connected to the CAN communication system.
Therefore, before starting troubleshooting, check that there is no trouble in theCAN communication system ().
Result:
Display (DTC Output) Proceed To
CAN communication system DTCs A
No output B
A. PROCEED TO CAN
COMMUNICATION SYSTEM
B. Go to step 5
5.CHECK DTC AND FREEZE FRAME DATA
NOTICE:
Record or print DTCs and freeze frame data, if necessary. Refer to the relevant
pages ().
NEXT
6.CLEAR DTC AND FREEZE FRAME DATA
HINT:
Refer to the relevant pages ().
NEXT
7.VISUAL INSPECTION
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 54/614
NEXT
8.PROBLEM SYMPTOM CONFIRMATION
Result:
Result Proceed To
Symptom does not occur A
Symptom occurs B
A. Go to step 9
B. Go to step 10
9.SYMPTOM SIMULATION
HINT:
Refer to the relevant pages ().
NEXT
10.DTC CHECK
HINT:Refer to the relevant pages ().
Result:
Display (DTC Output) Proceed To
Output A
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 55/614
No output B
A. Go to step 11
B. Go to step 12
11.DTC CHART
HINT:
Refer to the relevant pages ().
NEXT
Go to step 13
12.PROBLEM SYMPTOMS TABLE
HINT:Refer to the relevant pages ().
NEXT
13.CIRCUIT INSPECTION
HINT:
Refer to the relevant pages ().
NEXT
14.IDENTIFICATION OF PROBLEM
NEXT
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 56/614
15.ADJUSTMENT, REPAIR
NEXT
16.CONFIRMATION TEST
NEXT
END
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 57/614
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >INITIALIZATION
for Preparation
INITIALIZATION AND LEARNING USING INTELLIGENT TESTER
HINT:
• By using an intelligent tester, initialization and learning of the multi-mode manual
transmission system can be performed sequentially. Under manual operation (not
using intelligent tester), initialization and learning must be performedindividually.
• The learning values and the DTC history of the multi-mode manual transmission
system are stored in the EEPROM in the transmission control ECU. The storedinformation is not cleared even when the negative terminal of the battery is
disconnected. To clear all the stored information, initialize the transmission
control ECU.
• Perform the procedure below to ensure that the initialized transmission controlECU stores the adjusted clutch position (stopper position, clamp position, and
standby position) or gear position (shift position and select position).
• If the initialization cannot be performed normally, there may be a malfunction in
the shift lever position sensor, NE signals, or CAN communication.
• When replacing the following parts, proceed with the operation in the order listed
in the table below.
Parts installed Operation orderSee
procedure1. INITIALIZATION OF MULTI-MODEMANUAL TRANSMISSION SYSTEM
[Initialization of ECU]
See below
2. LEARNING OF MULTI-MODEMANUAL TRANSMISSION SYSTEM
See below
• Transmission assembly
• Transmission parts
(inside gear box)
• Shift and select actuator
(with clutch actuator)
• Transmission control3. SYNCHRONIZATION POSITION
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 58/614
ECU CALIBRATION
1. INITIALIZATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM
[Initialization of transmission]
See below
2. LEARNING OF MULTI-MODEMANUAL TRANSMISSION SYSTEM
See below
• Shift stroke sensor
• Select stroke sensor
3. SYNCHRONIZATION POSITION
CALIBRATION
1. INITIALIZATION OF MULTI-MODEMANUAL TRANSMISSION SYSTEM
[Initialization of clutch]
See below• Clutch actuator
• Clutch stroke sensor
• Clutch disc and clutch
cover
• Clutch release bearing
• Clutch release fork
•
Clutch release lever• Flywheel
• End plate (2SZ-FE
only)
• Crankshaft
2. LEARNING OF MULTI-MODE
MANUAL TRANSMISSION SYSTEMSee below
1. Prepare the vehicle:
• Stop the vehicle
• Shift the shift lever to the N position.
• Turn the ignition switch off.
2. Connect the intelligent tester to the DLC3.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 59/614
3. Turn the ignition switch on (IG).
4. Turn the intelligent tester ON.5. Select the following menu items: Powertrain / Multi-Mode M/T / Utility / Parts
Exchange.
6. Read the information.
7. Press the Next key.
8. Read the information.
9. After checking the vehicle condition, press the Next key.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 60/614
10.
Read the information.11. Press the Next key.
12. Read the information.
13. Press the Next key.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 61/614
14. On the Multi-Mode M/T / Utility screen, select Step 3 Initial Learning.
15. Press the Next key.
16. Select the appropriate operation.
HINT:
• Initialization of clutch: when removing and installing the following partsrelated to the clutch system.
Clutch actuator, clutch stroke sensor, clutch disc and clutch cover, clutchrelease bearing, clutch release fork or fork lever, flywheel, and end plate.
• Initialization of transmission: when removing and installing the parts
related to the shift and select operation of the transmission assembly.
• Initialization of ECU: This initializes learned values of both the clutch and
transmission.
17. Press the Next key.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 62/614
18.
Read the information.19. Press the Next key after turning the ignition switch off.
20. Wait 10 seconds.
HINT:Count down the seconds from 10 to 0.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 63/614
21. Read the information.
22. Press the Next key after turning the ignition switch on (IG).
23.
Wait 40 seconds.
HINT:
Count down the seconds from 40 to 0.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 64/614
24. Press the Exit key.25. Complete Initialization and Learning.
26. Turn the intelligent tester OFF and turn the ignition switch off.
27. Wait at least 20 seconds.28. Turn the ignition switch on (IG).
29. Depress the brake pedal with the shift lever position in the N position.
30. Start the engine and wait at least 10 seconds.
31. Shift the gear from neutral to any other position.
HINT:
• When [Initialization of transmission] was selected at step (p), add the
following step between steps (w) and (x).
Additional step: (w') Wait at least 30 seconds.
• If the Initialization and Learning operations fail, perform the operations
again from step (a) more than 15 seconds after turning the ignition switchoff.
• Perform Synchronization Position Calibration after performing
Initialization of transmission or Initialization of ECU.
• Shifting the gear from neutral to any other position at last, the
transmission control ECU learns the standby point. At this time, the value
of Learn-Clutch Standby Point in the Data List changes from [Notexec] to
[Exec].
INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION SYSTEM
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 65/614
WITHOUT USING INTELLIGENT TESTER
HINT:
• The learning values and the DTC history of the multi-mode manual transmissionsystem are stored in the EEP ROM in the transmission control ECU. The stored
information is not cleared even when the negative terminal of the battery isdisconnected. To clear all the stored information, initialize the transmissioncontrol ECU.
• If the initialization of the multi-mode manual transmission system fails, perform
the operation again from step (a) more than 15 seconds after turning the ignitionswitch off.
• If the initialization cannot be performed normally, there may be a malfunction in
the shift lever position sensor, NE signals, or CAN communication.
• When replacing the following parts, proceed with the operations in the order
listed in the table below.
Parts installed Operation orderSee
procedure
1. INITIALIZATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM
[Initialization of ECU]
See below
2. LEARNING OF MULTI-MODEMANUAL TRANSMISSION SYSTEM
See below
• Transmission assembly
• Transmission parts
(inside gear box)
• Shift and select actuator(with clutch actuator)
• Transmission control
ECU 3. SYNCHRONIZATION POSITION
CALIBRATION
1. INITIALIZATION OF MULTI-MODEMANUAL TRANSMISSION SYSTEM
[Initialization of transmission]
See below
2. LEARNING OF MULTI-MODEMANUAL TRANSMISSION SYSTEM
See below
• Shift stroke sensor
• Select stroke sensor
3. SYNCHRONIZATION POSITION
CALIBRATION
1. INITIALIZATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM[Initialization of clutch] See below
• Clutch actuator
•
Clutch stroke sensor• Clutch disc and clutch
cover
• Clutch release bearing
• Clutch release fork
• Clutch release lever
• Flywheel
• End plate (2SZ-FE
2. LEARNING OF MULTI-MODEMANUAL TRANSMISSION SYSTEM
See below
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 66/614
only)
• Crankshaft
1. Prepare the vehicle:
•
Stop the vehicle.• Shift the lever to the N position.
• Turn the ignition switch off.
2. Using SST, connect terminals TC (13) and CG (4) of the DLC3.
SST09843-18040
3. Wait at least 10 seconds.
4. Turn the ignition switch on (IG).
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 67/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 68/614
9.
Depress the brake pedal once.
0. The buzzer sounds at intervals of 0.5 seconds as follows (an interval of 2.5
seconds exists between each cycle).
• Twice when initializing the ECU (one cycle)
• Three times when initializing the clutch (one cycle)
• Four times when initializing the transmission (one cycle)
HINT:
• If the buzzer does not sound as specified, wait at least 15 seconds
after turning the ignition switch off. Then, perform the procedurefrom step (a) again.
• If the buzzer sounds at intervals of 1 second (not at intervals of 0.5
seconds), wait at least 15 seconds after turning the ignition switch
off. Then, perform the procedure from step (a) again.10. Depress the brake pedal 3 times or more within 2 seconds.
0. The buzzer sounds twice with an interval of 0.25 seconds.11. Turn the ignition switch off and wait at least 10 seconds.
12. The initialization is complete.
13. Disconnect the SST from terminals TC and CG of the DLC3.
LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM WITHOUTUSING INTELLIGENT TESTER
HINT:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 69/614
• Perform the procedure below to ensure that the initialized transmission control
ECU stores the adjusted clutch position or gear position.
• If the learning of the multi-mode manual transmission system fails, perform the
operation again from step (a) more than 15 seconds after turning the ignition
switch off.
1. Prepare the vehicle:
• Stop the vehicle.
• Shift the shift lever to the N position.
• Turn the ignition switch off.2. Turn the ignition switch on (IG).
3. Wait at least 40 seconds.
4. Turn the ignition switch off.5. Wait at least 20 seconds.
6. Turn the ignition switch on (IG).
7. Start the engine under the following conditions:
•
Shift lever is in the N position.• Brake pedal is depressed.
HINT:
The shift N position indicator blinks when the engine starts.
8. Wait at least 10 seconds.9. Check that the shift N position indicator turns on continuously (stops blinking).
10. The learning is complete.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 70/614
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
CALIBRATIONfor Preparation
SYNCHRONIZATION POSITION CALIBRATION
For smoother shifting, the transmission control ECU learns the synchronization position
of the transmission gears. Perform the synchronization position calibration of the multi-
mode manual transmission while driving the vehicle after repairing system components.
HINT:When replacing the following parts, proceed with the operation in the order listed
in the table below.
Parts installed Operation orderSee
procedure
1. INITIALIZATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM[Initialization of ECU]
2. LEARNING OF MULTI-MODEMANUAL TRANSMISSION SYSTEM
• Transmission assembly
• Transmission parts(inside gear box)
•
Shift and select actuator(with clutch actuator)
• Transmission control
ECU 3. SYNCHRONIZATION POSITIONCALIBRATION
See below
• Shift stroke sensor1. INITIALIZATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 71/614
[Initialization of transmission]
2. LEARNING OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM• Select stroke sensor
3. SYNCHRONIZATION POSITIONCALIBRATION
See below
1. INITIALIZATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM[Initialization of clutch]
• Clutch actuator
• Clutch stroke sensor
• Clutch disc and clutch
cover
• Clutch release bearing
• Clutch release fork
• Clutch release lever
• Flywheel
• End plate (2SZ-FEonly)
•
Crankshaft
2. LEARNING OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM
1. While driving the vehicle in M-mode, shift up and down between 1st and 5th at
the vehicle speeds specified below.2. Check that the gears shift smoothly.
Recommended Gear Shifting Speeds
Gear Change Gear Position Vehicle Speed
1st→2nd 25 to 40 km/h (15.5 to 24.8 mph)
2nd→3rd 45 to 80 km/h (27.9 to 49.7 mph)
3rd→4th 60 to 110 km/h (37.2 to 68.3 mph)Up shift
4th→5th 75 to 140 km/h (46.6 to 86.9 mph)
Down shift 2nd→1st 25 to 35 km/h (15.5 to 21.7 mph)
3. HINT:
• Leave an interval of more than 2 seconds between gear changes.
• If there is a shock when changing gears after the synchronization position
calibration, perform the synchronization position calibration again.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 72/614
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > PROBLEMSYMPTOMS TABLE
for Preparation
HINT:
• When a malfunction cannot be confirmed by conducting a DTC check and the
cause of the problem cannot be identified through a basic inspection, troubleshootin accordance with the priority order indicated in the table below.
• Inspect the fuse and relay before confirming the suspected areas as shown in the
chart below.
NOTICE:When removing the following parts, perform the operations correctly by
following the precautions on the relevant pages.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 73/614
Problem Symptoms for Multi-Mode Manual Transmission
Symptom Suspected areaSee
page
1. Transmission unit (Gears, bearings,
shift fork, synchronizer ring, shift key,etc.)
2. Clutch disk (Clutch cover)
3. Clutch stroke sensor
4. Clutch actuator assembly
5. Shift stroke sensor
6. Select stroke sensor
7. Shift and select actuator
8. Shift lever position sensor
9. Shift lever assembly
10. Speed signal circuit
No up-shift, No down-shift
11. Transmission control ECU
1. Multi-mode manual transmissionwarning light circuit
2. IG signal circuit
3. ECU power source circuit
Multi-mode manual transmission
warning light defective
4. Transmission control ECU1. Multi-mode manual transmission
warning light circuit
2. IG signal circuitShift position indicator light defective
3. Transmission control ECU
Buzzer does not sound when incorrect
operation occurs (built into transmissioncontrol ECU)
1. Transmission control ECU
1. Multi-mode manual transmission
warning light circuit
2. IG signal circuit
3. Front door courtesy switch
4. Combination meter
Buzzer does not sound when incorrectoperation occurs (built into combination
meter)
5. Transmission control ECU
Shift impossible to any gear1. Transmission unit (Gears, bearings,shift fork, synchronizer ring, shift key,
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 74/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 75/614
2. Transmission shift main switch
3. Shift lever position sensor
down during E mode driving
4. Transmission control ECU
1. Transmission shift main switch
2. Shift lever assemblyMode switch impossible (E to M)
3. Transmission control ECU
1. Shift lever position sensorSetting to 1st or R positions impossible
2. Transmission control ECU
1. Accelerator pedal position sensor
(1KR-FE)
2. Accelerator pedal position sensor(2SZ-FE)
Shift timing delays occur during M
mode driving
3. Transmission control ECU
1. Parking brake switch circuitAssist control does not operate when
engine started 2. Transmission control ECU
1. SFI system (1KR-FE)
2. SFI system (2SZ-FE)
3. Starter signal circuit
4. Stop light switch circuit
5. Shift lever position sensor
6. Starter (for 1KR-FE 0.9 kW)
7. Starter (for 1KR-FE 1.3 kW)8. Starter (for 2SZ-FE)
Engine does not crank
10. Transmission control ECU
1. Oil (level low)
2. Oil (Wrong)
3. Gear (Worn or damaged) Noise
4. Bearing (Worn or damaged)
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)Oil leakage
4. O-ring (Worn or damaged)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 76/614
MULTI-MODE MANUALTRANSAXLE SYSTEM >
TERMINALS OF ECU
for Preparation
Transmission Control ECU:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 77/614
Symbols(Terminal
No.)
WiringColor
Terminal Description ConditionSpecifiedCondition
+B - GND
(D79-1 -D79-6)
B - W-BBattery (ECU power
source)Always 10 to 14 V
IG - GND
(D79-3 -
D79-6)
O - W-B Ignition switchIgnition switch off →
on (IG)Below 1 V→
10 to 14 V
PKB - GND(D79-4 -
D79-6)
P - W-B Parking brake switch
Ignition switch on(IG),
Parking brake switch
OFF→ ON
(Parking brake leverreleased→ pulled)
10 to 14 V →
Below 1 V
SLS - GND
(D79-5 -
D79-6)
LG - W-
BShift lock solenoid
Ignition switch on
(IG),Brake pedal depressed
→ Released
10 to 14 V →
Below 1 V
GND - Body
ground(D79-6 -
Body
ground)
W-B -
Bodyground
Ground Always Below 1 Ω
MDSW -
GND
(D79-10 -
D79-6)
L - W-BTransmission shift
main switch
Ignition switch on
(IG),
Shift lever position E→ M
10 to 14 V → Below 1 V
LS4C -
GNDB - W-B
Shift lever position
sensor
Ignition switch on
(IG),
10 to 14 V →
Below 1 V
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 78/614
(D79-11 -
D79-6)
Shift lever position N→ except N
LS3C -GND
(D79-12 -
D79-6)
W - W-BShift lever position
sensor
Ignition switch on(IG),
Shift lever position E
or M→ R or N
10 to 14 V →
Below 1 V
LS2C -GND
(D79-13 -
D79-6)
LG - W-
B
Shift lever position
sensor
Ignition switch on(IG),
Shift lever position R→ Except R
10 to 14 V →
Below 1 V
LSW5 -GND
(D79-15 -
D79-6)
R - W-BShift lever position
sensor
Ignition switch on(IG),
Shift lever position
except [-] → [-]
10 to 14 V →
Below 1 V
LSW4 -
GND(D79-16 -
D79-6)
G - W-B Shift lever positionsensor
Ignition switch on
(IG),Shift lever position
except N→ N
10 to 14 V → Below 1 V
LSW3 -
GND(D79-17 -
D79-6)
B - W-BShift lever position
sensor
Ignition switch on
(IG),
Shift lever position R
or N→ Except R and N
10 to 14 V → Below 1 V
LSW2 -
GND
(D79-18 -D79-6)
W - W-BShift lever position
sensor
Ignition switch on
(IG),
Shift lever positionexcept R→ R
10 to 14 V →
Below 1 V
LSW1 -
GND(D79-19 -
D79-6)
GR - W-
B
Shift lever position
sensor
Ignition switch on
(IG),Shift lever position
except [+] → [+]
10 to 14 V →
Below 1 V
PWR - GND
(D79-23 -
D79-6)
GR - W-
BPattern select switch
Ignition switch on
(IG),Pattern select switch
OFF→ ON
10 to 14 V →
Below 1 V
DG - GND(D79-25 -D79-6)
P - W-B Terminal TC of DLC3 Ignition switch on (IG)→ Connect terminalsTC and CG of DLC3
10 to 14 V → Below 1 V
INDC -
GND
(D79-29 -D79-6)
R - W-BCommunication line
with combination
meter
Always Below 1.44 V
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 79/614
INDA -
GND
(D79-31 -D79-6)
Y - W-B
Communication line
with combinationmeter
Ignition switch on (IG)
Pulse
generation
(See waveform1)
STP - GND
(D79-34 -D79-6)
G - W-B Stop light switch Brake pedal depressed→ Released 10 to 14 V → Below 1 V
ST1- - GND(D79-35 -
D79-6)
Y - W-B Stop light switch
Ignition switch on
(IG),
Brake pedal released→ depressed
10 to 14 V → Below 1 V
CAN+ -
CAN-
(A38-1 -A38-2)
W - B CAN communication Ignition switch on (IG)
Pulse
generation
(See waveform2)
MREL -GND
(A38-5 -D79-6)
LG - W-
B
AMT relay (motor
power source)
Ignition switch off →
on (IG)
Below 1 V→
10 to 14 V
STA - GND(A38-6 -
D79-6)
SB - W-BStarter relay operation
signal
(input)
Ignition switch off,
Brake pedal depressed,
Shift lever position N→ Starter operates
Below 1 V→
10 to 14 V
RSW - GND
(A38-9 -
D79-6)
R - W-B Back-up light switch
Ignition switch on
(IG),
Shift lever positionexcept R→ R
Below 1 V→
10 to 14 V
NE - GND
(A38-10 -
D79-6)
L - W-BEngine speed signal
from ECMIdling
Pulse
generation(See waveform
3)
NIP- - NIP+
(A38-15 -
A38-16)
V - PTransmission
revolution sensor
Engine running,
Clutch engaged
(during driving)
Pulse
generation(See waveform
4)
E2S1 - GND(A38-17 -D79-6)
P - W-B Shift stroke sensorground(main)
Always Below 1Ω
VSS1 -
GND
(A38-18 -D79-6)
B - W-BShift stroke sensor
voltage monitor
(main)
Ignition switch on (IG) 0.5 V to 4.5 V
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 80/614
VCS1 -
GND
(A38-19 -D79-6)
W - W-BShift stroke sensor
power source (main)Ignition switch on (IG) 4.5 V to 5.5 V
VCL1 -
GND(A38-20 -
D79-6)
O - W-B Select stroke sensor power source (main)
Ignition switch on (IG) 4.5 V to 5.5 V
VSL1 -
GND(A38-21 -
D79-6)
V - W-B
Select stroke sensor
voltage monitor
(main)
Ignition switch on (IG) 0.5 V to 4.5 V
E2L1 -
GND(A38-22 -
D79-6)
Y - W-BSelect stroke sensor
ground (main)Always Below 1 Ω
SPD - GND
(A38-23 -
D79-6)
V - W-B Vehicle speed signal
Ignition switch on
(IG),
during driving
Pulse
generation(See waveform
5)
E2L2 -
GND(A38-24 -
D79-6)
GR - W-
B
Select stroke sensor
ground (sub)Always Below 1 Ω
E2R1 -
GND(A38-25 -
D79-6)
LG - W-B Clutch stroke sensorground (main) Always Below 1 Ω
VSR1 -GND
(A38-26 -
D79-6)
B - W-B
Clutch stroke sensor
voltage monitor
(main)
Ignition switch on (IG) 0.5 V to 4.5 V
VCR1 -GND
(A38-27 -
D79-6)
W - W-BClutch stroke sensor
power source (main)Ignition switch on (IG) 4.5 V to 5.5 V
E2S2 - GND(A38-28 -
D79-6)
GR - W-
B
Shift stroke sensor
ground (sub)Always Below 1 Ω
VSS2 -
GND(A38-29 -
D79-6)
BR - W-
B
Shift stroke sensor
voltage monitor (sub)Ignition switch on (IG) 0.5 V to 4.5 V
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 81/614
VCS2 -
GND
(A38-30 -D79-6)
R - W-BShift stroke sensor
power source (sub)Ignition switch on (IG) 4.5 V to 5.5 V
VCL2 -
GND(A38-31 -
D79-6)
L - W-B Select stroke sensor power source (sub)
Ignition switch on (IG) 4.5 V to 5.5 V
VSL2 -
GND(A38-32 -
D79-6)
LG - W-
B
Select stroke sensor
voltage monitor (sub)Ignition switch on (IG) 0.5 V to 4.5 V
E2R2 -
GND(A38-33 -
D79-6)
GR - W-
B
Clutch stroke sensor
ground (sub)Always Below 1 Ω
VSR2 -
GND(A38-34 -
D79-6)
BR - W-
B
Clutch stroke sensor
voltage monitor (sub)Ignition switch on (IG) 0.5 V to 4.5 V
VCR2 -
GND(A38-35 -
D79-6)
G - W-BClutch stroke sensor
power source (sub)Ignition switch on (IG) 4.5 V to 5.5 V
MSF+ -
GND(A37-1 -
D79-6)
B - W-B Shift motor
Ignition switch on
(IG),motor not operating→
operating
Pulse
generation()
+BM - GND(A37-2 -
D79-6)
B - W-B Motor power sourceIgnition switch off →
on (IG)
Below 1 V→
10 to 14 V
MSF- -
GND(A37-3 -
D79-6)
W - W-B Shift motor
Ignition switch on
(IG),motor not operating→
operating
Below 1 V→
Pulsegeneration
()
MSL- -GND(A37-4 -
D79-6)
L - W-B Select motorIgnition switch on(IG),
motor not operating→
operating
Below 1 V→ Pulsegeneration
()
MSL+ -
GND(A37-5 -
D79-6)
B - W-B Select motor
Ignition switch on
(IG),motor not operating→
operating
Below 1 V→
Pulsegeneration
()
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 82/614
MCL- -
GND
(A37-6 -D79-6)
GR - W-
BClutch motor
Ignition switch on
(IG),
motor not operating→ operating
Below 1 V→
Pulse
generation()
MCL+ -
GND(A37-7 -
D79-6)
G - W-B Clutch motor
Ignition switch on
(IG),motor not operating→
operating
Below 1 V→
Pulsegeneration
()
PGND -
Bodyground
(A37-8 -
Bodyground)
W-B -
Bodyground
Ground Always Below 1 Ω
1. Waveform 1:
Communication with Combination Meter
Terminal INDA - GND
Gauge set 2 V/DIV, 500 μs/DIV
Condition Ignition switch on (IG)
2.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 83/614
3. Waveform 2:
CAN Communication Terminal
Terminal CAN+ - CAN-
Gauge set 1 V/DIV, 50 μs/DIV
Condition Ignition switch on (IG)
4.
5. Waveform 3:
Engine speed signal from ECM
Terminal NE - GND
Gauge set 5 V/DIV, 5 ms/DIV
Condition Engine idling
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 84/614
6.
7. Waveform 4:
Transmission Revolution Sensor Terminal
Terminal NIP- - NIP+
Gauge set 500 mV/DIV, 500 μs/DIV
ConditionVehicle speed of
approximately 30 km/h (19
mph)
8.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 85/614
9. Waveform 5:
Vehicle Speed Signal Terminal
Terminal SPD - GND
Gauge set 5 V/DIV, 20 ms/DIV
ConditionVehicle speed of
approximately 20 km/h (12
mph)
ECM:
Symbols
(Terminal No.)Wiring Color
Terminal
DescriptionCondition
Specified
Condition
CAN+ - CAN-
(A32-34 - A32-
26)
W - BCAN
Communication
Ignition switch
on (IG)
Pulse
generation(See waveform
1)
NEO - E1(C33-64 - A32-
1)
L - W-BEngine speed
signalEngine idling
Pulse
generation(See waveform
2)
E1 - Body
ground(A32-1 - Body
ground)
W-B - Body
groundGround Always Below 1 Ω
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 86/614
1. Waveform 1:
CAN Communication Terminal
Terminal CAN+ - CAN-
Gauge set 1 V/DIV, 50 μs/DIV
Condition Ignition switch on (IG)
2.
3. Waveform 2:
Engine speed signal
Terminal NEO - E1
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 87/614
Gauge set 5 V/DIV, 5 ms/DIV
Condition Engine idling
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
DIAGNOSIS SYSTEMfor Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 88/614
DESCRIPTION
• The transmission control ECU has a self-diagnosis system. If the ECU, the multi-mode manual transmission system or any components fail to operate correctly, the
ECU detects the malfunction, and illuminates the multi-mode manualtransmission warning light on the combination meter.
The multi-mode manual transmission warning light is illuminated when the multi-
mode manual transmission system malfunctions.
•
• When troubleshooting Euro-OBD vehicles, the only difference from the usualtroubleshooting procedure is that an OBD scan tool (complying with ISO 15765-
4) or an intelligent tester is connected to the vehicle, and various data output fromthe vehicle ECU is read.
• Euro-OBD regulations require that the vehicle's on board computer illuminates
the MIL (Malfunction Indicator Lamp) on the combination meter when the ECM(Engine Control Module) detects a malfunction in: 1) the emission control
systems and components, or 2) the powertrain control components (which affect
vehicle emissions), or 3) the ECM. Therefore, the transmission control ECU
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 89/614
illuminates the MIL and multi-mode manual transmission warning light together
if malfunctions related to these systems or components are detected.
• If the malfunction does not recur on 3 consecutive trips, the MIL goes out
automatically. However, the DTCs remain recorded in the transmission control
ECU memory.
•
• To check DTCs, connect the OBD scan tool or intelligent tester to the DLC3(Data Link Connector 3) on the vehicle. The OBD scan tool or intelligent tester
also enables the DTCs to be erased and the freeze frame data and various forms of
engine data to be checked. See the instruction manual of the OBD scan tool orintelligent tester for details.
• The DTCs include ISO controlled codes and manufacturer controlled codes. ISO
controlled codes must be set as prescribed by the ISO, while manufacturer
controlled codes can be set by the manufacturer within prescribed limits ().
FREEZE FRAME DATA
• Freeze frame data record the vehicle conditions (engine speed, vehicle speed,
transmission gear position, shift position, etc.) when malfunctions are detected.When troubleshooting, the freeze frame data can help determine if the vehicle was
moving or stationary, if the engine was warmed up or not, the transmission gearwas in neutral or not, and other data, from the time the malfunction occurred.
DLC3 (Data Link Connector 3)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 90/614
1. The ECU uses ISO 15765-4 for communication. The terminal arrangement of theDLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format.
SymbolTerminal
No. Name
Reference
terminalResult Condition
SIL 7 Bus "+" line5-Signal
ground
Pulse
generation
During
transmission
CG 4Chassisground
Body ground 1 Ω or less Always
SG 5Signal
groundBody ground 1 Ω or less Always
BAT 16 Battery positive
Body ground 9 to 14 V Always
14 - CANL 54 to 69 Ω Ignition switch
off *
Battery positive
1 MΩ orhigher
Ignition switchoff *
CANH 6CAN "High"
line
4 - CG1 k Ω or
higher
Ignition switch
off *
Battery
positive
1 MΩ or
higher
Ignition switch
off *
CANL 14
CAN "Low"
line4 - CG
1 k Ω or
higher
Ignition switch
off *
2.
NOTICE:
3. *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and
do not operate the ignition switch, any other switches or the doors.
4. HINT:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 91/614
5. The DLC3 is the interface prepared for reading various data from the vehicle's
ECU. After connecting the cable of an intelligent tester or OBD scan tool, turn theignition switch on (IG) and turn the tester or scan tool ON.
6. If a communication failure message is displayed on the tester or scan tool screen
(on the tester: no information available), a problem exists in either the vehicle or
tester. In order to identify the location of the problem, connect the tester toanother vehicle.
If communication is normal: Inspect the DLC3 on the original vehicle.
If communication is impossible: The problem is probably with the tester itself.
Consult the service department listed in the instruction manual.
CHECK MULTI-MODE MANUAL TRANSMISSION WARNING LIGHT
1. Turn the ignition switch on (IG).
2. Check that the warning light illuminates for 5 seconds. If the warning light does
not illuminate, proceed to troubleshooting the multi-mode manual transmissionwarning light circuit ().
BATTERY VOLTAGE
1. Measure the voltage of the battery.
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge the battery before proceeding.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 92/614
2. Inspect the battery, fuses, fusible links, wiring harness, connectors and ground.
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > DTC
CHECK / CLEAR
for Preparation
HINT:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 93/614
DTCs which are stored in the transmission control ECU can be displayed on the
intelligent tester.
CHECK DTC (Using intelligent tester)
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and turn the intelligent tester ON.3. Select the following menu items: Powertrain / Multi-Mode M/T.
4. Check DTCs and freeze frame data, and write them down.
5. See DTC chart to confirm the details of the DTCs ().
HINT:Intelligent testers can display current DTC data, pending DTC data and historical
DTC data. Touch the [Current], [Pending] or [History] button on the DTC displayscreen.
[Current]: Displays the current DTC data.
[Pending]: Displays the pending DTC data
[History]: Displays the historical DTC data (past codes).
FREEZE FRAME DATA
1.
Connect the intelligent tester to the DLC3.2. Turn the ignition switch on (IG) and turn the intelligent tester ON.3. Read DTCs by selecting the following menu items: Powertrain / Multi-Mode M/T
/ DTC.4. Select the parameter(s) to check the freeze frame data.
5. Note down the DTC(s) and freeze frame data.
HINT:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 94/614
• A "!" displayed to the left of DTC data shown in red indicates that freeze
frame data has been recorded for that parameter.
• For further information about using the intelligent tester, refer to the
instruction manual.
CLEAR DTCs AND FREEZE FRAME DATA (Using intelligent tester)
1. Connect the intelligent tester to the DLC3.2. Turn the ignition switch on (IG) and turn the intelligent tester ON.3. Select the following menu items: Powertrain / Multi-Mode M/T / DTC / Clear.
4. Erase DTCs and freeze frame data by pressing the YES button on the tester.
HINT:
For further information about using the intelligent tester, refer to the instruction
manual.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 95/614
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > FAIL-SAFE CHART
for Preparation
FAIL-SAFE CHART
1.
If any of the following codes is recorded, the transmission control ECU enters thefail-safe mode.
DTC No. Malfunction Areas Fail-safe Functions Fail-safe D
• P0806
• P0807
• P0808
• P0810
• P0900
• Clutch stroke
sensor or its circuit
• Clutch
actuator assembly or
its circuit
• Gear does
not change
• Vehicle doesnot start moving
again after stopping
Either (a) or
10. cond
•
•
•
•
11.
dete
off
• P0807
• P0808
• P0906
• P0907
• P0916
• Clutch stroke
sensor or its circuit
• Select stroke
sensor or its circuit
• Shift stroke
• Limit to 3rd
gears or lower
Either of (a)
22. follo
•
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 96/614
• P0917 sensor or its circuit
•
•
•
23. dete
off
• P0905
•
P0906• P0907
• P0909
• P0910
• P0915
• P0916
• P0917
• P0919
• P0920
• Shift stroke
sensor or its circuit• Shift
actuator assembly or
its circuit
• Select stroke
sensor or its circuit
• Select
actuator assembly or
its circuit
• Gear does
not change
• Vehicle does
not start moving
again after stopping
Either (a) or
40. cond
•
•
•
41.
dete
off
• P0725• Engine speed
input circuit
• Convert
engine revolutionsignals into CAN
communication
signals
• No effect
Either (a) or
46. cond
•
•
•
47.
dete
off
• P0500
• P0715
• Vehicle
speed sensor or its
circuit
• Gear does
not shift down while
driving
Either (a) or
54.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 97/614
• Transmission
revolution sensor or
its circuit
• Only
possible to drive in
1st or reverse gears
after vehicle stops
cond
•
•
•
•
55.
dete
off
• P0603
• P0885
• Transmission
control ECU• Clutch
actuator, shiftactuator, select
actuator power
source circuit
• Gear doesnot change
•
Enginecannot be started
• Transmissioncontrol ECU stops
engine when vehicle
stops
Pass conditi
ignition swi
• P0820
• Shift lever
position sensor or itscircuit
•
Transmissionshift main switch orits circuit
• Impossibleto enter M-mode
• Gear does
not shift to 1st orreverse (and forward
or backward gears)
Pass conditi
ignition swi
• P0335
• P0339
• Crankshaft
position sensor or its
circuit
• Gear does
not changePass conditi
ignition swi
• U0100• CAN
communication
signal circuit
• Gear doesnot change
• Only
possible to drive in1st or reverse gears
after vehicle stops
Either (a) or
76. cond
•
•
•
•
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 98/614
77.
dete
off
HINT:
• *: Transmission gear: Actual transmission gear position
• The transmission control ECU identifies the actual transmission gear
position through the signals from the shift stroke sensor and select stroke
sensor.
• The transmission control ECU identifies the shift lever position through
the signal from the shift lever position sensor.
MULTI-MODE MANUAL
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 99/614
TRANSAXLE SYSTEM > DATA
LIST / ACTIVE TEST
for Preparation
DATA LIST
HINT:
By reading the Data List displayed on an intelligent tester, you can check values,
including those of the switches, sensors, and actuators, without removing any parts. Reading the Data List as the first step of troubleshooting is one method of
shortening diagnostic time. NOTICE:
In the table below, the values listed under Normal Conditions are for referenceonly. Do not depend solely on these values when determining whether or not a
part is faulty.
1. Warm up the engine.
2. Turn the ignition switch off.3.
Connect an intelligent tester to the DLC3.
4. Turn the ignition switch on (IG) and turn the tester ON.
5. Select the following menu items: Powertrain / Multi-Mode M/T / Data List.
6. Check the values by referring to the table below.
Items[Abbreviation]
MeasurementItems: Display
NormalConditions
Diagnostic Notes
MIL Status
[MIL Status]
MIL status:
OFF or ON
ON: MIL
comes on-
CalculatedEngine Load
[Calc E/G
Load]
Load calculated by ECM:
Min.: 0 %, Max.:
100 %
1KR-FE:
11 to 25 %:Idling
15 to 35 %:Runningwithout load
(2,500 rpm)
2SZ-FE:12.8 to 19.2 %:
Idling
-
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 100/614
10.3 to 17.9 %:
Running
without load(2,500 rpm)
Engine
CoolantTemperature
[Coolant
Temp]
Coolanttemperature:
Min.: -40°C,
Max.: 140°C
1KR-FE:
75 to 95°C (167to 203°F):
After engine
warmed up
2SZ-FE:80 to 100°C
(176 to 212°F):
After enginewarmed up
• If value -40 °C(-40 °F): sensor circuit
open
• If value 140 °C(284 °F): sensor circuit
shorted
Engine Run
Time
[Eng RunTime]
Engine run time:
Min.: 0 s, Max.:65535 s
Time since
engine start -
Engine
Revolution
[Engine Rev]
Engine
revolutions per
minute:Min.: 0 rpm,
Max.: 16,383.75
rpm
1KR-FE:
730 to 830 rpm:
Idling2SZ-FE:
600 to 700 rpm:
Idling
If NE signal circuit has a short
or open circuit, back-up engine
speed data from CANcommunication displayed
Vehicle Speed
[Vehicle Spd]
Vehicle speed:Min.: 0 km/h,
Max.: 255 km/h
0 km/h (0 mph):
Vehicle
stationaryApproximatelysame value as
combination
meter display
When vehicle speed signalmalfunctions, speed value
calculated from input
revolution signal displayed
Battery
Voltage
[Batt]
Battery voltage:
Min.: 0 V, Max.:
65.535 V
10 to 15 V:
Idling-
Drive Mile
afterMalfunction
[Driving
Mileage]
Accumulateddriving mileage
sincemalfunction
detection:Min.: 0 km/h,
Max.: 65,535
km/h
0 km/h (0 mph):
System normal
Distance driven sinceoccurrence of diagnosis
malfunction displayed
Running Time
from MIL ON
Running time
from MIL ON:
Equivalent to
running time-
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 101/614
[MIL On Run
Time]
Min.: 0 min,
Max.: 65535 min
since MIL ON
WarmupCycle Cleard
DTC
[Wu Cyc DTCclear]
Warm-up cyclesince DTC
cleared:
Min.: 0 , Max.:255
- Number of warm-up cycles
since DTC cleared
Distance from
DTC Cleared
[Dist DTCClear]
Distance since
DTC cleared:
Min.: 0 Km,Max.: 65535 Km
Equivalent to
drive distance
since DTCserased
-
Time after
DTC Cleared
[Time DTCClear]
Time since DTC
cleared:
Min.: 0 min,Max.: 65535 min
Equivalent totime since
DTCs erased
-
Vehicle SpeedSignal
[Vehicle Spd
Sig]
Vehicle speedsignal:
Min.: 0 km/h,Max.: 327.675
km/h
0 km/h (0 mph):
Vehicle
stationary
When vehicle speed signalmalfunctions, speed value
calculated from input
revolution signal displayed
Input
Revolution[Input Rev.]
Transmission
input revolution:Min.: 0 rpm,
Max.: 12,800
rpm
0 rpm: Vehicle
stationary
When input revolution signal
malfunctions, value calculated
from vehicle speed signaldisplayed
BackupEngine Speed
[Bacup Engin
Spd]
Back-up enginespeed from CAN
communication:
Min.: 0 rpm,
Max.: 8,160 rpm
Approximatelysame as
tachometer
reading: Enginerunning
0 rpm: Engine
stopped
0 rpm displayed when CAN
communication malfunctions
AcceleratorPedal Angle
[Accel Pedl
Angl]
Accelerator pedal angle:
Min.: 0 %, Max.:
100 %
0 %:
Accelerator pedal released
0 % displayed when CANcommunication malfunctions
TheoreticalEngine Torque
[Theoretic
Torq]
Theoreticalengine torque:
Min.: 0 N*m,
Max.: 255 N*m
0 N*m: Idling -
Clutch
Position
(Current)
Current clutch
position:
Min.: 0 mm,
19.0 mm (0.74
in.) to 44.0 mm
(1.73 in.)
Current clutch position
displayed
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 102/614
[Clutch Pos-
Cur]
Max.: 127.998
mm
Shift Position
(Current)
[Shift Pos-Cur]
Current shift position:
Min.: 0 mm,
Max.: 127.998mm
5.0 mm (0.20
in.) to 31.9 mm
(1.25 in.)
Current shift position value
displayed (1st, 3rd, 5th, or
Neutral, or 2nd, 4th, Reverse)
Select Position(Current)
[Select Pos-
Cur]
Current select
position:
Min.: 0 mm,Max.: 127.998
mm
3.0 mm (0.11in.) to 29.0 mm
(1.14 in.)
Current select position valuedisplayed (gear shift fork shaft
No. 1, No. 2 or No. 3)
Shift Lever
Position Judge
[Shift Pos
Judge]
Shift lever
position:INVALID
POSITION, P,R, N, E, M
Actual shift
lever position
displayed
-
Calculated AT
OilTemperature
[AT Oil
Temp]
Transmissionfluid temperature
calculated by
ECU:Min.: -128°C,
Max.: 127°C
Equivalent to
actualtransmission
fluid
temperature
-
Shift Lever
SwitchSignal1
[Shift SW
Sig1]
Shift lever
switch signal
(+):OFF or ON
ON: Shift lever
position in (+)
OFF: Otherthan above
LSW1(LSW+) terminal signal
of transmission control ECU
Shift LeverSwitch
Signal2
[Shift SWSig2]
Shift lever
switch signal(R):
OFF or ON
ON: Shift lever
position in (R)OFF: Other
than above
LSW2 (LSWR) terminal signalof transmission control ECU
Shift LeverSwitch
Signal3
[Shift SWSig3]
Shift lever
switch signal
(M) or (E):OFF or ON
ON: Shift lever
position in (E),
(M), (+) or (-)
OFF: Shift lever position in (R)
or (N)
LSW3 (LSWS) terminal signal
of transmission control ECU
Shift LeverSwitch
Signal4
[Shift SW
Shift leverswitch signal
(N):
OFF or ON
ON: Shift lever position in (N)
OFF: Other
than above
LSW4 (LSWN) terminal signalof transmission control ECU
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 103/614
Sig4]
Shift Lever
SwitchSignal5
[Shift SW
Sig5]
Shift lever
switch signal (-):
OFF or ON
ON: Shift lever
position in (-)
OFF: Other
than above
LSW5 (LSW-) terminal signal
of transmission control ECU
Shift Lever
Check Signal1[Shift Chek
Sig1]
Check signal of
shift lever switchsignal 2:
OFF or ON
OFF: Shift lever
position in (R)ON: Other than
above
LS2C (LSRC) terminal signalof transmission ECU
Reversal signal of LSW2
(LSWR) (ON and OFFreversed)
Shift LeverCheck Signal2
[Shift Chek
Sig2]
Check signal ofshift lever switch
signal 3:
OFF or ON
OFF: Shift lever
position in (E),
(M), (+) or (-)ON: Shift lever
position in (R)or (N)
LS3C (LSSC) terminal signalof transmission control ECU
Reversal signal of LSW3
(LSWS) (ON and OFF
reversed)
Shift Lever
Check Signal3[Shift Chek
Sig3]
Check signal of
shift lever switchsignal 4:
OFF or ON
OFF: Shift lever
position in (N)ON: Other than
above
LS4C (LSNC) terminal signalof transmission ECU
Reversal signal of LSW4
(LSWN) (ON and OFFreversed)
T/M ReverseSwitch Signal
[T/M R SW
Sig]
Transmissionreverse switch
signal:
OFF or ON
ON:
Transmission
gear in reverseOFF: Other
than above
During malfunctions, indicatorshows either OFF or ON
continuously, regardless of
gear position
Ignition Signal
[Ignition Sig]
Ignition switch
signal:OFF or ON
ON: Ignition
switch on (IG)-
Mode Switch
Signal
[Mode SWSig]
Transmission
shift main switch
signal:OFF or ON
ON: Sequential
shift control
(M-mode)selected
-
Es Mode
Switch Signal[Es SW Sig]
Es Mode Switch
Signal:OFF or ON
ON: Sporty [Es]
mode selected
(Automaticshift control)
-
Parking Brake
Signal
[Pkb Sig]
Parking brake
switch signal:
OFF or ON
ON: Parking
brake appliedOFF: Parking
brake released
-
Brake Switch Brake switch OFF: Brake ST1- terminal signal of
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 104/614
Signal2
[Brake SW
Sig2]
signal (ST1-):
OFF or ON
pedal depressed
ON: Brake
pedal released
transmission control ECU
Brake Switch
Signal1
[Brake SWSig1]
Brake switch
signal (STP):OFF or ON
ON: Brake
pedal depressed
OFF: Brake pedal released
STP terminal signal of
transmission control ECU
STA Switch
Signal
[STA SW Sig]
STA signal:OFF or ON
ON: Duringcranking
-
Gear Position(Current)
[Gear Pos-
Cur]
Current gear position:
Min.: 0, Max.:
255
Actual gear
positiondisplayed
0 = Non1 to 6 = 1st to 6th
254 = Neutral
255 = Reverse
Gear Position
(Target)
[Gear Pos-Tar]
Target gear position:
Min.: 0, Max.:
255
When shift
lever notoperated:
Target gear position equals
current gear
position
0 = Non1 to 6 = 1st to 6th
254 = Neutral
255 = Reverse
Clutch
Position(Target)
[Clutch Pos-
Tar]
Target clutch
position:Min.: 0 mm,
Max.: 127.998
mm
Difference between actual
and target
clutch positions:
Maximum of 15
mm during gearchange control
operation
(varies withvehicle
condition)
-
Shift Position
(Target)
[Shift Pos-Tar]
Target shift position:
Min.: 0 mm,
Max.: 127.998mm
Difference
between actualand target shift
positions:Maximum of 15
mm during gearchange control
operation
(varies withvehicle
condition)
-
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 105/614
Select Position
(Target)[Select Pos-
Tar]
Target select
position:
Min.: 0 mm,Max.: 127.998
mm
Difference
between actual
and target select positions:
Maximum of 15
mm during gearchange control
operation
(varies withvehicle
condition)
-
Clutch Motor
Current Req
[Clutch MotorReq]
Requested clutch
motor currentfrom CPU:
Min.: -50 A,
Max.: 50 A
-20 to 20 AInstruction (calculated) current
value from CPU
Clutch MotorCurrent MMT
[Clutch
Motor]
Actual clutchmotor current:
Min.: -50 A,
Max.: 50 A
-20 to 20 A0 A: When clutch motor not in
operation
Shift Motor
Current Req[Shift Motor
Req]
Requested shiftmotor current
from CPU:
Min.: -50 A,Max.: 50 A
-40 to 40AInstruction (calculated) currentvalue from CPU
Shift MotorCurrent MMT
[Shift Motor]
Actual shift
motor current:Min.: -50 A,Max.: 50 A
-40 to 40A 0 A: When shift motor not inoperation
Select MotorCurrent Req
[Select Motor
Req]
Requested select
motor currentfrom CPU:
Min.: -50 A,
Max.: 50 A
-25 to 25 AInstruction (calculated) current
value from CPU
Select Motor
Current MMT
[Select Motor]
Actual selectmotor current:
Min.: -50 A,Max.: 50 A
-25 to 25 A0 A: When select motor not in
operation
Base Clutch
Load[Base Clutch
Load]
Base clutch load:
Min.: -1000 N,Max.: 1000 N
Learning valueshown
Base clutch load:Calculated from average clutch
motor current when ECU
performing initialization andlearning of clutch system
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 106/614
Current ClutchLoad
[Current
Clutch Load]
Current clutchload (calculated
value):
Min.: -1000 N,
Max.: 1000 N
Reference value
(varies with
vehiclecondition)
39.33 to 45.29:
Stopper position
37.07 to 43.03:
Completeengagement
position
24.5 to 35.25:Standby
position
Current clutch load:Calculated from average clutch
motor current
Difference between BaseClutch Load and Current
Clutch Load increases as clutch
disks wear away
After performing LCCadjustment, difference
decreases (Almost same as
Base Clutch Load value)
Clutch AdjustCount
[Clutch AdjCnt]
Number of LCC
(Load Controlled
Clutch cover)adjustment
performed:Min.: 0 , Max.:
255
-When clutch motor strokeamount reaches certain value,the count increases by 1
Clutch Adjust
Fail Count[Clutch Adj
Fail]
Number of LCC
(Load ControlledClutch cover)
adjustment
judged
unnecessary:Min.: 0 , Max.:
255
-
When difference between Base
Clutch Load and CurrentClutch Load exceeds threshold,
the count increases by 1
Clutch Adjust
Detection[Clutch Adj
Detect]
Number of LCC(Load Controlled
Clutch cover)
adjustment
required:Min.: 0 , Max.:
255
-
When difference between Base
Clutch Load and CurrentClutch Load exceeds threshold,
the count increases by 1
Mode Changes
[Mode
Changes]
System controlmode:
Min.: 0, Max.:
255
-
11: System wake-up control
mode12: Vehicle driving control
mode
13: System end control mode14: System initialization mode
17: Engine starting control
mode20: Fixed gear shift control
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 107/614
mode
21: Gear shift control mode
22: Shift lever lock controlmode
25: Shut-down control mode
26: Vehicle stationary controlmode
27: Vehicle start off control
mode
Gear Mode
Changes[Gear Mode]
Gear changemode indication:
Min.: 0, Max.:
255
- -
1st Uplock
Signal
[1st Uplock
Sig]
1st gear up-lock
signal:
OFF or ON
2nd Uplock
Signal
[2nd Uplock
Sig]
2nd gear up-lock
signal:OFF or ON
3rd Uplock
Signal
[3rd UplockSig]
3rd gear up-locksignal:
OFF or ON
4th Uplock
Signal
[4th UplockSig]
4th gear up-locksignal:
OFF or ON
5th Uplock
Signal
[5th UplockSig]
5th gear up-locksignal:
OFF or ON
Rev Uplock
Signal
[Rev Uplock
Sig]
Reverse gear up-lock signal:
OFF or ON
-
If gear shift fails, uplock signal
indicates whether transmission
up-lock has occurred or notUp-lock:
Transmission gear momentarily
cannot be engaged due tomechanical reasons (notmalfunction)
Vehicle Speed
Signal Open
[Vehicle SpdOpen]
Vehicle speed
signal circuit
open judgement:OFF or ON
OFF: During
vehicle running
ON: When momentarilyinterruption in vehicle speed
signal
Input Rev
Signal Open
Input revolution
signal circuit
OFF: During
engine running
ON: When abnormal pulse
interval detected
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 108/614
[In Rev Open] open judgement:
OFF or ON
Creep Control
[Creep Ctrl]
Vehicle creep
control mode:
OFF or ON
ON: Clutch partial
engagement
continues forlong time
Clutch partially engaged whenfollowing conditions met:
•
Engine running• Transmission
gear in 1st, 2nd or
Reverse
• Brake pedal not
depressed
• Parking brakereleased
• Accelerator
pedal released
Low Voltage
Signal[Low Volt]
+B terminal lowvoltage
judgement:
OFF or ON
OFF: +B
terminal voltage8 V or more
-
Run Off
Signal[Run Off Sig]
Vehicle run-off
judgementOFF or ON
OFF: Whilevehicle running
ON: High differential spinoccurred sharply at differential
gear
When following conditionsmet, transmission control ECU
detects run-off in vehicle and
restricts gear shift:
• Accelerator pedal angle exceeds
threshold
• SPD signalchange rate above
threshold
• Shift position in
1st, 2nd or 3rd
Clutch Heat
[Clt Heat]
Clutch heat
judgement:OFF or ON
OFF: Engine
idling, gear inneutral
ON: Calculated clutchtemperature 280°C (536°F) or
moreClutch temperature calculated
from relative revolution speed
between engine andtransmission input shaft, clutch
torque, heat radiation, heat
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 109/614
conduction, sum of current
clutch temperature and
variation in clutch temperature,etc.
Clutch Heat
and Overuse[Clt Heat
Overuse]
Clutch heat and
overuse judgement:
OFF or ON
OFF: Engineidling, gear in
neutral
ON: Calculated clutchtemperature 330°C (626°F) or
more
Clutch Motor
CurrentEnable
[Clt Curr Ena]
Clutch motor
current enabledOFF or ON
OFF: Target
clutch motorcurrent less than
1 A
ON: OFFcondition not
met
-
Motor Relay
Signal
[Mot RelaySig]
AMT relay drive
signal:
OFF or ON
ON: Ignitionswitch on (IG)OFF: Ignition
switch off and
after system
shut-down
-
Shift LeverLock Solenoid
[SLS]
Shift lever lock
solenoid
operation:OFF or ON
OFF: Shift leverlocked
-
Clutch TouchPosition
[Clt Touch
Pos]
Clutch touch
position:
Min.: 0 mm,Max.: 127.998
mm
Learning value
shown
Difference between ClutchTouch position and Clutch
Clamp Position within 4.0 mm
(0.16 in.) to 16.0 mm (0.63 in.)
Clutch Clamp
Position
[Clt ClampPos]
Clutch clamp
position:Min.: 0 mm,
Max.: 127.998
mm
Learning value
shown
Difference between Clutch
Touch position and Clutch
Clamp Position within 4.0 mm(0.16 in.) to 16.0 mm (0.63 in.)
Neutral
Position(Shift)
[N Pos (Shift)]
Neutral position
(shift position):Min.: 0 mm,
Max.: 127.998mm
Learning valueshown
Median value between [3rd Pos(Shift)] and [4th Pos (Shift)]displayed
Neutral
Position
(Select)
Neutral position
(select position):
Min.: 0 mm,
Learning valueshown
Median value between [1st Pos
(Sel)] and [5th Pos (Sel)]
displayed
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 110/614
[N Pos (Sel)] Max.: 127.998
mm
1st Gear
Position(Shift)
[1st Pos
(Shift)]
1st gear position
(shift position):Min.: 0 mm,
Max.: 127.998
mm
Learning valueshown
• Difference between [1st Pos
(Shift)] and [2nd Pos
(Shift)] within 15.0 mm(0.59 in.) to 19.5 mm
(0.77 in.)
• Difference
between [1st Pos(Shift)] and [3rd Pos
(Shift)] within 1.5 mm
(0.06 in.)
1st Gear
Position(Select)[1st Pos (Sel)]
1st gear position
(select position):Min.: 0 mm,
Max.: 127.998
mm
Learning valueshown
Difference between [1st Pos
(Sel)] and [3rd Pos (Sel)]within 5.5 mm (0.22 in.) to 8.5mm (0.33 in.)
2nd Gear
Position
(Shift)[2nd Pos
(Shift)]
2nd gear position
(shift position):
Min.: 0 mm,Max.: 127.998
mm
Learning value
shown
Difference between [1st Pos(Shift)] and [2nd Pos (Shift)]
within 15.0 mm (0.59 in.) to
19.5 mm (0.77 in.)
2nd Gear
Position(Select)[2nd Pos (Sel)]
2nd gear position(select position):
Min.: 0 mm,Max.: 127.998
mm
Learning valueshown
Difference between [2nd Pos
(Sel)] and [4th Pos (Sel)]within 5.5 mm (0.22 in.) to 8.5mm (0.33 in.)
3rd Gear
Position(Shift)
[3rd Pos
(Shift)]
3rd gear position
(shift position):Min.: 0 mm,
Max.: 127.998
mm
Learning value
shown
• Difference
between [3rd Pos
(Shift)] and [4th Pos
(Shift)] within 15.0 mm(0.59 in.) to 19.5 mm
(0.77 in.)
• Difference between [5th Pos
(Shift)] and [3rd Pos(Shift)] within 1.5 mm
(0.06 in.)
3rd Gear
Position
(Select)
3rd gear position
(select position):
Min.: 0 mm,
Learning valueshown
Difference between [3rd Pos
(Sel)] and [5th Pos (Sel)]
within 5.5 mm (0.22 in.) to 8.5
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 111/614
[3rd Pos (Sel)] Max.: 127.998
mm
mm (0.33 in.)
4th Gear
Position(Shift)
[4th Pos
(Shift)]
4th gear position
(shift position):Min.: 0 mm,
Max.: 127.998
mm
Learning valueshown
• Difference between [3rd Pos
(Shift)] and [4th Pos
(Shift)] within 15.0 mm(0.59 in.) to 19.5 mm
(0.77 in.)
• Difference
between [R Pos (Shift)]and [4th Pos (Shift)]
within 1.5 mm (0.06
in.)
4th Gear
Position(Select)[4th Pos (Sel)]
4th gear position
(select position):Min.: 0 mm,
Max.: 127.998
mm
Learning valueshown
Difference between [R Pos
(Sel)] and [4th Pos (Sel)]within 5.5 mm (0.22 in.) to 8.5mm (0.33 in.)
5th GearPosition
(Shift)
[5th Pos
(Shift)]
5th gear position(shift position):
Min.: 0 mm,
Max.: 127.998
mm
Learning value
shown
• Difference
between [R Pos (Shift)]
and [5th Pos (Shift)]within 15.0 mm (0.59
in.) to 19.5 mm (0.77
in.)
• Difference
between [3rd Pos(Shift)] and [5th Pos(Shift)] within 1.5 mm
(0.06 in.)
5th Gear
Position(Select)
[5th Pos (Sel)]
5th gear position
(select position):
Min.: 0 mm,
Max.: 127.998mm
Learning valueshown
Difference between [5th Pos
(Sel)] and [3rd Pos (Sel)]within 5.5 mm (0.22 in.) to 8.5
mm (0.33 in.)
Reverse GearPos (Shift)
[R Pos (Shift)]
Reverse gear position (shift position):
Min.: 0 mm,
Max.: 127.998mm
Learning valueshown
• Difference
between [R Pos (Shift)]and [5th Pos (Shift)]
within 15.0 mm (0.59in.) to 19.5 mm (0.77
in.)
• Difference
between [R Pos (Shift)]
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 112/614
and [4th Pos (Shift)]
within 1.5 mm (0.06
in.)
Reverse Gear
Pos (Select)[R Pos (Sel)]
Reverse gear
position (select position):
Min.: 0 mm,
Max.: 127.998mm
Learning valueshown
Difference between [R Pos(Sel)] and [4th Pos (Sel)]within 5.5 mm (0.22 in.) to 8.5
mm (0.33 in.)
Possibility of
T/M Uplock
[T/M Uplock]
Possibility oftransmission up-
lock:
No or Yes
No:Initialization
and learning
complete
Yes: Transmission gear
temporarily could not be
engaged due to mechanicalreasons during gear position
learning
Learn-ClutchStandby Point
[Lern-Stby_Pnt]
Clutch actuatorstandby position
learning:
Notexec, Fail orExec
Exec:Initialization
and learningcomplete
-
Learning-T/M
[Lern-T/M]
Learning T/M
system: Notexec, Fail or
Exec
Exec:
Initializationand learning
complete
-
Learn-Clutch
Stopper Point[Lern-Stppr_Pnt]
Clutch actuator
stopper positionlearning:
Notexec, Fail or
Exec
Exec:
Initializationand learningcomplete
-
# Codes
[# Codes]
Number ofcodes:
Min.: 0, Max.:
255
- Number of detected DTCs
Check Mode[Check Mode]
Check mode:OFF or ON
ON: Checkmode ON
-
ACTIVE TEST
HINT:
Performing an Active Test enables components including the relays, VSV
(Vacuum Switching Valve), and actuators, to be operated without removing any parts. The Active Test can be performed with an intelligent tester. Performing an
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 113/614
Active Test as the first step of troubleshooting is one method of shortening
diagnostic time.Data List can be displayed during Active Tests.
1. Connect an intelligent tester to the DLC3.
2.
Turn the ignition switch on (IG) and turn the tester ON.3. Select the following menu items: Powertrain / Multi-Mode M/T / Active Test.4. Perform the Active Test by referring to the table below.
ItemsTest Details/Vehicle
conditionsDiagnosis Notes
Target Gear
PositionControl
[Test Details]
Target gear position control
(Gear position) N, 1st, 2nd, 3rd, 4th, 5th, R
[Vehicle Conditions]Ignition switch on (IG),
Engine stopped, Vehicle
stationary, Shift lever N position
If shift and select actuator does not
shift to the gear indicated, there
could be some malfunctions in the
following parts:Shift stroke sensor
Select stroke sensor
Shift and select actuator assemblyAMT relay
Transmission assembly
Transmission control ECU
TargetClutchControl
[Test Details]
Target clutch controlStandby position: Standby
Clamp position: Clamp[Vehicle Conditions]Ignition switch on (IG),
Engine stopped, Vehicle
stationary, Shift lever N
position
If clutch actuator does not operate tothe position indicated, there could be
some malfunctions in the following
parts:Clutch stroke sensor
Clutch actuator assembly
AMT relayClutch release bearing
Clutch release fork
Transmission control ECU
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 114/614
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
ADJUSTMENT
for Preparation
1. USING INTELLIGENT TESTER: CLAMP POSITION ADJUSTMENT (CLUTCH
POSITION ADJUSTMENT)
HINT:
• The multi-mode manual transmission system has a load controlled clutch cover(adjustment system). The pressure plate moves depending on the wear condition
of the clutch disc lining.
•
When removing or installing any parts related to the multi-mode manual
transmission system, move the clutch actuator to the clutch clamp position. This is
for normal operation of the load controlled clutch cover (adjustment system).
• If the clutch position adjustment operation input fails, perform the operation again
from step (a) more than 15 seconds after turning the ignition switch off.
NOTICE:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 115/614
Do not depress the brake pedal while performing the clamp position adjustment
using an intelligent tester.
1. Prepare the vehicle:
• Stop the vehicle.
•
Shift the lever into the N position.• Turn the ignition switch off.
• Apply the parking brake.
2. Connect the intelligent tester to the DLC3.
3. Turn the ignition switch on (IG).
4. Turn the intelligent tester ON.
5. Select the following menu items: Powertrain / Multi-Mode M/T / Utility / Parts
Exchange.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 116/614
6. Read the information.
7. Press the Next key.
8. Read the information.
9. After checking the vehicle condition, press the Next key.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 117/614
10. Read the information.
11. Press the Next key.
12. Read the information.
13. Press the Next key.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 118/614
14. On the Multi-Mode M/T / Utility screen, select Step 1 Clutch Position Adjustment
(Clamp Position Adjustment).
15.
Press the Next key.
16. Read the information.
17. Press the Next key.
18. Complete Clutch Position Adjustment.
19. Turn the intelligent tester OFF.
20. Turn the ignition switch off.
21. Replace the malfunctioning parts.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 119/614
HINT:
Perform [Initialization and Learning] after repairing the multi-mode manualtransmission control system ().
2. WITHOUT USING INTELLIGENT TESTER: CLAMP POSITION ADJUSTMENT
(CLUTCH POSITION ADJUSTMENT)
HINT:
• The multi-mode manual transmission system has a load controlled clutch cover(adjustment system). The pressure plate moves depending on the wear condition
of the clutch disc lining.
• When removing or installing any parts related to the multi-mode manualtransmission system, move the clutch actuator to the clutch clamp position. This is
for normal operation of the load controlled clutch cover (adjustment system).
•
If the clutch position adjustment operation input fails, perform the operation againfrom step (a) more than 15 seconds after turning the ignition switch off.
1. Prepare the vehicle.
• Stop the vehicle.
• Shift the lever into the N position.
• Turn the ignition switch off.
• Apply the parking brake.
2. Using SST, connect terminals TC (13) and CG (4) of the DLC3
SST
09843-18040
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 120/614
3. Turn the ignition switch on (IG) with the brake pedal released.
4. Depress the brake pedal 7 times or more within 3 seconds.
1. The buzzer sounds twice with an interval of 0.25 seconds.
5. Depress the brake pedal.
6.
Shift the shift lever in the following sequence with the brake pedal depressed: N→E→M→+→M→+→M→+→M→+→M→E→ N.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 121/614
7. Release the brake pedal.
8. Depress the brake pedal again.
1. The buzzer sounds once at intervals of 2.5 seconds.
HINT:
If the buzzer does not sound at this time, wait at least 15 seconds after turning the
ignition switch off. Then, perform the procedure from step (a) again.
9. Depress the brake pedal 3 times or more within 2 seconds.
1.
The buzzer sounds twice with an interval of 0.25 seconds.
10. Depress the brake pedal.
11. Shift the shift lever to the [-] position with the brake pedal depressed.
12. Release the brake pedal.
13. Complete clutch position adjustment.
14. Turn the ignition switch OFF and wait at least 10 seconds.
15. Disconnect the SST from terminals TC and CG of the DLC3.
16. Repair the malfunctioning parts.
HINT:Perform [Initialization and Learning] after repairing the multi-mode manual
transmission control system ().
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 122/614
MULTI-MODE MANUAL TRANSAXLE SYSTEM > Starter SignalCircuit
for Preparation
DESCRIPTION
In this vehicle, since the starter motor control depends on the ECM due to cranking
holding function, the ST relay that supplies power to the starter motor is operated by the
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 123/614
ECM. When the appropriate vehicle conditions are satisfied (the brake pedal is depressed
and the transmission gear is in neutral) the engine can be cranked. If the brake pedal isnot depressed or the transmission gear is not in neutral, the engine cannot be cranked.
During cranking, the ST relay operation signal (STA signal) is input into the STA
terminal of the transmission control ECU, and is used to control the multi-mode manual
transmission system.
WIRING DIAGRAM
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 124/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 125/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 126/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 127/614
INSPECTION PROCEDURE
1.READ VALUE USING INTELLIGENT TESTER
1.
Connect an intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and turn the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data List / STA
Switch Signal.
4.
Check the value displayed on the tester when the ignition switch is turned on (IG)and the engine starts.
Items
[Abbreviation]
Measurement Items:
Display Normal Conditions
Diagnostic
Notes
STA Switch
Signal[STA SW Sig]
STA signal:ON or OFF
ON: Duringcranking
-
5. OK:
6.
[ON] displays in the STA Switch Signal during cranking.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 128/614
OK
PROCEED TO NEXT CIRCUIT
INSPECTION SHOWN IN PROBLEMSYMPTOMS TABLE
NG
2.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU -
ECM)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 129/614
1.
Disconnect the transmission control ECU connector.
2. Disconnect the ECM connector.
3. Remove the ST relay from the engine room relay block.
4. Check the resistance.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 130/614
Standard resistance:
Tester ConnectionsSpecified
Conditions
1KR-FE:
STA (A32-27) -
STA (A38-6)2SZ-FE:
STA (A21-48) -
STA (A38-6)
Below 1 Ω
STA (A38-6) - Bodyground
10 k Ωor higher
5. Reconnect the transmission control ECU connector.
6. Reconnect the ECM connector.
7. Reinstall the ST relay.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 131/614
NG
REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
GO TO STARTER SIGNAL CIRCUIT (ENGINE CONTROL SYSTEM)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 132/614
MULTI-MODE MANUAL TRANSAXLE SYSTEM > Pattern SelectSwitch Circuit
for Preparation
DESCRIPTION
While the vehicle is driven with the shift lever in the E position, the most appropriate
gear is automatically selected in accordance with the accelerator pedal opening angle andvehicle speed. In this time, shift control can be switched between normal mode (E) and
sports mode (Es) by pressing the pattern select switch.
WIRING DIAGRAM
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 133/614
INSPECTION PROCEDURE
1.INSPECT PATTERN SELECT SWITCH ASSEMBLY
1. Remove the pattern select switch.
2. Check the resistance of the pattern select switch terminals.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 134/614
Standard resistance:
Tester
Connections
Switch
Conditions
Specified
Conditions
1 - 4 ON Below 1 Ω
1 - 4 OFF10 k Ω or
higher
3. Reinstall the pattern select switch.
NG REPLACE PATTERN SELECTSWITCH ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 135/614
OK
2.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU -
BODY GROUND)
1. Disconnect the transmission control ECU connector.
2. Check the resistance.
Standard resistance:
Tester
Connections
Switch
Conditions
Specified
Conditions
PWR (D79-
23) - Body
ground
OFF10 k Ω or
higher
PWR (D79-23) - Body
ground
ON Below 1 Ω
3. Reconnect the transmission control ECU connector.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 136/614
NG
REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
3.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY (PWR TERMINAL
VOLTAGE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 137/614
1. Turn the ignition switch on (IG).
2. Measure the voltage between the terminal of the transmission control ECU
connector and the body ground when the pattern select switch is ON and OFF.
Standard voltage:
Tester
Connections
Switch
Conditions
Specified
Conditions
PWR (D79-
23) - Body
ground
Pattern
selectswitch
OFF
10 to 14 V
PWR (D79-
23) - Bodyground
Pattern
selectswitch ON
Below 1 V
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 138/614
NG
REPLACE TRANSMISSION
CONTROL ECU ASSEMBLY
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS
TABLE
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 139/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 140/614
INSPECTION PROCEDURE
1.READ VALUE USING INTELLIGENT TESTER
1. Connect the intelligent tester to the DLC3
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 141/614
2. Turn the ignition switch on (IG) and turn the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data List /
Ignition Signal.
4.
Read the value.
Items[Abbreviation]
Measurement Items:Display
Normal ConditionsDiagnostic
Notes
Ignition
Signal
[Ignition Sig]
Ignition switch signal:OFF or ON
ON: Ignition switch on(IG)
-
5. OK:6. [ON] displays in the item [Ignition Signal] when the ignition switch is turned on
(IG).
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 142/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 143/614
1. Disconnect the transmission control ECU connector.
2. Turn the ignition switch on (IG).
3. Measure the voltage between the terminal of the transmission control ECU
connector and the body ground.
Standard voltage:
Tester
Connections
IgnitionSwitch
Conditions
Specified
Conditions
IG (D79-3) -Body ground
Ignitionswitch off
Below 1 V
IG (D79-3) -Body ground
Ignition
switch on
(IG)
10 to 14 V
4. Reconnect the transmission control ECU connector.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 144/614
OK
REPLACE TRANSMISSION
CONTROL ECU ASSEMBLY
NG
3.INSPECT INTEGRATION RELAY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 145/614
1. Remove the integration relay from the engine room relay block.
2.
Measure the voltage between the terminal of the integration relay and the body
ground.
Standard voltage:
Tester ConnectionsSpecified
Conditions
Integration relay (1C-
1) - Body ground10 to 14 V
3. Reinstall the integration relay.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 146/614
NG
REPAIR OR REPLACE HARNESS OR
CONNECTOR (INTEGRATIONRELAY - BATTERY)
OK
4.INSPECT INTEGRATION RELAY (AM2 FUSE AND IG2 RELAY)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 147/614
1. Inspect the AM2 fuse.1. Remove the AM2 fuse.
2. Check the fuse resistance.
Standard resistance:Below 1 Ω
3. Reinstall the fuse.
2. Inspect the relay.
1. Check the relay resistance.
Standard resistance:
Tester
Connections
Specified
Conditions
1C-1 - 1B-4 10 k Ω or higher
1C-1 - 1B-4
Below 1 Ω
(When battery
voltage applied toterminals 1B-2 and
1B-3)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 148/614
NG REPLACE INTEGRATION RELAY
OK
5.INSPECT FUSE (IGN FUSE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 149/614
1. Remove the IGN fuse from the main body ECU.
2. Check the fuse resistance.
Standard resistance:
Below 1 Ω
3. Reinstall the IGN fuse.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 150/614
NG
CHECK FOR SHORT IN ALL
HARNESSES AND CONNECTORS
CONNECTED TO FUSE ANDREPLACE FUSE
OK
6.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU -
INTEGRATION RELAY)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 151/614
1.
Remove the integration relay.
2. Disconnect the transmission control ECU connector.
3. Check the resistance.
Standard resistance (Check for open):
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 152/614
Tester ConnectionsSpecified
Conditions
Integration relay (1B-4) - IG (D79-3)
Below 1 Ω
Standard resistance (Check for short):
Tester ConnectionsSpecified
Conditions
IG (D79-3) - Bodyground
10 k Ω or higher
4. Reinstall the integration relay.
5. Reconnect the ECU connector
Result:
ResultProceed
To
Outside normal range A
Within normal range (with
Entry and Start System)B
Within normal range(without Entry and Start
System)
C
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 153/614
B Go to step 7
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 154/614
C Go to step 8
A
REPAIR OR REPLACE HARNESS OR CONNECTOR
7.CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - MAIN BODYECU)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 155/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 156/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 157/614
NG
REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
CHECK ENTRY AND START SYSTEM
8.CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - IGNITIONSWITCH)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 158/614
1.
Remove the integration relay.
2. Disconnect the ignition switch connector.
3. Check the resistance.
Standard resistance (Check for open):
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 159/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 160/614
NG
REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
9.INSPECT IGNITION SWITCH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 161/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 162/614
NG REPLACE IGNITION SWITCH
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (IGNITION SWITCH -BATTERY)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 163/614
MULTI-MODE MANUAL TRANSAXLE SYSTEM > Shift LockSolenoid Circuit
for Preparation
DESCRIPTION
The shift lock solenoid is built into the shift lever assembly. When the ignition switch isturned off, or when the shift lever is in the N position without depressing the brake pedalalthough the ignition switch is turned on (IG), the shift lock solenoid restricts the shift
lever movement.
The transmission control ECU sends the shift lock cancellation signal to the shift locksolenoid to cancel the shift lock when the multi-mode manual transmission system
conditions are satisfied.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 164/614
WIRING DIAGRAM
INSPECTION PROCEDURE
1.INSPECT SHIFT LOCK SOLENOID
1. Disconnect the shift lever assembly connector.
2. Measure the shift lock solenoid resistance.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 165/614
Standard resistance:
Tester
Connections
Specified
Conditions
IG (D81-2) - E
(D81-6)
30 to 35 Ω at 20°C
(68°F)
NG REPLACE SHIFT LOCK SOLENOID
OK
2.CHECK HARNESS AND CONNECTOR (SHIFT LOCK SOLENOID -
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 166/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 167/614
E (D81-6) - Body
groundBelow 1 Ω
SLS (D79-5) - Bodyground
10 k Ω or higher
4.
Reconnect the transmission control ECU connector.
5. Reconnect the shift lever assembly connector.
NG REPAIR OR REPLACE HARNESS ORCONNECTOR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 168/614
OK
3.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY
1. Turn the ignition switch on (IG).
2. Measure the voltage between the terminal of the transmission control ECU and
the body ground when the brake pedal is operated.
Standard voltage:
Pedal
Conditions
Tester
Connections
Specified
Conditions
Brake
pedaldepressed
SLS (D79-5)
- Bodyground
10 to 14 V
Brake
pedal
released
SLS (D79-5)Body ground
Below 1 V
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 169/614
NG
REPLACE TRANSMISSION
CONTROL ECU ASSEMBLY
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS
TABLE
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 170/614
MULTI-MODE MANUAL TRANSAXLE SYSTEM > Multi -ModeManual Transmission Warning Light Circuit
for Preparation
DESCRIPTION
The combination meter interprets the multi-mode manual transmission system conditionthrough information from the INDC and INDA circuits, and if necessary, illuminates
(blinks) the multi-mode manual transmission warning light and sounds the buzzer.
• INDC Terminal Circuit:The battery voltage is constantly supplied to the INDC circuit. If the INDC circuit
is open, the combination meter detects a malfunction in the circuit and illuminates
the multi-mode manual transmission warning light. The INDC circuit is used tosend the multi-mode manual transmission warning light signal to the combination
meter when the ignition switch is off.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 171/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 172/614
meter)
Shift
positionindicator
*1
ON
depends oncommunication
signal
ON
depends oncommunication
signal
OFF OFF OFF OFF
Multi-mode
manualtransmission
warning
light
ON
depends on
communicationsignal
ON
depends on
communicationsignal
ON ON OFF ON
*1: when shift position indicator ON, the number or letter segments are illuminated.
WIRING DIAGRAM
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 173/614
INSPECTION PROCEDURE
HINT:
• Check that the multi-mode manual transmission warning light and shift position
indicator light come on.Under normal conditions, the shift position indicator indicates the current gear
position while the ignition switch is turned on (IG), and the multi-mode manual
transmission warning light comes on for a bulb check for approximately 5seconds when the ignition switch is turned from off to on (IG).
If the shift position indicator light does not come on, the INDA circuit may bemalfunctioning. If the multi-mode manual transmission warning light does not
come on, the INDA and/or INDC circuits may be malfunctioning.
• The buzzer built into the combination meter sounds when the followingconditions are met:
• The shift lever is in any position except N.
•
The driver's door is open.• Vehicle speed is 10 km/h (6.21 mph) or less.
• Engine speed is 400 rpm or more.
1.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU -
COMBINATION METER ASSEMBLY)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 174/614
1. Disconnect the transmission control ECU connector.
2. Disconnect the combination meter connector
3. Check the resistance.
Standard resistance:
Tester ConnectionsSpecified
Conditions
INDC (D79-29) -BRQ (D1-13)
Below 1 Ω
INDA (D79-31) -
TX+ (D1-8)Below 1 Ω
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 175/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 176/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 177/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 178/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 179/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 180/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 181/614
NG
REPLACE PARKING BRAKE
SWITCH ASSEMBLY
OK
2.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU -
BODY GROUND)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 182/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 183/614
NG
REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
3.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 184/614
1. Turn the ignition switch on (IG).
2. Measure the voltage between the terminal of the transmission control ECU
connector and the body ground when the parking brake switch is ON and OFF.
Standard voltage:
Tester
Connections
Switch
Conditions
Specified
Conditions
PKB (D79-
4) - Body
ground
Parking
brakeswitch
OFF
10 to 14 V
PKB (D79-
4) - Bodyground
Parking
brakeswitch
ON
Below 1 V
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 185/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 186/614
MULTI-MODE MANUAL TRANSAXLE SYSTEM > TC and CGTerminal Circuit
for Preparation
DESCRIPTION
Terminal TC and CG are located in the DLC3. When performing [Clamp PositionAdjustment] and [Initialization and Learning] without using an intelligent tester,
connecting terminals TC and CG is necessary. If the TC terminal circuit is open, thesecalibration procedures cannot be performed without using an intelligent tester.
WIRING DIAGRAM
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 187/614
INSPECTION PROCEDURE
1.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU -
DLC3)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 188/614
1. Disconnect the transmission control ECU connector.
2. Check the resistance.
Standard resistance:
Tester Connections
Specified
Conditions
DG (D79-25) - TC
(D15-13)Below 1 Ω
DG (D79-25) -Body ground
10 k Ωor higher
3.
Reconnect the transmission control ECU connector.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 189/614
NGREPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
2.CHECK HARNESS AND CONNECTOR (DLC3 - BODY GROUND)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 190/614
1. Check the resistance.
Standard resistance:
Tester Connections SpecifiedConditions
CG (D15-4) - Body
groundBelow 1 Ω
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 191/614
NG
REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
REPLACE TRANSMISSION CONTROL ECU ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 192/614
MULTI-MODE MANUAL
TRANSAXLE OIL > ON-VEHICLE
INSPECTION
for Preparation
1. INSPECT TRANSAXLE OIL
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 193/614
1. Stop the vehicle on a level place.
2. Remove the filler plug and gasket.
3.
Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of thefiller plug opening.
NOTICE:
• An excessively large or small amount of oil may cause problems.
• After replacing the oil, drive the vehicle and check the oil level again.
4. When the oil level is low, check for oil leakage.
5. Install the filler plug and a new gasket.
Torque:
39 N*m 400 kgf*cm , 29 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 194/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 195/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 196/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 197/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 198/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 199/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 200/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 201/614
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. DRAIN TRANSAXLE OIL
1. Remove the filler plug and gasket.
2. Remove the drain plug and gasket, and drain the oil.
3. Install the drain plug with a new gasket.
Torque:
39 N*m 400 kgf*cm , 29 ft.*lbf
3. REMOVE FRONT WHEELS
4. REMOVE FRONT AXLE SHAFT LH NUT
1. Using SST and a hammer, release the staked part of the axle hub nut.
SST
09930-00010
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 202/614
NOTICE:
• Insert SST into the groove with the flat surface facing up.
• Do not damage the tip of SST using grinders.
• Completely unstake the staked part before removing the axle hub nut.
•
Do not damage the threads of the drive shaft.
2. Using a 30 mm socket wrench, remove the axle hub nut.
5. REMOVE FRONT AXLE SHAFT RH NUT
HINT:The removal procedure for the RH side is the same as that for the LH side.
6. SEPARATE SPEED SENSOR FRONT LH
1. Remove the bolt and separate the speed sensor and flexible hose.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 203/614
2. Remove the bolt and separate the speed sensor from the steering knuckle.
NOTICE:
• Keep the speed sensor tip and installation portion free of foreign matter.
• Remove the speed sensor without turning it from its original installation
angle.
7. SEPARATE SPEED SENSOR FRONT RH
HINT:
The separation procedure for the RH side is the same as that for the LH side.
8. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 204/614
1. Remove the clip and castle nut.
2. Using SST, separate the lower arm.
SST
09628-00011 NOTICE:
• Do not damage the lower ball joint dust cover.
• Suspend SST with a piece of string or the equivalent.
9. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH
HINT:
The separation procedure for the RH side is the same as that for the LH side.
10. SEPARATE TIE ROD END SUB-ASSEMBLY LH
1.
Remove the cotter pin and castle nut.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 205/614
2. Using SST, separate the tie rod end from the steering knuckle.
SST
09628-62011 NOTICE:
Do not damage the tie rod end dust cover.
11. SEPARATE TIE ROD END SUB-ASSEMBLY RH
HINT:
The separation procedure for the RH side is the same as that for the LH side.
12. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
1. Remove the nut and separate the stabilizer link from the shock absorber.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 206/614
HINT:
If the ball joint turns together with the nut, use a socket hexagon wrench 6 to holdthe stud.
13. REMOVE FRONT STABILIZER LINK ASSEMBLY RH
HINT:
The separation procedure for the RH side is the same as that for the LH side.
14. REMOVE FRONT AXLE ASSEMBLY LH
1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting
between the drive shaft and front axle.
HINT:
If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass bar and hammer.
2. Push the front axle out of the vehicle to remove the drive shaft from the front
axle.
NOTICE:
• Do not push the front axle further out of the vehicle than is necessary.
•
Do not damage the outboard joint boot.• Do not damage the speed sensor rotor.
• Suspend the drive shaft with a piece of string or the equivalent.
15. REMOVE FRONT AXLE ASSEMBLY RH
HINT:
The removal procedure for the RH side is the same as that for the LH side.
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 207/614
1. Using SST, remove the drive shaft.
SST09520-01010
09520-24010 (09520-32040)
NOTICE:
• Do not damage the oil seal.
• Do not damage the inboard joint boot.
• Do not drop the drive shaft.
17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
1. Using a screwdriver and hammer, remove the drive shaft.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 208/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 209/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 210/614
DIFFERENTIAL OIL SEAL >
INSTALLATIONfor Preparation
1. INSTALL TRANSAXLE CASE OIL SEAL
1. Coat a new oil seal lip with MP grease.
2. Using SST and a hammer, install the oil seal.
SST
09636-20010Drive in depth:
1.7 to 2.7mm (0.067 to 0.106 in.)
NOTICE:Do not damage the oil seal lip.
2. INSTALL TRANSMISSION CASE OIL SEAL
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 211/614
1. Coat a new oil seal lip with MP grease.
2. Using SST and a hammer, install the oil seal.
SST
09316-60011 (09316-00011)Drive in depth:
2.1 to 3.1mm (0.083 to 0.122 in.)
NOTICE:
Do not damage the oil seal lip.
3. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
1. Coat the spline of the inboard joint with gear oil.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 212/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 213/614
6. INSTALL FRONT AXLE ASSEMBLY RH
HINT:
The installation procedure for the RH side is the same as that for the LH side.
7. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
1. Install the stabilizer link with the nut.
Torque:
74 N*m 755 kgf*cm , 55 ft.*lbf
HINT:If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold
the stud.
8. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
The installation procedure for the RH side is the same as that for the LH side.
9. INSTALL TIE ROD END SUB-ASSEMBLY LH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 214/614
1. Install the tie rod end onto the steering knuckle with a new castle nut.
Torque:
49 N*m 500 kgf*cm , 36 ft.*lbf NOTICE:
If the holes for the clip are not aligned, tighten the nut by a further turn of up to
60°.
2. Install a new cotter pin.
10. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT:
The installation procedure for the RH side is the same as that for the LH side.
11. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 215/614
1. Install the lower arm onto the steering knuckle with a new castle nut.
Torque:98 N*m 1,000 kgf*cm , 72 ft.*lbf
NOTICE:
If the holes for the clip are not aligned, tighten the nut by a further turn of up to
60°.
2. Install a new clip.
12. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH
HINT: The installation procedure for the RH side is the same as that for the LH side.
13. INSTALL SPEED SENSOR FRONT LH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 216/614
1. Install the speed sensor onto the steering knuckle with the bolt.
Torque:
8.5 N*m 87 kgf*cm , 75 in.*lbf NOTICE:
• Check that the speed sensor tip and installation portion are free of foreign
matter.
• Install the speed sensor without turning it from its original installation
angle.
2. Install the flexible hose and speed sensor with the bolt.
Torque:29 N*m 300 kgf*cm , 22 ft.*lbf
NOTICE:
Install the flexible hose and speed sensor without twisting them.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 217/614
14. INSTALL SPEED SENSOR FRONT RH
HINT:
The installation procedure for the RH side is the same as that for the LH side.
15. INSTALL FRONT AXLE SHAFT LH NUT
1. Using a 30 mm socket wrench, install a new axle hub nut.
Torque:
216 N*m 2,203 kgf*cm , 160 ft.*lbf
2. Using a chisel and hammer, caulk the axle hub nut.
16. INSTALL FRONT AXLE SHAFT RH NUT
HINT:
The installation procedure for the RH side is the same as that for the LH side.
17. INSTALL FRONT WHEELS
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 218/614
18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque:
5.4 N*m 55 kgf*cm , 48 in.*lbf
19. ADD TRANSAXLE OIL
20. INSPECT AND ADJUST TRANSAXLE OIL
1.
Stop the vehicle on a level place.
2. Remove the filler plug and gasket.
3. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the
filler plug opening.
NOTICE:
• An excessively large or small amount of oil may cause problems.
• After replacing the oil, drive the vehicle and check the oil level again.
4. When the oil level is low, check for oil leakage.
5. Install the filler plug and a new gasket.
Torque:
39 N*m 400 kgf*cm , 29 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 219/614
21. INSPECT ABS SPEED SENSOR SIGNAL
()
22. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
()
23. CHECK FOR TRANSAXLE OIL LEAKAGE
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 220/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 221/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 222/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 223/614
1 / 2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 224/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 225/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 226/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 227/614
1. INSPECT SHIFT LOCK SOLENOID
1. Disconnect the indicator light wire connector.
2. Using an ohmmeter, measure the resistance between terminals 2 and 6.
Standard Resistance:
30 to 35 Ω at 20°C (68°F)
If the resistance is not as specified, replace the shift lever assembly.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 228/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 229/614
4. Move the shift lever to the E position.
5. Using an ohmmeter, measure the resistance according to the value in the table
below.
Standard Resistance:
Shift position
TerminalsSpecifiedcondition
E 4 - 810 k Ω or
higher
If the result is not as specified, replace the shift lever assembly.
6. Connect the indicator light wire connector.
3. INSPECT SHIFT LEVER POSITION SENSOR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 230/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 231/614
SHIFT LEVER > REMOVAL
for Preparation
1. REMOVE REAR CONSOLE BOX COVER
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 232/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 233/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 234/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 235/614
2. Disengage the 4 claws and remove the position indicator light guide from the shiftlever assembly.
3. Disengage the 4 claws and remove the position indicator housing from the position indicator light guide.
3. REMOVE POSITION INDICATOR SLIDE COVER
4. REMOVE POSITION INDICATOR SLIDE COVER NO. 2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 236/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 237/614
3. Using a screwdriver with its tip wrapped in protective tape, release the secondary
lock.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 238/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 239/614
1. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY
1.
Connect marked wire harnesses 2 and 4 to the indicator light wire connector asshown in the illustration.
2. Connect wire harnesses 6 and 8 to the indicator light wire connector as shown in
the illustration.
3. Lock the secondary lock.
4. Install the bulb onto the indicator light wire.
5. Connect the indicator light wire connector onto the shift lever assembly.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 240/614
2. INSTALL SHIFT LOCK RELEASE BUTTON
1. Apply MP grease to the shift lock release button and spring.
2. Install the shift lock release button and spring onto the shift lever.
3. INSTALL POSITION INDICATOR SLIDE COVER NO. 2
4. INSTALL POSITION INDICATOR SLIDE COVER
5. INSTALL POSITION INDICATOR LIGHT GUIDE
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 241/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 242/614
3. Connect the indicator light wire onto the shift lever assembly.
6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 243/614
SHIFT LEVER > INSTALLATION
for Preparation
1. INSTALL SHIFT LEVER ASSEMBLY
1. Install the shift lever assembly with the 4 bolts.
Torque:12 N*m 122 kgf*cm , 8.9 ft.*lbf
2. Connect the 2 connectors.
2. INSTALL REAR CONSOLE BOX ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 244/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 245/614
MULTI-MODE MANUAL
TRANSAXLE ASSEMBLY >
COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 246/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 247/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 248/614
1 / 10
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 249/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 250/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 251/614
2 / 10
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 252/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 253/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 254/614
3 / 10
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 255/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 256/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 257/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 258/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 259/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 260/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 261/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 262/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 263/614
6 / 10
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 264/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 265/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 266/614
7 / 10
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 267/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 268/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 269/614
8 / 10
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 270/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 271/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 272/614
9 / 10
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 273/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 274/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 275/614
10 / 10
MULTI-MODE MANUAL
TRANSAXLE ASSEMBLY >
REMOVAL
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 276/614
1. CLUTCH POSITION ADJUSTMENT
()
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE COLUMN HOLE COVER SILENCER SHEET
1. Remove the floor carpet and 2 clips and remove the column hole cover silencer.
4. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 277/614
1. Use a seat belt to fix the steering wheel assembly, in order to avoid breakage of
the spiral cable.
2. Place matchmarks on the sliding yoke of the steering intermediate shaft assembly
and the power steering.
3. Loosen bolt A, remove bolt B and separate the steering intermediate shaft
assembly.
5. REMOVE FRONT WHEELS
6. REMOVE ENGINE UNDER COVER LH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 278/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 279/614
2. Remove the nut and front wiper arm.
11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RHHINT:
Use the same procedure as for the LH side.
12. REMOVE HOOD TO COWL TOP SEAL
1. Disengage the 7 clips and remove the hood to cowl top seal.
13. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for LHD)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 280/614
1. Disengage the 2 hooks and remove cowl top ventilator louver center No. 1.
2. Disconnect the washer hose.
3. Disengage the 11 claws and clip.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 281/614
4. Disconnect the washer hose and remove the cowl top ventilator louver sub-assembly.
14. REMOVE COWL TOP VENTILATOR LOUVER LH (for LHD)
1. Remove the 2 clips.
2.
Disengage the 4 claws and remove the cowl top ventilator louver LH.
15. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for RHD)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 282/614
1. Disconnect the washer hose.
2. Disengage the 10 claws and clip and remove the cowl top ventilator louver sub-
assembly.
16. REMOVE COWL TOP VENTILATOR LOUVER LH (for RHD)
1. Remove the clip.
2. Disengage the 4 claws and remove the cowl top ventilator louver LH.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 283/614
17. REMOVE WINDSHIELD WIPER MOTOR AND LINK
1. Remove the 2 bolts.
2. Slide the wiper link. Disengage the meshing of the rubber pin, then disconnect the
connector and remove the front wiper motor and link.
18. REMOVE COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 284/614
1. Disengage the claws and remove cowl to resister duct No. 2.
19. REMOVE COWL TOP PANEL OUTER
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 285/614
1. Disengage the clamp and separate the wiper motor connector.
2. Remove the 9 bolts and the cowl top panel outer.
20. REMOVE AIR CLEANER INLET NO.1 (for 2SZ-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 286/614
1. Remove the air cleaner inlet No. 1.
21. REMOVE BATTERY HOLD DOWN CLAMP
22. REMOVE BATTERY CLAMP SUB-ASSEMBLY
23. REMOVE BATTERY
24. REMOVE BATTERY TRAY
25. REMOVE BATTERY CARRIER (for 1KR-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 287/614
1. Remove the 4 bolts and the battery carrier.
26. REMOVE BATTERY CARRIER (for 2SZ-FE)
1. Remove the 5 bolts and the battery carrier.
27. REMOVE CLUTCH ACTUATOR ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 288/614
1. Remove the bolt and separate the wire harness bracket.
2. Disconnect the clutch stroke sensor connector and motor connector.
NOTICE:
Do not forcibly pull the connector as this may damage the wire harness.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 289/614
3. Remove the 3 bolts and clutch actuator assembly.
NOTICE:
• Loosen the bolts slowly, and be careful not to get your fingers caught as
the clutch actuator assembly moves due to the reaction force from theclutch cover.
• Do not drop the removed clutch actuator assembly or subject it to any
impacts.
28. DISCONNECT WIRE HARNESS
1. Remove the bolt, then disconnect the wire harness.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 290/614
29. DISCONNECT CONNECTOR
1.
Disconnect the shift stroke sensor connector.
2. Disconnect the select stroke sensor connector.
3. Disconnect the transmission revolution sensor connector.
4. Disconnect the back-up light switch connector.
5. Disconnect the neutral start switch connector.
6. Disconnect the shift and select motor connectors.
30. REMOVE STARTER ASSEMBLY (for 1KR-FE)
1. Remove the terminal cap.
2. Separate the harness clamp.
3. Remove the nut and disconnect terminal 30.
4. Disconnect the connector.
5. Remove the 2 bolts and remove the starter assembly.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 291/614
31. REMOVE STARTER ASSEMBLY (for 2SZ-FE)
1. Remove the terminal cap.
2. Remove the nut and disconnect terminal 30.
3. Disconnect the connector.
4. Remove the 2 bolts and remove the starter assembly.
32. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 1KR-FE)
1. Remove the 4 bolts and 4 compression springs.
2. Remove exhaust pipe support No. 4 and the exhaust front pipe assembly.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 292/614
3. Remove the 2 exhaust pipe gaskets.
33. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2SZ-FE)
1. Remove the 2 bolts and 2 compression springs.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 293/614
2. Remove the 3 No. 4 exhaust pipe supports and remove the exhaust pipe assembly
front.
34. REMOVE FRONT AXLE SHAFT LH NUT
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 294/614
1. Using SST and a hammer, release the staked part of the axle hub nut.
SST09930-00010
NOTICE:
• Insert SST into the groove with the flat surface facing up.
• Do not damage the tip of SST using grinders.
• Completely unstake the staked part before removing the axle hub nut.
• Do not damage the threads of the drive shaft.
2. Using a 30 mm socket wrench, remove the axle hub nut.
35. REMOVE FRONT AXLE SHAFT RH NUT
HINT:The removal procedure for the RH side is the same as that for the LH side.
36. SEPARATE SPEED SENSOR FRONT LH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 295/614
1. Remove the bolt and separate the speed sensor and flexible hose.
2. Remove the bolt and separate the speed sensor from the steering knuckle.
NOTICE:
• Keep the speed sensor tip and installation portion free of foreign matter.
• Remove the speed sensor without turning it from its original installation
angle.
37. SEPARATE SPEED SENSOR FRONT RH
HINT:The separation procedure for the RH side is the same as that for the LH side.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 296/614
38. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
1. Remove the clip and castle nut.
2. Using SST, separate the lower arm.
SST
09628-00011 NOTICE:
• Do not damage the lower ball joint dust cover.
• Suspend SST with a piece of string or the equivalent.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 297/614
39. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH
HINT:
The separation procedure for the RH side is the same as that for the LH side.
40. SEPARATE TIE ROD END SUB-ASSEMBLY LH
1. Remove the cotter pin and castle nut.
2. Using SST, separate the tie rod end from the steering knuckle.
SST
09628-62011
NOTICE:Do not damage the tie rod end dust cover.
41. SEPARATE TIE ROD END SUB-ASSEMBLY RH
HINT:
The separation procedure for the RH side is the same as that for the LH side.
42. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 298/614
1. Remove the nut and separate the stabilizer link from the shock absorber.
HINT:
If the ball joint turns together with the nut, use a socket hexagon wrench 6 to holdthe stud.
43. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT:
The separation procedure for the RH side is the same as that for the LH side.
44. REMOVE FRONT AXLE ASSEMBLY LH
1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting between the drive shaft and front axle.
HINT:
If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass bar and hammer.
2. Push the front axle out of the vehicle to remove the drive shaft from the frontaxle.
NOTICE:
• Do not push the front axle further out of the vehicle than is necessary.
• Do not damage the outboard joint boot.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 299/614
• Do not damage the speed sensor rotor.
• Suspend the drive shaft with a piece of string or the equivalent.
45. REMOVE FRONT AXLE ASSEMBLY RH
HINT:
The removal procedure for the RH side is the same as that for the LH side.
46. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
1. Using SST, remove the drive shaft.
SST09520-01010
09520-24010 (09520-32040)
NOTICE:
• Do not damage the oil seal.
• Do not damage the inboard joint boot.
•
Do not drop the drive shaft.
47. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 300/614
1.
Using a screwdriver and hammer, remove the drive shaft.
NOTICE:
• Do not damage the oil seal.
• Do not damage the inboard joint boot.
• Do not drop the drive shaft.
48. SUSPEND ENGINE ASSEMBLY (for 1KR-FE)
1. Install the 2 hangers in the correct direction.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 301/614
Parts No.:
No. 1 engine hanger 12281-40030 No. 2 engine hanger 12282-40010
Bolt 91671-80820
Torque:
28 N*m 286 kgf*cm , 21 ft.*lbf
2. Attach the engine chain hoist to the hangers.
NOTICE:
Do not attempt to hang the engine by hooking the chain to any other part.
49. SUSPEND ENGINE ASSEMBLY (for 2SZ-FE)
1. Install the 2 hangers in the correct direction.
Parts No.:
No. 1 engine hanger 12281-23021 No. 2 engine hanger 12282-23010
Bolt 91671-80820
Torque:
35 N*m 357 kgf*cm , 26 ft.*lbf
2. Attach the engine chain hoist to the hangers.
NOTICE:
Do not attempt to hang the engine by hooking the chain to any other part.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 302/614
50. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
1. Remove the bolt and separate the engine moving control rod.
2. Support the front suspension crossmember with a transmission jack.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 303/614
3. Remove the 6 bolts and remove the suspension crossmember.
51. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING CONTROL BRACKET
1. Remove the 3 bolts and the engine moving control rod bracket.
52. SUPPORT MULTI-MODE MANUAL TRANSAXLE ASSEMBLY
1. Support the multi-mode manual transaxle with a transmission jack.
53. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for1KR-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 304/614
1. Remove the bolt and nut, then separate the engine mounting insulator LH.
2. Remove the 4 bolts and the engine mounting insulator LH.
54. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZ-
FE)
1. Remove the bolt and nut, then separate the engine mounting insulator LH.
2. Remove the 5 bolts and the engine mounting insulator LH.
55. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KR-
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 305/614
FE)
1. Remove the 4 bolts and the engine mounting bracket LH.
56. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZ-FE)
1. Remove the 4 bolts and the engine mounting bracket LH.
57. REMOVE MULTI-MODE MANUAL TRANSAXLE ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 306/614
1. Remove the 9 bolts and multi-mode manual transaxle from the engine.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 307/614
MULTI-MODE MANUALTRANSAXLE ASSEMBLY >
INSTALLATION
for Preparation
1. INSTALL MULTI-MODE MANUAL TRANSAXLE ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 308/614
1. Align the input shaft with the clutch disc and install the manual transaxle onto the
engine.
2. Install the 9 bolts.
Torque:
64 N*m 653 kgf*cm , 47 ft.*lbf for bolt A39 N*m 398 kgf*cm , 29 ft.*lbf for bolt B
NOTICE:
• Insert dowel pins into dowel holes securely so that the end face of
transaxle assembly fits close against engine assembly before tightening the
bolts between the engine and transaxle.
•
Make sure that the dowel pins are not loose, bent, damaged or scratched
and then install the transaxle onto the engine with the contact surfaces of
the engine and transaxle flat against each other.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 309/614
2. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KR-FE)
1. Install the engine mounting bracket LH with the 4 bolts.
Torque:
64 N*m 653 kgf*cm , 47 ft.*lbf
3. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZ-FE)
1. Install the engine mounting bracket LH with the 4 bolts.
Torque:
64 N*m 653 kgf*cm , 47 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 310/614
4. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 1KR-
FE)
1.
Install the engine mounting insulator LH with the 4 bolts.
Torque:52 N*m 530 kgf*cm , 38 ft.*lbf for bolt A
64 N*m 653 kgf*cm , 47 ft.*lbf for bolt B
2. Install the engine mounting bracket LH and engine mounting insulator LH with
the bolt and nut.
Torque:52 N*m 530 kgf*cm , 38 ft.*lbf for nut C
5. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZ-
FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 311/614
1. Install the engine mounting insulator LH with the 5 bolts.
Torque:
52 N*m 530 kgf*cm , 38 ft.*lbf
2. Install the engine mounting bracket LH and engine mounting insulator LH with
the bolt and nut.
Torque:
52 N*m 530 kgf*cm , 38 ft.*lbf
6. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING CONTROL BRACKET
1. Install the engine mounting control bracket with the 3 bolts.
Torque:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 312/614
39 N*m 398 kgf*cm , 29 ft.*lbf
7. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
1. Support the front suspension crossmember with a transmission jack.
2. Provisionally install the front suspension crossmember onto the body with the 6 bolts.
Bolt Underhead Length (mm)A 38
B 99
C 45
3. By inserting SST into the datum holes in the front suspension crossmembers RHand LH alternately, tighten bolts A, B and C on both sides to the specified torque,
in several steps.
SST
09670-00011Torque:
70 N*m 714 kgf*cm , 52 ft.*lbf for Bolt A
160 N*m 1,631 kgf*cm , 118 ft.*lbf for Bolt B95 N*m 969 kgf*cm , 70 ft.*lbf for Bolt C
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 313/614
NOTICE:
• Insert SST into the datum hole in a vertical orientation.
• If SST can not be inserted into the datum hole vertically, loosen all the
bolts and then insert SST again.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 314/614
4. Install the engine moving control rod with the bolt.
Torque:120 N*m 1,224 kgf*cm , 89 ft.*lbf
8. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
1. Coat the spline of the inboard joint with gear oil.
2. Align the inboard joint splines and install the drive shaft with a screwdriver and
hammer.
NOTICE:
• Face the cut area of the front drive inboard joint hole snap ring downward.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 315/614
• Do not damage the oil seal.
• Do not damage the inboard joint boot.
HINT:
Confirm whether the drive shaft is securely driven in by checking the reaction
force and sound.
9. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
HINT:
The installation procedure for the RH side is the same as that for the LH side.
10. INSTALL FRONT AXLE ASSEMBLY LH
1. Push the front axle out of the vehicle to align the spline of the drive shaft with the
front axle and insert the front axle.
NOTICE:
• Do not push the front axle further out of the vehicle than is necessary.
• Do not damage the outboard joint boot.
• Check for any foreign matter on the speed sensor rotor and insertion part.
• Do not damage the speed sensor rotor.
11. INSTALL FRONT AXLE ASSEMBLY RH
HINT:
The installation procedure for the RH side is the same as that for the LH side.
12. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 316/614
1. Install the stabilizer link with the nut.
Torque:74 N*m 755 kgf*cm , 55 ft.*lbf
HINT:
If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold
the stud.
13. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
The installation procedure for the RH side is the same as that for the LH side.
14. INSTALL TIE ROD END SUB-ASSEMBLY LH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 317/614
1. Install the tie rod end onto the steering knuckle with a new castle nut.
Torque:49 N*m 500 kgf*cm , 36 ft.*lbf
NOTICE:
If the holes for the clip are not aligned, tighten the nut by a further turn of up to60°.
2. Install a new cotter pin.
15. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT:
The installation procedure for the RH side is the same as that for the LH side.
16. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
1. Install the lower arm onto the steering knuckle with a new castle nut.
Torque:98 N*m 1,000 kgf*cm , 72 ft.*lbf
NOTICE:
If the holes for the clip are not aligned, tighten the nut by a further turn of up to60°.
2. Install a new clip.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 318/614
17. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH
HINT:
The installation procedure for the RH side is the same as that for the LH side.
18. INSTALL SPEED SENSOR FRONT LH
1. Install the speed sensor onto the steering knuckle with the bolt.
Torque:
8.5 N*m 87 kgf*cm , 75 in.*lbf NOTICE:
• Check that the speed sensor tip and installation portion are free of foreignmatter.
• Install the speed sensor without turning it from its original installation
angle.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 319/614
2. Install the flexible hose and speed sensor with the bolt.
Torque:
29 N*m 300 kgf*cm , 22 ft.*lbf NOTICE:
Install the flexible hose and speed sensor without twisting them.
19. INSTALL SPEED SENSOR FRONT RH
HINT:
The installation procedure for the RH side is the same as that for the LH side.
20. INSTALL FRONT AXLE SHAFT LH NUT
1. Using a 30 mm socket wrench, install a new axle hub nut.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 320/614
Torque:
216 N*m 2,203 kgf*cm , 160 ft.*lbf
2. Using a chisel and hammer, caulk the axle hub nut.
21. INSTALL FRONT AXLE SHAFT RH NUT
HINT:The installation procedure for the RH side is the same as that for the LH side.
22. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 1KR-FE)
1. Using vernier calipers, measure the free length of the compression spring.
Minimum length (Front Side):
40.5 mm (1.594 in.)Minimum length (Rear Side):
38.5 mm (1.516 in.)
If the length is not as specified, replace the compression spring.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 321/614
2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket
until its surface is flush with the exhaust manifold.
NOTICE:
• Install the exhaust pipe gasket in the correct direction.
• Do not damage the outer surface of the exhaust pipe gasket.
• Do not reuse the exhaust pipe gasket.
• Do not push in the gasket with the exhaust pipe when connecting it.
3. Install the 3 exhaust pipe support No. 4.
4. Install the exhaust front pipe assembly and a new exhaust pipe gasket with the 4compression springs and 4 bolts.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 322/614
Torque:
43 N*m 439 kgf*cm , 32 ft.*lbf
23. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2SZ-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 323/614
1. Using vernier calipers, measure the free length of the compression spring.
Minimum length:40.5 mm (1.594 in.)
If the length is not as specified, replace the compression spring.
2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket
until its surface is flush with the exhaust manifold.
NOTICE:
•
Install the exhaust pipe gasket in the correct direction.
• Do not damage the outer surface of the exhaust pipe gasket.
• Do not reuse the exhaust pipe gasket.
• Do not push in the gasket with the exhaust pipe when connecting it.
3. Install the 3 No. 4 exhaust pipe supports.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 324/614
4. Install the exhaust pipe assembly front with the 2 compression springs and 2 bolts.
Torque:43 N*m 439 kgf*cm , 32 ft.*lbf
24. INSTALL STARTER ASSEMBLY (for 1KR-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 325/614
1. Install the starter assembly with the 2 bolts.
Torque:
37 N*m 377 kgf*cm , 27 ft.*lbf
2. Connect the connector.
3. Connect terminal 30 with the nut.
Torque:
9.8 N*m 100 kgf*cm , 87 in.*lbf
4. Close the terminal cap.
5.
Install the harness clamp.
25. INSTALL STARTER ASSEMBLY (for 2SZ-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 326/614
1. Install the starter assembly with the 2 bolts.
Torque:
37 N*m 377 kgf*cm , 27 ft.*lbf
2. Connect the connector.
3. Connect terminal 30 with the nut.
Torque:
9.8 N*m 100 kgf*cm , 87 in.*lbf
4. Close the terminal cap.
26. CONNECT CONNECTOR
1. Connect the shift and select motor connectors.
2. Connect the neutral start switch connector.
3. Connect the back-up light switch connector.
4.
Connect the transmission revolution sensor connector.
5. Connect the select stroke sensor connector.
6. Connect the shift stroke sensor connector.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 327/614
27. CONNECT WIRE HARNESS
1. Connect the wire harness with the bolt.
Torque:
26 N*m 260 kgf*cm , 19 ft.*lbf
28. INSTALL CLUTCH ACTUATOR ASSEMBLY NOTICE:
Perform the following procedure ((1) to (5)) to set a new clutch actuator in the
clutch clamp position because it is not originally placed in that position.(1) Connect the clutch stroke sensor connector and motor connector to the clutch
actuator.
(2) Connect the battery negative terminal.(3) Perform clutch position adjustment (clutch clamp position)
()
(4) Disconnect the battery negative terminal.(5) Disconnect the clutch stroke sensor connector and motor connector.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 328/614
1. Apply grease to the clutch release lever.
Sealant:
Toyota Genuine Release Hub Grease or Equivalent
2. Set the clutch actuator to the transaxle and provisionally tighten the 3 bolts.
NOTICE:
Keep the clearance between the bolt head and actuator flange.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 329/614
3. Gently hold down the clutch actuator assembly toward flat surface of transmission
assembly and slide it so that the convex portion of the clutch actuator rod comes
into contact with the concave portion of the release lever.
NOTICE:
• Do no apply excessive load to them during the operation.
• Make sure that the convex portion of the clutch actuator rod is securely
fitted into the concave portion of the release lever.
• 1KR-FE and 2SZ-FE clutch actuators have their own discrimination stamp
on the housing upper.
Engine Discrimination Color
1KR-FE Green
2SZ-FE Blue
4. Tighten the 3 bolts by hand while holding the clutch actuator assembly.
NOTICE:
Support the clutch actuator assembly until all the 3 bolts are tightened.
5. Tighten the 3 bolts to the specified torque in the order A, B, and C, as shown.
Torque:17 N*m 173 kgf*cm , 13 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 330/614
6. Connect the clutch stroke sensor connector and motor connector.
7. Install the wire harness bracket onto the transaxle with the bolt.
Torque:
13 N*m 131 kgf*cm , 9.5 ft.*lbf
29. INSTALL BATTERY CARRIER (for 1KR-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 331/614
1. Install the battery carrier with the 4 bolts.
Torque:17 N*m 175 kgf*cm , 13 ft.*lbf
30. INSTALL BATTERY CARRIER (for 2SZ-FE)
1. Install the battery carrier with the 5 bolts.
Torque:17 N*m 175 kgf*cm , 13 ft.*lbf
31. INSTALL BATTERY TRAY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 332/614
32. INSTALL BATTERY
33. INSTALL BATTERY HOLD DOWN CLAMP
34. INSTALL AIR CLEANER INLET NO.1 (for 2SZ-FE)
1. Install the air cleaner inlet No. 1.
35. INSTALL COWL TOP PANEL OUTER
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 333/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 334/614
1. Engage the 2 claws and install cowl to register duct No. 2.
37. INSTALL FR WIPER MOTOR AND LINK ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 335/614
1. Connect the connector.
2. Slide the wiper link as shown in the illustration and engage the rubber pin with
the body.
3. Install the front wiper motor and link with the 2 bolts.
Torque:
5.5 N*m 56 kgf*cm , 49 in.*lbf
38. INSTALL COWL TOP VENTILATOR LOUVER LH (for LHD)
1. Engage the 4 claws and install the cowl top ventilator louver LH.
2. Install the 2 clips.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 336/614
39. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for LHD)
1. Connect the washer hose.
2.
Engage the 11 claws and install the cowl top ventilator louver sub-assembly.
3. Install the clip.
4. Connect the washer hose.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 337/614
5. Engage the 2 hooks and install cowl top ventilator louver center No. 1.
40. INSTALL COWL TOP VENTILATOR LOUVER LH (for RHD)
1.
Engage the 4 claws and install the cowl top ventilator louver LH.
2. Install the clip.
41. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for RHD)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 338/614
1. Engage the 10 claws and install the cowl top ventilator louver sub-assembly.
2. Install the clip.
3. Connect the washer hose.
42. INSTALL HOOD TO COWL TOP SEAL
1. Engage the 7 clips and install the hood to cowl top seal.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 339/614
43. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
1. Scrape any metal powder off the serrated part of the wiper arm with a round file
or the equivalent (when reinstalling).
2. Clean the wiper pivot serrations with a wire brush.
3. Operate the wiper, then stop the windshield wiper motor in the automatic stop
position.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 340/614
4. Align the blade tip with the mark on the windshield glass, as shown in the
illustration.
5. Tighten the nut of the front wiper arm.
Torque:
26 N*m 265 kgf*cm , 19 ft.*lbf
44. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 341/614
1. Scrape any metal powder off the serrated part of the wiper arm with a round file
or the equivalent (when reinstalling).
2. Clean the wiper pivot serrations with a wire brush.
3. Operate the wiper, then stop the windshield wiper motor in the automatic stop
position.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 342/614
4. Align the blade tip with the mark on the windshield glass, as shown in the
illustration.
5. Tighten the nut of the front wiper arm.
Torque:
26 N*m 265 kgf*cm , 19 ft.*lbf
45. INSTALL HOOD SUB-ASSEMBLY
46. INSPECT HOOD SUB-ASSEMBLY
1.
Check that the clearance measurements are within the standard ranges.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 343/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 344/614
(0.297 to 0.533 in.) (0.079 to 0.197 in.)
F1.65 to 5.65 mm
(0.065 to 0.222 in.)- -
47. ADJUST HOOD SUB-ASSEMBLY
1. Loosen the hood side hinge bolts.
2. Move the hood to adjust the clearance to within the standard range.
3.
Tighten the hood side hinge bolts after the adjustment.
Torque:
13 N*m 133 kgf*cm , 10 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 345/614
4. Adjust the height of the hood front end by turning the cushion rubber.
HINT:The cushion rubber can be raised and lowered by turning it.
5. Adjust the hood lock.
1. Loosen the 3 bolts.
2. Adjust the hood lock position so that the striker can enter it smoothly.
3. Tighten the 3 bolts after the adjustment.
Torque:
7.5 N*m 76 kgf*cm , 66 in.*lbf
48. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 346/614
1. Align the matchmarks and install the sliding yoke onto the intermediate shaft.
Torque:28 N*m 290 kgf*cm , 21 ft.*lbf
2.
Tighten bolt A.
Torque:
28 N*m 290 kgf*cm , 21 ft.*lbf
49. INSTALL COLUMN HOLE COVER SILENCER SHEET
1. Install the column hole cover silencer sheet with the 2 clips.
2. Install the floor carpet.
50. ADD TRANSAXLE OIL
51. INSPECT AND ADJUST TRANSAXLE OIL
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 347/614
1. Stop the vehicle on a level place.
2. Remove the filler plug and gasket.
3.
Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of thefiller plug opening.
NOTICE:
• An excessively large or small amount of oil may cause problems.
• After replacing the oil, drive the vehicle and check the oil level again.
4. When the oil level is low, check for oil leakage.
5. Install the filler plug and a new gasket.
Torque:
39 N*m 400 kgf*cm , 29 ft.*lbf
52. INSTALL ENGINE UNDER COVER RH
53. INSTALL ENGINE UNDER COVER LH
54. INSTALL FRONT WHEELS
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 348/614
55. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque:
5.4 N*m 55 kgf*cm , 48 in.*lbf
56. INITIALIZATION OF MULTI-MODE MANUAL TRANSAXLE ECU
()
57. LEARNING OF MULTI-MODE MANUAL TRANSAXLE SYSTEM
()
58. SYNCHRONIZATION POSITION CALIBRATION
()
59. INSPECT ABS SPEED SENSOR SIGNAL
()
60. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
()
61. CHECK FOR EXHAUST GAS LEAKAGE
62. CHECK FOR TRANSAXLE OIL LEAKAGE
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 349/614
MULTI-MODE MANUAL
TRANSAXLE UNIT >COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 350/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 351/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 352/614
1 / 3
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 353/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 354/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 355/614
2 / 3
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 356/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 357/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 358/614
3 / 3
MULTI-MODE MANUAL
TRANSAXLE UNIT >
DISASSEMBLY
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 359/614
1. REMOVE SHIFT STROKE SENSOR
2. REMOVE CLUTCH RELEASE FORK
3. REMOVE CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL
4. INSPECT NEUTRAL POSITION
1. Remove the plug from the shift and select actuator.
2. Look through the plug and check that the slit of the shift and select shaft is in the position shown in the illustration.
If not, turn it with a screwdriver.
5. REMOVE LOCK BALL ASSEMBLY NO.1
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 360/614
1. Using an 18 mm socket wrench, remove the lock ball assembly from the transaxle
case.
6. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Using SST, remove the park/neutral position switch with the gasket from the
transaxle case.
SST
09817-16011
7. REMOVE SHIFT AND SELECT ACTUATOR ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 361/614
1.
Remove the 6 bolts.
2. Tap the actuator flange with a plastic hammer to remove it.
8. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
1. Using SST, remove the back-up light switch with the gasket from the transaxle
case.
SST
09817-16011
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 362/614
9. REMOVE TRANSMISSION REVOLUTION SENSOR
1. Remove the bolt and transmission case protector.
2. Remove the bolt and transmission revolution sensor.
3. Using a small screwdriver, remove the O-ring from the transmission revolution
sensor.
10. REMOVE REVERSE IDLER GEAR SHAFT BOLT
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 363/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 364/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 365/614
3. Remove gear shift head No.1 and gear shift fork No. 1.
4. Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork
shaft No. 1.
14. REMOVE GEAR SHIFT FORK SHAFT NO.3
1. Using a magnetic finger, remove the straight pin from gear shift fork No. 3.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 366/614
2. Using 2 screwdrivers and a hammer, remove the 2 snap rings from gear shift fork
shaft No. 3.
3. Cover gear shift fork shaft No.3 with a piece of cloth gear shift fork shaft No. 3 atthe upper edge with pliers as shown in the illustration, and pull gear shift fork
shaft No. 3 out of the transaxle case to remove gear shift fork No. 3, compression
spring and gear shift head No. 3.
15. REMOVE REVERSE IDLER GEAR SHAFT
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 367/614
1. Remove the reverse idler gear shaft from the transaxle case.
16. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
1. Remove the 2 bolts and reverse shift arm bracket from the transaxle case.
17. REMOVE GEAR SHIFT FORK SHAFT NO.2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 368/614
1. Using a magnetic finger, remove the straight pin from the reverse shift fork.
2. Shift hub sleeve No. 2 into the 3rd gear, as shown.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 369/614
3. Remove the set bolt from gear shift fork No. 2.
4. Pull out gear shift fork snap rings, gear shift fork and the reverse shift fork from
the transaxle case.
5. Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork
shaft No. 2.
6. Remove the reverse shift fork from gear shift fork shaft No. 2.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 370/614
7. Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork
shaft No. 2.
8.
Remove gear shift fork No. 2 from gear shift fork shaft No. 2.
18. REMOVE INPUT SHAFT
1. Remove the input shaft assembly from the manual transaxle case.
19. REMOVE OUTPUT SHAFT
1. Remove the output shaft assembly from the manual transaxle case.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 371/614
20. REMOVE FRONT DIFFERENTIAL CASE
1. Remove the differential case assembly from the front transaxle case.
21. REMOVE OIL RECEIVER PIPE NO. 2
1. Remove the oil receiver pipe No. 2 from the manual transmission case.
NOTICE:Do not damage oil receiver pipe No. 2.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 372/614
22. REMOVE TRANSMISSION MAGNET
1. Remove the transmission magnet from the front transaxle case.
23. REMOVE FRONT TRANSAXLE CASE OIL SEAL
1. Using a screwdriver, remove the front transaxle case oil seal.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 373/614
24. REMOVE OUTPUT SHAFT FRONT BEARING
1. Using SST, remove the output shaft front bearing (outer race) from the front
transaxle case.
SST
09308-00010
25. REMOVE OUTPUT SHAFT COVER
1. Remove the output shaft cover from the front transaxle case.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 374/614
26. REMOVE TRANSMISSION CASE OIL SEAL
1. Using a screwdriver, remove the transmission case oil seal.
27. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the front differential case rear tapered roller bearing and the
shim.
SST
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 375/614
09950-60010 (09951-00560)
09950-70010 (09951-07200)
28. REMOVE TRANSAXLE CASE OIL SEAL
1. Using a screwdriver, remove the transaxle case oil seal from the front transaxle
case.
29. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 376/614
1. Using a brass bar and hammer, remove the front differential case front tapered
roller bearing.
30. REMOVE INPUT SHAFT REAR BEARING SHIM
1. Remove the input shaft rear bearing shim.
31. REMOVE OUTPUT SHAFT REAR BEARING
1. Using SST, remove the output shaft rear bearing.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 377/614
SST
09527-3001009612-65014 (09612-01030, 09612-01050)
32. REMOVE OUTPUT SHAFT REAR BEARING SHIM
1. Remove the output shaft rear bearing shim.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 378/614
MULTI-MODE MANUAL
TRANSAXLE UNIT > INSPECTION
for Preparation
1. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
1.
Using a micrometer, measure the outer diameter of the reverse idler gear shaft.
Standard outer diameter:15.97 to 15.98 mm (0.6287 to 0.6291 in.)
Minimum outer diameter:
15.97 mm (0.6287 in.)
If the outer diameter is less than the minimum, replace the reverse idler gear shaft.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 379/614
2. Using a caliper gauge, measure the inside diameter of the reverse idler gear.
Standard inside diameter:16.04 to 16.05 mm (0.6315 to 0.6319 in.)
Maximum inside diameter:
16.05 mm (0.6319 in.)
If the inside diameter exceeds the maximum, replace the reverse idler gear.
2. INSPECT REVERSE SHIFT FORK
1. Using a caliper gauge, measure the inside diameter of the reverse shift fork.
Standard inside diameter:
14.27 to 14.42 mm (0.5591 to 0.5677 in.) for A
14.01 to 14.03 mm (0.5516 to 0.5524 in.) for BMaximum inside diameter:
14.42 mm (0.5677 in.) for A14.03 mm (0.5524 in.) for B
If the inside diameter exceeds the maximum, replace the reverse shift fork.
3. INSPECT GEAR SHIFT FORK SHAFT NO.1
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 380/614
1. Using a micrometer, measure the outer diameter of gear shift fork shaft No. 1.
Standard outer diameter:13.97 to 13.98 mm (0.5500 to 0.5504 in.)
Minimum outer diameter:
13.97 mm (0.5500 in.)
If the outer diameter is less than the minimum, replace gear shift fork shaft No. 1.
4. INSPECT GEAR SHIFT FORK SHAFT NO.2
1. Using a micrometer, measure the outer diameter of gear shift fork shaft No. 2.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 381/614
Standard outer diameter:
13.97 to 13.98 mm (0.5500 to 0.5504 in.)Minimum outer diameter:
13.97 mm (0.5500 in.)
If the outer diameter is less than the minimum, replace gear shift fork shaft No. 2.
5. INSPECT GEAR SHIFT FORK SHAFT NO.3
1. Using a micrometer, measure the outer diameter of gear shift fork shaft No. 3.
Standard outer diameter:
13.97 to 13.98 mm (0.5500 to 0.5504 in.)Minimum outer diameter:
13.97 mm (0.5500 in.)
If the outer diameter is less than the minimum, replace gear shift fork shaft No. 3.
6. INSPECT GEAR SHIFT FORK NO.1
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 382/614
1. Using vernier calipers, measure the inside diameter of gear shift fork No. 1.
Standard inside diameter and thickness:9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A
9.9 to 10.0 mm (0.3898 to 0.3937 in.) for B
14.00 to 14.02 mm (0.5512 to 0.5520 in.) for C
If the inside diameter and thickness are outside the specifications, replace gear
shift fork No. 1.
7. INSPECT GEAR SHIFT FORK NO.2
1. Using vernier calipers, measure the inside diameter of gear shift fork No. 2.
Standard inside diameter and thickness:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 383/614
9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A
14.00 to 14.02 mm (0.5512 to 0.5520 in.) for B
If the inside diameter and thickness are outside the specifications, replace gear
shift fork No. 2.
8. INSPECT GEAR SHIFT FORK NO.3
1. Using vernier calipers, measure the inside diameter of gear shift fork No. 3.
Standard inside diameter and thickness:
9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A14.00 to 14.02 mm (0.5512 to 0.5520 in.) for B
If the inside diameter and thickness are outside the specifications, replace gear
shift fork No. 3.
9. INSPECT GEAR SHIFT HEAD NO.1
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 384/614
1. Using vernier calipers, measure the inside diameter of gear shift head No. 1.
Standard inside diameter:14.00 to 14.05 mm (0.5512 to 0.5531 in.)
Maximum inside diameter:14.05 mm (0.5531 in.)
If the inside diameter exceeds the maximum, replace gear shift head No. 1.
10. INSPECT GEAR SHIFT HEAD NO.3
1. Using vernier calipers, measure the inside diameter of gear shift head No. 3.
Standard inside diameter:14.00 to 14.05 mm (0.5512 to 0.5531 in.) for A
14.2 to 14.4 mm (0.5591 to 0.5669 in.) for B
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 385/614
Maximum inside diameter:
14.05 mm (0.5531 in.) for A14.4 mm (0.5669 in.) for B
If the inside diameter exceeds the maximum, replace gear shift head No. 3.
MULTI-MODE MANUALTRANSAXLE UNIT >
REASSEMBLY
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 386/614
1. INSTALL TRANSAXLE CASE STRAIGHT PIN
1. Install the transaxle case straight pin.
Standard depth:10.5 to 11.5 mm (0.4134 to 0.4528 in.)
2. INSTALL OUTPUT SHAFT COVER
1. Install the output shaft cover as shown in the illustration.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 387/614
3. INSTALL OUTPUT SHAFT FRONT BEARING
1. Using SST and a press, press in the output shaft front bearing (outer race).
SST09950-60010 (09951-00510)
09950-70010 (09951-07150)
4. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, press in the front differential case front tapered roller
bearing (outer race).
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 388/614
SST
09350-32014 (09351-32111, 09351-32130)
5. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Install the shim onto the manual transmission case.
HINT:
When re-using the output shaft rear tapered roller bearing, first install a shim ofthe same thickness as before. If installing a new output shaft rear tapered roller
bearing, first select and install a shim which is thinner than the original.
2. Using SST and a press, press in the FR differential case rear tapered roller bearing
(outer race).
SST
09950-60010 (09951-00620)
09950-70010 (09951-07100)
6. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 389/614
1. Coat the differential case assembly with gear oil, and install it onto the front
transaxle case.
2. Install the manual transmission case with the 13 bolts.
Torque:
29 N*m 300 kgf*cm , 22 ft.*lbf HINT:
Manual transmission case side: 8 bolts
Front transaxle case side: 5 bolts
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 390/614
3. 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
09564-32011
4. Using SST and a torque wrench, measure the preload.
SST
09564-32011
Preload (at starting): New bearing:
0.78 to 1.57 N*m (7.95 to 16.00 kgf*cm, 6.9 to 13.89 in.*lbf)
Used bearing:
0.49 to 0.98 N*m (5.00 to 9.99 kgf*cm, 4.3 to 8.67 in.*lbf)
5. Select another shim.
Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.)
AA 2.10 (0.0827) HH 2.45 (0.0965) QQ 2.80 (0.1102)
BB 2.15 (0.0847) JJ 2.50 (0.0984) RR 2.85 (0.1122)
CC 2.20 (0.0866) KK 2.55 (0.1004) SS 2.90 (0.1142)
DD 2.25 (0.0886) LL 2.60 (0.1024) TT 2.95 (0.1161)EE 2.30 (0.0906) MM 2.65 (0.1043) UU 3.00 (0.1181)
FF 2.35 (0.0925) NN 2.70 (0.1063) - -
GG 2.40 (0.0945) PP 2.75 (0.1083) - -
6. Remove the 13 bolts and the manual transmission case from the front transaxle
case.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 391/614
7. Remove the differential case assembly from the front transaxle case.
7. INSTALL OUTPUT SHAFT REAR BEARING
1. Install the output shaft rear bearing shim onto the manual transmission case.
HINT:
When re-using the output shaft rear tapered roller bearing, first install a shim of
the same thickness as before. If installing a new output shaft rear tapered roller bearing, first select and install a shim which is thinner than the original.
2. Using SST and a press, press in the output shaft rear bearing (outer race).
SST
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 392/614
09950-60010 (09951-00570)
09950-70010 (09951-07200)
8. ADJUST OUTPUT SHAFT BEARING PRELOAD
1. Install the output shaft assembly and the differential case assembly onto the front
transaxle case.
2. Install the manual transmission case onto the front transaxle case with the 13
bolts.
Torque:
29 N*m 300 kgf*cm , 22 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 393/614
3. Using SST and a torque wrench, turn the output shaft assembly and differential
case assembly right and left 2 or 3 times to allow the bearings to settle.
SST
09564-32011
4. Using SST and a torque wrench, measure the preload.
SST
09564-32011
Preload (at starting):
New bearing:
3.46 to 6.91 N*m (35.3 to 70.5 kgf*cm, 30.6 to 61.2 in.*lbf) for 1KR-FE3.18 to 6.35 N*m (32.4 to 64.7 kgf*cm, 28.1 to 56.2 in.*lbf) for 2SZ-FE
Used bearing:2.16 to 4.32 N*m (22.0 to 44.1 kgf*cm, 19.1 to 38.2 in.*lbf) for 1KR-FE
1.98 to 3.97 N*m (20.2 to 40.5 kgf*cm, 17.5 to 35.1 in.*lbf) for 2SZ-FE
5. Select another output shaft rear bearing shim.
MarkThickness
mm (in.)Mark
Thickness
mm (in.)
A 1.55(0.0610) J 1.95(0.0768)
B1.60
(0.0630)K
2.00
(0.0787)
C1.65
(0.0650)L
2.05(0.0807)
D 1.70 M 2.10
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 394/614
(0.0669) (0.0827)
E1.75
(0.0689) N
2.15
(0.0846)
F1.80
(0.0709)P
2.20(0.0866)
G1.85
(0.0728)Q
2.25
(0.0886)
H1.90
(0.0748)
6. Remove the 13 bolts and the manual transmission case from the front transaxle
case.
7. Remove the output shaft assembly from the front transaxle case.
8. Remove the differential case assembly from the front transaxle case.
9. INSTALL INPUT SHAFT REAR BEARING SHIM
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 395/614
1. Using vernier calipers, accurately measure dimensions A and B.
2.
Select an input shaft rear bearing shim that brings the value within thespecifications.
Shim thickness:
Shim thickness (B - A) should be more than 0 mm (0 in.) and less than 0.1 mm
(0.0039 in.)
MarkThickness
mm (in.)Mark
Thickness
mm (in.)
F1.80
(0.0709) N
2.15
(0.0846)
G 1.85(0.0728)
P 2.20(0.0866)
H1.90
(0.0748)Q
2.25
(0.0886)
J1.95
(0.0768)R
2.30(0.0906)
K 2.00 S 2.35
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 396/614
(0.0787) (0.0925)
L2.05
(0.0807)T
2.40
(0.0945)
M2.10
(0.0827)- -
3. Install the input shaft rear bearing shim.
10. INSTALL TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, install a new transmission case oil seal into the manual
transmission case.
SST
09950-60010 (09951-00370)09950-70010 (09951-07150)
Drive in depth:
2.1 to 3.1 mm (0.083 to 0.122 in.)
2.
Coat the tip of the transmission oil seal with MP grease.
11. INSTALL TRANSAXLE CASE OIL SEAL
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 397/614
1. Using SST and a hammer, install the transaxle case oil seal to the front transaxle
case.
SST
09316-60011 (09316-00011)
Drive in depth:1.7 to 2.7 mm (0.067 to 0.106 in.)
2. Coat the tip of the transmission case oil seal with MP grease.
12. INSTALL FRONT TRANSAXLE CASE OIL SEAL
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 398/614
1. Using SST and a hammer, install the front transaxle case oil seal into the front
transaxle case.
SST
09710-20011 (09710-06071)
09950-70010 (09951-07150)Drive in depth:14.4 to 15.4 mm (0.567 to 0.606 in.)
2. Coat the tip of the front transaxle case oil seal with MP grease.
13. INSTALL TRANSMISSION MAGNET
1. Clean the transmission magnet and then install it onto the front transaxle case.
14. INSTALL OIL RECEIVER PIPE NO. 2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 399/614
1. Install oil receiver pipe No. 2 onto the manual transmission case.
NOTICE:Do not damage oil receiver pipe No. 2.
15. INSTALL FRONT DIFFERENTIAL CASE
1. Coat the differential case tapered roller bearings with gear oil, and install themonto the front transaxle case.
16. INSTALL OUTPUT SHAFT
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 400/614
1. Install the output shaft assembly onto the front transaxle case.
17. INSTALL INPUT SHAFT
1. Coat the sliding and rotating surfaces of the input and output shafts assembly with
gear oil, and install them onto the front transaxle case.
18. INSTALL GEAR SHIFT FORK SHAFT NO.2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 401/614
1.
Install gear shift fork No. 2 onto gear shift fork shaft No. 2.
2. Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft
No. 2.
3. Install the reverse shift fork onto gear shift fork shaft No. 2.
4.
Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft
No. 2.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 402/614
5. Shift hub sleeve No. 2 into the 3rd gear, as shown.
6. Install gear shift fork shaft No. 2 with the 2 snap rings.
7. Install gear shift fork No.2 and reverse shift fork onto the transaxle case.
8. Set gear shift fork No. 2 onto hub sleeve No. 2.
9. Install the set bolt onto gear shift fork No. 2.
Torque:
16 N*m 160 kgf*cm , 12 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 403/614
10. Using a magnetic finger, install the straight pin into the reverse shift fork.
NOTICE:
Insert the straight pin along the groove on gear shift fork shaft No. 2, as shown inthe illustration.
19. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
1.
Install the reverse shift arm bracket onto the transaxle case with the 2 bolts.
Torque:
17 N*m 175 kgf*cm , 13 ft.*lbf NOTICE:
Fit the edge of the reverse shift fork into the hole in the reverse shift arm bracket.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 404/614
20. INSTALL REVERSE IDLER GEAR SHAFT
1. Coat the reverse idler gear shaft with gear oil, and install it onto the transmission
case.
NOTICE:
Set the top of the reverse shift arm bracket into the groove on the reverse idler
gear, as shown in the illustration.
2. Align the mark on the reverse idler gear shaft with the bolt hole, as shown in the
illustration.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 405/614
21. INSTALL GEAR SHIFT FORK SHAFT NO.3
1. Install gear shift fork No. 3, the compression spring and gear shift head No. 3 onto
gear shift fork shaft No. 3.
2. Install gear shift fork shaft No. 3 onto the transaxle case together with gear shift
fork No. 3, the compression spring and shift head No. 3.
3. Set gear shift fork No. 3 onto hub sleeve No. 3.
4. Using a screwdriver and hammer, tap 2 new snap rings onto gear shift fork shaft
No. 3.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 406/614
5. Using a magnetic finger, install the straight pin onto gear shift fork No. 3.
22. INSTALL GEAR SHIFT FORK SHAFT NO.1
1. Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft
No. 1.
2. Set gear shift fork No. 1 onto the reverse gear.
3. Set gear shift head No. 1 onto gear shift fork No. 1.
4. Install gear shift fork shaft No. 1 onto the transaxle case with the snap ring.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 407/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 408/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 409/614
2. Coat the 13 bolts with sealant.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
3. Install the transmission case onto the transaxle case with the 13 bolts.
Torque:
29 N*m 300 kgf*cm , 22 ft.*lbf
26. INSTALL REVERSE IDLER GEAR SHAFT BOLT
1. Apply sealant to the reverse idler gear shaft lock bolt threads.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 410/614
2. Install the reverse idler gear shaft lock bolt with a new gasket.
Torque:29 N*m 300 kgf*cm , 22 ft.*lbf
27. INSTALL TRANSMISSION REVOLUTION SENSOR
1. Install a new O-ring onto the transmission revolution sensor.
2. Install the transmission revolution sensor with the bolt.
Torque:
7.8 N*m 80 kgf*cm , 69 in.*lbf
3. Install the transmission case protector with the bolt.
Torque:18 N*m 185 kgf*cm , 13 ft.*lbf
28. INSTALL SHIFT AND SELECT ACTUATOR ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 411/614
1. Apply FIPG to the transmission case as shown.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
2. Apply sealant to the actuator set bolt threads.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
3. Install the shift and select actuator with the 6 bolts and wire harness clamp.
Torque:
18 N*m 184 kgf*cm , 13 ft.*lbf
29. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 412/614
1. Using SST, install the park/neutral position switch with a new gasket onto thetransaxle case.
Torque:
40 N*m 410 kgf*cm , 30 ft.*lbf SST
09817-16011
30. INSTALL LOCK BALL ASSEMBLY NO.1
1. Apply sealant to the lock ball assembly threads.
Sealant:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 413/614
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
2. Using an 18 mm socket wrench, install the lock ball assembly onto the
transmission case.
Torque:37 N*m 375 kgf*cm , 27 ft.*lbf
31. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
1.
Using SST, install the back-up light switch with a new gasket onto the transaxlecase.
SST
09817-16011
Torque:40 N*m 410 kgf*cm , 30 ft.*lbf
32. INSTALL CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL
33. INSTALL CLUTCH RELEASE FORK
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 414/614
34. INSTALL SHIFT STROKE SENSOR
INPUT SHAFT > COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 415/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 416/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 417/614
1 / 2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 418/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 419/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 420/614
2 / 2
INPUT SHAFT > DISASSEMBLY
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 421/614
1. INSPECT 3RD GEAR THRUST CLEARANCE
1.
Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum clearance:0.35 mm (0.0138 in.)
If the clearance exceeds the maximum, replace the 3rd gear synchronizer ring.
2. INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 5th gear thrust clearance.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 422/614
Standard clearance:
0.10 to 0.50 mm (0.0039 to 0.0197 in.)Maximum clearance:
0.50 mm (0.0197 in.)
If the clearance exceeds the maximum, replace the 5th gear synchronizer ring.
3. INSPECT 3RD GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 3rd gear radial clearance.
Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing
or the shaft.
4. INSPECT 4TH GEAR RADIAL CLEARANCE
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 423/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 424/614
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 5th gear needle roller bearing
or the shaft.
6. REMOVE 5TH GEAR
1.
Using SST and a press, remove the input shaft rear radial ball bearing, hub sleeve
No. 3, 5th gear synchronizer ring and 5th gear from the input shaft.
SST
09950-00020
09612-24014 (09612-10061)HINT:
• Support the input shaft by hand to prevent it from dropping off.
• Set the claw of SST between the 4th gear and 5th gear, as shown in the
illustration.
NOTICE:
Do not excessively tighten SST.
7. REMOVE TRANSMISSION CLUTCH HUB NO.3
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 425/614
1. Remove the 2 shifting key springs No. 1 from the transmission clutch hub No. 3.
2. Remove the transmission hub sleeve No. 3 from the transmission clutch hub No.
3.
3. Remove the 3 shifting keys No. 3 from the transmission clutch hub No. 3.
8. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
1. Remove the 5th gear needle roller bearing from the input shaft.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 426/614
9. REMOVE 5TH GEAR BEARING SPACER
1. Remove the 5th gear bearing spacer from the input shaft.
10. INSPECT 4TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 4th gear thrust clearance.
Standard clearance:0.10 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 427/614
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace the 4th gear synchronizer ring.
11. REMOVE 5TH GEAR SHAFT SNAP RING
1. Using a snap ring expander, remove the 5th gear shaft snap ring from the input
shaft.
HINT:Do not damage the journal surface of the input shaft.
12. REMOVE 5TH GEAR THRUST WASHER
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 428/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 429/614
1. Remove the 4th gear from the input shaft.
15. REMOVE 4TH GEAR NEEDLE ROLLER BEARING
1. Remove the 4th gear needle roller bearing from the input shaft.
16. REMOVE 4TH GEAR BEARING SPACER
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 430/614
1. Remove the 4th gear bearing spacer from the input shaft.
17. REMOVE 4TH GEAR SYNCHRONIZER RING
1. Remove the 4th gear synchronizer ring from the clutch hub No. 2.
18. REMOVE CLUTCH HUB NO.2 SETTING SHAFT SNAP RING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 431/614
1. Using a snap ring expander, remove the clutch hub No. 2 setting shaft snap ringfrom the input shaft.
HINT:
Do not damage the journal surface of the input shaft.
19. REMOVE 3RD GEAR
1. Using SST and a press, remove the hub sleeve No. 2, 3rd gear synchronizer ring
and 3rd gear from the input shaft.
SST
09950-00020
NOTICE:
• Do not excessively tighten SST.
• Support the input shaft by hand to prevent it from dropping off
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 432/614
20. REMOVE TRANSMISSION CLUTCH HUB NO.2
1. Remove the 2 shifting key springs No. 1 from the transmission clutch hub No. 2.
2.
Remove the transmission hub sleeve No. 2 from the transmission clutch hub No.
2.
3. Remove the 3 shifting keys No. 2 from the transmission clutch hub No. 2.
21. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 433/614
1. Remove the 3rd gear needle roller bearing from the input shaft.
22. REMOVE INPUT SHAFT FRONT BEARING
1. Using a press, remove the input shaft front bearing from the input shaft.
SST
09950-00020
HINT:Support the input shaft by hand to prevent it from dropping off.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 434/614
INPUT SHAFT > INSPECTION
for Preparation
1. INSPECT INPUT SHAFT
1. Check the input shaft for wear and damage.
2. Using a dial indicator, check the input shaft runout.
Maximum runout:
0.03 mm (0.0012 in.)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 435/614
If the runout exceeds the maximum, replace the input shaft.
3. Using a micrometer, measure the outer diameter of the input shaft journal surface.
Standard:
Measured
Part
Outer Diameter mm
(in.)
A25.502 to 25.515
(1.0040 to 1.00453)
B30.985 to 31.000(1.2199 to 1.2205)
C, D33.985 to 34.000(1.3380 to 1.3386)
E23.002 to 23.015
(0.9056 to 0.9091)
F22.967 to 23.000
(0.9042 to 0.9055)
If the outer diameters are below the minimum, replace the input shaft.
2. INSPECT 3RD GEAR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 436/614
1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.
Standard inside diameter:
39.015 to 39.031 mm (1.5360 to 1.5367 in.)
Maximum inside diameter:39.031 mm (1.5367 in.)
If the inside diameter exceeds the maximum, replace the 3rd gear.
3. INSPECT 4TH GEAR
1. Using a cylinder gauge, measure the inside diameter of the 4th gear.
Standard inside diameter:
39.015 to 39.031 mm (1.5360 to 1.5367 in.)
Maximum inside diameter:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 437/614
39.031 mm (1.5367 in.)
If the inside diameter exceeds the maximum, replace the 4th gear.
4. INSPECT 5TH GEAR
1. Using a cylinder gauge, measure the inside diameter of the 5th gear.
Standard inside diameter:
36.015 to 36.031 mm (1.4179 to 1.4185 in.)Maximum inside diameter:
36.031 mm (1.4185 in.)
If the inside diameter exceeds the maximum, replace the 5th gear.
5. INSPECT 3RD GEAR SYNCHRONIZER RING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 438/614
1. Check for wear and damage.
2. Coat the 3rd gear cone with gear oil.
3.
Turn the 3rd gear synchronizer ring in one direction while pushing it against the3rd gear cone.
4. Check that the ring locks.If the synchronizer ring does not lock, replace the synchronizer ring or the 3rd
gear.
5.
Using a feeler gauge, measure the clearance between the synchronizer ring back
and the gear spline end.
Standard clearance:
0.75 to 1.65 mm (0.0295 to 0.0650 in.)Minimum clearance:
0.75 mm (0.0295 in.)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 439/614
If the clearance is less than the minimum, replace the synchronizer ring or the 3rd
gear.
6. INSPECT 4TH GEAR SYNCHRONIZER RING
1. Check for wear and damage.
2. Coat the 4th gear cone with gear oil.
3.
Turn the synchronizer ring in one direction while pushing it against the 4th gear
cone.
4. Check that the ring locks.If the synchronizer ring does not lock, replace the synchronizer ring or the 4th
gear.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 440/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 441/614
2. Coat the 5th gear cone with gear oil.
3. Turn the synchronizer ring in one direction while pushing it against the 5th gear
cone.
4.
Check that the ring locks.If the synchronizer ring does not lock, replace the synchronizer ring or the 5th
gear.
5. Using a feeler gauge, measure the clearance between the synchronizer ring backand the gear spline end.
Standard clearance:0.75 to 1.65 mm (0.0295 to 0.0650 in.)
Minimum clearance:
0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 5th
gear.
8. INSPECT TRANSMISSION HUB SLEEVE NO.2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 442/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 443/614
0.15 to 0.35 mm (0.0059 to 0.0138 in.)
If the clearance is outside the specifications, replace the transmission hub sleeve
No. 3 and gear shift fork No. 3.
INPUT SHAFT > REASSEMBLY
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 444/614
1. INSTALL INPUT SHAFT FRONT BEARING
1.
Using SST and a press, install a new input shaft front bearing onto the input shaft.
SST
09515-10010
2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
1. Coat the 3rd gear needle roller bearing with gear oil, and install it onto the inputshaft.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 445/614
3. INSTALL 3RD GEAR
1.
Coat the 3rd gear with gear oil, and install it onto the input shaft.
4. INSTALL 3RD GEAR SYNCHRONIZER RING
1.
Coat the 3rd gear synchronizer ring with gear oil, and install it onto the 3rd gear.
5. INSTALL TRANSMISSION CLUTCH HUB NO.2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 446/614
1. Install the 3 shifting keys No. 2, 2 shifting key springs and transmission hub
sleeve No. 2 onto the clutch hub No. 2.
NOTICE:
Assemble the transmission hub sleeve No. 2 and transmission clutch hub No. 2 in
the correct orientations, as shown in the illustration.
2. Using SST and a press, install the transmission clutch hub sleeve No. 2 onto the
input shaft.
SST
09506-35010
6. INSTALL CLUTCH HUB NO.2 SETTING SHAFT SNAP RING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 447/614
1. Select a snap ring that allows the minimum axial play.
Standard clearance:0.1 mm (0.0039 in.) or less.
MarkThickness
mm (in.)Mark
Thickness
mm (in.)
A2.28(0.0898)
D2.46(0.0969)
B2.34
(0.0921)E
2.52
(0.0992)
C2.40(0.0945) F
2.58(0.1016)
2. Using a snap ring expander, install the new snap ring onto the input shaft.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 448/614
HINT:
Do not damage the journal surface of the input shaft.
7. INSPECT 3RD GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum clearance:
0.35 mm (0.0138 in.)
If the clearance exceeds the maximum, replace the 3rd gear synchronizer ring.
8. INSPECT 3RD GEAR RADIAL CLEARANCE
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 449/614
1. Using a dial indicator, measure the 3rd gear radial clearance.
Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 3rd gear needle roller bearingor the shaft.
9. INSTALL 4TH GEAR SYNCHRONIZER RING
1. Coat the 4th gear synchronizer ring with gear oil, and install it onto transmission
clutch hub No. 2.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 450/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 451/614
12. INSTALL 4TH GEAR
1. Coat the 4th gear with gear oil, and install it onto the input shaft.
13. INSTALL 5TH GEAR THRUST WASHER BALL
1. Install the 5th gear thrust washer ball onto the input shaft.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 452/614
14. INSTALL 5TH GEAR THRUST WASHER
1.
Coat the 5th gear thrust washer with gear oil, and install it onto the input shaft.
15. INSTALL 5TH GEAR SHAFT SNAP RING
1.
Select a snap ring, using the table below, that makes the thrust clearance of the5th gear thrust washer less than 0.1 mm (0.0039 in.).
MarkThickness
mm (in.)Mark
Thickness
mm (in.)
12.28
(0.0898)4
2.46
(0.0969)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 453/614
22.34
(0.0921)5
2.52
(0.0992)
32.40(0.0945)
62.58(0.1016)
2. Using a snap ring expander, install a new snap ring onto the input shaft.
HINT:Do not damage the journal surface of the input shaft.
16. INSPECT 4TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 4th gear thrust clearance.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 454/614
Standard clearance:
0.1 to 0.55 mm (0.0039 to 0.0217 in.)Maximum clearance :
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace the 4th gear synchronizer ring.
17. INSPECT 4TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 4th gear radial clearance.
Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 4th gear needle roller bearing
or the shaft.
18. INSTALL 5TH GEAR BEARING SPACER
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 455/614
1. Coat the 5th gear bearing spacer with gear oil, and install it onto the input shaft.
19. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
1. Coat the 5th gear needle roller bearing with gear oil, and install it onto the input
shaft.
20. INSTALL 5TH GEAR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 456/614
1. Coat the 5th gear with gear oil, and install it onto the input shaft.
21. INSTALL 5TH GEAR SYNCHRONIZER RING
1. Coat the 5th gear synchronizer ring with gear oil, and install it onto the 5th gear.
22. INSTALL TRANSMISSION CLUTCH HUB NO.3
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 457/614
1. Install the 3 shifting keys No. 3, 2 shifting key springs No. 1 and transmission hubsleeve No. 3 onto the transmission clutch hub No. 3.
NOTICE:
Assemble the transmission hub sleeve No. 3 and the transmission clutch hub No.3 in the correct orientations, as shown in the illustration.
2. Place the 5th gear synchronizer ring on the 5th gear, and align the synchronizerring slots with the shifting keys No. 3.
3.
Using SST and a press, press the No. 3 hub sleeve into the input shaft.
SST
09515-10010
NOTICE:Install the transmission hub sleeve No. 3 in the correct orientation, as shown in
the illustration.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 458/614
23. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING
1. Using SST and a press, install a new input shaft rear radial ball bearing onto the
input shaft.
SST
09515-10010
24. INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 5th gear thrust clearance.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 459/614
Standard clearance:
0.10 to 0.50 mm (0.0039 to 0.0197 in.)Maximum clearance:
0.50 mm (0.0197 in.)
If the clearance exceeds the maximum, replace the 5th gear synchronizer ring.
25. INSPECT 5TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 5th gear needle roller bearing
or the shaft.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 460/614
OUTPUT SHAFT > COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 461/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 462/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 463/614
1 / 2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 464/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 465/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 466/614
2 / 2
OUTPUT SHAFT > DISASSEMBLY
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 467/614
1. REMOVE OUTPUT SHAFT REAR BEARING
1.
Using SST and a press, remove the output shaft rear bearing.
SST
09950-60010 (09951-00220)
09950-70010 (09951-07100)
2. INSPECT 1ST GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 468/614
0.45 mm (0.0177 in.)
If the clearance exceeds the maximum, replace the 1st gear synchronizer ring.
3. INSPECT 2ND GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 2nd gear thrust clearance.
Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)Maximum clearance:
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace the 2nd gear synchronizer ring.
4. INSPECT 1ST GEAR RADIAL CLEARANCE
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 469/614
1. Using a dial indicator, measure the 1st gear radial clearance.
Standard clearance:
0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the 1st gear needle roller bearingor the shaft.
5. INSPECT 2ND GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 2nd gear radial clearance.
Standard clearance:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 470/614
0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the 2nd gear needle roller bearing
or the shaft.
6. REMOVE COUNTER 5TH GEAR SHAFT SNAP RING
1.
Using 2 screwdrivers and a hammer, remove the counter 5th gear shaft snap ringfrom the output shaft.
7. REMOVE 4TH DRIVEN GEAR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 471/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 472/614
1. Using SST and a press, remove the 3rd driven gear and 2nd gear from the output
shaft.
SST
09950-00020
10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
1. Remove the 2nd gear needle roller bearing from the output shaft.
11. REMOVE 2ND GEAR BEARING SPACER
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 473/614
1. Remove the 2nd gear bearing spacer from the output shaft.
12. REMOVE 2ND GEAR SYNCHRONIZER RING
1. Remove the 2nd gear synchronizer ring from the reverse gear.
13. REMOVE CLUTCH HUB NO.1 SHAFT SNAP RING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 474/614
1. Using 2 screwdrivers, remove the clutch hub No. 1 shaft snap ring from the outputshaft.
HINT:
Do not damage the journal surface of the output shaft.
14. REMOVE 1ST GEAR
1. Using a press, remove the transmission clutch hub No. 1 and 1st gear from the
output shaft.
15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 475/614
1. Remove the 1st gear needle roller bearing from the output shaft.
16. REMOVE OUTPUT SHAFT FRONT BEARING
1. Using SST and a press, remove the output shaft front bearing from the output
shaft.
SST
09950-00020
17. REMOVE TRANSMISSION CLUTCH HUB NO.1
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 476/614
1. Remove the 2 shifting key springs No. 1, 3 shifting keys No. 1 and reverse gear
from the transmission clutch hub No. 1.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 477/614
OUTPUT SHAFT > INSPECTIONfor Preparation
1. INSPECT OUTPUT SHAFT
1. 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.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 478/614
2. Using a micrometer, measure the outer diameter of the output shaft journal
surface.
Standard:
Measured
Part
Outer Diameter mm
(in.)
A23.002 to 23.015
(0.9056 to 0.9061)
B, C 28.3 (1.1142)
D, E33.985 to 34.000
(1.3380 to 1.3386)
F25.002 to 25.015
(0.9843 to 0.9847)
If the outer diameters are below the minimum, replace the input shaft.
2. INSPECT 1ST GEAR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 479/614
1. Using a cylinder gauge, measure the inside diameter of the 1st gear.
Standard inside diameter:
39.015 to 39.031 mm (1.5360 to 1.5367 in.)
Maximum inside diameter:39.031 mm (1.5637 in.)
If the inside diameter exceeds the maximum, replace the 1st gear.
3. INSPECT 2ND GEAR
1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.
Standard inside diameter:
39.015 to 39.031 mm (1.5360 to 1.5367 in.)
Maximum inside diameter:
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 480/614
39.031 mm (1.5367 in.)
If the inside diameter exceeds the maximum, replace the 2nd gear.
4. INSPECT 1ST GEAR SYNCHRONIZER RING
1. Check for wear and damage.
2. Coat the 1st gear cone with gear oil.
3.
Turn the synchronizer ring in one direction while pushing it against the 1st gear
cone.
4. Check that the ring locks.If the synchronizer ring does not lock, replace the synchronizer ring or the 1st
gear.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 481/614
5. Using a feeler gauge, measure the clearance between the synchronizer ring backand the gear spline end.
Standard clearance:
0.8 to 1.6 mm (0.031 to 0.063 in.)Minimum clearance:0.80 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 1st
gear.
5. INSPECT 2ND GEAR SYNCHRONIZER RING
1. Check for wear and damage.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 482/614
2. Coat the 2nd gear cone with gear oil.
3. Turn the synchronizer ring in one direction while pushing it against the 2nd gear
cone.
4.
Check that the ring locks.If the synchronizer ring does not lock, replace the synchronizer ring or the 2nd
gear.
5. Using a feeler gauge, measure the clearance between the synchronizer ring backand the gear spline end.
Standard clearance:0.8 to 1.6 mm (0.031 to 0.063 in.)
Minimum clearance:
0.80 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 2nd
gear.
6. INSPECT REVERSE GEAR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 483/614
1. Using vernier calipers, measure the clearance between the reverse gear and the
reveres gear fork.
Standard clearance (A-B):
0.15 to 0.35 mm (0.0059 to 0.0138 in.)
If the clearance is outside the specifications, replace the reverse gear fork and
reverse gear.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 484/614
OUTPUT SHAFT > REASSEMBLY
for Preparation
1. INSTALL OUTPUT SHAFT FRONT BEARING
1. Using SST and a press, install the output shaft front bearing onto the output shaft.
SST
09710-22021 (09710-01051)
2. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 485/614
1. Coat the 1st gear needle roller bearing with gear oil, and install it onto the outputshaft.
3. INSTALL 1ST GEAR
1. Coat the 1st gear with gear oil, and install it onto the output shaft.
4. INSTALL 1ST GEAR SYNCHRONIZER RING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 486/614
1. Coat the 1st gear synchronizer ring with gear oil, and install it onto the 1st gear.
5. INSTALL TRANSMISSION CLUTCH HUB NO.1
1. Install 2 shifting key springs No. 1, 3 shifting keys No. 1 and the reverse gear
onto the transmission clutch hub No. 1.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 487/614
2. Using SST and a press, install the transmission clutch hub No. 1 onto the output
shaft.
SST
09316-60011 (09316-00011, 09316-00071) NOTICE:Install the reverse gear assembly in the correct orientation, as shown in the
illustration.
6. INSTALL CLUTCH HUB NO.1 SHAFT SNAP RING
1. Select a snap ring that allows the minimum axial play.
Standard clearance:0 to 0.1 mm (0 to 0.0039 in.)
Mark Thickness Mark Thickness
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 488/614
mm (in.) mm (in.)
A2.28
(0.0898)D
2.46
(0.0969)
B2.34
(0.0921)E
2.52(0.0992)
C2.40
(0.0945)F
2.58
(0.1016)
2. Using a snap ring expander, install the new snap ring onto the output shaft.
7. INSPECT 1ST GEAR THRUST CLEARANCE
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 489/614
1. Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance:
0.45 mm (0.0177 in.)
If the clearance exceeds the maximum, replace the 1st gear synchronizer ring.
8. INSPECT 1ST GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 1st gear radial clearance.
Standard clearance:0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:
0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the 1st gear needle roller bearing
or the shaft.
9. INSTALL 2ND GEAR BEARING SPACER
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 490/614
1. Coat the 2nd gear bearing spacer with gear oil and install it onto the output shaft.
10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
1. Coat the 2nd gear needle roller bearing with gear oil, and install it onto the output
shaft.
11. INSTALL 2ND GEAR SYNCHRONIZER RING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 491/614
1. Coat the 2nd synchronizer ring with gear oil, and install it onto the reverse gear.
12. INSTALL 2ND GEAR
1. Coat the 2nd gear with gear oil, and install it onto the output shaft.
13. INSTALL 3RD DRIVEN GEAR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 492/614
1. Using SST and a press, install the 3rd driven gear onto the output shaft.
SST09316-60011 (09316-00041)
14. INSPECT 2ND GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 2nd gear thrust clearance.
Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)Maximum clearance :
0.55 mm (0.0217 in.)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 493/614
If the clearance exceeds the maximum, replace the 2nd gear synchronizer ring.
15. INSPECT 2ND GEAR RADIAL CLEARANCE
1.
Using a dial indicator, measure the 2nd gear radial clearance between the gear and
shaft.
Standard clearance:
0.015 to 0.056 mm (0.0006 to 0.0023 in.)Maximum clearance:
0.056 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 2nd gear needle roller bearing
or the shaft.
16. INSTALL OUTPUT SHAFT SPACER
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 494/614
1. Install the output shaft spacer onto the output shaft.
17. INSTALL 4TH DRIVEN GEAR
1. Using SST and a press, install the 4th driven gear onto the output shaft.
SST09223-00010
09316-60011 (09316-00021)
18. INSTALL 5TH DRIVEN GEAR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 495/614
1. Using SST and a press, install the 5th driven gear onto the output shaft.
SST09223-00010
09316-60011 (09316-00021)
19. INSTALL COUNTER 5TH GEAR SHAFT SNAP RING
1. Select a snap ring, using the table below, that makes the thrust clearance of the
5th driven gear less than 0.1 mm (0.0039 in.).
MarkThicknessmm (in.)
Mark Thicknessmm (in.)
A2.22
(0.0874)F
2.52(0.0992)
B 2.28 G 2.58
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 496/614
(0.0898) (0.1016)
C2.34
(0.0921)H
2.64
(0.1039)
D2.40
(0.0945)J
2.70(0.1063)
E2.46
(0.0969)- -
2. Using a brass bar and hammer, tap the new snap ring onto the output shaft.
20. INSTALL OUTPUT SHAFT REAR BEARING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 497/614
1. Using SST and a press, install the output shaft rear bearing onto the output shaft.
SST09612-22011
DIFFERENTIAL CASE >
COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 498/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 499/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 500/614
1 / 1
DIFFERENTIAL CASE >
DISASSEMBLY
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 501/614
1. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the front differential case front tapered roller bearing.
SST09950-00020
09950-00030
HINT:
Set the claw of SST to the bearing inner race at the indented part of the
differential case.
2. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 502/614
1. Using SST, remove the front differential case rear tapered roller bearing.
SST09950-00020
09950-00030
3. REMOVE FRONT DIFFERENTIAL RING GEAR
1. Place matchmarks on the front differential ring gear and the front differential
case.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 503/614
2. Remove the 6 bolts. Using a hammer, remove the front differential ring gear fromthe front differential case.
4. REMOVE FRONT DIFFERENTIAL CASE
1. Using a pin punch and hammer, remove the pinion shaft slotted spring pin.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 504/614
2. Remove the pinion shaft from the differential case.
3. Remove the 2 pinion gears, 2 side gears and the 4 thrust washers from each gear.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 505/614
DIFFERENTIAL CASE >
REASSEMBLYfor Preparation
1. INSTALL FRONT DIFFERENTIAL CASE
1. Install the appropriate thrust washers and side gears. Refer to the table below andselect thrust washers that bring the backlash to within the specifications. Select
washers of the same size for both sides.
Standard backlash:0.05 to 0.20 mm (0.0020 to 0.0079 in.)
Thickness mm (in.) Thickness mm (in.)
0.50 (0.0197) 0.75 (0.0295)
0.55 (0.0217) 0.80 (0.0315)0.60 (0.0236) 0.85 (0.0335)
0.65 (0.0256) 0.90 (0.0354)
0.70 (0.0276) 0.95 (0.0374)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 506/614
2. Install the thrust washers and the side gears into the differential case.
3. Install the pinion shaft.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 507/614
4. 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 to 0.20 mm (0.0020 to 0.0079 in.)
If the backlash is not within the specification, install a thrust washer of a different
thickness.
5. Using a pin punch and a hammer, install the pinion shaft slotted spring pinthrough the front differential case and the hole in the pinion shaft.
6. Using a chisel and hammer, caulk the pin holes around the circumference of thefront differential case.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 508/614
2. INSTALL FRONT DIFFERENTIAL RING GEAR
1. Using a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).
2. Clean the contact surface of the front differential case.
3. Aligning the matchmarks, quickly install the front differential ring gear onto the
front differential case with the 6 bolts.
Torque:124 N*m 1,260 kgf*cm , 91 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 509/614
3. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, install the front differential case rear tapered roller
bearing.
SST
09350-32014 (09351-32120, 09351-32140)
4. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1.
Using SST and a press, install the front differential case front tapered roller
bearing.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 510/614
SST
09350-32014 (09351-32120, 09351-32140)
SHIFT STROKE SENSOR >
COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 511/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 512/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 513/614
1 / 2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 514/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 515/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 516/614
2 / 2
SHIFT STROKE SENSOR >
REMOVAL
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 517/614
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE AIR CLEANER INLET NO.1 (for 2SZ-FE)
1. Remove the air cleaner inlet No. 1.
3. REMOVE BATTERY HOLD DOWN CLAMP
4. REMOVE BATTERY
5. REMOVE BATTERY TRAY
6. REMOVE BATTERY CARRIER (for 1KR-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 518/614
1. Remove the 4 bolts and the battery carrier.
7. REMOVE BATTERY CARRIER (for 2SZ-FE)
1. Remove the 5 bolts and the battery carrier.
8. REMOVE SHIFT STROKE SENSOR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 519/614
1. Remove the bolt and separate the wire harness bracket.
2. Disconnect the shift stroke sensor connector.
3. Remove the 2 screws and the shift stroke sensor from the shift and select actuator.
4. Remove the O-ring from the shift stroke sensor.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 520/614
SHIFT STROKE SENSOR >
INSPECTION
for Preparation
1. INSPECT SHIFT STROKE SENSOR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 521/614
1. Connect the 3 dry batteries of 1.5 V in series.
2. Connect the battery positive (+) lead to terminal A and the negative (-) lead to
terminal B.
3. Turn the sensor arm and check the voltage between terminals B and C.
Reference: Voltage (Power source voltage at 4.5 V):
Sensor
angle
Terminal (B - C) output
voltage55° 4.05 V
0° 2.25 V
-55° 0.45 V
Voltage (Power source voltage at 4.7 to 5.3 V):
Sensor
angle
Terminal (B - C) output
voltage
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 522/614
55° 4.5 V
0° 2.5 V
-55° 0.5 V
NOTICE:
• Do not apply more than 6 V.
• Do not drop the clutch stroke sensor. If dropped, replace it with a new one.
If the voltage is not as specified, replace the stroke sensor.
SHIFT STROKE SENSOR >
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 523/614
INSTALLATION
for Preparation
1. INSTALL SHIFT STROKE SENSOR
1. Apply MP grease to a new O-ring.
2.
Install the new O-ring onto the stroke sensor.
3. Set the stroke senor so that the sensor side and the actuator side sensor arms are in
the positions shown in the illustration.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 524/614
4. Turn the stroke sensor clockwise and fix it with the 2 screws.
Torque:
2.0 N*m 20 kgf*cm , 18 in.*lbf
5. Connect the shift stroke sensor connector.
6. Install the wire harness bracket onto the transaxle with the bolt.
Torque:13 N*m 131 kgf*cm , 9.5 ft.*lbf
2. INSTALL BATTERY CARRIER (for 1KR-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 525/614
1. Install the battery carrier with the 4 bolts.
Torque:17 N*m 175 kgf*cm , 13 ft.*lbf
3. INSTALL BATTERY CARRIER (for 2SZ-FE)
1. Install the battery carrier with the 5 bolts.
Torque:17 N*m 175 kgf*cm , 13 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 526/614
4. INSTALL BATTERY TRAY
5. INSTALL BATTERY
6. INSTALL BATTERY HOLD DOWN CLAMP
7. INSTALL AIR CLEANER INLET NO.1 (for 2SZ-FE)
1. Install the air cleaner inlet No. 1.
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque:5.4 N*m 55 kgf*cm , 48 in.*lbf
9. INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION ECU
()
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 527/614
10. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM
()
11. SYNCHRONIZATION POSITION CALIBRATION()
SELECT STROKE SENSOR >
COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 528/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 529/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 530/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 531/614
1 / 2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 532/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 533/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 534/614
2 / 2
SELECT STROKE SENSOR >
REMOVAL
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 535/614
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE AIR CLEANER INLET NO.1 (for 2SZ-FE)
1. Remove the air cleaner inlet No. 1.
3. REMOVE BATTERY HOLD DOWN CLAMP
4. REMOVE BATTERY
5. REMOVE BATTERY TRAY
6. REMOVE BATTERY CARRIER (for 1KR-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 536/614
1. Remove the 4 bolts and the battery carrier.
7. REMOVE BATTERY CARRIER (for 2SZ-FE)
1. Remove the 5 bolts and the battery carrier.
8. REMOVE SELECT STROKE SENSOR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 537/614
1. Remove the bolt and separate the wire harness bracket.
2. Disconnect the select stroke sensor connector.
3. Remove the 2 screws and select stroke sensor from the shift and select actuator.
4. Remove the O-ring from the select stroke sensor.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 538/614
SELECT STROKE SENSOR >
INSPECTION
for Preparation
1. INSPECT SELECT STROKE SENSOR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 539/614
1. Connect the 3 dry batteries of 1.5 V in series.
2. Connect the battery positive (+) lead to terminal A and the negative (-) lead to
terminal B.
3. Turn the sensor arm and check the voltage between terminals B and C.
Reference: Voltage (Power source voltage at 4.5 V):
Sensor
angle
Terminal (B - C) output
voltage55 ° 4.05 V
0° 2.25 V
-55° 0.45 V
Voltage (Power source voltage at 4.7 to 5.3V):
Sensor
angle
Terminal (B - C) output
voltage
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 540/614
55 ° 4.5 V
0° 2.5 V
-55° 0.5 V
NOTICE:
• Do not apply more than 6 V.
• Do not drop the clutch stroke sensor. If dropped, replace it with a new one.
If the voltage is not as specified, replace the stroke sensor.
SELECT STROKE SENSOR >
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 541/614
INSTALLATION
for Preparation
1. INSTALL SELECT STROKE SENSOR
1. Apply MP grease to a new O-ring.
2.
Install the new O-ring onto the stroke sensor.
3. Set the stroke sensor so that the sensor side and the actuator side sensor arms are
in the positions shown in the illustration.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 542/614
4. Turn the stroke sensor clockwise and fix it with the 2 screws.
Torque:
2.0 N*m 20 kgf*cm , 18 in.*lbf
5. Connect the select stroke sensor connector.
6. Install the wire harness bracket onto the transaxle with the bolt
Torque:13 N*m 131 kgf*cm , 9.5 ft.*lbf
2. INSTALL BATTERY CARRIER (for 1KR-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 543/614
1. Install the battery carrier with the 4 bolts.
Torque:17 N*m 175 kgf*cm , 13 ft.*lbf
3. INSTALL BATTERY CARRIER (for 2SZ-FE)
1. Install the battery carrier with the 5 bolts.
Torque:17 N*m 175 kgf*cm , 13 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 544/614
4. INSTALL BATTERY TRAY
5. INSTALL BATTERY
6. INSTALL BATTERY HOLD DOWN CLAMP
7. INSTALL AIR CLEANER INLET NO.1 (for 2SZ-FE)
1. Install the air cleaner inlet No. 1.
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque:5.4 N*m 55 kgf*cm , 48 in.*lbf
9. INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION ECU
()
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 545/614
10. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM
()
11. SYNCHRONIZATION POSITION CALIBRATION()
TRANSMISSION REVOLUTION
SENSOR > COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 546/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 547/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 548/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 549/614
1 / 1
TRANSMISSION REVOLUTION
SENSOR > REMOVAL
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 550/614
1. DRAIN TRANSAXLE OIL
1.
Remove the filler plug and the gasket.
2. Remove the drain plug and gasket and drain the transaxle oil.
3. Install a new gasket and the drain plug.
Torque:39 N*m 400 kgf*cm , 29 ft.*lbf
2. REMOVE TRANSMISSION REVOLUTION SENSOR
1. Disconnect the revolution sensor connector.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 551/614
2. Remove the bolt and transmission case protector.
3. Remove the bolt and transmission revolution sensor.
4. Using a screwdriver, remove the O-ring from the transmission revolution sensor.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 552/614
TRANSMISSION REVOLUTION
SENSOR > INSPECTION
for Preparation
1. INSPECT TRANSMISSION REVOLUTION SENSOR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 553/614
1. Using an ohmmeter, measure the resistance between the terminals.
Standard Resistance:560 to 680 Ω at 20 °C(68°F)
If the resistance is not as specified, replace the revolution sensor.
TRANSMISSION REVOLUTION
SENSOR > INSTALLATION
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 554/614
1. INSTALL TRANSMISSION REVOLUTION SENSOR
1. Install a new O-ring onto the transmission revolution sensor.
2. Install the transmission revolution sensor with the bolt.
Torque:
7.8 N*m 80 kgf*cm , 69 in.*lbf
3. Install the transmission case protector with the bolt.
Torque:
18 N*m 185 kgf*cm , 13 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 555/614
4. Connect the revolution sensor connector.
2. ADD TRANSAXLE OIL
3. INSPECT AND ADJUST TRANSAXLE OIL
1. Stop the vehicle on a level place.
2. Remove the filler plug and gasket.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 556/614
3. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the
filler plug opening.
NOTICE:
•
An excessively large or small amount of oil may cause problems.• After replacing the oil, drive the vehicle and check the oil level again.
4. When the oil level is low, check for oil leakage.
5. Install the filler plug and a new gasket.
Torque:
39 N*m 400 kgf*cm , 29 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 557/614
BACK-UP LIGHT SWITCH >
COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 558/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 559/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 560/614
1 / 4
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 561/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 562/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 563/614
2 / 4
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 564/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 565/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 566/614
3 / 4
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 567/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 568/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 569/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 570/614
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE AIR CLEANER INLET NO.1 (for 2SZ-FE)
1. Remove the air cleaner inlet No. 1.
3. REMOVE BATTERY HOLD DOWN CLAMP
4. REMOVE BATTERY
5. REMOVE BATTERY TRAY
6. REMOVE BATTERY CARRIER (for 1KR-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 571/614
1. Remove the 4 bolts and the battery carrier.
7. REMOVE BATTERY CARRIER (for 2SZ-FE)
1. Remove the 5 bolts and the battery carrier.
8. SUPPORT MULTI-MODE MANUAL TRANSAXLE ASSEMBLY
9. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 1KR-
FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 572/614
1. Remove the bolt and nut, then separate the engine mounting insulator LH.
2. Remove the 4 bolts and the engine mounting insulator LH.
10. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZ-
FE)
1. Remove the bolt and nut, then separate the engine mounting insulator LH.
2. Remove the 5 bolts and the engine mounting insulator LH.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 573/614
11. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KR-
FE)
1. Remove the 4 bolts and the engine mounting bracket LH.
12. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZ-
FE)
1. Remove the 4 bolts and the engine mounting bracket LH.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 574/614
13. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
1. Disconnect the back-up light switch connector.
2. Separate the back-up light switch wire harness from the 2 clamps.
3. Using SST, remove the back-up light switch and gasket from the transaxle case.
SST
09817-16011
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 575/614
BACK-UP LIGHT SWITCH >
INSPECTION
for Preparation
1. INSPECT BACK-UP LIGHT SWITCH ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 576/614
1. Using an ohmmeter, measure the resistance between the terminals.
Standard Resistance:
Condition Specified conditionReleased Below 1 Ω
Pushed 10 k Ω or higher
If the result is not as specified, replace the back-up light switch.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 577/614
BACK-UP LIGHT SWITCH >
INSTALLATION
for Preparation
1. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
1. Using SST, install the back-up light switch with a new gasket onto the transaxle
case.
SST09817-16011
Torque:
40 N*m 410 kgf*cm , 30 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 578/614
2. Install the back-up light switch wire harness into the 2 clamps.
3. Connect the back-up light switch connector.
2. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KR-
FE)
1.
Install the engine mounting bracket LH with the 4 bolts.
Torque:64 N*m 653 kgf*cm , 47 ft.*lbf
3. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZ-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 579/614
1. Install the engine mounting bracket LH with the 4 bolts.
Torque:
64 N*m 653 kgf*cm , 47 ft.*lbf
4. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 1KR-
FE)
1. Install the engine mounting insulator LH with the 4 bolts.
Torque:52 N*m 530 kgf*cm , 38 ft.*lbf for bolt A
64 N*m 653 kgf*cm , 47 ft.*lbf for bolt B
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 580/614
2. Install the engine mounting bracket LH and engine mounting insulator LH with
the bolt and nut.
Torque:
52 N*m 530 kgf*cm , 38 ft.*lbf for nut C
5. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZ-FE)
1. Install the engine mounting insulator LH with the 5 bolts.
Torque:52 N*m 530 kgf*cm , 38 ft.*lbf
2. Install the engine mounting bracket LH and engine mounting insulator LH withthe bolt and nut.
Torque:52 N*m 530 kgf*cm , 38 ft.*lbf
6. INSTALL BATTERY CARRIER (for 1KR-FE)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 581/614
1. Install the battery carrier with the 4 bolts.
Torque:17 N*m 175 kgf*cm , 13 ft.*lbf
7. INSTALL BATTERY CARRIER (for 2SZ-FE)
1. Install the battery carrier with the 5 bolts.
Torque:17 N*m 175 kgf*cm , 13 ft.*lbf
8. INSTALL BATTERY TRAY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 582/614
9. INSTALL BATTERY
10. INSTALL BATTERY HOLD DOWN CLAMP
11. INSTALL AIR CLEANER INLET NO.1 (for 2SZ-FE)
1. Install the air cleaner inlet No. 1.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque:5.4 N*m 55 kgf*cm , 48 in.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 583/614
PARK / NEUTRAL POSITION
SWITCH > COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 584/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 585/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 586/614
1 / 1
PARK / NEUTRAL POSITION
SWITCH > REMOVAL
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 587/614
1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Disconnect the park/neutral position switch connector.
2.
Using SST, remove the park/neutral position switch with the gasket from thetransaxle case.
SST
09817-16011
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 588/614
PARK / NEUTRAL POSITION
SWITCH > INSPECTION
for Preparation
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 589/614
1. Using an ohmmeter, measure the resistance between the terminals.
Standard Resistance:
Condition Specified conditionReleased Below 1 Ω
Pushed 10 k Ω or higher
If the result is not as specified, replace the park/neutral position switch.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 590/614
PARK / NEUTRAL POSITION
SWITCH > INSTALLATION
for Preparation
1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
SST09817-16011
1.
Using SST, install the park/neutral position switch with a new gasket onto the
transaxle case.
Torque:
40 N*m 410 kgf*cm , 30 ft.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 591/614
2. Connect the park/neutral position switch connector.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 592/614
SHIFT AND SELECT ACTUATOR >
COMPONENTS
for Preparation
1 / 1
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 593/614
SHIFT AND SELECT ACTUATOR >
DISASSEMBLY
for Preparation
1. REMOVE SELECT STROKE SENSOR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 594/614
1. Remove the 2 screws and select stroke sensor.
2. Remove the O-ring from the select stroke sensor.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 595/614
SHIFT AND SELECT ACTUATOR >INSPECTION
for Preparation
1. INSPECT SHIFT AND SELECT ACTUATOR ASSEMBLY
1. Check the resistance between the terminals of the shift motor.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 596/614
Standard Resistance:
Tester
connection
Specified
condition
1 - 2 0.1 to 100 Ω
If the resistance is not as specified, replace the shift and select actuator.
2. Check the resistance between the terminals of the select motor.
Standard Resistance:
Tester
connection
Specified
condition
1 - 2 0.1 to 100 Ω
If the resistance is not as specified, replace the shift and select actuator.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 597/614
SHIFT AND SELECT ACTUATOR >
REASSEMBLY
for Preparation
1. INSTALL SELECT STROKE SENSOR
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 598/614
1. Apply MP grease to a new O-ring.
2. Install the new O-ring onto the select stroke sensor.
3. Set the stroke sensor so that the sensor side and the actuator side sensor arms are
in the positions shown in the illustration.
4.
Turn the select stroke sensor clockwise and fix it with the 2 screws.
Torque:
2.0 N*m 20 kgf*cm , 18 in.*lbf
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 599/614
MULTI-MODE MANUAL
TRANSAXLE ECU >
COMPONENTS
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 600/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 601/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 602/614
1 / 2
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 603/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 604/614
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 605/614
2 / 2
MULTI-MODE MANUAL
TRANSAXLE ECU > REMOVAL
for Preparation
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 606/614
1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER
()
2. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (for RHD)
1. Slightly deform the upper part of the glove compartment door assembly to releasethe 2 stoppers and open the glove compartment door assembly until it becomes
horizontal.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 607/614
2. Pull the glove compartment door assembly out horizontally to disengage the hinge
portion and remove the glove compartment door assembly.
NOTICE:
Pull the glove compartment door out horizontally, otherwise, installation failure
caused by excessive play around the hinge portion will result.
3. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for LHD)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 608/614
1. Disconnect the 3 connectors.
2. Remove the 2 bolts.
3. Disengage the clip and remove the transmission control ECU.
4. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for RHD)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 609/614
1. Disconnect the 3 connectors.
2. Remove the bolt and screw, then remove the transmission control ECU.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 610/614
MULTI-MODE MANUAL
TRANSAXLE ECU > REMOVAL
for Preparation
1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER
()
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 611/614
2. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (for RHD)
1. Slightly deform the upper part of the glove compartment door assembly to releasethe 2 stoppers and open the glove compartment door assembly until it becomes
horizontal.
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 612/614
2. Pull the glove compartment door assembly out horizontally to disengage the hinge
portion and remove the glove compartment door assembly.
NOTICE:
Pull the glove compartment door out horizontally, otherwise, installation failure
caused by excessive play around the hinge portion will result.
3. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for LHD)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 613/614
1. Disconnect the 3 connectors.
2. Remove the 2 bolts.
3. Disengage the clip and remove the transmission control ECU.
4. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for RHD)
8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf
http://slidepdf.com/reader/full/c551a-multi-mode-manual-transaxle-1pdf 614/614
Top Related