Table of Contents 302 Manual Transmissions & Transaxles Section 4: Manual Transaxle Section 4 Topics ................................................................................. 71 Transaxle Components ....................................................................... 72 Input and Output Shafts .................................................................. 72 Differential ....................................................................................... 73 Open Differential ............................................................................. 73 C140 and C150 Series Construction ..............................................
74 C60 Series 6-Speed Transaxle Construction ................................. 75 E Series Transaxle ......................................................................... 76 Lubrication .......................................................................................... 77 S & C Series Lubrication ................................................................. 77 E Series Lubrication ........................................................................ 77 Transaxle Powerflow ........................................................................... 78 Gears ..................................................................................................
79 Gear Shift Controls ............................................................................. 80 Shift Control Cable Adjustment ....................................................... 81 Shift and Select Assembly .............................................................. 82 Shift Mechanisms ................................................................................ 83 Shift Detent Mechanisms ................................................................ 83 Double Meshing Prevention ............................................................ 84 Mis-shift Prevention ........................................................................
84 C & E Series Reverse One-way Mechanism .................................. 85 Operation .................................................................................... 86 Bearings .............................................................................................. 87 Synchronizer Assemblies ................................................................... 88 Key Type Synchronizer Assembly .................................................. 88 Key-less Type Synchronizer Assembly .......................................... 88 Key-less Type Synchronizer Operation ..........................................
89 1 st Stage – Initial Synchronizer ................................................... 89 2 nd Stage – Synchronizing ........................................................... 90 3 rd Stage – Synchronized Mesh .................................................. 91 Section 5: Diagnostic Procedures Section 5 Topics ................................................................................. 93 Introduction ......................................................................................... 94 Six-step Diagnosis .............................................................................. 94 1. Verify the Customer Concern ..................................................... 95 2.
Identify the Symptoms ................................................................ 95 3. Isolate the Cause ........................................................................ 95 4. List Recommended Repairs ....................................................... 96 5. Perform Repair ........................................................................... 96 6. Verify Operation .......................................................................... 96 Common Transmission/Transaxle Problems ...................................... 97 Symptom Diagnosis Chart ...............................................................
97 Diagnostic Flowcharts ......................................................................... 98 Hard to Shift or Will Not Shift .......................................................... 98 Technical Training iii