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Transmission / Drive Axle
3.1 Warnings and Notices.....................3-3
3.1.1 Warnings and Notices...........................................3-3
3.2 Clutch System.................................3-4
3.2.1 Specifications...........................................3-4
3.2.1.1 Fastener Tightening Specifications....................3-4
3.2.1.2 General Specifications.......................................3-4
3.2.2 Description and Operation........................3-5
3.2.2.1 Description and Operation..................................3-5
3.2.3 System Working Principle.........................3-6
3.2.3.1 System Working Principle..................................3-6
3.2.4 Disassemble View....................................3-7
3.2.4.1 Disassemble View..............................................3-7
3.2.5 Diagnostic Information and Procedures.....3-
9
3.2.5.1 Diagnosis Description.........................................3-9
3.2.5.2 Clutch Inseparable Malfunction (Gearshift Lever
Can Not Select Gear).....................................................3-9
3.2.5.3 Clutch Slipping.................................................3-10
3.2.5.4 Clutch Pedal Hard to Push...............................3-12
3.2.5.5 Clutch Pedal Does Not Return.........................3-12
3.2.5.6 Clutch Bearings Noisy When Release.............3-13
3.2.6 Removal and Installation........................3-15
3.2.6.1 Clutch Pedal Replacement...............................3-15
3.2.6.2 Clutch Master Cylinder Replacement...............3-17
3.2.6.3 Hydraulic Clutch Bleeding................................3-19
3.2.6.4 Clutch Pedal Free Travel Adjustment...............3-21
3.2.6.5 Clutch Assembly Replacement........................3-22
3.2.6.6 Clutch Pilot Bearing Replacement....................3-22
3.2.6.7 Clutch Slave Cylinder Replacement.................3-24
3.2.7 Special Tools and Equipment.................3-26
3.2.7.1 Special Tools List.............................................3-26
3.3 Manual Transmission....................3-27
3.3.1 Specifications.........................................3-27
3.3.1.1 Fastener Tightening Specifications..................3-27
3.3.1.2 Manual Transmission Specifications................3-27
3 Transmission / Drive Axle
Table of Contents
3.3.2 Description and Operation......................3-30
3.3.2.1 Transmission System Operation......................3-30
3.3.3 System Working Principle.......................3-31
3.3.3.1 Shifting Working Principle................................3-31
3.3.3.2 Vehicle Speed Sensor Working Principle.........3-34
3.3.3.3 Reverse Switch Working Principle...................3-34
3.3.4 Component Locator................................3-35
3.3.4.1 Transmission Assembly Location.....................3-35
3.3.4.2 Vehicle Speed Sensor, Reverse Switch Location. . .
3-36
3.3.5 Disassemble View..................................3-37
3.3.5.1 Gear Components and Gear Box Disassemble View
.....................................................................................3-37
3.3.5.2 Control Mechanism, Fork Component Disassemble
View..............................................................................3-38
3.3.6 Schematic...............................................3-40
3.3.6.1 Reverse Switch, Vehicle Speed Sensor Circuit
Schematic.....................................................................3-40
3.3.7 Diagnostic Information and Procedures.....3-
41
3.3.7.1 Diagnosis Description.......................................3-41
3.3.7.2 Visual Inspection..............................................3-41
3.3.7.3 Hard to Shift.....................................................3-42
3.3.7.4 Jumping Out Of Gear.......................................3-44
3.3.7.5 Hard to Disengage...........................................3-46
3.3.7.6 Abnormal Sound When Running......................3-47
3.3.8 Removal and Installation........................3-49
3.3.8.1 Transmission Fluid Level Inspection................3-49
3.3.8.2 Vehicle Speed Sensor Replacement................3-50
3.3.8.3 Transmission Assembly Replacement.............3-52
3.3.8.4 Shift Control Assembly Replacement...............3-60
3.3.8.5 Shift Control Assembly Disassemble and Assemble
.....................................................................................3-67
3.3.8.6 Shift Shaft Replacement...................................3-72
3.3.8.7 Input Shaft Disassemble and Assemble...........3-85
3.3.8.8 Main shaft Disassemble and Assemble...........3-94
3.3.8.9 Shift Lever Replacement................................3-102
3.3.8.10 Transmission Input Shaft Oil Seal Replacement...
3-111
EC718/EC718RV EC715/EC715RV 10/2009
3-1
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