I had to replace the clutch on my GF’s Cuore (200’000 km) and I thought I would open the gearbox also because it whines, especially in the first 2 gears.
To my surprise all bearings are in very good shape, some of them even feel like new, none whistle nor grind, no marks on the forks, magnet pretty clean. Damn even the differentials’ bearings are in good shape.
I haven’t disassembled the shafts so I can’t say for the synchro rings but it shifts like a dream in all gears so I’m not going further with these.
I managed to find some documentations through the manuals’ section here —> https://livetodai.com/t/workshop-manuals/52
It’s not exactly the proper manual for my 2004 L251 Cuore (Mira) so I have some doubts and questions.
Mine is a 5 speed manual and the engine is a 1.0 liter EJ-DE I think if I’ve done my homeworks right, it doesn’t have VVT.
This is the L700 manual I used —> https://procarmanuals.com/pdf-online-daihatsu-motor-cuore-mira-l701-1998-2003-service-repair-manual/
The gearbox looks to be pretty much the same except that some gears have some sorts of back up preloaded plate (they move like if there was a spring behind), I’ll put some pictures.
Because of that I’m taking all the gaps, plays and measurements mentionned in the manual with a pinch of salt.
My questions for those that have already opened a similar gearbox:
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How much free play is the input shaft supposed to have ? Mine rocks quite a bit.
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The interlock plates. The manual doesn’t specify how to mount them, took me a while to see IRL that they were not symetrical, one side has an angled cut out but the measurements from left to right (straight side VS the angled / cut side) look to be the same though…
So I don’t get why they are not symetrical, what does it do? And why the manual doesn’t mention anything about the proper way to mount them?
The drawings don’t really help.
This is from the disassembling section:
I’ll put more pictures from my phone later.
