MANUAL TRANSMISSION
I
CONTENTS
I
PREPARATION
ON-VEHICLE SERVICE..
REMOVAL AND INSTALLATION
I
MAJOR OVERHAUL
DISASSEMBLY
I
NSPECTI ON
ASSEMBLY
.
..........
.....
.
..........
........
........
..................
SECTION
I
FS5W71C & FS5R30AI
.....................
.........................
.........
I
FS5W71CI
.....................
......................
....... ..... ....
..................
....
MT
...
.....
... ...
...........
....
.....
MT- 2
MT- 7
MT- 8
MT- 9
MT-12
MT-17
MT-19
I
r
MAJOR OVERHAUL
DISASSEMBLY
INSPECTION.
ASSEMBLY
I
SERVICE DATA AND SPECIFICATIONS
........... ............... .........
............
............
........
IFS5W71C & FS5R30AI
I
FS5R30A
I
......
........
......
... .
............. ...... ...
(S
D.S
)
....... ..... . .
I
MT-29
MT-33
MT-40
MT-42
1
MT-54
PREPARATION
I
FS5W71C
I
Tool number
(Kent-Moore
Tool name
No
~
1
ST2381 0001
(-)
Adapter setting plate
KV32101330
(See
J26349-A)
Puller
KV31100401
(-)
Transmission press
stand
ST22520000
(526348)
Wrench
Description
SPECIAL
SERVICE
TOOLS
-
for
FS5W71C
Fixing adapter plate with gear assembly
Removing overdrive mainshaft bearing
Pressing counter gear and mainshaft
ST23540000
(J25689-A)
Pin Dunch
ST3003 1000
(522912.01)
Puller
ST23860000
(-)
Drift
ST22360002
(J25679-01
I
Drift
ST22350000
(J25678-01)
Drift
a
Removing and installing fork rod retaining
Din
Removing and installing
1st
gear bushing
Removing maw drwe gear bearing
Installing counter drive gear
a
38
mm
I1
mm
50 in1 dia
I1
30
1n1
dv
b
33
Installing counter gear front and rear end
bearings
8
29
mm
I1
14
in1
34
10
In)
on1
in1
die
dm
dia
du
Installing 0 D
gear
bushing
b
23
mm
I091
a
34
mm
28
mm
(1
I1
b
ST23800000
(J25691-01
I
Drift
a
44
b
mm
31
mm
MT-2
I1
I1
73
22
an1
In1
dm
dm
Installing front cover oil
seal
Tool number
(Kent-Moore
Tool name
No
I
PREPARATION
I
Description
FS5W71C
ST33400001
(J26082)
Drift
ST33290001
(J25810-A)
Puller
ST30720000
(-)
Drift
ST30613000
(J25742-3)
Drift
ST33200000
(J260821
Drift
U
a
77
b
55
a
71
b
47 5
a
60
b
44 5 mm
mm
5
mm
5
mm
mm
mm
I3
(2
12
12
I1
I1
03
36
inl
185
815
870
In1
752
dm
In)
ml
#"I
dm
In)
din
dm
daa
din
Installing rear oil
Removing rear oil
seal
seal
Installing mainshaft ball bearing
Installing main drive gear bearing
Installing counter rear bearing
Installing 3rd
&
4th synchronizer
assembly
Tool name
Puller
COMMERCIAL SERVICE
TOOL
-
for
FS5W71C
Removing counter bearings. counter drive
and
0
D
gears
MT-3
P
RE
PA RAT
I
0
N
(FS5R30AJ
Tool number
(Kent-Moore
No
Tool name
ST23540000
(J25689-A)
Pin punch
ST30031000
(J22912-01)
Puller
ST33290001
(J25810-A)
Puller
ST33230000
(-)
Drift
SPECIAL
)
Description
SERVICE
TOOLS
-
for
FS5R3OA
~~
Removing and installing retaining pin
Removing
1st
&
2nd synchronizer assembly
Removing counter gear rear thrust bearing
Removing main drive bearing
Removing rear
oil
seal
Removing mainshaft and counter gear
a
51
mm
(2
01
in)
b
28
5
mm
I1 122
dta
an)
dia
ST22350000
(525678-01)
Drift
KV38 100300
(J25523)
Drift
ST30720000
@
(534286)
@
(J34331)
Drift
ST33210000
@
(525523)
@
(J25803-01
Drift
ST30613000
(J25742-3)
Drift
Removing counter gear front bearing
(Use with KV38100300)
il
34
mm
I1
34
In)
b
28
mm
(1
10
in1
dm
dm
Removing counter gear front bearing
(Use with ST22350000)
Installing counter gear rear bearing
a
54
mm
12 13
In)
b
32
mm
(1 26
a
77
mm
55 5
(3
mm
b
on)
03
in)
(2 185
dia
dia
doa
in)
dm
@
Removing mainshaft front bearing
@
Installing mainshaft front bearing
@
Installing counter gear front bearing
@
Installing front cover oil
seal
I
a
44
rnrn
(1
73
an1
b
245
mm
a
72
mm
40
mm
12 83
I1 89
b
(0
94
in)
in1
In)
dia
doa
dta
Installing main drive gear bearing
dia
MT-4
Tool number
(Kent-Moore
Tool name
ST37750000
@
(J34286)
@
(J34332)
@
(534334)
@
(525679-01
Drift
No
1
PREPARATION
)
Description
a
40mm1157#
b
31
mm
I1
22
an1
dna
@
Removing counter gear rear bearing
@
Installing
0
Installing reverse cone
0
Installing reverse counter gear
@
Installing counter gear rear end bearing
0
D
gear bushing
-1
~
ST22452000
(534337)
Drift
ST33400001
(J26082)
Drift
(J26349-3)
Puller leg
(J34328)
Puller
(.I260921
Drift
a
/
a
Installing reverse hub
Installing mainshaft rear bearing
a
45
mm
I1
77
14
b
36
mm
I1
a
60
mm
44
38
47
mm
5
mm
5
mm
12
I1
b
a
b
42
36
85
I1
752
I1 516
in)
m)
tn)
dm
dm
dm
dm
ml
dm
~n)
doa
Installing rear oil
Installing mainshaft and counter gear
(Use with J34328)
Installing mainshaft and counter gear
(Use with J26349-3)
Installing sub-gear snap ring
seal
(J34342)
Drift
ST36730000
(-)
Drift
a
4
a
b
a
=
b
=
44
5
mm
40
5
mm
50
mm
39
mm
MT-5
I1
I1
I1
I1
752
594
97
54
an)
an)
in)
in1
doa
dia
dia
dm
Installing
Installing reverse gear bushing
Installing sub-gear on reverse
idler gear
0
D
main gear
PREPARATION
pEiKl
Tool
Puller
name
Description
COMMERCIAL SERVICE
Removing counter gear rear end bearing
Removing mainshaft rear bearing
Removing reverse synchronizer hub
Removing reverse counter gear
TOOL
-
FS5R30A
~
MT-6
ON-VEHICLE SERVICE
&
Fill
to
this
level
LFiller
plug
SMAlO
Checking
Check manual transmission for leakage.
Check
Replacing Rear Oil Seal
oil
M/T
level
Oil
MT-
7
REMOVAL
Removal
0
Insert plug into
0
CAUTION
0
0
0
AND
INSTALLATION
Remove exhaust front tube, catalytic converter and exhaust
manifold connecting tube
to
Refer
section
EM.
Remove propeller shaft.
Refer
to section
PD
rear
oil seal after removing propeller shaft.
Support engine by placing a jack under oil pan
:
Be
careful not to damage spline, sleeve
seal,
when removing propeller shaft.
Do
not
place jack under
Remove shift lever
the
oil
pan drain plug.
(FS5W71C).
yoke
and rear oil
Bolt
No
1
2
3
4
MT-8
Tightening
39 - 49 (4
39
-
29
-
-
29
torque
49 (4.0
39 (3.0 - 4
39
0
(3
0 - 4
N
-
5
-
5
in
(kg-m, ft-lb)
0.29
-
361
0,29 - 361
0,22
.29l
0,22
-
291
P
65
60
55
25
mm
(in)
(2
561
(2 36)
(2
17)
(0
981
MAJOR
OVERHAUL
-1
MT-9
MAJOR OVERHAUL
Maan
drive gear
ball
am
bearing
drwe gear
Washer7
Gear
Components
-&Y
-
FS5W71C
..
Shifting insert
/
flanrhaft ball bearing
Mainshaft rear end bearmg
Insert retainer Reverse
OD
hub
'Overdrive counter gear
Reverse counter gear spacer
kounter rear bearing
idler
gear
Speedometer
Without
Reverse idler thrust warhei
verse
Idler gear bearing
Tool
Countershaft lock
Snap
ring
0
draw
nut
gear
1231
0
..-...
"""
snap ring
....
counter
drwe gear
~
0
+ubilear spring
Subgar bracket
*
*
MT-1
0
'Reverse idler thrust washer
Reverse
idler
shaft
Apply
war
oil
to
wnchroniren,
Select with
*
Pay
attention
N
rn
wars,
and
buringr
proper
to
Ikg-rn,ft-lbl
shafts.
thckners
bts
dsrectlon
when
esrnbllng
SMT74
?A
MAJOR
Shift Control Components-FS5W71 C
(With mainshaft braking mechanism)
OVERHAUL
I
FS5Wq
a
MT-11
DISASSEMBLY
Case Components
1
Remove rear extension
a
Remove control housing, check
select check plunger and return springs
ball,
return spring plug,
I
FS5W71C
I
v
SMT982
b.
Remove
2
Remove front cover, gasket, shim of countershaft front
bearing, and snap ring of main drive
rear
extension by lightly tapping
It
gear
ball bearing
I
SMTO35
3.
Separate transmission case from adapter plate
TM753
Remove
/
4
Be careful
oil
not
seal
of front cover
to
damage mating surface
of
front cover.
MT-12
iR3540000
J25689-AI
TM754
D
I
SASS
EM B LY
1
FK1
Shift Control Components
1
Set
up
Tool on adapter plate.
2
Remove check ball plugs, check springs, and check balls
3
Drive out retaining pins Then drive out fork rods and remove
interlock balls
4
Remove lever bracket securing bolt.
5.
Draw out 3rd4th fork rod.
6. Remove E-ring from 0.D.-rev. fork rod.
MT-13
D
I
SASS
EM
B
LY
Shift Control Components (Cont'd)
7.
Draw out 0 D.-rev. fork shaft by rotating 0.D.-rev bracket
counterclockwise.
I
Gear
End
play
mm
piiF]
(in)
UT025
v
1
St
2nd
3rd
OD
Mesh 2nd
2
and
reverse gear, then draw out counter front
bearing with suitable puller.
3
Remove
spring
snap
and
ring and then remove sub-gear bracket, sub-gear
sub-gear
031 041 (00122-00161)
011 -021 (00043-000831
0
11 0 21
0
32
(0
0043.0 0083)
-
0
39
(00126.0 0154)
rSunable
puller
SMTl62A
4
I
Draw out counter drive gear with main drive gear assembly
with suitable puller
When drawing out main drive gear assembly, be careful not
drop
pilot
bearing and baulk ring.
to
MT-14
DISASSEMBLY
Gear
5
a
Components (Cont'd)
Disassemble
Release
loosen these nuts
parts
staking on countershaft nut and mainshaft nut and
Mainshaft nut: Left-hand thread
at rear of adapter plate
as
follows
-1
~
I
I
(See
J26349
AI
SMTl63A
Y
I
b. Pull out 0.D counter
c Draw out reverse counter
d Remove snap rings from reverse idler shaft, and draw out
reverse idler gear, thrust washers and reverse idler gear bearing
e
Remove speedometer drive
f
Remove snap ring and pull out overdrive mainshaft bearing,
then remove snap ring
g
Remove mainshaft nut
h. Remove thrust washer, steel roller, roller bearing and washer
I
Remove 0 D main
(0
D
)
J
Remove
insert springs
0
D
coupling sleeve, shifting inserts and shifting
gear
with bearing with suitable puller
gear
and spacer
gear
and steel ball.
gear,
needle bearing and baulk ring
I
SMT383A
k.
Press out mainshaft and counter
Make sure to alternate pressing
as
not
to
allow the
of
surface
6
Remove front side components on mainshaft
a
Remove 1st gear washer and steel ball
b. Remove 1st main gear and 1st gear needle bearing
the other.
front
surface of one
gear
alternately
of
mainshaft and counter gear
to
contact the rear
MT-15
so
D
I
SASS
E
MB
LY
-1
In291201
SMT385P
Gear
c
d
1
e
Components (Cont'd)
Press
out 2nd main
&
2nd synchronizer assembly
1st
Remove mainshaft front snap ring
Press
out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd
gear
together with 1st gear bushing and
gear
needle bearing
7.
Remove main drive
a
IJ.
ST30031000
152291201)
I
U
I
I
SMT420A
Remove snap ring and washer
b Remove main drive
gear
gear
bearing
bearing
MT-16
INSPECTION
-1
I
Counter
gear
SMTl37
SMT386A
Shift
0
Control Components
Check contact surface and sliding surface of fork rods for
wear, scratches, projections or other damage
Gear Components
GEARS AND SHAFTS
Check shafts for cracks, wear or bending
Check gears for excessive wear, chlps or cracks
L
SMT550r
SMT026
SYNCHRONIZERS
Check spline portion of coupling sleeves, hubs and gears for
wear or cracks
0
Check baulk rings for cracks or deformation.
0
Check shifting inserts for wear or deformation
0
Check insert springs for deformation
MT-17
SMT140
1st&2nd
3rd
&
main drive
Standard
1
20- 1 60
(0
0472.0
120-
(0
0472 - 0
100- 140
0630)
160
06301
Wear limit
08(0031)
0
8
(0
031)
I
I
BEARINGS
MT-18