Nissan Sentra 2002 Owner's Manual
C TRANSMISSION/TRANSAXLE
SECTION
A
B
CONTENTS
RS5F70A
PRECAUTIONS .......................................................... 4
Caution ..................................................................... 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 7
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 9
NVH Troubleshooting Chart ..................................... 9
DESCRIPTION .......................................................... 10
CROSS-SECTIONAL VIEW ................................... 10
DOUBLE-CONE SYNCHRONIZER .................... 10
M/T OIL ......................................................................11
Replacement ........................................................... 11
DRAINING ............................................................ 11
FILLING ................................................................11
Checking .................................................................11
OIL LEAKAGE AND OIL LEVEL ..........................11
SIDE OIL SEAL ........................................................ 12
Removal and Installation ........................................ 12
POSITION SWITCH .................................................. 13
Position Switch Check ............................................ 13
BACK-UP LAMP SWITCH .................................. 13
PNP SWITCH ...................................................... 13
CONTROL LINKAGE ............................................... 14
Removal and Installation ........................................ 14
TRANSAXLE GEAR CONTROL ......................... 14
STRIKING ROD OIL SEAL ................................. 15
TRANSAXLE ASSEMBLY ........................................ 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 18
Component Parts ................................................... 18
CASE COMPONENTS ........................................ 19
GEAR COMPONENTS ....................................... 20
SHIFT CONTROL COMPONENTS .................... 21
FINAL DRIVE COMPONENTS ........................... 22
Disassembly and Assembly ................................... 22
DISASSEMBLY ................................................... 22
ASSEMBLY ......................................................... 29
MANUAL TRANSAXLE
INPUT SHAFT AND GEARS .................................... 40
Disassembly ...........................................................40
Inspection ...............................................................41
GEAR AND SHAFT .............................................41
SYNCHRONIZERS .............................................42
BEARING ............................................................43
Assembly ................................................................ 43
MAINSHAFT AND GEARS .......................................47
Disassembly ...........................................................47
Inspection ...............................................................49
GEAR AND SHAFT .............................................49
SYNCHRONIZERS .............................................49
BEARING ............................................................50
Assembly ................................................................ 51
FINAL DRIVE ............................................................57
Pre-inspection ......................................................... 57
DIFFERENTIAL CASE SIDE ...............................57
Disassembly ...........................................................57
Inspection ...............................................................58
GEAR, WASHER, SHAFT AND CASE ...............58
BEARING ............................................................58
Assembly ................................................................ 59
SHIFT CONTROL .....................................................61
Inspection ...............................................................61
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 62
General Specifications ............................................ 62
TRANSAXLE ....................................................... 62
FINAL GEAR ....................................................... 62
Gear End Play ........................................................ 63
Clearance Between Baulk Ring and Gear ..............63
3RD, 4TH, 5TH, REVERSE BAULK RING ..........63
1ST AND 2ND BAULK RING .............................. 63
Available Snap Rings .............................................63
SNAP RING ......................................................... 63
Available C-rings ....................................................63
4TH INPUT GEAR C-RING .................................63
5TH INPUT GEAR REAR C-RING ...................... 64
MAINSHAFT C-RING ..........................................64
Available Adjusting Shims ......................................64
INPUT SHAFT REAR BEARING ADJUSTING
MT
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MT-1
SHIM .................................................................... 64
MAINSHAFT ADJUSTING SHIM ........................ 65
MAINSHAFT REAR BEARING ADJUSTING
SHIM .................................................................... 65
Available Thrust Washer .........................................66
MAINSHAFT THRUST WASHER ........................ 66
Available Washers ..................................................66
DIFFERENTIAL SIDE GEAR THRUST WASHER
Available Shims — Differential Side Bearing Pre-
load and Adjusting Shim .........................................67
BEARING PRELOAD ..........................................67
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIMS .................................................................67
...66
RS5F51A
PRECAUTIONS ......................................................... 68
Caution ................................................................... 68
PREPARATION ......................................................... 69
Special Service Tools .............................................69
Commercial Service Tools ......................................71
NOISE, VIBRAT ION, AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................. 72
NVH Troubleshooting Chart ....................................72
DESCRIPTION .......................................................... 73
Cross-sectional View .............................................. 73
DOUBLE-CONE SYNCHRONIZER ....................74
REVERSE GEAR ................................................74
M/T OIL ......................................................................75
Replacement .......................................................... 75
DRAINING ........................................................... 75
FILLING ...............................................................75
Checking .................................................................75
OIL LEAKAGE AND OIL LEVEL ......................... 75
SIDE OIL SEAL ......................................................... 76
Removal and Installation ........................................ 76
REMOVAL ........................................................... 76
INSTALLATION ....................................................76
POSITION SWITCH ..................................................77
Checking .................................................................77
BACK-UP LAMP SWITCH ...................................77
PARK/NEUTRAL POSITION SWITCH ................ 77
CONTROL LINKAGE ................................................78
Removal and Installation of Control Device and
Cable ......................................................................78
AIR BREATHER HOSE .............................................79
Removal and Installation ........................................ 79
TRANSAXLE ASSEMBLY ........................................ 80
Removal and Installation ........................................ 80
REMOVAL ........................................................... 80
INSTALLATION ....................................................81
Component Parts ....................................................82
CASE AND HOUSING COMPONENTS ..............82
GEAR COMPONENTS ........................................ 83
SHIFT CONTROL COMPONENTS .....................85
FINAL DRIVE COMPONENTS ............................86
Disassembly and Assembly ....................................86
DISASSEMBLY ...................................................86
ASSEMBLY ..........................................................89
Adjustment ..............................................................94
INPUTSHAFT END PLAY .................................... 94
DIFFERENTIAL SIDE BEARING PRELOAD .......95
MAINSHAFT END PLAY ......................................96
REVERSE IDLER GEAR END PLAY ..................97
INPUT SHAFT AND GEARS ..................................... 99
Disassembly and Assembly .................................... 99
DISASSEMBLY ....................................................99
INSPECTION AFTER DISASSEMBLY ..............100
ASSEMBLY ........................................................101
MAINSHAFT AND GEARS .....................................107
Disassembly and Assembly ..................................107
DISASSEMBLY ..................................................107
INSPECTION AFTER DISASSEMBLY ..............108
ASSEMBLY ........................................................110
REVERSE IDLER SHAFT AND GEARS ................115
Disassembly and Assembly ..................................115
DISASSEMBLY ..................................................115
INSPECTION AFTER DISASSEMBLY ..............115
ASSEMBLY ........................................................116
FINAL DRIVE ..........................................................117
Disassembly and Assembly ..................................117
PRE-INSPECTION ............................................117
DISASSEMBLY ..................................................117
INSPECTION AFTER DISASSEMBLY ..............118
ASSEMBLY ........................................................118
SHIFT CONTROL ....................................................121
Inspection ..............................................................121
SHIFT FORK ......................................................121
SERVICE DATA AND SPECIFICATIONS (SDS) ....122
General Specifications ..........................................122
TRANSAXLE ......................................................122
FINAL GEAR ......................................................122
Gear End Play .......................................................123
Clearance Between Baulk Ring and Gear ............123
3RD, 4TH, 5TH & REVERSE BAULK RING ......123
1ST AND 2ND DOUBLE BAULK RING .............123
Available Snap Rings ............................................123
INPUT SHAFT SPACER ....................................123
5TH MAIN GEAR ...............................................123
Available C-rings ...................................................124
MAINSHAFT C-RING ........................................124
Available Thrust Washers .....................................124
INPUT SHAFT THRUST WASHER ...................124
DIFFERENTIAL SIDE GEAR THRUST WASHER
Available Adjusting Shims .....................................125
MAINSHAFT ADJUSTING SHIM .......................125
INPUT SHAFT REAR BEARING ADJUSTING
SHIM ..................................................................125
MAINSHAFT REAR BEARING ADJUSTING
SHIM ..................................................................125
REVERASE IDLER GEAR ADJUSTING SHIM .126
Available Shims ....................................................126
BEARING PRELOAD .........................................126
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) .............................................................126
.124
MT-2
RS6F51H
PRECAUTIONS ...................................................... 127
Caution ................................................................. 127
PREPARATION ....................................................... 128
Special Service Tools ........................................... 128
Commercial Service Tools .................................... 130
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................ 131
NVH Troubleshooting Chart ................................. 131
DESCRIPTION ........................................................ 132
Cross-sectional View ............................................ 132
DOUBLE-CONE SYNCHRONIZER .................. 133
REVERSE GEAR .............................................. 133
M/T OIL ................................................................... 134
Replacement ........................................................ 134
DRAINING ......................................................... 134
FILLING ............................................................. 134
Checking .............................................................. 134
OIL LEAKAGE AND OIL LEVEL ....................... 134
SIDE OIL SEAL ...................................................... 135
Removal and Installation ...................................... 135
REMOVAL ......................................................... 135
INSTALLATION ................................................. 135
POSITION SWITCH ................................................ 136
Checking .............................................................. 136
BACK-UP LAMP SWITCH ................................ 136
PARK/NEUTRAL POSITION SWITCH ............. 136
CONTROL LINKAGE ............................................. 137
Removal and Installation of Control Device and
Cable .................................................................... 137
AIR BREATHE R HOSE .......................................... 138
Removal and Installation ...................................... 138
TRANSAXLE ASSEMBLY ...................................... 139
Removal and Installation ...................................... 139
REMOVAL ......................................................... 139
INSTALLATION ................................................. 140
Component Parts ................................................. 141
CASE AND HOUSING COMPONENTS ........... 141
GEAR COMPONENTS ..................................... 142
SHIFT CONTROL COMPONENTS .................. 144
FINAL DRIVE COMPONENTS ......................... 145
Disassembly and Assembly ................................. 145
DISASSEMBLY ................................................. 145
ASSEMBLY ....................................................... 148
Adjustment ........................................................... 153
INPUTSHAFT END PLAY ................................. 153
DIFFERENTIAL SIDE BEARING PRELOAD .... 154
MAINSHAFT END PLAY ................................... 156
REVERSE IDLER GEAR END PLAY ................ 157
INPUT SHAFT AND GEARS ..................................158
Disassembly and Assembly ..................................158
DISASSEMBLY .................................................158
INSPECTION AFTER DISASSEMBLY ..............159
ASSEMBLY .......................................................160
MAINSHAFT AND GEARS .....................................165
Disassembly and Assembly ..................................165
DISASSEMBLY .................................................165
INSPECTION AFTER DISASSEMBLY ..............166
ASSEMBLY .......................................................168
REVERSE IDLER SHAFT AND GEARS ................173
Disassembly and Assembly ..................................173
DISASSEMBLY .................................................173
INSPECTION AFTER DISASSEMBLY ..............173
ASSEMBLY .......................................................174
FINAL DRIVE ..........................................................175
Disassembly and Assembly ..................................175
DISASSEMBLY .................................................175
INSPECTION AFTER DISASSEMBLY ..............175
ASSEMBLY .......................................................175
SHIFT CONTROL ...................................................177
Inspection .............................................................177
SHIFT FORK .....................................................177
SERVICE DATA AND SPECIFICATIONS (SDS) ....178
General Specifications ..........................................178
TRANSAXLE .....................................................178
FINAL GEAR .....................................................179
Gear End Play ......................................................179
Clearance Between Baulk Ring and Gear ............179
3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING .179
1ST AND 2ND DOUBLE BAULK RING .............179
Available Snap Rings ...........................................180
6TH BUSHING ..................................................180
Available C-rings ..................................................180
MAINSHAFT C-RING ........................................180
Available Thrust Washers .....................................180
INPUT SHAFT THRUST WASHER ...................180
Available Adjusting Shims ....................................181
MAINSHAFT ADJUSTING SHIM ......................181
INPUT SHAFT REAR BEARING ADJUSTING
SHIM .................................................................181
MAINSHAFT REAR BEARING ADJUSTING
SHIM .................................................................181
REVERASE IDLER GEAR ADJUSTING SHIM .182
6TH MAIN GEAR ADJUSTING SHIM ...............182
Available Shims ....................................................182
BEARING PRELOAD ........................................182
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) .............................................................182
A
B
MT
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MT-3
PRECAUTIONS
[RS5F70A]
PRECAUTIONS
PFP:00001
Caution ECS004A3
● Do
● Check
● During
● Check
● In
● Be
not reuse transaxle oil, once it has been drained.
oil level or replace oil with vehicle on level ground.
removal or installation, keep inside of transaxle clear of dust or dirt.
for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
careful not to damage sliding surfaces and mating surfaces.
MT-4
PREPARATION
[RS5F70A]
PREPARATION PFP:00002
Special Servic e Tools ECS004A4
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
KV38107700
(J39027)
Preload adapter
NT087
KV38106000
(J34291-B)
Height gauge adapter
(differential side bearing)
Description
Measuring turning torque of final drive assembly
Measuring total turning torque
Measuring clearance between side gear and
differential case with washer
Selecting differential side bearing adjusting
shim [Use with KV38106000 (J34291-B).]
Selecting differential side bearing adjusting
shim [Use with KV38107700 (J39027).]
a: 140 mm (5.51 in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 × 1.25P
A
B
MT
D
E
F
KV32101000
(J25689-A)
Pin punch
KV31100300
(J25689-A)
Pin punch
ST30031000
(J22912-O1)
Puller
ST30021000
(J22912-O1)
Puller
NT418
NT410
NT410
NT411
NT411
Removing and installing retaining pin
Removing and installing lock pin
Removing selector shaft
Removing welch plug
a: 4 mm (0.16 in) dia.
Removing and installing retaining pin
a: 4.5 mm (0.177 in) dia.
Removing 3rd, 5th input gear
Removing 3rd & 4th and 5th & Rev synchronizer hub
Removing mainshaft rear bearing
Removing 2nd gear, 5th gear bush
Removing 1st & 2nd synchronizer hub, 1st
and 4th main gear
Removing and installing differential side bearing
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
Removing input shaft front and rear bearing
Installing input shaft front and rear bearing
Installing 5th input gear, 3rd main gear and
4th main gear
Installing 1st & 2nd, 3rd & 4th and 5th & Rev
synchronizer hub
Installing 2nd gear bush, 5th gear bush, Rev
gear bush
Installing mainshaft rear bearing
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
G
H
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MT-5
Tool number
(Kent-Moore No.)
Tool name
ST33061000
(J8107-2)
Drift
ST33290001
(J34286)
Puller
ST33230000
(J25805-O1)
Drift
PREPARATION
NT073
NT414
[RS5F70A]
Description
Removing differential side bearing
a: 39 mm (1.54 in) dia.
b: 29.5 mm (1.16 in) dia.
● Removing
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
Removing differential oil seal
Installing differential side bearing
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
idler gear bearing outer race
ST30720000
(J25405)
Drift
ST22350000
(J25678-O1)
Drift
ST22452000
(J34335)
Drift
ST37750000
(J34335)
Drift
NT084
NT115
NT065
NT065
NT065
Installing differential side bearing outer race
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
Installing input shaft front and rear bearing
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
Installing 3rd and 4th main gear
Installing 5th gear bush
Installing 5th & Rev synchronizer hub
Installing Rev gear bush
Installing mainshaft rear bearing
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
Installing input shaft oil seal
Installing 5th synchronizer
Installing mainshaft rear bearing
Installing 5th main gear
Installing 3rd & 4th synchronizer hub
Installing striking rod oil seal
Installing clutch housing dust seal
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
MT-6
PREPARATION
[RS5F70A]
Tool number
(Kent-Moore No.)
Tool name
ST30621000
(J35869)
Drift
NT073
ST30611000
(J25742-1)
Drift handle
NT419
Description
Installing differential side bearing outer race
[Use with ST30611000 (J25742-1).]
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
Installing differential side bearing outer race
[Use with ST30621000 (J35869).]
a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 in) dia.
d: M12 × 1.5P
Commercial Service Tools ECS004A5
Tool name Description
Drift Installing differential side bearing inner race
a: 56 mm (2.20 in) dia.
b: 50.5 mm (1.988 in) dia.
A
B
MT
D
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NT065
Drift Removing input shaft rear bearing
Removing mainshaft rear bearing
a: 22 mm (0.87 in) dia.
b: 16 mm (0.63 in) dia.
NT065
Drift Installing differential oil seal
(Transaxle case side)
a: 58 mm (2.28 in) dia.
b: 50 mm (1.97 in) dia.
NT065
Drift Installing differential oil seal
(Clutch housing side)
a: 54 mm (2.13 in) dia.
b: 50 mm (1.97 in) dia.
NT065
Drift Installing 2nd gear bush
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
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MT-7
NT065
PREPARATION
[RS5F70A]
Tool name Description
Drift Installing 3rd & 4th and 1st & 2nd synchroniz-
er hub
Installing mainshaft front bearing
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
NT065
Drift Installing input shaft oil seal
Installing 5th input gear
a: 39 mm (1.54 in) dia.
b: 30 mm (1.18 in) dia.
NT065
MT-8
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[RS5F70A]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart ECS004A6
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.
MT-22
Reference page
MT-11
MT-11
MT-11
MT-19
MT-14
MT-21
damaged)
or
(Worn
BALL
MT-20,
A
B
MT
D
E
F
SUSPECTED PARTS (Possible cause)
Noise 1 2 3 3
Symptom
Oil leakage 31222
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3
CHECK
AND
SPRING
damaged)
damaged)
or
low)
is
level
(Oil
high)
is
oil)
level
(Wrong
(Oil
(Damaged)
GASKET
(Worn
SEAL
OIL
(Worn)
or
(Worn
O-RING
RETURN
ROD
PLUG
CONTROL
CHECK
(Worn)
FORK
SHIFT
damaged)
or
(Worn
GEAR
damaged)
or
damaged)
or
(Worn
(Worn
RING
BEARING
BAULK
(Damaged)
INSERT
SHIFTING
SPRING,
INSERT
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MT-9
DESCRIPTION
[RS5F70A]
DESCRIPTION
PFP:00000
CROSS-SECTIONAL VIEW ECS004A7
DOUBLE-CONE SYNCH RONIZER
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.
MT-10
WCIA0017E
SMT837DA
M/T OIL
[RS5F70A]
M/T OIL PFP:KLD20
Replacement ECS004A8
DRAINING
1. Start the engine and let it run to warm up the transaxle.
2. Stop the engine. Remove drain plug and drain oil.
3. Set a gasket on the drain plug and install it on the transaxle.
Drain plug : 10 - 19 N·m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
CAUTION:
Do not reuse gasket.
SMA145AA
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole.
Oil grade : API GL-4, Viscosity SAE 75W-85
Capacity (reference)
2. After refilling oil, check oil level. Assemble gasket on to filler plug, then install it on the transaxle body.
Filler plug : 10 - 19 N·m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
CAUTION:
Do not reuse gasket.
: Approximately 3.0
(3
1/8 US qt, 2 5/8 Imp qt)
A
B
MT
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Checking ECS004A9
OIL LEAKAGE AND OIL LEVEL
● Check
● Check
ure.
CAUTION:
Never start engine while checking oil level.
● Set
CAUTION:
Do not reuse gasket.
that oil is not leaking from transaxle.
oil level from filler plug mounting hole as shown in the fig-
a
new gasket on the filler plug and install it on the transaxle.
Filler plug : 10 - 19 N·m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
SMA066C
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MT-11
SIDE OIL SEAL
[RS5F70A]
SIDE OIL SEAL
PFP:32113
Removal and Installation ECS004AA
1. Remove drain plug and drain gear oil from transaxle.
2. Remove drive shafts. Refer to FAX-16, "
3. Remove differential oil seal using Tool.
4. Install differential oil seal with a suitable tool.
● Apply
multi-purpose grease to seal lip of oil seal before install-
ing.
Removal" .
SMT563A
5. Install drive shafts. Refer to FAX-18, "
● Install
differential oil seal so that dimension “A” and “B” are
Installation" .
within specifications.
Item Model A B
Dimension
QG18DE
(RS5F70A)
0.5 (0.020) or less 5.5 - 6.5 (0.217 - 0.256)
SMT126DB
Unit: mm (in)
WCIA0001E
MT-12
POSITION SWITCH
[RS5F70A]
POSITION SWITCH PFP:32005
Position Switch Check ECS004AB
BACK-UP LAMP SWITCH
● Check
continuity.
Gear position Continuity
Reverse Yes
Except reverse No
A
B
MT
D
PNP SWITCH
● Check
continuity.
Gear position Continuity
Except neutral No
Neutral Yes
SMT715BD
E
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MT-13
M
CONTROL LINKAGE
[RS5F70A]
CONTROL LINKAGE
PFP:34103
Removal and Installation ECS004AC
TRANSAXLE GEAR CONTROL
Refer to the figure below for removal and installation procedure.
1. Control lever knob 2. Boot 3. Finisher
4. Control lever bracket 5. Dust cover 6. Socket
7. Control lever 8. O-ring 9. O-ring
10. Ring spring 11. Bearing seat 12. Seat
13. Return spring 14. Control rod 15. Bushing
16. Collar 17. Bushing 18. Bracket
19. Bushing 20. Collar 21. Washer
22. Support rod bracket 23. Support rod
MT-14
SMT904D
CONTROL LINKAGE
STRIKING ROD OIL SEAL
1. Remove transaxle control rod from yoke.
2. Remove retaining pin of yoke using Tool.
● Be
careful not to damage boot.
3. Remove the boot.
[RS5F70A]
A
B
MT
4. Remove striking rod oil seal with a suitable tool.
5. Install striking rod oil seal using Tool.
● Apply
multi-purpose grease to seal lip of oil seal before install-
ing.
6. Install the boot.
7. Install yoke and retaining pin.
8. Connect the transaxle control rod to the yoke.
SMT143DB
SMT566A
SMT570AA
D
E
F
G
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MT-15
L
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TRANSAXLE ASSEMBLY
[RS5F70A]
TRANSAXLE ASSEMBLY
PFP:32010
Removal and Installation ECS004AD
REMOVAL
WMT009
1. Remove battery negative terminal.
2. Remove air cleaner and air duct.
3. Remove clutch operating cylinder from transaxle. Refer to CL-
11, "Removal" .
4. Disconnect back-up lamp switch, speedometer sensor, PNP
switch and ground harness connectors.
5. Remove starter motor from transaxle. Refer to SC-20,
"Remova l" .
WMT010
WCIA0006E
MT-16
TRANSAXLE ASSEMBLY
6. Remove air breather hose.
7. Remove shift control rod and support rod from transaxle.
8. Remove the drain plug and drain gear oil from transaxle.
9. Draw out drive shafts from transaxle. Refer to FAX-16,
"Removal" .
[RS5F70A]
A
B
MT
SMT132D
D
E
F
G
WMT005
10. Support engine by placing a jack under oil pan.
CAUTION:
Do not place jack under oil pan drain plug.
11. Remove LH side and rear side mounting bolts.
12. Remove lower housing bolts.
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WMT007
MT-17
SMT658B
TRANSAXLE ASSEMBLY
13. Remove bolts securing transaxle.
14. Lower transaxle while supporting it with a jack.
INSTALLATION
● Tighten
starter motor to transaxle.
Starter motor bolt tightening torque : 31 - 42 N·m (3.2 - 4.3 kg-m, 23 - 31 ft-lb)
[RS5F70A]
SMT659B
● Tighten
● Install
Front gusset to engine 30 - 40 (3.1 - 4.1, 22 - 30) 20 (0.79)
Rear gusset to
engine
LH
and rear mounts to the specified torque. Refer to EM-54, "Removal and Installation" .
transaxle and any part removed.
Bolt No.
130
230
316
A
B20
Tightening torque
N·m (kg-m, ft-lb)
- 40
(3.1 - 4.1, 22 - 30) 50 (1.97)
- 40
(3.1 - 4.1, 22 - 30) 30 (1.18)
- 21
(1.6 - 2.1, 12 - 15) 25 (0.98)
16 - 21 (1.6 - 2.1, 12 - 15)
“” mm (in)
17.5 (0.689)
(0.79)
WMT018
WMT019
Component Parts ECS004AE
MT-18
CASE COMPONENTS
TRANSAXLE ASSEMBLY
[RS5F70A]
A
B
MT
D
E
F
G
1. Clutch housing 2. Dust seal 3. Oil pocket
4. Check plug 5. Input shaft oil seal 6. Oil channel
7. Mainshaft front bearing 8. Bearing retainer 9. Reverse idler gear front thrust
washer
10. Reverse idler gear 11. Reverse idler gear bearing 12. Reverse idler gear rear thrust
washer
13. O-ring 14. Reverse idler gear shaft 15. Snap ring
16. Back-up lamp switch 17. Filler plug 18. Side cover gasket
19. Side cover 20. Welch plug 21. Mainshaft bearing snap ring
22. Mainshaft rear bearing adjusting
shim
25. Differential oil seal 26. Drain plug 27. PNP switch
28. Transmission case 29. Oil gutter 30. Welch plug
23. O-ring 24. Rear cover
H
I
J
K
L
M
WMT014
MT-19
TRANSAXLE ASSEMBLY
31. Boot 32. Striking rod oil seal 33. Welch plug
34. Differential oil seal 35. O-ring 36. Speedometer pinion
GEAR COMPONENTS
[RS5F70A]
1. Reverse idler gear front thrust
washer
4. Reverse idler gear rear thrust
washer
7. Snap ring 8. Input shaft front bearing 9. Input shaft
10. 3rd gear needle bearing 11. 3rd input gear 12. 3rd gear baulk ring
13. Coupling sleeve 14. Spread spring 15. Shifting insert
16. 3rd & 4th synchronizer hub 17. Spread spring 18. 4th gear C-ring
19. 4th gear needle bearing 20. 4th gear baulk ring 21. 4th input gear
22. 5th gear front C-ring 23. 5th input gear 24. 5th gear rear C-ring
25. C-ring holder
28. Input shaft rear bearing adjusting
shim
31. 1st gear needle bearing 32. 1st main gear 33. 1st inner baulk ring
34. 1st synchronizer cone 35. 1st outer baulk ring 36. 1st & 2nd synchronizer hub
37. Coupling sleeve 38. Insert spring 39. 2nd gear bushing
40. 2nd gear needle bearing 41. 2nd gear outer baulk ring 42. 2nd gear synchronizer cone
43. 2nd inner baulk ring 44. 2nd main gear 45. 3rd main gear
46. Spacer 47. Mainshaft adjusting shim 48. 4th main gear
49. 5th gear bushing 50. 5th gear needle bearing 51. 5th main gear
52. 5th gear baulk ring 53. Spread spring 54. Shifting insert
55. 5th & reverse synchronizer hub 56. Spread spring 57. Coupling sleeve
58. Reverse gear bushing 59. Reverse gear needle bearing 60. Reverse gear baulk ring
61. Reverse main gear 62. Sub-gear 63. Sub-gear washer
2. Reverse idler gear 3. Reverse idler gear bearing
5. O-ring 6. Reverse idler gear shaft
26. Input shaft rear bearing 27. Oil channel
29. Mainshaft front bearing 30. Mainshaft
SMT641DA
MT-20
TRANSAXLE ASSEMBLY
64. Snap ring 65. Mainshaft thrust washer 66. Mainshaft rear bearing
67. Mainshaft C-ring 68. C-ring holder 69. Snap ring
SHIFT CONTROL COMPONENTS
[RS5F70A]
A
B
MT
D
E
F
G
1. Clutch housing 2. 3rd & 4th bracket 3. 3rd & 4th shift fork
4. Retaining pin 5. Check ball 6. Check pin
7. Check spring 8. Check plug 9. Stopper ring
10. 3rd & 4th fork rod 11. Selector shaft pin 12. Selector
13. 5th & reverse bracket 14. Reverse switch bracket 15. Retaining pin
16. 5th & reverse shift fork 17. Interlock plunger 18. Check ball
19. Interlock pin 20. Stopper ring 21. 5th & reverse fork rod
22. Striking lever 23. Retaining pin 24. 1st & 2nd bracket
25. 1st & 2nd shift fork 26. Check ball 27. 1st & 2nd fork rod
28. Transaxle case 29. Check ball 30. Check spring
31. Check plug 32. Select check leaf spring 33. Return spring
34. Steel ball 35. Reverse gate 36. Return bearing
37. Selector arm 38. Bushing 39. Welch plug
40. Selector shaft 41. Striking yoke 42. Retaining pin
43. Striking rod 44. Dust boot 45. Striking rod oil seal
46. Welch plug
WMT015
H
I
J
K
L
M
MT-21
FINAL DRIVE COMPONENTS
TRANSAXLE ASSEMBLY
[RS5F70A]
WCIA0003E
1. D ifferential side bearing adjusting
shim
4. Final gear 5. Differential case 6. Speedometer drive gear
7. Speedometer stopper 8. Differential side bearing 9. D ifferential side bearing outer race
10. Pinion mate thrust washer 11. Pinion mate gear 12. Side gear thrust washer
13. Side gear 14. Pinion mate shaft 15. Lock pin
2. Differential side bearing outer race 3. D ifferential side bearing
Disassembly and Assembly ECS0 04AF
DISASSEMBLY
Transaxle Case
1. Remove back-up lamp switch, PNP switch, drain plug, and filler
plug from transaxle case.
WMT023
MT-22
TRANSAXLE ASSEMBLY
2. Remove snap rings from reverse idler shaft.
3. Remove side cover and rear cover from case.
4. Remove O-ring and mainshaft bearing adjusting shim.
5. Remove reverse idler gear shaft.
a. Attach bolt (M6) to thread of reverse idler gear shaft end.
b. Pull out the attached bolt, and remove reverse idler gear shaft
from case.
6. Remove reverse idler gear, thrust washer (front, rear), and bearing from case.
[RS5F70A]
A
B
MT
SMT644D
D
E
F
G
SMT645D
7. Remove snap ring of mainshaft bearing from case.
8. Remove check plugs, springs, and check balls from case.
9. Remove mounting bolts.
10. Remove input shaft rear bearing adjusting shim from transaxle
case.
SMT646D
SMT647D
H
I
J
K
L
M
MT-23
SMT649D
TRANSAXLE ASSEMBLY
11. Remove oil gutter from case.
12. Remove differential side bearing outer race and adjusting shim
from case using Tool.
[RS5F70A]
SMT650D
13. Remove differential oil seal from case using Tool.
14. Remove welch plugs from case using Tool.
SMT651DA
SMT653DA
SMT839DA
MT-24
TRANSAXLE ASSEMBLY
Clutch Housing
1. Remove transaxle case from clutch housing.
2. Remove check plugs, check springs, check pins, and check
balls from housing.
[RS5F70A]
A
B
MT
3. Remove 3rd & 4th bracket retaining pin using Tool.
4. Remove 3rd & 4th shift fork stopper ring.
5. Remove 3rd & 4th fork rod.
6. Remove 3rd & 4th shift fork and bracket.
SMT654D
SMT656DA
D
E
F
G
H
I
J
K
7. Remove interlock plunger and check ball.
8. Remove 5th & reverse bracket stopper ring.
SMT655D
L
M
SMT658D
MT-25
TRANSAXLE ASSEMBLY
9. Remove retaining pin from 5th & reverse shift fork and reverse
switch bracket using Tool.
10. Remove 5th & reverse fork rod.
11. Remove interlock pin from 5th & reverse fork rod using Tool.
12. Remove reverse switch bracket and 5th & reverse bracket.
13. Remove check ball from housing.
14. Remove retaining pin for 1st & 2nd shift fork and bracket using
Tool.
15. Remove 1st & 2nd fork rod.
16. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd
bracket.
[RS5F70A]
SMT657DA
17. Remove both input shaft and mainshaft assemblies from housing.
18. Remove final drive assembly from housing.
19. Remove oil pocket from housing.
SMT659DA
SMT660D
SMT661D
20. Remove mainshaft bearing retainer from housing.
21. Cut off oil channel using a cutter as shown in the figure.
MT-26
SMT662D
TRANSAXLE ASSEMBLY
[RS5F70A]
22. Remove mainshaft front bearing from housing using Tool.
23. Using a magnet or other suitable tool, remove selector pin from
selector shaft.
24. Remove selector shaft and plug, then remove selector using
Tool.
SMT663DA
SMT664D
A
B
MT
D
E
F
G
H
I
25. Remove reamer bolts, then remove select check leaf spring,
return spring, steel ball, reverse gate, selector arm, bearing, and
bushing.
CAUTION:
Be careful not to lose the steel ball.
J
K
SMT665DA
L
M
SMT666DA
MT-27
TRANSAXLE ASSEMBLY
26. Remove retaining pin and plug from striking lever using Tool.
27. Remove striking rod, then striking lever from housing.
28. Using a flat-head screwdriver or other suitable tool, remove dust
seal, input shaft oil seal, and striking rod oil seal from housing.
CAUTION:
When removing dust and oil seals, be careful not to damage
mounting surfaces of dust seal and oil seal.
[RS5F70A]
SMT667DA
29. Remove differential oil seal from housing using Tool.
30. Remove differential side outer race from housing using Tool.
SMT668D
WMT021
MT-28
SMT670DA
TRANSAXLE ASSEMBLY
ASSEMBLY
Clutch Housing
1. Hammer the striking rod oil seal into clutch housing as far as it
will go using Tool.
CAUTION:
Do not reuse striking rod oil seal.
[RS5F70A]
A
B
MT
D
SMT722DA
2. Hammer the differential oil seal into clutch housing with a suitable tool until it becomes flush with clutch housing end face.
CAUTION:
Do not reuse differential oil seal.
3. Hammer input shaft oil seal into clutch housing as far as it will go
with a suitable tool.
CAUTION:
Do not reuse input shaft oil seal.
SMT723DA
SMT724DA
E
F
G
H
I
J
K
L
4. Hammer the dust seal into clutch housing as far as it will go
using Tool.
CAUTION:
Do not reuse dust seal.
MT-29
M
SMT725DA
TRANSAXLE ASSEMBLY
5. Install outer race of differential side bearing using Tool.
6. Install new oil channel (mainshaft).
CAUTION:
Pay attention to installation direction of oil channel.
[RS5F70A]
SMT726DA
7. Align the notches on mainshaft front bearing and transaxle case.
Then, install mainshaft front bearing with a suitable tool.
8. Install mainshaft bearing retainer, and tighten bolts with specified torque.
SMT727D
SMT728DA
MT-30
SMT729D
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