NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[FS5W71C]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
PFP:00003
ECS006I4
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 part s.
Reference page
MA-35
SUSPECTED PARTS
(Possible cause)
MT-18
MT-22
MT-24
Symptom
OIL (Oil level is low .)
OIL (Wrong oil.)
OIL (Oil level is high.)
GASKET (Damaged)
OIL SEAL (Worn or damaged)
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
SHIFT FORK (Worn)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
BAULK RING (Worn or damaged)
Noise1233
Oil leakage3122
Hard to shift or will not shift1122
Jumps out of gear122
INSERT SPRING (Damaged)
MT-6
DESCRIPTION
[FS5W71C]
DESCRIPTIONPFP:00000
CROSS-SECTIONAL VIEW
ECS006I5
A
B
MT
D
E
F
G
H
K
M
I
J
L
MT-7
WCIA0175E
DESCRIPTION
[FS5W71C]
1.Steel ball2.Mainshaft front bearing3.Reverse main gear
1.Remove the propeller shaft. Refer to PR-8, "Removal an d Installation" .
2.Remove rear oil seal using Tool.
● Always replace with a new seal once it has been
removed.
Tool number: ST33290001 (J34286)
INSTALLATION
1.Install new rear oil seal using Tool until it stops.
● Apply multi-purpose grease to seal lip of oil seal before
installing.
Tool number: ST33400001 (J26082)
ECS006I6
WCIA0176E
A
B
MT
D
E
F
G
2.Installation is in the reverse order of removal.
Position Switch Check
●Check continuity.
SwitchGear positionContinuity
Back-up lamp switch
Park/neutral position
(PNP) switch
ReverseYes
Except reverseNo
NeutralYes
Except neutralNo
SMT480CA
ECS006I7
H
I
J
K
L
M
MT-9
SMT981D
TRANSMISSION ASSEMBLY
[FS5W71C]
TRANSMISSION ASSEMBLY
Removal and Installation
REMOVAL
PFP:32010
ECS006I8
WMT030
CAUTION:
Before separating the transmission from the engine, remove the crankshaft position sensor (OBD)
from the transmission. Be careful not to damage sensor edge or ring gear teeth.
MT-10
TRANSMISSION ASSEMBLY
[FS5W71C]
NOTE:
To prevent oil s pills, drain transmission oil before remo ving transmission or insert plug into rear oil
seal after removing propeller shaft.
●Be careful not to damage spline, sleeve yoke, and rear oil seal when removing propeller shaft.
1.Remove battery negative terminal.
2.Remove the crankshaft position sensor (OBD) from transmission upper side.
3.Remove the clutch operating cylinder fr om transmission. Refer to CL-9, "
4.Disconnect the vehicle speed sensor, back-up switch, and park/neutral position (PNP) switch harness
connectors.
5.Remove the starter motor. Refer to SC-23, "
6.Disconnect the exhaust hanger. Refer to EX-3, "
7.Remove the propeller shaft. Refer to PR-8, "
Removal and Ins tallation" .
Removal and Installation" .
Removal and Installation" .
8.Remove the shift lever.
9.Support the engine by placing a jack under the oil pan.
14. Apply sealant to select ch ec k plu gs . Tighten se le ct ch ec k pl ugs.
● Use Genuine Anae rob ic Li quid Gasket , or eq uiva lent. Refer to
MA-12, "
Select check
plugs
RECOMMENDED FLUIDS AND LUBRICANTS" .
: 20 - 29 N·m (2.0 - 3.0 kg-m,
14 - 22 ft-lb)
15. In s tall control housing and new gasket.
Control housing
bolts
: 14 - 18 N·m (1.4 - 1.8 kg-m,
10 - 13 ft-lb)
B
MT
D
E
SMT161D
F
G
H
I
K
M
J
L
MT-21
SHIFT CONTROL COMPONENTS
[FS5W71C]
SHIFT CONTROL COMPONENTS
Disassembly
1.Set up Tool on adapter plate.
Tool number: ST23810001 ( — )
2.Remove striking rod from adapter pl ate.
3.Remove check ball plugs, check springs, and check balls.
NOTE:
Mark locations of interlock balls to ensure proper installation.
4.Drive out retaining pins. Then drive out fork rods and remove
interlock balls.
PFP:32982
ECS006IC
SMT545A
Inspection
●Check contact and sliding surfaces of fork rods for wear,
scratches, projecti on s an d ot h er dama ge.
SMT984
ECS006ID
MT-22
SMT075C
SHIFT CONTROL COMPONENTS
[FS5W71C]
Assembly
1.Install fork rods, interlock plunger, interlock balls and check
balls.
2.Install 1st and 2nd shift fork, then drive in retaining pin.
3.Install 3rd and 4th shift fork, then drive in retaining pin.
ECS006IE
SMT992-A
SMT989
A
B
MT
D
E
F
G
H
4.Install overdrive and reverse shift fork, then drive in retaining
pin.
I
J
K
SMT990
L
M
SMT991
MT-23
GEAR COMPONENTS
[FS5W71C]
GEAR COMPONENTS
Disassembly
1.Before disassembly, measure the end play of each gear.
● If end play is no t within the specified limit, d isassemble and
inspect the parts.
● Replace any part whic h is worn or da maged. R efer to MT-35,
"Gear End Play" .
2.Mesh 2nd and reverse gear, then remove counter gear front
bearing using a suitable puller.
3.Remove counter gear s nap rin g, then r emove s ub-ge ar brac ket,
sub-gear spring and sub-gear.
PFP:31460
ECS006IF
SMT025
4.Remove counter drive gear together with main drive gear
assembly using a suitable puller. Remove woodruff keys and
pilot bearing.
● When removing main drive gear assembly, be careful not to
drop pilot bear ing or baulk ring.
5.Remove mainshaft front snap ring, then remove 3rd and 4th
synchronizer assembly, 3rd main gear and needle bearing using
suitable puller.
6.Disassemble parts at rear of ad apter plate as follows:
a.Release staking o n both counter gear and main shaft lock nuts,
then loosen both nuts.
Mainshaft lock nut: Left-hand thread
SMT174A
SMT162A
WCIA0181E
MT-24
GEAR COMPONENTS
[FS5W71C]
b.Remove overdrive counter gear together with counter gear rear
end bearing using a suitable puller.
c.Remove reverse counter ge ar an d reve rs e co un ter ge ar spacer.
d.Remove snap rings from reverse idler shaft, then remove
steel ball, reverse idler thrust washer and reverse idler gear
bearing.
SMT547A
e.Remove overdrive mainshaft bearing snap ring and pull out overdrive mainshaft bearing using Tool, then
remove snap ring.
A
B
MT
D
Tool number: (J-26349-A), (J-25726-B)
f.Remove mainshaft lock nut.
g.Remove speedometer drive gear and steel ball.
h.Remove thrust w asher, steel roller, roller bearing and washer.
i.Remove overdrive main gear, needle bearing and overdrive baulk ring.
j.Remove counter gear by tapping on rear end of counter gear.
k.Press out overdrive gear bushing and overdrive & reverse synchronizer assembly.
l.Remove reverse main gear and needle bearing.
m. Press out reverse main gear bushing.
n.Remove mainshaft by tapping on rear end of mainshaft.
7.Remove 1st gear thrust washer, steel ball, 1st main gear and
needle bearing and 1st and 2nd synchronizer assembly.
● Be careful not to lose steel ball.
SMT554A
E
F
G
H
I
J
K
L
M
MT-25
SMT383A
GEAR COMPONENTS
8.Press out 1st gear bushing together with 2nd main gear using
Tool.
Tool number: ST30031000 (J22912-01)
9.Remove 2nd gear needle bearing.
10. Remove main drive gear ball bearing.
a.Remove main drive gear ball bearing snap ring.
b.Remove main drive gear ball bearing using Tool.
Tool number: ST30031000 (J22912-01)
11. Disassemble adapter plate components.
a.Remove bearing retainer.
b.Remove oil gutter
c.Remove reverse idler shaft.
d.Remove main shaft ball bearing and counter rear be aring using
suitable tool.
[FS5W71C]
TM049A
SMT420A
Inspection
GEARS AND SHAFTS
●Check shafts for cracks, wear and bending.
●Check gears for excessive wear, chips and cracks .
ECS006IG
SMT386A
MT-26
SMT550A
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