Nissan X-Trail 2001 Owner's Manual

MANUAL TRANSAXLE

C TRANSMISSION/TRANSAXLE

SECTION

CONTENTS

PRECAUTIONS .......................................................... 3

Caution ..................... ................................................ 3

PREPARATION ..................................... ...................... 4

Special Service Tools ............................................... 4

Commercial Service Tools ........................................ 6

NOISE, VIBRATION, AND HARSHNESS (NVH)

TROUBLESHOOTING .......................... ...................... 7

NVH Troubleshooting Chart ..................................... 7

MANUAL TRANSAXLE ......................................... 7

DESCRIPTION ......................... ................................... 8

Cross-Sectional View ............................................... 8

DOUBLE-CONE SYNCHRONIZER ...................... 9

REVERSE GEAR NOISE PREVENTION FUNC-

TION (SYNCHRONIZING METHOD) ................... 9

M/T OIL ..................................................................... 10

Changing M/T Oil ............................................ ....... 10

DRAINING ................................ ............. .............. 10

FILLING .............................. ...... ........................... 10

Checking M/T Oil .................................................... 10

OIL LEAKAGE AND OIL LEVEL ......................... 10

SIDE OIL SEAL .........................................................11

Removal and Installation .........................................11

REMOVAL ............................................................11

INSTALLATION ....................................................11

POSITION SWITCH .................................................. 12

Checking ................................................................ 12

BACK-UP LAMP SWITCH .................................. 12

PARK/NEUTRA L PO SI TION SWITCH ............... 12

CONTROL LINKAGE ............................................... 13

Removal and Installation of Control Device and

Cable .............................. ........................................ 13

AIR BREATHER HOSE ............................................ 14

Removal and Installation ........................................ 14

TRANSAXLE ASSEMBLY ........................................ 15

Removal and Installation ........................................ 15

REMOVAL ........................................................... 15

INSTALLATION ................................................... 16

Component Parts (RS5F51A) ................................ 17

MANUAL TRANSAXLE

CASE AND HOUSING COMPONENTS ..............17

GEAR COMPONENTS .......................................18

SHIFT CONTROL COMPONENTS .....................20

FINAL DRIVE COMPONENTS ...........................21

Component Parts (RS6F51A) .................................22

CASE AND HOUSING COMPONENTS ..............22

GEAR COMPONENTS ....................................... 23

SHIFT CONTROL COMPONENTS .....................25

FINAL DRIVE COMPONENTS ...........................26

Disassembly and Assembly (RS5F51A) .................26

DISASSEMBLY ................................................... 26

ASSEMBLY ......................................................... 30

Disassembly and Assembly (RS6F51A) .................35

DISASSEMBLY ................................................... 35

ASSEMBLY ......................................................... 39

Adjustment (RS5F51A) ...........................................45

INPUT SHAFT END PLAY .................................. 45

MAINSHAFT END PLAY .....................................46

DIFFERENTIAL SIDE BEARING PRELOAD ......47

REVERSE IDLER GEAR END PLAY .................. 48

Adjustment (RS6F51A) ...........................................49

INPUT SHAFT END PLAY .................................. 49

MAINSHAFT END PLAY .....................................50

DIFFERENTIAL SIDE BEARING PRELOAD ......51

REVERSE IDLER GEAR END PLAY .................. 52

INPUT SHAFT AND GEARS ....................................54

Assembly and Disassembly (RS5F51A) .................54

DISASSEMBLY ................................................... 54

INSPECTION AFTER DISASSEMBLY ................55

ASSEMBLY ......................................................... 57

Assembly and Disassembly (RS6F51A) .................61

DISASSEMBLY ................................................... 61

INSPECTION AFTER DISASSEMBLY ................62

ASSEMBLY ......................................................... 64

MAINSHAFT AND GEARS ....................................... 68

Assembly and Disassembly (RS5F51A) .................68

DISASSEMBLY ................................................... 68

INSPECTION AFTER DISASSEMBLY ................69

MT-1

ASSEMBLY .........................................................71

Assembly and Disassembly (RS6F51A) .................76

DISASSEMBLY ...................................................76

INSPECTION AFTER DISASSEMBLY ................77

ASSEMBLY .........................................................79

REVERSE IDLER SHAFT AND GEARS ........... ....... 84

Assembly and Disassembly (RS5F51A) .................84

DISASSEMBLY ...................................................84

INSPECTION AFTER DISASSEMBLY ................84

ASSEMBLY .........................................................85

Assembly and Disassembly (RS6F51A) .................85

DISASSEMBLY ...................................................85

INSPECTION AFTER DISASSEMBLY ................85

ASSEMBLY .........................................................86

FINAL DRIVE ............................................................87

Assembly and Disassembly (RS5F51A) .................87

PRE-INSPECTION ..............................................87

DISASSEMBLY ...................................................87

INSPECTION AFTER DISASSEMBLY ................88

ASSEMBLY .........................................................88

Assembly and Disassembly (RS6F51A) .................90

PRE-INSPECTION ..............................................90

DISASSEMBLY ...................................................91

INSPECTION AFTER DISASSEMBLY ................92

ASSEMBLY .........................................................92

SHIFT CONTROL ...................................................... 95

Inspection (RS5F51A) ............................................95

SHIFT FORK .......................................................95

Inspection (RS6F51A) ............................................96

SHIFT FORK .......................................................96

SERVICE DATA AND SPECIFICATIONS (SDS) ......97

General Specifications ............................................97

TRANSAXLE ................... ....... ...... ....... ...... ....... ....97

FINAL GEAR ........................................................98

Gear End Play .........................................................98

Clearance Between Baulk Ring and Gear ..............98

3RD,4TH,5TH,6TH & REVERSE BAULK RING ...98

1ST AND 2ND DOUBLE BAULK RING ...............98

Available Snap Rings ..............................................99

INPUT SHAFT SPACER ......................................99

6TH BUSHING .....................................................99

5TH MAIN GEAR .................................................99

Available C-Rings ...................................................99

MAINSHAFT C-RING ..........................................99

Available Thrust Washer .......................................100

INPUT SHAFT THRUST WASHER ...................100

DIFFERENTIAL SIDE GEAR THRUST WASHER

.100

Available Adjusting Shims .....................................100

MAINSHAFT ADJUSTING SHIM .......................100

INPUT SHAFT REAR BEARING ADJUSTING

SHIM ......................... .........................................101

MAINSHAFT REAR BEARING ADJUSTING

SHIM ......................... .........................................101

REVERSE IDLER GEAR ADJUSTING SHIM ....101

6TH MAIN GEAR ADJUSTING SHIM ................101

Available Shims ....................................................102

BEARING PRELOAD .........................................102

DIFFERENTIAL SIDE BEARING ADJUSTING

SHIM(S) .............................................................102

MT-2

PRECAUTIONS

PRECAUTIONS PFP:00001

Caution ECS008BM

● Do not reuse transaxle oil, once it has been drained.

● Check oil level or replace oil with vehicle on level ground.

● During removal or installation, keep inside of transaxle clear of dust or dirt.

● Check for the correct installatio n status prior to rem oval or d isassembly. If mating marks are requ ired, be

certain they do not interfere with the function of the parts they are applied to.

● In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If

tightening se quence is specified, ob serve it.

● Be careful no t to damage sliding surfaces and mating surfaces.

MT-3

PREPARATION

PFP:00002

Special Service Tools ECS008BN

Tool name Tool number

Puller KV381054S0

ZZA0601D

Drift ST35321000 a: 49 mm (1.93 in) dia. b: 41 mm (1.61 in) dia.

ZZA1000D

Drift ST30720000 a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia.

ZZA0811D

Description

● Side bearing outer race removal

● Mainshaft front bearing removal

● Input shaft oil seal installation

● Reverse main gear installation

● 1st bushing installation

● 1st-2nd synchronizer hub installation

● 2nd bushing installation

● 3rd main gear installation

● Differential side bearing removal

● Differential oil seal installation

● Differential side bearing outer race

installation

● Mainshaft rear bearing installation

● Differential side bearing installation

Drift ST33200000 a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia.

Drift KV40105320 a: 88 mm (3.46 in) dia.

Drift ST33061000 a: 38 mm (1.50 in) dia. b: 28.5 mm (1.122 in) dia.

● Mainshaft front bearing installation

● 6th bushing installation (RS6F51A)

● 4th main gear installation

● 5th main gear installation

● 6th main gear installation (RS6F51A)

ZZA1002D

● Differential side bearing outer race

installation

ZZA0898D

● Bore plug i nstallation

● Differential side bearing removal

ZZA1000D

MT-4

PREPARATION

Tool name Tool number

Drift ST33052000 a: 22 mm (0.87 in) dia. b: 28 mm (1.10 in) dia.

Drift KV40105020 a: 39.7 mm (1.563 in) dia. b: 35 mm (1.38 in) dia. c: 15 mm (0.59 in)

Press stand KV40105710 a: 46 mm (1.81 in) dia. b: 41 mm (1.61 in)

ZZA1023D

ZZA1133D

ZZA1058D

Description

● Welch plug installation

● Input shaft rear bearing removal

● Input shaft bearing spacer and 5th stopper

removal (RS5F51A)

● 5th bushing, thrust washer, 4th input gear,

4th gear bushing, 3rd-4th synchronizer hub and 3rd input gear removal

● Input shaft front bearing installation

● 6th input gear and 6th bushing removal

(RS6F51A)

● Mainshaft rear bearing removal

● 4th main gear and 5th main gear removal

● 6th main gear removal (RS6F51A)

● 5th input gear and synchronizer hub

removal

● 3rd main gear, 2nd main gear, 2nd bushing,

1st-2nd synchronizer hub, 1st main gear, reverse main gear and 1st bushing removal

● 3rd-4th synchronizer hub installation

● 4th bushing installation

● 5th bushing installation

● 5th synchronizer hub installation

(RS5F51A)

● 5th-6th synchronizer hub installation

(RS6F51A)

● 2nd bushing installation

● 3rd main gear installation

Press stand ST38220000 a: 63 mm (2.48 in) dia. b: 65 mm (2.56 in)

Drift ST30032000 a: 80 mm (3.15 in) dia. b: 38 mm (1.50 in) dia. c: 31 mm (1.22 in) dia.

Drift ST30901000 a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35.2 mm (1.386 in) dia.

MT-5

ZZA1058D

ZZA0978D

● Reverse main gear installation

● 1st bushing installation

● 1st-2nd synchronizer hub installation

● 5th stopper and input shaft bearing spacer

installation (RS5F51A)

● Input shaft front bearing installation

● Input shaft rear bearing installation

● 4th main gear installation

● 5th main gear installation

● 6th main gear installation (RS6F51A)

● Mainshaft rear bearing installation

PREPARATION

Tool name Tool number

Puller ST30031000

Drift KV40101630 a: 68 mm (2.68 in) dia. b: 60 mm (2.36 in) dia.

Drift KV38102510 a: 71 mm (2.80 in) dia. b: 65 mm (2.56 in) dia.

Description

● Measuring wear of 1st and 2nd baulk ring

ZZA0537D

● Reverse main gear installation

ZZA1003D

● 1st bushing installation

● 1st-2nd synchronizer hub installation

● Differential side bearing installation

ZZA0838D

Drift KV40104830 a: 70 mm (2.76 in) dia.

● Differential side bearing installation

b: 63.5 mm (2.500 in) dia.

ZZA0936D

Commercial Service Tools

Tool name Description

Puller Each bearing gear and bushing removal

ZZA0537D

Puller Each bearing gear and bushing removal

NT077

ECS008BO

Pin punch Tip diameter: 4.5 mm (0.177 in) dia.

Each retaining pin removal and installation

ZZA0815D

MT-6

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart ECS008BP

Use the chart be low to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

MANUAL TRANSAXLE

Reference page

SUSPECTED PARTS (Possible cause)

MA-35

MT-13

(RS5F51A), MT-22 (RS6 F 51A )

MT-17(RS5F51A), MT-22 (RS6F51A)

MT-17

(RS5F51A), MT-25 (RS6 F 51A )

(RS5F51A), MT-23 (RS6 F 51A )

MT-20(RS5F51A), MT-25 (RS6F51A)

MT-20

MT-18

Symptoms

OIL (Oil level is low.)

OIL (Wrong oil.)

OIL (Oil level is high.)

GASKET (Damaged)

OIL SEAL (Worn or damaged)

O-RING (Worn or damaged)

SHIFT CONTROL LINKAGE (Worn)

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) Noise 1 2 3 3 Oil leakage 3 1 2 2 2 Hard to shift or will not shift 1 1 2 3 3 Jumps out of gear 1 2 3 3

MT-7

INSERT SPRING (Damaged)

DESCRIPTION

PFP:00000

Cross-Sectional View ECS008BQ

MT-8

SCIA0749E

DESCRIPTION

DOUBLE-CONE SYNCHRONIZER

Double-cone synchronizer is adopted for 1st and 2nd gears to reduce opera ting force of the shift lever.

REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)

The gear can be matched smoothly in a structure by setting synchronizer hub, coupling sleeve, baulk ring and insert spring to reverse gear, and letting gear be sy nchronized.

SCIA0750E

SCIA0751E

MT-9

M/T OIL

PFP:KLD20

Changing M/T Oil ECS008BR

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 to the transaxle.

Drain plug:

: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)

CAUTION:

Do not reuse gasket.

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 Capacit y (reference)

2. After refilling oil, check oil level. Assemble gasket to filler plug, then install it to transaxle body.

Filler plug:

: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)

CAUTION:

Do not reuse gasket.

: Approx. 2.3 (4 lmp pt)

Checking M/T Oil ECS008BS

OIL LEAKAGE AND OIL LEVEL

● Check that oil is not leaking from transaxle or around it.

● Check oil level from filler plug mounting hole as shown in the fig-

ure.

CAUTION:

Never start engine while checking oil level.

● Set a new gasket on the filler plug and install it on the transaxle.

Filler plug:

: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)

CAUTION:

Do not reuse gasket.

SCIA0361E

MT-10

SIDE OIL SEAL

SIDE OIL SEAL PFP:32113

Removal and Installation ECS008BT

REMOVAL

● Clutch housing side oil seal used on 4WD vehicles is attached to the transfer. Be sure to replace it

when transfer is removed.

1. Remove the drive shaft from the transaxle.

2. Remove oil seal with flat tip screwdriver.

CAUTION:

Be careful not to damage the case surface when removing the oil seal.

INSTALLATION

1. Using a drif t (s pe c ial s erv ic e too l), drive the oil seal straight until it protrudes from th e case end equal to dimension A show n in the figure.

Dimension "A":

Within 0.5 mm (0.020 in) of flush with the case.

Drift to be used: Transaxle case side: ST30720000 Clutch housing side: ST30720000

CAUTION:

● When installing oil seals, apply multi-purpose grease to oil seal lips.

● Oil seals are not reusable. Never reus e them.

2. Install all parts in reverse order of removal and check oil level after installation.

SCIA0824E

SCIA0352E

MT-11

POSITION SWITCH

PFP:32005

Checking ECS008BU

BACK-UP LAMP SWITCH

● Check continuity.

Gear position Continuity Reverse Yes Except reverse No

SCIA0708E

PARK/NEUTRAL POSITION SWITCH

● Check continuity.

Gear position Continuity Neutral Yes Except neutral No

MT-12

CONTROL LINKAGE

CONTROL LINKAGE PFP:34103

Removal and Installation of Control Device and Cable ECS008BV

Refer to the figure for removal and installati on proc ed ure .

SCIA0711E

CAUTION:

● Keep in mind that the select side lock plate for securing the control cable is different from the one

on the shift side.

● After assembly, make sure selector leve r automa ticall y retu rns to Ne utral wh en it is move d to 1st,

2nd, or Reverse.

MT-13

AIR BREATHER HOSE

PFP:31098

Removal and Installation ECS008BW

Refer to the figure for air breather hose removal and installation information.

QR engine models

SCIA0354E

YD engine models

SCIA0747E

CAUTION:

● Make sure there are no pi nched or restricted areas on the air breather hose c aus ed by be ndi ng o r

winding when installing it.

● Be sure to insert hose into the transaxle tube until ov erlap area reaches the spool.

MT-14

TRANSAXLE ASSEMBLY

TRANSAXLE ASSEMBLY PFP:32010

Removal and Installation ECS008BX

REMOVAL

1. Remove air cleaner, air duct, and battery.

2. Remove the air breather hose.

3. Remov e clu tc h op erating cylinder.

CAUTION:

Do not depress clutch pedal during removal procedure.

4. Disconnect control cable from transaxle.

5. Drain gear oil from transaxle.

6. Disconnect PNP switch, back-up lamp switc h, and ground harness conn ectors.

7. Remove exhaust front tube and the drive shaft.

8. Remove transfer.

● Refer to TF- 11, "Removal and Installation from Vehicle" .

9. Remove starter motor.

10. Place a jack onto the transaxle.

CAUTION:

When setting jack, be careful not to bring it into contact with the switch.

11. Remove center member, engine insulator and engine mount bracket.

● Refer to EM-69, "ENGINE ASSEMBLY" (QR engine models) or EM -193, "ENGINE ASSEMBLY" (YD

engine models).

12. Remove suspension members.

● Refer to FSU-12, "FRONT SUSPENSION MEMBER" .

13. Su pport engine by placing a jack under oil pan.

14. Remove bolts securing transaxle to engine.

SCIA0845E

MT-15

TRANSAXLE ASSEMBLY

15. Remove transaxle from vehicle.

INSTALLATION

Paying attention to the following items, install in the reverse order of removal.

● When installing the transaxle to the engine, tighten to the specified torque.

CAUTION:

When installing transaxle, be careful not to bring transaxle input shaft into contact with the clutch cover.

QR engine models:

Bolt No. 1 2 3* 4 5 6 Quantity 2 1 1 2 2 2

“ ” mm (in)

Tightening torque N·m (kg - m, ft- lb)

*: Tightening the bolt for 4WD models.

(1.57)75(2.95)45(1.77)40(1.57)30(1.18)

69.6 - 79.4

(7.1 - 8.1, 52 - 58)

YD engine models:

39.2 - 46.1

(4.0 - 4.7, 29 - 34)

(1.57)

30.4 - 40.2 (3.1 - 4.1, 23 - 29)

MTD0062D

SCIA0353E

Bolt No. 1 2 3 4 5 6 Quantity 2 2 1 1 3 1

“ ” mm (in) Tightening torque

N·m (kg - m, ft- lb)

● After installation, check oil level, and look for leaks and loose

(2.17)70(2.76)

(4.0 - 5.0, 29 - 36)

120

(4.72)45(1.77)40(1.57)

40 - 49

(1.38)

31 - 36

(3.1 - 3.7, 23 - 26)

mechanisms.

SCIA0748E

MT-16

TRANSAXLE ASSEMBLY

Component Parts (RS5F51A) ECS008BY

CASE AND HOUSING COMPONENTS

1. C l utch housing 2. Inp ut sh af t oil seal 3. Oil chann el

4. Magnet 5. Differential oil seal 6. Ball pin

7. Washer 8. Transaxle case 9. Welch plug

10. Bore plug 11. Differential oil seal 12. Park/Neutral position switch

13. Oil gutter 14. Back-up lamp switch 15. Air breather tube

16. Baffle plate 17. Filler plug 18. Gasket

19. Drain plug 20. Gasket

SCIA1112E

MT-17

GEAR COMPONENTS

TRANSAXLE ASSEMBLY

SCIA0385E

1. Input shaf t fron t bearing 2. Input shaf t 3. Needle bearing

4. 3rd input ge ar 5. 3rd baulk ring 6. Spread sp ring

7. 3rd & 4th shifting insert 8. 3rd & 4th synchronizer hub 9. 4th baulk ring

10. 3rd & 4th coupling sleeve 11. Bushing 12. Needle bearing

13. 4th input gear 14. Thrust washer 15. Bushing

16. Needle bearing 17. 5th input gear 18. 5th baulk ring

19. 5th shifting insert 20. 5th synchronizer hub 21. 5th coupling sleeve

22. 5th stopper 23. Input shaft bearing spacer 24. Snap ring

25. Input shaft rear bearing 26. Oil channel 27. Input shaf t rear bearing adjusting shim

28. Retaining pin 29. Reverse idler shaft 30. Thrust needle bearing

31. Needle bearing 32. Reverse idler gear (Front) 33. Reverse baulk ring

34. Reverse coupling sleeve 35. Insert spring 36. Reverse idler gear (Rear)

37. Reverse idler gear adjusting shim

MT-18

TRANSAXLE ASSEMBLY

1. Mainshaft front bearing 2. Mainshaft bearing retainer 3. Mainshaft

4. Reverse main gear 5. 1st mai n gear 6. Bushing

7. Needle bearing 8. 1st inner baul k ring 9. 1st gear synchronizer cone

10. 1st outer baulk ring 11. Spread spring 12. 1st & 2nd shifting insert

13. 1st & 2nd synchronizer hub 14. 2nd outer baulk ring 15. 2nd gear synchronizer cone

16. 2nd inner baulk ring 17. 1st &2nd coupling sleeve 18. Bushing

19. Needle bearing 20. 2nd ma in ge ar 21. 3rd main gear

22. 3rd &4th mainshaft spacer 23. 4th main adjusting shim 24. 4th main gear

25. 5th main gear 26. Snap ring 27. Mainshaft rear bearing

28. Mainshaft C ring 29. C ring holder 30. Snap ring

31. Snap ring 32. Mainshaft rear bearing adjust i ng shi m

SCIA0386E

MT-19

SHIFT CONTROL COMPONENTS

TRANSAXLE ASSEMBLY

1. Reverse shift fork 2. Shifter cap 3. Reverse fork rod

4. Reverse lever assembly 5. 5th & reverse bracket 6. 5th & reverse fork rod

7. 5th shift fork 8. Retaining pin 9. 3rd & 4th bracket

10. 3rd & 4th shift fork 11. 3rd & 4th fork rod 12. 1st & 2nd shift fork

13. 1st & 2nd bracket 14. 1st & 2nd fork rod 15. Shift check sleeve

16. Inter lock pin 17. Chec k bal l 18. Shift check sleeve

19. Check spring 20. Check plug 21. Control assembly

22. O ring 23. Shift check 24. Stopper bolt

25. Stopper ring

SCIA0387E

MT-20

FINAL DRIVE COMPONENTS

TRANSAXLE ASSEMBLY

SCIA0388E

1. Differential side bearing outer race 2. Differential side bear i ng 3. Differential case

4. Final gear 5. Differential side beari ng 6. Differential side bearing outer race

7. Differential side bearing adjusting shim

10. Side gear thrust washer 11. Pinion mate gear 12. Pinion mate gear washer

13. Retaining pin

8. Pinion mate shaft 9. Side gear

MT-21

TRANSAXLE ASSEMBLY

Component Parts (RS6F51A)

CASE AND HOUSING COMPONENTS

ECS008BZ

1. Clutch housing 2. Input shaft oil seal 3. Oil channel

4. Magnet 5. Differential oil seal 6. Ball pin

7. Washer 8. Transaxle case 9. Welch plug

10. Bore plug 11. Differential oil seal 12. Park/Neutral positio n switch

13. Oil gutter 14. Back-up lamp switch 15. Air breather tube

16. Baffle plate 17. Filler plug 18. Gasket

19. Drain plug 20. Gasket

MT-22

SCIA1112E

GEAR COMPONENTS

TRANSAXLE ASSEMBLY

SCIA0956E

1. I nput shaft front bearing 2. Input shaft 3. Needle bearing

4. 3rd input gear 5. 3rd baulk ring 6. Spread spring

7. 3rd & 4th shifting insert 8. 3rd & 4th synchronizer hub 9. 4th baulk ring

10. 3rd & 4th coupling sleeve 11. Bushing 12. Needle bearing

13. 4th input gear 14. Thrust washer 15. Bushing

16. Needle bearing 17. 5th input gear 18. 5th baulk ring

19. 5th & 6th shifting insert 20. 5th & 6th synchronizer hub 21. 5th & 6th coupling sleeve

22. 6th baulk ring 23. 6th input gear 24. Needle bearing

25. Bushing 26. Snap ring 27. Input shaft rear bearing

28. Oil channel 29. Input shaft rear bearing adjusting shim

31. Reverse idler shaft 32. Thrust needle bearing 33. Needle bearing

34. Reverse idler gear (Front ) 35. Reverse baulk ring 3 6. Rever se coupling sleeve

37. Insert spring 38. Reverse idler gear (Rear) 39. Reverse idler gear adjusting shim

30. Retaining pin

MT-23

TRANSAXLE ASSEMBLY

1. Mainshaft front bearing 2. Mainshaft bearing retainer 3. Mainshaft

4. Reve rse main gea r 5. 1st main gear 6. Bushing

7. Need le be aring 8. 1st inner baulk ring 9. 1st gear synchronizer cone

10. 1st outer baulk ring 1 1. Spread spring 12. 1st & 2nd shifting insert

13. 1st & 2nd synchronizer hub 14. 2nd outer baulk ring 15. 2nd gear synchronizer cone

16. 2nd inner baulk ring 17. 1st & 2nd coupling sleeve 18. Bushing

19. Needle bearing 20. 2nd main gear 21. 3rd main gear

22. 3rd & 4th mainshaft spacer 23. 4th main adjusting shim 24. 4th main gear

25. 5th main gear 26. 6th main gear 27. Mainsha ft rea r beari ng

28. Mainshaft C ring 29. C ring holder 30. Snap ring

31. Snap ring 32. Mainshaft rear bearing adjusting shim 33. 5th & 6th mainsh aft spacer

34. 6th main adjusting shim

SCIA0957E

MT-24

SHIFT CONTROL COMPONENTS

TRANSAXLE ASSEMBLY

1. R everse shift fork 2. Shifter cap 3 . Reverse fork rod

4. R everse lever assembly 5 . 5th & 6th bracket 6. 5th & 6th fork rod

7. 5th & 6th shift fork 8. Retaining pin 9. 3rd & 4th bracket

10. 3rd & 4th shift fork 11. 3rd & 4th fork rod 12. 1st & 2nd shift fork

13. 1st & 2nd fork rod bracket 14. 1st & 2nd fork rod 15. Shift check sleeve

16. Inter lock pin 17. Check ball 18. Shift check sleeve

19. Check spring 20. Check plug 21. Control assembl y

22. O ring 23. Shift check 24. Stopper bolt

25. Stopper ring 26. Reverse br acket fork rod 27. Reverse bracket

SCIA0958E

MT-25

FINAL DRIVE COMPONENTS

TRANSAXLE ASSEMBLY

SCIA0388E

1. Differential side bearing outer race 2. Differential side bea ring 3. Differential case

4. Final gear 5. Differential side bearing 6. Differential side bea ring out er race

7. Differential side bearing adjusting shim 8. Pinion mate shaft 9. Side gear

10. Side gear thrust washer 11. Pinion mate gear 12. Pinion mate gear washer

13. Retaining pin

Disassembly and Assembly (RS5F51A) ECS008C0

DISASSEMBLY

1. Remove drain plug and filler plug.

2. Remove park/neutral position switch and back-up lamp switch.

3. After removing shift check and stopper bolt, remove control assembly.

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TRANSAXLE ASSEMBLY

4. Remove check plugs ( 3 pi ec es) , c he ck spri ngs ( 3 pie ce s), ch eck balls (3 pieces) and shift check sleeve (1 piece).

5. Remove transaxle case fixing bolts.

6. Remove bore plug .

CAUTION:

Be careful not to damage transaxle case.

7. While spreading the snap ring of mainshaft rear bearing located at bore plug hole, remove transaxle case.

8. Remove oil gutter, baffle plate.

9. Remove snap ring, mainshaft rear bearing adjusting shim and input shaft rear bearing adjusting shim from transaxle case.

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10. Remove differential side bearing outer race (transaxle case side) and then adjus t shim.

11. Remove welch plug.

12. Remove differential oil seal (tansaxle case side).

13. Remove magnet from clutch housing.

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TRANSAXLE ASSEMBLY

14. With shift lever in 5th position, remove bracket bolts from reverse lever assembly. Lift reverse lever assembly to remove.

CAUTION:

Be careful not to lose shifter cap.

15. Pull out reverse fork rod then remove reverse shift fork.

16. Shift 3rd & 4th fork rod to 3rd position. Remove retaining pin of 5th shift fork using pin punch.

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17. Remove stopper rings for 5th & reverse bracket.

18. Pull ou t 5 th & rev erse fork rod an d r em ov e 5t h shift fork and 5th & reverse bracket.

19. Remove check balls (2 pieces) and inter lock pin.

20. Remove retaining pin of 3rd & 4th bracket using pin punch.

21. Remove stopper rings for 3rd & 4th shift fork.

22. Pull out 3rd & 4th fork rod and remove 3rd & 4th shift fork and bracket.

23. Remove shift check sleeve from clutch housing.

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24. Remove retaining pin of 1st & 2nd shift fork using pin punch.

25. Pull out 1st & 2nd fork rod with brack et.

26. Remove 1st & 2nd shift fork.

27. Remove retaining pin of 1st & 2nd bracket using pin punch and separat e 1st & 2nd fork rod and brac ket.

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TRANSAXLE ASSEMBLY

28. Remove gear components from clutch housing in the following procedure.

a. While tapping input shaft with plastic hammer, remove input

shaft assembly, mainshaft assembly and reverse idler gear assembly as a set.

CAUTION:

Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clu tch hou sing side.

b. Remove final drive assembly.

29. Remove bearing retainer and then mainsh aft front bearing.

30. Remove oil channel on mainshaft side.

31. Remove differ ential oil seal (clutch housing side).

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32. Remove differential side bearing outer race (clutch housing side).

33. Remove input shaft oil seal.

CAUTION:

Be careful not to damage clutch housing.

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TRANSAXLE ASSEMBLY

ASSEMBLY

1. Using a drift, i nstall input shaft oi l seal from clutch housing end of side to the depth of 1.8 to 2.8 mm (0.071 to 0.110 in).

CAUTION:

Do not reuse oil seals.

2. Using a drift, install di fferent ial oi l seal until the f ace is fl ush w ith clutch housing.

CAUTION:

Do not reuse oil seals.

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3. Install oil channel on mainshaft side.

CAUTION:

Be careful with orientation of installation.

4. Using a drift, install ma in sh af t front beari ng .

CAUTION:

Be careful with orientation of installation.

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