Nissan X-Trail 2004 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 .......................... ...................... 8

NVH Troubleshooting Chart ..................................... 8

MANUAL TRANSAXLE ......................................... 8

DESCRIPTION ......................... ................................... 9

Cross-Sectional View ............................................... 9

DOUBLE-CONE SYNCHRONIZER .................... 10

TRIPLE-CONE SYNCHRONIZER ...................... 10

REVERSE GEAR NOISE PREVENTION FUNC-

TION (SYNCHRONIZING METHOD) ................. 10

M/T OIL ......................................................................11

Changing M/T Oil ............................................ ........11

DRAINING ................................ ............. ...............11

FILLING .............................. ...... ............................11

Checking M/T Oil .....................................................11

OIL LEAKAGE AND OIL LEVEL ..........................11

SIDE OIL SEAL ........................................................ 12

Removal and Installation ........................................ 12

REMOVAL ........................................................... 12

INSTALLATION ................................................... 12

POSITION SWITCH .................................................. 13

Checking ................................................................ 13

BACK-UP LAMP SWITCH .................................. 13

PARK/NEUTRA L PO SI TION SWITCH ............... 13

CONTROL LINKAGE ............................................... 14

Components of Control Device and Cable ............. 14

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

AIR BREATHER HOSE ............................................ 16

Removal and Installation ........................................ 16

TRANSAXLE ASSEMBLY ........................................ 17

Removal and Installation ........................................ 17

REMOVAL ........................................................... 17

INSTALLATION ................................................... 18

Component Parts (RS5F51A) ................................ 19

MANUAL TRANSAXLE

CASE AND HOUSING COMPONENTS ..............19

GEAR COMPONENTS .......................................20

SHIFT CONTROL COMPONENTS .....................22

FINAL DRIVE COMPONENTS ...........................23

Component Parts (RS6F51A) .................................24

CASE AND HOUSING COMPONENTS ..............24

GEAR COMPONENTS ....................................... 25

SHIFT CONTROL COMPONENTS .....................27

FINAL DRIVE COMPONENTS ...........................28

Disassembly and Assembly (RS5F51A) .................28

DISASSEMBLY ................................................... 28

ASSEMBLY ......................................................... 32

Disassembly and Assembly (RS6F51A) .................37

DISASSEMBLY ................................................... 37

ASSEMBLY ......................................................... 41

Adjustment (RS5F51A) ...........................................47

INPUT SHAFT END PLAY .................................. 47

MAINSHAFT END PLAY .....................................48

DIFFERENTIAL SIDE BEARING PRELOAD ......48

REVERSE IDLER GEAR END PLAY .................. 49

Adjustment (RS6F51A) ...........................................50

INPUT SHAFT END PLAY .................................. 50

MAINSHAFT END PLAY .....................................51

DIFFERENTIAL SIDE BEARING PRELOAD ......52

REVERSE IDLER GEAR END PLAY .................. 53

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 .........................................................72

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

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

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

ASSEMBLY .........................................................80

REVERSE IDLER SHAFT AND GEARS ........... ....... 85

Assembly and Disassembly (RS5F51A) .................85

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

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

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

Assembly and Disassembly (RS6F51A) .................86

DISASSEMBLY ...................................................86

INSPECTION AFTER DISASSEMBLY ................87

ASSEMBLY .........................................................87

FINAL DRIVE ............................................................89

Assembly and Disassembly (RS5F51A) .................89

PRE-INSPECTION ..............................................89

DISASSEMBLY ...................................................89

INSPECTION AFTER DISASSEMBLY ................90

ASSEMBLY .........................................................90

Assembly and Disassembly (RS6F51A) .................92

PRE-INSPECTION ..............................................92

DISASSEMBLY ...................................................92

INSPECTION AFTER DISASSEMBLY ................93

ASSEMBLY .........................................................94

SHIFT CONTROL ...................................................... 96

Inspection (RS5F51A) ............................................96

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

Inspection (RS6F51A) ............................................97

SHIFT FORK .......................................................97

SERVICE DATA AND SPECIFICATIONS (SDS) ......98

General Specifications ............................................98

TRANSAXLE ................... ....... ...... ....... ...... ....... ....98

FINAL GEAR ........................................................99

End Play ..................................................................99

Baulk Ring Clearance .............................................99

Available Snap Rings ............................................100

INPUT SHAFT BEARING SPACER ...................100

6TH INPUT GEAR BUSHING ............................100

5TH MAIN GEAR ...............................................100

Available C-Rings .................................................100

MAINSHAFT C-RING ........................................100

Available Thrust Washer .......................................101

INPUT SHAFT THRUST WASHER ...................101

DIFFERENTIAL SIDE GEAR THRUST WASHER

.101

Available Adjusting Shims .....................................101

4TH MAIN GEAR ADJUSTING SHIM ................101

INPUT SHAFT REAR BEARING ADJUSTING

SHIM ......................... .........................................102

MAINSHAFT REAR BEARING ADJUSTING

SHIM ......................... .........................................102

REVERSE IDLER GEAR ADJUSTING SHIM ....102

6TH MAIN GEAR ADJUSTING SHIM ................102

Available Shims ....................................................103

BEARING PRELOAD .........................................103

DIFFERENTIAL SIDE BEARING ADJUSTING

SHIM(S) .............................................................103

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

PREPARATION PFP:00002 Special Service Tools ECS008BN

Tool number Tool name

KV381054S0 Puller

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

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

ZZA0601D

ZZA1000D

Description

● Differential side bearing outer race removal

● Mainshaft front bearing removal

● Input shaft oil seal installation

● Reverse main gear installation

● 1st main gear bushing installation

● 1st-2nd synchronizer hub assemb ly

installation

● 2nd main gear bushing installation

● 3rd main gear installation

● Differential side bearing (clutch housing

side) removal

● Differential oil seal installation

● Differential side bearing outer race

installation

● Mainshaft rear bearing installation

● Differential side bearing installation

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

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

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

ZZA0811D

ZZA1002D

ZZA0898D

ZZA1000D

● Mainshaft front bearing installation

● 6th input gear bushing installation

(RS6F51A)

● 4th main gear installation

● 5th main gear installation

● 6th main gear installation (RS6F51A)

Differential side bearing outer race installation

● Bore plug i nstallation

● Differential side bearing (transaxle case

side) removal

MT-4

PREPARATION

Tool number Tool name

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

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

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

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

ZZA1023D

ZZA1133D

ZZA1058D

Description

● Welch plug installation

● Input shaft rear bearing removal

● Input shaft bearing spacer and 5th stopper

removal (RS5F51A)

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

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

● Input shaft front bearing installation

● 6th input gear and 6th input gear bushing

removal (RS6F51A)

● Mainshaft rear bearing removal

● 4th main gear and 5th main gear removal

● 6th main gear removal (RS6F51A)

● 5th input gear and 5th synchronizer hub

assembly removal

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

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

● 3rd-4th synchronizer hub assembly

installation

● 4th input gear bushing installation

● 5th input gear bushing installation

● 5th synchronizer hub assembly installation

(RS5F51A)

● 5th-6th synchronizer hub assembly

installation (RS6F51A)

● 2nd main gear bushing installation

● 3rd main gear installation

● Reverse main gear installation

● 1st main gear bushing installation

● 1st-2nd synchronizer hub assembly

installation

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

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

ZZA1058D

● 5th stopper and input shaft bearing spacer

installation (RS5F51A)

● Input shaft front bearing installation

ZZA0978D

● Input shaft rear bearing installation

● 4th main gear installation

● 5th main gear installation

● 6th main gear installation (RS6F51A)

● Mainshaft rear bearing installation

ZZA0978D

MT-5

PREPARATION

Tool number Tool name

ST30031000 Puller

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

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

KV40104830 Drift a: 70 mm (2.76 in) dia. b: 63.5 mm (2.500 in) dia.

Description

Measuring wear of inner baulk ring

ZZA0537D

Reverse main gear installation

ZZA1003D

● 1st main gear bushing installation

● 1st-2nd synchronizer hub assemb ly

installation

● Differential side bearing (transaxle case

side) installation

ZZA0838D

Differential side bearing (clutch housing side) installation

ZZA0936D

ST15243000

Measuring end play of side gear Drift a: φ 30mm

SCIA1088J

Commercial Service Tools ECS008BO

Tool name Description Puller Each bearing, gear and bushing removal

ZZA0537D

MT-6

PREPARATION

Tool name Description Puller Each bearing, gear and bushing removal

NT077

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

ZZA0815D

Each retaining pin removal and installation

MT-7

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003 NVH Troubleshooting Chart ECS008BP

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.

MANUAL TRANSAXLE

Reference page

SUSPECTED PARTS (Possible cause)

MA-37

(RS5F51A), MT-24 (RS6 F 51A )

MT-19(RS5F51A), MT-24 (RS6F51A)

MT-19

MT-14

(RS5F51A), MT-24 (RS6 F 51A )

MT-19

(RS5F51A), MT-27 (RS6 F 51A )

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

MT-22(RS5F51A), MT-27 (RS6F51A)

MT-22

MT-20

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 31222 Hard to shift or will not shift 1 1 2 3 3 Jumps out of gear 1 2 3 3

MT-8

INSERT SPRING (Damaged)

DESCRIPTION

DESCRIPTION PFP:00000

Cross-Sectional View ECS008BQ

1. 3rd input gear 2. 3rd-4th synchronizer hub 3. 3rd-4th coupling sleeve

4. 4th input gear 5. 5th input gear 6. 5th synchronizer hub

7. 5th coupling sleeve 8. Input shaft rear bearing 9. Mainshaft rear bearing

10. 5th main gear 11. 4th main gear 12. 3rd main gear

13. 2nd main gear 14. 1st-2nd coupling sleeve 15. 1st-2nd synchronizer hub

16. 1st main gear 17. Reverse main gear 18. Differential side bearing

19. Differential case 20. Final gear 21. Differential side bearing

22. Mainshaft front bearing 23. Mainshaft 24. Input shaft

25. Input shaft front bearing 26. Clutch housing 27. Reverse idler shaft

28. Reverse idler gear (Front) 29. Reverse coupling sleeve 30. Reverse synchronizer hub

31. Reverse idler gear (Rear) 32. 5th input gear 33. 5th-6th syn chr oni zer hub

34. 5th-6th coupling sleeve 35. 6th input gear 36. Input shaft rea r bea ring

37. Mainshaft rear bearing 38. 5th main gear 39. 6th main gear

PCIB0773E

MT-9

DESCRIPTION

DOUBLE-CONE SYNCHRONIZER

Double-cone synchronizer is adopted for 1st gear to reduce operating force of the shift lever.

TRIPLE-CONE SYNCHRONIZER

Triple-cone synchronizer is ad op ted for 2nd gear to red uc e op era tin g forc e of the shi ft lev er.

REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)

Reverse gear can be matc hed sm ooth ly in a struc ture b y set ting syn chronizer hub, coupling sleeve, baulk ring and insert spring to reverse gear, and letting reverse gear be synchronized.

PCIB0774E

PCIB0775E

MT-10

M/T OIL

M/T OIL PFP:KLD20

Changing M/T Oil ECS008BR

DRAINING

1. Start engine and let it run to warm up transaxle.

2. Stop engine. Remove drain plug and drain oil.

3. Set a new gask et on d rain p lug an d install i t to t ransaxl e. Ref er to MT-19, "

PONENTS" , MT-24, "CASE AND HOUSING COMPONENTS" .

CAUTION:

Do not reuse gasket.

CASE AND HOUSING COM-

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 Oil cap acity (reference)

: Approx. 2.3 (4 lmp pt)

2. After refillin g oil, check oil le vel. Assem ble a new gasket to filler plug, the n install it to transaxl e. Refer to

MT-19, "

CASE AND HOUSING COMPONENTS" , MT-24, "CASE AND HOUSING COMPONENTS" .

CAUTION:

Do not reuse gasket.

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 fill er plug and install it on transaxle . Refer

to MT-19, "

"CASE AND HOUSING COMPONENTS" .

CAUTION:

Do not reuse gasket.

CASE AND HOUSING COMPONENTS" , MT-24,

SCIA0361E

MT-11

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 transfer. Be sure to replace it

when transfer is removed.

1. Remove drive shaft from transaxle. Refer to FAX-11, "

2. Remove oil seal with a flat-bladed scr ewdriver.

CAUTION:

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

INSTALLATION

1. Using a drift, drive the oil seal straight until it protrudes from the case end equal to dimension A shown in the figure.

Dimension "A":

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

Removal and I nstallation" .

SCIA0824E

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

CAUTION:

● When installing oil seals , apply multi-purpose grea se to

oil seal lips.

● Oil seals are not reusable. Never reuse them.

2. Install all parts in reverse order of removal and check oil level after installation. Refer to MT-11, "

M/T Oil" .

SCIA0352E

Checking

MT-12

POSITION SWITCH

POSITION SWITCH PFP:32005

Checking ECS008BU

BACK-UP LAMP SWITCH

● Check continuity.

Gear position Continuity Reverse Yes Except reverse No

PARK/NEUTRAL POSITION SWITCH

● Check continuity.

Gear position Continuity Neutral Yes Except neutral No

SCIA0708E

MT-13

CONTROL LINKAGE

CONTROL LINKAGE PFP:34103 Components of Control Device and Cable ECS008BV

1. Control lever knob 2. Select cable 3. Shift cable

4. Lock plate 5. Lock plate 6. Clutch housing

7. Cable mounting bracket 8. Control device assembly 9. Control lever

10. Lock plate 11. Washer 12. Snap pin

13. Washer

MT-14

PCIB0777E

CONTROL LINKAGE

Removal and Installation ECS00CY6

CAUTION:

● Keep in mind that the select side lock plate for securing 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.

● Shift control lever to the neutral position for removal.

Install select cable according to the following procedure.

1. Install select cable of transaxle side to control assembly.

2. Install sele ct cable to pin on select lever part of control devi ce assembly.

3. Push lock part (A) of select cable all the way to the direction of the arrow. (6 M/T model only)

4. Slide stopp er part (B) all the way to lock part (A) as shown by the arrow. (6 M/T model only)

CAUTION:

Make sure that select cable and select lever are installed securely.

PCIB0815E

PCIB0817E

MT-15

AIR BREATHER HOSE

AIR BREATHER HOSE PFP:31098 Removal and Installation ECS008BW

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

QR engine model

1. Air cleaner case 2. Transaxle 3. Clip

4. Air breather hose 5. Clip 6. PCV hose

7. Resonator

YD engine model

PCIB0778E

PCIB0779E

1. Air cleaner case 2. Transaxle 3. Clip

4. Clip 5. Air breather hose 6. Clip

7. Bracket 8. Mass air flow sensor

CAUTION:

● Make sure there are n o pinched or restricted areas on air bre ather hose caused by bending or

winding when installing it.

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

MT-16

TRANSAXLE ASSEMBLY

TRANSAXLE ASSEMBLY PFP:32010

Removal and Installation ECS008BX

PCIB0780E

1. Center member 2. Insulator assembly 3. Grommet

4. Transaxle 5. Rear engi ne m ounting bracket 6. Rear engine mounting insulator

7. Stopper rubber (YD engine model) 8. Stopper 9. LH engine mount i ng in sulat or

10. LH engine mounting bracket

REMOVAL

1. Remove air cleaner, air duct, and battery. Refer to EM-15, "Removal and Installation" ,EM-133, "Removal

and Instal lation"

2. Remove air breather hose. Refer to MT-16, "Removal and Installation" .

3. Remove clutc h op era ting cylinder. Refer to CL-10, "

CAUTION:

Do not depress clutch pedal during removal procedure.

4. Disconnect control cable from transaxle. Refer to MT-15, "

5. Drain gear oil from transaxle. Refer to MT-11, "

6. Disconnect park/neutral position switch, back-up lamp swi tch, and ground harness co nnectors.

7. Remove exhaust front tube and the drive shaft. Refer to EX-2, "

8. Remove transfer. Refer to TF-55, "

9. Remove starter motor. Refer to SC-25, "

Removal and Installation" .

10. Place a jack onto transaxle.

CAUTION:

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

11. Remove center member, engine insulator and engine mount bracket. Refer to EM-78, "

BLY" (QR engine model) or EM-208, "ENGINE ASSEMBLY" (YD engine model).

12. Remove suspension members. Refer to FSU-12, "

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

Removal and Installation" .

DRAINING" .

Removal and Ins tallation" .

ENGINE ASSEM-

FRONT SUSPENSION MEMBER" .

MT-17

TRANSAXLE ASSEMBLY

14. Remove bolts securing transaxle to engine.

15. Remove transaxle from vehicle.

INSTALLATION

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

● When installing transaxle to engine, tigh ten bolts to the specified torque.

CAUTION:

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

QR engine model:

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)

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

74.5

(7.6, 55)

42.7

(4.4, 31)

(1.57)

35.3

(3.6, 26 )

MTD0062D

YD engine model:

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)

● Afte r installation, chec k oil level, and check for leaks and loose

(2.17)50(2.76)

mechanisms . Refer to MT-11, "

120

(4.72)45(1.77)40(1.57)

(4.5, 32)

Checking M/T Oil" .

(1.38)

33.5

(3.4, 25)

SCIA0353E

SCIA0748E

MT-18

TRANSAXLE ASSEMBLY

Component Parts (RS5F51A) ECS008BY

CASE AND HOUSING COMPONENTS

1. Clutch housing 2. Differential oil seal 3. Ball pin

4. Washer 5. Input shaf t oil sea l 6. Oil channel

7. Ma gnet 8. Back-up lam p sw itch 9. Oil gutter

10. Baffle plate 11. Transaxle case 12. Filler plug

13. Gasket 14. Welch plug 15. Bore plug

16. Drain plug 17. Differential oil seal 18. Park/Neutral position switch

19. Air breat her tube

PCIB0781E

MT-19

GEAR COMPONENTS

TRANSAXLE ASSEMBLY

1. Input shaft front bearing 2. Input shaft 3. 3rd needle bearing

4. 3rd input gear 5. 3rd baulk ring 6. 3rd-4th sprea d spring

7. 3rd-4th shifting inse rt 8. 3rd-4th synchr onizer hub 9. 4th baulk ring

10. 3rd-4th coupling sleeve 11. 4th input gear bushing 12. 4th needle bearing

13. 4th input gear 14. Thrust washer 15. 5th input gear bushing

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

19. 5th spread spring 20. 5th shifting insert 21. 5th synchronizer hub

22. 5th coupling sleeve 23. 5th stopper 24. Input shaft bearing spacer

25. Snap ring 26. Input shaft rear bearing 27. Oil channel

28. Input shaft rear bearing adjusting shim

31. Thrust needle bearing 32. Reverse idler gear needle bearing 33. Reverse insert spring

34. Reverse idler gear (Fron t) 35. Reverse baulk ring 36. Reverse coupling sleeve

37. Reverse idler gear (Rear) 38. Reverse idler gear adjusting shim

29. Retaining pin 30. Reverse idler shaft

PCIB0782E

MT-20

TRANSAXLE ASSEMBLY

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

4. Reverse main gear 5. 1st main gear 6. 1st main gear bushing

7. 1st needle bearing 8. 1st inner baulk ring 9. 1st gear synchro ni zer cone

10. 1st outer baulk ring 11. 1st-2nd 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. 2nd main gear bushing

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

22. 3rd-4th mainshaft spacer 23. 4th main gear adjusting shi m 24. 4th ma in 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. Mainsh aft rea r bea ring adj ust ing shi m

PCIB0783E

MT-21

SHIFT CONTROL COMPONENTS

TRANSAXLE ASSEMBLY

1. 3rd-4th brack et 2. Retaining pin 3. Stopper ring

4. 5th-reverse bracket 5. Reverse lever assembly 6. Shifter cap

7. Reverse shift fork 8. Reverse fork rod 9. Check plug

10. Check spring 11. Shift chec k sl eeve 12. Check ball

13. 5th-reverse fork rod 14. 5th shift fork 15. Check spring

16. 3rd-4th fork rod 17. Interlock pin 18. Shift check sleeve

19. 1st-2nd fork rod 20. 1st-2nd bracket 21. 1st-2nd shift fork

22. 3rd-4th shift fork 23. Control assembly 24. Stopper bolt

25. Shift check 26. O-ring

PCIB0784E

MT-22

FINAL DRIVE COMPONENTS

TRANSAXLE ASSEMBLY

1. Differential side bearing outer race 2. Differential side bearing (clutch housing side)

4. Final gear 5. Differential side bearing (transaxle case side)

7. Differential side bearing adjusting

shim

10. Retaining pin 11. Pinion mate thrust washer 12. Pinion mate gear

13. Pinion mate shaft

8. Side gear 9. Side gear thrust washer

3. Differential case

6. Differential side bearing outer race

PCIB0785E

MT-23

TRANSAXLE ASSEMBLY

Component Parts (RS6F51A) ECS008BZ

CASE AND HOUSING COMPONENTS

1. Clutch housing 2. Differential oil seal 3. Ball pin

4. Washer 5. Input shaft oil seal 6. Oil channel

7. Magnet 8. Back-up lamp swi tc h 9. Oil gutter

10. Baffle plate 11. Transaxle case 12. Filler plug

13. Gasket 14. Welch plug 15. Bore plug

16. Drain plug 17. Differential oil seal 18. Park/ N eut ral posit io n sw itch

19. Air breather tube

MT-24

PCIB0781E

GEAR COMPONENTS

TRANSAXLE ASSEMBLY

PCIB0786E

1. Inp ut sh aft front bear in g 2. Input shaf t 3. 3rd needle bearing

4. 3rd input gear 5. 3rd baulk ring 6. 3rd-4th spread spring

7. 3rd- 4t h shif ting i nser t 8. 3rd-4th synchronizer hub 9 . 4th baulk ring

10. 3rd-4th coup ling sleeve 11. 4th input gear bushing 1 2. 4th needle bearing

13. 4th input gear 14. Thrust washer 15. 5th input gear bushing

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

19. 5th-6th spread spring 20. 5th-6th shifting i nsert 21. 5th-6th synchronizer hub

22. 5th-6th coupling sleeve 23. 6th baulk ring 24. 6th input gear

25. 6th needle beari ng 26. 6th input gear bushing 27. Snap ring

28. Input shaft rear bearing 2 9. Oil channel 3 0. Input shaft rear bearing adjusting shim

31. Retaining pin 32. Rever se i dler shaft 33. Thrust needle bearing

34. Reverse idle r gea r need le bearing 35. Reverse insert spring 36. Reverse idler gear (Front)

37. Reverse balk ring 38. Re ver se coupling sleeve 39. Reverse idler gear (Rear)

40. Reverse idle r gea r adjust i ng shi m

MT-25

TRANSAXLE ASSEMBLY

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

4. Reverse main gear 5. 1st main gear 6. 1st main gear bushing

7. 1st needle bearing 8. 1st inner baulk ring 9. 1s t gear sync hronizer cone

10. 1st outer baulk ring 11. 1st-2nd 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. 2nd main gear bushing

19. 2nd 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. 6th m ai n gear 27. Mainshaft rear bearing

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

31. Snap ring 32. Mainshaft rea r bea ring adj ust ing shi m 33. 5th- 6th mainshaft spacer

34. 6th main adjusting shim

PCIB0787E

MT-26

SHIFT CONTROL COMPONENTS

TRANSAXLE ASSEMBLY

1. 3rd-4th bracket 2. Retaining pin 3. Check plug

4. 5th -6th br acket 5. Stopper ring 6. Reverse bracket

7. Re ver se l ever assembly 8. Shifter cap 9. Reverse shift fork

10. Reverse fork rod 11. Check spring 12. Shift check sleeve

13. Check ball 1 4. Reverse bracket fork rod 15. 5th-6th shift fork

16. 5th-6th fork rod 17. Interlock pin 18. Shift check sleeve

19. Check spri ng 20. Check spring 21 . 3rd-4th f ork rod

22. 3rd-4th shif t fork 23. 1st-2nd fork rod 24. 1st-2nd fork rod bracket

25. 1st-2nd shift fork 26. Stopper bolt 27. Shift check

28. O-ring 29. Control assembly

PCIB0788E

MT-27

FINAL DRIVE COMPONENTS

TRANSAXLE ASSEMBLY

PCIB0785E

1. Differential side bearing outer race 2. Differential side bearing (c lu tch housing side)

4. Final gear 5. Differential side bearing (tra nsaxle case side)

7. D ifferential side bearing adjusting shim 8. Side gear 9. Side gear thrust washer

10. Retaining pin 11. Pinion mate thrust washer 12. Pinion m at e gear

13. Pinion mate shaft

3. Differential case

6. Differential side bearing out er race

Disassembly and Assembly (RS5F51A) ECS008C0

DISASSEMBLY

1. Remove drai n plug and filler plug from transaxle case.

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

3. Remove shift check and stopper bolt from transaxle case, and then remove control assembly from transaxle case.

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MT-28

TRANSAXLE ASSEMBLY

4. Remove check plugs ( 3 pi ec es), c he ck sp rin gs (3 p ie ce s), chec k balls (3 pieces) and shift check sleeve (1 piece) from transaxle case.

5. Remove transaxle case mounting bolts.

6. Remove bore plug from transaxle case.

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 from clutch housing.

8. Remove oil gutter, baffle plate from transaxle case .

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) from transaxle case using the puller, and then remove differential side bearing adjusting shim from transaxle case.

11. Remove welc h pl ug from tran saxle case.

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

13. Remove magnet from clutch housing.

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MT-29

TRANSAXLE ASSEMBLY

14. With shift lever in 5th position, remove mounting 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-4t h f ork ro d to 3 r d posi t io n. R emov e r e ta i ni ng pin o f 5 th shift fork using a pin punch.

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

18. Pull out 5th-reverse fork rod and remove 5th shift fork and 5threverse bracket.

19. Remove check balls (2 pieces) from clutch housing.

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

21. Remove stopp er rings for 3rd-4th shift fork.

22. Pull out 3r d-4th fork rod and remove 3rd-4 th shift fork an d 3rd4th bracket.

23. Remove interlock pin and shift ch eck sleeve from clutch housing.

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

25. Pull out 1st-2nd fork rod with 1st-2nd bracket.

26. Remove 1st-2nd shift fork.

27. Remove retaining pin of 1st-2nd bracket using a pin punch and separate 1st-2nd fork rod and 1st-2nd bracket.

MT-30

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