Nissan X-Trail 2004 Owner's Manual

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Page 1

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

Page 2

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

Page 3

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

Page 4

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

Page 5

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

Page 6

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

Page 7

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

Page 8

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)

Page 9

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

Page 10

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

Page 11

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

Page 12

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

Page 13

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

Page 14

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

Page 15

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

Page 16

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

Page 17

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

Page 18

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

Page 19

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

Page 20

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

Page 21

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

Page 22

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

Page 23

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

Page 24

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

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Page 25

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

Page 26

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

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MT-26

Page 27

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

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MT-27

Page 28

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

Page 29

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

Page 30

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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Page 31

TRANSAXLE ASSEMBLY

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

a. Remove input shaft assembly, mainshaft assembly and reverse

idler gear assembly as a set, tapping input shaft with plastic hammer.

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 mainshaft bearing retainer and then mainshaft front bearing from clutch housing using the pu ller.

30. Remove oil channel from clutch housing.

31. Remove differential oil seal (clutch housing side) from clutch housing.

CAUTION:

Be careful not to damage clutch housing.

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32. Remove differential side bearing outer race (clutch housing side) from clutch housing using the puller.

33. Remove input shaft oil seal from clutch housing.

CAUTION:

Be careful not to damage clutch housing.

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MT-31

Page 32

TRANSAXLE ASSEMBLY

ASSEMBLY

1. Apply multi-purpose grease to input shaft oil seal lip. Install a new input shaft oil seal 1.8-2.8mm (0.071-0.110 in) above from clutch housing edge surface using the drift.

CAUTION:

Do not reuse oil seals.

2. Apply multi-purp ose grease to differential oil seal lip, and then install a new oil seal to clutch housing using the drift.

CAUTION:

Do not reuse oil seals.

3. Install oil channel on mainshaft side.

CAUTION:

Be careful with the orientation of installation.

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MT-32

Page 33

TRANSAXLE ASSEMBLY

4. Install mainshaft front bearing to clutch housing using the drift.

CAUTION:

Be careful with the orientation of installation.

5. Install mains haft bearing retainer to clut ch housing and tighten mounting bolt to the specified torque . Refer to MT-20, "

COMPONENTS" .

CAUTION:

Install with punched surface facing up.

GEAR

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PCIB0789E

6. Install di f f ere nt i al side be ar ing ou te r rac e t o c lu tch h ou si ng us in g the drift s.

7. Install fi nal drive assembly into clutch housing.

8. Install input shaft assembly, mainshaft assembly, and reverse idler gear assembly into clutch housing.

CAUTION:

Be sure not to damage input shaft oil seal.

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MT-33

Page 34

TRANSAXLE ASSEMBLY

9. Install 1st-2nd bracket onto 1st-2nd fork rod, and then install a new retaining pin to 1st-2nd bracket.

CAUTION:

Do not reuse retaining pins.

10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install a new retaining pin to1st-2nd shift fork.

CAUTION:

Do not reuse retaining pins.

11. Install shift check sleeve to clutch housing.

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12. Install interlock pin to 3rd-4th fork rod.

13. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod.

14. Install a new stopper ring onto 3rd-4th shift fork.

CAUTION:

Do not reuse stopper ring.

15. Install a new retaining pin onto 3rd-4th bracket.

CAUTION:

Do not reuse retaining pins.

16. Install 2 check balls to clutch housing.

17. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork rod.

18. Install a new stopper ring onto 5th-reverse bracket.

CAUTION:

Do not reuse stopper ring.

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19. Install a new retaining pin onto 5th shift fork.

CAUTION:

Do not reuse retaining pins.

20. Install reverse shift fork and reverse fork rod.

21. Install reverse lever assembly fo llowing the procedures below.

a. Install shifter cap onto reverse lever assembly cam, and then

install them onto reverse shift fork.

CAUTION:

Do not drop shifter cap.

MT-34

SCIA0391E

Page 35

TRANSAXLE ASSEMBLY

b. While lifting reverse shift fork, align cam with 5th-reverse

bracket.

c. Install reverse lever assembly to clutch housing, and then

tighten mounting bolts to the specified torque. Refer to MT-22,

"SHIFT CONTROL COMPONENTS" .

22. Install check ball, shift check sleeve, check spring and a new check plug to clutc h hous in g.

CAUTION:

● Do not reuse check plug.

● Do not drop check ball.

23. Install the magnet onto clutch housing.

24. App ly multi-purpose grease to differential oil seal lip, and then install a new differential oi l seal to transaxle case using the drift.

CAUTION:

Do not reuse differential oil seals .

25. Install sele ct ed i nput sh aft re ar bear i ng adj u st ing sh im o nto i np ut shaft.

● For selection of adjusting shims, refer to MT-47, "INPUT

SHAFT END PLAY" .

26. Ins tall selected differential si de bearing adjusting s him and differential side bearing. For selection adjusting shim, refer to MT-

48, "DIFFERENTIAL SIDE BEARING PRELOAD" .

27. Install baffle plate and oil gutter to transaxle case.

28. Install transaxle case following the procedures below.

a. Install selected mainshaft rear bearing adjusting shim into transaxle case.

● For selection of adjusting shims, refer to MT-48, "MAINSHAFT END PLAY" .

b. Temporarily install a new snap ring of mainshaft rear bearing into transaxle case.

CAUTION:

Do not reuse snap ring.

c. Apply recommended sealant to mating surfaces of transaxle

case and clutch housing.

CAUTION:

Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.

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PCIB0816E

MT-35

Page 36

TRANSAXLE ASSEMBLY

d. With snap ring of mainshaft rear bearing temporarily installed,

place transaxle case over clutch housing.

e. Through bore plug mounting hole, with snap ring stretched, and

lift up mainshaft assembly from the cont rol assembly mounting hole.

f. Securely install snap ring onto main shaft rear bearing.

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g. Tighten mounting bolts to the specified torque.

Bolt A:

: 52 N·m (5.3 kg-m, 38 ft-lb)

Bolt B:

: 65 N·m (6.6 kg-m, 48 ft-lb)

CAUTION:

Always replace bolts B as they are self-sealing bolts.

h. Install control assembly to transaxle case.

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CAUTION:

Do not reuse O-ring.

i. Install a new shift check to transaxle case, and then tighten shift check to the specified torque. Refer to

MT-22, "

SHIFT CONTROL COMPONENTS" .

CAUTION:

Do not reuse shift check.

j. Install a new st opper bolt to transax le ca se , an d t he n ti ghten stopper bolt to th e s pe ci fied torque. Refer to

MT-22, "

SHIFT CONTROL COMPONENTS" .

CAUTION:

Do not reuse stopper bolt.

MT-36

Page 37

TRANSAXLE ASSEMBLY

29. Install a new bore plug to transaxle case using the drift.

CAUTION:

Do not reuse bore plug.

30. Install a new w elch plug to transaxle case using the drift.

CAUTION:

Do not reuse welch plug.

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31. Install 2 check balls, 2 check springs and 2 new check plugs to transaxle case, and then tighten check plug to the specified torque. Refer to MT-22, "

SHIFT CONTROL COMPONENTS" .

CAUTION:

Do not reuse check plug.

32. Install new O-ring applied gear oil on control assembly. And then install control assembly on transaxle case. After the previous service tighten bolts to the specified torque. Refer to MT-22,

"SHIFT CONTROL COMPONENTS" .

CAUTION:

Do not reuse O-ring.

33. Apply genuine liqui d gas ket or eq uiva len t to thre ads of pa rk/ne utral positio n switch and back- up lamp switch. T hen install them into transaxle case. Tighten park/neutral position switch and back-up lamp switch to the specified torque. Refer to MT-19,

"CASE AND HOUSING COMPONENTS" .

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34. Ins tall n ew ga sk e ts onto drain plug a nd filler plug, an d th en in sta ll th em i nto transaxle ca se . Tighten park/ neutral position switch and back-up lamp switch to the specified torque. Refer to MT-19, "

CASE AND

HOUSING COMPONENTS" .

CAUTION:

● Do not reuse gasket.

● After oil is filled, tighten filler plug to specified torque.

Disassembly and Assembly (RS6F51A) ECS008C1

DISASSEMBLY

1. Remove dra in plug and filler plug from transa x le ca se .

MT-37

Page 38

TRANSAXLE ASSEMBLY

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.

4. Remove check pl ugs ( 4 pie ce s), ch ec k s pri ng s (4 pi eces ) , ch eck balls (4 pieces) and shift check sleeve (2 pieces) from transaxle case.

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5. Remove transaxle case mounting bolts.

6. Remove bore plug fro m tr an sa xl e case.

CAUTION:

Be careful not to damage transaxle case.

7. While spreading the s nap ri ng of main shaf t rear beari ng lo cate d 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.

10. Remove differential side bearing outer race (transaxle case side) from transaxle case usin g the puller, and then remove di fferential side bearing adjusting shim from transaxle case.

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11. Remove welch plug from transaxle case.

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MT-38

Page 39

TRANSAXLE ASSEMBLY

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

13. Remove magnet from clutch housing.

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. Remove retai ning pin of reverse bracket using a pin punch.

17. Pull out reverse bracket and reverse bracket fork rod.

18. Remove check ball (2 pieces) and interlock pin from clutch housing.

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19. Shift 3rd-4th f ork r od to 3rd pos it i on. R e mo ve re taining pin of 5th

- 6th shift fork using a pin punch.

20. Remove stopper rings for 5th-6th bracket.

21. Pul l out 5th-6th fork rod and remo ve 5th-6th shift fork and 5th6th bracket.

22. Remove check balls (2 pieces) and interlock pin.

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MT-39

Page 40

TRANSAXLE ASSEMBLY

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

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

25. Pull out 3rd-4th fork rod and remove 3rd-4th shift fork and 3rd4th bracket.

26. Remove shift check sleeve from clutch housing.

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

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

29. Remove 1st-2nd shift fork.

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

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

a. Remove input shaft assembly, mainshaft assembly and reverse

idler gear assembly as a set, tapping input shaft with plastic hammer.

CAUTION:

Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.

b. Remove final drive assembly.

32. Remove mainshaft bearing retainer and then mainshaft front bearing from clutch housing using the puller.

33. Remove oil channel from clutch housing.

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34. Remove differential oil seal (clutch housing side) from clutch housing.

CAUTION:

Be careful not to damage clutch housing.

MT-40

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Page 41

TRANSAXLE ASSEMBLY

35. Remove differential side bearing outer race (clutch housing side) from clutch housing using the puller.

36. Remove input shaft oil seal from clutch housing.

CAUTION:

Be careful not to damage clutch housing.

ASSEMBLY

1. Apply multi-purpose grease to input shaft oil seal lip. Install a new input shaft oil seal 1.8-2 .8 mm (0. 071-0.110 in) above from clutch housing edg e surface using the drift.

CAUTION:

Do not reuse oil seals.

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2. Apply multi-purpose grease to differential oil seal lip, and then install a ne w oil seal to clutch housing using the drift.

CAUTION:

Do not reuse oil seals.

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MT-41

Page 42

TRANSAXLE ASSEMBLY

3. Install oil channel on mainshaft side.

CAUTION:

Be careful with the orientation of installation.

4. Install mainshaft front bea ring to clutch housing using the drift.

CAUTION:

Be careful with the orientation of installation.

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5. Install mainsh aft bearing retainer to cl utch housing and tigh ten mounting bolt to the specified torque . Refer to MT-25, "

GEAR

COMPONENTS" .

CAUTION:

Install with punched surface facing up.

6. Instal l di fferential side bear i ng oute r ra ce t o cl ut c h hous in g u si ng the drifts.

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7. Install final drive assembly into clutch housing.

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MT-42

Page 43

TRANSAXLE ASSEMBLY

8. Install input shaft assembly, mainshaft assembly, and reverse idler gear assembly into clutch housing.

CAUTION:

Be sure not to damage input shaft oil seal.

9. Install 1st-2nd bracket onto 1st-2nd fork rod, and then install a new retaini ng pin to 1st-2nd bracket.

CAUTION:

Do not reuse retaining pin.

10. Install 1s t-2nd fork rod and 1s t-2nd shift fork, and th en install a new retaining pin to 1st-2nd shift fork.

CAUTION:

Do not reuse retaining pin.

11. Install shift check sleeve to clutch housing.

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12. Install int erlock pin to 3rd-4th fork rod.

13. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod.

14. Install a new stopper ring onto 3rd-4th shift fork.

CAUTION:

Do not reuse stopper ring.

15. Install a new retaining pin onto 3rd-4th bracket.

CAUTION:

Do not reuse retaining pin.

16. Install 2 check balls to clutch housing.

17. Install 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod with interlock pin.

18. Install a new stopper ring onto 5th-6th bracket.

CAUTION:

Do not reuse stopper ring.

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MT-43

Page 44

TRANSAXLE ASSEMBLY

19. Install a new retaining pin onto 5th-6th shift fork.

CAUTION:

Do not reuse retaining pin.

20. Install 2 chec k ba lls .

21. Install check ball, shift check sleeve, check spring and a new check plug.

CAUTION:

● Do not reuse check plug.

● Do not drop check ball.

22. Install reverse bracket fork rod and reverse bracket.

23. Install a new retaining pin onto reverse bracket.

CAUTION:

Do not reuse retaining pin.

24. Install reverse shift fork and reverse fork rod.

25. Install reverse lever assembly fo llowing the procedures below.

a. Install shifter cap onto reverse lever assembly cam, and then

install them onto reverse shift fork.

CAUTION:

Do not drop shifter cap.

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b. While lifting reverse shift fork, align cam with reverse bracket.

c. Install reverse lever assembly to clutch housing, and then

tighten mounting bolts to the specified torque. Re fer to MT-27,

"SHIFT CONTROL COMPONENTS" .

26. Install check ball, shift check sleeve, check spring and a new check plug to clutch housing.

CAUTION:

● Do not reuse check plug.

● Do not drop check ball.

27. Install the magnet onto clutch housing.

28. Apply mul ti-purpose grease to differential oil seal lip, and then install a new differential oil seal to transaxle case using the drift.

CAUTION:

Do not reuse differential oil seals.

29. Install selected input shaft rear bearing adjusting shim onto input shaft.

● For selection of adjusting shims, refer to MT-50, "INPUT

SHAFT END PLAY" .

30. Install selected differential side bearing adjusting shim and differential side bearin g. For select ion adjusti ng shim , refe r to MT-

52, "DIFFERENTIAL SIDE BEARING PRELOAD" .

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MT-44

Page 45

TRANSAXLE ASSEMBLY

31. Install baffle plate and oil gutter to transaxle case.

32. Install transaxle case following the procedures below. a. Install selected mainshaft rear bearing adjusting shim into transaxle case.

● For selection of adjusting shims, refer toMT-51, "MAINSHAFT END PLAY" .

b. Temporarily install a new snap ring of mainshaft rear bearing into transaxle case.

CAUTION:

Do not reuse snap ring.

c. Apply recommended sealant to mating surfaces of transaxle

case and clutch housing.

CAUTION:

Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.

d. With snap ring of mainshaft rear bearing temporarily installed,

place transaxle case over clutch housing.

e. Through bo re plug moun ting hole , with snap rin g stretch ed, and

lift up mainshaft assembly from the control assembly mounting hole.

f. Securely install snap ring onto mainshaft rear bearing.

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MT-45

Page 46

TRANSAXLE ASSEMBLY

g. Tighten mounting bolts to the specified torque.

Bolt A:

: 52 N·m (5.3 kg-m, 38 ft-lb)

Bolt B:

: 65 N·m (6.6 kg-m, 48 ft-lb)

CAUTION:

Always replace bolts B as they are self-sealing bolts.

h. Install control assembly to transaxle case to transaxle case.

CAUTION:

Do not reuse O-ring.

i. Install a new shift check to transaxle case, and then tighten shift check to the specified torque. Refer to

MT-27, "

SHIFT CONTROL COMPONENTS" .

CAUTION:

Does not reuse shift check.

j. Install a new st opper bolt to transax le ca se , an d t he n ti ghten stopper bolt to th e s pe ci fied torque. Refer to

MT-27, "

SHIFT CONTROL COMPONENTS" .

CAUTION:

Do not reuse stopper bolt.

33. Install a new bore plug to transaxle case using the drift.

CAUTION:

Do not reuse bore plug.

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34. Install a new welch plug to transaxle case using the drift.

CAUTION:

Do not reuse welch plug.

35. Install 2 check balls, 2 check springs and 2 new check plugs to transaxle case, and then tighten check plug to the specified torque. Refer to MT-27, "

SHIFT CONTROL COMPONENTS" .

CAUTION:

Do not reuse check plug.

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MT-46

Page 47

TRANSAXLE ASSEMBLY

36. Install new O-ring applied gear oil on control assembly. And then install control assembly on transaxle case. After the precious service tighten bolts to the specified torque. Refer to MT-27,

"SHIFT CONTROL COMPONENTS" .

CAUTION:

Do not reuse O-ring.

37. Apply genuine liqui d gas ket or eq uiva len t to thre ads of pa rk/ne utral positio n switch and back- up lamp switch. T hen install them into transaxle case. Tighten park/neutral position switch and back-up lamp switch to the specified torque. Refer to MT-24,

"CASE AND HOUSING COMPONENTS" .

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38. Ins tall n ew ga sk ets o nt o d r ai n plug and filler pl ug , and then instal l th em i nto transaxle ca se. Tighten drain plug and filler plug to the specified torque. Refer to MT-24, "

CASE AND HOUSING COMPONENTS" .

CAUTION:

● Do not reuse gasket.

● After oil is filled, tighten filler plug to specified torque.

Adjustment (RS5F51A) ECS008C2

INPUT SHAFT END PLAY

● When adjusting input shaft end play, select adjusting shim for

input shaft rear bearing. To select adjusting shim, measure clearance between transaxle case and input shaft rear bearing. Refer to MT-10 2, "

SHIM" .

CAUTION:

Only 1 adjusting shim can be selected.

● Calculate dime nsion "O" (thickness of ad justin g shim) using the

following procedure to satisfy specification of end play for input shaft rear bearing.

End play: 0 - 0.06 mm (0 - 0.0024 in)

Dimension“O” = (O

O: Thickness of adjusting sh im

1 : Dista nce betwee n transaxle case end fac e and

2 : Distance between clutch housing end face

INPUT SHAFT REAR BEARING ADJUSTING

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1 - O2 ) - End play

mounting face of adjusting shim

and end face of input shaft rear bearing

1. Using de pth micrometer and straig htedge, measure dimensi on "O

1 " between transaxle case end face and mounting face of

adjusting shim.

MT-47

SCIA1002E

Page 48

TRANSAXLE ASSEMBLY

2. Using depth micrometer and straightedge as shown in the figure, measure dime nsion " O and end face of input shaft rear bearing.

3. Install selected input shaft rear bearing adjusting shim onto input shaft.

MAINSHAFT END PLAY

● When adjusting mainshaft end play, select adjusting shim for

mainshaft rear bearing. T o select adjusting shim, measure clearance “M” between t ransaxle case and mainshaft rear bearing. Refer to MT-102, "

SHIM" .

CAUTION:

Only 1 adjusting shim can be selecte d.

● C alculate dim ension "P" (thi ckness of adjus ting shim) us ing the

following procedure to satisfy specification of end play for mainshaft rear bearing.

End play: 0 - 0.06 mm (0 - 0.0024 in)

Dimension“P” = "M" - End play

P: Thickness of adjustin g shim M: Distance between mainshaft rear bearing end

MAINSHAFT REAR BEARING ADJUSTING

face and transaxle case end face

2 " between clutch housing end face

PCIB0792E

PCIB0793E

1. Install mainshaf t ass em bl y to cl utch housing.

2. Install snap ring to transax le cas e.

3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install temporarily snap ring to mainshaft rear bearing.

4. Install dial gauge to bore plug mounting hole, and expand snap ring. Lift mainsha ft assembly thro ugh control assemb ly installation hole, and push it ag ai nst t ransa x le ca se. T his s tate shal l be defined as bas e. Moving distance of mainsh aft assembly, with snap ring fit on main rear bearing, becomes “M”.

PCIB0794E

DIFFERENTIAL SIDE BEARING PRELOAD

● When adjusting differential side bearing preload, select adjust-

ing shim for differenti al side bearing. To select adjust ing shim, measure clearanc e “L” between transaxle ca se and differential side bearing outer race. Refer to MT-103, "

SIDE BEARING ADJUSTING SHIM(S)" .

CAUTION:

Up to 2 adjusting shims can be selected.

● C alculate dimension “L ” (thickness of adjusting shi m) using the

following proce dure to satisfy s pecification of p reload for differential side bearing .

DIFFERENTIAL

PCIB0795E

MT-48

Page 49

TRANSAXLE ASSEMBLY

Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)

Dimension“L” = (L

1 - L2 ) + Preload

L: Thickness of adjusting shim L

1 : Distance between transaxle case end face and

mounting face of adjusting shim

2 : Distance between differential side bearing

outer race and clutch housing end face

1. Using de pth micrometer and straig htedge, measure dimensi on "L

1 " between transaxle case end face and mounting face of

adjusting shim.

2. Install differential side bering outer race onto differential side bearing on final gear side. Holding lightly differential side bearing outer race ho r izon tally by hand, rota te fina l gea r five ti me s or more (for smooth movement of bearing roller).

3. Using dep th micrometer and straightedge as sh own in the figure, measure dimension "L

2 " between differential side bearing

outer race and clutch housing end face.

SCIA1078E

4. Install selected differential side bearing adjusting shim, and then install differential side bearing outer race using the drift.

REVERSE IDLER GEAR END PLAY

● When adjusting reverse idler gear end play, select adjusting

shim for reverse idler gear. To select adjusting shim, meas ure clearance betw een transa xle cas e and reve rse idle r gear. Refer to MT-102, "

CAUTION:

Only 1 adjusting shim can be selected.

● Calculate dime nsion "Q" (thickness of ad justin g shim) using the

following procedure to satisfy specification of end play for reverse idler gear.

REVERSE IDLER GEAR ADJUSTING SHIM" .

SCIA1079E

SCIA0898E

End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)

Dimension“Q” = (Q

1 - Q2 ) - End play

MT-49

PCIB0796E

Page 50

TRANSAXLE ASSEMBLY

Q: Thickness of adjusting shim

1 : Distance between transaxle case end face and

mounting face of adjusting shim

2 : Distance between clutch housing end face

and end face of reverse idler gear (Rear)

1. Using depth m icrometer and straight edge, measure dimension "Q

1 " between transaxle case end face and mounting face of

adjusting shim.

2. Using depth micrometer and straightedge as shown in the figure, measure dime nsion " Q and end face of reverse idler gear (Rear).

3. Install selected reverse idler gear adjusting shim onto reverse idler gear assembly.

2 " between clutch housing end face

SCIA1003E

PCIB0797E

Adjustment (RS6F51A) ECS008C3

INPUT SHAFT END PLAY

● When adjusting input shaft end play, select adjusting shim for

input shaft rear bearing. To select adjusting shim, measure clearance betwee n transaxle case and input shaft rear bearing. Refer to MT-102, "

SHIM" .

CAUTION:

Only 1 adjusting shim can be selecte d.

● C alculate di mension "O" (thicknes s of adjusting s him) using th e

following procedure to satisfy specification of end play for input shaft rear bearing.

End play: 0 - 0.06 mm (0 - 0.0024 in)

Dimension“O” = (O

O: Thickness of adjusting shim

O :

INPUT SHAFT REAR BEARING ADJUSTING

SCIA1001E

1 - O2 ) - End play

Distance between transaxle case end face and mounting face of adjusting shim

Distance between clutch housing end face and end face of input shaft rear bearing

MT-50

Page 51

TRANSAXLE ASSEMBLY

1. Using de pth micrometer and straig htedge, measure dimensi on "O

1 " between transaxle case end face and mounting face of

adjusting shim.

2. Using dep th micrometer and straightedge as sh own in the figure, measure dimension "O and end face of input shaft rear bearing.

3. Install sel e ct ed inp ut shaf t re ar be ar ing a dj u stin g sh im o nto i np ut shaft.

2 " between clutch housin g end face

SCIA1002E

PCIB0792E

MAINSHAFT END PLAY

● When adjusting mainshaft end play, select adjusting shim for

mainshaft rear be ari ng . To select adjusting shi m, meas ur e clear ance “M” between transaxle case and mainshaft rear bearing. Refer to MT-102, "

SHIM" .

CAUTION:

Only 1 adjusting shim can be selected.

● Calculate dime nsion "P" (thic kness of adjus ting shim) usi ng the

following proc edure to s atisf y specif ication of end play for mainshaft rear bearing.

End play: 0 - 0.06 mm (0 - 0.0024 in)

Dimension“P” = "M" - End play

P: Thickness of adjusting shim M: Distance between mainshaft rear bearing end

face and tran saxle case end face

1. Install mainshaft assembly to clut ch housing.

2. Install snap ring to transaxle case.

3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install temporarily snap ring to mainshaft rear bearing.

4. Install dia l gauge to bore p lug moun ting hole , and expan d snap ring. Lift mainshaft assembly through control assembly installation hole, an d push it ag ai nst trans axl e cas e. Th is s tate sha ll be defined as base. Moving distance of mainshaft assembly, with snap ring fit on main rear bearing, becomes “M”.

MAINSHAFT REAR BEARING ADJUSTING

PCIB0793E

PCIB0794E

MT-51

Page 52

TRANSAXLE ASSEMBLY

DIFFERENTIAL SIDE BEARING PRELOAD

● When adjusting differential side bearing preload, select adjust-

ing shim for differenti al side bearing. To select adjust ing shim, measure clearanc e “L” between transaxle ca se and differential side bearing outer race. Refer to MT-103, "

SIDE BEARING ADJUSTING SHIM(S)" .

CAUTION:

Up to 2 adjusting shims can be selected.

● C alculate dimension “L ” (thickness of adjusting shi m) using the

following proce dure to satisfy s pecification of p reload for differential side bearing .

Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)

Dimension“L” = (L

1 - L2 ) + Preload

L: Thickness of adjusting shim

1 : Distance between transaxle case end face

and mounting face of adjusting shim

2 : Distance between differential side bearing

outer race and clutch housing end face

1. Using depth m icrometer and straight edge, measure dimension "L

1 " between transaxle case end face and mounting face of

adjusting shim.

2. Install differential side bearing outer race onto differential side bearing on final gear side. Holding lightly differential sid e bearing outer race ho ri zo nt a l ly by ha nd , rotate final gear five tim es or more (for smooth movement of bearing rolle r).

DIFFERENTIAL

PCIB0795E

3. Using depth micrometer and straightedge as shown in the figure, measure dimension "L

2 " between differential side b earing

outer race and clutch hous in g end face .

4. Install selected differential side bearing adjusting shim, and then install differential side bearing outer race using the drift.

SCIA1078E

SCIA1079E

SCIA0898E

MT-52

Page 53

TRANSAXLE ASSEMBLY

REVERSE IDLER GEAR END PLAY

● When adjusting reverse idler gear end play, select adjusting

shim for reverse idler gear. To select adjusting shim, meas ure clearance betw een transa xle cas e and reve rse idle r gear. Refer to MT-102, "

CAUTION:

Only 1 adjusting shim can be selected.

● Calculate dime nsion "Q" (thickness of ad justin g shim) using the

following procedure to satisfy specification of end play for reverse idler gear.

REVERSE IDLER GEAR ADJUSTING SHIM" .

End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)

Dimension“Q” = (Q

1 - Q2 ) - End play

Q: Thickness of adjusting shim

1 : Distance bet ween tra nsaxl e ca se en d fa ce and

mounting face of adjusting shim

2 : Distance between clutch housing end face and

end face of reverse idler gear (Rear)

1. Using de pth micrometer and straig htedge, measure dimensi on

1 " between transaxle case end face and mounting face of

"Q adjusting shim.

2. Using dep th micrometer and straightedge as sh own in the figure, measure dimension "Q

2 " between clutch housin g end face

and end face of reverse idler gear (Rear).

3. Install selected reverse idler gear adjusting shim onto reverse idler gear assembly.

PCIB0796E

SCIA1003E

PCIB0797E

MT-53

Page 54

INPUT SHAFT AND GEARS

INPUT SHAFT AND GEARS PFP:32200 Assembly and Disassembly (RS5F51A) ECS008C4

DISASSEMBLY

1. Before disassembling, measure end play for 3rd, 4th, and 5th input gears.

End play standard value

3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in) 4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in) 5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

2. Remove oil channel.

SCIA0914E

3. Press out input shaft rear bearing using the drift and a puller.

4. Remove the snap ring.

5. Press out input sh aft bearing spacer and 5t h stopper using the drift and a puller.

SCIA0915E

SCIA0916E

SCIA0917E

MT-54

Page 55

INPUT SHAFT AND GEARS

6. Press out 5th input gear and 5th synchronizer hub assembly using the drift and a puller .

7. Remove 5th needle bearing.

8. Press out 5 th input gear bushing, thrus t washer, 4th input gear, 4th needle bearing, 4th input gear bushing, 4th baulk ring, 3rd4th synchronizer hub assembly, 3rd baulk ring and 3rd input gear using the drift and a puller.

9. Remove 3rd needle bearing.

SCIA0918E

SCIA0919E

10. Pres s out inp ut sh aft front bearing using a puller.

INSPECTION AFTER DISASSEMBLY Input Shaft and Gears

Check items below. If necessary, replace them with new ones.

● Damage, peeling , den t, un ev en wear, bending, etc. of shaft

● Excessive wear, damage, peeling, etc. of gears

SCIA0920E

SCIA1073J

MT-55

Page 56

INPUT SHAFT AND GEARS

Synchronizer

Check items belo w. If necessary, replace them with new ones.

● Damage and excessive wear of contact surfaces of coupling

sleeve, synch ronizer hub, and shifting insert

● Coupling sleeve and synchronizer hub must move smoothly.

● If any crack, damage, or exces sive wea r is f ou nd on cam fa ce of

baulk ring or working face of insert, replace it.

SMT387A

Baulk ring clearance

● Push baulk ring on the cone, and measure the clearance

between baulk ring and cone. If measurement is below limit, replace it with a new one.

Clearance

Standard value

3rd and 4th : 0.9 - 1.45 mm (0.035 - 0.057 in) 5th : 0.95 - 1.4 mm (0.037 - 0.055 i n)

Limit value : 0.7 mm (0.028 in)

Bearing

Check items belo w. If necessary, replace them with new ones.

● D am ag e an d roug h rotatio n of be ari ng

SMT867D

SMT140

MTF0041D

MT-56

Page 57

INPUT SHAFT AND GEARS

ASSEMBLY

1. Install 3rd needle bearing to input shaft.

2. Install 3rd input gear and 3rd baulk ring to input shaft.

3. Install 3rd-4th spread spring, 3rd-4th shifting insert and a new 3rd-4th synchronizer hub onto a new 3rd4th coupling sleeve.

CAUTION:

● Be careful with orientation of 3rd-4th synchronizer hub.

● Do not reuse 3rd-4th synchronizer hub.

SCIA0921E

● Be careful with orientation of 3rd-4th coupling sleeve.

● Do not reuse 3rd-4th coupling sleeve.

● Be sure not to hook center projection of 2 spread springs

on same shifting insert.

4. Press in 3rd-4th synchronizer hub assembly using the press stand.

CAUTION:

Align grooves of 3rd-4th shifting insert and 3rd baulk ring.

PCIB0799E

SCIA1083E

SCIA0922E

MT-57

Page 58

INPUT SHAFT AND GEARS

5. Press in 4th input gear bushing using the press stand.

6. Install 4th baulk ring.

7. Instal l 4th needle bearing and 4t h input gear to input shaft.

8. Select thrust washer so that dimension “C2” satisfies the standard value below. Then install thrust washer onto input shaft. Refer to MT-101, "

Standard for dimension C2

: 154.7 - 154.8 mm (6.091 - 6.094 in)

CAUTION:

Only one thrust washer can be selected.

INPUT SHAFT THRUST WASHER" .

PCIB0800E

SCIA0925E

9. Press in a new 5th input gear bushing using the press stand.

CAUTION:

Do not reuse 5th input gear bushing.

10. Install 5th needle bearing and 5th input gear to input shaft.

11. Install 5th baulk ring.

SCIA0926E

12. Install a new 5th synchronizer hub and 5th spread spring, 5th shifting insert onto a new 5th coupling sleeve.

MT-58

Page 59

INPUT SHAFT AND GEARS

CAUTION:

● Be careful with ori entation of 5th synchronizer hub and

shifting insert.

● Do not reuse 5th synchronizer hub.

● Be careful with orientation of 5th coupling sleeve.

● Do not reuse 5th coupling sleeve.

● Be sure not to hook center projection of 2 spread springs

on same shifting insert.

SCIA0927E

SCIA0994E

SCIA1083E

13. Press in 5th synchronizer hub assembly using the press stand.

CAUTION:

Align grooves of 5th shifting insert and 5th baulk ring.

MT-59

SCIA0928E

Page 60

INPUT SHAFT AND GEARS

14. Press in 5th stopper and then input shaft be aring spacer using the drift.

15. Install a new snap ring on to inpu t shaft, an d chec k that end play (gap between snap ring and groove) of input shaft bearing spacer satisfies the standard value.

End play standard value : 0 - 0.1 mm (0 - 0.004 in)

● If measurement is outside the standard range, select snap

ring. Refer to MT-100, "

CAUTION:

Do not reuse snap ring.

INPUT SHAFT BEARING SPACER" .

SCIA0929E

16. Press in input shaft rear bearing using the drift.

CAUTION:

Install input shaft rear bearing with its brown surface facing the input gear side.

17. Press in input shaft front bearing using the drifts.

18. Install oil channel onto input shaf t.

SCIA0930E

SCIA0931E

PCIB0825E

19. Check end play of 3rd, 4th, and 5th input gears.

End play standard value

3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in) 4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in) 5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

SCIA0914E

MT-60

Page 61

INPUT SHAFT AND GEARS

Assembly and Disassembly (RS6F51A) ECS008C5

DISASSEMBLY

1. Before disassembling, measure end play for 3rd, 4th, 5th and 6th input gears.

End play standard value

3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in) 4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in) 5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in) 6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

2. Remove oil channel.

SCIA0966E

3. Press out input shaft rear bearing using the drift and a puller.

4. Remove snap ring.

5. Press out 6th input gear, 6th needle bearing and 6th input gear bushing using the drift and a puller.

6. Remove 6th baulk ring.

7. Press out 5th input gear and 5th- 6th synchronizer hub assembly using the drift and a puller .

8. Remove 5th needle bearing.

SCIA0967E

SCIA0968E

SCIA0918E

MT-61

Page 62

INPUT SHAFT AND GEARS

9. Press out 5th input gear bushing, thrust washer, 4th input gear, 4th needle bearing, 4th input gear bushing, 4th baulk ring, 3rd4th synchronizer hub assembly, 3rd baulk ring and 3rd input gear using the drift and a puller.

10. Remove 3rd needle bearing.

11. Press out input shaft front bearing using a puller.

SCIA0919E

INSPECTION AFTER DISASSEMBLY Input Shaft and Gears

Check items belo w. If necessary, replace them with new ones.

● Damage, peeling, dent, uneven wear, bending, etc. of shaft

● Excessive wear, damage, peeling, etc. of gears

Synchronizer

Check items belo w. If necessary, replace them with new ones.

● Damage and excessive wear of contact surfaces of coupling

sleeve, synch ronizer hub, and shifting insert

● Coupling sleeve and synchronizer hub must move smoothly.

SCIA0920E

SCIA1074J

SMT387A

MT-62

Page 63

INPUT SHAFT AND GEARS

● If any crack, dam ag e, or ex ce ssiv e w ear is foun d o n ca m f ace of

baulk ring or working face of insert, replace it.

Baulk ring clearance

● Push baulk ring on the cone, and measure the clearance

between baulk ring and cone. If measurement is below limit, replace it with a new one.

Clearance

Standard value

3rd and 4th : 0.9 - 1.45 mm (0 .035 - 0.057 in) 5th and 6th : 0.95 - 1.4 mm (0.037 - 0.055 in)

Limit value : 0.7 mm (0.028 in)

Bearing

Check items below. If necessary, replace them with new ones.

● Damage and rough rotation of bearing

SMT867D

SMT140

MTF0041D

MT-63

Page 64

INPUT SHAFT AND GEARS

ASSEMBLY

1. Install 3rd needle bearing to input shaft.

2. Install 3rd input gear and 3rd baulk ring to inpu t shaft.

3. Install 3rd-4th sprea d spr ing,3 rd-4 th sh ift ing ins ert and a new 3rd- 4th sy nchr oni zer hub onto a new 3r d-4t h coupling sleeve.

CAUTION:

● Be careful with orientation of 3rd-4th synchronizer hub.

● Do not reuse 3rd-4th synchronizer hub.

SCIA0921E

● Be careful with orientation of 3rd-4th coupling sleeve.

● Do not reuse 3rd-4th coupling sleeve.

● Be sure not to hook center projection of 2 spread springs

on same shifting insert.

4. Press in 3rd-4th synchronizer hub assembly using the press stand.

CAUTION:

Align grooves of 3rd-4th shifting insert and 3rd baulk ring.

PCIB0799E

SCIA1083E

SCIA0922E

MT-64

Page 65

INPUT SHAFT AND GEARS

5. Press in 4th in put gear bushing using the press stand.

6. Install 4th baulk ring.

7. Install 4th needle bearing and 4th input gear to input shaft.

8. Select thrust washer so that dimension “C2” satisfies the standard value below. Then install thrust washer onto input shaft. Refer to MT-101, "

Standard value for dimension C2

: 154.7 - 154.8 mm (6.091 - 6.094 in)

CAUTION:

Only one thrust washer can be selected.

INPUT SHAFT THRUST WASHER" .

PCIB0800E

SCIA0925E

9. Press in a new 5th input gear bushing using the press stand.

CAUTION:

Do not reuse 5th input gear bushing.

10. Install 5th needle bearing and 5th input gear to input shaft.

11. Install 5th baulk ring.

SCIA0926E

12. Install a new 5 th-6 th sy nchro nize r hu b, 5th -6th s pre ad spri ng a nd 5th- 6th sh ift ing in ser t onto a new 5 th- 6th coupling slee ve .

MT-65

Page 66

INPUT SHAFT AND GEARS

CAUTION:

● Be careful with orientation of 5th-6th synchronizer hub.

● Do not reuse 5th-6th synchronize r hub.

● Be careful with orientation of 5th-6th coupling sleeve.

● Do not reuse 5th-6th coupling sleeve.

SCIA0921E

● Be sure not to hook center projection of 2 spread springs

on same shifting insert.

13. Press in 5th-6th synchronizer hub assembly using the press stand.

CAUTION:

Align grooves of 5th-6t h shifting insert and 5th baulk ring and 6th baulk ring.

PCIB0801E

SCIA1083E

SCIA0928E

MT-66

Page 67

INPUT SHAFT AND GEARS

14. Install 6th needle bearing, 6th input gear, 6th baulk ring onto 6th input gear bushing, and then press in 6th bushing onto input shaft using the drift.

15. Install a new snap ring onto input shaft, and check that end play (gap between snap ring and groove) of 6th input gear bushing satisfies the standard value.

End play standard value : 0 - 0.1 mm (0 - 0.004 in)

● If measurement is outside the standard range, select snap

ring. Refer to MT-100, "

CAUTION:

Do not reuse snap ring.

6TH INPUT GEAR BUSHING" .

SCIA0969E

SCIA0970E

16. Press in input shaft rear bearing using the drift.

CAUTION:

Install input shaft rear bearing with its brown surface facing the 6th input gear side.

17. Press in input shaft front bearing using the drifts.

18. Install oil channel onto input shaft.

19. Check end play of 3rd, 4th, 5th and 6th input gears.

SCIA0971E

PCIB0826E

End play standard value

3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in) 4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in) 5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in) 6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

SCIA0966E

MT-67

Page 68

MAINSHAFT AND GEARS

MAINSHAFT AND GEARS PFP:32241 Assembly and Disassembly (RS5F51A) ECS008C6

DISASSEMBLY

1. Before disassembling, measure the end play of 1st and 2nd main gears.

End play standard value

1st main gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in) 2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

SCIA0933E

2. Remove snap ring.

3. Remove C-ring holder, and then remove mainshaft C-ring.

4. Remove mainshaft rear bearing using the drift and pullers.

5. Remove snap ring.

PCIB0802E

SCIA0935E

SCIA0936E

MT-68

Page 69

MAINSHAFT AND GEARS

6. Press ou t 4 th ma in ge ar an d 5th ma in g ear us ing the dr ift and a puller.

7. Remove 4th main gear adjusting shim.

8. Remove 3rd-4th mainshaft spacer.

9. Press out 3rd main gear, 2nd main gear, 2nd needle bearing , 2nd main gear bushing, 1st-2nd synchronizer hub assembly, 1st main gear, 1st needle bearing, and 1st main gear bushing reverse main gear using the drift.

SCIA0937E

SCIA0938E

INSPECTION AFTER DISASSEMBLY Mainshaft and Gears

Check items below. If necessary, replace them with new ones.

● Damage, peelin g, dent, uneven wear, bending, and other non-

standard conditions of the shaft.

● Excessive wear, damage, peeling, and other non-standard con-

ditions of the gears.

SCIA1075J

MT-69

Page 70

MAINSHAFT AND GEARS

Synchronizer

Check items belo w. If necessary, replace them with new ones.

● Damage and unusual wear on contact surfaces of coupling

sleeve, synch ronizer hub, and shifting insert.

● Coupling sleeve and synchronizer hub must move smoothly.

● If any crack, damage, or exces sive wea r is f ou nd on cam fa ce of

baulk ring or working face of insert, replace it.

SMT387A

Baulk ring clearance

● Double cone synchronizer (1st)

Follow the instructions below and inspect the clearance of outer baulk ring, synchronizer cone, inner baulk ring.

CAUTION:

Outer baulk ring, synchronizer cone and inner baulk ring control clearance s “A” an d “B” as a set . Repl ace the m as a set if they are outside the limit value.

1. Measure clearance A at 2 or more points diagonally opposite using a dial ga uge, and calculate mean value.

Clearance A

Standard value : 0.6 - 0.8 mm (0.024 - 0.031 in) Limit value : 0.2 mm (0.008 in)

SMT867D

SCIA0950E

PCIB0818E

MT-70

Page 71

MAINSHAFT AND GEARS

2. Measure clearance B at 2 or more points diagonally opposite using a feeler gauge, and calculate mean value.

Clearance B

Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in) Limit value : 0.2 mm (0.008 in)

● Triple cone synchronizer (2nd)

Follow the instructions below and inspect the clearance of outer baulk ri ng, synchronizer cone, inner baulk ring.

CAUTION:

Outer baulk ring, synchron izer cone and i nner baulk ring control clearances “A”, “B” and “C” as a set. Replace them as a set if they are outside the limit value.

SCIA1084E

1. Measure clearance “A” at 2points or more on the opposite side using a feeler gauge when pressing baulk ring toward clutch gear taper cone. Then calculate the average.

Clearance “A”

Standard value : 0.6 - 1.2 mm (0.024 - 0.047 in) Limit value : 0.3 mm (0.012 in)

2. Measure c learanc e “B” at 2 poi nts or more o n the op posite si de using a feeler gauge. Then calculate the average.

Clearance “B”

Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in) Limit value : 0.2 mm (0.008 in)

PCIB0603E

PCIB0808E

PCIB0605E

3. Measure clearance “C” at 2 points or more on the opposite side using a feeler gauge when pressing baulk ring toward clutch gear taper cone. Then calculate the average.

Clearance “C”

Standard value : 0.7 - 1.1 mm (0.028 - 0.043 in) Limit value : 0.3 mm (0.012 in)

MT-71

PCIB0809E

Page 72

MAINSHAFT AND GEARS

Bearing

Check items belo w. If necessary, replace them with new ones.

● D am ag e an d roug h rotatio n of be ari ng

ASSEMBLY

1. Press in reverse main gear using the drifts and the press stand.

MTF0041D

CAUTION:

● Be careful with orientation of reverse main gear.

● Do not reuse reverse main gear.

2. Press in 1st main gear bushing using the drifts and the press stand.

3. Install 1st needle be aring, and then 1st main gear.

SCIA0939E

SCIA0992E

SCIA0940E

4. Install 1st-2nd spread spring, 1st-2nd shifting insert and a new 1st-2nd synchronizer hub onto a new 1st2nd coupling slee ve.

MT-72

Page 73

MAINSHAFT AND GEARS

CAUTION:

● Be careful with orientation of 1st-2nd synchronizer hub.

● Do not reuse 1st-2nd synchronizer hub.

● Be careful with orientation of 1st-2nd coupling sleeve.

● Do not reuse 1st-2nd coupling sleeve.

● Be sure not to hook center projection of 2 spread springs

on same 1st-2nd shifting insert.

SCIA0921E

PCIB0803E

SCIA1083E

5. Install 1st inner baulk ring, 1st synchronizer cone, 1st outer baulk ring onto mainshaft, and then press in 1st-2nd synchronizer hub assembly onto mainshaft using the drifts and the press stand.

CAUTION:

● Outer baulk ring, synchronizer cone, and inner baulk ring

on 2nd gear-side must have been removed.

● Be careful with orientation of coupling sleeve.

MT-73

SCIA0941E

Page 74

MAINSHAFT AND GEARS

6. Press in 2nd main gear bushing using the drift and the press stand.

7. Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd inner baulk ring.

8. Install 2nd needle be arin g an d 2nd mai n gear.

9. Press in a new 3rd main gear us ing the dri ft and t he pre ss st an d.

CAUTION:

● Be careful with orientation of 3rd main gear.

● Do not reuse 3rd main gear.

10. Install 3rd-4t h mai ns ha ft spac er.

SCIA0942E

11. Select 4th main g ear adjus ting shim so tha t di mens ion “C1 ” sa tisfies the standard value below, and install 4th main gear adjusting shim onto mainshaft. Refer to MT-101, "

4TH MAIN GEAR

ADJUSTING SHIM" .

Standard value for dime nsion C1

: 173.85 - 173.95 mm (6.844 - 6.848 in)

CAUTION:

Only one adjusting shim can be selected.

SCIA0943E

PCIB0804E

12. Press in a new 4th main gear using the drifts.

CAUTION:

● Be careful with orientation of 4th main gear.

● Do not reuse 4th main gear.

SCIA0945E

MT-74

Page 75

MAINSHAFT AND GEARS

13. Press in a new 5th main gear using the drifts.

CAUTION:

● Be careful with orientation of 5th main gear.

● Do not reuse 5th main gear.

14. Ins tall snap ring ont o mainshaft, and check that en d play of 5th main gear satisfies the standard value.

End play standard value : 0 - 0.1 mm (0 - 0.004 in)

● If measurement is outside the standard range, reselect snap

ring. Refer to MT-100, "

5TH MAIN GEAR" .

SCIA0946E

SCIA0947E

15. Press in mainshaft rear bearing using the drifts.

16. Ins tall main shaf t C-ring onto m ains haft, an d che ck tha t end pl ay of mainshaft rear bearing satisfies the standard value.

End play standar d value : 0 - 0. 06 mm (0 - 0.00 24 i n)

● If measurement is outside the standard range, reselect main-

shaft C-ring. Refer to MT-100, "

MAINSHAFT C-RING" .

17. Install C-ring holder, and then install a new snap ring.

CAUTION:

Do not reuse snap ring.

SCIA0948E

SCIA0949E

PCIB0802E

MT-75

Page 76

MAINSHAFT AND GEARS

18. Check end play of 1st and 2nd main gears.

End play standard value

1st main gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in) 2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

SCIA0933E

Assembly and Disassembly (RS6F51A) ECS008C7

DISASSEMBLY

1. Before disassembling, measure the end play of 1st and 2nd main gears.

End play standard value

1st main gea r : 0.20 - 0.30 mm (0.0079 - 0.01 18 in) 2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

2. Remove snap ring.

3. Remove C-ring holder, and then remove mainshaft C-ring.

4. Press out mainshaft rear bearing, 6th main adjusting shim and 6th main gear using the drift and a puller.

5. Remove 5th-6th mainshaft spacer.

SCIA0973E

PCIB0805E

SCIA0976E

MT-76

Page 77

MAINSHAFT AND GEARS

6. Press ou t 4 th ma in ge ar an d 5th ma in g ear us ing the dr ift and a puller.

7. Remove 4th main gear adjusting shim.

8. Remove 3rd-4th mainshaft spacer.

SCIA0937E

SCIA0938E

INSPECTION AFTER DISASSEMBLY Mainshaft and Gears

Check items below. If necessary, replace them with new ones.

● Damage, peelin g, dent, uneven wear, bending, and other non-

standard conditions of the shaft.

● Excessive wear, damage, peeling, and other non-standard con-

ditions of the gears.

Synchronizer

Check items below. If necessary, replace them with new ones.

● Damage and unusual wear on contact surfaces of coupling

sleeve, synchronizer hub, and shifting insert.

● Coupling sleeve and synchronizer hub must move smoothly .

SCIA1076J

SMT387A

MT-77

Page 78

MAINSHAFT AND GEARS

● If any crack, damage, or exces sive wea r is f ou nd on cam fa ce of

baulk ring or working face of insert, replace it.

Baulk ring clearance

● Double cone synchronizer (1st)

Follow the instructions below and inspect the clearance of outer baulk ring, synchronizer cone, inner baulk ring.

CAUTION:

Outer baulk ring, synchronizer cone, and inner baulk ring control clearance s “A” an d “B” as a set . Repl ace the m as a set if they are outside the limit value.

SMT867D

1. Measure clearance A at 2 or more points diagonally opposite using a dial ga uge, and calculate mean value.

Clearance A

Standard value : 0.6 - 0.8 mm (0.024 - 0.031 in) Limit value : 0.2 mm (0.008 in)

2. Measure clearance B at 2 or more points diagonally opposite using a feeler gauge, and calculate mean value.

Clearance B

Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in) Limit value : 0.2 mm (0.008 in)

SCIA0950E

PCIB0818E

SCIA1084E

● Triple cone synchronizer (2nd)

Follow the instructions below and inspect the clearance of outer baulk ring, synchronizer cone, inner baulk ring.

CAUTION:

Outer baulk ring, synchronizer cone and inner baulk ring control clearanc es “ A ” , “B” and “C” as a set. Replace the m as a set if they are outside the limit value.

MT-78

PCIB0603E

Page 79

MAINSHAFT AND GEARS

1. Measure c learanc e “A” at 2 poi nts or more o n the op posite si de using a feeler gauge when pressing baulk ring toward clutch gear taper cone. Then calculate the average.

Clearance “A”

Standard value : 0.6 - 1.2 mm (0.024- 0.047) Limit value : 0.3 mm (0.012 in)

2. Measure c learanc e “B” at 2 poi nts or more o n the op posite si de using a feeler gauge. Then calculate the average.

Clearance “B”

Standard value : 0.6 - 1.1 mm (0.02 4 - 0.043) Limit value : 0.2 mm (0.008 in)

3. Measure clearance “C” at 2 points or more on the opposite side using a feeler gauge when pressing baulk ring toward clutch gear taper cone. Then calculate the average.

PCIB0808E

PCIB0605E

Clearance “C”

Standard value : 0.7 - 1.1 mm (0.028 - 0.043 in) Limit value : 0.3 mm (0.012 in)

Bearing

Check items below. If necessary, replace them with new ones.

● Damage and rough rotation of bearing

PCIB0809E

MTF0041D

MT-79

Page 80

MAINSHAFT AND GEARS

ASSEMBLY

1. Press in reverse main gear using the drifts and the press stand.

CAUTION:

● Be careful with orientation of reverse main gear.

● Do not reuse reverse main gear.

SCIA0939E

2. Press in 1st main gear bushing using the drifts and the press stand.

3. Install 1st needle be aring, and then 1st main gear.

4. Install 1st-2nd sp read spring, 1st-2nd s hifting insert and a new 1st-2nd synchronizer hub onto a new 1st-2nd coupling sleeve.

CAUTION:

● Be careful with orientation of 1st-2nd synchronizer hub.

● Do not reuse 1st-2nd synchronizer hub.

SCIA0992E

SCIA0940E

SCIA0921E

MT-80

Page 81

MAINSHAFT AND GEARS

● Be careful with orientation of 1st-2nd coupling sleeve.

● Do not reuse 1st-2nd coupling sleeve.

● Be sure not to hook center projection of 2 spread springs

on same 1st-2nd shifting insert.

PCIB0803E

SCIA1083E

5. Install 1st inner baulk ring, 1st synchronizer cone, 1st outer baulk ring onto mainshaft, and then press in 1st-2nd sync hronizer hub assembly onto mainshaft using the drifts and the press stand.

CAUTION:

● Outer baulk ring, synchronizer cone, and inner baulk ring

on 2nd gear-side must have been removed.

● Be careful with orientation of coupling sleeve.

6. Press in 2nd main gear bushing using the drift and the press stand.

7. Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd inner baulk ring.

8. Install 2n d needle bearing and 2nd main gear.

9. Press in a new 3r d mai n gear u sing the dr ift a nd th e pr ess st and.

CAUTION:

● Be careful with orientation of 3rd main gear.

● Do not reuse 3rd main gear.

10. Install 3rd- 4th mainshaft spacer.

SCIA0941E

SCIA0942E

SCIA0943E

MT-81

Page 82

MAINSHAFT AND GEARS

11. Select 4th main g ear adjus ting shim so tha t di mens ion “C1 ” sa tisfies the standard value below, and install 4th main gear adjusting shim onto mainshaft. Refer to MT-101, "

ADJUSTING SHIM" .

Standard value for dime nsion C1

: 173.85 - 173.95 mm (6.844 - 6.848 in)

CAUTION:

Only one adjusting shim can be selected.

4TH MAIN GEAR

12. Press in a new 4th main gear using the drifts.

CAUTION:

● Be careful with orientation of 4th main gear.

● Do not reuse 4th main gear.

13. Press in a new 5th main gear using the drifts.

CAUTION:

● Be careful with orientation of 5th main gear.

● Do not reuse 5th main gear.

14. Install 5th-6th mainshaft spacer.

PCIB0804E

SCIA0945E

SCIA0946E

15. Press in 6th main gear using the drifts.

CAUTION:

Do not reuse 6th main gear.

SCIA0977E

MT-82

Page 83

MAINSHAFT AND GEARS

16. Select 6th main adjusting shim and then install it onto mainshaft.

● Calculate thickness “S” of 6th main adjusting shim following

the procedure be low so that end pl ay dime nsion b etween 6th main gear and mainshaft rear bearing becomes the dimension shown below. Refer to MT-102, "

6TH MAIN GEAR

ADJUSTING SHIM" .

End play: 0 - 0.1 mm (0 - 0.004 in)

Dimension“S” = (S

1 - S2 ) - End play

S: Thickne ss of adjus t ing sh im

1 : Dimension from mainshaft standard face to

mainshaft rear bearing press-fit end face

2 : Dimension from mainshaft standard face to

6th main gear end face

CAUTION:

Only one adjusting shim can be selected.

a. Using heig ht ga ug e, me as ure dimension “S

1 ” and “S2 ”.

b. Install selected 6th main adjusting s him to mainshaft.

17. Press in mainshaft rear bearing using the drifts.

SCIA0995E

18. Ins tall main shaf t C-ring onto m ains haft, an d che ck tha t end pl ay of mainshaft rear bearing satisfies the standard value.

End play standar d value : 0 - 0.06 mm (0 - 0.0024 in)

● If measurement is outside the standard range, reselect main-

shaft C-ring. Refer to MT-100, "

MAINSHAFT C-RING" .

SCIA0978E

SCIA0979E

MT-83

Page 84

MAINSHAFT AND GEARS

19. Install C-ring holder, and then install a new snap ring.

CAUTION:

Do not reuse snap ring.

20. Check end play of 1st and 2nd main gears.

End play standard value

1st main gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in) 2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

PCIB0805E

SCIA0973E

MT-84

Page 85

REVERSE IDLER SHAFT AND GEARS

REVERSE IDLER SHAFT AND GEARS PFP:32281

Assembly and Disassembly (RS5F51A) ECS008C8

DISASSEMBLY

1. Remove reverse idler gear adjusting shim.

2. Remove reverse idler gear (rear), reverse coupling sleeve and reverse insert spring simultaneously.

3. Remove revers e idl er ge ar nee dl e be arin g.

4. Remove thrust needle bearing.

5. Remove reverse baulk ring.

6. Remove reverse idler gear (fron t).

7. Remove revers e idl er ge ar nee dl e be arin g.

8. Remove thrust needle bearing.

9. Remove retaining pin from reverse idler shaft.

CAUTION:

Do not reuse retaining pin.

INSPECTION AFTER DISASSEMBLY Reverse Idler Shaft and Gears

Check items below. If necessary, replace them with new ones.

● Damage, peelin g, dent, uneven wear, bending, and other non-

standard conditions of the shaft.

● Excessive wear, damage, peeling, and other non-standard con-

ditions of the gears.

Synchronizer

Check items below. If necessary, replace them with new ones.

● Damage and unu sual wear on co ntact surfaces of reverse cou-

pling sleeve, reverse synchronizer hub, and reverse insert spring.

● Reverse coupling sleeve and reverse synchronizer hub must

move smoothly.

SCIA0953J

● If any crack, dam ag e, or ex ce ssiv e w ear is foun d o n ca m f ace of

reverse baulk ring or workin g fac e of in se rt, repl ac e it.

MT-85

SMT637A

SMT867D

Page 86

REVERSE IDLER SHAFT AND GEARS

Baulk ring clearance

● Push baulk ring on the cone, and measure the clearance

between baulk rin g and cone. If th e measurement i s be lo w li mi t, replace it with a new one.

Clearance

Standard value : 0.95 - 1.4 mm (0.037 - 0.055 in) Limit value : 0.7 mm (0.028 in)

Bearing

Check items belo w. If necessary, replace them with new ones.

● D am ag e an d roug h rotatio n of be ari ng .

ASSEMBLY

Paying attention to the following work, assemble in reverse order of disassembly.

CAUTION:

● Be careful with orientation of reverse insert spring.

SMT140

SCIA0954E

Assembly and Disassembly (RS6F51A) ECS008C9

DISASSEMBLY

1. Remove reverse idler gear adjusting shim.

2. Remove reverse idler gear (rear), reverse coupling sleeve and reverse insert spring simultaneously.

3. Remove reverse idler gear needle bearing.

4. Remove thrust needle bearing.

5. Remove reverse baulk ring.

6. Remove reverse idler gear (front).

7. Remove reverse idler gear needle bearing.

8. Remove thrust needle bearing.

9. Remove retaining pin fr om reverse idler shaft.

CAUTION:

Do not reuse retaining pin.

MT-86

Page 87

REVERSE IDLER SHAFT AND GEARS

INSPECTION AFTER DISASSEMBLY Reverse Idler Shaft and Gears

Check items below. If necessary, replace them with new ones.

● Damage, peelin g, dent, uneven wear, bending, and other non-

standard conditions of the shaft.

● Excessive wear, damage, peeling, and other non-standard con-

ditions of the gears.

SCIA0953J

Synchronizer

Check items below. If necessary, replace them with new ones.

● Damage and unu sual wear on co ntact surfaces of reverse cou-

pling sleeve, reverse synchronizer hub, and reverse insert spring.

● Reverse coupling sleeve and reverse synchronizer hub must

move smoothly.

● If any crack, dam ag e, or ex ce ssiv e w ear is foun d o n ca m f ace of

reverse baulk ring or workin g fac e of in se rt, repl ac e it.

SMT637A

SMT867D

Baulk ring clearance

● Push baulk ring on the cone, and measure the clearance

between baulk ring and cone. If the measurement is below limit, replace it with a new one.

Clearance

Standard value : 0.95 - 1.4 mm (0.037 - 0.055 in) Limit value : 0.7 mm (0.028 in)

Bearing

Check items below. If necessary, replace them with new ones.

● Damage and rough rotation of bearing .

ASSEMBLY

Paying attention to the following work, assemble in reverse order of disassembly.

MT-87

SMT140

Page 88

REVERSE IDLER SHAFT AND GEARS

CAUTION:

● Be careful with orientation of reverse insert spring.

SCIA0954E

MT-88

Page 89

FINAL DRIVE

FINAL DRIVE PFP:38411

Assembly and Disassembly (RS5F51A) ECS008CA

PRE-INSPECTION

● Check the cle aranc e be tween si de ge ar an d differ entia l case as

follows.

1. Clean final drive assembly sufficiently to prevent side gear thrust washer, differential ca se, s i de ge ar, and other parts from stick ing by gear oil.

2. Upright differential case so that side gear to be measured faces upward.

3. Place the drift below and a dial gauge onto side gear. Move side gear up and down, and measure the clearance.

Clearance between side gear and differential case

: 0.1 - 0.2 mm (0. 004 - 0.008 in)

CAUTION:

There should be no resistance and gears should rotate freely.

4. If not wi thin s peci fica tion, a dj ust th e cle aran ce by chan gi ng si de gear thrust washer thickness.

5. Turn differential case upside down, and measure the clearance between side g ear and d ifferential cas e on the ot her side in the same way.

DISASSEMBLY

1. Remove final g ear mounting bolts, and then separate the final gear from dif ferential case.

2. Remove differential side bearing (clutch housing side) using the drift and pulle rs.

PCIB0806E

SMT611A

3. Remove differential side bearing (transaxle case side) using the drift and pulle rs.

MT-89

SCIA0906E

SCIA0907E

Page 90

FINAL DRIVE

4. Remove retaining pin from differential case, and then remove pinion mate shaft using a pin punch.

5. Rotate pinion mate g ea rs, an d re mo ve p i nion ma te ge ars , pi nion mate thrust washers, side gears, and side gear thrust washers from differential case.

INSPECTION AFTER DISASSEMBLY Gear, Washer, Shaft and Case

● Check side gears, side gear thrust washers, pinion mate shaft,

pinion mate gears, pinion mate thrust washers and differential case. If necessary, replace with a new one.

SCIA0908E

Bearing

● Check for bearing damage and rough rotation. If necessary,

replace with a new one.

CAUTION:

When replacing tapered roller beari ng, replace outer and inner races as a set.

ASSEMBLY

1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.

2. Install side gear thrust washers and side gears into differential case.

3. While rotating pinion mate thrust washers and pinion mate gears, aligning them diagonally, install them into differential case.

MTK0135D

SPD715

SMT839

MT-90

Page 91

FINAL DRIVE

4. Insert pinion mate shaft into differential case.

CAUTION:

Be sure not to damage pinion mate thrust washers.

5. Measure end play of side gears following the procedure below. Then select side gear thrust washer.

a. Upright the differential case so that its side gear to be measured

faces upward.

b. Place the dri ft below and a dial gauge onto side gears.

MTK0132D

PCIB0806E

c. Move side gears up and down to m easure end play, and select

thrust washer so tha t it sat isfi es the st anda rd val ue. Re fer to MT-

101, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .

End play standard value

: 0.1 - 0.2 mm (0.004 - 0.008 in)

CAUTION:

● There should be no resistance and gears should rotate

freely.

● Place differential case upside down. Be sure to measure

end play for opposite side-gears likewise.

● Only one thrust washer can be selected.

6. Install a new retaining pin into pinion mate shaft using a pin punch.

CAUTION:

Do not reuse retaining pin.

SMT611A

SCIA0908E

7. Press in differential side bearing (transaxle case side) to differential case using the drifts.

MT-91

SCIA0910E

Page 92

FINAL DRIVE

8. Press in differential side bearing (clutch housing side) to differential case using the drifts.

9. Install final gear into differential case, and tighten final gear mounting bolts to t he specified torque . Refer to MT-23, "

DRIVE COMPONENTS" .

FINAL

SCIA0911E

SCIA0912E

Assembly and Disassembly (RS6F51A) ECS008CB

PRE-INSPECTION

● C heck the clea rance betw een side gea r an d differen ti al ca se a s

follows.

1. Clean final drive asse mb ly s ufficiently to pre ve nt s i de g ea r t hru st washer, differenti al c as e, s id e g ea r, and other parts from sticki ng by gear oil.

PCIB0806E

2. Upright differential case so that side gear to be measured faces upward.

3. Place the drift below and a dial gauge onto side gear. Move side gear up and down, and measure the clearance.

Clearance between side gear and differential case

: 0.1 - 0.2 mm (0.004 - 0.008 in)

CAUTION:

There should be no resistance and gears should rotate freely.

4. If not within specification, adjust the clearance by changing side gear thrust washer thickness.

5. Turn differential case upside down, and measure the clearance between side ge ar and differe ntial case on the othe r side in th e same way.

SMT611A

DISASSEMBLY

1. Remove final gear mounting bolts, and then separate the final gear from differential case.

MT-92

Page 93

FINAL DRIVE

2. Remove differential side bearing (clutch housing side) using the drift and pulle rs.

3. Remove differential side bearing (transaxle case side) using the drift and pulle rs.

SCIA0906E

SCIA0907E

4. Remove retaining pin from differential case, and then remove pinion mate shaft using a pin punch.

5. Rotate pini o n m ate g ea r s, an d re mo ve pini o n ma te g ea r s, pi n io n mate thrust washers, side gears, and side gear thrust washers from differential case.

INSPECTION AFTER DISASSEMBLY Gear, Washer, Shaft and Case

● Check side gea rs, side gear thrust w ashers, pinion ma te shaft,

pinion mate gears , p inion mate thrust was hers an d different ial case. If necessary, repl ace with a new one.

SCIA0908E

MTK0135D

MT-93

Page 94

FINAL DRIVE

Bearing

● Check for bearing damage and rough rotation. If necessary,

replace with a new one.

CAUTION:

When replacing tapered roller beari ng, replace outer and inner races as a set.

ASSEMBLY

1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.

2. Install side gear thrust washers and side gears into differential case.

3. While rotating pinion mate thrust washers and pinion mate gears, aligning them diagonally, install them into differential case.

SPD715

4. Insert pinion mate shaft into differential case.

CAUTION:

Be sure not to damage pinion mate thrust washers.

5. Measure end play of side gears following the procedure below. Then select side gear thrust washer.

a. Upright the differential case so that its side gear to be measured

faces upward .

b. Place the drift below and a dial gauge onto side gears.

SMT839

MTK0132D

PCIB0806E

MT-94

Page 95

FINAL DRIVE

c. Move side gears up and down to m easure end play, and select

thrust washer so tha t it sat isfi es the st anda rd val ue. Re fer to MT-

101, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .

End play standard value

: 0.1 - 0.2 mm (0.004 - 0.008 in)

CAUTION:

● There should be no resistance and gears should rotate

freely.

● Place differential case upside down. Be sure to measure

end play for opposite side-gears likewise.

● Only one thrust washer can be selected.

6. Install a new retaining pin into pinion mate shaft using a pin punch.

CAUTION:

Do not reuse retaining pin.

SMT611A

7. Press in differential side bearing (transaxle case side) to differential case using the drifts.

8. Press in differential side bearing (clutch housing side) to differential case using the drifts.

SCIA0908E

SCIA0910E

SCIA0911E

9. Install final gear into differential case, and tighten final gear mounting bolts to the specified torq ue. Refer to MT-28, "

FINAL

DRIVE COMPONENTS" .

MT-95

SCIA0912E

Page 96

SHIFT CONTROL

SHIFT CONTROL PFP:32982 Inspection (RS5F51A) ECS008CC

● Check contact surfaces and sliding area for wear, damage,

bending, etc. If necessary, replace parts.

SHIFT FORK

● Check if the width of shift fork hook (sliding area with coupling

sleeve) is within allowable specification below.

Item One-side wear specification Sliding width of new part

1st-2nd 0 .2 mm (0 .0 0 8 in)

3rd-4th 0.2 mm (0.008 in)

5th 0.2 mm (0.008 in)

Reverse 0.2 mm (0.008 in)

7.80 - 7.93 m m

(0.3071 - 0.3122 in)

7.80 - 7.93 m m

(0.3071 - 0.3122 in)

6.10 - 6.23 m m

(0.2402 - 0.2453 in)

12.80 - 12.93 mm

(0.5039 - 0.5091 in)

SCIA0913E

SMT801D

MT-96

Page 97

SHIFT CONTROL

Inspection (RS6F51A) ECS008CD

● Check contact surfaces and sliding area for wear, damage,

bending, etc. If necessary, replace parts.

SHIFT FORK

● Check if the width of shift fork hoo k (sliding area with coupling

sleeve) is within allowable specifi c ation below.

Item One-side wear specificati on Sliding width of new part

1st-2nd 0.2 mm (0.008 in)

3rd-4th 0.2 mm (0.008 in)

5th-6th 0.2 mm (0.008 in)

Reverse 0.2 mm (0.008 in)

7.80 - 7.93 mm

(0.3071 - 0.3122 in)

7.80 - 7.93 mm

(0.3071 - 0.3122 in)

6.10 - 6.23 mm

(0.2402 - 0.2453 in)

12.80 - 12.93 mm

(0.5039 - 0.5091 in)

SCIA0913E

SMT801D

MT-97

Page 98

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030 General Specifications EC S 008CE

TRANSAXLE

Engine QR20DE QR25DE YD22DDTi Transaxle model RS5F51A RS6F51A Model code number EQ000 EQ008 EQ068 Number of speed 5 6 Synchromesh type Warner Shift pattern

5 speed

SCIA0821E

6 speed

SCIA0955E

Gear ratio 1st 3.500 3.416 3.500

2nd 1.944 3rd 1.258 4th 0.947 5th 0.772 0.733 0.772 6th — 0.630 Reverse 3.374 3.252 3.374

Number of teeth Input gear 1st 14 12 14

2nd 18 3rd 31 4th 38 5th 444544 6th — 46 Reverse141214

Main gear 1st 49 41 49

2nd 35 3rd 39 4th 36 5th 343334 6th — 29 Reverse 38

Reverse idler gear

Oil capacity

(Imp pt)

Front 37 Rear 46 38 46

2.3 (4)

MT-98

Page 99

SERVICE DATA AND SPECIFICATIONS (SDS)

Engine QR20DE QR25DE YD22DDTi Transaxle model RS5F51A RS6F51A Model code number EQ000 EQ008 EQ068 Remarks Reverse synchronizer Installed

Double-cone synchronizer 1st Triple-cone synchronizer 2nd

FINAL GEAR

Engine QR20DE QR25DE YD22DDTi Transaxle model RS5F51A RS6F51A Model code number EQ000 EQ008 EQ068 Final gear ratio 4.750 4.428 Number of teeth Fi nal gear /Pini on 76/ 16 62/14

Side gear/Pinion mate gear 14/10

End Play ECS008CF

Unit: mm (in)

Gear End play 1st main gear 0.20 - 0.30 (0.0079 - 0.0118) 2nd main gear 0.06 - 0.16 (0.0024 - 0.0063) 3rd input gear 0.18 - 0.31 (0.0071 - 0.0122) 4th input gear 0 .2 0 - 0.30 (0.0079 - 0.0118) 5th input gear 0.06 - 0.16 (0.0024 - 0.0063) 6th input gear (For RS6F51A model) 0.06 - 0.16 (0.0024 - 0.0063)

Baulk Ring Clearance ECS00CV4

Unit: mm (in)

Measurement point Standard Limit value

1st (Double-cone synchronizer)

2nd (Triple-cone synchronizer)

● Clearance between synchronizer co ne

and inner baulk ring end face “A”

● Clearance between outer baulk ring pawl

and synchronizer cone “B”

PCIB0249E

● Clearance between synchronizer co ne

and clutch gear end face “A”

● Clearance between outer baulk ring pawl

and synchronizer cone “B”

● Clearance between inner baulk ring and

clutch gear end face “C”

A: 0.6 - 0.8 (0.024 - 0.031) B: 0.6 - 1.1 (0.024 -0.043)

A: 0.6 - 1.2 (0.024 - 0.047) B: 0.6 - 1.1 (0.024 - 0.043) C: 0.7 - 1.1 (0.028 - 0.043)

0.2 (0.008)

0.3 (0.012)

0.2 (0.008)

0.3 (0.012)

PCIB0772E

3rd&4th 0.9 - 1.45 (0.035 - 0.057) 0.7 (0.028)

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SERVICE DATA AND SPECIFICATIONS (SDS)

Measurement point Standard Limit value 5th 0.95 - 1.4 (0.037 - 0.055) 0.7 (0.028) 6th (For RS6F51A model) 0.95 - 1.4 (0.037 - 0.055) 0.7 (0.028) Reverse 0.95 - 1.4 (0.037 - 0.055) 0.7 (0.028)

Available Snap Rings ECS008CH

INPUT SHAFT BEARING SPACER

—For RS5F51A Model—

End play 0 - 0.1 mm (0 - 0.004 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

1.71 (0.0673)

1.76 (0.0693)

1.81 (0.0713)

1.86 (0.0732)

1.91 (0.0752)

1.96 (0.0772)

*: Always check with the Parts Department for the latest parts information.

6TH INPUT GEAR BUSHING

—For RS6F51A Model—

End play 0 - 0.1 mm (0 - 0.004 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

1.76 (0.0693)

1.81 (0.0713)

1.86 (0.0732)

1.91 (0.0752)

1.96 (0.0772)

*: Always check with the Parts Department for the latest parts information.

32204 8H510 32204 8H511 32204 8H512 32204 8H513 32204 8H514 32204 8H515

32204 8H511 32204 8H512 32204 8H513 32204 8H514 32204 8H515

2.01 (0.0791)

2.06 (0.0811)

2.11 (0.0831)

2.16 (0.0850)

2.21 (0.0870)

2.26 (0.0890)

2.01 (0.0791)

2.06 (0.0811)

2.11 (0.0831)

2.16 (0.0850)

2.21 (0.0870)

32204 8H516 32204 8H517 32204 8H518 32204 8H519 32204 8H520 32204 8H521

32204 8H516 32204 8H517 32204 8H518 32204 8H519 32204 8H520

5TH MAIN GEAR

—For RS5F51A Model—

End play 0 - 0.1 mm (0 - 0.004 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

1.85 (0.0728)

1.90 (0.0748)

1.95 (0.0768)

2.00 (0.0787)

*: Always check with the Parts Department for the latest parts information.

32204 8H500 32204 8H501 32204 8H502 32204 8H503

2.05 (0.0807)

2.10 (0.0827)

2.15 (0.0846)

2.20 (0.0866)

32204 8H504 32204 8H505 32204 8H506 32204 8H507

Available C-Rings ECS008CI

MAINSHAFT C-RING

End play 0 - 0.06 mm (0 - 0.0024 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

2.535 (0.0998)

2.565 (0.1010)

2.595 (0.1022)

2.625 (0.1033)

2.655 (0.1045)

2.685 (0.1057)

2.715 (0.1069)

2.745 (0.1081)

2.775 (0.1093)

2.805 (0.1104)

*: Always check with the Parts Department for the latest parts information.

32348 8H800 32348 8H801 32348 8H802 32348 8H803 32348 8H804 32348 8H805 32348 8H806 32348 8H807 32348 8H808 32348 8H809

2.835 (0.1116)

2.865 (0.1128)

2.895 (0.1140)

2.925 (0.1152)

2.955 (0.1163)

2.985 (0.1175)

3.015 (0.1187)

3.045 (0.1199)

3.075 (0.1211)

32348 8H810 32348 8H811 32348 8H812 32348 8H813 32348 8H814 32348 8H815 32348 8H816 32348 8H817 32348 8H818

MT-100