Nissan X-Trail 2006 Owner's Manual

MANUAL TRANSAXLE

C TRANSMISSION/TRANSAXLE

SECTION MT

CONTENTS

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

Service Notice or Precautions .................................. 3

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

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

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

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING .......................... ...................... 8

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

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

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

DOUBLE-CONE SYNCHRONIZER .....................11

TRIPLE-CONE SYNCHRONIZER .......................11

REVERSE GEAR NOISE PREVENTION FUNC-

TION (SYNCHRONIZING METHOD) ..................11

M/T OIL ..................................................................... 12

Changing M/T Oil ............................................ ....... 12

DRAINING ................................ ............. .............. 12

FILLING .............................. ...... ........................... 12

Checking M/T Oil .................................................... 12

OIL LEAKAGE AND OIL LEVEL ......................... 12

SIDE OIL SEAL ........................................................ 14

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

REMOVAL ........................................................... 14

INSTALLATION ................................................... 14

POSITION SWITCH .................................................. 15

Checking ................................................................ 15

BACK-UP LAMP SWITCH .................................. 15

PARK/NEUTRAL POSITION (PNP) SWITCH ..... 15

CONTROL LINKAGE ............................................... 16

Components of Control Device and Cable ............. 16

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

AIR BREATHER HOSE ............................................ 18

Removal and Installation ........................................ 18

TRANSAXLE ASSEMBLY ........................................ 19

Removal and Installation ........................................ 19

COMPONENTS .................................................. 19

REMOVAL ........................................................... 20

INSTALLATION ................................................... 21

Disassembly and Assembly (RS5F51A) ................ 22

COMPONENTS .................................................. 22

MANUAL TRANSAXLE

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

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

ADJUSTMENT ....................................................36

Disassembly and Assembly (RS6F51A) .................40

COMPONENTS ..................... ..............................40

DISASSEMBLY ...................................................44

ASSEMBLY .........................................................48

ADJUSTMENT ....................................................54

INPUT SHAFT AND GEARS ....................................58

Disassembly and Assembly (RS5F51A) .................58

DISASSEMBLY ...................................................58

INSPECTION AFTER DISASSEMBLY ................59

ASSEMBLY .........................................................62

Disassembly and Assembly (RS6F51A) .................66

DISASSEMBLY ...................................................66

INSPECTION AFTER DISASSEMBLY ................67

ASSEMBLY .........................................................69

MAINSHAFT AND GEARS .......................................74

Disassembly and Assembly (RS5F51A) .................74

DISASSEMBLY ...................................................74

INSPECTION AFTER DISASSEMBLY ................75

ASSEMBLY .........................................................77

Disassembly and Assembly (RS6F51A) .................81

DISASSEMBLY ...................................................81

INSPECTION AFTER DISASSEMBLY ................82

ASSEMBLY .........................................................84

REVERSE IDLER SHAFT AND GEARS ..................90

Disassembly and Assembly (RS5F51A) .................90

DISASSEMBLY ...................................................90

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

ASSEMBLY .........................................................91

Disassembly and Assembly (RS6F51A) .................91

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

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

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

FINAL DRIVE .................................... ....... ...... ....... ....94

Disassembly and Assembly (RS5F51A) .................94

PRE-INSPECTION ................ ..............................94

DISASSEMBLY ...................................................94

INSPECTION AFTER DISASSEMBLY ................95

MT-1

ASSEMBLY .........................................................95

Disassembly and Assembly (RS6F51A) .................98

PRE-INSPECTION ..............................................98

DISASSEMBLY ...................................................98

INSPECTION AFTER DISASSEMBLY ................99

ASSEMBLY .........................................................99

SHIFT CONTROL ....................................................102

Inspection (RS5F51A) ..........................................102

SHIFT FORK .....................................................102

Inspection (RS6F51A) ..........................................103

SHIFT FORK .....................................................103

SERVICE DATA AND SPECIFICATIONS (SDS) ....104

General Specifications ..........................................104

TRANSAXLE .....................................................104

Gear End Play ............................. ....... ...... ....... .....105

Baulk Ring Clearance ...........................................105

Available Snap Rings ............................................106

INPUT SHAFT BEARING SPACER ..................106

6TH INPUT GEAR BUSHING ...........................106

5TH MAIN GEAR ...............................................106

Available C-Rings .................................................106

MAINSHAFT C-RING ........................................106

Available Thrust Washer .......................................107

INPUT SHAFT THRUST WASHER ...................107

DIFFERENTIAL SIDE GEAR THRUST WASHER

.107

Available Adjusting Shims .....................................107

4TH MAIN GEAR ADJUSTING SHIM ................107

INPUT SHAFT REAR BEARING ADJUSTING

SHIM ......................... .........................................108

MAINSHAFT REAR BEARING ADJUSTING

SHIM ......................... .........................................108

REVERSE IDLER GEAR ADJUSTING SHIM ....108

6TH MAIN GEAR ADJUSTING SHIM ................108

Available Shims ....................................................109

BEARING PRELOAD .........................................109

DIFFERENTIAL SIDE BEARING ADJUSTING

SHIM(S) .............................................................109

MT-2

PRECAUTIONS

PRECAUTIONS PFP:00001

Service Notice or Precautions BCS0009U

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

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

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

● Check for the correc t installation status pri or to removal or dis assembly. If matching marks are require d,

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

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

tightening sequence is specified, use it.

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

MT-3

PREPARATION

PREPARATION PFP:00002 Special Service Tools BCS0009V

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

● Removing differential side bearing outer

race

● Removing mainshaft front bearing

● Installing input shaft oil seal

● Installing reverse main gear

● Installing 1st main gear bushing

● Installing 1st-2nd synchronizer hub

assembly

● Installing 2nd main gear bushing

● Installing 3rd main gear

● Removing differential side bearing (clutch

housing side for 4WD models)

● Installing differential side oil seal

● Installing differential side bearing outer race

● Installing mainshaft rear bearing

● Installing differential side bearing

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

● Installing mainshaft front bearing

● Installing 6th input gear bushing

(RS6F51A)

● Installing 4th main gear

● Installing 5th main gear

● Installing 6th main gear (RS6F51A)

Installing differential side bearing outer race

● Installing bore plug

● Removing differential side bearing (clutch

housing side for 2WD models)

● Removing differential side bearing

(transaxle case side for 4WD models)

MT-4

PREPARATION

Tool number Tool name

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

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

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

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

ZZA1023D

ZZA1133D

ZZA1058D

Description

● Installing welch plug

● Removing input shaft rear bearing

● Removing input shaft bearing spacer and

5th stopper (RS5F51A)

● Removing 5th input gear bushing, thrust

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

● Installing input shaft front bearing

● Removing 6th input gear and 6th input gear

bushing (RS6F51A)

● Removing mainshaft rear bearing

● Removing 4th main gear and 5th main gear

● Removing 6th main gear (RS6F51A)

● Removing 5th input gear, 5th synchronizer

hub assembly (RS5F51A) and 5th-6th synchronizer hub assembly (RS6F51A)

● Removing 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

● Installing 3rd-4th synchronizer hub

assembly

● Installing 4th input gear bushing

● Installing 5th input gear bushing

● Installing 5th synchronizer hub assembly

(RS5F51A)

● Installing 5th-6th synchronizer hub

assembly (RS6F51A)

● Installing 2nd main gear bushing

● Installing 3rd main gear

● Installing reverse main gear

● Installing 1st main gear bushing

● Installing 1st-2nd synchronizer hub

assembly

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

● Installing 5th stopper and input shaft

bearing spacer (RS5F51A)

● Installing input shaft front bearing

ZZA0978D

● Installing input shaft rear bearing

● Installing 4th main gear

● Installing 5th main gear

● Installing 6th main gear (RS6F51A)

● Installing mainshaft rear bearing

ZZA0978D

MT-5

PREPARATION

Tool number Tool name

ST30031000 Puller

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

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

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

ZZA0537D

ZZA1003D

ZZA0838D

Description

Measuring wear of inner baulk ring

Installing reverse main gear

● Installing 1st main gear bushing

● Installing 1st-2nd synchronizer hub

assembly

● Installing differential side bearing (clutch

housing side for 2WD models)

● Installing differential side bearing (transaxle

case side for 4WD models)

Installing differential side bearing (clutch housing side for 4WD models)

ZZA0936D

ST15243000

Measuring end play of side gear Drift a: 30 mm (1.18 in) dia.

SCIA1088J

Commercial Service Tools BCS0009W

Tool name Description Puller Removing each bearing, gear and bushing

ZZA0537D

MT-6

PREPARATION

Tool name Description Puller Removing each bearing, gear and bushi ng

NT077

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

ZZA0815D

Removing and installing each retaining pin

MT-7

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003 NVH Troubleshooting Chart BCS0009X

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.

Reference page

SUSPECTED PARTS (Possible cause)

MA-39

MT-22 (RS5F51A ), MT-40 (RS6F51A)

MT-16

(RS5F51A), MT-41 (RS6F51A)

MT-25 (RS5F51A ), MT-43 (RS6F51A)

MT-23

Symptoms

OIL (Oil level is low.)

OIL (Wrong oil.)

OIL (Oil level is high.)

GASKET (Damaged)

OIL SEAL (Worn or damaged)

O-RING (Worn or damaged)

SHIFT CONTROL LINKAGE (Worn)

CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)

SHIFT FORK (Worn)

GEAR (Worn or damaged)

BEARING (Worn or damaged)

BAULK RING (Worn or damaged) Noise 1 2 3 3 Oil leakage 31222 Hard to shift or will not shift 1 1 2 3 3 Jumps out of gear 1 2 3 3

MT-8

INSERT SPRING (Damaged)

DESCRIPTION

DESCRIPTION PFP:00000

Cross-Sectional View BCS0009Y

2WD models

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. Speedometer drive gear 23. Mainshaft front bearing 24. Mainshaft

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

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

31. Reverse synchronizer hub 32. Reverse idler gear (Rear) 33. 5th input gear

34. 5th-6th synchronizer hub 35. 5th-6t h coupli ng sl eev e 36. 6th input gear

37. Input shaft rear bearing 38. Mainshaft rear bearing 39. 5th main gear

40. 6th main gear

PCIB1456E

MT-9

DESCRIPTION

4WD models

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. R everse idler gear (Rear) 32. 5 th input gear 33. 5th-6th synchronizer hub

34. 5t h-6 th coupl i ng sleeve 35. 6th input gear 36. Input shaft rear bearing

37. M ai nshaft rear bearing 38. 5th main gear 39. 6th ma in ge ar

MT-10

PCIB0773E

DESCRIPTION

DOUBLE-CONE SYNCHRONIZER

Double-cone synchronizer is adopted for 3rd gear to reduce operating force of the shift lever.

TRIPLE-CONE SYNCHRONIZER

Triple-cone synchronizer i s adopted for 1st and 2nd gears to reduce operating force of the shift lever.

PCIB1454E

REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)

Reverse gear ca n be mat ched s moot hly in a s truct ure by sett ing sy nchronizer hub, coupling sleeve, baulk ring and insert spring to reverse gear, and letting reverse gear be synchronized.

PCIB0775E

MT-11

M/T OIL

M/T OIL PFP:KLD20 Changing M/T Oil BCS0009Z

DRAINING

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

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

3. Set a gasket on drain plug and install it to transaxle case. Tighten drain plug to the specified torque. Refer to MT-22, " (RS6F51A).

CAUTION:

Do not reuse gasket.

FILLING

1. Remove plug (for 2WD mode ls) or fille r plug (for 4WD models ). Fill with new oil to transaxle.

Case and Housing Components" (RS5F51A) or MT-40, "Case and Housing Components"

Oil grade and vi scosity: Refer to MA-17, "

Fluids and

Lubricants" .

Oil capacity (reference):

Approx. 2.2 (3-7/8 lmp pt)

2. After refilling oil, check oil level.

3. Set a O-ring on plug (for 2WD models) or gasket on filler plug (for 4WD models) and then install it to clutch housing.

CAUTION:

PCIB1572E

Do not reuse O-ring or gasket.

4. T ighten plug mounting bolt (for 2WD models) or filler plug (for 4WD models) to the spec ified torque. Refer to MT-22, "

Case and Housing Components" (RS5F51A) or MT-40, "Case and Housing Components"

(RS6F51A).

Checking M/T Oil BCS000A0

OIL LEAKAGE AND OIL LEVEL

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

● Remove plug (for 2WD models) or filler plug (for 4WD models).

● Measure oil level using a suitable gauge as shown in the figure, and then check if it is within the specifica-

tions.

CAUTION:

Do not start engine while checking oil level.

– For 2WD models

Oil level “L”: 55.0 - 61.0 mm (2.17 - 2.40 in)

PCIB1477E

MT-12

M/T OIL

– For 4WD models

Oil level “L” : 168.0 - 174.0 mm (6.61 - 6.85 in)

PCIB1478E

● Set a O-ring on plug (for 2WD models) or gasket on filler plug (for 4WD models) and then install it to clutch

housing.

CAUTION:

Do not reuse O-ring or gasket.

● Tight e n plug mounting bolt (for 2WD models) or filler plug (for 4WD models) to the specified torque. Refer

to MT-22, " (RS6F51A).

Case and Housing Components" (RS5F51A) or MT-40, "Case and Ho using Components"

MT-13

SIDE OIL SEAL

SIDE OIL SEAL PFP:32113 Removal and Installation BCS000A1

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 using a flat-bladed screwdriver.

CAUTION:

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

INSTALLATION

1. Drive the oil seal straight until it protrudes from the case end equal to the dimension “A” shown in the figure by using the drift.

Dimension “A”:

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

FRONT DRIVE SHAFT" .

SCIA0824E

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

CAUTION:

● Apply multi-purpose grease onto oil seal lip (for clutch

housing side of 4WD models).

● Do not reuse oil seal.

2. Install all parts in the reverse order of removal and check oil level after installation. Refer to MT-12, "

Checking M/T Oil" .

SCIA1776E

MT-14

POSITION SWITCH

POSITION SWITCH PFP:32005

Checking BCS000A2

BACK-UP LAMP SWITCH

● Check continuity.

Gear position Continuity Reverse Yes Except reverse No

PARK/NEUTRAL POSITION (PNP) SWITCH

● Check continuity.

Gear position Continuity Neutral Yes Except neutral No

SCIA5644E

MT-15

CONTROL LINKAGE

CONTROL LINKAGE PFP:34103 Components of Control Device and Cable BCS000A3

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

4. Lock plate (shift side) 5. Lock plate (select side) 6. C lu tc h housi ng

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

10. Lock plate 11. Washer 12. Snap pin

13. Washer

MT-16

PCIB0777E

CONTROL LINKAGE

Removal and Installation BCS000A 4

Note the following, when removal and installation.

● Shift the control lever to the neutral position for removal.

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

plate.

● After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st, 2nd, or

Reverse.

Install select cable according to the following procedure.

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

2. Install select ca ble 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 (for 6M/T models).

4. Slide stopper part (B) all th e way to lock part (A) as shown by the arrow (for 6M/T models).

CAUTION:

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

PCIB0815E

PCIB0817E

MT-17

AIR BREATHER HOSE

AIR BREATHER HOSE PFP:31098 Removal and Installation BCS000A5

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

QR engine models

1. Air cleaner case 2. Transaxle assembl y 3. Clip

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

7. Resonator

YD engine models

PCIB0778E

PCIB0779E

1. Air cleaner case 2. Transaxle assembl y 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 air breather hose into air breather tube until overlap area reaches the spool.

MT-18

TRANSAXLE ASSEMBLY

TRANSAXLE ASSEMBLY PFP:32010

Removal and Installation BCS000A 6

COMPONENTS

2WD models

PCIB0866E

1. Rear engine mounting insulator 2. Rubber seat 3. Rear engine mountin g brac ket

4. Grommet 5. Center member 6. Transaxle assembly

7. LH engine mounting insulator 8. Stopper 9. Rubber seat

10. LH engine mounting bracket

MT-19

TRANSAXLE ASSEMBLY

4WD models

PCIB1476E

1. Center member 2. Front engine mounting insulator 3. Grommet

4. Transaxle assembly 5. Rear engine mounting bracket 6. Rear engine mounting insulator

7. LH engine mounting insulator 8. Stopper 9. LH engine mounting bracket

REMOVAL

1. Disconnect the battery cable from the negative terminal .

2. Remove battery. Refer to SC-12, "

3. Remove air cleaner and air duct. Refer to EM-16, "Removal and Installation" (QR engine models) or EM-

141, "Removal and Installation" (YD engine models).

4. Remove air breather hose. Refer to MT-18, "

5. Remove clutch operating cylinder. Refer to CL-12, "

CAUTION:

Do not depress clutch pedal during removal procedure.

6. Disconnect control cable from transaxle assembly. Refer to MT-17, "

7. Drain gear oil. Refer to MT-12, "

8. Disconnect PNP switch, back-up lamp switch and ground harness connectors.

9. Remove exhaust front tube. Refer to EX -2, "

10. Remove drive shaft. Refer to FAX-11, "

11. Remove transfer (for 4WD models). Refer to TF-57, "

12. Remove starter motor. Refer to SC-27, "Removal and Installation" .

13. Support transaxle assembly wi th a jac k .

CAUTION:

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

14. Remove center member, engine insulator and engine mount bracket. Refer to EM-81, "

BLY" (QR engine models) or EM-227, "ENGINE ASSEMBLY" (YD engine models).

15. Remove suspen sion members (for 4WD models). Refer to FSU-12, "

16. Support engine with a jack under oil pan.

Removal and Installation" .

Changing M/T Oil" .

Removal and Installation" .

FRONT DRIVE SHAFT" .

Removal and Installation" .

ENGINE ASSEM-

Removal and Installation" .

MT-20

TRANSAXLE ASSEMBLY

17. Remove transaxle assembly mounting bolts.

18. Remove transaxle assembly from the vehicle.

CAUTION:

Secure transaxle assembly to a jack while removing it.

MTD0062D

INSTALLATION

Note the following, and install in the reverse order of removal.

● When installing the transaxle assembly to the engine, install the m ounting bolts following t he standard

below.

CAUTION:

When installing transaxl e ass embly, be careful not to brin g transa xle i nput sh aft into co ntact with clutch cover.

– QR engine models

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

Bolt len g th “ ” mm (in)

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

*: Tightening the bolt for 4WD models.

– YD engine models

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

Bolt len g th “ ” mm (in)

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

● After installation, check oil level, and check for leak s and loose

mechanisms. Refe r to MT-12, "

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

74.5

(7.6, 55)

(2.17)50(2.76)

(4.5, 32)

120

(4.72)45(1.77)40(1.57)

42.7

(4.4, 31)

Checking M/T Oil" .

(3.4, 25)

(1.57)

35.3

(3.6, 26)

SCIA0353E

(1.38)

33.5

SCIA0748E

MT-21

TRANSAXLE ASSEMBLY

Disassembly and Assembly (RS5F51A) BCS000A7

COMPONENTS Case and Housing Components

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

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

7. Magnet 8. Gasket 9. Filler plug

10. O-ring 11. Plug 12. Air breather tube

13. Back-up lamp switch 14. Oil gutter 15. Baffle plate

16. Transaxle case 17. Plug 18. Welch plug

19. Bore plug 20. Drain plug 21. Differential side oil seal

22. Park/Neutral position (PNP) switch

MT-22

PCIB1459E

Gear Components

TRANSAXLE ASSEMBLY

PCIB1458E

1. Input shaft front bear in g 2. Input shaft 3. 3rd needle bearing

4. 3rd input gear 5. 3rd inner baulk ring 6. 3rd synchronizer cone

7. 3rd outer baul k ring 8. 3rd-4th spread spring 9. 3rd-4th shifting insert

10. 3rd-4th synchr oni zer hub 11. 4th baulk ring 12. 3rd-4th coupling sleeve

13. 4th input gear bushin g 14. 4th needle bearing 15. 4th input gear

16. Thrust washer 17. 5th input gear bushing 18. 5th needle bearing

19. 5th input gear 20. 5th baulk ring 21. 5th spread spring

22. 5th shifting insert 23. 5th synchronizer hub 24. 5th coupling sleeve

25. 5th stopper 26. Input shaf t beari ng spacer 27. Snap ring

28. Input shaft rear bea ring 29. Oil channel 30. Inp ut shaf t rear bea ring adj usting shim

31. Retaining pin 32. Reverse idler shaft 3 3. Thrust needle bearing

34. Reverse idler gea r need le bearing 35. Reverse insert spring 36. Rever se i dl er gea r (Front )

37. Reverse baulk ring 38. Reverse coupling sleeve 39. Reverse idler gear (Rear)

40 Reverse idler gear adjusting shim

MT-23

TRANSAXLE ASSEMBLY

1. Mainshaft front bearing 2. M ai nshaft bearing retainer 3. Mainshaft

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

7. 1st needle bearing 8. 1st inne r baulk r ing 9. 1st synchronize r 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. 2 nd synchronizer cone

16. 2nd inner baulk ring 17 . 1st-2nd coupling sleeve 18 . 2nd main gear bushing

19. 2nd needle bearing 20. 2nd main gear 21. 3rd m ain gear

22. 3rd-4th mainshaft spacer 23. 4th main gear adjusting shim 24. 4 th mai n gear

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

28. Mainshaft C-ring 29. C-ring hold er 30. Snap ring

31. Snap ring 32. Mainshaft rear beari ng ad jus ting shim

PCIB0783E

MT-24

Shift Control Components

TRANSAXLE ASSEMBLY

1. 3rd-4th bra cket 2. Retaining pin 3. Stopper ring

4. 5th-r ever se br acket 5. Reverse lever a ssembly 6. Shifte r cap

7. Rever se shif t fork 8. Reverse fork rod 9. Check plug

10. Check spring 11. Shift check sleeve 12. Check ball

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

16. 3rd-4th fork rod 17. Interlo ck 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. Transaxle case

25. Stopper bolt 26. Shift check 2 7. O-ring

PCIB0868E

MT-25

Final Drive Components

TRANSAXLE ASSEMBLY

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

4. Differential case 5. Final gear 6. Differential side bearing (transaxle

7. Differential side bearing outer race (transaxle case side)

10. S ide gear 11. Si de gear thrust washer 12. Pinion mate gear

13. Pinion mate thrust washer 14. Retaining pin

2. Differential side bearing (clutch housing side)

8. Differential side bearing adjusting shim

3. Speedometer drive gear (for 2WD models)

case side)

9. Pinion mate shaft

DISASSEMBLY

1. Remove plug (for 2WD models) or filler plug (for 4WD models) from clutch housing.

2. Remove dr ain plug and plug from transaxle case.

3. Remove park/neutral position (PNP) switch and back-up lamp switch from transaxle case.

4. Remove shift ch eck and stopper bolt from transaxle case, and then remove control assembly from transaxle case.

PCIB0869E

PCIB1653E

MT-26

TRANSAXLE ASSEMBLY

5. Remove check plu gs (3 pi ec es), c heck sp rin gs (3 p iec es) , ch ec k balls (3 pieces) and shift check sleeve (1 piece).

6. Remove transaxle case mounting bolts.

7. Remove bore plug from transaxle case.

CAUTION:

Be careful not to damage transaxle case.

8. While spreading the snap ring of mainshaft rear bearing located at bore plug hole, remove transaxle case from clutch housing.

9. Remove oil gut ter, baffle plate from transaxle case.

10. Rem ove snap ring, mainshaft rear be aring adjusting shim from transaxle ca se .

11. Remove input shaft rear bearing adjusting shim and reverse idler gear adjusting shim.

12. Rem ove differe ntial side bea ring ou ter ra ce f rom tr an saxl e ca se using the puller, and then remove differential side bearing adjusting shim from transaxle case.

SCIA0396E

SCIA0983E

13. Rem ov e we lc h pl ug from transaxle case.

SCIA0897E

SCIA0402E

MT-27

TRANSAXLE ASSEMBLY

14. Remove differential side oil seal from transaxle case.

CAUTION:

Be careful not to damage transaxle case.

15. Remove magnet from clutch housing.

16. 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.

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

SCIA0397E

18. Shift 3rd-4t h f ork rod t o 3 rd p osi t ion. Re mov e r e ta i ni ng pi n o f 5 th shift fork using a pin punch.

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

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

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

SCIA0390E

SCIA0391E

SCIA0392E

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

23. Remove stopper rings for 3rd-4th shift fork.

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

25. Remove interlock pin and shift c heck sleeve from clutch housing.

MT-28

SCIA0393E

TRANSAXLE ASSEMBLY

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

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

28. Remove 1st-2nd shift fork.

29. Rem ove retaining pin of 1st-2nd br acket using a pin punch and separate 1st-2nd fork rod and 1st-2n d bracket.

30. 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.

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

32. Remove oil channel from clutch housing.

SCIA0394E

SCIA0395E

33. Remove differ ential side oil seal fro m clutch housing.

CAUTION:

Be careful not to damage clutch housing.

34. Remove differential side bearing outer race from clutch housing using the puller.

SCIA1077J

SCIA1068J

SCIA1069J

MT-29

TRANSAXLE ASSEMBLY

35. Remove input shaft oil seal from clutch housing.

CAUTION:

Be careful not to damage clutch housing.

ASSEMBLY

1. Install input shaft oil seal to clutch housing using the drift.

Dimension “A”: 1.8 - 2.8 mm (0.071 - 0.110 in)

SCIA0398E

2. Install differential side oil seal until it become flush with end face of clutch housing using the drift.

CAUTION:

● Do not reuse differential side oil seal.

● Apply multi-purpose grease onto oil seal lip (for 4WD

models).

3. Install oil channel on mainshaft side.

CAUTION:

Be careful with the orientation of installation.

PCIB0873E

SCIA1070J

SCIA0986E

MT-30

+ 80 hidden pages