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MANUAL TRANSMISSION

C TRANSMISSION/TRANSAXLE

B
SECTION
MANUAL TRANSMISSION MT

E
CONTENTS
PRECAUTIONS ......................................................... 2 . REAR OIL SEAL ........................................................ 8
. F
Caution .................................................................... 2
. Removal and Installation ......................................... 8 .
Precautions for Battery Service ............................... 2 . REMOVAL ............................................................ 8
.
PREPARATION .......................................................... 3 . INSTALLATION .................................................... 8 . G
Special Service Tools .............................................. 3 . POSITION SWITCH ................................................... 9 .
Commercial Service Tool ........................................ 3 . Checking .................................................................. 9
.
NOISE, VIBRATION, AND HARSHNESS (NVH) COMPONENT LOCATION ................................... 9 .
H
TROUBLESHOOTING ............................................... 4 . BACK-UP LAMP SWITCH ................................... 9 .
NVH Troubleshooting Chart .................................... 4 . PARK/NEUTRAL POSITION SWITCH ................. 9 .
MANUAL TRANSMISSION .................................. 4 . SHIFT CONTROL .................................................... 10 .
DESCRIPTION ........................................................... 5. Removal and Installation of Control Lever Assembly 10 ... I
Cross-Sectional View .............................................. 5 . REMOVAL .......................................................... 10
.
DOUBLE-CONE SYNCHRONIZER ..................... 6 . INSTALLATION .................................................. 11 .
M/T OIL ...................................................................... 7
. INSPECTION AFTER INSTALLATION .............. 13 . J
Replacement ........................................................... 7
. AIR BREATHER HOSE ........................................... 14 .
DRAINING ............................................................ 7
. Removal and Installation ....................................... 14 .
FILLING ................................................................ 7
. TRANSMISSION ASSEMBLY ................................. 15 .
K
Checking ................................................................. 7
. Removal and Installation from Vehicle .................. 15 .
OIL LEAKAGE AND OIL LEVEL .......................... 7 . REMOVAL .......................................................... 15
.
INSTALLATION .................................................. 17 .
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 18 . L
General Specifications ........................................... 18 .

MT-1
PRECAUTIONS

PRECAUTIONS PFP:00001

Caution ACS0015D

q If any malfunctions occur in the FS6R31A model transmission, replace the entire transmission assembly.
q Do not reuse transmission oil, once it has been drained.
q Check oil level or replace oil with vehicle on level ground.
q During removal or installation, keep inside of transmission clear of dust or dirt.
Precautions for Battery Service ACS001MA

This vehicle is equipped with the automatic window adjusting function. When a door is opened, the window
automatically lowers slightly to avoid contact between the window and the side roof panel. After the door is
closed, the window will automatically raise slightly.

On vehicles equipped with the automatic window adjusting function, lower both the driver and front passenger
side windows before disconnecting the battery cables. This will prevent interference between the side window
and the roof panel when either door is opened/closed.

CAUTION:
After the battery cables are disconnected, do not open/close the driver and/or front passenger door
with the window in the full up position. The automatic window adjusting function will not work and the
side roof panel may be damaged.

MT-2
PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ACS0015E

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
B
(Kent-Moore No.) Description
Tool name
MT
ST33400001
(J26082)
Drift Rear oil seal installation D
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
ZZA0814D
E

Oil seal puller F
KV381054S0 Rear oil seal removal
( -- )

G
ZZA0601D

Commercial Service Tool ACS0015F

H
Tool name Description

Power tool Loosening bolts and nuts
J
PBIC0190E

MT-3
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

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

NVH Troubleshooting Chart ACS0015G

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
MANUAL TRANSMISSION

MT-10
MT-7

MT-7

MT-8
--

--
Reference page

CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
SUSPECTED PARTS
(Possible cause)

SHIFT CONTROL LINKAGE (Worn)

BAULK RING (Worn or damaged)
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)

INSERT SPRING (Damaged)
GEAR (Worn or damaged)
OIL (Oil level is high.)

GASKET (Damaged)

SHIFT FORK (Worn)
OIL (Oil level is low.)

OIL (Wrong oil.)

Noise 1 2 3 3
Oil leakage 3 1 4 2
Symptoms
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3

MT-4
DESCRIPTION

DESCRIPTION PFP:00000
A
Cross-Sectional View ACS0015H

SCIA1559E

MT-5
DESCRIPTION

1. Front cover 2. Main drive gear 3. 5th - 6th synchronizer hub
4. 5th - 6th coupling sleeve 5. Transmission case 6. 6th main gear
7. 2nd main gear 8. 1st - 2nd synchronizer hub 9. 1st - 2nd coupling sleeve
10. 1st main gear 11. 3rd main gear 12. 4th main gear
13. Reverse main gear 14. Reverse coupling sleeve 15. Reverse synchronizer hub
16. Striking rod 17. Counter drive gear 18. Filler plug
19. 6th counter gear 20. 2nd counter gear 21. 1st counter gear
22. 3rd counter gear 23. 3rd - 4th synchronizer hub 24. 3rd - 4th coupling sleeve
25. Drain plug 26. 4th counter gear 27. Reverse idler gear
28. Reverse idler shaft 29. Reverse counter gear 30. Mainshaft
31. Rear extension

DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.

SCIA0820E

MT-6
M/T OIL

M/T OIL PFP:KLD20
A
Replacement ACS0015I

DRAINING
1. Start the engine and warm up the transmission unit sufficiently.
B
2. Stop the engine, remove filler plug and drain plug and then drain fluid.
3. Set a new gasket on drain plug and install it to the transmission.
Drain plug: MT

: 30 - 39 N-m (3.1 - 3.9 kg

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