Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan 300ZX 1984-1985,1988,1990,1994-1996 Approved 1988 Manual Transmission
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MANUAL TRANSMISSION
SECTION MT
CONTENTS
I 1 FS5W71C & FS5R30A 1
PREPARATION ........................................................... MT- 2
.v
ON-VEHICLE SERVICE .................................................... MT- 7
REMOVAL AND INSTALLATION ........................................... MT- 8
1 I FS5W71CI
MAJOR OVERHAUL ...................................................... MT- 9
...........................................................
DISASSEMBLY MT-12
INSPECTION ............................................................. MT-17
ASSEMBLY .............................................................. MT-19
I 1 FS5R30A r I
MAJOR OVERHAUL ...................................................... MT-31
DISASSEMBLY ........................................................... MT-35
INSPECTION ............................................................. MT-42
ASSEMBLY .............................................................. MT-44
I IFS5W71C & FS5R30AI I
SERVICE DATA AND SPECIFICATIONS (S.D.S.) .............................. MT-56
SPECIAL SERVICE TOOLS - for FS5W71C
Tool number
(KencMoore No.) Description
Tool name
ST23810001 Fixing adapter plate with gear assembly
( - 1
Adapter setting plate
[Ex
KV31100401 Pressing counter gear and mainshaft
( - 1
Transmission press
stand
ST22520000
(5263481
Wrench
~ ~
ST23540000 Removing and installing fork rod retaining
(J25689-AI pin
Pin Dunch
ST30031000 Removing and installing 1st gear bushing
lJ22912-01) Removing main drive gear bearing
Puller Measuring wear of baulk rings
ST23860000 Installing counter drive gear
( - 1
Drift
a: 38 m m 11.50 in) d i r
a b: 33 m m 11.30 in) dim.
ST22360002 A Installing counter gear front and rear end
(52567941I bearings
Drift
I 29 mm 11.14 in) dia.
:
b: 23 m m (0.91 in1 dia.
ST22350000 Installing O.D. gear bushing
(52567841 I
Drift
a: 34 mm (1.34 in) d i r
b: 28 mm 11.10 in) d.
i
ST23800000 Installing front cover oil seal
152569141)
Drift
a: 44 mm (1.73 in1 dh.
b: 31 mm (1.22 in1 d i r
MT-2
Tool number
(Kent-Moore No.) Description
Tool name
I
ST33400001 Installing rear oil seal
(526082)
Drift
a: 60 mm (2.36in1 die.
b 47 mm (1.85 in) dia.
Puller
ST30720000 Installing mainshaft ball bearing
( - )
Drift
in1
a: 77 mm (3.03 dia.
b: 55.5 mm (2.185 in) dia.
ST30613000 Installing main drive gear bearing
(525742-3)
Drift
a: 71.5 mm 12.815 in1 dia.
b: 47.5 mm 11.870 in) dia.
ST33200000 Installing counter rear bearing
(526082) Installing 3rd & 4th synchronizer
Drift assembly
a: 60mm 1236 In) d h
b: 44.5 mm (1.762 in) di..
COMMERCIAL SERVICE TOOL - for FS5W71C
Tool name Description
Puller Removing counter bearings, counter drive
and O.D. gears
MT-3
PREPARATION pEi5q
SPECIAL SERVICE TOOLS - for FS5R30A
Tool number
(KentMoore No.) Description
Tool name
ST23540000 Removing and installing retaining pin
(525689-A)
Pin punch
ST30031000 Removing 1st & 2nd synchronizer assembly
(52291241) Removing counter gear rear thrust bearing
Puller Removing main drive bearing
ST33290001 Removing rear oil seal
(525810-A)
Puller
"
ST33230000 Removing mainshaft and counter gear
( - 1
Drift
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 id di8.
ST22350000 Removing counter gear front bearing
(525678.01 I (Use with KV38100300)
Drift
a: 34mm 11.34in)dia.
b: 28 mm 11.10 in) dia.
KV38100300 Removing counter gear front bearing
iJ255231 (Use with ST22350000)
Drift Installing counter gear rear bearing
a: 54 m m 12.13 in) dia.
b: 32 mm (1.26 in1 dia.
ST30720000 @ Removing mainshaft front bearing
@ (534286) @ Installing mainshaft front bearing
@ (534331)
Drift a: 77 mm (3.03in) dia.
b 55.5 mm 12.185 in1 dia.
ST33210000 @ Installing counter gear front bearing
@ (525523) @ Installing front cover oil seal
@ I
(525803.01)
Drift : 44 mm 11.73 in) dia.
: 24.5 mm (0.985 in) dia.
ST30613000 Installing main drive gear bearing
(525742-3)
Drift
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
MT-4
PREPARATION pziiiij
Tool number
IKentMoore No.) Dexription
Tool name
~~
ST37750000 @ Removing counter gear rear bearing
@ (J34286) @ Installing 0.0. gear bushing
@ (534332) @ Installing reverse cone
@ (534334) @ Installing reverse counter gear
@ (J25679-01) @ Installing counter gear rear end bearing
Drift
a: 40mm 11.57 in) dia.
b: 31 mm 11.22 in) dia.
ST22452000 Installing reverse hub
(534337) Installing mainshaft rear bearing
@
Drift
a: 45 mm (1.77 in) dia.
a b: 36 mm (1.42 in) dia.
ST33400001 Installing rear oil seal
(J26082I
Drift
a: 60 mm (2.36in1 die..
b: 47 mm 11.85 in1 dia.
(J26349-3) Installing mainshaft and counter gear
Puller leg (Use with 534328)
~
(J343281 Installing mainshaft and counter gear
Puller (Use with 526349-3)
(J26092) Installing sub-gear snap ring
Drift
a: 44.5 mm (1.752 in) dia.
a b: 38.5 mm (1.516 in) dla.
(J34342) Installing 0.0. main F a r
Drift Installing reverse gear bushing
a: 44.5 mm 11.752 in) dia.
b: 40.5 mm 11.594 in1 dia.
ST36730000 Installing wb-gear on reverse
( - 1 idler gear
Drift
P REPARATlON pziq
COMMERCIAL SERVICE TOOL - for FS5R30A
Tool name Description
Puller Removing caunter gear rear end bearing
Removing mainshaft rear bearing
Removing reverse synchronizer hub
Removing reverse counter gear
MT-6
ON-VEHICLE SERVICE
Checking M/T Oil
Check manual transmission for leakage.
&
Check oil level.
Fill to this level
LFiller plug
SMAlO:
Replacing Rear Oil Seal
MT-7
REMOVAL AND INSTALLATION
Removal
Remove exhaust front tube, catalytic converter and exhaust
manifold connecting tube.
Refer t o Section EM.
Remove propeller shaft.
Refer t o section PD
Insert plug into rear oil seal after removing propeller shaft.
Support engine by placing a jack under oil pan.
CAUTION:
TOSSA
Be careful not to damage spline, sleeve yoke and rear oil
seal, when removing propeller shaft.
Do not place jack under the oil pan drain plug.
Remove shift lever (FS5W71C).
WARNING:
Support Manual Transmission, while removing it.
Remove shift knob and console boot finisher (FS5R30A).
Dust cover must not be removed from shift lever.
Installation
0 Tighten bolt securing transmission.
1 Tightening torque N m (kg-m, ft-lb)-[
~~ ~~
Bolt No. P mm (in)
1 39 - 49 (4.0 - 5.0,29 - 36) 65 (2.56)
2 39 - 49 (4.0 - 5.0,29 - 36) 60 (2.36)
3 29 - 39 (3.0- 4.0,22 .29) 55 (2.17)
4 29 - 39 (3.0- 4.0, 22 - 29) 25 (0.98)
MT-8
MAJOR OVERHAUL 1FS5W71C I
SMT74KA
MT-9
MAJOR OVERHAUL
I FS5W71C]
Gear Components - FS5W71C
Needle
bearing
Main drive gear blibearing
coupling sleeve
1 & 4th
3rd
synchronizer hub*
Spread Spring
I roller
-7 Mainshaft bail bearing
Mainshaft rear end bearing
-
(14.0. 17.0. 101 1231
st washer Without Tool
.D.(5th) main gear
Shifting insert spring Reverse counter gear
B mal" gear
Overdrive counter gear
Reverse counter gear spacer
auntel rear bearing
Insert retainer
O.D. (5th) synchronizer
*
'
Rewrse idler thrust washer
hub
-w u n i e r gear Z3' Reverse idler gear bearing
Reverse idler thrust washer
Counter
drive gear* Reverse idler shaft
Subgear Apply g r oil to W m , ihdts,
.
svnchmnlren, and h i mwhmn -bun&
Counter shaft
front bearing
Subgear spring *
Select with proper thickness.
Snap ring* 0 Sub-gear bracket * Psv mention t o its direction.
: N m (kg-m, ft-lb)
SMTCI378
MT-10
MAJOR OVERHAUL I FS5W71C I
Shift Control Components-FS5W71 C
(With mainshaft braking mechanism)
SMT039B
MT-11
DISASSEMBLY 1F S 5 W y
Case Components
1. Remove rear extension.
a. Remove control housing, check ball, return spring plug,
select check plunger and return springs.
b. Remove rear extension by lightly tapping it.
SMT98
2. Remove front cover, gasket, shim of countershaft front
bearing, and snap ring of main drive gear ball bearing.
3. Separate transmission c s from adapter plate.
ae
TM753
4. Remove oil seal of front cover.
Be careful not to damage mating surface of front cover.
MT-12
DISASSEMBLY pi
iq
Shift Control Components
1. Set up Tool on adapter plate.
2. Remove check ball plugs, check springs, and check balls,
sl73810001
( - 1
TM75
3. Drive out retaining pins. Thep drive out fork rods and remove
interlock balls.
T23540000
125689-AI
.
4. Remove lever bracket securing bolt.
5. Draw out 3rd4th fork rod.
6. Remove E-ring from 0.D.-rev. fork rod.
MT-13
DISAS SE MBLY I FS5W71C I
Shift Control Components (Cont'd)
7. Draw out 0.D.-rev. fork shaft by rotating 0.D.-rev. bracket
counterclockwise.
SMT792A
Gear Components
1. Before disassembly, measure each gear end play.
0 If end play is not within the specified limit, disassemble and
check the parts.
0 Replace any part which is worn or damaged.
Gear End play rnm (in)
1 It 0.31 - 0.41 (0.0122 - 0.0161)
2nd 0.1 1 .0.21 (0.0043 - 0.0083)
iMT025
" I 3rd 0.11 .0.21 (0.0043 - 0.0083)
O.D. 0.24 - 0.41 (0.0094 - 0.0161)
2. Mesh 2nd and reverse gear, then draw out counter front
bearing with suitable puller.
3. Remove snap ring and then remove sub-gear bracket, sub-gear
spring and sub-gear.
SMT174P
TSuitable puller 4. Draw out counter drive gear with main drive gear assembly
with suitable puller.
When drawing out main drive gear assembly, be careful not t o
drop pilot bearing and baulk ring.
MT-14
DISASSEMBLY LFs5w71cJ
Gear Components (Cont'd)
5. Disassemble parts a t rear of adapter plate as follows.
a. Release staking on countershaft nut and mainshaft nut and
loosen these nuts.
Mainshaft nut: Left-hand thread
.I
SMT163A
b. Pull out O.D. counter gear with bearing with suitable puller.
c. Draw out reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft, and draw out
reverse idler gear, thrust washers and reverse idler gear bear-
ing.
e. Remove speedometer drive gear and steel ball.
I
f. Remove snap ring and pull out overdrive mainshaft bearing,
then remove snap ring.
g. Remove mainshaft nut.
h. Remove thrust washer, steel roller, roller bearing and washer.
i. Remove O.D. main gear, needle bearing and baulk ring
(O.D.).
j. Remove O.D. coupling sleeve, shifting inserts and shifting
insert springs.
SMTMOE
k. Press out mainshaft and counter gear alternately.
Make sure t o alternate pressing of mainshaft and counter gear so
as not t o allow the front surface of one to contact the rear
surface of the other.
6. Remove front side components on mainshaft.
a. Remove 1st gear washer and steel ball.
b. Remove 1st main gear and 1st gear needle bearing.
SMT383A
MT-15
DISASSEMBLY I FS5W71C 1
Gear Components (Cont'd)
c. Press out 2nd main gear together with 1st gear bushing and
1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.
ST3J031000
lL?291201)
e. Press out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd gear needle bearing.
SMT385P
7. Remove main drive gear bearing.
H ST30031WO
a. Remove snap ring and washer.
b. Remove main drive gear bearing.
1.12291201 I
-
tm
-
MT-16
INSPECTION (Fs5w71Cl
Shift Control Components
Check contact surface and sliding surface of fork rods for
wear, scratches, projections or other damage.
d
SMT137
Mainrhaft and gear Gear Components
GEARS AND SHAFTS
Check shafts for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.
SMT386A
I Counter gear
L SMT550P
SYNCHRONIZERS
e
l
Shifting insert
Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
Check insert springs for deformation.
1
SMT026
MT-17
INSPECTION I FS5W71C I
Gear Components (Cont'd)
r I Measure clearance between baulk ring and gear.
BaulK ring to
Clearance between baulk ring and gear
gear clearance
Unit: mm f i n )
I
I
Standard I
I
Wear limit
1st I I
3rd
Main drive 1 1 . 2 - 1.6
(0.047- 0.063)
1 0.8 (0.031)
OD.
L SMTl4,
Innmr b8uk ring
\2nd inner bauik ring .
Synchronizer cone
Dimension Standard Wear limit
0.7 - 0.9
0.2(0.008)
( 0 . 0 2 8 - 0.035)
h n r bwk ring
- Svnchronizer cone
2nd outer baulk ring
0 2 (0.008)
.
c. I f dimension "A" or "B" is smaller than the wear limit, re-
place baulk ring.
7%' Synchronizer cone
LZnd outer baulk ring SMT0428 I
BEARINGS
Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
MT-I a
AS SEM BLY I FS5W71C I
Mainrhaft ball bearing in adapter plate
Gear Components
1. Install bearings into case components.
Counter rear bearing in adapter plate
2. Assemble adapter plate parts.
Install oil gutter on adapter plate and expand on rear side.
a
:,
. ,
---
Front
, I
I SMT153L
~
Install bearing retainer.
a. Insert reverse shaft, then install bearing retainer.
SMT028
MT-19
ASS E MBLY [FS5W71C I
Gear Components (Cont'd)
3. Install main drive gear bearing.
a. Press in main drive gear bearing.
b. Install main drive gear spacer.
c. Select proper main drive gear snap ring t o minimize clearance
of groove.
Allowable clearance of groove:
0.0.13 m m (0 - 0.0051 in)
Main drive gear snap ring
Thickness mm (in) Part number
1.73 (0.0681) 32204-78005
1.80 (0.0709) 32204-78000
1.87 (0.0736) 32204-78001
1.94 (0.0764) 32204-78002
2.01 (0.0791) 32204-78003
2.08 (0.0819) 32204-78004
~
d. Install selected snap ring on main drive gear.
4. Assemble synchronizers.
1st & 2nd synchronizer
MT-20
~
ASS EMBLY (Fs5w71cJ
Gear Components (Cont'd)
4ub nd muplinp s l r n
\
~
Coupling sleeve
Front rid. SMT0451
I
SMT0460
baulk ring
SMT0470
I 3rd & 4th synchronizer
Synchronizer hub
MT-21
ASSEMBLY I FS5W71C I
Gear Components (Cont'd)
I A h i f t i n q insert spring OD. synchronizer
Front
15th) synchronizer
SMT095A
5. Assemble 2nd main gear, needle bearing and 1st & 2nd
synchronizer assembly, then press 1st gear bushing on
mainshaft.
Pay attention t o direction of 1st & 2nd synchronizer assembly.
6. Install 1st main gear.
7. Install steel ball and thrust washer.
Before installing steel ball and thrust washer, apply grease t o
them.
8 . Press mainshaft assembly t o adapter plate with Tool.
9. Press counter gear into adapter plate with Tool.
10. Install 3rd main gear and then press 3rd & 4th synchronizer
assembly.
...
I I
MT-22
ASSEMBLY IFs5W71cJ
Gear Components (Cont'd)
Pay attention t o direction of 3rd 814th synchronizer hub.
11. Install thrust washer on mainshaft and secure it with main-
shaft front snap ring.
Select proper snap ring to minimize clearance of groove in main-
shaft
Mainshaft front snap ring:
Refer t o S.D.S.
12. Apply gear oil t o mainshaft pilot bearing and install it on
mainshaft.
TM441
13. Press counter drive gear with main drive gear with Tool.
KV31100401
1 - 1
Pay attention t o direction of counter drive gear.
FrontC I I
U SMT620P
14. Install sub-gear components.
a. Install sub-gear and sub-gear bracket on counter drive gear
and then select proper snap ring t o minimize clearance of
groove in counter gear.
Allowable clearance of groove:
0 - 0.18 mm (0.0.0071 in)
MT-23
ASS EMBLY I FS5W71C I
Parts number Thickness m m (in)
322 15-E9000 1.4 (0.055)
322 15-E9001 1.5 (0.0591
32215-E9W2 1.6 (0.063)
c. Reinstall sub-gear, sub-gear spring and sub-gear bracket.
I Lsubgear spring I
LSubgear bracket
SMT528A
15. Install selected counter drive gear snap ring.
TM366
16. Press counter gear front bearing onto counter gear.
KV31100401
( - )
TMdd
17. Assemble parts a t rear of adapter plate as follows:
I a. Install reverse idler gear t o reverse idler shaft with spacers,
snap rings and needle bearing.
c
Front
TM45
MT-24
ASSEMBLY I FS5W71C 1
Gear Components (Cont'd)
Ilnrerf shifting spring
b. Install insert retainer and O.D.synchronizer t o mainshaft.
Shifting insert, / Pay attention t o direction of hub.
1.0. 15th) synchronizer]
ub
a SMT095A
c. Install O.D. war bushing with Tool.
d. Install O.D. main gear and needle bearing.
e. Install spacer, reverse counter gear and O.D. counter gear.
O.D. main gear and O.D. counter gear should be handled as a
matched set.
f. Install washer, roller bearing, steel roller and thrust washer.
g. Tighten mainshaft lock nut temporarily.
Always use new lock nut.
SMT53
ST22360W2 h. Install countershaft rear end bearing with Tool.
151567901I
18. Mesh 2nd and reverse gears, then tighten mainshaft lock nut
with Tool.
SMTOOJ
MT-25
Gear Components (Cont'd)
tool c7 Use the left chart when deciding the reading torque.
Torque wrench (Length of torque wrench vs. setting or reading torque)
11.51 12.01 (2.5) I f t 19. Tighten countershaft lock nut.
MT004A L: Length of torque wrench Always use new lock nut.
Mainshaft Countershaft 20. Stake mainshaft lock nut and countershaft lock nut with a
punch.
21. Measure gear end play. For the description, refer t o Disassem-
bly of Gear Components.
Shift Control Components
1. Install shift rods, interlock plunger, interlock balls and check
balls.
Interlock plunger
SMT99:
a. 1st-2nd shift fork
SMT989
MT-26
~ ~
ASSEMBLY IFs5w71cI
Shift Control Components (Cont'd)
b. 3rd-4th shift fork
SMT991
c. 0.D.-reverse shift fork
2. Install 0.D.-rev. fork shaft by rotating 0.D.-rev. bracket
clockwise.
SMT791A
3. Install E-ring on 0.D.-rev. fork rod.
4. Install lever bracket securing bolt.
MT-27
ASS E MB LY I FS5W71C1
Case Components
1. Install front cover oil seal.
Apply multi-purposegrease to seal lip.
SMTOJS
2. A Av sea lnt ' mating surface of transv ssion case.
3. Slide gear assembly onto adapter plate b y lightly tapping
with a soft hammer.
e
, .~.
4. Apply sealant t o mating surfac f d i ter plate.
5. Install rear extension.
6. Fit main drive bearing snap ring.
MT-28
ASS EMB LY IFs5w71c1
Case Components (Cont'd)
7. Select counter front bearing shim.
A: Oirtanae from bearing
surface to transmission I Unit: mm (in)
"A" I Thicknessof shim I Part number
4.52 - 4.71
Not necessary
(0.1780.0.1854)
1 Transmission care
4.42.4.51
2 Counter gear front bearing 0.1 (0.004) 3221EV5000
3 Counter gear (0.1740 - 0.1776)
4.32 - 4.41
0.2 (0.008) 3221EV5001
(0.1701 -0.1736)
4.22 - 4.31
(0.1661 .0.1697)
I 0.3 (0.012) I 32218-V5002
4.12.4.21
(0.1622.0.1657)
I 0.4 (0.016) I 32218.V5003
4.02.4.1 1
(0.1583.0.1618)
I 0.5 (0.020) I 32218-V5004
3.92 .4.01
0.6 (0.024) 32218.V5005
(0.1543-0.1579)
8. Install gasket and front cover.
9. Install return spring plugs, check bail, return springs and
select check plunger.
10. Install control housing and gasket.
MT-29
ASS EMBLY 1-
NOTE
MT-30
.. ..
ED
MT-31
MAJOR OVERHAUL pGiq
Gear Components - FS5R30A
-
MT-32
MAJOR OVERHAUL I FS5R30A I
Gear Components - FS5R30A (Cont'd)
i
SMT830A
MT-33
MAJOR OVERHAUL I FS5R30A I
Shift Control Components - FS5R30A
SMT838A
MT-34
DISASSEMBLY I FS5R30A 1
II I! Case Components
1. Remove check ball plug, check spring and check ball. Then
remove interlock stopper.
If interlock assembly is removed as a unit, the check ball can
fall into transmission case.
2. Remove control housing, return spring and check ball.
3. Drive out retaining pin from striking arm.
4. Remove rear extension together with striking arm by tapping
lightly.
SMT369A
MT-35
DISASSEMBLY
Case Components (Cont'd)
5. Remove front cover and gasket.
6. Remove stopper ring and main drive bearing snap ring.
7. Remove transmission case by tapping lightly.
8. Remove front cover oil sea
U
SMT392A
Shift Control Components
1. Mount adapter plate on vise.
2. Remove O.D. & reverse fork rod.
MT-36
DISASSEMBLY 1-
Shift Control Components (Cont'd)
3. Remove check ball plug, check ball and return spring.
4. Drive out retaining pin from striking lever.
5. While pulling out striking rod, remove striking lever and
striking interlock. Then remove 1st & 2nd. 3rd & 4th and
reverse shift fork.
6. DI it retaining pi from O.D. shift fork.
7. Pull out O.D. fork rod and then remove O.D. shift fork.
Gear End play mm (in)
1st main gear 0.23 .0.33 (0,0091 .0.0130)
2nd main gear 0.23 - 0.33 10.0091 .0.0130)
3rd main gear 0.23 - 0.33 (0,0091 - 0.0130)
O.D. counter gear 0.23 .0.33 10.0091 - 0.0130)
Reverse main gear 0.33 .0.43 (0.0130 - 0.0169)
0 If not within specification, disassemble and check contact
surface of gear t o hub, washer, bushing, needle bearing and
shaft.
MT-37
Gear Components (Cont'd)
2. Remove rear side components on mainshaft and counter gear.
a. Remove snap ring, speedometer drive gear and steel ball.
b. Remove reverse coupling sleeve.
c. Remove mainshaft rear snap ring and counter gear rear snap
ring.
d. Remove C-ring holder and mainshaft C-rings from mainshaft.
Use punch and hammer t o remove C-rings.
e. Pull out counter gear rear end bearing.
f. Remove reverse idler gear and reverse idler thrust washers.
g. Remove sub-gear from reverse jler gear.
h. Pull out mainshaft rear bearing (2WD model).
MT-38
DISASSEMBLY 1-
Gear Components (Cont'd)
i. Pull out reverse main gear together with mainshaft spacer and
reverse synchronizer hub. Then remove reverse war needle
bearings.
j. Pull out reverse counter gear.
k. Remove O.D. coupling sleeve together with O.D. baulk ring,
reverse baulk ring and spring inserts.
I SMT773A I
I. Pull out reverse gear bushing.
m. Pull out O.D. counter gear together with reverse cone.
MT-39
DISASSEMBLY
Gear Components (Cont'd)
3. Press out mainshaft and counter gear alternately.
Make sure to alternate press between mainshaft and counter gear not to allow
the front surface of one to contact the rear surface of the other. SMT772L
4. Remove front side components on mainshaft.
a. Remove 1st gear washer and steel ball.
b. Remove 1st main gear and 1st gear needle bearing.
SMT383A
c. Press out 2nd main gear together with 1st gear bushing and
1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.
e. Press out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd gear needle bearing.
W
MT-40
DISASSEMBLY IFS5R30A I
Gear Components (Cont'd)
5. Remove front side components on counter gear.
a. Remove counter gear rear thrust bearing.
b. Remove sub gear components.
6. Remove main drive gear bearing.
a. Remove main drive gear snap ring and spacer.
b. Press out main drive gear bearing.
7. Remove bearings from case components.
MT-41
INSPECTION I FS5R30A I
I Shift fork 1 Shift Control Components
Check contact surface and sliding surface for wear, scratches,
projections or other damage.
Gear Components
GEARS AND SHAFTS
Check shafts for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.
I Counter gear
Shifting insert I SYNCHRONIZERS
Check spline portion of coupling sleeves, hubs, and gears for
23 wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
Check insert springs for deformation.
t
Baulk ring
gear c1eara
Standard Wear limit
1st I 2nd
3 1.05 . 1.3 (0.0413 - 0.0512) 0.7 (0.028)
3rd &main drive 1.05 - 1.3 (0.0413 -0.05121 0.7 (0.028)
O.D. 1.05- 1.3 (0.0413-0.0512) 0.7 (0.028)
If the clearance is smaller than the wear limit, replace baulk ring.
SMT
MT-42
INSPECTION 1 FS5R30AI
Standard Wear limit
Dimension "A*
1 -0.1 to 0.35
1-0.0039 to 0.0138)
1 0.7 (0.028)
c. If dimension "A" is larger than the wear limit, replace baulk
ring.
BEARINGS
Make sure bearings roll freely and are free from noise,.crack,
pitting or wear.
MT-43
AS SEM B LY [TGiiiZl
Gear Components
1. Install bearings into case components.
:ounter gear front bearing in transmisaion Mainthaft front bearing in adapter plate
n
SMT397A
Counter gear rear bearing in adapter plate
n
4
SMT395A
2. Install main drive gear bearing.
a. Press main drive gear bearing.
b. Install main drive gear spacer.
c. Select proper main drive gear snap ring t o minimize clearance
of groove.
Allowable clearance of groove:
0 - 0.1 rnrn ( 0 - 0.004 in)
Main drive gear snap ring
1.89 (0.0744) 32204-01GOO
1.98 (0.0780) 32204-01G01
2.05 (0.0807) 32204-01G02
2.12 (0.0835) 32204-01G03
d. Install selected snap ring on main drive gear.
MT-44
ASS E MB LY I FS5R30A I
Gear Components (Cont'd)
3. Install components on counter gear.
a. Install sub-gear components.
When installing sub-gear snap ring, tap sub-gear snap ring into
position on counter gear.
b. Install counter gear rear thrust bearing.
4. Install front side components on mainshaft.
a. Assemble 1st & 2nd synchronizer.
Synchronizer hub
SMT421P
b. Assemble 3rd & 4th synchronizer
,-Synchronizer hub I
SMT422A
c. Press on 3rd & 4th synchronizer assembly together with 3rd
main gear and 3rd gear needle bearing.
Pay attention t o direction of synchronizer assembly.
MT-45
ASSEMBLY I-[
Gear Components (Cont'd)
d. Select proper snap ring t o minimize clearance of groove.
Allowable clearance of groove:
0.0.1 mm (0.0.004 in)
Mainshaft front snap rina
Thickness mm (in) Part number
1.89 (0.07441 32204-01600
1.98 (0.0780) 32204-01601
2.05 (0.08071 32204-01602
SMT400J 2.12 (0.0835) 32204-01603
2.19 (0.08621 32204-01604
e. Install selected snap ring on mainshaft.
M f. Press on 1st & 2nd synchronizer assembly together with 2nd
main gear and 2nd gear needle bearing.
SMT40lA
U g. Press on 1st gear bushing using 1st gear washer.
h. Install 1st main gear and needle bearing.
1 6 1 gear
washer
SMT402A
i. Install steel ball and 1st gear washer.
Apply multi-purpose grease to steel ball and 1st gear washer
before installing.
SMT4031
MT-46
ASS E M BLY JFS5R30AI
Gear Components (Cont'd)
5. Select proper counter gear front bearing shim when replacing
Counter gear front transmission case, counter gear, counter gear thrust bearing
or sub-gear components.
a. Install counter gear with sub-gear components, counter gear
front and rear thrust bearing on adapter plate.
Counter b. Remove counter gear front bearing shim from transmission
gear
case.
c. Place adapter plate and counter gear assembly in transmission
case (case inverted).
SMT427A
R d. Tighten adapter plate t o transmission case using 2 bolts.
e. Place dial indicator on rear end of counter gear.
f. Move counter gear up and down and measure dial indicator
deflection.
g. Select proper shim using table below as a guide.
Counter gear end play:
0.10 - 0.25 mm (0.0039 0.0098 in)
-
Table for selecting proper counter gear front bearing shim
~~ ~ .
Thickness of
Dial indicator deflection
proper washer Part number
mm (in)
mm (in)
0.93 - 1.02 (0.0366 - 0.0402) 0.8 (0.031 3221801GOO
1.03-1.12 (0.0406-0.0441) 0.9 (0.035) 3221801G01
1.13 . 1.22 (0.0445 - 0.04801 1 .O (0.039) 3221801 GO2
1.23 - 1.32 (0.0484 - 0.0520) 1.1 (0.043) 3221801G03
1.33 - 1.42 (0.0524 .0.0559) 1.2 (0.047) 3221801G04
-counter gear
1.43. 1.52 (0.0563.0.0598) 1.3 (0.051 ) 3221841GO5
Measured 1.53 - ?I .62 (0.0602 - 0.0638) 1.4 (0.055) 32218 0 1GO6
. .
end Dlav
SMT578L
MT-47
ASSEMBLY 1-
everie idler shaft
Reverse idler
front thrust washer
Reverse idler gear
Thickness mm (in) Part number
8
1.97 (0.0776)
2.07 (0.0815) I 32284-01G10
32284-01G11
b. Place dial indicator on front end of reverse idler shaft.
c. Put straightedge on front surface of rear extension as a
stopper of reverse idler shaft.
d. Move reverse idler shaft up and down and measure reverse
idler gear end play.
Reverse idler gear end play:
0.30 - 0.53 rnm (0.0118 - 0.0209 in)
e. If not within specification, replace reverse idler rear thrust
washer with the other ( A or B ) and check again.
MT-48
ASS EMBLY I FS5R30A
Gear Components (Cont'd)
7. Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft.
a. Mount adapter plate on vise and apply multi-purpose grease
t o counter gear rear bearing.
b. Install mainshaft a little on mainshaft front bearing.
To allow for installation of counter gear, do not install
mainshaft completely.
SMT440L
c. Install counter gear on counter gear rear bearing and install
main drive gear, pilot bearing and spacer on mainshaft.
Push up with screwdriver, I When installing counter gear into counter gear rear bearing,
push up on upper roller of counter gear rear bearing with screw-
driver.
d. Install Tools (J26349-3) onto adapter plate and C-ring and
C-ring holder on mainshaft.
e. Install Tool (J34328) on mainshaft.
MT-49
ASSEMBLY
Gear Components (Cont'd)
f. Install mainshaft and counter gear completely by extending
length of J26349-3.
SMT579A
8. Install rear side components on mainshaft and counter gear.
a. Install O.D. gear bushing while pushing on the front of
counter gear.
SMTdMA
h b. Install O.D. main gear.
Pay attention t o direction of O.D. main gear. (B is wider than
A as shown a t left.)
c. Install adapter plate with gear assembly onto transmission
case.
d. Install O.D. gear needle bearing and then install O.D. counter
gear and reverse idler shaft.
e. Install reverse gear bushing.
f. Install reverse cone.
SMT582A
MT-50
ASSEMBLY 1 FS5R30A I
7
1 ST22452000
Gear Components (Cont'd)
I. Install mainshaft spacer and mainshaft rear bearing.
m. Install speedometer drive gear.
.
-
t > SMT586A1
n. Install counter gear rear end bearing.
0. Separate adapter plate from transmission case and Mount
adapter plate on vice again.
Thickness mrn (in) Part number Thickness mm (in) Part number
2.63 (0.1035) 32348-01615 3.19 (0.1256) 32348-01607
2.70 (0.1063) 32348-01600 3.26 (0.1283) 32348-01608
MT452A 2.77 (0.1091) 32348-01601 3.33 (0.1311) 32348-01609
2.84 (0.1 118) 32348-01602 3.40 (0.1339) 32348-01610
2.91 (0.1 146) 32348-01603 3.47 (0.1366) 32348-01611
2.98 (0.1173) 32348-01604 3.54 (0.1394) 32348-01612
3.05 (0.1201) 32348-01605 3.61 (0.1421) 32348-01613
3.12 10.1228) 32348-01606 3.68 (0.14491 32348-01614
q. Install selected C-ring, C-ring holder and mainshaft rear snap
ring.
SMT454A
MT-52
ASSEMBLY
I FS5R30A 1
Thickness mm (in) Part number
1.26 (0.0496) 32236-01608
1.32 (0.0520) 32236-01600
1.38 (0.0543) 32236-01601
1.44 (0.0567) 32236-01602
1.50 (0.0591) 32236-01603
1.56 (0.0614) 32236-01604
1.62 (0.0638) 32236-01GO5
1.68 (0.06611 32236-01606
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