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C TRANSMISSION/TRANSAXLE
A
B
SECTION
MANUAL TRANSAXLE MT
D
E
CONTENTS
RS5F70A INPUT SHAFT AND GEARS ................................... 40 . F
Disassembly .......................................................... 40
.
PRECAUTIONS ......................................................... 4 . Inspection .............................................................. 41
.
Caution .................................................................... 4
. GEAR AND SHAFT ............................................ 41 . G
PREPARATION .......................................................... 5 . SYNCHRONIZERS ............................................ 42 .
Special Service Tools .............................................. 5 . BEARING ........................................................... 43
.
Commercial Service Tools ....................................... 7 . Assembly ............................................................... 43
.
NOISE, VIBRATION, AND HARSHNESS (NVH) H
MAINSHAFT AND GEARS ...................................... 47 .
TROUBLESHOOTING ............................................... 9 . Disassembly .......................................................... 47
.
NVH Troubleshooting Chart .................................... 9 . Inspection .............................................................. 49
.
DESCRIPTION ......................................................... 10 . GEAR AND SHAFT ............................................ 49 . I
CROSS-SECTIONAL VIEW .................................. 10 . SYNCHRONIZERS ............................................ 49 .
DOUBLE-CONE SYNCHRONIZER ................... 10 . BEARING ........................................................... 50
.
M/T OIL .....................................................................11
. Assembly ............................................................... 51
. J
Replacement ..........................................................11
. FINAL DRIVE ........................................................... 57
.
DRAINING ...........................................................11
. Pre-inspection ........................................................ 57
.
FILLING ...............................................................11
. DIFFERENTIAL CASE SIDE .............................. 57 .
Checking ................................................................11
. K
Disassembly .......................................................... 57
.
OIL LEAKAGE AND OIL LEVEL .........................11 . Inspection .............................................................. 58
.
SIDE OIL SEAL ....................................................... 12 . GEAR, WASHER, SHAFT AND CASE .............. 58 .
Removal and Installation ....................................... 12 . BEARING ........................................................... 58
. L
POSITION SWITCH ................................................. 13 . Assembly ............................................................... 59
.
Position Switch Check ........................................... 13 . SHIFT CONTROL .................................................... 61 .
BACK-UP LAMP SWITCH ................................. 13 . Inspection .............................................................. 61
. M
PNP SWITCH ..................................................... 13 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 62 .
CONTROL LINKAGE .............................................. 14 . General Specifications ........................................... 62 .
Removal and Installation ....................................... 14 . TRANSAXLE ...................................................... 62 .
TRANSAXLE GEAR CONTROL ........................ 14 . FINAL GEAR ...................................................... 62.
STRIKING ROD OIL SEAL ................................ 15 . Gear End Play ....................................................... 63
.
TRANSAXLE ASSEMBLY ....................................... 16 . Clearance Between Baulk Ring and Gear ............. 63 .
Removal and Installation ....................................... 16 . 3RD, 4TH, 5TH, REVERSE BAULK RING ......... 63 .
REMOVAL .......................................................... 16. 1ST AND 2ND BAULK RING ............................. 63 .
INSTALLATION .................................................. 18 . Available Snap Rings ............................................ 63 .
Component Parts .................................................. 18 . SNAP RING ........................................................ 63
.
CASE COMPONENTS ....................................... 19 . Available C-rings ................................................... 63
.
GEAR COMPONENTS ...................................... 20 . 4TH INPUT GEAR C-RING ................................ 63 .
SHIFT CONTROL COMPONENTS ................... 21 . 5TH INPUT GEAR REAR C-RING ..................... 64 .
FINAL DRIVE COMPONENTS .......................... 22 . MAINSHAFT C-RING ......................................... 64 .
Disassembly and Assembly .................................. 22 . Available Adjusting Shims ..................................... 64 .
DISASSEMBLY .................................................. 22 . INPUT SHAFT REAR BEARING ADJUSTING
ASSEMBLY ........................................................ 29 .
MT-1
SHIM ................................................................... 64
. ASSEMBLY .........................................................89 .
MAINSHAFT ADJUSTING SHIM ....................... 65 . Adjustment .............................................................94
.
MAINSHAFT REAR BEARING ADJUSTING INPUTSHAFT END PLAY ...................................94 .
SHIM ................................................................... 65
. DIFFERENTIAL SIDE BEARING PRELOAD ......95 .
Available Thrust Washer ........................................ 66 . MAINSHAFT END PLAY .....................................96 .
MAINSHAFT THRUST WASHER ....................... 66 . REVERSE IDLER GEAR END PLAY .................97 .
Available Washers ................................................. 66 . INPUT SHAFT AND GEARS ....................................99 .
DIFFERENTIAL SIDE GEAR THRUST WASHER Disassembly and Assembly ...................................99 .
... 66 DISASSEMBLY ...................................................99 .
Available Shims -- Differential Side Bearing Pre- INSPECTION AFTER DISASSEMBLY ............. 100 .
load and Adjusting Shim ........................................ 67 . ASSEMBLY ....................................................... 101 .
BEARING PRELOAD ......................................... 67 . MAINSHAFT AND GEARS .................................... 107 .
DIFFERENTIAL SIDE BEARING ADJUSTING Disassembly and Assembly ................................. 107 .
SHIMS ................................................................ 67
. DISASSEMBLY ................................................. 107 .
INSPECTION AFTER DISASSEMBLY ............. 108 .
RS5F51A ASSEMBLY ....................................................... 110 .
REVERSE IDLER SHAFT AND GEARS ............... 115 .
PRECAUTIONS ........................................................ 68 . Disassembly and Assembly ................................. 115 .
Caution .................................................................. 68
. DISASSEMBLY ................................................. 115 .
PREPARATION ........................................................ 69 . INSPECTION AFTER DISASSEMBLY ............. 115 .
Special Service Tools ............................................ 69 . ASSEMBLY ....................................................... 116 .
Commercial Service Tools ..................................... 71 . FINAL DRIVE ......................................................... 117.
NOISE, VIBRATION, AND HARSHNESS (NVH) Disassembly and Assembly ................................. 117 .
TROUBLESHOOTING ............................................. 72 . PRE-INSPECTION ........................................... 117 .
NVH Troubleshooting Chart ................................... 72 . DISASSEMBLY ................................................. 117 .
DESCRIPTION ......................................................... 73 . INSPECTION AFTER DISASSEMBLY ............. 118 .
Cross-sectional View ............................................. 73 . ASSEMBLY ....................................................... 118 .
DOUBLE-CONE SYNCHRONIZER ................... 74 . SHIFT CONTROL ................................................... 121 .
REVERSE GEAR ............................................... 74 . Inspection ............................................................. 121
.
M/T OIL ..................................................................... 75
. SHIFT FORK ..................................................... 121 .
Replacement ......................................................... 75. SERVICE DATA AND SPECIFICATIONS (SDS) ... 122 .
DRAINING .......................................................... 75. General Specifications ......................................... 122 .
FILLING .............................................................. 75
. TRANSAXLE ..................................................... 122 .
Checking ................................................................ 75
. FINAL GEAR ..................................................... 122 .
OIL LEAKAGE AND OIL LEVEL ........................ 75 . Gear End Play ...................................................... 123
.
SIDE OIL SEAL ........................................................ 76 . Clearance Between Baulk Ring and Gear ........... 123 .
Removal and Installation ....................................... 76 . 3RD, 4TH, 5TH & REVERSE BAULK RING ..... 123 .
REMOVAL .......................................................... 76 . 1ST AND 2ND DOUBLE BAULK RING ............ 123 .
INSTALLATION ................................................... 76 . Available Snap Rings ........................................... 123 .
POSITION SWITCH ................................................. 77 . INPUT SHAFT SPACER ................................... 123 .
Checking ................................................................ 77
. 5TH MAIN GEAR .............................................. 123 .
BACK-UP LAMP SWITCH .................................. 77 . Available C-rings .................................................. 124
.
PARK/NEUTRAL POSITION SWITCH ............... 77 . MAINSHAFT C-RING ....................................... 124 .
CONTROL LINKAGE ............................................... 78 . Available Thrust Washers .................................... 124 .
Removal and Installation of Control Device and INPUT SHAFT THRUST WASHER .................. 124 .
Cable ..................................................................... 78
. DIFFERENTIAL SIDE GEAR THRUST WASHER
AIR BREATHER HOSE ............................................ 79 . .124
Removal and Installation ....................................... 79 . Available Adjusting Shims .................................... 125 .
TRANSAXLE ASSEMBLY ....................................... 80 . MAINSHAFT ADJUSTING SHIM ...................... 125 .
Removal and Installation ....................................... 80 . INPUT SHAFT REAR BEARING ADJUSTING
REMOVAL .......................................................... 80 . SHIM ................................................................. 125
.
INSTALLATION ................................................... 81 . MAINSHAFT REAR BEARING ADJUSTING
Component Parts ................................................... 82 . SHIM ................................................................. 125
.
CASE AND HOUSING COMPONENTS ............. 82 . REVERASE IDLER GEAR ADJUSTING SHIM .126
GEAR COMPONENTS ....................................... 83 . Available Shims ................................................... 126.
SHIFT CONTROL COMPONENTS .................... 85 . BEARING PRELOAD ........................................ 126 .
FINAL DRIVE COMPONENTS ........................... 86 . DIFFERENTIAL SIDE BEARING ADJUSTING
Disassembly and Assembly ................................... 86 . SHIM(S) ............................................................ 126
.
DISASSEMBLY .................................................. 86 .
MT-2
RS6F51H INPUT SHAFT AND GEARS ................................. 158 .
Disassembly and Assembly ................................. 158 . A
PRECAUTIONS ..................................................... 127 . DISASSEMBLY ................................................ 158 .
Caution ................................................................ 127
. INSPECTION AFTER DISASSEMBLY ............. 159 .
PREPARATION ...................................................... 128 . ASSEMBLY ...................................................... 160 .
Special Service Tools .......................................... 128 . B
MAINSHAFT AND GEARS .................................... 165 .
Commercial Service Tools ................................... 130 . Disassembly and Assembly ................................. 165 .
NOISE, VIBRATION, AND HARSHNESS (NVH) DISASSEMBLY ................................................ 165 .
TROUBLESHOOTING ........................................... 131 . INSPECTION AFTER DISASSEMBLY ............. 166 . MT
NVH Troubleshooting Chart ................................ 131 . ASSEMBLY ...................................................... 168 .
DESCRIPTION ....................................................... 132 . REVERSE IDLER SHAFT AND GEARS ............... 173 .
Cross-sectional View ........................................... 132 . Disassembly and Assembly ................................. 173 . D
DOUBLE-CONE SYNCHRONIZER ................. 133 . DISASSEMBLY ................................................ 173 .
REVERSE GEAR ............................................. 133 . INSPECTION AFTER DISASSEMBLY ............. 173 .
M/T OIL .................................................................. 134
. ASSEMBLY ...................................................... 174 . E
Replacement ....................................................... 134 . FINAL DRIVE ......................................................... 175
.
DRAINING ........................................................ 134 . Disassembly and Assembly ................................. 175 .
FILLING ............................................................ 134
. DISASSEMBLY ................................................ 175 .
Checking ............................................................. 134
. INSPECTION AFTER DISASSEMBLY ............. 175 . F
OIL LEAKAGE AND OIL LEVEL ...................... 134 . ASSEMBLY ...................................................... 175 .
SIDE OIL SEAL ..................................................... 135 . SHIFT CONTROL .................................................. 177 .
Removal and Installation ..................................... 135 . Inspection ............................................................ 177
. G
REMOVAL ........................................................ 135 . SHIFT FORK .................................................... 177 .
INSTALLATION ................................................ 135 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 178 .
POSITION SWITCH ............................................... 136 . General Specifications ......................................... 178 . H
Checking ............................................................. 136
. TRANSAXLE .................................................... 178 .
BACK-UP LAMP SWITCH ............................... 136 . FINAL GEAR .................................................... 179 .
PARK/NEUTRAL POSITION SWITCH ............ 136 . Gear End Play ..................................................... 179
.
CONTROL LINKAGE ............................................ 137 . I
Clearance Between Baulk Ring and Gear ........... 179 .
Removal and Installation of Control Device and 3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING 179 .
Cable ................................................................... 137
. 1ST AND 2ND DOUBLE BAULK RING ............ 179 .
AIR BREATHER HOSE ......................................... 138 . Available Snap Rings .......................................... 180 . J
Removal and Installation ..................................... 138 . 6TH BUSHING ................................................. 180 .
TRANSAXLE ASSEMBLY ..................................... 139 . Available C-rings ................................................. 180
.
Removal and Installation ..................................... 139 . MAINSHAFT C-RING ....................................... 180 . K
REMOVAL ........................................................ 139 . Available Thrust Washers .................................... 180 .
INSTALLATION ................................................ 140 . INPUT SHAFT THRUST WASHER .................. 180 .
Component Parts ................................................ 141 . Available Adjusting Shims ................................... 181 .
CASE AND HOUSING COMPONENTS .......... 141 . L
MAINSHAFT ADJUSTING SHIM ..................... 181 .
GEAR COMPONENTS .................................... 142 . INPUT SHAFT REAR BEARING ADJUSTING
SHIFT CONTROL COMPONENTS ................. 144 . SHIM ................................................................ 181
.
FINAL DRIVE COMPONENTS ........................ 145 . MAINSHAFT REAR BEARING ADJUSTING M
Disassembly and Assembly ................................ 145 . SHIM ................................................................ 181
.
DISASSEMBLY ................................................ 145 . REVERASE IDLER GEAR ADJUSTING SHIM . 182
ASSEMBLY ...................................................... 148 . 6TH MAIN GEAR ADJUSTING SHIM .............. 182 .
Adjustment .......................................................... 153
. Available Shims ................................................... 182
.
INPUTSHAFT END PLAY ................................ 153 . BEARING PRELOAD ....................................... 182 .
DIFFERENTIAL SIDE BEARING PRELOAD ... 154 . DIFFERENTIAL SIDE BEARING ADJUSTING
MAINSHAFT END PLAY .................................. 156 . SHIM(S) ............................................................ 182
.
REVERSE IDLER GEAR END PLAY ............... 157 .
MT-3
PRECAUTIONS
[RS5F70A]
PRECAUTIONS PFP:00001
Caution ECS004A3
q Do not reuse transaxle 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 transaxle clear of dust or dirt.
q Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
q In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
q Be careful not to damage sliding surfaces and mating surfaces.
MT-4
PREPARATION
[RS5F70A]
PREPARATION PFP:00002
A
Special Service Tools ECS004A4
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
KV38107700 Measuring turning torque of final drive assem-
(J39027) bly MT
Preload adapter Measuring total turning torque
Measuring clearance between side gear and
differential case with washer
Selecting differential side bearing adjusting D
shim [Use with KV38106000 (J34291-B).]
NT087
KV38106000 Selecting differential side bearing adjusting E
(J34291-B) shim [Use with KV38107700 (J39027).]
Height gauge adapter a: 140 mm (5.51 in)
(differential side bearing) b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia. F
d: M8 ◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo