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C TRANSMISSION/TRANSAXLE
A
B
SECTION
MANUAL TRANSMISSION MT
D
E
CONTENTS
FS5W71C 2ND & 3RD BAULK RING .................................. 36 . F
Available Snap Rings ............................................ 36 .
PREPARATION .......................................................... 3
. MAIN DRIVE GEAR BALL BEARING SNAP
Special Service Tools .............................................. 3. RING .................................................................. 36
. G
Commercial Service Tools ....................................... 5 . MAINSHAFT FRONT SNAP RING ..................... 36 .
NOISE, VIBRATION, AND HARSHNESS (NVH) COUNTER DRIVE GEAR SNAP RING .............. 36 .
TROUBLESHOOTING ............................................... 6 . OD MAINSHAFT BEARING SNAP RING .......... 37 .
NVH Troubleshooting Chart .................................... 6 . H
Available Shims ..................................................... 37
.
DESCRIPTION ........................................................... 7
. COUNTERSHAFT FRONT BEARING SHIM ..... 37 .
CROSS-SECTIONAL VIEW .................................... 7 .
ON-VEHICLE SERVICE ............................................ 9 . I
Replacing Rear Oil Seal .......................................... 9 .
FS5R30A
REMOVAL ............................................................ 9
. PREPARATION ........................................................ 38.
INSTALLATION .................................................... 9 . Special Service Tools ............................................ 38 . J
Position Switch Check ............................................. 9 . Commercial Service Tool ....................................... 40 .
TRANSMISSION ASSEMBLY ................................. 10 . NOISE, VIBRATION, AND HARSHNESS (NVH)
Removal and Installation ....................................... 10 . TROUBLESHOOTING ............................................. 41 .
REMOVAL .......................................................... 10
. K
NVH Troubleshooting Chart .................................. 41 .
INSTALLATION ...................................................11 . DESCRIPTION ......................................................... 42
.
Overhaul ................................................................ 12
. Description ............................................................. 42
.
CASE COMPONENTS ....................................... 12 . CROSS-SECTIONAL VIEW -- 2WD MODEL .... 42 . L
GEAR COMPONENTS ...................................... 14 . CROSS-SECTIONAL VIEW -- 4WD MODEL .... 44 .
SHIFT CONTROL COMPONENTS ................... 16 . ON-VEHICLE SERVICE ........................................... 46 .
CASE COMPONENTS ............................................ 18 . Replacing Rear Oil Seal -- 2WD Model ................ 46 . M
Disassembly .......................................................... 18
. REMOVAL .......................................................... 46
.
Assembly ............................................................... 19
. INSTALLATION .................................................. 46 .
SHIFT CONTROL COMPONENTS ......................... 22 . Position Switch Check ........................................... 46 .
Disassembly .......................................................... 22
. TRANSMISSION ASSEMBLY ................................. 48 .
Inspection .............................................................. 22
. Removal and Installation ....................................... 48 .
Assembly ............................................................... 23
. REMOVAL .......................................................... 48
.
GEAR COMPONENTS ............................................ 24 . INSTALLATION .................................................. 50 .
Disassembly .......................................................... 24
. Overhaul ................................................................ 51
.
Inspection .............................................................. 26
. CASE COMPONENTS ....................................... 51 .
GEARS AND SHAFTS ....................................... 26 . GEAR COMPONENTS ...................................... 53 .
SYNCHRONIZERS ............................................ 27 . SHIFT CONTROL COMPONENTS (2/4WD
BEARINGS ......................................................... 27
. MODELS) ........................................................... 57
.
Assembly ............................................................... 27
. CASE COMPONENTS ............................................. 59 .
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 35 . Disassembly .......................................................... 59
.
General Specifications .......................................... 35 . Assembly ............................................................... 61
.
Gear End Play ....................................................... 35
.
Clearance Between Baulk Ring and Gear ............ 36 .
MT-1
SHIFT CONTROL COMPONENTS .......................... 63 . Clearance Between Single Baulk Ring and Gear ...81
Disassembly .......................................................... 63
. DOUBLE BAULK RING ......................................82 .
Inspection .............................................................. 63
. Distance Between Rear Surface of Reverse Cone
Assembly ............................................................... 63
. and Reverse Baulk Ring ........................................82 .
GEAR COMPONENTS ............................................. 65 . Available Snap Ring ...............................................82
.
Disassembly .......................................................... 65
. MAIN DRIVE GEAR SNAP RING .......................82 .
Inspection .............................................................. 69
. MAINSHAFT FRONT BEARING SNAP RING ....82 .
GEARS AND SHAFTS ....................................... 69 . COUNTER GEAR REAR SNAP RING ...............83 .
SYNCHRONIZERS ............................................ 69 . Available C-ring ......................................................83
.
BEARINGS ......................................................... 70
. MAINSHAFT C-RING .........................................83 .
Assembly ............................................................... 70
. Available Shim and Washer ...................................83 .
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 81 . TABLE FOR SELECTING PROPER COUNTER
General Specifications ........................................... 81 . GEAR FRONT BEARING SHIM .........................83 .
Gear End Play ....................................................... 81
. REVERSE IDLER REAR THRUST WASHER ....83 .
MT-2
PREPARATION
[FS5W71C]
PREPARATION PFP:00002
A
Special Service Tools ECS006I2
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number (Kent-Moore No.) Tool Description
B
name
ST23810001 Fixing adapter plate with gear assembly
( -- ) a: 166 mm (6.54 in)
Adapter setting plate b: 270 mm (10.63 in) MT
D
NT407
KV32101330 Removing overdrive mainshaft bearing
(See J34286) a: 447 mm (17.60 in) E
Puller b: 100 mm (3.94 in)
F
NT408
KV31100401 Pressing counter gear, mainshaft, counter G
( -- ) drive gear and main drive gear
Transmission press stand
H
NT068
I
ST22520000 Tightening mainshaft lock nut
(J26348) a: 100 mm (3.94 in)
Wrench b: 41 mm (1.61 in)
J
NT409 K
ST23540000 Removing and installing fork rod retaining pin
(J25689-A) a: 2.3 mm (0.091 in) dia.
Pin punch b: 4 mm (0.16 in) dia. L
M
NT442
ST30031000 Removing and installing 1st gear bushing
(J22912-01) Removing main drive gear ball bearing
Puller a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
NT411
ST23860000 Installing counter drive gear
( -- ) a: 38 mm (1.50 in) dia.
Drift b: 33 mm (1.30 in) dia.
NT065
MT-3
PREPARATION
[FS5W71C]
Tool number (Kent-Moore No.) Tool Description
name
ST22360002 Installing counter gear front and rear end
(J25679-01) bearings
Drift a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.
NT065
ST22350000 Installing OD gear bushing
(J25678-01) a: 34 mm (1.34 in) dia.
Drift b: 28 mm (1.10 in) dia.
NT065
ST23800000 Installing front cover oil seal
(J25691-01) a: 44 mm (1.73 in) dia.
Drift b: 31 mm (1.22 in) dia.
NT065
ST33400001 Installing rear oil seal
(J26082) a: 60 mm (2.36 in) dia.
Drift b: 47 mm (1.85 in) dia.
NT086
ST33290001 Removing rear oil seal
(J34286) a: 250 mm (9.84 in)
Puller b: 160 mm (6.30 in)
NT414
ST30720000 Installing mainshaft ball bearing
(J25405) a: 77 mm (3.03 in) dia.
Drift b: 55.5 mm (2.185 in) dia.
NT115
ST30613000 Installing main drive gear ball bearing
(J25742-3) a: 71.5 mm (2.815 in) dia.
Drift b: 47.5 mm (1.870 in) dia.
NT073
MT-4
PREPARATION
[FS5W71C]
Tool number (Kent-Moore No.) Tool Description
name A
ST33200000 Installing counter rear bearing and counter
(J26082) gear assembly
Drift a: 60 mm (2.36 in) dia. B
b: 44.5 mm (1.752 in) dia.
MT
NT091
(J-26349-A) Removing and installing mainshaft bearing
Bearing Remover and Installer Set (Use with J-25726-B)
D
E
WMT065
(J-34286) Removing races
Rear Race Puller
F
G
WMT066
(J-39856) Removing gears and bearings H
Gear and Bearing Removal Kit
I
WMT067
J
Commercial Service Tools ECS006I3
Tool name Description K
Puller Removing counter bearings, counter drive
and OD gears
L
M
NT077
Drift Installing countershaft rear end bearing
a: 40 mm (1.57 in) dia.
b: 30 mm (1.18 in) dia.
NT074
MT-5
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[FS5W71C]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart ECS006I4
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.
MA-35
MT-18
MT-22
MT-24
Reference page
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
SUSPECTED PARTS
(Possible cause)
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 2 2
Symptom
Hard to shift or will not shift 1 1 2 2
Jumps out of gear 1 2 2
MT-6
DESCRIPTION
[FS5W71C]
DESCRIPTION PFP:00000
A
CROSS-SECTIONAL VIEW ECS006I5
B
MT
D
E
F
G
H
I
J
K
L
M
WCIA0175E
MT-7
DESCRIPTION
[FS5W71C]
1. Steel ball 2. Mainshaft front bearing 3. Reverse main gear
4. Bushing 5. Needle bearing 6. OD & Reverse coupling sleeve
7. OD & Reverse synchronizer hub 8. OD gear bushing 9. Needle bearing
10. OD main gear 11. Striking rod 12. Control housing
13. Shift lever 14. Dust cover 15. Oil seal
16. Rear extension 17. Mainshaft 18. Speedometer drive gear
19. OD mainshaft bearing 20. Steel roller 21. Counter gear rear end bearing
22. OD counter gear 23. Reverse idler shaft 24. Reverse counter gear
25. Reverse idler gear bushing 26. Reverse idler gear 27. Counter gear rear bearing
28. Drain plug 29. Counter gear 30. Counter drive gear
31. Sub gear bracket 32. Sub gear 33. counter gear front bearing
34. Oil seal 35. Front cover 36. Main drive gear ball bearing
37. Transmission case 38. Main drive gear 39. Pilot bearing
40. 3rd & 4th synchronizer hub 41. 3rd & 4th coupling sleeve 42. 3rd main gear
43. 2nd main gear 44. 1st & 2nd synchronizer hub 45. 1st & 2nd coupling sleeve
46. 1st main gear 47. Adapter plate
MT-8
ON-VEHICLE SERVICE
[FS5W71C]
ON-VEHICLE SERVICE PFP:00000
A
Replacing Rear Oil Seal ECS006I6
REMOVAL
1. Remove the propeller shaft. Refer to PR-8, "Removal and Installation" .
B
2. Remove rear oil seal using Tool.
q Always replace with a new seal once it has been
removed. MT
Tool number : ST33290001 (J34286)
D
E
WCIA0176E
INSTALLATION
1. Install new rear oil seal using Tool until it stops. F
q Apply multi-purpose grease to seal lip of oil seal before
installing.
G
Tool number : ST33400001 (J26082)
2. Installation is in the reverse order of removal.
H
SMT480CA I
Position Switch Check ECS006I7
q Check continuity. J
Switch Gear position Continuity
Reverse Yes
Back-up lamp switch K
Except reverse No
Park/neutral position Neutral Yes
(PNP) switch Except neutral No L
M
SMT981D
MT-9
TRANSMISSION ASSEMBLY
[FS5W71C]
TRANSMISSION ASSEMBLY PFP:32010
Removal and Installation ECS006I8
REMOVAL
WMT030
CAUTION:
Before separating the transmission from the engine, remove the crankshaft position sensor (OBD)
from the transmission. Be careful not to damage sensor edge or ring gear teeth.
MT-10
TRANSMISSION ASSEMBLY
[FS5W71C]
NOTE:
To prevent oil spills, drain transmission oil before removing transmission or insert plug into rear oil A
seal after removing propeller shaft.
q Be careful not to damage spline, sleeve yoke, and rear oil seal when removing propeller shaft.
1. Remove battery negative terminal. B
2. Remove the crankshaft position sensor (OBD) from transmission upper side.
3. Remove the clutch operating cylinder from transmission. Refer to CL-9, "OPERATING CYLINDER" .
4. Disconnect the vehicle speed sensor, back-up switch, and park/neutral position (PNP) switch harness MT
connectors.
5. Remove the starter motor. Refer to SC-23, "Removal and Installation" .
6. Disconnect the exhaust hanger. Refer to EX-3, "Removal and Installation" . D
7. Remove the propeller shaft. Refer to PR-8, "Removal and Installation" .
8. Remove the shift lever.
E
9. Support the engine by placing a jack under the oil pan.
q Do not place jack under oil pan drain plug.
10. Remove the transmission crossmember. F
11. Separate the transmission from the engine.
WARNING:
Support manual transmission while removing it. G
SMT099A
H
INSTALLATION
1. Tighten transmission bolts.
I
Bolt No. Tightening torque N◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo