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MT


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                                                                                          MANUAL TRANSMISSION                                                             GI




                                                                                                SECTION                      MT                                           MA

                                                                                                                                                                          EM

                                                                                                                                                                          LC

                                                                                                                                                                          EC

                                                               CONTENTS                                                                                                   FE


                                 FS5W71C                                               Case Components .....................................................27
                                                                                                                                                                          CL
                                                                                          ASSEMBLY .............................................................27
PREPARATION ...............................................................3
                                                                                     SERVICE DATA AND SPECIFICATIONS (SDS) .........30
  Special Service Tools ..................................................3
                                                                                       General Specifications...............................................30
  Commercial Service Tools ...........................................5
                                                                                       Gear End Play ...........................................................30
NOISE, VIBRATION AND HARSHNESS (NVH)
                                                                                       Clearance Between Baulk Ring and Gear ................31                           AT
TROUBLESHOOTING .....................................................6
                                                                                       2nd & 3rd Baulk Ring ................................................31
  NVH Troubleshooting Chart.........................................6
                                                                                       Available Snap Rings ................................................31
     MANUAL TRANSMISSION..........................................6
                                                                                          MAIN DRIVE GEAR BEARING ..................................31                    TF
DESCRIPTION .................................................................7            MAINSHAFT FRONT ................................................31
  Cross-sectional View ...................................................7               COUNTER DRIVE GEAR .........................................31
ON-VEHICLE SERVICE ..................................................8                    OD MAINSHAFT BEARING ......................................32                   PD
  Replacing Rear Oil Seal ..............................................8              Available Shims .........................................................32
     REMOVAL .................................................................8           COUNTERSHAFT FRONT BEARING ........................32
     INSTALLATION..........................................................8                                                                                              AX
  Position Switch Check .................................................8                                             FS5R30A
REMOVAL AND INSTALLATION ...................................9
                                                                                     PREPARATION .............................................................33
                                                                                                                                                                          SU
  Removal.......................................................................9
  Installation..................................................................10     Special Service Tools ................................................33
OVERHAUL ...................................................................11         Commercial Service Tool...........................................35               BR
  Case Components .....................................................11            NOISE, VIBRATION AND HARSHNESS (NVH)
  Gear Components .....................................................12            TROUBLESHOOTING ...................................................36
  Shift Control Components .........................................13                 NVH Troubleshooting Chart.......................................36                 ST
DISASSEMBLY..............................................................14               MANUAL TRANSMISSION........................................36
  Case Components .....................................................14            DESCRIPTION ...............................................................37
     DISASSEMBLY ........................................................14            Cross-sectional View - 2WD Model...........................37                      RS
  Shift Control Components .........................................14                 Cross-sectional View - 4WD Model...........................38
     DISASSEMBLY ........................................................14          ON-VEHICLE SERVICE ................................................39
                                                                                                                                                                          BT
  Gear Components .....................................................15              Replacing Rear Oil Seal - 2WD Model .....................39
     DISASSEMBLY ........................................................15               REMOVAL ...............................................................39
INSPECTION..................................................................18            INSTALLATION........................................................39          HA
  Shift Control Components .........................................18                 Position Switch Check ...............................................40
     INSPECTION ...........................................................18        REMOVAL AND INSTALLATION .................................41
  Gear Components .....................................................18              Removal.....................................................................41     SC
     INSPECTION ...........................................................18             2WD MODEL ...........................................................41
ASSEMBLY....................................................................20            4WD MODEL ...........................................................42
  Gear Components .....................................................20              Installation..................................................................43   EL
     ASSEMBLY .............................................................20        OVERHAUL ...................................................................44
  Shift Control Components .........................................27                 Case Components .....................................................44
     ASSEMBLY .............................................................27          Gear Components .....................................................45
                                                                                                                                                                          IDX
                                                  CONTENTS                                 (Cont'd)
  Shift Control Components .........................................47                ASSEMBLY .............................................................65
DISASSEMBLY..............................................................48      SERVICE DATA AND SPECIFICATIONS (SDS) .........67
  Case Components .....................................................48          General Specifications...............................................67
    DISASSEMBLY ........................................................48         Gear End Play ...........................................................67
  Shift Control Components .........................................49             Clearance Between Baulk Ring and Gear ................67
    DISASSEMBLY ........................................................49            2ND AND 3RD BAULK RING ....................................68
  Gear Components .....................................................50          Distance between Rear Surface of Reverse
    DISASSEMBLY ........................................................50         Cone and Reverse Baulk Ring..................................68
INSPECTION..................................................................54     Available Snap Ring ..................................................68
  Shift Control Components .........................................54                MAIN DRIVE GEAR SNAP RING ..............................68
    INSPECTION ...........................................................54          MAINSHAFT FRONT SNAP RING .............................68
  Gear Components .....................................................54             COUNTER GEAR REAR SNAP RING .......................69
    INSPECTION ...........................................................54       Available C-ring .........................................................69
ASSEMBLY....................................................................56        MAINSHAFT C-RING ...............................................69
  Gear Components .....................................................56          Available Shim and Washer ......................................69
    ASSEMBLY .............................................................56            TABLE FOR SELECTING PROPER COUNTER
  Shift Control Components .........................................64                  GEAR FRONT BEARING THRUST WASHER ............69
    ASSEMBLY .............................................................64            REVERSE IDLER REAR THRUST WASHER .............70
  Case Components .....................................................65




                                                                            MT-2
                                                      PREPARATION                                                        FS5W71C
                                                                                                                  Special Service Tools

                                                     Special Service Tools                                                         NGMT0045
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
                                                                                                                                              GI
 Tool number (Kent-          Description
 Moore No.) Tool name

 ST23810001                                                                       Fixing adapter plate with gear assembly                     MA
 (     --        )                                                                a: 166 mm (6.54 in)
 Adapter setting plate                                                            b: 270 mm (10.63 in)
                                                                                                                                              EM

                                                                                                                                              LC
                             NT407

 KV32101330                                                                       Removing overdrive mainshaft bearing
 (See J26349-A)                                                                   a: 447 mm (17.60 in)
                                                                                                                                              EC
 Puller                                                                           b: 100 mm (3.94 in)

                                                                                                                                              FE

                             NT408                                                                                                            CL
 KV31100401                                                                       Pressing counter gear and mainshaft
 (     --       )
 Transmission press
 stand

                             NT068                                                                                                            AT
 ST22520000                                                                       Tightening mainshaft lock nut
 (J26348)                                                                         a: 100 mm (3.94 in)
 Wrench                                                                           b: 41 mm (1.61 in)                                          TF

                                                                                                                                              PD
                             NT409

 ST23540000                                                                       Removing and installing fork rod retaining pin
 (J25689-A)                                                                       a: 2.3 mm (0.091 in) dia.                                   AX
 Pin punch                                                                        b: 4 mm (0.16 in) dia.

                                                                                                                                              SU
                             NT442

 ST30031000                                                                       Removing and installing 1st gear bushing
 (J22912-01)                                                                      Removing main drive gear bearing                            BR
 Puller                                                                           a: 90 mm (3.54 in) dia.
                                                                                  b: 50 mm (1.97 in) dia.
                                                                                                                                              ST

                             NT411                                                                                                            RS
 ST23860000                                                                       Installing counter drive gear
 (     --         )                                                               a: 38 mm (1.50 in) dia.
 Drift                                                                            b: 33 mm (1.30 in) dia.                                     BT

                             NT065                                                                                                            HA
 ST22360002                                                                       Installing counter gear front and rear end bearings
 (J25679-01)                                                                      a: 29 mm (1.14 in) dia.
 Drift                                                                            b: 23 mm (0.91 in) dia.                                     SC

                             NT065                                                                                                            EL

                                                                                                                                              IDX
                                                               MT-3
                                        PREPARATION                                        FS5W71C
Special Service Tools (Cont'd)

 Tool number (Kent-       Description
 Moore No.) Tool name

 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 bearing
 (J25742-3)                                           a: 71.5 mm (2.815 in) dia.
 Drift                                                b: 47.5 mm (1.870 in) dia.




                          NT073

 ST33200000                                           Installing counter rear bearing
 (J26082)                                             a: 60 mm (2.36 in) dia.
 Drift                                                b: 44.5 mm (1.752 in) dia.




                          NT091




                                           MT-4
                          PREPARATION                                       FS5W71C
                                                                Commercial Service Tools

                          Commercial Service Tools                                  NGMT0046


Tool name   Description                                                                        GI
Puller                                   Removing counter bearings, counter drive and OD
                                         gears
                                                                                               MA

                                                                                               EM
            NT077


                                                                                               LC

                                                                                               EC

                                                                                               FE

                                                                                               CL




                                                                                               AT

                                                                                               TF

                                                                                               PD

                                                                                               AX

                                                                                               SU

                                                                                               BR

                                                                                               ST

                                                                                               RS

                                                                                               BT

                                                                                               HA

                                                                                               SC

                                                                                               EL

                                                                                               IDX
                               MT-5
                            NOISE, VIBRATION AND HARSHNESS (NVH)                                                                                                                                                                                                                                                                                 NGMT0047

                                      TROUBLESHOOTING                                                                                                                                                                                                                                                         FS5W71C
NVH Troubleshooting Chart

                                                   NVH Troubleshooting Chart                                                                                                                                                                                                                                                                  NGMT0047S01
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                                                                                                                                                                                                                                                                                                                          NGMT0047S0101




                                                                         MA-34




                                                                                                                                                                         MT-13


                                                                                                                                                                                                                                     MT-13


                                                                                                                                                                                                                                                         MT-12


                                                                                                                                                                                                                                                                                  MT-12


                                                                                                                                                                                                                                                                                                              MT-12


                                                                                                                                                                                                                                                                                                                                                   MT-12
                                                                                                                         MT-11


                                                                                                                                            MT-11
 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
                                    NGMT0048

 DESCRIPTION                 FS5W71C
                       Cross-sectional View

Cross-sectional View              NGMT0048S01


                                                GI

                                                MA

                                                EM

                                                LC

                                                EC

                                                FE

                                                CL




                                                AT

                                                TF

                                                PD

                                                AX

                                                SU

                                                BR

                                                ST

                                                RS

                                                BT

                                                HA

                                                SC

                                  SMT153D       EL

                                                IDX
     MT-7
                                ON-VEHICLE SERVICE                                      FS5W71C
Replacing Rear Oil Seal

                                     Replacing Rear Oil Seal                                      NGMT0028
                                     REMOVAL                                                  NGMT0028S01
                                     1.   Remove the propeller shaft. Refer to PD-7, "Removal and
                                          Installation".
                                     2.   Remove rear oil seal using Tool.
                                     



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