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MT


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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



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