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MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
A
B
SECTION
MANUAL TRANSAXLE MT
D
E
CONTENTS
RS5F30A CASE AND HOUSING COMPONENTS ............. 19 . F
GEAR COMPONENTS ...................................... 20 .
PRECAUTIONS ......................................................... 4 . SHIFT CONTROL COMPONENTS .................... 21 .
Caution .................................................................... 4
. Disassembly and Assembly ................................. .. 22 . G
PREPARATION .......................................................... 5 . DISASSEMBLY .................................................. 22 .
Special Service Tools .............................................. 5 . ASSEMBLY ...................................................... .. 24
.
Commercial Service Tools ....................................... 7 . Adjustment ........................................................... .. 27
.
NOISE, VIBRATION, AND HARSHNESS (NVH) H
DIFFERENTIAL SIDE BEARING PRELOAD ..... 27 .
TROUBLESHOOTING ............................................... 8 . MAINSHAFT BEARING PRELOAD ................... 28 .
NVH Troubleshooting Chart .................................... 8 . INPUT SHAFT AND GEARS ................................... 30 .
MANUAL TRANSAXLE ........................................ 8 . Assembly and Disassembly ................................. .. 30 . I
DESCRIPTION ........................................................... 9. DISASSEMBLY .................................................. 30 .
Cross-Sectional View .............................................. 9 . INSPECTION AFTER DISASSEMBLY ............... 31 .
DOUBLE-CONE SYNCHRONIZER ................... 10 . ASSEMBLY ...................................................... .. 32
. J
M/T OIL .....................................................................11
. MAINSHAFT AND GEARS ...................................... 34 .
Changing M/T Oil ...................................................11 . Assembly and Disassembly ................................. .. 34 .
DRAINING ...........................................................11. DISASSEMBLY .................................................. 34 .
FILLING ...............................................................11
. K
INSPECTION AFTER DISASSEMBLY ............... 36 .
Checking M/T Oil ....................................................11. ASSEMBLY ...................................................... .. 37
.
OIL LEAKAGE AND OIL LEVEL .........................11 . FINAL DRIVE ........................................................... 40
.
SIDE OIL SEAL ....................................................... 12 . Assembly and Disassembly ................................. .. 40 . L
Removal and Installation ....................................... 12 . PRE-INSPECTION ............................................. 40 .
REMOVAL .......................................................... 12 . DISASSEMBLY .................................................. 40 .
INSTALLATION .................................................. 12 . INSPECTION AFTER DISASSEMBLY ............... 41 . M
STRIKING ROD OIL SEAL ..................................... 13 . ASSEMBLY ...................................................... .. 41
.
Removal and Installation ....................................... 13 . SHIFT CONTROL .................................................... 44 .
REMOVAL .......................................................... 13 . Inspection .............................................................. 44
.
INSTALLATION .................................................. 13 . SHIFT FORK .................................................... .. 44
.
POSITION SWITCH ................................................. 14 . CASE AND HOUSING ............................................. 45 .
Checking ............................................................... 14
. Assembly and Disassembly ................................. .. 45 .
BACK-UP LAMP SWITCH ................................. 14 . INPUT SHAFT OIL SEAL ................................. .. 45 .
PNP SWITCH ..................................................... 14 . INPUT SHAFT REAR BEARING ........................ 45 .
CONTROL LINKAGE .............................................. 15 . MAINSHAFT FRONT BEARING OUTER RACE
Removal and Installation ....................................... 15 . AND OIL CHANNEL ........................................... 46 .
AIR BREATHER HOSE ........................................... 16 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 48 .
Removal and Installation ....................................... 16 . General Specifications ........................................... 48 .
TRANSAXLE ASSEMBLY ....................................... 17 . TRANSAXLE .................................................... .. 48.
Removal and Installation ....................................... 17 . FINAL GEAR .................................................... .. 48
.
REMOVAL .......................................................... 17 . Gear End Play ....................................................... 49
.
INSTALLATION .................................................. 18 . Clearance Between Baulk Ring and Gear ............. 49 .
Component Parts .................................................. 19 .
MT-1
3RD, 4TH & 5TH BAULK RING .......................... 49 . REMOVAL ...........................................................65.
1ST AND 2ND DOUBLE BAULK RING .............. 49 . INSTALLATION ...................................................66 .
Available Check Plugs ........................................... 49. Component Parts ...................................................67 .
REVERSE CHECK PLUGS ................................ 49 . CASE AND HOUSING COMPONENTS .............67 .
Available Snap Rings ............................................. 49
. GEAR COMPONENTS .......................................68 .
INPUT SHAFT FRONT BEARING ..................... 49 . SHIFT CONTROL COMPONENTS ....................69 .
INPUT SHAFT 5TH SYNCHRONIZER HUB ...... 50 . FINAL DRIVE COMPONENTS ...........................70 .
INPUT SHAFT REAR BEARING ........................ 50 . Disassembly and Assembly ................................. ..70 .
Available C-rings .................................................... 50
. DISASSEMBLY ...................................................70 .
MAINSHAFT C-RING ......................................... 50 . ASSEMBLY .........................................................77 .
Available Thrust Washer ........................................ 50 . INPUT SHAFT AND GEARS ....................................88 .
DIFFERENTIALSIDEGEARTHRUSTWASHER Assembly and Disassembly ................................. ..88 .
... 50 DISASSEMBLY ...................................................88 .
Available Adjusting Shims ..................................... 51 . INSPECTION AFTER DISASSEMBLY ...............89 .
BEARING PRELOAD ......................................... 51 . ASSEMBLY .........................................................91 .
MAINSHAFT REAR BEARING ADJUSTING MAINSHAFT AND GEARS ......................................95 .
SHIMS ................................................................ 51
. Assembly and Disassembly ................................. ..95 .
DIFFERENTIAL SIDE BEARING ADJUSTING DISASSEMBLY ...................................................95 .
SHIMS ................................................................ 51
. INSPECTION AFTER DISASSEMBLY ...............97 .
ASSEMBLY .........................................................99 .
RS5F70A FINAL DRIVE ......................................................... 106.
Assembly and Disassembly ................................. 106 .
PRECAUTIONS ........................................................ 52 . PRE-INSPECTION ........................................... 106 .
Caution .................................................................. 52
. DISASSEMBLY ................................................. 106 .
PREPARATION ........................................................ 53 . INSPECTION AFTER DISASSEMBLY ............. 107 .
Special Service Tools ............................................ 53 . ASSEMBLY ....................................................... 108 .
Commercial Service Tools ..................................... 55 . SHIFT CONTROL ................................................... 110 .
NOISE, VIBRATION, AND HARSHNESS (NVH) Inspection ............................................................. 110
.
TROUBLESHOOTING ............................................. 56 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 111 .
NVH Troubleshooting Chart ................................... 56 . General Specification ........................................... 111 .
MANUAL TRANSAXLE ...................................... 56 . TRANSAXLE ..................................................... 111 .
DESCRIPTION ......................................................... 57 . FINAL GEAR ..................................................... 111 .
Cross-sectional View ............................................. 57 . Gear End Play ...................................................... 112
.
DOUBLE-CONE SYNCHRONIZER ................... 58 . Clearance Coupling Sleeve ................................. 112 .
M/T OIL ..................................................................... 59
. 1ST, 2ND, 3RD, 4TH, 5TH & REVERSE COU-
Changing M/T Oil ................................................... 59 . PLING SLEEVE ................................................ 112 .
DRAINING .......................................................... 59 . Clearance Between Baulk Ring and Gear ........... 112 .
FILLING .............................................................. 59
. 3RD, 4TH, 5TH, REVERSE BAULK RING ....... 112 .
Checking M/T Oil ................................................... 59 . 1ST AND 2ND DOUBLE BAULK RING ............ 112 .
OIL LEAKAGE AND OIL LEVEL ........................ 59 . Available Snap Rings ........................................... 112 .
SIDE OIL SEAL ........................................................ 60 . SNAP RING ...................................................... 112 .
Removal and Installation ....................................... 60 . Available C-rings .................................................. 113
.
REMOVAL .......................................................... 60 . 4TH INPUT GEAR C-RING .............................. 113 .
INSTALLATION ................................................... 60 . 5TH INPUT GEAR REAR C-RING ................... 113 .
STRIKING ROD OIL SEAL ...................................... 61 . MAINSHAFT C-RING ....................................... 113 .
Removal and Installation ....................................... 61 . Available Thrust Washer ...................................... 114 .
REMOVAL .......................................................... 61 . MAINSHAFT THRUST WASHER ..................... 114 .
INSTALLATION ................................................... 61 . DIFFERENTIALSIDEGEARTHRUSTWASHER
POSITION SWITCH ................................................. 62 . . 114
Checking ................................................................ 62
. Available Adjusting Shims .................................... 114 .
BACK-UP LAMP SWITCH .................................. 62 . MAINSHAFT ADJUSTING SHIM ...................... 114 .
PNP SWITCH ..................................................... 62 . INPUT SHAFT REAR BEARING ADJUSTING
CONTROL LINKAGE ............................................... 63 . SHIM ................................................................. 115
.
Removal and Installation ....................................... 63 . MAINSHAFT REAR BEARING ADJUSTING
AIR BREATHER HOSE ............................................ 64 . SHIM ................................................................. 115
.
Removal and Installation ....................................... 64 . Available Shims ................................................... 116.
TRANSAXLE ASSEMBLY ....................................... 65 . BEARING PRELOAD ........................................ 116 .
Removal and Installation ....................................... 65 . DIFFERENTIAL SIDE BEARING ADJUSTING
MT-2
SHIMS ...............................................................116
. INPUT SHAFT AND GEARS ................................. 151 .
Assembly and Disassembly ................................. 151 . A
RS6F51A DISASSEMBLY ................................................ 151 .
INSPECTION AFTER DISASSEMBLY ............. 152 .
PRECAUTIONS ......................................................117 . ASSEMBLY ...................................................... 153 . B
Caution .................................................................117
. MAINSHAFT AND GEARS .................................... 158 .
PREPARATION .......................................................118 . Assembly and Disassembly ................................. 158 .
Special Service Tools ...........................................118 . DISASSEMBLY ................................................ 158 .
Commercial Service Tools ................................... 120 . INSPECTION AFTER DISASSEMBLY ............. 159 . MT
NOISE, VIBRATION, AND HARSHNESS (NVH) ASSEMBLY ...................................................... 161 .
TROUBLESHOOTING ........................................... 121 . REVERSE IDLER SHAFT AND GEARS ............... 167 .
NVH Troubleshooting Chart ................................ 121 . Assembly and Disassembly ................................. 167 . D
MANUAL TRANSAXLE .................................... 121 . DISASSEMBLY ................................................ 167 .
DESCRIPTION ....................................................... 122 . INSPECTION AFTER DISASSEMBLY ............. 167 .
Cross-Sectional View .......................................... 122 . ASSEMBLY ...................................................... 168 . E
DOUBLE-CONE SYNCHRONIZER ................. 123 . FINAL DRIVE ......................................................... 169
.
REVERSE GEAR NOISE PREVENTION FUNC- Assembly and Disassembly ................................. 169 .
TION (SYNCHRONIZING METHOD) .............. 123 . PRE-INSPECTION ........................................... 169 .
M/T OIL .................................................................. 124
. DISASSEMBLY ................................................ 169 . F
Changing M/T Oil ................................................ 124 . INSPECTION AFTER DISASSEMBLY ............. 170 .
DRAINING ........................................................ 124 . ASSEMBLY ...................................................... 170 .
FILLING ............................................................ 124
. SHIFT CONTROL .................................................. 173 . G
Checking M/T Oil ................................................. 124 . Inspection ............................................................ 173
.
OIL LEAKAGE AND OIL LEVEL ...................... 124 . SHIFT FORK .................................................... 173 .
SIDE OIL SEAL ..................................................... 125 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 174 . H
Removal and Installation ..................................... 125 . General Specifications ......................................... 174 .
REMOVAL ........................................................ 125 . TRANSAXLE .................................................... 174 .
INSTALLATION ................................................ 125 . FINAL GEAR .................................................... 175 .
POSITION SWITCH ............................................... 126 . I
Gear End Play ..................................................... 175
.
Checking ............................................................. 126
. Clearance Between Baulk Ring and Gear ........... 175 .
BACK-UP LAMP SWITCH ............................... 126 . 3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING 175 .
PARK/NEUTRAL POSITION SWITCH ............ 126 . 1ST AND 2ND DOUBLE BAULK RING ............ 175 . J
CONTROL LINKAGE ............................................ 127 . Available Snap Rings .......................................... 175 .
Removal and Installation of Control Device and 6TH BUSHING ................................................. 175 .
Cable ................................................................... 127
. Available C-rings ................................................. 176
. K
AIR BREATHER HOSE ......................................... 128 . MAINSHAFT C-RING ....................................... 176 .
Removal and Installation ..................................... 128 . Available Thrust Washer ...................................... 176 .
TRANSAXLE ASSEMBLY ..................................... 129 . INPUT SHAFT THRUST WASHER .................. 176 .
L
Removal and Installation ..................................... 129 . DIFFERENTIALSIDEGEARTHRUSTWASHER
REMOVAL ........................................................ 129 . . 176
INSTALLATION ................................................ 130 . Available Adjusting Shims ................................... 177 .
Component Parts ................................................. 131 MAINSHAFT ADJUSTING SHIM ..................... 177 . M
CASE AND HOUSING COMPONENTS .......... 131 . INPUT SHAFT REAR BEARING ADJUSTING
GEAR COMPONENTS .................................... 132 . SHIM ................................................................ 177
.
SHIFT CONTROL COMPONENTS ................. 134 . MAINSHAFT REAR BEARING ADJUSTING
FINAL DRIVE COMPONENTS ........................ 135 . SHIM ................................................................ 177
.
Disassembly and Assembly ................................ 135 . REVERSE IDLER GEAR ADJUSTING SHIM .. 177 .
DISASSEMBLY ................................................ 135 . 6TH MAIN GEAR ADJUSTING SHIM .............. 178 .
ASSEMBLY ...................................................... 139 . Available Shims ................................................... 178
.
Adjustment .......................................................... 146
. BEARING PRELOAD ....................................... 178 .
INPUTSHAFT END PLAY ................................ 146 . DIFFERENTIAL SIDE BEARING ADJUSTING
DIFFERENTIAL SIDE BEARING PRELOAD ... 147 . SHIM (S) ........................................................... 178
.
MAINSHAFT END PLAY .................................. 148 .
REVERSE IDLER GEAR END PLAY ............... 149 .
MT-3
PRECAUTIONS
[RS5F30A]
PRECAUTIONS
[RS5F30A] PFP:00001
Caution ECS005GI
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
[RS5F30A]
PREPARATION PFP:00002
A
Special Service Tools ECS006BN
Tool number
Description
Tool name B
q Measuring turning torque of final drive
assembly
q Measuring total turning torque MT
KV38105900
Preload adapter q Measuring clearance between side gear
and differential case with washer
q Selecting differential side bearing D
NT087 adjusting shim (Use with KV38106000.)
KV38106000
E
Height gauge adapter
(differential side bearing)
q Selecting differential side bearing
a: 140 mm (5.51 in)
adjusting shim (Use with KV38105900.)
b: 40 mm (1.57 in) F
c: 16 mm (0.63 in) dia.
d: M8 x 1.25P NT418
G
KV32101000
Pin punch q Removing and installing retaining pin
H
a: 4 mm (0.16 in) dia.
NT410
I
ST22730000
q Removing mainshaft front and rear
Puller
bearing inner race
J
a: 82 mm (3.23 in) dia.
Removing 5th main gear
b: 30 mm (1.18 in) dia.
NT411 K
ST30031000 L
Puller q Removing differential side bearing inner
a: 90 mm (3.54 in) dia. race
b: 50 mm (1.97 in) dia.
M
NT411
ST30021000
Puller
q Removing 5th synchronizer
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
NT411
q Removing differential oil seal
ST33290001
q Removing mainshaft front bearing outer
Puller
race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in) q Removing differential side bearing outer
race
NT414
MT-5
PREPARATION
[RS5F30A]
Tool number
Description
Tool name
ST33400001
Drift
q Installing differential oil seal
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
NT086
KV38102100
Drift
q Installing input shaft rear bearing
a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.
NT427
ST33200000
Drift q Installing mainshaft front bearing outer
a: 60 mm (2.36 in) dia. race
b: 44.5 mm (1.752 in) dia.
NT091
ST22350000
Drift
q Installing input shaft front bearing
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
NT065
ST22452000
Drift
q Installing 1st & 2nd synchronizer
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
NT065
q Installing 5th main gear
ST37750000
Drift q Installing 3rd & 4th synchronizer
a: 40 mm (1.57 in) dia. q Installing input shaft oil seal
b: 31 mm (1.22 in) dia.
q Installing 5th synchronizer
NT065
ST22360002
Drift q Installing mainshaft rear bearing inner
a: 29 mm (1.14 in) dia. race
b: 23 mm (0.91 in) dia.
NT065
MT-6
PREPARATION
[RS5F30A]
Tool number
Description A
Tool name
ST30621000 B
q Installing differential side bearing outer
Drift
race
a: 79 mm (3.11 in) dia.
(Use with ST30611000.)
b: 59 mm (2.32 in) dia.
MT
NT073
ST30611000 D
Drift handle
q Installing differential side bearing outer
a: 15 mm (0.59 in)
race
b: 335 mm (13.19 in)
(Use with ST30621000.) E
c: 25 mm (0.98 in) dia.
d: M12 x 1.5P
NT419
Commercial Service Tools ECS006BO
F
Tool name Description
G
Puller q Removing input shaft front bearing H
NT077
I
Drift J
q Installing mainshaft front bearing inner
a: 26 mm (1.02 in) dia.
race
b: 21 mm (0.83 in) dia.
NT065
K
L
Drift
q Installing differential side bearing inner
a: 56 mm (2.20 in) dia.
race
b: 50.5 mm (1.988 in) dia.
M
NT065
Drift
a: 38 mm (1.50 in) dia. q Installing striking rod oil seal
b: 32 mm (1.26 in) dia.
NT065
MT-7
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[RS5F30A]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart ECS005GL
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 TRANSAXLE
MT-19
MT-19
MT-19
MT-15
MT-21
MT-21
MT-20
MT-20
MT-20
MT-20
MT-11
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)
SHIFT CONTROL ROD (Worn)
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
INSERT SPRING (Damaged)
O-RING (Worn or damaged)
GEAR (Worn or damaged)
GASKET (Damaged)
SHIFT FORK (Worn)
(Oil level is high.)
(Oil level is low.)
(Wrong oil)
Noise 1 2 3 3
Oil leakage 3 1 2 2 2
Symptoms Hard to shift or
1 1 2 3 3
will not shift
Jumps out of
1 2 3 3
gear
MT-8
DESCRIPTION
[RS5F30A]
DESCRIPTION PFP:00000
A
Cross-Sectional View ECS005GM
B
MT
D
E
F
G
H
I
J
K
L
M
MCIA0001E
MT-9
DESCRIPTION
[RS5F30A]
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.
SMT837DA
MT-10
M/T OIL
[RS5F30A]
M/T OIL PFP:KLD20
A
Changing M/T Oil ECS005GN
DRAINING
1. Start the engine and let it run to warm up the transaxle.
B
2. Stop the engine. Remove drain plug and drain oil.
3. Set a gasket on the drain plug and install it to the transaxle.
Drain plug: MT
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