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MANUAL TRANSMISSION
C TRANSMISSION/TRANSAXLE
A
SECTION
MANUAL TRANSMISSION
MT B
MT
D
E
CONTENTS
PRECAUTIONS ......................................................... 2 . SHIFT CONTROL .................................................... 13. F
Service Notice or Precautions ................................. 2 . Removal and Installation ....................................... 13 .
PREPARATION .......................................................... 3 . COMPONENTS .................................................. 13 .
Special Service Tools .............................................. 3 . REMOVAL .......................................................... 13
. G
Commercial Service Tools ....................................... 5 . INSTALLATION .................................................. 13.
NOISE, VIBRATION AND HARSHNESS (NVH) INSPECTION AFTER INSTALLATION ............... 14 .
TROUBLESHOOTING ............................................... 6 . AIR BREATHER HOSE ........................................... 15 .
H
NVH Troubleshooting Chart .................................... 6 . Removal and Installation ....................................... 15 .
DESCRIPTION ........................................................... 7. TRANSMISSION ASSEMBLY ................................. 16 .
Cross-Sectional View .............................................. 7 . Removal and Installation from Vehicle .................. 16 .
DOUBLE-CONE SYNCHRONIZER ..................... 8 . COMPONENTS .................................................. 16 . I
TRIPLE-CONE SYNCHRONIZER ....................... 8 . REMOVAL .......................................................... 17
.
M/T OIL ...................................................................... 9
. INSTALLATION .................................................. 18.
Changing M/T Oil .................................................... 9 . Disassembly and Assembly ................................... 19 . J
DRAINING ............................................................ 9
. COMPONENTS .................................................. 19 .
FILLING ................................................................ 9
. DISASSEMBLY .................................................. 25 .
Checking M/T Oil ..................................................... 9. INSPECTION AFTER DISASSEMBLY ............... 40 .
K
OIL LEAKAGE AND OIL LEVEL .......................... 9 . ASSEMBLY ........................................................ 44
.
REAR OIL SEAL ..................................................... 10 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 67 .
Removal and Installation ....................................... 10 . General Specifications ........................................... 67
.
REMOVAL .......................................................... 10 . Gear End Play ....................................................... 68
. L
INSTALLATION ...................................................11 . Snap Rings ............................................................ 68
.
POSITION SWITCH ................................................. 12 . Baulk Ring Clearance ............................................ 69.
Checking ............................................................... 12
. M
BACK-UP LAMP SWITCH ................................. 12 .
PARK/NEUTRAL POSITION (PNP) SWITCH .... 12 .
MT-1
PRECAUTIONS
PRECAUTIONS PFP:00001
Service Notice or Precautions ECS00ICY
q Do not reuse transmission oil, once it has been drained.
q Check oil level or replace oil with vehicle on level surface.
q During removal or installation, keep inside of transmission clear of dust or dirt.
q Check for the correct installation status prior to removal or disassembly. If matching mark are required, be
certain they do not interfere with the function of the parts they are applied.
q In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
q Be careful not to damage sliding surfaces and mating surfaces.
MT-2
PREPARATION
PREPARATION PFP:00002
A
Special Service Tools ECS00ICZ
Tool number
Description
Tool name B
ST30911000 q Installing mainshaft bearing
Inserter q Installing 5th-6th synchronizer hub
a: 98 mm (3.86 in) dia. assembly MT
b: 40 mm (1.57 in) dia.
q Installing reverse main gear bushing
q Installing 3rd gear bushing
D
q Installing 3rd-4th synchronizer hub
ZZA0920D
assembly
ST30022000 q Installing 3rd main gear
Inserter E
q Installing 4th main gear
a: 110 mm (4.33 in) dia.
b: 46 mm (1.81 in) dia.
F
ZZA0920D
ST27861000 q Installing 1st-2nd synchronizer hub G
Support ring assembly
a: 62 mm (2.44 in) dia. q Installing 1st gear bushing
b: 52 mm (2.05 in) dia.
H
ZZA0832D
I
ST30032000 Installing counter rear bearing inner race
Inserter
a: 80 mm (3.15 in) dia.
b: 31 mm (1.22 in) dia. J
ZZA0920D
K
KV32102700 Installing main drive gear bearing
Drift
a: 48 mm (1.89 in) dia. L
b: 41 mm (1.61 in) dia.
M
ZZA0534D
ST23860000 Installing reverse counter gear
Drift
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
ZZA0534D
ST01530000 Installing reverse synchronizer hub assembly
Drift
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
ZZA0534D
MT-3
PREPARATION
Tool number
Description
Tool name
KV381054S0 Removing rear oil seal
Puller
ZZA0601D
ST33200000 q Installing counter rear bearing
Drift q Installing rear oil seal
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
ZZA1002D
KV38100500 Installing dust seal (for 2WD models)
Drift
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia.
S-NT086
KV40100630 Installing 4th counter gear thrust washer
Inserter
a: 67 mm (2.64 in) dia.
b: 38 mm (1.50 in) dia.
ZZA0920D
KV38102100 Installing front cover oil seal
Drift
a: 44 mm (1.73 in) dia.
b: 28 mm (1.10 in) dia.
NT084
KV32103300 Installing reverse synchronizer hub assembly
Press plate
a: 73 mm (2.87 in)
PCIB0165J
MT-4
PREPARATION
Tool number
Description A
Tool name
ST30031000 Measuring wear of inner baulk ring
Puller
B
MT
ZZC0499D
ST22490000 Holding a adapter plate
Adapter setting plate D
E
ZZC0465D
Commercial Service Tools ECS00ID0
F
Tool name Description
Puller Removing each bearing, gear and bushing G
H
ZZB0823D
I
Pin punch Removing and installing each retaining pin
Tip diameter: 6.0 mm (0.236 in) dia.
J
K
ZZA0815D
Puller q Removing reverse synchronizer hub
assembly
L
q Removing reverse main gear
q Removing reverse counter gear
M
NT077
Drift Installing counter end bearing
a: 32 mm (1.26 in) dia.
LCIA0362E
Puller Removing counter end bearing
S-NT134
MT-5
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart ECS00ID1
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.
MT-19
MT-13
MT-23
MT-21
MT-9
Reference page
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
SUSPECTED PARTS
(Possible cause)
SHIFT CONTROL LINKAGE (Worn)
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
Symptoms
Hard to shift or will not shift 1 1 2 2 2
Jumps out of gear 1 1 2 2
MT-6
DESCRIPTION
DESCRIPTION PFP:00000
A
Cross-Sectional View ECS00ID2
B
MT
D
E
F
G
H
I
J
K
L
PCIB1297E M
1. Mainshaft 2. Reverse synchronizer hub 3. Reverse coupling sleeve
4. Reverse main gear 5. 4th main gear 6. 3rd main gear
7. 1st main gear 8. 1st-2nd coupling sleeve 9. 1st-2nd synchronizer hub
10. 2nd main gear 11. 6th main gear 12. 5th-6th coupling sleeve
13. 5th-6th synchronizer hub 14. Main drive gear 15. Front cover
16. Transmission case 17. Counter gear 18. Filler plug
19. 3rd counter gear 20. 3rd-4th synchronizer hub 21. 3rd-4th coupling sleeve
22. Drain plug 23. Adapter plate 24. 4th counter gear
25. Reverse idler gear 26. Reverse idler shaft 27. Reverse counter gear
28. OD gear case 29. Rear extension
MT-7
DESCRIPTION
DOUBLE-CONE SYNCHRONIZER
The 1st, 3rd and 4th gears is equipped with a double-cone synchronizer to reduce the operating force of the
shift lever.
TRIPLE-CONE SYNCHRONIZER
The 2nd gear is equipped with a triple-cone synchronizer to reduce the operating force of the shift lever.
PCIB0594E
MT-8
M/T OIL
M/T OIL PFP:KLD20
A
Changing M/T Oil ECS00ID3
DRAINING
1. Start engine and let it run to warm up transmission.
B
2. Stop engine. Remove drain plug and gasket and then drain oil.
3. Set a gasket on drain plug and install it to transmission case. Tighten drain plug to the specified torque.
Refer to MT-19, "Case Components" . MT
CAUTION:
Do no reuse gasket.
FILLING D
1. Remove filler plug and gasket. Fill with new oil until oil level reaches the specified limit near filler plug
mounting hole.
Oil grade and viscosity: Refer to MA-14, "Fluids and Lubricants" . E
Oil capacity
2WD models: Approx. 3.99 (7 Imp pt) F
4WD models: Approx. 4.32 (7-5/8 Imp pt)
2. After refilling oil, check oil level. Set a gasket to filler plug, then install it to transmission case. Tighten filler
plug to the specified torque. Refer to MT-19, "Case Components" . G
CAUTION:
Do no reuse gasket.
H
Checking M/T Oil ECS00ID4
OIL LEAKAGE AND OIL LEVEL
q Make sure that oil is not leaking from transmission or around it.
I
q Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
J
Do not start engine while checking oil level.
q Set a gasket on filler plug and install it to transmission case.
Tighten filler plug to the specified torque. Refer to MT-19, "Case
Components" . K
CAUTION:
Do not reuse gasket.
L
PCIB0268E
M
MT-9
REAR OIL SEAL
REAR OIL SEAL PFP:33140
Removal and Installation ECS00ID5
REMOVAL
For 2WD Models
1. Remove rear propeller shaft. Refer to PR-8, "Removal and Installation" .
2. Remove dust seal and rear oil seal using a suitable tool.
CAUTION:
Do not damage rear extension.
LCIA0383E
For 4WD Models
1. Remove front and rear propeller shafts. Refer to PR-4, "Removal and Installation" (front) and PR-8,
"Removal and Installation" (rear).
2. Remove transfer assembly. Refer to TF-111, "Removal and Installation" .
3. Remove rear oil seal using the drift.
CAUTION:
Do not damage OD gear case.
PCIB1631E
MT-10
REAR OIL SEAL
INSTALLATION
Note the following, and install in the reverse order of removal. A
q For 2WD models
Drive the rear oil seal (1) and dust seal (2) using the drift.
CAUTION: B
Do not incline the dust seal and rear oil seal during installa-
tion.
Tool number MT
For oil seal : ST33200000
For dust seal : KV38100500
D
Dimension "H1 ": 1.2 - 2.2 mm (0.047 - 0.087 in)
Dimension "H2 ": 0.5 - 1.5 mm (0.020 - 0.059 in)
E
(A): Seal lip
F
G
H
PCIB1660E
q For 4WD models
Drive the rear oil seal using the drift. I
Tool number : ST33200000
Dimension "A": -0.5 - 0.5 mm (-0.020 - 0.020 in) J
CAUTION:
Do not incline the rear oil seal during installation.
K
q Check the transmission oil level after installation. Refer to MT-9,
"Checking M/T Oil" .
L
PCIB1632E
M
MT-11
POSITION SWITCH
POSITION SWITCH PFP:32005
Checking ECS00ID6
BACK-UP LAMP SWITCH
q Check continuity.
Gear position Continuity
Reverse Yes
Except reverse No
PCIB1633E
PARK/NEUTRAL POSITION (PNP) SWITCH
q Check continuity.
Gear position Continuity
Neutral Yes
Except neutral No
MT-12
SHIFT CONTROL
SHIFT CONTROL PFP:34103
A
Removal and Installation ECS00ID7
COMPONENTS
B
MT
D
E
F
G
H
I
J
K
L
M
PCIB1634E
1. Cover 2. Control lever boot 3. Insulator
4. Shift knob 5. Control lever assembly 6. Clip (A)
7. Boot 8. Guide plate 9. Socket
10. Bushing 11. Clip (B) 12. Spring
REMOVAL
1. Remove console boot. Refer to IP-14, "CONSOLE BOOT M/T" .
2. Remove shift knob.
3. Remove cover mounting bolts and then remove cover, control lever boot and insulator.
4. Remove clip (B) and then separate boot from control housing.
5. Remove guide plate mounting bolts and then separate guide plate.
6. Remove control lever assembly and spring from the transmission.
INSTALLATION
Note the following, and install in the reverse order of removal.
MT-13
SHIFT CONTROL
q Install shift knob according to the following.
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