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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
Replacing Rear Oil Seal - 2WD Model .....................39
BT
Gear Components .....................................................15
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 .........................................26 Case Components .....................................................44
ASSEMBLY .............................................................26 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 DOUBLE 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
(J-26349-A) Removing and installing mainshaft bearing
Bearing Remover and (Use with J-25726-B)
Puller Set
WMT065
MT-4
PREPARATION FS5W71C
Special Service Tools (Cont'd)
Tool number (Kent- Description
Moore No.) Tool name
GI
(J-34286) Removing races
Rear Race Puller
MA
EM
WMT066
LC
(J-39856) Removing gears and bearing
Gear and Bearing
Removal Kit EC
FE
WMT067
CL
Commercial Service Tools NGMT0046
Tool name Description
Puller Removing counter bearings, counter drive and OD
gears AT
TF
NT077
Drift Installing countershaft rear end bearing PD
a: 40 mm (1.57 in) dia.
b: 30 mm (1.18 in) dia.
AX
NT074
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
Refer to MA-38, "Checking M/T Oil".
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-8, "Removal and
Installation".
2. Remove rear oil seal using Tool.
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