Nissan 2001 X Trail Owners Manual MT

: Nissan Nissan-2001-Nissan-X-Trail-Owners-Manual-818350 nissan-2001-nissan-x-trail-owners-manual-818350 nissan pdf

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MANUAL TRANSAXLE

C TRANSMISSION/TRANSAXLE
A

SECTION

MANUAL TRANSAXLE

B

MT

D

CONTENTS
PRECAUTIONS .......................................................... 3
Caution ..................................................................... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 6
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 7
NVH Troubleshooting Chart ..................................... 7
MANUAL TRANSAXLE ......................................... 7
DESCRIPTION ............................................................ 8
Cross-Sectional View ............................................... 8
DOUBLE-CONE SYNCHRONIZER ...................... 9
REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD) ................... 9
M/T OIL ..................................................................... 10
Changing M/T Oil ................................................... 10
DRAINING ........................................................... 10
FILLING ............................................................... 10
Checking M/T Oil .................................................... 10
OIL LEAKAGE AND OIL LEVEL ......................... 10
SIDE OIL SEAL .........................................................11
Removal and Installation .........................................11
REMOVAL ............................................................11
INSTALLATION ....................................................11
POSITION SWITCH .................................................. 12
Checking ................................................................ 12
BACK-UP LAMP SWITCH .................................. 12
PARK/NEUTRAL POSITION SWITCH ............... 12
CONTROL LINKAGE ............................................... 13
Removal and Installation of Control Device and
Cable ...................................................................... 13
AIR BREATHER HOSE ............................................ 14
Removal and Installation ........................................ 14
TRANSAXLE ASSEMBLY ........................................ 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
Component Parts (RS5F51A) ................................ 17

CASE AND HOUSING COMPONENTS .............. 17
GEAR COMPONENTS ....................................... 18
SHIFT CONTROL COMPONENTS ..................... 20
FINAL DRIVE COMPONENTS ........................... 21
Component Parts (RS6F51A) ................................. 22
CASE AND HOUSING COMPONENTS .............. 22
GEAR COMPONENTS ....................................... 23
SHIFT CONTROL COMPONENTS ..................... 25
FINAL DRIVE COMPONENTS ........................... 26
Disassembly and Assembly (RS5F51A) ................. 26
DISASSEMBLY ................................................... 26
ASSEMBLY ......................................................... 30
Disassembly and Assembly (RS6F51A) ................. 35
DISASSEMBLY ................................................... 35
ASSEMBLY ......................................................... 39
Adjustment (RS5F51A) ........................................... 45
INPUT SHAFT END PLAY .................................. 45
MAINSHAFT END PLAY ..................................... 46
DIFFERENTIAL SIDE BEARING PRELOAD ...... 47
REVERSE IDLER GEAR END PLAY .................. 48
Adjustment (RS6F51A) ........................................... 49
INPUT SHAFT END PLAY .................................. 49
MAINSHAFT END PLAY ..................................... 50
DIFFERENTIAL SIDE BEARING PRELOAD ...... 51
REVERSE IDLER GEAR END PLAY .................. 52
INPUT SHAFT AND GEARS .................................... 54
Assembly and Disassembly (RS5F51A) ................. 54
DISASSEMBLY ................................................... 54
INSPECTION AFTER DISASSEMBLY ................ 55
ASSEMBLY ......................................................... 57
Assembly and Disassembly (RS6F51A) ................. 61
DISASSEMBLY ................................................... 61
INSPECTION AFTER DISASSEMBLY ................ 62
ASSEMBLY ......................................................... 64
MAINSHAFT AND GEARS ....................................... 68
Assembly and Disassembly (RS5F51A) ................. 68
DISASSEMBLY ................................................... 68
INSPECTION AFTER DISASSEMBLY ................ 69

MT-1

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ASSEMBLY ......................................................... 71
Assembly and Disassembly (RS6F51A) ................. 76
DISASSEMBLY ................................................... 76
INSPECTION AFTER DISASSEMBLY ................ 77
ASSEMBLY ......................................................... 79
REVERSE IDLER SHAFT AND GEARS .................. 84
Assembly and Disassembly (RS5F51A) ................. 84
DISASSEMBLY ................................................... 84
INSPECTION AFTER DISASSEMBLY ................ 84
ASSEMBLY ......................................................... 85
Assembly and Disassembly (RS6F51A) ................. 85
DISASSEMBLY ................................................... 85
INSPECTION AFTER DISASSEMBLY ................ 85
ASSEMBLY ......................................................... 86
FINAL DRIVE ............................................................ 87
Assembly and Disassembly (RS5F51A) ................. 87
PRE-INSPECTION .............................................. 87
DISASSEMBLY ................................................... 87
INSPECTION AFTER DISASSEMBLY ................ 88
ASSEMBLY ......................................................... 88
Assembly and Disassembly (RS6F51A) ................. 90
PRE-INSPECTION .............................................. 90
DISASSEMBLY ................................................... 91
INSPECTION AFTER DISASSEMBLY ................ 92
ASSEMBLY ......................................................... 92
SHIFT CONTROL ...................................................... 95
Inspection (RS5F51A) ............................................ 95
SHIFT FORK ....................................................... 95
Inspection (RS6F51A) ............................................ 96
SHIFT FORK ....................................................... 96

SERVICE DATA AND SPECIFICATIONS (SDS) ......97
General Specifications ............................................97
TRANSAXLE ........................................................97
FINAL GEAR ........................................................98
Gear End Play .........................................................98
Clearance Between Baulk Ring and Gear ..............98
3RD,4TH,5TH,6TH & REVERSE BAULK RING...98
1ST AND 2ND DOUBLE BAULK RING ...............98
Available Snap Rings ..............................................99
INPUT SHAFT SPACER ......................................99
6TH BUSHING .....................................................99
5TH MAIN GEAR .................................................99
Available C-Rings ...................................................99
MAINSHAFT C-RING ..........................................99
Available Thrust Washer ....................................... 100
INPUT SHAFT THRUST WASHER ................... 100
DIFFERENTIAL SIDE GEAR THRUST WASHER
.100
Available Adjusting Shims ..................................... 100
MAINSHAFT ADJUSTING SHIM ....................... 100
INPUT SHAFT REAR BEARING ADJUSTING
SHIM .................................................................. 101
MAINSHAFT REAR BEARING ADJUSTING
SHIM .................................................................. 101
REVERSE IDLER GEAR ADJUSTING SHIM .... 101
6TH MAIN GEAR ADJUSTING SHIM ................ 101
Available Shims .................................................... 102
BEARING PRELOAD ......................................... 102
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) ............................................................. 102

MT-2

PRECAUTIONS
PRECAUTIONS
Caution
●
●
●
●

●

●

PFP:00001

A
ECS008BM

Do not reuse transaxle oil, once it has been drained.
B
Check oil level or replace oil with vehicle on level ground.
During removal or installation, keep inside of transaxle clear of dust or dirt.
Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
MT
certain they do not interfere with the function of the parts they are applied to.
In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
D
Be careful not to damage sliding surfaces and mating surfaces.

E

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MT-3

PREPARATION
PREPARATION
Special Service Tools

PFP:00002
ECS008BN

Tool name
Tool number

Description

Puller
KV381054S0

●

Side bearing outer race removal

●

Mainshaft front bearing removal

●

Input shaft oil seal installation

●

Reverse main gear installation

●

1st bushing installation

●

1st-2nd synchronizer hub installation

●

2nd bushing installation

●

3rd main gear installation

●

Differential side bearing removal

●

Differential oil seal installation

●

Differential side bearing outer race
installation

●

Mainshaft rear bearing installation

●

Differential side bearing installation

●

Mainshaft front bearing installation

●

6th bushing installation (RS6F51A)

●

4th main gear installation

●

5th main gear installation

●

6th main gear installation (RS6F51A)

●

Differential side bearing outer race
installation

●

Bore plug installation

●

Differential side bearing removal

ZZA0601D

Drift
ST35321000
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
ZZA1000D

Drift
ST30720000
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ZZA0811D

Drift
ST33200000
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
ZZA1002D

Drift
KV40105320
a: 88 mm (3.46 in) dia.
ZZA0898D

Drift
ST33061000
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
ZZA1000D

MT-4

PREPARATION
Tool name
Tool number

Description

Drift
ST33052000
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.

●

Welch plug installation

●

Input shaft rear bearing removal

●

Input shaft bearing spacer and 5th stopper
removal (RS5F51A)

●

5th bushing, thrust washer, 4th input gear,
4th gear bushing, 3rd-4th synchronizer hub
and 3rd input gear removal

●

Input shaft front bearing installation

●

6th input gear and 6th bushing removal
(RS6F51A)

●

Mainshaft rear bearing removal

●

4th main gear and 5th main gear removal

●

6th main gear removal (RS6F51A)

●

5th input gear and synchronizer hub
removal

●

3rd main gear, 2nd main gear, 2nd bushing,
1st-2nd synchronizer hub, 1st main gear,
reverse main gear and 1st bushing removal

G

●

3rd-4th synchronizer hub installation

H

●

4th bushing installation

●

5th bushing installation

●

5th synchronizer hub installation
(RS5F51A)

●

5th-6th synchronizer hub installation
(RS6F51A)

ZZA1023D

Drift
KV40105020
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)

A

B

MT

D

E

F

ZZA1133D

Press stand
KV40105710
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in)
ZZA1058D

●

2nd bushing installation

●

3rd main gear installation

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Press stand
ST38220000
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)

●

Reverse main gear installation

●

1st bushing installation

●

1st-2nd synchronizer hub installation

M

ZZA1058D

Drift
ST30032000
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.

●

5th stopper and input shaft bearing spacer
installation (RS5F51A)

●

Input shaft front bearing installation

●

Input shaft rear bearing installation

●

4th main gear installation

●

5th main gear installation

●

6th main gear installation (RS6F51A)

●

Mainshaft rear bearing installation

ZZA0978D

Drift
ST30901000
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
ZZA0978D

MT-5

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PREPARATION
Tool name
Tool number

Description

Puller
ST30031000

●

Measuring wear of 1st and 2nd baulk ring

●

Reverse main gear installation

●

1st bushing installation

●

1st-2nd synchronizer hub installation

●

Differential side bearing installation

●

Differential side bearing installation

ZZA0537D

Drift
KV40101630
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.
ZZA1003D

Drift
KV38102510
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
ZZA0838D

Drift
KV40104830
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.500 in) dia.
ZZA0936D

Commercial Service Tools

ECS008BO

Tool name

Description

Puller

Each bearing gear and bushing removal

ZZA0537D

Puller

Each bearing gear and bushing removal

NT077

Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.

Each retaining pin removal and installation

ZZA0815D

MT-6

Symptoms

1

2

Oil leakage

3

1

Hard to shift or will not shift

1

1

2

Jumps out of gear

MT-7

2

SUSPECTED PARTS
(Possible cause)

1

2

3

3

3

2

2

3
INSERT SPRING (Damaged)

BEARING (Worn or damaged)

MT-18(RS5F51A), MT-23 (RS6F51A)

MT-18(RS5F51A), MT-23 (RS6F51A)

MT-18(RS5F51A), MT-23 (RS6F51A)

MT-18(RS5F51A), MT-23 (RS6F51A)

MT-20(RS5F51A), MT-25 (RS6F51A)

MT-20(RS5F51A), MT-25 (RS6F51A)

MT-13

MT-17(RS5F51A), MT-22 (RS6F51A)

MT-17(RS5F51A), MT-22 (RS6F51A)

MT-17(RS5F51A), MT-22 (RS6F51A)

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

BAULK RING (Worn or damaged)

GEAR (Worn or damaged)

SHIFT FORK (Worn)

CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)

SHIFT CONTROL LINKAGE (Worn)

O-RING (Worn or damaged)

OIL SEAL (Worn or damaged)

GASKET (Damaged)

MA-35

Reference page

OIL (Oil level is high.)

OIL (Wrong oil.)

Noise
OIL (Oil level is low.)

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
ECS008BP

A

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

3

3

B

MANUAL TRANSAXLE
MT

D

E

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DESCRIPTION
DESCRIPTION
Cross-Sectional View

PFP:00000
ECS008BQ

SCIA0749E

MT-8

DESCRIPTION
DOUBLE-CONE SYNCHRONIZER
A

Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.

B

MT

SCIA0750E

D

REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)
The gear can be matched smoothly in a structure by setting synchronizer hub, coupling sleeve, baulk ring and insert spring to reverse
gear, and letting gear be synchronized.

E

F

G

SCIA0751E

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MT-9

M/T OIL
M/T OIL
Changing M/T Oil

PFP:KLD20
ECS008BR

DRAINING
1.
2.
3.

Start the engine and let it run to warm up the transaxle.
Stop the engine. Remove drain plug and drain oil.
Set a gasket on the drain plug and install it to the transaxle.
Drain plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
CAUTION:
Do not reuse gasket.

FILLING
1.

Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole.
Oil grade
Capacity (reference)

2.

: API GL-4
: Approx. 2.3

(4 lmp pt)

After refilling oil, check oil level. Assemble gasket to filler plug, then install it to transaxle body.
Filler plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
CAUTION:
Do not reuse gasket.

Checking M/T Oil

ECS008BS

OIL LEAKAGE AND OIL LEVEL
●
●

●

Check that oil is not leaking from transaxle or around it.
Check oil level from filler plug mounting hole as shown in the figure.
CAUTION:
Never start engine while checking oil level.
Set a new gasket on the filler plug and install it on the transaxle.
Filler plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
CAUTION:
Do not reuse gasket.

SCIA0361E

MT-10

SIDE OIL SEAL
SIDE OIL SEAL
Removal and Installation

PFP:32113

A
ECS008BT

REMOVAL
●

1.
2.

Clutch housing side oil seal used on 4WD vehicles is attached to the transfer. Be sure to replace it B
when transfer is removed.
Remove the drive shaft from the transaxle.
Remove oil seal with flat tip screwdriver.
MT
CAUTION:
Be careful not to damage the case surface when removing
the oil seal.
D

E

SCIA0824E

F

INSTALLATION
1.

2.

Using a drift (special service tool), drive the oil seal straight until
it protrudes from the case end equal to dimension A shown in
the figure.

G

Dimension "A":
Within 0.5 mm (0.020 in) of flush with the case.

H

Drift to be used:
Transaxle case side:
Clutch housing side:

I

ST30720000
ST30720000

CAUTION:
● When installing oil seals, apply multi-purpose grease to oil seal lips.
● Oil seals are not reusable. Never reuse them.
Install all parts in reverse order of removal and check oil level after installation.

SCIA0352E

J

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MT-11

POSITION SWITCH
POSITION SWITCH
Checking

PFP:32005
ECS008BU

BACK-UP LAMP SWITCH
●

Check continuity.
Gear position

Continuity

Reverse

Yes

Except reverse

No

SCIA0708E

PARK/NEUTRAL POSITION SWITCH
●

Check continuity.
Gear position

Continuity

Neutral

Yes

Except neutral

No

MT-12

CONTROL LINKAGE
CONTROL LINKAGE
Removal and Installation of Control Device and Cable

PFP:34103

A
ECS008BV

Refer to the figure for removal and installation procedure.
B

MT

D

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SCIA0711E

CAUTION:
●
Keep in mind that the select side lock plate for securing the control cable is different from the one
on the shift side.
●
After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st,
2nd, or Reverse.

MT-13

AIR BREATHER HOSE
AIR BREATHER HOSE
Removal and Installation

PFP:31098
ECS008BW

Refer to the figure for air breather hose removal and installation information.

QR engine models

SCIA0354E

YD engine models

SCIA0747E

CAUTION:
●
Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
●
Be sure to insert hose into the transaxle tube until overlap area reaches the spool.

MT-14

TRANSAXLE ASSEMBLY
TRANSAXLE ASSEMBLY
Removal and Installation

PFP:32010

A
ECS008BX

B

MT

D

E

F

G

H

I
SCIA0845E

J

REMOVAL
1.
2.
3.

4.
5.
6.
7.
8.
9.
10.

11.

12.
13.
14.

Remove air cleaner, air duct, and battery.
Remove the air breather hose.
Remove clutch operating cylinder.
CAUTION:
Do not depress clutch pedal during removal procedure.
Disconnect control cable from transaxle.
Drain gear oil from transaxle.
Disconnect PNP switch, back-up lamp switch, and ground harness connectors.
Remove exhaust front tube and the drive shaft.
Remove transfer.
● Refer to TF-11, "Removal and Installation from Vehicle" .
Remove starter motor.
Place a jack onto the transaxle.
CAUTION:
When setting jack, be careful not to bring it into contact with the switch.
Remove center member, engine insulator and engine mount bracket.
● Refer to EM-69, "ENGINE ASSEMBLY" (QR engine models) or EM-193, "ENGINE ASSEMBLY" (YD
engine models).
Remove suspension members.
● Refer to FSU-12, "FRONT SUSPENSION MEMBER" .
Support engine by placing a jack under oil pan.
Remove bolts securing transaxle to engine.

MT-15

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TRANSAXLE ASSEMBLY
15. Remove transaxle from vehicle.

MTD0062D

INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
●
When installing the transaxle to the engine, tighten to the specified torque.
CAUTION:
When installing transaxle, be careful not to bring transaxle input shaft into contact with the clutch
cover.
QR engine models:
Bolt No.

1

2

3*

4

5

6

Quantity

2

1

1

2

2

2

40
(1.57)

75
(2.95)

45
(1.77)

40
(1.57)

30
(1.18)

40
(1.57)

“

” mm (in)

Tightening torque
N·m (kg - m, ft- lb)

69.6 - 79.4
(7.1 - 8.1, 52 - 58)

39.2 - 46.1
(4.0 - 4.7, 29 - 34)

30.4 - 40.2
(3.1 - 4.1,
23 - 29)

*: Tightening the bolt for 4WD models.
SCIA0353E

YD engine models:
Bolt No.

1

2

3

4

5

6

Quantity

2

2

1

1

3

1

55
(2.17)

70
(2.76)

120
(4.72)

45
(1.77)

40
(1.57)

35
(1.38)

“

” mm (in)

Tightening torque
N·m (kg - m, ft- lb)
●

40 - 49
(4.0 - 5.0, 29 - 36)

31 - 36
(3.1 - 3.7, 23 - 26)

After installation, check oil level, and look for leaks and loose
mechanisms.
SCIA0748E

MT-16

TRANSAXLE ASSEMBLY
Component Parts (RS5F51A)

ECS008BY

A

CASE AND HOUSING COMPONENTS

B

MT

D

E

F

G

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SCIA1112E

1.

Clutch housing

2.

Input shaft oil seal

3.

Oil channel

4.

Magnet

5.

Differential oil seal

6.

Ball pin

7.

Washer

8.

Transaxle case

9.

Welch plug

10. Bore plug

11. Differential oil seal

13. Oil gutter

14. Back-up lamp switch

15. Air breather tube

16. Baffle plate

17. Filler plug

18. Gasket

19. Drain plug

20. Gasket

MT-17

12. Park/Neutral position switch

TRANSAXLE ASSEMBLY
GEAR COMPONENTS

SCIA0385E

1.

Input shaft front bearing

2.

Input shaft

3.

Needle bearing

4.
7.

3rd input gear

5.

3rd baulk ring

6.

Spread spring

3rd & 4th shifting insert

8.

3rd & 4th synchronizer hub

9.

4th baulk ring

10. 3rd & 4th coupling sleeve

11. Bushing

12. Needle bearing

13. 4th input gear

14. Thrust washer

15. Bushing

16. Needle bearing

17. 5th input gear

18. 5th baulk ring

19. 5th shifting insert

20. 5th synchronizer hub

21. 5th coupling sleeve

22. 5th stopper

23. Input shaft bearing spacer

24. Snap ring

25. Input shaft rear bearing

26. Oil channel

27. Input shaft rear bearing adjusting
shim

28. Retaining pin

29. Reverse idler shaft

30. Thrust needle bearing

31. Needle bearing

32. Reverse idler gear (Front)

33. Reverse baulk ring

34. Reverse coupling sleeve

35. Insert spring

36. Reverse idler gear (Rear)

37. Reverse idler gear adjusting shim

MT-18

TRANSAXLE ASSEMBLY
A

B

MT

D

E

F

G

H

SCIA0386E

1.

Mainshaft front bearing

2.

Mainshaft bearing retainer

3.

Mainshaft

4.

Reverse main gear

5.

1st main gear

6.

Bushing

7.

Needle bearing

8.

1st inner baulk ring

9.

1st gear synchronizer cone

10. 1st outer baulk ring

11. Spread spring

12. 1st & 2nd shifting insert

13. 1st & 2nd synchronizer hub

14. 2nd outer baulk ring

15. 2nd gear synchronizer cone

16. 2nd inner baulk ring

17. 1st &2nd coupling sleeve

18. Bushing

19. Needle bearing

20. 2nd main gear

21. 3rd main gear

22. 3rd &4th mainshaft spacer

23. 4th main adjusting shim

24. 4th main gear

25. 5th main gear

26. Snap ring

27. Mainshaft rear bearing

28. Mainshaft C ring

29. C ring holder

30. Snap ring

31. Snap ring

32. Mainshaft rear bearing adjusting shim

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MT-19

TRANSAXLE ASSEMBLY
SHIFT CONTROL COMPONENTS

SCIA0387E

1.

Reverse shift fork

2.

Shifter cap

3.

Reverse fork rod

4.

Reverse lever assembly

5.

5th & reverse bracket

6.

5th & reverse fork rod

7.

5th shift fork

8.

Retaining pin

9.

3rd & 4th bracket

10. 3rd & 4th shift fork

11. 3rd & 4th fork rod

12. 1st & 2nd shift fork

13. 1st & 2nd bracket

14. 1st & 2nd fork rod

15. Shift check sleeve

16. Inter lock pin

17. Check ball

18. Shift check sleeve

19. Check spring

20. Check plug

21. Control assembly

22. O ring

23. Shift check

24. Stopper bolt

25. Stopper ring

MT-20

TRANSAXLE ASSEMBLY
FINAL DRIVE COMPONENTS
A

B

MT

D

E

F

G

H

SCIA0388E

1.

Differential side bearing outer race

2.

Differential side bearing

3.

Differential case

4.

Final gear

5.

Differential side bearing

6.

Differential side bearing outer race

7.

Differential side bearing adjusting
shim

8.

Pinion mate shaft

9.

Side gear

10. Side gear thrust washer

11. Pinion mate gear

I

J

12. Pinion mate gear washer

K

13. Retaining pin

L

M

MT-21

TRANSAXLE ASSEMBLY
Component Parts (RS6F51A)

ECS008BZ

CASE AND HOUSING COMPONENTS

SCIA1112E

1.

Clutch housing

2.

Input shaft oil seal

3.

Oil channel

4.

Magnet

5.

Differential oil seal

6.

Ball pin

7.

Washer

8.

Transaxle case

9.

Welch plug

10. Bore plug

11. Differential oil seal

12. Park/Neutral position switch

13. Oil gutter

14. Back-up lamp switch

15. Air breather tube

16. Baffle plate

17. Filler plug

18. Gasket

19. Drain plug

20. Gasket

MT-22

TRANSAXLE ASSEMBLY
GEAR COMPONENTS
A

B

MT

D

E

F

G

H

SCIA0956E

1.

Input shaft front bearing

2.

Input shaft

3.

Needle bearing

4.

3rd input gear

5.

3rd baulk ring

6.

Spread spring

7.

3rd & 4th shifting insert

8.

3rd & 4th synchronizer hub

9.

4th baulk ring

10. 3rd & 4th coupling sleeve

11. Bushing

12. Needle bearing

13. 4th input gear

14. Thrust washer

15. Bushing

16. Needle bearing

17. 5th input gear

18. 5th baulk ring

19. 5th & 6th shifting insert

20. 5th & 6th synchronizer hub

21. 5th & 6th coupling sleeve

22. 6th baulk ring

23. 6th input gear

24. Needle bearing

25. Bushing

26. Snap ring

27. Input shaft rear bearing

28. Oil channel

29. Input shaft rear bearing adjusting
shim

30. Retaining pin

31. Reverse idler shaft

32. Thrust needle bearing

33. Needle bearing

34. Reverse idler gear (Front)

35. Reverse baulk ring

36. Reverse coupling sleeve

37. Insert spring

38. Reverse idler gear (Rear)

39. Reverse idler gear adjusting shim

MT-23

I

J

K

L

M

TRANSAXLE ASSEMBLY

SCIA0957E

1.

Mainshaft front bearing

2.

Mainshaft bearing retainer

3.

Mainshaft

4.

Reverse main gear

5.

1st main gear

6.

Bushing

7.

Needle bearing

8.

1st inner baulk ring

9.

1st gear synchronizer cone

10. 1st outer baulk ring

11. Spread spring

12. 1st & 2nd shifting insert

13. 1st & 2nd synchronizer hub

14. 2nd outer baulk ring

15. 2nd gear synchronizer cone

16. 2nd inner baulk ring

17. 1st & 2nd coupling sleeve

18. Bushing

19. Needle bearing

20. 2nd main gear

21. 3rd main gear

22. 3rd & 4th mainshaft spacer

23. 4th main adjusting shim

24. 4th main gear

25. 5th main gear

26. 6th main gear

27. Mainshaft rear bearing

28. Mainshaft C ring

29. C ring holder

30. Snap ring

31. Snap ring

32. Mainshaft rear bearing adjusting shim

33. 5th & 6th mainshaft spacer

34. 6th main adjusting shim

MT-24

TRANSAXLE ASSEMBLY
SHIFT CONTROL COMPONENTS
A

B

MT

D

E

F

G

H

I

J
SCIA0958E

1.

Reverse shift fork

2.

Shifter cap

3.

Reverse fork rod

4.

Reverse lever assembly

5.

5th & 6th bracket

6.

5th & 6th fork rod

7.

5th & 6th shift fork

8.

Retaining pin

9.

3rd & 4th bracket

10. 3rd & 4th shift fork

11. 3rd & 4th fork rod

12. 1st & 2nd shift fork

13. 1st & 2nd fork rod bracket

14. 1st & 2nd fork rod

15. Shift check sleeve

16. Inter lock pin

17. Check ball

18. Shift check sleeve

19. Check spring

20. Check plug

21. Control assembly

22. O ring

23. Shift check

24. Stopper bolt

25. Stopper ring

26. Reverse bracket fork rod

27. Reverse bracket

MT-25

K

L

M

TRANSAXLE ASSEMBLY
FINAL DRIVE COMPONENTS

SCIA0388E

1.

Differential side bearing outer race

2.

Differential side bearing

3.

Differential case

4.

Final gear

5.

Differential side bearing

6.

Differential side bearing outer race

7.

Differential side bearing adjusting shim

8.

Pinion mate shaft

9.

Side gear

10. Side gear thrust washer

11. Pinion mate gear

12. Pinion mate gear washer

13. Retaining pin

Disassembly and Assembly (RS5F51A)

ECS008C0

DISASSEMBLY
1.
2.
3.

Remove drain plug and filler plug.
Remove park/neutral position switch and back-up lamp switch.
After removing shift check and stopper bolt, remove control
assembly.

SCIA0389E

MT-26

TRANSAXLE ASSEMBLY
4.

Remove check plugs (3 pieces), check springs (3 pieces), check
balls (3 pieces) and shift check sleeve (1 piece).

A

B

MT
SCIA0396E

D

5.
6.

7.
8.
9.

Remove transaxle case fixing bolts.
Remove bore plug.
CAUTION:
Be careful not to damage transaxle case.
While spreading the snap ring of mainshaft rear bearing located
at bore plug hole, remove transaxle case.
Remove oil gutter, baffle plate.
Remove snap ring, mainshaft rear bearing adjusting shim and
input shaft rear bearing adjusting shim from transaxle case.

E

F

G
SCIA0983E

10. Remove differential side bearing outer race (transaxle case
side) and then adjust shim.

H

I

J

SCIA0897E

K

11. Remove welch plug.
L

M

SCIA0402E

12. Remove differential oil seal (tansaxle case side).
13. Remove magnet from clutch housing.

SCIA0397E

MT-27

TRANSAXLE ASSEMBLY
14. With shift lever in 5th position, remove bracket bolts from
reverse lever assembly. Lift reverse lever assembly to remove.
CAUTION:
Be careful not to lose shifter cap.
15. Pull out reverse fork rod then remove reverse shift fork.

SCIA0390E

16. Shift 3rd & 4th fork rod to 3rd position. Remove retaining pin of
5th shift fork using pin punch.

SCIA0391E

17. Remove stopper rings for 5th & reverse bracket.
18. Pull out 5th & reverse fork rod and remove 5th shift fork and 5th
& reverse bracket.
19. Remove check balls (2 pieces) and inter lock pin.

SCIA0392E

20. Remove retaining pin of 3rd & 4th bracket using pin punch.
21. Remove stopper rings for 3rd & 4th shift fork.
22. Pull out 3rd & 4th fork rod and remove 3rd & 4th shift fork and
bracket.
23. Remove shift check sleeve from clutch housing.

SCIA0393E

24.
25.
26.
27.

Remove retaining pin of 1st & 2nd shift fork using pin punch.
Pull out 1st & 2nd fork rod with bracket.
Remove 1st & 2nd shift fork.
Remove retaining pin of 1st & 2nd bracket using pin punch and
separate 1st & 2nd fork rod and bracket.

SCIA0394E

MT-28

TRANSAXLE ASSEMBLY
28. Remove gear components from clutch housing in the following
procedure.
a. While tapping input shaft with plastic hammer, remove input
shaft assembly, mainshaft assembly and reverse idler gear
assembly as a set.
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.

A

B

MT

SCIA0395E

D

29. Remove bearing retainer and then mainshaft front bearing.
30. Remove oil channel on mainshaft side.
E

F

G
SCIA1077J

31. Remove differential oil seal (clutch housing side).

H

I

J

SCIA1068J

32. Remove differential side bearing outer race (clutch housing
side).

K

L

M

SCIA1069J

33. Remove input shaft oil seal.
CAUTION:
Be careful not to damage clutch housing.

SCIA0398E

MT-29

TRANSAXLE ASSEMBLY
ASSEMBLY
1.

Using a drift, install input shaft oil seal from clutch housing end
of side to the depth of 1.8 to 2.8 mm (0.071 to 0.110 in).
CAUTION:
Do not reuse oil seals.

SCIA0399E

2.

Using a drift, install differential oil seal until the face is flush with
clutch housing.
CAUTION:
Do not reuse oil seals.

SCIA1070J

3.

Install oil channel on mainshaft side.
CAUTION:
Be careful with orientation of installation.

SCIA0986E

4.

Using a drift, install mainshaft front bearing.
CAUTION:
Be careful with orientation of installation.

SCIA0401E

MT-30

TRANSAXLE ASSEMBLY
5.

Install bearing retainer.
CAUTION:
Install with punched surface facing up.

A

B

MT
SCIA0400E

D

6.

Install differential side bearing outer race.
E

F

G
SCIA0987E

7.

Install final drive assembly into clutch housing.

H

I

J

SCIA0888E

8.

Install input shaft assembly, mainshaft assembly, and reverse
idler gear assembly into clutch housing.
CAUTION:
Be sure not to damage input shaft oil seal.

K

L

M

SCIA0395E

9.

Install 1st-2nd fork rod bracket onto 1st-2nd fork rod, and then
install retaining pin.
CAUTION:
Do not reuse retaining pins.

SCIA0889E

MT-31

TRANSAXLE ASSEMBLY
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install
retaining pin.
CAUTION:
Do not reuse retaining pins.
11. Install shift check sleeve.

SCIA0394E

12. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod
with inter lock pin.
13. Install stopper ring onto 3rd-4th shift fork.
CAUTION:
Do not reuse stopper ring.
14. Install retaining pin onto 3rd-4th bracket.
CAUTION:
Do not reuse retaining pins.
15. Install 2 check balls.
SCIA0393E

16. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork
rod.
17. Install stopper ring onto 5th-reverse bracket.
CAUTION:
Do not reuse stopper ring.

SCIA0392E

18. Install retaining pin onto 5th shift fork.
CAUTION:
Do not reuse retaining pins.
19. Install reverse shift fork and reverse fork rod.
20. Install reverse lever assembly following procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then
install them onto reverse shift fork.
CAUTION:
Do not drop shifter cap.
SCIA0391E

b.

While lifting reverse shift fork, align cam with 5th-reverse
bracket.

SCIA0890E

MT-32

TRANSAXLE ASSEMBLY
c.

Tighten mounting bolts to specified torque, and then install
reverse lever assembly.
21. Install check ball, 5th-reverse shift check sleeve, check spring
and 5th-reverse check ball plug.
CAUTION:
● Do not reuse check ball plug.
● Do not drop check ball.
22. Install the magnet onto clutch housing.

A

B

MT

SCIA0390E

23. Using a drift, install differential oil seal until it is flush with end
face of transaxle case.
CAUTION:
Do not reuse oil seals.
24. Install selected input shaft adjusting shim onto input shaft.
● For selection of adjusting shims, refer to MT-45, "INPUT
SHAFT END PLAY" .
25. Install baffle plate and oil gutter.
26. Install transaxle case following procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
● For selection of adjusting shims, refer to MT-46, "MAINSHAFT END PLAY" .
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse the snap ring.
c. Apply recommended sealant to mating surfaces of transaxle
case and clutch housing.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.

D

E

F

G
SCIA0887E

H

I

J

K

L
SCIA0891E

d.

M

With snap ring of mainshaft rear bearing temporarily installed,
place transaxle case over clutch housing.

SCIA0892E

MT-33

TRANSAXLE ASSEMBLY
e.

f.

Through bore plug mounting hole, with snap ring stretched, and
lift up mainshaft assembly from the control assembly mounting
hole.
Securely install snap ring onto mainshaft rear bearing.

SCIA0893E

g.

Tighten mounting bolts.
Bolt A:
: 50.0 - 53.9 N·m (5.1 - 5.4 kg-m, 37 - 39 ft-lb)
Bolt B:
: 63.0 - 66.9 N·m (6.5 - 6.8 kg-m, 47 - 49 ft-lb)

CAUTION:
Always replace bolts B as they are self-sealing bolts.
h. Install control assembly.
CAUTION:
Do not reuse the O-ring.
i. Install shift check and stopper bolt.
CAUTION:
Does not reuse shift check and stopper bolt.
27. Using a drift, install bore plug.
CAUTION:
Do not reuse bore plug.

SCIA1064E

SCIA0894E

MT-34

TRANSAXLE ASSEMBLY
28. Using a drift, install welch plug.
CAUTION:
Do not reuse welch plug.

A

B

MT
SCIA0403E

D

29. Install 2 check balls, 2 check springs and 2 check ball plugs.
CAUTION:
Do not reuse check ball plug.

E

F

G
SCIA1668J

30. Apply recommended sealant to threads of neutral switch and
reverse lamp switch. Then install them into transaxle case.
31. Install gaskets onto drain plug and filler plug, and then install
them into transaxle case.
CAUTION:
● Do not reuse gasket.
● After oil is filled, tighten filler plug to specified torque.

H

I

J

SCIA0895E

Disassembly and Assembly (RS6F51A)

K

ECS008C1

DISASSEMBLY
1.
2.
3.

L

Remove drain plug and filler plug.
Remove park/neutral position switch and back-up lamp switch.
After removing shift check and stopper bolt, remove control
assembly.

M

SCIA0389E

MT-35

TRANSAXLE ASSEMBLY
4.

Remove check plugs (4 pieces), check springs (4 pieces), check
balls (4 pieces) and shift check sleeve (2 pieces).

SCIA0959E

5.
6.

7.
8.
9.

Remove transaxle case fixing bolts.
Remove bore plug.
CAUTION:
Be careful not to damage transaxle case.
While spreading the snap ring of mainshaft rear bearing located
at bore plug hole, remove transaxle case.
Remove oil gutter, baffle plate.
Remove snap ring, mainshaft rear bearing adjusting shim and
input shaft rear bearing adjusting shim from transaxle case.
SCIA0983E

10. Remove differential side bearing outer race (transaxle case
side) and then adjusting shim.

SCIA0897E

11. Remove welch plug.

SCIA0402E

12. Remove differential oil seal (transaxle case side).
13. Remove magnet from clutch housing.

SCIA0397E

MT-36

TRANSAXLE ASSEMBLY
14. With shift lever in 5th position, remove bracket bolts from
reverse lever assembly. Lift reverse lever assembly to remove.
CAUTION:
Be careful not to lose shifter cap.
15. Pull out reverse fork rod then remove reverse shift fork.

A

B

MT

SCIA0960E

16. Remove retaining pin of reverse bracket.
17. Pull out reverse bracket and reverse bracket fork rod.
18. Remove check ball (2 pieces) and inter lock pin.

D

E

F

G
SCIA0961E

19. Shift 3rd & 4th fork rod to 3rd position. Remove retaining pin of
5th & 6th shift fork using pin punch.

H

I

J

SCIA0962E

20. Remove stopper rings for 5th & 6th bracket.
21. Pull out 5th & 6th fork rod and remove 5th & 6th shift fork and
5th & 6th bracket.
22. Remove check balls (2 pieces) and inter lock pin.

K

L

M

SCIA0963E

23. Remove retaining pin of 3rd & 4th bracket using pin punch.
24. Remove stopper rings for 3rd & 4th shift fork.
25. Pull out 3rd & 4th fork rod and remove 3rd & 4th shift fork and
bracket.
26. Remove shift check sleeve from clutch housing.

SCIA0393E

MT-37

TRANSAXLE ASSEMBLY
27.
28.
29.
30.

Remove retaining pin of 1st & 2nd shift fork using pin punch.
Pull out 1st & 2nd fork rod with bracket.
Remove 1st & 2nd shift fork.
Remove retaining pin of 1st & 2nd bracket using pin punch and
separate fork rod and bracket.

SCIA0394E

31. Remove gear components from clutch housing in the following
procedure.
a. While tapping input shaft with plastic hammer, remove input
shaft assembly, mainshaft assembly and reverse idler gear
assembly as a set.
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.
SCIA0964E

32. Remove main bearing retainer and then mainshaft front bearing.
33. Remove oil channel on mainshaft side.

SCIA1077J

34. Remove differential oil seal (clutch housing side).

SCIA1068J

35. Remove differential side bearing outer race (clutch housing
side).

SCIA1069J

MT-38

TRANSAXLE ASSEMBLY
36. Remove input shaft oil seal.
CAUTION:
Be careful not to damage clutch housing.

A

B

MT

SCIA0398E

ASSEMBLY
1.

Using a drift, install input shaft oil seal from clutch housing end
of side to the depth of 1.8 to 2.8 mm (0.071 to 0.110 in).
CAUTION:
Do not reuse oil seals.

D

E

F

G
SCIA0399E

2.

H

Using a drift, install differential oil seal until the face is flush with
clutch housing.
CAUTION:
Do not reuse oil seals.

I

J

K
SCIA1070J

3.

Install oil channel on mainshaft side.
CAUTION:
Be careful with orientation of installation.

L

M

SCIA0986E

MT-39

TRANSAXLE ASSEMBLY
4.

Using a drift, install mainshaft front bearing.
CAUTION:
Be careful with orientation of installation.

SCIA0401E

5.

Install bearing retainer.
CAUTION:
Install with punched surface facing up.

SCIA0400E

6.

Install differential side bearing outer race.

SCIA0987E

7.

Install final drive assembly into clutch housing.

SCIA0888E

8.

Install input shaft assembly, mainshaft assembly, and reverse
idler gear assembly into clutch housing.
CAUTION:
Be sure not to damage input shaft oil seal.

SCIA0964E

MT-40

TRANSAXLE ASSEMBLY
9.

Install 1st-2nd fork rod bracket onto 1st-2nd fork rod, and then
install retaining pin.
CAUTION:
Do not reuse retaining pin.

A

B

MT

SCIA0889E

10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install
retaining pin.
CAUTION:
Do not reuse retaining pin.
11. Install shift check sleeve.

D

E

F

G
SCIA0394E

12. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod
with inter lock pin.
13. Install stopper ring onto 3rd-4th shift fork.
CAUTION:
Do not stopper ring.
14. Install retaining pin onto 3rd-4th bracket.
CAUTION:
Do not reuse retaining pin.
15. Install 2 check balls.

H

I

J

SCIA0393E

16. Install 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod
with inter lock pin.
17. Install stopper ring onto 5th-6th bracket.
CAUTION:
Do not stopper ring.

L

M

SCIA0963E

18. Install retaining pin onto 5th-6th shift fork.
CAUTION:
Do not reuse retaining pin.
19. Install 2 check balls.
20. Install check ball, 5th-6th shift check sleeve, 5th-6th check
spring and 5th-6th check ball plug.
CAUTION:
● Do not reuse check ball plug.
● Do not drop check ball.
21. Install reverse bracket fork rod and reverse lever bracket.

MT-41

K

SCIA0962E

TRANSAXLE ASSEMBLY
22. Install retaining pin onto reverse bracket.
CAUTION:
Do not reuse retaining pin.
23. Install reverse shift fork and reverse fork rod.
24. Install reverse lever assembly following procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then
install them onto reverse shift fork.
CAUTION:
Do not drop shifter cap.
SCIA0961E

b.

While lifting reverse shift fork, align cam with reverse bracket.

SCIA0965E

c.

Tighten mounting bolts to specified torque, and then install
reverse lever assembly.
25. Install check ball, reverse shift check sleeve, reverse check
spring and reverse check ball plug.
CAUTION:
● Do not reuse check ball plug.
● Do not drop check ball.
26. Install the magnet onto clutch housing.
SCIA0960E

27. Using a drift, install differential oil seal until it is flush with end
face of transaxle case.
CAUTION:
Do not reuse oil seals.
28. Install selected input shaft adjusting shim onto input shaft.
● For selection of adjusting shims, refer toMT-49, "INPUT
SHAFT END PLAY" .
29. Install baffle plate and oil gutter.
30. Install transaxle case following procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
● For selection of adjusting shims, refer toMT-50, "MAINSHAFT END PLAY" .
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse the snap ring.

MT-42

SCIA0887E

TRANSAXLE ASSEMBLY
c.

Apply recommended sealant to mating surfaces of transaxle
case and clutch housing.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.

A

B

MT
SCIA0891E

D

d.

With snap ring of mainshaft rear bearing temporarily installed,
place transaxle case over clutch housing.
E

F

G
SCIA0892E

e.

f.

Through bore plug mounting hole, with snap ring stretched, and
lift up mainshaft assembly from the control assembly mounting
hole.
Securely install snap ring onto mainshaft rear bearing.

H

I

J

K

L

M

SCIA0893E

g.

Tighten mounting bolts.
Bolt A:
: 50.0 - 53.9 N·m (5.1 - 5.4 kg-m, 37 - 39 ft-lb)
Bolt B:
: 63.0 - 66.9 N·m (6.5 - 6.8 kg-m, 47 - 49 ft-lb)

h.

CAUTION:
Always replace bolts B as they are self-sealing bolts.
Install control assembly.

MT-43

SCIA1064E

TRANSAXLE ASSEMBLY
CAUTION:
Do not reuse the O-ring.
i. Install shift check and stopper bolt.
CAUTION:
Does not reuse shift check and stopper bolt.
31. Using a drift, install bore plug.
CAUTION:
Do not reuse bore plug.

SCIA0894E

32. Using a drift, install welch plug.
CAUTION:
Do not reuse welch plug.

SCIA0403E

33. Install 2 check balls, 2 check springs and 2 check ball plugs.
CAUTION:
Do not reuse check ball plug.

SCIA1667E

34. Apply recommended sealant to threads of neutral switch and
reverse lamp switch. Then install them into transaxle case.
35. Install gaskets onto drain plug and filler plug, and then install
them into transaxle case.
CAUTION:
● Do not reuse gasket.
● After oil is filled, tighten filler plug to specified torque.

SCIA0895E

MT-44

TRANSAXLE ASSEMBLY
Adjustment (RS5F51A)

ECS008C2

A

INPUT SHAFT END PLAY
●

●

When adjusting input shaft end play, select adjusting shim for
input shaft bearing. To select adjusting shim, measure clearance
between transaxle case and input shaft rear bearing.
Calculate dimension "O" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.

B

MT

End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension“O” = (O1 - O2 ) + End play
O:
Thickness of adjusting shim
O1 : Distance between transaxle case end face and
mounting face of adjusting shim
O2 : Distance between clutch housing case end
face and end face of input shaft rear bearing

D
SCIA1006E

E

Adjusting Shim

F

Shim thickness

Part number

Shim thickness

Part number

Shim thickness

Part number

0.40 mm (0.0157 in)
0.44 mm (0.0173 in)
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)

32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510
32225 8H511

0.88 mm (0.0346 in)
0.92 mm (0.0362 in)
0.96 mm (0.0378 in)
1.00 mm (0.0394 in)
1.04 mm (0.0409 in)
1.08 mm (0.0425 in)
1.12 mm (0.0441 in)
1.16 mm (0.0457 in)
1.20 mm (0.0472 in)
1.24 mm (0.0488 in)
1.28 mm (0.0504 in)
1.32 mm (0.0520 in)

32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521
32225 8H522
32225 8H523

1.36 mm (0.0535 in)
1.40 mm (0.0551 in)
1.44 mm (0.0567 in)
1.48 mm (0.0583 in)
1.52 mm (0.0598 in)
1.56 mm (0.0614 in)
1.60 mm (0.0630 in)
1.64 mm (0.0646 in)
1.68 mm (0.0661 in)
1.72 mm (0.0677 in)

32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566
32225 8H567
32225 8H568

H

I

J

CAUTION:
Only 1 adjusting shim can be selected.

1.

G

Using depth micrometer and straight edge, measure dimension
"O1 " between transaxle case end face and mounting face of
adjusting shim.

K

L

M

SCIA1002E

2.

3.

Using depth micrometer and straight edge as shown in the figure, measure dimension "O2 " between clutch housing case end
face and end face of input shaft rear bearing.
Install selected input shaft rear bearing adjusting shim onto input
shaft.

SCIA1004E

MT-45

TRANSAXLE ASSEMBLY
MAINSHAFT END PLAY
●

●

When adjusting mainshaft end play, select adjusting shim for
mainshaft rear bearing. To select adjusting shim, measure clearance “M” between transaxle case and mainshaft rear bearing.
Calculate dimension "P" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for mainshaft rear bearing.
End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension“P” = "M" + End play
P: Thickness of adjusting shim
M: Distance between mainshaft rear bearing and
transaxle case

SCIA0904E

Adjusting Shim
Shim thickness

Part number

0.44 mm (0.0173 in)
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)
0.96 mm (0.0378 in)
1.00 mm (0.0394 in)
1.04 mm (0.0409 in)
1.08 mm (0.0425 in)

32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561

CAUTION:
Only 1 adjusting shim can be selected.

1.
2.
3.
4.

Install mainshaft assembly to clutch housing.
Install snap ring to transaxle case.
Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install temporarily snap ring to mainshaft rear bearing.
Install dial gauge to snap ring access hole, and expand snap
ring. Lift mainshaft assembly through control assembly installation hole, and push it against transaxle case. This state shall be
defined as base. Moving distance of mainshaft assembly, with
snap ring fit on main bearing, becomes “M”.

SCIA1017E

MT-46

TRANSAXLE ASSEMBLY
DIFFERENTIAL SIDE BEARING PRELOAD
●

●

A

When adjusting differential side bearing preload, select adjusting shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race.
Calculate dimension “L” (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differential side bearing.
Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L1 - L2 ) + Preload
L:
Thickness of adjusting shim
Distance between clutch housing case end
L1
:
face and mounting face of adjusting shim
Distance between differential side bearing and
L2
:
transaxle case

B

MT

SCIA0896E

E

Adjusting Shim

F

Shim thickness

Part number

0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)

31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11

G

H

I

J

CAUTION:
Up to 2 adjusting shims can be selected.

1.

2.

D

Using depth micrometer and straightedge, measure dimension
"L1 " between clutch housing case end face and mounting face
of adjusting shim.
Install outer race onto differential side bearing on final gear side.
Holding lightly the outer race horizontally by hand, rotate final
gear five times or more (for smooth movement of bearing roller).

K

L

M
SCIA1078E

3.

Using depth micrometer and straightedge as shown in the figure, measure dimension "L2 " between differential side bearing
outer race and transaxle case end face.

SCIA1079E

MT-47

TRANSAXLE ASSEMBLY
4.

Install selected adjusting shim and then differential side bearing
outer race.

SCIA0898E

REVERSE IDLER GEAR END PLAY
●

●

When adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear.
Calculate dimension "Q" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)
Dimension“Q” = (Q1 - Q2 ) + End play
Q:
Thickness of adjusting shim
Q1 : Distance between transaxle case end face and
mounting face of adjusting shim
Q2 : Distance between clutch housing case end
face and end face of reverse idler gear

SCIA1007E

Adjusting Shim
Shim thickness

Part number

Shim thickness

Part number

1.76 mm (0.0693 in)
1.80 mm (0.0709 in)
1.84 mm (0.0724 in)
1.88 mm (0.0740 in)
1.92 mm (0.0756 in)
1.96 mm (0.0772 in)
2.00 mm (0.0787 in)
2.04 mm (0.0803 in)
2.08 mm (0.0819 in)
2.12 mm (0.0835 in)
2.16 mm (0.0850 in)
2.20 mm (0.0866 in)

32237 8H800
32237 8H801
32237 8H802
32237 8H803
32237 8H804
32237 8H805
32237 8H806
32237 8H807
32237 8H808
32237 8H809
32237 8H810
32237 8H811

2.24 mm (0.0882 in)
2.28 mm (0.0898 in)
2.32 mm (0.0913 in)
2.36 mm (0.0929 in)
2.40 mm (0.0945 in)
2.44 mm (0.0961 in)
2.48 mm (0.0976 in)
2.52 mm (0.0992 in)
2.56 mm (0.1008 in)
2.60 mm (0.1024 in)
2.64 mm (0.1039 in)

32237 8H812
32237 8H813
32237 8H814
32237 8H815
32237 8H816
32237 8H817
32237 8H818
32237 8H819
32237 8H820
32237 8H821
32237 8H822

CAUTION:
Only 1 adjusting shim can be selected.

1.

Using depth micrometer and straight edge, measure dimension
"Q1 " between transaxle case end face and mounting face of
adjusting shim.

SCIA1003E

MT-48

TRANSAXLE ASSEMBLY
2.

3.

Using depth micrometer and straight edge as shown in the figure, measure dimension "Q2 " between clutch housing case end
face and end face of reverse idler gear.
Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.

A

B

MT
SCIA1005E

D

Adjustment (RS6F51A)

ECS008C3

INPUT SHAFT END PLAY
●

●

E

When adjusting input shaft end play, select adjusting shim for
input shaft bearing. To select adjusting shim, measure clearance
between transaxle case and input shaft rear bearing.
Calculate dimension "O" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.

F

End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension“O” = (O1 - O2 ) + End play
O:
Thickness of adjusting shim
Distance between transaxle case end face and
O1
:
mounting face of adjusting shim
Distance between clutch housing case end
O2
:
face and end face of input shaft rear bearing

G

SCIA1001E

H

I

Adjusting Shim
Shim thickness

Part number

Shim thickness

Part number

Shim thickness

Part number

0.40 mm (0.0157 in)
0.44 mm (0.0173 in)
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)

32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510

0.84 mm (0.0331 in)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)
0.96 mm (0.0378 in)
1.00 mm (0.0394 in)
1.04 mm (0.0409 in)
1.08 mm (0.0425 in)
1.12 mm (0.0441 in)
1.16 mm (0.0457 in)
1.20 mm (0.0472 in)
1.24 mm (0.0488 in)

32225 8H511
32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521

1.28 mm (0.0504 in)
1.32 mm (0.0520 in)
1.36 mm (0.0535 in)
1.40 mm (0.0551 in)
1.44 mm (0.0567 in)
1.48 mm (0.0583 in)
1.52 mm (0.0598 in)
1.56 mm (0.0614 in)
1.60 mm (0.0630 in)
1.64 mm (0.0646 in)

32225 8H522
32225 8H523
32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566

CAUTION:
Only 1 adjusting shim can be selected.

1.

Using depth micrometer and straight edge, measure dimension
"O1 " between transaxle case end face and mounting face of
adjusting shim.

SCIA1002E

MT-49

J

K

L

M

TRANSAXLE ASSEMBLY
2.

3.

Using depth micrometer and straight edge as shown in the figure, measure dimension "O2 " between clutch housing case end
face and end face of input shaft rear bearing.
Install selected input shaft rear bearing adjusting shim onto input
shaft.

SCIA1004E

MAINSHAFT END PLAY
●

●

When adjusting mainshaft end play, select adjusting shim for
mainshaft rear bearing. To select adjusting shim, measure clearance “M” between transaxle case and mainshaft rear bearing.
Calculate dimension "P" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for mainshaft rear bearing.
End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension“P” = "M" + End play
P: Thickness of adjusting shim
M: Distance between mainshaft rear bearing and
transaxle case

SCIA0904E

Adjusting Shim
Shim thickness

Part number

0.44 mm (0.0173 in)
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)
0.96 mm (0.0378 in)
1.00 mm (0.0394 in)
1.04 mm (0.0409 in)
1.08 mm (0.0425 in)

32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561

CAUTION:
Only 1 adjusting shim can be selected.

1.
2.
3.

Install mainshaft assembly to clutch housing.
Install snap ring to transaxle case.
Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install temporarily snap ring to mainshaft rear bearing.

MT-50

TRANSAXLE ASSEMBLY
4.

Install dial gauge to snap ring access hole, and expand snap
ring. Lift mainshaft assembly through control assembly installation hole, and push it against transaxle case. This state shall be
defined as base. Moving distance of mainshaft assembly, with
snap ring fit on main bearing, becomes “M”.

A

B

MT
SCIA1017E

D

DIFFERENTIAL SIDE BEARING PRELOAD
●

●

When adjusting differential side bearing preload, select adjusting shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race.
Calculate dimension “L” (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differential side bearing.
Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L1 - L2 ) + Preload
L:
Thickness of adjusting shim
Distance between clutch housing case end
L1
:
face and mounting face of adjusting shim
Distance between differential side bearing and
L2
:
transaxle case

E

F

G
SCIA0896E

H

I

Adjusting Shim
Shim thickness

Part number

0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)

31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11

J

K

L

M

CAUTION:
Up to 2 adjusting shims can be selected.

1.

2.

Using depth micrometer and straightedge, measure dimension
"L1 " between clutch housing case end face and mounting face
of adjusting shim.
Install outer race onto differential side bearing on final gear side.
Holding lightly the outer race horizontally by hand, rotate final
gear five times or more (for smooth movement of bearing roller).

SCIA1078E

MT-51

TRANSAXLE ASSEMBLY
3.

Using depth micrometer and straightedge as shown in the figure, measure dimension "L2 " between differential side bearing
outer race and transaxle case end face.

SCIA1079E

4.

Install selected adjusting shim and then differential side bearing
outer race.

SCIA0898E

REVERSE IDLER GEAR END PLAY
●

●

When adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear.
Calculate dimension "Q" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)
Dimension“Q” = (Q1 - Q2 ) + End play
Q:
Thickness of adjusting shim
Q1 : Distance between transaxle case end face and
mounting face of adjusting shim
Q2 : Distance between clutch housing case end
face and end face of reverse idler gear

SCIA1007E

Adjusting Shim
Shim thickness

Part number

Shim thickness

Part number

1.76 mm (0.0693 in)
1.80 mm (0.0709 in)
1.84 mm (0.0724 in)
1.88 mm (0.0740 in)
1.92 mm (0.0756 in)
1.96 mm (0.0772 in)
2.00 mm (0.0787 in)
2.04 mm (0.0803 in)
2.08 mm (0.0819 in)
2.12 mm (0.0835 in)
2.16 mm (0.0850 in)
2.20 mm (0.0866 in)

32237 8H800
32237 8H801
32237 8H802
32237 8H803
32237 8H804
32237 8H805
32237 8H806
32237 8H807
32237 8H808
32237 8H809
32237 8H810
32237 8H811

2.24 mm (0.0882 in)
2.28 mm (0.0898 in)
2.32 mm (0.0913 in)
2.36 mm (0.0929 in)
2.40 mm (0.0945 in)
2.44 mm (0.0961 in)
2.48 mm (0.0976 in)
2.52 mm (0.0992 in)
2.56 mm (0.1008 in)
2.60 mm (0.1024 in)
2.64 mm (0.1039 in)

32237 8H812
32237 8H813
32237 8H814
32237 8H815
32237 8H816
32237 8H817
32237 8H818
32237 8H819
32237 8H820
32237 8H821
32237 8H822

CAUTION:
Only 1 adjusting shim can be selected.

MT-52

TRANSAXLE ASSEMBLY
1.

Using depth micrometer and straight edge, measure dimension
"Q1 " between transaxle case end face and mounting face of
adjusting shim.

A

B

MT
SCIA1003E

D

2.

3.

Using depth micrometer and straight edge as shown in the figure, measure dimension "Q2 " between clutch housing case end
face and end face of reverse idler gear.
Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.

E

F

G
SCIA1005E

H

I

J

K

L

M

MT-53

INPUT SHAFT AND GEARS
INPUT SHAFT AND GEARS
Assembly and Disassembly (RS5F51A)

PFP:32200
ECS008C4

DISASSEMBLY
1.

Before disassembling, measure end play for 3rd, 4th, and 5th
input gears.
End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

2.

Remove oil channel.
SCIA0914E

3.

Remove input shaft rear bearing.

SCIA0915E

4.

Remove the snap ring.

SCIA0916E

5.

Remove input shaft bearing spacer and 5th stopper simultaneously.

SCIA0917E

MT-54

INPUT SHAFT AND GEARS
6.
7.

Remove 5th input gear and synchronizer hub assembly simultaneously.
Remove 5th needle bearing.

A

B

MT
SCIA0918E

D

8.

9.

Remove 5th bushing, thrust washer, 4th input gear, 4th needle
bearing, 4th gear bushing, 3rd-4th synchronizer hub assembly,
3rd-4th baulk ring and 3rd input gear simultaneously.
Remove 3rd needle bearing.

E

F

G
SCIA0919E

10. Remove input shaft front bearing.

H

I

J

SCIA0920E

K

INSPECTION AFTER DISASSEMBLY
Input Shaft and Gears
L

Check items below. If necessary, replace them with new ones.
●
Damage, peeling, dent, uneven wear, bending, etc. of shaft
●
Excessive wear, damage, peeling, etc. of gears

M

SCIA1073J

MT-55

INPUT SHAFT AND GEARS
Synchronizer
Check items below. If necessary, replace them with new ones.
●
Damage and excessive wear of contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert
●
Coupling sleeve and synchronizer hub must move smoothly.

SMT387A

●

If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.

SMT867D

Baulk ring clearance
●
Press baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it
with a new one.
Clearance
Standard
3rd and 4th
5th
Limit value

: 0.9 - 1.45 mm (0.0354 - 0.0571 in)
: 0.95 - 1.4 mm (0.0374 - 0.0551 in)
: 0.7 mm (0.0276 in)
SMT140

Bearing
Check items below. If necessary, replace them with new ones.
●
Damage and rough rotation of bearing

MTF0041D

MT-56

INPUT SHAFT AND GEARS
ASSEMBLY
1.
2.
3.

A

Install 3rd needle bearing.
Install 3rd input gear and 3rd baulk ring.
Install spread spring, shifting insert and 3rd-4th synchronizer hub onto 3rd-4th coupling sleeve.
CAUTION:
● Be careful with orientation of synchronizer hub.
● Do not reuse 3rd-4th synchronizer hub.

B

MT

D

E
SCIA0921E

●

Be careful with orientation of coupling sleeve.

F

G

H

SCIA0993E

●

Be sure not to hook center projection of 2 spread springs
on same shifting insert.

I

J

K

L
SCIA1083E

4.

M

Install 3rd-4th synchronizer hub assembly.
CAUTION:
Align grooves of shifting insert and 3rd baulk ring.

SCIA0922E

MT-57

INPUT SHAFT AND GEARS
5.
6.
7.

Install 4th bushing.
Install 4th baulk ring.
Install 4th input gear and 4th needle bearing.

SCIA0923E

8.

Select thrust washer so that dimension “C2” satisfies standard
below. Then install it onto input shaft.
Standard for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)

SCIA0925E

Thrust Washer
Thickness

Part number

Thickness

Part number

3.84mm (0.1512 in)
3.90mm (0.1535 in)
3.96mm (0.1559 in)

32347 8H500
32347 8H501
32347 8H502

4.02mm (0.1583 in)
4.08mm (0.1606 in)
4.14mm (0.1630 in)

32347 8H503
32347 8H504
32347 8H505

CAUTION:
Only one thrust washer can be selected.

9. Install 5th bushing.
10. Install 5th needle bearing and 5th input gear.
11. Install 5th baulk ring.

SCIA0926E

12. Install spread spring, shifting insert and 5th synchronizer hub onto 5th coupling sleeve.

MT-58

INPUT SHAFT AND GEARS
CAUTION:
● Be careful with orientation of synchronizer hub and shifting insert.

A

B

MT

SCIA0927E

●

D

Be careful with orientation of coupling sleeve.
E

F

G
SCIA0994E

●

H

Be sure not to hook center projection of 2 spread springs
on same shifting insert.

I

J

K
SCIA1083E

13. Install 5th synchronizer hub assembly.
CAUTION:
Align grooves of 5th shifting insert and 5th baulk ring.

L

M

SCIA0928E

MT-59

INPUT SHAFT AND GEARS
14. Install 5th stopper and then input shaft bearing spacer.

SCIA0929E

15. Install snap ring onto input shaft, and check that end play (gap
between snap ring and groove) of input shaft bearing spacer
satisfies standard.
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
●

If measurement is outside the standard range, select snap
ring.

SCIA0930E

Snap Rings
Thickness

Part number

Thickness

Part number

1.71mm (0.0673 in)
1.76mm (0.0693 in)
1.81mm (0.0713 in)
1.86mm (0.0732 in)
1.91mm (0.0752 in)
1.96mm (0.0772 in)

32204 8H510
32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515

2.01mm (0.0791 in)
2.06mm (0.0811 in)
2.11mm (0.0831 in)
2.16mm (0.0850 in)
2.21mm (0.0870 in)
2.26mm (0.0890 in)

32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
32204 8H521

16. Install input shaft rear bearing.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the input gear side.

SCIA0931E

17. Install input shaft front bearing.
18. Install oil channel onto input shaft.

SCIA0932E

MT-60

INPUT SHAFT AND GEARS
19. Check end play of 3rd, 4th, and 5th input gears.
A

End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

B

MT
SCIA0914E

Assembly and Disassembly (RS6F51A)

D
ECS008C5

DISASSEMBLY
1.

Before disassembling, measure end play for 3rd, 4th, 5th and
6th input gears.

E

End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
2.

F

G

Remove oil channel.
SCIA0966E

3.
4.

H

Remove input shaft rear bearing.
Remove the snap ring.
I

J

K
SCIA0967E

5.
6.

Remove 6th input gear, 6th bushing and 6th needle bearing.
Remove 6th baulk ring, 5th-6th coupling sleeve and shifting
insert.

L

M

SCIA0968E

MT-61

INPUT SHAFT AND GEARS
7.
8.

Remove 5th input gear and 5th synchronizer hub assembly
simultaneously.
Remove 5th needle bearing.

SCIA0918E

9.

Remove 5th bushing, thrust washer, 4th input gear, 4th needle
bearing, 4th gear bushing, 3rd-4th synchronizer hub assembly,
3rd-4th baulk ring and 3rd input gear simultaneously.
10. Remove 3rd needle bearing.

SCIA0919E

11. Remove input shaft front bearing.

SCIA0920E

INSPECTION AFTER DISASSEMBLY
Input Shaft and Gears
Check items below. If necessary, replace them with new ones.
●
Damage, peeling, dent, uneven wear, bending, etc. of shaft
●
Excessive wear, damage, peeling, etc. of gears

SCIA1074J

MT-62

INPUT SHAFT AND GEARS
Synchronizer
A

Check items below. If necessary, replace them with new ones.
●
Damage and excessive wear of contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert
●
Coupling sleeve and synchronizer hub must move smoothly.

B

MT

SMT387A

●

If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.

D

E

F

G
SMT867D

H

Baulk ring clearance
●
Press baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it
with a new one.

I

Clearance
Standard
3rd and 4th : 0.9 - 1.45 mm (0.0354 - 0.0571 in)
5th and 6th : 0.95 - 1.4 mm (0.0374 - 0.0551 in)
Limit value
: 0.7 mm (0.0276 in)

J

K
SMT140

L

Bearing
Check items below. If necessary, replace them with new ones.
●
Damage and rough rotation of bearing

M

MTF0041D

MT-63

INPUT SHAFT AND GEARS
ASSEMBLY
1.
2.
3.

Install 3rd needle bearing.
Install 3rd input gear and 3rd baulk ring.
Install spread spring, shifting insert and 3rd-4th synchronizer hub onto 3rd-4th coupling sleeve.
CAUTION:
● Be careful with orientation of synchronizer hub.
● Do not reuse 3rd-4th synchronizer hub.

SCIA0921E

●

Be careful with orientation of coupling sleeve.

SCIA0993E

●

Be sure not to hook center projection of 2 spread springs
on same shifting insert.

SCIA1083E

4.

Install 3rd-4th synchronizer hub assembly.
CAUTION:
Align grooves of shifting insert and 3rd baulk ring.

SCIA0922E

MT-64

INPUT SHAFT AND GEARS
5.
6.
7.

Install 4th bushing.
Install 4th baulk ring.
Install 4th input gear and 4th needle bearing.

A

B

MT
SCIA0923E

D

8.

Select thrust washer so that dimension “C2” satisfies standard
below. Then install it onto input shaft.
Standard for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)

E

F

G

H

I

J

SCIA0925E

Thrust Washer
Thickness

Part number

Thickness

Part number

3.84mm (0.1512 in)
3.90mm (0.1535 in)
3.96mm (0.1559 in)

32347 8H500
32347 8H501
32347 8H502

4.02mm (0.1583 in)
4.08mm (0.1606 in)
4.14mm (0.1630 in)

32347 8H503
32347 8H504
32347 8H505

K

L

CAUTION:
Only one thrust washer can be selected.

M

9. Install 5th bushing.
10. Install 5th needle bearing and 5th input gear.
11. Install 5th baulk ring.

SCIA0926E

12. Install 5th-6th synchronizer hub, spread spring and shifting insert onto 5th-6th coupling sleeve.

MT-65

INPUT SHAFT AND GEARS
CAUTION:
● Be careful with orientation of synchronizer hub.
● Do not reuse 5th-6th synchronizer hub.

SCIA0921E

●

Be sure not to hook center projection of 2 spread springs
on same shifting insert.

SCIA1083E

13. Install 5th-6th synchronizer hub assembly.
CAUTION:
Align grooves of 5th-6th shifting insert and 5th-6th baulk
ring.

SCIA0928E

14. Install 6th needle bearing, 6th input gear onto 6th bushing, and
then install them onto input shaft.

SCIA0969E

MT-66

INPUT SHAFT AND GEARS
15. Install snap ring onto input shaft, and check that end play (gap
between snap ring and groove) of 6th bushing satisfies standard.
End play standard value
●

A

: 0 - 0.1 mm (0 - 0.004 in)
B

If measurement is outside the standard range, select snap
ring.

MT
SCIA0970E

D

Snap Rings
Thickness

Part number

Thickness

Part number

1.76 mm (0.0693 in)
1.81 mm (0.0713 in)
1.86 mm (0.0732 in)
1.91 mm (0.0752 in)
1.96 mm (0.0772 in)

32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515

2.01 mm (0.0791 in)
2.06 mm (0.0811 in)
2.11 mm (0.0831 in)
2.16 mm (0.0850 in)
2.21 mm (0.0870 in)

32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520

E

F

16. Install input shaft rear bearing.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the 6th input gear side.

G

H

I
SCIA0971E

J

17. Install input shaft front bearing.
18. Install oil channel onto input shaft.

K

L

M
SCIA0972E

19. Check end play of 3rd, 4th, 5th and 6th input gears.
End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

SCIA0966E

MT-67

MAINSHAFT AND GEARS
MAINSHAFT AND GEARS
Assembly and Disassembly (RS5F51A)

PFP:32241
ECS008C6

DISASSEMBLY
1.

Before disassembling, measure end play of 1st and 2nd main
gears.
End play standard value
1st gear
: 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear
: 0.06 - 0.16 mm (0.0024 - 0.0063 in)

SCIA0933E

2.
3.

Remove the snap ring.
Remove C-ring holder, and then mainshaft C-ring.

SCIA0934E

4.

Remove mainshaft rear bearing.

SCIA0935E

5.

Remove the snap ring.

SCIA0936E

MT-68

MAINSHAFT AND GEARS
6.
7.
8.

Remove 4th main gear and 5th main gear simultaneously.
Remove adjusting shim.
Remove 3rd-4th mainshaft spacer.

A

B

MT
SCIA0937E

D

9.

Remove 3rd main gear, 2nd main gear, 2nd gear needle bearing, 2nd bushing, 1st-2nd synchronizer hub assembly, 1st main
gear, reverse main gear, 1st gear needle bearing, and 1st bushing simultaneously.

E

F

G
SCIA0938E

INSPECTION AFTER DISASSEMBLY
Mainshaft and Gears

H

Check items below. If necessary, replace them with new ones.
●
Damage, peeling, dent, uneven wear, bending, and other nonstandard conditions of the shaft.
●
Excessive wear, damage, peeling, and other non-standard conditions of the gears.

I

J

K
SCIA1075J

L

M

MT-69

MAINSHAFT AND GEARS
Synchronizer
Check items below. If necessary, replace them with new ones.
●
Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert.
●
Coupling sleeve and synchronizer hub must move smoothly.

SMT387A

●

If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.

SMT867D

Baulk ring clearance
●
Double cone synchronizer (1st and 2nd)
Check clearance of outer baulk ring, synchronizer cone, and
inner baulk ring of 1st and 2nd double cone synchronizers, following procedure below.
CAUTION:
Outer baulk ring, synchronizer cone, and inner baulk ring
as a set control clearance A and B. If measurement exceeds
service limit value, replace all of them as a set.

SCIA0950E

1.

Using a dial gauge, measure clearance A at 2 or more points
diagonally opposite, and calculate mean value.
Clearance A
Standard
Limit value

: 0.6 - 0.8 mm (0.024 - 0.031 in)
: 0.2 mm (0.008 in) or less

SCIA0951E

MT-70

MAINSHAFT AND GEARS
2.

Using a feeler gauge, measure clearance B at 2 or more points
diagonally opposite, and calculate mean value.
Clearance B
Standard
Limit value

A

: 0.6 - 1.1 mm (0.024 - 0.043 in)
: 0.2 mm (0.008 in) or less

B

MT
SCIA1084E

D

Bearing
Check items below. If necessary, replace them with new ones.
●
Damage and rough rotation of bearing

E

F

G
MTF0041D

ASSEMBLY
1.

H

Install reverse main gear.
I

J

K
SCIA0939E

L

CAUTION:
Be careful with orientation of reverse main gear.

M

SCIA0992E

MT-71

MAINSHAFT AND GEARS
2.
3.

Install 1st bushing.
Install needle bearing, and then 1st main gear.

SCIA0940E

4.

Install spread spring, shifting insert and 1st-2nd synchronizer hub onto 1st-2nd coupling sleeve.
CAUTION:
● Be careful with orientation of synchronizer hub.
● Do not reuse 1st-2nd synchronizer hub.

SCIA0921E

●

Be careful with orientation of coupling sleeve.

SCIA0989E

●

Be sure not to hook center projection of 2 spread springs
on same shifting insert.

SCIA1083E

MT-72

MAINSHAFT AND GEARS
5.

Install 1st gear synchronizer assembly onto mainshaft, and synchronizer hub assembly onto mainshaft.
CAUTION:
● Outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side must have been removed.
● Be careful with orientation of coupling sleeve.

A

B

MT
SCIA0941E

D

6.
7.
8.

Install 2nd bushing.
Install outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side.
Install 2nd needle bearing and 2nd gear.

E

F

G
SCIA0942E

9.

Install 3rd main gear.
CAUTION:
Be careful with orientation of 3rd main gear.
10. Install 3rd-4th mainshaft spacer.

H

I

J

SCIA0943E

K

11. Select suitable adjusting shim so that dimension “C1” satisfies
standard value below, and install it onto mainshaft.
L

Standard for dimension C1
: 173.85 - 173.95 mm (6.844 - 6.848 in)

M

SCIA0944E

MT-73

MAINSHAFT AND GEARS
Adjusting Shim
Thickness

Part number

Thickness

Part number

0.52 mm (0.0205 in)
0.60 mm (0.0236 in)
0.68 mm (0.0268 in)
0.76 mm (0.0299 in)

32238 8H500
32238 8H501
32238 8H502
32238 8H503

0.84 mm (0.0331 in)
0.92 mm (0.0362 in)
1.00 mm (0.0394 in)
1.08 mm (0.0425 in)

32238 8H504
32238 8H505
32238 8H506
32238 8H507

CAUTION:
Only one adjusting shim can be selected.

12. Install 4th main gear.
CAUTION:
Be careful with orientation of 4th main gear.

SCIA0945E

13. Install 5th main gear.
CAUTION:
Be careful with orientation of 5th main gear.

SCIA0946E

14. Install snap ring onto mainshaft, and check that end play of 5th
main gear satisfies standard value.
End play standard value
●

: 0 - 0.1 mm (0 - 0.004 in)

If measurement is outside the standard range, reselect snap
ring.

SCIA0947E

Snap Rings
Thickness

Part number

Thickness

Part number

1.85 mm (0.0728 in)
1.90 mm (0.0748 in)
1.95 mm (0.0768 in)
2.00 mm (0.0787 in)

32204 8H500
32204 8H501
32204 8H502
32204 8H503

2.05 mm (0.0807 in)
2.10 mm (0.0827 in)
2.15 mm (0.0846 in)
2.20 mm (0.0866 in)

32204 8H504
32204 8H505
32204 8H506
32204 8H507

MT-74

MAINSHAFT AND GEARS
15. Install mainshaft rear bearing.
A

B

MT
SCIA0948E

D

16. Install C-ring onto mainshaft, and check that end play of mainshaft rear bearing satisfies standard value.
End play standard value
●

: 0 - 0.06 mm (0 - 0.0024 in)

E

If measurement is outside the standard range, reselect C-ring.
F

G
SCIA0949E

C-ring
Thickness

Part number

Thickness

Part number

2.535 mm (0.0866 in)
2.565 mm (0.1010 in)
2.595 mm (0.1022 in)
2.625 mm (0.1033 in)
2.655 mm (0.1045 in)
2.685 mm (0.1057 in)
2.715 mm (0.1069 in)
2.745 mm (0.1081 in)
2.775 mm (0.1093 in)
2.805 mm (0.1104 in)

32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H809

2.835 mm (0.1116 in)
2.865 mm (0.1128 in)
2.895 mm (0.1140 in)
2.925 mm (0.1152 in)
2.955 mm (0.1163 in)
2.985 mm (0.1175 in)
3.015 mm (0.1187 in)
3.045 mm (0.1199 in)
3.075 mm (0.1211 in)

32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818

H

I

J

K

17. Fit C-ring holder, and install snap ring.
18. Check end play of 1st and 2nd main gears.
L

End play standard value
1st gear
: 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear
: 0.06 - 0.16 mm (0.0024 - 0.0063 in)

M

SCIA0934E

MT-75

MAINSHAFT AND GEARS
Assembly and Disassembly (RS6F51A)

ECS008C7

DISASSEMBLY
1.

Before disassembling, measure end play of 1st and 2nd main
gears.
End play standard value
1st gear
: 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear
: 0.06 - 0.16 mm (0.0024 - 0.0063 in)

SCIA0973E

2.
3.

Remove the snap ring.
Remove C-ring holder, and then mainshaft C-ring.

SCIA0974E

4.
5.

Remove mainshaft rear bearing, adjust shim and 6th main gear.
Remove 5th-6th mainshaft spacer.

SCIA0976E

6.
7.
8.

Remove 4th main gear and 5th main gear simultaneously.
Remove adjusting shim.
Remove 3rd & 4th mainshaft spacer.

SCIA0937E

MT-76

MAINSHAFT AND GEARS
9.

Remove 3rd main gear, 2nd main gear, 2nd gear needle bearing, 2nd bushing, 1st-2nd synchronizer hub assembly, 1st main
gear, reverse main gear, 1st gear needle bearing, and 1st bushing simultaneously.

A

B

MT
SCIA0938E

D

INSPECTION AFTER DISASSEMBLY
Mainshaft and Gears
Check items below. If necessary, replace them with new ones.
●
Damage, peeling, dent, uneven wear, bending, and other nonstandard conditions of the shaft.
●
Excessive wear, damage, peeling, and other non-standard conditions of the gears.

E

F

G

SCIA1076J

H

Synchronizer
Check items below. If necessary, replace them with new ones.
●
Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert.
●
Coupling sleeve and synchronizer hub must move smoothly.

I

J

K

SMT387A

●

L

If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
M

SMT867D

MT-77

MAINSHAFT AND GEARS
Baulk ring clearance
●
Double cone synchronizer (1st and 2nd)
Check clearance of outer baulk ring, synchronizer cone, and
inner baulk ring of 1st and 2nd double cone synchronizers, following procedure below.
CAUTION:
Outer baulk ring, synchronizer cone, and inner baulk ring
as a set control clearance A and B. If measurement exceeds
service limit value, replace all of them as a set.

SCIA0950E

1.

Using a dial gauge, measure clearance A at 2 or more points
diagonally opposite, and calculate mean value.
Clearance A
Standard
Limit value

: 0.6 - 0.8 mm (0.024 - 0.031 in)
: 0.2 mm (0.008 in) or less

SCIA0951E

2.

Using a feeler gauge, measure clearance B at 2 or more points
diagonally opposite, and calculate mean value.
Clearance B
Standard
Limit value

: 0.6 - 1.1 mm (0.024 - 0.043 in)
: 0.2 mm (0.008 in) or less

SCIA1084E

Bearing
Check items below. If necessary, replace them with new ones.
●
Damage and rough rotation of bearing

MTF0041D

MT-78

MAINSHAFT AND GEARS
ASSEMBLY
1.

A

Install reverse main gear.

B

MT

SCIA0939E

CAUTION:
Be careful with orientation of reverse main gear.

D

E

F

G

SCIA0992E

2.
3.

Install 1st bushing.
Install needle bearing, and then 1st main gear.

H

I

J

K
SCIA0940E

4.

L

Install spread spring, shifting insert and 1st-2nd synchronizer hub onto 1st-2nd coupling sleeve.
CAUTION:
● Be careful with orientation of synchronizer hub.
● Do not reuse 1st-2nd synchronizer hub.

M

SCIA0921E

MT-79

MAINSHAFT AND GEARS
●

Be careful with orientation of coupling sleeve.

SCIA0989E

●

Be sure not to hook center projection of 2 spread springs
on same shifting insert.

SCIA1083E

5.

Install 1st gear synchronizer assembly onto mainshaft, and synchronizer hub assembly onto mainshaft.
CAUTION:
● Outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side must have been removed.
● Be careful with orientation of coupling sleeve.

SCIA0941E

6.
7.
8.

Install 2nd bushing.
Install outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side.
Install 2nd needle bearing and 2nd gear.

SCIA0942E

9.

Install 3rd main gear.
CAUTION:
Be careful with orientation of 3rd main gear.
10. Install 3rd-4th mainshaft spacer.

SCIA0943E

MT-80

MAINSHAFT AND GEARS
11. Select suitable adjusting shim so that dimension “C1” satisfies
standard value below, and install it onto mainshaft.

A

Standard for dimension C1
: 173.85 - 173.95 mm (6.844 - 6.848 in)

B

MT

D

E

F

G
SCIA0944E

Adjusting Shim
Thickness

Part number

Thickness

Part number

0.52 mm (0.0205 in)
0.60 mm (0.0236 in)
0.68 mm (0.0268 in)
0.76 mm (0.0299 in)

32238 8H500
32238 8H501
32238 8H502
32238 8H503

0.84 mm (0.0331 in)
0.92 mm (0.0362 in)
1.00 mm (0.0394 in)
1.08 mm (0.0425 in)

32238 8H504
32238 8H505
32238 8H506
32238 8H507

H

I

CAUTION:
Only one adjusting shim can be selected.

J

12. Install 4th main gear.
CAUTION:
Be careful with orientation of 4th main gear.

K

L

M
SCIA0945E

13. Install 5th main gear.
CAUTION:
Be careful with orientation of 5th main gear.
14. Install 5th-6th mainshaft spacer.

SCIA0946E

MT-81

MAINSHAFT AND GEARS
15. Install 6th main gear.

SCIA0977E

16. Select 6th main adjusting shim and then install it onto mainshaft.
● Calculate thickness “S” of 6th main adjusting shim by procedure below so that end play dimension between 6th main
gear and mainshaft rear bearing becomes the dimension
shown below.
End play: 0 - 0.1 mm (0 - 0.004 in)
Dimension“S” = (S1 - S2 ) + End play
S:
Thickness of adjusting shim
S1 : Dimension from mainshaft standard face to
mainshaft rear bearing press-fit end face
S2 : Dimension from mainshaft standard face to
6th main gear end face

SCIA0995E

Adjusting Shim
Thickness

Part number

Thickness

Part number

0.88 mm (0.0346 in)
0.96 mm (0.0378 in)
1.04 mm (0.0409 in)
1.12 mm (0.0441 in)

32237 8H560
32237 8H561
32237 8H562
32237 8H563

1.20 mm (0.0472 in)
1.28 mm (0.0504 in)
1.36 mm (0.0535 in)

32237 8H564
32237 8H565
32237 8H566

CAUTION:
Only one adjusting shim can be selected.

a. Using height gauge, measure dimension “S1 ” and “S2 ”.
b. Install selected 6th main adjusting shim to mainshaft.
17. Install mainshaft rear bearing.

SCIA0978E

MT-82

MAINSHAFT AND GEARS
18. Install C-ring onto mainshaft, and check that end play of mainshaft rear bearing satisfies standard value.
End play standard value
●

A

: 0 - 0.06 mm (0 - 0.0024 in)

If measurement is outside the standard range, reselect C-ring.

B

MT
SCIA0979E

D

C-ring
Thickness

Part number

Thickness

Part number

2.535 mm (0.0998 in)
2.565 mm (0.1010 in)
2.595 mm (0.1022 in)
2.625 mm (0.1033 in)
2.655 mm (0.1045 in)
2.685 mm (0.1057 in)
2.715 mm (0.1069 in)
2.745 mm (0.1081 in)
2.775 mm (0.1093 in)
2.805 mm (0.1104 in)

32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H809

2.835 mm (0.1116 in)
2.865 mm (0.1128 in)
2.895 mm (0.1140 in)
2.925 mm (0.1152 in)
2.955 mm (0.1163 in)
2.985 mm (0.1175 in)
3.015 mm (0.1187 in)
3.045 mm (0.1199 in)
3.075 mm (0.1211 in)

32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818

E

F

G

19. Fit C-ring holder, and install snap ring.

H

I

J

SCIA0974E

K

20. Check end play of 1st and 2nd main gears.
End play standard value
1st gear
: 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear
: 0.06 - 0.16 mm (0.0024 - 0.0063 in)

L

M

SCIA0973E

MT-83

REVERSE IDLER SHAFT AND GEARS
REVERSE IDLER SHAFT AND GEARS
Assembly and Disassembly (RS5F51A)

PFP:32281
ECS008C8

DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.

Remove reverse idler gear adjusting shim.
Remove reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
Remove reverse idler gear needle bearing.
Remove thrust needle bearing.
Remove reverse baulk ring.
Remove reverse idler gear (front).
Remove reverse idler gear needle bearing.
Remove thrust needle bearing.
Pull off locking pin from reverse idler shaft.

INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft and Gears
Check items below. If necessary, replace them with new ones.
●
Damage, peeling, dent, uneven wear, bending, and other nonstandard conditions of the shaft.
●
Excessive wear, damage, peeling, and other non-standard conditions of the gears.

SCIA0953J

Synchronizer
Check items below. If necessary, replace them with new ones.
●
Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and insert spring.
●
Coupling sleeve and synchronizer hub must move smoothly.

SMT637A

●

If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.

SMT867D

MT-84

REVERSE IDLER SHAFT AND GEARS
Baulk ring clearance
●
Press baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it
with a new one.
Clearance
Standard
Limit value

A

B

: 0.95 - 1.4 mm (0.0374 - 0.0551 in)
: 0.7 mm (0.0276 in)

MT

SMT140

D

Bearing
Check items below. If necessary, replace them with new ones.
●
Damage and rough rotation of bearing.

E

ASSEMBLY
F

Paying attention to following work, assemble in reverse order of disassembly.
CAUTION:
●
Be careful with orientation of insert spring.

G

H

I
SCIA0954E

Assembly and Disassembly (RS6F51A)

J
ECS008C9

DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.

Remove reverse idler gear adjusting shim.
Remove reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
Remove reverse idler gear needle bearing.
Remove thrust needle bearing.
Remove reverse baulk ring.
Remove reverse idler gear (front).
Remove reverse idler gear needle bearing.
Remove thrust needle bearing.
Pull off locking pin from reverse idler shaft.

K

L

M

INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft and Gears
Check items below. If necessary, replace them with new ones.
●
Damage, peeling, dent, uneven wear, bending, and other nonstandard conditions of the shaft.
●
Excessive wear, damage, peeling, and other non-standard conditions of the gears.

SCIA0953J

MT-85

REVERSE IDLER SHAFT AND GEARS
Synchronizer
Check items below. If necessary, replace them with new ones.
●
Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and insert spring.
●
Coupling sleeve and synchronizer hub must move smoothly.

SMT637A

●

If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.

SMT867D

Baulk ring clearance
●
Press baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it
with a new one.
Clearance
Standard
Limit value

: 0.95 - 1.4 mm (0.0374 - 0.0551 in)
: 0.7 mm (0.0276 in)

SMT140

Bearing
Check items below. If necessary, replace them with new ones.
●
Damage and rough rotation of bearing.

ASSEMBLY
Paying attention to following work, assemble in reverse order of disassembly.
CAUTION:
●
Be careful with orientation of insert spring.

SCIA0954E

MT-86

FINAL DRIVE
FINAL DRIVE
Assembly and Disassembly (RS5F51A)

PFP:38411

A
ECS008CA

PRE-INSPECTION
●

1.

Check the clearance between side gear and differential case as
follows.
Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.

B

MT

D

SCIA1020E

2.
3.

Upright the differential case so that the side gear to be measured faces upward.
Place final drive adapter and dial indicator onto side gear. Move
side gear up and down, and measure the clearance.

F

Clearance between side gear and differential case
: 0.1 - 0.2 mm (0.004 - 0.008 in)

4.
5.

CAUTION:
There should be no resistance and gears should rotate
freely.
If not within specification, adjust the clearance by changing
thrust washer thickness.
Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.

G

H

SMT611A

DISASSEMBLY
1.
2.

E

I

J

Remove mounting bolts.Then, separate the final gear from differential case.
Using a drift and puller, remove differential side bearing (clutch
housing side).

K

L

M
SCIA0906E

3.

Using a drift and puller, remove differential side bearing (transaxle case side).

SCIA0907E

MT-87

FINAL DRIVE
4.
5.

Using a pin punch, pull out lock pin and pinion mate shaft.
Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.

SCIA0908E

INSPECTION AFTER DISASSEMBLY
Gear, Washer, Shaft and Case
●

Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.

MTK0135D

Bearing
Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
●

SPD715

ASSEMBLY
1.
2.
3.

Apply gear oil to sliding area of differential case, each gear, and thrust washer.
Install side gear thrust washers and side gears into differential
case.
While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.

SMT839

MT-88

FINAL DRIVE
4.

Insert pinion mate shaft into differential case.
CAUTION:
Be sure not to damage pinion mate thrust washers.

A

B

MT
MTK0132D

D

5.
a.
b.

Measure end play of side gears following procedure below.
Then select side gear thrust washer.
Upright the differential case so that its side gear to be measured
face upward.
Place final drive adapter and dial indicator onto side gears.

E

F

G
SCIA1020E

c.

Move side gears up and down to measure end play, and select
thrust washer so that it satisfies standard.

H

End play standard value
: 0.1 - 0.2 mm (0.004 - 0.008 in)

I

CAUTION:
● There should be no resistance and gears should rotate
freely.
● Place differential case upside down. Be sure to measure
end play for opposite side-gears likewise.

J

SMT611A

K

Thrust washer
Thickness

Part number

0.75 mm (0.0295 in)
0.80 mm (0.0315 in)
0.85 mm (0.0335 in)
0.90 mm (0.0354 in)
0.95 mm (0.0374 in)

38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04

L

M

CAUTION:
Only one thrust washer can be selected.

6.

Using a pin punch, drive a lock pin into the pinion mate shaft.
CAUTION:
Do not reuse the lock pin.

SCIA0908E

MT-89

FINAL DRIVE
7.

Using a drift (special service tool), install differential side bearing
(transaxle case side).

SCIA0910E

8.

Using a drift (special service tool), install differential side bearing
(clutch housing side).

SCIA0911E

9.

Install final gear into differential case, and tighten final gear
mounting bolts.

SCIA0912E

Assembly and Disassembly (RS6F51A)

ECS008CB

PRE-INSPECTION
●

1.

Check the clearance between side gear and differential case as
follows.
Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.

SCIA1020E

2.

Upright the differential case so that the side gear to be measured faces upward.

MT-90

FINAL DRIVE
3.

Place final drive adapter and dial indicator onto side gear. Move
side gear up and down, and measure the clearance.

A

Clearance between side gear and differential case
: 0.1 - 0.2 mm (0.004 - 0.008 in)

4.
5.

CAUTION:
There should be no resistance and gears should rotate
freely.
If not within specification, adjust the clearance by changing
thrust washer thickness.
Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.

B

MT
SMT611A

D

DISASSEMBLY
1.
2.

E

Remove mounting bolts.Then, separate the final gear from differential case.
Using a drift and puller, remove differential side bearing (clutch
housing side).

F

G

H
SCIA0906E

3.

I

Using a drift and puller, remove differential side bearing (transaxle case side).

J

K

L
SCIA0907E

4.
5.

Using a pin punch, pull out lock pin and pinion mate shaft.
Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.

M

SCIA0908E

MT-91

FINAL DRIVE
INSPECTION AFTER DISASSEMBLY
Gear, Washer, Shaft and Case
●

Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.

MTK0135D

Bearing
Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
●

SPD715

ASSEMBLY
1.
2.
3.

Apply gear oil to sliding area of differential case, each gear, and thrust washer.
Install side gear thrust washers and side gears into differential
case.
While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.

SMT839

4.

Insert pinion mate shaft into differential case.
CAUTION:
Be sure not to damage pinion mate thrust washers.

MTK0132D

MT-92

FINAL DRIVE
5.
a.
b.

Measure end play of side gears following procedure below.
Then select side gear thrust washer.
Upright the differential case so that its side gear to be measured
faces upward.
Place final drive adapter and dial indicator onto side gears.

A

B

MT
SCIA1020E

D

c.

Move side gears up and down to measure end play, and select
thrust washer so that it satisfies standard.
End play standard value
: 0.1 - 0.2 mm (0.004 - 0.008 in)

E

CAUTION:
● There should be no resistance and gears should rotate
freely.
● Place differential case upside down. Be sure to measure
end play for opposite side-gears likewise.

F

G
SMT611A

Thrust washer
Thickness

Part number

0.75 mm (0.0295 in)
0.80 mm (0.0315 in)
0.85 mm (0.0335 in)
0.90 mm (0.0354 in)
0.95 mm (0.0374 in)

38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04

H

I

J

CAUTION:
Only one thrust washer can be selected.

6.

Using a pin punch, drive a lock pin into the pinion mate shaft.
CAUTION:
Do not reuse the lock pin.

K

L

M
SCIA0908E

7.

Using a drift (special service tool), install differential side bearing
(transaxle case side).

SCIA0910E

MT-93

FINAL DRIVE
8.

Using a drift (special service tool), install differential side bearing
(clutch housing side).

SCIA0911E

9.

Install final gear into differential case, and tighten final gear
mounting bolts.

SCIA0912E

MT-94

SHIFT CONTROL
SHIFT CONTROL
Inspection (RS5F51A)

PFP:32982

A
ECS008CC

Check contact surfaces and sliding area for wear, damage,
bending, etc. If necessary, replace parts.

●

B

MT

D

E

F

G

H
SCIA0913E

SHIFT FORK
Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.

●

Item

One-side wear specification

Sliding width of new part

1st & 2nd

0.2 mm (0.008 in)

7.80 - 7.93 mm
(0.3071 - 0.3122 in)

3rd & 4th

0.2 mm (0.008 in)

7.80 - 7.93 mm
(0.3071 - 0.3122 in)

5th

0.2 mm (0.008 in)

6.10 - 6.23 mm
(0.2402 - 0.2453 in)

Reverse

0.2 mm (0.008 in)

12.80 - 12.93 mm
(0.5039 - 0.5091 in)

I

J

K

SMT801D

L

M

MT-95

SHIFT CONTROL
Inspection (RS6F51A)
●

ECS008CD

Check contact surfaces and sliding area for wear, damage,
bending, etc. If necessary, replace parts.

SCIA0913E

SHIFT FORK
●

Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
Item

One-side wear specification

Sliding width of new part

1st & 2nd

0.2 mm (0.008 in)

7.80 - 7.93 mm
(0.3071 - 0.3122 in)

3rd & 4th

0.2 mm (0.008 in)

7.80 - 7.93 mm
(0.3071 - 0.3122 in)

5th & 6th

0.2 mm (0.008 in)

6.10 - 6.23 mm
(0.2402 - 0.2453 in)

Reverse

0.2 mm (0.008 in)

12.80 - 12.93 mm
(0.5039 - 0.5091 in)

MT-96

SMT801D

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications

PFP:00030

A
ECS008CE

TRANSAXLE
Engine

QR20DE

Transaxle model

QR25DE

YD22DDTi

RS5F51A

Model code number

8H500

Number of speed

9H608

8H868

5

Synchromesh type

B

RS6F51A

6

MT

Warner

Shift pattern

D
5 speed

E
SCIA0821E

F

G

6 speed

H

SCIA0955E

Gear ratio

1st

3.500

1.944

3rd

1.258

4th

0.947

5th

0.772

6th

Input gear

1st

I

0.772

3.374

3.252

3.374

14

12

14

18

3rd

31

4th

38
44

6th

45
—

46
12

14

1st

49

41

49

2nd

35

3rd

39

4th

36

6th

33
—
38

Front

37

Rear

46

Oil capacity
(Imp pt)

38
2.3 (4)

MT-97

34
29

Reverse

K

44

14

34

J

L

Reverse

5th

Reverse idler
gear

3.500

0.630

2nd

5th

Main gear

0.733
—

Reverse
Number of teeth

3.416

2nd

46

M

SERVICE DATA AND SPECIFICATIONS (SDS)
Engine

QR20DE

Transaxle model

YD22DDTi

RS5F51A

Model code number
Remarks

QR25DE

8H500

RS6F51A
9H608

Reverse synchronizer

8H868

Installed

Double baulk ring type synchronizer

1st & 2nd synchronizer

FINAL GEAR
Engine

QR20DE

Transaxle model

QR25DE

YD22DDTi

RS5F51A

RS6F51A

Model code number

8H500

Final gear ratio

4.750

4.428

76/16

62/14

Number of teeth

Final gear/Pinion

9H608

Side gear/Pinion mate gear

8H868

14/10

Gear End Play

ECS008CF

Unit: mm (in)
Gear

End play

1st main gear

0.20 - 0.30 (0.0079 - 0.0118)

2nd main gear

0.06 - 0.16 (0.0024 - 0.0063)

3rd input gear

0.18 - 0.31 (0.0071 - 0.0122)

4th input gear

0.20 - 0.30 (0.0079 - 0.0118)

5th input gear

0.06 - 0.16 (0.0024 - 0.0063)

6th input gear (For RS6F51A model)

0.06 - 0.16 (0.0024 - 0.0063)

Clearance Between Baulk Ring and Gear

ECS008CG

3RD,4TH,5TH,6TH & REVERSE BAULK RING
— 6th for RS6F51A Models —
Unit: mm (in)
Standard

Wear limit

3rd

0.9 - 1.45 (0.0354 - 0.0571)

0.7 (0.0276)

4th

0.9 - 1.45 (0.0354 - 0.0571)

0.7 (0.0276)

5th

0.95 - 1.4 (0.0374 - 0.0551)

0.7 (0.0276)

6th (For RS6F51A model)

0.95 - 1.4 (0.0374 - 0.0551)

0.7 (0.0276)

Reverse

0.95 - 1.4 (0.0374 - 0.0551)

0.7 (0.0276)

1ST AND 2ND DOUBLE BAULK RING
Unit: mm (in)

SCIA0950E

Dimension

Standard

Wear limit

A

0.6 - 0.8 (0.024 - 0.031)

0.2 (0.008)

B

0.6 - 1.1 (0.024 - 0.043)

0.2 (0.008)

MT-98

SERVICE DATA AND SPECIFICATIONS (SDS)
Available Snap Rings

ECS008CH

A

INPUT SHAFT SPACER
—For RS5F51A Models—
End play

0 - 0.1 mm (0 - 0.004 in)

Thickness

mm (in)

1.71 (0.0673)
1.76 (0.0693)
1.81 (0.0713)
1.86 (0.0732)
1.91 (0.0752)
1.96 (0.0772)

Part number*

Thickness

32204 8H510
32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515

mm (in)

2.01 (0.0791)
2.06 (0.0811)
2.11 (0.0831)
2.16 (0.0850)
2.21 (0.0870)
2.26 (0.0890)

B

Part number*
32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
32204 8H521

MT

D

*: Always check with the Parts Department for the latest parts information.

6TH BUSHING

E

—For RS6F51A Models—
End play

0 - 0.1 mm (0 - 0.004 in)

Thickness

mm (in)

1.76 (0.0693)
1.81 (0.0713)
1.86 (0.0732)
1.91 (0.0752)
1.96 (0.0772)

Part number*

Thickness

32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515

mm (in)

2.01 (0.0791)
2.06 (0.0811)
2.11 (0.0831)
2.16 (0.0850)
2.21 (0.0870)

Part number*

F

32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520

G

*: Always check with the Parts Department for the latest parts information.

H

5TH MAIN GEAR
—For RS5F51A Models—
End play

I

0 - 0.1 mm (0 - 0.004 in)

Thickness

mm (in)

1.85 (0.0728)
1.90 (0.0748)
1.95 (0.0768)
2.00 (0.0787)

Part number*

Thickness

32204 8H500
32204 8H501
32204 8H502
32204 8H503

mm (in)

2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)

Part number*
32204 8H504
32204 8H505
32204 8H506
32204 8H507

J

K

*: Always check with the Parts Department for the latest parts information.

Available C-Rings

ECS008CI

MAINSHAFT C-RING

L

End play
Thickness

0 - 0.06 mm (0 - 0.0024 in)
mm (in)

2.535 (0.0998)
2.565 (0.1010)
2.595 (0.1022)
2.625 (0.1033)
2.655 (0.1045)
2.685 (0.1057)
2.715 (0.1069)
2.745 (0.1081)
2.775 (0.1093)
2.805 (0.1104)

Part number*

Thickness

32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H809

mm (in)

2.835 (0.1116)
2.865 (0.1128)
2.895 (0.1140)
2.925 (0.1152)
2.955 (0.1163)
2.985 (0.1175)
3.015 (0.1187)
3.045 (0.1199)
3.075 (0.1211)

*: Always check with the Parts Department for the latest parts information.

MT-99

Part number*
32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818

M

SERVICE DATA AND SPECIFICATIONS (SDS)
Available Thrust Washer

ECS008CJ

INPUT SHAFT THRUST WASHER

SCIA1008E

Standard length “C2”
Thickness

154.7 - 154.8 mm (6.091 - 6.094 in)

mm (in)

Part number*

3.84 (0.1512)
3.90 (0.1535)
3.96 (0.1559)

Thickness

32347 8H500
32347 8H501
32347 8H502

mm (in)

Part number*

4.02 (0.1583)
4.08 (0.1606)
4.14 (0.1630)

32347 8H503
32347 8H504
32347 8H505

*: Always check with the Parts Department for the latest parts information.

DIFFERENTIAL SIDE GEAR THRUST WASHER
Allowable clearance between side gear and differential case with
washer
Thickness

0.1 - 0.2 mm (0.004 - 0.008 in)

mm (in)

Part number*

0.75 (0.0295)
0.80 (0.0315)
0.85 (0.0335)
0.90 (0.0354)
0.95 (0.0374)

38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04

*: Always check with the Parts Department for the latest parts information.

Available Adjusting Shims

ECS008CK

MAINSHAFT ADJUSTING SHIM

SCIA1009E

Standard length “C1”
Thickness

mm (in)

0.52 (0.0205)
0.60 (0.0236)
0.68 (0.0268)
0.76 (0.0299)

173.85 - 173.95 mm (6.844 - 6.848 in)
Part number*

Thickness

32238 8H500
32238 8H501
32238 8H502
32238 8H503

mm (in)

0.84 (0.0331)
0.92 (0.0362)
1.00 (0.0394)
1.08 (0.0425)

*: Always check with the Parts Department for the latest parts information.

MT-100

Part number*
32238 8H504
32238 8H505
32238 8H506
32238 8H507

SERVICE DATA AND SPECIFICATIONS (SDS)
INPUT SHAFT REAR BEARING ADJUSTING SHIM
A
End play

0 - 0.06 mm (0 - 0.0024 in)

Thickness mm (in)

Part number*

0.40 (0.0157)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)

32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510
32225 8H511

Thickness

mm (in)

0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0394)
1.04 (0.0409)
1.08 (0.0425)
1.12 (0.0441)
1.16 (0.0457)
1.20 (0.0472)
1.24 (0.0488)
1.28 (0.0504)
1.32 (0.0520)

Part number*

Thickness

32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521
32225 8H522
32225 8H523

mm (in)

Part number*

1.36 (0.0535)
1.40 (0.0551)
1.44 (0.0567)
1.48 (0.0583)
1.52 (0.0598)
1.56 (0.0614)
1.60 (0.0630)
1.64 (0.0646)
1.68 (0.0661)
1.72 (0.0677)

32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566
32225 8H567**
32225 8H568**

B

MT

D

E

*: Always check with the Parts Department for the latest parts information.
**: RS5F51A model only.

F

MAINSHAFT REAR BEARING ADJUSTING SHIM
End play

0 - 0.06 mm (0 - 0.0024 in)

Thickness

mm (in)

0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)

Part number*

Thickness

32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518

mm (in)

0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0394)
1.04 (0.0409)
1.08 (0.0425)

Part number*
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561

G

H

I

*: Always check with the Parts Department for the latest parts information.

J

REVERSE IDLER GEAR ADJUSTING SHIM
End play

0.04 - 0.10 mm (0.0016 - 0.0039 in)

Thickness

mm (in)

1.76 (0.0693)
1.80 (0.0709)
1.84 (0.0724)
1.88 (0.0740)
1.92 (0.0756)
1.96 (0.0772)
2.00 (0.0787)
2.04 (0.0803)
2.08 (0.0819)
2.12 (0.0835)
2.16 (0.0850)
2.20 (0.0866)

Part number*

Thickness

32237 8H800
32237 8H801
32237 8H802
32237 8H803
32237 8H804
32237 8H805
32237 8H806
32237 8H807
32237 8H808
32237 8H809
32237 8H810
32237 8H811

mm (in)

2.24 (0.0882)
2.28 (0.0898)
2.32 (0.0913)
2.36 (0.0929)
2.40 (0.0945)
2.44 (0.0961)
2.48 (0.0976)
2.52 (0.0992)
2.56 (0.1008)
2.60 (0.1024)
2.64 (0.1039)

Part number*
32237 8H812
32237 8H813
32237 8H814
32237 8H815
32237 8H816
32237 8H817
32237 8H818
32237 8H819
32237 8H820
32237 8H821
32237 8H822

*: Always check with the Parts Department for the latest parts information.

6TH MAIN GEAR ADJUSTING SHIM
—For RS6F51A Models—
End play

0 - 0.1 mm (0 - 0.004 in)

Thickness

mm (in)

0.88 (0.0346)
0.96 (0.0378)
1.04 (0.0409)
1.12 (0.0441)

Part number*

Thickness

32237 8H560
32237 8H561
32237 8H562
32237 8H563

mm (in)

1.20 (0.0472)
1.28 (0.0504)
1.36 (0.0535)

*: Always check with the Parts Department for the latest parts information.

MT-101

Part number*
32237 8H564
32237 8H565
32237 8H566

K

L

M

SERVICE DATA AND SPECIFICATIONS (SDS)
Available Shims

ECS008CL

— Differential Side Bearing Preload and Adjusting Shim

BEARING PRELOAD
Differential side bearing preload: L*

0.15 - 0.21 mm (0.0059 - 0.0083 in)

*: Install shims which are “deflection of differential case” + “L” in thickness.

DIFFERENTIAL SIDE BEARING ADJUSTING SHIM(S)
Thickness

mm (in)

0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)

Part number*

Thickness

31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05

mm (in)

0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)

*: Always check with the Parts Department for the latest parts information.

MT-102

Part number*
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11



---

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