Nissan 2004 X Trail Owners Manual MT

2015-10-23

: Nissan Nissan-2004-Nissan-X-Trail-Owners-Manual-818351 nissan-2004-nissan-x-trail-owners-manual-818351 nissan pdf

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MANUAL TRANSAXLE

C TRANSMISSION/TRANSAXLE
A

SECTION

MANUAL TRANSAXLE

CONTENTS
PRECAUTIONS .......................................................... 3
Caution ..................................................................... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 8
NVH Troubleshooting Chart ..................................... 8
MANUAL TRANSAXLE ......................................... 8
DESCRIPTION ............................................................ 9
Cross-Sectional View ............................................... 9
DOUBLE-CONE SYNCHRONIZER .................... 10
TRIPLE-CONE SYNCHRONIZER ...................... 10
REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD) ................. 10
M/T OIL ......................................................................11
Changing M/T Oil ....................................................11
DRAINING ............................................................11
FILLING ................................................................11
Checking M/T Oil .....................................................11
OIL LEAKAGE AND OIL LEVEL ..........................11
SIDE OIL SEAL ........................................................ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
POSITION SWITCH .................................................. 13
Checking ................................................................ 13
BACK-UP LAMP SWITCH .................................. 13
PARK/NEUTRAL POSITION SWITCH ............... 13
CONTROL LINKAGE ............................................... 14
Components of Control Device and Cable ............. 14
Removal and Installation ........................................ 15
AIR BREATHER HOSE ............................................ 16
Removal and Installation ........................................ 16
TRANSAXLE ASSEMBLY ........................................ 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
Component Parts (RS5F51A) ................................ 19

CASE AND HOUSING COMPONENTS .............. 19
GEAR COMPONENTS ....................................... 20
SHIFT CONTROL COMPONENTS ..................... 22
FINAL DRIVE COMPONENTS ........................... 23
Component Parts (RS6F51A) ................................. 24
CASE AND HOUSING COMPONENTS .............. 24
GEAR COMPONENTS ....................................... 25
SHIFT CONTROL COMPONENTS ..................... 27
FINAL DRIVE COMPONENTS ........................... 28
Disassembly and Assembly (RS5F51A) ................. 28
DISASSEMBLY ................................................... 28
ASSEMBLY ......................................................... 32
Disassembly and Assembly (RS6F51A) ................. 37
DISASSEMBLY ................................................... 37
ASSEMBLY ......................................................... 41
Adjustment (RS5F51A) ........................................... 47
INPUT SHAFT END PLAY .................................. 47
MAINSHAFT END PLAY ..................................... 48
DIFFERENTIAL SIDE BEARING PRELOAD ...... 48
REVERSE IDLER GEAR END PLAY .................. 49
Adjustment (RS6F51A) ........................................... 50
INPUT SHAFT END PLAY .................................. 50
MAINSHAFT END PLAY ..................................... 51
DIFFERENTIAL SIDE BEARING PRELOAD ...... 52
REVERSE IDLER GEAR END PLAY .................. 53
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

ASSEMBLY ......................................................... 72
Assembly and Disassembly (RS6F51A) ................. 76
DISASSEMBLY ................................................... 76
INSPECTION AFTER DISASSEMBLY ................ 77
ASSEMBLY ......................................................... 80
REVERSE IDLER SHAFT AND GEARS .................. 85
Assembly and Disassembly (RS5F51A) ................. 85
DISASSEMBLY ................................................... 85
INSPECTION AFTER DISASSEMBLY ................ 85
ASSEMBLY ......................................................... 86
Assembly and Disassembly (RS6F51A) ................. 86
DISASSEMBLY ................................................... 86
INSPECTION AFTER DISASSEMBLY ................ 87
ASSEMBLY ......................................................... 87
FINAL DRIVE ............................................................ 89
Assembly and Disassembly (RS5F51A) ................. 89
PRE-INSPECTION .............................................. 89
DISASSEMBLY ................................................... 89
INSPECTION AFTER DISASSEMBLY ................ 90
ASSEMBLY ......................................................... 90
Assembly and Disassembly (RS6F51A) ................. 92
PRE-INSPECTION .............................................. 92
DISASSEMBLY ................................................... 92
INSPECTION AFTER DISASSEMBLY ................ 93
ASSEMBLY ......................................................... 94
SHIFT CONTROL ...................................................... 96
Inspection (RS5F51A) ............................................ 96
SHIFT FORK ....................................................... 96
Inspection (RS6F51A) ............................................ 97
SHIFT FORK ....................................................... 97

SERVICE DATA AND SPECIFICATIONS (SDS) ......98
General Specifications ............................................98
TRANSAXLE ........................................................98
FINAL GEAR ........................................................99
End Play ..................................................................99
Baulk Ring Clearance .............................................99
Available Snap Rings ............................................ 100
INPUT SHAFT BEARING SPACER ................... 100
6TH INPUT GEAR BUSHING ............................ 100
5TH MAIN GEAR ............................................... 100
Available C-Rings ................................................. 100
MAINSHAFT C-RING ........................................ 100
Available Thrust Washer ....................................... 101
INPUT SHAFT THRUST WASHER ................... 101
DIFFERENTIAL SIDE GEAR THRUST WASHER
.101
Available Adjusting Shims ..................................... 101
4TH MAIN GEAR ADJUSTING SHIM ................ 101
INPUT SHAFT REAR BEARING ADJUSTING
SHIM .................................................................. 102
MAINSHAFT REAR BEARING ADJUSTING
SHIM .................................................................. 102
REVERSE IDLER GEAR ADJUSTING SHIM .... 102
6TH MAIN GEAR ADJUSTING SHIM ................ 102
Available Shims .................................................... 103
BEARING PRELOAD ......................................... 103
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) ............................................................. 103

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.

MT-3

PREPARATION
PREPARATION
Special Service Tools

PFP:00002
ECS008BN

Tool number
Tool name

Description

KV381054S0
Puller

●

Differential side bearing outer race removal

●

Mainshaft front bearing removal

●

Input shaft oil seal installation

●

Reverse main gear installation

●

1st main gear bushing installation

●

1st-2nd synchronizer hub assembly
installation

●

2nd main gear bushing installation

●

3rd main gear installation

●

Differential side bearing (clutch housing
side) removal

●

Differential oil seal installation

●

Differential side bearing outer race
installation

●

Mainshaft rear bearing installation

●

Differential side bearing installation

●

Mainshaft front bearing installation

●

6th input gear bushing installation
(RS6F51A)

●

4th main gear installation

●

5th main gear installation

●

6th main gear installation (RS6F51A)

ZZA0601D

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

ZZA1000D

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

ZZA0811D

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

ZZA1002D

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

Differential side bearing outer race installation

ZZA0898D

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

ZZA1000D

MT-4

●

Bore plug installation

●

Differential side bearing (transaxle case
side) removal

PREPARATION
Tool number
Tool name

Description

ST33052000
Drift
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 input gear bushing, thrust washer, 4th
input gear, 4th gear bushing, 3rd-4th
synchronizer hub assembly and 3rd input
gear removal

●

Input shaft front bearing installation

●

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

●

Mainshaft rear bearing removal

●

4th main gear and 5th main gear removal

●

6th main gear removal (RS6F51A)

●

5th input gear and 5th synchronizer hub
assembly removal

●

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

ZZA1023D

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

ZZA1133D

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

●

3rd-4th synchronizer hub assembly
installation

●

4th input gear bushing installation

●

5th input gear bushing installation

●

5th synchronizer hub assembly installation
(RS5F51A)

●

5th-6th synchronizer hub assembly
installation (RS6F51A)

●

2nd main gear bushing installation

●

3rd main gear installation

●

Reverse main gear installation

●

1st main gear bushing installation

●

1st-2nd synchronizer hub assembly
installation

ZZA1058D

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

M
ZZA1058D

ST30032000
Drift
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

ST30901000
Drift
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

PREPARATION
Tool number
Tool name

Description

ST30031000
Puller

Measuring wear of inner baulk ring

ZZA0537D

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

Reverse main gear installation

ZZA1003D

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

●

1st main gear bushing installation

●

1st-2nd synchronizer hub assembly
installation

●

Differential side bearing (transaxle case
side) installation

ZZA0838D

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

Differential side bearing (clutch housing side)
installation

ZZA0936D

ST15243000
Drift
a: φ 30mm

Measuring end play of side gear

SCIA1088J

Commercial Service Tools

ECS008BO

Tool name

Description

Puller

Each bearing, gear and bushing removal

ZZA0537D

MT-6

PREPARATION
Tool name

Description

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

E
ZZA0815D

MT-7

Symptoms

Oil leakage

Hard to shift or will not shift

Jumps out of gear

MT-8

MT-19(RS5F51A), MT-24 (RS6F51A)

O-RING (Worn or damaged)

MT-22(RS5F51A), MT-27 (RS6F51A)
MT-20(RS5F51A), MT-25 (RS6F51A)
MT-20(RS5F51A), MT-25 (RS6F51A)
MT-20(RS5F51A), MT-25 (RS6F51A)
MT-20(RS5F51A), MT-25 (RS6F51A)

SHIFT FORK (Worn)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
BAULK RING (Worn or damaged)
INSERT SPRING (Damaged)

MT-22(RS5F51A), MT-27 (RS6F51A)

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

MT-14

MT-19(RS5F51A), MT-24 (RS6F51A)

OIL SEAL (Worn or damaged)

SHIFT CONTROL LINKAGE (Worn)

MT-19(RS5F51A), MT-24 (RS6F51A)

SUSPECTED PARTS
(Possible cause)

GASKET (Damaged)

MA-37

Reference page

OIL (Oil level is high.)

OIL (Wrong oil.)

Noise
OIL (Oil level is low.)

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

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

PFP:00003
ECS008BP

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.

MANUAL TRANSAXLE

DESCRIPTION
DESCRIPTION
Cross-Sectional View

PFP:00000

A
ECS008BQ

PCIB0773E

3rd input gear

3rd-4th synchronizer hub

3rd-4th coupling sleeve

4th input gear

5th input gear

5th synchronizer hub

5th coupling sleeve

Input shaft rear bearing

Mainshaft rear bearing

10. 5th main gear

11. 4th main gear

12. 3rd main gear

13. 2nd main gear

14. 1st-2nd coupling sleeve

15. 1st-2nd synchronizer hub

16. 1st main gear

17. Reverse main gear

18. Differential side bearing

19. Differential case

20. Final gear

21. Differential side bearing

22. Mainshaft front bearing

23. Mainshaft

24. Input shaft

25. Input shaft front bearing

26. Clutch housing

27. Reverse idler shaft

28. Reverse idler gear (Front)

29. Reverse coupling sleeve

30. Reverse synchronizer hub

31. Reverse idler gear (Rear)

32. 5th input gear

33. 5th-6th synchronizer hub

34. 5th-6th coupling sleeve

35. 6th input gear

36. Input shaft rear bearing

37. Mainshaft rear bearing

38. 5th main gear

39. 6th main gear

MT-9

DESCRIPTION
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 1st gear to reduce operating force of the shift lever.

TRIPLE-CONE SYNCHRONIZER
Triple-cone synchronizer is adopted for 2nd gear to reduce operating force of the shift lever.

PCIB0774E

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

PCIB0775E

MT-10

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

PFP:KLD20

A
ECS008BR

DRAINING
1.
2.
3.

Start engine and let it run to warm up transaxle.
B
Stop engine. Remove drain plug and drain oil.
Set a new gasket on drain plug and install it to transaxle. Refer to MT-19, "CASE AND HOUSING COMPONENTS" , MT-24, "CASE AND HOUSING COMPONENTS" .
MT
CAUTION:
Do not reuse gasket.

FILLING
1.

Oil grade
Oil capacity (reference)
2.

Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole.
: API GL-4
: Approx. 2.3

(4 lmp pt)

After refilling oil, check oil level. Assemble a new gasket to filler plug, then install it to transaxle. Refer to
MT-19, "CASE AND HOUSING COMPONENTS" , MT-24, "CASE AND HOUSING COMPONENTS" .
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 filler plug and install it on transaxle. Refer
to MT-19, "CASE AND HOUSING COMPONENTS" , MT-24,
"CASE AND HOUSING COMPONENTS" .
CAUTION:
Do not reuse gasket.

K
SCIA0361E

MT-11

SIDE OIL SEAL
SIDE OIL SEAL
Removal and Installation

PFP:32113
ECS008BT

REMOVAL
●

1.
2.

Clutch housing side oil seal used on 4WD vehicles is attached to transfer. Be sure to replace it
when transfer is removed.
Remove drive shaft from transaxle. Refer to FAX-11, "Removal and Installation" .
Remove oil seal with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage the case surface when removing
oil seal.

SCIA0824E

INSTALLATION
1.

Using a drift, drive the oil seal straight until it protrudes from the
case end equal to dimension A shown in the figure.
Dimension "A":
Within 0.5 mm (0.020 in) of flush with the case.
Drift to be used:
Transaxle case side:
Clutch housing side:

ST30720000
ST30720000

CAUTION:
SCIA0352E
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. Refer to MT-11, "Checking
M/T Oil" .
●

MT-12

POSITION SWITCH
POSITION SWITCH
Checking

PFP:32005

A
ECS008BU

BACK-UP LAMP SWITCH
●

Check continuity.
Gear position

B
Continuity

Reverse

Yes

Except reverse

SCIA0708E

PARK/NEUTRAL POSITION SWITCH
●

Check continuity.
F
Gear position

Continuity

Neutral

Yes

Except neutral

MT-13

CONTROL LINKAGE
CONTROL LINKAGE
Components of Control Device and Cable

PFP:34103
ECS008BV

PCIB0777E

Control lever knob

Select cable

Shift cable

Lock plate

Clutch housing

Cable mounting bracket

Control device assembly

Control lever

10. Lock plate

11. Washer

12. Snap pin

13. Washer

MT-14

CONTROL LINKAGE
Removal and Installation

ECS00CY6

A
CAUTION:
●
Keep in mind that the select side lock plate for securing 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, B
2nd, or Reverse.
●
Shift control lever to the neutral position for removal.
MT
Install select cable according to the following procedure.
1. Install select cable of transaxle side to control assembly.
2. Install select cable to pin on select lever part of control device
D
assembly.
E

PCIB0815E

Push lock part (A) of select cable all the way to the direction of
the arrow. (6 M/T model only)
4. Slide stopper part (B) all the way to lock part (A) as shown by
the arrow. (6 M/T model only)
CAUTION:
Make sure that select cable and select lever are installed
securely.

J
PCIB0817E

MT-15

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 model

PCIB0778E

Air cleaner case

Transaxle

Clip

Air breather hose

Clip

PCV hose

Resonator

YD engine model

PCIB0779E

Air cleaner case

Transaxle

Clip

Air breather hose

Clip

Bracket

Mass air flow sensor

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

MT-16

TRANSAXLE ASSEMBLY
TRANSAXLE ASSEMBLY
Removal and Installation

PFP:32010

A
ECS008BX

I
PCIB0780E

Center member

Insulator assembly

Grommet

Transaxle

Rear engine mounting bracket

Rear engine mounting insulator

Stopper rubber (YD engine model)

Stopper

LH engine mounting insulator

10. LH engine mounting bracket

REMOVAL
1.
2.
3.

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

11.
12.
13.

Remove air cleaner, air duct, and battery. Refer to EM-15, "Removal and Installation" ,EM-133, "Removal
and Installation"
Remove air breather hose. Refer to MT-16, "Removal and Installation" .
Remove clutch operating cylinder. Refer to CL-10, "Removal and Installation" .
CAUTION:
Do not depress clutch pedal during removal procedure.
Disconnect control cable from transaxle. Refer to MT-15, "Removal and Installation" .
Drain gear oil from transaxle. Refer to MT-11, "DRAINING" .
Disconnect park/neutral position switch, back-up lamp switch, and ground harness connectors.
Remove exhaust front tube and the drive shaft. Refer to EX-2, "Removal and Installation" .
Remove transfer. Refer to TF-55, "Removal and Installation" .
Remove starter motor. Refer to SC-25, "Removal and Installation" .
Place a jack onto transaxle.
CAUTION:
When setting jack, be careful not to bring it into contact with switch.
Remove center member, engine insulator and engine mount bracket. Refer to EM-78, "ENGINE ASSEMBLY" (QR engine model) or EM-208, "ENGINE ASSEMBLY" (YD engine model).
Remove suspension members. Refer to FSU-12, "FRONT SUSPENSION MEMBER" .
Support engine by placing a jack under oil pan.

MT-17

TRANSAXLE ASSEMBLY
14. Remove bolts securing transaxle to engine.
15. Remove transaxle from vehicle.

MTD0062D

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

Quantity

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)

74.5
(7.6, 55)

42.7
(4.4, 31)

35.3
(3.6, 26 )

SCIA0353E

YD engine model:
Bolt No.

Quantity

55
(2.17)

50
(2.76)

120
(4.72)

45
(1.77)

40
(1.57)

35
(1.38)

“

” mm (in)

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

44
(4.5, 32)

33.5
(3.4, 25)

After installation, check oil level, and check for leaks and loose
mechanisms. Refer to MT-11, "Checking M/T Oil" .

MT-18

SCIA0748E

TRANSAXLE ASSEMBLY
Component Parts (RS5F51A)

ECS008BY

CASE AND HOUSING COMPONENTS

PCIB0781E

Clutch housing

Differential oil seal

Ball pin

Washer

Input shaft oil seal

Oil channel

Magnet

Back-up lamp switch

Oil gutter

10. Baffle plate

11. Transaxle case

12. Filler plug

13. Gasket

14. Welch plug

15. Bore plug

16. Drain plug

17. Differential oil seal

18. Park/Neutral position switch

19. Air breather tube

MT-19

TRANSAXLE ASSEMBLY
GEAR COMPONENTS

PCIB0782E

Input shaft front bearing

Input shaft

3rd needle bearing

3rd input gear

3rd baulk ring

3rd-4th spread spring

3rd-4th shifting insert

3rd-4th synchronizer hub

4th baulk ring

10. 3rd-4th coupling sleeve

11. 4th input gear bushing

12. 4th needle bearing

13. 4th input gear

14. Thrust washer

15. 5th input gear bushing

16. 5th needle bearing

17. 5th input gear

18. 5th baulk ring

19. 5th spread spring

20. 5th shifting insert

21. 5th synchronizer hub

22. 5th coupling sleeve

23. 5th stopper

24. Input shaft bearing spacer

25. Snap ring

26. Input shaft rear bearing

27. Oil channel

28. Input shaft rear bearing adjusting
shim

29. Retaining pin

30. Reverse idler shaft

31. Thrust needle bearing

32. Reverse idler gear needle bearing

33. Reverse insert spring

34. Reverse idler gear (Front)

35. Reverse baulk ring

36. Reverse coupling sleeve

37. Reverse idler gear (Rear)

38. Reverse idler gear adjusting shim

MT-20

TRANSAXLE ASSEMBLY
A

PCIB0783E

Mainshaft front bearing

Reverse main gear

1st main gear

1st main gear bushing

1st needle bearing

1st inner baulk ring

1st gear synchronizer cone

10. 1st outer baulk ring

Mainshaft bearing retainer

11. 1st-2nd 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. 2nd main gear bushing

19. 2nd needle bearing

20. 2nd main gear

21. 3rd main gear

22. 3rd-4th mainshaft spacer

23. 4th main gear 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

MT-21

Mainshaft

TRANSAXLE ASSEMBLY
SHIFT CONTROL COMPONENTS

PCIB0784E

3rd-4th bracket

Retaining pin

5th-reverse bracket

Reverse lever assembly

Shifter cap

Reverse shift fork

Reverse fork rod

Check plug

10. Check spring

11. Shift check sleeve

Stopper ring

12. Check ball

13. 5th-reverse fork rod

14. 5th shift fork

15. Check spring

16. 3rd-4th fork rod

17. Interlock pin

18. Shift check sleeve

19. 1st-2nd fork rod

20. 1st-2nd bracket

21. 1st-2nd shift fork

22. 3rd-4th shift fork

23. Control assembly

24. Stopper bolt

25. Shift check

26. O-ring

MT-22

TRANSAXLE ASSEMBLY
FINAL DRIVE COMPONENTS
A

PCIB0785E

Differential side bearing outer race

Differential side bearing (clutch
housing side)

Differential case

Final gear

Differential side bearing (transaxle
case side)

Differential side bearing outer race

Differential side bearing adjusting
shim

Side gear

Side gear thrust washer

10. Retaining pin

K
11. Pinion mate thrust washer

12. Pinion mate gear

13. Pinion mate shaft

MT-23

TRANSAXLE ASSEMBLY
Component Parts (RS6F51A)

ECS008BZ

CASE AND HOUSING COMPONENTS

PCIB0781E

Clutch housing

Differential oil seal

Ball pin

Washer

Input shaft oil seal

Oil channel

Magnet

Back-up lamp switch

Oil gutter

10. Baffle plate

11. Transaxle case

12. Filler plug

13. Gasket

14. Welch plug

15. Bore plug

16. Drain plug

17. Differential oil seal

18. Park/Neutral position switch

19. Air breather tube

MT-24

TRANSAXLE ASSEMBLY
GEAR COMPONENTS
A

J
PCIB0786E

Input shaft front bearing

Input shaft

3rd needle bearing

3rd input gear

3rd baulk ring

3rd-4th spread spring

3rd-4th shifting insert

3rd-4th synchronizer hub

4th baulk ring

10. 3rd-4th coupling sleeve

11. 4th input gear bushing

12. 4th needle bearing

13. 4th input gear

14. Thrust washer

15. 5th input gear bushing

16. 5th needle bearing

17. 5th input gear

18. 5th baulk ring

19. 5th-6th spread spring

20. 5th-6th shifting insert

21. 5th-6th synchronizer hub

22. 5th-6th coupling sleeve

23. 6th baulk ring

24. 6th input gear

25. 6th needle bearing

26. 6th input gear bushing

27. Snap ring

28. Input shaft rear bearing

29. Oil channel

30. Input shaft rear bearing adjusting
shim

31. Retaining pin

32. Reverse idler shaft

33. Thrust needle bearing

34. Reverse idler gear needle bearing

35. Reverse insert spring

36. Reverse idler gear (Front)

37. Reverse balk ring

38. Reverse coupling sleeve

39. Reverse idler gear (Rear)

40. Reverse idler gear adjusting shim

MT-25

TRANSAXLE ASSEMBLY

PCIB0787E

Mainshaft front bearing

Reverse main gear

1st main gear

1st main gear bushing

1st needle bearing

1st inner baulk ring

1st gear synchronizer cone

10. 1st outer baulk ring

Mainshaft bearing retainer

Mainshaft

11. 1st-2nd 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. 2nd main gear bushing

19. 2nd 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-26

TRANSAXLE ASSEMBLY
SHIFT CONTROL COMPONENTS
A

J
PCIB0788E

3rd-4th bracket

Retaining pin

Check plug

5th-6th bracket

Stopper ring

Reverse bracket

Reverse lever assembly

Shifter cap

Reverse shift fork

10. Reverse fork rod

11. Check spring

12. Shift check sleeve

13. Check ball

14. Reverse bracket fork rod

15. 5th-6th shift fork

16. 5th-6th fork rod

17. Interlock pin

18. Shift check sleeve

19. Check spring

20. Check spring

21. 3rd-4th fork rod

22. 3rd-4th shift fork

23. 1st-2nd fork rod

24. 1st-2nd fork rod bracket

25. 1st-2nd shift fork

26. Stopper bolt

27. Shift check

28. O-ring

29. Control assembly

MT-27

TRANSAXLE ASSEMBLY
FINAL DRIVE COMPONENTS

PCIB0785E

Differential side bearing outer race

Differential side bearing (clutch
housing side)

Differential case

Final gear

Differential side bearing (transaxle
case side)

Differential side bearing outer race

Differential side bearing adjusting shim

Side gear

Side gear thrust washer

10. Retaining pin

11. Pinion mate thrust washer

12. Pinion mate gear

13. Pinion mate shaft

Disassembly and Assembly (RS5F51A)

ECS008C0

DISASSEMBLY
1.
2.
3.

Remove drain plug and filler plug from transaxle case.
Remove park/neutral position switch and back-up lamp switch
from transaxle case.
Remove shift check and stopper bolt from transaxle case, and
then remove control assembly from transaxle case.

SCIA0389E

MT-28

TRANSAXLE ASSEMBLY
4.

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

MT
SCIA0396E

5.
6.

7.
8.
9.

Remove transaxle case mounting bolts.
Remove bore plug from transaxle case.
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 from clutch housing.
Remove oil gutter, baffle plate from transaxle case.
Remove snap ring, mainshaft rear bearing adjusting shim and
input shaft rear bearing adjusting shim from transaxle case.

G
SCIA0983E

10. Remove differential side bearing outer race (transaxle case
side) from transaxle case using the puller, and then remove differential side bearing adjusting shim from transaxle case.

SCIA0897E

11. Remove welch plug from transaxle case.
L

SCIA0402E

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

SCIA0397E

MT-29

TRANSAXLE ASSEMBLY
14. With shift lever in 5th position, remove mounting 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 a pin punch.

SCIA0391E

17. Remove stopper rings for 5th-reverse bracket.
18. Pull out 5th-reverse fork rod and remove 5th shift fork and 5threverse bracket.
19. Remove check balls (2 pieces) from clutch housing.

SCIA0392E

20. Remove retaining pin of 3rd-4th bracket using a 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 3rd4th bracket.
23. Remove interlock pin and shift check sleeve from clutch housing.

SCIA0393E

24.
25.
26.
27.

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

SCIA0394E

MT-30

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

SCIA0395E

29. Remove mainshaft bearing retainer and then mainshaft front
bearing from clutch housing using the puller.
30. Remove oil channel from clutch housing.

G
SCIA1077J

31. Remove differential oil seal (clutch housing side) from clutch
housing.
CAUTION:
Be careful not to damage clutch housing.

SCIA1068J

32. Remove differential side bearing outer race (clutch housing
side) from clutch housing using the puller.

SCIA1069J

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

SCIA0398E

MT-31

TRANSAXLE ASSEMBLY
ASSEMBLY
1.

Apply multi-purpose grease to input shaft oil seal lip. Install a
new input shaft oil seal 1.8-2.8mm (0.071-0.110 in) above from
clutch housing edge surface using the drift.
CAUTION:
Do not reuse oil seals.

PCIB0807E

Apply multi-purpose grease to differential oil seal lip, and then
install a new oil seal to clutch housing using the drift.
CAUTION:
Do not reuse oil seals.

SCIA1070J

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

SCIA0986E

MT-32

TRANSAXLE ASSEMBLY
4.

Install mainshaft front bearing to clutch housing using the drift.
CAUTION:
Be careful with the orientation of installation.

MT
SCIA0401E

Install mainshaft bearing retainer to clutch housing and tighten
mounting bolt to the specified torque. Refer to MT-20, "GEAR
COMPONENTS" .
CAUTION:
Install with punched surface facing up.

G
PCIB0789E

Install differential side bearing outer race to clutch housing using
the drifts.

SCIA0987E

Install final drive assembly into clutch housing.
L

SCIA0888E

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

SCIA0395E

MT-33

TRANSAXLE ASSEMBLY
9.

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

SCIA0889E

10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install a
new retaining pin to1st-2nd shift fork.
CAUTION:
Do not reuse retaining pins.
11. Install shift check sleeve to clutch housing.

SCIA0394E

12. Install interlock pin to 3rd-4th fork rod.
13. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod.
14. Install a new stopper ring onto 3rd-4th shift fork.
CAUTION:
Do not reuse stopper ring.
15. Install a new retaining pin onto 3rd-4th bracket.
CAUTION:
Do not reuse retaining pins.
16. Install 2 check balls to clutch housing.
SCIA0393E

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

SCIA0392E

19. Install a new retaining pin onto 5th shift fork.
CAUTION:
Do not reuse retaining pins.
20. Install reverse shift fork and reverse fork rod.
21. Install reverse lever assembly following the 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

MT-34

TRANSAXLE ASSEMBLY
b.

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

PCIB0790E

Install reverse lever assembly to clutch housing, and then
tighten mounting bolts to the specified torque. Refer to MT-22,
"SHIFT CONTROL COMPONENTS" .
22. Install check ball, shift check sleeve, check spring and a new
check plug to clutch housing.
CAUTION:
● Do not reuse check plug.
● Do not drop check ball.
23. Install the magnet onto clutch housing.

G
SCIA0390E

24. Apply multi-purpose grease to differential oil seal lip, and then
install a new differential oil seal to transaxle case using the drift.
CAUTION:
Do not reuse differential oil seals.
25. Install selected input shaft rear bearing adjusting shim onto input
shaft.
● For selection of adjusting shims, refer to MT-47, "INPUT
SHAFT END PLAY" .
26. Install selected differential side bearing adjusting shim and differential side bearing. For selection adjusting shim, refer to MT48, "DIFFERENTIAL SIDE BEARING PRELOAD" .
27. Install baffle plate and oil gutter to transaxle case.
28. Install transaxle case following the procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
● For selection of adjusting shims, refer to MT-48, "MAINSHAFT END PLAY" .
b. Temporarily install a new snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse 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.

SCIA0887E

PCIB0816E

MT-35

TRANSAXLE ASSEMBLY
d.

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

SCIA0892E

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

Tighten mounting bolts to the specified torque.
Bolt A:
: 52 N·m (5.3 kg-m, 38 ft-lb)
Bolt B:
: 65 N·m (6.6 kg-m, 48 ft-lb)

CAUTION:
Always replace bolts B as they are self-sealing bolts.
Install control assembly to transaxle case.
SCIA1064E
CAUTION:
Do not reuse O-ring.
Install a new shift check to transaxle case, and then tighten shift check to the specified torque. Refer to
MT-22, "SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse shift check.
Install a new stopper bolt to transaxle case, and then tighten stopper bolt to the specified torque. Refer to
MT-22, "SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse stopper bolt.

MT-36

TRANSAXLE ASSEMBLY
29. Install a new bore plug to transaxle case using the drift.
CAUTION:
Do not reuse bore plug.

MT
SCIA0894E

30. Install a new welch plug to transaxle case using the drift.
CAUTION:
Do not reuse welch plug.

G
SCIA0403E

31. Install 2 check balls, 2 check springs and 2 new check plugs to
transaxle case, and then tighten check plug to the specified
torque. Refer to MT-22, "SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse check plug.
32. Install new O-ring applied gear oil on control assembly. And then
install control assembly on transaxle case. After the previous
service tighten bolts to the specified torque. Refer to MT-22,
"SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse O-ring.

SCIA1668J

33. Apply genuine liquid gasket or equivalent to threads of park/neutral position switch and back-up lamp switch. Then install them
into transaxle case. Tighten park/neutral position switch and
back-up lamp switch to the specified torque. Refer to MT-19,
"CASE AND HOUSING COMPONENTS" .

SCIA0895E

34. Install new gaskets onto drain plug and filler plug, and then install them into transaxle case. Tighten park/
neutral position switch and back-up lamp switch to the specified torque. Refer to MT-19, "CASE AND
HOUSING COMPONENTS" .
CAUTION:
● Do not reuse gasket.
● After oil is filled, tighten filler plug to specified torque.

Disassembly and Assembly (RS6F51A)
DISASSEMBLY
1.

Remove drain plug and filler plug from transaxle case.

MT-37

ECS008C1

TRANSAXLE ASSEMBLY
2.
3.

Remove park/neutral position switch and back-up lamp switch
from transaxle case.
Remove shift check and stopper bolt from transaxle case, and
then remove control assembly from transaxle case.

SCIA0389E

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

SCIA0959E

5.
6.

7.
8.
9.

10. Remove differential side bearing outer race (transaxle case
side) from transaxle case using the puller, and then remove differential side bearing adjusting shim from transaxle case.

SCIA0897E

11. Remove welch plug from transaxle case.

SCIA0402E

MT-38

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

SCIA0397E

14. With shift lever in 5th position, remove mounting 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.

G
SCIA0960E

16. Remove retaining pin of reverse bracket using a pin punch.
17. Pull out reverse bracket and reverse bracket fork rod.
18. Remove check ball (2 pieces) and interlock pin from clutch
housing.

SCIA0961E

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

SCIA0962E

20. Remove stopper rings for 5th-6th bracket.
21. Pull out 5th-6th fork rod and remove 5th-6th shift fork and 5th6th bracket.
22. Remove check balls (2 pieces) and interlock pin.

SCIA0963E

MT-39

TRANSAXLE ASSEMBLY
23. Remove retaining pin of 3rd-4th bracket using a 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 3rd4th bracket.
26. Remove shift check sleeve from clutch housing.

SCIA0393E

27.
28.
29.
30.

SCIA0394E

31. Remove gear components from clutch housing in the following
procedure.
a. Remove input shaft assembly, mainshaft assembly and reverse
idler gear assembly as a set, tapping input shaft with plastic
hammer.
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 mainshaft bearing retainer and then mainshaft front
bearing from clutch housing using the puller.
33. Remove oil channel from clutch housing.

SCIA1077J

34. Remove differential oil seal (clutch housing side) from clutch
housing.
CAUTION:
Be careful not to damage clutch housing.

SCIA1068J

MT-40

TRANSAXLE ASSEMBLY
35. Remove differential side bearing outer race (clutch housing
side) from clutch housing using the puller.

SCIA1069J

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

G
SCIA0398E

ASSEMBLY
1.

Apply multi-purpose grease to input shaft oil seal lip. Install a
new input shaft oil seal 1.8-2.8 mm (0.071-0.110 in) above from
clutch housing edge surface using the drift.
CAUTION:
Do not reuse oil seals.

PCIB0807E

Apply multi-purpose grease to differential oil seal lip, and then
install a new oil seal to clutch housing using the drift.
CAUTION:
Do not reuse oil seals.

SCIA1070J

MT-41

TRANSAXLE ASSEMBLY
3.

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

SCIA0986E

Install mainshaft front bearing to clutch housing using the drift.
CAUTION:
Be careful with the orientation of installation.

SCIA0401E

Install mainshaft bearing retainer to clutch housing and tighten
mounting bolt to the specified torque. Refer to MT-25, "GEAR
COMPONENTS" .
CAUTION:
Install with punched surface facing up.

PCIB0789E

Install differential side bearing outer race to clutch housing using
the drifts.

SCIA0987E

Install final drive assembly into clutch housing.

SCIA0888E

MT-42

TRANSAXLE ASSEMBLY
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

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

G
SCIA0889E

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

SCIA0394E

SCIA0393E

17. Install 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod
with interlock pin.
18. Install a new stopper ring onto 5th-6th bracket.
CAUTION:
Do not reuse stopper ring.

SCIA0963E

MT-43

TRANSAXLE ASSEMBLY
19. Install a new retaining pin onto 5th-6th shift fork.
CAUTION:
Do not reuse retaining pin.
20. Install 2 check balls.
21. Install check ball, shift check sleeve, check spring and a new
check plug.
CAUTION:
● Do not reuse check plug.
● Do not drop check ball.
22. Install reverse bracket fork rod and reverse bracket.
23. Install a new retaining pin onto reverse bracket.
CAUTION:
Do not reuse retaining pin.
24. Install reverse shift fork and reverse fork rod.
25. Install reverse lever assembly following the 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.

SCIA0962E

SCIA0961E

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

PCIB0791E

Install reverse lever assembly to clutch housing, and then
tighten mounting bolts to the specified torque. Refer to MT-27,
"SHIFT CONTROL COMPONENTS" .
26. Install check ball, shift check sleeve, check spring and a new
check plug to clutch housing.
CAUTION:
● Do not reuse check plug.
● Do not drop check ball.
27. Install the magnet onto clutch housing.
SCIA0960E

28. Apply multi-purpose grease to differential oil seal lip, and then
install a new differential oil seal to transaxle case using the drift.
CAUTION:
Do not reuse differential oil seals.
29. Install selected input shaft rear bearing adjusting shim onto input
shaft.
● For selection of adjusting shims, refer to MT-50, "INPUT
SHAFT END PLAY" .
30. Install selected differential side bearing adjusting shim and differential side bearing. For selection adjusting shim, refer to MT52, "DIFFERENTIAL SIDE BEARING PRELOAD" .

MT-44

SCIA0887E

TRANSAXLE ASSEMBLY
31. Install baffle plate and oil gutter to transaxle case.
32. Install transaxle case following the procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
● For selection of adjusting shims, refer toMT-51, "MAINSHAFT END PLAY" .
b. Temporarily install a new snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse 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.

F
PCIB0816E

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

SCIA0892E

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

MT-45

TRANSAXLE ASSEMBLY
g.

Tighten mounting bolts to the specified torque.
Bolt A:
: 52 N·m (5.3 kg-m, 38 ft-lb)
Bolt B:
: 65 N·m (6.6 kg-m, 48 ft-lb)

CAUTION:
Always replace bolts B as they are self-sealing bolts.
h. Install control assembly to transaxle case to transaxle case.
SCIA1064E
CAUTION:
Do not reuse O-ring.
i. Install a new shift check to transaxle case, and then tighten shift check to the specified torque. Refer to
MT-27, "SHIFT CONTROL COMPONENTS" .
CAUTION:
Does not reuse shift check.
j. Install a new stopper bolt to transaxle case, and then tighten stopper bolt to the specified torque. Refer to
MT-27, "SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse stopper bolt.
33. Install a new bore plug to transaxle case using the drift.
CAUTION:
Do not reuse bore plug.

SCIA0894E

34. Install a new welch plug to transaxle case using the drift.
CAUTION:
Do not reuse welch plug.

SCIA0403E

35. Install 2 check balls, 2 check springs and 2 new check plugs to
transaxle case, and then tighten check plug to the specified
torque. Refer to MT-27, "SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse check plug.

SCIA1667E

MT-46

TRANSAXLE ASSEMBLY
36. Install new O-ring applied gear oil on control assembly. And then
install control assembly on transaxle case. After the precious
service tighten bolts to the specified torque. Refer to MT-27,
"SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse O-ring.
37. Apply genuine liquid gasket or equivalent to threads of park/neutral position switch and back-up lamp switch. Then install them
into transaxle case. Tighten park/neutral position switch and
back-up lamp switch to the specified torque. Refer to MT-24,
"CASE AND HOUSING COMPONENTS" .

MT
SCIA0895E

38. Install new gaskets onto drain plug and filler plug, and then install them into transaxle case. Tighten drain
plug and filler plug to the specified torque. Refer to MT-24, "CASE AND HOUSING COMPONENTS" .
CAUTION:
● Do not reuse gasket.
● After oil is filled, tighten filler plug to specified torque.

Adjustment (RS5F51A)

ECS008C2

INPUT SHAFT END PLAY
●

●

When adjusting input shaft end play, select adjusting shim for
input shaft rear bearing. To select adjusting shim, measure
clearance between transaxle case and input shaft rear bearing.
Refer to MT-102, "INPUT SHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.
Calculate dimension "O" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.
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 end face
and end face of input shaft rear bearing

SCIA1006E

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

SCIA1002E

MT-47

TRANSAXLE ASSEMBLY
2.

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

PCIB0792E

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.
Refer to MT-102, "MAINSHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.
Calculate dimension "P" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for mainshaft rear bearing.
PCIB0793E

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 end
face and transaxle case end face
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 bore plug mounting 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 rear bearing, becomes “M”.

PCIB0794E

DIFFERENTIAL SIDE BEARING PRELOAD
●

●

MT-48

TRANSAXLE ASSEMBLY
Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L1 - L2 ) + Preload
L:
Thickness of adjusting shim
L1 : Distance between transaxle case end face and
mounting face of adjusting shim
L2 : Distance between differential side bearing
outer race and clutch housing end face
1.

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

F
SCIA1078E

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

J
SCIA1079E

Install selected differential side bearing adjusting shim, and then
install differential side bearing outer race using the drift.

M
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. Refer
to MT-102, "REVERSE IDLER GEAR ADJUSTING SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.
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

MT-49

PCIB0796E

TRANSAXLE ASSEMBLY
Q:
Q1 :
Q2 :
1.

Thickness of adjusting shim
Distance between transaxle case end face and
mounting face of adjusting shim
Distance between clutch housing end face
and end face of reverse idler gear (Rear)

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

SCIA1003E

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

PCIB0797E

Adjustment (RS6F51A)

ECS008C3

INPUT SHAFT END PLAY
●

●

When adjusting input shaft end play, select adjusting shim for
input shaft rear bearing. To select adjusting shim, measure
clearance between transaxle case and input shaft rear bearing.
Refer to MT-102, "INPUT SHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.
Calculate dimension "O" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.
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 end face
O2
:
and end face of input shaft rear bearing

MT-50

SCIA1001E

TRANSAXLE ASSEMBLY
1.

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

MT
SCIA1002E

G
PCIB0792E

MAINSHAFT END PLAY
●

●

1.
2.
3.
4.

K
PCIB0793E

PCIB0794E

MT-51

TRANSAXLE ASSEMBLY
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. Refer to MT-103, "DIFFERENTIAL
SIDE BEARING ADJUSTING SHIM(S)" .
CAUTION:
Up to 2 adjusting shims can be selected.
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 transaxle case end face
L1 :
and mounting face of adjusting shim
Distance between differential side bearing
L2 :
outer race and clutch housing end face

PCIB0795E

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

SCIA1078E

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

SCIA1079E

Install selected differential side bearing adjusting shim, and then
install differential side bearing outer race using the drift.

SCIA0898E

MT-52

TRANSAXLE ASSEMBLY
REVERSE IDLER GEAR END PLAY
●

●

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 end face and
end face of reverse idler gear (Rear)
1.

PCIB0796E

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

I
SCIA1003E

M
PCIB0797E

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)

Remove oil channel.
SCIA0914E

Press out input shaft rear bearing using the drift and a puller.

SCIA0915E

Remove the snap ring.

SCIA0916E

Press out input shaft bearing spacer and 5th stopper using the
drift and a puller.

SCIA0917E

MT-54

INPUT SHAFT AND GEARS
6.
7.

Press out 5th input gear and 5th synchronizer hub assembly
using the drift and a puller.
Remove 5th needle bearing.

MT
SCIA0918E

Press out 5th input gear bushing, thrust washer, 4th input gear,
4th needle bearing, 4th input gear bushing, 4th baulk ring, 3rd4th synchronizer hub assembly, 3rd baulk ring and 3rd input
gear using the drift and a puller.
Remove 3rd needle bearing.

G
SCIA0919E

10. Press out input shaft front bearing using a puller.

SCIA0920E

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

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

: 0.9 - 1.45 mm (0.035 - 0.057 in)
: 0.95 - 1.4 mm (0.037 - 0.055 in)
: 0.7 mm (0.028 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 to input shaft.
Install 3rd input gear and 3rd baulk ring to input shaft.
Install 3rd-4th spread spring, 3rd-4th shifting insert and a new 3rd-4th synchronizer hub onto a new 3rdB
4th coupling sleeve.
CAUTION:
● Be careful with orientation of 3rd-4th synchronizer hub.
MT
● Do not reuse 3rd-4th synchronizer hub.

E
SCIA0921E

F
●
●

Be careful with orientation of 3rd-4th coupling sleeve.
Do not reuse 3rd-4th coupling sleeve.
G

I
PCIB0799E

●

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

SCIA1083E

Press in 3rd-4th synchronizer hub assembly using the press
stand.
CAUTION:
Align grooves of 3rd-4th shifting insert and 3rd baulk ring.

SCIA0922E

MT-57

INPUT SHAFT AND GEARS
5.
6.
7.

Press in 4th input gear bushing using the press stand.
Install 4th baulk ring.
Install 4th needle bearing and 4th input gear to input shaft.

PCIB0800E

Select thrust washer so that dimension “C2” satisfies the standard value below. Then install thrust washer onto input shaft.
Refer to MT-101, "INPUT SHAFT THRUST WASHER" .
Standard for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)
CAUTION:
Only one thrust washer can be selected.

SCIA0925E

Press in a new 5th input gear bushing using the press stand.
CAUTION:
Do not reuse 5th input gear bushing.
10. Install 5th needle bearing and 5th input gear to input shaft.
11. Install 5th baulk ring.

SCIA0926E

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

MT-58

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

SCIA0927E

●
●

Be careful with orientation of 5th coupling sleeve.
Do not reuse 5th coupling sleeve.

G
SCIA0994E

H
●

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

K
SCIA1083E

13. Press in 5th synchronizer hub assembly using the press stand.
CAUTION:
Align grooves of 5th shifting insert and 5th baulk ring.

SCIA0928E

MT-59

INPUT SHAFT AND GEARS
14. Press in 5th stopper and then input shaft bearing spacer using
the drift.

SCIA0929E

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

If measurement is outside the standard range, select snap
ring. Refer to MT-100, "INPUT SHAFT BEARING SPACER" .
CAUTION:
Do not reuse snap ring.
SCIA0930E

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

SCIA0931E

17. Press in input shaft front bearing using the drifts.
18. Install oil channel onto input shaft.

PCIB0825E

19. Check end play of 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)

SCIA0914E

MT-60

INPUT SHAFT AND GEARS
Assembly and Disassembly (RS6F51A)

ECS008C5

DISASSEMBLY
1.

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

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.

Remove oil channel.
SCIA0966E

3.
4.

Press out input shaft rear bearing using the drift and a puller.
Remove snap ring.

SCIA0967E

5.
6.

Press out 6th input gear, 6th needle bearing and 6th input gear
bushing using the drift and a puller.
Remove 6th baulk ring.

K
SCIA0968E

7.
8.

Press out 5th input gear and 5th-6th synchronizer hub assembly
using the drift and a puller.
Remove 5th needle bearing.

SCIA0918E

MT-61

INPUT SHAFT AND GEARS
9.

SCIA0919E

11. Press out input shaft front bearing using a puller.

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

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

MT-62

INPUT SHAFT AND GEARS
●

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

MT
SMT867D

: 0.9 - 1.45 mm (0.035 - 0.057 in)
: 0.95 - 1.4 mm (0.037 - 0.055 in)
: 0.7 mm (0.028 in)

G
SMT140

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

K
MTF0041D

MT-63

INPUT SHAFT AND GEARS
ASSEMBLY
1.
2.
3.

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

SCIA0921E

●
●

Be careful with orientation of 3rd-4th coupling sleeve.
Do not reuse 3rd-4th coupling sleeve.

PCIB0799E

●

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

SCIA1083E

Press in 3rd-4th synchronizer hub assembly using the press
stand.
CAUTION:
Align grooves of 3rd-4th shifting insert and 3rd baulk ring.

SCIA0922E

MT-64

INPUT SHAFT AND GEARS
5.
6.
7.

Press in 4th input gear bushing using the press stand.
Install 4th baulk ring.
Install 4th needle bearing and 4th input gear to input shaft.

MT
PCIB0800E

Select thrust washer so that dimension “C2” satisfies the standard value below. Then install thrust washer onto input shaft.
Refer to MT-101, "INPUT SHAFT THRUST WASHER" .

Standard value for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)
F

CAUTION:
Only one thrust washer can be selected.

SCIA0925E

SCIA0926E

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

MT-65

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

SCIA0921E

●
●

Be careful with orientation of 5th-6th coupling sleeve.
Do not reuse 5th-6th coupling sleeve.

PCIB0801E

●

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

SCIA1083E

13. Press in 5th-6th synchronizer hub assembly using the press
stand.
CAUTION:
Align grooves of 5th-6th shifting insert and 5th baulk ring
and 6th baulk ring.

SCIA0928E

MT-66

INPUT SHAFT AND GEARS
14. Install 6th needle bearing, 6th input gear, 6th baulk ring onto 6th
input gear bushing, and then press in 6th bushing onto input
shaft using the drift.

MT
SCIA0969E

15. Install a new snap ring onto input shaft, and check that end play
(gap between snap ring and groove) of 6th input gear bushing
satisfies the standard value.
End play standard value
●

: 0 - 0.1 mm (0 - 0.004 in)

If measurement is outside the standard range, select snap
ring. Refer to MT-100, "6TH INPUT GEAR BUSHING" .
CAUTION:
Do not reuse snap ring.

G
SCIA0970E

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

SCIA0971E

17. Press in input shaft front bearing using the drifts.
18. Install oil channel onto input shaft.

PCIB0826E

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

SCIA0933E

2.
3.

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

PCIB0802E

Remove mainshaft rear bearing using the drift and pullers.

SCIA0935E

Remove snap ring.

SCIA0936E

MT-68

MAINSHAFT AND GEARS
6.
7.
8.

Press out 4th main gear and 5th main gear using the drift and a
puller.
Remove 4th main gear adjusting shim.
Remove 3rd-4th mainshaft spacer.

MT
SCIA0937E

Press out 3rd main gear, 2nd main gear, 2nd needle bearing,
2nd main gear bushing, 1st-2nd synchronizer hub assembly, 1st
main gear, 1st needle bearing, and 1st main gear bushing
reverse main gear using the drift.

G
SCIA0938E

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.

K
SCIA1075J

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)
Follow the instructions below and inspect the clearance of outer
baulk ring, synchronizer cone, inner baulk ring.
CAUTION:
Outer baulk ring, synchronizer cone and inner baulk ring
control clearances “A” and “B” as a set. Replace them as a
set if they are outside the limit value.

SCIA0950E

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

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

PCIB0818E

MT-70

MAINSHAFT AND GEARS
2.

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

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

MT
SCIA1084E

D
●

Triple cone synchronizer (2nd)
Follow the instructions below and inspect the clearance of
outer baulk ring, synchronizer cone, inner baulk ring.
CAUTION:
Outer baulk ring, synchronizer cone and inner baulk ring
control clearances “A”, “B” and “C” as a set. Replace
them as a set if they are outside the limit value.

G
PCIB0603E

Measure clearance “A” at 2points or more on the opposite side
using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. Then calculate the average.
Clearance “A”
Standard value
Limit value

: 0.6 - 1.2 mm (0.024 - 0.047 in)
: 0.3 mm (0.012 in)

K
PCIB0808E

Measure clearance “B” at 2 points or more on the opposite side
using a feeler gauge. Then calculate the average.
Clearance “B”
Standard value
Limit value

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

PCIB0605E

Measure clearance “C” at 2 points or more on the opposite side
using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. Then calculate the average.
Clearance “C”
Standard value
Limit value

: 0.7 - 1.1 mm (0.028 - 0.043 in)
: 0.3 mm (0.012 in)

PCIB0809E

MT-71

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

MTF0041D

ASSEMBLY
1.

Press in reverse main gear using the drifts and the press stand.

SCIA0939E

CAUTION:
Be careful with orientation of reverse main gear.
● Do not reuse reverse main gear.
●

SCIA0992E

2.
3.

Press in 1st main gear bushing using the drifts and the press
stand.
Install 1st needle bearing, and then 1st main gear.

SCIA0940E

Install 1st-2nd spread spring, 1st-2nd shifting insert and a new 1st-2nd synchronizer hub onto a new 1st2nd coupling sleeve.

MT-72

MAINSHAFT AND GEARS
CAUTION:
● Be careful with orientation of 1st-2nd synchronizer hub.
● Do not reuse 1st-2nd synchronizer hub.

SCIA0921E

●
●

Be careful with orientation of 1st-2nd coupling sleeve.
Do not reuse 1st-2nd coupling sleeve.

G
PCIB0803E

●

Be sure not to hook center projection of 2 spread springs
on same 1st-2nd shifting insert.

K
SCIA1083E

Install 1st inner baulk ring, 1st synchronizer cone, 1st outer
baulk ring onto mainshaft, and then press in 1st-2nd synchronizer hub assembly onto mainshaft using the drifts and the press
stand.
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

MT-73

MAINSHAFT AND GEARS
6.
7.
8.

Press in 2nd main gear bushing using the drift and the press
stand.
Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd
inner baulk ring.
Install 2nd needle bearing and 2nd main gear.

SCIA0942E

Press in a new 3rd main gear using the drift and the press stand.
CAUTION:
● Be careful with orientation of 3rd main gear.
● Do not reuse 3rd main gear.
10. Install 3rd-4th mainshaft spacer.

SCIA0943E

11. Select 4th main gear adjusting shim so that dimension “C1” satisfies the standard value below, and install 4th main gear adjusting shim onto mainshaft. Refer to MT-101, "4TH MAIN GEAR
ADJUSTING SHIM" .
Standard value for dimension C1
: 173.85 - 173.95 mm (6.844 - 6.848 in)
CAUTION:
Only one adjusting shim can be selected.

PCIB0804E

12. Press in a new 4th main gear using the drifts.
CAUTION:
● Be careful with orientation of 4th main gear.
● Do not reuse 4th main gear.

SCIA0945E

MT-74

MAINSHAFT AND GEARS
13. Press in a new 5th main gear using the drifts.
CAUTION:
● Be careful with orientation of 5th main gear.
● Do not reuse 5th main gear.

MT
SCIA0946E

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

: 0 - 0.1 mm (0 - 0.004 in)

If measurement is outside the standard range, reselect snap
ring. Refer to MT-100, "5TH MAIN GEAR" .
F

G
SCIA0947E

15. Press in mainshaft rear bearing using the drifts.

SCIA0948E

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

: 0 - 0.06 mm (0 - 0.0024 in)

If measurement is outside the standard range, reselect mainshaft C-ring. Refer to MT-100, "MAINSHAFT C-RING" .

SCIA0949E

17. Install C-ring holder, and then install a new snap ring.
CAUTION:
Do not reuse snap ring.

PCIB0802E

MT-75

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

SCIA0933E

Assembly and Disassembly (RS6F51A)

ECS008C7

DISASSEMBLY
1.

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

SCIA0973E

2.
3.

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

PCIB0805E

4.
5.

Press out mainshaft rear bearing, 6th main adjusting shim and
6th main gear using the drift and a puller.
Remove 5th-6th mainshaft spacer.

SCIA0976E

MT-76

MAINSHAFT AND GEARS
6.
7.
8.

Press out 4th main gear and 5th main gear using the drift and a
puller.
Remove 4th main gear adjusting shim.
Remove 3rd-4th mainshaft spacer.

MT
SCIA0937E

G
SCIA0938E

INSPECTION AFTER DISASSEMBLY
Mainshaft and Gears

K
SCIA1076J

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

MT-77

MAINSHAFT AND GEARS
●

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)
Follow the instructions below and inspect the clearance of outer
baulk ring, synchronizer cone, inner baulk ring.
CAUTION:
Outer baulk ring, synchronizer cone, and inner baulk ring
control clearances “A” and “B” as a set. Replace them as a
set if they are outside the limit value.

SCIA0950E

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

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

PCIB0818E

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

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

SCIA1084E

●

Triple cone synchronizer (2nd)
Follow the instructions below and inspect the clearance of outer
baulk ring, synchronizer cone, inner baulk ring.
CAUTION:
Outer baulk ring, synchronizer cone and inner baulk ring
control clearances “A”, “B” and “C” as a set. Replace them
as a set if they are outside the limit value.

PCIB0603E

MT-78

MAINSHAFT AND GEARS
1.

Measure clearance “A” at 2 points or more on the opposite side
using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. Then calculate the average.
Clearance “A”
Standard value
Limit value

: 0.6 - 1.2 mm (0.024- 0.047)
: 0.3 mm (0.012 in)

PCIB0808E

Measure clearance “B” at 2 points or more on the opposite side
using a feeler gauge. Then calculate the average.
Clearance “B”
Standard value
Limit value

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

G
PCIB0605E

: 0.7 - 1.1 mm (0.028 - 0.043 in)
: 0.3 mm (0.012 in)

PCIB0809E

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

MTF0041D

MT-79

MAINSHAFT AND GEARS
ASSEMBLY
1.

Press in reverse main gear using the drifts and the press stand.

SCIA0939E

CAUTION:
Be careful with orientation of reverse main gear.
● Do not reuse reverse main gear.
●

SCIA0992E

2.
3.

Press in 1st main gear bushing using the drifts and the press
stand.
Install 1st needle bearing, and then 1st main gear.

SCIA0940E

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

SCIA0921E

MT-80

MAINSHAFT AND GEARS
●
●

Be careful with orientation of 1st-2nd coupling sleeve.
Do not reuse 1st-2nd coupling sleeve.

MT
PCIB0803E

D
●

Be sure not to hook center projection of 2 spread springs
on same 1st-2nd shifting insert.
E

G
SCIA1083E

SCIA0941E

6.
7.
8.

Press in 2nd main gear bushing using the drift and the press
stand.
Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd
inner baulk ring.
Install 2nd needle bearing and 2nd main gear.

SCIA0942E

Press in a new 3rd main gear using the drift and the press stand.
CAUTION:
● Be careful with orientation of 3rd main gear.
● Do not reuse 3rd main gear.
10. Install 3rd-4th mainshaft spacer.

SCIA0943E

MT-81

MAINSHAFT AND GEARS
11. Select 4th main gear adjusting shim so that dimension “C1” satisfies the standard value below, and install 4th main gear adjusting shim onto mainshaft. Refer to MT-101, "4TH MAIN GEAR
ADJUSTING SHIM" .
Standard value for dimension C1
: 173.85 - 173.95 mm (6.844 - 6.848 in)
CAUTION:
Only one adjusting shim can be selected.

PCIB0804E

12. Press in a new 4th main gear using the drifts.
CAUTION:
● Be careful with orientation of 4th main gear.
● Do not reuse 4th main gear.

SCIA0945E

13. Press in a new 5th main gear using the drifts.
CAUTION:
● Be careful with orientation of 5th main gear.
● Do not reuse 5th main gear.
14. Install 5th-6th mainshaft spacer.

SCIA0946E

15. Press in 6th main gear using the drifts.
CAUTION:
Do not reuse 6th main gear.

SCIA0977E

MT-82

MAINSHAFT AND GEARS
16. Select 6th main adjusting shim and then install it onto mainshaft.
● Calculate thickness “S” of 6th main adjusting shim following
the procedure below so that end play dimension between 6th
main gear and mainshaft rear bearing becomes the dimension shown below. Refer to MT-102, "6TH MAIN GEAR
ADJUSTING SHIM" .

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

a.
b.

CAUTION:
Only one adjusting shim can be selected.
Using height gauge, measure dimension “S1 ” and “S2 ”.
Install selected 6th main adjusting shim to mainshaft.

G
SCIA0995E

17. Press in mainshaft rear bearing using the drifts.

K
SCIA0978E

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

: 0 - 0.06 mm (0 - 0.0024 in)

If measurement is outside the standard range, reselect mainshaft C-ring. Refer to MT-100, "MAINSHAFT C-RING" .

SCIA0979E

MT-83

MAINSHAFT AND GEARS
19. Install C-ring holder, and then install a new snap ring.
CAUTION:
Do not reuse snap ring.

PCIB0805E

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

SCIA0973E

MT-84

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

PFP:32281

A
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 reverse 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.
Remove retaining pin from reverse idler shaft.
CAUTION:
Do not reuse retaining pin.

INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft and Gears

I
SCIA0953J

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

M
SMT637A

●

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

SMT867D

MT-85

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

: 0.95 - 1.4 mm (0.037 - 0.055 in)
: 0.7 mm (0.028 in)

SMT140

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

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

SCIA0954E

Assembly and Disassembly (RS6F51A)
DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.

MT-86

ECS008C9

REVERSE IDLER SHAFT AND GEARS
INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft and Gears

D
SCIA0953J

Synchronizer

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

H
SMT637A

●

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

SMT867D

Baulk ring clearance
Push baulk ring on the cone, and measure the clearance
between baulk ring and cone. If the measurement is below limit,
replace it with a new one.

●

Clearance
Standard value
Limit value

: 0.95 - 1.4 mm (0.037 - 0.055 in)
: 0.7 mm (0.028 in)

SMT140

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

ASSEMBLY
Paying attention to the following work, assemble in reverse order of disassembly.

MT-87

REVERSE IDLER SHAFT AND GEARS
CAUTION:
●
Be careful with orientation of reverse insert spring.

SCIA0954E

MT-88

FINAL DRIVE
FINAL DRIVE
Assembly and Disassembly (RS5F51A)

PFP:38411

A
ECS008CA

PRE-INSPECTION
●

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.

PCIB0806E

2.
3.

Upright differential case so that side gear to be measured faces upward.
Place the drift below and a dial gauge onto side gear. Move side
gear up and down, and measure the clearance.

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 side
gear 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.

SMT611A

DISASSEMBLY
1.
2.

Remove final gear mounting bolts, and then separate the final gear from differential case.
Remove differential side bearing (clutch housing side) using the
drift and pullers.

M
SCIA0906E

Remove differential side bearing (transaxle case side) using the
drift and pullers.

SCIA0907E

MT-89

FINAL DRIVE
4.
5.

Remove retaining pin from differential case, and then remove
pinion mate shaft using a pin punch.
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-90

FINAL DRIVE
4.

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

MT
MTK0132D

5.
a.
b.

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

G
PCIB0806E

Move side gears up and down to measure end play, and select
thrust washer so that it satisfies the standard value. Refer to MT101, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .

End play standard value
: 0.1 - 0.2 mm (0.004 - 0.008 in)
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.
● Only one thrust washer can be selected.
Install a new retaining pin into pinion mate shaft using a pin
punch.
CAUTION:
Do not reuse retaining pin.

●

SMT611A

SCIA0908E

Press in differential side bearing (transaxle case side) to differential case using the drifts.

SCIA0910E

MT-91

FINAL DRIVE
8.

Press in differential side bearing (clutch housing side) to differential case using the drifts.

SCIA0911E

Install final gear into differential case, and tighten final gear
mounting bolts to the specified torque. Refer to MT-23, "FINAL
DRIVE COMPONENTS" .

SCIA0912E

Assembly and Disassembly (RS6F51A)

ECS008CB

PRE-INSPECTION
●

PCIB0806E

2.
3.

Upright differential case so that side gear to be measured faces upward.
Place the drift below and a dial gauge onto side gear. Move side
gear up and down, and measure the clearance.
Clearance between side gear and differential case
: 0.1 - 0.2 mm (0.004 - 0.008 in)

4.
5.

DISASSEMBLY
1.

Remove final gear mounting bolts, and then separate the final gear from differential case.

MT-92

SMT611A

FINAL DRIVE
2.

Remove differential side bearing (clutch housing side) using the
drift and pullers.

MT
SCIA0906E

Remove differential side bearing (transaxle case side) using the
drift and pullers.
E

G
SCIA0907E

4.
5.

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

MT-93

FINAL DRIVE
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.

SMT839

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

MTK0132D

5.
a.
b.

PCIB0806E

MT-94

FINAL DRIVE
c.

Move side gears up and down to measure end play, and select
thrust washer so that it satisfies the standard value. Refer to MT101, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .

●

MT
SMT611A

G
SCIA0908E

Press in differential side bearing (transaxle case side) to differential case using the drifts.

SCIA0910E

Press in differential side bearing (clutch housing side) to differential case using the drifts.

SCIA0911E

Install final gear into differential case, and tighten final gear
mounting bolts to the specified torque. Refer to MT-28, "FINAL
DRIVE COMPONENTS" .

SCIA0912E

MT-95

SHIFT CONTROL
SHIFT CONTROL
Inspection (RS5F51A)

PFP:32982
ECS008CC

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

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

SHIFT CONTROL
Inspection (RS6F51A)
●

ECS008CD

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

G
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)

K
SMT801D

MT-97

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

PFP:00030
ECS008CE

TRANSAXLE
Engine

QR20DE

Transaxle model

QR25DE

YD22DDTi

RS5F51A

Model code number

EQ000

Number of speed

RS6F51A
EQ008

EQ068

Synchromesh type

6
Warner

Shift pattern

5 speed

SCIA0821E

6 speed

SCIA0955E

Gear ratio

1st

3.500

1.944

3rd

1.258

4th

0.947

5th

0.772

6th

Input gear

1st

0.772

3.374

3.252

3.374

3rd

4th

38
44

6th

45
—

44
46

Reverse

1st

2nd

3rd

4th

5th

6th

Reverse idler
gear

3.500

0.630

2nd

5th

Main gear

0.733
—

Reverse
Number of teeth

3.416

2nd

33
—

Reverse

Front

Rear

Oil capacity
(Imp pt)

38
2.3 (4)

MT-98

SERVICE DATA AND SPECIFICATIONS (SDS)
Engine

QR20DE

Transaxle model

YD22DDTi

RS5F51A

Model code number
Remarks

QR25DE

EQ000

EQ008

Reverse synchronizer

RS6F51A
EQ068

Installed

Double-cone synchronizer

1st

Triple-cone synchronizer

2nd

FINAL GEAR
Engine

QR20DE

Transaxle model

YD22DDTi

RS5F51A

Model code number

EQ000

Final gear ratio
Number of teeth

QR25DE

Final gear/Pinion

EQ068

4.750

4.428

76/16

62/14

Side gear/Pinion mate gear

RS6F51A
EQ008

14/10

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)

Baulk Ring Clearance

I
ECS00CV4

Unit: mm (in)
Measurement point
1st
(Double-cone synchronizer)

●

Standard

Clearance between synchronizer cone
and inner baulk ring end face “A”

A: 0.6 - 0.8 (0.024 - 0.031)
B: 0.6 - 1.1 (0.024 -0.043)

Limit value
0.2 (0.008)
0.2 (0.008)

Clearance between outer baulk ring pawl
and synchronizer cone “B”

M
PCIB0249E

2nd
(Triple-cone synchronizer)

●

Clearance between synchronizer cone
and clutch gear end face “A”

●

Clearance between outer baulk ring pawl
and synchronizer cone “B”

●

Clearance between inner baulk ring and
clutch gear end face “C”

A: 0.6 - 1.2 (0.024 - 0.047)
B: 0.6 - 1.1 (0.024 - 0.043)
C: 0.7 - 1.1 (0.028 - 0.043)

0.3 (0.012)
0.2 (0.008)
0.3 (0.012)

0.9 - 1.45 (0.035 - 0.057)

0.7 (0.028)

PCIB0772E

3rd&4th

MT-99

SERVICE DATA AND SPECIFICATIONS (SDS)
Measurement point

Standard

Limit value

5th

0.95 - 1.4 (0.037 - 0.055)

0.7 (0.028)

6th (For RS6F51A model)

0.95 - 1.4 (0.037 - 0.055)

0.7 (0.028)

Reverse

0.95 - 1.4 (0.037 - 0.055)

0.7 (0.028)

Available Snap Rings

ECS008CH

INPUT SHAFT BEARING SPACER
—For RS5F51A Model—
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)

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

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

6TH INPUT GEAR BUSHING
—For RS6F51A Model—
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*
32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520

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

5TH MAIN GEAR
—For RS5F51A Model—
End play

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

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

Available C-Rings

ECS008CI

MAINSHAFT C-RING
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-100

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

SERVICE DATA AND SPECIFICATIONS (SDS)
Available Thrust Washer

ECS008CJ

INPUT SHAFT THRUST WASHER

D
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

4TH MAIN GEAR 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-101

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

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

0 - 0.06 mm (0 - 0.0024 in)

Thickness

mm (in)

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)

Part number*
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**

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

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

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

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 Model—
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-102

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

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)

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

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

MT-103

SERVICE DATA AND SPECIFICATIONS (SDS)

MT-104

Source Exif Data:

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File Type Extension             : pdf
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Create Date                     : 2004:04:01 19:23:28Z
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Modify Date                     : 2004:04:15 12:20:03+02:00
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Producer                        : Acrobat Distiller 4.05 for Windows
Mod Date                        : 2004:04:15 12:20:03+02:00
Metadata Date                   : 2004:04:15 12:20:03+02:00
Title                           : MT.fm

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Nissan 2004 X Trail Owners Manual MT

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