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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QUICK REFERENCE INDEX
Table of Contents

MT-1

MANUAL TRANSAXLE

C TRANSMISSION/TRANSAXLE

CONTENTS

SECTION

MANUAL TRANSAXLE

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 FUNC-

TION (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-2

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

PRECAUTIONS

MT-3

PRECAUTIONS PFP:00001

Caution ECS008BM

●Do not reuse transaxle oil, once it has been drained.

●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

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.

●Be careful not to damage sliding surfaces and mating surfaces.

MT-4

PREPARATION

PREPARATION PFP:00002

Special Service Tools ECS008BN

Tool number

Tool name Description

KV381054S0

Puller

●Differential side bearing outer race removal

●Mainshaft front bearing removal

ST35321000

Drift

a: 49 mm (1.93 in) dia.

b: 41 mm (1.61 in) dia.

●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

ST30720000

Drift

a: 77 mm (3.03 in) dia.

b: 55.5 mm (2.185 in) dia.

●Differential oil seal installation

●Differential side bearing outer race

installation

●Mainshaft rear bearing installation

●Differential side bearing installation

ST33200000

Drift

a: 60 mm (2.36 in) dia.

b: 44.5 mm (1.752 in) dia.

●Mainshaft front bearing installation

●6th input gear bushing installation

(RS6F51A)

●4th main gear installation

●5th main gear installation

●6th main gear installation (RS6F51A)

KV40105320

Drift

a: 88 mm (3.46 in) dia.

Differential side bearing outer race installation

ST33061000

Drift

a: 38 mm (1.50 in) dia.

b: 28.5 mm (1.122 in) dia.

●Bore plug installation

●Differential side bearing (transaxle case

side) removal

ZZA0601D

ZZA1000D

ZZA0811D

ZZA1002D

ZZA0898D

ZZA1000D

PREPARATION

MT-5

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)

KV40105020

Drift

a: 39.7 mm (1.563 in) dia.

b: 35 mm (1.38 in) dia.

c: 15 mm (0.59 in)

●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

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

ST38220000

Press stand

a: 63 mm (2.48 in) dia.

b: 65 mm (2.56 in)

●Reverse main gear installation

●1st main gear bushing installation

●1st-2nd synchronizer hub assembly

installation

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

ST30901000

Drift

a: 79 mm (3.11 in) dia.

b: 45 mm (1.77 in) dia.

c: 35.2 mm (1.386 in) dia.

●Input shaft rear bearing installation

●4th main gear installation

●5th main gear installation

●6th main gear installation (RS6F51A)

●Mainshaft rear bearing installation

Tool number

Tool name Description

ZZA1023D

ZZA1133D

ZZA1058D

ZZA0978D

MT-6

PREPARATION

Commercial Service Tools ECS008BO

ST30031000

Puller

Measuring wear of inner baulk ring

KV40101630

Drift

a: 68 mm (2.68 in) dia.

b: 60 mm (2.36 in) dia.

Reverse main gear installation

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

KV40104830

Drift

a: 70 mm (2.76 in) dia.

b: 63.5 mm (2.500 in) dia.

Differential side bearing (clutch housing side)

installation

ST15243000

Drift

a: φ 30mm

Measuring end play of side gear

Tool number

Tool name Description

ZZA0537D

ZZA1003D

ZZA0838D

ZZA0936D

SCIA1088J

Tool name Description

Puller Each bearing, gear and bushing removal

ZZA0537D

PREPARATION

MT-7

Puller Each bearing, gear and bushing removal

Pin punch

Tip diameter: 4.5 mm (0.177 in) dia.

Each retaining pin removal and installation

Tool name Description

NT077

ZZA0815D

MT-8

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

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

NVH Troubleshooting Chart ECS008BP

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-

tion. If necessary, repair or replace these parts.

MANUAL TRANSAXLE

Reference page

MA-37

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

MT-14

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

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

SUSPECTED PARTS

(Possible cause)

OIL (Oil level is low.)

OIL (Wrong oil.)

OIL (Oil level is high.)

GASKET (Damaged)

OIL SEAL (Worn or damaged)

O-RING (Worn or damaged)

SHIFT CONTROL LINKAGE (Worn)

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

SHIFT FORK (Worn)

GEAR (Worn or damaged)

BEARING (Worn or damaged)

BAULK RING (Worn or damaged)

INSERT SPRING (Damaged)

Symptoms

Noise 1 2 3 3

Oil leakage 31222

Hard to shift or will not shift 1 1 2 3 3

Jumps out of gear 1 2 3 3

DESCRIPTION

MT-9

DESCRIPTION PFP:00000

Cross-Sectional View ECS008BQ

1. 3rd input gear 2. 3rd-4th synchronizer hub 3. 3rd-4th coupling sleeve

4. 4th input gear 5. 5th input gear 6. 5th synchronizer hub

7. 5th coupling sleeve 8. Input shaft rear bearing 9. 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

PCIB0773E

MT-10

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.

REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)

Reverse gear can be matched smoothly in a structure by setting syn-

chronizer hub, coupling sleeve, baulk ring and insert spring to

reverse gear, and letting reverse gear be synchronized.

PCIB0774E

PCIB0775E

M/T OIL

MT-11

M/T OIL PFP:KLD20

Changing M/T Oil ECS008BR

DRAINING

1. Start engine and let it run to warm up transaxle.

2. Stop engine. Remove drain plug and drain oil.

3. Set a new gasket on drain plug and install it to transaxle. Refer to MT-19, "CASE AND HOUSING COM-

PONENTS" , MT-24, "CASE AND HOUSING COMPONENTS" .

CAUTION:

Do not reuse gasket.

FILLING

1. Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole.

2. 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 fig-

ure.

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.

Oil grade : API GL-4

Oil capacity (reference) : Approx. 2.3 (4 lmp pt)

SCIA0361E

MT-12

SIDE OIL SEAL

SIDE OIL SEAL PFP:32113

Removal and Installation ECS008BT

REMOVAL

●Clutch housing side oil seal used on 4WD vehicles is attached to transfer. Be sure to replace it

when transfer is removed.

1. Remove drive shaft from transaxle. Refer to FAX-11, "Removal and Installation" .

2. Remove oil seal with a flat-bladed screwdriver.

CAUTION:

Be careful not to damage the case surface when removing

oil seal.

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.

CAUTION:

●When installing oil seals, apply multi-purpose grease to

oil seal lips.

●Oil seals are not reusable. Never reuse them.

2. Install all parts in reverse order of removal and check oil level after installation. Refer to MT-11, "Checking

M/T Oil" .

SCIA0824E

Dimension "A":

Within 0.5 mm (0.020 in) of flush with the case.

Drift to be used:

Transaxle case side: ST30720000

Clutch housing side: ST30720000

SCIA0352E

POSITION SWITCH

MT-13

POSITION SWITCH PFP:32005

Checking ECS008BU

BACK-UP LAMP SWITCH

●Check continuity.

PARK/NEUTRAL POSITION SWITCH

●Check continuity.

Gear position Continuity

Reverse Yes

Except reverse No

SCIA0708E

Gear position Continuity

Neutral Yes

Except neutral No

MT-14

CONTROL LINKAGE

CONTROL LINKAGE PFP:34103

Components of Control Device and Cable ECS008BV

1. Control lever knob 2. Select cable 3. Shift cable

4. Lock plate 5. Lock plate 6. Clutch housing

7. Cable mounting bracket 8. Control device assembly 9. Control lever

10. Lock plate 11. Washer 12. Snap pin

13. Washer

PCIB0777E

CONTROL LINKAGE

MT-15

Removal and Installation ECS00CY6

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,

2nd, or Reverse.

●Shift control lever to the neutral position for removal.

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

assembly.

3. 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.

PCIB0815E

PCIB0817E

MT-16

AIR BREATHER HOSE

AIR BREATHER HOSE PFP:31098

Removal and Installation ECS008BW

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

QR engine model

YD engine model

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.

PCIB0778E

1. Air cleaner case 2. Transaxle 3. Clip

4. Air breather hose 5. Clip 6. PCV hose

7. Resonator

PCIB0779E

1. Air cleaner case 2. Transaxle 3. Clip

4. Clip 5. Air breather hose 6. Clip

7. Bracket 8. Mass air flow sensor

TRANSAXLE ASSEMBLY

MT-17

TRANSAXLE ASSEMBLY PFP:32010

Removal and Installation ECS008BX

REMOVAL

1. Remove air cleaner, air duct, and battery. Refer to EM-15, "Removal and Installation" ,EM-133, "Removal

and Installation"

2. Remove air breather hose. Refer to MT-16, "Removal and Installation" .

3. Remove clutch operating cylinder. Refer to CL-10, "Removal and Installation" .

CAUTION:

Do not depress clutch pedal during removal procedure.

4. Disconnect control cable from transaxle. Refer to MT-15, "Removal and Installation" .

5. Drain gear oil from transaxle. Refer to MT-11, "DRAINING" .

6. Disconnect park/neutral position switch, back-up lamp switch, and ground harness connectors.

7. Remove exhaust front tube and the drive shaft. Refer to EX-2, "Removal and Installation" .

8. Remove transfer. Refer to TF-55, "Removal and Installation" .

9. Remove starter motor. Refer to SC-25, "Removal and Installation" .

10. Place a jack onto transaxle.

CAUTION:

When setting jack, be careful not to bring it into contact with switch.

11. Remove center member, engine insulator and engine mount bracket. Refer to EM-78, "ENGINE ASSEM-

BLY" (QR engine model) or EM-208, "ENGINE ASSEMBLY" (YD engine model).

12. Remove suspension members. Refer to FSU-12, "FRONT SUSPENSION MEMBER" .

13. Support engine by placing a jack under oil pan.

1. Center member 2. Insulator assembly 3. Grommet

4. Transaxle 5. Rear engine mounting bracket 6. Rear engine mounting insulator

7. Stopper rubber (YD engine model) 8. Stopper 9. LH engine mounting insulator

10. LH engine mounting bracket

PCIB0780E

MT-18

TRANSAXLE ASSEMBLY

14. Remove bolts securing transaxle to engine.

15. Remove transaxle from vehicle.

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:

YD engine model:

●After installation, check oil level, and check for leaks and loose

mechanisms. Refer to MT-11, "Checking M/T Oil" .

MTD0062D

Bolt No. 1 2 3 4 5 6

Quantity 2 1 1 2 2 2

“ ” mm (in) 40

(1.57)

(2.95)

(1.77)

(1.57)

(1.18)

(1.57)

Tightening torque

N·m (kg - m, ft- lb)

74.5

(7.6, 55)

42.7

(4.4, 31)

35.3

(3.6, 26 )

SCIA0353E

Bolt No. 1 2 3 4 5 6

Quantity 2 2 1 1 3 1

“ ” mm (in) 55

(2.17)

(2.76)

120

(4.72)

(1.77)

(1.57)

(1.38)

Tightening torque

N·m (kg - m, ft- lb)

(4.5, 32)

33.5

(3.4, 25)

SCIA0748E

TRANSAXLE ASSEMBLY

MT-19

Component Parts (RS5F51A) ECS008BY

CASE AND HOUSING COMPONENTS

1. Clutch housing 2. Differential oil seal 3. Ball pin

4. Washer 5. Input shaft oil seal 6. Oil channel

7. Magnet 8. Back-up lamp switch 9. 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

PCIB0781E

MT-20

TRANSAXLE ASSEMBLY

GEAR COMPONENTS

1. Input shaft front bearing 2. Input shaft 3. 3rd needle bearing

4. 3rd input gear 5. 3rd baulk ring 6. 3rd-4th spread spring

7. 3rd-4th shifting insert 8. 3rd-4th synchronizer hub 9. 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

PCIB0782E

TRANSAXLE ASSEMBLY

MT-21

1. Mainshaft front bearing 2. Mainshaft bearing retainer 3. Mainshaft

4. Reverse main gear 5. 1st main gear 6. 1st main gear bushing

7. 1st needle bearing 8. 1st inner baulk ring 9. 1st gear synchronizer cone

10. 1st outer baulk ring 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

PCIB0783E

MT-22

TRANSAXLE ASSEMBLY

SHIFT CONTROL COMPONENTS

1. 3rd-4th bracket 2. Retaining pin 3. Stopper ring

4. 5th-reverse bracket 5. Reverse lever assembly 6. Shifter cap

7. Reverse shift fork 8. Reverse fork rod 9. Check plug

10. Check spring 11. Shift check sleeve 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

PCIB0784E

TRANSAXLE ASSEMBLY

MT-23

FINAL DRIVE COMPONENTS

1. Differential side bearing outer race 2. Differential side bearing (clutch

housing side)

3. Differential case

4. Final gear 5. Differential side bearing (transaxle

case side)

6. Differential side bearing outer race

7. Differential side bearing adjusting

shim

8. Side gear 9. Side gear thrust washer

10. Retaining pin 11. Pinion mate thrust washer 12. Pinion mate gear

13. Pinion mate shaft

PCIB0785E

MT-24

TRANSAXLE ASSEMBLY

Component Parts (RS6F51A) ECS008BZ

CASE AND HOUSING COMPONENTS

1. Clutch housing 2. Differential oil seal 3. Ball pin

4. Washer 5. Input shaft oil seal 6. Oil channel

7. Magnet 8. Back-up lamp switch 9. 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

PCIB0781E

TRANSAXLE ASSEMBLY

MT-25

GEAR COMPONENTS

1. Input shaft front bearing 2. Input shaft 3. 3rd needle bearing

4. 3rd input gear 5. 3rd baulk ring 6. 3rd-4th spread spring

7. 3rd-4th shifting insert 8. 3rd-4th synchronizer hub 9. 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

PCIB0786E

MT-26

TRANSAXLE ASSEMBLY

1. Mainshaft front bearing 2. Mainshaft bearing retainer 3. Mainshaft

4. Reverse main gear 5. 1st main gear 6. 1st main gear bushing

7. 1st needle bearing 8. 1st inner baulk ring 9. 1st gear synchronizer cone

10. 1st outer baulk ring 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

PCIB0787E

TRANSAXLE ASSEMBLY

MT-27

SHIFT CONTROL COMPONENTS

1. 3rd-4th bracket 2. Retaining pin 3. Check plug

4. 5th-6th bracket 5. Stopper ring 6. Reverse bracket

7. Reverse lever assembly 8. Shifter cap 9. 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

PCIB0788E

MT-28

TRANSAXLE ASSEMBLY

FINAL DRIVE COMPONENTS

Disassembly and Assembly (RS5F51A) ECS008C0

DISASSEMBLY

1. Remove drain plug and filler plug from transaxle case.

2. Remove park/neutral position switch and back-up lamp switch

from transaxle case.

3. Remove shift check and stopper bolt from transaxle case, and

then remove control assembly from transaxle case.

1. Differential side bearing outer race 2. Differential side bearing (clutch

housing side)

3. Differential case

4. Final gear 5. Differential side bearing (transaxle

case side)

6. Differential side bearing outer race

7. Differential side bearing adjusting shim 8. Side gear 9. Side gear thrust washer

10. Retaining pin 11. Pinion mate thrust washer 12. Pinion mate gear

13. Pinion mate shaft

PCIB0785E

SCIA0389E

TRANSAXLE ASSEMBLY

MT-29

4. Remove check plugs (3 pieces), check springs (3 pieces), check

balls (3 pieces) and shift check sleeve (1 piece) from transaxle

case.

5. Remove transaxle case mounting bolts.

6. Remove bore plug from transaxle case.

CAUTION:

Be careful not to damage transaxle case.

7. While spreading the snap ring of mainshaft rear bearing located

at bore plug hole, remove transaxle case from clutch housing.

8. Remove oil gutter, baffle plate from transaxle case.

9. Remove snap ring, mainshaft rear bearing adjusting shim and

input shaft rear bearing adjusting shim from transaxle case.

10. Remove differential side bearing outer race (transaxle case

side) from transaxle case using the puller, and then remove dif-

ferential side bearing adjusting shim from transaxle case.

11. Remove welch plug from transaxle case.

12. Remove differential oil seal (tansaxle case side) from transaxle

case.

13. Remove magnet from clutch housing.

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MT-30

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.

16. Shift 3rd-4th fork rod to 3rd position. Remove retaining pin of 5th

shift fork using a pin punch.

17. Remove stopper rings for 5th-reverse bracket.

18. Pull out 5th-reverse fork rod and remove 5th shift fork and 5th-

reverse bracket.

19. Remove check balls (2 pieces) from clutch housing.

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 3rd-

4th bracket.

23. Remove interlock pin and shift check sleeve from clutch hous-

ing.

24. Remove retaining pin of 1st-2nd shift fork using a pin punch.

25. Pull out 1st-2nd fork rod with 1st-2nd bracket.

26. Remove 1st-2nd shift fork.

27. Remove retaining pin of 1st-2nd bracket using a pin punch and

separate 1st-2nd fork rod and 1st-2nd bracket.

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TRANSAXLE ASSEMBLY

MT-31

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.

29. Remove mainshaft bearing retainer and then mainshaft front

bearing from clutch housing using the puller.

30. Remove oil channel from clutch housing.

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

housing.

CAUTION:

Be careful not to damage clutch housing.

32. Remove differential side bearing outer race (clutch housing

side) from clutch housing using the puller.

33. Remove input shaft oil seal from clutch housing.

CAUTION:

Be careful not to damage clutch housing.

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MT-32

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.

2. 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.

3. Install oil channel on mainshaft side.

CAUTION:

Be careful with the orientation of installation.

PCIB0807E

SCIA1070J

SCIA0986E

TRANSAXLE ASSEMBLY

MT-33

4. Install mainshaft front bearing to clutch housing using the drift.

CAUTION:

Be careful with the orientation of installation.

5. 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.

6. Install differential side bearing outer race to clutch housing using

the drifts.

7. Install final drive assembly into clutch housing.

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.

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PCIB0789E

SCIA0987E

SCIA0888E

SCIA0395E

MT-34

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.

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.

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.

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.

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.

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SCIA0393E

SCIA0392E

SCIA0391E

TRANSAXLE ASSEMBLY

MT-35

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

bracket.

c. 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.

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 dif-

ferential side bearing. For selection adjusting shim, refer to MT-

48, "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.

PCIB0790E

SCIA0390E

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PCIB0816E

MT-36

TRANSAXLE ASSEMBLY

d. With snap ring of mainshaft rear bearing temporarily installed,

place transaxle case over clutch housing.

e. Through bore plug mounting hole, with snap ring stretched, and

lift up mainshaft assembly from the control assembly mounting

hole.

f. Securely install snap ring onto mainshaft rear bearing.

g. Tighten mounting bolts to the specified torque.

CAUTION:

Always replace bolts B as they are self-sealing bolts.

h. Install control assembly to transaxle case.

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-22, "SHIFT CONTROL COMPONENTS" .

CAUTION:

Do 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-22, "SHIFT CONTROL COMPONENTS" .

CAUTION:

Do not reuse stopper bolt.

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SCIA0893E

Bolt A:

: 52 N·m (5.3 kg-m, 38 ft-lb)

Bolt B:

: 65 N·m (6.6 kg-m, 48 ft-lb)

SCIA1064E

TRANSAXLE ASSEMBLY

MT-37

29. Install a new bore plug to transaxle case using the drift.

CAUTION:

Do not reuse bore plug.

30. Install a new welch plug to transaxle case using the drift.

CAUTION:

Do not reuse welch plug.

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.

33. Apply genuine liquid gasket or equivalent to threads of park/neu-

tral 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" .

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) ECS008C1

DISASSEMBLY

1. Remove drain plug and filler plug from transaxle case.

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MT-38

TRANSAXLE ASSEMBLY

2. Remove park/neutral position switch and back-up lamp switch

from transaxle case.

3. Remove shift check and stopper bolt from transaxle case, and

then remove control assembly from transaxle case.

4. Remove check plugs (4 pieces), check springs (4 pieces), check

balls (4 pieces) and shift check sleeve (2 pieces) from transaxle

case.

5. Remove transaxle case mounting bolts.

6. Remove bore plug from transaxle case.

CAUTION:

Be careful not to damage transaxle case.

7. While spreading the snap ring of mainshaft rear bearing located

at bore plug hole, remove transaxle case from clutch housing.

8. Remove oil gutter, baffle plate from transaxle case.

9. Remove snap ring, mainshaft rear bearing adjusting shim and

input shaft rear bearing adjusting shim from transaxle case.

10. Remove differential side bearing outer race (transaxle case

side) from transaxle case using the puller, and then remove dif-

ferential side bearing adjusting shim from transaxle case.

11. Remove welch plug from transaxle case.

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TRANSAXLE ASSEMBLY

MT-39

12. Remove differential oil seal (transaxle case side) from transaxle

case.

13. Remove magnet from clutch housing.

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.

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.

19. Shift 3rd-4th fork rod to 3rd position. Remove retaining pin of 5th

- 6th shift fork using a pin punch.

20. Remove stopper rings for 5th-6th bracket.

21. Pull out 5th-6th fork rod and remove 5th-6th shift fork and 5th-

6th bracket.

22. Remove check balls (2 pieces) and interlock pin.

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SCIA0961E

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SCIA0963E

MT-40

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 3rd-

4th bracket.

26. Remove shift check sleeve from clutch housing.

27. Remove retaining pin of 1st-2nd shift fork using a pin punch.

28. Pull out 1st-2nd fork rod with 1st-2nd bracket.

29. Remove 1st-2nd shift fork.

30. Remove retaining pin of 1st-2nd bracket using a pin punch and

separate fork rod and 1st-2nd bracket.

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.

32. Remove mainshaft bearing retainer and then mainshaft front

bearing from clutch housing using the puller.

33. Remove oil channel from clutch housing.

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

housing.

CAUTION:

Be careful not to damage clutch housing.

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SCIA1068J

TRANSAXLE ASSEMBLY

MT-41

35. Remove differential side bearing outer race (clutch housing

side) from clutch housing using the puller.

36. Remove input shaft oil seal from clutch housing.

CAUTION:

Be careful not to damage clutch housing.

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.

2. 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.

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PCIB0807E

SCIA1070J

MT-42

TRANSAXLE ASSEMBLY

3. Install oil channel on mainshaft side.

CAUTION:

Be careful with the orientation of installation.

4. Install mainshaft front bearing to clutch housing using the drift.

CAUTION:

Be careful with the orientation of installation.

5. 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.

6. Install differential side bearing outer race to clutch housing using

the drifts.

7. Install final drive assembly into clutch housing.

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PCIB0789E

SCIA0987E

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TRANSAXLE ASSEMBLY

MT-43

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.

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 pin.

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.

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 pin.

16. Install 2 check balls to clutch housing.

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.

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MT-44

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.

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

c. 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.

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 dif-

ferential side bearing. For selection adjusting shim, refer to MT-

52, "DIFFERENTIAL SIDE BEARING PRELOAD" .

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PCIB0791E

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TRANSAXLE ASSEMBLY

MT-45

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.

d. With snap ring of mainshaft rear bearing temporarily installed,

place transaxle case over clutch housing.

e. Through bore plug mounting hole, with snap ring stretched, and

lift up mainshaft assembly from the control assembly mounting

hole.

f. Securely install snap ring onto mainshaft rear bearing.

PCIB0816E

SCIA0892E

SCIA0893E

MT-46

TRANSAXLE ASSEMBLY

g. Tighten mounting bolts to the specified torque.

CAUTION:

Always replace bolts B as they are self-sealing bolts.

h. Install control assembly to transaxle case to transaxle case.

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.

34. Install a new welch plug to transaxle case using the drift.

CAUTION:

Do not reuse welch plug.

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.

Bolt A:

: 52 N·m (5.3 kg-m, 38 ft-lb)

Bolt B:

: 65 N·m (6.6 kg-m, 48 ft-lb)

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TRANSAXLE ASSEMBLY

MT-47

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/neu-

tral 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" .

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.

1. Using depth micrometer and straightedge, measure dimension

"O1 " between transaxle case end face and mounting face of

adjusting shim.

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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

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MT-48

TRANSAXLE ASSEMBLY

2. Using depth micrometer and straightedge as shown in the fig-

ure, measure dimension "O2 " between clutch housing end face

and end face of input shaft rear bearing.

3. Install selected input shaft rear bearing adjusting shim onto input

shaft.

MAINSHAFT END PLAY

●When adjusting mainshaft end play, select adjusting shim for

mainshaft rear bearing. To select adjusting shim, measure clear-

ance “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 main-

shaft rear bearing.

1. Install mainshaft assembly to clutch housing.

2. Install snap ring to transaxle case.

3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install tempo-

rarily snap ring to mainshaft rear bearing.

4. Install dial gauge to bore plug mounting hole, and expand snap

ring. Lift mainshaft assembly through control assembly installa-

tion 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”.

DIFFERENTIAL SIDE BEARING PRELOAD

●When adjusting differential side bearing preload, select adjust-

ing 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 differ-

ential side bearing.

PCIB0792E

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

PCIB0793E

PCIB0794E

PCIB0795E

TRANSAXLE ASSEMBLY

MT-49

1. Using depth micrometer and straightedge, measure dimension

"L1 " between transaxle case end face and mounting face of

adjusting shim.

2. Install differential side bering outer race onto differential side

bearing on final gear side. Holding lightly differential side bear-

ing outer race horizontally by hand, rotate final gear five times or

more (for smooth movement of bearing roller).

3. Using depth micrometer and straightedge as shown in the fig-

ure, measure dimension "L2 " between differential side bearing

outer race and clutch housing end face.

4. Install selected differential side bearing adjusting shim, and then

install differential side bearing outer race using the drift.

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.

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

SCIA1078E

SCIA1079E

SCIA0898E

End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)

Dimension“Q” = (Q1 - Q2 ) - End play

PCIB0796E

MT-50

TRANSAXLE ASSEMBLY

1. Using depth micrometer and straightedge, measure dimension

"Q1 " between transaxle case end face and mounting face of

adjusting shim.

2. Using depth micrometer and straightedge as shown in the fig-

ure, measure dimension "Q2 " between clutch housing end face

and end face of reverse idler gear (Rear).

3. Install selected reverse idler gear adjusting shim onto reverse

idler gear assembly.

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.

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)

SCIA1003E

PCIB0797E

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

mounting face of adjusting shim

:Distance between clutch housing end face

and end face of input shaft rear bearing

SCIA1001E

TRANSAXLE ASSEMBLY

MT-51

1. Using depth micrometer and straightedge, measure dimension

"O1 " between transaxle case end face and mounting face of

adjusting shim.

2. Using depth micrometer and straightedge as shown in the fig-

ure, measure dimension "O2 " between clutch housing end face

and end face of input shaft rear bearing.

3. Install selected input shaft rear bearing adjusting shim onto input

shaft.

MAINSHAFT END PLAY

●When adjusting mainshaft end play, select adjusting shim for

mainshaft rear bearing. To select adjusting shim, measure clear-

ance “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 main-

shaft rear bearing.

1. Install mainshaft assembly to clutch housing.

2. Install snap ring to transaxle case.

3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install tempo-

rarily snap ring to mainshaft rear bearing.

4. Install dial gauge to bore plug mounting hole, and expand snap

ring. Lift mainshaft assembly through control assembly installa-

tion 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”.

SCIA1002E

PCIB0792E

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

PCIB0793E

PCIB0794E

MT-52

TRANSAXLE ASSEMBLY

DIFFERENTIAL SIDE BEARING PRELOAD

●When adjusting differential side bearing preload, select adjust-

ing 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 differ-

ential side bearing.

1. Using depth micrometer and straightedge, measure dimension

"L1 " between transaxle case end face and mounting face of

adjusting shim.

2. Install differential side bearing outer race onto differential side

bearing on final gear side. Holding lightly differential side bear-

ing outer race horizontally by hand, rotate final gear five times or

more (for smooth movement of bearing roller).

3. Using depth micrometer and straightedge as shown in the fig-

ure, measure dimension "L2 " between differential side bearing

outer race and clutch housing end face.

4. Install selected differential side bearing adjusting shim, and then

install differential side bearing outer race using the drift.

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

PCIB0795E

SCIA1078E

SCIA1079E

SCIA0898E

TRANSAXLE ASSEMBLY

MT-53

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.

1. Using depth micrometer and straightedge, measure dimension

"Q1 " between transaxle case end face and mounting face of

adjusting shim.

2. Using depth micrometer and straightedge as shown in the fig-

ure, measure dimension "Q2 " between clutch housing end face

and end face of reverse idler gear (Rear).

3. Install selected reverse idler gear adjusting shim onto reverse

idler gear assembly.

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)

PCIB0796E

SCIA1003E

PCIB0797E

MT-54

INPUT SHAFT AND GEARS

INPUT SHAFT AND GEARS PFP:32200

Assembly and Disassembly (RS5F51A) ECS008C4

DISASSEMBLY

1. Before disassembling, measure end play for 3rd, 4th, and 5th

input gears.

2. Remove oil channel.

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

4. Remove the snap ring.

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

drift and a puller.

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

SCIA0915E

SCIA0916E

SCIA0917E

INPUT SHAFT AND GEARS

MT-55

6. Press out 5th input gear and 5th synchronizer hub assembly

using the drift and a puller.

7. Remove 5th needle bearing.

8. Press out 5th input gear bushing, thrust washer, 4th input gear,

4th needle bearing, 4th input gear bushing, 4th baulk ring, 3rd-

4th synchronizer hub assembly, 3rd baulk ring and 3rd input

gear using the drift and a puller.

9. Remove 3rd needle bearing.

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

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

SCIA0918E

SCIA0919E

SCIA0920E

SCIA1073J

MT-56

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.

●If any crack, damage, or excessive wear is found on cam face of

baulk ring or working face of insert, replace it.

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.

Bearing

Check items below. If necessary, replace them with new ones.

●Damage and rough rotation of bearing

SMT387A

SMT867D

Clearance

Standard value

3rd and 4th : 0.9 - 1.45 mm (0.035 - 0.057 in)

5th : 0.95 - 1.4 mm (0.037 - 0.055 in)

Limit value : 0.7 mm (0.028 in)

SMT140

MTF0041D

INPUT SHAFT AND GEARS

MT-57

ASSEMBLY

1. Install 3rd needle bearing to input shaft.

2. Install 3rd input gear and 3rd baulk ring to input shaft.

3. 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.

●Be careful with orientation of 3rd-4th coupling sleeve.

●Do not reuse 3rd-4th coupling sleeve.

●Be sure not to hook center projection of 2 spread springs

on same shifting insert.

4. Press in 3rd-4th synchronizer hub assembly using the press

stand.

CAUTION:

Align grooves of 3rd-4th shifting insert and 3rd baulk ring.

SCIA0921E

PCIB0799E

SCIA1083E

SCIA0922E

MT-58

INPUT SHAFT AND GEARS

5. Press in 4th input gear bushing using the press stand.

6. Install 4th baulk ring.

7. Install 4th needle bearing and 4th input gear to input shaft.

8. Select thrust washer so that dimension “C2” satisfies the stan-

dard value below. Then install thrust washer onto input shaft.

Refer to MT-101, "INPUT SHAFT THRUST WASHER" .

CAUTION:

Only one thrust washer can be selected.

9. 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.

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

sleeve.

PCIB0800E

Standard for dimension C2

: 154.7 - 154.8 mm (6.091 - 6.094 in)

SCIA0925E

SCIA0926E

INPUT SHAFT AND GEARS

MT-59

CAUTION:

●Be careful with orientation of 5th synchronizer hub and

shifting insert.

●Do not reuse 5th synchronizer hub.

●Be careful with orientation of 5th coupling sleeve.

●Do not reuse 5th coupling sleeve.

●Be sure not to hook center projection of 2 spread springs

on same shifting insert.

13. Press in 5th synchronizer hub assembly using the press stand.

CAUTION:

Align grooves of 5th shifting insert and 5th baulk ring.

SCIA0927E

SCIA0994E

SCIA1083E

SCIA0928E

MT-60

INPUT SHAFT AND GEARS

14. Press in 5th stopper and then input shaft bearing spacer using

the drift.

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.

●If measurement is outside the standard range, select snap

ring. Refer to MT-100, "INPUT SHAFT BEARING SPACER" .

CAUTION:

Do not reuse snap ring.

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.

17. Press in input shaft front bearing using the drifts.

18. Install oil channel onto input shaft.

19. Check end play of 3rd, 4th, and 5th input gears.

SCIA0929E

End play standard value : 0 - 0.1 mm (0 - 0.004 in)

SCIA0930E

SCIA0931E

PCIB0825E

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

INPUT SHAFT AND GEARS

MT-61

Assembly and Disassembly (RS6F51A) ECS008C5

DISASSEMBLY

1. Before disassembling, measure end play for 3rd, 4th, 5th and

6th input gears.

2. Remove oil channel.

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

4. Remove snap ring.

5. Press out 6th input gear, 6th needle bearing and 6th input gear

bushing using the drift and a puller.

6. Remove 6th baulk ring.

7. Press out 5th input gear and 5th-6th synchronizer hub assembly

using the drift and a puller.

8. Remove 5th needle bearing.

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

SCIA0967E

SCIA0968E

SCIA0918E

MT-62

INPUT SHAFT AND GEARS

9. Press out 5th input gear bushing, thrust washer, 4th input gear,

4th needle bearing, 4th input gear bushing, 4th baulk ring, 3rd-

4th synchronizer hub assembly, 3rd baulk ring and 3rd input

gear using the drift and a puller.

10. Remove 3rd needle bearing.

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

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

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.

SCIA0919E

SCIA0920E

SCIA1074J

SMT387A

INPUT SHAFT AND GEARS

MT-63

●If any crack, damage, or excessive wear is found on cam face of

baulk ring or working face of insert, replace it.

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.

Bearing

Check items below. If necessary, replace them with new ones.

●Damage and rough rotation of bearing

SMT867D

Clearance

Standard value

3rd and 4th : 0.9 - 1.45 mm (0.035 - 0.057 in)

5th and 6th : 0.95 - 1.4 mm (0.037 - 0.055 in)

Limit value : 0.7 mm (0.028 in)

SMT140

MTF0041D

MT-64

INPUT SHAFT AND GEARS

ASSEMBLY

1. Install 3rd needle bearing to input shaft.

2. Install 3rd input gear and 3rd baulk ring to input shaft.

3. 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.

●Be careful with orientation of 3rd-4th coupling sleeve.

●Do not reuse 3rd-4th coupling sleeve.

●Be sure not to hook center projection of 2 spread springs

on same shifting insert.

4. Press in 3rd-4th synchronizer hub assembly using the press

stand.

CAUTION:

Align grooves of 3rd-4th shifting insert and 3rd baulk ring.

SCIA0921E

PCIB0799E

SCIA1083E

SCIA0922E

INPUT SHAFT AND GEARS

MT-65

5. Press in 4th input gear bushing using the press stand.

6. Install 4th baulk ring.

7. Install 4th needle bearing and 4th input gear to input shaft.

8. Select thrust washer so that dimension “C2” satisfies the stan-

dard value below. Then install thrust washer onto input shaft.

Refer to MT-101, "INPUT SHAFT THRUST WASHER" .

CAUTION:

Only one thrust washer can be selected.

9. 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.

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

coupling sleeve.

PCIB0800E

Standard value for dimension C2

: 154.7 - 154.8 mm (6.091 - 6.094 in)

SCIA0925E

SCIA0926E

MT-66

INPUT SHAFT AND GEARS

CAUTION:

●Be careful with orientation of 5th-6th synchronizer hub.

●Do not reuse 5th-6th synchronizer hub.

●Be careful with orientation of 5th-6th coupling sleeve.

●Do not reuse 5th-6th coupling sleeve.

●Be sure not to hook center projection of 2 spread springs

on same shifting insert.

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.

SCIA0921E

PCIB0801E

SCIA1083E

SCIA0928E

INPUT SHAFT AND GEARS

MT-67

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.

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.

●If measurement is outside the standard range, select snap

ring. Refer to MT-100, "6TH INPUT GEAR BUSHING" .

CAUTION:

Do not reuse snap ring.

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.

17. Press in input shaft front bearing using the drifts.

18. Install oil channel onto input shaft.

19. Check end play of 3rd, 4th, 5th and 6th input gears.

SCIA0969E

End play standard value : 0 - 0.1 mm (0 - 0.004 in)

SCIA0970E

SCIA0971E

PCIB0826E

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-68

MAINSHAFT AND GEARS

MAINSHAFT AND GEARS PFP:32241

Assembly and Disassembly (RS5F51A) ECS008C6

DISASSEMBLY

1. Before disassembling, measure the end play of 1st and 2nd

main gears.

2. Remove snap ring.

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

4. Remove mainshaft rear bearing using the drift and pullers.

5. Remove snap ring.

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

PCIB0802E

SCIA0935E

SCIA0936E

MAINSHAFT AND GEARS

MT-69

6. Press out 4th main gear and 5th main gear using the drift and a

puller.

7. Remove 4th main gear adjusting shim.

8. Remove 3rd-4th mainshaft spacer.

9. 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.

INSPECTION AFTER DISASSEMBLY

Mainshaft and Gears

Check items below. If necessary, replace them with new ones.

●Damage, peeling, dent, uneven wear, bending, and other non-

standard conditions of the shaft.

●Excessive wear, damage, peeling, and other non-standard con-

ditions of the gears.

SCIA0937E

SCIA0938E

SCIA1075J

MT-70

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.

●If any crack, damage, or excessive wear is found on cam face of

baulk ring or working face of insert, replace it.

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.

1. Measure clearance A at 2 or more points diagonally opposite

using a dial gauge, and calculate mean value.

SMT387A

SMT867D

SCIA0950E

Clearance A

Standard value : 0.6 - 0.8 mm (0.024 - 0.031 in)

Limit value : 0.2 mm (0.008 in)

PCIB0818E

MAINSHAFT AND GEARS

MT-71

2. Measure clearance B at 2 or more points diagonally opposite

using a feeler gauge, and calculate mean value.

●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.

1. 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.

2. Measure clearance “B” at 2 points or more on the opposite side

using a feeler gauge. Then calculate the average.

3. 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 B

Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in)

Limit value : 0.2 mm (0.008 in)

SCIA1084E

PCIB0603E

Clearance “A”

Standard value : 0.6 - 1.2 mm (0.024 - 0.047 in)

Limit value : 0.3 mm (0.012 in)

PCIB0808E

Clearance “B”

Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in)

Limit value : 0.2 mm (0.008 in)

PCIB0605E

Clearance “C”

Standard value : 0.7 - 1.1 mm (0.028 - 0.043 in)

Limit value : 0.3 mm (0.012 in)

PCIB0809E

MT-72

MAINSHAFT AND GEARS

Bearing

Check items below. If necessary, replace them with new ones.

●Damage and rough rotation of bearing

ASSEMBLY

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

CAUTION:

●Be careful with orientation of reverse main gear.

●Do not reuse reverse main gear.

2. Press in 1st main gear bushing using the drifts and the press

stand.

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

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

2nd coupling sleeve.

MTF0041D

SCIA0939E

SCIA0992E

SCIA0940E

MAINSHAFT AND GEARS

MT-73

CAUTION:

●Be careful with orientation of 1st-2nd synchronizer hub.

●Do not reuse 1st-2nd synchronizer hub.

●Be careful with orientation of 1st-2nd coupling sleeve.

●Do not reuse 1st-2nd coupling sleeve.

●Be sure not to hook center projection of 2 spread springs

on same 1st-2nd shifting insert.

5. Install 1st inner baulk ring, 1st synchronizer cone, 1st outer

baulk ring onto mainshaft, and then press in 1st-2nd synchro-

nizer 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.

SCIA0921E

PCIB0803E

SCIA1083E

SCIA0941E

MT-74

MAINSHAFT AND GEARS

6. Press in 2nd main gear bushing using the drift and the press

stand.

7. Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd

inner baulk ring.

8. Install 2nd needle bearing and 2nd main gear.

9. 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.

11. Select 4th main gear adjusting shim so that dimension “C1” sat-

isfies the standard value below, and install 4th main gear adjust-

ing shim onto mainshaft. Refer to MT-101, "4TH MAIN GEAR

ADJUSTING SHIM" .

CAUTION:

Only one adjusting shim can be selected.

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.

SCIA0942E

SCIA0943E

Standard value for dimension C1

: 173.85 - 173.95 mm (6.844 - 6.848 in)

PCIB0804E

SCIA0945E

MAINSHAFT AND GEARS

MT-75

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 snap ring onto mainshaft, and check that end play of 5th

main gear satisfies the standard value.

●If measurement is outside the standard range, reselect snap

ring. Refer to MT-100, "5TH MAIN GEAR" .

15. Press in mainshaft rear bearing using the drifts.

16. Install mainshaft C-ring onto mainshaft, and check that end play

of mainshaft rear bearing satisfies the standard value.

●If measurement is outside the standard range, reselect main-

shaft C-ring. Refer to MT-100, "MAINSHAFT C-RING" .

17. Install C-ring holder, and then install a new snap ring.

CAUTION:

Do not reuse snap ring.

SCIA0946E

End play standard value : 0 - 0.1 mm (0 - 0.004 in)

SCIA0947E

SCIA0948E

End play standard value : 0 - 0.06 mm (0 - 0.0024 in)

SCIA0949E

PCIB0802E

MT-76

MAINSHAFT AND GEARS

18. Check end play of 1st and 2nd main gears.

Assembly and Disassembly (RS6F51A) ECS008C7

DISASSEMBLY

1. Before disassembling, measure the end play of 1st and 2nd

main gears.

2. Remove snap ring.

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

4. Press out mainshaft rear bearing, 6th main adjusting shim and

6th main gear using the drift and a puller.

5. Remove 5th-6th mainshaft spacer.

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

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

PCIB0805E

SCIA0976E

MAINSHAFT AND GEARS

MT-77

6. Press out 4th main gear and 5th main gear using the drift and a

puller.

7. Remove 4th main gear adjusting shim.

8. Remove 3rd-4th mainshaft spacer.

9. 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.

INSPECTION AFTER DISASSEMBLY

Mainshaft and Gears

Check items below. If necessary, replace them with new ones.

●Damage, peeling, dent, uneven wear, bending, and other non-

standard conditions of the shaft.

●Excessive wear, damage, peeling, and other non-standard con-

ditions of the 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.

SCIA0937E

SCIA0938E

SCIA1076J

SMT387A

MT-78

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.

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.

1. Measure clearance A at 2 or more points diagonally opposite

using a dial gauge, and calculate mean value.

2. Measure clearance B at 2 or more points diagonally opposite

using a feeler gauge, and calculate mean value.

●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.

SMT867D

SCIA0950E

Clearance A

Standard value : 0.6 - 0.8 mm (0.024 - 0.031 in)

Limit value : 0.2 mm (0.008 in)

PCIB0818E

Clearance B

Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in)

Limit value : 0.2 mm (0.008 in)

SCIA1084E

PCIB0603E

MAINSHAFT AND GEARS

MT-79

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.

2. Measure clearance “B” at 2 points or more on the opposite side

using a feeler gauge. Then calculate the average.

3. 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.

Bearing

Check items below. If necessary, replace them with new ones.

●Damage and rough rotation of bearing

Clearance “A”

Standard value : 0.6 - 1.2 mm (0.024- 0.047)

Limit value : 0.3 mm (0.012 in)

PCIB0808E

Clearance “B”

Standard value : 0.6 - 1.1 mm (0.024 - 0.043)

Limit value : 0.2 mm (0.008 in)

PCIB0605E

Clearance “C”

Standard value : 0.7 - 1.1 mm (0.028 - 0.043 in)

Limit value : 0.3 mm (0.012 in)

PCIB0809E

MTF0041D

MT-80

MAINSHAFT AND GEARS

ASSEMBLY

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

CAUTION:

●Be careful with orientation of reverse main gear.

●Do not reuse reverse main gear.

2. Press in 1st main gear bushing using the drifts and the press

stand.

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

4. 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.

SCIA0939E

SCIA0992E

SCIA0940E

SCIA0921E

MAINSHAFT AND GEARS

MT-81

●Be careful with orientation of 1st-2nd coupling sleeve.

●Do not reuse 1st-2nd coupling sleeve.

●Be sure not to hook center projection of 2 spread springs

on same 1st-2nd shifting insert.

5. Install 1st inner baulk ring, 1st synchronizer cone, 1st outer

baulk ring onto mainshaft, and then press in 1st-2nd synchro-

nizer 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.

6. Press in 2nd main gear bushing using the drift and the press

stand.

7. Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd

inner baulk ring.

8. Install 2nd needle bearing and 2nd main gear.

9. 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.

PCIB0803E

SCIA1083E

SCIA0941E

SCIA0942E

SCIA0943E

MT-82

MAINSHAFT AND GEARS

11. Select 4th main gear adjusting shim so that dimension “C1” sat-

isfies the standard value below, and install 4th main gear adjust-

ing shim onto mainshaft. Refer to MT-101, "4TH MAIN GEAR

ADJUSTING SHIM" .

CAUTION:

Only one adjusting shim can be selected.

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.

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.

15. Press in 6th main gear using the drifts.

CAUTION:

Do not reuse 6th main gear.

Standard value for dimension C1

: 173.85 - 173.95 mm (6.844 - 6.848 in)

PCIB0804E

SCIA0945E

SCIA0946E

SCIA0977E

MAINSHAFT AND GEARS

MT-83

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 dimen-

sion shown below. Refer to MT-102, "6TH MAIN GEAR

ADJUSTING SHIM" .

CAUTION:

Only one adjusting shim can be selected.

a. Using height gauge, measure dimension “S1 ” and “S2 ”.

b. Install selected 6th main adjusting shim to mainshaft.

17. Press in mainshaft rear bearing using the drifts.

18. Install mainshaft C-ring onto mainshaft, and check that end play

of mainshaft rear bearing satisfies the standard value.

●If measurement is outside the standard range, reselect main-

shaft C-ring. Refer to MT-100, "MAINSHAFT C-RING" .

End play: 0 - 0.1 mm (0 - 0.004 in)

Dimension“S” = (S1 - S2 ) - End play

S: Thickness of adjusting shim

S1 : Dimension from mainshaft standard face to

mainshaft rear bearing press-fit end face

S2 : Dimension from mainshaft standard face to

6th main gear end face

SCIA0995E

SCIA0978E

End play standard value : 0 - 0.06 mm (0 - 0.0024 in)

SCIA0979E

MT-84

MAINSHAFT AND GEARS

19. Install C-ring holder, and then install a new snap ring.

CAUTION:

Do not reuse snap ring.

20. Check end play of 1st and 2nd main gears.

PCIB0805E

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

REVERSE IDLER SHAFT AND GEARS

MT-85

REVERSE IDLER SHAFT AND GEARS PFP:32281

Assembly and Disassembly (RS5F51A) ECS008C8

DISASSEMBLY

1. Remove reverse idler gear adjusting shim.

2. Remove reverse idler gear (rear), reverse coupling sleeve and reverse insert spring simultaneously.

3. Remove reverse idler gear needle bearing.

4. Remove thrust needle bearing.

5. Remove reverse baulk ring.

6. Remove reverse idler gear (front).

7. Remove reverse idler gear needle bearing.

8. Remove thrust needle bearing.

9. Remove retaining pin from reverse idler shaft.

CAUTION:

Do not reuse retaining pin.

INSPECTION AFTER DISASSEMBLY

Reverse Idler Shaft and Gears

Check items below. If necessary, replace them with new ones.

●Damage, peeling, dent, uneven wear, bending, and other non-

standard conditions of the shaft.

●Excessive wear, damage, peeling, and other non-standard con-

ditions of the gears.

Synchronizer

Check items below. If necessary, replace them with new ones.

●Damage and unusual wear on contact surfaces of reverse cou-

pling sleeve, reverse synchronizer hub, and reverse insert

spring.

●Reverse coupling sleeve and reverse synchronizer hub must

move smoothly.

●If any crack, damage, or excessive wear is found on cam face of

reverse baulk ring or working face of insert, replace it.

SCIA0953J

SMT637A

SMT867D

MT-86

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.

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.

Assembly and Disassembly (RS6F51A) ECS008C9

DISASSEMBLY

1. Remove reverse idler gear adjusting shim.

2. Remove reverse idler gear (rear), reverse coupling sleeve and reverse insert spring simultaneously.

3. Remove reverse idler gear needle bearing.

4. Remove thrust needle bearing.

5. Remove reverse baulk ring.

6. Remove reverse idler gear (front).

7. Remove reverse idler gear needle bearing.

8. Remove thrust needle bearing.

9. Remove retaining pin from reverse idler shaft.

CAUTION:

Do not reuse retaining pin.

Clearance

Standard value : 0.95 - 1.4 mm (0.037 - 0.055 in)

Limit value : 0.7 mm (0.028 in)

SMT140

SCIA0954E

REVERSE IDLER SHAFT AND GEARS

MT-87

INSPECTION AFTER DISASSEMBLY

Reverse Idler Shaft and Gears

Check items below. If necessary, replace them with new ones.

●Damage, peeling, dent, uneven wear, bending, and other non-

standard conditions of the shaft.

●Excessive wear, damage, peeling, and other non-standard con-

ditions of the gears.

Synchronizer

Check items below. If necessary, replace them with new ones.

●Damage and unusual wear on contact surfaces of reverse cou-

pling sleeve, reverse synchronizer hub, and reverse insert

spring.

●Reverse coupling sleeve and reverse synchronizer hub must

move smoothly.

●If any crack, damage, or excessive wear is found on cam face of

reverse baulk ring or working face of insert, replace it.

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.

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.

SCIA0953J

SMT637A

SMT867D

Clearance

Standard value : 0.95 - 1.4 mm (0.037 - 0.055 in)

Limit value : 0.7 mm (0.028 in)

SMT140

MT-88

REVERSE IDLER SHAFT AND GEARS

CAUTION:

●Be careful with orientation of reverse insert spring.

SCIA0954E

FINAL DRIVE

MT-89

FINAL DRIVE PFP:38411

Assembly and Disassembly (RS5F51A) ECS008CA

PRE-INSPECTION

●Check the clearance between side gear and differential case as

follows.

1. Clean final drive assembly sufficiently to prevent side gear thrust

washer, differential case, side gear, and other parts from sticking

by gear oil.

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

3. Place the drift below and a dial gauge onto side gear. Move side

gear up and down, and measure the clearance.

CAUTION:

There should be no resistance and gears should rotate

freely.

4. If not within specification, adjust the clearance by changing side

gear thrust washer thickness.

5. Turn differential case upside down, and measure the clearance

between side gear and differential case on the other side in the

same way.

DISASSEMBLY

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

2. Remove differential side bearing (clutch housing side) using the

drift and pullers.

3. Remove differential side bearing (transaxle case side) using the

drift and pullers.

PCIB0806E

Clearance between side gear and differential case

: 0.1 - 0.2 mm (0.004 - 0.008 in)

SMT611A

SCIA0906E

SCIA0907E

MT-90

FINAL DRIVE

4. Remove retaining pin from differential case, and then remove

pinion mate shaft using a pin punch.

5. Rotate pinion mate gears, and remove pinion mate gears, pinion

mate thrust washers, side gears, and side gear thrust washers

from differential case.

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.

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.

ASSEMBLY

1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.

2. Install side gear thrust washers and side gears into differential

case.

3. While rotating pinion mate thrust washers and pinion mate

gears, aligning them diagonally, install them into differential

case.

SCIA0908E

MTK0135D

SPD715

SMT839

FINAL DRIVE

MT-91

4. Insert pinion mate shaft into differential case.

CAUTION:

Be sure not to damage pinion mate thrust washers.

5. Measure end play of side gears following the procedure below.

Then select side gear thrust washer.

a. Upright the differential case so that its side gear to be measured

faces upward.

b. Place the drift below and a dial gauge onto side gears.

c. Move side gears up and down to measure end play, and select

thrust washer so that it satisfies the standard value. Refer to MT-

101, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .

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.

6. Install a new retaining pin into pinion mate shaft using a pin

punch.

CAUTION:

Do not reuse retaining pin.

7. Press in differential side bearing (transaxle case side) to differ-

ential case using the drifts.

MTK0132D

PCIB0806E

End play standard value

: 0.1 - 0.2 mm (0.004 - 0.008 in)

SMT611A

SCIA0908E

SCIA0910E

MT-92

FINAL DRIVE

8. Press in differential side bearing (clutch housing side) to differ-

ential case using the drifts.

9. Install final gear into differential case, and tighten final gear

mounting bolts to the specified torque. Refer to MT-23, "FINAL

DRIVE COMPONENTS" .

Assembly and Disassembly (RS6F51A) ECS008CB

PRE-INSPECTION

●Check the clearance between side gear and differential case as

follows.

1. Clean final drive assembly sufficiently to prevent side gear thrust

washer, differential case, side gear, and other parts from sticking

by gear oil.

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

3. Place the drift below and a dial gauge onto side gear. Move side

gear up and down, and measure the clearance.

CAUTION:

There should be no resistance and gears should rotate

freely.

4. If not within specification, adjust the clearance by changing side

gear thrust washer thickness.

5. Turn differential case upside down, and measure the clearance

between side gear and differential case on the other side in the

same way.

DISASSEMBLY

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

SCIA0911E

SCIA0912E

PCIB0806E

Clearance between side gear and differential case

: 0.1 - 0.2 mm (0.004 - 0.008 in)

SMT611A

FINAL DRIVE

MT-93

2. Remove differential side bearing (clutch housing side) using the

drift and pullers.

3. Remove differential side bearing (transaxle case side) using the

drift and pullers.

4. Remove retaining pin from differential case, and then remove

pinion mate shaft using a pin punch.

5. Rotate pinion mate gears, and remove pinion mate gears, pinion

mate thrust washers, side gears, and side gear thrust washers

from differential case.

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.

SCIA0906E

SCIA0907E

SCIA0908E

MTK0135D

MT-94

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.

ASSEMBLY

1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.

2. Install side gear thrust washers and side gears into differential

case.

3. While rotating pinion mate thrust washers and pinion mate

gears, aligning them diagonally, install them into differential

case.

4. Insert pinion mate shaft into differential case.

CAUTION:

Be sure not to damage pinion mate thrust washers.

5. Measure end play of side gears following the procedure below.

Then select side gear thrust washer.

a. Upright the differential case so that its side gear to be measured

faces upward.

b. Place the drift below and a dial gauge onto side gears.

SPD715

SMT839

MTK0132D

PCIB0806E

FINAL DRIVE

MT-95

c. Move side gears up and down to measure end play, and select

thrust washer so that it satisfies the standard value. Refer to MT-

101, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .

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.

6. Install a new retaining pin into pinion mate shaft using a pin

punch.

CAUTION:

Do not reuse retaining pin.

7. Press in differential side bearing (transaxle case side) to differ-

ential case using the drifts.

8. Press in differential side bearing (clutch housing side) to differ-

ential case using the drifts.

9. Install final gear into differential case, and tighten final gear

mounting bolts to the specified torque. Refer to MT-28, "FINAL

DRIVE COMPONENTS" .

End play standard value

: 0.1 - 0.2 mm (0.004 - 0.008 in)

SMT611A

SCIA0908E

SCIA0910E

SCIA0911E

SCIA0912E

MT-96

SHIFT CONTROL

SHIFT CONTROL PFP:32982

Inspection (RS5F51A) ECS008CC

●Check contact surfaces and sliding area for wear, damage,

bending, etc. If necessary, replace parts.

SHIFT FORK

●Check if the width of shift fork hook (sliding area with coupling

sleeve) is within allowable specification below.

SCIA0913E

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)

SMT801D

SHIFT CONTROL

MT-97

Inspection (RS6F51A) ECS008CD

●Check contact surfaces and sliding area for wear, damage,

bending, etc. If necessary, replace parts.

SHIFT FORK

●Check if the width of shift fork hook (sliding area with coupling

sleeve) is within allowable specification below.

SCIA0913E

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)

SMT801D

MT-98

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications ECS008CE

TRANSAXLE

Engine QR20DE QR25DE YD22DDTi

Transaxle model RS5F51A RS6F51A

Model code number EQ000 EQ008 EQ068

Number of speed 5 6

Synchromesh type Warner

Shift pattern

5 speed

6 speed

Gear ratio 1st 3.500 3.416 3.500

2nd 1.944

3rd 1.258

4th 0.947

5th 0.772 0.733 0.772

6th — 0.630

Reverse 3.374 3.252 3.374

Number of teeth Input gear 1st 14 12 14

2nd 18

3rd 31

4th 38

5th 444544

6th — 46

Reverse141214

Main gear 1st 49 41 49

2nd 35

3rd 39

4th 36

5th 343334

6th — 29

Reverse 38

Reverse idler

gear

Front 37

Rear 46 38 46

Oil capacity

(Imp pt) 2.3 (4)

SCIA0821E

SCIA0955E

SERVICE DATA AND SPECIFICATIONS (SDS)

MT-99

FINAL GEAR

End Play ECS008CF

Unit: mm (in)

Baulk Ring Clearance ECS00CV4

Unit: mm (in)

Remarks Reverse synchronizer Installed

Double-cone synchronizer 1st

Triple-cone synchronizer 2nd

Engine QR20DE QR25DE YD22DDTi

Transaxle model RS5F51A RS6F51A

Model code number EQ000 EQ008 EQ068

Engine QR20DE QR25DE YD22DDTi

Transaxle model RS5F51A RS6F51A

Model code number EQ000 EQ008 EQ068

Final gear ratio 4.750 4.428

Number of teeth Final gear/Pinion 76/16 62/14

Side gear/Pinion mate gear 14/10

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)

Measurement point Standard Limit value

1st

(Double-cone synchronizer)

●Clearance between synchronizer cone

and inner baulk ring end face “A”

●Clearance between outer baulk ring pawl

and synchronizer cone “B”

A: 0.6 - 0.8 (0.024 - 0.031)

B: 0.6 - 1.1 (0.024 -0.043)

0.2 (0.008)

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)

3rd&4th 0.9 - 1.45 (0.035 - 0.057) 0.7 (0.028)

PCIB0249E

PCIB0772E

MT-100

SERVICE DATA AND SPECIFICATIONS (SDS)

Available Snap Rings ECS008CH

INPUT SHAFT BEARING SPACER

—For RS5F51A Model—

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

6TH INPUT GEAR BUSHING

—For RS6F51A Model—

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

5TH MAIN GEAR

—For RS5F51A Model—

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

Available C-Rings ECS008CI

MAINSHAFT C-RING

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

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)

Measurement point Standard Limit value

End play 0 - 0.1 mm (0 - 0.004 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

1.71 (0.0673)

1.76 (0.0693)

1.81 (0.0713)

1.86 (0.0732)

1.91 (0.0752)

1.96 (0.0772)

32204 8H510

32204 8H511

32204 8H512

32204 8H513

32204 8H514

32204 8H515

2.01 (0.0791)

2.06 (0.0811)

2.11 (0.0831)

2.16 (0.0850)

2.21 (0.0870)

2.26 (0.0890)

32204 8H516

32204 8H517

32204 8H518

32204 8H519

32204 8H520

32204 8H521

End play 0 - 0.1 mm (0 - 0.004 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

1.76 (0.0693)

1.81 (0.0713)

1.86 (0.0732)

1.91 (0.0752)

1.96 (0.0772)

32204 8H511

32204 8H512

32204 8H513

32204 8H514

32204 8H515

2.01 (0.0791)

2.06 (0.0811)

2.11 (0.0831)

2.16 (0.0850)

2.21 (0.0870)

32204 8H516

32204 8H517

32204 8H518

32204 8H519

32204 8H520

End play 0 - 0.1 mm (0 - 0.004 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

1.85 (0.0728)

1.90 (0.0748)

1.95 (0.0768)

2.00 (0.0787)

32204 8H500

32204 8H501

32204 8H502

32204 8H503

2.05 (0.0807)

2.10 (0.0827)

2.15 (0.0846)

2.20 (0.0866)

32204 8H504

32204 8H505

32204 8H506

32204 8H507

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

Thickness mm (in) Part number* Thickness mm (in) Part number*

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)

32348 8H800

32348 8H801

32348 8H802

32348 8H803

32348 8H804

32348 8H805

32348 8H806

32348 8H807

32348 8H808

32348 8H809

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)

32348 8H810

32348 8H811

32348 8H812

32348 8H813

32348 8H814

32348 8H815

32348 8H816

32348 8H817

32348 8H818

SERVICE DATA AND SPECIFICATIONS (SDS)

MT-101

Available Thrust Washer ECS008CJ

INPUT SHAFT THRUST WASHER

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

DIFFERENTIAL SIDE GEAR THRUST WASHER

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

Available Adjusting Shims ECS008CK

4TH MAIN GEAR ADJUSTING SHIM

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

Standard length “C2” 154.7 - 154.8 mm (6.091 - 6.094 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

3.84 (0.1512)

3.90 (0.1535)

3.96 (0.1559)

32347 8H500

32347 8H501

32347 8H502

4.02 (0.1583)

4.08 (0.1606)

4.14 (0.1630)

32347 8H503

32347 8H504

32347 8H505

SCIA1008E

Allowable clearance between side gear and differential case with

washer 0.1 - 0.2 mm (0.004 - 0.008 in)

Thickness 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

Standard length “C1” 173.85 - 173.95 mm (6.844 - 6.848 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

0.52 (0.0205)

0.60 (0.0236)

0.68 (0.0268)

0.76 (0.0299)

32238 8H500

32238 8H501

32238 8H502

32238 8H503

0.84 (0.0331)

0.92 (0.0362)

1.00 (0.0394)

1.08 (0.0425)

32238 8H504

32238 8H505

32238 8H506

32238 8H507

SCIA1009E

MT-102

SERVICE DATA AND SPECIFICATIONS (SDS)

INPUT SHAFT REAR BEARING ADJUSTING SHIM

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

**: RS5F51A model only.

MAINSHAFT REAR BEARING ADJUSTING SHIM

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

REVERSE IDLER GEAR ADJUSTING SHIM

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

6TH MAIN GEAR ADJUSTING SHIM

—For RS6F51A Model—

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

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

Thickness mm (in) Part number* Thickness mm (in) Part number* Thickness mm (in) Part number*

0.40 (0.0157)

0.44 (0.0173)

0.48 (0.0189)

0.52 (0.0205)

0.56 (0.0220)

0.60 (0.0236)

0.64 (0.0252)

0.68 (0.0268)

0.72 (0.0283)

0.76 (0.0299)

0.80 (0.0315)

0.84 (0.0331)

32225 8H500

32225 8H501

32225 8H502

32225 8H503

32225 8H504

32225 8H505

32225 8H506

32225 8H507

32225 8H508

32225 8H509

32225 8H510

32225 8H511

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)

32225 8H512

32225 8H513

32225 8H514

32225 8H515

32225 8H516

32225 8H517

32225 8H518

32225 8H519

32225 8H520

32225 8H521

32225 8H522

32225 8H523

1.36 (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**

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

Thickness mm (in) Part number* Thickness mm (in) Part number*

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)

32238 8H510

32238 8H511

32238 8H512

32238 8H513

32238 8H514

32238 8H515

32238 8H516

32238 8H517

32238 8H518

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)

32238 8H519

32238 8H520

32238 8H521

32238 8H522

32238 8H523

32238 8H524

32238 8H560

32238 8H561

End play 0.04 - 0.10 mm (0.0016 - 0.0039 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

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)

32237 8H800

32237 8H801

32237 8H802

32237 8H803

32237 8H804

32237 8H805

32237 8H806

32237 8H807

32237 8H808

32237 8H809

32237 8H810

32237 8H811

2.24 (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)

32237 8H812

32237 8H813

32237 8H814

32237 8H815

32237 8H816

32237 8H817

32237 8H818

32237 8H819

32237 8H820

32237 8H821

32237 8H822

End play 0 - 0.1 mm (0 - 0.004 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

0.88 (0.0346)

0.96 (0.0378)

1.04 (0.0409)

1.12 (0.0441)

32237 8H560

32237 8H561

32237 8H562

32237 8H563

1.20 (0.0472)

1.28 (0.0504)

1.36 (0.0535)

32237 8H564

32237 8H565

32237 8H566

SERVICE DATA AND SPECIFICATIONS (SDS)

MT-103

Available Shims ECS008CL

— Differential Side Bearing Preload and Adjusting Shim

BEARING PRELOAD

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

DIFFERENTIAL SIDE BEARING ADJUSTING SHIM(S)

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

Differential side bearing preload: L* 0.15 - 0.21 mm (0.0059 - 0.0083 in)

Thickness mm (in) Part number* Thickness mm (in) Part number*

0.48 (0.0189)

0.52 (0.0205)

0.56 (0.0220)

0.60 (0.0236)

0.64 (0.0252)

0.68 (0.0268)

31438 80X00

31438 80X01

31438 80X02

31438 80X03

31438 80X04

31438 80X05

0.72 (0.0283)

0.76 (0.0299)

0.80 (0.0315)

0.84 (0.0331)

0.88 (0.0346)

0.92 (0.0362)

31438 80X06

31438 80X07

31438 80X08

31438 80X09

31438 80X10

31438 80X11

MT-104

SERVICE DATA AND SPECIFICATIONS (SDS)

Nissan 2004 X Trail Owners Manual MT

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