MANUAL TRANSAXLE SECTION

MT

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PREPARATION Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name KV38105210 ( ) Preload adapter
NT075

Description Measuring turning torque of final drive assembly Measuring total turning torque

KV32101000 (J25689-A) Pin punch

NT410

Removing and installing retaining pin

a: 4 mm (0.16 in) dia.

ST22730000 (J25681) Puller

Removing mainshaft front and rear bearing inner race

NT411

a: 82 mm (3.23 in) dia. b: 30 mm (1.18 in) dia.

ST30031000 (J22912-01) Puller

Removing input shaft front and rear bearing Removing 4th & 5th main gear

NT411

a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia.

ST30021000 (J22912-01) Puller

Removing 5th synchronizer Removing 3rd & 4th synchronizer Removing 2nd & 3rd main gear
a: 110 mm (4.33 in) dia. b: 68 mm (2.68 in) dia.

NT411

ST3306S001 (J22888-D) Differential side bearing puller set k 1 ST33051001 (J22888-D) Puller k 2 ST33061000 (J8107-2) Adapter ST33290001 (J34286) Puller

Removing differential side bearing inner race

NT413

a: 38 mm (1.50 in) dia. b: 28.5 mm (1.122 in) dia. c: 130 mm (5.12 in) d: 135 mm (5.31 in) e: 100 mm (3.94 in)

Removing differential oil seal Removing mainshaft rear bearing outer race Removing differential side bearing outer race

NT414

a: 250 mm (9.84 in) b: 160 mm (6.30 in)

MT-2

PREPARATION Special Service Tools (Contd)

ST33400001 (J26082) Drift
NT086

Installing differential oil seal (50A and 50V right side)

a: 60 mm (2.36 in) dia. b: 47 mm (1.85 in) dia.

Tool number (Kent-Moore No.) Tool name ST30600000 (J25863-01) Drift

Description Installing input shaft front bearing

NT065

a: 36 mm (1.42 in) dia. b: 31 mm (1.22 in) dia.

ST22452000 (J34335) Drift

NT065

Installing 3rd, 4th and 5th main gear

a: 45 mm (1.77 in) dia. b: 36 mm (1.42 in) dia.

ST30621000 (J25742-5) Drift

NT073

Installing mainshaft rear bearing outer race (Use with ST30611000.)

a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia.

ST30611000 (J25742-1)

(Use with ST30621000.)

a: 15 mm (0.59 in) b: 335 mm (13.19 in) c: 25 mm (0.98 in) dia. d: M12 x 1.5P

NT419

KV38100300 ( ) Drift

Installing differential side bearing

NT085

a: 54 mm (2.13 in) dia. b: 46 mm (1.81 in) dia. c: 32 mm (1.26 in) dia.

ST30613000 ( ) Drift

Installing differential side bearing

NT073

a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia.

(J34290) Shim selecting tool set

Selecting differential side bearing adjusting shim

NT080

MT-3

PREPARATION Special Service Tools (Contd)

(J34305) Snap ring remover and installer Removing and installing stopper ring of shift fork

NT081

(J25407-2)

Measuring reverse baulk ring wear

NT082

MT-4

PREPARATION Special Service Tools (Contd)

Tool number (Kent-Moore No.) Tool name KV38106500 (J34284) Preload adapter
NT087

Description Measuring turning torque of final drive assembly

(J34291) Shim setting gauge set

Selecting side gear thrust washer

NT101

Commercial Service Tools

Tool name Drift Description Installing differential side bearing inner race

NT065

a: 45 mm (1.77 in) dia. b: 41 mm (1.61 in) dia.

Drift

Installing differential side bearing outer race

NT065

a: 69 mm (2.72 in) dia. b: 64 mm (2.52 in) dia.

Drift

Installing striking rod oil seal

NT065

a: 38 mm (1.50 in) dia. b: 20 mm (0.79 in) dia.

Drift

Installing differential oil seal (50V left side)

NT065

a: 92 mm (3.62 in) dia. b: 72 mm (2.83 in) dia.

Drift

Installing differential side bearing outer race (50V)

NT065

a: 99 mm (3.90 in) dia. b: 94 mm (3.70 in) dia.

MT-5

MANUAL TRANSAXLE

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

Symptom Jumps out of gear Hard to shift or will not shift 1 Oil leakage 3 Noise (Oil level is low.) (Wrong oil) (Oil level is high.) GASKET (Damaged) OIL SEAL (Worn or damaged) O-RING (Worn or damaged) CONTROL ROD (Worn) 1 2

SUSPECTED PARTS (Possible cause)

Refer to MA section (Checking M/T Oil, CHASSIS AND BODY MAINTENANCE).

Reference page

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

MT-6
1 2 3 3

1 2 2 2 3 3

1 2 3 3

MT-12 MT-12 MT-12 MT-11 MT-14 MT-14 MT-13 MT-13 MT-13 MT-13

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)

DESCRIPTION Cross-sectional View

RS5F50A AND 50V

SMT025D

MT-7

ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION Replacing Oil Seal

DIFFERENTIAL OIL SEAL
1. 2. 3. Drain gear oil from transaxle. Remove drive shafts. Refer to FA section (Removal, FRONT AXLE Drive Shaft). Remove differential oil seal.

SMT563A

4. 5.

Install differential oil seal. Apply multi-purpose grease to seal lip of oil seal before installing. Install drive shafts. Refer to FA section (Installation, FRONT AXLE Drive Shaft).

SMT564A

STRIKING ROD OIL SEAL

1. 2. Remove transaxle control rod from yoke. Remove retaining pin. Be careful not to damage boot.

SMT565A

3.

Remove striking rod oil seal.

SMT566A

4.

Install striking rod oil seal. Apply multi-purpose grease to seal lip of oil seal before installing.

SMT570A

MT-8

ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION Position Switch Check

BACK-UP LAMP SWITCH AND NEUTRAL POSITION SWITCH
Check continuity.
Gear position Reverse Neutral Except reverse and neutral
SMT346B

Continuity k 2 -k 4 k 1 -k 3 No

Viscous Coupling Check

1. Apply parking brake firmly and place shift lever in the neutral position. 2. Jack up front wheels. 3. Rotate one front wheel and check turning direction of the other front wheel. Turning direction of the two wheels is opposite: The viscous coupling is not functioning normally. Turning direction of the two wheels is the same: If differential side gear and pinion mate gear thrust washers are OK, viscous coupling is functioning normally.

SMT108C

Removal
CAUTION: Remove the crankshaft position sensor (POS) from transaxle assembly before separating transaxle from engine. Be careful not to damage sensor edge. 1. Remove battery and its bracket. 2. Remove air cleaner box with mass air flow sensor.

SMT109C

3. 4. 5. 6. 7.
SMT650C

Remove clutch operating cylinder from transaxle. Tighten clutch operating cylinder bolts to the specified torque. Refer to CL section (CLUTCH SYSTEM Hydraulic Type). Remove clutch hose clamp. Disconnect speedometer pinion, position switch and ground harness connectors. Remove starter motor from transaxle. Tighten starter motor blots to the specified torque. Refer to EL section (INSTALLATION, STARTING SYSTEM). Remove crankshaft position sensor (POS) from transaxle front side.

MT-9

ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION Removal (Contd)

8. Remove shift control rod and support rod bracket from transaxle. 9. Drain gear oil from transaxle. 10. Draw out drive shafts from transaxle. Refer to FA section (Removal, FRONT AXLE Drive Shaft). 11. Support engine of transaxle by placing a jack under oil pan. CAUTION: Do not place jack under oil pan drain plug. 12. Remove bolts securing center member. Tighten center member bolts to the specified torque. Refer to EM section (ENGINE REMOVAL). 13. Remove LH mount. Tighten LH mount bolts to the specified torque. Refer to EM section (ENGINE REMOVAL). 14. Remove bolts securing transaxle. 15. Lower transaxle while supporting it with a jack.

SMT651C

SMT652C

Installation
Tighten all transaxle bolts.
Bolt No. k 1 k 2 k 3 k 4
SMT638C

Tightening torque Nm (kg-m, ft-lb) 70 - 79 (7.1 - 8.1, 51 - 59) 70 - 79 (7.1 - 8.1, 51 - 59) 70 - 79 (7.1 - 8.1, 51 - 59) 35.1 - 47.1 (3.58 - 4.80, 25.89 - 34.74) 35.1 - 47.1 (3.58 - 4.80, 25.89 - 34.74)

mm (in) 52 (2.05) 65 (2.56) 124 (4.88) 40 (1.57) 40 (1.57)

k 5

k 3 with starter k 4 with support rod bracket

MT-10

TRANSAXLE GEAR CONTROL

SMT860C

k 1 k 2 k 3 k 4 k 5

Shift lever knob Boot retainer Boot Shift lever socket Seat-bearing set

k 6 k 7 k 8 k 9 k 10

Shift lever Bushing O-ring Collar Plate bolt

k 11 k 12 k 13 k 14 k 15

Transaxle hole cover Return spring Support rod Shift control rod Shift support rod bracket

MT-11

MAJOR OVERHAUL Case Components

SMT744CB

k 1 k 2 k 3 k 4 k 5 k 6 k 7

Speedometer pinion Differential oil seal Drain plug Boot Striking rod oil seal Magnet Clutch housing

k 8 k 9 k 10 k 11 k 12 k 13 k 14

Input shaft oil seal Oil channel (Mainshaft) Oil pocket Box breather Oil gutter Oil channel (Input shaft) Transmission case

k 15 k 16 k 17 k 18 k 19 k 20

Filler plug O-ring Movable plate assembly Position switch Breather hose Breather pipe

MT-12

MAJOR OVERHAUL Gear Components

SMT861CA

k 1 k 2 k 3 k 4 k 5 k 6 k 7 k 8 k 9 k 10 k 11 k 12 k 13 k 14 k 15 k 16 k 17 k 18 k 19

Input shaft Input shaft front bearing 3rd input gear 3rd & 4th synchronizer hub Snap ring Coupling sleeve 4th baulk ring 4th input gear Reverse baulk ring Reverse synchronizer cone 5th synchronizer hub Input shaft rear bearing Input shaft bearing adjusting shim 3rd baulk ring Insert spring 4th input gear thrust washer Thrust washer ring 5th input gear 5th baulk ring

k 20 k 21 k 22 k 23 k 24 k 25 k 26 k 27 k 28 k 29 k 30 k 31 k 32 k 33 k 34 k 35 k 36 k 37

1st outer baulk ring 2nd inner baulk ring Snap ring Mainshaft bearing spacer Mainshaft front bearing Mainshaft 1st main gear 1st & 2nd synchronizer hub Reverse main gear (Coupling sleeve) 2nd outer baulk ring 2nd gear synchronizer cone 2nd main gear 3rd main gear 4th main gear 5th main gear Mainshaft rear bearing Mainshaft bearing adjusting shim Differential side bearing

k 38 k 39 k 40 k 41 k 42 k 43 k 44 k 45 k 46 k 47 k 48 k 49 k 50 k 51 k 52 k 53 k 54

Speedometer drive gear Differential case Viscous coupling Final gear Reverse idler gear Pinion mate gear thrust washer Pinion mate gear Pinion mate shaft Side gear Side gear thrust washer Differential side bearing Differential side bearing adjusting shim Bushing Reverse idler shaft Retaining pin 1st gear synchronizer cone 1st inner baulk ring

MT-13

MAJOR OVERHAUL Shift Control Components

SMT862CA

k 1 k 2 k 3 k 4 k 5 k 6 k 7 k 8 k 9 k 10 k 11 k 12 k 13 k 14

Retaining pin 1st & 2nd shift fork 1st & 2nd check plug Return spring Check ball 1st & 2nd fork rod 1st & 2nd bracket Interlock plunger 3rd & 4th bracket Return spring Reverse gate Select arm Return bearing Bush

k 15 k 16 k 17 k 18 k 19 k 20 k 21 k 22 k 23 k 24 k 25 k 26 k 27

Yoke Striking rod Striking lever Selector Selector shaft O-ring Return spring Cam pin Reverse check cam Check ball Select check spring Interlock plunger 3rd & 4th fork rod

k 28 k 29 k 30 k 31 k 32 k 33 k 34 k 35 k 36 k 37 k 38 k 39 k 40

Interlock ball Stopper ring 3rd & 4th check plug 3rd & 4th shift fork 5th shift fork 5th fork rod 5th & reverse check plug Reverse lever spring Reverse lock spring 5th & reverse bracket Reverse lever assembly Reverse arm shaft Control lever spring

MT-14

DISASSEMBLY
1. 2. Before removing transmission case, remove bolts and plugs as shown left. Remove transmission case.

SMT017B

3.

Remove position switch.

SMT017A

4.

Mesh 4th gear, and then remove reverse idler shaft and reverse idler gear.

SMT659C

5.

Pull out retaining pin.

SMT660C

6.

Remove reverse lever spring and reverse lock spring from reverse lever assembly.

SMT661C

MT-15

DISASSEMBLY
7. Remove reverse arm shaft while rotating it.

SMT662C

8.

Remove reverse lever assembly. Be careful not to lose check ball.

SMT663C

9.

Remove 5th & reverse check plug, spring and ball.

SMT018B

10. Remove stopper rings and retaining pins from 5th and 3rd & 4th fork rods. 11. Remove 5th and 3rd & 4th fork rods. Then remove forks and brackets.

SMT664C

12. Remove both input and mainshafts with 1st & 2nd fork and fork rod as a set. 13. Remove final drive assembly. Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.

SMT105C

MT-16

DISASSEMBLY
14. Remove reverse gate assembly. Be careful not to lose check ball.

SMT138A

15. Remove retaining pin and detach the selector.

SMT618A

SMT027A

16. Remove drain plug for convenience in removing retaining pin which holds striking lever to striking rod.

SMT028A

17. Remove retaining pin and then withdraw striking lever and striking rod.

SMT619A

MT-17

REPAIR FOR COMPONENT PARTS Input Shaft and Gears

DISASSEMBLY
1. Before disassembly, check 3rd, 4th and 5th input gear end plays. Gear end play: Refer to SDS, MT-42.

SMT121C

If not within specification, disassemble and check contact surface of gear, shaft and hub. Check clearance of snap ring groove. Refer to ASSEMBLY, MT-20.

SMT476C

2.

Remove input shaft rear bearing.

SMT634A

3.

Remove 5th & reverse synchronizer and 5th input gear.

SMT205B

4.

Remove thrust washer ring, 4th input gear thrust washers and 4th input gear.

SMT474CA

MT-18

REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Contd)

5. Remove snap ring.

SMT040A

6.

Remove 3rd & 4th synchronizer and 3rd input gear.

SMT041A

7.

Remove input shaft front bearing.

SMT042A

INSPECTION Gear and shaft

Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.

SMT636A

Synchronizer
Check spline portion of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for wear or deformation.

SMT637A

MT-19

REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Contd)

Measure clearance between baulk ring and gear (3rd, 4th and 5th). Clearance between baulk ring and gear: Standard 1.0 - 1.35 mm (0.0394 - 0.0531 in) Wear limit 0.7 mm (0.028 in)

SMT140

a. b.

c.

Measure wear of reverse baulk ring. Place reverse baulk ring on Tool and then place reverse synchronizer cone on reverse baulk ring. Make sure projection of synchronizer cone is positioned over the recess on Tool. While holding reverse synchronizer cone against reverse baulk ring as firmly as possible, measure dimension A with dial indicator. Wear limit: Dimension A 1.2 mm (0.047 in) If dimension A is smaller than the wear limit, replace baulk ring.

SMT580B

Bearing
Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

SMT148A

ASSEMBLY

SMT122C

MT-20

REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Contd)

1. Place inserts in three grooves on coupling sleeve (3rd & 4th synchronizer).

SMT441C

2. 3. 4.

Install 3rd input gear and 3rd baulk ring. Press on 3rd & 4th synchronizer hub. Pay attention to its direction. Select proper snap ring of 3rd & 4th synchronizer hub to minimize clearance of groove, and then install it. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Snap ring of 3rd & 4th synchronizer hub: Refer to SDS, MT-43.

SMT477C

SMT123C

5. 6.

Install 4th input gear. Select proper thrust washers to minimize clearance of groove. Then install them and thrust washer ring. Allowable clearance of groove: 0 - 0.06 mm (0 - 0.0024 in) 4th input gear thrust washer: Refer to SDS, MT-43.

SMT442C

7. a.

Install 5th & reverse synchronizer assembly. Hook insert springs on reverse baulk ring.

SMT206B

MT-21

REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Contd)

b. c. d. Install insert springs with reverse baulk ring onto coupling sleeve. Pay attention to position of insert springs. Place 5th baulk ring on 5th input gear. Install reverse synchronizer cone on reverse baulk ring.

SMT752C

e.

Place reverse synchronizer assembly on 5th input gear. Mesh recesses of 5th input gear with projections of reverse synchronizer cone. Put insert spring mounts on reverse baulk ring upon those on 5th baulk ring.

SMT208B

f.

Press on 5th & reverse synchronizer assembly with 5th input gear.

SMT124C

8. 9.

Install input shaft front and rear bearings. Measure gear end play as a final check. Refer to DISASSEMBLY, MT-18.

SMT753C

MT-22

REPAIR FOR COMPONENT PARTS Mainshaft and Gears

DISASSEMBLY
1. Before disassembly, check 1st and 2nd main gear end plays. Gear end play: Refer to SDS, MT-42. If not within specification, disassemble and check contact surface of gear, shaft and hub. Check clearance of snap ring groove. Refer to ASSEMBLY, MT-25.

SMT191A

2.

Press out mainshaft rear bearing.

SMT638A

3.

Remove thrust washer and snap ring.

SMT044A

4.

Press out 5th main gear and 4th main gear.

SMT045A

5.

Press out 3rd main gear and 2nd main gear.

SMT131A

MT-23

REPAIR FOR COMPONENT PARTS Mainshaft and Gears (Contd)

6. Remove snap ring.

SMT047A

7.

Remove 1st & 2nd synchronizer hub and 1st main gear.

SMT048A

8.

Remove mainshaft front bearing.

SMT639A

INSPECTION Gear and shaft

Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.

SMT640A

Synchronizer
Check spline portion of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for deformation.

SMT637A

MT-24

REPAIR FOR COMPONENT PARTS Mainshaft and Gears (Contd)

SMT420C

a. b.

c.

Measure wear of 1st and 2nd double baulk rings. Place baulk rings in position on synchronizer cone. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions A and B. Standard: A 0.6 - 0.8 mm (0.024 - 0.031 in) B 0.6 - 1.1 mm (0.024 - 0.043 in) Wear limit: 0.2 mm (0.008 in) If dimension A or B is smaller than the wear limit, replace baulk ring.

Bearing
Make sure bearings roll freely and are free from noise, cracks, pitting or wear. When replacing tapered roller bearing, replace outer and inner race as a set.

SPD715

ASSEMBLY

SMT996B

1. 2.

Press on 1st main gear, 1st baulk ring and 1st & 2nd synchronizer hub. Pay attention to direction of 1st & 2nd synchronizer hub. Select proper snap ring of 1st & 2nd synchronizer hub to minimize clearance of groove and then install it. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Snap ring of 1st & 2nd synchronizer hub: Refer to SDS, MT-43.

SMT804B

MT-25

REPAIR FOR COMPONENT PARTS Mainshaft and Gears (Contd)

SMT472C

3. 4.

Install 2nd synchronizer cone, inner & outer baulk rings. Insert springs and 1st & 2nd coupling sleeve. Install 2nd main gear. Ensure four protrusions of 2nd synchronizer cone are set in holes of 2nd main gear.

SMT805B

5. 6.

Press on 3rd main gear. Press on 4th main gear.

SMT600CB

7. 8.

Press on 5th main gear. Select proper snap ring of 5th main gear to minimize clearance of groove and then install it. Allowable clearance of groove: 0 - 0.15 mm (0 - 0.0059 in) Snap ring of 5th main gear: Refer to SDS, MT-43.

SMT473CB

9. Press on thrust washer and press on mainshaft rear bearing. 10. Press on mainshaft front bearing. 11. Measure gear end play as a final check. Refer to DISASSEMBLY, MT-23.

SMT059A

MT-26

REPAIR FOR COMPONENT PARTS Final Drive

DISASSEMBLY
1. 2. 3. RS5F50A Remove final gear. Remove speedometer drive gear by cutting it. Press out differential side bearings. Be careful not to mix up the right and left bearings.

SMT744AB

4. 5.

Drive out retaining pin and draw out pinion mate shaft. Remove pinion mate gears and side gears.

SMT891-A

RS5F50V 1. Remove final gear.

SMT696B

2.

Press out differential side bearings.

SMT697B

3.

Remove speedometer drive gear.

SAT313D

MT-27

REPAIR FOR COMPONENT PARTS Final Drive (Contd)

4. Remove viscous coupling.

SMT698B

5. 6.

Separate differential cases. Make paint marks to identify their original positions. Remove pinion mate shaft with gears.

SAT311F

INSPECTION Gear, washer, shaft and case

Check mating surfaces of differential case, viscous coupling, side gears and pinion mate gears. Check washers for wear.

SMT724C

Viscous coupling
Check case for cracks. Check silicone oil for leakage.

SMT508B

MT-28

REPAIR FOR COMPONENT PARTS Final Drive (Contd)

Bearings
Make sure bearings roll freely and are free from noise, cracks, pitting or wear. When replacing taper roller bearing, replace outer and inner race as a set.

SPD715

ASSEMBLY
1. Attach side gear thrust washers to side gears, then install pinion mate washers and pinion mate gears in place.

SMT062A

2.

Insert pinion mate shaft. When inserting, be careful not to damage pinion mate thrust washers.

SMT087A

RS5F50A 3. Measure clearance between side gear and differential case with washers following the procedure below: a. Set Tool and dial indicator on side gear. b. Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears. Clearance between side gear and differential case with washers: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT610AA

c.

If not within specification, adjust clearance by changing thickness of side gear thrust washers. Side gear thrust washer: Refer to SDS, MT-43.

SMT611A

MT-29

REPAIR FOR COMPONENT PARTS Final Drive (Contd)

4. Install retaining pin. Make sure that retaining pin is flush with case.

SMT612A

5. 6.

Install final gear. Install speedometer drive gear.

SMT609A

7.

Press on differential side bearings.

SMT648

RS5F50V 3. Measure clearance between side gear and differential case & viscous coupling with washers using the following procedure: Differential case side a. Set tool on the differential case and lock gauging cylinder in place with set screw.

SAT313FA

b.

Install gauging plunger into cylinder.

SAT314F

MT-30

REPAIR FOR COMPONENT PARTS Final Drive (Contd)

c. d. e. Install pinion mate gears and side gear with thrust washer on differential case. Set tool and allow gauging plunger to rest on side gear thrust washer. Measure gap between plunger and cylinder. This measurement should give exact clearance between side gear and differential case with washers. Standard clearance: 0.1 - 0.2 mm (0.004 - 0.008 in) If not within specification adjust clearance by changing thickness of side gear thrust washer. Side gear thrust washers for differential case side: Refer to SDS, MT-44.

f.
SAT315FA

Viscous coupling side a. Place side gear and thrust washer on pinion mate gears installed on differential case. b. Measure dimension X. Measure dimension X in at least four places. a. Set tool on viscous coupling and lock gauging cylinder in place with set screw.

SAT316FA

b.

Install gauging plunger into cylinder.

SAT314F

c.

Install pinion mate gears and side gears with original washers on differential cases. Align paint marks. d. Tighten differential case bolts. e. Set tool and allow plunger to rest on side gear thrust washer. f. Measure gap between plunger and cylinder. This measurement should give exact clearance between side gear and differential case with washers. Standard clearance: 0.1 - 0.2 mm (0.004 - 0.008 in)
SAT318FA

g.

If not within specification, adjust clearance by changing thickness of side gear thrust washer. Side gear thrust washers for viscous coupling side: Refer to SDS, MT-44.

MT-31

REPAIR FOR COMPONENT PARTS Final Drive (Contd)

4. Install viscous coupling.

SMT711B

5.

Install speedometer drive gear on differential case. Align the projection of speedometer drive gear with the groove of differential case.

SAT313D

6.

Press differential side bearings on differential case.

SMT445C

7.

Install final gear and tighten fixing bolts in a crisscross pattern.

SAT471C

MT-32

REPAIR FOR COMPONENT PARTS Shift Control Components

INSPECTION
Check contact surface and sliding surface for wear, scratches, projections or other damage.

SMT665C

Case Components
REMOVAL AND INSTALLATION Input shaft oil seal

SMT030A

Apply multi-purpose grease to seal lip of oil seal before installing.

SMT031A

Mainshaft front bearing outer race Extract the oil channel and remove the mainshaft front bearing outer race. Mainshaft rear bearing outer race Refer to ADJUSTMENT, MT-35. Differential side bearing outer race Refer to ADJUSTMENT, MT-34.
SMT034A

MT-33

ADJUSTMENT Input Shaft End Play and Differential Side Bearing Preload
If any of the following parts are replaced, adjust input shaft end play. Input shaft Input shaft bearing Clutch housing Transmission case If any of the following parts are replaced, adjust differential side bearing preload. Differential case Differential side bearing Clutch housing Transmission case

1.

Remove differential side bearing outer race (transmission case side) and shim(s).

SMT132A

2. 3. 4.

Reinstall differential side bearing outer race without shim(s). Install input shaft and final drive assembly on clutch housing. Install transmission case without input shaft bearing shim(s). Then tighten it to the specified torque. Refer to MT-12.

SMT845B

5. a.

Using the following procedures, measure clearance between bearings and transmission case. Differential side Attach dial indicator. If clamp diameter of dial indicator is too small or too large, attach dial indicator using a magnetic stand.

SMT074A

MT-34

ADJUSTMENT Input Shaft End Play and Differential Side Bearing Preload (Contd)
b. Insert Tool all the way into differential side gear. Move Tool up and down and measure dial indicator deflection.

SMT075A

a. b. 6. 7.

Input shaft side Set dial indicator on end of input shaft. Move input shaft up and down and measure dial indicator deflection. Select shims with proper thickness with SDS table as a guide. Refer to MT-46. Install selected differential side bearing adjusting shim and differential side bearing outer race.

SMT076A

8. a. b.

Check differential side bearing turning torque. Install final drive assembly on clutch housing. Install transmission case on clutch housing. Tighten transmission case fixing bolts to the specified torque. Refer to MT-12.

SMT475C

c.

Measure turning torque of final drive assembly. Turning torque of final drive assembly (New bearing): 4.9 - 7.8 Nm (50 - 80 kg-cm, 43 - 69 in-lb) When old bearing is used again, turning torque will be slightly less than the above. Make sure torque is close to the specified range.

SAT478E

Mainshaft Bearing Preload

If any of the following parts are replaced, adjust mainshaft bearing preload. Mainshaft Mainshaft bearings Clutch housing Transmission case

MT-35

ADJUSTMENT Mainshaft Bearing Preload (Contd)

1. Remove mainshaft rear bearing outer race and shim(s).

SMT077A

2. 3. 4.

Reinstall mainshaft rear bearing outer race without shims. Clean mating surfaces of clutch housing and transmission case with solvent. Install mainshaft and mainshaft front bearing outer race into transmission case. Turn mainshaft while holding bearing outer race so that bearings are properly seated.

SMT644A

5.

Place Tools (bridge and gauging cylinder) onto machined surface of transmission case. Allow gauging cylinder to rest on surface of mainshaft front bearing outer race. Use proper screw in bridge to lock gauging cylinder in place.

SMT998B

6.

Turn bridge over and place Tool (gauging plunger) into gauging cylinder.

SMT133A

7.

Place bridge, legs up, onto machined surface of clutch housing. Allow gauging plunger to rest upon mating surface where mainshaft front bearing outer race fits.

SMT999B

MT-36

ADJUSTMENT Mainshaft Bearing Preload (Contd)

8. Measure with feeler gauge distance between gauging cylinder and shoulder of gauging plunger. 9. Use feeler gauge reading to select correct mainshaft preload shim(s). Mainshaft bearing adjusting shim: Refer to SDS, MT-44. 10. Install selected mainshaft bearing adjusting shim and mainshaft bearing outer race. 11. Check total turning torque after assembly. Refer to ASSEMBLY, MT-41.
SMT001C

SMT467B

MT-37

ASSEMBLY
1. Install striking lever and striking rod.

SMT029A

2.

Install selector and retaining pin.

SMT645A

3.

Install reverse gate assembly. Be careful not to lose check ball.

SMT138A

4. 5.

Install final drive assembly. Install input shaft and mainshaft with 1st & 2nd shift fork assembly. Be careful not to damage input shaft oil seal.

SAT601C

6.

Install interlock balls and plunger.

SMT065A

MT-38

ASSEMBLY
7. Install 3rd & 4th shift fork and bracket, then install 3rd & 4th fork rod, stopper ring and retaining pin.

SMT066A

8.

Install interlock balls.

SMT067A

9.

Install 5th shift fork, then install fork rod, stopper ring and retaining pin.

SMT666C

10. Install 5th & reverse check plug, spring and ball. Apply sealant to bolt threads. Refer to MT-14.

SMT018B

11. Install reverse lock spring on 5th & reverse bracket. Pay attention to its direction.

SMT201B

MT-39

ASSEMBLY
12. Install check ball and reverse lever spring on reverse lever assembly. Apply multi-purpose grease to check ball. Pay attention to direction of reverse lever spring.

SMT667C

13. Install reverse lever assembly on clutch housing.

SMT668C

14. Install reverse arm shaft and retaining pin.

SMT669C

15. Hook reverse lock spring and reverse lever spring on reverse lever assembly.

SMT670C

16. Mesh 4th gear, then install reverse idler gear and shaft. Pay attention to direction of tapped hole.

SMT671C

MT-40

ASSEMBLY
17. Place magnet on clutch housing.

SMT070A

18. If bearing preload of mainshaft was adjusted, install selected shim(s) into transmission case. To aid in installation of transmission case, place shift selector in the 1st and 2nd shift bracket or between 1st and 2nd bracket and 3rd and 4th bracket. 19. Apply sealant to mating surface of transmission case and install it. Refer to MT-12. 20. Install position switch.

SMT446C

21. Apply sealant to threads of check plugs. Install balls, springs and plugs. Refer to MT-14. 22. After assembly, check that you can shift into each gear smoothly.

SMT017B

23. Measure total turning torque. Total turning torque (New bearing): 8.8 - 21.6 Nm (90 - 220 kg-cm, 78 - 191 in-lb) When old bearing is used again, preload will be slightly less than the above. Make sure torque is close to the specified range.

SAT478E

MT-41

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

TRANSAXLE
Engine Transaxle model Number of speeds Synchromesh type RS5F50A 5 Warner VQ30DE RS5F50V

FINAL GEAR
Engine Transaxle model Final gear ratio Number of teeth Final gear/Pinion Side gear/Pinion 14/10 65/17 16/10 VQ30DE RS5F50A RS5F50V

3.823

Shift pattern

Number of teeth Gear ratio Input gear 1st 2nd 3rd 4th 5th Rev. Reverse idler gear Oil capacity liter (US pt, Imp pt) Double baulk ring type synchronizer 4.5 - 4.8 (9-1/2 - 10-1/8, 7-7/8 - 8-1/2) 3.285 1.850 1.272 0.954 0.795 3.428 14 20 33 44 49 14 29 4.3 - 4.5 (9-1/8 - 9-1/2, 7-5/8 - 7-7/8) Main gear 46 37 42 42 39 48

Remarks

1st & 2nd synchronizer

Inspection and Adjustment

GEAR END PLAY
Unit: mm (in) Gear 1st main gear 2nd main gear 3rd input gear 4th input gear 5th input gear End play 0.23 - 0.43 (0.0091 - 0.0169) 0.23 - 0.58 (0.0091 - 0.0228) 0.23 - 0.43 (0.0091 - 0.0169) 0.25 - 0.55 (0.0098 - 0.0217) 0.23 - 0.48 (0.0091 - 0.0189) 3rd & 4th 5th Standard 1.0 - 1.35 (0.0394 - 0.0531) 1.0 - 1.35 (0.0394 - 0.0531)

CLEARANCE BETWEEN BAULK RING AND GEAR 3rd, 4th & 5th
Unit: mm (in) Wear limit 0.7 (0.028) 0.7 (0.028)

MT-42

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Contd)

1st and 2nd double baulk ring
Unit: mm (in)

3rd & 4th synchronizer hub (At input shaft)

Allowable clearance Thickness mm (in) 1.95 (0.0768) 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 0 - 0.1 mm (0 - 0.004 in) Part number 32269-03E03 32269-03E00 32269-03E01 32269-03E02

5th main gear (At mainshaft)

Allowable clearance Thickness mm (in)
SMT806B

0 - 0.15 mm (0 - 0.0059 in) Part number 32348-05E00 32348-05E01 32348-05E02 32348-05E03

1.95 (0.0768) 2.05 (0.0807) 2.15 (0.0846)

Dimension A B

Standard 0.6 - 0.8 (0.024 - 0.031)

Wear limit

0.2 (0.008) 0.6 - 1.1 (0.024 - 0.043)

2.25 (0.0886)

AVAILABLE THRUST WASHER 4th input gear (At input shaft)

Allowable clearance Thickness mm (in) 4.500 (0.1772) 4.525 (0.1781) 4.550 (0.1791) 4.575 (0.1801) 0 - 0.06 mm (0 - 0.0024 in) Part number 32278-03E01 32278-03E02 32278-03E03 32278-03E04

Reverse baulk ring

Differential side gear thrust washer RS5F50A

SMT581B

Dimension A

Wear limit 1.2 mm (0.047 in)

Allowable clearance between side gear and differential case with washer Thickness mm (in) 0.75 - 0.80 (0.0295 - 0.0315) 0.80 - 0.85 (0.0315 - 0.0335) 0.85 - 0.90 (0.0335 - 0.0354) 0.90 - 0.95 (0.0354 - 0.0374)

0.1 - 0.2 mm (0.004 - 0.008 in) Part number 38424-E3020 38424-E3021 38424-E3022 38424-E3023

AVAILABLE SNAP RING 1st & 2nd synchronizer hub (At mainshaft)
Allowable clearance Thickness mm (in) 1.95 (0.0768) 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 0 - 0.1 mm (0 - 0.004 in) Part number 32269-03E03 32269-03E00 32269-03E01 32269-03E02

MT-43

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Contd)

Differential side gear thrust washer RS5F50V
Allowable clearance between side gear and (differential case or viscous coupling) with washer 0.1 - 0.2 mm (0.004 - 0.008 in) Part number 38424-E3000 38424-E3001 38424-E3002 38424-E3003 38424-51E10 38424-51E11 38424-51E12 38424-51E13 38424-51E14 Dimension C 0.30 - 0.34 (0.0118 - 0.0134) 0.34 - 0.38 (0.0134 - 0.0150)
SMT467B

Table for selecting mainshaft bearing adjusting shim

Unit: mm (in)

Thickness mm (in) 0.75 - 0.80 (0.0295 - 0.0315) Differential case side 0.80 - 0.85 (0.0315 - 0.0335) 0.85 - 0.90 (0.0335 - 0.0354) 0.90 - 0.95 (0.0354 - 0.0374) 0.43 - 0.45 (0.0169 - 0.0177) 0.52 - 0.54 (0.0205 - 0.0213) Viscous coupling side 0.61 - 0.63 (0.0240 - 0.0248) 0.70 - 0.72 (0.0276 - 0.0283) 0.79 - 0.81 (0.0311 - 0.0319)

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

AVAILABLE SHIM INPUT SHAFT END PLAY AND MAINSHAFT AND DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM Bearing preload and end play
Unit: mm (in) Mainshaft bearing preload Input shaft end play Differential side bearing preload 0.06 - 0.11 (0.0024 - 0.0043) 0 - 0.05 (0 - 0.0020) 0.40 - 0.45 (0.0157 - 0.0177)

0.38 - 0.42 (0.0150 - 0.0165) 0.42 - 0.46 (0.0165 - 0.0181) 0.46 - 0.50 (0.0181 - 0.0197) 0.50 - 0.54 (0.0197 - 0.0213) 0.54 - 0.58 (0.0213 - 0.0228) 0.58 - 0.62 (0.0228 - 0.0244) 0.62 - 0.66 (0.0244 - 0.0260) 0.66 - 0.70 (0.0260 - 0.0276) 0.70 - 0.74 (0.0276 - 0.0291) 0.74 - 0.78 (0.0291 - 0.0307) 0.78 - 0.82 (0.0307 - 0.0323) 0.82 - 0.86 (0.0323 - 0.0339) 0.86 - 0.90 (0.0339 - 0.0354) 0.90 - 0.94 (0.0354 - 0.0370) 0.94 - 0.98 (0.0370 - 0.0386) 0.98 - 1.02 (0.0386 - 0.0402) 1.02 - 1.06 (0.0402 - 0.0417) 1.06 - 1.10 (0.0417 - 0.0433) 1.10 - 1.14 (0.0433 - 0.0449) 1.14 - 1.18 (0.0449 - 0.0465) 1.18 - 1.22 (0.0465 - 0.0480) 1.22 - 1.26 (0.0480 - 0.0496) 1.26 - 1.30 (0.0496 - 0.0512) 1.30 - 1.34 (0.0512 - 0.0528) 1.34 - 1.38 (0.0528 - 0.0543) 1.38 - 1.42 (0.0543 - 0.0559) 1.42 - 1.46 (0.0559 - 0.0575) 1.46 - 1.50 (0.0575 - 0.0591)

Turning torque (New bearing)

Unit: Nm (kg-cm, in-lb) Final drive only Total 4.9 - 7.8 (50 - 80, 43 - 69) 8.8 - 21.6 (90 - 220, 78 - 191)

Mainshaft bearing adjusting shim

Thickness mm (in) 0.40 (0.0157) 0.44 (0.0173) 0.48 (0.0189) 0.52 (0.0205) 0.56 (0.0220) 0.60 (0.0236) 0.64 (0.0252) 0.68 (0.0268) 0.72 (0.0283) 0.76 (0.0299) 0.80 (0.0315) 1.20 (0.0472) Part number 32139-03E11 32139-03E00 32139-03E01 32139-03E12 32139-03E02 32139-03E03 32139-03E04 32139-03E05 32139-03E06 32139-03E07 32139-03E08 32139-03E13

MT-44

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Contd)

Input shaft bearing adjusting shim
Thickness mm (in) 0.40 (0.0157) 0.44 (0.0173) 0.48 (0.0189) 0.52 (0.0205) 0.56 (0.0220) 0.60 (0.0236) 0.64 (0.0252) 0.68 (0.0268) 0.72 (0.0283) 0.76 (0.0299) 0.80 (0.0315) 1.20 (0.0472) Part number 32225-08E00 32225-08E01 32225-08E02 32225-08E03 32225-08E04 32225-08E05 32225-08E06 32225-08E07 32225-08E08 32225-08E09 32225-08E10 32225-08E11 Thickness mm (in) 0.40 (0.0157) 0.44 (0.0173) 0.48 (0.0189) 0.52 (0.0205) 0.56 (0.0220) 0.60 (0.0236) 0.64 (0.0252) 0.68 (0.0268) 0.72 (0.0283) 0.76 (0.0299) 0.80 (0.0315) 0.84 (0.0331) Part number 38453-96E00 38453-96E01 38453-96E02 38453-96E03 38453-96E04 38453-96E05 38453-96E06 38453-96E07 38453-96E08 38453-96E09 38453-96E10 38453-96E11 38453-96E12 38453-96E13

Differential side bearing adjusting shim RS5F50A

Table for selecting input shaft bearing adjusting shim

Unit: mm (in) Dial indicator indication 0.65 - 0.69 (0.0256 - 0.0272) 0.69 - 0.73 (0.0272 - 0.0287) 0.73 - 0.77 (0.0287 - 0.0303) 0.77 - 0.81 (0.0303 - 0.0319) 0.81 - 0.85 (0.0319 - 0.0335) 0.85 - 0.89 (0.0335 - 0.0350) 0.89 - 0.93 (0.0350 - 0.0366) 0.93 - 0.97 (0.0366 - 0.0382) 0.97 - 1.01 (0.0382 - 0.0398) 1.01 - 1.05 (0.0398 - 0.0413) 1.05 - 1.09 (0.0413 - 0.0429) 1.09 - 1.13 (0.0429 - 0.0445) 1.13 - 1.17 (0.0445 - 0.0461) 1.17 - 1.21 (0.0461 - 0.0476) 1.21 - 1.25 (0.0476 - 0.0492) 1.25 - 1.29 (0.0492 - 0.0508) 1.29 - 1.33 (0.0508 - 0.0524) 1.33 - 1.37 (0.0524 - 0.0539) 1.37 - 1.41 (0.0539 - 0.0555) 1.41 - 1.45 (0.0555 - 0.0571) 1.45 - 1.49 (0.0571 - 0.0587) 1.49 - 1.53 (0.0587 - 0.0602) 1.53 - 1.57 (0.0602 - 0.0618) 1.57 - 1.61 (0.0618 - 0.0634) 1.61 - 1.65 (0.0634 - 0.0650) 1.65 - 1.69 (0.0650 - 0.0665) Suitable shim(s) 0.64 (0.0252) 0.68 (0.0268)

0.88 (0.0346) 1.20 (0.0472)

Differential side bearing adjusting shim RS5F50V

Thickness mm (in) Part number 38753-56E00 38753-56E01 38753-56E02 38753-56E03 38753-56E04 38753-56E05 38753-56E06 38753-56E07 38753-56E08 38753-56E09 38753-56E10 38753-56E11 38753-56E12 38753-56E13 38753-56E14 0.36 (0.0142)

0.72 (0.0283) 0.76 (0.0299) 0.40 (0.0157) 0.80 (0.0315) 0.44 (0.0173) 0.40 + 0.44 (0.0157 + 0.0173) 0.48 (0.0189) 0.44 + 0.44 (0.0173 + 0.0173) 0.52 (0.0205) 0.44 + 0.48 (0.0173 + 0.0189) 0.56 (0.0220) 0.48 + 0.48 (0.0189 + 0.0189) 0.60 (0.0236) 0.48 + 0.52 (0.0189 + 0.0205) 0.64 (0.0252) 0.52 + 0.52 (0.0205 + 0.0205) 0.68 (0.0268) 0.52 + 0.56 (0.0205 + 0.0220) 0.72 (0.0283) 0.56 + 0.56 (0.0220 + 0.0220) 0.76 (0.0299) 0.56 + 0.60 (0.0220 + 0.0236) 0.80 (0.0315) 0.60 + 0.60 (0.0236 + 0.0236) 0.84 (0.0331) 0.60 + 0.64 (0.0236 + 0.0252) 0.88 (0.0346) 0.64 + 0.64 (0.0252 + 0.0252) 0.92 (0.0362) 0.64 + 0.68 (0.0252 + 0.0268) 0.68 + 0.68 (0.0268 + 0.0268) 0.68 + 0.72 (0.0268 + 0.0283) 0.72 + 0.72 (0.0283 + 0.0283) 0.72 + 0.76 (0.0283 + 0.0299) 0.76 + 0.76 (0.0299 + 0.0299) 0.76 + 0.80 (0.0299 + 0.0315) 0.80 + 0.80 (0.0315 + 0.0315) 0.44 + 1.20 (0.0173 + 0.0472)

MT-45

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Contd)

Table for selecting differential side bearing adjusting shim(s) RS5F50A
Unit: mm (in) Dial indicator deflection 0.47 - 0.51 (0.0185 - 0.0201) 0.51 - 0.55 (0.0201 - 0.0217) 0.55 - 0.59 (0.0217 - 0.0232) 0.59 - 0.63 (0.0232 - 0.0248) 0.63 - 0.67 (0.0248 - 0.0264) 0.67 - 0.71 (0.0264 - 0.0280) 0.71 - 0.75 (0.0280 - 0.0295) 0.75 - 0.79 (0.0295 - 0.0311) 0.79 - 0.83 (0.0311 - 0.0327) 0.83 - 0.87 (0.0327 - 0.0343) 0.87 - 0.91 (0.0343 - 0.0358) 0.91 - 0.95 (0.0358 - 0.0374) 0.95 - 0.99 (0.0374 - 0.0390) 0.99 - 1.03 (0.0390 - 0.0406) 1.03 - 1.07 (0.0406 - 0.0421) 1.07 - 1.11 (0.0421 - 0.0437) 1.11 - 1.15 (0.0437 - 0.0453) 1.15 - 1.19 (0.0453 - 0.0469) 1.19 - 1.23 (0.0469 - 0.0484) 1.23 - 1.27 (0.0484 - 0.0500) 1.27 - 1.31 (0.0500 - 0.0516) Suitable shim(s) 0.44 + 0.48 (0.0173 + 0.0189) 0.48 + 0.48 (0.0189 + 0.0189) 0.48 + 0.52 (0.0189 + 0.0205) 0.52 + 0.52 (0.0205 + 0.0205) 0.52 + 0.56 (0.0205 + 0.0220) 0.56 + 0.56 (0.0220 + 0.0220) 0.56 + 0.60 (0.0220 + 0.0236) 0.60 + 0.60 (0.0236 + 0.0236) 0.60 + 0.64 (0.0236 + 0.0252) 0.64 + 0.64 (0.0252 + 0.0252) 0.64 + 0.68 (0.0252 + 0.0268) 0.68 + 0.68 (0.0268 + 0.0268) 0.68 + 0.72 (0.0268 + 0.0283) 0.72 + 0.72 (0.0283 + 0.0283) 0.72 + 0.76 (0.0283 + 0.0299) 0.76 + 0.76 (0.0299 + 0.0299) 1.07 - 1.11 (0.0421 - 0.0437) 0.76 + 0.80 (0.0299 + 0.0315) 0.80 + 0.80 (0.0315 + 0.0315) 0.44 + 1.20 (0.0173 + 0.0472) 0.48 + 1.20 (0.0189 + 0.0472) 0.52 + 1.20 (0.0205 + 0.0472) 1.11 - 1.15 (0.0437 - 0.0453) 1.15 - 1.19 (0.0453 - 0.0469) 1.19 - 1.23 (0.0469 - 0.0484) 1.23 - 1.27 (0.0484 - 0.0500) 1.27 - 1.31 (0.0500 - 0.0516) 0.76 + 0.80 (0.0299 + 0.0315) 0.80 + 0.80 (0.0315 + 0.0315) 0.72 + 0.92 (0.0283 + 0.0362) 0.76 + 0.92 (0.0299 + 0.0362) 0.80 + 0.92 (0.0315 + 0.0362) 0.76 + 0.76 (0.0299 + 0.0299) Dial indicator deflection 0.47 - 0.51 (0.0185 - 0.0201) 0.51 - 0.55 (0.0201 - 0.0217) 0.55 - 0.59 (0.0217 - 0.0232) 0.59 - 0.63 (0.0232 - 0.0248) 0.63 - 0.67 (0.0248 - 0.0264) 0.67 - 0.71 (0.0264 - 0.0280) 0.71 - 0.75 (0.0280 - 0.0295) 0.75 - 0.79 (0.0295 - 0.0311) 0.79 - 0.83 (0.0311 - 0.0327) 0.83 - 0.87 (0.0327 - 0.0343) 0.87 - 0.91 (0.0343 - 0.0358) 0.91 - 0.95 (0.0358 - 0.0374) 0.95 - 0.99 (0.0374 - 0.0390) 0.99 - 1.03 (0.0390 - 0.0406) 1.03 - 1.07 (0.0406 - 0.0421)

Table for selecting differential side bearing adjusting shim(s) RS5F50V

Unit: mm (in) Suitable shim(s) 0.44 + 0.48 (0.0173 + 0.0189) 0.48 + 0.48 (0.0189 + 0.0189) 0.48 + 0.52 (0.0189 + 0.0205) 0.52 + 0.52 (0.0205 + 0.0205) 0.52 + 0.56 (0.0205 + 0.0220) 0.56 + 0.56 (0.0220 + 0.0220) 0.56 + 0.60 (0.0220 + 0.0236) 0.60 + 0.60 (0.0236 + 0.0236) 0.60 + 0.64 (0.0236 + 0.0252) 0.64 + 0.64 (0.0252 + 0.0252) 0.64 + 0.68 (0.0252 + 0.0268) 0.68 + 0.68 (0.0268 + 0.0268) 0.68 + 0.72 (0.0268 + 0.0283) 0.72 + 0.72 (0.0283 + 0.0283) 0.72 + 0.76 (0.0283 + 0.0299)

MT-46

MANUAL TRANSAXLE SECTION

MT

CONTENTS
PREPARATION ................................................................2 Special Service Tools ..................................................2 Commercial Service Tools ...........................................5 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................6 NVH Troubleshooting Chart.........................................6 DESCRIPTION .................................................................7 Cross-sectional View ...................................................7 ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION ................................................................8 Replacing Oil Seal .......................................................8 Position Switch Check .................................................9 Viscous Coupling Check..............................................9 Removal.......................................................................9 Installation..................................................................10 TRANSAXLE GEAR CONTROL ...................................11 MAJOR OVERHAUL .....................................................12 Case Components .....................................................12 Gear Components .....................................................13 Shift Control Components .........................................14 DISASSEMBLY ..............................................................15 REPAIR FOR COMPONENT PARTS ............................18 Input Shaft and Gears ...............................................18 Mainshaft and Gears .................................................23 Final Drive..................................................................27 Shift Control Components .........................................33 Case Components .....................................................33 ADJUSTMENT ...............................................................34 Input Shaft End Play and Differential Side Bearing Preload .........................................................34 Mainshaft Bearing Preload ........................................35 ASSEMBLY ....................................................................38 SERVICE DATA AND SPECIFICATIONS (SDS) ..........42 General Specifications...............................................42 Inspection and Adjustment ........................................42