RA61 Manual Transaxle

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION SYSTEM
MT1
MANUAL TRANSMISSION SYSTEM

PROBLEM SYMPTOMS TABLE
Use the table below to help determine the cause of the problems. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in the order suggested. If necessary, replace the applicable parts.
Symptom 1. Oil level (Low) Abnormal noise 2. Oil (Wrong) 3. Gears (Worn or damaged) 4. Bearings (Worn or damaged) 1. Oil level (High) Oil leakage 2. Gasket (Damaged) 3. Oil seal (Worn or damaged) 4. O-Ring (Worn or damaged) Hard shifting or will not shift 1. Synchronizer ring (Worn or damaged) 2. Shift key spring (Damaged) 1. Locking ball spring (Damaged) Jumps out of gear 2. Shift fork (Worn) 3. Gears (Worn or damaged) 4. Bearings (Worn or damaged) Suspected area MT-2 MT-2 MT-2 See page
MT
MT2
RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION OIL
MANUAL TRANSMISSION OIL

ON-VEHICLE INSPECTION
1. INSPECT TRANSMISSION OIL (a) Park the vehicle in a level place. (b) Remove the transmission filler plug and gasket. (c) Check that the oil surface is within 5 mm (0.20 in.) of the lowest point of the transmission filler plug opening. NOTICE: Problems may occur when the oil level is too high or low. After replacing the oil, drive the vehicle and check the oil level again. (d) Check for oil leakage when the oil level is low. (e) Install the transmission filler plug and a new gasket. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
0 to 5 mm (0 to 0.20 in.)
D025304E01
MT
RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY
MT3
MANUAL TRANSMISSION ASSEMBLY

RA61F MANUAL TRANSMISSION TRANSMISSION
COMPONENTS
CONSOLE UPPER REAR PANEL SUB-ASSEMBLY
PARKING BRAKE HOLE COVER SUB-ASSEMBLY
for Manual Transmission: SHIFT LEVER KNOB SUB-ASSEMBLY
FRONT CONSOLE BOX
for Transfer: SHIFT LEVER KNOB SUB-ASSEMBLY
SHIFT LEVER BOOT ASSEMBLY
MT
FLOOR SHIFT SHIFT LEVER ASSEMBLY
TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY
SNAP RING
C133794E01
MT4
COMPRESSION SPRING GASKET FRONT EXHAUST PIPE ASSEMBLY
43 (438, 32)
43 (438, 32)
GASKET
48 (489, 35)
COMPRESSION SPRING
x2 GASKET
54 (554, 40)
x2
GASKET
x2
54 (554, 40)
NO. 2 FRONT EXHAUST PIPE ASSEMBLY
MT
N*m (kgf*cm, ft*lbf) :Specified torque Non-reusable part
C136408E01
MT5
REAR NO. 1 ENGINE MOUNTING INSULATOR x4 EXHAUST PIPE STOPPER BRACKET

72 (734, 53) 65 (663, 48)
x2 x2
19 (194, 14)
NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
PROPELLER SHAFT HEAT INSULATOR FRONT SUSPENSION MEMBER BRACKET x4

33 (336, 24) 72 (734, 53)
x2
16 (160, 12)
x4
19 (189, 14)
x2
FRONT SUSPENSION MEMBER BRACKET LH

33 (336, 24) 88 (899, 65)
x4
88 (899, 65)
x4
x4
PROPELLER SHAFT ASSEMBLY
88 (899, 65)
MT
x4
88 (899, 65)
x4 FRONT PROPELLER SHAFT ASSEMBLY
N*m (kgf*cm, ft*lbf) :Specified torque

C136394E01
MT6
x3 MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
12 (117, 8.5)
40 (408, 30)
x3
72 (730, 53) 39 (398, 29)
x2 x2
12 (117, 8.5)
CLIP ACCUMULATOR TO FLEXIBLE HOSE TUBE
x5 MANIFOLD STAY
15 (153, 11)
15 (153, 11)
37 (380, 28)
x4
19 (194, 14)
x3
CLUTCH ACCUMULATOR ASSEMBLY

12 (120, 8.7)
STARTER ASSEMBLY FLYWHEEL HOUSING SIDE COVER x3
15 (153, 11) 40 (408, 30)
MT
NO. 2 MANIFOLD STAY CLUTCH RELEASE CYLINDER ASSEMBLY
15 (153, 11) 12 (120, 8.7) 12 (120, 8.7)
x2
NO. 1 CLUTCH HOUSING COVER
x2
12 (120, 8.7)
N*m (kgf*cm, ft*lbf) :Specified torque Non-reusable part

C133796E01
MT7
x3
24 (245, 18)
24 (245, 18)
x5
MT
TRANSFER ASSEMBLY
N*m (kgf*cm, ft*lbf) :Specified torque

C133793E01
MT8
REMOVAL
1. 2. 3. 4. 5. 6. 7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE PARKING BRAKE HOLE COVER SUBASSEMBLY (See page IP-11) REMOVE CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-12) REMOVE FRONT CONSOLE BOX (See page IP-12) REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Transfer) REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transmission) REMOVE SHIFT LEVER BOOT ASSEMBLY (a) Remove the 4 screws and 2 clips, then remove the shift lever boot.
C135788
8.
Front
REMOVE TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY (a) Using needle-nose pliers, remove the snap ring and pull out the shift lever from the shift lever retainer.
Select Return Spring
Tip of Shift Lever

C113710E04
MT
9.
REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY (a) Separate the shift lever cap boot from the manual transmission.
F051062

Down
MT9
(b) Cover the shift lever cap with a cloth. (c) Pressing down on the shift lever cap, turn it counterclockwise to remove the shift lever. (d) Pull out the shift lever. 10. DRAIN MANUAL TRANSMISSION OIL (a) Remove the drain plug and gasket and then drain the manual transmission oil. (b) Install a new gasket and drain plug. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 11. REMOVE NO. 2 FRONT EXHAUST PIPE ASSEMBLY (See page EX-4) 12. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See page EX-4) 13. REMOVE PROPELLER SHAFT HEAT INSULATOR (a) Remove the 2 bolts and remove the propeller shaft heat insulator. 14. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR-2) 15. REMOVE PROPELLER SHAFT ASSEMBLY (See page PR-9)
C133778
Cloth
Counterclockwise
F051209E01
16. REMOVE NO. 2 MANIFOLD STAY (a) Remove the 3 bolts and remove the No. 2 manifold stay.
F051648
17. REMOVE MANIFOLD STAY (a) Remove the 3 bolts and remove the manifold stay. 18. REMOVE STARTER ASSEMBLY (See page ST-7)
MT
F051649
MT10
19. REMOVE FLYWHEEL HOUSING SIDE COVER (a) Remove the flywheel housing side cover from the cylinder block. 20. REMOVE NO. 1 CLUTCH HOUSING COVER (See page CL-16) 21. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (See page CL-16)
F050352
22. REMOVE ACCUMULATOR TO FLEXIBLE HOSE TUBE (a) Using SST, disconnect the hose tube. (for accumulator side) SST 09023-00101 (b) Remove the 3 nuts and disconnect the hose tube.
C135783
(c) Using SST, disconnect the hose tube. (for flexible hose side) SST 09023-00101 (d) Remove the clip 23. REMOVE CLUTCH ACCUMULATOR ASSEMBLY (See page CL-19) 24. SUPPORT MANUAL TRANSMISSION WITH TRANSFER (a) Support the manual transmission with a transmission jack. 25. REMOVE FRONT SUSPENSION MEMBER BRACKET LH (a) Remove the 4 bolts and remove the front suspension member bracket LH.
C135784
MT
C129541
26. REMOVE FRONT SUSPENSION MEMBER BRACKET (a) Remove the 4 bolts and remove the front suspension member bracket RH.
C129542
MT11
27. REMOVE NO. 3 FRAME CROSSMEMBER SUBASSEMBLY (a) Remove the 4 bolts from the No. 3 frame crossmember sub-assembly. (b) Remove the 4 nuts and 4 bolts and remove the No. 3 frame crossmember sub-assembly.
C135785
28. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (a) Remove the 4 bolts and engine mounting insulator rear from the manual transmission. 29. DISCONNECT CONNECTOR (a) Tilt down the transmission. (b) Disconnect the 2 transfer indicator switch connectors. (c) Disconnect the speedometer sensor connector. (d) Disconnect the back-up light switch connector. 30. DISCONNECT WIRE HARNESS 31. REMOVE MANUAL TRANSMISSION WITH TRANSFER (a) Remove the 9 bolts. (b) Separate and remove the manual transmission.
C135786
F051064
32. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY (a) Remove the 3 bolts and 2 nuts and remove the manual transmission case cover. 33. REMOVE TRANSFER ASSEMBLY (See page TF-18)
MT
C135787
MT12
INSTALLATION
1. 2. INSTALL TRANSFER ASSEMBLY (See page TF-43) INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY (a) Install the manual transmission case cover with the 3 bolts and 2 nuts. Torque: 12 N*m (117 kgf*cm, 8.5 ft.*lbf)
C135787
A A
A A
3.
INSTALL MANUAL TRANSMISSION WITH TRANSFER (a) Install the manual transmission with transfer with the 9 bolts. Torque: 72 N*m (730 kgf*cm, 53 ft.*lbf) for bolt A 37 N*m (380 kgf*cm, 28 ft.*lbf) for bolt B CONNECT WIRE HARNESS CONNECT CONNECTOR (a) Connect the back-up light switch connector. (b) Connect the speedometer sensor connector. (c) Connect the 2 transfer indicator switch connectors. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (a) Install engine mounting insulator rear No. 1 with the 4 bolts. Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
A B B B B
F051064E02
4. 5.
6.
C135786
MT
7.
INSTALL NO. 3 FRAME CROSSMEMBER SUBASSEMBLY (a) Install the No. 3 frame crossmember sub-assembly with the 4 bolts and 4 nuts. Torque: 72 N*m (734 kgf*cm, 53 ft.*lbf) (b) Install the No. 3 frame crossmember sub-assembly with the 4 bolts. Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf)
C135785
MT13
8.
INSTALL FRONT SUSPENSION MEMBER BRACKET LH (a) Install the front suspension member bracket LH with the 4 bolts. Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)
C129541
9.
INSTALL FRONT SUSPENSION MEMBER BRACKET (a) Install the front suspension member bracket RH with the 4 bolts. Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)
10. INSTALL CLUTCH ACCUMULATOR ASSEMBLY (See page CL-20)
C129542
11. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE (a) Using SST, connect the hose tube. (for flexible hose side) SST 09023-00101 Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) (b) Install a new clip.
C135784
(c) Using SST, connect the hose tube. (for accumulator side) SST 09023-00101 Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) (d) Install the 3 nuts and connect the hose tube. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 12. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (See page CL-17)
C135783
MT
13. INSTALL NO. 1 CLUTCH HOUSING COVER (See page CL-17) 14. INSTALL FLYWHEEL HOUSING SIDE COVER (a) Install the flywheel housing side cover onto the cylinder block. 15. INSTALL STARTER ASSEMBLY (See page ST-15)
F050352
MT14
16. INSTALL MANIFOLD STAY (a) Install the manifold stay with the 3 bolts. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
F051649
17. INSTALL NO. 2 MANIFOLD STAY (a) Install the No. 2 manifold stay with the 3 bolts. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 18. INSTALL PROPELLER SHAFT ASSEMBLY (See page PR-14) 19. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (See page PR-6)
F051648
20. INSTALL PROPELLER SHAFT HEAT INSULATOR (a) Install the propeller shaft heat insulator with the 2 bolts. Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) 21. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See page EX-4) 22. INSTALL NO. 2 FRONT EXHAUST PIPE ASSEMBLY (See page EX-5)
C133778
23. ADD MANUAL TRANSMISSION OIL 24. ADJUST MANUAL TRANSMISSION OIL (See page MT-2) 25. INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY (a) Apply MP grease to the tip of the shift lever.
MT
MP grease
F051066E02

Down
MT15
(b) Cover the shift lever cap with a cloth. (c) Pressing down on the shift lever cap, turn it clockwise to install the shift lever.
Cloth
Clockwise
F051824E01
Installation
Front
26. REMOVE TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY (a) Install the transfer shift lever onto the shift lever retainer. (b) Using needle-nose pliers, install the snap ring.
Select Return Spring
Tip of Shift Lever

C113710E03
27. INSTALL SHIFT LEVER BOOT ASSEMBLY (a) Install the shift lever boot with the 4 screws and 2 clips. 28. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual transmission) 29. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Transfer) 30. INSTALL FRONT CONSOLE BOX (See page IP-31)
C135788
31. INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-31) 32. INSTALL PARKING BRAKE HOLE COVER SUBASSEMBLY (See page IP-32) 33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 34. CHECK FOR EXHAUST GAS LEAKAGE
MT
MT16
RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION UNIT
MANUAL TRANSMISSION UNIT

COMPONENTS
OUTPUT SHAFT REAR BEARING OUTER RACE

20 (204, 15)
x4
FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY
NO. 2 TAPER ROLLER BEARING OUTPUT SHAFT ADJUST NUT

37 (377, 27) 18 (184, 13)
33 (340, 25)
SHIFT LEVER HOUSING

40 (408, 30)
x4 GASKET
x10 OUTPUT SHAFT REAR BEARING OUTER RACE
SPACER
MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
11 (115, 8.3)
BALL
25 (250, 18)
COMPRESSION SPRING
MT
BEARING LOCK PLATE OIL SEPARATOR PACKING SEAL EXTENSION HOUSING OIL RECEIVER PIPE
37 (377, 27)
TRANSMISSION REAR CASE
GASKET
COUNTER GEAR REAR RADIAL BALL BEARING
N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

C114073E03
MT17
44 (449, 33)
BACK-UP LIGHT SWITCH ASSEMBLY
GASKET
TRANSMISSION CASE OIL SEAL
40 (408, 30)
x5 x3
40 (408, 30) 39 (400, 29)
FRONT BEARING SHAFT SNAP RING
NO. 1 OIL RECEIVER PIPE
TRANSMISSION FRONT CASE
TRANSMISSION MIDDLE CASE
NO. 2 OIL RECEIVER 8.5 (87, 75 in.*lbf) PIPE x2
MT
x3
40 (408, 30)
TRANSMISSION OIL SEPARATOR
GASKET GASKET
37 (377, 27)
28 (286, 21)
N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

C114219E05
MT18
INPUT SHAFT ASSEMBLY
OUTPUT SHAFT ASSEMBLY
COUNTER GEAR ASSEMBLY
SHIFT AND SELECT LEVER
MT
SHIFT AND SELECT LEVER CAM
SHIFT AND SELECT LEVER SHAFT
E-RING REVERSE IDLER GEAR BEARING

33 (340, 25)
COMPRESSION SPRING LOCK BALL PIN
REVERSE IDLER GEAR SHAFT REVERSE IDLER GEAR N*m (kgf*cm, ft*lbf) :Specified torque Non-reusable part
C136409E01
MT19
20 (199, 14)
NO. 3 GEAR SHIFT FORK

20 (199, 14)
SLOTTED SPRING PIN NO. 2 GEAR SHIFT FORK SHAFT NO. 3 GEAR SHIFT FORK SHAFT 1ST AND REVERSE SHIFT ARM NO. 1 GEAR SHIFT HEAD PIN
SHIFT DETENT BALL
E-RING
21 (214, 15)
x4
PIN
COMPRESSION SPRING
PIN NO. 1 GEAR SHIFT FORK SHAFT NO. 4 GEAR SHIFT FORK SHAFT SLOTTED SPRING PIN SHIFT ARM PIVOT NO. 2 GEAR SHIFT HEAD
MT
SLOTTED SPRING PIN
SHIFT INTERLOCK BRACKET
N*m (kgf*cm, ft*lbf) :Specified torque Non-reusable part Apply MP grease NO. 1 GEAR SHIFT FORK
C136404E01
MT20
DISASSEMBLY
1. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY (a) Remove the 4 bolts, then remove the floor shift control shift lever retainer.
F051567
(b) Using a plastic hammer, remove the floor shift control shift lever retainer.
D033729
2.
REMOVE SHIFT LEVER HOUSING (a) Remove the bolt, then separate the shift lever housing.
F051568
3.
REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY (a) Remove the 4 bolts, then remove the transmission case cover.
MT
F051569
4.
REMOVE SHIFT DETENT BALL PLUG (a) Using a socket hexagon wrench (10 mm), remove the shift detent ball plug from the transmission rear case. (b) Remove the ball and compression spring from the transmission rear case.
F051570
MT21
5.
REMOVE OUTPUT SHAFT ADJUST NUT (a) Using a chisel and hammer, unstake the nut.
D033734
SST
(b) Place the gearshift into 5th gear, and then fix the input shaft using SST. SST 09556-16030 (c) Using a belt and wooden block, fasten the transmission to the workbench.
D033631E01
(d) Using a socket wrench (60 mm), remove the nut from the transmission rear case. (e) Remove the belt and wooden block from the transmission.
F051825
(f)
Remove taper roller bearing No. 2 and the spacer.
MT
D033736
6.
REMOVE TRANSMISSION REAR CASE (a) Remove the 10 bolts and 3 clamps.
Clamp
Clamp
D033738E01
MT22
(b) Using a plastic hammer, carefully tap out the rear case. HINT: Place the brass bar against the rib portion of the case.
D033739
7.
REMOVE MANUAL TRANSMISSION FILLER PLUG (a) Remove the 2 transmission filler plugs and 2 gaskets from the transmission rear case.
F051572
8.
REMOVE EXTENSION HOUSING OIL RECEIVER PIPE (a) Remove the extension housing oil receiver pipe from the transmission rear case.
F051573
9.
REMOVE OIL SEPARATOR PACKING SEAL (a) Remove the oil separator packing seal from the transmission rear case.
MT
F051828
SST
10. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE (a) Using SST, remove the 2 bearing outer races. SST 09308-00010
SST
D033748E01
MT23
11. REMOVE COUNTER GEAR REAR RADIAL BALL BEARING (a) Remove the bolt, then remove the bearing lock plate.
D033746
SST
(b) Using SST, remove the counter gear rear radial ball bearing from the transmission rear case. SST 09308-00010
F051574E01
12. REMOVE TRANSMISSION OIL SEPARATOR (a) Remove the 2 bolts, then remove the oil separator.
F051575
13. REMOVE REVERSE IDLER GEAR SHAFT BOLT (a) Remove the reverse idler gear shaft bolt from the transmission middle case.
MT
D033649
14. REMOVE TRANSMISSION MIDDLE CASE (a) Remove the 11 bolts, then remove the transmission middle case.
D033740
MT24
(b) Using a plastic hammer, carefully tap out the middle case. HINT: Place the brass bar against the rib portion of the case.
D033741
15. REMOVE DRAIN PLUG SUB-ASSEMBLY (a) Remove the drain plug and gasket from the transmission middle case.
F051576
16. REMOVE NO. 2 OIL RECEIVER PIPE (a) Remove the No. 2 oil receiver pipe from the transmission middle case.
F051577
17. REMOVE SHIFT AND SELECT LEVER SHAFT (a) Remove the shift and select lever shaft from the reverse gear shaft.
MT
F051578
18. REMOVE SHIFT AND SELECT LEVER (a) Remove the bolt, then remove the shift and select lever. (b) Remove the lock ball pin and spring from the shift and select lever.
F051579
MT25
19. REMOVE SHIFT AND SELECT LEVER CAM (a) Using a screwdriver, remove the E ring and the shift and select lever cam from the shift and select lever shaft.
F051580
20. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY (a) Using SST, remove the back-up light switch and gasket. SST 09817-16011
SST
F051581E01
D033776
21. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the thrust clearance. Standard clearance: 0.10 to 0.25 mm (0.0039 to 0.0098 in.) Maximum clearance: 0.25 mm to (0.0098 in.) If the clearance exceeds the maximum, replace the reverse idler gear shaft, reverse idler gear or transmission front case. 22. REMOVE REVERSE IDLER GEAR (a) Remove the reverse idler gear shaft, needle roller bearing and reverse idler gear.
MT
D033634
23. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the radial clearance. Standard clearance: 0.015 to 0.050 mm (0.0006 to 0.0020 in.) Maximum clearance: 0.050 mm (0.0020 in.) If the clearance exceeds the maximum, replace the needle roller bearing.
D033777
MT26
24. REMOVE TRANSMISSION FRONT CASE (a) Remove the 4 bolts from the interlock bracket.
F051582
(b) Using a hexagon wrench (24 mm), remove the plug.
F051583
(c) Tie the input shaft, counter gear and control assembly with a piece of rope or string.
D033636
(d) Expand the 2 snap rings, and lift up the output shaft, input shaft, counter gear and control assembly.
MT
D033637
D033638
(e) Remove the output shaft, input shaft, counter gear shaft and control assembly while gently tapping the clutch housing with a plastic hammer. NOTICE: Take care not to subject the output shaft, input shaft, counter gear shaft and control assembly to any impact. This could cause the ball and spring to come out. (f) Separate the output shaft, input shaft, counter gear shaft and control assembly.
MT27
25. REMOVE NO. 1 OIL RECEIVER PIPE (a) Remove the No. 1 oil receiver pipe from the transmission front case.
F051585
26. REMOVE FRONT BEARING SHAFT SNAP RING (a) Using snap ring pliers, remove the 2 snap rings.
D033639
SST
27. REMOVE TRANSMISSION CASE OIL SEAL (a) Using SST, remove the transmission case oil seal from the transmission front case. SST 09308-00010
F051587E01
28. REMOVE NO. 3 GEAR SHIFT FORK (a) Remove the bolt, then remove the No. 3 gear shift fork.
MT
F051588
29. REMOVE NO. 3 GEAR SHIFT FORK SHAFT (a) Remove the No. 3 shift fork shaft , boll, spring, No. 2 interlock pin and No. 3 interlock pin.
F051829
MT28
30. REMOVE NO. 2 GEAR SHIFT FORK (a) Remove the bolt, then remove the No. 2 gear shift fork.
F051589
31. REMOVE NO. 2 GEAR SHIFT FORK SHAFT (a) Remove the No. 2 shift fork shaft, ball, spring, No. 2 interlock pin and No. 3 interlock pin.
F051830
32. REMOVE NO. 1 GEAR SHIFT HEAD (a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted pin.
D033718
33. REMOVE NO. 1 GEAR SHIFT FORK SHAFT (a) Remove the No. 1 shift fork shaft, ball, spring, No. 1 shift head and No. 1 interlock pin.
MT
F051831
34. REMOVE NO. 1 GEAR SHIFT FORK (a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted pin.
D033720
MT29
(b) Remove the No. 2 shift head and No. 1 shift fork.
D033721
35. REMOVE NO. 4 GEAR SHIFT FORK (a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted pin. (b) Remove the No. 4 shift fork.
D033722
36. REMOVE NO. 4 GEAR SHIFT FORK SHAFT (a) Remove the No. 4 shift fork shaft, ball and spring.
D033723
37. REMOVE 1ST AND REVERSE SHIFT ARM (a) Using a screwdriver, remove the E-ring.
MT
D033724
(b) Remove the shift arm pivot and shift arm.
D033725
MT30
REASSEMBLY
1. INSTALL 1ST AND REVERSE SHIFT ARM (a) Install the shift arm and shift arm pivot onto the interlock bracket.
D033725
(b) Install a new E-ring onto the shift arm pivot.
D033724
2.
INSTALL NO. 4 GEAR SHIFT FORK SHAFT (a) Install the spring and ball onto the interlock bracket. (b) Install the No. 4 shift fork shaft.
D033723
3.
MT
C136398
INSTALL NO. 4 GEAR SHIFT FORK (a) Install the No. 4 shift fork onto the No. 4 shift fork shaft . (b) Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted pin into the No. 4 shaft fork and No. 4 shift fork shaft. Drive in depth: 0 to 0.5 mm (0 to 0.050 in.)
4.
INSTALL NO. 1 GEAR SHIFT FORK (a) Install the No. 1 shift fork and No. 2 shift head onto the No. 4 shift fork shaft. (b) Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted pin into the No. 2 shaft head and No. 4 shift fork shaft. Drive in depth: 0 to 0.5 mm (0 to 0.050 in.)
C136399
MT31
5.
INSTALL NO. 1 GEAR SHIFT FORK SHAFT (a) Apply MP grease to the No. 1 interlock pin and install it into the interlock bracket. (b) Install the spring and ball into the interlock bracket. (c) Install the No. 1 shift fork shaft onto the interlock bracket. HINT: Place the No. 4 shift fork shaft in the neutral position.
F051831
6.
INSTALL NO. 1 GEAR SHIFT HEAD (a) Install the No. 1 shift head into the No. 1 shift fork shaft. (b) Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted pin into the No. 1 shaft head and No. 1 shift fork shaft. Drive in depth: 0 to 0.5 mm (0 to 0.050 in.)
C136400
7.
INSTALL NO. 2 GEAR SHIFT FORK SHAFT (a) Apply MP grease to the No. 2 and No. 3 interlock pins, then install them onto the interlock bracket. (b) Install the spring and ball into the interlock bracket. (c) Install the No. 2 shift fork shaft onto the interlock bracket. HINT: Place the No. 3 and No. 4 shift fork shafts in the neutral position.
F051830
8.
INSTALL NO. 2 GEAR SHIFT FORK (a) Install the No. 2 shift fork with the bolt. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf)
MT
F051589
9.
INSTALL NO. 3 GEAR SHIFT FORK SHAFT (a) Apply MP grease to the No. 2 and No. 3 interlock pins, then install them onto the interlock bracket. (b) Install the spring and ball into the interlock bracket. (c) Install the No. 3 shift fork shaft onto the interlock bracket. HINT: Place the No. 2, No. 1 and No. 4 shift fork shafts in the neutral position.
F051829
MT32
10. INSTALL NO. 3 GEAR SHIFT FORK (a) Install the No. 3 shift fork with the bolt. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf)
F051588
SST A
11. INSTALL TRANSMISSION CASE OIL SEAL (a) Using SST and a hammer, tap a new oil seal into the front case in accordance with the dimension specified in the illustration. SST 09950-70010 (09951-07100), 09950-60010 (09951-00470) Dimension A: 60.0 to 60.8 mm (2.362 to 2.394 in.) (b) Apply gear oil to the lip of the oil seal.
D033643E01
12. INSTALL FRONT BEARING SHAFT SNAP RING (a) Using snap ring pliers, install the 2 snap rings.
D033639
MT
D033642
13. INSTALL NO. 1 OIL RECEIVER PIPE (a) Install the No. 1 oil receiver pipe onto the transmission front case. HINT: Align the convex portion of the oil receiver pipe with the cutout of the front case and install the oil receiver pipe onto the clutch housing.
14. INSTALL TRANSMISSION FRONT CASE (a) Apply gear oil to all sliding and rotating parts. (b) Provisionally install the output shaft, input shaft, counter gear shaft and control assembly, and tie them with a piece of rope or string.
D033644
MT33
(c) Using a snap ring expander, extend the 2 snap rings and install the output shaft, input shaft, counter gear shaft and control assembly. HINT: Make sure that the snap ring is fitted into the grooves of the input shaft and front bearing of the counter gear shaft. (d) Untie the output shaft, input shaft, counter gear shaft and control assembly.
D033637
(e) Using a hexagonal wrench (24 mm), install the plug onto the front case. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
F051583
(f)
Install the interlock bracket with the 4 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
D033635
15. INSTALL REVERSE IDLER GEAR (a) Install the reverse idler gear, reverse idler gear bearing and reverse idler gear shaft. HINT: Make sure that the reverse idler gear faces the correct direction as shown in the illustration. NOTICE: Make sure that the hole in the reverse idler shaft is in the position shown in the illustration.
MT
15
C116297E01
MT34
16. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY (a) Using SST, install the back-up light switch with a new gasket onto the transmission front case. SST 09817-16011 Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)
SST
F051581E01
17. INSTALL SHIFT AND SELECT LEVER CAM (a) Install the shift and select lever cam onto the shaft and install a new E-ring.
F051580
18. INSTALL SHIFT AND SELECT LEVER (a) Install the lock ball pin and spring onto the shift and select lever. (b) Install the shift and select lever onto the shift and select lever cam and shaft. (c) Install the bolt onto the shift and select lever. Torque: 33 N*m (340 kgf*cm, 25 ft.*lbf)
F051579
19. INSTALL SHIFT AND SELECT LEVER SHAFT (a) Align the groove of the shift and select cam with the reverse idler shaft, and the claw with the groove of the control assembly, and install them.
MT
D033647
20. INSTALL NO. 2 OIL RECEIVER PIPE (a) Install the No. 2 oil receiver pipe into the transmission middle case.
F051577
MT35
21. INSTALL DRAIN PLUG SUB-ASSEMBLY (a) Install the drain plug with a new gasket onto the transmission middle case. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
F051576
FIPG
D033756E01
22. INSTALL TRANSMISSION MIDDLE CASE (a) Apply FIPG to the transmission middle case, as shown in the illustration. FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: Parts must be assembled within 10 minutes of the application. Otherwise, the packing (FIPG) material must be removed and reapplied. (b) Install the transmission middle case with the 11 bolts onto the transmission front case. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) Bolt length: Bolt A: 40 mm (1.57 in.) Bolt B: 80 mm (3.15 in.)
D033740
23. INSTALL REVERSE IDLER GEAR SHAFT BOLT (a) Install a new gasket and the reverse idler gear shaft bolt onto the reverse idler gear shaft. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
MT
D033649
24. INSTALL TRANSMISSION OIL SEPARATOR (a) Install the transmission oil separator with the 2 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
F051575
MT36
SST
25. INSTALL COUNTER GEAR REAR RADIAL BALL BEARING (a) Coat a new counter gear rear radial ball bearing with gear oil, and using SST and a press, install it into the transmission rear case. SST 09950-70010 (09951-07360), 09950-60010 (09951-00650)
D033750E01
(b) Install the bearing lock plate with the bolt. Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
D033746
SST SST
26. INSTALL OUTPUT SHAFT REAR BEARING OUTER RACE (a) Using SST and a press, press in 2 new bearing outer races. SST 09950-70010 (09951-07100, 09951-07360), 09950-60020 (09951-00790)
D033749E01
MT
D033752
27. INSTALL OIL SEPARATOR PACKING SEAL (a) Install the oil separator packing seal onto the transmission rear case. HINT: Insert the protruding part of the oil separator packing seal into the groove on the transmission rear case.
28. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE (a) Install the extension housing oil receiver pipe onto the transmission rear case.
F051573
MT37
29. INSTALL MANUAL TRANSMISSION FILLER PLUG (a) Install the 2 transmission filler plugs with 2 new gaskets onto the transmission rear case. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
F051572
FIPG
D033757E01
30. INSTALL TRANSMISSION REAR CASE (a) Apply FIPG to the transmission rear case, as shown in the illustration. FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: Parts must be assembled within 10 minutes of the application. Otherwise, the packing (FIPG) material must be removed and reapplied. (b) Install the transmission rear case with the 10 bolts and 3 brackets onto the transmission middle case. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
Clamp
Clamp
D033738E01
31. INSTALL SHIFT DETENT BALL PLUG (a) Install the ball and compression spring onto the transmission rear case. (b) Install a new shift detent ball plug, and install it onto the transmission rear case. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
MT
F051570
32. INSTALL OUTPUT SHAFT ADJUST NUT (a) Using a belt and wooden block, fasten the transmission to the workbench. (b) Install a new spacer and output shaft taper roller bearing No. 2.
D033736
MT38
(c) Using a socket wrench (60 mm), provisionally tighten a new nut until there is no slack in the output shaft. HINT: No preload should be applied to the nut. (d) Fit the bearing into the output shaft by turning the output shaft 15 times.
F051841
D033759
(e) Place the gearshift into 5th gear and check the initial torque of the input shaft. (f) Using a socket wrench (60 mm), tighten the nut. (g) Place the gearshift into 5th gear and check the initial torque of the input shaft. (h) Confirm that the difference between (e) and (g) is within the specified values. Preload (at starting): 0.45 to 1.35 N*m (4.59 to 13.77 kgf*cm, 3.98 to 11.95 in.*lbf) If the result is not as specified, tighten and adjust the output shaft adjusting nut. NOTICE: If the output shaft adjusting nut is loose or removed due to a large preload, always replace the spacer with a new one. (i) Using a chisel and hammer, caulk the output shaft adjust nut.
D033734
MT
F051645
33. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY (a) Apply FIPG to the transmission case cover, as shown in the illustration. FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: Parts must be assembled within 10 minutes of the application. Otherwise, the packing (FIPG) material must be removed and reapplied.
MT39
(b) Install the transmission case cover with the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
F051569
34. INSTALL SHIFT LEVER HOUSING (a) Install the shift lever housing with the bolt. Torque: 33 N*m (340 kgf*cm, 25 ft.*lbf)
F051568
FIPG
D033761E01
35. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY (a) Apply FIPG to the floor shift control shift lever retainer, as shown in the illustration. FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: Parts must be assembled within 10 minutes of the application. Otherwise, the packing (FIPG) material must be removed and reapplied. (b) Install the floor shift control shift lever retainer with the 4 bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
MT
F051567
MT40
RA61F MANUAL TRANSMISSION INPUT SHAFT
INPUT SHAFT
COMPONENTS
3RD GEAR NEEDLE ROLLER BEARING
3RD GEAR THRUST WASHER
SNAP RING STRAIGHT PIN 3RD GEAR SPACER
NO. 1 SYNCHRONIZER SHIFTING KEY NO. 1 SYNCHRONIZER SHIFTING KEY SPRING
NO. 2 TRANSMISSION HUB SLEEVE
BALL
MT
SNAP RING NO. 3 TRANSMISSION CLUTCH HUB 6TH GEAR 6TH GEAR NEEDLE ROLLER BEARING NO. 3 SYNCHRONIZER RING (FOR 6TH GEAR)
SPACER
Non-reusable part
C136410E01
MT41
INPUT SHAFT FRONT BEARING
INPUT SHAFT SNAP RING
SYNCHRONIZER SHIFTING KEY SPRING SYNCHRONIZER SHIFTING KEY NO. 2 TRANSMISSION HUB SLEEVE
BALL
SNAP RING
NO. 2 SYNCHRONIZER RING SET 4TH GEAR NO. 3 SYNCHRONIZER RING (FOR 4TH GEAR) NO. 2 TRANSMISSION CLUTCH HUB
MT
4TH GEAR NEEDLE ROLLER BEARING
Non-reusable part
C136403E01
MT42
DISASSEMBLY
1. INSPECT 6TH GEAR THRUST CLEARANCE (a) Using a dial indicator, measure the 6th gear thrust clearance. Standard clearance: 0.20 to 0.49 mm (0.0079 to 0.0193 in.) If the clearance is outside the specification, replace the defective gear, spacer or shaft.
F051109E01
2.
INSPECT 3RD GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the 3rd gear thrust clearance. Standard clearance: 0.09 to 0.52 mm (0.0035 to 0.0205 in.) If the clearance is outside the specification, replace the defective gear, thrust washer, clutch hub or shaft.
F051110E01
3.
INSPECT 4TH GEAR THRUST CLEARANCE (a) Using a dial indicator, measure the 4th gear thrust clearance. Standard clearance: 0.12 to 0.38 mm (0.0047 to 0.0150 in.) If the clearance is outside the specification, replace the defective gear, clutch hub or shaft.
F051111E01
4.
MT
F051106E01
INSPECT 6TH GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 6th gear radial clearance. Standard clearance: 0.015 to 0.065 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
5.
INSPECT 3RD GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 3rd gear radial clearance. Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
F051107E01
MT43
6.
INSPECT 4TH GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 4th gear radial clearance. Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
F051108E01
7.
REMOVE TRANSMISSION CLUTCH HUB NO.3 SHAFT SNAP RING (a) Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: Use a shop rag or a piece of cloth to prevent the snap ring from flying off.
D033652E01
8.
SST
D033653E01
REMOVE 6TH GEAR (a) Using SST and a press, remove transmission clutch hub No. 3, the hub sleeve, synchronizer ring and 6th gear from the input shaft. SST 09950-00020, 09950-70010 (09951-07200), 09950-60010 (09951-00300) NOTICE: Do not tighten SST excessively. Support the input shaft by hand so that it does not fall off. REMOVE 6TH GEAR NEEDLE ROLLER BEARING (a) Remove the 6th gear needle roller bearing from the input shaft.
9.
MT
F051087E01
10. REMOVE SPACER (a) Remove the spacer from the input shaft.
F051088E01
MT44
11. REMOVE GEAR THRUST WASHER SHAFT SNAP RING (a) Using a snap ring expander, remove the snap ring from the input shaft.
D033654E01
12. REMOVE 3RD GEAR THRUST WASHER (a) Remove the 3rd gear thrust washer from the input shaft.
F051090E01
13. REMOVE 3RD GEAR (a) Remove the 3rd gear from the input shaft.
F051091E01
14. REMOVE STRAIGHT PIN (a) Remove the straight pin from the input shaft.
MT
F051092E01
15. REMOVE 3RD GEAR NEEDLE ROLLER BEARING (a) Remove the 3rd gear needle roller bearing from the input shaft.
F051093E01
MT45
16. REMOVE SPACER (a) Remove the spacer from the input shaft.
F051094E01
17. REMOVE NO. 2 SYNCHRONIZER RING SET (a) Remove the No. 2 synchronizer ring set from the input shaft.
F051095E01
18. REMOVE CLUTCH HUB NO.2 SETTING SHAFT SNAP RING (a) Using a snap ring expander, remove the snap ring from the input shaft.
D033657E01
SST
19. REMOVE 4TH GEAR (a) Using SST and a press, remove transmission clutch hub No. 2, the hub sleeve, synchronizer ring and 4th gear from the input shaft. SST 09950-00020 NOTICE: Support the input shaft by hand so that it does not fall off.
D033658E01
MT
20. REMOVE 4TH GEAR NEEDLE ROLLER BEARING (a) Remove the 4th gear needle roller bearing from the input shaft.
F051098E01
MT46
21. REMOVE INPUT SHAFT FRONT BEARING SNAP RING (a) Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: Use a shop rag or piece of cloth to prevent the snap ring from flying off.
D033659E01
SST
22. REMOVE INPUT SHAFT FRONT BEARING (a) Using SST and a press, remove the input shaft front bearing from the input shaft. SST 09950-00020 NOTICE: Support the input shaft by hand so that it does not fall off.
D033660E01
Spring Ball Synchromesh Shifting Key

C136406E01
23. REMOVE NO. 2 TRANSMISSION CLUTCH HUB (a) Remove the clutch hub, 3 synchromesh shifting keys, 3 balls and 3 springs from the hub sleeve. HINT: Use a shop rag or piece of cloth to prevent the ball and spring from flying off. 24. REMOVE NO. 3 TRANSMISSION CLUTCH HUB (a) Perform the same procedures as for the No. 2 clutch hub.
INSPECTION
1. INSPECT INPUT SHAFT (a) Using a dial indicator and 2 V-blocks, measure the shaft runout. Maximum runout: 0.03 mm (0.0012 in.) If the runout exceeds the maximum, replace the input shaft.
MT
F051113E01
MT47
(b) Using a micrometer, measure the outer diameters of the input shaft journal surface, at the specified positions. Standard
Part A B C D E Outer diameter mm (in.) 34.002 to 34.015 (1.3387 to 1.3392) 44.985 to 45.000 (1.7711 to 1.7717) 44.985 to 45.000 (1.7711 to 1.7717) 41.985 to 42.000 (1.6530 to 1.6535) 32.967 to 32.974 (1.2979 to 1.2982)
Minimum
Part A B C D Outer diameter mm (in.) 34.002 (1.3387) 44.985 (1.7711) 44.985 (1.7711) 41.985 (1.6530) 32.967 (1.2979)
C D
D033763E01
If any of the outer diameters are less than the minimum, replace the input shaft. 2. INSPECT 6TH GEAR (a) Using a cylinder gauge, measure the inside diameter of the 6th gear. Standard inside diameter: 51.015 to 51.040 mm (2.0085 to 2.0095 in.) Maximum inside diameter: 51.040 mm (2.0095 in.) If the inside diameter exceeds the maximum, replace the 4th gear.
F051115E01
3.
INSPECT 3RD GEAR (a) Using a cylinder gauge, measure the inside diameter of the 3rd gear. Standard inside diameter: 51.015 to 51.040 mm (2.0085 to 2.0095 in.) Maximum inside diameter: 51.040 mm (2.0095 in.) If the inside diameter exceeds the maximum, replace the 3rd gear.
MT
F051116E01
4.
INSPECT 4TH GEAR (a) Using a cylinder gauge, measure the inside diameter of the 4th gear. Standard inside diameter: 51.015 to 51.040 mm (2.0085 to 2.0095 in.) Maximum inside diameter: 51.040 mm (2.0095 in.) If the inside diameter exceeds the maximum, replace the 4th gear.
F051117E01
MT48
5.
INSPECT NO. 2 TRANSMISSION HUB SLEEVE (a) Check the sliding condition between the No. 2 transmission hub and No. 2 transmission hub sleeve. (b) Check that the spline gear teeth of the No. 2 transmission hub sleeve are not worn.
C067843E01
(c) Using vernier calipers, measure the width of the No. 2 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 2 or No. 3 gear shift forks (B), and calculate the clearance. Standard clearance: (A - B); 0.28 to 0.84 mm (0.0110 to 0.0331 in.) for No. 2 gear shift fork 0.28 to 0.65 mm (0.0110 to 0.0256 in.) for No. 3 gear shift fork If the clearance is outside the specification, replace the No. 2 transmission hub sleeve and gear shift fork.
B
F051119E01
6.
MT
F051611E01
INSPECT NO. 3 SYNCHRONIZER RING (FOR 6TH GEAR) (a) Using a feeler gauge, measure the clearance between the synchronizer ring and the 6th gear. Standard clearance: 0.70 to 1.50 mm (0.0276 to 0.0591 in.) Minimum clearance: 0.70 mm (0.0276 in.) If the clearance is less than the minimum, replace the synchronizer ring. (b) Coat the 6th gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the 6th gear cone. Check that the ring locks.
F051612E01
MT49
7.
F051613E01
INSPECT NO. 2 SYNCHRONIZER RING SET (FOR 3RD GEAR) (a) Using a feeler gauge, measure the clearance between the synchronizer ring and the 3rd gear. Standard clearance: Inner: 1.20 to 2.20 mm (0.0472 to 0.0866 in.) Middle: 0.60 to 1.80 mm (0.0236 to 0.0709 in.) Outer: 0.80 to 1.80 mm (0.0315 to 0.0709 in.) Minimum clearance: Inner: 1.20 mm (0.0472 in.) Middle: 0.60 mm (0.0236 in.) Outer: 0.80 mm (0.0315 in.) If the clearance is less than the minimum, replace the synchronizer ring. (b) Coat the 3rd gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the 3rd gear cone. Check that the ring locks.
F051614E01
8.
F051611E01
INSPECT NO. 3 SYNCHRONIZER RING (FOR 4TH GEAR) (a) Using a feeler gauge, measure the clearance between the synchronizer ring and 4th gear. Standard clearance: 0.70 to 1.50 mm (0.0276 to 0.0591 in.) Minimum clearance: 0.70 mm (0.0276 in.) If the clearance is less than the minimum, replace the synchronizer ring. (b) Coat the 4th gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the 4th gear cone. Check that the ring locks.
MT
F051612E01
MT50
9.
INSPECT 3RD GEAR THRUST WASHER (a) Using a micrometer, measure the thrust washer thickness. Standard thickness: 7.12 to 7.18 mm (0.2803 to 0.2827 in.) Minimum thickness: 7.12 mm (0.2803 in.) If the thickness is less than the minimum, replace the thrust washer.
F051615E01
REASSEMBLY
1.
SST
INSTALL INPUT SHAFT FRONT BEARING (a) Using SST and a press, install the input shaft front bearing onto the input shaft. SST 09950-00020 HINT: Make sure that the groove of the bearing faces the correct direction as shown in the illustration.
D033669E01
2.
INSTALL INPUT SHAFT FRONT BEARING SNAP RING (a) Select a snap ring that will allow minimum axial play. Standard clearance: 0.1 mm (0.004 in.) or less Snap ring thickness
Part No. 90520-31026 Thickness: mm (in.) 2.65 to 2.70 (0.1043 to 0.1063) 2.70 to 2.75 (0.1063 to 0.1083) 2.75 to 2.80 (0.1083 to 0.1102) 2.80 to 2.85 (0.1102 to 0.1122) 2.85 to 2.90 (0.1122 to 0.1142) 2.90 to 2.95 (0.1142 to 0.1161) Mark A B C D E F
F051102E01
90520-31027 90520-31028 90520-31029 90520-31030 90520-31031
MT
(b) Using a brass bar and hammer, install the snap ring onto the input shaft.
MT51
3.
4th Gear Side:
3rd Gear Side:
INSTALL NO. 2 TRANSMISSION CLUTCH HUB (a) Apply a light coat of gear oil to the sleeve and hub. (b) Install the clutch hub sleeve onto the No. 2 clutch hub. (c) Put the ball into the keyhole from the bottom.(*1) (d) Put the spring under the ball.(*2) (e) Insert the ball and spring into the No. 2 clutch hub while attached onto the key.(*3) NOTICE: Prevent the ball from flying off. HINT: Perform the same procedure (*1 through *3) for all the 3 portions. Make sure that the No. 2 clutch hub faces the correct direction as shown in the illustration.
A A>B B
C136402E01
4.
6th Gear Side:
5th Gear Side:
INSTALL NO. 3 TRANSMISSION CLUTCH HUB (a) Apply a light coat of gear oil to the sleeve and hub. (b) Install the clutch hub sleeve onto the No. 3 clutch hub. (c) Put the ball into the keyhole from the bottom.(*1) (d) Put the spring under the ball.(*2) (e) Insert the ball and spring into the No. 3 clutch hub while attached onto the key.(*3) NOTICE: Prevent the ball from flying off. HINT: Perform the same procedure (*1 through *3) for all the 3 portions. Make sure that the No. 3 clutch hub faces the correct direction as shown in the illustration.
MT
C136401E01
5.
INSTALL 4TH GEAR NEEDLE ROLLER BEARING (a) Coat the 4th gear needle roller bearing with gear oil, then install it onto the input shaft. INSTALL 4TH GEAR (a) Coat the 4th gear and No. 3 synchronizer ring with gear oil, then install them onto the input shaft.
6.
F051098E01
MT52
SST
(b) Using SST and a press, install the No. 2 clutch hub onto the input shaft. SST 09308-14010 HINT: Align the convex portion of the synchronizer ring with the groove of the clutch hub. (c) Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.
F051618E01
7.
INSTALL CLUTCH HUB NO.2 SETTING SHAFT SNAP RING (a) Select a snap ring that will allow minimum axial play. Standard clearance: 0.1 mm (0.004 in.) or less Snap ring thickness
Part No. 90520-42012 Thickness: mm (in.) 1.77 to 1.82 (0.0697 to 0.0717) 1.82 to 1.87 (0.0717 to 0.0736) 1.87 to 1.92 (0.0736 to 0.0756) 1.92 to 1.97 (0.0756 to 0.0776) 1.97 to 2.02 (0.0776 to 0.0795) 2.02 to 2.07 (0.0795 to 0.0815) 2.07 to 2.12 (0.0815 to 0.0835) Mark A B C D E F G
D033657E01
90520-42013 90520-42014 90520-42015 90520-42016 90520-42017 90520-42018
(b) Using a snap ring expander, install the snap ring onto the input shaft. 8. INSTALL NO. 2 SYNCHRONIZER RING SET (a) Coat the No. 2 synchronizer ring set with gear oil, then install it onto the input shaft.
MT
F051095E01
MT53
9.
INSTALL SPACER (a) Coat the spacer with gear oil, and install it onto the input shaft.
F051094E01
10. INSTALL 3RD GEAR NEEDLE ROLLER BEARING (a) Coat the 3rd gear needle roller bearing with gear oil, and install it onto the input shaft.
F051093E01
11. INSTALL STRAIGHT PIN (a) Install the straight pin into the input shaft.
F051092E01
12. INSTALL 3RD GEAR (a) Coat the 3rd gear with gear oil, and install it onto the input shaft.
MT
F051091E01
13. INSTALL 3RD GEAR THRUST WASHER (a) Coat the 3rd gear thrust washer with gear oil, and install it onto the input shaft. HINT: Align the straight pin with the groove of the gear thrust washer and install it.
F051090E01
MT54
14. INSTALL GEAR THRUST WASHER SHAFT SNAP RING (a) Select a snap ring that will allow minimum axial play. Standard clearance: 0.1 mm (0.004 in.) or less Snap ring thickness
Part No. 90520-39026
D033654E01
Thickness: mm (in.) 2.07 to 2.12 (0.0815 to 0.0835) 2.12 to 2.17 (0.0835 to 0.0854) 2.17 to 2.22 (0.0854 to 0.0874) 2.22 to 2.27 (0.0874 to 0.0894) 2.27 to 2.32 (0.0894 to 0.0913) 2.32 to 2.37 (0.0913 to 0.0933)
Mark A B C D E F
90520-39027 90520-39028 90520-39029 90520-39030 90520-39031
(b) Using a snap ring expander, install the snap ring onto the input shaft. 15. INSTALL SHAFT SNAP RING (a) Coat the shaft snap ring with gear oil, and install it onto the input shaft.
F051088E01
16. INSTALL 6TH GEAR NEEDLE ROLLER BEARING (a) Coat the 6th gear needle roller bearing with gear oil, and install it onto the input shaft.
MT
F051087E01
MT55
SST
17. INSTALL 6TH GEAR (a) Install the 6th gear onto the input shaft. (b) Install the synchronizer ring onto the input shaft. (c) Using SST and a press, install the clutch hub onto the input shaft. SST 09309-37010, 09950-00020 (d) Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.
SST
F051619E01
18. INSTALL TRANSMISSION CLUTCH HUB NO.3 SHAFT SNAP RING (a) Select a snap ring that will allow minimum axial play. Standard clearance: 0.1 mm (0.004 in.) or less Snap ring thickness
Part No. 90520-33022
F051105E01
Thickness: mm (in.) 2.10 to 2.15 (0.0827 to 0.0847) 2.15 to 2.20 (0.0847 to 0.0866) 2.20 to 2.25 (0.0866 to 0.0886) 2.25 to 2.30 (0.0886 to 0.0906) 2.30 to 2.35 (0.0906 to 0.0925) 2.35 to 2.40 (0.0925 to 0.0945) 2.40 to 2.45 (0.0945 to 0.0965)
Mark A B C D E F G
90520-33023 90520-33024 90520-33025 90520-33026 90520-33027 90520-33028
MT
(b) Using a brass bar and a hammer, install the snap ring onto the input shaft.
MT56
19. INSPECT 6TH GEAR THRUST CLEARANCE (a) Using a dial indicator, measure the 6th gear thrust clearance. Standard clearance: 0.20 to 0.49 mm (0.0079 to 0.0193 in.) If the clearance is outside the specification, replace the defective gear, spacer or shaft.
F051109E01
20. INSPECT 3RD GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the 3rd gear thrust clearance. Standard clearance: 0.09 to 0.52 mm (0.0035 to 0.0205 in.) If the clearance is outside the specification, replace the defective gear, thrust washer, clutch hub or shaft.
F051110E01
21. INSPECT 4TH GEAR THRUST CLEARANCE (a) Using a dial indicator, measure the 4th gear thrust clearance. Standard clearance: 0.12 to 0.38 mm (0.0047 to 0.0150 in.) If the clearance is outside the specification, replace the defective gear, clutch hub or shaft.
F051111E01
MT
F051106E01
22. INSPECT 6TH GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 6th gear radial clearance. Standard clearance: 0.015 to 0.065 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
23. INSPECT 3RD GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 3rd gear radial clearance. Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
F051107E01
MT57
24. INSPECT 4TH GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 4th gear radial clearance. Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
F051108E01
MT
MT58
RA61F MANUAL TRANSMISSION OUTPUT SHAFT
OUTPUT SHAFT
COMPONENTS
OUTPUT SHAFT REAR BEARING
OUTPUT SHAFT NO. 3 SYNCHRONIZER RING OUTPUT SHAFT CENTER BEARING
MT
Non-reusable part Apply MP grease

C114068E03
MT59
DISASSEMBLY
1. REMOVE NO. 3 SYNCHRONIZER RING (a) Remove the No. 3 synchronizer ring from the output shaft. REMOVE OUTPUT SHAFT CENTER BEARING (a) Remove the output shaft center bearing from the output shaft. REMOVE OUTPUT SHAFT REAR BEARING (a) Using SST and a press, remove the output shaft rear bearing from the output shaft. SST 09950-00020, 09950-70010 (09951-07100), 09950-60010 (09951-00510)
2.
3.
SST
F051075E01
INSPECTION
1. INSPECT OUTPUT SHAFT (a) Using a cylinder gauge, measure the inside diameter of the output shaft. Standard inside diameter: 45.017 to 45.025 mm (1.7723 to 1.7726 in.) Maximum inside diameter: 45.025 mm (1.7726 in.) If the diameter exceeds the maximum, replace the output shaft. INSPECT NO. 3 SYNCHRONIZER RING (a) Using a feeler gauge, measure the clearance between the synchronizer ring and gear spline. Standard clearance: 0.70 to 1.50 mm (0.0276 to 0.0591 in.) Minimum clearance: 0.70 mm (0.0276 in.) If the clearance is less than the minimum, replace the synchronizer ring.
F051607
2.
MT
F051608
(b) Coat the output shaft and synchronizer ring cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
F051609
MT60
REASSEMBLY
1.
SST
INSTALL OUTPUT SHAFT REAR BEARING (a) Using SST and a press, install a new output shaft rear bearing onto the output shaft. SST 09316-60011 (09316-00011) (b) Apply a light coat of MP grease to the bearing. INSTALL OUTPUT SHAFT CENTER BEARING (a) Apply gear grease to the output shaft center bearing and install it onto the output shaft. INSTALL NO. 3 SYNCHRONIZER RING (a) Apply gear oil to the No. 3 synchronizer ring, and install it onto the output shaft.
2.
F051076E01
3.
MT
RA61F MANUAL TRANSMISSION COUNTER GEAR AND REVERSE IDLER GEAR
MT61
COUNTER GEAR AND REVERSE IDLER GEAR

COMPONENTS
NO. 3 SYNCHROMESH SHIFTING KEY SPRING REVERSE GEAR BEARING RACE INNER
REVERSE GEAR NEEDLE ROLLER BEARING
SNAP RING NO. 4 SYNCHROMESH SHIFTING KEY COUNTERSHAFT REVERSE GEAR NO. 3 TRANSMISSION HUB SLEEVE
COUNTER GEAR FRONT BEARING OR ROLLER
1ST GEAR NEEDLE ROLLER BEARING
MT
BALL NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR) COUNTERSHAFT GEAR 1ST SPEED NO. 4 SYNCHRONIZER RING
REVERSE GEAR SPLINE PIECE
Non-reusable part
C114072E07
MT62
2ND GEAR NEEDLE ROLLER BEARING
BALL NO. 1 SYNCHROMESH SHIFTING KEY
NO. 1 SYNCHROMESH SHIFTING KEY SPRING
COUNTER SHAFT 2ND SPEED GEAR
NO. 1 SYNCHRONIZER RING SET (FOR 2ND GEAR) NO. 1 TRANSMISSION CLUTCH HUB SNAP RING
NO. 1 TRANSMISSION HUB SLEEVE
SNAP RING RADIAL BALL BEARING INNER RACE
MT
COUNTER GEAR
Non-reusable part
C114071E04
MT63
DISASSEMBLY
1. INSPECT REVERSE GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the reverse gear thrust clearance. Standard clearance: 0.125 to 0.375 mm (0.0049 to 0.0148 in.) If the clearance is outside the specification, replace the defective gear, spline piece or bearing race.
F051532E01
2.
INSPECT 1ST GEAR THRUST CLEARANCE (a) Using a dial indicator, measure the 1st gear thrust clearance. Standard clearance: 0.10 to 0.43 mm (0.0039 to 0.0169 in.) If the clearance is outside the specification, replace the defective gear, clutch hub, spline piece or counter gear.
F051533E01
3.
INSPECT 2ND GEAR THRUST CLEARANCE (a) Using a dial indicator, measure the 2nd gear thrust clearance. Standard clearance: 0.10 to 0.43 mm (0.0039 to 0.0169 in.) If the clearance is outside the specification, replace the defective gear, clutch hub or counter gear.
F051534E01
4.
INSPECT REVERSE GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the reverse gear radial clearance. Standard clearance: 0.015 to 0.065 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the reverse gear needle roller bearing or shaft.
MT
F051535E01
5.
INSPECT 1ST GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 1st gear radial clearance. Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the 1st gear needle roller bearing or shaft.
F051536E01
MT64
6.
INSPECT 2ND GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 2nd gear radial clearance. Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the 2nd gear needle roller bearing or shaft.
F051537E01
7.
REMOVE COUNTER GEAR FRONT BEARING SNAP RING NO.1 (a) Using a snap ring expander, remove the snap ring from the counter gear.
D033690E01
8.
SST
REMOVE COUNTER GEAR FRONT BEARING OR ROLLER (a) Using SST and a press, remove the counter gear front bearing or roller from the counter gear. SST 09950-00020, 09950-70010 (09951-07100), 09950-60010 (09951-00320)
F051539E01
9.
REMOVE REVERSE GEAR BEARING RACE INNER (a) Remove the reverse gear bearing race inner from the counter gear.
MT
F051540E01
10. REMOVE COUNTERSHAFT REVERSE GEAR (a) Remove the countershaft reverse gear from the counter gear. (b) Remove the hub sleeve, 2 shifting keys and key spring from the countershaft reverse gear.
F051541E01
MT65
11. REMOVE REVERSE GEAR NEEDLE ROLLER BEARING (a) Remove the reverse gear needle roller bearing from the counter gear.
F051542E01
12. REMOVE NO. 4 SYNCHRONIZER RING (a) Remove the No. 4 synchronizer ring from the counter gear.
F051543E01
13. REMOVE BALL (a) Remove the ball from the counter gear.
F051544E01
SST
14. REMOVE COUNTERSHAFT GEAR 1ST SPEED (a) Using a press, remove the countershaft gear 1st speed together with the reverse gear spline piece from the counter gear. SST 09950-00020
MT
F051630E01
15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING (a) Remove the 1st gear needle roller bearing from the counter gear.
F051546E01
MT66
16. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR) (a) Remove the No. 1 synchronizer ring set from the counter gear.
C136407
17. REMOVE CLUTCH HUB NO.1 SHAFT SNAP RING (a) Using a snap ring expander, remove the snap ring from the counter gear.
D033696E01
SST
18. REMOVE COUNTER SHAFT 2ND SPEED GEAR (a) Using a press, remove the counter shaft 2nd speed gear together with the No. 1 transmission clutch hub from the counter gear. SST 09950-00020
F051632E01
19. REMOVE 2ND GEAR NEEDLE ROLLER BEARING (a) Remove the 2nd needle roller bearing from the counter gear.
MT
F051551E01
20. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 2ND GEAR) (a) Remove the No. 1 synchronizer ring set from the 2nd gear.
F051633E01

Clutch Hub
MT67
21. REMOVE NO. 1 TRANSMISSION CLUTCH HUB (a) Remove the hub sleeve, 3 synchromesh shifting keys, 3 balls and 3 springs from the clutch hub. HINT: Use a shop rag or piece of cloth to prevent the ball and spring from flying off.
Hub Sleeve
Spring Ball
Synchromesh Shifting Key

F051634E02
22. REMOVE SNAP RING COUNTER GEAR REAR BEARING (a) Using a snap ring expander, remove the snap ring from the counter gear.
D033689E01
SST
23. REMOVE RADIAL BALL BEARING INNER RACE (a) Using SST and a press, remove the needle roller bearing inner race. SST 09950-00020
F051635E01
INSPECTION
1. INSPECT COUNTER GEAR (a) Using a dial indicator and 2 V-blocks, measure the shaft runout. Maximum runout: 0.03 mm (0.0012 in.) If the runout exceeds the maximum, replace the counter gear.
MT
F051553E01
MT68
(b) Using a micrometer, measure the outer diameters of the input shaft journal surface, at the specified positions. Standard
Part A B C D E Outer diameter mm (in.) 34.002 to 34.015 (1.3387 to 1.3392) 36.985 to 37.000 (1.4561 to 1.4567) 47.985 to 48.000 (1.8892 to 1.8898) 53.985 to 54.000 (2.1254 to 2.1260) 34.002 to 34.015 (1.3387 to 1.3392)
Minimum
Part A B C D Outer diameter mm (in.) 34.002 (1.3387) 36.985 (1.4561) 47.985 (1.8892) 53.985 (2.1254) 34.002 (1.3387)
A B
E
D033700E01
If any of the diameters are less than the minimum, replace the counter gear shaft. 2. INSPECT COUNTERSHAFT REVERSE GEAR (a) Using a cylinder gauge, measure the inside diameter of the reverse gear. Standard inside diameter: 51.015 to 51.040 mm (2.0085 to 2.0095 in.) Maximum inside diameter: 51.040 mm (2.0095 in.) If the inside diameter exceeds the maximum, replace the reverse gear.
F051555E01
3.
MT
F051556E01
INSPECT COUNTERSHAFT GEAR 1ST SPEED (a) Using a cylinder gauge, measure the inside diameter of the 1st gear. Standard inside diameter: 54.015 to 54.040 mm (2.1266 to 2.1276 in.) Maximum inside diameter: 54.040 mm (2.1276 in.) If the inside diameter exceeds the maximum, replace the 1st gear.
4.
INSPECT COUNTER SHAFT 2ND SPEED GEAR (a) Using a cylinder gauge, measure the inside diameter of the 2nd gear. Standard inside diameter: 60.015 to 60.040 mm (2.3628 to 2.3638 in.) Maximum inside diameter: 60.040 mm (2.3638 in.) If the inside diameter exceeds the maximum, replace the 2nd gear.
F051557E01
MT69
5.
A
INSPECT NO. 3 TRANSMISSION HUB SLEEVE (a) Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove (A) and the thickness of the claw part on the gear shift fork No. 4 (B), and calculate the clearance. Standard clearance (A - B): 0.26 to 0.84 mm (0.0102 to 0.0331 in.) If the clearance is outside the specification, replace the No. 3 transmission hub sleeve and No. 4 gear shift fork.
B
F051559E01
6.
INSPECT NO. 1 TRANSMISSION HUB SLEEVE (a) Check the sliding condition between the No. 1 transmission hub and No. 1 transmission hub sleeve. (b) Check that the spline gear teeth of the No. 1 transmission hub sleeve are not worn.
C067843E01
(c) Using vernier calipers, measure the width of the No. 1 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 1 gear shift fork (B), and calculate the clearance. Standard clearance (A - B): 0.15 to 0.35 mm (0.0059 to 0.0138 in.) If the clearance is outside the specification, replace the No. 1 transmission hub sleeve and No. 1 gear shift fork.
MT
B
F051558E01
MT70
7.
INSPECT NO. 4 SYNCHRONIZER RING (a) Using a feeler gauge, measure the clearance between the synchronizer ring and reverse gear. Standard clearance: 0.70 to 1.30 mm (0.0276 to 0.0512 in.) Minimum clearance: 0.70 mm (0.0276 in.) If the clearance is less than the minimum, replace the synchronizer ring.
F051636E01
(b) Coat the reverse gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the reverse gear cone. Check that the ring locks.
D033665E01
Middle Outer
8.
Inner
F051638E01
MT
INSPECT NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR) (a) Using a feeler gauge, measure the clearance between the synchronizer ring and 1st gear. Standard clearance: Inner: 1.48 to 2.12 mm (0.0583 to 0.0835 in.) Middle: 0.68 to 1.92 mm (0.0268 to 0.0756 in.) Outer: 0.88 to 1.72 mm (0.0346 to 0.0677 in.) Minimum clearance: Inner: 1.48 mm (0.0583 in.) Middle: 0.68 mm (0.0268 in.) Outer: 0.88 mm (0.0346 in.) If the clearance is less than the minimum, replace the synchronizer ring. (b) Coat the 1st gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the 1st gear cone. Check that the ring locks.
F051639E01

Middle Outer
MT71
9.
Inner
F051638E01
INSPECT NO. 1 SYNCHRONIZER RING SET (FOR 2ND GEAR) (a) Using a feeler gauge, measure the clearance between the synchronizer ring and 2nd gear. Standard clearance: Inner: 1.48 to 2.12 mm (0.0583 to 0.0835 in.) Middle: 0.68 to 1.92 mm (0.0268 to 0.0756 in.) Outer: 0.88 to 1.72 mm (0.0346 to 0.0677 in.) Minimum clearance: Inner: 1.48 mm (0.0583 in.) Middle: 0.68 mm (0.0268 in.) Outer: 0.88 mm (0.0346 in.) If the clearance is less than the minimum, replace the synchronizer ring. (b) Coat the 2nd gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the 2nd gear cone. Check that the ring locks.
F051639E01
REASSEMBLY
1.
SST
INSTALL RADIAL BALL BEARING INNER RACE (a) Using SST and a press, install a new needle roller bearing inner race. SST 09950-60010 (09951-00540)
MT
F051640E01
2.
INSTALL SNAP RING COUNTER GEAR REAR BEARING (a) Select a snap ring that will allow minimum axial play. Standard clearance: 0.1 mm (0.004 in.) or less Snap ring thickness
Part No. 90520-31015 Thickness: mm (in.) 2.35 to 2.40 (0.0925 to 0.0945) 2.40 to 2.45 (0.0945 to 0.0965) 2.45 to 2.50 (0.0965 to 0.0984) Mark A B C
D033689E01
90520-31016 90520-31017
MT72

Part No. 90520-31018 90520-31019 90520-31020 90520-31021 90520-31022 90520-31023 90520-31024 90520-31025 90520-31033 Thickness: mm (in.) 2.50 to 2.55 (0.0984 to 0.1004) 2.55 to 2.60 (0.1004 to 0.1024) 2.60 to 2.65 (0.1024 to 0.1043) 2.65 to 2.70 (0.1043 to 0.1063) 2.70 to 2.75 (0.1063 to 0.1083) 2.75 to 2.80 (0.1083 to 0.1102) 2.80 to 2.85 (0.1102 to 0.1122) 2.85 to 2.90 (0.1122 to 0.1142) 2.90 to 2.95 (0.1142 to 0.1161) Mark D E F G H J K L M
(b) Using a snap ring expander, install the snap ring onto the counter gear. 3. INSTALL NO. 1 TRANSMISSION CLUTCH HUB (a) Apply a light coat of gear oil to the sleeve and hub. (b) Install the clutch hub sleeve onto the clutch hub. (c) Install the 3 shifting keys onto the clutch hub. (d) Install the 3 shifting key springs onto the clutch hub. (e) Place the ball in the hole in the shifting key, and install the hub sleeve while pushing in the ball. NOTICE: Prevent the ball from flying off.
1st Gear Side:
2nd Gear Side:
MT
F051641E01
4.
INSTALL 2ND GEAR NEEDLE ROLLER BEARING (a) Coat the 2nd gear needle roller bearing with gear oil, then install it onto the counter gear.
F051551E01
MT73
5.
SST
F051642E01
INSTALL COUNTER SHAFT 2ND SPEED GEAR (a) Coat the countershaft 2nd speed gear with gear oil, then install it onto the counter gear. (b) Coat the No. 1 synchronizer ring set with gear oil, then install it onto the counter gear. (c) Using SST and a press, install the No. 1 transmission clutch hub onto the counter gear. SST 09308-14010 HINT: Align the convex portion of the synchronizer ring with the groove of the clutch hub. (d) Install the clutch hub and confirm that the gear and synchronizer ring move smoothly. INSTALL CLUTCH HUB NO.1 SHAFT SNAP RING (a) Select a snap ring that will allow minimum axial play. Standard clearance: 0.1 mm (0.004 in.) or less Snap ring thickness
Part No. 90520-45013 90520-45014 90520-45015 90520-45016 90520-45017 90520-45018 90520-45019 Thickness: mm (in.) 2.28 to 2.33 (0.0898 to 0.0917) 2.33 to 2.38 (0.0917 to 0.0937) 2.38 to 2.43 (0.0937 to 0.0957) 2.43 to 2.48 (0.0957 to 0.0976) 2.48 to 2.53 (0.0976 to 0.0996) 2.53 to 2.58 (0.0996 to 0.1016) 2.58 to 2.63 (0.1016 to 0.1035) Mark A B C D E F G
6.
D033696E01
(b) Using a snap ring expander, install the snap ring onto the counter gear. 7. INSTALL NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR) (a) Coat the No. 1 synchronizer ring set with gear oil, then install it onto the counter gear.
MT
F051547E01
MT74
8.
INSTALL 1ST GEAR NEEDLE ROLLER BEARING (a) Coat the 1st gear needle roller bearing with gear oil, then install it onto the counter gear.
F051546E01
9.
SST
INSTALL COUNTERSHAFT GEAR 1ST SPEED (a) Coat the countershaft gear 1st speed with gear oil, and install it onto the counter gear. (b) Using SST and a press, install the reverse gear spline piece. SST 09309-37010
F051561E01
10. INSTALL BALL (a) Install the ball into the counter gear.
F051544E01
11. INSTALL NO. 4 SYNCHRONIZER RING (a) Coat the No. 4 synchronizer ring with gear oil, and install it onto the counter gear.
MT
F051543E01
12. INSTALL REVERSE GEAR NEEDLE ROLLER BEARING (a) Coat the reverse gear needle roller bearing with gear oil, and install it onto the counter gear.
F051542E01
MT75
Reverse Gear Hub Sleeve Shifting keys
13. INSTALL COUNTERSHAFT REVERSE GEAR (a) Install the key spring and 2 shifting keys onto the reverse gear. HINT: Install the shifting key with its groove on the reverse gear side. Install the key spring with its claw on the reverse gear side. Refer to the illustration when installing the key spring. (b) Install the hub sleeve onto the reverse gear. (c) Coat the countershaft reverse gear with gear oil, then install it onto the counter gear.
Key Spring
F051643E01
14. INSTALL REVERSE GEAR BEARING RACE INNER (a) Align the groove of the reverse gear bearing race inner with the ball, and install them.
F051564E01
SST
Groove
15. INSTALL COUNTER GEAR FRONT BEARING OR ROLLER (a) Using SST and a press, install the counter gear front bearing or roller onto the counter gear. SST 09608-06041 HINT: Make sure that the groove of the bearing faces the correct direction as shown in the illustration.
MT
F051644E01
16. INSTALL NO. 1 COUNTER GEAR FRONT BEARING SNAP RING (a) Select a snap ring that will allow minimum axial play. Standard clearance: 0.1 mm (0.004 in.) or less Snap ring thickness
Part No. 90520-31015
F051566E01
Thickness: mm (in.) 2.35 to 2.40 (0.0925 to 0.0945)
Mark A
MT76

Part No. 90520-31016 90520-31017 90520-31018 90520-31019 90520-31020 90520-31021 90520-31022 90520-31023 90520-31024 90520-31025 0520-31033 Thickness: mm (in.) 2.40 to 2.45 (0.0945 to 0.0965) 2.45 to 2.50 (0.0965 to 0.0984) 2.50 to 2.55 (0.0984 to 0.1004) 2.55 to 2.60 (0.1004 to 0.1024) 2.60 to 2.65 (0.1024 to 0.1043) 2.65 to 2.70 (0.1043 to 0.1063) 2.70 to 2.75 (0.1063 to 0.1083) 2.75 to 2.80 (0.1083 to 0.1102) 2.80 to 2.85 (0.1102 to 0.1122) 2.85 to 2.90 (0.1122 to 0.1142) 2.90 to 2.95 (0.1142 to 0.1161) Mark B C D E F G H J K L M
(b) Using a snap ring expander, install the snap ring onto the counter gear. 17. INSPECT REVERSE GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the reverse gear thrust clearance. Standard clearance: 0.125 to 0.375 mm (0.0049 to 0.0148 in.) If the clearance is outside the specification, replace the defective gear, spline piece or bearing race.
F051532E01
MT
18. INSPECT 1ST GEAR THRUST CLEARANCE (a) Using a dial indicator, measure the 1st gear thrust clearance. Standard clearance: 0.10 to 0.43 mm (0.0039 to 0.0169 in.) If the clearance is outside the specification, replace the defective gear, clutch hub, spline piece or counter gear.
F051533E01
MT77
19. INSPECT 2ND GEAR THRUST CLEARANCE (a) Using a dial indicator, measure the 2nd gear thrust clearance. Standard clearance: 0.10 to 0.43 mm (0.0039 to 0.0169 in.) If the clearance is outside the specification, replace the defective gear, clutch hub or counter gear.
F051534E01
20. INSPECT REVERSE GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the reverse gear radial clearance. Standard clearance: 0.015 to 0.065 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the reverse gear needle roller bearing or shaft.
F051535E01
21. INSPECT 1ST GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 1st gear radial clearance. Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the 1st gear needle roller bearing or shaft.
F051536E01
22. INSPECT 2ND GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 2nd gear radial clearance. Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 in.) If the clearance is outside the specification, replace the 2nd gear needle roller bearing or shaft.
MT
F051537E01

RA61 Manual Transaxle

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What are the main components of a manual transmission system?

What are the main components of a manual transmission system?

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What are some common manual transmission problems and their suspected causes?

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION SYSTEM

MANUAL TRANSMISSION SYSTEM

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION OIL

MANUAL TRANSMISSION OIL

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

MANUAL TRANSMISSION ASSEMBLY

CONSOLE UPPER REAR PANEL SUB-ASSEMBLY

PARKING BRAKE HOLE COVER SUB-ASSEMBLY

for Manual Transmission: SHIFT LEVER KNOB SUB-ASSEMBLY

FRONT CONSOLE BOX

for Transfer: SHIFT LEVER KNOB SUB-ASSEMBLY

SHIFT LEVER BOOT ASSEMBLY

FLOOR SHIFT SHIFT LEVER ASSEMBLY

TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

COMPRESSION SPRING GASKET FRONT EXHAUST PIPE ASSEMBLY

NO. 2 FRONT EXHAUST PIPE ASSEMBLY

N*m (kgf*cm, ft*lbf) :Specified torque Non-reusable part

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

REAR NO. 1 ENGINE MOUNTING INSULATOR x4 EXHAUST PIPE STOPPER BRACKET

NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

PROPELLER SHAFT HEAT INSULATOR FRONT SUSPENSION MEMBER BRACKET x4

FRONT SUSPENSION MEMBER BRACKET LH

PROPELLER SHAFT ASSEMBLY

x4 FRONT PROPELLER SHAFT ASSEMBLY

N*m (kgf*cm, ft*lbf) :Specified torque

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

x3 MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY

CLIP ACCUMULATOR TO FLEXIBLE HOSE TUBE

CLUTCH ACCUMULATOR ASSEMBLY

STARTER ASSEMBLY FLYWHEEL HOUSING SIDE COVER x3

15 (153, 11) 40 (408, 30)

NO. 2 MANIFOLD STAY CLUTCH RELEASE CYLINDER ASSEMBLY

15 (153, 11) 12 (120, 8.7) 12 (120, 8.7)

NO. 1 CLUTCH HOUSING COVER

N*m (kgf*cm, ft*lbf) :Specified torque Non-reusable part

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

N*m (kgf*cm, ft*lbf) :Specified torque

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

Select Return Spring

Tip of Shift Lever

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

10. INSTALL CLUTCH ACCUMULATOR ASSEMBLY (See page CL-20)

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY

Select Return Spring

Tip of Shift Lever

RA61F MANUAL TRANSMISSION MANUAL TRANSMISSION UNIT

MANUAL TRANSMISSION UNIT

OUTPUT SHAFT REAR BEARING OUTER RACE

FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY

NO. 2 TAPER ROLLER BEARING OUTPUT SHAFT ADJUST NUT

Nm (kgfcm, ft*lbf) :Specified torque Non-reusable part

Nm (kgfcm, ft*lbf) :Specified torque

Nm (kgfcm, ft*lbf) :Specified torque Non-reusable part

Nm (kgfcm, ft*lbf) :Specified torque

Nm (kgfcm, ft.*lbf) : Specified torque Non-reusable part

Nm (kgfcm, ft.*lbf) : Specified torque Non-reusable part