MANUAL TRANSMISSION

C TRANSMISSION/TRANSAXLE

SECTION

MANUAL TRANSMISSION

MT

MT

CONTENTS
PRECAUTIONS ..................................................... ..... 2 Caution ................................................................ ..... 2 PREPARATION ...................................................... ..... 3 Special Service Tools .......................................... ..... 3 Commercial Service Tools ................................... ..... 4 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ........................................... ..... 5 NVH Troubleshooting Chart ................................ ..... 5 MANUAL TRANSMISSION .............................. ..... 5 DESCRIPTION ....................................................... ..... 6 Cross-Sectional View .......................................... ..... 6 DOUBLE-CONE SYNCHRONIZER ................. ..... 6 M/T OIL .................................................................. ..... 7 Replacement ....................................................... ..... 7 DRAINING ........................................................ ..... 7 FILLING ............................................................ ..... 7 Checking ............................................................. ..... 7 OIL LEAKAGE AND OIL LEVEL ...................... ..... 7 REAR OIL SEAL ................................................... ..... 8 Removal and Installation ..................................... ..... 8 REMOVAL ........................................................ ..... 8 INSTALLATION ................................................ ..... 8 POSITION SWITCH ............................................... ..... 9 Checking ............................................................. ..... 9 BACK-UP LAMP SWITCH ............................... ..... 9 CONTROL LINKAGE ............................................ ... 10 Removal and Installation of Control Device and Cable ................................................................... ... 10 Shift Position Inspection ...................................... ... 10 Shift Position Adjustment ..................................... ... 10 SHIFT CABLE .................................................. ... 10 SELECT CABLE ............................................... ... 11 AIR BREATHER HOSE ......................................... ... 12 Removal and Installation ..................................... ... 12 TRANSMISSION ASSEMBLY ............................... ... 13 Removal and Installation from Vehicle ................ ... 13 REMOVAL ........................................................ ... 13 INSTALLATION ................................................ ... 13 Component Parts Drawing .................................. ... 15 CASE COMPONENTS ..................................... ... 15 GEAR COMPONENTS .................................... ... 16 SHIFT CONTROL COMPONENTS .................. ... 17 Disassembly and Assembly ................................. ... 18 DISASSEMBLY ................................................ ... 18 INSPECTION AFTER DISASSEMBLY ............. ... 22 ASSEMBLY ...................................................... ... 25 SERVICE DATA AND SPECIFICATIONS (SDS) ... ... 36 General Specifications ......................................... ... 36 Backlash .............................................................. ... 36 End Play .............................................................. ... 37 Snap Rings .......................................................... ... 37 Adjusting Shim ..................................................... ... 37 Baulk Ring Clearance .......................................... ... 38

MT-1

PRECAUTIONS PRECAUTIONS Caution

G G G G

PFP:00001
ECS004K0

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

MT-2

PREPARATION PREPARATION Special Service Tools

Tool name Tool number Description
PFP:00002

A
ECS004K1

Drift ST33400001 a: 60 mm (2.36 in) dia. b: 47 mm (1.85 in) dia.

ZZA0814D

MT
Rear oil seal installation

E
Pin punch KV31100300 Tip diameter: 4.5 mm (0.177 in) dia.
ZZA0815D

Retaining pin removal and installation

G
Puller KV32101330 a: 447 mm (17.60 in) b: 100 mm (3.94 in)
NT408

Overdrive mainshaft bearing removal

Puller ST30031000

G G

1st gear bushing removal Main drive gear bearing removal

ZZA0537D

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

ZZA0811D

L
Mainshaft ball bearing installation

Drift ST30613000 a: 71.5 mm (2.815 in) dia. b: 47.5 mm (1.870 in) dia.
ZZA1000D

Main drive gear ball bearing installation

Main shaft assembly and counter gear installation 3rd & 4th synchronizer assembly installation Counter gear front bearing installation

Transmission stand KV31100401

G
ZZA1232D

MT-3

PREPARATION
Tool name Tool number Description

Drift ST23860000 a: 38 mm (1.50 in) dia. b: 33 mm (1.30 in) dia.

ZZA0534D

Main drive gear and counter drive gear installation

Drift ST22360002 a: 32 mm (1.26 in) dia. b: 23 mm (0.91 in) dia.

ZZA0534D

G G

Counter gear front bearing installation Counter shaft rear bearing installation

Drift ST22350000 a: 34 mm (1.34 in) dia. b: 28 mm (1.10 in) dia.

ZZA0534D

Overdrive gear bushing installation

Lock nut wrench ST22520000

Lock nut tightening

ZZA0954D

Drift ST23800000 a: 44 mm (1.73 in) dia. b: 31 mm (1.22 in) dia.

ZZA0534D

Front cover oil seal installation

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

ZZA1002D

G G

Counter gear rear bearing installation 3rd & 4th synchronizer assembly installation

Commercial Service Tools

Tool name Description

ECS004K2

Counter bearings removal Counter drive gear removal Overdrive counter gear removal

Puller

G G

NT077

MT-4

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

A
ECS004K3

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

MANUAL TRANSMISSION
MT-15 MT-15 MT-10 MT-17 MT-17 MT-16 MT-16 MT-16 MT-16 MT-7 MT-7 MT-7 Reference page

MT

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

SHIFT CONTROL LINKAGE (Worn)

SUSPECTED PARTS (Possible cause) OIL SEAL (Worn or damaged)

G
BAULK RING (Worn or damaged) BEARING (Worn or damaged)

INSERT SPRING (Damaged)

GEAR (Worn or damaged)

OIL (Oil level is high.)

GASKET (Damaged)

SHIFT FORK (Worn)

OIL (Oil level is low.)

OIL (Wrong oil.)

Noise Oil leakage Symptoms Hard to shift or will not shift Jumps out of gear

2 3 1 1 1 2 2 2 1 1 2

K
2 2

MT-5

DESCRIPTION DESCRIPTION Cross-Sectional View

PFP:00000
ECS004K4

SCIA0780E

DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 2nd and 3rd gears to reduce operating force of the shift lever.

SCIA0820E

MT-6

M/T OIL M/T OIL Replacement

DRAINING
1. 2. 3. Start the engine and warm up the transmission unit sufficiently. B Stop the engine. Remove drain plug and drain oil. Apply Three Bond TB1215, Locktite Part No.51813 or equivalent to drain plug, and install it to the transmission unit. Tighten it to the specified torque. MT Drain plug: : 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)
D
PFP:KLD20

A
ECS004K5

FILLING
1. Remove filler plug. Fill new oil into the transmission to the level of the filler plug mounting hole. Oil grade: Viscosity: Oil capacity: 2. API GL-4 Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" Approx. 2.0 (3-1/2 lmp pt)
E

After oil filling, check the oil level and apply Three Bond TB1215, Locktite Part No.51813 or equivalent to filler plug. Then install it to the transmission unit, and tighten it to the specified torque. Filler plug: : 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)
G

Checking
OIL LEAKAGE AND OIL LEVEL
G G

H
ECS004K6

Check that oil is not leaking from transmission or around it. Check oil level from filler plug mounting hole as shown in the figure. CAUTION: Never start engine while checking oil level. To install filler plug, apply Three Bond TB1215, Locktite Part No.51813 or equivalent to filler plug and install it to the transmission unit. Filler plug: : 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)
SMA103

MT-7

REAR OIL SEAL REAR OIL SEAL Removal and Installation

REMOVAL
1. 2. Remove propeller shaft. Pull out oil seal.
PFP:33140
ECS004K7

SMT658A

INSTALLATION
1. After applying multi-purpose grease to oil seal lip, using a drift (special service tool), drive the oil seal until it becomes flush with the case end. CAUTION: G Oil seals are not reusable.Never reuse them. G When installing, do not incline the oil seal. 2. Install propeller shaft. CAUTION: If oil leaks during this operation, check the oil level, refer to MT7, "Checking" after completing the operation.

SMT659A

MT-8

POSITION SWITCH POSITION SWITCH Checking

BACK-UP LAMP SWITCH
G

PFP:32005

A
ECS004K8

Check continuity.
Reverse Except reverse Yes No

MT

SCIA0645E

MT-9

CONTROL LINKAGE CONTROL LINKAGE Removal and Installation of Control Device and Cable
Refer to the figure above for removal and installation procedure.
PFP:34103
ECS004K9

SCIA0586E

Shift Position Inspection

1.

ECS004KA

2. 3.

When operating shift lever to each position with the vehicle stopped and run, check the shift lever for distortion, binding, unusual noise, backlash, and interference, etc. Check that the shift lever operates smoothly. Check the shift lever knob is not dislocated. When shifted from 1st to 2nd gear and from 5th gear to reverse, shift lever shall return to the neutral position automatically.
ECS004KB

Shift Position Adjustment

SHIFT CABLE
1. 2. 3. 4. Separate control device from shift cable. Insert the pin into device stopper, and shift the lever to the neutral position. Shift transmission shift lever to the neutral position. Adjust the shift cable length so that control device matches with shift cable ball joint.

SMT340C

MT-10

CONTROL LINKAGE
SELECT CABLE
1. 2. 3. 4. Separate control cable from select cable. Insert the pin into device stopper, and shift the lever to the neutral position. Shift the transmission selector lever to the neutral position. Adjust the select cable length so that control device matches with selector cable ball joint.
A

MT

E
SMT342C

MT-11

AIR BREATHER HOSE AIR BREATHER HOSE Removal and Installation

Refer to the figure for air breather hose removal and installation information.
PFP:31098
ECS004KC

SCIA0534E

CAUTION: G Make sure there are no pinched or blocked areas on the air breather hose caused by bending or winding when installing it. G Be sure to insert the hose until the overlap area reaches the tube edge or the pressing part of spool, insulator, etc.

MT-12

TRANSMISSION ASSEMBLY TRANSMISSION ASSEMBLY Removal and Installation from Vehicle

PFP:32010

A
ECS004KD

MT

G
SCIA0581E

REMOVAL
1. Remove exhaust tube and propeller shaft. CAUTION: G Insert plug into oil seal after removing propeller shaft. G Be careful not to damage spline, sleeve yoke and rear oil seal when removing propeller shaft. 2. Remove control cable from transmission. 3. Remove clutch operating cylinder. CAUTION: Do not depress clutch pedal during removal procedure. 4. Remove back-up lamp switch, vehicle speed sensor (for speedometer), and connector and harness including ground wire, etc. 5. Remove starter motor. 6. Remove air breather hose. 7. Set jack to the transmission. CAUTION: When setting jack, be careful not to contact with the switch. 8. Remove rear engine mount. 9. Remove engine and transmission mounting bolts. 10. Remove transmission from the vehicle. CAUTION: Support transmission while removing it.
H

INSTALLATION
To install, reverse the removal procedure, following the cautions below: G When installing transmission to the engine, install mounting bolts in accordance with the standards below. CAUTION: When installing, be careful to avoid interference between transmission main drive shaft and clutch cover.

MT-13

TRANSMISSION ASSEMBLY
KA20DE engine model:
Bolt No. Quantity mm (in) 1 2 64 (2.52) 2 2 60 (2.36) 3* 1 45 (1.77) 4* 1 30 (1.18)

Tightening torque Nm (kg-m, ft-lb)

39 - 49 (4.0 - 4.9, 29 - 36)

29 - 39 (3.0 - 3.9, 22 - 28)

*: The No. 3 and 4 bolts also secure gussets.

Engine gusset cylinder block mounting bolts Engine LH-side gusset mounting bolts Bolt length: Front 30 mm (1.18 in) Rear 40 mm (1.57 in) : 29 - 39 Nm (3.0 - 3.9 kg-m, 22 - 28 ft-lb) Engine RH-side gusset mounting bolts Bolt length: : 40 mm : 29 - 39 Nm (3.0 - 3.9 kg-m, 22 - 28 ft-lb) ZD30DD engine model:
Bolt No. Quantity mm (in) 1 4 80 (3.15) 2* 4 45 (1.77) 39 - 49 (4.0 - 4.9, 29 - 36)

SCIA0579E

Tightening torque Nm (kg-m, ft-lb) *: The No. 2 bolt also secures gussets.

Engine gusset cylinder block mounting bolts Bolt length: : 20 mm (0.79 in) : 29 - 39 Nm (3.0 - 3.9 kg-m, 22 - 28 ft-lb)
G

SCIA0580E

After installation, check oil level, and oil leaks and loose mechanisms.

MT-14

TRANSMISSION ASSEMBLY Component Parts Drawing

CASE COMPONENTS
ECS004KE

MT

SCIA0762E

MT-15

TRANSMISSION ASSEMBLY
GEAR COMPONENTS

WMT036

MT-16

TRANSMISSION ASSEMBLY
SHIFT CONTROL COMPONENTS
A

MT

SCIA0641E

MT-17

TRANSMISSION ASSEMBLY Disassembly and Assembly

DISASSEMBLY Case Components
1. Remove rear extension mounting bolts. Using a soft hammer, etc., lightly tap the rear extension to remove.
ECS004KF

SMT549A

2.

Remove front cover. Then remove gaskets, counter gear front bearing shims, and main drive gear bearing snap ring.

SCIA0588J

3.

Lightly tap the transmission case to separate adapter plate from transmission case.

SCIA0589J

4.

Remove front cover oil seal. CAUTION: Be careful not to damage the front cover.

SCIA0590J

MT-18

TRANSMISSION ASSEMBLY
Shift Control Components
1. 2. Secure the adapter plate in a vise. Remove check ball plug, check spring, and check ball.
A

MT

SCIA0591J

3.

Drive out the retaining pin for each shift fork, pull out the fork rod, and remove interlock ball and plunger.

G
SCIA0592E

Gear Components
1. Before disassembly, measure the end play and backlash for each gear. End play standards 1st gear: 2nd gear: 3rd gear: Overdrive gear: Reverse idler gear: Counter gear: Backlash standards Main drive gear: 1st gear: 2nd gear: 3rd gear: Overdrive gear: Reverse idler gear:
G G

0.31 - 0.41 mm (0.0122 - 0.0161 in) 0.11 - 0.21 mm (0.0043 - 0.0083 in) 0.11 - 0.21 mm (0.0043 - 0.0083 in) 0.24 - 0.41 mm (0.0094 - 0.0161 in) 0.05 - 0.50 mm (0.0020 - 0.0197 in) 0 - 0.16 mm (0 - 0.0063 in)

K
SCIA0593E

0.05 - 0.10 mm (0.0020 - 0.0039 in) 0.05 - 0.10 mm (0.0020 - 0.0039 in) 0.05 - 0.10 mm (0.0020 - 0.0039 in) 0.05 - 0.10 mm (0.0020 - 0.0039 in) 0.05 - 0.10 mm (0.0020 - 0.0039 in) 0.05 - 0.10 mm (0.0020 - 0.0039 in)

SCIA0594E

If the end play or backlash is outside the standards, disassemble and inspect. If the gear face is damaged or worn out, replace with a new one.

MT-19

TRANSMISSION ASSEMBLY
2. Engage the 2nd gear and reverse gear. Then using a suitable puller, remove counter gear front bearing.

SMT174A

3.

Remove snap ring. Then remove sub-gear bracket, sub-gear spring, and sub-gear.

SCIA0596J

4.

5.

Using a suitable puller, remove counter drive gear with main drive gear assembly. CAUTION: When removing the main drive gear assembly, be careful not to drop pilot bearing and baulk ring. Remove snap ring. Then remove 3rd & 4th synchronizer assembly and 3rd main gear.

SMT162A

6. a.

Remove adapter plate mounting parts following the steps below. Make double-engagement of 2nd gear and reverse gear to prevent rotation, and remove mainshaft and counter gear lock nuts. CAUTION: Be careful of loosening direction of mainshaft lock nut because it has a left-hand thread.

SCIA0598J

MT-20

TRANSMISSION ASSEMBLY
b. c. d. Using a suitable puller, remove overdrive counter gear and counter gear rear end bearing. Remove reverse counter gear and spacer. Remove snap ring from reverse idler shaft. Then remove reverse idler gear, needle bearing, and thrust washer.
A

MT
SMT547A

e. f. g. h. i. j. k. l.

Remove snap ring. Then remove overdrive mainshaft bearing. Remove snap ring. Remove mainshaft lock nut. Then remove speedometer drive gear and steel ball. Remove thrust washer, roller bearing, and spacer. Remove overdrive main gear, needle bearing, and overdrive baulk ring. Remove overdrive & reverse coupling sleeve, shifting insert, and spread spring. Lightly tap the counter gear to remove. Remove overdrive gear bushing, overdrive &reverse synchronizer hub, reverse baulk ring, reverse main gear, needle bearing, and reverse gear bushing all together.

G
SMT165AA

SCIA0601J

7.

8.

Remove 1st main gear thrust washer and steel ball from mainshaft. CAUTION: Be careful not to lose the steel ball. Remove 1st main gear and needle bearing.

SCIA0602J

9.

Set Tool to the 2nd gear. Then, press the 1st gear, bushing, 1st & 2nd synchronizer assembly, 2nd gear, and needle bearing to remove. 10. Remove main drive gear bearing following the steps below. a. Remove snap ring and spacer.

SMT384A

MT-21

TRANSMISSION ASSEMBLY
b. Remove main drive gear bearing with a press.

SMT420AA

INSPECTION AFTER DISASSEMBLY Shift Control Components

G

If the contact surface on striking lever, fork rod, fork, etc. has excessive wear, abrasion, bend, or any other damage, replace the components.

SCIA0605J

Gear Components
Gear and Shaft G If the contact surface on each gear, mainshaft, main drive gear, or counter gear, etc. has damage, peeling, abrasion, dent, bent, or any other damage, replace the components.

SMT386A

MT-22

TRANSMISSION ASSEMBLY
A

MT
SMT550A

Synchronizer G If the contact surface on coupling sleeve, synchronizer hub, and shifting insert has damage or abrasion, replace the components. G Coupling sleeve and synchronizer hub shall move smoothly.

G
SMT387A

H
G

If the cam surface on baulk ring or contact surface on insert has damage or excessive wear, replace with a new one. If insert spring is damaged, replace with a new one.

K
SCIA0608J

Baulk Ring Clearance Single Cone Synchronizer (1st, 4th, and overdrive) G Press the baulk ring against cone, and measure the clearance between baulk ring and cone. If the clearance is smaller than the limit, replace it. Clearance Standard: Wear limit: 1.2 - 1.6 mm (0.047 - 0.063 in) 0.8 mm (0.031 in)

SMT140

MT-23

TRANSMISSION ASSEMBLY
Double-Cone Synchronizer (2nd and 3rd) G Check the clearance between outer baulk ring, synchronizer cone, and inner baulk ring of 2nd and 3rd double-cone synchronizer as follows. CAUTION: The clearances A and B are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set. If the clearance is outside the limit, the above three parts shall be replaced as a set.
SCIA0814E

1.

Using a dial gauge, measure the clearance A at diagonally opposite 2 points (or more), and calculate the mean value. Clearance A Standard: Wear limit: 0.7 - 0.9 mm (0.028 - 0.035 in) 0.2 mm (0.008 in) or less

SCIA0763E

2.

Using a thickness gauge, measure the clearance B at diagonally opposite 2 points (or more), and calculate the mean value. Clearance B Standard: Wear limit: 0.6 - 1.1 mm (0.024 - 0.043 in) 0.2 mm (0.008 in) or less

AMT192

Reverse Synchronizer Assembly G Using a thickness gauge, measure the reverse baulk ring back clearance at diagonally opposite 2 points (or more), and calculate the mean value. If it is outside the limit, replace with a new one. Clearance Standard: Wear limit: 1.1 - 1.55 mm (0.043 - 0.061 in) 0.7 mm (0.028 in) or less
SCIA0819E

Bearing

MT-24

TRANSMISSION ASSEMBLY
G

If the bearing does not rotate smoothly or the contact surface on ball or race is damaged or peeled, replace with new ones.

MT
SMT418A

ASSEMBLY Gear Components

1. Set mainshaft ball bearing to the adapter plate, and drive it in with a drift (special service tool).

SCIA0609E

2.

Set counter gear rear bearing to the adapter plate, and drive it with a drift (special service tool).
I

K
SCIA0610E

3.

Install oil gutter to the adapter plate, and extend the rear side to secure.

SMT153A

MT-25

TRANSMISSION ASSEMBLY
4. Insert reverse idler shaft and install bearing retainer.

SCIA0612J

5.

Tighten bearing retainer with the mounting bolts to the specified torque, and crimp each bolt at two points.

SCIA0613J

6.

Install main drive gear ball bearing to the main drive gear. Press main drive gear ball bearing.

SMT425AA

7.

Install spacer to main drive gear. Then select the snap ring so that the end play for main drive gear (clearance between snap ring and groove) is within the specified range below. End play standards: 0 - 0.13 mm (0 - 0.0051 in)

SMT426A

MT-26

TRANSMISSION ASSEMBLY
Main drive gear snap ring
Thickness 1.87 mm (0.0736 in) 1.94 mm (0.0764 in) 2.01 mm (0.0791 in) Part No. 32204 78001 32204 78002 32204 78003

8.

Install coupling sleeve and insert spring to 1st & 2nd synchronizer hub. CAUTION: G Install insert spring to the position (recess) of coupling sleeve in the figure. G Install coupling sleeve with its groove facing front (double-cone synchronizer side). G Check that hub and coupling can be moved smoothly by hand.

MT

SCIA0815E

9.

Install coupling sleeve and insert spring to 3rd & 4th synchronizer hub. CAUTION: G Install insert spring to the position (recess) of coupling sleeve in the figure. G Install coupling sleeve with its groove facing rear (double-cone synchronizer side). G Check that hub and coupling can be moved smoothly by hand.

SCIA0816E

MT-27

TRANSMISSION ASSEMBLY
10. Install coupling sleeve, shifting insert, and spread spring to overdrive & reverse synchronizer hub. CAUTION: G Install shifting insert to the position (recess) of coupling sleeve in the figure. G Hook the spread spring end (the perpendicular side) onto the slit inside the shifting insert. G Never hook front and rear spread spring ends onto the same shifting insert. G Installation directions of the synchronizer hub shall be followed as shown in the figure. G Install coupling sleeve with its wider taper surface at the overdrive side. G Check that hub and coupling can be moved smoothly by hand.

SCIA0817E

11. Install 2nd main gear, needle bearing, and 1st & 2nd synchronizer assembly to mainshaft. Then press with the 1st gear bushing. CAUTION: Press in the 1st gear bushing by contacting the thrust washer of 1st main gear. 12. Install 1st main gear.

SMT752A

13. Apply multi-purpose grease to steel ball and thrust washer, and install it to mainshaft.

TM358

14. Press mainshaft assembly into adapter plate using Tool.

TM439-A

MT-28

TRANSMISSION ASSEMBLY
15. Press counter gear into adapter plate using Tool.
A

MT
SCIA0618E

16. After installing 3rd main gear and needle bearing to mainshaft, press 3rd & 4th synchronizer assembly onto the mainshaft.
E

G
SCIA0619E

CAUTION: Be careful with the installation direction of synchronizer hub.

K
SMT031

17. Install thrust washer and snap ring to the mainshaft. Then check that the end play (clearance between snap ring and groove) of mainshaft is within the specified range below. End play standards:
G

0 - 0.18 mm (0 - 0.0071 in)

If it is outside the specified range, select the snap ring.

SCIA0621E

Mainshaft snap ring

Thickness 2.4 mm (0.094 in) 2.5 mm (0.098 in) Part No. 32263 V5200 32263 V5201

18. Apply gear oil to mainshaft pilot bearing and install it to the mainshaft.

MT-29

TRANSMISSION ASSEMBLY
19. Set gear assembly to transmission stand (special service tool). Then using a drift (special service tool), install counter drive gear together with main drive gear.

SCIA0622E

CAUTION: Installation directions of the counter drive gear shall be as shown in the figure.

SMT620A

20. Install counter drive gear, sub-gear, and sub-gear bracket to the counter gear. 21. Install snap ring to the counter gear. Then using a feeler gauge, check that the end play is within the specified range below. End play standards: 0 - 0.16 mm (0 - 0.0063 in) CAUTION: Sub-gear spring shall be removed. G If it is outside the specified range, select the snap ring.

SMT201D

Counter drive gear snap ring

Thickness 1.4 mm (0.055 in) 1.5 mm (0.059 in) 1.6 mm (0.063 in) Part No. 32215 E9000 32215 E9001 32215 E9002

22. Remove snap ring. Then remove sub-gear and sub-gear bracket. 23. Install sub-gear, sub-gear spring, and sub-gear bracket. Then install selected snap ring.

SMT202D

MT-30

TRANSMISSION ASSEMBLY
24. Set gear assembly to the transmission stand (special service tool). Then using a drift (special service tool), install counter gear front bearing to the counter gear.
A

MT
TM443-A

25. Install reverse idler gear with spacer, snap ring, and needle bearing to the reverse idler shaft. 26. Install retainer and overdrive & reverse synchronizer assembly to the mainshaft.

G
AMT134

27. 28. 29. 30.

Using a drift (special service tool), install overdrive gear bushing. Install overdrive main gear and needle bearing. Install spacer, reverse counter gear, and overdrive counter gear. Install spacer, roller bearing, and thrust washer, and temporarily tighten the mainshaft lock nut. CAUTION: Always use new lock nut.

SMT531-A

31. Using a drift (special service tool), install counter shaft rear end bearing.

SMT043-A

MT-31

TRANSMISSION ASSEMBLY
32. Make double-engagement of gears. Then using a lock nut wrench (special service tool), tighten the mainshaft lock nut to the specified torque. CAUTION: There will be an error for torque wrench length. Read the converted torque.

SMT003AA

Read the converted torque value in the figure. NOTE: How to calculate the converted torque by calculation formula.
G

SCIA0631E

33. Tighten the lock nut. CAUTION: Always use new lock nut. 34. After tightening the lock nut to the specified torque, crimp it as shown in the figure. 35. Measure the end play for each gear. G Disassembly; Refer to MT-19, "Gear Components"

SCIA0632E

MT-32

TRANSMISSION ASSEMBLY
Shift Control Components
1. Install fork rod, interlock plunger, interlock ball, and check ball.
A

MT

SMT992-A

2.

Using a pin punch (special service tool), drive the retaining pin into 1-2 fork and 3-4 fork.

SCIA0592E

3.

Drive retaining pin into 5-R fork and 5-R fork bracket.
I

K
SCIA0634J

Case Components
1. Apply multi-purpose grease to oil seal lip. Then using a drift (special service tool), install it to the front cover.

SMT036-A

MT-33

TRANSMISSION ASSEMBLY
2. Apply genuine anaerobic liquid gasket, Three Bond TB1215, Locktite Part No. 51813 or equivalent to mounting surface of the transmission case.

SMT061C

3.

Install gear assembly to the transmission case. Then using a soft hammer tap the adapter plate to install the gear assembly.

SMT013

4.

Install main drive gear ball bearing snap ring.

SMT672A

5.

6. 7.

Apply genuine anaerobic liquid gasket Three Bond TB1215, Locktite Part No. 51813 or equivalent to mounting surface of the adapter plate. Place shift forks in neutral position. Install striking rod to the adapter plate until the striking lever matches with shift bracket.

SMT062C

MT-34

TRANSMISSION ASSEMBLY
8. Install rear extension.
A

MT
SCIA0638J

9.

Measure height A of counter gear front bearing and transmission case edge surface. Select and install adjusting shim in accordance with the height.

G
SMT205D

Adjusting Shim
Measurement height A 4.52 - 4.71 mm (0.1780 - 0.1854 in) 4.42 - 4.51 mm (0.1740 - 0.1776 in) 4.32 - 4.41 mm (0.1701 - 0.1736 in) 4.22 - 4.31 mm (0.1661 - 0.1697 in) 4.12 - 4.21 mm (0.1622 - 0.1657 in) 4.02 - 4.11 mm (0.1583 - 0.1618 in) 3.92 - 4.01 mm (0.1543 - 0.1579 in) Shim thickness 0.1 mm (0.004 in) 0.2 mm (0.008 in) 0.3 mm (0.012 in) 0.4 mm (0.016 in) 0.5 mm (0.020 in) 0.6 mm (0.024 in) Part No. (Shim unnecessary) 32218 V5000 32218 V5001 32218 V5002 32218 V5003 32218 V5004 32218 V5005

10. Install gasket and front cover to the transmission case.

K

MT-35

SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications
Applied model Transmission Number of speed KA24DE,ZD30DD RS5W71C 5
PFP:00030
ECS004KG

Shift pattern

SCIA0821E

Synchromesh type 1st 2nd Gear ratio 3rd 4th OD Reverse Drive 1st Mainshaft (Number of teeth) 2nd 3rd OD Reverse Drive 1st Countershaft gear (Number of teeth) 2nd 3rd OD Reverse Reverse idler gear (Number of teeth) Oil capacity (Imp pt) Reverse synchronizer Remarks Double cone synchronizer Sub-gear

Warner 3.592 2.246 1.415 1.000 0.821 3.657 21 33 28 26 21 36 32 14 19 28 39 15 21 2.0 (3-1/2) Installed 2nd & 3rd Counter drive gear & reverse idler gear
ECS004KH

Backlash
Item Main drive gear 1st gear 2nd gear 3rd gear 4th gear Standard 0.05 - 0.10 (0.0020 - 0.0039) 0.05 - 0.20 (0.0020 - 0.0079) 0.05 - 0.20 (0.0020 - 0.0079) 0.05 - 0.20 (0.0020 - 0.0079)

Unit: mm (in)

MT-36

SERVICE DATA AND SPECIFICATIONS (SDS)

Item Overdrive gear Reverse idler gear Standard 0.05 - 0.20 (0.0020 - 0.0079) 0.05 - 0.20 (0.0020 - 0.0079)
ECS004KI

End Play
Item 1st gear 2nd gear 3rd gear 4th gear Overdrive gear Reverse idler gear Counter drive gear Main drive gear axial end play Mainshaft front OD main shaft bearing Standard 0.31 - 0.41 (0.0122 - 0.0161) 0.11 - 0.21 (0.0043 - 0.0083) 0.11 - 0.21 (0.0043 - 0.0083) 0.24 - 0.41 (0.0094 - 0.0161) 0.05 - 0.50 (0.0020 - 0.0197) 0 - 0.16 (0 - 0.0063) 0 - 0.13 (0 - 0.0051) 0 - 0.18 (0 - 0.0071) 0 - 0.14 (0 - 0.0055)

Unit: mm (in)

MT

Snap Rings
Selective parts Main drive gear Thickness 1.87 (0.0736) 1.94 (0.0764) 2.01 (0.0791) 1.4 (0.055) 1.5 (0.059) 1.6 (0.063) Front side Main shaft Shaft rear-end 2.4 (0.094) 2.5 (0.098) 1.1 (0.043) 1.2 (0.047) 1.3 (0.051) 1.4 (0.055) Part No. 32204 78001 32204 78002 32204 78003 32215 E9000 32215 E9001 32215 E9002 32263 V5200 32263 V5201 32228 32228 32228 32228 20100 20101 20102 20103

G
ECS004KJ

Unit: mm (in)

Counter drive gear

Adjusting Shim
Selective parts Measurement height 4.52 - 4.71 (0.1780 - 0.1854) 4.42 - 4.51 (0.1740 - 0.1776) 4.32 - 4.41 (0.1701 - 0.1736) 4.22 - 4.31 (0.1661 - 0.1697) 4.12 - 4.21 (0.1622 - 0.1657) 4.02 - 4.11 (0.1583 - 0.1618) 3.92 - 4.01 (0.1543 - 0.1579) Thickness 0.1 (0.004) 0.2 (0.008) 0.3 (0.012) 0.4 (0.016) 0.5 (0.020) 0.6 (0.024) Part No. Not necessary 32218 V5000 32218 V5001 32218 V5002 32218 V5003 32218 V5004 32218 V5005

ECS004KK

Unit: mm (in)

Counter front bearing

MT-37

SERVICE DATA AND SPECIFICATIONS (SDS) Baulk Ring Clearance

Measurement point 1st 2nd & 3rd Inner baulk ring clearance A Outer baulk ring clearance B Standard 1.20 - 1.60 (0.0472 - 0.0630) 0.70 - 0.90 (0.0276 - 0.0354) 0.60 - 1.10 (0.0236 - 0.0433) Wear limit 0.8 (0.031) or less 0.2 (0.008) or less 0.2 (0.008) or less
ECS004KL

Unit: mm (in)

SCIA0818E

Main drive & overdrive Reverse

1.20 - 1.60 (0.0472 - 0.0630) 1.10 - 1.55 (0.0433 - 0.0610)

0.8 (0.031) or less 0.7 (0.028) or less

MT-38