Manual Transmission Workshop Manual Y16MD

FOREWORD This manual explains the disassembly, inspection, repair, and reassembly procedures for the above-indicated manual transmission. In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully. The information in this manual is current up to March, 2003. Any changes that occur after that time will not be reflected in this particular manual. Therefore, the contents of this manual may not exactly match the mechanism that you are currently servicing. Mazda Motor Corporation HIROSHIMA, JAPAN

CONTENTS Title Section

GENERAL INFORMATION TRANSMISSION/TRANSAXLE

2003 Mazda Motor Corporation PRINTED IN U.S.A., MARCH 2003 Form No. 17741U03C Part No. 999995T15MD

00 05

GENERAL INFORMATION
Toc of SCT INFORMATION . . . . 00-00 GENERAL Toc of SCT

00
SECTION

0000

0000

GENERAL INFORMATION
Inspection During Removal, Disassembly . . . . . . . . . . . . . . . . . . . . Arrangement of Parts . . . . . . . . . . . . . . Cleaning of Parts . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . Rubber Parts and Tubing . . . . . . . . . . . Hose Clamps . . . . . . . . . . . . . . . . . . . . Torque Formulas . . . . . . . . . . . . . . . . . Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM. . . . . . . . . . . . . . Connectors . . . . . . . . . . . . . . . . . . . . . . SAE STANDARDS . . . . . . . . . . . . . . . . . ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00006 00007 00007 00007 00008 00008 00008 00008 00009 00009 00009 000011 000011

HOW TO USE THIS MANUAL . . . . . . . . . 00001 Range of Topics . . . . . . . . . . . . . . . . . . 00001 Service Procedure. . . . . . . . . . . . . . . . . 00002 Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00004 Advisory Messages . . . . . . . . . . . . . . . . 00004 UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00005 Conversion to SI Units (Systme International d'Units) . . . . . 00005 Rounding Off . . . . . . . . . . . . . . . . . . . . . 00005 Upper and Lower Limits . . . . . . . . . . . . 00005 FUNDAMENTAL PROCEDURES . . . . . . 00006 Preparation of Tools and Measuring Equipment . . . . . . . . . . . . . . . . . . . . . . 00006 Special Service Tools . . . . . . . . . . . . . . 00006 Disassembly . . . . . . . . . . . . . . . . . . . . . 00006

End of Toc
HOW TO USE THIS MANUAL
CHU000000001M01

Range of Topics This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: Removal/Installation Disassembly/Assembly Replacement Inspection Adjustment Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.

00001

GENERAL INFORMATION
Service Procedure Inspection, adjustment Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations.

SHOWS PROCEDURE ORDER FOR SERVICE

Fluid Pressure Inspection 1. Assemble the SSTs as shown in the figure. Tightening torque 3949 Nm {4.05.0 kgfm, 2936 ftlbf}

49 1232 670A 49 H002 671 49 H032 322 SHOWS TIGHTENING TORQUE SPECIFICATIONS

Caution Connect the gauge set from under the vehicle to prevent contact with the drive belt and the cooling fan.

WGIWXX0009E

00002

GENERAL INFORMATION
Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown. 3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or additional information concerning a procedure. Refer to this information when servicing the related part.

0000

YLU000WA0

00003

GENERAL INFORMATION
Symbols There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols show application points or use of these materials during service.
Symbol Meaning Kind New appropriate engine oil or gear oil

OIL

Apply oil

BRAKE FLUID

Apply brake fluid

New appropriate brake fluid New appropriate automatic transaxle/ transmission fluid Appropriate grease

ATF

Apply automatic transaxle/ transmission fluid

Apply grease

SEALANT

SST

Advisory Messages You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this manual. Warning A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored. Note A Note provides added information that will help you to complete a particular procedure. Specification The values indicate the allowable range when performing inspections or adjustments. Upper and lower limits The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.

End Of Sie

00004

GREASE

Apply sealant

Appropriate sealant Appropriate petroleum jelly O-ring, gasket, etc.

Apply petroleum jelly

Replace part

Use SST or equivalent

Appropriate tools

GENERAL INFORMATION
UNITS
Electric current Electric power Electric resistance Electric voltage Length A (ampere) W (watt) ohm V (volt) mm (millimeter) in (inch) kPa (kilo pascal) mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch) rpm (revolutions per minute) Nm (Newton meter) kgfm (kilogram force meter) kgfcm (kilogram force centimeter) ftlbf (foot pound force) inlbf (inch pound force) L (liter) US qt (U.S. quart) Imp qt (Imperial quart) ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) g (gram) oz (ounce)
CHU000000002M01

0000

Negative pressure

Positive pressure

Number of revolutions

Torque

Volume

Weight

Conversion to SI Units (Systme International d'Units) All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values. Rounding Off Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8. Upper and Lower Limits When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications: 210260 kPa {2.12.7 kgf/cm2, 3038 psi} 270310 kPa {2.73.2 kgf/cm2, 3945 psi} The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is used as a lower limit, so the converted values are rounded up to 270 and 39.

End Of Sie

00005

GENERAL INFORMATION
FUNDAMENTAL PROCEDURES Preparation of Tools and Measuring Equipment Be sure that all necessary tools and measuring equipment are available before starting any work.
CHU000000004M01

CHU0014W003

Special Service Tools Use special service tools or equivalent when they are required.
49 SE01 310

WGIWXX0024E

Disassembly If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.

WGIWXX0027E

Inspection During Removal, Disassembly When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems.

WGIWXX0028E

00006

GENERAL INFORMATION
Arrangement of Parts All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

0000

WGIWXX0029E

Cleaning of Parts All parts to be reused should be carefully and thoroughly cleaned in the appropriate method. Warning Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective eye wear whenever using compressed air.

WGIWXX0030E

Reassembly Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, the following parts should be replaced with new ones: Oil seals Gaskets O-rings Lock washers Cotter pins Nylon nuts Depending on location: Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage. Oil should be applied to the moving components of parts. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.

WGIWXX0031E

CHU0014W006

00007

GENERAL INFORMATION
Adjustment Use suitable gauges and testers when making adjustments.

CHU0014W005

Rubber Parts and Tubing Prevent gasoline or oil from getting on rubber parts or tubing.

WGIWXX0034E

Hose Clamps When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit.

WGIWXX0035E

Torque Formulas When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you.
Torque Unit Nm kgfm kgfcm ftlbf inlbf Formula Nm [L/(L+A)] kgfm [L/(L+A)] kgfcm [L/(L+A)] ftlbf [L/(L+A)] inlbf [L/(L+A)]

SST
3

1
0

2
3

L
WGIWXX0036E

A : The length of the SST past the torque wrench drive. L : The length of the torque wrench.

00008

GENERAL INFORMATION
Vise When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.

End Of Sie
0000

PROTECTIVE PLATES
CHU0014W010

ELECTRICAL SYSTEM Connectors Disconnecting connectors When disconnecting connector, grasp the connectors, not the wires.

CHU000000006M01

GOOD

NO GOOD

CHU0000W014

Connectors can be disconnected by pressing or pulling the lock lever as shown.

WGIWXX0042E

Locking connector When locking connectors, listen for a click indicating they are securely locked.

WGIWXX0043E

00009

GENERAL INFORMATION
Inspection When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side. Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side. Caution To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into terminal.

GOOD

NO GOOD

CHU0000W011

End Of Sie
GOOD NO GOOD

CHU0000W012

000010

GENERAL INFORMATION
SAE STANDARDS In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents.
SAE Standard Abbreviation Name AP Accelerator Pedal APP Accelerator Pedal Position ACL Air Cleaner A/C Air Conditioning A/F Air Fuel Ratio BARO Barometric Pressure B+ Battery Positive Voltage CMP sensor Camshaft Position Sensor LOAD Calculated Load Value CAC Charge Air Cooler CLS Closed Loop System CTP Closed Throttle Position CPP Clutch Pedal Position Continuous Fuel Injection CIS System CKP sensor Crankshaft Position Sensor DLC Data Link Connector DTM Diagnostic Test Mode DTC Diagnostic Trouble Code(s) DI Distributor Ignition DLI Distributorless Ignition EI Electronic Ignition ECT Engine Coolant Temperature EM Engine Modification EVAP Evaporative Emission EGR Exhaust Gas Recirculation FC Fan Control FF Flexible Fuel 4GR Fourth Gear GEN Generator GND Ground HO2S IAC IAT KS MIL Heated Oxygen Sensor Idle Air Control Intake Air Temperature Knock Sensor Malfunction Indicator Lamp Remark SAE Standard Abbreviation Name MAP Manifold Absolute Pressure MAF Mass Air Flow MAF sensor Mass Air Flow Sensor MFL Multiport Fuel Injection OBD On-board Diagnostic System OL Open Loop OC Oxidation Catalytic Converter O2S Oxygen Sensor PNP Park/Neutral Position PID Parameter Identification PSP Power Steering Pressure PCM Powertrain Control Module PAIR Pulsed Secondary Air Injection
CHU000000003M02

Remark

0000

#3 Pulsed injection Injection with air pump

AIR #1 SAPV SFI #2 3GR TWC TB TP TP sensor TCC TCM TR TC VSS VR VAF sensor WU-TWC WOP

Secondary Air Injection Secondary Air Pulse Valve Sequential Multiport Fuel Injection Third Gear Three Way Catalytic Converter Throttle Body Throttle Position Throttle Position Sensor Torque Converter Clutch Transmission (Transaxle) Control Module Transmission (Transaxle) Range Turbocharger Vehicle Speed Sensor Voltage Regulator Volume Air Flow Sensor Warm Up Three Way Catalytic Converter Wide Open Throttle

With heater

#4

#1 #2 #3 #4

: Diagnostic trouble codes depend on the diagnostic test mode. : Controlled by the PCM : Device that controls engine and powertrain : Directly connected to exhaust manifold

End Of Sie
ABBREVIATIONS
SST Special Service Tool
CHU000000011M02

End Of Sie

000011

TRANSMISSION/TRANSAXLE
Toc of SCT TRANSMISSION. . . . 05-11 MANUAL

05
SECTION

0511

SERVICE TOOLS. . . . . . . . . . . 05-60

TECHNICAL DATA . . . . . . . . . . 05-50

Toc of SCT

0511

MANUAL TRANSMISSION
Snap Ring (Friction Gear) Assembly Note . . . . . . . . . . . . . . . . . . 051117 Roller Bearing Assembly Note . . . . . . . 051117 Snap Ring (Roller Bearing) Assembly Note . . . . . . . . . . . . . . . . . . 051117 MAIN DRIVE GEAR AND MAINSHAFT COMPONENT ASSEMBLY . . . . . . . . . . 051118 Bearing Assembly Note . . . . . . . . . . . . 051119 Snap Ring (Bearing) Assembly Note . . 051119 Clutch Hub Component (5th/Reverse) Assembly Note . . . . . . . . . . . . . . . . . . 051119 Snap Ring (Reverse Gear) Assembly Note . . . . . . . . . . . . . . . . . . 051120 Clutch Hub Component (1st/2nd) Assembly Note . . . . . . . . . . . . . . . . . . 051120 6th Gear Assembly Note . . . . . . . . . . . 051121 Snap Ring (6th Gear) Assembly Note . 051121 CLUTCH HOUSING COMPONENT, SHIFT FORK AND SHIFT ROD COMPONENT ASSEMBLY . . . . . . . . . . 051122 Reverse Idler Gear Component Assembly Note . . . . . . . . . . . . . . . . . . 051123 Clutch Housing Assembly Note . . . . . . 051123 Bolt and Gasket Assembly Note. . . . . . 051123 3rd/4th Shift Fork and Shift Arm (Reverse) Assembly Note . . . . . . . . . 051124 5th/Reverse Counter Lever Assembly Note . . . . . . . . . . . . . . . . . . 051124 TRANSMISSION CASE AND 6TH GEAR COMPONENT ASSEMBLY . . . . . . . . . . 051125 Shift Rod Assembly Note . . . . . . . . . . . 051126 Transmission Case Assembly Note . . . 051126 Bolt and Gasket Assembly Note. . . . . . 051127 Oil Seal Assembly Note . . . . . . . . . . . . 051127 Inner Shift Lever Assembly Note . . . . . 051128 Clutch Hub Component (6th) Assembly Note . . . . . . . . . . . . . . . . . . 051128 Snap Ring Assembly Note . . . . . . . . . . 051128 6th Shift Fork Assembly Note . . . . . . . . 051129 Plug Assembly Note . . . . . . . . . . . . . . . 051129 EXTENSION HOUSING COMPONENT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 051130 Oil Seal Assembly Note . . . . . . . . . . . . 051131 Torsion Spring Assembly Note. . . . . . . 051131

PRECAUTION . . . . . . . . . . . . . . . . . . . . . 05112 EXTENSION HOUSING COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05113 TRANSMISSION CASE AND 6TH GEAR COMPONENT DISASSEMBLY . . . . . . . 05114 Snap Ring Disassembly Note . . . . . . . . 05115 Clutch Hub Component (6th) Disassembly Note . . . . . . . . . . . . . . . . 05115 Inner Shift Lever Disassembly Note . . . 05115 Clutch Hub Sleeve Disassembly Note . . . . . . . . . . . . . . . . 05115 CLUTCH HOUSING COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . 05116 Front Cover Disassembly Note . . . . . . . 05117 SHIFT FORK AND SHIFT ROD COMPONENT DISASSEMBLY . . . . . . . 05117 MAIN DRIVE GEAR AND MAINSHAFT COMPONENT DISASSEMBLY . . . . . . . 05118 Bearing Disassembly Note . . . . . . . . . . 05119 1st Gear Disassembly Note . . . . . . . . . 05119 2nd Gear Disassembly Note . . . . . . . . . 05119 Reverse Gear Disassembly Note . . . . . 05119 COUNTERSHAFT COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . 051110 Roller Bearing Disassembly Note . . . . . 051111 Counter Drive Gear Disassembly Note . . . . . . . . . . . . . . . . 051111 Counter 3rd Gear Disassembly Note . . . . . . . . . . . . . . . . 051111 MANUAL TRANSMISSION INSPECTION . . . . . . . . . . . . . . . . . . . . . 051112 Drive Gear Inspection . . . . . . . . . . . . . . 051112 Reverse Idler Gear and Reverse Idler Shaft Inspection . . . . . . . . . . . . . . . . . 051113 Synchronizer Ring Inspection . . . . . . . . 051113 Mainshaft Inspection . . . . . . . . . . . . . . . 051113 Countershaft Inspection . . . . . . . . . . . . 051113 Clutch Hub Sleeve and Shift Fork Inspection . . . . . . . . . . . . . . . . . . . . . . 051114 COUNTERSHAFT COMPONENT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 051114 Clutch Hub Component (3rd/4th) Assembly Note . . . . . . . . . . . . . . . . . . 051115 Thrust Washer Assembly Note . . . . . . . 051116 Counter Drive Gear Assembly Note . . . 051116

End of Toc

05111

MANUAL TRANSMISSION
PRECAUTION
CHU051117010M01

1. Clean the transmission exterior thoroughly using a steam cleaner or cleaning solvents before disassembly. Warning Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. Caution Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the bearing. 2. 3. 4. 5. 6. 7. 8. 9. Clean the removed parts using cleaning solvent, and dry them using compressed air. Clean out all holes and passages using compressed air, and check that there are no obstructions. Use a plastic hammer when disassembling the transmission case and other light alloy metal parts. Make sure each part is cleaned before assembling. Coat all movable parts with the specified oil. Replace parts whenever required. Remove old sealant from contact surfaces before applying new sealant. Assemble the parts within 10 min after applying sealant. Allow all sealant to cure at least 30 min after assembling before filling the transmission with transmission oil. Warning Although the stand has a self-locking brake system, there is a possibility that the brake may not hold when the transmission is held in a lopsided position on the stand. This would cause the transmission to turn suddenly, causing serious injury. Never keep the transmission tilted to one side. Always hold the rotating handle firmly when turning the transmission.

End Of Sie

05112

MANUAL TRANSMISSION
EXTENSION HOUSING COMPONENT DISASSEMBLY 1. Disassemble in the order indicated in the table.
.

CHU051117010M02

2 3

0511
12 8 13 A 9 10 11 6 25 14 15

27 5 4 1 20 17 18 23 16 7 24 22

A 19

21

26

BHJ0511M101

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

Clutch release collar Clutch release fork Dust cover Pivot pin Filler plug, gasket Drain plug, gasket Neutral switch Back-up light switch Plug Pressure spring Push pin component Control case Gasket Tubular pin

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

Control rod end Extension housing component Retaining ring Torsion spring Shift lever Shift rod Oil passage Stopper block Oil funnel Lever support Breather Baffle plate Oil seal

End Of Sie

05113

MANUAL TRANSMISSION
TRANSMISSION CASE AND 6TH GEAR COMPONENT DISASSEMBLY
CHU051117010M03

Note Measure the thrust and radial clearance of 6th gear before disassembly. (See 051112 Drive Gear Inspection.) 1. Disassemble in the order indicated in the table.
.

29 31 30 28 10 12 11 32 27

22 21 17 24 9 14

13 5

3 SST

4 19 8 18 25 26 23

1
16

20

15
BHJ0511M103

1 2 3

4 5 6 7 8 9 10 11 12

Spring pin Snap ring (See 05115 Snap Ring Disassembly Note.) Clutch hub component (6th) (See 05115 Clutch Hub Component (6th) Disassembly Note.) 6th shift fork Synchronizer ring 6th gear Needle bearing Thrust washer Pin Spring pin Inner shift lever (See 05115 Inner Shift Lever Disassembly Note.) Interlock sleeve

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Bearing cover component Snap ring (rear) Plug Steel ball, pressure spring Plug Shift rod Steel ball Steel ball Plug Bolt, gasket Bolt, gasket Bolt Transmission case Pressure spring, steel ball Retaining ring

05114

MANUAL TRANSMISSION
28 Clutch hub sleeve (See 05115 Clutch Hub Sleeve Disassembly Note.) Steel ball 30 31 32 Synchronizer key Synchronizer key spring Clutch hub

29

Snap Ring Disassembly Note 1. Remove the snap ring using two flathead screwdrivers and a hammer.

FLATHEAD SCREWDRIVER

0511

CHU0511M104

Clutch Hub Component (6th) Disassembly Note 1. Remove the clutch hub component (6th) and the 6th shift fork together using the SST.
49 N017 2A1

BHJ0511M105

Inner Shift Lever Disassembly Note 1. Attach a flathead screwdriver as shown in the figure, and remove the inner shift lever by tapping the shift rod with a plastic hammer.

BHJ0511M106

Clutch Hub Sleeve Disassembly Note 1. Remove the clutch hub sleeve covering the clutch hub component with a rag to prevent the steel balls and synchronizer key springs from springing out.

End Of Sie

BHJ0511M107

05115

MANUAL TRANSMISSION
CLUTCH HOUSING COMPONENT DISASSEMBLY 1. Disassemble in the order indicated in the table.
.

CHU051117010M04

8 6

10

4 3
A

9 15

16 11 12 13

14

BHJ0511M108

1 2 3 4 5 6 7 8

Crank lever shaft 5th/reverse counter lever Front cover (See 05117 Front Cover Disassembly Note.) Oil seal Snap ring (front) Main drive gear, mainshaft component Countershaft component Shift fork and shift rod component

9 10 11 12 13 14 15 16

Reverse idler shaft Reverse idler gear component Snap ring Spacer Friction gear Torsion spring Reverse idler gear Clutch housing

05116

MANUAL TRANSMISSION
Front Cover Disassembly Note 1. Remove the front cover by prying with a flathead screwdriver as shown in the figure.

End Of Sie

0511

BHJ0511M109

SHIFT FORK AND SHIFT ROD COMPONENT DISASSEMBLY 1. Disassemble in the order indicated in the table.
.

CHU051117030M01

11

12 13

10 9 8

5 6 4

3
BHJ0511M110

1 2 3 4 5 6 7

Spring pin Shift arm (reverse) 3rd/4th shift fork Spring pin Stopper block shift arm (5th) Pressure spring, steel ball

8 9 10 11 12 13

Shift rod 5th/reverse shift fork Interlock sleeve 1st/2nd shift fork Snap ring Shift rod

05117

MANUAL TRANSMISSION
MAIN DRIVE GEAR AND MAINSHAFT COMPONENT DISASSEMBLY
End Of Sie

CHU051117050M01

Note Measure the thrust and radial clearance of 1st, 2nd and reverse gear before disassembly. (See 051112 Drive Gear Inspection.) 1. Disassemble in the order indicated in the table.
.

31

30 3

2
32 29 5 4
SST

16

28 10
SST

11 12

8 27 14 24 26 23 25
SST

15 13 31 30

18 19

32 29

20
21 22 17
SST

BHJ0511M111

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

Main drive gear component Synchronizer ring Needle bearing Snap ring (bearing) (See 05115 Snap Ring Disassembly Note.) Bearing (See 05119 Bearing Disassembly Note.) Main drive gear Snap ring (6th gear) (See 05115 Snap Ring Disassembly Note.) 1st gear (See 05119 1st Gear Disassembly Note.) 6th gear Bearing Inner race Needle bearing

13 14 15 16 17 18 19 20 21 22 23 24 25 26

Synchronizer ring Middle ring Inner ring Steel ball 2nd gear (See 05119 2nd Gear Disassembly Note.) Clutch hub component (1st/2nd) Synchronizer ring Middle ring Inner ring Needle bearing Snap ring (reverse gear) Reverse gear (See 05119 Reverse Gear Disassembly Note.) Clutch hub component (5th/reverse) Synchronizer ring

05118

MANUAL TRANSMISSION
27 28 29 Needle bearing Mainshaft Clutch hub sleeve (See 05115 Clutch Hub Sleeve Disassembly Note.) 30 31 32 Steel ball, synchronizer key spring Synchronizer key Clutch hub

Bearing Disassembly Note 1. Remove the bearing using the SST.

0511

49 G030 370

BHJ0511M112

1st Gear Disassembly Note 1. Shift the clutch hub component (1st/2nd) to the 2nd gear. 2. Remove the 6th gear, bearing and 1st gear together using the SST and a press.

49 N017 101

BHJ0511M113

2nd Gear Disassembly Note 1. Remove the clutch hub component (1st/2nd) and 2nd gear together using the SST and a press.

49 N017 101

BHJ0511M114

Reverse Gear Disassembly Note 1. Remove the clutch hub component (5th/reverse) and reverse gear together using the SST and a press.

End Of Sie

49 N017 101

BHJ0511M115

05119

MANUAL TRANSMISSION
COUNTERSHAFT COMPONENT DISASSEMBLY
CHU051117050M02

Note Measure the thrust and radial clearance of 3rd and 4th gear before disassembly. (See 051112 Drive Gear Inspection.) 1. Disassemble in the order indicated in the table.
4
SST
.

SST

3 15 14 13 12

11 SST

16

17

16 10 9 21 19

8
7

20
22

18

BHJ0511M116

1 2 3 4

5 6 7 8 9 10 11

Snap ring (roller bearing) Roller bearing (See 051111 Roller Bearing Disassembly Note.) Snap ring (friction gear) Counter drive gear (See 051111 Counter Drive Gear Disassembly Note.) Snap ring Retaining ring Thrust washer Inner race Counter 4th gear Synchronizer ring Counter 3rd gear (See 051111 Counter 3rd Gear Disassembly Note.)

12 13 14 15 16 17 18

19 20 21 22

Clutch hub component (3rd/4th) Synchronizer ring Middle ring Inner ring Needle bearing Countershaft gear Clutch hub sleeve (See 05115 Clutch Hub Sleeve Disassembly Note.) Steel ball Synchronizer key spring Synchronizer key Clutch hub

051110

MANUAL TRANSMISSION
Roller Bearing Disassembly Note 1. Remove the roller bearing using the SSTs and a press.
49 B032 317 49 H027 002

0511

BHJ0511M117

Counter Drive Gear Disassembly Note 1. Remove the counter drive gear using the SST and a press.
49 N017 102

BHJ0511M118

Counter 3rd Gear Disassembly Note 1. Remove the counter 3rd gear and clutch hub component (3rd/4th) together using the SST and a press.

End Of Sie
49 G030 370

BHJ0511M119

051111

MANUAL TRANSMISSION
MANUAL TRANSMISSION INSPECTION Drive Gear Inspection Thrust clearance inspection 1. Measure the thrust clearance of each gear using a feeler gauge and a dial gauge as shown in the figure.
CHU051117050M03

REVERSE

2ND

1ST

4TH

3RD

6TH
CHU0511M120

3RD, REVERSE
CHU0511M121

Thrust clearance (mm {in})

Gear 1st 2nd 3rd 4th 6th Reverse Thrust clearance 0.150.40 {0.0060.015} 0.100.45 {0.0040.017} 0.100.35 {0.0040.013} 0.100.35 {0.0040.013} 0.100.40 {0.0040.015} 0.100.45 {0.0040.017}
1ST, 2ND, 4TH 6TH
CHU0511M122

If not within the specification, replace the malfunctioning parts. Radial clearance inspection 1. Measure the radial clearance of each gear using a dial gauge. Radial clearance (mm {in})
Gear 1st 2nd 3rd 4th 5th (Drive gear) 6th Reverse Radial clearance 0.0150.066 {0.00060.0025} 0.0150.066 {0.00060.0025} 0.0150.068 {0.00060.0026} 0.0650.115 {0.00260.0045} 0.0290.072 {0.00120.0028} 0.0150.068 {0.00060.0026} 0.0150.066 {0.00060.0025}

BHJ0511M123

If not within the specification, replace the synchronizer ring.

051112

MANUAL TRANSMISSION
Reverse Idler Gear and Reverse Idler Shaft Inspection Radial clearance inspection 1. Secure the reverse idler gear and reverse idler shaft in a vise, and measure the radial clearance using a dial gauge. Radial clearance 0.0400.082 mm {0.00160.0032 in} If not within the specification, replace the reverse idler gear and the reverse idler shaft.

0511

BHJ0511M124

Synchronizer Ring Inspection 1. Set the synchronizer ring evenly in the gear, and measure the clearance between the synchronizer ring and flank surface of the gear all around the circumference using a feeler gauge. Clearance (mm {in})
Gear Inner ring 1st Middle ring 2nd 3rd Synchronizer ring 4th 5th 6th Reverse Clearance 0.981.62 {0.040.06} 0.681.92 {0.030.07} 0.881.72 {0.040.06} 0.801.60 {0.040.06} 0.881.52 {0.040.05}
BHJ0511M125

If not within the specification, replace the synchronizer ring. Mainshaft Inspection 1. Hold the mainshaft with the V-blocks and measure the runout using a dial gauge as shown in the figure. Maximum runout 0.03 mm {0.0012 in} If it exceeds the maximum specification, replace the mainshaft.
V-blocks
CHU0511M126

Countershaft Inspection 1. Hold the countershaft with the V-blocks and measure the runout using a dial gauge as shown in the figure. Maximum runout 0.03 mm {0.0012 in} If it exceeds the maximum specification, replace the countershaft.
V-blocks

CHU0511M127

051113

MANUAL TRANSMISSION
Clutch Hub Sleeve and Shift Fork Inspection 1. Measure the shift fork thickness and the groove width of the clutch hub sleeve with a vernier caliper, and calculate the clearance. Clearance 0.150.35 mm {0.0060.013 in} If not within the specification, replace the clutch hub sleeve and shift fork.

End Of Sie
BHJ0511M128

COUNTERSHAFT COMPONENT ASSEMBLY 1. Assemble in the order indicated in the table. 2. Verify the following after assembly. (1) The gear rotates smoothly when rotated by hand. (2) The synchronizer ring is not stuck.
.

CHU051117050M04

SELECTIVE USE R SELECTIVE USE R

19

SST

SST

20
SST

8 9 10 11 12

21

22

7
13 4 15 17 16 SELECTIVE
USE FRONT

14

FRONT

18
R

5
OIL

APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

CHU0511M129

1 2 3 4 5 6

Clutch hub Synchronizer key Synchronizer key spring Steel ball Clutch hub sleeve Countershaft gear

7 8 9 10 11

Needle bearing Counter 3rd gear Inner ring Middle ring Synchronizer ring

051114

MANUAL TRANSMISSION
12 Clutch hub component (3rd/4th) (See 051115 Clutch Hub Component (3rd/4th) Assembly Note.) Synchronizer ring Counter 4th gear Inner race Thrust washer (See 051116 Thrust Washer Assembly Note.) Retaining ring Snap ring 19 Counter drive gear (See 051116 Counter Drive Gear Assembly Note.) Snap ring (friction gear) (See 051117 Snap Ring (Friction Gear) Assembly Note.) Roller bearing (See 051117 Roller Bearing Assembly Note.) Snap ring (roller bearing) (See 051117 Snap Ring (Roller Bearing) Assembly Note.)

13 14 15 16 17 18

20

21 22

0511

Clutch Hub Component (3rd/4th) Assembly Note 1. Securely align the tabs on each ring of the 3rd gear side with the installation hole of the 3rd gear and the key groove of the clutch hub.
C B CLUTCH HUB COMPONENT

SYNCHRONIZER RING

MIDDLE RING A INNER RING B GEAR A

CHU0511M143

2. Securely align the tab on the synchronizer ring of 4th gear side with the key groove of the clutch hub. Caution Do not damage the synchronizer ring when installing the clutch hub component.

BHJ0511M130

051115

MANUAL TRANSMISSION
3. Carefully install the clutch hub component (3rd/ 4th) using the SSTs and a press.
49 F401 331

49 M005 796

BHJ0511M131

Thrust Washer Assembly Note 1. Install the thrust washer removed during disassembly, and measure the clearance between the thrust washer and the installation groove using a feeler gauge. 2. Select the new thrust washer from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear with the identification mark facing up. Clearance 00.1 mm {00.0039 in} Thrust washer size (mm {in})
Identification mark A B C D Thickness 3.75 {0.148} 3.80 {0.150} 3.85 {0.152} 3.90 {0.154} Identification mark E F G H Thickness 3.95 {0.156} 4.00 {0.157} 4.05 {0.159} 4.10 {0.161}

THRUST WASHER

CHU0511M132

Counter Drive Gear Assembly Note 1. Install the counter drive gear using the SSTs.
49 N017 104
STEEL PLATE

49 M005 796

CHU0511M133

051116

MANUAL TRANSMISSION
Snap Ring (Friction Gear) Assembly Note 1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge. 2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear.
SNAP RING

0511

Clearance 00.1 mm {00.0039 in} Snap ring size (mm {in})

Identification Thickness Identification Thickness mark mark A 1.80 {0.071} D 1.95 {0.077} B 1.85 {0.073} E 2.00 {0.079} C 1.90 {0.075} F 2.05 {0.081}
CHU0511M134

Roller Bearing Assembly Note 1. Install the roller bearing using the SSTs.
49 H025 004
STEEL PLATE

49 M005 796

CHU0511M135

Snap Ring (Roller Bearing) Assembly Note 1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge. 2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear. Clearance 00.1 mm {00.0039 in} Snap ring size (mm {in})
Identification mark A B C D Thickness 3.75 {0.148} 3.80 {0.150} 3.85 {0.152} 3.90 {0.154} Identification mark E F G H Thickness 3.95 {0.156} 4.00 {0.157} 4.05 {0.159} 4.10 {0.161}

SNAP RING

CHU0511M136

End Of Sie

051117

MANUAL TRANSMISSION
MAIN DRIVE GEAR AND MAINSHAFT COMPONENT ASSEMBLY 1. Assemble in the order indicated in the table. 2. Verify the following after assembly. (1) The gear rotates smoothly when rotated by hand. (2) The synchronizer ring is not stuck.
.

CHU051117050M05

33
7

9 8

FRONT

10

11 5 4 23

1
3
USE

SST

2 SST
12 13 27 25 24
7

31 30 29 28 32
R
SELECTIVE USE

FRONT

R SELECTIVE

26 9 8
FRONT

SST

14 16
SELECTIVE R USE

22

15
SST

6 21

20
19 17
OIL

FRONT

10

18

APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

CHU0511M137

1 2 3

4 5 6 7 8 9 10 11 12 13 14 15

Main drive gear Bearing (See 051119 Bearing Assembly Note.) Snap ring (bearing) (See 051119 Snap Ring (Bearing) Assembly Note.) Synchronizer ring Needle bearing Clutch hub Synchronizer key Synchronizer key spring Steel ball Clutch hub sleeve Mainshaft Needle bearing Reverse gear Synchronizer ring Clutch hub component (5th/reverse) (See 051119 Clutch Hub Component (5th/ Reverse) Assembly Note.)

16

17 18 19 20 21 22

23 24 25 26 27 28 29 30

Snap ring (reverse gear) (See 051120 Snap Ring (Reverse Gear) Assembly Note.) Needle bearing 2rd gear Inner ring Middle ring Synchronizer ring Clutch hub component (1st/2nd) (See 051120 Clutch Hub Component (1st/2nd) Assembly Note.) Steel ball Synchronizer ring Middle ring Inner ring 1st gear Needle bearing Inner race Bearing

051118

MANUAL TRANSMISSION
31 32 6th gear (See 051121 6th Gear Assembly Note.) Snap ring (6th gear) (See 051121 Snap Ring (6th Gear) Assembly Note.) Main drive gear component

33

Bearing Assembly Note 1. Install the bearing using the SSTs.

49 0500 330

0511

49 B019 007

BHJ0511M138

Snap Ring (Bearing) Assembly Note 1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge. 2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the main drive gear. Clearance 00.1 mm {00.0039 in} Snap Ring size (mm {in})
Identification Thickness Identification Thickness mark mark 0 1.95 {0.077} 3 2.10 {0.083} 1 2.00 {0.079} 4 2.15 {0.085} 2 2.05 {0.081} 5 2.20 {0.087}

SNAP RING

CHU0511M139

Clutch Hub Component (5th/Reverse) Assembly Note 1. Securely align the tab on the synchronizer ring with the key groove of the clutch hub. Caution Do not damage the synchronizer ring when installing the clutch hub component.

BHJ0511M140

051119

MANUAL TRANSMISSION
2. Carefully install the clutch hub component (5th/ reverse) using the SSTs and a press.
STEEL PLATE

49 N017 104

49 N017 102

CHU0511M141

Snap Ring (Reverse Gear) Assembly Note 1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge. 2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the mainshaft. Clearance 00.1 mm {00.0039 in} Snap Ring size (mm {in})
Identification Thickness Identification Thickness mark mark A 1.80 {0.071} D 1.95 {0.077} B 1.85 {0.073} E 2.00 {0.079} C 1.90 {0.075} F 2.05 {0.081}
SNAP RING

CHU0511M142

Clutch Hub Component (1st/2nd) Assembly Note 1. Securely align the tab on each ring with the installation hole of the 2nd gear and the key groove of the clutch hub. Caution Do not damage each synchronizer ring when installing the clutch hub component.
C B CLUTCH HUB COMPONENT

SYNCHRONIZER RING

MIDDLE RING A INNER RING B GEAR A

CHU0511M143

051120

MANUAL TRANSMISSION
2. Carefully install the clutch hub component (1st/ 2nd) using the SSTs and a press.
49 N017 103
STEEL PLATE

49 N017 104

0511
49 N017 102
CHU0511M144

6th Gear Assembly Note 1. Install the bearing and 6th gear using the SSTs and a press.
49 N017 103
STEEL PLATE

49 N017 102
CHU0511M145

Snap Ring (6th Gear) Assembly Note 1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge. 2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the mainshaft. Clearance 00.11 mm {00.0043 in} Snap Ring size (mm {in})
Identification mark A B C D E F Thickness 2.67 {0.105} 2.73 {0.107} 2.79 {0.110} 2.85 {0.122} 2.91 {0.115} 2.97 {0.117} Identification mark G H J K L Thickness 3.03 {0.119} 3.09 {0.122} 3.15 {0.124} 3.21 {0.126} 3.27 {0.129}

SNAP RING

CHU0511M146

End Of Sie

051121

MANUAL TRANSMISSION
CLUTCH HOUSING COMPONENT, SHIFT FORK AND SHIFT ROD COMPONENT ASSEMBLY 1. Assemble in the order indicated in the table.
3
.

CHU051117030M02

18

21

1
4 5 16 15

20

22 R 19

12

27
SEALANT

23
A

24 13 SST
R

3247 {3.34.7, 2434}

25 6 11

17 14 26 9 10
R

Nm {kgfm, ftlbf}
CHU0511M147

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

14 15

Shift rod Snap ring 1st/2nd shift fork Interlock sleeve 5th/reverse shift fork Reverse idler gear Torsion spring Friction gear Spacer Snap ring Reverse idler shaft Countershaft component Reverse idler gear component (See 051123 Reverse Idler Gear Component Assembly Note.) Clutch housing (See 051123 Clutch Housing Assembly Note.) Main drive gear and mainshaft component

16 17 18 19 20 21 22 23

24

25 26

27

Shift fork and shift rod component (mainshaft) Bolt and gasket (See 051123 Bolt and Gasket Assembly Note.) Shift arm (5th) Pressure spring, steel ball Shift rod Stopper block Spring pin 3rd/4th shift fork (See 051124 3rd/4th Shift Fork and Shift Arm (Reverse) Assembly Note.) Shift arm (reverse) (See 051124 3rd/4th Shift Fork and Shift Arm (Reverse) Assembly Note.) Spring pin 5th/reverse counter lever (See 051124 5th/Reverse Counter Lever Assembly Note.) Crank lever shaft

051122

MANUAL TRANSMISSION
Reverse Idler Gear Component Assembly Note 1. Turn the friction gear counterclockwise by hand, and align the reverse idler gear hole with the friction gear. 2. Insert the SST (49 N017 204) through the holes from the reverse idler gear side, and secure the friction gear.

49 N017 204

0511

FRICTION GEAR

REVERSE IDLER GEAR

CHU0511M148

Clutch Housing Assembly Note 1. Install the countershaft component and the reverse idler gear component installed with the SSTs and the main drive gear and mainshaft component, shift fork and shift rod component (mainshaft) onto the clutch housing together. 2. Remove the SSTs installed to the countershaft component and the reverse idler gear component after installing.

MAIN DRIVE GEAR AND MAINSHAFT COMPONENT SHIFT FORK AND SHIFT ROD COMPONENT (MAINSHAFT) COUNTERSHAFT COMPONENT

REVERSE IDLER GEAR COMPONENT

49 N017 204

CLUTCH HOUSING
CHU0511M149

Bolt and Gasket Assembly Note 1. Install a new gasket and bolt into the clutch housing and tighten temporarily. 2. Fully tighten the new gasket and bolt after installing the transmission case.

051123

MANUAL TRANSMISSION
3rd/4th Shift Fork and Shift Arm (Reverse) Assembly Note 1. Temporarily install the 3rd/4th shift fork and shift arm (reverse) into the clutch housing. 2. Pass the shift rod through the 3rd/4th shift fork and shift arm (reverse). 3. Tap a new spring pin into the shift arm (reverse) head. SHIFT ROD

3RD/4TH SHIFT FORK

SHIFT ARM (REVERSE)

CHU0511M150

5th/Reverse Counter Lever Assembly Note 1. Install the 5th/reverse counter lever as shown in the figure, and secure it with the crank lever shaft.

End Of Sie

5TH/REVERSE COUNTER LEVER CRANK LEVER SHAFT

CHU0511M151

051124

MANUAL TRANSMISSION
TRANSMISSION CASE AND 6TH GEAR COMPONENT ASSEMBLY 1. Assemble in the order indicated in the table. 2. Verify the following after assembly. (1) The gear rotates smoothly when rotated by hand. (2) The synchronizer is not stuck.
.

CHU051117010M05

4 5

0511

19
SST R R R

2 1
6

12 18 16

SEALANT

17
R

20

12.823.5 {1.32.3, 9.517.3}

11
SEALANT

27 25 23

SELECTIVE USE

FRONT

15 22

FRONT

11.821.5 {1.22.1, 8.715.8}

SEALANT

33

13.823.5 {1.42.3, 10.217.3}

2748 {2.84.8, 2035}

14

21
SEALANT

26 SST
2435 {2.53.5, 1825}

2340 {2.44.0, 1729}

24

13 9 28 10
R

29 SST 32
R

8
SST
SEALANT

30 31
2433 {2.53.3, 1824}

SEALANT

13.823.5 {1.42.3, 10.217.3}

Nm {kgfm, ftlbf}
CHU0511M152

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17

Clutch hub Synchronizer key Synchronizer key spring Steel ball Retaining ring Clutch hub sleeve Steel ball Shift rod (See 051126 Shift Rod Assembly Note.) Transmission case (See 051126 Transmission Case Assembly Note.) Pressure spring, steel ball Snap ring (rear) Snap ring (front) Bolt and gasket (See 051127 Bolt and Gasket Assembly Note.) Bolt Plug Oil seal (See 051127 Oil Seal Assembly Note.) Front cover

18 19 20 21 22 23 24 25 26

27 28 29 30 31 32 33

Interlock sleeve Inner shift lever (See 051128 Inner Shift Lever Assembly Note.) Bearing cover component Pin Thrust washer Needle bearing 6th gear Synchronizer ring Clutch hub component (6th) (See 051128 Clutch Hub Component (6th) Assembly Note.) Snap ring (See 051128 Snap Ring Assembly Note.) Steel ball 6th shift fork (See 051129 6th Shift Fork Assembly Note.) Steel ball, pressure spring Plug Spring pin Plug (See 051129 Plug Assembly Note.)

051125

MANUAL TRANSMISSION
Shift Rod Assembly Note 1. Install the SST into the clutch housing. 2. Install the steel ball into the shift arm (5th). 3. Taking care so that the steel ball does not drop out, carefully insert the shift rod until it contacts the SST installed to the clutch housing. 4. Turn the notch of the shift rod end toward the shift rod A.
SHIFT ROD

SHIFT ROD A

NOTCH

49 N017 207
CHU0511M153

Transmission Case Assembly Note 1. Set the shift operation system to the neutral position. Note If the countershaft center bearing interferes with the transmission case when installing, pry the roller of the bearing lightly using a screw driver covered with a rag.

VIEW FROM A

VIEW FROM A

NEUTRAL POSITION
CHU0511M154

051126

MANUAL TRANSMISSION
2. Install the pressure spring and steel ball into the transmission case, then install the transmission case onto the clutch housing pressing with a pin punch so that the steel ball does not spring out.
PRESSURE SPRING STEEL BALL PIN PUNCH

0511

SHIFT ROD

CHU0511M158

Bolt and Gasket Assembly Note 1. Tighten the transmission case mounting bolt, then tighten the new gasket and bolt A (for the reverse idler shaft). 2. Tighten bolt B tightened temporarily on the clutch housing. Tightening torque (Bolt A and B) 2433 Nm {2.53.3 kgfm, 1824 ftlbf}

BHJ0511M155

Oil Seal Assembly Note 1. Install the new oil seal in the front cover using the SSTs and a hammer.
49 G030 797

49 N017 209

BHJ0511M156

051127

MANUAL TRANSMISSION
Inner Shift Lever Assembly Note 1. Install the inner shift lever using a suitable pipe and a hammer.

BHJ0511M157

Clutch Hub Component (6th) Assembly Note 1. Securely align the tab on the synchronizer ring with the key groove of the clutch hub. Caution Do not damage the synchronizer ring when installing the clutch hub component.

BHJ0511M130

2. Carefully install the clutch hub component (6th) using the SST.

49 N017 2A0

BHJ0511M159

Snap Ring Assembly Note 1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge. 2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear. Clearance 00.1 mm {00.0039 in} Snap ring size (mm {in})
Identification Thickness Identification Thickness mark mark A 2.80 {0.110} D 2.95 {0.116} B 2.85 {0.112} E 3.00 {0.118} C 2.90 {0.114} F 3.05 {0.120}

SNAP RING

CHU0511M160

051128

MANUAL TRANSMISSION
6th Shift Fork Assembly Note 1. Install the 6th shift fork in the clutch hub component. 2. Insert the steel ball from the transmission case. 3. Pass the SST through the 6th shift fork and install in the shift rod. 4. Pull the SST up, then install the steel ball, pressure spring and plug from outside of the transmission case and secure the shift rod.
6TH SHIFT FORK

49 N017 208

0511

CHU0511M161

Plug Assembly Note 1. Remove the SST installed to the clutch housing, and install the plug.

End Of Sie

49 N017 207
BHJ0511M162

051129

MANUAL TRANSMISSION
EXTENSION HOUSING COMPONENT ASSEMBLY Note Do not attempt to shift the transmission until after the extension housing is properly installed. 1. Assemble in the order indicated in the table.
.

CHU051117010M06

27
3544 {3.64.4, 2632}

28

*
GREASE

13.825.4 {1.42.5, 10.218.7}

17
R

3245 {3.34.5, 2433}

21
R
A

16 14
2748 {2.84.8, 2035}

23 26
R

20

19

15 18 3 R

2435 {2.53.5, 1825}

R SST

1
GREASE

24
*
GREASE

25

2748 {2.84.8, 2035}

4 6
1723 {1.82.3, 1316}

11 9 12 10

1724 {1.82.4, 1317}

5 13 22
3039 {3.13.9, 2328}

7
A
3245 {3.34.5, 2433}

SEALANT

5.910.7 Nm {61109 kgfcm, 53.094.6 inlbf}

* MOLYBDENUM SULFIDE

7.910.7 Nm {81109 kgfcm, 70.394.6 inlbf}

GREASE

Nm {kgfm, ftlbf}
CHU0511M163

1 2 3 4 5 6 7 8 9 10 11

Oil seal (See 051131 Oil Seal Assembly Note.) Baffle plate Breather Lever support Oil funnel Stopper block Oil passage Shift rod Shift lever Torsion spring (See 051131 Torsion Spring Assembly Note.) Shift rod and shift lever component

12 13 14 15 16 17 18 19 20 21 22 23 24

Retaining ring Extension housing component Control rod end Tubular pin Gasket Control case Push pin component Pressure spring Plug Back-up light switch Neutral switch Drain plug, gasket Filler plug, gasket

051130

MANUAL TRANSMISSION
25 26 Clutch release collar Pivot pin 27 28 Dust cover Clutch release fork

Oil Seal Assembly Note 1. Install a new oil seal in the extension housing using the SSTs and a hammer.

49 B025 001

49 G030 797

0511

BHJ0511M167

Torsion Spring Assembly Note 1. Install the torsion spring to the shift lever as shown in the figure.

End Of Sie

BHJ0511M166

051131

TECHNICAL DATA

0550
End of Toc

TECHNICAL DATA

TECHNICAL DATA . . . . . . . . . . . . . . . . . 05501

TECHNICAL DATA
Item Manual transmission type Type Viscosity All-season Capacity (L {US qt, lmp qt}) 1st 2nd 3rd Drive gear thrust (mm {in}) clearance 4th 6th Reverse 1st 2nd 3rd Drive gear radial (mm {in}) 4th clearance 5th (drive gear) 6th Reverse Reverse idler gear radial clearance (mm {in}) Inner ring 1st, 2nd, 3rd Middle ring Clearance between synchronizer ring and (mm {in}) Synchronizer ring flank surface of gear 4th, 5th 6th, Reverse Mainshaft maximum runout (mm {in}) Countershaft maximum runout (mm {in}) Clearance between clutch hub sleeve and shift fork (mm {in}) Clearance between 4th gear inner race and thrust washer (mm {in}) Clearance between counter drive gear and snap ring (mm {in}) Clearance between roller bearing (countershaft) and snap ring (mm {in}) Clearance between bearing (main drive gear) and snap ring (mm {in}) Clearance between clutch hub component (5th/reverse) and snap ring (mm {in}) Clearance between 6th gear and snap ring (mm {in}) Clearance between clutch hub component (6th) and snap ring (mm {in}) Transmission oil

CHU055001029M01

Specification Y16M-D API Service GL-4 or GL-5 SAE 75W-90 1.75 {1.85, 1.54} 0.150.40 {0.0060.015} 0.100.45 {0.0040.017} 0.100.35 {0.0040.013} 0.100.35 {0.0040.013} 0.100.40 {0.0040.015} 0.100.45 {0.0040.017} 0.0150.066 {0.00060.0025} 0.0150.066 {0.00060.0025} 0.0150.068 {0.00060.0026} 0.0650.115 {0.00260.0045} 0.0290.072 {0.00120.0028} 0.0150.068 {0.00060.0026} 0.0150.066 {0.00060.0025} 0.0400.082 {0.00160.0032} 0.981.62 {0.040.06} 0.681.92 {0.030.07} 0.881.72 {0.040.06} 0.801.60 {0.040.06} 0.881.52 {0.040.05} 0.03 {0.0012} 0.03 {0.0012} 0.150.35 {0.0060.013} 00.1 {00.0039} 00.1 {00.0039} 00.1 {00.0039} 00.1 {00.0039} 00.1 {00.0039} 00.11 {00.0043} 00.1 {00.0039}

0550

End Of Sie

05501

SERVICE TOOLS

0560
End of Toc

SERVICE TOOLS

SERVICE TOOLS . . . . . . . . . . . . . . . . . . 05601

SERVICE TOOLS
49 N017 2A1 Clutch hub puller set 49 G030 370 Removing plate 49 N017 101 Plate

CHU056001029M01

0560

49 B032 317 Bearing and oil seal remover

49 H027 002 Bearing remover

49 N017 102 Plate

49 F401 331 Body

49 M005 796 Body

49 N017 104 Joint pipe

49 H025 004 Bearing installer set

49 0500 330 Bearing installer set

49 B019 007 Preload adapter

49 N017 103 Gear installer

49 N017 204 Setting plate

49 N017 207 Shaft stopper

49 G030 797 Handle

49 N017 209 Oil seal installer

49 N017 2A0 Clutch hub installer set

49 N017 208 Guide pin

49 B025 001 Body

End Of Sie

05601