MANUAL TRANSMISSION
C TRANSMISSION/TRANSAXLE
CONTENTS
PRECAUTIONS .......................................................... 2
Caution ..................................................................... 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tool ......................................... 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
MT-1
B
SECTION
MANUAL TRANSMISSION MT
E
Cable ...................................................................... 10 F
Shift Position Inspection ......................................... 10
Shift Position Adjustment ........................................ 10
SHIFT CABLE ..................................................... 10 G
SELECT CABLE .................................................. 11
AIR BREATHER HOSE ............................................ 12
Removal and Installation ........................................ 12
H
TRANSMISSION ASSEMBLY .................................. 13
Removal and Installation from Vehicle ................... 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13 I
Component Prts Drawing ....................................... 15
CASE COMPONENTS ........................................ 15
GEAR COMPONENTS ....................................... 16 J
SHIFT CONTROL COMPONENTS ..................... 17
Disassembly and Assembly .................................... 18
DISASSEMBLY ................................................... 18
K
INSPECTION AFTER DISASSEMBLY ................ 22
ASSEMBLY ......................................................... 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 36
General Specifications ............................................ 36 L
Backlash ................................................................. 36
End Play ................................................................. 37
Snap Rings ............................................................. 37 M
Adjusting Shim ........................................................ 37
Baulk Ring Clearance ............................................. 38
 PRECAUTIONS

PRECAUTIONS PFP:00001

Caution 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 PFP:00002
A
Special Service Tools ECS004K1

Tool name
Description
Tool number B

Drift MT
ST33400001
Rear oil seal installation
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
D
ZZA0814D

E
Pin punch
KV31100300 Retaining pin removal and installation
Tip diameter: 4.5 mm (0.177 in) dia.
F
ZZA0815D

G
Puller
KV32101330
Overdrive mainshaft bearing removal
a: 447 mm (17.60 in) H
b: 100 mm (3.94 in)

NT408
I

Puller 1st gear bushing removal

J
ST30031000 Main drive gear bearing removal

ZZA0537D K

Drift
L
ST30720000
Mainshaft ball bearing installation
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
M
ZZA0811D

Drift
ST30613000
Main drive gear ball bearing installation
a: 71.5 mm (2.815 in) dia.
b: 47.5 mm (1.870 in) dia.

ZZA1000D

Main shaft assembly and counter gear

installation
Transmission stand
3rd & 4th synchronizer assembly
KV31100401
installation
Counter gear front bearing installation
ZZA1232D

MT-3
 PREPARATION

Tool name
Description
Tool number

Drift
ST23860000 Main drive gear and counter drive gear
a: 38 mm (1.50 in) dia. installation
b: 33 mm (1.30 in) dia.

ZZA0534D

Drift
ST22360002 Counter gear front bearing installation
a: 32 mm (1.26 in) dia. Counter shaft rear bearing installation
b: 23 mm (0.91 in) dia.

ZZA0534D

Drift
ST22350000
Overdrive gear bushing installation
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.

ZZA0534D

Lock nut wrench

Lock nut tightening
ST22520000

ZZA0954D

Drift
ST23800000
Front cover oil seal installation
a: 44 mm (1.73 in) dia.
b: 31 mm (1.22 in) dia.

ZZA0534D

Drift Counter gear rear bearing installation

ST33200000
a: 60 mm (2.36 in) dia. 3rd & 4th synchronizer assembly
b: 44.5 mm (1.752 in) dia. installation

ZZA1002D

Commercial Service Tool ECS004K2

Tool name Description

Counter bearings removal

Puller Counter drive gear removal
Overdrive counter gear removal

NT077

MT-4
 NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

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

A
NVH Troubleshooting Chart ECS004K3

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

D

SUSPECTED PARTS G
(Possible cause)

SHIFT CONTROL LINKAGE (Worn)

BAULK RING (Worn or damaged)

BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)

INSERT SPRING (Damaged)

H

GEAR (Worn or damaged)

OIL (Oil level is high.)

GASKET (Damaged)

SHIFT FORK (Worn)

OIL (Oil level is low.)

I
OIL (Wrong oil.)

Noise 1 2 3 3
K
Oil leakage 3 1 2 2
Symptoms
Hard to shift or will not shift 1 1 2 2 2
Jumps out of gear 1 1 2 2 L

MT-5
 DESCRIPTION

DESCRIPTION PFP:00000

Cross-sectional View 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 PFP:KLD20

A
Replacement ECS004K5

DRAINING
1. Start the engine and warm up the transmission unit sufficiently.
B
2. Stop the engine. Remove drain plug and drain oil.
3. Apply Three Bond TB1215, Loctite Part No.51813 or equivalent to drain plug, and install it to the transmis-
sion unit. Tighten it to the specified torque. MT
Drain plug:
: 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb) D
FILLING
1. Remove filler plug. Fill new oil into the transmission to the level of the filler plug mounting hole.
E
Oil grade: API GL-4
Viscosity: Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS"
Oil capacity: Approx. 2.0 (3-1/2 lmp pt) F
2. After oil filling, check the oil level and apply Three Bond TB1215, Loctite Part No.51813 or equivalent to
filler plug. Then install it to the transmission unit, and tighten it to the specified torque.
G
Filler plug:
: 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)
H
Checking ECS004K6

OIL LEAKAGE AND OIL LEVEL

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

MT-7
 REAR OIL SEAL

REAR OIL SEAL PFP:33140

Removal and Installation ECS004K7

REMOVAL
1. Remove propeller shaft.
2. Pull out oil seal.

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:
Oil seals are not reusable.Never reuse them.

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 MT-
7, "Checking" after completing the operation. SMT659A

MT-8
 POSITION SWITCH

POSITION SWITCH PFP:32005

A
Checking ECS004K8

BACK-UP LAMP SWITCH

Check continuity. B
Reverse Yes
Except reverse No
MT

SCIA0645E
E

MT-9
 CONTROL LINKAGE

CONTROL LINKAGE PFP:34103

Removal and Installation of Control Device and Cable ECS004K9

Refer to the figure above for removal and installation procedure.

SCIA0586E

Shift Position Inspection ECS004KA

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

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

SMT340C

MT-10
 CONTROL LINKAGE

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

MT

E
SMT342C

MT-11
 AIR BREATHER HOSE

AIR BREATHER HOSE PFP:31098

Removal and Installation ECS004KC

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

SCIA0534E

CAUTION:
Make sure there are no pinched or blocked areas on the air breather hose caused by bending or
winding when installing it.
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 PFP:32010

A
Removal and Installation from Vehicle ECS004KD

MT

G
SCIA0581E

REMOVAL
1. Remove exhaust tube and propeller shaft. H
CAUTION:
Insert plug into oil seal after removing propeller shaft.

Be careful not to damage spline, sleeve yoke and rear oil seal when removing propeller shaft. I
2. Remove control cable from transmission.
3. Remove clutch operating cylinder.
CAUTION: J
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. K
5. Remove starter motor.
6. Remove air breather hose.
L
7. Set jack to the transmission.
CAUTION:
When setting jack, be careful not to contact with the switch.
M
8. Remove rear engine mount.
9. Remove engine and transmission mounting bolts.
10. Remove transmission from the vehicle.
CAUTION:
Support transmission while removing it.
INSTALLATION
To install, reverse the removal procedure, following the cautions below:
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. 1 2 3* 4*
Quantity 2 2 1 1
64 60 45 30
mm (in)
(2.52) (2.36) (1.77) (1.18)
Tightening torque 39 - 49 29 - 39
Nm (kg-m, ft-lb) (4.0 - 4.9, 29 - 36) (3.0 - 3.9, 22 - 28)
*: The No. 3 and 4 bolts also secure gussets.

Engine gusset cylinder block mounting bolts SCIA0579E

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. 1 2*
Quantity 4 4

mm (in) 80 (3.15) 45 (1.77)

Tightening torque 39 - 49
Nm (kg-m, ft-lb) (4.0 - 4.9, 29 - 36)
*: The No. 2 bolt also secures gussets.

Engine gusset cylinder block mounting bolts SCIA0580E

Bolt length: : 20 mm (0.79 in)
: 29 - 39 Nm (3.0 - 3.9 kg-m, 22 - 28 ft-lb)
After installation, check oil level, and oil leaks and loose mechanisms.

MT-14
 TRANSMISSION ASSEMBLY

Component Prts Drawing ECS004KE

CASE COMPONENTS A

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 ECS004KF

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

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. Secure the adapter plate in a vise. A
2. Remove check ball plug, check spring, and check ball.

MT

SCIA0591J D

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

SCIA0592E

Gear Components H
1. Before disassembly, measure the end play and backlash for
each gear.
I
End play standards
1st gear: 0.31 - 0.41 mm (0.0122 - 0.0161 in)
2nd gear: 0.11 - 0.21 mm (0.0043 - 0.0083 in) J
3rd gear: 0.11 - 0.21 mm (0.0043 - 0.0083 in)
Overdrive gear: 0.24 - 0.41 mm (0.0094 - 0.0161 in)
Reverse idler gear: 0.05 - 0.50 mm (0.0020 - 0.0197 in) K
Counter gear: 0 - 0.16 mm (0 - 0.0063 in) SCIA0593E

Backlash standards L

Main drive gear: 0.05 - 0.10 mm (0.0020 - 0.0039 in)

1st gear: 0.05 - 0.10 mm (0.0020 - 0.0039 in) M
2nd gear: 0.05 - 0.10 mm (0.0020 - 0.0039 in)
3rd gear: 0.05 - 0.10 mm (0.0020 - 0.0039 in)
Overdrive gear: 0.05 - 0.10 mm (0.0020 - 0.0039 in)
Reverse idler gear: 0.05 - 0.10 mm (0.0020 - 0.0039 in)
If the end play or backlash is outside the standards, disas- SCIA0594E
semble 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. 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.
5. Remove snap ring. Then remove 3rd & 4th synchronizer assem-
bly and 3rd main gear.

SMT162A

6. Remove adapter plate mounting parts following the steps below.

a. Make double-engagement of 2nd gear and reverse gear to pre-
vent 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. Using a suitable puller, remove overdrive counter gear and

counter gear rear end bearing. A
c. Remove reverse counter gear and spacer.
d. Remove snap ring from reverse idler shaft. Then remove
reverse idler gear, needle bearing, and thrust washer. B

MT

SMT547A
D
e. Remove snap ring. Then remove overdrive mainshaft bearing.
f. Remove snap ring.
g. Remove mainshaft lock nut. Then remove speedometer drive E
gear and steel ball.
h. Remove thrust washer, roller bearing, and spacer.
i. Remove overdrive main gear, needle bearing, and overdrive F
baulk ring.
j. Remove overdrive & reverse coupling sleeve, shifting insert, and
spread spring. G
k. Lightly tap the counter gear to remove. SMT165AA

l. Remove overdrive gear bushing, overdrive &reverse synchro- H

nizer hub, reverse baulk ring, reverse main gear, needle bear-
ing, and reverse gear bushing all together.

SCIA0601J
K
7. Remove 1st main gear thrust washer and steel ball from main-
shaft.
L
CAUTION:
Be careful not to lose the steel ball.
8. Remove 1st main gear and needle bearing.
M

SCIA0602J

MT-21
 TRANSMISSION ASSEMBLY

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

b. Remove main drive gear bearing with a press.

SMT420AA

INSPECTION AFTER DISASSEMBLY

Shift Control Components
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

MT-22
 TRANSMISSION ASSEMBLY

If the contact surface on each gear, mainshaft, main drive gear,

or counter gear, etc. has damage, peeling, abrasion, dent, bent, A
or any other damage, replace the components.

MT

SMT386A
D

SMT550A G

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

SMT387A K

If the cam surface on baulk ring or contact surface on insert has

damage or excessive wear, replace with a new one. L
If insert spring is damaged, replace with a new one.

SCIA0608J

Baulk Ring Clearance

MT-23
 TRANSMISSION ASSEMBLY

Single Cone Synchronizer (1st, 4th, and overdrive)

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: 1.2 - 1.6 mm (0.047 - 0.063 in)
Wear limit: 0.8 mm (0.031 in)

SMT140

Double-Cone Synchronizer (2nd and 3rd)

Check the clearance between outer baulk ring, synchronizer
cone, and inner baulk ring of 2nd and 3rd double-cone synchro-
nizer 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: 0.7 - 0.9 mm (0.028 - 0.035 in)
Wear limit: 0.2 mm (0.008 in) or less

SCIA0763E

2. Using a thickness gauge, measure the clearance B at diago-

nally opposite 2 points (or more), and calculate the mean value.
Clearance B
Standard: 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit: 0.2 mm (0.008 in) or less

AMT192

MT-24
 TRANSMISSION ASSEMBLY

Reverse Synchronizer Assembly

Using a thickness gauge, measure the reverse baulk ring back A
clearance at diagonally opposite 2 points (or more), and calcu-
late the mean value. If it is outside the limit, replace with a new
one. B
Clearance
Standard: 1.1 - 1.55 mm (0.043 - 0.061 in)
MT
Wear limit: 0.7 mm (0.028 in) or less
SCIA0819E
D
Bearing
If the bearing does not rotate smoothly or the contact surface on
ball or race is damaged or peeled, replace with new ones. E

SMT418A
H
ASSEMBLY
Gear Components
1. Set mainshaft ball bearing to the adapter plate, and drive it in
I
with a drift (special service tool).

SCIA0609E
L
2. Set counter gear rear bearing to the adapter plate, and drive it
with a drift (special service tool).
M

SCIA0610E

MT-25
 TRANSMISSION ASSEMBLY

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

SMT153A

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 Part No.
A

1.87 mm (0.0736 in) 32204 78001

1.94 mm (0.0764 in) 32204 78002
2.01 mm (0.0791 in) 32204 78003 B
8. Install coupling sleeve and insert spring to 1st & 2nd synchro-
nizer hub.
CAUTION: MT
Install insert spring to the position (recess) of coupling
sleeve in the figure.
Install coupling sleeve with its groove facing front (dou- D
ble-cone synchronizer side).
Check that hub and coupling can be moved smoothly by
hand. E

SCIA0815E I

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

SCIA0816E

MT-27
 TRANSMISSION ASSEMBLY

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

SCIA0817E

11. Install 2nd main gear, needle bearing, and 1st & 2nd synchro-
nizer assembly to mainshaft. Then press with the 1st gear bush-
ing.
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
D
16. After installing 3rd main gear and needle bearing to mainshaft,
press 3rd & 4th synchronizer assembly onto the mainshaft.
E

G
SCIA0619E

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

K
SMT031

L
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.
M
End play standards: 0 - 0.18 mm (0 - 0.0071 in)
If it is outside the specified range, select the snap ring.

SCIA0621E

Mainshaft snap ring

Thickness Part No.
2.4 mm (0.094 in) 32263 V5200
2.5 mm (0.098 in) 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.
If it is outside the specified range, select the snap ring.

SMT201D

Counter drive gear snap ring

Thickness Part No.
1.4 mm (0.055 in) 32215 E9000
1.5 mm (0.059 in) 32215 E9001
1.6 mm (0.063 in) 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 A
gear front bearing to the counter gear.

MT

TM443-A
D
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 E
to the mainshaft.

G
AMT134

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

SMT531-A K

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

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.

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.
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 D

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

SCIA0592E
H
3. Drive retaining pin into 5-R fork and 5-R fork bracket.

K
SCIA0634J

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

SMT036-A

MT-33
 TRANSMISSION ASSEMBLY

2. Apply genuine anaerobic liquid gasket, Three Bond TB1215,

Loctite 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. Apply genuine anaerobic liquid gasket Three Bond TB1215,

Loctite Part No. 51813 or equivalent to mounting surface of the
adapter plate.
6. Place shift forks in neutral position.
7. 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
D
9. Measure height A of counter gear front bearing and transmis-
sion case edge surface. Select and install adjusting shim in
accordance with the height. E

G
SMT205D

Adjusting Shim
H
Measurement height A Shim thickness Part No.
4.52 - 4.71 mm (0.1780 - 0.1854 in) (Shim unnecessary)
4.42 - 4.51 mm (0.1740 - 0.1776 in) 0.1 mm (0.004 in) 32218 V5000 I
4.32 - 4.41 mm (0.1701 - 0.1736 in) 0.2 mm (0.008 in) 32218 V5001
4.22 - 4.31 mm (0.1661 - 0.1697 in) 0.3 mm (0.012 in) 32218 V5002
4.12 - 4.21 mm (0.1622 - 0.1657 in) 0.4 mm (0.016 in) 32218 V5003
4.02 - 4.11 mm (0.1583 - 0.1618 in) 0.5 mm (0.020 in) 32218 V5004 J
3.92 - 4.01 mm (0.1543 - 0.1579 in) 0.6 mm (0.024 in) 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) PFP:00030

General Specifications ECS004KG

Applied model KA24DE,ZD30DD

Transmission RS5W71C
Number of speed 5

Shift pattern

SCIA0821E

Synchromesh type Warner

1st 3.592
2nd 2.246
3rd 1.415
Gear ratio
4th 1.000
OD 0.821
Reverse 3.657
Drive 21
1st 33

Mainshaft 2nd 28
(Number of teeth) 3rd 26
OD 21
Reverse 36
Drive 32
1st 14

Countershaft gear 2nd 19

(Number of teeth) 3rd 28
OD 39
Reverse 15
Reverse idler gear (Number of teeth) 21
Oil capacity
2.0 (3-1/2)
(Imp pt)
Reverse synchronizer Installed
Remarks Double cone synchronizer 2nd & 3rd
Sub-gear Counter drive gear & reverse idler gear

Backlash ECS004KH

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

MT-36
 SERVICE DATA AND SPECIFICATIONS (SDS)

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

End Play ECS004KI B

Unit: mm (in)
Item Standard
MT
1st gear 0.31 - 0.41 (0.0122 - 0.0161)
2nd gear 0.11 - 0.21 (0.0043 - 0.0083)
3rd gear 0.11 - 0.21 (0.0043 - 0.0083) D
4th gear
Overdrive gear 0.24 - 0.41 (0.0094 - 0.0161)
E
Reverse idler gear 0.05 - 0.50 (0.0020 - 0.0197)
Counter drive gear 0 - 0.16 (0 - 0.0063)
Main drive gear axial end play 0 - 0.13 (0 - 0.0051) F
Mainshaft front 0 - 0.18 (0 - 0.0071)
OD main shaft bearing 0 - 0.14 (0 - 0.0055)
G
Snap Rings ECS004KJ

Unit: mm (in)
Selective parts Thickness Part No.
H
1.87 (0.0736) 32204 78001
Main drive gear 1.94 (0.0764) 32204 78002
2.01 (0.0791) 32204 78003
I
1.4 (0.055) 32215 E9000
Counter drive gear 1.5 (0.059) 32215 E9001
1.6 (0.063) 32215 E9002
2.4 (0.094) 32263 V5200
J
Front side
2.5 (0.098) 32263 V5201

Main shaft 1.1 (0.043) 32228 20100

1.2 (0.047) 32228 20101 K
Shaft rear-end
1.3 (0.051) 32228 20102
1.4 (0.055) 32228 20103

Adjusting Shim ECS004KK

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

MT-37
 SERVICE DATA AND SPECIFICATIONS (SDS)

Baulk Ring Clearance ECS004KL

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

SCIA0818E

Main drive & overdrive 1.20 - 1.60 (0.0472 - 0.0630) 0.8 (0.031) or less
Reverse 1.10 - 1.55 (0.0433 - 0.0610) 0.7 (0.028) or less

MT-38