ST23860000
TM442
Fig
MT
42
l
talling
counte
haft
drive
gear
Available
counter
drive
gear
map
ring
No
Thickness
mm
in
I
2
3
1
4
0
055
1
5
0
059
1
6
0
063
II
TM366
Fig
MT
43
Installing
nap
ring
5
Press
countershaft
front
bearing
onto
countershaft
with
Drift
C
ST22360002
See
Figure
MT
44
ST22360002
KV3
II
00400
TM443
Fig
MT
44
Installing
counte
haft
front
bearing
Manual
Transmission
6
Support
adapter
plate
in
a
vise
with
Setting
Plate
Adapter
ST238
10001
with
mainshaft
facing
down
7
Install
mainshaft
reverse
gear
plain
washer
on
the
rear
of
mainshaft
and
install
mainshaft
nut
Tighten
mainshaft
nut
temporarily
8
Install
counter
reverse
gear
on
the
rear
of
countershaft
and
secure
with
map
ring
Use
snap
ring
to
give
a
minimum
gear
end
play
See
Figure
MT
45
No
Thickness
mm
in
I
2
3
1
4
0
055
1
5
0
059
1
6
0
063
o
TM361
Fig
MT
45
Imtalling
counter
reverse
gear
nap
ring
9
Install
reverse
idler
gear
on
re
verse
idler
shaft
10
With
1st
and
2nd
gears
doubly
engaged
tighten
mainshaft
nut
to
the
converted
torque
Cn
See
Figure
MT
48
using
Wrench
ST22520000
See
Figure
MT
4
7
ST22520000
TM768
Fig
MT
46
Tightening
mainshaft
nut
MTll
Explanation
of
converted
torque
Mainshaft
nut
should
be
tightened
to
14
to
17
kg
m
101
to
123
ft
lb
torque
with
the
aid
of
Wrench
ST22520000
When
doing
so
the
amount
of
torque
to
be
read
on
wrench
needle
should
be
modified
according
to
the
following
formula
L
C
kg
m
14
x
to
L
O
lO
L
17
x
L
0
10
or
L
C
ft
lb
101
x
L
0
33
to
L
123
x
L
0
33
Where
C
Value
read
on
the
torque
wrench
kg
m
ft
lb
L
Effective
length
of
torque
wrench
m
ft
ST22520000
Torque
wrench
Lm
ft
c
h
I
O
IOm
0
33
ft
TM587
Fig
MT
47
Setting
wrench
Example
When
a
0
40
m
1
31
ft
long
tor
que
wrench
is
used
the
Cn
in
Figure
MT
48
will
be
11
2
to
13
6
kg
m
81
to
98
ft
lb
I
Upper
limit
line
I
r
6
1
f
fdl
13
Converted
torque
90
I
Lower
limit
line
80
11
70
10
V
S
s
15
110
15
c
u
c
c
9
S
c
o
C
U
100
14
9
0
2
0
3
1
0
0
4
Manual
Transmission
0
5
0
6
2
0
0
7
0
8
m
2
5
It
1
5
L
Effective
length
of
torque
wrench
Fig
MT
48
CO
1Vert
d
torque
11
Tighten
mainshaft
nut
to
14
0
to
17
0
kg
m
101
to
123
ft
lb
torque
and
stake
mainshaft
nut
to
groove
of
main
shaft
with
a
punch
See
Figure
MT49
TM362
Fig
MT
49
Staking
mai
haft
nut
12
Measure
gear
end
play
and
back
lash
Make
sure
that
they
are
held
within
the
specified
values
For
details
refer
to
the
instructions
under
topic
Inspection
Note
The
main
drive
gear
and
coun
ter
driVe
gear
should
be
handled
as
a
matched
set
When
you
replace
a
main
drive
gear
or
counter
drive
gear
be
sure
to
replace
as
a
set
of
main
drive
gear
and
counter
drive
gear
ShUt
fork
nd
fork
rod
mbly
I
Place
1st
2nd
shift
fork
in
groove
in
1st
2nd
coupling
sleeve
and
slide
1st
2nd
fork
rod
through
adapter
plate
and
1st
2nd
shift
fork
Prior
to
installing
1st
2nd
fork
rod
install
3rd
4th
shift
fork
in
groove
in
3rd
4th
coupling
sleeve
Note
Shift
forks
for
1st
2nd
and
3rd
4th
are
one
and
the
same
parts
Make
sure
that
the
long
end
of
shift
fork
for
lot
2nd
is
placed
on
the
counter
gear
side
and
the
long
end
for
3rd
4th
is
on
the
e
side
MT12
Secure
1st
2nd
fork
rod
to
shift
fork
with
a
new
retaining
pin
2
Install
check
ball
check
ball
spring
and
check
ball
plug
Prior
to
tightening
check
ball
plug
apply
sealant
to
check
ball
plug
Align
notch
in
1st
2nd
fork
rod
with
check
ball
See
Figure
MT
50
TM367
Fig
MT
50
l
talling
1st
2nd
fork
rod
3
Slide
3rd
4th
fork
rod
through
adapter
plate
and
3rd
4th
shift
fork
and
secure
with
a
new
retaining
pin
Note
Prior
to
a
mbling
3rd
4th
fork
rod
install
two
2
interlock
balls
into
dap
er
plat
own
in
Figure
MT
16
4
Install
check
ball
and
check
ball
spring
Apply
sealant
to
check
ball
plug
and
install
it
in
place
Align
notch
in
3rd
4th
fork
rod
with
check
ball
by
sliding
3rd
4th
fork
rod
as
necessary
See
Figure
MT51
TM368
Fig
MT
51
Installing
3rd
4th
fork
rod
5
Place
reverse
shift
fork
in
reverse
idler
gear
Slide
reverse
fork
rod
through
re
verse
shift
fork
and
adapter
plate
and
secure
with
a
new
retaining
pin
Note
Prior
to
assembling
reverse
fork
rod
instaU
two
2
interlock
balls
into
adapter
piate
as
shown
in
Figure
MT
I6
6
Install
check
ball
and
check
ball
spring
Apply
sealant
to
check
ball
plug
and
install
it
in
place
Align
notch
in
reverse
fork
rod
with
check
ball
See
Figure
MT
52
TM369
Fig
MT
52
Installing
reverse
fork
rod
7
Torque
each
check
ball
plug
to
1
9
to
2
5
kg
m
14
to
18
ft
Ib
Note
BaD
plug
for
ht
2nd
fork
rod
is
longer
than
those
for
rev
shift
fork
rod
and
3rd
4th
fork
rod
8
Apply
gear
oil
to
all
sliding
sur
faces
and
check
to
see
that
shift
rods
operate
correctly
and
gears
are
engaged
smoothly
TRANSMISSION
ASSEMBLY
Tran
mis
lon
ea
mbly
1
Clean
mating
surfaces
of
adapter
plate
and
transmission
case
Apply
sealant
to
mating
surfaces
of
adapter
plate
and
transmission
case
2
Slide
transmission
case
onto
adapter
plate
by
lightly
tapping
with
a
soft
hammer
until
case
bears
against
adapter
plate
Carefully
install
main
drive
bearing
and
countershaft
front
bearing
Make
certain
that
mainshaft
rotates
freely
3
Fit
main
drive
bearing
snap
ring
to
groove
in
main
drive
bearing
by
using
Expander
See
Figure
MT
53
Manual
Transmission
Fig
MT
53
Fitting
main
drive
bearing
snap
ring
R
ar
xt
nslon
ass
mbly
I
Clean
mating
surfaces
of
adapter
plate
and
fear
extension
Apply
sealant
to
mating
surfaces
of
adapter
plate
and
rear
extension
2
With
fork
rods
in
their
neutral
positions
graduaUy
slide
rear
exten
sion
onto
adapter
plate
making
sure
that
speed
change
cross
lever
engages
with
fork
rod
brackets
correctly
3
Install
washers
and
through
bolts
and
torque
to
1
6
to
2
1
kg
m
12
to
15
ft
lb
Available
shim
Front
eov
r
s
mbly
I
Select
countershaft
front
bearing
shim
as
follows
See
Figure
MT
54
1
Measure
depth
A
from
front
end
of
transmission
case
to
counter
shaft
front
bearing
2
Select
a
shim
of
thickness
A
measured
D
A
JJ
ID
@
2J1
I
Transmission
case
2
Countershaft
front
bearing
3
Countershaft
4
Shim
TM371
Fig
MT
54
Selecting
countershafl
front
bearing
shim
No
A
Countershaft
front
rnm
in
bearing
shim
mm
in
I
2
92
to
3
01
0
1150
to
0
1185
0
6
0
024
2
3
02
to
3
11
0
1189
to
0
1224
0
5
0
020
3
3
12
to
3
21
0
1228
to
0
1264
0
4
0
016
4
3
22
to
3
3
I
0
1268
to
0
1303
0
3
0
012
5
3
32
to
3
41
0
1307
to
0
1343
0
2
0
008
6
3
42
to
3
5
I
0
1346
to
0
1382
0
1
0
004
7
3
52
to
3
61
0
1386
to
0
1421
8
3
62
to
3
71
0
1425
to
0
1461
2
Clean
mating
surfaces
of
front
cover
and
transmission
case
Apply
grease
to
shim
selected
to
retain
it
on
front
cover
install
front
cover
to
transmission
case
with
gasket
in
place
Install
through
bolts
with
washers
under
them
and
tighten
to
1
6
to
2
1
kg
m
12
to
15
ft
lb
torque
Apply
sealant
to
threads
of
through
bolts
before
installation
MT13
3
Install
speedometer
pinion
assem
bly
on
rear
extension
After
making
Sure
that
lock
plate
is
lined
up
with
groove
in
speedometer
pinion
sleeve
install
through
bolts
and
torque
to
0
4
to
0
5
kg
m
3
to
4
ft
lb
4
Install
back
up
lamp
switch
and
torque
to
2
0
to
3
0
kg
m
14
to
22
ft
lb
Be
sure
to
apply
sealant
before
installation
5
Apply
a
light
coat
of
multi
purpose
grease
to
withdrawal
lever
release
bearing
and
bearing
sleeve
in
stall
them
on
clutch
housing
After
connecting
them
with
holder
spring
instaU
dust
cover
on
clutch
housing
6
Install
control
lever
temporarily
and
shift
control
lever
through
all
gears
to
make
sure
that
gears
opera
Ie
smoothly
Note
Install
drain
plug
and
filler
plug
ith
sealant
in
place
Manual
Transmission
INSTALLATION
Install
the
transmission
in
the
reo
verse
order
uf
removal
paying
atten
tion
to
the
following
points
1
Before
installing
dean
mating
surfaces
of
engine
rear
plate
and
trans
mission
case
2
Before
installing
lightly
apply
grease
to
spline
parts
of
clutch
disc
and
main
drive
gear
3
Tighten
bolts
securing
trans
mission
to
engine
to
specifications
See
Figure
MT
55
5
SPEED
TRANSMISSION
TYPE
DESCRIPTION
REMOVAL
DISASSEMBL
Y
TRANSMISSION
CASE
DISASSEMBLY
DISASSEMBL
Y
OF
GEAR
ASSEMBLY
REAR
EXTENSION
DISASSEMBLY
ADAPTER
PLATE
DISASSEMBLY
INSPECTION
TRANSMISSION
CASE
AND
REAR
EXTENSION
HOUSING
DESCRIPTION
The
transmission
is
of
a
5
speed
forward
with
overdrive
4
OD
speed
fully
synchronized
constant
mesh
type
that
uses
helical
gears
The
5
speed
transmission
covered
in
this
section
is
similar
in
all
respects
to
the
4
speed
transmission
type
F4W71B
stated
previously
except
the
CONTENTS
MT14
MT17
MT17
MT17
MT17
MT18
MT19
MT19
4
4
to
5
9
kg
m
32
to
43
ft
Ib
1
0
9
to
1
2
kg
m
7
to
9
rt
lb
TM773
Fig
MT
55
Tightening
torque
4
Remove
filler
plug
and
fIll
trans
mission
with
recommended
gear
oil
to
the
level
of
the
plug
hole
Approxi
mately
I
7
liters
3
pt
3
pt
FS5W71B
BEARING
GEARS
AND
SHAFTS
BAULK
RING
OIL
SEAL
ASSEMBL
Y
FRONT
COVER
ASSEMBLY
REAR
EXTENSION
ASSEMBLY
GEAR
ASSEMBLY
TRANSMISSION
ASSEMBLY
INSTALLATION
MT19
overdrive
position
of
it
The
overdrive
gear
rides
on
the
mainshaft
freely
through
the
needle
roller
bearing
and
counter
overdrive
gear
is
fitted
to
the
countershaft
by
splines
The
overdrive
synchronizer
system
is
on
the
mainshaft
rear
side
MT14
MT19
MT19
MT19
MT19
MT19
MT19
MT19
MT19
MT
20
MT20
Placing
the
control
lever
in
over
drive
position
brings
the
reverse
OD
coupling
sleeve
reverse
gear
on
main
shaft
into
mesh
with
overdrive
clutch
gear
The
reverse
OD
synchronizer
hub
is
fItted
to
the
mainshaft
by
splines
so
the
overdrive
gear
on
main
shaft
turns
together
with
the
main
shaft
Manual
Transmission
@
I
j
b
00
7
@
f
1
Front
cover
2
Front
cover
oil
seal
3
Front
cover
gasket
4
Transmission
case
5
Adapte
plate
6
Maimhaft
bearing
7
Bearing
retainer
8
Rear
extension
9
Breather
10
Rear
extension
oil
seal
11
Sleeve
yoke
dust
cover
f
@3
TM046A
Fig
MT
56
FS5W71B
transmission
case
components
MT15
Manual
Transmission
j
W
h
I
l
1
Main
drive
gear
2
Baulk
ring
3
Shifting
insert
4
Shifting
insert
spring
5
Synchronir
c
r
hub
6
Coupling
slee
7
3rd
main
gear
g
Needle
bearing
9
Mainshaft
10
2nd
main
gear
11
Bushing
12
1st
main
gear
13
O
revcrse
synchronizer
hub
14
Rever
gear
15
Circlip
16
Thrwt
block
t
7
Brake
band
18
Synchronizer
ring
19
Overdrive
main
gear
20
Overdrive
gear
bushing
21
Washer
22
Mainshaft
nut
13
Overdrive
mainshaft
bearing
24
Speedometer
drive
gear
25
COlplteBhaft
fr
mt
bearing
shim
26
Countershaft
front
bearing
27
Countershaft
drive
gear
28
Coontcrshaft
29
Countershaft
bearing
30
Reverse
counter
gear
spacer
31
Rever
C
counter
gear
32
rdrive
counter
gear
33
Countershaft
zear
bearing
34
C
untershaft
nut
3S
Reverse
idler
lIhaCt
36
Reverse
idlcrthrust
washer
37
Reverse
idler
gear
38
Reye
nc
idler
gear
bearing
39
Reverse
idler
thrust
w8
her
TM041A
MT
16
Fig
MT
51
FS5W11B
tru
miasion
gear
componenta
Manual
Transmission
CD
t
e
I
2
3
4
5
6
7
8
9
10
11
12
13
14
17
18
19
O
20
o
21
24
25
j
@
Striking
lever
Lock
pin
Q
ring
Striking
guide
Oil
seal
Striking
rod
Expansion
plug
Stopper
guide
pin
Return
spring
Return
spring
plug
Return
spring
plunger
Check
ball
plUS
Check
spring
Check
ball
Retaining
pin
Interlock
ball
ist
2nd
shift
fork
1st
2nd
fork
rod
3rd
4th
fork
rod
Reverse
OD
fork
rod
3rd
4th
shift
fork
Revene
OD
shift
fork
Con
trol1ever
Con
trol1cver
pin
Con
trollever
bushing
TM048A
Fig
MT
58
FS5W71B
trammi
ion
shift
control
component
3
Draw
out
counter
drive
gear
com
plete
with
main
drive
gear
assembly
by
means
of
a
gear
puller
When
drawing
out
main
drive
gear
assembly
be
careful
not
to
drop
pilot
needle
bearing
onto
floor
from
the
front
end
of
mainshaft
See
Figure
MT
60
REMOVAL
Same
as
for
the
F4W71B
DISASSEMBLY
TRANSMISSION
CASE
DISASSEMBLY
Same
as
for
the
F4W71
B
DISASSEMBLY
OF
GEAR
ASSEMBLY
Fork
rod
Same
as
for
the
F4W71
B
Geer
sembi
I
With
gears
doubly
engaged
draw
out
counte
haft
front
bearing
using
a
suitable
gear
puller
See
Figure
MT
59
2
Remove
counter
drive
gear
snap
ring
TM398
Fig
MT
59
Removing
countershaft
front
bearing
MT
17
TM756
Fig
MT
60
Removing
counter
drive
gear
and
main
drive
gear
4
Rem6vesnap
ring
and
then
thrust
washer
from
mainshaft
front
end
Draw
out
3rd
4th
synchronizer
assembly
and
remove
3rd
gear
assem
bly
5
Remove
snap
ring
and
then
draw
out
speedometer
gear
and
bearing
from
mainshaft
rear
side
6
With
gea
doubly
engaged
re
lease
caulking
on
countershaft
and
mainshaft
nuts
then
loosen
them
Remove
countershaft
nut
TM757
Fig
MT
61
Removing
counterahaft
nut
Note
When
removing
mainshaft
as
sembly
loosen
mainshaft
nut
7
Draw
out
counter
overdrive
gear
and
bearing
from
countershaft
rear
end
by
using
a
suitable
gear
puller
See
Figure
MT
62
TM758
Fig
MT
62
Removing
count
r
overdriv
gear
and
bearing
8
Remove
counter
reverse
idler
gear
and
spacer
9
Remove
countershaft
by
lightly
tapping
the
rear
end
with
a
soft
hammer
Be
careful
not
to
drop
off
gear
shaft
10
Remove
reverse
idler
gear
snap
ring
TM759
Fig
MT
63
Removing
reverse
idler
gear
nap
ring
Manual
Transmission
II
Remove
reverse
idler
gear
12
Remove
snap
ring
of
mainshaft
end
bearing
Draw
out
bearing
using
Mainshaft
Rear
Bearing
Puller
KV32101330
Remove
other
snap
ring
of
mainshafl
end
bearing
See
Figure
MT
64
tw
KV32101330
TM160
Fig
MT
64
Removing
mai
haft
nd
bearing
13
Remove
mainshaft
nut
thrust
washer
mainshaft
reverse
gear
OD
synchronizer
and
overdrive
gear
14
Draw
out
mainshaft
gear
assem
bly
together
with
countershaft
by
lightly
tapping
the
rear
end
with
a
soft
hainmer
Me
holding
the
front
of
mainshaft
gear
assembly
by
hand
Be
careful
not
to
drop
off
gear
shaft
See
Figure
MT
65
k
r
IT
TM761
Fig
MT
65
Driving
out
gear
sembly
Malnahaft
Same
as
for
the
F4W7IB
Main
drive
ear
Same
as
for
the
F4W71
B
Counterahaft
aaaembly
Same
as
for
the
F4W7l
B
REAR
EXTENSION
DISASSEMBLY
Remove
lock
pin
from
striking
lever
and
remove
siriking
rod
Note
Do
not
disassemble
rear
exten
sion
bushing
from
rear
extension
J
l
J
@
1
Striking
lever
2
Striking
rod
3
Stopper
pin
4
Control
lever
5
Striking
rod
guide
6
Reverse
select
plunger
7
Reverse
select
plug
TM767
Fig
MT
66
Exploded
view
of
shifting
mechanilm
MT1B