5SPEED TRANSMISSION [Model: BW T-5 (FS5R90A)l
REAR EXTENSION
DISASSEMBLY
1
2 Drain oil
3
damper sleeve
Wipe off drt and grease
Remove sluft lever assembly and
4 Remove pm from offset lever
-.. - ._
'.* .I El
-.. n
5 Remove rear extension, offset
lever, detent
spnng and ball by tappmg
it
7
When disassembling rear extension,
be careful not to lose thrust race
and funnel.
INSPECTION
1 Clean with solvent and check for
cracks
2 Check mating surface of rear
extension for small nicks, prolec-
tions or sealant
If the rear extension bushing or guide
plate are worn, cracked or broken,
replace them as an assembly of bush-
ing, guide plate and rear extension
housing.
ASSEMBLY
1 Clean matmg surfaces of case and
rear extension
2 Apply a contmuous bead of
sealant to the matmg surface of the
case
3 Retam the needle thrust bearmg,
race and funnel
to the rear of the
countershaft with Petroleum Jelly
4 Place detent ball, spnng and offset
lever mto position on guide plate and
install extension houslng to the
transmission case
5 Ahgn the hole ?n the shifter shaft
with the hole
m the offset lever and
mstall the retammg pm
MT-23
6 Install rear extenQon bolts to
transmission case
0 : 27 - 62 Nm
(2 8 -6 3 kg-m,
20 - 46 ft-lb)
7 Apply a contmuous bead of
sealant to shlft cover opening of
rear extension
8 Assemble damper sleeve mto
offset lever and install shlft lever
@ :20-34Nm
(2.0 - 3.5 kgm,
14 .25 ft-lb)
9 Make sure that gears operate
smoothly
10 Apply sealant to thread and
install dram plug
0.20 - 34 N m
(2 0 - 3.5 kg-m,
14
- 25 ft-lb)
CASE COVER
DISASSEMBLY
1 Remove rear extension Refer to
rear extension for disassembly
2 Remove cover bolts and cover
by tapping it with dnver Shde cover
to nght side of case and hft
3 Pull shifter shaft to rear and re-
move stnkmg lever to shlfter shaft
roll pm
5SPEED TRANSMISSION [Model: BW T-5 (FS5R90A)I
4 Remove shifter shaft through rear
of case cover
5 Slide selector plates from shift
fork assembhes
. __ - - . . I
INSPECTION
1 Clean with solvent and check for
wear, scratches, projections, damage,
breakage
or other faulty conditions
Replace any part whch is worn or
damaged
2 Inspect shft fork inserts for wear
or damage Replace if necessary
ASSEMBLY
I Assemble selector plates to sluft
fork assembhes
2 Install shifter shaft through open-
mg m rear of case cover and assemble
to
1-2 duft fork, mterlock plate,
strkmg lever and
3-4 sluft fork
Install shfter shaft roll pin
to stnkmg
lever
3 Apply a contmuous bead of
sealant to case cover matlng surface
4 Install cover to case
5 Apply sealant to threads and
install two ahgnment dowels into
cover
6 Apply sealant to threads and
install case cover bolts
@ : 8.1 - 14.7 N m
(0.83 - 1.5 kg-m,
6.0 - 10 8 ft-lb)
7 Install rear extension Refer to
rear extension for assembly
TRANSMISSION CASE
DISASSEMBLY
1 Remove rear extenson Refer to
rear extension for disassembly
2 Remove case cover Refer to case
cover for disassembly
3 Remove back-up hght swltch
4 Remove retamer rmg and pivot
Pm
5 Remove funnel, thrust race, and
needle thrust beanng
6 Remove snap nng and thrust
race from rear
of 5th speed synchro-
nuer hub
MT-24
7 Remove pin from 5th speed hft
fork
8 Remove 5th speed shift fork,
synchronizer and counter gear
9 Remove front bearmg retamer
10 Remove mput shaft and mam
drive gear assembly Position flat area
of mam drive gear toward the counter
gear and remove
through the front
of the case
