Page 1977 of 3833

MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
D
E
F
G
H
I
J
K
L
M
SECTION
A
B
MT
MANUAL TRANSAXLE
PRECAUTIONS .......................................................... 3
Caution ..................................................................... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 6
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 7
NVH Troubleshooting Chart ..................................... 7
MANUAL TRANSAXLE ......................................... 7
DESCRIPTION ............................................................ 8
Cross-Sectional View ............................................... 8
DOUBLE-CONE SYNCHRONIZER ...................... 9
REVERSE GEAR NOISE PREVENTION FUNC-
TION (SYNCHRONIZING METHOD) ................... 9
M/T OIL ..................................................................... 10
Changing M/T Oil ................................................... 10
DRAINING ........................................................... 10
FILLING ............................................................... 10
Checking M/T Oil .................................................... 10
OIL LEAKAGE AND OIL LEVEL ......................... 10
SIDE OIL SEAL .........................................................11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
POSITION SWITCH .................................................. 12
Checking ................................................................ 12
BACK-UP LAMP SWITCH .................................. 12
PARK/NEUTRAL POSITION SWITCH ............... 12
CONTROL LINKAGE ............................................... 13
Removal and Installation of Control Device and
Cable ...................................................................... 13
AIR BREATHER HOSE ............................................ 14
Removal and Installation ........................................ 14
TRANSAXLE ASSEMBLY ........................................ 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
Component Parts (RS5F51A) ................................ 17CASE AND HOUSING COMPONENTS .............. 17
GEAR COMPONENTS ....................................... 18
SHIFT CONTROL COMPONENTS ..................... 20
FINAL DRIVE COMPONENTS ........................... 21
Component Parts (RS6F51A) ................................. 22
CASE AND HOUSING COMPONENTS .............. 22
GEAR COMPONENTS ....................................... 23
SHIFT CONTROL COMPONENTS ..................... 25
FINAL DRIVE COMPONENTS ........................... 26
Disassembly and Assembly (RS5F51A) ................. 26
DISASSEMBLY ................................................... 26
ASSEMBLY ......................................................... 30
Disassembly and Assembly (RS6F51A) ................. 35
DISASSEMBLY ................................................... 35
ASSEMBLY ......................................................... 39
Adjustment (RS5F51A) ........................................... 45
INPUT SHAFT END PLAY .................................. 45
MAINSHAFT END PLAY ..................................... 46
DIFFERENTIAL SIDE BEARING PRELOAD ...... 47
REVERSE IDLER GEAR END PLAY .................. 48
Adjustment (RS6F51A) ........................................... 49
INPUT SHAFT END PLAY .................................. 49
MAINSHAFT END PLAY ..................................... 50
DIFFERENTIAL SIDE BEARING PRELOAD ...... 51
REVERSE IDLER GEAR END PLAY .................. 52
INPUT SHAFT AND GEARS .................................... 54
Assembly and Disassembly (RS5F51A) ................. 54
DISASSEMBLY ................................................... 54
INSPECTION AFTER DISASSEMBLY ................ 55
ASSEMBLY ......................................................... 57
Assembly and Disassembly (RS6F51A) ................. 61
DISASSEMBLY ................................................... 61
INSPECTION AFTER DISASSEMBLY ................ 62
ASSEMBLY ......................................................... 64
MAINSHAFT AND GEARS ....................................... 68
Assembly and Disassembly (RS5F51A) ................. 68
DISASSEMBLY ................................................... 68
INSPECTION AFTER DISASSEMBLY ................ 69
Page 1978 of 3833

MT-2
ASSEMBLY ......................................................... 71
Assembly and Disassembly (RS6F51A) ................. 76
DISASSEMBLY ................................................... 76
INSPECTION AFTER DISASSEMBLY ................ 77
ASSEMBLY ......................................................... 79
REVERSE IDLER SHAFT AND GEARS .................. 84
Assembly and Disassembly (RS5F51A) ................. 84
DISASSEMBLY ................................................... 84
INSPECTION AFTER DISASSEMBLY ................ 84
ASSEMBLY ......................................................... 85
Assembly and Disassembly (RS6F51A) ................. 85
DISASSEMBLY ................................................... 85
INSPECTION AFTER DISASSEMBLY ................ 85
ASSEMBLY ......................................................... 86
FINAL DRIVE ............................................................ 87
Assembly and Disassembly (RS5F51A) ................. 87
PRE-INSPECTION .............................................. 87
DISASSEMBLY ................................................... 87
INSPECTION AFTER DISASSEMBLY ................ 88
ASSEMBLY ......................................................... 88
Assembly and Disassembly (RS6F51A) ................. 90
PRE-INSPECTION .............................................. 90
DISASSEMBLY ................................................... 91
INSPECTION AFTER DISASSEMBLY ................ 92
ASSEMBLY ......................................................... 92
SHIFT CONTROL ...................................................... 95
Inspection (RS5F51A) ............................................ 95
SHIFT FORK ....................................................... 95
Inspection (RS6F51A) ............................................ 96
SHIFT FORK ....................................................... 96SERVICE DATA AND SPECIFICATIONS (SDS) ...... 97
General Specifications ......................................... ... 97
TRANSAXLE ........................................................ 97
FINAL GEAR ........................................................ 98
Gear End Play ......................................................... 98
Clearance Between Baulk Ring and Gear .............. 98
3RD,4TH,5TH,6TH & REVERSE BAULK RING ... 98
1ST AND 2ND DOUBLE BAULK RING ............... 98
Available Snap Rings ........................................... ... 99
INPUT SHAFT SPACER ...................................... 99
6TH BUSHING ..................................................... 99
5TH MAIN GEAR ................................................. 99
Available C-Rings ................................................... 99
MAINSHAFT C-RING .......................................... 99
Available Thrust Washer .......................................100
INPUT SHAFT THRUST WASHER ...................100
DIFFERENTIAL SIDE GEAR THRUST WASHER
.100
Available Adjusting Shims .....................................100
MAINSHAFT ADJUSTING SHIM .......................100
INPUT SHAFT REAR BEARING ADJUSTING
SHIM ..................................................................101
MAINSHAFT REAR BEARING ADJUSTING
SHIM ..................................................................101
REVERSE IDLER GEAR ADJUSTING SHIM ....101
6TH MAIN GEAR ADJUSTING SHIM ................101
Available Shims ....................................................102
BEARING PRELOAD .........................................102
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) .............................................................102
Page 1979 of 3833
PRECAUTIONS
MT-3
D
E
F
G
H
I
J
K
L
MA
B
MT
PRECAUTIONSPFP:00001
CautionECS008BM
●Do not reuse transaxle oil, once it has been drained.
●Check oil level or replace oil with vehicle on level ground.
●During removal or installation, keep inside of transaxle 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.
Page 1980 of 3833

MT-4
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsECS008BN
Tool name
Tool numberDescription
Puller
KV381054S0
●Side bearing outer race removal
●Mainshaft front bearing removal
Drift
ST35321000
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
●Input shaft oil seal installation
●Reverse main gear installation
●1st bushing installation
●1st-2nd synchronizer hub installation
●2nd bushing installation
●3rd main gear installation
●Differential side bearing removal
Drift
ST30720000
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
●Differential oil seal installation
●Differential side bearing outer race
installation
●Mainshaft rear bearing installation
●Differential side bearing installation
Drift
ST33200000
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
●Mainshaft front bearing installation
●6th bushing installation (RS6F51A)
●4th main gear installation
●5th main gear installation
●6th main gear installation (RS6F51A)
Drift
KV40105320
a: 88 mm (3.46 in) dia.
●Differential side bearing outer race
installation
Drift
ST33061000
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
●Bore plug installation
●Differential side bearing removal
ZZA0601D
ZZA1000D
ZZA0811D
ZZA1002D
ZZA0898D
ZZA1000D
Page 1981 of 3833

PREPARATION
MT-5
D
E
F
G
H
I
J
K
L
MA
B
MTDrift
ST33052000
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
●Welch plug installation
●Input shaft rear bearing removal
●Input shaft bearing spacer and 5th stopper
removal (RS5F51A)
●5th bushing, thrust washer, 4th input gear,
4th gear bushing, 3rd-4th synchronizer hub
and 3rd input gear removal
●Input shaft front bearing installation
●6th input gear and 6th bushing removal
(RS6F51A)
●Mainshaft rear bearing removal
●4th main gear and 5th main gear removal
●6th main gear removal (RS6F51A)
Drift
KV40105020
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)
●5th input gear and synchronizer hub
removal
●3rd main gear, 2nd main gear, 2nd bushing,
1st-2nd synchronizer hub, 1st main gear,
reverse main gear and 1st bushing removal
Press stand
KV40105710
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in)
●3rd-4th synchronizer hub installation
●4th bushing installation
●5th bushing installation
●5th synchronizer hub installation
(RS5F51A)
●5th-6th synchronizer hub installation
(RS6F51A)
●2nd bushing installation
●3rd main gear installation
Press stand
ST38220000
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)
●Reverse main gear installation
●1st bushing installation
●1st-2nd synchronizer hub installation
Drift
ST30032000
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.
●5th stopper and input shaft bearing spacer
installation (RS5F51A)
●Input shaft front bearing installation
Drift
ST30901000
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
●Input shaft rear bearing installation
●4th main gear installation
●5th main gear installation
●6th main gear installation (RS6F51A)
●Mainshaft rear bearing installation Tool name
Tool numberDescription
ZZA1023D
ZZA1133D
ZZA1058D
ZZA1058D
ZZA0978D
ZZA0978D
Page 1982 of 3833
MT-6
PREPARATION
Commercial Service Tools
ECS008BO
Puller
ST30031000●Measuring wear of 1st and 2nd baulk ring
Drift
KV40101630
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.
●Reverse main gear installation
Drift
KV38102510
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
●1st bushing installation
●1st-2nd synchronizer hub installation
●Differential side bearing installation
Drift
KV40104830
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.500 in) dia.
●Differential side bearing installation Tool name
Tool numberDescription
ZZA0537D
ZZA1003D
ZZA0838D
ZZA0936D
Tool nameDescription
PullerEach bearing gear and bushing removal
PullerEach bearing gear and bushing removal
Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.Each retaining pin removal and installation
ZZA0537D
NT077
ZZA0815D
Page 1983 of 3833

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
MT-7
D
E
F
G
H
I
J
K
L
MA
B
MT
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartECS008BP
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.
MANUAL TRANSAXLE
Reference pageMA-35
MT-17
(RS5F51A), MT-22
(RS6F51A)
MT-17
(RS5F51A), MT-22
(RS6F51A)
MT-17
(RS5F51A), MT-22
(RS6F51A)
MT-13
MT-20
(RS5F51A), MT-25
(RS6F51A)
MT-20
(RS5F51A), MT-25
(RS6F51A)
MT-18
(RS5F51A), MT-23
(RS6F51A)
MT-18
(RS5F51A), MT-23
(RS6F51A)
MT-18
(RS5F51A), MT-23
(RS6F51A)
MT-18
(RS5F51A), MT-23
(RS6F51A)
SUSPECTED PARTS
(Possible cause)
OIL (Oil level is low.)
OIL (Wrong oil.)
OIL (Oil level is high.)
GASKET (Damaged)
OIL SEAL (Worn or damaged)
O-RING (Worn or damaged)
SHIFT CONTROL LINKAGE (Worn)
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
SHIFT FORK (Worn)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
BAULK RING (Worn or damaged)
INSERT SPRING (Damaged)
SymptomsNoise 1 2 3 3
Oil leakage 3 1 2 2 2
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3
Page 1984 of 3833
MT-8
DESCRIPTION
DESCRIPTION
PFP:00000
Cross-Sectional ViewECS008BQ
SCIA0749E