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7. Using a drift (special service tool), install differential side bearing
(transaxle case side).
8. Using a drift (special service tool), install differential side bearing
(clutch housing side).
9. Install differential gear into differential case, and tighten final
gear mounting bolts.
Assembly and Disassembly (RS6F51A)ECS004UW
PRE-INSPECTION
lCheck the clearance between side gear and differential case as
follows.
1. Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
2. Upright the differential case so that the side gear to be measured faces upward.
SCIA0910E
SCIA0911E
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FINAL DRIVE
3. Place final drive adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.
4. If not within specification, adjust the clearance by changing
thrust washer thickness.
5. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
DISASSEMBLY
1. Remove mounting bolts.Then, separate the final gear from differential case.
2. Using a drift and puller, remove differential side bearing (clutch
housing side).
3. Using a drift and puller, remove differential side bearing (tran-
saxle case side).
4. Using a pin punch, pull out lock pin and pinion mate shaft.
5. Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.Clearance between side gear and differential case
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
SCIA0906E
SCIA0907E
SCIA0908E
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INSPECTION AFTER DISASSEMBLY
Gear, Washer, Shaft and Case
lCheck side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.
Bearing
lCheck for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
ASSEMBLY
1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.
2. Install side gear thrust washers and side gears into differential
case.
3. While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.
4. Insert pinion mate shaft into differential case.
CAUTION:
Be sure not to damage pinion mate thrust washers.
MTK0135D
SPD715
SMT839
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FINAL DRIVE
5. Measure end play of side gears following procedure below.
Then select side gear thrust washer.
a. Upright the differential case so that its side gear to be measured
faces upward.
b. Place final drive adapter and dial gauge onto side gears.
c. Move side gears up and down to measure end play, and select
thrust washer so that it satisfies standard.
CAUTION:
Place differential case upside down. Be sure to measure
end play for opposite side-gears likewise.
Thrust washer
CAUTION:
Only one thrust washer can be selected.
6. Using a pin punch (special service tool), drive a lock pin into the
pinion mate shaft.
CAUTION:
Do not reuse the lock pin.
7. Using a drift (special service tool), install differential side bearing
(transaxle case side).
SMT610AG
Endplaystandardvalue
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
Thickness Part number
0.75 mm (0.0295 in)
0.80 mm (0.0315 in)
0.85 mm (0.0335 in)
0.90 mm (0.0354 in)
0.95 mm (0.0374 in)38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04
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8. Using a drift (special service tool), install differential side bearing
(clutch housing side).
9. Install differential gear into differential case, and tighten final
gear mounting bolts.
SCIA0911E
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MT-94
SHIFT CONTROL
SHIFT CONTROL
PFP:32982
Inspection (RS5F51A)ECS004US
lCheck contact surfaces and sliding area for wear, damage,
bending, etc. If necessary, replace parts.
SHIFT FORK
lCheck if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
SCIA0913E
Item One-side wear specification Sliding width of new part
1st & 2nd 0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd & 4th 0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th 0.2 mm (0.008 in)6.10 - 6.23 mm
(0.2402 - 0.2453 in)
Reverse 0.2 mm (0.008 in)12.80 - 12.93 mm
(0.5039 - 0.5091 in)
SMT801D
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SHIFT CONTROL
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Inspection (RS6F51A)ECS004UX
lCheck contact surfaces and sliding area for wear, damage,
bending, etc. If necessary, replace parts.
SHIFT FORK
lCheck if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
SCIA0913E
Item One-side wear specification Sliding width of new part
1st & 2nd 0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd & 4th 0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th & 6th 0.2 mm (0.008 in)6.10 - 6.23 mm
(0.2402 - 0.2453 in)
Reverse 0.2 mm (0.008 in)12.80 - 12.93 mm
(0.5039 - 0.5091 in)
SMT801D
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MT-96
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
General SpecificationsECS004PE
TRANSAXLE
Engine QR20DE YD22DDTi
Transaxle model RS5F51A RS6F51A
Model code number 8H500 8H868
Number of speed 5 6
Synchromesh typeWarner
Shift pattern
Gear ratio 1st 3.500
2nd 1.9440
3rd 1.258
4th 0.947
5th 0.772
6th — 0.630
Reverse 3.374
Number of teeth Input gear 1st 14
2nd 18
3rd 31
4th 38
5th 44
6th — 46
Reverse 14
Main gear 1st 49
2nd 35
3rd 39
4th 36
5th 34
6th — 29
Reverse 38
Reverse idler gearFront 37
Rear 46
Oil capacity
(Imp pt)2.3 (4)
RemarksReverse synchronizer Installed
Double baulk ring type synchronizer 1st & 2rd synchronizer
SCIA0821ESCIA0955E