Page 1937 of 4179

PREPARATION
MT-5
D
E
F
G
H
I
J
K
L
MA
B
MT
ST33052000
Drift
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 input gear bushing, thrust washer, 4th
input gear, 4th gear bushing, 3rd-4th
synchronizer hub assembly and 3rd input
gear removal
Input shaft front bearing installation
6th input gear and 6th input gear bushing
removal (RS6F51A)
Mainshaft rear bearing removal
4th main gear and 5th main gear removal
6th main gear removal (RS6F51A)
KV40105020
Drift
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 5th synchronizer hub
assembly removal
3rd main gear, 2nd main gear, 2nd main
gear bushing, 1st-2nd synchronizer hub
assembly, 1st main gear, reverse main gear
and 1st main gear bushing removal
KV40105710
Press stand
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in)
3rd-4th synchronizer hub assembly
installation
4th input gear bushing installation
5th input gear bushing installation
5th synchronizer hub assembly installation
(RS5F51A)
5th-6th synchronizer hub assembly
installation (RS6F51A)
2nd main gear bushing installation
3rd main gear installation
ST38220000
Press stand
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)
Reverse main gear installation
1st main gear bushing installation
1st-2nd synchronizer hub assembly
installation
ST30032000
Drift
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
ST30901000
Drift
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 number
Tool nameDescription
ZZA1023D
ZZA1133D
ZZA1058D
ZZA1058D
ZZA0978D
ZZA0978D
Page 1938 of 4179
MT-6
PREPARATION
Commercial Service ToolsECS008BO
ST30031000
PullerMeasuring wear of inner baulk ring
KV40101630
Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.Reverse main gear installation
KV38102510
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
1st main gear bushing installation
1st-2nd synchronizer hub assembly
installation
Differential side bearing (transaxle case
side) installation
KV40104830
Drift
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.500 in) dia.Differential side bearing (clutch housing side)
installation
ST15243000
Drift
a: φ 30mmMeasuring end play of side gear Tool number
Tool nameDescription
ZZA0537D
ZZA1003D
ZZA0838D
ZZA0936D
SCIA1088J
Tool nameDescription
PullerEach bearing, gear and bushing removal
ZZA0537D
Page 1939 of 4179
PREPARATION
MT-7
D
E
F
G
H
I
J
K
L
MA
B
MT
PullerEach bearing, gear and bushing removal
Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.Each retaining pin removal and installation Tool nameDescription
NT077
ZZA0815D
Page 1940 of 4179

MT-8
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
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-37
MT-19
(RS5F51A), MT-24
(RS6F51A)
MT-19
(RS5F51A), MT-24
(RS6F51A)
MT-19
(RS5F51A), MT-24
(RS6F51A)
MT-14
MT-22
(RS5F51A), MT-27
(RS6F51A)
MT-22
(RS5F51A), MT-27
(RS6F51A)
MT-20
(RS5F51A), MT-25
(RS6F51A)
MT-20
(RS5F51A), MT-25
(RS6F51A)
MT-20
(RS5F51A), MT-25
(RS6F51A)
MT-20
(RS5F51A), MT-25
(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 31222
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3
Page 1941 of 4179

DESCRIPTION
MT-9
D
E
F
G
H
I
J
K
L
MA
B
MT
DESCRIPTIONPFP:00000
Cross-Sectional ViewECS008BQ
1. 3rd input gear 2. 3rd-4th synchronizer hub 3. 3rd-4th coupling sleeve
4. 4th input gear 5. 5th input gear 6. 5th synchronizer hub
7. 5th coupling sleeve 8. Input shaft rear bearing 9. Mainshaft rear bearing
10. 5th main gear 11. 4th main gear 12. 3rd main gear
13. 2nd main gear 14. 1st-2nd coupling sleeve 15. 1st-2nd synchronizer hub
16. 1st main gear 17. Reverse main gear 18. Differential side bearing
19. Differential case 20. Final gear 21. Differential side bearing
22. Mainshaft front bearing 23. Mainshaft 24. Input shaft
25. Input shaft front bearing 26. Clutch housing 27. Reverse idler shaft
28. Reverse idler gear (Front) 29. Reverse coupling sleeve 30. Reverse synchronizer hub
31. Reverse idler gear (Rear) 32. 5th input gear 33. 5th-6th synchronizer hub
34. 5th-6th coupling sleeve 35. 6th input gear 36. Input shaft rear bearing
37. Mainshaft rear bearing 38. 5th main gear 39. 6th main gear
PCIB0773E
Page 1942 of 4179
MT-10
DESCRIPTION
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 1st gear to reduce operating force of the shift lever.
TRIPLE-CONE SYNCHRONIZER
Triple-cone synchronizer is adopted for 2nd gear to reduce operating force of the shift lever.
REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)
Reverse gear can be matched smoothly in a structure by setting syn-
chronizer hub, coupling sleeve, baulk ring and insert spring to
reverse gear, and letting reverse gear be synchronized.
PCIB0774E
PCIB0775E
Page 1943 of 4179

M/T OIL
MT-11
D
E
F
G
H
I
J
K
L
MA
B
MT
M/T OILPFP:KLD20
Changing M/T OilECS008BR
DRAINING
1. Start engine and let it run to warm up transaxle.
2. Stop engine. Remove drain plug and drain oil.
3. Set a new gasket on drain plug and install it to transaxle. Refer to MT-19, "
CASE AND HOUSING COM-
PONENTS" , MT-24, "CASE AND HOUSING COMPONENTS" .
CAUTION:
Do not reuse gasket.
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole.
2. After refilling oil, check oil level. Assemble a new gasket to filler plug, then install it to transaxle. Refer to
MT-19, "
CASE AND HOUSING COMPONENTS" , MT-24, "CASE AND HOUSING COMPONENTS" .
CAUTION:
Do not reuse gasket.
Checking M/T OilECS008BS
OIL LEAKAGE AND OIL LEVEL
Check that oil is not leaking from transaxle or around it.
Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Never start engine while checking oil level.
Set a new gasket on filler plug and install it on transaxle. Refer
to MT-19, "
CASE AND HOUSING COMPONENTS" , MT-24,
"CASE AND HOUSING COMPONENTS" .
CAUTION:
Do not reuse gasket.Oil grade : API GL-4
Oil capacity (reference)
: Approx. 2.3 (4 lmp pt)
SCIA0361E
Page 1944 of 4179
MT-12
SIDE OIL SEAL
SIDE OIL SEALPFP:32113
Removal and InstallationECS008BT
REMOVAL
Clutch housing side oil seal used on 4WD vehicles is attached to transfer. Be sure to replace it
when transfer is removed.
1. Remove drive shaft from transaxle. Refer to FAX-11, "
Removal and Installation" .
2. Remove oil seal with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage the case surface when removing
oil seal.
INSTALLATION
1. Using a drift, drive the oil seal straight until it protrudes from the
case end equal to dimension A shown in the figure.
CAUTION:
When installing oil seals, apply multi-purpose grease to
oil seal lips.
Oil seals are not reusable. Never reuse them.
2. Install all parts in reverse order of removal and check oil level after installation. Refer to MT-11, "
Checking
M/T Oil" .
SCIA0824E
Dimension "A":
Within 0.5 mm (0.020 in) of flush with the case.
Drift to be used:
Transaxle case side: ST30720000
Clutch housing side: ST30720000
SCIA0352E