Page 2737 of 2870
5MT-25
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
899824100 PRESS Used for installing speedometer shaft oil seal.
499987100 SOCKET WRENCH
(35)Used for removing and installing drive pinion lock
nut.
899984103 SOCKET WRENCH
(35)Used for removing and installing drive pinion lock
nut.
498057300 INSTALLER Used for installing extension oil seal. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-899824100
ST-499987100
ST-899984103
ST-498057300
Page 2738 of 2870
5MT-26
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
498255400 PLATE Used for measuring backlash.
498077400 SYNCHRONIZER
CONE REMOVER Used for removing synchronizer cone of main
shaft.
Used for removing 5th driven gear of drive pin-
ion shaft.
41099AA010 ENGINE SUPPORT
BRACKETUsed for supporting engine.
41099AA020 ENGINE SUPPORT Used for supporting engine. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498255400
ST-498077400
ST41099AA010
ST41099AA020
Page 2739 of 2870
5MT-27
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
398527700 PULLER ASSY Used for removing extension case roller bear-
ing.
Used for removing front differential side
retainer bearing outer race.
Used for removing front differential side
retainer oil seal.
398643600 GAUGE Used for measuring total end play, extension end
play and drive pinion height.
398177700 INSTALLER Used for installing bearing cone of transfer
driven gear (transfer case side).
Used for installing ball bearing of transfer drive
gear.
398507703 DUMMY COLLAR Used for installing input shaft holder oil seal.
For dual-range model. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-398527700
ST-398643600
ST-398177700
ST-398507703
Page 2740 of 2870
5MT-28
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
398663600 PLIERS Used for removing and installing input shaft
snap ring.
For dual-range model.
499757001 SNAP RING GUIDE Used for installing snap ring (OUT 25).
For dual-range model.
899858600 RETAINER Used for removing ball bearing.
For dual-range model.
899474100 EXPANDER Used for removing and installing snap ring.
For dual-range model. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-398663600
ST-499757001
ST-899858600
ST-899474100
Page 2741 of 2870
5MT-29
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
899580100 INSTALLER Used when pressing ball bearings into input
shaft.
For dual-range model.
399513600 INSTALLER Used when pressing ball bearings into input
shaft.
For dual-range model.
28399SA000 FRONT DRIVE
SHAFT REMOVERUsed for removing front drive shaft. (Commonly
used for MT model and AT model)
28399SA010 FRONT DRIVE
SHAFT OIL SEAL
PROTECTORUsed for protecting oil seal when installing front
drive shaft. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-899580100
ST-399513600
ST28399SA000
ST28399SA010
Page 2742 of 2870
5MT-30
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
2. GENERAL TOOL
18675AA000 DIFFERENTIAL
SIDE OIL SEAL
INSTALLERUsed for installing differential side retainer oil
seal.
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and ampere.ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST18675AA000
Page 2743 of 2870

5MT-31
MANUAL TRANSMISSION AND DIFFERENTIAL
Transmission Gear Oil
2. Transmission Gear Oil
A: INSPECTION
1) Park the vehicle on a level surface.
2) Turn the ignition switch to OFF, and wait until the
engine cools.
3) Remove the oil level gauge and wipe it clean.
4) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper direction.
5) Pull out the oil level gauge again and check the
oil level on it. If it is below the lower level, add oil
through the oil level gauge hole to bring the level up
to the upper level.
B: REPLACEMENT
1) Pull out the oil level gauge.
2) Lift-up the vehicle.
3) Drain the transmission gear oil completely.
CAUTION:
Directly after the engine has been running,
the transmission gear oil is hot. Be careful not
to burn yourself.
Be sure not to spill the transmission gear oil
on exhaust pipe to prevent it from emitting
smoke or firing. When the transmission gear oil
is split on exhaust pipe, wipe it away complete-
ly.4) Tighten the transmission gear oil drain plug us-
ing a new gasket.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gas-
ket)
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)
5) Lower the vehicle.
6) Pour gear oil into the gauge hole.
Recommended gear oil:
Use GL-5 (75 W — 90) or equivalent.
Gear oil capacity:
Single-range model;
Model without oil pump
3.52 (3.7 US qt, 3.1 Imp qt)
Model with oil pump
3.92 (4.1 US qt, 3.4 Imp qt)
Dual-range model;
4.02 (4.2 US qt, 3.5 Imp qt)
7) Measure the level of transmission gear oil, and
then check the level within the specified range.
CAUTION:
When inserting the level gauge into transmis-
sion gear, align the protrusion on the side of
the top part of level gauge with the notch in the
gauge hole.
(A) Oil level gauge
(B) Upper level
(C) Lower level
PM-00030
(B)
(C) (A)
(A) Drain plug
(B) Gasket
MT-00061
(A) (B)
Page 2744 of 2870

5MT-32
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
3. Manual Transmission As-
sembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Drain the transmission gear oil completely.
to 5MT-31, REPLACEMENT, Transmission Gear
Oil.>
4) Open the front hood fully, and support with stay.
5) Remove the air intake duct and air cleaner case.
(Non-turbo model)
AL, Air Intake Duct.>
MOVAL, Air Cleaner Case.>
6) Remove the air cleaner case stay. (Non-turbo
model)
7) Remove the intercooler. (Turbo model)
IN(H4DOTC)-10, REMOVAL, Intercooler.>
8) Disconnect the following connectors and trans-
mission cable.
(1) Neutral position switch connector
(2) Back-up light switch connector
(3) High-low switch connector (Dual-range
model)
Non-turbo model Turbo model
(4) Vehicle speed sensor
9) Remove the snap pin and pin from drive select
cable.
10) Remove the drive select cable on transmission.
(Dual-range model)
11) Remove the starter.
MOVAL, Starter.>
ME-00062
MT-00063
(A) Snap pin
(B) Clevis pin
(C) Drive select cable
MT-00064
MT-00065
MT-00066
(A)
(B)
(C)