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MT-60
TRANSMISSION ASSEMBLY
3. Install oil gutter to transmission case.
4. Install counter front bearing to transmission case.
CAUTION:
Apply multi-purpose grease to counter front bearing.
5. Apply recommended sealant to mating surface of transmission
case as shown in the figure.
CAUTION:
Remove old sealant adhering to the mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
both mating surfaces.
6. Install transmission case to adapter plate assembly.
7. Install snap ring to main drive gear bearing using a snap ring pli-
ers.
CAUTION:
Do not reuse snap ring.
PCIB1228E
PCIB0436E
PCIB1270E
PCIB1227E
SCIA1532E
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TRANSMISSION ASSEMBLY
MT-61
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8. Tighten baffle plate mounting nut to the specified torque. Refer
toMT-19, "
Case Components".
9. Tighten baffle plate mounting bolt to the specified torque. Refer
toMT-19, "
Case Components".
10. Install front cover oil seal to front cover using the drift.
CAUTION:
When installing, do not incline front cover oil seal.
11. Install front cover according to the following.
SCIA1443E
PCIB1271E
Dimension “A”: 8.55 - 9.55 (0.336 - 0.376 in)
PCIB1424E
Page 2379 of 3171

MT-62
TRANSMISSION ASSEMBLY
a. Install front cover gasket and front cover to transmission case.
CAUTION:
lDo not reuse front cover gasket.
lRemove any moisture, oil, or foreign material adhering to
both mating surfaces.
lDo not damage front cover oil seal.
b. Temporary tightening 2 bolts in the positions shown in the fig-
ure.
c. Temporary tightening remaining 9 bolts.
d. Tighten bolts to the specified torque in order as shown on the
figure. Refer toMT-19, "
Case Components".
CAUTION:
Do not reuse bolts indicated as A in the figure.
12. Install washer to withdrawal lever ball pin, and then install it to
front cover. Tighten withdrawal lever ball pin to the specified
torque. Refer toMT-19, "
Case Components".
13. Install counter end bearing to rear extension (or OD gear case)
using a suitable drift [32 mm (1.26 in) dia.].
CAUTION:
Install counter end bearing with maker stamp at upper side.
PCIB1273E
PCIB1274E
PCIB1224E
Dimension “A”: 0.5 - 1.5 (0.020 - 0.059 in)
PCIB1636E
Page 2380 of 3171
TRANSMISSION ASSEMBLY
MT-63
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14. Install rear oil seal (1) to rear extension (or OD gear case) using
the drift.
CAUTION:
When installing, do not incline rear oil seal.
(B): Seal lip
15. Install dust seal (1) to rear extension using the drift (for 2WD
models).
CAUTION:
When installing, do not incline dust seal.
(B): Seal lip
16. Install rear extension oil gutter according to the following (for 2WD models).
a. Install cap to rear extension oil gutter.
b. Install rear extension oil gutter to rear extension, and then
tighten mounting bolt to specified torque. Refer toMT-19, "
Case
Components". Tool number A: ST33200000
Dimension “H
1”:
2WD models : 1.2 - 2.2 mm (0.047 - 0.087 in)
4WD models : -0.5 - 0.5 mm (-0.020 - 0.020 in)
SCIA7341E
Tool number A: KV38100500
Dimension “H
2”: 0.5 - 1.5 mm (0.020 - 0.059 in)
SCIA7342E
PCIB1221E
Page 2381 of 3171
MT-64
TRANSMISSION ASSEMBLY
17. Apply recommended sealant to mating surface of rear extension
(or OD gear case) as shown in the figure.
CAUTION:
Remove old sealant adhering to the mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
both mating surfaces.
18. Install rear extension (or OD gear case) to adapter plate, and
then tighten mounting bolts to the specified torque in order as
shown on the figure. Refer toMT-19, "
Case Components".
19. Install check shift pin and pivot bolt to transmission case, and
then tighten them to the specified torque. Refer toMT-19, "
Case
Components".
20. Install return spring plunger, return spring and return spring plug
to rear extension (or OD gear case), and then tighten return
spring plug to the specified torque. Refer toMT-23, "
Shift Con-
trol Components".
21. Install park/neutral position (PNP) switch and back-up lamp switch according to the following.
PCIB1278E
PCIB1279E
PCIB1226E
PCIB1643E
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TRANSMISSION ASSEMBLY
MT-65
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a. Install plungers to rear extension (or OD gear case).
b. Apply recommended sealant to threads of park/neutral position
(PNP) switch and back-up lamp switch.
c. Install park/neutral position (PNP) switch and back-up lamp
switch to rear extension (or OD gear case), and tighten them to
the specified torque. Refer toMT-19, "
Case Components".
22. Install clips to PNP switch and back-up lamp switch.
CAUTION:
lThread harness through the notch of clip.
lBe careful when threading harness as shown in the fig-
ure.
23. Install striking arm according to the following.
a. Install striking arm to striking rod assembly.
b. Install retaining pin to striking arm using a pin punch.
CAUTION:
Do not reuse retaining pin.
24. Install control housing according to the following.
PCIB1215E
PCIB1638E
PCIB1639E
PCIB1219E
Page 2383 of 3171
MT-66
TRANSMISSION ASSEMBLY
a. Install gasket and control housing to rear extension (or OD gear
case).
CAUTION:
lDo not reuse gasket.
lRemove any moisture, oil, or foreign material adhering to
both mating surfaces.
b. Tighten mounting bolts to the specified torque in order as shown
on the figure. Refer toMT-19, "
Case Components".
25. Install gasket to drain plug, and then install it to transmission
case. Tighten drain plug to the specified torque. Refer toMT-19,
"Case Components".
26. Install gasket to filler plug, and then install it to transmission
case. Tighten filler plug to the specified torque. Refer toMT-19,
"Case Components".
CAUTION:
After oil is filled, tighten filler plug to specified torque.
PCIB1216E
PCIB1214E
PCIB1229E
Page 2384 of 3171
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-67
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsECS00IDB
Engine typeYD25DDTi
Transmission modelFS6R31A
Axle type 2WD 4WD
Number of speed6
Synchromesh typeWarner
Shift pattern
Gear ratio1st 4.692
2nd 2.705
3rd 1.747
4th 1.291
5th 1.000
6th 0.827
Reverse 4.260
Main gear
(Number of teeth)Drive 23
1st 37
2nd 32
3rd 31
4th 28
6th 25
Reverse 42
Counter gear
(Number of teeth)Drive 35
1st 12
2nd 18
3rd 27
4th 33
6th 46
Reverse 15
Reverse idler gear (Number of teeth) 26
Oil capacity (Approx.)
(Imp pt)3.99 (7) 4.32 (7-5/8)
RemarksReverse synchronizer Installed
Double cone synchronizer 1st, 3rd and 4th
Triple cone synchronizer 2nd
SCIA0955E