Professional Documents
Culture Documents
Manual Transaxle Section
Manual Transaxle Section
Manual Transaxle Section
SECTION MT
CONTENTS
PREPARATION ...............................................................3 INSPECTION ...........................................................33
Special Service Tools ..................................................3 ASSEMBLY .............................................................33
Commercial Service Tools ...........................................6 Shift Control Components .........................................35
NOISE, VIBRATION AND HARSHNESS (NVH) INSPECTION ...........................................................35
MT
TROUBLESHOOTING .....................................................7 ADJUSTMENT OF INPUT SHAFT BRAKING
MECHANISM ...........................................................36
NVH Troubleshooting Chart.........................................7
Case Components .....................................................37
ON-VEHICLE SERVICE ..................................................8
REMOVAL AND INSTALLATION ................................37
Replacing Oil Seal .......................................................8
ADJUSTMENT ...............................................................39
DIFFERENTIAL OIL SEAL ..........................................8
STRIKING ROD OIL SEAL..........................................8
Differential Side Bearing Preload ..............................39
Position Switch Check .................................................9 ASSEMBLY....................................................................41
BACK-UP LAMP SWITCH...........................................9
NEUTRAL POSITION SWITCH ...................................9 RS5F70A
REMOVAL AND INSTALLATION .................................10
DESCRIPTION ...............................................................45
Removal.....................................................................10
Cross-sectional View .................................................45
Installation..................................................................12
DOUBLE-CONE SYNCHRONIZER ............................46
MAJOR OVERHAUL .....................................................47
RS5F32A Transaxle Gear Control .............................................47
DESCRIPTION ...............................................................13 Case Components .....................................................48
Cross-sectional View .................................................13 Gear Components .....................................................49
MAJOR OVERHAUL .....................................................14 Shift Control Components .........................................50
Transaxle Gear Control .............................................14 Final Drive Components ............................................51
Case Components .....................................................15 DISASSEMBLY..............................................................52
Gear Components .....................................................16 Transaxle Case..........................................................52
Shift Control Components .........................................17 Clutch Housing ..........................................................54
DISASSEMBLY..............................................................18 REPAIR FOR COMPONENT PARTS ...........................58
REPAIR FOR COMPONENT PARTS............................21 Input Shaft and Gears ...............................................58
Input Shaft and Gears ...............................................21 DISASSEMBLY ........................................................58
DISASSEMBLY ........................................................21 INSPECTION ...........................................................59
INSPECTION ...........................................................22 ASSEMBLY .............................................................60
ASSEMBLY .............................................................23 Mainshaft and Gears .................................................63
Mainshaft and Gears .................................................24 DISASSEMBLY ........................................................63
DISASSEMBLY ........................................................24 INSPECTION ...........................................................64
INSPECTION ...........................................................26 ASSEMBLY .............................................................66
ASSEMBLY .............................................................28 Final Drive..................................................................71
Final Drive..................................................................32 PRE-INSPECTION ...................................................71
DISASSEMBLY ........................................................32 DISASSEMBLY ........................................................72
INSPECTION ...........................................................72
CONTENTS (Cont’d)
ASSEMBLY .............................................................73 AVAILABLE C-RINGS ...............................................87
Shift Control Components .........................................74 AVAILABLE SPACERS .............................................88
INSPECTION ...........................................................74 AVAILABLE WASHERS ............................................88
ASSEMBLY....................................................................76 AVAILABLE SHIMS - DIFFERENTIAL SIDE
Clutch Housing ..........................................................76 BEARING PRELOAD AND ADJUSTING SHIM............88
Transaxle Case..........................................................80 INPUT SHAFT BRAKING MECHANISM .....................89
MAINSHAFT END PLAY ...........................................89
RS5F70A
SERVICE DATA AND SPECIFICATIONS (SDS) ..........86
SERVICE DATA AND SPECIFICATIONS (SDS) .........90
General Specifications - RS5F32A and RS5F70A....86
TRANSAXLE ...........................................................86
Inspection and Adjustment - RS5F70A .....................90
FINAL GEAR ...........................................................86 GEAR END PLAY ....................................................90
CLEARANCE BETWEEN BAULK RING AND
GEAR .....................................................................90
RS5F32A AVAILABLE SNAP RINGS ........................................90
SERVICE DATA AND SPECIFICATIONS (SDS) ..........87 AVAILABLE C-RINGS ..............................................90
Inspection and Adjustment - RS5F32A .....................87 AVAILABLE ADJUSTING SHIMS ...............................91
AVAILABLE THRUST WASHER ................................92
GEAR END PLAY ....................................................87
AVAILABLE WASHERS ............................................92
CLEARANCE BETWEEN BAULK RING AND
AVAILABLE SHIMS - DIFFERENTIAL SIDE
GEAR .....................................................................87
BEARING PRELOAD AND ADJUSTING SHIM ...........92
AVAILABLE CHECK PLUGS .....................................87
AVAILABLE SNAP RINGS ........................................87
MT-2
PREPARATION
Special Service Tools
Tool number
Description
Tool name
NT418
NT410
NT410
MT-3
PREPARATION
Special Service Tools (Cont’d)
Tool number
Description
Tool name
NT073
NT414
NT091
NT084
NT086
NT427
NT120
NT115
MT-4
PREPARATION
Special Service Tools (Cont’d)
Tool number
Description
Tool name
NT065
NT065
NT065
ST01530000 Installing 3rd & 4th and 1st & 2nd synchronizer
Drift hub
Installing mainshaft front bearing
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
NT065
NT065
NT073
MT-5
PREPARATION
Special Service Tools (Cont’d)
Tool number
Description
Tool name
NT431
NT419
NT417
NT077
NT065
NT065
NT065
MT-6
tion. If necessary, repair or replace these parts.
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
Symptom
(Possible cause)
SUSPECTED PARTS
Reference page
Oil leakage
Noise
1 (Oil level is low.)
MAINTENANCE”).
(Oil level is high.)
MT-7
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged) MT-17, 50
2
NCMT0003S01
NCMT0003
INSERT SPRING, SHIFTING INSERT (Damaged) MT-16, 49
3
ON-VEHICLE SERVICE
Replacing Oil Seal
SMT563A
.
Drift: LH side ST33400001 (F31A)
KV31103000 and ST35325000 (F32A
& F32V) RH side ST30720000 (F31A)
LH and RH side KV38100200 (F70A) SMT564AB
F32A I Install differential oil seal so that dimension “A” and “B”
Clutch housing side
Transmission are within specifications.
case side
Unit: mm (in)
Item A B
SMT738B
F70A
Transaxle case side Clutch housing side
SMT869D
SMT565A
MT-8
ON-VEHICLE SERVICE
Replacing Oil Seal (Cont’d)
SMT566A
SMT570A
I Check continuity
Neutral position
Back-up lamp
switch harness
switch connector Gear Position Continuity
connector
Reverse Yes
Except reverse No
SMT715B
NEUTRAL POSITION SWITCH NCMT0006S02
I Check continuity.
F70A
Gear position Continuity
Back-up lamp Neutral position Neutral Yes
switch harness switch harness
connector connector
Except neutral No
NMT090
MT-9
REMOVAL AND INSTALLATION
Removal
Removal NCMT0007S01
.
SMT653B
.
Starter motor
Front SMT654B
.
F31A and F32A
7. Remove shift control rod and support rod from transaxle.
8. Drain gear oil from transaxle.
Shift control rod
9. Remove exhaust front tube.
SMT655B
.
F70A
.
Support rod
.
Control rod
NMT091
10. Draw out drive shafts from transaxle — Refer to section FA.
Knuckle
spindle Drive shaft
upper nut
SMT656B
MT-10
REMOVAL AND INSTALLATION
Removal (Cont’d)
.
F31A and F32A 11. Supprt engine by placing a jack under oil pan.
CAUTION:
Do not place jack under oil pan drain plug.
12. Remove rear and LH mounts.
SMT657B
.
F70A
NMT092
13. Raise jack for access to lower housing bolts. Remove bolts.
Lower jack.
Center
member
Front
SMT658B
MT-11
REMOVAL AND INSTALLATION
Installation
SMT659B
Installation NCMT0007S02
Tightening torque
Bolt No. in mm (in)
N·m (kg-m, ft-lb)
SR engine models:
: M/T to engine
: Engine to M/T Tightening torque
Bolt No. in mm (in)
N·m (kg-m, ft-lb)
1 70 - 79 (7.1 - 8.1, 51 - 59) 55 (2.17)
2 70 - 79 (7.1 - 8.1, 51 - 59) 65 (2.56)
3 30 - 40 (3.1 - 4.1, 22 - 30) 35 (1.38)
4 30 - 40 (3.1 - 4.1, 22 - 30) 45 (1.77)
SMT661B
MT-12
DESCRIPTION RS5F32A
Cross-sectional View
Cross-sectional View
SMT123D
MT-13
MAJOR OVERHAUL RS5F32A
Transaxle Gear Control
12 - 15
(1.2 - 1.5, 9 - 11)
12 - 15
(1.2 - 1.5, 9 - 11)
NMT097
p
1 Control lever knob p
7 Plate bolt p
13 Collar
p
2 Boot p
8 Transaxle hole cover p
14 Bushing
p
3 Control lever socket p
9 Support rod p
15 Control rod
p
4 Control lever p
10 Plate p
16 Return spring
p
5 Bushing p
11 Collar p
17 Holder bracket
p
6 Hand lever socket p
12 Bushing p
18 Dynamic damper
MT-14
MAJOR OVERHAUL RS5F32A
Case Components
Case Components
YMT004
MT-15
SEC. 322
Gear Components
MT-16
3rd gear synchronizer cone Differential case
.
3rd outer baulk ring Final gear
Coupling sleeve
3rd & 4th synchronizer hub
Gear Components
MAJOR OVERHAUL
Insert spring
Baulk ring
4th main gear
Pinion mate shaft
4th gear bushing .
5th main gear Side gear Thrust washer ★
Spacer ★
Mainshaft rear bering
C-ring ★
C-ring holder
Snap ring Pinion mate shaft
Differential side bearing adjusting shim ★ Thrust washer
Snap ring
Differential side bearing
NMT024
: Apply gear oil
MAJOR OVERHAUL RS5F32A
Shift Control Components
.
6.3 - 8.3
(0.64 0.85, 55.6 - 73.8)
12 - 16
(1.2 - 1.6, 9 - 12)
.
6.3 - 8.3
(0.64 - 0.85, 55.6 - 73.8)
.
: Apply gear oil
: Do not re-use
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
p
L : Apply locking sealant
★: Select correct length
✩: Select correct part. Adjustment required
NMT025
p
1 Check plunger p
11 Shift check ball p
21 Control bracket pin
p
2 Select return spring p
12 Check spring p
22 Retaining pin
p
3 O-ring p
13 Fork shaft support spring p
23 Striking rod
p
4 Check sleeve p
14 Fork shaft p
24 Retaining pin
p
5 Striking lever p
15 5th shift fork p
25 Yoke
p
6 Snap ring p
16 Shifter cap p
26 Reverse check plug
p
7 Striking interlock p
17 3rd & 4th shift fork p
27 Check ball (Large)
p
8 Reverse brake cam p
18 Shifter cap p
28 Check ball (Small)
p
9 Reverse brake cam spring p
19 1st & 2nd shift fork p
29 Stopper pin
p
10 Check ball plug p
20 Control bracket
MT-17
DISASSEMBLY RS5F32A
SMT664B
Snap ring
SMT665B
SMT666B
SMT667B
SMT188A
MT-18
DISASSEMBLY RS5F32A
.
1st & 2nd shift
fork
Control bracket
SMT668B
Bearing retainer
SMT669B
SMT670B
SMT671B
8. Remove oil pocket, shift check ball, check spring and check
Check spring ball plug.
Shift check ball I Be careful not to lose check ball.
Check ball plug
SMT648A
MT-19
DISASSEMBLY RS5F32A
SMT599A
SMT583
10. Remove reverse check plug, then detach reverse check spring
and check balls.
I Be careful not to lose check balls.
I If the smaller ball does not come out, remove it together
with check sleeve assembly.
SMT584
SMT585
MT-20
REPAIR FOR COMPONENT PARTS RS5F32A
Input Shaft and Gears
SMT673B
5th input gear 3. Remove 5th synchronizer, 5th input gear and 5th gear needle
bearing.
Set tool below
5th input gear
5th synchronizer
hub
ST30021000
SMT417CA
4. Remove snap ring of input shaft front bearing and input gear
spacer.
Snap ring
Spacer
Input shaft
front bearing
SMT674B
MT-21
REPAIR FOR COMPONENT PARTS RS5F32A
Input Shaft and Gears (Cont’d)
Puller
Bearing retainer
Vise
SMT675B
INSPECTION
Gear and shaft
I Check shaft for cracks, wear or bending.
I Check gears for excessive wear, chips or cracks.
SMT602A
Synchronizer
Shifting insert Spline
area I Check spline area of coupling sleeves, hubs and gears for
wear or cracks.
I Check baulk rings for cracks or deformation.
I Check insert springs for wear or deformation.
NMT022
SMT140
Bearing
● Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT148A
MT-22
REPAIR FOR COMPONENT PARTS RS5F32A
Input Shaft and Gears (Cont’d)
ASSEMBLY
1. Assemble 5th synchronizer.
SMT736A
Spread spring
Bearing retainer
SMT731
SMT708B
6. Install 5th gear needle bearing, 5th input gear, 5th synchro-
nizer and 5th stopper.
7. Measure gear end play as a final check — Refer to “Disassem-
bly”.
5th
synchronizer
ST37750000 hub
SMT779A
MT-23
REPAIR FOR COMPONENT PARTS RS5F32A
Input Shaft and Gears (Cont’d)
SMT591
Gear
DISASSEMBLY
Feeler gauge
1. Before disassembly, measure gear end play.
Gear end play:
Snap ring
C-ring holder
SMT709B
Snap ring
C-ring holder
C-ring
Bearing
SMT676B
MT-24
REPAIR FOR COMPONENT PARTS RS5F32A
Mainshaft and Gears (Cont’d)
Puller
Suitable
drift
Mainshaft bearing
Spacer
SMT677B
SMT593
5. Remove 4th main gear, 4th gear bushing and steel ball.
I Take care not to lose steel ball.
4th main gear
Bushing
Steel ball
SMT418C
SMT679B
MT-25
REPAIR FOR COMPONENT PARTS RS5F32A
Mainshaft and Gears (Cont’d)
SMT740B
8. Remove 1st & 2nd synchronizer hub and 1st main gear.
Drift
SMT681B
INSPECTION
Gear and shaft
I Check shaft for cracks, wear or bending.
I Check gears for excessive wear, chips or cracks.
SMT604A
MT-26
REPAIR FOR COMPONENT PARTS RS5F32A
Mainshaft and Gears (Cont’d)
Shifting insert
Synchronizer
Spline
area
I Check spline area of coupling sleeves, hubs and gears for
wear or cracks.
I Check baulk rings for cracks or deformation.
I Check insert springs for deformation.
NMT022
SMT695B
MT-27
REPAIR FOR COMPONENT PARTS RS5F32A
Mainshaft and Gears (Cont’d)
Synchronizer cone
SMT682B
Bearing
I Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
I The mainshaft front bearing cannot be re-used. It must be
replaced once removed.
SPD715
ASSEMBLY
1. Install 1st gear needle bearing, 1st main gear and baulk ring.
2. Press on 1st & 2nd synchronizer hub.
ST22452000
SMT689B
MT-28
REPAIR FOR COMPONENT PARTS RS5F32A
Mainshaft and Gears (Cont’d)
1st 2nd
gear gear
SMT701B
3. Install 2nd synchronizer cone, outer & inner baulk ring and 1st
& 2nd coupling sleeve.
SMT683B
4. Install steel ball, 2nd main gear, 2nd & 3rd bushing.
2nd & 3rd gear
bushing I Apply gear oil to 2nd & 3rd gear bushing.
I Apply multi-purpose grease to steel ball before installing
2nd gear it.
I 2nd & 3rd bushing has a groove in which steel ball fits.
Steel ball
SMT680B
MT-29
REPAIR FOR COMPONENT PARTS RS5F32A
Mainshaft and Gears (Cont’d)
5. Install 3rd main gear, synchronizer cone, and outer & inner
baulk ring.
6. Press on 3rd & 4th synchronizer hub.
ST37750000
SMT690B
7. Install 3rd & 4th coupling sleeve and 4th baulk ring.
I Ensure correct fitting of 3rd & 4th synchronizer hub.
4th 3rd
gear gear
SMT702B
Steel ball
SMT691B
MT-30
REPAIR FOR COMPONENT PARTS RS5F32A
Mainshaft and Gears (Cont’d)
ST37750000
SMT692B
SMT693B
ST22360002
SMT694B
MT-31
REPAIR FOR COMPONENT PARTS RS5F32A
Mainshaft and Gears (Cont’d)
Snap ring
13. Select proper C-ring to minimize clearance of groove in main-
shaft and install it.
C-ring holder Allowable clearance of groove:
C-ring 0 - 0.1 mm (0 - 0.004 in)
Mainshaft C-rings:
Bearing Refer to SDS, MT-87.
SMT676B
C-ring
SMT712B
Final Drive
DISASSEMBLY
1. Remove final gear.
SMT647A
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.
SMT699B
MT-32
REPAIR FOR COMPONENT PARTS RS5F32A
Final Drive (Cont’d)
INSPECTION
Gear, washer, shaft and case
I Check mating surfaces of differential case, side gears and
pinion mate gears.
I Check washers for wear.
SMT083A
Bearing
I Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
I When replacing tapered roller bearing, replace outer and
inner race as a set.
SPD715
ASSEMBLY
1. Attach side gear thrust washers to side gears, then install pin-
ion mate washers and pinion mate gears in place.
SMT839
SMT840
Dial gauge 3. Measure clearance between side gear and differential case
with washers using the following procedure:
a. Set Tool and dial indicator on side gear.
KV38107700
b. Move side gear up and down to measure dial indicator deflec-
tion. Always measure indicator deflection on both side gears.
Clearance between side gear and differential case
with washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
c. If not within specification, adjust clearance by changing thick-
ness of side gear thrust washers.
SMT610A
MT-33
REPAIR FOR COMPONENT PARTS RS5F32A
Final Drive (Cont’d)
SMT611A
SMT699B
SMT609A
Drift
SMT648
MT-34
REPAIR FOR COMPONENT PARTS RS5F32A
Shift Control Components
Control bracket
SMT703B
SMT727B
MT-35
REPAIR FOR COMPONENT PARTS RS5F32A
Shift Control Components (Cont’d)
Clutch housing
SMT774B
Height
gauge
Striking lever
Control bracket
.
fitting surface Reverse brake cam
SMT728B
SMT729B
MT-36
REPAIR FOR COMPONENT PARTS RS5F32A
Case Components
Case Components
REMOVAL AND INSTALLATION
Input shaft oil seal
Drift
SMT660A
SMT751BA
SMT705B
SMT704B
SMT705B
MT-37
REPAIR FOR COMPONENT PARTS RS5F32A
Case Components (Cont’d)
SMT706B
Bearing
retainer
SMT707B
Mainshaft
front bearing
SMT714B
Oil groove
SMT595
Drift
SMT752BA
MT-38
ADJUSTMENT RS5F32A
Differential Side Bearing Preload
ST33290001
SMT645
SMT646A
KV38107700
SMT454
MT-39
ADJUSTMENT RS5F32A
Differential Side Bearing Preload (Cont’d)
MT-40
ASSEMBLY RS5F32A
SMT584
6. Install check ball plug, shift check ball and check spring.
Check spring
7. Install oil pocket.
Shift check ball
Check ball plug
SMT648A
SMT671B
MT-41
ASSEMBLY RS5F32A
.
SMT670B
Bearing retainer
.
SMT669B
SMT666
Control bracket
Clutch housing
SMT774B
SMT596
MT-42
ASSEMBLY RS5F32A
SMT587
SMT666B
Snap ring
SMT665B
SMT758B
MT-43
ASSEMBLY RS5F32A
SMT775B
SMT664B
MT-44
NCMT0004
DESCRIPTION RS5F70A
Cross-sectional View
Clutch housing
3rd input gear
3rd & 4th synchronizer
Input shaft
Mainshaft
Mainshaft rear
bearing
.
Sub-gear Mainshaft front
bearing
Reverse main gear
SMT834D
MT-45
DESCRIPTION RS5F70A
Cross-sectional View (Cont’d)
MT-46
NCMT0008
MT-47
MAJOR OVERHAUL RS5F70A
Case Components
3.7 - 5.0
(0.38 - 0.51, 33 - 44)
6.3 - 8.3
(0.64 - 0.85, 56 - 74)
10 - 19 (1.0 - 2.0,
87 - 174)
7.4 - 9.7
(0.75 - 0.99,
65 - 86)
1. Clutch housing 13. Reverse idler gear front thrust 25. Rear cover
2. Welch plug washer 26. Differential oil seal
3. Oil pocket 14. O-ring 27. Drain plug
4. Check plug 15. Reverse idler gear shaft 28. PNP switch
5. Input shaft oil seal 16. Snap ring 29. Transmission case
6. Oil channel 17. Reverse switch 30. Oil gutter
7. Mainshaft front bearing 18. Filler plug 31. Welch plug
8. Bearing retainer 19. Side cover gasket 32. Magnet
9. Magnet 20. Side cover 33. Boot
10. Reverse idler gear rear thrust 21. Welch plug 34. Striking rod oil seal
washer 22. Mainshaft bearing snap ring 35. Welch plug
11. Reverse idler gear 23. Mainshaft bearing adjusting shim 36. Differential oil seal
12. Reverse idler gear bearing 24. O-ring 37. O-ring
38. Speedometer pinion
(If so equipped)
MT-48
MAJOR OVERHAUL RS5F70A
Gear Components
SMT641D
1. Reverse idler gear rear thrust 24. 5th gear rear C-ring 47. Mainshaft adjusting shim
washer 25. C-ring holder 48. 4th main gear
2. Reverse idler gear 26. Input shaft rear bearing 49. 5th gear bushing
3. Reverse idler gear bearing 27. Oil channel 50. 5th gear needle bearing
4. Reverse idler gear front thrust 28. Input shaft rear bearing adjusting 51. 5th main gear
washer shim 52. 5th gear baulk ring
5. O-ring 29. Mainshaft front bearing 53. Spread spring
6. Reverse idler gear shaft 30. Mainshaft 54. Shifting insert
7. Snap ring 31. 1st gear needle bearing 55. 5th & reverse synchronizer hub
8. Input shaft front bearing 32. 1st main gear 56. Spread spring
9. Input shaft 33. 1st inner baulk ring 57. Coupling sleeve
10. 3rd gear needle bearing 34. 1st synchronizer cone 58. Reverse gear bush
11. 3rd input gear 35. 1st outer baulk ring 59. Reverse gear needle bearing
12. 3rd gear baulk ring 36. 1st & 2nd synchronizer hub 60. Reverse gear baulk ring
13. Coupling sleeve 37. Coupling sleeve 61. Reverse main gear
14. Spread spring 38. Insert spring 62. Sub-gear
15. Shifting insert 39. 2nd gear bushing 63. Sub-gear washer
16. Coupling sleeve 40. 2nd gear needle bearing 64. Snap ring
17. Spread spring 41. 2nd gear outer baulk ring 65. Mainshaft thrust washer
18. 4th gear C-ring 42. 2nd gear synchronizer cone 66. Mainshaft rear bearing
19. 4th gear needle bearing 43. 2nd inner baulk ring 67. Mainshaft C-ring
20. 4th gear baulk ring 44. 2nd main gear 68. C-ring holder
21. 4th input gear 45. 3rd main gear 69. Snap ring
22. 5th gear front C-ring 46. Spacer
23. 5th input gear
MT-49
MAJOR OVERHAUL RS5F70A
Shift Control Components
16 - 21
(1.6 -2.1, 12 - 15)
MT-50
MAJOR OVERHAUL RS5F70A
Final Drive Components
SMT643D
1. Differential side bearing adjusting 6. Speedometer drive gear 11. Pinion mate gear
shim 7. Speedometer stopper 12. Side gear thrust washer
2. Differential side bearing outer race 8. Differential side bearing 13. Side gear
3. Differential side bearing 9. Differential side bearing outer race 14. Pinion mate shaft
4. Final gear 10. Pinion mate thrust washer 15. Lock pin
5. Differential case
MT-51
NCMT0009
DISASSEMBLY RS5F70A
Transaxle Case
SMT648D
Rear cover
Bolt (M6)
5. Remove reverse idler gear shaft.
a. Attach bolt (M6) to thread of reverse idler gear shaft end.
b. Pull out the attached bolt, and remove reverse idler gear shaft
from case.
6. Remove reverse idler gear, thrust washer, and bearing from
case.
SMT645D
Flat-head screwdriver
SMT646D
SMT647D
MT-52
DISASSEMBLY RS5F70A
Transaxle Case (Cont’d)
Clutch housing
9. Remove mounting bolts.
10. Remove input shaft rear bearing adjusting shim from transaxle
case.
SMT650D
12. Remove differential side bearing outer race and adjusting shim
from case.
SMT651D
SMT653D
SMT839D
MT-53
DISASSEMBLY RS5F70A
Clutch Housing
Check plug
Clutch
housing
SMT654D
SMT656D
Stopper ring
5. Remove 3rd & 4th shift fork stopper ring.
6. Remove 3rd & 4th fork rod.
7. Remove 3rd & 4th shift fork and bracket.
Check ball
Interlock plunger
SMT658D
10. Remove retaining pin from 5th & reverse shift fork and reverse
switch bracket.
5th & reverse
shift fork
11. Remove 5th & reverse fork rod.
5th & reverse 12. Remove interlock pin from 5th & reverse fork rod.
bracket 13. Remove reverse switch bracket and 5th & reverse bracket.
SMT657D
MT-54
DISASSEMBLY RS5F70A
Clutch Housing (Cont’d)
Check balls
SMT659D
18. Remove both input shaft and mainshaft assemblies from hous-
Mainshaft assembly
ing.
Input shaft
assembly
SMT660D
Final drive
19. Remove final drive assembly from housing.
Oil pocket assembly 20. Remove oil pocket from housing.
SMT661D
Oil channel
Mainshaft bearing
retainer
SMT662D
SMT663D
MT-55
DISASSEMBLY RS5F70A
Clutch Housing (Cont’d)
SMT664D
SMT665D
26. Remove reamer bolt, then remove selector leaf spring, return
Selector leaf spring spring, steel ball, reverse gate, selector arm, bearing, and
bushing.
CAUTION:
Be careful not to lose the steel ball.
Return spring
SMT666D
Striking lever
SMT667D
Input shaft
oil seal
Dust seal SMT668D
MT-56
DISASSEMBLY RS5F70A
Clutch Housing (Cont’d)
Differential
oil seal
SMT669D
Differential
side bearing
outer race
SMT670D
MT-57
REPAIR FOR COMPONENT PARTS RS5F70A
Input Shaft and Gears
Input shaft
SMT671D
Input shaft
rear bearing
SMT672D
Flat-head screwdriver
5th gear rear C-ring
SMT673D
SMT674D
MT-58
REPAIR FOR COMPONENT PARTS RS5F70A
Input Shaft and Gears (Cont’d)
8. Remove 4th input gear, baulk ring, 4th gear needle bearing,
3rd & 4th and 4th gear C-ring from input shaft.
synchronizer
hub assembly 9. Press out both 3rd & 4th synchronizer hub assembly and 3rd
input gear from input shaft.
10. Remove 3rd gear needle bearing.
11. Press out input shaft front bearing from input shaft.
Input shaft
front bearing
SMT676D
INSPECTION NCMT0011
SMT693D
Synchronizers NCMT0011S02
SMT637A
SMT867D
MT-59
REPAIR FOR COMPONENT PARTS RS5F70A
Input Shaft and Gears (Cont’d)
I Measure the movement (play, dimension “L”) of 3rd & 4th cou-
pling sleeve with their end fixed and the other end lifted as
shown in the figure. If the movement exceeds specification,
Fixed 3rd & 4th coupling sleeve
replace the sleeve.
SMT841D
SMT140
Bearing NCMT0011S03
I Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT148A
ASSEMBLY NCMT0012
Input shaft
SMT696D
Shifting insert
3. Install spread spring, shifting insert, and 3rd & 4th synchronizer
(3rd & 4th) (5th & reverse) hub onto 3rd & 4th coupling sleeve.
I Pay attention to the shape of spread spring and shifting insert
for correct assembly.
Flat shape R-shape Do not install spread spring hook onto the same shifting insert.
CAUTION:
Spread spring
Do not reuse 3rd & 4th synchronizer hub.
MT-60
REPAIR FOR COMPONENT PARTS RS5F70A
Input Shaft and Gears (Cont’d)
I Install synchronizer hub with its three grooves facing the front
side (3rd input gear side).
Front
SMT695D
I Install 3rd & 4th coupling sleeve with its chamfered surface
facing the 4th input gear side.
SMT699D
SMT698D
6. Measure the end play of 3rd & 4th synchronizer hub, and
check if it is within allowable specification below.
Feeler gauge
End play specification:
3rd & 4th 0 - 0.06 mm (0 - 0.0024 in)
synchronizer
hub assembly 7. If not within specification, adjust the end play by changing
thickness of 4th gear C-ring.
Available C-ring:
Refer to SDS, MT-90.
4th gear C-ring
SMT700D
8. Install 4th gear needle bearing, 4th gear baulk ring, and 5th
5th gear front C-ring gear front C-ring.
9. Install 4th input gear.
4th gear needle
bearing
SMT701D
MT-61
REPAIR FOR COMPONENT PARTS RS5F70A
Input Shaft and Gears (Cont’d)
5th input gear 10. Position 5th input gear as shown in the figure, and install it on
input shaft.
SMT703D
SMT702D
SMT705D
Input shaft
SMT671D
MT-62
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears
Mainshaft assembly
Mainshaft and Gears
DISASSEMBLY NCMT0013
SMT677D
C-ring holder
Mainshaft C-ring
SMT678D
Mainshaft rear
4. Press out mainshaft rear bearing from mainshaft.
bearing
SMT679D
Reverse main
gear assembly
SMT680D
MT-63
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
SMT681D
9. Place bearing replacer between 3rd and 4th main gears, and
press out both 5th gear bushing and 4th main gear.
5th gear bush
SMT682D
SMT683D
12. Remove 2nd double cone assembly, 2nd gear bushing, and
coupling sleeve assembly.
13. Place bearing replacer on 1st gear front side, and press out all
of 2nd gear bushing, 1st & 2nd synchronizer hub, 1st main
2nd gear bush gear, and 1st double cone.
14. Remove 1st gear needle bearing.
1st & 2nd
synchronizer hub
SMT684D
INSPECTION NCMT0014
SMT693D
MT-64
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
Synchronizers NCMT0014S02
SMT637A
SMT867D
SMT140
Bearing NCMT0014S03
I Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT148A
MT-65
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
Synchronizer cone
SMT714CB
ASSEMBLY NCMT0015
1st gear needle bearing
1. Install 1st gear needle bearing and 1st main gear onto main-
1st main gear shaft.
2. Install 1st double cone assembly onto mainshaft.
Mainshaft
SMT706D
3. Install 1st & 2nd synchronizer hub with its three grooves fac-
ing the front side (1st main gear side) onto mainshaft.
CAUTION:
Do not reuse 1st & 2nd synchronizer hub.
Front
SMT695D
MT-66
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
SMT707D
SMT994BB
6. Install 1st & 2nd coupling sleeve with its chamfered surface
facing the 1st main gear side onto 1st & 2nd synchronizer hub.
7. Install 2nd gear bushing with its flange surface facing 1st & 2nd
synchronizer hub side.
SMT709D
SMT710D
MT-67
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
151.35 - 151.45 mm
(5.9586 - 5.9626 in)
12. Position 4th main gear as shown in the figure, and install it onto
mainshaft.
SMT712D
14. Install 5th gear bushing with its flange surface facing the 4th
main gear side.
SMT714D
MT-68
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
15. Install 5th needle bearing, 5th main gear, and 5th gear baulk
ring onto mainshaft.
Reverse
SMT761D
Shifting insert 16. Being careful of the following points, install spread spring, shift-
(3rd & 4th) (5th & reverse) ing insert, and 5th & reverse synchronizer hub onto 5th &
reverse coupling sleeve.
I Pay attention to the shape of spread spring and shifting insert
Flat shape R-shape for correct assembly.
Spread spring
Do not install spread spring hook onto the same shifting insert.
I Install synchronizer hub with its three grooves facing the front
side (5th main gear side).
CAUTION:
Do not reuse 5th & reverse synchronizer hub.
Front
SMT695D
I Install 5th & reverse coupling sleeve with its chamfered surface
facing the reverse main gear side.
Reverse
main gear 5th main gear
SMT715D
MT-69
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
SMT717D
Sub-gear 21. Install sub-gear, sub-gear washer, and snap ring onto reverse
Reverse main gear
washer main gear.
Sub-gear CAUTION:
Reverse
main gear I Pay attention to direction of sub-gear washer.
I Do not reuse snap ring.
Sub-gear washer
Thrust washer
Dimension “M”
SMT719D
Mainshaft
rear bearing
SMT720D
MT-70
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
Mainshaft C-ring
SMT721D
Mainshaft C-ring
SMT678D
SMT677D
SMT610AE
MT-71
REPAIR FOR COMPONENT PARTS RS5F70A
Final Drive (Cont’d)
DISASSEMBLY NCMT0016
Chamfer
1. Remove mounting bolts. Then, separate the final gear from
differential case.
2. Make a notch and remove speedometer drive gear using a
scraper or other suitable tool.
I Bearing replacer cannot be positioned unless speedom-
eter drive gear is removed.
SMT609A
SMT840D
SMT689D
SMT839
INSPECTION NCMT0017
I Check side gear, side gear thrust washer, pinion mate shaft,
pinion mate gear, pinion mate gear washer, and differential
case.
I Check washers for wear.
SMT083A
MT-72
REPAIR FOR COMPONENT PARTS RS5F70A
Final Drive (Cont’d)
Bearing NCMT0017S04
I Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
I When replacing tapered roller bearing, replace outer and
inner race as a set.
SPD715
ASSEMBLY NCMT0018
SMT062A
SMT087A
SMT750D
MT-73
REPAIR FOR COMPONENT PARTS RS5F70A
Final Drive (Cont’d)
Alignment
Installation position
direction
SMT842D
Speedometer
drive gear
SMT751D
13. Install final gear into differential case. Apply sealant onto
mounting bolts, and tighten them in order as shown in the fig-
ure with specified torque.
Tightening torque:
Refer to MT-48.
SMT752D
I Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
One-side wear
One-side wear One-side wear
Item Sliding width of new part
specification
Sliding width of
new part 7.80 - 7.93 mm
1st & 2nd 0.2 mm (0.008 in)
(0.3071 - 0.3122 in)
SMT801D
7.80 - 7.93 mm
3rd & 4th 0.2 mm (0.008 in)
(0.3071 - 0.3122 in)
7.80 - 7.93 mm
5th & reverse 0.2 mm (0.008 in)
(0.3071 - 0.3122 in)
MT-74
REPAIR FOR COMPONENT PARTS RS5F70A
Shift Control Components (Cont’d)
MT-75
NCMT0023
ASSEMBLY RS5F70A
Clutch Housing
1. Hammer the striking rod oil seal into clutch housing as far as
it will go.
CAUTION:
Do not reuse striking rod oil seal.
Striking rod
oil seal
SMT722D
3. Hammer input shaft oil seal into clutch housing as far as it will
go.
CAUTION:
Do not reuse input shaft oil seal.
4. Hammer the dust seal into clutch housing as far as it will go.
CAUTION:
Do not reuse dust seal.
Dust seal
SMT725D
MT-76
ASSEMBLY RS5F70A
Clutch Housing (Cont’d)
SMT727D
Notch on Transaxle 7. Align the notches on mainshaft front bearing and transaxle
bearing case case. Then, install mainshaft front bearing.
Mounting direction
of bearing
Mainshaft
front bearing
SMT728D
6.3 - 8.3
(0.64 - 0.85, 56 - 74)
SMT667D
10. Hammer the welch plug (striking lever side) with a general-
purpose drift [OD: 12 mm (0.47 in)].
CAUTION:
Do not reuse welch plug.
Drift
Welch plug
drift depth
MT-77
ASSEMBLY RS5F70A
Clutch Housing (Cont’d)
11. Install selector, selector shaft, and selector shaft pin into clutch
Selector shaft pin housing.
Selector
Welch plug
12. Hammer the welch plug (selector shaft side) with a general-
purpose drift [OD: 12 mm (0.47 in)].
CAUTION:
Drift
Do not reuse welch plug.
Welch plug
Welch plug drift depth
0 - 0.5 mm
(0 - 0.020 in)
Welch plug
SMT732D
13. Install selector leaf spring, return spring, steel ball, reverse
Reamer bolt gate, selector arm, bushing, and return bearing. Then, tighten
(short)
two reamer bolts with specified torque.
Reamer bolt
Selector
(long)
CAUTION:
leaf spring
Use correct reamer bolts for each installation point, because
Return
spring
Bushing each bolt has a different length.
Reverse
Return bearing
gate
Selector
Steel ball arm
SMT733D
N·m
(kg-m, ft-lb)
16 - 21
(1.6 - 2.1, 12 - 15) SMT734D
SMT735D
MT-78
ASSEMBLY RS5F70A
Clutch Housing (Cont’d)
SMT736D
Check balls
SMT659D
20. Install interlock pin into 5th & reverse fork rod.
21. Install reverse switch bracket, 5th & reverse bracket, and fork
5th & reverse
shift fork rod.
5th & reverse 22. Install retaining pin for 5th & reverse shift fork and reverse
bracket switch bracket.
CAUTION:
Do not reuse retaining pin.
23. Install 5th & reverse bracket stopper ring.
CAUTION:
SMT657D Do not reuse stopper pin.
SMT656D
Stopper ring
27. Install 3rd & 4th shift fork stopper ring.
CAUTION:
Do not reuse stopper ring.
28. Install check ball, check pin, and check spring, and apply
Three Bond TB1215, Loctite Part No. 51813 or equivalent onto
check plug. Then, tighten it with specified torque.
Tightening torque:
Refer to MT-48.
3rd & 4th
shift fork
.
3rd & 4th bracket SMT655D
MT-79
ASSEMBLY RS5F70A
Transaxle Case
Drift
Welch plug
drift depth
Welch plug
Welch plug
1.0 - 1.5 mm
(0.039 - 0.059 in) SMT739D
SMT741D
MT-80
ASSEMBLY RS5F70A
Transaxle Case (Cont’d)
Scale b. Install outer race onto differential side bearing on final gear
side. Holding lightly the outer race horizontally by hand, rotate
final gear five times or more (for smooth movement of bearing
roller).
c. Using dial gauge and scale as shown in the figure, measure
Scale dimension “N2” between differential side bearing outer race
and transaxle case end face.
SMT742D
Outer race
SMT738D
MT-81
ASSEMBLY RS5F70A
Transaxle Case (Cont’d)
Scale
Block gauge
SMT744D
Block gauge
SMT745D
SMT650D
SMT755D
SMT802D
MT-82
ASSEMBLY RS5F70A
Transaxle Case (Cont’d)
11. Install transaxle case onto clutch housing, and tighten mount-
Clutch housing ing bolts with specified torque.
Tightening torque:
Refer to MT-48.
Reverse switch 12. Apply Three Bond TB1215, Loctite Part No. 51813 or equiva-
PNP switch lent to threads of reverse switch, PNP switch, and drain plug,
and install them. (Fill the case with oil before installation of filler
plug.)
13. Install speedometer pinion assembly.
CAUTION:
Do not reuse O-ring.
SMT648D
14. Install check springs and check balls. Apply sealant to the
thread on the check plug, and install it.
Check balls
Check springs
Check plugs
16 - 22
(1.6 -2.2,
12 -16)
Rear cover
15. Calculate thickness of adjusting shim using the following pro-
cedure to satisfy specification of end play for mainshaft rear
Mainshaft rear bearing
bearing.
adjusting shim End play: 0 - 0.06 mm (0 - 0.0024 in)
Mainshaft rear Dimension “P” = (P1 − P2) + End play
bearing
P : Thickness of adjusting shim
P1: Distance between transaxle case end face
and mainshaft rear bearing
P2: Distance between adjusting shim end face of
Dimension “P” rear cover and transaxle mounting face
SMT746D
Available mainshaft rear bearing adjusting shims:
Refer to SDS, MT-92.
MT-83
ASSEMBLY RS5F70A
Transaxle Case (Cont’d)
Rear cover
SMT748D
16. Using snap ring pliers as shown in the figure, install snap ring.
CAUTION:
Do not reuse snap ring.
17. Install selected mainshaft adjusting shim.
Flat-head screwdriver
SMT646D
Reverse idler gear rear thrust washer 18. Install reverse idler gear, O-ring, thrust washers (front, rear),
Reverse idler gear
and bearing onto reverse idler shaft.
19. Install snap ring into transaxle case using snap ring pliers.
Reverse idler gear bearing CAUTION:
I Do not reuse snap ring.
I Do not reuse O-ring.
I Before installation, apply gear oil to O-ring.
Reverse idler gear front
thrust washer
O-ring
Reverse idler gear shaft SMT753D
Snap ring 20. Using feeler gauge, measure the end play of snap ring, and
Feeler gauge
select a snap ring suitable to satisfy the following specification.
End play:
0.05 - 0.25 mm (0.0020 - 0.0098 in)
Available snap ring:
Refer to SDS, MT-90.
SMT754D
MT-84
ASSEMBLY RS5F70A
Transaxle Case (Cont’d)
MT-85
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications — RS5F32A and RS5F70A
Number of speeds 5
Shift pattern
NMT031
2nd 22 22
3rd 28 28
4th 41 41
5th 45 45
Rev. 14 14
2nd 43 43
3rd 36 36
4th 38 38
5th 33 34
Rev. 45 45
Oil capacity (Reference) (Imp pt) 3.6 - 3.8 (6-3/8 - 6-3/4) 3.0 (5-1/4)
FINAL GEAR
Engine QG16DE QG18DE/ SR20DE CD20T
Final gear/
71/16 71/17 70/18
Number of Pinion
teeth Side gear/
16/10 14/10 14/10
Pinion
MT-86
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F32A
Inspection and Adjustment — RS5F32A
MT-87
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F32A
Inspection and Adjustment — RS5F32A (Cont’d)
SMT693B
Turning torque (New bearing)
Unit: N·m (kg-cm, in-lb)
230.15 - 230.25 mm
Bearing distance: C Final drive 2.9 - 6.9 (30 - 70, 26 - 61)
(9.0610 - 9.0649 in)
Thickness mm (in) Part number
0.80 - 0.85
38424-D2112
(0.0315 - 0.0335)
0.85 - 0.90
38424-D2113
(0.0335 - 0.0354)
0.90 - 0.95
38424-D2114
(0.0354 - 0.0374)
0.95 - 1.00
38424-D2115
(0.0374 - 0.0394)
MT-88
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F32A
Inspection and Adjustment — RS5F32A (Cont’d)
Striking lever
MAINSHAFT END PLAY
Mainshaft end play
0 - 0.1 mm
Control bracket (Clearance between end of case cover and
fitting surface (0 - 0.004 in)
Reverse brake cam mainshaft rear bearing outer race)
SMT735B
SMT760B
MT-89
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
Inspection and Adjustment — RS5F70A
MT-90
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
Inspection and Adjustment — RS5F70A (Cont’d)
*: Always check with the parts department for the latest informa- 1.38 mm (0.0543 in) 32225-6J019
tion. 1.42 mm (0.0559 in) 32225-6J020
*: Always check with the parts department for the latest informa-
tion.
MT-91
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
Inspection and Adjustment — RS5F70A (Cont’d)
6.28 mm (0.2472 in) 32246-6J003 *: Always check with the parts department for the latest informa-
tion.
6.36 mm (0.2504 in) 32246-6J004
*: Always check with the parts department for the latest informa-
tion.
MT-92