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Manual Transaxle: Service Data and Specifications (SDS) Have Been Changed
Manual Transaxle: Service Data and Specifications (SDS) Have Been Changed
MODIFICATION NOTICE:
SECTION MT MA
EM
LC
I Service data and specifications (SDS) have been changed.
EC
CONTENTS FE
MT-2
CONTENTS (Cont’d)
General Specifications.............................................123 General Specifications.............................................131 GI
TRANSAXLE .........................................................123 TRANSAXLE .........................................................131
FINAL GEAR .........................................................123 FINAL GEAR .........................................................131
Gear End Play .........................................................124 Gear End Play .........................................................132 MA
Clearance Coupling Sleeve .....................................124 Clearance Between Baulk Ring and Gear ..............132
1ST, 2ND, 3RD, 4TH, 5TH & REVERSE 3RD, 4TH & 5TH BAULK RING ...............................132
COUPLING SLEEVE ..............................................124 1ST AND 2ND DOUBLE BAULK RING ....................132 EM
Clearance Between Baulk Ring and Gear ..............124 REVERSE BAULK RING ........................................132
3RD, 4TH, 5TH, REVERSE BAULK RING ................124 Available Snap Rings ..............................................133
1ST AND 2ND DOUBLE BAULK RING ....................124 1ST & 2ND SYNCHRONIZER HUB (AT LC
Available Snap Rings ..............................................125 MAINSHAFT) .........................................................133
SNAP RING...........................................................125 3RD & 4TH SYNCHRONIZER HUB (AT INPUT
Available C-rings......................................................125 SHAFT) .................................................................133
EC
4TH INPUT GEAR C-RING .....................................125 5TH MAIN GEAR (AT MAINSHAFT) ........................133
5TH INPUT GEAR REAR C-RING ...........................125 Available Thrust Washer..........................................133
4TH INPUT GEAR (AT INPUT SHAFT) ....................133
FE
MAINSHAFT C-RING .............................................126
Available Adjusting Shims .......................................127 DIFFERENTIAL SIDE GEAR THRUST WASHER ......133
INPUT SHAFT REAR BEARING ADJUSTING Available Shims .......................................................134 CL
SHIM ....................................................................127 BEARING PRELOAD AND END PLAY ....................134
MAINSHAFT ADJUSTING SHIM..............................128 TOTAL TURNING TORQUE (NEW BEARING) ..........134
MAINSHAFT REAR BEARING ADJUSTING SHIM ....128 MAINSHAFT BEARING ADJUSTING SHIM ..............134
Available Thrust Washer..........................................129 TABLE FOR SELECTING MAINSHAFT BEARING
MAINSHAFT THRUST WASHER .............................129 ADJUSTING SHIM(S) .............................................134
Available Washers ...................................................129 INPUT SHAFT BEARING ADJUSTING SHIM ...........135 AT
DIFFERENTIAL SIDE GEAR THRUST WASHER ......129 TABLE FOR SELECTING INPUT SHAFT BEARING
Available Shims - Differential Side Bearing ADJUSTING SHIM(S) .............................................135
Preload and Adjusting Shim ....................................130 DIFFERENTIAL SIDE BEARING ADJUSTING AX
SHIM ....................................................................135
BEARING PRELOAD .............................................130
TABLE FOR SELECTING DIFFERENTIAL SIDE
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIMS ..................................................................130
BEARING ADJUSTING SHIM(S) .............................136 SU
RS5F50A BR
SERVICE DATA AND SPECIFICATIONS (SDS) .......131
ST
RS
BT
HA
SC
EL
IDX
MT-3
PREPARATION RS5F30A
Special Service Tools
Tool number
Description
Tool name
NT418
NT410
NT411
NT411
NT411
NT414
MT-4
PREPARATION RS5F30A
Special Service Tools (Cont’d)
Tool number
Description
Tool name
GI
ST33400001 Installing differential oil seal
Drift a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia. MA
EM
NT086
EC
NT427
NT091
NT065 AX
ST22452000 Installing 1st & 2nd synchronizer
Drift a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia. SU
NT065 BR
ST37750000 Installing 5th main gear
Drift Installing 3rd & 4th synchronizer
Installing input shaft oil seal ST
Installing 5th synchronizer
a: 40 mm (1.57 in) dia.
NT065 b: 31 mm (1.22 in) dia. RS
ST22360002 Installing mainshaft rear bearing inner race
Drift a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia. BT
NT065 HA
ST30621000 Installing differential side bearing outer race
Drift (Use with ST30611000.)
a: 79 mm (3.11 in) dia. SC
b: 59 mm (2.32 in) dia.
EL
NT073
IDX
MT-5
PREPARATION RS5F30A
Special Service Tools (Cont’d)
Tool number
Description
Tool name
NT419
NT077
NT065
NT065
NT065
MT-6
PREPARATION RS5F70A
Special Service Tools
Tool number
Description GI
Tool name
FE
NT418
NT410
AX
NT410 SU
ST30031000 Removing 3rd, 5th input gear
Puller Removing 3rd & 4th and 5th & Rev synchronizer
hub BR
Removing mainshaft rear bearing
Removing 2nd gear, 5th gear bush
Removing 1st & 2nd synchronizer hub, 1st and ST
4th main gear
Removing and installing differential side bearing
NT411 a: 90 mm (3.54 in) dia. RS
b: 50 mm (1.97 in) dia.
IDX
MT-7
PREPARATION RS5F70A
Special Service Tools (Cont’d)
Tool number
Description
Tool name
NT414
NT084
NT115
NT065
NT065
MT-8
PREPARATION RS5F70A
Commercial Service Tools (Cont’d)
NT065
Drift Installing 3rd & 4th and 1st & 2nd synchronizer AT
hub
Installing mainshaft front bearing
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
AX
NT065
ST
RS
BT
HA
SC
EL
IDX
MT-9
PREPARATION RS5F50A
Special Service Tools
Tool number
Description
Tool name
NT075
NT410
NT411
NT411
NT411
NT675
NT414
MT-10
PREPARATION RS5F50A
Special Service Tools (Cont’d)
Tool number
Description
Tool name
GI
ST33400001 Installing differential oil seal
Drift a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia. MA
EM
NT086
EC
NT065
CL
NT065
BR
NT419
NT087 RS
KV38106500 Measuring turning torque of final drive assembly
Preload adapter
BT
NT087
HA
Commercial Service Tools NJMT0002
NT065 IDX
MT-11
PREPARATION RS5F50A
Commercial Service Tools (Cont’d)
NT065
NT065
MT-12
MANUAL TRANSAXLE
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-
Symptoms
(Possible cause)
SUSPECTED PARTS
Reference page
Oil leakage
Noise
2
MT-13
OIL SEAL (Worn or damaged) MT-30 (RS5F30A), MT-54 (RS5F70A), MT-92 (RS5F50A)
2
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged) MT-32 (RS5F30A), MT-56 (RS5F70A), MT-94 (RS5F50A)
2
BAULK RING (Worn or damaged) MT-31 (RS5F30A), MT-55 (RS5F70A), MT-93 (RS5F50A)
3
NJMT0003S0101
NJMT0003S01
NJMT0003
INSERT SPRING (Damaged) MT-31 (RS5F30A), MT-55 (RS5F70A), MT-93 (RS5F50A)
3
IDX
EL
SC
HA
BT
RS
ST
BR
SU
AX
AT
CL
FE
EC
LC
EM
MA
GI
M/T OIL RS5F30A, RS5F70A
Changing M/T Oil
SMT512C
Checking NJMT0087
OIL LEAK AND OIL LEVEL NJMT0087S01
1. Check that oil is not leaking from transaxle or around it.
2. Check oil level.
Never start engine while checking oil level.
Filler plug:
: 10 - 19 N·m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
SMA066C
MT-14
M/T OIL RS5F50A
Changing M/T Oil
FE
CL
Checking NJMT0089
OIL LEAK AND OIL LEVEL AT
NJMT0089S01
Check for oil leakage and oil level.
Never start engine while checking oil level. AX
Filler plug:
: 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
SU
BR
SMA066C
ST
RS
BT
HA
SC
EL
IDX
MT-15
NJMT0034
DESCRIPTION
Cross-sectional View — RS5F30A
SMT953DB
MT-16
DESCRIPTION
Cross-sectional View — RS5F70A
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
SMT924D
MT-17
DESCRIPTION
Cross-sectional View — RS5F50A
SMT196DA
MT-18
DESCRIPTION
Cross-sectional View — RS5F50A (Cont’d)
DOUBLE-CONE SYNCHRONIZER NJMT0034S0403
— RS5F30A (For double baulk ring type), RS5F70A and
RS5F50A — GI
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.
MA
EM
SMT837DA LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
MT-19
ON-VEHICLE SERVICE
Replacing Oil Seal
SMT563AA
SMT564AB
SMT925DA
Item Model A B
RS5F30A
RS5F50A
SMT926DA
SMT927D
MT-20
ON-VEHICLE SERVICE
Replacing Oil Seal (Cont’d)
STRIKING ROD OIL SEAL NJMT0035S02
1. Remove transaxle control rod from yoke.
2. Remove retaining pin of yoke. GI
I Be careful not to damage boot.
MA
EM
SMT143DC LC
3. Remove striking rod oil seal.
EC
FE
CL
SMT566A
AX
SU
BR
SMT570A
RS
BT
HA
SMT876D
Except reverse No
SMT715BD
MT-21
ON-VEHICLE SERVICE
Position Switch Check (Cont’d)
PNP SWITCH NJMT0036S02
— RS5F70A — NJMT0036S0201
I Check continuity.
Gear position Continuity
Neutral Yes
Except neutral No
Reverse 1-3
Neutral 2-4
SMT939D
MT-22
NJMT0008
Removal NJMT0008S01
CAUTION:
Remove the crankshaft position sensor (POS) from transaxle GI
assembly before separating transaxle from engine.
Be careful not to damage sensor edge.
1. Remove battery and its bracket.
MA
2. Remove air cleaner box with mass air flow sensor.
EM
SMT928D LC
3. Remove clutch operating cylinder from transaxle.
4. Remove clutch hose clamp.
EC
5. Disconnect speedometer pinion, back-up lamp, PNP switch
(F70A) harness connectors and ground harness.
6. Remove starter motor from transaxle. FE
7. Remove crankshaft position sensor (POS) from transaxle front
side.
8. Remove shift control rod and support rod bracket from tran- CL
saxle.
9. Drain gear oil from transaxle.
SMT130DB
10. Draw out drive shafts from transaxle. Refer to AX-10,
“Removal”.
11. Support engine of transaxle by placing a jack under oil pan. AT
CAUTION:
Do not place jack under oil pan drain plug.
12. Remove bolts securing center member. AX
SU
BR
13. Remove LH mount and rear side mounting bolts. Refer to
EM-150, “Removal and Installation”. ST
14. Remove bolts securing gusset and transaxle.
RS
BT
HA
SC
EL
IDX
SMT133D
MT-23
REMOVAL AND INSTALLATION RS5F30A, RS5F70A
Removal (Cont’d)
15. Lower transaxle while supporting it with a jack.
SMT652C
Installation NJMT0008S02
I Tighten LH mount, rear side mount and center member bolts.
Refer to EM-150, “Removal and Installation”.
I Tighten clutch operating cylinder bolts. Refer to CL-14, “Instal-
lation”.
I Tighten starter motor bolts. Refer to SC-23, “Removal and
Installation”.
I Install drive shafts. Refer to AX-12, “Installation”.
I Tighten all transaxle bolts and any part removed.
Front gusset A to
30 - 40 (3.1 - 4.1, 22 - 30) 20 (0.79)
SMT930D
engine
Rear gusset B to
16 - 21 (1.6 - 2.1, 12 - 15) 16 (0.63)
engine
MT-24
REMOVAL AND INSTALLATION RS5F30A, RS5F70A
Installation (Cont’d)
MODEL QG18DE ENGINE =NJMT0008S0202
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
MT-25
NJMT0090
Removal NJMT0090S01
CAUTION:
Remove the crankshaft position sensor (POS) from transaxle
assembly before separating transaxle from engine.
Be careful not to damage sensor edge.
1. Remove battery and its bracket.
2. Remove fuse box from battery bracket.
3. Remove air cleaner box with mass air flow sensor.
4. Remove air breather hose and vacuum pump hose.
5. Remove fuel filter bracket bolts (YD22E model).
SMT928D
13. Remove shift control rod and support rod bracket from tran-
saxle.
14. Drain gear oil from transaxle.
15. Draw out drive shafts from transaxle. Refer to AX-10,
“Removal”.
16. Support engine and transaxle by placing a jack under the tran-
saxle.
17. Remove bolts securing center member.
SMT929D
SMT950D
MT-26
REMOVAL AND INSTALLATION RS5F50A
Removal (Cont’d)
22. Pick up EGI harness clamp and install engine slinger. Next, set
chain block.
23. Jack up the air compressor engine bracket. GI
24. Remove engine front mounting.
25. Remove LH side mounting. Refer to EM-150, “Removal and
Installation”. MA
EM
SMT940D LC
EC
FE
CL
SMT951D
26. Jack up until engine oil filter bracket bolts are just about to
touch the side frame. AT
AX
SU
BR
SMT952D
SC
EL
IDX
SMT941D
MT-27
REMOVAL AND INSTALLATION RS5F50A
Installation
Installation NJMT0090S02
1. Put transaxle under the engine compartment.
2. Set chain block on transaxle and hang.
3. Lift up transaxle case so as not to hit against the side frame
and suspension member.
4. Assemble transaxle to engine.
I Tighten LH mount, rear side mount and center member bolts.
Refer to EM-150, “Removal and Installation”.
I Tighten clutch operating cylinder bolts. Refer to CL-14, “Instal-
lation”.
I Tighten starter motor bolts. Refer to SC-23, “Removal and
Installation”.
I Install drive shafts. Refer to AX-12, “Installation”.
I Tighten all transaxle bolts and any part removed.
SMT941D
SMT932D
MT-28
NJMT0038
Components NJMT0038S01
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
SMT933DA
HA
1. Control lever knob 9. Hand lever socket 17. Bushing
2. Boot 10. Plate bolt 18. Collar
SC
3. Control lever socket 11. Transaxle hole cover 19. Bushing
4. Control lever 12. Mass damper 20. Collar
5. Bearing seat spring 13. Holder bracket 21. Support rod EL
6. Seat 14. Return spring rubber 22. Plate
7. Bushing 15. Return spring 23. Support rod bracket
8. O-ring 16. Control rod IDX
MT-29
NJMT0039
OVERHAUL RS5F30A
Case Components
SMT956DA
MT-30
OVERHAUL RS5F30A
Gear Components
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
SMT954DA
BR
1. Reverse idler gear 21. 1st gear needle bearing 39. Final gear
2. Reverse idler bushing 22. Steel ball 40. Differential side bearing adjusting
3. Reverse idler spacer 23. 2nd & 3rd bushing shim ST
4. Snap ring 24. 4th main gear 41. Differential side bearing
5. Spacer 25. 5th main gear 42. Retaining pin
6. Input shaft front bearing 26. Thrust washer 43. Pinion mate thrust washer RS
7. Input shaft 27. Mainshaft C-ring 44. Speedometer drive gear
8. Oil plug 28. C-ring holder 45. Speedometer stopper
9. 5th gear needle bearing 29. Mainshaft rear bearing 46. Side gear BT
10. 5th input gear 30. Spacer 47. Pinion mate gear
11. Coupling sleeve 31. Mainshaft rear bearing adjusting 48. Pinion mate shaft
12. Baulk ring shim 49. Side gear thrust washer HA
13. 5th synchronizer hub 32. 4th bushing 50. Snap ring
14. Spread spring 33. 3rd & 4th synchronizer hub 51. 1st inner baulk ring
15. Shifting insert 34. 3rd main gear 52. 1st synchronizer cone SC
16. 5th stopper 35. 2nd main gear 53. 1st outer baulk ring
17. Input shaft rear bearing 36. 1st & 2nd synchronizer hub 54. 2nd outer baulk ring
18. Mainshaft front bearing 37. Reverse main gear (Coupling 55. 2nd synchronizer cone EL
19. Mainshaft sleeve) 56. 2nd inner baulk ring
20. 1st main gear 38. Differential case
IDX
MT-31
OVERHAUL RS5F30A
Shift Control Components
SMT592D
1. Reverse check spring 10. 3rd & 4th shift fork 18. Striking lever
2. Reverse check plug 11. 1st & 2nd shift fork 19. Check ball (Large)
3. Check ball plug 12. Control bracket 20. Check ball (Small)
4. Shift check ball 13. Striking interlock 21. Check sleeve
5. Shift check spring 14. Retaining pin 22. O-ring
6. Fork shaft support spring 15. Retaining pin 23. Select return spring
7. Shifter cap 16. Yoke 24. Check plunger
8. Fork shaft 17. Striking rod 25. Stopper pin
9. 5th shift fork
MT-32
NJMT0040
DISASSEMBLY RS5F30A
MA
EM
SMT571 LC
2. Draw out reverse idler spacer and fork shaft, then remove 5th
and 3rd & 4th shift forks.
I Be careful not to lose shifter cap.
EC
FE
CL
SMT188A
AX
SU
BR
SMT082A
BT
HA
SMT577
SMT579
MT-33
DISASSEMBLY RS5F30A
SMT580
5. Remove oil pocket, shift check ball, shift check spring and
check ball plug.
SMT648AA
SMT599AA
SMT583
SMT584
MT-34
DISASSEMBLY RS5F30A
GI
MA
EM
SMT585 LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
MT-35
REPAIR FOR COMPONENT PARTS RS5F30A
Input Shaft and Gears
SMT734A
SMT750BA
5. Remove snap ring of input shaft front bearing and input gear
spacer.
SMT697C
SMT601A
MT-36
REPAIR FOR COMPONENT PARTS RS5F30A
Input Shaft and Gears (Cont’d)
INSPECTION NJMT0043
Input Shaft and Gears
I Check shaft for cracks, wear or bending.
NJMT0043S01
GI
I Check gears for excessive wear, chips or cracks.
MA
EM
SMT602A LC
Synchronizer NJMT0043S02
I Check spline portion of coupling sleeves, hubs and gears for EC
wear or cracks.
I Check baulk rings for cracks or deformation.
I Check shifting inserts for wear or deformation. FE
CL
SMT387A
BR
SMT140
Bearing
I
NJMT0043S03
Make sure bearings roll freely and are free from noise, cracks,
ST
pitting or wear.
RS
BT
HA
SMT148A
ASSEMBLY NJMT0044
SC
1. Assemble 5th synchronizer.
EL
IDX
SMT736A
MT-37
REPAIR FOR COMPONENT PARTS RS5F30A
Input Shaft and Gears (Cont’d)
I Be careful not to hook front and rear ends of spread
spring to the same insert.
SMT761B
SMT731-A
5. Select and install snap ring that gives the proper clearance of
input shaft groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Snap ring of input shaft front bearing:
Refer to SDS, MT-120.
SMT735A
6. Install 5th gear needle bearing, 5th input gear, 5th synchro-
nizer and 5th stopper.
7. Measure gear end play as the final check. Refer to
“DISASSEMBLY”, MT-36.
SMT779AA
8. Select and install snap ring that gives the proper clearance of
input shaft groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Snap ring of input shaft 5th synchronizer hub:
Refer to SDS, MT-120.
SMT591
MT-38
REPAIR FOR COMPONENT PARTS RS5F30A
Input Shaft and Gears (Cont’d)
9. Install input shaft rear bearing.
10. Select and install snap ring that gives the proper clearance of
input shaft groove. GI
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Snap ring of input shaft rear bearing:
MA
Refer to SDS, MT-120.
EM
SMT938D LC
Mainshaft and Gears
DISASSEMBLY NJMT0045
EC
1. Before disassembly, check 1st, 2nd, 3rd and 4th main gear end
plays.
Gear end play: FE
Refer to SDS, MT-119.
I If not within specification, disassemble and check contact sur- CL
face of gear, shaft and hub. Then check clearance of C-ring
groove. Refer to “ASSEMBLY”, MT-42.
SMT605
AX
SU
BR
SMT641-A
RS
BT
HA
SMT638-A
EL
IDX
SMT592-A
MT-39
REPAIR FOR COMPONENT PARTS RS5F30A
Mainshaft and Gears (Cont’d)
5. Press out 5th main gear.
SMT593-A
SMT687C
7. Remove 3rd & 4th synchronizer, 3rd main gear, 2nd & 3rd
bushing, steel ball and 2nd main gear.
I Be careful not to lose steel ball.
SMT780AA
8. Remove 1st & 2nd synchronizer and 1st main gear, then
remove 1st gear needle bearing.
SMT594
MT-40
REPAIR FOR COMPONENT PARTS RS5F30A
Mainshaft and Gears (Cont’d)
INSPECTION NJMT0046
Mainshaft and Gears
I Check shaft for cracks, wear or bending.
NJMT0046S01
GI
I Check gears for excessive wear, chips or cracks.
MA
EM
SMT604A LC
Synchronizer NJMT0046S02
I Check spline portion of coupling sleeves, hubs and gears for EC
wear or cracks.
I Check baulk rings for cracks or deformation.
I Check shifting inserts for wear or deformation. FE
CL
SMT387A
BR
SMT140
ST
RS
BT
HA
SMT714CD
I Measure wear of 1st and 2nd baulk ring (For double baulk ring SC
type).
a) Place baulk rings in position on synchronizer cone.
b) While holding baulk ring against synchronizer cone as far as it
EL
will go, measure dimensions “A” and “B”.
Standard: IDX
A 0.7 - 0.9 mm (0.028 - 0.035 in)
B 0.7 - 1.0 mm (0.028 - 0.039 in)
Wear limit:
0.2 mm (0.008 in)
MT-41
REPAIR FOR COMPONENT PARTS RS5F30A
Mainshaft and Gears (Cont’d)
I If dimension “A” or “B” is smaller than the wear limit,
replace outer baulk ring, inner baulk ring and synchro-
nizer cone as a set.
Bearing NJMT0046S03
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 NJMT0047
1. Assemble 1st & 2nd and 3rd & 4th synchronizers.
SMT603A
SMT761B
SMT605AA
MT-42
REPAIR FOR COMPONENT PARTS RS5F30A
Mainshaft and Gears (Cont’d)
4. Install steel ball, 2nd main gear, 2nd & 3rd bushing, 3rd main
gear and 3rd & 4th synchronizer.
I Apply multi-purpose grease to steel ball before installing GI
it.
I 2nd & 3rd bushing has a groove in which steel ball fits.
MA
EM
SMT085CA LC
5. Install steel ball, 4th bushing and 4th main gear.
I Apply multi-purpose grease to steel ball before installing
it.
EC
I 4th bushing has a groove in which steel ball fits.
FE
CL
SMT687C
AX
SU
BR
SMT606AA
EL
IDX
SMT607AA
MT-43
REPAIR FOR COMPONENT PARTS RS5F30A
Mainshaft and Gears (Cont’d)
11. Press on mainshaft front bearing.
12. Measure gear end play as the final check — Refer to
“DISASSEMBLY”, MT-39.
SMT639
Final Drive
DISASSEMBLY NJMT0048
1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
I Be careful not to mix up the right and left bearings.
SMT647-A
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.
SMT147AA
INSPECTION NJMT0049
Gear, Washer, Shaft and Case NJMT0049S01
I Check mating surfaces of differential case, side gears and
pinion mate gears.
I Check washers for wear.
SMT083A
Bearings NJMT0049S03
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
MT-44
REPAIR FOR COMPONENT PARTS RS5F30A
Final Drive (Cont’d)
ASSEMBLY NJMT0050
1. Attach side gear thrust washers to side gears and install in
differential case. GI
2. Install pinion mate thrust washers and pinion mate gears.
MA
EM
SMT839 LC
3. Insert pinion mate shaft.
I When inserting, be careful not to damage pinion mate
thrust washers.
EC
FE
CL
SMT087A
AX
SU
BR
SMT610AB
EL
IDX
SMT147AA
MT-45
REPAIR FOR COMPONENT PARTS RS5F30A
Final Drive (Cont’d)
6. Install final gear.
I Apply locking sealant to final gear fixing bolts before
installing them.
7. Install speedometer drive gear and stopper.
SMT609A
SMT648
SMT086C
Case Components
DISASSEMBLY AND ASSEMBLY NJMT0052
Input Shaft Oil Seal NJMT0052S01
1. Drive out input shaft oil seal.
SMT660A
SMT751BA
MT-46
REPAIR FOR COMPONENT PARTS RS5F30A
Case Components (Cont’d)
Input Shaft Rear Bearing NJMT0052S02
1. Remove welch plug from transmission case.
GI
MA
EM
SMT688C LC
2. Remove input shaft rear bearing by tapping it from welch plug
hole.
EC
FE
CL
SMT633
AX
SU
BR
SMT634
RS
BT
HA
SMT635-A
IDX
SMT636-A
MT-47
REPAIR FOR COMPONENT PARTS RS5F30A
Case Components (Cont’d)
3. Install oil channel.
I Ensure the oil groove faces the oil pocket.
SMT595
SMT752BA
MT-48
NJMT0091
ADJUSTMENT RS5F30A
Differential Side Bearing Preload
LC
1. Remove differential side bearing outer race (transmission case
side) and shim(s).
EC
FE
CL
SMT645-A
SU
BR
SMT646-A
IDX
SMT454-A
MT-49
ADJUSTMENT RS5F30A
Differential Side Bearing Preload (Cont’d)
c. Measure turning torque of final drive assembly.
Turning torque of final drive assembly (New bearing):
Refer to SDS, MT-121.
I When old bearing is used again, turning torque will be
slightly less than the above.
I Make sure torque is close to the specified range.
I Changes in turning torque of final drive assembly per
revolution should be within 1.0 N·m (10 kg-cm, 8.7 in-lb)
without binding.
SMT600-A
SMT613AB
SMT650A
MT-50
NJMT0092
ASSEMBLY RS5F30A
EM
SMT586 LC
2. Install reverse check sleeve assembly.
3. Install check balls, reverse check spring and check plug.
EC
FE
CL
SMT584
6. Install check ball plug, shift check ball and shift check spring.
7. Install oil pocket.
ST
RS
BT
HA
SMT648AA
EL
IDX
SMT580
MT-51
ASSEMBLY RS5F30A
SMT737A
SMT577
SMT664
SMT666
SMT596
MT-52
ASSEMBLY RS5F30A
MA
EM
SMT587 LC
15. Measure total turning torque.
Total (Final drive + Mainshaft) turning torque (New
bearing):
EC
Refer to SDS, MT-121.
I When old bearing is used again, turning torque will be FE
slightly less than the above.
I Make sure torque is close to the specified range.
CL
SMT600-A
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
MT-53
NJMT0054
OVERHAUL RS5F70A
Case Components
SMT942D
MT-54
OVERHAUL RS5F70A
Gear Components
GI
MA
EM
LC
EC
FE
CL
AT
SMT641DA
AX
1. Reverse idler gear front thrust 24. 5th gear rear C-ring 47. Mainshaft adjusting shim SU
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 BR
4. Reverse idle gear rear 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
6. Reverse idler gear shaft
53. Spread spring ST
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 RS
9. Input shaft 33. 1st inner baulk ring 57. Coupling sleeve
10. 3rd gear needle bearing 34. 1st synchronizer cone 58. Reverse gear bushing
11. 3rd input gear 35. 1st outer baulk ring 59. Reverse gear needle bearing BT
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 HA
15. Shifting insert 39. 2nd gear bushing 63. Sub-gear washer
16. 3rd & 4th synchronizer hub 40. 2nd gear needle bearing 64. Snap ring
17. Spread spring 41. 2nd gear outer baulk ring 65. Mainshaft thrust washer SC
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 EL
21. 4th input gear 45. 3rd main gear 69. Snap ring
22. 5th gear front C-ring 46. Spacer
23. 5th input gear IDX
MT-55
OVERHAUL RS5F70A
Shift Control Components
SMT642DB
1. Clutch housing 17. Interlock plunger 32. Select check leaf spring
2. 3rd & 4th bracket 18. Check ball 33. Return spring
3. 3rd & 4th shift fork 19. Interlock pin 34. Steel ball
4. Retaining pin 20. Stopper ring 35. Reverse gate
5. Check ball 21. 5th & reverse fork rod 36. Return bearing
6. Check pin 22. Striking lever 37. Selector arm
7. Check spring 23. Retaining pin 38. Bushing
8. Check plug 24. 1st & 2nd bracket 39. Welch plug
9. Stopper ring 25. 1st & 2nd shift fork 40. Selector shaft
10. 3rd & 4th fork rod 26. Check ball 41. Striking yoke
11. Selector shaft pin 27. 1st & 2nd fork rod 42. Retaining pin
12. Selector 28. Transaxle case 43. Striking rod
13. 5th & reverse bracket 29. Check ball 44. Dust boot
14. Reverse switch bracket 30. Check spring 45. Striking rod oil seal
15. Retaining pin 31. Check plug 46. Welch plug
16. 5th & reverse shift fork
MT-56
OVERHAUL RS5F70A
Final Drive Components
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
SMT936D
BR
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 ST
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 RS
BT
HA
SC
EL
IDX
MT-57
NJMT0055
DISASSEMBLY RS5F70A
Transaxle Case
SMT648D
SMT644D
SMT645D
SMT646D
SMT647D
MT-58
DISASSEMBLY RS5F70A
Transaxle Case (Cont’d)
9. Remove mounting bolts.
10. Remove input shaft rear bearing adjusting shim from transaxle
case. GI
MA
EM
SMT649D LC
11. Remove oil gutter from case.
EC
FE
CL
SMT650D
12. Remove differential side bearing outer race and adjusting shim
from case. AT
AX
SU
BR
SMT651DB
RS
BT
HA
SMT653DB
EL
IDX
SMT839DB
MT-59
DISASSEMBLY RS5F70A
Clutch Housing
SMT654D
SMT656DC
SMT655D
SMT658D
10. Remove retaining pin from 5th & reverse shift fork and reverse
switch bracket.
11. Remove 5th & reverse fork rod.
12. Remove interlock pin from 5th & reverse fork rod.
13. Remove reverse switch bracket and 5th & reverse bracket.
SMT657DC
MT-60
DISASSEMBLY RS5F70A
Clutch Housing (Cont’d)
14. Remove check ball from housing.
15. Remove retaining pin for 1st & 2nd shift fork and bracket.
16. Remove 1st & 2nd fork rod. GI
17. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd
bracket.
MA
EM
SMT659DC LC
18. Remove both input shaft and mainshaft assemblies from hous-
ing.
EC
FE
CL
SMT660D
AX
SU
BR
SMT661D
RS
BT
HA
SMT662D
EL
IDX
SMT663DB
MT-61
DISASSEMBLY RS5F70A
Clutch Housing (Cont’d)
24. Using a magnet or other suitable tool, remove retaining pin
from selector shaft.
SMT664D
SMT665DB
26. Remove reamer bolt, then remove select check leaf spring,
return spring, steel ball, reverse gate, selector arm, bearing,
and bushing.
CAUTION:
Be careful not to lose the steel ball.
SMT666DA
SMT667DB
SMT668D
MT-62
DISASSEMBLY RS5F70A
Clutch Housing (Cont’d)
30. Remove differential oil seal from housing.
GI
MA
EM
SMT669DB LC
31. Remove differential side outer race from housing.
EC
FE
CL
SMT670DB
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
MT-63
REPAIR FOR COMPONENT PARTS RS5F70A
Input Shaft and Gears
SMT759D
SMT671D
SMT672DB
SMT673D
SMT674DB
MT-64
REPAIR FOR COMPONENT PARTS RS5F70A
Input Shaft and Gears (Cont’d)
8. Remove 4th input gear, baulk ring, 4th gear needle bearing,
and 4th gear C-ring from input shaft.
9. Press out both 3rd & 4th synchronizer hub assembly and 3rd GI
input gear from input shaft.
10. Remove 3rd gear needle bearing.
MA
EM
SMT675DB LC
11. Press out input shaft front bearing from input shaft.
EC
FE
CL
SMT676DB
INSPECTION NJMT0057
Input Shaft and Gears NJMT0057S01
AT
I Check shaft for cracks, wear or bending.
I Check gears for excessive wear, chips or cracks. AX
SU
BR
SMT693D
Synchronizers
I
NJMT0057S02
Check spline area of coupling sleeves, hubs and gears for
ST
wear or cracks.
I Check baulk rings for cracks or deformation. RS
I Check insert springs for wear or deformation.
BT
HA
SMT637A
EL
IDX
SMT867D
MT-65
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,
replace the sleeve.
Coupling sleeve length “L”:
Refer to SDS, MT-124.
SMT841D
SMT140
Bearing NJMT0057S03
I Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT148A
ASSEMBLY NJMT0058
1. Press on input shaft front bearing.
2. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring
bearing to input shaft.
SMT696DB
3. Install spread spring, shifting insert, and 3rd & 4th synchronizer
hub onto 3rd & 4th coupling sleeve.
I Pay attention to the shape of spread spring and shifting insert
for correct assembly.
Do not install spread spring hook onto the same shifting insert.
CAUTION:
Do not reuse 3rd & 4th synchronizer hub.
SMT694D
MT-66
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).
GI
MA
EM
SMT695D LC
I Install 3rd & 4th coupling sleeve with its chamfered surface
facing the 4th input gear side.
EC
FE
CL
SMT699D
SU
BR
SMT698DB
6. Measure the end play of 3rd & 4th synchronizer hub, and
check if it is within allowable specification below. ST
End play:
0 - 0.06 mm (0 - 0.0024 in) RS
7. If not within specification, adjust the end play by changing
thickness of 4th input gear C-ring.
4th input gear C-ring: BT
Refer to SDS, MT-125.
HA
SMT700DA
8. Install 4th gear needle bearing, 4th gear baulk ring, and 5th SC
gear front C-ring.
9. Install 4th input gear.
EL
IDX
SMT701DB
MT-67
REPAIR FOR COMPONENT PARTS RS5F70A
Input Shaft and Gears (Cont’d)
10. Position 5th input gear as shown in the figure, and install it on
input shaft.
SMT703D
SMT702DB
13. Measure the end play of 5th input gear, and check if it is within
the allowable specification below.
End play:
0 - 0.06 mm (0 - 0.0024 in)
14. If not within specification, adjust the end play by changing
thickness of the 5th input gear rear C-ring.
5th input gear rear C-ring:
Refer to SDS, MT-125.
SMT704DA
SMT705DB
SMT671D
MT-68
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears
SMT760D LC
2. Remove snap ring.
EC
FE
CL
SMT677D
AX
SU
BR
SMT678D
RS
BT
HA
SMT679DB
IDX
SMT680D
MT-69
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
7. Place bearing replacer between 5th & reverse synchronizer
hub and 5th main gear, and press out both reverse gear bush-
ing and 5th & reverse synchronizer assembly.
8. Remove 5th main gear, 5th gear baulk ring, and 5th gear
needle bearing.
SMT681DB
9. Place bearing replacer between 3rd and 4th main gears, and
press out both 5th gear bushing and 4th main gear.
SMT682DB
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
gear, and 1st double cone.
14. Remove 1st gear needle bearing.
SMT684DB
INSPECTION NJMT0060
Mainshaft and Gears NJMT0060S01
I Check shaft for cracks, wear or bending.
I Check gears for excessive wear, chips or cracks.
SMT693D
MT-70
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
Synchronizers NJMT0060S02
I Check spline area of coupling sleeves, hubs and gears for
wear or cracks. GI
I Check baulk rings for cracks or deformation.
I Check insert springs for wear or deformation.
MA
EM
SMT637A LC
I If any crack, damage, or excessive wear is found on cam face
of baulk ring or working face of insert, replace it.
EC
FE
CL
SMT867D
BR
SMT868D
BT
HA
SMT140
SC
EL
IDX
SMT714CD
MT-71
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
I Measure wear of 1st and 2nd baulk ring.
a) Place baulk rings in position on synchronizer cone.
b) While holding baulk ring against synchronizer cone as far as it
will go, measure dimensions “A” and “B”.
Standard:
A 0.6 - 0.8 mm (0.024 - 0.031 in)
B 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit:
0.2 mm (0.008 in)
I If dimension “A” or “B” is smaller than the wear limit,
replace outer baulk ring, inner baulk ring and synchro-
nizer cone as a set.
Bearing NJMT0060S03
I Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT148A
ASSEMBLY NJMT0061
1. Install 1st gear needle bearing and 1st main gear onto main-
shaft.
2. Install 1st double cone assembly onto mainshaft.
SMT706D
MT-72
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
3. Install 1st & 2nd synchronizer hub with its three grooves fac-
ing the front side (1st main gear side) onto mainshaft.
CAUTION: GI
Do not reuse 1st & 2nd synchronizer hub.
MA
EM
SMT695D LC
4. Install 1st & 2nd synchronizer hub.
EC
FE
CL
SMT707DB
AX
SU
BR
SMT994BB
6. Install 1st & 2nd coupling sleeve with its chamfered surface
facing the 1st main gear side onto 1st & 2nd synchronizer hub. ST
RS
BT
HA
SMT708D
7. Install 2nd gear bushing with its flange surface facing 1st & 2nd SC
synchronizer hub side.
EL
IDX
SMT709DD
MT-73
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
8. Install 2nd needle bearing, 2nd double cone assembly, and
2nd main gear onto mainshaft.
9. Position 3rd main gear as shown in the figure, and install it.
CAUTION:
Do not reuse 3rd main gear.
SMT710DB
SMT711D
12. Position 4th main gear as shown in the figure, and install it onto
mainshaft.
SMT713D
SMT712DB
MT-74
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
14. Install 5th gear bushing with its flange surface facing the 4th
main gear side.
GI
MA
EM
SMT714DB LC
15. Install 5th needle bearing, 5th main gear, and 5th gear baulk
ring onto mainshaft.
EC
FE
CL
SMT761D
16. Being careful of the following points, install spread spring, shift-
ing insert, and 5th & reverse synchronizer hub onto 5th & AT
reverse coupling sleeve.
I Pay attention to the shape of spread spring and shifting insert
for correct assembly. AX
Do not install spread spring hook onto the same shifting insert.
SU
BR
SMT694D
I Install synchronizer hub with its three grooves facing the front
side (5th main gear side). ST
CAUTION:
Do not reuse 5th & reverse synchronizer hub. RS
BT
HA
SMT695D
I Install 5th & reverse coupling sleeve with its chamfered surface SC
facing the reverse main gear side.
EL
IDX
SMT716D
MT-75
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
17. Install 5th & reverse synchronizer hub assembly.
SMT715DB
SMT717DB
21. Install sub-gear, sub-gear washer, and snap ring onto reverse
main gear.
CAUTION:
I Pay attention to direction of sub-gear washer.
I Do not reuse snap ring.
SMT718D
SMT719D
MT-76
REPAIR FOR COMPONENT PARTS RS5F70A
Mainshaft and Gears (Cont’d)
24. Install mainshaft rear bearing.
GI
MA
EM
SMT720DB LC
25. Install mainshaft C-ring.
26. Using feeler gauge, measure the end play of mainshaft rear
bearing, and check if it satisfies the following specification.
EC
End play:
0 - 0.06 mm (0 - 0.0024 in) FE
Mainshaft C-rings:
Refer to SDS, MT-126.
CL
SMT721D
AX
SU
BR
SMT678D
RS
BT
HA
SMT677D
Final Drive SC
PRE-INSPECTION NJMT0062
I Check the clearance between side gear and differential case EL
as follows.
1. Clean final drive assembly sufficiently to prevent side gear
thrust washer, differential case, side gear, and other parts from IDX
sticking by gear oil.
SMT610AH
MT-77
REPAIR FOR COMPONENT PARTS RS5F70A
Final Drive (Cont’d)
2. Upright the differential case so that the side gear to be mea-
sured faces upward.
3. Place final drive adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.
Clearance between side gear and differential case:
0.1 - 0.2 mm (0.004 - 0.008 in)
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
SMT685DC same way.
DISASSEMBLY NJMT0063
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
SMT647-C
SMT689DB
SMT839
MT-78
REPAIR FOR COMPONENT PARTS RS5F70A
Final Drive (Cont’d)
INSPECTION NJMT0064
Gear, Washer, Shaft and Case
I Check mating surfaces of differential case, side gears and
NJMT0064S01
GI
pinion mate gears.
I Check washers for wear. MA
EM
SMT083A LC
Bearing NJMT0064S03
I Make sure bearings roll freely and are free from noise, cracks, EC
pitting or wear.
I When replacing tapered roller bearing, replace outer and
inner race as a set. FE
CL
SPD715
ASSEMBLY NJMT0065
1. Apply gear oil to sliding area of differential case, each gear, AT
and thrust washer.
2. Install side gear thrust washer and side gear into differential
case. AX
3. Position pinion mate gear and pinion mate thrust washer
diagonally, and install them into differential case while rotating.
SU
BR
SMT062A
RS
BT
HA
SMT087A
SMT699BB
SMT842D
SMT751DB
13. Install differential 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-57.
SMT752D
MT-80
REPAIR FOR COMPONENT PARTS RS5F70A
Shift Control Components
7.80 - 7.93 mm EM
1st & 2nd 0.2 mm (0.008 in)
(0.3071 - 0.3122 in)
7.80 - 7.93 mm
SMT801D 3rd & 4th 0.2 mm (0.008 in) LC
(0.3071 - 0.3122 in)
7.80 - 7.93 mm
5th & reverse 0.2 mm (0.008 in)
(0.3071 - 0.3122 in) EC
FE
CL
I Check if shift check groove of fork rod or 5th & reverse check
groove is worn, or has any other abnormalities. AT
AX
SU
BR
SMT692D
ST
RS
BT
HA
SC
EL
IDX
MT-81
NJMT0067
ASSEMBLY RS5F70A
Clutch Housing
SMT722DB
SMT723DA
3. Hammer input shaft oil seal into clutch housing as far as it will
go.
CAUTION:
Do not reuse input shaft oil seal.
SMT724DA
4. Hammer the dust seal into clutch housing as far as it will go.
CAUTION:
Do not reuse dust seal.
SMT725DB
SMT726DB
MT-82
ASSEMBLY RS5F70A
Clutch Housing (Cont’d)
6. Install new oil channel (mainshaft).
CAUTION:
Pay attention to installation direction of oil channel. GI
MA
EM
SMT727D LC
7. Align the notches on mainshaft front bearing and transaxle
case. Then, install mainshaft front bearing.
EC
FE
CL
SMT728DA
AX
SU
BR
SMT729D
HA
SMT667DB
10. Hammer the welch plug (striking lever side) with a general- SC
purpose drift [OD: 12 mm (0.47 in)].
CAUTION:
Do not reuse welch plug. EL
IDX
SMT730D
MT-83
ASSEMBLY RS5F70A
Clutch Housing (Cont’d)
11. Install selector, selector shaft, and selector shaft pin into clutch
housing.
SMT731D
12. Hammer the welch plug (selector shaft side) with a general-
purpose drift [OD: 12 mm (0.47 in)].
CAUTION:
Do not reuse welch plug.
SMT732D
13. Install select check leaf spring, return spring, steel ball, reverse
gate, selector arm, bushing, and return bearing. Then, tighten
two reamer bolts with specified torque.
CAUTION:
Use correct reamer bolts for each installation point, because
each bolt has a different length.
SMT733DA
SMT734D
SMT735D
MT-84
ASSEMBLY RS5F70A
Clutch Housing (Cont’d)
15. Install differential assembly, input shaft assembly, and main-
shaft assembly into clutch housing.
CAUTION: GI
Be careful not to damage input shaft oil seal during installa-
tion of input shaft assembly.
MA
EM
SMT736D LC
16. Install 5th & reverse shift fork.
17. Install 1st & 2nd shift fork, bracket, and fork rod.
EC
18. Install retaining pin for 1st & 2nd bracket.
CAUTION:
Do not reuse retaining pin. FE
19. Install two check balls.
CL
SMT659DC
20. Install interlock pin into 5th & reverse fork rod.
21. Install reverse switch bracket, 5th & reverse bracket, and fork AT
rod.
22. Install retaining pin for 5th & reverse shift fork and reverse
switch bracket. AX
CAUTION:
Do not reuse retaining pin.
SU
23. Install 5th & reverse bracket stopper ring.
CAUTION:
Do not reuse stopper pin. BR
SMT657DC
BT
HA
SMT656DC
SMT655D
MT-85
ASSEMBLY RS5F70A
Transaxle Case
SMT737DA
SMT739D
SMT741D
MT-86
ASSEMBLY RS5F70A
Transaxle Case (Cont’d)
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 GI
roller).
c. Using dial gauge and scale as shown in the figure, measure
dimension “N2” between differential side bearing outer race MA
and transaxle case end face.
EM
SMT742D LC
4. Install selected shim and bearing outer race.
EC
FE
CL
SMT738DB
EL
IDX
MT-87
ASSEMBLY RS5F70A
Transaxle Case (Cont’d)
a. Using block gauge, scale, and dial gauge, measure dimension
“O1” between transaxle case end face and mounting face of
adjusting shim.
SMT744D
SMT745D
SMT650D
SMT755D
SMT802D
MT-88
ASSEMBLY RS5F70A
Transaxle Case (Cont’d)
11. Install transaxle case onto clutch housing, and tighten mount-
ing bolts with specified torque.
Tightening torque: GI
Refer to MT-54.
MA
EM
SMT649D LC
12. Apply Three Bond TB1215, Loctite Part No. 51813 or equiva-
lent to threads of reverse switch, PNP switch, and drain plug,
and install them. (Fill the case with oil before installation of filler EC
plug.)
13. Install speedometer pinion assembly.
FE
CAUTION:
Do not reuse O-ring.
CL
SMT648D
14. Install check springs and check balls. Apply sealant to the
thread on the check plug, and install it. AT
AX
SU
BR
SMT749D
EL
IDX
MT-89
ASSEMBLY RS5F70A
Transaxle Case (Cont’d)
a. Using dial gauge as shown in the figure, measure dimension
“P1” between transaxle case end face and mainshaft rear
bearing.
SMT747D
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.
SMT646D
18. Install reverse idler gear, O-ring, thrust washers (front, rear),
and bearing onto reverse idler shaft.
19. Install snap ring into transaxle case using snap ring pliers.
CAUTION:
I Do not reuse snap ring.
I Do not reuse O-ring.
I Before installation, apply gear oil to O-ring.
SMT753DA
20. Using feeler gauge, measure the end play of snap ring, and
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-125.
SMT754D
MT-90
ASSEMBLY RS5F70A
Transaxle Case (Cont’d)
21. Install selected snap ring.
CAUTION:
Do not reuse snap ring. GI
22. Apply gear oil to rear cover O-ring, and install rear cover, side
cover gasket, and side cover. Then tighten mounting bolts with
specified torque. MA
Tightening torque:
Refer to MT-54. EM
CAUTION:
Do not reuse mounting bolts for rear cover and side cover.
SMT644D LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
MT-91
NJMT0009
OVERHAUL RS5F50A
Case Components
SMT943D
MT-92
OVERHAUL RS5F50A
Gear Components
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
SMT937D
BR
1. Input shaft 19. 5th baulk ring 37. Differential side bearing
2. Input shaft front bearing 20. 1st outer baulk ring 38. Speedometer drive gear
3. 3rd input gear 21. 2nd inner baulk ring 39. Differential case ST
4. 3rd & 4th synchronizer hub 22. Snap ring 40. Pinion mate shaft
5. Snap ring 23. Mainshaft bearing spacer 41. Side gear
6. Coupling sleeve 24. Mainshaft front bearing 42. Side gear thrust washer RS
7. 4th baulk ring 25. Mainshaft 43. Pinion mate gear
8. 4th input gear 26. 1st main gear 44. Pinion mate gear thrust washer
9. Reverse baulk ring 27. 1st & 2nd synchronizer hub 45. Retaining pin BT
10. Reverse synchronizer cone 28. Reverse main gear & 1st-2nd cou- 46. Final gear
11. 5th synchronizer hub pling sleeve 47. Differential side bearing
12. Input shaft rear bearing 29. 2nd outer baulk ring 48. Differential side bearing adjusting HA
13. Input shaft bearing adjusting shim 30. 2nd gear synchronizer cone shim
14. 3rd baulk ring 31. 2nd main gear 49. Reverse idler gear
15. Insert spring 32. 3rd main gear 50. Bushing SC
16. 4th input gear thrust washer 33. 4th main gear 51. Reverse idler shaft
17. Thrust washer ring 34. 5th main gear 52. 1st gear synchronizer cone
18. 5th input gear 35. Mainshaft rear bearing 53. 1st inner baulk ring EL
36. Mainshaft bearing adjusting shim
IDX
MT-93
OVERHAUL RS5F50A
Shift Control Components
SMT862CA
MT-94
NJMT0010
DISASSEMBLY RS5F50A
EM
SMT626D LC
3. Remove PNP switch.
EC
FE
CL
SMT017AA
4. Mesh 4th gear, and then remove reverse idler shaft and
reverse idler gear. AT
AX
SU
BR
SMT659C
RS
BT
HA
SMT660C
EL
IDX
SMT661C
MT-95
DISASSEMBLY RS5F50A
SMT662C
SMT663C
SMT018B
10. Remove stopper rings and retaining pins from 5th and 3rd &
4th fork rods.
When removing stopper rings. Use snap ring remover and
installer.
11. Remove 5th and 3rd & 4th fork rods. Then remove forks and
brackets.
SMT664C
12. Remove both input and mainshafts with 1st & 2nd fork and fork
rod as a set.
13. Remove final drive assembly.
I Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
SMT105C
MT-96
DISASSEMBLY RS5F50A
MA
EM
SMT138A LC
15. Remove retaining pin and detach the selector.
EC
FE
CL
SMT618AA
AT
AX
SU
BR
SMT027A
RS
BT
HA
SMT028A
17. Remove retaining pin and then withdraw striking lever and SC
striking rod.
EL
IDX
SMT619AA
MT-97
REPAIR FOR COMPONENT PARTS RS5F50A
Input Shaft and Gears
SMT121C
SMT476C
SMT634AA
SMT205BA
4. Remove thrust washer ring, 4th input gear thrust washers and
4th input gear.
SMT474CA
MT-98
REPAIR FOR COMPONENT PARTS RS5F50A
Input Shaft and Gears (Cont’d)
5. Remove snap ring.
GI
MA
EM
SMT040A LC
6. Remove 3rd & 4th synchronizer and 3rd input gear.
EC
FE
CL
SMT041AA
AX
SU
BR
SMT042AA
INSPECTION NJMT0012 ST
Input shaft and Gears NJMT0012S01
I Check input shaft for cracks, wear or bending.
I Check gears for excessive wear, chips or cracks. RS
BT
HA
SMT636A
Synchronizer NJMT0012S02
SC
I Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
I Check baulk rings for cracks or deformation. EL
I Check insert springs for wear or deformation.
IDX
SMT637A
MT-99
REPAIR FOR COMPONENT PARTS RS5F50A
Input Shaft and Gears (Cont’d)
I Measure clearance between baulk ring and gear (3rd, 4th and
5th).
Clearance between baulk ring and gear:
Standard
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)
SMT140
SMT516B
Bearing NJMT0012S03
I Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT148A
ASSEMBLY NJMT0013
SMT122C
MT-100
REPAIR FOR COMPONENT PARTS RS5F50A
Input Shaft and Gears (Cont’d)
1. Place inserts in three grooves on coupling sleeve (3rd & 4th
synchronizer).
GI
MA
EM
SMT441C LC
2. Install 3rd input gear and 3rd baulk ring.
3. Press on 3rd & 4th synchronizer hub.
EC
I Pay attention to its direction.
4. Select proper snap ring of 3rd & 4th synchronizer hub to mini-
mize clearance of groove, and then install it. FE
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Snap ring of 3rd & 4th synchronizer hub:
CL
Refer to SDS, MT-133.
SMT477C
AT
AX
SU
BR
SMT123C
HA
SMT442C
EL
IDX
SMT206B
MT-101
REPAIR FOR COMPONENT PARTS RS5F50A
Input Shaft and Gears (Cont’d)
b. Install insert springs with reverse baulk ring onto coupling
sleeve.
I Pay attention to position of insert springs.
c. Place 5th baulk ring on 5th input gear.
d. Install reverse synchronizer cone on reverse baulk ring.
SMT752C
SMT208B
SMT124C
SMT753CA
MT-102
REPAIR FOR COMPONENT PARTS RS5F50A
Mainshaft and Gears
SMT191A LC
2. Press out mainshaft rear bearing.
EC
FE
CL
SMT638AA
AX
SU
BR
SMT044A
RS
BT
HA
SMT045AA
EL
IDX
SMT131AA
MT-103
REPAIR FOR COMPONENT PARTS RS5F50A
Mainshaft and Gears (Cont’d)
6. Remove snap ring.
SMT047A
7. Remove 1st & 2nd synchronizer hub and 1st main gear.
SMT048A
SMT639AA
INSPECTION NJMT0015
Mainshaft and Gears NJMT0015S01
I Check mainshaft for cracks, wear or bending.
I Check gears for excessive wear, chips or cracks.
SMT640A
Synchronizer NJMT0015S02
I Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
I Check baulk rings for cracks or deformation.
I Check insert springs for deformation.
SMT637A
MT-104
REPAIR FOR COMPONENT PARTS RS5F50A
Mainshaft and Gears (Cont’d)
GI
MA
EM
SMT420CA
LC
I Measure wear of 1st and 2nd double baulk rings.
a) Place baulk rings in position on synchronizer cone. EC
b) While holding baulk ring against synchronizer cone as far as it
will go, measure dimensions “A” and “B”.
Standard: FE
A 0.6 - 0.8 mm (0.024 - 0.031 in)
B 0.6 - 1.1 mm (0.024 - 0.043 in) CL
Wear limit:
0.2 mm (0.008 in)
c) If dimension “A” or “B” is smaller than the wear limit, replace
outer baulk ring, inner baulk ring and synchronizer cone as a
set.
AT
AX
SU
BR
Bearing
I
NJMT0015S03
Make sure bearings roll freely and are free from noise, cracks,
ST
pitting or wear.
I When replacing tapered roller bearing, replace outer and RS
inner race as a set.
BT
HA
SPD715
ASSEMBLY NJMT0016
SC
EL
IDX
SMT996B
MT-105
REPAIR FOR COMPONENT PARTS RS5F50A
Mainshaft and Gears (Cont’d)
1. Press on 1st main gear, 1st synchronizer cone, inner & outer
baulk rings and 1st & 2nd synchronizer hub.
Refer to the illustration for step 3.
I Pay attention to direction of 1st & 2nd synchronizer hub.
2. Select proper snap ring of 1st & 2nd synchronizer hub to mini-
mize clearance of groove and then install it.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Snap ring of 1st & 2nd synchronizer hub:
Refer to SDS, MT-133.
SMT804BA
SMT472C
3. Install 2nd synchronizer cone, inner & outer baulk rings. Insert
springs and 1st & 2nd coupling sleeve.
4. Install 2nd main gear.
I Ensure four protrusions of 2nd synchronizer cone are set in
holes of 2nd main gear.
SMT805B
SMT600CA
SMT473CA
MT-106
REPAIR FOR COMPONENT PARTS RS5F50A
Mainshaft and Gears (Cont’d)
9. Press on thrust washer and press on mainshaft rear bearing.
10. Press on mainshaft front bearing.
11. Measure gear end play as a final check. Refer to GI
“DISASSEMBLY”, MT-103.
MA
EM
SMT059A LC
Final Drive
DISASSEMBLY NJMT0017
EC
1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings. FE
I Be careful not to mix up the right and left bearings.
CL
SMT744AA
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears. AT
AX
SU
BR
SMT612AA
INSPECTION NJMT0018 ST
Gear, Washer, Shaft and Case NJMT0018S01
I Check mating surfaces of differential case, viscous coupling,
side gears and pinion mate gears. RS
I Check washers for wear.
BT
HA
SMT083A
Bearings NJMT0018S03
SC
I Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
I When replacing taper roller bearing, replace outer and EL
inner race as a set.
IDX
SPD715
MT-107
REPAIR FOR COMPONENT PARTS RS5F50A
Final Drive (Cont’d)
ASSEMBLY NJMT0019
1. Attach side gear thrust washers to side gears, then install pin-
ion mate washers and pinion mate gears in place.
SMT062A
SMT087A
SMT610AH
SMT611A
SMT612AA
MT-108
REPAIR FOR COMPONENT PARTS RS5F50A
Final Drive (Cont’d)
5. Install final gear.
6. Install speedometer drive gear.
GI
MA
EM
SMT609A LC
7. Press on differential side bearings.
EC
FE
CL
SMT648
SU
BR
ST
RS
BT
HA
SMT665C
Case Components SC
REMOVAL AND INSTALLATION NJMT0021
Input Shaft Oil Seal NJMT0021S01 EL
IDX
SMT030A
MT-109
REPAIR FOR COMPONENT PARTS RS5F50A
Case Components (Cont’d)
I Apply multi-purpose grease to seal lip of oil seal before
installing.
SMT031A
SMT034A
MT-110
NJMT0022
ADJUSTMENT RS5F50A
Input Shaft End Play and Differential Side Bearing Preload
CL
AX
SU
BR
SMT132AA
BT
HA
SMT845B
SMT074A
MT-111
ADJUSTMENT RS5F50A
Input Shaft End Play and Differential Side Bearing Preload (Cont’d)
2. Insert Tool all the way into differential side gear. Move Tool up
and down and measure dial indicator deflection.
SMT075AA
SMT076A
SMT475C
SMT077AA
MT-112
ADJUSTMENT RS5F50A
Mainshaft Bearing Preload (Cont’d)
2. Reinstall mainshaft rear bearing outer race without shims.
3. Clean mating surfaces of clutch housing and transmission
case with solvent. GI
4. Install mainshaft and mainshaft front bearing outer race into
transmission case. Turn mainshaft while holding bearing outer
race so that bearings are properly seated. MA
EM
SMT644AA LC
5. Put straightedge [width must be more than 50 mm (1.97 in)] on
transmission case, and measure the distance from upper sur-
face of straightedge to surface of the bearing outer race using EC
a depth micrometer.
I Measure at three places on bearing outer race, and take
the average.
FE
6. Determine dimension A to be used by the following equation.
Dimension A = Width of straightedge − measured dis- CL
tance
7. Measure the distance from mating surface of clutch housing to
SMT078A portion with which mainshaft front bearing outer race is to be
mated.
I Measure at three places on the portion, and take the aver-
age. AT
Dimension B = Measured distance
8. Determine dimension C to be used by the following equation. AX
Dimension “C” = B − A
9. Determine total thickness of shims with SDS table as a guide.
Mainshaft bearing adjusting shim: SU
Refer to SDS, MT-134.
10. Install selected mainshaft bearing adjusting shim and main- BR
SMT079A shaft bearing outer race.
11. Check total turning torque after assembly — Refer to
“ASSEMBLY”, MT-114. ST
RS
BT
HA
SC
EL
IDX
MT-113
NJMT0093
ASSEMBLY RS5F50A
SMT029AA
SMT645AA
SMT138A
SAT601C
SMT065A
MT-114
ASSEMBLY RS5F50A
7. Install 3rd & 4th shift fork and bracket, then install 3rd & 4th
fork rod, stopper ring and retaining pin.
When installing stopper rings, use snap ring remover and GI
installer.
MA
EM
SMT066A LC
8. Install interlock balls.
EC
FE
CL
SMT067A
9. Install 5th shift fork, then install fork rod, stopper ring and
retaining pin. AT
When installing stopper rings, use snap ring remover and
installer.
AX
SU
BR
SMT666C
10. Install 5th & reverse check plug, spring and ball.
I Apply sealant to bolt threads. Refer to “Shift Control
ST
Components”, MT-94.
RS
BT
HA
SMT018B
EL
IDX
SMT201B
MT-115
ASSEMBLY RS5F50A
12. Install check ball and reverse lever spring on reverse lever
assembly.
I Apply multi-purpose grease to check ball.
I Pay attention to direction of reverse lever spring.
SMT667C
SMT668C
SMT669C
15. Hook reverse lock spring and reverse lever spring on reverse
lever assembly.
SMT670C
16. Mesh 4th gear, then install reverse idler gear and shaft.
I Pay attention to direction of tapped hole.
SMT671C
MT-116
ASSEMBLY RS5F50A
GI
MA
EM
SMT070A LC
18. If bearing preload of mainshaft was adjusted, install selected
shim(s) into transmission case.
I To aid in installation of transmission case, place shift
EC
selector in the 1st and 2nd shift bracket or between 1st
and 2nd bracket and 3rd and 4th bracket.
FE
19. Apply sealant to mating surface of transmission case and
install it. Refer to “Case Components”, MT-92.
20. Install PNP switch. CL
SMT446C
SU
BR
SMT626D
HA
SAT478EA
SC
EL
IDX
MT-117
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F30A
General Specifications
General areas
General areas (With catalyzer) Europe
Applied model (Without catalyzer) QG16DE*
QG13DE QG15DE
Number of speeds 5
Shift pattern
2nd 23 23 22
3rd 29 29 28
4th 41 41 41
5th 45 45 45
Rev. 12 12 14
2nd 41 41 43
3rd 35 35 36
4th 37 37 38
5th 33 34 34
Rev. 41 41 45
*: General areas - In production since February 2001/Middle East - In production since July 2001
**: With 1st & 2nd double baulk ring type synchronizer
MT-118
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F30A
General Specifications (Cont’d)
*: General areas - In production since February 2001/Middle East - In production since July 2001
AT
AX
SU
SMT906D BR
Dimension Standard Wear limit
RS
Available Check Plugs NJMT0071
REVERSE CHECK PLUGS NJMT0071S01
BT
Reverse check turning torque (At striking rod) N·m (kg-cm, in-lb) 4.9 - 7.4 (50 - 75, 43 - 65)
MT-119
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F30A
Available Snap Rings
*: Always check with the Parts Department for the latest parts information.
*: Always check with the Parts Department for the latest parts information.
*: Always check with the Parts Department for the latest parts information.
*: Always check with the Parts Department for the latest parts information.
MT-120
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F30A
Available Washers
*: Always check with the Parts Department for the latest parts information.
MT-121
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F30A
Available Shims — Mainshaft and Differential Side Bearing Preload and Adjusting Shim (Cont’d)
DIFFERENTIAL SIDE BEARING ADJUSTING SHIMS NJMT0073S07
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
MT-122
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
General Specifications
QG18DE
MA
Model code number 7J006 8E009
FE
Gear ratio 1st 3.333 3.333
CL
2nd 1.955 1.955
3rd 28 28
SU
4th 41 41
5th 45 45
BR
Rev. 14 14
3rd 36 36
RS
4th 38 38
5th 34 33
BT
Rev. 45 45
Reverse sub-gear
EL
*: General areas - Production before February 2001/Middle East - Production before July 2001
MT-123
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
General Specifications (Cont’d)
*: General areas - Production before February 2001/Middle East - Production before July 2001
3rd
SMT906D
MT-124
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
Available Snap Rings
*: Always check with the parts department for the latest information. EC
Available C-rings NJMT0080
4TH INPUT GEAR C-RING NJMT0080S01
FE
End play 0 - 0.06 mm (0 - 0.0024 in)
*: Always check with the parts department for the latest information. AX
5TH INPUT GEAR REAR C-RING NJMT0080S02
SU
End play 0 - 0.06 mm (0 - 0.0024 in)
HA
SC
EL
IDX
MT-125
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
Available C-rings (Cont’d)
MAINSHAFT C-RING NJMT0080S03
*: Always check with the parts department for the latest information.
MT-126
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
Available Adjusting Shims
BT
HA
SC
EL
IDX
MT-127
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
Available Adjusting Shims (Cont’d)
MAINSHAFT ADJUSTING SHIM NJMT0081S02
SMT907D
*: Always check with the parts department for the latest information.
*: Always check with the parts department for the latest information.
MT-128
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
Available Thrust Washer
MA
EM
LC
SMT843D
EC
Standard length “M” 244.20 - 244.30 mm (9.6142 - 9.6181 in)
Clearance between side gear and differential case 0.1 - 0.2 mm (0.004 - 0.008 in)
SU
Thickness mm (in) Part number*
BT
HA
SC
EL
IDX
MT-129
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F70A
Available Shims — Differential Side Bearing Preload and Adjusting Shim
*: Always check with the parts department for the latest information.
MT-130
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F50A
General Specifications
EC
FE
Gear ratio 1st 3.400 3.400
2nd 22 22 AX
3rd 33 29
4th 44 47 SU
5th 50 53
Rev. 14 14 BR
Main gear 1st 51 51
2nd 43 32 ST
3rd 42 35
4th 42 39 RS
5th 37 34
Rev. 48 48 BT
Reverse idler gear 29
Oil capacity (US pt, Imp pt) 4.5 - 4.8 (9-1/2 - 10-1/8, 7-7/8 - 8-1/2) HA
Remarks 1st & 2nd double baulk ring type synchronizer
SC
FINAL GEAR NJMT0024S02
MT-131
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F50A
Gear End Play
3rd, 4th & 5th 1.0 - 1.35 (0.0394 - 0.0531) 0.7 (0.028)
SMT806B
SMT581B
MT-132
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F50A
Available Snap Rings
*: Always check with the Parts Department for the latest parts information.
LC
3RD & 4TH SYNCHRONIZER HUB (AT INPUT SHAFT) NJMT0027S02
*: Always check with the Parts Department for the latest parts information.
SU
Available Thrust Washer NJMT0028
4TH INPUT GEAR (AT INPUT SHAFT) NJMT0028S01
BR
Allowable clearance 0 - 0.06 mm (0 - 0.0024 in)
*: Always check with the Parts Department for the latest parts information.
BT
DIFFERENTIAL SIDE GEAR THRUST WASHER NJMT0028S02
Allowable clearance between side gear and differential case with washer 0.1 - 0.2 mm (0.004 - 0.008 in)
HA
Thickness mm (in) Part number*
IDX
MT-133
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F50A
Available Shims
Total turning torque (new bearing) 8.8 - 21.6 (90 - 220, 78 - 191)
*: Always check with the Parts Department for the latest parts information.
MT-134
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F50A
Available Shims (Cont’d)
INPUT SHAFT BEARING ADJUSTING SHIM NJMT0029S05
*: Always check with the Parts Department for the latest parts information. EC
TABLE FOR SELECTING INPUT SHAFT BEARING ADJUSTING SHIM(S) NJMT0029S06
Unit: mm (in) FE
Dial indicator indication Suitable shim(s)
*: Always check with the Parts Department for the latest parts information.
MT-135
SERVICE DATA AND SPECIFICATIONS (SDS) RS5F50A
Available Shims (Cont’d)
TABLE FOR SELECTING DIFFERENTIAL SIDE BEARING ADJUSTING SHIM(S) =NJMT0029S08
Unit: mm (in)
MT-136