Text preview for : Cambio manuale.pdf part of NISSAN Almera Tino Body e Trim (pag. 68) - Manual Transaxale (pag. 102)
Back to : Almera Tino____03___.part | Home
MANUAL TRANSAXLE SECTION
GI MA EM LC EC
MT
CONTENTS
RS5F70A PREPARATION ...............................................................4 Special Service Tools ..................................................4 Commercial Service Tools ...........................................5 RS5F50A PREPARATION ...............................................................7 Special Service Tools ..................................................7 Commercial Service Tools ...........................................8 RS5F70A, RS5F50A NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................10 NVH Troubleshooting Chart.......................................10 MANUAL TRANSAXLE .............................................10 RS5F70A M/T OIL ..........................................................................11 Changing M/T Oil.......................................................11 Checking ....................................................................11 OIL LEAK AND OIL LEVEL .......................................11 RS5F50A M/T OIL ..........................................................................12 Changing M/T Oil.......................................................12 Checking ....................................................................12 OIL LEAK AND OIL LEVEL .......................................12 RS5F70A, RS5F50A DESCRIPTION ...............................................................13 Cross-sectional View - RS5F70A ..............................13 Cross-sectional View - RS5F50A ..............................14 DOUBLE-CONE SYNCHRONIZER ............................15 ON-VEHICLE SERVICE ................................................16 Replacing Oil Seal .....................................................16 RS5F70A REMOVAL AND INSTALLATION .................................19 Removal.....................................................................19 Installation..................................................................20 MODEL QG18DE ENGINE .......................................20 RS5F50A REMOVAL AND INSTALLATION .................................21 Removal.....................................................................21 Installation..................................................................23 MODEL YD ENGINE ................................................23 RS5F70A, RS5F50A TRANSAXLE GEAR CONTROL ...................................24 Components...............................................................24 RS5F70A OVERHAUL ...................................................................25 Case Components .....................................................25 Gear Components .....................................................26 Shift Control Components .........................................27 Final Drive Components ............................................28 DISASSEMBLY..............................................................29 Transaxle Case..........................................................29 Clutch Housing ..........................................................31 REPAIR FOR COMPONENT PARTS ...........................35 Input Shaft and Gears ...............................................35 DISASSEMBLY ........................................................35 INSPECTION ...........................................................36 ASSEMBLY .............................................................37
DIFFERENTIAL OIL SEAL ........................................16 STRIKING ROD OIL SEAL .......................................16
FE CL
Position Switch Check ...............................................17 BACK-UP LAMP SWITCH ........................................17 PNP SWITCH ..........................................................17 BACK-UP LAMP SWITCH AND PNP SWITCH ...........18
AT AX SU BR ST RS BT HA SC EL IDX
CONTENTS
Mainshaft and Gears .................................................40 DISASSEMBLY ........................................................40 INSPECTION ...........................................................41 ASSEMBLY .............................................................43 Final Drive..................................................................48 PRE-INSPECTION ...................................................48 DISASSEMBLY ........................................................49 INSPECTION ...........................................................49 ASSEMBLY .............................................................50 Shift Control Components .........................................51 INSPECTION ...........................................................51 ASSEMBLY....................................................................53 Clutch Housing ..........................................................53 Transaxle Case..........................................................57 RS5F50A OVERHAUL ...................................................................63 Case Components .....................................................63 Gear Components .....................................................64 Shift Control Components .........................................65 DISASSEMBLY..............................................................66 REPAIR FOR COMPONENT PARTS ...........................69 Input Shaft and Gears ...............................................69 DISASSEMBLY ........................................................69 INSPECTION ...........................................................70 ASSEMBLY .............................................................71 Mainshaft and Gears .................................................74 DISASSEMBLY ........................................................74 INSPECTION ...........................................................75 ASSEMBLY .............................................................76 Final Drive..................................................................78 DISASSEMBLY ........................................................78 INSPECTION ...........................................................78 ASSEMBLY .............................................................79 Shift Control Components .........................................80 INSPECTION ...........................................................80 Case Components .....................................................80 REMOVAL AND INSTALLATION ...............................80 ADJUSTMENT ...............................................................82 Input Shaft End Play and Differential Side Bearing Preload .........................................................82 DIFFERENTIAL SIDE ...............................................82 INPUT SHAFT SIDE.................................................83 Mainshaft Bearing Preload ........................................83 ASSEMBLY....................................................................85 RS5F70A SERVICE DATA AND SPECIFICATIONS (SDS) .........89 General Specifications...............................................89 TRANSAXLE ...........................................................89 FINAL GEAR ...........................................................89 Gear End Play ...........................................................90 Clearance Coupling Sleeve .......................................90
(Cont'd)
1ST, 2ND, 3RD, 4TH, 5TH & REVERSE COUPLING SLEEVE ................................................90
Clearance Between Baulk Ring and Gear ................90 3RD, 4TH, 5TH, REVERSE BAULK RING ..................90 1ST AND 2ND DOUBLE BAULK RING ......................90 Available Snap Rings ................................................91 SNAP RING.............................................................91 Available C-rings........................................................91 4TH INPUT GEAR C-RING .......................................91 5TH INPUT GEAR REAR C-RING .............................91 MAINSHAFT C-RING ...............................................92 Available Adjusting Shims .........................................93
INPUT SHAFT REAR BEARING ADJUSTING SHIM ......................................................................93 MAINSHAFT ADJUSTING SHIM................................94 MAINSHAFT REAR BEARING ADJUSTING SHIM ......94
Available Thrust Washer............................................95 MAINSHAFT THRUST WASHER ...............................95 Available Washers .....................................................95 DIFFERENTIAL SIDE GEAR THRUST WASHER ........95 Available Shims - Differential Side Bearing Preload and Adjusting Shim ......................................96 BEARING PRELOAD ...............................................96
DIFFERENTIAL SIDE BEARING ADJUSTING SHIMS ....................................................................96
RS5F50A SERVICE DATA AND SPECIFICATIONS (SDS) .........97 General Specifications...............................................97 TRANSAXLE ...........................................................97 FINAL GEAR ...........................................................97 Gear End Play ...........................................................98 Clearance Between Baulk Ring and Gear ................98 3RD, 4TH & 5TH BAULK RING .................................98 1ST AND 2ND DOUBLE BAULK RING ......................98 REVERSE BAULK RING ..........................................98 Available Snap Rings ................................................99
1ST & 2ND SYNCHRONIZER HUB (AT MAINSHAFT) ...........................................................99 3RD & 4TH SYNCHRONIZER HUB (AT INPUT SHAFT) ...................................................................99 5TH MAIN GEAR (AT MAINSHAFT) ..........................99
Available Thrust Washer............................................99 4TH INPUT GEAR (AT INPUT SHAFT) ......................99 DIFFERENTIAL SIDE GEAR THRUST WASHER ........99 Available Shims .......................................................100 BEARING PRELOAD AND END PLAY ....................100 TOTAL TURNING TORQUE (NEW BEARING) ..........100 MAINSHAFT BEARING ADJUSTING SHIM ..............100
TABLE FOR SELECTING MAINSHAFT BEARING ADJUSTING SHIM(S) .............................................100 INPUT SHAFT BEARING ADJUSTING SHIM ...........101 TABLE FOR SELECTING INPUT SHAFT BEARING ADJUSTING SHIM(S) .............................................101
MT-2
CONTENTS
DIFFERENTIAL SIDE BEARING ADJUSTING SHIM ....................................................................101 TABLE FOR SELECTING DIFFERENTIAL SIDE BEARING ADJUSTING SHIM(S) .............................102
(Cont'd)
GI MA EM LC EC FE CL
AT AX SU BR ST RS BT HA SC EL IDX
MT-3
PREPARATION
Special Service Tools
RS5F70A
Special Service Tools
Tool number Tool name KV38107700 Preload adapter Description
NLMT0032
NT087
Measuring turning torque of final drive assembly Measuring total turning torque Measuring clearance between side gear and differential case with washer Selecting differential side bearing adjusting shim (Use with KV38106000.) Selecting differential side bearing adjusting shim (Use with KV38107700.) a: 140 mm (5.51 in) b: 40 mm (1.57 in) c: 16 mm (0.63 in) dia. d: M8 x 1.25P
KV38106000 Height gauge adapter (differential side bearing)
NT418
KV32101000 Pin punch
Removing and installing retaining pin Removing and installing lock pin Removing selector shaft Removing welch plug a: 4 mm (0.16 in) dia.
NT410
KV31100300 Pin punch
Removing and installing retaining pin a: 4.5 mm (0.177 in) dia.
NT410
ST30031000 Puller
NT411
Removing 3rd, 5th input gear Removing 3rd & 4th and 5th & Rev synchronizer hub Removing mainshaft rear bearing Removing 2nd gear, 5th gear bush Removing 1st & 2nd synchronizer hub, 1st and 4th main gear Removing and installing differential side bearing a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia. Removing input shaft front and rear bearing Installing input shaft front and rear bearing Installing 5th input gear, 3rd main gear and 4th main gear Installing 1st & 2nd, 3rd & 4th and 5th & Rev synchronizer hub Installing 2nd gear bush, 5th gear bush, Rev gear bush Installing mainshaft rear bearing a: 110 mm (4.33 in) dia. b: 68 mm (2.68 in) dia.
ST30021000 Puller
NT411
MT-4
PREPARATION
Tool number Tool name ST33290001 Puller Description
RS5F70A
Special Service Tools (Cont'd)
GI
Removing idler gear bearing outer race a: 250 mm (9.84 in) b: 160 mm (6.30 in)
MA EM
NT414
ST33230000 Drift
Removing differential oil seal Installing differential side bearing a: 51 mm (2.01 in) dia. b: 28.5 mm (1.122 in) dia.
LC EC FE
NT084
ST30720000 Drift
Installing differential side bearing outer race a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia.
CL
NT115
ST22350000 Drift
Installing input shaft front and rear bearing a: 34 mm (1.34 in) dia. b: 28 mm (1.10 in) dia.
AT AX
NT065
ST22452000 Drift
NT065
Installing 3rd and 4th main gear Installing 5th gear bush Installing 5th & Rev synchronizer hub Installing Rev gear bush Installing mainshaft rear bearing a: 45 mm (1.77 in) dia. b: 36 mm (1.42 in) dia. Installing input shaft oil seal Installing 5th synchronizer Installing mainshaft rear bearing Installing 5th main gear Installing 3rd & 4th synchronizer hub Installing striking rod oil seal Installing clutch housing dust seal a: 40 mm (1.57 in) dia. b: 31 mm (1.22 in) dia.
SU BR ST RS BT HA
NLMT0033
ST37750000 Drift
NT065
Commercial Service Tools
Tool name Drift Description Installing welch plug a: 12 mm (0.47 in) dia. b: 10 mm (0.39 in) dia.
SC EL IDX
NT065
MT-5
PREPARATION
Commercial Service Tools (Cont'd)
Tool name Drift Description Removing input shaft rear bearing Removing mainshaft rear bearing a: 22 mm (0.87 in) dia. b: 16 mm (0.63 in) dia.
NT065
RS5F70A
Drift
Installing differential oil seal a: 58 mm (2.28 in) dia. b: 50 mm (1.97 in) dia.
NT065
Drift
Installing differential oil seal a: 54 mm (2.13 in) dia. b: 50 mm (1.97 in) dia.
NT065
Drift
Installing 2nd gear bush a: 38 mm (1.50 in) dia. b: 33 mm (1.30 in) dia.
NT065
Drift
Installing 3rd & 4th and 1st & 2nd synchronizer hub Installing mainshaft front bearing a: 50 mm (1.97 in) dia. b: 41 mm (1.61 in) dia.
NT065
Drift
Installing input shaft oil seal Installing 5th input gear a: 39 mm (1.54 in) dia. b: 30 mm (1.18 in) dia.
NT065
MT-6
PREPARATION Special Service Tools
Tool number Tool name KV38105210 Preload adapter Description
RS5F50A
Special Service Tools
NLMT0001
GI
Measuring turning torque of final drive assembly Measuring total turning torque
MA EM
NT075
KV32101000 Pin punch
Removing and installing retaining pin a: 4 mm (0.16 in) dia.
LC EC
NT410
ST22730000 Puller
Removing mainshaft front and rear bearing inner race a: 82 mm (3.23 in) dia. b: 30 mm (1.18 in) dia.
FE CL
NT411
ST30031000 Puller
Removing input shaft front and rear bearing Removing 4th & 5th main gear a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia.
AT AX SU
NT411
ST30021000 Puller
Removing 5th synchronizer Removing 3rd & 4th synchronizer Removing 2nd & 3rd main gear a: 110 mm (4.33 in) dia. b: 68 mm (2.68 in) dia.
BR ST RS BT HA SC
NT411
ST3306S001 Differential side bearing puller set 1 ST33051001 Puller 2 ST33061000 Adapter
Removing differential side bearing inner race a: 38 mm (1.50 in) dia. b: 28.5 mm (1.122 in) dia. c: 130 mm (5.12 in) d: 135 mm (5.31 in) e: 100 mm (3.94 in)
NT675
ST33290001 Puller
Removing differential oil seal Removing mainshaft rear bearing outer race Removing differential side bearing outer race a: 250 mm (9.84 in) b: 160 mm (6.30 in)
EL IDX
NT414
MT-7
PREPARATION
Special Service Tools (Cont'd)
Tool number Tool name ST33400001 Drift Description Installing differential oil seal a: 60 mm (2.36 in) dia. b: 47 mm (1.85 in) dia.
RS5F50A
NT086
ST30600000 Drift
Installing input shaft front bearing a: 36 mm (1.42 in) dia. b: 31 mm (1.22 in) dia.
NT065
ST22452000 Drift
Installing 3rd, 4th and 5th main gear a: 45 mm (1.77 in) dia. b: 36 mm (1.42 in) dia.
NT065
ST30621000 Drift
Installing mainshaft rear bearing outer race (Use with ST30611000.) a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia.
NT073
ST30611000
(Use with ST30621000.) a: 15 mm (0.59 in) b: 335 mm (13.19 in) c: 25 mm (0.98 in) dia. d: M12 x 1.5P
NT419
KV38107700 Preload adapter
Measuring clearance between side gear and differential case with washer
NT087
KV38106500 Preload adapter
Measuring turning torque of final drive assembly
NT087
Commercial Service Tools
Tool name Drift Description Installing differential side bearing inner race a: 45 mm (1.77 in) dia. b: 41 mm (1.61 in) dia.
NLMT0002
NT065
MT-8
PREPARATION
Tool name Drift Description
RS5F50A
Commercial Service Tools (Cont'd)
Installing differential side bearing outer race a: 69 mm (2.72 in) dia. b: 64 mm (2.52 in) dia.
GI MA
NT065
Drift
Installing striking rod oil seal a: 38 mm (1.50 in) dia. b: 20 mm (0.79 in) dia.
EM LC
NT065
EC FE CL
AT AX SU BR ST RS BT HA SC EL IDX
MT-9
NVH Troubleshooting Chart
MANUAL TRANSAXLE
Symptoms Noise Oil leakage Jumps out of gear 1 (Oil level is low.) (Wrong oil) (Oil level is high.) GASKET (Damaged) OIL SEAL (Worn or damaged) O-RING (Worn or damaged) SHIFT CONTROL ROD (Worn) CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged) SHIFT FORK (Worn) 3 GEAR (Worn or damaged) BEARING (Worn or damaged) BAULK RING (Worn or damaged) INSERT SPRING (Damaged) 3 MT-11 (RS5F70A), MT-12 (RS5F50A) MT-11 (RS5F70A), MT-12 (RS5F50A) MT-11 (RS5F70A), MT-12 (RS5F50A) MT-25 (RS5F70A), MT-63 (RS5F50A) MT-25 (RS5F70A), MT-63 (RS5F50A) MT-25 (RS5F70A), MT-63 (RS5F50A) MT-24 MT-27 (RS5F70A), MT-65 (RS5F50A) MT-27 (RS5F70A), MT-65 (RS5F50A) MT-26 (RS5F70A), MT-64 (RS5F50A) MT-26 (RS5F70A), MT-64 (RS5F50A) MT-26 (RS5F70A), MT-64 (RS5F50A) MT-26 (RS5F70A), MT-64 (RS5F50A) 2 3 1 2 1 1 Hard to shift or will not shift
Reference page
SUSPECTED PARTS (Possible cause)
NVH Troubleshooting Chart
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING RS5F70A, RS5F50A
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.
MT-10
2 2 1 2 3 3 2 3 3
NLMT0003
NLMT0003S01
NLMT0003S0101
M/T OIL Changing M/T Oil
1. 2.
RS5F70A
Changing M/T Oil
NLMT0086
SMA145AA
Drain oil from drain plug and refill with new gear oil. Check oil level. Oil grade: API GL-4 Viscosity: Refer to MA-20, "RECOMMENDED FLUIDS AND LUBRICANTS". Capacity: RS5F70A 3.0 (5-1/4 Imp pt) Oil level (Reference data): RS5F70A 75.5 - 80.5 mm (2.972 - 3.169 in) Drain plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
GI MA EM LC EC FE CL
SMT512C
Checking
OIL LEAK AND OIL LEVEL
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)
NLMT0087 NLMT0087S01
AT AX SU BR
SMA066C
ST RS BT HA SC EL IDX
MT-11
M/T OIL
Changing M/T Oil
RS5F50A
Changing M/T Oil
1. 2.
NLMT0088
SMA067C
Drain oil from drain plug and refill with new gear oil. Check oil level. Oil grade: API GL-4 Viscosity: Refer to MA-20, "RECOMMENDED FLUIDS AND LUBRICANTS". Capacity: RS5F50A 4.5 - 4.8 (7-7/8 - 8-1/2 Imp pt) Drain plug: : 15 - 20 N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
Checking
OIL LEAK AND OIL LEVEL
Check for oil leakage and oil level. Never start engine while checking oil level. Filler plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
NLMT0089 NLMT0089S01
SMA066C
MT-12
NLMT0034
DESCRIPTION
RS5F70A, RS5F50A
Cross-sectional View -- RS5F70A
Cross-sectional View -- RS5F70A
NLMT0034S03
GI MA EM LC EC FE CL
AT AX SU BR ST RS BT HA SC EL IDX
SMT924D
MT-13
DESCRIPTION
Cross-sectional View -- RS5F50A
RS5F70A, RS5F50A
Cross-sectional View -- RS5F50A
NLMT0034S04
SMT196DA
MT-14
DESCRIPTION
DOUBLE-CONE SYNCHRONIZER
RS5F70A, RS5F50A
Cross-sectional View -- RS5F50A (Cont'd)
NLMT0034S0403
-- RS5F70A and RS5F50A -- Double-cone synchronizer is adopted for 1st and 2nd gears to reduce operating force of the shift lever.
GI MA EM
SMT837DA
LC EC FE CL
AT AX SU BR ST RS BT HA SC EL IDX
MT-15
ON-VEHICLE SERVICE
Replacing Oil Seal
RS5F70A, RS5F50A
Replacing Oil Seal
DIFFERENTIAL OIL SEAL
1. 2. 3. Drain gear oil from transaxle. Remove drive shafts. Refer to AX-11, "Removal". Remove differential oil seal.
NLMT0035 NLMT0035S01
SMT563AA
4. ¼ 5.
Install differential oil seal. Apply multi-purpose grease to seal lip of oil seal before installing. Install drive shafts. Refer to AX-11, "Installation".
SMT564AB
¼
Install differential oil seal so that dimension "A" and "B" are within specifications.
Unit: mm (in) Item Dimension RS5F50A Model RS5F70A -0.5 (-0.020) to 0.5 (0.020) A B
SMT926DA
SMT927D
STRIKING ROD OIL SEAL
1. 2. ¼ Remove transaxle control rod from yoke. Remove retaining pin of yoke. Be careful not to damage boot.
NLMT0035S02
SMT143DC
MT-16
ON-VEHICLE SERVICE
3. Remove striking rod oil seal.
RS5F70A, RS5F50A
Replacing Oil Seal (Cont'd)
GI MA EM
SMT566A
LC
4. ¼ Install striking rod oil seal. Apply multi-purpose grease to seal lip of oil seal before installing.
EC FE CL
SMT570A
¼
Drive it in as far as it will go.
AT AX SU BR
SMT876D
Position Switch Check
BACK-UP LAMP SWITCH -- RS5F70A --
¼ Check continuity.
Gear position Reverse Except reverse
SMT715BD
NLMT0036 NLMT0036S01 NLMT0036S0101
ST RS BT HA
Continuity Yes No
PNP SWITCH -- RS5F70A --
¼ Check continuity.
Gear position Neutral Except neutral Continuity Yes No
NLMT0036S02 NLMT0036S0201
SC EL IDX
MT-17
ON-VEHICLE SERVICE
Position Switch Check (Cont'd)
RS5F70A, RS5F50A
BACK-UP LAMP SWITCH AND PNP SWITCH -- RS5F50A --
¼ Check continuity.
Gear position Reverse Neutral Except reverse and neutral
SMT939D
NLMT0036S03 NLMT0036S0301
Continuity 1-3 2-4 No
MT-18
NLMT0008
REMOVAL AND INSTALLATION Removal
RS5F70A
Removal
NLMT0008S01
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 air cleaner box with mass air flow sensor.
GI MA EM
SMT928D
LC
3. 4. 5. Remove clutch operating cylinder from transaxle. Remove clutch hose clamp. Disconnect speedometer pinion, back-up lamp, PNP switch (F70A) harness connectors and ground harness. 6. Remove starter motor from transaxle. 7. Remove crankshaft position sensor (POS) from transaxle front side. 8. Remove shift control rod and support rod bracket from transaxle. 9. Drain gear oil from transaxle. 10. Draw out drive shafts from transaxle. Refer to AX-11, "Removal". 11. Support engine of transaxle by placing a jack under oil pan. CAUTION: Do not place jack under oil pan drain plug. 12. Remove bolts securing center member.
EC FE CL
SMT130DB
AT AX SU BR
13. Remove LH mount and rear side mounting bolts. Refer to EM-70, "Removal and Installation". 14. Remove bolts securing gusset and transaxle.
ST RS BT HA SC EL IDX
SMT133D
MT-19
REMOVAL AND INSTALLATION
Removal (Cont'd)
RS5F70A
15. Lower transaxle while supporting it with a jack.
SMT652C
Installation
¼ ¼ ¼ ¼ ¼
NLMT0008S02
Tighten LH mount, rear side mount and center member bolts. Refer to EM-70, "Removal and Installation". Tighten clutch operating cylinder bolts. Refer to CL-15, "Installation". Tighten starter motor bolts. Refer to SC-19, "Removal and Installation". Install drive shafts. Refer to AX-11, "Installation". Tighten all transaxle bolts and any part removed.
MODEL QG18DE ENGINE
Bolt No. 1 2 3 4 A
SMT931D
NLMT0008S0202
Tightening torque
N·m (kg-m, ft-lb)
" "
mm (in)
31 - 40 (3.1 - 4.1, 23 - 29) 31 - 40 (3.1 - 4.1, 23 - 29) 16 - 21 (1.6 - 2.2, 12 - 15) 31 - 40 (3.1 - 4.1, 23 - 29) 31 - 40 (3.1 - 4.1, 23 - 29) 31 - 40 (3.1 - 4.1, 23 - 29) 15 - 20 (1.5 - 2.1, 11 - 15)
70 (2.76) 80 (3.15) 25 (0.98) 30 (1.18) 20 (0.79) 20 (0.79) 17.5 (0.69)
B C
MT-20
NLMT0090
REMOVAL AND INSTALLATION Removal
RS5F50A
Removal
NLMT0090S01
SMT928D
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. 6. 7. 8. 9. 10. Remove terminal and connector from starter motor. Remove starter motor from transaxle. Remove clutch hose clamp. Remove clutch operating cylinder from transaxle. Disconnect speedometer pinion, PNP switch harness connectors and ground harness. 11. Remove crankshaft position sensor (POS) from transaxle front side. 12. Remove front exhaust tube.
GI MA EM LC EC FE CL
SMT650CB
13. Remove shift control rod and support rod bracket from transaxle. 14. Drain gear oil from transaxle. 15. Draw out drive shafts from transaxle. Refer to AX-11, "Removal". 16. Support engine and transaxle by placing a jack under the transaxle. 17. Remove bolts securing center member.
AT AX SU BR
SMT929D
18. Take out engine mounting bracket and transaxle installation bolts. Refer to EM-197, "Removal and Installation". 19. Remove bolts securing transaxle under side. 20. Temporarily tighten center member. 21. Lower the lift.
ST RS BT HA
SMT950D
SC EL IDX
MT-21
REMOVAL AND INSTALLATION
Removal (Cont'd)
RS5F50A
22. Pick up EGI harness clamp and install engine slinger. Next, set chain block. 23. Jack up the air compressor engine bracket. 24. Remove engine front mounting. 25. Remove LH side mounting. Refer to EM-197, "Removal and Installation".
SMT940D
SMT951D
26. Jack up until engine oil filter bracket bolts are just about to touch the side frame.
SMT952D
27. Remove bolts securing transaxle. 28. While the transaxle is suspended, withdraw the transaxle case from the engine without hitting suspension member. ¼ Open the front of the transaxle when the clutch cover appears. Then, lower the transaxle pulling it toward the right front. ¼ The spacer between the engine and transaxle should be left at the engine side. 29. Remove spacer.
SMT941D
MT-22
REMOVAL AND INSTALLATION Installation
1. 2. 3. 4. ¼ ¼ ¼ ¼ ¼
RS5F50A
Installation
NLMT0090S02
Put transaxle under the engine compartment. Set chain block on transaxle and hang. Lift up transaxle case so as not to hit against the side frame and suspension member. Assemble transaxle to engine. Tighten LH mount, rear side mount and center member bolts. Refer to EM-197, "Removal and Installation". Tighten clutch operating cylinder bolts. Refer to CL-15, "Installation". Tighten starter motor bolts. Refer to SC-19, "Removal and Installation". Install drive shafts. Refer to AX-11, "Installation". Tighten all transaxle bolts and any part removed.
GI MA EM LC EC FE CL
SMT941D
MODEL YD ENGINE
Bolt No. 1 2 3 Tightening torque N·m (kg-m, ft-lb) " "
NLMT0090S0201
mm (in)
AT AX SU BR
40 - 49 (4.0 - 5.0, 29 - 36) 30.4 - 36.3 (3.1 - 3.7, 23 - 26) 30.4 - 36.3 (3.1 - 3.7, 23 - 26)
70 (2.76) 60 (2.36) 55 (2.17)
SMT932D
ST RS BT HA SC EL IDX
MT-23
NLMT0038
TRANSAXLE GEAR CONTROL
Components
RS5F70A, RS5F50A
Components
NLMT0038S01
NMT133
1. 2. 3. 4. 5. 6. 7. 8.
Control lever knob Boot Control lever socket Control lever Bearing seat spring Seat Bushing O-ring
9. 10. 11. 12. 13. 14. 15. 16.
Hand lever socket Plate bolt Transaxle hole cover Mass damper Holder bracket Return spring rubber Return spring Control rod
17. 18. 19. 20. 21. 22. 23.
Bushing Collar Bushing Collar Support rod Plate Support rod bracket
MT-24
NLMT0054
OVERHAUL Case Components
RS5F70A
Case Components
NLMT0054S02
GI MA EM LC EC FE CL
AT AX SU BR ST
SMT942D
RS BT HA SC EL IDX
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Clutch housing Dust seal Oil pocket Check plug Input shaft oil seal Oil channel Mainshaft front bearing Bearing retainer Bushing Reverse idler gear front thrust washer 11. Reverse idler gear 12. Reverse idler gear bearing 13. Reverse idler gear rear thrust washer
14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
O-ring Reverse idler gear shaft Snap ring Reverse switch Filler plug Side cover gasket Side cover Welch plug Mainshaft bearing snap ring Mainshaft rear bearing adjusting shim 24. O-ring 25. Rear cover
26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38.
Differential oil seal Drain plug PNP switch Transmission case Oil gutter Welch plug Magnet Boot Striking rod oil seal Welch plug Differential oil seal O-ring Speedometer pinion
MT-25
OVERHAUL
Gear Components
RS5F70A
Gear Components
=NLMT0054S03
SMT641DA
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Reverse idler gear front thrust washer Reverse idler gear Reverse idler gear bearing Reverse idle gear rear thrust washer O-ring Reverse idler gear shaft Snap ring Input shaft front bearing Input shaft 3rd gear needle bearing 3rd input gear 3rd gear baulk ring Coupling sleeve Spread spring Shifting insert 3rd & 4th synchronizer hub Spread spring 4th gear C-ring 4th gear needle bearing 4th gear baulk ring 4th input gear 5th gear front C-ring 5th input gear
24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.
5th gear rear C-ring C-ring holder Input shaft rear bearing Oil channel Input shaft rear bearing adjusting shim Mainshaft front bearing Mainshaft 1st gear needle bearing 1st main gear 1st inner baulk ring 1st synchronizer cone 1st outer baulk ring 1st & 2nd synchronizer hub Coupling sleeve Insert spring 2nd gear bush 2nd gear needle bearing 2nd gear outer baulk ring 2nd gear synchronizer cone 2nd inner baulk ring 2nd main gear 3rd main gear Spacer
47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69.
Mainshaft adjusting shim 4th main gear 5th gear bush 5th gear needle bearing 5th main gear 5th gear baulk ring Spread spring Shifting insert 5th & reverse synchronizer hub Spread spring Coupling sleeve Reverse gear bush Reverse gear needle bearing Reverse gear baulk ring Reverse main gear Sub-gear Sub-gear washer Snap ring Mainshaft thrust washer Mainshaft rear bearing Mainshaft C-ring C-ring holder Snap ring
MT-26
OVERHAUL Shift Control Components
RS5F70A
Shift Control Components
=NLMT0054S04
GI MA EM LC EC FE CL
AT AX SU
SMT642DB
BR
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Clutch housing 3rd & 4th bracket 3rd & 4th shift fork Retaining pin Check ball Check pin Check spring Check plug Stopper ring 3rd & 4th fork rod Selector shaft pin Selector 5th & reverse bracket Reverse switch bracket Retaining pin 5th & reverse shift fork 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. Interlock plunger Check ball Interlock pin Stopper ring 5th & reverse fork rod Striking lever Retaining pin 1st & 2nd bracket 1st & 2nd shift fork Check ball 1st & 2nd fork rod Transaxle case Check ball Check spring Check plug 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. Select check leaf spring Return spring Steel ball Reverse gate Return bearing Selector arm Bushing Welch plug Selector shaft Striking yoke Retaining pin Striking rod Dust boot Striking rod oil seal Welch plug
ST RS BT HA SC EL IDX
MT-27
OVERHAUL
Final Drive Components
RS5F70A
Final Drive Components
=NLMT0054S05
YMT001
1. 2. 3. 4. 5.
Differential shim Differential Differential Final gear Differential
side bearing adjusting side bearing outer race side bearing case
6. 7. 8. 9. 10.
Speedometer drive gear Speedometer stopper Differential side bearing Differential side bearing outer race Pinion mate thrust washer
11. 12. 13. 14. 15.
Pinion mate gear Side gear thrust washer Side gear Pinion mate shaft Lock pin
MT-28
NLMT0055
DISASSEMBLY Transaxle Case
1.
RS5F70A
Transaxle Case
NLMT0055S01
Remove reverse switch, PNP switch, drain plug, and filler plug from transaxle case.
GI MA EM
SMT648D
LC
2. 3. 4. Remove snap rings from reverse idler shaft. Remove side cover and rear cover from case. Remove O-ring and mainshaft bearing adjusting shim.
EC FE CL
SMT644D
5. a. b. 6.
Remove reverse idler gear shaft. Attach bolt (M6) to thread of reverse idler gear shaft end. Pull out the attached bolt, and remove reverse idler gear shaft from case. Remove reverse idler gear, thrust washer (front, rear), and bearing from case.
AT AX SU BR
SMT645D
7.
Remove snap ring of mainshaft bearing from case.
ST RS BT HA
SMT646D
8.
Remove check plugs, springs, and check balls from case.
SC EL IDX
SMT647D
MT-29
DISASSEMBLY
Transaxle Case (Cont'd)
RS5F70A
9. Remove mounting bolts. 10. Remove input shaft rear bearing adjusting shim from transaxle case.
SMT649D
11. Remove oil gutter from case.
SMT650D
12. Remove differential side bearing outer race and adjusting shim from case.
SMT651DB
13. Remove differential oil seal from case.
SMT653DB
14. Remove welch plugs from case.
SMT839DB
MT-30
DISASSEMBLY Clutch Housing
1. 2. 3.
RS5F70A
Clutch Housing
NLMT0055S02
Remove transaxle case from clutch housing. Remove magnet from housing. Remove check plugs, check springs, check pins, and check balls from housing.
GI MA EM
SMT654D
LC
4. Remove 3rd & 4th bracket retaining pin.
EC FE CL
SMT656DC
5. 6. 7.
Remove 3rd & 4th shift fork stopper ring. Remove 3rd & 4th fork rod. Remove 3rd & 4th shift fork and bracket.
AT AX SU BR
SMT655D
8. 9.
Remove interlock plunger and check ball. Remove 5th & reverse bracket stopper ring.
ST RS BT HA
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.
SC EL IDX
SMT657DC
MT-31
DISASSEMBLY
Clutch Housing (Cont'd)
RS5F70A
14. 15. 16. 17.
Remove check ball from housing. Remove retaining pin for 1st & 2nd shift fork and bracket. Remove 1st & 2nd fork rod. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd bracket.
SMT659DC
18. Remove both input shaft and mainshaft assemblies from housing.
SMT660D
19. Remove final drive assembly from housing. 20. Remove oil pocket from housing.
SMT661D
21. Remove mainshaft bearing retainer from housing. 22. Cut off oil channel using a cutter as shown in the figure.
SMT662D
23. Remove mainshaft front bearing from housing.
SMT663DB
MT-32
DISASSEMBLY
RS5F70A
Clutch Housing (Cont'd)
24. Using a magnet or other suitable tool, remove retaining pin from selector shaft.
GI MA EM
SMT664D
LC
25. Remove selector shaft and plug, then remove selector.
EC FE CL
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.
AT AX SU BR
SMT666DA
27. Remove retaining pin and plug from striking lever. 28. Remove striking rod, then striking lever from housing.
ST RS BT HA
SMT667DB
29. Using a flat-head screwdriver or other suitable tool, remove dust seal, input shaft oil seal, and striking rod oil seal from housing. CAUTION: When removing dust and oil seals, be careful not to damage mounting surfaces of dust seal and oil seal.
SC EL IDX
SMT668D
MT-33
DISASSEMBLY
Clutch Housing (Cont'd)
RS5F70A
30. Remove differential oil seal from housing.
SMT669DB
31. Remove differential side outer race from housing.
SMT670DB
MT-34
REPAIR FOR COMPONENT PARTS Input Shaft and Gears
DISASSEMBLY
1.
RS5F70A
Input Shaft and Gears
NLMT0056
¼
Before disassembly, measure the end plays of 3rd and 4th input gears. Gear end play: Refer to SDS, MT-90. If end play is not within specification, disassemble and check the parts.
GI MA EM LC
SMT759D
2.
Remove oil channel from input shaft rear bearing.
EC FE CL
SMT671D
3.
Press out input shaft rear bearing.
AT AX SU BR
SMT672DB
4. 5.
Remove C-ring holder. Remove 5th gear rear C-ring.
ST RS BT HA
SMT673D
6. 7.
Remove 5th input gear from input shaft. Remove 5th gear front C-ring.
SC EL IDX
SMT674DB
MT-35
REPAIR FOR COMPONENT PARTS
Input Shaft and Gears (Cont'd)
RS5F70A
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 input gear from input shaft. 10. Remove 3rd gear needle bearing.
SMT675DB
11. Press out input shaft front bearing from input shaft.
SMT676DB
INSPECTION Input Shaft and Gears
¼ ¼ Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.
NLMT0057 NLMT0057S01
SMT693D
Synchronizers
¼ ¼ ¼
NLMT0057S02
Check spline area of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for wear or deformation.
SMT637A
¼
If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.
SMT867D
MT-36
REPAIR FOR COMPONENT PARTS
¼
RS5F70A
Input Shaft and Gears (Cont'd)
Measure the movement (play, dimension "L") of 3rd & 4th coupling 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-90.
GI MA EM
SMT841D
LC
¼ Measure clearance between baulk ring and gear. Clearance between baulk ring and gear: Refer to SDS, MT-90.
EC FE CL
SMT140
Bearing
¼
NLMT0057S03
Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
AT AX SU BR
SMT148A
ASSEMBLY
1. 2.
NLMT0058
Press on input shaft front bearing. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring bearing to input shaft.
ST RS BT HA
SMT696DB
Install spread spring, shifting insert, and 3rd & 4th synchronizer hub onto 3rd & 4th coupling sleeve. ¼ 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.
3.
SC EL IDX
SMT694D
MT-37
REPAIR FOR COMPONENT PARTS
Input Shaft and Gears (Cont'd)
RS5F70A
¼
Install synchronizer hub with its three grooves facing the front side (3rd input gear side).
SMT695D
¼
Install 3rd & 4th coupling sleeve with its chamfered surface facing the 4th input gear side.
SMT699D
4. ¼ 5.
Position bearing replacer to the front side of input shaft front bearing. Align grooves of shifting insert and 3rd gear baulk ring. Then, press it onto 3rd & 4th synchronizer hub assembly using a drift. Install 4th gear C-ring onto input shaft.
SMT698DB
6.
7.
Measure the end play of 3rd & 4th synchronizer hub, and check if it is within allowable specification below. End play: 0 - 0.06 mm (0 - 0.0024 in) If not within specification, adjust the end play by changing thickness of 4th input gear C-ring. 4th input gear C-ring: Refer to SDS, MT-91.
SMT700DA
8. 9.
Install 4th gear needle bearing, 4th gear baulk ring, and 5th gear front C-ring. Install 4th input gear.
SMT701DB
MT-38
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.
GI MA EM
SMT703D
LC
11. Install 5th input gear. CAUTION: Do not reuse 5th input gear. 12. Install 5th gear rear C-ring onto input shaft.
EC FE CL
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-91.
AT AX SU BR
SMT704DA
15. Install C-ring holder onto 5th gear rear C-ring. CAUTION: Do not reuse C-ring holder. 16. Install input shaft rear bearing. CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.
ST RS BT HA
SMT705DB
17. Install oil channel onto input shaft. 18. Measure gear end play as a final check. Refer to, MT-35.
SC EL IDX
SMT671D
MT-39
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears
RS5F70A
Mainshaft and Gears
DISASSEMBLY
1.
NLMT0059
¼
Before disassembly, measure gear end play. Gear end play: Refer to SDS, MT-90. If end play is not within the specificed limit, disassemble and check the parts.
SMT760D
2.
Remove snap ring.
SMT677D
3.
Remove C-ring holder and mainshaft C-ring.
SMT678D
4.
Press out mainshaft rear bearing from mainshaft.
SMT679DB
5. 6.
Remove mainshaft thrust washer. Remove snap ring from mainshaft. Then, remove reverse main gear assembly, reverse gear needle bearing, and reverse gear baulk ring.
SMT680D
MT-40
REPAIR FOR COMPONENT PARTS
7.
RS5F70A
Mainshaft and Gears (Cont'd)
8.
Place bearing replacer between 5th & reverse synchronizer hub and 5th main gear, and press out both reverse gear bushing and 5th & reverse synchronizer assembly. Remove 5th main gear, 5th gear baulk ring, and 5th gear needle bearing.
GI MA EM
SMT681DB
LC
9. Place bearing replacer between 3rd and 4th main gears, and press out both 5th gear bushing and 4th main gear.
EC FE CL
SMT682DB
10. Remove mainshaft adjusting shim and spacer. 11. Place bearing replacer between 2nd main gear and 1st & 2nd synchronizer hub, and press out both 3rd and 2nd main gears.
AT AX SU BR
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.
ST RS BT HA
SMT684DB
INSPECTION Mainshaft and Gears
¼ ¼ Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.
NLMT0060 NLMT0060S01
SC EL IDX
SMT693D
MT-41
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont'd)
RS5F70A
Synchronizers
¼ ¼ ¼
NLMT0060S02
Check spline area of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for wear or deformation.
SMT637A
¼
If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.
SMT867D
¼
Measure the movement (play, dimension "L") of 1st & 2nd coupling sleeve and 5th & reverse coupling 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-90.
SMT868D
¼
Measure clearance between baulk ring and gear. Clearance between baulk ring and gear: Refer to SDS, MT-90.
SMT140
SMT714CD
MT-42
REPAIR FOR COMPONENT PARTS
¼ a) b)
RS5F70A
Mainshaft and Gears (Cont'd)
¼
Measure wear of 1st and 2nd baulk ring. Place baulk rings in position on synchronizer cone. 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) If dimension "A" or "B" is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.
GI MA EM LC EC FE CL
Bearing
¼
NLMT0060S03
Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
AT AX SU BR
SMT148A
ASSEMBLY
1. 2.
NLMT0061
Install 1st gear needle bearing and 1st main gear onto mainshaft. Install 1st double cone assembly onto mainshaft.
ST RS BT HA
SMT706D
3.
Install 1st & 2nd synchronizer hub with its three grooves facing the front side (1st main gear side) onto mainshaft. CAUTION: Do not reuse 1st & 2nd synchronizer hub.
SC EL IDX
SMT695D
MT-43
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont'd)
RS5F70A
4.
Install 1st & 2nd synchronizer hub.
SMT707DB
5.
Install insert spring onto 1st & 2nd coupling sleeve.
SMT994BB
6.
Install 1st & 2nd coupling sleeve with its chamfered surface facing the 1st main gear side onto 1st & 2nd synchronizer hub.
SMT708D
7.
Install 2nd gear bushing with its flange surface facing 1st & 2nd synchronizer hub side.
SMT709DB
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.
8.
SMT710DB
MT-44
REPAIR FOR COMPONENT PARTS
RS5F70A
Mainshaft and Gears (Cont'd)
10. Install spacer and mainshaft adjusting shim onto mainshaft. 11. Select a mainshaft adjusting shim suitable to satisfy the following specification of dimension "L" and install it onto mainshaft. Specification of dimension "L": 151.35 - 151.45 mm (5.9586 - 5.9626 in) Mainshaft adjusting shims: Refer to SDS, MT-94.
GI MA EM LC EC FE CL
SMT711D
12. Position 4th main gear as shown in the figure, and install it onto mainshaft.
AT AX SU BR
SMT713D
13. Install 4th main gear onto mainshaft. CAUTION: Do not reuse 4th main gear.
ST RS BT HA
SMT712DB
14. Install 5th gear bushing with its flange surface facing the 4th main gear side.
SC EL IDX
SMT714DB
MT-45
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont'd)
RS5F70A
15. Install 5th needle bearing, 5th main gear, and 5th gear baulk ring onto mainshaft.
SMT761D
16. Being careful of the following points, install spread spring, shifting insert, and 5th & reverse synchronizer hub onto 5th & reverse coupling sleeve. ¼ 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.
SMT694D
¼
Install synchronizer hub with its three grooves facing the front side (5th main gear side). CAUTION: Do not reuse 5th & reverse synchronizer hub.
SMT695D
¼
Install 5th & reverse coupling sleeve with its chamfered surface facing the reverse main gear side.
SMT716D
17. Install 5th & reverse synchronizer hub assembly.
SMT715DB
MT-46
REPAIR FOR COMPONENT PARTS
18. Install reverse gear baulk ring. 19. Install reverse gear busing. 20. Install reverse gear needle bearing.
RS5F70A
Mainshaft and Gears (Cont'd)
GI MA EM
SMT717DB
LC
21. Install sub-gear, sub-gear washer, and snap ring onto reverse main gear. CAUTION: ¼ Pay attention to direction of sub-gear washer. ¼ Do not reuse snap ring.
EC FE CL
SMT718D
22. Install reverse main gear assembly onto mainshaft. 23. Select a thrust washer suitable to satisfy the following specification of dimension "M" (as shown in the figure), and install it onto mainshaft. Specification of dimension "M": 244.20 - 244.30 mm (9.6142 - 9.6181 in) Available mainshaft thrust washers: Refer to SDS, MT-95.
AT AX SU BR ST RS BT HA
SMT719D
24. Install mainshaft rear bearing.
SC EL IDX
SMT720DB
MT-47
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont'd)
RS5F70A
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. End play: 0 - 0.06 mm (0 - 0.0024 in) Mainshaft C-rings: Refer to SDS, MT-92.
SMT721D
27. Install C-ring holder.
SMT678D
28. Install snap ring. 29. Measure gear end play as a final check. Refer to, MT-40.
SMT677D
Final Drive
PRE-INSPECTION
¼ 1.
NLMT0062
Check the clearance between side gear and differential case as follows. Clean final drive assembly sufficiently to prevent side gear thrust washer, differential case, side gear, and other parts from sticking by gear oil.
SMT610AH
2. 3.
4. 5.
SMT685DC
Upright the differential case so that the side gear to be measured faces upward. 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) If not within specification, adjust the clearance by changing thrust washer thickness. Turn differential case upside down, and measure the clearance between side gear and differential case on the other side in the same way.
MT-48
REPAIR FOR COMPONENT PARTS
DISASSEMBLY
1. 2. ¼
RS5F70A
Final Drive (Cont'd)
NLMT0063
Remove mounting bolts. Then, separate the final gear from differential case. Make a notch and remove speedometer drive gear using a scraper or other suitable tool. Bearing replacer cannot be positioned unless speedometer drive gear is removed.
GI MA EM
SMT609A
LC
3. 4. ¼ 5. Remove differential side bearing of final gear side. Turn differential case upside down, and remove differential side bearing of speedometer drive gear side. Be careful not to mix up the differential side bearings. Remove speedometer stopper.
EC FE CL
SMT647-C
6.
Remove lock pins from pinion mate shaft.
AT AX SU BR
SMT689DB
7. 8.
Remove pinion mate shaft. Rotate pinion mate gear, and remove pinion mate gear, pinion mate thrust washer, side gear, and side gear thrust washer from differential case.
ST RS BT HA
SMT839
INSPECTION Gear, Washer, Shaft and Case
¼ ¼
NLMT0064 NLMT0064S01
SC EL IDX
Check mating surfaces of differential case, side gears and pinion mate gears. Check washers for wear.
SMT083A
MT-49
REPAIR FOR COMPONENT PARTS
Final Drive (Cont'd)
RS5F70A
Bearing
¼ ¼
NLMT0064S03
Make sure bearings roll freely and are free from noise, cracks, pitting or wear. When replacing tapered roller bearing, replace outer and inner race as a set.
SPD715
ASSEMBLY
1. 2. 3.
NLMT0065
Apply gear oil to sliding area of differential case, each gear, and thrust washer. Install side gear thrust washer and side gear into differential case. Position pinion mate gear and pinion mate thrust washer diagonally, and install them into differential case while rotating.
SMT062A
4.
Insert pinion mate shaft into differential case.
SMT087A
5. 6. 7.
SMT685DC
8. ¼
Upright the differential case so that its side gear to be measured faces upward. Place preload adapter and dial gauge onto side gear. Move side gear up and down, and measure the clearance. Turn differential case upside down, and measure the clearance between side gear and differential case on the other side in the same way. Clearance of side gear and differential case: 0.1 - 0.2 mm (0.004 - 0.008 in) Differential side gear thrust washers: Refer to SDS, MT-95. Install retaining pin. Make sure that retaining pin is flush with case.
SMT699BB
MT-50
REPAIR FOR COMPONENT PARTS
RS5F70A
Final Drive (Cont'd)
9. Align and install speedometer drive gear into differential case. 10. Install speedometer stopper.
GI MA EM
SMT842D
LC
11. Install differential side bearing. 12. Turn differential case upside down, and install another differential side bearing on the other side in the same way.
EC FE CL
SMT751DB
13. Install differential gear into differential case. Apply sealant onto mounting bolts, and tighten them in order as shown in the figure with specified torque. Tightening torque: Refer to MT-28.
AT AX SU BR
SMT752D
Shift Control Components
INSPECTION
¼
NLMT0066
ST RS BT HA SC EL IDX
Check if the width of shift fork hook (sliding area with coupling sleeve) is within allowable specification below.
Item One-side wear specification 0.2 mm (0.008 in) 0.2 mm (0.008 in) 0.2 mm (0.008 in) Sliding width of new part 7.80 - 7.93 mm (0.3071 - 0.3122 in) 7.80 - 7.93 mm (0.3071 - 0.3122 in) 7.80 - 7.93 mm (0.3071 - 0.3122 in)
1st & 2nd 3rd & 4th 5th & reverse
SMT801D
MT-51
REPAIR FOR COMPONENT PARTS
Shift Control Components (Cont'd)
RS5F70A
¼
Check if shift check groove of fork rod or 5th & reverse check groove is worn, or has any other abnormalities.
SMT692D
MT-52
NLMT0067
ASSEMBLY Clutch Housing
1.
RS5F70A
Clutch Housing
NLMT0067S01
Hammer the striking rod oil seal into clutch housing as far as it will go. CAUTION: Do not reuse striking rod oil seal.
GI MA EM
SMT722DB
LC
2. Hammer the differential oil seal into clutch housing until it becomes flush with clutch housing end face. CAUTION: Do not reuse differential oil seal.
EC FE CL
SMT723DA
Hammer input shaft oil seal into clutch housing as far as it will go. CAUTION: Do not reuse input shaft oil seal.
3.
AT AX SU BR
SMT724DA
4. Hammer the dust seal into clutch housing as far as it will go. CAUTION: Do not reuse dust seal.
ST RS BT HA
SMT725DB
5.
Install outer race of differential side bearing.
SC EL IDX
SMT726DB
MT-53
ASSEMBLY
Clutch Housing (Cont'd)
RS5F70A
6. Install new oil channel (mainshaft). CAUTION: Pay attention to installation direction of oil channel.
SMT727D
7.
Align the notches on mainshaft front bearing and transaxle case. Then, install mainshaft front bearing.
SMT728DA
8.
Install mainshaft bearing retainer, and tighten bolts with specified torque.
SMT729D
Attach boot, striking rod, and striking lever to clutch housing. And install retaining pin for selector lever. CAUTION: ¼ Before installing striking rod, wrap the end with a vinyl tape or the like to prevent oil seal from being damaged. ¼ Do not reuse retaining pin.
9.
SMT667DB
10. Hammer the welch plug (striking lever side) with a generalpurpose drift [OD: 12 mm (0.47 in)]. CAUTION: Do not reuse welch plug.
SMT730D
MT-54
ASSEMBLY
RS5F70A
Clutch Housing (Cont'd)
11. Install selector, selector shaft, and selector shaft pin into clutch housing.
GI MA EM
SMT731D
LC
12. Hammer the welch plug (selector shaft side) with a generalpurpose drift [OD: 12 mm (0.47 in)]. CAUTION: Do not reuse welch plug.
EC FE CL
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.
AT AX SU BR
SMT733DA
ST RS BT HA
SMT734D
14. Install oil pocket.
SC EL IDX
SMT735D
MT-55
ASSEMBLY
Clutch Housing (Cont'd)
RS5F70A
15. Install differential assembly, input shaft assembly, and mainshaft assembly into clutch housing. CAUTION: Be careful not to damage input shaft oil seal during installation of input shaft assembly.
SMT736D
16. Install 5th & reverse shift fork. 17. Install 1st & 2nd shift fork, bracket, and fork rod. 18. Install retaining pin for 1st & 2nd bracket. CAUTION: Do not reuse retaining pin. 19. Install two check balls.
SMT659DC
20. Install interlock pin into 5th & reverse fork rod. 21. Install reverse switch bracket, 5th & reverse bracket, and fork rod. 22. Install retaining pin for 5th & reverse shift fork and reverse switch bracket. CAUTION: Do not reuse retaining pin. 23. Install 5th & reverse bracket stopper ring. CAUTION: Do not reuse stopper pin.
SMT657DC
24. Install check ball and interlock plunger. 25. Install 3rd & 4th shift fork, bracket, and fork rod. 26. Install 3rd & 4th bracket retaining pin. CAUTION: Do not reuse retaining pin.
SMT656DC
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-27.
SMT655D
MT-56
ASSEMBLY Transaxle Case
1.
RS5F70A
Transaxle Case
NLMT0067S02
Insert differential oil seal into differential case until it becomes flush with case end face.
GI MA EM
SMT737DA
LC
2. Install welch plug into transaxle case.
EC FE CL
SMT739D
3.
SMT740D
Calculate dimension "N" (thickness of adjusting shim) using the following procedure to satisfy specification of end play for differential side bearing. End play: 0.15 - 0.21 mm (0.0059 - 0.0083 in) Dimension "N" = (N1 N2) + End play N: Thickness of adjusting shim N1: Distance between clutch housing case end face and mounting face of adjusting shim N2: Distance between differential side bearing and transaxle case Differential side bearing adjusting shims: Refer to SDS, MT-96.
AT AX SU BR ST RS BT HA
a.
Using dial gauge and scale, measure dimension "N1" between clutch housing case end face and mounting face of adjusting shim.
SC EL IDX
SMT741D
MT-57
ASSEMBLY
Transaxle Case (Cont'd)
RS5F70A
b.
c.
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). Using dial gauge and scale as shown in the figure, measure dimension "N2" between differential side bearing outer race and transaxle case end face.
SMT742D
4.
Install selected shim and bearing outer race.
SMT738DB
5.
¼ ¼ ¼
SMT600-F
Measure turning torque of final drive assembly. Turning torque of final drive assembly (New bearing): 2.9 - 6.9 N·m (30 - 70 kg-cm, 26 - 61 in-lb) When old bearing is used again, turning torque will be slightly less than the above. Make sure torque is close to the specified range. 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. Calculate dimension "O" (thickness of adjusting shim) using the following procedure to satisfy specification of end play for input shaft rear bearing. End play: 0 - 0.06 mm (0 - 0.0024 in) Dimension "O" = (O1 O2) + End play O: Thickness of adjusting shim O1: Distance between transaxle case end face and mounting face of adjusting shim O2: Distance between clutch housing case end face and end face of input shaft rear bearing Input shaft rear bearing adjusting shims: Refer to SDS, MT-93.
6.
SMT743D
MT-58
ASSEMBLY
a.
RS5F70A
Transaxle Case (Cont'd)
Using block gauge, scale, and dial gauge, measure dimension "O1" between transaxle case end face and mounting face of adjusting shim.
GI MA EM
SMT744D
LC
b. Using gauge block, scale, and dial gauge as shown in the figure, measure dimension "O2" between clutch housing case end face and end face of input shaft rear bearing. Install selected input shaft rear bearing adjusting shim onto input shaft.
EC FE CL
7.
SMT745D
8.
Install oil gutter into transaxle case.
AT AX SU BR
SMT650D
9.
Install two magnets.
ST RS BT HA
SMT755D
10. Clean mating surfaces of clutch housing and transaxle case. Check for cracks and damage. Then, apply Three Bond TB1215, Loctite Part No. 51813 or equivalent.
SC EL IDX
SMT802D
MT-59
ASSEMBLY
Transaxle Case (Cont'd)
RS5F70A
11. Install transaxle case onto clutch housing, and tighten mounting bolts with specified torque. Tightening torque: Refer to MT-25.
SMT649D
12. Apply Three Bond TB1215, Loctite Part No. 51813 or equivalent 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.
SMT749D
SMT746D
15. Calculate thickness of adjusting shim using the following procedure to satisfy specification of end play for mainshaft rear bearing. End play: 0 - 0.06 mm (0 - 0.0024 in) Dimension "P" = (P1 P2) + End play P: Thickness of adjusting shim P1: Distance between transaxle case end face and mainshaft rear bearing P2: Distance between adjusting shim end face of rear cover and transaxle mounting face Mainshaft rear bearing adjusting shims: Refer to SDS, MT-94.
MT-60
ASSEMBLY
a.
RS5F70A
Transaxle Case (Cont'd)
Using dial gauge as shown in the figure, measure dimension "P1" between transaxle case end face and mainshaft rear bearing.
GI MA EM
SMT747D
LC
b. Using dial gauge as shown in the figure, measure dimension "P2" between adjusting shim mounting face of rear cover and transaxle mounting face.
EC FE CL
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.
AT AX SU BR
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: ¼ Do not reuse snap ring. ¼ Do not reuse O-ring. ¼ Before installation, apply gear oil to O-ring.
ST RS BT HA
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-91.
SC EL IDX
SMT754D
MT-61
ASSEMBLY
Transaxle Case (Cont'd)
RS5F70A
21. Install selected snap ring. CAUTION: Do not reuse snap ring. 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. Tightening torque: Refer to MT-25. CAUTION: Do not reuse mounting bolts for rear cover and side cover.
SMT644D
MT-62
NLMT0009
OVERHAUL Case Components
RS5F50A
Case Components
NLMT0009S02
GI MA EM LC EC FE CL
AT AX SU
SMT943D
BR
1. 2. 3. 4. 5. 6. 7. Speedometer pinion Differential oil seal Drain plug Boot Striking rod oil seal Magnet Clutch housing 8. 9. 10. 11. 12. 13. Input shaft oil seal Oil channel (Mainshaft) Oil pocket Oil gutter Oil channel (Input shaft) Transmission case 14. 15. 16. 17. 18. 19. Filler plug O-ring Movable plate assembly PNP switch (where fitted) Breather hose Breather pipe
ST RS BT HA SC EL IDX
MT-63
OVERHAUL
Gear Components
RS5F50A
Gear Components
NLMT0009S03
SMT937D
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Input shaft Input shaft front bearing 3rd input gear 3rd & 4th synchronizer hub Snap ring Coupling sleeve 4th baulk ring 4th input gear Reverse baulk ring Reverse synchronizer cone 5th synchronizer hub Input shaft rear bearing Input shaft bearing adjusting shim 3rd baulk ring Insert spring 4th input gear thrust washer Thrust washer ring 5th input gear
19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.
5th baulk ring 1st outer baulk ring 2nd inner baulk ring Snap ring Mainshaft bearing spacer Mainshaft front bearing Mainshaft 1st main gear 1st & 2nd synchronizer hub Reverse main gear & 1st-2nd coupling sleeve 2nd outer baulk ring 2nd gear synchronizer cone 2nd main gear 3rd main gear 4th main gear 5th main gear Mainshaft rear bearing Mainshaft bearing adjusting shim
37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53.
Differential side bearing Speedometer drive gear Differential case Pinion mate shaft Side gear Side gear thrust washer Pinion mate gear Pinion mate gear thrust washer Retaining pin Final gear Differential side bearing Differential side bearing adjusting shim Reverse idler gear Bushing Reverse idler shaft 1st gear synchronizer cone 1st inner baulk ring
MT-64
OVERHAUL Shift Control Components
RS5F50A
Shift Control Components
NLMT0009S04
GI MA EM LC EC FE CL
AT AX SU
SMT862CA
BR
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Retaining pin 1st & 2nd shift fork 1st & 2nd check plug Return spring Check ball 1st & 2nd fork rod 1st & 2nd bracket Interlock plunger 3rd & 4th bracket Return spring Reverse gate Select arm Return bearing Bushing 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. Yoke Striking rod Striking lever Selector Selector shaft O-ring Return spring Cam pin Reverse check cam Check ball Select check spring Interlock plunger 3rd & 4th fork rod 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. Interlock ball Stopper ring 3rd & 4th check plug 3rd & 4th shift fork 5th shift fork 5th fork rod 5th & reverse check plug Reverse lever spring Reverse lock spring 5th & reverse bracket Reverse lever assembly Reverse arm shaft Control lever spring
ST RS BT HA SC EL IDX
MT-65
NLMT0010
DISASSEMBLY
1. ¼ 2.
RS5F50A
Before removing transmission case, remove bolts, check plugs, springs and check balls as shown left. Be careful not to lose check balls. Remove transmission case.
SMT626D
3.
Remove PNP switch.
SMT017AA
4.
Mesh 4th gear, and then remove reverse idler shaft and reverse idler gear.
SMT659C
5.
Pull out retaining pin.
SMT660C
6.
Remove reverse lever spring and reverse lock spring from reverse lever assembly.
SMT661C
MT-66
DISASSEMBLY
7. Remove reverse arm shaft while rotating it.
RS5F50A
GI MA EM
SMT662C
LC
8. ¼ Remove reverse lever assembly and check ball. Be careful not to lose check ball.
EC FE CL
SMT663C
9. ¼
Remove 5th & reverse check plug, spring and ball. Be careful not to lose check ball.
AT AX SU BR
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.
ST RS BT HA
SMT664C
12. Remove both input and mainshafts with 1st & 2nd fork and fork rod as a set. 13. Remove final drive assembly. ¼ Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.
SC EL IDX
SMT105C
MT-67
DISASSEMBLY
14. Remove reverse check assembly and check ball. ¼ Be careful not to lose check ball.
RS5F50A
SMT138A
15. Remove retaining pin and detach the selector.
SMT618AA
SMT027A
16. Remove drain plug for convenience in removing retaining pin which holds striking lever to striking rod.
SMT028A
17. Remove retaining pin and then withdraw striking lever and striking rod.
SMT619AA
MT-68
REPAIR FOR COMPONENT PARTS Input Shaft and Gears
DISASSEMBLY
1.
RS5F50A
Input Shaft and Gears
NLMT0011
Before disassem