Manual Transmission 5-SPEED TRANSMISSION (Model : FSS5W60A) Tightening torque: Nim (kgm, fb) @® 10-16 (1.0-1.6,7-12) © 69-9.8(0.7-1.0,5.1-7.2) © 16-22(1.6-2.2, 12-16) © 20-34(2.0-35, 14-28) © 25-3925-4.0,18- 29) @o® aor 1 Frontenes 9 Newt ene 17 Din ig 2 Front oe ol sal 10 Panmiaon ce aneny 18 Rove deck steve 3 Fron cov: Oring 11 haste pte 1D Renrereson ast cor 4 ontcover sing shin 12 Breer inet wach po 13. Return sing bushing 20 Sperone pin 6 Topnarsich M4 ler pe 2 Syedomet: dere > OB ger oh 15 being einer 2 Resin pn @ Reese lamp svitch 16 Renroxtenson sey es mt once PR GM 7 \N) ral a 78 ‘main gear | Le x “0 em suri6s ST ante I s yw‘Return spring plug 49-9805 Striking lever Ist 2nd fork rod D: Nem kgm, fetb) DISASSEMBLY TRANSMISSION CASE DISASSEMBLY 1, Prior to disassembling transmis- sion, thoroughly wipe off dirt and grease front it 2. Drain oil thoroughly. 3. Remove dust cover from trans- mission case. Remove release bearing and with- drawal lever. 4, Remove reverse lamp, neutral, Top and O.D. gear switches (if so equipped). 5. Remove speedometer pinion as- sembly. ‘Check bal plug of Pc al arog etaning (| ising Manual Transmission Oil seal Expansion plug (09 -1.2,6.5-8.7) ‘Check ball pug Check ball Interlock plunger Fevaning shift fork OLD. & reverse fork rod Ast & 2nd shift fork 6. Remove nut and stopper pin bolt from rear end of rear extension, MT-4 Control lever boot CControt lever ‘bushing survi67 7. Remove return spring plug, return spring, and plunger from rear exten- sion.8. Remove reverse check sleeves as- sembly. 9. Remove front cover. Detach O- ring and front cover adjusting shim. T7085 10. Remove main drive bearing snap ring with snap ring pliers. 11, Remove rear extension secur- ing bolts and tum striking rod clock- Drive out rear extension backward using a standard puller. 12. Separate transmission case from adapter plate by evenly tapping around it with a soft hammer. CAUTION: Do not pry transmission case or rear extension from adapter plate with serewdriver. Manual Transmission suri71 13. Set up Adapter Setting Plate KV32100300 on adapter plate. Place the above assembly in a vise. KV32100300 14. Detach washer. thrust counter gear DISASSEMBLY OF GEAR ASSEMBLY Shift forks and fork rods 1. Drive out retaining pins from each fork rod with Fork Rod Pin Punch ST23540000. suri73 2. Remove three (3) check ball plugs. Mrs 3. Drive out fork rods from adapter plate by lightly tapping on the front end Detach shift forks. Note: a. Be careful not to lose three (3) check balls and two (2) interlock plungers, b. Each gear and shaft can be de- tached from adapter plate without removing each fork rod. 1. Check ball plug 2. Fork rod (Ist & 2nd) 3 Interlock plunger 4 Fork rod Grd & 4th) 5 Fork rod (0.0, & Reverse) 6 Check ball Gear mbly Note: It is necessary to measure end play, before disassembling main- shaft and after reassembling main- shaft, Refer to Inspection for Gears and Shafts. 1, Remove snap ring of mainshaft end bearing. Draw out bearing using Bearing Puller KV32101330. Remove