MANUAL TRANSMISSION

SECTION MT
CONTENTS
I 1 FS5W71C & FS5R30A 1
PREPARATION ........................................................... MT- 2

.v
ON-VEHICLE SERVICE .................................................... MT- 7
REMOVAL AND INSTALLATION ........................................... MT- 8

1 I FS5W71CI
MAJOR OVERHAUL ...................................................... MT- 9
...........................................................
DISASSEMBLY MT-12
INSPECTION ............................................................. MT-17
ASSEMBLY .............................................................. MT-19

I 1 FS5R30A r I
MAJOR OVERHAUL ...................................................... MT-31
DISASSEMBLY ........................................................... MT-35
INSPECTION ............................................................. MT-42
ASSEMBLY .............................................................. MT-44

I IFS5W71C & FS5R30AI I

SERVICE DATA AND SPECIFICATIONS (S.D.S.) .............................. MT-56
 SPECIAL SERVICE TOOLS - for FS5W71C
Tool number
(KencMoore No.) Description
Tool name

ST23810001 Fixing adapter plate with gear assembly

( - 1
Adapter setting plate

[Ex
KV31100401 Pressing counter gear and mainshaft
( - 1
Transmission press
stand

ST22520000
(5263481
Wrench

~ ~

ST23540000 Removing and installing fork rod retaining

(J25689-AI pin
Pin Dunch

ST30031000 Removing and installing 1st gear bushing

lJ22912-01) Removing main drive gear bearing
Puller Measuring wear of baulk rings

ST23860000 Installing counter drive gear

( - 1
Drift
a: 38 m m 11.50 in) d i r
a b: 33 m m 11.30 in) dim.

ST22360002 A Installing counter gear front and rear end

(52567941I bearings
Drift
I: 29 mm 11.14 in) dia.
b: 23 m m (0.91 in1 dia.

ST22350000 Installing O.D. gear bushing

(52567841 I
Drift
a: 34 mm (1.34 in) d i r
b: 28 mm 11.10 in) di.

ST23800000 Installing front cover oil seal

152569141)
Drift
a: 44 mm (1.73 in1 dh.
b: 31 mm (1.22 in1 d i r

MT-2
Tool number
(Kent-Moore No.) Description
Tool name
I
ST33400001 Installing rear oil seal
(526082)
Drift
a: 60 mm (2.36in1 die.
b 47 mm (1.85 in) dia.

Puller

ST30720000 Installing mainshaft ball bearing

( - )
Drift
a: 77 mm (3.03in1 dia.
b: 55.5 mm (2.185 in) dia.

ST30613000 Installing main drive gear bearing

(525742-3)
Drift
a: 71.5 mm 12.815 in1 dia.
b: 47.5 mm 11.870 in) dia.

ST33200000 Installing counter rear bearing

(526082) Installing 3rd & 4th synchronizer
Drift assembly
a: 60mm 1236 In) d h
b: 44.5 mm (1.762 in) di..

COMMERCIAL SERVICE TOOL - for FS5W71C

Tool name Description

Puller Removing counter bearings, counter drive

and O.D. gears

MT-3
 PREPARATION pEi5q
SPECIAL SERVICE TOOLS - for FS5R30A
Tool number
(KentMoore No.) Description
Tool name

ST23540000 Removing and installing retaining pin

(525689-A)
Pin punch

ST30031000 Removing 1st & 2nd synchronizer assembly

(52291241) Removing counter gear rear thrust bearing
Puller Removing main drive bearing

ST33290001 Removing rear oil seal

(525810-A)
Puller

"
ST33230000 Removing mainshaft and counter gear
( - 1
Drift
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 id di8.

ST22350000 Removing counter gear front bearing

(525678.01 I (Use with KV38100300)
Drift
a: 34mm 11.34in)dia.
b: 28 mm 11.10 in) dia.

KV38100300 Removing counter gear front bearing

iJ255231 (Use with ST22350000)
Drift Installing counter gear rear bearing
a: 54 m m 12.13 in) dia.
b: 32 mm (1.26 in1 dia.

ST30720000 @ Removing mainshaft front bearing

@ (534286) @ Installing mainshaft front bearing
@ (534331)
Drift a: 77 mm (3.03in) dia.
b 55.5 mm 12.185 in1 dia.

ST33210000 @ Installing counter gear front bearing

@ (525523) @ Installing front cover oil seal
@ I
(525803.01)
Drift : 44 mm 11.73 in) dia.
: 24.5 mm (0.985 in) dia.

ST30613000 Installing main drive gear bearing

(525742-3)
Drift
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.

MT-4
 PREPARATION pziiiij
Tool number
IKentMoore No.) Dexription
Tool name
~~

ST37750000 @ Removing counter gear rear bearing

@ (J34286) @ Installing 0.0. gear bushing
@ (534332) @ Installing reverse cone
@ (534334) @ Installing reverse counter gear
@ (J25679-01) @ Installing counter gear rear end bearing
Drift

a: 40mm 11.57 in) dia.

b: 31 mm 11.22 in) dia.

ST22452000 Installing reverse hub

(534337) Installing mainshaft rear bearing

@
Drift
a: 45 mm (1.77 in) dia.
a b: 36 mm (1.42 in) dia.

ST33400001 Installing rear oil seal

(J26082I
Drift
a: 60 mm (2.36in1 die..
b: 47 mm 11.85 in1 dia.

(J26349-3) Installing mainshaft and counter gear

Puller leg (Use with 534328)

(J343281 Installing mainshaft and counter gear

Puller (Use with 526349-3)

(J26092) Installing sub-gear snap ring

Drift

a: 44.5 mm (1.752 in) dia.

a b: 38.5 mm (1.516 in) dla.

(J34342) Installing 0.0. main F a r

Drift Installing reverse gear bushing

a: 44.5 mm 11.752 in) dia.

b: 40.5 mm 11.594 in1 dia.

ST36730000 Installing wb-gear on reverse

( - 1 idler gear
Drift
 P REPARATlON pziq
COMMERCIAL SERVICE TOOL - for FS5R30A
Tool name Description

Puller Removing caunter gear rear end bearing

Removing mainshaft rear bearing
Removing reverse synchronizer hub
Removing reverse counter gear

MT-6
 ON-VEHICLE SERVICE

Checking M/T Oil

Check manual transmission for leakage.

&
Check oil level.

Fill to this level

LFiller plug
SMAlO:

Replacing Rear Oil Seal

MT-7
REMOVAL AND INSTALLATION

Removal
Remove exhaust front tube, catalytic converter and exhaust
manifold connecting tube.
Refer t o Section EM.
Remove propeller shaft.
Refer t o section PD
Insert plug into rear oil seal after removing propeller shaft.
Support engine by placing a jack under oil pan.
CAUTION:
TOSSA
Be careful not to damage spline, sleeve yoke and rear oil
seal, when removing propeller shaft.
Do not place jack under the oil pan drain plug.
Remove shift lever (FS5W71C).

WARNING:
Support Manual Transmission, while removing it.
Remove shift knob and console boot finisher (FS5R30A).
Dust cover must not be removed from shift lever.

Installation
0 Tighten bolt securing transmission.

1 Tightening torque N m (kg-m, ft-lb)-[

~~ ~~

Bolt No. P mm (in)

1 39 - 49 (4.0 - 5.0,29 - 36) 65 (2.56)

2 39 - 49 (4.0 - 5.0,29 - 36) 60 (2.36)
3 29 - 39 (3.0- 4.0,22 .29) 55 (2.17)
4 29 - 39 (3.0- 4.0, 22 - 29) 25 (0.98)

MT-8
MAJOR OVERHAUL 1FS5W71C I

SMT74KA

MT-9
 MAJOR OVERHAUL
I FS5W71C]
Gear Components - FS5W71C

Needle
bearing

Main drive gear blibearing

coupling sleeve
13rd & 4th
synchronizer hub*
Spread Spring

I roller

-7 Mainshaft bail bearing

Mainshaft rear end bearing

-
(14.0. 17.0. 101 1231
st washer Without Tool

.D.(5th) main gear

Shifting insert spring Reverse counter gear

B mal" gear
Overdrive counter gear
Reverse counter gear spacer
auntel rear bearing

Insert retainer

O.D. (5th) synchronizer

*
'
Rewrse idler thrust washer
hub
-w u n i e r gear Z3' Reverse idler gear bearing
Reverse idler thrust washer
Counter
drive gear* Reverse idler shaft

Subgear Apply g.r oil to W m , ihdts,

svnchmnlren, and h i mwhmn -bun&
Counter shaft
front bearing
Subgear spring *
Select with proper thickness.
Snap ring* 0 Sub-gear bracket * Psv mention t o its direction.
: N m (kg-m, ft-lb)
SMTCI378

MT-10
MAJOR OVERHAUL I FS5W71C I
Shift Control Components-FS5W71 C
(With mainshaft braking mechanism)

SMT039B

MT-11
 DISASSEMBLY 1F S 5 W y
Case Components
1. Remove rear extension.
a. Remove control housing, check ball, return spring plug,
select check plunger and return springs.

b. Remove rear extension by lightly tapping it.

SMT98

2. Remove front cover, gasket, shim of countershaft front

bearing, and snap ring of main drive gear ball bearing.

3. Separate transmission case from adapter plate.

TM753

4. Remove oil seal of front cover.

Be careful not to damage mating surface of front cover.

MT-12
 DISASSEMBLY piiq
Shift Control Components
1. Set up Tool on adapter plate.
2. Remove check ball plugs, check springs, and check balls,

sl73810001
( - 1

TM75

3. Drive out retaining pins. Thep drive out fork rods and remove
interlock balls.
T23540000
125689-AI
.

4. Remove lever bracket securing bolt.

5. Draw out 3rd4th fork rod.

6. Remove E-ring from 0.D.-rev. fork rod.

MT-13
 DISAS SE MBLY I FS5W71C I
Shift Control Components (Cont'd)
7. Draw out 0.D.-rev. fork shaft by rotating 0.D.-rev. bracket
counterclockwise.

SMT792A

Gear Components
1. Before disassembly, measure each gear end play.
0 If end play is not within the specified limit, disassemble and
check the parts.
0 Replace any part which is worn or damaged.

Gear End play rnm (in)

1 It 0.31 - 0.41 (0.0122 - 0.0161)

2nd 0.1 1 .0.21 (0.0043 - 0.0083)
iMT025
" I 3rd 0.11 .0.21 (0.0043 - 0.0083)
O.D. 0.24 - 0.41 (0.0094 - 0.0161)

2. Mesh 2nd and reverse gear, then draw out counter front
bearing with suitable puller.
3. Remove snap ring and then remove sub-gear bracket, sub-gear
spring and sub-gear.

SMT174P

TSuitable puller 4. Draw out counter drive gear with main drive gear assembly
with suitable puller.
When drawing out main drive gear assembly, be careful not t o
drop pilot bearing and baulk ring.

MT-14
 DISASSEMBLY LFs5w71cJ
Gear Components (Cont’d)
5. Disassemble parts a t rear of adapter plate as follows.
a. Release staking on countershaft nut and mainshaft nut and
loosen these nuts.
Mainshaft nut: Left-hand thread

.I
SMT163A

b. Pull out O.D. counter gear with bearing with suitable puller.
c. Draw out reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft, and draw out
reverse idler gear, thrust washers and reverse idler gear bear-
ing.
e. Remove speedometer drive gear and steel ball.

I
f. Remove snap ring and pull out overdrive mainshaft bearing,
then remove snap ring.
g. Remove mainshaft nut.
h. Remove thrust washer, steel roller, roller bearing and washer.
i. Remove O.D. main gear, needle bearing and baulk ring
(O.D.).
j. Remove O.D. coupling sleeve, shifting inserts and shifting
insert springs.

SMTMOE

k. Press out mainshaft and counter gear alternately.

Make sure t o alternate pressing of mainshaft and counter gear so
as not t o allow the front surface of one to contact the rear
surface of the other.

6. Remove front side components on mainshaft.

a. Remove 1st gear washer and steel ball.
b. Remove 1st main gear and 1st gear needle bearing.

SMT383A

MT-15
 DISASSEMBLY I FS5W71C 1
Gear Components (Cont'd)
c. Press out 2nd main gear together with 1st gear bushing and
1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.

ST3J031000
lL?291201)

e. Press out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd gear needle bearing.

SMT385P

7. Remove main drive gear bearing.

H ST30031WO
a. Remove snap ring and washer.
b. Remove main drive gear bearing.
1.12291201 I

-
t-m

MT-16
 INSPECTION (Fs5w71Cl
Shift Control Components
Check contact surface and sliding surface of fork rods for
wear, scratches, projections or other damage.

d
SMT137

Mainrhaft and gear Gear Components

GEARS AND SHAFTS
Check shafts for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.

SMT386A

I Counter gear

L SMT550P

SYNCHRONIZERS

e
l
Shifting insert
Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
Check insert springs for deformation.

SMT026

MT-17
 INSPECTION I FS5W71C I
Gear Components (Cont'd)
r I Measure clearance between baulk ring and gear.
BaulK ring to
Clearance between baulk ring and gear
gear clearance
Unit: mm f i n )

I
I
Standard I
I
Wear limit

1st I I
3rd
Main drive 1 1 . 2 - 1.6
(0.047- 0.063)
1 0.8 (0.031)
OD.
L SMTl4,

Innmr b8uk ring

\2nd inner bauik ring .
Synchronizer cone

Dimension Standard Wear limit

0.7 - 0.9
0.2(0.008)
( 0 . 0 2 8 - 0.035)
h n r bwk ring
- Svnchronizer cone
2nd outer baulk ring
0.2 (0.008)

c. I f dimension "A" or "B" is smaller than the wear limit, re-

place baulk ring.

7%' Synchronizer cone

LZnd outer baulk ring SMT0428 I
BEARINGS
Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

MT-I a
 AS SEM BLY I FS5W71C I
Mainrhaft ball bearing in adapter plate
Gear Components
1. Install bearings into case components.

Counter rear bearing in adapter plate

2. Assemble adapter plate parts.

Install oil gutter on adapter plate and expand on rear side.

a
:., ,
---
Front
, I

I SMT153L
~

Install bearing retainer.

a. Insert reverse shaft, then install bearing retainer.

SMT028

MT-19
 ASS E MBLY [FS5W71C I
Gear Components (Cont’d)

3. Install main drive gear bearing.

a. Press in main drive gear bearing.
b. Install main drive gear spacer.

c. Select proper main drive gear snap ring t o minimize clearance

of groove.
Allowable clearance of groove:
0.0.13 m m (0 - 0.0051 in)
Main drive gear snap ring

Thickness mm (in) Part number

1.73 (0.0681) 32204-78005
1.80 (0.0709) 32204-78000
1.87 (0.0736) 32204-78001
1.94 (0.0764) 32204-78002
2.01 (0.0791) 32204-78003
2.08 (0.0819) 32204-78004
~

d. Install selected snap ring on main drive gear.

4. Assemble synchronizers.
1st & 2nd synchronizer

MT-20
 ~

ASS EMBLY (Fs5w71cJ

Gear Components (Cont'd)
4ub nd muplinp s l r n

\
~

Coupling sleeve

Front rid. SMT0451

SMT0460

baulk ring

SMT0470

I 3rd & 4th synchronizer

Synchronizer hub

MT-21
 ASSEMBLY I FS5W71C I
Gear Components (Cont'd)
I A h i f t i n q insert spring OD. synchronizer

Front

15th) synchronizer
SMT095A

5. Assemble 2nd main gear, needle bearing and 1st & 2nd
synchronizer assembly, then press 1st gear bushing on
mainshaft.
Pay attention t o direction of 1st & 2nd synchronizer assembly.
6. Install 1st main gear.

7. Install steel ball and thrust washer.

Before installing steel ball and thrust washer, apply grease t o
them.

8 . Press mainshaft assembly t o adapter plate with Tool.

9. Press counter gear into adapter plate with Tool.

10. Install 3rd main gear and then press 3rd & 4th synchronizer
assembly.

...
I I

MT-22
 ASSEMBLY IFs5W71cJ
Gear Components (Cont'd)
Pay attention t o direction of 3rd 814th synchronizer hub.

11. Install thrust washer on mainshaft and secure it with main-

shaft front snap ring.
Select proper snap ring to minimize clearance of groove in main-
shaft
Mainshaft front snap ring:
Refer t o S.D.S.
12. Apply gear oil t o mainshaft pilot bearing and install it on
mainshaft.

TM441

13. Press counter drive gear with main drive gear with Tool.

KV31100401
1 - 1

Pay attention t o direction of counter drive gear.

FrontC I I
U SMT620P

14. Install sub-gear components.

a. Install sub-gear and sub-gear bracket on counter drive gear
and then select proper snap ring t o minimize clearance of
groove in counter gear.
Allowable clearance of groove:
0 - 0.18 mm (0.0.0071 in)

MT-23
 ASS EMBLY I FS5W71C I

Parts number Thickness m m (in)

322 15-E9000 1.4 (0.055)
322 15-E9001 1.5 (0.0591
32215-E9W2 1.6 (0.063)

c. Reinstall sub-gear, sub-gear spring and sub-gear bracket.

I Lsubgear spring I
LSubgear bracket
SMT528A

15. Install selected counter drive gear snap ring.

TM366

16. Press counter gear front bearing onto counter gear.

KV31100401
( - )
TMdd

17. Assemble parts a t rear of adapter plate as follows:

I a. Install reverse idler gear t o reverse idler shaft with spacers,
snap rings and needle bearing.

c
Front

TM45

MT-24
 ASSEMBLY I FS5W71C 1
Gear Components (Cont'd)
Ilnrerf shifting spring
b. Install insert retainer and O.D.synchronizer t o mainshaft.
Shifting insert, / Pay attention t o direction of hub.

1.0. 15th) synchronizer]

ub
a SMT095A

c. Install O.D. war bushing with Tool.

d. Install O.D. main gear and needle bearing.
e. Install spacer, reverse counter gear and O.D. counter gear.
O.D. main gear and O.D. counter gear should be handled as a
matched set.
f. Install washer, roller bearing, steel roller and thrust washer.
g. Tighten mainshaft lock nut temporarily.
Always use new lock nut.

SMT53

ST22360W2 h. Install countershaft rear end bearing with Tool.

151567901I

18. Mesh 2nd and reverse gears, then tighten mainshaft lock nut
with Tool.

SMTOOJ

MT-25
 Gear Components (Cont'd)
tool c7 Use the left chart when deciding the reading torque.
Torque wrench (Length of torque wrench vs. setting or reading torque)

11.51 12.01 (2.5) I f t 19. Tighten countershaft lock nut.

MT004A L: Length of torque wrench Always use new lock nut.
Mainshaft Countershaft 20. Stake mainshaft lock nut and countershaft lock nut with a
punch.
21. Measure gear end play. For the description, refer t o Disassem-
bly of Gear Components.

Shift Control Components

1. Install shift rods, interlock plunger, interlock balls and check
balls.

Interlock plunger

SMT99:

a. 1st-2nd shift fork

SMT989

MT-26
 ~ ~

ASSEMBLY IFs5w71cI
Shift Control Components (Cont'd)
b. 3rd-4th shift fork

SMT991

c. 0.D.-reverse shift fork

2. Install 0.D.-rev. fork shaft by rotating 0.D.-rev. bracket

clockwise.

SMT791A

3. Install E-ring on 0.D.-rev. fork rod.

4. Install lever bracket securing bolt.

MT-27
 ASS E MB LY I FS5W71C1
Case Components
1. Install front cover oil seal.
Apply multi-purposegrease to seal lip.

SMTOJS

2. A Av sea lnt ' mating surface of transv ssion case.

3. Slide gear assembly onto adapter plate b y lightly tapping

with a soft hammer.

e
, .~.

4. Apply sealant t o mating surfac f d i ter plate.

5. Install rear extension.

6. Fit main drive bearing snap ring.

MT-28
 ASS EMB LY IFs5w71c1
Case Components (Cont'd)
7. Select counter front bearing shim.
A: Oirtanae from bearing
surface to transmission I Unit: mm (in)

"A" I Thicknessof shim I Part number

4.52 - 4.71
Not necessary
(0.1780.0.1854)
1 Transmission care
4.42.4.51
2 Counter gear front bearing 0.1 (0.004) 3221EV5000
3 Counter gear (0.1740 - 0.1776)
4.32 - 4.41
0.2 (0.008) 3221EV5001
(0.1701 -0.1736)
4.22 - 4.31
(0.1661 .0.1697)
I 0.3 (0.012) I 32218-V5002

4.12.4.21
(0.1622.0.1657)
I 0.4 (0.016) I 32218.V5003

4.02.4.1 1
(0.1583.0.1618)
I 0.5 (0.020) I 32218-V5004

3.92 .4.01
0.6 (0.024) 32218.V5005
(0.1543-0.1579)

8. Install gasket and front cover.

9. Install return spring plugs, check bail, return springs and
select check plunger.
10. Install control housing and gasket.

MT-29
 ASS EMBLY 1-
NOTE

MT-30
 .. ..
ED

MT-31
MAJOR OVERHAUL pGiq

Gear Components - FS5R30A

-

MT-32
MAJOR OVERHAUL I FS5R30A I
Gear Components - FS5R30A (Cont’d)

SMT830A

MT-33
MAJOR OVERHAUL I FS5R30A I
Shift Control Components - FS5R30A

SMT838A

MT-34
 DISASSEMBLY I FS5R30A 1
II I! Case Components
1. Remove check ball plug, check spring and check ball. Then
remove interlock stopper.
If interlock assembly is removed as a unit, the check ball can
fall into transmission case.

2. Remove control housing, return spring and check ball.

3. Drive out retaining pin from striking arm.

4. Remove rear extension together with striking arm by tapping

lightly.

SMT369A

MT-35
 DISASSEMBLY
Case Components (Cont'd)
5. Remove front cover and gasket.

6. Remove stopper ring and main drive bearing snap ring.

7. Remove transmission case by tapping lightly.

8. Remove front cover oil sea

U
SMT392A

Shift Control Components

1. Mount adapter plate on vise.
2. Remove O.D. & reverse fork rod.

MT-36
DISASSEMBLY 1-
Shift Control Components (Cont'd)
3. Remove check ball plug, check ball and return spring.

4. Drive out retaining pin from striking lever.

5. While pulling out striking rod, remove striking lever and
striking interlock. Then remove 1st & 2nd. 3rd & 4th and
reverse shift fork.

6. DI it retaining pi from O.D. shift fork.

7. Pull out O.D. fork rod and then remove O.D. shift fork.

Gear End play mm (in)

1st main gear 0.23 .0.33 (0,0091 .0.0130)

2nd main gear 0.23 - 0.33 10.0091 .0.0130)
3rd main gear 0.23 - 0.33 (0,0091 - 0.0130)
O.D. counter gear 0.23 .0.33 10.0091 - 0.0130)
Reverse main gear 0.33 .0.43 (0.0130 - 0.0169)

0 If not within specification, disassemble and check contact

surface of gear t o hub, washer, bushing, needle bearing and
shaft.

MT-37
Gear Components (Cont’d)
2. Remove rear side components on mainshaft and counter gear.
a. Remove snap ring, speedometer drive gear and steel ball.
b. Remove reverse coupling sleeve.

c. Remove mainshaft rear snap ring and counter gear rear snap
ring.
d. Remove C-ring holder and mainshaft C-rings from mainshaft.
Use punch and hammer t o remove C-rings.

e. Pull out counter gear rear end bearing.

f. Remove reverse idler gear and reverse idler thrust washers.

g. Remove sub-gear from reverse jler gear.

h. Pull out mainshaft rear bearing (2WD model).

MT-38
 DISASSEMBLY 1-
Gear Components (Cont'd)
i. Pull out reverse main gear together with mainshaft spacer and
reverse synchronizer hub. Then remove reverse war needle
bearings.

j. Pull out reverse counter gear.

k. Remove O.D. coupling sleeve together with O.D. baulk ring,
reverse baulk ring and spring inserts.

I SMT773A I
I. Pull out reverse gear bushing.

m. Pull out O.D. counter gear together with reverse cone.

MT-39
 DISASSEMBLY
Gear Components (Cont'd)
3. Press out mainshaft and counter gear alternately.

Make sure to alternate press between mainshaft and counter gear not to allow
the front surface of one to contact the rear surface of the other. SMT772L

4. Remove front side components on mainshaft.

a. Remove 1st gear washer and steel ball.
b. Remove 1st main gear and 1st gear needle bearing.

SMT383A

c. Press out 2nd main gear together with 1st gear bushing and
1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.

e. Press out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd gear needle bearing.

MT-40
 DISASSEMBLY IFS5R30A I
Gear Components (Cont'd)
5. Remove front side components on counter gear.
a. Remove counter gear rear thrust bearing.

b. Remove sub gear components.

6. Remove main drive gear bearing.

a. Remove main drive gear snap ring and spacer.
b. Press out main drive gear bearing.

7. Remove bearings from case components.

MT-41
 INSPECTION I FS5R30A I
I Shift fork 1 Shift Control Components
Check contact surface and sliding surface for wear, scratches,
projections or other damage.

Gear Components
GEARS AND SHAFTS
Check shafts for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.

I Counter gear

Shifting insert I SYNCHRONIZERS

Check spline portion of coupling sleeves, hubs, and gears for
23 wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
Check insert springs for deformation.
t
Baulk ring
gear c1eara
Standard Wear limit

1st I3 2nd 1.05 . 1.3 (0.0413 - 0.0512) 0.7 (0.028)

3rd &main drive 1.05 - 1.3 (0.0413 -0.05121 0.7 (0.028)
O.D. 1.05- 1.3 (0.0413-0.0512) 0.7 (0.028)

If the clearance is smaller than the wear limit, replace baulk ring.
SMT

MT-42
 INSPECTION 1 FS5R30AI

Standard Wear limit

Dimension "A*
1 -0.1 to 0.35
1-0.0039 to 0.0138)
1 0.7 (0.028)

c. If dimension "A" is larger than the wear limit, replace baulk

ring.

BEARINGS
Make sure bearings roll freely and are free from noise,.crack,
pitting or wear.

MT-43
 AS SEM B LY [TGiiiZl
Gear Components
1. Install bearings into case components.
:ounter gear front bearing in transmisaion Mainthaft front bearing in adapter plate
n

SMT397A

Counter gear rear bearing in adapter plate

n
4

SMT395A

2. Install main drive gear bearing.

a. Press main drive gear bearing.
b. Install main drive gear spacer.

c. Select proper main drive gear snap ring t o minimize clearance

of groove.
Allowable clearance of groove:
0 - 0.1 rnrn ( 0 - 0.004 in)
Main drive gear snap ring

1.89 (0.0744) 32204-01GOO

1.98 (0.0780) 32204-01G01
2.05 (0.0807) 32204-01G02
2.12 (0.0835) 32204-01G03

d. Install selected snap ring on main drive gear.

MT-44
 ASS E MB LY I FS5R30A I
Gear Components (Cont'd)
3. Install components on counter gear.
a. Install sub-gear components.
When installing sub-gear snap ring, tap sub-gear snap ring into
position on counter gear.

b. Install counter gear rear thrust bearing.

4. Install front side components on mainshaft.

a. Assemble 1st & 2nd synchronizer.
Synchronizer hub

SMT421P

b. Assemble 3rd & 4th synchronizer

,-Synchronizer hub I

SMT422A

c. Press on 3rd & 4th synchronizer assembly together with 3rd

main gear and 3rd gear needle bearing.
Pay attention t o direction of synchronizer assembly.

MT-45
 ASSEMBLY I-[
Gear Components (Cont'd)
d. Select proper snap ring t o minimize clearance of groove.
Allowable clearance of groove:
0.0.1 mm (0.0.004 in)
Mainshaft front snap rina
Thickness mm (in) Part number

1.89 (0.07441 32204-01600

1.98 (0.0780) 32204-01601
2.05 (0.08071 32204-01602
SMT400J 2.12 (0.0835) 32204-01603
2.19 (0.08621 32204-01604

e. Install selected snap ring on mainshaft.

M f. Press on 1st & 2nd synchronizer assembly together with 2nd

main gear and 2nd gear needle bearing.

SMT40lA

U g. Press on 1st gear bushing using 1st gear washer.

h. Install 1st main gear and needle bearing.

1 6 1 gear
washer

SMT402A

i. Install steel ball and 1st gear washer.

Apply multi-purpose grease to steel ball and 1st gear washer
before installing.

SMT4031

MT-46
 ASS E M BLY JFS5R30AI
Gear Components (Cont'd)
5. Select proper counter gear front bearing shim when replacing
Counter gear front transmission case, counter gear, counter gear thrust bearing
or sub-gear components.
a. Install counter gear with sub-gear components, counter gear
front and rear thrust bearing on adapter plate.
Counter b. Remove counter gear front bearing shim from transmission
gear
case.
c. Place adapter plate and counter gear assembly in transmission
case (case inverted).

SMT427A

R d. Tighten adapter plate t o transmission case using 2 bolts.

e. Place dial indicator on rear end of counter gear.
f. Move counter gear up and down and measure dial indicator
deflection.
g. Select proper shim using table below as a guide.
Counter gear end play:
0.10 - 0.25 mm (0.0039- 0.0098 in)
Table for selecting proper counter gear front bearing
~~ ~ .shim

Thickness of
Dial indicator deflection
proper washer Part number
mm (in)
mm (in)

0.93 - 1.02 (0.0366 - 0.0402) 0.8 (0.031 3221801GOO

1.03-1.12 (0.0406-0.0441) 0.9 (0.035) 3221801G01
1.13 . 1.22 (0.0445 - 0.04801 1 .O (0.039) 3221801 GO2
1.23 - 1.32 (0.0484 - 0.0520) 1.1 (0.043) 3221801G03
1.33 - 1.42 (0.0524 .0.0559) 1.2 (0.047) 3221801G04
-counter gear
1.43. 1.52 (0.0563.0.0598) 1.3 (0.051 ) 3221841GO5
Measured 1.53 - ?I .62 (0.0602 - 0.0638) 1.4 (0.055) 32218 0 1GO6
end .Dlav.
SMT578L

MT-47
 ASSEMBLY 1-

everie idler shaft

Reverse idler
front thrust washer

Reverse idler gear

Thickness mm (in) Part number

8
1.97 (0.0776)
2.07 (0.0815) I 32284-01G10
32284-01G11

b. Place dial indicator on front end of reverse idler shaft.

c. Put straightedge on front surface of rear extension as a
stopper of reverse idler shaft.
d. Move reverse idler shaft up and down and measure reverse
idler gear end play.
Reverse idler gear end play:
0.30 - 0.53 rnm (0.0118 - 0.0209 in)
e. If not within specification, replace reverse idler rear thrust
washer with the other ( A or B ) and check again.

MT-48
 ASS EMBLY I FS5R30A
Gear Components (Cont'd)
7. Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft.
a. Mount adapter plate on vise and apply multi-purpose grease
t o counter gear rear bearing.

b. Install mainshaft a little on mainshaft front bearing.

To allow for installation of counter gear, do not install
mainshaft completely.

SMT440L

c. Install counter gear on counter gear rear bearing and install

main drive gear, pilot bearing and spacer on mainshaft.

Push up with screwdriver, I When installing counter gear into counter gear rear bearing,
push up on upper roller of counter gear rear bearing with screw-
driver.

d. Install Tools (J26349-3) onto adapter plate and C-ring and

C-ring holder on mainshaft.
e. Install Tool (J34328) on mainshaft.

MT-49
 ASSEMBLY
Gear Components (Cont’d)
f. Install mainshaft and counter gear completely by extending
length of J26349-3.

SMT579A

8. Install rear side components on mainshaft and counter gear.

a. Install O.D. gear bushing while pushing on the front of
counter gear.

SMTdMA

h b. Install O.D. main gear.

Pay attention t o direction of O.D. main gear. (B is wider than
A as shown a t left.)
c. Install adapter plate with gear assembly onto transmission
case.
d. Install O.D. gear needle bearing and then install O.D. counter
gear and reverse idler shaft.

e. Install reverse gear bushing.

f. Install reverse cone.

SMT582A

MT-50
 ASSEMBLY 1 FS5R30A I

7
1 ST22452000
Gear Components (Cont’d)
I. Install mainshaft spacer and mainshaft rear bearing.
m. Install speedometer drive gear.

.-t > SMT586A1

n. Install counter gear rear end bearing.

0. Separate adapter plate from transmission case and Mount
adapter plate on vice again.

Thickness mrn (in) Part number Thickness mm (in) Part number

2.63 (0.1035) 32348-01615 3.19 (0.1256) 32348-01607

2.70 (0.1063) 32348-01600 3.26 (0.1283) 32348-01608
MT452A 2.77 (0.1091) 32348-01601 3.33 (0.1311) 32348-01609
2.84 (0.1 118) 32348-01602 3.40 (0.1339) 32348-01610
2.91 (0.1 146) 32348-01603 3.47 (0.1366) 32348-01611
2.98 (0.1173) 32348-01604 3.54 (0.1394) 32348-01612
3.05 (0.1201) 32348-01605 3.61 (0.1421) 32348-01613
3.12 10.1228) 32348-01606 3.68 (0.14491 32348-01614

q. Install selected C-ring, C-ring holder and mainshaft rear snap

ring.

SMT454A

MT-52
 ASSEMBLY
I FS5R30A 1

Thickness mm (in) Part number

1.26 (0.0496) 32236-01608

1.32 (0.0520) 32236-01600
1.38 (0.0543) 32236-01601
1.44 (0.0567) 32236-01602
1.50 (0.0591) 32236-01603
1.56 (0.0614) 32236-01604
1.62 (0.0638) 32236-01GO5
1.68 (0.06611 32236-01606
1.74 (0.0685) 32236-01607

t. Install reverse coupling sleeve.

Pay attention t o its direction.
u. Measure each gear end play as a final check - Refer t o
"DISASSEMBLY".

Shift Control Components

1. Install O.D. fork rod and O.D. shift fork. Then install
retaining pin into O.D. shift fork.
2. Install 1st & 2nd. 3rd & 4th and reverse shift fork onto
coupling sleeve.

3. Install striking rod into hole of shift forks, striking lever and
interlock and then install retaining pin into striking lever.
Make sure that striking rod moves smoothly.

MT-53
 ASSEMBLY I FS5R30A
Shift Control Components (Cont'd)
4. Install check ball, return spring and check ball plug.
Apply sealant to thread of check ball plug.

Case Components
1. Install front cover oil seal.
Apply multi-purpose grease t o seal lip.
2. Install selected counter gear front bearing shim onto
transmission case.
Apply multi-purposegrease.
3. Apply sealant to mating surface of transmission case.

4. Install gear assembly onto transmission case.

5. Install check spring and check ball into interlock stopper.
Apply multi-purpose grease t o check ball.

6. Install interlock stopper assembly and then tighte Ct. :k

ball plug.
Apply sealant to thread of check ball plug.

7. Install stopper ring and main drive bearing snap ring.

MT-54
 ASS E MB LY I FS5R30A I
Case Components (Cont'd)
8. Install front cover and gasket.
Apply sealant to thread of 3 bolts shown left.
9. Apply sealant to mating surface of adapter plate.

I SMT459A

10. Install rear extension together with striking arm.

\
SMT4616

11. Install retaining pin into striking arm.

12. Install return spring and check ball and then install control
housing.
Apply sealant to mating surface of rear extension.

13. Tighten control housing bolts.

MT-55
 SERVICE DATA AND SPECIFICATIONS (S.D.S.)

General Specifications
Engine VG30E Engine VG30ET

Transmission model FS5W71C Transmission model FS5R30A

Shift pattern Shift pattern

1 3 5 1 3

t-14
2 4 R H4
2 4 R

Synchromesh type Warner Synchromesh t y w Warner

Gear ratio Gear ratio

IS 3.321 1s t 3.324
2nd 1.902 2nd 2.077
3rd 1.308 3rd 1.360
4th 1.ooo 4th 1.000
O.D. 0.759 O.D. 0.711
Reverse 3.382 Reverse 3.636

Number of teeth Number of teeth

Main drive gear 22 Main drive gaar 22
Main gear 1I t 33 Main gear 1R 32
2nd 27 2nd 30
3rd 26 3rd 29
O.D. 21 0.0. 22
Reverse 36 Reverse 30

Counter drive gear 31 Counter drive gaar 32

Counter gear 1st 14 Counter gear 1st 14
2nd 28
20 2nd 21
3rd 3rd 31
OD. 39 O.D. 45
Reverse 15 REW,*e 12
Reverse idler gear 21 Reverse idler gear 22

Oil capacity liter IUS pt, Imp p t l 2.0 (4-1/4. 3-1/21 Oil capacity liter (US pt, Imp p t l 2.4 (5-1/8,4-1/41

MT-56
 SERVICE DATA AND SPECIFICATIONS (S.D.S.) [piq
Inspection and Adjustment - FS5W71C
Mainshaft front
Gear End play mrn lid Allowable clearance 0 -0.18mrn (0-0.0071 in1

1st gear 0.31 -0.41 (0.0122 -0.01611 Thickneu mm (in) Part number
2nd gear 0.11 -0.21 IO.0043-0.0083) 2.4 10.094I 32263-V5200
3rd gear 0.11 -0.21 ~0.0043-0.0083l 2.5 10.0981 32263-V5201
2.6 10.1021 32263-V5202
0.0.gear 0.24 - 0.41 ~0.0094~0.0161l

CLEARANCE BETWEEN BAULK RING Mainshaft rear end bearing

AND GEAR Allowable clmrance 0 -0.14 rnm (0 -0.0055 in)
lst, 3rd. main drive and O.D. baulk ring
Unit: mm linl Thickness mrn (in1 Part number

I Standard I Wear limit

1.1
1.2
(0.0431
10.0471
32228-20100
32228-20101
1S I 1.3 (0.051) 32228-20102
1.4 10.0551 32228-20103
3rd
0.8 10.031 I
Main drive 10.047 .0.063)
Counter drive gear
0.0. ~~ ~

Allowable clearance

Thickness mm linl Part number

2nd baulk rino
Outer baulk ring 1.4 10.0551 32215-E9000
1.5 (0.0591 32215-E9001
1.6 (0.0631 32215-E9002

-t- AVAILABLE SHIMS

Counter front bearing Unit: mrn (in1

Dimension Standard Wear limit

A: Distance from bearing
surface to transmission
0.7 - 0.9 case
A 0.2 (0.008l
10.028 - 0.0351

I 0.6 - 1.1
10.024-0.0431 I 0.2 (0.0081
1 Transmission case
2 Counter gear front bearing
3 Counter gear

AVAILABLE SNAP RINGS

Main drive gear bearing
"A"

4.52-4.71 10.1780-0.18541
II of shim I Part number

Not necessav
Allowable clearance 0-0.13mm(O-O.W51 in)
4:42 -4.51 10.1740-0.17761 0.1 10.004l 32218-V5000
Thickness rnm (in1 P a n number 4.32 -4.41 (0.1701 -0.17361 0.2 10.008l 32218-V5001
4.22 -4.31 (0.1661 -0.1697) 0.3 (0.0121 32218-V5002
1.73 10.0681) 32204-78005
4.12 -4.21 10.1622 -0.16571 0.4 (0.0161 32218-V5003
1.80 10.07091 32204-78000
4.02 -4.11 10.1583 -0.16181 0.5 (0.0201 32218-V5004
1.87 10.07361 32204-78001
3.92 -4.01 10.1543 -0.15791 0.6 10.0241 322 18-V5005
1.94 10.07641 32204-78002
2.01 10.07911 32204-78003
208 10.08191 32204-78004
 SERVICE DATA AND SPECIFICATIONS (S.D.S.) I FS5R30A1
Inspection and Adjustment - FS5R30A
Mainshaft front snap ring
Gear End play mm (in1

l i t maingear 0.23-0.33 10.0091 -0.01301 Thickness mm linl Part number

2nd main gear 0.23 -0.33 10.0091 -0.01301
1.89 10.07441 3220401 GOO
3rd main gear 0.23-0.33 10.0091 -0.01301
1 9 8 10.07801 3220401G01
O.D. counter gear 0.23 -0.33 10.0091 -0.01301
2.05 10.08071 3220401 GO2
0.33 -0.43 10.0130 -0.01691
2.12 10.08351 3220401 GO3
Counter gear 0.10 -0.25 10.0039 -0.00981 2.19 10.08621 3220401G04
Reverre idler m a r 0.30 -0.53 10.0118 -0.02091

Counter gear rear snap ring

CLEARANCE BETWEEN BAULK RING Allowable clearance 0 -0.1 mm 10 .0.004 in1

AND GEAR Thickness mm linl I Part number

Unit mm Iml
1.26 10.04961 3223601G08
I Standard I ear limit
1.32 10,05201 3223601GOO
1 .05 - 1 .3
1st & 2nd 0.7 10.0281 1.38 10.05431 3223601G01
10.0413 - 0.05121
1.44 100567 I 3223601G02
3rd E main 1.05 - 1.3
0.7 10.0281 1.50 IO0591 I
drive 10.0413 - 0.05121 3223601603

O.D.
1 1.05 - 1.3
10.041 3 - 0.0512 I
I 0.7 10.0281
1.56 10.06141
1.62 10.06381
3223601 6 0 4
3223601605
1.68 10.0661 I 3223601G06
1.74 10.06851 3223601G07

DISTANCE BETWEEN REAR SURFACE

OF REVERSE CONE AND
REVERSE BAULK RING
AVAILABLE C-RING
[ R e y cone Mainshaft C-ring
~~~

Allowable clearance 0 -0.1 mm 10 -0.004 m l

Reverse baulk ring 1 Unit mm lint

Thickness
mm (in1
1 Part number
Thickness
Part number

3234801G07
I Standard I wear limit
3234801608
-0.1 to0.35
Dimension " A ' 0.7 10.0281
1-0.0039 to0.01381 3234801609
3234801610
3234801611
3234801612
AVAILABLE SNAP RING 3234801G13
Main drive gear snap ring 3234801014
~~~ ~

Allowable clearance 0 -0.1 mm I O -0.004 1n1

Thickness mm linl I Part number

1 8 9 1007441 3220401 GOO

1 9 8 10.07801 3220401601
2.05 10.08071 3220401G02
2.12 10.08351 3220401G03
2.19 1008621 3220401G04

MT-58
 SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Inspection and Adjustment - FS5R30A (Cont'd)
AVAILABLE SHIM AND WASHER Reverse idler rear thrust washer
Table for selecting proper counter gear
-
front bearina shim
Thickness mm (in1

1 9 7 10.07761
Part number

3228401610
Thickness of
Dial indicator deflenion 2.07 10.08151 3228401611
proper washer Part number
m m (in1
mm linl

0 9 3 - 1 0 2 10.0366-0.04021 0 8 100311 3221801G00

1.03-1.12 10.0406-0.04411 0.9 10.0351 3221801G01
1.13-122 100445-0.04801 1.0 10.039) 3221801GOZ
123-1.32 10.0484-0.05201 1.1 10.0431 3221801G03
1.33-1.42 10.0524-0.05591 1 2 10.0471 3221801604
1.43-1.52 10.0563-0.05981 1.3 10.0511 3221801G05
1.53-1.62 10.0602 -0.06381 1.4 10.055) 3221801G06

Tightening Torque
TRANSMISSION INSTAL LATION GEAR ASSEMBLY - FS5W71C
Unit N.m kg-m ft-lb U"lt N .m kg-m ft-lb

Clutch operating cylinder 30 - 40 3.1 - 4.1 22 .30 Rear extension 16.20 1 .6.2.0 12-14
to transmission care
Transmission securing bolt Refer t o Removal and Installation.
Front cover to 16-21 1.6-2.1 12 - 1 5
Engine gusset to engine 29 - 39 3.0 - 4.0 22 - 29 transmission care
Rear mounting insulator Refer to section EM. Control housing to
t o rear extension rear extension 14-18 1 .4 - 1 .8 10.13
Starter motor fixing bolt Refer to section EM. Ball pin 20-34 2.0-35 14 - 2 5
Filler plug 25 - 34 2.5. 3.5 18 -25
Drain plug 25 . 34 2.5. 3.5 18-25
Speedometer sleeve 4-5 0.4 - 0.5 2.9 - 3.6
installation
Return spring plug 20.29 2 . 0 . 3.0 14-22
Reverse check sleeve to 4.5 0.4 -0.5 2.9 - 3.6
reat extension

Check ball Plug 19 - 2 5 1.9 - 2.5 14 - 18

Mainshaft lock nut 137-167 14.0.17.0 101 -123
lwithout Tool1
Countershaft lock nut 98-127 10.0-13.0 72-94
Striking lever lock nut 9-12 09-12 65-8.7
Bearing retainer to 19-25 19-2.5 14-18
adapter plate
Reverse lamp switch 20-29 2.0.3.0 14-22
Neutral w i t c h 20-29 2.0-3.0 14-22

Mi-59
 SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Tightening Torque (Cont'd)
GEAR ASSEMBLY - FS5R30A
Unit N .m kgm ftlb

Rear extension 31 - 4 2 3.2 -4.3 23 -31

to transmission case
Front cover to 16-21 1.5-2.1 12-15
transmission care
Control housing to 16-21 1.6-2.1 12-15
rear extension
Ball pin 31 - 4 2 3.2 -4.3 23 - 3 1
Filler plug 25-34 25-3.5 18-25
Drain plug 25-34 2.5-3.5 18-25
Speedometer pinion 4-5 0.4-0.5 2.9-3.6
installation
Interlock stopper 31 - 4 2 3.2-4.3 23-31
fixing bolt
Check ball plug 19-25 1.9-2.6 14-19
Select check plug 20-29 2.0 -3.0 14 - 2 2
Reverse check sleeve 6 3 -8.3 0.64 -0.85 4.6 -6.1
fixing bolt
O.D. & r e v e m fork rod 25-29 25-3.0 18-22
t o rwerse shift fork
O.D. and reverse rhift fork 29-34 3.0 -3.5 22 -25
connecting bolt
Guide plate to rear 6.3 -8.3 0.64 -0.85 4.6 -6.1
extension
Bearing retainer to adopter 16-21 1.6-2.1 12-15
plate
Reverse lamp w i t c h 20-29 2.0 -3.0 14 - 2 2
Neutral w i t c h 20-29 2.0 -3.0 14 - 2 2

MT-60