Black plate (1,1)

Transmission & Clutch Overhaul

TRANSMISSION OVERHAUL
3.2
(MANUAL)

F5M41
21A CLUTCH

22A MANUAL TRANSMISSION <F5M41>

Model YR 2006
English Edition RDWE-06HA080
Destination: MHR
April 2006 Printed in Malaysia

Copyright

Perusahaan Otomobil
Nasional Berhad
(Company No.: 100995-U)
 Black plate (2,1)

Printed in Malaysia 19 April 2006 Eng

 Black plate (3,1)

TRANSMISSION OVERHAUL (MANUAL) TC02

Content /I

21A CLUTCH

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/1
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/1
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/1

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/3
REMOVAL AND INSTALLATION <F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/3
REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/5
INSTALLATION SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/6
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/6
CLUTCH DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/6
CLUTCH RELEASE BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/6

CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/7

DISASSEMBLY AND REASSEMBLY<F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/7
DISASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/8
REASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/8
CLUTCH RELEASE CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A/8

22A MANUAL TRANSMISSION <F5M41>

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/1

<F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/2
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/2
SEALANTS AND ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/3
FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/3
FORM-IN-PLACE GASKET APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/3
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/4
SNAP RINGS, SPACERS AND THRUST PLATE ADJUSTMENT . . . . . . . . . . . . . 22A/4

Copyright

Perusahaan Otomobil
Nasional Berhad
(Company No.: 100995-U)

Printed in Malaysia 19 April 2006 Eng

 Black plate (4,1)

TC02 TRANSMISSION OVERHAUL (MANUAL)

/II Content

TORQUE SPECIFICATIONS ............................................. 22A/5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/6

TRANSMISSION <F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/9

DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/9
DISASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/14
ADJUSTMENT BEFORE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/16
SPACER SELECTION FOR DIFFERENTIAL CASE END PLAY ADJUSTMENT . . . . . . . . . . . . . . 22A/16
REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/17
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/21
BACK-UP LAMP SWITCH ....................................................... 22A/21

INPUT SHAFT <F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/22

DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/22
DISASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/23
REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/29
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/29
NEEDLE ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/29
SYNCHRONIZER RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/29
SYNCHRONIZER SLEEVE AND HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/30
SYNCHRONIZER SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/30
SPEED GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/30

OUTPUT SHAFT <F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/31

DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/31
DISASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/32
REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/33
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/36
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/36
NEEDLE ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/36
SYNCHRONIZER RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/36
SYNCHRONIZER SLEEVE AND HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/37
SYNCHRONIZER SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/37
SPEED GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/37

SPEEDOMETER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/38

DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/38

SELECT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/39

DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/39
REASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/40

CONTROL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/40

DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/40
DISASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/41
REASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/41

CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/44

DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/44
DISASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/45
REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/45

TRANSMISSION CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/48

DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/48
REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/49

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/51
DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/51
DISASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/52
REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A/52

Printed in Malaysia 19 April 2006 Eng

 Black plate (5,1)

TRANSMISSION OVERHAUL (MANUAL) TC02

Content /III

All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

Printed in Malaysia 19 April 2006 Eng

 Black plate (6,1)

21A CLUTCH
/1 SPECIFICATIONS

SPECIFICATIONS WTC21ASPECS001

SERVICE SPECIFICATIONS

Items Limit
Clutch disc facing rivet sink 0.3 mm (0.011 in)
Diaphragm spring end height difference 0.5 mm (0.019 in)
Release cylinder I.D to piston O.D clearance 0.15 mm (0.005 in)

TORQUE SPECIFICATIONS

Items Specified torque

Clutch damper mounting bolt 1.8 kgm (18 Nm; 1.207 ft.lbs)
Clutch fluid line bracket 1.8 kgm (18 Nm; 1.207 ft.lbs)
Clutch release cylinder air bleeder 1.1 kgm (11 Nm; 0.738 ft.lbs)
Clutch release cylinder mounting bolt 1.8 kgm (18 Nm; 1.207 ft.lbs)
Clutch release cylinder union bolt 2.2 kgm (22 Nm; 1.476 ft.lbs)
Clutch tube flare nut 1.5 kgm (15 Nm; 1.006 ft.lbs)
Fulcrum 3.5 kgm (35 Nm; 2.348 ft.lbs)

LUBRICANTS

Items Specified lubricants Quantity

Clutch release bearing inner surface Part No. 0101011 As required
(grease)
Release fork and fulcrum contact surface Part No. 0101011 As required
(grease)
Release fork and release bearing contact surface Part No. 0101011 As required
(grease)
Release fork and release cylinder push rod Part No. 0101011 As required
contact surface (grease)
Piston and piston cup outer surface Brake fluid DOT 3 or As required
Release cylinder inner surface DOT 4 As required

Printed in Malaysia 19 April 2006 Eng

 Black plate (7,1)

CLUTCH 21A
SPECIFICATIONS /2
NOTE

Printed in Malaysia 19 April 2006 Eng

 Black plate (8,1)

21A CLUTCH
/3 CLUTCH

CLUTCH WTC21ASASSY001

REMOVAL AND INSTALLATION <F5M41>

DOIIT21AR9002 @98%

Printed in Malaysia 19 April 2006 Eng

 Black plate (9,1)

CLUTCH 21A
CLUTCH /4

DOIIC000R9058

Grease (multipurpose grease unless there is a brand or type specified)

Removal steps
1. Clutch fluid line bracket
2. Insulator
3. Washer
4. Clutch tube
5. Union bolt
6. Union
7. Gasket
8. Clutch release cylinder
9. Clutch cover
10. Clutch disc
11. Return clip
12. Clutch release bearing
13. Release fork
14. Release fork boot
15. Fulcrum
T1 : 1.8 kgm (18 Nm; 1.207 ft.lbs)
T2 : 1.5 kgm (15 Nm; 1.006 ft.lbs)
T3 : 2.2 kgm (22 Nm; 1.476 ft.lbs)
T4 : 1.8 kgm (18 Nm; 1.207 ft.lbs)
T5 : 3.5 kgm (35 Nm; 2.348 ft.lbs)

Printed in Malaysia 19 April 2006 Eng

 Black plate (10,1)

21A CLUTCH
/5 CLUTCH

REMOVAL SERVICE POINT WTC21ASASSY003

RELEASE FORK REMOVAL

Move the release fork (13) in the direction
shown to remove the clip from the fulcrum.

DOIIT21AR9003

INSTALLATION SERVICE POINTS

RELEASE FORK INSTALLATION
Apply pack grease to the illustrated position of
the release fork.
Specified grease: Part No. 0101011

DOIIT21AR9004

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CLUTCH 21A
CLUTCH /6

CLUTCH RELEASE BEARING INSTALLATION

Apply grease to the illustrated position of the
clutch release bearing.
Specified grease: Part No. 0101011
INSPECTION
CLUTCH COVER
Check the diaphragm spring end for wear and
uneven height.
Replace if wear is evident or height difference
exceeds the limit.
DOIIT21AR9005 Limit: 0.5 mm (0.019 in)
Check the pressure plate surface for wear, cracks
and discoloration.
Check the rivets of the strap plate for looseness.
If loose, replace the clutch cover.

CLUTCH DISC

CAUTION
Don’t clean the clutch disc in a cleaning fluid.
Check the facing for loose rivets, uneven
contact, evidence of seizure, or deposited oils
and greases. If defective, replace the clutch disc.
Measure the rivet sink and replace the clutch
disc if it is out of specification.
Limit : 0.3 mm (0.011 in)
Check the torsion spring for looseness and
damage. If defective, replace the clutch disc.
DOIIT21AR9006
Combine the clutch disc with the input shaft
and check for sliding condition and play in the
rotating direction. If poor sliding condition is
evident, clean, reassemble, and recheck.
If excessive looseness is evident, replace the
clutch disc and/or input shaft.
CLUTCH RELEASE BEARING

CAUTION
Release bearing is packed with grease.
Therefore, do not wash it in a cleaning fluid
and like.
Check for seizure, damage, noise or improper
rotation.
Check for wear on the surface which contacts
with the diaphragm spring.
Check for wear on the surface which contacts
with release fork. If abnormally worn, replace.

Printed in Malaysia 19 April 2006 Eng

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21A CLUTCH
/7 CLUTCH RELEASE CYLINDER

CLUTCH RELEASE CYLINDER WTC21ASHAUL001

DISASSEMBLY AND REASSEMBLY<F5M41>

DOIIT21AR9007 @98%

Printed in Malaysia 19 April 2006 Eng

 Black plate (13,1)

CLUTCH 21A
CLUTCH RELEASE CYLINDER /8

Disassembly steps
1. Cap
2. Air bleeder
3. Push rod
4. Boot
5. Piston cup
6. Piston
7. Conical spring
8. Release cylinder

DISASSEMBLY SERVICE POINT

PISTON CUP / PISTON REMOVAL
Remove the piston from the release cylinder
using compressed air.
CAUTION
(1) Cover with shop towel to prevent the
piston from popping out.
(2) Apply compressed air slowly to prevent
brake fluid from splashing.

DOIIT21AR9008

DOIIT21AR9009

REASSEMBLY SERVICE POINT

PISTON / PISTON CUP INSTALLATION
After applying brake fluid to the inside wall
surface of the release cylinder and all the
circumferential surfaces of the piston and
piston cup, insert the piston and piston cup
into the cylinder.
Specified brake fluid: DOT 3 or DOT 4

INSPECTION
DOIIT21AR9010
CLUTCH RELEASE CYLINDER INSPECTION
Check the inside wall surface of the release
cylinder for rust and damage.

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21A CLUTCH
/9 CLUTCH RELEASE CYLINDER

Using a cylinder gauge, measure the inside

diameter of the release cylinder at about three
positions (the deepest, middle and brim posi-
tions). If the clearance from the outside dia-
meter of the piston exceeds the limit, replace
the release cylinder as an assembly.
Limit: 0.15 mm (0.005 in)

Printed in Malaysia 19 April 2006 Eng

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CLUTCH 21A
CLUTCH RELEASE CYLINDER /10
NOTE

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22A MANUAL TRANSMISSION <F5M41>

/1 GENERAL INFORMATION

GENERAL INFORMATION WTC22AGINFO001

<F5M41>

DOIIT22AR9001 @98%

Printed in Malaysia 19 April 2006 Eng

 Black plate (17,1)

MANUAL TRANSMISSION <F5M41> 22A

SPECIFICATIONS /2

Items
1. Reverse gear meshing noise prevention device
2. 5th-reverse speed synchronizer
3. 5th speed gear
4. 4th speed gear
5. 3rd-4th speed synchronizer
6. 3rd speed gear
7. Transmission case
8. Clutch housing
9. Release bearing retainer
10. Input shaft
11. Differential
12. 1st speed gear
13. 1st-2nd speed gear
14. 2nd speed gear
15. Output shaft

SPECIFICATIONS WTC22ASPECS001

GENERAL SPECIFICATIONS

Items Specifications
Model F5M41
Applicable engine 4G18
Gear ratio
1st 3.583
2nd 1.947
3rd 1.343
4th 0.976
5th 0.804
Reverse 3.416
Final gear ratio 4.052
Speedometer gear ratio (driven/drive) 30/36

SERVICE SPECIFICATIONS

Items Allowable range Limit

Input shaft front bearing end play -0.01 mm (-0 in) — —
0.12 mm (0.004 in)
Input shaft rear bearing end play -0.01 mm (-0 in) — —
0.09 mm (0.003 in)
Input shaft 5th speed gear end play -0.01 mm (-0 in) — —
0.09 mm (0.003 in)
Output shaft front bearing end play -0.01 mm (-0 in) — —
0.12 mm (0.004 in)
Output shaft rear bearing end play -0.01 mm (-0 in) — —
0.09 mm (0.003 in)

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 Black plate (18,1)

22A MANUAL TRANSMISSION <F5M41>

/3 SPECIFICATIONS

Items Allowable range Limit

Output shaft 3rd speed gear end play -0.01 mm (-0 in) — —
0.09 mm (0.003 in)
Differential case end play 0.05 mm (0.001 in) — —
0.17 mm (0.006 in)
Differential case pinion backlash 0.025 mm (0 in) — —
0.150 mm (0.005 in)
Synchronizer ring back surface to gear clearance — 0.5 mm (0.019
in)

SEALANTS AND ADHESIVES

Items Specified sealants and adhesive

Clutch housing – transmission case mating sur-
face Genuine sealant part No. MD997740 or equiva-
Control housing – transmission case mating sur- lent
face
Air breather 3M SUPER WEATHER-STRIP No. 8001 or equiva-
lent
Differential drive gear bolt
Front bearing retainer bolt (countersink head 3M STUD Locking No. 4170 or equivalent
bolt)

FORM-IN-PLACE GASKET
The transmission has several areas where the form-in- place gasket (FIPG) is in use. To ensure that the
gasket fully serves its purpose. It is necessary to observe some precautions when applying the gasket.
Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks.
Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or
narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is
absolutely necessary to apply the gasket evenly without a break, while observing the correct bead
size.
Since the RTV hardens as it reacts with the moisture in the atmospheric air, it is normally used in the
metallic flange areas.
DISASSEMBLY
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly
striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in
between the joined surfaces.
In this case, however, care must be taken to prevent damage to the joined surfaces.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surface, using a gasket scraper
or wire brush. Check to ensure that the surface to which the FIPG is to be applied is flat. Make sure
that there are no oils, grease and foreign substance deposits on the application surfaces. Do not
forget to remove the old sealant remaining in the bolt holes.
FORM-IN-PLACE GASKET APPLICATION
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional pre-cut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do

Printed in Malaysia 19 April 2006 Eng

 Black plate (19,1)

MANUAL TRANSMISSION <F5M41> 22A

SPECIFICATIONS /4

not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
LUBRICANTS

Items Specified lubricants

Drive shaft oil seal lip area
Input shaft oil seal lip area
Select lever shoe
PETRONAS GL-4 SAE 80W or HYPOID GEAR OIL API GL-4 SAE
75W-85W or 75W-90W
Genuine grease part No. 0101011 or equivalent

SNAP RINGS, SPACERS AND THRUST PLATE ADJUSTMENT

Identification sym-
Part name Thickness Part No.
bol
Snap ring 2.24 mm (0.088 in) None MD706537
(For adjustment of input shaft front 2.31 mm (0.09 in) Blue MD706538
bearing end play
2.38 mm (0.093 in) Brown MD706539
Snap ring 1.43 mm (0.056 in) Green (2) MD746708
(For adjustment of output shaft front 1.51 mm (0.059 in) White (2) MD746709
bearing end play)
1.59 mm (0.062 in) Yellow (2) MD746710
Snap ring: 2.31 mm (0.09 in) Black (2) MD748800
(For adjustment of output shaft rear 2.35 mm (0.092 in) None MD748801
bearing end play)
2.39 mm (0.094 in) Blue MD748802
2.43 mm (0.095 in) Brown MD748803
2.47 mm (0.097 in) Green MD748804
2.51 mm (0.098 in) White MD748805
2.55 mm (0.1 in) Yellow MD748806
2.59 mm (0.101 in) Black MD748807
2.63 mm (0.103 in) Orange MD748808
2.67 mm (0.105 in) Blue MD748809
2.71 mm (0.106 in) Brown MD748810
Snap ring: 2.81 mm (0.11 in) Green MD748782
(For adjustment of output shaft 3rd 2.85 mm (0.112 in) White MD748783
speed gear end play)
2.89 mm (0.113 in) Yellow MD748784
2.93 mm (0.115 in) Black MD748785
2.97 mm (0.116 in) Orange MD748786
3.01 mm (0.118 in) Red MD748787
3.05 mm (0.12 in) Pink MD748788
3.09 mm (0.121 in) Blue MD748789

Printed in Malaysia 19 April 2006 Eng

 Black plate (20,1)

22A MANUAL TRANSMISSION <F5M41>

/5 SPECIFICATIONS

Identification sym-
Part name Thickness Part No.
bol
Spacer: 1.04 mm (0.04 in) 04 MD720944
(For adjustment of differential case 1.13 mm (0.044 in) D MD700270
end play)
1.22 mm (0.048 in) G MD700271
1.31 mm (0.051 in) E MD706574
Spacer 0.75-0.82 mm MA180862
—
(For adjustment of differential case (0.029-0.032 in)
backlash) 0.83-0.92 mm MA180861
(0.032-0.036 in) —

0.93-1.00 mm MA180860
(0.036-0.039 in) —

1.01-1.08 mm MA180875
(0.039-0.042 in) —

1.09-1.16 mm MA180876
(0.042-0.045 in) —

TORQUE SPECIFICATIONS

Items Specifications
Interlock plate bolt 3.0 kgm (30 Nm; 2.013 ft.lbs)
Clutch housing-transmission case mounting bolt 4.4 kgm (44 Nm; 2.952 ft.lbs)
Clutch release bearing retainer mounting bolt 0.98 kgm (9.8 Nm; 0.657 ft.lbs)
Control housing mounting bolt 1.8 kgm (18 Nm; 1.207 ft.lbs)
Shift cable bracket mounting bolt 1.8 kgm (18 Nm; 1.207 ft.lbs)
Speedometer gear mounting bolt 0.39 kgm (3.9 Nm; 0.261 ft.lbs)
Stopper bracket mounting bolt 2.2 kgm (22 Nm; 1.476 ft.lbs)
Select lever mounting bolt 1.8 kgm (18 Nm; 1.207 ft.lbs)
Select lever mounting nut 1.1 kgm (11 Nm; 0.738 ft.lbs)
Differential drive gear mounting bolt 13.2 kgm (132 Nm; 8.858 ft.lbs)
Back –up lamp switch 3.2 kgm (32 Nm; 2.147 ft.lbs)
Front bearing retainer mounting bolt 1.8 kgm (18 Nm; 1.207 ft.lbs)
Poppet spring 3.2 kgm (32 Nm; 2.147 ft.lbs)
Restrict ball 3.2 kgm (32 Nm; 2.147 ft.lbs)
Reverse idler gear shaft mounting bolt 4.8 kgm (48 Nm; 3.221 ft.lbs)
Reverse shift lever mounting bolt 1.8 kgm (18 Nm; 1.207 ft.lbs)
Roll stopper bracket mounting bolt 6.9 kgm (69 Nm; 4.63 ft.lbs)

Printed in Malaysia 19 April 2006 Eng

 Black plate (21,1)

MANUAL TRANSMISSION <F5M41> 22A

SPECIAL TOOLS /6

SPECIAL TOOLS WTC22ASTOOL001

Tool Number Name Use

MB990926 Installer adapter Installation of clutch
housing input shaft
oil seal

DOIIT22AR9003

MB990927 Installer adapter Installation sealing

cap

DOIIT22AR9004

MB990934 Installer adapter Installation of roller

bearing outer race

DOIIT22AR9005

MB990935 Installer adapter Installation of dif-

ferential case topper
roller bearing outer
race

DOIIT22AR9006

MB990938 Handle Use with installer

adapter

DOIIT22AR9007

MB998325 Differential oil sea Installation of dif-

installer ferential oil seal

DOIIT22AR9008

Printed in Malaysia 19 April 2006 Eng

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22A MANUAL TRANSMISSION <F5M41>

/7 SPECIAL TOOLS

Tool Number Name Use

MB998348 Bearing outer race Removal of roller
removal bearing outer race

DOIIT22AR9009

MB998772 Valve spring com- Removal of roller

pressor bearing outer race

DOIIT22AR9010

MB998801 Bearing removal Installation and

removal of gears,
bearings and sleeves

DOIIT22AR9011

MD998812 Installer cap Use with installer

and installer adapter

DOIIT22AR9012

MD998813 Installer -100 Use with installer

cap and installer
adapter

DOIIT22AR9013

MD998814 Installer -200 Use with installer

cap and installer
adapter

DOIIT22AR9014

Printed in Malaysia 19 April 2006 Eng

 Black plate (23,1)

MANUAL TRANSMISSION <F5M41> 22A

SPECIAL TOOLS /8

Tool Number Name Use

MD998817 Installer adapter Installation of input
(34) shaft front bearing

DOIIT22AR9016

MD998818 Installer adapter Installation of input

(38) shaft rear bearing,
roller bearing inner
race, reverse gear,
needle roller
bearing, and
reverse bearing
DOIIT22AR9017
sleeve
MD998820 Installer adapter Installation of 5th
(42) speed gear sleeve,
2nd speed gear
sleeve

DOIIT22AR9019

MD998822 Installer adapter Installation of 1st

(46) speed sleeve, 1st-
2nd speed synchro-
nizer hub .

DOIIT22AR9020

MD998826 Installer adapter Installation of 3rd-

(54) 4th speed synchro-
nizer hub.

DOIIT22AR9024

MD998917 Bearing remover Installation and

removal of gears,
bearings and sleeves

DOIIT22AR9025

Printed in Malaysia 19 April 2006 Eng

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22A MANUAL TRANSMISSION <F5M41>

/9 TRANSMISSION <F5M41>

TRANSMISSION <F5M41> WTC22ASHAUL001

DISASSEMBLY AND REASSEMBLY

DOIIT22AR9027 @98%

Printed in Malaysia 19 April 2006 Eng

 Black plate (25,1)

MANUAL TRANSMISSION <F5M41> 22A

TRANSMISSION <F5M41> /10

Disassembly steps
1. Roll stopper bracket
2. Insulator washer
3. Shift cable bracket
4. Insulator washer
5. Select lever
6. Speedometer gear
7. Back-up lamp switch
8. Gasket
9. Restrict ball
10. gasket
11. Poppet spring
12. Gasket
T1 : 1.8 kgm (18 Nm; 1.207 ft.lbs)
T2 : 3.2 kgm (32 Nm; 2.147 ft.lbs)
T3 : 6.9 kgm (69 Nm; 4.63 ft.lbs)
T4 : 0.39 kgm (3.9 Nm; 0.261 ft.lbs)

Printed in Malaysia 19 April 2006 Eng

 Black plate (26,1)

22A MANUAL TRANSMISSION <F5M41>

/11 TRANSMISSION <F5M41>

DOIIT22AR9028

Printed in Malaysia 19 April 2006 Eng

 Black plate (27,1)

MANUAL TRANSMISSION <F5M41> 22A

TRANSMISSION <F5M41> /12

Lubricate all internal parts with gear oil during reassembly

Disassembly steps
13. Interlock plate bolt
14. Gasket
15. Control housing
16. Neutral return spring
17. Reverse idle gear shaft bolt
18. Gasket
19. Sealing cap
20. Transmission case
21. Reverse idle gear shaft
22. Reverse idle gear
23. Reverse shift lever shoe
24. Reverse shift lever
25. Oil guide
26. Magnet holder
27. Magnet
28. Spacer
T1 : 1.8 kgm (18 Nm; 1.207 ft.lbs)
T2 : 3.0 kgm (30 Nm; 2.013 ft.lbs)
T3 : 4.8 kgm (48 Nm; 3.221 ft.lbs)
T4 : 4.4 kgm (44 Nm; 2.952 ft.lbs)

Printed in Malaysia 19 April 2006 Eng

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22A MANUAL TRANSMISSION <F5M41>

/13 TRANSMISSION <F5M41>

DOIIT22AR9029

Printed in Malaysia 19 April 2006 Eng

 Black plate (29,1)

MANUAL TRANSMISSION <F5M41> 22A

TRANSMISSION <F5M41> /14

Lubricate all internal parts with gear oil during reassembly

Disassembly steps
29. Spring pin
30. 1st-2nd speed shift rail
31. 1st-2nd speed shift fork
32. Spring pin
33. Spring pin
34. 5th speed shift rail
35. 5th speed shift fork
36. Reverse shift lug
37. Snap ring
38. Reverse interlock rail
39. Steel ball
40. 3rd-4th speed shift rail
41. 3rd-4th speed shift fork
42. Front bearing retainer
43. Input shaft
44. Output shaft
45. Differential
46. Clutch housing
T1 : 1.8 kgm (18 Nm; 1.207 ft.lbs)

DISASSEMBLY SERVICE POINTS

WTC22ASHAUL002

SEALING CAP REMOVAL

Drive a screwdriver into the sealing cap (19) at
the center, then pry of the sealing cap with the
screw driver

DOIIT22AR9030

Printed in Malaysia 19 April 2006 Eng

 Black plate (30,1)

22A MANUAL TRANSMISSION <F5M41>

/15 TRANSMISSION <F5M41>

TRANSMISSION CASE REMOVAL

Expand the snap ring (37) to remove it from the
snap ring groove of the ball bearing.
NOTE
Expansion of the snap ring causes the snap ring
groove to get out of position because of the
output shaft’s own weight.

DOIIT22AR9031

REVERSE IDLER GEAR SHAFT REMOVAL

Shift 3rd-4th speed synchronizer sleeve (A)
toward the 4th speed side.

DOIIT22AR9032

3RD-4TH SPEED SHIFT RAIL / 3RD-4TH SPEED

SHIFT FORK / 5TH SPEED SHIFT FORK / SNAP
RING / REVERSE SHIFT LUG / 5TH SPEED
SHIFT RAIL / STEEL BALL / REVERSE
INTERLOCK RAIL REMOVAL
1. While sliding the reverse shift lug (36) in the
direction shown, remove the 5th speed shift
fork, 5th speed shift rail, reverse shift lug,
snap ring, steel ball and reverse interlock
rail.

DOIIT22AR9033

2. While sliding the 3rd-4th speed shift rail

(40) in the direction shown, remove it
together with the shift fork.

DOIIT22AR9034

Printed in Malaysia 19 April 2006 Eng

 Black plate (31,1)

MANUAL TRANSMISSION <F5M41> 22A

TRANSMISSION <F5M41> /16

INPUT SHAFT / OUTPUT SHAFT REMOVAL

Remove the input shaft (43) and output shafts
(44) together.

DOIIT22AR9035

ADJUSTMENT BEFORE REASSEMBLY

WTC22ASHAUL003

SPACER SELECTION FOR DIFFERENTIAL CASE

END PLAY ADJUSTMENT
1. Put solders (about 10 mm (0.393 in) long,
1.6 mm (0.062 in) in diameter) in the
illustrated positions of the transmission case
and install the differential.
2. Install the clutch housing and tighten the
bolts to the specified torque.
3. If the solders (B) are not crushed, put larger
DOIIT22AR9036 diameter solders and repeat Steps (1) and
(2).

4. Measure the thickness (T) of the crushed

solder with a micrometer and select a
according to the following equation.
Spacer thickness:[T- 0.05 mm (0.001 in)] to
[T- 0.17 mm (0.006 in)]

DOIIT22AR9037

Printed in Malaysia 19 April 2006 Eng

 Black plate (32,1)

22A MANUAL TRANSMISSION <F5M41>

/17 TRANSMISSION <F5M41>

REASSEMBLY SERVICE POINTS WTC22ASHAUL004

OUTPUT SHAFT / INPUT SHAFT
INSTALLATION
While placing the reverse brake cone detent in
the illustrated position, install the input and
output shafts together. (Testing only.... Refer to
Transmission and Clutch Overhaul 21A/5)

DOIIT22AR9038

FRONT BEARING RETAINER INSTALLATION

Apply a sealant to the front bearing retainer
mounting bolts (countersunk bolts only).
Specified sealant: 3M stud locking No.4170 or
equivalent

DOIIT22AR9039

REVERSE INTERLOCK RAIL / STEEL BALL /

5TH SPEED SHIFT RAIL / REVERSE SHIFT LUG
/ SNAP RING / 5TH SPEED SHIFT FORK / 3RD-
4TH SPEED SHIFT FORK / 3RD-4TH SPEED
SHIFT RAIL INSTALLATION
1. Install the 3rd-4th shift rail (40) and 3rd-4th
shift fork (41).

DOIIT22AR9040

2. Install the reverse interlock rail (38), steel

ball (39), 5th speed shift rail (34), 5th speed
shift fork (35), reverse shift lug (36) and
snap ring (37) in the illustrated positions.

DOIIT22AR9041

Printed in Malaysia 19 April 2006 Eng

 Black plate (33,1)

MANUAL TRANSMISSION <F5M41> 22A

TRANSMISSION <F5M41> /18

DOIIT22AR9042

3. While sliding the reverse shift lug (36) in the

direction shown, install the 5th speed shift
fork, 5th speed shift rail, reverse shift lug,
snap ring, steel ball and reverse interlock
rail.

DOIIT22AR9043

SPRING PIN INSTALLATION

SPACER INSTALLATION
Install the spacer selected in the section
‘‘ADJUSTMENT BEFORE REASSEMBLY’’

DOIIT22AR9044

OIL GUIDE (25) INSTALLATION

DOIIT22AR9045

Printed in Malaysia 19 April 2006 Eng

 Black plate (34,1)

22A MANUAL TRANSMISSION <F5M41>

/19 TRANSMISSION <F5M41>

REVERSE IDLE GEAR SHAFT INSTALLATION

1. Shift the 3rd-4th speed synchronizer sleeve
(A) toward the 4th speed side.

DOIIT22AR9032

2. Face the threaded hole of the reverse idle

gear shaft (21) toward the direction shown.

DOIIT22AR9047

TRANSMISSION CASE INSTALLATION

1. Apply at 1.5 mm (0.059 in) bead of sealant
to the illustrated positions of the transmis-
sion case.
Specified sealant: Part No. MD997740 or
equivalent
CAUTION
Squeeze out the sealant uniformly, while
making sure that it is not broken or
excessively applied.

DOIIT22AR9048

2. Install the transmission case and expend the

snap ring (37).
3. Tighten the transmission case mounting
bolt to the specified torque.
NOTE
Place the transmission upside down and let
the snap ring fit in the groove by taking
advantage of the output shaft’s own
weight.

DOIIT22AR9049

Printed in Malaysia 19 April 2006 Eng

 Black plate (35,1)

MANUAL TRANSMISSION <F5M41> 22A

TRANSMISSION <F5M41> /20

SEALING CAP INSTALLATION

Press-fit the sealing cap (19) all the way up to
the illustrated position.

DOIIT22AR9050

DOIIT22AR9051

REVERSE IDLE GEAR SHAFT BOLT

INSTALLATION
Using a screwdriver (8 mm (0.314 in)in shaft
diameter), center the bolt hole.

DOIIT22AR9052

CONTROL HOUSING INSTALLATION

Apply a 1.5 mm (0.059 in) bead of sealant to the
illustrated position of the transmission case.
Specified sealant: Part No. MD997740 or
equivalent
CAUTION
Squeeze out the sealant uniformly, while mak-
ing sure that it is not broken or excessively
applied

DOIIT22AR9053

Printed in Malaysia 19 April 2006 Eng

 Black plate (36,1)

22A MANUAL TRANSMISSION <F5M41>

/21 TRANSMISSION <F5M41>

SPEEDOMETER GEAR INSTALLATION

Apply transmission oil to the O-ring (C) the
speedometer gear.
Transmission oil: PETRONAS GL-4 SAE 80W or
HYPOID GEAR OIL API GL-4 SAE 75W-85W or
75W-90W.

DOIIT22AR9054

SELECT LEVER INSTALLATION

Apply grease to the control shaft (D) sliding
portion of the select lever shoe (5).
Specified grease:Part No. 0101011 or equivalent

DOIIT22AR9055

INSPECTION WTC22ASHAUL005

BACK-UP LAMP SWITCH

Check for continuity between terminals.

Switch condition Continuity

Pressed Not exist
Released Exists

DOIIT22AR9056

Printed in Malaysia 19 April 2006 Eng

 Black plate (37,1)

MANUAL TRANSMISSION <F5M41> 22A

INPUT SHAFT <F5M41> /22

INPUT SHAFT <F5M41> WTC22ASHAUL011

DISASSEMBLY AND REASSEMBLY

DOIIT22AR9083 @98%

Printed in Malaysia 19 April 2006 Eng

 Black plate (38,1)

22A MANUAL TRANSMISSION <F5M41>

/23 INPUT SHAFT <F5M41>

Lubricate all internal part with gear oil during reassembly

Disassembly steps
1. Snap ring 15. 4th speed gear
2. Ball bearing 16. Needle roller bearing
17. 4th speed gear sleeve
3. Reverse brake sleeve
18. Synchronizer ring
4. Needle roller bearing
19. Synchronizer spring
5. Reverse brake cone
6. Reverse brake ring 20. Synchronizer sleeve
7. Synchronizer spring 21. 3rd-4th speed Synchronizer hub
8. Synchronizer sleeve 22. Synchronizer ring
9. 5th-reverse speed Synchronizer hub 23. Synchronizer spring
10. Synchronizer ring 24. 3rd speed gear
11. Synchronizer spring 25. Needle roller bearing
26. Snap ring
12. 5th speed gear
13. Needle roller bearing 27. Ball bearing
14. 5th speed gear sleeve 28. Oil seal
29. Input shaft

DISASSEMBLY SERVICE POINTS

WTC22ASHAUL012

BALL BEARING REMOVAL

Use the special tools to remove the ball bearing.

DOIIT22AR9084

REVERSE BRAKE SLEEVE REMOVAL

Mount a special tool on the 5th speed gear and
remove the reverse brake sleeve.

DOIIT22AR9085

Printed in Malaysia 19 April 2006 Eng

 Black plate (39,1)

MANUAL TRANSMISSION <F5M41> 22A

INPUT SHAFT <F5M41> /24

5TH-REVERSE SPEED SYNCHRONIZER HUB

REMOVAL
Mount a special tool on the 5th speed gear and
remove the 5th-reverse synchronizer hub.

DOIIT22AR9086

5TH SPEED GEAR SLEEVE REMOVAL

Mount a special tool on the 4th speed gear and
remove the 5th speed gear sleeve.

DOIIT22AR9087

4TH SPEED GEAR SLEEVE REMOVAL

Mount a special tool on the 3th speed gear and
remove the 4th speed gear sleeve.

DOIIT22AR9088

BALL BEARING REMOVAL

Use the special tools to remove the ball bearing

DOIIT22AR9089

Printed in Malaysia 19 April 2006 Eng

 Black plate (40,1)

22A MANUAL TRANSMISSION <F5M41>

/25 INPUT SHAFT <F5M41>

REASSEMBLY SERVICE POINTS WTC22ASHAUL013

OIL SEAL INSTALLATION
Drive in the oil seal (28) all the way up to the
illustrated dimension.

DOIIT22AR9090

BALL BEARING INSTALLATION

Use the special tools to install the ball bearing.

DOIIT22AR9091

SNAP RING INSTALLATION

Select and install a snap ring (26) so that the
input shaft front bearing end play will have the
standard value.
Standard value: -0.01 mm (-0 in)-
0.12 mm (0.004 in)

DOIIT22AR9092

SYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring (7,11,19,23)
securely up to the illustrated position of the
synchronizer ring.

DOIIT22AR9093

Printed in Malaysia 19 April 2006 Eng

 Black plate (41,1)

MANUAL TRANSMISSION <F5M41> 22A

INPUT SHAFT <F5M41> /26

3RD-4TH SPEED SYNCHRONIZER HUB

INSTALLATION
Install the 3rd-4th speed synchronizer hub in
such a way that it will be oriented in the
direction shown.

Symbol Description
A Identification
Rear of transmission

DOIIT22AR9094

CAUTION
When the hub is installed, make sure that the
synchronizer ring is not caught.

DOIIT22AR9095

SYNCHRONIZER SLEEVE INSTALLATION

1. Install the synchronizer sleeve in such a way
that it will be oriented in the direction
shown.

Symbol Description
B Identification
Rear of transmission

DOIIT22AR9096

2. When the synchronizer sleeve (20) is

installed, make sure that the deep groove
portion of the synchronizer hub (21) is
aligned with the projecting portion of the
sleeve.

DOIIT22AR9097

Printed in Malaysia 19 April 2006 Eng

 Black plate (42,1)

22A MANUAL TRANSMISSION <F5M41>

/27 INPUT SHAFT <F5M41>

4TH SPEED GEAR SLEEVE INSTALLATION

Use the special tools to install the 4th speed
gear sleeve.

DOIIT22AR9098

5TH SPEED GEAR SLEEVE INSTALLATION

Use the special tools to install the 5th speed
gear sleeve.

DOIIT22AR9099

5TH-REVERSE SPEED SYNCHRONIZER HUB

INSTALLATION
Install the 5th-reverse speed synchronizer hub
in such a way that it will be oriented in the
direction shown.

Symbol Description
A Identification
Rear of transmission

DOIIT22AR9100

CAUTION
When the 5th-reverse speed synchronizer hub
is installed, make sure that the synchronizer
ring is not caught.

DOIIT22AR9101

Printed in Malaysia 19 April 2006 Eng

 Black plate (43,1)

MANUAL TRANSMISSION <F5M41> 22A

INPUT SHAFT <F5M41> /28

SYNCHRONIZER SLEEVE INSTALLATION

1. Install the synchronizer sleeve in such a way
that it will be oriented in the direction
shown.

Symbol Description
B Identification
Rear of transmission

DOIIT22AR9102

2. When the synchronizer sleeve (8) is

installed, make sure that the deep groove
portion of the synchronizer hub (9) is
aligned with the projecting portion of the
sleeve.

DOIIT22AR9103

REVERSE BRAKE SLEEVE INSTALLATION

Use the special tools to install the reverse brake
sleeve.

DOIIT22AR9104

BALL BEARING INSTALLATION

Use the special tools to install the ball bearing.

DOIIT22AR9105

Printed in Malaysia 19 April 2006 Eng

 Black plate (44,1)

22A MANUAL TRANSMISSION <F5M41>

/29 INPUT SHAFT <F5M41>

SNAP RING INSTALLATION

Select and install a snap ring so that the input
shaft rear bearing end play will have the
standard value.
Standard value: -0.01 mm (-0 in)-
0.09 mm (0.003 in)

DOIIT22AR9106

INSPECTION WTC22ASHAUL014

INPUT SHAFT
1. Check the outside diameter of the needle
bearing mounting portion for damage,
abnormal wear and seizure.
2. Check the splines for damage and wear.
NEEDLE ROLLER BEARING
1. Check to ensure that when the input shaft,
sleeve and gear are combined and made to
rotate, they rotate smoothly without noise.
DOIIT22AR9107 2. Check to ensure that the cage is not
deformed.

SYNCHRONIZER RING
1. Check to ensure that the clutch gear tooth
surfaces are not damaged and broken.
2. Check to ensure that the cone inside
diameter is not damaged or worn and that
the threads are not crushed.

DOIIT22AR9108

Printed in Malaysia 19 April 2006 Eng

 Black plate (45,1)

MANUAL TRANSMISSION <F5M41> 22A

INPUT SHAFT <F5M41> /30

3. Press the synchronizer ring (10,22) against

the gear (C) and check clearance ‘‘A’’. If ‘‘A’’
is less than the limit, replace.
Limit: 0.5 mm (0.019 in)

DOIIT22AR9109

SYNCHRONIZER SLEEVE AND HUB

1. Check to ensure that when the synchronizer
sleeve and hub are combined and made to
slide, they slide smoothly without binding.
2. Check to ensure that the front and rear
ends of the sleeve inside surface are not
damaged.
CAUTION
When replacement of either the synchroni-
zer sleeve or hub is necessary, make sure
that the synchronizer sleeve and hub are
replaced as a set.
DOIIT22AR9110
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging,
deformed or broken.

SPEED GEARS
1. Check to ensure that the helical and clutch
gear tooth surfaces are not damaged or
worn.
2. Check to ensure that the synchronizer cone
surfaces are not roughened, damaged or
worn.
3. Check to ensure that the gear inside
diameter and front and rear surfaces are
not damaged and worn.

DOIIT22AR9111

Printed in Malaysia 19 April 2006 Eng

 Black plate (46,1)

22A MANUAL TRANSMISSION <F5M41>

/31 OUTPUT SHAFT <F5M41>

OUTPUT SHAFT <F5M41> WTC22ASHAUL019

DISASSEMBLY AND REASSEMBLY

DOIIT22AR9136 @98%

Printed in Malaysia 19 April 2006 Eng

 Black plate (47,1)

MANUAL TRANSMISSION <F5M41> 22A

OUTPUT SHAFT <F5M41> /32

Lubricate all internal part with gear oil during reassembly

Disassembly step
1. Snap ring 12. Synchronizer spring
2. Ball bearing 13. Synchronizer sleeve
3. Collar 14. 1st-2nd speed synchronizer
4. 5th speed gear 15. Synchronizer ring
5. 4th speed gear 16. Synchronizer spring
6. Snap ring
17. 1st speed gear
7. 3rd speed gear 18. Needle roller bearing
8. 2nd speed gear 19. 1st speed gear sleeve
9. Needle roller bearing
20. Snap ring
10. 2nd speed gear sleeve
21. Roller bearing inner race
11. Synchronizer ring
22. Output shaft

DISASSEMBLY SERVICE POINTS

WTC22ASHAUL020

BALL BEARING REMOVAL

Use the special tool to remove the ball bearing.

DOIIT22AR9137

2ND SPEED GEAR SLEEVE REMOVAL

Mount a special tool on the synchronizer sleeve
and remove the 2nd speed gear sleeve.

DOIIT22AR9138

Printed in Malaysia 19 April 2006 Eng

 Black plate (48,1)

22A MANUAL TRANSMISSION <F5M41>

/33 OUTPUT SHAFT <F5M41>

1ST SPEED GEAR SLEEVE REMOVAL

Use the special tool to remove the 1st speed
gear sleeve.

DOIIT22AR9139

ROLLER BEARING INNER RACE REMOVAL

Use the special tool to remove the roller bearing
inner race (21).

DOIIT22AR9140

REASSEMBLY SERVICE POINTS WTC22ASHAUL021

ROLLER BEARING INNER RACE
INSTALLATION
Use the special tool to install the roller bearing
inner race (21).

DOIIT22AR9141

SNAP RING INSTALLATION

Select and install a snap ring so that the output
shaft front bearing end play will have the
standard value.
Standard value: -0.01 mm (-0 in)-
0.12 mm (0.004 in)

DOIIT22AR9142

Printed in Malaysia 19 April 2006 Eng

 Black plate (49,1)

MANUAL TRANSMISSION <F5M41> 22A

OUTPUT SHAFT <F5M41> /34

1ST SPEED GEAR SLEEVE INSTALLATION

Use the special tool to install the 1st speed gear
sleeve (19).

DOIIT22AR9143

SYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring (12,16) securely
up to the illustrated position of the synchroni-
zer ring.

DOIIT22AR9144

1ST-2ND SPEED SYNCHRONIZER HUB

INSTALLATION
Install the 1st-2nd speed synchronizer hub in
such a way that it will be oriented in the
direction shown.

Symbol Description
A Identification mark
Rear of transmission

DOIIT22AR9145

CAUTION
When the hub is installed, make sure that the
synchronizer ring is not caught.

DOIIT22AR9146

Printed in Malaysia 19 April 2006 Eng

 Black plate (50,1)

22A MANUAL TRANSMISSION <F5M41>

/35 OUTPUT SHAFT <F5M41>

SYNCHRONIZER SLEEVE INSTALLATION

1. Install the synchronizer sleeve in such a way
that it will be oriented in the direction
shown.

Symbol Description
Rear of transmission.

DOIIT22AR9147

2. When the synchronizer sleeve (13) is

installed, make sure that the deep groove
portion of the synchronizer hub (14) is
aligned with the projecting portion of the
sleeve.

DOIIT22AR9148

2ND SPEED GEAR SLEEVE INSTALLATION

Use the special tools to install the 2nd speed
gear sleeve.

DOIIT22AR9149

SNAP RING INSTALLATION

Select and install a snap ring (6) so that the
output shaft 3rd speed gear end play will have
the standard value.
Standard value -0.01 mm (-0 in)-
0.09 mm (0.003 in)

DOIIT22AR9150

Printed in Malaysia 19 April 2006 Eng

 Black plate (51,1)

MANUAL TRANSMISSION <F5M41> 22A

OUTPUT SHAFT <F5M41> /36

BALL BEARING INSTALLATION

Use the special tools to install the ball bearing.

DOIIT22AR9151

SNAP RING INSTALLATION

Select and install a snap ring (1) so that the
output shaft rear bearing end play will have the
standard value.
Standard value -0.01 mm (-0 in)-
0.09 mm (0.003 in)

DOIIT22AR9152

INSPECTION WTC22ASHAUL022

OUTPUT SHAFT

Check the splines for damage and wear.

NEEDLE ROLLER BEARING

1. Check to ensure that when the bearing

sleeve and gear are combined and made to
rotate, they rotate smoothly without noise.
2. Check to ensure that the cage is not
DOIIT22AR9153 deformed.

SYNCHRONIZER RING
1. Check to ensure that the clutch gear tooth
surfaces are not damaged and broken.
2. Check to ensure that the cone inside
diameter is not damaged or worn and that
the threads are not crushed.

DOIIT22AR9154

Printed in Malaysia 19 April 2006 Eng

 Black plate (52,1)

22A MANUAL TRANSMISSION <F5M41>

/37 OUTPUT SHAFT <F5M41>

3. Press the synchronizer ring (11,15) against

the gear (B) and check clearance ‘‘A’’. If ‘‘A’’
is less than the limit, replace.
Limit: 0.5 mm (0.019 in)

DOIIT22AR9155

SYNCHRONIZER SLEEVE AND HUB

1. Check to ensure that when the synchronizer
sleeve and hub are combined and made to
slide, they slide smoothly without binding.
2. Check to ensure that the front and rear
ends of the sleeve inside surface are not
damaged.
CAUTION
When replacement of either the synchroni-
zer sleeve or hub is necessary, make sure
that the synchronizer sleeve and hub are
replaced as a set.
DOIIT22AR9156
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging,
deformed or broken.

SPEED GEARS
1. Check to ensure that the helical and clutch
gear tooth surfaces are not damaged or
worn.
2. Check to ensure that the synchronizer cone
surfaces are not roughened, damaged or
worn.
3. Check to ensure that the gear inside
diameter and front and rear surfaces are
not damaged and worn.

DOIIT22AR9157

Printed in Malaysia 19 April 2006 Eng

 Black plate (53,1)

MANUAL TRANSMISSION <F5M41> 22A

SPEEDOMETER GEAR /38

SPEEDOMETER GEAR WTC22ASHAUL028

DISASSEMBLY AND REASSEMBLY

DOIIT22AR9193

Lubricate all internal part with gear oil during reassembly

Disassembly
1. E-clip
2. Speedometer driven gear
3. O-ring
4. Sleeve

Printed in Malaysia 19 April 2006 Eng

 Black plate (54,1)

22A MANUAL TRANSMISSION <F5M41>

/39 SELECT LEVER

SELECT LEVER WTC22ASHAUL029

DISASSEMBLY AND REASSEMBLY

DOIIT22AR9194

Disassembly steps
1. Dust cover 6. Select lever shoe
2. Nut 7. Select lever
3. Spring washer 8. Select lever bushing
4. Washer 9. Dust cover
5. Select lever bushing 10. Select lever shaft
T1 : 1.1 kgm (11 Nm; 0.738 ft.lbs)

Printed in Malaysia 19 April 2006 Eng

 Black plate (55,1)

MANUAL TRANSMISSION <F5M41> 22A

CONTROL HOUSING /40

REASSEMBLY SERVICE POINT

DUST COVER (1,9) INSTALLATION

DOIIT22AR9195

CONTROL HOUSING WTC22ASHAUL030

DISASSEMBLY AND REASSEMBLY

DOIIT22AR9196

Disassembly steps

Printed in Malaysia 19 April 2006 Eng

 Black plate (56,1)

22A MANUAL TRANSMISSION <F5M41>

/41 CONTROL HOUSING

1. Lock pin 11. Spacer

2. Inter lock plate 12. Control shaft
3. Control finger 13. Air breather
4. Pin 14. Control shaft boot
5. Return spring 15. Oil seal
6. Stopper plate 16. Needle bearing
7. Spring pin
17. Spring washer
8. Spring pin 18. Stopper bracket
9. Stopper body 19. Control housing
10. Neutral return spring
T1 : 2.2 kgm (22 Nm; 1.476 ft.lbs)

DISASSEMBLY SERVICE POINT WTC22ASHAUL031

LOCK PIN REMOVAL
Drive the lock pin (1) out of position from the
direction shown.

Symbol Description
3 Control finger

DOIIT22AR9197

REASSEMBLY SERVICE POINT

NEEDLE BEARING INSTALLATION
Press fit the needle bearing (16) up the
illustrated dimension, while making sure that
the model number stamped side (A) is oriented
in the direction shown.

Symbol Description
19 Control housing

DOIIT22AR9198

OIL SEAL INSTALLATION

Apply transmission oil to the oil seal lip area.
Transmission oil: Hypoid gear oil SAE 75W-85W
conforming to API classification GL-3 or higher

DOIIT22AR9199

Printed in Malaysia 19 April 2006 Eng

 Black plate (57,1)

MANUAL TRANSMISSION <F5M41> 22A

CONTROL HOUSING /42

AIR BREATHER INSTALLATION

1. Apply a sealant to the outside circumfer-
ence of the inserting portion.
Specified sealant: 3M SUPER WEATHER-
STRIP No. 8001 or equivalent

DOIIT22AR9200

2. Make sure that the projecting portion is

oriented in the direction shown.

DOIIT22AR9201

SPRING PIN INSTALLATION

Symbol Description
B Installation direction
C Slit
8 Spring pin
9 Stopper body
12 Control shaft

DOIIT22AR9202

SPRING PIN (7) INSTALLATION

DOIIT22AR9203

Printed in Malaysia 19 April 2006 Eng

 Black plate (58,1)

22A MANUAL TRANSMISSION <F5M41>

/43 CONTROL HOUSING

LOCK PIN INSTALLATION

Drive in the lock pin (1) in the direction shown
in the illustration

Symbol Description
3 Control finger

DOIIT22AR9204

Printed in Malaysia 19 April 2006 Eng

 Black plate (59,1)

MANUAL TRANSMISSION <F5M41> 22A

CLUTCH HOUSING /44

CLUTCH HOUSING WTC22ASHAUL032

DISASSEMBLY AND REASSEMBLY

DOIIT22AR9205 @98%

Printed in Malaysia 19 April 2006 Eng

 Black plate (60,1)

22A MANUAL TRANSMISSION <F5M41>

/45 CLUTCH HOUSING

Disassembly
1. Clutch release bearing retainer 5. Outer race
2. Oil seal 6. Oil guide
3. Oil seal 7. Bushing
(1)
4. Outer race 8. Clutch housing
T1 : 0.98 kgm (9.8 Nm; 0.657 ft.lbs)
NOTE:
(1) If so equipped

DISASSEMBLY SERVICE POINTS

OUTER RACE REMOVAL
Use the special tools to remove the outer race .

DOIIT22AR9207

REASSEMBLY SERVICE POINTS

BUSHING INSTALLATION
Press fit the bushing up to the illustrated
position, while making sure that the split ends
(A) of the bushing do not coincide with the air
purge groove (B).

DOIIT22AR9208

DOIIT22AR9209

Printed in Malaysia 19 April 2006 Eng

 Black plate (61,1)

MANUAL TRANSMISSION <F5M41> 22A

CLUTCH HOUSING /46

OUTER RACE INSTALLATION

1. Install the outer race so that the model
number stamped side (C) will be oriented in
the direction shown.

DOIIT22AR9210

2. Use the special tools to install the outer

race.

DOIIT22AR9211

OIL SEAL INSTALLATION

Apply transmission oil to the oil seal lip area.
Specified oil: PETRONAS GL-4 SAE 80W or
HYPOID GEAR OIL API GL-4 SAE 75W-85W or
75W-90W.

DOIIT22AR9213

DOIIT22AR9214

Printed in Malaysia 19 April 2006 Eng

 Black plate (62,1)

22A MANUAL TRANSMISSION <F5M41>

/47 CLUTCH HOUSING

OIL SEAL INSTALLATION

Pack grease in the oil seal lip area
Specified grease:Part No. 0101011 or equivalent

DOIIT22AR9215

DOIIT22AR9216

Printed in Malaysia 19 April 2006 Eng

 Black plate (63,1)

MANUAL TRANSMISSION <F5M41> 22A

TRANSMISSION CASE /48

TRANSMISSION CASE WTC22ASHAUL033

DISASSEMBLY AND REASSEMBLY

DOIIT22AR9217

Disassembly steps
1. Oil seal
2. Needle bearing
3. Oil guide
4. Snap ring
5. Bushing
6. Transmission case

Printed in Malaysia 19 April 2006 Eng

 Black plate (64,1)

22A MANUAL TRANSMISSION <F5M41>

/49 TRANSMISSION CASE

REASSEMBLY SERVICE POINTS

BUSHING INSTALLATION
Press fit the bushing up to illustrated position,
while making sure that the split ends (A) of the
bushing do not coincide with the air purge
groove (B).

DOIIT22AR9218

DOIIT22AR9219

NEEDLE BEARING INSTALLATION

Press fit the needle bearing until it is flush with
the case, while making sure that the model
number stamped side is oriented in the direc-
tion shown.

DOIIT22AR9220

OIL SEAL INSTALLATION

Apply transmission oil to the oil seal lip area.
Specified oil: PETRONAS GL-4 SAE 80W or
HYPOID GEAR OIL API GL-4 SAE 75W-85W or
75W-90W.

DOIIT22AR9221

Printed in Malaysia 19 April 2006 Eng

 Black plate (65,1)

MANUAL TRANSMISSION <F5M41> 22A

TRANSMISSION CASE /50

DOIIT22AR9222

Printed in Malaysia 19 April 2006 Eng

 Black plate (66,1)

22A MANUAL TRANSMISSION <F5M41>

/51 DIFFERENTIAL

DIFFERENTIAL WTC22ASHAUL034

DISASSEMBLY AND REASSEMBLY

DOIIT22AR9223 @98%

Printed in Malaysia 19 April 2006 Eng

 Black plate (67,1)

MANUAL TRANSMISSION <F5M41> 22A

DIFFERENTIAL /52

Lubricate all internal part with gear oil during reassembly

Disassembly steps
1. Differential drive gear 6. Pinion
2. Ball bearing 7. Washer
(1)
3. Taper roler bearing 8. Side gear
4. Lock pin 9. Spacer
5. Pinion shaft 10. Differential case
T1 : 13.2 kgm (132 Nm; 8.858 ft.lbs)
NOTE:
(1) If so equipped

DISASSEMBLY SERVICE POINTS

BALL BEARING REMOVAL
Use the special tool to remove the ball bearing.

DOIIT22AR9224

REASSEMBLY SERVICE POINTS

SPACER / SIDE GEAR / WASHER / PINION /
PINION SHAFT INSTALLATION
1. After spacer has been mounted on the back
surface of the side gear, install the side gear
in the differential case.
NOTE
When a new side gear is to be installed,
mount a medium thickness spacer (
0.93-1.00 mm (0.036-0.039 in)).
2. Set the washer on the back of each pinion,
DOIIT22AR9226 and put both pinions simultaneously in
mesh with the side gears. While rotating
them, install them in position.

Printed in Malaysia 19 April 2006 Eng

 Black plate (68,1)

22A MANUAL TRANSMISSION <F5M41>

/53 DIFFERENTIAL

3. Insert the pinion shaft.

DOIIT22AR9227

4. Measure the backlash between the side

gear and pinion.
Standard value: 0.025 mm (0 in)–
0.150 mm (0.005 in)
5. If the backlash is out of specification, select
a spacer and re-measure the backlash
NOTE
Adjust until the backlashes on both sides
are equal.

DOIIT22AR9228

LOCK PIN INSTALLATION

Install the lock pin in such a way that it will be
oriented in the direction shown.

DOIIT22AR9229

BALL BEARING INSTALLATION

Use the special tools to install the ball bearing
(2)

DOIIT22AR9231

Printed in Malaysia 19 April 2006 Eng

 Black plate (69,1)

MANUAL TRANSMISSION <F5M41> 22A

DIFFERENTIAL /54

DIFFERENTIAL DRIVE GEAR INSTALLATION

1. Apply a sealant to the entire threaded
portion of the bolt.
Specified sealant: 3M STUD Locking No.
4170 or equivalent

DOIIT22AR9232

2. Tighten to the specified torque in the

illustrated sequence.ence.

DOIIT22AR9233

Printed in Malaysia 19 April 2006 Eng

 Black plate (70,1)

22A MANUAL TRANSMISSION <F5M41>

/55 DIFFERENTIAL

NOTE

Printed in Malaysia 19 April 2006 Eng

 Black plate (71,1)

TRANSMISSION OVERHAUL (MANUAL) TC02

INDEX /1

Printed in Malaysia 19 April 2006 Eng

 3
Content

Printed in Malaysia 19 April 2006 Eng

Black plate (72,1)

F5M41 Model YR 2006 English Edition RDWE-06HA080 April 2006 Printed in Malaysia