MANUAL TRANSMISSION

SECTION MT IJIJ\\

CONTENTS
FSSW71C ASSEMBLY .................................... . ... 21
Gear Components........................... ... 21
PREPARATION ...... ...................... . ············· ... 2
Special Service Tools ..... 2
Shift Control Components....... ...................... 28 fli"
Case Components ..... ............. 29
Commercial Service Tools ....... . .... 3

FSSR30A
FSSR30A
MAJOR OVERHAUL .................. . ....................... 33
PREPARATION ....... ................ . ······· 4
Case Components ................ . .................... 33
Special Service Tools ................ . ...... 4
Gear Components ............. . ........................ 34
Commercial Service Tool..... . ............................ 5
Shift Control Components .... . ....................... 36 i'\1(
DISASSEMBLY ........................... ................................ 37
FS5W71C & FSSR30A
Case Components......... ...... ........................ 37
ON-VEHICLE SERVICE ... ......................................... 6 Shift Control Components ..................................... 38 'iili'
Checking MiT Oil .................................................. 6 Gear Components . .............. . ··············· ........ 39
Replacing Rear Oil seal - 2WD Model ............... 6 INSPECTION ............................ . ................. .43
REMOVAL AND INSTALLATION ................................ 7 Shift Control Components .. ................ .43 ~lili
Removal - 2WD Model. ..... ............ ··········· 7 Gear Components................. .................. ...... .43
Removal - 4WD Model . ...... 7 ASSEMBLY ............................................................. .45 fl~
Installation ....................................................... . .... 8 Gear Components.................................... .... .45
Shift Control Components..... ........................ 53
FSSW71C Case Components ................................................. 54 12J,7Jl

MAJOR OVERHAUL ....................... . ................. 10

FS5W71C & FS5R30A
Case Components..... .................... 10
Gear Components - 2WD model ........................ 11 SERVICE DATA AND SPECIFICATIONS (SDS). ...... 56
Gear Components- 4WD model ........................ 12 General Specifications ........................... . ..... 56
Shift Control Components - 2WD model. ............ 13
Shift Control Components- 4WD model ............. 14 FS5W71C
DISASSEMBLY. .. ..... ..... ............... 15
Inspection and Adjustment.. ... ........................ 57 ISliP
Case Components...................... .................. 15
Shift Control Components... ...... 15
FS5R30A
Gear Components........................ ...... 17
INSPECTION ...... ... ..... .. ... .... .... ........................ 19 Inspection and Adjustment... ............. 59
Shift Control Components. ............................ 19
Gear Components ..... ......................... 19

489
 PREPARATION FS5W71C

Special Service Tools

Tciornumber Description
(Kent-Moore No.)
Tool name
ST23810001 Fixing adapter plate with gear assembly
( )
Adapter setting plate

NT066

KV32101330 Removing overdrive mainshaft bearing

(See J26349-A)
Puller

NT067

KV31100401 Pressing counter gear and mainshaft

( )
Transmission press stand

NT068

ST22520000 Tightening mainshaft lock nut

(J26348)
Wrench

NT069

ST23540000 Removing and installing fork rod retaining

(J25689-A) pin
Pin punch

NT070

ST30031000 Removing and installing 1st gear bushing

(J22912-01) Removing main drive gear bearing
Puller

NT071

ST23860000 Installing counter drive gear

( )
Drift
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
NT065

ST22360002 Installing counter gear front and rear end

(J25679-01) bearings
Drift
a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 In) dia.
NT065

ST22350000 Installing OD gear bushing

(J25678-01)
Drift
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
NT065

MT-2
490
 PREPARATION FS5W71C

Special Service Tools (Cont'd)

Tool number Description
'(Kent-Moore No.)
Tool name
ST23800000 Installing front cover oil seal
(J25691-01)
Drift
a a: 44 mm (1.73 in} dia.
b: 31 mm (1.22 In) dia.
NT065

ST33400001 Installing rear oil seal

(J26082)
Drift
a: 60 mm {2.36 in) dia.
b: 47 mm {1.85 In) dia.
NT086

ST33290001 Removing rear oil seal

(J25810-A)
Puller

NT076

ST30720000 Installing mainshaft ball bearing

( )
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
NT115

ST30613000 Installing main drive gear bearing

~
(J25742-3)
Drift
a: 71.5 mm (2.815 in) dia.

a b: 47.5 mm (1.870 in) dia.

NT073

ST33200000 Installing counter rear bearing

(J26082)
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
NT091

Commercial Service Tools

Tool name Description
Puller Removing counter bearings, counter drive
and OD gears

NT077

Drift Installing countershaft rear end bearing

(FS5W71C-4WD model)

a: 40 mm (1.57 In) dia.

b: 30 mm {1.18 In) dia.
NT074

"IL

MT-3
491
 PREPARATION FSSR30A

Special Service Tools

TOol number Description
(Kent~Moore No.)
Tool name
ST23540000 Removing and installing retaining pin
(J25689-A)
Pin punch
NT070

ST30031000 Removing ~st & 2nd synchronizer assem-

(J22912-01) bly
Puller Removing counter gear rear thrust bearing
Removing main drive bearing
NT071

ST33290001 Removing rear oil seal

(J25810-A)
Puller

NT076

ST33230000 Removing mainshaft and counter gear

( )
Drift a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.

NTD84
ST22350000 Removing counter gear front bearing
(J25678-01) (Use with KV38100300)
Drift
a: 34 mm (1.34 in) dia.

NT065
b: 28 mm (1.10 in) dia.

KV38100300 Removing counter gear front bearing

(J25523) (Use with ST22350000)
Drift Installing counter gear rear bearing
a a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.
NT065

ST30720000 G) Removing mainshaft front bearing

G) (J34286) @ Installing mainshaft front bearing
® (J34331) a: 77 mm (3.03 In) dia.
Drift b: 55.5 mm (2.185 in) dia.
NT115

ST33220000 Removing and installing counter gear rear

(J25804-01) end bearing (4WD model)
Drift
a: 37 mm (1.46 in) dia.
b: 22 mm (0.87 in) dia.
NT084

ST33210000 CD Installing counter gear front bearing

G) (J25523) @ Installing front cover oil seal
® (J25803-01)
Drift a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.
NT084

ST30613000 Installing main drive gear bearing

~
(J25742-3) a: 72 mm {2.83 in) dia.
Drift b: 48 mm (1.89 in) dia.

NT073 a

MT-4
492
 PREPARATION I FS5R30A I
Special Service Tools (Cont'd)
Tool number Description
(Kent-Moore No.)
Tool name
ST37750000 CDRemoving counter gear rear bearing
(j) (J34286) ® Installing OD gear bushing Iilli
@ (J34332) ® Installing reverse cone
@ (J34334) @ Installing reverse counter gear
@ (J25679-01) @ Installing counter gear rear end bear-
Drift ing
a: 40 mm {1.57 in) dla.
l~l'Ml
NT065 b: 31 mm {1.22 in) dia.

ST22452000 Installing reverse hub

(J34337) Installing mainshaft rear bearing
Drift (2WD model)
a a: 45 mm (1.77 in) dia.
l"f'@,
b: 36 .mm (1.42 in) dia.
NT065 ~[:;
ST33400001 Installing rear oil seal
(J26082)
Drift
a: 60 mm {2.36 in) dia.
b: 47 mm (1.85 In) dla.
NT086

(J26349-3) Installing mainshaft and counter gear

~
Puller leg (Use with J34328)

NT078

Installing mainshaft and counter gear

~
(J34328)
Puller (Use with J26349-3)

NT079

(J26092) Installing sub-gear snap ring

Drift

a: 44.5 mm (1.752 In) dla.

a
b: 38.5 mm (1.516 in) dla.

NT065

(J34342) Installing OD main gear

Drift Installing reverse gear bushing

a: 44.5 mm (1.752 in) dia.

b: 40.5 mm (1.594 in) dla.
NT065

Commercial Service Tool

Tool name Description

Puller Removing counter gear rear end bearing

Removing mainshaft rear bearing (2WD
model)
Removing reverse synchronizer hub
Removing reverse counter gear
NT077

MT-5 493
 ON-VEHICLE SERVICE I FS5W71C & FS5R30A I

Checking M/T Oil

• Check manual transmission for oil leakage.

SMA429A

• Check oil level.

Filler plug Fill to this level

Replacing Rear Oil seal - 2WD Model

MT-6 494
 REMOVAL AND INSTALLATION I FSSW71C & FS5R30A I

Removal - 2WD Model

• Remove propeller shaft. - Refer to section PD.
• Insert plug into rear oil seal after removing propeller shaft.
CAUTION:
@[
Be careful not to damage spline, sleeve yoke and rear oil seal,
when removing propeller shaft.
• Remove exhaust front tube A. (VG30E engine model) - ~~&:1
Refer to section FE.

• Remove shift lever.

• Support engine by placing a jack under oil pan.
CAUTION:
Do not place jack under the oil pan drain plug.
• Remove transmission from engine.
WARNING:
Support Manual Transmission, while removing it.

SMT099A

Removal - 4WD Model

• Remove front and rear propeller shafts.- Refer to section
PD.
• Insert plug into rear oil seal of transfer after removing pro- I!J'ii'
peller shalt.
CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal TF
of transfer, when removing propeller shaft.
• Remove exhaust front tube A. (VG30E engine model) -
Refer to section FE. ]"~
• Remove torsion bar springs.- Refer to REMOVAL of Tor-
sion Bar Spring in section FA. Then remove second cross-
member. 'fill

• Remove shift lever of transmission and transfer.

• Support engine by placing a jack under oil pan.
CAUTION:
Do not place jack under the oil pan drain plug.
• Remove transmission with transfer from engine.
WARNING:
Support Manual Transmission with transfer, while removing it.
~~

\ ~A
MT-7 495
 REMOVAL AND INSTALLATION FS5W71C & FS5R30A

Installation
• Apply sealant as below: - 4WD model
KA24E engine model
Stanernootor
Sealant~

Engine block
("#iif~
Engine block

Engine rear plate

Transmission case

Mating surface of engine block Mating surface of engine rear plate

and engine rear plate and transmission case

ltS>-M: Apply recommended sealant (Nissan genuine part:

Transmission KP510-00150) or equivalent.
case
Engine block ~ : Apply recommended sealant (Nissan genuine part:
KP610-00250) or equivalent.

SMT481A

MT-8 496
 REMOVAL AND INSTALLATION FS5W71C & FS5R30A

Installation (Cont'd)
,--~~~~~~~~~~~~~~~~~~~~~~~~~~~-----------

VG30E engine model

Engine rear plate

Engine rear plate

Transmission
ca'e
Engine rear plate
Transmission
me

Engine block
Mating surface of engine Mating surface of engine rear
block and engine rear plate plate and transmission case

I.I2IliDl : Apply recommended sealant (Nissan genuine part: !GiL

KP510-00150) or equivalent.
~ : Apply recommended sealant (Nissan genuine part:
KP61()..00250) or equivalent.

SMT499C

• Tighten bolt securing transmission.

• KA24E engine model

Bolt No. Tightening torque N·m (kg-m, ft-lb) [ mm (in)

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

® 39- 49 (4.0- 5.0, 29 - 36) 60 (2.36)

@. 16- 22 (1.6- 2.2, 12- 16) 25 (0.98)

0 M/T to engine @ 16- 22 (1.6- 2.2, 12- 16) 20 (0.79)

@ Engine rear plate to MIT *. W1th nut
SMT305C

• VG30E engine model

Bolt No. Tightening torque N·m (kg-m, ft-lb) [ mm (in)

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

® 39- 49 (4.0- 5.0, 29 - 36) 60 (2.36)

@ 29 - 39 (3.0 - 4.0, 22 - 29) 55 (2.17)
@ 29 - 39 (3.0 - 4.0, 22 - 29) 25 (0.98)

0 M/T to engine ® 29 - 39 (3.0 - 4.0, 22 - 29) 25 (0.98)

® Engine (gusset) to M/T SMT573A

MT-9 497
 ~~4-5
~ (0.4 ' 0.5, 2.9 • 3.6)
Reverse check sleeve (FS5W71C)

~ 16 • 20 (1.6- 2.0, 12 • 14)

Reverse
~ lamp
20. 29
switch
(2.0 - 3.0, 14- 221 ~~
'-
'
,
Rear extension
r:;! Thread of bolts o ~"- ~- ~~ s:
0 l>
Ill
Transmission case
~ Mating surface to engine
,---- ~ Bearing retainer
Ill
(I)
c..
0
:0
s: rear plate (4WD model 0
-4
....• - Refer to "REMOVAL
and INSTALLATION"
) Bearing
Adapter plate D Mating surface to transmission case and
0
3
0
<
0 in MT-8.) rear extension (or OD gear case) "C m
Filler plug ~ 25 - 34 (2.5 - 3.5, 18 - 25) D Thread of bolt 0 :0
:::J ::r::
~ ~ OD gear case

-
(I)
:::J
I ll
l>
c:
r

Oit seal ~l!2i!l Seal lip

~
~ ~ o N•m (kg-m, ft·lb)

,.,.~
~ : Apply recommended sealant (Nissan genuine
part: KP610-00250) or equivalent.
498
 MAJOR OVERHAUL I FS5W71C I

Gear c omponents - 2WD model

Washer
~I
Snap ring*~

Pilot bearing EB
. Snap ring~
Main drive gear ball bearin~

"'" ..:7.~$QJ
Main drive

!Cll

Malnshaft lock nut..,.

""
.-. 137 - 167 (1 4 .., 101 - 123)
Without Tool ·0- 17.0,

*.
Apply gear oil to
and bearln
S I gs when gears, shafts, synchronizers
assembll
. e ect proper th' ng.
<:r : Pay atte ,. lckness.
~~-~:
1'!""n n1onto't. 1
N•m (kg-m, ft-lb) s direction.

SMT613C ~~J)}Z

MT-11 499
 MAJOR OVERHAUL FS5W71C

Gear Components - 4WD model

3rd main gear /Needle bearing

7/ ~
Washer\
\ Baulk nng
Coupling ~leeve
1
Snapnng*~-\ \ ~- ~
:1\ )
I
Mainshaft ball bearing 1

Polot beanng 1!i51\\, \ Spread spnng/\ R~~ Thrust washer l!i5l

Snap nng ~~ \\ \ / '( \~~ 1st main gear 1 I /

:::pd:·:::;~;~bll)1
l (n~
~~~\_)~
~~ )~0 ) 3rd &
'"""'"-"II tJ/
4th synchronozer hub" ""'"\\:') ,
~~1j
~'&,)

Main drive ~~r~

r
~

1st and

2nd out.er baulk ring

Sh1ft1ng msert

::~~~n~~:~:~hu~bl~~r
~;:;:J' . ,;:-~ ~
~Q_/

\__ Needle
beanng

Synchronizer cone
n _/ /. ~ Baulk ring
2nd maon gear\ ~~~ ~ &" Coupling sleeve

~~
Ma1nshatt 7
Needle beanng \
\ ~ 2nd 1nner baulk nng

Steel roller 1!i51\ / ~lfj;

Steel ball I!Ei!!l El/"'''·'"'
0
'

SMT614C

MT-12 500
 o-Shift knob
Return spring plug
~Thread of bolts
Return spring
~20 • 29 (2.0 • 3.0, 14. 22)
Retaining pin~~
Bushing
Control lever
IlEa! Mating surface to control lever

ii;~ Return spring

Check ball
./1
Select check plunger~~K__ \
__///~ Snap ring~

_p"-.
vA 0
Washer

~ ~
Check spring Check ball
Rubber
Lock pin ;---- Check ball plug seat s:)>
Striking rod . ~""
@@ 1:;1 Thread
(1.9 of bolts til
:::T
Striking lever
------&../
_j ~ 0
\ ""''9-25
.-. - 2.5, 14 - 18)
Socket!:E!
=
c..
0

~
Mating surface
~ 9 - 12 (0.9 - 1.2, 6.5- 8.7)
s:-1 to housing 0 ::D

...'. Retaining pin ~

and control
lever
-
0
::;,
....
0
<

~
(;,) ~Spring m

y_
1st & 2nd fork rod
2. ::D
0 :I:
0 )>
Boot 3 c:
"C r-
0
::;,
\ -j
3rd & 4th fork rod
V Lower boot
retainer
-
CD
::;,
I ll

N
::IE
Check ball ~ c

7L~ . ~
OD & reverse shift fork
3rd & 4th
3
0
shift fork
~ 19 • 25 (1.9 • 2.5, 14 • 18)
a.
CD

~no~
~
~: N•m (kg-m, ft-lb)
"'
I reverse fork rod ~ : Apply recommended sealant (Nissan genuine
part: KP610-00250) or equivalent.
501

[J-J'tj ~
'"
:g] 821 0';/J ·:.Clil :2QJ "'lf>J 9
~
"@) =ml F
~
r ~ "Ull ~ 2l5J JS;o ~ ~J
""' c...C Ulfil
mnllr1flJ
rt""'!J 'Ill (~
'""
~
§
d&'
,;;)J

""
 Return spring plug D Thread of bolt

Return spring
~ 20 - 29 (2.0 - 3.0, 14 - 22)

Lock
~~
pin~~
[; Select check plunger
Bushing
~ Striking lever
m, Mating surface to control lever
D-Shlftknob

Striking rod----........_
~~ ~~Reverse
~ ~
check plug
DThread of bolt
Control lever

~~
""26 - 36 (2.7 - 3.7, 20 - 27)
(§/~<i\11''
0
.-. spnng
J @. -............._ Return

~0.>. ~Check ball ·~

~ 9- 12 (0.9- 1.2, 6.5- 8.7)
Select check plunger /
Return spnng_j
~~Return
1
D
spnng plug
Thread of bolt
Snap ring~

~ 20 - 29 (2.0 - 3.0, 14 - 22)

Check spnng Washer

~I
/Checkball
Rubber (/) :s::
Y
/! ~Thread
)>

v -
Check ball plug seat ::r
.r-. of bolts :::;: c..
~19- 25
0
::J""'" Socket!Ei! (') ::D
:s::
-...
(1.9 - 2.5, 14 - 18) Upper boot retainer

8- Mating surface 0 0
7.... to housmg and :I
<
control lever
0 m
""' 1st & 2nd fork rod
ti)-spnng ~ (')
::D
:::1:

rls ~Boot
0
3
)>
c:
r-

Ly_·-·~·-
"C
0
Retaining pin~ :I
(I)
:I
iii
Control housing
I
""'
:::e
c
3
3rd & 4th shift fork 0
00 & reverse shift fork c.
(I)

"'
i
~ : Apply recommended sealant (Nissan genuine
part: KP610-00250) or equivalent.
~ : N·m (kg-m. ft-lb) ·~
~
502
 DISASSEMBLY I FS5W71C I

Case Components
1. Remove rear extension.
a. Remove control housing, check ball, return spring plug,
select check plunger and return springs.

SMT982

b. Drive out striking arm retaining pin.

c. Remove striking arm from striking rod.
d. Remove rear extension by lightly tapping it.

SMT800B ~l

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.

4. Remove oil seal of front cover.

Be careful not to damage mating surface of front cover.

( SMT035

Shift Control Components

1. Set up Tool on adapter plate.
2. Remove striking rod from adapter plate.
3. Remove check ball plugs, check springs, and check balls.

MT-15 503
 DISASSEMBLY I FS5W71C I
Shift Control Components (Cont'd)
4. Drive out retaining pins. Then drive out fork rods and
remove interlock balls.
ST23540000
(J25689-A)

SMT984

5. Remove lever bracket securing bolt (2WD model).

SMT788A

6. Draw out 3rd-4th fork rod (2WD model).

7. Remove E-ring from OD-rev. fork rod (2WD model).

8. Draw out OD-rev. fork shaft by rotating OD-rev. bracket

counterclockwise (2WD model).

SMT792A

MT-16 504
 DISASSEMBLY I FSSW71C I

Gear Components
1. Before disassembly, measure each gear end play.
• If end play is not within the specified limit, disassemble and
check the parts.
• Replace any part which is worn or damaged.
Gear end play:
Refer to SDS, MT-57.

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.

~~ ~

~===~~~~~======~ 4. Draw out counter drive gear with main drive gear assem-
bly with suitable puller.
• When drawing out main drive gear assembly, be careful not
to drop pilot bearing and baulk ring.
5. Remove snap ring and draw out 3rd & 4th synchronizer and fil.l
3rd gear.

6. Disassemble parts at rear of adapter plate as follows:

a. Release staking on countershaft nut and mainshaft nut and "!ffil
loosen these nuts.
Mainshaft nut: Left-hand thread

SMT546A

b. Pull out OD counter gear with bearing with suitable puller.

c. Draw out reverse counter gear and spacer. ~F
d. Remove snap rings from reverse idler shaft, and draw out
reverse idler gear, thrust washers and reverse idler gear
bearing. ~&1

MT-17 505
 DISASSEMBLY FS5W71C

Gear Components (Cont'd)

e. Remove snap ring and pull out overdrive mainshaft
bearing, then remove snap ring. (2WD model)
f. Remove mainshaft nut.
g. Remove speedometer drive gear and steel ball. (2WD
model)
h. Remove thrust washer, steel roller, roller bearing and
washer.
i. Remove OD main gear, needle bearing and baulk ring (OD).
j. Remove reverse main gear (2WD), OD & reverse coupling
sleeve (4WD), shifting inserts and shifting insert springs.
k. Remove counter gear by tapping rear end of counter gear.
I. Press out OD gear bushing, insert retainer and OD synchro-
nizer hub.

SMT554A

7. Remove thrust washer, steel ball, 1st main gear and nee-
dle bearing.
Be careful not to lose steel ball.

8. Press out 1st gear mainshalt bushing together with 2nd

main gear with Tool.
Then remove 2nd gear needle bearing.

ST30031000
(J22912.Q1)

9. Remove main drive gear bearing.

a. Remove snap ring and washer.
b. Remove main drive gear bearing.
ST30031000
(J22912-011

SMT420A

MT-18 506
 INSPECTION I FS5W71C I

Shift Control Components

• Check contact surface and sliding surface of fork rods for
wear, scratches, projections or other damage.

*.
~
SMT075C

Gear Components

•
Mainshaft and gear

GEARS AND SHAFTS

• Check shafts for cracks, wear or bending.
• Check gears for excessive wear, chips or cracks.

1i'IF

Counter gear

SMTSSOA

Shifting insert
SYNCHRONIZERS
• Check spline portion of coupling sleeves, hubs and gears ~IP
for wear or cracks.
• Check baulk rings for cracks or deformation.
• Check shifting inserts for wear or deformation. ~1'\
• Check insert springs for deformation.

MT-19 507
 INSPECTION FS5W71C

Gear Components (Cont'd)

Baulk ring to • Measure wear of bau\k rings.
gear clearance a. Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear:
Refer to SDS, MT -57.
If the clearance is smaller than the wear limit, replace baulk
ring.

SMT140

Inner baulk ring • Measure wear of 2nd baulk rings.

\2nd inner baulk ring a. Place baulk rings in position on synchronizer cone.
b. While holding baulk rings against synchronizer cone as far

':if;:'""'""" " as it will go, measure dimensions "A" and "8".

Dimension Standard
Unit· mm (in)

Wear limit
0.6-1.1
A
(0.024 - 0.043)
0.2 (0.008)
ST30031000 0.7- 0.9
- (J22912-01) 8
SMTD418 (0.028 -0.035)

Outer bau lk ring

c. If dimension "A" or "B" is smaller than the wear limit,
Synchronizer cone
replace baulk ring.
~~·~~){2nd outer baulk ring
Feeler gauge

~:..~"-
2nd outer baulk ring

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

MT-20 508
 ASSEMBLY I FS5W71C I

Gear Components

Malnshaft ball bearing In adapter plate Countershaft rear end bearing In OD gear case
(4WD model)

~rA
I/' 0
Drift
@~

~/!\

Be flush with front surface !:i%1]

of OD gear case.
Counter rear bearing In adapter plate

'"~
!:IF~
1'1.:

IP!i'

SMT481CA
1-:IL
1. Install bearings into case components.
CJ~

. 'L~.---
Upper
2.
•
Assemble adapter plate parts.
Install oil gutter on adapter plate and expand on rear side. /i\11'

• ~7
::~ ~/
~
Front
' \
SMT153A

• Install bearing retainer.

a. Insert reverse shaft, then install bearing retainer.

b. Tighten each screw, then stake each at two points.

MT-21 509
 ASSEMBLY FSSW71C

Gear Components (Cont'd)

3. 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 to minimize clear-

ance of groove and install it.
Allowable clearance of groove:
0- 0.13 mm (0 - 0.0051 in)
Main drive gear snap ring:
Refer to SDS, MT-57.

4. Assemble synchronizers.
• 1st synchronizer

SMT054C

Check coupling sleeve and synchronizer hub orientation.

~
~~
~ Coupling sleeve

Frontsy ~arside

Synchronizer hub

SMT206C

MT-22 510
 ASSEMBLY I FS5W71C I
Gear Components (Cont'd)
• 2nd double baulk ring type synchronizer

@0
• 3rd & 4th synchronizer

•
Spread spring
The 3 gutters of synchronizer should be at the rear.

·~-;~
~~ ~~-\
9 8
(0.35) (0.31)
HH

Front~ Front~
•
2WD 4WD
Unit: mm (in)
SMT306C

• OD & reverse synchronizer

(2WD model)

<f?'«<il!!
t?
Front
~
00 (5th) synchronizer _./'fJ
hub fltP SMT095AA

MT-23 511
 ASSEMBLY FS5W71C

Gear Components (Cont'd)

(4WD model)

Front

Shifting
insert

5. Install front side components on mainshaft.

a. Assemble 2nd main gear, needle bearing and 1st & 2nd
synchronizer assembly, then press 1st gear bushing on
mainshaft.
b. Install 1st main gear.

c. Install steel ball and 1st gear washer.

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

TM35'8

6. Install mainshalt and counter gear on adapter plate and

main drive gear on mainshaft as follows:
a. Press mainshalt assembly to adapter plate with Tool.

KV31100401
( - )

MT-24 512
 ASSEMBLY FS5W71C

Gear Components (Cont'd)

b. Press counter gear into adapter plate with Tool.
c. Install 3rd main gear and then press 3rd & 4th synchronizer
assembly.
• Pay attention to direction of 3rd & 4th synchronizer.
@I

============================SM=T=75~0 d. Install thrust washer on mainshaft and secure it with main-

~~
shaft front snap ring. ~~&:
Select proper snap ring to minimize clearance of groove in
mainshaft.
Allowable clearance of groove: lEI¥' I!<
0- 0.18 mm (0- 0.0071 in) 11':1!.:
Mainshaft front snap ring:
Refer to SDS, MT -57. !¥'·~
e. Apply gear oil to mainshaft pilot bearing and install it on
mainshaft.

============================T=M=44~1 f. Press counter drive gear with main drive gear with Tool. ret
• Pay attention to direction of counter drive gear.

SMT412C

g. Install sub-gear components.

(1) Install sub-gear and sub-gear bracket on counter drive gear 1¥'81
and then select proper snap ring to minimize clearance of
groove in counter gear.
Allowable clearance of groove: ~b\
0- 0.18 mm (0 - 0.0071 in)
Counter drive gear snap ring:
Refer to SDS, MT -57. ~~
(2) Remove snap ring, sub-gear bracket and sub-gear from
counter gear.
SMT528A (3) Reinstall sub-gear, sub-gear spring and sub-gear bracket. i§ili'

h. Install selected counter drive gear snap ring.

TM366

MT-25 513
 ASSEMBLY I FS5W71C I
Gear Components {Cont'd)
i. Press counter gear front bearing onto counter gear.

ST22360002
(J25679-01)

TM443

7. Install rear side components on mainshaft and counter

gear as follows:
a. Install reverse idler gear to reverse idler shaft with
spacers, snap rings and needle bearing.

TM451

b. Install insert retainer and 00 synchronizer to mainshaft.

(2WO model)
Pay attention to direction of hub.

t?
Front ~
OD (5th) synchronizer ~
hub tarr SMT095AA

b. Install bushing and 00 & reverse synchronizer to main-

shaft. (4WO model)
Pay attention to direction of hub.

Shift~'ng
IOSert ,
.,..
...

f:f

Front

Shifting
insert
SMT207CA

MT-26 514
 ASSEMBLY I FS5W71C I
Gear Components (Cont'd)
c. Install 00 gear bushing with Tool.
Gear bushing d. Install 00 main gear and needle bearing.
e. Install spacer, reverse counter gear and 00 counter gear.
• OD main gear and OD counter gear should be handled as
a matched set. @:I
f. Install washer, roller bearing, steel roller and thrust
washer.
g. Tighten mainshalt lock nut temporarily. ~lil\
• Always use new lock nut.

SMT531 [i":~l

~====;;;;:;;;:======~ h. Install countershalt rear end bearing with Tool.

SMT043 ([:l
~==============~ 8. Mesh 2nd and reverse gears, then tighten mainshaft lock
nut with Tool.

SMT003A

Tool c • Use the left chart when deciding the reading torque.
Torque wrench (Length of torque wrench vs. setting or reading torque)
9. Tighten countershaft lock nut.
• Always use new lock nut.

(110)

,•
\!
0
;;, (100)
c
:g
•
c:
(.) (90)

(80)
0.8
m
(1.5) (2.0) (2.5) {h)
L: Length of torque wrench

SMT004A

MT-27
515
 ASSEMBLY I FS5W71C I
Gear Components (Cont'd)
Mainshaft Counter shaft 10. Stake mainshaft lock nut and countershaft lock nut with a
punch.
11. Measure gear end play. For the description, refer to DIS-
ASSEMBLY for Gear Components, MT-17.

Shift Control Components

Fork rod 1. Install shift rods, interlock plunger, interlock balls and
(1st & 2nd)
check balls.

SMT992AA

a. 1st-2nd shift fork

b. 3rd-4th shift fork

c. OD-reverse shift fork or reverse shift fork

SMT991

MT-28 516
 ASSEMBLY I FS5W71C I
Shift Control Components (Cont'd)
2. Install OD-rev. fork shaft by rotating OD-rev. bracket clock-
wise (2WD model). ·

3. Install E-ring on OD-rev. fork rod (2WD model).

4. Install lever bracket securing bolt (2WD model).

Case Components
1. Install front cover oil seal.
• Apply multi-purpose grease to seal lip.

SMT036

2. Apply sealant to mating surface of transmission case.

SMT061C

MT-29 517
 ASSEMBLY I FS5W71C I
Case Components (Cont'd)
3. Slide gear assembly onto adapter plate by lightly tapping
with a soft hammer.

4. Install main drive bearing snap ring.

5. Apply sealant to mating surface of adapter plate.

SMT062C

6. Set shift forks in neutral position.

'od
7. Install striking lever onto adapter plate and align striking
lever with shift brackets.
Shift

lever

8. Install rear extension.

9. Fit main drive bearing snap ring.

SMT802B

MT-30 518
 ASSEMBLY I FS5W71C I
Case Components (Cont'd)
10. Install striking arm retaining pin.

SMTBOOB

A A: Distance from bearing 11. Select counter front bearing shim.

surface to transmission Counter front bearing shim:
case Refer to SDS, MT-58.

CD Transmission case [P~

® Counter gear front bearing
@ Counter gear

~==========================T=M=37~1 12. Install gasket and front cover.

~~
13. Install return spring plugs, check ball, return springs and
select check plunger.
14. Install control housing and gasket.

1F

SMT982

MT-31 519
 ASSEMBLY I FS5W71C I

NOTE

MT-32 520
 . [2Womodei]
Neutral pos•t•on sw1tch ~ _ ( . _ 2.1, 12- 15)
~20- 29 (2.0- 3.0, 14- 22) , , - . 16 21 1 6
D Thread of bolt

Reverse lamp switch ~ Control housmg

~ Thread of bolt I .
Plug
[;} ~~ Matmg suriace to rear
I extension

Filler plug~ ~~~ ~

/:>~ ~~~~Oust
~25- 34
(2.5 - 3.5•. 18 - 25) cover
~ Thread of bolt
~
Adapter plate
~Mating surface \__ Rear oil seal
Transmission case----- transmission case mseallip
~Mating surtace to engine
rear plate (4WD model 0
5:
- Refer to "REMOVAL Ill
1/)
>
c..
and INSTALLATION"
in MT-9.) CD 0
%1
5: (1.6- 2.1, 12 - 15) 0
0 0
!B!Il <
'w
""
(,)
Slide ball bearing
Gasket~ \
/4WD model/ 3
"C m
%1
ball bearing m A~ 16 . • 12 - 15)
_ 21 (1.6 _ 21
0
:I ::1:
Front cover

·(j'
\) ) ~
Neutral position switch
20 - 29 (2.0 _ 3.0, 7 ) ~, ~Mating
/Control housing
surface to OD -
CD
:I
1 /)
>
c
r-

~
'
14 22
D Thread of bolt j gear case

~ -r'"""
'

L'J•·•~·~" fc~'~'"
..l.r~!
J ~ 6.3-8.3

~ -~ -~~()
roHoo'l -.. -25 . (0.64- 0.85, 4.6- 6.1)
-,_Wi>'l811 e'""'-. t!j' > r<>..

~ -~ ~ sw;;c~
m Seal lip I Thread of bolt _______)
~-o®
~20-29(2.0-
~31- 42
Ball pin
(3.2_ -31)
23 4.3, r: ,.,
,-.
~
Sealing gremmet (4

16- 21 (1.6- 2.1, 12- 15) "ASSEMBLY" ;n MT-54.

~ Thread of boIt - Refer to
wo model)
~~Thread
Reverse lamp
of bolt
.•
14 - 22) '
-~Baffle plate

~
"' toJ : N•m (kg-m, ft-lb)
~
~ : Apply recommended sealant (Nissan genuine
part: KP610-00250) ·or equivalent. OD gear case
521

m .-tril F' JmJ ~

!;'! IPQl 29 =;::-cjj
~ b 0
""JmJ !ftrjffl'j]
!1i!
'""
©) @l)
F ~ CijJ 2m 20 ~ ;g 9 r (,""'J "l1l G:1J § )0
~
~
 4th baulk ring
Mains haft front snap ring*~

Pilot bearing
Spacer
Steel ball I!E3!I ~
0
I /l
Main drive gear Mainshaft

Main drive gear bearing~

Spacerl

ring*~\
~'"-· ~"'\:J'O~
. ar snap \ o

s::
Steel ball IE!\ Ci)
CD >
c..
Ill

~
]' \0 /l spring~
Sub-gear-, 0 ~ 0
::tl
s:: 0

~/')Jf I --h()O'
Sub-gear . 0 0
-1 Counter gear rear bearing
'
w thrust washer 3 <
m

.~0
"C
"" ::tl

I QO~
@ 0
1st gear washer m :I ::I:
c>
CD
~ge~r bushm7
:I
iii r-
L J JI
con
Main drive!'aring Counter gear y
snap nng ..., front bearing ~ 1st baulk nng ~~
Cou~ter ghea~t f~;~her * !:I:! ~1st & 2nd coupling sleeve ~~
~ ~0\)1
beanng t ru

r- Shoftong

beann~-.,p '~ ~
Counter gear front msert
thrust bearing
Sub-gear snap ring ~
m 2nd gear needle
\_,
{ '--1st main gear
(With

irRI~\0~,g""\J \_Spread spnng sub-gear)

'~\ "'---1st & 2nd @

\ synchron~zer hub

2n~- in:=,.~~ulk ring J \

Synchronizer cone
'\...._2nd outer baulk ring

~
522
 Reverse cou li
P ng sleeve_,
Mainshaft
spacer~ \
\
\
Mamshaf1

\
rear beanng
C-nng *

""""~"-'" "-"• Reverse gear needle bReverse

i I.- Ma~nshaft rearsnapnng~

. h ub _, C-nng holder
@
( Reverse mal eanng
11 \ \ \ r

-·~~~~(~~
-- l/

I
'-·-
·

I
·-"NO

-·
00 m ·
eter drive gear..._
mode!)
""
\~ ,~~
w
\

.
\

tergear
"' "'
"",w '
2WD -

J
\ rfl:

. ,
~~1 1\J.l:J\)IJIJ! Q•••rear

~-- ~:::~:.e~aring~~ \~\(yMa~nshaft

~
Reversegear
Counter uusnrng
e - .-- --·

"s::

\
Jcl\!:lill
anng~rrear ~ ~~U ~ •-: \
~
(J)
rf'\i I» 0
""-" I
rfo{f' "-' w •
\_ ..J' _ _,_
1m lY

m Q',a'-
... ::tl

~.::r·--··~
s::-1 ~0
•
,3 <
(o) 1
U1 m
0 ::tl
:I ::1:

-~~~ " \
(J) )>
::!.c:
'--Insert sp.nng Ill r-

I~
.-.
0
0 gear bushlngj
00 I
D gear needle b
L
~ j 00 co

unter gear
00 couphng s eeve-t, 0
:I
~
c.
._..

~
~~\~~~~Reverse
eanng

-------~\ ~
idler rear thru
Reverse ldl st washer* tr
>a er needle beanng
0
Reverse idler gear

! \
~
Reverse ·idler front th rust
Reverse idl washern

I
Apply gear oil to gears, shafts, synchronizers
Retaining pin er shaft
and bearings when assembling.
"' *:
~
Select with proper thickness.
*: Pay attention to its direction.
523

1m ~ ijEI w 9 ~ Til mLru=u ~

lS:2J
~
IF ~ Ciil 9
If@
2]]
20
~
Ciil
~ ""
rg ~ 9
0
F 1m ocru
1§3
IF
co
Nil
~
~
~
 Control lever knob -0

OD & reverse fork rod Snap ring ~\ .

©- \:b: 1
\
~ 29 (2.5 - 3.0, 18 • 22) Washer\~ ~Control lever

~
.-_.31 - 42 (3.2 - 4.3, 23- 31) --~" ©

[~ ~19 Washer~
Check ball plug
• 25 (1.9 - 2.6, 14 - 19) I 'r( /Upper boot retwner

[ D Bolt thread Interlock stopper ~:e; !:a~3.0 - 3.5, 22 - 25) ~ ©---© . ~ ./Boot

I@ m Contact surface to control lev~ ~lower boot retainer

~~- -~:t.':ng pin ~jj r~d Snap ring~ ~
I '

'Qt--
Check ball m
-Striking
.
I

B . en s::
>
-
:r
Check spring
Free length: "'-.... _.......-- Socket , · :;: c..
32.8 mm (1.291 In)'\ '· "' I l!'a!l Contact surface to control le~ L./ Control housing 0
~ ~ ~· 0 :rJ
....s::
t -...
Reverse shift fork Spring ] Bushing
I I _. 0 0
Retaining pin ~ . . . ~ Q';,"' Efi!l Contact surface to control lever ::I
w
en
' ~ ~ Select check plug Retaining pin~~" VReturn spring
g_
<
m
~ ~ ~ 20 - 29 (2.0 - 3.0, 14 - 22), Free length :rJ
ro rJ Bolt thread 2WD model: 47.4 mm (1.866 In)
0\~ ~ I Select check spring~ . 4WD model: 50.4 mm (1.984 in) 0
0
::1:
>
~ Checkbaii c:
Select check plunger I R 3
1!8! Contact surface to. striking arm \ ~evercse ct hetck srtleevet "C r
1 < ~ on_ac su ace o 0
Striking interlock
Striking lever*
3rd & 4th shift fork
r loo \

00 shift fork
Retaining pin
rod bracket
I
0
~2
.::l" ..........._~strlkmg lever
/ 0 "<()~ ~.;~..; ~-~-85,
4.6 - 6.1)
::I

-
CD
::I
I ll

Snap ring~ · Guide nll'lfA

!..~20
Select check plug
_ 29 (2.0 • 3.0, 14 _ 22)
~ , / / ~ Bolt thread
,-. 6.3- 8.3 (0.64- o.a5, 4.6- 6.1,-
Select check spnng

Select check plunger

~: N·m (kg-m, ft-ibl Ei3! Contact surface to striking arm
~ : Apply recommended sealant (Nissan genuine

I
part: KP610-Q0250) or equivalent.
~
~ ©: Apply locking sealant.
~
;:
*:Pay attention to its direction.
524
 DISASSEMBLY I FS5R30A 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. lilJ~

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

3. Drive out retaining pin from striking arm.

4. Remove rear extension (or OD gear case) together with

striking arm by tapping lightly. !Fffi\

5. Remove front cover and gasket.

MT-37
525
 DISASSEMBLY I FS5R30A I
Case Components (Cont'd)
6. Remove stopper ring and main drive bearing snap ring.

7. Remove transmission case by tapping lightly.

Soft hammer

/
SMT3J2A

8. Remove front cover oil seal.

Shift Control Components

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

3. Drive out retaining pin from striking lever.

1 ST23540000 4. While pulling out striking rod, remove striking lever and
IJ25689-A)
striking interlock. Then remove 1st & 2nd, 3rd & 4th and
reverse shift fork.

MT-38 526
 DISASSEMBLY I FS5R30A I
Shift Control Components (Cont'd)
5. Drive out retaining pin from OD shift fork.
6. Pull out OD fork rod and then remove OD shift fork.

~I

Gear Components
1. Before removing gears and shafts, measure each gear end IL©
play.
Gear end play: !ElF ill
Refer to SDS, MT -59. IE©
• If not within specification, disassemble and check contact
surface of gear to hub, washer, bushing, needle bearing
and shaft. li'!E

2. Remove rear side components on mainshaft and counter

gear.
a. Remove reverse coupling sleeve.

b. Remove mainshaft rear snap ring and counter gear rear

snap ring. IF/AI
c. Remove G-ring holder and mainshaft C-rings from main-
shaft. Use punch and hammer to remove C-rings.

d. Pull out counter gear rear end bearing.

e. Remove reverse idler gear and reverse idler thrust wash- Ill"
ers.

MT-39 527
 DISASSEMBLY I FS5R30A I
Gear Components (Cont'd)
f. Pull out mainshaft rear bearing (2WD model).

g. Pull out reverse main gear together with mainshaft spacer

and reverse synchronizer hub. Then remove reverse gear
needle bearings.

h. Pull out reverse counter gear.

i. Remove OD coupling sleeve together with OD baulk ring,
reverse baulk ring and spring inserts.

j. Pull out reverse gear bushing.

k. Pull out OD counter gear together with reverse cone.

MT-40 528
 DISASSEMBLY I FS5R30A I
Gear Components (Cont'd)
3. Press out mainshaft and counter gear alternately.

~
...-
AlterLtely
............
ST33230000____.-( ..
F1 I - )

~
L~~~
~~-~~ ..
..

UC::?
~,

Be sure to press mainshaft and counter gear alternately so as not to allow

the front surface of one to contact the rear surface of the other.
SMT772A

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.

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

ST30031000
IJ22912.Q1l

SMT482C

e. Press out 3rd main gear together with 3rd & 4th synchro-
nizer assembly and 3rd gear needle bearing. ffiif'

MT-41 529
 DISASSEMBLY FS5R30A

Gear Components (Cont'd)

5. Remove front side components on counter gear.
a. Remove counter gear rear thrust bearing.

ST30031000

rf:~~~~~~J2:::2l912.01)

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.
ST30031000
(J22912 -011

sMT420A 7. Remove bearings from case components.

Counter gear front bearing In transmission case Mainshaft front bearing in adapter plate
fr

SMT388A SMT396A
Counter gear rear end bearing In OD gear case Counter gear rear bearing In adapter plate
(4WD model)

ST37750000
(J34286)

SMT483CA
SMT390A

MT-42 530
 INSPECTION I FS5R30A I

Shift fork Shift Control Components

• Check contact surface and sliding surface for wear,
scratches, projections or other damage.

l!lil

....... ·-~';, ""

~============S:::M:_:T3=98~A ~~
Mainshaff and gear Gear Components
GEARS AND SHAFTS
• Check shafts for cracks, wear or bending.
• Check gears for excessive wear, chips or cracks.

Counter gear

/J\1

SMT423A

Shifting insert
SYNCHRONIZERS
• Check spline portion of coupling sleeves, hubs, and gears Fli\
for wear or cracks.
• Check baulk rings for cracks or deformation.
• Check shifting inserts for wear or deformation. ~/)\
• Check insert springs for deformation.

SMT427C iJf
~=====sa=u=lk=ci=n9=,o=====~ Clearance between baulk ring and gear
gea< clearance • Measure wear of main drive, 1st and OD baulk rings.
Unit: mm (in)

Standard Wear limit

1st 1.05- 1.3 (0.0413- 0.0512) 0.7 (0.028)

Main drive 1.05- 1.3 (0.0413- 0.0512) 0.7 (0.028)
OD 1.05- 1.3 (0.0413- 0.0512) 0.7 (0.028)

If the clearance is smaller than the wear limit, replace baulk

SMT14D ring.

MT-43 531
 INSPECTION FS5R30A

Gear Components (Cont'd)

Inner baulk ring • Measure wear of 2nd and 3rd baulk rings.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk rings against synchronizer cone as far
as it will go, measure dimensions "A" and "B".
Unit· mm (in)

Dimension Standard Wear limit

A 0.6 " 1.1 (0.024 " 0.043)
0.2 (0.008)
B 0.7 " 0.9 (0.028 " 0.035)

c. If dimension "A" or "B" is smaller than the wear limit,

replace baulk ring.
Outer baulk ring
Synchronizer cone
~~~~~2nd outer baulk ring
Feeler gauge

SMT042B

• Measure wear of reverse baulk ring.

a. Place baulk ring in position on reverse cone.
b. While holding baulk ring against reverse cone as far as it
will go, measure dimension "A" with dial indicator.
Dimension "A":
Standard -0.1 to 0.35 mm (-0.0039 to 0.0138 in)
Wear limit 0.7 mm (0.028 in)
c. If dimension "A" is larger than the wear limit, replace baulk
ring.

SMT424A

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

MT-44 532
 ASSEMBLY I FS5R30A I

Gear Components
Counter gear front bearing in transmission case Mainshalt front bearing in adapter plate

-{;( ~0 0 Iilli

SMT397A
Counter gear rear bearing in adapter plate

/ _1:)..

--- KV38100300
(J25523)

SMT391A SMT484CA ~l

1. Install bearings into case components.

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 to minimize clear-

ance of groove. rp~
Allowable clearance of groove:
0- 0.1 mm (0- 0.004 in)
Main drive gear snap ring: ~LA\
Refer to SDS, MT -59.
d. Install selected snap ring on main drive gear.

3. Install components on counter gear.

a. Install sub-gear components. [i!if
When installing sub-gear snap ring, tap sub-gear snap ring
into position on counter gear.

SMT577A

MT-45 533
 ASSEMBLY I FS5R30A I
Gear Components (Cont'd)
b. Install counter gear rear thrust bearing.

SMT405A

4. Install front side components on mainshaft.

a. Assemble 1st & 2nd synchronizer.

SMT614B

b. Assemble 3rd & 4th synchronizer.

Rear Q

SMT615B

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

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

SMT399A

d. Select proper snap ring to minimize clearance of groove.

Allowable clearance of groove:
0 - 0.1 mm (0- 0.004 in)
Mainshaft front snap ring:
Refer to SDS, MT-59.
e. Install selected snap ring on mainshaft.

SMT400A

MT-46 534
 ASSEMBLY I FS5R30A I
Gear Components (Cont'd)
f. Press on 1st & 2nd synchronizer assembly together with
2nd main gear and 2nd gear needle bearing.

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

h. Install 1st main gear and needle bearing.

~~ ~
!"!":

1~~~~~;;:==============S=M=T®=2lA i. Install steel ball and 1st gear washer. ~~

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

5. Select proper counter gear front bearing thrust washer

when replacing transmission case, counter gear, counter ["&1
Counter gear front gear thrust bearing or sub-gear components.
thrust a. Install counter gear with sub-gear components, counter
Sub-gear gear front and rear bearing thrust washer on adapter plate. ~lt!l
components b. Remove counter gear front bearing thrust washer from
transmission case.
gear c. Place adapter plate and counter gear assembly in trans- Bi11
mission case (case inverted).

SMT427AA

MT-47 535
 ASSEMBLY I FS5R30A I
Gear Components (Cont'd)
d. Tighten adapter plate to 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 indica-
tor deflection.
g. Select proper thrust washer 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
thrust washer:
Refer to SDS, MT -60.

SMT578A

6. Select proper reverse idler rear thrust washer when replac-

A--Reverse idler shaft
U/ Reverse idler
~front thrust washer
a.
ing rear extension (or OD gear case), reverse idler gear,
reverse idler shaft or reverse idler thrust washer.
Install reverse idler gear, reverse idler needle bearings,
reverse idler thrust washers and reverse idler shaft into
rear extension (or OD gear case).
When replacing reverse idler rear washer, install either A
or B.
Reverse idler rear thrust washer:
Refer to SDS, MT-60.

SMT432A

MT-48 536
 ASSEMBLY I FS5R30A I
Gear Components (Cont'd)
b. Place dial indicator on front end of reverse idler shaft.
c. Put straightedge on front surface of rear extension (or OD
gear case.) 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 mm (0.0118 - 0.0209 in)
e. If not within specification, replace reverse idler rear thrust l~ffil
washer with the other (A or B) and check again.

Straightedge

SMT433A

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 to counter gear rear bearing.

11'

b. Install mainshafl a little on mainshafl front bearing.

To allow for installation of counter gear, do not install main- if$\
shalt completely.

c. Install counter gear on counter gear rear bearing and

install main drive gear, pilot bearing and spacer on main- ~!"
shaft.

MT-49 537
 ASSEMBLY I FS5R30A I
Gear Components (Cont'd)
Push up with When installing counter gear into counter gear rear bearing,
push up on upper roller of counter gear rear bearing with
screwdriver.

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

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

i and
C-ring holder

f. Install mainshafl and counter gear completely by extending

length of J26349-3.

8. Install rear side components on mainshafl and counter

gear.
a. Install 00 gear bushing while pushing on the front of
counter gear.

b. Install 00 main gear.

Pay attention to direction of OD main gear. (B is wider than
A as shown at left.)
c. Install adapter plate with gear assembly onto transmission
case.
d. Install 00 gear needle bearing and then install 00 counter
gear and reverse idler shaft.

MT-50 538
 ASSEMBLY I FSSR30A I
Gear Components (Cont'd)
e. Install reverse gear bushing with speedometer drive gear
(2WD model).

f. Install reverse cone.

ST37750000
(J34332)

SMT582A

Insert spring g. Install insert springs and reverse baulk ring on OD coupling
sleeve. Then install them and OD baulk ring on OD counter
gear.
Reverse baulk ring Pay attention to direction of OD coupling sleeve.

SMT571AA

h. Install reverse counter gear.

i. Install reverse gear needle bearing and then install reverse ~i'
main gear, reverse idler gear and reverse idler thrust
washers.

IJ343341

1!1!1
MT-51
539
 ASSEMBLY I FS5R30A I
Gear Components (Cont'd)
j. Install reverse hub.
Pay attention to its direction.

k. Install mainshaft spacer and mainshaft rear bearing (2WD

model).

I. Install counter gear rear end bearing.

m. Separate adapter plate from transmission case and mount
adapter plate on vice again.

n. Select proper mainshaft C-ring to minimize clearance of

groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Mainshafl C-ring:
Refer to SDS, MT-60.

SMT452A

o. Install selected C-ring, C-ring holder and mainshaft rear

snap ring.

MT-52 540
 ASSEMBLY I FS5R30A I
Gear Components (Cont'd)
p. Install spacer and then select proper counter gear rear
snap ring to minimize clearance of groove.
Allowable clearance of groove:
0- 0.1 mm (0- 0.004 in)
Counter gear rear snap ring: @I
Refer to SDS, MT -60.
q. Install selected counter gear rear snap ring.

r. Install reverse coupling sleeve.

Pay attention to its direction.
s. Measure each gear end play as a final check - Refer to
"DISASSEMBLY", MT-39.

Shift Control Components

1. Install OD fork rod and OD shift fork. Then install retaining IF&\
pin into OD shift fork.
2. Install 1st & 2nd, 3rd & 4th and reverse shift fork onto cou-
pling sleeve.

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

MT-53 541
 ASSEMBLY I FS5R30A I

Case Components
1. Install front cover oil seal.
Apply multi-purpose grease to seal lip.
2. Install selected counter gear front bearing shim onto trans-
ST33210000
(J25803-01) mission case.
Apply multi-purpose grease.
3. Apply sealant to mating surface of transmission case.

SMT393A

4. Install gear assembly onto transmission case.

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

6. Install interlock stopper assembly and then tighten check

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

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

8. Install front cover and gasket.

Apply sealant to thread of 3 bolts shown left.
9. Apply sealant to mating surface of adapter plate.

MT-54 542
 ASSEMBLY I FS5R30A I
Case Components (Cont'd)
10. Install rear extension (or OD gear case) together with strik-
ing arm.

11. Install retaining pin into striking arm.

u:

12. Install return spring and check ball and then install control
housing.
Apply sealant to mating surface of rear extension (or OD
gear case).

2WD model 4WDmodel 13. Tighten control housing bolts.

Boll head size:
A bolts 12 mm (0.47 in)
B bolls 13 mm (0.51 in)

SMT572A

MT-55 543
 SERVICE DATA AND SPECIFICATIONS (SDS) IFS5W71C & FS5R30A!

General Specifications
KA24E VG30E

Applied model 2WO

2WO 4WO 4WO
Truck Wagon

Transmission FS5W71C FS5R30A

Number of speed 5

1 3 5

~.)_j
Shift pattern
2
II
4 A

Synchromesh type Warner

Gear ratio

1st 3.321 3.985 3.580 4.061

2nd 1.902 2.246 2.077 2.357

3rd 1.308 1.415 1.360 1.490

4th 1.000 1.000 1.000 1.000

00 0.838 0.821 0.811 0.862

Reverse 3.382 3.657 3.636 4.125

Number of teeth

Mainshaft

Drive 22 21 22 20

1st 33 34 32 32

2nd 27 28 30 30

3rd 26 26 29 28

00 22 21 24 23

Reverse 36 36 30 30

Counters haft

Drive 31 32 32 33

1st 14 13 13 13

2nd 20 19 21 21

3rd 28 28 31 31

00 37 39 43 44

Reverse 15 15 12 12

Reverse idler gear 21 21 22 22

Oil capacity
2.0 (4-114, 3-1/2) 4.0 (8-112, 7) 2.4 (5-1/8, 4-1/4) 3.6 (7-518, 6-318)
C (US pt, Imp pt)

Mainshaft braking Reverse synchro-

Remarks mechanism nizer 2nd & 3rd double baulk ring type synchronizer
2nd double baulk ring type synchronizer

MT-56 544
 SERVICE OAT A AND SPECIFICATIONS (SDS) FS5W71C

Inspection and Adjustment

GEAR END PLAY AVAILABLE SNAP RINGS
Unit: mm (in)
Main drive gear bearing
1st gear 0.31. 0.41 (0.0122. 0.0161)
@~
2nd gear 0.11 - 0.21 (0.0043 - 0.0083) Allowable clearance 0 - 0.13 mm {0 - 0.0051 in)

3rd gear 0.11 . 0.21 (0.0043 . 0.0083) Thickness mm (in) Part number

1.73 (0.0681) 32204-78005 ~II\

OD gear 0.24. 0.41 (0.0094. 0.0161)
1.80 (0.0709) 32204-78000
1.87 (0.0736) 32204-78001
CLEARANCE BETWEEN BAULK RING AND 1 94 (0.0764) 32204-78002 li"~TI
GEAR 2.01 (0.0791) 32204-78003
Unit: mm (in) 2.08 (0.0819) 32204-78004

Standard
u:
1s1 1.20 - 1.60 (0.0472 - 0.0630)
Mainshaft front
!'!F ~
3rd & main drive 1.20 - 1.60 (0.0472 - 0.0630)
Allowable clearance 0- 0.18 mm (0- 0.0071 in) !Ell:
DO 1.20- 1.60 (0.0472- 0.0630)
Thickness mm (in) Part number
Reverse (4WD) 1.10. 1.55 (0.0433- 0.0610)
2.4 (0.094) 32263-V5200 T~
Wear limit 2.5 (0.098) 32263-V5201
2.6 (0.102) 32263-V5202
1s1 0.80 (0.0315)
!:l
3rd & main drive 0.80 (0.0315)

OD 0.80 (0.0315)
Mainshaft rear end bearing
Reverse (4WD) 0.70 (0.0276) (2WD model)

Allowable clearance 0-0.14 mm {0- 0.0055 in)

2nd baulk ring
Thickness mm {in) Part number
Unit mm {in)
1.1 (0.043) 32228-20100
Outer baulk ring 1.2 (0.047) 32228-20101
1.3 (0.051) 32228-20102
B 1.4 (0.055) 32228-20103

Counter drive gear

Allowable clearance 0- 0.18 mm (0- 0.0071 in)

Inner baulk ring Thickness mm (in) Part number

1.4 (0.055) 32215-E9000

\..__ Synchronizer cone
1.5 (0.059) 32215-E9001
SMT0448 1.6 (0.063) 32215-E9002

Dimension Standard Wear limit

0.6-1.1
A
(0 024 . 0.043)
0.2 (0.008)
0.7- 0.9
B
(0.028 - 0.035)

MT-57 545
 SERVICE DATA AND SPECIFICATIONS (SDS) I FS5W71C I
Inspection and Adjustment (Cont'd)
AVAILABLE SHIMS
Counter front bearing
Unit mm {in)

A A: Distance from bearing

surface to transmission
case

G) Transmission case
(2) Counter gear front bearing
@ Counter gear
TM371

Thickness of
"A" Part number
shim

4.52-4.71 (0.1780- 0.1854) Not necessary

4.42-4.51 (0.1740- 0.1776). 0.1 (0.004) 32218-VSOOO

4.32-4.41 (0.1701- 0.1736) 0.2 (0.008) 32218-V5001

4.22-4.31 (0.1661- 0.1697) 0.3 (0.012) 32218-V5002

4.12-4.21 (0.1622- 0.1657) 0.4 (0.016) 32218-V5003

4.02-4.11 (0.1583- 0.1618) 0.5 (0.020) 32218- v5004

392-4.01 (0.1543- 0.1579) 0.6 (0.024) 32218-VSOOS

MT-58 546
 SERVICE DATA AND SPECIFICATIONS (SDS) I FS5R30A I

Inspection and Adjustment

GEAR END PLAY DISTANCE BETWEEN REAR SURFACE OF
REVERSE CONE AND REVERSE BAULK
Gear End play mm (in) RING
1st main gear 0.23- 0.33 (0.0091 - 0.0130) ---------------------

2nd main gear 0.23- 0.33 (0.0091 - 0.0130) (Re~emcone

~
3rd main gear 0.23- 0.33 (0.0091 - 0.0130)

OD counter gear 0.23- 0.33 (00091 - 0.0130)

Reverse main gear 0.33- 0.43 (0.0130- 0.0169) rin~

Reverse baulk

Counter gear 0.10-0.25 (0.0039- 0.0098)

Reverse idler gear 0.30- 0.53 (0.0118- 0.0209) Unit· mm (in)

Standard Wear limit

CLEARANCE BETWEEN BAULK RING AND Dimension "A"

-0.1 to 0.35
0.7 (0.028)
GEAR (-0.0039 to 0.0138} ~n
Unit: mm (in) ~t

Standard Wear limit AVAILABLE SNAP RING

1st 1.05- 1.3 (0.0413- 0.0512) 0.7 (0028) Main drive gear snap ring
Main drive 1.05- 1.3 {0.0413- 0.0512) 0.7 (0028)
Allowable clearance 0 ~ 0.1 mm (O- 0.004 in)
00 1.05- 1.3 (0.0413- 0.0512) 0.7 (0.028)
Thickness mm (in) Part number

1.89 (0.0744) 32204-01G60

2nd and 3rd baulk ring
1.95 (0.0768) 32204-01G61
Outer baulk ring 1.99 (0.0783) 32204-01G62

8
2.03 (0.0799) 32204-01 G63 121T
2.07 (0.0815) 32204-01 G64

2.11 (0.0831) 32204-01G65

2.15 (0.0846) 32204-01 G66

2.19 (0.0862) 32204-01 G67

Inner baulk ring

\.__ Synchronizer cone Mainshafl front snap ring

SMT0448 Allowable clearance 0-0.1 mm (0- 0.004 in)
Unit: mm (in) Thickness mm (in) Part number
-----
Dimension Standard Wear limit 1.89 (0.0744) 32204-01G60
0.6 - 1.1 1.95 (0.0768) 32204-01G61
A 0.2 (0.008)
(0.024- 0.043)
1.99 (0.0783) 32204-01G62
0.7- 0.9
B 0.2 (0.008) 2.03 (0.0799) 32204-01 G63
(0.028- 0.035)
2.07 (0.0815) 32204-01 G64

2.11 (0.0831) 32204-01 G65

2.15 (0.0846) 32204-01 G66

2.19 (0.0862) 32204-01 G67

MT-59 547
 SERVICE DATA AND SPECIFICATIONS (SDS) FS5R30A
Inspection and Adjustment (Cont'd)
Counter gear rear snap ring AVAILABLE SHIM AND WASHER

Allowable clearance 0-0.1 mm (0- 0.004 in) Table for selecting proper counter gear
front bearing thrust washer
Thickness mm (in) Part number
1.26 (0.0496) 32236-01 GOB Thickness of
Dial indicator deflection
1.32 (0.0520) 32236-01800 proper washer Part number
mm (in)
mm (in)
1.38 (0.0543) 32236-01 G01
0.93 - 1.02 (0.0366 - 0.0402) 0.88 (0.0346) 32218-01G11
1.44 (0.0567) 32236-01 G02
1.03- 1.12 (0.0406- 0.0441) 0 96 (0 0378) 32218-01G12
1.50 (0.0591) 32236-01803
1.13-1.22 (0.0445- 0.0480) 1.04 {0.0409) 32218-01G13
1.56 (0.0614) 32236-01 G04
1.23- 1.32 (0.0484- 0.0520) 1.12 (0.0441) 32218-01G14
1.62 (0.0638) 32236-01 G05
1.33- 1.42 (0.0524- 0.0559) 1.28 (0.0504) 32218-01G15
1.68 (0.0661) 32236-01 G06
1.43 - 1.52 (0.0563 - 0.0598) 1.36 (0.0535) 32218-01G16
1.74 (0.0685) 32236-01 G07
1.53 - 1.62 (0.0602 - 0.0638) 1.44 (0.0567) 32218-01G17

AVAILABLE C-RING
Reverse idler rear thrust washer
Mainshaft C-ring
Thickness mm (in) Part number
Allowable clearance 0-0.1 mm (0- 0.004 in) 1.97 (0.0776) 32284-01G10
Thickness mm (in) Part number 2.07 (0.0815) 32284-01G11
2.63 (0.1035) 32348-01815

2.70 (0.1063) 32348-01 GOO

2.77 (0.1091) 32348-01 G01

2.84 {0.1118) 32348-01802

2.91 (0.1146) 32348-01803

2.98 (0.1173) 32348-01 G04

3.05 (0.1201) 32348-01 G05

3.12 (0.1228) 32348-01 G06

3.19 (0.1256) 32348-01807

3.26 (0.1283) 32348-01808

3.33 (0.1311) 32348-01 G09

3.40 (0.1339) 32348-01 G 10

3.47 (0.1366) 32348-01G11

3.54 (0.1394) 32348-01G12

3.61 (0.1421) 32348-01G13

3.68 (0.1449) 32348-01G14

MT-60 548