Manual Transaxle: Section

MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
SECTION
MANUAL TRANSAXLE
MT B
MT
E
CONTENTS
JR5 SEPARATING THE HOUSINGS ............................... 20 F
Removal ................................................................. 20
PREPARATION ........................................................... 3 REPAIRING THE GEARBOX ................................... 22
Special Service Tools ............................................... 3 Removal ................................................................. 22 G
Commercial Service Tools ........................................ 4 Removing The Gearing .......................................... 23
DESCRIPTION ............................................................ 5 Checking Parts ....................................................... 23
Cross-Sectional View — JR5 ................................... 5 Refitting The Gearing ............................................. 24
DOUBLE-CONE SYNCHRONIZER ...................... 6 H
TRANSAXLE CASE BEARING ................................ 25
REMOVAL AND INSTALLATION ............................... 7 Removing The Bearing, Input Shaft Side ............... 25
Removal ................................................................... 7 Refitting .................................................................. 25
Installation ................................................................ 7 CLUTCH HOUSING BEARING ................................ 26 I
TIGHTENING TORQUES ........................................... 8 Removal and Installation ........................................ 26
Description ............................................................... 8 SELECTOR SHAFT RINGS ...................................... 27
COMPONENTS .......................................................... 9 Removal ................................................................. 27 J
Gear Components .................................................... 9 DIFFERENTIAL BEARINGS ..................................... 28
Differential Gear ..................................................... 10 Removal and Installation ........................................ 28
Shift Control Components ...................................... 10 SELECTOR SHAFT .................................................. 29
Case Components ..................................................11 K
Removal ................................................................. 29
Clutch Housing ........................................................11 Refitting .................................................................. 29
CONTROL LINKAGE ............................................... 12 REPAIRING THE GEARBOX ................................... 30
Removal and Installation of Control Device and Setting The Pre-tensioning of The Mainshaft Bear- L
Cable ...................................................................... 12 ings ......................................................................... 30
RATIOS ..................................................................... 13 ASSEMBLY ............................................................... 31
NISSAN Gearbox ................................................... 13 Refitting .................................................................. 31 M
CONSUMABLES ...................................................... 14 HOUSING ASSEMBLY ............................................. 33
Description ............................................................. 14 Assembly ................................................................ 33
CAPACITIES - LUBRICANTS .................................. 15
Description ............................................................. 15
TROUBLE DIAGNOSIS ............................................ 16
RS6F51R
Symptom Chart ...................................................... 16 PRECAUTIONS ........................................................ 36
Back-up Lamp Switch ............................................ 16 Caution ................................................................... 36
PRECAUTIONS ........................................................ 17 PREPARATION ......................................................... 37
Precautions ............................................................ 17 Special Service Tools ............................................. 37
PARTS TO BE REPLACED SYSTEMATICALLY ..... 18 Commercial Service Tools ...................................... 39
Description ............................................................. 18 NOISE, VIBRATION AND HARSHNESS (NVH)
CHECKING ............................................................... 19 TROUBLESHOOTING .............................................. 40
Bearings ................................................................. 19 NVH Troubleshooting Chart ................................... 40
Gearing .................................................................. 19 MANUAL TRANSAXLE ....................................... 40
Synchronizer Ring .................................................. 19
Sliding Gear Hub .................................................... 19
MT-1
DESCRIPTION .......................................................... 41 MAINSHAFT AND GEARS .......................................77
Cross-Sectional View .............................................. 41 Assembly and Disassembly ....................................77
DOUBLE-CONE SYNCHRONIZER .................... 42 DISASSEMBLY ....................................................77
REVERSE GEAR NOISE PREVENTION FUNC- INSPECTION AFTER DISASSEMBLY ................78
TION (SYNCHRONIZING METHOD) .................. 42 ASSEMBLY ..........................................................80
M/T OIL ...................................................................... 43 REVERSE IDLER SHAFT AND GEARS ..................86
Changing M/T Oil .................................................... 43 Assembly and Disassembly ....................................86
DRAINING ........................................................... 43 DISASSEMBLY ....................................................86
FILLING ............................................................... 43 INSPECTION AFTER DISASSEMBLY ................86
Checking M/T Oil .................................................... 43 ASSEMBLY ..........................................................87
OIL LEAKAGE AND OIL LEVEL ......................... 43 FINAL DRIVE ............................................................88
SIDE OIL SEAL ......................................................... 44 Assembly and Disassembly ....................................88
Removal and Installation ........................................ 44 PRE-INSPECTION ..............................................88
REMOVAL ........................................................... 44 DISASSEMBLY ....................................................88
INSTALLATION .................................................... 44 INSPECTION AFTER DISASSEMBLY ................89
POSITION SWITCH .................................................. 45 ASSEMBLY ..........................................................89
Checking ................................................................. 45 SHIFT CONTROL ......................................................92
BACK-UP LAMP SWITCH ................................... 45 Inspection ................................................................92
NEUTRAL POSITION SWITCH .......................... 45 SHIFT FORK ........................................................92
CONTROL LINKAGE ................................................ 46 SERVICE DATA AND SPECIFICATIONS (SDS) ......93
Removal and Installation of Control Device and General Specifications ............................................93
Cable ...................................................................... 46 TRANSAXLE ........................................................93
AIR BREATHER HOSE ............................................. 47 FINAL GEAR ........................................................93
Removal and Installation ........................................ 47 Gear End Play .........................................................94
TRANSAXLE ASSEMBLY ........................................ 48 Clearance Between Baulk Ring and Gear ..............94
Removal and Installation ........................................ 48 3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING...94
REMOVAL ........................................................... 48 1ST AND 2ND DOUBLE BAULK RING ...............94
INSTALLATION .................................................... 49 Available Snap Rings ..............................................94
Component Parts .................................................... 50 6TH BUSHING .....................................................94
CASE AND HOUSING COMPONENTS .............. 50 Available C-rings .....................................................95
GEAR COMPONENTS ........................................ 51 MAINSHAFT C-RING ..........................................95
SHIFT CONTROL COMPONENTS ..................... 53 Available Thrust Washer .........................................95
FINAL DRIVE COMPONENTS ............................ 54 INPUT SHAFT THRUST WASHER .....................95
Disassembly and Assembly .................................... 54 DIFFERENTIALSIDEGEARTHRUSTWASHER
DISASSEMBLY ................................................... 54 ...95
ASSEMBLY ......................................................... 58 Available Adjusting Shims .......................................96
Adjustment .............................................................. 65 MAINSHAFT ADJUSTING SHIM .........................96
INPUTSHAFT END PLAY ................................... 65 INPUT SHAFT REAR BEARING ADJUSTING
DIFFERENTIAL SIDE BEARING PRELOAD ...... 66 SHIM ....................................................................96
MAINSHAFT END PLAY ..................................... 67 MAINSHAFT REAR BEARING ADJUSTING
REVERSE IDLER GEAR END PLAY .................. 68 SHIM ....................................................................96
INPUT SHAFT AND GEARS .................................... 70 REVERSE IDLER GEAR ADJUSTING SHIM ......96
Assembly and Disassembly .................................... 70 6TH MAIN GEAR ADJUSTING SHIM ..................97
DISASSEMBLY ................................................... 70 Available Shims ......................................................97
INSPECTION AFTER DISASSEMBLY ................ 71 BEARING PRELOAD ...........................................97
ASSEMBLY ......................................................... 72 DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM (S) ..............................................................97
MT-2
PREPARATION
[JR5]
PREPARATION
[JR5] PFP:00002
A
Special Service Tools ECS00F40
Tool number
Description
Tool name B
B. Vi. 1581 Disassembly and assembly for transmission or
Transmission stand transaxle
MT
D
YMT029
B. Vi. 31-01 Removing and installing retaining pin

Pin punch
E
F
YMT030
B. Vi. 1170 Removing 5th synchronizer

Puller G
YMT031
B. Vi. 22-01 Removing 5th gear I

Puller
B. Vi. 1000-01 Removing 5th gear
Puller J
MCIB0026E
L
B. Vi. 1576 Removing input shaft bearing

Mandrel
M
YMT032
B. Vi. 1601 Installing bearing guide of mainshaft

Mandrel
YMT033
MT-3
PREPARATION
[JR5]
Tool number
Description
Tool name
Power tool Installing bearing race
YMT034
B. Vi. 1175 Installing 5th gear

Installer
YMT035
B. Vi. 1666 Installing differential oil seal

Drift
YMT036
Commercial Service Tools ECS00F41
Tool name Description

Power tool Loosening bolts and nuts
PBIC0190E
MT-4
DESCRIPTION
[JR5]
DESCRIPTION PFP:00000
A
Cross-Sectional View — JR5 ECS00F42
MT
MCIB0070E
MT-5
DESCRIPTION
[JR5]
DOUBLE-CONE SYNCHRONIZER
— JR5 —
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.
YMT037
MT-6
REMOVAL AND INSTALLATION
[JR5]
REMOVAL AND INSTALLATION PFP:00000
A
Removal ECS00F43
CAUTION:
Remove the crankshaft position sensor (POS) from transaxle assembly before separating transaxle B
from engine. Be careful not to damage sensor edge.
1. Remove the engine room cover. Refer to EM-241, "ENGINE ROOM COVER" .
2. Remove the air cleaner duct. Refer to EM-244, "AIR CLEANER AND AIR DUCT" . MT
3. Disconnect the cable end ball of select cable and the cable end of shift cable. Refer to MT-12, "CONTROL
LINKAGE" .
4. Disconnect the clutch tube. Refer to CL-20. D
5. Remove the engine mounting LH side installation bolts. Refer to EM-268, "ENGINE ASSEMBLY" .
6. Set the engine hunger.
E
MBIB0585E
H
7. Remove the LH and RH drive shafts. Refer to AX-10, “Drive shaft”.
8. Remove the transaxle mounting nuts and bolts, and the remove the transaxle.
I
Installation ECS00F44
Install in the reverse order of removal.

J
MT-7
TIGHTENING TORQUES
[JR5]
TIGHTENING TORQUES PFP:32010
Description ECS00F46
Tightening portion N·m (kg-m, ft-lb)

Gearbox casing bolt 25 (2.6, 18)
Mainshaft bolt 70 (7.1, 52)
Input shaft nut 190 (19, 140)
Rear cover bolt 25 (2.6, 18)
Back-up lamp switch 25 (2.6, 18)
Clutch operating cylinder bolt 21 (2.1, 15)
Selector shaft bolt 20 (2.0, 15)
Gear shift catch bolt 10 (1.0, 7)
Reverse gear fork support bolt 25 (2.6, 18)
Drain bolt 25 (2.6, 18)
Selector shaft balls 23 (2.3, 17)
MT-8
COMPONENTS
[JR5]
COMPONENTS PFP:32010
A
Gear Components ECS00F47
MT
G
MCIB0071E
1. Oil channel 2. Mainshaft front bearing 3. Mainshaft

4. 1st main gear 5. Synchronizer ring 6. Spread spring H
7. 1st & 2nd synchronizer hub 8. Mainshaft bearing 9. 2nd main gear
10. Adapter plate 11. 3rd main gear 12. Baulk ring
13. 3rd & 4th synchronizer hub and 14. 4th main gear 15. Mainshaft rear bearing I
reverse gear
16. 5th main gear 17. Bolt 18. Bearing guide
19. Input shaft 20. Retaining clip 21. Input shaft rear bearing
J
22. 2nd & 3rd gear bushing 23. 5th main gear 24. 5th synchronizer hub
25. Nut
MT-9
COMPONENTS
[JR5]
Differential Gear ECS00F48
1 Oil seal
2 Differential side bearing
3 Differential case
4 Speedometer gear
5 Pinion mate gear
6 Bevel side gear
7 Pinion mate shaft
8 Shaft retaining spring
9 Side gear thrust washer
MCIB0011E
Shift Control Components ECS00F49
1 Control assembly
2 Striking interlock assembly
3 Fork rod (For 1st and 2nd)
4 Fork rod (For 3rd and 4th)
5 Fork rod (For 5th)
6 Lock pin
7 Check ball
8 Check ball spring
9 Special bolt [20 N·m (2.0 kg-m, 15 ft-lb)]
10 Lock pin
11 Interlock pin
12 Lock pin
13 Reverse idler gear assembly
14 Interlock pin
MCIB0012E
MT-10
COMPONENTS
[JR5]
Case Components ECS00F4A
A
1 Transaxle case
2 Filler plug
3 Dowel pin B
4 Oil gutter
5 Breather pipe
MT
6 Back-up lamp switch
7 O-ring
8 Transaxle case cover D
9 Gearbox edge bolt [25 N·m (2.6 kg-m, 18 ft-lb)]
10 Fifth gear housing bolt [25 N·m (2.6 kg-m, 18 ft-lb)]
E
MCIB0013E
Clutch Housing ECS00F4B

H
1 Clutch housing
2 Drain bolt [25 N·m (2.6 kg-m, 18 ft-lb)] I
3 Magnet
4 Clutch operating cylinder
J
5 Clutch operating cylinder bolt [21 N·m (2.1 kg-m, 15 ft-lb)]
MCIB0014E
MT-11
CONTROL LINKAGE
[JR5]
CONTROL LINKAGE PFP:34103
Removal and Installation of Control Device and Cable ECS00F45
Refer to the figure for removal and installation procedure.
YMT039
CAUTION:
● Keep in mind that the select side lock plate for securing the control cable is different from the one
on the shift side.
● After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st,
2nd, or Reverse.
MT-12
RATIOS
[JR5]
RATIOS PFP:32010
A
NISSAN Gearbox ECS00F4C
Suffix First Second Third Fourth Fifth Reverse gear Final drive
JR5-106 11:41 21:43 28:37 35:34 42:31 11:39 15:56 B
JR5-114 11:41 21:43 28:37 35:34 42:31 11:39 15:56
MT
MT-13
CONSUMABLES
[JR5]
CONSUMABLES PFP:32010
Description ECS00F4D
Types Packaging Parts Department No. Component

Gearbox oil Cover all parts
RHODORSEAL 100 g tubes 77 01 404 452 Housing assembly
LOCTITE 518 24 ml syringe 77 01 421 162 Back-up lamp switch threading
MT-14
CAPACITIES - LUBRICANTS
[JR5]
CAPACITIES - LUBRICANTS PFP:32010
A
Description ECS00F4E
Capacity Grade
B
2.3 (2 Imp qt) TRJ 75W80
Fill to the level of the fuel filler cap hole.

MT
MCIB0015E
MT-15
TROUBLE DIAGNOSIS
[JR5]
TROUBLE DIAGNOSIS PFP:00004
Symptom Chart ECS00F4F
Symptoms (after checking

Possible causes
the clutch)
Engine
Oil level External Synchro- Sliding Fork and
Symptoms Gearing Bearings mounting
or grade control nizer gear hub balls
- housing
Gear grinding 1 2 3 4
One or more gears
1 2 3 4
cannot be selected
Gear disengagement 2 4 4 3 1
One or more gears
1 4 2 3
locked
Noisy 1 3 2
NOTE:
The numbers indicate the order of priority for diagnostics.
Back-up Lamp Switch ECS00F4G
Gear position Continuity

Reverse Yes
Except reverse No
YMT038
MT-16
PRECAUTIONS
[JR5]
PRECAUTIONS PFP:00001
A
Precautions ECS00F4H
Removing and handling the parts must be carried out on a workbench with a knockproof cover. (rubber or thick
plastic) B
Cover all turning and synchronizer points in oil.
Observe the tightening torques.
Carefully carry out the specific settings and adjustments.
Be sure to properly refit parts in the same order and position after removal. MT
Marking the position of the sliding rods in relation to the hubs before removal is recommended.
During refitting, make sure the inside of the box remains free of dust or impurities.
D
MT-17
PARTS TO BE REPLACED SYSTEMATICALLY
[JR5]
PARTS TO BE REPLACED SYSTEMATICALLY PFP:32010
Description ECS00F4I
If they have been removed:

● the lip seals,
● the O-rings,
● the gear supporting rings,
● the roll pins,
● the input shaft bearing circlips,
● the sliding gear hub springs.
MT-18
CHECKING
[JR5]
CHECKING PFP:32010
A
Bearings ECS00F4Y
Check that the bearings show no signs of damage and that they turn
evenly. Replace them if necessary. B
MT
MCIB0017E
E
Gearing ECS00F4Z
NOTE:
The inspection focuses mainly on the appearance of the teeth, espe- F
cially in terms of claw chamfers.
1. Check that the teeth (A) are not broken or chipped.
2. Check that the claws (B) are not broken, chipped or worn. G
3. Check that the friction cone (C) shows no scratches or blueness.
MCIB0018E
I
Synchronizer Ring ECS00F50
Check that the grooves and ridges on the ring are not worn or dam-
J
aged.
1. Checking put the ring onto the gear cone.
2. Checking rotate the ring while applying force in the direction of
K
the cone (D).
3. Checking the ring should lock against the cone.
Otherwise, replace the synchronizer ring. L
MCIB0019E
M
Sliding Gear Hub ECS00F51
Make sure the sliding gear turns smoothly in the hub.

Check that the rollers or keys are in good condition.
MCIB0020E
MT-19
SEPARATING THE HOUSINGS
[JR5]
SEPARATING THE HOUSINGS PFP:32010
Removal ECS00F4J
Fit the B. Vi. 1581 support plate on a Desvil stand.

Fit the gearbox on the B. Vi. 1581 support.
MCIB0021E
1. Remove the clutch operating cylinder.

2. Remove the bolts located inside the housing.
MCIB0022E
3. Remove the rear housing. This must be removed along the hori-
zontal axis of the gearbox because it has a lubrication spline
which is located in the input shaft bore.
MCIB0023E
Remove the two reverse gear fork support mounting bolts (A).
Drive in the 5th gear fork using B. Vi. 31-01.
Shift the 3rd gear on the gear selector lever and the 5th gear by slid-
ing the 5th gear fork on its shaft.
4. Remove the mainshaft bolt (B).
5. Remove the input shaft nut (C).
6. Remove the reverse gear synchronizer.
7. Remove the 5th gear fork and sliding gear.
MCIB0024E
MT-20
SEPARATING THE HOUSINGS
[JR5]
Remove the 5th gear hub using B. Vi. 1170.
To do this, fit the sliding gear B. Vi. 1170 and rotate it so that the A
splines are opposite those of the input shaft hub.
MT
MCIB0025E
D
Remove the fixed 5th gear using B. Vi. 22-01 and B. Vi. 1000-01.
Remove the gearbox edge bolts.
E
G
MCIB0026E
Remove the back-up lamp switch (B). H

Engage 3rd gear.
Lift and remove the mechanism housing.
I
K
MCIB0027E
MT-21
REPAIRING THE GEARBOX
[JR5]
REPAIRING THE GEARBOX PFP:32010
Removal ECS00F4K
1. Remove the 4th-gear pinion.
MCIB0028E
2. Remove the 3rd/4th gear shaft/fork and sliding gear assembly

while gently lifting the mainshaft assembly.
MCIB0029E
3. Remove mainshaft assembly.
MCIB0030E
4. Remove input shaft assembly.
MCIB0031E
MT-22
[JR5]
5. Remove the 1st/2nd shaft and fork and the 5th gear shaft.
A
MT
MCIB0032E
D
6. Remove the pin from the reverse gear and remove the reverse
gear.
E
G
MCIB0033E
Removing The Gearing ECS00F4L

H
NOTE:
The rings underneath the 2nd, 3rd and 4th gears are fitted tightened.
They will be systematically replaced during refitting. I
1. Remove the ring/hub/3rd gear assembly with the press, resting
underneath the third gear claw teeth.
J
MCIB0072E
L
2. Remove the rings/1st and 2nd gears/hub/sliding gear assembly
with the press, resting underneath the 1st gear.
M
MCIB0073E
Checking Parts ECS00F4M
The sprocket teeth and the claws should not be chipped or excessively worn.
Also ensure that there are no signs of grating or abnormal wear on the surfaces of the shafts or the inner walls
of the sprockets.
It is advisable to mark the position of the sliding shafts in relation to the hub.
MT-23
[JR5]
Refitting The Gearing ECS00F4N
A hot plate with a setting of 150°C (302°F) should be used for refit-
ting.
Place the new rings on the cold hot plate. Heat them for 15 minutes
with a thermostat setting of 150°C (302°F).
MCIB0074E
Proceed in the reverse order to removal.

Refit the rings:
Remove a ring from the heating plate, using pliers, and use a tube
with an internal diameter of 33 mm (1.30 in) to fit it on the shaft until
it is resting on the hub.
NOTE:
The first/second gear has double-cone synchronizer, bring the
notches of the synchro rings together with those on the hubs and
gears.
MCIB0075E
MT-24
TRANSAXLE CASE BEARING
[JR5]
TRANSAXLE CASE BEARING PFP:32010
A
Removing The Bearing, Input Shaft Side ECS00F4O
Remove the circlips and drive the bearing inside the housing using
tool B. Vi. 1576. B
MT
MCIB0076E
E
Refitting ECS00F4P
Fit a new circlip.

Fit the bearing using tool B. Vi. 1576. F
Remove the bearing race, mainshaft side using a tube with a diame-
ter of 55 mm (2.17 in).
MCIB0077E
I
Refit the race using a 60 mm (2.36 in) diameter tube.
L
MCIB0078E
MT-25
CLUTCH HOUSING BEARING
[JR5]
CLUTCH HOUSING BEARING PFP:32010
Removal and Installation ECS00F4Q
1. Cut the base of the deflector plastic hollow needle located at the
centre of the bearing.
Drive out the cup using a puller.
MCIB0079E
2. Fit a new deflector, then the bearing race using a 55 mm (2.17

in) diameter tube.
MCIB0080E
3. Remove the input shaft bearing guide using the press and a 38
mm (1.50 in) diameter tube.
MCIB0044E
4. Refit the bearing guide using the press and tool B. Vi. 1601.
MCIB0045E
MT-26
SELECTOR SHAFT RINGS
[JR5]
SELECTOR SHAFT RINGS PFP:32010
A
Removal ECS00F4R
1. Remove the rings with an inertia puller.

B
MT
MCIB0046E
E
2. Refit the rings using a 14.5 mm (0.57 in) tube down to the thrust
bearing.
F
H
MCIB0047E
MT-27
DIFFERENTIAL BEARINGS
[JR5]
DIFFERENTIAL BEARINGS PFP:32010
Removal and Installation ECS00F4S
1. Remove the bearing using an antisticking pin.
MCIB0048E
2. Refit the bearings using a tube with a diameter of 40 mm (1.57

in).
MCIB0049E
3. Remove the bearing races using a roll pin punch.
MCIB0050E
4. Refit the bearing races using tools C-F from the B. Vi. 1554 kit.
MCIB0051E
MT-28
SELECTOR SHAFT
[JR5]
SELECTOR SHAFT PFP:32010
A
Removal ECS00F4T
After removing the pin from the selector finger (B), remove the
mounting bolts (C) and remove the control shaft unit. B
MT
MCIB0052E
MCIB0053E
Refitting ECS00F4U I
Proceed in the reverse order to removal.
NOTE:
J
Replace the O-ring (D).
MCIB0054E
MT-29
[JR5]
REPAIRING THE GEARBOX PFP:32010
Setting The Pre-tensioning of The Mainshaft Bearings ECS00F4V
NOTE:
This operation is carried out in the event of replacing the bearings,
housings or mainshaft.
Clutch housing without differential and without input shaft.
Fit the mainshaft in the clutch housing with the bearings and the pre-
setting washer B. Vi. 1161, or equivalent, of 1.60 mm (0.06 in) (large
outer ý).
Fit the transaxle case assembly.
Fit and tighten to torque the box belt bolts.
Fit the dial indicator support plate B. Vi. 1161, or equivalent, on the
tripod basin mountings.
MCIB0081E
1. Fit the B. Vi. 1527 special spacer (A).

2. Fit the bolt (C).
3. Fit the dial indicator with its magnetic holder.
1 Rotate the mainshaft several times to fit the bearings.
2 Set the dial gauge to zero.
3 Pull the mainshaft upwards by making a lever out of two screwdrivers.
4 Take a reading from the dial gauge.
Repeat the operations several times (1 to 4).
Calculate the average of the readings. MCIB0082E
Calculation of the value of the pre-load washer.

Prescribed value + value of the pre-setting washer + average of the readings on the dial gauge = value of the
pre-tensioning dial indicator washer.
Example: [Value in mm (in)]
0.26 + 0.49 + 1.60 = 2.35
↓ ↓ ↓ ↓
Prescribed value Average reading Pre-setting washer value Pre-load washer value
NOTE:
A set of pre-load washers of 2.15 mm (0.08 in) to 2.43 mm (0.10 in) from 0.04 mm (0.002 in) to 0.04 mm
(0.002 in) thickness is supplied as replacement parts.
MT-30
ASSEMBLY
[JR5]
ASSEMBLY PFP:00000
A
Refitting ECS00F4W
1. Fit the mainshaft and 1st/2nd gear fork assembly.

B
MT
MCIB0055E
E
2. Fit the input shaft.
H
MCIB0056E
3. Fit the reverse gear assembly. I
MCIB0057E
L
4. Fit the two locking shafts.

M
MCIB0058E
MT-31
ASSEMBLY
[JR5]
5. The 5th gear shaft and the 3rd/4th gear shaft/fork and sliding
gear assembly while gently lifting the mainshaft assembly.
Rotate the reverse gear assembly to position the 5th gear fork
(A).
MCIB0059E
6. Pin the reverse gear assembly.
MCIB0060E
7. Shift to third gear and insert the rollers and clawing springs.
MCIB0061E
8. Refit the 4th gear fitted with its synchronizer ring.

The adjustment washer and the mainshaft bearing.
MCIB0028E
MT-32
HOUSING ASSEMBLY
[JR5]
HOUSING ASSEMBLY PFP:32010
A
Assembly ECS00F4X
Fit the 1st/2nd 3rd/4th and 5th gear locking balls into the transaxle
case. B
Engage 3rd gear.
MT
MCIB0062E
E
1. Check the positioning of the centring dowels (A).
2. Check the positioning of magnet (B).
F
H
MCIB0063E
Apply a line of LOCTITE 518 to the gasket face. I

Offer up the housing while guiding the selector finger (C) into fork (D)
of the 3rd gear.
J
L
MCIB0064E
Pretighten the peripheral bolts and rotate the input shaft to check
that they make contact with the bearings. M
Tighten the bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
Put three drops of LOCTITE Frenbloc on the splines of the fixed 5th
gear and fit it using tool B. Vi. 1175.
MCIB0065E
MT-33
HOUSING ASSEMBLY
[JR5]
3. On the input shaft, fit the support washer (top side gear side).
4. On the input shaft, fit the sprocket bush.
5. On the input shaft, fit the 5th gear pinion fitted with its synchro-
nizer ring.
6. On the input shaft, fit the 5th gear hub fitted with its spring.
MCIB0066E
Refit the 5th gear fork/sliding gear/reverse gear fork assembly.

Fit the reverse gear synchronizer.
Screw on the reverse gear fork support and tighten the bolts (A) to
torque [25 N·m (2.6 kg-m, 18 ft-lb)].
Slide the 5th gear fork on its shaft to engage 5th gear.
MCIB0067E
Tighten the gear bolt and nut to torque:

mainshaft bolt (B) : [70 N·m (7.1 kg-m, 52 ft-lb)]
input shaft nut (C) : [190 N·m (19 kg-m, 140 ft-lb)]
Reset to neutral and pin the 5th gear fork.
MCIB0024E
Fit a new O-ring, position the 5th gear cover and tighten the bolts to
torque [25 N·m (2.6 kg-m, 18 ft-lb)].
Fit the back-up lamp switch (A) and tighten to torque [25 N·m (2.6
kg-m, 18 ft-lb)].
MCIB0068E
MT-34
HOUSING ASSEMBLY
[JR5]
Refit the new differential output seals using B. Vi. 1666.
A
MT
MCIB0069E
D
Refit the clutch operating cylinder and tighten the bolts.
Tightening torque : 21 N·m (2.1 kg-m, 15 ft-lb)
E
G
MCIB0022E
MT-35
PRECAUTIONS
[RS6F51R]
PRECAUTIONS
[RS6F51R] PFP:00001
Caution ECS00F38
● If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder). CSC
insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts may damage
CSC seal and may cause clutch fluid leak.
● Do not reuse transaxle oil, once it has been drained.
● Check oil level or replace oil with vehicle on level ground.
● During removal or installation, keep inside of transaxle clear of dust or dirt.
● Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
● In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
● Be careful not to damage sliding surfaces and mating surfaces.
MT-36
PREPARATION
[RS6F51R]
PREPARATION PFP:00002
A
Special Service Tools ECS00F39
Tool number
Description
Tool name B
KV381054S0 ● Side bearing outer race removal
Puller ● Mainshaft front bearing removal
MT
D
ZZA0601D
ST35321000 ● Input shaft oil seal installation

Drift ● Reverse main gear installation E
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia. ● 1st bushing installation
● 1st-2nd synchronizer hub installation
● 2nd bushing installation F
ZZA1000D
● 3rd main gear installation
ST30720000 ● Differential oil seal installation G

Drift ● Differential side bearing outer race
a: 77 mm (3.03 in) dia. installation
b: 55.5 mm (2.185 in) dia.
● Mainshaft rear bearing installation H
● Differential side bearing installation
ZZA0811D
I
ST33200000 ● Mainshaft front bearing installation
Drift ● 6th bushing installation
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia. ● 4th main gear installation
J
● 5th main gear installation
● 6th main gear installation
ZZA1002D K
ST33061000 ● Bore plug installation
Drift ● Differential side bearing removal
a: 38 mm (1.50 in) dia. L
b: 28.5 mm (1.122 in) dia.
M
ZZA1000D
ST33052000 ● Welch plug installation

Drift ● Input shaft rear bearing removal
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia. ● 5th bushing, thrust washer, 4th input gear,
4th gear bushing, 3rd-4th synchronizer hub
and 3rd input gear removal
● Input shaft front bearing installation
● 6th input gear and 6th bushing removal
● Mainshaft rear bearing removal
ZZA1023D
● 4th main gear and 5th main gear removal
● 6th main gear removal
MT-37
PREPARATION
[RS6F51R]
Tool number
Description
Tool name
KV40105020 ● 5th input gear and synchronizer hub

Drift removal
a: 39.7 mm (1.563 in) dia. ● 3rd main gear, 2nd main gear, 2nd bushing,
b: 35 mm (1.38 in) dia.
1st-2nd synchronizer hub, 1st main gear,
c: 15 mm (0.59 in)
reverse main gear and 1st bushing removal
ZZA1133D
KV40105710 ● 3rd-4th synchronizer hub installation

Press stand ● 4th bushing installation
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in) ● 5th busing installation
● 5th-6th synchronizer hub installation
● 2nd bushing installation
ZZA1058D
● 3rd main gear installation
ST38220000 ● Reverse main gear installation

Press stand ● 1st bushing installation
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in) ● 1st-2nd synchronizer hub installation
ZZA1058D
ST30032000 ● Input shaft front bearing installation

Drift
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.
ZZA0978D
ST30901000 ● Input shaft rear bearing installation

Drift ● 4th main gear installation
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia. ● 5th main gear installation
c: 35.2 mm (1.386 in) dia. ● 6th main gear installation
● Mainshaft rear bearing installation
ZZA0978D
ST30031000 ● Measuring wear of 1st and 2nd baulk ring

Puller
ZZA0537D
KV40101630 ● Reverse main gear installation

Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.
ZZA1003D
MT-38
PREPARATION
[RS6F51R]
Tool number
Description A
Tool name
KV38102510 ● 1st bushing installation

Drift ● 1st-2nd synchronizer hub installation
a: 71 mm (2.80 in) dia. B
b: 65 mm (2.56 in) dia. ● Differential side bearing installation
MT
ZZA0838D
KV38105900 ● Checking differential side gear end play

Preload adapter D
NT087
Commercial Service Tools ECS00F3A

F
Tool name Description
Puller ● Each bearing gear and bushing removal G
ZZB0823D
I
Puller ● Each bearing gear and bushing removal
NT077
K
Pin punch ● Each retaining pin removal and installation

Tip diameter: 4.5 mm (0.177 in) dia.
L
M
ZZA0815D
Power tool ● Loosening bolts and nuts
PBIC0190E
MT-39
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[RS6F51R]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart ECS00F3B
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
MANUAL TRANSAXLE
MT-43
MT-50
MT-50
MT-50
MT-46
MT-53
MT-53
MT-51
MT-51
MT-51
MT-51
Reference page
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)

SUSPECTED PARTS
(Possible cause)
SHIFT CONTROL LINKAGE (Worn)
BAULK RING (Worn or damaged)

BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
INSERT SPRING (Damaged)

O-RING (Worn or damaged)
GEAR (Worn or damaged)

OIL (Oil level is high.)
GASKET (Damaged)
SHIFT FORK (Worn)

OIL (Oil level is low.)
OIL (Wrong oil.)
Noise 1 2 3 3
Oil leakage 3 1 2 2 2
Symptoms
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3
MT-40
DESCRIPTION
[RS6F51R]
DESCRIPTION PFP:00000
A
Cross-Sectional View ECS00F3C
MT
MCIA0009E
MT-41
DESCRIPTION
[RS6F51R]
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.
SCIA0750E
REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)

The gear can be matched smoothly in a structure by setting synchro-
nizer hub, coupling sleeve, baulk ring and insert spring to reverse
gear, and letting gear be synchronized.
SCIA0751E
MT-42
M/T OIL
[RS6F51R]
M/T OIL PFP:KLD20
A
Changing M/T Oil ECS00F3D
DRAINING
1. Start the engine and let it run to warm up the transaxle.
B
2. Stop the engine. Remove drain plug and drain oil.
3. Set a gasket on the drain plug and install it to the transaxle.
Drain plug: MT
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)

CAUTION: D
Do not reuse gasket.
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole. E
Oil grade : Genuine Nissan gear oil, SAE viscosity

75w - 80 or exact equivalent
F
Capacity (reference) : Approx. 2.3 (4 lmp pt)
2. After refilling oil, check oil level. Assemble gasket to filler plug, then install it to transaxle body.
Filler plug: G
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)

CAUTION: H
Do not reuse gasket.
Checking M/T Oil ECS00F3E
OIL LEAKAGE AND OIL LEVEL I

● Check that oil is not leaking from transaxle or around it.
● Check oil level from filler plug mounting hole as shown in the fig-
J
ure.
CAUTION:
Never start engine while checking oil level.
K
● Set a new gasket on the filler plug and install it on the transaxle.
Filler plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb) L
CAUTION:
Do not reuse gasket. SCIA0361E
M
MT-43
SIDE OIL SEAL
[RS6F51R]
SIDE OIL SEAL PFP:32113
Removal and Installation ECS00F3F
REMOVAL
1. Remove the drive shaft from the transaxle. Refer to AX-11, “Removal”.
2. Remove oil seal with a slotted screwdriver.
CAUTION:
Be careful not to damage the case surface when removing
the oil seal.
SCIA0824E
INSTALLATION
1. Using a drift (special service tool), drive the oil seal straight until
it protrudes from the case end equal to dimension A shown in
the figure.
Dimension A : Within 0.5 mm of flush with the case.
MCIA0141E
Drift to be used:
Transaxle case side
ST3072 0000
Clutch housing side
CAUTION:
● When installing oil seals, apply multi-purpose grease to oil seal lips.
● Do not reuse oil seal.
2. Install all parts in reverse order of removal and check oil level after installation.
MT-44
POSITION SWITCH
[RS6F51R]
POSITION SWITCH PFP:32005
A
Checking ECS00F3G
BACK-UP LAMP SWITCH

● Check continuity. B
Reverse Yes
MT
Except reverse No
SCIA0708E
E
NEUTRAL POSITION SWITCH
● Check continuity.
F
Neutral Yes
Except neutral No G
MT-45
CONTROL LINKAGE
[RS6F51R]
CONTROL LINKAGE PFP:34103
Removal and Installation of Control Device and Cable ECS00F3H
Refer to the figure for removal and installation procedure.
MCIA0120E
CAUTION:
● Keep in mind that the select side lock plate for securing the control cable is different from the one
on the shift side.
● After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st,
2nd, or Reverse.
MT-46
AIR BREATHER HOSE
[RS6F51R]
AIR BREATHER HOSE PFP:31098
A
Removal and Installation ECS00F3I
Refer to the figure for air breather hose removal and installation information.
B
MT
SCIA0747E
CAUTION: H
● Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
● Be sure to insert hose into the transaxle tube until overlap area reaches the spool. I
MT-47
TRANSAXLE ASSEMBLY
[RS6F51R]
TRANSAXLE ASSEMBLY PFP:32010
Removal and Installation ECS00F3J
MCIA0121E
REMOVAL
1. Remove battery and its bracket.
2. Remove fuse box from battery bracket.
3. Remove air cleaner box with mass air flow sensor.
4. Remove air breather hose and vacuum pump hose.
5. Remove fuel filter bracket.
6. Remove clutch operating cylinder.
CAUTION:
Do not depress clutch pedal during removal procedure.
7. Disconnect control cable from transaxle.
8. Drain gear oil from transaxle.
9. Disconnect neutral switch and back-up lamp switch harness connectors.
10. Remove starter motor.
11. Remove crankshaft position sensor (POS) from transaxle.
12. Remove exhaust front tube and the drive shaft.
13. Place a jack onto the transaxle.
CAUTION:
When setting jack, be careful not to bring it into contact with the switch.
14. Remove center member, engine insulator and engine mount bracket.
15. Support engine by placing a jack under oil pan.
16. Remove bolts securing transaxle to engine.
MT-48
TRANSAXLE ASSEMBLY
[RS6F51R]
17. Remove transaxle from vehicle.
A
MT
MTD0062D
D
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
● When installing the transaxle to the engine, tighten to the specified torque. E
CAUTION:
When installing transaxle, be careful not to bring transaxle input shaft into contact with the clutch
cover.
F
Bolt No. 1 2 3 4 5 6
Quantity 2 2 1 1 3 1
G
55 70 120 45 40 35
“ ” mm (in)
(2.17) (2.76) (4.72) (1.77) (1.57) (1.38)
Tightening torque 39 - 49 42 - 52
H
N·m (kg-m, ft-lb) (4.0 - 5.0, 29 - 36) (4.2 - 5.3, 30 - 38)
● After installation, check oil level, and look for leaks and loose
mechanisms.
I
MCIA0014E
MT-49
TRANSAXLE ASSEMBLY
[RS6F51R]
Component Parts ECS00F3K
CASE AND HOUSING COMPONENTS SMA for VIN >SJNxxAN16U0513417
MCIB0121E
1. Clutch housing 2. Input shaft oil seal 3. Oil channel

4. Magnet 5. Differential oil seal 6. Ball pin
7. Washer 8. Transaxle case 9. Welch plug
10. Bore plug 11. Differential oil seal 12. Park/Neutral position switch
13. Oil gutter 14. Back-up lamp switch 15. Air breather tube
16. Baffle plate 17. Filler plug 18. Gasket
19. Drain plug 20. Gasket
MT-50
TRANSAXLE ASSEMBLY
[RS6F51R]
GEAR COMPONENTS
A
MT
MCIB0122E
I
1. Input shaft front bearing 2. Input shaft 3. Needle bearing
4. 3rd input gear 5. 3rd baulk ring 6. Spread spring
7. 3rd & 4th shifting insert 8. 3rd & 4th synchronizer hub 9. 4th baulk ring J
10. 3rd & 4th coupling sleeve 11. Bushing 12. Needle bearing
13. 4th input gear 14. Thrust washer 15. Bushing
16. Needle bearing 17. 5th input gear 18. 5th baulk ring
K
19. 5th & 6th shifting insert 20. 5th & 6th synchronizer hub 21. 5th & 6th coupling sleeve
22. 6th baulk ring 23. 6th input gear 24. Needle bearing
L
25. Bushing 26. Snap ring 27. Input shaft rear bearing
28. Oil channel 29. Input shaft rear bearing adjusting 30. Retaining pin
shim
31. Reverse idler shaft 32. Thrust bearing washer 33. Thrust bearing M
34. Needle bearing 35. Reverse idler gear (Front) 36. Reverse baulk ring
37. Reverse coupling sleeve 38. Insert spring 39. Reverse idler gear (Rear)
40. Reverse idler gear adjusting shim
MT-51
TRANSAXLE ASSEMBLY
[RS6F51R]
MCIB0123E
1. Mainshaft front bearing 2. Mainshaft bearing retainer 3. Mainshaft

4. Reverse main gear 5. 1st main gear 6. Bushing
7. Needle bearing 8. 1st inner baulk ring 9. 1st gear synchronizer cone
10. 1st outer baulk ring 11. Spread spring 12. 1st & 2nd shifting insert
13. 1st & 2nd synchronizer hub 14. 2nd outer baulk ring 15. 2nd gear synchronizer cone
16. 2nd inner baulk ring 17. 1st & 2nd coupling sleeve 18. Bushing
19. Needle bearing 20. 2nd main gear 21. 3rd main gear
22. 3rd & 4th mainshaft spacer 23. 4th main adjusting shim 24. 4th main gear
25. 5th main gear 26. 6th main gear 27. Mainshaft rear bearing
28. Mainshaft C ring 29. C ring holder 30. Snap ring
31. Snap ring 32. Mainshaft rear bearing adjusting 33. 5th & 6th mainshaft spacer
shim
34. 6th main adjusting shim
MT-52
TRANSAXLE ASSEMBLY
[RS6F51R]
SHIFT CONTROL COMPONENTS
A
MT
J
MCIB0124E
1. Reverse shift fork 2. Shifter cap 3. Reverse fork rod

4. Reverse lever assembly 5. 5th & 6th bracket 6. 5th & 6th fork rod K
7. 5th & 6th shift fork 8. Retaining pin 9. 3rd & 4th bracket
10. 3rd & 4th shift fork 11. 3rd & 4th fork rod 12. 1st & 2nd shift fork
13. 1st & 2nd bracket 14. 1st & 2nd fork rod 15. Shift check sleeve L
16. Inter lock pin 17. Check ball 18. Shift check sleeve
19. Check spring 20. Check plug 21. Control assembly
22. O ring 23. Shift check 24. Stopper bolt M
25. Stopper ring 26. Reverse bracket fork rod 27. Reverse bracket
MT-53
TRANSAXLE ASSEMBLY
[RS6F51R]
FINAL DRIVE COMPONENTS
MCIB0125E
1. Differential side bearing outer race 2. Differential side bearing 3. Speedometer drive gear
4. Differential case 5. Final gear 6. Differential side bearing
7. Differential side bearing outer race 8. Differential side bearing adjusting 9. Pinion mate shaft
shim
10. Side gear 11. Side gear thrust washer 12. Pinion mate gear
13. Pinion mate gear washer 14. Retaining pin
Disassembly and Assembly SMA for VIN >SJNxxAN16U0513417 ECS00F3L
DISASSEMBLY
1. Remove drain plug and filler plug.
2. Remove park/neutral position switch and back-up lamp switch.
3. After removing shift check and stopper bolt, remove control
assembly.
SCIA0389E
MT-54
TRANSAXLE ASSEMBLY
[RS6F51R]
4. Remove check plugs (4 pieces), check springs (4 pieces), check
balls (4 pieces) and shift check sleeve (2 pieces). A
MT
SCIA0959E
D
5. Remove transaxle case fixing bolts.
6. Remove bore plug.
E
CAUTION:
Be careful not to damage transaxle case.
7. While spreading the snap ring of mainshaft rear bearing located
at bore plug hole, remove transaxle case. F
8. Remove oil gutter, baffle plate.
9. Remove snap ring, mainshaft rear bearing adjusting shim and
input shaft rear bearing adjusting shim from transaxle case. G
SCIA0983E
10. Remove differential side bearing outer race (transaxle case H

side) and then adjusting shim.
K
SCIA0897E
11. Remove welch plug.

L
SCIA0402E
MT-55
TRANSAXLE ASSEMBLY
[RS6F51R]
12. Remove differential oil seal (transaxle case side).
13. Remove magnet from clutch housing.
SCIA0397E
14. With shift lever in 5th position, remove bracket bolts from
reverse lever assembly. Lift reverse lever assembly to remove.
CAUTION:
Be careful not to lose shifter cap.
15. Pull out reverse fork rod then remove reverse shift fork.
SCIA0960E
16. Remove retaining pin of reverse bracket using pin punch.

17. Pull out reverse bracket and reverse bracket fork rod.
18. Remove check ball (2 pieces) and inter lock pin.
SCIA0961E
19. Shift 3rd & 4th fork rod to 3rd position. Remove retaining pin of
5th & 6th shift fork using pin punch.
SCIA0962E
MT-56
TRANSAXLE ASSEMBLY
[RS6F51R]
20. Remove stopper rings for 5th & 6th bracket.
21. Pull out 5th & 6th fork rod and remove 5th & 6th shift fork and A
5th & 6th bracket.
22. Remove check balls (2 pieces) and inter lock pin.
B
MT
SCIA0963E
D
23. Remove retaining pin of 3rd & 4th bracket using pin punch.
24. Remove stopper rings for 3rd & 4th shift fork.
E
25. Pull out 3rd & 4th fork rod and remove 3rd & 4th shift fork and
bracket.
26. Remove shift check sleeve from clutch housing.
F
G
SCIA0393E
27. Remove retaining pin of 1st & 2nd shift fork using pin punch. H
28. Pull out 1st & 2nd fork rod with bracket.
29. Remove 1st & 2nd shift fork.
I
30. Remove retaining pin of 1st & 2nd bracket using pin punch and
separate fork rod and bracket.
J
K
SCIA0394E
31. Remove gear components from clutch housing in the following

L
procedure.
a. While tapping input shaft with plastic hammer, remove input
shaft assembly, mainshaft assembly and reverse idler gear
assembly as a set. M
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.
SCIA0964E
MT-57
TRANSAXLE ASSEMBLY
[RS6F51R]
32. Remove mainshaft bearing retainer and then mainshaft front
bearing.
33. Remove oil channel on mainshaft side.
34. Remove differential oil seal (clutch housing side).
MCIA0030E
35. Remove differential side bearing outer race (clutch housing

side).
MCIA0031E
36. Remove input shaft oil seal.

CAUTION:
Be careful not to damage clutch housing.
SMA for VIN >SJNxxAN16U0513417 SCIA0398E
ASSEMBLY
1. Using a drift, press fit input shaft oil seal into clutch housing to
the depth of 1.8 to 2.8 mm (0.071 to 0.110 in).
CAUTION:
Do not reuse oil seal.
SCIA0399E
MT-58
TRANSAXLE ASSEMBLY
[RS6F51R]
2. Using a drift, install differential oil seal until the face is flush with
clutch housing. A
CAUTION:
B
MT
MCIA0032E
D
3. Install oil channel on mainshaft side.
CAUTION:
Be careful with orientation of installation. E
G
SCIA0986E
4. Using a drift, install mainshaft front bearing. H

CAUTION:
Be careful with orientation of installation.
I
K
SCIA0401E
5. Install bearing retainer.

L
CAUTION:
Install with punched surface facing up.
M
SCIA0400E
MT-59
TRANSAXLE ASSEMBLY
[RS6F51R]
6. Install differential side bearing outer race.
MCIA0016E
7. Install final drive assembly into clutch housing.
SCIA0888E
8. Install input shaft assembly, mainshaft assembly, and reverse

idler gear assembly into clutch housing.
CAUTION:
Be sure not to damage input shaft oil seal.
SCIA0964E
9. Install 1st-2nd fork rod bracket onto 1st-2nd fork rod, and then
install retaining pin.
CAUTION:
Do not reuse retaining pin.
SCIA0889E
MT-60
TRANSAXLE ASSEMBLY
[RS6F51R]
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install
retaining pin. A
CAUTION:
11. Install shift check sleeve. B
MT
SCIA0394E
D
12. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod
with inter lock pin.
13. Install stopper ring onto 3rd-4th shift fork. E
CAUTION:
Do not reuse stopper ring.
14. Install retaining pin onto 3rd-4th bracket. F
CAUTION:
15. Install 2 check balls. G
SCIA0393E
16. Install 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod H
with interlock pin.
17. Install stopper ring onto 5th-6th bracket.
I
CAUTION:
Do not reuse stopper ring.
K
SCIA0963E
18. Install retaining pin onto 5th-6th shift fork.

L
CAUTION:
19. Install 2 check balls.
M
20. Install reverse bracket fork rod and reverse lever bracket.
SCIA0962E
MT-61
TRANSAXLE ASSEMBLY
[RS6F51R]
21. Install retaining pin onto reverse bracket.
CAUTION:
22. Install reverse shift fork and reverse fork rod.
23. Install reverse lever assembly following procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then
install them onto reverse shift fork.
CAUTION:
Do not drop shifter cap.
SCIA0961E
b. While lifting reverse shift fork, align cam with reverse bracket.
MCIB0126E
c. Tighten mounting bolts to specified torque, and then install

reverse lever assembly.
24. Install the magnet onto clutch housing.
SCIA0960E
25. Using a drift, install differential oil seal until it is flush with end
face of transaxle case.
CAUTION:
SCIA0887E
26. Install selected input shaft adjusting shim onto input shaft.
● For selection of adjusting shims: Refer to MT-65, "INPUTSHAFT END PLAY" .
27. Install baffle plate and oil gutter.

28. Install transaxle case following procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
● For selection of adjusting shims: Refer to MT-67, "MAINSHAFT END PLAY" .
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse the snap ring.
MT-62
TRANSAXLE ASSEMBLY
[RS6F51R]
c. Apply recommended sealant to mating surfaces of transaxle
case and clutch housing. A
CAUTION:
● Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to B
application and mounting surfaces.
● Make sure no flaw or damage is on the mounting sur-
faces.
MT
SCIA0891E
D
d. With snap ring of mainshaft rear bearing temporarily installed,
place transaxle case over clutch housing.
E
G
SCIA0892E
e. Through bore plug mounting hole, with snap ring stretched, and H
lift up mainshaft assembly from the control assembly mounting
hole.
f. Securely install snap ring onto mainshaft rear bearing.
I
SCIA0893E
g. Tighten mounting bolts.

Bolt A:
: 50.0 - 53.9 N·m (5.1 - 5.4 kg-m, 37 - 39 ft-lb)
Bolt B:
: 63.0 - 66.9 N·m (6.5 - 6.8 kg-m, 47 - 49 ft-lb)
CAUTION:
Always replace bolts B as they are self-sealing bolts.
h. Install control assembly. MCIA0146E
MT-63
TRANSAXLE ASSEMBLY
[RS6F51R]
CAUTION:
Do not reuse the O-ring.
i. Install shift check and stopper bolt.
CAUTION:
Do not reuse shift check and stopper bolt.
29. Using a drift, install bore plug.
CAUTION:
Do not reuse bore plug.
SCIA0894E
30. Using a drift, install welch plug.

CAUTION:
Do not reuse welch plug.
MCIA0033E
31. Install 2 shift check sleeves, 4 check balls, 4 check springs, and
4 check ball plugs.
CAUTION:
Do not reuse check ball plug.
SCIA0959E
32. Apply recommended sealant to threads of neutral switch and

reverse lamp switch. Then install them into transaxle case.
33. Install gaskets onto drain plug and filler plug, and then install
them into transaxle case.
CAUTION:
● Do not reuse gasket.
● After oil is filled, tighten plug to specified torque.
SCIA0895E
MT-64
TRANSAXLE ASSEMBLY
[RS6F51R]
Adjustment ECS00F3M
INPUTSHAFT END PLAY A

● When adjusting input shaft end play, select adjusting shim for
input shaft bearing. To select adjusting shim, measure clearance
between transaxle case and input shaft rear bearing. B
● Calculate dimension “O” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing. MT
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension “O” = (O1 − O2 ) + End play
O : Thickness of adjusting shim D
O1 : Distance between transaxle case end face SCIA1001E
and mounting face of adjusting shim

E
O2 : Distance between clutch housing case end
face and end face of input shaft rear bearing
Adjusting Shim F
Shim thickness Part number Shim thickness Part number Shim thickness Part number
0.40 mm (0.0157 in) 32225 8H500 0.88 mm (0.0346 in) 32225 8H512 1.36 mm (0.0535 in) 32225 8H524
0.44 mm (0.0173 in) 32225 8H501 0.92 mm (0.0362 in) 32225 8H513 1.40 mm (0.0551 in) 32225 8H560 G
H
0.72 mm (0.0283 in) 32225 8H508 1.20 mm (0.0472 in) 32225 8H520 1.68 mm (0.0661 in) 32225 8H567 I
0.80 mm (0.0315 in) 32225 8H510 1.28 mm (0.0504 in) 32225 8H522
0.84 mm (0.0331 in) 32225 8H511 1.32 mm (0.0520 in) 32225 8H523
CAUTION:
J
Only 1 adjusting shim can be selected.
1. Using depth micrometer and straight edge, measure dimension
“O1 ” between transaxle case end face and mounting face of K
adjusting shim.
SCIA1002E
2. Using depth micrometer and straight edge as shown in the fig-

ure, measure dimension “O2 ” between clutch housing case end
face and end face of input shaft rear bearing.
3. Install selected input shaft rear bearing adjusting shim onto input
shaft.
SCIA1004E
MT-65
TRANSAXLE ASSEMBLY
[RS6F51R]
DIFFERENTIAL SIDE BEARING PRELOAD
● When adjusting differential side bearing preload, select adjust-
ing shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race.
● Calculate dimension “L” (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differ-
ential side bearing.
Preload : 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension “L” = (L1 − L2 ) + Preload
L : Thickness of adjusting shim SCIA0896E
L1 : Distance between transaxle case end face and

mounting face of adjusting shim
L2 : Distance between differential side bearing and
transaxle case
Adjusting Shim
Shim thickness Part number
0.48 mm (0.0189 in) 31438 80X00
0.52 mm (0.0205 in) 31438 80X01
0.56 mm (0.0220 in) 31438 80X02
0.60 mm (0.0236 in) 31438 80X03
0.64 mm (0.0252 in) 31438 80X04
0.68 mm (0.0268 in) 31438 80X05
0.72 mm (0.0283 in) 31438 80X06
0.76 mm (0.0299 in) 31438 80X07
0.80 mm (0.0315 in) 31438 80X08
0.84 mm (0.0331 in) 31438 80X09
0.88 mm (0.0346 in) 31438 80X10
0.92 mm (0.0362 in) 31438 80X11
CAUTION:
Up to 2 adjusting shims can be selected.
1. Using depth micrometer and straightedge, measure dimension
“L1 ” between transaxle case end face and mounting face of
adjusting shim.
2. Install outer race onto differential side bearing on final gear side.
Holding lightly the outer race horizontally by hand, rotate final
gear five times or more (for smooth movement of bearing roller).
SCIA1078E
3. Using depth micrometer and straightedge as shown in the fig-

ure, measure dimension “L2 ” between differential side bearing
outer race and transaxle case end face.
SCIA1079E
MT-66
TRANSAXLE ASSEMBLY
[RS6F51R]
4. Install selected adjusting shim and then differential side bearing
outer race. A
MT
SCIA0898E
D
MAINSHAFT END PLAY
● When adjusting mainshaft end play, select adjusting shim for
mainshaft rear bearing. To select adjusting shim, measure clear-
ance “M” between transaxle case and mainshaft rear bearing. E
● Calculate dimension “P” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for main-
shaft rear bearing. F
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension “P” = “M” + End play
G
P : Thickness of adjusting shim
M : Distance between mainshaft rear bearing and SCIA0904E
transaxle case H
Adjusting Shim
I
0.44 mm (0.0173 in) 32238 8H510
0.48 mm (0.0189 in) 32238 8H511
0.52 mm (0.0205 in) 32238 8H512
0.56 mm (0.0220 in) 32238 8H513 J
0.60 mm (0.0236 in) 32238 8H514
0.64 mm (0.0252 in) 32238 8H515
0.68 mm (0.0268 in) 32238 8H516
0.72 mm (0.0283 in) 32238 8H517 K
0.76 mm (0.0299 in) 32238 8H518
0.80 mm (0.0315 in) 32238 8H519
0.84 mm (0.0331 in) 32238 8H520 L
0.88 mm (0.0346 in) 32238 8H521
0.92 mm (0.0362 in) 32238 8H522
0.96 mm (0.0378 in) 32238 8H523
1.00 mm (0.0394 in) 32238 8H524 M
1.04 mm (0.0409 in) 32238 8H560
1.08 mm (0.0425 in) 32238 8H561
CAUTION:
1. Install mainshaft assembly to clutch housing.
2. Install snap ring to transaxle case.
3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install tempo-
rarily snap ring to mainshaft rear bearing.
MT-67
TRANSAXLE ASSEMBLY
[RS6F51R]
4. Install dial indicator to snap ring access hole, and expand snap
ring. Lift mainshaft assembly through control assembly installa-
tion hole, and push it against transaxle case. This state shall be
defined as base. Moving distance of mainshaft assembly, with
snap ring fit on main bearing, becomes “M”.
MCIB0127E
REVERSE IDLER GEAR END PLAY

● When adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear.
● Calculate dimension “Q” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
End play : 0.04 - 0.14 mm (0.0016 - 0.0055 in)
Dimension “Q” = (Q1 − Q2 ) + End play
Q : Thickness of adjusting shim
Q1 : Distance between transaxle case end face and SCIA1007E
mounting face of adjusting shim

Q2 : Distance between clutch housing case end
face and end face of reverse idler gear
Adjusting Shim
Shim thickness Part number Shim thickness Part number
1.76 mm (0.0693 in) 32237 8H800 2.24 mm (0.0882 in) 32237 8H812
1.84 mm (0.0724 in) 32237 8H802 2.32 mm (0.0913 in) 32237 8H814
1.92 mm (0.0756 in) 32237 8H804 2.40 mm (0.0945 in) 32237 8H816
2.00 mm (0.0787 in) 32237 8H806 2.48 mm (0.0976 in) 32237 8H818
2.08 mm (0.0819 in) 32237 8H808 2.56 mm (0.1008 in) 32237 8H820
2.16 mm (0.0850 in) 32237 8H810 2.64 mm (0.1039 in) 32237 8H822
CAUTION:
1. Using depth micrometer and straight edge, measure dimension
“Q1 ” between transaxle case end face and mounting face of
adjusting shim.
SCIA1003E
MT-68
TRANSAXLE ASSEMBLY
[RS6F51R]
2. Using depth micrometer and straight edge as shown in the fig-
ure, measure dimension “Q2 ” between clutch housing case end A
face and end face of reverse idler gear.
3. Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly. B
MT
SCIA1005E
MT-69
INPUT SHAFT AND GEARS
[RS6F51R]
INPUT SHAFT AND GEARS PFP:32200
Assembly and Disassembly ECS00F3N
DISASSEMBLY
1. Before disassembling, measure end play for 3rd, 4th, 5th and
6th input gears.
End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0966E
2. Remove oil channel.

3. Remove input shaft rear bearing.
4. Remove the snap ring.
SCIA0967E
5. Remove 6th input gear, 6th bushing and 6th needle bearing.
6. Remove 6th baulk ring, 5th-6th coupling sleeve and shifting
insert.
SCIA0968E
7. Remove 5th input gear and 5th synchronizer hub assembly

simultaneously.
8. Remove 5th needle bearing.
SCIA0918E
MT-70
[RS6F51R]
9. Remove 5th bushing, thrust washer, 4th input gear, 4th needle
bearing, 4th bushing, 4th baulk ring, 3rd-4th synchronizer hub A
assembly, 3rd baulk ring and 3rd input gear simultaneously.
10. Remove 3rd needle bearing.
B
MT
SCIA0919E
D
11. Remove input shaft front bearing.
G
SCIA0920E
INSPECTION AFTER DISASSEMBLY H

Input Shaft and Gear
Check items below. If necessary, replace them with new ones.
● Damage, peeling, dent, uneven wear, bending, etc. of shaft I
● Excessive wear, damage, peeling, etc. of gears
SCIA1074J
Synchronizer L
● Damage and excessive wear of contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert M
● Coupling sleeve and synchronizer hub must move smoothly.
SMT387A
MT-71
[RS6F51R]
● If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
SMT867D
Baulk ring clearance

● Press baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it
with a new one.
Clearance
Standard
3rd and 4th : 0.9 - 1.45 mm (0.0354 - 0.0571 in)
5th and 6th : 0.95 - 1.4 mm (0.0374 - 0.0551 in)
Limit value : 0.7 mm (0.0276 in)
SMT140
Bearing
● Damage and rough rotation of bearing
MTF0041D
ASSEMBLY
1. Install 3rd needle bearing.
2. Install 3rd input gear and 3rd baulk ring.
3. Install spread spring, shifting insert and 3rd-4th synchronizer
hub onto 3rd-4th coupling sleeve.
CAUTION:
● Be careful with orientation of synchronizer hub.
● Do not reuse 3rd-4th synchronizer hub.
SCIA0921E
MT-72
[RS6F51R]
● Be careful with orientation of coupling sleeve.
A
MT
SCIA0993E
D
● Be sure not to hook center projection of 2 spread springs
on same shifting insert.
E
G
MCIA0145E
4. Install 3rd-4th synchronizer hub assembly. H

CAUTION:
Align grooves of shifting insert and 3rd baulk ring.
I
K
SCIA0922E
5. Install 4th bushing.

L
6. Install 4th baulk ring.
7. Install 4th input gear and 4th needle bearing.
M
SCIA0923E
MT-73
[RS6F51R]
8. Select thrust washer so that dimension “C2” satisfies standard
below. Then install it onto input shaft.
Standard for dimension C2 : 154.7 - 154.8 mm (6.091 -
6.094 in)
SCIA0925E
Thrust Washer
Thickness Part number Thickness Part number
3.84 mm (0.1512 in) 32347 8H500 4.02 mm (0.1583 in) 32347 8H503
3.90 mm (0.1535 in) 32347 8H501 4.08 mm (0.1606 in) 32347 8H504
3.96 mm (0.1559 in) 32347 8H502 4.14 mm (0.1630 in) 32347 8H505
CAUTION:
Only one thrust wahser can be selected.
9. Install 5th bushing.
10. Install 5th needle bearing and 5th input gear.
11. Install 5th baulk ring.
SCIA0926E
12. Install 5th-6th synchronizer hub, spread spring and shifting

insert onto 5th-6th coupling sleeve.
CAUTION:
● Do not reuse 5th-6th synchronizer hub.
SCIA0921E
MT-74
[RS6F51R]
on same shifting insert. A
MT
SMT136E
D
13. Install 5th-6th synchronizer hub assembly.
CAUTION:
Align grooves of 5th-6th shifting insert and 5th-6th baulk E
ring.
G
SCIA0928E
14. Install 6th needle bearing, 6th input gear onto 6th bushing, and H
then install them onto input shaft.
K
SCIA0969E
15. Install snap ring onto input shaft, and check that end play (gap
L
between snap ring and groove) of 6th bushing satisfies stan-
dard.
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
M
● If measurement is outside the standard range, select snap
ring.
SCIA0970E
MT-75
[RS6F51R]
Snap Rings
1.76 mm (0.0693 in) 32204 8H511 2.01 mm (0.0791 in) 32204 8H516
1.81 mm (0.0713 in) 32204 8H512 2.06 mm (0.0811 in) 32204 8H517
1.86 mm (0.0732 in) 32204 8H513 2.11 mm (0.0831 in) 32204 8H518
1.91 mm (0.0752 in) 32204 8H514 2.16 mm (0.0850 in) 32204 8H519
1.96 mm (0.0772 in) 32204 8H515 2.21 mm (0.0870 in) 32204 8H520
16. Install input shaft rear bearing.

CAUTION:
Install input shaft rear bearing with its brown surface facing
the 6th input gear side.
SCIA0971E
17. Install input shaft front bearing.

18. Install oil channel onto input shaft.
SCIA0972E
19. Check end play of 3rd, 4th, 5th and 6th input gears.
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0966E
MT-76
MAINSHAFT AND GEARS
[RS6F51R]
MAINSHAFT AND GEARS PFP:32241
A
Assembly and Disassembly ECS00F3O
DISASSEMBLY
1. Before disassembling, measure end play of 1st and 2nd main
B
gears.
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in) MT
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0973E
E
2. Remove the snap ring.
3. Remove C-ring holder, and then mainshaft C-ring.
F
SCIA0974E
I
4. Remove mainshaft rear bearing, adjust shim and 6th main gear.
5. Remove 5th-6th mainshaft spacer.
J
L
SCIA0976E
6. Remove 4th main gear and 5th main gear simultaneously. M

7. Remove adjusting shim.
8. Remove 3rd & 4th mainshaft spacer.
SCIA0937E
MT-77
MAINSHAFT AND GEARS
[RS6F51R]
9. Remove 3rd main gear, 2nd main gear, 2nd gear needle bear-
ing, 2nd bushing, 1st-2nd synchronizer assembly, 1st main gear,
reverse main gear, 1st gear needle bearing, and 1st bushing
simultaneously.
SCIA0938E
INSPECTION AFTER DISASSEMBLY

Mainshaft and Gears
● Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
● Excessive wear, damage, peeling, and other non-standard con-
ditions of the gears.
SCIA1076J
Synchronizer
● Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert.
SMT387A

SMT867D
MT-78
MAINSHAFT AND GEARS
[RS6F51R]
● Double cone synchronizer (1st and 2nd) A
Check clearance of outer baulk ring, synchronizer cone, and
inner baulk ring of 1st and 2nd double cone synchronizers, fol-
lowing procedure below. B
CAUTION:
Outer baulk ring, synchronizer cone, and inner baulk ring
as a set control clearance A and B. If measurement exceeds MT
service limit value, replace all of them as a set.
SCIA0950E
D
1. Using a dial indicator, measure clearance A at 2 or more points

diagonally opposite, and calculate mean value. E
Clearance A
Standard : 0.6 - 0.8 mm (0.024 - 0.031 in) F
Limit value : 0.2 mm (0.008 in) or less
SCIA0951E
H
2. Using a feeler gauge, measure clearance B at 2 or more points
diagonally opposite, and calculate mean value.
I
Clearance B
Standard : 0.6 - 1.1 mm (0.024 - 0.043 in)
Limit value : 0.2 mm (0.008 in) or less J
K
SMT139E
Bearing L
● Damage and rough rotation of bearing
M
MTF0041D
MT-79
MAINSHAFT AND GEARS
[RS6F51R]
ASSEMBLY
1. Install reverse main gear.
MCIA0034E
CAUTION:
Be careful with orientation of reverse main gear.
SCIA0992E
2. Install 1st bushing.

3. Install needle bearing, and then 1st main gear.
SCIA0940E
4. Install spread spring, shifting insert and 1st-2nd synchronizer

hub onto 1st-2nd coupling sleeve.
CAUTION:
● Do not reuse 1st-2nd synchronizer hub.
SCIA0921E
MT-80
MAINSHAFT AND GEARS
[RS6F51R]
A
MT
SCIA0989E
D
on same shifting insert.
E
G
MCIA0145E
5. Install 1st gear synchronizer assembly onto mainshaft, and syn- H

chronizer hub assembly onto mainshaft.
CAUTION:
● Outer baulk ring, synchronizer cone, and inner baulk ring I
on 2nd gear-side must have been removed.
J
K
SCIA0941E
6. Install 2nd bushing.

L
7. Install outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side.
8. Install 2nd needle bearing and 2nd gear.
M
SCIA0942E
MT-81
MAINSHAFT AND GEARS
[RS6F51R]
9. Install 3rd main gear.
CAUTION:
Be careful with orientation of 3rd main gear.
10. Install 3rd-4th mainshaft spacer.
SCIA0943E
11. Select suitable adjusting shim so that dimension “C1” satisfies

standard value below, and install it onto mainshaft.
Standard for dimension C1 : 173.85 - 173.95 mm
(6.844 - 6.848 in)
SCIA0944E
Adjusting Shim
0.52 mm (0.0205 in) 32238 8H500 0.84 mm (0.0331 in) 32238 8H504
0.60 mm (0.0236 in) 32238 8H501 0.92 mm (0.0362 in) 32238 8H505
0.68 mm (0.0268 in) 32238 8H502 1.00 mm (0.0394 in) 32238 8H506
0.76 mm (0.0299 in) 32238 8H503 1.08 mm (0.0425 in) 32238 8H507
CAUTION:
Only one adjusting shim can be selected.
12. Install 4th main gear.
CAUTION:
Be careful with orientation of 4th main gear.
SCIA0945E
MT-82
MAINSHAFT AND GEARS
[RS6F51R]
CAUTION: A
Be careful with orientation of 5th main gear.
14. Install 5th-6th mainshaft spacer.
B
MT
SCIA0946E
D
G
SCIA0977E
16. Select 6th main adjusting shim and then install it onto mainshaft. H
● Calculate thickness “S” of 6th main adjusting shim by proce-
dure below so that end play dimension between 6th main
gear and mainshaft rear bearing becomes the dimension I
shown below.
End play : 0 - 0.1 mm (0 - 0.004 in)
J
Dimension “S” = (S1 − S2 ) + End play
S : Thickness of adjusting shim
S1 : Dimension from mainshaft standard face to K
mainshaft rear bearing press-fit end face
S2 : Dimension from mainshaft standard face to
6th main gear end face L
SCIA0995E
Adjusting Shim
0.88 mm (0.0346 in) 32237 8H560 1.20 mm (0.0472 in) 32237 8H564
0.96 mm (0.0378 in) 32237 8H561 1.28 mm (0.0504 in) 32237 8H565
1.04 mm (0.0409 in) 32237 8H562 1.36 mm (0.0535 in) 32237 8H566
1.12 mm (0.0441 in) 32237 8H563
CAUTION:
Only one adjusting shim can be selected.
a. Using height gauge, measure dimension “S1 ” and “S2 ”.
MT-83
MAINSHAFT AND GEARS
[RS6F51R]
b. Install selected 6th main adjusting shim to mainshaft.
17. Install mainshaft rear bearing.
SCIA0978E
18. Install C-ring onto mainshaft, and check that end play of main-
shaft rear bearing satisfies standard value.
End play standard value : 0 - 0.06 mm (0 - 0.0024 in)
● If measurement is outside the standard range, reselect C-ring.
SCIA0979E
C-ring
2.535 mm (0.0998 in) 32348 8H800 2.835 mm (0.1116 in) 32348 8H810
2.565 mm (0.1010 in) 32348 8H801 2.865 mm (0.1128 in) 32348 8H811
2.595 mm (0.1022 in) 32348 8H802 2.895 mm (0.1140 in) 32348 8H812
2.625 mm (0.1033 in) 32348 8H803 2.925 mm (0.1152 in) 32348 8H813
2.655 mm (0.1045 in) 32348 8H804 2.955 mm (0.1163 in) 32348 8H814
2.685 mm (0.1057 in) 32348 8H805 2.985 mm (0.1175 in) 32348 8H815
2.715 mm (0.1069 in) 32348 8H806 3.015 mm (0.1187 in) 32348 8H816
2.745 mm (0.1081 in) 32348 8H807 3.045 mm (0.1199 in) 32348 8H817
2.775 mm (0.1093 in) 32348 8H808 3.075 mm (0.1211 in) 32348 8H818
2.805 mm (0.1104 in) 32348 8H809
19. Fit C-ring holder, and install snap ring.
SCIA0974E
MT-84
MAINSHAFT AND GEARS
[RS6F51R]
20. Check end play of 1st and 2nd main gears.
A
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in) B
MT
SCIA0973E
MT-85
REVERSE IDLER SHAFT AND GEARS
[RS6F51R]
REVERSE IDLER SHAFT AND GEARS PFP:32281
Assembly and Disassembly ECS00F3P
DISASSEMBLY
1. Remove reverse idler gear adjusting shim.
2. Remove reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
3. Remove reverse idler gear needle bearing.
4. Remove thrust needle bearing.
5. Remove reverse baulk ring.
6. Remove reverse idler gear (front).
7. Remove reverse idler gear needle bearing.
8. Remove thrust needle bearing.
9. Pull off locking pin from reverse idler shaft.
Reverse Idler Shaft and Gears
● Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
● Excessive wear, damage, peeling, and other non-standard con-
ditions of the gears.
SCIA0953J
Synchronizer
● Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and insert spring.
SMT637A

SMT867D
MT-86
REVERSE IDLER SHAFT AND GEARS
[RS6F51R]
● Press baulk ring against cone, and measure clearance between A
baulk ring and cone. If measurement is below limit, replace it
with a new one.
Clearance B
Standard : 0.95 - 1.4 mm (0.0374 - 0.0551 in)

Limit value : 0.7 mm (0.0276 in) MT
SMT140
D
Bearing
● Damage and rough rotation of bearing. E
ASSEMBLY
Paying attention to following work, assemble in reverse order of disassembly.
CAUTION: F
● Be careful with orientation of insert spring.
I
SCIA0954E
MT-87
FINAL DRIVE
[RS6F51R]
FINAL DRIVE PFP:38411
Assembly and Disassembly ECS00F3Q
PRE-INSPECTION
● Check the clearance between side gear and differential case as
follows.
1. Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
MCIB0128E
2. Upright the differential case so that the side gear to be mea-

sured faces upward.
3. Place final drive adapter and dial indicator onto side gear. Move
side gear up and down, and measure the clearance.
Clearance : 0.1 - 0.2 mm (0.004 - 0.008 in)
between side gear
and differential
case
CAUTION:
There should be no resistance and gears should rotate SMT611A
freely.
4. If not within specification, adjust the clearance by changing thrust washer thickness.
5. Turn differential case upside down, and measure the clearance between side gear and differential case on
the other side in the same way.
DISASSEMBLY
1. Remove mounting bolts. Then, separate the final gear from differential case.
2. Remove speedometer drive gear.
3. Using a drift and puller, remove differential side bearing (clutch
housing side).
MCIA0019E
4. Using a drift and puller, remove differential side bearing

(transaxle case side).
SCIA0907E
MT-88
FINAL DRIVE
[RS6F51R]
5. Using a pin punch, pull out lock pin and pinion mate shaft. A
6. Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.
B
MT
SCIA0908E
D
Gear Washer, Shaft and Case
● Check side gears, side gear thrust washers, pinion mate shaft, E
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.
F
H
MTK0135D
Bearing
● Check for bearing damage and rough rotation. If necessary, I
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and J
inner race as a set.
SPD715 L
ASSEMBLY
1. Apply gear oil to sliding area of differential case, each gear, and
thrust washer. M
2. Install side gear thrust washer and side gears into differential
case.
3. While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.
SMT839
MT-89
FINAL DRIVE
[RS6F51R]
4. Insert pinion mate shaft into differential case.
CAUTION:
Be sure not to damage pinion mate thrust washers.
MTK0132D
5. Measure end play of side gears following procedure below.

Then select side gear thrust washer.
a. Upright the differential case so that its side gear to be measured
face upward.
b. Place final drive adapter and dial gauge onto side gears.
MCIB0128E
c. Move side gears up and down to measure end play, and select
thrust washer so that it satisfies standard.
End play standard : 0.1 - 0.2 mm (0.004 - 0.008 in)
value
CAUTION:
● There should be no resistance and gears should rotate
freely.
● Place differential case upside down. Be sure to measure
end play for opposite side-gears likewise.
SMT611A
Thrust washer
0.75 mm (0.0295 in) 38424 81X00
0.80 mm (0.0315 in) 38424 81X01
0.85 mm (0.0335 in) 38424 81X02
0.90 mm (0.0354 in) 38424 81X03
0.95 mm (0.0374 in) 38424 81X04
CAUTION:
Only one thrust washer can be selected.
6. Using a pin punch (special service tool), drive a lock pin into the
pinion mate shaft.
CAUTION:
Do not reuse the lock pin.
SCIA0908E
MT-90
FINAL DRIVE
[RS6F51R]
7. Using a drift (special service tool), install differential side bearing
(transaxle case side). A
MT
SCIA0910E
D
8. Align and install speedometer drive gear onto differential case.
G
SMT842D
9. Using a drift (special service tool), install differential side bearing H

(clutch housing side).
K
MCIA0020E
10. Install final gear into differential case, and tighten final gear
L
mounting bolts.
SCIA0912E
MT-91
SHIFT CONTROL
[RS6F51R]
SHIFT CONTROL PFP:32982
Inspection ECS00F3R
● Check contact surfaces and sliding area for wear, damage,

bending, etc. If necessary, replace parts.
SCIA0913E
SHIFT FORK
● Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
One-side wear specifi-
Item Sliding width of new part
cation
7.80 - 7.93 mm
1st & 2nd 0.2 mm (0.008 in)
(0.3071 - 0.3122 in)
7.80 - 7.93 mm
3rd & 4th 0.2 mm (0.008 in)
(0.3071 - 0.3122 in)
6.10 - 6.23 mm
5th & 6th 0.2 mm (0.008 in)
(0.2402 - 0.2453 in) SMT801D
12.80 - 12.93 mm
Reverse 0.2 mm (0.008 in)
(0.5039 - 0.5091 in)
MT-92
SERVICE DATA AND SPECIFICATIONS (SDS)
[RS6F51R]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
A
General Specifications ECS00F3S
TRANSAXLE
Engine YD22DDTi B
Transaxle model RS6F51R
Model code number AW664
Number of speed 6
MT
Synchromesh type Warner
Shift pattern
D
SCIA0955E
Gear ratio 1st 3.500 F

2nd 1.944
3rd 1.258
G
4th 0.947
5th 0.722
6th 0.673 H
Reverse 3.374
Number of teeth Input gear 1st 14
I
2nd 18
3rd 31
4th 38 J
5th 44
6th 49
K
Reverse 14
Main gear 1st 49
2nd 35 L
3rd 39
4th 36
M
5th 34
6th 33
Reverse 38
Reverse idler gear Front 37
Rear 46
Oil capacity (Imp pt) 2.3 (4)
Remarks Reverse synchronizer Installed

Double baulk ring type synchro-
1st & 2rd synchronizer
nizer
FINAL GEAR
Engine YD22DDTi
Transaxle model RS6F51R
Model code number AW664
MT-93
[RS6F51R]
Final gear ratio 3.812
Final gear/Pinion 61/16
Number of teeth
Side gear/Pinion mate gear 14/11
*: Refer to MA section, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Gear End Play ECS00F3T
Unit: mm (in)
Gear End play
1st main gear 0.20 - 0.30 (0.0079 - 0.0118)
2nd main gear 0.06 - 0.16 (0.0024 - 0.0063)
3rd input gear 0.18 - 0.31 (0.0071 - 0.0122)
4th input gear 0.20 - 0.30 (0.0079 - 0.0118)
5th input gear 0.06 - 0.16 (0.0024 - 0.0063)
6th input gear 0.06 - 0.16 (0.0024 - 0.0063)
Clearance Between Baulk Ring and Gear ECS00F3U
3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING

Unit: mm (in)
Standard Wear limit
3rd 0.9 - 1.45 (0.0354 - 0.0571)
4th 0.9 - 1.45 (0.0354 - 0.0571)
5th 0.95 - 1.4 (0.0374 - 0.0551) 0.7 (0.0276)
6th 0.95 - 1.4 (0.0374 - 0.0551)
Reverse 0.95 - 1.4 (0.0374 - 0.0551)
1ST AND 2ND DOUBLE BAULK RING

Unit: mm (in)
SMT138E
Dimension Standard Wear limit

A 0.6 - 0.8 (0.024 - 0.031)
0.2 (0.008)
B 0.6 - 1.1 (0.024 - 0.043)
Available Snap Rings ECS00F3V
6TH BUSHING
End play 0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in) Part number* Thickness mm (in) Part number*
1.76 (0.0693) 32204 8H511 2.01 (0.0791) 32204 8H516
1.81 (0.0713) 32204 8H512 2.06 (0.0811) 32204 8H517
1.86 (0.0732) 32204 8H513 2.11 (0.0831) 32204 8H518
1.91 (0.0752) 32204 8H514 2.16 (0.0850) 32204 8H519
1.96 (0.0772) 32204 8H515 2.21 (0.0870) 32204 8H520
*: Always check with the Parts Department for the latest parts information.
MT-94
[RS6F51R]
Available C-rings ECS00F3W
MAINSHAFT C-RING A
End play 0 - 0.06 mm (0 - 0.0024 in)
B
2.535 (0.0998) 32348 8H800 2.835 (0.1116) 32348 8H810
2.565 (0.1010) 32348 8H801 2.865 (0.1128) 32348 8H811
2.595 (0.1022) 32348 8H802 2.895 (0.1140) 32348 8H812
2.625 (0.1033) 32348 8H803 2.925 (0.1152) 32348 8H813 MT
2.655 (0.1045) 32348 8H804 2.955 (0.1163) 32348 8H814
2.685 (0.1057) 32348 8H805 2.985 (0.1175) 32348 8H815
2.715 (0.1069) 32348 8H806 3.015 (0.1187) 32348 8H816
2.745 (0.1081) 32348 8H807 3.045 (0.1199) 32348 8H817 D
2.775 (0.1093) 32348 8H808 3.075 (0.1211) 32348 8H818
2.805 (0.1104) 32348 8H809
*: Always check with the Parts Department for the latest parts information. E
Available Thrust Washer ECS00F3X
INPUT SHAFT THRUST WASHER

F
I
SCIA1008E
Standard length “C2” 154.7 - 154.8 mm (6.091 - 6.094 in)

J
3.84 (0.1512) 32347 8H500 4.02 (0.1583) 32347 8H503
3.90 (0.1535) 32347 8H501 4.08 (0.1606) 32347 8H504
3.96 (0.1559) 32347 8H502 4.14 (0.1630) 32347 8H505 K
DIFFERENTIAL SIDE GEAR THRUST WASHER L

Allowable clearance between side gear and differential case with
0.1 - 0.2 mm (0.004 - 0.008 in)
washer
Thickness mm (in) Part number* M
0.75 (0.0295) 38424 81X00
0.80 (0.0315) 38424 81X01
0.85 (0.0335) 38424 81X02
0.90 (0.0354) 38424 81X03
0.95 (0.0374) 38424 81X04
MT-95
[RS6F51R]
Available Adjusting Shims ECS00F3Y
MAINSHAFT ADJUSTING SHIM
SCIA1009E
Standard length “C1” 173.85 - 173.95 mm (6.844 - 6.848 in)

0.52 (0.0205) 32238 8H500 0.84 (0.0331) 32238 8H504
0.60 (0.0236) 32238 8H501 0.92 (0.0362) 32238 8H505
0.68 (0.0268) 32238 8H502 1.00 (0.0394) 32238 8H506
0.76 (0.0299) 32238 8H503 1.08 (0.0425) 32238 8H507
INPUT SHAFT REAR BEARING ADJUSTING SHIM

End play 0 - 0.06 mm (0 - 0.0024 in)
Thickness mm (in) Part number* Thickness mm (in) Part number* Thickness mm (in) Part number*
0.40 (0.0157) 32225 8H500 0.88 (0.0346) 32225 8H512 1.36 (0.0535) 32225 8H524
0.44 (0.0173) 32225 8H501 0.92 (0.0362) 32225 8H513 1.40 (0.0551) 32225 8H560
0.48 (0.0189) 32225 8H502 0.96 (0.0378) 32225 8H514 1.44 (0.0567) 32225 8H561
0.52 (0.0205) 32225 8H503 1.00 (0.0394) 32225 8H515 1.48 (0.0583) 32225 8H562
0.56 (0.0220) 32225 8H504 1.04 (0.0409) 32225 8H516 1.52 (0.0598) 32225 8H563
0.60 (0.0236) 32225 8H505 1.08 (0.0425) 32225 8H517 1.56 (0.0614) 32225 8H564
0.64 (0.0252) 32225 8H506 1.12 (0.0441) 32225 8H518 1.60 (0.0630) 32225 8H565
0.68 (0.0268) 32225 8H507 1.16 (0.0457) 32225 8H519 1.64 (0.0646) 32225 8H566
0.72 (0.0283) 32225 8H508 1.20 (0.0472) 32225 8H520
0.76 (0.0299) 32225 8H509 1.24 (0.0488) 32225 8H521
0.80 (0.0315) 32225 8H510 1.28 (0.0504) 32225 8H522
0.84 (0.0331) 32225 8H511 1.32 (0.0520) 32225 8H523
*: Always check with the parts department for the latest information.
MAINSHAFT REAR BEARING ADJUSTING SHIM

End play 0 - 0.06 mm (0 - 0.0024 in)
0.44 (0.0173) 32238 8H510 0.80 (0.0315) 32238 8H519
0.48 (0.0189) 32238 8H511 0.84 (0.0331) 32238 8H520
0.52 (0.0205) 32238 8H512 0.88 (0.0346) 32238 8H521
0.56 (0.0220) 32238 8H513 0.92 (0.0362) 32238 8H522
0.60 (0.0236) 32238 8H514 0.96 (0.0378) 32238 8H523
0.64 (0.0252) 32238 8H515 1.00 (0.0394) 32238 8H524
0.68 (0.0268) 32238 8H516 1.04 (0.0409) 32238 8H560
0.72 (0.0283) 32238 8H517 1.08 (0.0425) 32238 8H561
0.76 (0.0299) 32238 8H518
REVERSE IDLER GEAR ADJUSTING SHIM

End play 0.04 - 0.14 mm (0.0016 - 0.0055 in)
MT-96
[RS6F51R]
A
1.76 (0.0693) 32237 8H800 2.24 (0.0882) 32237 8H812
1.84 (0.0724) 32237 8H802 2.32 (0.0913) 32237 8H814
1.92 (0.0756) 32237 8H804 2.40 (0.0945) 32237 8H816
2.00 (0.0787) 32237 8H806 2.48 (0.0976) 32237 8H818 B
2.08 (0.0819) 32237 8H808 2.56 (0.1008) 32237 8H820
2.16 (0.0850) 32237 8H810 2.64 (0.1039) 32237 8H822
MT
6TH MAIN GEAR ADJUSTING SHIM
End play 0 - 0.1 mm (0 - 0.004 in)
D
0.88 (0.0346) 32237 8H560 1.20 (0.0472) 32237 8H564
0.96 (0.0378) 32237 8H561 1.28 (0.0504) 32237 8H565
1.04 (0.0409) 32237 8H562 1.36 (0.0535) 32237 8H566 E
1.12 (0.0441) 32237 8H563
F
Available Shims ECS00F3Z
— Differential Side Bearing Preload and Adjusting Shim

BEARING PRELOAD G
Differential side bearing preload: L* 0.15 - 0.21 mm (0.0059 - 0.0083 in)

*: Install shims which are “deflection of differential case” + “L” in thickness. H
DIFFERENTIAL SIDE BEARING ADJUSTING SHIM (S)
I
0.48 (0.0189) 31438 80X00 0.72 (0.0283) 31438 80X06
0.52 (0.0205) 31438 80X01 0.76 (0.0299) 31438 80X07
0.56 (0.0220) 31438 80X02 0.80 (0.0315) 31438 80X08
0.60 (0.0236) 31438 80X03 0.84 (0.0331) 31438 80X09 J
0.64 (0.0252) 31438 80X04 0.88 (0.0346) 31438 80X10
0.68 (0.0268) 31438 80X05 0.92 (0.0362) 31438 80X11
*: Always check with the Parts Department for the latest parts information. K
MT-97
[RS6F51R]
MT-98

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MANUAL TRANSAXLE

B. Vi. 31-01 Removing and installing retaining pin

B. Vi. 1170 Removing 5th synchronizer

B. Vi. 22-01 Removing 5th gear I

B. Vi. 1576 Removing input shaft bearing

B. Vi. 1601 Installing bearing guide of mainshaft

B. Vi. 1175 Installing 5th gear

B. Vi. 1666 Installing differential oil seal

Commercial Service Tools ECS00F41

Tool name Description

Install in the reverse order of removal.

Tightening portion N·m (kg-m, ft-lb)

1. Oil channel 2. Mainshaft front bearing 3. Mainshaft

Shift Control Components ECS00F49

Clutch Housing ECS00F4B

Removal and Installation of Control Device and Cable ECS00F45

Refer to the figure for removal and installation procedure.

Types Packaging Parts Department No. Component

Fill to the level of the fuel filler cap hole.

Symptom Chart ECS00F4F

Symptoms (after checking

Gear position Continuity

If they have been removed:

Make sure the sliding gear turns smoothly in the hub.

Fit the B. Vi. 1581 support plate on a Desvil stand.

1. Remove the clutch operating cylinder.

Remove the back-up lamp switch (B). H

1. Remove the 4th-gear pinion.

2. Remove the 3rd/4th gear shaft/fork and sliding gear assembly

3. Remove mainshaft assembly.

4. Remove input shaft assembly.

Removing The Gearing ECS00F4L

Checking Parts ECS00F4M

Proceed in the reverse order to removal.

Fit a new circlip.

Removal and Installation ECS00F4Q

2. Fit a new deflector, then the bearing race using a 55 mm (2.17

1. Remove the rings with an inertia puller.

Removal and Installation ECS00F4S

1. Remove the bearing using an antisticking pin.

2. Refit the bearings using a tube with a diameter of 40 mm (1.57

3. Remove the bearing races using a roll pin punch.

Setting The Pre-tensioning of The Mainshaft Bearings ECS00F4V

1. Fit the B. Vi. 1527 special spacer (A).

Calculation of the value of the pre-load washer.

1. Fit the mainshaft and 1st/2nd gear fork assembly.

3. Fit the reverse gear assembly. I

4. Fit the two locking shafts.

6. Pin the reverse gear assembly.

8. Refit the 4th gear fitted with its synchronizer ring.

Apply a line of LOCTITE 518 to the gasket face. I

Refit the 5th gear fork/sliding gear/reverse gear fork assembly.

Tighten the gear bolt and nut to torque:

ST35321000 ● Input shaft oil seal installation

ST30720000 ● Differential oil seal installation G

ST33052000 ● Welch plug installation

KV40105020 ● 5th input gear and synchronizer hub

KV40105710 ● 3rd-4th synchronizer hub installation

ST38220000 ● Reverse main gear installation

ST30032000 ● Input shaft front bearing installation

ST30901000 ● Input shaft rear bearing installation

ST30031000 ● Measuring wear of 1st and 2nd baulk ring

KV40101630 ● Reverse main gear installation