MT PDF

TRANSMISSION/TRANSAXLE
MT
A
B
SECTION
MANUAL TRANSMISSION MT
E
CONTENTS
FS5W71C TRANSMISSION ASSEMBLY .......................... 11 F
Removal and Installation .........................................11
SERVICE INFORMATION ............................ 2 Overhaul ..................................................................12
G
PRECAUTIONS ................................................... 2 CASE COMPONENTS ...................................... 19
Precaution for Supplemental Restraint System Disassembly ............................................................19
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Assembly .................................................................20
SIONER" ................................................................... 2 H
SHIFT CONTROL COMPONENTS ................... 23
PREPARATION ................................................... 3 Disassembly ............................................................23
Special Service Tool ................................................. 3 Inspection ................................................................24 I
Commercial Service Tool .......................................... 5 Assembly .................................................................24
NOISE, VIBRATION AND HARSHNESS GEAR COMPONENTS ...................................... 26
(NVH) TROUBLESHOOTING ............................. 6 Disassembly ............................................................26 J
NVH Troubleshooting Chart ...................................... 6 Inspection ................................................................28
Assembly .................................................................29
DESCRIPTION .................................................... 7 K
CROSS-SECTIONAL VIEW ...................................... 7 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 37
M/T OIL ................................................................ 9 General Specification ..............................................37
Changing ................................................................... 9 L
Gear End Play .........................................................37
Checking ................................................................... 9 Clearance Between Baulk Ring and Gear ...............38
ON-VEHICLE SERVICE .....................................10 Available Shims .......................................................38
M
Replacing Rear Oil Seal .......................................... 10
Position Switch Check ............................................. 10
Revision: April 2013 MT-1 2013 D22 LCV

PRECAUTIONS
< SERVICE INFORMATION > [FS5W71C]
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000008945221
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.

PREPARATION
PREPARATION
A
Special Service Tool INFOID:0000000008945222
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. B
Tool number Description
(Kent-Moore No.)
Tool name
MT
ST23810001 Fixing adapter plate with gear assembly
( — ) a: 166 mm (6.54 in)
Adapter setting plate b: 270 mm (10.63 in)
D
E
NT407
KV32101330 Removing OD mainshaft bearing

(See J-34286) a: 447 mm (17.60 in)
Puller b: 100 mm (3.94 in) F
NT408
KV31100401 Pressing counter gear, mainshaft, counter H

( — ) drive gear and main drive gear
Transmission press stand
NT068
J
ST22520000 Tightening mainshaft lock nut
(J-26348) a: 100 mm (3.94 in)
Wrench b: 41 mm (1.61 in)
K
L
NT409
ST23540000 Removing and installing fork rod retaining pin

(J-25689-A) a: 2.3 mm (0.091 in) dia. M
Pin punch b: 4 mm (0.16 in) dia.
NT442
ST30031000 Removing 1st gear bushing O

(J-22912-01) Removing main drive gear ball bearing
Puller a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
P
NT411

PREPARATION
(Kent-Moore No.)
Tool name
ST23860000 Installing counter drive gear
( — ) a: 38 mm (1.50 in) dia.
Drift b: 33 mm (1.30 in) dia.
NT065
ST22360002 Installing counter gear front and rear end

(J-25679-01) bearings
Drift a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.
NT065
ST22350000 Installing OD gear bushing

(J-25678-01) a: 34 mm (1.34 in) dia.
NT065
ST23800000 Installing front cover oil seal

(J-25691-01) a: 44 mm (1.73 in) dia.
NT065
ST33400001 Installing rear oil seal

(J-26082) a: 60 mm (2.36 in) dia.
NT086
ST33290001 Removing rear oil seal

(J-34286) a: 250 mm (9.84 in)
Puller b: 160 mm (6.30 in)
NT414
ST30720000 Installing mainshaft ball bearing

(J-25405) a: 77 mm (3.03 in) dia.
Drift b: 55.5 mm (2.185 in) dia.
NT115

PREPARATION
(Kent-Moore No.) A
Tool name
ST30613000 Installing main drive gear ball bearing
(J-25742-3) a: 71.5 mm (2.815 in) dia. B
Drift b: 47.5 mm (1.870 in) dia.
MT
NT073
ST33200000 Installing counter rear bearing and counter D

(J-26082) gear assembly
Drift a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
E
NT091 F
— Removing and installing mainshaft bearing
(J-26349-A) (Use with J-25726-B)
Bearing Remover and Installer Set G
H
WMT065
— Removing races
(J-34286) I
Rear Race Puller
WMT066
K
— Removing gears and bearings
(J-39856)
Gear and Bearing Removal Kit
L
M
WMT067
Commercial Service Tool INFOID:0000000008945223
Tool name Description

Puller Removing counter bearings, counter drive O
and OD gears
NT077

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000008945224
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.
MT-19
MT-23
MT-26
MT-9
Reference page
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)

SUSPECTED PARTS
(Possible cause)
BAULK RING (Worn or damaged)

BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
INSERT SPRING (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
Symptom
Hard to shift or will not shift 1 1 2 2
Jumps out of gear 1 2 2

DESCRIPTION
DESCRIPTION
A
CROSS-SECTIONAL VIEW INFOID:0000000008945225
MT
P
AWDIA0506ZZ
1. Steel ball 2. Mainshaft ball bearing 3. Reverse main gear

4. Reverse gear bushing 5. Needle bearing 6. OD & Reverse coupling sleeve
7. OD & Reverse synchronizer hub 8. OD gear bushing 9. Needle bearing
10. OD main gear 11. Striking rod 12. Control housing

DESCRIPTION
13. Shift lever 14. Dust cover 15. Rear oil seal
16. Rear extension 17. Mainshaft 18. Speedometer drive gear
19. OD mainshaft bearing 20. Steel roller 21. Counter gear rear end bearing
22. OD counter gear 23. Reverse idler shaft 24. Reverse counter gear
25. Reverse idler gear bearing 26. Reverse idler gear 27. Counter rear bearing
28. Drain plug 29. Counter gear 30. Counter drive gear
31. Sub gear bracket 32. Sub gear 33. counter gear front bearing
34. Front cover oil seal 35. Front cover 36. Main drive gear ball bearing
37. Transmission case 38. Main drive gear 39. Pilot bearing
40. 3rd & 4th synchronizer hub 41. 3rd & 4th coupling sleeve 42. 3rd main gear
43. 2nd main gear 44. 1st & 2nd synchronizer hub 45. 1st & 2nd coupling sleeve
46. 1st main gear 47. Adapter plate

M/T OIL
M/T OIL
A
Changing INFOID:0000000008945226
DRAINING B
1. Remove the transmission drain plug and drain the oil.
2. Apply sealant to the drain plug and install it to the transmission. Tighten the drain plug to the specified
torque. Refer to MT-12, "Overhaul". MT
• Apply Genuine liquid Gasket, Three Bond 1215 or equivalent.
FILLING
D
1. Remove the filler plug. Fill with new oil until oil level reaches the
specified limit near the filler plug hole. After refilling the oil, check
oil level.
E
Oil grade and Viscosity:
Refer to MA-9, "Fluids and Lubricants".
F
Oil capacity:
Refer to MA-9, "Fluids and Lubricants".
2. Apply sealant to the filler plug, then install it to the transmission. G
Tighten the filler plug to the specified torque. Refer to MT-12,
SMA103
"Overhaul".
• Apply Genuine liquid Gasket, Three Bond 1215 or equivalent. H
Checking INFOID:0000000008945227
OIL LEAKAGE AND OIL LEVEL I

1. Make sure that oil is not leaking from the transmission or around it.
2. Check oil level from the filler plug hole as shown. J
CAUTION:
Do not start engine while checking oil level.
3. Apply sealant to the filler plug and install it to the transmission.
Tighten the filler plug to the specified torque. Refer to MT-12, K
"Overhaul".
• Apply Genuine liquid Gasket, Three Bond 1215 or equivalent.
L
SMA103
M

ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
Replacing Rear Oil Seal INFOID:0000000008945228
REMOVAL
1. Remove the propeller shaft. Refer to PR-8, "Removal and Installation".
2. Remove rear oil seal using Tool.
• Always replace with a new seal once it has been removed.
Tool number : ST33290001 (J-34286)
WCIA0176E
INSTALLATION
1. Install new rear oil seal using Tool until it stops.
• Apply multi-purpose grease to seal lip of oil seal before
installing.
Tool number : ST33400001 (J-26082)

2. Installation is in the reverse order of removal.
SMT480CA
Position Switch Check INFOID:0000000008945229
• Check continuity.
Switch Gear position Continuity

Reverse Yes
Back-up lamp switch
Except reverse No
Park/neutral position Neutral Yes

(PNP) switch Except neutral No
SMT981D

TRANSMISSION ASSEMBLY
A
Removal and Installation INFOID:0000000008945230
REMOVAL B
MT
WMT030
CAUTION: P
• Before separating the transmission from the engine, remove the crankshaft position sensor (OBD)
from the transmission. Be careful not to damage sensor edge or ring gear teeth.
• Be careful not to damage spline, sleeve yoke, and rear oil seal when removing propeller shaft.
NOTE:
To prevent oil spills, drain transmission oil before removing transmission or insert plug into rear oil seal after
removing propeller shaft.
1. Remove battery negative terminal. Refer to SC-6, "Removal and Installation".

2. Remove the crankshaft position sensor (OBD) from transmission upper side.
3. Remove the clutch operating cylinder from transmission. Refer to CL-10.
4. Disconnect the vehicle speed sensor, back-up lamp switch, and park/neutral position (PNP) switch har-
ness connectors.
5. Remove the starter motor. Refer to SC-14, "Removal and Installation".
6. Disconnect the exhaust hanger. Refer to EX-4, "Removal and Installation".
7. Remove the propeller shaft. Refer to PR-8, "Removal and Installation".
8. Remove the shift lever.
9. Support the engine and transmission using suitable jacks.
CAUTION:
Do not place jack under oil pan drain plug.
10. Remove the transmission crossmember.
11. Separate the transmission from the engine.
WARNING:
Support manual transmission while removing it.
SMT099A
INSTALLATION
Installation is in the reverse order of removal.
Tighten transmission bolts to the specified torque.
Bolt No. Tightening torque N·m (kg-m, ft-lb) mm (in)

1 39 - 49 (4.0 - 5.0, 29 - 36) 65 (2.56)
2 39 - 49 (4.0 - 5.0, 29 - 36) 58 (2.28)
3* 16 - 21 (1.6 - 2.2, 12 - 15) 25 (0.98)
4 16 - 21 (1.6 - 2.2, 12 - 15) 16 (0.63)
*: With nut
AMT190
Overhaul INFOID:0000000008945231
CASE COMPONENTS

MT
AWDIA1101ZZ
P
1. Park/neutral position (PNP) switch 2. Clip 3. Dust cover
4. Rear oil seal 5. Reverse check sleeve bolt 6. O-ring
7. Vehicle speed sensor 8. Rear extension bolt 9. Rear extension
10. Bearing retainer 11. Mainshaft ball bearing 12. Adapter plate
13. Filler plug 14. Drain plug 15. Gasket
16. Front cover oil seal 17. Front cover 18. Ball pin

19. Washer 20. Front cover bolt 21. Transmission case
22. Back-up lamp switch Apply Genuine Liquid Gasket, Three
Bond 1215 or equivalent.
AWDIA0511ZZ
A. Lead wire B. Clip cutout C. Pulling direction

D. 10 mm (0.39 in) E. OK condition F. NG condition
G. Rubber R. 5 mm (0.20 in)
CAUTION:
• The lead wire must pass through clip cutout.
• The lead wire must be loosened to a radius of at least 5 mm (0.20 in). Loosen lead wire by pulling
lead wire in pulling direction.
GEAR COMPONENTS

MT
AWDIA0522GB
P
1. Main drive gear 2. Main drive gear ball bearing snap 3. Main drive gear ball bearing
ring
4. Snap ring 5. Pilot bearing 6. Mainshaft front snap ring
7. 4th baulk ring 8. Spread spring 9. 3rd baulk ring
10. Needle bearing 11. 3rd main gear 12. 3rd and 4th coupling sleeve
13. 3rd and 4th synchronizer hub 14. Shifting insert 15. Steel ball (for mainshaft thrust washer -
small)

16. Steel roller (for OD main gear thrust 17. Steel ball (for speedometer main- 18. Needle bearing
washer) shaft drive gear - large)
19. 2nd main gear 20. 2nd baulk ring 21. 1st & 2nd synchronizer hub
22. 1st gear thrust washer 23. Mainshaft ball bearing 24. 1st main gear
25. 1st gear bushing 26. Needle bearing 27. 1st baulk ring
28. 1st & 2nd coupling sleeve 29. Insert spring 30. Reverse gear bushing
31. Reverse main gear 32. Needle bearing 33. Reverse baulk ring
34. Spread spring 35. OD and reverse synchronizer hub 36. Spread spring
37. OD and reverse coupling sleeve 38. OD baulk ring 39. OD main gear
40. Needle bearing 41. OD gear bushing 42. Washer
43. Roller bearing 44. Thrust washer 45. Speedometer drive gear
46. Mainshaft lock nut 47. OD mainshaft bearing 48. OD mainshaft bearing snap ring
49. OD mainshaft bearing snap ring 50. Shifting insert 51. Counter gear front bearing shim
52. Counter gear front bearing 53. Sub-gear spring 54. Sub-gear
55. Counter drive gear 56. Woodruff key 57. Counter gear
58. Counter rear bearing 59. Reverse counter gear spacer 60. Reverse counter gear
61. OD counter gear 62. Counter gear rear end bearing 63. Counter gear lock-nut
64. Sub-gear bracket 65. Counter gear snap ring 66. Reverse idler shaft
67. Reverse idler gear 68. Sub-gear 69. Sub-gear spring
70. Reverse idler gear bearing 71. Reverse idler thrust washer 72. Snap ring
73. Snap ring 74. Sub-gear bracket 75. Steel ball
SHIFT CONTROL COMPONENTS

CAUTION:
To avoid damage when replacing shift knob, remove shift lever with knob, as assembled.

MT
N
AWDIA1100ZZ
1. Striking rod 2. Lock pin 3. Select check plungerx

4. Retainer pin 5. Return spring 6. Select check plug O
7. Bushing 8. Check spring 9. Check ball
10. Striking arm 11. Striking lever 12. Check ball plug
13. Control housing bolt 14. Snap ring 15. Socket P
16. Spring 17. Shift knob 18. Shift lever
19. Upper boot retainer 20. Boot 21. Lower boot retainer
22. Control housing 23. Gasket 24. OD and reverse bracket
25. OD and reverse shift fork 26. OD & reverse fork rod 27. 3rd and 4th shift fork
28. 3rd & 4th fork rod 29. Interlock plunger 30. 1st and 2nd shift fork

31. 1st & 2nd fork rod 32. Interlock ball 33. Reverse check bolt
C: Apply cement Apply Genuine Liquid Gasket, Three Bond 1215 or equivalent.

CASE COMPONENTS
CASE COMPONENTS
A
Disassembly INFOID:0000000008945232
1. Remove drain plug from transmission case and drain gear oil. B
2. Remove filler plug from transmission case.
3. Remove rear extension.
a. Remove control housing, gasket, check spring (1), check ball MT
(2), select check plugs (3), return springs (4) and select check
plungers (5).
CAUTION: D
Be careful not to lose check balls.
AWDIA0524ZZ
F
b. Drive out striking arm retaining pin.
c. Remove striking arm from striking rod.
d. Remove rear extension by lightly tapping on it. G
I
SMT162D
4. Remove front cover, gasket, counter gear front bearing shim J

and main drive gear ball bearing snap ring.
5. Separate transmission case from adapter plate by lightly tapping
on it. K
AMT131 M
6. Remove front cover oil seal (1) from front cover (2) using suit-
able tool. N
CAUTION:
Be careful not to damage mating surface of front cover.
O
AWDIA0525ZZ

CASE COMPONENTS
Assembly INFOID:0000000008945233
1. Install front cover oil seal using Tool.

• Apply multi-purpose grease to seal lip.
Tool number : ST23800000 (J-25691-01)
SMT036
2. Apply sealant to mating surface of transmission case as shown.

• Use Genuine Liquid Gasket, Three Bond 1215 or equivalent.
SMT061C
3. Install adapter plate into transmission case by lightly tapping it

using a soft hammer.
SMT013
4. Install main drive gear ball bearing snap ring.
SMT672A

CASE COMPONENTS
5. Apply sealant to mating surface of adapter plate as shown.
• Use Genuine Liquid Gasket, Three Bond 1215 or equivalent. A
MT
SMT062C
D
6. Place shift forks in neutral position.
7. Install striking lever and striking rod onto adapter plate and align
striking lever with shift brackets. E
G
SMT801B
8. Install rear extension. Tighten mounting bolts to the specified

H
torque. Refer to MT-12, "Overhaul".
• Tighten rear extension bolts equally in a crisscross pattern.
SMT180D
K
9. Install striking arm retaining pin.
N
SMT162D
10. Select counter gear front bearing shim. O
Allowable clearance (A) : Refer to MT-38, "Avail-

from bearing surface to able Shims". P
transmission case
11. Install new gasket and front cover.
SMT205D

CASE COMPONENTS
12. Install front cover. Tighten front cover bolts to the specified torque. Refer to MT-12, "Overhaul".
13. Install check ball (2), check spring (1), select check plungers (5)
and return springs (4).
14. Apply sealant to select check plugs (3). Tighten select check
plugs to the specified torque. Refer to MT-12, "Overhaul".
15. Install control housing and new gasket. Tighten control housing
bolts and reverse check bolt to the specified torque. Refer to
MT-12, "Overhaul".
16. Install drain plug to transmission case. Tighten drain plug to the
specified torque. Refer to MT-12, "Overhaul".
AWDIA0525ZZ
17. Install filler plug to transmission case. Tighten filler plug to the
specified torque. Refer to MT-12, "Overhaul".

A
1. Set up Tool on adapter plate. B
Tool number : ST23810001 ( — )

2. Remove striking rod from adapter plate. MT
3. Remove check ball plugs, check springs, and check balls.
NOTE:
Mark locations of interlock balls to ensure proper installation. D
SMT545A E
4. Drive out retaining pins. Then drive out fork rods and remove
interlock balls.
F
SMT984
I
5. Draw out 3rd & 4th and OD & reverse fork rods.
L
SMT789A

Inspection INFOID:0000000008945235
• Check contact and sliding surfaces of fork rods for wear, scratches,
projections and other damage.
SMT075C
1. Install fork rods, interlock plunger, interlock balls and check

balls.
SMT992-A
2. Install 1st and 2nd shift fork, then drive in retaining pin.
SMT989

3. Install 3rd and 4th shift fork, then drive in retaining pin.
A
MT
SMT990
D
4. Install OD and reverse shift fork, then drive in retaining pin.
G
SMT991

GEAR COMPONENTS
GEAR COMPONENTS
1. Before disassembly, measure the end play of each gear.

• If end play is not within the specified limit, disassemble and
inspect the parts.
• Replace any part which is worn or damaged. Refer to MT-37,
"Gear End Play".
SMT025
2. Mesh 2nd and reverse gear, then remove counter gear front
bearing using a suitable puller.
3. Remove counter gear snap ring, then remove sub-gear bracket,
sub-gear spring and sub-gear.
SMT174A
4. Remove counter drive gear together with main drive gear

assembly using a suitable puller. Remove woodruff keys and
pilot bearing.
• When removing main drive gear assembly, be careful not to
drop pilot bearing or baulk ring.
5. Remove mainshaft front snap ring, then remove 3rd & 4th syn-
chronizer assembly, 3rd main gear and needle bearing using
suitable puller.
SMT162A
6. Disassemble parts at rear of adapter plate as follows:

a. Release staking on both counter gear and mainshaft lock nuts,
then loosen both nuts.
CAUTION:
Mainshaft lock nut is left-handed thread.
WCIA0181E

GEAR COMPONENTS
b. Remove OD counter gear together with counter gear rear end
bearing using a suitable puller. A
c. Remove reverse counter gear and reverse counter gear spacer.
d. Remove snap rings from reverse idler shaft, then remove
reverse idler gear, sub-gear, sub-gear spring, sub-gear bracket, B
steel ball, reverse idler thrust washer and reverse idler gear
bearing.
MT
SMT547A
D
e. Remove OD mainshaft bearing snap ring and pull out OD mainshaft bearing using Tool, then remove snap
ring.
E
Tool number : KV32101330 (J-26349-A)
: — (J-25726-B)
f. Remove mainshaft lock nut. F
g. Remove speedometer drive gear and steel ball.
h. Remove thrust washer, steel roller, roller bearing and washer.
G
i. Remove OD main gear, needle bearing and OD baulk ring.
j. Remove counter gear by tapping on rear end of counter gear.
k. Press out OD gear bushing and OD & reverse synchronizer assembly. H
l. Remove reverse main gear and needle bearing.
m. Press out reverse main gear bushing.
I
SMT554A
L
n. Remove mainshaft by tapping on rear end of mainshaft.
7. Remove 1st gear thrust washer, steel ball, 1st main gear and
needle bearing and 1st & 2nd synchronizer assembly. M
• Be careful not to lose steel ball.
SMT383A

GEAR COMPONENTS
8. Press out 1st gear bushing together with 2nd main gear using
Tool.
Tool number : ST30031000 (J-22912-01)
TM049A
9. Remove needle bearing.

10. Remove main drive gear ball bearing.
a. Remove main drive gear ball bearing snap ring.
b. Remove main drive gear ball bearing using Tool.
Tool number : ST30031000 (J-22912-01)

11. Disassemble adapter plate components.
a. Remove bearing retainer.
b. Remove oil gutter.
c. Remove reverse idler shaft. SMT420A
d. Remove mainshaft ball bearing and counter rear bearing using

suitable tool.
Inspection INFOID:0000000008945238
GEARS AND SHAFTS

• Check shafts for cracks, wear and bending.
SMT386A
• Check gears for excessive wear, chips and cracks.
SMT550A
SYNCHRONIZERS

GEAR COMPONENTS
• Check spline portion of coupling sleeves, synchronizer hubs, and
gears for wear, chips, and cracks. A
• Check baulk rings for cracks and deformation.
• Check shifting inserts for wear and deformation.
• Check insert springs for deformation.
B
MT
SMT427C
D
• Check spread springs for deformation.
• Measure baulk ring wear.
1. Measure clearance between baulk ring and gear. Refer to MT- E
38, "Clearance Between Baulk Ring and Gear".
• If the clearance is less than the wear limit, replace baulk ring.
F
G
SMT140
BEARINGS H
• Make sure all bearings roll freely and are free from noise, cracks,
pitting or wear.
I
K
SMT418A
1. Install bearings into case components.

M
AMT185
P
Tool numbers
Mainshaft ball bearing : ST30720000 (J-25405)
Counter rear bearing : ST33200000 (J-26082)

GEAR COMPONENTS
2. Assemble adapter plate parts.
a. Install oil gutter on adapter plate and expand on rear side.
b. Insert reverse idler shaft, then install bearing retainer.
SMT175D
c. Tighten bearing retainer bolts to the specified torque, refer to

MT-12, "Overhaul". Then stake each bolt at two points.
SMT674C
3. Install main drive gear ball bearing.

a. Press main drive gear ball bearing using Tool.
Tool number : ST30613000 (J-25742-3)
SMT425A
b. Select and install a main drive gear ball bearing snap ring so
that the end play comes within the standard value.
End play standard value : Refer to MT-37, "Gear

End Play".
SMT426A
4. Assemble synchronizers.
• Assemble the 1st & 2nd synchronizer.
SMT054C

GEAR COMPONENTS
• Check coupling sleeve and synchronizer hub orientation.
A
MT
G
SMT206C
• Assemble the 3rd & 4th synchronizer. H
N
WMT053

GEAR COMPONENTS
• Assemble the OD & reverse synchronizer.
SMT207CA
5. Assemble front side components to mainshaft.

a. Install 2nd main gear, needle bearing and 1st & 2nd synchro-
nizer assembly; then press 1st gear bushing onto the mainshaft.
b. Install 1st main gear.
SMT752A
c. Install steel ball and 1st gear thrust washer.

• Before installation, apply multi-purpose grease to steel ball
and to both sides of the 1st gear thrust washer.
TM358
6. Install mainshaft and counter gear on adapter plate and main

drive gear on mainshaft as follows:
a. Press mainshaft assembly into adapter plate using Tool.
Tool number : KV31100401 ( — )
TM439

GEAR COMPONENTS
b. Press counter gear into adapter plate using Tool.
A
Tool number : ST33200000 (J-26082)
: KV31100401 ( — )
B
MT
SMT750
D
c. Install 3rd main gear and needle bearing, then press 3rd and 4th synchronizer assembly onto mainshaft.
• Pay attention to the direction of 3rd and 4th synchronizer.
d. Select and install a mainshaft front snap ring so that the end
E
play comes within the standard value.

F
End Play".
e. Apply gear oil to mainshaft pilot bearing and install it on main-
shaft.
G
TM441
H
f. Press counter drive gear together with main drive gear using
Tool.
• Pay attention to the direction of counter drive gear. I
Tool number : ST23860000 ( — )

: KV31100401 ( — ) J
K
SMT412C
g. Install sub-gear and sub-gear bracket on counter drive gear and L

then select proper counter gear snap ring so that the end play
comes within the standard value.
M
End Play".
SMT201D O

GEAR COMPONENTS
h. Remove snap ring, sub-gear bracket and sub-gear from counter
gear.
i. Reinstall sub-gear, sub-gear spring, sub-gear bracket and
selected counter gear snap ring.
SMT202D
j. Press counter gear front bearing onto counter gear using Tool.
Tool number : ST22360002 (J-25679-01)

: KV31100401 ( — )
TM443
7. Install rear side components on mainshaft and counter gear as

follows:
a. Install sub-gear, sub-gear spring, sub-gear bracket, steel ball
and snap ring on the reverse idler gear.
b. Install reverse idler gear assembly, reverse idler thrust washer,
snap ring and reverse idler gear bearing on the reverse idler
shaft.
AMT134
c. Install reverse main gear bushing, needle bearing, reverse main

gear and OD & reverse synchronizer to mainshaft.
CAUTION:
Pay attention to the direction of synchronizer hub.
SMT207CA

GEAR COMPONENTS
d. Install OD gear bushing to mainshaft using Tool.
A
Tool number : ST22350000 (J-25678-01)
e. Install OD main gear and needle bearing to mainshaft.
B
f. Install reverse counter gear spacer, reverse counter gear and
OD counter gear to counter gear.
• OD main gear and OD counter gear should be handled as a
matched set. MT
g. Install washer, roller bearing, steel roller and thrust washer.
h. Install steel ball and speedometer drive gear. SMT531
D
i. Tighten mainshaft lock nut temporarily.
CAUTION:
Always use new mainshaft lock nut.
E
j. Install counter gear rear end bearing using Tool.
Tool number : ST2236002 (J-25679-01) F
H
SMT043
8. Mesh 2nd and reverse gears, then tighten mainshaft lock nut to
the specified torque using Tool. Refer to MT-12, "Overhaul". I
CAUTION:
Always use new mainshaft lock nut.
J
Tool number : ST22520000 (J-26348)
SMT003A
L

GEAR COMPONENTS
• Use the chart shown to determine the proper reading torque.
(Length of torque wrench vs. setting or reading torque)
Reference: Formula to convert torque wrench indication to the
true torque value:
T = (0.1 m (0.33 ft) + L) /L × C
If the specified torque is T kg-m (ft-lb), the torque wrench scale
indication C is determined using the following formula.
C = (T × L)/(0.1 m (0.33 ft) + L)
SMT004A
9. Tighten counter gear lock nut to the specified torque. Refer to MT-12, "Overhaul".
CAUTION:
Always use new lock nut.
10. Stake mainshaft lock nut and counter gear lock nut using a
punch.
WCIA0182E
11. Measure the end play of each gear.

12. Install OD mainshaft bearing using Tool. Select proper OD main-
shaft bearing snap ring so that the end play comes within the
standard value.
Tool number : — (J-26349-A)

: — (J-25726-B)
End play standard : Refer to MT-37, "Gear

value End Play". SMT025

SERVICE DATA AND SPECIFICATIONS (SDS)
A
General Specification INFOID:0000000008945240
B
KA24DE
Applied model
2WD/4WD
Transmission FS5W71C MT
Number of speed 5
Shift pattern
E
MT-SDS-2
F
Synchromesh type Warner
1st 3.592
2nd 2.246 G
3rd 1.415
Gear ratio
4th 1.000
H
OD 0.821
Reverse 3.657
Drive 21 I
1st 33
Mainshaft 2nd 28
(Number of teeth) 3rd 26 J
OD 21
Reverse 36
K
Drive 32
1st 14
Countershaft gear 2nd 19 L

(Number of teeth) 3rd 28
OD 39
M
Reverse 15
Reverse idler gear (Number of teeth) 21
Oil capacity
2.0 (2-1/8, 1-3/4)
N
(US qt, Imp qt)
Reverse synchronizer Installed
Remarks
Sub gear Counter drive gear and reverse idler gear O
Gear End Play INFOID:0000000008945241
P
Unit: mm (in)
1st gear 0.31 - 0.41 (0.0122 - 0.0161)

2nd gear 0.11 - 0.21 (0.0044 - 0.0083)
3rd gear 0.11 - 0.21 (0.0044 - 0.0083)
Overdrive gear 0.24 - 0.41 (0.0095 - 0.0161)
Mainshaft (front side) 0 - 0.18 (0 - 0.0071)

Main drive gear 0 - 0.13 (0 - 0.0051)
Counter drive gear 0 - 0.13 (0 - 0.0051)
OD mainshaft bearing 0 - 0.14 (0 - 0.0055)
Clearance Between Baulk Ring and Gear INFOID:0000000008945242
Unit: mm (in)
1st & 2nd 1.20 - 1.60 (0.0473 - 0.0629)

3rd & main drive 1.20 - 1.60 (0.0473 - 0.0629)
Standard
Overdrive 1.20 - 1.60 (0.0473 - 0.0629)
Reverse 1.10 - 1.55 (0.0433 - 0.0610)
1st & 2nd 0.80 (0.0315)
3rd & main drive 0.80 (0.0315)
Wear limit
Overdrive 0.80 (0.0315)
Reverse 0.70 (0.0276)
Available Shims INFOID:0000000008945243
COUNTERSHAFT FRONT BEARING SHIM

Unit: mm (in)
Allowable clearance “A” from bearing surface to transmission case 0 - 0.16 (0 - 0.0063)
SMT205D
“A” Thickness of shim

4.52 - 4.71 (0.1780 - 0.1854) Not necessary
4.42 - 4.51 (0.1741 - 0.1775) 0.1 (0.004)
4.32 - 4.41 (0.1701 - 0.1736) 0.2 (0.008)
4.22 - 4.31 (0.1662 - 0.1691) 0.3 (0.012)
4.12 - 4.21 (0.1622 - 0.1657) 0.4 (0.016)
4.02 - 4.11 (0.1583 - 0.1618) 0.5 (0.020)
3.92 - 4.01 (0.1544 - 0.1578) 0.6 (0.024)

MT PDF

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TRANSMISSION/TRANSAXLE

Revision: April 2013 MT-1 2013 D22 LCV

Revision: April 2013 MT-2 2013 D22 LCV

KV32101330 Removing OD mainshaft bearing

KV31100401 Pressing counter gear, mainshaft, counter H

ST23540000 Removing and installing fork rod retaining pin

ST30031000 Removing 1st gear bushing O

Revision: April 2013 MT-3 2013 D22 LCV

ST22360002 Installing counter gear front and rear end

ST22350000 Installing OD gear bushing

ST23800000 Installing front cover oil seal

ST33400001 Installing rear oil seal

ST33290001 Removing rear oil seal

ST30720000 Installing mainshaft ball bearing

Revision: April 2013 MT-4 2013 D22 LCV

ST33200000 Installing counter rear bearing and counter D

Commercial Service Tool INFOID:0000000008945223

Tool name Description

Revision: April 2013 MT-5 2013 D22 LCV

CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)

BAULK RING (Worn or damaged)

INSERT SPRING (Damaged)

SHIFT FORK (Worn)

OIL (Wrong oil.)

Revision: April 2013 MT-6 2013 D22 LCV

1. Steel ball 2. Mainshaft ball bearing 3. Reverse main gear

Revision: April 2013 MT-7 2013 D22 LCV

Revision: April 2013 MT-8 2013 D22 LCV

OIL LEAKAGE AND OIL LEVEL I

Revision: April 2013 MT-9 2013 D22 LCV

Tool number : ST33290001 (J-34286)

Tool number : ST33400001 (J-26082)

Position Switch Check INFOID:0000000008945229

Switch Gear position Continuity

Park/neutral position Neutral Yes

Revision: April 2013 MT-10 2013 D22 LCV

Revision: April 2013 MT-11 2013 D22 LCV

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

Revision: April 2013 MT-12 2013 D22 LCV

Revision: April 2013 MT-13 2013 D22 LCV

A. Lead wire B. Clip cutout C. Pulling direction

Revision: April 2013 MT-14 2013 D22 LCV

Revision: April 2013 MT-15 2013 D22 LCV

SHIFT CONTROL COMPONENTS

Revision: April 2013 MT-16 2013 D22 LCV

1. Striking rod 2. Lock pin 3. Select check plungerx

Revision: April 2013 MT-17 2013 D22 LCV

Revision: April 2013 MT-18 2013 D22 LCV

4. Remove front cover, gasket, counter gear front bearing shim J

Revision: April 2013 MT-19 2013 D22 LCV

1. Install front cover oil seal using Tool.

Tool number : ST23800000 (J-25691-01)

2. Apply sealant to mating surface of transmission case as shown.

3. Install adapter plate into transmission case by lightly tapping it

4. Install main drive gear ball bearing snap ring.

Revision: April 2013 MT-20 2013 D22 LCV

8. Install rear extension. Tighten mounting bolts to the specified

10. Select counter gear front bearing shim. O

Allowable clearance (A) : Refer to MT-38, "Avail-

Revision: April 2013 MT-21 2013 D22 LCV

Revision: April 2013 MT-22 2013 D22 LCV

1. Set up Tool on adapter plate. B

Tool number : ST23810001 ( — )