MANUAL TRANSMISSION
C TRANSMISSION/TRANSAXLE
CONTENTS
PRECAUTIONS .......................................................... 2
How to use this manual ............................................ 2
Components ............................................................. 2
SYMBOLS ............................................................. 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 5
DESCRIPTION ............................................................ 6
Cross-Sectional View ............................................... 6
DOUBLE-CONE SYNCHRONIZER ...................... 7
TRIPLE-CONE SYNCHRONIZER ........................ 7
COMPONENTS .......................................................... 8
Case Components ................................................... 8
Gear Components .................................................... 9
Shift Control Components .......................................11
DISASSEMBLY ......................................................... 13
Case Components ................................................. 13
MT-1
B
SECTION
MANUAL TRANSMISSION MT
E
Shift Control Components ...................................... 16 F
Gear Components .................................................. 19
INSPECTION AFTER DISASSEMBLY ..................... 24
Shift Control Components ...................................... 24 G
Gear Components .................................................. 24
GEAR AND SHAFT ............................................. 24
SYNCHRONIZER ................................................ 25
H
BAULK RING CLEARANCE ................................ 25
BEARING ............................................................ 27
ASSEMBLY ............................................................... 28
Gear Components .................................................. 28 I
Shift Control Components ...................................... 38
Case Components .................................................. 41
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 46 J
General Specifications ............................................ 46
End Play ................................................................. 47
Baulk Ring Clearance ............................................. 47
K
 PRECAUTIONS

PRECAUTIONS PFP:00001

How to use this manual GCS001QC

● This manual describes removal, installation, disassembly, assembly, inspection, and etc. of FS6R31A
type manual transmission assembly (model code number: CD009).
● It is omitted from this manual to describe the different parts resulting from the difference of manual trans-
mission type or specifications. For these parts, refer to the service manual.
● Do not judge commonality and compatibility of the part with this manual.
Components GCS001QD

SYMBOLS
● The symbols used in component figures are as shown below.

SAIA0749E

Service Notice or Precautions GCS00156

● Do not reuse transmission oil, once it has been drained.

● During removal or installation, keep inside of transmission clear of dust or dirt.
● Check for the correct installation status prior to removal or disassembly. If matching marks are required,
be certain they do not interfere with the function of the parts they are applied.
● In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
● Be careful not to damage sliding surfaces and mating surfaces.
● Do not hold control lever housing to prevent bushing of control lever housing from deformation when mov-
ing transmission assembly.

MT-2
 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools GCS00157

Tool number
Description
Tool name B
KV381054S0 Removing rear oil seal
Oil seal puller
MT

D
ZZA0601D

ST22490000 Holding a adapter plate

Adapter setting plate E

ZZC0465D

ST30031000 Measuring wear of inner baulk ring G

Puller

ZZC0499D

I
ST30911000 ● Installing 5th-6th synchronizer assembly
a: 98 mm (3.86 in) dia. ● Installing main shaft bearing
b: 40 mm (1.57 in) dia.
Inserter ● Installing reverse main gear bushing
J
● Installing 3rd gear bushing
● Installing 3rd-4th synchronizer assembly

ZZA0920D K
ST27861000 ● Installing 1st-2nd synchronizer assembly
a: 62 mm (2.44 in) dia. ● Installing 1st gear bushing
b: 52 mm (2.05 in) dia. L
Support ring

M
ZZA0832D

ST30022000 ● Installing 3rd main gear

a: 110 mm (4.33 in) dia. ● Installing 4th main gear
b: 46 mm (1.81 in) dia.
Inserter

ZZA0920D

KV40100630 Installing 4th counter gear thrust washer

a: 67 mm (2.64 in) dia.
b: 38 mm (1.50 in) dia.
Inserter

ZZA0920D

MT-3
 PREPARATION

Tool number
Description
Tool name

ST30032000 Installing counter rear bearing inner race

a: 80 mm (3.15 in) dia.
b: 31 mm (1.22 in) dia.
Inserter

ZZA0920D

KV32102700 Installing main drive gear bearing

a: 48 mm (1.89 in) dia.
b: 41 mm (1.61 in) dia.
Drift

ZZA0534D

ST33200000 Installing counter rear bearing

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

ZZA1002D

KV32103300 Installing reverse synchronizer assembly

Press plate
a: 73 mm (2.87 in)

PCIB0165J

ST01530000 Installing reverse synchronizer assembly

a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
Drift

ZZA0534D

ST23860000 Installing reverse counter gear

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

ZZA0534D

KV38102100 Installing front cover oil seal

a: 44 mm (2.36 in) dia.
b: 28 mm (1.10 in) dia.
Drift

NT084

MT-4
 PREPARATION

Tool number
Description A
Tool name

ST33061000 Installing striking rod oil seal

a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia. B
Drift

MT
ZZA1023D

ST33400001 Installing rear oil seal

a: 60 mm (2.36 in) dia. D
b: 47 mm (1.85 in) dia.
Drift

ZZA0814D

Commercial Service Tools GCS00158

F

Tool name Description

Pin punch Removing and installing each retaining pin G

Tip diameter: 6.0 mm (0.24 in) dia.

ZZA0815D
I
Puller ● Removing reverse main gear
● Removing reverse synchronizer assembly
● Removing reverse counter gear J

K
NT077

Puller Removing each bearing, gear and bushing

M
ZZB0823D

MT-5
 DESCRIPTION

DESCRIPTION PFP:00000

Cross-Sectional View GCS0015A

PCIB0672E

1. Front cover 2. Main drive gear 3. 5th-6th synchronizer hub

4. 5th-6th coupling sleeve
7. 2nd main gear
10. 1st main gear
13. Reverse main gear
16. Striking rod
19. 6th counter gear
22. 3rd counter gear
25. Drain plug
28. Reverse idler shaft
31. Rear extension
5. Transmission case
8. 1st-2nd synchronizer hub
11. 3rd main gear
14. Reverse coupling sleeve
17. Counter shaft
20. 2nd counter gear
23. 3rd-4th synchronizer hub
26. 4th counter gear
29. Reverse counter gear
6. 6th main gear
9. 1st-2nd coupling sleeve
12. 4th main gear
15. Reverse synchronizer hub
18. Filler plug
21. 1st counter gear
24. 3rd-4th coupling sleeve
27. Reverse idler gear
30. Main shaft

MT-6
 DESCRIPTION

DOUBLE-CONE SYNCHRONIZER
The 4th gear is equipped with a double-cone synchronizer to reduce the operating force of the shift lever. A

TRIPLE-CONE SYNCHRONIZER
The 1st, 2nd and 3rd gears is equipped with a triple-cone synchro- B
nizer to reduce the operating force of the shift lever.

MT

PCIB1432E
E

MT-7
 COMPONENTS

COMPONENTS PFP:00009

Case Components GCS00166

PCIB1385E

1. Front cover gasket 2. Front cover 3. Withdrawal lever ball pin

4. Washer 5. Front cover oil seal 6. Oil gutter
7. Bushing 8. Bushing 9. Dowel pin
10. Bushing 11. Breather 12. Filler plug
13. Bracket 14. Gasket 15. Transmission case
16. Drain plug 17. Sliding ball bearing 18. Bushing
19. Magnet 20. Baffle plate 21. Adapter plate
22. Main shaft bearing retainer 23. Bushing 24. Rear extension oil gutter
25. Bracket 26. Rear extension 27. Back-up lamp switch
28. Rear oil seal 29. Rear extension dust cover 30. Striking rod oil seal
31. Sliding ball bearing 32. Check ball 33. Check select spring

MT-8
 COMPONENTS

34. Rear extension upper cover 35. Rear extension upper cover gasket 36. Plunger
37. Bracket 38. Sliding ball bearing 39. Park/neutral position (PNP) switch A
40. Sliding ball bearing 41. Sliding ball bearing

Gear Components GCS00167

B

MT

J
PCIB1354E

1. Snap ring 2. Snap ring 3. Main drive gear bearing

4. Main drive gear
7. Snap ring
10. 5th-6th shifting insert
13. 6th baulk ring
16. Main shaft
19. 2nd inner baulk ring
22. 1st-2nd spread spring
25. 1st-2nd coupling sleeve
28. 1st inner baulk ring
31. 1st gear bushing
34. 4th main gear
37. Reverse main gear
40. Reverse baulk ring
43. Reverse shifting insert
46. Snap ring
5. Main pilot bearing
8. 5th baulk ring
11. 5th-6th synchronizer hub
14. 6th main gear
17. 2nd main gear
20. 2nd synchronizer cone
23. 1st-2nd synchronizer hub
26. 1st outer baulk ring
29. 1st main gear
32. 3rd main gear
35. Main shaft bearing
38. Reverse main needle bearing
41. Reverse spread spring
44. Reverse coupling sleeve
6. Pilot bearing spacer K
9. 5th-6th spread spring
12. 5th-6th coupling sleeve
15. 6th needle bearing L
18. 2nd needle bearing
21. 2nd outer baulk ring
24. 1st-2nd shifting insert M
27. 1st synchronizer cone
30. 1st needle bearing
33. 3rd-4th main spacer
36. Snap ring
39. Reverse main gear bushing
42. Reverse synchronizer hub
45. Snap ring

MT-9

1. Snap ring
4. Counter rear bearing
7. 4th gear bushing
10. Counter shaft
13. 3rd counter gear
16. 3rd outer baulk ring
19. 3rd-4th shifting insert
22. 4th synchronizer cone
25. Reverse idler needle bearing
28. 4th counter gear
COMPONENTS
2. Reverse counter gear
5. Counter rear bearing inner race
8. 4th needle bearing
11. 3rd gear bushing
14. 3rd inner baulk ring
17. 3rd-4th spread spring
20. 3rd-4th coupling sleeve
23. 4th inner baulk ring
26. Reverse idler gear
29. Counter end bearing
MT-10
PCIB1355E
3. Counter rear bearing spacer
6. 4th counter shaft thrust washer
9. Counter front bearing
12. 3rd needle bearing
15. 3rd synchronizer cone
18. 3rd-4th synchronizer hub
21. 4th outer baulk ring
24. Reverse idler shaft
27. Reverse idler thrust washer
 COMPONENTS

Shift Control Components GCS00168

MT

I
PCIB1356E

1. Check ball plug 2. Check ball spring 3. Check ball

4. Interlock pin
7. 3rd-4th fork rod bracket
10. 1st-2nd fork rod
13. 5th-6th shift fork
16. Shifter cap
19. 5th-6th control lever
22. Reverse shift fork
25. Stopper ring
5. Retaining pin 6. Striking lever
J
8. 3rd-4th fork rod 9. 3rd-4th fork rod (reversal side)
11. 1st-2nd shift fork 12. 3rd-4th shift fork
14. 5th-6th fork rod (reversal side) 15. 5th-6th fork rod
K
17. 3rd-4th control lever 18. 5th-6th fork rod bracket
20. Adapter plate 21. Reverse fork rod
23. Striking rod 24. Low/high control lever L
26. Interlock plunger

MT-11
 COMPONENTS

PCIB1357E

1. Control lever spring 2. Control lever housing 3. Control lever assembly

4. Check shift pin 5. Control bracket 6. Return spring plug
7. Return spring plunger 8. Return spring 9. Rear extension
10. Return spring 11. Return spring plunger 12. Boot
13. Boot 14. Control rod 15. Retaining pin
16. Check ball 17. Check select spring 18. Dynamic damper bracket
19. Dynamic damper

MT-12
 DISASSEMBLY

DISASSEMBLY PFP:00000
A
Case Components GCS0015K

1. Remove rear extension upper cover mounting bolts.

2. Remove rear extension upper cover and rear extension upper B
cover gasket from the rear extension.

MT

PCIB1343E

E
3. Remove check select spring and check ball from the rear exten-
sion.
F

H
PCIB1344E

4. Remove retaining pin using a pin punch, and remove control rod
and boots. I
5. Remove PNP switch, plunger and back-up lamp switch from the
rear extension.
J

PCIB1345E
L
6. Remove control bracket mounting bolts. Then remove check
shift pin and control bracket as one unit from the rear extension.
M

PCIB1346E

MT-13
 DISASSEMBLY

7. Remove right and left return spring plugs. Then remove return
springs and return spring plungers from the rear extension.
CAUTION:
Return spring and return spring plunger have different
lengths for right and left sides. Identify right and left side
and then store.

PCIB1347E

8. Remove rear oil seal from the rear extension using an oil seal
puller.
Tool number : KV381054S0
CAUTION:
Be careful not to damage rear extension.

PCIB1348E

9. Remove rear extension mounting bolts. Using a soft hammer,

tap rear extension assembly to remove.
CAUTION:
Do not hold control lever housing to prevent bushing of
control lever housing from deformation when moving trans-
mission assembly.
10. Remove control lever housing mounting bolts, and remove con-
trol lever housing from the rear extension.
11. Remove striking rod oil seal from the rear extension.
CAUTION: PCIB1349E
Be careful not to damage rear extension.
12. Remove rear extension oil gutter from the rear extension.

13. Remove reverse idler thrust washer, reverse idler gear and
reverse idler needle bearing from the reverse idler shaft.
14. Remove reverse idler shaft from the adapter plate.

PCIB0152E

MT-14
 DISASSEMBLY

15. Remove withdrawal lever ball pin and washer from the front
cover. A
16. Remove front cover mounting bolts, then remove front cover and
front cover gasket from the transmission case.
B

MT

PCIB0600E

D
17. Remove front cover oil seal from the front cover assembly, using
a flat-bladed screwdriver.
CAUTION: E
Be careful not to damage front cover mating surface.

G
SCIA1399E

18. Remove baffle plate mounting nut from the transmission case. H

SCIA1443E
K
19. Remove snap ring from the main drive gear bearing, using snap
ring pliers.
L

SCIA1532E

20. Using a soft hammer to carefully tap main shaft and counter
shaft from the transmission case side, and then separate
adapter plate and transmission case.

SCIA1687E

MT-15
 DISASSEMBLY

21. Remove counter front bearing from the transmission case.

22. Remove oil gutter and breather from the transmission case.

PCIB0436E

Shift Control Components GCS0015L

1. Install adapter setting plate to the adapter plate and then fixing
in adapter setting plate using a vise.
Tool number : ST22490000
CAUTION:
Do not directly secure the surface in a vise.

PCIB0254E

2. Remove baffle plate mounting bolts, and remove baffle plate

from the adapter plate.
3. Remove magnet from the adapter plate.

PCIB0154E

4. Remove retaining pin using a pin punch, and remove striking

lever and striking rod.

PCIB0414E

MT-16
 DISASSEMBLY

5. Remove check ball plugs and then remove check ball springs
and check balls from the adapter plate. A

MT

PCIB0143E

D
6. Remove 3rd-4th control lever mounting bolts and then remove
3rd-4th control lever and shifter cap.
CAUTION: E
Be careful not to lose shifter cap.

G
PCIB0235E

7. Remove check ball plug and then remove check ball spring and H
check ball from the adapter plate.

PCIB0144E
K
8. Using a pin punch to knock out retaining pin, and then remove
3rd-4th fork rod bracket and 3rd-4th fork rod.
L

PCIB0145E

9. Using a pin punch to knock out retaining pin, and then remove
3rd-4th shift fork and 3rd-4th fork rod (reversal side).

PCIB0601E

MT-17
 DISASSEMBLY

10. Remove check balls and interlock pin from the adapter plate.

PCIB0146E

11. Using a pin punch to knock out retaining pin, and then remove
1st-2nd shift fork and 1st-2nd fork rod.

PCIB0602E

12. Remove interlock plunger and interlock pin from the adapter
plate.

PCIB0147E

13. Using a pin punch to knock out retaining pin, and then remove
reverse shift fork and reverse fork rod.

SCIA1447E

14. Remove check balls from the adapter plate.

PCIB0148E

MT-18
 DISASSEMBLY

15. Remove 5th-6th control lever mounting bolts and then remove
5th-6th control lever from the adapter plate. A

MT

PCIB0238E
D
16. Using a pin punch to knock out retaining pin, and then remove
5th-6th fork rod bracket and 5th-6th fork rod.
E

G
PCIB0239E

17. Using a pin punch to knock out retaining pin, and then remove H
5th-6th fork rod (reversal side) and 5th-6th shift fork.

PCIB0412E K

Gear Components GCS0015M

● Before disassembly, measure end play for each position. If the end play is outside the standards, disas- L
semble and inspect.
– Main drive gear
M
End play: 0 - 0.10 mm (0 - 0.004 in)

PCIB0484E

MT-19
 DISASSEMBLY

– Main shaft
End play: 0 - 0.10 mm (0 - 0.004 in)

PCIB0225E

– Counter shaft
End play: 0 - 0.10 mm (0 - 0.004 in)

PCIB0226E

1. After removing snap ring and reverse coupling snap ring, using
a puller to remove reverse main gear and reverse synchronizer
assembly.
2. Remove reverse main needle bearing.

SCIA1683E

3. After removing snap ring, using the puller to remove reverse

counter gear and counter rear bearing spacer.

SCIA1682E

4. Remove main shaft bearing retainer mounting bolts, and then

remove main shaft bearing retainer.

PCIB1238E

MT-20
 DISASSEMBLY

5. Remove snap ring from the main shaft bearing.

A

MT

SCIA1691E
D
6. Carefully tap main shaft with a plastic hammer and then remove
main shaft assembly, main drive gear assembly and counter
shaft assembly from adapter plate. E
7. Remove main pilot bearing, pilot bearing spacer and 5th baulk
ring.
F

G
SCIA1456E

8. Remove counter rear bearing from the adapter plate. H

PCIB0244E K

9. Remove snap ring from the main drive gear using snap ring pli-
ers.
L

SCIA1461E

10. Set the suitable puller on the main drive gear and then using a
press to remove main drive gear bearing from the main drive
gear.

SCIA1533E

MT-21
 DISASSEMBLY

11. Using a press to remove the reverse main gear bushing, main
shaft bearing and 4th main gear.
12. Remove 3rd-4th main spacer.

SCIA1386E

13. Using a press to remove 1st main gear and 3rd main gear.
CAUTION:
Be careful not to damage the baulk ring.
14. Remove 1st needle bearing.

SCIA1458E

15. Using a press to remove 1st gear bushing, 1st-2nd synchronizer

assembly and 2nd main gear.
CAUTION:
Be aware that when using the press, if the main shaft gear
positioner catches on the V-block, etc., the main shaft could
be damaged.
16. Remove 2nd needle bearing.

SCIA1459E

17. After removing snap ring, using a press to remove 6th main gear
and 5th-6th synchronizer assembly.
18. Remove 6th needle bearing.

SCIA1460E

19. Using a press to remove the 3rd counter gear, 3rd-4th synchro-
nizer assembly, 4th counter gear, 4th needle bearing, 4th gear
bushing, 4th counter gear thrust washer and counter rear bear-
ing inner race.
20. Remove 3rd needle bearing.

SCIA1389E

MT-22
 DISASSEMBLY

21. Using a press to remove the 3rd gear bushing.

A
CAUTION:
Do not use oil hole of 3rd gear bushing when press out.

MT

PCIB1327E
D

MT-23
 INSPECTION AFTER DISASSEMBLY

INSPECTION AFTER DISASSEMBLY PFP:00009

Shift Control Components GCS0015N

If the contact surface on striking lever, fork rod, shift fork, etc. has
excessive wear, abrasion, bend, or any other damage, replace the
components.

SCIA1681E

Gear Components GCS0015O

GEAR AND SHAFT

If the contact surface on each gear, main shaft, main drive gear, and
counter shaft, etc. has damage, peeling, abrasion, dent, bent, or any
other damage, replace the components.

PCIB0437E

PCIB0438E

MT-24
 INSPECTION AFTER DISASSEMBLY

SYNCHRONIZER
● If the contact surface on coupling sleeve, synchronizer hub, and A
shifting insert has damage or abrasion, replace the components.
● Coupling sleeve and synchronizer hub shall move smoothly.
B

MT

SMT387A
D

● If the cam surface on baulk ring or contact surface on insert has

damage or excessive wear, replace with a new one. E
● If spread spring is damaged, replace with a new one.

SCIA0608J

H
BAULK RING CLEARANCE
Single-Cone Synchronizer (5th and 6th)
Push baulk ring on the cone, and measure the clearance between
I
baulk ring and cone. If the measurement is below limit, replace it with
a new one.
Clearance J
Standard value: 0.70 - 1.35 mm (0.028 - 0.053 in)
Limit value: 0.5 mm (0.020 in)
K

PCIB1328E
L
Double-Cone Synchronizer (4th)
Check the clearance between outer baulk ring, synchronizer cone,
and inner baulk ring as follows. M
CAUTION:
The clearances “A” and “B” are controlled with outer baulk
ring, synchronizer cone, and inner baulk ring as a set. Replace
them as a set if the clearances are outside the limit value.

SCIA1679E

MT-25
 INSPECTION AFTER DISASSEMBLY

1. Measure the clearance “A” at 2 points or more diagonally oppo-

site using a dial indicator. And then calculate mean value.
Clearance “A”
Standard value: 0.50 - 0.70 mm (0.020 - 0.028 in)
Limit value: 0.3 mm (0.012 in)

SCIA0951E

2. Measure the clearance “B” at 2 points or more diagonally oppo-

site using a feeler gauge. And then calculate mean value.
Clearance “B”
Standard value: 0.85 - 1.35 mm (0.033 - 0.053 in)
Limit value: 0.7 mm (0.028 in)

SCIA1084E

Triple-Cone Synchronizer (1st, 2nd and 3rd)

Check the clearance between outer baulk ring, synchronizer cone
and inner baulk ring as follows.
CAUTION:
The clearances “A”, “B” and “C” are controlled with outer baulk
ring, synchronizer cone, and inner baulk ring as a set. Replace
them as a set if the clearances are outside the limit value.

PCIB1358E

1. Measure the clearance “A” at 2 points or more diagonally oppo-

site using a feeler gauge when pressing baulk ring toward gear
taper cone. And then calculate mean value.
Clearance “A”
Standard value
1st: 0.65 - 1.25 mm (0.026 - 0.049 in)
2nd, 3rd: 0.60 - 1.30 mm (0.024 - 0.051 in)
Limit value: 0.3 mm (0.012 in)
PCIB1359E

MT-26
 INSPECTION AFTER DISASSEMBLY

2. Measure the clearance “B” at 2 points or more diagonally oppo-

site using a feeler gauge. And then calculate mean value. A
Clearance “B”
Standard value: 0.85 - 1.35 mm (0.033 - 0.053 in)
B
Limit value: 0.7 mm (0.028 in)

MT

PCIB1360E

D
3. Measure the clearance “C” at 2 points or more diagonally oppo-
site using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
E
Clearance “C”
Standard value
1st: 0.8 - 1.2 mm (0.031 - 0.047 in) F
2nd, 3rd: 0.75 - 1.25 mm (0.030 - 0.049 in)
Limit value: 0.3 mm (0.012 in)
G
PCIB1361E

Reverse Synchronizer
H
Push baulk ring on the cone, and measure the clearance between
baulk ring and cone. If the measurement is below limit, replace it with
a new one.
I
Clearance
Standard value: 0.75 - 1.20 mm (0.030 - 0.047 in)
Limit value: 0.5 mm (0.020 in) J

K
PCIB1328E

BEARING
If the bearing does not rotate smoothly or the contact surface on ball L
or race is damaged or peeled, replace with new ones.

SMT418A

MT-27
 ASSEMBLY

ASSEMBLY PFP:00000

Gear Components GCS0015P

1. Install 5th-6th coupling sleeve and 5th-6th shifting inserts in the 5th-6th synchronizer hub.
CAUTION:
● Do not reuse 5th-6th coupling sleeve and 5th-6th synchronizer hub.

● Replace 5th-6th coupling sleeve and 5th-6th synchronizer hub as a set.

● Install 5th-6th coupling sleeve with the large chamfer on

the rear side.

PCIB1362E

2. Install 5th-6th spread springs in the 5th-6th shifting inserts.

CAUTION:
● Do not install 5th-6th spread spring hook onto the same
5th-6th shifting insert.

SCIA1600E

● Be careful with the shape of reverse shifting insert to

avoid misassembly.

PCIB0608E

3. Install 6th needle bearing, 6th main gear and 6th baulk ring on
the main shaft and then using an inserter and a press to press fit
the 5th-6th synchronizer assembly.
Tool number : ST30911000
CAUTION:
●Apply recommended grease to 6th needle bearing.

PCIB0219E

MT-28
 ASSEMBLY

● When press fitting, install with the side having the three
boss edge oil grooves facing the rear side. A

MT

PCIB1363E

D
NOTE:
5th and 6th baulk rings have three spaces that four gear teeth
are missing as shown in the figure. E

PCIB1330E

H
4. Select and install a snap ring so that the end play comes within
the standard value. For selecting snap ring, refer to the latest
parts information.
I
End play: 0 - 0.10 mm (0 - 0.004 in)
CAUTION:
Do not reuse snap ring. J

K
PCIB0609E

5. Install 1st-2nd coupling sleeve and 1st-2nd shifting inserts into the 1st-2nd synchronizer hub. L
CAUTION:
● Do not reuse 1st-2nd coupling sleeve and 1st-2nd synchronizer hub.

● Replace 1st-2nd coupling sleeve and 1st-2nd synchronizer hub as a set.

M
● Install 1st-2nd coupling sleeve with the thicker flange
faced the front side.

PCIB0610E

6. Install 1st-2nd spread springs in the 1st-2nd shifting inserts.

MT-29
 ASSEMBLY

CAUTION:
● Do not install 1st-2nd spread spring hook onto the same
1st-2nd shifting insert.

SCIA1600E

● Be careful with the shape of reverse shifting insert to

avoid misassembly.

PCIB0608E

7. Install 2nd main gear, 2nd needle bearing, 2nd inner baulk ring,
2nd synchronizer cone and 2nd outer baulk ring on the main
shaft and then using a support ring and a press to press fit the
1st-2nd synchronizer assembly.
Tool number : ST27861000
CAUTION:
● Apply recommended grease to 2nd needle bearing.
● Replace 2nd inner baulk ring, 2nd synchronizer cone and
2nd outer baulk ring as a set.
PCIB0202E

● When press fitting, install with the side having the three
boss edge oil grooves facing the front side.

PCIB1364E

MT-30
 ASSEMBLY

NOTE:
1st baulk ring has three spaces that four gear tooth is missing A
and 2nd baulk ring has three spaces that two gear teeth are
missing.
B

MT

PCIB1314E D

8. Using a support ring and a press to press fit the 1st gear bush-
ing.
E
Tool number : ST27861000

PCIB0203E

9. Install 1st outer baulk ring, 1st synchronizer cone, 1st inner H
baulk ring, 1st needle bearing and 1st main gear on the main
shaft and then using the inserter and a press to press fit the 3rd
main gear. I
Tool number : ST30022000
CAUTION:
● Do not reuse 3rd main gear.
J
● Apply recommended grease to 1st needle bearing.

● Replace 1st outer baulk ring, 1st synchronizer cone and

1st inner baulk ring as a set. PCIB0745E
K

10. Install 3rd-4th main spacer on the main shaft and then using the
inserter and a press to press fit the 4th main gear. L
Tool number : ST30022000
CAUTION:
● Do not reuse 4th main gear.
M
● When installing, set boss to rear side.

PCIB0612E

MT-31
 ASSEMBLY

11. Using the inserter and a press to press fit the main shaft bearing
onto the main shaft.
Tool number : ST30911000

PCIB0405E

12. Using the inserter and a press to press fit the reverse main gear
bushing onto the main shaft.
Tool number : ST30911000

PCIB0206E

13. Using the inserter and a press to press fit the 3rd gear bushing
onto the counter shaft.
Tool number : ST30911000

PCIB0406E

14. Install 3rd-4th coupling sleeve and 3rd-4th shifting inserts into the 3rd-4th synchronizer hub.
CAUTION:
● Do not reuse 3rd-4th coupling sleeve and 3rd-4th synchronizer hub.

● Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer hub as a set.

● Install 3rd-4th coupling sleeve with the thicker flange

faced the front side.

PCIB1366E

15. Install 3rd-4th spread springs in the 3rd-4th shifting inserts.

MT-32
 ASSEMBLY

CAUTION:
● Do not install 3rd-4th spread spring hook onto the same A
3rd-4th shifting insert.

MT

SCIA1600E D

● Be careful with the shape of reverse shifting insert to

avoid misassembly. E

PCIB0608E

H
16. Install 3rd needle bearing, 3rd counter gear, 3rd inner baulk ring,
3rd synchronizer cone and 3rd outer baulk ring on the counter
shaft and then using the inserter and a press to press fit the 3rd- I
4th synchronizer assembly.
Tool number : ST30911000
J
CAUTION:
● Replace 3rd inner baulk ring, 3rd synchronizer cone and
3rd outer baulk ring as a set.
K
● Apply recommended grease to 3rd needle bearing.

● 3rd-4th synchronizer hub must apply the gear oil on the PCIB0615E

hole spline press fitting side.

L
NOTE:
4th baulk ring has three spaces that one gear tooth is missing
but 3rd baulk ring doesn't. M

PCIB0451E

MT-33
 ASSEMBLY

17. Install 4th outer baulk ring, 4th synchronizer cone, 4th inner
baulk ring, 4th needle bearing and 4th counter gear onto the
counter shaft and then using the inserter and a press to press fit
the 4th gear bushing and 4th counter gear thrust washer.
Tool number : KV40100630
CAUTION:
● Replace 4th outer baulk ring, 4th synchronizer cone and
4th inner baulk ring as a set.
● Apply recommended grease to 4th needle bearing.

PCIB0209E

18. Using the inserter and a press to press fit the counter rear bear-
ing inner race onto the counter shaft.
Tool number : ST30032000
CAUTION:
Replace counter rear bearing inner race, counter rear bear-
ing and counter rear bearing spacer as a set.

PCIB0210E

19. Using the drift and a press to press fit the main drive gear bear-
ing onto the main drive gear.
Tool number : KV32102700

PCIB0215E

20. Select and install a snap ring to the main drive gear bearing so
that the end play comes within the standard value. For selecting
snap ring, refer to the latest parts information.
End play: 0 - 0.10 mm (0 - 0.004 in)
CAUTION:
Do not reuse snap ring.
21. Install main pilot bearing, pilot bearing spacer and 5th baulk ring
to main drive gear.
CAUTION:
Apply recommended grease to main pilot bearing. PCIB0484E

22. Install main drive gear assembly, main shaft assembly and
counter shaft assembly combined in one unit to adapter plate,
and fix bearing with snap ring.
CAUTION:
Do not reuse snap ring.

PCIB0151E

MT-34
 ASSEMBLY

23. Install counter rear bearing onto the adapter plate using the drift.
CAUTION: A
Replace counter rear bearing inner race, counter rear bear-
ing and counter rear bearing spacer as a set.
B

MT

PCIB1386E

D
24. Apply recommended thread locking sealant to the end of the
bolts (first 3 to 4 threads), screw the bolts into the main shaft
bearing retainer, and tighten it to the specified torque. Refer to
E
MT-8, "Case Components" .

G
PCIB1238E

25. Install reverse coupling sleeve and reverse shifting inserts into the reverse synchronizer hub. H
CAUTION:
● Do not reuse reverse coupling sleeve and reverse synchronizer hub.

● Replace reverse coupling sleeve and reverse synchronizer hub as a set.

I
● Install reverse coupling sleeve with the flat flange on the
rear side.
J

L
PCIB0617E

26. Install reverse spread springs in the reverse shifting inserts.

M
CAUTION:
● Do not install reverse spread spring hook onto the same
reverse shifting insert.

SCIA1600E

MT-35
 ASSEMBLY

● Be careful with the shape of 1st-2nd, 3rd-4th and 5th-6th

shifting insert to avoid misassembly.

PCIB0608E

27. Install snap ring to reverse synchronizer hub.

CAUTION:
● Do not reuse snap ring.

● Do not align the snap ring notch with synchronizer hub

groove when assembling.

PCIB1237E

28. After installing reverse main gear bushing, reverse main needle
bearing, reverse main gear and reverse baulk ring onto the main
shaft, using the drift and press plate and a press to press fit the
reverse synchronizer assembly.
Tool number A: KV32103300
B: ST01530000
CAUTION:
●Apply recommended grease to reverse main needle bear-
ing.

PCIB0242E

● When installing, face the side with three ditches to the

front side.

PCIB1367E

MT-36
 ASSEMBLY

NOTE:
Reverse baulk ring has three spaces that two gear teeth are A
missing, and each space has small ditch for identification as
shown in the figure.
B

MT

PCIB0168E D

29. Select and install a snap ring so that the end play comes within
the standard value. For selecting snap ring, refer to the latest
E
parts information.
End play: 0 - 0.10 mm (0 - 0.004 in)
CAUTION: F
Do not reuse snap ring.

PCIB0225E

H
30. After installing counter rear bearing spacer, press and fit reverse
counter gear onto counter shaft with drift and press.
Tool number : ST23860000
I
CAUTION:
● Do not reuse reverse counter gear.

● When installing counter rear bearing spacer, identifica- J

tion ditch should face to the rear side.
● Replace counter rear bearing inner race, counter rear
bearing and counter rear bearing spacer as a set. K
PCIB0411E

31. Select and install a snap ring so that the end play comes within
the standard value. For selecting snap ring, refer to the latest L
parts information.
End play: 0 - 0.10 mm (0 - 0.004 in)
M
CAUTION:
Do not reuse snap ring.

PCIB0226E

MT-37
 ASSEMBLY

Shift Control Components GCS0015Q

1. Install 5th-6th shift fork to the 5th-6th coupling sleeve.

2. Install 5th-6th fork rod (reversal side) to the 5th-6th shift fork.
3. Using a pin punch to tap the retaining pin into the 5th-6th shift
fork.
CAUTION:
Do not reuse retaining pin.

PCIB0412E

4. Install 5th-6th fork rod to the adapter plate.

5. Install 5th-6th fork rod bracket to the 5th-6th fork rod.
6. Using a pin punch to tap the retaining pin into the 5th-6th fork
rod bracket.
CAUTION:
Do not reuse retaining pin.

PCIB0238E

7. Install 5th-6th control lever to the adapter plate and then tighten
mounting bolts to the specified torque. Refer to MT-11, "Shift
Control Components" .
CAUTION:
Set the projection upward.

PCIB0172E

8. Install check balls to the adapter plate.

CAUTION:
Apply recommended grease to check ball.

PCIB0148E

MT-38
 ASSEMBLY

9. Install reverse shift fork to the reverse coupling sleeve.

10. Install reverse fork rod to the reverse shift fork. A
11. Using a pin punch to tap the retaining pin into the reverse shift
fork.
CAUTION: B
Do not reuse retaining pin.

MT

SCIA1447E

D
12. Install interlock pin and interlock plunger to the adapter plate.
CAUTION:
Apply recommended grease to interlock pin and interlock E
plunger.

G
PCIB0147E

13. Install 1st-2nd shift fork to the 1st-2nd coupling sleeve. H

14. Install 1st-2nd fork rod to the 1st-2nd shift fork.
15. Using a pin punch to tap the retaining pin into the 1st-2nd shift
fork. I
CAUTION:
Do not reuse retaining pin.
J

PCIB0602E
K
16. Install 3rd-4th shift fork to the 3rd-4th coupling sleeve.
17. Install 3rd-4th fork rod (reversal side) to 3rd-4th shift fork.
L
18. Using a pin punch to tap the retaining pin into the 3rd-4th shift
fork (reversal side).
CAUTION:
Do not reuse retaining pin. M

PCIB0601E

19. Install interlock pin and check balls to the adapter plate.
CAUTION:
Apply recommended grease to interlock pin and check ball.

PCIB0146E

MT-39
 ASSEMBLY

20. Install 3rd-4th fork rod to the adapter plate.

21. Install 3rd-4th fork rod bracket to the 3rd-4th fork rod.
22. Using a pin punch to tap the retaining pin into the 3rd-4th fork
rod bracket.
CAUTION:
Do not reuse retaining pin.

PCIB0145E

23. Install check ball and check ball spring into the adapter plate,
apply recommended sealant to threads of check ball plugs, and
tighten check ball plug to the specified torque. Refer to MT-11,
"Shift Control Components" .
CAUTION:
Apply recommended grease to check ball.

PCIB0144E

24. Install 3rd-4th control lever to the adapter plate, and then tighten
mounting bolts to the specified torque. Refer to MT-11, "Shift
Control Components" .
CAUTION:
● Make sure the top and bottom are oriented correctly.

● Do not drop shifter cap.

PCIB1352E

25. Install check balls and check ball springs into the adapter plate,
apply recommended sealant to threads of check ball plugs, and
tighten check ball plugs to the specified torque. Refer to MT-11,
"Shift Control Components" .

PCIB0143E

26. Install striking rod to the adapter plate.

27. Install striking lever to the striking rod.
28. Using a pin punch to tap the retaining pin into the striking lever.
CAUTION:
Do not reuse retaining pin.

PCIB0414E

MT-40
 ASSEMBLY

29. Install magnet to the adapter plate.

A
30. Install baffle plate to the adapter plate, and then tighten mount-
ing bolts to the specified torque. Refer to MT-8, "Case Compo-
nents" .
B

MT

PCIB0154E
D
Case Components GCS0015R

1. Install counter front bearing to the transmission case.

2. Install oil gutter to transmission case. E
3. Install breather to transmission case.
CAUTION:
Do not reuse breather. F

PCIB0436E

H
4. Apply recommended sealant to the transmission case adapter
plate mounting surface as shown in the figure.
CAUTION: I
Complete remove all moisture and oil, etc., from the trans-
mission case and adapter plate mounting surfaces.
J

K
PCIB1373E

5. Place the adapter plate in the transmission case, using a soft

L
hammer to tap the adapter plate to install it into the transmission
case.

SCIA1436E

MT-41
 ASSEMBLY

6. Install snap ring to main drive gear bearing, using snap ring pli-
ers.
CAUTION:
Do not reuse snap ring.

SCIA1532E

7. Tighten baffle plate mounting nut to the specified torque. Refer

to MT-8, "Case Components" .

SCIA1443E

8. Apply multi-purpose grease to the lip of the front cover oil seal.
Using a drift, to install oil seal approx. 8.55 - 9.55 mm (0.336 -
0.376 in) above from the front cover edge surface.
Tool number : KV38102100
CAUTION:
● Do not reuse front cover oil seal.
● When installing, do not incline the front cover oil seal.

PCIB0415E

9. Install front cover gasket and front cover to the transmission

case.
CAUTION:
● Do not reuse front cover gasket.

● Do not damage front cover oil seal.

10. Temporary tightening 2 bolts in the positions shown in the figure.

PCIB0454J

MT-42
 ASSEMBLY

11. Temporary tightening remaining 9 bolts.

CAUTION: A
Four bolts pointed by arrows in the figure are not reusable.

MT

PCIB0455J

D
12. Tighten bolts to the specified torque in order as shown on the
figure. Refer to MT-8, "Case Components" .
E

G
PCIB0258E

13. Install washer to the withdrawal lever ball pin and then install it H
to front cover. Tighten withdrawal lever ball pin to the specified
torque. Refer to MT-8, "Case Components" .

PCIB0456E
K
14. Install rear extension oil gutter to rear extension, and then tighten bolt to specified torque. Refer to MT-8,
"Case Components" .
15. Install reverse idler shaft, reverse idler needle bearing, reverse idler gear and reverse idler thrust washer L
to the adapter plate.
CAUTION:
Apply recommended grease to reverse idler needle bearing. M
16. Apply multi-purpose grease to the striking rod oil seal lip, and
then using the drift to install striking rod oil seal.
Tool number : ST33061000
CAUTION:
● Do not reuse striking rod oil seal.

● When installing, do not incline the striking rod oil seal.

PCIB0213E

MT-43
 ASSEMBLY

17. Apply multi-purpose grease to the lip of the rear oil seal. Using a
drift, to install rear oil seal. 1.2 - 2.2 mm (0.047 - 0.087 in) above
from the rear extension edge surface.
Tool number : ST33400001
CAUTION:
● Do not reuse rear oil seal.
● When installing, do not incline the rear oil seal.

PCIB0619E

18. Apply recommended sealant to the adapter plate rear extension

mounting surface as shown in the figure.
CAUTION:
Completely remove all moisture, oil, etc., from the adapter
plate and rear extension mounting surfaces.

PCIB1374E

19. Install rear extension to adapter plate and then tighten mounting
bolts to the specified torque in order as shown on the figure.
Refer to MT-8, "Case Components" .
CAUTION:
Do not damage rear oil seal and striking rod oil seal.
20. Install control lever housing to the rear extension and then
tighten mounting bolts to the specified torque. Refer to MT-11,
"Shift Control Components" .
CAUTION:
Do not hold control lever housing to prevent bushing of
control lever housing from deformation when moving trans- PCIB0256E

mission assembly.

21. Install return spring plungers and return springs into the rear
extension, apply recommended sealant to threads of return
spring plugs, and then tighten return spring plugs to the speci-
fied torque. Refer to MT-11, "Shift Control Components" .
Region Return spring identification mark Plunger notch
RH Brown No
LH Blue Yes

CAUTION:
● The right and left return springs and return spring plung-
SCIA1607E
ers are different, so make sure they are installed cor-
rectly.
● Apply gear oil to return spring plunger.

MT-44
 ASSEMBLY

22. Install shift check pin as a one unit with the control bracket to
rear extension and then tighten mounting bolts to the specified A
torque. Refer to MT-11, "Shift Control Components" .
23. Install plunger to the rear extension, and then screwing PNP
switch and back-up lamp switch to the rear extension with 1 - 2 B
pitches. Apply recommended sealant to threads of switches,
and tighten switches to the specified torque. Refer to MT-8,
"Case Components" .
MT

PCIB1346E

D
24. Install retaining pin into the control rod, using a pin punch.
CAUTION:
Do not reuse retaining pin. E

G
PCIB1345E

25. Install check ball and check select spring into the rear extension. H

PCIB1344E
K
26. Install rear extension upper cover gasket and rear extension
upper cover to rear extension.
CAUTION: L
● Do not reuse rear extension upper cover gasket.

● Avoid tangling check select spring.

27. Tighten rear extension upper cover bolts to the specified torque M
in order as shown on the figure. Refer to MT-8, "Case Compo-
nents" .

PCIB1353E

MT-45
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications GCS0015D

Model code number CD009

Number of speed 6

Shift pattern

SCIA0955E

Synchromesh type Warner

1st 3.794
2nd 2.324
3rd 1.624
Gear ratio
4th 1.271
5th 1.000
6th 0.794
Reverse 3.446
Drive 26
1st 37
2nd 34
Main gear
(Number of teeth) 3rd 33
4th 31
6th 31
Reverse 42
Drive 32
1st 12
2nd 18
Counter shaft gear
(Number of teeth) 3rd 25
4th 30
6th 48
Reverse 15
Reverse idler gear (Number of teeth) 26
Oil capacity (Approx.) (Imp qt) 2.9 (2-1/2)
Reverse synchronizer Installed
Remarks Double-cone synchronizer 4th
Triple-cone synchronizer 1st, 2nd and 3rd

MT-46
 SERVICE DATA AND SPECIFICATIONS (SDS)

End Play GCS0015E

Unit: mm (in) A
Item Standard
Counter shaft 0 - 0.10 (0 - 0.004)
B
Main drive gear 0 - 0.10 (0 - 0.004)
Main shaft 0 - 0.10 (0 - 0.004)
MT
Baulk Ring Clearance GCS0015G

Unit: mm (in)
Measurement point Standard value Limit value D
Double-cone synchronizer Clearance between synchronizer cone 0.50 - 0.70 (0.020 - 0.028) 0.3 (0.012)
(4th) and inner baulk ring end face “A”
Clearance between outer baulk ring 0.85 - 1.35 (0.033 -0.053) 0.7 (0.028) E
pawl and synchronizer cone “B”

PCIB0249E

Triple-cone synchronizer Clearance between synchronizer cone 1st: 0.65 - 1.25 (0.026 - 0.049) 0.3 (0.012) G
(1st, 2nd and 3rd) and clutch gear end face “A” 2nd: 0.60 - 1.30 (0.024 - 0.051) 0.3 (0.012)
3rd: 0.60 - 1.30 (0.024 - 0.051) 0.3 (0.012)
Clearance between outer baulk ring 0.85 - 1.35 (0.033 - 0.053) 0.7 (0.028)
H
pawl and synchronizer cone “B”
Clearance between inner baulk ring and 1st: 0.8 - 1.2 (0.031 - 0.047) 0.3 (0.012)
clutch gear end face “C” 2nd: 0.75 - 1.25 (0.030 - 0.049) 0.3 (0.012)
3rd: 0.75 - 1.25 (0.030 - 0.049) 0.3 (0.012) I
PCIB0835J

5th and 6th 0.70 - 1.35 (0.028 - 0.053) 0.5 (0.020)

Reverse 0.75 - 1.20 (0.030 - 0.047) 0.5 (0.020) J

MT-47
SERVICE DATA AND SPECIFICATIONS (SDS)

MT-48