MANUAL TRANSMISSION

SECTION

MT

GI
MA
EM
LC
EC

CONTENTS
FS5W71C
PREPARATION ...............................................................3
Special Service Tools ..................................................3
Commercial Service Tools ...........................................5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .....................................................6
NVH Troubleshooting Chart.........................................6
MANUAL TRANSMISSION..........................................6
DESCRIPTION .................................................................7
Cross-sectional View ...................................................7
ON-VEHICLE SERVICE ..................................................8
Replacing Rear Oil Seal ..............................................8
REMOVAL .................................................................8
INSTALLATION..........................................................8
Position Switch Check .................................................8
REMOVAL AND INSTALLATION ...................................9
Removal.......................................................................9
Installation..................................................................10
OVERHAUL ...................................................................11
Case Components .....................................................11
Gear Components .....................................................12
Shift Control Components .........................................13
DISASSEMBLY..............................................................14
Case Components .....................................................14
DISASSEMBLY ........................................................14
Shift Control Components .........................................14
DISASSEMBLY ........................................................14
Gear Components .....................................................15
DISASSEMBLY ........................................................15
INSPECTION..................................................................18
Shift Control Components .........................................18
INSPECTION ...........................................................18
Gear Components .....................................................18
INSPECTION ...........................................................18
ASSEMBLY....................................................................20
Gear Components .....................................................20
ASSEMBLY .............................................................20
Shift Control Components .........................................26
ASSEMBLY .............................................................26

FE

Case Components .....................................................27

ASSEMBLY .............................................................27
SERVICE DATA AND SPECIFICATIONS (SDS) .........30
General Specifications...............................................30
Gear End Play ...........................................................30
Clearance Between Baulk Ring and Gear ................31
Available Snap Rings ................................................31
MAIN DRIVE GEAR BEARING ..................................31
MAINSHAFT FRONT ................................................31
COUNTER DRIVE GEAR .........................................31
OD MAINSHAFT BEARING ......................................32
Available Shims .........................................................32
COUNTERSHAFT FRONT BEARING ........................32
FS5R30A
PREPARATION .............................................................33
Special Service Tools ................................................33
Commercial Service Tool...........................................35
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...................................................36
NVH Troubleshooting Chart.......................................36
MANUAL TRANSMISSION........................................36
DESCRIPTION ...............................................................37
Cross-sectional View - 2WD Model...........................37
Cross-sectional View - 4WD Model...........................38
ON-VEHICLE SERVICE ................................................39
Replacing Rear Oil Seal - 2WD Model .....................39
REMOVAL ...............................................................39
INSTALLATION........................................................39
Position Switch Check ...............................................40
REMOVAL AND INSTALLATION .................................41
Removal.....................................................................41
2WD MODEL ...........................................................41
4WD MODEL ...........................................................42
Installation..................................................................43
OVERHAUL ...................................................................44
Case Components .....................................................44
Gear Components .....................................................45
Shift Control Components (2/4WD models) ..............47

CL

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX

CONTENTS
DISASSEMBLY..............................................................48
Case Components .....................................................48
DISASSEMBLY ........................................................48
Shift Control Components .........................................49
DISASSEMBLY ........................................................49
Gear Components .....................................................50
DISASSEMBLY ........................................................50
INSPECTION..................................................................54
Shift Control Components .........................................54
INSPECTION ...........................................................54
Gear Components .....................................................54
INSPECTION ...........................................................54
ASSEMBLY....................................................................56
Gear Components .....................................................56
ASSEMBLY .............................................................56
Shift Control Components .........................................64
ASSEMBLY .............................................................64
Case Components .....................................................65

(Contd)

ASSEMBLY .............................................................65
SERVICE DATA AND SPECIFICATIONS (SDS) .........67
General Specifications...............................................67
Gear End Play ...........................................................67
Clearance Between Single Baulk Ring and Gear .....67
DOUBLE BAULK RING ............................................68
Distance Between Rear Surface of Reverse
Cone and Reverse Baulk Ring..................................68
Available Snap Ring ..................................................68
MAIN DRIVE GEAR SNAP RING ..............................68
MAINSHAFT FRONT SNAP RING .............................68
COUNTER GEAR REAR SNAP RING .......................69
Available C-ring .........................................................69
MAINSHAFT C-RING ...............................................69
Available Shim and Washer ......................................69

MT-2

TABLE FOR SELECTING PROPER COUNTER

GEAR FRONT BEARING THRUST WASHER ............69
REVERSE IDLER REAR THRUST WASHER .............70

PREPARATION

FS5W71C
Special Service Tools

Special Service Tools

NEMT0050

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number (Kent-Moore
No.) Tool name

Description

ST23810001
(

)
Adapter setting plate

Fixing adapter plate with gear assembly

a: 166 mm (6.54 in)
b: 270 mm (10.63 in)

GI
MA
EM
LC

NT407

Removing overdrive mainshaft bearing

a: 447 mm (17.60 in)
b: 100 mm (3.94 in)

KV32101330
(See J34286)
Puller

EC
FE
CL

NT408

Pressing counter gear and mainshaft

KV31100401
(

)
Transmission press stand

AT

NT068

Tightening mainshaft lock nut

a: 100 mm (3.94 in)
b: 41 mm (1.61 in)

ST22520000
(J26348)
Wrench

TF
PD

NT409

Removing and installing fork rod retaining pin

a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.

ST23540000
(J25689-A)
Pin punch

AX
SU

NT442

Removing and installing 1st gear bushing

Removing main drive gear bearing
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.

ST30031000
(J22912-01)
Puller

BR
ST
RS

NT411

ST23860000
(

Drift

Installing counter drive gear

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

BT
HA

NT065

Installing counter gear front and rear end bearings

a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.

ST22360002
(J25679-01)
Drift

SC
EL

NT065

MT-3

IDX

PREPARATION

FS5W71C

Special Service Tools (Contd)

Tool number (Kent-Moore
No.) Tool name

Description

ST22350000
(J25678-01)
Drift

Installing OD gear bushing

a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.

NT065

Installing front cover oil seal

a: 44 mm (1.73 in) dia.
b: 31 mm (1.22 in) dia.

ST23800000
(J25691-01)
Drift

NT065

Installing rear oil seal

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

ST33400001
(J26082)
Drift

NT086

Removing rear oil seal

a: 250 mm (9.84 in)
b: 160 mm (6.30 in)

ST33290001
(J34286)
Puller

NT414

Installing mainshaft ball bearing

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

ST30720000
(J25405)
Drift

NT115

Installing main drive gear bearing

a: 71.5 mm (2.815 in) dia.
b: 47.5 mm (1.870 in) dia.

ST30613000
(J25742-3)
Drift

NT073

Installing counter rear bearing

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

ST33200000
(J26082)
Drift

NT091

MT-4

PREPARATION

FS5W71C
Commercial Service Tools

Commercial Service Tools

Tool name

NEMT0051

GI

Description

Puller

Removing counter bearings, counter drive and OD

gears

MA
EM

NT077

Installing countershaft rear end bearing

a: 40 mm (1.57 in) dia.
b: 30 mm (1.18 in) dia.

Drift

LC
EC

NT074

FE
CL

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL

MT-5

IDX

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING

NEMT0052

FS5W71C

NVH Troubleshooting Chart

NVH Troubleshooting Chart

NEMT0052S01

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

MANUAL TRANSMISSION

MT-11

MT-11

MT-13

MT-13

MT-12

MT-12

MT-12

MT-12

OIL SEAL (Worn or damaged)

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

SHIFT FORK (Worn)

GEAR (Worn or damaged)

BEARING (Worn or damaged)

BAULK RING (Worn or damaged)

INSERT SPRING (Damaged)

Reference page

GASKET (Damaged)

Refer to MA-37,
Checking M/T Oil.

NEMT0052S0101

OIL (Oil level is high.)

OIL (Wrong oil.)

Noise

OIL (Oil level is low.)

SUSPECTED PARTS
(Possible cause)

Oil leakage

Hard to shift or will not shift

Symptom
Jumps out of gear

MT-6

NEMT0053

DESCRIPTION

FS5W71C
Cross-sectional View

Cross-sectional View

NEMT0053S01

GI
MA
EM
LC
EC
FE
CL

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
SMT153D

MT-7

EL
IDX

ON-VEHICLE SERVICE

FS5W71C

Replacing Rear Oil Seal

Replacing Rear Oil Seal

NEMT0054

REMOVAL
1.
2.

NEMT0054S01

Remove the propeller shaft. Refer to PD-9, Removal and

Installation.
Remove rear oil seal using Tool.
Always replace with a new seal once it has been removed.

AMT079

INSTALLATION
1.

2.

NEMT0054S02

Install new oil seal until it stops.

Apply multi-purpose grease to seal lip of oil seal before
installing.
Install any part removed.

SMT480CA

Position Switch Check

NEMT0055

Check continuity.
Switch

Gear position

Continuity

Reverse

Yes

Except reverse

No

Neutral

Yes

Except neutral

No

Back-up lamp switch

Park/neutral position
(PNP) switch

SMT981D

MT-8

NEMT0056

REMOVAL AND INSTALLATION

FS5W71C
Removal

Removal

NEMT0056S01

GI
MA
EM
LC
EC
FE
CL

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
WMT030

CAUTION:
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.

MT-9

SC
EL
IDX

REMOVAL AND INSTALLATION

FS5W71C

Removal (Contd)

NOTE:
To prevent oil spills, drain transmission oil before removing
transmission or insert plug into rear oil seal after removing
propeller shaft.
Be careful not to damage spline, sleeve yoke, and rear oil
seal when removing propeller shaft.
1. Remove battery negative terminal.
2. Remove the crankshaft position sensor (OBD) from transmission upper side.
3. Remove the clutch operating cylinder from transmission.
4. Disconnect the vehicle speed sensor, back-up switch, and
park/neutral position (PNP) switch harness connectors.
5. Remove the starter motor from transmission.
6. Disconnect the exhaust hanger.
7. Remove the propeller shaft. Refer to PD-9, Removal and
Installation.

8. Remove the shift lever.

9. Support the engine by placing a jack under the oil pan.
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
1.

AMT190

NEMT0056S02

Tighten bolts securing transmission.

Bolt No.

Tightening torque Nm (kg-m, ft-lb)

mm (in)

39 - 49 (4.0 - 5.0, 29 - 36)

65 (2.56)

39 - 49 (4.0 - 5.0, 29 - 36)

58 (2.28)

3*

16 - 22 (1.6 - 2.2, 12 - 16)

25 (0.98)

16 - 22 (1.6 - 2.2, 12 - 16)

16 (0.63)

*: With nut

2.

Tighten clutch operating cylinder to the specified torque. Refer

to CL-5, CLUTCH SYSTEM.

MT-10

NEMT0057

OVERHAUL

FS5W71C
Case Components

Case Components

NEMT0057S01

GI
MA
EM
LC
EC
FE
CL

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
WMT055

MT-11

EL
IDX

OVERHAUL

FS5W71C

Gear Components

Gear Components

NEMT0057S02

AMT156

MT-12

OVERHAUL

FS5W71C
Shift Control Components

Shift Control Components

NEMT0057S03

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

GI
MA
EM
LC
EC
FE
CL

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
WMT040

EL

MT-13

IDX

DISASSEMBLY

FS5W71C

Case Components

Case Components
DISASSEMBLY
1.
a.

NEMT0058

Remove rear extension.

Remove control housing, check ball, return spring plugs, select
check plungers and return springs. Also remove reverse check
plug, check spring and check ball.
Be careful not to lose check balls.

b.
c.
d.

Drive out striking lever retaining pin.

Remove striking lever from striking rod.
Remove rear extension by lightly tapping on it.

2.

Remove front cover, gasket, counter gear front bearing shim

and main drive gear ball bearing snap ring.
Separate transmission case from adapter plate by lightly tapping on it.

SMT161D

AMT132

3.

AMT131

4.

Remove oil seal from front cover.

Be careful not to damage mating surface of front cover.

SMT166D

Shift Control Components

DISASSEMBLY
1.
2.
3.

NEMT0059

Set up Tool on adapter plate.

Remove striking rod from adapter plate.
Remove check ball plugs, check springs, and check balls.

SMT545A

MT-14

DISASSEMBLY

FS5W71C
Shift Control Components (Contd)

4.

Drive out retaining pins. Then drive out fork rods and remove
interlock balls.

GI
MA
EM
LC

SMT984

Gear Components
DISASSEMBLY
1.

NEMT0060

EC

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 Gear
End Play, MT-30.

FE

Mesh 2nd and reverse gear, then remove counter gear front
bearing using a suitable puller.
Remove snap ring, then remove sub-gear bracket, sub-gear
spring and sub-gear.

AT

CL

SMT025

2.
3.

TF
PD
AX

SMT174A

4.

5.

Remove counter drive gear together with main drive gear

assembly using a suitable puller.
When removing main drive gear assembly, be careful not
to drop pilot bearing or baulk ring.
Remove snap ring, then remove 3rd and 4th synchronizer
assembly and 3rd main gear.

SU
BR
ST
RS

SMT162A

6.
a.

Disassemble parts at rear of adapter plate as follows:

Release staking on both countergear and mainshaft lock nuts,
then loosen both nuts.
Mainshaft lock nut: Left-hand thread

BT
HA
SC
EL

AMT133

MT-15

IDX

DISASSEMBLY

FS5W71C

Gear Components (Contd)

b.
c.
d.

Remove overdrive counter gear together with counter gear

rear end bearing using a suitable puller.
Remove reverse counter gear and spacer.
Remove snap rings from reverse idler shaft, then remove
reverse idler gear, thrust washers and reverse idler gear bearing.

SMT547A

e.

WMT033

Remove snap ring and pull out overdrive mainshaft bearing,

then remove snap ring. (2WD model)
f. Remove mainshaft lock nut.
g. Remove speedometer drive gear and steel ball. (2WD model)
h. Remove thrust washer, steel roller, roller bearing and washer.
i. Remove overdrive main gear, needle bearing and baulk ring
(overdrive).
j. Remove counter gear by tapping on rear end of counter gear.
k. Press out overdrive gear bushing and overdrive & reverse
synchronizer assembly.
l. Remove reverse main gear and needle bearing.
m. Press out reverse gear bushing.

SMT554A

7.

Remove thrust washer, steel ball, 1st main gear and needle
bearing.
Be careful not to lose steel ball.

SMT383A

8.

Press out 1st gear bushing together with 2nd main gear using
Tool.
Remove 2nd gear needle bearing.

TM049A

MT-16

DISASSEMBLY

FS5W71C
Gear Components (Contd)

9.
a.
b.

Remove main drive gear ball bearing.

Remove snap ring.
Remove main drive gear ball bearing.

GI
MA
EM
LC

SMT420A

EC
FE
CL

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL

MT-17

IDX

INSPECTION

FS5W71C

Shift Control Components

Shift Control Components

INSPECTION

NEMT0061

Check contact and sliding surfaces of fork rods for wear,

scratches, projections and other damage.

SMT075C

Gear Components
INSPECTION
Gears and Shafts

NEMT0062
NEMT0062S01

Check shafts for cracks, wear and bending.

Check gears for excessive wear, chips and cracks.

SMT386A

SMT550A

Synchronizers

NEMT0062S02

Check spline portion of coupling sleeves, synchronizer hubs,

and gears for wear, chips, and cracks.
Check baulk rings for cracks and deformation.
Check shifting inserts for wear and deformation.
Check insert spread springs for deformation.

SMT427C

MT-18

INSPECTION

FS5W71C
Gear Components (Contd)

1)

Measure baulk ring wear.

Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear:
Refer to Clearance Between Baulk Ring and Gear,
MT-31.
If the clearance is less than the wear limit, replace baulk ring.

GI
MA
EM
LC

SMT140

Bearings

NEMT0062S03

Make sure all bearings roll freely and are free from noise,
cracks, pitting or wear.

EC
FE
CL

SMT418A

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL

MT-19

IDX

ASSEMBLY

FS5W71C

Gear Components

Gear Components
ASSEMBLY

NEMT0063

AMT185

1.
2.

a.

Install bearings into case components.

Assemble adapter plate parts.
Install oil gutter on adapter plate and expand on rear side.
Install bearing retainer.
Insert reverse idler shaft, then install bearing retainer.

b.

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

3.
a.

Install main drive gear ball bearing.

Press main drive gear ball bearing.

SMT778C

SMT674C

SMT425A

MT-20

ASSEMBLY

FS5W71C
Gear Components (Contd)

b.

Select and install proper main drive gear snap ring to achieve
proper clearance of groove.
Allowable clearance of groove:
0 - 0.13 mm (0 - 0.0051 in)
Main drive gear bearing snap ring:
Refer to MAIN DRIVE GEAR BEARING, MT-31.

GI
MA
EM
LC

SMT170D

4.

Assemble synchronizers.
Assemble the 1st and 2nd synchronizer.

EC
FE
CL

SMT054C

Check coupling sleeve and synchronizer hub orientation.

AT
TF
PD
AX
SU
BR
ST
RS
SMT206C

BT
HA
SC
EL

MT-21

IDX

ASSEMBLY

FS5W71C

Gear Components (Contd)

Assemble the 3rd and 4th synchronizer.

Assemble the overdrive and reverse synchronizer.

5.
a.

Assemble front side components to mainshaft.

Install 2nd main gear, needle bearing and 1st and 2nd synchronizer assembly; then press 1st gear bushing onto the
mainshaft.
Install 1st main gear.

WMT053

SMT207CA

b.

SMT752A

MT-22

ASSEMBLY

FS5W71C
Gear Components (Contd)

c.

Install steel ball and 1st gear washer.

Before installation, apply multi-purpose grease to steel
ball and to both sides of the 1st gear washer.

GI
MA
EM
LC

TM358

6.
a.

Install mainshaft and counter gear on adapter plate and main

drive gear on mainshaft as follows:
Press mainshaft assembly into adapter plate using Tool.

EC
FE
CL

TM439

b.
c.

Press counter gear into adapter plate using Tool.

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.

AT
TF
PD
AX

SMT750

d.

e.

Install front mainshaft snap ring.

Select proper front mainshaft snap ring to achieve proper
clearance of groove.
Allowable clearance of groove:
0 - 0.18 mm (0 - 0.0071 in)
Mainshaft front snap ring:
Refer to MAINSHAFT FRONT, MT-31.
Apply gear oil to mainshaft pilot bearing and install it on mainshaft.

SU
BR
ST
RS

TM441

f.

Press counter drive gear together with main drive gear using
Tool.
Pay attention to the direction of counter drive gear.

BT
HA
SC
EL

SMT412C

MT-23

IDX

ASSEMBLY

FS5W71C

Gear Components (Contd)

g.
i.

Install sub-gear components.

Install sub-gear and sub-gear bracket on counter drive gear
and then select proper snap ring that will minimize clearance
of groove in counter gear.
Do not install sub-gear spring at this time.
Allowable clearance of groove:
0 - 0.13 mm (0 - 0.0051 in)
Counter drive gear snap ring:
Refer to COUNTER DRIVE GEAR, MT-31.

SMT201D

ii.

Remove snap ring, sub-gear bracket and sub-gear from

counter gear.
iii. Reinstall sub-gear, sub-gear spring, sub-gear bracket and
snap ring.

SMT202D

h.

Press counter/gear front bearing onto counter gear using Tool.

7.

Install rear side components on mainshaft and counter gear as

follows:
Install sub-gear parts (sub-gear, sub-gear spring, sub-gear
bracket, steel ball and snap ring) on the reverse idler gear.
Install reverse idler gear to reverse idler shaft along with
reverse idler thrust washer, snap rings and reverse idler gear
bearing.

TM443

a.
b.

AMT134

MT-24

ASSEMBLY

FS5W71C
Gear Components (Contd)

c.

Install bushing, reverse main gear and overdrive and reverse

synchronizer to mainshaft.
Pay attention to the direction of synchronizer hub.

GI
MA
EM
LC
EC
FE
CL

SMT207CA

d.
e.
f.

g.
h.

Install overdrive gear bushing to mainshaft using Tool.

Install overdrive main gear and needle bearing to mainshaft.
Install spacer, reverse counter gear and overdrive counter gear
to counter/gear.
OD main gear and OD counter gear should be handled as
a matched set.
Install washer, roller bearing, steel roller and thrust washer.
Tighten mainshaft lock nut temporarily.
Always use new lock nut.

i.

Install counter/gear rear end bearing using Tool.

AT
TF
PD
AX

SMT531

SU
BR
ST
RS

SMT043

8.

Mesh 2nd and reverse gears, then tighten mainshaft lock nut
using Tool.
Always use new lock nut.
Mainshaft lock nut:
: 137 - 167 Nm (14.0 - 17.0 kg-m, 101 - 123 ft-lb)

BT
HA
SC
EL

SMT003A

MT-25

IDX

ASSEMBLY

FS5W71C

Gear Components (Contd)

9.

Use the chart shown at left 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)
Tighten counter gear lock nut.
Always use new lock nut.
Counter gear lock nut:
: 98 - 127 Nm (10.0 - 13.0 kg-m, 72 - 94 ft-lb)

SMT004A

10. Stake mainshaft lock nut and counter gear lock nut using a
punch.
11. Measure gear end play. Refer to DISASSEMBLY, MT-15.
12. Install snap ring and OD mainshaft bearing, then snap ring.
Allowable clearance:
0 - 0.14 mm (0 - 0.0055 in)
OD mainshaft bearing snap ring:
Refer to OD MAINSHAFT BEARING, MT-32.
AMT145

Shift Control Components

ASSEMBLY

NEMT0064

1.

Install fork rods, interlock plunger, interlock balls and check

balls.

2.

Install 1st and 2nd shift fork, then drive in retaining pin.

SMT992-A

SMT989

MT-26

ASSEMBLY

FS5W71C
Shift Control Components (Contd)

3.

Install 3rd and 4th shift fork, then drive in retaining pin.

GI
MA
EM
LC

SMT990

4.

Install overdrive and reverse shift fork, then drive in retaining

pin.

EC
FE
CL

SMT991

Case Components
ASSEMBLY
1.

AT
NEMT0065

Install front cover oil seal using Tool.

Apply multi-purpose grease to seal lip.

TF
PD
AX

SMT036

2.

Apply sealant to mating surface of transmission case as shown

in the figure at left.
Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.

SU
BR
ST
RS

SMT061C

3.

Slide gear assembly onto adapter plate by lightly tapping it

using a soft hammer.

BT
HA
SC
EL

SMT013

MT-27

IDX

ASSEMBLY

FS5W71C

Case Components (Contd)

4.

Install main drive gear ball bearing snap ring.

5.

Apply sealant to mating surface of adapter plate as shown at

left.
Use genuine anaerobic liquid gasket Three Bond TB1215,
Loctite Part No. 51813 or equivalent.

SMT672A

SMT062C

6.
7.

Place shift forks in neutral position.

Install striking lever and rod onto adapter plate and align striking lever with shift brackets.

8.

Install rear extension.

Tighten mounting bolts equally in a criss-cross pattern.

9.

Install striking lever retaining pin.

SMT801B

SMT180D

AMT132

MT-28

ASSEMBLY

FS5W71C
Case Components (Contd)

10. Select counter gear front bearing shim.

Allowable clearance (A) from bearing surface to transmission case:
0 - 0.16 mm (0 - 0.0063 in)
Countershaft front bearing shim:
Refer to COUNTERSHAFT FRONT BEARING,
MT-32.
11. Install gasket and front cover.

GI
MA
EM
LC

SMT205D

12. Install check ball, return springs, select check plungers and
plugs.
13. Install control housing and gasket.

EC
FE
CL

SMT161D

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL

MT-29

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5W71C

General Specifications

General Specifications

NEMT0066

KA24DE
Applied model
2WD
Transmission

FS5W71C

Number of speed

Shift pattern

MT-SDS-2

Synchromesh type

Warner
1st

3.321

2nd

1.902

3rd

1.308

4th

1.000

OD

0.838

Reverse

3.382

Gear ratio

Mainshaft
(Number of teeth)

Countershaft gear
(Number of teeth)

Drive

22

1st

33

2nd

27

3rd

26

OD

22

Reverse

36

Drive

31

1st

14

2nd

20

3rd

28

OD

37

Reverse

15

Reverse idler gear (Number of teeth)

21

Oil capacity

(US pt, Imp pt)

2.0 (4-1/4, 3-1/2)

Reverse synchronizer

Installed

Remarks
Sub gear

Counter drive gear and reverse idler gear

Gear End Play

NEMT0067

Unit: mm (in)
1st gear

0.31 - 0.41 (0.0122 - 0.0161)

2nd gear

0.11 - 0.21 (0.0043 - 0.0083)

3rd gear

0.11 - 0.21 (0.0043 - 0.0083)

Overdrive gear

0.24 - 0.41 (0.0094 - 0.0161)

MT-30

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5W71C

Clearance Between Baulk Ring and Gear

Clearance Between Baulk Ring and Gear

NEMT0068

Unit: mm (in)
1st & 2nd

1.20 - 1.60 (0.0472 - 0.0630)

3rd & main drive

1.20 - 1.60 (0.0472 - 0.0630)

Overdrive

1.20 - 1.60 (0.0472 - 0.0630)

Reverse

1.10 - 1.55 (0.0433 - 0.0610)

MA

Standard

1st & 2nd

0.80 (0.0315)

3rd & main drive

0.80 (0.0315)

Overdrive

0.80 (0.0315)

Reverse

0.70 (0.0276)

EM
LC

Wear limit

Available Snap Rings

GI

EC
NEMT0069

MAIN DRIVE GEAR BEARING

NEMT0069S01

FE

Unit: mm (in)
Allowable clearance

0 - 0.13 (0 - 0.0051)

CL

Thickness

Part number*

1.87 (0.0736)

32204-78001

1.94 (0.0764)

32204-78002

2.01 (0.0791)

32204-78003

AT

*Always check with the Parts Department for the latest parts information.

MAINSHAFT FRONT

NEMT0069S02

Unit: mm (in)
Allowable clearance

0 - 0.18 (0 - 0.0071)

TF
PD

Thickness

Part number*

2.4 (0.094)

32263-V5200

2.5 (0.098)

32263-V5201

AX

*Always check with the Parts Department for the latest parts information.

SU

COUNTER DRIVE GEAR

NEMT0069S03

Unit: mm (in)
Allowable clearance

BR

0 - 0.13 (0 - 0.0051)
Thickness

Part number*

1.4 (0.055)

32215-E9000

1.5 (0.059)

32215-E9001

1.6 (0.063)

32215-E9002

*Always check with the Parts Department for the latest parts information.

ST
RS
BT
HA
SC
EL

MT-31

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5W71C

Available Snap Rings (Contd)

OD MAINSHAFT BEARING

NEMT0069S04

Unit: mm (in)
Allowable clearance

0 - 0.14 (0 - 0.0055)
Thickness

Part number*

1.1 (0.043)

32228-20100

1.2 (0.047)

32228-20101

1.3 (0.051)

32228-20102

1.4 (0.055)

32228-20103

*Always check with the Parts Department for the latest parts information.

Available Shims

NEMT0070

COUNTERSHAFT FRONT BEARING

NEMT0070S01

Unit: mm (in)
Allowable clearance A 0 - 0.16 (0 - 0.0063)

SMT205D

Thickness of shim

4.52 - 4.71 (0.1780 - 0.1854)

Part number*
Not necessary

4.42 - 4.51 (0.1740 - 0.1776)

0.1 (0.004)

32218-V5000

4.32 - 4.41 (0.1701 - 0.1736)

0.2 (0.008)

32218-V5001

4.22 - 4.31 (0.1661 - 0.1697)

0.3 (0.012)

32218-V5002

4.12 - 4.21 (0.1622 - 0.1657)

0.4 (0.016)

32218-V5003

4.02 - 4.11 (0.1583 - 0.1618)

0.5 (0.020)

32218-V5004

3.92 - 4.01 (0.1543 - 0.1579)

0.6 (0.024)

32218-V5005

*Always check with the Parts Department for the latest parts information.

MT-32

PREPARATION

FS5R30A
Special Service Tools

Special Service Tools

NEMT0001

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name

GI

Description

MA
Removing and installing retaining pin
a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.

ST23540000
(J25689-A)
Pin punch

EM
LC

NT442

Removing 1st & 2nd synchronizer assembly

Removing counter gear rear thrust bearing
Removing main drive bearing
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.

ST30031000
(J22912-01)
Puller

EC
FE

NT411

Removing rear oil seal

a: 250 mm (9.84 in)
b: 160 mm (6.30 in)

ST33290001
(J34286)
Puller

CL

AT
NT414

ST33230000
(

Drift

Removing mainshaft and counter gear

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

TF
PD
AX

NT084

Removing counter gear front bearing (Use with

KV38100300)
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.

ST22350000
(J25678-01)
Drift

SU
BR

NT065

Removing counter gear front bearing (Use with

ST22350000)
Installing counter gear rear bearing
a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.

KV38100300
(J25523)
Drift

ST
RS

NT065

1 Removing mainshaft front bearing

2 Installing mainshaft front bearing
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.

ST30720000
1 (J34286)
2 (J34331)
Drift

BT
HA

NT115

1 Installing counter gear front bearing

2 Installing front cover oil seal
a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.

ST33210000
1 (J25523)
2 (J25803-01)
Drift

SC
EL

NT084

MT-33

IDX

PREPARATION

FS5R30A

Special Service Tools (Contd)

Tool number
(Kent-Moore No.)
Tool name

Description

ST30613000
(J25742-3)
Drift

Installing main drive gear bearing

a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.

NT073

1 Removing counter gear rear bearing

2 Installing OD gear bushing
2 Removing and installing mainshaft rear bearing
(4WD model)
2 Installing reverse cone
3 Installing reverse counter gear
4 Installing counter gear rear end bearing
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.

ST37750000
1 (J34286)
2 (J34332)
3 (J34334)
4 (J25679-01)
Drift
NT065

Installing reverse hub

Installing mainshaft rear bearing (2WD model)
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.

ST22452000
(J34337)
Drift

NT065

Installing rear oil seal

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

ST33400001
(J26082)
Drift

NT086

Installing mainshaft and counter gear

(Use with J34328)

(J26349-3)
Puller leg

NT078

(J34328)
Puller

Installing mainshaft and counter gear

(Use with J26349-3)

NT079

Installing sub-gear snap ring

a: 44.5 mm (1.752 in) dia.
b: 38.5 mm (1.516 in) dia.

(J26092)
Drift

NT065

Installing OD main gear

Installing reverse gear bushing
a: 44.5 mm (1.752 in) dia.
b: 40.5 mm (1.594 in) dia.

(J34342)
Drift

NT065

MT-34

PREPARATION

FS5R30A
Special Service Tools (Contd)

Tool number
(Kent-Moore No.)
Tool name

Description

GI

ST33220000
(J25804-01)
Drift

Installing mainshaft rear bearing

a: 37 mm (1.46 in) dia.
b: 22 mm (0.87 in) dia.

MA
EM

NT084

Commercial Service Tool

Tool name

LC
NEMT0002

Description

EC

Puller

Removing
Removing
Removing
Removing

counter gear rear end bearing

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

FE
CL

NT077

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL

MT-35

IDX

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING

NEMT0023

FS5R30A

NVH Troubleshooting Chart

NVH Troubleshooting Chart

NEMT0023S01

Use the chart below to help you find the cause of the problem. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

MANUAL TRANSMISSION

MT-47

MT-45

MT-45

MT-45

MT-45

GEAR (Worn or damaged)

BEARING (Worn or damaged)

BAULK RING (Worn or damaged)

INSERT SPRING (Damaged)

SHIFT FORK (Worn)

MT-47

Hard to shift or will not shift

CHECK PLUG RETURN SPRING AND

CHECK BALL (Worn or damaged)

MT-47

O-RING (Worn or damaged)

Oil leakage

MT-44

OIL SEAL (Worn or damaged)

MT-44

OIL (Wrong)

Noise

OIL (Level low)

SUSPECTED PARTS
(Possible cause)

GASKET (Damaged)

Reference page

OIL (Level too high)

MA-37 Checking M/T Oil.

NEMT0023S0101

Symptom
Jumps out of gear

MT-36

NEMT0005

DESCRIPTION

FS5R30A
Cross-sectional View 2WD Model

Cross-sectional View 2WD Model

NEMT0005S01

GI
MA
EM
LC
EC
FE
CL

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
WMT041

MT-37

EL
IDX

DESCRIPTION

FS5R30A

Cross-sectional View 4WD Model

Cross-sectional View 4WD Model

NEMT0005S02

SMT320D

MT-38

ON-VEHICLE SERVICE

FS5R30A
Replacing Rear Oil Seal 2WD Model

Replacing Rear Oil Seal 2WD Model

REMOVAL
1.
2.

NEMT0003
NEMT0003S01

Remove the propeller shaft. Refer to PD-9, Removal and

Installation.
Remove rear oil seal using Tool.
Always replace with a new seal once it has been removed.

GI
MA
EM
LC

SMT479CA

INSTALLATION
1.

2.

NEMT0003S02

Install new oil seal until it stops.

Apply multi-purpose grease to seal lip of oil seal before
installing.
Install any part removed.

EC
FE
CL

SMT480CA

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL

MT-39

IDX

ON-VEHICLE SERVICE

FS5R30A

Position Switch Check

Position Switch Check

Switch

NEMT0004

Gear position

Continuity

Reverse

Yes

Except reverse

No

Neutral

Yes

Except neutral

No

Back-up lamp switch

Park/neutral position
(PNP) switch

SMT981D

AMT205

MT-40

NEMT0006

REMOVAL AND INSTALLATION

FS5R30A
Removal

Removal

NEMT0006S01

CAUTION:
When removing the M/T assembly from engine, first remove
the crankshaft position sensor (OBD) from the M/T assembly.
Be careful not to damage sensor edge.

GI
MA
EM
LC
EC
FE
CL

AMT189

2WD MODEL

NEMT0006S0101

AT

Remove battery negative terminal.

Remove shift lever with control housing from transmission.
Remove crankshaft position sensor (OBD) from upper side of
transmission case.
Remove clutch operating cylinder from transmission. Tighten
clutch operating cylinder to the specified torque. Refer to CL-5,
CLUTCH SYSTEM.
Disconnect vehicle speed sensor, back-up lamp switch, heated
oxygen sensor (rear) and park/neutral position (PNP) switch
harness connectors.
Remove starter motor from transmission.
: 41 - 52 Nm (4.2 - 5.3 kg-m, 30 - 38 ft-lb)
Remove propeller shaft. Refer to PD-9, Removal and Installation.
Insert plug into rear oil seal after removing propeller shaft.
Be careful not to damage spline, sleeve yoke and rear oil
seal when removing propeller shaft.
Remove gussets from transmission or engine.

TF

Remove exhaust tube mounting bracket from transmission.

Refer to FE-8, EXHAUST SYSTEM.
10. Support manual transmission with a jack.
11. Remove rear mounting member. Tighten rear mounting member to the specified torque. Refer to EM-112, Removal and
Installation.
12. Lower manual transmission as much as possible.
WARNING:
Support manual transmission together with transfer, while
removing it.

BT

1.
2.
3.
4.

5.

6.
7.

8.
9.

PD
AX
SU
BR
ST
RS

HA
SC
EL

SMT099A

MT-41

IDX

REMOVAL AND INSTALLATION

FS5R30A

Removal (Contd)

AMT203

4WD MODEL
1.
2.

NEMT0006S0102

Disconnect the battery negative terminal.

Remove shift lever from transmission and control lever from
transfer.
3. Remove clutch operating cylinder from transmission. Tighten
clutch operating cylinder to the specified torque. Refer to CL-5,
CLUTCH SYSTEM.
4. Disconnect the vehicle speed sensor, back-up lamp switch,
heated oxygen sensor (rear) and Park/neutral position (PNP)
switch harness connectors.
5. Remove the starter motor from transmission.
: 41 - 52 Nm (4.2 - 5.3 kg-m, 30 - 38 ft-lb)
6. Remove front and rear propeller shafts. Refer to PD-9, PROPELLER SHAFT.
Insert plug into rear oil seal after removing propeller shaft.
Be careful not to damage spline, sleeve yoke and rear oil
seal when removing propeller shaft.
7. Remove exhaust tube mounting bracket from transmission.
Refer to FE-8, EXHAUST SYSTEM.
8. Remove front exhaust tubes and center pipe.
9. Remove the torsion bars and mounts. Refer to SU-14,
Removal.
10. Remove the rear torsion bar cross member.
11. Remove the gussets from the transmission or engine.
12. Support the manual transmission with a jack.
13. Remove rear mounting member. Tighten rear mounting member to the specified torque. Refer to EM-112, Engine Mounting.
14. Lower manual transmission as much as possible.
WARNING:
Support manual transmission together with transfer while
removing it.

MT-42

REMOVAL AND INSTALLATION

FS5R30A
Removal (Contd)

15. Remove crankshaft position sensor (OBD) from upper side of

transmission case.
16. Remove transmission bolts.
WARNING:
Support manual transmission together with transfer while
removing it.

GI
MA
EM
LC

SMT558A

EC
FE
CL

Installation

SMT573AB

NEMT0006S02

Tighten the bolts securing the transmission to the specified

torques in the chart below.
Bolt No.

Tightening torque Nm (kg-m, ft-lb)

mm (in)

39 - 49 (4.0 - 5.0, 29 - 36)

65 (2.56)

39 - 49 (4.0 - 5.0, 29 - 36)

58 (2.28)

29 - 39 (3.0 - 4.0, 22 - 29)

25 (0.98)

4 (Gusset to
engine)

29 - 39 (3.0 - 4.0, 22 - 29)

20 (0.79)

AT
TF
PD
AX
SU
BR
ST
RS

Adjust the torsion bars for the correct vehicle height. Refer to
SU-15, INSTALLATION AND ADJUSTMENT.

BT
HA
SC
EL

WMT054

MT-43

IDX

NEMT0007

OVERHAUL

FS5R30A

Case Components

Case Components

NEMT0007S01

WMT060

MT-44

OVERHAUL

FS5R30A
Gear Components

Gear Components

NEMT0007S02

GI
MA
EM
LC
EC
FE
CL

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
WMT047

MT-45

EL
IDX

OVERHAUL

FS5R30A

Gear Components (Contd)

WMT048

MT-46

OVERHAUL

FS5R30A
Shift Control Components (2/4WD models)

Shift Control Components (2/4WD models)

NEMT0007S03

GI
MA
EM
LC
EC
FE
CL

AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
WMT032

MT-47

EL
IDX

DISASSEMBLY

FS5R30A

Case Components

Case Components
DISASSEMBLY
1.

NEMT0008

Remove check ball plug, check spring and check ball. Then
remove interlock stopper.
If interlock assembly is removed as a unit, the check ball
can fall into transmission case.
Be careful not to lose check ball.

2.

Remove control housing, return spring and check ball.

Be careful not to lose check ball.

3.

Drive out retaining pin from striking arm.

4.

Remove rear extension (or OD gear case) together with striking arm by tapping lightly.

5.

Remove front cover and gasket.

SMT366A

SMT367A

SMT368A

SMT135C

SMT370A

MT-48

DISASSEMBLY

FS5R30A
Case Components (Contd)

6.

Remove stopper ring and main drive bearing snap ring.

GI
MA
EM
LC

SMT371A

7.

Remove transmission case by tapping lightly.

EC
FE
CL
SMT372A

8.

Remove front cover oil seal.

AT
TF
PD
AX
SMT392A

Shift Control Components

DISASSEMBLY
1.
2.

SU
NEMT0009

Mount adapter plate on vise.

Remove OD & reverse fork rod.

BR
ST
RS

SMT373A

3.
4.

Drive out retaining pin from striking lever.

While pulling out striking rod, remove striking lever and striking interlock. Then remove 1st and 2nd, 3rd and 4th, and
reverse shift forks.

BT
HA
SC
EL

SMT374A

MT-49

IDX

DISASSEMBLY

FS5R30A

Shift Control Components (Contd)

5.
6.

Drive out retaining pin from OD shift fork.

Pull out OD fork rod and then remove OD shift fork.

SMT375A

Gear Components
DISASSEMBLY
1.

NEMT0010

Before removing gears and shafts, measure each gear end

play. Refer to Gear End Play, MT-67.
If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft.

SMT376A

2.
a.

Remove rear side components on mainshaft and counter gear.

Remove reverse coupling sleeve.

b.

Remove mainshaft rear snap ring and counter gear rear snap
ring.
Remove C-ring holder and mainshaft C-rings from mainshaft.
Use punch and hammer to remove C-rings.

SMT463A

c.

SMT377A

d.
e.

Pull out counter gear rear end bearing.

Remove reverse idler gear and reverse idler thrust washers.

SMT378A

MT-50

DISASSEMBLY

FS5R30A
Gear Components (Contd)

f.

Pull out mainshaft rear bearing (2WD model).

GI
MA
EM
LC

SMT379A

g.

Pull out reverse main gear together with mainshaft spacer and
reverse synchronizer hub. Then remove reverse gear needle
bearings.

EC
FE
CL

SMT380A

h.
i.

Pull out reverse counter gear.

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

AT
TF
PD
AX

SMT773A

j.

Pull out reverse gear bushing.

SU
BR
ST
RS

SMT770A

k.

Pull out OD counter gear together with reverse cone.

BT
HA
SC
EL

SMT771A

MT-51

IDX

DISASSEMBLY

FS5R30A

Gear Components (Contd)

3.

Press out mainshaft and counter gear alternately.

AMT174A

4.
a.
b.

Remove front side components on mainshaft.

Remove 1st gear washer and steel ball.
Remove 1st main gear and 1st gear needle bearing.
Be careful not to lose steel ball.

c.

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

SMT383A

d.

SMT482C

e.

Press out 3rd main gear together with 3rd and 4th synchronizer
assembly and 3rd gear needle bearing.

SMT385A

MT-52

DISASSEMBLY

FS5R30A
Gear Components (Contd)

5.
a.

Remove front side components on counter gear.

Remove counter gear rear thrust bearing.

GI
MA
EM
LC

SMT404A

b.

Remove sub-gear components.

EC
FE
CL
SMT470A

6.
a.
b.

Remove main drive gear bearing.

Remove main drive gear snap ring.
Press out main drive gear bearing.

AT
TF
PD
AX

SMT420A

7.

Remove bearings from case components.

SU
BR
ST
RS
BT
HA
SC
AMT173

MT-53

EL
IDX

INSPECTION

FS5R30A

Shift Control Components

Shift Control Components

INSPECTION

NEMT0011

Check contact surface and sliding surface for wear, scratches,

projections or other damage.

SMT398A

Gear Components
INSPECTION
Gears and Shafts

NEMT0012
NEMT0012S01

Check shafts for cracks, wear or bending.

Check gears for excessive wear, chips or cracks.

SMT386A

SMT423A

Synchronizers

NEMT0012S02

Check spline portion of coupling sleeves, hubs, and gears for

wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
Check insert springs for deformation.

SMT427C

Measure wear of main drive, 1st (VG33E model) and OD baulk

rings. Refer to Clearance Between Baulk Ring and Gear,
MT-67.
If the clearance is smaller than the wear limit, replace baulk
ring.

SMT140

MT-54

INSPECTION

FS5R30A
Gear Components (Contd)

a)
b)

WMT049

Measure wear of 1st, 2nd and 3rd double baulk rings.

1st, 2nd and 3rd double baulk rings: VG33ER model.
2nd and 3rd double baulk rings: VG33E model.
Place baulk rings in position on synchronizer cone.
While holding baulk rings against synchronizer cone as far as
it will go, measure dimensions A and B.
Standard:
A 0.7 - 0.9 mm (0.028 - 0.035 in)
B 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit:
0.2 mm (0.008 in)
If dimension A or B is smaller than the wear limit, replace
outer baulk ring, inner baulk ring and synchronizer cone as a
set.

GI
MA
EM
LC
EC
FE
CL

WMT050

a)
b)

c)

Measure wear of reverse baulk ring.

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

AT
TF
PD
AX

SMT424A

Bearings

NEMT0012S03

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

SU
BR
ST
RS

SMT418A

BT
HA
SC
EL

MT-55

IDX

ASSEMBLY

FS5R30A

Gear Components

Gear Components
ASSEMBLY

NEMT0013

AMT172

1.
2.
a.

Install bearings into case components.

Install main drive gear bearing.
Press main drive gear bearing.

b.

Select proper main drive gear snap ring to minimize clearance

of groove. Refer to MAIN DRIVE GEAR SNAP RING, MT-68.
Allowable clearance of groove:
0 - 0.11 mm (0 - 0.004 in)
Install selected snap ring on main drive gear.

SMT425A

c.

SMT426A

3.
a.

Install components on counter gear.

Install sub-gear components.
When installing sub-gear snap ring, tap sub-gear snap
ring into position on counter gear.

SMT577A

MT-56

ASSEMBLY

FS5R30A
Gear Components (Contd)

b.

Install counter gear rear thrust bearing.

GI
MA
EM
LC

SMT405A

4.
a.

Install front side components on mainshaft.

Assemble 1st and 2nd synchronizer.

EC
FE
CL

SMT614B

b.

Assemble 3rd and 4th synchronizer.

AT
TF
PD
AX
SMT615B

c.

Press on 3rd and 4th synchronizer assembly together with 3rd

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

SU
BR
ST
RS

SMT399A

d.

e.

Select proper snap ring to minimize clearance of groove. Refer

to MAINSHAFT FRONT SNAP RING, MT-68.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Install selected snap ring on mainshaft.

BT
HA
SC
EL

SMT400A

MT-57

IDX

ASSEMBLY

FS5R30A

Gear Components (Contd)

f.

Press on 1st and 2nd synchronizer assembly together with 2nd

main gear and 2nd gear needle bearing.

g.
h.

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

Install 1st main gear and needle bearing.

i.

Install steel ball and 1st gear washer.

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

5.

Select proper counter gear front bearing thrust washer when

replacing transmission case, counter gear, counter gear rear
thrust bearing or sub-gear components.
Install counter gear with sub-gear components, counter gear
front and rear bearing thrust washer on adapter plate.
Remove counter gear front bearing thrust washer from transmission case.
Place adapter plate and counter gear assembly in transmission case (case inverted).

SMT401A

SMT402A

SMT403A

a.
b.
c.

SMT427AA

MT-58

ASSEMBLY

FS5R30A
Gear Components (Contd)

d.
e.
f.
g.

Tighten adapter plate to transmission case using 2 bolts.

Place dial indicator on rear end of counter gear.
Move counter gear up and down and measure dial indicator
deflection.
Select proper thrust washer using the table as a guide. Refer
to TABLE FOR SELECTING PROPER COUNTER GEAR
FRONT BEARING THRUST WASHER, MT-69.
Counter gear end play:
0.10 - 0.26 mm (0.0040 - 0.0102 in)

GI
MA
EM
LC
EC
FE
CL

SMT578A

6.

a.

Select proper reverse idler rear thrust washer when replacing

rear extension (or OD gear case), reverse idler gear, reverse
idler shaft or reverse idler front thrust washer.
Install reverse idler gear, reverse idler needle bearings,
reverse idler front thrust washers and reverse idler shaft into
rear extension (or OD gear case).
When replacing reverse idler rear thrust washer, install
either A or B. Refer to REVERSE IDLER REAR THRUST
WASHER, MT-70.

AT
TF
PD
AX
SU
BR
ST
RS

WMT051

BT
HA
SC
EL

MT-59

IDX

ASSEMBLY

FS5R30A

Gear Components (Contd)

b.
c.
d.

e.

Place dial indicator on front end of reverse idler shaft.

Put straightedge on front surface of rear extension (or O/D
gear case) as a stopper of reverse idler shaft.
Move reverse idler shaft up and down and measure reverse
idler gear end play.
Reverse idler gear end play:
0.30 - 0.53 mm (0.0119 - 0.0208 in)
If not within specification, replace reverse idler rear thrust
washer with the other (A or B) and check again.

SMT433A

7.
a.

Install mainshaft and counter gear on adapter plate and main

drive gear on mainshaft.
Mount adapter plate on vise and apply multi-purpose grease to
counter gear rear bearing.

SMT438A

b.

Install mainshaft a little on mainshaft front bearing.

To allow for installation of counter gear, do not install
mainshaft completely.

c.

Install counter gear on counter gear rear bearing and install

main drive gear, pilot bearing and spacer on mainshaft.

SMT440A

SMT441A

MT-60

ASSEMBLY

FS5R30A
Gear Components (Contd)

When installing counter gear into counter gear rear

bearing, push up on upper roller of counter gear rear bearing with screwdriver.

GI
MA
EM
LC

SMT442A

d.
e.

Install Tools (J26349-3) onto adapter plate and C-ring and

C-ring holder on mainshaft.
Install Tool (J34328) on mainshaft.

EC
FE
CL

SMT064C

f.

Install mainshaft and counter gear completely by extending

length of (J26349-3).

AT
TF
PD
AX

SMT579A

8.
a.

Install rear side components on mainshaft and counter gear.

Install OD gear bushing while pushing on the front of counter
gear.

SU
BR
ST
RS

SMT444A

b.

c.
d.

Install OD main gear.

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

BT
HA
SC
EL

SMT580AA

MT-61

IDX

ASSEMBLY

FS5R30A

Gear Components (Contd)

e.

Install reverse gear bushing with speedometer drive gear

(2WD model).

f.

Install reverse cone.

g.

Install insert springs and reverse baulk ring on OD coupling

sleeve. Then install them and OD baulk ring on OD counter
gear.
Pay attention to direction of OD coupling sleeve.

SMT581A

SMT582A

SMT571AA

SMT583A

h.
i.

Install reverse counter gear.

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

SMT584A

MT-62

ASSEMBLY

FS5R30A
Gear Components (Contd)

j.

Install reverse hub.

Pay attention to its direction.

GI
MA
EM
LC

SMT585A

k.

Install mainshaft spacer and mainshaft rear bearing (2WD

model).

EC
FE
CL

SMT586A

l. Install counter gear rear end bearing.

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

AT
TF
PD
AX

SMT485C

n.

Select proper mainshaft C-ring to minimize clearance of

groove. Refer to MAINSHAFT C-RING, MT-69.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)

SU
BR
ST
RS

SMT452A

o.

Install selected C-ring, C-ring holder and mainshaft rear snap

ring.

BT
HA
SC
EL

SMT454A

MT-63

IDX

ASSEMBLY

FS5R30A

Gear Components (Contd)

p.

q.

Select proper counter gear rear snap ring to minimize clearance of groove. Refer to COUNTER GEAR REAR SNAP
RING, MT-69.
Allowable clearance of groove:
0 - 0.11 mm (0 - 0.004 in)
Install selected counter gear rear snap ring.

SMT453A

SMT455A

r.

s.

Install reverse coupling sleeve.

Pay attention to its direction.
Measure each gear end play as a final check. Refer to
DISASSEMBLY, MT-50.

SMT456A

Shift Control Components

ASSEMBLY
1.
2.

NEMT0014

Install OD fork rod and OD shift fork. Then install retaining pin
into OD shift fork.
Install 1st and 2nd, 3rd and 4th, and reverse shift forks onto
coupling sleeve.

SMT457A

3.

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

SMT374A

MT-64

ASSEMBLY

FS5R30A
Case Components

Case Components
ASSEMBLY
1.

2.

NEMT0015

3.

Install front cover oil seal.

Apply multi-purpose grease to seal lip.
Install selected counter gear front bearing shim onto transmission case.
Apply multi-purpose grease.
Apply sealant to mating surface of transmission case.

4.
5.

Install gear assembly onto transmission case.

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

GI
MA
EM
LC

SMT393A

EC
FE
CL

SMT588A

6.

Install interlock stopper assembly and then tighten check ball

plug. Refer to Shift Control Components, MT-47.
Apply sealant to thread of check ball plug.

AT
TF
PD
AX

SMT460A

7.

Install stopper ring and main drive bearing snap ring.

SU
BR
ST
RS

SMT371A

8.

9.

Install front cover and gasket. Refer to Case Components,

MT-44.
Apply sealant to thread of 3 bolts shown left.
Apply sealant to mating surface of adapter plate.

BT
HA
SC
EL

SMT459A

MT-65

IDX

ASSEMBLY

FS5R30A

Case Components (Contd)

10. Install OD gear case together with striking arm.

SMT461A

11. Install retaining pin into striking arm.

SMT368A

12. Install return spring and check ball and then install control
housing.
Apply sealant to mating surface of OD gear case.
Refer to Case Components, MT-44.

SMT462A

13. Tighten control housing bolts.

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

SMT572A

MT-66

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5R30A
General Specifications

General Specifications

NEMT0016

GI

VG33E/VG33ER
FS5R30A
Transmission
2WD

MA

4WD

Number of speed

EM
Shift pattern

LC
MT-SDS-2

Synchromesh type

EC

Warner
Number of teeth
Gear ratio
Mainshaft

Countershaft

22

32

1st

3.580

32

13

2nd

2.077

30

21

3rd

1.360

29

31

4th

1.000

OD

0.811

24

43

Reverse

3.636

30

12

Drive

Reverse idler gear

Oil capacity
(US pt, Imp pt)
Remarks

FE
CL

AT
TF

22
2.8 (5-7/8, 4-7/8) 2WD model

5.1 (10-3/4, 9) 4WD model

PD

2nd & 3rd double baulk ring type synchronizerVG33E model

1st, 2nd & 3rd double baulk ring type synchronizerVG33ER model

AX

Gear End Play

NEMT0017

Unit: mm (in)
Gear

SU

End play

1st main gear

0.23 - 0.33 (0.0091 - 0.0130)

2nd main gear

0.23 - 0.33 (0.0091 - 0.0130)

3rd main gear

0.06 - 0.16 (0.0024 - 0.0063)

OD counter gear

0.23 - 0.33 (0.0091 - 0.0130)

Reverse main gear

0.33 - 0.43 (0.0130 - 0.0169)

Counter gear

0.10 - 0.25 (0.0039 - 0.0098)

Reverse idler gear

0.30 - 0.53 (0.0118 - 0.0209)

BR
ST
RS

Clearance Between Single Baulk Ring and Gear BT

NEMT0018

Unit: mm (in)
Standard
1st (VG33E model)

1.05 - 1.3 (0.0413 - 0.0512)

Main drive

1.05 - 1.3 (0.0413 - 0.0512)

OD

1.05 - 1.3 (0.0413 - 0.0512)

Wear limit

HA

0.7 (0.028)

SC
EL

MT-67

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5R30A

Clearance Between Single Baulk Ring and Gear (Contd)

DOUBLE BAULK RING

NEMT0018S01

Unit: mm (in)
VG33E model
VG33ER model

2nd & 3rd baulk rings

1st, 2nd & 3rd baulk rings

SMT742C

Dimension

Standard

Wear limit

0.7 - 0.9 (0.028 - 0.035)

0.6 - 1.1 (0.024 - 0.043)

0.2 (0.008)

Distance Between Rear Surface of Reverse

Cone and Reverse Baulk Ring

NEMT0019

Unit: mm (in)

SMT428C

Dimension

Standard

Wear limit

0.1 to 0.35 (0.0039 to 0.0138)

0.7 (0.028)

Available Snap Ring

NEMT0020

MAIN DRIVE GEAR SNAP RING

NEMT0020S01

Unit: mm (in)
Allowable clearance

0 - 0.11 (0 - 0.004)

Thickness

Part number*

Thickness

Part number*

1.89 (0.0744)

32204-01G60

2.03 (0.0799)

32204-01G63

1.95 (0.0768)

32204-01G61

2.07 (0.0815)

32204-01G64

1.99 (0.0783)

32204-01G62

2.11 (0.0831)

32204-01G65

*Always check with the Parts Department for the latest parts information.

MAINSHAFT FRONT SNAP RING

NEMT0020S02

Unit: mm (in)
Allowable clearance

0 - 0.1 (0 - 0.004)

Thickness

Part number*

Thickness

Part number*

1.99 (0.0783)

32204-01G62

2.11 (0.0831)

32204-01G65

2.03 (0.0799)

32204-01G63

2.15 (0.0846)

32204-01G66

2.07 (0.0815)

32204-01G64

2.19 (0.0862)

32204-01G67

*Always check with the Parts Department for the latest parts information.

MT-68

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5R30A

Available Snap Ring (Contd)

COUNTER GEAR REAR SNAP RING

NEMT0020S03

Unit: mm (in)
Allowable clearance

GI

0 - 0.11 (0 - 0.004)

Thickness

Part number*

Thickness

Part number*

1.32 (0.0520)

32236-01G00

1.56 (0.0614)

32236-01G04

1.38 (0.0543)

32236-01G01

1.62 (0.0638)

32236-01G05

1.44 (0.0567)

32236-01G02

1.68 (0.0661)

32236-01G06

1.50 (0.0591)

32236-01G03

1.74 (0.0685)

32236-01G07

MA
EM
LC

*Always check with the Parts Department for the latest parts information.

Available C-ring

NEMT0021

MAINSHAFT C-RING

EC

NEMT0021S01

Unit: mm (in)
Allowable clearance

FE

0 - 0.1 (0 - 0.004)

Thickness

Part number*

Thickness

Part number*

2.63 (0.1035)

32348-01G15

3.19 (0.1256)

32348-01G07

2.70 (0.1063)

32348-01G00

3.26 (0.1283)

32348-01G08

2.77 (0.1091)

32348-01G01

3.33 (0.1311)

32348-01G09

2.84 (0.1118)

32348-01G02

3.40 (0.1339)

32348-01G10

2.91 (0.1146)

32348-01G03

3.47 (0.1366)

32348-01G11

2.98 (0.1173)

32348-01G04

3.54 (0.1394)

32348-01G12

3.05 (0.1201)

32348-01G05

3.61 (0.1421)

32348-01G13

3.12 (0.1228)

32348-01G06

3.68 (0.1449)

32348-01G14

CL

AT
TF
PD

*Always check with the Parts Department for the latest parts information.

Available Shim and Washer

NEMT0022
AX
TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER
NEMT0022S01

Unit: mm (in)
Allowable clearance

SU

0.10 - 0.26 (0.040 - 0.0102)

Dial indicator deflection

Thickness of proper washer

Part number*

0.93 - 1.02 (0.0366 - 0.0402)

0.80 (0.0315)

32218-01G00

1.01 - 1.10 (0.0398 - 0.0433)

0.88 (0.0346)

32218-01G11

1.09 - 1.18 (0.0429 - 0.0465)

0.96 (0.0378)

32218-01G12

1.17 - 1.26 (0.0461 - 0.0496)

1.04 (0.0409)

32218-01G13

1.25 - 1.34 (0.0492 - 0.0528)

1.12 (0.0441)

32218-01G14

1.33 - 1.42 (0.0524 - 0.0559)

1.20 (0.0472)

32218-01G04

1.41 - 1.50 (0.0555 - 0.0591)

1.28 (0.0504)

32218-01G15

1.49 - 1.58 (0.0587 - 0.0622)

1.36 (0.0535)

32218-01G16

1.57 - 1.66 (0.0618 - 0.0654)

1.44 (0.0567)

32218-01G17

BR
ST
RS
BT
HA

*Always check with the Parts Department for the latest parts information.

SC
EL

MT-69

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5R30A

Available Shim and Washer (Contd)

REVERSE IDLER REAR THRUST WASHER

NEMT0022S02

Unit: mm (in)
Allowable clearance

0.30 - 0.53 (0.0119 - 0.0208)

Thickness

Part number*

1.97 (0.0776)

32284-01G10

2.07 (0.0815)

32284-01G11

*Always check with the Parts Department for the latest parts information.

MT-70