C TRANSMISSION/TRANSAXLE
A
SECTION
MANUAL TRANSMISSION
MT
CONTENTS
PRECAUTIONS .......................................................... 2
Caution ..................................................................... 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tool ......................................... 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
MANUAL TRANSMISSION ................................... 5
DESCRIPTION ............................................................ 6
Cross-sectional View ................................................ 6
DOUBLE-CONE SYNCHRONIZER ...................... 6
M/T OIL ....................................................................... 7
Replacement ............................................................ 7
DRAINING ............................................................. 7
FILLING ................................................................. 7
Checking .................................................................. 7
OIL LEAKAGE AND OIL LEVEL ........................... 7
REAR OIL SEAL ........................................................ 8
Removal and Installation .......................................... 8
REMOVAL ............................................................. 8
INSTALLATION ..................................................... 8
POSITION SWITCH .................................................... 9
Checking .................................................................. 9
BACK-UP LAMP SWITCH .................................... 9
CONTROL LINKAGE ............................................... 10
Removal and Installation of Control Device and
Cable ...................................................................... 10
Shift Position Inspection ......................................... 10
Shift Position Adjustment ........................................ 10
SHIFT CABLE ..................................................... 10
SELECT CABLE .................................................. 11
AIR BREATHER HOSE ............................................ 12
Removal and Installation ........................................ 12
TRANSMISSION ASSEMBLY .................................. 13
Removal and Installation from Vehicle ................... 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
Component Prts Drawing ....................................... 15
CASE COMPONENTS ........................................ 15
GEAR COMPONENTS ....................................... 16
SHIFT CONTROL COMPONENTS ..................... 17
Disassembly and Assembly .................................... 18
DISASSEMBLY ................................................... 18
INSPECTION AFTER DISASSEMBLY ................ 22
ASSEMBLY ......................................................... 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 36
General Specifications ............................................ 36
Backlash ................................................................. 36
End Play ................................................................. 37
Snap Rings ............................................................. 37
Adjusting Shim ........................................................ 37
Baulk Ring Clearance ............................................. 38
MT-1
PRECAUTIONS
PRECAUTIONS
Caution
PFP:00001
ECS004K0
MT-2
PREPARATION
PREPARATION
Special Service Tools
PFP:00002
A
ECS004K1
Tool name
Tool number
Description
Drift
ST33400001
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
MT
D
ZZA0814D
E
Pin punch
KV31100300
Tip diameter: 4.5 mm (0.177 in) dia.
F
ZZA0815D
G
Puller
KV32101330
a: 447 mm (17.60 in)
b: 100 mm (3.94 in)
NT408
Puller
ST30031000
ZZA0537D
Drift
ST30720000
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
L
Mainshaft ball bearing installation
ZZA0811D
Drift
ST30613000
a: 71.5 mm (2.815 in) dia.
b: 47.5 mm (1.870 in) dia.
ZZA1000D
Transmission stand
KV31100401
ZZA1232D
MT-3
PREPARATION
Tool name
Tool number
Description
Drift
ST23860000
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
ZZA0534D
Drift
ST22360002
a: 32 mm (1.26 in) dia.
b: 23 mm (0.91 in) dia.
ZZA0534D
Drift
ST22350000
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
ZZA0534D
ZZA0954D
Drift
ST23800000
a: 44 mm (1.73 in) dia.
b: 31 mm (1.22 in) dia.
ZZA0534D
Drift
ST33200000
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
ZZA1002D
ECS004K2
Tool name
Description
Puller
NT077
MT-4
PFP:00003
A
ECS004K3
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.
Symptoms
Oil leakage
MT-16
MT-16
MT-16
MT-16
MT-17
MT-17
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
MT
MT-10
GASKET (Damaged)
Noise
SUSPECTED PARTS
(Possible cause)
MT-15
MT-15
MT-7
Reference page
MT-7
MT-7
MANUAL TRANSMISSION
2
2
1
2
1
MT-5
DESCRIPTION
DESCRIPTION
Cross-sectional View
PFP:00000
ECS004K4
SCIA0780E
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 2nd and 3rd gears to
reduce operating force of the shift lever.
SCIA0820E
MT-6
M/T OIL
M/T OIL
Replacement
PFP:KLD20
A
ECS004K5
DRAINING
1.
2.
3.
FILLING
1.
2.
Remove filler plug. Fill new oil into the transmission to the level of the filler plug mounting hole.
Oil grade:
Viscosity:
API GL-4
Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS"
Oil capacity:
Approx. 2.0
After oil filling, check the oil level and apply Three Bond TB1215, Loctite Part No.51813 or equivalent to
filler plug. Then install it to the transmission unit, and tighten it to the specified torque.
G
Filler plug:
: 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)
Checking
ECS004K6
Filler plug:
: 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)
L
SMA103
MT-7
PFP:33140
ECS004K7
REMOVAL
1.
2.
SMT658A
INSTALLATION
1.
MT-8
SMT659A
POSITION SWITCH
POSITION SWITCH
Checking
PFP:32005
A
ECS004K8
Check continuity.
Reverse
Yes
Except reverse
No
MT
SCIA0645E
MT-9
CONTROL LINKAGE
CONTROL LINKAGE
Removal and Installation of Control Device and Cable
PFP:34103
ECS004K9
SCIA0586E
2.
3.
ECS004KA
When operating shift lever to each position with the vehicle stopped and run, check the shift lever for distortion, binding, unusual noise, backlash, and interference, etc. Check that the shift lever operates
smoothly.
Check the shift lever knob is not dislocated.
When shifted from 1st to 2nd gear and from 5th gear to reverse, shift lever shall return to the neutral position automatically.
ECS004KB
SHIFT CABLE
1.
2.
3.
4.
SMT340C
MT-10
CONTROL LINKAGE
SELECT CABLE
1.
2.
3.
4.
MT
SMT342C
MT-11
PFP:31098
ECS004KC
Refer to the figure for air breather hose removal and installation information.
SCIA0534E
CAUTION:
Make sure there are no pinched or blocked areas on the air breather hose caused by bending or
winding when installing it.
Be sure to insert the hose until the overlap area reaches the tube edge or the pressing part of
spool, insulator, etc.
MT-12
TRANSMISSION ASSEMBLY
TRANSMISSION ASSEMBLY
Removal and Installation from Vehicle
PFP:32010
A
ECS004KD
MT
G
SCIA0581E
REMOVAL
1.
INSTALLATION
To install, reverse the removal procedure, following the cautions below:
When installing transmission to the engine, install mounting bolts in accordance with the standards below.
CAUTION:
When installing, be careful to avoid interference between transmission main drive shaft and clutch
cover.
MT-13
TRANSMISSION ASSEMBLY
KA20DE engine model:
Bolt No.
3*
4*
Quantity
64
(2.52)
60
(2.36)
45
(1.77)
30
(1.18)
mm (in)
Tightening torque
Nm (kg-m, ft-lb)
39 - 49
(4.0 - 4.9, 29 - 36)
29 - 39
(3.0 - 3.9, 22 - 28)
SCIA0579E
40 mm (1.57 in)
2*
Quantity
80 (3.15)
45 (1.77)
mm (in)
Tightening torque
Nm (kg-m, ft-lb)
39 - 49
(4.0 - 4.9, 29 - 36)
After installation, check oil level, and oil leaks and loose mechanisms.
MT-14
SCIA0580E
TRANSMISSION ASSEMBLY
Component Prts Drawing
ECS004KE
CASE COMPONENTS
MT
SCIA0762E
MT-15
TRANSMISSION ASSEMBLY
GEAR COMPONENTS
WMT036
MT-16
TRANSMISSION ASSEMBLY
SHIFT CONTROL COMPONENTS
A
MT
SCIA0641E
MT-17
TRANSMISSION ASSEMBLY
Disassembly and Assembly
ECS004KF
DISASSEMBLY
Case Components
1.
SMT549A
2.
SCIA0588J
3.
SCIA0589J
4.
SCIA0590J
MT-18
TRANSMISSION ASSEMBLY
Shift Control Components
1.
2.
MT
SCIA0591J
3.
Drive out the retaining pin for each shift fork, pull out the fork
rod, and remove interlock ball and plunger.
G
SCIA0592E
Gear Components
1.
2nd gear:
3rd gear:
Overdrive gear:
Reverse idler gear:
Counter gear:
Backlash standards
Main drive gear:
SCIA0593E
1st gear:
2nd gear:
3rd gear:
Overdrive gear:
If the end play or backlash is outside the standards, disassemble and inspect.
If the gear face is damaged or worn out, replace with a new one.
MT-19
SCIA0594E
TRANSMISSION ASSEMBLY
2.
Engage the 2nd gear and reverse gear. Then using a suitable
puller, remove counter gear front bearing.
SMT174A
3.
SCIA0596J
4.
5.
SMT162A
6.
a.
SCIA0598J
MT-20
TRANSMISSION ASSEMBLY
b.
c.
d.
MT
SMT547A
e.
f.
g.
h.
i.
j.
k.
l.
G
SMT165AA
Remove overdrive gear bushing, overdrive &reverse synchronizer hub, reverse baulk ring, reverse main gear, needle bearing, and reverse gear bushing all together.
SCIA0601J
7.
8.
Remove 1st main gear thrust washer and steel ball from mainshaft.
CAUTION:
Be careful not to lose the steel ball.
Remove 1st main gear and needle bearing.
SCIA0602J
MT-21
TRANSMISSION ASSEMBLY
9.
Set Tool to the 2nd gear. Then, press the 1st gear, bushing, 1st
& 2nd synchronizer assembly, 2nd gear, and needle bearing to
remove.
10. Remove main drive gear bearing following the steps below.
a. Remove snap ring and spacer.
SMT384A
b.
SMT420AA
If the contact surface on striking lever, fork rod, fork, etc. has
excessive wear, abrasion, bend, or any other damage, replace
the components.
SCIA0605J
Gear Components
Gear and Shaft
MT-22
TRANSMISSION ASSEMBLY
MT
SMT386A
SMT550A
Synchronizer
If the contact surface on coupling sleeve, synchronizer hub, and
shifting insert has damage or abrasion, replace the components.
SMT387A
SCIA0608J
MT-23
TRANSMISSION ASSEMBLY
Single Cone Synchronizer (1st, 4th, and overdrive)
Press the baulk ring against cone, and measure the clearance
between baulk ring and cone. If the clearance is smaller than the
limit, replace it.
Clearance
Standard:
Wear limit:
1.
SCIA0763E
2.
Using a thickness gauge, measure the clearance B at diagonally opposite 2 points (or more), and calculate the mean value.
Clearance B
Standard:
Wear limit:
AMT192
MT-24
TRANSMISSION ASSEMBLY
Reverse Synchronizer Assembly
MT
Bearing
G
SMT418A
ASSEMBLY
Gear Components
1.
SCIA0609E
2.
Set counter gear rear bearing to the adapter plate, and drive it
with a drift (special service tool).
M
SCIA0610E
MT-25
TRANSMISSION ASSEMBLY
3.
Install oil gutter to the adapter plate, and extend the rear side to
secure.
SMT153A
4.
SCIA0612J
5.
SCIA0613J
6.
Install main drive gear ball bearing to the main drive gear. Press
main drive gear ball bearing.
SMT425AA
7.
Install spacer to main drive gear. Then select the snap ring so
that the end play for main drive gear (clearance between snap
ring and groove) is within the specified range below.
End play standards:
SMT426A
MT-26
TRANSMISSION ASSEMBLY
Main drive gear snap ring
8.
Thickness
Part No.
32204 78001
32204 78002
32204 78003
Install coupling sleeve and insert spring to 1st & 2nd synchronizer hub.
CAUTION:
Install insert spring to the position (recess) of coupling
sleeve in the figure.
Install coupling sleeve with its groove facing front (double-cone synchronizer side).
Check that hub and coupling can be moved smoothly by
hand.
MT
SCIA0815E
9.
Install coupling sleeve and insert spring to 3rd & 4th synchronizer hub.
CAUTION:
Install insert spring to the position (recess) of coupling
sleeve in the figure.
Install coupling sleeve with its groove facing rear (double-cone synchronizer side).
Check that hub and coupling can be moved smoothly by
hand.
SCIA0816E
MT-27
TRANSMISSION ASSEMBLY
10. Install coupling sleeve, shifting insert, and spread spring to overdrive & reverse synchronizer hub.
CAUTION:
Install shifting insert to the position (recess) of coupling
sleeve in the figure.
Hook the spread spring end (the perpendicular side) onto
the slit inside the shifting insert.
Never hook front and rear spread spring ends onto the
same shifting insert.
Installation directions of the synchronizer hub shall be
followed as shown in the figure.
Install coupling sleeve with its wider taper surface at the
overdrive side.
Check that hub and coupling can be moved smoothly by
hand.
SCIA0817E
11. Install 2nd main gear, needle bearing, and 1st & 2nd synchronizer assembly to mainshaft. Then press with the 1st gear bushing.
CAUTION:
Press in the 1st gear bushing by contacting the thrust
washer of 1st main gear.
12. Install 1st main gear.
SMT752A
13. Apply multi-purpose grease to steel ball and thrust washer, and
install it to mainshaft.
TM358
TM439-A
MT-28
TRANSMISSION ASSEMBLY
15. Press counter gear into adapter plate using Tool.
A
MT
SCIA0618E
16. After installing 3rd main gear and needle bearing to mainshaft,
press 3rd & 4th synchronizer assembly onto the mainshaft.
G
SCIA0619E
CAUTION:
Be careful with the installation direction of synchronizer
hub.
K
SMT031
17. Install thrust washer and snap ring to the mainshaft. Then check
that the end play (clearance between snap ring and groove) of
mainshaft is within the specified range below.
End play standards:
SCIA0621E
Part No.
32263 V5200
32263 V5201
18. Apply gear oil to mainshaft pilot bearing and install it to the mainshaft.
MT-29
TRANSMISSION ASSEMBLY
19. Set gear assembly to transmission stand (special service tool).
Then using a drift (special service tool), install counter drive gear
together with main drive gear.
SCIA0622E
CAUTION:
Installation directions of the counter drive gear shall be as
shown in the figure.
SMT620A
20. Install counter drive gear, sub-gear, and sub-gear bracket to the counter gear.
21. Install snap ring to the counter gear. Then using a feeler gauge,
check that the end play is within the specified range below.
End play standards:
CAUTION:
Sub-gear spring shall be removed.
If it is outside the specified range, select the snap ring.
SMT201D
Part No.
32215 E9000
32215 E9001
32215 E9002
22. Remove snap ring. Then remove sub-gear and sub-gear bracket.
23. Install sub-gear, sub-gear spring, and sub-gear bracket. Then
install selected snap ring.
SMT202D
MT-30
TRANSMISSION ASSEMBLY
24. Set gear assembly to the transmission stand (special service
tool). Then using a drift (special service tool), install counter
gear front bearing to the counter gear.
MT
TM443-A
25. Install reverse idler gear with spacer, snap ring, and needle
bearing to the reverse idler shaft.
26. Install retainer and overdrive & reverse synchronizer assembly
to the mainshaft.
G
AMT134
27.
28.
29.
30.
SMT531-A
31. Using a drift (special service tool), install counter shaft rear end
bearing.
SMT043-A
MT-31
TRANSMISSION ASSEMBLY
32. Make double-engagement of gears. Then using a lock nut
wrench (special service tool), tighten the mainshaft lock nut to
the specified torque.
CAUTION:
There will be an error for torque wrench length. Read the
converted torque.
SMT003AA
SCIA0631E
SCIA0632E
MT-32
TRANSMISSION ASSEMBLY
Shift Control Components
1.
Install fork rod, interlock plunger, interlock ball, and check ball.
MT
SMT992-A
2.
Using a pin punch (special service tool), drive the retaining pin
into 1-2 fork and 3-4 fork.
G
SCIA0592E
3.
Drive retaining pin into 5-R fork and 5-R fork bracket.
I
K
SCIA0634J
Case Components
1.
SMT036-A
MT-33
TRANSMISSION ASSEMBLY
2.
SMT061C
3.
SMT013
4.
SMT672A
5.
6.
7.
SMT062C
MT-34
TRANSMISSION ASSEMBLY
8.
MT
SCIA0638J
9.
Measure height A of counter gear front bearing and transmission case edge surface. Select and install adjusting shim in
accordance with the height.
G
SMT205D
Adjusting Shim
Measurement height A
4.52 - 4.71 mm (0.1780 - 0.1854 in)
4.42 - 4.51 mm (0.1740 - 0.1776 in)
4.32 - 4.41 mm (0.1701 - 0.1736 in)
4.22 - 4.31 mm (0.1661 - 0.1697 in)
4.12 - 4.21 mm (0.1622 - 0.1657 in)
4.02 - 4.11 mm (0.1583 - 0.1618 in)
3.92 - 4.01 mm (0.1543 - 0.1579 in)
H
Shim thickness
0.1 mm
0.2 mm
0.3 mm
0.4 mm
0.5 mm
0.6 mm
(0.004
(0.008
(0.012
(0.016
(0.020
(0.024
in)
in)
in)
in)
in)
in)
Part No.
(Shim unnecessary)
32218 V5000
32218 V5001
32218 V5002
32218 V5003
32218 V5004
32218 V5005
MT-35
PFP:00030
ECS004KG
Applied model
KA24DE,ZD30DD
Transmission
RS5W71C
Number of speed
Shift pattern
SCIA0821E
Synchromesh type
Gear ratio
Mainshaft
(Number of teeth)
Countershaft gear
(Number of teeth)
Warner
1st
3.592
2nd
2.246
3rd
1.415
4th
1.000
OD
0.821
Reverse
3.657
Drive
21
1st
33
2nd
28
3rd
26
OD
21
Reverse
36
Drive
32
1st
14
2nd
19
3rd
28
OD
39
Reverse
15
21
Oil capacity
(Imp pt)
2.0 (3-1/2)
Reverse synchronizer
Remarks
Installed
Sub-gear
Backlash
ECS004KH
Unit: mm (in)
Item
Standard
1st gear
2nd gear
3rd gear
4th gear
MT-36
Standard
Overdrive gear
End Play
ECS004KI
Unit: mm (in)
Item
Standard
1st gear
2nd gear
3rd gear
4th gear
Overdrive gear
0 - 0.16 (0 - 0.0063)
0 - 0.13 (0 - 0.0051)
Mainshaft front
0 - 0.18 (0 - 0.0071)
0 - 0.14 (0 - 0.0055)
MT
Snap Rings
ECS004KJ
Unit: mm (in)
Selective parts
Thickness
Part No.
1.87 (0.0736)
1.94 (0.0764)
2.01 (0.0791)
32204 78001
32204 78002
32204 78003
1.4 (0.055)
1.5 (0.059)
1.6 (0.063)
32215 E9000
32215 E9001
32215 E9002
Front side
2.4 (0.094)
2.5 (0.098)
32263 V5200
32263 V5201
Shaft rear-end
1.1
1.2
1.3
1.4
32228
32228
32228
32228
Main shaft
(0.043)
(0.047)
(0.051)
(0.055)
20100
20101
20102
20103
Adjusting Shim
ECS004KK
Unit: mm (in)
Selective parts
Measurement height
Thickness
MT-37
0.1
0.2
0.3
0.4
0.5
0.6
(0.004)
(0.008)
(0.012)
(0.016)
(0.020)
(0.024)
Part No.
Not necessary
32218 V5000
32218 V5001
32218 V5002
32218 V5003
32218 V5004
32218 V5005
ECS004KL
Unit: mm (in)
Measurement point
1st
2nd & 3rd
Standard
Wear limit
SCIA0818E
Reverse
MT-38