MANUAL TRANSMISSION GI

SECTION MT MA

EM

LC

EC

CONTENTS FE

FS5W71C Case Components .....................................................27

CL
ASSEMBLY .............................................................27
PREPARATION ...............................................................3
SERVICE DATA AND SPECIFICATIONS (SDS) .........30
Special Service Tools ..................................................3
General Specifications...............................................30
Commercial Service Tools ...........................................5
Gear End Play ...........................................................30
NOISE, VIBRATION AND HARSHNESS (NVH)
Clearance Between Baulk Ring and Gear ................31 AT
TROUBLESHOOTING .....................................................6
2nd & 3rd baulk ring ..................................................31
NVH Troubleshooting Chart.........................................6
Available Snap Rings ................................................31
MANUAL TRANSMISSION..........................................6
MAIN DRIVE GEAR BEARING ..................................31 TF
DESCRIPTION .................................................................7 MAINSHAFT FRONT ................................................31
Cross-sectional View ...................................................7 COUNTER DRIVE GEAR .........................................31
ON-VEHICLE SERVICE ..................................................8 OD MAINSHAFT BEARING ......................................32 PD
Replacing Rear Oil Seal ..............................................8 Available Shims .........................................................32
REMOVAL .................................................................8 COUNTERSHAFT FRONT BEARING ........................32
INSTALLATION..........................................................8 AX
Position Switch Check .................................................8 FS5R30A
REMOVAL AND INSTALLATION ...................................9
PREPARATION .............................................................33
SU
Removal.......................................................................9
Installation..................................................................10 Special Service Tools ................................................33
OVERHAUL ...................................................................11 Commercial Service Tool...........................................35 BR
Case Components .....................................................11 NOISE, VIBRATION AND HARSHNESS (NVH)
Gear Components .....................................................12 TROUBLESHOOTING ...................................................36
Shift Control Components .........................................13 NVH Troubleshooting Chart.......................................36 ST
DISASSEMBLY..............................................................14 MANUAL TRANSMISSION........................................36
Case Components .....................................................14 DESCRIPTION ...............................................................37
DISASSEMBLY ........................................................14 Cross-sectional View - 2WD Model...........................37 RS
Shift Control Components .........................................14 Cross-sectional View - 4WD Model...........................38
DISASSEMBLY ........................................................14 ON-VEHICLE SERVICE ................................................39
BT
Gear Components .....................................................15 Replacing Rear Oil Seal - 2WD Model .....................39
DISASSEMBLY ........................................................15 REMOVAL ...............................................................39
INSPECTION..................................................................18 INSTALLATION........................................................39 HA
Shift Control Components .........................................18 Position Switch Check ...............................................40
INSPECTION ...........................................................18 REMOVAL AND INSTALLATION .................................41
Gear Components .....................................................18 Removal.....................................................................41 SC
INSPECTION ...........................................................18 2WD MODEL ...........................................................41
ASSEMBLY....................................................................20 4WD MODEL ...........................................................42
Gear Components .....................................................20 Installation..................................................................43 EL
ASSEMBLY .............................................................20 OVERHAUL ...................................................................44
Shift Control Components .........................................27 Case Components .....................................................44
ASSEMBLY .............................................................27 Gear Components .....................................................45
IDX
 CONTENTS (Contd)
Shift Control Components .........................................47 ASSEMBLY .............................................................65
DISASSEMBLY..............................................................48 SERVICE DATA AND SPECIFICATIONS (SDS) .........67
Case Components .....................................................48 General Specifications...............................................67
DISASSEMBLY ........................................................48 Gear End Play ...........................................................67
Shift Control Components .........................................49 Clearance Between Baulk Ring and Gear ................67
DISASSEMBLY ........................................................49 2ND AND 3RD BAULK RING ....................................68
Gear Components .....................................................50 Distance between Rear Surface of Reverse
DISASSEMBLY ........................................................50 Cone and Reverse Baulk Ring..................................68
INSPECTION..................................................................54 Available Snap Ring ..................................................68
Shift Control Components .........................................54 MAIN DRIVE GEAR SNAP RING ..............................68
INSPECTION ...........................................................54 MAINSHAFT FRONT SNAP RING .............................68
Gear Components .....................................................54 COUNTER GEAR REAR SNAP RING .......................69
INSPECTION ...........................................................54 Available C-ring .........................................................69
ASSEMBLY....................................................................56 MAINSHAFT C-RING ...............................................69
Gear Components .....................................................56 Available Shim and Washer ......................................69
ASSEMBLY .............................................................56 TABLE FOR SELECTING PROPER COUNTER
Shift Control Components .........................................64 GEAR FRONT BEARING THRUST WASHER ............69
ASSEMBLY .............................................................64 REVERSE IDLER REAR THRUST WASHER .............69
Case Components .....................................................65

MT-2
 PREPARATION FS5W71C
Special Service Tools

Special Service Tools NGMT0045

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

ST23810001 Fixing adapter plate with gear assembly MA

( ) a: 166 mm (6.54 in)
Adapter setting plate b: 270 mm (10.63 in)
EM

LC
NT407

KV32101330 Removing overdrive mainshaft bearing

(See J26349-A) a: 447 mm (17.60 in)
EC
Puller b: 100 mm (3.94 in)

FE

NT408 CL
KV31100401 Pressing counter gear and mainshaft
( )
Transmission press
stand

NT068 AT
ST22520000 Tightening mainshaft lock nut
(J26348) a: 100 mm (3.94 in)
Wrench b: 41 mm (1.61 in) TF

PD
NT409

ST23540000 Removing and installing fork rod retaining pin

(J25689-A) a: 2.3 mm (0.091 in) dia. AX
Pin punch b: 4 mm (0.16 in) dia.

SU
NT442

ST30031000 Removing and installing 1st gear bushing

(J22912-01) Removing main drive gear bearing BR
Puller a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST

NT411 RS
ST23860000 Installing counter drive gear
( ) a: 38 mm (1.50 in) dia.
Drift b: 33 mm (1.30 in) dia. BT

NT065 HA
ST22360002 Installing counter gear front and rear end bearings
(J25679-01) a: 29 mm (1.14 in) dia.
Drift b: 23 mm (0.91 in) dia. SC

NT065 EL

IDX
MT-3
 PREPARATION FS5W71C
Special Service Tools (Contd)

Tool number (Kent- Description

Moore No.) Tool name

ST22350000 Installing OD gear bushing

(J25678-01) a: 34 mm (1.34 in) dia.
Drift b: 28 mm (1.10 in) dia.

NT065

ST23800000 Installing front cover oil seal

(J25691-01) a: 44 mm (1.73 in) dia.
Drift b: 31 mm (1.22 in) dia.

NT065

ST33400001 Installing rear oil seal

(J26082) a: 60 mm (2.36 in) dia.
Drift b: 47 mm (1.85 in) dia.

NT086

ST33290001 Removing rear oil seal

(J34286) a: 250 mm (9.84 in)
Puller b: 160 mm (6.30 in)

NT414

ST30720000 Installing mainshaft ball bearing

(J25405) a: 77 mm (3.03 in) dia.
Drift b: 55.5 mm (2.185 in) dia.

NT115

ST30613000 Installing main drive gear bearing

(J25742-3) a: 71.5 mm (2.815 in) dia.
Drift b: 47.5 mm (1.870 in) dia.

NT073

ST33200000 Installing counter rear bearing

(J26082) a: 60 mm (2.36 in) dia.
Drift b: 44.5 mm (1.752 in) dia.

NT091

MT-4
 PREPARATION FS5W71C
Commercial Service Tools

Commercial Service Tools NGMT0046

Tool name Description GI

Puller Removing counter bearings, counter drive and OD
gears
MA

EM
NT077

LC

EC

FE

CL

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX
MT-5
 NOISE, VIBRATION AND HARSHNESS (NVH) NGMT0047

TROUBLESHOOTING FS5W71C
NVH Troubleshooting Chart

NVH Troubleshooting Chart NGMT0047S01

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
MANUAL TRANSMISSION NGMT0047S0101

Checking M/T Oil,

MT-13

MT-13

MT-12

MT-12

MT-12

MT-12
MT-11

MT-11
Reference page

Refer to

MA-35.

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

SUSPECTED PARTS
(Possible cause)

BAULK RING (Worn or damaged)

BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)

INSERT SPRING (Damaged)

GEAR (Worn or damaged)
OIL (Oil level is high.)

GASKET (Damaged)

SHIFT FORK (Worn)

OIL (Oil level is low.)

OIL (Wrong oil.)

Noise 1 2 3 3

Oil leakage 3 1 2 2
Symptom
Hard to shift or will not shift 1 1 2 2

Jumps out of gear 1 2 2

MT-6
 NGMT0048

DESCRIPTION FS5W71C
Cross-sectional View

Cross-sectional View NGMT0048S01

GI

MA

EM

LC

EC

FE

CL

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

SMT153D EL

IDX
MT-7
 ON-VEHICLE SERVICE FS5W71C
Replacing Rear Oil Seal

Replacing Rear Oil Seal NGMT0028

REMOVAL NGMT0028S01
1. Remove the propeller shaft. Refer to PD section (Removal
and Installation, PROPELLER SHAFT).
2. Remove rear oil seal using Tool.
Always replace with a new seal once it has been removed.

AMT079

INSTALLATION NGMT0028S02
1. Install new oil seal until it stops.
Apply multi-purpose grease to seal lip of oil seal before
installing.
2. Install any part removed.

SMT480CA

Position Switch Check NGMT0029

Check continuity.
Switch Gear position Continuity

Reverse Yes
Back-up lamp switch
Except reverse No

Park/neutral position Neutral Yes

(PNP) switch Except neutral No

AMT205

MT-8
 NGMT0030

REMOVAL AND INSTALLATION FS5W71C

Removal

Removal NGMT0030S01

GI

MA

EM

LC

EC

FE

CL

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

AMT183 EL

IDX
MT-9
 REMOVAL AND INSTALLATION FS5W71C
Removal (Contd)
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.
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 crankshaft position sensor (OBD) from transmission
upper side.
3. Remove clutch operating cylinder from transmission.
4. Remove back-up switch and park/neutral position (PNP)
switch harness connectors.
5. Remove starter motor from transmission.
6. Remove propeller shaft. Refer to Removal and Installation,
PROPELLER SHAFT, PD-7.

7. Remove shift lever.

8. Support engine by placing a jack under oil pan.
Do not place jack under oil pan drain plug.
9. Separate transmission from engine.
WARNING:
Support manual transmission while removing it.

SMT099A

Installation NGMT0030S02
1. Tighten bolts securing transmission.
Bolt No. Tightening torque Nm (kg-m, ft-lb)
mm (in)

1 39 - 49 (4.0 - 5.0, 29 - 36) 65 (2.56)

2 39 - 49 (4.0 - 5.0, 29 - 36) 58 (2.28)

3* 16 - 22 (1.6 - 2.2, 12 - 16) 25 (0.98)

4 16 - 22 (1.6 - 2.2, 12 - 16) 16 (0.63)

AMT190 *: With nut

2. Tighten clutch operating cylinder to the specified torque. Refer
to CLUTCH SYSTEM, CL-5.

MT-10
 NGMT0031

OVERHAUL FS5W71C
Case Components

Case Components NGMT0031S01

GI

MA

EM

LC

EC

FE

CL

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

AMT182 EL

IDX
MT-11
 OVERHAUL FS5W71C
Gear Components

Gear Components NGMT0031S02

AMT201

MT-12
 OVERHAUL FS5W71C
Shift Control Components

Shift Control Components NGMT0031S04

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

EM

LC

EC

FE

CL

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC
AMT199

EL

IDX
MT-13
 DISASSEMBLY FS5W71C
Case Components

Case Components
DISASSEMBLY NGMT0032
1. Remove rear extension.
a. 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.

SMT161D

b. Drive out striking lever retaining pin.

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

AMT132

2. Remove front cover, gasket, counter gear front bearing shim

and main drive gear ball bearing snap ring.
3. Separate transmission case from adapter plate by lightly tap-
ping on it.

AMT131

4. Remove oil seal from front cover.

Be careful not to damage mating surface of front cover.

SMT166D

Shift Control Components

DISASSEMBLY NGMT0033
1. Set up Tool on adapter plate.
2. Remove striking rod from adapter plate.
3. 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

SMT984 LC
Gear Components
DISASSEMBLY NGMT0034
EC
1. Before disassembly, measure the end play of each gear.
If end play is not within the specified limit, disassemble and
inspect the parts. FE
Replace any part which is worn or damaged.
Gear end play: CL
Refer to SDS, MT-30.

SMT025

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

PD

AX
SMT174A

4. Remove counter drive gear together with main drive gear

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

RS
SMT162A

6. Disassemble parts at rear of adapter plate as follows: BT

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

SC

EL
AMT133
IDX
MT-15
 DISASSEMBLY FS5W71C
Gear Components (Contd)
b. Remove overdrive counter gear together with counter gear
rear end bearing using a suitable puller.
c. Remove reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft, then remove
reverse idler gear, thrust washers and reverse idler gear bear-
ing.

SMT547A

e. Remove snap ring and pull out overdrive mainshaft bearing,

then remove snap ring.
f. Remove mainshaft lock nut.
g. Remove speedometer drive gear and steel ball.
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.
SMT165A
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. Remove main drive gear ball bearing.
a. Remove snap ring.
b. Remove main drive gear ball bearing. GI

MA

EM

SMT420A LC

EC

FE

CL

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX
MT-17
 INSPECTION FS5W71C
Shift Control Components

Shift Control Components

INSPECTION NGMT0035
Check contact and sliding surfaces of fork rods for wear,
scratches, projections and other damage.

SMT075C

Gear Components
INSPECTION NGMT0036
Gears and Shafts NGMT0036S01
Check shafts for cracks, wear and bending.
Check gears for excessive wear, chips and cracks.

SMT386A

SMT550A

Synchronizers NGMT0036S02
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)
Measure baulk ring wear.
1) Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear: GI
Refer to SDS, MT-MT-31.
If the clearance is less than the wear limit, replace baulk ring. MA

EM

SMT140 LC
Measure 2nd and 3rd baulk ring wear.
1) Place baulk rings in position on synchronizer cone.
EC
2) While holding baulk rings against synchronizer cone as far as
possible, measure dimensions A and B.
Standard: FE
Inner A: 0.7 0.9 mm (0.028 0.035 in)
Outer B: 0.6 1.1 mm (0.024 0.043 in)
Wear limit:
CL
0.2 mm (0.008 in)
If dimension A or B is smaller than the wear limit, replace
AMT191
outer baulk ring, inner baulk ring and synchronizer cone as a
set.
AT

TF

PD

AX
AMT192

Bearings

NGMT0036S03
Make sure all bearings roll freely and are free from noise,
SU
cracks, pitting or wear.
BR

ST

RS
SMT418A

BT

HA

SC

EL

IDX
MT-19
 ASSEMBLY FS5W71C
Gear Components

Gear Components
ASSEMBLY NGMT0037

AMT185

1. Install bearings into case components.

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

SMT778C

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

SMT674C

3. Install main drive gear ball bearing.

a. Press main drive gear ball bearing.

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: GI
0 - 0.13 mm (0 - 0.0051 in)
Main drive gear bearing snap ring:
Refer to SDS, MT-31.
MA

EM

SMT170D LC
4. Assemble synchronizers.
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

IDX
MT-21
 ASSEMBLY FS5W71C
Gear Components (Contd)
2nd and 3rd double baulk ring type synchronizer.

SMT046B

SMT047B

3rd & 4th synchronizer

SMT054C

SMT206C

MT-22
 ASSEMBLY FS5W71C
Gear Components (Contd)
Overdrive & reverse synchronizer

GI

MA

EM

LC

EC

FE

CL

SMT207CA

5. Assemble front side components to mainshaft.

a. Install 2nd main gear, needle bearing and 1st & 2nd synchro- AT
nizer assembly; then press 1st gear bushing on mainshaft.
b. Install 1st main gear.
TF

PD

AX
SMT752A

c. Install steel ball and 1st gear washer.

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

ST

RS
TM358

6. Install mainshaft and counter gear on adapter plate and main BT

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

SC

EL
TM439
IDX
MT-23
 ASSEMBLY FS5W71C
Gear Components (Contd)
b. Press counter gear into adapter plate using Tool.
c. Install 3rd main gear and needle bearing, then press 3rd & 4th
synchronizer assembly onto mainshaft.
Pay attention to the direction of 3rd & 4th synchronizer.

SMT750

d. 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 SDS, MT-31.
e. Apply gear oil to mainshaft pilot bearing and install it on main-
shaft.

TM441

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

SMT412C

g. Install sub-gear components.

i. 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 - 0.18 mm (0 - 0.0071 in)
Counter drive gear snap ring:
Refer to SDS, 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

MT-24
 ASSEMBLY FS5W71C
Gear Components (Contd)
h. Press counter/gear front bearing onto counter gear using Tool.

GI

MA

EM

TM443 LC
7. Install rear side components on mainshaft and counter gear as
follows:
a. Install sub-gear parts (sub-gear, sub-gear spring, sub-gear
EC
bracket, steel ball and snap ring) on the reverse idler gear.
b. Install reverse idler gear to reverse idler shaft along with FE
reverse idler thrust washer, snap rings and reverse idler gear
bearing.
CL

AMT134

c. Install bushing, reverse main gear and overdrive & reverse

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

TF

PD

AX

SU

BR

ST

RS
SMT207CA

d. Install overdrive gear bushing to mainshaft using Tool. BT

e. Install overdrive main gear and needle bearing to mainshaft.
f. Install spacer, reverse counter gear and overdrive counter gear
to counter/gear. HA
OD main gear and OD counter gear should be handled as
a matched set.
SC
g. Install washer, roller bearing, steel roller and thrust washer.
h. Tighten mainshaft lock nut temporarily.
Always use new lock nut. EL
SMT531
IDX
MT-25
 ASSEMBLY FS5W71C
Gear Components (Contd)
i. Install counter/gear rear end bearing using Tool.

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)

SMT003A

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)
9. 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 Gear Components,
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 SDS, MT-32.
AMT145

MT-26
 ASSEMBLY FS5W71C
Shift Control Components

Shift Control Components

ASSEMBLY
1.
NGMT0038
Install fork rods, interlock plunger, interlock balls and check
GI
balls.
MA

EM

SMT992-A LC
2. Install 1st & 2nd shift fork, then drive in retaining pin.
EC

FE

CL

SMT989

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

TF

PD

AX
SMT990

4. Install overdrive & reverse shift fork, then drive in retaining pin.
SU

BR

ST

RS
SMT991

Case Components BT
ASSEMBLY NGMT0039
1. Install front cover oil seal using Tool. HA
Apply multi-purpose grease to seal lip.

SC

EL
SMT036
IDX
MT-27
 ASSEMBLY FS5W71C
Case Components (Contd)
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.

SMT061C

3. Slide gear assembly onto adapter plate by lightly tapping it

using a soft hammer.

SMT013

4. Install main drive gear ball bearing snap ring.

SMT672A

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.

SMT062C

6. Place shift forks in neutral position.

7. Install striking lever and rod onto adapter plate and align strik-
ing lever with shift brackets.

SMT801B

MT-28
 ASSEMBLY FS5W71C
Case Components (Contd)
8. Install rear extension.
Tighten mounting bolts equally in a criss-cross pattern.
GI

MA

EM

SMT180D LC
9. Install striking lever retaining pin.
EC

FE

CL

AMT132

10. Select counter gear front bearing shim.

Allowable clearance (A) from bearing surface to trans- AT
mission case:
0 - 0.16 mm (0 - 0.0063 in)
Countershaft front bearing shim: TF
Refer to SDS, MT-32.
11. Install gasket and front cover. PD

AX
SMT205D

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

ST

RS
SMT161D

BT

HA

SC

EL

IDX
MT-29
 SERVICE DATA AND SPECIFICATIONS (SDS) FS5W71C
General Specifications

General Specifications NGMT0040

Applied model KA24DE

Transmission FS5W71C

Number of speed 5

Shift pattern

MT-SDS-2

Synchromesh type Warner

1st 3.592

2nd 2.246

3rd 1.415
Gear ratio
4th 1.000

OD 0.821

Reverse 3.657

Drive 21

1st 33

Mainshaft 2nd 28
(Number of teeth)
3rd 26

OD 21

Reverse 36

Drive 32

1st 14

Countershaft gear 2nd 19

(Number of teeth)
3rd 28

OD 39

Reverse 15

Reverse idler gear (Number of teeth) 21

Oil capacity
2.0 (4/14, 3-1/2)

(US pt, Imp pt)

Reverse synchronizer Installed

Remarks Double cone synchronizer 2nd & 3rd

Sub-gear Counter drive gear & reverse idler gear

Gear End Play NGMT0041

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 NGMT0042

Unit: mm (in)
GI
1st 1.20 - 1.60 (0.0472 - 0.0630)

Main drive 1.20 - 1.60 (0.0472 - 0.0630)

Standard MA
Overdrive 1.20 - 1.60 (0.0472 - 0.0630)

Reverse 1.10 - 1.55 (0.0433 - 0.0610)

EM
1st & 2nd 0.80 (0.0315)

3rd & main drive 0.80 (0.0315)

Wear limit LC
Overdrive 0.80 (0.0315)

Reverse 0.70 (0.0276)

EC
2nd & 3rd baulk ring NGMT0042S02

Dimension Standard Wear limit FE

0.7 - 0.9
A
(0.028 - 0.035
0.2 (0.008)
CL
0.6 - 1.1
B
(0.024 - 0.043)

Available Snap Rings NGMT0043

MAIN DRIVE GEAR BEARING NGMT0043S01 AT
Unit: mm (in)

Allowable clearance 0 - 0.13 (0 - 0.0051)

TF
Thickness Part number*

1.87 (0.0736) 32204-78001

PD
1.94 (0.0764) 32204-78002

2.01 (0.0791) 32204-78003

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

MAINSHAFT FRONT NGMT0043S02

Unit: mm (in)
SU
Allowable clearance 0 - 0.18 (0 - 0.0071)

Thickness Part number*

BR
2.4 (0.094) 32263-V5200

2.5 (0.098) 32263-V5201

ST
*Always check with the Parts Department for the latest parts information.
RS
COUNTER DRIVE GEAR NGMT0043S03
Unit: mm (in)

Allowable clearance 0 - 0.18 (0 - 0.0071) BT

Thickness Part number*

1.4 (0.055) 32215-E9000 HA

1.5 (0.059) 32215-E9001

1.6 (0.063) 32215-E9002 SC

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

IDX
MT-31
 SERVICE DATA AND SPECIFICATIONS (SDS) FS5W71C
Available Snap Rings (Contd)

OD MAINSHAFT BEARING NGMT0043S04

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 NGMT0044

COUNTERSHAFT FRONT BEARING NGMT0044S01
Unit: mm (in)

SMT205D

A Thickness of shim Part number*

4.52 - 4.71 (0.1780 - 0.1854) 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 NGMT0001

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
GI
Tool number
(Kent-Moore No.) Description
Tool name
MA
ST23540000 Removing and installing retaining pin
(J25689-A) a: 2.3 mm (0.091 in) dia.
Pin punch b: 4 mm (0.16 in) dia. EM

NT442 LC
ST30031000 Removing 1st & 2nd synchronizer assembly
(J22912-01) Removing counter gear rear thrust bearing
Puller Removing main drive bearing EC
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
FE
NT411

ST33290001 Removing rear oil seal CL

(J25810-A) a: 250 mm (9.84 in)
Puller b: 160 mm (6.30 in)

AT
NT414

ST33230000 Removing mainshaft and counter gear TF

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

NT084 AX
ST22350000 Removing counter gear front bearing (Use with
(J25678-01) KV38100300)
Drift a: 34 mm (1.34 in) dia. SU
b: 28 mm (1.10 in) dia.

NT065 BR
KV38100300 Removing counter gear front bearing (Use with
(J25523) ST22350000)
Drift Installing counter gear rear bearing ST
a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.
NT065 RS
ST30720000 1 Removing mainshaft front bearing
1 (J34286) 2 Installing mainshaft front bearing
2 (J34331) a: 77 mm (3.03 in) dia. BT
Drift b: 55.5 mm (2.185 in) dia.

NT115
HA
ST33210000 1 Installing counter gear front bearing
1 (J25523) 2 Installing front cover oil seal SC
2 (J25803-01) a: 44 mm (1.73 in) dia.
Drift b: 24.5 mm (0.965 in) dia.
EL
NT084

IDX
MT-33
 PREPARATION FS5R30A
Special Service Tools (Contd)

Tool number
(Kent-Moore No.) Description
Tool name

ST30613000 Installing main drive gear bearing

(J25742-3) a: 72 mm (2.83 in) dia.
Drift b: 48 mm (1.89 in) dia.

NT073

ST37750000 1 Removing counter gear rear bearing

1 (J34286) 2 Installing OD gear bushing
2 (J34332) 2 Removing and installing mainshaft rear bearing
3 (J34334) (4WD model)
4 (J25679-01) 2 Installing reverse cone
Drift 3 Installing reverse counter gear
4 Installing counter gear rear end bearing
NT065
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.

ST22452000 Installing reverse hub

(J34337) Installing mainshaft rear bearing (2WD model)
Drift a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.

NT065

ST33400001 Installing rear oil seal

(J26082) a: 60 mm (2.36 in) dia.
Drift b: 47 mm (1.85 in) dia.

NT086

(J26349-3) Installing mainshaft and counter gear

Puller leg (Use with J34328)

NT078

(J34328) Installing mainshaft and counter gear

Puller (Use with J26349-3)

NT079

(J26092) Installing sub-gear snap ring

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

NT065

(J34342) Installing OD main gear

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

NT065

MT-34
 PREPARATION FS5R30A
Special Service Tools (Contd)

Tool number
(Kent-Moore No.) Description
Tool name GI
ST33220000 Installing mainshaft rear bearing
(J25804-01) a: 37 mm (1.46 in) dia. MA
Drift b: 22 mm (0.87 in) dia.

EM
NT084

Commercial Service Tool LC

NGMT0002

Tool name Description

EC
Puller Removing counter gear rear end bearing
Removing mainshaft rear bearing (2WD model)
Removing reverse synchronizer hub FE
Removing reverse counter gear

CL
NT077

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX
MT-35
 NOISE, VIBRATION AND HARSHNESS (NVH) NGMT0023

TROUBLESHOOTING FS5R30A
NVH Troubleshooting Chart

NVH Troubleshooting Chart NGMT0023S01

Use the chart below to help you find the cause of the problem. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
MANUAL TRANSMISSION NGMT0023S0101

Checking M/T Oil,

MT-44

MT-44

MT-47

MT-47

MT-47

MT-45

MT-45

MT-45

MT-45
Reference page

Refer to

MA-35.

CHECK PLUG RETURN SPRING AND

CHECK BALL (Worn or damaged)

BAULK RING (Worn or damaged)

BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)

INSERT SPRING (Damaged)

O-RING (Worn or damaged)

GEAR (Worn or damaged)

SUSPECTED PARTS

GASKET (Damaged)

SHIFT FORK (Worn)

OIL (Level too high)
(Possible cause)

OIL (Level low)

OIL (Wrong)

Noise 1 2 3 3

Oil leakage 3 1 2 2 2
Symptom
Hard to shift or will not shift 1 1 2 2

Jumps out of gear 1 2 2

MT-36
 NGMT0005

DESCRIPTION FS5R30A
Cross-sectional View 2WD Model

Cross-sectional View 2WD Model NGMT0005S01

GI

MA

EM

LC

EC

FE

CL

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

SMT209D EL

IDX
MT-37
 DESCRIPTION FS5R30A
Cross-sectional View 4WD Model

Cross-sectional View 4WD Model NGMT0005S02

SMT320D

MT-38
 ON-VEHICLE SERVICE FS5R30A
Replacing Rear Oil Seal 2WD Model

Replacing Rear Oil Seal 2WD Model NGMT0003

REMOVAL NGMT0003S01
GI

MA

EM

SMT479CA LC
INSTALLATION NGMT0003S02

EC

FE

CL

SMT480CA

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX
MT-39
 ON-VEHICLE SERVICE FS5R30A
Position Switch Check

Position Switch Check NGMT0004

Switch Gear position Continuity

Reverse Yes
Back-up lamp switch
Except reverse No

Park/neutral position Neutral Yes

(PNP) switch Except neutral No

AMT202

AMT205

MT-40
 NGMT0006

REMOVAL AND INSTALLATION FS5R30A

Removal

Removal NGMT0006S01
CAUTION:
When removing the M/T assembly from engine, first remove GI
the crankshaft position sensor (OBD) from the M/T assembly.
Be careful not to damage sensor edge.
MA

EM

LC

EC

FE

CL

AMT189
AT
2WD MODEL NGMT0006S0101
1. Remove battery negative terminal. TF
2. Remove shift lever with control housing from transmission.
3. Remove crankshaft position sensor (OBD) from upper side of
transmission case. PD
4. Remove clutch operating cylinder from transmission. Tighten
clutch operating cylinder to the specified torque. Refer to
CLUTCH SYSTEM, CL-5.
AX
5. Disconnect speed sensor, back-up lamp switch, rear heated
oxygen sensor and park/neutral position (PNP) switch harness SU
connectors.
6. Remove starter motor from transmission.
: 41 - 52 Nm (4.2 - 5.3 kg-m, 30 - 38 ft-lb) BR
7. Remove propeller shaft. Refer to Removal, PROPELLER
SHAFT, PD-7.
ST
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. RS
8. Remove gussets from transmission or engine.
9. Remove exhaust tube mounting bracket from transmission. BT
Refer to EXHAUST SYSTEM, FE-8.
10. Support manual transmission with a jack.
11. Remove rear mounting member. Tighten rear mounting mem- HA
ber to the specified torque. Refer to ENGINE REMOVAL,
EM-99.
12. Lower manual transmission as much as possible. SC
WARNING:
Support Manual Transmission while removing it. EL
SMT099A
IDX
MT-41
 REMOVAL AND INSTALLATION FS5R30A
Removal (Contd)

AMT203

4WD MODEL NGMT0006S0102

1. Remove battery negative terminal.
2. 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
CLUTCH SYSTEM, CL-5.
4. Disconnect speed sensor, back-up lamp switch, rear heated
oxygen sensor and Park/neutral position (PNP) switch harness
connectors.
5. Remove 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 Removal,
PROPELLER SHAFT, PD-7.
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 EXHAUST SYSTEM, FE-8.
8. Remove front exhaust tubes and center pipe.
9. Remove torsion bars and mounts.
10. Remove rear torsion bar cross mounts.
11. Remove gussets from transmission or engine.
12. Support manual transmission with a jack.
13. Remove rear mounting member. Tighten rear mounting mem-
ber to the specified torque. Refer to ENGINE REMOVAL,
EM-99.
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. GI
WARNING:
Support Manual Transmission together with transfer, while
removing it. MA

EM

SMT558A LC
Installation NGMT0006S02
Apply sealant as below: 4WD model EC

FE

CL

AT

TF

PD

AX

SU

BR
AMT163
ST

RS

Tighten bolt securing transmission. BT

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

1 39 - 49 (4.0 - 5.0, 29 - 36) 65 (2.56) HA

2 39 - 49 (4.0 - 5.0, 29 - 36) 58 (2.28)

3 29 - 39 (3.0 - 4.0, 22 - 29) 25 (0.98) SC

Gusset to engine 29 - 39 (3.0 - 4.0, 22 - 29) 20 (0.79)
EL
SMT573AB
IDX
MT-43
 NGMT0007

OVERHAUL FS5R30A
Case Components

Case Components NGMT0007S01

AMT193

MT-44
 OVERHAUL FS5R30A
Gear Components

Gear Components NGMT0007S02

GI

MA

EM

LC

EC

FE

CL

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

AMT177 EL

IDX
MT-45
 OVERHAUL FS5R30A
Gear Components (Contd)

AMT188

MT-46
 OVERHAUL FS5R30A
Shift Control Components

Shift Control Components NGMT0007S03

GI

MA

EM

LC

EC

FE

CL

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

AMT179 EL

IDX
MT-47
 DISASSEMBLY FS5R30A
Case Components

Case Components
DISASSEMBLY NGMT0008
1. 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.

SMT366A

2. Remove control housing, return spring and check ball.

Be careful not to lose check ball.

SMT367A

3. Drive out retaining pin from striking arm.

SMT368A

4. Remove rear extension (or OD gear case) together with strik-

ing arm by tapping lightly.

SMT135C

5. Remove front cover and gasket.

SMT370A

MT-48
 DISASSEMBLY FS5R30A
Case Components (Contd)
6. Remove stopper ring and main drive bearing snap ring.

GI

MA

EM

SMT371A LC
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 SU

DISASSEMBLY NGMT0009
1. Mount adapter plate on vise.
2. Remove OD & reverse fork rod. BR

ST

RS
SMT373A

3. Drive out retaining pin from striking lever. BT

4. While pulling out striking rod, remove striking lever and strik-
ing interlock. Then remove 1st & 2nd, 3rd & 4th and reverse
shift fork. HA

SC

EL
SMT374A
IDX
MT-49
 DISASSEMBLY FS5R30A
Shift Control Components (Contd)
5. Drive out retaining pin from OD shift fork.
6. Pull out OD fork rod and then remove OD shift fork.

SMT375A

Gear Components
DISASSEMBLY NGMT0010
1. Before removing gears and shafts, measure each gear end
play.
Gear end play:
Refer to SDS, MT-67.
If not within specification, disassemble and check contact sur-
face of gear to hub, washer, bushing, needle bearing and shaft.

SMT376A

2. Remove rear side components on mainshaft and counter gear.

a. Remove reverse coupling sleeve.

SMT463A

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

SMT377A

d. Pull out counter gear rear end bearing.

e. 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

SMT379A LC
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. Pull out reverse counter gear.

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

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
IDX
MT-51
 DISASSEMBLY FS5R30A
Gear Components (Contd)
3. Press out mainshaft and counter gear alternately.

AMT174A

4. Remove front side components on mainshaft.

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

SMT383A

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

SMT482C

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

SMT385A

MT-52
 DISASSEMBLY FS5R30A
Gear Components (Contd)
5. Remove front side components on counter gear.
a. Remove counter gear rear thrust bearing.
GI

MA

EM

SMT404A LC
b. Remove sub-gear components.
EC

FE

CL

SMT470A

6. Remove main drive gear bearing.

a. Remove main drive gear snap ring. AT
b. Press out main drive gear bearing.
TF

PD

AX
SMT420A

7. Remove bearings from case components.

SU

BR

ST

RS

BT

HA

SC

AMT173
EL

IDX
MT-53
 INSPECTION FS5R30A
Shift Control Components

Shift Control Components

INSPECTION NGMT0011
Check contact surface and sliding surface for wear, scratches,
projections or other damage.

SMT398A

Gear Components
INSPECTION NGMT0012
Gears and Shafts NGMT0012S01
Check shafts for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.

SMT386A

SMT423A

Synchronizers NGMT0012S02
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 and OD baulk rings.

Clearance between baulk ring and gear:
Refer to SDS, MT-67.
If the clearance is smaller than the wear limit, replace baulk
ring.

SMT140

MT-54
 INSPECTION FS5R30A
Gear Components (Contd)
Measure wear of 2nd and 3rd baulk rings.
a) Place baulk rings in position on synchronizer cone.
b) While holding baulk rings against synchronizer cone as far as GI
it will go, measure dimensions A and B.
Standard:
A 0.7 - 0.9 mm (0.028 - 0.035 in)
MA
B 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit: EM
0.2 mm (0.008 in)
If dimension A or B is smaller than the wear limit, replace
SMT041B
outer baulk ring, inner baulk ring and synchronizer cone as a LC
set.
EC

FE

CL

SMT042B

Measure wear of reverse baulk ring.

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

AX
SMT424A

Bearings

NGMT0012S03
Make sure bearings roll freely and are free from noise, crack,
SU
pitting or wear.
BR

ST

RS
SMT418A

BT

HA

SC

EL

IDX
MT-55
 ASSEMBLY FS5R30A
Gear Components

Gear Components
ASSEMBLY NGMT0013

AMT172

1. Install bearings into case components.

2. Install main drive gear bearing.
a. Press main drive gear bearing.

SMT425A

b. Select proper main drive gear snap ring to minimize clearance

of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Main drive gear snap ring:
Refer to SDS, MT-68.
c. Install selected snap ring on main drive gear.

SMT426A

3. Install components on counter gear.

a. 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

SMT405A LC
4. Install front side components on mainshaft.
a. Assemble 1st & 2nd synchronizer.
EC

FE

CL

SMT614B

b. Assemble 3rd & 4th synchronizer.

AT

TF

PD

AX
SMT615B

c. Press on 3rd & 4th synchronizer assembly together with 3rd

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

ST

RS
SMT399A

d. Select proper snap ring to minimize clearance of groove. BT

Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Mainshaft front snap ring: HA
Refer to SDS, MT-68.
e. Install selected snap ring on mainshaft. SC

EL
SMT400A
IDX
MT-57
 ASSEMBLY FS5R30A
Gear Components (Contd)
f. Press on 1st & 2nd synchronizer assembly together with 2nd
main gear and 2nd gear needle bearing.

SMT401A

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

h. Install 1st main gear and needle bearing.

SMT402A

i. Install steel ball and 1st gear washer.

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

SMT403A

5. Select proper counter gear front bearing thrust washer when

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

SMT427AA

MT-58
 ASSEMBLY FS5R30A
Gear Components (Contd)
d. Tighten adapter plate to transmission case using 2 bolts.
e. Place dial indicator on rear end of counter gear.
f. Move counter gear up and down and measure dial indicator GI
deflection.
g. Select proper thrust washer using table below as a guide.
Counter gear end play:
MA
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Table for selecting proper counter gear front bearing EM
thrust washer:
Refer to SDS, MT-69.
LC

EC

FE

CL

SMT578A

6. Select proper reverse idler rear thrust washer when replacing

rear extension (or OD gear case), reverse idler gear, reverse AT
idler shaft or reverse idler front thrust washer.
a. Install reverse idler gear, reverse idler needle bearings,
reverse idler front thrust washers and reverse idler shaft into TF
rear extension (or OD gear case).
When replacing reverse idler rear thrust washer, install
either A or B. PD
Reverse idler rear thrust washer:
Refer to SDS, MT-69. AX

SU

BR

ST

RS
AMT170

BT

HA

SC

EL

IDX
MT-59
 ASSEMBLY FS5R30A
Gear Components (Contd)
b. Place dial indicator on front end of reverse idler shaft.
c. Put straightedge on front surface of rear extension (or OD gear
case) as a stopper of reverse idler shaft.
d. Move reverse idler shaft up and down and measure reverse
idler gear end play.
Reverse idler gear end play:
0.30 - 0.53 mm (0.0118 - 0.0209 in)
e. If not within specification, replace reverse idler rear thrust
washer with the other (A or B) and check again.

SMT433A

7. Install mainshaft and counter gear on adapter plate and main

drive gear on mainshaft.
a. 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.

SMT440A

c. Install counter gear on counter gear rear bearing and install

main drive gear, pilot bearing and spacer on mainshaft.

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 bear-
ing with screwdriver. GI

MA

EM

SMT442A LC
d. Install Tools (J26349-3) onto adapter plate and C-ring and
C-ring holder on mainshaft.
e. 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. Install rear side components on mainshaft and counter gear.

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

ST

RS
SMT444A

b. Install OD main gear. BT

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

EL
SMT580AA
IDX
MT-61
 ASSEMBLY FS5R30A
Gear Components (Contd)
e. Install reverse gear bushing with speedometer drive gear
(2WD model).

SMT581A

f. Install reverse cone.

SMT582A

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.

SMT571AA

SMT583A

h. Install reverse counter gear.

i. 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

SMT585A LC
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 AT
adapter plate on vice again.

TF

PD

AX
SMT485C

n. Select proper mainshaft C-ring to minimize clearance of

groove. SU
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in) BR
Mainshaft C-ring:
Refer to SDS, MT-69.
ST

RS
SMT452A

o. Install selected C-ring, C-ring holder and mainshaft rear snap BT

ring.

HA

SC

EL
SMT454A
IDX
MT-63
 ASSEMBLY FS5R30A
Gear Components (Contd)
p. Select proper counter gear rear snap ring to minimize clear-
ance of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Counter gear rear snap ring:
Refer to SDS, MT-69.
q. Install selected counter gear rear snap ring.

SMT453A

SMT455A

r. Install reverse coupling sleeve.

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

SMT456A

Shift Control Components

ASSEMBLY NGMT0014
1. Install OD fork rod and OD shift fork. Then install retaining pin
into OD shift fork.
2. Install 1st & 2nd, 3rd & 4th and reverse shift fork 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. Install front cover oil seal.
NGMT0015
GI
Apply multi-purpose grease to seal lip.
2. Install selected counter gear front bearing shim onto transmis- MA
sion case.
Apply multi-purpose grease.
3. Apply sealant to mating surface of transmission case. EM

SMT393A LC
4. Install gear assembly onto transmission case.
5. Install check spring and check ball into interlock stopper.
EC
Apply multi-purpose grease to check ball.

FE

CL

SMT588A

6. Install interlock stopper assembly and then tighten check ball

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

PD

AX
SMT460A

7. Install stopper ring and main drive bearing snap ring.

SU

BR

ST

RS
SMT371A

8. Install front cover and gasket. BT

Apply sealant to thread of 3 bolts shown left.
Refer to Case Components, MT-44.
9. Apply sealant to mating surface of adapter plate. HA

SC

EL
SMT459A
IDX
MT-65
 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 NGMT0016

VG33E GI
FS5R30A
Transmission
2WD 4WD MA
Number of speed 5

EM
Shift pattern
LC
MT-SDS-2

Synchromesh type Warner EC

Number of teeth
Gear ratio
Mainshaft Countershaft FE
Drive 22 32

1st 3.580 32 13 CL
2nd 2.077 30 21

3rd 1.360 29 31

4th 1.000

OD 0.811 24 43 AT
Reverse 3.636 30 12

Reverse idler gear 22 TF

Oil capacity
(US pt, Imp pt) 2.4 (5-1/8, 4-1/4) 5.1 (10-3/4, 9)

Remarks 2nd & 3rd double baulk ring type synchronizer PD

Gear End Play NGMT0017

Unit: mm (in)
AX
Gear End play

1st main gear 0.23 - 0.33 (0.0091 - 0.0130)

SU
2nd main gear 0.23 - 0.33 (0.0091 - 0.0130)

3rd main gear 0.06 - 0.16 (0.0024 - 0.0063)

BR
OD counter gear 0.23 - 0.33 (0.0091 - 0.0130)

Reverse main gear 0.33 - 0.43 (0.0130 - 0.0169)

ST
Counter gear 0.10 - 0.25 (0.0039 - 0.0098)
RS
Reverse idler gear 0.30 - 0.53 (0.0118 - 0.0209)

Clearance Between Baulk Ring and Gear NGMT0018

BT
Unit: mm (in)

Standard Wear limit

HA
1st 1.05 - 1.3 (0.0413 - 0.0512)

Main drive 1.05 - 1.3 (0.0413 - 0.0512) 0.7 (0.028)

SC
OD 1.05 - 1.3 (0.0413 - 0.0512)

EL

IDX
MT-67
 SERVICE DATA AND SPECIFICATIONS (SDS) FS5R30A
Clearance Between Baulk Ring and Gear (Contd)

2ND AND 3RD BAULK RING NGMT0018S01

Unit: mm (in)

SMT742C

Dimension Standard Wear limit

A 0.7 - 0.9 (0.028 - 0.035)

0.2 (0.008)
B 0.6 - 1.1 (0.024 - 0.043)

Distance between Rear Surface of Reverse

Cone and Reverse Baulk Ring NGMT0019
Unit: mm (in)

SMT428C

Standard Wear limit

Dimension A 0.1 to 0.35 (0.0039 to 0.0138) 0.7 (0.028)

Available Snap Ring NGMT0020

MAIN DRIVE GEAR SNAP RING NGMT0020S01
Unit: mm (in)

Allowable clearance 0 - 0.1 (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 NGMT0020S02

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 NGMT0020S03

Unit: mm (in)

Allowable clearance 0 - 0.1 (0 - 0.004)

GI
Thickness Part number Thickness Part number*

1.32 (0.0520) 32236-01G00 1.56 (0.0614) 32236-01G04

MA
1.38 (0.0543) 32236-01G01 1.62 (0.0638) 32236-01G05

1.44 (0.0567) 32236-01G02 1.68 (0.0661) 32236-01G06

EM
1.50 (0.0591) 32236-01G03 1.74 (0.0685) 32236-01G07
LC
*Always check with the Parts Department for the latest parts information.

Available C-ring NGMT0021 EC

MAINSHAFT C-RING NGMT0021S01
Unit: mm (in)

Allowable clearance 0 - 0.1 (0 - 0.004) FE

Thickness Part number Thickness Part number*

2.63 (0.1035) 32348-01G15 3.19 (0.1256) 32348-01G07 CL

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

AT
2.98 (0.1173) 32348-01G04 3.54 (0.1394) 32348-01G12

3.05 (0.1201) 32348-01G05 3.61 (0.1421) 32348-01G13

TF
3.12 (0.1228) 32348-01G06 3.68 (0.1449) 32348-01G14

*Always check with the Parts Department for the latest parts information.
PD
Available Shim and Washer
TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER
NGMT0022
AX
NGMT0022S01
Unit: mm (in)

Dial indicator deflection Thickness of proper washer Part number* SU

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 BR

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 ST

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 RS

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 BT

1.57 - 1.66 (0.0618 - 0.0654) 1.44 (0.0567) 32218-01G17

*Always check with the Parts Department for the latest parts information. HA
REVERSE IDLER REAR THRUST WASHER NGMT0022S02
Unit: mm (in) SC
Thickness Part number*

A 1.97 (0.0776) 32284-01G10 EL

B 2.07 (0.0815) 32284-01G11

IDX
MT-69
 SERVICE DATA AND SPECIFICATIONS (SDS) FS5R30A
Available Shim and Washer (Contd)
*Always check with the Parts Department for the latest parts information.

MT-70