22B-1

MANUAL
TRANSMISSION
OVERHAUL
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . 2 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . 27

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 4 REVERSE IDLER GEAR . . . . . . . . . . . . . . . 35

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 4 SPEEDOMETER GEAR . . . . . . . . . . . . . . . . 36

SEALANTS AND ADHESIVES . . . . . . . . . . . . 5 SELECT LEVER . . . . . . . . . . . . . . . . . . . . . . . 37

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CONTROL HOUSING . . . . . . . . . . . . . . . . . . 38

SNAP RINGS, SPACERS AND THRUST CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . 41

PLATES FOR ADJUSTMENT . . . . . . . . . . . . . 6
TRANSMISSION CASE . . . . . . . . . . . . . . . . . 44
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 9
CENTER DIFFERENTIAL . . . . . . . . . . . . . . . 46
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 10
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 13

INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 20
22B-2 MANUAL TRANSMISSION OVERHAUL – General Information

GENERAL INFORMATION
SECTIONAL VIEW – Without Front Limited Slip Differential (Front LSD)
 MANUAL TRANSMISSION OVERHAUL – General Information 22B-3
SECTIONAL VIEW – With Front Limited Slip Differential (Front LSD)
 Specifications /
22B-4 MANUAL TRANSMISSION OVERHAUL – Service Specifications

SPECIFICATIONS
TRANSMISSION MODEL TABLE
Transmission model Gear ratio Speedometer gear ratio Final gear ratio Front LSD

W5M51-1-X6A A 29/36 4.529 Not available

W5M51-1-X6A1 A 29/36 4.529 Available

W5M51-1-X7A A 30/36 4.529 Not available

W5M51-1-X7A1 A 30/36 4.529 Available

W5M51-1-Z6A B 29/36 4.875 Not available

W5M51-1-Z6A1 B 29/36 4.875 Available

W5M51-1-Z7A B 30/36 4.875 Not available

W5M51-1-Z7A1 B 30/36 4.875 Available

GEAR RATIO TABLE

A B

1st 2.785 ←

2nd 1.950 ←

3rd 1.407 1.444

4th 1.031 1.096

5th 0.761 0.825

Reverse 3.416 ←

Transfer gear ratio 0.3018 ←

SERVICE SPECIFICATIONS
Items Allowable range Limit

Input shaft end play mm 0.05 – 0.17 –

Input shaft front bearing clearance mm 0 – 0.12 –

Input shaft rear bearing clearance mm 0 – 0.12 –

Input shaft 5th speed gear clearance mm 0 – 0.09 –

Output shaft preload mm 0.13 – 0.18 –

Output shaft bearing clearance mm 0 – 0.09 –

Output shaft 3rd speed gear clearance mm 0 – 0.09 –

Center differential case preload mm 0.05 – 0.11 –

Center differential case pinion backlash mm 0.025 – 0.150 –

Synchronizer ring back surface to gear clearance mm – 0.5

 MANUAL TRANSMISSION OVERHAUL – Sealants and Adhesives 22B-5
SEALANTS AND ADHESIVES
TRANSMISSION
Items Specified sealants and adhesives

Clutch housing-transmission case mating surface THREEBOND 1216

Control housing-transmission case mating surface

Under cover-transmission case mating surface

Air breather THREEBOND 1501

Center differential drive gear bolt THREEBOND 1303 or LOKTITE 648

TRANSFER
Items Specified sealants and adhesives

Air breather THREEBOND 1501

FORM-IN-PLACE GASKET
The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure that
the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.
Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks.
Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing
of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary
to apply the gasket evenly without a break, while observing the correct bead size.
DISASSEMBLY
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
SURFACE PREPARATION
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remaining in the bolt holes.
FORM-IN-PLACE GASKET APPLICATION
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 10 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
 MANUAL TRANSMISSION Lubricants / Snap Rings, Spacers
22B-6 OVERHAUL – and Thrust Plates for Adjustment

LUBRICANTS
TRANSMISSION
Items Specified lubricants

Drive shaft oil seal lip area DIA QUEEN MULTI-GEAR OIL 75W/85W
(Transmission oil)
Input shaft oil seal lip area

Control shaft oil seal lip area

Select lever shoe MOLYWHITE TA No.1 or No.2

TRANSFER
Items Specified lubricants

Drive shaft oil seal lip area DIA QUEEN MULTI-GEAR OIL 75W/85W
(Transmission oil)
Front differential oil seal lip area

O-rings

SNAP RINGS, SPACERS AND THRUST PLATES FOR

ADJUSTMENT
Part name Thickness mm Identification symbol Part No.

Spacer 1.34 34 MD723600

(For adj
adjustment
stment of inp
inputt shaft end pla
play))
1.43 43 MD723603

1.52 52 MD723606

1.61 61 MD723609

1.70 70 MD756760

1.79 79 MD756763

Snap ring 1.43 Green (2) MD746708

(For adjustment
adj stment of input
inp t shaft front bearing
clearance) 1.51 White (2) MD746709

1.59 Yellow (2) MD746710

Snap ring 1.44 None MD746602

(For adj
adjustment
stment of inp
inputt shaft rear bearing
clearance) 1.51 Blue MD746603

1.58 Brown MD746604

 MANUAL TRANSMISSION Snap Rings, Spacers and Thrust Plates
OVERHAUL – for Adjustment 22B-7

Part name Thickness mm Identification symbol Part No.

Thrust plate 3.82 0 MD748465

adj stment of input
(For adjustment inp t shaft 5th speed gear
clearance) 3.86 2 MD748466

3.90 3 MD748467

3.94 5 MD748468

3.98 6 MD748469

4.02 7 MD748470

4.06 8 MD748471

4.10 9 MD748472

Spacer 0.86 86 MD720938

(For adjustment
adj stment of output
o tp t shaft preload)
0.89 89 MD720939

0.92 92 MD720940

0.95 95 MD720941

0.98 98 MD720942

1.01 01 MD720943

1.04 04 MD720944

1.07 07 MD720945

1.10 J MD710454

1.13 D MD700270

1.16 K MD710455

1.19 L MD710456

1.22 G MD700271

1.25 M MD710457

1.28 N MD710458

1.31 E MD706574

1.34 O MD710459

1.37 P MD710460

1.40 None MD706573

1.43 Q MD710461

1.46 R MD710462
 MANUAL TRANSMISSION Snap Rings, Spacers and Thrust Plates
22B-8 OVERHAUL – for Adjustment

Part name Thickness mm Identification symbol Part No.

Snap ring 1.36 Yellow MD748449

adj stment of output
(For adjustment o tp t shaft bearing clear
clear-
ance) 1.40 Green MD748450

1.44 None MD746602

1.48 Black MD748451

1.51 Blue MD746603

1.55 White MD748452

1.58 Brown MD746604

1.63 Orange MD748453

1.68 Blue MD748454

Snap ring 2.81 None MD746594

(For adjustment
adj stment of o
output
tp t shaft 3rd speed gear
clearance) 2.85 Blue MD746595

2.89 Brown MD746596

2.93 Yellow MD746597

2.97 Green MD746598

3.01 Black MD746599

3.05 White MD746600

3.09 Orange MD746601

Spacer 0.74 74 MD727660

adj stment of center differential case
(For adjustment
p
preload) 0.77 77 MD754476

0.80 80 MD727661

0.83 83 MD720937

0.86 86 MD720938

0.89 89 MD720939

0.92 92 MD720940

0.95 95 MD720941

0.98 98 MD720942

1.01 01 MD720943

1.04 04 MD720944

1.07 07 MD720945

1.10 J MD710454

1.13 D MD700270

1.16 K MD710455
 MANUAL TRANSMISSION Snap Rings, Spacers and Thrust Plates
OVERHAUL – for Adjustment / Torque Specifications 22B-9

Part name Thickness mm Identification symbol Part No.

Spacer 1.19 L MD710456

adj stment of center differential case
(For adjustment
p
preload) 1.22 G MD700271

1.25 M MD710457

1.28 N MD710458

1.31 E MD706574

Spacer 0.6 – MD748362

adj stment of center differential case pinion
(For adjustment
backlash) 0.7 – MD748363

0.8 – MD748364

0.9 – MD748365

1.0 – MD748366

1.1 – MD748367

TORQUE SPECIFICATIONS
TRANSMISSION
Items Nm {kgf@m}

Under cover mounting bolt 6.9 {0.7}

Interlock plate bolt 30 {3.1}

Clutch housing-transmission case mounting bolt 44 {4.5}

Clutch release bearing retainer mounting bolt 9.8 {1.0}

Control housing mounting bolt 18 {1.9}

Shift cable bracket mounting bolt 18 {1.9}

Speedometer gear mounting bolt 3.9 {0.4}

Stopper bracket mounting bolt 18 {1.9}

Select lever mounting bolt 18 {1.9}

Select lever mounting nut 11 {1.2}

Center differential drive gear mounting bolt 132 {13.5}

Back-up lamp switch 32 {3.3}

Poppet spring plug 32 {3.3}

Reverse idler gear shaft mounting bolt 48 {4.9}

Roll stopper bracket mounting bolt 69 {7.0}

 Torque Specifications /
22B-10 MANUAL TRANSMISSION OVERHAUL – Special tools

TRANSFER
Items Nm {kgf@m}

Transfer cover mounting bolt 23 {2.4}

Transmission-transfer mounting bolt 69 {7.0}

SPECIAL TOOLS
Tool Number Name Use
MB990887 Arm bushing Installation of transfer oil seal
remover & installer
ring

MB990891 Bushing remover & Installation of transfer oil seal

installer base

MB990928 Installer adapter Installation of input shaft oil seal

MB990932 Installer adapter Removal of differential case taper roller bearing

MB990933 Installer adapter Installation of transfer oil seal

MB990935 Installer adapter Installation of output shaft front taper roller

bearing outer race

MB990937 Installer adapter Installation of differential case taper roller

bearing
 MANUAL TRANSMISSION OVERHAUL – Special Tools 22B-11

Tool Number Name Use

MB990938 Handle Use with Installer adapter

MB991445 Bushing remover Installation of differential case taper roller

and installer base bearing outer race

MD998304 Oil seal installer Installation of transfer extension housing oil

seal

MD998364 Camshaft oil seal Installation of gear, bearing and sleeve

installer

MD998800 Oil seal installer Installation of differential oil seal and transfer
cover oil seal

MD998801 Bearing remover Installation and removal of gear, bearing and

sleeve

MD998812 Installer cap Use with Installer and installer adapter

MD998813 Installer-100 Use with Installer cap and installer adapter

MD998814 Installer-200 Use with Installer cap and installer adapter

22B-12 MANUAL TRANSMISSION OVERHAUL – Special Tools

Tool Number Name Use

MD998818 Installer adapter Installation of input shaft front bearing
(38)

MD998819 Installer adapter Installation of input shaft rear bearing and

(40) output shaft taper roller bearing

MD998820 Installer adapter Installation of reverse gear bearing sleeve

(42)

MD998821 Installer adapter Installation of 4th speed gear, 5th speed gear
(44) sleeve and 5th-reverse speed synchronizer
hub

MD998824 Installer adapter Installation of 1st-2nd speed synchronizer hub,

(50) 2nd speed gear sleeve and 3rd speed gear

MD998825 Installer adapter Installation of 1st speed gear sleeve, 3rd-4th

(52) speed synchronizer hub, 4th speed gear
sleeve, 5th speed gear and thrust plate stopper

MD998917 Bearing remover Removal and installation of gear, bearing and

sleeve

MD999566 Claw Removal of taper roller bearing outer race

 MANUAL TRANSMISSION OVERHAUL – Transmission 22B-13
TRANSMISSION
DISASSEMBLY AND REASSEMBLY

18 {1.9}
18 {1.9}
32 {3.3}
5
6 32 {3.3} 10
4 11
69 {7.0} 8
3.9 {0.4}
9

7
3

3
1

69 {7.0}
69 {7.0}

Unit: Nm {kgf@m}

Disassembly steps
1. Transfer "HA 7. Speedometer gear
"JA 2. O-ring 8. Back-up lamp switch
3. Roll stopper bracket 9. Gasket
4. Insulator washer 10. Plug
5. Shift cable bracket 11. Gasket
"IA 6. Select lever
22B-14 MANUAL TRANSMISSION OVERHAUL – Transmission

Apply gear oil to all

moving parts before
installation.
14

18 {1.9}

30 {3.1}

15 12
13
44 {4.5}

20
23
21

18 17
48 {4.9}
26 19
24

16
3.9 {0.7}
27
22
25

Unit: Nm {kgf@m}

Disassembly steps
12. Interlock plate bolt "EA 20. Transmission case
13. Gasket 21. Outer race
"GA 14. Control housing 22. Outer race
15. Neutral return spring "DA 23. Spacer
"FA 16. Under cover "DA 24. Spacer
17. Reverse idler gear shaft bolt "DA 25. Spacer
18. Gasket 26. Oil guide
19. Reverse idler gear 27. Oil guide
 MANUAL TRANSMISSION OVERHAUL – Transmission 22B-15

Apply gear oil to all

moving parts before 29 31
installation.
32
28
30

37 34
36

35
33

40

38

39

Disassembly steps
"CA 28. Spring pin AB" "BA 35. 5th-reverse speed shift rail
29. 1st-2nd speed shift rail AB" "BA 36. 5th-reverse speed shift fork
30. 1st-2nd speed shift fork AC" "AA 37. Center differential
"CA 31. Spring pin AC" "AA 38. Output shaft
AA" "CA 32. Spring pin AC" "AA 39. Input shaft
AB" "BA 33. 3rd-4th speed shift rail 40. Clutch housing
AB" "BA 34. 3rd-4th speed shift fork
22B-16 MANUAL TRANSMISSION OVERHAUL – Transmission

5th-reverse DISASSEMBLY SERVICE POINTS

shift fork
AA" SPRING PIN REMOVAL
Shift the 5th-reverse shift fork in the direction shown in the
illustration.

AB" 3RD-4TH SPEED SHIFT RAIL / 3RD-4TH SPEED

3rd-4th SHIFT FORK / 5TH-REVERSE SPEED SHIFT
speed
shift rail RAIL / 5TH-REVERSE SPEED SHIFT FORK
REMOVAL
5th-reverse
shift rail Pull out the shift rails from the shift rail holes in the clutch
housing.

AC" CENTER DIFFERENTIAL / OUTPUT SHAFT /

Output shaft Input
INPUT SHAFT REMOVAL
shaft Remove the input shaft, output shaft and center differential
Center together.
differential

ADJUSTMENT BEFORE REASSEMBLY

Output shaft Input SPACER SELECTION FOR ADJUSTING INPUT SHAFT
shaft END PLAY / OUTPUT SHAFT PRELOAD /
Center DIFFERENTIAL PRELOAD
differential
(1) Install the input shaft, output shaft and center differential
as a set to the clutch housing.

Solders (2) Place two pieces of solder (1.6 mm in diameter and approx.
10 mm in length) on the input shaft rear bearing at the
positions shown in the illustration.
 MANUAL TRANSMISSION OVERHAUL – Transmission 22B-17
(3) Place two pieces of solder (1.6 mm in diameter and approx.
Solders 10 mm in length) on the transmission case at the positions
shown in the illustration.
(4) Install the bearing outer race.
(5) Install the transmission case and tighten the bolts to the
specified torque.

(6) Remove the transmission case. If the solder is not crushed,

repeat the steps (2) through (5) using the solder with
Solders
larger diameter.

(7) Measure the thickness of the crushed solder with a

micrometer and select spacers that will provide the
standard end play/preload value.
Standard value:
Input shaft end play . . . . . . . . . . 0 – 0.17 mm
Output shaft end play . . . . . . . . 0.13 – 0.18 mm
Center differential preload . . . . 0.05 – 0.11 mm

REASSEMBLY SERVICE POINTS

Output shaft Input "AA INPUT SHAFT / OUTPUT SHAFT / CENTER
shaft DIFFERENTIAL INSTALLATION
Center Install the input shaft, output shaft and differential as a unit.
differential

3rd-4th speed "BA 5TH-REVERSE SPEED SHIFT FORK /

shift fork 5TH-REVERSE SPEED SHIFT RAIL / 3RD-4TH
5th-reverse SPEED SHIFT FORK / 3RD-4TH SPEED SHIFT
5th-reverse speed shift rail RAIL INSTALLATION
speed shift fork
(1) Install the 3rd-4th speed shift rails and fork, and
5th-reverse speed shift rail and fork.

3rd-4th speed
shift rail
22B-18 MANUAL TRANSMISSION OVERHAUL – Transmission

(2) Slide the shift rails into the shift rail holes in the clutch
3rd-4th speed
housing.
shift rail

5th-reverse
speed shift
rail

Shift rail "CA SPRING PIN INSTALLATION

Install the spring pin with its slit directed as shown in the
illustration.

Spring pin

"DA SPACER INSTALLATION

Install the spacer selected in the section “ADJUSTMENT
BEFORE REASSEMBLY”.

f 2 mm "EA TRANSMISSION CASE INSTALLATION

Apply sealant to the illustrated position of the transmission
case.
Specified sealant: THREEBOND 1216
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.

"FA UNDER COVER INSTALLATION

f 2 mm
Apply sealant to the illustrated position of the transmission
case.
Specified sealant: THREEBOND 1216
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.
MANUAL TRANSMISSION OVERHAUL – Transmission 22B-19
"GA CONTROL HOUSING INSTALLATION
Apply sealant to the illustrated position of the transmission
case.
Specified sealant: THREEBOND 1216
f 2 mm Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.

"HA SPEEDOMETER GEAR INSTALLATION

Apply transmission oil to the O-ring of the speedometer gear.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

Control shaft "IA SELECT LEVER INSTALLATION

Apply grease to the control shaft sliding portion of the select
lever shoe.
Select Specified grease: MOLYWHITE TA No.1 or No.2
lever
shoe

"JA O-RING INSTALLATION

Lubricate O-ring with transmission oil.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

INSPECTION
BACK-UP LAMP SWITCH
Check for continuity between terminals.
Switch condition Continuity
Pressed Not exist
Released Exists
22B-20 MANUAL TRANSMISSION OVERHAUL – Input Shaft

INPUT SHAFT
DISASSEMBLY AND REASSEMBLY

Apply gear oil to all 12

moving parts before 14
installation. 13
15
16
17

9
18 10
11
2
20 4
21

22 6
7 1
8

3
18
5
19

Disassembly steps
"MA 1. Snap ring "EA 12. 3rd-4th speed synchronizer hub
AA" "LA 2. Ball bearing 13. Outer synchronizer ring
AB" "KA 3. Thrust plate stopper "DA 14. Synchronizer spring
"JA 4. Thust plate 15. Synchronizer cone
AC" "IA 5. 5th speed gear 16. Inner synchronizer ring
6. 4th speed gear 17. 3rd speed gear
7. Needle roller bearing 18. Needle roller bearing
AD" "HA 8. 4th speed gear sleeve "CA 19. Snap ring
9. Synchronizer ring AE" "BA 20. Ball bearing
"GA 10. Synchronizer spring "AA 21. Oil seal
"FA 11. Synchronizer sleeve 22. Input shaft
 MANUAL TRANSMISSION OVERHAUL – Input Shaft 22B-21
MD998801 DISASSEMBLY SERVICE POINTS
AA" BALL BEARING REMOVAL

AB" THRUST PLATE STOPPER REMOVAL

Using a screwdriver, pry up the position shown in the illustration
and remove the thrust plate stopper.

MD998801 AC" 5TH SPEED GEAR REMOVAL

AD" 4TH SPEED GEAR SLEEVE REMOVAL

MD998801 Install the special tool to the 3rd speed gear and remove
the 4th speed gear sleeve.

AE" BALL BEARING REMOVAL

MD998801
22B-22 MANUAL TRANSMISSION OVERHAUL – Input Shaft

REASSEMBLY SERVICE POINTS

Oil seal 3.5 mm
"AA OIL SEAL INSTALLATION
Make sure that the oil seal is pressed into the position shown
in the illustration.

"BA BALL BEARING INSTALLATION

MD998812

MD998813
MD998801
MD998818

"CA SNAP RING INSTALLATION

Select and install a snap ring so that the input shaft front
bearing end play will have the standard value.
Standard value: 0 – 0.12 mm

Snap ring

"DA SYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring securely to the illustrated
position of the outer synchronizer ring.

Synchronizer spring

Installation "EA 3RD-4TH SPEED SYNCHRONIZER HUB

direction INSTALLATION
Install the synchronizer hub in such a way that it will be oriented
in the direction shown.

Identification mark
 MANUAL TRANSMISSION OVERHAUL – Input Shaft 22B-23

MD998812
Caution
When the hub is installed, make sure that the synchronizer
ring is not caught.
MD998813
MD998801
MD998825

"FA SYNCHRONIZER SLEEVE INSTALLATION

Identification groove
(1) Install the synchronizer sleeve in such a way that it will
be oriented in the direction shown.

Installation
direction

Synchronizer sleeve projections (2) When the synchronizer sleeve is installed, make sure
that the deep groove portion of the synchronizer hub
is aligned with the projecting portion of the sleeve.

Synchronizer hub
deep grooves

"GA SYNCHRONIZER SPRING INSTALLATION

Synchronizer spring

"HA 4TH SPEED GEAR SLEEVE INSTALLATION

MD998812

MD998813
MD998801
MD998825
22B-24 MANUAL TRANSMISSION OVERHAUL – Input Shaft

"IA 5TH SPEED GEAR INSTALLATION

MD998812

MD998813

MD998801 MD998825

"JA THRUST PLATE INSTALLATION

Select and install a thrust plate so that the input shaft 5th
Stamped
surface
speed gear clearance will have the standard value.
Standard value: 0 – 0.09 mm
Caution
Install the plate with its identification stamped surface
faced against the thrust plate stopper.

Thrust plate

"KA THRUST PLATE STOPPER INSTALLATION

MD998812 Install the thrust plate stopper by pressing the special tools
with hand. Make sure that the stopper is not installed aslant.
MD998813

MD998825

"LA BALL BEARING INSTALLATION

MD998812

MD998819
MD998801

"MASNAP RING INSTALLATION

Select and install a snap ring so that the input shaft rear
bearing clearance will have the standard value.
Standard value: 0 – 0.12 mm

Snap ring
 MANUAL TRANSMISSION OVERHAUL – Input Shaft 22B-25
INSPECTION
INPUT SHAFT
(1) Check the outside diameter of the needle bearing
mounting portion for damage, abnormal wear and seizure.
(2) Check the splines for damage and wear.

NEEDLE ROLLER BEARING

(1) Check to ensure that when the input shaft and gear are
combined and made to rotate, they rotate smoothly without
looseness and noise.
(2) Check to ensure that the cage is not deformed.

SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside surface is not
damaged or worn and that the threads are not crushed.

(3) Press the synchronizer ring against the gear and check
clearance “A”. If “A” is less than the limit, replace.
Gear
Synchronizer Limit: 0.5 mm
ring

OUTER SYNCHRONIZER RING / INNER

Damage, Break SYNCHRONIZER RING / SYNCHRONIZER CONE
Damage, Break (1) Check to ensure that the clutch gear tooth surface and
cone surface are not damaged and broken.

Damage,
Break
22B-26 MANUAL TRANSMISSION OVERHAUL – Input Shaft

(2) Install the outer ring, inner ring and cone, press them
against the gear, and check clearance “A”. If “A” is less
Outer ring
Cone than the limit, replace.
Limit: 0.5 mm
Caution
When any of the outer ring, inner ring or cone has
to be replaced, replace them as a set.

Inner ring

SYNCHRONIZER SLEEVE AND HUB

Sleeve
(1) Check to ensure that when the synchronizer sleeve and
hub are combined and made to slide, they slide smoothly
without binding.
(2) Check to ensure that the front and rear ends of the sleeve
inside surface are not damaged.
Caution
Hub When replacement of either the synchronizer sleeve
or hub is necessary, make sure that the synchronizer
sleeve and hub are replaced as a set.

SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.

SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces
are not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
 MANUAL TRANSMISSION OVERHAUL – Output Shaft 22B-27
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before 21
installation. 22
23
24
26 25
28
27
30
29 19 18
20

33
4 1

5
3

32 31
35
13 2

36 12 4
15 14

17 7 6
34 8
9
11
10
13

16

Disassembly steps
"PA 1. Snap ring 19. Needle roller bearing
AA" "OA 2. Taper roller bearing AE" "GA 20. 2nd speed gear sleeve
AB" "NA 3. Reverse gear bearing sleeve 21. Inner synchronizer ring
"NA 4. Needle roller bearing 22. Synchronizer cone
"NA 5. Reverse gear 23. Outer synchronizer ring
6. Synchronizer ring "DA 24. Synchronizer spring
"LA 7. Synchronizer spring "FA 25. Synchronizer sleeve
"FA 8. Synchronizer sleeve "EA 26. 1st-2nd speed synchronizer hub
AC" "MA 9. 5th-reverse speed synchronizer hub 27. Outer synchronizer ring
10. Synchronizer ring "DA 28. Synchronizer spring
"LA 11. Synchronizer spring 29. Inner synchronizer ring
12. 5th speed gear 30. Synchronizer cone
13. Needle roller bearing 31. 1st speed gear
"KA 14. 5th speed gear sleeve 32. Needle roller bearing
"JA 15. 4th speed gear AF" "CA 33. 1st speed gear sleeve
"IA 16. Snap ring AG" "BA 34. Taper roller bearing
AD" "HA 17. 3rd speed gear "AA 35. Oil seal
18. 2nd speed gear 36. Output shaft
22B-28 MANUAL TRANSMISSION OVERHAUL – Output Shaft

MD998801
DISASSEMBLY SERVICE POINTS
Taper roller bearing
AA" TAPER ROLLER BEARING REMOVAL

Reverse gear AB" REVERSE GEAR BEARING SLEEVE REMOVAL

MD998801 bearing sleeve Mount a special tool on the reverse gear and remove the
reverse gear bearing sleeve.

5th-reverse AC" 5TH-REVERSE SPEED SYNCHRONIZER HUB

speed REMOVAL
MD998801 synchronizer
hub Mount a special tool on the 4th speed gear and remove
the 5th-reverse speed synchronizer hub.

AD" 3RD SPEED GEAR REMOVAL

Mount a special tool on the 2nd speed gear and remove
3rd speed gear the 3rd speed gear.
MD998917

AE" 2ND SPEED GEAR SLEEVE REMOVAL

2nd speed Mount a special tool on the 1st speed gear and remove the
gear sleeve 2nd speed gear sleeve.
MD998917
 MANUAL TRANSMISSION OVERHAUL – Output Shaft 22B-29
AF" 1ST SPEED GEAR SLEEVE REMOVAL

MD998801 1st speed

gear sleeve

AG" TAPER ROLLER BEARING REMOVAL

MD998801 Taper roller bearing

REASSEMBLY SERVICE POINTS

Oil seal 3.5 mm "AA OIL SEAL INSTALLATION
Make sure that the oil seal is pressed into the position shown
in the illustration.

"BA TAPER ROLLER BEARING INSTALLATION

MD998812
MD998801 MD998819
Taper roller
bearing

"CA 1ST SPEED GEAR SLEEVE INSTALLATION

MD998812

MD998814

1st speed MD998824

gear sleeve

MD998364
22B-30 MANUAL TRANSMISSION OVERHAUL – Output Shaft

"DA SYNCHRONIZER SPRING INSTALLATION

Synchronizer spring

"EA 1ST-2ND SPEED SYNCHRONIZER HUB

INSTALLATION
Install the 1st-2nd speed synchronizer hub in such a way
that it will be oriented in the direction shown.

Installation
direction

Caution
MD998812 When the hub is installed, make sure that the synchronizer
ring is not caught.
MD998814
1st-2nd speed
synchronizer MD998824
hub

MD998364

"FA SYNCHRONIZER SLEEVE INSTALLATION

Identification groove
(1) Install the synchronizer sleeve in such a way that it will
be oriented in the direction shown.

Installation
direction

Synchronizer sleeve projections (2) When the synchronizer sleeve is installed, make sure
that the deep groove portion of the synchronizer hub
is aligned with the projecting portion of the sleeve.

Synchronizer hub deep grooves

 MANUAL TRANSMISSION OVERHAUL – Output Shaft 22B-31
"GA 2ND SPEED GEAR SLEEVE INSTALLATION
MD998812

2nd speed MD998814

gear sleeve
MD998824

MD998364

"HA 3RD SPEED GEAR INSTALLATION

MD998812

MD998814
3rd speed gear
MD998824

MD998364

"IA SNAP RING INSTALLATION

Select and install a snap ring so that the output shaft 3rd
speed gear clearance will have the standard value.
Standard value: 0 – 0.09 mm

Snap ring

MD998812 "JA 4TH SPEED GEAR INSTALLATION

MD998813

MD998821

4th speed
gear

MD998364

MD998812
"KA 5TH SPEED GEAR SLEEVE INSTALLATION

MD998813
MD998821

5th speed
gear sleeve

MD998364
22B-32 MANUAL TRANSMISSION OVERHAUL – Output Shaft

"LA SYNCHRONIZER SPRING INSTALLATION

Synchronizer spring

"MA5TH-REVERSE SPEED SYNCHRONIZER HUB

INSTALLATION
Install the 5th-reverse speed synchronizer hub in such a way
that it will be oriented in the direction shown.

Installation
direction

Caution
MD998812
When the hub is installed, make sure that the synchronizer
5th-reverse speed
synchronizer hub MD998813 ring is not caught.
MD998821

MD998364

"NA REVERSE GEAR / NEEDLE ROLLER BEARING /

MD998812
REVERSE GEAR BEARING SLEEVE
MD998820 INSTALLATION
Reverse gear Reverse gear
bearing sleeve

MD998364

"OA TAPER ROLLER BEARING INSTALLATION

MD998812
MD998819

Taper roller
bearing

MD998364
 MANUAL TRANSMISSION OVERHAUL – Output Shaft 22B-33
"PA SNAP RING INSTALLATION
Snap ring
Select and install a snap ring so that the output shaft rear
bearing clearance will have the standard value.
Standard value: 0 – 0.09 mm

INSPECTION
OUTPUT SHAFT
Check the splines for damage and wear.

NEEDLE ROLLER BEARING

(1) Check to ensure that when the bearing sleeve and gear
are combined and made to rotate, they rotate smoothly
without looseness and noise.
(2) Check the cage for deformation.

SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside diameter is not
damaged or worn and that the threads are not crushed.

(3) Press the synchronizer ring against the gear and check
clearance “A”. If “A” is less than the limit, replace.
Gear
Synchronizer Limit: 0.5 mm
ring
22B-34 MANUAL TRANSMISSION OVERHAUL – Output Shaft

OUTER SYNCHRONIZER RING / INNER

Damage, Break SYNCHRONIZER RING / SYNCHRONIZER CONE
Damage, Break (1) Check to ensure that the clutch gear tooth surfaces and
cone surfaces are not damaged and broken.

Damage,
Break

Gear (2) Install the outer ring, inner ring and cone, press them
against the gear, and check clearance “A”. If “A” is less
than the limit, replace.
Outer ring Limit: 0.5 mm
Cone
Caution
When any of the outer ring, inner ring or cone has
to be replaced, replace them as a set.

Inner ring

SYNCHRONIZER SLEEVE AND HUB

Sleeve
(1) Check to ensure that when the synchronizer sleeve and
hub are combined and made to slide, they slide smoothly
without binding.
(2) Check to ensure that the front and rear ends of the sleeve
inside surface are not damaged.
Caution
Hub When replacement of either the synchronizer sleeve
or hub is necessary, make sure that the synchronizer
sleeve and hub are replaced as a set.

SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.

SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces
are not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
 MANUAL TRANSMISSION OVERHAUL – Reverse Idler Gear 22B-35
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY

Apply gear oil to all

moving parts before
installation.

3
4

TFM0807

Disassembly steps
1. Snap ring
2. Thrust washer
3. Reverse idler gear
4. Needle roller bearing
5. Reverse idler gear shaft

INSPECTION
NEEDLE ROLLER BEARING
(1) Check to ensure that when the shaft and gear are combined
and made to rotate, they rotate smoothly without looseness
and noise.
(2) Check to ensure that the cage is not deformed.
22B-36 MANUAL TRANSMISSION OVERHAUL – Speedometer Gear

SPEEDOMETER GEAR
DISASSEMBLY AND REASSEMBLY

Apply gear oil to all

moving parts before
installation.

1
TFM0593

Disassembly steps
1. e-clip
2. Speedometer driven gear
3. O-ring
4. Sleeve
 MANUAL TRANSMISSION OVERHAUL – Select Lever 22B-37
SELECT LEVER
DISASSEMBLY AND REASSEMBLY

7
1
11 {1.2}
8
2
9
3

10

Unit: Nm {kgf@m}

Disassembly steps
"AA 1. Dust cover 6. Select lever shoe
2. Nut 7. Select lever
3. Spring washer 8. Select lever bushing
4. Washer "AA 9. Dust cover
5. Select lever bushing 10. Select lever shaft

Dust cover REASSEMBLY SERVICE POINT

"AA DUST COVER INSTALLATION
22B-38 MANUAL TRANSMISSION OVERHAUL – Control Housing

CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY

12 7
9

14 6
5 2
15 4
8 3
16
13

19
11
10

18

17

18 {1.9}

Unit: Nm {kgf@m}

Disassembly steps
AA" "FA 1. Lock pin 11. Spacer
2. Interlock plate 12. Control shaft
3. Control finger "CA 13. Air breather
4. Pin 14. Control shaft boot
5. Return spring "BA 15. Oil seal
6. Stopper plate "AA 16. Needle bearing
"EA 7. Spring pin 17. Spring washer
"DA 8. Spring pin 18. Stopper bracket
9. Stopper body 19. Control housing
10. Neutral return spring
 MANUAL TRANSMISSION OVERHAUL – Control Housing 22B-39
DISASSEMBLY SERVICE POINT
Lock pin AA" LOCK PIN REMOVAL
Drive the lock pin out of position from the direction shown.

Control
finger

Control REASSEMBLY SERVICE POINTS

housing "AA NEEDLE BEARING INSTALLATION
Press fit the needle bearing to the position shown in the
illustration, while making sure that the model number stamped
Model Needle side is oriented in the direction shown.
number bearing
stamped
side

2 mm

"BA OIL SEAL INSTALLATION

Apply transmission oil to the oil seal lip area.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

"CA AIR BREATHER INSTALLATION

(1) Apply a sealant to the outside circumference of the
inserting portion.
Specified sealant: THREEBOND 1501

(2) Make sure that the projecting portion is oriented in the

direction shown.
22B-40 MANUAL TRANSMISSION OVERHAUL – Control Housing

Control shaft Stopper body "DA SPRING PIN INSTALLATION

Installation
direction

Slit

Spring pin

"EA SPRING PIN INSTALLATION

Spring pin

"FA LOCK PIN INSTALLATION

Lock pin Drive in the lock pin in the direction shown in the illustration.

Control finger
 MANUAL TRANSMISSION OVERHAUL – Clutch Housing 22B-41
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY

3
7

5*

9.8 {1.0} 1

Unit: Nm {kgf@m}

Disassembly steps
1. Clutch release bearing retainer "BA 5. Bushing*
"EA 2. Oil seal "AA 6. Cover-A
AA" "DA 3. Outer race "AA 7. Cover-B
AB" "CA 4. Outer race 8. Clutch housing

NOTE:
*: Never remove the bushings from the clutch housing.
Only the case when installing new bushings into a new clutch housing, refer to "BA.
22B-42 MANUAL TRANSMISSION OVERHAUL – Clutch Housing

DISASSEMBLY SERVICE POINTS

MD999566
AA" OUTER RACE REMOVAL

Outer race

AB" OUTER RACE REMOVAL

MD999566

Cover-B REASSEMBLY SERVICE POINTS

"AA COVER-A / COVER-B INSTALLATION
Install the covers directed as shown in the illustration

Cover-A

"BA BUSHING INSTALLATION

Press fit the bushing to the illustrated position, while making
sure that the split ends of the bushing do not coincide with
Bushing the air purge groove.

Air purge groove

Bushing

1 mm
 MANUAL TRANSMISSION OVERHAUL – Clutch Housing 22B-43
"CA OUTER RACE INSTALLATION

MB990938
MB990935

"DA OUTER RACE INSTALLATION

MB990938
MB991445

"EA OIL SEAL INSTALLATION

Apply transmission oil to the oil seal lip area.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

MB990938

MB990928
22B-44 MANUAL TRANSMISSION OVERHAUL – Transmission Case

TRANSMISSION CASE
DISASSEMBLY AND REASSEMBLY

2*

3*

Disassembly steps
"CA 1. Oil seal
"BA 2. Needle bearing*
"AA 3. Bushing*
4. Transmission case

NOTE:
*: Never remove the bearing and bushing from the transmission case.
Only the case when installing new bearing and bushing into a new transmission case, refer to "AA
and "BA.
 MANUAL TRANSMISSION OVERHAUL – Transmission Case 22B-45

Air purge groove

REASSEMBLY SERVICE POINTS
"AA BUSHING INSTALLATION
Press fit the bushing to the illustrated position, while making
sure that the split ends of the bushing do not coincide with
the air purge groove.
Bushing

Bushing

3 mm

"BA NEEDLE BEARING INSTALLATION

Needle bearing Model No.
stamped surface Press fit the needle bearing until it is flush with the case,
while making sure that the model number stamped side is
oriented in the direction shown.

"CA OIL SEAL INSTALLATION

Apply transmission oil to the oil seal lip area.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

MD998800
22B-46 MANUAL TRANSMISSION OVERHAUL – Center Differential

CENTER DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY

1 3
Apply gear oil to all 2
moving parts before
installation.

12 6
7
11
132 {13.5}
12
4
17
14
9 10

12

13
12 11
8

9
16
15
Unit: Nm {kgf@m}

Disassembly steps
"DA 1. Center differential drive gear "CA 10. Pinion shaft holder
"CA 2. Center differential flange "CA 11. Pinion
AA" "BA 3. Taper roller bearing "CA 12. Washer
"CA 4. Snap ring "CA 13. Side gear
"CA 5. Front output shaft "CA 14. Spacer
"CA 6. Spacer AB" "AA 15. Taper roller bearing
"CA 7. Side gear 16. Speedometer drive gear
"CA 8. Lock pin 17. Differential case
"CA 9. Pinion shaft

DISASSEMBLY SERVICE POINTS

MD998917
AA" TAPER ROLLER BEARING REMOVAL
Use the special tool to remove the taper roller bearing.
 MANUAL TRANSMISSION OVERHAUL – Center Differential 22B-47
AB" TAPER ROLLER BEARING REMOVAL
MD998917 Use the special tools to remove the taper roller bearing.
MB990932

REASSEMBLY SERVICE POINTS

MB990937
"AA TAPER ROLLER BEARING INSTALLATION
Use the special tool to install the taper roller bearing.

"BA TAPER ROLLER BEARING INSTALLATION

Use the special tools to install the taper roller bearing.
MD998823 MD998812

"CA SPACER / SIDE GEAR / WASHER /

PINION/PINION HOLDER / PINION SHAFT /
LOCK PIN / FRONT OUTPUT SHAFT / SNAP
RING / CENTER DIFFERENTIAL FLANGE
INSTALLATION
(1) Install the side gear in the center differential case with
the spacer attached.
NOTE
If a new side gear is to be installed, select a spacer
with medium thickness (0.8 – 0.9 mm).

(2) Fit the washer on the back of each pinion. Engage the
Differential case 4 pinions simultaneously in the side gear.
Lock pin Rotate the gears to place them in position, then install
Pinion shaft the pinion shaft holder.
(3) Insert the pinion shafts.
(4) Install the lock pins in the illustrated direction.
22B-48 MANUAL TRANSMISSION OVERHAUL – Center Differential

(5) Install the front output shaft to the side gear and fit the
snap ring.
(6) Attach the spacer on the other side gear, then install
the side gear in the center differential case.
NOTE
If a new side gear is to be installed, select a spacer
with medium thickness (0.8 – 0.9 mm).

(7) Install the center differential flange on the case while

aligning the mating marks, then secure it temporarily with
machine screw.

(8) Measure the backlash between the side gear and the
pinion.
Standard value: 0.025 – 0.150 mm
(9) If the measurement deviates from the standard value,
correct the backlash using a spacer of different thickness
and check it again.
NOTE
The backlash must be the same on both sides.

"DA CENTER DIFFERENTIAL DRIVE GEAR

INSTALLATION
(1) Apply sealant to the entire threaded portion of the bolt.
Specified sealant:
THREEBOND 1303 or LOKTITE 648

1 (2) Tighten the bolts to the specified torque in the illustrated

3 10 sequence.
5
8
7
6
9
4
2
 MANUAL TRANSMISSION OVERHAUL – Transfer 22B-49
TRANSFER
DISASSEMBLY AND REASSEMBLY

1
3

6
4

8
7 11

Apply gear oil to all

9 moving parts before
installation.

10

23 {2.4}

Unit: Nm {kgf@m}

Disassembly steps
"FA 1. Air breather
2. Dust seal guard
"EA 3. Oil seal
"DA 4. Oil seal
"AA 5. O-ring
"AA 6. O-ring
"CA 7. Oil seal
"BA 8. Oil seal
"AA 9. O-ring
10. Transfer cover
11. Transfer
22B-50 MANUAL TRANSMISSION OVERHAUL – Transfer

REASSEMBLY SERVICE POINTS

"AA O-RING INSTALLATION
Apply transmission oil to the O-ring.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

"BA OIL SEAL INSTALLATION

MD998800 (1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

"CA OIL SEAL INSTALLATION

MB990938
MB990933 (1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

MB990891
"DA OIL SEAL INSTALLATION
MB990887 (1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

"EA OIL SEAL INSTALLATION

(1) Apply transmission oil to the oil seal lip area.
MD998304
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.
MANUAL TRANSMISSION OVERHAUL – Transfer 22B-51
"FA AIR BREATHER INSTALLATION
Apply sealant to the air breather.
Specified sealant: THREEBOND 1501