<SUPPLEMENT-I>

MANUAL TRANSAXLE

SECTION MT
CONTENTS

PREPARATION ................................................... 1002 Gear Components............................................ 1012

Special Service Tools ...................................... 1002 Shift Control Components................................ 1014
Commercial Service Tools............................... 1004 DISASSEMBLY.................................................... 1015
NOISE, VIBRATION AND HARSHNESS (NVH) Case Components ........................................... 1015
TROUBLESHOOTING ......................................... 1005 Shift Control Components................................ 1015
NVH Troubleshooting Chart............................. 1005 Gear Components............................................ 1018
ON-VEHICLE SERVICE ...................................... 1006 INSPECTION........................................................ 1024
Replacing Rear Oil Seal .................................. 1006 Shift Control Components................................ 1024
Position Switch Check ..................................... 1006 Gear Components............................................ 1024
REMOVAL AND INSTALLATION ....................... 1007 ASSEMBLY.......................................................... 1026
Removal ........................................................... 1007 Shift Control Components................................ 1026
Installation ........................................................ 1008 Gear Components............................................ 1028
DESCRIPTION ..................................................... 1009 SERVICE DATA AND SPECIFICATIONS
Cross-sectional View ....................................... 1009 (SDS).................................................................... 1037
AIR BREATHER .................................................. 1010 General Specifications ..................................... 1037
Air Breather Piping........................................... 1010 Inspection and Adjustment .............................. 1038
MAJOR OVERHAUL ........................................... 1011
Case Components ........................................... 1011
 PREPARATION FS5R50B

Special Service Tools

Tool number
Description
Tool name
KV321022S1 Removing OD gear bushing
Bushing hook set Removing 3rd gear bushing
V1 KV32102211
Bushing hook
V KV32102221
2
Spacer
V KV32102240
3
Spacer
V KV32102231
4
Bolt (M12) a: 75 (2.95) dia.
V KV32102250
5 b: 59 (2.32) dia.
Bolt (M8) c: 15 (0.59)
d: 55 (2.17) dia.
e: 42.2 (1.661) dia.
f: 55 (2.17) dia.
g: 40.2 (1.583) dia.
NT730 Unit: mm (in)
KV32102400 Installing OD gear bushing
Counter gear stop-
per

a: 48 (1.89)
b: 48 (1.89)
c: 12 (0.47)
d: 15 (0.59)
e: 49 (1.93)
f: 40 (1.57)
g: 5 (0.20)
NT731 Unit: mm (in)
KV32102501 Installing mainshaft bearing
Mainshaft stopper Installing OD main gear
Installing mainshaft rear end bearing

a: 2 (0.08)
b: 212 (8.35)
c: 2 (0.08)
d: 85 (3.35)
e: 75 (2.95)
f: 16 (0.63)
g: 38 (1.50)
h: 115 (4.53)
i: 140 (5.51)
j: 110 (4.33)
NT732 Unit: mm (in)
KV31100300 Removing and installing retaining pin for
Pin punch reverse check assembly, reverse shift
fork, reverse fork rod bracket, striking
lever, and shift lever bracket
a: 4.5 (0.177) dia.
b: 12 (0.47) dia.
NT442 Unit: mm (in)

MT-1002
 PREPARATION FS5R50B
Special Service Tools (Cont’d)
Tool number
Description
Tool name
ST25420001 Installing sub-gear components
Clutch spring com-
pressor

NT443 a: 157 mm (6.18 in)

ST30031000 Removing OD main gear
Puller Removing main drive gear bearing

a: 90 (3.54) dia.
b: 50 (1.97) dia.
NT411 Unit: mm (in)
ST30613000 Installing main drive gear bearing
Drift Installing OD synchronizer cone

a: 71.5 (2.815) dia.

b: 47.5 (1.870) dia.
NT073 Unit: mm (in)
ST33200000 Installing 3rd gear bushing
Drift Installing 3rd & 4th synchronizer assem-
bly
Installing counter gear front bearing
Installing counter gear rear bearing
(Use with KV40100630)
a: 60 (2.36) dia.
NT091
b: 44.5 (1.752) dia.
Unit: mm (in)
KV40100630 Installing counter gear rear bearing
Drift (Use with ST33200000)
a: 67.5 (2.657) dia.
b: 44 (1.73) dia.
c: 38.5 (1.516) dia.
NT107
Unit: mm (in)
KV38102100 Installing front cover oil seal
Drift

a: 44 (1.73) dia.
b: 24.5 (0.965) dia.
NT084 Unit: mm (in)
ST22452000 Installing OD gear bushing
Drift Installing OD main gear
Installing mainshaft rear end bearing
a: 45 (1.77) dia.
b: 36 (1.42) dia.
NT065
Unit: mm (in)
ST30720000 Installing rear oil seal
Drift
a: 77 (3.03) dia.
b: 55.5 (2.185) dia.
NT086 Unit: mm (in)

MT-1003
 PREPARATION FS5R50B

Commercial Service Tools

Tool name Description
Puller Removing companion flange
Removing mainshaft rear end bearing
Removing OD synchronizer assembly
Removing OD gear bushing
Removing OD main gear
Removing mainshaft bearing
Removing reverse synchronizer hub
Removing 3rd & 4th synchronizer hub
Removing 3rd gear bushing

NT077

Puller Removing mainshaft low gear bearing

Removing counter low & high gear front
bearing
Removing counter gear front and rear
bearing
NT726

Puller Installing reverse synchronizer hub

Installing 1st & 2nd synchronizer hub
Installing mainshaft bearing
a: 48.6 (1.913) dia.
b: 41.6 (1.638) dia.
c: 410 (16.14)
NT733 Unit: mm (in)
Drift Removing slide ball bearing
Installing slide ball bearing
a: 16 (0.63) dia.
b: 18 (0.71) dia.
c: 30 (1.18)
d: 300 (11.81)
NT734 Unit: mm (in)

MT-1004
 Symptom
Reference page

(Possible cause)
SUSPECTED PARTS

Noise
Oil leakage

Jumps out of gear

Hard to shift or will not shift
Transmission model FS5R50B

1
OIL (Level low)
inspection. If necessary, repair or replace these parts.

Refer to MA section (‘‘Checking M/T Oil’’,

1
3
2
OIL (Wrong)

MT-1005
‘‘CHASSIS AND BODY MAINTENANCE’’).

1
1
OIL (Level too high)

2
TROUBLESHOOTING

LIQUID GASKET (Damaged) MT-1011

2
OIL SEAL (Worn or damaged) MT-1011

CHECK PLUG RETURN SPRING AND

1
MT-1014
CHECK BALL (Worn or damaged)
NVH Troubleshooting Chart

2
SHIFT FORK (Worn) MT-1014
NOISE, VIBRATION AND HARSHNESS (NVH)

2
3
GEAR (Worn or damaged) MT-1012
3
BEARING (Worn or damaged) MT-1012

2
BAULK RING (Worn or damaged) MT-1012
2
FS5R50B

INSERT SPRING (Damaged) MT-1012

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the
 ON-VEHICLE SERVICE FS5R50B

Replacing Rear Oil Seal

REMOVAL
1. Remove transfer assembly. — Refer to TF section.
2. Pull out rear oil seal.

SMT321B

INSTALLATION
1. Install rear oil seal.
● Before installing apply multi-purpose grease to seal lip.
2. Install transfer assembly. — Refer to TF section.

SMT322B

Position Switch Check

Switch Gear position Continuity
Reverse Yes
Reverse position switch
Except reverse No
Neutral Yes
Neutral position switch
Reverse position Except neutral No
switch

Neutral position switch

SMT274D

MT-1006
 REMOVAL AND INSTALLATION FS5R50B

Removal

Exhaust front tube

Front

Exhaust rear tube

Clutch operating cylinder

Rear propeller tube

Front propeller tube

SMT321D

1. Remove front and rear propeller shafts. Refer to PD section

(‘‘Removal and Installation’’, ‘‘PROPELLER SHAFT’’).
2. Remove clutch operating cylinder.
3. Remove exhaust front and rear tubes. Refer to FE section
(‘‘EXHAUST SYSTEM’’).
4. Disconnect vehicle speed sensor, back-up lamp switch, 4WD
switch and neutral position switch harness connector.
5. Remove center brake cable. Refer to BR section.
6. Remove shift lever of transmission. Refer to MT-1014
(FS5R50B).
7. Remove transfer control lever. Refer to TF section
(‘‘Removal’’, ‘‘REMOVAL AND INSTALLATION’’).
8. Support engine by placing a jack under oil pan.
● Do not place jack under the oil pan drain plug.
9. Remove transmission with transfer from engine.
WARNING:
Support Manual Transmission with transfer, while removing
it.

MT-1007
 REMOVAL AND INSTALLATION FS5R50B

Installation
● Apply sealant as below:

Engine rear plate Transmission case

Engine block

23.6 (0.929)

23.6 (0.929)

1) Place
: Sticked out portion for engine rear plate
from transmission case.
Do not apply sealant : Mating surface of transmission case and
in this range. rear plate.
Sealant 2) Sealant
Rear plate : Apply genuine anaerobic liquid gasket,
Three Bond TB1207B or TB1207D.
: Apply genuine anaerobic liquid gasket,
Three Bond TB1215 or TB1207D.

Transmission case
Grommet
Starter Engine rear plate

Unit: mm (in)
SMT280D

ZD30DDTi engine ● Tighten bolts securing transmission.

Dowel hole
For starter Tightening torque
Engine Bolts ! mm (in)
N·m (kg-m, ft-lb)
83 - 113
Dowel hole 1
V M/T to engine block 100 (3.94)
(8.5 - 11.5, 61 - 83)
29 - 39
ZD30DDTi 2
V M/T to engine oil pan 100 (3.94)
(3.0 - 4.0, 22 - 29)
29 - 39
3
V Engine oil pan to M/T 70 (2.76)
M/T to engine (Not used) (3.0 - 4.0, 22 - 29)
Engine to M/T
SMT324DB

MT-1008
 2nd main gear Striking rod

1st & 2nd coupling sleeve Control housing

3rd main gear
1st main gear
Gear shift housing Shift lever
Slide ball bearing
3rd & 4th coupling sleeve
Mainshaft bearing
Main drive gear Reverse main gear
Reverse coupling sleeve Slide ball bearing

OD main gear

Clutch housing Mainshaft rear end

bearing

Main drive gear ball bearing

Front

MT-1009
Release sleeve
DESCRIPTION

Mainshaft
Cross-sectional View

OD synchronizer cone

OD coupling sleeve
Front cover
Reverse idler gear OD gear case
Counter gear front bearing Reverse idler gear shaft
OD counter gear
Sub-gear
Drain plug
Counter gear Filler plug Counter gear rear end bearing

Transmission case
FS5R50B

SMT269D
 AIR BREATHER FS5R50B

Air Breather Piping

Remarks:
1. Route rubber hoses so that they are not bent pinched.
2. Hose insertion
• Insert the tube bulge spool into the spool.
• Insert the tube bulge into the right-angle bend section of the tube.
• Insert unit bulge until the hose connot go in any further.

Place hose clamp at the hose joint

Front (made of resin) as illustrated so as
Breather hose not to pinch the rubber hose.

Breather tube White paint mark

Details at A

Make two paint marks on the breather hose

facing up.

White paint mark

Transmission case

10.8 - 14.7
(1.1 - 1.5, 8 - 11) OD case

Install so that the white paint marks

are facing to the left hand side of
Yellow paint
the vehicle.
mark

Yellow paint mark

Transfer
(front case)
Transfer
Transfer
(rear case)
(center case)

Breather hose

Pink paint mark

Hose clamp (4 places marked with .)

Tube to side member

Clamp-hose tab here must be placed facing up. : N·m (kg-m, ft-lb)

SMT547D

MT-1010
 MAJOR OVERHAUL FS5R50B

Case Components

16 - 21 (1.6 - 2.1, 12 - 15)

16 - 21 (1.6 - 2.1, 12 - 15) Gear shift housing
Control housing
Mating surfaces to gear shift
housing cover Liquid gasket
16 - 21 (1.6 - 2.1, 12 - 15)
(Self-sealing bolt ) Mating 57 - 75 (5.8 - 7.6, 42 - 55)
surface D (Self-sealing bolt )
2 - 6 (0.08 - 0.24)
Gear shift housing 19 - 24
(1.9 - 2.4, 14 - 17)
Mating surface D

Rear oil seal Seal lip

OD gear case

Transmission case 16 - 21
(1.6 - 2.1, 12 - 15) Liquid gasket
Filler plug Mating
25 - 34 surface B
(2.5 - 3.5, 18 - 25)
Thread of bolt 2 - 6 (0.08 - 0.24)

Mating OD gear case

surface C

54 - 72 Mating surface C
(5.5 - 7.3, 40 - 53)
16 - 21 (1.6 - 2.1, 12 - 15) Transmission case

Bearing retainer 2-6

Drain plug (0.08 - 0.24)
54 - 72 25 - 34 (2.5 - 3.5, 18 - 25)
(5.5 - 7.3, 40 - 53)
Thread of bolt
Front
Front cover oil seal
Seal lip
Liquid gasket

Mating surface B
Mating
surface A Clutch housing

Front cover

Front To cylinder block

cover Liquid gasket
Gusset RH

2 - 6 (0.08 - 0.24)
To cylinder block
Mating surface A
Sealing grommet

54 - 72 (5.5 - 7.3, 40 - 53) Gusset LH

32 - 42 (3.3 - 4.3, 24 - 31) To clutch housing

19 - 24 (1.9 - 2.4, 14 - 17)

(Self-sealing bolt ) Illustration for TB42S engine
model
29 - 39 (3.0 - 4.0, 22 - 29)

Unit: mm (in)
: N·m (kg-m, ft-lb)
: Apply genuine anaerobic liquid gasket, 29 - 39 (3.0 - 4.0, 22 - 29)
Three Bond TB1215, Loctite Part No.
51813 or equivalent.

SMT270D

MT-1011
 MAJOR OVERHAUL FS5R50B

Gear Components

3rd gear bushing

3rd gear needle bearing

3rd main gear
3rd inner baulk ring
Synchronizer cone
3rd outer baulk ring
3rd & 4th coupling sleeve

Shifting insert
Shifting insert spring >
4th baulk ring

Main drive gear

Shifting insert spring >

Main drive bearing
snap ring 3rd & 4th synchronizer hub >

3rd & 4th hub snap ring .

Pilot bearing
1st gear needle bearing
1st main gear

Main drive bearing > 1st inner baulk ring

Main drive gear snap
ring . Synchronizer cone

1st outer baulk ring

Shifting insert Mainshaft

2nd main gear

2nd gear
needle
1st & 2nd coupling sleeve
bearing
Shifting insert spring
1st & 2nd synchronizer hub >
Shifting insert spring

1st & 2nd hub snap ring .

2nd outer baulk ring
Synchronizer cone
Counter gear
2nd inner baulk ring

Sub-gear washer

Sub-gear snap ring 16 - 21 N·m

(1.6 - 2.1 kg-m, 12 - 15 ft-lb)

Lock plate

Sub-gear
(Inner race)
Sub-gear spring >
(Outer race)

Counter gear front bearing >

Reverse idler shaft

Reverse idler needle bearing

Reverse idler gear >

SMT271D

MT-1012
 MAJOR OVERHAUL FS5R50B
Gear Components (Cont’d)

OD main gear >

Mainshaft bearing snap ring

Mainshaft bearing >

Reverse coupling sleeve >

Mainshaft spacer
Shifting insert >
Mainshaft rear end bearing
Shifting insert spring
Mainshaft rear snap ring

Shifting insert spring

Reverse synchronizer hub >

Reverse baulk ring

Reverse gear needle bearing

Reverse main gear

Counter gear rear snap ring

OD synchronizer cone

Shifting insert spring >

OD gear needle bearing

OD counter gear bushing

OD baulk ring
Thrust washer
OD coupling sleeve >

Shifting insert >

OD counter gear

Snap ring

(Inner race) (Outer race)

Counter gear rear

bearing >

Transmission case

Apply gear oil to gears, shafts, synchronizers and

bearings when assembling.
. : Select with proper thickness.
> : Pay attention to its direction.

SMT272D

MT-1013
 MAJOR OVERHAUL FS5R50B

Shift Control Components

Bushing
Boot band Shift knob
Select check plunger
Contact surface to shift lever bracket
Boot
Select check spring (Color: white)
Shift lever
Boot band

Resin seat
Select check plug
Snap ring
20 - 29
(2.0 - 3.0, 14 - 22) Snap ring

Socket
Spring
Plug
16 - 21 (1.6 - 2.1, 12 - 15)
Cam pin
16 - 21
Bracket
(1.6 - 2.1, 12 - 15)
Control housing
Select check plunger Contact surface to shift lever bracket

16 - 21 Select check spring (Color: black)

(1.6 - 2.1, 12 - 15) Air breather
Select check plug
Neutral position switch 20 - 29 (2.0 - 3.0, 14 - 22)
20 - 29 (2.0 - 3.0, 14 - 22) Check plunger
Spacer
Reverse check spring
Reverse position switch Plunger
Thrust washer
20 - 29 (2.0 - 3.0, 14 - 22)
E-ring Fork rod cap
Slide ball bearing
Striking rod cap
Striking rod cap

Fork rod cap

Plug Check ball
20 - 29
(2.0 - 3.0, 14 - 22)
Interlock plunger
Interlock pin
Check ball

Reverse fork rod

Check ball spring

Retaining pin
Check ball
Reverse shift fork
Gear shift housing Retaining pin
Clip
16 - 21 (1.6 - 2.1, 12 - 15) Shift lever bracket
Striking rod
Fork rod cap

16 - 21 (1.6 - 2.1, 12 - 15) Retaining pin

Retaining pin
Striking lever 3rd & 4th rod bracket
1st & 2nd rod bracket
Retaining pin
Interlock pin
Retaining pin
3rd & 4th fork rod

OD fork rod

OD shift fork
1st & 2nd fork rod

Retaining pin
3rd & 4th shift fork
: N·m (kg-m, ft-lb) 1st & 2nd shift fork
: Apply genuine anaerobic liquid gasket, Three Retaining pin
Bond TB1215, Loctite Part No. 51813 or
equivalent.

SMT273D

MT-1014
 DISASSEMBLY FS5R50B

Case Components
Control housing
1. Remove transmission case outer parts.
● Control housing
● Gear shift housing
● Clutch housing
Gear shift housing
● OD gear case
● Front cover

OD gear case

Transmission case

Clutch housing
Front cover

SMT276D

2. Remove front cover oil seal.

Front cover

SMT305D

3. Remove rear oil seal.

SMT551D

Control housing Shift Control Components

● Remove and disassemble gear shift housing and control
housing parts.

Gear shift housing

SMT290D

MT-1015
 DISASSEMBLY FS5R50B
Shift Control Components (Cont’d)
Select check spring CONTROL HOUSING
(Color: white) Cam pin
1. Remove select check plugs, springs and select check plung-
Control housing
Plug ers.
Select check plunger
Select check
plug Select check
Select check plug
plunger
Air breather
Select check spring
Check plunger (Color: black)
Reverse check spring Spacer
Thrust washer
E-ring
SMT548D

2. Remove E-ring, thrust washer, reverse check spring, spacer,

Reverse check assembly Cam pin
check plunger and cam pin.
3. Remove plug.

E-ring

SMT298D

Reverse position switch GEAR SHIFT HOUSING

Interlock plunger Neutral position switch 1. Remove reverse and neutral position switch.
● Do not lose check balls and plungers.
2. Remove plug, check balls, interlock pin and interlock plunger.
Plug
● Do not lose check balls.
Interlock pin

Check ball

SMT295D

Shift lever bracket

3. Drive out retaining pin from shift lever bracket.

SMT292D

4. Remove retaining pin and plug.

Gear shift housing a. Drive out retaining pin from striking lever through plug on
Striking lever
gear shift housing.

SMT293D

MT-1016
 DISASSEMBLY FS5R50B
Shift Control Components (Cont’d)
Mating surface

Striking lever

Gear shift housing

Striking rod
Retaining pin Striking rod cap

SMT549D

b. Drive out retaining pin from reverse shift fork, then drive out
3rd & 4th rod bracket
1st & 2nd shift fork
reverse fork rod and fork rod cap with brass bar.
1st & 2nd rod bracket c. Remove interlocking parts.
d. Drive out retaining pins from 3rd & 4th shift fork and 3rd &
Alignment portion
1st & 2nd fork rod 4th rod bracket, then drive out 3rd & 4th fork rod and fork rod
cap with brass bar.
e. Drive out retaining pins from 1st & 2nd shift fork and 1st &
2nd rod bracket, then drive out 1st & 2nd fork rod and fork
rod cap with brass bar.

Front

Gear shift housing

Reverse shift fork

3rd & 4th fork
rod Striking lever
3rd & 4th shift fork
Striking rod

Reverse fork rod

SMT296D

Check ball Check ball spring

Plug

Interlock plunger
Interlock pin
SMT545D

5. Drive out striking rod with brass bar through control rod plug
on gear shift housing.

SMT294D

MT-1017
 DISASSEMBLY FS5R50B
Shift Control Components (Cont’d)
6. Drive out slide ball bearing using SST.
Slide ball bearing Slide ball bearing

Tool
Gear shift housing
SMT328D

7. Remove caps.

SMT291D

Gear Components
Mainshaft rear end bearing
TRANSMISSION CASE
Snap ring
1. Remove snap ring for mainshaft rear end bearing.

Rear
SMT277D

2. Pull out mainshaft rear end bearing, then remove mainshaft

Mainshaft spacer
spacer.
Puller

SMT278D

3. Check OD counter gear end play.

Gear end play

Gear End play mm (in)
OD counter gear 0.20 - 0.47 (0.0079 - 0.0185)

● If not within specification, disassemble and check contact

surface of gear to hub, washer, bushing, needle bearing and
shaft.
Feeler gauge
SMT264B

MT-1018
 DISASSEMBLY FS5R50B
Gear Components (Cont’d)
4. Remove counter gear rear snap ring.

SMT265B

5. Remove lock plate of reverse idler shaft and then remove

reverse idler gear, washers, reverse idler needle bearings
and reverse idler shaft.

SMT863A

6. Pull out the following parts.

● OD counter gear
● OD synchronizer assembly with OD shift fork and OD fork
rod

Puller

SMT266B

7. Pull out OD gear bushing and thrust washer.

Mainshaft 8. Remove bolts securing bearing retainer and then remove
bearing retainer.

OD gear bushing

Bearing retainer
Rear
SMT279D

9. Pull out OD main gear.

Puller

SMT268B

MT-1019
 DISASSEMBLY FS5R50B
Gear Components (Cont’d)
10. Remove mainshaft bearing snap ring.
Mainshaft bearing 11. Pull out mainshaft bearing.

Rear

Puller

SMT281D

12. Support mainshaft with hoist.

13. Remove bolts securing front cover and then remove front
cover.

Rear

SMT319D

14. Remove counter gear front bearing outer race.

● Tap rear end of counter gear lightly before removing
bearing.

SMT282D

15. Remove counter gear rear bearing outer race.

● Tap front end of counter gear lightly before removing
bearing.
16. Settle counter gear assembly down on bottom of transmis-
sion case.
(Outer race)

Counter gear rear bearing

(Inner race)
SMT283D

17. Remove main drive gear assembly.

Upper
● Set cutting portion of clutch gear on main drive gear to
upper side.

Rear view

Front
SMT284D

MT-1020
 DISASSEMBLY FS5R50B
Gear Components (Cont’d)
18. Remove mainshaft assembly.

Mainshaft
assembly

Rear
SMT285D

19. Remove counter gear assembly.

Counter gear

Rear

SMT286D

MAIN DRIVE GEAR

1. Remove main drive gear snap ring and main drive bearing
snap ring.
2. Press out main drive gear bearing.

SMT420AA

MAINSHAFT AND GEARS

2nd main gear
3rd main gear 1. Before disassembly, check 1st, 2nd, 3rd and reverse main
gear end play.
Front Gear end play:
Unit: mm (in)

Gears End play

Reverse main gear
1st main gear 0.20 - 0.48 (0.0079 - 0.0189)
1st main gear
Feeler gauge 2nd main gear 0.20 - 0.60 (0.0079 - 0.0236)
Main drive gear 3rd main gear 0.20 - 0.45 (0.0079 - 0.0177)
SMT287D
OD counter gear 0.20 - 0.47 (0.0079 - 0.0185)
3rd main gear
Dial indicator
Reverse main gear 0.20 - 0.44 (0.0079 - 0.0173)
● If not within specification, disassemble and check contact
surface of gears to hub, washer, bushing, needle bearing and
shaft.

Puller
SMT907A

MT-1021
 DISASSEMBLY FS5R50B
Gear Components (Cont’d)
2. Remove 3rd & 4th hub snap ring.
3. Pull out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd gear needle bearing.
Puller

SMT908A

4. Pull out 3rd gear bushing.

5. Remove 2nd main gear and 2nd gear needle bearing.
Puller

SMT839A

6. Pull out reverse synchronizer assembly.

7. Remove reverse main gear and reverse gear needle bearing.
8. Remove 1st & 2nd hub snap ring.
Puller

SMT274B

9. Press out 1st main gear together with 1st & 2nd synchronizer
assembly.

SMT911A

COUNTER GEAR
1. Remove sub-gear components.
a. Remove sub-gear snap ring.
b. Remove sub-gear, sub-gear washer and sub-gear spring.

SMT333D

MT-1022
 DISASSEMBLY FS5R50B
Gear Components (Cont’d)
Counter gear front Counter gear rear 2. Pull out counter gear front and rear bearing inner race.
bearing inner race bearing outer race

Puller Puller

SMT924A

MT-1023
 INSPECTION FS5R50B

Shift Control Components

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

SMT301D

Gear Components
GEAR AND SHAFT
● Check for cracks, wear or bending.
● Check gears for excessive wear, chips or cracks.

SMT276B

SMT946A

SMT925A

SYNCHRONIZER
shifting insert Spline
portion ● 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.

SMT387A

MT-1024
 INSPECTION FS5R50B
Gear Components (Cont’d)
● Measure clearance between baulk ring and gear.
Baulk ring to gear Clearance between baulk rings and main gears:
clearance
Unit: mm (in)

Gears Standard Wear limit

Main drive gear 1.00 - 1.45 (0.0394 - 0.0571)
OD counter gear 1.00 - 1.45 (0.0394 - 0.0571) 0.7 (0.028)
Reverse main gear 1.00 - 1.45 (0.0394 - 0.0571)

SMT140

Inner baulk ring ● Measure wear of 1st, 2nd and 3rd baulk rings.
Inner baulk ring a. Place inner baulk ring in position on synchronizer cone.
Synchronizer cone
b. Hold baulk ring evenly against synchronizer cone and mea-
sure distance ‘‘A’’.
c. Place outer baulk ring in position on synchronizer cone.
d. Hold baulk ring evenly against synchronizer cone and mea-
sure distance ‘‘B’’.
Standard:
Dial indicator
Inner-A 0.7 - 0.9 mm (0.028 - 0.035 in)
Outer-B 1.4 - 1.6 mm (0.055 - 0.063 in)
SMT041BA Wear Limit:
0.2 mm (0.008 in)
Outer baulk ring e. If distance ‘‘A’’ or ‘‘B’’ is smaller than the wear limit, replace
outer baulk ring, inner baulk ring and synchronizer cone as
Outer baulk ring a set.

Synchronizer cone

SMT330D

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

SMT552D

MT-1025
 ASSEMBLY FS5R50B

Select check spring Shift Control Components

(Color: white) Cam pin

Plug
Control housing CONTROL HOUSING
Select check plunger 1. Install select check plunger, select check spring and select
Select check
plug Select check check plug.
Select check plug
plunger 2. Install reverse check parts.
Air breather a. Install cam pin.
Select check spring
Check plunger (Color: black)
Reverse check spring Spacer
Thrust washer
E-ring
SMT548D

b. Install check plunger, spacer, reverse check spring and

Reverse check assembly
thrust washer.

SMT299D

c. Install E-ring.
Reverse check assembly E-ring

SMT300D

3. Assemble control housing parts as shown on left.

SMT304D

Slide ball bearing GEAR SHIFT HOUSING

1. Assemble gear shift housing.
2. Install slide ball bearing into gear shift housing using SST.
Press in 35 mm (1.38 in)
Press in 4 mm (0.16 in)

SMT329D

MT-1026
 ASSEMBLY FS5R50B
Shift Control Components (Cont’d)
3. Install striking rod through striking lever and shift lever
3rd & 4th rod bracket
1st & 2nd shift fork
bracket.
1st & 2nd rod bracket ● Pay attention to direction of each part.
● Pay attention to direction of each part.
Alignment portion
1st & 2nd fork rod ● Align cutout portion of striking lever, 1st & 2nd rod
bracket, 3rd & 4th rod bracket and reverse shift fork.
4. Install 1st & 2nd shift fork, 1st & 2nd rod bracket and 1st &
2nd fork rod.
5. Install 3rd & 4th rod bracket, 1st & 2nd and 3rd & 4th shift
forks and 3rd & 4th fork rod.
6. Insert interlock plunger and check ball for interlock part, then
Front
install reverse shift fork and reverse fork rod.

Gear shift housing

Reverse shift fork

3rd & 4th fork
rod Striking lever
3rd & 4th shift fork
Striking rod

Reverse fork rod

SMT296D

Check ball Check ball spring

Plug

Interlock plunger
Interlock pin
SMT545D

7. Drive in retaining pins into striking lever, each shift fork and
bracket.

Reverse fork
rod

Striking lever

SMT302D

Shift lever bracket

8. Install retaining pin into shift lever bracket.

SMT292D

MT-1027
 ASSEMBLY FS5R50B
Shift Control Components (Cont’d)
9. Install fork rod caps by tapping lightly.
Striking rod cap

Fork rod cap

Striking
lever cap

Fork rod cap

Gear shift housing

Shift rod cap

SMT303D

Reverse position switch 10. Install reverse and neutral position switches.
Interlock plunger Neutral position switch

Plug

Interlock pin

Check ball

SMT295D

Gear Components
MAIN DRIVE GEAR
1. Press main drive gear bearing.

SMT425AA

2. Select proper main drive gear snap ring to minimize clear-

ance of groove, then install it.
Allowable clearance of groove:
0 - 0.15 mm (0 - 0.0059 in)
Main drive gear snap ring:
Refer to SDS, MT-1038.

SMT426A

Coupling sleeve MAIN SHAFT

Synchronizer 1. Assemble synchronizers.
hub 1st & 2nd synchronizer
● Opening of shifting insert springs must not be aligned
with each other.
Shifting insert

Shifting insert

Shifting insert spring

SMT914A

MT-1028
 ASSEMBLY FS5R50B
Gear Components (Cont’d)
3rd & 4th synchronizer

Shifting insert spring

Shifting insert
spring

Coupling
sleeve

Shifting insert

SMT288D

Synchronizer hub Reverse synchronizer

Stopper
Shifting insert
● Pay attention to direction of synchronizer hub, shifting
Coupling sleeve
inserts and coupling sleeve.
● Openings of shift insert springs must not be aligned with
each other.

Front

SMT331D

2. Press reverse synchronizer assembly together with reverse

main gear and reverse gear needle bearing.
Drift ● Pay attention to direction of reverse synchronizer hub
assembly.
3. Install 1st main gear and 1st gear needle bearing.

SMT278B

MT-1029
 ASSEMBLY FS5R50B
Gear Components (Cont’d)
4. Press 1st & 2nd synchronizer assembly.
● 1st baulk ring and 2nd baulk ring are different.

Drift

This groove is only

on front side.

SMT289D

5. Select proper 1st & 2nd hub snap ring to minimize clearance
of groove, then install it.
Allowable clearance of groove:
1st & 2nd hub snap 0 - 0.13 mm (0 - 0.0051 in)
ring
1st & 2nd hub snap ring:
Refer to SDS, MT-1038.

SMT280B

6. Install 2nd main gear and 2nd gear needle bearing.

7. Press 3rd gear bushing.
8. Install 3rd main gear and 3rd gear needle bearing.

SMT281B

9. Press 3rd & 4th synchronizer assembly.

● Pay attention to direction of synchronizer assembly.

Front

SMT282B

MT-1030
 ASSEMBLY FS5R50B
Gear Components (Cont’d)
10. Select proper 3rd & 4th hub snap ring to minimize clearance
of groove, then install it.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
3rd & 4th hub snap ring:
Refer to SDS, MT-1038.
11. Measure 1st, 2nd, 3rd and reverse main gear end plays as
the final check. — Refer to ‘‘Disassembly’’.

SMT332D

Counter gear front Counter gear rear COUNTER GEAR

bearing inner race bearing outer race
1. Press on counter gear front and rear bearing inner race.

SMT924A

2. Install sub-gear, sub-gear spring, sub-gear washer, and snap

Front
ring, while compressing sub-gear spring.
● Pay attention to direction of sub-gear spring.
Sub-gear
spring

SMT334D

TRANSMISSION CASE
Reverse idler gear
1. Install reverse idler shaft, thrust washers, needle bearings
and gear.
● Pay attention to direction of reverse idler gear and wash-
ers.
2. Install lock plate of reverse idler shaft.

Front

Transmission
case SMT306D

3. Settle counter gear assembly on bottom of transmission

Counter gear case.

Front

SMT307D

MT-1031
 ASSEMBLY FS5R50B
Gear Components (Cont’d)
4. Place mainshaft assembly on top of counter gear assembly
Mainshaft and then support it with hoist.
assembly

Front

SMT308D

● Align matching portion of counter gear and sub-gear

tooth to upper side.

SMT309D

Upper
5. Install main drive gear assembly by tapping front end of it
lightly.
● Set cutting portion of clutch gear on main drive gear to
the upper side.
Rear view

Soft hammer
SMT310D

6. Install counter gear front bearing outer race by tapping it

lightly while holding counter gear assembly.
● Pay attention to direction.

Front
Soft hammer
SMT311D

7. Install counter gear rear bearing outer race by tapping it

lightly while holding counter gear assembly.
● Pay attention to direction.
8. Take off hoist from mainshaft.

Front

Tool
SMT312D

MT-1032
 ASSEMBLY FS5R50B
Gear Components (Cont’d)
9. Install Tool onto transmission case.

SMT313D

10. Install OD gear bushing.

11. Remove KV32102400 (Counter gear stopper).

SMT308B

12. Install front cover oil seal.

● Apply multi-purpose grease to lip of oil seal before
installing.

SMT942AA

13. Install front cover.

● Always use new bolts at portion V A as they are self-
sealing bolts.
Tightening torque:
Refer to Case Components, MT-1011.

SMT295B

14. Install clutch housing.

Tightening torque:
Refer to Case Components, MT-1011.

SMT319B

MT-1033
 ASSEMBLY FS5R50B
Gear Components (Cont’d)
15. Install Tool onto transmission case.

Adjusting bolt

SMT314D

16. Stand transmission case assembly on two wooden blocks

placed under clutch housing.
17. Install mainshaft bearing without snap ring to prevent it from
damaging transmission case.
Drift ● Pay attention to direction.
18. Put snap ring back in place.

Front

SMT309B

19. Install OD main gear.

● Pay attention to direction.
20. Remove KV32102500 (Mainshaft stopper).

Front
SMT872A

21. Install bearing retainer and then stake 4 torx bolts at two
points.
● Install thrust washer and OD counter gear bushing.

SMT310B

MT-1034
 ASSEMBLY FS5R50B
Gear Components (Cont’d)
22. Install the following parts.
Rear side
a. Assemble OD synchronizer onto OD counter gear.
OD coupling sleeve
● Pay attention to direction of shifting inserts and OD cou-
pling sleeve.

OD shifting insert

Front

OD synchronizer assembly
(with OD counter gear)

SMT315D

b. Install OD counter gear with OD synchronizer assembly, OD

shift fork and rod.

SMT311B

23. Install OD synchronizer cone.

24. Install OD synchronizer cone washer.

SMT312B

25. Select proper counter gear rear snap ring to minimize clear-
ance of groove, then install it.
Allowable clearance of groove:
0 - 0.15 mm (0 - 0.0059 in)
Counter gear rear snap ring:
Refer to SDS, MT-1038.
● Measure OD counter gear end play as the final check —
Refer to ‘‘SDS’’, MT-1038.

SMT313B

MT-1035
 ASSEMBLY FS5R50B
Gear Components (Cont’d)
26. Install mainshaft spacer and mainshaft rear end bearing.

SMT985A

27. Select proper set of mainshaft rear end bearing snap ring to
minimize clearance of groove, then install it.
Mainshaft rear
end bearing
Allowable clearance of groove:
0 - 0.15 mm (0 - 0.0059 in)
Mainshaft rear end bearing snap ring:
Refer to SDS, MT-1038.

Snap ring
SMT318D

28. Install rear oil seal.

● Apply multi-purpose grease to lip of oil seal on OD gear
case before installing.

SMT304B

29. Install OD gear case and then tighten fixing bolts.

● Always use new bolts at portion V A as they are self-
sealing bolts.
Tightening torque:
Refer to Case Components, MT-1011.

OD gear case

SMT316D

Gear shift housing

30. Install gear shift housing and control housing onto transmis-
sion case.
● Always use new bolts at portion V A as they are self-
sealing bolts.

Front
Control housing
SMT317D

MT-1036
 SERVICE DATA AND SPECIFICATIONS (SDS) FS5R50B

General Specifications
ZD30DDTi
Applied model Hardtop & Wagon
4WD
Transmission FS5R50B
Number of speed 5
Transmission control Floor direct

Shift pattern

Synchromesh type Warner

Gear ratio
1st 4.262
2nd 2.456
3rd 1.488
4th 1.000
OD 0.851
Reverse 3.972
Number of teeth
Mainshaft
Drive 27
1st 44
2nd 39
3rd 39
OD 25
Reverse 41
Countershaft
Drive 34
1st 13
2nd 20
3rd 33
OD 37
Reverse 13
Reverse idler gear 27
Oil capacity ! (Imp pt) 3.8 (6-3/4)
1st, 2nd and 3rd double baulk ring type synchronizer
Remarks
Reverse synchronizer type

MT-1037
 SERVICE DATA AND SPECIFICATIONS (SDS) FS5R50B

Inspection and Adjustment

GEAR END PLAY 1st & 2nd hub snap ring
Unit: mm (in) Unit: mm (in)

Gear End play Allowable clearance 0 - 0.13 (0 - 0.0051)

1st main gear 0.20 - 0.48 (0.0079 - 0.0189) Thickness Part number
2nd main gear 0.20 - 0.60 (0.0079 - 0.0236) 2.05 (0.0807) 32348-0T200
3rd main gear 0.20 - 0.45 (0.0079 - 0.0177)
OD counter gear 0.20 - 0.47 (0.0079 - 0.0185) 2.15 (0.0846) 32348-0T201
Reverse main gear 0.20 - 0.44 (0.0079 - 0.0173)
3rd & 4th hub snap ring
Unit: mm (in)
CLEARANCE BETWEEN BAULK RING
AND GEAR Allowable clearance 0 - 0.10 (0 - 0.0039)
Thickness Part number
Main drive, OD and reverse baulk ring
Unit: mm (in) 1.95 (0.0768) 32348-0T210
2.00 (0.0787) 32348-0T211
Gear Standard Wear limit 2.05 (0.0807) 32348-0T212
1.00 - 1.45 2.10 (0.0827) 32348-0T213
Main drive gear
(0.0394 - 0.0571) 2.15 (0.0846) 32348-0T214
1.00 - 1.45 2.20 (0.0866) 32348-0T215
OD counter gear 0.7 (0.028)
(0.0394 - 0.0571)
1.00 - 1.45 Counter gear rear snap ring
Reverse gear
(0.0394 - 0.0571)
Unit: mm (in)

Allowable clearance 0 - 0.15 (0 - 0.0059)

1st, 2nd and 3rd baulk ring (double baulk
Thickness Part number
ring)
1.35 (0.0531) 32204-VB000
1.45 (0.0571) 32204-VB001
Outer baulk ring
1.55 (0.0610) 32204-VB002
1.65 (0.0650) 32204-VB003
1.75 (0.0689) 32204-VB004
1.85 (0.0728) 32204-VB005

Mainshaft rear end bearing snap ring

Unit: mm (in)
Inner baulk ring
Allowable clearance 0 - 0.15 (0 - 0.0059)
Synchronizer cone
Thickness Part number
1.8 (0.071) 32204-VB010
SMT327D
1.9 (0.075) 32204-VB011
Unit: mm (in) 2.0 (0.079) 32204-VB012
Dimension Standard Wear limit 2.1 (0.083) 32204-VB013
2.2 (0.087) 32204-VB014
0.7 - 0.9
A 0.2 (0.008) 2.3 (0.091) 32204-VB015
(0.028 - 0.035)
2.4 (0.094) 32204-VB016
1.4 - 1.6
B 0.2 (0.008)
(0.055 - 0.063)

AVAILABLE SNAP RING

Main drive gear snap ring
Unit: mm (in)

Allowable clearance 0 - 0.15 (0 - 0.0059)

Thickness Part number
2.05 (0.0807) 32348-0T200
2.15 (0.0846) 32348-0T201
2.25 (0.0886) 32348-0T202

MT-1038