MT PDF

C TRANSMISSION/TRANSAXLE
B
SECTION
MANUAL TRANSAXLE MT
E
CONTENTS
RS5F70A INPUT SHAFT AND GEARS .................................... 38 F
Disassembly ........................................................... 38
PRECAUTIONS .......................................................... 3 Inspection ............................................................... 39
Precautions .............................................................. 3 GEAR AND SHAFT ............................................. 39 G
PREPARATION ........................................................... 4 SYNCHRONIZERS ............................................. 40
Special Service Tools ............................................... 4 BEARING ............................................................ 41
Commercial Service Tools ........................................ 6 Assembly ................................................................ 41
NOISE, VIBRATION, AND HARSHNESS (NVH) H
MAINSHAFT AND GEARS ....................................... 45
TROUBLESHOOTING ................................................ 8 Disassembly ........................................................... 45
NVH Troubleshooting Chart ..................................... 8 Inspection ............................................................... 47
DESCRIPTION ............................................................ 9 GEAR AND SHAFT ............................................. 47 I
Cross-sectional View ................................................ 9 SYNCHRONIZERS ............................................. 47
DOUBLE-CONE SYNCHRONIZER ...................... 9 BEARING ............................................................ 48
M/T OIL ..................................................................... 10 Assembly ................................................................ 49 J
Replacement .......................................................... 10 FINAL DRIVE ............................................................ 55
DRAINING ........................................................... 10 Pre-inspection ......................................................... 55
FILLING ............................................................... 10 DIFFERENTIAL CASE SIDE ............................... 55
Checking ................................................................ 10 K
Disassembly ........................................................... 55
OIL LEAKAGE AND OIL LEVEL ......................... 10 Inspection ............................................................... 56
SIDE OIL SEAL .........................................................11 GEAR, WASHER, SHAFT AND CASE ............... 56
Removal and Installation .........................................11 BEARING ............................................................ 56 L
POSITION SWITCH .................................................. 12 Assembly ................................................................ 56
Position Switch Check ............................................ 12 SHIFT CONTROL ..................................................... 59
BACK-UP LAMP SWITCH .................................. 12 Inspection ............................................................... 59 M
PNP SWITCH ...................................................... 12 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 60
CONTROL LINKAGE ............................................... 13 General Specifications ............................................ 60
Removal and Installation ........................................ 13 TRANSAXLE ....................................................... 60
TRANSAXLE GEAR CONTROL ......................... 13 FINAL GEAR ....................................................... 60
STRIKING ROD OIL SEAL ................................. 14 Gear End Play ........................................................ 61
TRANSAXLE ASSEMBLY ........................................ 15 Clearance Between Baulk Ring and Gear .............. 61
Removal and Installation ........................................ 15 3RD, 4TH, 5TH, REVERSE BAULK RING .......... 61
REMOVAL ........................................................... 15 1ST AND 2ND BAULK RING .............................. 61
INSTALLATION ................................................... 17 Available Snap Rings ............................................. 61
Component Parts ................................................... 18 SNAP RING ......................................................... 61
CASE COMPONENTS ........................................ 18 Available C-rings .................................................... 61
GEAR COMPONENTS ....................................... 19 4TH INPUT GEAR C-RING ................................. 61
SHIFT CONTROL COMPONENTS .................... 20 5TH INPUT GEAR REAR C-RING ...................... 62
FINAL DRIVE COMPONENTS ........................... 21 MAINSHAFT C-RING .......................................... 62
Disassembly and Assembly ................................... 21 Available Adjusting Shims ...................................... 62
DISASSEMBLY ................................................... 21 INPUT SHAFT REAR BEARING ADJUSTING
ASSEMBLY ......................................................... 28
MT-1
SHIM .................................................................... 62 Disassembly and Assembly ....................................85
MAINSHAFT ADJUSTING SHIM ........................ 63 DISASSEMBLY ....................................................85
MAINSHAFT REAR BEARING ADJUSTING ASSEMBLY ..........................................................89
SHIM .................................................................... 63 Adjustment ..............................................................96
Available Thrust Washer ......................................... 64 INPUTSHAFT END PLAY ....................................96
MAINSHAFT THRUST WASHER ........................ 64 DIFFERENTIAL SIDE BEARING PRELOAD .......97
Available Washers .................................................. 64 MAINSHAFT END PLAY ......................................98
DIFFERENTIAL SIDE GEAR THRUST WASHER REVERSE IDLER GEAR END PLAY ..................99
... 64 INPUT SHAFT AND GEARS ................................... 101
Available Shims — Differential Side Bearing Pre- Disassembly and Assembly .................................. 101
load and Adjusting Shim ......................................... 65 DISASSEMBLY .................................................. 101
BEARING PRELOAD .......................................... 65 INSPECTION AFTER DISASSEMBLY .............. 102
DIFFERENTIAL SIDE BEARING ADJUSTING ASSEMBLY ........................................................ 103
SHIMS ................................................................. 65 MAINSHAFT AND GEARS ..................................... 108
Disassembly and Assembly .................................. 108
RS6F51H DISASSEMBLY .................................................. 108
INSPECTION AFTER DISASSEMBLY .............. 109
PRECAUTIONS ......................................................... 66 ASSEMBLY ........................................................ 112
Caution ................................................................... 66 REVERSE IDLER SHAFT AND GEARS ................ 117
PREPARATION ......................................................... 67 Disassembly and Assembly .................................. 117
Special Service Tools ............................................. 67 DISASSEMBLY .................................................. 117
Commercial Service Tools ...................................... 69 INSPECTION AFTER DISASSEMBLY .............. 117
NOISE, VIBRATION, AND HARSHNESS (NVH) ASSEMBLY ........................................................ 118
TROUBLESHOOTING .............................................. 70 FINAL DRIVE .......................................................... 119
NVH Troubleshooting Chart .................................... 70 Disassembly and Assembly .................................. 119
DESCRIPTION .......................................................... 71 DISASSEMBLY .................................................. 119
Cross-sectional View .............................................. 71 INSPECTION AFTER DISASSEMBLY .............. 119
DOUBLE-CONE SYNCHRONIZER .................... 72 ASSEMBLY ........................................................ 119
TRIPLE-CONE SYNCHRONIZER ....................... 72 SHIFT CONTROL .................................................... 121
REVERSE GEAR ................................................ 72 Inspection .............................................................. 121
M/T OIL ...................................................................... 73 SHIFT FORK ...................................................... 121
Replacement .......................................................... 73 SERVICE DATA AND SPECIFICATIONS (SDS) .... 122
DRAINING ........................................................... 73 General Specifications .......................................... 122
FILLING ............................................................... 73 TRANSAXLE ...................................................... 122
Checking ................................................................. 73 FINAL GEAR ...................................................... 123
OIL LEAKAGE AND OIL LEVEL ......................... 73 Gear End Play ....................................................... 123
SIDE OIL SEAL ......................................................... 74 Clearance Between Baulk Ring and Gear ............ 123
Removal and Installation ........................................ 74 3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING.123
REMOVAL ........................................................... 74 1ST AND 2ND BAULK RING ............................. 124
INSTALLATION .................................................... 74 Available Snap Rings ............................................ 124
POSITION SWITCH .................................................. 75 6TH BUSHING ................................................... 124
Checking ................................................................. 75 Available C-rings ................................................... 124
BACK-UP LAMP SWITCH ................................... 75 MAINSHAFT C-RING ........................................ 124
PARK/NEUTRAL POSITION SWITCH ................ 75 Available Thrust Washers ..................................... 125
CONTROL LINKAGE ................................................ 76 INPUT SHAFT THRUST WASHER ................... 125
Removal and Installation of Control Device and Available Adjusting Shims ..................................... 125
Cable ...................................................................... 76 MAINSHAFT ADJUSTING SHIM ....................... 125
Cable Adjustment ................................................... 77 INPUT SHAFT REAR BEARING ADJUSTING
AIR BREATHER HOSE ............................................. 78 SHIM .................................................................. 125
Removal and Installation ........................................ 78 MAINSHAFT REAR BEARING ADJUSTING
TRANSAXLE ASSEMBLY ........................................ 79 SHIM .................................................................. 126
Removal and Installation ........................................ 79 REVERSE IDLER GEAR ADJUSTING SHIM .... 126
REMOVAL ........................................................... 79 6TH MAIN GEAR ADJUSTING SHIM ................ 126
INSTALLATION .................................................... 80 Available Shims – Differential Side Bearing Preload
Component Parts .................................................... 81 and Adjusting Shim(s) ........................................... 126
CASE AND HOUSING COMPONENTS .............. 81 BEARING PRELOAD ......................................... 126
GEAR COMPONENTS ........................................ 82 DIFFERENTIAL SIDE BEARING ADJUSTING
SHIFT CONTROL COMPONENTS ..................... 84 SHIM(S) ............................................................. 126
FINAL DRIVE COMPONENTS ............................ 85
MT-2
PRECAUTIONS
[RS5F70A]
PRECAUTIONS PFP:00001
A
Precautions ECS005TD
● Do not reuse transaxle oil, once it has been drained.

● Check oil level or replace oil with vehicle on level ground. B
● During removal or installation, keep inside of transaxle clear of dust or dirt.
● Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to. MT
● In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
● Be careful not to damage sliding surfaces and mating surfaces. D
MT-3
PREPARATION
[RS5F70A]
PREPARATION PFP:00002
Special Service Tools ECS005TE
The actual shapes of the Kent-Moore tools may differ from those of the special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name
KV38107700 Measuring turning torque of final drive assem-
(J39027) bly
Preload adapter Measuring total turning torque
Measuring clearance between side gear and
differential case with washer
Selecting differential side bearing adjusting
shim [Use with KV38106000 (J34291-B).]
NT087
KV38106000 Selecting differential side bearing adjusting

(J34291-B) shim [Use with KV38107700 (J39027).]
Height gauge adapter a: 140 mm (5.51 in)
(differential side bearing) b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 × 1.25P
NT418
KV32101000 Removing and installing retaining pin

(J25689-A) Removing and installing lock pin
Pin punch Removing selector shaft
Removing welch plug
a: 4 mm (0.16 in) dia.
NT410
KV31100300 Removing and installing retaining pin

(J25689-A) a: 4.5 mm (0.177 in) dia.
Pin punch
NT410
ST30031000 Removing 3rd, 5th input gear

(J22912-01) Removing 3rd & 4th and 5th & Rev synchro-
Puller nizer hub
Removing mainshaft rear bearing
Removing 2nd gear, 5th gear bush
Removing 1st & 2nd synchronizer hub, 1st
and 4th main gear
Removing and installing differential side bear-
ing
NT411
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000 Removing input shaft front and rear bearing
(J22912-01) Installing input shaft front and rear bearing
Puller Installing 5th input gear, 3rd main gear and
4th main gear
Installing 1st & 2nd, 3rd & 4th and 5th & Rev
synchronizer hub
Installing 2nd gear bush, 5th gear bush, Rev
gear bush
Installing mainshaft rear bearing
NT411
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
MT-4
PREPARATION
[RS5F70A]
Tool number
(Kent-Moore No.) Description A
Tool name
ST33061000 Removing differential side bearing
(J8107-2) a: 39 mm (1.54 in) dia. B
Drift b: 29.5 mm (1.16 in) dia.
MT
NT073
ST33290001 ● Removing idler gear bearing outer race D

(J34286) a: 250 mm (9.84 in)
Puller b: 160 mm (6.30 in)
NT414
ST33230000 Removing differential oil seal

F
(J25805-01) Installing differential side bearing
Drift a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia. G
NT084 H
ST30720000 Installing differential side bearing outer race
(J25405) a: 77 mm (3.03 in) dia.
Drift b: 55.5 mm (2.185 in) dia.
I
J
NT115
ST22350000 Installing input shaft front and rear bearing

(J25678-01) a: 34 mm (1.34 in) dia.
Drift b: 28 mm (1.10 in) dia. K
L
NT065
ST22452000 Installing 3rd and 4th main gear

(J34335) Installing 5th gear bush M
Drift Installing 5th & Rev synchronizer hub
Installing Rev gear bush
Installing mainshaft rear bearing
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
NT065
ST37750000 Installing input shaft oil seal

(J34335) Installing 5th synchronizer
Drift Installing mainshaft rear bearing
Installing 5th main gear
Installing 3rd & 4th synchronizer hub
Installing striking rod oil seal
Installing clutch housing dust seal
a: 40 mm (1.57 in) dia.
NT065
b: 31 mm (1.22 in) dia.
MT-5
PREPARATION
[RS5F70A]
Tool number
Tool name
(J35869) [Use with ST30611000 (J25742-1).]
b: 59 mm (2.32 in) dia.
NT073

(J25742-1) [Use with ST30621000 (J35869).]
Drift handle a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 in) dia.
d: M12 × 1.5P
NT419
Commercial Service Tools ECS005TF
Tool name Description

Drift Installing differential side bearing inner race
a: 56 mm (2.20 in) dia.
b: 50.5 mm (1.988 in) dia.
NT065
Drift Removing input shaft rear bearing

Removing mainshaft rear bearing
a: 22 mm (0.87 in) dia.
b: 16 mm (0.63 in) dia.
NT065
Drift Installing differential oil seal

(Transaxle case side)
a: 58 mm (2.28 in) dia.
b: 50 mm (1.97 in) dia.
NT065
Drift Installing differential oil seal

(Clutch housing side)
a: 54 mm (2.13 in) dia.
b: 50 mm (1.97 in) dia.
NT065
Drift Installing 2nd gear bush

a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
NT065
MT-6
PREPARATION
[RS5F70A]
A
Drift Installing 3rd & 4th and 1st & 2nd synchroniz-
er hub
Installing mainshaft front bearing
a: 50 mm (1.97 in) dia. B
b: 41 mm (1.61 in) dia.
NT065 MT
Drift Installing input shaft oil seal
Installing 5th input gear
a: 39 mm (1.54 in) dia. D
b: 30 mm (1.18 in) dia.
E
NT065
MT-7
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[RS5F70A]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart ECS005TG
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.
MT-19, MT-21
MT-10
MT-10
MT-10
MT-18
MT-13
MT-20
Reference page
Check Plug Return Spring and Check Ball (Worn or damaged)
Insert Spring, Shifting Insert (Damaged)

Suspected Parts (Possible cause)
Baulk Ring (Worn or damaged)

Oil Seal (Worn or damaged)
Bearing (Worn or damaged)

O-Ring (Worn or damaged)
Gear (Worn or damaged)

Control Rod (Worn)
Gasket (Damaged)
Shift Fork (Worn)

(Oil level is high)
(Oil level is low)
(Wrong oil)
Noise 1 2 3 3
Oil leakage 3 1 2 2 2
Symptom
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3
MT-8
DESCRIPTION
[RS5F70A]
DESCRIPTION PFP:00000
A
Cross-sectional View ECS005TH
MT
WCIA0017E
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is used for 1st and 2nd gears to reduce
operating force of the shift lever.
SMT837DA
MT-9
M/T OIL
[RS5F70A]
M/T OIL PFP:KLD20
Replacement ECS005TI
DRAINING
1. Start the engine and let it run to warm up the transaxle.
2. Stop the engine. Remove drain plug and drain oil.
3. Set a gasket on the drain plug and install it on the transaxle.
Drain plug : 10 - 19 N·m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
CAUTION:
Do not reuse gasket.
SMA145AA
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the
specified limit near filler plug mounting hole as shown.
Oil grade : API GL-4, Viscosity SAE 75W-85
Capacity : 3.0 (3 1/8 US qt, 2 5/8 Imp qt)
(approximately)
2. After refilling oil, check oil level as shown.
3. Install the filler plug in the transaxle case using a new gasket.
Filler plug : 10 - 19 N·m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
SMA066C
CAUTION:
Checking ECS005TJ
OIL LEAKAGE AND OIL LEVEL

1. Check that oil is not leaking from transaxle.
2. Check oil level from filler plug mounting hole as shown.
CAUTION:
Never start the engine while checking the oil level.
3.
Install the filler plug in the transaxle case using a new gasket.
Filler plug : 10 - 19 N·m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
CAUTION:
SMA066C
MT-10
SIDE OIL SEAL
[RS5F70A]
SIDE OIL SEAL PFP:32113
A
Removal and Installation ECS005TK
1. Remove drain plug and drain the oil from transaxle. Refer to MT-10, "DRAINING" .
2. Remove drive shafts. Refer to FAX-14, "Removal" . B
3. Remove differential oil seal using Tool.
MT
E
SMT563A
4. Install differential oil seal with a suitable tool (drift). F

● Apply multi-purpose grease to seal lip of oil seal before install-
ing.
G
SMT126DB I
5. Install drive shafts. Refer to FAX-16, "Installation" .

● Install differential oil seal so that dimensions “A” and “B” are
J
within specifications.
Unit: mm (in)
Model Dimension “A” Dimension “B” K
QG18DE
0.5 (0.020) or less 5.5 - 6.5 (0.217 - 0.256)
(RS5F70A)
L
WCIA0001E
M
6. Refill the transaxle oil and install the drain plug using a new gasket. Refer to MT-10, "FILLING" .
MT-11
POSITION SWITCH
[RS5F70A]
POSITION SWITCH PFP:32005
Position Switch Check ECS005TL
NOTE:
For removal and installation of the switches. Refer to MT-18, "CASE COMPONENTS" .
BACK-UP LAMP SWITCH
● Check continuity.
Gear position Continuity
Reverse Yes
Except reverse No
SMT715BD
PNP SWITCH
Neutral Yes
Except neutral No
MT-12
CONTROL LINKAGE
[RS5F70A]
CONTROL LINKAGE PFP:34103
A
Removal and Installation ECS005TM
TRANSAXLE GEAR CONTROL

Refer to the illustration for the removal and installation procedure. B
MT
WCIA0135E
1. Control lever knob 2. Boot 3. Finisher

4. Control lever bracket 5. Socket 6. Control lever
7. O-ring 8. O-ring 9. Ring spring
10. Bearing seat 11. Ring spring 12. Seat
13. Return spring 14. Control rod 15. Bushing
16. Collar 17. Bushing 18. Bracket
19. Bushing 20. Collar 21. Washer
22. Support rod bracket 23. Support rod
MT-13
CONTROL LINKAGE
[RS5F70A]
STRIKING ROD OIL SEAL
1. Remove the transaxle control rod from yoke.
2. Remove the retaining pin from the yoke using Tool as shown.
CAUTION:
Be careful not to damage the boot.
SMT143DB
3. Remove the boot.

4. Remove the striking rod oil seal with a suitable tool (drift).
SMT566A
5. Install the striking rod oil seal using Tool as shown.

● Apply multi-purpose grease to the seal lip of the oil seal
before installing.
SMT570AA
6. Install the boot.

7. Install the yoke and retaining pin.
8. Connect the transaxle control rod to the yoke.
MT-14
TRANSAXLE ASSEMBLY
[RS5F70A]
TRANSAXLE ASSEMBLY PFP:32010
A
Removal and Installation ECS005TN
MT
WMT009
G
REMOVAL
1. Disconnect the negative battery terminal. H
2. Remove the air cleaner and air duct. Refer to EM-13, "Removal
and Installation" .
I
K
WMT010
3. Disconnect the clutch operating cylinder from the transaxle and L

position aside. Refer to CL-11, "Removal" .
WCIA0006E
4. Disconnect back-up lamp switch, VSS sensor, PNP switch, and ground harness connectors.
5. Remove the starter motor. Refer to SC-20, "Removal" .
MT-15
TRANSAXLE ASSEMBLY
[RS5F70A]
6. Remove the air breather hose.
SMT132D
7. Remove the shift control rod and support rod from transaxle.
WMT005
8. Remove the drain plug and drain the gear oil from the transaxle.
SMA145AA
9. Remove the drive shafts from the transaxle. Refer to FAX-14, "Removal" .
10. Support the engine by placing a jack under the oil pan as shown.
CAUTION:
Do not place the jack under the oil pan drain plug.
SMT659B
MT-16
TRANSAXLE ASSEMBLY
[RS5F70A]
11. Remove LH side and rear side mounting bolts.
A
MT
G
WMT007
12. Remove the lower housing bolts.

H
SMT658B
K
13. Remove the bolts securing the transaxle to the engine.
14. Lower the transaxle while supporting it with the jack.
L
INSTALLATION
Installation is in the reverse order of removal.
● Tighten the starter motor bolts to specification. M
Starter motor bolts : 31 - 42 N·m (3.2 - 4.3 kg-m, 23 - 31 ft-lb)
● Tighten the LH and rear mounts to specification. Refer to MT-15, "Removal and Installation" .
● Tighten the transaxle to engine bolts to specification.
Tightening torque
Bolt No. " " mm (in)
N·m (kg-m, ft-lb)
1 30 - 40 (3.1 - 4.1, 22 - 30) 70 (2.76)
2 30 - 40 (3.1 - 4.1, 22 - 30) 80 (3.15)
3 30 - 40 (3.1 - 4.1, 22 - 30) 30 (1.18)
4* 16 - 21 (1.6 - 2.1, 12 - 15) 25 (0.98)
Front gusset A to engine 30 - 40 (3.1 - 4.1, 22 - 30) 20 (0.79)
SMT930D
Rear gusset B to engine 16 - 21 (1.6 - 2.1, 12 - 15) 16 (0.63)
*: With gussets
MT-17
TRANSAXLE ASSEMBLY
[RS5F70A]
Component Parts ECS005TO
CASE COMPONENTS
WMT014
1. Clutch housing 2. Dust seal 3. Oil pocket

4. Check plug 5. Input shaft oil seal 6. Oil channel
7. Mainshaft front bearing 8. Bearing retainer 9. Reverse idler gear front thrust washer
10. Reverse idler gear 11. Reverse idler gear bearing 12. Reverse idler gear rear thrust washer
13. O-ring 14. Reverse idler gear shaft 15. Snap ring
16. Back-up lamp switch 17. Filler plug 18. Side cover gasket
19. Side cover 20. Welch plug 21. Mainshaft bearing snap ring
22. Mainshaft rear bearing adjusting shim 23. O-ring 24. Rear cover
25. Differential oil seal 26. Drain plug 27. PNP switch
28. Transmission case 29. Oil gutter 30. Welch plug
31. Boot 32. Striking rod oil seal 33. Welch plug
34. Differential oil seal 35. O-ring 36. Speedometer pinion
MT-18
TRANSAXLE ASSEMBLY
[RS5F70A]
GEAR COMPONENTS
A
MT
SMT641DA
I
1. Reverse idler gear front thrust washer 2. Reverse idler gear 3. Reverse idler gear bearing
4. Reverse idler gear rear thrust washer 5. O-ring 6. Reverse idler gear shaft
7. Snap ring 8. Input shaft front bearing 9. Input shaft J
10. 3rd gear needle bearing 11. 3rd input gear 12. 3rd gear baulk ring
13. Coupling sleeve 14. Spread spring 15. Shifting insert
16. 3rd & 4th synchronizer hub 17. Spread spring 18. 4th gear C-ring
K
19. 4th gear needle bearing 20. 4th gear baulk ring 21. 4th input gear
22. 5th gear front C-ring 23. 5th input gear 24. 5th gear rear C-ring
L
25. C-ring holder 26. Input shaft rear bearing 27. Oil channel
28. Input shaft rear bearing adjusting shim 29. Mainshaft front bearing 30. Mainshaft
31. 1st gear needle bearing 32. 1st main gear 33. 1st inner baulk ring
M
34. 1st synchronizer cone 35. 1st outer baulk ring 36. 1st & 2nd synchronizer hub
37. Coupling sleeve 38. Insert spring 39. 2nd gear bushing
40. 2nd gear needle bearing 41. 2nd gear outer baulk ring 42. 2nd gear synchronizer cone
43. 2nd inner baulk ring 44. 2nd main gear 45. 3rd main gear
46. Spacer 47. Mainshaft adjusting shim 48. 4th main gear
49. 5th gear bushing 50. 5th gear needle bearing 51. 5th main gear
52. 5th gear baulk ring 53. Spread spring 54. Shifting insert
55. 5th & reverse synchronizer hub 56. Spread spring 57. Coupling sleeve
58. Reverse gear bushing 59. Reverse gear needle bearing 60. Reverse gear baulk ring
61. Reverse main gear 62. Sub-gear 63. Sub-gear washer
64. Snap ring 65. Mainshaft thrust washer 66. Mainshaft rear bearing
67. Mainshaft C-ring 68. C-ring holder 69. Snap ring
MT-19
TRANSAXLE ASSEMBLY
[RS5F70A]
SHIFT CONTROL COMPONENTS
WMT015
1. Clutch housing 2. 3rd & 4th bracket 3. 3rd & 4th shift fork
4. Retaining pin 5. Check ball 6. Check pin
7. Check spring 8. Check plug 9. Stopper ring
10. 3rd & 4th fork rod 11. Selector shaft pin 12. Selector
13. 5th & reverse bracket 14. Reverse switch bracket 15. Retaining pin
16. 5th & reverse shift fork 17. Interlock plunger 18. Check ball
19. Interlock pin 20. Stopper ring 21. 5th & reverse fork rod
22. Striking lever 23. Retaining pin 24. 1st & 2nd bracket
25. 1st & 2nd shift fork 26. Check ball 27. 1st & 2nd fork rod
28. Transaxle case 29. Check ball 30. Check spring
31. Check plug 32. Select check leaf spring 33. Return spring
34. Steel ball 35. Reverse gate 36. Return bearing
37. Selector arm 38. Bushing 39. Welch plug
40. Selector shaft 41. Striking yoke 42. Retaining pin
43. Striking rod 44. Dust boot 45. Striking rod oil seal
46. Welch plug
MT-20
TRANSAXLE ASSEMBLY
[RS5F70A]
FINAL DRIVE COMPONENTS
A
MT
J
WCIA0003E
1. Differential side bearing adjusting shim 2. Differential side bearing outer race 3. Differential side bearing
4. Final gear 5. Differential case 6. Speedometer drive gear K
7. Speedometer stopper 8. Differential side bearing 9. Differential side bearing outer race
10. Pinion mate thrust washer 11. Pinion mate gear 12. Side gear thrust washer
13. Side gear 14. Pinion mate shaft 15. Lock pin L
Disassembly and Assembly ECS005TP
DISASSEMBLY
M
Transaxle Case
1. Remove the back-up lamp switch, PNP switch, drain plug, and
filler plug from the transaxle case.
WMT023
MT-21
TRANSAXLE ASSEMBLY
[RS5F70A]
2. Remove snap ring from reverse idler shaft as shown.
3. Remove side cover and rear cover from case.
SMT644D
4. Remove O-ring and mainshaft bearing adjusting shim.

5. Remove reverse idler gear shaft.
a. Attach bolt (M6) to thread of reverse idler gear shaft end as
shown.
b. Pull out the attached bolt (M6), and remove reverse idler gear
shaft from case.
SMT645D
6. Remove reverse idler gear, thrust washer (front and rear), and bearing from case.
7. Remove mainshaft rear bearing snap ring from case.
SMT646D
8. Remove check plugs, springs, and check balls from case.
SMT647D
MT-22
TRANSAXLE ASSEMBLY
[RS5F70A]
9. Remove transaxle case mounting bolts.
A
MT
SMT649D
D
10. Remove input shaft rear bearing adjusting shim from transaxle case.
11. Remove oil gutter from transaxle case.
E
SMT650D
H
12. Remove differential side bearing outer race and adjusting shim
from transaxle case using Tool.
I
K
SMT651DA
13. Remove differential oil seal from transaxle case using Tool.
L
SMT653DA
MT-23
TRANSAXLE ASSEMBLY
[RS5F70A]
14. Remove welch plugs from transaxle case using Tool.
SMT839DA
Clutch Housing
1. Remove transaxle case from the clutch housing.
2. Remove check plugs, check springs, check pins, and check
balls from the clutch housing.
SMT654D
3. Remove 3rd & 4th bracket retaining pin using Tool.
SMT656DA
4. Remove 3rd & 4th shift fork stopper ring.

5. Remove 3rd & 4th fork rod.
6. Remove 3rd & 4th shift fork and bracket.
SMT655D
MT-24
TRANSAXLE ASSEMBLY
[RS5F70A]
7. Remove interlock plunger and check ball.
8. Remove 5th & reverse bracket stopper ring. A
MT
SMT658D
D
9. Remove retaining pins from 5th & reverse shift fork and 5th &
reverse bracket using Tool.
10. Remove 5th & reverse fork rod. E
11. Remove interlock pin from 5th & reverse fork rod using Tool.
12. Remove reverse switch bracket and 5th & reverse bracket.
F
G
SMT657DA
13. Remove check ball from housing.

H
14. Remove retaining pin for 1st & 2nd shift fork and 1st & 2nd
bracket using Tool.
15. Remove 1st & 2nd fork rod. I
16. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd
bracket.
J
SMT659DA
K
17. Remove both input shaft and mainshaft assemblies from hous-
ing.
L
SMT660D
18. Remove final drive assembly from housing.

19. Remove oil pocket from housing.
SMT661D
MT-25
TRANSAXLE ASSEMBLY
[RS5F70A]
20. Remove mainshaft bearing retainer from housing.
21. Cut off oil channel using a cutter as shown.
SMT662D
22. Remove mainshaft front bearing from housing using Tool.
SMT663DA
23. Using a magnet or other suitable tool, remove selector pin from
selector shaft.
SMT664D
24. Remove selector shaft and plug, then remove selector using
Tool.
SMT665DA
25. Remove reamer bolts, then remove select check leaf spring,
return spring, steel ball, reverse gate, selector arm, bearing, and
bushing.
CAUTION:
Be careful not to lose the steel ball.
SMT666DA
MT-26
TRANSAXLE ASSEMBLY
[RS5F70A]
26. Remove retaining pin and plug from striking lever using Tool.
27. Remove striking rod, then striking lever from housing. A
MT
SMT667DA
D
28. Using a flat-head screwdriver or other suitable tool, remove dust
seal, input shaft oil seal, and striking rod oil seal from housing.
CAUTION: E
When removing dust and oil seals, be careful not to damage
mounting surfaces of dust seal and oil seal.
F
G
SMT668D
29. Remove differential oil seal from housing using Tool. H
WMT021 K
30. Remove differential side outer race from housing using Tool.
L
SMT670DA
MT-27
TRANSAXLE ASSEMBLY
[RS5F70A]
ASSEMBLY
Clutch Housing
1. Hammer the new striking rod oil seal into clutch housing as far
as it will go using Tool.
CAUTION:
Do not reuse striking rod oil seal.
SMT722DA
2. Hammer the differential oil seal into clutch housing with a suit-
able tool until it becomes flush with clutch housing end face.
CAUTION:
Do not reuse differential oil seal.
SMT723DA
3. Hammer input shaft oil seal into clutch housing as far as it will go
with a suitable tool.
CAUTION:
Do not reuse input shaft oil seal.
SMT724DA
4. Hammer the dust seal into clutch housing as far as it will go

using Tool.
CAUTION:
Do not reuse dust seal.
SMT725DA
MT-28
TRANSAXLE ASSEMBLY
[RS5F70A]
5. Install outer race of differential side bearing using Tool.
A
MT
SMT726DA
D
6. Install new oil channel (mainshaft).
CAUTION:
Pay attention to installation direction of oil channel. E
G
SMT727D
7. Align the notches on mainshaft front bearing and transaxle case.

H
Then, install mainshaft front bearing with a suitable tool.
SMT728DA
K
8. Install mainshaft bearing retainer, tighten bolt to specification.
SMT729D
9. Attach boot, striking rod, and striking lever to clutch housing.

Install new retaining pin for striking lever using Tool.
CAUTION:
● Before installing striking rod, wrap the end with a vinyl
tape or similar product to prevent oil seal from being
damaged.
● Do not reuse retaining pin.
SMT667DA
MT-29
TRANSAXLE ASSEMBLY
[RS5F70A]
10. Hammer the new welch plug (striking lever side) with a general-
purpose drift [OD: 12 mm (0.47 in)].
CAUTION:
Do not reuse welch plug.
SMT730D
11. Install selector, selector shaft, and selector shaft pin into clutch
housing.
SMT731D
12. Hammer the new welch plug (selector shaft side) with a general-
purpose drift [OD: 12 mm (0.47 in)].
CAUTION:
Do not reuse welch plug.
SMT732D
13. Install select check leaf spring, return spring, steel ball, reverse
gate, selector arm, bushing, and return bearing.
SMT733DA
14. Tighten the two reamer bolts to specification.

CAUTION:
Use correct reamer bolts for each installation point,
because each bolt has a different length.
SMT734D
MT-30
TRANSAXLE ASSEMBLY
[RS5F70A]
15. Install oil pocket.
A
MT
SMT735D
D
16. Install differential assembly, input shaft assembly, and mainshaft
assembly into clutch housing.
CAUTION: E
Be careful not to damage input shaft oil seal during installa-
tion of input shaft assembly.
F
G
SMT736D
17. Install 5th & reverse shift fork. H

18. Install 1st & 2nd shift fork, bracket, and fork rod.
19. Install retaining pin for 1st & 2nd bracket using Tool.
CAUTION: I
Do not reuse retaining pin.
20. Install two check balls.
J
SMT659DB
L
21. Install interlock pin into 5th & reverse fork rod using Tool.
22. Install reverse switch bracket, 5th & reverse bracket, and fork
rod. M
23. Install new retaining pin for 5th & reverse shift fork and reverse
switch bracket using Tool.
CAUTION:
SMT657DB
24. Install 5th & reverse bracket stopper ring.

CAUTION:
Do not reuse stopper pin.
25. Install check ball and interlock plunger.
MT-31
TRANSAXLE ASSEMBLY
[RS5F70A]
26. Install 3rd & 4th shift fork, bracket, and fork rod.
27. Install 3rd & 4th bracket retaining pin using Tool.
CAUTION:
SMT656DB
28. Install 3rd & 4th shift fork stopper ring.

CAUTION:
Do not reuse stopper ring.
29. Install check ball, check pin, and check spring, and apply Anaer-
obic Liquid Gasket or equivalent onto the check plug. Then,
tighten the check plug to specification.
Refer to MT-20, "SHIFT CONTROL COMPONENTS" .
SMT655D
Transaxle Case
1. Insert differential oil seal into differential case with a suitable tool
until it becomes flush with case end face.
SMT737DA
2. Install welch plug into transaxle case with a suitable tool.
SMT739D
MT-32
TRANSAXLE ASSEMBLY
[RS5F70A]
3. Calculate dimension “N” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for differ- A
ential side bearing.
End play : 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension “N” = (“N1 ” – “N2 ”) + End play B
“N” : Thickness of adjusting shim
“N1 ” : Distance between clutch housing case
MT
end face and mounting face of adjusting
shim
SMT740D
“N2 ” : Distance between differential side bearing
D
and transaxle case
Use the “Available Shims” table for the available shim sizes. Refer to MT-65, "Available Shims — Differen-
tial Side Bearing Preload and Adjusting Shim" . E
a. Using dial gauge and scale, measure dimension “N1 ” between

clutch housing case end face and mounting face of adjusting F
shim.
b. Install outer race onto differential side bearing on final gear side.
Holding the outer race horizontally by hand, rotate the final gear
five times or more (for smooth movement of bearing roller). G
SMT741D
I
c. Using dial gauge and scale as shown, measure dimension “N2 ”
between differential side bearing outer race and transaxle case
end face.
J
L
SMT742D
4. Install the selected shim and bearing outer race using Tool.
M
SMT738DA
MT-33
TRANSAXLE ASSEMBLY
[RS5F70A]
5. Measure the turning torque of the final drive assembly using
Tool.
Turning torque of : 2.9 - 6.9 N-m (30 - 70 kg-cm,
final drive assembly 26 - 61 in-lb)
(New bearing)
● When the old bearing is used again, turning torque will be
slightly less than the above.
● Make sure turning torque is close to the specified range.
● Changes in turning torque of final drive assembly per revolu-
tion should be within 1.0 N-m (10 kg-cm, 8.7 in-lb) without SMT600-E
binding.
6. Calculate dimension “O” (thickness of adjusting shim) using the

following procedure to satisfy specification of end play for input
shaft rear bearing.
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension “O” = (“O1 ” – “O2 ”) + End play
“O” : Thickness of adjusting shim
“O1 ” : Distance between transaxle case
end face and mounting face of
adjusting shim
SMT743D
“O2 ” : Distance between clutch housing
case end face and end face of
input shaft rear bearing
Use the “Available Shims” table for the available shim sizes. Refer to MT-62, "Available Adjusting Shims" .
a. Using block gauge, scale, and dial gauge, measure dimension

“O1 ” between transaxle case end face and mounting face of
adjusting shim.
SMT744D
b. Using block gauge, scale, and dial gauge as shown in the figure,
measure dimension “O2 ” between clutch housing case end face
and end face of input shaft rear bearing.
SMT745D
7. Install selected input shaft rear bearing adjusting shim onto input shaft.
MT-34
TRANSAXLE ASSEMBLY
[RS5F70A]
8. Install oil gutter into transaxle case.
A
MT
SMT650D
D
9. Clean mating surfaces of clutch housing and transaxle case.
Check for cracks and damage, then apply sealant. Use Genuine
Anaerobic Liquid Gasket or equivalent. Refer to GI-45, "Recom-
E
mended Chemical Products and Sealants" .
G
SMT802D
10. Install transaxle case onto clutch housing, and tighten mounting
H
bolts with specified torque.
Transaxle case mounting : Refer to MT-18, "CASE
bolts COMPONENTS" . I
SMT649D
K
11. Apply sealant to threads of back-up lamp switch, PNP switch,
and drain plug, then install them. Use Genuine Anaerobic Liquid
Gasket or equivalent. Refer to GI-45, "Recommended Chemical L
Products and Sealants" .
NOTE:
Fill the case with oil before installation of the filler plug. M
WMT023
12. Install speedometer pinion assembly.

CAUTION:
Do not reuse O-ring.
MT-35
TRANSAXLE ASSEMBLY
[RS5F70A]
13. Install check springs and check balls. Apply sealant to the
thread on the check plug, and install it.
SMT749D
14. Calculate thickness “P” of the adjusting shim using the following
procedure to satisfy the specification of the end play for the
mainshaft rear bearing.
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension “P” = (“P1 ” – “P2 ”) + End play
“P” : Thickness of adjusting shim
“P1 ” : Distance between transaxle case
end face and mainshaft rear bearing
“P2 ” : Distance between adjusting shim
SMT746D
end face of rear cover and transaxle
mounting face
Use the "Available Shims" table for the available shim sizes. Refer to MT-62, "Available Adjusting Shims" .
a. Using a dial gauge as shown, measure dimension “P1 ” between

the transaxle case end face and the mainshaft rear bearing.
SMT747D
b. Using a dial gauge as shown, measure dimension “P2 ” between

the adjusting shim mounting face of rear cover and the transaxle
mounting face.
SMT748D
MT-36
TRANSAXLE ASSEMBLY
[RS5F70A]
15. Using snap ring pliers and flat-head screwdriver as shown,
install snap ring. A
CAUTION:
Do not reuse snap ring.
B
MT
SMT646D
D
16. Install selected mainshaft adjusting shim.
17. Install reverse idler gear, O-ring, thrust washers (front and rear),
and bearing onto reverse idler shaft. E
SMT753DA
H
18. Install snap ring into transaxle case using snap ring pliers.
CAUTION:
● Do not reuse snap ring.
I
● Do not reuse O-ring.
● Before installation, apply gear oil to O-ring.
19. Using feeler gauge, measure the end play of snap ring, and J
select a snap ring suitable to meet the specified end play.
End play : 0.05 - 0.25 mm (0.0020 - 0.0098 in)
Use the "Available Shims" table for the available shim sizes. K
Refer to MT-61, "Available Snap Rings" .
SMT754D M
20. Install selected snap ring with a suitable tool.

CAUTION:
Do not reuse snap ring.
21. Apply gear oil to rear cover O-ring, and install rear cover, side
cover gasket, and side cover. Then tighten mounting bolts with
specified torque.
Use the "Available Shims" table for the available shim sizes.
Refer to MT-18, "CASE COMPONENTS" .
CAUTION:
Do not reuse mounting bolts for rear cover and side cover.
SMT644D
MT-37
INPUT SHAFT AND GEARS
[RS5F70A]
INPUT SHAFT AND GEARS PFP:32200
Disassembly ECS005TQ
1. Before disassembly, measure the end plays of 3rd and 4th input
gears with a suitable tool. Refer to MT-61, "Gear End Play" .
● If end play is not within specification, disassemble and check
the parts.
SMT759D
2. Remove oil channel from input shaft rear bearing.
SMT671D
3. Press out input shaft rear bearing using Tool.
SMT672DA
4. Remove C-ring holder.

5. Remove 5th gear rear C-ring.
SMT673D
MT-38
[RS5F70A]
6. Remove 5th input gear from input shaft using Tool.
7. Remove 5th gear front C-ring. A
MT
SMT674DA
D
8. Remove 4th input gear, baulk ring, 4th gear needle bearing, and
4th gear C-ring from input shaft.
9. Press out both 3rd & 4th synchronizer hub assembly and 3rd E
input gear from input shaft using Tool.
10. Remove 3rd gear needle bearing.
F
G
SMT675DA
11. Press out input shaft front bearing from input shaft using Tool. H
K
SMT676DA
Inspection ECS005TR
GEAR AND SHAFT L

● Check shaft for cracks, wear or bending.
● Check gears for excessive wear, chips or cracks.
M
SMT693D
MT-39
[RS5F70A]
SYNCHRONIZERS
● Check spline area of coupling sleeves, hubs and gears for wear
or cracks.
● Check baulk rings for cracks or deformation.
● Check insert springs for wear or deformation.
SMT637A
● If any crack, damage, or excessive wear is found on cam face of

baulk ring or working face of insert, replace it.
SMT867D
● Measure the movement (free play in dimension “L”) of 3rd & 4th
coupling sleeve with the end fixed and the other end lifted as
shown in the figure. If the movement exceeds specification,
replace the sleeve.
Coupling sleeve Dimension “L”
3rd & 4th 0 - 0.95 mm (0 - 0.0374 in)
SMT841D
● Measure clearance between baulk ring and gear. Refer to MT-

61, "Clearance Between Baulk Ring and Gear" .
SMT140
MT-40
[RS5F70A]
BEARING
Make sure bearings roll freely and are free from noise, cracks, pitting A
or wear.
MT
SMT148A
D
Assembly ECS005TS
1. Press on input shaft front bearing using Tool. E
SMT696DA H
2. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring bearing to input shaft.
3. Install spread spring, shifting insert, and 3rd & 4th synchronizer I
hub onto 3rd & 4th coupling sleeve.
● Pay attention to the shape of spread spring and shifting insert
for correct assembly. J
Do not install spread spring hook onto the same shifting
insert.
CAUTION:
Do not reuse 3rd & 4th synchronizer hub. K
SMT694D L
● Install synchronizer hub with its three grooves facing the front
side (3rd input gear side). M
SMT695D
MT-41
[RS5F70A]
● Install 3rd & 4th coupling sleeve with its chamfered surface
facing the 4th input gear side.
SMT699D
4. Position bearing replacer to the front side of input shaft front

bearing.
● Align grooves of shifting insert and 3rd gear baulk ring. Then,
press it onto 3rd & 4th synchronizer hub assembly using a
drift.
SMT698DA
5. Install 4th gear C-ring onto input shaft using Tool.

6. Measure the end play of 3rd & 4th synchronizer hub with a suit-
able tool, and check if it is within allowable specification.
End play : 0 - 0.06 mm (0 - 0.0024 in)
7. If not within specification, adjust the end play by changing thick-
ness of 4th (input) gear C-ring. Refer to MT-61, "Available C-
rings" .
SMT700D
8. Install 4th gear needle bearing, 4th gear baulk ring, and 5th gear
front C-ring.
SMT701DA
9. Install 4th input gear using Tool.
MT-42
[RS5F70A]
10. Position 5th input gear as shown, to install it on input shaft.
A
MT
SMT703D
D
11. Install 5th input gear using Tool as shown.
CAUTION:
Do not reuse 5th input gear. E
G
SMT702DA
12. Install 5th gear rear C-ring onto input shaft using Tool.
H
13. Measure the end play of 5th input gear with a suitable tool, and
check if it is within the allowable specification below.
End play : 0 - 0.06 mm (0 - 0.0024 in) I
K
SMT704D
14. If not within specification, adjust the end play by changing thickness of the 5th (input gear) rear C-ring.
Refer to MT-61, "Available C-rings" . L
15. Install C-ring holder onto 5th gear rear C-ring using Tool.
CAUTION:
Do not reuse C-ring holder. M
16. Install input shaft rear bearing using Tool.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the input gear side.
SMT705DA
MT-43
[RS5F70A]
17. Install oil channel onto input shaft.
SMT671D
18. Measure gear end play as a final check. Refer to MT-61, "Gear End Play" .
MT-44
MAINSHAFT AND GEARS
[RS5F70A]
MAINSHAFT AND GEARS PFP:32241
A
Disassembly ECS005TT
1. Before disassembly, measure gear end play with a suitable tool.

Refer to MT-61, "Gear End Play" . B
● If end play is not within the specified limit, disassemble and
check the parts.
MT
SMT760D
E
2. Remove snap ring with a suitable tool.
H
SMT677D
3. Remove C-ring holder and mainshaft C-ring.

I
SMT678D
L
4. Press out mainshaft rear bearing from mainshaft using Tool.
SMT679DA
MT-45
MAINSHAFT AND GEARS
[RS5F70A]
5. Remove mainshaft thrust washer.
SMT680D
6. Remove snap ring from mainshaft. Then, remove reverse main gear assembly, reverse gear needle bear-
ing, and reverse gear baulk ring.
7. Place bearing replacer between 5th & reverse synchronizer hub
and 5th main gear, and press out both reverse gear bushing and
5th & reverse synchronizer assembly using Tool.
WMT024
8. Remove 5th main gear, 5th gear baulk ring, and 5th gear needle bearing.
9. Place bearing replacer between 3rd and 4th main gears, and
press out both 5th gear bushing and 4th main gear using Tool.
WMT025
10. Remove mainshaft adjusting shim and spacer.
SMT683D
11. Place bearing replacer between 2nd main gear and 1st & 2nd synchronizer hub, and press out both 3rd
and 2nd main gears.
12. Remove 2nd double cone assembly, 2nd gear bushing, and coupling sleeve assembly.
MT-46
MAINSHAFT AND GEARS
[RS5F70A]
13. Place bearing replacer on 1st gear front side, and press out all
of 2nd gear bushing, 1st & 2nd synchronizer hub, 1st main gear, A
and 1st double cone using Tool.
MT
WMT026
D
14. Remove 1st gear needle bearing.
Inspection ECS005TU
GEAR AND SHAFT E

● Check shaft for cracks, wear or bending.
● Check gears for excessive wear, chips or cracks.
F
H
SMT693D
SYNCHRONIZERS I
● Check spline area of coupling sleeves, hubs and gears for wear
or cracks.
● Check baulk rings for cracks or deformation. J
● Check insert springs for wear or deformation.
L
SMT637A
● If any crack, damage, or excessive wear is found on cam face of M

SMT867D
MT-47
MAINSHAFT AND GEARS
[RS5F70A]
● Measure the movement (play, dimension “L”) of 1st & 2nd cou-
pling sleeve and 5th & reverse coupling sleeve with their end
fixed and the other end lifted as shown in the figure. If the move-
ment exceeds specification, replace the sleeve.
Coupling sleeve Length “L”
1st & 2nd 0 - 0.68 mm (0 - 0.0268 in)
5th & Reverse 0 - 0.89 mm (0 - 0.0350 in)
SMT868D
● Measure clearance between baulk ring and gear. Refer to MT-

61, "Clearance Between Baulk Ring and Gear" .
SMT140
BEARING
● Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT148A
● Measure wear of inner and outer baulk ring as shown.
WMT017
– Place baulk rings in position on synchronizer cone.

– While holding baulk ring against synchronizer cone as far as it will go, measure dimensions “A” and “B”
using Tool.
Standard
“A” : 0.6 - 0.8 mm (0.024 - 0.031 in)
“B” : 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit : 0.2 mm (0.008 in)
MT-48
MAINSHAFT AND GEARS
[RS5F70A]
● If dimension “A” or “B” is smaller than the wear limit, replace outer baulk ring, inner baulk ring and syn-
chronizer cone as a set. A
Assembly ECS005TV
1. Install 1st gear needle bearing and 1st main gear onto main-
B
shaft.
MT
SMT706D
E
2. Install 1st double cone assembly onto mainshaft.
3. Install 1st & 2nd synchronizer hub with its three grooves facing
the front side (1st main gear side) onto mainshaft. F
CAUTION:
Do not reuse 1st & 2nd synchronizer hub.
G
SMT695D
I
4. Install 1st & 2nd synchronizer hub using Tool.
L
SMT707DA
5. Install insert spring onto 1st & 2nd coupling sleeve. M
SMT994BB
MT-49
MAINSHAFT AND GEARS
[RS5F70A]
6. Install 1st & 2nd coupling sleeve with its chamfered surface fac-
ing the 1st main gear side onto 1st & 2nd synchronizer hub.
SMT708D
7. Install 2nd gear bushing with its flange surface facing 1st & 2nd
synchronizer hub side using Tool.
WMT027
8. Install 2nd needle bearing, 2nd double cone assembly, and 2nd
main gear onto mainshaft using Tool.
9. Position 3rd main gear as shown, and install it using Tool.
CAUTION:
Do not reuse 3rd main gear.
SMT710DA
10. Install spacer and mainshaft adjusting shim onto mainshaft.

11. Select a mainshaft adjusting shim suitable to satisfy the follow-
ing specification of dimension “L” and install it onto mainshaft.
Dimension “L” : 151.35 - 151.45 mm
(5.9586 - 5.9626 in)
Mainshaft adjusting : Refer to MT-62, "Available
shims Adjusting Shims" .
SMT711D
MT-50
MAINSHAFT AND GEARS
[RS5F70A]
12. Position 4th main gear as shown, and install it onto mainshaft.
A
MT
SMT713D
D
13. Install 4th main gear onto mainshaft using Tool.
CAUTION:
Do not reuse 4th main gear. E
G
SMT712DA
14. Install 5th gear bushing with its flange surface facing the 4th
H
main gear side using Tool.
WMT028
K
15. Install 5th needle bearing, 5th main gear, and 5th gear baulk ring
onto mainshaft.
L
SMT761D
16. Being careful of the following points, install spread spring, shift-
ing insert, and 5th & reverse synchronizer hub onto 5th &
reverse coupling sleeve.
SMT694D
MT-51
MAINSHAFT AND GEARS
[RS5F70A]
● Pay attention to the shape of spread spring and shifting insert

for correct assembly.
Do not install spread spring hook onto the same shifting
insert.
● Install synchronizer hub with its three grooves facing the front
side (5th main gear side).
CAUTION:
Do not reuse 5th & reverse synchronizer hub.
SMT695D
● Install 5th & reverse coupling sleeve with its chamfered sur-
face facing the reverse main gear side.
SMT716D
17. Install 5th & reverse synchronizer hub assembly using Tool.
SMT715DA
18. Install reverse gear baulk ring using Tool.

19. Install reverse gear bushing using Tool.
20. Install reverse gear needle bearing using Tool.
WMT029
21. Install sub-gear, sub-gear washer, and snap ring onto reverse
main gear.
CAUTION:
● Pay attention to direction of sub-gear washer.
● Do not reuse snap ring.
SMT718D
MT-52
MAINSHAFT AND GEARS
[RS5F70A]
22. Install reverse main gear assembly onto mainshaft.
23. Select a thrust washer suitable to satisfy the following specifica- A
tion of dimension “M” as shown, and install it onto mainshaft.
Dimension “M” : 244.20 - 244.30 mm
B
(9.6142 - 9.6181 in)
Available thrust : Refer to MT-64, "Avail-
washers able Thrust Washer" .
MT
G
SMT719D
24. Install mainshaft rear bearing using Tool.

H
SMT720DA
K
25. Install mainshaft C-ring.
26. Using feeler gauge, measure the end play of mainshaft rear
bearing with a suitable tool, and check if it satisfies the following L
specification.
End play : 0 - 0.06 mm (0 - 0.0024 in)
Mainshaft C-rings : Refer to MT-61, "Available C- M
rings" .
SMT721D
27. Install C-ring holder.
SMT678D
MT-53
MAINSHAFT AND GEARS
[RS5F70A]
28. Install snap ring with a suitable tool.
SMT677D
29. Measure gear end play as a final check. Refer to MT-61, "Gear End Play" .
MT-54
FINAL DRIVE
[RS5F70A]
FINAL DRIVE PFP:38411
A
Pre-inspection ECS005TW
DIFFERENTIAL CASE SIDE

1. Clean final drive assembly sufficiently to prevent side gear thrust washer, differential case, side gear, and
B
other parts from sticking by gear oil.
2. Upright the differential case so that the side gear to be mea-
sured faces upward.
MT
3. Place final drive adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance using Tool.
Side gear and differential : 0.1 - 0.2 mm
D
case clearance (0.004 - 0.008 in)
SMT685DA
4. If not within specification, adjust the clearance by changing thrust washer thickness. F
5. Turn differential case upside down, and measure the clearance between side gear and differential case on
the other side in the same way using Tool.
G
Disassembly ECS005TX
1. Remove mounting bolts. Then, separate the final gear from dif-
ferential case.
H
2. Make a notch and remove speedometer drive gear using a
scraper or other suitable tool.
● Bearing replacer cannot be positioned unless speedome-
I
ter drive gear is removed.
SMT609A
K
3. Remove differential side bearing of final gear side using Tool.
4. Turn differential case upside down, and remove differential side
bearing of speedometer drive gear side using Tool.
L
● Be careful not to mix up the differential side bearings.
WCIA0005E
5. Remove speedometer stopper.

6. Remove lock pins from pinion mate shaft using Tool.
SMT689DA
MT-55
FINAL DRIVE
[RS5F70A]
7. Remove pinion mate shaft.
8. Rotate pinion mate gear, and remove pinion mate gear, pinion
mate thrust washer, side gear, and side gear thrust washer from
differential case.
SMT839
Inspection ECS005TY
GEAR, WASHER, SHAFT AND CASE

● Check mating surfaces of differential case, side gears and pin-
ion mate gears.
● Check washers for wear.
WCIA0004E
BEARING
● Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
CAUTION:
When replacing tapered roller bearing, replace outer and
inner race as a set.
SPD715
Assembly ECS005TZ
1. Apply gear oil to sliding area of differential case, each gear, and
thrust washer.
2. Install side gear thrust washer and side gear into differential
case.
3. Position pinion mate gear and pinion mate thrust washer diago-
nally, and install them into differential case while rotating.
SMT062A
MT-56
FINAL DRIVE
[RS5F70A]
4. Insert pinion mate shaft into differential case.
A
MT
SMT087A
D
5. Upright the differential case so that its side gear to be measured
faces upward.
6. Place preload adapter and dial gauge onto side gear. Move side E
gear up and down, and measure the clearance using Tool.
7. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
F
same way using Tool.
Clearance of side : 0.1 - 0.2 mm (0.004 - 0.008 in)
gear and differential G
case SMT685DA
Differential side gear : Refer to MT-64, "Available

thrust washers Washers" . H
8. Install retaining pin using Tool.
● Make sure that retaining pin is flush with case.
I
K
SMT699B
9. Align and install speedometer drive gear into differential case. L

10. Install speedometer stopper.
SMT842D
MT-57
FINAL DRIVE
[RS5F70A]
11. Install differential side bearing using Tool.
12. Turn differential case upside down, and install another differen-
tial side bearing on the other side in the same way using Tool.
SMT751DA
13. Install differential gear into differential case. Apply sealant onto
mounting bolts, and tighten them in order as shown in the figure
with specified torque.
Differential gear : Refer to MT-21, "FINAL DRIVE
mounting bolts COMPONENTS" .
SMT752D
MT-58
SHIFT CONTROL
[RS5F70A]
SHIFT CONTROL PFP:32982
A
Inspection ECS005U0
● Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below. B
Item One-side wear Sliding width of new part
7.80 - 7.93 mm
1st & 2nd 0.2 mm (0.008 in)
(0.3071 - 0.3122 in) MT
7.80 - 7.93 mm
3rd & 4th 0.2 mm (0.008 in)
(0.3071 - 0.3122 in)
D
7.80 - 7.93 mm
5th & reverse 0.2 mm (0.008 in)
(0.3071 - 0.3122 in)
SMT801D
E
● Check if shift check groove of fork rod or 5th & reverse check
groove is worn, or has any other abnormalities.
F
H
SMT692D
MT-59
SERVICE DATA AND SPECIFICATIONS (SDS)
[RS5F70A]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
General Specifications ECS005U1
TRANSAXLE
Engine QG18DE
Transaxle model RS5F70A
Number of speeds 5
Synchromesh type Warner
Shift pattern
Gear ratio 1st 3.333

2nd 1.955
3rd 1.286
4th 0.926
5th 0.756
Reverse 3.214
Number of teeth Input gear 1st 15
2nd 22
3rd 28
4th 41
5th 45
Rev. 14
Main gear 1st 50
2nd 43
3rd 36
4th 38
5th 34
Rev. 45
Reverse idler gear 37
Oil level (reference) mm (in)*1 75.5 - 80.5 (2.972 - 3.169)
Oil capacity (US qt, Imp qt) 3.0 (3 1/8, 2 5/8)

Remarks 1st & 2nd double baulk ring type synchronizer
Reverse sub-gear
*1: Refer to MA-13, "Fluids and Lubricants" .
FINAL GEAR
Engine QG18DE
Transaxle model RS5F70A
Final gear ratio 4.176
Final gear/pinion 71/17
Number of teeth
Side gear/pinion mate gear 16/10
MT-60
[RS5F70A]
Gear End Play ECS005U2
Unit: mm (in) A
Gear End play
1st main gear
B
2nd main gear
5th main gear 0.18 - 0.31 (0.0071 - 0.0122)
Reverse main gear MT
3rd input gear
4th input gear 0.17 - 0.44 (0.0067 - 0.0173)
D
Clearance Between Baulk Ring and Gear ECS005U3
3RD, 4TH, 5TH, REVERSE BAULK RING

Unit: mm (in) E
Gear Standard Wear limit
3rd
4th 0.90 - 1.45 (0.0354 - 0.0571) F
0.7 (0.028)
5th
Reverse 0.9 - 1.35 (0.0354 - 0.0531)
G
1ST AND 2ND BAULK RING
Unit: mm (in)
H
K
SMT906D
Dimension Standard Wear limit

A 0.6 - 0.8 (0.024 - 0.031) L
0.2 (0.008)
B 0.6 - 1.1 (0.024 - 0.043)
Available Snap Rings ECS005U4
SNAP RING M
End play 0.05 - 0.25 mm (0.0020 - 0.0098 in)

Thickness Part number*
1.45 mm (0.0571 in) 32204-6J000
1.55 mm (0.0610 in) 32204-6J001
1.65 mm (0.0650 in) 32204-6J002
1.75 mm (0.0689 in) 32204-6J003
1.85 mm (0.0728 in) 32204-6J004
*: Always check with the parts department for the latest information.
Available C-rings ECS005U5
4TH INPUT GEAR C-RING

End play 0 - 0.06 mm (0 - 0.0024 in)
MT-61
[RS5F70A]
3.00 mm (0.1181 in) 32205-6J000
3.03 mm (0.1193 in) 32205-6J001
3.06 mm (0.1205 in) 32205-6J002
3.09 mm (0.1217 in) 32205-6J003
3.12 mm (0.1228 in) 32205-6J004
5TH INPUT GEAR REAR C-RING

End play 0 - 0.06 mm (0 - 0.0024 in)
2.59 mm (0.1020 in) 32205-6J005
2.62 mm (0.1031 in) 32205-6J006
2.65 mm (0.1043 in) 32205-6J007
2.68 mm (0.1055 in) 32205-6J008
2.71 mm (0.1067 in) 32205-6J009
2.74 mm (0.1079 in) 32205-6J010
MAINSHAFT C-RING
End play 0 - 0.06 mm (0 - 0.0024 in)
3.48 mm (0.1370 in) 32348-6J000
3.51 mm (0.1382 in) 32348-6J001
3.54 mm (0.1394 in) 32348-6J002
3.57 mm (0.1406 in) 32348-6J003
3.60 mm (0.1417 in) 32348-6J004
3.63 mm (0.1429 in) 32348-6J005
3.66 mm (0.1441 in) 32348-6J006
3.69 mm (0.1453 in) 32348-6J007
3.72 mm (0.1465 in) 32348-6J008
3.75 mm (0.1476 in) 32348-6J009
3.78 mm (0.1488 in) 32348-6J010
3.81 mm (0.1500 in) 32348-6J011
3.84 mm (0.1512 in) 32348-6J012
3.87 mm (0.1524 in) 32348-6J013
3.90 mm (0.1535 in) 32348-6J014
3.93 mm (0.1547 in) 32348-6J015
3.96 mm (0.1559 in) 32348-6J016
Available Adjusting Shims ECS005U6
INPUT SHAFT REAR BEARING ADJUSTING SHIM

End play 0 - 0.06 mm (0 - 0.0024 in)
0.74 mm (0.0291 in) 32225-6J003
0.78 mm (0.0307 in) 32225-6J004
0.82 mm (0.0323 in) 32225-6J005
0.86 mm (0.0339 in) 32225-6J006
MT-62
[RS5F70A]
0.90 mm (0.0354 in) 32225-6J007
A
0.94 mm (0.0370 in) 32225-6J008
0.98 mm (0.0386 in) 32225-6J009
1.02 mm (0.0402 in) 32225-6J010 B
1.06 mm (0.0417 in) 32225-6J011
1.10 mm (0.0433 in) 32225-6J012
1.14 mm (0.0449 in) 32225-6J013 MT
1.18 mm (0.0465 in) 32225-6J014
1.22 mm (0.0480 in) 32225-6J015
D
1.26 mm (0.0496 in) 32225-6J016
1.30 mm (0.0512 in) 32225-6J017
1.34 mm (0.0528 in) 32225-6J018 E
1.38 mm (0.0543 in) 32225-6J019
1.42 mm (0.0559 in) 32225-6J020
F
1.46 mm (0.0575 in) 32225-6J021
1.50 mm (0.0591 in) 32225-6J022
1.54 mm (0.0606 in) 32225-6J023 G
1.58 mm (0.0622 in) 32225-6J024
1.62 mm (0.0638 in) 32225-6J060
H
1.66 mm (0.0654 in) 32225-6J061
MAINSHAFT ADJUSTING SHIM I
SMT907D
Standard length “L” 151.35 - 151.45 mm (5.9586 - 5.9626 in) M

0.48 mm (0.0189 in) 32238-6J000
0.56 mm (0.0220 in) 32238-6J001
0.64 mm (0.0252 in) 32238-6J002
0.72 mm (0.0283 in) 32238-6J003
0.80 mm (0.0315 in) 32238-6J004
0.88 mm (0.0346 in) 32238-6J005
MAINSHAFT REAR BEARING ADJUSTING SHIM

End play 0 - 0.06 mm (0 - 0.0024 in)
2.99 mm (0.1177 in) 32238-6J010
3.03 mm (0.1193 in) 32238-6J011
MT-63
[RS5F70A]
3.07 mm (0.1209 in) 32238-6J012
3.11 mm (0.1224 in) 32238-6J013
3.15 mm (0.1240 in) 32238-6J014
3.19 mm (0.1256 in) 32238-6J015
3.23 mm (0.1272 in) 32238-6J016
3.27 mm (0.1287 in) 32238-6J017
3.31 mm (0.1303 in) 32238-6J018
3.35 mm (0.1319 in) 32238-6J019
3.39 mm (0.1335 in) 32238-6J020
3.43 mm (0.1350 in) 32238-6J021
3.47 mm (0.1366 in) 32238-6J022
3.51 mm (0.1382 in) 32238-6J023
Available Thrust Washer ECS005U7
MAINSHAFT THRUST WASHER
SMT843D
Standard length “M” 244.20 - 244.30 mm (9.6142 - 9.6181 in)

6.04 mm (0.2378 in) 32246-6J000
6.12 mm (0.2409 in) 32246-6J001
6.20 mm (0.2441 in) 32246-6J002
6.28 mm (0.2472 in) 32246-6J003
6.36 mm (0.2504 in) 32246-6J004
Available Washers ECS005U8
DIFFERENTIAL SIDE GEAR THRUST WASHER

Clearance between side gear and differential case 0.1 - 0.2 mm (0.004 - 0.008 in)
Thickness mm (in) Part number*
0.75 - 0.80 (0.0295 - 0.0315) 38424-D2111
0.80 - 0.85 (0.0315 - 0.0335) 38424-D2112
0.85 - 0.90 (0.0335 - 0.0354) 38424-D2113
0.90 - 0.95 (0.0354 - 0.0374) 38424-D2114
0.95 - 1.00 (0.0374 - 0.0394) 38424-D2115
MT-64
[RS5F70A]
Available Shims — Differential Side Bearing Preload and Adjusting Shim ECS005U9
BEARING PRELOAD A
Unit: mm (in)
Differential side bearing preload T* 0.15 - 0.21 (0.0059 - 0.0083)
* Install shims which are “deflection of differential case” + “T” in thickness. B
DIFFERENTIAL SIDE BEARING ADJUSTING SHIMS

Thickness mm (in) Part number* MT
0.44 (0.0173) 38454-M8000
0.48 (0.0189) 38454-M8001
D
0.52 (0.0205) 38454-M8002
0.56 (0.0220) 38454-M8003
0.60 (0.0236) 38454-M8004 E
0.64 (0.0252) 38454-M8005
0.68 (0.0268) 38454-M8006
0.72 (0.0283) 38454-M8007 F
0.76 (0.0299) 38454-M8008
0.80 (0.0315) 38454-M8009
G
0.84 (0.0331) 38454-M8010
0.88 (0.0346) 38454-M8011
*: Always check with the parts department for the latest information. H
MT-65
PRECAUTIONS
[RS6F51H]
PRECAUTIONS PFP:00001
Caution ECS005V2
● Do not reuse transaxle oil, once it has been drained.

● Check oil level, and drain and refill transaxle oil with the vehicle on level ground.
● During removal or installation, keep inside of transaxle clean of dust and dirt.
● Check for the correct installation orientation prior to removal or disassembly. If mating marks are required,
be certain they do not interfere with the function of the parts they are applied to.
● In principle, tighten bolts or nuts gradually in several steps working diagonally and from inside to outside
as applicable. If a tightening sequence is specified, follow it as specified.
● Be careful not to damage the sliding surfaces and mating surfaces of parts.
MT-66
PREPARATION
[RS6F51H]
PREPARATION PFP:00002
A
Special Service Tools ECS005V3
The actual shapes of the Kent-Moore tools may differ from those of the special tools illustrated here.
Tool number B
Tool name
KV381054S0 Side bearing outer race removal MT
(J34286) Mainshaft front bearing removal
Puller
ZZA0601D
E
ST35321000 Input shaft oil seal installation
( — ) Reverse main gear installation
Drift 1st bushing installation
1st-2nd synchronizer hub installation F
2nd bushing installation
3rd main gear installation
a: 49 mm (1.93 in) dia.
ZZA1000D b: 41 mm (1.61 in) dia. G
ST30720000 Differential oil seal installation
(J25405) Differential side bearing outer race installation
Drift Mainshaft rear bearing installation H
Differential side bearing installation
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
I
ZZA0811D
ST33200000 Mainshaft front bearing installation

(J26082) 6th bushing installation J
Drift 4th main gear installation
5th main gear installation
a: 60 mm (2.36 in) dia. K
b: 44.5 mm (1.752 in) dia.
ZZA1002D
ST33061000 Bore plug installation L

(J8107-2) Differential side bearing removal
b: 28.5 mm (1.122 in) dia.
M
ZZA1000D
ST33052000 Welch plug installation

( — ) Input shaft rear bearing removal
Drift 5th bushing, thrust washer, 4th input gear, 4th
gear bushing, 3rd-4th synchronizer hub and
3rd input gear removal
Input shaft front bearing installation
6th input gear and 6th bushing removal
Mainshaft rear bearing removal
4th main gear and 5th main gear removal
ZZA1023D 6th main gear removal
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
MT-67
PREPARATION
[RS6F51H]
Tool number
Tool name
KV40105020 5th input gear and synchronizer hub removal
( — ) 3rd main gear, 2nd main gear, 2nd bushing,
Drift 1st-2nd synchronizer hub, 1st main gear, re-
verse main gear and 1st bushing removal
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)
ZZA1133D
KV40105710 3rd-4th synchronizer hub installation

( — ) 4th bushing installation
Press stand 5th bushing installation
5th-6th synchronizer hub installation
2nd bushing installation
3rd main gear installation
a: 46 mm (1.81 in) dia.
ZZA1058D b: 41 mm (1.61 in)
ST38220000 Reverse main gear installation
( — ) 1st bushing installation
Press stand 1st-2nd synchronizer hub installation
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)
ZZA1058D
ST30032000 Input shaft front bearing installation

(J26010-01) a: 80 mm (3.15 in) dia.
Drift b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.
ZZA0978D
ST30901000 Input shaft rear bearing installation

(J26010-01) 4th main gear installation
Drift 5th main gear installation
Mainshaft rear bearing installation
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
ZZA0978D c: 35.2 mm (1.386 in) dia.
ST30031000 Measuring wear of 1st and 2nd baulk ring
(J22912-01)
Puller
ZZA0537D
MT-68
PREPARATION
[RS6F51H]
Tool number
(Kent-Moore No.) Description A
Tool name
KV40101630 Reverse main gear installation
(J35870) a: 68 mm (2.68 in) dia. B
Drift b: 60 mm (2.36 in) dia.
MT
ZZA1003D
KV38102510 1st bushing installation D

( — ) 1st-2nd synchronizer hub installation
Drift Differential side bearing installation
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia. E
ZZA0838D
F
Commercial Service Tools ECS005V4

G
Puller Each bearing gear and bushing removal
ZZB0823D I
Puller Each bearing gear and bushing removal
K
NT077
Pin punch Each retaining pin removal and installation

Tip: 4.5 mm (0.177 in) dia.
L
M
ZZA0815D
MT-69
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[RS6F51H]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart ECS005V5
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.
MA-13, "Fluids and Lubricants"

MA-30, "Checking M/T Oil"
MA-30, "Checking M/T Oil"
MT-102, MT-109
MT-121
MT-74
MT-76
Reference page
Check plug return spring and check ball (Worn or damaged)
Insert spring, shifting insert (Damaged)

Control device and cable (Worn)
Suspected parts (Possible cause)
Baulk ring (Worn or damaged)

Bearing (Worn or damaged)
Oil seal (Worn or damaged)
O-Ring (Worn or damaged)
Gear (Worn or damaged)

Gasket (Damaged)
(Oil level is high)
Shift fork (Worn)

(Oil level is low)
(Wrong oil)
Noise 1 2 3 3
Oil leakage 3 1 2 2 2
Symptom
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3
MT-70
DESCRIPTION
[RS6F51H]
DESCRIPTION PFP:00000
A
Cross-sectional View ECS005V6
RS6F51H
B
MT
WCIA0364E
MT-71
DESCRIPTION
[RS6F51H]
1. Input shaft rear bearing 2. 6th input gear 3. 5th & 6th synchronizer
4. 5th input gear 5. 4th input gear 6. 3rd & 4th synchronizer
7. 3rd input gear 8. Reverse idler gear (rear) 9. Reverse synchronizer
10. Reverse idler gear (front) 11. Reverse idler shaft 12. Clutch housing
13. Input shaft front bearing 14. Input shaft 15. Mainshaft
16. Mainshaft front bearing 17. Speedometer drive gear 18. Differential side bearing (front)
19. Final gear 20. Differential case 21. Differential side bearing (rear)
22. Reverse main gear 23. 1st main gear 24. 1st & 2nd synchronizer
25. 2nd main gear 26. 3rd main gear 27. 4th main gear
28. 5th main gear 29. 6th main gear 30. Mainshaft rear bearing
DOUBLE-CONE SYNCHRONIZER
The 1st gear is equipped with a double-cone synchronizer to reduce
the operating force of the shift lever as shown.
WCIA0202E
TRIPLE-CONE SYNCHRONIZER
The 2nd gear is equipped with a triple-cone synchronizer to reduce
the operating force of the control lever as shown.
WCIA0204E
REVERSE GEAR
Description of the reverse gear components are as shown.
SCIA0751E
MT-72
M/T OIL
[RS6F51H]
M/T OIL PFP:KLD20
A
Replacement ECS005V7
DRAINING
1. Start the engine and let it run to warm up the transaxle oil.
B
2. Stop the engine. Remove drain plug and drain oil.
3. Set a new gasket on the drain plug and install it in transaxle
body. MT
Drain plug : 30 - 39 N·m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
CAUTION:
Do not reuse gasket. D
E
WCIA0022E
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the F
specified limit near filler plug mounting hole.
Oil grade : API GL-4, Viscosity SAE 75W-85
G
Capacity : 2.2 (2 3/8 US qt, 2 Imp qt)
(approximately)
2. After refilling oil, check oil level. Assemble a new gasket on to H
filler plug, then install it in transaxle body.
Filler plug : 30 - 39 N·m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
CAUTION: WCIA0022E
I
Checking ECS005V8
J
OIL LEAKAGE AND OIL LEVEL
● Check that oil is not leaking from transaxle.
● Check oil level from filler plug mounting hole as shown. K
CAUTION:
Never start engine while checking oil level.
● Set a new gasket on the filler plug and install it in transaxle body. L
Filler plug : 30 - 39 N·m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
CAUTION:
Do not reuse gasket. M
WCIA0022E
MT-73
SIDE OIL SEAL
[RS6F51H]
SIDE OIL SEAL PFP:32113
Removal and Installation ECS005V9
REMOVAL
1. Remove the drive shaft from the transaxle body. Refer to FAX-14, "Removal" .
2. Remove oil seal with a slotted screwdriver.
CAUTION:
Be careful not to damage the case surface when removing
the oil seal.
WCIA0023E
INSTALLATION
Installation is in the reverse order of removal.
● Using Tool (drift), drive the new oil seal straight until it protrudes
from the case end equal to dimension "A" as shown.
Dimension "A" : Within 0.5 mm (0.02 in) or flush with
the case.
Tool (drift) : ST30720000 (J25405)
CAUTION:
● Before installing oil seal, apply multi-purpose grease to
oil seal lips.
● Oil seal is not reusable.
SCIA1010E
● Check oil level after installation. Refer to MT-73, "Checking" .
MT-74
POSITION SWITCH
[RS6F51H]
POSITION SWITCH PFP:32005
A
Checking ECS005VA
NOTE:
For removal and installation of the switches. Refer to MT-81, "Component Parts" . B
BACK-UP LAMP SWITCH
MT
Reverse Yes
Except reverse No D
SCIA0708E
F
PARK/NEUTRAL POSITION SWITCH
Gear position Continuity G
Neutral Yes
Except neutral No H
MT-75
CONTROL LINKAGE
[RS6F51H]
CONTROL LINKAGE PFP:34103
Removal and Installation of Control Device and Cable ECS006H6
WCIA0136E
1. Snap pin 2. Washer 3. Cable

4. Manual lever 5. Shift cable 6. Lock plate
7. Control device assembly 8. Lock plate 9. Select cable
10. Shift cable 11. Control lever knob 12. Control lever
MT-76
CONTROL LINKAGE
[RS6F51H]
13. Control device assembly 14. Cover 15. Select cable
16. Floor 17. Pin 18. Shift cable A
19. Washer 20. Clutch housing 21. Cable mounting bracket
22. Select cable 23. Shift cable 24. Lock plate
25. Lock plate B
CAUTION:
● Note that the select side lock plate for securing the control cable is different from the one on the
MT
shift side.
● After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st,
2nd, or Reverse.
D
Cable Adjustment ECS006S7
NOTE:
After installation of the select cable, the cable must be adjusted for proper operation. This adjustment is per- E
formed before installing the interior console and shift boot.
1. Slide clip “B” from under clip “A” as shown.
F
LCIA0303E
I
2. Shift the control lever to the neutral position.
CAUTION:
Do not move the control lever when adjusting the cables. J
3. Push clip “A” into the cable end case until it snaps into place as
shown.
K
M
LCIA0304E
4. Slide clip “B” back over clip “A” until it snaps into place and holds
clip “A” in place as shown.
LCIA0305E
MT-77
AIR BREATHER HOSE
[RS6F51H]
AIR BREATHER HOSE PFP:31098
Removal and Installation ECS005VC
LCIA0033E
CAUTION:
● Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
● Insert the air breather hose into the transaxle tube until the overlap area reaches the spool.
MT-78
TRANSAXLE ASSEMBLY
[RS6F51H]
TRANSAXLE ASSEMBLY PFP:32010
A
Removal and Installation ECS005VD
MT
WCIA0109E
REMOVAL J
1. Remove the air cleaner and air duct.
2. Remove the battery.
K
3. Remove the air breather hose.
4. Remove the clutch operating cylinder.
CAUTION: L
Do not depress the clutch pedal during the removal procedure.
5. Remove the engine under cover.
6. Disconnect the control cable from the transaxle. Refer to MT-76, "Removal and Installation of Control M
Device and Cable" .
7. Drain the gear oil from the transaxle. Refer to MA-30, "Changing M/T Oil" .
8. Remove the connectors and harnesses for:
● PNP switch
● Speed sensor
● Back-up lamp switch
● Ground
9. Remove the exhaust front tube. Refer to EX-3, "Removal and Installation" .
10. Remove the drive shaft. Refer to FAX-14, "Removal" .
11. Remove the starter motor. Refer to SC-20, "Removal and Installation" .
12. Place a suitable jack under the transaxle.
CAUTION:
When setting the jack, be careful not to bring it into contact with the switches.
13. Remove the center member, engine insulator, and engine mount bracket.
14. Support the engine by placing a jack under the engine oil pan.
MT-79
TRANSAXLE ASSEMBLY
[RS6F51H]
15. Remove the bolts that mount the engine to the transaxle.
16. Remove the transaxle from the vehicle as shown.
MTD0062D
INSTALLATION
Installation is the reverse order of removal.
● When installing the transaxle to the engine, use them specified tightening torque in the numerical
sequence as shown.
CAUTION:
When installing the transaxle, do not allow the transaxle input shaft to make contact with the
clutch cover.
Bolt No. 1 2 3 4 5 6 7 8 9 10
“ ” mm (in) 40 82 47 47 52 40 40 40 30 30
Tightening
30 - 40
torque
(3.1 - 4.1, 70 - 80 (7.1 - 8.1, 52 - 59) 30 - 40 (3.1 - 4.1, 22 - 29)
N·m (kg-m,
22 - 29)
ft-lb)
● After installation, check the transaxle oil level. Refer to MT-73,

"Checking" .
● After installation, check for any leaks and any loose mecha-
nisms.
LCIA0036E
MT-80
TRANSAXLE ASSEMBLY
[RS6F51H]
Component Parts ECS005VE
CASE AND HOUSING COMPONENTS A
MT
SCIA1062E
1. Clutch housing 2. Input shaft oil seal 3. Oil channel

4. Magnet 5. Differential oil seal 6. Ball pin
7. Washer 8. Transaxle case 9. Welch plug
10. Bore plug 11. Differential oil seal 12. Park/Neutral position switch
13. Oil gutter 14. Back-up lamp switch 15. Air breather tube
16. Baffle plate 17. Filler plug 18. Gasket
19. Drain plug 20. Gasket
MT-81
TRANSAXLE ASSEMBLY
[RS6F51H]
GEAR COMPONENTS
SCIA0956E
1. Input shaft front bearing 2. Input shaft 3. Needle bearing

4. 3rd input gear 5. 3rd baulk ring 6. Spread spring
7. 3rd & 4th shifting insert 8. 3rd & 4th synchronizer hub 9. 4th baulk ring
10. 3rd & 4th coupling sleeve 11. Bushing 12. Needle bearing
13. 4th input gear 14. Thrust washer 15. Bushing
16. Needle bearing 17. 5th input gear 18. 5th baulk ring
19. 5th & 6th shifting insert 20. 5th & 6th synchronizer hub 21. 5th & 6th coupling sleeve
22. Baulk ring 23. 6th input gear 24. Needle bearing
25. Bushing 26. Snap ring 27. Input shaft rear bearing
28. Oil channel 29. Input shaft rear bearing adjusting shim 30. Retaining pin
31. Reverse idler shaft 32. Thrust bearing 33. Needle bearing
34. Reverse idler gear (front) 35. Reverse baulk ring 36. Reverse coupling sleeve
37. Insert spring 38. Reverse idler gear (rear) 39. Reverse idler gear adjusting shim
MT-82
TRANSAXLE ASSEMBLY
[RS6F51H]
MT
SCIA0957E
1. Mainshaft front bearing 2. Mainshaft bearing retainer 3. Mainshaft

I
4. Reverse main gear 5. 1st main gear 6. Bushing
7. Needle bearing 8. 1st inner baulk ring 9. 1st gear synchronizer cone
J
10. 1st outer baulk ring 11. Spread spring 12. 1st & 2nd shifting insert
13. 1st & 2nd synchronizer hub 14. 2nd outer baulk ring 15. 2nd gear synchronizer cone
16. 2nd inner baulk ring 17. 1st & 2nd coupling sleeve 18. Bushing
K
19. Needle bearing 20. 2nd main gear 21. 3rd main gear
22. 3rd & 4th mainshaft spacer 23. 4th main adjusting shim 24. 4th main gear
25. 5th main gear 26. 6th main gear 27. Mainshaft rear bearing
L
28. Mainshaft C-ring 29. C-ring holder 30. Snap ring
31. Snap ring 32. Mainshaft rear bearing adjusting shim 33. 5th & 6th mainshaft spacer
34. 6th main adjusting shim
M
MT-83
TRANSAXLE ASSEMBLY
[RS6F51H]
SHIFT CONTROL COMPONENTS
SCIA0958E
1. Reverse shift fork 2. Shifter cap 3. Reverse fork rod

4. Reverse lever assembly 5. 5th & 6th bracket 6. 5th & 6th fork rod
7. 5th & 6th shift fork 8. Retaining pin 9. 3rd & 4th bracket
10. 3rd & 4th shift fork 11. 3rd & 4th fork rod 12. 1st & 2nd shift fork
13. 1st & 2nd bracket 14. 1st & 2nd fork rod 15. Shift check sleeve
16. Inter lock pin 17. Check ball 18. Shift check sleeve
19. Check spring 20. Check plug 21. Control assembly
22. O-ring 23. Shift check 24. Stopper bolt
25. Stopper ring 26. Reverse bracket fork rod 27. Reverse bracket
MT-84
TRANSAXLE ASSEMBLY
[RS6F51H]
FINAL DRIVE COMPONENTS
A
MT
WCIA0207E
I
1. Differential side bearing outer race 2. Differential side bearing 3. Speedometer drive gear
4. Differential case 5. Final gear 6. Differential side bearing
7. Differential side bearing outer race 8. Differential side bearing adjusting shim J
Disassembly and Assembly ECS005VF
DISASSEMBLY K
1. Remove the drain plug and filler plug.
2. Remove the park/neutral position switch and back-up lamp
switch. L
3. After removing the shift check and stopper bolt, remove the con-
trol assembly.
M
SCIA0389E
4. Remove the 2 check ball plugs, 2 check springs, and 2 check

balls as shown. Discard the check ball plug.
CAUTION:
Check ball plugs are not reusable.
LCIA0302E
MT-85
TRANSAXLE ASSEMBLY
[RS6F51H]
5. Remove the transaxle case bolts as shown.
SCIA0983E
6. Remove the bore plug.

CAUTION:
Be careful not to damage transaxle case.
7. While spreading the snap ring of the mainshaft rear bearing located at bore plug hole, remove the tran-
saxle case.
8. Remove the oil gutter and baffle plate.
9. Remove the snap ring, mainshaft rear bearing adjusting shim, and input shaft rear bearing adjusting shim
from the transaxle case.
10. Remove the differential side bearing outer race (transaxle case
side) using Tool as shown, and then remove the adjusting shim.
SCIA1021E
11. Remove the welch plug with a suitable punch and hammer as
shown.
SCIA0402E
12. Remove the differential oil seal with a suitable tool as shown.
SCIA0397E
13. Remove the magnet from the clutch housing.
MT-86
TRANSAXLE ASSEMBLY
[RS6F51H]
14. Remove the reverse check ball plug, reverse check spring, reverse shift check sleeve, and check ball.
Discard the check ball plug. A
CAUTION:
● Do not reuse the check ball plug.
● Do not drop the check ball. B

15. With the shift lever in 5th position, remove the bracket bolts from
the reverse lever assembly as shown. Lift the reverse lever
assembly to remove. MT
CAUTION:
Retain the shifter cap for installation.
D
E
SCIA0960E
16. Pull out the reverse fork rod then remove the reverse shift fork. F
17. Remove the retaining pin of the reverse bracket.
I
SCIA0961E
18. Pull out the reverse lever and the reverse bracket fork rod. J
19. Remove the two check balls and the interlock pin.
20. Shift the 3rd-4th fork rod to the 3rd position. Remove the retain-
ing pin of the 5th-6th shift fork using a pin punch. K
SCIA0962E
21. Remove the stopper rings for the 5th-6th bracket.
SCIA0963E
22. Pull out the 5th-6th fork rod and remove the 5th-6th shift fork and the 5th-6th bracket.
23. Remove the check balls (2 pieces) and interlock pin.
MT-87
TRANSAXLE ASSEMBLY
[RS6F51H]
24. Remove the retaining pin of 3rd-4th bracket using pin punch.
25. Remove the stopper rings for 3rd-4th shift fork.
SCIA0393E
26. Pull out the 3rd-4th fork rod and remove 3rd-4th shift fork and bracket.
27. Remove the shift check sleeve from the clutch housing.
28. Remove the retaining pin of 1st-2nd shift fork using a suitable
pin punch.
SCIA0394E
29. Pull out the 1st-2nd fork rod with bracket.

30. Remove the 1st-2nd shift fork.
31. Remove the retaining pin of 1st-2nd bracket using a suitable pin punch and separate the fork rod and
bracket.
32. Remove the gear components from the clutch housing.
a. While tapping the input shaft with a plastic hammer, remove the
input shaft assembly, mainshaft assembly, and reverse idler
gear assembly as a set.
CAUTION:
Always withdraw the mainshaft straight out. Failure to do
so can damage the resin oil channel on the clutch housing
side.
b. Remove the final drive assembly.
SCIA0964E
33. Remove the bearing retainer and then the mainshaft front bear-
ing as shown.
34. Remove the oil channel on the mainshaft side.
SCIA0400E
MT-88
TRANSAXLE ASSEMBLY
[RS6F51H]
35. Remove the differential oil seal (clutch housing side) using Tool
as shown. A
MT
SMT117E
D
36. Remove the differential side bearing outer race (clutch housing
side) using Tool as shown.
E
G
SMT116E
37. Remove the input shaft oil seal using a suitable tool as shown.
H
CAUTION:
Do not damage the clutch housing sealing surface.
I
SCIA0398E
K
ASSEMBLY
1. Install a new input shaft oil seal from the clutch housing end of
the side, to the depth of 1.8 - 2.8 mm (0.071 - 0.110 in) using L
Tool (drift) as shown.
CAUTION:
Oil seals are not reusable. M
SCIA1022E
MT-89
TRANSAXLE ASSEMBLY
[RS6F51H]
2. Install a new differential oil seal using Tool (drift) as shown.
CAUTION:
Oil seals are not reusable.
SCIA1023E
3. Install the oil channel on the mainshaft side as shown.

CAUTION:
Position the oil channel with the orientation as shown, for
installation.
SCIA0986E
4. Install the mainshaft front bearing using Tool (drift) as shown.

CAUTION:
Position the mainshaft front bearing with the orientation as
shown, for installation
SCIA1024E
5. Install the mainshaft front bearing retainer.

CAUTION:
Install the bearing retainer with the punched surface facing
up.
Bearing retainer bolt : 6.27 - 8.33 N·m (0.64 -
0.84 kg-m, 56 - 73 in-lb)
SCIA0400E
6. Install the differential side bearing outer race using Tool as

shown.
SCIA1063E
MT-90
TRANSAXLE ASSEMBLY
[RS6F51H]
7. Install the final drive assembly into the clutch housing.
A
MT
SCIA0888E
D
8. Install the input shaft assembly, mainshaft assembly, and
reverse idler gear assembly into the clutch housing.
CAUTION: E
Do not damage the input shaft oil seal.
G
SCIA0964E
9. Install the 1st-2nd fork rod bracket onto the 1st-2nd fork rod, and
H
then install a new retaining pin as shown.
CAUTION:
Retaining pins are not reusable.
I
SCIA0889E
K
10. Install the 1st-2nd fork rod and the 1st-2nd shift fork, and then
install a new retaining pin.
CAUTION: L
SCIA0394E
11. Install the shift check sleeve.

12. Install the 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with the interlock pin.
MT-91
TRANSAXLE ASSEMBLY
[RS6F51H]
13. Install the new stopper rings onto the 3rd-4th shift fork.
CAUTION:
Stopper rings are not reusable.
14. Install a new retaining pin onto the 3rd-4th bracket.
CAUTION:
SCIA0393E
15. Install the 2 check balls.

16. Install the 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod.
17. Install new stopper rings onto the 5th-6th bracket with interlock
pin.
CAUTION:
Stopper rings are not reusable.
SCIA0963E
18. Install a new retaining pin onto the 5th-6th shift fork.
CAUTION:
SCIA0962E
19. Install the two check balls.

20. Install the check ball, 5th-6th shift check sleeve, 5th-6th check spring, and 5th-6th check ball plug. Discard
the check ball plug.
CAUTION:
● Do not drop the check ball.
21. Install the reverse bracket fork rod and reverse lever bracket.
22. Install a new retaining pin onto the reverse bracket.
CAUTION:
SCIA0961E
23. Install the reverse shift fork and reverse fork rod.
MT-92
TRANSAXLE ASSEMBLY
[RS6F51H]
24. Install the reverse lever assembly using the following steps:
a. Install the shifter cap onto the reverse lever assembly cam, and then install them onto the reverse shift A
fork.
CAUTION:
Do not drop the shifter cap. B
b. While lifting the reverse shift fork, align the cam with the reverse
bracket.
MT
E
SCIA0965E
c. Tighten the bracket bolts to specification, and install the reverse F

lever assembly.
Bracket bolts : 11.8 - 15.6 N·m (1.2 - 1.5 kg-m,
9 - 11 ft-lb) G
SCIA0960E I
25. Install the check ball, reverse shift check sleeve, reverse check spring, and reverse check ball plug.
CAUTION:
J
● Do not drop the check ball.
26. Install the magnet onto the clutch housing.

K
27. Install the selected input shaft adjusting shim onto the input shaft.
● For selection of adjusting shims, refer to MT-96, "INPUTSHAFT END PLAY" .
28. Install the baffle plate and oil gutter. L

29. Install the transaxle case using the following steps:
a. Install the selected mainshaft rear bearing adjusting shim into the transaxle case.
● For selection of adjusting shims, refer to MT-98, "MAINSHAFT END PLAY" . M
b. Temporarily install the snap ring of the mainshaft rear bearing into the transaxle case.
CAUTION:
Do not reuse the snap ring.
c. Apply sealant to the mating surfaces of the transaxle case and
clutch housing as shown. Use Genuine Anaerobic Liquid Gasket
or equivalent. Refer to GI-45, "Recommended Chemical Prod-
ucts and Sealants" .
CAUTION:
Remove any old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the sealant application and mounting surfaces.
SCIA0891E
MT-93
TRANSAXLE ASSEMBLY
[RS6F51H]
d. Using a snap ring of the mainshaft rear bearing temporarily,
install the transaxle case over the clutch housing as shown.
SCIA0892E
e. Through the bore plug mounting hole, with the snap ring
stretched, lift up the mainshaft assembly from the control
assembly mounting hole.
f. Securely install the snap ring onto the mainshaft rear bearing as
shown.
SCIA0893E
g. Tighten the “A” bolts (gold) and new “B” bolts (black) to specifi-
cation.
“A” Bolt : 50.0 - 53.9 N·m (5.1 - 5.4 kg-m, 37 - 39 ft-lb)
“B” Bolt : 63.0 - 66.9 N·m (6.5 - 6.8 kg-m, 47 - 49 ft-lb)
CAUTION:
Always replace the “B” bolts as they are self-sealing bolts.
SCIA1064E
h. Install the control assembly using new O-rings.

CAUTION:
Do not reuse the O-ring.
i. Install a new shift check and a new stopper bolt.
CAUTION:
Shift check and stopper bolt are not reusable.
MT-94
TRANSAXLE ASSEMBLY
[RS6F51H]
30. Install a new bore plug using Tool (drift) as shown.
CAUTION: A
Bore plugs are not reusable.
MT
SCIA1025E
D
31. Install the new welch plug using Tool (drift).
CAUTION:
Do not reuse the welch plug E
G
SMT131E
32. Install the 2 check balls, 2 check springs, and 2 new check ball
H
plugs.
CAUTION:
Check ball plugs are not reusable.
I
LCIA0302E
K
33. Apply sealant to the threads of the neutral switch and reverse
lamp switch. Then install them into the transaxle case. Refer to
MT-81, "CASE AND HOUSING COMPONENTS" . Use Genuine L
Anaerobic Liquid Gasket or equivalent. Refer to GI-45, "Recom-
mended Chemical Products and Sealants" .
M
SCIA0895E
34. Install new gaskets onto the drain plug and filler plug, and then install them into the transaxle case.
CAUTION:
● Gaskets are not reusable.
● After oil is filled, tighten filler plug to specification. Refer to MT-81, "CASE AND HOUSING COM-
PONENTS" .
MT-95
TRANSAXLE ASSEMBLY
[RS6F51H]
Adjustment ECS005VG
INPUTSHAFT END PLAY

● When adjusting the input shaft end play, select the adjusting
shim for the input shaft bearing. To select the correct thickness
for the adjusting shim, measure the clearance between the tran-
saxle case and input shaft rear bearing.
● Calculate the dimension “O” (thickness of adjusting shim) using
the following steps to adjust the input shaft rear bearing for the
specified end play.
SCIA1001E
CAUTION:
Only 1 adjusting shim can be selected.
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension “O” = (“O1 ” - “O2 ”) + End play
“O” : Thickness of adjusting shim.
“O1 ” : Distance between transaxle case end face and mounting face of adjusting shim.
“O2 ” : Distance between clutch housing case end face and end face of input shaft rear
bearing.
Adjusting Shims
Shim thickness Part number Shim thickness Part number Shim thickness Part number
0.40 mm (0.0157 in) 32225 8H500 0.88 mm (0.0346 in) 32225 8H512 1.36 mm (0.0520 in) 32225 8H524
0.72 mm (0.0283 in) 32225 8H508 1.20 mm (0.0472 in) 32225 8H520
0.76 mm (0.0299 in) 32225 8H509 1.24 mm (0.0488 in) 32225 8H521
0.80 mm (0.0315 in) 32225 8H510 1.28 mm (0.0504 in) 32225 8H522
0.84 mm (0.0331 in) 32225 8H511 1.32 mm (0.0520 in) 32225 8H523
1. Using a depth micrometer and straight edge, measure the

dimension “O1 ” between the transaxle case end face and
mounting face of the adjusting shim as shown.
SCIA1002E
MT-96
TRANSAXLE ASSEMBLY
[RS6F51H]
dimension “O2 ” between the clutch housing case end face and A
end face of the input shaft rear bearing as shown.
MT
SCIA1004E
D
3. Install the selected input shaft rear bearing adjusting shim onto the input shaft.
DIFFERENTIAL SIDE BEARING PRELOAD
● When adjusting differential side bearing preload, select adjust- E
ing shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race. F
● Calculate dimension “L” (thickness of adjusting shim) using the
following procedure to meet specification of preload for differen-
tial side bearing. G
Preload : 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension “L” = (“L1 ” - “L2 ”) + Preload
“L” : Thickness of adjusting shim H
SCIA0896E
“L1 ” : Distance between clutch housing case end

face and mounting face of adjusting shim
I
“L2 ” : Distance between differential side bearing
and transaxle case
CAUTION: J
Up to only 2 adjusting shims can be selected.
Adjusting Shim
Shim thickness Part number
K
0.48 mm (0.0189 in) 31438 80X00

0.52 mm (0.0205 in) 31438 80X01
0.56 mm (0.0220 in) 31438 80X02 L
0.60 mm (0.0236 in) 31438 80X03
0.64 mm (0.0252 in) 31438 80X04
0.68 mm (0.0268 in) 31438 80X05
0.72 mm (0.0283 in) 31438 80X06 M
0.76 mm (0.0299 in) 31438 80X07
0.80 mm (0.0315 in) 31438 80X08
0.84 mm (0.0331 in) 31438 80X09
0.88 mm (0.0346 in) 31438 80X10
0.92 mm (0.0362 in) 31438 80X11

dimension “L1 ” between the clutch housing case end face and
SCIA1078E
MT-97
TRANSAXLE ASSEMBLY
[RS6F51H]
2. Install the outer race onto the differential side bearing on the final gear side. Holding the outer race hori-
zontally by hand, rotate the final gear five times or more (for smooth movement of the bearing roller).
dimension “L2 ” between the differential side bearing outer race
and transaxle case end face as shown.
SCIA1079E
4. Install the selected adjusting shim and then the differential side
bearing outer race using Tool as shown.
SCIA1026E
MAINSHAFT END PLAY

● When adjusting the mainshaft end play, select the adjusting
shim for the mainshaft rear bearing. To select the adjusting
shim, measure clearance “M” between the transaxle case and
● Calculate the dimension “P” (thickness of adjusting shim) using
the following procedure to meet specification of end play for
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension “P” = “M” + End play
“P” : Thickness of adjusting shim SCIA0904E
“M” : Distance between mainshaft rear bearing

and transaxle case
CAUTION:
MT-98
TRANSAXLE ASSEMBLY
[RS6F51H]
Adjusting Shim
A
0.44 mm (0.0173 in) 32238 8H510

0.48 mm (0.0189 in) 32238 8H511
0.52 mm (0.0205 in) 32238 8H512 B
0.56 mm (0.0220 in) 32238 8H513
0.60 mm (0.0236 in) 32238 8H514
0.64 mm (0.0252 in) 32238 8H515
0.68 mm (0.0268 in) 32238 8H516 MT
0.72 mm (0.0283 in) 32238 8H517
0.76 mm (0.0299 in) 32238 8H518
0.80 mm (0.0315 in) 32238 8H519
D
0.84 mm (0.0331 in) 32238 8H520
0.88 mm (0.0346 in) 32238 8H521
0.92 mm (0.0362 in) 32238 8H522
0.96 mm (0.0378 in) 32238 8H523 E
1.00 mm (0.0396 in) 32238 8H524
1.04 mm (0.0409 in) 32238 8H560
1.08 mm (0.0425 in) 32238 8H561
F
1. Install the mainshaft assembly to the clutch housing.
2. Install the snap ring to the transaxle case.
G
3. Install the transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Temporarily
install the snap ring to the mainshaft rear bearing.
4. Install the dial gauge to the snap ring access hole, and expand
H
the snap ring as shown. Lift the mainshaft assembly through the
control assembly installation hole, and push it against the tran-
saxle case. This state shall be defined as base. Moving the dis-
tance of the mainshaft assembly, with the snap ring installed on I
the main bearing, becomes “M”.
SCIA1017E
K
REVERSE IDLER GEAR END PLAY
● When adjusting the reverse idler gear end play, select the
adjusting shim for the reverse idler gear. To select the correct L
thickness of adjusting shim, measure the clearance between the
transaxle case and reverse idler gear.
● Calculate the dimension “Q” (thickness of adjusting shim) using M
the following steps to adjust the end play of the reverse idler
gear to specification.
End play : 0.04 - 0.14 mm (0.0016 - 0.0055 in)
Dimension “Q” = (“Q1 ” - “Q2 ”) + End play
“Q” : Thickness of adjusting shim SCIA1007E
“Q1 ” : Distance between transaxle case end face

and mounting face of adjusting shim
“Q2 ” : Distance between clutch housing case end
face and end face of reverse idler gear
CAUTION:
MT-99
TRANSAXLE ASSEMBLY
[RS6F51H]
Adjusting Shim
1.76 mm (0.0693 in) 32237 8H500
1.84 mm (0.0724 in) 32237 8H501
1.92 mm (0.0756 in) 32237 8H502
2.00 mm (0.0787 in) 32237 8H503
2.08 mm (0.0819 in) 32237 8H504
2.16 mm (0.0850 in) 32237 8H505
2.24 mm (0.0882 in) 32237 8H506
2.32 mm (0.0913 in) 32237 8H507
2.40 mm (0.0945 in) 32237 8H508
2.48 mm (0.0976 in) 32237 8H509
2.56 mm (0.1008 in) 32237 8H510
2.64 mm (0.1039 in) 32237 8H511

dimension “Q1 ” between the transaxle case end face and the
SCIA1003E

dimension “Q2 ” between the clutch housing case end face and
the end face of reverse idler gear as shown.
SCIA1005E
3. Install the selected reverse idler gear adjusting shim onto the reverse idler gear.
MT-100
[RS6F51H]
INPUT SHAFT AND GEARS PFP:32200
A
Disassembly and Assembly ECS005VH
DISASSEMBLY
1. Before disassembling, measure the end play for 3rd, 4th, 5th,
B
and 6th input gears.
End play standard values
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in) MT
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in) D
CAUTION:
If measurement is outside the standard value, disassemble SCIA0966E
E
to check the contact surfaces of the gear, shaft, and, hub.
Adjust using the correct size snap ring for assembly.
2. Remove the oil channel. F

3. Remove the input shaft rear bearing using Tool as shown.
4. Remove the snap ring.
G
I
SCIA1037E
5. Remove the 6th input gear, 6th bushing, and 6th needle bearing J
using Tool as shown.
6. Remove the 6th baulk ring, 5th-6th coupling sleeve, and shifting
insert. K
SCIA1038E M
7. Remove the 5th input gear and synchronizer hub assembly

simultaneously using Tool as shown.
8. Remove the 5th needle bearing.
SMT137E
MT-101
[RS6F51H]
9. Remove the 5th bushing, thrust washer, 4th input gear, 4th nee-
dle bearing, 4th bushing, 4th baulk ring, 3rd-4th synchronizer
hub assembly, 3rd baulk ring, and 3rd input gear simultaneously
10. Remove the 3rd needle bearing.
SCIA1030E
11. Remove the input shaft front bearing using Tool as shown.
SCIA0920E
INSPECTION AFTER DISASSEMBLY

Input Shaft and Gear
Inspect the components for the following conditions as shown. If
necessary, replace them with new ones.
● Damage, peeling, dent, uneven wear, or bending of the input
shaft.
● Excessive wear, damage, or peeling of the input gears.
SMT636A
Synchronizer
Check the items below. If necessary, replace them with new ones.
● Damage and excessive wear of the contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert.
● Coupling sleeve and synchronizer hub must move smoothly as
shown.
SMT387A
MT-102
[RS6F51H]
● If any cracks, damage, or excessive wear is found on the cam
face of baulk ring or working face of the insert as shown, replace A
it.
MT
SMT867D
D
Baulk ring clearance
Press the baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it with a E
new one.
Clearance - standard
3rd and 4th : 0.9 - 1.45 mm (0.035 - 0.0571 in) F
5th and 6th : 0.95 - 1.4 mm (0.0374 - 0.055 in)
Limit : 0.7 mm (0.028 in) G
SMT140
H
Bearing
● Rough rotation of the bearing as shown. I
● Damage to the bearing.
MTF0041D
ASSEMBLY L
1. Install the 3rd needle bearing.
2. Install the 3rd input gear and 3rd baulk ring.
3. Install the spread spring, shifting insert, and a new 3rd-4th synchronizer hub onto the 3rd-4th coupling M
sleeve.
CAUTION:
Do not reuse the 3rd-4th synchronizer hub.
● Install with orientation of the synchronizer hub as shown.
SCIA0921E
MT-103
[RS6F51H]
● Install with orientation of coupling sleeve as shown.
SCIA0993E
● Be sure not to hook the ends of the 2 spread springs (front

and back have two each) on the same shifting insert.
SCIA1083E
4. Install 3rd-4th coupling sleeve assembly using Tool as shown.

CAUTION:
Align the grooves of the shifting insert and the 3rd baulk
ring.
SCIA1031E
5. Install the 4th bushing using Tool as shown.

6. Install the 4th baulk ring.
7. Install the 4th input gear and 4th needle bearing.
SCIA1032E
MT-104
[RS6F51H]
8. Measure the dimension “C2 ” as shown. Select a thrust washer
so that dimension “C2 ” satisfies standard dimension specifica- A
tion. Then install the thrust washer onto the input shaft.
Standard for dimension “C2 ” : 154.7 - 154.8 mm
(6.091 - 6.094 in) B
CAUTION:
Only 1 thrust washer can be selected.
MT
G
SCIA0925E
Thrust Washer
Thickness Part number Thickness Part number H
3.84 mm (0.1512 in) 32347 8H500 4.02 mm (0.1583 in) 32347 8H503
3.90 mm (0.1535 in) 32347 8H501 4.08 mm (0.1606 in) 32347 8H504
3.96 mm (0.1559 in) 32347 8H502 4.14 mm (0.1630 in) 32347 8H505 I
9. Install the 5th bushing using Tool as shown.

10. Install the 5th needle bearing and 5th input gear. J
11. Install the 5th baulk ring.
SCIA1033E
M
12. Install the synchronizer assembly onto a new 5th-6th synchro-
nizer hub.
CAUTION:
Do not reuse the 5th-6th synchronizer hub.
● Install with the orientation of the synchronizer hub as shown.
SCIA0921E
MT-105
[RS6F51H]
● Be sure not to hook the ends of the 2 spread springs (front
SCIA1083E
13. Install the 5th-6th synchronizer hub assembly using Tool as

shown.
CAUTION:
Align the grooves of the 5th-6th shifting insert and 5th-6th
baulk ring.
SCIA1039E
14. Install the needle bearing, 6th input gear and then 6th bushing
SCIA1040E
15. Install the snap ring onto the input shaft, and measure to check
that end play (gap between snap ring and groove) of the 6th
bushing is within specification.
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
● If the measurement is outside the standard value, select the
appropriate size snap ring.
SCIA0970E
Snap Rings
Thickness Part number Thickness Part number
1.76 mm (0.0693 in) 32204 8H511 2.01 mm (0.0791 in) 32204 8H516
1.81 mm (0.0713 in) 32204 8H512 2.06 mm (0.0811 in) 32204 8H517
1.86 mm (0.0732 in) 32204 8H513 2.11 mm (0.0831 in) 32204 8H518
1.91 mm (0.0752 in) 32204 8H514 2.16 mm (0.0850 in) 32204 8H519
1.96 mm (0.0772 in) 32204 8H515 2.21 mm (0.0871 in) 32204 8H520
MT-106
[RS6F51H]
16. Install the input shaft rear bearing using Tool as shown.
CAUTION: A
Install input shaft rear bearing with its brown surface facing
the input gear side.
B
MT
SCIA1041E
D
17. Install the input shaft front bearing using Tool as shown.
18. Install the oil channel onto the input shaft.
E
G
SCIA1042E
19. Check the end play of the 3rd, 4th, 5th and 6th input gears as
H
shown.
End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in) I
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
J
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0966E
K
MT-107
MAINSHAFT AND GEARS
[RS6F51H]
MAINSHAFT AND GEARS PFP:32241
Disassembly and Assembly ECS005VI
DISASSEMBLY
1. Before disassembling, measure the end play of 1st and 2nd
main gears as shown.
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
CAUTION:
If the measurement is outside the standard value, disas-
semble to check the contact surfaces of gear, shaft, and
hub. Adjust with the snap ring at assembly.
SCIA0973E
2. Remove the snap ring.

3. Remove the C-ring holder, and then mainshaft C-ring as shown.
SCIA0974E
4. Remove the mainshaft rear bearing, adjust shim, and 6th main
gear using Tool as shown.
5. Remove the 5th-6th mainshaft spacer.
SCIA1056E
6. Remove the 4th main gear and 5th main gear simultaneously
7. Remove the adjusting shim.
8. Remove the 3rd-4th mainshaft spacer.
SCIA1044E
MT-108
MAINSHAFT AND GEARS
[RS6F51H]
9. Remove the 3rd main gear, 2nd main gear, 2nd gear needle
bearing, 2nd bushing, 1st-2nd synchronizer assembly, 1st main A
gear, reverse main gear, 1st gear needle bearing, and 1st bush-
ing simultaneously using Tool as shown.
B
MT
SCIA1045E
D
Mainshaft and Gears
Check the items listed as shown. If necessary, replace them with E
new ones.
● Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the mainshaft.
F
● Excessive wear, damage, peeling, and other non-standard con-
ditions of the mainshaft gears.
G
SMT640A H
Synchronizer
Check the items listed as shown. If necessary, replace them with
new ones. I
● Damage, unusual wear on contact surfaces of coupling sleeve,
synchronizer hub, and shifting insert.
● Coupling sleeve and synchronizer hub must move smoothly as J
shown.
SMT387A
L
● If any cracks, damage, or excessive wear is found on the cam
face of baulk ring or working face of the insert, replace it.
M
SMT867D
MT-109
MAINSHAFT AND GEARS
[RS6F51H]
Baulk Ring Clearance
Double Cone Synchronizer (1st)
Check the clearance of outer baulk ring, synchronizer cone, and
inner baulk ring of 1st double cone synchronizer, using the following
steps.
NOTE:
The mean value is the middle value of a set of measurements
between the highest and lowest values. It is calculated by adding the
highest and lowest measured value and dividing their sum by two:
[(high value) + (low value)] / 2 = mean value.
CAUTION:
Outer baulk ring, synchronizer cone, and inner baulk ring act as SMT138E
a set to control the clearances “A” and “B”. If the measurement

exceeds the service limit value, replace all of them as a set.
1. Using a dial gauge and Tool, measure clearance “A” at two or

more points diagonally opposite, and calculate mean value.
Clearance “A”
Standard : 0.6 - 0.8 mm (0.024 - 0.031 in)
Limit value : 0.2 mm (0.008 in) or less
SCIA1046E
2. Using a feeler gauge, measure clearance “B” at two or more

points diagonally opposite, and calculate mean value as shown.
Clearance “B”
Standard : 0.6 - 1.1 mm (0.024 - 0.043 in)
Limit value : 0.2 mm (0.008 in) or less
SCIA1084E
Triple Cone Synchronizer (2nd)

Check the clearance of the outer baulk ring, synchronizer cone, and
inner baulk ring of the 2nd triple cone synchronizers, using the fol-
lowing procedure.
CAUTION:
The outer baulk ring, synchronizer cone, and inner baulk ring
operate as a set to control the clearances “A”, “B”, and “C”. If
the measured clearances exceed the service limit value, replace
the components as a set.
NOTE:
To calculate the mean value of two or more measured values, add
the highest and lowest measured values and divide by two. WCIA0195E
MT-110
MAINSHAFT AND GEARS
[RS6F51H]
3. Press the baulk ring on to the clutch gear taper cone by hand,
then measure the clearance “A” at two or more points diagonally A
opposite with a feeler gauge, and then calculate the mean value.
Clearance “A”
Standard : 0.6 - 1.2 mm (0.024 - 0.047 in) B
Limit : 0.3 mm (0.012 in)
MT
LCIA0298E
D
4. Measure clearances “B” at two or more points diagonally oppo-
site with a feeler gauge, and then calculate the mean value.
Clearance “B” E
Standard : 0.6 - 1.1 mm (0.024 - 0.043 in)
Limit : 0.2 mm (0.008 in)
F
G
SCIA1084E
5. Press the baulk ring on to the clutch gear taper cone by hand,
then measure the clearance “C” at two or more points diagonally H
opposite with a feeler gauge, and then calculate the mean value.
Clearance “C”
Standard : 0.7 - 1.1 mm (0.028 - 0.043 in) I
Limit : 0.3 mm (0.012 in)
J
LCIA0300E
K
Bearing
● Rough rotation of the bearing as shown. L
● Damage to the bearing.
MTF0041D
MT-111
MAINSHAFT AND GEARS
[RS6F51H]
ASSEMBLY
1. Install the reverse main gear using Tool as shown.
SCIA1048E
CAUTION:
Install with the orientation of reverse main gear as shown.
SCIA0992E
2. Install the 1st bushing using Tool as shown.

3. Install the needle bearing, and then the 1st main gear.
SCIA1049E
4. Install the spread spring, shifting insert, and a new 1st-2nd synchronizer hub onto the 1st-2nd coupling
sleeve.
CAUTION:
● Do not reuse 1st-2nd synchronizer hub
● Install with the orientation of the new synchronizer hub

as shown.
SCIA0921E
MT-112
MAINSHAFT AND GEARS
[RS6F51H]
● Install with the orientation of coupling sleeve as shown.
A
MT
SCIA0989E
D
● Do not hook the ends of the two spread springs (front
E
G
SCIA1083E
5. Install the 1st-2nd coupling sleeve assembly onto the mainshaft,

H
and the synchronizer hub assembly onto the mainshaft using
Tool as shown.
CAUTION:
● Outer baulk ring, synchronizer cone, and inner baulk ring
I
on the 2nd gear-side must have been removed.
● Install the coupling sleeve with the proper orientation.
J
SCIA1050E
K
6. Install the 2nd bushing using Tool as shown.
7. Install the outer baulk ring, synchronizer cone, and inner baulk
ring on 2nd gear-side. L
8. Install the 2nd needle bearing and 2nd gear.
SCIA1051E
9. Install the 3rd main gear.

CAUTION:
Install the 3rd main gear with the orientation as shown.
10. Install the 3rd-4th mainshaft spacer.
SCIA1052E
MT-113
MAINSHAFT AND GEARS
[RS6F51H]
11. Measure the dimension “C1 ”. Select a suitable adjusting shim
so that the dimension “C1 ” satisfies the specified standard
value, and install it onto the mainshaft.
Standard for : 173.85 - 173.95 mm (6.844 - 6.848 in)
dimension “C1 ”
CAUTION:
SCIA0944E
Adjusting Shim
0.52 mm (0.0205 in) 32238 8H500 0.84 mm (0.0331 in) 32238 8H504
0.60 mm (0.0236 in) 32238 8H501 0.92 mm (0.0362 in) 32238 8H505
0.68 mm (0.0268 in) 32238 8H502 1.00 mm (0.0394 in) 32238 8H506
0.76 mm (0.0299 in) 32238 8H503 1.08 mm (0.0425 in) 32238 8H507
12. Install the 4th main gear with the specified orientation as shown,
CAUTION:
Install the 4th main gear with the orientation as shown.
SCIA1053E
13. Install the 5th main gear with the specified orientation as shown,
CAUTION:
Install the 5th main gear with the orientation as shown.
14. Install the 5th-6th mainshaft spacer.
SCIA1054E
MT-114
MAINSHAFT AND GEARS
[RS6F51H]
15. Install the 6th main gear using Tool as shown.
A
MT
SCIA1057E
D
16. Select the 6th main adjusting shim and then install it onto the mainshaft.
● Calculate thickness “S” of 6th main adjusting shim by proce-
dure below so that end play dimension between 6th main E
gear and mainshaft rear bearing becomes the dimension
specified.
End play : 0 - 0.1 mm (0 - 0.004 in) F
Dimension “S” = (“S1 ” – “S2 ”) + End play
“S” : Thickness of adjusting shim
“S2 ” : Dimension from mainshaft standard face to G
mainshaft rear bearing press-fit end face
“S2 ” : Dimension from mainshaft standard face to
6th main gear end face H
CAUTION:
I
K
SCIA0995E
Adjusting Shim
Thickness Part number Thickness Part number L
0.88 mm (0.0346 in) 32237 8H560 1.20 mm (0.0472 in) 32237 8H564
0.96 mm (0.0378 in) 32237 8H561 1.28 mm (0.0504 in) 32237 8H565
1.04 mm (0.0409 in) 32237 8H562 1.36 mm (0.0535 in) 32237 8H566 M
1.12 mm (0.0441 in) 32237 8H563
a. Using a height gauge, measure the dimension “S1 ” and “S2 ” as shown.
b. Install the selected 6th main adjusting shim to the mainshaft.
17. Install the mainshaft rear bearing using Tool as shown.
SCIA1058E
MT-115
MAINSHAFT AND GEARS
[RS6F51H]
18. Install the C-ring onto the mainshaft, and check that the end play
of mainshaft rear bearing meets specifications.
End play standard value : 0 - 0.06 mm (0 - 0.0024 in)
● If the measurement is outside the specified standard value,
reselect a new C-ring.
SCIA0979E
C-Ring
2.535 mm (0.0866 in) 32348 8H800 2.835 mm (0.1116 in) 32348 8H810
2.565 mm (0.1010 in) 32348 8H801 2.865 mm (0.1128 in) 32348 8H811
2.595 mm (0.1022 in) 32348 8H802 2.895 mm (0.1140 in) 32348 8H812
2.625 mm (0.1033 in) 32348 8H803 2.925 mm (0.1152 in) 32348 8H813
2.655 mm (0.1045 in) 32348 8H804 2.955 mm (0.1163 in) 32348 8H814
2.685 mm (0.1057 in) 32348 8H805 2.985 mm (0.1175 in) 32348 8H815
2.715 mm (0.1069 in) 32348 8H806 3.015 mm (0.1187 in) 32348 8H816
2.745 mm (0.1081 in) 32348 8H807 3.045 mm (0.1199 in) 32348 8H817
2.775 mm (0.1093 in) 32348 8H808 3.075 mm (0.1211 in) 32348 8H818
2.805 mm (0.1104 in) 32348 8H809
19. Fit the C-ring holder, and install the snap ring as shown.
SCIA0974E
20. Check the end play of 1st and 2nd main gears as shown.
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0973E
MT-116
REVERSE IDLER SHAFT AND GEARS
[RS6F51H]
REVERSE IDLER SHAFT AND GEARS PFP:32281
A
Disassembly and Assembly ECS005VJ
DISASSEMBLY
1. Remove the reverse idler gear adjusting shim.
B
2. Remove the reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
3. Remove the reverse idler gear needle bearing.
4. Remove the thrust needle bearing. MT
5. Remove the reverse baulk ring.
6. Remove the reverse idler gear (front).
7. Remove the reverse idler gear needle bearing. D
8. Remove the thrust needle bearing.
9. Pull off the locking pin from the reverse idler shaft.
E
Reverse Idler Shaft and Gears
Check the parts listed. If necessary, replace them with new ones. F
● Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the reverse idler shaft.
● Excessive wear, damage, peeling, and other non-standard con- G
ditions of the reverse idler gears.
SCIA0953E I
Synchronizer
Check parts listed. If necessary, replace them with new ones.
J
● Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and insert spring.
● Coupling sleeve and synchronizer hub must move smoothly as
shown. K
SMT637A
M
● If any crack, damage, or excessive wear is found on cam face of
SMT867D
MT-117
REVERSE IDLER SHAFT AND GEARS
[RS6F51H]
Baulk ring clearance
● Press the baulk ring against the cone, and measure the clear-
ance between the baulk ring and cone as shown. If the mea-
surement is below the specified limit, replace it with a new one.
Baulk ring to gear clearance
Standard : 0.95 - 1.4 mm (0.0374 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
Bearing
Check the parts listed. If necessary, replace them with new ones.
● Damage and rough rotation of the bearing.
ASSEMBLY
Assembly is in the reverse order of disassembly.
CAUTION:
● Install the insert spring with the orientation as shown.
SCIA0954E
MT-118
FINAL DRIVE
[RS6F51H]
FINAL DRIVE PFP:38411
A
Disassembly and Assembly ECS005VK
DISASSEMBLY
1. Remove the mounting bolts. Then, separate the final gear from the differential case.
B
2. Remove the speedometer drive gear.
3. Using a puller and Tool (drift), remove the differential side bear-
ing (clutch housing side) as shown. MT
SCIA1019E
F
4. Using a puller and Tool (drift), remove the differential side bear-
ing (transaxle case side) as shown.
I
SCIA1060E
INSPECTION AFTER DISASSEMBLY J

Bearing
Check for bearing damage and rough rotation as shown. If neces-
sary, replace with a new one. K
CAUTION:
When replacing the tapered roller bearing, replace the outer and
inner races as a set.
L
SPD715
ASSEMBLY
1. Using Tool (drift), install the differential side bearing (transaxle
case side) as shown.
SCIA1061E
MT-119
FINAL DRIVE
[RS6F51H]
2. Align and install the speedometer drive gear onto the differential
case as shown.
SMT842D
3. Using Tool (drift), install the differential side bearing (clutch

housing side) as shown.
SCIA1018E
4. Install the final gear into the differential case, and tighten the
final gear bolts to specification.
Final gear bolts : Refer to MT-85, "FINAL DRIVE
COMPONENTS" .
SCIA0912E
MT-120
SHIFT CONTROL
[RS6F51H]
SHIFT CONTROL PFP:32982
A
Inspection ECS005VL
Check the contact surfaces and sliding area for wear, damage, or
bending as shown. If necessary, replace the parts. B
MT
H
SCIA0913E
SHIFT FORK
Check if the width of the shift fork hook (sliding area with coupling I
sleeve) is within specification, as shown.
SMT801D L
Shift Fork
Item One-side wear specification Sliding width of new part M
7.80 - 7.93 mm
1st & 2nd 0.2 mm (0.008 in)
(0.3071 - 0.3122 in)
7.80 - 7.93 mm
3rd & 4th 0.2 mm (0.008 in)
(0.3071 - 0.3122 in)
6.10 - 6.23 mm
5th & 6th 0.2 mm (0.008 in)
(0.2402 - 0.2453 in)
12.80 - 12.93 mm
Reverse 0.2 mm (0.008 in)
(0.5039 - 0.5091 in)
MT-121
[RS6F51H]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
General Specifications ECS005VM
TRANSAXLE
Engine QR25DE
Transaxle model RS6F51H
Model code number 7Y076
Number of speed 6
Synchromesh type Warner
Shift pattern
SCIA0955E
Gear ratio 1st 3.153

2nd 1.944
3rd 1.392
4th 1.055
5th 0.809
6th 0.630
Reverse 3.002
Number of teeth Input gear 1st 13
2nd 18
3rd 31
4th 36
5th 42
6th 46
Reverse 13
Main gear 1st 41
2nd 35
3rd 39
4th 38
5th 34
6th 29
Reverse 38
Front 37
Reverse idler gear
Rear 38
Oil capacity (US qt, Imp qt) 2.2 (2 3/8, 2)

Reverse synchronizer Installed
Remarks Double baulk ring type synchronizer 1st synchronizer
Triple baulk ring type synchronizer 2nd synchronizer
MT-122
[RS6F51H]
FINAL GEAR
Engine QR25DE
A
Transaxle model RS6F51H

Model code number 7Y076 B
Final gear ratio 4.133
Final gear/Pinion 62/15
Number of teeth
Side gear/Pinion mate gear — MT
Gear End Play ECS005VN
Unit: mm (in) D
Gear End play
1st main gear 0.20 - 0.30 (0.0079 - 0.0118)
2nd main gear 0.06 - 0.16 (0.0024 - 0.0063)
E
3rd input gear 0.18 - 0.31 (0.0071 - 0.0122)

4th input gear 0.20 - 0.30 (0.0079 - 0.0118)
F
5th input gear 0.06 - 0.16 (0.0024 - 0.0063)
6th input gear 0.06 - 0.16 (0.0024 - 0.0063)
G
Clearance Between Baulk Ring and Gear ECS005VO
3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING

Unit: mm (in)
H
Gear Standard Wear limit
3rd 0.9 - 1.45 (0.035 - 0.0571) 0.7 (0.028)
4th 0.9 - 1.45 (0.035 - 0.0571) 0.7 (0.028) I
5th 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
6th 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
Reverse 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
J
MT-123
[RS6F51H]
1ST AND 2ND BAULK RING
Unit: mm (in)
1st Double Baulk Ring
SMT138E
2nd Triple Baulk Ring
WCIA0195E
Standard Wear limit

Dimension
Double baulk ring Triple baulk ring Double baulk ring Triple baulk ring
A 0.6 - 0.8 (0.024 - 0.031) 0.6 - 1.2 (0.024 - 0.047) 0.2 (0.008) 0.3 (0.012)
B 0.6 - 1.1 (0.024 - 0.043) 0.6 - 1.1 (0.024 - 0.043) 0.2 (0.008) 0.2 (0.008)
C — 0.7 - 1.1 (0.028 - 0.043) — 0.3 (0.012)
Available Snap Rings ECS005VP
6TH BUSHING
End play 0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in) Part number* Thickness mm (in) Part number*
1.76 (0.0693) 32204 8H511 2.01 (0.0791) 32204 8H516
1.81 (0.0713) 32204 8H512 2.06 (0.0811) 32204 8H517
1.86 (0.0732) 32204 8H513 2.11 (0.0831) 32204 8H518
1.91 (0.0752) 32204 8H514 2.16 (0.0850) 32204 8H519
1.96 (0.0772) 32204 8H515 2.21 (0.0871) 32204 8H520
*: Always check with the Parts Department for the latest parts information.
Available C-rings ECS005VQ
MAINSHAFT C-RING
End play 0 - 0.06 mm (0 - 0.0024 in)
2.535 (0.0866) 32348 8H800 2.835 (0.1116) 32348 8H810
2.565 (0.1010) 32348 8H801 2.865 (0.1128) 32348 8H811
2.595 (0.1022) 32348 8H802 2.895 (0.1140) 32348 8H812
2.625 (0.1033) 32348 8H803 2.925 (0.1152) 32348 8H813
2.655 (0.1045) 32348 8H804 2.955 (0.1163) 32348 8H814
2.685 (0.1057) 32348 8H805 2.985 (0.1175) 32348 8H815
2.715 (0.1069) 32348 8H806 3.015 (0.1187) 32348 8H816
2.745 (0.1081) 32348 8H807 3.045 (0.1199) 32348 8H817
2.775 (0.1093) 32348 8H808 3.075 (0.1211) 32348 8H818
2.805 (0.1104) 32348 8H809
MT-124
[RS6F51H]
Available Thrust Washers ECS005VR
INPUT SHAFT THRUST WASHER A
MT
SCIA1008E
Standard length “C2 ” 154.7 - 154.8 mm (6.091 - 6.094in) E

3.84 (0.1512) 32347 8H500 4.02 (0.1583) 32347 8H503
3.90 (0.1535) 32347 8H501 4.08 (0.1606) 32347 8H504 F
3.96 (0.1559) 32347 8H502 4.14 (0.1630) 32347 8H505
G
Available Adjusting Shims ECS005VS
MAINSHAFT ADJUSTING SHIM

H
SCIA1009E K
Standard length “C1 ” 173.85 - 173.95 mm (6.844 - 6.848in)
L
0.52 (0.0205) 32238 8H500 0.84 (0.0331) 32238 8H504
0.60 (0.0236) 32238 8H501 0.92 (0.0362) 32238 8H505
0.68 (0.0268) 32238 8H502 1.00 (0.0394) 32238 8H506
0.76 (0.0299) 32238 8H503 1.08 (0.0425) 32238 8H507 M
INPUT SHAFT REAR BEARING ADJUSTING SHIM

End play 0 - 0.06 mm (0 - 0.0024 in)
Thickness mm (in) Part number* Thickness mm (in) Part number* Thickness mm (in) Part number*
0.40 (0.0157) 32225 8H500 0.88 (0.0346) 32225 8H512 1.36 (0.0520) 32225 8H524
0.44 (0.0173) 32225 8H501 0.92 (0.0362) 32225 8H513 1.40 (0.0551) 32225 8H560
0.48 (0.0189) 32225 8H502 0.96 (0.0378) 32225 8H514 1.44 (0.0567) 32225 8H561
0.52 (0.0205) 32225 8H503 1.00 (0.0396) 32225 8H515 1.48 (0.0583) 32225 8H562
0.56 (0.0220) 32225 8H504 1.04 (0.0409) 32225 8H516 1.52 (0.0598) 32225 8H563
0.60 (0.0236) 32225 8H505 1.08 (0.0425) 32225 8H517 1.56 (0.0614) 32225 8H564
0.64 (0.0252) 32225 8H506 1.12 (0.0441) 32225 8H518 1.60 (0.0630) 32225 8H565
6.68 (0.0268) 32225 8H507 1.16 (0.0457) 32225 8H519 1.64 (0.0646) 32225 8H566
0.72 (0.0283) 32225 8H508 1.20 (0.0472) 32225 8H520
0.76 (0.0299) 32225 8H509 1.24 (0.0488) 32225 8H521
0.80 (0.0315) 32225 8H510 1.28 (0.0504) 32225 8H522
0.84 (0.0331) 32225 8H511 1.32 (0.0520) 32225 8H523
MT-125
[RS6F51H]
MAINSHAFT REAR BEARING ADJUSTING SHIM

End play 0 - 0.06 mm (0 - 0.0024 in)
0.44 (0.0173) 32238 8H510 0.80 (0.0315) 32238 8H519
0.48 (0.0189) 32238 8H511 0.84 (0.0331) 32238 8H520
0.52 (0.0205) 32238 8H512 0.88 (0.0346) 32238 8H521
0.56 (0.0220) 32238 8H513 0.92 (0.0362) 32238 8H522
0.60 (0.0236) 32238 8H514 0.96 (0.0378) 32238 8H523
0.64 (0.0252) 32238 8H515 1.00 (0.0396) 32238 8H524
0.68 (0.0268) 32238 8H516 1.04 (0.0409) 32238 8H560
0.72 (0.0283) 32238 8H517 1.08 (0.0425) 32238 8H561
0.76 (0.0299) 32238 8H518
REVERSE IDLER GEAR ADJUSTING SHIM

End play 0.04 - 0.14 mm (0.0016 - 0.0055 in)
1.76 (0.0693) 32237 8H500 2.24 (0.0882) 32237 8H506
1.84 (0.0724) 32237 8H501 2.32 (0.0913) 32237 8H507
1.92 (0.0756) 32237 8H502 2.40 (0.0945) 32237 8H508
2.00 (0.0787) 32237 8H503 2.48 (0.0976) 32237 8H509
2.08 (0.0819) 32237 8H504 2.56 (0.1008) 32237 8H510
2.16 (0.0850) 32237 8H505 2.64 (0.1039) 32237 8H511
6TH MAIN GEAR ADJUSTING SHIM

End play 0 - 0.1 mm (0 - 0.004 in)
0.88 (0.0346) 32237 8H560 1.20 (0.0472) 32237 8H564
0.96 (0.0378) 32237 8H561 1.28 (0.0504) 32237 8H565
1.04 (0.0409) 32237 8H562 1.36 (0.0520) 32237 8H566
1.12 (0.0441) 32237 8H563
Available Shims – Differential Side Bearing Preload and Adjusting Shim(s) ECS005VT
BEARING PRELOAD
Differential side bearing preload L* 0.15 - 0.21 mm (0.0059 - 0.0083)
*: Install shims which are “deflection of differential case” + “L” in thickness.
DIFFERENTIAL SIDE BEARING ADJUSTING SHIM(S)

0.48 (0.0189) 31438 80X00 0.72 (0.0283) 31438 80X06
0.52 (0.0205) 31438 80X01 0.76 (0.0299) 31438 80X07
0.56 (0.0220) 31438 80X02 0.80 (0.0315) 31438 80X08
0.60 (0.0236) 31438 80X03 0.84 (0.0331) 31438 80X09
0.64 (0.0252) 31438 80X04 0.88 (0.0346) 31438 80X10
0.68 (0.0268) 31438 80X05 0.92 (0.0362) 31438 80X11
MT-126

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C TRANSMISSION/TRANSAXLE

● Do not reuse transaxle oil, once it has been drained.

Special Service Tools ECS005TE

KV38106000 Selecting differential side bearing adjusting

KV32101000 Removing and installing retaining pin

KV31100300 Removing and installing retaining pin

ST30031000 Removing 3rd, 5th input gear

ST33290001 ● Removing idler gear bearing outer race D

ST33230000 Removing differential oil seal

ST22350000 Installing input shaft front and rear bearing

ST22452000 Installing 3rd and 4th main gear

ST37750000 Installing input shaft oil seal

ST30611000 Installing differential side bearing outer race

Commercial Service Tools ECS005TF

Tool name Description

Drift Removing input shaft rear bearing

Drift Installing differential oil seal

Drift Installing differential oil seal

Drift Installing 2nd gear bush

NVH Troubleshooting Chart ECS005TG

Check Plug Return Spring and Check Ball (Worn or damaged)

Insert Spring, Shifting Insert (Damaged)

Baulk Ring (Worn or damaged)

Bearing (Worn or damaged)

Gear (Worn or damaged)

Shift Fork (Worn)

OIL LEAKAGE AND OIL LEVEL

4. Install differential oil seal with a suitable tool (drift). F

5. Install drive shafts. Refer to FAX-16, "Installation" .

Position Switch Check ECS005TL

TRANSAXLE GEAR CONTROL

1. Control lever knob 2. Boot 3. Finisher

3. Remove the boot.

5. Install the striking rod oil seal using Tool as shown.

6. Install the boot.

3. Disconnect the clutch operating cylinder from the transaxle and L

12. Remove the lower housing bolts.

1. Clutch housing 2. Dust seal 3. Oil pocket

Disassembly and Assembly ECS005TP

4. Remove O-ring and mainshaft bearing adjusting shim.

8. Remove check plugs, springs, and check balls from case.

3. Remove 3rd & 4th bracket retaining pin using Tool.

4. Remove 3rd & 4th shift fork stopper ring.

13. Remove check ball from housing.

18. Remove final drive assembly from housing.

22. Remove mainshaft front bearing from housing using Tool.

29. Remove differential oil seal from housing using Tool. H

4. Hammer the dust seal into clutch housing as far as it will go

7. Align the notches on mainshaft front bearing and transaxle case.

9. Attach boot, striking rod, and striking lever to clutch housing.

14. Tighten the two reamer bolts to specification.

17. Install 5th & reverse shift fork. H

24. Install 5th & reverse bracket stopper ring.

28. Install 3rd & 4th shift fork stopper ring.

2. Install welch plug into transaxle case with a suitable tool.

a. Using dial gauge and scale, measure dimension “N1 ” between

6. Calculate dimension “O” (thickness of adjusting shim) using the

a. Using block gauge, scale, and dial gauge, measure dimension

12. Install speedometer pinion assembly.