MANUAL TRANSMISSION MT SECTION CONTENTS. r I FS5R30A I I I I FS5W71C & FS5R30AI I

Transcription

1 I MANUAL TRANSMISSION MT SECTION CONTENTS I I FS5W71C & FS5R30AI I PREPARATION MT- 2 ON-VEHICLE SERVICE MT- 7 REMOVAL AND INSTALLATION MT- 8 I I FS5W71CI MAJOR OVERHAUL MT- 9 DISASSEMBLY MT-12 I NSPECTI ON MT-17 ASSEMBLY MT-19 r I FS5R30A I I MAJOR OVERHAUL MT-29 DISASSEMBLY MT-33 INSPECTION MT-40 ASSEMBLY MT-42 I IFS5W71C & FS5R30AI 1 SERVICE DATA AND SPECIFICATIONS (S D.S ) MT-54

2 ~ PREPARATION I FS5W71C I SPECIAL SERVICE TOOLS - for FS5W71C Tool number (Kent-Moore No 1 Tool name Description ST ( - ) Adapter setting plate Fixing adapter plate with gear assembly KV (See J26349-A) Puller Removing overdrive mainshaft bearing KV ( - ) Transmission press stand Pressing counter gear and mainshaft ST (526348) Wrench ST (J25689-A) Pin Dunch Removing and installing fork rod retaining Din ST ( ) Puller Removing and installing 1st gear bushing Removing maw drwe gear bearing ST ( - ) Drift a 38 mm I1 50 in1 dia b 33 mm I1 30 1n1 dv Installing counter drive gear ST (J I Drift 8 29 mm I1 14 in1 die b 23 mm I091 in1 dm Installing counter gear front and rear end bearings ST (J ) Drift a a 34 mm (1 34 In) dia b 28 mm I1 10 on1 du Installing 0 D gear bushing ST (J I Drift a 44 mm I1 73 an1 dm b 31 mm I1 22 In1 dm Installing front cover oil seal MT-2

3 PREPARATION I FS5W71C Tool number (Kent-Moore No I Tool name Description ST (J26082) Drift Installing rear oil seal ST (J25810-A) Puller Removing rear oil seal ST ( - ) Drift ST (J ) Drift ST (J Drift U a 77 mm I3 03 inl dm b 55 5 mm In) din a 71 5 mm ml dm b 47 5 mm I1 870 #"I daa a 60 mm (236 In1 dm b 44 5 mm I1 752 In) din Installing mainshaft ball bearing Installing main drive gear bearing Installing counter rear bearing Installing 3rd & 4th synchronizer assembly COMMERCIAL SERVICE TOOL - for FS5W71C Tool name Puller Removing counter bearings. counter drive and 0 D gears MT-3

4 P RE PA RAT I 0 N (FS5R30AJ SPECIAL SERVICE TOOLS - for FS5R3OA Tool number (Kent-Moore No ) Tool name Description ST (J25689-A) Pin punch ~~ Removing and installing retaining pin ST (J ) Puller Removing 1st & 2nd synchronizer assembly Removing counter gear rear thrust bearing Removing main drive bearing ST (J25810-A) Puller Removing rear oil seal ST ( - ) Drift ST ( ) Drift KV (J25523) Drift (J34331) Drift (J I Drift ST (J ) Drift a 51 mm (2 01 in) dta b 28 5 mm I1 122 an) dia il 34 mm I1 34 In) dm b 28 mm (1 10 in1 dm a 54 mm In) dia b 32 mm (126 on) dia a 77 mm (303 in) doa b 55 5 mm (2 185 in) dm a 44 rnrn (173 an1 doa b 245 mm (094 In) dta a 72 mm in) dia b 40 mm I1 89 in1 dia Removing mainshaft and counter gear Removing counter gear front bearing (Use with KV ) Removing counter gear front bearing (Use with ST ) Installing counter gear rear Removing mainshaft front Installing mainshaft front Installing counter gear front Installing front cover oil seal Installing main drive gear bearing MT-4

5 ~ PREPARATION 1 - Tool number (Kent-Moore No ) Tool name Description ( Removing counter gear rear Installing 0 D gear bushing 0 Installing reverse cone 0 Installing reverse counter Installing counter gear rear end bearing ST (534337) Drift ST (J26082) Drift (J ) Puller leg a / a 40mm1157# b 31 mm I1 22 an1 dna a 45 mm I dm b 36 mm I1 42 in) dm a 60 mm m) dm b 47 mm I1 85 tn) dm Installing reverse hub Installing mainshaft rear bearing Installing rear oil seal Installing mainshaft and counter gear (Use with J34328) (J34328) Puller Installing mainshaft and counter gear (Use with J ) (.I Drift (J34342) Drift ST ( - ) Drift a a 4 a 44 5 mm I1 752 ml dm b 38 5 mm I1 516 ~n) doa a 44 5 mm I1 752 an) doa b 40 5 mm I1 594 an) dia Installing sub-gear snap ring Installing 0 D main gear Installing reverse gear bushing Installing sub-gear on reverse idler gear a = 50 mm I1 97 in) dia b = 39 mm I1 54 in1 dm MT-5

6 ~ PREPARATION peikl COMMERCIAL SERVICE TOOL - FS5R30A Tool name Description Puller Removing counter gear rear end bearing Removing mainshaft rear bearing Removing reverse synchronizer hub Removing reverse counter gear MT-6

7 ON-VEHICLE SERVICE Checking M/T Oil Check manual transmission for leakage. & Fill to this level LFiller plug SMAlO Check oil level Replacing Rear Oil Seal MT- 7

8 REMOVAL AND INSTALLATION Removal 0 Remove exhaust front tube, catalytic converter and exhaust manifold connecting tube Refer to section EM. Remove propeller shaft. Refer to section PD Insert plug into rear oil seal after removing propeller shaft. 0 Support engine by placing a jack under oil pan CAUTION : 0 Be careful not to damage spline, sleeve yoke and rear oil seal, when removing propeller shaft. 0 Do not place jack under the oil pan drain plug. 0 Remove shift lever (FS5W71C). Bolt No Tightening torque N in (kg-m, ft-lb) ( ( , ( ,22.29l ( , P mm (in) 65 ( (2 36) 55 (2 17) 25 (0 981 MT-8

9 MAJOR OVERHAUL 1 - MT-9

10 MT-1 0 MAJOR OVERHAUL Washer7 Gear Components - FS5W71C Maan drive gear ball bearing am drwe gear.. Shifting insert -&Y / flanrhaft ball bearing Mainshaft rear end bearmg Speedometer draw gear Without Tool 1231 Countershaft lock nut 0 'Overdrive counter gear Reverse counter gear spacer kounter rear bearing OD hub Insert retainer Reverse idler gear Snap ring 0 Reverse idler thrust warhei verse Idler gear bearing counter drwe gear * 'Reverse Reverse idler shaft idler thrust washer..-..."""... ~ snap ring 0 +ubilear spring * Subgar bracket Apply war oil to wars, shafts. wnchroniren, and buringr when esrnbllng Select with proper thckners * Pay attention to bts dsrectlon N rn Ikg-rn,ft-lbl SMT74?A

11 MT-11 MAJOR OVERHAUL Shift Control Components-FS5W71 C (With mainshaft braking mechanism) I F S5Wq a

12 DISASSEMBLY I FS5W71C I Case Components 1 Remove rear extension a Remove control housing, check ball, return spring plug, select check plunger and return springs v SMT982 b. Remove rear extension by lightly tapping It 2 Remove front cover, gasket, shim of countershaft front bearing, and snap ring of main drive gear ball bearing 3. Separate transmission case from adapter plate I / TM753 4 Remove oil seal of front cover Be careful not to damage mating surface of front cover. SMTO35 MT-12

13 D I SASS EM B LY 1 F K 1 Shift Control Components 1 Set up Tool on adapter plate. 2 Remove check ball plugs, check springs, and check balls ir J25689-AI TM754 3 Drive out retaining pins Then drive out fork rods and remove interlock balls 4 Remove lever bracket securing bolt. 5. Draw out 3rd4th fork rod. 6. Remove E-ring from 0.D.-rev. fork rod. MT-13

14 MT-14 D I SASS EM B LY piif] Shift Control Components (Cont'd) 7. Draw out 0 D.-rev. fork shaft by rotating 0.D.-rev bracket counterclockwise. I Gear End play mm (in) UT025 v 1 S t 2nd 3rd OD ( ) ( ( ) ( ) 2 3 Mesh 2nd and reverse gear, then draw out counter front bearing with suitable puller. Remove snap ring and then remove sub-gear bracket, sub-gear spring and sub-gear rsunable puller I 4 Draw out counter drive gear with main drive gear assembly with suitable puller When drawing out main drive gear assembly, be careful not to drop pilot bearing and baulk ring. SMTl62A

15 ~ DISASSEMBLY 1 - Gear Components (Cont'd) 5 a Disassemble parts at rear of adapter plate as follows Release staking on countershaft nut and mainshaft nut and loosen these nuts Mainshaft nut: Left-hand thread I SMTl63A I Y I b. Pull out 0.D counter gear with bearing with suitable puller c Draw out reverse counter gear and spacer d Remove snap rings from reverse idler shaft, and draw out reverse idler gear, thrust washers and reverse idler gear bear- e ing Remove speedometer drive gear and steel ball. (See J26349 AI f Remove snap ring and pull out overdrive mainshaft bearing, then remove snap ring g Remove mainshaft nut h. Remove thrust washer, steel roller, roller bearing and washer I Remove 0 D main gear, needle bearing and baulk ring (0 D ) J Remove 0 D coupling sleeve, shifting inserts and shifting insert springs k. Press out mainshaft and counter gear alternately Make sure to alternate pressing of mainshaft and counter gear so as not to allow the front surface of one to contact the rear surface of the other. 6 Remove front side components on mainshaft a Remove 1st gear washer and steel ball b. Remove 1st main gear and 1st gear needle bearing I SMT383A MT-15

16 MT-16 D I SASS E MB LY 1 - Gear Components (Cont'd) c d Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly Remove mainshaft front snap ring In e Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing IJ. SMT385P ST ) 7. Remove main drive gear bearing a Remove snap ring and washer b Remove main drive gear bearing I U I I SMT420A

17 INSPECTION 1 - I Shift Control Components 0 Check contact surface and sliding surface of fork rods for wear, scratches, projections or other damage SMTl37 Gear Components GEARS AND SHAFTS Check shafts for cracks, wear or bending Check gears for excessive wear, chlps or cracks SMT386A Counter gear L SMT550r SYNCHRONIZERS Check spline portion of coupling sleeves, hubs and gears for wear or cracks 0 Check baulk rings for cracks or deformation. 0 Check shifting inserts for wear or deformation 0 Check insert springs for deformation SMT026 MT-17

18 SMT140 1st&2nd 3rd & main drive Standard ( ) ( Wear limit 08(0031) 0 8 (0 031) I I BEARINGS MT-18

19 ASS EM B LY 1 - Mainrhaft ball bearing in adapter plate Gear Components 1 Install bearings into case components Counter rear bearing in adapter plate 2 Assemble adapter plate parts Install oil gutter on adapter plate and expand on rear side I, ' SMT153i a Install bearing retainer Insert reverse shaft, then install bearing retainer MT-19

20 ASS EM B LY Gear Components (Cont'd) b Tighten each screw, then stake it at two points I FS5W71C1 3 Install main drive gear bearing a. Press in main drive gear bearing b Install main drive gear spacer Thickness mm (in) 1 73 (00681) 1 80 (00709) 1 87 ( (00764) 2 01 (00791) 208(00819) Part number Assemble synchronizers MT-20

21 3rd and 4th I 8,Synchronizer hub ASS EM B LY Gear Components (Cont'd) 1 FS5W71C I I SMT024 0 D 15th) rvnehronlzer I hub SMT095A 5 Assemble 2nd main gear, needle bearing and 1st & 2nd synchronizer assembly, then press 1st gear bushing on mainshaft 6. Install 1st main gear.. 7. Install steel ball and thrust washer Before installing steel ball and thrust washer, apply grease to them. 8 Press mainshaft assembly to adapter plate with Tool KV I - ) T..".," MT-21

22 MT-22 ASS EM B LY Gear Components (Cont d) 9 [FS5W71C I Press counter gear into adapter plate with Tool 10. Install 3rd main gear and then press 3rd & 4th synchronizer assem bly I Pay attention to direction of 3rd & 4th synchronizer. Front c SMT Install thrust washer on mainshaft and secure it with mainshaft front snap ring Select proper snap ring to minimize clearance of groove in mainshaft. Mainshaft front snap ring: Refer to S.D.S. 12 Apply gear oil to mainshaft pilot bearing and install it on mainshaft 13 Press counter drive gear with main drive gear with Tool KV TM44; Pay attention to direction of counter drive gear.

23 0 ASS EM B LY Gear Components (Cont'd) 14 Install sub-gear components a Install sub-gear and sub-gear bracket on counter drive gear and then select proper snap ring to minimize clearance of groove in counter gear Allowable clearance of groove: 0 ~ 18 rnm ( in) Counter drive gear snap ring: Parts number I Thickness mm (in) (0 055) 1 5 (0 059) 1 6 (0 063) Subgear bracket LSub+ear rprtng SMT528A 15 Install selected counter drive gear snap ring 16 Press counter gear front bearing onto counter gear KV u TM Assemble parts at rear of adapter plate as follows a. Install reverse idler gear to reverse idler shaft with spacers, snap rings and needle bearing TM45 MT-23

24 ASS EM B LY I FS5W71C I rlnrert shifting spring I Gear Components (Cont'd) b. Install insert retainer and O.D. synchronizer to mainshaft Pay attention to direction of hub 1 D 15th) synchronizer1 &" Nub SMT095A c. install 0 D gear bushing with Tool d. Install 0 D main gear and needle bearing e. Install spacer, reverse counter gear and 0 D counter gear O.D. main gear and 0 D. counter gear should be handled as a matched set f. Install washer, roller bearing, steel roller and thrust washer g. Tighten mainshaft lock nut temporarily Always use new lock nut. ST lr SMT531 h. Install countershaft rear end bearing wlth Tool 18 Mesh 2nd and reverse gears, then tighten mainshaft lock nut with Tool. SMTOOJA MT-24

25 Torque wrench ASS EM BLY I FS5W71C 1 Gear Components (Cont'd) Use the left chart when deciding the readmg torque (Length of torque wrench vs setting or reading torque) 0 - g I151 ol D L u ) ) ( MT004A Mainshaft, 111 I If1 L Length of torque wrench Countershah 19. Tighten countershaft lock nut Always use new lock nut 20 Stake rnainshaft lock nut and countershaft lock nut with a punch 21 Measure gear end play For the description, refer to Disassernbly of Gear Components Shift Control Components 1 Install shift rods, interlock plunger, interlock balls and check balls a 1st-2nd shift fork L SMT989 MT-25

26 ASS EM B LY Shift Control Components (Cont'd) b 3rd-4th shift fork I F S5W7q c 0 D -reverse shift fork SMT Install 0.D.-rev. fork shaft by rotating 0.D -rev bracket clockwise. SMT791A 3. Install E-ring on 0.D.-rev. fork rod. 4. Install lever bracket securing bolt MT-26

27 ASS EM B LY 1 - Case Components 1 Install front cover oil seal Apply multi-purpose grease to seal lip. SMT036 2 Apply sez r 1g SUI ce c transmission case 3 Slide gear assembly onto adapter plate by lightly tapping with a soft hammer 4 Apply sealant to mating surface of adapter plate 5 Install rear extension 6 Fit main drive bearing snap ring MT-27

28 ASSEMBLY [Fs5w71cI A A Distance from bearmg surface to transmisimn Case Components (Cont d) 7. Select counter front bearing shim Unit mm (in) 1 Tranrmirrion care 2 Counter gear front bearing 3 Counter gear ( ) TU?, ( ) A I Thickness of shim I Part number ( ) ( O ( ) ( ) ( ) 0 1 (0 004) V (0 008) V (0 016) Not necessary I 03 (00121 I V5002 I V (00201 I V (0024) V Install gasket and front cover 9 Install return spring plugs, check ball, return springs and select check plunger 10 Install control housing and gasket MT-28

29 MAJOR OVERHAUL I FS5R30q SMTEZSA

30 MT-30 MAJOR OVERHAUL I FS5R30A I Gear Components - FS5R30A

31 MAJOR OVERHAUL Gear Components - FS5R30A (Cont d) 1 FS5R30A I 1 MT-31 SMT83OA

32 MT-32 MAJOR OVERHAUL I FS5R30A I Shift Control Components - FS5R30A SMT838A

33 DISASSEMBLY I FS5R30A I Case Components 1 Remove checlc ball plug, check spring and check ball Then remove interlock stopper If interlock assembly is removed as a unit, the check ball can fall into transmission case. 2 Remove control housing, return spring and check ball 3 Drive out retaining pin from striking arm 4. Remove rear extension together with striking arm by tapping lightly. SMT369A MT-33

34 MT-34 DISASSEMBLY Case Components (Cont'd) Remove front cover and gasket I FS5R30A I Remove stopper ring and main drive bearing snap ring Remove transmission case by tapping lightly CMTR72A Remove front cover oil seal U SMT392A Shift Control Components 1 Mount adapter plate on vise 2 Remove 0 D & reverse fork rod

35 DISASSEMBLY I FS5R30AJ Shift Control Components (Cont'd) 3. Remove check ball plug, check ball and return spring 4 Drive out retaining pin from striking lever 5 While pulling out striking rod, remove striking lever and striking interlock Then remove 1st & 2nd. 3rd & 4th and reverse shift fork 6 Drive out retaining pin 3m 0 D shift ork 7. Pull out 0 D. fork rod and then remove 0 D shift fork Gear Components 1 Before removing gears and shafts, measure each gear end play, Gear 1st main gear 2nd main gear 3rd main gear 0 D counter gear Reverse main geat End play mm (in) ( ) ( ) ( ) ( ) ( ) MT-35

36 DISASSEMBLY I FS5R30AI Gear Components (Cont d) 2. Remove rear side components on mainshaft and counter gear. a. Remove snap ring, speedometer drive gear and steel ball b. Remove reverse coupling sleeve. c. Remove mainshaft rear snap ring and counter gear rear snap ring d. Remove C-ring holder and mainshaft C-rings from mainshaft Use punch and hammer to remove C-rings SMT377A e. Pull out counter gear rear end bearing f Remove reverse idler gear and reverse idler thrust washers g. Remove sub-gear from reverse idler gear. h. Pull out mainshaft rear bearing (2WD model) \ Ill \ LPuller i l MT-36

37 DISASSEMBLY 1 FS5R30A I Gear Components (Cont'd) I. Pull out reverse main gear together with mainshaft spacer and reverse synchronizer hub Then remove reverse gear needle bearings SMT380L j Pull out reverse counter gear k. Remove 0 D coupling sleeve together with 0.D baulk ring, reverse baulk ring and spring inserts I Pull out reverse gear bushing SMT770A m. Pull out 0 D counter gear together with reverse cone MT-37

38 MT-38 D I SASS E MB LY Gear Components (Cont'd) 3 Press out mainshaft and counter gear alternately!i Make sure to alternate press between r,inshaft and wunter near - not to allow the front surface of one to contact the rear surface of the other 4 a b Remove front side components on mainshaft Remove 1st gear washer and steel ball Remove 1st main gear and 1st gear needle bearing SMT772i SMT383A w I c d Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly Remove mainshaft front snap ring e Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing SMT385A

39 DISASSEMBLY Gear Components (Cont'd) 5 a Remove front side components on counter gear Remove counter gear rear thrust bearing I FS5R30A I SMT404D b Remove sub gear components. SMT470A ST /J I 6 a b Remove main drive gear bearing Remove main drive gear snap ring and spacer Press out main drive gear bearing Zounter gear front bearing in transmission case 7. Remove bearings from case components Mainshaft front bearing in adapter plate Counter gear rear bearing in adapter plate ST377500CQ (J SMT394A MT-39

40 INSPECTION 1 - MT-40 ihift fork Shift Control Components a Check contact surface and sliding surface for wear, scratches, projections or other damage rmalnrhaft and gear I Gear Components GEARS AND SHAFTS a Check shafts for cracks, wear or bending a Check gears for excessive wear, chips or cracks I I Counter qear SMT386A I SMT423A SYNCHRONIZERS a Check spline portion of coupling sleeves, hubs, and gears for wear or cracks a Check baulk rings for cracks or deformation a Check shifting inserts for wear or deformation a Check insert springs for deformation 1st & 2nd 3rd & masn drive OD Standard ( ) ( ) ( ) Wear limit 0 7 (0028) 0 7 (0028) 0 7 (0028) If the clearance is smaller than the wear limit, replace baulk ring

41 ~ INSPECTION Gear Components (Cont'dl (FS5R30Al Dimens~on "A' Standard -0 1 to 0 35 ( to ) Wear limit 0 7 (0 028) - MT-41

42 Sounter sear front bearing in transmission ASS EM B LY Gear Components 1 Install bearings into case components Mainshaft front bearing in adapter plate n [ FS5R30A I Counter gear rear bearing in adapter plate n SMT397A KV Install main drive gear bearing a Press main drive gear bearing b Install main drive gear spacer SMT395A c Select proper main drive gear snap ring to minimize clearance of groove Allowable clearance of groove: mm ( in) Main drive gear snap ring Thickness mm (in) 1 Part number d 1 89 (0 0744) 1 98 (0 0780) ) 2 12 (0 0835) 2 19 ( OlGOO GO G GO4 Install selected snap ring on main drive gear MT-42

43 ASS EM BLY Gear Components (Cont'd) I FS5R30A I 3 Install components on counter gear a Install sub-gear components When installing sub-gear snap ring, tap sub-gear snap ring into position on counter gear. b Install counter gear rear thrust bearing 4 a Install front side components on mainshaft Assemble 1st & 2nd synchronlzer I,Svnchronlzer hub I b Assemble 3rd & 4th synchronizer SMT422A c Press on 3rd & 4th synchronlzer assembly together with 3rd main gear and 3rd gear needle bearing Pay attention to directlon of synchronlzer assembly. MT-43

44 ASS EM B LY Gear Components (Cont'd) d Select proper snap ring to minimize clearance of groove Allowable clearance of groove' mm ( in) Mainshaft front snap ring SMT400A Thickness mm (in) 1 89 (0 0744) 1 98 (0 0780) 2 05 (0 0807) 2 12 (0 0835) 2 19 (0 0862) Part number GO e Install selected snap ring on mainshaft f Press on 1st & 2nd synchronizer assembly together with 2nd main gear and 2nd gear needle bearing M SMT401D g h Press on 1st gear bushing using 1st gear washer Install 1st main gear and needle bearing i Install steel ball and 1st gear washer Apply multi-purpose grease to steel ball and 1st gear washer before installing. SMT403 MT-44,

45 ~ I - counter near front thrust bearing Counter gear rear -e3 ASS EM B LY piiq Gear Components (Cont'd) 5 Select proper counter gear front bearing shim when replacing transmission case, counter gear, counter gear thrust bearing a b c or sub-gear components. Install counter gear with sub-gear components, counter gear front and rear thrust bearing on adapter plate Remove counter gear front bearing shim from transmission case Place adapter plate and counter gear assembly in transmission case (case inverted) d. Tighten adapter plate to transmission case using 2 bolts e Place dial indicator on rear end of counter gear f Move counter gear up and down and measure dial indicator deflection g. Select proper shim using table below as a guide Counter gear end play: mm ( in) Table for selecting proper counter gear front bearing shim Dial indicator deflection mm (in) Thickness of proper washer mm (in) Part number ( ) ( ) ( ) ( ) ( ) ( ) ( ) 0 8 (0 031 ) 0 9 (0 035) 1 0 (0 039) 11 (0043) 1 2 (0 047) 1 3 (0 051 ) 1 4 (0 055) GOO GOl GO GO G05 322t8Ol GO6 I SMT578 MT-45

46 ASS EM B LY I FS5R30A 1 Reverse idler shaft Reverse idler front thrust washer -Reverse idler gear Thickness mm (in) Part number rear thrust washer A B 1 97 (0 0776) G (0 0815) G11 SMT432i b Place dial indicator on front end of reverse idler shaft c. Put straightedge on front surface of rear extension as a stopper of reverse idler shaft d Move reverse idler shaft up and down and measure reverse idler gear end play Reverse idler gear end play e mm ( in) If not within specification, replace reverse idler rear thrust washer with the other (A or 6) and check again MT-46

47 ASS EM B LY Gear Components (Cont'd) 7 a Install mainsheft and counter gear on adapter plate and main drive gear on mainshaft Mount adapter plate on vise and apply multi-purpose grease to counter gear rear bearing b Install mainshaft a little on mainshaft front bearing To allow for installation of counter gear, do not install mainshaft completely. c. Install counter gear on counter gear rear bearing and install main drive gear, pilot bearing and spacer on mainshaft Push up with screwdriver7 When installing counter gear into counter gear rear bearing, push up on upper roller of counter gear rear bearing w~th screwdriver. d e. Install Tools ( ) onto adapter plate and C-ring and C-ring holder on mainshaft. Install Tool (J34328) on mainshaft MT-47

48 ASSEMBLY I FS5R30A Gear Components (Cont d) f Install mainshaft and counter gear completely by extending length of J a Install rear side components on mainshaft and counter gear Install 0 D gear bushing while pushing on the front of counter gear b C d Install 0.D main gear Pay attention to direction of O.D. main gear (B is wider than A as shown at left.) Install adapter plate with gear assembly onto transmission case Install O.D. gear needle bearing and then install 0 D counter gear and reverse idler shaft e. Install reverse gear bushing. f Install reverse cone MT-48

49 Reverse baulk ring ASS EM B LV Gear Components (Cont'd) g I FS5R30A I Install insert siprings and reverse baulk ring on 0 D coupling sleeve. Then install them and 0 D baulk ring on 0 D counter gear Pay attention lo direction of O.D. coupling sleeve. h Install reverse counter gear I. 1. Install sub-gear on reverse idler gear. Install reverse gear needle bearing and then install reverse main gear, reverse idler gear and reverse idler thrust washers. I I k. Install reverse hub. Pay attention to its direction. MT-49

50 MT-50 ASS EM BLY Gear Components (Cont d) I. Install mainshaft spacer and mainshaft rear bearing m. Install speedometer drive gear. I FS5R30A I 71ST n Install counter gear rear end bearing 0. Separate adapter plate from transmission case and Mount adapter plate on vice again imt45za P. Select proper mainshaft C-ring to minimize clearance of groove Allowable clearance of t groove: rnrn ( in) Mainshaft C-ring Thickness mm (in: Part number hickness mm (in) Part number 2 63 ( G (01256) GO (0 1063) GOO 3 26 (01283) lG (01091) GO1 333 (01311) lG ( G (01339) ) GO ) (01173) (01394) G12 305(01201) GO5 361 (01421) (01228) (01449) q Install selected C-ring, C-ring holder and mainshaft rear snap ring

51 ASSEMBLY 1 FS5R30A [ SMT453A Snap ring pliers Thickness mm (in) 1 26 (0 0496) 1 32 (0 0520) 1 38 (0 0543) 1 44 (0 0567) 1 50 (0 0591) 1 56 (0 0614) 1 62 (0 0638) 1 68 ( (0 0685) Part number G GOO GO GO s. Install selected counter gear rear snap ring t. Install reverse coupling sleeve Pay attention to its direction. u. Measure each gear end play as a final check - Refer to "DISASSEMBLY" Shift Control Components 1 Install 0 D fork rod and 0 D shift fork Then install retaining pin into 0 D shift fork 2 Install 1st & 2nd, 3rd & 4th and reverse shift fork onto coupling sleeve SMT457A 3 Install striking rod into hole of shift forks, striking lever and interlock and then install retaining pin into striking lever Make sure that striking rod moves smoothly MT- 5 1

52 MT-52 ASS EM B LY Shift Control Components (Cont'd) 4. Install check ball, return spring and check ball plug. Apply sealant to thread of check ball plug. [FS5R30A I I Case components 1 Install front cover oil seal Apply multi-purpose grease to seal lip. 2. Install selected counter gear front bearing shim onto transmission case Apply multi-purpose grease. 3 Apply sealant to mating surface of transmission case 4. Install gear assembly onto transmission case 5 Install check spring and check ball into interlock stopper Apply multi-purpose grease to check ball 6 Install interlock stopper assembly and then tighten check ball plug Apply sealant to thread of check ball plug. 7 Install stopper ring and main drive bearing snap ring

53 ASS EM B LV Case Components (Cont'd) 8 9 Install front cover and gasket Apply sealant to thread of 3 bolts shown left. Apply sealant io mating surface of adapter plate I FS5R30A I I I SMT459A 10. Install rear extension together with striking arm. \ SMT461t 11 Install retaining pin into striking arm 12 Install return spring and check ball and then install control housing Apply sealant to mating surface of rear extension. control housing SMT462A - 13 Tighten control housing bolts MT-53

54 ~ ~ MT-54 SERVICE DATA AND SPECIFICATIONS (S.D.S.) General Specifications Engine VG30E Engine VG30ET Transmission model FS5W71C Transmisscon model FS5R30A Shift pattern b4=1 2 4 R Shift pattern t" il 2 4 R Svnchromesh tvde Warner Synchromesh type Warner Gear ratio 1 st 2nd 3rd 4th OD Reverse Gear ratio 1 It 2nd 3rd 4th OD Reverse Number of teeth Main drive gear Main bear 1St 2nd 3rd OD Reverse Number of teeth Main drive gear Main gear 1 It 2nd 3rd OD Reverse Counter drivegsar Counter gear 1st 2nd 3rd OD Reverse Reverse idler gear Counter drbve gear Counter gear 1st 2nd 3rd OD Reverse Reverse idler gear capacity liter IUS pt, Imp ptl /4.3-1/ /8,4-1/4)

55 ~ ~ Wear ~ ~~~ SERVICE DATA AND SPECIFICATIONS (S.D.S.) 1 - GEAR END PLAY Gear I End play mm linl 1st gear 2nd gear 3rd gear 0 D gear ) Inspection and Adjustment - FS5W71 C Mainshaft rear end bearing - Allowable clearance - Thickness mm Iinl mm IO ml Part number 1 1 IO IO IO 051 I CLEARANCE BETWEEN BAULK RING AND GEAR I Standard I ~ Unit mm (In) lmlt I I st &2nd 0 8 (0031) rd and main drive 0 8 IO 031 ) I OD I ) 10 0%.O 0551 Counter drive aear Allowable clearance - Thickness mm Inn1 1 4 IO 055) 1 5 IO 059) 1 6 IO 0631 AVAILABLE SHIMS Counter front bearing A mm ml Part number E E EW02 Unit mm (in1 AVAILABLE SNAP RINGS Main drive gear bearing A Distance from bearing surface to transmission case Allowable clearance Thickness mm (In1 173 I IO IO IO mm IO tn) Part number Tranmmon care 2 Counter gear front bearing 3 Counter gear TM371 "A I Th'ckners Part number of shim I ( I Not necessary Mainshaft front Allowable clearance Thickness mm (in) 0 O18mm(O in1 Part number IO ) ) IO ( ( IO 024) V V V VWO V V IO V V V5202 MT-55

56 ~~~ ~ ~~ ~ SERVICE DATA AND SPECIFICATIONS (S.D.S.) pgz.1 GEAR END PLAY Inspection and Adjustment - FS5R30A Mainshaft front snap ring Gear I End D I~Y mm Iinl Allowable clearance 0-01mm10 O004in) 1st main gear I Thickness mm lml Part number 2nd main gear 3rd main gear 0 D counter gear Reverse main gear IO IO ( IO GOO GO GO GO3 Counter gear GO4 Reverse bdler ear Counter gear rear snap ring CLEARANCE BETWEEN BAULK RING AND GEAR I Standard I wear limit I 1 st & 2nd IO rd & mam drive OD I Unit mm Iinl 0 7 IO IO 0281 I DISTANCE BETWEEN REAR SURFACE OF REVERSE CONE AND REVERSE BAULK RING Dimension "A' Reverse baulk ring cone Unit I Stand a f d I wear limit -0 1 to 0 35 I-00039t AVAILABLE SNAP RING Main drive gear snap ring mm lml.. Allowable clearance Thickness mm (in IO IO I 1 50 IO 0591 I 1 56 IO ( I 1 74 IO AVAILABLE C-RING Mainshaft C-ring mm IO in) Part number G GOO GO G G G G G Allowable clearance mm IO OD04 in1 Th'ckness I Part number Th'ckness I Part number mm lml 2 63 IO IO I G G GO G G G Allowable clearance mm IO.O 004 in1 Thickness mm Iml 1 Part number 1 89 ( IO GOO G GO GO G04

57 Dial indicator deflectm rnm Iml Thickness of proper warher mm 11") Part number 2 07 IO ) IO IO ) 153-l ~ G IO G IO 051 I G06 Tightening Torque TRANSMISSION INSTALLATION GEAR ASSEMBLY - FS5W71C U"lt Nm kg-m ft-lb U"4t Nm kg m ft Ib Clutch operating cylinder Rear extension Tranrmirsion recuring bolt Refer to Removal and Installation Enginegussettoengine to transmission case Front cover to transmission case Rear mounting insulator to rear extenson Refer to section EM Control housing to rear erten$lon Starter motor fixino bolt Refer to section EM M8 bolt M12 bolt Ball PI" Flller plug Drain plug Speedometer sleeve lnrallatlo" Return sprmg plug Reverse check sleeve to rear e*te"slon Check ball plug Mainhaft lock nut lwrthout Tool) Countsrshaft lock nut Striking lever lock nut Bearing retainer IO adapter plate Reverse lamp rwlteh Neutral switch MT-57

58 GEAR ASSEMBLY - FS5R30A SERVICE DATA AND SPECIFICATIONS (S.D.S.) Tightening Torque (Cont'd) U"lt Nm kgm ft-lb Rear extension to transmission case Front cover to transmission case Control housing to rear extension Ball pin Filler plug Drain plug Speedometer pinion 4-5 installation Interlock stopper fixing bolt Check ball plug Select ch-k plug Reverse check sleeve fixfng bolt 0 D & reverse fork rod to reverse shift fork 0 D and reverse shift fork connecting bolt Guide plate to rear extension Bearing retainer to adopter plate Reverse lamp witch Neutral switch MT-58

59 Courtesy Nissan 1777 North Central Expressway Richardson, TX (800) NISSAN FACTORY SERVICE MANUAL CDROM END-USER LICENSE AGREEMENT NOTICE TO USER: THIS IS A CONTRACT. BY PURCHASING AND USING THE SERVICE MANUAL ON CDROM, YOU ACCEPT ALL THE TERMS AND CONDITIONS OF THIS AGREEMENT. This End User License Agreement accompanies the Service Manual on CDROM product and related explanatory materials. Please read this Agreement carefully. By purchasing and using the Service Manual on CDROM, you are implying that you have carefully read, agree with, and will adhere to the conditions set forth in this agreement. If you do not wish to accept the terms of this End User Agreement please do not use the Service Manual on CDROM. You will not be permitted to use the Service Manual on CDROM without consenting to this end user agreement. Upon your acceptance of this Agreement, Courtesy Nissan grants to you a nonexclusive license to use the Service Manual on CDROM, provided that you agree to the following: USE OF SOFTWARE You may install the contents of the CD on a hard disk or other storage device for personal use only. Each Service Manual on CDROM comes with a single user license. Under no circumstances should the contents of the Service Manual CDROM be placed on a server for purposes of distributing or allowing access to the material over a network. COPYRIGHT AND TRADEMARK RIGHTS The Service Manual CDROM is owned by Courtesy Nissan and its structure and organization, all graphics and coding are considered intellectual property of Courtesy Nissan. The Service Manual on CDROM is also protected by United States Copyright Law and International Treaty provisions. This Agreement does not grant you any intellectual property or resale rights to the Service Manual CDROM. RESTRICTIONS You agree not to modify, adapt, translate, reverse engineer, decompile or disassemble the PDF file on the Service Manual CDROM. The Service Manual on CDROM is licensed and distributed by Courtesy Nissan for single user utilization of its contents only. Licensed users will be permitted to use the contents of the Service Manual CDROM for multimedia presentation to an audience from a single machine using a large display or projection device but the Service Manual CDROM may not otherwise be distributed, sold to or made accessible to multiple users. NO WARRANTY The software is being delivered to you AS IS and Courtesy Nissan makes no warranty as to its use or performance. COURTESY NISSAN DOES NOT AND CANNOT WARRANT THE PERFORMANCE OR RESULTS YOU MAY OBTAIN BY USING THE SERVICE MANUAL CDROM OR DOCUMENTATION, NOR MAKES ANY WARRANTIES, EXPRESS OR IMPLIED, AS TO NONINFRINGEMENT OF THIRD-PARTY RIGHTS, MERCHANTABILITY, OR FITNESS FOR ANY PARTICULAR PURPOSE. IN NO EVENT WILL COURTESY NISSAN BE LIABLE TO YOU FOR ANY CONSEQUENTIAL, INCIDENTAL, OR SPECIAL DAMAGES FOR ANY REASON.

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