MANUAL TRANSMISSION Click on the applicable bookmark to selected the required model year.

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1 MNUL TRNSMISSION Click on the applicable bookmark to selected the required model year.

2 22-1 MNUL TRNSMISSION CONTENTS GENERL INFORMTION... 2 LUBRICNTS... 2 SELNTS... 2 SPECIL TOOL... 2 TROUBLESHOOTI <SS4 II>... 3 ON-VEHICLE SERVICE... 6 Transmission Oil Check... 6 Oil Replacement W etection Switch Continuity Check <V5MT1>... 7 High/Low etection Switch Continuity Check <V5MT1>... 7 TRNSMISSION CONTROL <V5MT1>... 8 TRNSMISSION CONTROL <V5MT3>... 9 TRNSMISSION SSEMBLY W INICTOR-ECU/TRNSFER-ECU... 17

3 22-2 MNUL TRNSMISSION - General Information/Lubricants/Sealants/Special Tool GENERL INFORMTION Items Specifications Transmission model V5MT1 V5M31 Engine model M4 6G7 Type 5-speed, floor-shift Gear ratio 1st nd rd th th Reverse Transfer type 2-speed Gear ratio High Low LUBRICNTS Items Specified lubricants Quantity L Transmission oil Transfer oil SELNTS Hypoid gear oil SE 75W-90 or 75W-85W conforming to PI GL-4 Hypoid gear oil SE 75W-90 or 75W-85W conforming to PI GL Items Specified sealant Remarks Oil filler plug 3M T Part No or equivalent Semi-drying sealant Oil drain plug 3M T Part No or equivalent Semi-drying sealant SPECIL TOOL Tool Number Name Use M Test harness (4P, square) Inspection of lever position sensor

4 MNUL TRNSMISSION - Troubleshooting <SS4 II> 22-3 TROUBLESHOOTI <SS4 II> For items other than the following service procedures, refer to GROUP 23 - Troubleshooting <SS4 II>. INSPECTION CHRT FOR IGNOSIS COES iagnosis iagnosis item code 21 Lever position sensor (LPS) system <45> Open circuit/malfunction of sensor INSPECTION PROCEURE FOR IGNOSIS COES Code No.21 Lever position sensor (LPS) system <45> If the LPS output voltage becomes 0.2 V or less at idling, code No.21 will be set as open circuit or maladjustment of the LPS. Probable cause Reference page 22-3 Malfunction of the LPS Malfunction of harness or connector Malfunction of transfer-ecu Malfunction of the glow-ecu MUT-II ata list No.1 LPS : Refer to P.23-5, T LIST REFERENCE TBLE. Intermittent malfunction (Refer to GROUP 00 - Points to Note for Transient Malfunctions.) Check the LPS. (Refer to GROUP 17 - Emission Control System) Replace Check the following connector: B-02 Measure at LPS connector B-02. isconnect the connector and measure at the harness side. Voltage between 2 and earth (Ignition switch: ON) : V To the next page Measure at glow-ecu connector ECU terminal voltage measurement Ignition switch: ON Voltage between terminal 7 and earth : V Check the following connector: -114 Check the harness wire between the LPS and the glow-ecu, and repair if necessary. Check the trouble symptoms. Check the following connector: -114 Check the harness wire between the LPS and the glow-ecu, and repair if necessary. Replace the glow-ecu.

5 22-4 From the previous page Measure at LPS connector B-02. Use the test harness (M998464) to connect connector terminals No. 1, No. 2, No.3 only, and measure at the pick-up harness. Ignition switch: ON (1) Voltage between terminal 3 and earth : 0.5 V or less (2) Voltage between 2 and earth (Ignition switch: ON) : V (3) Voltage between terminal 1 and earth : ccelerator pedal fully released 800-1,000 mv ccelerator pedal fully depressed 3,700-4,900 mv Measure at transfer-ecu connector E-105. ECU terminal voltage measurement Ignition switch: ON Voltage between terminal 5 and earth : ccelerator pedal fully closed 800-1,000 mv ccelerator pedal fully depressed 3,700-4,900 mv MNUL TRNSMISSION - Troubleshooting <SS4 II> (1),(2) (3) Check the following connector: -114 Check the harness wire between the LPS and the glow-ecu, and repair if necessary. djust the LPS. (Refer to GROUP 17 - Emission Control System) Check the following connectors: E-113, E-105 Check the following connectors: E-105, E-113 Check the harness wire between the LPS and the transfer-ecu, and repair if necessary. Check the following connector: E-105 Check the trouble symptoms. Replace the transfer-ecu. djust Check the harness wire between the LPS and the transfer-ecu, and repair if necessary.

6 MNUL TRNSMISSION - Troubleshooting <SS4 II> 22-5 T LIST REFERENCE TBLE ata list No. Check item Check conditions Normal condition 1 Lever position Engine: Stopped ccelerator pedal: Fully closed 800-1,000 mv sensor (LPS) Selector lever position: ccelerator pedal: epressed Gradually increases from <45> P the above value. ccelerator pedal: Fully open 3,700-4,900 mv CHECK T TRNSFER-ECU TERMINL Terminal No. Check item Check conditions Standard value 5 Lever position sensor ccelerator pedal: Fully closed (engine stopped) V (LPS) <45> ccelerator pedal: Fully open (engine stopped) V

7 22-6 MNUL TRNSMISSION - On-vehicle Service ON-VEHICLE SERVICE Transmission oil Transmission <V5MT1> Transmission <V5M31> Transfer <V5MT1> Filler plug hole Oil filler plug Oil drain plug Oil filler plug Oil drain plug Oil filler plug TRNSMISSION OIL CHECK 1. Remove the oil filler plug. 2. Oil level should be at the lower portion of the filler plug hole. 3. Check that the transmission oil is not noticeably dirty, and that it has a suitable viscosity. 4. Tighten the filler plug to the specified torque. Tightening torque: 32 ± 2N m OIL REPLCEMENT 1. Remove oil filler plug and oil drain plug. 2. rain oil. 3. pply sealant to the oil drain plug threads. 4. Tighten the oil drain plug to the specified torque. Tightening torque: V5MT1 39 ± 5N m V5M31 32 ± 2N m Transfer 32 ± 2N m Specified sealant: 3M T Part No or equivalent 5. Fill with specified oil till the level comes to the lower portion of oil filler plug hole. Specified transmission oil: Hypoid gear oil SE 75W-90 or 75W-85W conforming to PI GL-4 Quantity: Transmission 3.2 L Transfer 2.5 L 6. pply sealant to the oil filler plug threads. 7. Tighten the oil filler plug to the specified torque. Tightening torque: 32 ± 2N m Specified sealant: 3M T Part No or equivalent Oil drain plug Transfer <V5M31> Oil Oil drain drain plug plug Oil Oil filler filler plug plug

8 MNUL TRNSMISSION - On-vehicle Service W ETECTION SWITCH CONTINUITY CHECK <V5MT1> Check the continuity between terminals of the black connector indicated in the illustration. Transfer lever position Terminal No H 4H HIGH/LOW ETECTION SWITCH CONTINUITY CHECK <V5MT1> Check the continuity between terminals of the gray connector indicated in the illustration. Transfer lever position Terminal No H 4L 4H-4L

9 22-8 MNUL TRNSMISSION - Transmission Control <V5MT1> TRNSMISSION CONTROL <V5MT1> REMOVL N INSTLLTION Pre-removal Operation Shift the Transmission Control Lever to the N Position. Shift the Transfer Control Lever to the 4H Position. Post-installation Operation Check the Operation of the Transmission and Transfer Control Levers and the Movement in Each Lever Position Transmission control lever assembly removal steps Indicator panel (Refer to GROUP 52 - Floor Console) 1. Retainer plate 2. Shift control boot 3. Snap ring 4. Transmission control lever assembly Transfer control lever assembly removal steps Indicator panel (Refer to GROUP 52 - Floor Console) 1. Retainer plate 2. Shift control boot 3. Snap ring 5. Transfer control lever assembly

10 MNUL TRNSMISSION - Transmission Control <V5MT3> 22-9 TRNSMISSION CONTROL <V5MT3> REMOVL N INSTLLTION Pre-removal Operation Shift the Transmission Control Lever to the N Position. Post-installation Operation Check the Operation of the Transmission and Transfer Control Levers and the Movement in Each Lever Position ± 1.0 N m ± 2N m Transmission control lever assembly removal steps Indicator panel (Refer to GROUP 52 - Floor Console) 1. Transfer select switch assembly 2. Retainer plate 3. Shift control boot 4. Snap ring 5. Transmission control lever assembly Transfer select switch assembly removal steps Indicator panel (Refer to GROUP 52 - Floor Console) 6. Transfer select switch 7. Transfer select switch bracket 4LLc 4HLc 4H 2H INSPECTION TRNSFER SELECT SWITCH CONTINUITY CHECK Switch posi- Terminal number tion H 4H 4HLc 4LLc

11 22-10 MNUL TRNSMISSION - Transmission ssembly TRNSMISSION SSEMBLY REMOVL N INSTLLTION Caution The rear propeller shaft is made of fiber-reinforced plastic tube, so always refer to GROUP 25 prior to its removal. Pre-removal Operation Transmission and Transfer Control Lever Removal (Refer to P.22-8.) Transmission and Transfer Oil raining (Refer to P.22-6.) Front and Rear Propeller Shaft Removal (Refer to GROUP 25 - Propeller Shaft.) Front and Center Exhaust Pipe Removal (Refer to GROUP 15 - Exhaust Pipe and Main Muffler) Post-installation Operation Front and Center Exhaust Pipe Installation (Refer to GROUP 15 - Exhaust Pipe and Main Muffler) Front and Rear Propeller Shaft Installation (Refer to GROUP 25 - Propeller Shaft.) Transmission and Transfer Oil Filling (Refer to P.22-6.) Transmission and Transfer Control Lever Installation (Refer to P.22-8.) Transmission and Transfer Control Lever Operation Check <45 with V5MT1> 9 24 ± 5N m ± 6N m 6 24 ± 5N m 53 ± 5N m 23 ± 3N m ± 6N m 8 2 m ± 2.0 N m 26 ± 4N m

12 <45 with V5M31> MNUL TRNSMISSION - Transmission ssembly ± 5N m ± 6N m 53 ± 5N m 24 ± 5N m 23 ± 3N m 48 ± 6N m ± 4N m 9.0 ± 2.0 N m Removal steps 1. Clutch release cylinder 2. Space rubber 3. Bell housing cover 4. Starter motor 5. ynamic damper assembly 6. Tension wire bracket Support the transmission transmission jack with a " 7. Transmission mount center member assembly 8. Transmission mount insulator assembly 9. Transmission wiring harness connector connection " 10. Transmission assembly 11. Tension wire

13 22-12 <4M4 with V5M31> MNUL TRNSMISSION - Transmission ssembly Pre-removal and Post-installation Operations Skid Plate and Under Cover Removal and Installation Transmission Fluid and Transfer Oil raining and Refilling (Refer to P.22-6.) Front and Rear Propeller Shaft Removal and Installation (Refer to GROUP 25.) Front Exhaust Pipe and Catalytic Converter Removal and Installation (Refer to GROUP 15.) Radiator Shroud Lower Cover Removal and Installation (Refer to GROUP 14.) Intercooler Removal and Installation (Refer to GROUP 15) ± 5N m ± 5N m 48 ± 6N m 24 ± 5N m 11 ± 1N m 8 48 ± 6N m ± 6N m 26 ± 4N m Removal steps 1. Clutch release cylinder (Refer to GROUP15) 2. Clutch dumper assembly (Refer to GROUP15) 3. Exhaust support bracket 4. Battery cable connection 5. Spacing rubber 6. ust cover 7. Heater hose connection 8. Starter motor

14 MNUL TRNSMISSION - Transmission ssembly ynamic damper 10. Tension wire bracket Support the transmission with a transmission jack 11. Transmission mount center member assembly 12. Transmission mount insulator assembly " 13. Transmission harness connector connection B" Clutch release bearing disconnection " 14. Transmission assembly 15. Tension wire

15 22-14 <6G7 with V5M31> MNUL TRNSMISSION - Transmission ssembly Pre-removal and Post-installation Operations Skid Plate and Under Cover Removal and Installation Transmission Fluid and Transfer Oil raining and Refilling (Refer to P.22-6.) Front and Rear Propeller Shaft Removal and Installation (Refer to GROUP 25.) Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) Radiator Shroud Lower Cover Removal and Installation (Refer to GROUP 14.) ± 5N m ± 10 N m ± 5N m 24 ± 5N m 5 30 ± 3N m ± 9N m 3 11 ± 1N m 6 11 ± 1N m 5.9 ± 0.9 N m ± 5N m 26 ± 4N m

16 MNUL TRNSMISSION - Transmission ssembly Removal steps 1. Clutch release cylinder (Refer to GROUP15) 2. Heater hose connection 3. Cover 4. Starter motor 5. Starter cover 6. Oil pan connection bolts 7. Battery cable connection 8. ynamic damper 9. Tension wire bracket " B" Support the transmission with a transmission jack 10. Transmission mount center member assembly 11. Transmission mount insulator assembly 12. Transmission harness connector connection Clutch release bearing disconnection " 13. Transmission assembly 14. Tension wire <V5MT1> P G J K REMOVL SERVICE POINT " TRNSMISSION WIRI HRNESS CONNECTOR ISCONNECTION 1. Lower the transmission to a position where the transmission harness connector can be disconnected, and then disconnect the connector. 2. Place the disconnected transmission harness so that it stays on the vehicle body. <V5M31> B C S E R F Q P O G H I L N M Code B C E F G H I J K L M N O P Q R S Connector name Transmission wiring harness and battery wiring harness combination Select rail switch <4M4> 1st and 2nd rail switch <4M4> 4LLC (irect low range 4W) switch 2W operation detection switch Rear propeller shaft speed sensor Vehicle speed sensor Oxygen sensor (Rear) Shift actuator High range/low range detection switch 4W operation detection switch 2W/4W detection switch 4H (Full time 4W) switch Center differential lock detection switch Front propeller shaft speed sensor Back-up lamp switch Oxygen sensor (Front) Back-up lamp switch <4M4> 3rd and 4th rail switch <4M4>

17 22-16 MNUL TRNSMISSION - Transmission ssembly B" CLUTCH RELESE BERI ISCONNECTION 1. Remove the service hole cover at the clutch housing. 2. Operate the release fork, and push the release bearing towards the clutch side. 3. Insert the flat-tipped screwdriver to separate the release bearing. Release fork Release bearing <45> Starter motor C L B C INSTLLTION SERVICE POINT " TRNSMISSION SSEMBLY INSTLLTION The sizes of the mounting bolts are different. So be sure not to confuse them. <45> Bolt 10 x 45 B iameter () x Length (L) mm 8x30 <4M4> E C C C 10 x x 25 E 10 x 35 <4M4> Bolt iameter () x Length (L) mm Starter motor B B B B 12 x 25 B 10 x 45 <6G7> C 10 x 50 Starter motor B B <6G7> Bolt 12 x 40 iameter () x Length (L) mm B 12 x 55

18 MNUL TRNSMISSION - 4W Indicator-ECU/Transfer-ECU W INICTOR-ECU/TRNSFER-ECU REMOVL N INSTLLTION Pre-removal and Post-installation Operation Indicator panel, Floor console front panel removal and installation (Refer to GROUP52 - Floor console) 4W indicator-ecu Bracket 4.9 ± 1.0 N m 4.9 ± 1.0 N m Transfer-ECU View INSPECTION 4W INICTOR-ECU 1. Measure the voltage with the control unit and harness still connected. 2. Earth terminal (8) and then measure terminal voltage.

19 22-18 MNUL TRNSMISSION - 4W Indicator-ECU/Transfer-ECU Terminal No. Inspection item Inspection condition 1: Ignition switch Inspection condition 2: Transfer lever position Terminal voltage 1 Free wheel engage ON 2H System voltage switch 4H* 1 0V 2 4W detection ON 2H System voltage switch 4H, 4L 0V 3 Ignition switch (IG1) OFF - 0 V ON - System voltage 6 HI/LOW detection switch ON Shifting from 4H to 4L or vice versa System voltage 2H, 4H, 4L 0V 7 Free wheel clutch ON 4H, 4L 0V changeover solenoid valve 2H* 2 System voltage 10 4W Indicator lamp ON 2H 0 V 4H, 4L System voltage NOTE * 1 : When vehicle has been moved once. * 2 : Shift the lever from 4H to 2H, and then turn the ignition switch to OFF and then back to ON. TRNSFER-ECU Measure the terminal voltage (Refer to P.22-3).

20 GENERL OUTLINE OF CHE MNUL TRNSMISSION - Gneral/Troubleshooting <SS4 II> 22-1 GROUP 22 MNUL TRNSMISSION With additional vehicle with Emission Regulation Step III compatible 45 engine, the service procedure different from service adjustment procedure of the vehicle with 45 engine has been established. TROUBLESHOOTI <SS4 II> INSPECTION CHRT FOR IGNOSIS COE iagnosis iagnosis item code 21 ccelerator pedal position sensor (PS) system <45> INSPECTION PROCEURE FOR IGNOSIS COE Code No.21 ccelerator pedal position sensor (PS) system <45> Code No.21 is output to indicate an open circuit in the PS or an incorrect adjustment when the PS output voltage drops below 0.2 V while the engine is idling. Open circuit/malfunction of sensor Probable cause Reference page 22-1 Malfunction of PS Malfunction of harness or connector Malfunction of transfer-ecu Malfunction of engine-ecu MUT-II ata List No. 1 PS : Refer to P.22-2 (ata List Reference Table). PS check Transient malfunction (Refer to GROUP 00 - Points to Note for Transient Malfunctions.) Replace Check the following connector: -135 Measure at PS connector -135 isconnect the connector and measure at the harness side. Voltage between terminal 8 and earth (Ignition switch: ON) : V Measure at engine-ecu connector Measure at ECU terminal. Ignition switch: ON Voltage between terminal 60 and earth : V Checkthefollowingconnector:-112 Replace the engine-ecu. Check the following connectors: -135, -112 To the next page Check the harness between the PS and the engine-ecu. Check the trouble symptoms. Replace the engine-ecu.

21 22-2 From the previous page Measure at PS connector Use the test harness to connect only terminals 6, 7 and 8, and measure at the pickup harness. Ignition switch: ON (1) Voltage between terminal 7 and earth : 0.5 V or less (2) Voltage between terminal 8 and earth : V (3) Voltage between terminal 6 and earth : Fully close the accelerator 985-1,085 mv fully open the accelerator 4,000 mv or more MNUL TRNSMISSION - Troubleshooting <SS4 II> (1), (2) (3) Checkthefollowingconnector:-112 Check the harness between the PS and the engine-ecu, and repair if necessary. PS adjustment Check the following connectors: E-113, E-105 Check the harness between the PS and the transfer-ecu, and repair if necessary. Measure at transfer-ecu connector E-105 Measure at ECU terminals. Ignition switch: ON Voltage between terminal 5 and earth : Check the following connectors: E-105, E-113 Fully close the accelerator 985-1,085 mv fully open the accelerator 4,000 mv or more Checkthefollowingconnector:E-105 Check the harness between the PS and the transfer-ecu, and repair if necessary. Check the trouble symptoms. Replace the transfer-ecu. T LIST REFERENCE TBLE ata list No. Check item Check conditions Normal condition 1 ccelerator ped- al position sensor (PS) <45> Engine: Stopped Selector lever position: ii P CHECK T TRNSFER-ECU TERMINL ccelerator pedal: Fully closed ccelerator pedal: epressed ccelerator pedal: Fully open 985-1,085 mv Gradually increases from the above value. 4,000 mv or more Terminal Check item Check conditions Standard value No. 5 ccelerator pedal position ccelerator pedal: Fully closed (engine stopped) V sensor (PS) <45> ccelerator pedal: Fully open (engine stopped) 4.0 V or more

Items Vehicles with 4G63 engine Vehicles with 4D56 engine. Type 5-speed, floor-shift 5-speed, floor-shift. 2nd rd

22-2 MANUAL TRANSMISSION General Information GENERAL INFORMATION 22100010113 Items Vehicles with 4G63 engine Vehicles with 4D56 engine Transmission model R5M21-5 R5M21-5 Type 5-speed, floor-shift 5-speed,