MANUAL TRANSMISSION SECTION MT CONTENTS. 'iili' IJIJ\\ Gear Components Shift Control Components...

MANUAL TRANSMISSION SECTION MT IJIJ\\ CONTENTS FSSW71C PREPARATION......... 2 Special Service Tools... 2 Commercial Service Tools...... 3 FSSR3A PREPARATION....... Special Service Tools.... 4... 4 Commercial Service Tool....... 5 FS5W71C & FSSR3A ON-VEHICLE SERVICE...... 6 Checking MiT Oil... 6 Replacing Rear Oil seal - 2WD Model... 6 REMOVAL AND INSTALLATION... 7 Removal - 2WD Model.... Removal - 4WD Model... 7.... 7 Installation....... 8 FSSW71C MAJOR OVERHAUL...... 1 Case Components...... 1 Gear Components - 2WD model... 11 Gear Components- 4WD model... 12 Shift Control Components - 2WD model.... 13 Shift Control Components- 4WD model... 14 DISASSEMBLY............. 15 Case Components....... 15 Shift Control Components...... 15 Gear Components...... 17 INSPECTION....................... 19 Shift Control Components. Gear Components...... 19... 19 ASSEMBLY....... 21 Gear Components...... 21 Shift Control Components...... 28 fli" Case Components...... 29 FSSR3A MAJOR OVERHAUL...... 33 Case Components...... 33 Gear Components...... 34 Shift Control Components...... 36 i'\1( DISASSEMBLY...... 37 Case Components.......... 37 Shift Control Components... 38 Gear Components....... 39 INSPECTION......43 Shift Control Components......43 Gear Components.........43 ASSEMBLY...45 Gear Components......45 Shift Control Components....... 53 Case Components... 54 FS5W71C & FS5R3A SERVICE DATA AND SPECIFICATIONS (SDS). General Specifications.... FS5W71C.... 56.... 56 Inspection and Adjustment......... 57 ISliP FS5R3A Inspection and Adjustment....... 59 'iili' lili fl 12J,7Jl 489

PREPARATION FS5W71C Special Service Tools Tcior number (Kent-Moore No.) Tool name Description ST23811 ( ) Adapter setting plate Fixing adapter plate with gear assembly NT66 KV321133 (See J26349-A) Puller Removing overdrive mainshaft bearing NT67 KV31141 ( ) Transmission press stand Pressing counter gear and mainshaft NT68 ST2252 (J26348) Wrench Tightening mainshaft lock nut NT69 ST2354 (J25689-A) Pin punch Removing and installing fork rod retaining pin NT7 ST331 (J22912-1) Puller Removing and installing 1st gear bushing Removing main drive gear bearing ST2386 ( ) Drift ST22362 (J25679-1) Drift ST2235 (J25678-1) Drift NT71 NT65 NT65 NT65 Installing counter drive gear a: 38 mm (1.5 in) dia. b: 33 mm (1.3 in) dia. Installing counter gear front and rear end bearings a: 29 mm (1.14 in) dia. b: 23 mm (.91 In) dia. Installing OD gear bushing a: 34 mm (1.34 in) dia. b: 28 mm (1.1 in) dia. MT-2 49

PREPARATION Special Service Tools (Cont'd) FS5W71C Tool number Description '(Kent-Moore No.) Tool name ST238 Installing front cover oil seal (J25691-1) Drift a a: 44 mm (1.73 in} dia. b: 31 mm (1.22 In) dia. NT65 ST3341 Installing rear oil seal (J2682) Drift a: 6 mm {2.36 in) dia. b: 47 mm {1.85 In) dia. NT86 ST33291 Removing rear oil seal (J2581-A) Puller NT76 ST372 Installing mainshaft ball bearing ( ) Drift a: 77 mm (3.3 in) dia. b: 55.5 mm (2.185 in) dia. NT115 ST3613 (J25742-3) Drift NT73 a Installing main drive gear bearing a: 71.5 mm (2.815 in) dia. b: 47.5 mm (1.87 in) dia. ST332 Installing counter rear bearing (J2682) Drift a: 6 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia. NT91 Commercial Service Tools Tool name Description Puller Removing counter bearings, counter drive and OD gears NT77 Drift Installing countershaft rear end bearing (FS5W71C-4WD model) a: 4 mm (1.57 In) dia. b: 3 mm {1.18 In) dia. NT74 "IL MT-3 491

PREPARATION FSSR3A Special Service Tools TOol number (KentMoore No.) Tool name Description ST2354 Removing and installing retaining pin (J25689-A) Pin punch NT7 ST331 Removing st & 2nd synchronizer assem (J22912-1) bly Puller Removing counter gear rear thrust bearing Removing main drive bearing NT71 ST33291 (J2581-A) Removing rear oil seal Puller NT76 ST3323 Removing mainshaft and counter gear ( ) Drift a: 51 mm (2.1 in) dia. b: 28.5 mm (1.122 in) dia. NTD84 ST2235 Removing counter gear front bearing (J25678-1) (Use with KV3813) Drift a: 34 mm (1.34 in) dia. NT65 b: 28 mm (1.1 in) dia. KV3813 Removing counter gear front bearing (J25523) (Use with ST2235) Drift a Installing counter gear rear bearing a: 54 mm (2.13 in) dia. NT65 b: 32 mm (1.26 in) dia. ST372 G) (J34286) (J34331) Drift NT115 G) Removing mainshaft front bearing @ Installing mainshaft front bearing a: 77 mm (3.3 In) dia. b: 55.5 mm (2.185 in) dia. ST3322 Removing and installing counter gear rear (J2584-1) end bearing (4WD model) Drift a: 37 mm (1.46 in) dia. b: 22 mm (.87 in) dia. NT84 ST3321 G) (J25523) (J2583-1) Drift CD Installing counter gear front bearing @ Installing front cover oil seal a: 44 mm (1.73 in) dia. b: 24.5 mm (.965 in) dia. NT84 ST3613 (J25742-3) Drift NT73 a Installing main drive gear bearing a: 72 mm {2.83 in) dia. b: 48 mm (1.89 in) dia. MT-4 492

PREPARATION Special Service Tools (Cont'd) I FS5R3A I Tool number (Kent-Moore No.) Tool name Description ST3775 (j) (J34286) @ (J34332) @ (J34334) @ (J25679-1) Drift NT65 CD Removing counter gear rear bearing Installing OD gear bushing Installing reverse cone @ Installing reverse counter gear @ Installing counter gear rear end bearing a: 4 mm {1.57 in) dla. b: 31 mm {1.22 in) dia. Iilli ll'ml ST22452 (J34337) Drift NT65 a Installing reverse hub Installing mainshaft rear bearing (2WD model) a: 45 mm (1.77 in) dia. b: 36.mm (1.42 in) dia. l"f'@, [:; ST3341 (J2682) Drift NT86 Installing rear oil seal a: 6 mm {2.36 in) dia. b: 47 mm (1.85 In) dla. (J26349-3) Puller leg Installing mainshaft and counter gear (Use with J34328) NT78 (J34328) Puller Installing mainshaft and counter gear (Use with J26349-3) NT79 (J2692) Drift Installing sub-gear snap ring a a: 44.5 mm (1.752 In) dla. b: 38.5 mm (1.516 in) dla. NT65 (J34342) Drift Installing OD main gear Installing reverse gear bushing a: 44.5 mm (1.752 in) dia. b: 4.5 mm (1.594 in) dla. NT65 Tool name Puller Description NT77 Commercial Service Tool Removing counter gear rear end bearing Removing mainshaft rear bearing (2WD model) Removing reverse synchronizer hub Removing reverse counter gear MT-5 493

ON-VEHICLE SERVICE I FS5W71C & FS5R3A I Checking M/T Oil Check manual transmission for oil leakage. SMA429A Check oil level. Filler plug Fill to this level Replacing Rear Oil seal - 2WD Model MT-6 494

REMOVAL AND INSTALLATION I FSSW71C & FS5R3A I Removal - 2WD Model Remove propeller shaft. - Refer to section PD. Insert plug into rear oil seal after removing propeller shaft. CAUTION: @[ Be careful not to damage spline, sleeve yoke and rear oil seal, when removing propeller shaft. Remove exhaust front tube A. (VG3E engine model) - &: 1 Refer to section FE. Remove shift lever. Support engine by placing a jack under oil pan. CAUTION: Do not place jack under the oil pan drain plug. Remove transmission from engine. WARNING: Support Manual Transmission, while removing it. SMT99A Removal - 4WD Model Remove front and rear propeller shafts.- Refer to section PD. Insert plug into rear oil seal of transfer after removing pro- I!J'ii' peller shalt. CAUTION: Be careful not to damage spline, sleeve yoke and rear oil seal TF of transfer, when removing propeller shaft. Remove exhaust front tube A. (VG3E engine model) - Refer to section FE. ]" Remove torsion bar springs.- Refer to REMOVAL of Torsion Bar Spring in section FA. Then remove second crossmember. 'fill \ A Remove shift lever of transmission and transfer. Support engine by placing a jack under oil pan. CAUTION: Do not place jack under the oil pan drain plug. Remove transmission with transfer from engine. WARNING: Support Manual Transmission with transfer, while removing it. MT-7 495

REMOVAL AND INSTALLATION FS5W71C & FS5R3A KA24E engine model Stanernootor Sealant Installation Apply sealant as below: - 4WD model ("#iif Engine block Engine block Engine rear plate Transmission case Mating surface of engine block and engine rear plate Mating surface of engine rear plate and transmission case Transmission case Engine block lts>-m: Apply recommended sealant (Nissan genuine part: KP51-15) or equivalent. : Apply recommended sealant (Nissan genuine part: KP61-25) or equivalent. SMT481A MT-8 496

,------------- REMOVAL AND INSTALLATION Installation (Cont'd) FS5W71C & FS5R3A VG3E engine model Engine rear plate Engine rear plate Engine rear plate Transmission me Transmission ca'e Mating surface of engine block and engine rear plate Engine block Mating surface of engine rear plate and transmission case I.I2IliDl : Apply recommended sealant (Nissan genuine part: KP51-15) or equivalent. : Apply recommended sealant (Nissan genuine part: KP61()..25) or equivalent.!gil SMT499C Tighten bolt securing transmission. KA24E engine model M/T to engine @ Engine rear plate to MIT SMT35C *. W1th nut Bolt No. Tightening torque N m (kg-m, ft-lb) [ mm (in) G) 39-49 (4.- 5., 29-36) 65 (2.56) 39-49 (4.- 5., 29-36) 6 (2.36) @. 16-22 (1.6-2.2, 12-16) 25 (.98) @ 16-22 (1.6-2.2, 12-16) 2 (.79) VG3E engine model M/T to engine Engine (gusset) to M/T SMT573A Bolt No. Tightening torque N m (kg-m, ft-lb) [ mm (in) G) 39-49 (4.- 5., 29-36) 65 (2.56) 39-49 (4.- 5., 29-36) 6 (2.36) @ 29-39 (3. - 4., 22-29) 55 (2.17) @ 29-39 (3. - 4., 22-29) 25 (.98) 29-39 (3. - 4., 22-29) 25 (.98) MT-9 497

4-5 (.4 '.5, 2.9 3.6) Reverse check sleeve (FS5W71C) s: -4... switch '-, Reverse 2. 29 lamp (2. - 3., 14-221 ' r:;! Thread of bolts o "- - Transmission case Mating surface to engine rear plate (4WD model - Refer to "REMOVAL and INSTALLATION" in MT-8.),---- ) Bearing Bearing retainer 16 2 (1.6-2., 12 14) Rear extension Adapter plate D Mating surface to transmission case and rear extension (or OD gear case) Filler plug 25-34 (2.5-3.5, 18-25) D Thread of bolt OD gear case Ill Ill (I) 3 "C :::J (I) :::J -Ill s: l> c.. : < m : ::r:: l> c: r Oit seal l!2i!l Seal lip,. o N m (kg-m, ft lb) : Apply recommended sealant (Nissan genuine part: KP61-25) or equivalent. 498

MAJOR OVERHAUL I FS5W71C I Gear c omponents - 2WD model Washer Snap ring* Pilot bearing EB I. Snap ring Main drive gear ball bearin "'".. :7.$QJ Main drive!cll "" Malnshaft lock nut..,..-. 137-167 (1.., 11-123) Without Tool 4-17., *. S I gs when assembll synchronizers Apply gear oil to and bearln gears, shafts,. e ect proper th' ng. <:r : Pay atte,. lckness. 1'!""n n1onto't. -: N m (kg-m, ft-lb) 1 s direction. MT-11 SMT613C J)}Z 499

MAJOR OVERHAUL FS5W71C Gear Components - 4WD model 3rd main gear /Needle bearing 7 \ Baulk nng 1 Washer\ Coupling leeve / Snapnng*-\ \ - :1\ ) Mainshaft ball bearing 1 Polot beanng 1!i51\, \ Spread spnng/\ R Thrust washer l!i5l I Snap nng \\ \ / '( \ 1st main gear1 I / :::pd: :::;;bll)1 \_) '"""'"-"II tj/ 1 l (n ) ) 3rd & 4th synchronozer hub" ""'"\\:'), j '&,) Sh1ft1ng msert Q_/ Main drive r r Steel roller 1!i51\ Steel ball I!Ei!!l ' 1st and ::n::hubl r \.,;:- beanng Needle n _/ /. Baulk ring 2nd out.er baulk ring ;:;:J' Synchronizer cone 2nd maon gear\ &" Coupling sleeve Needle beanng \ Ma1nshatt 7 \ 2nd 1nner baulk nng / lfj; El/"''' '"' SMT614C MT-12 5

Return spring Retaining pin ii; Select check plungerk \ /// Return spring plug Thread of bolts 2 29 (2. 3., 14. 22) Bushing IlEa! Mating surface to control lever Return spring Check ball./1 Snap ring o-shift knob Control lever s: -1... '. (;,) _p"-. Check spring Check ball Lock pin ;---- Check ball plug. @@ v 1:;1 Thread of bolts Striking rod "" A (1.9 Striking lever _j \ ""''9-25 ------&../.-. - 2.5, 14-18) 9-12 (.9-1.2, 6.5-8.7) Retaining pin 1st & 2nd fork rod Washer Rubber seat Spring Socket!:E! Mating surface to housing and control lever y_ Boot \ -j Lower boot V retainer til :::T = ::;, -... 2. 3 "C ::;, CD ::;, -Ill s: )> c.. ::D < m ::D :I: )> c: r- 51 "' I :g] [J-J'tj r 3rd & 4th fork rod 821 "Ull Check ball 3rd & 4th shift fork ';/J :.Clil 2l5J 7L.. no reverse fork rod :2QJ JS;o "'lf>j "@) J 9 ""' c...c '" OD & reverse shift fork 19 25 (1.9 2.5, 14 18) : N m (kg-m, ft-lb) : Apply recommended sealant (Nissan genuine part: KP61-25) or equivalent. =ml Ulfil mnllr1flj rt""'!j 'Ill "" F ( '"" d&',;;)j N ::IE c 3 a. CD

:s:: 7... ""' "' i Return spring plug D Thread of bolt 2-29 (2. - 3., 14-22) Return spring [; Select check plunger Bushing m, Mating surface to control lever Striking lever Lock pin Reverse check plug Striking rod----..._ DThread of bolt ( /<i\11''.-. J.>. Check ball @. -..._ Return spnng ""26-36 (2.7-3.7, 2-27) 9-12 (.9-1.2, 6.5-8.7) Select check plunger / Return 1 spnng plug Return spnng_j 1st & 2nd fork rod 3rd & 4th shift fork Check spnng /Checkball Y I.r-. D Thread of bolt 2-29 (2. - 3., 14-22) Check ball plug /! Thread of bolts 19-25 (1.9-2.5, 14-18) Retaining pin & reverse shift fork Snap ring Washer Rubber seat v ::J""'" Socket!Ei! Upper surface to housmg and 8-Mating control lever D-Shlftknob Control lever boot retainer ti)-spnng rls Boot Ly_ - - Control housing : Apply recommended sealant (Nissan genuine part: KP61-25) or equivalent. : N m (kg-m. ft-lb) - )> ::r :::;: c.. (') ::D... m (/) :s:: -:I < ::D (') :::1: )> 3 c: "C r- :I (I) :I iii I :::e ""' c 3 c. (I) 52

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. SMT982 b. Drive out striking arm retaining pin. c. Remove striking arm from striking rod. d. Remove rear extension by lightly tapping it. SMT8B 2. 3. Remove front cover, gasket, shim of countershaft front bearing, and snap ring of main drive gear ball bearing. Separate transmission case from adapter plate. l 4. Remove oil seal of front cover. Be careful not to damage mating surface of front cover. ( SMT35 Shift Control Components 1. Set up Tool on adapter plate. 2. Remove striking rod from adapter plate. 3. Remove check ball plugs, check springs, and check balls. MT-15 53

ST2354 (J25689-A) I FS5W71C I DISASSEMBLY Shift Control Components (Cont'd) 4. Drive out retaining pins. Then drive out fork rods and remove interlock balls. SMT984 5. Remove lever bracket securing bolt (2WD model). SMT788A 6. Draw out 3rd-4th fork rod (2WD model). 7. Remove E-ring from OD-rev. fork rod (2WD model). 8. Draw out OD-rev. fork shaft by rotating OD-rev. bracket counterclockwise (2WD model). SMT792A MT-16 54

DISASSEMBLY I FSSW71C I Gear Components 1. Before disassembly, measure each gear end play. If end play is not within the specified limit, disassemble and check the parts. Replace any part which is worn or damaged. Gear end play: Refer to SDS, MT-57. 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, subgear spring and sub-gear. ========= 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. 5. Remove snap ring and draw out 3rd & 4th synchronizer and fil.l 3rd gear. 6. Disassemble parts at rear of adapter plate as follows: a. Release staking on countershaft nut and mainshaft nut and "!ffil loosen these nuts. Mainshaft nut: Left-hand thread SMT546A b. c. d. Pull out OD counter gear with bearing with suitable puller. Draw out reverse counter gear and spacer. F Remove snap rings from reverse idler shaft, and draw out reverse idler gear, thrust washers and reverse idler gear bearing. & 1 MT-17 55

FS5W71C DISASSEMBLY Gear Components (Cont'd) e. Remove snap ring and pull out overdrive mainshaft bearing, then remove snap ring. (2WD model) f. Remove mainshaft nut. g. Remove speedometer drive gear and steel ball. (2WD model) h. Remove thrust washer, steel roller, roller bearing and washer. i. Remove OD main gear, needle bearing and baulk ring (OD). j. Remove reverse main gear (2WD), OD & reverse coupling sleeve (4WD), shifting inserts and shifting insert springs. k. Remove counter gear by tapping rear end of counter gear. I. Press out OD gear bushing, insert retainer and OD synchronizer hub. SMT554A 7. Remove thrust washer, steel ball, 1st main gear and needle bearing. Be careful not to lose steel ball. 8. Press out 1st gear mainshalt bushing together with 2nd main gear with Tool. Then remove 2nd gear needle bearing. ST331 (J22912.Q1) ST331 (J22912-11 9. Remove main drive gear bearing. a. Remove snap ring and washer. b. Remove main drive gear bearing. SMT42A MT-18 56

INSPECTION I FS5W71C I Shift Control Components Check contact surface and sliding surface of fork rods for wear, scratches, projections or other damage. *. SMT75C Mainshaft and gear Gear Components GEARS AND SHAFTS Check shafts for cracks, wear or bending. Check gears for excessive wear, chips or cracks. 1i'IF Counter gear SMTSSOA Shifting insert SYNCHRONIZERS Check spline portion of coupling sleeves, hubs and gears IP for wear or cracks. Check baulk rings for cracks or deformation. Check shifting inserts for wear or deformation. 1'\ Check insert springs for deformation. MT-19 57

Baulk ring to gear clearance INSPECTION Gear Components (Cont'd) FS5W71C Measure wear of bau\k rings. a. Measure clearance between baulk ring and gear. Clearance between baulk ring and gear: Refer to SDS, MT -57. If the clearance is smaller than the wear limit, replace baulk ring. SMT14 Inner baulk ring \2nd inner baulk ring ':if;:'""'""" " Measure wear of 2nd baulk rings. a. Place baulk rings in position on synchronizer cone. b. While holding baulk rings against synchronizer cone as far as it will go, measure dimensions "A" and "8". Unit mm (in) Dimension Standard Wear limit ST331 - (J22912-1) SMTD418 A 8.6-1.1 (.24 -.43).7-.9 (.28 -.35).2 (.8) Outer bau lk ring Synchronizer cone ){2nd outer baulk ring Feeler gauge c. If dimension "A" or "B" is smaller than the wear limit, replace baulk ring. :.. "- 2nd outer baulk ring BEARINGS Make sure bearings roll freely and are free from noise, crack, pitting or wear. MT-2 58

ASSEMBLY I FS5W71C I Gear Components Malnshaft ball bearing In adapter plate Countershaft rear end bearing In OD gear case (4WD model) ra I/' Drift @ /!\ Counter rear bearing In adapter plate Be flush with front surface of OD gear case.!:i%1] '"!:IF 1'1.: IP!i' CJ.. 'L.--- Upper Front 7 :: / \ ' SMT153A 1. Install bearings into case components. SMT481CA 2. Assemble adapter plate parts. Install oil gutter on adapter plate and expand on rear side. /i\11' Install bearing retainer. a. Insert reverse shaft, then install bearing retainer. 1-:IL b. Tighten each screw, then stake each at two points. MT-21 59

ASSEMBLY Gear Components (Cont'd) 3. Install main drive gear bearing. a. Press main drive gear bearing. b. Install main drive gear spacer. FSSW71C c. Select proper main drive gear snap ring to minimize clearance of groove and install it. Allowable clearance of groove: -.13 mm ( -.51 in) Main drive gear snap ring: Refer to SDS, MT -57. 4. Assemble synchronizers. 1st synchronizer SMT54C Coupling sleeve Check coupling sleeve and synchronizer hub orientation. Frontsy arside Synchronizer hub SMT26C MT-22 51

ASSEMBLY Gear Components (Cont'd) 2nd double baulk ring type synchronizer I FS5W71C I @ Spread spring -; -\ 3rd & 4th synchronizer The 3 gutters of synchronizer should be at the rear. Front Front 9 8 (.35) (.31) HH Unit: mm (in) 2WD 4WD SMT36C OD & reverse synchronizer (2WD model) <f?'«<il!! t? Front (5th) synchronizer _./'fj hub fltp SMT95AA MT-23 511

ASSEMBLY Gear Components (Cont'd) (4WD model) FS5W71C Front Shifting insert 5. Install front side components on mainshaft. a. Assemble 2nd main gear, needle bearing and 1st & 2nd synchronizer assembly, then press 1st gear bushing on mainshaft. b. Install 1st main gear. c. Install steel ball and 1st gear washer. Apply multi-purpose grease to steel ball and 1st gear washer before installing. TM35'8 6. Install mainshalt and counter gear on adapter plate and main drive gear on mainshaft as follows: a. Press mainshalt assembly to adapter plate with Tool. KV31141 ( - ) MT-24 512

ASSEMBLY Gear Components (Cont'd) FS5W71C b. Press counter gear into adapter plate with Tool. c. Install 3rd main gear and then press 3rd & 4th synchronizer assembly. Pay attention to direction of 3rd & 4th synchronizer. @I ============================SM=T=75 ============================T=M=441 d. Install thrust washer on mainshaft and secure it with mainshaft front snap ring. &: Select proper snap ring to minimize clearance of groove in mainshaft. Allowable clearance of groove: lei ' I!< -.18 mm (-.71 in) 11':1!.: Mainshaft front snap ring: Refer to SDS, MT -57.! ' e. Apply gear oil to mainshaft pilot bearing and install it on mainshaft. f. Press counter drive gear with main drive gear with Tool. Pay attention to direction of counter drive gear. ret SMT412C SMT528A g. Install sub-gear components. (1) Install sub-gear and sub-gear bracket on counter drive gear 1 '81 and then select proper snap ring to minimize clearance of groove in counter gear. Allowable clearance of groove: b\ -.18 mm ( -.71 in) Counter drive gear snap ring: Refer to SDS, MT -57. (2) Remove snap ring, sub-gear bracket and sub-gear from counter gear. (3) Reinstall sub-gear, sub-gear spring and sub-gear bracket. i ili' h. Install selected counter drive gear snap ring. TM366 MT-25 513

ASSEMBLY Gear Components {Cont'd) i. Press counter gear front bearing onto counter gear. I FS5W71C I ST22362 (J25679-1) TM443 7. Install rear side components on mainshaft and counter gear as follows: a. Install reverse idler gear to reverse idler shaft with spacers, snap rings and needle bearing. TM451 b. Install insert retainer and synchronizer to mainshaft. (2WO model) Pay attention to direction of hub. t? Front OD (5th) synchronizer hub tarr SMT95AA b. Install bushing and & reverse synchronizer to mainshaft. (4WO model) Pay attention to direction of hub. Shift'ng.,.. IOSert,... f:f Front Shifting insert SMT27CA MT-26 514

Gear bushing I FS5W71C I ASSEMBLY Gear Components (Cont'd) c. Install gear bushing with Tool. d. Install main gear and needle bearing. e. Install spacer, reverse counter gear and counter gear. OD main gear and OD counter gear should be handled as a matched set. @:I f. Install washer, roller bearing, steel roller and thrust washer. g. Tighten mainshalt lock nut temporarily. lil\ Always use new lock nut. ====;;;;:;;;:====== h. Install countershalt rear end bearing with Tool. SMT531 [i":l ============== 8. Mesh 2nd and reverse gears, then tighten mainshaft lock nut with Tool. SMT43 ([:l SMT3A Tool Torque wrench c Use the left chart when deciding the reading torque. (Length of torque wrench vs. setting or reading torque) 9. Tighten countershaft lock nut. Always use new lock nut. (11), \! ;;, (1) c :g c: (.) (9) (8).8 m (1.5) (2.) (2.5) {h) L: Length of torque wrench SMT4A MT-27 515

Mainshaft Counter shaft I FS5W71C I ASSEMBLY Gear Components (Cont'd) 1. Stake mainshaft lock nut and countershaft lock nut with a punch. 11. Measure gear end play. For the description, refer to DIS ASSEMBLY for Gear Components, MT-17. Fork rod (1st & 2nd) Shift Control Components 1. Install shift rods, interlock plunger, interlock balls and check balls. SMT992AA a. 1st-2nd shift fork b. 3rd-4th shift fork c. OD-reverse shift fork or reverse shift fork SMT991 MT-28 516

I FS5W71C I ASSEMBLY Shift Control Components (Cont'd) 2. Install OD-rev. fork shaft by rotating OD-rev. bracket clockwise (2WD model). 3. Install E-ring on OD-rev. fork rod (2WD model). 4. Install lever bracket securing bolt (2WD model). Case Components 1. Install front cover oil seal. Apply multi-purpose grease to seal lip. SMT36 2. Apply sealant to mating surface of transmission case. SMT61C MT-29 517

ASSEMBLY Case Components (Cont'd) I FS5W71C I 3. Slide gear assembly onto adapter plate by lightly tapping with a soft hammer. 4. Install main drive bearing snap ring. 5. Apply sealant to mating surface of adapter plate. SMT62C Shift 'od 6. 7. Set shift forks in neutral position. Install striking lever onto adapter plate and align striking lever with shift brackets. lever 8. Install rear extension. 9. Fit main drive bearing snap ring. SMT82B MT-3 518

ASSEMBLY Case Components (Cont'd) 1. Install striking arm retaining pin. I FS5W71C I A SMTBOOB A: Distance from bearing surface to transmission case 11. Select counter front bearing shim. Counter front bearing shim: Refer to SDS, MT -58. CD Transmission case Counter gear front bearing @ Counter gear ==========================T=M=371 12. Install gasket and front cover. 13. Install return spring plugs, check ball, return springs and select check plunger. 14. Install control housing and gasket. [P 1F SMT982 MT-31 519

ASSEMBLY I FS5W71C I NOTE MT-32 52

. [2Womodei] Neutral pos t on sw1tch 16 _ 21 ( 1. 6 _ 2.1, 12-15) 2-29 (2.- 3., 14-22),,-. D Thread of bolt Reverse lamp switch Control housmg Thread of bolt I. 5: '"" w (,) Front cover Filler plug 25-34 (2.5-3.5. 18-25) Thread of bolt Transmission case---- Mating surtace to engine rear plate (4WD model - Refer to "REMOVAL and INSTALLATION" in MT-9.) Slide ball bearing!b!il Gasket \ (j'\))) ' ' Adapter plate Mating surface transmission case I Plug [;} Matmg suriace to rear extension /:> Oust cover (1.6-2.1, 12-15) /4WD model/ \ Rear oil seal mseallip ball bearing m A 16 _ 21 (1.6 _ 21 12. - 15) Neutral position switch /Control housing 2-29 (2. _ 3., ) 14722, Mating surface to OD D Thread of bolt j gear case..l.r! -r'""" J 6.3-8.3 rohoo'l -.. -25. (.64-.85, 4.6-6.1) - m Seal lip I Thread of bolt ) -() Reverse lamp sw;;c 14-22) ' -,_Wi>'l811 e'""'-. t!j' L'J " > r<>.. fc''" r: 23 (3.2_ -31) 4.3, Sealing gr emmet ( wo model) 4 31-42 - 2-29(2.-. Ball pin Thread of bolt,., 16-21 (1.6-2.1, 12-15) "ASSEMBLY" ;n MT-54.,-. Thread of bo It - Refer to -o -Baffle plate Ill 1/) CD 3 "C :I CD :I -1/) 5: c.. > %1 < m %1 ::1: > c r- 521 "' ) m F '"" toj : N m (kg-m, ft-lb) : Apply recommended sealant (Nissan genuine part: KP61-25) or equivalent. @l) IPQl CijJ!;'! 2m 29 2.-tril =;::-cjj ;g b 9 OD gear case r "" JmJ!ftrjffl'j] (,""'J "l1l F' G:1J JmJ!1i! )

4th baulk ring Mains haft front snap ring* Spacer Pilot bearing Steel ball I!E3!I /l I Main drive gear Mainshaft Main drive gear bearing Spacerl s:: -1 ' w "". ar snap ring*\ \ o '"- Sub-gear "'\:J'O ]' \ /l spring. QO /')Jf I L Main drive!'aring Steel ball IE!\ Sub-gear-,. I --h()o' Counter gear J y I snap nng..., front bearing J Couter gheat f;her *!:I:! beanng t ru Counter gear front thrust bearing m Sub-gear snap ring @ Counter gear rear bearing thrust washer 1st gear washer m ger bushm7 1st & 2nd coupling sleeve \)1 Shoftong con 1st baulk nng r- msert \J \_, 2nd gear needle beann-.,p { ' '--1st main gear (With irri\,g"" \_Spread spnng sub-gear) '\ "'---1st & 2nd @ \ synchronzer hub Ci) CD Ill 3 "C :I CD :I iii s:: > c.. ::tl < m ::tl ::I: c > r- 2n- in:=,.ulk ring J \ '\..._2nd outer baulk ring Synchronizer cone 522

Mainshaft \ Mamshaf1 Reverse cou li spacer \ rear beanng P ng sleeve_, \ \ C-nng * Reverse gear needle b Reverse. h ub _, C-nng holder @ Reverse mal eanng r ( """""-'" i "-" 11 \ \ \ I.- Manshaft rearsnapnng s:: -1 (o) U1 523 "' ls:2j 1m IF @ -- l/ -"NO eter drive gear..._ \ 2WD - \ rfl: ' "" - "' "' - I mode!) m w - - \ "",w ' I \ 1,. 1\J.l:J \)IJIJ! Reverse Q tergear J (., Counter gear rear uusnrng e -.-- -- Jcl\!:lill -- -: ::::.earing \\(y \ ijei Ciil 1 m \ anngrrear U \_.. J - " \ '--Insert sp. nng I "-' w ',_ Q',a'-.::r -- ""-" rfo{f' rf'\i 1m ly Manshaft j L gear bushlngj I co couphng s I eeve-t, D gear needle b unter gear eanng \Reverse idler rear thru -------\ Reverse ldl st washer* tr!>a er needle b eanng Reverse idler gear Reverse idler front th rust Reverse idl washern \ Retaining pin er shaft w 9 If@ 2]] 2 Ciil "" rg 9 9 F Til 1m Apply gear oil to gears, shafts, synchronizers and bearings when assembling. * : Select with proper thickness. * : Pay attention to its direction. mlru=u ocru 1 3 IF co Nil "s:: (J) I»... ::tl 3 <, m ::tl :I ::1: (J) )> ::!.c: Ill r-.-. :I c.._.. I

Control lever knob - s::... w en Check spring 'Qt-- [ [ \ - 29 (2.5-3., 18 22) Washer\ \:b: 1 OD & reverse fork rod Snap ring \..-_.31-42 (3.2-4.3, 23-31) --" Check ball plug Control lever 19 25 (1.9-2.6, 14-19) Washer I 'r( /Upper boot retwner D Bolt thread Interlock stopper :e;!:a3. - 3.5, 22-25) ---../Boot I@ I ' Check - -:t.':ng pin jj -Striking rd I Snap ring m Contact surface to control lev lower boot retainer ball m. B. Free length: "'-... _...-- Socket, 32.8 mm (1.291 In)'\ ' "' I l!'a!l Contact surface to control le L./ Control housing t Reverse shift fork Spring ] Bushing I I _. Retaining pin... Q';,"' Efi!l Contact surface to control lever ' Select check plug Retaining pin" VReturn spring 2-29 (2. - 3., 14-22), Free length ro rj Bolt thread 2WD model: 47.4 mm (1.866 In) \ I Select check spring. 4WD model: 5.4 mm (1.984 in) Striking interlock Striking lever* 3rd & 4th shift fork Checkbaii Select check plunger I R 1!8! Contact surface to. striking arm \ evercse ct hetck srtleevet 1 < on_ac su ace o r \ Retaining pin.::l"..._strlkmg lever loo rod bracket 2 / "<().;..; --85, shift fork I 4.6-6.1) -en :r > :;: c.. :rj -::I... < g_ s:: m :rj ::1: > 3 c: "C r ::I CD ::I -Ill Snap ring!.. Select check plug Guide nll'lfa 2 _ 29 (2. 3., 14 _ 22), / / Bolt thread,-. 6.3-8.3 (.64- o.a5, 4.6-6.1, Select check spnng ;: : N m (kg-m, ft-ibl : Apply recommended sealant (Nissan genuine part: KP61-Q25) or equivalent. : Apply locking sealant. * : Pay attention to its direction. Select check plunger Ei3! Contact surface to striking arm I 524

DISASSEMBLY I FS5R3A I Case Components 1. Remove check 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. lilj 2. Remove control housing, return spring and check ball. 3. Drive out retaining pin from striking arm. 4. Remove rear extension (or OD gear case) together with striking arm by tapping lightly.!fffi\ 5. Remove front cover and gasket. MT-37 525

DISASSEMBLY Case Components (Cont'd) I FS5R3A I 6. Remove stopper ring and main drive bearing snap ring. 7. Remove transmission case by tapping lightly. Soft hammer / SMT3J2A 8. Remove front cover oil seal. Shift Control Components 1. Mount adapter plate on vise. 2. Remove OD & reverse fork rod. 1 ST2354 IJ25689-A) 3. Drive out retaining pin from striking lever. 4. While pulling out striking rod, remove striking lever and striking interlock. Then remove 1st & 2nd, 3rd & 4th and reverse shift fork. MT-38 526

DISASSEMBLY Shift Control Components (Cont'd) 5. Drive out retaining pin from OD shift fork. 6. Pull out OD fork rod and then remove OD shift fork. I FS5R3A I I Gear Components 1. Before removing gears and shafts, measure each gear end IL play. Gear end play:!elf ill Refer to SDS, MT -59. IE If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft. li'!e 2. Remove rear side components on mainshaft and counter gear. a. Remove reverse coupling sleeve. b. Remove mainshaft rear snap ring and counter gear rear snap ring. c. Remove G-ring holder and mainshaft C-rings from mainshaft. Use punch and hammer to remove C-rings. IF/AI d. Pull out counter gear rear end bearing. e. Remove reverse idler gear and reverse idler thrust wash- Ill" ers. MT-39 527

DISASSEMBLY Gear Components (Cont'd) f. Pull out mainshaft rear bearing (2WD model). I FS5R3A I g. Pull out reverse main gear together with mainshaft spacer and reverse synchronizer hub. Then remove reverse gear needle bearings. h. Pull out reverse counter gear. i. Remove OD coupling sleeve together with OD baulk ring, reverse baulk ring and spring inserts. j. Pull out reverse gear bushing. k. Pull out OD counter gear together with reverse cone. MT-4 528

DISASSEMBLY Gear Components (Cont'd) 3. Press out mainshaft and counter gear alternately. AlterLtely...-... I FS5R3A I ST3323.-(.. I - ) F1 - L.... UC::?, Be sure to press mainshaft and counter gear alternately so as not to allow the front surface of one to contact the rear surface of the other. SMT772A 4. Remove front side components on mainshaft. a. Remove 1st gear washer and steel ball. b. Remove 1st main gear and 1st gear needle bearing. c. Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly. d. Remove mainshaft front snap ring. IF&\ ST331 IJ22912.Q1l SMT482C e. Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing. ffiif' MT-41 529

DISASSEMBLY Gear Components (Cont'd) 5. Remove front side components on counter gear. a. Remove counter gear rear thrust bearing. FS5R3A ST331 rf:j2:::2l912.1) b. Remove sub gear components. ST331 (J22912-11 6. Remove main drive gear bearing. a. Remove main drive gear snap ring and spacer. b. Press out main drive gear bearing. smt42a 7. Remove bearings from case components. Counter gear front bearing In transmission case fr Mainshaft front bearing in adapter plate SMT388A Counter gear rear end bearing In OD gear case (4WD model) Counter gear rear bearing In adapter plate SMT396A ST3775 (J34286) SMT39A SMT483CA MT-42 53

INSPECTION I FS5R3A I Shift fork Shift Control Components Check contact surface and sliding surface for wear, scratches, projections or other damage.... -';, l!lil "" ============S:::M:_:T3=98A Mainshaff and gear Gear Components GEARS AND SHAFTS Check shafts for cracks, wear or bending. Check gears for excessive wear, chips or cracks. Counter gear /J\1 SMT423A Shifting insert SYNCHRONIZERS Check spline portion of coupling sleeves, hubs, and gears Fli\ for wear or cracks. Check baulk rings for cracks or deformation. Check shifting inserts for wear or deformation. /)\ Check insert springs for deformation. SMT427C =====sa=u=lk=ci=n9=,o===== gea< clearance Clearance between baulk ring and gear Measure wear of main drive, 1st and OD baulk rings. Unit: mm (in) ijf 1st Main drive OD Standard 1.5-1.3 (.413-.512) 1.5-1.3 (.413-.512) 1.5-1.3 (.413-.512) Wear limit.7 (.28).7 (.28).7 (.28) SMT14D If the clearance is smaller than the wear limit, replace baulk ring. MT-43 531

Inner baulk ring FS5R3A INSPECTION Gear Components (Cont'd) Measure wear of 2nd and 3rd baulk rings. a. Place baulk rings in position on synchronizer cone. b. While holding baulk rings against synchronizer cone as far as it will go, measure dimensions "A" and "B". Unit mm (in) Dimension Standard Wear limit A.6 " 1.1 (.24 ".43) B.7 ".9 (.28 ".35).2 (.8) Outer baulk ring Synchronizer cone 2nd outer baulk ring Feeler gauge c. If dimension "A" or "B" is smaller than the wear limit, replace baulk ring. SMT42B Measure wear of reverse baulk ring. a. Place baulk ring in position on reverse cone. b. While holding baulk ring against reverse cone as far as it will go, measure dimension "A" with dial indicator. Dimension "A": Standard -.1 to.35 mm (-.39 to.138 in) Wear limit.7 mm (.28 in) c. If dimension "A" is larger than the wear limit, replace baulk ring. SMT424A BEARINGS Make sure bearings roll freely and are free from noise, crack, pitting or wear. MT-44 532

ASSEMBLY I FS5R3A I Gear Components Counter gear front bearing in transmission case Mainshalt front bearing in adapter plate -{;( Iilli Counter gear rear bearing in adapter plate SMT397A / _1:).. -- KV3813 (J25523) SMT391A SMT484CA l 1. Install bearings into case components. 2. Install main drive gear bearing. a. Press main drive gear bearing. b. Install main drive gear spacer. c. Select proper main drive gear snap ring to minimize clearance of groove. Allowable clearance of groove: -.1 mm (-.4 in) Main drive gear snap ring: Refer to SDS, MT -59. d. Install selected snap ring on main drive gear. rp LA\ 3. Install components on counter gear. a. Install sub-gear components. [i!if When installing sub-gear snap ring, tap sub-gear snap ring into position on counter gear. SMT577A MT-45 533

ASSEMBLY Gear Components (Cont'd) b. Install counter gear rear thrust bearing. I FS5R3A I SMT45A 4. Install front side components on mainshaft. a. Assemble 1st & 2nd synchronizer. SMT614B b. Assemble 3rd & 4th synchronizer. Rear Q SMT615B c. Press on 3rd & 4th synchronizer assembly together with 3rd main gear and 3rd gear needle bearing. Pay attention to direction of synchronizer assembly. SMT399A d. Select proper snap ring to minimize clearance of groove. Allowable clearance of groove: -.1 mm (-.4 in) Mainshaft front snap ring: Refer to SDS, MT-59. e. Install selected snap ring on mainshaft. SMT4A MT-46 534

I FS5R3A I ASSEMBLY Gear Components (Cont'd) f. Press on 1st & 2nd synchronizer assembly together with 2nd main gear and 2nd gear needle bearing. g. Press on 1st gear bushing using 1st gear washer. h. Install 1st main gear and needle bearing.!"!": ;;:==============S=M=T =2lA 1 i. Install steel ball and 1st gear washer. Apply multi-purpose grease to steel ball and 1st gear washer before installing. Counter gear front thrust Sub-gear components gear 5. Select proper counter gear front bearing thrust washer when replacing transmission case, counter gear, counter ["& 1 gear thrust bearing or sub-gear components. a. Install counter gear with sub-gear components, counter gear front and rear bearing thrust washer on adapter plate. lt!l b. Remove counter gear front bearing thrust washer from transmission case. c. Place adapter plate and counter gear assembly in trans- Bi11 mission case (case inverted). SMT427AA MT-47 535

ASSEMBLY Gear Components (Cont'd) I FS5R3A I 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 thrust washer using table below as a guide. Counter gear end play:.1-.25 mm (.39-.98 in) Table for selecting proper counter gear front bearing thrust washer: Refer to SDS, MT -6. SMT578A A--Reverse idler shaft U / Reverse idler front thrust washer 6. Select proper reverse idler rear thrust washer when replacing rear extension (or OD gear case), reverse idler gear, reverse idler shaft or reverse idler thrust washer. a. Install reverse idler gear, reverse idler needle bearings, reverse idler thrust washers and reverse idler shaft into rear extension (or OD gear case). When replacing reverse idler rear washer, install either A or B. Reverse idler rear thrust washer: Refer to SDS, MT -6. SMT432A MT-48 536

ASSEMBLY Gear Components (Cont'd) I FS5R3A I b. Place dial indicator on front end of reverse idler shaft. c. Put straightedge on front surface of rear extension (or OD gear case.) 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:.3-.53 mm (.118 -.29 in) e. If not within specification, replace reverse idler rear thrust lffil washer with the other (A or B) and check again. Straightedge SMT433A 7. a. Install mainshaft 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. 11' b. Install mainshafl a little on mainshafl front bearing. To allow for installation of counter gear, do not install mainshalt completely. if$\ c. Install counter gear on counter gear rear bearing and install main drive gear, pilot bearing and spacer on main-!" shaft. MT-49 537

Push up with ASSEMBLY Gear Components (Cont'd) I FS5R3A I When installing counter gear into counter gear rear bearing, push up on upper roller of counter gear rear bearing with screwdriver. d. Install Tools (J26349-3) onto adapter plate and G-ring and G-ring holder on mainshaft. e. Install Tool (J34328) on mainshaft. i and C-ring holder f. Install mainshafl and counter gear completely by extending length of J26349-3. 8. Install rear side components on mainshafl and counter gear. a. Install gear bushing while pushing on the front of counter gear. b. Install main gear. Pay attention to direction of OD main gear. (B is wider than A as shown at left.) c. Install adapter plate with gear assembly onto transmission case. d. Install gear needle bearing and then install counter gear and reverse idler shaft. MT-5 538

ASSEMBLY Gear Components (Cont'd) I FSSR3A I e. Install reverse gear bushing with speedometer drive gear (2WD model). f. Install reverse cone. ST3775 (J34332) Insert spring Reverse baulk ring SMT582A g. Install insert springs and reverse baulk ring on OD coupling sleeve. Then install them and OD baulk ring on OD counter gear. Pay attention to direction of OD coupling sleeve. SMT571AA h. Install reverse counter gear. i. Install reverse gear needle bearing and then install reverse i' main gear, reverse idler gear and reverse idler thrust washers. IJ343341 1!1!1 MT-51 539

ASSEMBLY Gear Components (Cont'd) j. Install reverse hub. Pay attention to its direction. I FS5R3A I k. Install mainshaft spacer and mainshaft rear bearing (2WD model). I. Install counter gear rear end bearing. m. Separate adapter plate from transmission case and mount adapter plate on vice again. n. Select proper mainshaft C-ring to minimize clearance of groove. Allowable clearance of groove: -.1 mm ( -.4 in) Mainshafl C-ring: Refer to SDS, MT -6. SMT452A o. Install selected C-ring, C-ring holder and mainshaft rear snap ring. MT-52 54

ASSEMBLY Gear Components (Cont'd) I FS5R3A I p. Install spacer and then select proper counter gear rear snap ring to minimize clearance of groove. Allowable clearance of groove: -.1 mm (-.4 in) Counter gear rear snap ring: Refer to SDS, MT -6. q. Install selected counter gear rear snap ring. @I r. Install reverse coupling sleeve. Pay attention to its direction. s. Measure each gear end play as a final check - Refer to "DISASSEMBLY", MT-39. Shift Control Components 1. 2. Install OD fork rod and OD shift fork. Then install retaining IF&\ pin into OD shift fork. Install 1st & 2nd, 3rd & 4th and reverse shift fork onto coupling sleeve. 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. il!l" MT-53 541

ASSEMBLY I FS5R3A I ST3321 (J2583-1) 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. SMT393A 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. 8. Install front cover and gasket. Apply sealant to thread of 3 bolts shown left. 9. Apply sealant to mating surface of adapter plate. MT-54 542

I FS5R3A I ASSEMBLY Case Components (Cont'd) 1. Install rear extension (or OD gear case) together with striking arm. 11. Install retaining pin into striking arm. u: 12. Install return spring and check ball and then install control housing. Apply sealant to mating surface of rear extension (or OD gear case). 2WD model 4WDmodel 13. Tighten control housing bolts. Boll head size: A bolts 12 mm (.47 in) B bolls 13 mm (.51 in) SMT572A MT-55 543

SERVICE DATA AND SPECIFICATIONS (SDS) I FS5W71C & FS5R3A! General Specifications KA24E VG3E Applied model 2WO 2WO 4WO 4WO Truck Wagon Transmission FS5W71C FS5R3A Number of speed 5 Shift pattern 1 3 5.)_j II 2 4 A Synchromesh type Warner Gear ratio 1st 3.321 3.985 3.58 4.61 2nd 1.92 2.246 2.77 2.357 3rd 1.38 1.415 1.36 1.49 4th 1. 1. 1. 1..838.821.811.862 Reverse 3.382 3.657 3.636 4.125 Number of teeth Mainshaft Drive 22 21 22 2 1st 33 34 32 32 2nd 27 28 3 3 3rd 26 26 29 28 22 21 24 23 Reverse 36 36 3 3 Counters haft Drive 31 32 32 33 1st 14 13 13 13 2nd 2 19 21 21 3rd 28 28 31 31 37 39 43 44 Reverse 15 15 12 12 Reverse idler gear 21 21 22 22 Oil capacity C (US pt, Imp pt) 2. (4-114, 3-1/2) 4. (8-112, 7) 2.4 (5-1/8, 4-1/4) 3.6 (7-518, 6-318) Mainshaft braking Reverse synchro- Remarks mechanism nizer 2nd & 3rd double baulk ring type synchronizer 2nd double baulk ring type synchronizer MT-56 544

SERVICE OAT A AND SPECIFICATIONS (SDS) FS5W71C Inspection and Adjustment GEAR END PLAY 1st gear 2nd gear 3rd gear OD gear.31..41 (.122..161).11 -.21 (.43 -.83).11..21 (.43..83).24..41 (.94..161) Unit: mm (in) CLEARANCE BETWEEN BAULK RING AND GEAR Standard 1s1 3rd & main drive DO Reverse (4WD) Wear limit 1s1 3rd & main drive OD Reverse (4WD) Unit: mm (in) 1.2-1.6 (.472 -.63) 1.2-1.6 (.472 -.63) 1.2-1.6 (.472-.63) 1.1. 1.55 (.433-.61).8 (.315).8 (.315).8 (.315).7 (.276) AVAILABLE SNAP RINGS Main drive gear bearing Allowable clearance -.13 mm { -.51 in) Thickness mm (in) Part number 1.73 (.681) 3224-785 1.8 (.79) 3224-78 1.87 (.736) 3224-781 1 94 (.764) 3224-782 2.1 (.791) 3224-783 2.8 (.819) 3224-784 Mainshaft front Allowable clearance -.18 mm (-.71 in) Thickness mm (in) Part number 2.4 (.94) 32263-V52 2.5 (.98) 32263-V521 2.6 (.12) 32263-V522 Mainshaft rear end bearing (2WD model) @ II\ li"ti u:!'!f!ell: T!:l 2nd baulk ring Unit mm {in) Allowable clearance Thickness mm {in) 1.1 (.43) -.14 mm {-.55 in) Part number 32228-21 Outer baulk ring 1.2 (.47) 32228-211 B 1.3 (.51) 1.4 (.55) 32228-212 32228-213 Counter drive gear Allowable clearance -.18 mm (-.71 in) Inner baulk ring Thickness mm (in) Part number \.. Synchronizer cone 1.4 (.55) 1.5 (.59) 32215-E9 32215-E91 SMT448 1.6 (.63) 32215-E92 Dimension A B Standard.6-1.1 ( 24..43).7-.9 (.28 -.35) Wear limit.2 (.8) MT-57 545

AVAILABLE SHIMS Counter front bearing SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd) Unit mm {in) I FS5W71C I A A: Distance from bearing surface to transmission case G) Transmission case (2) Counter gear front bearing @ Counter gear TM371 "A" 4.52-4.71 (.178-.1854) 4.42-4.51 (.174-.1776). 4.32-4.41 (.171-.1736) 4.22-4.31 (.1661-.1697) 4.12-4.21 (.1622-.1657) 4.2-4.11 (.1583-.1618) 392-4.1 (.1543-.1579) Thickness of shim Not necessary Part number.1 (.4) 32218-VSOOO.2 (.8) 32218-V51.3 (.12) 32218-V52.4 (.16) 32218-V53.5 (.2) 32218-v 54.6 (.24) 32218-VSOOS MT-58 546

SERVICE DATA AND SPECIFICATIONS (SDS) I FS5R3A I Inspection and Adjustment GEAR END PLAY DISTANCE BETWEEN REAR SURFACE OF REVERSE CONE AND REVERSE BAULK Gear End play mm (in) RING 1st main gear 2nd main gear 3rd main gear OD counter gear Reverse main gear Counter gear Reverse idler gear.23-.33 (.91 -.13) ---------------------.23-.33 (.91 -.13).23-.33 (.91 -.13).23-.33 (91 -.13).33-.43 (.13-.169).1-.25 (.39-.98).3-.53 (.118-.29) CLEARANCE BETWEEN BAULK RING AND GEAR Standard 1st 1.5-1.3 (.413-.512) Main drive 1.5-1.3 {.413-.512) 1.5-1.3 (.413-.512) Unit: mm (in) Wear limit.7 (28).7 (28).7 (.28) Dimension "A" (Reemcone Reverse baulk rin Standard -.1 to.35 (-.39 to.138} AVAILABLE SNAP RING Main drive gear snap ring Unit mm (in) Wear limit.7 (.28) Allowable clearance.1 mm (O-.4 in) Thickness mm (in) Part number n t 2nd and 3rd baulk ring 1.89 (.744) 1.95 (.768) 3224-1G6 3224-1G61 Outer baulk ring 1.99 (.783) 3224-1G62 8 2.3 (.799) 3224-1 G63 121T 2.7 (.815) 3224-1 G64 2.11 (.831) 3224-1G65 2.15 (.846) 3224-1 G66 2.19 (.862) 3224-1 G67 Inner baulk ring \. Synchronizer cone Mainshafl front snap ring SMT448 Allowable clearance -.1 mm (-.4 in) Dimension Standard Unit: mm (in) ----- Wear limit Thickness mm (in) 1.89 (.744) Part number 3224-1G6 A B.6-1.1 (.24-.43).7-.9 (.28-.35).2 (.8).2 (.8) 1.95 (.768) 1.99 (.783) 2.3 (.799) 3224-1G61 3224-1G62 3224-1 G63 2.7 (.815) 3224-1 G64 2.11 (.831) 3224-1 G65 2.15 (.846) 3224-1 G66 2.19 (.862) 3224-1 G67 MT-59 547

SERVICE DATA AND SPECIFICATIONS (SDS) FS5R3A Inspection and Adjustment (Cont'd) Counter gear rear snap ring AVAILABLE SHIM AND WASHER Allowable clearance -.1 mm (-.4 in) Table for selecting proper counter gear front bearing thrust washer Thickness mm (in) Part number 1.26 (.496) 1.32 (.52) 1.38 (.543) 1.44 (.567) 1.5 (.591) 1.56 (.614) 1.62 (.638) 1.68 (.661) 1.74 (.685) 32236-1 GOB 32236-18 32236-1 G1 32236-1 G2 32236-183 32236-1 G4 32236-1 G5 32236-1 G6 32236-1 G7 Thickness of Dial indicator deflection proper washer mm (in) mm (in) Part number.93-1.2 (.366 -.42).88 (.346) 32218-1G11 1.3-1.12 (.46-.441) 96 ( 378) 32218-1G12 1.13-1.22 (.445-.48) 1.4 {.49) 32218-1G13 1.23-1.32 (.484-.52) 1.12 (.441) 32218-1G14 1.33-1.42 (.524-.559) 1.28 (.54) 32218-1G15 1.43-1.52 (.563 -.598) 1.36 (.535) 32218-1G16 1.53-1.62 (.62 -.638) 1.44 (.567) 32218-1G17 AVAILABLE C-RING Mainshaft C-ring Allowable clearance Thickness mm (in) 2.63 (.135) 2.7 (.163) 2.77 (.191) 2.84 {.1118) 2.91 (.1146) 2.98 (.1173) 3.5 (.121) 3.12 (.1228) 3.19 (.1256) 3.26 (.1283) 3.33 (.1311) 3.4 (.1339) 3.47 (.1366) 3.54 (.1394) 3.61 (.1421) 3.68 (.1449) -.1 mm (-.4 in) Part number 32348-1815 32348-1 GOO 32348-1 G1 32348-182 32348-183 32348-1 G4 32348-1 G5 32348-1 G6 32348-187 32348-188 32348-1 G9 32348-1 G 1 32348-1G11 32348-1G12 32348-1G13 32348-1G14 Reverse idler rear thrust washer Thickness mm (in) Part number 1.97 (.776) 2.7 (.815) 32284-1G1 32284-1G11 MT-6 548