mt.pdf

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MANUAL TRANSMISSION
SECTION MT
CONTENTS
PREPARATION ................................................................2
Special Service Tools ..................................................2
Commercial Service Tools ...........................................4
TRANSMISSION FS5R30A .............................................5
Replacing the Rear Oil Seal ........................................5
DISASSEMBLY ..............................................................14
Case Components .....................................................14
Shift Control Components .........................................15
Gear Components .....................................................16
INSPECTION . .................................................................21
Shift Control Components .........................................21
Gear Components .....................................................21
ASSEMBLY ....................................................................23
Gear Components .....................................................23
Shift Control Components .........................................31
Case Components .....................................................32
General Specifications ...............................................34
Inspection and Adjustment ........................................35
FS5R30A
ON-VEHICLE SERVICE ..................................................6
Check of Position Switches .........................................6
REMOVAL AND INSTALLATION ....................................7
Removal .......................................................................7
Installation ....................................................................8
MAJOR OVERHAUL .....................................................10
Case Components .....................................................10
Gear Components ..................................................... 11
Shift Control Components .........................................13
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PREPARATION
Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool name
Description
ST23540000*
Pin punch
Removing and installing retaining pin
ST30031000*
Puller
Removing 1st & 2nd synchronizer assembly
Removing counter gear rear thrust bearing
Removing main drive bearing
ST33290001*
Puller
Removing rear oil seal
ST33230000*
Drift
Removing mainshaft and counter gear
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
ST22350000*
Drift
Removing counter gear front bearing
(Use with KV38100300)
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
KV38100300*
Drift
Removing counter gear front bearing
(Use with ST22350000)
Installing counter gear rear bearing
a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.
ST30720000*
Drift
Removing mainshaft front bearing
Installing mainshaft front bearing
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
MT-2
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PREPARATION
Special Service Tools (Cont’d)
*: Special tool or commercial equivalent
Tool number
Tool name
Description
ST33210000*
Drift
Installing counter gear front bearing
Installing front cover oil seal
a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.
ST33220000*
Drift
Removing and installing counter gear rear end
bearing
a: 37 mm (1.46 in) dia.
b: 22 mm (0.87 in) dia.
ST30613000*
Drift
Installing main drive gear bearing
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
ST37750000*
Drift
Removing counter gear rear bearing
Installing OD gear bushing
Installing reverse cone
Installing reverse counter gear
Installing counter gear rear end bearing
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
ST22452000*
Drift
Installing reverse hub
Installing mainshaft rear bearing
a: 40 mm (1.57 in) dia.
b: 36 mm (1.42 in) dia.
ST33400001*
Drift
Installing rear oil seal
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
ST36730000*
Drift
Installing sub-gear on reverse
idler gear
a: 50 mm (1.97 in) dia.
b: 39 mm (1.54 in) dia.
MT-3
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PREPARATION
Commercial Service Tools
Tool name
Description
Puller
Removing counter gear rear end bearing
Removing mainshaft rear bearing
Removing reverse synchronizer hub
Removing reverse counter gear
NT077
Drift
Installing sub-gear snap ring
a: 44.5 mm (1.752 in) dia.
b: 38.5 mm (1.516 in) dia.
ST22452000
Drift
Installing OD main gear
Installing reverse gear bushing
a: 44.5 mm (1.752 in) dia.
b: 40.5 mm (1.594 in) dia.
ST22452000
MT-4
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TRANSMISSION FS5R30A
Replacing the Rear Oil Seal
REMOVAL
1.
Remove transfer assembly. See Section TF.
2.
Remove rear oil seal.
SMT321B
REPLACEMENT
1.
Install rear oil seal.
Before installation, apply multi-purpose grease to oil seal lip.
2.
Install transfer assembly. See Section TF.
SMT453B
MT-5
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