mt.pdf

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MANUAL TRANSAXLE
SECTION MT
CONTENTS
RS5F30A
Cross-sectional View - RS5F70A ..............................17
Cross-sectional View - RS5F50A ..............................18
DOUBLE-CONE SYNCHRONIZER ............................19
ON-VEHICLE SERVICE ................................................20
Replacing Oil Seal .....................................................20
DIFFERENTIAL OIL SEAL ........................................20
STRIKING ROD OIL SEAL .......................................21
Position Switch Check ...............................................21
BACK-UP LAMP SWITCH ........................................21
PNP SWITCH ..........................................................22
PREPARATION ...............................................................4
Special Service Tools ..................................................4
Commercial Service Tools ...........................................6
RS5F70A
PREPARATION ...............................................................7
Special Service Tools ..................................................7
Commercial Service Tools ...........................................9
RS5F50A
RS5F30A, RS5F70A
PREPARATION .............................................................10
Special Service Tools ................................................10
Commercial Service Tools .........................................12
REMOVAL AND INSTALLATION .................................23
Removal .....................................................................23
Installation ..................................................................24
MODEL QG15DE ENGINE .......................................24
MODEL QG18DE ENGINE .......................................25
TROUBLESHOOTING ...................................................13
NVH Troubleshooting Chart .......................................13
MANUAL TRANSAXLE .............................................13
RS5F50A
REMOVAL AND INSTALLATION .................................26
Removal .....................................................................26
Installation ..................................................................28
MODEL YD ENGINE ................................................28
RS5F30A, RS5F70A
M/T OIL ..........................................................................14
Changing M/T Oil .......................................................14
Checking ....................................................................14
OIL LEAK AND OIL LEVEL .......................................14
TRANSAXLE GEAR CONTROL ...................................29
Components ...............................................................29
RS5F50A
RS5F30A
M/T OIL ..........................................................................15
Changing M/T Oil .......................................................15
Checking ....................................................................15
OIL LEAK AND OIL LEVEL .......................................15
OVERHAUL ...................................................................30
Case Components .....................................................30
Gear Components .....................................................31
Shift Control Components .........................................32
DISASSEMBLY ..............................................................33
REPAIR FOR COMPONENT PARTS ...........................36
Input Shaft and Gears ...............................................36
DISASSEMBLY ........................................................36
DESCRIPTION ...............................................................16
Cross-sectional View - RS5F30A ..............................16
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CONTENTS (Cont’d)
INSPECTION ...........................................................37
ASSEMBLY .............................................................37
Mainshaft and Gears .................................................39
DISASSEMBLY ........................................................39
INSPECTION ...........................................................41
ASSEMBLY .............................................................42
Final Drive ..................................................................44
DISASSEMBLY ........................................................44
INSPECTION ...........................................................44
ASSEMBLY .............................................................45
Shift Control Components .........................................46
INSPECTION ...........................................................46
Case Components .....................................................46
DISASSEMBLY AND ASSEMBLY . .............................46
ADJUSTMENT ...............................................................49
Differential Side Bearing Preload ..............................49
Mainshaft Bearing Preload ........................................50
ASSEMBLY . ...................................................................51
DISASSEMBLY ..............................................................95
REPAIR FOR COMPONENT PARTS ...........................98
Input Shaft and Gears ...............................................98
DISASSEMBLY ........................................................98
INSPECTION ...........................................................99
ASSEMBLY ...........................................................100
Mainshaft and Gears ...............................................103
DISASSEMBLY ......................................................103
INSPECTION .........................................................104
ASSEMBLY ...........................................................105
Final Drive ................................................................107
DISASSEMBLY ......................................................107
INSPECTION .........................................................107
ASSEMBLY ...........................................................108
Shift Control Components .......................................109
INSPECTION .........................................................109
Case Components ...................................................109
REMOVAL AND INSTALLATION .............................109
ADJUSTMENT ............................................................. 111
Bearing Preload ....................................................... 111
DIFFERENTIAL SIDE ............................................. 111
INPUT SHAFT SIDE ............................................... 112
Mainshaft Bearing Preload ...................................... 112
ASSEMBLY .................................................................. 114
RS5F70A
OVERHAUL ...................................................................54
Case Components .....................................................54
Gear Components .....................................................55
Shift Control Components .........................................56
Final Drive Components ............................................57
DISASSEMBLY . .............................................................58
Transaxle Case ..........................................................58
Clutch Housing ..........................................................60
REPAIR FOR COMPONENT PARTS ...........................64
Input Shaft and Gears ...............................................64
DISASSEMBLY ........................................................64
INSPECTION ...........................................................65
ASSEMBLY .............................................................66
Mainshaft and Gears .................................................69
DISASSEMBLY ........................................................69
INSPECTION ...........................................................70
ASSEMBLY .............................................................72
Final Drive ..................................................................77
PRE-INSPECTION ...................................................77
DISASSEMBLY ........................................................78
INSPECTION ...........................................................79
ASSEMBLY .............................................................79
Shift Control Components .........................................81
INSPECTION ...........................................................81
ASSEMBLY . ...................................................................82
Clutch Housing ..........................................................82
Transaxle Case ..........................................................86
RS5F30A
General Specifications ............................................. 118
TRANSAXLE ......................................................... 118
FINAL GEAR ......................................................... 118
Gear End Play ......................................................... 119
FITTED) ................................................................ 119
Available Check Plugs ............................................. 119
REVERSE CHECK PLUGS ..................................... 119
Available Snap Rings ..............................................120
INPUT SHAFT FRONT BEARING ...........................120
INPUT SHAFT REAR BEARING ..............................120
Available C-rings. .....................................................120
MAINSHAFT C-RING .............................................120
Available Washers ...................................................121
Bearing Preload and Adjusting Shim .......................121
TURNING TORQUE (NEW BEARING) .....................121
SHIMS ..................................................................122
RS5F50A
OVERHAUL ...................................................................92
Case Components .....................................................92
Gear Components .....................................................93
Shift Control Components .........................................94
MT-2
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CONTENTS (Cont’d)
RS5F70A
RS5F50A
General Specifications .............................................123
TRANSAXLE .........................................................123
FINAL GEAR .........................................................123
Gear End Play .........................................................124
Clearance Coupling Sleeve .....................................124
COUPLING SLEEVE ..............................................124
3RD, 4TH, 5TH, REVERSE BAULK RING ................124
1ST AND 2ND DOUBLE BAULK RING ....................124
Available Snap Rings ..............................................125
SNAP RING ...........................................................125
Available C-rings ......................................................125
4TH INPUT GEAR C-RING .....................................125
5TH INPUT GEAR REAR C-RING ...........................125
MAINSHAFT C-RING .............................................126
Available Adjusting Shims .......................................127
SHIM ....................................................................127
MAINSHAFT ADJUSTING SHIM . .............................128
Available Thrust Washer ..........................................129
MAINSHAFT THRUST WASHER .............................129
Available Washers ...................................................129
Preload and Adjusting Shim ....................................130
BEARING PRELOAD .............................................130
SHIMS ..................................................................130
General Specifications .............................................131
TRANSAXLE .........................................................131
FINAL GEAR .........................................................131
Gear End Play .........................................................132
3RD, 4TH & 5TH BAULK RING ...............................132
1ST AND 2ND DOUBLE BAULK RING ....................132
REVERSE BAULK RING ........................................132
Available Snap Rings ..............................................133
MAINSHAFT) .........................................................133
SHAFT) .................................................................133
5TH MAIN GEAR (AT MAINSHAFT) ........................133
Available Thrust Washer ..........................................133
4TH INPUT GEAR (AT INPUT SHAFT) ....................133
Available Shims .......................................................134
BEARING PRELOAD AND END PLAY ....................134
ADJUSTING SHIM(S) .............................................134
ADJUSTING SHIM(S) .............................................135
SHIM ....................................................................135
BEARING ADJUSTING SHIM(S) .............................136
MT-3
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PREPARATION
RS5F30A
Special Service Tools
Special Service Tools
NJMT0030
Tool number
Tool name
Description
KV38105900
Preload adapter
Measuring turning torque of final drive assembly
Measuring total turning torque
Measuring clearance between side gear and differ-
ential case with washer
Selecting differential side bearing adjusting shim
(Use with KV38106000.)
NT087
KV38106000
Height gauge adapter
(differential side bear-
ing)
Selecting differential side bearing adjusting shim
(Use with KV38105900.)
a: 140 mm (5.51 in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 x 1.25P
NT418
KV32101000
Pin punch
Removing and installing retaining pin
a: 4 mm (0.16 in) dia.
NT410
ST22730000
Puller
Removing mainshaft front and rear bearing inner
race
Removing 5th main gear
a: 82 mm (3.23 in) dia.
b: 30 mm (1.18 in) dia.
NT411
ST30031000
Puller
Removing differential side bearing inner race
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
NT411
ST30021000
Puller
Removing 5th synchronizer
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
NT411
MT-4
294535323.016.png
PREPARATION
RS5F30A
Special Service Tools (Cont’d)
Tool number
Tool name
Description
ST33290001
Puller
Removing differential oil seal
Removing mainshaft front bearing outer race
Removing differential side bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
NT414
ST33400001
Drift
Installing differential oil seal
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
NT086
KV38102100
Drift
Installing input shaft rear bearing
a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.
NT427
ST33200000
Drift
Installing mainshaft front bearing outer race
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
NT091
ST22350000
Drift
Installing input shaft front bearing
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
NT065
ST22452000
Drift
Installing 1st & 2nd synchronizer
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
NT065
ST37750000
Drift
Installing 5th main gear
Installing 3rd & 4th synchronizer
Installing input shaft oil seal
Installing 5th synchronizer
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
NT065
ST22360002
Drift
Installing mainshaft rear bearing inner race
a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.
NT065
MT-5
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