MANUAL TRANSAXLE.pdf

MANUAL TRANSAXLE

SECTION MT

CONTENTS

RS5F70A

Position Switch Check ...............................................16

BACK-UP LAMP SWITCH ........................................16

PNP SWITCH ..........................................................16

BACK-UP LAMP SWITCH AND PNP SWITCH ...........17

PREPARATION ...............................................................3

Special Service Tools ..................................................3

Commercial Service Tools ...........................................5

RS5F70A

RS5F50A

REMOVAL AND INSTALLATION .................................18

Removal .....................................................................18

Installation ..................................................................19

MODEL QG18DE ENGINE .......................................19

PREPARATION ...............................................................6

Special Service Tools ..................................................6

Commercial Service Tools ...........................................8

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING .....................................................9

NVH Troubleshooting Chart .........................................9

MANUAL TRANSAXLE ...............................................9

RS5F50A

REMOVAL AND INSTALLATION .................................20

Removal .....................................................................20

Installation ..................................................................22

MODEL YD ENGINE ................................................22

RS5F70A

M/T OIL ..........................................................................10

Changing M/T Oil .......................................................10

Checking ....................................................................10

OIL LEAK AND OIL LEVEL .......................................10

TRANSAXLE GEAR CONTROL ...................................23

Components ...............................................................23

RS5F70A

RS5F50A

OVERHAUL ...................................................................24

Case Components .....................................................24

Gear Components .....................................................25

Shift Control Components .........................................26

Final Drive Components ............................................27

DISASSEMBLY ..............................................................28

Transaxle Case ..........................................................28

Clutch Housing ..........................................................30

REPAIR FOR COMPONENT PARTS ...........................34

Input Shaft and Gears ...............................................34

DISASSEMBLY ........................................................34

INSPECTION ...........................................................35

ASSEMBLY .............................................................36

Mainshaft and Gears .................................................39

DISASSEMBLY ........................................................39

INSPECTION ...........................................................40

M/T OIL .......................................................................... 11

Changing M/T Oil ....................................................... 11

Checking .................................................................... 11

OIL LEAK AND OIL LEVEL ....................................... 11

DESCRIPTION ...............................................................12

Cross-sectional View - RS5F70A ..............................12

Cross-sectional View - RS5F50A ..............................13

DOUBLE-CONE SYNCHRONIZER ............................14

ON-VEHICLE SERVICE ................................................15

Replacing Oil Seal .....................................................15

DIFFERENTIAL OIL SEAL ........................................15

STRIKING ROD OIL SEAL .......................................15

CONTENTS (Cont’d)

ASSEMBLY .............................................................42

Final Drive ..................................................................47

PRE-INSPECTION ...................................................47

DISASSEMBLY ........................................................48

INSPECTION ...........................................................49

ASSEMBLY .............................................................49

Shift Control Components .........................................51

INSPECTION ...........................................................51

ASSEMBLY . ...................................................................52

Clutch Housing ..........................................................52

Transaxle Case ..........................................................56

3RD, 4TH, 5TH, REVERSE BAULK RING ..................89

1ST AND 2ND DOUBLE BAULK RING ......................89

Available Snap Rings ................................................90

SNAP RING . ............................................................90

Available C-rings. .......................................................90

4TH INPUT GEAR C-RING .......................................90

5TH INPUT GEAR REAR C-RING .............................90

MAINSHAFT C-RING ...............................................91

Available Adjusting Shims .........................................92

INPUT SHAFT REAR BEARING ADJUSTING

SHIM ......................................................................92

MAINSHAFT ADJUSTING SHIM ................................93

MAINSHAFT REAR BEARING ADJUSTING SHIM ......93

Available Thrust Washer ............................................94

MAINSHAFT THRUST WASHER ...............................94

Available Washers .....................................................94

DIFFERENTIAL SIDE GEAR THRUST WASHER ........94

Available Shims - Differential Side Bearing

Preload and Adjusting Shim ......................................95

BEARING PRELOAD ...............................................95

DIFFERENTIAL SIDE BEARING ADJUSTING

SHIMS ....................................................................95

RS5F50A

OVERHAUL ...................................................................62

Case Components .....................................................62

Gear Components .....................................................63

Shift Control Components .........................................64

DISASSEMBLY . .............................................................65

REPAIR FOR COMPONENT PARTS ...........................68

Input Shaft and Gears ...............................................68

DISASSEMBLY ........................................................68

INSPECTION ...........................................................69

ASSEMBLY .............................................................70

Mainshaft and Gears .................................................73

DISASSEMBLY ........................................................73

INSPECTION ...........................................................74

ASSEMBLY .............................................................75

Final Drive ..................................................................77

DISASSEMBLY ........................................................77

INSPECTION ...........................................................77

ASSEMBLY .............................................................78

Shift Control Components .........................................79

INSPECTION ...........................................................79

Case Components .....................................................79

REMOVAL AND INSTALLATION ...............................79

ADJUSTMENT ...............................................................81

Input Shaft End Play and Differential Side

Bearing Preload .........................................................81

DIFFERENTIAL SIDE ...............................................81

INPUT SHAFT SIDE . ................................................82

Mainshaft Bearing Preload ........................................82

ASSEMBLY . ...................................................................84

RS5F50A

SERVICE DATA AND SPECIFICATIONS (SDS) .........96

General Specifications ...............................................96

TRANSAXLE ...........................................................96

FINAL GEAR ...........................................................96

Gear End Play ...........................................................97

Clearance Between Baulk Ring and Gear ................97

3RD, 4TH & 5TH BAULK RING .................................97

1ST AND 2ND DOUBLE BAULK RING ......................97

REVERSE BAULK RING ..........................................97

Available Snap Rings ................................................98

1ST & 2ND SYNCHRONIZER HUB (AT

MAINSHAFT) ...........................................................98

3RD & 4TH SYNCHRONIZER HUB (AT INPUT

SHAFT) ...................................................................98

5TH MAIN GEAR (AT MAINSHAFT) ..........................98

Available Thrust Washer ............................................98

4TH INPUT GEAR (AT INPUT SHAFT) ......................98

DIFFERENTIAL SIDE GEAR THRUST WASHER ........98

Available Shims .........................................................99

BEARING PRELOAD AND END PLAY ......................99

TOTAL TURNING TORQUE (NEW BEARING) ............99

MAINSHAFT BEARING ADJUSTING SHIM ................99

TABLE FOR SELECTING MAINSHAFT BEARING

ADJUSTING SHIM(S) ...............................................99

INPUT SHAFT BEARING ADJUSTING SHIM ...........100

TABLE FOR SELECTING INPUT SHAFT BEARING

ADJUSTING SHIM(S) .............................................100

DIFFERENTIAL SIDE BEARING ADJUSTING

SHIM ....................................................................100

TABLE FOR SELECTING DIFFERENTIAL SIDE

BEARING ADJUSTING SHIM(S) .............................101

RS5F70A

SERVICE DATA AND SPECIFICATIONS (SDS) .........88

General Specifications ...............................................88

TRANSAXLE ...........................................................88

FINAL GEAR ...........................................................88

Gear End Play ...........................................................89

Clearance Coupling Sleeve .......................................89

1ST, 2ND, 3RD, 4TH, 5TH & REVERSE

COUPLING SLEEVE ................................................89

Clearance Between Baulk Ring and Gear ................89

MT-2

PREPARATION

RS5F70A

Special Service Tools

NLMT0032

Tool number

Tool name

Description

KV38107700

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 bearing)

Selecting differential side bearing adjusting shim

(Use with KV38107700.)

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

Removing and installing lock pin

Removing selector shaft

Removing welch plug

a: 4 mm (0.16 in) dia.

NT410

KV31100300

Pin punch

Removing and installing retaining pin

a: 4.5 mm (0.177 in) dia.

NT410

ST30031000

Puller

Removing 3rd, 5th input gear

Removing 3rd & 4th and 5th & Rev synchronizer

hub

Removing mainshaft rear bearing

Removing 2nd gear, 5th gear bush

Removing 1st & 2nd synchronizer hub, 1st and

4th main gear

Removing and installing differential side bearing

a: 90 mm (3.54 in) dia.

b: 50 mm (1.97 in) dia.

NT411

ST30021000

Puller

Removing input shaft front and rear bearing

Installing input shaft front and rear bearing

Installing 5th input gear, 3rd main gear and 4th

main gear

Installing 1st & 2nd, 3rd & 4th and 5th & Rev syn-

chronizer hub

Installing 2nd gear bush, 5th gear bush, Rev gear

bush

Installing mainshaft rear bearing

a: 110 mm (4.33 in) dia.

b: 68 mm (2.68 in) dia.

NT411

MT-3

PREPARATION

RS5F70A

Special Service Tools (Cont’d)

Tool number

Tool name

Description

ST33290001

Puller

Removing idler gear bearing outer race

a: 250 mm (9.84 in)

b: 160 mm (6.30 in)

NT414

ST33230000

Drift

Removing differential oil seal

Installing differential side bearing

a: 51 mm (2.01 in) dia.

b: 28.5 mm (1.122 in) dia.

NT084

ST30720000

Drift

Installing differential side bearing outer race

a: 77 mm (3.03 in) dia.

b: 55.5 mm (2.185 in) dia.

NT115

ST22350000

Drift

Installing input shaft front and rear bearing

a: 34 mm (1.34 in) dia.

b: 28 mm (1.10 in) dia.

NT065

ST22452000

Drift

Installing 3rd and 4th main gear

Installing 5th gear bush

Installing 5th & Rev synchronizer hub

Installing Rev gear bush

Installing mainshaft rear bearing

a: 45 mm (1.77 in) dia.

b: 36 mm (1.42 in) dia.

NT065

ST37750000

Drift

Installing input shaft oil seal

Installing 5th synchronizer

Installing mainshaft rear bearing

Installing 5th main gear

Installing 3rd & 4th synchronizer hub

Installing striking rod oil seal

Installing clutch housing dust seal

a: 40 mm (1.57 in) dia.

b: 31 mm (1.22 in) dia.

NT065

MT-4

PREPARATION

RS5F70A

Commercial Service Tools

NLMT0033

Tool name

Description

Drift

Installing welch plug

a: 12 mm (0.47 in) dia.

b: 10 mm (0.39 in) dia.

NT065

Drift

Removing input shaft rear bearing

Removing mainshaft rear bearing

a: 22 mm (0.87 in) dia.

b: 16 mm (0.63 in) dia.

NT065

Drift

Installing differential oil seal

a: 58 mm (2.28 in) dia.

b: 50 mm (1.97 in) dia.

NT065

Drift

Installing differential oil seal

a: 54 mm (2.13 in) dia.

b: 50 mm (1.97 in) dia.

NT065

Drift

Installing 2nd gear bush

a: 38 mm (1.50 in) dia.

b: 33 mm (1.30 in) dia.

NT065

Drift

Installing 3rd & 4th and 1st & 2nd synchronizer

hub

Installing mainshaft front bearing

a: 50 mm (1.97 in) dia.

b: 41 mm (1.61 in) dia.

NT065

Drift

Installing input shaft oil seal

Installing 5th input gear

a: 39 mm (1.54 in) dia.

b: 30 mm (1.18 in) dia.

NT065

MT-5

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