MANUAL TRANSMISSION

SECTION MT
CONTENTS
PREPARATION................................................................2 DISASSEMBLY..............................................................14
Special Service Tools ..................................................2 Case Components .....................................................14
Commercial Service Tools ...........................................4 Shift Control Components .........................................15
TRANSMISSION FS5R30A .............................................5 Gear Components .....................................................16
Replacing the Rear Oil Seal........................................5 INSPECTION..................................................................21
Shift Control Components .........................................21
FS5R30A Gear Components .....................................................21
ASSEMBLY....................................................................23
ON-VEHICLE SERVICE ..................................................6 Gear Components .....................................................23
Check of Position Switches .........................................6 Shift Control Components .........................................31
REMOVAL AND INSTALLATION ....................................7 Case Components .....................................................32
Removal.......................................................................7 SERVICE DATA AND SPECIFICATIONS (SDS) ..........34
Installation....................................................................8 General Specifications...............................................34
MAJOR OVERHAUL .....................................................10 Inspection and Adjustment ........................................35
Case Components .....................................................10
Gear Components .....................................................11
Shift Control Components .........................................13
 PREPARATION

Special Service Tools

*: Special tool or commercial equivalent
Tool number
Description
Tool name
ST23540000* Removing and installing retaining pin
Pin punch

ST30031000* Removing 1st & 2nd synchronizer assembly

Puller Removing counter gear rear thrust bearing
Removing main drive bearing

ST33290001* Removing rear oil seal

Puller

ST33230000* Removing mainshaft and counter gear

Drift

a: 51 mm (2.01 in) dia.

b: 28.5 mm (1.122 in) dia.
ST22350000* Removing counter gear front bearing
Drift (Use with KV38100300)

a: 34 mm (1.34 in) dia.

b: 28 mm (1.10 in) dia.
KV38100300* Removing counter gear front bearing
Drift (Use with ST22350000)
Installing counter gear rear bearing

a: 54 mm (2.13 in) dia.

b: 32 mm (1.26 in) dia.
ST30720000* Removing mainshaft front bearing
Drift Installing mainshaft front bearing

a: 77 mm (3.03 in) dia.

b: 55.5 mm (2.185 in) dia.

MT-2
 PREPARATION
Special Service Tools (Contd)
*: Special tool or commercial equivalent
Tool number
Description
Tool name
ST33210000* Installing counter gear front bearing
Drift Installing front cover oil seal

a: 44 mm (1.73 in) dia.

b: 24.5 mm (0.965 in) dia.
ST33220000* Removing and installing counter gear rear end
Drift bearing

a: 37 mm (1.46 in) dia.

b: 22 mm (0.87 in) dia.
ST30613000* Installing main drive gear bearing
Drift

a: 72 mm (2.83 in) dia.

b: 48 mm (1.89 in) dia.
ST37750000* Removing counter gear rear bearing
Drift 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* Installing reverse hub
Drift Installing mainshaft rear bearing

a: 40 mm (1.57 in) dia.

b: 36 mm (1.42 in) dia.
ST33400001* Installing rear oil seal
Drift

a: 60 mm (2.36 in) dia.

b: 47 mm (1.85 in) dia.
ST36730000* Installing sub-gear on reverse
Drift idler gear

a: 50 mm (1.97 in) dia.

b: 39 mm (1.54 in) dia.

MT-3
 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.

ST22452000 b: 38.5 mm (1.516 in) dia.

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
 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
 ON-VEHICLE SERVICE FS5R30A

Check of Position Switches

Switch Gear position Continuity
4WD Yes
q
1 4WD* Transfer case
Except 4WD No

Transmission Reverse Yes

q
2 Back-up lamp
case Except reverse No

*: Ensure both sides of 4WD 2-pole double-throw switch is operational, refer to

Warning lamps wiring diagram in EL-Section.

YMT009

MT-6
REMOVAL AND INSTALLATION FS5R30A

Removal
Transmission has to be removed as a unit together with transfer
box.
Remove transmission assembly as follows:
I Disconnect negative battery terminal.
I Remove shift levers of transmission and transfer.
I Remove front and rear propeller shafts. Refer to PD section.
I Insert plug into rear oil seal after removing propeller shaft.
I Remove RPM-sensor from transmission upper side.

CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal,
when removing propeller shaft.
I Remove torsion bar spring. Refer to FA Section.
I Remove third crossmember (the one supporting front differen-
tial).
I Remove fifth crossmember (the one situated at the rear of
transfer).
I Support transmission and transfer with a suitable transmission
jack.

WARNING:
Support transmission and transfer with suitable jacks, while
removing them.
I Remove fourth crossmember (the one supporting transmis-
sion).
I Remove clutch operating cylinder.
I Remove starter motor.
I Remove exhaust tube bracket from transmission.
I Disconnect electrical connectors.
I Remove transmission from engine.

MT-7
REMOVAL AND INSTALLATION FS5R30A

Installation
Transmission has to be installed as a unit together with transfer
box.
Install transmission assembly as follows:
I Apply sealant as below:

NMT002

Bolt length L -
Bolt No. Tightening torque Nm (kg-m, ft-lb)
mm (in)
1 39 - 49 (4.0 - 5.0, 29 - 36) 57 (2.244)
2 18 - 22 (1.9 - 2.2, 14 - 16) 11 (0.433)
3 29 - 39 (3.0 - 4.0, 22 - 29) 100 (3.94)

NMT027

MT-8
REMOVAL AND INSTALLATION FS5R30A
Installation (Contd)
I Raise the unit with a hoist.
I Position the transmission assembly on a portable jack and
secure it with a suitable tool.
Lift the assembly until the gearbox input shaft faces its hous-
ing.
Move the assembly towards the engine. The assembly must be
rotated slightly so that the starter motor housing clears the
projection on the companion floor. Insert input shaft into its
housing (slightly raising the rear of the transfer box may facili-
tate the introduction of the shaft into its housing).
I Tighten the screws securing the gearbox to the engine.
: 39 - 49 Nm (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
I Connect the electrical wiring. Secure with the respective clips.
I Fit the RPM-sensor to the transmission upper side.
I Fit the exhaust pipe support bracket to the transfer box.
: 13 - 16 Nm (1.3 - 1.6 kg-m, 9 - 12 ft-lb)
I Fit the starter motor. Secure the earth wire to the starter motor
lower screw.
: 31 - 41 Nm (3.2 - 4.2 kg-m, 23 - 30 ft-lb)
I Fit the clutch slave cylinder.
: 30 - 40 Nm (3.1 - 4.1 kg-m, 22 - 30 ft-lb)
I Install fourth crossmember (Note the front mark).
Crossmember fixing bolts to chassis:
: 41 - 52 Nm (4.2 - 5.3 kg-m, 30 - 38 ft-lb)
Crossmember fixing bolts to transmission:
: 68 - 87 Nm (6.9 - 8.9 kg-m, 50 - 64 ft-lb)
I Take away the portable jack holding boxes assembly.
I Install fifth crossmember.
: 59 - 78 Nm (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
I Install third crossmember.
: Screws: 41 - 52 Nm (4.2 - 5.3 kg-m,
30 - 38 ft-lb)
Nuts: 68 - 87 Nm (6.9 - 8.9 kg-m,
50 - 64 ft-lb)
I Install torsion bar springs. Refer to FA section.
I Install front and rear propeller shafts. Refer to PD section.
I Install shift levers of transmission and transfer.
: 14 - 18 Nm (1.4 - 1.8 kg-m, 10 - 13 ft-lb)
Bolt head dimensions:
Bolt A: 12 mm (0.472 in)
Bolt B: 13 mm (0.512 in)
I Connect negative battery cable.

SMT446B

MT-9
MAJOR OVERHAUL FS5R30A

Case Components

NMT041

MT-10
MAJOR OVERHAUL FS5R30A

Gear Components

MT-3010

MT-11
MAJOR OVERHAUL FS5R30A
Gear Components (Contd)

NMT028

MT-12
MAJOR OVERHAUL FS5R30A

Shift Control Components

SMT437B

MT-13
 DISASSEMBLY

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.

SMT366A

2. Remove control housing, return spring and check ball.

SMT438B

3. Drive out retaining pin from striking arm.

SMT439B

4. Remove OD gear case together with striking arm by tapping

lightly.

SMT440B

SMT444B

MT-14
 DISASSEMBLY
Case Components (Contd)
5. Remove front cover and gasket.

SMT441B

6. Remove stopper ring and main drive bearing snap ring.

SMT371A

7. Remove transmission case by tapping lightly.

SMT372A

8. Remove front cover oil seal.

SMT392A

Shift Control Components

1. Mount adapter plate on vise.
2. Remove OD & reverse fork rod.

SMT373A

MT-15
 DISASSEMBLY
Shift Control Components (Contd)
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.

SMT374A

5. Drive out retaining pin from OD shift fork.

6. Pull out OD fork rod and then remove OD shift fork.

SMT375A

Gear Components
1. Before removing gears and shafts, measure each gear end
play.

Gear End play mm (in)

1st main gear 0.23 - 0.33 (0.0091 - 0.0130)
2nd main gear 0.23 - 0.33 (0.0091 - 0.0130)
3rd main gear 0.23 - 0.33 (0.0091 - 0.0130)
OD counter gear 0.23 - 0.33 (0.0091 - 0.0130)
SMT376A
Reverse main gear 0.33 - 0.43 (0.0130 - 0.0169)

I If not within specification, disassemble and check contact sur-

face of gear to hub, washer, bushing, needle bearing and shaft.

2. Remove rear side components on mainshaft and counter gear.

a. Remove reverse coupling sleeve.

SMT463A

MT-16
 DISASSEMBLY
Gear Components (Contd)
b. Remove mainshaft rear snap ring and counter gear snap ring.
c. Remove C-ring holder and mainshaft C-rings from mainshaft.
Use punch and hammer to remove C-rings.

SMT377A

d. Pull out counter gear ring and bearing.

e. Remove reverse idler gear and reverse idler thrust washers.

SMT378A

f. Pull out reverse main gear together with mainshaft spacer and
reverse synchronizer hub. Then remove reverse gear needle
bearings.

SMT380A

g. Pull out reverse counter gear.

h. Remove OD coupling sleeve together with OD baulk ring,
reverse baulk ring and spring inserts.

SMT773A

i. Pull out reverse gear bushing.

SMT770A

MT-17
 DISASSEMBLY
Gear Components (Contd)
j. Pull out OD counter gear together with reverse cone.

SMT771A

3. Press out mainshaft and counter gear alternately.

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.

SMT383A

c. Press out 2nd main gear together with 1st gear bushing and 1st
& 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.

SMT384A

MT-18
 DISASSEMBLY
Gear Components (Contd)
e. Press out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd gear needle bearing.

SMT385A

5. Remove front side components on counter gear.

a. Remove counter gear rear thrust bearing.

SMT404A

b. Remove sub-gear components.

SMT470A

6. Remove main drive gear bearing.

a. Remove main drive gear snap ring and spacer.
b. Press out main drive gear bearing.

SMT420A

MT-19
 DISASSEMBLY
Gear Components (Contd)
7. Remove bearings from case components.

SMT394A

MT-20
 INSPECTION

Shift Control Components

I Check contact surface and sliding surface for wear, scratches,
projections or other damage.

SMT398A

Gear Components
GEARS AND SHAFTS
I Check shafts for cracks, wear or bending.
I Check gears for excessive wear, chips or cracks.

SMT386A

SMT423A

SYNCHRONIZERS
I Check spline portion of coupling sleeves, hubs, and gears for
wear or cracks.
I Check baulk rings for cracks or deformation.
I Check shifting inserts for wear or deformation.
I Check insert springs for deformation.

SMT387A

Clearance between baulk ring and gear

Unit: mm (in)
Standard Wear limit
1st & 2nd 1.05 - 1.3 (0.0413 - 0.0512) 0.7 (0.028)
3rd & main drive 1.05 - 1.3 (0.0413 - 0.0512) 0.7 (0.028)
OD 1.05 - 1.3 (0.0413 - 0.0512) 0.7 (0.028)

If the clearance is smaller than the wear limit, replace baulk ring.
SMT140

MT-21
 INSPECTION
Gear Components (Contd)
I 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.
Unit: mm (in)
Standard Wear limit
0.1 to 0.35
Dimension A 0.7 (0.028)
(0.0039 to 0.0138)

c. If dimension A is larger than the wear limit, replace baulk ring.

SMT424A

BEARINGS
I Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

SMT418A

MT-22
 ASSEMBLY

Gear Components
1. Install bearings into case components.

SMT395A

2. Install main drive gear bearing.

a. Press main drive gear bearing.
b. Install main drive gear spacer.

SMT425A

c. Select proper main drive gear snap ring to minimize clearance

of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Main drive gear snap ring

Thickness mm (in) Part number

1.89 (0.0744) 32204-01G00
1.98 (0.0780) 32204-01G01
2.05 (0.0807) 32204-01G02
SMT426A
2.12 (0.0835) 32204-01G03
2.19 (0.0862) 32204-01G04

MT-23
 ASSEMBLY
Gear Components (Contd)
d. Install selected snap ring on main drive gear.

3. Install components on counter gear.

a. Install sub-gear components.
When installing sub-gear snap ring, tap sub-gear snap ring
into position on counter gear.

SMT577A

b. Install counter gear rear thrust bearing.

SMT405A

4. Install front side components on mainshaft.

a. Assemble 1st & 2nd synchronizer.

SMT421A

b. Assemble 3rd & 4th synchronizer.

SMT422A

MT-24
 ASSEMBLY
Gear Components (Contd)
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:
0 - 0.1 mm (0 - 0.004 in)
Mainshaft front snap ring

Thickness mm (in) Part number

1.89 (0.0744) 32204-01G00
1.98 (0.0780) 32204-01G01
2.05 (0.0807) 32204-01G02

SMT400A 2.12 (0.0835) 32204-01G03

2.19 (0.0862) 32204-01G04

e. Install selected snap ring on mainshaft.

f. Press on 1st & 2nd synchronizer assembly together with 2nd

main gear and 2nd gear needle bearing.

SMT401A

g. Press on 1st gear bushing using 1st gear washer.

h. Install 1st main gear and needle bearing.

SMT402A

MT-25
 ASSEMBLY
Gear Components (Contd)
i. Install steel ball and 1st gear washer.
Apply multi-purpose grease to steel ball and 1st gear washer
before installing.

SMT403A

5. Select proper counter gear front bearing shim when replacing

transmission case, counter gear, counter gear thrust bearing or
sub-gear components.
a. Install counter gear with sub-gear components, counter gear
front and rear thrust bearing on adapter plate.
b. Remove counter gear front bearing shim from transmission
case.
c. Place adapter plate and counter gear assembly in transmission
case (case inverted).

SMT427A

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 shim using table below as a guide.
Counter gear end play:
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Table for selecting proper counter gear front bearing shim

Thickness of
Dial indicator deflection
proper washer Part number
mm (in)
mm (in)
0.93 - 1.02 (0.0366 - 0.0402) 0.88 (0.0346) 32216-01G11
1.03 - 1.12 (0.0406 - 0.0441) 0.96 (0.0378) 32216-01G12
1.13 - 1.22 (0.0445 - 0.0480) 1.04 (0.0409) 32216-01G13
1.23 - 1.32 (0.0484 - 0.0520) 1.12 (0.0441) 32216-01G14
1.33 - 1.42 (0.0524 - 0.0559) 1.28 (0.0504) 32216-01G15
1.43 - 1.52 (0.0563 - 0.0598) 1.36 (0.0535) 32216-01G16
1.53 - 1.62 (0.0602 - 0.0638) 1.44 (0.0567) 32216-01G17

SMT578A

MT-26
 ASSEMBLY
Gear Components (Contd)
6. Select proper reverse idler rear trust washer when replacing
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 OD gear case.
When replacing reverse idler rear washer, install either A or B.
Reverse idler rear thrust washer.

Thickness mm (in) Part number

A 1.97 (0.0776) 32284-01G10
B 2.07 (0.0815) 32284-01G11

SMT442B

b. Place dial indicator on front end of reverse idler shaft.

c. Put straightedge on front surface of OD gear case as a stop-
per for reverse idler shaft.
d. Move reverse idler shaft up and down and measure reverse
idler gear end play.
Reverse idler gear end play:
0.30 - 0.53 mm (0.0118 - 0.0209 in)
e. If not within specification, replace reverse idler rear thrust
washer with the other (A or B) and check again.

SMT433A

MT-27
 ASSEMBLY
Gear Components (Contd)
7. Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft.
a. Mount adapter plate on vise and apply multi-purpose grease to
counter gear rear bearing.

SMT436A

b. Install mainshaft a little on mainshaft front bearing.

To allow for installation of counter gear, do not install main-
shaft completely.

SMT440A

c. Install counter gear on counter gear rear bearing and install

main drive gear, pilot bearing and spacer on mainshaft.

SMT441A

When installing counter gear into counter gear rear bearing,

push up on upper roller of counter gear rear bearing with
screwdriver.

SMT442A

d. Install mainshaft and counter gear completely by tapping rear

side of adapter plate and pulling mainshaft.

SMT443A

MT-28
 ASSEMBLY
Gear Components (Contd)
8. Install rear side components on mainshaft and counter gear.
a. Install OD gear bushing while pushing on the front of counter
gear.

SMT444A

b. Install OD 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 OD gear needle bearing and then install OD counter gear
and reverse idler shaft.

SMT580A

e. Install reverse cone.

SMT582A

f. 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.

SMT571A

SMT583A

MT-29
 ASSEMBLY
Gear Components (Contd)
g. Install reverse counter gear.
h. Install reverse gear needle bearing and then install reverse
main gear, reverse idler gear and reverse idler thrust washers.

SMT584A

i. Install reverse hub.

Pay attention to its direction.

SMT585A

j. Install counter rear gear end bearing.

k. Separate adapter plate from transmission case and mount
adapter plate on vice again.

SMT587A

l. Select proper mainshaft C-ring to minimize clearance of

groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Mainshaft C-ring

Thickness Thickness
Part number Part number
mm (in) mm (in)
2.63 (0.1035) 32348-01G15 3.19 (0.1256) 32348-01G07
2.70 (0.1063) 32348-01G00 3.26 (0.1283) 32348-01G08
SMT452A
2.77 (0.1091) 32348-01G01 3.33 (0.1311) 32348-01G09
2.84 (0.1118) 32348-01G02 3.40 (0.1339) 32348-01G10
2.91 (0.1146) 32348-01G03 3.47 (0.1366) 32348-01G11
2.98 (0.1173) 32348-01G04 3.54 (0.1394) 32348-01G12
3.05 (0.1201) 32348-01G05 3.61 (0.1421) 32348-01G13
3.12 (0.1228) 32348-01G06 3.68 (0.1449) 32348-01G14

m. Install selected C-ring, C-ring holder and mainshaft rear snap

ring.
SMT454A

MT-30
 ASSEMBLY
Gear Components (Contd)
n. Install spacer and then select proper counter gear rear snap
ring to minimize clearance of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Counter gear rear snap ring

Thickness mm (in) Part number

1.26 (0.0496) 32236-01G08
1.32 (0.0520) 32236-01G00
1.38 (0.0543) 32236-01G01
SMT453A
1.44 (0.0567) 32236-01G02
1.50 (0.0591) 32236-01G03
1.56 (0.0614) 32236-01G04
1.62 (0.0638) 32236-01G05
1.68 (0.0661) 32236-01G06
1.74 (0.0685) 32236-01G07

o. Install selected counter gear rear snap ring.

SMT455A

p. Install reverse coupling sleeve.

Pay attention to its direction.
q. Measure each gear end play as a final check. Refer to
DISASSEMBLY, MT-14.

SMT456A

Shift Control Components

1. Install OD fork rod and OD shift fork. Then install retaining pin
into OD shift fork.
2. Install 1st & 2nd, 3rd & 4th and reverse shift fork onto coupling
sleeve.

SMT457A

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.

SMT374A

MT-31
 ASSEMBLY

Case Components
1. Install front cover oil seal.
Apply multi-purpose grease to seal lip.
2. Install selected counter gear front bearing shim onto transmis-
sion 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.

SMT588A

6. Install interlock stopper assembly and then tighten check ball

plug.
Apply sealant to thread of check ball plug.

SMT460A

7. Install stopper ring and main drive bearing snap ring.

SMT371A

8. Install front cover and gasket.

Apply sealant to thread of 3 bolts shown left.
9. Apply sealant to mating surface of adapter plate.

SMT443B

MT-32
 ASSEMBLY
Case Components (Contd)
10. Install OD gear case together with striking arm.

SMT444B

11. Install retaining pin into striking arm.

SMT439B

12. Install return spring and check ball and then install control hous-
ing.
Apply sealant to mating surface of OD gear case.

SMT445B

13. Tighten control housing bolts.

Bolt head size:
A bolts 12 mm
B bolts 13 mm

SMT446B

MT-33
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
Engine TD27Ti and ZD30DDTi
Transmission model FS5R30A
No. of speeds 5
Shift pattern

Synchromesh type Warner

Gear ratio
1st 3.580
2nd 2.077
3rd 1.360
4th 1.000
OD 0.811
Reverse 3.631
No. of teeth
Mainshaft
drive
1st 32
2nd 30
3rd 29
4th 22
OD 24
Reverse 30
Countershaft
Drive
1st 13
2nd 21
3rd 31
4th 32
OD 43
Reverse 12
Reverse idler gear 22
Oil capacity  (lmp pt) 3.6 (6-3/8)

MT-34
 SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment

GEAR END PLAY
Mainshaft front snap ring
Gear End play mm (in)
1st main gear 0.23 - 0.33 (0.0091 - 0.0130) Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
2nd main gear 0.23 - 0.33 (0.0091 - 0.0130) Thickness mm (in) Part number
3rd main gear 0.23 - 0.33 (0.0091 - 0.0130) 1.89 (0.0744) 32204-01G00
OD counter gear 0.23 - 0.33 (0.0091 - 0.0130) 1.98 (0.0780) 32204-01G01
Reverse main gear 0.33 - 0.43 (0.0130 - 0.0169) 2.05 (0.0807) 32204-01G02
Counter gear 0.10 - 0.25 (0.0039 - 0.0098) 2.12 (0.0835) 32204-01G03
Reverse idler gear 0.30 - 0.53 (0.0118 - 0.0209) 2.19 (0.0862) 32204-01G04

CLEARANCE BETWEEN BAULK RING AND Counter gear rear snap ring
GEAR
Unit: mm (in) Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in) Part number
Standard Wear limit
1.26 (0.0496) 32236-01G08
1.05 - 1.3
1st & 2nd 0.7 (0.028)
(0.0413 - 0.0512) 1.32 (0.0520) 32236-01G00
3rd & main- 1.05 - 1.3 1.38 (0.0543) 32236-01G01
0.7 (0.028)
drive (0.0413 - 0.0512) 1.44 (0.0567) 32236-01G02
1.05 - 1.3 1.50 (0.0591) 32236-01G03
OD 0.7 (0.028)
(0.0413 - 0.0512)
1.56 (0.0614) 32236-01G04
1.62 (0.0638) 32236-01G05
DISTANCE BETWEEN REAR SURFACE OF
REVERSE CONE AND 1.68 (0.0661) 32236-01G06
REVERSE BAULK RING 1.74 (0.0685) 32236-01G07

AVAILABLE C-RING
Mainshaft C-ring
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)

Unit: mm (in) Thickness Thickness

Part number Part number
mm(in) mm (in)
Standard Wear limit
2.63 (0.1035) 32348-01G15 3.19 (0.1256) 32348-01G07
Dimension 0.1 to 0.36
0.7 (0.028) 2.70 (0.1063) 32348-01G00 3.26 (0.1283) 32348-01G08
A (0.0039 to 0.0142)
2.77 (0.1091) 32348-01G01 3.33 (0.1311) 32348-01G09
AVAILABLE SNAP RING 2.84 (0.1118) 32348-01G02 3.40 (0.1339) 32348-01G10

Main drive gear snap ring 2.91 (0.1146) 32348-01G03 3.47 (0.1366) 32348-01G11
2.98 (0.1173) 32348-01G04 3.54 (0.1394) 32348-01G12
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
3.05 (0.1201) 32348-01G05 3.61 (0.1421) 32348-01G13
Thickness mm (in) Part number
3.12 (0.1228) 32348-01G06 3.68 (0.1449) 32348-01G14
1.89 (0.0744) 32204-01G00
1.98 (0.0780) 32204-01G01
2.05 (0.0807) 32204-01G02
2.12 (0.0835) 32204-01G03
2.19 (0.0862) 32204-01G04

MT-35
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Contd)

AVAILABLE SHIM AND WASHER Reverse idler rear thrust washer

Table for selecting proper counter gear Thickness mm (in) Part number
front bearing shim
1.97 (0.0776) 32284-01G10
Thickness of 2.07 (0.0815) 32284-01G11
Dial indicator deflection
proper washer Part number
mm (in)
mm (in)
0.93 - 1.02 (0.0366 - 0.0402) 0.88 (0.0346) 32218-01G11
1.03 - 1.12 (0.0406 - 0.0441) 0.96 (0.0378) 32218-01G12
1.13 - 1.22 (0.0445 - 0.0480) 1.04 (0.0409) 32218-01G13
1.23 - 1.32 (0.0484 - 0.0520) 1.12 (0.0441) 32218-01G14
1.33 - 1.42 (0.0524 - 0.0559) 1.28 (0.0504) 32218-01G15
1.43 - 1.52 (0.0563 - 0.0598) 1.36 (0.0535) 32218-01G16
1.53 - 1.62 (0.0602 - 0.0638) 1.44 (0.0567) 32218-01G17

MT-36