MANUAL TRANSAXLE

SECTION MT
CONTENTS
PREPARATION 2 RS5F32A
Special
Commercial

Replacing
Position
Service

ON-VEHICLE SERVICE
Oil Seal
Switch
REMOVAL AND INSTAllATION
Tools
Service

Check
Tools
2
4
5
5
6
7
MAJOR OVERHAUl
Case Components
Gear Components
Shift Control
DiSASSEMBly " ,.,.,
Components
,
REPAIR FOR COMPONENT PARTS
,
, , ,

,
33
33
34
35
36
39
•
Removal , 7
Input Shaft and Gears 39
Installation ' 8
Mainshaft and Gears 42
TRANSAXlE GEAR CONTROL 9
Final Drive .47
Shift Control Components 49
RS5F30A & RS5F31A Case Components ' 51
MAJOR OVERHAUL 10 ADJUSTMENT , , ", 54
Case Components 10 Differential Side Bearing Preload , 54
Gear Components , 11 ASSEMBLY ', 56
Shift Control Components , 12
DiSASSEMBly , 13 '----_-JI RS5F30A & RS5F31A & RS5F32A
REPAIR FOR COMPONENT PARTS 16
SERVICE DATA AND SPECIFICATIONS (SDS) 60
Input Shaft and Gears 16
General Specifications 60
Mainshaft and Gears 19
Inspection and Adjustment - RS5F30A &
Final Drive , , 23
RS5F31 A ' 61
Shift Control Components 25
Inspection and Adjustment - RS5F32A 64
Case Components , 25
ADJUSTMENT , ,.., 28
Differential Side Bearing Preload 28
Mainshaft Bearing Preload , 29
ASSEMBly , 30
 PREPARATION

Special Service Tools

Tool number
Description
Tool name
KV38105900.For F30A & Measuring turning torque of final drive
F31A assembly
KV38107700.For F32A Measuring total turning torque
Preload adapter Measuring clearance between side gear
and differential case with washer
Selecting differential side bearing
adjusting shim (Use with KV38106000.)
NT087

KV38106000 Selecting differential side bearing

Height gauge adapter adjusting shim (Use with KV38105900 or
(differential side bearing) KV38107700.)

a: 140 mm (5.51 in)

b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
NT418 d: M8 x 1.25P
KV32101000 Removing and installing retaining pin
Pin punch

NT410 a: 4 mm (0.16 in) dia.

8T22730000 Removing mainshafl front and rear bear-
Puller ing inner race (F30A & F31A)
Removing 5th main gear

a: 82 mm (3.23 in) dia.

NT411 b: 30 mm (1.18 in) dia.
8T30031000 Removing differential side bearing
Puller inner race (F30A & F31A)
Removing 3rd and 4th synchronizer
Measuring wear of 2nd & 3rd baulk ring
(F32A)

a: 90 mm (3.54 in) dia.

NT411 b: 50 mm (1.97 in) dia.
8T30021000 Removing 5th synchronizer
Puller

a: 110 mm (4.33 in) dia.

NT411 b: 68 mm (2.68 in) dia.
ST33290001 Removing differential oil seal
Puller Removing mainshafl front bearing outer
race (F30A & F31A)
Removing differential side bearing outer
race

a: 250 mm (9.84 in)

NT414 b: 160 mm (6.30 in)

MT-2
 PREPARATION
Special Service Tools (Coni' d)
Tool number
Description
Tool name
ST33400001 Installing differential oil seal (F30A &
Drift F31A)

a: 60 mm (2.36 in) dia.

NT086 b: 47 mm (1.85 in) dia.
KV31103000 Installing differential oil seal (F32A)
Drift Right and left sides
(Use with ST35325000.)

a: 56 mm (2.20 in) dia.

NT105 b: 49 mm (1.93 in) dia.
ST35325000 Installing differential oil seal (F32A)
Drift handle a- (Use with KV31103000.)

a: 215 mm (8.46 in)

c b: 25 mm (0.98 in) dia.
c: M12 x 1.5P

•
NT417

KV38102100 Installing input shaft rear bearing

Drift

a: 44 mm (1.73 in) dia.

NT427 b: 24.5 mm (0.965 in) dia.
ST33200000 Installing mainshaft front bearing outer
Drift race (F30A & F31A)
Installing mainshaft front bearing (F32A)

a: 60 mm (2.36 in) dia.

NT091 b: 44.5 mm (1.752 in) dia.
ST22350000 Installing input shaft front bearing
Drift

a
a: 34 mm (1.34 in) dia.
NT065 b: 28 mm (1.10 in) dia.
ST22452000 Installing 1st & 2nd synchronizer
Drift Installing 3rd & 4th synchronizer (F32A)

a a: 45 mm (1.77 in) dia.

NT065 b: 36 mm (1.42 in) dia.
ST37750000 Installing 5th main gear
Drift Installing 3rd & 4th synchronizer
Installing input shaft oil seal
Installing 5th synchronizer
(F30A & F31A)
Install ing mainshaft rear bearing (F32A)
a

a: 40 mm (1.57 in) dia.

NT065 b: 31 mm (1.22 in) dia.

MT-3
 PREPARATION
Special Service Tools (Coni' d)
Tool number
Description
Tool name
ST22360002 Installing rnainshaft rear bearing inner
Drift race (F30A & F31A)

a
a: 29 mm (1.14 in) dia.
NT065 b: 23 mm (0.91 in) dia.

ST30621000 Installing differential side bearing outer

Drift race
(Use with ST30611000.)

~ a
a: 79 mm (3.11 in) dia.
NT073 b: 59 mm (2.32 in) dia.

ST30611000 Installing differential side bearing outer

Drift handle race
(Use with ST30621000.)

a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 In) dia.
NT419 d: M12 x 1.5P

Commercial Service Tools

Tool name Description

Puller Removing input shaft front bearing

m:
(F30A & F31A)
Removing mainshaft rear bearing (F32A)
o 0

NT077

Drift Installing mainshaft front bearing inner

race
a: 26 mm (1.02 in) dia.
b: 21 mm (0.83 in) dia. (F30A)
a
a: 31 mm (1.22 in) dia.
NT065 b: 26 mm (1.02 in) dia. (F31A & F32A)

Drift Installing differential side bearing inner

race

a: 56 mm (2.20 In) dia.

NT065 b: 50.5 mm (1.988 in) dia.

Drift Installing striking rod oil seal

a: 38 mm (1.50 In) dia.

NT065 b: 32 mm (1.26 in) dla.

MT-4
 ON-VEHICLE SERVICE

Replacing Oil Seal

DIFFERENTIAL OIL SEAL
1. Drain gear oil from transaxle.
2. Remove drive shafts. Refer to FA section ("Removal",
"FRONT AXLE - Drive Shaft").
3. Remove differential oil seal.

4. Install differential oil seal.

• Apply multi-purpose grease to seal lip of oil seal before
installing.
5.- Install drive shafts - Refer to FA section ("Installation",
"FRONT AXLE - Drive Shaft").

F30A F31A
- F30A & F31A- •

LH and RH sides LH and RH sides

Drift
ST33400001
SMT684C

F32A Clutch housing side -F32A -

Transmission • Install differential oil seal so that dimension "A" and"B"
case side
are within specifications.
Unit: mm (in)

A B
Oil seal
5.9 - 6.1 (0.232 - 0.240) 0.5 (0.020) or less

.P SMT7388

MT-5
 ON-VEHICLE SERVICE
Replacing Oil Seal (Cont'd)
STRIKING ROD OIL SEAL
1. Remove transaxle control rod from yoke.
2. Remove yoke retaining pin.
• Be careful not to damage boot.

3. Remove striking rod oil seal.

4. Install striking rod oil seal.

• Apply multi-purpose grease to seal lip of oil seal before
installing.

Position Switch Check

DISCONNECT
• Check continuity.
eJ
Neutral position Switch Gear position Continuity
switch harness
connector Reverse Yes
Back-up lamp switch
Except reverse No

Neutral Yes
Neutral position switch
Except neutral No
~
SMT715BB

MT-6
REMOVAL AND INSTALLATION

Removal
1. Remove battery negative terminal.
2. Remove air duct.

3. Disconnect clutch control cable. (Except for CD20 engine

models)
Remove clutch operating cylinder and clutch operating cyl-
inder bracket from transaxle. (CD20 engine models)
4. Disconnect back-up lamp switch, neutral position switch,
speedometer sensor and ground harness connectors.
5. Remove starter motor from transaxle.

6.
7.
8.
Remove shift control rod and support rod from transaxle.
Drain gear oil from transaxle.
Remove drive shafts. Refer to FA section ("Removal",
•
"FRONT AXLE - Drive Shaft").

9. Jack up transaxle together with engine slightly and insert

wooden block between center member and engine oil pan.
CAUTION:
Do not place jack under oil pan drain plug.

10. Remove rear and LH mounts supporting transaxle with jack.

11. Remove bolts securing transaxle.
12. Lower transaxle.

MT-7
 REMOVAL AND INSTAllATION

CD Installation
@ M/T to engine
Tighten bolts securing transaxle and install any part removed.
• GA engine models

Tightening torque
Bolt No. "C" mm (in)
N'm (kg-m, ft-Ib)
G) 30 - 40 (3.1 - 4.1,22 - 30) 70 (2.76)

@ 30 - 40 (3.1 - 4.1,22 - 30) 85 (3.35)

@ 30 - 40 (3.1 - 4.1, 22 - 30) 30(1.18)

@ 16 - 21 (1.6 - 2.1,12 - 15) 25 (0.98)

Front gusset to
30 - 40 (3.1 - 4.1,22 - 30) 20 (0.79)
engine
Rear gusset to
16 - 21 (1.6 - 2.1,12 - 15) 16 (0.63)
engine

@ M/T
Q9
to engine ~
Engine to M/T

~o". Q~.\
leV • SR engine models

Bolt No.
Tightening torque
N'm (kg-m, ft-Ib)
"C" mm (in)
--
G) 70 - 79 (7.1 - 8.1,51 - 59) 55 (2.17)

17
SMT747C
@
@
@
30 - 40 (3.1 - 4.1,22 - 30)

30 - 40 (3.1 - 4.1,22 - 30)

70 - 79 (7.1 - 8.1,51 - 59)

35 (1.38)

45 (1.77)

65 (2.56)

• CD20 engine models

Tightening torque
Boll No. "C" mm (in)
N'm (kg-m, ft-Ib)

G) 30 - 40 (3.1 - 4.1, 22 - 30) 120 (4.72)

CD @ 30 - 40 (3.1 - 4.1,22 - 30) 85 (3.35)

@ 44 - 54 (4.5 - 5.5, 33 - 40) 75 (2.95)

@ 16 - 21 (1.6 - 2.1,12 - 15) 30 (1.18)

@ 16 - 21 (1.6 - 2.1,12 - 15) 25 (0.98)

SMT740A
Front gusset to
30 - 40 (3.1 - 4.1, 22 - 30) 35 (1.38)
engine

Rear gusset to
30 - 40 (3.1 - 4.1, 22 - 30) 40 (1.57)
engine

MT-8
 TRANSAXlE GEAR CONTROL

SEC. 341

m
. ..--~~
. ,39.1. 52.1)
~~O
~ 4.4.5.9 (0.45 • 060
't~~~

•
3

t"J t"J 12 • 15 (jj)~~~~l '

35 • 47
(3 6
(1.2 • 1 5
. , 9 • 11) ~~
._le' - ...--~

12

/"rIiJ 10 . 13 ~ I\~~ ~ ;~; '~.5, 9 • 11)

,{y"'''
'\ iI5J _Y (1.0 • 1.3,
87 • 113)
"",/'
I t
L, t"J"@
>
22 • 29 (2.2 . 3.0. 16 • 22)
16
-~ 18. 24 (1.8 • 2.4, 13 • 17)

~ . Nom (kg-m, in-Ib)

f?:!-
:g.~
W ~ 14. 18 (1 .4. .,
18 1O. 13)
~ : Nom (kg-m, ft-Ib)

Control lever kn b Hand Iever socket @ Collar

Boot 0 Plate bolt @ Bushing
Control lever socke Transaxle
S h 0 Ie cover @) Control rod
Control lever t upport rod @ Return spring
Bearing seat s . Plate @ Return s pring
. rubb
Seat pring Hold er
Collar @ er bracket
Bushing Bushing @ Mass dam p e r (CD20 engine
only)
O-ring Support rod bracket

MT-9
 MAJOR OVERHAUL I RS5F30A & RS5F31 A I

Case Components

SEC. 320

.. -- RS5F31A---
~16 - 21
(1.6 - 2.1, 12. 15)

@ ~ Mating
surface to
transmiSSion
case ----

@ ~ 15 - 20 (1.5 - 2.0, 11 - 14)

~ Thread of bolt

@ ~20 - 29 (2.0 - 3.0, 14 - 22)-

~ Thread of bolt
Ij] : Nom (kg-m, in-I b)
tr'J : Nom (kg-m, ft-Ib)
~ : Apply recommended sealant
(Nissan genuine part: KP610-00250) or equivalent.
*: : Pay attention to its direction.
SMT755C

(1) Clutch housing @) O-ring @ Striking rod oil seal

@ Input shaft oil seal @ Case cover @J Boot
@ Oil pocket @ Back-up lamp switch @ Neutral position switch (GA
@ Bearing retainer @ Differential oil seal engine) or switch plug (CD
engine)
@ Bearing retainer @ Drain plug
@ Torx screw @l Transmission case
@ Differential oil seal

(J) Filler plug @ Oil gutter

@ O-ring

@ Air breather @ Reverse idler shaft

@ Speedometer pinion assembly

@ Welch plug @ Oil channel

MT-10
 MAJOR OVERHAUL I RS5F30A & RS5F31 A I

SEC. 322

•
45 t:r

Apply gear oil to gears, shifts. synchronizers

and bearings when assembling.
~ (iJ : Apply locking sealant
*. Select proper thickness.
11 : Pay attention to its direction.

SMT686C

G) Reverse idler gear @ Spread spring @ C-ring holder @) Differential side

@ Reverse idler @ Shifting insert @ Mainshaft rear bearing adjusting
bushing @ bearing shim
5th stopper
@ Reverse idler @ Input shaft rear @ Spacer @ Differential side
spacer bearing @ Mainshaft bearing bearing
@ Snap ring @ Mainshaft front adjusting shim @ Retaining pin
@ Spacer bearing @ 4th bushing @ Pinion mate thrust
@ Input shaft front @l Mainshaft @ 3rd & 4th synchro- washer
bearing nizer hub @ Speedometer drive
@J 1st main gear
(]) Input shaft @ 3rd main gear gear
@ 1st gear needle
@ @ Speedometer
@ Oil plug bearing 2nd main gear
stopper
@ 5th gear needle @ Steel ball @ 1st & 2nd synchro-
@ Side gear
bearing @ 2nd & 3rd bushing nizer hub
@ 5th input gear @ Reverse main gear
@ Pinion mate gear
@ 4th main gear
@ Coupling sleeve (Coupling sleeve) @ Pinion mate shaft
@ 5th main gear
@ Differential case @ Side gear thrust
@ Baulk ring @ Thrust washer
@ Final gear washer
@ 5th synchronizer @ Mainshaft C-ring
hub

MT-11
 MAJOR OVERHAUL I RS5F30A & RS5F31A I

Shift Control Components

SEC. 328

@*
[OJ 12 . 16
(1.2 • 1.6, 9 • 12)
~ Ch> Thread of plug

~ \~ 6.3 • U (0.64 • 0.6'. 55.6 • 13.61

~ : N.m (kg-m. in-Ib)

[OJ : N.m (kg-m. ft-Ib)
~ Ch> : Apply locking sealant.
* : Select proper length.

SMT750C

G) Reverse check spring @ 3rd & 4th shift fork @ Striking lever
@ Reverse check plug @ 1st & 2nd shift fork @ Check ball (Large)
@ Check ball plug @ Control bracket @J Check ball (Small)
@ Shift check ball @ Striking interlock @ Check sleeve
@ Shift check spring @ Retaining pin @ G-ring
@ Fork shaft support spring @) Retaining pin @ Select return spring
(J) Shifter cap @) Yoke @ Check plunger
@ Fork shaft @ Striking rod @ Stopper pin
@ 5th shift fork

MT-12
 DISASSEMBL V I RSSF30A & RSSF31 A I

1. Remove transmission case while slightly tilting it to prevent

5th shift fork from interfering with case.

SMT571

2. Draw out reverse idler spacer and fork shaft, then remove
5th and 3rd & 4th shift forks.
5th shift - • Be careful not to lose shifter cap.
fork

3.
•
Remove control bracket with 1st & 2nd shift fork.
Be careful not to lose shifter cap.
•
SMT082A

4. Remove gear components from clutch housing.

- RS5F30A-
a. Remove three screws and detach bearing retainer.
Suitable • One of these three screws is torx type and should be
tool removed with a suitable tool, as shown.

SMT577

b. Remove input shaft together with mainshaft by tapping

lightly.
• Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
• Do not draw out reverse idler shaft from clutch housing
because these fittings will be loose.
• When removing input shaft, be careful not to scratch oil seal
lip with shaft spline.

SMT579

MT-13
 DISASSEMBL Y I RS5F30A & RS5F31A I

c. Remove reverse idler gear and final drive assembly.

SMT580

- RS5F31A-
a. Remove mainshaft and final drive assembly.
• Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.

SMT720

SMT721

b. Remove bearing retainer securing bolts.

SMT646A

c. Remove input shaft together with bearing retainer and

Soft hammer reverse idler gear by tapping lightly.
• Do not draw out reverse idler shaft from clutch housing
because these fittings will be loose.
• Be careful not to scratch oil seal lip with shaft spline when
removing input shaft.

SMT722

MT-14
 DISASSEMBL Y RS5F30A & RS5F31 A

5. Remove oil pocket, shift check ball, shift check spring and
check ball plug.

SMT648AA

6. Drive retaining pin out of striking lever, then remove strik-

ing rod, striking lever and striking interlock.
KV32101000 • Select a position where retaining pin does not interfere with
. clutch housing when removing retaining pin .

SMT599AA

• Be careful not to damage oil seal lip, when removing

ing rod. If necessary, tape edges of striking rod.
strik- •
SMT583

7. Remove reverse check plug, then detach reverse check

/ Reverse check plug spring and check balls,
~ " Reverse check spring
S/
V Check ball (Large)
"--_Check ball (Small)

SMT584

8. Remove check sleeve assembly.

SMT585

MT-15
 REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31 A I

Input Shaft and Gears

DISASSEMBLY
1. Before disassembly, check 5th input gear end play.
Gear end play:
Refer to SOS, MT -61.
EndPlaY • If not within specification, disassemble and check contact
Gear
surface of gear, shaft and hub. Then check clearance of
snap ring groove. Refer to "ASSEMBLY", MT-17.
~ Needle bearing
SMT734A

2. Remove snap ring and 5th stopper.

3. Remove 5th synchronizer, 5th input gear and 5th gear nee-
dle bearing.

5th synchronizer hub

5th input gear

Set Tool below

5th input gear.

SMT750BA

4. Remove snap ring of input shaft front bearing and input gear
spacer.

5. Pull out input shaft front bearing.

6. Remove bearing retainer.

SMT601A

MT-16
 REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31A I
Input Shaft and Gears (Cont'd)
INSPECTION
Gear and shaft
• Check shaft for cracks, wear or bending.
• Check gears for excessive wear, chips or cracks.

SMT602A

Synchronizer
Shifting insert
• Check spline portion of coupling sleeves, hubs and gears
for wear or cracks.
• Check baulk rings for cracks or deformation.
• Check shifting inserts for wear or deformation.

t
Baulk ring to
gear clearance
SMT387A

• Measure clearance between baulk ring and gear.

Clearance between baulk ring and gear:
Standard
•
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)

SMT140

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

SMT148A

ASSEMBLY
1. Assemble 5th synchronizer.

MT-17
 REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31A I
Input Shaft and Gears (Cont'd)
• Be careful not to hook front and rear ends of spread spring
to the same insert.

SMT7618

2. Install bearing retainer.

3. Press on input shaft front bearing.
4. Install spacer.

~" O~0 Bearing retainer

~~ SMT731-A

5. Select and install snap ring that gives the proper clearance
of input shaft groove.
Allowable clearance of groove:
o- 0.1 mm (0 - 0.004 in)
Snap ring of input shaft front bearing:
Refer to SOS, MT -61.

6. Install 5th gear needle bearing, 5th input gear, 5th synchro-
nizer and 5th stopper.
7. Measure gear end playas the final check. Refer to
"DISASSEMBLY", MT-16.

5T37750000
5th synchronizer hub

SMT779AA

8. Select and install snap ring that gives the proper clearance
of input shaft groove.
Allowable clearance of groove:
0-0.1 mm (0 - 0.004 in)
Snap ring of 5th synchronizer:
Refer to SOS, MT -61.

SMT591

MT-18
 REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31 A I

Mainshaft and Gears

DISASSEMBL Y
1. Before disassembly, check 1st, 2nd, 3rd and 4th main gear
end plays.
Gear end play:
Refer to 50S, MT -61.
• If not within specification, disassemble and check contact
surface of gear, shaft and hub. Then check clearance of
C-ring groove. Refer to "ASSEMBLY", MT-21.

2. Press out mainshaft front bearing.

ST22730000

SMT641-A

3. Press out mainshaft rear bearing. •

SMT638-A

4. Remove C-ring holder, mainshaft C-rings and thrust

~ C-ring holder
washer.
~~ Mainshaft C-ring

8--- Thrust washer

SMT592-A

5. Press out 5th main gear.

5T,22730, OOO~~""~/ i~;~<~:(

-',
'.
"~"
-----~""""."•.~,
-'::-.

>~\. J.
,---

'.~
'/ Hook tool under

flange as indicated
by arrows.
"-~, ",' .' //
" /!~'(';Y
I -\ --...

Y:<"~_. ~~w" -, ~
--...' ....~"'I "

SMT593-A

MT-19
 REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31A I
Mainshaft and Gears (Conl'd)
6. Remove 4th main gear, 4th bushing and steel ball.
• Be careful not to lose steel ball.

Steel ball

SMT687C

7. Remove 3rd & 4th synchronizer, 3rd main gear, 2nd & 3rd
bushing, steel ball and 2nd main gear.
• Be careful not to lose steel ball.

3rd & 4th

synchronizer hub r ST30031 000

SMT780AA

8. Remove 1st & 2nd synchronizer and 1st main gear, then
remove 1st gear needle bearing.

1st & 2nd

, synchronizer
/ / 1st main
.~/\ gear

t-r=-~~'c
SMT594

INSPECTION
Gear and shaft
• Check shaft for cracks, wear or bending.
• Check gears for excessive wear, chips or cracks.

MT-20
 REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31A I
Mainshaft and Gears (Cont'd)
Synchronizer
Shifting insert
• Check spline portion of coupling sleeves, hubs and gears
for wear or cracks.
• Check baulk rings for cracks or deformation.
• Check shifting inserts for wear or deformation.

t
Baulk ring to
• Measure clearance between baulk ring and gear.
gear clearance Clearance between baulk rings and 1st-4th main gears:
Standard
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)

SMT140

Bearing
• Make sure bearings roll freely and are free from noise,
cracks, pitting or wear.
•
• When replacing tapered roller bearing, replace outer and
inner race as a set.

ASSEMBLY
1. Assemble 1st & 2nd and 3rd & 4th synchronizers.

• Be careful not to hook front and rear ends of spread spring

to the same insert.

SMT761B

MT-21
 REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31A I
Mainshaft and Gears (Cont'd)
2. Install 1st gear needle bearing and 1st main gear.
3. Press on 1st & 2nd synchronizer.
ST22452000

SMT605AA

4. Install steel ball, 2nd main gear, 2nd & 3rd bushing, 3rd
main gear and 3rd & 4th synchronizer.
• Apply multi-purpose grease to steel ball before installing it.
• 2nd & 3rd bushing has a groove in which steel ball fits.
ST37750000 -
3rd & 4th
synchronizer hub

SMT085CA

5. Install steel ball, 4th bushing and 4th main gear.

• Apply multi-purpose grease to steel ball before installing it.
• 4th bushing has a groove in which steel ball fits.

Steel ball

SMT687C

6. Press on 5th main gear.

/ 5th main gear

SMT606AA

7. Install thrust washer.

~ C-ring holder
8. Select and install mainshaft C-ring that gives proper clear-
~~ Mainshaft C-ring ance of groove in mainshaft.
Allowable clearance of groove:
@---Thrust washer 0-0.1 mm (O . 0.004 in)
Mainshaft C-ring:
Refer to 50S, MT -61.
9. Install C-ring holder.

SMT592-A

MT-22
 REPAIR FOR COMPONENT PARTS I RSSF30A & RSSF31A I
Mainshaft and Gears (Cont'd)
10. Press on mainshaft rear bearing.

ST22360002

SMT607AA

11. Press on mainshaft front bearing.

12. Measure gear end playas the final check - Refer to
"DISASSEM BL y", MT -19.

SMT639

Final Drive
DISASSEMBL Y
•
1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
• Be careful not to mix up the right and left bearings.

[ .

SMT647-A

4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.

Retaining
pin

SMT147AA

INSPECTION
Gear, washer, shaft and case
• Check mating surfaces of differential case, side gears and
pinion mate gears.
• Check washers for wear.

SMT083A

MT-23
 REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31A I
Final Drive (Conl'd)
Bearing
• Make sure bearings roll freely and are free from noise,
cracks, pitting or wear.
• When replacing tapered roller bearing, replace outer and
inner race as a set.

SPD715

ASSEMBLY
1. Attach side gear thrust washers to side gears and install in
differential case.
2. Install pinion mate thrust washers and pinion mate gears.

SMT839

3. Insert pinion mate shaft.

• When inserting, be careful not to damage pinion mate thrust
washers.

SMT087A

4. Measure clearance between side gear and differential case

with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
KV381 05900

SMT610AB

b. Move side gear up and down to measure dial indicator

deflection. Always measure indicator deflection on both
side gears.
Clearance between side gear and differential case with
washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
c. If not within specification, adjust clearance by changing
thickness of side gear thrust washers.
Side gear thrust washer:
Refer to 50S, MT -62.
SMT611A

MT-24
 REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31A I
Final Drive (Cont'd)
5. Install retaining pin.
• Make sure that retaining pin is flush with case.

Retaining
pin

SMT147AA

6. Install final gear.

• Apply locking sealant to final gear fixing bolts before install-
ing them.
7-. Install speedometer drive gear and stopper .

1/
SMT609A

8. Press on differential side bearings. •

;? Control b~'Ck:t ,
Shift Control Components
INSPECTION
.. ~-t' • Check contact surface and sliding surface for wear,
If 0
scratches, projections or other damage.
Shift fork and shifter cap ",0

~
SMT086C

Case Components
Input shaft oil seal
1. Drive out input shaft oil seal.

MT-25
 REPAIR FOR COMPONENT PARTS I RSSF30A & RSSF31A I
Case Components (Cont'd)
2. Install input shaft oil seal.
• Apply multi-purpose grease to seal lip of oil seal before
installing.

SMT751BA

Input shaft rear bearing

1. Remove welch plug from transmission case.

SMT688C

2. Remove input shaft rear bearing by tapping it from welch

plug hole.
r Welch plug hole

SMT633

3. Install welch plug.

• Apply recommended sealant to mating surface of transmis-
sion case.

4. Install input shaft rear bearing.

MT-26
 REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31A I
Case Components (Cont'd)
Mainshaft front bearing outer race and oil channel
1. Remove mainshaft front bearing outer race.
2. Remove oil channel.

SMT636-A

3. Install oil channel.

Toward
• Ensure the oil groove faces the oil pocket.
oil pocket

SMT595

4. Install mainshaft front bearing outer race. •

Mainshaft rear bearing outer race
• Refer to "Differential Side Bearing Preload", MT -29.
Differential side bearing outer race
• Refer to "Mainshaft Bearing Preload", MT -28.

MT-27
 ADJUSTMENT I RS5F30A & RS5F31 A I

Differential Side Bearing Preload

If any of the following parts are replaced, adjust differential side
bearing preload.
• Differential case
• Differential side bearing
• Clutch housing
• Transmission case

1. Remove differential side bearing outer race (transmission

case side) and shim(s).

2. Reinstall differential side bearing outer race without

shim(s).
3. Install final drive assembly on clutch housing.
4. Install transmission case on clutch housing.
• Tighten transmission case fixing bolts to the specified
torque. Refer to MT-10.

SMT646-A

5. Set dial indicator on front end of differential case.

6. Insert Tool all the way into differential side gear.
KV38106000
I"
7. Move Tool up and down and measure dial indicator deflec-
tion.
8. Select shim considering bearing preload.
Suitable shim thickness =
Dial indicat~r deflection
+ specified bearing preload
Differential side bearing preload and adjusting shims:
Refer to 50S, MT -62, 63.
9. Install selected shim(s) and differential side bearing outer
race.

10. Check differential side bearing turning torque.

a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.
• Tighten transmission case fixing bolts to the specified
torque. Refer to MT-10.

SMT454-A

MT-28
 ADJUSTMENT I RS5F30A & RS5F31A I
Differential Side Bearing Preload (Cont'd)
c. Measure turning torque of final drive assembly.
Turning torque of final drive assembly
(New bearing):
Refer to SOS, MT -62.
• When old bearing is used again, turning torque will be
slightly less than the above.
• Make sure torque is close to the specified range.
• Changes in turning torque of final drive assembly per rev-
olution should be within 1.0 N'm (10 kg-em, 8.7 in-Ib) with-
out binding.

Mainshaft Bearing Preload

If any of the following parts are replaced, adjust mainshaft bear-
il}g preload.
• Mainshaft
• Mainshaft bearings
• Clutch housing
• Transmission case

~casecover
"U--0-ring
~spacer
1. Remove case cover, O-ring, spacer, mainshaft bearing
adjusting shim and mainshaft rear bearing outer race from
transmission case.
•
2. Install mainshaft assembly on clutch housing.
Mainshaft rear bearing ~ Mainshaft 3. Install transmission case on clutch housing.
outer race ~ bearing
0
• Tighten transmission case fixing bolts to the specified
- \ adjusting torque. Refer to MT-10.
shim

I ~--

SMT613AA

4. Install mainshaft rear bearing outer race on inner race.

5. Measure distance from transmission case to bearing outer

race.
• Make sure that bearing is properly seated.
6. Select shim. Refer to SDS, MT-62.
7. Check total turning torque after assembling. Refer to
"ASSEMBLY", MT-30.

SMT599

MT-29
 ASSEMBLY I RS5F30A & RS5F31 A I

1. Install striking rod, lever and interlock.

• Tape edges of striking rod to avoid damaging oil seal lip
during installation.
• When taped edges of striking rod are past the oil seal,
remove tape.

2. Install reverse check sleeve assembly.

3. Install check balls, reverse check spring and check plug.

4. Check reverse check turning torque (At striking rod).

Reverse check turning torque (At striking rod):
Refer to SOS, MT -61.
• If not within specification, select another check plug having
a different length and reinstall it.
Reverse check plug:
Refer to SOS, MT -61.
5. Install selected reverse check plug.
• Apply locking sealant to thread of plug before installing it.

6. Install check ball plug, shift check ball and shift check
spring.
7. Install oil pocket.

SMT648AA

8. Install gear components onto clutch housing.

- RS5F30A-
a. Install final drive assembly and reverse idler gear.

SMT580

MT-30
 ASSEMBLY I RS5F30A & RS5F31 A I

b. Install mainshaft and input gear as a set.

• Take care not to damage oil seal lip with splines of input
shaft while shaft is being inserted into clutch housing.
• Take care not to damage oil channel when inserting main-
shaft into clutch housing.

SMT737A

c. Install bearing retainer.

• One of these three screws is torx type and should be
installed with suitable tool, as shown.
Suitable
tool

d. After installing torx screw, stake it at two points. •

SMT664

- RS5F31A-
a. Install input shaft assembly and reverse idler gear.
~ "-- Soft hammer • Be careful not to damage oil seal lip with splines of input
shaft.

SMT614A

Final drive assembly b. Install final drive assembly.

/{(/

SMT721

MT-31
 ASSEMBLY I RSSF30A & RSSF31 A I

c. Install mainshaft assembly.

• Take care not to damage oil channel when inserting main-
shaft into clutch housing.

SMT720

9. Apply grease to shifter caps, then install it to control

bracket. Install control bracket with 1st & 2nd shift fork.
10. Install 3rd & 4th and 5th shift forks.

11. Insert fork shaft.

• Apply multi-purpose grease to support spring before install-
ing.
12. Install reverse idler spacer.

13. Apply recommended sealant to mating surface of clutch

housing.
14. Install transmission case on clutch housing.

15. Measure total turning torque.

Total (Final drive + Mainshaft) turning torque (New
bearing):
Refer to SOS, MT -62.
• When old bearing is used again, turning torque will be
slightly less than the above.
• Make sure torque is close to the specified range.

MT-32
 MAJOR OVERHAUL I RS5F32A I

Case Components
SEC.320 ~ 3.7 • 5.0 (0.38 • 0.51, 33.0 - 44.3)

CD ~

;1 Mating surface to
transmission case

1J2»~
I
~

o//~ ~3J

d~~~
CID.:. m
. ~)
Seal lip

~
(]? i~=1D.
//\
\
\
!-~~

1~
•
~'

@~ 10.20 (1.0 - 2.0, 87 - 174)

W~ Mating surface to ~ Thread of bolt

"""mi"ioo '"" \1:.01 ~ /', J

(15,'

. WO ,,~., .,.~

~~~> '\
\

@~ Mating surface to
\L~ 6.3 . 8.3
(0.64 - 0.85, 55.6 - 73.8)

t,,~~~~
I:::t:\ ~___--
o __ ~j)\~
~.L'

*
@~Mating

~i)~/(ro\~\~)
. ------ ~~,/ ~Q~ I f""\
~~~ ..~ Q{

t~A
!13i
26 - 30 (2.7 - 3.1, 20 - 22)

~ 25 _ 34 ~ N.m (kg-m, In-Ib\

(2.5 - 3.5, 18 - 25) A N.m (kg-m, ft-Ib)

~ Thread of bolt ~ . Apply recommended sealant
(fl) to.J 20 - 29 \ (Nissan genuine part: KP610-00250) or equivalent
- (2.0 - 3.0, 14 - 22) 12)~. m Seal lip ~ ,.1..', Apply locking sealant
~ Thread of bolt * : Select proper thickness.
-tI . Pay attention to its direction,
SMT751C

G) Clutch housing (9) O-ring @ Bearing retainer

@ Reverse idler shaft @ Case cover @l Striking rod oil seal
@ Input shaft oil seal CfD Back-up lamp switch QID Boot
@ Oil pocket @ Differential oil seal @ Neutral position switch
@ Bearing retainer @ Drain plug @ Differential oil seal
@ Filler plug @ Transmission case @ O-ring
(J) Air breather @ Oil gutter @ Speedometer pinion assembly
@ Welch plug @ Oil channel

MT-33
 MAJOR OVERHAUL I RS5F32A I

Gear Components
SEC. 322

u : Pay attention to its direction.

* : Select proper thickness.
~ ~) : Apply locking sealant.
• : Apply gear oil. SMT593CB

CD Reverse idler gear @ 1st main gear @ 5th main gear

@ Reverse idler bushing @ Baulk ring I[~ Spacer
@ Reverse idler spacer @ 1st gear needle bearing ~~ Mainshaft rear bearing
@ Snap ring @ Reverse main gear ~ID Mainshaft C-ring
@ Spacer (Coupling sleeve) @ C-ring holder
@ Input shaft front bearing @ Insert spring @ Snap ring
(j) Input shaft @ 1st & 2nd synchronizer hub @ Snap ring
@ 5th gear needle bearing @ 2nd outer baulk ring @ Differential side bearing
@ 5th input gear @ 2nd synchronizer cone @ Speedometer stopper
@) Baulk ring @ 2nd inner baulk ring @ Speedometer drive gear
@ Coupling sleeve @ 2nd main gear @ Differential case
@ Spread spring @ 2nd & 3rd bushing {4) Final gear
@ Shifting insert @ 3rd main gear @ Differential side bearing
@ 5th gear synchronizer hub @ 3rd inner baulk ring @ Differential side bearing
@ Spread spring @ 3rd synchronizer cone adjusting shim
@l 5th stopper @ID 3rd outer baulk ring @ Retaining pin
@ Snap ring @ Coupling sleeve @ Pinion mate thrust washer
@ Input shaft bearing @ 3rd & 4th synchronizer hub @ Pinion mate gear
@l Mainshaft front bearing @ Insert spring ~O) Thrust washer
@) Steel ball @ Baulk ring @ Side gear
@ Mainshaft @".!J 4th main gear @ Pinion mate shaft
@ 4th bushing

MT-34
 MAJOR OVERHAUL I RSSF32A I

Shift Control Components

SEC. 328

~~
CV-~
~
CID~ 6~~
~~
~ ~lil6.3-8.3
(0.64 • 0.85,
~ 55.6 • 73.8)
~ 5 *~-
...12 - 16
(1.2 - 1.6, 9 - 12)
~ Cbl Plug thread

•
/

r /~

I
<Si~~
J
"@lEa!
lil: N.m (kg-m, in-Ib)
~ : N.m (kg-m, ft-Ib)
~ Cbl : Apply locking sealant.
* : Select proper length.
~ : Select proper part. Adjustment is required.

SMT695CB

CD Check plunger @ Fork shaft @ Retaining pin

@ Select return spring @ Fork shaft support spring @ Yoke
@ Stopper pin @ 5th shift fork @ Reverse check plug
@ Striking lever @ Shifter cap @ Check ball (Large)
@ Striking interlock @ 3rd & 4th shift fork @ Check ball (Small)
@ E-ring @ Shifter cap @ Check sleeve
(J) Reverse brake cam @ 1st & 2nd shift fork @ O-ring
@ Check ball plug @ Control bracket @ Reverse check spring
@ Shift check ball @J Interlock pin
@) Shift check spring @ Retaining pin
@ Reverse brake cam spring @ Striking rod

MT-35
 DISASSEMBL Y I RS5F32A I
1. Remove case cover.

SMT6648

2. Remove mainshaft bearing snap ring.

3. Remove transmission case while slightly tilting it to prevent

5th shift fork from interfering with case.

SMT6668

4. Draw out reverse idler spacer and fork shaft.

SMT6678

5. Remove 5th and 3rd & 4th shift forks.

• Be careful not to lose shifter cap.
5th shift
fork

MT-36
 DISASSEMBl Y I RS5F32A I

6. Remove control bracket with 1st & 2nd shift fork.

7. Remove gear components from clutch housing.

a. Remove input shaft front bearing retainer securing bolts .

b.

•
Remove input shaft with bearing retainer, mainshaft assem-
bly and reverse idler gear.
Always withdraw mainshaft straight out. Failure to do so
•
can damage resin oil channel on clutch housing side.
• Do not draw out reverse idler shaft from clutch housing
because these fittings will be loose.
When removing input shaft, be careful not to scratch oil seal
lip with shaft spline.

SMT6708

c. Remove final drive assembly.

SMT6718

8. Remove oil pocket, shift check ball, shift check spring and
check ball plug.

SMT64BAA

MT-37
 DISASSEMBL V I RS5F32A I

9. Drive retaining pin out of striking lever, then remove strik-

ing rod, striking lever and striking interlock.
• Select a position where retaining pin does not interfere with
clutch housing when removing retaining pin.

SMT599AA

• Be careful not to damage oil seal lip, when removing strik-

ing rod. If necessary, tape edges of striking rod.

SMT583

10. Remove reverse check plug, then detach reverse check

spring and check balls.
• If the smaller ball does not come out, remove it together
with check sleeve assembly.

11. Remove check sleeve assembly.

Check sleeve
assembly
SMT585

MT-38
 REPAIR FOR COMPONENT PARTS I RS5F32A I

Input Shaft and Gears

DISASSEMBL Y
1. Before disassembly, check 5th input gear end play.
Gear end play:
Refer to 50S, MT -64.
• If not within specification, disassemble and check contact
surface of gear, shaft and hub. Check clearance of snap ring
groove. Refer to "ASSEMBLY", MT-40.

2. Remove snap ring and 5th stopper.

~
5th input gear

Set Tool below

5th input gear.
3. Remove 5th synchronizer,
dle bearing.
5th input gear and 5th gear nee- •
- r 5th synchronizer hub

/ ST30021 000

SMT417CA

4. Remove snap ring of input shaft front bearing and input gear
spacer.

Spacer
Input shaft
front bearing

SMT674B

5. Remove input shaft front bearing.

6. Remove bearing retainer.

MT-39
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Input Shaft and Gears (Cont'd)
INSPECTION
Gear and shaft
• Check shaft for cracks, wear or bending.
• Check gears for excessive wear, chips or cracks.

SMT602A

5th synchronizer
Shifting insert
• Check spline portion of coupling sleeves, hubs and gears
for wear or cracks.
• Check baulk rings for cracks or deformation.
• Check insert springs for wear or deformation.

SMT387A

Baulk ring to
• Measure clearance between baulk ring and gear.
gear clearance Clearance between baulk ring and gear:
Standard
0.90 - 1.50 mm (0.0354 - 0.0591 in)
Wear limit
0.7 mm (0.028 in)

SMT140

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

ASSEMBLY
1. Assemble 5th synchronizer.

MT-40
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Input Shaft and Gears (Cont'd)
• Be careful not to hook front and rear ends of spread spring
to the same insert.

SMT761B

2. Install bearing retainer.

3. Press on input shaft front bearing.
4. Install input gear spacer.

~= Bearing retainer

SMT731-A

Snap ring
5. Select and install snap ring that gives proper clearance
input shaft groove.
Allowable clearance of groove:
of •
o- 0.1 mOl (0 - 0.004 in)
Snap rings of input shaft front bearing:
Refer to SOS, MT -65.

SMT708B

• Be sure to replace 5th gear synchronizer hub with new one

when it is removed.
6. Install 5th gear needle bearing, 5th input gear, 5th synchro-
nizer and 5th stopper.
• Input shaft must be vertical to press on synchronizer hub.
ST37750000 ~ 7. Measure gear end playas a final check. Refer to
5th synchronizer hub "DISASSEMBLY", MT-39.

SMT779AA

8. Select and install snap ring that gives proper clearance of

input shaft groove.
Allowable clearance of groove:
o - 0.1 mm (0 - 0.004 in)
Snap ring of 5th synchronizer:
Refer to SOS, MT-65.

SMT591

MT-41
 REPAIR FOR COMPONENT PARTS I RS5F32A I

Mainshaft and Gears

End play
DISASSEMBL Y
1. Before disassembly, measure gear end play.
Gear end play:
Refer to 50S, MT -64.
• If end play is not within the specified limit, disassemble and
check the parts.

2. Remove mainshaft rear bearing snap ring, Coring holder

and mainshaft C-rings.

Snap ring

C-ring holder

SMT709B

~Snapring

@--- C-ring holder

~~ Malnshaft C-r1ng

- Mainshaft rear
bearing

SMT676BB

3. Remove mainshaft rear bearing and spacer.

Puller-

./- Suitable
drift
Mainshaft rear
bearing

SMT677BA

4. Remove 5th main gear.

SMT593-A

MT-42
 REPAIR FOR COMPONENT PARTS I RSSF32A I
Mainshaft and Gears (Cont'd)
5. Remove 4th main gear, bushing and steel ball.
• Take care not to lose steel ball.

SMT418C

6. Remove 3rd & 4th synchronizer and 3rd main gear .

2nd & 3rd~

bushing
2nd gear
-'-~)
~
SMT766BA

7.
•
Remove 2nd & 3rd bushing and 2nd main gear.
Take care not to lose the steel ball.
•
AMT053

8. Remove 1st & 2nd synchronizer hub and 1st main gear.

1st main gear

AMT056

INSPECTION
Gear and shaft
• Check shaft for cracks, wear or bending.
• Check gears for excessive wear, chips or cracks.

SMT604A

MT-43
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Mainshaft and Gears (Cont'd)
Synchronizer
• Check spline portion of coupling sleeves, hubs and gears
for wear or cracks.
• Check baulk rings for cracks or deformation.
• Check insert springs for deformation.

t
SMT7198

Baulk ring to • Measure clearance between baulk ring and gear.

gear clearance Clearance between baulk rings and gears,
for 1st and 4th gear only:
Standard
1st 0.95. 1.45 mm (0.0374 • 0.0571 in)
4th 0.90. 1.45 mm (0.0354 • 0.0571 in)
Wear limit
0.7 mm (0.028 in)
• 2nd and 3rd gears have inner and outer baulk rings and so
have different measurements.
SMT140

Outer baulk ring --\

Synchronizer

ST30031000
,fli 10M'
~
baolk 'fOM FA
B

SMT714CA

• Measure wear of 2nd and 3rd baulk rings.

a. Place inner baulk ring in position on synchronizer cone.
b. Hold baulk ring evenly against synchronizer cone and mea-
sure distance "A".
c. Place outer baul.k ring in position on synchronizer cone.
d. Hold baulk ring evenly against synchronizer cone and mea-
sure distance "B".
Standard:
Inner-A 0.7 - 0.9 mm (0.028 - 0.035 in)
Outer-B 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit:
0.2 mm (0.008 in)
e. If distance "A" or "B" is smaller than the wear limit, replace
baulk ring.

MT-44
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Mainshaft and Gears (Cont'd)
Bearing
• Make sure bearings roll freely and are free from noise,
cracks, pitting or wear.
• The mainshaft front bearing cannot be re-used. It must be
replaced once removed.

SPD715

ASSEMBLY
1. Install 1st gear needle bearing, 1st main gear and baulk
ring.
2. Press on 1st & 2nd synchronizer hub.

SMT089CA

• Ensure correct fitting of 1st & 2nd synchronizer hub . •

1stmain. 2nd main
gear • gear

SMT7018

3. Install 2nd synchronizer cone, outer & inner baulk ring and
reverse main gear (coupling sleeve).

SMT6838

4. Install steel ball, 2nd main gear, 2nd & 3rd bushing.
• Apply gear oil to 2nd & 3rd bushing before installing it.
• Apply multi-purpose grease to steel ball before installing it.

.....
ST23860000 • 2nd & 3rd bushing has a groove in which steel ball fits.

Front

rr=DJ
KV31100401 -
SMT412CA

MT-45
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Mainshaft and Gears (Cont'd)
5. Install 3rd main gear, synchronizer cone, outer & inner
baulk ring.
6. Press on 3rd & 4th synchronizer hub.

SMT090CA

• Ensure correct fitting of 3rd & 4th synchronizer hub.

7. Install 3rd & 4th coupling sleeve and 4th baulk ring.

4th main ..... ..... 3rd main

gear ...... .".. gear

SMT7028

8. Install steel ball, 4th bushing and 4th main gear.

~ 4th m.lo g.. ' • Apply multi-purpose grease to steel ball before installing it.
• 4th bushing has a groove in which steel ball fits.

~-
~ 4th bushing

mAr-51""'"
l(~J SMT422C

9. Press on 5th main gear.

ST3n50000

SMT091CA

10. Select proper mainshaft bearing spacer to give correct

Mainshaft rear bearing
bearing distance.
Mainshaft adjusting
spacer
Bearing distance "e":
230.15 - 230.25 mm (9.0610 - 9.0649 in)
Spacers available:
Refer to SOS, MT -65.

SMT6938

MT-46
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Mainshaft and Gears (Cont'd)
11. Press on mainshaft rear bearing.

ST37750000

SMT092CA

12. Select and install mainshaft C-ring that gives proper clear-
@-Snapring
ance of groove in mainshaft.
e--- C-ring holder Allowable clearance of groove:
~~ Mainshaft C-ring
o - 0.1 mm (0 - 0.004 in)
Mainshaft C-rings:
Refer to 50S, MT -65.
Mainshaft rear
13. Install C-ring holder and snap ring.
bearing
14. Measure gear end playas the final check. Refer to

•
"DISASSEMBLY", MT-42.

SMT676BB

C-ring

SMT712B

Final Drive
DISASSEMBL Y
1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
• Be careful not to mix up the right and left bearings.

SMT647-A

4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.

MT-47
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Final Drive (Cont'd)
INSPECTION
Gear, washer, shaft and case
• Check mating surfaces of differential case, side gears and
pinion mate gears.
• Check washers for wear.

SMT083A

Bearing
• Make sure bearings roll freely and are free from noise,
cracks, pitting or wear.
• When replacing tapered roller bearing, replace outer and
inner race as a set.

SPD715

ASSEMBLY
1. Attach side gear thrust washers to side gears, then install
pinion mate washers and pinion mate gears in place.

SMT839

2. Insert pinion mate shaft.

• When inserting, be careful not to damage pinion mate thrust
washers.

3. Measure clearance between side gear and differential case

with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
KV381 05900

SMT610AB

MT-48
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Final Drive (Cont'd)
b. Move side gear up and down to measure dial indicator
deflection. Always measure indicator deflection on both
side gears.
Clearance between side gear and differential case with
washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
c. If not within specification, adjust clearance by changing
thickness of side gear thrust washers.
Side gear thrust washer:
Refer to SOS, MT -65.
SMT611A

4. Install retaining pin.

• Make sure that retaining pin is flush with case .

5.
•
Install final gear.
Apply locking sealant to final gear fixing bolts before install-
ing them.
•
6. Install speedometer drive gear.

SMT609A

7. Press on differential side bearings.

SMT648

Striking rod Control bracket Shift Control Components

~
_.~0
.~ INSPECTION
• Check contact surface and sliding
scratches, projections or other damage.
surface for wear,

Shift fork an};Jd"

shifter cap •
s:;

'l@ SMT093C

MT-49
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Shift Control Components (Cont'd)
Striking lever

Reverse brake earn

SMT099C

ADJUSTMENT OF INPUT SHAFT BRAKING MECHANISM

1. Install striking lever & rod, striking interlock assembly and
control bracket on clutch housing exactly.
• When installing control bracket on clutch housing, assure
protrusion beneath bracket is correctly seated.

SMT774B

2. Measure maximum height "H" while shifting from neutral to

reverse position.
Maximum height "H":
67.16 - 67.64 mm (2.6441 .2.6630 in)

Height
gauge

1st & 2nd shifter

Control bracket
fitting surface ~
Reverse brake carn
SMT728B

MT-SO
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Shift Control Components (Cont'd)
3. Measure clearance "C" between reverse brake cam and
striking lever while shifting to reverse position.
Clearance "C":
0.05 - 0.125 mm (0.0020 - 0.0049 in)
If "H" or "C" is not within specification, replace the follow-
ing parts as a set.
• Striking lever assembly
• Striking interlock assembly (This includes reverse brake
earn.)
• Control bracket assembly

Reverse brake eam

SMT729B

Case Components
REMOVAL AND INSTALLATION
•
Input shaft oil seal
1. Drive out input shaft oil seal.

2. Install input shaft oil seal.

• Apply multi-purpose grease to seal lip of oil seal before
installing.

SMT751BA

Input shaft rear bearing

1. Remove welch plug from transmission case.

SMT705B

MT-51
 REPAIR FOR COMPONENT PARTS I RS5F32A I
Case Components (Cont'd)
2. Remove input shaft rear bearing by tapping it from welch
plug hole.

SMT704B

3. Install welch plug.

• Apply recommended sealant to mating surface of transmis-
sion case.

SMT705B

4. Install input shaft rear bearing.

SMT706BA

Mainshaft front bearing and oil channel

1. Remove mainshaft front bearing retainer.

SMT707B

2. Remove mainshaft front bearing.

ST33290001 3. Remove oil channel.

SMT714BA

MT-52
 REPAIR FOR COMPONENT PARTS I RSSF32A I
Case Components (Cont'd)
4. Install oil channel.
Toward
• Ensure the oil groove faces the oil pocket.
oil pocket

SMT595

5. Install mainshaft front bearing.

6. Install mainshaft front bearing retainer.
• Apply locking sealant to thread of screw before installation .

MT-53
 ADJUSTMENT I RS5F32A I

Differential Side Bearing Preload

If any of the following parts are replaced, adjust differential side
bearing preload.
• Differential case
• Differential side bearing
• Clutch housing
• Transmission case

1. Remove differential side bearing outer race (transmission

case side) and shim.

2. Install differential side bearing outer race without shim.

3. Install final drive assembly on clutch housing.
4. Install transmission case on clutch housing.
• Tighten transmission case fixing bolts to the specified
torque. Refer to MT-33.

SMT646-A

5. Set dial indicator on front end of differential case.

6. Insert Tool all the way into differential side gear.
7. Move Tool up and down and measure dial indicator deflec-
tion.
8. Select shim considering bearing preload.

• Suitable shim thickness = Dial indicator deflection +

Specified bearing preload

Differential side bearing preload and adjusting shims:

Refer to SDS, MT-66.
Bearing preload:
0.25 - 0.30 mm (0.0098 - 0.0118 in)

9. Install selected shim and differential side bearing outer

race.
10. Check differential side bearing turning torque.
a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.
• Tighten transmission case fixing bolts to the specified
torque. Refer to MT-33.

SMT454-B

MT-54
 ADJUSTMENT I RS5F32A I
Differential Side Bearing Preload (Cont'd)
c. Measure turning torque of final drive assembly.
Turning torque of final drive assembly
(New bearing):
2.9 - 6.9 N'm (30 - 70 kg-em, 26 - 61 in-Ib)
• When old bearing is used again, turning torque will be
slightly less than the above.
• Make sure torque is close to the specified range.
• Changes in turning torque of final drive assembly per rev-
olution should be within 1.0 N'm (10 kg-em, 8.7 in-Ib) with-
out binding.

MT-55
 ASSEMBLY I RS5F32A ,

1. Install striking rod, lever and interlock.

• Tape edges of striking rod to avoid damaging oil seal lip
during installation. When taped edges of striking rod are
past the oil seal, remove tape.

2. Install reverse check sleeve assembly.

J Reverse check plug 3. Install check balls, reverse check spring and check plug.
~ Reverse check spring
V Check ball (Large)
"-- Check ball (Small)
b~6
, ~
l ~---- -'.

SMT584

4. Check reverse check turning torque (At striking rod).

Reverse check turning torque (At striking rod):
4.9 - 7.4 N'm (50 - 75 kg-em, 43 - 65 in-Ib)
• If not within specification, select another check plug having
a different length and reinstall it.
Available reverse check plugs:
Refer to 50S, MT -64.
5. Install selected reverse check plug.
• Apply locking sealant to thread of plug before installing it.

SMT688

6. Install check ball plug, shift check ball and shift check
spring.
7. Install oil pocket.

SMT648AA

8. Install gear components onto clutch housing.

a. Install final drive assembly.

SMT671B

MT-56
 ASSEMBLY I RSSF32A I

b. Install input shaft assembly with bearing retainer, mainshaft

assembly and reverse idler gear.
• Be careful not to damage oil seal lip with splines of input
shaft.
• Be careful not to damage oil channel when inserting main-
shaft into clutch housing.

c. Install input shaft front bearing retainer.

9. Apply grease to shifter caps, then install it to control

bracket. Install control bracket with 1st & 2nd shift fork.
•
SMT666

• When installing control bracket on clutch housing, ensure

bracket is correctly seated.
10. Install 3rd & 4th and 5th shift forks.

SMT774B

11. Insert fork shaft.

• Apply multi-purpose grease to support spring before install-
ing.
12. Install reverse idler spacer.

SMT596

MT-57
 ASSEMBLY I RS5F32A I
13. Apply recommended sealant to mating surface of clutch
housing.

14. Install transmission case on clutch housing.

SMT666B

15. Install mainshaft front bearing snap ring.

Snap ring

SMT665B

16. -Check mainshaft bearing end play.

Mainshaft bearing end play:
o- 0.1 mm (0 - 0.004 in)
• Make sure that bearing is properly seated. If not, tap main
shaft end with a rubber hammer.
• If not within specification, select another case cover having
a different thickness.
Available case covers:
Refer to 50S, MT -64.

SMT775B

MT-58
 ASSEMBLY I RS5F32A I
17. Install O-ring and case cover on transmission case.
• Apply recommended sealant to mating surface of transmis-
sion case.

SMT6648

MT-59
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
TRANSAXLE

Except for
Except for
Europe Europe and Europe Australia Europe
Europe
Australia
Applied model
GA14DE GA15DE GA16DE
Without SR20DE CD20
With catalyzer
catalyzer
Transaxle model RS5F30A RS5F31A RS5F32A RS5F31A
Number of speeds 5
Synchromesh type Warner
Shift pattern
1 3 5

~tJ
II
2 4 A

Gear ratio 1st 3.333 3.333 3.063 3.063 3.333

2nd 1.955 1.955 1.826 1.826 1.955
3rd 1286 1.286 1.286 1.286 1.286
4th 0.902 0.926 0.975 0.975 0.902
5th 0.733 0.756 0.810 0.756 0,756
Reverse 3.417 3.417 3.417 3.153 3.417
Number of Input 1st 15 15 16 16 15
teeth gear 2nd 22 22 23 23 22
3rd 28 28 28 28 28
4th 41 41 40 40 41
5th 45 45 42 45 45
Rev. 12 12 12 13 12
Main 1st 50 50 49 49 50
gear 2nd 43 43 42 42 43
3rd 36 36 36 36 36
4th 37 38 39 37
5th 33 34 34 39/
34 34
Rev. 41 41 41 41 41
Reverse idler
30 30
gear 31
3.7 - 3.9 2.9 - 3.2
Oil capacity C (Imp pt) 2.8 - 3.0 (4-7/8 - 5-1/4) 2.9 - 3.2 (5-1/8 - 5-5/8)
(6-1/2 - 6-7/8) (5-1/8 - 5-5/8)
.
39 - 44 54 - 61
Oillevel* mm (in) 58 - 66 (2.28 - 2.60) 57 - 66 (2.24 - 2.60)
(1.54 - 1.73) (2.13 - 2.40)

*: Refer to MA. section.

FINAL GEAR

Engine GA14DE GA15DE GA16DE SR20DE CD20

Final gear ratio 4.167 3.789 4.167 4.176 3.650

Final gear/Pinion 75/18 72/19 75/18 71/17 73/20

Number of
teeth Side gear/Pinion
14/10 14/10 16/10 14/10 16/10
mate gear

MT.60
 SERVICE DATA AND SPECIFICATIONS (SOS)

Inspection and Adjustment - RS5F30A &

RS5F31A
GEAR END PLAY AVAILABLE SNAP RINGS
Input shaft front bearing
Gear End play mm (in)

1st main gear 0,18 - 0,31 (0,0071 - 0,0122) Allowable clearance 0- 0,1 mm (0 - 0,004 in)

2nd main gear 0,20 - 0,30 (0,0079 - 0,0118) Thickness mm (in) Part number

3rd main gear 0,20 - 0,30 (0,0079 - 0,0118) 1,27 (0,0500) 32204-M8004

4th main gear 0,20 - 0,30 (0,0079 - 0,0118) 1,33 (0,0524) 32204-M8005

5th input gear 0,18 - 031 (0,0071 - 0,0122) 1,39 (0,0547) 32204-M8006

1.45 (0,0571) 32204-M8007

CLEARANCE BETWEEN BAULK RING AND

GEAR Input shaft 5th synchronizer hub
1st, 2nd, 3rd, 4th, 5th baulk ring Allowable clearance 0- 0,1 mm (0 - 0,004 in)
Unit: mm (in)
Thickness mm (in) Part number

•
Standard Wear limit
2,00 (00787) 32311-M8812
1.0 - 1.35 (0.0394 - 0.0531) 0.7 (0.028)
2,05 (0,0807) 32311-M8813

2,10 (0,0827) 32311-M8814

2,15 (0,0846) 32311-M8815

AVAILABLE CHECK PLUGS
2,20 (0.0866) 32311-M8816
Reverse check plug 2.25 (0.0886) 32311-M8817

2.30 (0.0906) 32311-M8818

Reverse check turning
4.9 - 7.4
torque (At striking rod)
(50 - 75, 43 - 65)
N'm (kg-em, in-Ib)

Thickness mm (in) Part number AVAILABLE C-RINGS

8.3 (0.327) 32188-M8001'
Mainshaft C-ring
7.1 (0.280) 32188-M8002

7.7 (0.303) 32188-M8003 Allowable clearance 0- 01 mm (0 - 0.004 in)

8.9 (0.350) 32188-M8004 Thickness Thickness

Part number Part number
mm (in) mm (in)
, Standard size check plug
3.63 (0 1429) 32348-M8800 4.12 (0.1622) 32348-M8807

3.70 (0.1457) 32348-M8801 4.19 (0,1650) 32348-M8808

3.77 (0.1484) 32348-M8802 4.26 (0.1677) 32348-M8809

3.84 (0.1512) 32348-M8803 4.33 (0.1705) 32348-M8810

3.91 (0.1539) 32348-M8804 4.40 (0.1732) 32348-M8811

3,98 (0.1567) 32348-M8805 4.47 (0.1760) 32348-M8812

4.05 (0.1594) 32348-M8806 4.54 (0.1787) 32348-M8813

MT-61
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment - RS5F30A &
RS5F31 A (Cont'd)
AVAILABLE WASHERS Mainshaft bearing adjusting shims
Differential side gear thrust washer Thickness mm (in) Part number
• GA 16DE and CD20 engine models 0.10 (0.0039) 32137-M8000
0.15 (0.0059) 32137-M8001
Allowable clearance between
0.1 - 0.2 mm 0.20 (0.0079) 32137-M8002
side gear and differential case
(0.004 - 0.008 in) 0.25 (0.0098) 32137-M8003
with washer
0.30 (0.0118) 32137-M8004
Thickness mm (in) Part number
035 (0.0138) 32137-M8005
0.75 - 0.80 (0.0295 - 0.0315) 38424-02111
0.40 (0.0157) 32137-M8006
0.80 - 0.85 (0.0315 - 0.0335) 38424-02112
0.45 (00177) 32137-M8007
0.85 - 0.90 (0.0335 - 0.0354) 38424-02113 0.50 (0.0197) 32137-M8008
0.90 - 0.95 (0.0354 - 0.0374) 38424-02114 0.55 (0.0217) 32137-M8009

0.95 - 1.00 (0.0374 - 0.0394) 38424-02115 0.60 (0.0236) 32137-M8010

0.65 (0.0256) 32137-M8011
0.70 (0.0276) 32137-M8012
• Except for GA16DE and CD20 engine models
0.75 (0.0295) 32137-M8013
Allowable clearance between 080 (0.0315) 32137-M8014
0.1 - 0.2 mm
side gear and differential case 0.85 (0.0335) 32137-M8015
(0.004 - 0.008 in)
with washer
0.90 (0.0354) 32137-M8016
Thickness mm (in) Part number
095 (0.0374) 32137-M8017
076 - 0.81 (0.0299 - 0.0319) 38424-01 M10 1.00 (0.0394) 32137-M8018
0.81 - 0.86 (0.0319 - 0.0339) 38424-01 M11

0.86 - 0.91 (0.0339 - 0.0358) 38424-01 M12

0.91 - 0.96 (0.0358 - 0.0378) 38424-01M13 Table for selecting mainshaft bearing
adjusting shim
Unit: mm (in)
AVAILABLE SHIMS
MAINSHAFT AND DIFFERENTIAL SIDE Measured distance Suitable shim thickness
BEARING PRELOAD AND ADJUSTING 2.35 - 2.40 (0.0925 - 0.0945) 0.10 (0.0039)

SHIM 2.40 - 2.45 (0.0945 - 0.0965) 0.15 (0.0059)

2.45 - 2.50 (0.0965 - 0.0984) 0.20 (0.0079)
Bearing preload (Reused bearing)
2.50 - 2.55 (0.0984 - 0.1004) 0.25 (0.0098)
Unit: mm (in)
2.55 - 2.60 (0.1004 - 0.1024) 0.30 (0.0118)
Oifferential side
Mainshafl bearing 2.60 - 2.65 (0.1024 - 0.1043) 0.35 (0.0138)
bearing
2.65 - 2.70 (0.1043 - 0.1063) 0.40 (0.0157)
0.18 - 0.23 0.24 - 0.32
RS5F30A 2.70 - 2.75 (0.1063 - 0.1083) 0.45 (0.0177)
(0.0071 - 0.0091) (0.0094 - 0.0126)
2.75 - 2.80 (0.1083 - 0.1102) 0.50 (0.0197)
0.18 - 0.27 0.20 - 0.25
RS5F31A 2.80 - 2.85 (0.1102 - 0.1122) 0.55 (0.0217)
(0.0071 - 0.0106) (0.0079 - 0.0098)
2.85 - 2.90 (0.1122 - 0.1142) 0.60 (0.0236)
2.90 - 2.95 (0.1142 - 0.1161) 0.65 (0.0256)
Turning torque (New bearing) 0.70 (0.0276)
2.95 - 3.00 (0.1161 - 0.1181)
Unit: N'm (kg-em, in-Ib)
3.00 - 3.05 (0.1181 - 0.1201) 0.75 (0.0295)
Total 3.05 - 3.10 (0.1201 - 0.1220) 0.80 (0.0315)
Final drive only (Final drive +
3.10 - 315 (0.1220 - 0.1240) 0.85 (0.0335)
Mainshafl)
3.15 - 3.20 (0.1240 - 0.1260) 0.90 (0.0354)
2.0 - 7.8 3.9 - 12.3
RS5F30A 3.20 - 3.25 (0.1260 - 0.1280) 0.95 (0.0374)
(20 - 80, 17 - 69) (40 - 125, 35 - 109)
3.25 - 3.30 (0.1280 - 0.1299) 1.00 (0.0394)
2.0 - 7.8 3.9 - 13.7
RS5F31A
(20 - 80, 17 - 69) (40 - 140, 35 - 122)

MT-62
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment - RS5F30A &
RS5F31A (Cont'd)
Differential side bearing adjusting shims

Thickness mm (in) Part number

0.44 (0.0173) 38454-M8000

0.48 (0.0189) 38454-M8001

0.56 (0.0220) 38454-M8003

0.60 (0.0236) 38454-M8004

0.64 (0.0252) 38454-M8005

0.68 (0.0268) 38454-M8006

0.72 (0.0283) 38454-M8007

0.76 (0.0299) 38454-M8008

0.80 (0.0315) 38454-M8009

0.84 (0.0331) 38454-M8010

0.88 (0.0346) 38454-M8011

MT-63
 SERVICE DATA AND SPECIFICATIONS (SOS)

Inspection and Adjustment - RS5F32A

GEAR END PLAY AVAILABLE REVERSE CHECK PLUGS AND
CASE COVERS
Gear End play mm (in)
Reverse check plug
1st main gear 0.18 - 0.31 (0.0071 - 0.0122)

2nd main gear 0.20 - 0.30 (0.0079 - 0.0118) Reverse check turning torque 4.9 - 7.4 N'm
3rd main gear 0.20 - 0.30 (0.0079 - 0.0118) (At striking rod) (50 - 75 kg-em, 43 - 65 in-Ib)

4th main gear 0.20 - 0.30 (0.0079 - 0.0118) Length mm (in) Part number

0.18 - 0.31 (0.0071 - 0.0122) 8.3 (0.327) 32188-M8001*

5th input gear
7.1 (0.280) 32188-M8002

7.7 (0.303) 32188-M8003

CLEARANCE BETWEEN BAULK RING AND 8.9 (0.350) 32188-M8004

GEAR * Standard size check plug

1st, 4th, 5th baulk ring

Unit: mm (in)
Case cover
Standard Wear limit

0.95 - 1.45 Main shalt bearing end play 0- 0.1 mm (0 - 0.004 in)
1st
(0.0374 - 0.0571)
Thickness mm (in) Part number
0.90 - 1.45
4th 07 (0.028) 10.78 (0.4244) 32131-50JOO
(0.0354 - 0.0571)
10.83 (0.4264) 32131-50J01
0.90 - 1.50
5th
(0.0354 - 0.0591) 10.88 (0.4283) 32131-50J02

10.93 (0.4303) 32131-50J03

10.98 (0.4323) 32131-50J04

2nd and 3rd baulk ring 11.03 (0.4343) 32131-50J05

Unit: mm (in)

:I{ ~ '00" ',,'k ,iog

\..- Synchronizer cone SMT757C

Dimension Standard Wear limit

0.7 - 0.9
A
(0.028 - 0.035)
02 (0008)
0.6 - 1.1
B
(0.024 - 0.043)

MT-64
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment - RS5F32A (Cont'd)
AVAILABLE SNAP RINGS AVAILABLE SPACERS
Input shaft front bearing Mainshaft bearing adjusting spacer

Allowable clearance 0 - 0.1 mm (0 - 0.004 in)

Mainshaft rear bearing
Thickness mm (in) Part number
Mainshaft adjusting
1.27 (0.0500) 32204-M8004 spacer
133 (0.0524) 32204-M8005

1.39 (0.0547) 32204-M8006

1.45 (0.0571) 32204-M8007

c
SMT6938

Input shaft 5th synchronizer hub 230.15 - 230.25 mm

Bearing distance "C"
(9.0610 - 9.0649 in)

Allowable clearance 0- 0.1 mm (0 - 0.004 in) Thickness mm (in) Part number

Thickness mm (in) Part number 1891 (0.7445) 32347-50JOO

2.00 (0.0787) 32311-M8812 18.98 (0.7472) 32347-50J01

2.05 (0.0807) 32311-M8813 19.05 (0.7500) 32347-50J02

2.10 (0.0827)

2.15 (0.0846)

2.20 (0.0866)

225 (0.0886)

2.30 (0.0906)
32311-M8814

32311-M8815

32311-M8816

32311-M8817

32311-M8818
1912 (0.7528)

1919 (0.7555)

19.26 (0.7583)

1933 (0.7610)

19.40 (0.7638)
32347-50J03

32347-50J04

32347-50J05

32347-50J06

32347-50J07
•
19.47 (0.7665) 32347 -50J08

AVAILABLE C-RINGS
Mainshaft C-ring
AVAILABLE WASHERS
Allowable clearance 0- 0.1 mm (0 - 0.004 in) Differential side gear thrust washer
Thickness mm (in) Part number
Allowable clearance between
4.45 (0.1752) 32348-50JOO 01 - 0.2 mm
side gear and differential case
(0.004 - 0.008 in)
4.52 (01780) 32348-50J01 with washer

4 59 (0.1807) 32348-50J02 Thickness mm (in) Part number

4.66 (0 1835) 32348-50J03 075 - 0.80

38424-02111
(0.0295 - 0.0315)
473 (0.1862) 32348-50J04
0.80 - 085
480 (0.1890) 32348-50J05 38424-02112
(0.0315 - 0.0335)
487 (0.1917) 32348-50J06
0.85 - 0.90
38424-02113
4.94 (0.1945) 32348-50J07 (0.0335 - 0.0354)

0.90 - 0.95
38424-02114
(00354 - 0.0374)

0.95 - 1.00
38424-02115
(0.0374 - 0.0394)

MT-65
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment - RS5F32A (Cont'd)
INPUT SHAFT BRAKING MECHANISM AVAILABLE SHIMS
DIFFERENTIAL SIDE BEARING
Reverse brake earn
PRELOAD AND ADJUSTING SHIM
Bearing preload (Reused bearing)
Unit: mm (in)

H Differential side bearing 0.25 - 0.30 (0.0098 - 0.0118)

Turning torque (New bearing)

Unit: N'm (kg-cm, in-I b)

Reverse brake cam Final drive 2.9 - 6.9 (30 - 70, 26 - 61)

SMT735B

Maximum height "H" between

the control bracket fitting sur- 67.16 - 67.64
Differential side bearing adjusting shims
face and 1-2 shiller (2.6441 - 2.6330)
mm (in) Thickness mm (in) Part number

0.44 (0.0173) 38454-M8000

0.48 (0.0189) 38454-M8001

0.56 (0.0220) 38454-M8003

0.60 (0.0236) 38454-M8004

0.64 (0.0252) 38454-M8005

c
0.68 (0.0268) 38454-M8006

0.72 (00283) 38454-M8007

0.76 (00299) 38454-M8008

0.80 (0.0315) 38454-M8009

SMT736B 0.84 (0.0331) 38454-M8010

Clearance "C" between 0.88 (0.0346) 38454-M8011

reverse brake carn and striking 0.05 - 0.125
lever (0.0020 - 0.0049)
mrn (in)

MT-66