MANUAL TRANSMISSION

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22-2 MANUAL TRANSMISSION – General Information

GENERAL INFORMATION 22100010113

Items Vehicles with 4G63 engine Vehicles with 4D56 engine

Transmission model R5M21-5 R5M21-5

Type 5-speed, floor-shift 5-speed, floor-shift

Gear ratio 1st 4.330 4.330

2nd 2.355 2.355

3rd 1.509 1.509

4th 1.000 1.000

5th 0.827 0.827

Reverse 4.142 4.142

Speedometer gear ratio (driven/drive) 29/8 26/8

Items Vehicles with 4G64 engine Vehicles with 4D56 engine

Transmission model V5M21-9 V5MT1-4

Type 5-speed, floor-shift 5-speed, floor-shift

Gear ratio 1st 3.967 3.918

2nd 2.136 2.261

3rd 1.360 1.395

4th 1.000 1.000

5th 0.856 0.829

Reverse 3.578 3.925

Transfer type 2-speed 2-speed

Gear ratio High 1.000 1.000

Low 1.925 1.925

Speedometer gear ratio (driven/drive) 27/8 25/8

 MANUAL TRANSMISSION – Lubricants/Sealants/On-vehicle Service 22-3
LUBRICANTS 22100040167

Items Specified lubricants Quantity

Transmission oil Hypoid gear oil SAE 75W-90, 75W-85W or 80W <R5M21> 2.3
conforming to API GL-4 <V5M21,V5MT1> 2.2

Transfer oil Hypoid gear oil SAE 75W-90, 75W-85W or 80W 2.3
conforming to API GL-4

SEALANTS 22100050054

Items Specified sealant Remarks

Oil filler plug <V5MT1> 3M ATD Part No. 8660 or equivalent Semi-drying sealant

Oil drain plug <V5MT1> 3M ATD Part No. 8660 or equivalent Semi-drying sealant

Control lever gasket 3M ATD Part No. 8661 or equivalent Semi-drying sealant

Control lever assembly mounting bolt 3M Stud Locking No. 4170 or equivalent Anaerobic sealant

ON-VEHICLE SERVICE 22100090193

TRANSMISSION OIL CHECK

Filler plug hole
Transmission oil 1. Remove the oil filler plug.
2. Oil level should be at the lower portion of the filler plug
hole.
3. Check that the transmission oil is not noticeably dirty,
and that it has a suitable viscosity.
4. Tighten the filler plug to the specified torque.
Tightening torque:
<R5M21, V5M21> 32 Nm
<V5MT1> 70 Nm
22-4 MANUAL TRANSMISSION – On-vehicle Service

Transmission-R5M21, V5M21 OIL REPLACEMENT 22100100179

Oil filler plug
1. Remove oil filler plug and oil drain plug.
2. Drain oil.
3. Tighten the oil drain plug to the specified torque.
Specified torque:
<R5M21,V5M21> 32 Nm
<V5MT1> 70 Nm
Oil drain plug NOTE (Only V5MT1)
Apply sealant to the oil drain plug threads.
Specified sealant:
3M ATD Part No. 8660 or equivalent
Transmission-V5MT1
4. Fill with specified oil till the level comes to the lower portion
Oil filler plug of oil filler plug hole.
Oil drain plug Specified transmission oil:
Hypoid gear oil SAE 75W-90, 75W-85W or 80W
conforming to API GL-4
Quantity:
Transmission
<R5M21> 2.3

<V5M21, V5MT1> 2.2

Transfer 2.3

Transfer 5. Tighten the oil filler plug to the specified torque.
Specified torque:
Oil filler plug
<R5M21, V5M21> 32 Nm
<V5MT1> 70 Nm
NOTE (Only V5MT1)
Apply sealant to the oil filler plug threads.
Specified sealant:
3M ATD Part No. 8660 or equivalent
Oil drain plug
MANUAL TRANSMISSION – On-vehicle Service 22-5
4WD DETECTION SWITCH CONTINUITY
CHECK <4WD> 22100170026

Check the continuity between terminals of the black connector

indicated in the illustration.

Transfer lever position Terminal No.

1 2

2H

4H

HIGH/LOW DETECTION SWITCH CONTINUITY

CHECK <4WD> 22100210025

Check the continuity between terminals of the gray connector

indicated in the illustration.

Transfer lever position Terminal No.

1 2

4H

4L

4H-4L
22-6 MANUAL TRANSMISSION – Transmission Control <2WD>

TRANSMISSION CONTROL <2WD> 22100380146

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
(1) Front Console Removal (Refer to GROUP 52A.) (1) Check the Operation of the Transmission Control
(2) Shift the Control Lever to the N position Lever and the Movement in Each Lever Position
(2) Front Console Installation (Refer to GROUP 52A.)

Caution: SRS
Be careful not to subject the SRS-diagnosis unit
to any shocks during removal and installation of
the control lever assembly.

10 – 13 Nm
8

1
7
3
6
5
2
4

Control lever assembly

mounting bolt
8
7 5

4 Apply the sealant both Apply the sealant to

sides of the gasket upper side of the gasket
Specified adhesive:
Sealant: 3M Stud Locking No.
3M ATD Part No. 8661 or equivalent 4170 or equivalent

Removal steps
1. Retainer plate 5. Gasket
"BA 2. Dust Cover 6. Stopper plate
"AA 3. Control lever assembly 7. Gasket
4. Control lever bushing 8. Control lever
 MANUAL TRANSMISSION – Transmission Control <2WD> 22-7
INSTALLATION SERVICE POINTS
"AA CONTROL LEVER ASSEMBLY INSTALLATION
1. Remove the adhesive sticking to the control lever
assembly mounting bolts.
2. Use a tap (M8 x 1.25) to remove the adhesive sticking
to the bolt holes in the control housing, and clean it by
blowing in air.
3. Apply specified adhesive to the threads of the control
lever assembly mounting bolts.
Specified adhesive:
3M Stud Locking No. 4170 or equivalent

4. The dimensions of the mounting bolts vary according

B
to their mounting locations, so do not confuse them when
installing.

Bolt Diameter x Length mm

A 8 x 23

B 8 x 22
A

"BA DUST COVER INSTALLATION

Petrol- Diesel- Install the dust cover so that they face as shown in the
powered powered illustration.
vehicles vehicles

Front Front
22-8 MANUAL TRANSMISSION – Transmission Control <4WD>

TRANSMISSION CONTROL <4WD> 22100380153

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
(1) Front Floor Console Assembly Removal (1) Check the Operation of the Transmission and
(Refer to GROUP 52A.) Transfer Control Levers and the Movement in Each
(2) Shift the Transmission Control Lever to the N Lever Position.
Position. (2) Front Floor Console Assembly Installation
(3) Shift the Transfer Control Lever to the 4H Position. (Refer to GROUP 52A.)

Caution: SRS
Be careful not to subject the SRS-diagnosis unit
to any shocks during removal and installation of
the control lever assembly.

10 – 13 Nm

5 Nm

1
13 8
12 6
9 5 3
11 2
4
10
7

Control lever assembly

mounting bolt
8 10,
4, 6
12

7 Apply the sealant to Apply the sealant to

both sides of the both sides of the
gasket gasket
Specified adhesive:
Sealant: 3M Stud Locking No.
3M ATD Part No. 8661 or equivalent 4170 or equivalent

Transmission control lever Transfer control lever assembly

assembly removal steps removal steps
1. Retainer 1. Retainer plate
"CA 2. Dust cover "CA 2. Dust cover
"BA 3. Transmission control lever "BA 9. Transfer control lever assembly
assembly 10. Gasket
4. Gasket "AA 11. Stopper plate
"AA 5. Stopper plate 12. Gasket
6. Gasket 13. Transfer control lever
7. Control lever bushing
8. Transmission control lever
 MANUAL TRANSMISSION – Transmission Control <4WD> 22-9
INSTALLATION SERVICE POINTS
<Transfer>
"AA STOPPER PLATE INSTALLATION
Install the stopper plates so that they face as shown in the
illustration.
Front

<Transmission>

Front

<L.H. drive vehicles> "BA TRANSFER CONTROL LEVER ASSEMBLY/

C B C TRANSMISSION CONTROL LEVER ASSEMBLY
Front
1. Remove the adhesive sticking to the control lever
C assembly mounting bolts.
C
2. Use a tap (M8 x 1.25) to remove the adhesive sticking
to the bolt holes in the control housing, and clean it by
blowing in air.
3. Apply specified adhesive to the threads of the control
lever assembly mounting bolts.
Front A C B
<R.H. drive vehicles> Specified adhesive:
3M Stud Locking No. 4170 or equivalent
4. The dimensions of the mounting bolts vary according
to their mounting locations, so do not confuse them when
installing.
Bolt Diameter x Length mm
A 8 x 18
B 8 x 22
C 8 x 23

"CA DUST COVER INSTALLATION

Install the dust cover so that they face as shown in the
Petrol-powered Diesel-
vehicles powered illustration.
vehicles
Front Front
22-10 MANUAL TRANSMISSION – Transmission Assembly <2WD>

TRANSMISSION ASSEMBLY <2WD> 22100270191

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
(1) Transmission Control Lever Removal (1) Propeller Shaft Installation (Refer to GROUP 25.)
(Refer to P. 22-6.) (2) Transmission Oil Filling (Refer to 22-4.)
(2) Transmission Oil Draining (Refer to P. 22-4.) (3) Transmission Shift Lever Installation
(3) Propeller Shaft Removal (Refer to GROUP 25.) (Refer to P. 22-6.)
(4) Shift Lever Operation Check
(5) Speedometer Operation Check

7
25 Nm
10
50 Nm 50 Nm
26 Nm

18 Nm

3
24 Nm
2
8 1
20 – 24 Nm
50 Nm

5
6

10 – 12 Nm 4
9 Nm
47 Nm
36 Nm

Removal steps
1. Back-up lamp switch connector 8. Exhaust pipe clamp mounting
2. Earth cable connection bracket
3. Speedometer cable connection D Support the transmission with a
AA" 4. Clutch release cylinder transmission jack
5. Bell housing cover 9. No. 2 crossmember assembly
AB" 6. Starter motor AC" "AA 10. Transmission assembly
7. Exhaust pipe clamp mounting bolt

REMOVAL SERVICE POINTS

AA" CLUTCH RELEASE CYLINDER REMOVAL
Remove the clutch release cylinder without disconnecting
the fluid line. Then suspend them with a cord.
AB" STARTER MOTOR REMOVAL
Remove the starter motor with the starter motor harnesses
still connected, and secure it inside the engine compartment.
 MANUAL TRANSMISSION – Transmission Assembly <2WD> 22-11
AC" TRANSMISSION ASSEMBLY REMOVAL
Caution
When removing the transmission assembly from the
engine, care must be taken not to shake or rock with
force, because to do so might cause damage to the end
of the main drive gear, the pilot bearing, or the clutch
disc, etc.

INSTALLATION SERVICE POINT

A "AA TRANSMISSION ASSEMBLY INSTALLATION
C The sizes of the mounting bolts are different. So be sure
B not to confuse them.

Bolt Diameter x Length mm

D D A 8 x 55

B 10 x 44

C 10 x 55

D 10 x 65
22-12 MANUAL TRANSMISSION – Transmission Assembly <4WD>

TRANSMISSION ASSEMBLY <4WD> 22100350031

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
(1) Transmission and Transfer Control Lever Removal (1) Front and Rear Propeller Shaft Installation
(Refer to P. 22-8.) (Refer to GROUP 25.)
(2) Transfer Case Protector Removal (2) Transmission and Transfer Oil Filling
(3) Transmission and Transfer Oil Draining (Refer to P. 22-4.)
(Refer to P. 22-4.) (3) Transfer Case Protector Installation
(4) Front and Rear Propeller Shaft Removal (4) Transmission and Transfer Control Lever
(Refer to GROUP 25.) Installation (Refer to P.22-8)
(5) Transmission and Transfer Control Lever Operation
Check
(6) Speedometer Operation Check

5
25 Nm 17 1 2
9 10 3
24 Nm
25 Nm 26 Nm
50 Nm 6

22 Nm

45 Nm
4
36 Nm 14 13
7
36 Nm
12 22 Nm 15
10 – 12 Nm 36 Nm

11 8
40 Nm 26 Nm
9 Nm

16

65 Nm

Removal steps
1. HIGH/LOW detection switch con- 9. Exhaust pipe clamp mounting bolt
nector <4G64>
2. 4WD detection switch connector 10. Transmission hanger bracket
3. Back-up lamp switch connector <4G64>
<4D56> 11. Bell housing cover
4. Back-up lamp switch connector AB" 12. Starter motor
<4G64> D Support the transmission with a
5. Earth cable transmission jack
6. Speedometer cable connection "BA 13. Transfer roll stopper
AA" 7. Clutch release cylinder, bracket 14. Transfer mount bracket
assembly <4G64> 15. Transfer support bracket
AA" 8. Clutch release cylinder <4D56> 16. No. 2 cross member
AC" "AA 17. Transmission assembly
 MANUAL TRANSMISSION – Transmission Assembly <4WD> 22-13
REMOVAL SERVICE POINTS
AA" CLUTCH RELEASE CYLINDER, BRACKET
ASSEMBLY <4G64>/CLUTCH RELEASE
CYLINDER <4D56> REMOVAL
Remove the clutch release cylinder without disconnecting
fluid line. Then suspend them with a cord.

AB" STARTER MOTOR REMOVAL

Remove the starter motor with the starter motor harnesses
still connected, and secure it inside the engine compartment.

AC" TRANSMISSION ASSEMBLY REMOVAL

Caution
When removing the transmission assembly from the
engine, care must be taken not to shake or rock with
force, because to do so might cause damage to the end
of the main drive gear, the pilot bearing, or the clutch
disc, etc.

<4G64> INSTALLATION SERVICE POINT

A "AA TRANSMISSION ASSEMBLY INSTALLATION
B
The sizes of the mounting bolts are different. So be sure
not to confuse them.
C <4G64>

Bolt Diameter x Length mm

E D
A 10 x 35

B 10 x 40
<4D56> C 10 x 60

D 10 x 65
A B E 10 x 75

<4D56>
C
C Bolt Diameter x Length mm

A 10 x 45
D D
B 8 x 30

C 10 x 80

D 10 x 25
22-14 MANUAL TRANSMISSION – Transmission Assembly <4WD>

Transfer roll stopper "BA TRANSFER ROLL STOPPER INSTALLATION

outer a: Approx. 10 mm
1. Tighten the transfer roll stopper provisionally.
2. Make the engine and transmission assembly rest on the
engine mount.
3. Tighten the transfer roll stoppers inner and outer finally
so that the clearance (a) between the two are at the
Transfer roll shown dimension.
stopper inner
4. Check that the right and left clearances (b) between the
stoppers are equal.
b b

5. Check that the clearances (c) between the transfer roll

Transfer roll stopper outer stopper and transfer mounting bracket are equal.
NOTE
c When new, a transfer roll stopper consists of one part,
but will separate into outer and inner part during use.
c
This is normal.

Transfer mounting bracket

 MANUAL TRANSMISSION – 4WD Indicator-ECU 22-15
4WD INDICATOR-ECU 22100620019

REMOVAL AND INSTALLATION

3
1
4
2

Removal steps
1. Front scuff plate attaching screw
2. Cowl side trim
3. Rear differential lock-ECU
4. 4WD indicator-ECU

INSPECTION
A 4WD INDICATOR-ECU
1. Measure the voltage with the control unit and harness
still connected.
2. Earth terminal (8) and then measure terminal voltage.
View A
22-16 MANUAL TRANSMISSION – 4WD Indicator-ECU

Terminal No. Inspection item Inspection condition Inspection condition Terminal voltage
1: Ignition switch 2: Transfer lever position

1 Free wheel engage ON 2H System voltage

switch
4H*1 0V

2 4WD detection ON 2H System voltage

switch
4H, 4L 0V

3 Ignition switch (IG1) OFF – 0V

ON – System voltage

5 Free wheel differen- ON 2H System voltage

tial indicator lamp
lam
4H*1 0V

6 HI/LOW detection ON Shifting from 4H to 4L System voltage

switch or vice versa

2H, 4H, 4L 0V

7 Free wheel clutch ON 4H, 4L 0V

changeover solenoid
valve 2H*2 System voltage

10 4WD Indicator lamp ON 2H 0V

4H, 4L System voltage

NOTE
*1: When vehicle has been moved once.
*2: Shift the lever from 4H to 2H, and then turn the ignition switch to OFF and then back to ON.
 MANUAL TRANSMISSION – General/General Information 22-1
GROUP 22
MANUAL TRANSMISSION
GENERAL
OUTLINE OF CHANGE
Due to the addition of the vehicles with emission regulation step III compatible 4D5 engine, R5M21
type transmission has been changed.

GENERAL INFORMATION
Items Specifications

Engine model 4D56-Step III

Transmission model R5M21-5

Type 5-speed, floor-shift

Gear ratio 1st 3.967

2nd 2.136

3rd 1.360

4th 1.000

5th 0.856

Reverse 3.578

Speedometer gear ratio (driven/drive) 26/8

NOTES