Almera Tino V10 (2003 year). Manual — part 225
MT-54
[RS6F51R]
REVERSE IDLER SHAFT AND GEARS
Baulk ring clearance
●
Press baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it
with a new one.
Bearing
Check items below. If necessary, replace them with new ones.
●
Damage and rough rotation of bearing.
ASSEMBLY
Paying attention to following work, assemble in reverse order of disassembly.
CAUTION:
●
Be careful with orientation of insert spring.
Clearance
Standard
: 0.95 - 1.4 mm (0.0374 - 0.0551 in)
Limit value
: 0.7 mm (0.0276 in)
SMT140
SCIA0954E
FINAL DRIVE
MT-55
[RS6F51R]
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FINAL DRIVE
PFP:38411
Assembly and Disassembly
ECS00960
PRE-INSPECTION
●
Check the clearance between side gear and differential case as
follows.
1.
Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
2.
Upright the differential case so that the side gear to be mea-
sured faces upward.
3.
Place final drive adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.
CAUTION:
There should be no resistance and gears should rotate
freely.
4.
If not within specification, adjust the clearance by changing thrust washer thickness.
5.
Turn differential case upside down, and measure the clearance between side gear and differential case on
the other side in the same way.
DISASSEMBLY
1.
Remove mounting bolts. Then, separate the final gear from differential case.
2.
Remove speedometer drive gear.
3.
Using a drift and puller, remove differential side bearing (clutch
housing side).
4.
Using a drift and puller, remove differential side bearing (tran-
saxle case side).
SMT610AH
Clearance
between side gear
and differential
case
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
MCIA0019E
SCIA0907E
MT-56
[RS6F51R]
FINAL DRIVE
5.
Using a pin punch, pull out lock pin and pinion mate shaft.
6.
Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.
INSPECTION AFTER DISASSEMBLY
Gear Washer, Shaft and Case
●
Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.
Bearing
●
Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and
inner race as a set.
ASSEMBLY
1.
Apply gear oil to sliding area of differential case, each gear, and
thrust washer.
2.
Install side gear thrust washer and side gears into differential
case.
3.
While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.
SCIA0908E
MTK0135D
SPD715
SMT839
FINAL DRIVE
MT-57
[RS6F51R]
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4.
Insert pinion mate shaft into differential case.
CAUTION:
Be sure not to damage pinion mate thrust washers.
5.
Measure end play of side gears following procedure below.
Then select side gear thrust washer.
a.
Upright the differential case so that its side gear to be measured
face upward.
b.
Place final drive adapter and dial gauge onto side gears.
c.
Move side gears up and down to measure end play, and select
thrust washer so that it satisfies standard.
CAUTION:
●
There should be no resistance and gears should rotate
freely.
●
Place differential case upside down. Be sure to measure
end play for opposite side-gears likewise.
Thrust washer
CAUTION:
Only one thrust washer can be selected.
6.
Using a pin punch (special service tool), drive a lock pin into the
pinion mate shaft.
CAUTION:
Do not reuse the lock pin.
MTK0132D
SMT610AH
End play standard
value
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
Shim thickness
Part number
0.75 mm (0.0295 in)
0.80 mm (0.0315 in)
0.85 mm (0.0335 in)
0.90 mm (0.0354 in)
0.95 mm (0.0374 in)
38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04
SCIA0908E
MT-58
[RS6F51R]
FINAL DRIVE
7.
Using a drift (special service tool), install differential side bearing
(transaxle case side).
8.
Align and install speedometer drive gear onto differential case.
9.
Using a drift (special service tool), install differential side bearing
(clutch housing side).
10. Install final gear into differential case, and tighten final gear
mounting bolts.
SCIA0910E
SMT842D
MCIA0020E
SCIA0912E
SHIFT CONTROL
MT-59
[RS6F51R]
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SHIFT CONTROL
PFP:32982
Inspection
ECS00961
●
Check contact surfaces and sliding area for wear, damage,
bending, etc. If necessary, replace parts.
SHIFT FORK
●
Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
SCIA0913E
Item
One-side wear specifi-
cation
Sliding width of new part
1st & 2nd
0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd & 4th
0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th & 6th
0.2 mm (0.008 in)
6.10 - 6.23 mm
(0.2402 - 0.2453 in)
Reverse
0.2 mm (0.008 in)
12.80 - 12.93 mm
(0.5039 - 0.5091 in)
SMT801D
MT-60
[RS6F51R]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
General Specifications
ECS00962
TRANSAXLE
FINAL GEAR
Engine
YD22DDTi
Transaxle model
RS6F51R
Model code number
AW664
Number of speed
6
Synchromesh type
Warner
Shift pattern
Gear ratio
1st
3.500
2nd
1.944
3rd
1.258
4th
0.947
5th
0.722
6th
0.673
Reverse
3.374
Number of teeth
Input gear
1st
14
2nd
18
3rd
31
4th
38
5th
44
6th
49
Reverse
14
Main gear
1st
49
2nd
35
3rd
39
4th
36
5th
34
6th
33
Reverse
38
Reverse idler gear
Front
37
Rear
46
Oil capacity
(Imp pt)
2.3 (4)
Remarks
Reverse synchronizer
Installed
Double baulk ring type synchro-
nizer
1st & 2rd synchronizer
SCIA0955E
Engine
YD22DDTi
Transaxle model
RS6F51R
Model code number
AW664
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-61
[RS6F51R]
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*: Refer to MA section, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Gear End Play
ECS00963
Unit: mm (in)
Clearance Between Baulk Ring and Gear
ECS00964
3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING
Unit: mm (in)
1ST AND 2ND DOUBLE BAULK RING
Unit: mm (in)
Available Snap Rings
ECS00965
6TH BUSHING
*: Always check with the Parts Department for the latest parts information.
Final gear ratio
3.812
Number of teeth
Final gear/Pinion
61/16
Side gear/Pinion mate gear
14/11
Gear
End play
1st main gear
0.20 - 0.30 (0.0079 - 0.0118)
2nd main gear
0.06 - 0.16 (0.0024 - 0.0063)
3rd input gear
0.18 - 0.31 (0.0071 - 0.0122)
4th input gear
0.20 - 0.30 (0.0079 - 0.0118)
5th input gear
0.06 - 0.16 (0.0024 - 0.0063)
6th input gear
0.06 - 0.16 (0.0024 - 0.0063)
Standard
Wear limit
3rd
0.9 - 1.45 (0.0354 - 0.0571)
0.7 (0.0276)
4th
0.9 - 1.45 (0.0354 - 0.0571)
5th
0.95 - 1.4 (0.0374 - 0.0551)
6th
0.95 - 1.4 (0.0374 - 0.0551)
Reverse
0.95 - 1.4 (0.0374 - 0.0551)
Dimension
Standard
Wear limit
A
0.6 - 0.8 (0.024 - 0.031)
0.2 (0.008)
B
0.6 - 1.1 (0.024 - 0.043)
SMT138E
End play
0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in)
Part number*
Thickness mm (in)
Part number*
1.76 (0.0693)
1.81 (0.0713)
1.86 (0.0732)
1.91 (0.0752)
1.96 (0.0772)
32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515
2.01 (0.0791)
2.06 (0.0811)
2.11 (0.0831)
2.16 (0.0850)
2.21 (0.0870)
32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
MT-62
[RS6F51R]
SERVICE DATA AND SPECIFICATIONS (SDS)
Available C-rings
ECS00966
MAINSHAFT C-RING
*: Always check with the Parts Department for the latest parts information.
Available Thrust Washer
ECS00967
INPUT SHAFT THRUST WASHER
*: Always check with the Parts Department for the latest parts information.
DIFFERENTIAL SIDE GEAR THRUST WASHER
*: Always check with the Parts Department for the latest parts information.
End play
0 - 0.06 mm (0 - 0.0024 in)
Thickness mm (in)
Part number*
Thickness mm (in)
Part number*
2.535 (0.0998)
2.565 (0.1010)
2.595 (0.1022)
2.625 (0.1033)
2.655 (0.1045)
2.685 (0.1057)
2.715 (0.1069)
2.745 (0.1081)
2.775 (0.1093)
2.805 (0.1104)
32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H809
2.835 (0.1116)
2.865 (0.1128)
2.895 (0.1140)
2.925 (0.1152)
2.955 (0.1163)
2.985 (0.1175)
3.015 (0.1187)
3.045 (0.1199)
3.075 (0.1211)
32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818
Standard length “C2”
154.7 - 154.8 mm (6.091 - 6.094 in)
Thickness mm (in)
Part number*
Thickness mm (in)
Part number*
3.84 (0.1512)
3.90 (0.1535)
3.96 (0.1559)
32347 8H500
32347 8H501
32347 8H502
4.02 (0.1583)
4.08 (0.1606)
4.14 (0.1630)
32347 8H503
32347 8H504
32347 8H505
SCIA1008E
Allowable clearance between side gear and differential case with
washer
0.1 - 0.2 mm (0.004 - 0.008 in)
Thickness mm (in)
Part number*
0.75 (0.0295)
0.80 (0.0315)
0.85 (0.0335)
0.90 (0.0354)
0.95 (0.0374)
38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-63
[RS6F51R]
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Available Adjusting Shims
ECS00968
MAINSHAFT ADJUSTING SHIM
*: Always check with the Parts Department for the latest parts information.
INPUT SHAFT REAR BEARING ADJUSTING SHIM
*: Always check with the parts department for the latest information.
MAINSHAFT REAR BEARING ADJUSTING SHIM
*: Always check with the Parts Department for the latest parts information.
REVERSE IDLER GEAR ADJUSTING SHIM
Standard length “C1”
173.85 - 173.95 mm (6.844 - 6.848 in)
Thickness mm (in)
Part number*
Thickness mm (in)
Part number*
0.52 (0.0205)
0.60 (0.0236)
0.68 (0.0268)
0.76 (0.0299)
32238 8H500
32238 8H501
32238 8H502
32238 8H503
0.84 (0.0331)
0.92 (0.0362)
1.00 (0.0394)
1.08 (0.0425)
32238 8H504
32238 8H505
32238 8H506
32238 8H507
SCIA1009E
End play
0 - 0.06 mm (0 - 0.0024 in)
Thickness mm (in)
Part number*
Thickness mm (in)
Part number*
Thickness mm (in)
Part number*
0.40 (0.0157)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510
32225 8H511
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0394)
1.04 (0.0409)
1.08 (0.0425)
1.12 (0.0441)
1.16 (0.0457)
1.20 (0.0472)
1.24 (0.0488)
1.28 (0.0504)
1.32 (0.0520)
32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521
32225 8H522
32225 8H523
1.36 (0.0535)
1.40 (0.0551)
1.44 (0.0567)
1.48 (0.0583)
1.52 (0.0598)
1.56 (0.0614)
1.60 (0.0630)
1.64 (0.0646)
32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566
End play
0 - 0.06 mm (0 - 0.0024 in)
Thickness mm (in)
Part number*
Thickness mm (in)
Part number*
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0394)
1.04 (0.0409)
1.08 (0.0425)
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561
End play
0.04 - 0.14 mm (0.0016 - 0.0055 in)
MT-64
[RS6F51R]
SERVICE DATA AND SPECIFICATIONS (SDS)
*: Always check with the Parts Department for the latest parts information.
6TH MAIN GEAR ADJUSTING SHIM
*: Always check with the Parts Department for the latest parts information.
Available Shims
ECS00969
— Differential Side Bearing Preload and Adjusting Shim
BEARING PRELOAD
*: Install shims which are “deflection of differential case” + “L” in thickness.
DIFFERENTIAL SIDE BEARING ADJUSTING SHIM (S)
*: Always check with the Parts Department for the latest parts information.
Thickness mm (in)
Part number*
Thickness mm (in)
Part number*
1.76 (0.0693)
1.84 (0.0724)
1.92 (0.0756)
2.00 (0.0787)
2.08 (0.0819)
2.16 (0.0850)
32237 8H800
32237 8H802
32237 8H804
32237 8H806
32237 8H808
32237 8H810
2.24 (0.0882)
2.32 (0.0913)
2.40 (0.0945)
2.48 (0.0976)
2.56 (0.1008)
2.64 (0.1039)
32237 8H812
32237 8H814
32237 8H816
32237 8H818
32237 8H820
32237 8H822
End play
0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in)
Part number*
Thickness mm (in)
Part number*
0.88 (0.0346)
0.96 (0.0378)
1.04 (0.0409)
1.12 (0.0441)
32237 8H560
32237 8H561
32237 8H562
32237 8H563
1.20 (0.0472)
1.28 (0.0504)
1.36 (0.0535)
32237 8H564
32237 8H565
32237 8H566
Differential side bearing preload: L*
0.15 - 0.21 mm (0.0059 - 0.0083 in)
Thickness mm (in)
Part number*
Thickness mm (in)
Part number*
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11
MANUAL TRANSAXLE
CONTENTS
RS5F70A
PREPARATION . . . . . . . . . . . . . . . ...4
Special Service Tools . . . . . . . . . . . . ..4
Commercial Service Tools . . . . . . . . . . ...5
RS5F50A
PREPARATION . . . . . . . . . . . . . . . ...7
Special Service Tools . . . . . . . . . . . . ..7
Commercial Service Tools . . . . . . . . . . ...8
RS5F70A, RS5F50A
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . . ...10
NVH Troubleshooting Chart. . . . . . . . . ...10
. . . . . . . . . . . .10
RS5F70A
M/T OIL . . . . . . . . . . . . . . . . . . .. 11
Changing M/T Oil. . . . . . . . . . . . . ... 11
Checking . . . . . . . . . . . . . . . . . 11
. . . . . . . . . ... 11
RS5F50A
M/T OIL . . . . . . . . . . . . . . . . . . ..12
Changing M/T Oil. . . . . . . . . . . . . ...12
Checking . . . . . . . . . . . . . . . . . 12
. . . . . . . . . ...12
RS5F70A, RS5F50A
DESCRIPTION . . . . . . . . . . . . . . . ...13
Cross-sectional View - RS5F70A . . . . . . . ..13
Cross-sectional View - RS5F50A . . . . . . . ..14
. . . . . . . 15
ON-VEHICLE SERVICE . . . . . . . . . . . . 16
Replacing Oil Seal . . . . . . . . . . . . . .16
. . . . . . . . . . 16
. . . . . . . . . ...16
Position Switch Check . . . . . . . . . . . ...17
. . . . . . . . . . 17
. . . . . . . . . . . . . . ..17
BACK-UP LAMP SWITCH AND PNP SWITCH
. . ...18
RS5F70A
REMOVAL AND INSTALLATION . . . . . . . . .19
Removal. . . . . . . . . . . . . . . . . .19
Installation. . . . . . . . . . . . . . . . ..20
. . . . . . . . . ...20
RS5F50A
REMOVAL AND INSTALLATION . . . . . . . . .21
Removal. . . . . . . . . . . . . . . . . .21
Installation. . . . . . . . . . . . . . . . ..23
. . . . . . . . . . . . 23
RS5F70A, RS5F50A
TRANSAXLE GEAR CONTROL . . . . . . . . ...24
Components. . . . . . . . . . . . . . . ...24
RS5F70A
OVERHAUL . . . . . . . . . . . . . . . . ...25
Case Components . . . . . . . . . . . . . .25
Gear Components . . . . . . . . . . . . . .26
Shift Control Components . . . . . . . . . . .27
Final Drive Components . . . . . . . . . . . 28
DISASSEMBLY. . . . . . . . . . . . . . . ..29
Transaxle Case. . . . . . . . . . . . . . ..29
Clutch Housing . . . . . . . . . . . . . . ..31
REPAIR FOR COMPONENT PARTS . . . . . . ...35
Input Shaft and Gears . . . . . . . . . . . ...35
. . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . ...36
. . . . . . . . . . . . . . . .37
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
Mainshaft and Gears . . . . . . . . . . . . .40
. . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . ...41
. . . . . . . . . . . . . . . .43
Final Drive. . . . . . . . . . . . . . . . ..48
. . . . . . . . . . . . ...48
. . . . . . . . . . . . . . 49
. . . . . . . . . . . . . . ...49
. . . . . . . . . . . . . . . .50
Shift Control Components . . . . . . . . . . .51
. . . . . . . . . . . . . . ...51
ASSEMBLY. . . . . . . . . . . . . . . . . 53
Clutch Housing . . . . . . . . . . . . . . ..53
Transaxle Case. . . . . . . . . . . . . . ..57
RS5F50A
OVERHAUL . . . . . . . . . . . . . . . . ...63
Case Components . . . . . . . . . . . . . .63
Gear Components . . . . . . . . . . . . . .64
Shift Control Components . . . . . . . . . . .65
DISASSEMBLY. . . . . . . . . . . . . . . ..66
REPAIR FOR COMPONENT PARTS . . . . . . ...69
Input Shaft and Gears . . . . . . . . . . . ...69
. . . . . . . . . . . . . . 69
. . . . . . . . . . . . . . ...70
. . . . . . . . . . . . . . . .71
Mainshaft and Gears . . . . . . . . . . . . .74
. . . . . . . . . . . . . . 74
. . . . . . . . . . . . . . ...75
. . . . . . . . . . . . . . . .76
Final Drive. . . . . . . . . . . . . . . . ..78
. . . . . . . . . . . . . . 78
. . . . . . . . . . . . . . ...78
. . . . . . . . . . . . . . . .79
Shift Control Components . . . . . . . . . . .80
. . . . . . . . . . . . . . ...80
Case Components . . . . . . . . . . . . . .80
. . . . . . . ...80
ADJUSTMENT . . . . . . . . . . . . . . . ...82
Input Shaft End Play and Differential Side
Bearing Preload . . . . . . . . . . . . . . .82
. . . . . . . . . . . ...82
Mainshaft Bearing Preload . . . . . . . . . . 83
ASSEMBLY. . . . . . . . . . . . . . . . . 85
RS5F70A
SERVICE DATA AND SPECIFICATIONS (SDS) . . .89
General Specifications. . . . . . . . . . . ...89
. . . . . . . . . . . . . . ...89
. . . . . . . . . . . . . . ...89
Gear End Play . . . . . . . . . . . . . . ...90
Clearance Coupling Sleeve . . . . . . . . . ...90
1ST, 2ND, 3RD, 4TH, 5TH & REVERSE
COUPLING SLEEVE
. . . . . . . . . . . . 90
Clearance Between Baulk Ring and Gear . . . . 90
3RD, 4TH, 5TH, REVERSE BAULK RING
. . . . ..90
. . . . . ..90
Available Snap Rings . . . . . . . . . . . . 91
. . . . . . . . . . . . . . . .91
Available C-rings. . . . . . . . . . . . . . 91
. . . . . . . . . ...91
. . . . . . . .91
. . . . . . . . . . . ...92
Available Adjusting Shims . . . . . . . . . . .93
INPUT SHAFT REAR BEARING ADJUSTING
SHIM
. . . . . . . . . . . . . . . . . ..93
. . . . . . . . 94
MAINSHAFT REAR BEARING ADJUSTING SHIM
. ..94
Available Thrust Washer. . . . . . . . . . . 95
. . . . . . . ...95
Available Washers . . . . . . . . . . . . . .95
DIFFERENTIAL SIDE GEAR THRUST WASHER
. . 95
Available Shims - Differential Side Bearing
Preload and Adjusting Shim . . . . . . . . . ..96
. . . . . . . . . . . ...96
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIMS
. . . . . . . . . . . . . . . . . 96
RS5F50A
SERVICE DATA AND SPECIFICATIONS (SDS) . . .97
General Specifications. . . . . . . . . . . ...97
. . . . . . . . . . . . . . ...97
. . . . . . . . . . . . . . ...97
Gear End Play . . . . . . . . . . . . . . ...98
Clearance Between Baulk Ring and Gear . . . . 98
. . . . . . . . .98
. . . . . ..98
. . . . . . . . . . ..98
Available Snap Rings . . . . . . . . . . . . 99
1ST & 2ND SYNCHRONIZER HUB (AT
MAINSHAFT)
. . . . . . . . . . . . . . ...99
3RD & 4TH SYNCHRONIZER HUB (AT INPUT
SHAFT)
. . . . . . . . . . . . . . . . ...99
. . . . . . ..99
Available Thrust Washer. . . . . . . . . . . 99
4TH INPUT GEAR (AT INPUT SHAFT)
. . . . . ..99
DIFFERENTIAL SIDE GEAR THRUST WASHER
. . 99
Available Shims . . . . . . . . . . . . . ...100
. . . . . 100
TOTAL TURNING TORQUE (NEW BEARING)
. . ..100
MAINSHAFT BEARING ADJUSTING SHIM
. . . ..100
TABLE FOR SELECTING MAINSHAFT BEARING
ADJUSTING SHIM(S)
. . . . . . . . . . . .100
INPUT SHAFT BEARING ADJUSTING SHIM
. . ...101
TABLE FOR SELECTING INPUT SHAFT BEARING
ADJUSTING SHIM(S)
. . . . . . . . . . . .101
CONTENTS
(Cont’d)
MT-2
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM
. . . . . . . . . . . . . . . . . 101
TABLE FOR SELECTING DIFFERENTIAL SIDE
BEARING ADJUSTING SHIM(S)
. . . . . . . .102
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CONTENTS
(Cont’d)
MT-3
Special Service Tools
NLMT0032
Tool number
Tool name
Description
KV38107700
Preload adapter
NT087
Measuring turning torque of final drive assembly
Measuring total turning torque
Measuring clearance between side gear and differ-
ential case with washer
Selecting differential side bearing adjusting shim
(Use with KV38106000.)
KV38106000
Height gauge adapter
(differential side bearing)
NT418
Selecting differential side bearing adjusting shim
(Use with KV38107700.)
a: 140 mm (5.51 in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 x 1.25P
KV32101000
Pin punch
NT410
Removing and installing retaining pin
Removing and installing lock pin
Removing selector shaft
Removing welch plug
a: 4 mm (0.16 in) dia.
KV31100300
Pin punch
NT410
Removing and installing retaining pin
a: 4.5 mm (0.177 in) dia.
ST30031000
Puller
NT411
Removing 3rd, 5th input gear
Removing 3rd & 4th and 5th & Rev synchronizer
hub
Removing mainshaft rear bearing
Removing 2nd gear, 5th gear bush
Removing 1st & 2nd synchronizer hub, 1st and
4th main gear
Removing and installing differential side bearing
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000
Puller
NT411
Removing input shaft front and rear bearing
Installing input shaft front and rear bearing
Installing 5th input gear, 3rd main gear and 4th
main gear
Installing 1st & 2nd, 3rd & 4th and 5th & Rev syn-
chronizer hub
Installing 2nd gear bush, 5th gear bush, Rev gear
bush
Installing mainshaft rear bearing
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
PREPARATION
RS5F70A
Special Service Tools
MT-4
Tool number
Tool name
Description
ST33290001
Puller
NT414
Removing idler gear bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST33230000
Drift
NT084
Removing differential oil seal
Installing differential side bearing
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
ST30720000
Drift
NT115
Installing differential side bearing outer race
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST22350000
Drift
NT065
Installing input shaft front and rear bearing
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
ST22452000
Drift
NT065
Installing 3rd and 4th main gear
Installing 5th gear bush
Installing 5th & Rev synchronizer hub
Installing Rev gear bush
Installing mainshaft rear bearing
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
ST37750000
Drift
NT065
Installing input shaft oil seal
Installing 5th synchronizer
Installing mainshaft rear bearing
Installing 5th main gear
Installing 3rd & 4th synchronizer hub
Installing striking rod oil seal
Installing clutch housing dust seal
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
Commercial Service Tools
NLMT0033
Tool name
Description
Drift
NT065
Installing welch plug
a: 12 mm (0.47 in) dia.
b: 10 mm (0.39 in) dia.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PREPARATION
RS5F70A
Special Service Tools (Cont’d)
MT-5
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