MANUAL TRANSAXLE SECTION M T CONTENTS DESCRIPTION OVERHAUL .... REPAIR FOR COMPONENT PARTS SERVICE DATA AND SPECIFICATIONS (S.0.S.) MT-7010DESCRIPTION RS5F30A DOUBLE-CONE SYNCHRONIZER wr Guten gear cousin — RSSFIOA — IN. synchronize: | DOuble-cone synchronizer is adopted for 1st and 2nd gears to a reduce operating force of the shift lever. o ‘Outer bavi ring Synchronizer cone ner bale ring ‘2nd main gear suraaz0n] MT-7002OVERHAUL [RssF30a] Case Components Case Components ome SEC. 320 [tating surtace to transmission his. a1 = Bi 27-50 (16 = 24, 12 - 15) a (0.38 - 0.51, 33.0 - 44.3) \ OG ware seme OMs-1 \® . \ 8 (sa, x \s OZ mating surtace 715) ® ° (7) 20 - 29 WC = 3.0, oe (3a eu ip BE 174) i trrend of bot \ to transmission | EJ Mating surface seventh af ® ae ! Mating surace’ < @ [P25 -34 (25 - 35, 18 - 25) Gi Tread of bot | Phas - 20 Gar, 20-2 | | eterna \ 3 es beni tp transmission case sa-a3 20-29 (os "08, Go-30, 4-22) Seen Bm tam in) 1D): tm kgm, tpt gonune sass tue goss, Tes Bord ror2t,tocto No. S18T9 om euhalt se: Papeete 1 ke act samrosso! 1. Chie housing 10. Case cover 19, Boot 2. input shat ol seal it) Backup lamp switch 20. itera ol sel Ol pocket 12. Dien ot seal 21. ong 4 Boaneg retainer 13. Drain pug 22. Speedometer pian asenbly & Ttazew 14. Tranemisston cate 22. Magnet, 8 Filer pug 16. Ol guter 24. Ear term 7. Ar breather ube 16. Rovere ier shat 25. Ween pug 8 Wek pg 17, Of channel 28. welch pug 8. Ong 18. Sting odo ea 27. PNP owich MT-7003OVERHAUL [RSSFI0A] Gear Components Gear Components + Select proper thickness ey L @ Boma teen $ : Pay attention to its direction, surps4o 1. Reverse ister gear 2). tet gear neesie bearing 99, Final gear 2. Reverse idler bushing 22, Stel ball 40, Diferentil side bearing adjusting 3, Reverse idler spacer 23, 2nd & 3rd bushing ‘shim 48 Shap ring 24, th main gear 41, Diferential side bearing 5. Spacer 2, sth main gear 42, Retaining pin 6. Input shaft front bearing (26. Thrust washer 43. Pinion mate thrust washer 7. Input shat 27. Menshatt Cring 44, Speedometer dive gear & Oi'plug 28. Ceing holder 45, Speedometer stopper 9. Sth gear neede bearing 29, Mainshatt rear bearing 46. Side gear 10. 5th input gear 30. Spacer 47. Pinion mate gear 11. Coupling sieeve 31, Mains rear bearing adjusting 48, Pinion mate shaft 12. Bauk ring shim 49, Side gear thrust washer 13. Sth synchronizer hub 32, th bushing 50. Snap ring 14. Spread spring 32, 3rd & An synchronizer hub 51. tat inner bauk rng 18. Shittng insert 34, Sed main gear 52, 1st synchronizer cone 16. 5th stopper 25. 2nd main gear 59, Tet outer baulk ting 17, Input shalt rear bearing 38. 1st & 2nd synchronizer hud 54. 2nd outer bauk ring 18. Mainshatt tron bearing 837. Reverse main gear (Couping 55. 2nd synchronizer cone 19. Mainshat sleeve) 88. 2nd inner baulk ring 20, ist main gear 38. Differential case MT-7004OVERHAUL [RS5F30A] ‘Shift Control Components Shift Control Components says SEC. 328 Bae oo (ate | GAO Tread oF plug | ro | 08. 55.5 - 72.8) Nem (kg-m, ino) TA): tem cag, tab) oO * TAO : Aoniy locking sealant. Select proper length l surse20 1. Reverse check spring 10. &rd & ath shi fork 18. Strking lever 2. Reverse check plug 11, tet & 2nd shit fork 18. Gheck ball (Large) 3. Check bal plug 12 Control bracket 20. Check ball (Small) 44 Shift check ball 13. Striking interiock 21. Check sleeve 5. Shi check spring 14. Retaining pin 22. Oring 8. Fork shaft support spring 15. Retaining pin 23. Select retum spring 7. Shilter cap 16. Yoke 24. Check plunger 8. Fork shaft 17. Striking rod 25. Stopper pin 8. 5th shit fork MT-7005REPAIR FOR COMPONENT PARTS RSSF30A laput Shaft and Gears End play Newate bearing currses) 7 Sth synetronizer hub ssra0g2t000 ser 101 been ‘th input goer sur7soeal Input shatt front Bearing sureare] suntou Input Shaft and Gears DISASSEMBLY 1, Before disassembly, check 5th input gear end play. Gear end play: Refer to SDS, MT-65. © if not within specification, disassemble and check contact sur- face of gear, shaft and hub. Then check clearance of snap ring groove. Refer to “ASSEMBLY”, MT-7007. Remove snap ring and rear bearing. Remove snap ring and Sth stopper. 4. Remove 5th synchronizer, 5th input gear and 5th gear needle bearing. Pay 5. Remove snap ring of input shaft front bearing and input gear spacer. 6. Pull out input shaft front bearing, 7. Remove bearing retainer. MT-7006‘apt Shaft and Gears REPAIR FOR COMPONENT PARTS RS5F30A. sur7si- urrasA) ‘5th aynenronize: nud sure ‘ASSEMBLY 1 6 7% Assemble Sth synchronizer. Be careful not to hook front and rear ends of spread spring to the same insert. Install bearing retainer. Press on input shaft front bearing. Install spacer. 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 input shaft front bearing: Refer to SDS, MT-65. Install 5th gear needle bearing, 5th input gear, 5th synchro- nizer and 5th stopper. Measure gear end play as the final check. Refer to “DISASSEMBLY”, MT-7006. MT-7007REPAIR FOR COMPONENT PARTS. RS5F30A_ yom sere sus Snap ring Input shatt tear bearing ‘swres80} Input Shaft and Gears 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 input shaft Sth synchronizer hub: Refer to SDS, MT-65. 9. Install input shaft rear bearing. 10. 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 input shaft rear bearing: Refer to SDS, MT-7011. MT-7008REPAIR FOR COMPONENT PARTS ‘ear clearance j= sursad ‘Synchronizer rawr 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. © Measure clearance between baulk ring and 1st-ath main gears. 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) Synchronizer ‘5190031000 ‘Outer baulk ing A Synchronizer cone surrico. © Measure wear of 1st and 2nd baulk ring (For Europe model) a) Place baulk rings in position on synchronizer cone. b) While holding baulk ring against synchronizer cone as tar as it will go, measure dimensions “A” and “B”. Standard: 0.7 - 0.9 mm (0.028 - 0.035 in) B 0.7 - 1.0 mm (0.028 - 0.039 in) Wear limi 0.2 mm (0.008 in) © If dimension “A” or “B” is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchro- nizer cone as a set. MT-7009SERVICE DATA AND SPECIFICATIONS (SDS) RSSF30A_ General Specifications General Specifications amon TRANSAXLE sre, “Aso6d mace cara 6A) Model code number rey "aNoOA “ransala model SSra0A Number of speeds = Sypchvomesh pe Wainer Shit pao Tas I HH rfl Gear ato et 3399 ana 172 a6 1207 an 0902 ah 0786 0738 Rovere aai7 ‘Number of teeth input ova 1 6 ad % ae = an a sth 6 Rew @ Main gear 1s 0 2a a Ea % a a7 an a = Few. a verse idler gear 3% Oi eapaciy_¢ (imp pt 28-30 6718-5474) (Oil fevel (Reference dete) mm (in) 58-66 (228-260) Remarks 1518 2nd double bauk ing ype synchwonizor FINAL GEAR a Engine cara sas Fina goar rato wari 3.605 Final goarPinion 7eA7 7an9 Number of teth Sie goarPinen mato goa vanto MT-7010SERVICE DATA AND SPECIFICATIONS (SDS) RS5SF30A General Speciications 1ST AND 2ND DOUBLE BAULK RING oes unt tiny Outer baulk rng ‘Synehronia6e cone inner bauik ring thee suTo060 Dimension ‘Standard Wear tit a 0,7 -0.9 (0.028 - 0.095) 02 (0.008) @ 07-10 028 -0.098) INPUT SHAFT REAR BEARING ameece ‘Alowable clearance 0 0.1 mm (00.008 in) “Tics mm fy Par number 127 00500) sea0eaMa0o 1.33 (0.0526) sea0aaot 1.38 0.0547) 32008 aate 145 (00571) 32204-4409 “TAwaye check wh the Parts Department fr the latest pars information Mainshaft and Differential Side Bearing Preload BEARING PRELOAD (REUSED BEARING) a Unitrin} Mainahat bearag Diferential side bearing (0.20 - 0.25 (0.0079 - 0.0008) TURNING TORQUE (NEW BEARING) Final crive only 20- 7.8 (20-60, 17-69) MT- (0.24 -0.32 (0.0094 - 0.0128) Unit: Nim (gece) ‘Total (Final deve + Mainshat) ‘39-123 (40 125, 85-108) 7011