Skrzynia manualna.pdf

MANUAL TRANSAXLE

SECTION MT

CONTENTS

PREPARATION ...............................................................3

Special Service Tools ..................................................3

Commercial Service Tools ...........................................6

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING .....................................................7

NVH Troubleshooting Chart .........................................7

ON-VEHICLE SERVICE ..................................................8

Replacing Oil Seal .......................................................8

DIFFERENTIAL OIL SEAL ..........................................8

STRIKING ROD OIL SEAL . .........................................8

Position Switch Check .................................................9

BACK-UP LAMP SWITCH ...........................................9

NEUTRAL POSITION SWITCH ...................................9

REMOVAL AND INSTALLATION .................................10

Removal .....................................................................10

Installation ..................................................................12

INSPECTION ...........................................................33

ASSEMBLY .............................................................33

Shift Control Components .........................................35

INSPECTION ...........................................................35

ADJUSTMENT OF INPUT SHAFT BRAKING

MECHANISM ...........................................................36

Case Components .....................................................37

REMOVAL AND INSTALLATION ................................37

ADJUSTMENT ...............................................................39

Differential Side Bearing Preload ..............................39

ASSEMBLY ....................................................................41

RS5F70A

DESCRIPTION ...............................................................45

Cross-sectional View .................................................45

DOUBLE-CONE SYNCHRONIZER ............................46

MAJOR OVERHAUL .....................................................47

Transaxle Gear Control .............................................47

Case Components .....................................................48

Gear Components .....................................................49

Shift Control Components .........................................50

Final Drive Components ............................................51

DISASSEMBLY ..............................................................52

Transaxle Case ..........................................................52

Clutch Housing ..........................................................54

REPAIR FOR COMPONENT PARTS ...........................58

Input Shaft and Gears ...............................................58

DISASSEMBLY ........................................................58

INSPECTION ...........................................................59

ASSEMBLY .............................................................60

Mainshaft and Gears .................................................63

DISASSEMBLY ........................................................63

INSPECTION ...........................................................64

ASSEMBLY .............................................................66

Final Drive ..................................................................71

PRE-INSPECTION ...................................................71

DISASSEMBLY ........................................................72

INSPECTION ...........................................................72

RS5F32A

DESCRIPTION ...............................................................13

Cross-sectional View .................................................13

MAJOR OVERHAUL .....................................................14

Transaxle Gear Control .............................................14

Case Components .....................................................15

Gear Components .....................................................16

Shift Control Components .........................................17

DISASSEMBLY ..............................................................18

REPAIR FOR COMPONENT PARTS ............................21

Input Shaft and Gears ...............................................21

DISASSEMBLY ........................................................21

INSPECTION ...........................................................22

ASSEMBLY .............................................................23

Mainshaft and Gears .................................................24

DISASSEMBLY ........................................................24

INSPECTION ...........................................................26

ASSEMBLY .............................................................28

Final Drive ..................................................................32

DISASSEMBLY ........................................................32

CONTENTS (Cont’d)

ASSEMBLY .............................................................73

Shift Control Components .........................................74

INSPECTION ...........................................................74

ASSEMBLY . ...................................................................76

Clutch Housing ..........................................................76

Transaxle Case ..........................................................80

AVAILABLE C-RINGS ...............................................87

AVAILABLE SPACERS .............................................88

AVAILABLE WASHERS ............................................88

AVAILABLE SHIMS - DIFFERENTIAL SIDE

BEARING PRELOAD AND ADJUSTING SHIM . ...........88

INPUT SHAFT BRAKING MECHANISM .....................89

MAINSHAFT END PLAY ...........................................89

RS5F70A

SERVICE DATA AND SPECIFICATIONS (SDS) ..........86

General Specifications - RS5F32A and RS5F70A ....86

TRANSAXLE ...........................................................86

FINAL GEAR ...........................................................86

SERVICE DATA AND SPECIFICATIONS (SDS) .........90

Inspection and Adjustment - RS5F70A .....................90

GEAR END PLAY ....................................................90

CLEARANCE BETWEEN BAULK RING AND

GEAR .....................................................................90

AVAILABLE SNAP RINGS ........................................90

AVAILABLE C-RINGS ..............................................90

AVAILABLE ADJUSTING SHIMS ...............................91

AVAILABLE THRUST WASHER ................................92

AVAILABLE WASHERS ............................................92

AVAILABLE SHIMS - DIFFERENTIAL SIDE

BEARING PRELOAD AND ADJUSTING SHIM ...........92

RS5F32A

SERVICE DATA AND SPECIFICATIONS (SDS) ..........87

Inspection and Adjustment - RS5F32A .....................87

GEAR END PLAY ....................................................87

CLEARANCE BETWEEN BAULK RING AND

GEAR .....................................................................87

AVAILABLE CHECK PLUGS .....................................87

AVAILABLE SNAP RINGS ........................................87

MT-2

PREPARATION

Special Service Tools

NCMT0001

Tool number

Tool name

Description

KV38107700

Preload adapter

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.)

NT087

KV38106000

Height gauge adapter

(differential side bearing)

Selecting differential side bearing adjusting shim

(Use with KV38107700 or KV38105900.)

a: 140 mm (5.51 in)

b: 40 mm (1.57 in)

c: 16 mm (0.63 in) dia.

d: M8

1.25P

NT418

KV32101000

Pin punch

Removing and installing retaining pin

Removing and installing lock pin

Removing selector shaft

Removing welch plug

a: 4 mm (0.16 in) dia.

NT410

KV31100300

Pin punch

Removing and installing retaining pin

a: 4.5 mm (0.177 in) dia.

NT410

ST30031000

Puller

Removing 3rd, 5th input gear

Removing 3rd & 4th and 5th & Rev synchronizer

hub

Removing mainshaft rear bearing

Removing 2nd gear, 5th gear bushing

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.

NT411

ST30021000

Puller

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

bushing

Installing mainshaft rear bearing

a: 110 mm (4.33 in) dia.

b: 68 mm (2.68 in) dia.

NT411

ST22730000

Puller

Removing mainshaft front and rear bearing inner

race (F31A)

Removing 5th main gear

NT411

a: 82 mm (3.23 in) dia.

b: 30 mm (1.18 in) dia.

MT-3

PREPARATION

Special Service Tools(Cont’d)

Tool number

Tool name

Description

ST35321000

Drift

Removing differential side bearing

a: 49 mm (1.93 in) dia.

b: 41 mm (1.61 in) dia.

NT073

KV381054S0

Puller

Removing idler gear bearing outer race

a: 250 mm (9.84 in)

b: 160 mm (6.30 in)

NT414

ST33200000

Drift

Installing mainshaft front bearing outer race

(F31A)

Installing mainshaft front bearing (F32A)

a: 60 mm (2.36 in) dia.

b: 44.5 mm (1.752 in) dia.

NT091

ST33230000

Drift

Removing differential oil seal

Installing differential side bearing

a: 51 mm (2.01 in) dia.

b: 28.5 mm (1.122 in) dia.

NT084

ST33400001

Drift

Installing differential oil seal (F31A)

a: 60 mm (2.36 in) dia.

b: 47 mm (1.85 in) dia.

NT086

KV38102100

Drift

Installing differential oil seal

a: 44 mm (1.73 in) dia.

b: 24.5 mm (0.965 in) dia.

NT427

KV38100200

Drift

Installing differential oil seal

a: 65 mm (2.56 in) dia.

b: 49 mm (1.93 in) dia.

NT120

ST3072000

Drift

Installing side bearing outer race

a: 77 mm (3.03 in) dia.

b: 55.5 mm (2.185 in) dia.

NT115

MT-4

PREPARATION

Special Service Tools(Cont’d)

Tool number

Tool name

Description

ST22350000

Drift

Installing input shaft front and rear bearing

a: 34 mm (1.34 in) dia.

b: 28 mm (1.10 in) dia.

NT065

ST22360002

Drift

Installing mainshaft rear bearing inner race (F31A)

a: 29 mm (1.14 in) dia.

b: 23 mm (0.91 in) dia.

NT065

ST22452000

Drift

Installing 3rd and 4th main gear

Installing 5th gear bush

Installing 5th & Rev synchronizer hub

Installing Rev gear bush

Installing mainshft rear bearing

a: 45 mm (1.77 in) dia.

b: 36 mm (1.42 in) dia.

NT065

ST37750000

Drift

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.

NT065

ST23860000

Drift

Installing 2nd gear bush

a: 38 mm (1.50 in) dia.

b: 33 mm (1.30 in) dia.

NT065

ST01530000

Drift

Installing 3rd & 4th and 1st & 2nd synchronizer

hub

Installing mainshaft front bearing

a: 50 mm (1.97 in) dia.

b: 41 mm (1.61 in) dia.

NT065

KV38100130

Drift

Installing input shaft oil seal

Installing 5th input gear

a: 39 mm (1.54 in) dia.

b: 30 mm (1.18 in) dia.

NT065

ST30621000

Drift

Installing differential side bearing outer race

(Use with ST30611000.)

a: 79 mm (3.11 in) dia.

b: 59 mm (2.32 in) dia.

NT073

KV31103000

Drift

Installing differential oil seal (F32A)

Right and left sides

(Use with ST35325000.)

a: 56 mm (2.20 in) dia.

b: 49 mm (1.93 in) dia.

NT105

MT-5

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