MANUAL TRANSMISSION C …

1 MT-1 MANUAL TRANSMISSIONC TRANSMISSION /TRANSAXLECONTENTSDEFGHIJKLM SECTION MTABMTR evision; 2004 April2003 350 ZMANUAL TRANSMISSIONPRECAUTIONS .. 2 Caution .. 2 Precautions for Battery Service .. 2 PREPARATION .. 3 Special Service Tools .. 3 Commercial Service Tools .. 6 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .. 7 NVH Troubleshooting Chart .. 7 MANUAL TRANSMISSION .. 7 DESCRIPTION .. 8 Cross-Sectional View .. 8 DOUBLE-CONE SYNCHRONIZER (MODEL CODE NUMBER. CD000) .. 9 DOUBLE-CONE SYNCHRONIZER (MODEL CODE NUMBER. CD005) .. 9 TRIPLE-CONE SYNCHRONIZER (MODEL CODE NUMBER. CD005) .. 9M/T OIL .. 10 Replacement .. 10 DRAINING .. 10 FILLING .. 10 Checking .. 10 OIL LEAKAGE AND OIL LEVEL .. 10 REAR OIL SEAL ..11 Removal and Installation ..11 REMOVAL ..11 INSTALLATION.

2 11 POSITION SWITCH .. 12 Checking .. 12 COMPONENT LOCATION .. 12 BACK-UP LAMP SWITCH .. 12 NEUTRAL POSITION SWITCH .. 12 SHIFT CONTROL .. 13 Removal and Installation of Control Lever Assembly .. 13 REMOVAL .. 13 INSTALLATION .. 15 INSPECTION AFTER INSTALLATION .. 17 AIR BREATHER HOSE .. 18 Removal and Installation .. 18 TRANSMISSION ASSEMBLY .. 19 Removal and Installation from Vehicle .. 19 REMOVAL .. 19 INSTALLATION .. 21 Component Parts Drawing .. 22 CASE COMPONENTS .. 22 GEAR COMPONENTS (MODEL CODE NUM-BER. CD000) .. 23 GEAR COMPONENTS (MODEL CODE NUM-BER. CD005) .. 25 SHIFT CONTROL COMPONENTS .. 27 Disassembly and Assembly .. 29 DISASSEMBLY .. 29 INSPECTION AFTER DISASSEMBLY .. 39 ASSEMBLY .. 44 SERVICE DATA AND SPECIFICATIONS (SDS) .. 61 General Specifications.

3 61 End Play .. 62 Snap Rings .. 62 Baulk Ring Clearance (Model code number. CD000) .. 63 Baulk Ring Clearance (Model code number. CD005) .. 63MT-2 PRECAUTIONSR evision; 2004 April2003 350 ZPRECAUTIONSPFP:00001 CautionACS003TP Do not reuse TRANSMISSION oil, once it has been drained. Check oil level or replace oil with vehicle on level ground. During removal or installation, keep inside of TRANSMISSION clear of dust or dirt. Check for the correct installation status prior to removal or disassembly. If mating marks are required, becertain they do not interfere with the function of the parts they are applied to. In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. Iftightening sequence is specified, observe it. Be careful not to damage sliding surfaces and mating for Battery ServiceACS003 TQBefore disconnecting the battery, lower both the driver and passenger windows.

4 This will prevent any interfer-ence between the window edge and the vehicle when the door is opened/closed. During normal operation, thewindow slightly raises and lowers automatically to prevent any window to vehicle interference. The automaticwindow function will not work with the battery ; 2004 April2003 350 ZPREPARATIONPFP:00002 Special Service ToolsACS003T8 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated number(Kent-Moore No.)Tool nameDescriptionST30911000( )a: 98 mm ( in) : 40 mm ( in) ball bearing installation5th - 6th synchronizer assembly installationReverse main gear installationST30022000( )a: 110 mm ( in) : 46 mm ( in) main gear installation4th main gear installationST27861000( )a: 62 mm ( in) : 52 mm ( in) ring1st - 2nd synchronizer assembly installation1st gear bushing installationST33400001(J26082)a: 60 mm ( in) : 47 mm ( in) oil seal installationKV381054S0( )Oil seal pullerRemove rear oil sealST30032000(J26010-01)a: 80 mm ( in) : 31 mm ( in) rear bearing inner race installationZZA0920 DZZA0920 DZZA0832 DZZA0814 DZZA0601 DZZA0920 DMT-4 PREPARATIONR evision.

5 2004 April2003 350 ZKV32102700( )a: 48 mm ( in) : 41 mm ( in) drive gear ball bearing installationST23860000( )a: 38 mm ( in) : 33 mm ( in) counter gear installationST01530000( )a: 50 mm ( in) : 41 mm ( in) synchronizer assembly installationST35291000( )a: 40 mm ( in) : mm ( in) : mm ( in) shaft oil seal installationKV40100630(J26092)a: 67 mm ( in) : 38 mm ( in) 4th counter gear thrust washer installation 4th counter gear bushing installationKV38102100(J25803-01)a: 44 mm ( in) : 28 mm ( in) cover oil seal installationKV32103300(J46529)Press plateReverse main gear installation Tool number(Kent-Moore No.)Tool nameDescriptionZZA0534 DZZA0534 DZZA0534 DSCIA1575 EZZA0920 DZZA1002 DPCIB0165 JPREPARATIONMT-5 DEFGHIJKLMABMTR evision; 2004 April2003 350 ZST30031000(J22912-01)PullerInter balk ring supportST224490000( )Adapter plateHold a adapterTool number(Kent-Moore No.)

6 Tool nameDescriptionZZC0499 DZZC0465 DMT-6 PREPARATIONR evision; 2004 April2003 350 ZCommercial Service ToolsACS003T9 Tool nameDescriptionPullerEach bearing gear and bushing removalPin punchTip diameter: mm ( in) retaining pin removal and installationPower toolLoosening bolts and nutsPullerReverse synchronizer assembly removalReverse counter gear removalReverse main gear removalZZB0823 DZZA0815 DPBIC0190 ENT077 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGMT-7 DEFGHIJKLMABMTR evision; 2004 April2003 350 ZNOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003 NVH Troubleshooting ChartACS003 TAUse the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-tion. If necessary, repair or replace these TRANSMISSIONR eference pageMT-10MT-10MT-10MT-22MT-22MT-13MT-27M T-27MT-23MT-23MT-23MT-23 SUSPECTED PARTS(Possible cause)OIL (Oil level is low.)

7 OIL (Wrong oil.)OIL (Oil level is high.)GASKET (Damaged)OIL SEAL (Worn or damaged)SHIFT CONTROL LINKAGE (Worn)CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)SHIFT FORK (Worn)GEAR (Worn or damaged)BEARING (Worn or damaged)BAULK RING (Worn or damaged)INSERT SPRING (Damaged)SymptomsNoise1233 Oil leakage3122 Hard to shift or will not shift11222 Jumps out of gear1122MT-8 DESCRIPTIONR evision; 2004 April2003 350 ZDESCRIPTIONPFP:00000 Cross-Sectional ViewACS003 TRSCIA1559 EDESCRIPTIONMT-9 DEFGHIJKLMABMTR evision; 2004 April2003 350 ZDOUBLE-CONE SYNCHRONIZER (MODEL CODE NUMBER. CD000)Double-cone synchronizer is adopted for 1st and 2nd gear to reduceoperating force of the shift SYNCHRONIZER (MODEL CODE NUMBER. CD005)The 1st and 3rd, 4th gears is equipped with a double-cone synchronizer to reduce the operating force of theshift lever as SYNCHRONIZER (MODEL CODE NUMBER.)

8 CD005)The 2nd gear is equipped with a triple -cone synchronizer to reduce the operating force of the shift lever drive gear (5th gear) - 6th synchronizer - 6th coupling main main - 2nd synchronizer - 2nd coupling sleeve10. 1st main gear11. 3rd main gear12. 4th main gear13. Reverse main gear14. Reverse coupling sleeve15. Reverse synchronizer hub16. Control rod17. Countershaft18. Filler plug19. 6th counter gear20. 2nd counter gear21. 1st counter gear22. 3rd counter gear23. 3rd - 4th synchronizer hub24. 3rd - 4th coupling sleeve25. Drain plug26. 4th counter gear27. Reverse idler gear28. Reverse idler shaft29. Reverse counter gear30. Mainshaft31. Rear extension caseSCIA0820 EPCIB0233 EMT-10M/T OILR evision; 2004 April2003 350ZM/T OILPFP:KLD20 ReplacementACS003 TCDRAINING1.

9 Start the engine and warm up the TRANSMISSION unit After stopping engine, remove filler plug and drain plug and then drain After replace a new gasket on drain plug, screw drain plug into TRANSMISSION body and tighten to the spec-ified :Gaskets are not reusable. Never reuse Remove filler plug. Fill new oil into the TRANSMISSION to the level of the filler plug mounting After filling, check fluid level, replace a new gasket on filler plug, screw filler plug into TRANSMISSION body,and tighten to the specified :Gaskets are not reusable. Never reuse LEAKAGE AND OIL LEVEL Check if oil is leaking from TRANSMISSION or around it. Check oil level from filler plug mounting hole as shown in the :Never start engine while checking oil level. When screwing in filler plug with a new gasket, first screw intothe TRANSMISSION by hand, then tighten to the specified :Gaskets are not reusable.

10 Never reuse plug:: 30 - 39 N m ( - kg-m, 23 - 28 ft-lb)Oil grade:API GL-4 Viscosity:Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .Oil capacity:Approx. (3-1/4 US qt, 2-3/4 lmp qt)Filler plug:: 30 - 39 N m ( - kg-m, 23 - 28 ft-lb)Filler plug:: 30 - 39 N m ( - kg-m, 23 - 28 ft-lb)PCIB0268 EREAR OIL SEALMT-11 DEFGHIJKLMABMTR evision; 2004 April2003 350 ZREAR OIL SEALPFP:33140 Removal and InstallationACS003 TEREMOVAL1. Remove propeller shaft. Refer to PR-7, "REMOVAL" .CAUTION:Do not impact or damage propeller shaft Using oil seal puller, remove oil Apply multi-purpose grease to oil seal lip. Using a drift, drive inoil seal until the edge is approximately - mm ( in) above the boss : Oil seals are not reusable. Never reuse them. When installing, do not incline the oil Install propeller shaft.