Transcription of MANUAL TRANSMISSION C …
1 MT-1 MANUAL TRANSMISSIONC TRANSMISSION /TRANSAXLECONTENTSDEFGHIJKLM SECTION MTABMTR evision: 2004 December 2004 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 .. 8 TRIPLE-CONE SYNCHRONIZER .. 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 ..11 POSITION SWITCH .. 12 Checking .. 12 COMPONENT LOCATION .. 12 BACK-UP LAMP SWITCH .. 12 NEUTRAL POSITION SWITCH.
2 12 SHIFT CONTROL .. 13 Removal and Installation .. 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 .. 23 SHIFT CONTROL COMPONENTS .. 25 Disassembly and Assembly .. 27 DISASSEMBLY .. 27 INSPECTION AFTER DISASSEMBLY .. 37 ASSEMBLY .. 41 SERVICE DATA AND SPECIFICATIONS (SDS) .. 58 General Specifications .. 58 End Play .. 58 Snap Rings .. 59 Baulk Ring Clearance .. 60MT-2 PRECAUTIONSR evision: 2004 December 2004 350 ZPRECAUTIONSPFP:00001 CautionACS004NF Do not reuse TRANSMISSION oil, once it has been drained. Check oil level or replace oil with vehicle on level ground.
3 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 ServiceACS004 NGBefore disconnecting the battery, lower both the driver and passenger windows. 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.
4 The automaticwindow function will not work with the battery : 2004 December 2004 350 ZPREPARATIONPFP:00002 Special Service ToolsACS004 NHThe 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) Main shaft bearing installation 5th-6th synchronizer assembly installation Reverse main gear bushing installation 3rd gear bushing installation 3rd-4th synchronizer assembly installationST30022000( )a: 110 mm ( in) : 46 mm ( in) 3rd main gear installation 4th main gear installationST27861000( )a: 62 mm ( in) : 52 mm ( in) ring 1st-2nd synchronizer assembly installation 1st 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 December 2004 350 ZKV32102700( )a: 48 mm ( in) : 41 mm ( in) drive gear 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) rod oil seal installationKV40100630(J26092)a: 67 mm ( in) : 38 mm ( in) counter gear thrust washer installationKV38102100(J25803-01)a: 44 mm ( in) : 28 mm ( in) cover oil seal installationKV32103300(J46529)Press platea: 73 mm ( in)Reverse synchronizer assembly installation Tool number(Kent-Moore No.)Tool nameDescriptionZZA0534 DZZA0534 DZZA0534 DSCIA1575 EZZA0920 DNT084 PCIB0165 JPREPARATIONMT-5 DEFGHIJKLMABMTR evision: 2004 December 2004 350 ZST30031000(J22912-01)PullerInner baulk ring supportST22490000( )Adapter setting plateHold a adapter plateTool number(Kent-Moore No.)
6 Tool nameDescriptionZZC0499 DZZC0465 DMT-6 PREPARATIONR evision: 2004 December 2004 350 ZCommercial Service ToolsACS004 NITool 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 December 2004 350 ZNOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003 NVH Troubleshooting ChartACS004 NJUse 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-25M T-25MT-25MT-25MT-25MT-25 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 December 2004 350 ZDESCRIPTIONPFP:00000 Cross-Sectional ViewACS004 NKDOUBLE-CONE SYNCHRONIZERThe 1st and 3rd, 4th gears is equipped with a double-cone synchronizer to reduce the operating force of theshift lever as drive gear synchronizer coupling main main synchronizer coupling sleeve10. 1st main gear11. 3rd main gear12. 4th main gear13. Reverse main gear14. Reverse coupling sleeve15.
8 Reverse synchronizer hub16. Striking rod17. Counter shaft18. 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. Main shaft31. Rear extension PCIB0672 EDESCRIPTIONMT-9 DEFGHIJKLMABMTR evision: 2004 December 2004 350 ZTRIPLE-CONE SYNCHRONIZER The 2nd gear is equipped with a triple-cone synchronizer to reduce the operating force of the shift lever OILR evision: 2004 December 2004 350ZM/T OILPFP:KLD20 ReplacementACS004 NLDRAINING1. 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 torque.
9 Refer to MT-22, "CASE COMPONENTS" .CAUTION: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 torque. Refer to MT-22, "CASE COMPONENTS" .CAUTION: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 to MT-22, "CASE COMPONENTS" .CAUTION:Gaskets are not reusable.
10 Never reuse grade:API GL-4 Viscosity:Refer to MA-12, "Fluids and Lubricants" .Oil capacity:Approx. ( 3-1/8 US qt, 2-1/2 lmp qt)PCIB0268 EREAR OIL SEALMT-11 DEFGHIJKLMABMTR evision: 2004 December 2004 350 ZREAR OIL SEALPFP:33140 Removal and InstallationACS004 NNREMOVAL1. Remove propeller shaft. Refer to PR-7, "REMOVAL" .CAUTION:Do not impact or damage propeller shaft Using oil seal puller, remove rear oil Apply multi-purpose grease to rear oil seal lip. Using a drift,drive in rear oil seal until the edge is approximately - mm( - in) above the boss : Rear oil seals are not reusable. Never reuse them. When installing, do not incline the rear oil Install propeller shaft. Refer to PR-8, "INSTALLATION" .CAUTION: Do not impact or damage propeller shaft tube.
