6speed Manual Trans & Diff For Subaru WRX 2005

MANUAL TRANSMISSION
AND DIFFERENTIAL
6-SPEED (6MT)
GENERAL DESCRIPTION
MANUAL TRANSMISSION AND DIFFERENTIAL
1. General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND FRONT DIFFERENTIAL
Type 6-forward speeds and 1-reverse
1st 3.636
2nd 2.375
3rd 1.761
Transmission gear ratio 4th 1.346
5th 0.971
6th 0.756
Reverse 3.545
Front reduc- Type of gear Hypoid
Final
tion gear Gear ratio 3.900
Type of gear Helical
Transfer
Rear reduc- Gear ratio 1.000
tion gear Type of gear Hypoid
Final
Gear ratio 3.900
Front differ-
Type and number of gear AP TRAC
ential
Planetary gear
Center differ-
Type and number of gear (Internal gear: 1, Pinion gear: 6, Sun gear: 1 and Electromagnetic floating vari-
ential
able control multiple clutch)
Transmission gear oil GL-5
Transmission gear oil capacity 4.1 2 (4.3 US qt, 3.6 Imp qt)
2. TRANSMISSION GEAR OIL

Recommended oil
(1)
(2)
(3)
GL-5
(4)
( C) -30 -26 -15 -5 0 15 25 30
( F) -22 -15 5 23 32 59 77 86
90
85W
80W
75W -90
MT-00001
(1) Item
(2) Transmission gear oil
(3) API classification
(4) SAE viscosity No. and applicable temperature
6MT-2
GENERAL DESCRIPTION
B: COMPONENT
1. CLUTCH HOUSING
(2)
(3) (7)
(4)
(1) (6)
(5)
T2
(8)
(9)
(10)
(12)
T3
(13)
(11)
T1
T4
MT-00434
(1) Oil level gauge (8) Clutch housing Tightening torque: N·m (kgf-m, ft-lb)
(2) Oil seal (9) Speedometer driven gear T1: 6.4 (0.65, 4.7)
(3) Snap ring (10) Snap ring T2: 41 (4.2, 30.2)
(4) Washer (11) Gasket T3: 50 (5.1, 36.9)
(5) Speedometer gear shaft (12) Oil seal T4: 70 (7.1, 51.6)
(6) Pitching stopper bracket (13) Clutch release bearing guide
(7) Clip
6MT-3
GENERAL DESCRIPTION
2. ADAPTER PLATE
(1)
T3
(2)
T2
T2
(3)
(4)
(5) (7)
(9) (8)
(6) (10)
T1
T3
(12)
(13)
(11)
T1
MT-00435
(1) Breather hose (7) Plug (13) Oil chamber

(2) Transmission harness stay (8) Gasket
(3) Plug (9) Spring Tightening torque: N·m (kgf-m, ft-lb)
(4) Gasket (10) Ball T1: 6.4 (0.65, 4.7)
(5) Spring (11) Lubrication pipe T2: 37 (3.8, 27.3)
(6) Plunger (12) Adapter plate T3: 50 (5.1, 36.9)
6MT-4
GENERAL DESCRIPTION
3. TRANSMISSION CASE
T1
(4)
(9)
(2)
T3
T4 T1
(10)
(16)
(1) (6) T3
(16)
(16) (4)
(11)
(3)
(12)
(13)
(14)
(5) (16)
(15)
(8)
(16)
T5
T2
T2
(7)
T3
T3
(16) T1
MT-00436
(1) Pilot bolt (9) Return spring Tightening torque: N·m (kgf-m, ft-lb)
(2) Neutral switch (10) Pressure relief valve T1: 13 (1.3, 9.6)
(3) Back-up light switch (11) Return spring T2: 16 (1.6, 11.8)
(4) O-ring (12) Ball T3: 32 (3.3, 23.6)
(5) Adapter plate (13) Plunger T4: 34 (3.5, 25.1)
(6) Transmission case (14) Spring T5: 41 (4.2, 30.2)
(7) Oil pipe (15) Plug
(8) Harness bracket (16) Gasket
6MT-5
GENERAL DESCRIPTION
4. OIL PAN AND OIL PUMP
(2) (3)
(11)
(4)
(1)
T3
(12)
T3
(9)
(5) (13)
(6)
(7)
T2
(8)
T4
(10)
T1
MT-00438
(1) Main case (8) Oil pan Tightening torque: N·m (kgf-m, ft-lb)
(2) Oil pump cover (9) Plate T1: 6.4 (0.65, 4.7)
(3) Oil guide (10) Gasket T2: 10 (1.0, 7.4)
(4) Oil pump driven gear ASSY (11) Oil guide T3: 25 (2.5, 18.1)
(5) Oil pump rotor ASSY (12) Oil pipe T4: 44 (4.5, 32.5)
(6) Strainer ASSY (13) O-ring
(7) Magnet
6MT-6
GENERAL DESCRIPTION
5. EXTENSION CASE AND CENTER DIFFERENTIAL
(5) (17)
(4) (15)
(3) (16)
(2)
(14)
(1)
T3
(18)
(21)
(22)
(10)
(23)
(19) (24)
(9) (13) (20)
(8) (12)
(11) (31)
(25)
(27)
T1 (26)
(28)
(7)
(29) T2
(30)
(6)
MT-00945
(1) Taper roller bearing (13) Extension guide (25) Reverse check lever COMPL
(2) Transfer driven gear (14) Extension case (26) Straight pin
(3) Taper roller bearing (15) Oil seal (27) Reverse check plug
(4) Shim (16) Oil seal (28) Spring
(5) Oil plate (17) Dust cover (29) Gasket
(6) Center differential (18) Snap ring (30) Plug
(7) Shim (19) Washer (31) Plunger
(8) Needle bearing (20) Bush
(9) Needle bearing (21) Spring Tightening torque: N·m (kgf-m, ft-lb)
(10) Transfer drive gear (22) Reverse check shaft T1: 25 (2.5, 18.1)
(11) Ball bearing (with flange) (23) Ball bearing T2: 41 (4.2, 30.2)
(12) Snap ring (24) Oil seal T3: 48 (4.9, 35.4)
6MT-7
GENERAL DESCRIPTION
6. SHIFTER FORK AND FORK ROD
(10)
(9)
(8)
(7)
(15)
(1)
(1)
(6) (18)
(14) (1)
(5)
(4)
(1)
(3)
(1)
(1)
(2) (22)
(17)
(1)
(1)
(1)
(13)
(1)
(12) (16)
(1)
(20) (21)
(11)
(1)
(19)
(23)
(24)
MT-00980
(1) Spring pin (9) Support (17) 5th-6th shifter arm

(2) Interlock arm (10) Snap ring (18) 5th-6th fork COMPL
(3) Interlock block (11) Reverse fork COMPL (19) 3rd-4th fork rod
(4) Reverse interlock block (12) Reverse shifter arm (20) 3rd-4th shifter arm
(5) Interlock arm (13) Reverse fork rod (21) 1st-2nd shifter arm
(6) Striking rod (14) Selector arm COMPL (22) 3rd-4th fork COMPL
(7) Selector arm No. 2 (15) Shifter arm shaft (23) 1st-2nd fork rod
(8) Neutral set spring (16) 5th-6th fork rod (24) 1st-2nd fork COMPL
6MT-8
GENERAL DESCRIPTION
7. MAIN SHAFT ASSY
(13)
(1)
(12)
(9)
(11)
(10)
(8)
(7)
(6)
(5)
(4)
(3)
(2)
(22)
(20) (29)
(28)
(27)
(21) (26)
(25)
(19)
(24)
(15)
(18) (23)
(14) (17)
(16)
MT-00442
(1) Main shaft (12) 4th bush (23) Needle bearing

(2) Needle bearing (13) Needle bearing (24) 6th bush
(3) 3rd drive gear (14) 5th bush (25) Taper roller bearing
(4) Inner baulk ring (15) Needle bearing (26) Snap ring
(5) Synchro cone (16) 5th drive gear (27) Washer
(6) Outer baulk ring (17) 5th baulk ring (28) Washer
(7) 3rd-4th sleeve (18) 5th-6th sleeve (29) Lock nut
(8) 3rd-4th hub (19) 5th-6th hub
(9) Shifting insert (20) Shifting sleeve Tightening torque: N·m (kgf-m, ft-lb)
(10) 4th baulk ring (21) 6th baulk ring T: 392 (40.0, 289)
(11) 4th gear (22) 6th drive gear
6MT-9
GENERAL DESCRIPTION
8. DRIVE PINION AND DRIVEN SHAFT ASSY
(7)
(6)
(5)
(4)
(3)
(2)
T3 T1
(15)
(14)
(13) (24)
(1)
(23)
(12)
(11) (22)
(10)
(9)
(21)
(20)
(27)
(8)
(19) (26)
(25) T2
(18)
(17)
(16)
MT-00443
(1) Drive pinion shaft (13) 1st-2nd sleeve (25) Lock nut
(2) Taper roller bearing (14) Shifting insert (26) Shim
(3) Shim (15) 1st-2nd hub (27) Collar
(4) Washer (16) Outer baulk ring
(5) Lock nut (17) Synchro cone Tightening torque: N·m (kgf-m, ft-lb)
(6) Thrust bearing (18) Inner baulk ring T1: 285 (29.1, 210)
(7) Needle bearing (19) 2nd driven gear * 265 (27.0, 195)
(8) Driven shaft (20) Needle bearing T2: 570 (58.1, 420)
(9) Key (21) 2nd bush * 530 (54.0, 391)
(10) Needle bearing (22) 3rd-4th driven gear T3: 54 (5.5, 39.8)
(11) 1st driven gear (23) 5th-6th driven gear * Tightening torque when using ST.
(12) 1st synchro ring ASSY (24) Ball bearing
6MT-10
GENERAL DESCRIPTION
9. REVERSE IDLER GEAR ASSY
(7)
(6)
(5)
(4)
(3) (17)
T
(16)
(2) (15)
(1) (14)
(13)
(8)
(12)
(11)
(18)
(19) (10)
(9)
MT-00444
(1) Base (9) Reverse coupling sleeve (17) Reverse idler holder
(2) Washer (10) Reverse idler gear (18) Spring pin
(3) Reverse idler gear No. 2 (11) Spring (19) Knock pin
(4) Needle bearing (12) Sub gear
(5) Reverse idler synchro set (13) Friction plate Tightening torque: N·m (kgf-m, ft-lb)
(6) Reverse idler gear bush (14) Snap ring T: 25 (2.5, 18.1)
(7) Needle bearing (15) Washer
(8) Shifting insert (16) Snap ring
6MT-11
GENERAL DESCRIPTION
10.FRONT DIFFERENTIAL
(1)
(3)
(11) (2)
(4)
T2
(10) (7)
(6)
(8)
(7)
(3)
(5)
(8)
(6) (9)
(10)
T1
(5)
T1
(9)
MT-00446
(1) Drive pinion shaft (6) Differential side retainer (11) Speedometer drive gear
(2) Hypoid driven gear (7) O-ring
(3) Roller bearing (8) Axle drive shaft Tightening torque: N·m (kgf-m, ft-lb)
(4) Differential ASSY (9) Retainer lock plate T1: 25 (2.5, 18.1)
(5) Oil seal (10) Circlip T2: 69 (7.0, 50.9)
6MT-12
GENERAL DESCRIPTION
11.TRANSMISSION MOUNTING
(4) (6)
(3)
T4 (5)
(2)
T3
T2 T5
(1) T1 (7)
(8)
(3)
(2)
(9)
(7)
T2
(11)
T5
(10)
T5
T6
MT-00972
(1) Pitching stopper (7) Cushion D Tightening torque: N·m (kgf-m, ft-lb)
(2) Spacer (8) Center crossmember T1: 7.5 (0.76, 5.5)
(3) Cushion C (9) Rear plate T2: 35 (3.6, 25.8)
(4) Front plate (10) Front crossmember T3: 50 (5.1, 36.9)
(5) Rear cushion rubber (11) Dynamic dumper T4: 58 (5.9, 42.8)
(6) Rear crossmember T5: 70 (7.1, 51.6)
T6: 140 (14.3, 103)
6MT-13
GENERAL DESCRIPTION
C: CAUTION • Be sure to tighten fasteners including bolts and

• Wear working clothing, including a cap, protec- nuts to the specified torque.
tive goggles, and protective shoes during opera- • Place shop jacks or safety stands at the specified
tion. points.
• Remove contamination including dirt and corro- • Apply gear oil onto sliding or revolution surfaces
sion before removal, installation, and disassembly. before installation.
• Keep the disassembled parts in order and pro- • Replace deformed or otherwise damaged snap
tect them from dust or dirt. rings with new ones.
• Before removal, installation or disassembly, be • Before installing O-rings or oil seals, apply suffi-
sure to clarify the failure. Avoid unnecessary re- cient amount of gear oil to avoid damage and defor-
moval, installation, disassembly and replacement. mation.
• When disassembling the case and other light al- • Be careful not to incorrectly install or fail to install
loy parts, use a plastic hammer to force it apart. Do O-rings, snap rings and other such parts.
not pry it apart with a screwdriver or other tool. • Before securing a part on a vise, place cushion-
• Be careful not to burn your hands, because each ing material such as wood blocks, aluminum plate,
part on the vehicle is hot after running. or shop cloth between the part and the vise.
• Use SUBARU genuine gear oil, grease etc. or • Avoid damaging the mating surface of the case.
the equivalent. Do not mix gear oil, grease etc. with • Before applying sealant, completely remove the
that of another grade or from other manufacturers. old seal.
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
398791700 REMOVER Used for removing and installing spring pin (6
mm).
ST-398791700
399527700 PULLER SET Used for removing and installing roller bearing
(Differential).
(1) BOLT
(2) PULLER
(3) HOLDER
(4) ADAPTER
(5) BOLT
(6) NUT
ST-399527700
6MT-14
GENERAL DESCRIPTION

498515700 REMOVER Used for removing roller bearing of drive pinion
shaft.
ST-498515700
498147000 DEPTH GAUGE Used for adjusting main shaft axial end play.
ST-49814700
498247001 MAGNET BASE • Used for measuring backlash between side
gear and pinion, and hypoid gear.
• Used with DIAL GAUGE (498247100).
ST-498247001
498247100 DIAL GAUGE • Used for measuring backlash between side
gear and pinion, and hypoid gear.
• Used with MAGNET BASE (498247001).
ST-498247100
6MT-15
GENERAL DESCRIPTION

498077000 REMOVER Used for removing differential taper roller bear-
ing.
ST-498077000
899858600 REMOVER Used for removing roller bearing.
ST-899858600
399513600 INSTALLER Used for installing oil seal.
ST-399513600
499757002 INSTALLER Used for installing bearing cone of transfer
driven gear (extension core side).
ST-499757002
6MT-16
GENERAL DESCRIPTION

499787000 WRENCH ASSY Used for removing and installing differential side
retainer.
ST-499787000
499827000 PRESS Used for installing speedometer oil seal when
installing speedometer cable to transmission.
ST-499827000
499877000 RACE 4-5 Used for disassembling driven shaft and transfer
INSTALLER driven gear.
ST-499877000
899864100 REMOVER Used for removing parts on transmission main
shaft and drive pinion.
ST-899864100
6MT-17
GENERAL DESCRIPTION

899904100 REMOVER Used for removing and installing straight pin.
ST-899904100
899824100 PRESS Used for installing speedometer shaft oil seal.
ST-899824100
498057300 INSTALLER Used for installing extension oil seal.
ST-498057300
498255400 PLATE Used for measuring backlash.
ST-498255400
6MT-18
GENERAL DESCRIPTION

41099AA000 ENGINE SUPPORT Used for supporting engine.
BRACKET (1) ENGINE SUPPORT BRACKET
(41099AA010)
(2) ENGINE SUPPORT (41099AA020)
(1)
(2)
ST41099AA000
398527700 PULLER ASSY Used for removing extension case oil seal and
clutch housing oil seal.
ST-398527700
499575500 GAUGE Used for measuring total end play, extension
end play and drive pinion height.
ST-499575500
398177700 INSTALLER Used for assembling main shaft.
ST-398177700
6MT-19
GENERAL DESCRIPTION

399893600 PLIERS • Used for removing and installing neutral set
spring.
• Used with CLAW (18756AA000).
ST-399893600
499247300 INSTALLER • Used for removing axle shaft.
• Used with REMOVER ASSY (499095500).
ST-499247300
499095500 REMOVER ASSY • Used for removing axle shaft.
• Used with INSTALLER (499247300).
ST-499095500
499247400 INSTALLER Used for installing transfer drive gear ball bear-
ing.
ST-499247400
6MT-20
GENERAL DESCRIPTION

499797000 OIL SEAL Used for installing differential side retainer oil
INSTALLER seal.
ST-499797000
398497701 SEAT Used for installing transfer drive gear ball bear-
ing.
ST-398497701
398437700 INSTALLER Used for installing front differential side bearing.
ST-398437700
18632AA000 STAND ASSY Used for disassembling and assembling trans-
(Newly adopted tool) mission.
ST18632AA000
6MT-21
GENERAL DESCRIPTION

18671AA000 OIL SEAL GUIDE • Used for installing oil seal to reverse check.
(Newly adopted tool) • Used with INSTALLER (18657AA010).
ST18671AA000
18657AA010 INSTALLER • Used for installing oil seal to reverse check.
(Newly adopted tool) • Used with OIL SEAL GUIDE (18671AA000).
ST18657AA010
18657AA000 INSTALLER Used for installing oil seal to shift rod.
(Newly adopted tool)
ST18657AA000
18758AA000 PULLER Used for removing extension taper roller bearing
(Newly adopted tool) outer race.
ST18758AA000
6MT-22
GENERAL DESCRIPTION

18831AA000 GAUGE Used for measuring extension taper roller bear-
(Newly adopted tool) ing.
ST18831AA000
18631AA000 HANDLE Used for measuring front differential backlash.
ST18631AA000
18756AA000 CLAW • Used for installing and removing neutral set
(Newly adopted tool) spring.
• Used with PLIERS (399893600).
ST18756AA000
18754AA000 REMOVER Used for removing each parts of driven gear.
ST18754AA000
6MT-23
GENERAL DESCRIPTION

18757AA000 STRAIGHT PIN Used for installing reverse idler gear.
(Newly adopted tool) REMOVER
ST18757AA000
18665AA000 HOLDER • Used for installing and removing main shaft
(Newly adopted tool) lock nut.
• Used with BASE (18664AA000).
ST18665AA000
18666AA000 HOLDER • Used for installing and removing driven shaft
ST18666AA000
18667AA000 HOLDER • Used for installing and removing drive pinion
(Newly adopted tool) shaft lock nut.
ST18667AA000
6MT-24
GENERAL DESCRIPTION

18664AA000 BASE • Used for installing and removing main shaft
• Used for installing and removing drive pinion
shaft lock nut.
• Used for installing and removing driven shaft
lock nut.
ST18664AA000
18722AA010 REMOVER Used for disassembling main shaft.
ST18722AA010
18651AA000 INSTALLER Used for assembling main shaft.
ST18651AA000
18852AA000 TORQUE WRENCH • Used for tightening main shaft lock nut.
(Newly adopted tool) • Used for tightening drive pinion shaft lock nut.
• Used for tightening driven shaft lock nut.
ST18852AA000
6MT-25
GENERAL DESCRIPTION

18668AA000 PUNCH Used for caulking main shaft lock nut.
ST18668AA000
18669AA000 PUNCH Used for caulking driven shaft lock nut.
ST18669AA000
18670AA000 PUNCH Used for caulking drive pinion shaft lock nut.
ST18670AA000
18620AA000 ADAPTER Used for installing and removing driven gear
(Newly adopted tool) WRENCH shaft lock nut.
ST18620AA000
6MT-26
GENERAL DESCRIPTION

18621AA000 ADAPTER Used for installing and removing drive pinion
(Newly adopted tool) WRENCH shaft lock nut.
ST18621AA000
18723AA000 REMOVER Used for disassembling the driven shaft.
ST18723AA000
18630AA000 WRENCH ASSY Used for removing and installing differential side
(Newly adopted tool) retainer (left side).
ST18630AA000
18672AA000 GUIDE CLIP Used for installing reverse idler gear snap ring.
ST18672AA000
6MT-27
GENERAL DESCRIPTION

18720AA000 REMOVER Used for disassembling main shaft.
ST18720AA000
18654AA000 INSTALLER Used for assembling driven shaft.
ST18654AA000
18663AA000 SOCKET Used for installing and removing oil pump cover.
ST18663AA000
18853AA000 HEIGHT GAUGE Used for selecting shift rod.
ST18853AA000
6MT-28
GENERAL DESCRIPTION

18760AA000 CLAW • Used for removing front side retainer bearing
(Newly adopted tool) outer race.
• Used with PULLER ASSEMBLY (398527700).
ST18760AA000
2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS
Circuit Tester Used for measuring resistance, voltage and ampere.
6MT-29
TRANSMISSION GEAR OIL
2. Transmission Gear Oil B: REPLACEMENT

1) Pull out the oil level gauge.
A: INSPECTION 2) Lift-up the vehicle.
1) Park the vehicle on a level surface. 3) Remove the transmission under cover.
2) Turn the ignition switch to OFF, and wait until the 4) Drain the transmission gear oil completely.
engine cools.
3) Remove the oil level gauge and wipe it clean. CAUTION:
4) Reinsert the level gauge all the way. Be sure that Directly after the engine has been running, the
the level gauge is correctly inserted and in the transmission gear oil is hot. Be careful not to
proper direction. burn yourself.
5) Pull out the oil level gauge again and check the NOTE:
oil level on it. If it is below the lower level, add oil • Tighten the transmission gear oil drain plug after
through the oil level gauge hole to bring the level up draining transmission gear oil.
to the upper level. • Always use a new gasket.
Tightening torque:
(A)
Oil pan side
44 N·m (4.5 kgf-m, 32.5 ft-lb)
(A) Clutch housing side
70 N·m (7.1 kgf-m, 51.6 ft-lb)
(B)
(C)
(A)
MT-00449
(B)
(A) Oil level gauge
(B) Upper level
(C) Lower level
MT-00450
(A) Drain plug (Oil pan side)

(B) Drain plug (Clutch housing side)
5) Lower the vehicle.

6) Pour gear oil into the gauge hole.
Recommended gear oil:
Use GL-5 or equivalent.
Gear oil capacity:
4.1 2 (4.3 US qt, 3.6 Imp qt)
7) Check the level of the transmission gear oil.
NOTE:
• When inserting the level gauge into transmission
gear, align the protrusion on the side of the top part
of the level gauge with the notch in the gauge hole.
• The gear oil level should be within the specified
range marked on the level gauge.
6MT-30
OIL SEAL
3. Oil Seal 6) Using the ST, install the oil seal.

ST 498057300 INSTALLER
A: INSPECTION
Inspect for oil leakage from the oil seal. Replace
the oil seal if the lips is deformed, hardened, dam-
aged, worn or defective if any.
B: REPLACEMENT
1) Clean the transmission exterior.
2) Drain the gear oil completely.
NOTE:
• Tighten the drain plug after draining gear oil.
• Always use a new gasket. MT-00099
Tightening torque: 7) Install the propeller shaft. <Ref. to DS-15, IN-

Oil pan side STALLATION, Propeller Shaft.>
44 N·m (4.5 kgf-m, 32.5 ft-lb) 8) Install the rear exhaust pipe and muffler.
Clutch housing side 9) Pour gear oil and check the oil level. <Ref. to
70 N·m (7.1 kgf-m, 51.6 ft-lb) 6MT-30, REPLACEMENT, Transmission Gear
Oil.>
(A)
(B)
MT-00450

3) Remove the rear exhaust pipe and muffler.

4) Remove the propeller shaft. <Ref. to DS-14, RE-
MOVAL, Propeller Shaft.>
5) Using the ST, remove the oil seal.
ST 398527700 PULLER ASSY
(A)
ST
MT-00451
(A) Oil seal
6MT-31
VEHICLE SPEED SENSOR
4. Vehicle Speed Sensor

A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the intercooler. <Ref. to IN(H4DOTC)-
10, REMOVAL, Intercooler.>
3) Disconnect the vehicle speed sensor connector.
MT-00452
4) Remove the vehicle speed sensor.

B: INSTALLATION
1) Align the tip end of vehicle speed sensor key
with key groove on the end of speedometer shaft,
and then install it.
Tightening torque:
5.9 N·m (0.6 kgf-m, 4.4 ft-lb)
NOTE:
• Ensure the sensor mounting hole is clean and
free of foreign matter.
• Discard the vehicle speed sensor after removal,
and replace it with a new one.
MT-00452
2) Connect the connector to vehicle speed sensor.

3) Install the intercooler. <Ref. to IN(H4DOTC)-10,
INSTALLATION, Intercooler.>
C: INSPECTION
Inspect that the speedometer is normally operated,
because vehicle speed sensor cannot be inspected
as a single part. If it is not normally operated, in-
spect the combination meter system. <Ref. to IDI-
3, INSPECTION, Combination Meter System.>
6MT-32
TRANSMISSION MOUNTING SYSTEM
5. Transmission Mounting Sys- B: INSTALLATION

tem 1. PITCHING STOPPER
A: REMOVAL 1) Install the pitching stopper.
1. PITCHING STOPPER Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
1) Disconnect the ground cable from battery. T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
3) Remove the pitching stopper.
T1
T2
MT-00085
2) Install the intercooler.

MT-00069 <Ref. to IN(H4DOTC)-10, INSTALLATION, Inter-
cooler.>
2. CROSSMEMBER AND CUSHION RUB- 3) Connect the battery ground cable to battery.
BER
2. CROSSMEMBER AND CUSHION RUB-
BER
2) Jack-up the vehicle and support it with sturdy
racks. 1) Install the rear cushion rubber.
3) Remove the center exhaust pipe. <Ref. to Tightening torque:
EX(H4DOTC)-8, REMOVAL, Center Exhaust 35 N·m (3.6 kgf-m, 25.8 ft-lb)
Pipe.>
2) Install the crossmember.
4) Remove the rear exhaust pipe and muffler.
5) Set the transmission jack under the transmission Tightening torque:
body. T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb)
CAUTION: T2: 140 N·m (14.3 kgf-m, 103 ft-lb)
Always support the transmission case with a
transmission jack.
6) Remove the rear crossmember.
T1 T1
T2
T2
MT-00453
3) Remove the transmission jack.

4) Install the center exhaust pipe. <Ref. to
MT-00454 EX(H4DOTC)-9, INSTALLATION, Center Exhaust
7) Remove the rear cushion rubber. Pipe.>
5) Install the rear exhaust pipe and muffler.
6MT-33
TRANSMISSION MOUNTING SYSTEM
C: INSPECTION
Repair or replace parts if the results of the inspec-
tion below are not satisfactory.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Make sure that the rubber is not stiff,
cracked, or otherwise damaged.
2. CROSSMEMBER AND CUSHION RUB-
BER
Make sure that the crossmember is not bent or
damaged. Make sure that the cushion rubber is not
stiff, cracked, or otherwise damaged.
6MT-34
MANUAL TRANSMISSION ASSEMBLY
6. Manual Transmission As- 8) Disconnect the ground cable at upper side of

transmission case and body.
sembly
A: REMOVAL
1) Set the vehicle on a lift, and then open the front
hood and support it with hood stay.
NOTE:
Set the hood stay to its specified hole.
2) Remove the front wheel.
4) Remove the intercooler assembly. <Ref. to
IN(H4DOTC)-10, REMOVAL, Intercooler.> MT-00456
5) Lift-up the vehicle, and then remove the under
cover.
6) Remove the steering universal joint. <Ref. to
PS-18, REMOVAL, Universal Joint.>
7) Lower the vehicle and disconnect the connector
located on upper side of transmission.
(A)
MT-00457
(B)
9) Remove the starter assembly. <Ref. to
SC(H4SO)-7, REMOVAL, Starter.>
10) Remove the clutch operating cylinder.
NOTE:
MT-00455
Hang the removed operating cylinder with a wire,
etc.
(A) Transmission connector
(B) Vehicle speed sensor connector
MT-00458
11) Remove the clutch release shaft.

(1) Remove the plug with hexagon wrench.
(2) Install a 6 mm (0.24 in) bolt to the release
shaft, then pull out the release shaft.
(3) Lift up the release fork, and then remove it
from the release bearing claw. Pull it to the en-
gine side and set it free.
12) Remove the pitching stopper, and then remove
the pitching stopper bracket.
6MT-35
13) Set the ST. 18) Using the ST, remove the spring pin of front
ST 41099AA000 ENGINE SUPPORT drive shaft.
ST 398791700 REMOVER
NOTE:
Do not reuse the spring pin.
ST
MT-00459
14) Remove the center and rear exhaust pipe and

muffler. <Ref. to EX(H4DOTC)-8, REMOVAL, Cen-
ter Exhaust Pipe.>, <Ref. to EX(H4DOTC)-13, RE- MT-00461
MOVAL, Rear Exhaust Pipe.>, <Ref. to
EX(H4DOTC)-12, REMOVAL, Joint Pipe.> 19) Remove the front drive shaft.
15) Remove the propeller shaft. <Ref. to DS-14, 20) Set the transmission jack under the transmis-
REMOVAL, Propeller Shaft.> sion, then remove the front crossmember and rear
crossmember.
16) Remove the front stabilizer bolt.
MT-00454
MT-00076
21) Move the transmission to right side, then re-
17) Remove the ball joint of transverse link from
move the joint COMPL, stay bolt and reverse check
housing.
cable.
NOTE:
If the transmission is not moved, the joint COMPL
and stay bolt will contact body and damage may
occur.
(C)
(A)
MT-00460 (B)
MT-00886
(A) Joint COMPL bolt

(B) Stay bolt
(C) Reverse check cable
6MT-36
22) Remove the fixing bolt of engine and transmis- 3) Move the transmission to the right side, then in-
sion, then remove the transmission from vehicle. stall the joint COMPL bolt, stay bolt and reverse
NOTE: check cable.
• Rotate the ST (ENGINE SUPPORT ASSY) Tightening torque:
counterclockwise (to shorten the ST) and lower the T1: 11.8 N·m (1.2 kgf-m, 8.7 ft-lb)
rear side of engine to facilitate removal. T2: 32 N·m (3.3 kgf-m, 23.6 ft-lb)
• Take care not to contact the transmission with
body when pulling backward to remove. (A)
• Remove the clutch pipe and breather pipe care-
fully which may interfere each other. T1
T2
MT-00465
(A) Reverse check cable
MT-00462 4) Install the front crossmember and rear cross-

member.
NOTE:
Rotate the ST (ENGINE SUPPORT ASSY) turn
buckle clockwise (to make longer the ST) and lift up
the rear side of engine to facilitate installation.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb)
T2: 140 N·m (14.3 kgf-m, 103 ft-lb)
MT-00463
B: INSTALLATION
1) Set the release fork, release bearing and release T1 T1
shaft to transmission. <Ref. to CL-16, INSTALLA-
TION, Release Bearing and Lever.>
2) Install the transmission. T2
T2
NOTE:
• Make sure the main shaft spline part is inserted MT-00453
completely.
• Make sure the rear side of engine is lowered. 5) Lower the vehicle and install the fixing bolt.
Tightening torque: Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb) 50 N·m (5.1 kgf-m, 36.9 ft-lb)
MT-00466
MT-00464
6MT-37
6) Make sure the release bearing is installed com- 10) Install the starter assembly.
pletely.
Tightening torque:
NOTE: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
• Push the release fork to operating cylinder side 11) Install the transmission and body ground cable.
until you hear a “click” sound. Pull the release fork
to engine side. Setting is completed if the release
fork does not contact the case.
• Make sure the boot cover is firmly set.
MT-00456
MT-00467
7) Install the pitching stopper bracket.

Tightening torque:
41 N·m (4.2 kgf-m, 30.2 ft-lb)
8) Install the pitching stopper.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb) MT-00457
T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb) 12) Connect the connector located on the upper
side of transmission.
(A)
T1
T2
(B)
MT-00085
MT-00455
9) Install the clutch operating cylinder.
Tightening torque: (A) Vehicle speed sensor connector
41 N·m (4.2 kgf-m, 30.2 ft-lb) (B) Transmission connector
NOTE:
13) Lift-up the vehicle, and then install the drive
Check that the clutch hose is routed properly.
shaft.
14) Using the ST, install the spring pin of front drive
shaft.
MT-00458
6MT-38
NOTE: 19) Install the rear exhaust pipe and muffler. <Ref.
Align each chamfered part of front drive shaft and to EX(H4DOTC)-13, INSTALLATION, Rear Ex-
axle drive shaft spring pin hole, and assemble haust Pipe.>, <Ref. to EX(H4DOTC)-12, INSTAL-
them. Then insert the spring pin. LATION, Joint Pipe.>
20) Install the universal joint. <Ref. to PS-18, IN-
STALLATION, Universal Joint.>
21) Install the under cover.
22) Install the intercooler assembly. <Ref. to
IN(H4DOTC)-10, INSTALLATION, Intercooler.>
23) Connect the battery ground cable to battery.
MT-00461
15) Install the ball joint of transverse link to hous-

ing.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
MT-00460
16) Install the stabilizer nut.

Tightening torque:
45 N·m (4.6 kgf-m, 33.2 ft-lb)
NOTE:
Discard the loosened self-locking nut and replace
with a new one.
MT-00076
17) Install the propeller shaft. <Ref. to DS-15, IN-

STALLATION, Propeller Shaft.>
18) Install the center exhaust pipe. <Ref. to
EX(H4DOTC)-9, INSTALLATION, Center Exhaust
Pipe.>
6MT-39
PREPARATION FOR OVERHAUL
7. Preparation for Overhaul

A: PROCEDURE
1) Clean oil, grease, dirt and dust from transmis-
sion.
2) Remove the drain plug to drain oil. After drain-
ing, retighten it as before.
NOTE:
Replace the gasket with a new one.
Tightening torque:
Oil pan side
44 N·m (4.5 kgf-m, 32.5 ft-lb)
Clutch housing side
70 N·m (7.1 kgf-m, 51.6 ft-lb)
(A)
(B)
MT-00450

3) Attach the transmission to ST.

ST 18632AA000 STAND ASSY
ST
ST
ST
MT-00468
4) Rotating parts should be coated with oil prior to

assembly.
5) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.
6) Gaskets, lock washers and lock nut must be re-
placed with new ones.
7) Liquid gasket should be used where specified to
prevent leakage.
6MT-40
AIR BREATHER HOSE
8. Air Breather Hose

A: REMOVAL
Disconnect the air breather hose.
MT-00469
B: INSTALLATION
Install the air breather hose.
MT-00469
C: INSPECTION
Make sure the hose is not cracked or clogged.
6MT-41
OIL PIPE
9. Oil Pipe
A: REMOVAL
Remove the oil pipe.
NOTE:
Always use a new gasket.
MT-00470
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
32 N·m (3.3 kgf-m, 23.6 ft-lb)
MT-00470
C: INSPECTION
1) Make sure there is no damage on pipe. If there is
damage, replace the pipe.
2) Check the joint parts of pipe for oil leakage. If
there is oil leakage, replace the gasket.
6MT-42
BACK-UP LIGHT SWITCH
10.Back-up Light Switch B: INSTALLATION

1) Install the back-up light switch.
A: REMOVAL
1) Remove the manual transmission assembly Tightening torque:
from vehicle. <Ref. to 6MT-35, REMOVAL, Manual 32 N·m (3.3 kgf-m, 23.6 ft-lb)
Transmission Assembly.>
2) Disconnect the back-up light switch connector. (A)
(B)
(A)
(C)
(C)
MT-00472
(B) MT-00471 (A) Back-up light switch

(B) Neutral position switch
(A) Back-up light switch connector (White)
(B) Neutral position switch connector (Black)
2) Connect the back-up light switch connector.
(C) Clip
3) Remove the back-up light switch.
(A)
(A)
(B) (C)
(C)
(B) MT-00471

MT-00472 (B) Neutral position switch connector (Black)
(C) Clip
(A) Back-up light switch
3) Install the manual transmission assembly to ve-
hicle. <Ref. to 6MT-37, INSTALLATION, Manual
6MT-43
BACK-UP LIGHT SWITCH
C: INSPECTION
3) Disconnect the transmission harness and chas-
sis harness.
(A)
MT-00473
4) Measure the resistance between back-up light

switch terminals. If it is not within specifications, re-
place the back-up light switch.
Gear shift position Terminal No. Specified resistance
Back-up position Less than 1 Ω
3 and 6
Other positions More than 1 MΩ
3 2 1
6 5 4
MT-00946
6MT-44
NEUTRAL POSITION SWITCH
11.Neutral Position Switch B: INSTALLATION

1) Install the neutral position switch.
A: REMOVAL
2) Disconnect the neutral position switch connector (A)
and clip. (B)
(A)
(C)
(C)
MT-00472

(B) MT-00471 (B) Neutral position switch
(A) Back-up light switch connector (White) 2) Connect the neutral position switch connector
(B) Neutral position switch connector (Black)
and clip.
(C) Clip
3) Remove the neutral position switch.
(A)
(A)
(B) (C)
(C)
(B) MT-00471

MT-00472 (B) Neutral position switch connector (Black)
(C) Clip
6MT-45
NEUTRAL POSITION SWITCH
C: INSPECTION
3) Disconnect the transmission harness and chas-
sis harness.
(A)
MT-00473
4) Measure the resistance between neutral posi-

tion switch terminals. If it is not within specifica-
tions, replace the neutral position switch.
Gear shift position Terminal No. Specified resistance
Neutral position Less than 1 Ω
2 and 5
Other positions More than 1 MΩ
3 2 1
6 5 4
MT-00947
6MT-46
EXTENSION CASE
12.Extension Case 5) Install the extension case.
A: REMOVAL Tightening torque:

48 N·m (4.9 kgf-m, 35.4 ft-lb)
1) Remove the manual transmission assembly
from vehicle. <Ref. to 6MT-35, REMOVAL, Manual
2) Prepare the transmission for overhaul. <Ref. to
6MT-40, Preparation for Overhaul.>
3) Remove the extension case.
MT-00475
NOTE:
Insert the stopper portion of center differential be-
tween extension guides.
MT-00475 (B)
4) Completely remove the remaining liquid gasket

from the extension case and transmission case. (C)
B: INSTALLATION
1) Select the transfer driven gear thrust washer,
and then install it to extension case. <Ref. to 6MT-
49, ADJUSTMENT, Extension Case.>
2) Apply oil lightly to the outer periphery of bearing (A)
cone, and then install it to extension case. (D)
3) Select the thrust washer of transfer drive gear,
and then install it to center differential.
4) Apply liquid gasket to the transmission case.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007)
MT-00973
(A) Extension guides

(B) Stopper
(C) Center differential
MT-00476
(D) Extension case

6MT-47
EXTENSION CASE
C: DISASSEMBLY 5) Remove the thrust washer and oil plate.

1) Remove the transfer drive gear. <Ref. to 6MT-
56, REMOVAL, Transfer Drive Gear.> (B)
(A)
2) Remove the extension guide.
MT-00480
(A) Thrust washer

MT-00477 (B) Oil plate
3) Remove the shift bracket. 6) Remove the shifter arm oil seal.
(A)
MT-00478 MT-00481
4) Using the ST, remove the bearing cone. (A) Oil seal
ST 18758AA000 PULLER
7) Remove the reverse checking system. <Ref. to
6MT-53, REMOVAL, Reverse Checking System.>
(A)
8) Remove the extension oil seal. <Ref. to 6MT-31,
REPLACEMENT, Oil Seal.>
ST
MT-00479
(A) Bearing cone
6MT-48
EXTENSION CASE
D: ASSEMBLY 8) Install the extension guide, and then install the

1) Install the reverse checking system. <Ref. to transfer driven gear. <Ref. to 6MT-56, INSTALLA-
6MT-54, INSTALLATION, Reverse Checking Sys- TION, Transfer Drive Gear.>
tem.> E: INSPECTION
2) Install the extension case oil seal. <Ref. to 6MT- 1) Make sure there is no damage or crack on ex-
31, REPLACEMENT, Oil Seal.> tension case. If there is damage or crack, replace
3) Using the ST, install the shifter arm oil seal. the extension case.
ST1 18657AA000 INSTALLER 2) Check each oil seal and joint part of extension
ST2 18671AA000 OIL SEAL GUIDE case and transmission case for oil leakage. If there
is oil leakage, replace the oil seal and liquid gasket.
F: ADJUSTMENT
ST1
1. TRANSFER DRIVEN GEAR BEARING
THRUST WASHER ADJUSTMENT
(A) 1) Using the ST, remove the bearing cone from ex-
tension case.
ST 18758AA000 PULLER
ST2
MT-00482
(A)
(A) Oil seal

ST
4) Install the oil plate.
MT-00479
(A) Bearing cone
2) Remove the thrust washer.
MT-00483
5) Select the bearing thrust washer, and then install

it to extension case. <Ref. to 6MT-49, ADJUST-
MENT, Extension Case.>
6) Apply oil lightly to the outer periphery of bearing
cone, and then install it to extension case.
7) Install the shift bracket.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
MT-00478
6MT-49
EXTENSION CASE
3) Measure the depth “Z” between end of extension ST2 399863600 PLIERS
case and contact point of bearing cone.
ST 499575500 GAUGE
NOTE: ST2
To measure the depth “Z”, subtract the thickness of
ST [15 mm (0.59 in)] from the measured value.
ST1
ST MT-00486
8) Lift-up the striking rod and remove the spring

pin.
ST
(A)
(A)
(B)
MT-00487
(A) Striking rod

(B) Spring pin
MT-00948
9) Remove the selector arm No. 2 and shifter arm.
(A) 15 mm (0.59 in)
4) Remove the transfer driven gear. <Ref. to 6MT-

58, REMOVAL, Transfer Driven Gear.> (A)
5) Remove the center differential. <Ref. to 6MT-60,
REMOVAL, Center Differential.>
6) Remove the snap ring and support from selector
arm part.
(B)
(A)
MT-00976
(B)
(A) Selector arm No. 2

(B) Shifter arm
10) Install the bearing cone to transfer driven gear.
MT-00485
(A) Snap ring

(B) Support
7) Using the ST, remove the neutral set spring and

support.
ST1 18756AA000 CLAW
6MT-50
EXTENSION CASE
11) Set the ST. 15) Select the nearest thrust washer from the fol-
ST 18831AA000 GAUGE lowing table, according to the calculated value “t”.
Standard clearance between thrust washer and
taper roller bearing:
ST
−0.04 — 0.11 mm ( −0.0016 — 0.0043 in)
NOTE:
Make clearance within standard.
Thrust washer (50 × 61 × t)
Part No. Thickness mm (in)
803050060 0.50 (0.0197)
MT-00489 803050062 0.60 (0.0236)
803050064 0.70 (0.0276)
12) Rotate the transfer driven gear approx. ten 803050066 0.80 (0.0315)
times to get the bearing accustomed.
803050068 0.90 (0.0354)
13) Measure the depth “Y” between end of ST and
803050070 1.00 (0.0394)
bearing cone.
ST 18831AA000 GAUGE 803050072 1.10 (0.0433)
803050074 1.20 (0.0472)
803050076 1.30 (0.0512)
803050078 1.40 (0.0551)
16) Install the selector arm No. 2 and shifter arm.

ST
(A)
(B)
Y
MT-00976

(B) Shifter arm
17) Install a new spring pin.

18) Install the support to neutral set spring.
MT-00490 NOTE:
14) Calculate the value “t” of transfer driven gear Make sure to install the support in proper direction.
bearing thrust washer using the following equation.
t = Z − (100 − Y) − { −0.04 to 0.11 mm ( −0.0016 to
0.0043 in)}
t Thickness of transfer driven gear
mm (in) bearing thrust washer.
Y Depth from end of ST to bearing
mm (in) cone.
Z Depth from end of extension case
mm (in) to contact point of bearing cone.
−0.04 — 0.11 mm MT-00491
Standard clearance between thrust
(−0.0016 — 0.0043
washer and taper roller bearing.
in)
100 mm (3.94 in) Height of ST.
6MT-51
EXTENSION CASE
19) Using the ST, install the neutral set spring and 2) Measure the depth “Y” between end of ST and
support. transfer drive gear.
ST1 18756AA000 CLAW ST 499575500 GAUGE
ST2 399863600 PLIERS
ST
ST2
ST1
MT-00486 ST
20) Install the snap ring.

21) Install the center differential. Y
2. SELECTING THE TRANSFER DRIVE

GEAR THRUST WASHER
1) Measure the height “Z” between end of transmis-
sion case and end of ST.
ST 499575500 GAUGE
MT-00950
3) Calculate the value “t” of transfer drive gear

ST thrust washer using the following equation.
t = {Y − 15 mm (1.18 in)} − {Z − 15 mm (1.18 in)} −
0.45 to 0.65 mm (0.018 to 0.026 in)
Z t Thickness of transfer drive gear
mm (in) thrust washer
Y Depth from end of ST to transfer
MT-00949 mm (in) drive gear
Z Height from end of transmission
mm (in) case to the end of ST
0.45 — 0.65 mm Standard clearance between thrust
(0.018 — 0.026 in) washer and transfer drive gear.
15 mm (1.18 in) Thickness of ST
4) Select the nearest thrust washer from the follow-

ing table, according to the calculated value “t”.
Standard clearance between thrust washer and
transfer drive gear:
0.45 — 0.65 mm (0.018 — 0.026 in)
Thrust washer (36.3 × 52 × t)
803036070 0.80 (0.0315)
803036071 0.95 (0.0374)
803036072 1.10 (0.0433)
803036073 1.25 (0.0492)
803036074 1.40 (0.0551)
803036075 0.65 (0.0256)
5) Install the selected thrust washer.
6MT-52
REVERSE CHECKING SYSTEM
13.Reverse Checking System 6) Remove the spring pin, and then remove the re-
verse check lever and oil seal from reverse check
A: REMOVAL shaft.
1) Remove the manual transmission assembly NOTE:
from vehicle. <Ref. to 6MT-35, REMOVAL, Manual Do not reuse the oil seal.
6MT-40, Preparation for Overhaul.> (B)
3) Remove the extension case. <Ref. to 6MT-47, (C)
REMOVAL, Extension Case.>
4) Remove the snap ring and washer from reverse
check shaft. (A)
(B)
MT-00496
(A) Spring pin

(B) Reverse check lever
(A)
(C) Oil seal
7) Remove the plug from extension case, then re-

MT-00494
move the gasket, spring and plunger.
(A) Snap ring NOTE:
(B) Washer
Do not reuse the gasket.
5) Remove the reverse check shaft and spring from

extension case.
(D)
(C)
(B)
(A)
MT-00497
(A) Plug
MT-00495 (B) Gasket
(C) Spring
(D) Plunger
8) Remove the reverse lock plunger.
(A)
MT-00498
(A) Reverse lock plunger
6MT-53
B: INSTALLATION 3) Install the spring and reverse check shaft to ex-

1) Insert the reverse lock plunger. tension case.
2) Install in the order of reverse check plug, spring, NOTE:
gasket and plug. Be sure the spring end aligns with the hole of re-
Tightening torque: verse check shaft and cutout portion of extension
case.
41 N·m (4.2 kgf-m, 30.2 ft-lb)
(D) (B)
(C)
(B) (A)
(A)
MT-00497
(A) Plug
(B) Gasket (B)
(C) Spring
(A) (D)
(D) Reverse check plug
(C)
MT-00499
(A) Reverse check shaft

(B) Spring
(C) Hole
(D) Cutout portion
4) Install the washer and snap ring.
(B)
(A)
MT-00494
(A) Snap ring

(B) Washer
6MT-54
5) Set the ST1 to reverse check shaft. Install a new 9) Install the extension case. <Ref. to 6MT-47, IN-
oil seal, then press with ST2. STALLATION, Extension Case.>
ST1 18671AA000 OIL SEAL GUIDE 10) Install the manual transmission assembly to ve-
ST2 18657AA010 INSTALLER hicle. <Ref. to 6MT-37, INSTALLATION, Manual
ST2 C: INSPECTION
1) Make sure there is no damage on each parts.
ST1
2) Make sure the reverse check lever operates
smoothly.
(A) 3) Make sure there is no oil leakage on oil seal part
of reverse check shaft. If there is oil leakage, re-
place the oil seal.
4) Inspect the reverse check operation.
MT-00500 (1) The plunger can be pushed or the gear can
be shifted to reverse, when reverse check lever
(A) Oil seal is in the following position.
6) Insert the reverse check lever, then rotate the re-

verse check shaft until the plunger can be pushed
in first.
(A)
(B)
MT-00501
(A) Plunger
(B) Reverse check shaft
7) Align the hole of reverse check lever and reverse

check shaft, then install the spring pin.
MT-00503
(C)
(2) The plunger cannot be pushed or the gear
cannot be shifted to reverse, when reverse
check lever is in the following position.
(A) (B) MT-00502
(A) Reverse check shaft

(B) Reverse check lever
(C) Hole
MT-00504
8) Make sure the reverse check operates correctly.
<Ref. to 6MT-55, INSPECTION, Reverse Checking 5) If not as specified, reassemble the reverse
System.> check system.
6MT-55
TRANSFER DRIVE GEAR
14.Transfer Drive Gear C: DISASSEMBLY

1) Remove the snap ring.
A: REMOVAL
3) Remove the extension case. <Ref. to 6MT-47,
4) Remove the transfer drive gear.
MT-00506
2) Using the ST, remove the ball bearing.

ST 499877000 RACE 4-5 INSTALLER
NOTE:
Do not reuse the ball bearing.
MT-00505
ST
B: INSTALLATION
1) Install the transfer drive gear.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
MT-00507
D: ASSEMBLY
1) Using the ST, install the ball bearing.
ST1 499247400 INSTALLER
ST2 398497701 SEAT
ST2
MT-00505
2) If the ball bearing, transfer drive gear or snap

ring is replaced, select the transfer drive gear thrust
washer. <Ref. to 6MT-49, ASSEMBLY, Extension
Case.> ST1
3) Install the extension case. <Ref. to 6MT-47, IN-

STALLATION, Extension Case.> MT-00508
6MT-56
TRANSFER DRIVE GEAR
MT-00506
3) Inspect the clearance between snap ring and

ball bearing. <Ref. to 6MT-57, INSPECTION,
Transfer Drive Gear.>
E: INSPECTION
1) Bearings
Replace the bearings in the following cases.
• Broken or rusty bearings
• Worn or damaged
• Bearings that fail to turn smoothly or make ab-
normal noise.
2) Drive gear
Replace the drive gear in the following cases.
• If their tooth surface and shaft are excessively
broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.
Standard clearance between snap ring and in-
ner race:
0 — 0.15 mm (0 — 0.0059 in)
MT-00509
4) If the measurement is not within specifications,

select suitable snap ring.
Thrust washer
805045050 1.76 (0.069)
805045060 1.88 (0.074)
805045070 2.00 (0.079)
After replacement of the snap ring, inspect the

clearance again.
6MT-57
TRANSFER DRIVEN GEAR
15.Transfer Driven Gear C: DISASSEMBLY

1) Using the ST, remove the roller bearing of exten-
A: REMOVAL sion case side.
1) Remove the manual transmission assembly ST 498515700 REMOVER
6MT-40, Preparation for Overhaul.> ST
4) Remove the transfer driven gear.
MT-00511
2) Using the ST, remove the roller bearing of trans-

mission case side.
ST1 899858600 REMOVER
MT-00951
ST2
B: INSTALLATION ST1
1) Install the transfer driven gear.
MT-00512
D: ASSEMBLY
1) Using the ST, install the roller bearing of exten-
sion case side.
MT-00951 ST1 398177700 INSTALLER
2) If the bearing or transfer driven gear is replaced,
select the transfer driven thrust washer. <Ref. to CAUTION:
6MT-49, ADJUSTMENT, Extension Case.> Do not apply pressure in excess of 10 kN (1 ton,
3) Install the extension case. <Ref. to 6MT-47, IN- 1.1 US ton, 1.0 Imp ton).
STALLATION, Extension Case.>
ST2
(A) ST1
MT-00513
(A) Roller bearing
6MT-58
TRANSFER DRIVEN GEAR
2) Using the ST, install the roller bearing of trans-

mission case side.
CAUTION:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
ST
(A)
MT-00514
(A) Roller bearing
E: INSPECTION
1) Bearings
Replace the bearing in following cases.
• Broken or rusty bearings
• Worn or damaged
normal noise when turned after gear oil lubrication.
2) Driven gear
Replace the driven gear in following case.
• If their tooth surfaces and shaft are excessively
broken or damaged.
6MT-59
CENTER DIFFERENTIAL
16.Center Differential 2) Install the thrust washer and center differential.
A: REMOVAL
1) Remove the manual transmission case assem- (A)
bly from vehicle. <Ref. to 6MT-35, REMOVAL, (B)
Manual Transmission Assembly.>
58, REMOVAL, Transfer Driven Gear.> MT-00952
5) Disconnect the center differential connector.
6) Remove the thrust washer and center differen- (A) Thrust washer
tial. (B) Center differential
3) If replacing the center differential, select the

transfer drive gear and thrust washer and install.
(A)
(B)
<Ref. to 6MT-49, ADJUSTMENT, Extension
Case.>
4) Connect the center differential connector, and
secure it to oil guide.
5) Install the transfer driven gear. <Ref. to 6MT-58,
INSTALLATION, Transfer Driven Gear.>
MT-00952 STALLATION, Extension Case.>
7) Install the manual transmission case assembly
(A) Thrust washer to vehicle. <Ref. to 6MT-37, INSTALLATION, Man-
(B) Center differential
ual Transmission Assembly.>
C: INSPECTION
7) Remove the needle bearing.
Make sure there is no damage on the center differ-
ential, ball bearing and oil pump drive gear. Re-
place the center differential assembly if damaged.
MT-00516
B: INSTALLATION
1) Install the needle bearing.
MT-00516
6MT-60
OIL PUMP
17.Oil Pump ST2 399863600 PLIERS
A: REMOVAL
ST2
REMOVAL, Extension Case.> ST1
58, REMOVAL, Transfer Driven Gear.> MT-00486
5) Remove the center differential. <Ref. to 6MT-60, 9) Raise the striking rod up, and then remove the
REMOVAL, Center Differential.> spring pin.
6) Remove the oil guide.
(A)
(A)
(B)
MT-00487
MT-00953
(A) Striking rod

(A) Oil guide
(B) Spring pin
7) Remove the snap ring. 10) Remove the selector arm No. 2 and shifter arm.
(A)
(B) (A)
(B)
MT-00485
MT-00976
(A) Snap ring

(B) Support
(B) Shifter arm
8) Using the ST, remove the neutral set spring and
support.
ST1 18756AA000 CLAW
6MT-61
OIL PUMP
11) Remove the oil pump shaft assembly and plate. B: INSTALLATION
NOTE: 1) Apply oil to the outer periphery of outer rotor,
Remove the bolts using ST, because tool may then install to transmission case.
break if general tool is used.
ST 18663AA000 SOCKET
(B)
(A)
(B) (A)
MT-00523
MT-00521 (A) Outer rotor

(B) Inner rotor
(A) Oil pump shaft assembly
2) Install the thrust washer to main shaft part.
(B) Plate
3) Install the oil pump cover assembly.
12) Remove the oil pump cover assembly. Tightening torque:
NOTE: 25 N·m (2.5 kgf-m, 18.1 ft-lb)
Remove the bolts using ST, because tool may ST 18663AA000 SOCKET
break if general tool is used.
MT-00522
4) Install the oil pump shaft assembly and plate.

MT-00522
Tightening torque:
13) Remove the thrust washer on main shaft part. 25 N·m (2.5 kgf-m, 18.1 ft-lb)
14) Remove the oil pump rotor.
(B) (A)
(B)
(A)
MT-00523
MT-00521
(A) Outer rotor

(A) Oil pump shaft assembly
(B) Inner rotor
(B) Plate
6MT-62
OIL PUMP
5) If replacing the oil pump cover assembly, select 11) Install the oil guide.
the transfer driven gear and thrust washer, then in-
stall them to the extension case. <Ref. to 6MT-49,
(A)
ADJUSTMENT, Extension Case.>
6) Install the selector arm No. 2 and shifter arm.
(A)
MT-00953
(B) (A) Oil guide
MT-00976 12) Install the center differential. <Ref. to 6MT-60,

INSTALLATION, Center Differential.>
(A) Selector arm No. 2 13) Install the transfer driven gear. <Ref. to 6MT-
(B) Shift arm
58, INSTALLATION, Transfer Driven Gear.>
7) Install a new spring pin. STALLATION, Extension Case.>
8) Install the support to neutral set spring. 15) Install the manual transmission assembly to ve-
NOTE: hicle. <Ref. to 6MT-37, INSTALLATION, Manual
Make sure to install the support in proper direction. Transmission Assembly.>
C: INSPECTION
1) Make sure there is no damage on the inner rotor
and outer rotor. Replace the inner rotor and outer
rotor as assembly if damaged.
2) Clearance at tip
Install the inner rotor and outer rotor to transmis-
sion case. Align tip of the inner rotor and outer ro-
tor, then measure the clearance. Replace the inner
rotor and outer rotor as a set if clearance exceeds
specification.
MT-00491
Specification of clearance at tip:
9) Using the ST, install the neutral set spring and Less than 0.15 mm (0.0059 in)
support.
ST1 18756AA000 CLAW
ST2 399863600 PLIERS
ST2
MT-00524
ST1
MT-00486
6MT-63
OIL PUMP
3) Side clearance
Measure to the transmission case and rotor. Re-
place the inner rotor and outer rotor as a set if clear-
ance exceeds specification.
Specification of side clearance:
0.03 — 0.10 mm (0.0012 — 0.0039 in)
MT-00525
6MT-64
TRANSMISSION CASE
18.Transmission Case 10) Remove the pilot bolt.
A: REMOVAL
3) Remove the oil pipe, neutral position switch,
back-up light switch and harness. <Ref. to 6MT-42,
REMOVAL, Oil Pipe.>, <Ref. to 6MT-45, REMOV-
AL, Neutral Position Switch.>, <Ref. to 6MT-43,
REMOVAL, Back-up Light Switch.>
58, REMOVAL, Transfer Driven Gear.>
7) Remove the oil pump. <Ref. to 6MT-61, RE-
MOVAL, Oil Pump.>
8) Remove the shim and spacer of driven gear as-
sembly. MT-00528
11) Remove the holder reverse bolt.
(A)
MT-00526
(A) Driven gear assembly MT-00529
9) Remove the snap ring. 12) Remove the transmission case.

NOTE:
If the oil guide catches on shift fork, the transmis-
sion case may be difficult to be removed. Move the
oil guide right and left to remove. Do not pull the
transmission case by force.
MT-00527
MT-00530

on transmission case and adapter plate.
6MT-65
TRANSMISSION CASE
B: INSTALLATION 4) Make sure the interlock block and reverse inter-

1) Make sure that each shifter fork and interlock lock block are aligned in neutral position by inspect-
block is shifted to neutral position. If not, shift to ing through the pilot bolt installation hole. If not
neutral position. aligned, remove the transmission case, then shift
each shifter fork and interlock block to neutral posi-
tion.
(B)
(A)
MT-00533
(A)
(A) Interlock block

(B) Reverse interlock block
5) Using a new gasket, install the pilot bolts tempo-

(B)
rarily.
6) Tighten the transmission case with bolts and
(C)
nuts.
Tightening torque:
MT-00531
50 N·m (5.1 kgf-m, 36.9 ft-lb)
(A) Striking rod 7) Tighten the pilot bolts.
(B) Reverse interlock block Tightening torque:
(C) Interlock block 34 N·m (3.5 kgf-m, 25.1 ft-lb)
2) Apply liquid gasket to the adapter plate. 8) Tighten the holder reverse bolt.
Liquid gasket: Tightening torque:

THREE BOND 1215 (Part No. 004403007) 25 N·m (2.5 kgf-m, 18.1 ft-lb)
MT-00532
3) Install the transmission case.
6MT-66
TRANSMISSION CASE
9) Install the snap ring, washer and collar of driven C: DISASSEMBLY

gear assembly. 1) Remove the oil pipe and oil guide.
(C)
(B)
(B)
(A) (A)
MT-00535
(A) Oil pipe

(B) Oil guide
(A)
(C) 2) Remove the bolt, and then remove the O-ring,
relief spring and relief valve.
(A)
(B) (D) (B)
(C)
MT-00534
(A) Washer
(B) Snap ring
(C) Collar
(D) Washer MT-00536
10) Install the oil pump. <Ref. to 6MT-62, INSTAL-

(A) O-ring
LATION, Oil Pump.>
11) Install the center differential. <Ref. to 6MT-60, (B) Relief valve spring
INSTALLATION, Center Differential.> (C) Relief valve
12) Install the transfer driven gear. <Ref. to 6MT- 3) Remove the bolt, and then remove the O-ring,
58, INSTALLATION, Transfer Driven Gear.> valve spring and ball.
14) Install the oil pipe, neutral position switch,
back-up light switch and harness. <Ref. to 6MT-42, (A)
INSTALLATION, Oil Pipe.>, <Ref. to 6MT-45, IN- (B)
STALLATION, Neutral Position Switch.>, <Ref. to (C)
6MT-43, INSTALLATION, Back-up Light Switch.>
MT-00537
(A) O-ring
(B) Valve spring
(C) Ball
6MT-67
TRANSMISSION CASE
4) Remove the harness bracket. D: ASSEMBLY

1) Install the oil strainer and magnet.
Tightening torque:
10 N·m (1.0 kgf-m, 7.4 ft-lb)
(A)
MT-00538
5) Remove the oil pan. (B)
MT-00540
(A) Oil pan magnet

(B) Oil strainer
2) Apply liquid gasket to the oil pan.

Liquid gasket:
MT-00539

on transmission case and oil pan.
7) Remove the oil pan magnet, and then remove
the oil strainer.
(A)
MT-00541
3) Install the oil pan.

(B)
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
MT-00540
(A) Oil pan magnet

(B) Oil strainer
MT-00539
4) Install the relief valve, relief valve spring and

new O-ring.
6MT-68
TRANSMISSION CASE
5) Install the ball, valve spring and new O-ring.

Tightening torque:
T1: 13 N·m (1.3 kgf-m, 9.6 ft-lb)
T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb)
(A) T1
T1
(B)
(C) (A)
(D)
(E)
(F)
T2
MT-00542
(A) O-ring
(B) Relief valve spring
(C) Relief valve
(D) Valve spring
(E) Ball
(F) Harness bracket
E: INSPECTION
1) Completely remove with shop cloth if sludge is
adhered to the oil pan magnet.
2) Make sure there is no clog on the oil strainer. If
clogged, remove clog or replace the oil strainer.
3) Make sure there is no damage on each parts.
Replace damaged parts with new parts.
6MT-69
MAIN SHAFT ASSEMBLY
19.Main Shaft Assembly NOTE:

Do not reuse the gasket.
A: REMOVAL
58, REMOVAL, Transfer Driven Gear.> (A)
6) Remove the center differential. <Ref. to 6MT-60, (B)
(A)
(C) (C) (B)
REMOVAL, Center Differential.> (D) (E)
MOVAL, Oil Pump.>
8) Remove the transmission case. <Ref. to 6MT-
65, REMOVAL, Transmission Case.>
9) Remove the striking rod.
MT-00545
10) Using a screwdriver, shift to 4th gear position.
(A) Checking plug
(B) Gasket
(C) Checking spring
(D) Plunger
(E) Checking ball
(A) 13) Remove the bolt and gasket installing reverse

idler shaft.
MT-00543
(A) 3rd-4th shift rod
11) Remove the reverse idler holder.
MT-00546
(A)
14) Press the main shaft assembly, driven gear as-
sembly, reverse idler gear and each shifter fork,
then remove from the adapter plate at once.
NOTE:
MT-00544 Two people should do the work.
(A) Reverse idler holder
12) Remove all checking plug, gasket, checking

spring, plunger and checking ball from adapter
plate.
6MT-70
MAIN SHAFT ASSEMBLY
B: INSTALLATION 4) Install the main shaft assembly to 3rd-4th shifter

1) Adjust the 3rd-4th, and 5th-6th shifter fork rod. fork, and then assemble to driven gear assembly.
<Ref. to 6MT-117, ADJUSTMENT, Shifter Fork (A) (B)
and Rod.>
2) Turn the sub gear counterclockwise for approx. (D)
three teeth. Align the sub gear and reverse idler
gear hole, then insert the ST.
ST 18757AA000 STRAIGHT PIN
ST
(A)
(C)
(A) (B)
(B)
(D)
MT-00547
(A) Sub gear

(B) Reverse idler gear
(C)
3) Install the driven gear assembly to 1st-2nd MT-00549
shifter fork assembly.
(A) 3rd-4th shifter fork
(C) (B) 3rd-4th sleeve
(C) Driven gear assembly
(D) Main shaft assembly
5) Install the 5th-6th shifter fork assembly to main

shaft assembly.
(C) (B)
(B)
(A)
MT-00548
(A) 1st-2nd shifter fork

(B) Driven gear assembly
(C) 1st-2nd sleeve
(A)
MT-00550
(A) 5th-6th shifter fork

(B) 5th-6th sleeve
(C) Main shaft assembly
6MT-71
MAIN SHAFT ASSEMBLY
6) Install the reverse shifter fork assembly to re- Tightening torque:

verse idler gear assembly. 37 N·m (3.8 kgf-m, 27.3 ft-lb)
(B)
(A)
(C)
MT-00551
(A) Reverse idler gear assembly

(B) Reverse shifter fork
(C) Reverse sleeve (A)
(B)
(C)
7) Install the reverse idler gear assembly. (D)
(A)
MT-00553
(A) Checking plug

(C)
(B) Gasket
(B)
(C) Checking spring
MT-00552 (D) Plunger
(A) Reverse idler gear assembly

(B) 1st drive gear
(C) Reverse gear
8) Install the thrust bearing of driven gear assem-

bly.
9) Press each shifter fork, main shaft assembly,
driven gear assembly and reverse idler gear as-
sembly, then install them to the adapter plate at
once.
NOTE:
Two people should do the work.
10) Install the plunger, checking spring, new gasket
and checking plug.
6MT-72
MAIN SHAFT ASSEMBLY
11) Install the checking ball, checking spring, new 14) Install the reverse idler holder
gasket and checking plug.
Tightening torque:
37 N·m (3.8 kgf-m, 27.3 ft-lb)
(A)
MT-00544
(A) Reverse idler holder
15) Install the striking rod.

16) Install the transmission case. <Ref. to 6MT-66,
INSTALLATION, Transmission Case.>
17) Install the selected main shaft snap ring and
washer.
(A) 18) Install the oil pump. <Ref. to 6MT-62, INSTAL-
(C) (B)
(D) LATION, Oil Pump.>
19) Install the center differential. <Ref. to 6MT-60,
20) Install the transfer driven gear. <Ref. to 6MT-
MT-00554 21) Install the extension case. <Ref. to 6MT-47, IN-
(A) Checking plug 22) Install the oil pipe, neutral position switch,
(B) Gasket
INSTALLATION, Oil Pipe.>, <Ref. to 6MT-45, IN-
(C) Checking spring
STALLATION, Neutral Position Switch.>, <Ref. to
(D) Checking ball
12) Install the bolt and a new gasket. 23) Install the manual transmission assembly to ve-
Tightening torque: Transmission Assembly.>
25 N·m (2.5 kgf-m, 18.1 ft-lb)
C: DISASSEMBLY
NOTE:
Each sleeve and hub engage at a specified point.
Mark an engagement point on the sleeve and hub
before disassembly.
1) Secure the ST on workbench.
ST 18664AA000 BASE
2) Lift the caulking of lock nut.
MT-00546
13) Using a screwdriver, shift to 4th gear position.
6MT-73
MAIN SHAFT ASSEMBLY
3) Set the main shaft assembly on ST, then remove 6) Remove the 5th-6th sleeve, 6th needle bearing
the lock nut and washer. and 6th baulk ring.
ST1 18665AA000 HOLDER
ST2 18664AA000 BASE
NOTE: (A)
Use a 38 mm (1.50 in) socket wrench.
(B)
ST2
(C)
MT-00558
ST1 (A) Needle bearing

(B) 6th baulk ring
MT-00556
(C) 5th-6th sleeve
4) Remove the main shaft assembly from ST. 7) Set the ST on 3rd drive gear, then remove each
5) Set the ST1 on 6th drive gear, then remove the part using press.
taper roller bearing, bush and 6th drive gear using ST 18720AA000 REMOVER
press.
ST1 18722AA010 REMOVER
ST2 899864100 REMOVER (B)
ST2
ST1
ST (A)
ST
(A)
ST1 (B)
(B) (C)
MT-00559
(A) 3rd drive gear

MT-00557 (B) 3rd-4th sleeve
(A) Taper roller bearing

(B) Bush
(C) 6th drive gear
6MT-74
MAIN SHAFT ASSEMBLY
D: ASSEMBLY NOTE:
NOTE: Install the 3rd synchro cone, by aligning protrusion
portions of the 3rd synchro cone with 3rd drive gear
Replace the following parts as a set.
hole portion.
• Sleeve and hub
• Outer baulk ring, 3rd synchro cone and inner
baulk ring
• Taper roller bearing
1) Sufficiently apply gear oil to the main shaft, 3rd
needle bearing and inner periphery of 3rd drive
gear.
2) Install the 3rd needle bearing and 3rd drive gear
to main shaft.
MT-00562
4) Install the 3rd-4th hub and 4th bush.

(A)
(1) Set them to the main shaft, taking care of
3rd-4th hub installing direction.
(B) (A)
(B)
MT-00560
(A) 3rd needle bearing

(B) 3rd drive gear
3) Install the inner baulk ring, 3rd synchro cone and (C)
outer baulk ring. MT-00884
(A) Main shaft

(A)
(B) (B) 3rd-4th hub
(C) 3rd drive gear
MT-00561
(A) Inner baulk ring

(B) Outer baulk ring
6MT-75
MAIN SHAFT ASSEMBLY
(2) Set them to the main shaft, taking care not to (3) Using the ST, press in the 3rd-4th hub and
overlap the main shaft oil hole and 4th bush oil 4th bush at once.
hole. ST1 18651AA000 INSTALLER
(A)
A CAUTION:
Do not apply pressure in excess of 40 kN (4.0
(B) (C) ton, 4.4 US ton, 3.9 Imp ton).
NOTE:
A
When pressing in 3rd-4th hub and 4th bush, align
the protrusion portion of outer baulk ring and cutout
portion of 3rd-4th bush by moving the outer baulk
(D) ring.
(E) ST1
(C)
(A)
(A)
ST2
(C) (D)
A-A
MT-00885
(E)
(C)
(A) 4th bush (A)
(B) 3rd-4th hub

(C) 4th bush oil hole
(D) Main shaft oil hole (D)
(B)
MT-00555
(A) 3rd-4th hub

(C) Cutout portion of 3rd-4th hub
(D) Protrusion portion of outer baulk ring
(E) 4th bush
5) Make sure the 3rd drive gear is smoothly turned

by hand. If not, reassemble.
6MT-76
MAIN SHAFT ASSEMBLY
6) Install the 3rd-4th shifting insert key in proper 8) Install the 4th baulk ring.
place of 3rd-4th sleeve.
NOTE:
Angle of each shifting insert key is 120° apart.
MT-00564
9) Sufficiently apply gear oil to the main shaft, 4th

needle bearing and inner periphery of 4th drive
gear.
10) Install the 4th needle bearing and 4th drive
(A) gear.
(B) (B)
(A)
MT-00673
MT-00565
(A) 3rd-4th sleeve
(B) 3rd-4th shifting insert key
(A) 4th needle bearing
7) Install the 3rd-4th sleeve to 3rd-4th hub. (B) 4th drive gear
NOTE:
• 3rd-4th sleeve has a groove for identification.
• Install the 3rd-4th sleeve with groove facing to
3rd drive gear side.
(B)
(A)
MT-00563
(A) 3rd drive gear

(B) Groove (1) for identification of 3rd-4th sleeve
6MT-77
MAIN SHAFT ASSEMBLY
11) Install the 5th bush. 14) Install the 5th needle bearing and 5th drive
(1) Set it to the main shaft, taking care not to gear.
overlap the main shaft oil hole and 5th bush oil
hole. (B)
(A)
(A)
A
(D)
(C)
MT-00568
A
(A) 5th needle bearing

(B)
(E)
(B) 5th drive gear
15) Install the 5th baulk ring.
(C)
(A)
(C) (B)
A-A
MT-00566
(A) 5th bush MT-00569

(B) Main shaft oil hole
(C) Main shaft
16) Install the 5th-6th hub.
(1) Set it to the main shaft, taking care of 5th-6th
(D) 5th bush oil hole
hub installing direction.
(E) 4th drive gear
(2) Using the ST, press in the 5th bush. (A)

ST1 18651AA000 INSTALLER
(B)
CAUTION:
ton, 4.4 US ton, 3.9 Imp ton).
(C)
ST1
MT-00570
(A) Main shaft

(B) 5th-6th hub
(C) 5th drive gear
ST2
MT-00567
12) Make sure the 4th drive gear is smoothly turned

13) Sufficiently apply gear oil to the main shaft, 5th
gear.
6MT-78
MAIN SHAFT ASSEMBLY
(2) Using the ST, press in the 5th-6th hub. 18) Install the 5th-6th shifting insert key in proper
ST1 18651AA000 INSTALLER place of 5th-6th sleeve.
ST2 398177700 INSTALLER NOTE:
CAUTION: Angle of each shifting insert key is 120° apart.
ton, 4.4 US ton, 3.9 Imp ton).
NOTE:
When pressing in 5th-6th hub, align the protrusion
portion of outer baulk ring and cutout portion of 5th-
6th bush by moving the outer baulk ring.
ST1
(A)
(A)
ST2 (B)
(C) (A)
MT-00673
(D) (B) (A) 5th-6th sleeve

(B) Shifting insert key
19) Install the 5th-6th sleeve to 5th-6th hub.

MT-00571 NOTE:
• 5th-6th sleeve has two grooves for identification.
(A) 5th-6th hub • Install the 5th-6th sleeve with the groove facing
(B) Outer baulk ring to 5th drive gear side.
(C) Cutout portion of 5th-6th hub
17) Make sure the 5th drive gear is smoothly turned (B)
(A)
MT-00572
(A) 5th drive gear

(B) Groove (2) for identification of 5th-6th sleeve
6MT-79
MAIN SHAFT ASSEMBLY
20) Install the 6th baulk ring. 24) Set the 6th bush to main shaft, taking care not
to overlap the 6th bush oil hole and main shaft oil
hole.
(A)
MT-00573 (B)
(A)
21) Sufficiently apply gear oil to the main shaft, 6th MT-00576
gear.
(A) 6th bush oil hole
22) Install the 6th drive gear.
(B) Main shaft oil hole
25) Using the ST, install the 6th bush.

CAUTION:
ton, 4.4 US ton, 3.9 lmp ton).
ST1
MT-00574
23) Install the 6th needle bearing.
ST2
MT-00577
26) Make sure the 6th drive gear is smoothly turned

27) Using the ST, install the inner bearing inner
MT-00575 race.
CAUTION:
ST1
ST2
MT-00578
6MT-80
MAIN SHAFT ASSEMBLY
28) Using the ST, install the retainer and outer 31) Set the main shaft assembly to ST, then tighten
bearing inner race. the lock nut.
ST1 18651AA000 INSTALLER ST1 18665AA000 HOLDER
ST2 398177700 INSTALLER ST2 18664AA000 BASE
CAUTION: Tightening torque:
Do not apply pressure in excess of 40 kN (4.0 392 N·m (40.0 kgf-m, 289 ft-lb)
NOTE:
• Make sure to install the retainer in proper direc- ST2
tion.
• Press in until there is no backlash in retainer and
where bearing is smoothly turned by hand.
ST1 ST1
(B) MT-00556
(A)
32) Using the ST, caulk four portions on the lock
nut to obtain dimension A 27±0.3 mm (1.06±0.01
in).
ST 18668AA000 PUNCH
NOTE:
ST2
Do not crack the caulking part of lock nut.
ST
(A)
MT-00579
(A) Retainer
(B) Outer bearing inner race
29) Make sure the taper roller bearing is smoothly

turned by hand. If not, replace the taper roller bear- A
ing as a set and reassemble.
30) Install the lock washer and new lock nut.
A
MT-00580
6MT-81
MAIN SHAFT ASSEMBLY
E: INSPECTION 2) Set the height gauge to adapter plate. Lower the

Disassembled parts should be washed clean first indicator of height gauge to mating surface of
and then inspected carefully. adapter plate and case, then set to zero point.
1) Bearing ST 18853AA000 HEIGHT GAUGE
ST
• Worn, rusted and damaged bearing
normal noise when turned
• Bearings having other defects
2) Bushing (each gear)
Replace the bushings in the following case.
• When the sliding surface is damaged or abnor-
mally worn.
3) Gears MT-00582
Replace the gears in the following cases.
• Gear teeth surfaces are broken or excessively NOTE:
worn. • Remove the remaining gasket on edge surface
• Parts that contact the baulk ring is damaged. with scraper, since the adapter plate is base point
• The inner surface of gear is damaged. of measurement.
4) Baulk ring, synchro cone • Do not place the height gauge on shaded area in
Replace the baulk ring and synchro cone in the fol- the figure during measurement.
lowing case.
• Worn, rusted and damaged baulk ring
5) Shifting insert key
Replace the shifting insert key if deformed, exces-
sively worn or defective in any way.
MT-00583
MT-00581
F: ADJUSTMENT
1. SELECTION OF MAIN SHAFT SNAP
RING AND WASHER
NOTE:
Perform the following procedures when:
• Replacing the 1st to 6th driven gear.
• Replacing the 1st and 2nd synchro ring assem-
bly.
• Replacing the ball bearing.
• Replacing the adapter plate.
• Replacing the driven shaft.
1) Insert the drive pinion assembly in adapter plate.
NOTE:
Make sure the thrust bearing outer race is not re-
moved and drive pinion is not lift-up.
6MT-82
MAIN SHAFT ASSEMBLY
3) Measure the height to edge surface of ball bear- 4) According to measurement value, select the
ing (height H). snap ring and washer from the following table.
Snap ring
Thickness: mm
H: mm (in) Part No.
(in)
270.83 — 271.40 1.65
805072010
(10.66 — 10.69) (0.065)
271.41 — 271.98 1.95
805072011
(10.69 — 10.71) (0.077)
271.99 — 272.56 2.25
805072012
(10.71 — 10.73) (0.089)
Washer
(A) Thickness: mm
H H: mm (in) Part No.
(in)
270.83 — 271.40 1.6
803067012
(10.66 — 10.69) (0.063)
271.41 — 271.98 1.3
803067011
(10.69 — 10.71) (0.051)
271.99 — 272.56 1.0
803067010
(10.71 — 10.73) (0.039)
MT-00955
(A) Ball bearing
NOTE:
Set the indicator of height gauge near measuring
object, then lock the dial (1) as shown in the figure.
Turn dial (2) to set the indicator to edge surface of
bearing.
(2)
(1)
MT-00585
Measure the five points of ball bearing by turning

every approx. 120°. Round off each two upper and
lower measurement value. Use the remaining cen-
ter value as measurement value.
6MT-83
DRIVEN GEAR ASSEMBLY
20.Driven Gear Assembly NOTE:

Make sure to install the thrust needle bearing in
A: REMOVAL proper direction.
4) Remove the extension case. <Ref. to 6MT-47, MT-00587
5) Remove the transfer driven gear. <Ref. to 6MT- 4) Install the 1st needle bearing.
58, REMOVAL, Transfer Driven Gear.> 5) Install the driven gear assembly. <Ref. to 6MT-
6) Remove the center differential. <Ref. to 6MT-60, 71, INSTALLATION, Main Shaft Assembly.>
REMOVAL, Center Differential.> 6) Install the transmission case. <Ref. to 6MT-66,
7) Remove the oil pump. <Ref. to 6MT-61, RE- INSTALLATION, Transmission Case.>
MOVAL, Oil Pump.> 7) Adjust backlash at axial direction of driven gear
8) Remove the transmission case. <Ref. to 6MT- assembly. <Ref. to 6MT-91, ADJUSTMENT, Driv-
65, REMOVAL, Transmission Case.> en Gear Assembly.>
9) Remove the driven gear assembly. <Ref. to 8) Install the oil pump. <Ref. to 6MT-62, INSTAL-
6MT-70, REMOVAL, Main Shaft Assembly.> LATION, Oil Pump.>
10) Remove the needle bearing. 9) Install the center differential. <Ref. to 6MT-60,
MT-00586 13) Install the manual transmission assembly to ve-
11) Remove the thrust needle bearing. Transmission Assembly.>
B: INSTALLATION C: DISASSEMBLY
1) Adjust the main shaft snap ring. <Ref. to 6MT-
82, ADJUSTMENT, Main Shaft Assembly.> NOTE:
2) Adjust the 1st-2nd shifter rod. <Ref. to 6MT-117, Each sleeve and hub engage at a specified point.
ADJUSTMENT, Shifter Fork and Rod.> Mark an engagement point on the sleeve and hub
3) Install the thrust needle bearing. before disassembly.
1) Secure the ST on workbench.
ST 18664AA000 BASE
2) Lift the caulking of lock nut.
6MT-84
3) Install the ST3 to lock nut, set the driven gear as- 6) Remove the 2nd gear.
sembly on ST, then remove the lock nut.
ST2 18664AA000 BASE
ST3 18620AA000 ADAPTER WRENCH
ST3 ST2
MT-00591
7) Remove the needle bearing and 1st-2nd sleeve.
ST1
MT-00588
(A)
4) Install the ST1 to 4th gear, then remove the ball
bearing, 5th-6th driven gear and 3rd-4th driven (B)
gear.
ST1 18723AA000 REMOVER
ST2
MT-00592
(A)
ST1 (B) (A) Needle bearing

(C) (B) 1st-2nd sleeve
8) Remove the outer baulk ring, 2nd synchro cone

and inner baulk ring.
MT-00589
(C)
(A) Ball bearing (B)
(B) 5th-6th driven gear
(A)
(C) 3rd-4th driven gear
5) Remove the driven gear key.
MT-00593
(A) Outer baulk ring

(B) 2nd synchro cone
(C) Inner baulk ring
MT-00590
6MT-85
9) Using the ST, remove each part. 2) Install the 1st needle bearing.
ST 18754AA000 REMOVER
ST
MT-00595
3) Install the 1st driven gear to driven shaft.
(A)
(B)
(E) (C)
(D)
ST (F)
(G)
MT-00594 MT-00596
4) Install the inner baulk ring.

(A) 2nd bush
(B) 1st-2nd hub
(C) Outer baulk ring
(D) 1st synchro cone
(E) Inner baulk ring
(F) 1st driven gear
(G) 1st needle bearing
D: ASSEMBLY
NOTE:
MT-00597
Replace the following parts as a set.
• Sleeve and hub 5) Align protrusion portions of the 1st synchro cone
• Outer baulk ring, 1st synchro cone, inner baulk to the holes of 1st drive gear to install.
ring
• Outer baulk ring, 2nd synchro cone, inner baulk
ring
1) Sufficiently apply gear oil to the drive shaft, 1st
needle bearing and inner periphery of 1st driven
gear.
MT-00598
6MT-86
6) Install the outer baulk ring. 8) Using the ST, install the 2nd hub.
ST 18654AA000 INSTALLER
CAUTION:
ST
MT-00599 (A)
(B)
7) Install the 1st-2nd hub.
NOTE:
• Align the protrusion portion of outer baulk ring
MT-00601
and cutout portion of 1st-2nd hub, then install.
• Make sure to install the 1st-2nd hub in proper di-
rection. (A) 2nd bush
(B) 1st-2nd hub
(C) 9) Make sure the 1st drive gear is smoothly turned

(A) by hand. If not, reassemble.
10) Install the shifting insert key in proper place of
(D) (B) 1st-2nd sleeve.
(E) NOTE:
(A)
(E)
MT-00600
(A) 1st-2nd hub

(C) Cutout portion of 1st-2nd hub
(E) 1st driven gear
MT-00602
6MT-87
11) Install the 1st-2nd sleeve to 1st-2nd hub. 14) Install the inner baulk ring.
NOTE:
Make sure to install the 1st-2nd sleeve in proper di-
rection.
(B)
(A) MT-00606
15) Sufficiently apply gear oil to the bush, 2nd nee-

dle bearing and inner periphery of 2nd drive gear.
16) Install the 2nd needle bearing and 2nd driven
gear.
NOTE:
Align the protrusion portion of 2nd synchro cone
with 2nd driven gear hole, then install them.
(A)
(B) (B)
(C)
MT-00603
(A) 1st driven gear (C)

(B) 1st-2nd sleeve
(C) 1st driven gear side MT-00607
12) Install the outer baulk ring. (A) 2nd needle bearing
(B) 2nd driven gear
(C) Protrusion portion of 2nd synchro cone
17) Install the key.
MT-00604
13) Install the 2nd synchro cone.
MT-00608
MT-00605
6MT-88
18) Using the ST, install the 3rd-4th driven gear. 21) Using the ST, install the 5th-6th driven gear.
ST 18654AA000 INSTALLER ST 18654AA000 INSTALLER
CAUTION: CAUTION:
Do not apply pressure in excess of 40 kN (4.0 Do not apply pressure in excess of 40 kN (4.0
ton, 4.4 US ton, 3.9 lmp ton). ton, 4.4 US ton, 3.9 lmp ton).
NOTE: NOTE:
• Make sure to install the 3rd-4th driven gear in • Make sure to install the 5th-6th driven gear in
proper direction. proper direction.
• Align the groove of 3rd-4th driven gear with key. • Align the groove of 5th-6th driven gear with key.
ST ST
(A) (A)
(B)
(C)
(B)
(C)
MT-00609 MT-00611
(A) 4th gear (A) 6th gear

(B) 3rd gear (B) 5th gear
(C) 2nd gear (C) 4th gear
19) Make sure the 2nd driven gear is smoothly 22) Using the ST, install the ball bearing.
turned by hand. If not, reassemble. ST 18654AA000 INSTALLER
20) Install the key. CAUTION:
Do not apply pressure in excess of 40 kN (4.0 ton,
4.4 US ton, 3.9 lmp ton).
NOTE:
Make sure to install the ball bearing in proper direc-
tion.
ST
MT-00610
MT-00612
23) Make sure the ball bearing is smoothly turned

24) Install a new lock nut.
6MT-89
25) Install the ST3 to lock nut, then install the ST to 26) Using the ST, caulk four portions on the lock
driven gear assembly and tighten lock nut. nut to obtain dimension A 44±0.5 mm (1.73±0.02
ST1 18666AA000 HOLDER in).
ST2 18664AA000 BASE ST1 18669AA000 PUNCH DRIVEN SHAFT
ST3 18620AA000 ADAPTER WRENCH NOTE:
ST4 18852AA000 TORQUE WRENCH Do not crack the caulking part of lock nut.
Tightening torque:
530 N·m (54.0 kgf-m, 391 ft-lb) ST
ST4
ST3
ST2
ST1
MT-00613
NOTE:
If torque wrench except ST4 is used, calculate the
A
following equation, then tighten the lock nut.
T=L1/(0.1 + L1)×570
T N·m (kgf-m, ft-lb)
Setting value of torque
wrench
L1 m (in) Torque wrench length A
MT-00615
0.1 m (3.94 in) ST length
570 N·m (58.1 kgf-m, 420 ft-lb) Tightening torque of lock
nut
(A) L1
MT-00614
(A) 0.1 m (3.94 in)
6MT-90
E: INSPECTION F: ADJUSTMENT
Disassembled parts should be washed clean first 1) Measure length “H”, which is from transmission
and then inspected carefully. case and oil pump cover mating surface to ball
1) Bearing bearing edge.
• Worn, rusted and damaged bearing (A)
(C)
H
2) Bushing (each gear)
Replace the bushings in the following case.
• When the sliding surface is damaged or abnor-
(B)
mally worn.
3) Gears
MT-00616
Replace the gears in the following cases.
• Gear teeth surfaces are broken or excessively
(A) Transmission case
worn.
• Parts that contact the baulk ring is damaged. (B) Ball bearing
• The inner surface of gear is damaged. (C) Driven gear assembly
4) Baulk ring, synchro cone 2) Using the following equation, calculate the
Replace the baulk ring and synchro cone in the fol- washer thickness of driven gear assembly.
lowing case: T=H − {5.8±0.05 mm (0.23±0.002 in)} − {0.1 to 0.3
• Worn, rusted and damaged baulk ring mm (0.0039 to 0.0118 in)}
Replace the shifting insert key if deformed, exces- t Thickness of washer
sively worn or defective in any way. Length from transmission case and
H oil pump cover mating surface to ball
bearing edge
5.8±0.05 mm Thickness of collar
(0.23±0.002 in)
0.1 to 0.3 mm Backlash specification at axial direc-
(0.0039 to 0.0118 in) tion of driven gear assembly
3) Select 0 to 3 washers from the following table to

adjust backlash closest to specification.
Backlash specification at axial direction of driv-
MT-00581 en gear assembly:
0.1 — 0.3 mm (0.0039 — 0.0118 in)
Washer
Part No. Thickness t mm (in)
803072030 0.15 (0.0059)
803072031 0.30 (0.0118)
803072032 0.45 (0.0177)
803072033 0.60 (0.0236)
6MT-91
REVERSE IDLER GEAR ASSEMBLY
21.Reverse Idler Gear Assembly 1) Remove the spring pin.
A: REMOVAL
AL, Neutral Position Switch.>, <Ref. to 6MT-43, MT-00617
2) Remove the snap ring.
MOVAL, Oil Pump.>
9) Remove the reverse idler gear assembly. <Ref. MT-00618
to 6MT-70, REMOVAL, Main Shaft Assembly.>
3) Remove the washer and reverse idler gear.
B: INSTALLATION
1) Select the reverse fork rod. <Ref. to 6MT-117,
ADJUSTMENT, Shifter Fork and Rod.> (A)
2) Install the reverse idler gear assembly. <Ref. to
6MT-71, INSTALLATION, Main Shaft Assembly.>
4) Install the oil pump. <Ref. to 6MT-62, INSTAL- (B)
LATION, Oil Pump.>
INSTALLATION, Center Differential.> MT-00619
INSTALLATION, Transfer Driven Gear.> (A) Washer
7) Install the extension case. <Ref. to 6MT-47, IN- (B) Reverse idler gear
8) Install the oil pipe, neutral position switch, back- 4) Remove the knock pin and reverse idler gear
up light switch and harness. <Ref. to 6MT-42, IN- needle bearing.
STALLATION, Oil Pipe.>, <Ref. to 6MT-45, IN-
STALLATION, Neutral Position Switch.>, <Ref. to (B)
9) Install the manual transmission assembly to ve- (A)
C: DISASSEMBLY
NOTE:
Sleeve and reverse gear engage at a specified
point. Mark an engagement point on the sleeve and MT-00620
hub before disassembly.

(A) Knock pin
(B) Reverse idler gear needle bearing
6MT-92
5) Remove the collar. 9) Remove the washer and needle bearing.

6) Remove the reverse sleeve.
(A)
(B)
MT-00625
MT-00622
(A) Needle bearing
7) Remove the outer baulk ring, reverse synchro
(B) Washer
cone and inner baulk ring from reverse sleeve.
10) Remove the knock pin.
(B)
(C)
(D)
(A)
MT-00623
MT-00626
(A) Reverse sleeve
(B) Outer baulk ring 11) Remove the snap ring and friction plate from
(C) Reverse synchro cone
reverse gear.
(D) Inner baulk ring
8) Remove the reverse idler gear No. 2. (A)
(B)
MT-00627
(A) Snap ring

MT-00624 (B) Friction plate
6MT-93
12) Remove the sub gear and spring. 2) Install the friction plate and snap ring.
NOTE:
(A) (B) Make sure to install the friction plate in proper di-
rection.
(C)
(D)
A
(C) (B)
MT-00628
(A)
(A) Sub gear
(B) Spring MT-00630
(C) Punch mark (mark A)
(A) Friction plate
D: ASSEMBLY
(B) Snap ring
1) Install the sub gear and spring.
(C) Snap ring side
NOTE: (D) Sub gear side
• Install the spring with white marking on hook part
facing to sub gear side. 3) Sufficiently apply gear oil to the shaft, needle
• Install the sub gear with punch mark (mark A) bearing and inner periphery of reverse drive gear.
facing outside. 4) Install the knock pin.
(A) (B)
A
(C) MT-00628 MT-00626
5) Install the washer and needle bearing.

(A) Sub gear
(B) Spring
NOTE:
Install the washer with groove facing to reverse
(C) Punch mark (mark A)
idler gear.
• Install the spring and sub gear, taking care to in-
stall the sub gear installation hole in proper direc-
tion.
(C)
A
(B)
(A)
MT-00631
(A) (A) Groove

MT-00629 (B) Washer
(C) Needle bearing
(A) Installation hole
6MT-94
6) Install the reverse idler gear No. 2. 8) Install the reverse sleeve to reverse idler gear
No. 2.
NOTE:
Make sure to install the reverse sleeve in proper di-
rection.
MT-00632
7) Install the shifting insert key in proper place of

reverse sleeve.
NOTE:
MT-00634
9) Sufficiently apply gear oil to the collar, needle
(A) (B) bearing and inner periphery of reverse drive gear.
10) Install the outer baulk ring, reverse synchro
cone and inner baulk ring.
(A) (B)
(A)
(C)
MT-00635
(B)
(A) Outer baulk ring
(B) Reverse synchro cone
(C) Inner baulk ring
11) Install the collar and needle bearing, then in-

stall the knock pin.
MT-00633
(A) Reverse sleeve

(B) Shifting insert key (C)
(B)
(A)
MT-00636
(A) Collar
(B) Needle bearing
(C) Knock pin
6MT-95
12) Align the protrusion portion of reverse synchro 3) Gears

cone with reverse idler gear hole, then install the Replace the gears in the following cases:
reverse idler gear. • The gear teeth surfaces are broken or excessive-
ly worn.
• The parts that contact the baulk ring is damaged.
• The inner surface of gear is damaged.
(A)
(B) 4) Baulk ring, synchro cone
Replace the baulk ring and synchro cone in the fol-
lowing case:
• Worn, rusted and damaged baulk ring
Replace the shifting insert key if deformed, exces-
sively worn or defective in any way.
MT-00637
(A) Protrusion portion of reverse synchro cone

(B) Reverse idler gear hole
13) Install the washer with groove facing to reverse

idler gear.
14) Using the ST, install the snap ring.
ST 18672AA000 GUIDE CLIP
MT-00581
ST
6) Inspect the clearance between snap ring and
washer.
Specification of clearance:
0.1 — 0.3 mm (0.0039 — 0.0118 in)
MT-00638
15) Inspect and adjust the clearance between snap

ring and washer. <Ref. to 6MT-96, INSPECTION,
Reverse Idler Gear Assembly.>
16) Install a new spring pin.
E: INSPECTION
Disassembled parts should be washed clean first MT-00639
and then inspected carefully.
1) Bearings Select and replace the snap ring from the following
Replace the bearings in the following cases. table if clearance is out of specification.
Snap ring
Parts No. Thickness mm (in)
031319000 1.50 (0.059)
2) Bushing (each gear) 805019030 1.60 (0.062)
Replace the bushings in the following case: 805019010 1.72 (0.068)
• When the sliding surface is damaged or abnor- Inspect the clearance again after replacing snap
mally worn. ring.
6MT-96
DRIVE PINION SHAFT ASSEMBLY
22.Drive Pinion Shaft Assembly B: INSTALLATION

1) Completely remove the remaining gasket on
A: REMOVAL drive plate and clutch housing.
1) Remove the manual transmission assembly 2) Apply liquid gasket to the clutch housing.
Transmission Assembly.> Liquid gasket:
2) Prepare the transmission for overhaul. <Ref. to THREE BOND 1215 (Part No. 004403007)
MT-00532
REMOVAL, Center Differential.> 3) Install each gear assembly. <Ref. to 6MT-71, IN-
7) Remove the oil pump. <Ref. to 6MT-61, RE- STALLATION, Main Shaft Assembly.>
MOVAL, Oil Pump.> 4) Install the transmission case. <Ref. to 6MT-66,
8) Remove the transmission case. <Ref. to 6MT- INSTALLATION, Transmission Case.>
65, REMOVAL, Transmission Case.> 5) Install the oil pump. <Ref. to 6MT-62, INSTAL-
9) Remove each gear assembly. <Ref. to 6MT-70, LATION, Oil Pump.>
REMOVAL, Main Shaft Assembly.> 6) Install the center differential. <Ref. to 6MT-60,
10) Remove the drive pinion shaft assembly. INSTALLATION, Center Differential.>
9) Install the oil pipe, neutral position switch, back-
up light switch and harness. <Ref. to 6MT-42, IN-
STALLATION, Oil Pipe.>, <Ref. to 6MT-45, IN-
MT-00640
6MT-97
C: DISASSEMBLY 6) Using the ST, remove the taper roller bearing as-
sembly.
NOTE: ST 18723AA000 REMOVER
Replace the drive pinion shaft as a set with hypoid
driven gear.
1) Remove the pipe and oil chamber.
ST
(B) (A)
MT-00644
D: ASSEMBLY
MT-00641 1) Using the ST, measure dimension A of drive pin-
ion.
(A) Pipe
NOTE:
(B) Oil chamber Note dimension A for selection of drive pinion shim.
2) Remove the drive pinion shaft and shim from ST 398643600 GAUGE
adapter plate.
ST
A MT-00645
MT-00642
2) Install the inner bearing inner race to drive pinion
3) Secure the ST on workbench. shaft using ST and press.
ST 18664AA000 BASE ST 18723AA000 REMOVER
4) Lift the caulking of lock nut. CAUTION:
5) Install the ST3 to lock nut, then set drive pinion Do not apply pressure in excess of 40 kN (4.0
shaft to ST. Remove the lock nut and washer. ton, 4.4 US ton, 3.9 lmp ton).
ST2 18664AA000 BASE
ST3 18621AA000 ADAPTER WRENCH
ST
ST3
ST2
ST1 MT-00646
MT-00643
6MT-98
3) Install the retainer and outer bearing inner race

T N·m (kgf-m, ft-lb)
Setting value of torque
to drive pinion shaft using ST and press. wrench
ST 18723AA000 REMOVER L1 m (in) Torque wrench length
NOTE: 0.1 m (3.94 in) ST length
Press to the point where bearing is turned smoothly Tightening torque of lock
without slack. 285 N·m (29.0 kgf-m, 210 ft-lb)
nut
(A)
(A) L1
ST
MT-00647
MT-00614
(A) Retainer
(A) 0.1 m (3.94 in)
4) Install the washer and a new lock nut.
5) Set the ST to drive pinion, then tighten the lock 6) Measure the starting torque. <Ref. to 6MT-100,
nut. INSPECTION, Drive Pinion Shaft Assembly.>
ST1 18667AA000 HOLDER 7) Using the ST, caulk two portions on the lock nut
ST2 18664AA000 BASE to obtain dimension A 37±0.5 mm (1.46±0.02 in).
ST3 18621AA000 ADAPTER WRENCH ST 18670AA000 PUNCH
ST4 18852AA000 TORQUE WRENCH NOTE:
NOTE: Do not crack the caulking part of lock nut.
Tighten with the ST and torque wrench straight-
lined.
Tightening torque:
ST
265 N·m (27.0 kgf-m, 195 ft-lb)
ST3
ST4
ST2
ST1
MT-00648
NOTE: A
• If torque wrench except ST4 is used, calculate
the following equation, then tighten the lock nut.
Tighten with the ST and torque wrench straight-
lined.
T=L1/(0.1 + L1)×285 MT-00649
6MT-99
8) Using the ST, measure dimension B of the drive 11) Install the oil chamber and pipe.
pinion.
Tightening torque:
ST 398643600 GAUGE
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
ST
(B) (A)
B
MT-00650
MT-00641
9) Calculate the following formula, then select one
or two pieces of drive pinion shim from the table be- (A) Pipe
low. (B) Oil chamber
6.5±0.0625 mm − (B − A) [0.26±0.0025 in − (B − A)]
NOTE: E: INSPECTION
A: Measured value from step 1). 1) Using the spring balancer, measure the starting
B: Measured value from step 8). torque. If the starting torque is out of specification,
replace the taper roller bearing.
Drive pinion shim
Starting torque:
0 — 0.95 N (0 — 0.097 kgf, 0 — 0.21 lb)
32295AA270 0.15 (0.0059)
32295AA280 0.175 (0.0069)
32295AA290 0.20 (0.0079)
32295AA300 0.225 (0.0089)
32295AA310 0.25 (0.0098)
32295AA320 0.275 (0.0108)
10) Apply gear oil to the side face of taper roller

bearing, then install the drive pinion shaft and se-
lected shim to adapter plate.
Tightening torque: MT-00651
54 N·m (5.5 kgf-m, 40 ft-lb)
2) Gears
Replace the gears in the following case.
• Gear teeth surfaces are broken or excessively
worn.
3) Bearings
4) Adapter plate
MT-00642
Replace the adapter plate in the following cases.
• Damaged adapter plate
5) Make sure the pipe and pipe chamber is not
damaged or clogged. Repair or replace if damaged
or clogged.
6MT-100
F: ADJUSTMENT 5) Remove the drive pinion shaft assembly, and

1) Inspect and adjust the backlash between hypoid then check tooth contact. If it is inaccurate, adjust
driven gear and drive pinion. <Ref. to 6MT-108, the backlash or thickness of shim.
HYPOID GEAR BACKLASH, ADJUSTMENT, • Tooth contact
Front Differential Assembly.> Checking item:Tooth contact pattern is slightly
2) Apply a uniform thin coat of red lead on both shifted toward to toe side under no-load
teeth surfaces of three or four teeth of the hypoid rotation. [When loaded, contact pattern moves
driven gear. toward heel.]
(A)
(B)
MT-00652 AT-00207
3) Install the drive pinion shaft assembly to clutch (A) Toe side
housing, then tighten it with at least four bolts. (B) Heel side
NOTE:
Install it with the remaining liquid gasket to prevent • Face contact
the mating surface of clutch housing and adapter Checking item: Backlash is too large.
plate from damaging. Contact pattern
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
4) Using the ST, rotate several times.
ST 18631AA000 HANDLE
ST
AT-00208
Corrective action: Verify the backlash again, and

then adjust it.
MT-00653
AT-01253
6MT-101
• Flank contact • Heel contact (Outside end contact)

Checking item: Backlash is too small. Checking item: Contact areas is small.
Contact pattern Contact pattern
AT-00209 AT-00211
Corrective action: Verify the backlash again, and Corrective action: Increase thickness of drive pin-
then adjust it. ion shim in order to bring drive pinion close to
crown gear.
AT-01254
AT-00212
• Toe contact (Inside end contact)
Checking item: Contact areas is small.
Contact pattern
AT-00210
Corrective action: Reduce thickness of drive pinion

shim in order to move drive pinion away from crown
gear.
AT-00213
6MT-102
FRONT DIFFERENTIAL ASSEMBLY
23.Front Differential Assembly 12) Wrap the spline part of axle shaft around with
vinyl tape.
A: REMOVAL
1) Remove the manual transmission assembly. (A)
<Ref. to 6MT-35, REMOVAL, Manual Transmis-
sion Assembly.>
REMOVAL, Back-up Light Switch.> MT-00655
REMOVAL, Extension Case.> (A) Vinyl tape
58, REMOVAL, Transfer Driven Gear.> 13) Using the ST, remove the axle shaft.
6) Remove the center differential. <Ref. to 6MT-60, ST1 499247300 INSTALLER
REMOVAL, Center Differential.> ST2 499095500 REMOVER ASSY
7) Remove the oil pump. <Ref. to 6MT-61, RE- NOTE:
MOVAL, Oil Pump.> • Do not reuse the circlip.
8) Remove the transmission case. <Ref. to 6MT- • Mark to identify the right and left axle shaft.
9) Remove each gear assembly. <Ref. to 6MT-70,
REMOVAL, Main Shaft Assembly.>
10) Remove the drive pinion shaft assembly. <Ref.
to 6MT-97, REMOVAL, Drive Pinion Shaft Assem-
bly.>
11) Remove the lock plates on both side. ST2
ST1
MT-00656
(A)
MT-00654
(A) Lock plate
6MT-103
14) Using the ST, remove the differential side re- NOTE:
tainer on both sides. Be careful not to damage the oil seal.
ST1 499787000 WRENCH ASSY (RIGHT
SIDE) (B) ST1
ST2 18630AA000 WRENCH ASSY (LEFT SIDE)
NOTE:
Be careful not to damage the part of clutch case
where the retainer is to be installed.
(B) ST1
(A)
ST2
(A)
ST2
MT-00657
(A) Left side

(B) Right side
5) Install the axle shaft.

MT-00657 NOTE:
• Replace the circlip with a new one.
(A) Left side • Be careful not to confuse right and left axle shaft.
(B) Right side • Wrap vinyl tape around the spline part of axle
shaft.
15) Remove the front differential. 6) Check and adjust the hypoid gear backlash.
B: INSTALLATION <Ref. to 6MT-107, HYPOID GEAR BACKLASH,
1) Install the differential assembly into clutch hous- INSPECTION, Front Differential Assembly.>
ing. 7) Check and adjust the tooth contact. <Ref. to
2) Apply oil to the threaded portion part of side re- 6MT-101, ADJUSTMENT, Drive Pinion Shaft As-
tainer. sembly.>
3) Remove the O-ring from side retainer of both 8) Mark an engagement point on the right and left
sides. side retainer and clutch housing.
4) Using the ST, install the differential side retainer
to both sides.
SIDE)
MT-00658
9) Remove the differential side retainer from both

sides.
6MT-104
NOTE: 18) Install the oil pump. <Ref. to 6MT-62, INSTAL-

Note the rotating number of time till removal, when LATION, Oil Pump.>
removing the side retainer. 19) Install the center differential. <Ref. to 6MT-60,
10) Install a new O-ring to side retainer of both INSTALLATION, Center Differential.>
sides. 20) Install the transfer driven gear. <Ref. to 6MT-
11) Install the differential side retainer to both 58, INSTALLATION, Transfer Driven Gear.>
sides. 21) Install the extension case. <Ref. to 6MT-47, IN-
NOTE: 22) Install the oil pipe, neutral position switch,
Install the side retainer by screwing in the same ro- back-up light switch and harness. <Ref. to 6MT-42,
tating number of time till removal, and then align INSTALLATION, Oil Pipe.>, <Ref. to 6MT-45, IN-
the mark. STALLATION, Neutral Position Switch.>, <Ref. to
12) Install the lock plate. 6MT-43, INSTALLATION, Back-up Light Switch.>
Tightening torque: 23) Install the manual transmission assembly to ve-
25 N·m (2.5 kgf-m, 18.1 ft-lb) hicle. <Ref. to 6MT-37, INSTALLATION, Manual
NOTE:
Be careful not to confuse right and left lock plates. C: DISASSEMBLY
1. DIFFERENTIAL CASE
1) Secure the differential assembly on a vise, and
(A) (B) then remove the hypoid driven gear.
MT-00659
(A) Left
(B) Right
MT-00660
13) Completely remove the remaining gasket from 2) Using the ST, remove the hypoid driven gear
the clutch housing and adapter plate. side bearing.
14) Apply liquid gasket to the clutch housing. ST 399527700 PULLER SET
Liquid gasket:
ST
MT-00663
3) Using a screw driver, make clearance of 2 — 3

MT-00532
mm (0.079 — 0.118 in) between the speedometer
15) Install the drive pinion shaft assembly. <Ref. to drive gear and roller bearing.
6MT-97, INSTALLATION, Drive Pinion Shaft As-
sembly.>
16) Install each gear assembly at once. <Ref. to
6MT-105
NOTE: 3) Remove the claw of ST1, and then install the

Be careful not to damage the differential case. claw of ST2.
ST1 398527700 PULLER ASSY
ST2 18760AA000 CLAW
ST1
(A)
(A) (B)
MT-00664
(A) Speedometer drive gear

(B) Roller bearing
ST2
4) Using the ST, remove the roller bearing.
ST
MT-00668
(A) Claw
MT-00665 4) Remove the bearing outer race from side retain-
er.
2. SIDE RETAINER ST1 398527700 PULLER ASSY
1) Remove the O-ring from side retainer. ST2 18760AA000 CLAW
ST1
ST2
(A)
MT-00666 MT-00669
2) Remove the oil seal from side retainer. (A) Side retainer
D: ASSEMBLY
1. DIFFERENTIAL CASE
1) Using the ST, install a new speedometer drive
gear and right and left side bearing inner race to dif-
ferential case.
ST2 398497701 SEAT
MT-00667
6MT-106
CAUTION: E: INSPECTION
Do not apply pressure in excess of 20 kN (2.0 Repair or replace the front differential in following
ton, 2.2 US ton, 2.0 Imp ton). cases.
NOTE: • Each gear is damaged, seized, or excessively
Always replace the inner race and outer race as a worn.
set. • Sliding surface of the differential case is dam-
aged, seized or excessively worn.
• Bearings and bearings part are damaged, rusted
ST1 or worn.
• Bearings fail to turn smoothly or make abnormal
noise when turned.
1. HYPOID GEAR BACKLASH
Check the hypoid gear backlash. If it is not within
specifications, adjust it. <Ref. to 6MT-108, HY-
POID GEAR BACKLASH, Front Differential As-
ST2 sembly.>
MT-00670
2) Install the hypoid driven gear to differential case. 2. TOOTH CONTACT OF HYPOID GEAR
Tightening torque: 1) Be sure the hypoid gear backlash is within spec-
69 N·m (7.0 kgf-m, 50.9 ft-lb) ifications. If it is not within specifications, adjust it.
<Ref. to 6MT-108, HYPOID GEAR BACKLASH,
Front Differential Assembly.>
2) Apply a uniform thin coat of red lead on both
tooth surfaces of three or four teeth of the hypoid
driven gear.
MT-00660
2. SIDE RETAINER
1) Using the ST, install the oil seal.
ST 499797000 OIL SEAL INSTALLER MT-00652
3) Install the drive pinion shaft assembly, and then

ST
secure it with four bolts.
NOTE:
Use the old gasket and washer to prevent the mat-
ing surface of housing from damaging.
Tightening torque:
50 N·m (5.0 kgf-m, 36.9 ft-lb)
4) Rotate the drive pinion shaft to right and left for
MT-00671 several times.
5) Remove the drive pinion shaft assembly, and
2) Install the bearing outer race to retainer on both then check tooth contact. If tooth contact is inaccu-
sides. rate, adjust it. <Ref. to 6MT-101, ADJUSTMENT,
3) Install the O-ring to retainer on both sides. Drive Pinion Shaft Assembly.>
NOTE:
Be careful not to damage the O-ring.
6MT-107
• Correct tooth contact. 4) Using the ST, rotate the drive pinion shaft sever-
NOTE: al times.
Under no load, tooth contacts 50 — 60% from cen- ST 18631AA000 HANDLE
ter to toe side (tooth contact shifts to heel side
when driving). ST
(A)
(B) MT-00653
5) Repeat step 3) and 4) until the left side retainer

AT-00207 can not be rotated. For the right side retainer,
screw it in until the inner race and outer race con-
(A) Toe side tacts lightly. This condition is “0” backlash.
(B) Heel side 6) Mark an engagement point on the right and left
side retainer and clutch housing.
F: ADJUSTMENT
1. HYPOID GEAR BACKLASH
1) Install the right and left side retainer.
SIDE)
NOTE:
Screw in the right side retainer a bit further than left
side.
MT-00658
2) Install the drive pinion shaft assembly, and then
secure it with four bolts. 7) Return the left side retainer for three teeth, and
screw in the right side retainer for three teeth.
NOTE:
8) Using the ST, secure the drive pinion shaft.
Use the old gasket and washer to prevent the mat-
ing surface of housing from damaging. ST 18621AA000 ADAPTER WRENCH
Tightening torque:
ST
50 N·m (5.0 kgf-m, 36.9 ft-lb)
3) Using the ST, screw in the left side retainer until
the drive pinion and hypoid driven gear contacts
lightly. Then loosen the right side retainer.
SIDE)
MT-00674
6MT-108
9) After rotating the drive pinion shaft several

times, measure the hypoid gear backlash using the
ST.
ST1 498255400 PLATE
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
Hypoid gear backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
MT-00675
10) If the backlash is out of specification, adjust it

by turning the right and left side retainers.
11) Screw in the right side retainer for further 1.75
teeth.
2. TOOTH CONTACT OF HYPOID GEAR
Refer to the section of drive pinion shaft for check-
ing of tooth contact. <Ref. to 6MT-107, TOOTH
CONTACT OF HYPOID GEAR, INSPECTION,
Front Differential Assembly.>
6MT-109
SPEEDOMETER GEAR
24.Speedometer Gear 15) Remove the oil seal, speedometer shaft and
washer.
A: REMOVAL
Transmission Assembly.> (A)
(B)
3) Remove the oil pipe, neutral position switch, (C)
REMOVAL, Back-up Light Switch.> MT-00677
REMOVAL, Extension Case.> (A) Washer
5) Remove the transfer driven gear. <Ref. to 6MT- (B) Snap ring
58, REMOVAL, Transfer Driven Gear.> (C) Oil seal
REMOVAL, Center Differential.> 16) Remove the snap ring from speedometer shaft.
7) Remove the oil pump. <Ref. to 6MT-61, RE- B: INSTALLATION
MOVAL, Oil Pump.> 1) Install the oil seal, washer and snap ring to
8) Remove the transmission case. <Ref. to 6MT- speedometer shaft.
65, REMOVAL, Transmission Case.> 2) Insert the speedometer shaft. Using the ST,
9) Remove each gear assembly. <Ref. to 6MT-70, press the oil seal.
REMOVAL, Main Shaft Assembly.> ST 899824100 or 499827000PRESS
10) Remove the drive pinion shaft assembly. <Ref.
to 6MT-97, REMOVAL, Drive Pinion Shaft Assem-
bly.>
11) Remove the front differential assembly. <Ref. ST
to 6MT-103, REMOVAL, Front Differential Assem-
bly.>
12) Remove the vehicle speed sensor. <Ref. to
6MT-32, REMOVAL, Vehicle Speed Sensor.>
13) Remove the snap ring, and then remove the
speedometer driven gear.
MT-00678
NOTE:
(B) • Replace the oil seal with a new one.
• Insert the oil seal approx. 24 mm (0.94 in) from
the edge of clutch case.
(A)
(A)
MT-00676 (B)
(A) Snap ring

(C)
(B) Speedometer driven gear
14) Remove the speedometer shaft from clutch

housing. MT-00679
(A) Approx. 24 mm (0.94 in)

(B) Oil seal
(C) Speedometer shaft
6MT-110
SPEEDOMETER GEAR
3) Install the speedometer driven gear and snap

ring.
(B)
(A)
MT-00676
(A) Snap ring

(B) Speedometer driven gear
4) Install the vehicle speed sensor. <Ref. to 6MT-

32, INSTALLATION, Vehicle Speed Sensor.>
5) Install the front differential assembly. <Ref. to
6MT-104, INSTALLATION, Front Differential As-
sembly.>
6) Install the drive pinion shaft assembly. <Ref. to
6MT-97, INSTALLATION, Drive Pinion Shaft As-
sembly.>
LATION, Oil Pump.>
6MT-111
SHIFTER FORK AND ROD
25.Shifter Fork and Rod ST 398791700 REMOVER
A: REMOVAL
1) Remove the manual transmission assembly ST

AL, Neutral Position Switch.>, <Ref. to 6MT-43, MT-00680
2) Using the ST, remove the reverse shifter arm.
6) Remove the center differential. <Ref. to 6MT-60, ST
MOVAL, Oil Pump.>
9) Remove each gear assembly. <Ref. to 6MT-70,
REMOVAL, Main Shaft Assembly.> MT-00681
B: INSTALLATION
2. 1st-2nd, 3rd-4th SHIFTER FORK
6MT-71, INSTALLATION, Main Shaft Assembly.> 1) Using the ST, remove the 3rd-4th shifter fork.
2) Install the transmission case. <Ref. to 6MT-66, ST 398791700 REMOVER
LATION, Oil Pump.> ST
7) Install the oil pipe, neutral position switch, back-
MT-00682
up light switch and harness. <Ref. to 6MT-42, IN-
STALLATION, Oil Pipe.>, <Ref. to 6MT-45, IN- 2) Using the ST, remove the 3rd-4th shifter arm.
STALLATION, Neutral Position Switch.>, <Ref. to ST 398791700 REMOVER
ST
C: DISASSEMBLY
NOTE:
Discard the removed spring pin and replace it with
a new one.
1. REVERSE SHIFTER FORK
MT-00683
1) Using the ST, remove the reverse fork.
3) Using the ST, remove the 1st-2nd shifter arm
and 1st-2nd shifter fork.
6MT-112
ST 398791700 REMOVER ST 398791700 REMOVER
(B)
(A)
ST
MT-00684 MT-00687
(A) 1st-2nd shifter arm 5. STRIKING ROD

(B) 1st-2nd shifter fork 1) Remove the reverse interlock block and interlock
block from striking rod.
3. 5th-6th SHIFTER FORK
1) Using the ST, remove the 5th-6th shifter fork. (B) (A)
ST
MT-00688
(A) Reverse interlock block

MT-00685 (B) Interlock block
2) Using the ST, remove the 5th-6th shifter arm. 2) Using the ST, remove the reverse interlock arm.
ST 398791700 REMOVER ST 398791700 REMOVER
ST ST
(B) (A)
MT-00686 MT-00689
4. SHIFT ARM SHAFT (A) Reverse interlock arm

Using the ST, remove the selector arm. (B) Interlock arm
3) Using the ST, remove the interlock arm.
6MT-113
ST 398791700 REMOVER NOTE:

Make sure to install the reverse arm and rod in
proper direction.
ST (C)
(A)
(B)
MT-00690 (A)
(A) Interlock arm MT-00692
D: ASSEMBLY (A) Reverse arm

1. REVERSE SHIFTER FORK (B) Reverse rod
(C) Spring pin
1) Using the ST, install the reverse fork.
2. 1st-2nd, 3rd-4th SHIFTER FORK
NOTE:
1) Using the ST, install the 1st-2nd shifter fork.
Make sure to install the reverse fork and rod in
proper direction. ST 398791700 REMOVER
NOTE:
(A) Make sure to install the 1st-2nd shifter fork and rod
(C)
in proper direction.
(C)
(B)
(B)
MT-00691 (A)
(A) Reverse fork

(B) Reverse rod MT-00693
(C) Spring pin

(A) 1st-2nd shifter fork
2) Using the ST, install the reverse arm. (B) 1st-2nd shifter rod
ST 398791700 REMOVER (C) Spring pin
2) Using the ST, install the 1st-2nd shifter arm.

6MT-114
NOTE: NOTE:
Make sure to install the 1st-2nd shifter arm and fork Make sure to install the 3rd-4th shifter fork in proper
in proper direction. direction.
(C)
(A) (B)
(A)
(B)
MT-00694 MT-00697
(A) 1st-2nd shifter fork (A) 3rd-4th shifter fork

(B) 1st-2nd shifter arm (B) Spring pin
(C) Spring pin
3. 5th-6th SHIFTER FORK
3) Using the ST, install the 3rd-4th shifter arm.
ST 398791700 REMOVER 1) Using ST, install the 5th-6th shifter arm.
NOTE:
Make sure to install the 3rd-4th shifter arm and rod NOTE:
in proper direction. Make sure to install the 5th-6th shifter arm and rod
(A)
(B)
(C)
(C)
(B)
(A)
MT-00695
MT-00698
(A) 3rd-4th shifter rod

(A) 5th-6th shifter arm
(B) 3rd-4th shifter arm
(B) 5th-6th shifter rod
(C) Spring pin
(C) Spring pin
4) Install the 3rd-4th fork rod into 1st-2nd shifter
arm. 2) Using the ST, install the 5th-6th shifter fork.
MT-00696
5) Using the ST, install the 3rd-4th shifter fork.

6MT-115
NOTE: • Make sure to install the interlock arm and rod in

Make sure to install the 5th-6th shifter fork and arm proper direction.
(C) (C)
(C)
(A)
(B)
(B)
(A)
MT-00701
MT-00699
(A) Reverse interlock arm
(A) 5th-6th shifter fork (B) Interlock arm
(B) 5th-6th shifter arm (C) Spring pin
(C) Spring pin
2) Install the reverse interlock block and interlock
4. SHIFT ARM SHAFT block to striking rod.
NOTE:
Using the ST, install the selector arm.
Make sure to install the reverse interlock block and
ST 398791700 REMOVER interlock block in proper direction.
NOTE:
Make sure to install the selector arm and rod in
proper direction. (B) (A)
(B) MT-00688
(A) (A) Reverse interlock block

MT-00700 (B) Interlock block
(A) Selector rod E: INSPECTION

(B) Selector arm 1) Check the shift shaft and shift rod for damage.
Replace if damaged.
5. STRIKING ROD 2) Repair or replace the gearshift mechanism if ex-
1) Using the ST, install the reverse interlock arm cessively worn, bent, or defective in any way.
and interlock arm.
NOTE:
• Make sure to install the reverse interlock arm and
rod in proper direction.
6MT-116
F: ADJUSTMENT 4) Measure “B1” and “B2” as shown in the figure.
1. SELECTION OF 1st-2nd FORK ROD

NOTE:
• Perform the following procedures when.
Replacing the 1st, 2nd driven gear.
• Replacing the 1st, 2nd synchro ring assembly.
• Replacing the adapter plate. B2
B1
• Replacing the driven shaft.
• Replacing the 1st-2nd hub, sleeve assembly.
1) Insert the drive pinion assembly in adapter plate. MT-00979
NOTE: (1) Shift the 1st-2nd sleeve to 1st driven gear

Make sure the thrust bearing outer race is not re- side, then press down to the stopper and mea-
moved and drive pinion is not lift-up. sure “B1”.
2) Set the height gauge to adapter plate. Lower the
indicator of height gauge to mating surface of
adapter plate and case, then set to zero point.
(B)
ST 18853AA000 HEIGHT GAUGE
ST
(A) MT-00702
(A) 1st driven gear

(B) 1st-2nd sleeve
MT-00582
NOTE:
NOTE: • Set the indicator of height gauge near measuring
• Remove the remaining gasket on edge surface object, then lock the dial (1) as shown in the figure.
with scraper, since the adapter plate is base point Turn dial (2) to set the indicator to edge surface of
of measurement. sleeve 1st side.
• Do not place the height gauge on shaded area in • Measure five points of the sleeve turning every
the figure during measurement. approx. 72°. Round off each two upper and lower
measurement value. Use the remaining center val-
ue as measurement value.
(2)
(1)
MT-00583
3) Select the main shaft snap ring. <Ref. to 6MT-

82, ADJUSTMENT, Main Shaft Assembly.> MT-00585
6MT-117
(2) Set the height gauge indicator upside down. (4) According to both measurements, calculate
the 1st-2nd sleeve neutral position. Select the
fork rod which applies to the calculated value
from following equation.
Equation: T = (B1 + B2) / 2
T: 1st-2nd sleeve center position
(A) B1: Height from adapter plate edge to sleeve
edge when shifted to 1st gear.
B2: Height from adapter plate edge to sleeve
edge when shifted to 2nd gear. [measurement
MT-00703
value + 55 mm (2.17 in)]
NOTE:
(A) Indicator The indicator is installed upside down compared to
the setting procedure of zero point. Add d1 [fixing
(3) Shift the 1st-2nd sleeve to 2nd driven gear value: 55 mm (2.17 in)] from the following figure to
side, then press up to the stopper and measure “B2”, to obtain measurement value of “B2”.
“B2”.
d1
(A)
(B)
MT-00705
MT-00704
T mm (in) Lot No. (Mark)

(A) 2nd driven gear
62.93 — 63.23
(B) 1st-2nd sleeve 32801AA111 (1)
(2.4776 — 2.4894)
63.23 — 63.53
NOTE: (2.4894 — 2.5012)
32801AA131 (None)
• Set the indicator of height gauge near measuring
63.53 — 63.83
object, then lock the dial (1) as shown in the figure. (2.5012 — 2.5130)
32801AA141 (2)
sleeve 2nd side.
• Perform the measuring procedure with two peo-
ple, and measure the sleeve lifted up straight.
• Measure five points of the sleeve turning every
approx. 72° apart. Round off each two upper and
lower measurement value. Use the remaining cen-
ter value as measurement value.
(2)
(1)
MT-00585
6MT-118
2. SELECTION OF 3rd-4th FORK ROD 3) Using the height gauge, measure “C1” and “C2”
shown in the figure.
NOTE:
Perform the following procedures when.
• Replacing the main shaft.
• Replacing the 3rd, 3rd to 6th drive gear and
bush.
• Replacing the 3rd, 3rd to 6th synchro assembly.
• Replacing the 3rd-4th hub, sleeve assembly.
1) Insert the main shaft assembly in adapter plate.
2) Set the height gauge to adapter plate. Lower the C2
indicator of height gauge to upper surface of snap C1
ring groove, on the upper side of main rear bearing,
then set to zero point.
ST 18853AA000 HEIGHT GAUGE (B)
(A)
(A)
MT-00707
MT-00706
(A) 3rd drive gear
(B) 4th drive gear
(A) Roller bearing
(1) Shift the 3rd-4th sleeve to 4th gear side,
NOTE: then press up to the stopper and measure “C2”.
• Remove the remaining gasket on edge surface
with scraper, since the height gauge is set on
adapter plate during measurement. (A)
• Do not put the height gauge on shaded area in
the figure during the measurement.
MT-00708
(A) 4th drive gear
NOTE:
MT-00583 • Set the indicator of height gauge near measuring
• Turn dial (2) to set the indicator to edge surface
of sleeve 4th side.
• Perform the measuring procedure with two peo-
ple, and measure the sleeve lifted up straight.
6MT-119
• Measure five points of the sleeve turning every • Measure five points of the sleeve turning every
approx. 72°. Round off each two upper and lower approx. 72°. Round off each two upper and lower
measurement value. Use the remaining center val- measurement value. Use the remaining center val-
ue as measurement value. ue as measurement value.
(2) (2)
(1) (1)
MT-00585 MT-00585
(2) Set the height gauge indicator upside down. 4) According to both measurements, calculate the
3rd-4th sleeve neutral position. Select the fork rod
which applies to the calculated value from following
equation.
Equation: T = (C1 + C2) / 2
T: 3rd-4th sleeve center position
C1: Length from main shaft rear bearing snap
ring groove to sleeve edge when shifted to 3rd
(A) gear. [measurement value +55 mm (2.17 in)]
C2: Length from main shaft rear bearing snap
MT-00710 ring groove to sleeve edge when shifted to 4th
gear.
(A) Indicator NOTE:
The indicator is installed upside down compared to
(3) Shift the 3rd-4th sleeve to 3rd drive gear the setting procedure of zero point. Add d1 [fixing
side, then press down to the stopper and mea- value: 55 mm (2.17 in)] from the following figure to
sure “C1”. “C1”, to obtain measurement value of “C1”.
d1
(A)
MT-00711
MT-00705
(A) 3rd drive gear
NOTE:
sleeve 3rd side.
6MT-120
• Do not place the height gauge on shaded area in

Lot No. (Mark)
the figure during the measurement.
M.SFT M.SFT M.SFT
T mm (in) Snap ring Snap ring Snap ring
805072010 805072011 805072012
[t=1.65 mm [t=1.95 mm [t=2.25 mm
(0.065 in)] (0.077 in)] (0.089 in)]
137.22 —
137.52 32809AA171 32809AA181 32809AA191
(5.4024 — (None) (2) (4)
5.4142)
137.52 —
137.82 32809AA161 32809AA171 32809AA181
(5.4142 — (1) (None) (2) MT-00583
5.4260)
137.82 — 3) Using the height gauge, measure “D1” and “D2”
138.12 32809AA141 32809AA161 32809AA171 shown in the figure.
(5.4260 — (3) (1) (None)
5.4379)
T = Thickness
3. SELECTION OF 5th-6th FORK ROD

D2
NOTE:
D1 (B)
• Replacing the main shaft.
• Replacing the 3rd to 6th drive gear and bush.
• Replacing the 3rd to 6th synchro ring assembly.
• Replacing the 3rd-4th hub, sleeve assembly. (A)
• Replacing the 5th-6th hub, sleeve assembly.
1) Insert the main shaft assembly in adapter plate.
indicator of height gauge to upper surface of snap
ring groove, or the upper side of main rear bearing.
Then set to zero point.
(A)
MT-00712
(A) 5th main gear

(B) 6th main gear
MT-00706
(A) Ball bearing
NOTE:
• Remove the remaining gasket on edge surface
with scraper, since the height gauge is set on
adapter plate during measurement.
6MT-121
(1) Shift the 5th-6th sleeve to 6th main gear (3) Shift the 5th-6th sleeve to 5th main gear
side, then press up to the stopper and measure side, then press down to the stopper and mea-
“D2”. sure “D1”.
(A)
(A)
MT-00713 MT-00714
(A) 6th main gear (A) 5th main gear
NOTE: NOTE:
• Set the indicator of height gauge near measuring • Set the indicator of height gauge near measuring
object, then lock the dial (1) as shown in the figure. object, then lock the dial (1) as shown in the figure.
Turn dial (2) to set the indicator to edge surface of Turn dial (2) to set the indicator to edge surface of
sleeve 6th side. sleeve 5th side.
• Perform the measuring procedure with two peo- • Measure five points of the sleeve turning every
ple, and measure the sleeve lifted up straight. approx. 72°. Round off each two upper and lower
• Measure five points of the sleeve turning every measurement value. Use the remaining center val-
approx. 72°. Round off each two upper and lower ue as measurement value.
ue as measurement value. (2)
(2)
(1)
(1)
MT-00585
MT-00585
4) According to both measurements, calculate the
5th-6th sleeve neutral position. Select the fork rod,
(2) Set the height gauge indicator upside down. which applies to the calculated value from following
equation.
Equation: T = (D1 + D2) / 2
T: 5th-6th sleeve center position
D1: Length from the shaft rear bearing snap ring
groove to sleeve groove edge when shifted to
5th gear. [measurement value + 55 mm (2.17
in)]
(A) D2: Length from main shaft rear bearing snap
ring groove to sleeve groove edge when shift-
MT-00710
ed to 6th gear.
(A) Indicator
6MT-122
NOTE: Tightening torque:

The indicator is installed upside down compared to 25 N·m (2.5 kgf-m, 18.1 ft-lb)
the setting procedure of zero point. Add d1 [fixing
value: 55 mm (2.17 in)] from the following figure to
“D1”, to obtain measurement value of “D1”.
d1
MT-00546

indicator of height gauge to mating surface of
MT-00705
adapter plate and case, then set to zero point.
Lot No. (Mark)
M.SFT M.SFT M.SFT ST
T mm (in) Snap ring Snap ring Snap ring
805072010 805072011 805072012
[t=1.65 mm [t=1.95 mm [t=2.25 mm
(0.065 in)] (0.077 in)] (0.089 in)]
64.12 —
64.42 32945AA021 32945AA031 32945AA041
(2.5244 — (None) (2) (4)
2.5362)
64.42 —
64.72 32945AA011 32945AA021 32945AA031 MT-00582
(2.5362 — (1) (None) (2)
2.5480) NOTE:
64.72 — • Remove the remaining gasket on edge surface
65.02 32945AA001 32945AA011 32945AA021 with scraper, since the adapter plate is base point
(2.5480 — (3) (1) (None) of measurement.
2.5598) • Do not place the height gauge on shaded area in
T = Thickness the figure during measurement.
4. SELECTION OF REVERSE FORK ROD

NOTE:
• Replacing the reverse idler gear.
• Replacing the reverse idler gear No. 2.
• Replacing the adapter plate.
• Replacing the base.
1) Insert the reverse idler gear assembly in adapter
plate. MT-00583
2) Tighten the base COMPL fixing bolt.
6MT-123
4) Press the reverse sleeve to reverse side idler 5) According to measurement, calculate the re-
gear No. 2, then measure “T”. verse sleeve neutral position. Select the fork rod
which applies to the calculated value from following
equation.
Equation: T + 4.8 mm (0.189 in)
(A) T + 4.8 mm (0.189 in) Lot No. (Mark)

33.50 — 33.80
T 32816AA110 (1)
(1.3189 — 1.3307)
33.80 — 34.10
32816AA130 (None)
(1.3307 — 1.3425)
34.10 — 34.40
MT-00715 32816AA140 (2)
(1.3425 — 1.3543)
T = Thickness
(A) Reverse idler gear No. 2
(A) MT-00716
(A) Reverse idler gear No. 2
NOTE:
reverse sleeve side.
• Measure five points of the sleeve turning every
approx. 72°. Round off each two upper and lower
ue as measurement value.
(2)
(1)
MT-00585
6MT-124
CLUTCH HOUSING
26.Clutch Housing B: INSTALLATION

1) Install the pitching stopper bracket.
A: REMOVAL
Transmission Assembly.> 2) Install the speedometer gear. <Ref. to 6MT-110,
2) Prepare the transmission for overhaul. <Ref. to INSTALLATION, Speedometer Gear.>
6MT-40, Preparation for Overhaul.> 3) Install the vehicle speed sensor. <Ref. to 6MT-
3) Remove the oil pipe, neutral position switch, 32, INSTALLATION, Vehicle Speed Sensor.>
back-up light switch and harness. <Ref. to 6MT-42, 4) Install the front differential assembly. <Ref. to
REMOVAL, Oil Pipe.>, <Ref. to 6MT-45, REMOV- 6MT-104, INSTALLATION, Front Differential As-
AL, Neutral Position Switch.>, <Ref. to 6MT-43, sembly.>
REMOVAL, Back-up Light Switch.> 5) Install the drive pinion shaft assembly. <Ref. to
4) Remove the extension case. <Ref. to 6MT-47, 6MT-97, INSTALLATION, Drive Pinion Shaft As-
REMOVAL, Extension Case.> sembly.>
5) Remove the transfer driven gear. <Ref. to 6MT- 6) Install each gear assembly at once. <Ref. to
58, REMOVAL, Transfer Driven Gear.> 6MT-71, INSTALLATION, Main Shaft Assembly.>
6) Remove the center differential. <Ref. to 6MT-60, 7) Install the transmission case. <Ref. to 6MT-66,
REMOVAL, Center Differential.> INSTALLATION, Transmission Case.>
7) Remove the oil pump. <Ref. to 6MT-61, RE- 8) Install the oil pump. <Ref. to 6MT-62, INSTAL-
MOVAL, Oil Pump.> LATION, Oil Pump.>
8) Remove the transmission case. <Ref. to 6MT- 9) Install the center differential. <Ref. to 6MT-60,
65, REMOVAL, Transmission Case.> INSTALLATION, Center Differential.>
9) Remove each gear assembly. <Ref. to 6MT-70, 10) Install the transfer driven gear. <Ref. to 6MT-
REMOVAL, Main Shaft Assembly.> 58, INSTALLATION, Transfer Driven Gear.>
10) Remove the drive pinion shaft assembly. <Ref. 11) Install the extension case. <Ref. to 6MT-47, IN-
to 6MT-97, REMOVAL, Drive Pinion Shaft Assem- STALLATION, Extension Case.>
bly.> 12) Install the oil pipe, neutral position switch,
11) Remove the front differential assembly. <Ref. back-up light switch and harness. <Ref. to 6MT-42,
to 6MT-103, REMOVAL, Front Differential Assem- INSTALLATION, Oil Pipe.>, <Ref. to 6MT-45, IN-
bly.> STALLATION, Neutral Position Switch.>, <Ref. to
12) Remove the vehicle speed sensor. <Ref. to 6MT-43, INSTALLATION, Back-up Light Switch.>
6MT-32, REMOVAL, Vehicle Speed Sensor.> 13) Install the manual transmission assembly to ve-
13) Remove the speedometer gear. <Ref. to 6MT- hicle. <Ref. to 6MT-37, INSTALLATION, Manual
110, REMOVAL, Speedometer Gear.> Transmission Assembly.>
6MT-125
CLUTCH HOUSING
C: DISASSEMBLY D: ASSEMBLY
1) Remove the clutch release bearing guide. 1) Install the oil seal into clutch housing without
damaging.
ST
MT-00717
2) Remove the oil seal. MT-00719

ST 398527700 PULLER ASSY
NOTE: 2) Install the clutch release bearing guide.
Do not reuse the oil seal. Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
ST
MT-00718
MT-00717
E: INSPECTION
1) Make sure there is no damage or crack on the
clutch housing. Replace the clutch housing with a
new one if there is excessive damage.
2) Check the clutch housing for gear oil leakage. If
there is oil leakage, repair or replace the leakage
part.
6MT-126
G SENSOR
27.G Sensor
A: REMOVAL
FU-00009
2) Remove the console cover.

<Ref. to EI-43, Console Box.>
3) Disconnect the connector from G sensor.
4) Remove the G sensor from body.
CAUTION:
Do not drop or bump the G sensor.
(A)
MT-00726
(A) G sensor
B: INSTALLATION
CAUTION:
Do not drop or bump the G sensor.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
6MT-127
G SENSOR
C: INSPECTION
Step Check Yes No
1 CHECK G SENSOR. Is the voltage 2.3±0.2 V when Go to step 2. Replace the G
1)Turn the ignition switch to OFF. G sensor is horizontal? sensor.
2)Remove the G sensor from vehicle.
3)Connect the connector to G sensor.
4)Turn the ignition switch to ON.
5)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal
(B338) No. 2 (+) — No. 3 (−):
2 CHECK G SENSOR. Is the voltage 3.9±0.2 V when Go to step 3. Replace the G
Measure the voltage between G sensor con- G sensor is inclined forwards sensor.
nector terminals. to 90°?
(B338) No. 2 (+) — No. 3 (−):
3 CHECK G SENSOR. Is the voltage 0.7±0.2 V when G sensor is nor- Replace the G
Measure the voltage between G sensor con- G sensor is inclined backwards mal. sensor.
nector terminals. to 90°?
(B338) No. 2 (+) — No. 3 (−):
6MT-128
DRIVER’S CONTROL CENTER DIFFERENTIAL CONTROL MODULE
28.Driver’s Control Center Dif-

ferential Control Module
A: REMOVAL
1) Remove the ground cable from battery.
2) Remove the glove box.
<Ref. to EI-40, REMOVAL, Glove Box.>
3) Disconnect the connector after removing the bolt
from the inside of glove box, and then remove the
control module.
B: INSTALLATION
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
6MT-129
GENERAL DIAGNOSTIC TABLE
29.General Diagnostic Table

A: INSPECTION
1. MANUAL TRANSMISSION
Symptom Possible cause Remedy
1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer of Replace.
NOTE: internal spline of sleeve and reverse
The cause for difficulty in shifting gears driven gear
can be classified into two kinds: one is (b) Worn, damaged or burred chamfer of Replace.
malfunction of the gear shift system and spline of gears
the other is malfunction of the transmis-
(c) Worn or scratched bushings Replace.
sion. However, if the operation is heavy
and engagement of the gears is difficult, (d) Incorrect contact between synchro- Correct or replace.
defective clutch disengagement may also nizer ring and gear cone or wear
be responsible. Check whether the clutch
is correctly functioning, before checking
the gear shift system and transmission.
2. Gear slips out. (a) Defective pitching stopper adjustment Adjust.
• Gear slips out when coasting on rough (b) Loose engine mounting bolts Tighten or replace.
road. (c) Worn fork shifter, broken shifter fork Replace.
• Gear slips out during acceleration. rail spring
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines Replace.
of synchronizer hub and synchronizer
sleeve
(f) Worn tooth step of synchronizer hub Replace.
(responsible for slip-out of 3rd gear)
(g) Worn 1st driven gear, needle bearing Replace.
and race
(h) Worn 2nd driven gear, needle bearing Replace.
and race
(i) Worn 3rd drive gear and bushing Replace.
(j) Worn 4th drive gear and bushing Replace.
(k) Worn 5th drive gear and bushing Replace.
(l) Worn 6th drive gear and bushing Replace.
(m) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmis- (a) Insufficient or improper lubrication Lubricate or replace with specified oil.
sion. (b) Worn or damaged gears and bearings Replace.
NOTE: NOTE:
If an unusual noise is heard when the ve- If the trouble is only wear of the tooth sur-
hicle is parked with its engine idling and if faces, merely a high roaring noise will oc-
the noise ceases when the clutch is disen- cur at high speeds, but if any part is
gaged, it may be considered that the broken, rhythmical knocking sound will be
noise comes from the transmission. heard even at low speeds.
6MT-130
2. DIFFERENTIAL
Symptom Possible cause Remedy
1. Broken differential (case, gear, bear- (a) Insufficient or improper oil Replace.
ing, etc.) (b) Use of vehicle under severe condi- Replace.
NOTE: tions such as excessive load and
Abnormal noise will develop and finally it improper use of clutch
will become impossible to continue to run
(c) Improper adjustment of taper roller Adjust.
due to broken pieces obstructing the gear
bearing
revolution.
(d) Improper adjustment of drive pinion Adjust.
and hypoid driven gear
(e) Loose hypoid driven gear clamping Tighten.
bolts
2. Differential and hypoid gear noises (a) Insufficient oil Lubricate.
Troubles of the differential and hypoid (b) Improper adjustment of hypoid driven Check tooth contact.
gear always appear as noise problems. gear and drive pinion
Therefore noise is the first indication of (c) Worn teeth of hypoid driven gear and Replace as a set.
the trouble. However noises from the drive pinion Readjust bearing preload.
engine, muffler, tire, exhaust gas, bear-
(d) Loose roller bearing Readjust hypoid driven gear to drive pin-
ing, body, etc. are easily mistaken for the
ion backlash and check tooth contact.
differential noise. Pay special attention to
the hypoid gear noise because it is easily (e) Distorted hypoid driven gear or differ- Replace.
confused with other gear noises. There ential case
are the following four kinds of noises. (f) Broken or damaged LSD. Replace.
• Gear noise when driving: If noise
increases as the vehicle speed increases
it may be due to insufficient gear oil,
incorrect gear engagement, damaged
gears, etc.
• Gear noise when coasting: Damaged
gears due to maladjusted bearings and
incorrect shim adjustment
• Bearing noise when driving or when
coasting: Cracked, broken or damaged
bearings
• Noise which mainly occurs when turn-
ing: Unusual noise from the differential
side gear, differential pinion, differential
pinion shaft, etc.
6MT-131
6MT-132

6speed Manual Trans & Diff For Subaru WRX 2005

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MANUAL TRANSMISSION

2. TRANSMISSION GEAR OIL

(1) Breather hose (7) Plug (13) Oil chamber

4. OIL PAN AND OIL PUMP

5. EXTENSION CASE AND CENTER DIFFERENTIAL

6. SHIFTER FORK AND FORK ROD

(1) Spring pin (9) Support (17) 5th-6th shifter arm

7. MAIN SHAFT ASSY

(1) Main shaft (12) 4th bush (23) Needle bearing

8. DRIVE PINION AND DRIVEN SHAFT ASSY

9. REVERSE IDLER GEAR ASSY

C: CAUTION • Be sure to tighten fasteners including bolts and

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

2. GENERAL PURPOSE TOOLS

2. Transmission Gear Oil B: REPLACEMENT

(A) Drain plug (Oil pan side)

5) Lower the vehicle.

3. Oil Seal 6) Using the ST, install the oil seal.

Tightening torque: 7) Install the propeller shaft. <Ref. to DS-15, IN-

(A) Drain plug (Oil pan side)

3) Remove the rear exhaust pipe and muffler.

(A) Oil seal

4. Vehicle Speed Sensor

4) Remove the vehicle speed sensor.

2) Connect the connector to vehicle speed sensor.

5. Transmission Mounting Sys- B: INSTALLATION

2) Install the intercooler.

3) Remove the transmission jack.

6. Manual Transmission As- 8) Disconnect the ground cable at upper side of

11) Remove the clutch release shaft.

14) Remove the center and rear exhaust pipe and

(A) Joint COMPL bolt

(A) Reverse check cable

MT-00462 4) Install the front crossmember and rear cross-

7) Install the pitching stopper bracket.

15) Install the ball joint of transverse link to hous-

16) Install the stabilizer nut.

17) Install the propeller shaft. <Ref. to DS-15, IN-

7. Preparation for Overhaul

(A) Drain plug (Oil pan side)

3) Attach the transmission to ST.

4) Rotating parts should be coated with oil prior to

8. Air Breather Hose

10.Back-up Light Switch B: INSTALLATION