manual transmission system
MT–1
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION SYSTEM
MANUAL TRANSMISSION
SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help determine the cause of the
problems. The numbers indicate the ranked order of
probability of each of the possible causes. Check each part in
the order suggested. If necessary, replace the applicable
parts.
Symptom
Abnormal noise
Oil leakage
Hard shifting or will not shift
Jumps out of gear
Suspected area
See page
1. Oil level (Low)
MT-2
2. Oil (Wrong)
MT-2
3. Gears (Worn or damaged)
-
4. Bearings (Worn or damaged)
-
1. Oil level (High)
MT-2
2. Gasket (Damaged)
-
3. Oil seal (Worn or damaged)
-
4. O-Ring (Worn or damaged)
-
1. Synchronizer ring (Worn or damaged)
-
2. Shift key spring (Damaged)
-
1. Locking ball spring (Damaged)
-
2. Shift fork (Worn)
-
3. Gears (Worn or damaged)
-
4. Bearings (Worn or damaged)
-
MT
MT–2
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION OIL
MANUAL TRANSMISSION OIL
ON-VEHICLE INSPECTION
1.
0 to 5 mm
(0 to 0.20 in.)
D025304E01
MT
INSPECT TRANSMISSION OIL
(a) Park the vehicle in a level place.
(b) Remove the transmission filler plug and gasket.
(c) Check that the oil surface is within 5 mm (0.20 in.) of
the lowest point of the transmission filler plug
opening.
NOTICE:
• Problems may occur when the oil level is too
high or low.
• After replacing the oil, drive the vehicle and
check the oil level again.
(d) Check for oil leakage when the oil level is low.
(e) Install the transmission filler plug and a new gasket.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
MT–3
MANUAL TRANSMISSION ASSEMBLY
RA61F MANUAL TRANSMISSION
TRANSMISSION
COMPONENTS
CONSOLE UPPER REAR
PANEL SUB-ASSEMBLY
PARKING BRAKE HOLE
COVER SUB-ASSEMBLY
FRONT CONSOLE BOX
for Manual Transmission:
SHIFT LEVER KNOB
SUB-ASSEMBLY
for Transfer:
SHIFT LEVER KNOB SUB-ASSEMBLY
SHIFT LEVER BOOT ASSEMBLY
MT
TRANSFER HIGH AND LOW
SHIFT LEVER ASSEMBLY
FLOOR SHIFT SHIFT
LEVER ASSEMBLY
SNAP RING
C133794E01
MT–4
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
COMPRESSION SPRING
43 (438, 32)
GASKET
43 (438, 32)
FRONT EXHAUST PIPE ASSEMBLY
48 (489, 35)
GASKET
COMPRESSION SPRING
x2
GASKET
54 (554, 40)
x2
GASKET
x2
54 (554, 40)
NO. 2 FRONT EXHAUST
PIPE ASSEMBLY
MT
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
C136408E01
MT–5
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
REAR NO. 1 ENGINE MOUNTING INSULATOR
x4
65 (663, 48)
EXHAUST PIPE STOPPER BRACKET
x2
72 (734, 53)
NO. 3 FRAME CROSSMEMBER
SUB-ASSEMBLY
19 (194, 14)
x2
PROPELLER SHAFT
HEAT INSULATOR
FRONT SUSPENSION
MEMBER BRACKET
x2
x4
x4
72 (734, 53)
x2
16 (160, 12)
19 (189, 14)
33 (336, 24)
FRONT SUSPENSION
MEMBER BRACKET LH
x4
88 (899, 65)
x4
33 (336, 24)
88 (899, 65)
x4
PROPELLER SHAFT ASSEMBLY
MT
88 (899, 65)
x4
88 (899, 65)
x4
FRONT PROPELLER
SHAFT ASSEMBLY
N*m (kgf*cm, ft*lbf) :Specified torque
C136394E01
MT–6
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
x3
12 (117, 8.5)
MANUAL TRANSMISSION CASE
COVER SUB-ASSEMBLY
40 (408, 30)
x2
x3
12 (117, 8.5)
CLIP
39 (398, 29)
72 (730, 53)
x5
x2
ACCUMULATOR TO
FLEXIBLE HOSE TUBE
MANIFOLD STAY
15 (153, 11)
15 (153, 11)
19 (194, 14)
x4
x3
37 (380, 28)
CLUTCH ACCUMULATOR ASSEMBLY
12 (120, 8.7)
STARTER ASSEMBLY
15 (153, 11)
FLYWHEEL HOUSING SIDE COVER
x3
40 (408, 30)
15 (153, 11)
NO. 2 MANIFOLD STAY
MT
12 (120, 8.7)
CLUTCH RELEASE
CYLINDER ASSEMBLY
12 (120, 8.7)
NO. 1 CLUTCH HOUSING COVER
x2
x2
12 (120, 8.7)
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
C133796E01
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
MT–7
x3
24 (245, 18)
24 (245, 18)
x5
MT
TRANSFER ASSEMBLY
N*m (kgf*cm, ft*lbf) :Specified torque
C133793E01
MT–8
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
REMOVAL
1.
DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2.
REMOVE PARKING BRAKE HOLE COVER SUBASSEMBLY (See page IP-11)
3.
REMOVE CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-12)
4.
REMOVE FRONT CONSOLE BOX (See page IP-12)
5.
REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for
Transfer)
6.
REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for
Manual Transmission)
7.
REMOVE SHIFT LEVER BOOT ASSEMBLY
(a) Remove the 4 screws and 2 clips, then remove the
shift lever boot.
8.
REMOVE TRANSFER HIGH AND LOW SHIFT LEVER
ASSEMBLY
(a) Using needle-nose pliers, remove the snap ring and
pull out the shift lever from the shift lever retainer.
9.
REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY
(a) Separate the shift lever cap boot from the manual
transmission.
C135788
Front
Select Return Spring
Tip of Shift Lever
C113710E04
MT
F051062
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
(b) Cover the shift lever cap with a cloth.
(c) Pressing down on the shift lever cap, turn it
counterclockwise to remove the shift lever.
(d) Pull out the shift lever.
Down
Cloth
MT–9
Counterclockwise
10. DRAIN MANUAL TRANSMISSION OIL
(a) Remove the drain plug and gasket and then drain
the manual transmission oil.
(b) Install a new gasket and drain plug.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
F051209E01
11. REMOVE NO. 2 FRONT EXHAUST PIPE ASSEMBLY
(See page EX-4)
12. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See
page EX-4)
13. REMOVE PROPELLER SHAFT HEAT INSULATOR
(a) Remove the 2 bolts and remove the propeller shaft
heat insulator.
14. REMOVE FRONT PROPELLER SHAFT ASSEMBLY
(See page PR-2)
15. REMOVE PROPELLER SHAFT ASSEMBLY (See page
PR-9)
C133778
16. REMOVE NO. 2 MANIFOLD STAY
(a) Remove the 3 bolts and remove the No. 2 manifold
stay.
F051648
17. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts and remove the manifold stay.
18. REMOVE STARTER ASSEMBLY (See page ST-7)
F051649
MT
MT–10
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
19. REMOVE FLYWHEEL HOUSING SIDE COVER
(a) Remove the flywheel housing side cover from the
cylinder block.
20. REMOVE NO. 1 CLUTCH HOUSING COVER (See
page CL-16)
21. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY
(See page CL-16)
F050352
22. REMOVE ACCUMULATOR TO FLEXIBLE HOSE
TUBE
(a) Using SST, disconnect the hose tube. (for
accumulator side)
SST 09023-00101
(b) Remove the 3 nuts and disconnect the hose tube.
C135783
(c) Using SST, disconnect the hose tube. (for flexible
hose side)
SST 09023-00101
(d) Remove the clip
23. REMOVE CLUTCH ACCUMULATOR ASSEMBLY (See
page CL-19)
C135784
24. SUPPORT MANUAL TRANSMISSION WITH
TRANSFER
(a) Support the manual transmission with a
transmission jack.
25. REMOVE FRONT SUSPENSION MEMBER BRACKET
LH
(a) Remove the 4 bolts and remove the front
suspension member bracket LH.
MT
C129541
26. REMOVE FRONT SUSPENSION MEMBER BRACKET
(a) Remove the 4 bolts and remove the front
suspension member bracket RH.
C129542
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
MT–11
27. REMOVE NO. 3 FRAME CROSSMEMBER SUBASSEMBLY
(a) Remove the 4 bolts from the No. 3 frame
crossmember sub-assembly.
(b) Remove the 4 nuts and 4 bolts and remove the No.
3 frame crossmember sub-assembly.
C135785
28. REMOVE REAR NO. 1 ENGINE MOUNTING
INSULATOR
(a) Remove the 4 bolts and engine mounting insulator
rear from the manual transmission.
C135786
29. DISCONNECT CONNECTOR
(a) Tilt down the transmission.
(b) Disconnect the 2 transfer indicator switch
connectors.
(c) Disconnect the speedometer sensor connector.
(d) Disconnect the back-up light switch connector.
30. DISCONNECT WIRE HARNESS
31. REMOVE MANUAL TRANSMISSION WITH
TRANSFER
(a) Remove the 9 bolts.
(b) Separate and remove the manual transmission.
F051064
32. REMOVE MANUAL TRANSMISSION CASE COVER
SUB-ASSEMBLY
(a) Remove the 3 bolts and 2 nuts and remove the
manual transmission case cover.
33. REMOVE TRANSFER ASSEMBLY (See page TF-18)
C135787
MT
MT–12
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
INSTALLATION
1.
INSTALL TRANSFER ASSEMBLY (See page TF-43)
2.
INSTALL MANUAL TRANSMISSION CASE COVER
SUB-ASSEMBLY
(a) Install the manual transmission case cover with the
3 bolts and 2 nuts.
Torque: 12 N*m (117 kgf*cm, 8.5 ft.*lbf)
3.
INSTALL MANUAL TRANSMISSION WITH
TRANSFER
(a) Install the manual transmission with transfer with
the 9 bolts.
Torque: 72 N*m (730 kgf*cm, 53 ft.*lbf) for bolt A
37 N*m (380 kgf*cm, 28 ft.*lbf) for bolt B
4.
CONNECT WIRE HARNESS
5.
CONNECT CONNECTOR
(a) Connect the back-up light switch connector.
(b) Connect the speedometer sensor connector.
(c) Connect the 2 transfer indicator switch connectors.
6.
INSTALL REAR NO. 1 ENGINE MOUNTING
INSULATOR
(a) Install engine mounting insulator rear No. 1 with the
4 bolts.
Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
7.
INSTALL NO. 3 FRAME CROSSMEMBER SUBASSEMBLY
(a) Install the No. 3 frame crossmember sub-assembly
with the 4 bolts and 4 nuts.
Torque: 72 N*m (734 kgf*cm, 53 ft.*lbf)
(b) Install the No. 3 frame crossmember sub-assembly
with the 4 bolts.
Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf)
C135787
A
A
A
A
A
B
B
B
B
F051064E02
C135786
MT
C135785
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
MT–13
8.
INSTALL FRONT SUSPENSION MEMBER BRACKET
LH
(a) Install the front suspension member bracket LH with
the 4 bolts.
Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)
9.
INSTALL FRONT SUSPENSION MEMBER BRACKET
(a) Install the front suspension member bracket RH
with the 4 bolts.
Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)
C129541
10. INSTALL CLUTCH ACCUMULATOR ASSEMBLY (See
page CL-20)
C129542
11. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE
(a) Using SST, connect the hose tube. (for flexible hose
side)
SST 09023-00101
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
(b) Install a new clip.
C135784
(c) Using SST, connect the hose tube. (for accumulator
side)
SST 09023-00101
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
(d) Install the 3 nuts and connect the hose tube.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
12. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
(See page CL-17)
C135783
13. INSTALL NO. 1 CLUTCH HOUSING COVER (See page
CL-17)
14. INSTALL FLYWHEEL HOUSING SIDE COVER
(a) Install the flywheel housing side cover onto the
cylinder block.
15. INSTALL STARTER ASSEMBLY (See page ST-15)
F050352
MT
MT–14
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
16. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
F051649
17. INSTALL NO. 2 MANIFOLD STAY
(a) Install the No. 2 manifold stay with the 3 bolts.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
18. INSTALL PROPELLER SHAFT ASSEMBLY (See page
PR-14)
19. INSTALL FRONT PROPELLER SHAFT ASSEMBLY
(See page PR-6)
F051648
20. INSTALL PROPELLER SHAFT HEAT INSULATOR
(a) Install the propeller shaft heat insulator with the 2
bolts.
Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
21. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See
page EX-4)
22. INSTALL NO. 2 FRONT EXHAUST PIPE ASSEMBLY
(See page EX-5)
C133778
23. ADD MANUAL TRANSMISSION OIL
24. ADJUST MANUAL TRANSMISSION OIL (See page
MT-2)
25. INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY
(a) Apply MP grease to the tip of the shift lever.
MT
MP grease
F051066E02
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
(b) Cover the shift lever cap with a cloth.
(c) Pressing down on the shift lever cap, turn it
clockwise to install the shift lever.
Down
Cloth
MT–15
Clockwise
F051824E01
Installation
Select Return Spring
Front
26. REMOVE TRANSFER HIGH AND LOW SHIFT LEVER
ASSEMBLY
(a) Install the transfer shift lever onto the shift lever
retainer.
(b) Using needle-nose pliers, install the snap ring.
Tip of Shift Lever
C113710E03
27. INSTALL SHIFT LEVER BOOT ASSEMBLY
(a) Install the shift lever boot with the 4 screws and 2
clips.
28. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for
Manual transmission)
29. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for
Transfer)
30. INSTALL FRONT CONSOLE BOX (See page IP-31)
C135788
31. INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-31)
32. INSTALL PARKING BRAKE HOLE COVER SUBASSEMBLY (See page IP-32)
33. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
34. CHECK FOR EXHAUST GAS LEAKAGE
MT
MT–16
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MANUAL TRANSMISSION UNIT
RA61F MANUAL TRANSMISSION
TRANSMISSION
COMPONENTS
OUTPUT SHAFT REAR
BEARING OUTER RACE
20 (204, 15)
x4
NO. 2 TAPER
ROLLER BEARING
FLOOR SHIFT CONTROL SHIFT LEVER
RETAINER SUB-ASSEMBLY
OUTPUT SHAFT
ADJUST NUT
33 (340, 25)
SHIFT LEVER HOUSING
37 (377, 27)
18 (184, 13)
40 (408, 30)
x10
x4
GASKET
OUTPUT SHAFT
REAR BEARING
OUTER RACE
SPACER
MANUAL
TRANSMISSION
CASE COVER
SUB-ASSEMBLY
BALL
11 (115, 8.3)
25 (250, 18)
COMPRESSION SPRING
MT
37 (377, 27)
BEARING
LOCK PLATE
TRANSMISSION REAR CASE
GASKET
OIL SEPARATOR
PACKING SEAL
EXTENSION HOUSING
OIL RECEIVER PIPE
COUNTER GEAR REAR
RADIAL BALL BEARING
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
C114073E03
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT–17
44 (449, 33)
BACK-UP LIGHT
SWITCH ASSEMBLY
TRANSMISSION
CASE OIL SEAL
GASKET
40 (408, 30)
FRONT BEARING
SHAFT SNAP RING
x5
x3
NO. 1 OIL RECEIVER PIPE
40 (408, 30)
39 (400, 29)
TRANSMISSION FRONT CASE
NO. 2 OIL RECEIVER
8.5 (87, 75 in.*lbf)
PIPE
x2
TRANSMISSION
MIDDLE CASE
MT
x3
40 (408, 30)
GASKET
TRANSMISSION
OIL SEPARATOR
28 (286, 21)
GASKET
37 (377, 27)
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
C114219E05
MT–18
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
INPUT SHAFT ASSEMBLY
OUTPUT SHAFT ASSEMBLY
COUNTER GEAR ASSEMBLY
SHIFT AND SELECT LEVER
MT
SHIFT AND SELECT
LEVER SHAFT
SHIFT AND SELECT LEVER CAM
E-RING
COMPRESSION SPRING
REVERSE IDLER
GEAR BEARING
33 (340, 25)
LOCK BALL PIN
REVERSE IDLER GEAR SHAFT
REVERSE IDLER GEAR
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
C136409E01
MT–19
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
NO. 3 GEAR SHIFT FORK
20 (199, 14)
NO. 2 GEAR SHIFT FORK
20 (199, 14)
SLOTTED
SPRING PIN
NO. 2 GEAR SHIFT FORK SHAFT
NO. 3 GEAR SHIFT FORK SHAFT
1ST AND REVERSE SHIFT ARM
NO. 1 GEAR
SHIFT HEAD
SHIFT
DETENT BALL
PIN
E-RING
21 (214, 15)
PIN
x4
PIN
COMPRESSION
SPRING
NO. 1 GEAR SHIFT
FORK SHAFT
NO. 4 GEAR SHIFT
FORK SHAFT
SLOTTED SPRING PIN
SHIFT ARM PIVOT
SLOTTED
SPRING PIN
NO. 2 GEAR
SHIFT HEAD
SHIFT INTERLOCK
BRACKET
NO. 4 GEAR SHIFT FORK
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
Apply MP grease
NO. 1 GEAR SHIFT FORK
C136404E01
MT
MT–20
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
DISASSEMBLY
1.
REMOVE FLOOR SHIFT CONTROL SHIFT LEVER
RETAINER SUB-ASSEMBLY
(a) Remove the 4 bolts, then remove the floor shift
control shift lever retainer.
F051567
(b) Using a plastic hammer, remove the floor shift
control shift lever retainer.
D033729
2.
REMOVE SHIFT LEVER HOUSING
(a) Remove the bolt, then separate the shift lever
housing.
3.
REMOVE MANUAL TRANSMISSION CASE COVER
SUB-ASSEMBLY
(a) Remove the 4 bolts, then remove the transmission
case cover.
4.
REMOVE SHIFT DETENT BALL PLUG
(a) Using a socket hexagon wrench (10 mm), remove
the shift detent ball plug from the transmission rear
case.
(b) Remove the ball and compression spring from the
transmission rear case.
F051568
MT
F051569
F051570
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
5.
MT–21
REMOVE OUTPUT SHAFT ADJUST NUT
(a) Using a chisel and hammer, unstake the nut.
D033734
(b) Place the gearshift into 5th gear, and then fix the
input shaft using SST.
SST 09556-16030
(c) Using a belt and wooden block, fasten the
transmission to the workbench.
SST
D033631E01
(d) Using a socket wrench (60 mm), remove the nut
from the transmission rear case.
(e) Remove the belt and wooden block from the
transmission.
F051825
(f)
Remove taper roller bearing No. 2 and the spacer.
MT
D033736
6.
Clamp
Clamp
D033738E01
REMOVE TRANSMISSION REAR CASE
(a) Remove the 10 bolts and 3 clamps.
MT–22
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
(b) Using a plastic hammer, carefully tap out the rear
case.
HINT:
Place the brass bar against the rib portion of the
case.
D033739
7.
REMOVE MANUAL TRANSMISSION FILLER PLUG
(a) Remove the 2 transmission filler plugs and 2
gaskets from the transmission rear case.
8.
REMOVE EXTENSION HOUSING OIL RECEIVER
PIPE
(a) Remove the extension housing oil receiver pipe
from the transmission rear case.
9.
REMOVE OIL SEPARATOR PACKING SEAL
(a) Remove the oil separator packing seal from the
transmission rear case.
F051572
F051573
MT
F051828
SST
10. REMOVE OUTPUT SHAFT REAR BEARING OUTER
RACE
(a) Using SST, remove the 2 bearing outer races.
SST 09308-00010
SST
D033748E01
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT–23
11. REMOVE COUNTER GEAR REAR RADIAL BALL
BEARING
(a) Remove the bolt, then remove the bearing lock
plate.
D033746
(b) Using SST, remove the counter gear rear radial ball
bearing from the transmission rear case.
SST 09308-00010
SST
F051574E01
12. REMOVE TRANSMISSION OIL SEPARATOR
(a) Remove the 2 bolts, then remove the oil separator.
F051575
13. REMOVE REVERSE IDLER GEAR SHAFT BOLT
(a) Remove the reverse idler gear shaft bolt from the
transmission middle case.
MT
D033649
14. REMOVE TRANSMISSION MIDDLE CASE
(a) Remove the 11 bolts, then remove the transmission
middle case.
D033740
MT–24
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
(b) Using a plastic hammer, carefully tap out the middle
case.
HINT:
Place the brass bar against the rib portion of the
case.
D033741
15. REMOVE DRAIN PLUG SUB-ASSEMBLY
(a) Remove the drain plug and gasket from the
transmission middle case.
F051576
16. REMOVE NO. 2 OIL RECEIVER PIPE
(a) Remove the No. 2 oil receiver pipe from the
transmission middle case.
F051577
17. REMOVE SHIFT AND SELECT LEVER SHAFT
(a) Remove the shift and select lever shaft from the
reverse gear shaft.
MT
F051578
18. REMOVE SHIFT AND SELECT LEVER
(a) Remove the bolt, then remove the shift and select
lever.
(b) Remove the lock ball pin and spring from the shift
and select lever.
F051579
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT–25
19. REMOVE SHIFT AND SELECT LEVER CAM
(a) Using a screwdriver, remove the E ring and the shift
and select lever cam from the shift and select lever
shaft.
F051580
20. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
(a) Using SST, remove the back-up light switch and
gasket.
SST 09817-16011
SST
F051581E01
D033776
21. INSPECT REVERSE IDLER GEAR THRUST
CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance.
Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)
Maximum clearance:
0.25 mm to (0.0098 in.)
If the clearance exceeds the maximum, replace the
reverse idler gear shaft, reverse idler gear or
transmission front case.
22. REMOVE REVERSE IDLER GEAR
(a) Remove the reverse idler gear shaft, needle roller
bearing and reverse idler gear.
MT
D033634
23. INSPECT REVERSE IDLER GEAR RADIAL
CLEARANCE
(a) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.015 to 0.050 mm (0.0006 to 0.0020 in.)
Maximum clearance:
0.050 mm (0.0020 in.)
If the clearance exceeds the maximum, replace the
needle roller bearing.
D033777
MT–26
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
24. REMOVE TRANSMISSION FRONT CASE
(a) Remove the 4 bolts from the interlock bracket.
F051582
(b) Using a hexagon wrench (24 mm), remove the plug.
F051583
(c) Tie the input shaft, counter gear and control
assembly with a piece of rope or string.
D033636
(d) Expand the 2 snap rings, and lift up the output shaft,
input shaft, counter gear and control assembly.
MT
D033637
D033638
(e) Remove the output shaft, input shaft, counter gear
shaft and control assembly while gently tapping the
clutch housing with a plastic hammer.
NOTICE:
Take care not to subject the output shaft, input
shaft, counter gear shaft and control assembly
to any impact. This could cause the ball and
spring to come out.
(f) Separate the output shaft, input shaft, counter gear
shaft and control assembly.
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT–27
25. REMOVE NO. 1 OIL RECEIVER PIPE
(a) Remove the No. 1 oil receiver pipe from the
transmission front case.
F051585
26. REMOVE FRONT BEARING SHAFT SNAP RING
(a) Using snap ring pliers, remove the 2 snap rings.
D033639
27. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST, remove the transmission case oil seal
from the transmission front case.
SST 09308-00010
SST
F051587E01
28. REMOVE NO. 3 GEAR SHIFT FORK
(a) Remove the bolt, then remove the No. 3 gear shift
fork.
MT
F051588
29. REMOVE NO. 3 GEAR SHIFT FORK SHAFT
(a) Remove the No. 3 shift fork shaft , boll, spring, No. 2
interlock pin and No. 3 interlock pin.
F051829
MT–28
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
30. REMOVE NO. 2 GEAR SHIFT FORK
(a) Remove the bolt, then remove the No. 2 gear shift
fork.
F051589
31. REMOVE NO. 2 GEAR SHIFT FORK SHAFT
(a) Remove the No. 2 shift fork shaft, ball, spring, No. 2
interlock pin and No. 3 interlock pin.
F051830
32. REMOVE NO. 1 GEAR SHIFT HEAD
(a) Using a pin punch (5 mm (0.20 in.)) and hammer,
tap out the slotted pin.
D033718
33. REMOVE NO. 1 GEAR SHIFT FORK SHAFT
(a) Remove the No. 1 shift fork shaft, ball, spring, No. 1
shift head and No. 1 interlock pin.
MT
F051831
34. REMOVE NO. 1 GEAR SHIFT FORK
(a) Using a pin punch (5 mm (0.20 in.)) and hammer,
tap out the slotted pin.
D033720
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT–29
(b) Remove the No. 2 shift head and No. 1 shift fork.
D033721
35. REMOVE NO. 4 GEAR SHIFT FORK
(a) Using a pin punch (5 mm (0.20 in.)) and hammer,
tap out the slotted pin.
(b) Remove the No. 4 shift fork.
D033722
36. REMOVE NO. 4 GEAR SHIFT FORK SHAFT
(a) Remove the No. 4 shift fork shaft, ball and spring.
D033723
37. REMOVE 1ST AND REVERSE SHIFT ARM
(a) Using a screwdriver, remove the E-ring.
MT
D033724
(b) Remove the shift arm pivot and shift arm.
D033725
MT–30
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
REASSEMBLY
1.
INSTALL 1ST AND REVERSE SHIFT ARM
(a) Install the shift arm and shift arm pivot onto the
interlock bracket.
D033725
(b) Install a new E-ring onto the shift arm pivot.
D033724
2.
INSTALL NO. 4 GEAR SHIFT FORK SHAFT
(a) Install the spring and ball onto the interlock bracket.
(b) Install the No. 4 shift fork shaft.
3.
INSTALL NO. 4 GEAR SHIFT FORK
(a) Install the No. 4 shift fork onto the No. 4 shift fork
shaft .
(b) Using a pin punch (5 mm (0.20 in.)) and hammer,
tap a new slotted pin into the No. 4 shaft fork and
No. 4 shift fork shaft.
Drive in depth:
0 to 0.5 mm (0 to 0.050 in.)
4.
INSTALL NO. 1 GEAR SHIFT FORK
(a) Install the No. 1 shift fork and No. 2 shift head onto
the No. 4 shift fork shaft.
(b) Using a pin punch (5 mm (0.20 in.)) and hammer,
tap a new slotted pin into the No. 2 shaft head and
No. 4 shift fork shaft.
Drive in depth:
0 to 0.5 mm (0 to 0.050 in.)
D033723
MT
C136398
C136399
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT–31
5.
INSTALL NO. 1 GEAR SHIFT FORK SHAFT
(a) Apply MP grease to the No. 1 interlock pin and
install it into the interlock bracket.
(b) Install the spring and ball into the interlock bracket.
(c) Install the No. 1 shift fork shaft onto the interlock
bracket.
HINT:
Place the No. 4 shift fork shaft in the neutral
position.
6.
INSTALL NO. 1 GEAR SHIFT HEAD
(a) Install the No. 1 shift head into the No. 1 shift fork
shaft.
(b) Using a pin punch (5 mm (0.20 in.)) and hammer,
tap a new slotted pin into the No. 1 shaft head and
No. 1 shift fork shaft.
Drive in depth:
0 to 0.5 mm (0 to 0.050 in.)
7.
INSTALL NO. 2 GEAR SHIFT FORK SHAFT
(a) Apply MP grease to the No. 2 and No. 3 interlock
pins, then install them onto the interlock bracket.
(b) Install the spring and ball into the interlock bracket.
(c) Install the No. 2 shift fork shaft onto the interlock
bracket.
HINT:
Place the No. 3 and No. 4 shift fork shafts in the
neutral position.
8.
INSTALL NO. 2 GEAR SHIFT FORK
(a) Install the No. 2 shift fork with the bolt.
Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf)
F051831
C136400
F051830
MT
F051589
9.
F051829
INSTALL NO. 3 GEAR SHIFT FORK SHAFT
(a) Apply MP grease to the No. 2 and No. 3 interlock
pins, then install them onto the interlock bracket.
(b) Install the spring and ball into the interlock bracket.
(c) Install the No. 3 shift fork shaft onto the interlock
bracket.
HINT:
Place the No. 2, No. 1 and No. 4 shift fork shafts in
the neutral position.
MT–32
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
10. INSTALL NO. 3 GEAR SHIFT FORK
(a) Install the No. 3 shift fork with the bolt.
Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf)
F051588
11. INSTALL TRANSMISSION CASE OIL SEAL
(a) Using SST and a hammer, tap a new oil seal into
the front case in accordance with the dimension
specified in the illustration.
SST 09950-70010 (09951-07100), 09950-60010
(09951-00470)
Dimension A:
60.0 to 60.8 mm (2.362 to 2.394 in.)
(b) Apply gear oil to the lip of the oil seal.
SST
A
D033643E01
12. INSTALL FRONT BEARING SHAFT SNAP RING
(a) Using snap ring pliers, install the 2 snap rings.
D033639
13. INSTALL NO. 1 OIL RECEIVER PIPE
(a) Install the No. 1 oil receiver pipe onto the
transmission front case.
HINT:
Align the convex portion of the oil receiver pipe with
the cutout of the front case and install the oil
receiver pipe onto the clutch housing.
MT
D033642
14. INSTALL TRANSMISSION FRONT CASE
(a) Apply gear oil to all sliding and rotating parts.
(b) Provisionally install the output shaft, input shaft,
counter gear shaft and control assembly, and tie
them with a piece of rope or string.
D033644
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT–33
(c) Using a snap ring expander, extend the 2 snap rings
and install the output shaft, input shaft, counter gear
shaft and control assembly.
HINT:
Make sure that the snap ring is fitted into the
grooves of the input shaft and front bearing of the
counter gear shaft.
(d) Untie the output shaft, input shaft, counter gear
shaft and control assembly.
D033637
(e) Using a hexagonal wrench (24 mm), install the plug
onto the front case.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
F051583
(f)
Install the interlock bracket with the 4 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
D033635
15. INSTALL REVERSE IDLER GEAR
(a) Install the reverse idler gear, reverse idler gear
bearing and reverse idler gear shaft.
HINT:
Make sure that the reverse idler gear faces the
correct direction as shown in the illustration.
NOTICE:
Make sure that the hole in the reverse idler shaft
is in the position shown in the illustration.
15q
C116297E01
MT
MT–34
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
16. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
(a) Using SST, install the back-up light switch with a
new gasket onto the transmission front case.
SST 09817-16011
Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)
SST
F051581E01
17. INSTALL SHIFT AND SELECT LEVER CAM
(a) Install the shift and select lever cam onto the shaft
and install a new E-ring.
F051580
18. INSTALL SHIFT AND SELECT LEVER
(a) Install the lock ball pin and spring onto the shift and
select lever.
(b) Install the shift and select lever onto the shift and
select lever cam and shaft.
(c) Install the bolt onto the shift and select lever.
Torque: 33 N*m (340 kgf*cm, 25 ft.*lbf)
F051579
19. INSTALL SHIFT AND SELECT LEVER SHAFT
(a) Align the groove of the shift and select cam with the
reverse idler shaft, and the claw with the groove of
the control assembly, and install them.
MT
D033647
20. INSTALL NO. 2 OIL RECEIVER PIPE
(a) Install the No. 2 oil receiver pipe into the
transmission middle case.
F051577
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT–35
21. INSTALL DRAIN PLUG SUB-ASSEMBLY
(a) Install the drain plug with a new gasket onto the
transmission middle case.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
F051576
FIPG
D033756E01
22. INSTALL TRANSMISSION MIDDLE CASE
(a) Apply FIPG to the transmission middle case, as
shown in the illustration.
FIPG:
Toyota Genuine Seal Packing 1281, Three
Bond 1281 or Equivalent
NOTICE:
Parts must be assembled within 10 minutes of
the application. Otherwise, the packing (FIPG)
material must be removed and reapplied.
(b) Install the transmission middle case with the 11 bolts
onto the transmission front case.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
Bolt length:
Bolt A: 40 mm (1.57 in.)
Bolt B: 80 mm (3.15 in.)
D033740
23. INSTALL REVERSE IDLER GEAR SHAFT BOLT
(a) Install a new gasket and the reverse idler gear shaft
bolt onto the reverse idler gear shaft.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
MT
D033649
24. INSTALL TRANSMISSION OIL SEPARATOR
(a) Install the transmission oil separator with the 2 bolts.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
F051575
MT–36
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
25. INSTALL COUNTER GEAR REAR RADIAL BALL
BEARING
(a) Coat a new counter gear rear radial ball bearing
with gear oil, and using SST and a press, install it
into the transmission rear case.
SST 09950-70010 (09951-07360), 09950-60010
(09951-00650)
SST
D033750E01
(b) Install the bearing lock plate with the bolt.
Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
D033746
26. INSTALL OUTPUT SHAFT REAR BEARING OUTER
RACE
(a) Using SST and a press, press in 2 new bearing
outer races.
SST 09950-70010 (09951-07100, 09951-07360),
09950-60020 (09951-00790)
SST
SST
D033749E01
27. INSTALL OIL SEPARATOR PACKING SEAL
(a) Install the oil separator packing seal onto the
transmission rear case.
HINT:
Insert the protruding part of the oil separator
packing seal into the groove on the transmission
rear case.
MT
D033752
28. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE
(a) Install the extension housing oil receiver pipe onto
the transmission rear case.
F051573
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT–37
29. INSTALL MANUAL TRANSMISSION FILLER PLUG
(a) Install the 2 transmission filler plugs with 2 new
gaskets onto the transmission rear case.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
F051572
FIPG
D033757E01
30. INSTALL TRANSMISSION REAR CASE
(a) Apply FIPG to the transmission rear case, as shown
in the illustration.
FIPG:
Toyota Genuine Seal Packing 1281, Three
Bond 1281 or Equivalent
NOTICE:
Parts must be assembled within 10 minutes of
the application. Otherwise, the packing (FIPG)
material must be removed and reapplied.
(b) Install the transmission rear case with the 10 bolts
and 3 brackets onto the transmission middle case.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
Clamp
Clamp
D033738E01
31. INSTALL SHIFT DETENT BALL PLUG
(a) Install the ball and compression spring onto the
transmission rear case.
(b) Install a new shift detent ball plug, and install it onto
the transmission rear case.
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
F051570
32. INSTALL OUTPUT SHAFT ADJUST NUT
(a) Using a belt and wooden block, fasten the
transmission to the workbench.
(b) Install a new spacer and output shaft taper roller
bearing No. 2.
D033736
MT
MT–38
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
(c) Using a socket wrench (60 mm), provisionally
tighten a new nut until there is no slack in the output
shaft.
HINT:
No preload should be applied to the nut.
(d) Fit the bearing into the output shaft by turning the
output shaft 15 times.
F051841
D033759
(e) Place the gearshift into 5th gear and check the initial
torque of the input shaft.
(f) Using a socket wrench (60 mm), tighten the nut.
(g) Place the gearshift into 5th gear and check the initial
torque of the input shaft.
(h) Confirm that the difference between (e) and (g) is
within the specified values.
Preload (at starting):
0.45 to 1.35 N*m (4.59 to 13.77 kgf*cm, 3.98 to
11.95 in.*lbf)
If the result is not as specified, tighten and adjust
the output shaft adjusting nut.
NOTICE:
If the output shaft adjusting nut is loose or
removed due to a large preload, always replace
the spacer with a new one.
(i)
Using a chisel and hammer, caulk the output shaft
adjust nut.
D033734
MT
F051645
33. INSTALL MANUAL TRANSMISSION CASE COVER
SUB-ASSEMBLY
(a) Apply FIPG to the transmission case cover, as
shown in the illustration.
FIPG:
Toyota Genuine Seal Packing 1281, Three
Bond 1281 or Equivalent
NOTICE:
Parts must be assembled within 10 minutes of
the application. Otherwise, the packing (FIPG)
material must be removed and reapplied.
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT–39
(b) Install the transmission case cover with the 4 bolts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
F051569
34. INSTALL SHIFT LEVER HOUSING
(a) Install the shift lever housing with the bolt.
Torque: 33 N*m (340 kgf*cm, 25 ft.*lbf)
F051568
FIPG
D033761E01
35. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER
RETAINER SUB-ASSEMBLY
(a) Apply FIPG to the floor shift control shift lever
retainer, as shown in the illustration.
FIPG:
Toyota Genuine Seal Packing 1281, Three
Bond 1281 or Equivalent
NOTICE:
Parts must be assembled within 10 minutes of
the application. Otherwise, the packing (FIPG)
material must be removed and reapplied.
(b) Install the floor shift control shift lever retainer with
the 4 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
MT
F051567
MT–40
RA61F MANUAL TRANSMISSION – INPUT SHAFT
INPUT SHAFT
RA61F MANUAL TRANSMISSION
TRANSMISSION
COMPONENTS
3RD GEAR NEEDLE
ROLLER BEARING
3RD GEAR THRUST WASHER
SNAP RING
STRAIGHT PIN
3RD GEAR
SPACER
NO. 1 SYNCHRONIZER
SHIFTING KEY
NO. 1 SYNCHRONIZER
SHIFTING KEY SPRING
NO. 2 TRANSMISSION
HUB SLEEVE
BALL
MT
SNAP RING
NO. 3 TRANSMISSION
CLUTCH HUB
SPACER
6TH GEAR
6TH GEAR NEEDLE
ROLLER BEARING
NO. 3 SYNCHRONIZER
RING (FOR 6TH GEAR)
Non-reusable part
C136410E01
MT–41
RA61F MANUAL TRANSMISSION – INPUT SHAFT
INPUT SHAFT FRONT BEARING
INPUT SHAFT
SNAP RING
SYNCHRONIZER SHIFTING
KEY SPRING
NO. 2 TRANSMISSION
HUB SLEEVE
SYNCHRONIZER
SHIFTING KEY
SNAP
RING
BALL
MT
NO. 2 SYNCHRONIZER
RING SET
4TH GEAR NEEDLE
ROLLER BEARING
Non-reusable part
NO. 2 TRANSMISSION CLUTCH HUB
4TH GEAR
NO. 3 SYNCHRONIZER
RING (FOR 4TH GEAR)
C136403E01
MT–42
RA61F MANUAL TRANSMISSION – INPUT SHAFT
DISASSEMBLY
1.
INSPECT 6TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 6th gear thrust
clearance.
Standard clearance:
0.20 to 0.49 mm (0.0079 to 0.0193 in.)
If the clearance is outside the specification, replace
the defective gear, spacer or shaft.
2.
INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 3rd gear thrust
clearance.
Standard clearance:
0.09 to 0.52 mm (0.0035 to 0.0205 in.)
If the clearance is outside the specification, replace
the defective gear, thrust washer, clutch hub or
shaft.
3.
INSPECT 4TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 4th gear thrust
clearance.
Standard clearance:
0.12 to 0.38 mm (0.0047 to 0.0150 in.)
If the clearance is outside the specification, replace
the defective gear, clutch hub or shaft.
4.
INSPECT 6TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 6th gear radial
clearance.
Standard clearance:
0.015 to 0.065 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the defective gear, needle roller bearing or shaft.
5.
INSPECT 3RD GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 3rd gear radial
clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the defective gear, needle roller bearing or shaft.
F051109E01
F051110E01
F051111E01
MT
F051106E01
F051107E01
RA61F MANUAL TRANSMISSION – INPUT SHAFT
MT–43
6.
INSPECT 4TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 4th gear radial
clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the defective gear, needle roller bearing or shaft.
7.
REMOVE TRANSMISSION CLUTCH HUB NO.3
SHAFT SNAP RING
(a) Using 2 screwdrivers and a hammer, tap out the
snap ring.
HINT:
Use a shop rag or a piece of cloth to prevent the
snap ring from flying off.
8.
REMOVE 6TH GEAR
(a) Using SST and a press, remove transmission clutch
hub No. 3, the hub sleeve, synchronizer ring and 6th
gear from the input shaft.
SST 09950-00020, 09950-70010 (09951-07200),
09950-60010 (09951-00300)
NOTICE:
• Do not tighten SST excessively.
• Support the input shaft by hand so that it
does not fall off.
9.
REMOVE 6TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 6th gear needle roller bearing from the
input shaft.
F051108E01
D033652E01
SST
D033653E01
MT
F051087E01
10. REMOVE SPACER
(a) Remove the spacer from the input shaft.
F051088E01
MT–44
RA61F MANUAL TRANSMISSION – INPUT SHAFT
11. REMOVE GEAR THRUST WASHER SHAFT SNAP
RING
(a) Using a snap ring expander, remove the snap ring
from the input shaft.
D033654E01
12. REMOVE 3RD GEAR THRUST WASHER
(a) Remove the 3rd gear thrust washer from the input
shaft.
F051090E01
13. REMOVE 3RD GEAR
(a) Remove the 3rd gear from the input shaft.
F051091E01
14. REMOVE STRAIGHT PIN
(a) Remove the straight pin from the input shaft.
MT
F051092E01
15. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
(a) Remove the 3rd gear needle roller bearing from the
input shaft.
F051093E01
RA61F MANUAL TRANSMISSION – INPUT SHAFT
MT–45
16. REMOVE SPACER
(a) Remove the spacer from the input shaft.
F051094E01
17. REMOVE NO. 2 SYNCHRONIZER RING SET
(a) Remove the No. 2 synchronizer ring set from the
input shaft.
F051095E01
18. REMOVE CLUTCH HUB NO.2 SETTING SHAFT SNAP
RING
(a) Using a snap ring expander, remove the snap ring
from the input shaft.
D033657E01
19. REMOVE 4TH GEAR
(a) Using SST and a press, remove transmission clutch
hub No. 2, the hub sleeve, synchronizer ring and 4th
gear from the input shaft.
SST 09950-00020
NOTICE:
Support the input shaft by hand so that it does
not fall off.
SST
D033658E01
20. REMOVE 4TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 4th gear needle roller bearing from the
input shaft.
F051098E01
MT
MT–46
RA61F MANUAL TRANSMISSION – INPUT SHAFT
21. REMOVE INPUT SHAFT FRONT BEARING SNAP
RING
(a) Using 2 screwdrivers and a hammer, tap out the
snap ring.
HINT:
Use a shop rag or piece of cloth to prevent the snap
ring from flying off.
D033659E01
22. REMOVE INPUT SHAFT FRONT BEARING
(a) Using SST and a press, remove the input shaft front
bearing from the input shaft.
SST 09950-00020
NOTICE:
Support the input shaft by hand so that it does
not fall off.
SST
D033660E01
23. REMOVE NO. 2 TRANSMISSION CLUTCH HUB
(a) Remove the clutch hub, 3 synchromesh shifting
keys, 3 balls and 3 springs from the hub sleeve.
HINT:
Use a shop rag or piece of cloth to prevent the ball
and spring from flying off.
Spring
Ball
Synchromesh
Shifting Key
24. REMOVE NO. 3 TRANSMISSION CLUTCH HUB
(a) Perform the same procedures as for the No. 2
clutch hub.
C136406E01
INSPECTION
1.
MT
F051113E01
INSPECT INPUT SHAFT
(a) Using a dial indicator and 2 V-blocks, measure the
shaft runout.
Maximum runout:
0.03 mm (0.0012 in.)
If the runout exceeds the maximum, replace the
input shaft.
MT–47
RA61F MANUAL TRANSMISSION – INPUT SHAFT
(b) Using a micrometer, measure the outer diameters of
the input shaft journal surface, at the specified
positions.
Standard
Part
Outer diameter mm (in.)
A
34.002 to 34.015 (1.3387 to 1.3392)
B
44.985 to 45.000 (1.7711 to 1.7717)
C
44.985 to 45.000 (1.7711 to 1.7717)
D
41.985 to 42.000 (1.6530 to 1.6535)
E
32.967 to 32.974 (1.2979 to 1.2982)
Minimum
A
B
C D
E
Part
Outer diameter mm (in.)
A
34.002 (1.3387)
B
44.985 (1.7711)
C
44.985 (1.7711)
D
41.985 (1.6530)
E
32.967 (1.2979)
If any of the outer diameters are less than the
minimum, replace the input shaft.
D033763E01
2.
INSPECT 6TH GEAR
(a) Using a cylinder gauge, measure the inside
diameter of the 6th gear.
Standard inside diameter:
51.015 to 51.040 mm (2.0085 to 2.0095 in.)
Maximum inside diameter:
51.040 mm (2.0095 in.)
If the inside diameter exceeds the maximum,
replace the 4th gear.
3.
INSPECT 3RD GEAR
(a) Using a cylinder gauge, measure the inside
diameter of the 3rd gear.
Standard inside diameter:
51.015 to 51.040 mm (2.0085 to 2.0095 in.)
Maximum inside diameter:
51.040 mm (2.0095 in.)
If the inside diameter exceeds the maximum,
replace the 3rd gear.
F051115E01
F051116E01
4.
F051117E01
INSPECT 4TH GEAR
(a) Using a cylinder gauge, measure the inside
diameter of the 4th gear.
Standard inside diameter:
51.015 to 51.040 mm (2.0085 to 2.0095 in.)
Maximum inside diameter:
51.040 mm (2.0095 in.)
If the inside diameter exceeds the maximum,
replace the 4th gear.
MT
MT–48
RA61F MANUAL TRANSMISSION – INPUT SHAFT
5.
INSPECT NO. 2 TRANSMISSION HUB SLEEVE
(a) Check the sliding condition between the No. 2
transmission hub and No. 2 transmission hub
sleeve.
(b) Check that the spline gear teeth of the No. 2
transmission hub sleeve are not worn.
C067843E01
(c) Using vernier calipers, measure the width of the No.
2 transmission hub sleeve groove (A) and the
thickness of the claw part on the No. 2 or No. 3 gear
shift forks (B), and calculate the clearance.
Standard clearance:
(A - B);
0.28 to 0.84 mm (0.0110 to 0.0331 in.) for No. 2
gear shift fork
0.28 to 0.65 mm (0.0110 to 0.0256 in.) for No. 3
gear shift fork
If the clearance is outside the specification, replace
the No. 2 transmission hub sleeve and gear shift
fork.
A
B
F051119E01
6.
MT
F051611E01
INSPECT NO. 3 SYNCHRONIZER RING (FOR 6TH
GEAR)
(a) Using a feeler gauge, measure the clearance
between the synchronizer ring and the 6th gear.
Standard clearance:
0.70 to 1.50 mm (0.0276 to 0.0591 in.)
Minimum clearance:
0.70 mm (0.0276 in.)
If the clearance is less than the minimum, replace
the synchronizer ring.
(b) Coat the 6th gear cone with gear oil. Check the
braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to
the 6th gear cone. Check that the ring locks.
F051612E01
RA61F MANUAL TRANSMISSION – INPUT SHAFT
7.
F051613E01
MT–49
INSPECT NO. 2 SYNCHRONIZER RING SET (FOR
3RD GEAR)
(a) Using a feeler gauge, measure the clearance
between the synchronizer ring and the 3rd gear.
Standard clearance:
Inner:
1.20 to 2.20 mm (0.0472 to 0.0866 in.)
Middle:
0.60 to 1.80 mm (0.0236 to 0.0709 in.)
Outer:
0.80 to 1.80 mm (0.0315 to 0.0709 in.)
Minimum clearance:
Inner:
1.20 mm (0.0472 in.)
Middle:
0.60 mm (0.0236 in.)
Outer:
0.80 mm (0.0315 in.)
If the clearance is less than the minimum, replace
the synchronizer ring.
(b) Coat the 3rd gear cone with gear oil. Check the
braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to
the 3rd gear cone. Check that the ring locks.
F051614E01
8.
F051611E01
INSPECT NO. 3 SYNCHRONIZER RING (FOR 4TH
GEAR)
(a) Using a feeler gauge, measure the clearance
between the synchronizer ring and 4th gear.
Standard clearance:
0.70 to 1.50 mm (0.0276 to 0.0591 in.)
Minimum clearance:
0.70 mm (0.0276 in.)
If the clearance is less than the minimum, replace
the synchronizer ring.
(b) Coat the 4th gear cone with gear oil. Check the
braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to
the 4th gear cone. Check that the ring locks.
F051612E01
MT
MT–50
RA61F MANUAL TRANSMISSION – INPUT SHAFT
9.
INSPECT 3RD GEAR THRUST WASHER
(a) Using a micrometer, measure the thrust washer
thickness.
Standard thickness:
7.12 to 7.18 mm (0.2803 to 0.2827 in.)
Minimum thickness:
7.12 mm (0.2803 in.)
If the thickness is less than the minimum, replace
the thrust washer.
F051615E01
REASSEMBLY
1.
INSTALL INPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the input shaft front
bearing onto the input shaft.
SST 09950-00020
HINT:
Make sure that the groove of the bearing faces the
correct direction as shown in the illustration.
2.
INSTALL INPUT SHAFT FRONT BEARING SNAP
RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness
SST
D033669E01
Part No.
Thickness: mm (in.)
Mark
90520-31026
2.65 to 2.70
(0.1043 to 0.1063)
A
90520-31027
2.70 to 2.75
(0.1063 to 0.1083)
B
90520-31028
2.75 to 2.80
(0.1083 to 0.1102)
C
90520-31029
2.80 to 2.85
(0.1102 to 0.1122)
D
90520-31030
2.85 to 2.90
(0.1122 to 0.1142)
E
90520-31031
2.90 to 2.95
(0.1142 to 0.1161)
F
F051102E01
MT
(b) Using a brass bar and hammer, install the snap ring
onto the input shaft.
RA61F MANUAL TRANSMISSION – INPUT SHAFT
4th Gear Side:
MT–51
3.
INSTALL NO. 2 TRANSMISSION CLUTCH HUB
(a) Apply a light coat of gear oil to the sleeve and hub.
(b) Install the clutch hub sleeve onto the No. 2 clutch
hub.
(c) Put the ball into the keyhole from the bottom.(*1)
(d) Put the spring under the ball.(*2)
(e) Insert the ball and spring into the No. 2 clutch hub
while attached onto the key.(*3)
NOTICE:
Prevent the ball from flying off.
HINT:
• Perform the same procedure (*1 through *3) for
all the 3 portions.
• Make sure that the No. 2 clutch hub faces the
correct direction as shown in the illustration.
4.
INSTALL NO. 3 TRANSMISSION CLUTCH HUB
(a) Apply a light coat of gear oil to the sleeve and hub.
(b) Install the clutch hub sleeve onto the No. 3 clutch
hub.
(c) Put the ball into the keyhole from the bottom.(*1)
(d) Put the spring under the ball.(*2)
(e) Insert the ball and spring into the No. 3 clutch hub
while attached onto the key.(*3)
NOTICE:
Prevent the ball from flying off.
HINT:
• Perform the same procedure (*1 through *3) for
all the 3 portions.
• Make sure that the No. 3 clutch hub faces the
correct direction as shown in the illustration.
3rd Gear Side:
A
A>B
B
C136402E01
6th Gear Side:
5th Gear Side:
MT
C136401E01
F051098E01
5.
INSTALL 4TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 4th gear needle roller bearing with gear oil,
then install it onto the input shaft.
6.
INSTALL 4TH GEAR
(a) Coat the 4th gear and No. 3 synchronizer ring with
gear oil, then install them onto the input shaft.
MT–52
RA61F MANUAL TRANSMISSION – INPUT SHAFT
(b) Using SST and a press, install the No. 2 clutch hub
onto the input shaft.
SST 09308-14010
HINT:
Align the convex portion of the synchronizer ring
with the groove of the clutch hub.
(c) Install the clutch hub and confirm that the gear and
synchronizer ring move smoothly.
SST
F051618E01
7.
INSTALL CLUTCH HUB NO.2 SETTING SHAFT SNAP
RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness
Part No.
Thickness: mm (in.)
Mark
90520-42012
1.77 to 1.82
(0.0697 to 0.0717)
A
90520-42013
1.82 to 1.87
(0.0717 to 0.0736)
B
90520-42014
1.87 to 1.92
(0.0736 to 0.0756)
C
90520-42015
1.92 to 1.97
(0.0756 to 0.0776)
D
90520-42016
1.97 to 2.02
(0.0776 to 0.0795)
E
90520-42017
2.02 to 2.07
(0.0795 to 0.0815)
F
90520-42018
2.07 to 2.12
(0.0815 to 0.0835)
G
D033657E01
(b) Using a snap ring expander, install the snap ring
onto the input shaft.
8.
MT
F051095E01
INSTALL NO. 2 SYNCHRONIZER RING SET
(a) Coat the No. 2 synchronizer ring set with gear oil,
then install it onto the input shaft.
RA61F MANUAL TRANSMISSION – INPUT SHAFT
9.
MT–53
INSTALL SPACER
(a) Coat the spacer with gear oil, and install it onto the
input shaft.
F051094E01
10. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
(a) Coat the 3rd gear needle roller bearing with gear oil,
and install it onto the input shaft.
F051093E01
11. INSTALL STRAIGHT PIN
(a) Install the straight pin into the input shaft.
F051092E01
12. INSTALL 3RD GEAR
(a) Coat the 3rd gear with gear oil, and install it onto the
input shaft.
MT
F051091E01
13. INSTALL 3RD GEAR THRUST WASHER
(a) Coat the 3rd gear thrust washer with gear oil, and
install it onto the input shaft.
HINT:
Align the straight pin with the groove of the gear
thrust washer and install it.
F051090E01
MT–54
RA61F MANUAL TRANSMISSION – INPUT SHAFT
14. INSTALL GEAR THRUST WASHER SHAFT SNAP
RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness
Part No.
Thickness: mm (in.)
Mark
90520-39026
2.07 to 2.12
(0.0815 to 0.0835)
A
90520-39027
2.12 to 2.17
(0.0835 to 0.0854)
B
90520-39028
2.17 to 2.22
(0.0854 to 0.0874)
C
90520-39029
2.22 to 2.27
(0.0874 to 0.0894)
D
90520-39030
2.27 to 2.32
(0.0894 to 0.0913)
E
90520-39031
2.32 to 2.37
(0.0913 to 0.0933)
F
D033654E01
(b) Using a snap ring expander, install the snap ring
onto the input shaft.
15. INSTALL SHAFT SNAP RING
(a) Coat the shaft snap ring with gear oil, and install it
onto the input shaft.
F051088E01
16. INSTALL 6TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 6th gear needle roller bearing with gear oil,
and install it onto the input shaft.
MT
F051087E01
MT–55
RA61F MANUAL TRANSMISSION – INPUT SHAFT
17. INSTALL 6TH GEAR
(a) Install the 6th gear onto the input shaft.
(b) Install the synchronizer ring onto the input shaft.
(c) Using SST and a press, install the clutch hub onto
the input shaft.
SST 09309-37010, 09950-00020
(d) Install the clutch hub and confirm that the gear and
synchronizer ring move smoothly.
SST
SST
F051619E01
18. INSTALL TRANSMISSION CLUTCH HUB NO.3 SHAFT
SNAP RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness
Part No.
Thickness: mm (in.)
Mark
90520-33022
2.10 to 2.15
(0.0827 to 0.0847)
A
90520-33023
2.15 to 2.20
(0.0847 to 0.0866)
B
90520-33024
2.20 to 2.25
(0.0866 to 0.0886)
C
90520-33025
2.25 to 2.30
(0.0886 to 0.0906)
D
90520-33026
2.30 to 2.35
(0.0906 to 0.0925)
E
90520-33027
2.35 to 2.40
(0.0925 to 0.0945)
F
90520-33028
2.40 to 2.45
(0.0945 to 0.0965)
G
F051105E01
(b) Using a brass bar and a hammer, install the snap
ring onto the input shaft.
MT
MT–56
RA61F MANUAL TRANSMISSION – INPUT SHAFT
19. INSPECT 6TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 6th gear thrust
clearance.
Standard clearance:
0.20 to 0.49 mm (0.0079 to 0.0193 in.)
If the clearance is outside the specification, replace
the defective gear, spacer or shaft.
F051109E01
20. INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 3rd gear thrust
clearance.
Standard clearance:
0.09 to 0.52 mm (0.0035 to 0.0205 in.)
If the clearance is outside the specification, replace
the defective gear, thrust washer, clutch hub or
shaft.
F051110E01
21. INSPECT 4TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 4th gear thrust
clearance.
Standard clearance:
0.12 to 0.38 mm (0.0047 to 0.0150 in.)
If the clearance is outside the specification, replace
the defective gear, clutch hub or shaft.
F051111E01
22. INSPECT 6TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 6th gear radial
clearance.
Standard clearance:
0.015 to 0.065 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the defective gear, needle roller bearing or shaft.
MT
F051106E01
23. INSPECT 3RD GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 3rd gear radial
clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the defective gear, needle roller bearing or shaft.
F051107E01
RA61F MANUAL TRANSMISSION – INPUT SHAFT
MT–57
24. INSPECT 4TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 4th gear radial
clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the defective gear, needle roller bearing or shaft.
F051108E01
MT
MT–58
RA61F MANUAL TRANSMISSION – OUTPUT SHAFT
OUTPUT SHAFT
RA61F MANUAL TRANSMISSION
TRANSMISSION
COMPONENTS
OUTPUT SHAFT
REAR BEARING
OUTPUT SHAFT
NO. 3 SYNCHRONIZER RING
MT
OUTPUT SHAFT
CENTER BEARING
Non-reusable part
Apply MP grease
C114068E03
RA61F MANUAL TRANSMISSION – OUTPUT SHAFT
MT–59
DISASSEMBLY
1.
REMOVE NO. 3 SYNCHRONIZER RING
(a) Remove the No. 3 synchronizer ring from the output
shaft.
2.
REMOVE OUTPUT SHAFT CENTER BEARING
(a) Remove the output shaft center bearing from the
output shaft.
3.
REMOVE OUTPUT SHAFT REAR BEARING
(a) Using SST and a press, remove the output shaft
rear bearing from the output shaft.
SST 09950-00020, 09950-70010 (09951-07100),
09950-60010 (09951-00510)
SST
F051075E01
INSPECTION
1.
INSPECT OUTPUT SHAFT
(a) Using a cylinder gauge, measure the inside
diameter of the output shaft.
Standard inside diameter:
45.017 to 45.025 mm (1.7723 to 1.7726 in.)
Maximum inside diameter:
45.025 mm (1.7726 in.)
If the diameter exceeds the maximum, replace the
output shaft.
2.
INSPECT NO. 3 SYNCHRONIZER RING
(a) Using a feeler gauge, measure the clearance
between the synchronizer ring and gear spline.
Standard clearance:
0.70 to 1.50 mm (0.0276 to 0.0591 in.)
Minimum clearance:
0.70 mm (0.0276 in.)
If the clearance is less than the minimum, replace
the synchronizer ring.
F051607
F051608
(b) Coat the output shaft and synchronizer ring cone
with gear oil. Check the braking effect of the
synchronizer ring. Turn the synchronizer ring in one
direction while pushing it to the gear cone. Check
that the ring locks.
F051609
MT
MT–60
RA61F MANUAL TRANSMISSION – OUTPUT SHAFT
REASSEMBLY
1.
INSTALL OUTPUT SHAFT REAR BEARING
(a) Using SST and a press, install a new output shaft
rear bearing onto the output shaft.
SST 09316-60011 (09316-00011)
(b) Apply a light coat of MP grease to the bearing.
2.
INSTALL OUTPUT SHAFT CENTER BEARING
(a) Apply gear grease to the output shaft center bearing
and install it onto the output shaft.
3.
INSTALL NO. 3 SYNCHRONIZER RING
(a) Apply gear oil to the No. 3 synchronizer ring, and
install it onto the output shaft.
SST
F051076E01
MT
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
MT–61
COUNTER GEAR AND REVERSE IDLER GEAR
RA61F MANUAL TRANSMISSION
TRANSMISSION
COMPONENTS
NO. 3 SYNCHROMESH
SHIFTING KEY SPRING
REVERSE GEAR
BEARING RACE
INNER
REVERSE GEAR
NEEDLE ROLLER
BEARING
SNAP RING
NO. 4 SYNCHROMESH
SHIFTING KEY
COUNTER GEAR FRONT
BEARING OR ROLLER
NO. 3 TRANSMISSION
HUB SLEEVE
COUNTERSHAFT
REVERSE GEAR
1ST GEAR NEEDLE
ROLLER BEARING
MT
BALL
NO. 1 SYNCHRONIZER
RING SET (FOR 1ST GEAR)
COUNTERSHAFT
GEAR 1ST SPEED
NO. 4 SYNCHRONIZER
RING
REVERSE GEAR
SPLINE PIECE
Non-reusable part
C114072E07
MT–62
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
2ND GEAR NEEDLE
ROLLER BEARING
BALL
NO. 1 SYNCHROMESH
SHIFTING KEY SPRING
NO. 1 SYNCHROMESH
SHIFTING KEY
COUNTER SHAFT
2ND SPEED GEAR
NO. 1 SYNCHRONIZER
RING SET (FOR 2ND GEAR)
NO. 1 TRANSMISSION
HUB SLEEVE
NO. 1 TRANSMISSION CLUTCH HUB
SNAP RING
SNAP RING
RADIAL BALL BEARING
INNER RACE
MT
COUNTER GEAR
Non-reusable part
C114071E04
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
MT–63
DISASSEMBLY
1.
INSPECT REVERSE GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the reverse gear
thrust clearance.
Standard clearance:
0.125 to 0.375 mm (0.0049 to 0.0148 in.)
If the clearance is outside the specification, replace
the defective gear, spline piece or bearing race.
2.
INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 1st gear thrust
clearance.
Standard clearance:
0.10 to 0.43 mm (0.0039 to 0.0169 in.)
If the clearance is outside the specification, replace
the defective gear, clutch hub, spline piece or
counter gear.
3.
INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 2nd gear thrust
clearance.
Standard clearance:
0.10 to 0.43 mm (0.0039 to 0.0169 in.)
If the clearance is outside the specification, replace
the defective gear, clutch hub or counter gear.
4.
INSPECT REVERSE GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the reverse gear
radial clearance.
Standard clearance:
0.015 to 0.065 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the reverse gear needle roller bearing or shaft.
F051532E01
F051533E01
F051534E01
F051535E01
5.
F051536E01
INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 1st gear radial
clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the 1st gear needle roller bearing or shaft.
MT
MT–64
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
6.
INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 2nd gear radial
clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the 2nd gear needle roller bearing or shaft.
7.
REMOVE COUNTER GEAR FRONT BEARING SNAP
RING NO.1
(a) Using a snap ring expander, remove the snap ring
from the counter gear.
8.
REMOVE COUNTER GEAR FRONT BEARING OR
ROLLER
(a) Using SST and a press, remove the counter gear
front bearing or roller from the counter gear.
SST 09950-00020, 09950-70010 (09951-07100),
09950-60010 (09951-00320)
9.
REMOVE REVERSE GEAR BEARING RACE INNER
(a) Remove the reverse gear bearing race inner from
the counter gear.
F051537E01
D033690E01
SST
F051539E01
MT
F051540E01
10. REMOVE COUNTERSHAFT REVERSE GEAR
(a) Remove the countershaft reverse gear from the
counter gear.
(b) Remove the hub sleeve, 2 shifting keys and key
spring from the countershaft reverse gear.
F051541E01
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
MT–65
11. REMOVE REVERSE GEAR NEEDLE ROLLER
BEARING
(a) Remove the reverse gear needle roller bearing from
the counter gear.
F051542E01
12. REMOVE NO. 4 SYNCHRONIZER RING
(a) Remove the No. 4 synchronizer ring from the
counter gear.
F051543E01
13. REMOVE BALL
(a) Remove the ball from the counter gear.
F051544E01
14. REMOVE COUNTERSHAFT GEAR 1ST SPEED
(a) Using a press, remove the countershaft gear 1st
speed together with the reverse gear spline piece
from the counter gear.
SST 09950-00020
SST
F051630E01
15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the
counter gear.
F051546E01
MT
MT–66
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
16. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR
1ST GEAR)
(a) Remove the No. 1 synchronizer ring set from the
counter gear.
C136407
17. REMOVE CLUTCH HUB NO.1 SHAFT SNAP RING
(a) Using a snap ring expander, remove the snap ring
from the counter gear.
D033696E01
18. REMOVE COUNTER SHAFT 2ND SPEED GEAR
(a) Using a press, remove the counter shaft 2nd speed
gear together with the No. 1 transmission clutch hub
from the counter gear.
SST 09950-00020
SST
F051632E01
19. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
(a) Remove the 2nd needle roller bearing from the
counter gear.
MT
F051551E01
20. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR
2ND GEAR)
(a) Remove the No. 1 synchronizer ring set from the
2nd gear.
F051633E01
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
21. REMOVE NO. 1 TRANSMISSION CLUTCH HUB
(a) Remove the hub sleeve, 3 synchromesh shifting
keys, 3 balls and 3 springs from the clutch hub.
HINT:
Use a shop rag or piece of cloth to prevent the ball
and spring from flying off.
Clutch Hub
Spring
Ball
MT–67
Hub Sleeve
Synchromesh Shifting Key
F051634E02
22. REMOVE SNAP RING COUNTER GEAR REAR
BEARING
(a) Using a snap ring expander, remove the snap ring
from the counter gear.
D033689E01
23. REMOVE RADIAL BALL BEARING INNER RACE
(a) Using SST and a press, remove the needle roller
bearing inner race.
SST 09950-00020
SST
F051635E01
INSPECTION
1.
F051553E01
INSPECT COUNTER GEAR
(a) Using a dial indicator and 2 V-blocks, measure the
shaft runout.
Maximum runout:
0.03 mm (0.0012 in.)
If the runout exceeds the maximum, replace the
counter gear.
MT
MT–68
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
(b) Using a micrometer, measure the outer diameters of
the input shaft journal surface, at the specified
positions.
Standard
Part
Outer diameter mm (in.)
A
34.002 to 34.015 (1.3387 to 1.3392)
B
36.985 to 37.000 (1.4561 to 1.4567)
C
47.985 to 48.000 (1.8892 to 1.8898)
D
53.985 to 54.000 (2.1254 to 2.1260)
E
34.002 to 34.015 (1.3387 to 1.3392)
Minimum
A B
C
D
E
Part
Outer diameter mm (in.)
A
34.002 (1.3387)
B
36.985 (1.4561)
C
47.985 (1.8892)
D
53.985 (2.1254)
E
34.002 (1.3387)
If any of the diameters are less than the minimum,
replace the counter gear shaft.
D033700E01
2.
INSPECT COUNTERSHAFT REVERSE GEAR
(a) Using a cylinder gauge, measure the inside
diameter of the reverse gear.
Standard inside diameter:
51.015 to 51.040 mm (2.0085 to 2.0095 in.)
Maximum inside diameter:
51.040 mm (2.0095 in.)
If the inside diameter exceeds the maximum,
replace the reverse gear.
3.
INSPECT COUNTERSHAFT GEAR 1ST SPEED
(a) Using a cylinder gauge, measure the inside
diameter of the 1st gear.
Standard inside diameter:
54.015 to 54.040 mm (2.1266 to 2.1276 in.)
Maximum inside diameter:
54.040 mm (2.1276 in.)
If the inside diameter exceeds the maximum,
replace the 1st gear.
4.
INSPECT COUNTER SHAFT 2ND SPEED GEAR
(a) Using a cylinder gauge, measure the inside
diameter of the 2nd gear.
Standard inside diameter:
60.015 to 60.040 mm (2.3628 to 2.3638 in.)
Maximum inside diameter:
60.040 mm (2.3638 in.)
If the inside diameter exceeds the maximum,
replace the 2nd gear.
F051555E01
MT
F051556E01
F051557E01
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
MT–69
5.
INSPECT NO. 3 TRANSMISSION HUB SLEEVE
(a) Using vernier calipers, measure the width of the No.
3 transmission hub sleeve groove (A) and the
thickness of the claw part on the gear shift fork No. 4
(B), and calculate the clearance.
Standard clearance (A - B):
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
If the clearance is outside the specification, replace
the No. 3 transmission hub sleeve and No. 4 gear
shift fork.
6.
INSPECT NO. 1 TRANSMISSION HUB SLEEVE
(a) Check the sliding condition between the No. 1
transmission hub and No. 1 transmission hub
sleeve.
(b) Check that the spline gear teeth of the No. 1
transmission hub sleeve are not worn.
A
B
F051559E01
C067843E01
(c) Using vernier calipers, measure the width of the No.
1 transmission hub sleeve groove (A) and the
thickness of the claw part on the No. 1 gear shift fork
(B), and calculate the clearance.
Standard clearance (A - B):
0.15 to 0.35 mm (0.0059 to 0.0138 in.)
If the clearance is outside the specification, replace
the No. 1 transmission hub sleeve and No. 1 gear
shift fork.
A
B
F051558E01
MT
MT–70
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
7.
INSPECT NO. 4 SYNCHRONIZER RING
(a) Using a feeler gauge, measure the clearance
between the synchronizer ring and reverse gear.
Standard clearance:
0.70 to 1.30 mm (0.0276 to 0.0512 in.)
Minimum clearance:
0.70 mm (0.0276 in.)
If the clearance is less than the minimum, replace
the synchronizer ring.
F051636E01
(b) Coat the reverse gear cone with gear oil. Check the
braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to
the reverse gear cone. Check that the ring locks.
D033665E01
Middle
Outer
Inner
F051638E01
MT
8.
INSPECT NO. 1 SYNCHRONIZER RING SET (FOR
1ST GEAR)
(a) Using a feeler gauge, measure the clearance
between the synchronizer ring and 1st gear.
Standard clearance:
Inner:
1.48 to 2.12 mm (0.0583 to 0.0835 in.)
Middle:
0.68 to 1.92 mm (0.0268 to 0.0756 in.)
Outer:
0.88 to 1.72 mm (0.0346 to 0.0677 in.)
Minimum clearance:
Inner:
1.48 mm (0.0583 in.)
Middle:
0.68 mm (0.0268 in.)
Outer:
0.88 mm (0.0346 in.)
If the clearance is less than the minimum, replace
the synchronizer ring.
(b) Coat the 1st gear cone with gear oil. Check the
braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to
the 1st gear cone. Check that the ring locks.
F051639E01
MT–71
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
Middle
9.
Outer
Inner
F051638E01
INSPECT NO. 1 SYNCHRONIZER RING SET (FOR
2ND GEAR)
(a) Using a feeler gauge, measure the clearance
between the synchronizer ring and 2nd gear.
Standard clearance:
Inner:
1.48 to 2.12 mm (0.0583 to 0.0835 in.)
Middle:
0.68 to 1.92 mm (0.0268 to 0.0756 in.)
Outer:
0.88 to 1.72 mm (0.0346 to 0.0677 in.)
Minimum clearance:
Inner:
1.48 mm (0.0583 in.)
Middle:
0.68 mm (0.0268 in.)
Outer:
0.88 mm (0.0346 in.)
If the clearance is less than the minimum, replace
the synchronizer ring.
(b) Coat the 2nd gear cone with gear oil. Check the
braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to
the 2nd gear cone. Check that the ring locks.
F051639E01
REASSEMBLY
1.
SST
INSTALL RADIAL BALL BEARING INNER RACE
(a) Using SST and a press, install a new needle roller
bearing inner race.
SST 09950-60010 (09951-00540)
MT
F051640E01
2.
INSTALL SNAP RING COUNTER GEAR REAR
BEARING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness
Part No.
Thickness: mm (in.)
Mark
90520-31015
2.35 to 2.40
(0.0925 to 0.0945)
A
90520-31016
2.40 to 2.45
(0.0945 to 0.0965)
B
90520-31017
2.45 to 2.50
(0.0965 to 0.0984)
C
D033689E01
MT–72
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
Part No.
Thickness: mm (in.)
Mark
90520-31018
2.50 to 2.55
(0.0984 to 0.1004)
D
90520-31019
2.55 to 2.60
(0.1004 to 0.1024)
E
90520-31020
2.60 to 2.65
(0.1024 to 0.1043)
F
90520-31021
2.65 to 2.70
(0.1043 to 0.1063)
G
90520-31022
2.70 to 2.75
(0.1063 to 0.1083)
H
90520-31023
2.75 to 2.80
(0.1083 to 0.1102)
J
90520-31024
2.80 to 2.85
(0.1102 to 0.1122)
K
90520-31025
2.85 to 2.90
(0.1122 to 0.1142)
L
90520-31033
2.90 to 2.95
(0.1142 to 0.1161)
M
(b) Using a snap ring expander, install the snap ring
onto the counter gear.
1st Gear Side:
3.
INSTALL NO. 1 TRANSMISSION CLUTCH HUB
(a) Apply a light coat of gear oil to the sleeve and hub.
(b) Install the clutch hub sleeve onto the clutch hub.
(c) Install the 3 shifting keys onto the clutch hub.
(d) Install the 3 shifting key springs onto the clutch hub.
(e) Place the ball in the hole in the shifting key, and
install the hub sleeve while pushing in the ball.
NOTICE:
Prevent the ball from flying off.
4.
INSTALL 2ND GEAR NEEDLE ROLLER BEARING
(a) Coat the 2nd gear needle roller bearing with gear
oil, then install it onto the counter gear.
2nd Gear Side:
MT
F051641E01
F051551E01
MT–73
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
5.
INSTALL COUNTER SHAFT 2ND SPEED GEAR
(a) Coat the countershaft 2nd speed gear with gear oil,
then install it onto the counter gear.
(b) Coat the No. 1 synchronizer ring set with gear oil,
then install it onto the counter gear.
(c) Using SST and a press, install the No. 1
transmission clutch hub onto the counter gear.
SST 09308-14010
HINT:
Align the convex portion of the synchronizer ring
with the groove of the clutch hub.
(d) Install the clutch hub and confirm that the gear and
synchronizer ring move smoothly.
6.
INSTALL CLUTCH HUB NO.1 SHAFT SNAP RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness
SST
F051642E01
D033696E01
Part No.
Thickness: mm (in.)
Mark
90520-45013
2.28 to 2.33
(0.0898 to 0.0917)
A
90520-45014
2.33 to 2.38
(0.0917 to 0.0937)
B
90520-45015
2.38 to 2.43
(0.0937 to 0.0957)
C
90520-45016
2.43 to 2.48
(0.0957 to 0.0976)
D
90520-45017
2.48 to 2.53
(0.0976 to 0.0996)
E
90520-45018
2.53 to 2.58
(0.0996 to 0.1016)
F
90520-45019
2.58 to 2.63
(0.1016 to 0.1035)
G
(b) Using a snap ring expander, install the snap ring
onto the counter gear.
7.
F051547E01
INSTALL NO. 1 SYNCHRONIZER RING SET (FOR 1ST
GEAR)
(a) Coat the No. 1 synchronizer ring set with gear oil,
then install it onto the counter gear.
MT
MT–74
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
8.
INSTALL 1ST GEAR NEEDLE ROLLER BEARING
(a) Coat the 1st gear needle roller bearing with gear oil,
then install it onto the counter gear.
9.
INSTALL COUNTERSHAFT GEAR 1ST SPEED
(a) Coat the countershaft gear 1st speed with gear oil,
and install it onto the counter gear.
(b) Using SST and a press, install the reverse gear
spline piece.
SST 09309-37010
F051546E01
SST
F051561E01
10. INSTALL BALL
(a) Install the ball into the counter gear.
F051544E01
11. INSTALL NO. 4 SYNCHRONIZER RING
(a) Coat the No. 4 synchronizer ring with gear oil, and
install it onto the counter gear.
MT
F051543E01
12. INSTALL REVERSE GEAR NEEDLE ROLLER
BEARING
(a) Coat the reverse gear needle roller bearing with
gear oil, and install it onto the counter gear.
F051542E01
MT–75
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
Reverse Gear
Hub Sleeve
Shifting keys
13. INSTALL COUNTERSHAFT REVERSE GEAR
(a) Install the key spring and 2 shifting keys onto the
reverse gear.
HINT:
• Install the shifting key with its groove on the
reverse gear side.
• Install the key spring with its claw on the reverse
gear side.
• Refer to the illustration when installing the key
spring.
(b) Install the hub sleeve onto the reverse gear.
(c) Coat the countershaft reverse gear with gear oil,
then install it onto the counter gear.
Key Spring
F051643E01
14. INSTALL REVERSE GEAR BEARING RACE INNER
(a) Align the groove of the reverse gear bearing race
inner with the ball, and install them.
F051564E01
SST
Groove
15. INSTALL COUNTER GEAR FRONT BEARING OR
ROLLER
(a) Using SST and a press, install the counter gear
front bearing or roller onto the counter gear.
SST 09608-06041
HINT:
Make sure that the groove of the bearing faces the
correct direction as shown in the illustration.
F051644E01
16. INSTALL NO. 1 COUNTER GEAR FRONT BEARING
SNAP RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness
F051566E01
Part No.
Thickness: mm (in.)
Mark
90520-31015
2.35 to 2.40
(0.0925 to 0.0945)
A
MT
MT–76
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
Part No.
Thickness: mm (in.)
Mark
90520-31016
2.40 to 2.45
(0.0945 to 0.0965)
B
90520-31017
2.45 to 2.50
(0.0965 to 0.0984)
C
90520-31018
2.50 to 2.55
(0.0984 to 0.1004)
D
90520-31019
2.55 to 2.60
(0.1004 to 0.1024)
E
90520-31020
2.60 to 2.65
(0.1024 to 0.1043)
F
90520-31021
2.65 to 2.70
(0.1043 to 0.1063)
G
90520-31022
2.70 to 2.75
(0.1063 to 0.1083)
H
90520-31023
2.75 to 2.80
(0.1083 to 0.1102)
J
90520-31024
2.80 to 2.85
(0.1102 to 0.1122)
K
90520-31025
2.85 to 2.90
(0.1122 to 0.1142)
L
0520-31033
2.90 to 2.95
(0.1142 to 0.1161)
M
(b) Using a snap ring expander, install the snap ring
onto the counter gear.
17. INSPECT REVERSE GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the reverse gear
thrust clearance.
Standard clearance:
0.125 to 0.375 mm (0.0049 to 0.0148 in.)
If the clearance is outside the specification, replace
the defective gear, spline piece or bearing race.
F051532E01
18. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 1st gear thrust
clearance.
Standard clearance:
0.10 to 0.43 mm (0.0039 to 0.0169 in.)
If the clearance is outside the specification, replace
the defective gear, clutch hub, spline piece or
counter gear.
MT
F051533E01
RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
MT–77
19. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 2nd gear thrust
clearance.
Standard clearance:
0.10 to 0.43 mm (0.0039 to 0.0169 in.)
If the clearance is outside the specification, replace
the defective gear, clutch hub or counter gear.
F051534E01
20. INSPECT REVERSE GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the reverse gear
radial clearance.
Standard clearance:
0.015 to 0.065 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the reverse gear needle roller bearing or shaft.
F051535E01
21. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 1st gear radial
clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the 1st gear needle roller bearing or shaft.
F051536E01
22. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 2nd gear radial
clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the 2nd gear needle roller bearing or shaft.
F051537E01
MT
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