WORKSHOP MANUAL

TRANSMISSION & CLUTCH OVER-

HAUL

5MTT200A

Model YR 2011
English Edition RDCE-11GTRG080-00
Destination: ALL
July 2011 Printed in Malaysia

Copyright ©

Perusahaan Otomobil
Nasional Sdn. Bhd.
(Company No.: 100995-U)
Printed in Malaysia 12 July 2011 Eng
 WORKSHOP MANUAL -
Group Index /I

00 GENERAL ..................................................................................... 00/1 - 00/6

21C CLUTCH ................................................................................... 21C/1 - 21C/9
22D MANUAL TRANSMISSION <5MTT200A> ................................. 22D/1 - 22D/71

All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

Printed in Malaysia 12 July 2011 Eng

- WORKSHOP MANUAL
/ II Group Index

NOTE

Printed in Malaysia 12 July 2011 Eng

 GENERAL 00
Content /1

00 GENERAL
HOW TO USE THIS MANUAL ....................................................... 00/2
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS .... 00/2
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
DEFINITION OF TERMS ............................................................ 00/2
STANDARD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
REFERENCE VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
INDICATION OF TIGHTENING TORQUE ......................................... 00/2
EXPLANATION OF MANUAL CONTENTS ........................................ 00/3

Printed in Malaysia 12 July 2011 Eng

00 GENERAL
/2 HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL WTC000READS11001

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This manual provides explanations concerning the inspection, checking, adjustment, disassembly and
reassembly of the engine, transmission and major components after they have been removed from
the vehicle.
ON-VEHICLE SERVICE
“On - Vehicle Service” is procedures for performing inspections and adjustments of particularly im-
portant locations with regard to the construction and for maintenance and servicing, but other inspec-
tion (for looseness, play, cracking, damage and etc.) must also be performed.
INSPECTION
Under this title are presented inspection and checking procedures to be performed by using special
tools and measuring instruments and by feeling but for actual maintenance and servicing procedures,
visual inspections should always be performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value as the standard for judging the quality of a part of assembly on inspection or the
value to which the part or assembly is corrected and adjusted. It is given by tolerance
LIMIT
Shown the standard for judging the quality of a part or assembly on inspection and means the max-
imum or minimum value within which the part or assembly must be kept functionally or in strength.
It is a value established outside the range of standard value
REFERENCE VALUE
Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly
and adjustment procedures, and so they can be completed in a shorter time).
CAUTION
Indicates the presentation of information particularly vital to the worker during the performance of
maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or
damage to component parts, or a reduction of component or vehicle function or performance, etc.
INDICATION OF TIGHTENING TORQUE
The tightening torque shown in this manual is a basic value with a tolerance of ±10% except the fol-
lowings cases when the upper and lower limits of tightening torque are given.
1. The tolerance of the basic value is within ±10%
2. Special bolts or the like are in use.
3. Special tightening methods are used.

Printed in Malaysia 12 July 2011 Eng

 GENERAL 00
HOW TO USE THIS MANUAL /3

EXPLANATION OF MANUAL CONTENTS WTC000READS11002

DOIIC000R9001

Printed in Malaysia 12 July 2011 Eng

00 GENERAL
/4 HOW TO USE THIS MANUAL

SYMBOL DESCRIPTION
A Indicates the group title
B Indicates the section title
C Indicates the group number
D Indicates the page number
E Component Diagram
A diagram of the component parts is provided near the front of each section in order
to give a reader a better understanding of the installed condition of the component
parts.
F Denotes non reusable part
G Denotes tightening torque.
For bolts and nuts which do not have a tightening torque listed, refer to the “Tighten-
ing torque”
H Symbol for lubrication sealants and adhesives.
Information concerning the locations for lubrication and for application of sealants
and adhesives is provided, by using symbols, in the diagrams of component parts or
on the page following the component parts page, and explained.

Grease (multipurpose grease unless there is a brand

or type specified)
DOIIC000R9058

Sealant or adhesive
DOIIC000R9059

Brake fluid or automatic transmission fluid

DOIIC000R9060

Engine oil, gear oil or air condition compressor oil

DOIIC000R9061

Adhesive tape or butyl rubber tape.

DOIIC000R9062

Indicates procedures to be performed before the work in that section is started, and
J
procedures to be performed after the work in that section is finished.
Maintenance and servicing Procedures
The number provided within the diagram individual the sequence for maintenance
and servicing procedures.
1. A diagram of the components part is provided near the front of each section in
K order to give the reader a better understanding of the installed condition of
component parts.
2. The number provided within the diagram indicate the sequence for maintenance
and servicing procedures; the symbol N indicates a non reusable part; the tightening
torque is provided where applicable.
Removal steps:
The part designation number correspond to the number in the illustration to indicate
removal steps.

Printed in Malaysia 12 July 2011 Eng

 GENERAL 00
HOW TO USE THIS MANUAL /5

SYMBOL DESCRIPTION
Disassembly steps:
The part designation number correspond to the number in the illustration to indicate
disassembly steps.
Installation steps:
Specified in case installation is impossible in reverse order of removal steps
Reassembly steps:
Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted
if reassembly is possible in reverse order of disassembly steps.
Classifications of major maintenance/service points
When there are major points relative to maintenance and serving procedures (such as
L essential maintenance and service points, maintenance and service standard values,
information regarding the use of special tools, etc.) these are arranges together as
major maintenance and service points and explained in detail.

Indicates that there are essentials point for removal

or disassembly.
DOIIC000R9052

Indicates that there are essential point for installation

or reassembly
DOIIC000R9051

Indicates that there are essential points for both

DOIIC000R9053

M Operating procedures, caution etc. on removal, installation disassembly and reassembly

and reassembly are described.
N Table for graphic explaination

Printed in Malaysia 12 July 2011 Eng

00 GENERAL
/6 HOW TO USE THIS MANUAL

NOTE

Printed in Malaysia 12 July 2011 Eng

 CLUTCH 21C
Content /1

21C CLUTCH
SPECIFICATIONS ....................................................................... 21C/2
GENERAL SPECIFICATIONS ........................................................ 21C/2
SERVICE SPECIFICATIONS .......................................................... 21C/2
TORQUE SPECIFICATIONS ......................................................... 21C/2
LUBRICANTS ......................................................................... 21C/2

SPECIAL TOOLS (5MTT200A) ....................................................... 21C/2

TOOLS ................................................................................ 21C/2

CLUTCH ................................................................................. 21C/3

REMOVAL AND INSTALLATION ................................................... 21C/3

CLUTCH COVER AND DISC (5MTT200A) .......................................... 21C/4

CLUTCH COVER ASSEMBLY AND CLUTCH DISC REMOVAL ................. 21C/4
SERVICE POINTS OF INSTALLATION .............................................. 21C/4
INSPECTION .......................................................................... 21C/6
CLUTCH COVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21C/6
CLUTCH DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21C/6

CLUTCH ................................................................................. 21C/7

REMOVAL SERVICE POINTS ....................................................... 21C/7
INSTALLATION SERVICE POINTS .................................................. 21C/8
INSPECTION .......................................................................... 21C/8
CONCENTRIC SLAVE CYLINDER ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21C/8
CONCENTRIC SLAVE CYLINDER,HOSE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21C/9

Printed in Malaysia 12 July 2011 Eng

21C CLUTCH
/2 SPECIFICATIONS

SPECIFICATIONS WTC21CSPECS11001

GENERAL SPECIFICATIONS
Items Specification
Clutch operating method Hydraulic type
Clutch disc splines Clutch disc type
Clutch disc size OD x ID mm 200
Clutch cover type Diaphragm spring type
Clutch cover size OD x ID mm 254
SERVICE SPECIFICATIONS
Items Standard value / Limit
Clutch disc facing rivet sink Minumum 0.3 mm (0.012 in)
Diaphragm spring end height difference 0.5 mm (0.02 in)
TORQUE SPECIFICATIONS
Items Specified torque
Clutch Cover bolt 1.5 - 2.2 kgm (15 - 22 Nm, 1.01 - 1.48
ft.lbs)
Concentric slave cylinder mounting bolt 1.2 kgm (12 Nm, 0.81 ft.lbs) ± 0.18 kgm
(1.8 Nm, 0.12 ft.lbs)
LUBRICANTS
Items Specified lubricants
Clutch fluid Brake Fluid DOT 3 or DOT 4
Clutch disc splines Mitsubishi Part No. 0101011 or equival-
ent

SPECIAL TOOLS (5MTT200A) WTC21CSTOOL11001

TOOLS
Tool Number Name Use

EZT 0044 Flywheel stopper. • To lock flywheel.

DOIMT21AR11009

• To hold clutch
Clutch plate In-
EZT 0045 plate during install-
staller
ation.

DOIMT21AR11007

Printed in Malaysia 12 July 2011 Eng

 CLUTCH 21C
CLUTCH /3

CLUTCH WTC21CSHAUL11001

REMOVAL AND INSTALLATION

DOIMT21AR11001

Symbol:
— Non-reusable parts
— Grease: (multipurpose grease unless there is a board or type specified)
Removal steps
1. Clutch Cover
2. Clutch disc
3. Concentric slave cylinder, hose assy
4. Concentric slave cylinder adapter
5. Concentric slave cylinder
T1 :1.2 kgm (12 Nm, 0.81 ft.lbs) ± 0.18 kgm (1.8 Nm, 0.12 ft.lbs)
T2 :1.5 - 2.2 kgm (15 - 22 Nm, 1.01 - 1.48 ft.lbs)

Printed in Malaysia 12 July 2011 Eng

21C CLUTCH
/4 CLUTCH COVER AND DISC (5MTT200A)

CLUTCH COVER AND DISC

(5MTT200A) WTC21CSHAUL11002

CLUTCH COVER ASSEMBLY AND

CLUTCH DISC REMOVAL
1. Use the special tool to lock and secure the
clutch cover or clutch disc before remove the
bolts

Symbol Description
A Clutch disc (EZT 0045 )
B Flywheel (EZT 0044)

DOIMT21AR11008

2. Loosen clutch cover bolts diagonally as

shown in the illustration. Back off bolts in
succession, (one or two turns) in order to
avoid cover flange from bending.
CAUTION
Do not clean clutch disc or release bearing
with cleaning solvent.

DOIMT21AR11010

SERVICE POINTS OF INSTALLATION

CLUTCH COVER ASSEMBLY AND CLUTCH
DISC INSTALLATION
1. Fit 3 holes (A) of clutch cover to 3 dowel pins
located at flywheel.
2. Pre-tighten all 6 bolts of clutch cover assy.

DOIMC021R08009

Printed in Malaysia 12 July 2011 Eng

 CLUTCH 21C
CLUTCH COVER AND DISC (5MTT200A) /5

3. Tighten all 6 bolts in sequence as shown in

the illustration.
Specified torque : 1.5 - 2.2 kgm (15 - 22 Nm,
1.01 - 1.48 ft.lbs)

DOIMT21AR11011

4. Apply grease Molycoat BR2 plus or equival-

ent on the clutch disc spline approximately
0.3 g (0.011 oz, 0.003 N) before fitting tras-
mission by the input shaft.
5. By using the special tool (EZT 0045), position
the clutch disc to the flywheel

Symbol Description
A Grease molycoat BR2 plus

DOINC021R09002

Printed in Malaysia 12 July 2011 Eng

21C CLUTCH
/6 CLUTCH COVER AND DISC (5MTT200A)

INSPECTION
CLUTCH COVER ASSEMBLY
• Check the diaphragm spring end for wear
and uneven height. Replace if wear is evident
or height difference exceeds the limit.
Limit: 0.5 mm (0.02 in)
• Check the pressure plate surface for wear
,crack and colour change.
• Check the strap plate rivets for looseness and
replace the clutch cover assembly if loosed.

DOIPC21AR10016

CLUTCH DISC
• Check the facing for loose rivets, uneven
contact, deterioration due to seizure, adhe-
sion of oil or grease and replace the clutch
disc if defective.
• Measure the rivet sink and replace the clutch
disc if it is out of specification.
Limit: 0.3 mm (0.012 in)
• Check for torsion spring play and damage
and if defective , replace the clutch disc.
• Combine the clutch disc with the input shaft
and check sliding condition and check for
DOIMC021R08008
play in the rotating direction. If it does not
slide smoothly, check after cleaning and reas-
sembling. If the play is excessive, replace the
clutch disc and the input shaft.

Symbol Description
A Rivet sink

Printed in Malaysia 12 July 2011 Eng

 CLUTCH 21C
CLUTCH /7

CLUTCH WTC21CSHAUL11003

REMOVAL SERVICE POINTS

CONCENTRIC SLAVE CYLINDER (CSC) /CONCENTRIC SLAVE CYLINDER ADAPTER REMOVAL

DOIMT21AR11004

1. Carefully align concentric slave cylinder (csc) into transmission input shaft before sliding into pos-
ition
2. Ensure concentric slave cylinder (csc) seated firmly on csc seat and sleeve and align two mounting
holes to the holes on the transmission clutch housing
3. Tighten the flange bolt to the specified torque of 1.2 kgm (12 Nm, 0.81 ft.lbs) ± 0.18 kgm (1.8
Nm, 0.12 ft.lbs)
4. Align concentric slave cylinder adapter from clutch housing external hole as shown in illustra-
tion.Ensure the key on concentric slave cylinder adapter is aligned with key hole cast on transmission
clutch housing.
5. Insert concentric slave cylinder adapter into clutch housing hole until it fully enters concentric
slave cylinder (csc). Ensure the key on concentric slave cylinder adapter mates key seating surface
on clutch housing as shown in illustration.
6. Secure the fitment of concentric slave cylinder adapter in concentric slave cylinder (csc) by engaging
the snap-lock as shown in illustration

Symbol Description
1 Concentric slave cylinder adapter
2 Concentric slave cylinder (csc)

Printed in Malaysia 12 July 2011 Eng

21C CLUTCH
/8 CLUTCH

Symbol Description
3 Key-hole
4 Key
5 Snap-lock
6 Key resting surface
A View – A
B View – B
T1 1.2 kgm (12 Nm, 0.81 ft.lbs) ± 0.18 kgm (1.8 Nm, 0.12 ft.lbs)

INSTALLATION SERVICE POINTS

WTC21CSHAUL11004

CONCENTRIC SLAVE CYLINDER/CONCENTRIC

SLAVE CYLINDER ADAPTER INSTALLATION
1. After setting the concentric slave cylinder to
the transmission case, tighten the flange bolt
temporally.

DOIMT21AR11002

2. Assemble the concentric slave cylinder ad-

apter with the concentric slave cylinder.
3. Tighten the flange bolt to the specified
torque of 1.2 kgfm ± 0.18 kgfm

DOIMT21AR11003

INSPECTION
CONCENTRIC SLAVE CYLINDER ADAPTER
1. Check the O-ring for damage and deforma-
tion. If the O-ring is damaged or deformed,
replace the concentric slave cylinder adapter.
2. Check the surface that touches the concentric
slave cylinder for contamination. If contam-
inated, clean the surface with the specified
fluid.
Specified fluid: Brake Fluid DOT 3 or DOT 4
3. Make sure there are no deformed and/or
DOIMT21AR11005 missing clips.

Symbol Description
A O-ring

Printed in Malaysia 12 July 2011 Eng

 CLUTCH 21C
CLUTCH /9

CONCENTRIC SLAVE CYLINDER,HOSE ASSY

1. Check the O-ring for damage and deforma-
tion. If the O-ring is damaged or deformed,
replace the concentric slave cylinder,hose
assy.
2. Check the surface that touches the slave cyl-
inder adapter for contamination. If contam-
inated, clean the surface with the specified
fluid.
Specified fluid: Brake Fluid DOT 3 or DOT 4

Symbol Description
DOIMT21AR11006
B Concentric slave cylin-
der,hose assy
C O-ring

Printed in Malaysia 12 July 2011 Eng

21C CLUTCH
/ 10 CLUTCH

NOTE

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
Content /1

22D MANUAL TRANSMISSION <5MTT200A>

INTRODUCTION ....................................................................... 22D/4
Main Use and Application Scope ................................................ 22D/4
Apply Work Condition and Environment ...................................... 22D/4
Structure Type ....................................................................... 22D/4
Transport and Storage ............................................................. 22D/4
Driving ................................................................................ 22D/4
Maintaining .......................................................................... 22D/4
Environmental Protection ......................................................... 22D/4

GENERAL INFORMATION ............................................................ 22D/5

TRANSMISSION CROSS-SECTION VIEW ......................................... 22D/5
SYNCHRONIZER SYSTEM DESCRIPTION ......................................... 22D/7
TRANSMISSION CODE .............................................................. 22D/7
MAIN TECHNOLOGY PARAMETER ............................................... 22D/8
GEAR RATIO .......................................................................... 22D/8
AF6C-7002–AA (1.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/8
AF6C-7002–CA (1.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/8

SPECIFICATIONS ....................................................................... 22D/9

SERVICE SPECIFICATIONS .......................................................... 22D/9
Gear axle clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/9
Synchronizer reserve quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/9
Differential side gear normal backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/9
SEALANT AND ADHESIVES ........................................................ 22D/9
Form in Place Gasket (FIPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/10
Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/10
LUBRICANTS ......................................................................... 22D/10
TORQUE SPECIFICATIONS ......................................................... 22D/10
NON-REUSABLE PART .............................................................. 22D/11
GEAR SELECTION (VEHICLE SPEED) .............................................. 22D/11

SPECIAL TOOLS ........................................................................ 22D/11

SPECIAL TOOLS LIST ................................................................ 22D/11

TRANSMISSION ........................................................................ 22D/16

TRANS CASE AND CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY . 22D/16
DISASSEMBLY SERVICE POINTS ................................................... 22D/19
REASSEMBLY SERVICE POINTS .................................................... 22D/26

INPUT SHAFT ........................................................................... 22D/39

DISASSEMBLY AND REASSEMBLY ................................................ 22D/39
DISASSEMBLY SERVICE POINTS ................................................... 22D/40
CHECK AND INSPECTION .......................................................... 22D/40
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/40
BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/40
REASSEMBLY SERVICE POINTS .................................................... 22D/41

OUTPUT SHAFT ........................................................................ 22D/42

DISASSEMBLY AND REASSEMBLY ................................................ 22D/42
DISASSEMBLY SERVICE POINTS ................................................... 22D/43
SPEED GEAR CLEARANCE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/43
CHECK AND INSPECTION .......................................................... 22D/47
GEAR AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/47

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/2 Content

SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/47
BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/48
ASSEMBLY OF SYNCHRONIZER ................................................... 22D/48
SYNCHRONIZER SECTIONAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D/48
REASSEMBLY SERVICE POINTS .................................................... 22D/50

SELECT AND SHIFT LEVER ........................................................... 22D/54

DISASSEMBLY AND REASSEMBLY ................................................ 22D/54

CLUTCH HOUSING .................................................................... 22D/55

DISASSEMBLY AND REASSEMBLY ................................................ 22D/55
DISASSEMBLY SERVICE POINTS ................................................... 22D/56
REASSEMBLY SERVICE POINTS .................................................... 22D/57

TRANSMISSION CASE ................................................................ 22D/60

DISASSEMBLY AND REASSEMBLY ................................................ 22D/60
DISASSEMBLY SERVICE POINTS ................................................... 22D/61
REASSEMBLY SERVICE POINTS .................................................... 22D/62

DIFFERENTIAL .......................................................................... 22D/65

DISASSEMBLY AND REASSEMBLY ................................................ 22D/65
DISASSEMBLY SERVICE POINTS ................................................... 22D/66
REASSEMBLY SERVICE POINTS .................................................... 22D/68

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
Content /3

NOTE

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/4 INTRODUCTION

INTRODUCTION WTC22DGINFO001

Main Use and Application Scope

5MTT200A series transmissions are transverse and usher gearbox, which is design for matching PROTON
1.3 and 1.6L naturally aspirated engine.
Apply Work Condition and Environment
This transmission can adapt 1.3L and 1.6L naturally aspirated engine and its vehicle’s work environment
and condition.
Structure Type
5MTT200A is a manual and entire synchronizers (except reverse gear) shifting transmission, it have
agility and nice shifting handle, low noise, tighten structure, good airproof capability and strong
carrying capability.
Transport and Storage
1. It should have measures for prevent rusting.
2. Transmission should be packed before transporting, and the packing box must be fast to ensure
the transmission will be fine during transporting process.
Driving
Through gear selector locate in driving room operator can control select lever and shift lever. Operator
also can manipulate each gear according to different direction showing on gear selector handle ball.
When operator chooses no gear, the gear selector would come back to neutral position naturally.
1. Operator should tread clutch pedal completely, then manipulate gear selector before shifting. It
should use low gear when vehicle start.
2. It should use low gear when vehicle uphill, downhill and turning and it forbid clutch detached in
upward driving condition.
3. When driver shift into reverse gear, operator should tread clutch pedal completely three second
at least, then operate the shifting handle. Due to no-synchronizer for reverse gear, this process
can prevent reverse gears crash.
4. It can’t use excessive power to shift when operator find it’s hard to select gear, the right way is
stop the car and find out what happen.
Maintaining
1. Transmission maintain according to commercial vehicle request, generally it divided into three
kinds.
2. Transmission oil does not have to replace during the transmission useful life, but if the transmission
had been oil drained for repair, new oil replace be advised.
Environmental Protection
During maintaining and repairing the transmissions the dealers need disposal of wastes like oil, replaced
parts, etc, according the law and regulations to protect the environment.

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
GENERAL INFORMATION /5

GENERAL INFORMATION WTC22DGINFO002

TRANSMISSION CROSS-SECTION VIEW

DOIMT22DR10001

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/6 GENERAL INFORMATION

Items
1. Rear cover 10. 2nd speed ring gear
2. Transmission case 11. 3rd speed ring gear
3. Reverse gear 12. 3rd/4th speed synchronizer assembly
4. Clutch housing 13. 4th speed ring gear
5. Input shaft 14. 5th speed ring gear
6. Output shaft 15. 5th speed driving gear
7. Differential assembly 16. 5th speed synchronizer assembly
8. 1st speed ring gear 17. Reverse idler gear
9. 1st/2nd speed synchronizer assembly

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
GENERAL INFORMATION /7

SYNCHRONIZER SYSTEM DESCRIPTION

DOIMT22DR11027

Items
1. 1st speed driven gear
2. Clutch gear
3. Synchronizer outer ring
4. Synchronizer hub
5. 2nd speed driven gear
6. Synchronizer cone ring
7. Synchronizer inner ring
8. Synchronizer sleeve
TRANSMISSION CODE
Symbol Description
5 5 speed
M Manual
T Transmission
T Torque
200 Torque capability is 200N.m (Max. Torque)
A The first product code

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/8 GENERAL INFORMATION

MAIN TECHNOLOGY PARAMETER

Item Information
Torque capacity 185 N.m
Type Manual
Driven model FF
Gear number 5
Gear ratio Refer table below
Speedometer ratio Refer table below
Clutch type Hydraulic pressure
Weight (kg) 35 kg (without gear oil)
Gear oil specification Castrol BOT130M
WSD-M2C200–C
Way of filling gear oil From the speedometer cavity
Way of check gear oil From the reverse lamp switch hole
Gear oil volume 1.8 L
GEAR RATIO
AF6C-7002–AA (1.3)
Items Specifications
Model 5MTT200A (AF6C-7002–AA)
Applicable engine 1.3L NAFE
Gear ratio Output shaft Input shaft teeth Differential drive
teeth gear teeth
1st 39 11 3.545
2nd 45 22 2.045
3rd 41 29 1.414
4th 41 37 1.108
5th 36 41 0.878
Reverse 47 13 3.615
Final gear ratio 15 57 3.8
Speedometer gear ratio (speedometer gear teeth/Differential case) 31/36
AF6C-7002–CA (1.6)
Items Specifications
Model 5MTT200A (AF6C-7002–CA)
Applicable engine 1.6L NAFE
Gear ratio Output shaft Input shaft teeth Differential drive
teeth gear teeth
1st 43 12 3.583
2nd 52 27 1.926
3rd 41 32 1.281
4th 39 41 0.951
5th 34 45 0.756
Reverse 47 13 3.615

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
SPECIFICATIONS /9

Final gear ratio 15 57 3.8

Speedometer gear ratio (speedometer gear teeth/Differential case) 31/36

SPECIFICATIONS WTC22DSPECS001

SERVICE SPECIFICATIONS
Gear axle clearance
Items Allowed range (mm) Remark
1st speed gear clearance along axial direction D1=0.06~0.24 If actual clearance
2nd speed gear clearance along axial direction D2=0.165~0.43 out the allowed
range need replace
3rd speed gear clearance along axial direction D3=0.09~0.21
the part
4th speed gear clearance along axial direction D4=0.175~0.335
5th speed gear clearance along axial direction D5=0.125~0.475
Synchronizer reserve quantity
Items Allowed range (mm) Remark
1st speed synchronizer ring reserve quantity L1=0.62~1.54 If actual reserve
2nd speed synchronizer ring reserve quantity L1=0.62~1.54 quantity out the al-
lowed range need re-
3rd speed synchronizer ring reserve quantity L2=0.612~1.262
place the part
4th speed synchronizer ring reserve quantity L3=0.643~1.273
5th speed synchronizer ring reserve quantity L3=0.643~1.273
Differential side gear normal backlash
Items Allowed range (mm) Remark
Normal backlash 0.05~0.20 If actual differential
bevel gears backlash
overstep the allowed,
it need to replace the
side gear
SEALANT AND ADHESIVES
Items Specified sealants and adhesive
Contacting surface of clutch housing and transmission case LT5182 sealant
Contacting surface of transmission case and back cover LT5900 sealant
Interlock retainer assembly
LT222 sealant
The bolt above the vent plug
Form in Place Gasket (FIPG)
The transmission has several areas where the form in place gasket (FIPG) is in use. To ensure that the
gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.
Based size, continuity and location are of paramount importance. Too thin a bead could cause leaks.
Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing
of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely ne-
cessary to apply the gasket evenly without a break, while observing the correct bead size.
Sine the RTV hardens as it reacts with the moisture in the atmospheric air, it is normally used in the
metallic flange areas.

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 10 SPECIFICATIONS

Disassembly
The parts assembled with the FIPG can be easily disassembly without use of a special method. In same
cases, however, the sealant between the joined surface may have to broken by lightly striking with
a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined
surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surface, using a gasket scraper
or wire brush. Check to ensure that the surface to which the FIPG is to be applied is flat. Make sure
that there are no oils, grease and foreign substance deposits on the application surfaces. Do not forget
to remove the old sealant remaining in the bolts holes.
LUBRICANTS
Items Specified lubricants Quantity
Transmission oil Castrol BOT130M 1.8 litre
WSD-M2C200–C
Items Specified lubricants
Input shaft spline High temperature lithium-based grease
(WSS- M1C273-A OKS422)
Shift lever pin Lubricant grease
(WSD-M1C244-A GLY801 )
Input shaft oil seal Lubricant grease
Shift shaft oil seal assembly (WSD-M1C220-A LY261)

TORQUE SPECIFICATIONS
Part name Application Specification
Stud M6x16+M6x18 Transmission case to rear cover 2.9~4.9 kgm (29~49 Nm,
1.95~3.29 ft.lbs)
Stud M8x40+M8x15 Clutch housing to transmission case 2.2~3.0 kgm (22~30 Nm,
1.48~2.01 ft.lbs)
Bolt M8x40 1.9~2.5 kgm (19~25 Nm,
1.28~1.68 ft.lbs)
Bolt M6x16 Transmission case to rear cover 1.0~1.3 kgm (10~13 Nm,
0.67~0.87 ft.lbs)
Bolt M10x1x19.8 Differential case to final drive ring 10.0~11.0 kgm (100~110
gear Nm, 6.71~7.38 ft.lbs)
Shift shaft screw M7x19 Select lever to shift lever 2.2~2.6 kgm (22~26 Nm,
1.48~1.74 ft.lbs)
Drain plug M16x1.5x12 Clutch housing drain hole 2.9~ 4.1 kgm (29~ 41 Nm,
1.95~ 2.75 ft.lbs)
Bolt with pad M6x25 Speedo sensor 0.9~1.1 kgm (9~11 Nm,
0.6~0.74 ft.lbs)
Interlock retainer assembly Interlock retainer assembly to transmis- 2.0~2.6 kgm (20~26 Nm,
M18x1.5 sion case 1.34~1.74 ft.lbs)
Reverse gear switch assembly Reverse gear switch assembly to clutch 2.0~2.5 kgm (20~25 Nm,
M16x1.5 housing 1.34~1.68 ft.lbs)
Bolt M8x15 Gate assembly to clutching housing 1.9~2.5 kgm (19~25 Nm,
1.28~1.68 ft.lbs)

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
SPECIAL TOOLS / 11

NON-REUSABLE PART
Part name Quantity Application
Retainer ring 2 Fastening transaxle differential shaft
Retainer ring 1 Fastening 1st/2nd gear synchronizer hub
Retainer ring 1 Fastening 3rd/4th gear synchronizer hub
Retainer ring 1 Fastening output shaft rear bearing
Snap ring 1 Fastening the 5th drive gear
Screw 8 Fastening differential case to final drive ring
gear
E type retainer ring 1 Fastening the shift lever
Retainer ring 1 Fastening 5th synchronizer spacer
Spring pin 1 Fastening the 5th gear fork assembly
Input shaft oil seal 1
Shift shaft oil seal assembly 1
Differential oil seal 2
Magnet 1
Speedometer drive gear 1 Driving speedometer
GEAR SELECTION (VEHICLE SPEED)
Gear selection Speed (km/hour)
0-Rev 0 km/h
0-1st 0 km/h
1st-2nd 30 km/h (18.64 mph)
2nd-3rd 50 km/h (31.07 mph)
3rd-4th 70 km/h (43.5 mph)
4th-5th 90 km/h (55.92 mph)
5th-4th 90 km/h (55.92 mph)
4th-3rd 70 km/h (43.5 mph)
3rd-2nd 50 km/h (31.07 mph)
2nd-1st 30 km/h (18.64 mph)

SPECIAL TOOLS WTC22DSTOOL001

SPECIAL TOOLS LIST

Tool Number Name Use
G921-01 Uninstaller • To disassemble 5th speed
driving gear

DOIMT22DR10002

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 12 SPECIAL TOOLS

Tool Number Name Use

G922-13 Oriented mass • Oriented input shaft
fasten ring

DOIMT22DR10011

G922-14 Oriented mass • Oriented output shaft

fasten ring

DOIMT22DR10012

G922–15 Mounter (Assy) • To install 5th speed drive

gear

DOIMT22DR10013

G922–15–01 Mounter (Base)

DOIMT22DR11014

G922–15–02 Mounter (Guide) • To install 5th speed drive

gear

DOIMT22DR11015

G922–15–03 Mounter (Installer)

DOIMT22DR11016

G922–17 Mounter • To install differential oil

seal

DOIMT22DR11012

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
SPECIAL TOOLS / 13

Tool Number Name Use

G922–18 Mounter • To install input shaft oil
seal

DOIMT22DR11017

G922–19 Oriented mass • Oriented input shaft oil

seal

DOIMT22DR11018

AZBST008–00A Output shaft mounting • To support output shaft

a : 100 mm dia rack when removing and install-
b : 19 mm dia ation output shaft part
c : 9.5 mm dia

DOIMT22CR07009

AZBST003–00A Puller assembly A • To remove output shaft

front bearing outer ring

DOIMT22CR07007

MB990628 Snap ring plier • To remove the snap ring

DOIMT22CR07005

MB990938 Handle To use with installer ad-

apter
• Install differential tapper
rolling bearing
• Install differential oil seal
• Install input shaft oil seal
DOIIT22AR9007

MB990939 Cooper bar • To install clutch housing

plug

DOIMT22CR07110

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 14 SPECIAL TOOLS

Tool Number Name Use

MB991202 • To remove differential
tapper roller bearing

DOIMT22DR10152

MB998917 Bearing removal • To remove differential

tapper roller bearing

DOIMT22DR11001

MD998801 Bearing removal • To remove and install in-

put shaft rear and front
bearing
• To remove output shaft
rear bearing

DOIIT22AR9011

MD998812 Installer cap • To install input shaft

front and rear bearing
• To install output shaft
front bearing inner ring
• To install output shaft
rear bearing
DOIIT22AR9012 • To install differential
tapper roller bearing inner
ring
• To install differential
outer race
• To install output shaft
front bearing outer ring
MD998813 Installer – 100 •To i Install input shaft rear
bearing
• To install output shaft
front bearing inner ring
• To install output shaft
rear bearing
DOIIT22AR9013 • To install differential
tapper roller bearing inner
ring
MD998814 Installer – 200 •To install input shaft front
bearing
• To install differential
outer race
• To install output shaft
front bearing outer ring
DOIIT22AR9014

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
SPECIAL TOOLS / 15

Tool Number Name Use

MD998816 Installer adapter (30) • To install input shaft
front bearing
• To install output shaft
rear bearing

DOIIT22AR9015

MD998817 Installer adapter (34) • To install input shaft rear

bearing

DOIMT22DR11003

MD998820 Installer adapter (42) • To install output shaft

front bearing inner ring

DOIIT22AR9019

MD998821 Installer adapter (44) • To install differential

tapper rolling bearing

DOIIT22AR9020

MD998827 Installer adapter (56) • To install differential

outer race

DOIMT22DR10156

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 16 TRANSMISSION

TRANSMISSION WTC22DSHAUL001

TRANS CASE AND CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY

DOIMT22DR10020

— Apply Sealant (LT222)

— Non-reusable part
Items :
1. Drain oil plug
2. E type retainer ring
3. Shift shaft screw
4. Select and shift lever
5. Interlock retainer
6. Reverse lamp switch
7. Speedometer
T1 : 0.9~1.1 kgm (9~11 Nm, 0.6~0.74 ft.lbs)
T2 : 2.0~2.5 kgm (20~25 Nm, 1.34~1.68 ft.lbs)
T3 : 2.0~2.6 kgm (20~26 Nm, 1.34~1.74 ft.lbs)
T4 : 2.2~2.6 kgm (22~26 Nm, 1.48~1.74 ft.lbs)
T5 : 2.9~4.1 kgm (29~41 Nm, 1.95~2.75 ft.lbs)

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 17

DOIMT22DR10021

— Apply Sealant (LT5182 and LT5900)

— Non-reusable part
Items :
8. Rear cover
9. Retainer ring
10. Spring pin
11. 5th fork assembly
12. 5th gear spacer
13. 5th gear synchronizer assembly
14. 5th speed ring gear
15. Snap ring
16. 5th speed drive gear
17. Transmission case
T6 : 1.9~2.5 kgm (19~25 Nm, 1.28~1.68 ft.lbs)
T7 : 2.2~3.0 kgm (22~30 Nm, 1.48~2.01 ft.lbs)
T8 : 2.9~4.9 kgm (29~49 Nm, 1.95~3.29 ft.lbs)

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 18 TRANSMISSION

DOIMT22DR10022

— Non-reusable part
Items :
18. Input shaft
19. Output shaft
20. 3rd/4th gear fork assembly
21. 1st/2nd gear fork assembly
22. Reverse idler gear
23. Interlock plate
24. Shift shaft assembly
25. 5th/Rev fork shaft assembly
26. Differential assembly
27. Gate assembly
28. Magnet
29. Clutch housing
T6 : 1.9~2.5 kgm (19~25 Nm, 1.28~1.68 ft.lbs)

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 19

DISASSEMBLY SERVICE POINTS

WTC22DSHAUL002

TRANSMISSION REMOVAL
1. Pull up the select lever and push the shift
lever at 5th gear position before overhauling
the transmission.

Symbol Description
A Select lever
B Shift lever

DOIMT22DR10024

2. Remove the drain oil plug using a torque

wrench.

Symbol Description
A Drain oil plug

DOIMT22DR10025

3. Use a screw driver to remove the E type re-

tainer ring.

Symbol Description
A E type retainer ring

DOIMT22DR10026

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 20 TRANSMISSION

4. Remove the shift shaft screw.

Symbol Description
A Shift shaft screw
CAUTION:
Please be careful not to damage the shift
shaft oil seal.

DOIMT22DR10027

5. Remove the select and shift lever properly.

Symbol Description
A Select and shift lever

DOIMT22DR10028

6. Remove the interlock retainer assembly by

using ring spanner.

Symbol Description
A Interlock retainer assembly

DOIMT22DR10029

7. Remove the reverse lamp switch assembly.

Symbol Description
A Reverse lamp switch

DOIMT22DR10030

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 21

8. Remove the speedometer bolt and pull out

carefully with several gentle rotations. Do
not use strong power during removing the
part vertically.

Symbol Description
A Speedometer

DOIMT22DR10032

9. Remove the rear cover bolts (5 pieces ) and

stud (1 piece).

DOIMT22DR10033

10. Remove the rear cover manually and some

times probably use a rubber hammer to
knock the cover in order to separate the
cover and the sealant.

Symbol Description
A Rear cover

DOIMT22DR10034

11. Remove the retainer ring using a circlip plier.

Symbol Description
A Retainer ring

DOIMT22DR10035

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 22 TRANSMISSION

12. Remove the spring pin using common chisel

(size 4).

Symbol Description
A Spring pin
CAUTION:
(1) Never reuse the spring pin.
(2) If spring pin dropped into clutch housing
assembly, pick up it using magnet.

DOIMT22DR10036

13. Remove the 5th fork with 5th synchronizer,

spacer and 5th speed ring gear manually to-
gether.

Symbol Description
A 5th fork with 5th synchron-
izer, spacer and 5th speed
ring gear

DOIMT22DR10037

14. Remove the snap ring using a circlip plier.

Symbol Description
A Snap ring

DOIMT22DR10038

15. Remove the 5th speed drive gear using the

special tool G921–01.

Symbol Description
A 5th speed drive gear
NOTE
During using the special tool, hold the upper
handle and at the same time turn the lower
handle anti-clock wise direction as shown in
the illustration.

DOIMT22DR10039

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 23

16. Remove the transmission case mounting bolts

(12 pieces) and studs (2 pieces).

DOIMT22DR10040

17. By using a circlip plier, expend the input and

output fastening rings from bearings’
groove.
At the same time, knock along the transmis-
sion case edge and then remove the transmis-
sion case manually.

Symbol Description
A Input fastening ring
B Output fastening ring
C Transmission case

DOIMT22DR10041

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 24 TRANSMISSION

18. Remove the Input shaft assembly, output

shaft assembly and forks together along the
shown direction.

Symbol Description
A Input shaft assembly
B Output shaft assembly
C 1st/2nd
D 3rd/4th fork

DOIMT22DR10042

19. Remove the reverse idler gear manually.

Symbol Description
A Reverse idler gear

DOIMT22DR10043

20. Remove the interlock plate, shift shaft and

fork shaft manually.

Symbol Description
A Interlock plate
B Shift shaft
C 5th /rev gear fork shaft

DOIMT22DR10044

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 25

21. Remove the differential assembly manually.

Symbol Description
A Differential assembly

DOIMT22DR10045

22. Remove the gate assembly.

Symbol Description
A Gate assembly

DOIMT22DR10046

23. Remove the magnet manually.

Symbol Description
A Magnet

DOIMT22DR10047

SEALANT REMOVAL
1. Clean the entire old sealant using scrapper
without damaging transmission case surface.

DOIMT22DR10134

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 26 TRANSMISSION

2. Clean the entire old sealant using scrapper

without damaging clutch housing surface.

DOIMT22DR10135

3. Clean the entire old sealant using scrapper

without damaging transmission case surface.

DOIMT22DR10136

4. Clean the entire old sealant using scrapper

without damaging rear cover surface.

DOIMT22DR10137

REASSEMBLY SERVICE POINTS

WTC22DSHAUL003

TRANSMISSION INSTALLATION
1. Install the magnet.

Symbol Description
A Magnet

DOIMT22DR10047

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 27

2. Install the gate assembly and tighten the bolt

to the specified torque.
Specified torque:
1.9~2.5 kgf.m

Symbol Description
A Gate assembly

DOIMT22DR10046

3. Install the differential assembly.

Symbol Description
A Differential assembly

DOIMT22DR10045

4. Insert screw driver into reverse lamp switch

hole.

Symbol Description
A Screw driver

DOIMT22DR11006

5. Install shift shaft assembly.

Locate the shaft pin rest on the gate as
shown in the illustration.

Symbol Description
A Shift shaft assembly
B Shaft pin

DOIMT22DR10110

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 28 TRANSMISSION

6. Install the 5th/Rev shaft assembly as shown

in the illustration. Match the shift shaft fin-
ger with 5th/Rev shaft and ensure both parts
are matching to each other.

Symbol Description
A 5th/Rev shaft assembly
B Shift finger

DOIMT22DR10111

CAUTION
The pin of the shift shaft should be in posi-
tion as shown in the illustration (5th speed
position).

Symbol Description
A Shift shaft pin

DOIMT22DR10112

7. Install the reverse idler gear manually.

Put reverse idler gear and reverse lever into
right position

Symbol Description
A Reverse idler gear
B Reverse lever

DOIMT22DR10113

8. Install the input shaft assembly but do not

put into the final position. Just locate on the
clutch housing as shown in the illustration.

Symbol Description
A Input shaft assembly

DOIMT22DR10114

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 29

9. Install the interlock plate but do not put into

the final position.

Symbol Description
A Interlock plate

DOIMT22DR10115

10. Mount the two forks on the output shaft

assembly as shown in the illustration.

Symbol Description
A Output shaft assembly
B 3rd/4th gear fork assembly
C 1st/2nd gear fork assembly

DOIMT22DR10116

11. Locate forks assembly and output shaft onto

the 5th/rev shaft. Ensure the output shaft
matching with the differential ring gear.

Symbol Description
A Output shaft and fork as-
sembly
B 5th/Rev shaft assembly
C Differential ring gear

DOIMT22DR10117

CAUTION:
Notice the position of the parts as shown in
the illustration.

DOIMT22DR10118

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 30 TRANSMISSION

12. Match the output shaft and input shaft

gears. Then locate two shafts down into the
final position.

DOIMT22DR10119

CAUTION:
To get the interlock plate in the right posi-
tion, some adjustment is necessary. The in-
put shaft and output shaft must be rotated
freely.

Symbol Description
A Interlock plate

DOIMT22DR10120

13. Apply recommended sealant to mating face

of clutch housing assembly as shown in the
illustration.
Specified sealant:
LT5182

Symbol Description
A Sealant center line

DOIMT22DR10121

14. Mounting two special tool G922–13 and

G922–14 into place as shown in the illustra-
tion.

DOIMT22DR10122

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 31

15. Mount the transmission case on the clutch

housing.

DOIMT22DR10132

16. Tighten the 12 pieces bolt and 2 pieces stud

to the specified torque in sequence order as
shown in illustration.

Symbol Description
A Stud
Specified torque:
Bolt 1.9~2.5 kgm (19~25 Nm,
1.28~1.68 ft.lbs)
Stud 2.2~3.0 kgm (22~30 Nm,
1.48~2.01 ft.lbs)

DOIMT22DR10123

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 32 TRANSMISSION

17. Use a small handle to lift the output shaft in

order to make sure output shaft and input
shaft fastening ring can be stayed in the right
position. Then adjust the rings position as
shown in the illustration.

Symbol Description
A Input shaft fastening ring
B Output shaft fastening ring
C Handle

DOIMT22DR10124

18. Use the special tool G922–15–01,

G922–15–02, G922–15–03 and press machine
to install the 5th speed drive gear.

Symbol Description
A 5th speed drive gear

DOIMT22DR11019

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 33

19. Use a circlip plier to install a new snap ring.

Symbol Description
A Snap ring

DOIMT22DR10038

20. 20.1 Check the 5th gear synchronizer ring

clearance before its installation.
20.2 By using a feeler gauge check the dimen-
sion L3.
CAUTION
If actual clearance not within the al-
lowed range, replace the part.
Specified clearance:
Symbol Allowed range
L3 0.643~1.273 mm
(0.025~0.05 in)

20.3 Install the 5th speed ring gear and syn-

chronizer ring.

Symbol Description
A 5th speed ring gear &
synchronizer

DOIMT22DR11026

21. Put the 5th gear fork assembly and 5 th gear

synchronizer assembly in the right position.

Symbol Description
A 5th gear fork assembly
B 5th gear synchronizer as-
sembly
NOTE:
Notice the orientation of 5th gear synchron-
izer assembly, and make sure the hub’s side
which has letters is below.
DOIMT22DR10127

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 34 TRANSMISSION

Add the 5th gear fork and synchronizer as-

sembly then, put the 5th gear synchronizer
spacer in place. Make sure the claws of spacer
matching to the hub’s slider grooves.

Symbol Description
A 5th gear synchronizer spacer

DOIMT22DR10128

22. Use a circlip plier to install a new retainer

ring.

Symbol Description
A Retainer ring

DOIMT22DR10035

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 35

23. Install a new spring pin by using common

chisel (size 4) into the 5th fork and 5th /R
shaft as shown in the illustration.

Symbol Description
A Spring pin
NOTE:
(1) Ensure the spring pin is seating in 45°
angle.
(2) After this step the helper which had
been showed in step 4 can be pulled off.
CAUTION:
Never reuse spring pin.

DOIMT22DR10129

24. Apply recommended sealant to the rear

cover as shown in the illustration.
Specified sealant:
LT5900

Symbol Description
A Sealant center line

DOIMT22DR10130

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 36 TRANSMISSION

25. Mount the rear cover on transmission case

and then tighten the bolts (5 pieces) and stud
(1 piece) to the specified torque in sequence
order as shown in illustration.

Symbol Description
A Stud
Specified torque:
Bolt 1.0~1.3 kgm (10~13 Nm,
0.67~0.87 ft.lbs)
Stud 2.9~4.9 kgm (29~49 Nm,
1.95~3.29 ft.lbs)

DOIMT22DR10133

26. Put the speedometer assembly in place, and

then install the bolt. Tighten the bolt to the
specified torque.
Specified torque:
0.9~1.1 kgm (9~11 Nm, 0.6~0.74 ft.lbs)

Symbol Description
A Speedometer assembly

DOIMT22DR10032

27. Before installing the reverse lamp switch,

check the reverse lamp switch using multi-
meter.

DOIMT22DR10131

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION / 37

28. Mount the reverse lamp switch on clutch

housing and tighten to the specified torque.

Symbol Description
A Reverse lamp switch
Specified torque:
2.0~2.5 kgm (20~25 Nm, 1.34~1.68 ft.lbs)

DOIMT22DR10030

29. Mount the interlock retainer seat on the

transmission case and tighten to the specified
torque.
Specified torque:
2.0~2.6 kgm (20~26 Nm, 1.34~1.74 ft.lbs)

Symbol Description
A Interlock retainer assembly

DOIMT22DR10029

30. Install the select and shift lever.

Symbol Description
A Select and shift lever

DOIMT22DR10028

31. Install the shift shaft screw and tighten the

screw to the specified torque.
Specified torque:
2.0~2.6 kgm (20~26 Nm, 1.34~1.74 ft.lbs)

Symbol Description
A Shift shaft screw
CAUTION:
Please be careful not to break the shift shaft
oil seal.

DOIMT22DR10027

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 38 TRANSMISSION

32. Use a snap ring plier to connect E type retain-

er ring.

Symbol Description
A E type retainer ring

DOIMT22DR10026

33. Use a torque wrench to install the drain oil

plug on clutch housing and tighten the plug
to the specified torque.
Specified torque:
2.9~4.1 kgm (29~41 Nm, 1.95~2.75 ft.lbs)

Symbol Description
A Drain plug

DOIMT22DR10025

34. Check the select lever and shift lever opera-

tion condition.

Symbol Description
A Select lever
B Shift lever

DOIMT22DR10024

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
INPUT SHAFT / 39

INPUT SHAFT WTC22DSHAUL004

DISASSEMBLY AND REASSEMBLY

DOIMT22DR10023

Lubricate all internal part with gear oil during reassembly

— Non-reusable part
Disassembly steps
1. Input shaft front bearing
2. Input shaft rear bearing
3. Input shaft

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 40 INPUT SHAFT

DISASSEMBLY SERVICE POINTS

WTC22DSHAUL005

INPUT SHAFT REAR BEARING REMOVAL

By using special tool MD998801, press the input
shaft in order to remove the rear bearing.

Symbol Description
A Input shaft rear bearing

DOIMT22DR10048

INPUT SHAFT FRONT BEARING REMOVAL

By using special tool MD998801, press the input
shaft in order to remove the front bearing.

Symbol Description
A Input shaft front bearing

DOIMT22DR10049

CHECK AND INSPECTION WTC22DSHAUL006

INPUT SHAFT
1. Check shaft for cracks, wear or bending.
2. Check gears for excessive wear, chips or
cracks.
NOTE:
Replace new shaft if damage or wear.

DOIMT22DR10050

BEARING
Make sure bearing roll freely and free from
noise, cracks, pitting or wear.
NOTE:
Replace new bearing if damage or wear.

DOIMT22DR10051

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
INPUT SHAFT / 41

REASSEMBLY SERVICE POINTS

WTC22DSHAUL007

INPUT SHAFT FRONT BEARING

INSTALLATION
By using special tool MD998812, MD998813,
MD998816, and MD998801, press the input shaft
in order to install the front bearing.

Symbol Description
A Input shaft front bearing

DOIMT22DR11008

INPUT SHAFT REAR BEARING INSTALLATION

By using special tool MD998812, MD998813,
MD998817 and MD998801, press the input shaft
in order to install the rear bearing.

Symbol Description
A Input shaft rear bearing

DOIMT22DR10052

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 42 OUTPUT SHAFT

OUTPUT SHAFT WTC22DSHAUL008

DISASSEMBLY AND REASSEMBLY

DOIMT22DR10053

Lubricate all internal part with gear oil during reassembly

— Non-reusable part
Disassembly steps 14. 1st/2nd synchronizer inner ring
1. Retainer ring 15. Synchronizer cone ring
2. Output shaft rear bearing 16. 1st/2nd synchronizer outer ring
3. 4th speed ring gear 17. Retainer ring
4. 3rd/4th/5th synchronizer ring 18. 1st/2nd gear synchronizer spring
5. Retainer ring 19. 1st/2nd gear synchronizer slider
6. 3rd/4th synchronizer spring 20. 1st/2nd gear synchronizer hub
7. 3rd/4th synchronizer slider 21. 1st/2nd gear synchronizer sleeve
8. 3rd/4th synchronizer hub 22. 1st speed ring gear
9. 3rd/4th synchronizer sleeve 23. Retainer ring
10. 3rd speed ring gear 24. Output shaft front bearing inner ring
11. Stop ring 25. Output shaft
12. Stop washer
13. 2nd speed ring gear

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
OUTPUT SHAFT / 43

DISASSEMBLY SERVICE POINTS WTC22DSHAUL009

SPEED GEAR CLEARANCE CHECK

DOIMT22DR11024

1. Check each speed gear clearance before dis-

assembly the output shaft assy.
2. By using a feeler gauge check the dimension
D1, D2, D3 and D4.
CAUTION
If actual clearance out the allowed range
need replace the part.
Specified clearance:
Symbol Allowed range
D1 0.06~0.24 mm (0.002~0.009
in)
D2 0.165~0.43 mm (0.006~0.017
in)
D3 0.09~0.21 mm (0.004~0.008
in)
D4 0.175~0.335 mm
(0.007~0.013 in)

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 44 OUTPUT SHAFT

OUTPUT SHAFT RETAINER RING REMOVAL

By using a snap ring plier MB990628 and
AZBST008–00A remove the retainer ring.

Symbol Description
A Retainer ring

DOIMT22DR10138

OUTPUT SHAFT REAR BEARING REMOVAL

By using special tool MD998801 and bar, press
the output shaft in order to remove the output
shaft rear bearing.

Symbol Description
A Output shaft rear bearing
B Output shaft rear bearing
groove
C Bar
NOTE:
Ensure lip of the special tool seat in the rear
bearing groove.

DOIMT22DR10139

4TH SPEED RING GEAR AND SYNCHRONIZER

RING REMOVAL
Remove the 4th speed ring gear and synchronizer
ring pack manually.

Symbol Description
A 4th speed ring gear and syn-
chronizer ring

DOIMT22DR10140

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
OUTPUT SHAFT / 45

RETAINER RING REMOVAL

By using a snap ring plier MB990628, remove the
retainer ring.

Symbol Description
A Retainer ring

DOIMT22DR10141

3RD SPEED RING GEAR AND SYNCHRONIZER

REMOVAL
Remove the 3rd speed ring gear and synchronizer
pack manually.

Symbol Description
A 3rd speed ring gear and syn-
chronizer

DOIMT22DR10142

STOP RING REMOVAL

Remove the stop ring manually.

Symbol Description
A Stop ring

DOIMT22DR10143

STOP WASHER REMOVAL

Remove the stop washer manually.

Symbol Description
A Stop washer

DOIMT22DR10149

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 46 OUTPUT SHAFT

2ND SPEED RING GEAR AND SYNCHRONIZER

RING REMOVAL
Remove the 2nd speed ring gear and synchron-
izer rings manually.

Symbol Description
A 2nd speed ring gear & synchron-
izer ring

DOIMT22DR10144

RETAINER RING REMOVAL

By using a snap ring plier MB990628, remove the
retainer ring.

Symbol Description
A Retainer ring

DOIMT22DR10145

1ST SPEED RING GEAR AND SYNCHRONIZER

REMOVAL
Remove the 1st speed ring gear and synchronizer
pack manually.

Symbol Description
A 1st speed ring gear and syn-
chronizer pack

DOIMT22DR10146

RETAINER RING REMOVAL

By using a circlip plier, remove the retainer ring.

Symbol Description
A Retainer ring

DOIMT22DR10147

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
OUTPUT SHAFT / 47

OUTPUT SHAFT FRONT BEARING INNER RING

REMOVAL
By using special tool MD998801 and bar, press
the output shaft in order to remove the output
shaft front bearing inner ring.

Symbol Description
A Output shaft front bearing in-
ner ring
B Bar size 32 mm (1.26 in)

DOIMT22DR10148

CHECK AND INSPECTION WTC22DSHAUL010

GEAR AND SHAFT

1. Check shaft for cracks, wear or bending.
2. Check gears for excessive wear, chips or
cracks.

DOIMT22DR10054

SYNCHRONIZER
1. Check spline area of new coupling sleeves,
hubs and gears for wear or cracks.
2. Check the new synchronizer rings for cracks
or deformation.
3. Check shifting insert for wear or deforma-
tion.
CAUTION:
Never reuse synchronizer assembly (coupling
sleeve, hub and synchronizer ring).
4. By using a feeler gauge measure clearance
between new synchronizer ring and gear (for
single cone side).
Dimension “L1” :
0.62-1.54 mm (0.024-0.061 in) (Refer to page
22D/9 — Synchronizer ring clearance).

5. By using a feeler gauge measure clearance

between new synchronizer ring assembly and
gear (for double cone side).
Dimension “L3” :
0.643-1.273 mm (0.025-0.05 in) (Refer to page
22D/9 — Synchronizer ring clearance).

DOIMT22CR07150

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 48 OUTPUT SHAFT

Symbol Description
A Synchronizer ring
B Gear
C Synchronizer ring assembly
BEARING
Make sure new bearings roll freely and free from
noise, cracks, pitting or wear.
NOTE:
(1) Is damage or wear, replace new bearing (for
rear bearing only).
(2) Is damage or wear, replace new bearing and
shaft (for front bearing only).

DOIMT22DR10051

ASSEMBLY OF SYNCHRONIZER
WTC22DSHAUL011

SYNCHRONIZER SECTIONAL VIEW

Symbol Description
1 Synchronizer hub
2 Synchronizer slider
3 Synchronizer spring
4 Synchronizer sleeve
NOTE
Ensure synchronizer hub lettering is upper before
install at the shaft.

DOIMT22DR10055

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
OUTPUT SHAFT / 49

SYNCHRONIZER HUB INSTALLATION

Locate the sleeve and hub, by ensuring the
groove of the sleeve mating with the groove of
the hub.

Symbol Description
A Groove of the sleeve
B Groove of the hub

DOIMT22DR10056

SYNCHRONIZER SLIDER INSTALLATION

Insert the slider into the groove as shown in the
illustration.

Symbol Description
A Slider

DOIMT22DR10057

SYNCHRONIZER SPRING INSTALLATION

1. Fit the hook of the spring into the slider.

Symbol Description
A Spring

DOIMT22DR10058

2. Mount the spring on the other side, and then

wait for transmission installation.
NOTE:
Be careful, the spring orientation during in-
stallation. The orientation at one side is op-
posite to the other side.

Symbol Description
A Spring

DOIMT22DR10059

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 50 OUTPUT SHAFT

REASSEMBLY SERVICE POINTS

WTC22DSHAUL012

SYNCHRONIZER RING CLEARANCE CHECK

1. Check each gear except 5th gear synchronizer
ring clearance before reassembly the output
shaft assy.
2. By using a feeler gauge check the dimension
L1, L2 and L3.
CAUTION
If actual clearance out the allowed range
need replace the part.
Specified clearance:
Symbol Allowed range (mm)
L1 0.62~1.54 mm (0.024~0.061
in)
L2 0.612~1.262 mm (0.024~0.05
in)
L3 0.643~1.273 mm (0.025~0.05
in)

DOIMT22DR11025

OUTPUT SHAFT FRONT BEARING INNER RING

INSTALLATION
By using special tools MD998801, MD998812,
MD998813 and MD998820, press the front bear-
ing inner ring.

Symbol Description
A Output shaft front bearing in-
ner ring

DOIMT22DR10151

RETAINER RING INSTALLATION

By using circlip plier, install the retainer ring.

Symbol Description
A Retainer ring

DOIMT22DR10147

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
OUTPUT SHAFT / 51

1ST SPEED RING GEAR AND 1ST/2ND

SYNCHRONIZER PACK INSTALLATION
Locate the output shaft at special tool
AZBST008–00A and install 1st speed ring gear
and 1st/2nd synchronizer pack in place.

Symbol Description
A 1st speed ring gear & 1st/2nd
synchronizer pack
NOTE:
Notice the orientation of synchronizer assembly.
DOIMT22DR10146
Make sure the hub’s side which has letters is
above.

RETAINER RING INSTALLATION

By using a snap ring plier MB990628, install the
retainer ring.

Symbol Description
A Retainer ring

DOIMT22DR10145

2ND SPEED RING GEAR AND SYNCHRONIZER

RING INSTALLATION
Put the 2nd speed ring gear and synchronizer
rings in place.

Symbol Description
A 2nd speed ring gear & synchron-
izer ring

DOIMT22DR10144

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 52 OUTPUT SHAFT

STOP WASHER AND INSTALLATION

Put the stop washer in place.

Symbol Description
A Stop washer

DOIMT22DR10149

STOP RING INSTALLATION

Put the stop ring on the thrust washer.

Symbol Description
A Stop ring

DOIMT22DR10143

3RD SPEED RING GEAR AND SYNCHRONIZER

RING INSTALLATION
Put the 3rd speed ring gear and synchronizer
ring in place.

Symbol Description
A 3rd speed ring gear & synchron-
izer ring

DOIMT22DR10142

RETAINER RING INSTALLATION

By using snap ring plier MB990628, install the
retainer ring.

Symbol Description
A Retainer ring

DOIMT22DR10141

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
OUTPUT SHAFT / 53

4TH SPEED RING GEAR AND SYNCHRONIZER

RING INSTALLATION
Put the 4th speed ring gear and synchronizer
ring in place.

Symbol Description
A 4th speed ring gear & synchron-
izer ring

DOIMT22DR10140

OUTPUT SHAFT REAR BEARING

INSTALLATION
By using special tools MD998812, MD998813 and
MD998816, press the output shaft rear bearing.

Symbol Description
A Output shaft rear bearing

DOIMT22DR10150

RETAINER RING INSTALLATION

By using a snap ring plier MB990628, install the
retainer ring.

Symbol Description
A Retainer ring

DOIMT22DR10138

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 54 SELECT AND SHIFT LEVER

SELECT AND SHIFT LEVER WTC22DSHAUL013

DISASSEMBLY AND REASSEMBLY

DOIMT22DR10060

Apply lubricant grease (Type: WSD-M1C244–A GLY801)

Disassembly steps
1. Shift lever
2. Select lever sleeve
3. Select lever
4. Select lever slider

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
CLUTCH HOUSING / 55

CLUTCH HOUSING WTC22DSHAUL014

DISASSEMBLY AND REASSEMBLY

DOIMT22DR10061

— Apply Sealant (Type: LT222)

— Non-reusable part
Disassembly steps
1. E type retainer ring
2. Reverse shift lever
3. Reverse gear rebound spring
4. Clutch housing plug
5. Input shaft oil seal
6. Differential oil seal
7. Output shaft front bearing outer ring
8. Output shaft funnel
9. Differential outer race
10. Clutch housing

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 56 CLUTCH HOUSING

DISASSEMBLY SERVICE POINTS

WTC22DSHAUL015

SHIFT SHAFT CLIP REMOVAL

Use a screw driver to push out the E type retainer
ring and then, remove the reverse shift lever and
reverse gear rebound spring.

Symbol Description
A E type retainer ring
B Reverse shift lever
DOIMT22DR10083
C Reverse gear rebound spring

CLUTCH HOUSING PLUG REMOVAL

Use a chisel and hammer to knock the plug out
from the clutch housing.

Symbol Description
A Plug

DOIMT22DR10062

INPUT SHAFT OIL SEAL REMOVAL

By using screw driver, remove the input shaft oil
seal.

Symbol Description
A Input shaft oil seal

DOIMT22DR10063

DIFFERENTIAL OIL SEAL REMOVAL

By using screw driver, remove the differential oil
seal.

Symbol Description
A Differential oil seal

DOIMT22DR10064

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
CLUTCH HOUSING / 57

OUTPUT SHAFT FRONT BEARING OUTER

RING REMOVAL
By using special tool AZBST003–00A, remove the
output shaft front bearing outer ring from clutch
housing.

Symbol Description
A Output shaft front bearing
outer ring

DOIMT22DR10065

DIFFERENTIAL OUTER RACE REMOVAL

Use a chisel and hammer to knock the differen-
tial outer race out from the clutch housing.

Symbol Description
A Differential outer race

DOIMT22DR10066

REASSEMBLY SERVICE POINTS

WTC22DSHAUL016

DIFFERENTIAL OUTER RACE INSTALLATION

Install the differential outer race to the clutch
housing by using special tools MD998812,
MD998814 and MD998827.

Symbol Description
A Differential outer race

DOIMT22DR10067

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 58 CLUTCH HOUSING

OUTPUT SHAFT FRONT BEARING OUTER

RING INSTALLATION
CAUTION
Ensure the front bearing outer ring is correct
position before installation to the clutch hous-
ing.
Install the output shaft front bearing outer ring
to the clutch housing by using special tools
MD998812, MD998814 and MD998829 .

Symbol Description
A Output shaft front bearing
outer ring

DOIMT22DR11023

DIFFERENTIAL OIL SEAL INSTALLATION

NOTE
Install the oil seal after all transmission compon-
ent reassemble.
Install the differential oil seal by using special
tools G922–17.

Symbol Description
A Differential oil seal

DOIMT22DR11020

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
CLUTCH HOUSING / 59

INPUT SHAFT OIL SEAL INSTALLATION

NOTE
Install the oil seal after input shaft reassemble.
1. Put the special tool G922–19 on the input
shaft.
2. Slide the oil seal over the special tool
G922–19.
Fit the input shaft oil seal by using special tools
G922–18.

Symbol Description
A Input shaft oil seal

DOIMT22DR11022

CLUTCH HOUSING PLUG INSTALLATION

Apply sealant at the plug and then install the
plug to the clutch housing by using special tool
MB990939 .
Specified sealant:
LT222

Symbol Description
A Plug

DOIMT22DR10071

E-TYPE RETAINER RING INSTALLATION

Install reverse shift lever, reverse gear rebound
spring and fit the E-type retainer ring by using
plier.

Symbol Description
A E-type retainer ring
B Reverse shift lever
C Reverse gear rebound spring

DOIMT22DR10084

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 60 TRANSMISSION CASE

TRANSMISSION CASE WTC22DSHAUL017

DISASSEMBLY AND REASSEMBLY

DOIMT22DR10072

— Non-reusable part
Disassembly steps
1. Input shaft fastening ring
2. Output shaft fastening ring
3. Differential oil seal
4. Differential outer race
5. Double spring washer
6. Transmission stud
7. Shift shaft oil seal assy
8. Transmission case

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION CASE / 61

DISASSEMBLY SERVICE POINTS

WTC22DSHAUL018

INPUTSHAFT AND OUTPUT SHAFT

FASTENING RINGS REMOVAL
Remove the input shaft and output shaft
fastening rings from the transmission case.

Symbol Description
A Input shaft fastening ring
B Output shaft fastening ring

DOIMT22DR10073

DIFFERENTIAL OIL SEAL REMOVAL

By using screw driver, remove the differential oil
seal.

Symbol Description
A Differential oil seal

DOIMT22DR10074

DOUBLE SPRING WASHER AND

DIFFERENTIAL OUTER RACE REMOVAL
By using screw driver, push the double spring
washer first in order to remove the differential
outer race.

Symbol Description
A Double spring washer
B Differential outer race

DOIMT22DR10075

TRANSMISSION STUD REMOVAL

Remove the transmission stud as shown in the
illustration.

Symbol Description
A Transmission stud

DOIMT22DR10076

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 62 TRANSMISSION CASE

SHIFT SHAFT OIL SEAL REMOVAL

By using screw driver, push up the shift shaft oil
seal from the transmission case.

Symbol Description
A Shift shaft oil seal

DOIMT22DR10085

REASSEMBLY SERVICE POINTS

WTC22DSHAUL019

SHIFT SHAFT OIL SEAL INSTALLATION

1. Apply masking tape to the shift shaft.

Symbol Description
A Masking tape
B Shift shaft

DOIMT22DR10086

2. Install the shift shaft oil seal slowly and

carefully.

Symbol Description
A Shift shaft oil seal

DOIMT22DR10087

3. By using mallet and socket (size 21), knock

slowly and carefully the shift shaft oil seal.
Then remove the masking tape.

Symbol Description
A Shift shaft oil seal
B Socket size 21

DOIMT22DR10088

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
TRANSMISSION CASE / 63

TRANSMISSION STUD INSTALLATION

Install the transmission studs as shown in the il-
lustration.

Symbol Description
A Transmission stud

DOIMT22DR10077

DOUBLE SPRING WASHER INSTALLATION

Install the double spring washer as shown in the
illustration.

Symbol Description
A Double spring washer

DOIMT22DR10078

DIFFERENTIAL OUTER RACE INSTALLATION

Install the differential outer race by using special
tool MD998812 and MD998827.

Symbol Description
A Differential outer race

DOIMT22DR10079

DIFFERENTIAL OIL SEAL INSTALLATION

Install the differential oil seal by using special
tool G922–17.

Symbol Description
A Differential oil seal

DOIMT22DR11021

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 64 TRANSMISSION CASE

INPUT SHAFT AND OUTPUT SHAFT

FASTENING RINGS INSTALLATION
Install the fastening rings to the transmission
case slot as shown in the illustration.

Symbol Description
A Input shaft fastening ring
B Output shaft fastening ring

DOIMT22DR10081

Printed in Malaysia 12 July 2011 Eng

 MANUAL TRANSMISSION <5MTT200A> 22D
DIFFERENTIAL / 65

DIFFERENTIAL WTC22DSHAUL020

DISASSEMBLY AND REASSEMBLY

DOIMT22DR10082

— Non-reusable part
Disassembly steps
1. Differential taper rolling bearing
2. Speedometer drive gear
3. Bolt
4. Final drive ring gear
5. Retainer ring
6. Planet pinion shaft
7. Planet pinion
8. Differential gear
9. Differential lining
10. Differential case
T1: 10.0~11.0 kgm (100~110 Nm, 6.71~7.38 ft.lbs)

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 66 DIFFERENTIAL

DISASSEMBLY SERVICE POINTS

WTC22DSHAUL021

FINAL DRIVE RING GEAR REMOVAL

1. Create a marking (punch mark) at final drive
ring gear and differential case.

Symbol Description
A Punch mark at final drive
ring gear
B Punch mark at differential
case
DOIMT22DR10089

2. By using a torque wrench, remove the bolts

(8 pieces).
NOTE:
Do not reuse the bolts.

DOIMT22DR10090

3. By using mallet, knock slowly and carefully

the final drive ring gear from the differential
case.

DOIMT22DR10091

DIFFERENTIAL TAPER ROLLING BEARING

REMOVAL
By using the special tools MB990938, MB991202
and MB998917 remove the taper rolling bearing
inner ring.

DOIMT22DR11010

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
DIFFERENTIAL / 67

DIFFERENTIAL TAPER ROLLING BEARING AND

SPEEDOMETER DRIVE GEAR REMOVAL
By using the special tool MB990938, MB991202
and MD998801or MB998917, remove the taper
rolling bearing inner ring and speedometer
driving gear.

Symbol Description
A Differential taper rolling bear-
ing
B Speedometer drive gear
DOIMT22DR10093
NOTE:
Do not reuse the speedometer drive gear.

RETAINER RING REMOVAL

By using a circlip plier, remove the two retainer
rings from the planet pinion shaft.

DOIMT22DR10094

PLANET PINION SHAFT REMOVAL

By using suitable bar and hammer to knock the
planet pinion shaft.

DOIMT22DR10095

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 68 DIFFERENTIAL

PLANET PINION REMOVAL

Rotate the planet pinion to 90° and then remove
it from differential case.

Symbol Description
A Planet pinion

DOIMT22DR10096

DIFFERENTIAL GEAR REMOVAL

Remove the differential gear from differential
case.

Symbol Description
A Differential gear

DOIMT22DR10097

DIFFERENTIAL LINING REMOVAL

Remove the differential lining from differential
.

Symbol Description
A Differential lining

DOIMT22DR10098

REASSEMBLY SERVICE POINTS

WTC22DSHAUL022

DIFFERENTIAL LINING INSTALLATION

Insert the differential lining manually and then
after assembly, it should be oriented to the dif-
ferential shaft hole as shown in the illustration.

Symbol Description
A Differential lining
B Differential shaft hole
DOIMT22DR10099

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
DIFFERENTIAL / 69

PLANET PINION SHAFT INSTALLATION

By using mallet, knock slowly the planet pinion
shaft into half position.

Symbol Description
A Planet pinion shaft

DOIMT22DR10100

PLANET PINION INSTALLATION

Insert two pieces planet pinion into the planet
pinion shaft then continue knocking the planet
pinion shaft.

Symbol Description
A Planet pinion

DOIMT22DR10101

RETAINER RING INSTALLATION

By using a snap ring plier, install two retainer
rings.

Symbol Description
A Retainer ring

DOIMT22DR10102

DIFFERENTIAL GEAR INSTALLATION

Install the two differential gears manually.

Symbol Description
A Differential gear

DOIMT22DR10103

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 70 DIFFERENTIAL

FINAL DRIVE RING GEAR INSTALLATION

1. Install the final drive ring gear to the differ-
ential case by aligning the punch mark or
ensure the big chamfer at final drive ring
gear is below.
NOTE:
Notice the orientation of the final drive ring
gear. Please make sure the side of big
chamfer is below as shown in the illustra-
tion.

Symbol Description
A Big chamfer (Below)
B Small chamfer (Upper)
C Punch mark

DOIMT22DR10104

2. Install all final drive ring gear bolts and

tighten the bolt in sequence order to the
specified torque.
Specified torque:
10.0~11.0 kgm (100~110 Nm, 6.71~7.38 ft.lbs)

NOTE:
Never reuse final drive ring gear bolts.

DOIMT22DR10107

SPEEDOMETER DRIVE GEAR INSTALLATION

Install the speedometer drive gear on the differ-
ential case.
Please ensure the speedometer drive gear bulge
is aligning with differential case groove.

Symbol Description
A Speedometer drive gear bulge
B Differential case groove

DOIMT22DR10105

Printed in Malaysia 12 July 2011 Eng

MANUAL TRANSMISSION <5MTT200A> 22D
DIFFERENTIAL / 71

DIFFERENTIAL TAPER ROLLING BEARING

INSTALLATION
Install the differential taper rolling bearing on
differential case by using special tools MD998812,
MD998813 and MD998821.

Symbol Description
A Taper rolling bearing inner ring
B Speedometer drive gear

DOIMT22DR10106

Printed in Malaysia 12 July 2011 Eng

22D MANUAL TRANSMISSION <5MTT200A>
/ 72 DIFFERENTIAL

NOTE

Printed in Malaysia 12 July 2011 Eng

Printed in Malaysia 12 July 2011 Eng
5MTT200A Model YR 2011 English Edition RDCE-11GTRG080-00 July 2011 Printed in Malaysia