MANUAL TRANSMISSION GI

MT
MA

EM
SECTION
LC
MODIFICATION NOTICE:
I The VG30E engine with FS5R30A has been added on 2/4WD models for Australia. EC
I For TD27 engine models with FS5W71C, the synchronizer of baulk ring has been changed from “double
type” to “single type”.
I Information on FS5W71C and FS5R30A has been changed. FE

CONTENTS CL
FS5W71C Shift Control Components ...........................................9
OVERHAUL .....................................................................2
FS5W71C & FS5R30A
Case Components .......................................................2
Gear Components - 2WD Model with TD27 SERVICE DATA AND SPECIFICATIONS (SDS) ..........10 AT
Engine..........................................................................3 General Specifications...............................................10

FS5R30A
TF
FS5W71C
REMOVAL AND INSTALLATION ....................................4 SERVICE DATA AND SPECIFICATIONS (SDS) ..........11
Installation....................................................................4 Inspection and Adjustment ........................................11
PD
OVERHAUL .....................................................................5
Case Components .......................................................5 FS5R30A FA
Gear Components - VG30E Engine Model.................6
Gear Components - 4WD Model with QD32 SERVICE DATA AND SPECIFICATIONS (SDS) ..........12
Engine..........................................................................8 Inspection and Adjustment ........................................12 RA

BR

ST

RS

BT

HA

EL

IDX

MT-1
 OVERHAUL FS5W71C

Case Components

SMT023E

MT-2
 OVERHAUL FS5W71C

Gear Components — 2WD Model with TD27

Engine GI

MA

EM

LC

EC

FE

CL

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

SMT024E

MT-3
 REMOVAL AND INSTALLATION FS5R30A

Installation
I Apply sealant as below:

SMT796CC

I Tighten bolts securing transmission.

VG30E engine model

Bolt No. Tightening torque N⋅m (kg-m, ft-lb)  mm (in)

q
1 39 - 49 (4.0 - 5.0, 29 - 36) 65 (2.56)
q
2 29 - 39 (2.9 - 4.0, 21 - 28) 58 (2.28)
q
3 39 - 49 (3.9 - 5.0, 29 - 36) 58 (2.28)
q
4 30 - 39 (3.0 - 4.0, 22 - 28) 25 (0.98)
Gusset to engine 29 - 39 (3.0 - 4.0, 22 - 29) 20 (0.79)
SMT573AC

MT-4
 OVERHAUL FS5R30A

Case Components
GI

MA

EM

LC

EC

FE

CL

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

SMT639DA

MT-5
 OVERHAUL FS5R30A

Gear Components — VG30E Engine Model

SMT638DA

MT-6
 OVERHAUL FS5R30A
Gear Components — VG30E Engine Model
(Cont’d)
GI

MA

EM

LC

EC

FE

CL

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX
SMT816D

MT-7
 OVERHAUL FS5R30A

Gear Components — 4WD Model with QD32

Engine

SMT609D

MT-8
 OVERHAUL FS5R30A

Shift Control Components

GI

MA

EM

LC

EC

FE

CL

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

SMT817DA

MT-9
 SERVICE DATA AND
SPECIFICATIONS (SDS) FS5W71C & FS5R30A

General Specifications
2WD 4WD
Applied model
KA24DE Z24S TD27 VG30E KA24DE QD32 VG30E
Transmission FS5W71C FS5R30A FS5W71C FS5R30A
Number of speed 5

Shift pattern

Synchromesh type Warner

Gear ratio
1st 3.592 3.985 3.580 3.592 3.580 4.061
2nd 2.246 2.246 2.077 2.246 2.077 2.357
3rd 1.415 1.415 1.360 1.415 1.360 1.490
4th 1.000 1.000 1.000 1.000 1.000 1.000
OD 0.821 0.821 0.811 0.821 0.811 0.862
Reverse 3.657 3.657 3.636 3.657 3.636 4.125
Number of teeth
Mainshaft
Drive 21 21 22 21 22 20
1st 33 34 32 33 32 32
2nd 28 28 30 28 30 30
3rd 26 26 29 26 29 28
OD 21 21 24 21 24 23
Reverse 36 36 30 36 30 30
Countershaft
Drive 32 32 32 32 32 33
1st 14 13 13 14 13 13
2nd 19 19 21 19 21 21
3rd 28 28 31 28 31 31
OD 39 39 43 39 43 44
Reverse 15 15 12 15 12 12
Reverse idler gear 21 22 21 22
Oil capacity  (lmp pt) 2.0 (3-1/2) 2.8 (4-7/8) 4.9 (8-5/8) 5.1 (9)
Counter drive
Installed
gear
Sub-gear
Reverse idler
Installed Not installed Installed
Remarks gear
Double baulk ring type synchro-
2nd and 3rd gears Not installed 2nd and 3rd gears
nizer
Reverse synchronizer Installed Not installed Installed Not installed

MT-10
 SERVICE DATA AND SPECIFICATIONS (SDS) FS5W71C

Inspection and Adjustment

CLEARANCE BETWEEN BAULK RING AND 2nd and 3rd baulk ring (KA24DE & Z24S GI
GEAR engines)
KA24DE & Z24S engine MA
Unit: mm (in)

Standard
EM
1st 1.20 - 1.60 (0.0472 - 0.0630)

Main drive 1.20 - 1.60 (0.0472 - 0.0630)

LC
OD 1.20 - 1.60 (0.0472 - 0.0630)

Reverse 1.10 - 1.55 (0.0433 - 0.0610)

Wear limit EC
1st 0.80 (0.0315)
Main drive 0.80 (0.0315) SMT742C FE
OD 0.80 (0.0315) Unit: mm (in)
Reverse 0.70 (0.0276) Dimension Standard Wear limit CL
0.7 - 0.9
TD27 engine A
(0.028 - 0.035)
Unit: mm (in) 0.2 (0.008)
0.6 - 1.1
B
Standard (0.024 - 0.043)
1st & 2nd 1.20 - 1.60 (0.0472 - 0.0630)
AT
3rd & main drive 1.20 - 1.60 (0.0472 - 0.0630)

Overdrive 1.20 - 1.60 (0.0472 - 0.0630)

Reverse 1.10 - 1.55 (0.0433 - 0.0610)
TF
Wear limit

1st & 2nd 0.80 (0.0315) PD

3rd & main drive 0.80 (0.0315)

Overdrive 0.80 (0.0315) FA

Reverse 0.70 (0.0276)

RA

BR

ST

RS

BT

HA

EL

IDX

MT-11
 SERVICE DATA AND SPECIFICATIONS (SDS) FS5R30A

Inspection and Adjustment

GEAR END PLAY
Gear End play mm (in)

1st main gear 0.23 - 0.33 (0.0091 - 0.0130)

2nd main gear 0.23 - 0.33 (0.0091 - 0.0130)

3rd main gear 0.06 - 0.16 (0.0024 - 0.0063)

OD counter gear 0.23 - 0.33 (0.0091 - 0.0130)

Reverse main gear 0.33 - 0.43 (0.0130 - 0.0169)

Counter gear 0.10 - 0.25 (0.0039 - 0.0098)

Reverse idler gear 0.30 - 0.53 (0.0118 - 0.0209)

MT-12