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1 MENU

FOREWORD

This workshop manual covers Disassembly, Inspection and Assembly procedures for the following Manual
Transmission:

Manual Transmission: M550

For Onïvehicle Servicing (Inspection, Adjustment, Troubleshooting, Removal and installation) of the Manu-
al transmission, refer to the workshop manual for the applicable model.

All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.

If you find any failures in this manual, you are kindly requested to inform us by using the report form on the
next page.

2004 Hino Motors, Ltd.

All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Hino Motors, Ltd.
First Printing: Feb. 2004
 Workshop Manual Quality Report
Att.) Service Manager,
Your Distributor

Pub. No. Issue Date

Name of Name of
Dealer Reporter

Subject

Problem
Description

Correction
Proposal
 CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the use of persons who have special techniques and certifications. If nonïspecialized or uncerti-
fied technicians perform repairs or service only using this manual or without proper equipment or
tools, this may cause severe injury to you or other persons nearby and also cause damage to your
customer’s vehicle.

In order to prevent dangerous operation and damage to your customer’s vehicle, be sure to follow
the instructions shown below.

S This manual must be read thoroughly. It is especially important to have a good understanding
of all the contents written in the PRECAUTION of ”INTRODUCTION” section.

S The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using nonïspecified or tools other than recommended tools and
service methods, be sure to confirm the safety of the technicians and that there is no possibility
of causing personal injury or damage to the customer’s vehicle before starting the operation.

S If part replacement is necessary, the part must be replaced with the same part number or equiv-
alent part. Do not replace it with an inferior quality part.

S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or re-
duce the possibility that improper service or repair may damage the vehicle or render it unsafe.
It is also important to understand that these ”Cautions” and ”Notices” are not exaggerations
and are possible hazardous consequences that might result from failure to follow these instruc-
tions.
INTRODUCTION 1
PREPARATION 2
SERVICE SPECIFICATIONS 3
MANUAL TRANSMISSION/TRANSAXLE 41
ALPHABETICAL INDEX
INTRODUCTION

HOW TO USE THIS MANUAL

TRANSMISSION WORKSHOP MANUAL . . 01ï1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 01ï1
REPAIR INSTRUCTION FOR MANUAL
TRANSMISSION WORKSHOP MANUAL . . 01ï4
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01ï4
TERMS FOR MANUAL TRANSMISSION
WORKSHOP MANUAL . . . . . . . . . . . . . . . . . . 01ï5
ABBREVIATIONS USED IN THIS MANUAL . . . 01ï5
GLOSSARY OF SAE AND HINO TERMS . . . . . 01ï6
 INTRODUCTION ï HOW TO USE THIS MANUAL TRANSMISSION 01ï1
WORKSHOP MANUAL

HOW TO USE THIS MANUAL TRANSMISSION WORKSHOP

MANUAL
01077ï04

GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains ”Removing and Installing, Replacing, Disassembling, Installing and Checking,
Adjusting”, but ”Final Inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ”disassembled parts drawing” so that it enables you
to understand the fitting condition of the components.
(c) Nonïreusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:
Shift and Select Lever Shaft
EïRing
Select Spring Seat
Compression Spring
Shift Interlock Plate 6.4 (85, 56 in.·lbf)

Compression Spring
Dust Boot Washer
EïRing
Slotted Spring Pin

Shift Inner Lever No.1

Shift Inner Lever No.2 Lever Lock Pin
zOil Seal
Select Spring Seat No.2 Control Shaft Lever
Control Shaft Cover
N·m (kgf·cm, ft·lbf) : Specified torque zOïRing
z Nonïreusable part
MP Grease C91004
01ï2 INTRODUCTION ï HOW TO USE THIS MANUAL TRANSMISSION
WORKSHOP MANUAL

(d) Tightening torque, oil applying position, and nonïreusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a stepïbyïstep format:
() The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:

Illustration: Task heading: what to do

what to do and where
87. INSTALL INPUT SHAFT FRONT BEARING

(a) Coat the new input shaft front bearing with MP grease, using
SST and a press, install it to the front transaxle case.
Drive in depth: 0 to 0.3 mm (0 to 0.118 in.)
SST 09950ï 6000 (0995ï 00420)
Detailed text:
how to do task
Component part No.
Set part No.

D33285

HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.

5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.

6. TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being repaired.
HINT Provide additional information to help you perform the repair efficiently.
 INTRODUCTION ï HOW TO USE THIS MANUAL TRANSMISSION 01ï3
WORKSHOP MANUAL

7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N˜m (310 kgf˜cm, 22 ft˜lbf)
01ï4 INTRODUCTION ï REPAIR INSTRUCTION FOR MANUAL
TRANSMISSION WORKSHOP MANUAL

REPAIR INSTRUCTION FOR MANUAL TRANSMISSION

WORKSHOP MANUAL
01078ï04

PRECAUTION
1. BASIC REPAIR HINT

(a) PRECOATED PARTS

(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
Seal Lock Adhesive
adhesive and dry with compressed air. Then apply
Z11554 the specified seal lock adhesive to the bolt, nut or
threads.
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) GASKETS
When necessary, use a sealer on gaskets to prevent leaks.
(c) BOLTS, NUTS AND SCREWS
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
 INTRODUCTION ï TERMS FOR MANUAL TRANSMISSION WORKSHOP 01ï5
MANUAL

TERMS FOR MANUAL TRANSMISSION WORKSHOP

MANUAL
01079ï04

ABBREVIATIONS USED IN THIS MANUAL

Abbreviations Meaning
E/G Engine
FIPG Formed In Place Gasket
MAX Maximum
MIN Minimum
MP Multipurpose
M/T Manual Transmission
N Neutral
No. Number
RH RightïHand
SPEC Specification
SSM Special Service Materials
SST Special Service Tools
STD Standard
T/A Transaxle
T/M Transmission
w/ With
w/o Without
1st First
2nd Second
01ï6 INTRODUCTION ï TERMS FOR MANUAL TRANSMISSION WORKSHOP
MANUAL
0107Aï04

GLOSSARY OF SAE AND HINO TERMS

This glossary lists all SAEïJ1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their Hino equivalents.
SAE HINO TERMS
SAE TERMS
ABBREVIATIONS ( )ïïABBREVIATIONS
A/C Air Conditioning Air Conditioner
ACL Air Cleaner Air Cleaner
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal ï
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure ï
CAC Charge Air Cooler Inter cooler
CARB Carburetor Carburetor
CFI Continuous Fuel Injection ï
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft position Cam Angle
CPP Clutch Pedal Position ï
CTOX Continuous Trap Oxidizer ï
CTP Closed Throttle Position ï
DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition ï
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Total Diagnosis Communication Link (TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode ï
ECL Engine Control Level ï
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Control Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only
EEPROM (EEPROM),
Memory
Erasable Programmable Read Only Memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition Distributorless Ignition (DI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control ï
Flash Electrically Erasable Programmable
FEEPROM ï
Read Only Memory
FEPROM Flash Erasable Programmable Read Only Memory ï
FF Flexible Fuel ï
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)
IAC Idol Air Control Idol Speed Control (ISC)
IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module ï
IFI Indirect Fuel Injection Indirect Injection
IFS Inertia FuelïShutoff ï
 INTRODUCTION ï TERMS FOR MANUAL TRANSMISSION WORKSHOP 01ï7
MANUAL

ISC Idle Speed Control ï

KS Knock Sensor Knock Sensor
MAF Mass Air Flow Air Flow Meter
Manifold Pressure
MAP Manifold Absolute Pressure
Intake Vacuum
Electric Bleed Air Control Valve (EBCV)
MC Mixture Control Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure ï
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Light
MST Manifold Surface Temperature ï
MVZ Manifold Vacuum Zone ï
NVRAM NonïVolatile Random Access Memory ï
O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)
OBD OnïBoard Diagnostic OnïBoard Diagnostic (OBD)
OC Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CC0
OP Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module ï
PNP Park/Neutral Position ï
PROM Programmable Read Only Memory ï
PSP Power Steering Pressure ï
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)
RM Relay Module ï
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass ï
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter ï
SRI Service Reminder Indicator ï
SRT System Readiness Test ï
ST Scan Tool ï
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter
TCM Transmission Control Module Transmission ECU (Electronic Control Unit)
TP Throttle Position Throttle Position
TR Transmission Range ï
Bimetallic Vacuum Switching Valve (BVSV)
TVV Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)
ThreeïWay Catalytic (TWC)
TWC ThreeïWay Catalytic Converter
CCRO
TWC+OC ThreeïWay + Oxidation Catalytic Converter CCR + CCO
VAF Volume Air Flow Air Flow Meter
VR Voltage Regulator Voltage Regulator
VSS Vehicle Speed Sensor Vehicle Speed Sensor
WOT Wide Open Throttle Full Throttle
01ï8 INTRODUCTION ï TERMS FOR MANUAL TRANSMISSION WORKSHOP
MANUAL

WUïOC Warm Up Oxidation Catalytic Converter ï

WUïTWC Warm Up ThreeïWay Catalytic Converter Manifold Converter
3GR Third Gear ï
4GR Fourth Gear ï
PREPARATION

MANUAL TRANSMISSION/TRANSAXLE . . . . 02ï

PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï
 02ï
PREPARATION ï MANUAL TRANSMISSION/TRANSAXLE

MANUAL TRANSMISSION/TRANSAXLE
023YYï0

PREPARATION
SST
09222ï3000 Connecting Rod Bushing Remover SHIFT LEVER SHAFT HOUSING
& Replacer ASSY(M550)

09309ï3600 Transmission Rear Bearing MANUAL TRANSMISSION

Replacer ASSY(M550)

0936ï200 Transfer Bearing Replacer OUTPUT SHAFT ASSY(M550)

COUNTER GEAR ASSY(M550)

0936ï600 Transmission & Transfer Bearing INPUT SHAFT ASSY(M550)

Replacer COUNTER GEAR ASSY(M550)

(0936ï000) Replacer Pipe INPUT SHAFT ASSY(M550)

COUNTER GEAR ASSY(M550)

0939ï60020 Output Shaft Needle Roller MANUAL TRANSMISSION

Bearing Remover ASSY(M550)

09502ï200 Differential Bearing Replacer COUNTER GEAR ASSY(M550)

0953ï36040 Rear Axle Bearing Replacer COUNTER GEAR ASSY(M550)

09608ï0604 Front Hub Inner Bearing Cone COUNTER GEAR ASSY(M550)

Replacer

0967ï2800 Worm Bearing Adjusting Screw MANUAL TRANSMISSION

Lock Nut Wrench ASSY(M550)

0987ï60 Backïup Light Switch Tool MANUAL TRANSMISSION

ASSY(M550)

09950ï00020 Bearing Remover INPUT SHAFT ASSY(M550)

COUNTER GEAR ASSY(M550)
02ï2
PREPARATION ï MANUAL TRANSMISSION/TRANSAXLE

09950ï00030 Bearing Remover Attachment COUNTER GEAR ASSY(M550)

09950ï3002 Puller A Set MANUAL TRANSMISSION

ASSY(M550)

(0995ï0300) Upper Plate MANUAL TRANSMISSION

ASSY(M550)

(09953ï0300) Center Bolt MANUAL TRANSMISSION

ASSY(M550)

(09954ï0300) Arm MANUAL TRANSMISSION

ASSY(M550)

(09955ï0302) Claw No.2 MANUAL TRANSMISSION

ASSY(M550)

09950ï400 Puller B Set MANUAL TRANSMISSION

ASSY(M550)
COUNTER GEAR ASSY(M550)

(0995ï04020) Hanger 200 MANUAL TRANSMISSION

ASSY(M550)

(09953ï04030) Center Bolt 200 MANUAL TRANSMISSION

ASSY(M550)

(09957ï0400) Attachment MANUAL TRANSMISSION

ASSY(M550)
COUNTER GEAR ASSY(M550)

09950ï5003 Puller C Set MANUAL TRANSMISSION

ASSY(M550)

(09952ï0500) Slide Arm MANUAL TRANSMISSION

ASSY(M550)

(09954ï0502) Claw No.2 MANUAL TRANSMISSION

ASSY(M550)
 02ï3
PREPARATION ï MANUAL TRANSMISSION/TRANSAXLE

(09955ï0500) Adapter No. MANUAL TRANSMISSION

ASSY(M550)

09950ï6000 Replacer Set MANUAL TRANSMISSION

ASSY(M550)
INPUT SHAFT ASSY(M550)
OUTPUT SHAFT ASSY(M550)
COUNTER GEAR ASSY(M550)
SHIFT LEVER SHAFT HOUSING
ASSY(M550)

(0995ï0080) Replacer 8 COUNTER GEAR ASSY(M550)

(0995ï00200) Replacer 20 MANUAL TRANSMISSION

ASSY(M550)

(0995ï00290) Replacer 29 OUTPUT SHAFT ASSY(M550)

(0995ï00300) Replacer 30 COUNTER GEAR ASSY(M550)

(0995ï0030) Replacer 3 SHIFT LEVER SHAFT HOUSING

ASSY(M550)

(0995ï00330) Replacer 33 MANUAL TRANSMISSION

ASSY(M550)

(0995ï00350) Replacer 35 INPUT SHAFT ASSY(M550)

(0995ï00370) Replacer 37 COUNTER GEAR ASSY(M550)

(0995ï00470) Replacer 47 MANUAL TRANSMISSION

ASSY(M550)

(0995ï00480) Replacer 48 MANUAL TRANSMISSION

ASSY(M550)

(0995ï00590) Replacer 59 MANUAL TRANSMISSION

ASSY(M550)
02ï4
PREPARATION ï MANUAL TRANSMISSION/TRANSAXLE

(0995ï0060) Replacer 6 MANUAL TRANSMISSION

ASSY(M550)

(09952ï0600) Adapter MANUAL TRANSMISSION

ASSY(M550)
COUNTER GEAR ASSY(M550)

09950ï60020 Replacer Set No.2 MANUAL TRANSMISSION

ASSY(M550)

(0995ï00680) Replacer 68 MANUAL TRANSMISSION

ASSY(M550)

(0995ï00750) Replacer 75 MANUAL TRANSMISSION

ASSY(M550)

(0995ï00890) Replacer 89 MANUAL TRANSMISSION

ASSY(M550)

(09952ï0600) Adapter MANUAL TRANSMISSION

ASSY(M550)
COUNTER GEAR ASSY(M550)

09950ï7000 Handle Set MANUAL TRANSMISSION

ASSY(M550)
INPUT SHAFT ASSY(M550)
OUTPUT SHAFT ASSY(M550)
COUNTER GEAR ASSY(M550)
SHIFT LEVER SHAFT HOUSING
ASSY(M550)

(0995ï0700) Handle 00 MANUAL TRANSMISSION

ASSY(M550)
INPUT SHAFT ASSY(M550)
OUTPUT SHAFT ASSY(M550)
COUNTER GEAR ASSY(M550)
SHIFT LEVER SHAFT HOUSING
ASSY(M550)

(0995ï07360) Handle 360 MANUAL TRANSMISSION

ASSY(M550)

0995ï00700 Replacer 70 MANUAL TRANSMISSION

ASSY(M550)
OUTPUT SHAFT ASSY(M550)

0995ï0000 Replacer 00 MANUAL TRANSMISSION

ASSY(M550)
 02ï5
PREPARATION ï MANUAL TRANSMISSION/TRANSAXLE

Recomended Tools
0903ï00040 Pin Punch . MANUAL TRANSMISSION
ASSY(M550)
SHIFT LEVER SHAFT HOUSING
ASSY(M550)

09042ï00020 Torx Socket T40 MANUAL TRANSMISSION

ASSY(M550)

09905ï0002 Snap Ring No. Expander MANUAL TRANSMISSION

ASSY(M550)

Equipment
Aluminum plate
Belt
Brass bar
Chisel
Cylinder gauge
Dial indicator or dial indicator with magnetic base
Feeler gauge
Gear oil
Magnet finger
Micrometer
MP grease
Plastic hammer
Press
Protective tape
Rope or wire
Shop rag
Snapring plier
Socket wrench (50 mm)
Torque wrench
Vernier caliper
Wooden block
Work bench
Lubricant
Item Capacity Classification
Manual transmission oil w/o PTO 2.8 liters (2.96 US qts, 2.46 lmp. qts) API GLï4 or GLï5
w/ PTO 3. liters (3.28 US qts, 2.73 lmp. qts) SAE 75Wï90

SSM (Special Service Materials)

08826ï00090 ”Seal Packing 28,”
THREE BOND 28 or equivalent
(FIPG)

08833ï00080 Adhesive 344

THREE BOND 344
LOCTITE 242 or equivalent
SERVICE SPECIFICATIONS

STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . 03ï

HOW TO DETERMINE BOLT STRENGTH . . . . 03ï
SPECIFIED TORQUE FOR STANDARD
BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï2
HOW TO DETERMINE NUT STRENGTH . . . . . 03ï3
MANUAL TRANSMISSION /
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï4
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï4
TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . 03ï7
 03ï
SERVICE SPECIFICATIONS ï STANDARD BOLT

STANDARD BOLT
030Y3ï06

HOW TO DETERMINE BOLT STRENGTH

Bolt Type
Hexagon Head Bolt Class
Stud Bolt Weld Bolt
Normal Recess Bolt Deep Recess Bolt

4 4T

No Mark No Mark No Mark

5 5T

6 6T

w/Washer w/Washer

7 7T

8 8T

9 9T

0 0T

 T

B0643
03ï2
SERVICE SPECIFICATIONS ï STANDARD BOLT
030Y4ï06

SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Diameter Pitch
Class Hexagon head bolt Hexagon flange bolt
mm mm
N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf
6  5 55 48 in.·lbf 6 60 52 in.·lbf
8 .25 2.5 30 9 4 45 0
0 .25 26 260 9 29 290 2
4T
2 .25 47 480 35 53 540 39
4 .5 74 760 55 84 850 6
6 .5 5 ,50 83 ï ï ï

6  6.5 65 56 in.·lbf 7.5 75 65 in.·lbf

8 .25 5.5 60 2 7.5 75 3
0 .25 32 330 24 36 360 26
5T
2 .25 59 600 43 65 670 48
4 .5 9 930 67 00 ,050 76
6 .5 40 ,400 0 ï ï ï

6  8 80 69 in.·lbf 9 90 78 in.·lbf
8 .25 9 95 4 2 20 5
0 .25 39 400 29 44 440 32
6T
2 .25 7 730 53 80 80 59
4 .5 0 ,00 80 25 ,250 90
6 .5 70 ,750 27 ï ï ï

6  0.5 0 8 2 20 9

8 .25 25 260 9 28 290 2
0 .25 52 530 38 58 590 43
7T
2 .25 95 970 70 05 ,050 76
4 .5 45 ,500 08 65 ,700 23
6 .5 230 2,300 66 ï ï ï

8 .25 29 300 22 33 330 24

8T 0 .25 6 620 45 68 690 50
2 .25 0 ,00 80 20 ,250 90
8 .25 34 340 25 37 380 27
9T 0 .25 70 70 5 78 790 57
2 .25 25 ,300 94 40 ,450 05
8 .25 38 390 28 42 430 3
0T 0 .25 78 800 58 88 890 64
2 .25 40 ,450 05 55 ,600 6
8 .25 42 430 3 47 480 35
T 0 .25 87 890 64 97 990 72
2 .25 55 ,600 6 75 ,800 30
 03ï3
SERVICE SPECIFICATIONS ï STANDARD BOLT
030Y5ï06

HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard Old Standard Hexagon Nut Class
Hexagon Nut Cold Forging Nut Cutting Processed Nut

4N

No Mark

5N (4T)

No Mark (w/Washer) No Mark (w/Washer) No Mark

6N
6N

7N (5T)

8N
8N

0N (7T)
0N

No Mark

N
N

2N
2N

*: Nut with  or more marks on one side surface of the nut.

B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
03ï4
SERVICE SPECIFICATIONS ï MANUAL TRANSMISSION / TRANSAXLE

MANUAL TRANSMISSION / TRANSAXLE

030ZDï04

SERVICE DATA
MANUAL TRANSMISSION ASSY
Reverse idler gear thrust clearance STD 0.0 to 0.62 mm (0.0039 to 0.0244 in.)
Max. 0.62 mm (0.0244 in.)
Reverse idler gear radial clearance STD 0.05 to 0.059 mm (0.0006 to 0.0023 in.)
Max. 0.059 mm (0.0023 in.)
Reverse idler gear inside diameter STD 35.05 to 35.036 mm (.3785 to .3793 in.)
Max. 35.036 mm (.3793 in.)
Reverse idler gear shaft outer diameter STD 27.987 to 28.00 mm (.08 to .024 in.)
Min. 27.987 mm (.08 in.)
Front bearing retainer oil seal Drive in depth 3.8 to 4.6 mm (0.5433 to 0.5750 in.)
Synchronizer ring to gear clearance (counter shaft) 4th gear STD 0.78 to .62 mm (0.0307 to 0.0643 in.)
Min 0.78 mm (0.0307 in.)
Shift lever slotted pin
Drive in depth Shift fork shaft No. 0 to .0 mm (0 to 0.039 in.)
Shift fork shaft No.2 0 to .0 mm (0 to 0.039 in.)
Shift fork shaft No.4 0 to .0 mm (0 to 0.039 in.)
Shift & select lever shaft bimetal formed bush Drive in depth 49.0 to 50.0 mm (5.866 to 5.906 in.)
Select lever oil seal Drive in depth 0 to .0 mm (0 to 0.039 in.)
Output shaft tapered roller bearing preload at starting 0.3 to 0.8 N˜˜m (3.06 to 8.6 kgf˜˜cm, 2.66 to 7.0 in.˜˜lbf)
Rear bearing retainer oil seal Drive in depth 0 to 0.5 mm (0 to 0.097 in.)
INPUT SHAFT ASSY
5th gear thrust clearance STD 0.0 to 0.35 mm (0.0039 to 0.038 in.)
Max. 0.35 mm (0.038 in.)
5th gear radial clearance STD 0.05 to 0.068 mm (0.0006 to 0.0027 in.)
Max. 0.068 mm (0.0027 in.)
Input shaft runout Max. 0.05 mm (0.0006 in.)
Input shaft journal diameter A: STD 47.002 to 47.08 mm (.8505 to .85 in.)
Min. 47.002 mm (.8505 in.)
B: STD 47.984 to 48.000 mm (.889 to .8898 in.)
Min. 47.984 mm (.889 in.)
C: STD 38.8 to 38.30 mm (.5007 to .502 in.)
Min. 38.8 mm (.5007 in.)
5th gear inside diameter STD 55.05 to 55.040 mm (2.659 to 2.669 in.)
Max. 55.040 mm (2.669 in.)
5th gear thrust washer STD 4.95 to 5.05 mm (0.945 to 0.2004 in.)
Min. 4.95 mm (0.945 in.)
Synchronizer ring to gear clearance (counter shaft) 5th gear STD 0.78 to .62 mm (0.0307 to 0.0643 in.)
Min. 0.78 mm (0.0307 in.)
Wide of the hub sleeve
ï Thickness of the gear shift fork No.3 0.5 to 0.26 mm (0.0059 to 0.002 in.)
Input shaft front bearing snap ring thickness Mark
A 3.00 to 3.05 mm (0.8 to 0.20 in.)
B 3.05 to 3.0 mm (0.20 to 0.220 in.)
C 3.0 to 3.5 mm (0.220 to 0.240 in.)
D 3.5 to 3.20 mm (0.240 to 0.260 in.)
E 3.20 to 3.25 mm (0.260 to 0.280 in.)
F 3.25 to 3.30 mm (0.280 to 0.300 in.)
 03ï5
SERVICE SPECIFICATIONS ï MANUAL TRANSMISSION / TRANSAXLE

Input shaft snap ring thickness Mark

Clutch hub shaft No.3 A 2.60 to 2.65 mm (0.024 to 0.043 in.)
B 2.65 to 2.70 mm (0.043 to 0.063 in.)
C 2.70 to 2.75 mm (0.063 to 0.083 in.)
D 2.75 to 2.80 mm (0.083 to 0.02 in.)
E 2.80 to 2.85 mm (0.02 to 0.22 in.)
F 2.85 to 2.90 mm (0.22 to 0.42 in.)
OUTPUT SHAFT ASSY
Inside diameter of the output shaft bearing race STD 54.70 to 54.87 mm (2.327 to 2.333 in.)
Max. 54.87 mm (2.333 in.)
Synchronizer ring to gear clearance (output shaft) STD 0.78 to .62 mm (0.0307 to 0.0638 in.)
Min. 0.78 mm (0.0307 in.)
COUNTER GEAR ASSY
Reverse gear thrust clearance STD 0.0 to 0.45 mm (0.0039 to 0.077 in.)
Max. 0.45 mm (0.077 in.)
Reverse gear radial clearance STD 0.5 to 0.068 mm (0.0006 to 0.0027 in.)
Max. 0.068 mm (0.0027 in.)
st gear thrust clearance STD 0.0 to 0.45 mm (0.0039 to 0.077 in.)
Max. 0.45 mm (0.077 in.)
st gear radial clearance STD 0.5 to 0.068 mm (0.0006 to 0.0027 in.)
Max. 0.068 mm (0.0027 in.)
3rd gear thrust clearance STD 0.0 to 0.45 mm (0.0039 to 0.077 in.)
Max. 0.45 mm (0.077 in.)
3rd gear radial clearance STD 0.5 to 0.068 mm (0.0006 to 0.0027 in.)
Max. 0.068 mm (0.0027 in.)
2nd gear thrust clearance STD 0.0 to 0.35 mm (0.0039 to 0.038 in.)
Max. 0.35 mm (0.038 in.)
2nd gear radial clearance STD 0.5 to 0.068 mm (0.0006 to 0.0027 in.)
Max. 0.068 mm (0.0027 in.)
Counter gear shaft runout Max. 0.05 mm (0.0006 in.)
Counter gear shaft journal diameter A: STD 43.484 to 43.500 mm (.720 to .726 in.)
Max. 43.500 mm (.726 in.)
B: STD 48.984 to 49.000 mm (.9285 to .929 in.)
Max. 49.000 mm (.929 in.)
C: STD 53.984 to 54.000 mm (2.253 to 2.260 in.)
Max. 54.000 mm (2.260 in.)
D: STD 53.984 to 54.000 mm (2.253 to 2.260 in.)
Max. 54.000 mm (2.260 in.)
E: STD 40.002 to 40.08 mm (.5749 to .5755 in.)
Max. 40.08 mm (.5755 in.)
Reverse gear inside diameter STD 50.55 to 50.540 mm (.9888 to .9898 in.)
Max. 50.540 mm (.9898 in.)
st gear inside diameter STD 55.05 to 55.040 mm (2.2053 to 2.2063 in.)
Max. 55.040 mm (2.2063 in.)
2nd gear inside diameter STD 6.05 to 6.040 mm (2.4022 to 2.403 in.)
Max. 6.040 mm (2.403 in.)
3rd gear inside diameter STD 6.05 to 6.040 mm (2.4022 to 2.403 in.)
Max. 6.040 mm (2.403 in.)
2nd gear thrust washer thickness STD 5.45 to 5.55 mm (0.246 to 0.285 in.)
Min. 5.45 mm (0.246 in.)
3rd gear thrust washer thickness STD .45 to .55 mm (0.4508 to 0.4547 in.)
Min. .45 mm (0.4508 in.)
03ï6
SERVICE SPECIFICATIONS ï MANUAL TRANSMISSION / TRANSAXLE

Synchronizer ring to gear clearance (counter shaft) st gear STD .0 to 2.0 mm (0.0433 to 0.0822 in.)
Min
Min.  0 mm (0.0433
.0 (0 0433 in
in.))
2nd gear
g STD .0 to 2.0 mm ((0.0433 to 0.0822 in.))
Min. .0 mm (0.0433 in.)
3rd gear STD 0.78 to .62 mm (0.0307 to 0.0643 in.)
Min. 0.78 mm (0.0307 in.)
R
Reverse gear STD 0 78 tto 
0.78 62 mm (0.0307
.62 (0 0307 tto 0
0.0643
0643 iin.))
Min. 0.78 mm (0.0307 in.)
Wide of the hub sleeve
ï Thickness of the gear shift fork No. 0.25 to 0.85 mm (0.0098 to 0.0335 in.)
No.2 0.25 to 0.85 mm (0.0098 to 0.0335 in.)
Transmission clutch hub shaft snap ring No.2 Mark
 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
2 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
3 2.50 to 2.55 mm (0.0984 to 0.004 in.)
4 2.55 to 2.60 mm (0.004 to 0.024 in.)
5 2.60 to 2.65 mm (0.024 to 0.043 in.)
6 2.65 to 2.70 mm (0.043 to 0.063 in.)
3rd gear thrust washer hole snap ring Mark
 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
2 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
3 2.50 to 2.55 mm (0.0984 to 0.004 in.)
4 2.55 to 2.60 mm (0.004 to 0.024 in.)
5 2.60 to 2.65 mm (0.024 to 0.043 in.)
6 2.65 to 2.70 mm (0.043 to 0.063 in.)
Transmission clutch hub shaft snap ring No. Mark
A 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
B 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
C 2.50 to 2.55 mm (0.0984 to 0.004 in.)
D 2.55 to 2.60 mm (0.004 to 0.024 in.)
E 2.60 to 2.65 mm (0.024 to 0.043 in.)
F 2.65 to 2.70 mm (0.043 to 0.063 in.)
Counter gear front bearing hole snap ring Mark
A 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
B 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
C 2.50 to 2.55 mm (0.0984 to 0.004 in.)
D 2.55 to 2.60 mm (0.004 to 0.024 in.)
E 2.60 to 2.65 mm (0.024 to 0.043 in.)
F 2.65 to 2.70 mm (0.043 to 0.063 in.)
SHIFT LEVER SHAFT HOUSING ASSY
Control shaft cover bimetal formed bush Drive in depth 9.0 to 0.0 mm (0.3543 to 0.3937 in.)
Control shaft cover oil seal Drive in depth 0 to .0 mm (0 to 0.0394 in.)
Select lever shaft slotted pin
Drive in depth Select inner head 0 to .0 mm (0 to 0.039 in.)
Shift lever inner No. 0 to .0 mm (0 to 0.039 in.)
 03ï7
SERVICE SPECIFICATIONS ï MANUAL TRANSMISSION / TRANSAXLE
030Z8ï0

TORQUE SPECIFICATION
Part Tightened N˜˜m kgf˜˜cm ft˜˜lbf
Front bearing retainer x Transmission case 7 73 3
Gear shift fork No.3 x Shift fork shaft No.3 34 350 25
Shift detent ball plug x Transmission case 9 94 4
Shift lever inner x Clutch housing 23 235 7
Transmission oil receiver No. x Transmission case 23 235 7
Transmission oil separator x Transmission case 23 235 7
Clutch housing x Transmission 37 380 27
Reverse idler gear shaft bolt x Transmission case 28 286 2
Shift lever shaft housing assy x Transmission case 7 73 3
Shift lever shaft knock pin x Nut 7.8 80 69 in.˜˜lbf
Counter gear assy x Counter gear lock nut 32 ,346 97
Transmission rear bearing retainer x Transmission case 37 377 27
Speedometer driven gear x Transmission rear bearing retainer  2 8
Power takeïoff cover x Transmission case 4 43 0
Filler plug x Transmission case 37 377 27
Drain plug x Transmission case 37 377 27
Exhaust brake neutral switch assy x Transmission case 39 400 29
Backïup light switch x Transmission case 44 450 33
MANUAL TRANSMISSION/TRANSAXLE

MANUAL TRANSMISSION SYSTEM

(M550) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . 41ï1
MANUAL TRANSMISSION ASSY (M550) . . . . 41ï2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï2
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï6
INPUT SHAFT ASSY (M550) . . . . . . . . . . . . . . 41ï32
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï32
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï33
OUTPUT SHAFT ASSY (M550) . . . . . . . . . . . . 41ï40
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï40
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï41
COUNTER GEAR ASSY (M550) . . . . . . . . . . . 41ï44
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï44
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï46
SHIFT LEVER SHAFT HOUSING ASSY
(M550) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï64
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï64
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï65
 41ï1
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION SYSTEM (M550)

MANUAL TRANSMISSION SYSTEM (M550)

410CSï02

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspected Area See Page
1. Oil (Level low) L
2. Oil (Wrong) L
3. Gear (Worn or damaged) 41ï6
41ï33
41ï41
Noise
41ï46
4. Bearing (Worn or damaged) 41ï6
41ï33
41ï41
41ï46
1. Oil (Level too high) L
Oil leakage 2. Gasket (Damaged) 41ï6
3. Oil seal (Worn or damaged) 41ï6
1. Synchronizer ring (Worn or damaged) 41ï6
41ï33
Hard to shift or will not shift 41ï41
41ï46
2. Shift key spring (Damaged) 41ï6
1. Locking ball spring (Damaged) 41ï6
2. Shift fork (Worn) 41ï6
3. Gear (Worn or damaged) 41ï6
41ï33
41ï41
Jumps out of gear
41ï46
4. Bearing (Worn or damaged) 41ï6
41ï33
41ï41
41ï46
HINT:
L: See Pub. No. S1ïYXZE10A, page 41ï1
41ï2
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

MANUAL TRANSMISSION ASSY (M550)

410HDï01

COMPONENTS
Transmission Front Bearing Retainer
z Oil Seal
z Input Shaft Front Bearing Snap Ring

Transmission Oil Receiver No. 1

23 (235, 17)

z 17 (173, 13) Output Shaft Assy

Clutch Housing Assy
Input Shaft Assy

Reverse Idler Gear Shaft

Needle Roller Bearing

Reverse Idler Gear

Reverse Idler Gear Thrust Washer

z Counter Gear Front

Bearing Snap Ring
Counter Gear Assy
23 (235, 17)

z Counter Gear Front

Transmission Front Bearing Bearing (Outer Race)
Retainer Oil Receiver
23 (235, 17)

Transmission
N·m (kgf·cm, ft·lbf) : Specified torque Oil Separator
z Nonïreusable part
Apply Gear Oil 23 (235, 17)
Apply MP Grease D32783
 41ï3
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

Speedometer Sleeve
Speedometer Driven Gear Lock Plate
11 (112, 8)
z Output Shaft Rear Tapered
Roller Bearing (Inner Race)
Speedometer
Transmission Rear z OïRing Shaft Sleeve
Bearing Retainer

z Output Shaft Adjusting Nut

Clip

Speedometer Driven
Gear Pin (Ball)

z Output Shaft Rear

Tapered Roller
Bearing Spacer

37 (377, 27)
Transmission
Oil Receiver No. 3

Speedometer
Transmission Rear Bearing Drive Gear
Retainer Spacer
zTransmission
z Output Shaft Rear Tapered Rear Bearing
Roller Bearing (Outer Race) Retainer Oil Seal
Clutch Housing Assy

z Counter Gear
Rear Bearing

37 (377, 27) z 132 (1,346, 97)

Counter Gear
Transmission Case Lock Nut
z Output Shaft Front Tapered Roller
37 (377, 27) Bearing (Outer Race)

N·m (kgf·cm, ft·lbf) : Specified torque

z Nonïreusable part
Apply MP Grease D33133
41ï4
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

17 (173, 13)

Shift Lever Shaft Housing Assy

Select Return Spring No. 1 z Select Lever Shaft Oil Seal

Select Lever Shaft

Shift & Select Lever Shaft
Bimetal Formed Bush

7.8 (80, 69 in.˜˜lbf)

z Spring Washer Washer

Outer Select Lever

z Gasket
z Shift Lever Shaft Knock Pin

z Shift Detent Ball Plug

Transmission Filler Plug 19 (194, 14)
37 (377, 27)
Shift Detent Ball Compression Spring
Back Up Lamp Switch Assy
Shift Detent Ball

z Gasket z Reverse Idler Gear

Shaft Bolt
28 (286, 21)

Transmission Oil Receiver No. 2

z Gasket

Exhaust Brake Neutral

Switch Assy
Transmission Case

z Transmission Oil Separator Seal

37 (377, 27) z Gasket
Transmission Drain Plug
z Gasket Transmission Power Takeïoff Cover
N·m (kgf·cm, ft·lbf) : Specified torque 14 (143, 10)
z Nonïreusable part
Apply MP Grease
D33134
 41ï5
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

Shift Detent Ball Plug

z 19 (194, 14)

Shift Lever Inner Shift Detent Ball Plug

Compression Spring

Shift Detent Ball

23 (235, 17)
z Shift Fork Lock Bolt
46.3 (472, 34.2)

z EïRing

Shift Lever Inner Mount

23 (235, 17)
Shift Fork Shaft No. 3
Gear Shift Fork No. 3
Shift Lever Inner Pin
Shift Fork Slotted Pin

Shift Fork Shaft No. 4

Gear Shift Fork No. 2

Gear Shift Fork Guide

Shift Fork Shaft No. 2

Shift Fork Slotted Pin

Shift Fork Shaft No. 1

Shift Fork Slotted Pin

Clutch Housing Assy

Gear Shift Fork No. 1
N·m (kgf·cm, ft·lbf) : Specified torque
z Nonïreusable part
Apply Gear Oil D33135
41ï6
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)
410HEï01

OVERHAUL
NOTICE:
When working with FIPG (seal packing) material, you must observe the following items.
S Using a razor blade and gasket scraper, remove all old FIPG material from the gasket surfaces.
S Thoroughly clean all components.
S Clean both sealing surfaces with nonïresidue solvent.
S Apply FIPG to an approximately 1.2 mm (0.047 in.) wide bead of FIPG material along the sealing
surface.
S Parts must be assembled within 10 minutes after application of FIPG material. Otherwise, the
FIPG material must be removed and reapplied.

1. REMOVE BACK UP LAMP SWITCH ASSY

(a) Using SST, remove the switch and gasket.
SST SST 09817ï16011

D33025

2. REMOVE EXHAUST BRAKE NEUTRAL SWITCH

ASSY
(a) Using SST, remove the switch and gasket.
SST SST 09817ï16011

D33026

3. REMOVE TRANSMISSION FILLER PLUG

(a) Remove the filler plug and gasket.

D32785
 41ï7
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

4. REMOVE TRANSMISSION DRAIN PLUG

(a) Remove the drain plug and gasket.

D32786

5. REMOVE MANUAL TRANSMISSION POWER

TAKEïOFF COVER
(a) Remove the 6 bolts, cover and gasket.

D32787

6. REMOVE SPEEDOMETER DRIVEN GEAR SUBïASSY

(a) Remove the bolt, lock plate and driven gear.

D32791

(b) Remove the clip from the speedometer sleeve.

Clip Speedometer (c) Remove the driven gear from the sleeve.
Shaft sleeve (d) Remove the Oïring from the sleeve.
(e) Check the teeth of the speedometer driven gear.
If the driver gear is damaged, replace it.

Speedometer
Driven gear
D32862

7. REMOVE TRANSMISSION REAR BEARING

RETAINER
(a) Remove the 9 bolts.

D32793
41ï8
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

(b) Using a brass bar and hammer, carefully tap out the bear-
ing retainer.
HINT:
Make the brass bar touched the rib portion of the case.

D32794

8. REMOVE TRANSMISSION REAR BEARING

RETAINER OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
HINT:
Tape the screwdriver tip before use.

D32795

9. REMOVE TRANSMISSION REAR BEARING

RETAINER SPACER

D32796

10. REMOVE SPEEDOMETER DRIVE GEAR

D32797
 41ï9
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

11. REMOVE TRANSMISSION OIL RECEIVER NO. 3

D32799

12. REMOVE SPEEDOMETER DRIVE GEAR PIN (BALL)

D32798

13. REMOVE COUNTER GEAR LOCK NUT

(a) Using a chisel and hammer, unstake the lock nut.

D32805

(b) Fix the input shaft’s spline part through 2 protective alumi-
num plates and a shop rag in a vise, and move the gear
to the 4th place.

D33136

(c) Using 2 belts and a wooden block, fasten the transmis-

sion to the work bench.

D33137
41ï10
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

(d) Using a 50 mm socket wrench, remove the lock nut from

the counter gear.

D32806

14. REMOVE OUTPUT SHAFT ADJUSTING NUT

(a) Using a chisel and hammer, unstake the nut.

D32803

(b) Using SST, remove the nut from the output shaft.
SST 09617ï28010
(c) Remove the 2 belts and wooden block from the transmis-
sion.
(d) Move the gear back to neutral and remove the input shaft
spline part from the vise.

SST
D32804

15. REMOVE OUTER SELECT LEVER

(a) Remove the nut and spring washer from the select lever
shaft knock pin.
(b) Install the nut to the select lever shaft knock pin.
(c) Using a brass bar and hammer, tap the nut and disengage
the knock pin from the outer select lever.
NOTICE:
Do not directly tap the knock pin.
D32800 (d) Remove the select lever from the select lever shaft.

(e) Remove the washer from the select lever shaft.

D32801
 41ï11
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

16. REMOVE SHIFT LEVER SHAFT HOUSING ASSY

(a) Remove the 4 bolts, shift housing and select return spring
from the transmission case.

D32802

17. REMOVE REVERSE IDLER GEAR SHAFT BOLT

D32788

18. REMOVE SHIFT DETENT BALL

(a) Using a torx wrench (T40), remove the 2 plugs.

D32789

(b) Using a magnet finger, remove the 2 springs and 2 shift

detent balls.

19. REMOVE TRANSMISSION CASE

(a) Remove the 12 bolts.

D32790

D32807
41ï12
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

(b) Using SST, remove the counter gear rear bearing, output
SST shaft spacer and transmission case from the clutch hous-
ing.
SST SST 09950ï40011 (09951ï04020, 09953ï04030,
09957ï04010), 09950ï50013 (09952ï05010,
09954ï05021, 09955ï05010), 09950ï60010
(09951ï00330)

D32808

20. REMOVE TRANSMISSION OIL RECEIVER NO. 2

D32809

21. REMOVE SELECT LEVER SHAFT

D32810

22. REMOVE TRANSMISSION OIL SEPARATOR SEAL

D32811

23. REMOVE SELECT LEVER OIL SEAL

(a) Using a screwdriver, pry out the oil seal from the transmis-
sion case.
HINT:
Tape the screwdriver tip before use.

D32812
 41ï13
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

24. REMOVE TRANSMISSION OIL SEPARATOR

(a) Remove the 4 bolts and oil separate.

D32813

25. REMOVE TRANSMISSION OIL RECEIVER NO. 1

(a) Remove the 2 bolts and oil receiver.

D32814

26. INSPECT REVERSE IDLER GEAR THRUST

CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance.
Standard clearance:
0.10 to 0.62 mm (0.0039 to 0.0242 in.)
Maximum clearance:
0.62 mm (0.0242 in.)

D32815

27. INSPECT REVERSE IDLER GEAR RADIAL

CLEARANCE
(a) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.015 to 0.059 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.059 mm (0.0023 in.)
If the clearance is not as specified, replace the reverse idler
D32816 gear needle roller bearing.

28. REMOVE REVERSE IDLER GEAR

(a) Remove the gear shaft, needle roller bearing and gear.

D32817
41ï14
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

(b) Remove the idler gear thrust washer.

D32818

29. REMOVE OUTPUT SHAFT REAR TAPERED ROLLER

BEARING
(a) Using SST, remove the roller bearing from the transmis-
SST sion case.
SST 09950ï30012 (09951ï03010, 09953ï03010,
09954ï03010, 09955ï03021), 09950ï40011
(09957ï04010), 09950ï60020 (09951ï00750,
09952ï06010), 09951ï00700
D32823

30. REMOVE OUTPUT SHAFT FRONT TAPERED ROLLER

BEARING
(a) Using SST, remove the roller bearing from the transmis-
sion case.
SST 09950ï30012 (09951ï03010, 09953ï03010,
09954ï03010, 09955ï03021), 09950ï40011
(09957ï04010), 09950ï60010 (09951ï00590,
SST 09951ï00610, 09952ï06010)
D32824

31. REMOVE SHIFT AND SELECT LEVER SHAFT

B BIMETAL FORMED BUSH
(a) Using SST, remove the bush from the transmission case.
SST 09319ï60020
SST A NOTICE:
S Do not damage it.
S When setting SST A into the bush, do not tighten SST
B using a tool. Tighten it lightly with your hand.
D32825

32. REMOVE SHIFT LEVER INNER

(a) Remove the 2 bolts and shift lever from the clutch hous-
ing.

D32819
 41ï15
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

(b) Using a screwdriver, remove the Eïring, shift lever and

pin from the shift lever inner mount.

D32820

33. REMOVE SHAFT DETENT BALL

(a) Using a torx socket wrench (T40), remove the shift detent
ball plug from the clutch housing.

D32821

(b) Using a magnetic finger, remove the spring and ball from
the clutch housing.

D32822

34. REMOVE SHIFT FORK SHAFT NO. 3

(a) Remove the bolt, shift fork shaft and gear shift fork.

D32826

35. REMOVE SHIFT FORK SHAFT NO. 4

(a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out
the shift fork slotted pin, shift fork shaft and gear shift fork
guide.

D32827
41ï16
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

36. REMOVE SHIFT FORK SHAFT NO. 1

(a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out
the slotted pin, shift fork shaft and gear shift fork.

D32828

37. REMOVE SHIFT FORK SHAFT NO. 2

(a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out
the slotted pin, shift fork shaft and gear shift fork.

D32829

38. REMOVE OUTPUT SHAFT

(a) Remove the output shaft and synchronizer ring No.4.

D32830

39. FIX CLUTCH HOUSING ASSY

(a) Bind the input shaft and counter gear together with a rope
or wire.
(b) Place them on a wooden block and fix them to the work
bench with a belt.
NOTICE:
Be careful not to drop the clutch housing assy.

D33139

40. REMOVE TRANSMISSION FRONT BEARING

RETAINER
(a) Remove the 8 bolts and retainer.

D32832
 41ï17
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

41. REMOVE TRANSMISSION FRONT BEARING

RETAINER OIL SEAL
(a) Using a screwdriver, pry out the oil seal from the retainer.
HINT:
Tape the screwdriver tip before use.

D32833

42. REMOVE TRANSMISSION FRONT BEARING

RETAINER OIL RECEIVER
(a) Remove the oil receiver from the clutch housing.

D32834

43. REMOVE INPUT SHAFT FRONT BEARING SNAP

RING
(a) Using a snap ring expander, remove the snap ring from
the input shaft front bearing.

D32835

44. REMOVE COUNTER GEAR FRONT BEARING SNAP

RING
(a) Using a snap ring expander, remove the snap ring from
the counter gear front bearing.

D32836

45. REMOVE CLUTCH HOUSING ASSY

(a) Using a plastic hammer, tap out the clutch housing.
NOTICE:
Do not allow the clutch housing assy to fall.
(b) Remove the rope or wire from the input shaft and counter
gear.

D33140
41ï18
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

46. REMOVE COUNTER GEAR FRONT BEARING

(a) Using SST and a hammer, remove the bearing from the
clutch housing.
SST
SST 09950ï60020 (09951ï00680), 09950ï70010
(09951ï07100)

D32838

47. REMOVE REVERSE IDLER GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the gear.
Standard inside diameter:
35.015 to 35.036 mm (1.3785 to 1.3793 in.)
Maximum inside diameter: 35.036 mm (1.3793 in.)
If the inside diameter exceeds the maximum, replace the re-
verse idler gear.
(b) Using a micrometer, measure the outer diameter of the
idler gear shaft.
Standard outer diameter:
27.987 to 28.000 mm (1.1018 to 1.1024 in.)
Minimum outer diameter: 27.987 mm (1.1018 in.)
If the diameter is less than the minimum, replace the reverse
idler gear shaft.

D32839

48. INSTALL COUNTER GEAR FRONT BEARING

(a) Using SST and a hammer, tap in a new bearing to the
clutch housing.
SST
SST 09950ï60020 (09951ï00680), 09950ï70010
(09951ï07100)
NOTICE:
When installing, face the snap ring grooves to the engine
side.
D32838

49. INSTALL CLUTCH HOUSING ASSY

(a) Bind the input shaft and counter gear together with a rope
or wire.
(b) Place them on a wooden block and fix them to the work
bench with a belt.

D33141
 41ï19
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

(c) Using a plastic hammer, tap in the input shaft and counter
gear.
NOTICE:
S Do not allow the clutch housing to fall.
S Be careful not to damage or drop the counter gear
front bearing.

D33282

50. INSTALL INPUT SHAFT FRONT BEARING SNAP RING

(a) Using a snap ring expander, install a new snap ring to the
input shaft front bearing.

D32835

51. INSTALL COUNTER GEAR FRONT BEARING SNAP

RING
(a) Using a snap ring expander, install a new snap ring to the
counter gear front bearing.

D32836

52. INSTALL TRANSMISSION FRONT BEARING

SST
RETAINER OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal to the re-
tainer according to dimension A.
SST 09950ï60010 (09951ï00480), 09950ï70010
Dimension A
(09951ï07100)
Dimension A: 13.8 to 14.6 mm (0.543 to 0.575 in.)
(b) Coat the rip of the oil seal with MP grease.
D32842

53. INSTALL TRANSMISSION FRONT BEARING

RETAINER OIL RECEIVER
(a) Install the oil receiver to the transmission front bearing re-
tainer.
HINT:
When installing, align the turn stopper on the oil receiver with
the grooves on the bearing retainer.

D32841
41ï20
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

54. INSTALL TRANSMISSION FRONT BEARING

Seal Packing RETAINER
(a) Apply FIPG (seal packing) to the retainer as shown in the
illustration.
FIPG:
Part No. 08826ï00090, THREE BOND 1281 or equiva-
lent

D32843

(b) Coat 8 new bolts with sealant.

Adhesive:
Part No. 08833ï00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 17 N˜m (173 kgf˜cm, 13 ft˜lbf)
(c) Install the transmission front bearing retainer with the 8
sealantïcoated bolts.
(d) Remove the rope from the input shaft and counter gear.
D32832

55. INSTALL OUTPUT SHAFT

(a) Coat the output shaft and synchronizer ring with gear oil,
and install them.

D32830

56. INSTALL SHIFT FORK SHAFT NO. 2

(a) Coat the sliding and rotating surface of the gear shift fork
and shIft fork shaft with gear oil, and install them.
(b) Using a pin punch (5 mm (0.20 in.)) and hammer, tap in
the shaft fork slotted pin to the gear shift fork and shift fork
shaft.
Drive in depth: 0 to 1.0 mm (0 to 0.039 in.)

D33118

57. INSTALL SHIFT FORK SHAFT NO. 1

(a) Coat the sliding and rotating gear shift fork and shift fork
shaft with gear oil, and install them.
(b) Using a pin punch (5 mm (0.20 in.)) and hammer, tap in
the shift fork slotted pin to the gear shift fork and shift fork
shaft.
Drive in depth: 0 to 1.0 mm (0 to 0.039 in.)

D33169
 41ï21
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

58. INSTALL SHIFT FORK SHAFT NO. 4

(a) Coat the sliding and rotating surface of the gear shift fork
and shift fork shaft with gear oil, and install them.
(b) Using a pin punch (5 mm (0.20 in.)) and hammer, tap in
the shift fork slotted pin to the gear shift fork guide and
shift fork shaft.
Drive in depth: 0 to 1.0 mm (0 to 0.039 in.)

D33120

59. INSTALL SHIFT FORK SHAFT NO. 3

(a) Coat the sliding and rotating surface of the gear shift fork
and shift fork shaft with gear oil, and install them.
(b) Install a new shift fork lock bolt to the gear shift fork and
gear shift fork shaft.
Torque: 46 N˜m (469 kgf˜cm, 34 ft˜lbf)

D32826

60. INSTALL SHAFT DETENT BALL

(a) Install the ball and spring to the hole of the clutch housing.

D32847

(b) Using a torx wrench (T40), install a new plug to the clutch
housing.
Torque: 19 N˜m (194 kgf˜cm, 14 ft˜lbf)

D32821

61. INSTALL SHIFT LEVER INNER

(a) Install the shift lever and pin to the mount.
(b) Using pliers, install a new Eïring to the shift lever.

D33121
41ï22
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

(c) Install the shift lever to the clutch housing with the 2 bolts.
Torque: 23 N˜m (235 kgf˜cm, 17 ft˜lbf)

D32819

62. INSTALL SHIFT AND SELECT LEVER SHAFT

BIMETAL FORMED BUSH
(a) Using SST, a brass bar and hammer, tap in a new bush
SST
SST to the transmission case according to dimension A.
SST 09820ï36010
Dimension A: 149.0 to 150.0 mm (5.866 to 5.906 in.)
Bush
Dimension A
D32844

63. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER

BEARING
SST (a) Using SST and a press, press in a new bearing to the
transmission case.
SST 09950ï70010 (09951ï07100), 09951ï01000

D32845

64. INSTALL OUTPUT SHAFT FRONT TAPERED ROLLER

SST BEARING (OUTER RACE)
(a) Using SST and a press, press in a new bearing to the
transmission case.
SST 09950ï60020 (09951ï00890), 09950ï70010
(09951ï07360)

D32846

65. INSTALL REVERSE IDLER GEAR

(a) Aligning the turn stopper (protruding part) on the reverse
idler gear thrust washer with the hole on the clutch hous-
ing.

D32848
 41ï23
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

(b) Coat the sliding and rotating surface of the reverse idler
gear shaft, reverse idler gear needle roller bearing and re-
verse idler gear with gear oil, and install them.
NOTICE:
Align the mark on the reverse idler gear shaft and bolt hole
as shown in the illustration.

D32849

66. INSPECT REVERSE IDLER GEAR THRUST

CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance of the
reverse idler gear.
Standard clearance:
0.10 to 0.62 mm (0.0039 to 0.0244 in.)
Maximum clearance: 0.62 mm (0.0244 in.)

D32815

67. INSPECT REVERSE IDLER GEAR RADIAL

CLEARANCE
(a) Using a dial indicator, measure the radial clearance of the
reverse idler gear.
Standard clearance:
0.015 to 0.059 mm (0.0006 to 0.0023 in.)
Maximum clearance: 0.059 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the reverse
D32816 idler gear needle roller bearing.

68. INSTALL TRANSMISSION OIL RECEIVER NO. 1

Pipe
(a) Install the oil receiver with the 2 bolts.
Torque: 23 N˜m (235 kgf˜cm, 17 ft˜lbf)
HINT:
Install the pipe of the oil receiver to the hole of the reverse idler
gear shaft.

D32850

69. INSTALL TRANSMISSION OIL SEPARATOR

(a) Install the oil separator with the 4 bolts.
Torque: 23 N˜m (235 kgf˜cm, 17 ft˜lbf)
HINT:
While installing the oil separator, slightly lift up the counter gear.

D32813
41ï24
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

70. INSTALL SELECT LEVER OIL SEAL

(a) Using SST and a hammer, tap in a new select lever shaft
oil seal to the transmission according to dimension A.
Dimension A SST 09950ï60010 (09951ï00200), 09950ï70010
(09951ï07100)
Dimension A: 0 to 1.0 mm (0 to 0.039 in.)
(b) Apply MP grease to the lip of the oil seal.
SST
D32851

71. INSTALL TRANSMISSION OIL SEPARATOR SEAL

(a) Install a new seal to the transmission case.

D32811

72. INSTALL SELECT LEVER SHAFT

(a) Install the shaft to the transmission case.
NOTICE:
Make sure to set the select lever at the position shown in
the illustration, otherwise you may have trouble at a later
work.

D32810

73. INSTALL TRANSMISSION OIL RECEIVER NO. 2

(a) Install the oil receiver to the transmission case.
HINT:
Insert the protruding part on the oil receiver No. 2 into the
groove on the transmission case.

D33126

Seal Packing 74. INSTALL TRANSMISSION CASE

(a) Apply FIPG (seal packing) to the transmission case as
shown in the illustration.
FIPG:
Part No. 08826ï00090, THREE BOND 1281 or equiva-
lent
(b) Install the transmission case to the clutch housing with 12
new bolts.
D32852 Torque: 37 N˜m (377 kgf˜cm, 27 ft˜lbf)
 41ï25
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

D32807

(c) Using SST and a hammer, tap in a new counter gear rear
bearing to the counter gear.
SST SST 09309ï36010
(d) Install a new spacer and new output shaft rear tapered
roller bearing to the output shaft.
(e) Temporarily install a new output shaft adjusting nut to the
output shaft.
(f) Temporarily install a new counter gear lock nut to the
D32853 counter gear.

75. INSTALL SHIFT DETENT BALL

(a) Install the 2 balls and 2 springs into the transmission case.

D32863

(b) Using a torx wrench (T40), install 2 new plugs to the trans-
mission case.
Torque: 19 N˜m (194 kgf˜cm, 14 ft˜lbf)

D32789

76. INSTALL REVERSE IDLER GEAR SHAFT BOLT

(a) Install a new bolt to the transmission case.
Torque: 28 N˜m (286 kgf˜cm, 21 ft˜lbf)

D32788
41ï26
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

77. INSTALL SHIFT LEVER SHAFT HOUSING ASSY

Seal Packing
(a) Apply FIPG (seal packing) to the housing as shown in the
illustration.
FIPG:
Part No. 08826ï00090, THREE BOND 1281 or equiva-
lent

D32855

(b) Install the select return spring to the transmission case.

Select Lever
Shaft (c) Insert the tip of the select lever shaft into the hole on the
select inner head.
NOTICE:
Be careful not to let the select lever fall into the transmis-
sion case.
Select
Inner Head
D32854

(d) Install the housing to the transmission case with the 4

bolts.
Torque: 17 N˜m (173 kgf˜cm, 13 ft˜lbf)
NOTICE:
Be sure that the shift inner lever is inserted into the
grooves on the shift fork shaft No. 4 and shift fork No. 2.

D32802

78. INSTALL OUTER SELECT LEVER

(a) Install the washer to the select lever shaft.
(b) Install the lever to the select lever shaft.

D32801

(c) Using a brass bar and hammer, tap in a new select lever
shaft knock pin to the outer select lever.
(d) Secure the knock pin with a new spring washer and the
nut.
Torque: 7.8 N˜m (80 kgf˜cm, 69 in.˜lbf)

D32856
 41ï27
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

79. ADJUST OUTPUT SHAFT TAPERD ROLLER

BEARING PRELOAD
(a) Fix the input shaft’s spline part through 2 protective alumi-
num plates and a shop rag in a vise, and move the gear
to the 4th place.
NOTICE:
Be careful not to damage the spline area.

D33143

(b) Using 2 belts and a wooden block, fasten the transmis-

sion to the work bench.

D33144

(c) Using a 50 mm socket wrench, install the counter gear

lock nut.
Torque: 132 N˜m (1,346 kgf˜cm, 97 ft˜lbf)

D33145

(d) Install the output shaft rear set nut.

HINT:
S The output shaft rear set nut is used for measuring pre-
load.
S The output shaft rear set nut’s code is 90179ï24008.

D33146
41ï28
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

(e) Using SST, tighten the output shaft adjusting nut so that
the preload is within the standard.
SST 09617ï28010
Preload (at starting):
0.3 to 0.8 N˜m (3.06 to 8.16 kgf˜cm 2.66 to 7.10 in.˜lbf)
HINT:
SST Before preload measurement, return the gear to neutral.
If the result is not as specified, tighten and adjust the output
shaft adjusting nut.
NOTICE:
If the output shaft adjusting nut is loosened or removed
due to large preload, always replace the output shaft ta-
pered roller bearing spacer with a new spacer.
(f) Remove the output shaft rear set nut.
(g) Remove the 2 belts and wooden block from the transmis-
sion assy.
(h) Remove the gear to neutral and remove the input shaft
from the vise.
D33131
D33132 D33162

(i) Using a chisel and hammer, caulk the output shift adjust-
ing nut.

D32858

(j) Using a chisel and hammer, caulk the counter gear lock
nut.

D32859

80. INSTALL SPEEDOMETER DRIVE GEAR PIN (BALL)

(a) Apply MP grease to the pin (ball).
(b) Install the pin (ball) to the output shaft.

D32798
 41ï29
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

81. INSTALL TRANSMISSION OIL RECEIVER NO. 3

D32799

82. INSTALL SPEEDOMETER DRIVE GEAR

D32797

83. INSTALL TRANSMISSION REAR BEARING

RETAINER SPEACER
NOTICE:
Be careful with the installation direction.

D32796

84. INSTALL TRANSMISSION REAR BEARING

RETAINER OIL SEAL
(a) Place the transmission rear retainer on a wooden block.
Dimension A (b) Using SST and a hammer, tap in a new oil seal to the
transmission case according to the dimension A.
SST 09950ï60010 (09951ï00470, 09951ï00610,
09952ï06010), 09950ï70010 (09951ï07100)
Dimension A: 0 to 0.5 mm (0 to 0.0120 in.)
D32860 (c) Apply a light coat of grease to the lip of the transmission
rear retainer oil seal.
85. INSTALL TRANSMISSION REAR BEARING
Seal Packing RETAINER
(a) Apply FIPG (seal packing) to the retainer as shown in the
illustration.
FIPG:
Part No. 08826ï00090, THREE BOND 1281 or equiva-
lent.

D32861
41ï30
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

(b) Install the retainer with the 9 bolts.

Torque: 37 N˜m (377 kgf˜cm, 27 ft˜lbf)

D32793

86. INSTALL SPEEDOMETER DRIVEN GEAR SUBïASSY

Clip Speedometer (a) Install a new Oïring to the speedometer sleeve.
Shaft sleeve (b) Install the driven gear to the speedometer sleeve with the
clip.
NOTICE:
Make sure to install the clip in the direction shown in the
Speedometer illustration.
Driven gear (c) Install the driven gear to the transmission rear bearing re-
D32862 tainer.

(d) Install the speedometer sleeve lock plate to the transmis-

sion rear retainer with the bolt.
Torque: 11 N˜m (112 kgf˜cm, 8 ft˜lbf)

D32791

87. INSTALL MANUAL TRANSMISSION POWER

TAKEïOFF COVER
(a) Install a new gasket and the power takeïoff cover with the
6 bolts.
Torque: 14 N˜m (143 kgf˜cm, 10 ft˜lbf)

D32787

88. INSTALL TRANSMISSION FILLER PLUG

(a) Install a new gasket and the filler plug to the transmission
case.
Torque: 37 N˜m (377 kgf˜cm, 27 ft˜lbf)

D32786
 41ï31
MANUAL TRANSMISSION/TRANSAXLE ï MANUAL TRANSMISSION ASSY (M550)

89. INSTALL TRANSMISSION DRAIN PLUG

(a) Install a new gasket and the drain plug to the transmission
case.
Torque: 37 N˜m (377 kgf˜cm, 27 ft˜lbf)

D32785

90. INSTALL EXHAUST BRAKE NEUTRAL SWITCH ASSY

(a) Using SST, install the neutral switch.
SST 09817ï16011
SST Torque: 39 N˜m (398 kgf˜cm, 29 ft˜lbf)

D33026

91. INSTALL BACK UP LAMP SWITCH ASSY

(a) Using SST, install a new gasket and the back up switch.
SST SST 09817ï16011
Torque: 44 N˜m (449 kgf˜cm, 32 ft˜lbf)

D33025
41ï32
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY (M550)

INPUT SHAFT ASSY (M550)

410CVï02

COMPONENTS
Transmission
Clutch Hub
z Transmission Clutch Hub
No. 3 Transmission Shaft Snap Ring No. 3
Hub Sleeve
Synchromesh No. 3
Shifting Key

Synchromesh
Shifting Key
Spring Synchromesh
Shifting Key
Spring

Synchromesh
Shifting Key

5th Gear
Synchronizer Ring
5th Gear

5th Gear Needle

Roller Bearing
5th Gear
Thrust Washer

5th Gear Thrust

Washer Pin (Ball)

Input Shaft

z Input Shaft
z Input Shaft Front Bearing
Front Bearing
Snap Ring

z Nonïreusable part
Apply Gear Oil
Apply MP Grease
D33165
 41ï33
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY (M550)
410HFï01

OVERHAUL

1. INSPECT 5TH GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 5th gear thrust clear-
ance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum clearance: 0.35 mm (0.0138 in.)

D32864

2. INSPECT 5TH GEAR RADIAL CLEARANCE

(a) Fix the input shaft through 2 protective aluminum plates
in a vise.
(b) Using a dial indicator, measure the 5th gear radial clear-
ance.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
Maximum clearance: 0.068 mm (0.0027 in.)
D32865 If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
(c) Remove the input shaft from the vise.

3. REMOVE TRANSMISSION CLUTCH HUB SHAFT

SNAP RING NO. 3
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
NOTICE:
Use a shop rag to keep the shaft snap ring from flying.

D32866

4. REMOVE 5TH GEAR

(a) Using SST and a press, press out the 5th gear, clutch hub
No. 3, needle roller bearing and synchronizer ring.
SST
SST 09950ï60010 (09951ï00350), 09950ï70010
(09951ï07100)

D32867
41ï34
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY (M550)

5. REMOVE TRANSMISSION CLUTCH HUB NO. 3

(a) Using a screwdriver, remove the 2 key springs, 3 keys,
hub sleeve from the clutch hub No. 3.

D32868

6. REMOVE 5TH GEAR THRUST WASHER

(a) Using SST and a press, press out the thrust washer.
SST
SST 09950ï00020

D32869

7. REMOVE 5TH GEAR THRUST WASHER PIN (BALL)

D32870

8. REMOVE INPUT SHAFT FRONT BEARING SNAP

RING
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
NOTICE:
Use a shop rag to keep the shaft snap ring from flying.

D32871

9. REMOVE INPUT SHAFT FRONT BEARING

(a) Using a press, press out the bearing.
SST SST 09950ï00020

D32872
 41ï35
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY (M550)

10. INSPECT INPUT SHAFT ASSY

(a) Using a dial indicator, measure the input shaft runout.
Maximum runout: 0.015 mm (0.0006 in.)
If the runout exceeds the maximum, replace the input shaft
assy.

D33167

(b) Using a micrometer, measure the outer diameter of the in-

put shaft journal surface.
Standard:
Part Outer diameter
A 47.002 to 47.018 mm (1.8505 to 1.8511 in.)
B 47.984 to 48.000 mm (1.8891 to 1.8898 in.)
C 38.118 to 38.130 mm (1.5007 to 1.5012 in.)
Minimum:
Part Outer diameter
A 47.002 mm (1.8505 in.)
B 47.984 mm (1.8891 in.)
C 38.118 mm (1.5007 in.)
A B C If the diameter is less than the minimum, replace the input shaft.

D32874

11. INSPECT 5TH GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the gear.
Standard clearance:
55.015 to 55.040 mm (2.1659 to 2.1669 in.)
Maximum clearance: 55.040 mm (2.1669 in.)
If the clearance exceeds the maximum, replace the 5th gear.

D32875

12. INSPECT 5TH GEAR THRUST WASHER

(a) Using a micrometer, measure the thrust washer thick-
ness.
Standard thickness:
4.95 to 5.05 mm (0.1945 to 0.2004 in.)
Minimum thickness: 4.95 mm (0.1945 in.)
If the thickness is less than the minimum, replace the 5th gear
thrust washer.
D33123
41ï36
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY (M550)

13. INSPECT 5TH GEAR SYNCHRONIZER RING

(a) Using a feeler gauge, measure the clearance between
the synchronizer ring and gear spline.
Standard clearance:
0.78 to 1.62 mm (0.0307 to 0.0638 in.)
Minimum clearance: 0.78 mm (0.0307 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
D32877

(b) Coat the 5th 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 gear cone. Check
that the ring locks.

D32878

14. INSPECT TRANSMISSION HUB SLEEVE NO. 3

(a) Using a vernier caliper, measure the wide of the hub
sleeve and thickness of the gear shift fork No. 3 as shown
in the illustration.
A (b) Calculate the clearance using the formula below
Formula:
Clearance = A ï B
Standard: 0.15 to 0.26 mm (0.0059 to 0.0102 in.)
If the clearance not as specified, replace the transmission hub
Clearance = A ï B sleeve No. 3 and gear shift fork No. 3.

B
D32879

(c) Check the sliding condition between the hub sleeve and
clutch hub.
(d) Check that the spline gear’s edges of the hub sleeve are
not worn down.

D32880
 41ï37
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY (M550)

15. INSTALL INPUT SHAFT FRONT BEARING

(a) Using a press, press in a new bearing.

D32881

16. INSTALL INPUT SHAFT FRONT BEARING SNAP RING

(a) Select a snap ring that allows minimum axial play.
Standard clearance: 0.10 mm (0.0039 in.) or less
Mark Specified Condition
A 3.00 to 3.05 mm (0.1181 to 0.1201 in.)
B 3.05 to 3.10 mm (0.1201 to 0.1220 in.)
C 3.10 to 3.15 mm (0.1220 to 0.1240 in.)
D 3.15 to 3.20 mm (0.1240 to 0.1260 in.)

D32882
E 3.20 to 3.25 mm (0.1260 to 0.1280 in.)
F 3.25 to 3.30 mm (0.1280 to 0.1300 in.)
(b) Using a brass bar and hammer, tap in the snap ring.

17. INSTALL 5TH GEAR THRUST WASHER PIN (BALL)

(a) Coat the pin (ball) with gear oil and install it.

D32870

18. INSTALL 5TH GEAR THRUST WASHER

(a) Using SST and a press, press in the thrust washer.
SST
SST 09316ï60011 (09316ï00011)

D32883
41ï38
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY (M550)

19. INSTALL 5TH GEAR SYNCHRONIZER RING

(a) Coat the synchronizer ring with gear oil and install it to the
5th gear.

D32884

20. INSTALL 5TH GEAR NEEDLE ROLLER BEARING

(a) Coat the bearing with gear oil and install it.

D32885

21. INSTALL TRANSMISSION CLUTCH HUB NO. 3

With Direction (a) Coat the hub sleeve with gear oil and install it to the clutch
hub.
With Direction
HINT:
To Engine Set the hub sleeve and the clutch hub in correct orientation.
(b) Install the 2 key springs and 3 keys to the hub sleeve.
NOTICE:
Do not set both opening of the shifting key springs in the
D32959 same position.

22. INSTALL 5TH GEAR

(a) Coat the gear with gear oil.
SST Key Position
(b) Using SST and a press, press in the gear.
SST 09316ï60011 (09316ï00011)

For 5th Gear

D32886

23. INSTALL TRANSMISSION CLUTCH HUB SHAFT

SNAP RING NO. 3
(a) Select a snap ring that will allow minimum axial play.
Standard clearance: 0.10 mm (0.0039 in.) or less
Mark Specified Condition
A 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
B 2.65 to 2.70 mm (0.1043 to 0.1063 in.)
C 2.70 to 2.75 mm (0.1063 to 0.1083 in.)

D32887
D 2.75 to 2.80 mm (0.1083 to 0.1102 in.)
 41ï39
MANUAL TRANSMISSION/TRANSAXLE ï INPUT SHAFT ASSY (M550)

Mark Specified Condition

E 2.80 to 2.85 mm (0.1102 to 0.1122 in.)
F 2.85 to 2.90 mm (0.1122 to 0.1142 in.)
(b) Using a brass bar and hammer, and tap in the snap ring.

24. INSPECT 5TH GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the gear thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum clearance: 0.35 mm (0.0138 in.)

D32864

25. INSPECT 5TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance be-
tween the gear and shaft.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
Maximum clearance: 0.068 mm (0.0027 in.)
If the clearance is not as specified, replace the 5th gear needle
roller bearing.
D32865
41ï40
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY (M550)

OUTPUT SHAFT ASSY (M550)

410CXï02

COMPONENTS

z Output Shaft
Front Tapered
Roller Bearing
(Inner Race)

Output Shaft
Synchronizer
Ring No. 4
Output Shaft
Needle Roller
Bearing

z Snap Ring

z Nonïreusable part
Apply Gear Oil
D32888
 41ï41
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY (M550)
410HGï01

OVERHAUL

1. REMOVE SYNCHRONIZER RING NO. 4

(a) Remove the synchronizer ring.

D32889

2. REMOVE OUTPUT SHAFT NEEDLE ROLLER

BEARING
(a) Using a snap ring plier, remove the snap ring.

D32890

(b) Remove the needle roller bearing.

D32891

3. REMOVE OUTPUT SHAFT FRONT TAPERED ROLLER

SST BEARING (INNER RACE)
(a) Using SST and a press, press in the roller bearing (inner
SST race).
SST 09950ï00020 09950ï60010 (09951ï00290)
09950ï70010 (09951ï07100)

D32892
41ï42
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY (M550)

4. INSPECT OUTPUT SHAFT

(a) Using a cylinder gauge, measure the inside diameter of
the output shaft bearing race.
Standard inside diameter:
54.17 to 54.187 mm (2.1327 to 2.1333 in.)
Maximum inside diameter: 54.187 mm (2.1333 in.)
If the diameter exceeds the maximum, replace the output shaft.

D33124

5. INSPECT SYNCHRONIZER RING NO. 4

(a) Using a feeder gauge, measure the clearance between
the synchronizer ring and gear spline.
Standard clearance:
0.78 to 1.62 mm (0.0307 to 0.0638 in.)
Minimum clearance: 0.78 mm (0.0307 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
D32893

(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.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and 4th
gear cone. Lightly rub the synchronizer ring and 4th gear cone
together.
D32894 NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.

6. INSTALL OUTPUT SHAFT FRONT TAPERED ROLLER

BEARING
SST (a) Using SST and a press, press in a new bearing (inner
race).
SST 09316ï20011, 09950ï70010 (09951ï07100),
SST 09951ï00700

D32895
 41ï43
MANUAL TRANSMISSION/TRANSAXLE ï OUTPUT SHAFT ASSY (M550)

7. INSTALL OUTPUT SHAFT NEEDLE ROLLER

BEARING
(a) Coat the needle roller bearing with gear oil, and install it.

D32891

(b) Using a snap ring plier, install a new snap ring.

D32890

8. INSTALL SYNCHRONIZER RING NO. 4

(a) Coat the synchronizer ring with gear oil and install it.

D32889
41ï44
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

COUNTER GEAR ASSY (M550)

410HHï01

COMPONENTS

Synchronizer
Ring Set No. 1
1st Gear

1st Gear Needle

Roller Bearing

z Transmission Clutch Hub

Transmission Shaft Snap Ring No. 1
Hub Sleeve
No. 1
Transmission
Clutch Hub No. 1
Synchromesh
Shifting Key

Synchromesh
Shifting Key
Spring
Synchromesh
Shifting Key
Spring
Reverse Gear z Counter Gear Front
Bearing (Inner Race)
Reverse
Synchronizer
Ring

z Counter Gear Front

Bearing Hole Snap Ring

Reverse Gear
Needle Roller
Bearing
z Nonïreusable part
Apply Gear Oil
D33163
 41ï45
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

2nd Gear Needle

Roller Bearing

2nd Gear
Thrust
Washer
Counter Gear

2nd Gear Thrust

Washer Pin
Transmission
Hub Sleeve No. 2
Synchromesh
Shifting Key Spring
Transmission
Synchromesh Clutch Hub No. 2
Shifting Key
Spring
Synchronizer
Ring Set No. 2
2nd Gear

Synchromesh
Shifting Key

3rd Gear
Thrust Washer Pin
3rd Gear
z 3rd Gear
Thrust Washer
Synchronizer Hole Snap Ring
Ring No. 3

3rd Gear
Thrush Washer
3rd Gear
Needle Roller
Bearing
z Transmission Clutch
Hub Shaft Snap Ring No. 2

z Nonïreusable part
Apply Gear Oil
Apply MP Grease
D33164
41ï46
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)
410HIï01

OVERHAUL

1. INSPECT REVERSE GEAR THRUST CLEARANCE

(a) Fix the counter gear through 2 protective aluminum plates
in a vise
(b) Using a feeler gauge, measure the counter gear thrust
clearance.
Standard clearance:
0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance: 0.45 mm (0.0177 in.)
D32898

2. INSPECT REVERSE GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the reverse gear radial
clearance between the gear and shaft.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
Maximum clearance: 0.068 mm (0.0027 in.)
If the clearance exceeds the maximum, replace the reverse
gear needle roller bearing.
D32899

3. INSPECT 1ST GEAR THRUST CLEARANCE

(a) Using a feeler a gauge, measure the gear thrust clear-
ance.
Standard clearance:
0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance: 0.45 mm (0.0177 in.)

D32900

4. INSPECT 1ST GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 1st gear radial clear-
ance between the gear and shaft.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
Maximum clearance: 0.068 mm (0.0027 in.)
If the clearance exceeds the maximum, replace the gear needle
roller bearing.
D32901
 41ï47
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

5. INSPECT 3RD GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the gear thrust clearance.
Standard clearance:
0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance: 0.45 mm (0.0177 in.)

D32902

6. INSPECT 3RD GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the gear radial clearance
between the gear and shaft.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
Maximum clearance: 0.068 mm (0.0027 in.)
If the clearance exceeds the maximum, replace the 3rd gear
needle roller bearing.
D32903

7. INSPECT 2ND GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the gear thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum clearance: 0.35 mm (0.0138 in.)

D32904

8. INSPECT 2ND GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the gear radial clearance
between the gear and shaft.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
Maximum clearance: 0.068 mm (0.0027 in.)
If the clearance exceeds the maximum, replace the 2nd gear
needle roller bearing.
D32905

9. REMOVE COUNTER GEAR FRONT BEARING HOLE

SNAP RING
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
NOTICE:
Use a shop rag to keep the shaft snap ring from flying.

D32906
41ï48
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

10. REMOVE REVERSE GEAR

(a) Using SST, remove the reverse gear and counter gear
SST front bearing (inner race).
SST 09950ï00020, 09950ï00030, 09950ï40011
(09957ï04010), 09950ï60010 (09951ï00180,
09951ï00370, 09952ï06010)

D32907

11. REMOVE REVERSE SYNCHRONIZER RING

D32908

12. REMOVE REVERSE GEAR NEEDLE ROLLER

BEARING

D32909

13. REMOVE TRANSMISSION CLUTCH HUB SHAFT

SNAP RING NO. 1
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
NOTICE:
Use a shop rag to keep the shaft snap ring from flying.

D32910

14. REMOVE 1ST GEAR

(a) Using SST, remove the 1st gear, transmission clutch hub
No. 1 and synchronizer ring.
SST
SST 09950ï00020, 09950ï00030, 09950ï40011
(09957ï04010), 09950ï60010 (09951ï00370)

D32911
 41ï49
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

15. REMOVE TRANSMISSION CLUTCH HUB NO. 1

(a) Using a screwdriver, remove the 2 key springs, 3 keys and
hub sleeve from the clutch hub.

D32912

16. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

D32913

17. REMOVE 3RD GEAR THRUST WASHER HOLE SNAP

RING
(a) Using 2 screwdrivers and a hammer, tap out the hole snap
ring from the counter gear.
NOTICE:
Use a shop rag to keep the shaft snap ring from flying.

D32914

18. REMOVE 3RD GEAR

(a) Using SST and a press, press out the thrust washer.
SST
SST 09950ï00020

D32915

19. REMOVE 3RD GEAR THRUST WASHER PIN

(a) Remove the pin.

D32916
41ï50
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

20. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

D32917

21. REMOVE SYNCHRONIZER RING NO. 3

D32918

22. REMOVE TRANSMISSION CLUTCH HUB SHAFT

SNAP RING NO. 2
(a) Using 2 screwdrivers and a hammer, tap out snap ring.
NOTICE:
Use a shop rag to keep the shaft snap ring from flying.

D32919

23. REMOVE 2ND GEAR

(a) Using a press, press out the 2nd gear, transmission clutch
hub No. 2 and synchronizer ring.

D32920

24. REMOVE TRANSMISSION CLUTCH HUB NO. 2

(a) Using a screwdriver, remove the 2 key springs, 3 keys and
hub sleeve from the clutch hub.

D32921
 41ï51
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

25. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

D32922

26. REMOVE 2ND GEAR THRUST WASHER

(a) Using SST and a press, press out the thrust washer.
SST SST 09950ï00020

D32923

27. REMOVE 2 ND GEAR THRUST WASHER PIN

D32924

28. INSPECT COUNTER GEAR ASSY

(a) Using a dial indicator, measure for the shaft runout.
Maximum runout: 0.015 mm (0.0006 in.)
If the runout exceeds the maximum, replace the counter shaft
assy.

D32925
41ï52
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

(b) Using a micrometer, measure the diameter of the counter

shaft journal surface.
Standard:
Part Outer diameter
A 43.484 to 43.500 mm (1.7120 to 1.7126 in.)
B 48.984 to 49.000 mm (1.9285 to 1.9291 in.)
C 53.984 to 54.000 mm (2.1253 to 2.1260 in.)
D 53.984 to 54.000 mm (2.1253 to 2.1260 in.)
E 40.002 to 40.018 mm (1.5749 to 1.5755 in.)
Minimum:
Part Outer diameter
A 43.484 mm (1.7120 in.)
A B C D E B 48.984 mm (1.9285 in.)
C 53.984 mm (2.1253 in.)
D 53.984 mm (2.1253 in.)
E 40.002 mm (1.5749 in.)
If the diameter is less than the minimum, replace the output
shaft.
D32926

29. INSPECT REVERSE GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the gear.
Standard inside diameter:
50.515 to 50.540 mm (1.9888 to 1.9898 in.)
Maximum inside diameter: 50.540 mm (1.9898 in.)
If the inside diameter exceeds the maximum, replace the re-
verse gear.
D32927

30. INSPECT 1ST GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the gear.
Standard inside diameter:
56.015 to 56.040 mm (2.2053 to 2.2063 in.)
Maximum inside diameter: 56.040 mm (2.2063 in.)
If the inside diameter exceeds the maximum, replace the 1st
gear.
D32928

31. INSPECT 2ND GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the gear.
Standard inside diameter:
61.015 to 61.040 mm (2.4022 to 2.4031 in.)
Maximum inside diameter: 61.040 mm (2.4031 in.)
If the inside diameter exceeds the maximum, replace the 2nd
gear.
D32929
 41ï53
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

32. INSPECT 3RD GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the 3rd gear.
Standard inside diameter:
61.015 to 61.040 mm (2.4022 to 2.4031 in.)
Maximum inside diameter: 61.040 mm (2.4031 in.)
If the inside diameter exceeds the maximum, replace the 3rd
gear.
D32930

33. INSPECT 3RD GEAR THRUST WASHER

(a) Using a micrometer, measure the thrust washer thick-
ness.
Standard thickness:
11.45 to 11.55 mm (0.4508 to 0.4547 in.)
Minimum thickness: 11.45 mm (0.4508 in.)
If the thickness is less than the minimum, replace the 3rd gear
thrust washer.
D32931

34. INSPECT 2ND GEAR THRUST WASHER

(a) Using a micrometer, measure the thrust washer thick-
ness.
Standard thickness:
5.45 to 5.55 mm (0.2146 to 0.2185 in.)
Minimum thickness:
5.45 mm (0.2146 in.)
If the thickness is less than the minimum, replace the 2nd gear
D32932 thrust washer.

35. INSPECT SYNCHRONIZER RING SET NO. 1

(a) Using a feeler gauge, measure the clearance between
the synchronizer ring and 1st gear spline.
Standard clearance:
1.10 to 2.10 mm (0.0433 to 0.08217 in.)
Minimum clearance: 1.10 mm (0.0433 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
D32933

(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.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and 1st
gear cone. Lightly rub the synchronizer ring and 1st gear cone
together.
D32934
41ï54
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.

36. INSPECT REVERSE SYNCHRONIZER RING

(a) Using a feeler gauge, measure the clearance between
the synchronizer ring and reverse gear spline.
Standard clearance:
0.78 to 1.62 mm (0.0307 to 0.0638 in.)
Minimum clearance: 0.78 mm (0.0307 in.)
If the clearance is less than the minimum, replace the reverse
synchronizer ring.
D32935

(b) Coat the reverse gear cone with gear oil. Check the brak-
ing 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.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and re-
verse gear cone. Lightly rub the synchronizer ring and reverse
gear cone together.
D32936 NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.

37. INSPECT SYNCHRONIZER RING NO. 3

(a) Using a feeler gauge, measure the clearance between
the synchronizer ring and 3rd gear spline end.
Standard clearance:
0.78 to 1.62 mm (0.0307 to 0.0643 in.)
Minimum clearance: 0.78 mm (0.0307 in.)
If the clearance is less than minimum, replace the synchronizer
ring.
D32937

(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.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and 3rd
gear cone. Lightly rub the synchronizer ring and 3rd gear cone
together.
D32938
 41ï55
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.

38. INSPECT SYNCHRONIZER RING SET NO. 2

(a) Using a feeler gauge, measure the clearance between
the synchronizer ring and 2nd gear spline.
Standard clearance:
1.10 to 2.10 mm (0.0433 to 0.0827 in.)
Minimum clearance: 1.10 mm (0.0433 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
D32939

(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.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and 2nd
gear cone. Lightly rub the synchronizer ring and 2nd gear cone
together.
D32940 NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.

39. INSPECT TRANSMISSION HUB SLEEVE NO. 1

(a) Using a vernier caliper, measure the wide of the hub
sleeve and thickness of the gear shift fork No. 1 as shown
in the illustration.
A (b) Calculate the clearance using the formula below.
Formula:
Clearance = A ï B
Standard: 0.25 to 0.85 mm (0.0098 to 0.0335 in.)
Clearance = A ï B If the clearance not as specified, replace the transmission hub
sleeve No. 1 and gear shift fork No. 1.

D32941
41ï56
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

(c) Check the sliding condition between the hub sleeve and
clutch hub.

D32942

40. INSPECT TRANSMISSION HUB SLEEVE NO. 2

(a) Using a vernier caliper, measure the clearance between
gear shift fork No. 2 and transmission hub sleeve No. 2.
(b) Calculate the clearance using the formula below.
A Formula:
Clearance = A ï B
Standard clearance:
0.25 to 0.85 mm (0.0098 to 0.0335 in.)
Clearance = A ï B If the clearance exceeds the standard, replace the gear shift
fork No. 2 and transmission hub sleeve No. 2.

D32943

(c) Check the sliding condition between the hub sleeve and
clutch hub.

D32944

41. INSTALL 2ND GEAR THRUST WASHER PIN

(a) Coat the pin with gear oil and install it.

D32924
 41ï57
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

42. INSTALL 2ND GEAR THRUST WASHER

SST SST (a) Using SST and a press, press in the 2nd gear thrust wash-
er.
SST 09502ï12010, 09950ï60010 (09951ï00300),
SST 09950ï70010 (09951ï07100)

D32945

43. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

(a) Coat the needle roller bearing with gear oil and install it.

D32922

44. INSTALL SYNCHRONIZER RING SET NO. 2

(a) Coat the synchronizer ring with gear oil and install it.

D32946

45. INSTALL TRANSMISSION CLUTCH HUB NO. 2

(a) Coat the clutch hub with gear oil and install it to the hub
With Direction
sleeve.
With Direction HINT:
Set the hub sleeve and the clutch hub in correct orientation.
To Engine
(b) Install the 2 key springs and 3 keys to the hub sleeve.
NOTICE:
Do not set both opening of the shifting key springs in the
D32960 same position.
46. INSTALL 2ND GEAR
(a) Coat the 2nd gear with gear oil.
41ï58
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

(b) Using SST and a press, press in the 2nd gear.

SST 09316ï20011, 09513ï36040
SST 47. INSTALL TRANSMISSION CLUTCH HUB SHAFT
Key Position
SNAP RING NO. 2
(a) Select a snap ring that allows minimum axial play.
Standard clearance: 0.10 mm (0.0039 in.) or less
Snap ring thickness:
For 2nd Gear
Mark Specified Condition
D32947 A 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
B 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
C 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
D 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
E 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
F 2.65 to 2.70 mm (0.1043 to 0.1063 in.)

(b) Using a brass bar and hammer, tap in the snap ring.

D32948

48. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

(a) Coat the needle roller bearing with gear oil and install it.

D32917

49. INSTALL SYNCHRONIZER RING NO.3

Key Position (a) Coat the synchronizer ring with gear oil and install it.

For 3rd Gear

D33125
 41ï59
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

50. INSTALL 3RD GEAR

(a) Coat the gear with gear oil and install it.

D32949

51. INSTALL 3RD GEAR THRUST WASHER PIN

(a) Coat the pin with grease and install it.

D32916

52. INSTALL 3RD GEAR THRUST WASHER

SST (a) Using SST and a press, press in the thrust washer.
SST 09316ï60011 (09316ï00011)
53. INSTALL 3RD GEAR THRUST WASHER HOLE SNAP
RING
(a) Select a snap ring will allow the minimum axial play.
Standard clearance: 0.10 mm (0.039 in.) or less
Snap ring thickness:
D32950 Mark Specified Condition
1 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
2 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
3 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
4 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
5 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
6 2.65 to 2.70 mm (0.1043 to 0.1063 in.)

(b) Using a brass bar and hammer, tap in the snap ring.

D32951
41ï60
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

54. INSTALL 1ST GEAR NEEDLE ROLLER BEARING

(a) Coat the needle roller bearing with gear oil and install it.

D32913

55. INSTALL SYNCHRONIZER RING SET NO.1

(a) Coat the synchronizer ring with gear oil and install it on the
1st gear.

D32952

56. INSTALL TRANSMISSION CLUTCH HUB SLEEVE

With Direction ASSY NO. 1
(a) Coat the hub sleeve with gear oil and install it to the clutch
With Direction
hub.
To Engine HINT:
Set the hub sleeve and the transmission clutch hub No. 1 in cor-
rect orientation.
(b) Install the 2 key springs and 3 keys to the hub sleeve.
D32961 NOTICE:
Do not set both opening of the shifting key springs in the
same position.

57. INSTALL 1ST GEAR

SST (a) Coat the 1st gear with gear oil.
Key Position
(b) Using SST and a press, press in the 1st gear.
SST 09316ï60011 (09316ï00011)
58. INSTALL TRANSMISSION CLUTCH HUB SHAFT
SNAP RING NO. 1
For 1st Gear (a) Select a snap ring that allows minimum axial play.
Standard clearance: 0.10 mm (0.039 in.) or less
D32953 Mark Specified Condition
A 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
B 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
C 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
D 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
E 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
F 2.65 to 2.70 mm (0.1043 to 0.1063 in.)
 41ï61
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

(b) Using a brass bar and hammer, tap in the snap ring.

D32954

59. INSTALL REVERSE GEAR NEEDLE ROLLER

BEARING
(a) Coat the needle roller bearing with gear oil and install it.

D32909

60. INSTALL REVERSE SYNCHRONIZER RING

(a) Coat the synchronizer ring with gear oil and install it to the
transmission hub sleeve No. 1.

D32908

61. INSTALL REVERSE GEAR

SST (a) Coat the gear with gear oil.
(b) Using SST and a press, press in the reverse gear and a
Key Position
new counter gear front bearing (inner race).
SST 09608ï06041
62. INSTALL COUNTER GEAR FRONT BEARING HOLE
SNAP RING
For Revers Gear
(a) Select a hole snap ring that will allow minimum axial play.
D32955 Standard clearance: 0.10 mm (0.039 in.) or less
Snap ring thickness:
Mark Specified Condition
A 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
B 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
C 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
D 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
E 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
F 2.65 to 2.70 mm (0.1043 to 0.1063 in.)
41ï62
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

(b) Using a brass bar and hammer, tap in the snap ring.

D32956

63. INSPECT REVERSE GEAR THRUST CLEARANCE

(a) Fix the counter gear through 2 protective aluminum plates
in a vise.
(b) Using a feeler gauge, measure the gear thrust clearance.
Standard clearance:
0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance: 0.45 mm (0.0177 in.)

D32898

64. INSPECT REVERSE GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the reverse gear radial
clearance between the gear and shaft.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
Maximum clearance: 0.068 mm (0.0027 in.)
If the clearance is not as specified, replace the reverse gear
needle roller bearing.
D32899

65. INSPECT 1ST GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the gear thrust clearance.
Standard clearance:
0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance: 0.45 mm (0.0177 in.)

D32900

66. INSPECT 1ST GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the gear radial clearance
between the gear and shaft.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
Maximum clearance: 0.068 mm (0.0027 in.)
If the clearance is not as specified, replace the 1st gear needle
roller bearing.
D32901
 41ï63
MANUAL TRANSMISSION/TRANSAXLE ï COUNTER GEAR ASSY (M550)

67. INSPECT 3RD GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the gear thrust clearance.
Standard clearance:
0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance: 0.45 mm (0.0177 in.)

D32902

68. INSPECT 3RD GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the gear radial clearance
between the gear and shaft.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
Maximum clearance: 0.068 mm (0.0027 in.)
If the clearance is not as specified, replace the 3rd gear needle
roller bearing.
D32903

69. INSPECT 2ND GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the gear thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum clearance: 0.35 mm (0.0138 in.)

D32904

70. INSPECT 2ND GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the gear radial clearance
between the gear and shaft.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
Maximum clearance: 0.068 mm (0.0027 in.)
If the clearance is not as specified, replace the 2nd gear needle
roller bearing.
D32905 (b) Remove the counter gear from the vise.
41ï64
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY (M550)

SHIFT LEVER SHAFT HOUSING ASSY (M550)

410D1ï02

COMPONENTS

z Dust Boot

z Control Shaft
Cover Bimetal
Control Formed Bush
Shaft Cover

Shift Lever Shaft

z Oil Seal

z Snap Ring
Select Spring
Seat

Select Inner Head

Select Return Spring No. 2

z Slotted Pin
Shift Inner
Lock Plate

Shift Lever Inner No. 1

z Slotted Pin

z Nonïreusable part
Apply Gear Oil D32958
 41ï65
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY (M550)
410HJï01

OVERHAUL
1. REMOVE SHIFT LEVER INNER NO. 1
(a) Fix the shift lever shaft through 2 protective aluminium
plates in a vise.

(b) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out
slotted pin. Remove the shift lever and shift inner lock
plate from the shift lever shaft.

D33122

2. REMOVE SELECT INNER HEAD

(a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out
slotted pin.
(b) Remove the select inner head, select return spring and
select spring sheet from the shift lever shaft.

D32965

3. REMOVE CONTROL SHAFT COVER

(a) Using 2 screwdrivers and hammer, tap out the snap ring.
Remove the shift lever shaft from the control shaft cover.
(b) Remove the dust boots from the shift lever shaft.
(c) Remove the shift lever shaft from the vise.

D32966

4. REMOVE CONTROL SHAFT COVER OIL SEAL

(a) Using a screwdriver, pry out the oil seal from the control
shaft cover.
HINT:
Tape the screwdriver tip before use.

D32967
41ï66
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY (M550)

5. REMOVE CONTROL SHAFT COVER BIMETAL

FORMED BUSH
SST (a) Using SST and a press, press out the bush from the con-
trol shaft cover.
SST 09222ï30010

D32968

6. INSTALL CONTROL SHAFT COVER BIMETAL

FORMED BUSH
SST (a) Using SST and press, press in a new control shaft cover
bimetal foamed bush to the control shaft cover.
SST 09222ï30010
Drive in depth: 9.0 to 10.0 mm (0.3543 to 0.3937 in.)

D32969

7. INSTALL CONTROL SHAFT COVER OIL SEAL

SST (a) Using SST and a hammer, tap in a new oil seal to the con-
trol shaft cover.
SST 09950ï60010 (09951ï00310), 09950ï70010
(09951ï07100)
Drive in depth: 0 to 1.0 mm (0 to 0.0394 in.)
(b) Coat the control shaft cover oil seal with MP grease.

D32970

8. INSTALL CONTROL SHAFT COVER

(a) Coat the shift lever shaft and boot with MP grease.
(b) Install the control shaft cover to the shift lever shaft.

D32971

(c) Using a brass bar and hammer, tap in a new snap ring to
the shift lever shaft.

D32972
 41ï67
MANUAL TRANSMISSION/TRANSAXLE ï SHIFT LEVER SHAFT HOUSING ASSY (M550)

9. INSTALL SELECT INNER HEAD

(a) Fix the select lever shaft lever shaft through 2 protective
aluminum plates in a vise.
(b) Coat the select spring sheet with MP grease.
(c) Install the select spring sheet, select return spring and se-
lect inner head to the shift lever shaft.
(d) Using a pin punch (5 mm (0.20 in.)) and hammer, tap in
the slotted pin to the shift lever shaft.
D32973 Drive in depth: 0 to 1.0 mm (0 to 0.0394 .in)
NOTICE:
Be careful with the installation direction of the select inner
head.

10. INSTALL SHIFT LEVER INNER NO. 1

(a) Coat the shift lever and shift inner lock plate with MP
grease.
(b) Install the shift lever and shift inner lock plate to the shift
lever shaft.
(c) Using a pin punch (5 mm (0.20 in.)) and hammer, tap in
a new slotted pin to the shift lever shaft.
Drive in depth: 0 to 1.0 mm (0 to 0.0394 .in)
D32974 NOTICE:
Be careful with the installation directions of the shift lever
inner No. 1 and shift interlock plate.
(d) Remove the shift lever shaft from the vise.
 00ï

ALPHABETICAL INDEX
00ï2
ALPHABETICAL INDEX (A ï T)

A R
Page Page
ABBREVIATIONS USED IN THIS MANUAL (TERMS FOR REPAIR INSTRUCTION FOR MANUAL
MANUAL TRANSMISSION WORKSHOP MANUAL) 01ï5 TRANSMISSION WORKSHOP MANUAL . . . . . . . . . 01ï4

C S
COMPONENTS (COUNTER GEAR ASSY (M550)) . . . 41ï44 SERVICE DATA (MANUAL TRANSMISSION
COMPONENTS (INPUT SHAFT ASSY (M550)) . . . . . 41ï32 / TRANSAXLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï4
COMPONENTS (MANUAL TRANSMISSION ASSY SHIFT LEVER SHAFT HOUSING ASSY (M550) . . . . . 41ï64
(M550)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï2 SPECIFIED TORQUE FOR STANDARD BOLTS
COMPONENTS (OUTPUT SHAFT ASSY (M550)) . . . 41ï40 (STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï2
COMPONENTS (SHIFT LEVER SHAFT HOUSING STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï1
ASSY (M550)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï64
COUNTER GEAR ASSY (M550) . . . . . . . . . . . . . . . . . . . 41ï44
T
G TERMS FOR MANUAL TRANSMISSION WORKSHOP
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01ï5
GENERAL INFORMATION (HOW TO USE THIS TORQUE SPECIFICATION (MANUAL
MANUAL TRANSMISSION WORKSHOP MANUAL) 01ï1 TRANSMISSION /TRANSAXLE) . . . . . . . . . . . . . . . . 03ï7
GLOSSARY OF SAE AND HINO TERMS (TERMS
FOR MANUAL TRANSMISSION WORKSHOP
MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01ï6

H
HOW TO DETERMINE BOLT STRENGTH
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï1
HOW TO DETERMINE NUT STRENGTH
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï3
HOW TO USE THIS MANUAL TRANSMISSION
WORKSHOP MANUAL . . . . . . . . . . . . . . . . . . . . . . . . 01ï1

I
INPUT SHAFT ASSY (M550) . . . . . . . . . . . . . . . . . . . . . 41ï32

M
MANUAL TRANSMISSION / TRANSAXLE . . . . . . . . . . 03ï4
MANUAL TRANSMISSION ASSY (M550) . . . . . . . . . . . 41ï2
MANUAL TRANSMISSION SYSTEM (M550) . . . . . . . . 41ï1
MANUAL TRANSMISSION/TRANSAXLE . . . . . . . . . . . 02ï1

O
OUTPUT SHAFT ASSY (M550) . . . . . . . . . . . . . . . . . . . 41ï40
OVERHAUL (COUNTER GEAR ASSY (M550)) . . . . . . 41ï46
OVERHAUL (INPUT SHAFT ASSY (M550)) . . . . . . . . . 41ï33
OVERHAUL (MANUAL TRANSMISSION ASSY
(M550)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï6
OVERHAUL (OUTPUT SHAFT ASSY (M550)) . . . . . . . 41ï41
OVERHAUL (SHIFT LEVER SHAFT HOUSING
ASSY (M550)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41ï65

P
PRECAUTION (REPAIR INSTRUCTION FOR
MANUAL TRANSMISSION WORKSHOP MANUAL) 01ï4
PREPARATION (MANUAL TRANSMISSION
/TRANSAXLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï1
PROBLEM SYMPTOMS TABLE (MANUAL
TRANSMISSION SYSTEM (M550)) . . . . . . . . . . . . . 41ï1