CONTENTS

GENERAL General Information Outline of Transmission Special Tools Plant

2 2 2 3

INTERMEDIATE

GEAR ASSEMBL

34

OUTPUT SHAFT ASSEMBLY

DIFFERENTIAL ASSEMBLY

40
41

Adjustment Snap Rings and Spacers ...4 General Specifications 5 Service Specifications Sealant & Adhesive, lubricants Torque Specifications Troubleshooting Transmission Oil TRANSMISSION CONTROL 5 6 7 8 9 10 13 15 29

SHIFT CONTROL MECHANISM SHIFT FORK ASSEMBLY 5TH SPEED SYNCHRONIZER

44 45

ASSEMBLY
CLUTCH HOUSING ASSEMBLY SPEEDOMETER DRIVEN GEAR ASSEMBLY BACK-UP LAMP SWITCH

46 48

Shift Lever Assembly TRANSMISSION ASSEMBLY

51 52

INPUT SHAFT ASSEMBLY

22-2

MANUAL

TRANSMISSION

-General

Information

GENERAL INFORMATION
MODEL F5M21 (1) The F5M21 series manual transmission have been redesigned to improve merchantability through realization of good operating performance, very quiet operation and high power transmission efficiency and increase of durability and quality.

OUTLINE functions

OF TRANSMISSION combined

PLANT which has the gear reduction, diecdst housing ratio selection and case. and differential in the aluminium

The F5M21 series is a five speed manual transmission into one unit and housed

All these manual transmission have a large diameter ,large capacity synchronizer which, combined with improved shift control mechanism, reduces shift operation force and gives comfortable shift feeling. The shift control mechanism includes a new interlock device and a reverse shift error prevention device which ensure correct operation and prevent misoperation.

MANUAL TRANSMISSION

Special Tools

22-3

SPECIAL
Tool

TOOLS
Number MD998019

Name
Lock pin extractor

Use
Removal of spring pin and lock pin

MD998245 lock pin installer Installation of spring pin and lock

pin

MD998802

Input shaft holder

Installation and removal of input shaft and inter mediate gear lo~k nut Installation of input shaft bearing and input shaft gear

MD998320

Bearing installer

MD998325

Differential oil seal installer

Installation of differential oil seal

MD998369

Bearing installer

Installation of Input shaft front bearing

MD998321

Oil seal installer

Installation of input shaft front oil seal

MD998350

Bearing installer

Installation of Intermediate gear bearing and intermediate gear.

MD998801

Bearing remover

Removal of input shaft, intermediate gear and output shaft bearings and gears Removal of the lower arm joint and tie rod end ball

MB991113/ MB990635

Steering linkage puller

joint.

22-4

MANUAL TRANSMISSION

Adjustment

Snap Rings and Spacers

ADJUSTMENT

SNAP RINGS AND SPACERS

MANUAL

TRANSMISSION

-Specifications

22-5

SPECIFICATIONS
GENERAL SPECIFICATIONS
Items Model Applicable engine Gear ratio 1 st Specifications F5M21-1-VRAC 4G13 3,363 Gear shift control [cable-ope rated]

2nd
3rd 4th 5th Reverse Final gear ratio Speedometer gear ratio (driven/drive)

1.947
1.285 0.939

0.777
3.083 4.322 31/36

SERVICE SPECIFICATIONS
Items

Standard

mm{in)

Transmission
Intermediate Input shaft bearing gear bearing end play end play

0.01 T -0.12L 0.01T -0.14L O.OSL -O.17L O.O5T -O.17l

(0.0004T (0.0004T

-0.005L) -0.006L)

Intermediate shaft end play Output shaft end play Differential Differential case end play Differential pinion backlash

(O.OO2L -O.OO7L) (O.OO2T -O.OO7l:i

O.O5l -O.17l 0.025L -0.15L

(O.OO2l -O.OO7l) (0.001 L -0.006L

T: Tight (Preload) L: Loose (End play)

22-6

MANUAL TRANSMISSION

Sealant and Adhesives

/ lubricants

SEALANTS AND ADHESIVES

Items Transmission case Specified sealants and adhesives Proton genuine sealant Part No. MD997740 or equivalent Proton genuine sealant Part No. MD997740 or equivalent 3M STUD locking No. 4170 or equivalent 3M STUD Locking No. 4170 or equivalent 3M SUPER WEATHERSTRIP No. 8001 or equivalent

Quantity
As required

Clutch housing mating surfaces Transmission caserear cover mating surfaces Differential drive gear bolts

As required

As required

Bearing retainer bolts (flush bolt only) Air breather

As required

As required

LUBRICANTS
Items Manual transmission oil lit (Imp.qts)

Specified Lubricant
Hypoid gear oil SAE 75W-85W or 75W-90W conforming to API GL-4 or higher Wheel bearing grease SAE J310a, NLGI grade#2EP Wheel bearing grease SAE J31 Ga, NLGI grade # 2EP Wheel bearing grease SAE J310a, NLGI grade # 2EP Hypoid gear oil SAE 75W-85W or 75W-90W

Quantity

1.8 (1.58)

Shift lever and bushing contacting surface

As required

Inside of dust cover

As required

Shift lever sliding portion

As required

Speedometer driven gear shaft

As required

MANUAL TRANSMISSION
TORQUE SPECIFICATIONS
Items

Torque Specifications

22-7

kgm
assembly attaching bolt ..'.'.'."""" '..".'.'

Torque (ft. Ibs)

(7 -1 0) (7 -10) (14 -20) (14 -20) (22 -25) (22 -25) (20 -25) (22 -29) (65 -80) (65 -80) (43-51) (33 -43) (7 -9) (11 -25) (43 -52) (11-15) (22 -25) (22 -25) (22 -30) (2.5 -3.5) (102-112) (102-112) (32 -39) (26 -30) (11-15) (22 -25) (11 -15) (11-15) (94 -1 01 ) (15 -19) (32 -39)

Bracket

Transmission Control Lever Shift

lever (A)

cable

to to

bracket attaching lever filler drain

plug plug assembly (A)

bolt ..".,..,.""",.,.",.."".,..,.."""""

0.9 0.9 1 .9 1.9

-1.4 -1.4 -2.8 -2.8

Transmission Starter

motor

to mount

transmission

bracket

to

transmission body

bracket

3.0 -3.5 3.0 -3.5 2.7- 3.5 3.0 -4.0

9.0 -11.0 9.0 -11.0

Transmission Roll

rod

to

transmission roll

bracket rod

bracket

to

transmission .'."'.."""'."""".."".."""""

6.0 -7.0
Transmission Tie Backup Rear Lower Bell Poppet rodhousing cover arm end plug lamp ball to ""...'.' switch bolt cover switch joint knuckle to to transmission " knuckle "".'."""."""..."" , ,

4.5 -6.0 1 .0 -1.2 1.5 -3.5

6.0 -7.2
1.5 -2.2 3.0 -3.5

3.0 -3.5
3.0 -4.2
Speedometer sleeve bolt ,

Input

shaft

lock

nut

"

",.""",.,.""".".""...""""

Reverse Intermediate

idler

gear gear

shaftshaft

bolt bolt

"

"""""""."."""""", ,

Transmission Stopper Bearing Reverse Interlock Differential Restrict

ball shift retainer bracket plate

drive assembly bolt lever case

bolt bolt gear

.",.,...,."".""""""""""""",.""",., tightening assembly bolt ,

attaching

bolt

0.3 -0.5 14-16 14-16 4.3 -5.5 3.5 -4.2

1.5 -2.2 3.0 -3.5 15 -2.2 1.5 -2.2

13-14
2.0 -2.7
Transmission mounting bolt

4.3 -5.5

22-8

MANUAL TRANSMISSION

Troubleshooting

TROUBL.ESHOOTING
Symptom Vibration, noise
Probable cause
--

Remedy

a. Loose or damaged transmission and engine mountings

a. Tighten or replace mounting

b. Inadequate shaft end play

C. Worn of damaged gears
,: ,.

b. Correct end play c. Replace gears

-

d. Use or inadequate grade of oil

d. Replace with specified oil e. Replenish

f.
a-ring

e. Low oil level f. Inadequate engine idle speed

Oil leakage a. Broken or damaged, oil sea
b. Use of inadequate sealant 9 0r

Adjust idle speed

a. Replace oil seal or a-ring b. Reseal with specified sealant. a. Replace control cable b. Correct or replace

Hard shift

a. Faulty control cable

--.'

b. Poor contact or wear of synchronizer ring and gear cone

c. Weakened synchronizer spring

d. 'Use of inadequate grade of oil Jumps out of gear a. Worn gear shift fork or broken poppet spring b. Synchronizer hub to sleeve spline clearance too large Difficult or impossible to put in gear.

e synchronizer spring d. Replace with specified oil a. Replace shift fork or poppet spring b. Replace synchronizer hub and sleeve
Adjust
-

Improperly adjusted control cable

Clutch not disengaging properly Improperly adjusted control cable Worn shift lever bushing Weakened insulator

Slips out of gear or excessive play

Adjust or replace Adiust Replace Replace Replace Apply grease r-;~~-~~ or replace ~""""" -

Stiff lever operation

Insufficient grease on control cable Insufficient grease on shift lever bushing

Unusual noise during operation

Replace

MANUAL TRANSMISSION

Transmission Oil

22-9

TRANSMISSION OIL
Selection of Transmission Oil

The manual transmission is filled with a special oj) at the factory. If it becomes necessary to add oil to transmission, lubricants conforming to the API (American Petroleum Institute's) GL4 classification or higher should be used. Lubricant: Hypoid gear oil SAE 75W-85W

Checking Transmission Oil Level

Filler plug opening

The oil in transmission should be checked and, if necessary, replenished to the bottom of the filler plug opening with oil as specified above.

Oil level ~

Oil Change Procedure Raise vehicle on hoist. Place drain container with large opening, under drain plug (located in bottom of transmission under cover.) Remove filler-plug. Remove drain plug to let oil drain completely. Tighten drain plug to specified torque.

Apply recommended oil into transmission through oil filler hole. Tighten oil filler plug. Oil filler plug.
.3 -3.5 kgm (22-25 ft.lbs)

22-1 0

MANUAL TRANSMISSION

Transmission Control

TRANSMISSION
Ij

CONTROL
6
\

REMOVAL AND INSTAllATION

7
I

[C=:=J
-~

8 2

~
9
-C:{}

~3~

~~~
"
""4 ""'"

<~~~~:~~~/T
/j14m
/

13

0.9 -1.4 kgm

\
11
0.9 -1.4 kgm 7 -10ft. Ibs.

7-10ft.lbs.

"'"
15

.r

~.--J

14m

w(!10m

-t

t----J

0.9-1.4kgm
7 -10 ft. Ibs.

12

~
Removal steps 1. 2. 3. 4. 5. ..6. ..7. 8. 9. 10. 11. 12.

~ S
IS

~
13. 14. 15. 16. Clip Split pin Select cable Shift cable

Shift knob Rear ashtray Parking brake cover Plate Floor console Hazard lamp switch Rear window defogger switch Front console box Front console assemr>ly Clip Split pin Shift lever assembly

NOTE (1) Reverse the removal procedures to reinstall (2) ..Refer to "Service Points of Removal" (3) ..Refer to "Service Points of Installation" (4) m Non reusable parts
A100001

~
-. L ~16 ~ 5" ~~ ~J"

MAN UAL TRAN SM ISSION

Transmission Control

22-11

SERVICE POINTS OF REMOVAL

..15. REMOVAL OF SELECT CABLE /16. SHIFT CABLE Remove nuts shown in illustration from inside the passenger compartment, then pullout shift and select cables from engine compartment side.

1/

SERVICE POINTS OF INSTAllATION

..16. INSTAllATION OF SHIFT CABLE (1) With the transmission side select lever kept in the neutral position, move the transmission side shift lever in the direction shown in the illustration to set it in the 4th gear. NOTE If the shift lever does not move smoothly, the clutch pedal while moving the lever. depress

(2) Tilt the passenger compartment side shift lever in the direction shown in the illustration (4th gear) until the lever comes in contact with the stopper.

(3) Use the adjuster to bring the shift cable end to the illustrated position with respect to the passenger compartment side shift lever. (4) Install the shift cable to the passenger compartment side shift lever.

(5) Use the adjuster to adjust the length of the shift cable so that when the shift lever is put in the 3rd and 4th gears, clearance (A) and (8) between the shift lever and the respective stoppers are equal. (6) Put the shift lever in each position to make sure that the lever moves smoothly.

22-12

MANUAL TRANSMISSION
..15.

Transmission Control
OF SELECT CABLE side shift lever in the neutral

INSTAllATION position.

(1) Place the transmission

NOTE
If the transmission side shift lever is put into the neutral position, the transmission side select lever is set in neutral position.

(2) Keep the passenger compartment side select lever in the neutral position.

(3) Use the adjuster to bring the select cable end to the illustrated position with respect to the passenger compartment side select lever. (4) Install the select cable to the passenger compartment side select lever.

MANUAL

TRANSMISSION

-Shift

Lever Assembly

22-13

SHIFT LEVER ASSEMBLY

DISASSEMEILY AND REASSEMBLY

~
2 1.9 -2.8 kgm 14 -20 ft. Ibs.

3-

l@j) ~~ k q::1.
~
v.Je

(@-,-5
e
7

6-~=:
r
-..J

1.9 -2.8 kgm 14 -20 ft. Ibs.

10

.~

Disassembly steps 1. Stopper

2. Shift lever ..3. Bushing

4. Lever (A) ..5. Bushing ..6. Bushing 7. Snap ring 8. Lever (B) ..9. Bushing 10. Bracket assembly

NOTE

(1) Reverse the disassembly procedures to reassemble (2) ..: Refer to "Service Points of Disassembly". (3) ..: Refer to "Service Points of Reassembly".
A100002

~1

22-14

MANUAL

TRANSMISSION

-Shift

Lever Assembly

SERVICE POINTS OF REASSEMBLY

..9./6./5./3. LUBRICATION OF BUSHINGS
Multipurpose NLGI No.2 grease SAE J31 0, Apply specified grease to points shown in illustration. Specified grease:

Vehicle front.

/
A
A

-f~?~'
c
SECTION A-A
SECTION C-C

1~~L

,
SECTION B-B

:rlr
09UO096

&
SECTION D-D
Co

09UOO94

~ l "
D

~
dt
~ )~

~I

I'

'L
09UOO95

c:;rL~
09UOO97

09UOO98

A100003

~ ~ !
~"" ~1 ~

MANUAL TRANSMISSION

Transmission Assembly

22-15

TRANSMISSION

ASSEMBLY

REMOVAL AND INSTAllATION

Pre-removal Operation
.Draining .Removing Transmission Oil Undercover

Post removal Operation

.Adjusting .Filling .Installing Clutch Cable with Transmission Oil Undercover

10
1\

~I 3.0 -3.5 kgm 22 -25 ft. Ibs.

,/

-3.5 kgm
22 -25 ft. Ibs.

~
m
\

"--J

~12

8 ~-

1.3 -1.7 kgm/9-12ft.lbs.

m-

c:m' ~~

--'7

~
2.7 -3.4 kgm 20 -25 ft. Ibs.

Removal steps 1 .Drain plug 2. Filler plug 3. Battery terminal connection 4. Battery 5. Battery tray 6. Clutch cable connection 7. Ground cable connection 8. Shift cable connection 9. Select cable connection 10. Backup lamp harness connector connection 11. Starter wire connection. 12. Speedometer cable connection 13. Starter motor

13

11/
NOTE

(1) Reverse the removal procedures to reinstall. (2) m Non-reusable parts.

09UO122

" 1~
--'ftV" i\1\ 1 -3.0 -~~ ,6 ~,

22-16

MANUAL TRANSMISSION

Transmission Assembly

MANUAL

TRANSMISSION

-Transmission

Assembly

22-17

SERVICE POINTS OF REMOVAL

..15. DISCONNECTION OF LOWER ARM BALL JOINT . Using the special tool, disconnect the lower arm ball joint from the knuckle. Caution 1. Be sure to tie the cord of the special 2. nearby part. Loose the nut but do not remove it. tool to the

..16.

DISCONNECTION

OF TIE ROD END

Using the special tool, disconnect the tie rod end from the knuckle Caution 1. Be sure to tie the cord of the special nearby part. 2. Loose the nut but do not remove it., tool to the

..17.

DISCONNECTION

OF DRIVE SHAFT

Remove drive shaft in the following procedure. 1. Insert a pry bar between the transmission case and the drive shaft, and then pry the drive shaft from the transmission. Caution 1. Do not insert the pry bar too deep or the oil seal will be damaged. 2. Reckless bending of the T.J. joint will cause damage to the joint. Therefore, use care. 3. Do not insert the bar between the transmission case and drive shaft: doing so will damage the dust cover of the drive shaft. If the drive shaft is pulled out from the B.J. side, there is the danger of causing damage to the T.J.

22-18

MANUAL TRANSMISSION

Transmission Assembly

TRANSMISSION
F5M21

ASSEMBLY

FIVE SPEED TRANSMISSION

MANUAL TRANSMISSION
DISASSEMBLY AND REASSEMBLY

Transmission Assembly

22-19

1.5 -2.2 kgm

3.0 -3.5 kgm
22 -25 ft. Ibs.

m9

J
~\\

13 v

14-16 kgm

V' ~
(I

11 -15 ft. Ibs.

3.0 -4.2 kgm

22 -30 ft. Ibs.

m3--<9>

2-1

102-115ft.lbs. .~ 14 12 ~~""
15
1

""I "

..-1
14 -16 kgm

16

17
4 5 i

102 -115 ft. Ibs.

6 19

21

\)

6-8
;f;

J~

J
-7

-0.5 kgm 2.5 -3.5 ft. Ibs.

Disassembly steps

..1.
2. 3. 4. 5. 6. 7. ..8. 9. 10. 11. ..12. ..13. 14. 15. 16. 17. 18. 19. 20. 21.

Rearcover
Backup lamp switch Gasket Poppet plug Poppet spring Poppet ball Speedometer driven gear assembly Air breather Spring pin Lock nut Locknut 5th speed synchronizer assembly 5th speed shift fork Synchronizer ring 5th speed gear Needle bearing Bearing sleeve Snap ring Spacer. Roller bearing 5th speed intermediate gear

NOTE

(1) (2) (3) (4)

Reverse the disassembly procedures to reassembly ..: Refer to "Service Points of Dissasembly". ..: Refer to "Service Points of Reassembly". m: Non-reusable parts
TFMOOO1

""

_0.3 -11m -1 ,,'