MANUAL TRANSMISSION GROUP 22A 22A-1 CONTENTS TRANSMISSION CONTROL... 22A-5 GENERAL INFORMATION... 22A-2 SERVICE SPECIFICATION...

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1 22A-1 GROUP 22A MAUAL TRASMISSIO COTETS GEERAL IFORMATIO A-2 SERVICE SPECIFICATIO A-2 LUBRICAT A-2 SPECIAL TOOLS A-3 O-VEHICLE SERVICE A-4 TRASMISSIO OIL LEVEL CHECK A-4 TRASMISSIO OIL REPLACEMET... 22A-4 TRASMISSIO COTROL A-5 REMOVAL AD ISTALLATIO A-5 SHIFT LEVER ASSEMBLY A-7 DISASSEMBLY AD REASSEMBLY A A-8 REMOVAL AD ISTALLATIO <F5M41> 22A-8 REMOVAL AD ISTALLATIO <F5M42> A-13

2 22A-2 GEERAL IFORMATIO GEERAL IFORMATIO The manual transmission come in two models, namely, F5M41 and F5M42. M Item Specification Transmission model F5M41-1-V7B3 F5M41-1-R7B6 F5M42-2-R7B4 Engine model 4G13 4G18 4G63 Transmission type 5-speed, floor-shift Transmissiom gear ratio 1st nd rd th th Reverse Final reduction ratio (Differential gear ratio) Speedometer gear ratio 30/36 SERVICE SPECIFICATIO Item Standard value Protruding length of stabilizer bar mounting bolt mm 22 ± 1.5 M LUBRICAT Item Specified lubricant Transmission model Quantity L Transmission oil Gear oil SAE 75W-85W or 75W-90 F5M conforming to API GL-4 F5M M

3 22A-3 SPECIAL TOOLS SPECIAL TOOLS M Tool umber ame Use MB Engine hanger assembly When the engine hanger is used: Supporting the engine assembly during removal and installation of the transmission assembly B MB Engine hanger balancer OTE: Special tool MB is a part of engine hanger attachment set MB B MB Engine hanger B MB Engine hanger MB Slide bracket (HI) F A D B C E MB A: MB B: MB C: MB D: MB E: MB F: MB Engine hanger A: Joint (50) 2 B: Joint (90) 2 C: Joint (140) 2 D: Foot (standard) 4 E: Foot (short) 2 F: Chain and hook assembly B A AC B MB Ball joint remover Knuckle and tie rod end ball joint disconnection OTE: Steering linkage puller (MB or MB991113)is also used to disconnect knuckle and tie rod end ball joint. MB A: MB B: MB Axle shaft puller A: Puller shaft B: Puller bar Removal of the drive shaft MB990241AB

4 22A-4 O-VEHICLE SERVICE Tool umber ame Use MB Plug Prevention of transmission fluid drain and of entry of foreign objects MB End yoke holder Fixing of the hub B A B C AC100320AB A: MB B: MB C: MB A, B: Front hub remover and installer C: Spacer Removal of the hub Provisional holding of the wheel bearing Measurement of hub starting torque Measurement of wheel bearing axial play OTE: MB991000, which belongs to MB990998, should be used as a spacer. TRASMISSIO OIL LEVEL CHECK M O-VEHICLE SERVICE TRASMISSIO OIL REPLACEMET M Filler plug hole Filler plug Transmission oil Filler plug Drain plug AC210553AB 1. Remove the filler plug. 2. Check that the oil level is up to the lower edge of the filler plug hole. 3. Check that the oil is not noticeably dirty. 4. Tighten the filler plug to the specified torque. Tightening torque: 32 ± 2 m AC203434AC 1. Remove the filler plug. 2. Remove the drain plug and drain the oil. 3. Tighten the drain plug to the specified torque. Tightening torque: 32 ± 2 m 4. Fill with gear oil API classification GL-4 SAE 75W-85W or 75W-90 until the level comes to the lower portion of filler plug hole. Quantity: 2.1 L <F5M41> Quantity: 2.2 L <F5M42> 5. Tighten the filler plug to the specified torque. Tightening torque: 32 ± 2 m

5 22A-5 TRASMISSIO COTROL TRASMISSIO COTROL REMOVAL AD ISTALLATIO M ! WARIG Be careful not to subject the SRS-ECU to any shocks during removal and installation of the shift cable and select cable assembly. Pre-removal and Post-installation Operation Air Cleaner Assembly Removal and Installation (Refer to GROUP 15, Air Cleaner P.15-2). Battery and Battery Tray Removal and Installation ± 2 m ± 2 m Gearshift cable and select cable assembly removal steps 1. Gearshift lever knob Front floor console (Refer to GROUP 52A P.52A-7). 2. Sleeve 3. Snap pin 4. Select cable connection (Gearshift lever side) >>B<< 5. Gearshift cable clip 6. Gearshift cable connection (Gearshift lever side) SRS-ECU (Refer to GROUP 52B P.52B-206). 7. Snap pin <<A>> >>A<< 8. Select cable connection (Transmission side) <<A>> >>A<< 9. Gearshift cable connection (Transmission side) AC304524AB Gearshift cable and select cable assembly removal steps >>A<< 10. Gearshift link clip 11. Gearshift cable and select cable assembly Gearshift lever assembly removal steps 1. Gearshift lever knob Front floor console (Refer to GROUP 52A P.52A-7). 2. Sleeve 3. Snap pin 4. Select cable connection (Gearshift lever side) >>B<< 5. Gearshift cable clip 6. Gearshift cable connection (Gearshift lever side) 12. Gearshift lever assembly

6 22A-6 TRASMISSIO COTROL REMOVAL SERVICE POITS <<A>> SELECT CABLE COECTIO (TRASMISSIO SIDE)/GEAR SHIFT CABLE COECTIO (TRASMISSIO SIDE)/GEARSHIFT LIK CLIP REMOVAL ew gearshift link clip Claws Gearshift cable, Select cable Cable bracket Shift cable, Select cable Gearshift link clip AC210556AB Push up the claws of the gearshift link clip using a screwdriver, etc., and then remove the gearshift link clip from the bracket together with the cables. ISTALLATIO SERVICE POITS >>A<< GEARSHIFT CABLE AD SELECT CABLE ASSEMBLY/GEARSHIFT CABLE COECTIO (TRASMISSIO SIDE)/SELECT CABLE COECTIO (TRASMISSIO SIDE)/GEARSHIFT LIK CLIP ISTALLATIO Select lever AC210558AB Insert thoroughly the gearshift link clip, shift cable and select cable until they click in place. 3. After installing the new gearshift link clip to the cable bracket of the transmission, install the shift cable and select cable to the cable bracket. OTE: The clip is reversible. 4. Move the shift lever to all positions and check that the operation is smooth. >>B<< GEAR SHIFT CABLE CLIP ISTALLATIO eutral position AC210557AB 1. Set the transmission side shift lever and the passenger compartment side shift lever to the neutral position. 2. Install the painted part of the shift cable end (transmission side) and painted part of the select cable (transmission side) facing the snap pin. 9.5 mm 5-8 mm AC210559AB 1. Make sure that there is no excessive play at the shift cable end gearshift cable clip. If there is excessive play or the gearshift cable clip is disengaged from the shift cable end, check the clip opening gap. If the gap is more than 9.5 mm, squeeze the gearshift cable clip until the relaxed gap reaches 5 to 8 mm.

7 22A-7 SHIFT LEVER ASSEMBLY 2. Engage the gearshift cable clip with the shift cable hook securely, and push the gearshift cable clip with your thumbs until it clicks in place. 3. Install the shift cable to the shift lever. AC210560AB SHIFT LEVER ASSEMBLY DISASSEMBLY AD REASSEMBLY M ± 2 m ± 1 m Disassembly steps 1. Gearshift link bolt 2. Gearshift select lever 3. Gearshift link bushing 4. Gearshift lever spring 5. Gearshift link collar 6. Bolt 7. Gearshift lever retainer AC203438AC Disassembly steps (Continued) 8. Gearshift lever 9. Gearshift link bushing 10. Gearshift lever bracket distance piece 11. Gearshift link bushing 12. Gearshift lever bracket

8 22A-8 REMOVAL AD ISTALLATIO <F5M41> M *: Indicates parts which should be temporarily tightened, and then fully tightened after installing the engine into the vehicle. Pre-removal Operation Under Cover Removal Transmission Oil Draining (Refer to P.22A-4.) Battery and Battery Tray Removal Air Cleaner Assembly Removal (Refer to GROUP 15, Air Cleaner P.15-2.) Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P ) Post-installation Operation Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P ) Air Cleaner Assembly Installation (Refer to GROUP 15, Air Cleaner P.15-2.) Battery and Battery Tray Installation Transmission Oil Filling (Refer to P.22A-4.) Under Cover Installation 18 ± 3 m 9 18 ± 3 m 18 ± 3 m ± 5 m Removal steps 1. Transmission harness clamp 2. Back-up lamp switch connector 3. Vehicle speed sensor connector 4. Snap pin 5. Select cable connection <Transmission side> 6. Gearshift cable connection <Transmission side> 30 ± 3 m AC304230AB Removal steps (Continued) 7. Cable bracket and cable assembly <Transmission side> <<A>> 8. Starter motor connecting bolts 9. Clutch release cylinder and clutch oil pipe <<B>> 10. Transmission assembly upper part coupling bolts

9 22A-9 47 ± 7 m* 80 ± 7 m* ± 10 m ± 5 m ± 6 m ± 29 m ± 10 m 25 ± 5 m ± 1.0 m 52 ± 7 m* 23 ± 4 m ± 10 m 27 Removal steps 11. Wheel speed sensor cable connection <Vehicles with ABS> 12. Brake hose clamp <<C>> >>E<< 13. Drive shaft nut >>E<< 14. Washer >>D<< 15. Self-locking nut (stabilizer bar connection) 16. Stabilizer bar connection 17. Lower arm connecting bolt <<D>> 18. Self-locking nut (tie rod end connection) 19. Tie rod end connection 20. Lower arm connection <<E>> >>C<< 21. Drive shaft <L.H.> 22. Circlip <<E>> >>C<< 23. Drive shaft <R.H.> 24. Circlip 69 ± 10 m AC304295AB Removal steps (Continued) >>B<< 25. Transmission stay 26. Bell housing cover Rear roll stopper connecting bolt (Refer to GROUP 32, Engine roll stopper P.32-7.) 27. Centremember assembly 28. Rear roll mount bracket <<F>> 29. Transmission mount assembly >>A<< 30. Transmission mount stopper 31. Transmission mount bracket <<G>> Engine assembly support Support the transmission with a transmission jack 32. Transmission assembly lower part coupling bolts 33. Transmission assembly

10 22A-10 REMOVAL SERVICE POITS <<A>> STARTER MOTOR COECTIG BOLTS REMOVAL Remove the starter motor with the starter motor harness still connected, and secure it inside the engine compartment away from the engine. 1. Install special tool ball joint remover (MB991897) as shown in the figure. Parallel Bolt <<B>> UPPER PARTS COUPLIG BOLTS REMOVAL Do not fully unscrew the bolts from the engine and transmission assembly. Only loosen the bolts. Knob Good <<C>> DRIVE SHAFT UT REMOVAL Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft nut is loosened. Bad AC106821AB 2. Turn the bolt and knob as necessary to make the jaws of special tool parallel, tighten the bolt by hand and confirm that the jaws are still parallel. OTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure. 3. Tighten the bolt with a wrench to disconnect the tie rod end. <<E>> DRIVE SHAFT REMOVAL MB AC AC Use special tool end yoke holder (MB990767) to fix the hub and remove the drive shaft nut. MB <<D>> SELF-LOCKIG UT (TIE ROD ED COECTIO) REMOVAL Do not remove the nut from ball joint. Loosen it and use special tool to avoid possible damage to ball joint threads. Hang special tool with cord to prevent it from falling. MB AC AE 1. Use the following special tools to push out the drive shaft from the hub. Axle shaft puller (MB990241) End yoke holder (MB990767) Cord ut MB Drive shaft Ball joint Bolt AC208247AD AC102551AC 2. Remove the drive shaft from the hub by pulling the bottom of the brake disc towards you.

11 22A-11 Do not pull on the drive shaft; doing so will damage the TJ; be sure to use the pry bar. When pulling the drive shaft out from the transmission, be careful that the spline part of the drive shaft does not damage the oil seal. Transmission TJ assembly <<F>> TRASMISSIO MOUT ASSEMBLY REMOVAL While supporting the engine and transmission assembly with a garage jack, remove the transmission mount assembly. <<G>> EGIE ASSEMBLY SUPPORTIG 1. Support the engine and transmission assembly with a garage jack and remove the transmission mounting body side bracket, then install the engine hanger (special tool MB or MB991928). Pry bar AC100141AG 3. Insert a pry bar between the transmission case and the drive shaft, and then pry and remove the drive shaft from the transmission. MB AC AE MB AC AC 4. Use special tool plug (MB991460) to prevent the entry of foreign material into the transmission case. 2. <Engine hanger (special tool MB991895) is used> (1) Set special tool MB to the strut mounting nuts and the radiator support upper insulator mounting bolts, which are located in the engine compartment, as shown. OTE: Adjust the engine hanger balance by sliding the front side foot of the engine hanger (special tool MB991895). MB MB MB MB MB AC104013AF AC AC Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft is removed. If, however, vehicle weight must be applied to the bearing in moving the vehicle, temporarily secure the wheel bearing by using the following special tools. Spacer (MB991000) Front hub remover and installer (MB991017) (2) Set the chains of engine hanger (special tool MB991527) and engine hanger balancer (special tool MB991454), support the engine and transmission assembly and remove the garage jack, and unscrew the transmission assembly upper part coupling bolts that were priorly loosened. 3. <Engine hanger (special tool MB991928) is used>

12 22A-12 (1) Assemble the engine hanger (special tool MB991928). Set following parts to the base hanger. Slide bracket (HI) Foot (standard) (MB991932) Joint (90) (MB991930) ISTALLATIO SERVICE POITS >>A<< TRASMISSIO MOUT STOPPER ISTALLATIO Engine side Arrow Transmission mount stopper MB Transmission mount bracket MB MB AC AD (2) Set the engine hanger (special tool MB991928) to the strut mounting nuts and the radiator support upper insulator mounting bolts, which are located in the engine compartment, as shown. OTE: Adjust the engine hanger balance by sliding the slide bracket (HI). MB MB MB AC AC (3) Set the chains of engine hanger (special tool MB991527) and engine hanger balancer (special tool MB991454), support the engine and transmission assembly and remove the garage jack, and unscrew the transmission assembly upper part coupling bolts that were priorly loosened. AC210408AB Install the transmission mount stopper so that the arrow points as shown in the illustration. >>B<< TRASMISSIO STAY ISTALLATIO Install the transmission stay as below. 1. Tighten the engine-side bolts to the specified torque. Tightening torque: 23 ± 4 m 2. Tighten the transmission-side bolts to the specified torque. Tightening torque: 48 ± 6 m >>C<< DRIVE SHAFT ASSEMBLY ISTALLATIO When installing the drive shaft, be careful that the spline part of the drive shaft does not damage the oil seal. >>D<< SELF-LOCKIG UT (STABILIZER BAR COECTIO) ISTALLATIO A AC210393AC Install the stabilizer rubber and collar as shown in the figure, and tighten the self-locking nut so that the protruding length of the stabilizer bar mounting bolt protruding part meets its standard value (A). Standard value (A): 22 ± 1.5 mm

13 >>E<< WASHER/DRIVE SHAFT UT ISTALLATIO Washer MB A-13 AC102465AD 1. Be sure to install the drive shaft washer in the specified direction. Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged. 2. Using special tool end yoke holder (MB990767), tighten the drive shaft nut to the specified torque. Tightening torque: 245 ± 29 m REMOVAL AD ISTALLATIO <F5M42> M *: Indicates parts which should be temporarily tightened, and then fully tightened after installing the engine into the vehicle. Pre-removal Operation Under Cover Removal Transmission Oil Draining (Refer to P.22A-4.) Battery and Battery Tray Removal Air Cleaner Assembly Removal (Refer to GROUP 15, Air Cleaner P.15-2.) Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P ) Post-installation Operation Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P ) Air Cleaner Assembly Installation (Refer to GROUP 15, Air Cleaner P.15-2.) Battery and Battery Tray Installation Transmission Oil Filling (Refer to P.22A-4.) Under Cover Installation 18 ± 3 m 18 ± 3 m ± 3 m AC304410AB Removal steps 1. Transmission harness clamp 2. Back-up lamp switch connector Removal steps (Continued) 3. Vehicle speed sensor connector

14 22A-14 Removal steps (Continued) 4. Clutch release cylinder and clutch oil pipe 5. Vapour hose connection 6. Canister 7. Snap pin 8. Select cable connection <Transmission side> 9. Gearshift cable connection <Transmission side> 10. Cable bracket and cable assembly <Transmission side> Starter motor assembly (Refer to GROUP 16 P ) 82 ± 7 m* 47 ± 7 m* 48 ± 5 m ± 5 m ± 5 m ± 29 m ± 5 m ± 1.0 m 26 ± 5 m 69 ± 10 m ± 10 m ± 7 m* ± 10 m 27 Removal steps <<A>> 11. Transmission assembly upper part coupling bolts 12. Wheel speed sensor cable connection <Vehicles with ABS> 13. Brake hose clamp <<B>> >>D<< 14. Drive shaft nut 69 ± 10 m AC AC AB Removal steps (Continued) >>D<< 15. Washer >>C<< 16. Self-locking nut (stabilizer bar connection) 17. Stabilizer bar connection 18. Lower arm connecting bolt <<C>> 19. Self-locking nut (tie rod end connection)

15 Removal steps (Continued) 20. Tie rod end connection 21. Lower arm connection <<D>> >>B<< 22. Drive shaft <L.H.> 23. Circlip <<D>> >>B<< 24. Drive shaft <R.H.> 25. Circlip 26. Bell housing cover Rear roll stopper connecting bolt (Refer to GROUP 32, Engine roll stopper P.32-7.) 27. Centremember assembly 28. Rear roll mount bracket <<E>> 29. Transmission mount assembly >>A<< 30. Transmission mount stopper 31. Transmission mount bracket <<F>> Engine assembly support Support the transmission with a transmission jack 32. Transmission assembly lower part coupling bolts 33. Transmission assembly 22A-15

16 22A-16 REMOVAL SERVICE POITS <<A>> UPPER PARTS COUPLIG BOLTS REMOVAL Do not fully unscrew the bolts from the engine and transmission assembly. Only loosen the bolts. Parallel Bolt <<B>> DRIVE SHAFT UT REMOVAL Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft nut is loosened. MB AC AC Knob Good Bad 2. Turn the bolt and knob as necessary to make the jaws of special tool parallel, tighten the bolt by hand and confirm that the jaws are still parallel. OTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure. 3. Tighten the bolt with a wrench to disconnect the tie rod end. <<D>> DRIVE SHAFT REMOVAL AC106821AB Use special tool end yoke holder (MB990767) to fix the hub and remove the drive shaft nut. <<C>> SELF-LOCKIG UT (TIE ROD ED COECTIO) REMOVAL Do not remove the nut from ball joint. Loosen it and use special tool to avoid possible damage to ball joint threads. Hang special tool with cord to prevent it from falling. Cord MB MB AC AE 1. Use the following special tools to push out the drive shaft from the hub. Axle shaft puller (MB990241) End yoke holder (MB990767) ut MB Ball joint Bolt AC208247AD Drive shaft 1. Install special tool ball joint remover (MB991897) as shown in the figure. AC102551AC 2. Remove the drive shaft from the hub by pulling the bottom of the brake disc towards you.

17 22A-17 Do not pull on the drive shaft; doing so will damage the TJ; be sure to use the pry bar. When pulling the drive shaft out from the transmission, be careful that the spline part of the drive shaft does not damage the oil seal. Transmission <<E>> TRASMISSIO MOUT ASSEMBLY REMOVAL While supporting the engine and transmission assembly with a garage jack, remove the transmission mount assembly. <<F>> EGIE ASSEMBLY SUPPORTIG 1. Support the engine and transmission assembly with a garage jack and remove the transmission mounting body side bracket, then install the engine hanger (special tool MB or MB991928). TJ assembly Pry bar AC100141AG 3. Insert a pry bar between the transmission case and the drive shaft, and then pry and remove the drive shaft from the transmission. MB AC AE MB AC AC 4. Use special tool plug (MB991460) to prevent the entry of foreign material into the transmission case. 2. <Engine hanger (special tool MB991895) is used> (1) Set special tool MB to the strut mounting nuts and the radiator support upper insulator mounting bolts, which are located in the engine compartment, as shown. OTE: Adjust the engine hanger balance by sliding the front side foot of the engine hanger (special tool MB991895). MB MB MB MB MB AC104013AF AC AC Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft is removed. If, however, vehicle weight must be applied to the bearing in moving the vehicle, temporarily secure the wheel bearing by using the following special tools. Spacer (MB991000) Front hub remover and installer (MB991017) (2) Set the chains of engine hanger (special tool MB991527) and engine hanger balancer (special tool MB991454), support the engine and transmission assembly and remove the garage jack, and unscrew the transmission assembly upper part coupling bolts that were priorly loosened. 3. <Engine hanger (special tool MB991928) is used> (1) Assemble the engine hanger (special tool MB991928). Set following parts to the base hanger.

18 22A-18 Slide bracket (HI) Foot (standard) (MB991932) Joint (90) (MB991930) MB Install the transmission mount stopper so that the arrow points as shown in the illustration. >>B<< DRIVE SHAFT ASSEMBLY ISTALLATIO When installing the drive shaft, be careful that the spline part of the drive shaft does not damage the oil seal. MB MB AC AD (2) Set the engine hanger (special tool MB991928) to the strut mounting nuts and the radiator support upper insulator mounting bolts, which are located in the engine compartment, as shown. OTE: Adjust the engine hanger balance by sliding the slide bracket (HI). >>C<< SELF-LOCKIG UT (STABILIZER BAR COECTIO) ISTALLATIO A AC210393AC Install the stabilizer rubber and collar as shown in the figure, and tighten the self-locking nut so that the protruding length of the stabilizer bar mounting bolt protruding part meets its standard value (A). Standard value (A): 22 ± 1.5 mm MB MB MB >>D<< WASHER/DRIVE SHAFT UT ISTALLATIO AC AC (3) Set the chains of engine hanger (special tool MB991527) and engine hanger balancer (special tool MB991454), support the engine and transmission assembly and remove the garage jack, and unscrew the transmission assembly upper part coupling bolts that were priorly loosened. ISTALLATIO SERVICE POITS >>A<< TRASMISSIO MOUT STOPPER ISTALLATIO Engine side Transmission mount bracket Arrow Transmission mount stopper Washer MB AC102465AD 1. Be sure to install the drive shaft washer in the specified direction. Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged. 2. Using special tool end yoke holder (MB990767), tighten the drive shaft nut to the specified torque. Tightening torque: 245 ± 29 m AC210408AB