Pages 16-20-4 Thru 16-20-9A
16-20-4 Transmission, Manual-M5R2
DESCRIPTION (Continued)
IDENTIFICATION
The Vehicle Safety Compliance Certification Label (located on the driver's door lock pillar) lists applicable transmission identification codes. For identification of the label codes, refer to Section 10-01. Manual transmissions are equipped with service identification tags. The M5R2 transmission service tag is located on the LH side of the transmission.
DIAGNOSIS AND TESTING
For diagnosis and testing procedures, refer to Section 16-10.
REMOVAL AND INSTALLATION
Transmission Removal
1. Remove shift knob.
2. Remove console trim plate.
3. Remove shifter retaining bolts and remove shifter
4. Raise vehicle on a hoist.
5. Remove catalytic converter.
6. Remove body reinforcement.
7. Remove exhaust pipe and muffler assembly.
8. To maintain driveshaft balance, mark the rear driveshaft yoke and the companion flange so the driveshaft can be installed in its original position.
9. Remove four bolts retaining driveshaft to companion flange.
16-20-5 Transmission, Manual-M5R2
REMOVAL AND INSTALLATION (Continued)
10. Loosen axle assembly rear mounting nuts to crossmember approximately 6.4 mm (0.25 inch).
11. Position axle stand under front of axle housing and remove forward mounting nuts and bushings.
12. Pull vent tube from hole in sub-frame.
13. Lower front of axle housing with axle stand and slide driveshaft out of transmission above axle housing. Let driveshaft rest on the front drives support and axle assembly.
CAUTION: Use care when positioning driveshaft so not to nick, burr or contaminate driveshaft yoke or companion flange.
14. Disconnect hydraulic clutch line.
15. Disconnect electrical connectors.
16. Remove starter.
17. Position transmission jack.
18. Remove crossmember.
19. Remove bellhousing bolts.
20. Remove transmission.
Installation
1. Secure transmission assembly on transmission jack.
2. Position transmission into vehicle.
3. Install bellhousing bolts. Tighten to 55-68 N-m (40-50 ft.lbs.).
4. Install crossmember. Tighten bolts to 47-68 N-m (35-50 ft.lbs.).
5. Remove transmission jack.
6. Connect electrical connectors.
7. Connect hydraulic clutch line.
8. Slide driveshaft slip yoke into transmission.
NOTE: Lubricate the yoke splines with Long Life Lubricant C1AZ-19590-BA or equivalent.
9. Raise axle housing with axle stand and install bushings and retaining nuts. Tighten to 92-136 N-m (68-100 ft.lbs.). Remove axle stand.
10. Tighten axle assembly rear mounting nuts to 165-211 N-m (122-156 ft.lbs.).
16-20-6 Transmission, Manual-M5R2
REMOVAL AND INSTALLATION (Continued)
11. Position vent tube in hole of sub-frame.
12. Align driveshaft yoke and companion flange index marks and install retaining bolts. Tighten to 95-129 N-m (70-95 ft.lbs.).
NOTE: Ensure driveshaft yoke and companion flange are free of nicks, burrs and contamination.
13. Install catalytic converter assembly.
14. Install exhaust pipe and muffler assembly.
15. Install body reinforcement.
16. Install starter.
17. Lower vehicle.
18. Position shifter and install retaining bolts. Tighten to 24-33 N-m (18-24 ft.lbs.).
19. Install console trim plate and shifter knob.
DISASSEMBLY AND ASSEMBLY
Transmission
Disassembly
1. Using a 24 mm wrench, remove transmission drain plug and drain transmission.
2. Using a 10 mm socket, remove four shift control housing bolts and pry gently on the housing.
3. Using a 5/32-inch punch and hammer, remove the offset lever retaining pin located in the extension housing. Retrieve offset lever retaining pin using a pencil magnet.
NOTE: If it is necessary to remove rear seal from extension housing, extension housing must be installed to transmission case. Remove extension housing rear seal using Seal Remover T74P-77248-A or equivalent.
4. Using a 14 mm socket, remove nine extension housing retaining bolts. Pry gently at locations provided on extension housing and transmission case. Remove extension housing from case.
NOTE: Remove roll pin using a pencil magnet.
16-20-7 Transmission, Manual-M5R2
DISASSEMBLY AND ASSEMBLY (Continued)
5. Remove countershaft oil funnel by hand. Note position of tabs for assembly.
6. Remove shift rail and selector finger assembly from transmission case.
7. Using a 12 mm wrench, remove 10 top cover assembly retaining bolts. Remove top cover assembly.
8. Remove offset lever and control selector spring from extension housing.
9. If necessary, remove gear shift lever guide using a 10 mm socket to remove three bolts.
10. If necessary, remove fifth/reverse inhibitor assembly using a 10 mm socket to remove two bolts.
11. If necessary to remove shift rail bushings, remove bushing retaining rings. Using a 10 mm socket, remove four extension housing cover bolts and pry cover up gently. Using a hammer and suitable tool, tap bushings free from case.
16-20-8 Transmission, Manual-M5R2
DISASSEMBLY AND ASSEMBLY (Continued)
12. If necessary, remove rear oil trough from extension housing using a 10 mm socket. This oil trough provides lubrication to the extension housing bushing.
13. Remove and discard anti-spill oil seal from output shaft.
14. Remove the speedometer snap ring, drive gear and steel ball.
NOTE: For reference during assembly, observe and record speedometer drive color.
Green-E8TZ-17285-C (8 teeth RH)
15. Lock transmission into first and third gears.
16. Using Countershaft Locknut Staking Tool T77J- 7025-F or equivalent, release the staked areas securing output shaft and countershaft locknuts.
CAUTION: Staked areas of locknuts must be fully released or damage to shaft threads will result.
17. Using Mainshaft Locknut Wrench T88T-7025-A and Remover Tube T77J-7025-C or equivalents, remove and discard output shaft locknut.
18. Using a 32 mm socket, remove and discard the countershaft rear bearing locknut. Remove the countershaft bearing and thrust washer.
16-20-9 Transmission, Manual-M5R2
DISASSEMBLY AND ASSEMBLY (Continued)
19. Using a 17 mm wrench, remove reverse idler shaft fixing bolt and washer. Remove reverse idler gear assembly by grasping and pulling rearward.
20. Remove output shaft rear bearing from output shaft using Remover/Replacer Tube T85T- 7025-A, TOD Forcing Screw T84T-7025-B, Bearing Puller T77J-7025-H, and Puller Ring T77J-7025-A or equivalent.
16-20-9a Transmission, Manual-M5R2
DISASSEMBLY AND ASSEMBLY (Continued)
21. Remove reverse gear from output shaft by hand.
22. Remove sleeve from output shaft.
23. Remove counter reverse gear with two needle bearings and reverse synchronizer ring (brass).
24. Remove thrust washer and split washer from countershaft.
25. Using a 12 mm wrench, remove fifth/reverse shift rod fixing bolt.
26. Using a 10 mm wrench, remove the fifth/ reverse counter lever assembly fixing bolt and inner circlip. Remove counter lever assembly from transmission case.
NOTE: Do not remove the Torx nut retaining the counter lever pin at this time.
27. Remove the following parts as an assembly:
^ Fifth/reverse synchronizer hub and sleeve assembly (countershaft).
^ Fifth/reverse shift fork and rod.
^ Fifth gear, fifth gear bearing assembly (two piece) and fiber-lined blocker ring.
NOTE: Do not separate steel ball and spring (removed from shift fork groove) unless necessary.