CONTENTS

GENERAL 2

General Information 2

Outline of Transmission Plant 2

Special Tools 3

Adjustment Snap Rings and Spacers ...4General Specifications 5

Service Specifications 5

Sealant & Adhesive, lubricants 6

Torque Specifications 7

Troubleshooting 8Transmission Oil 9

TRANSMISSION CONTROL 10

Shift Lever Assembly 13

TRANSMISSION ASSEMBLY 15

INTERMEDIATE GEAR ASSEMBL Y 34

OUTPUT SHAFT ASSEMBLY 40

DIFFERENTIAL ASSEMBLY 41

SHIFT CONTROL MECHANISM 44

SHIFT FORK ASSEMBLY 45

46

5TH SPEED SYNCHRONIZERASSEMBLY

CLUTCH HOUSING ASSEMBLY 48

SPEEDOMETER DRIVEN GEARASSEMBLY 51

BACK-UP LAMP SWITCH 52

INPUT SHAFT ASSEMBLY 29

MANUAL TRANSMISSION -General Information22-2

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 OF TRANSMISSION PLANT

The F5M21 series is a five speed manual transmission which has the gear reduction, ratio selection and differential

functions combined into one unit and housed in the aluminium diecdst housing and case.

All these manual transmission have a large diameter ,large capacity synchronizer which, combined with improvedshift 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 TOOLS

Tool Number Name Use

MD998019 Lock pin extractor Removal of springpin and lock pin

MD998245 lock pin installer

-

Installation ofspring pin and lock

pin

MD998802 Input shaft holder Installation andremoval of inputshaft and intermediate gear lo~k nut

MD998320 Bearing installer Installation of inputshaft bearing andinput shaft gear

MD998325 Differential oil sealinstaller

Installation ofdifferential oil seal

MD998369 Bearing installer Installation of Inputshaft front bearing

MD998321 Oil seal installer Installation of input shaftfront oil seal

MD998350 Bearing installer Installation of Intermediategear bearing andintermediate gear.

MD998801 Bearing remover Removal of inputshaft, intermediategear and outputshaft bearings and gears

~

MB991113/MB990635

Steering linkagepuller

Removal of thelower arm joint andtie rod end ball

joint.

MANUAL TRANSMISSION Adjustment Snap Rings and Spacers22-4

ADJUSTMENT SNAP RINGS AND SPACERS

MANUAL TRANSMISSION -Specifications 22-5

SPECIFICATIONSGENERAL SPECIFICATIONS

Items Specifications

F5M21-1-VRAC

4G13

Gear shift control

[cable-ope rated]

3,363

1.9471.285

0.939

0.7773.083

4.322

31/36

Model

Applicable engineGear ratio

1 st

2nd3rd

4th

5th

Reverse

Final gear ratio

Speedometer gear ratio (driven/drive)

SERVICE SPECIFICATIONS

Items Standard mm{in)

TransmissionInput shaft bearing end play Intermediate gear bearing end play 0.01 T -0.12L (0.0004T -0.005L)

0.01T -0.14L (0.0004T -0.006L)

Intermediate shaft end play O.OSL -O.17L (O.OO2L -O.OO7L)

Output shaft end play O.O5T -O.17l (O.OO2T -O.OO7l:i

DifferentialDifferential case end play O.O5l -O.17l (O.OO2l -O.OO7l)

Differential pinion backlash 0.025L -0.15L (0.001 L -0.006L

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

MANUAL TRANSMISSION22-6 Sealant and Adhesives / lubricants

SEALANTS AND ADHESIVES

Items Quantity

As requiredTransmission case -

Clutch housing mating surfaces

Specified sealants and adhesives

Proton genuine sealantPart No. MD997740 or equivalent

Transmission case-rear cover mating surfaces

As requiredProton genuine sealantPart No. MD997740 or equivalent

Differential drive gear bolts 3M STUD locking No. 4170or equivalent

As required

3M STUD Locking No. 4170or equivalent

Bearing retainer bolts(flush bolt only)

As required

3M SUPER WEATHERSTRIP No. 8001or equivalent

Air breather As required

LUBRICANTS

QuantityItems Specified Lubricant

Manual transmission oil lit

(Imp.qts) 1.8 (1.58)Hypoid gear oil SAE75W-85W or 75W-90Wconforming to API GL-4 or higher

Shift lever and bushingcontacting surface

Wheel bearing greaseSAE J310a,NLGI grade#2EP

As required

Inside of dust coverAs required

Wheel bearing greaseSAE J31 Ga,NLGI grade # 2EP

Shift lever sliding portion Wheel bearing greaseSAE J310a,NLGI grade # 2EP

As required

Hypoid gear oil SAE75W-85W or 75W-90W

Speedometer drivengear shaft As required

MANUAL TRANSMISSION 22-7Torque Specifications

TORQUE SPECIFICATIONS

TorqueItems (ft. Ibs)kgm

(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)

0.9 -1.40.9 -1.41 .9 -2.81.9 -2.83.0 -3.53.0 -3.52.7- 3.53.0 -4.09.0 -11.0

9.0 -11.0

6.0 -7.04.5 -6.01 .0 -1.2

1.5 -3.56.0 -7.21.5 -2.2

3.0 -3.5

3.0 -3.53.0 -4.2

0.3 -0.514-1614-164.3 -5.53.5 -4.21.5 -2.2

3.0 -3.515 -2.2

1.5 -2.2

13-142.0 -2.7

4.3 -5.5

Bracket assembly attaching bolt ..'.'.'."""" '..".'.'

Control cable attaching bolt Shift lever to lever (A) Lever (A) to bracket assembly Transmission drain plug Transmission filler plug ..".,..,.""",.,.",.."".,..,.."""""

Starter motor to transmission Transmission mount bracket to body Transmission mount bracket to transmission bracket

Transmission bracket to transmission Roll rod to transmission Roll rod to roll rod bracket .'."'.."""'."""".."".."""""

Bell housing cover to transmission Tie rod end to knuckle Lower arm ball joint to knuckle Rear cover bolt , Backup lamp switch Transmission switch Poppet plug ""...'.' " "".'."""."""..."" ,

Speedometer sleeve bolt ,

Input shaft lock nut " ",.""",.,.""".".""...""""

Intermediate gear shaft bolt , Reverse idler gear shaft bolt " """""""."."""""",

Transmission case tightening Stopper bracket bolt Restrict ball assembly Reverse shift lever assembly attaching bolt Bearing retainer bolt , Differential drive gear bolt Interlock plate bolt .",.,...,."".""""""""""""",.""",.,

Transmission mounting bolt

MANUAL TRANSMISSION22-8 Troubleshooting

TROUBL.ESHOOTING

RemedySymptom

Vibration, noise

Probable cause--

a. Loose or damaged transmission and

engine mountings

a. Tighten or replace mounting

b. Correct end playb. Inadequate shaft end play

C. Worn of damaged gears,:,.

d. Use or inadequate grade of oil

c. Replace gears-

d. Replace with specified oil

e. Replenishe. Low oil level

f. Inadequate engine idle speed f. Adjust idle speed

Oil leakage a. Replace oil seal or a-ringb. Reseal with specified sealant.

a. Replace control cableHard shift

b. Correct or replace

a. Broken or damaged, oil sea9 0r a-ring

b. Use of inadequate sealant

a. Faulty control cable--.'

b. Poor contact or wear ofsynchronizer ring and gear cone

c. Weakened synchronizer spring

Jumps out of gear

e synchronizer spring

d. Replace with specified oil

a. Replace shift fork or poppetspring

b. Replace synchronizer hub andsleeve

d. 'Use of inadequate grade of oil

a. Worn gear shift fork or broken

poppet spring

b. Synchronizer hub to sleeve splineclearance too large

Difficult or impossibleto put in gear.

Improperly adjusted control cable Adjust-

Adjust or replace

Adiust

Clutch not disengaging properly-

Slips out of gear orexcessive play

Stiff lever operation

Replace

Replace~""""" -

Replace

Apply grease or replace

Improperly adjusted control cable

Worn shift lever bushing

Weakened insulator

Insufficient grease on control cable

Insufficient grease on shift lever bushingr-;~~-~~ReplaceUnusual noise during

operation

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, lubricantsconforming to the API (American Petroleum Institute's) GL4classification or higher should be used.

Lubricant: Hypoid gear oil SAE 75W-85W

Checking Transmission Oil LevelThe oil in transmission should be checked and, if necessary,replenished to the bottom of the filler plug opening with oil asspecified above.

Filler plugopening

Oil level ~

Oil Change Procedure

Raise vehicle on hoist.Place drain container with large opening, under drain plug (locatedin 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)

MANUAL TRANSMISSION22-1 0 Transmission Control

TRANSMISSION CONTROLREMOVAL AND INSTAllATION

6Ij \

7I [C=:=J

~J"

~8

~~

2

-~

9

~~3~~~~

<~~~~:~~~/-"

-C:{}

""4

5"~

14m/

T

/j-13

~""'"

~

14m/

0.9 -1.4 kgm7-10ft.lbs.

"'"\

w(!10m11

~.--J.r ~

15

~16

0.9 -1.4 kgm7 -10ft. Ibs.

t--- 0.9 -1.4 kgm--J 7 -10 ft. Ibs.

L

--t

12

-.

~G~ S

IS~~

Removal steps 13. Clip14. Split pin15. Select cable16. Shift cable

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

1. Shift knob2. Rear ashtray3. Parking brake cover4. Plate5. Floor console

..6. Hazard lamp switch

..7. Rear window defogger switch8. Front console box9. Front console assemr>ly

10. Clip11. Split pin12. Shift lever assembly

A100001

MAN U AL 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 theneutral position, move the transmission side shift leverin the direction shown in the illustration to set it in the 4th

gear.

NOTEIf the shift lever does not move smoothly, depressthe clutch pedal while moving the lever.

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

(3) Use the adjuster to bring the shift cable end to theillustrated position with respect to the passengercompartment side shift lever.

(4) Install the shift cable to the passenger compartment sideshift lever.

(5) Use the adjuster to adjust the length of the shift cable sothat when the shift lever is put in the 3rd and 4th gears,clearance (A) and (8) between the shift lever and therespective stoppers are equal.

(6) Put the shift lever in each position to make sure that thelever moves smoothly.

MANUAL TRANSMISSION22-12 Transmission Control

..15. INSTAllATION OF SELECT CABLE

(1) Place the transmission side shift lever in the neutral

position.NOTEIf the transmission side shift lever is put into the neutralposition, the transmission side select lever is set inneutral position.

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

(3) Use the adjuster to bring the select cable end to theillustrated position with respect to the passengercompartment side select lever.

(4) Install the select cable to the passenger compartmentside select lever.

MANUAL TRANSMISSION -Shift Lever Assembly 22-13

SHIFT LEVER ASSEMBLYDISASSEMEILY AND REASSEMBLY

~2

1.9 -2.8 kgm14 -20 ft. Ibs.

~1

3- l@j) k q::1. ~~~ (@-,-- 5

v.Je 7e

6-~=:r 9

-..J

1.9 -2.8 kgm14 -20 ft. Ibs.

~

.~

10

Disassembly steps1. Stopper2. Shift lever

..3. Bushing4. Lever (A)

..5. Bushing

..6. Bushing7. Snap ring8. Lever (B)

..9. Bushing10. 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

22-14 MANUAL TRANSMISSION -Shift Lever Assembly

SERVICE POINTS OF REASSEMBLY

..9./6./5./3. LUBRICATION OF BUSHINGSApply specified grease to points shown in illustration.

Specified grease: Multipurpose grease SAE J31 0,NLGI No.2

Vehicle front.

!

/

AA

-f~?~'

~

c

SECTION A-A SECTION C-C

1~~L

&:rlr

~

,B

09UO096

~1

09UOO94B

~ ~l"

SECTION B-B SECTION D-D

~

~I~Co

D

~""

D~ )~ c:;rL~I' 'Ldt

09UOO95 09UOO9709UOO98

A100003

MANUAL TRANSMISSION Transmission Assembly 22-15

TRANSMISSION ASSEMBLYREMOVAL AND INSTAllATION

Pre-removal Operation.Draining Transmission Oil.Removing Undercover

3 4

~,

\Post removal Operation.Adjusting Clutch Cable.Filling with Transmission Oil

.Installing Undercover

5

,6

101\

~I

1°~

3.0 -3.5 kgm22 -25 ft. Ibs.

1,/

~I2

-~~-3.0

-3.5 kgm22 -25 ft. Ibs.~

~12"--Jm

\ 9 8

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

~~ --'

~-m-

7c:m'

1

~

1

2.7 -3.4 kgm20 -25 ft. Ibs.

13

i\1\--'ftV""

11/

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

Removal steps

1 .Drain plug2. Filler plug3. Battery terminal connection4. Battery5. Battery tray6. Clutch cable connection7. Ground cable connection8. Shift cable connection9. Select cable connection

10. Backup lamp harness connector connection11. Starter wire connection.12. Speedometer cable connection13. Starter motor

09UO122

MANUAL TRANSMISSION22-16 Transmission Assembly

22-17MANUAL TRANSMISSION -Transmission Assembly

SERVICE POINTS OF REMOVAL..15. DISCONNECTION OF LOWER ARM BALL JOINT .

Using the special tool, disconnect the lower arm ball jointfrom the knuckle.

Caution1. Be sure to tie the cord of the special tool to the

nearby part.2. Loose the nut but do not remove it.

..16. DISCONNECTION OF TIE ROD END

Using the special tool, disconnect the tie rod end from theknuckle

Caution1. Be sure to tie the cord of the special tool to the

nearby part.2. Loose the nut but do not remove it.,

..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 thetransmission.

Caution1. 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 coverof the drive shaft. If the drive shaft is pulled out fromthe B.J. side, there is the danger of causing damageto the T.J.

MANUAL TRANSMISSION22-18 Transmission Assembly

TRANSMISSION ASSEMBLYF5M21 FIVE SPEED TRANSMISSION

MANUAL TRANSMISSION Transmission Assembly 22-19

DISASSEMBLY AND REASSEMBLY

1.5 -2.2 kgm11 -15 ft. Ibs.

m93.0 -3.5 kgm22 -25 ft. Ibs.

2-1m3--<9>

13 V' ~ (I 14 -16 kgm

~ 102 -115 ft.lbs. .~\\ v 14 12 ~~""

15 ""I 1 "

J

,,'

3.0 -4.2 kgm22 -30 ft. Ibs.

-1

..-116

1714 -16 kgm102 -115 ft. Ibs.

""

4 5 i

6

-11m

1921

\)6-8

J~J

_0.3

-0.5 kgm2.5 -3.5 ft. Ibs.

-7

;f;

~

Disassembly steps

..1. Rearcover2. Backup lamp switch3. Gasket4. Poppet plug5. Poppet spring6. Poppet ball7. Speedometer driven gear assembly

..8. Air breather9. Spring pin

10. Lock nut11. Locknut

..12. 5th speed synchronizer assembly..13. 5th speed shift fork

14. Synchronizer ring15. 5th speed gear16. Needle bearing17. Bearing sleeve18. Snap ring19. Spacer.20. Roller bearing21. 5th speed intermediate gear

NOTE(1) Reverse the disassembly procedures to reassembly(2) ..: Refer to "Service Points of Dissasembly".(3) ..: Refer to "Service Points of Reassembly".(4) m: Non-reusable parts

TFMOOO1