WORKSHOP MANUAL
C&E SERIES
MANUAL TRANSMISSION
(MAL model)
SECTION 5
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NOTICE
Before using this Workshop Manual to assist you in performing
vehicle service and maintenance operations, it is recommended that
you carefully read and thoroughly understand the information
contained in Section-0 under the headings “GENERAL REPAIR
INSTRUCTIONS”.
All material contained in this Manual is based on latest product
information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
Applicable Model:
C&E Series
This Manual is applicable to 2006 year model and later vehicles.
THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No.	CONTENTS
5C	Manual Transmission (MAL)
5G1	Side Power Take-Off (MAL)
Manual Transmission (MAL) 5C-1
TRANSMISSION/TRANSAXLE
Manual Transmission
(MAL)
TABLE OF
CONTENTS
General Description........................5C-2
General Description......................5C-2
Troubleshooting..........................5C-4
Main Data and Specifications.............5C-5
Fixing Torque............................5C-7
Special Tools............................5C-8
Service Standard.........................5C-9
Transmission..............................5C-10
Component...............................5C-10
Removal.................................5C-10
Installation............................5C-11
Transmission Assembly.....................5C-13
Component...............................5C-13
Disassembly.............................5C-14
Reassembly..............................5C-17
Inspection and Repair...................5C-24
Top Gear Shaft Assembly...................5C-27
Component...............................5C-27
Disassembly.............................5C-27
Reassembly..............................5C-27
Inspection and Repair...................5C-28
Main Shaft Assembly.......................5C-30
Component...............................5C-30
Disassembly.............................5C-30
Reassembly..............................5C-32
Inspection and Repair...................5C-36
Counter Shaft Assembly....................5C-39
Component...............................5C-39
Disassembly.............................5C-39
Reassembly..............................5C-40
Inspection and Repair...................5C-41
Lipper Quadrant Box Assembly..............5C-42
Component...............................5C-42
Disassembly.............................5C-43
Reassembly..............................5C-43
Inspection and Repair...................5C-45
Lower Quadrant Box Assembly...............5C-46
Component...............................5C-46
Disassembly.............................5C-46
Reassembly..............................5C-48
Inspection and Repair...................5C-51
Power Assistor Assembly...................5C-54
Component...............................5C-54
Disassembly.............................5C-55
Reassembly..............................5C-57
Inspection and Repair...................5C-61
Control Parts (RHD).......................5C-63
Component...............................5C-63
Disassembly.............................5C-64
Reassembly..............................5C-64
Inspection and Repair...................5C-65
Control Parts (LHD).......................5C-66
Component...............................5C-66
Disassembly.............................5C-66
Reassembly..............................5C-67
Inspection and Repair...................5C-67
Control Parts (Transmission Side).........5C-68
Component...............................5C-68
Disassembly.............................5C-68
Reassembly..............................5C-69
Inspection and Repair...................5C-70
Oil Cooler................................5C-71
Component...............................5C-71
Inspection..............................5C-72
5С-2 Manual Transmission (MAL)
General Description
General Description
Manual Transmission (6 Speed)
HCW55CLF004801
Manual Transmission (MAL) 5C-3
Identification Plate of Manual Transmission (For example)
5С-4 Manual Transmission (MAL)
Troubleshooting
Condition	Possible Cause	Correction
Abnormal Noise	Insufficient or improper lubricant	Replenish or replace lubricant
	Flywheel pilot bearing worn or broken	Replace flywheel pilot bearing
	Bearing(s) worn or broken (Top gearshaft, main shaft, countershaft, andreverse idler gear)	Replace bearing(s)
	Gear tooth contact surfaces worn or scuffed (Top gear, main shaft, counter shaft, and reverse idler gear)	Replace bearing(s)
	Spline worn (main shaft, synchronizer clutch hub)	Replace worn parts
	Floating gear on main shaft or bearing thrust face seized	Replace gear(s)
	Transmission misalignment	Realign transmission
	Lack of backlash between mating gears, or improper shimming of PTC UNITS	Replace gear(s)
	Vibration in power train (Engine, propeller shafts, joint angle, rear axle, differential, transfer)	Check and correct
Hard Shifting	Insufficient or improper lubricant	Replenish or replace lubricant
	Clutch improperly adjusted	Readjust clutch linkage
	Hard operating of change lever caused insufficient grease	Regrease
	Change lever sliding portions worn	Repair or replace applicable parts and regrease
	Control cable worn	Replace control cable
	Shift linkage improperly adjusted	Readjust shift linkage
	Shift shaft and/or bearing worn	Replace worn parts
	Power assister and/or air line malfunctioning	Correct or replace
	Shift rod and/or quadrant box sliding face worn	Replace worn parts
	Shift arm and synchronizer sleeve groove worn	Replace worn parts
	Synchronizer parts worn	Replace worn parts
	Thrust washer, collar, and/or gear thrust faces worn (main shaft and counter shaft thrust play)	Replace worn parts