In several design methods for Pass-transistor Logic (PTL) circuits, Boolean functions are expressed as OBDDs in decomposed form and then the component OBDDs are directly mapped to PTL cells. The total size of OBDDs (number of nodes) corresponds to the circuit size. In this paper, we investigate a method for PTL synthesis based on exact minimization of Free BDDs (FBDDs). FBDDs are well-studied extension of OBDDs with free variable ordering on each path. We present statistics showing that more than 56% of 616126 NPN-equivalence classes of 5-variable Boolean functions have minimum FBDDs with less size than their OBDDs. This result can be used for PTL synthesis as libraries. We also applied the exact minimization algorithm of FBDDs to the minimization of subcircuits in the synthesis for MCNC benchmarks and found up to 5% size reduction.