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MANUAL TRANSAXLE

MT
GI

SECTION MA

LC
CONTENTS
EC
PREPARATION........................................................... 2 Gear Components................................................. 15
Special Service Tools.............................................. 2 Shift Control Components..................................... 16
Commercial Service Tools ...................................... 4 DISASSEMBLY......................................................... 17 FE
NOISE, VIBRATION AND HARSHNESS (NVH) REPAIR FOR COMPONENT PARTS....................... 20
TROUBLESHOOTING ................................................ 5 Input Shaft and Gears .......................................... 20
NVH Troubleshooting Chart.................................... 5 Mainshaft and Gears ............................................ 25
CL
Manual Transaxle ............................................... 5 Final Drive............................................................. 29
DESCRIPTION ............................................................ 6 Shift Control Components..................................... 31 MT
Cross-sectional View .............................................. 6 Case Components ................................................ 31
ON-VEHICLE SERVICE ............................................. 7 ADJUSTMENT .......................................................... 33
Replacing Oil Seal .................................................. 7 Input Shaft End Play and Differential Side AT
Position Switch Check ............................................ 8 Bearing Preload .................................................... 33
REMOVAL AND INSTALLATION ............................... 9 Mainshaft Bearing Preload ................................... 34
Removal .................................................................. 9 ASSEMBLY............................................................... 37 FA
Installation ............................................................. 12 SERVICE DATA AND SPECIFICATIONS (SDS) ..... 41
TRANSAXLE GEAR CONTROL .............................. 13 General Specifications .......................................... 41 RA
MAJOR OVERHAUL ................................................ 14 Inspection and Adjustment.................................... 42
Case Components ................................................ 14
BR

IDX
PREPARATION

Special Service Tools
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

KV38106500 Measuring turning torque of final drive
(J34284) assembly
Preload adapter Measuring total turning torque
Measuring clearance between side gear and
differential case with washer
Selecting differential side bearing
NT087 adjusting shim

KV32101000 Removing and installing retaining pin
(J25689-A)
Pin punch

NT410 a: 4 mm (0.16 in) dia.

ST22730000 Removing mainshaft front and rear bearing
(J25681) inner race
Puller

a: 82 mm (3.23 in) dia.
NT411 b: 30 mm (1.18 in) dia.

ST30031000 Removing input shaft front and rear bearing
(J22912-01) Removing 4th & 5th main gear
Puller

a: 90 mm (3.54 in) dia.
NT411 b: 50 mm (1.97 in) dia.

ST30021000 Removing 5th synchronizer
(J22912-01) Removing 3rd & 4th synchronizer
Puller Removing 2nd & 3rd main gear

a: 110 mm (4.33 in) dia.
NT411 b: 68 mm (2.68 in) dia.

ST3306S001 Removing differential side bearing
(J22888-D) inner race
Differential side bearing
puller set
1 ST33051001
(J22888-D) a: 38 mm (1.50 in) dia.
Puller b: 28.5 mm (1.122 in) dia.
2 ST33061000 c: 130 mm (5.12 in)
(J8107-2) d: 135 mm (5.31 in)
Adapter AMT153 e: 100 mm (3.94 in)

MT-2
PREPARATION
Special Service Tools (Cont'd)
Tool number
(Kent-Moore No.) Description
Tool name GI
ST33290001 Removing differential oil seal
(J34286) Removing mainshaft rear bearing outer race
Puller Removing differential side bearing outer
MA
race

EM
a: 250 mm (9.84 in)
NT414 b: 160 mm (6.30 in)
LC
ST33400001 Installing differential oil seal
(J26082)
Drift EC

a: 60 mm (2.36 in) dia. FE
NT086 b: 47 mm (1.85 in) dia.

ST30600000 Installing input shaft front bearing CL
(J25863-01)
Drift
MT
a: 36 mm (1.42 in) dia.
NT065 b: 31 mm (1.22 in) dia. AT
ST22452000 Installing 3rd, 4th and 5th main gear
(J34335)
FA
Drift

RA
a: 45 mm (1.77 in) dia.
NT065 b: 36 mm (1.42 in) dia.

ST30621000 Installing mainshaft rear bearing outer race BR
(J25742-5) (Use with ST30611000.)
Drift
ST

a: 79 mm (3.11 in) dia.
NT073 b: 59 mm (2.32 in) dia.
RS

ST30611000 Installing mainshaft rear bearing outer race
(J25742-1) (Use with ST30621000.) BT
Drift
a: 15 mm (0.59 in)
b: 335 mm (13.19 in) HA
c: 25 mm (0.98 in) dia.
NT419 d: M12 x 1.5P
EL
ST307200000 Installing differential side bearing outer race
(J25405)
Drift IDX
a: 77 mm (3.03 in) dia.
NT115 b: 55.5 mm (2.185 in) dia.

MT-3
PREPARATION
Special Service Tools (Cont'd)
Tool number
(Kent-Moore No.) Description
Tool name

(J34290) Selecting differential side bearing adjusting
Shim selecting tool set shim

NT080

(J34305) Removing and installing stopper ring of shift
Snap ring remover and fork
installer

NT081

(J25407-2) Measuring reverse baulk ring wear

NT082

Commercial Service Tools
Tool name Description

Drift Installing differential side bearing inner race

a: 45 mm (1.77 in) dia.
NT065 b: 41 mm (1.61 in) dia.

Drift Installing striking rod oil seal

a: 38 mm (1.50 in) dia.
NT065 b: 20 mm (0.79 in) dia.

MT-4
Symptom
Reference page

(Possible cause)

Noise
SUSPECTED PARTS

Oil leakage

Jumps out of gear
MANUAL TRANSAXLE

Hard to shift or will not shift
1
OIL (Oil level is low.)
Refer to MA section (``Check-

1
3
2
OIL (Wrong oil) ing M/T Oil'', ``CHASSIS AND
BODY MAINTENANCE'').

1
1
inspection. If necessary, repair or replace these parts.

OIL (Oil level is too high.)

MT-5
2
GASKET (Damaged) MT-14

2
OIL SEAL (Worn or damaged) MT-14

2
O-RING (Worn or damaged) MT-14

1
2
CONTROL ROD (Worn) MT-13

2
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged) MT-16
NVH Troubleshooting Chart

3
SHIFT FORK (Worn) MT-16

3
3
GEAR (Worn or damaged) MT-15

3
BEARING (Worn or damaged) MT-15

3
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

BAULK RING (Worn or damaged) MT-15

3
INSERT SPRING (Damaged) MT-15
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of
GI

EL
FE

ST
FA

BT
CL
LC

RS
EC

HA
BR
EM
MA

IDX
MT
DESCRIPTION

Cross-sectional View
RS5F50A

WMT042

MT-6
ON-VEHICLE SERVICE

Replacing Oil Seal
DIFFERENTIAL OIL SEAL
GI
1. Drain gear oil from transaxle.
2. Remove drive shafts. Refer to FA section (``REMOVAL'',
``FRONT AXLE -- Drive Shaft''). MA
3. Remove differential oil seal with Tool.
q Always replace with a new seal once it has been removed.
EM
SMT563A

4. Install differential oil seal. LC
q Apply multi-purpose grease to seal lip of oil seal before
installing. EC
5. Install drive shafts. Refer to FA section (``INSTALLATION'',
``FRONT AXLE -- Drive Shaft'').
FE

CL
SMT564A
MT
STRIKING ROD OIL SEAL
1. Remove transaxle control rod from yoke.
2. Remove yoke retaining pin with Tool. AT
q Be careful not to damage boot.
FA

RA
SMT261C
BR
3. Remove striking rod oil seal.

BT
SMT220C
HA
4. Install striking rod oil seal.
q Apply multi-purpose grease to seal lip of oil seal before
installing. EL

IDX

SMT221C

MT-7
ON-VEHICLE SERVICE

Position Switch Check
BACK-UP LAMP SWITCH AND PARK/NEUTRAL
POSITION (PNP) SWITCH
q Check continuity.
Gear position Continuity
Reverse 1 -- 3

Neutral 2 -- 4

Except reverse and neutral No
AMT119

MT-8
REMOVAL AND INSTALLATION

Removal

WMT056
MT

BR
CAUTION:
Before separating transaxle from engine, remove the
crankshaft position sensor (OBD) from transaxle. ST
Be careful not to damage sensor edge or ring gear teeth.
1. Remove battery and its bracket.
2. Remove air cleaner housing with mass air flow sensor. RS
3. Remove air duct.
BT
AMT068
HA
4. Remove clutch operating cylinder from transaxle.
5. Disconnect speedometer pinion, park/neutral position
(PNP) switch and ground harness connectors. EL

IDX

SMT301C

MT-9
REMOVAL AND INSTALLATION
Removal (Cont'd)
6. Remove starter motor from transaxle.

SMT225C

7. Remove crankshaft position sensor (OBD) from transaxle.
q Be careful not to damage sensor tip.

AMT064

8. Remove shift control rod from transaxle.
9. Drain gear oil from transaxle.

SMT226C

10. Draw out drive shafts from transaxle. Refer to FA section
(``REMOVAL'', ``FRONT AXLE -- Drive Shaft'').

SMT227C

MT-10
REMOVAL AND INSTALLATION
Removal (Cont'd)
11. Support engine by placing a jack under oil pan.
CAUTION:
Do not place jack under oil pan drain plug. GI
12. Remove rear and LH engine mounts.

CL
SMT302C
MT
13. Raise jack for access to lower housing bolts. Remove bolts.
Lower jack.
AT

RA
AMT111
BR
14. Remove bolts securing transaxle.
15. Lower transaxle while supporting it with a jack.
ST

BT
SMT230C
HA

IDX

MT-11
REMOVAL AND INSTALLATION

Installation
q Tighten bolts securing transaxle and install any part
removed.

Tightening torque
Bolt No. l mm (in)
N m (kg-m, ft-lb)
1 40 - 49 (4.0 - 5.0, 29 - 36) 45 (1.77)
2 40 - 49 (4.0 - 5.0, 29 - 36) 48 (1.89)
3 30 - 40 (3.1 - 4.1, 22 - 30) 30 (1.18)
AMT001
4 30 - 40 (3.1 - 4.1, 22 - 30) 40 (1.57)

q Tighten starter motor to transaxle.
: 30.40 - 41.29 N m (3.1 - 4.2 kg-m, 22.4 - 30.5 ft-lb)
q Tighten clutch operating cylinder to transaxle.
: 30 - 40 N m (3.1 - 4.1 kg-m, 22 - 30 ft-lb)
q Install drive shafts. Refer to FA section (``INSTALLATION'',
``FRONT AXLE -- Drive Shaft'').

MT-12
TRANSAXLE GEAR CONTROL

IDX

AMT117

MT-13
MAJOR OVERHAUL

Case Components

WMT044

MT-14
MAJOR OVERHAUL

Gear Components

IDX

WMT045

MT-15
MAJOR OVERHAUL

Shift Control Components

WMT046

MT-16
DISASSEMBLY

1. Before removing transmission case, remove bolts, check
plugs, springs and check balls as shown left.
q Be careful not to lose check balls. GI
2. Remove transmission case.

EM
AMT091

3. Remove park/neutral position (PNP) switch. LC

CL
AMT147
MT
4. Mesh 4th gear, then remove reverse idler shaft and reverse
idler gear.
AT

RA
SMT195B
BR
5. Pull out retaining pin.

BT
SMT196B
HA
6. Remove reverse lever spring and reverse lock spring from
reverse lever assembly.
EL

IDX

SMT197B

MT-17
DISASSEMBLY

7. Remove reverse arm shaft while rotating it.

SMT198B

8. Remove reverse lever assembly and check ball.
q Be careful not to lose check ball.

SMT199B

9. Remove 5th & reverse check plug, spring and ball.
q Be careful not to lose check ball.

SMT018B

10. Remove stopper rings and retaining pins from 5th & reverse
and 3rd & 4th fork rods.
11. Remove 5th & reverse and 3rd & 4th fork rods. Then
remove forks and brackets.

SMT022A

12. Remove input shaft and mainshaft with 1st & 2nd fork and
fork rod as a set.
13. Remove final drive assembly.
CAUTION:
Always withdraw mainshaft straight out. Failure to do
so can damage resin oil channel on clutch housing
side.

SMT105C

MT-18
DISASSEMBLY

14. Remove reverse check assembly and check ball.
q Be careful not to lose check ball.
GI

EM
SMT138A

15. Remove retaining pin with Tool and detach the selector. LC

CL
SMT618A
MT

RA
SMT027A
BR
16. Remove drain plug for convenience in removing retaining
pin which holds striking lever to striking rod.
ST

BT
SMT028A
HA
17. Remove retaining pin with Tool and then withdraw striking
lever and striking rod.
EL

IDX

SMT619A

MT-19
REPAIR FOR COMPONENT PARTS

Input Shaft and Gears
DISASSEMBLY
1. Before disassembly, check 3rd, 4th and 5th input gear end
plays.
Gear end play:
Refer to SDS, MT-42.

q If not within specification, disassemble and check contact
surface of gear, shaft and hub. Check clearance of snap
SMT121C ring groove. Refer to ``ASSEMBLY'', MT-22.

SMT476C

2. Remove input shaft rear bearing with Tool.

SMT634A

3. Remove 5th & reverse synchronizer and 5th input gear with
Tool.

SMT205B

4. Remove thrust washer ring, thrust washers and 4th input
gear.

SMT242C

MT-20
REPAIR FOR COMPONENT PARTS
Input Shaft and Gears (Cont'd)
5. Remove snap ring.

EM
SMT040A

6. Remove 3rd & 4th synchronizer and 3rd input gear with LC
Tool.
EC

CL
SMT041A
MT
7. Remove input shaft front bearing with Tool.

RA
SMT042A
BR
INSPECTION
Gear and shaft
ST
q Check shaft for cracks, wear and bending.
q Check gears for excessive wear, chips and cracks.
RS

BT
SMT636A
HA
Synchronizer
q Check spline portion of coupling sleeves, hubs and gears
for wear or cracks. EL
q Check baulk rings for cracks and deformation.
q Check insert springs for wear and deformation.
IDX

SMT637A

MT-21
REPAIR FOR COMPONENT PARTS
Input Shaft and Gears (Cont'd)
q Measure clearance between baulk ring and gear (3rd, 4th
and 5th).
Clearance between baulk ring and gear:
Refer to SDS, MT-42.

SMT140

q Measure wear of reverse baulk ring.
a. Place reverse baulk ring on Tool and then place reverse
synchronizer cone on reverse baulk ring.
q Make sure projection of synchronizer cone is posi-
tioned over the recess on Tool.
b. While holding reverse synchronizer cone against reverse
baulk ring as firmly as possible, measure dimension ``A''
with dial indicator.
Wear limit (Dimension ``A''):
Refer to SDS, MT-42.
c. If dimension ``A'' is smaller than the wear limit, replace baulk
ring and synchronizer cone as a set.

SMT580B

Bearing
q Make sure bearings roll freely and are free from noise,
cracks, pitting and wear.

SMT148A

ASSEMBLY

SMT993B

MT-22
REPAIR FOR COMPONENT PARTS
Input Shaft and Gears (Cont'd)
1. Place inserts in three grooves on coupling sleeve (3rd & 4th
synchronizer).
GI

EM
SMT994B

2. Install 3rd input gear and 3rd baulk ring. LC
3. Press on 3rd & 4th synchronizer hub.
q Pay attention to its direction. EC
4. Select proper snap ring of 3rd & 4th synchronizer hub to
minimize clearance of groove, and then install it.
Allowable clearance of groove: FE
0 - 0.1 mm (0 - 0.004 in)
Snap ring of 3rd & 4th synchronizer hub:
Refer to SDS, MT-42. CL
SMT049A
MT

RA
SMT050A
BR
5. Install 4th input gear.
6. Select proper thrust washers to minimize clearance of
groove. ST
Then install them and thrust washer ring.
Allowable clearance of groove:
0 - 0.06 mm (0 - 0.0024 in) RS
4th Input gear thrust washer:
Refer to SDS, MT-43.
BT
SMT995B
HA
7. Install 5th & reverse synchronizer assembly.
a. Hook insert springs on reverse baulk ring.
EL

IDX

SMT206B

MT-23
REPAIR FOR COMPONENT PARTS
Input Shaft and Gears (Cont'd)
b. Install insert springs with reverse baulk ring onto coupling
sleeve.
q Pay attention to position of insert springs.
c. Place 5th baulk ring on 5th input gear.
d. Install reverse synchronizer cone on reverse baulk ring.

SMT752C

e. Place reverse synchronizer assembly on 5th input gear.
q Mesh recesses of 5th input gear with projections of
reverse synchronizer cone.
q Put insert spring mounts on reverse baulk ring upon
those on 5th baulk ring.

SMT208B

f. Press on 5th & reverse synchronizer assembly with 5th
input gear.

SMT051A

8. Install input shaft front and rear bearings with Tool.
9. Measure gear end play as the final check. Refer to ``DISAS-
SEMBLY'' MT-20.

SMT753C

MT-24
REPAIR FOR COMPONENT PARTS

Mainshaft and Gears
DISASSEMBLY
GI
1. Before disassembly, check 1st and 2nd main gear end
plays.
Gear end play: MA
Refer to SDS, MT-42.

q If not within specification, disassemble and check contact EM
surface of gear, shaft and hub. Then check clearance of
SMT191A snap ring groove. Refer to ``ASSEMBLY'', MT-27.
2. Press out mainshaft rear bearing with Tool. LC

CL
SMT638A
MT
3. Remove thrust washer and snap ring.

RA
SMT044A
BR
4. Press out 5th main gear and 4th main gear with Tool.

BT
SMT045A
HA
5. Press out 3rd main gear and 2nd main gear with Tool.

IDX

SMT131A

MT-25
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont'd)
6. Remove snap ring.

SMT047A

7. Remove 1st & 2nd synchronizer and 1st main gear.

SMT048A

8. Remove mainshaft front bearing with Tool.

SMT639A

INSPECTION
Gear and shaft
q Check shaft for cracks, wear and bending.
q Check gears for excessive wear, chips and cracks.

SMT640A

Synchronizer
q Check spline portion of coupling sleeves, hubs and gears
for wear and cracks.
q Check baulk rings for cracks and deformation.
q Check insert springs for deformation.

SMT637A

MT-26
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont'd)

EM
SMT420C

q Measure wear of 1st and 2nd baulk rings. LC
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk ring against synchronizer cone as far as
EC
it will go, measure dimensions ``A'' and ``B''.
Standard and wear limit:
Refer to SDS, MT-42. FE
c. If dimension ``A'' or ``B'' is smaller than the wear limit,
replace outer baulk ring, inner baulk ring and synchronizer
cone as a set. CL

MT
Bearing
q Make sure bearings roll freely and are free from noise,
cracks, pitting and wear. AT
q When replacing tapered roller bearing, replace outer
and inner race as a set.
FA

RA
SPD715
BR
ASSEMBLY

BT
SMT996B
HA
1. Press on 1st main gear, 1st synchronizer cone, inner and
outer baulk rings and 1st & 2nd synchronizer hub.
q Pay attention to direction of 1st & 2nd synchronizer EL
hub.
2. Select proper snap ring of 1st & 2nd synchronizer hub to
minimize clearance of groove and then install it. IDX
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Snap ring of 1st & 2nd synchronizer hub:
Refer to SDS, MT-42.
WMT004

MT-27
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont'd)

SMT054A

3. Install 2nd synchronizer cone, inner & outer baulk rings.
Insert springs and 1st & 2nd coupling sleeve.
4. Install 2nd main gear.
q Ensure four protrusions of 2nd synchronizer cone are set in
2nd main gear holes.

SMT805B

5. Use Tool to press on 3rd main gear.
6. Use Tool to press on 4th main gear.

AMT120

7. Use Tool to press on 5th main gear.
8. Select proper snap ring of 5th main gear to minimize clear-
ance of groove and then install it.
Allowable clearance of groove:
0 - 0.15 mm (0 - 0.0059 in)
Snap ring of 5th main gear:
Refer to SDS, MT-42.

AMT121

9. Press on thrust washer and press on mainshaft rear bear-
ing.

SMT059A

MT-28
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont'd)
10. Press on mainshaft front bearing.
11. Measure gear end play as the final check. Refer to ``DISAS-
SEMBLY'' MT-25.
GI

EM
SMT060A

LC
Final Drive
DISASSEMBLY
EC
1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
FE

CL
SMT505B
MT
3. Press out differential side bearings with Tool.
q Be careful not to mix up the right and left bearings.
AT

RA
SMT744AB
BR
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.
ST

BT
AMT112
HA
INSPECTION
Gear, washer, shaft and case
q Check mating surfaces of differential case, side gears and EL
pinion mate gears.
q Check washers for wear.
IDX

AMT113

MT-29
REPAIR FOR COMPONENT PARTS
Final Drive (Cont'd)
Bearing
q Make sure bearings roll freely and are free from noise,
cracks, pitting and wear.
q When replacing tapered roller bearing, replace outer
and inner race as a set.

SPD715

ASSEMBLY
1. Install side gear and thrust washers in differential case.
2. Install pinion mate gears and thrust washers in differential
case while rotating them.
q When inserting, be careful not to damage pinion mate
thrust washers.
q Apply gear oil to gears, shafts, synchronizers and bear-
ings when assembling.

SAT318D

3. Measure clearance between side gear and differential case
with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator
deflection. Always measure indicator deflection on both side
gears.
Clearance between side gear and differential case
with washers:
0.1 - 0.2 mm (0.004 - 0.008 in)

SMT610AA

c. If not within specification, adjust clearance by changing
thickness of side gear thrust washers.
Side gear thrust washer:
Refer to SDS, MT-43.

SMT631B

MT-30
REPAIR FOR COMPONENT PARTS
Final Drive (Cont'd)
4. Install retaining pin.
q Make sure that retaining pin is flush with case.
GI

EM
AMT112

6. Install final gear. LC
q Apply locking sealant to final gear fixing bolts before
installing. EC
7. Install speedometer drive gear.

CL
SMT609A
MT
8. Press on differential side bearings.

RA
SMT648
BR
Shift Control Components
INSPECTION ST
q Check contact surface and sliding surface for wear,
scratches, projections and other damage.
RS

BT
SMT106C
HA
Case Components
REMOVAL AND INSTALLATION EL
Input shaft oil seal
IDX

SMT030A

MT-31
REPAIR FOR COMPONENT PARTS
Case Components (Cont'd)
q Apply multi-purpose grease to seal lip of oil seal before
installing.

SMT031A

Mainshaft front bearing outer race
q Pull out oil channel (mainshaft) to remove front bearing
outer race.

SMT034A

Mainshaft rear bearing outer race
Refer to MT-34.

Differential side bearing outer race
Refer to MT-33.

MT-32
ADJUSTMENT

Input Shaft End Play and Differential Side
Bearing Preload
If any of the following parts are replaced, adjust input shaft end GI
play.
q Input shaft
q Input shaft bearing MA
q Clutch housing
q Transmission case
EM
If any of the following parts are replaced, adjust differential side
bearing preload.
q Differential case LC
q Differential side bearing
q Clutch housing
q Transmission case EC

MT
1. Remove differential side bearing outer race (transmission
case side) and shim(s).
AT

RA
SMT132A
BR
2. Install differential side bearing outer race without shim(s).
3. Install input shaft and final drive assembly on clutch hous-
ing. ST
4. Install transmission case without input shaft bearing
shim(s).
Tighten it to the specified torque. Refer to MT-14. RS

BT
AMT069
HA
5. Using the following procedures, measure clearance
between bearings and transmission case.
q Differential side EL
1. Attach dial indicator. If clamp diameter of dial indicator is too
small or too large, attach dial indicator using a magnetic
stand. IDX

SMT074A

MT-33
ADJUSTMENT
Input Shaft End Play and Differential Side
Bearing Preload (Cont'd)
2. Insert Tool all the way into differential side gear. Move Tool
up and down and measure dial indicator deflection.

SMT075A

q Input shaft side
1. Set dial indicator on rear end of input shaft.
2. Move input shaft up and down and measure dial indicator
deflection.
3. Select shims with proper thickness with SDS table as a
guide. Refer to MT-44.
4. Install selected differential side bearing adjusting shim and
differential side bearing outer race.

SMT076A

5. Check differential side bearing turning torque.
a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.
q Tighten transmission case fixing bolts to the specified
torque. Refer to ``Case Components'', MT-14.

SMT024A

Mainshaft Bearing Preload
If any of the following parts are replaced, adjust mainshaft bear-
ing preload.
q Mainshaft
q Mainshaft bearings
q Clutch housing
q Transmission case

1. Remove mainshaft rear bearing outer race and shim(s).

SMT077A

MT-34
ADJUSTMENT
Mainshaft Bearing Preload (Cont'd)
2. Reinstall mainshaft rear bearing outer race without shims.
3. Clean mating surfaces of clutch housing and transmission
case with solvent.
GI
4. Install mainshaft and mainshaft front bearing outer race into
transmission case. Turn mainshaft while holding bearing
outer race so that bearings are properly seated.
MA

EM
SMT644A

5. Place Tools (bridge and gauging cylinder) onto machined LC
surface of transmission case. Allow gauging cylinder to rest
on surface of mainshaft front bearing outer race. Use proper
EC
screw in bridge to lock gauging cylinder in place.

CL
SMT998B
MT
6. Turn bridge over and place Tool (gauging plunger) into
gauging cylinder.
AT

RA
SMT133AA
BR
7. Place bridge, legs up, onto machined surface of clutch
housing. Allow gauging plunger to rest upon mating surface
where mainshaft front bearing outer race fits. ST

BT
SMT999B
HA
8. Use feeler gauge to measure the distance between gaug-
ing cylinder and shoulder of gauging plunger.
9. Use feeler gauge reading to select correct mainshaft pre- EL
load shim(s).
Mainshaft bearing adjusting shim:
Refer to SDS, MT-43. IDX
10. Install selected mainshaft bearing adjusting shim and main-
shaft bearing outer race.
11. Check total turning torque after assembly. Refer to
``ASSEMBLY'' MT-37.
SMT001C

MT-35
ADJUSTMENT
Mainshaft Bearing Preload (Cont'd)

SMT467BA

MT-36
ASSEMBLY

1. Install striking lever and striking rod with Tool.

EM
SMT029A

2. Install selector and retaining pin with Tool. LC
NOTE:
Install drain plug. EC

CL
SMT645A
MT
3. Install check ball and reverse check assembly.
q Before installation, rotate striking rod as shown in the
figure to avoid interference. AT

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