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MANUAL TRANSMISSION GI

SECTION MT MA

EC
CONTENTS
FE
PREPARATION................................................................2 DISASSEMBLY..............................................................15
Special Service Tools ..................................................2 Case Components .....................................................15
Commercial Service Tools ...........................................3 Shift Control Components .........................................15 CL
NOISE, VIBRATION AND HARSHNESS (NVH) Gear Components .....................................................16
TROUBLESHOOTING .....................................................4 INSPECTION..................................................................19
NVH Troubleshooting Chart.........................................4 Shift Control Components .........................................19 MT
DESCRIPTION .................................................................5 Gear Components .....................................................19
Cross-sectional View -- 2WD Model -- .....................5 Gears And Shafts..................................................19
Cross-sectional View -- 4WD Model -- .....................6 Synchronizers........................................................19 AT
ON-VEHICLE SERVICE ..................................................7 Bearings ................................................................20
Replacing Rear Oil Seal -- 2WD Model -- ................7 ASSEMBLY....................................................................21
Position Switch Check .................................................7 Gear Components .....................................................21
TF
REMOVAL AND INSTALLATION ....................................8 Shift Control Components .........................................27
MAJOR OVERHAUL .....................................................11 Case Components .....................................................28 PD
Case Components .....................................................11 SERVICE DATA AND SPECIFICATIONS (SDS) ..........31
Gear Components -- 2WD Model --........................12 General Specifications...............................................31
Gear Components -- 4WD Model --........................13 Inspection and Adjustment ........................................32 FA
Shift Control Components .........................................14

IDX
PREPARATION

Special Service Tools
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name

ST23810001 Fixing adapter plate with gear assembly
( -- )
Adapter setting plate

a: 166 mm (6.54 in)
NT407 b: 270 mm (10.63 in)

KV32101330 Removing overdrive mainshaft bearing
(See J26349-A)
Puller

a: 447 mm (17.60 in)
NT408 b: 100 mm (3.94 in)

KV31100401 Pressing counter gear and mainshaft
( -- )
Transmission press stand

NT068

ST22520000 Tightening mainshaft lock nut
(J26348)
Wrench

a: 100 mm (3.94 in)
NT409 b: 41 mm (1.61 in)

ST23540000 Removing and installing fork rod retaining pin
(J25689-A)
Pin punch
a: 2.3 mm (0.091 in) dia.
NT442 b: 4 mm (0.16 in) dia.

ST30031000 Removing and installing 1st gear bushing
(J22912-01) Removing main drive gear bearing
Puller

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

ST23860000 Installing counter drive gear
( -- )
Drift
a: 38 mm (1.50 in) dia.
NT065 b: 33 mm (1.30 in) dia.

ST22360002 Installing counter gear front and rear end
(J25679-01) bearings
Drift
a: 29 mm (1.14 in) dia.
NT065 b: 23 mm (0.91 in) dia.

ST22350000 Installing OD gear bushing
(J25678-01)
Drift
a: 34 mm (1.34 in) dia.
NT065 b: 28 mm (1.10 in) dia.

MT-2
PREPARATION
Special Service Tools (Cont'd)
GI
Tool number Description
(Kent-Moore No.)
Tool name
MA
ST23800000 Installing front cover oil seal
(J25691-01)
Drift
EM
a: 44 mm (1.73 in) dia.
NT065 b: 31 mm (1.22 in) dia.

ST33400001 Installing rear oil seal LC
(J26082)
Drift
EC
a: 60 mm (2.36 in) dia.
NT086 b: 47 mm (1.85 in) dia.
FE
ST33290001 Removing rear oil seal
(J34286)
Puller
CL

a: 250 mm (9.84 in) MT
NT414 b: 160 mm (6.30 in)

ST30720000 Installing mainshaft ball bearing AT
(J25405)
Drift

a: 77 mm (3.03 in) dia. TF
NT115 b: 55.5 mm (2.185 in) dia.

ST30613000 Installing main drive gear bearing
(J25742-3)
PD
Drift

a: 71.5 mm (2.815 in) dia. FA
NT073 b: 47.5 mm (1.870 in) dia.

ST33200000 Installing counter rear bearing RA
(J26082)
Drift

BR
a: 60 mm (2.36 in) dia.
NT091 b: 44.5 mm (1.752 in) dia.

ST
Commercial Service Tools
Tool name Description RS
Puller Removing counter bearings, counter drive
and OD gears
BT

NT077
HA

Drift Installing countershaft rear end bearing
(FS5W71C-4WD model) EL
a: 40 mm (1.57 in) dia.
NT074 b: 30 mm (1.18 in) dia. IDX

MT-3
Symptom
Reference page

(Possible cause)

Noise
SUSPECTED PARTS

Oil leakage

Jumps out of gear
MANUAL TRANSMISSION

Hard to shift or will not shift
1
OIL (Oil level is low.)
tion. If necessary, repair or replace these parts.

Refer to MA secton
(``Checking M/T Oil'',

1
3
2
OIL (Wrong oil.)
CHASSIS AND BODY MAIN-
TENANCE'').

MT-4
1
1
OIL (Oil level is high.)

2
GASKET (Damaged) MT-11

2
OIL SEAL (Worn or damaged) MT-11

1
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged) MT-14
NVH Troubleshooting Chart

2
SHIFT FORK (Worn) MT-14

2
3
GEAR (Worn or damaged) MT-12, MT-13

3
BEARING (Worn or damaged) MT-12, MT-13
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

2
BAULK RING (Worn or damaged) MT-12, MT-13

2
INSERT SPRING (Damaged) MT-12, MT-13
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
DESCRIPTION

Cross-sectional View -- 2WD Model -- GI

IDX

SMT153D

MT-5
DESCRIPTION

Cross-sectional View -- 4WD Model --

SMT154D

MT-6
ON-VEHICLE SERVICE

Replacing Rear Oil Seal -- 2WD Model -- GI

REMOVAL MA
1. Remove the propeller shaft. Refer to PD section (``Removal
and Installation'', ``PROPELLER SHAFT'').
2. Remove rear oil seal using Tool. EM
q Always replace with a new seal once it has been removed.
LC
AMT079

INSTALLATION EC
1. Install new oil seal until it stops.
q Apply multi-purpose grease to seal lip of oil seal before FE
installing.
2. Install any part removed.
CL

MT
SMT480CA

Position Switch Check AT
q Check continuity.
Switch Gear position Continuity TF
Reverse Yes
Back-up lamp switch
Except reverse No PD
Park/neutral position Neutral Yes
(PNP) switch Except neutral No FA

RS
AMT158
BT

IDX

MT-7
REMOVAL AND INSTALLATION

Removal

AMT198

MT-8
REMOVAL AND INSTALLATION
Removal (Cont'd)
CAUTION: GI
Before separating the transmission from the engine, remove
the crankshaft position sensor (OBD) from the transmission.
Be careful not to damage sensor edge or ring gear teeth. MA

2WD MODEL
EM
NOTE: To prevent oil spills, drain transmission oil before
removing transmission or insert plug into rear oil seal
after removing propeller shaft. LC
q Be careful not to damage spline, sleeve yoke and rear oil
seal when removing propeller shaft.
1. Remove battery negative terminal. EC
2. Remove crankshaft position sensor (OBD) from transmission
upper side.
3. Remove clutch operating cylinder from transmission. FE
4. Remove back-up switch and park/neutral position (PNP)
switch harness connectors.
5. Remove starter motor from transmission. CL
6. Remove propeller shaft. Refer to PD section (``Removal and
Installation'', ``PROPELLER SHAFT'').
MT

7. Remove shift lever. AT
8. Support engine by placing a jack under oil pan.
q Do not place jack under oil pan drain plug.
TF
9. Separate transmission from engine.
WARNING:
Support manual transmission while removing it. PD

FA
SMT099A

4WD MODEL RA
NOTE: To prevent oil spills, drain transmission and transfer
oil before removing transmission or insert plug into BR
rear oil seal of transfer after removing propeller shafts.
q Always drain transmission and transfer oil whenever
separating transmission and transfer. ST
1. Remove battery negative terminal.
2. Remove crankshaft position sensor (OBD) from transmission
upper side. RS
3. Remove clutch operating cylinder from transmission.
SMT478A 4. Remove back-up switch and park/neutral position (PNP)
switch harness connector. BT
5. Remove starter motor from transmission.
6. Remove front and rear propeller shafts. Refer to PD section
(``Removal and Installation'', ``PROPELLER SHAFT''). HA
q Be careful not to damage splines, sleeve yokes and front
and rear oil seals of transfer when removing propeller
shafts. EL
7. Remove torsion bar springs. Refer to FA section (``Torsion Bar
Spring'', ``FRONT SUSPENSION''). Then remove second
crossmember. IDX

MT-9
REMOVAL AND INSTALLATION
Removal (Cont'd)
8. Remove transmission shift lever and transfer control lever.
9. Support engine by placing a jack under oil pan.
q Do not place jack under oil pan drain plug.
10. Support transmission with a jack and remove engine rear
member.
11. For clutch disc replacement, separate transmission with trans-
fer from engine. For transmission overhaul, remove transfer
from transmission, then separate transmission from engine.
WARNING:
Support manual transmission with transfer while removing it.
SMT558A

Installation
1. Apply sealant to areas shown below, -- 4WD model.

AMT169

2. Tighten bolts securing transmission.

Bolt No. Tightening torque N m (kg-m, ft-lb) l mm (in)
1 39 - 49 (4.0 - 5.0, 29 - 36) 65 (2.56)
2 39 - 49 (4.0 - 5.0, 29 - 36) 58 (2.28)
3 * 16 - 22 (1.6 - 2.2, 12 - 16) 25 (0.98)
4 16 - 22 (1.6 - 2.2, 12 - 16) 16 (0.63)
*: With nut
3. Tighten clutch operating cylinder to the specified torque. Refer
AMT097 to CL section (``CLUTCH SYSTEM'').
4. For transfer installation, refer to TF section (``Installation'',
``REMOVAL AND INSTALLATION'').

MT-10
MAJOR OVERHAUL

Case Components GI

IDX

AMT157

MT-11
MAJOR OVERHAUL

Gear Components -- 2WD Model --

AMT156

MT-12
MAJOR OVERHAUL

Gear Components -- 4WD Model -- GI

IDX

AMT155

MT-13
MAJO OVERHAUL
R

Shif ControComponents
t l
CAUTION:
d e n g t , e t
To avoi damag whe replacin shif knob remov shif lever
with knob as assembled.
,

AMT154

MT-14
DISASSEMBLY

Case Components GI
1. Remove rear extension.
a. Remove control housing, check ball, return spring plugs, select MA
check plungers and return springs. Also remove reverse check
plug, check spring and check ball.
q Be careful not to lose check balls. EM

LC
SMT161D

b. Drive out striking lever retaining pin. EC
c. Remove striking lever from striking rod.
d. Remove rear extension by lightly tapping on it.
FE

MT
AMT132

2. Remove front cover, gasket, counter gear front bearing shim AT
and main drive gear ball bearing snap ring.
3. Separate transmission case from adapter plate by lightly tap-
ping on it. TF

FA
AMT131

4. Remove oil seal from front cover. RA
q Be careful not to damage mating surface of front cover.
BR

RS
SMT166D
BT
Shift Control Components
1. Set up Tool on adapter plate.
2. Remove striking rod from adapter plate. HA
3. Remove check ball plugs, check springs, and check balls.

IDX
SMT545A

MT-15
DISASSEMBLY
Shift Control Components (Cont'd)
4. Drive out retaining pins. Then drive out fork rods and remove
interlock balls.

SMT984

Gear Components
1. Before disassembly, measure the end play of each gear.
q If end play is not within the specified limit, disassemble and
inspect the parts.
q Replace any part which is worn or damaged.
Gear end play:
Refer to SDS, MT-32.

SMT025

2. Mesh 2nd and reverse gear, then remove counter gear front
bearing using a suitable puller.
3. Remove snap ring, then remove sub-gear bracket, sub-gear
spring and sub-gear.

SMT174A

4. Remove counter drive gear together with main drive gear
assembly using a suitable puller.
q When removing main drive gear assembly, be careful not
to drop pilot bearing or baulk ring.
5. Remove snap ring, then remove 3rd & 4th synchronizer
assembly and 3rd main gear.

SMT162A

6. Disassemble parts at rear of adapter plate as follows:
a. Release staking on both countergear and mainshaft lock nuts,
then loosen both nuts.
Mainshaft Lock nut: Left-hand thread

AMT133

MT-16
DISASSEMBLY
Gear Components (Cont'd)
b. Remove overdrive counter gear together with counter gear GI
rear end bearing using a suitable puller.
c. Remove reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft, then remove MA
reverse idler gear, thrust washers and reverse idler gear bear-
ing.
EM

LC
SMT547A

EC
e. Remove snap ring and pull out overdrive mainshaft bearing,
then remove snap ring. (2WD model)
f. Remove mainshaft lock nut. FE
g. Remove speedometer drive gear and steel ball. (2WD model)
h. Remove thrust washer, steel roller, roller bearing and washer.
i. Remove overdrive main gear, needle bearing and baulk ring
CL
(overdrive).
j. Remove counter gear by tapping on rear end of counter gear.
k. Press out overdrive gear bushing and overdrive & reverse
synchronizer assembly.
MT
SMT165A l. Remove reverse main gear and needle bearing.

m. Press out reverse gear bushing. AT

FA
SMT554A

7. Remove thrust washer, steel ball, 1st main gear and needle RA
bearing.
q Be careful not to lose steel ball.
BR

RS
SMT383A

8. Press out 1st gear bushing together with 2nd main gear using
BT
Tool.
Remove 2nd gear needle bearing.
HA

IDX
TM049A

MT-17
DISASSEMBLY
Gear Components (Cont'd)
9. Remove main drive gear ball bearing.
a. Remove snap ring.
b. Remove main drive gear ball bearing.

SMT420A

MT-18
INSPECTION

Shift Control Components GI
q Check contact and sliding surfaces of fork rods for wear,
scratches, projections and other damage. MA

MT
SMT075C

Gear Components AT

GEARS AND SHAFTS
q Check shafts for cracks, wear and bending. TF
q Check gears for excessive wear, chips and cracks.
PD

FA
SMT386A

RS
SMT550A
BT
SYNCHRONIZERS
q Check spline portion of coupling sleeves, synchronizer hubs
and gears for wear, chips and cracks. HA
q Check baulk rings for cracks and deformation.
q Check shifting inserts for wear and deformation.
q Check insert spread springs for deformation. EL

IDX
SMT427C

MT-19
INSPECTION
Gear Components (Cont'd)
q Measure baulk ring wear.
a. Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear:
Refer to SDS, MT-32.
q If the clearance is less than the wear limit, replace baulk ring.

SMT140

q Measure 2nd baulk ring wear--4WD model.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk rings against synchronizer cone as far as
possible, measure dimensions ``A'' and ``B''.
Standard:
Inner ``A'': 0.7 - 0.9 mm (0.028 - 0.035 in)
Outer ``B'': 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit:
0.2 mm (0.008 in)
q If dimension ``A'' or ``B'' is smaller than the wear limit, replace
outer baulk ring, inner baulk ring and synchronizer cone as a
SMT041B
set.

SMT042B

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

SMT418A

MT-20
ASSEMBLY

Gear Components GI

MT
AMT146

1. Install bearings into case components. AT
2. Assemble adapter plate parts.
q Install oil gutter on adapter plate and expand on rear side.
q Install bearing retainer. TF
a. Insert reverse idler shaft, then install bearing retainer.
PD

FA
SMT778C

b. Tighten each screw, then stake each one at two points. RA

RS
SMT674C

3. Install main drive gear ball bearing.
BT
a. Press main drive gear ball bearing.
HA

IDX
SMT425A

MT-21
ASSEMBLY
Gear Components (Cont'd)
b. Select and install proper main drive gear snap ring to achieve
proper clearance of groove.
Allowable clearance of groove:
0 - 0.13 mm (0 - 0.0051 in)
Main drive gear bearing snap ring:
Refer to SDS, MT-32.

SMT170D

4. Assemble synchronizers.
q 1st and 2nd (2WD model) synchronizer

SMT054C

q Check coupling sleeve and synchronizer hub orientation.

SMT206C

q 2nd double baulk ring type synchronizer (4WD model)

SMT046B

MT-22
ASSEMBLY
Gear Components (Cont'd)
GI

LC
SMT047B

q 3rd & 4th synchronizer EC
q The three synchronizer gutters should be at the rear.
FE

FA
SMT306C

q Overdrive & reverse synchronizer RA

IDX
SMT207CA

MT-23
ASSEMBLY
Gear Components (Cont'd)
5. Assemble front side components to mainshaft.
a. Install 2nd main gear, needle bearing and 1st & 2nd synchro-
nizer assembly; then press 1st gear bushing on mainshaft.
b. Install 1st main gear.

SMT752A

c. Install steel ball and 1st gear washer.
q Before installation, apply multi-purpose grease to steel
ball and to both sides of the 1st gear washer.

TM358

6. Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft as follows:
a. Press mainshaft assembly into adapter plate using Tool.

TM439

b. Press counter gear into adapter plate using Tool.
c. Install 3rd main gear and needle bearing, then press 3rd & 4th
synchronizer assembly onto mainshaft.
q Pay attention to the direction of 3rd & 4th synchronizer.

SMT750

d. Install front mainshaft snap ring.
Select proper front mainshaft snap ring to achieve proper
clearance of groove.
Allowable clearance of groove:
0 - 0.18 mm (0 - 0.0071 in)
Mainshaft front snap ring:
Refer to SDS, MT-32.
e. Apply gear oil to mainshaft pilot bearing and install it on main-
shaft.

TM441

MT-24
ASSEMBLY
Gear Components (Cont'd)
f. Press counter drive gear together with main drive gear using GI
Tool.
q Pay attention to the direction of counter drive gear.
MA

LC
SMT412C

g. Install sub-gear components. EC
(1) Install sub-gear and sub-gear bracket on counter drive gear
and then select proper snap ring that will minimize clearance
of groove in counter gear. FE
q Do not install sub-gear spring at this time.
Allowable clearance of groove:
0 - 0.18 mm (0 - 0.0071 in) CL
Counter drive gear snap ring:
Refer to SDS, MT-32.
MT
SMT201D

(2) Remove snap ring, sub-gear bracket and sub-gear from AT
counter gear.
(3) Reinstall sub-gear, sub-gear spring, sub-gear bracket and
snap ring. TF

FA
SMT202D

h. Press counter/gear front bearing onto counter gear using Tool. RA

RS
TM443

7. Install rear side components on mainshaft and counter gear as
BT
follows:
a. Install sub-gear parts (sub-gear, sub-gear spring, sub-gear
bracket, steel ball and snap ring) on the reverse idler gear. HA
b. Install reverse idler gear to reverse idler shaft along with
reverse idler thrust washer, snap rings and reverse idler gear
bearing. EL

IDX
AMT134

MT-25
ASSEMBLY
Gear Components (Cont'd)
c. Install bushing, reverse main gear and overdrive & reverse
synchronizer to mainshaft.
q Pay attention to the direction of synchronizer hub.

SMT207CA

d. Install overdrive gear bushing to mainshaft using Tool.
e. Install overdrive main gear and needle bearing to mainshaft.
f. Install spacer, reverse counter gear and overdrive counter gear
to counter/gear.
q OD main gear and OD counter gear should be handled as
a matched set.
g. Install washer, roller bearing, steel roller and thrust washer.
h. Tighten mainshaft lock nut temporarily.
q Always use new lock nut.

SMT531

i. Install counter/gear rear end bearing using Tool.

SMT043

8. Mesh 2nd and reverse gears, then tighten mainshaft lock nut
using Tool.
q Always use new lock nut.
Mainshaft lock nut:
: 137 - 167 N m (14.0 - 17.0 kg-m, 101 - 123 ft-lb)

SMT003A

MT-26
ASSEMBLY
Gear Components (Cont'd)
q Use the chart shown at left to determine the proper reading GI
torque.
(Length of torque wrench vs. setting or reading torque)
Reference: Formula to convert torque wrench indication to the MA
true torque value:

T =
0.1 m (0.33 ft) + L

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