Page 485 of 513

CLUTCH
Clogged 
vent 
hole 
in 
reservoir
cap 
promotes
vacuum
in 
master
cylinder
allowing 
air
to
inf1ltrate
past 
the 
seal
Abnormal
lining 
wear
Insufficient
pedal 
free 
travel
The 
clutch
grabs
The 
clutch
slips 
Driver
steps 
unnecessarily 
on
pedal 
this
causes 
lin
jog 
wear
and
damage 
to 
release
bearing
Weakened
or
snapped 
pressure 
springs
Incorrectly 
installed
linings
Oil 
or
grease 
on
flywheel 
pressure 
plate 
and
linings
Loose
disc
linings 
due
to
poor 
rivet
tightness
Clutch 
disc
hub 
does 
not
slide
freely 
on
drive 
shaft
spline
Warped 
or 
cracked
pressure 
plate
Misalignment
Stiffened
hydraulic 
control 
mechanism
Wom 
out
lining
Insufficient 
clutch
pedal 
return
travel 
due
to 
the 
control 
and
pedal 
return
springs 
being
weak 
or
misadjusted
Weakened 
or 
broken
diaphragm 
spring
Oil 
or
grease 
on
linings
eLl5 
Clean 
reservoir
cap 
unclog 
the 
vent
hole 
and
bleed
the
system
Adjust 
clutch
pedal 
free 
travel
correctly
Advise 
driver
to 
discontinue
wrong
practice
and
step 
on
clutch
pedal 
only 
when 
ne
cessary
Check
pressure 
springs 
for 
tension 
as
speci
fied 
and
replace 
springs 
if
they 
are
unserviceable
Replace
linings 
with 
new 
ones
and 
install
them
correctly 
Check 
clutch 
disc 
for 
center
alignment
Remove 
cause
of
leakage 
clean
flywheel 
and
pressure
plate 
thoroughly 
replace 
linings
If
linings 
are 
not 
worn
replace 
defective
rivets
Otherwise
replace 
linings 
and 
clench
rivets
securely
Remove
any
foreign 
matter 
or
dirt
deposits
from 
shaft
splines 
When 
trouble 
is
still
present 
replace 
damaged 
parts
Replace 
pressure
plate
Locate 
the 
defective
point 
and 
if
possible
adjust 
alignment 
or
replace 
distorted
parts
Check
spring 
tension
If
necessary 
take
down
pedal 
and
lubricate
components
Install 
new
linings 
and
make 
sure 
tha
t 
the
clutch
disc
pressure 
plate 
and
flywheel 
are
not
damaged
Locate
cause 
of 
failure 
and
replace 
defective
springs
Overhaul 
clutch 
and
replace 
springs
Remove 
cause 
of
leakage 
and
replace 
linings
if
cleaning 
is
ineffective 
     
        
        Page 494 of 513

TRANSMISSION
15
Remove 
the
needle
bearing 
synchronizer 
hub 
thrust
washer
steel 
ball 
3rd 
4th
synchronizer 
mechanism
baulk
ring 
3rd
gear 
and 
main
shaft 
needle
bearing 
toward
the 
front 
side 
in
that 
order
S 
b
L
74FE
r
1 
Needle
bearing
2 
Thrust 
washer
3 
Steel 
ball
4
Coupling 
sleeve 
5
BauIk
ring
6 
3rd
gear
7 
Needle
bearing
Fig 
TM 
21
Layout 
of 
main
shaft
16 
Remove
the 
main
bearing 
from 
the 
main 
shaft
by
the 
use
of 
a
bearing
puller 
special 
tool 
ST2273
000 
and
a
press
1
ST22730000
r 
1
t
Jii
Fig 
TM 
22
Removing 
main
drive
l7earing
17 
Remove 
the 
thrust
washer 
I 
st
gear 
needle
bearing
baulk
ring 
1st 
2nd
synchronizer 
mechanism 
baulk
ring 
main 
shaft 
2nd
gear 
needle
bearing 
etc
from 
the
main 
shaft 
1
2
3
4 
5
Coupling 
sleeve
6 
Baulk
ring
7 
2nd
gear
8 
Needle
bearing
Thrust 
washer
1st
gear
Needle
bearing
Baulk
ring
Fig 
TM 
23
Layout 
of 
main
shaft
18 
Re
move 
the
bearing 
from 
the 
counter
gear
19 
Remove 
the
snap 
ring 
from 
the 
main
ge
f 
and
remove 
the 
main 
shaft
bearing
INSPECTI9N
Thoroughly 
clean 
all 
disassembled
parts 
with 
solvent
and 
check
them 
for 
wear
damage 
and 
other
defective
conditions
Transmission 
case 
and
rear 
extension
Clean 
them 
with 
solvent 
thoroughly 
and 
check 
for
crack
which
may 
cause 
oil
leaking 
and 
other 
defective
conditions
I
When 
burr
pitting 
and 
or 
other
damage 
exists 
on
the
joint 
repair 
or
replace
2
Remove 
adhesive 
from 
the
installing 
surface 
com
pletely
3
Repair 
or
replace 
the 
dowel
pin 
knock
pin 
if
damaged 
bent 
or
warped
4
When 
rear 
extension
bushing 
interior 
is 
worn
unevenly 
replace
TM 
7
Ii
01 
r 
     
        
        Page 495 of 513

I 
t
CHASSIS
Bearing
Thoroughly 
clean 
the
bearing 
dry 
and 
remove
dust
with
compressed 
air
2
When 
the 
ball
bearing 
inner 
race
and 
center 
race 
ball
sliding 
surfaces 
are 
worn
unevenly 
and 
or
unsmooth 
due
to 
crack 
or 
out
of 
round 
of 
ball 
is 
excessive
due 
to 
wear
or
rough 
surface
replace 
the
bearing 
with 
a
new 
one
6
Fig 
TM 
24
Inspecting 
baa
bearing
f
3
tplace 
needle
bearing 
if 
worn 
or
damaged
I
ePlace 
rear 
extension
bushing 
if 
worn 
or 
cracked
r 
r
Gear 
and 
shaft
I
Check 
the
gear 
for 
wear
damage 
and 
or 
crack 
and
replace 
if
required
2 
Check 
the 
shaft 
for
bending 
crack 
wear
and 
worn
spline 
and
replace 
if
required
1
i
STEP
WEAR
I
TWIST
Fig 
TM 
25
Checking 
main
shaft 
spline 
for 
twisting
0
I
l
lii 
j
o
iIk
j 
i
Measure 
each
gear 
backlash 
and
make 
sure 
that
backlash 
is 
in
range 
from 
0
08 
to 
0 
18
mm 
0 
0031 
to
0
0071 
in
When 
backlash 
exceeds
this
range 
recommend
both
driving 
and 
driven
gears 
be
replaced 
as 
a 
set
Fig 
TM
26
Measuring 
gear 
backlash
4 
End
play 
of 
the 
1st
2nd 
3rd
gears 
should 
be 
in
range 
from 
0
15 
to 
0
25 
mm 
0
0059 
to 
0
0098 
in
When
end
play 
is
deviated 
from 
this
range 
replace 
with
new
gears
Flg 
TM 
27
Measuring
gear 
end
play
i
Synchro 
hub
thrust 
washer
1 
When 
bronze
oil
stay 
is
worn
excessively 
replace 
the
synchro 
hub 
thrust
washer 
with
a 
new 
one
2 
When 
both 
surfaces
are
warped 
or
damaged 
replace
TM 
8 
     
        
        Page 496 of 513

TR
ANSMISSION
Baulk
ring
I
Check 
the 
baulk
rings 
for 
wear
pitting 
chips 
or
burrs
If
any 
abnormal 
conditions 
are 
detected
they 
must
be
replaced 
with 
new 
ones
2
Place 
the 
baulk
ring 
in
position 
on 
the 
cone 
of 
each
gear 
Push 
the
ring 
to 
the
gear 
and 
check 
the
gap 
between
the 
end 
face 
of 
the 
bauIk
ring 
and 
the 
front 
face 
of
the
clutch 
teeth 
This
gap 
should 
be 
within 
1 
05 
to
I 
4
mm
0
0413 
to 
0 
0551 
in
If 
it 
is 
less 
than 
0
5 
mm 
0
0197
in 
a
worn 
bauIk
ring 
may 
be 
the
cause 
and
a 
new
ring
should 
be 
fitted
ii 
V
ilillltII
l 
A
1 
05 
to 
1 
4
mm
0 
0413 
to 
0 
0551 
in
Fig 
TM 
28
ulk
ring 
to
cone
installing 
dimension
ShiftiAg 
insert
Replace 
if 
worn
excessively 
worn
unevenly 
de
formed 
or
damaged
Oil 
seal 
i
T
l
l
11
tT
Replace 
the 
oil 
seal 
with 
a 
new 
one 
if
lip 
is 
deformed
f
worn 
or 
cracked 
or 
when 
the
spring 
is
dropped 
off
When 
it 
is
necessary 
to
replace 
the 
transmission 
rear
oil
seal 
use 
the
following
procedurecto 
prevent 
d
age 
to 
the
extension
l
1 
Insert 
the 
transmission
rear 
oil
seal 
remover
ST23850000 
into 
the 
dust 
cover
2 
Attach
a 
pipe 
wrench 
to 
the 
dust
cover 
and 
drive 
out
the 
dust
cover
together 
with 
the
oil 
seal
by
rotating 
the
wrench 
four 
or 
five 
turns
I 
Oil 
seal
Extension 
IJ
y
Fig 
TM 
29
Removing 
rear 
oil 
seal
r
VI 
1
3
Apply 
a
coating 
of
sealing 
material
to 
the
periphery
of 
the 
dust 
cover 
when
pressing 
a 
new 
oil
seal 
into
position 
Never
apply 
an 
adhesive
caulking 
material
Rear
engine 
mounting 
insulator
Replace 
rear
engine 
mounting 
insulator
if
weakened
a
deteriorated 
or
cracked
7i 
1
rt
REASSEMBLY 
AND 
AD
JUSTMENT
Selecting 
counter
bearing 
thrust
washer
l 
Fit 
the 
counter
bearings 
to 
the
counter 
shaft 
both
front 
and
rear
by 
the
use 
of
a 
counter 
shaft
bearing 
press
stand
special 
tool
ST23030000 
and
by 
means 
of
pressing
r
j
Itf
Fig 
TM
JO
Fitting 
counter
shaft
bearing 
r
JJff 
i
it
l 
t
i
j
IlK
Ji 
t
l 
k
TM 
9