Page 313 of 2248
3) Install reverse arm fork spring, ball and interlock
plunger (5.56 x 19.6) to reverse fork rod arm
5. Insert
reverse fork rod
6into hole in reverse fork rod arm5, and
hold it with outer snap ring
7using ST.
ST 399411700 ACCENT BALL INSTALLER
CAUTION:
Apply grease to plunger to prevent it from falling.
4) Position ball
8(7.1438), spring9and gasket10in
reverse shifter rod hole, on left side transmission case, and
tighten checking ball plug
11.
CAUTION:
Replace gasket with a new one.
G3M0796
5) Adjustment of reverse idler gear position
(1) Move reverse shifter rod toward REV side. Adjust
clearance between reverse idler gear and transmission
case wall, using reverse shifter lever
1.
Clearance A:
6.0—7.5 mm (0.236—0.295 in)
Reverse shifter lever
Part No. No. Remarks
32820AA000 0 Further from case wall
32820AA010 No mark Standard
32820AA020 2 Closer to case wall
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B3M0063
(2) After installing a suitable reverse shifter lever, shift
into neutral. Using a thickness gauge, measure clear-
ance between reverse idler gear and transmission case
wall and adjust with washer(s).
Clearance:
0—0.5 mm (0—0.020 in)
Washer (20.5 x 26 x t)
Part No. Thickness mm (in)
803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)
B3M0333C
6) Installation of 1-2 shifter fork12and rod13
(1) Install 1-2 fork rod into 1-2 shifter fork via the hole
on the rear of transmission case.
(2) Align the holes in rod and fork, and drive straight
pin (6 x 22) into these holes using ST.
ST 398791700 STRAIGHT PIN REMOVER
NOTE:
Set other rods to neutral.
Make sure interlock plunger (5.56 x 19.6) is on the 3-4
fork rod side.
7) Installation of 3-4 shifter fork
14and rod15
(1) Install interlock plunger (3 x 11.9) onto 3-4 fork rod.
CAUTION:
Apply a coat of grease to plunger to prevent it from
falling.
(2) Install 3-4 fork rod into 3-4 shifter fork via the hole
on the rear of transmission case.
(3) Align the holes in rod and fork, and drive straight
pin (6 x 22) into these holes.
ST 398791700 STRAIGHT PIN REMOVER
NOTE:
Set reverse fork rod to neutral.
Make sure interlock plunger (installed before) is on the
reverse fork rod side.
8) Install 5th shifter fork
16onto the rear of reverse fork rod
6. Align holes in the two parts and drive straight pin into
place.
ST 398791700 STRAIGHT PIN REMOVER
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G3M0552
9) Position balls17, checking ball springs18and gaskets
19into 3-4 and 1-2 rod holes, and install plugs20.
CAUTION:
Replace gasket with a new one.
G3M0547
10) Installation of speedometer driven gear21
(1) Install washer and speedometer shaft, and press fit
oil seal with ST.
ST 899824100 or 499827000 PRESS
CAUTION:
Use new oil seal, if it has been removed.
(2) Install vehicle speed sensor 2.
CAUTION:
Use new vehicle speed sensor 2, if it has been
removed.
Tightening torque:
5.9±1.5 N⋅m (60±15 kg-cm, 52±13 in-lb)
(3) Install speedometer driven gear and snap ring.
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Page 316 of 2248
2. COMBINATION OF TRANSMISSION CASE
B3M0356A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 25 (2.5, 18)
T2: 29±3 (3.0±0.3, 21.7±2.2)
G3M0554
1) Alignment marks/numbers on hypoid gear set1
The upper number on driven pinion is the match number for
combining it with hypoid driven gear. The lower number is
for shim adjustment. If no lower number is shown, the value
is zero. The number on hypoid driven gear indicates a
number for combination with drive pinion.
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B3M0064A
2) Adjustment of drive pinion shim2
(1) Place drive pinion shaft assembly on right hand
transmission main case without shim and tighten bear-
ing mounting bolts.
(2) Inspection and adjustment of ST
NOTE:
Loosen the two bolts and adjust so that the scale indi-
cates 0.5 correctly when the plate end and the scale end
are on the same level.
Tighten the two bolts.
ST 499917500 DRIVE PINION GAUGE ASSY
A: Plate
B: Scale
B3M0065A
(3) Position the ST by inserting the knock pin of ST into
the knock hole in the transmission case.
(4) Slide the drive pinion gauge scale with finger tip
and read the value at the point where it matches with
the end face of drive pinion.
C: Adjust clearance to zero without shim.
(5) The thickness of shim shall be determined by add-
ing the value indicated on drive pinion to the value
indicated on the ST. (Add if the number on drive pinion
is prefixed by + and subtract if the number is prefixed
by .)
ST 499917500 DRIVE PINION GAUGE ASSY
Select one to three shims from the next table for the value
determined as described above and take a shim thickness
which is closest to the said value.
Drive pinion shim
Part No. Thickness mm (in)
32295AA031 0.150 (0.0059)
32295AA041 0.175 (0.0069)
32295AA051 0.200 (0.0079)
32295AA061 0.225 (0.0089)
32295AA071 0.250 (0.0098)
32295AA081 0.275 (0.0108)
32295AA091 0.300 (0.0118)
32295AA101 0.500 (0.0197)
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G3M0557
3) Install differential assembly3on left hand transmission
case.
CAUTION:
Be careful not to fold the sealing lip of oil seal.
NOTE:
Wrap the left and right splined sections of axle shaft with
vinyl tape to prevent scratches.
G3M0558
4) Install needle bearing and oil seal onto the front of
transmission main shaft assembly
4, and position in left
side transmission case.
CAUTION:
Wrap clutch splined section with vinyl tape to pre-
vent damage to oil seal.
Apply grease (Unilube #2 or equivalent) to the seal-
ing lip of oil seal.
NOTE:
Align the end face of seal with surface A of left side
transmission main case when installing oil seal.
Be careful not to drop oil seal when installing right side
transmission main case.
Make sure straight pin is positioned in hole in needle
bearing’s outer race.
G3M0575
5) Install drive pinion shaft assembly5with shims
selected before into transmission case.
NOTE:
Ensure that the knock pin of the case is fitted into the hole
in the bearing outer race.
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B3M0066A
B3M0067A
B3M0068A
6) Selection of suitable 1st-2nd, 3rd-4th and 5th shifter
fork
Set transmission main shaft assembly and drive pinion
shaft assembly in position (so there is no clearance
between the two when moved all the way to the front).
Select suitable 1st-2nd, 3rd-4th and 5th shifter fork so that
coupling sleeve and reverse driven gear are positioned in
the center of their synchronizing mechanisms.
Clearance mm (in)
1st driven gear
Ato reverse driven gearBa: 9.5 (0.374)
2nd driven gear
Cto reverse driven gearBb: 9.5 (0.374)
3rd drive gear
Dto coupling sleeveEc: 9.3 (0.366)
4th drive gear
Fto coupling sleeveEd: 9.3 (0.366)
5th drive gear
Gto coupling sleeveHe: 9.3 (0.366)
1st-2nd shifter fork
Part No. No. Remarks
32804AA060 1Approach to 1st gear by
0.2 mm (0.008 in)
32804AA070No
markStandard
32804AA080 3Approach to 2nd gear by
0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. No. Remarks
32810AA060 1Approach to 4th gear by
0.2 mm (0.008 in)
32810AA070No
markStandard
32810AA100 3Approach to 3rd gear by
0.2 mm (0.008 in)
5th shifter fork
Part No. No. Remarks
32812AA060 1Approach to 5th gear by
0.2 mm (0.008 in)
32812AA070No
markStandard
32812AA100 3Become distant from 5th gear
by 0.2 mm (0.008 in)
G3M0798
7) Inspection of rod end clearance
Measure rod end clearances A and B. If any clearance is
not within specifications, replace rod or fork as required.
A: 1st-2nd to 3rd-4th 0.5—1.5 mm (0.020—0.059 in)
B: 3rd-4th to 5th 0.6—1.4 mm (0.024—0.055 in)
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B3M0399A
B3M0331
8) Combination of transmission case
(1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline, and
apply liquid gasket, and then put case right side and left
side together.
Liquid gasket:
THREE BOND 1215 or equivalent
(2) Tighten 17 bolts with bracket, clip, etc. as shown in
the figure.
Tightening torque:
8 mm bolt
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
10 mm bolt
39±3 N⋅m (4.0±0.3 kg-m, 28.9±2.2 ft-lb)
NOTE:
Insert bolts from the bottom and tighten nuts at the top.
Put cases together so that drive pinion shim and input
shaft holder shim are not caught up in between.
Confirm that counter gear and speedometer gear are
meshed.
G3M0597
9) Tighten ball bearing attachment bolts.
Tightening torque:
29±3 N⋅m (3.0±0.3 kg-m, 21.7±2.2 ft-lb)
G3M0563
10) Backlash adjustment of hypoid gear and preload
adjustment of roller bearing
NOTE:
Support drive pinion assembly with ST.
ST 498427100 STOPPER
45
3-1SERVICE PROCEDURE
4. Transmission Case