Page 665 of 3342
4. Transmission Case
A: DISASSEMBLY
1. SEPARATION OF TRANSMISSION
B3M0614A
B3M0336C
1) Remove operating cylinder (hydraulic application type)
1and clutch release lever2.
[W3A2], [W5A0].>
G3M0597
2) Remove bearing mounting bolts.
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3-1SERVICE PROCEDURE
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G3M0598
3) Remove main shaft rear plate4.
B3M0330
4) Separating transmission case
(1) Put vinyl tape around splines of right and left axle
drive shafts to prevent damage to oil seals.
B3M0331
(2) Separate transmission case into right and left
cases by loosening seventeen coupling bolts and nuts.
B3M0101B
5) Remove drive pinion shaft assembly6from left side
transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
6) Remove main shaft assembly
7.
G3M0557
7) Remove differential assembly.
CAUTION:
Be careful not to confuse right and left roller bear-
ing outer races.
Be careful not to damage retainer oil seal.
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3-1SERVICE PROCEDURE
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2. TRANSMISSION CASE
B3M0060A
A: Front right hand transmission case
B3M0333A
1) Drive out spring pin1with ST, and remove 5th shifter
fork
2.
ST 398791700 STRAIGHT PIN REMOVER
2) Remove plugs
3, springs4and checking balls5.
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B3M0333B
3) Drive out spring pin6, and pull out 3-4 fork rod7and
shifter fork
8.
NOTE:
When removing rod, keep other rods in neutral. Also, when
pulling out straight pin, remove it toward inside of case so
that it may not hit against case.
4) Drive out straight pin
9, and pull out 1-2 fork rod10and
shifter fork
11.
G3M0602
5) Pull out straight pin12, and remove idler gear shaft13,
reverse idler gear
14and washer15.
6) Remove outer snap ring
16, and pull out reverse shifter
rod arm
17from reverse fork rod18. Then take out ball,
spring and interlock plunger from rod.
And then remove rod.
NOTE:
When pulling out reverse shifter rod arm, be careful not to
let ball pop out of arm.
7) Remove reverse shifter lever
19.
G3M0546
8) Remove differential side retainers using ST.
ST 499787000 WRENCH ASSY
G3M0547
9) Remove outer snap ring20and pull out speedometer
driven gear
21. Next, remove vehicle speed sensor 2, oil
seal, speedometer shaft
22and washer.
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B: ASSEMBLY
1. TRANSMISSION CASE
B3M0061A
A: To right hand transmission case
Tightening torque: N⋅m (kg-m, ft-lb)
T: 19.6±0.1 (2.00±0.015, 14.5±0.1)
B3M0062A
1) Position interlock plungers (5.56 x 19.6), one plunger in
hole between 1-2 and 3-4 fork rod holes, and one plunger
in hole between 3-4 and reverse fork rod holes.
B: Rod holes
G3M0604
2) Install reverse shifter lever1, reverse idler gear2and
reverse idler gear shaft
3, and secure with straight pin4.
NOTE:
Be sure to install reverse idler shaft from the rear side.
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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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4. Transmission Case