Page 144 of 396
MANUAL TRANSMISSION OVERHAUL – Transmission22B-14
Apply gear oil to all
moving parts before
installation.
12
13 14
15
1617 18
1920
21
22 23
24
25 26
27
Unit: Nm {kgfm}
18 {1.9}
30 {3.1}
48 {4.9}
3.9 {0.7} 44 {4.5}
Disassembly steps
12. Interlock plate bolt
13. Gasket
G14. Control housing
15. Neutral return spring
F16. Under cover
17. Reverse idler gear shaft bolt
18. Gasket
19. Reverse idler gearE20. Transmission case
21. Outer race
22. Outer race
D23. Spacer
D24. Spacer
D25. Spacer
26. Oil guide
27. Oil guide
Page 145 of 396
MANUAL TRANSMISSION OVERHAUL – Transmission22B-15
Apply gear oil to all
moving parts before
installation.
2829
3031
32
3334
3536 37
38
39 40
Disassembly steps
C28. Spring pin
29. 1st-2nd speed shift rail
30. 1st-2nd speed shift fork
C31. Spring pin
AC32. Spring pin
BB33. 3rd-4th speed shift rail
BB34. 3rd-4th speed shift forkBB35. 5th-reverse speed shift rail
BB36. 5th-reverse speed shift fork
CA37. Center differential
CA38. Output shaft
CA39. Input shaft
40. Clutch housing
Page 149 of 396
MANUAL TRANSMISSION OVERHAUL – Transmission22B-19
GCONTROL HOUSING INSTALLATION
Apply sealant to the illustrated position of the transmission
case.
Specified sealant: THREEBOND 1216
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.
HSPEEDOMETER GEAR INSTALLATION
Apply transmission oil to the O-ring of the speedometer gear.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W
ISELECT LEVER INSTALLATION
Apply grease to the control shaft sliding portion of the select
lever shoe.
Specified grease: MOLYWHITE TA No.1 or No.2
JO-RING INSTALLATION
Lubricate O-ring with transmission oil.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W
INSPECTION
BACK-UP LAMP SWITCH
Check for continuity between terminals.
Switch conditionContinuity
PressedNot exist
ReleasedExists
2 mm
Control shaft
Select
lever
shoe
Page 150 of 396
MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-20
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
1 2
3 4
5 6
79
810
Apply gear oil to all
moving parts before
installation.
21
19
11 12
14
13
15
16
17
18
20
1822
Disassembly steps
M1. Snap ring
AL2. Ball bearing
BK3. Thrust plate stopper
J4. Thust plate
CI5. 5th speed gear
6. 4th speed gear
7. Needle roller bearing
DH8. 4th speed gear sleeve
9. Synchronizer ring
G10. Synchronizer spring
F11. Synchronizer sleeveE12. 3rd-4th speed synchronizer hub
13. Outer synchronizer ring
D14. Synchronizer spring
15. Synchronizer cone
16. Inner synchronizer ring
17. 3rd speed gear
18. Needle roller bearing
C19. Snap ring
EB20. Ball bearing
A21. Oil seal
22. Input shaft
Page 152 of 396
MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-22
REASSEMBLY SERVICE POINTS
AOIL SEAL INSTALLATION
Make sure that the oil seal is pressed into the position shown
in the illustration.
BBALL BEARING INSTALLATION
CSNAP RING INSTALLATION
Select and install a snap ring so that the input shaft front
bearing end play will have the standard value.
Standard value: 0 – 0.12 mm
DSYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring securely to the illustrated
position of the outer synchronizer ring.
E3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
Install the synchronizer hub in such a way that it will be oriented
in the direction shown.Oil seal
3.5 mm
MD998801MD998812
MD998813
MD998818
Snap ring
Synchronizer spring
Installation
direction
Identification mark
Page 157 of 396
MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-27
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
18
19
20 21
22
23
35
1124
10 1213
987654
3
2 1
26
2725
13 14
15
16 172928
3231
36
3433
4 30
Disassembly steps
P1. Snap ring
AO2. Taper roller bearing
BN3. Reverse gear bearing sleeve
N4. Needle roller bearing
N5. Reverse gear
6. Synchronizer ring
L7. Synchronizer spring
F8. Synchronizer sleeve
CM9. 5th-reverse speed synchronizer hub
10. Synchronizer ring
L11. Synchronizer spring
12. 5th speed gear
13. Needle roller bearing
K14. 5th speed gear sleeve
J15. 4th speed gear
I16. Snap ring
DH17. 3rd speed gear
18. 2nd speed gear19. Needle roller bearing
EG20. 2nd speed gear sleeve
21. Inner synchronizer ring
22. Synchronizer cone
23. Outer synchronizer ring
D24. Synchronizer spring
F25. Synchronizer sleeve
E26. 1st-2nd speed synchronizer hub
27. Outer synchronizer ring
D28. Synchronizer spring
29. Inner synchronizer ring
30. Synchronizer cone
31. 1st speed gear
32. Needle roller bearing
FC33. 1st speed gear sleeve
GB34. Taper roller bearing
A35. Oil seal
36. Output shaft
Page 159 of 396
MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-29
F1ST SPEED GEAR SLEEVE REMOVAL
GTAPER ROLLER BEARING REMOVAL
REASSEMBLY SERVICE POINTS
AOIL SEAL INSTALLATION
Make sure that the oil seal is pressed into the position shown
in the illustration.
BTAPER ROLLER BEARING INSTALLATION
C1ST SPEED GEAR SLEEVE INSTALLATION
1st speed
gear sleeve MD998801
Taper roller bearing
MD998801
Oil seal3.5 mm
Taper roller
bearing MD998801MD998812
MD998819
1st speed
gear sleeve
MD998364
MD998812
MD998814
MD998824
Page 165 of 396
MANUAL TRANSMISSION OVERHAUL – Reverse Idler Gear22B-35
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
5
4321
TFM0807
Disassembly steps
1. Snap ring
2. Thrust washer
3. Reverse idler gear
4. Needle roller bearing
5. Reverse idler gear shaft
INSPECTION
NEEDLE ROLLER BEARING
(1) Check to ensure that when the shaft and gear are combined
and made to rotate, they rotate smoothly without looseness
and noise.
(2) Check to ensure that the cage is not deformed.
