Page 3208 of 4264
7B1-44 MANUAL TRANSMISSION
Clutch Hub Spline Play
Set a dial indicator to the clutch hub to be
measured.
226RS042
Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch Hub Spline Play
Standard Limit
1st-2nd
3rd-4th 0 - 0.1 mm
(0 - 0.004 in) 0.2 mm
(0.008 in)
Rev. 5th 0 - 0.2 mm
(0 - 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play
Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)
226RS043
Reassembly
1. Install center roller bearing (29) to counter gear
shaft (30).
Apply engine oil to the bearing inner and outer
circumferences.
Install the roller bearing in the proper direction.
NOTE: Check that outer race moves only in the
direction of arrow.
226RS044
2. Install front roller bearing (28) by performing the
following steps.
Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gear
shaft (30).
Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.
Page 3222 of 4264
7B1-58 MANUAL TRANSMISSION
3. WALKING OR JUMPING OUT OF GEAR
Checkpoint Trouble Cause Countermeasure
Shift rod and quadrant box
sliding faces
Detent ball
Replace the shift rod and/or
the quadrant box
Replace the detent ball
Worn shift rod and/or sliding
faces
Worn detent ball
Detent springRepair or replace the detent
spring
Replace the worn parts
Detent spring weak or broken
Insufficient stroke caused by
sliding position wear and
excessive play
OK
OKNG NG NG NG
OK OK
Change lever play
Continued on the next page
Mainshaft and countershaft
thrust playReplace the worn partsWorn thrust washer, collar,
and/or gear thrust faces
Replace the worn partsWorn shift arm and/or
synchronizer sleeve groove
NG NG
OKShift arm and synchronizer
sleeve
Page 3265 of 4264
MANUAL TRANSMISSION 7B1-101
Clutch Hub Spline Play
Set a dial indicator to the clutch hub to be
measured.
226RS042
Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch Hub Spline Play
Standard Limit
1st-2nd
3rd-4th 0 - 0.1 mm
(0 - 0.004 in) 0.2 mm
(0.008 in)
Rev. 5th 0 - 0.2 mm
(0 - 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play
Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)
226RS043
Reassembly
1. Install center roller bearing (29) to counter gear
shaft (30).
Apply engine oil to the bearing inner and outer
circumferences.
Install the roller bearing in the proper direction.
NOTE: Check that outer race moves only in the
direction of arrow.
226RS044
2. Install front roller bearing (28) by performing the
following steps.
Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gear
shaft (30).
Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.
Page 3279 of 4264
MANUAL TRANSMISSION 7B1-115
3. WALKING OR JUMPING OUT OF GEAR
Checkpoint Trouble Cause Countermeasure
Shift rod and quadrant box
sliding faces
Detent ball
Replace the shift rod and/or
the quadrant box
Replace the detent ball
Worn shift rod and/or sliding
faces
Worn detent ball
Detent springRepair or replace the detent
spring
Replace the worn parts
Detent spring weak or broken
Insufficient stroke caused by
sliding position wear and
excessive play
OK
OKNG NG NG NG
OK OK
Change lever play
Continued on the next page
Mainshaft and countershaft
thrust playReplace the worn partsWorn thrust washer, collar,
and/or gear thrust faces
Replace the worn partsWorn shift arm and/or
synchronizer sleeve groove
NG NG
OKShift arm and synchronizer
sleeve
Page 3444 of 4264
3B-14 POWER-ASSISTED STEERING SYSTEM
Tie-rod End
If looseness or play is found when checked by moving
the end of ball joint at tie-rod end, replace tie-rod end.
Tie-rod Assembly
If the resistance is insufficient or play is felt when
checked by moving the ball on the tie-rod, replace the
tie-rod assembly.
Rubber Parts
If wear or damage is found through inspection, replace
with new ones.
Reassembly
1. Install mounting rubber and dust cover (If removed).
2. Install oil line.
Torque: 10 - 15 N
m (1.0 – 1.5 kg
m/87 - 130 lb in)
3. Install tie-rod assembly with tab washer.
Apply grease to ball joint, install tie-rod and tab
washer, then tighten to specified torque.
Torque: 69 - 98 N
m (7.0 – 10.0 kg
m/51 - 72 lb ft)
After tightening, bend tab washer against width
across flat of inner ball joint.
4.
Apply a thin coat of grease to the shaft for smooth
installation. Then install bellows.
5. Install band and clip.
6. Install tie-rod end and tighten lock nut.
Torque:
92 - 104 N
m (9.4 – 10.6 kg
m/68 - 77 lb ft)
Main Data and Specifications
General Specifications
2WD 4WD
Power steering Without With
Type Rack and pinion
Rack stroke mm (in) 138 (5.43) 138 (5.43) 152 (5.98)
Steering unit
Lock to lock 4.84 3.38 3.26
Page 3503 of 4264
FRONT SUSPENSION 3C-11
NOTE: Paint mark to be outer side of after assembly to
vehicle.
2. Install nut (2), then tighten it to the specified
torque.
Torque: 55N
m (5.6kg
m/41lb ft)
3. Install bolt (7) and nut (4), then tighten to the
specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137N
m (14.0kg
m/101 lb ft)
NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.
RTW340SH001301-X
4. Install nut (6), then tighten it to the specified
torque.
Torque: 50N
m (5.1kg
m/37 lb ft)
5. Tighten the cam bolt (8) and nut (3), it to the
interim torque, then turn the cam bolt to the setting
mark applied during disassembly.
6. Install ball joint nut, then tighten it to the specified
torque with just enough additional torque to align
cotter pin holes. Install new cotter pin (5).
Torque: 147N
m (15.0kg
m/108 lb ft)
NOTE: Check the trim height. Refer to Front Alignment
Inspection and Adjustment.
7. Nut (3) tighten it to the specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186N
m (19.0kg
m/137 lb ft)
NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.
RTW340SH001301-X
8. Install wheel and tire assembly. Refer to wheel in
this section.
Page 3508 of 4264
3C-16 FRONT SUSPENSION
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the following parts :
Stabilizer bar
Rubber bushing
Link ball joint
Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket and bolt (5), then tighten it to the
specified torque.
Torque: 25 N
m (2.5kg
m/18 lb ft)
4. Install link.
5. Install nut (3), (4), then tighten it to the specified
torque.
Torque: 50 N
m (5.1kg
m/37 lb ft)
Page 3510 of 4264
3C-18 FRONT SUSPENSION
6. Remove the stabilizer link nut. Right and left.
7. Remove the wheel speed sensor from the knuckle.
8. Remove back plate.
9. Remove lower ball joint by using remover 5-8840- 2017-0.
CAUTION: Be careful not to damage the ball joint
boot.
P1010009
10. Remove upper ball joint by using remover 5-8840-
2017-0.
CAUTION: Be careful not to damage the ball joint
boot.
P1010011
11. Remove knuckle.
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the following parts:
Knuckle
Knuckle arm
Installation
1. Install knuckle assembly.
2. Install upper ball joint and tighten the nut to the
specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin (1).
Torque: 98 N
m (10.0kg
m/72 lb ft)
3. Install lower ball joint and tighten the nut to the specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin (4).
Torque: 147N
m (15.0kg
m/108 lb ft)
4. Install back plate.
5. Install wheel speed sensor.
6. Install stabilizer link nut. Right and left.
