MANUAL TRANSMISSION

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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MANUAL TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . 9 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 MANUAL TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . 15 INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 INTERMEDIATE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SPEEDOMETER SLEEVE ASSEMBLY . . . . . . . . . . . . . . . . . 45

GENERAL

GENERAL
SPECIFICATIONS
Manual transmission Type Gear ratio 1st 2nd 3rd 4th Reverse Final reduction ratio Type Gear ratio 1st 2nd 3rd 4th 5th Reverse Final gear ratio Speedometer gear ratio Quantity of oil lit. (U.S.qts., Imp.qts.) Backlash between differential side gear and pinion Differential case end play Intermediate shaft end play Output shaft pre-load Clearance between 5th shift lug and 3-4 speed shift lug (5-speed only) 4-speed, Floor-shift control 4.266 2.365 1.467 1.105 4.109 3.470 5-speed, Floor-shift control 4.266 2.365 1.467 1.105 0.955 4.109 3.470 Drive 19/Driven 16 2.1 (2.2, 1.8) 0.025-0.150 mm (0.001-0.006 in.) . . . . . Adjust with spacer 0-0.15 mm (0-0.006 in.) . . . . . . . . . . . . Adjust with 0-0.05 mm (0-0.002 in.) . . . . . . . . . . . . Adjust with 0.15-0.20 mm (0.006-0.0078 in.) . . . . Adjust with 0-0.4 mm (0-0.016 in.) . . . . . . . . . . . . . . Adjust with selector spacer spacer spacer spacer

SERVICE STANDARD
Manual transmission Standard value Free play of range selector lever end Approx. 5 mm (0.2 in.) Spacer for differential pinion backlash adjustment Thickness 0.75-0.82 mm (0.0295-0.0323 0.83-0.92 mm (0.0327-0.0362 0.93-1.00 mm (0.0366-0.0394 1.01-1.08 mm (0.0398-0.0425 1.09-1.16 mm (0.0429-0.0457 1.17-1.25 mm (0.0460-0.0492 1.26-1.34 mm (0.0496-0.0527 Spacer for differential case end play adjustment 1.31 mm (0.0516 in.)-E Thickness-ldent. mark 1.40 mm (0.0551 in.)-None 1.49 mm (0.0587 in.)-C

in.) in.) in.) in.) in.) in.) in.)

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GENERAL

1.58 mm (0.0622 in.)-B 1.67 mm (0.0657 in.)-A 1.76 mm (0.0693 in.)-F 1.85 mm (0.0728 in.)-G 1.94 mm (0.0764 in.)-H 2.03 mm (0.0799 in.)-1 2.12 mm (0.0835 in.)-J 2.21 mm (0.0870 in.)-K Snap ring for input shaft Thickness-ldent. color 2.24 mm (0.0882 in.)-None 2.31 mm (0.0909 in.)-Bule 2.38 mm (0.0937 in.)-Brown 1.84 1.87 1.90 1.93 1.96 1.99 2.02 2.05 2.08 2.11 2.14 2.17 2.20 2.23 2.26 2.29 2.32 2.35 2.38 2.41 2.44 2.47 2.50 2.53 2.56 2.59 2.62 2.65 2.68 mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm (0.0724 (0.0736 (0.0748 (0.0760 (0.0772 (0.0783 (0.0795 (0.0807 (0.0819 (0.0831 (0.0843 (0.0854 (0.0866 (0.0878 (0.0890 (0.0902 (0.0913 (0.0925 (0.0937 (0.0949 (0.0961 (0.0972 (0.0984 (0.0996 (0.1008 (0.1020 (0.1031 (0.1043 (0.1055 in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.)

Spacer for intermediate and outputshaft end play or preload adjustment Thickness

Selector spacer for shift lug clearance (5-speed only) Thickness-ldent. mark

0.6 mm (0.024 in.)-G 0.9 mm (0.035 in.)-F 1.2 mm (0.047 in.)-E 1.5 mm (0.059 in.)-D 1.8 mm (0.071 in.)-C 2.1 mm (0.083 in.)-B 2.4 mm (0.094 in.)-A 2.7 mm (0.106 in.)-None

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GENERAL

TIGHTENING TORQUE
Nm Manual transmission Extension to transmission Shift rod set screw Insulator to extension rod Bracket assembly attaching bolt Control cable attaching bolt Control cable clamp attaching bolt Transmission mounting bolt Starter motor mounting bolt Bell housing cover to transmission (8 x 20)* Bell housing cover to transmission (8 x 14)* Engine transmission Clutch cover bolt Transmission mounting bolt (M10-7T) Transmission mounting bolt (M8-10T) Front cover bolt Oil filler plug Oil drain plug Housing-to-case tightening bolt Front retainer bolt Input shaft locking nut Transmission mounting bracket bolt Differential drive gear bolt Speedometer sleeve plate bolt Reverse shift lever support bracket bolt Poppet plug bolt Backup lamp switch NOTE *Bolt O.D. x Length mm kg.cm Ib.ft

610-710 43-51 337 24 120-150 9-11 90-140 6.5-10 90-140 6.5-10 440-560 31-40 440-560 31-40 220-330 16-23 150-220 11-16 100-120 7-9 Refer to the table of components 15-21 150-210 11-15 43-53 440-540 32-39 30-34 300-350 22-25 10-11 100-110 7-8 30-34 300-350 22-25 30-34 300-350 22-25 30-41 300-420 22-30 15-21 150-210 11-15 89-107 900-1,100 65-79 30-41 300-420 22-30 128-137 1,300-1,400 94-101 3.0-4.5 30-45 2.5-3.5 15-21 150-210 11-15 27-33 270-340 20-24 30 310 22

60-70 33 12-15 9-14 9-14 9-14 43-55 22-32 15-22 10-12

LUBRICANTS
Recommended lubricant Manual transmission Manual transmission oil lit. (U.S.qts., Imp.qts.) Shift lever, bushing contacting surface Dust cover inside surface Shift lever sliding portion Quantity

API classification GL-4 Wheel bearing grease SAE J310a, NLGI grade #2 EP

2.1 (2.2, 1.8) As required As required As required

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GENERAL

SPECIAL TOOLS

43-5

GENERAL

Tool (Number and name) 09432-21300 Removing plate

Illustration

Use 1) Removal of the input shaft front bearing 2) Removal of the output shaft 2nd, 3rd and 4th gear

09432-21400 Taper bearing puller

1) Removal of the intermediate shaft taper bearing inner race 2) Removal of the output shaft taper bearing inner race 3) Removal of the transfer shaft taper bearing inner race 1) Installation of the input shaft front bearing 2) Installation of the output shaft synchronizer hub and gear sleeve

09432-21500 Bearing installer

09432-21600 Bearing installer

1) Installation of the input shaft rear bearing 2) Installation of the intermediate shaft front and rear bearing 3) Installation of the output shaft front and rear bearing 4) Installation of the taper roller bearing inner race of transfer shaft (use with 09500-21000)

09432-21700 Bearing outer race installer

1) Installation of intermediate shaft bearing outer race (use with 09500-21000) 2) Installation of output shaft bearing outer race (use with 09500-21000) 3) Installation of transfer shaft front bearing outer race (use with 09500-21000) 1) Removal of differential ball bearing (use with 09532-11301) 2) Removal of differential bearing

09433-21000 Removing plate

09437-31000 Shift lever remover

Removal and installation of the shift lever knob

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GENERAL

Tool (Number and name) 09438-21000 Poppet ball guide

Illustration

Use Installation of the poppet ball

43-7

GENERAL

TROUBLESHOOTING
Symptom Transmission vibration Probable cause Broken gear shift control Worn or pitting due to improper tooth Oil leakage Housing misaligned Worn seals or gaskets Loose transmission assembly Broken transmission mount Mounting bolts loose Does not shift to 5th (M/T) Malfunctioning actuator Malfunctioning vacuum control Short circuit in vacuum control Replace Replace Realign Replace parts as required Replace Retighten bolts Repair or replace as required Replace Replace Remedy

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MANUAL TRANSMISSION CONTROL

MANUAL TRANSMISSION CONTROL

COMPONENTS

From March, 1987

GEARSHIFT LEVER
Removal
1. 2. 3. 4. Remove the floor console box. On vehicles with rear heater duct, remove the rear heater duct. Remove the shift lever assembly attaching nuts from the floor. Pull the shift lever assembly downward from the vehicle.

5. Remove the extension rod from the transmission.

MANUAL TRANSMISSION CONTROL

6. After removing the lock wire, remove the shift rod set screw, and then remove the shift rod from the transmission.

7. Remove the shift rod and extension rod as an assembly.

8. Remove the dust cover at the end of the shift lever. 9. After the split pin has been removed, remove the shift rod. 10. Remove the extension rod to insulator attaching bolt and remove the extension rod. 11. Remove the dust cover and remove the bushing.

Inspection
1. 2. 3. 4. Check Check Check Check the shift rod joint for wear, sticking or rough movement. the rubber parts for damage or deterioration. all bushings for wear and damage. the return spring for deterioration.

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MANUAL TRANSMISSION CONTROL Installation

1. Apply the specified wheel bearing grease to the following areas: (a) Dust cover inside surface (b) Shift lever and bushing contacting surface (c) Shift lever sliding portion Recommended wheel bearing grease . . . . . . . . . . . . . . . . . . . . Wheel bearing grease SAE J310a, NLGI grade #2 EP.

2. Install a new lock wire to the set screw of the shift rod to prevent looseness.

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MANUAL TRANSMISSION

MANUAL TRANSMISSION
COMPONENTS

Nm A B C D E F 43-55 43-55 22-32 30-34 10-12 15-22

kg.cm 430-560 430-560 220-330 300-350 100-120 150-220

Ib.ft 31-40 31-40 16-23 22-25 7-9 11-16

O.D. x Length mm (in.)

Bolt identification

REMOVAL,
1. Remove the battery. 2. On vehicles with a 5-speed transmission, disconnect the connector of the select control valve.

NOTE: Do not reuse the collar removed when the pin for coupling the actuator to the shaft is removed, but use a new part.

3. Remove the speedometer cable. 4. Remove the clutch control cable. 5. Disconnect the connector of the backup lamp.

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MANUAL TRANSMISSION
6. Remove the harness from the starter motor. 7. Remove the transmission to engine coupling bolts from the top side of the transmission.

8. Remove the starter motor.

9. Lift up the vehicle and remove the under cover. 10. Drain the transmission oil.

11. Remove the extension rod and shift rod from under the engine compartment. 12. After the stabilizer bar has been removed from the lower arm, remove the lower arm at the body side, remove the right and left drive shafts, and hold them in appropriate positions. (Refer FRONT SUSPENSION).

MANUAL TRANSMISSION
13. Support the lower part of the transmission by using a transmission jack.

CAUTION Support a wide area of the transmission so that the oil pan is not partially pressed when supported.
14. Remove the bell housing cover. 15. Remove the bolts connecting the transmission with the engine from under the engine compartment.

16. Remove the transmission mount insulator bolt. 17. Remove the blind cover from inside the right fender shield and remove the transmission bracket assembly. 18. Remove the transmission mount bracket. 19. Slide the transmission assembly rightward from the vehicle and then take it out downward.

INSTALLATION
1. Install the transmission by reversing the procedures, and torque all part to specifications during installation. 2. Refill with transmission oil to the specified level. Recommended oil . . . . . . . . . . . . . . . . . API classification GL-4 Quantity . . . . . . . . . . . . . . . 2.1 lit. (2.2 U.S.qts., 1.8 Imp.qts.) 3. Adjust the play of the clutch control cable. 4. Operate the shift lever to confirm that the gears of the transmission are positively changed over.

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MANUAL TRANSMISSION ASSEMBLY

MANUAL TRANSMISSION ASSEMBLY

SECTIONAL VIEW
4-speed Manual Transmission

43-15

MANUAL TRANSMISSION ASSEMBLY 5-speed Manual Transmission

43-16

MANUAL TRANSMISSION ASSEMBLY

OPERATION OF 5-SPEED TRANSMISSION

1. When the control lever is shifted to the 5th position, the control finger engages with the 5th speed shift lug, shifting the 3-4th speed shift rail to the 4th speed side with the 5th shift lug, and the 4th speed gear is engaged. 2. When the select lever moves to the 5th speed position, the select switch is turned ON simultaneously. 3. When signals from the select switch enter the control relay, the relay excites the solenoid of the select control valve and turns it ON. 4. When the select control valve is ON, the valve closes the atmosphere side of V1 nipple and opens the passage of M - V1, actuating the manifold negative pressure on the H chamber of the select actuator. Meanwhile, the V2 nipple side is opened to the atmosphere, allowing the atmospheric pressure to enter the L chamber. 5. The pressure difference between H chamber and L chamber actuates the diaphragm of the select actuator, pulling the select rail to the E range and engaging the input high gear. The 5th speed is obtained in this way. 6. When the control lever is returned from 5th speed, the select switch is turned OFF, and the solenoid of the select control valve is also turned OFF by a relay. Then, the atmospheric pressure is introduced to H chamber through V1 nipple, causing the negative pressure to be actuated on L chamber through V2 nipple. As a result, the select rail is pulled to the P range and the input low gear is engaged.

NOTE: A slight clicking sound may be heard when shifting to 5th or reverse gears. This sound does not indicate any abnormality as it is produced by electric control of the shifting mechanism in the transmission.

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MANUAL TRANSMISSION ASSEMBLY

INSTALLATION OF VACUUM HOSE FOR 5-SPEED MANUAL TRANSMISSION

IDENTIFICATION
Nipple Nipple Ident. Mark A B C D E F l l l l ll l Color White White Green Green Yellow Ident. Mark nn nnn n n nn n Color White White White Green Green Yellow Vacuum hose Remarks

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MANUAL TRANSMISSION ASSEMBLY

COMPONENTS 4-speed Manual Transmission

1. Backup light switch 2. Gasket 3. Steel ball 4. Bolt 5. Locking plate 6. Speedometer gear assembly 7. Bolt (13) 8. Transmission case 9. Bearing outer race (2) 10. Spacer (2)-select 11. Air breather 12. Transmission case gasket 13. Poppet plug (3) 14. Gasket (3) 15. Poppet spring (3) 16. Poppet ball (3) 17. Reverse idler gear shaft 18. Reverse idler gear 19. Bolt (2) 20. Reverse shift lever assembly 21. Reverse shift rail

Nm A B C D E 15-21 35-41 3-5 27-33 30

kg.cm 150-210 360-420 30-50 270-340 300

Ib.ft 11-15 26-30 2.2-3.6 20-24 22

22. Spring pin (2) 23. 1-2 shift rail 24. 1-2 shift fork 25. 3-4 shift rail 26. 3-4 shift fork 27. Interlock plunger (2)
28. Output shaft assembly 29. Spacer-select 30. Differential assembly 31. Intermediate gear assembly 32. Bolt (3) 33. Bearing retainer 34. Input shaft assembly 35. Bearing outer race 36. Clutch housing

MOTE Numbers show order of disassembly. For reassembly, reverse order of disassembly.

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MANUAL TRANSMISSION ASSEMBLY

COMPONENTS 5-speed Manual Transmission

1. Select actuator 2. C o l l a r 3. O-ring 4. S e a t 5. P i n 6. Select rail fork assembly 7. Seat 8. Input shaft assembly 9. Bearing retainer 10. Spacer 11. Bearing outer race 12. Intermediate gear assembly 13. Speedometer driven gear assembly 14. Reverse idler gear shaft 15. Reverse idler gear 16. Reverse shift gear 17. Output shaft assembly 18. Bearing outer race 19. Spacer 20. Differential assembly 21. Reverse shift rail 22. 1-2 shift rail 23. 1-2 shift fork 24. 3-4 shift fork 25. Spring pin 26. 3-4 shift rail 27. 5-speed shift lub 28. Selector spacer 29. Poppet ball

30. Poppet spring 31. P l u g 32. Interlock plunger A 33. Interlock plunger B 34. Transmission bracket 35. Clutch cable bracket 36. Backup light switch 37. G a s k e t 38. Steel ball 39. Transmission case 40. Air breather 41. Select switch 42. Clutch housing assembly

Nm 15-22 35-42 3-5 27-34 29 55-59

kg.cm 150-220 360-430 30-50 270-350 290 560-600

Ib.ft 11-16 26-31 2.2-3.6 20-25 22 40-43

NOTE Numbers show order of disassembly. For reassembly reverse order of disassembly.

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MANUAL TRANSMISSION ASSEMBLY

DISASSEMBLY
1. Remove the transmission mounting bracket. 2. Remove the two select actuator mounting bolts (for 5-speed only).

3. Remove the clamp for harness of select switch (for 5-speed only) and backup light switch. 4. Remove the backup light switch and the steel ball. 5. Remove the select switch (for 5-speed only).

6. Pull the select actuator to remove its rod and shift rail connection from transmission (for 5-speed only). 7. Remove the collar and pin, and then remove the select actuator (for 5-speed only).

NOTE: Do not reuse the collar when reassembly. Use a new part.

8. Remove the speedometer gear assembly locking bolt. 9. Pull the speedometer gear assembly from the clutch housing. 10. Remove the transmission to clutch housing tightening bolt. 11. Remove the transmission case. 12. Remove the gasket. 13. Remove the spacer for differential end play adjustment.

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MANUAL TRANSMISSION ASSEMBLY

14. Remove the three poppet plugs and gasket, and then three poppet springs and steel balls.

15. Pull the reverse idler gear shaft and remove reverse idler gear. 16. Remove the reverse shift lever from clutch housing. 17. Remove reverse shift rail.

18. Use a pin punch to drive the spring pins from the shift forks and shift rails.

19. Remove the selector spacer (for 5-speed only).

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MANUAL TRANSMISSION ASSEMBLY

20. Pull the 1-2 shift rail from clutch housing then remove the 3-4 shift rail. Next, remove 1-2 shift rail and fork assembly, together with 3-4 shift rail and fork assembly. 21. Remove the two interlock plungers from the clutch housing. 22. Remove the 5th speed shift lug (for 5-speed only). 23. Remove the output shaft assembly. 24. Remove the differential assembly from clutch housing.

25. Remove the poppet plug, the poppet spring and the steel ball for select shift rail.

26. Remove the input shaft bearing retainer.

27. Remove the input shaft assembly together with the select shift fork, rail and intermediate shaft.

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MANUAL TRANSMISSION ASSEMBLY

REASSEMBLY
1. Turn the sub gear in direction of arrow to align 8 mm (0.31 in.) hole in the intermediate gear with that the sub gear, and then insert 8 mm (0.31 in.)-diameter, 35 mm (1.38 in.)-long dummy pin through the intermediate gear into sub gear hole.

2. Assemble the select shift fork and rail assembly to the synchronizer sleeve of input shaft, and then install these components and intermediate shaft as a unit.

3. Install the front bearing retainer and tighten the three bolts to 15 to 21.5 Nm (150 to 220 kg.cm, 11 to 15.5 Ib.ft).

4. Install the differential assembly to the clutch housing. 5. Install the output shaft assembly. 6. Make sure that the gears are meshed properly, and then remove dummy pin from the sub gear and intermediate gear.

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MANUAL TRANSMISSION ASSEMBLY

7. Install 5th speed shift fug to pin on the clutch housing.

CAUTION Pay attention to the direction of installation. If the shift lug is installed the wrong way, hard shifting may result.

8. Insert the two interlock plungers into the holes in the clutch housing. 9. Install 1-2 shift rail assembly together with 3-4 shift rail assembly or 3-4-5 shift rail assembly. Install one shift rail into its clutch housing hole, and then install the other. It is impossible to install both shift rails at the same time because of interference of interlock plunger.

10. Using Special Tool 09414-11100 or blunt punch, drive in spring pins. This spring pin must be driven in with its slit on shift rail center line. Make sure both ends of spring pin protrude same distance.

11. Select the spacer to make the adjustment to the specified clearance between the 3-4 shift lug and 5th shift lug. Then install the select spacer. Clearance between 3-4 shift lug and 5th shift lug . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1-0.5 mm (0.004-0.020 in.)

MANUAL TRANSMISSION ASSEMBLY Kind of Select Spacers

Thickness mm (in.) 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 (0.024) (0.035) (0.047) (0.059) (0.071) (0.083) (0.094) (0.106) Ident. mark

G
F E D C B A None

12. Install the reverse shift rail into the clutch housing. 13. Install the reverse shift lever, and tighten the two bolts to 17 Nm (173 kg.cm, 13 Ib.ft). 14. Install reverse idler gear with chamfered side upward, and then insert idler gear shaft through the gear into housing.

15. Place the reverse shaft rail in neutral position, and then measure dimension A in the illustration. If dimension A is less than standard value, replace reverse shift lever assembly. Dimension A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.05-38.65 mm (1.458-1.521 in.)

16. Clean gasket surfaces of clutch housing and transmission case. 17. Adjust the output shaft, intermediate shaft and differential case end play or preload as follows: (a) Remove the outer races of output shaft and intermediate shaft bearings from transmission case.

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MANUAL TRANSMISSION ASSEMBLY

(b) Place 2 pieces of solder, about 10 mm (0.4 in.)-long on outer race of transmission case. (c) Insert outer races to transmission case. Securely install the outer race so as not to move the solder.

(d) Place 2 pieces of solder about 20 mm (0.79 in.)-long on ball bearing outer race. (e) Place the new transmission case gasket on the clutch housing. (f) Install the new gasket and transmission case assembly on the clutch housing, and tighten 13 bolts 35 to 41 Nm (360 to 420 kg.cm, 26 to 30 Ib.ft). (g) Remove bolts and remove transmission case. (h) Measure thickness of crushed solder with micrometer. Select a spacer of proper thickness to ensure standard end play. Differential case end play . . . . . . . . . 0-0.15 mm (0-0.006 in.)

Kind of Spacers for Differential

Thickness mm (in.) 1.31 1.40 1.49 1.58 1.67 1.76 1.85 1.94 2.03 2.12 2.21 (0.0516) (0.0551) (0.0587) (0.0622) (0.0657) (0.0693) (0.0728) (0.0764) (0.0799) (0.0835) (0.0870) Ident. mark E None C B A F G H I J K

(i) Remove both ball bearing outer races from the transmission case.

CAUTION Before installing the outer race of bearing to intermediate and output shaft, make sure that it is installed to proper parts. If the outer race is installed to other parts, the end play and preload cannot be adjusted properly.

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MANUAL TRANSMISSION ASSEMBLY

(j) Remove the solder pieces from below the differential assembly thickness of the crushed solder with a micrometer. Select a spacer of proper thickness to ensure standard end play or pre-load. Intermediate gear end play . . . . . 0-0.15 mm (0-0.0020 in.) Output shaft pre-load . . . 0.15-0.20 mm (0.0059-0.0079 in.)

Range of Spacers
Thickness mm (in.) 1.84 1.87 1.90 1.93 0.96 1.99 2.02 2.05 2.08 2.11 2.14 2.17 2.20 2.23 2.26 2.29 2.32 2.35 2.38 2.41 2.44 2.47 2.50 2.53 2.56 2.59 2.62 2.65 2.68 (0.0724) (0.0736) (0.0748) (0.0760) (0.0772) (0.0783) (0.0795) (0.0807) (0.0819) (0.0831) (0.0843) (0.0854) (0.0866) (0.0878) (0.0890) (0.0902) (0.0913) (0.0925) (0.0937) (0.0949) (0.0961) (0.0972) (0.0984) (0.0996) (0.1008) (0.1020) (0.1031) (0.1043) (0.1055) Ident. mark 84 87 90 93 96 99 02 05 08 11 14 17 20 23 26 29 32 35 38 41 44 47 50 53 56 59 62 65 68

(k) Install spacers, selected in accordance with step 17, to the transmission case, and then install ball bearing outer races to the transmission case. (I) Place spacer, selected in accordance with step 17, on the differential ball bearing.

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MANUAL TRANSMISSION ASSEMBLY

18. Clean both gasket surfaces of clutch housing and transmission case. 19. Apply sealant to both sides of transmission case gasket. Apply drying sealant to clutch housing side of gasket and apply non-drying sealant to transmission case side, and then install gasket onto clutch housing.

CAUTION Do not apply drying sealant to both sides of transmission case gasket. Apply sealant uniformly without a break or excess.

20. Install the transmission case assembly on the clutch housing and tighten 13 bolts to 35 to 41 Nm (360 to 420 kg.cm, 26 to 30 Ib.ft). 21. With Special Tool (09431-21100) attached to control shaft, verify that control shifts smoothly.

22. install the speedometer gear assembly into the clutch housing and tighten the flange bolt. 23. Connect the select actuator rod to the select shift rail and insert the pin. Then install the new collar onto the pin. (5speed only) 24. Tighten the actuator mounting bolts to the specified torque. (5-speed only)

25. When installing the select switch, assure that the transmission is in Neutral, then align the mating marks as shown in the illustration. Tighten the bolts securely. (5-speed only) 26. Install the steel ball and the back-up light switch. 27. Install the transmission mounting bracket and clutch cable bracket.

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INPUT SHAFT

INPUT SHAFT
COMPONENTS

Snap ring Front bearing Input shaft Needle bearing Input low gear 1) Synchronizer sleeve 2) Synchronizer spring (2) 3) Synchronizer key (3) 4) Synchronizer hub 7. Synchronizer ring (2) 8. Gear sleeve 9. Needle bearing 10. Input high gear 11. Spacer 12. Rear bearing 13. Locking nut

1. 2. 3. 4. 5. 6.

Nm A 89-107

kg.cm 900-1100

Ib.ft 66-79

DISASSEMBLY
1. Clamp the input shaft in a vise with lock nut side up (protect input shaft splines from vise jaws). 2. Remove the staking from the locking nut lock with a blunt punch, then remove the locking nut.

3. Remove the front bearing snap ring with snap ring pliers. 4. With Special Tool, Removing Plate (09432-21300) press the input shaft and remove the front bearing.

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INPUT SHAFT
5. With the input low gear supported on a press base, press the input shaft down to remove rear bearing, gears and synchronizer (5 speed only).

INSPECTION
1. Check the splines for wear or damage; replace if necessary. 2. Check the gears for wear or damage; replace if necessary. 3. Check the bearings for noise or damage; replace if necessary.

REASSEMBLY (5 speed only)

1. Assemble the synchronizer hub and sleeve. Make sure the hub and sleeve slide smoothly. 2. Insert the three synchronizer keys into grooves of hub. 3. Install the two synchronizer springs, and make sure that they are installed in opposite directions.

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INPUT SHAFT
4. Insert the needle bearing for input low gear to the input shaft. 5. Install the input low gear onto the input shaft. 6. Install the synchronizer ring onto the cone portion of input low gear. 7. Install the assembled synchronizer to input shaft, and then use Special Tool (09432-21600) to press synchronizer assembly onto input shaft. 8. Using Special Tool (09432-21600), press input high gear sleeve onto the input shaft. 9. Install the needle bearing onto sleeve. 10. Install the synchronizer ring. 11. Install the assembled input high gear onto the needle bearing. 12. Install the oil slinger onto the input shaft. 13. Using Special Tool (09432-21600), press rear bearing onto input shaft rear end.

09432-21600

Rear bearing

14. Tighten input shaft rear end locking nut to specified torque and stake it. Stake locking nut only at notch of shaft illustrated.

CAUTION Shaft rear end deformed by staking will interfere with breather, resulting in breakage.
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89-107 Nm (900-1,100 kg.cm, 66-79 Ib.ft)

43-32

INPUT SHAFT
15. Using Special Tool 09432-21500, install front bearing onto input shaft.

16. Install front bearing snap ring. There are three types of snap rings available which differ in thickness. Select the thickest snap ring which fits in snap ring groove. When installing snap ring, be careful not to damage oil seal contacting surface of input shaft. Do not reuse used snap ring.

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INTERMEDIATE GEAR

INTERMEDIATE GEAR
COMPONENTS

Intermediate gear

DISASSEMBLY
1. To remove taper bearing inner race from intermediate gear, use Special Tool 09432-21400.

CAUTION When 09432-21400 is used, it is important that tool is held securely with cylinder. Do not reuse this bearing. Replace it with a new part.

REASSEMBLY
1. Do not reuse bearing removed from shaft. 2. Press inner race. Do not press cage, as deformation could result. Use Special Tool (09432-21600).

43-34

OUTPUT SHAFT

OUTPUT SHAFT
COMPONENTS

1. Taper roller bearing 2. Output shaft 3. 4th speed gear 4. Synchronizer ring (2) 5. Synchronizer spring (2) 6. 3-4 synchronizer hub 7. Synchronizer key (3) 8. 3-4 synchronizer sleeve 9. Gear sleeve 10. 3rd speed gear 11. Gear sleeve 12. 2nd speed gear 13. Synchronizer ring (2) 14. Synchronizer spring (2) 15. 1-2 synchronizer hub 16. Synchronizer key (3) 17. 1-2 synchronizer sleeve 18. 1st speed gear 19. Gear sleeve 20. Taper roller bearing

DISASSEMBLY
1. Using Special Tool 09432-21400, remove taper roller bearing inner race from output shaft.

CAUTION When 09432-21400 is used, it is important that tool is held securely with cylinder. Do not use this bearing. Replace it with a new part.

2. Holding 2nd speed gear on Special Tool 09432-21300 press rear end of shaft with press to remove 1st speed gear, gear sleeve, 1-2 synchronizer assembly and 2nd speed gear.

OUTPUT SHAFT
3. Holding 3rd speed gear in Special Tool, Gear Puller (0943221300), remove 2nd speed gear sleeve and 3rd speed gear. 4. Holding 3-4speed synchronizer ring in Gear Puller, remove 3rd speed gear sleeve and 3-4 speed synchronizer.

CAUTION (a) Step (3) must be done at first. (b) Step (4) never be done to remove the 3rd gear and 3-4 speed synchronizer at same time.

REASSEMBLY
1. Assemble the synchronizer hub and sleeve. Make sure the hub and sleeve slide smoothly. 2. Insert the three synchronizer keys into grooves of hub. 3. Install the two synchronizer springs, and make sure that they are installed in opposite directions. 4. Install the 4th speed gear onto the output shaft. 5. Install the synchronizer ring onto the cone portion of 4th speed gear.

43-36

OUTPUT SHAFT
6. Using Special Tool 09432-21500, press 3-4 synchronizer onto output shaft. Make sure that keyways of synchronizer ring are correctly aligned with synchronizer keys. After installation of synchronizer, make certain that 4th speed gear rotates smoothly. 7. Using Special Tool 09432-21500, press gear sleeve for 3rd speed gear onto output shaft. 8. Install the synchronizer ring onto the 3-4 synchronizer. 9. Install the 3rd speed gear onto the output shaft. 10. Using Special Tool 09432-21500, press gear sleeve for 2nd speed gear onto the output shaft. 11. Install the 2nd speed gear onto the output shaft. 12. Install the synchronizer ring onto the cone portion of 2nd speed gear. 13. Using Special Tool 09432-21500, press 1-2 synchronizer onto output shaft. Make sure that keyways of synchronizer ring are correctly aligned with synchronizer keys. 14. Install the synchronizer ring and 1st speed gear. 15. Insert the 1st speed gear sleeve onto the output shaft.

16. Using Special Tool 09432-21600, press taper roller bearing onto front and rear ends of output shaft. Be sure to set installer so that it will push only on bearing inner race.

43-37

DIFFERENTIAL

DIFFERENTIAL
COMPONENTS

DISASSEMBLY
1. Remove the drive gear retaining bolts and remove the drive gear from differential case. 2. Remove the ball bearing inner race by using Special Tool 09433-21000.

3. Drive out the lock pin with a punch inserted in hole A. 4. Pull out the pinion shaft, and then remove the pinion gears and washer. 5. Remove the side gears and spacers.

43-38

DIFFERENTIAL

REASSEMBLY
1. With spacers installed to back of differential side gears, install gears in differential case. If reusing removed parts, install them in original positions noted during disassembly. If using new differential side gears, install spacers of medium thickness 1.0 2. Install washers to back of pinion gears, and install gears in differential case, then insert pinion shaft. 3. Measure backlash between differential side gear and pinion. If specified backlash is not obtained, select spacers of proper size, disassemble and reassemble gears and then adjust backlash. Backlash of both right and left gears must be equal. Backlash . . . . . . . . . . . . . . . . 0.025-0.150 mm (0.001-0.006 in.)

Available spacers
Thickness 0.75-0.82 0.83-0.92 0.93-1.00 1.01-1.08 1.09-1.16 1.17-1.25 1.26-1.34 mm mm mm mm mm mm mm (0.0295-0.0323 (0.0327-0.0362 (0.0366-0.0394 (0.0398-0.0425 (0.0429-0.0457 (0.0460-0.0492 (0.0496-0.0527 in.) in.) in.) in.) in.) in.) in.)

4. Install pinion shaft lock pin in direction specified in illustration. After installation, check to ensure that projection is less than 3 mm (0.118 in.).

CAUTIONS (a) Lock pin must not be reused. (b) Lock pin requiring installation load of more than 1,960 N (440 lb) must not be used.

5. Press ball bearing inner races onto both ends of differential case. Apply load to inner race when pressing in bearings.

DIFFERENTIAL
6. Install the drive gear onto the case. 7. Apply a small amount of ATF, and then a generous amount of thread lock cement to the ring gear retaining bolts. Then assemble quickly and tighten bolts to specified torque in sequence shown in illustration. Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128-137 Nm (1,300-1,400 kg.cm, 94-101 Ib.ft)
Numbers (1) through (8) indicate the bolt tightening sequence

NOTE Clean the ring gear retaining bolts with thinner or equivalent prior to applying thread lock cement.

43-40

CLUTCH HOUSING

CLUTCH HOUSING
COMPONENTS

1. Input shaft oil seal 2. Taper roller bearing outer race 3. Spring retainer-4-speed only 4. Spring pin 5. Shift shaft-4-speed only 6. Neutral return spring-4-speed only 7. Distance collar 8. Control finger-4-speed only 9. Poppet ball 10. Poppet spring 11. Reverse restrict spring-4-speed only 12. O-ring 13. Spring retainer 14. Snap ring 15. Spring pin 16. Shift shaft 17. Neutral return spring 18. Distance collar 19. Control finger 20. Poppet ball 21. Poppet spring 22. 5th return spring, outer

23. 5th return spring, inner 24. O - r i n g 25. Snap ring 26. Selector lever 27. Bolt 28. Control shaft oil seal 29. Drive shaft oil seal 30. O - r i n g 31. Reverse restrict spring

DISASSEMBLY
1. Remove shift shaft spring pin using a suitable tool.

CAUTION Be careful not to damage the clutch housing when using the pliers.

CLUTCH HOUSING
2. Utilizing shift shaft hole (hole B in illustration), remove shift shaft in direction of arrow. 3. Cover bolts with fingers to prevent the poppet ball from jumping out and being lost when the shift shaft is removed. Then remove the control finger and the poppet ball.

4. Using a pin punch, remove select finger lock pin. Remove select shaft and select finger.

REASSEMBLY
1. Apply sealant to outside surface of new control shaft oil seal. Install oil seal with Special Tool 09431-21100.

CAUTION Do not reuse old oil seal.

2. Install new input shaft front oil seal with Special Tool 09432-21000.

CAUTION Do not reuse old oil seal.

43-42

CLUTCH HOUSING
3. Insert select shaft into housing and install select finger. 4. With select finger and shaft lock pin holes properly aligned, drive in lock pin. Be careful not to drive in lock pin too deep.

5. Install poppet spring and steel ball in control finger. Insert Special Tool 09438-21000, to hole it. Poppet spring to be used should not have identification color (white) and should have a free length of 18.9 mm (0.74 in.)

6. Insert the shift shaft into the clutch housing and install control finger and springs. 7. Install the spring retainer.

CLUTCH HOUSING
8. If oil seal hole has not been chamfered. chamfer hole using knurls provided on back of Special Tool 09431-21200, before installing oil seal. If not chamfered, oil seal periphery will be impaired, resulting in oil leaks.

CAUTION Do not reuse old oil seal.

9. Replace control shaft or control lug in following manner. diameter hole in 16 mm (a) Make a diameter boss located at lower part of engine side of clutch housing. This boss has center hole; make 12 mm (0.47 in.) hole concentric with this center hole. (b) Remove lock pin. (c) Remove control shaft and lug. (d) Install new control shaft and lug. Then, using Special Tool 09414-11100, drive in new lock pin. (5) Apply sealant to outside surface of 12 mm-diameter Sealing Cap (15732-12001). Press in sealing cap as shown in illustration.

43-44

SPEEDOMETER SLEEVE ASSEMBLY

SPEEDOMETER SLEEVE ASSEMBLY

COMPONENTS

DISASSEMBLY
Drive spring pin out, and gear and sleeve can be disassembled.

CAUTION Do not reuse O-rings and spring pin.

REASSEMBLY
1. Install new O-ring in O-ring groove in speedometer driven gear sleeve I.D. 2. After applying small amount of gear oil to speedometer driven gear shaft, insert sleeve. 3. Align pin hole in sleeve with pin slot in gear shaft, and drive in spring pin in such a direction that spring pin slit will not contact gear shaft. 4. Install new O-ring in O-ring groove in sleeve O.D.

43-45