Assembly

TRANSMISSION CASE





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





2. Install reverse shifter lever (1), reverse idler gear (2) and reverse idler gear shaft (3), and secure with straight pin (4).

NOTE: Be sure to install reverse idler shaft from the rear side.

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 (6) into hole in reverse fork rod arm (5), and hold it with outer snap ring (7) using Special Tool (ST). ST 399411700 Accent Ball Installer, or equivalent.

CAUTION: Apply grease to plunger to prevent it from falling.

4. Position ball (8) (7.1438), spring (9) and gasket (10) in reverse shifter rod hole, on left side transmission case, and tighten checking ball plug (11).

CAUTION: Replace gasket with a new one.





5. Adjustment of reverse idler gear position





a. Move reverse shifter rod toward REV side. Adjust clearance between reverse idler gear and transmission case wall, using reverse shifter lever (1). Clearance (A) should be within 6.0 - 7.5 mm (0.236 - 0.295 inch).








b. After installing a suitable reverse shifter lever, shift into neutral. Using a thickness gauge, measure clearance between reverse idler gear and transmission case wall and adjust with washer(s). Clearance should be within 0 - 0.5 mm (0 - 0.020 inch).





6. Installation of 1-2 shifter fork (12) and rod (13)
a. Install 1-2 fork rod into 1-2 shifter fork via the hole on the rear of transmission case.
b. Align the holes in rod and fork, and drive straight pin (6 x 22) into these holes using ST. ST 398791700 Straight Pin Remover, or equivalent.

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 (14) and rod (15)
a. 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.

b. Install 3-4 fork rod into 3-4 shifter fork via the hole on the rear of transmission case.
c. Align the holes in rod and fork, and drive straight pin (6 x 22) into these holes. ST 398791700 Straight Pin Remover, or equivalent.

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 (16) onto the rear of reverse fork rod (6). Align holes in the two parts and drive straight pin into place. ST 398791700 Straight Pin Remover, or equivalent.





9. Position balls (17), checking ball springs (18) and gaskets (19) into 3-4 and 1-2 rod holes, and install plugs (20).

CAUTION: Replace gasket with a new one.





10. Installation of speedometer driven gear (21)
a. Install washer and speedometer shaft, and press fit oil seal with ST. ST 899824100 or 499827000 press, or equivalents.

CAUTION: Use new oil seal, if it has been removed.

b. Install vehicle speed sensor 2.

CAUTION: Use new vehicle speed sensor 2, if it has been removed.

c. Install speedometer driven gear and snap ring. Tightening torque: 5.9 +/-1.5 Nm (52 +/-13 inch lbs.).





COMBINATION OF TRANSMISSION CASE





1. Alignment marks/numbers on hypoid gear set (1).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.





2. Adjustment of drive pinion shim (2)
a. Place drive pinion shaft assembly on right hand transmission main case without shim and tighten bearing mounting bolts.
b. Inspection and adjustment of ST. ST 499917500 Drive Pinion Gauge Assembly, or equivalent. (A): Plate (B): Scale.

NOTE:
- Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level.
- Tighten the two bolts.





c. Position the ST by inserting the knock pin of ST into the knock hole in the transmission case.
d. 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.





e. The thickness of shim shall be determined by adding 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 Assembly, or equivalent. Select one to three shims from the illustrated table for the value determined as described above and take a shim thickness which is closest to the said value.





3. Install differential assembly (3) on 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.





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 prevent damage to oil seal.
- Apply grease (Unilube #2 or equivalent) to the sealing 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.





5. Install drive pinion shaft assembly (5) with 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.

















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.





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.





8. Combination of transmission case
a. Wipe off grease, oil and dust on the mating surfaces 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.





b. Tighten 17 bolts with bracket, clip, etc. as shown in the image.
Tightening torque:
- 8 mm bolt: 25 +/-2 Nm (18.1 +/-1.4 ft. lbs.).
- * 10 mm bolt: 39 +/-3 Nm (28.9 +/-2.2 ft. lbs.).

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.





9. Tighten ball bearing attachment bolts. Tightening torque: 29 +/-3 Nm (21.7 +/-2.2 ft. lbs.).





10. Backlash adjustment of hypoid gear and preload adjustment of roller bearing

NOTE: Support drive pinion assembly with ST. ST 498427100 Stopper, or equivalent.





a. Place the transmission with case left side facing downward and put ST1 on bearing cup.
b. Screw retainer assembly into left case from the bottom with ST2. Fit ST3 on the transmission main shaft. Shift gear into 4th or 5th and turn the shaft several times. Screw in the retainer while turning ST3 until a slight resistance is felt on ST2. This is the contact point of hypoid gear and drive pinion shaft. Repeat the above sequence several times to ensure the contact point. ST1 399780104 Weight, ST2 499787000 Wrench Assembly or ST3 499927100 Handle, or equivalent.





c. Remove weight and screw in retainer without O-ring on the upper side and stop at the point where slight resistance is felt.

NOTE: At this point, the backlash between the hypoid gear and drive pinion shaft is zero. ST 499787000 Wrench Assembly, or equivalent.





d. Fit lock plate (11). Loosen the retainer on the lower side by 1-1/2 notches of lock plate and turn in the retainer on the upper side by the same amount in order to obtain the backlash.

NOTE: The notch on the lock plate moves by 1/2 notch if the plate is turned upside down.

e. Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper roller bearing.
f. Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later read justment.
g. Turn transmission main shaft several times while tapping around retainer lightly with plastic hammer.





h. Set ST1 and ST2. Insert the needle through transmission oil drain plug hole so that the needle comes in contact with the tooth surface at a right angle and check the backlash. ST1 498247001 Magnet Base or ST2 498247100 Dial Gauge, or equivalent. Backlash should be within 0.13 - 0.18 mm (0.0051 - 0.0071 inch).

NOTE:
- If backlash is outside specified range, adjust it by turning holder in right side case.
- Turning holder pawl 1/2 rotation changes backlash by approximately 0.04 mm (0.0016 inch).

i. Check tooth contact of hypoid gear as follows: Apply a uniform thin coat of red lead on both tooth surfaces of 3 or 4 teeth of the hypoid gear. Move the hypoid gear back and forth by turning the transmission main shaft until a definite contact pattern is developed on hypoid gear, and judge whether face contact is correct. If it is incorrect, make the following correction.





- Tooth contact is correct.
(1) Toe
(2) Coast side
(3) Heel
(4) Drive Side





- Backlash is excessive.
To reduce backlash, loosen holder on the upper side (case right side) and turn in the holder on the lower side (case left side) by the same amount.





- Backlash is insufficient.
To increase backlash, loosen holder on the lower side (case left side) and turn in the holder on the upper side (case right side) by the same amount.





- The drive pinion shim selected before is too thick. Reduce its thickness.





- The drive pinion shim selected before is too thin. Increase its thickness.





11. After checking the tooth contact of hypoid gears, remove the lock plate (11). Then loosen retainer until the O-ring groove appears. Fit O-ring into the groove and tighten retainer into the position where retainer has been tightened in. Tighten lock plate (11). Tightening torque: 25 +/-3 Nm (18.1 +/-2.2 ft. lbs.).

NOTE: Carry out this job on both upper and lower retainers.








12. Selecting of main shaft rear plate. Using ST, measure the amount A of ball bearing protrusion from transmission main case surface and select the proper plate in the illustrated table: ST 498147000 Depth Gauge, or equivalent.

NOTE: Before measuring, tap the end of main shaft with a plastic hammer lightly in order to make the clearance zero between the main case surface and the moving flange of bearing.





13. Install clutch release lever (1) and bearing (2).