Overhaul
MT Gear Shift LeverDISASSEMBLY
5MT MODEL
1. Remove the lock wires.
2. Remove the rod from lever.
3. Separate the rod and inner boot.
4. Remove the snap ring from the stay.
5. Separate the gear shift lever and the stay.
6. Remove the boot, bushing and snap ring from gear shift lever.
7. Remove the spring pin, and then remove the bushing and snap ring.
8. Remove the boss from the joint.
9. Remove the bushing and spacer from the boss.
10. Remove the bushing and cushion rubber from the stay.
6MT MODEL
1. Remove the spring pin from the slider.
2. Remove the slider and spring.
3. Cut the band clip.
4. Remove the reverse check cable from the cable plate.
5. Remove the reverse check cable from the gear shift assembly.
6. Remove the holder and spring.
7. Disassemble the lock wires.
NOTE: Do not reuse the lock wire.
8. Remove the boss from the rod.
9. Remove the rod from lever.
10. Separate the rod and inner boot.
11. Remove the snap ring from the stay.
12. Separate the gear shift lever and the stay.
13. Remove the boot and bushing from gear shift lever.
14. Remove the spring pin, and then remove the bushing and snap ring.
15. Remove the bushing and spacer from the boss.
16. Remove the bushing and cushion rubber from the stay.
ASSEMBLY
5MT MODEL
NOTE:
- Clean all the parts before assembly.
- Apply NIGTIGHT LYW No. 2 grease or the equivalent to each part.
1. Mount the bushing and cushion rubber to the stay.
2. Install the bushing and spacer to boss.
3. Using new self-locking nuts, install the boss to the joint.
Tightening torque: 12 N-m (1.2 kgf-m, 8.9 ft-lb)
4. Install the snap ring to gear shift lever and install the bushing.
NOTE: Apply grease to the bushing.
5. Apply grease to the bushing and O-ring, and then install to gear shift lever.
6. Apply sufficient grease into boss, and then install the gear shift lever to the stay.
7. Install the washer and snap ring.
8. Insert the gear shift lever and rod into boot hole.
9. Install the rod.
Tightening torque: 18 N-m (1.8 kgf-m, 13.3 ft-lb)
10. Install a new lock wire.
NOTE:
- Install the lock wire to the stay groove.
- Bend the extra wire to the same direction of lock wire winding.
6MT MODEL
NOTE:
- Clean all the parts before assembly.
- Apply NIGTIGHT LYW No. 2 grease or the equivalent to each part.
1. Mount the bushing and cushion rubber to the stay.
2. Install the bushing and spacer to boss.
3. Install the snap ring to gear shift lever and install the bushing.
NOTE: Apply grease to the bushing.
4. Apply grease to the bushing and O-ring, and then install to gear shift lever.
5. Apply sufficient grease to the boss, and then install the gear shift lever to the stay.
6. Install the washer and snap ring.
7. Insert the gear shift lever and rod into boot hole.
8. Install the rod.
Tightening torque: 12 N-m (1.2 kgf-m, 8.9 ft-lb)
9. Install the boss to the rod.
Tightening torque: 12 N-m (1.2 kgf-m, 8.9 ft-lb)
10. Install a new lock wire.
NOTE:
- Install the lock wire to the stay groove.
- Bend the extra wire to the same direction of lock wire winding.
11. Install the holder.
Tightening torque: 1.3 N-m (0.1 kgf-m, 1.0 ft-lb)
12. Insert the reverse check cable into the boot hole.
13. Insert the reverse check cable to the gear shift assembly, and affix with a band clip.
NOTE:
- Cut the excess band clip.
- Make sure that the reverse check cable is inserted into the gearshift lever with no gaps.
14. Attach the seat cushion and spring.
15. Use the spring pin to secure the end of the slider and the reverse check cable.
NOTE: Apply grease to the moving part of slider.
16. With the cable pulled (the slider is lowered), adjust the distance between the edge of cable plate and the reverse check cable to 84 mm (3-31 in), and tighten the lock nut.
Tightening torque: 6 N-m (0.6 kgf-m, 4.4 ft-lb)
17. Secure the reverse check cable to the stay clip.
NOTE: Install the reverse check cable on top of the stay.
INSPECTION
5MT MODEL
1. Check the parts (bushing, cushion rubber, spacer, boot, stay and rod, etc..for deformation, damage and wear. If necessary, correct or replace faulty parts. Compare the removed parts with new parts to judge if there are damages or not.
2. Check the swing torque of rod linked with the gear shift lever. If the torque exceeds the specifications, replace the bushing or retighten nuts.
Swing torque: 3.7 N (0.38 kgf, 0.83 lbf) or less
6MT MODEL
Check the parts (bushing, cushion rubber, spacer, boot, stay and rod, etc..for deformation, damage and wear. If necessary, correct or replace faulty parts. Compare the removed parts with new parts to judge if there are damages or not.
