Disassembly of transmission

SPEEDOMETER DRIVEN GEAR. SHIFT LEVER RETAINER, RESTRICT PINS, CLUTCH RELEASE BEARING AND FORK 2. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE (a) Remove the front bearing retainer. Remove the six bolts and pull off the extension housing. 4. REMOVE LOCKING BALLS AND SPRINGS (b) Using a magnetic finger, remove the three locking balls and springs. 5. REMOVE LEFT CASE FROM RIGHT CASE Separate the left case from the right case by tapping the projection with a plastic...

Inspection of transmission components

INSPECT OUTPUT SHAFT AND INNER RACES (a) Inspect the output shaft and inner races for wear or damage. (b) Using calipers, measure the thickness of the output shaft flange. Minimum thickness 4.0 mm (0.157 in.) (c) Using a micrometer, measure the outer diameter of the shaft bushing surface. Minimum diameter 37.8 mm (1.488 in.) (d) Using calipers, measure the thickness of each race flange. Minimum all gear race 3.8 mm (0.150 in.) (e) Using a micrometer, measure the outer diameter of each race....

Installation Of Lower

Install the lower arm to the crossmember with a bolt. Do not torque the bolt. 2. CONNECT STABILIZER BAR AND STRUT BAR TO LOWER ARM (al Connect the stabilizer bar to the lower arm with the bolt and nut. Torque the nut. Torque 180 kg-cm (13 ft-lb) (b) Connect the strut bar to the lower arm with the two nuts. Torque the two nuts. Torque 475 kg-cm (34 ft-lb) 5. INSTALL WHEEL AND LOWER VEHICLE 6. TORQUE BOLT HOLDING LOWER ARM TO CROSSMEMBER After bouncing the vehicle to settle the suspension, torque...

Installation of transmission

PLACE TRANSMISSION AT INSTALLATION POSITION, AND INSTALL TRANSMISSION MOUNT BOLTS (a) Align the input shaft spline with the clutch disc, and push the transmission fully into position. (b) Install the two set bolts of the upper transmission, and troque the bolts. 2. INSTALL ENGINE REAR MOUNTING Install and torque the eight bolts. Torque 530 kg-cm (38 ft-lb) 3. INSTALL TRANSMISSION BOLTS AND STIFFENER PLATE Install and torque the bolts. Torque 375 kg-cm (27 ft-lb) 4. INSTALL EXHAUST PIPE BRACKET...

Removal of clutch unit

REMOVE TRANSMISSION (See page MT-3, 4) NOTE Do not drain the transmission oil. 2. REMOVE CLUTCH COVER AND DISC (a) Loosen the set bolts one turn at a time until the spring tension is released. (b) Remove the set bolts and pull off theclutchassembly. 3. REMOVE BEARING. HUB AND FORK FROM TRANSMISSION (a) Remove the retaining clip and pull off the bearing and hub.

Remove Spider Bearings

(a) Using SST, push out the bearing from the propeller NOTE Sufficiently raise the part indicated by A so that it does not come into contact with the bearing. (b) Clamp the bearing outer race in a vise and tap off the propeller shaft with a hammer. NOTE Remove the bearing on the opposite side in the same procedure. (c) Install the two removed bearing outer races to the spider. (d) Using SST, push out the bearing from the yoke. SST 09332 25010 (e) Clamp the bearing outer race in a vise and tap...

Front Wheel Alignment

MAKE FOLLOWING CHECKS AND CORRECT ANY PROBLEMS (a) Check the tires for size, wear, and proper inflation. Correct tire pressure 1.7 kg cm2 (24 psi) Lateral runout Less than 1.0 mm (0.039 in.) (c) Check the front wheel bearings for looseness. (d) Check the front suspension for looseness. (e) Check the steering linkage for looseness. (f) Check that the front absorbers work properly by using the standard bounce test. If height of the vehicle is not as specified, try to level the vehicle by shaking...

Bleeding Of Clutch System

NOTE If any work is done on the clutch system or if air is suspected in the clutch lines, bleed the system of air. CAUTION DO NOT let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL CLUTCH RESERVOIR WITH BRAKE FLUID Check the reservoir frequently. Add fluid if necessary. 2. CONNECT VINYL TUBE TO BLEEDER PLUG Insert the other end of the tube in a half full container of brake fluid. a Slowly pump the clutch pedal several times. b While depressing the pedal, loosen the...

Check And Adjustment Of Clutch Pedal

CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet LHD 161-171 mm 6.34-6.73 in. RHD 162 - 172 mm 6.38 - 6.77 in. 2. IF NECESSARY, ADJUST PEDAL HEIGHT a Remove the instrument lower finish panel and air duct. b Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. 3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD PLAY ARE CORRECT Push in on the pedal until the beginning of clutch resis tance is felt. Pedal freeplay 13 - 23 mm 0.51 - 0.91 in....

Install Wheel Alignment Equipment

Follow the specific instructions of the equipment manufacturer. INSPECT CAMBER AND STEERING AXIS INCLINATION INSPECT CAMBER AND STEERING AXIS INCLINATION If camber or steering axis inclination checks are out of tolerance, inspect and replace damaged or worn front suspension parts. If caster is out of tolerance, adjust the caster with the staked nuts of the strut bar. Torque 925 kg-cm 67 ft-lb NOTE Decrease caster by lengthening the strut bar. Increase caster by shortening the strut bar. One...

Inspection Of Ball Joints

INSPECT BALL JOINTS FOR EXCESSIVE LOOSENESS a Jack up the front of the vehicle and place wooden blocks with a height of 180 200 mm 7.09-7.87 in.l under one front tire. b Lower the jack until there is about half a load on the front coil springs. Place stands under the vehicle for safety. c Make sure the front wheels arc in a straight forward position and block them with chocks. d Move the lower arm up and down and check that the ball joint has no excessive play. Maximum ball joint vertical...