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...

If Necessary Replace Rear Bearing Fifth Gear Reverse Gear And Center Bearing

(a) Using snap ring pliers, remove the snap ring, lb) Using a press and 12-mm socket wrench, press out the rear bearing and 5th gear. (c) Remove the reverse gear and center bearing. (d) Install the center bearing and reverse gear. (e) Using a press and SST, install the rear bearing and 5th gear. NOTE Lift the reverse gear to the upper side, and press in the bearing and 5th gear. (f) Select a snap ring that will allow minimum axial play and install it on the shaft.

Inspect Release Bearing

Turn the bearing by hand while applying force in the axial direction. NOTE The bearing is permanently lubricated and requires no cleaning or lubrication. 8. IF NECESSARY, REPLACE RELEASE BEARING (a) Using a press and SST, press the release bearing from (b) Using a press and SST, press a new release bearing into the hub. (c) After installing the bearing, check that there is no drag on the bearing when it is turned under pressure.

Inspection Of Front Shock Absorber Assembly

INSPECT STEERING KNUCKLE PART OF SHOCK ABSORBER Using a magnetic flaw detector or flaw detecting penetrant, inspect the steering knuckle part of the shock absorber for damage or cracks. (a) Pull out the shock absorber piston rod at a constant speed and check to see that the pull feeling throughout the stroke is the same. (b) Check that there is no change in the pull when the piston rod is suddenly moved up and down with a stroke of 5 - 10 mm (0.20 - 0.39 in.). (c) If the absorber operation is...

Inspection Of Propeller Shaft Components

INSPECT PROPELLER AND INTERMEDIATE SHAFTS FOR DAMAGE OR RUNOUT If shaft runout is greater than maximum, replace the shaft. (a) Inspect the spider bearings for wear or damage. (b) Check the spider bearing axial play by wriggling the yoke while holding the shaft tightly. Solid type Less than 0.05 mm (0.0020 in.) II necessary, replace the spider bearing. Shell type 0 mm (0 in.) If necessary, replace the propeller shaft. INSPECT CENTER SUPPORT BEARING FOR WEAR OR DAMAGE Check that the bearing turns...

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....

Install Left Case

(a) Clean the case joining surfaces and the places where the bearings fit in. (b) Apply liquid sealer to the case joining surface. (c) Apply liquid sealer to the bolt threads, and tighten the bolts equally, a little at a time, in the numerical order shown so as to complete the tightening in 3 to 4 passes. Torque 200 kg-cm (14 ft-lb) 22. AFTER ASSEMBLING CASE, CHECK FOLLOWING ITEMS (a) Turn the input shaft and output shaft and check to see that they turn smoothly. (b) Check to see that shifting...

Installation Of Front Axle

(a) Place MP grease in the palm of your hand. (b) Pack grease into the bearing, continuing until the grease oozes out from the other side. (c) Do the same around the bearing circumference. 2. COAT INSIDE OF HUB AND GREASE CAP WITH MP GREASE 3. INSTALL INNER BEARING AND OIL SEAL Place the inner bearing into the hub. Using SST, drive the oil seal into the hub. Coat the oil seal with MP grease. SST 09608-20011 (a) Place the axle hub on the spindle. (b) Install the outer bearing and thrust washer....

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...

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...

Install Fifth Gear And Spacer

a Install the spacer for the needle roller bearing. b Place the synchronizer ring on the gear, c Place the roller bearing in the gear. Id Install the 5th gear on the output shaft with the synchronizer ring slots aligned with the shifting keys. e Install the locking ball in the shaft. f Fit the spacer groove securely over the locking ball when installing the spacer on the shaft. Using a press and SST, install the rear bearing on the out CAUTION Support the 5th gear and inner race by hand. NOTE...

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...