Assembly of transmission

ASSEMBLE EACH CLUTCH HUB AND SLEEVE (al Install the clutch hub and shilling keys to the hub sleeve. NOTE Be careful not to install them backwards. (b) Install the shifting key springs under the keys. NOTE Install the key springs positioned so that their ends overlap. 2. INSTALL SECOND GEAR AND CLUTCH HUB NO. 1 (a) Apply MP grease to the shaft. (b) Install the needle roller bearing. (c) Place the synchronizer ring on the gear and align the ring slots with the shifting keys. (d) Using a press,...

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 Oil Seal And Bushing

09308 10010 with output shaft installed (b) Heat the extension housing end to 80 - 100 C (176 - 212 F) in an oil bath. (c) Using SST, remove the bushing. SST 09307-12010 (d) Using SST, install the new bushing. SST 09307-12010 NOTE The bushing oil hole is positioned upward. (e) Using SST, drive in the new oil seal. SST 09325 12010 (f) Apply MP grease to the oil seal.

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 clutch parts

INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using calipers, measure the rivet head depth. Minimum rivet depth 0.3 mm (0.012 in.) If a problem is found, replace the clutch disc. Using a dial indicator, check the disc runout. Maximum runout 0.8 mm (0.031 in.) If runout is excessive, replace the disc. Using a dial indicator, check the flywheel runout. If runout is excessive, repair or replace the flywheel.

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 clutch unit

Using SST, install the disc on the flywheel. SST 09301-36010 Tighten the bolts evenly and gradually. Make several passes around the cover until it is snug. Torque the bolts. Torque 195 kg-cm (14 ft-lb) 3. CHECK DIAPHRAGM SPRING TIP ALIGNMENT Using a feeler gauge and SST, measure the gap between the spring tips and the tool. SST 09301-00013 Maximum non-alignment 0.5 mm (0.020 in.) Using SST. bend the springs until alignment is correct. SST 09301 00013 5. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE...

Installation Of Front Shock Absorber Assembly

INSTALL BUMPER, COIL SPRING AND SPRING SEAT (a) Mount the front shock absorber on a stand. (b) Install the bumper to the shock absorber. (c) Align the coil spring end with the lower seat hollow and install. (d) Align the spring seat with the piston rod and install. (e) Install the dust seal on the spring seat. (f) Using SST, compress the coil spring. SST 09727 22031 (a) Using SST to hold the support, install the support with a new nut. Torque the nut. (b) Pack MP grease into the suspension...

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 transmission

REMOVE NEGATIVE BATTERY TERMINAL WIRE (b) Turn the distributor so it does not strike against the dash panel. 4. REMOVE SHIFT LEVER FROM INSIDE OF VEHICLE 5. RAISE VEHICLE AND DRAIN TRANSMISSION OIL CAUTION Be sure the vehicle is securely supported. 6. DISCONNECT PROPELLER SHAFT FLANGE FROM FLANGE ON DIFFERENTIAL (a) Place matchmarks on the flanges. (b) Remove the four bolts and nuts. 7. REMOVE CENTER SUPPORT BEARING FROM BODY (3-Joint Type) (a) Pull the yoke from the transmission. (b) Insert...

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....

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...