lock DATSUN 210 1979 Workshop Manual

are

clean
and
free
from

foreign
matter

Cearance
between

cylinder

bore
and

piston

Leu
than
0
15

mm

0
0059
in

ASSEMBLY

Assemble
clutch
master

cylinder
in

the
reverse
order
of

disassembly
Ob

serve
the
following

I

Dip
piston
cup
in
brake

fluid

before

installing
Make
sure
that

it
is

correctly
faced
in

position

1
Return

spring

2

Supply
valve
rod

3
Piston

4

Secondary

cup
5

Spring
seat

6
Valve

spring

7

Primary
cup

8
Push
rod

CL283

Fig
CL
7
Piston

Asaembly

2

Apply
a

coating
of
brake
fluid
to

cylinder
and

piston
when

assembling

if
Tightening
torque

Reservoir
band

0
25
to
0
4

kg
m

11
8
to
2
9
ft
lb

Supply
valve

stopper

0
15
to
0
3

kg
m

1
1
to
2
2
ft
Ib

INSTALLATION

Install
clutch
master

cylinder
in
the

reverse
order
of
removal
Observe
the

following

I

Bleed
air

out
of

hydraulic
system

Refer
to

Bleeding
Clutch

System
for

bleeding

2

Adjust
pedal
height
and

pedal

free

travel
Refer
to

Clutch
Pedal

Height
and
Clutch
Pedal
Free

Travel

for

adjustment
Clutch

if
Tightening
torque

Master

cylinder
to
dash

panel

securing
nut

0
8
to
1
2

kg
m

5
8
to
8
7
ft

Ib

Clutch
tube
flare
nut

1
5
to
1
8

kg
m

11

to
13
ft
lb

CAUTION

When

connecting
clutch
tube

use

F

lere
Nut

Torque
Wrench

GG94310000

Note
When

tightening
flare
nut
hold

pipe
by
hand
to

r
it

from

twilling

OPERATING

CYLINDER

REMOVAL

I
Disconnect
clutch
tube
from

clutch
hose
at
the

bracket
on

side

member

CAUTION

When

disconnecting
clutch
tube

use

suitable
flare
nut
wrench

Never
use
an

open
end
wrench
or

adjustable
wrench

2
Remove
lock

spring
then
dis

engage
hose
from
bracket

3
Remove
clutch
hose
from

oper

ating
cylinder

4
Remove

operating
cylinder

DISASSEMBLY

Remove

push
rod
and
dust

cover

2

Remove

piston
and

piston
cup
as

an

assembly

Note

Discard

piston
cup
and
dust

cover

3
Remove
bleeder
screw

Cl
5
1

4

v

I
Bleeder
screw

2

Cylinder
body

3
Piston

cup

4
Piston
5
Dust
cover

6
Push
rod

7
Lock
nut

8

Push
nut

CL203

Fig
CL
B

Operating
Cylinder

INSPECTION

Visually

inspect
all
disassembled

parts
and

replace

parts
which
are
worn

or

damaged
too

badly

beyond
specifi

cations

CAUTION

To
clean
or
WISh
all

parts
of

operating

cylinder
dean
brake
fluid
must
be

Used

Never

use
mineral
oils
such
as

gasoline

and
kerosene
It
will
ruin
the
rubber

parts
of
the

hydraulic
system

I

Check

cylinder
bore
and

piston

for
score
or
rust
and
if
found

replace

2
Check

cylinder
bore
and

piston

for
wear
If
clearance

between

cylinder

bore
and

piston
i5
more

than
the

specified
value

replace
piston
or

oper

ating
cylinder
assembly

3

Check
condition
of

piston

cup

and
dust
cover

Always

replace
them

after

disassembly

4
Check
bleeder
hole
to

be
sure

that
it
is

clean

Clearance
between

cyliniler
bore

and

piston

less
than
0
15
mm
0
0059
in

ASSEMBLY

Assemble

operating
cylinder
in

the

reverse
order
of

disassembly
Observe

the

following

t

Prior
to

lWembly

dip
a
new

piston
cup
in
clean

brake
fluid
To

install

piston
cup
on

piston
pay
par

ticular
auention
to
its

direction

2

Dip
cylinder
and

piston
in

clean

brake

fluid
before

assembly

INSTALLATION

Install

operating
cylinder
in
the

reverse
order
of

removal
Observe

the

following

1

Bleed
air

thoroughly
from
clutch

hydraulic
system
Refer
to

Bleeding

Clutch

System
for

bleeding

2

Adjust
clutch

pedal
free
travel

Refer
to

Clutch
Pedal
Free

Travel
for

adjustment

Note

a

Use
new

gasket

b
When

operating
cylinder
is
removed

from
or

instaUed
on
clutch
haus

ing
without

disconnecting
clutch

hose
from

operating
cylinder
loos

en
bleeder

screw
so
that

push
rod

mo

lightly

c
E
xer

e

care
not
to

p
or
wist

clutch
hose
Be

sure
to
install

clutch
hose

away
from

exhaust

tube

d
When

tightening
flare

nut
hold

pipe
by
hand
to

prevent
it
from

twisting

CAUTION

When

connecting
dutch
tuhe

uSe

Flare

Nut

Torque
Wrench

G694310000

@
Tightening
torque

Bleeder

screw

0
7
to
0
9

kg
m

5
1
to
6
5
ft
Ihl
Clutch

o

cylinder
to
clutch

housing
securing
bolts

3
1
to
4
1

kg
m

22
to
30
ft
lbl

Clutch
hose
to

operating

cyli
nder

1
7
to
2
0

kg
m

12
to
14
ft

lbl

Flare
nut

1
5
to
1
8

kg
m

11
to
13
ft
Ibl

CLUTCH
LINE

INSPECTION

Check
clutch
lines
tube

and
hose

for
evidence
of
cracks
deterioration
or

other

damage

Replace
if

necessary

If

leakage
occurs
at
or

around

joints
retighten
and
if

necessary
re

place
damaged

parts

REMOVAL

CAUTION

When

disconnecting
clutch
tube

use

suitable
flare

nut
wrench

Never

use
an

open
end
wrench
or

adjustable
wrench

1

Qisconnect
clutch
tube
from

clutch

hose
at
bracket
on
side
mem

ber

2
emove
lock

spring
then
disen

gage
hose
from
bracket

3

Remove
clutch
hose
from

oper

ating
cylinder

4

Disconnect
clutch
tube
from
mas

ter

cylinder

5

Remove

clamp
fIxing
clutch
tube

to
dash

panel
and
side

member

CL
6
INSTALLAnOlll

Wipe
the

opening
ends
of

hydraulic

line

to
remove

any
foreign
matter

before

malting
connections

I
Connect
clutch
tuhe
to

master

cylinder
with
flare
nut

2
Fix
clutch
tube
to
dash

panel

and
side

member
with

clamp

3
Then

tighten
flare

nut

@

Tightening
torque

Flar
nut

1
5
to
1
8

kg
m

11
to

13
ft

Ibl

2
InstaU
clutch
hose
on

operating

cylinder
with
a

gasket
in

place

Note

Use
new

gaslcet

@
Tightening
torque

1
7
to
2
0

kg
m

12
to
14ft
lbl

3

Engage
opposite
end
of

hose
with

bracket
InstaU
lock

spring
fIxing
hose

to
bracket

Note

a
When

tightening
flare

nut
hold

pipe
by
hand
to

prevent
it
from

twisting

b
Exercise
care
not
to

warp
or
twist

clu1ch
hose

4

Connect
clutch
tube
to

hose
with

flare
nut
and

tighten
it

5
Check
distance

between
clutch

line
and

adjacent
parts

especially
be

tween
hose
and
exhaust
tube

6

Bleed
air
out
of

hydraulic
system

Refer
to

Bleeding
Clutch

System

for

bleeding

CAUTION

When

tightening
flare

nut
use

Flare

Nut
Wrench

G
G9431
0000

Clutch

Clutch
cover

Diaphragm
spring
height
mm
in

Unevenness
of

diaphragm
spnng
toe

height
mm
in
29
0

to
31

0
1
142
to
1
220

Less
than
O
5
0
020

TIGHTENING
TORQUE

Pedal

stopper
lock
nut

Master

cylinder
push
rod
lock

nut

Operating
cylinder
push
rod

lock
nut

Operating
cylinder
bleeder
screw

Master

cylinder
to

dash

panel
securing

nut
kg
m
ft
lb

Clutch
tube
flare
nut

kg
m

ft
Ib
kg
m
ft
b

kg
m

ft
Ib

kg
m

ft
b

kg
m
ft
b
0
8

to
1
2
5

8
to
8

7

0
8
to
1
2
5

8
to
8
7

0
8

to
1
2
5
8
to
8
7

0

7
to
0
9
5
1

to
6
5

0
8

to
1
2
5

8
to
8
7

1
5

to
1
8
11
to

13

Operating
cylinder
to
clutch

housing

securing
bolt

Qutch
hose
to

operating
cylinder

Qutch
cover
bolt
kg
m
ft

lb

kg
m
ft
Ib

kg
m

ft
Ib
3
1

to
4
1
22
to
30

17

to
2
0

12
to
14

1

6
to
2
1

12
to
15

CL
11

I
ht
2nd

fork
r

2

3rd

top
fork
rod

3
Reverse
fork
rod

4

Retaining

pin

5
I
t

2nd
shift

fork

6
3rd

top
shift
fork

7

Checking
ball

plug

8

Check
ban

spring

9
Check
ball

10
Interlock

plunger

11

S

topper
ring

12

Shift
rod
A
bracket

13
Reverse

shift
fork

14
Lock

pin

15

Striking
lever
Manual
Transmission

16

Striking
rod

17
Return

spring
plug

18
Reverse

check

spring

19
Return

pring

20

Plunger

21
D

ring

22
Stopper
pin
bolt

23

Striking
guide
assembly

24

Striking
guide
oil
seal

REMOVAL

To

dismount
transmission

from
the

car

proceed
as
follows

Disconnect

battery
ground
cable

2

Remove
console
box

and
detach

rubber
boots
if

so

equipped

3

Place
transmission
control
lever

in

neutral

position
and
remove
it

m

TM781

Fig
MT
4

Removing
Control
Lever
@

@

25
Control
lever

bushing

26

Expansion
plug

27
Control

pin
bushing

28
Control
arm

pin

29
Control
lever
o

Tightening
torque
kg
m
ft
lb

@
0
5
to

0
8
3

6
tn
5
8

@
1
3
to
1
7

9
to
12

Fig
MT
3
F4W60L
Tra11lmiBSion

Shift
Control

Components
TM094A

4
Jack

up
the

car
and

support
its

weight
on

safety
stands
Use
a

hy

draulic
hoist
or

open
pit
if
available

Make

sure
that

safety
is

insured

5

Disconnect
front
exhaust
tube

and

remove
bolt

securing
exhaust

mounting
bracket
from

exhaust
front

tube

side

6

Disconnect
wires
from

reverse

back

up
lamp
switch

7

Disconnect

speedometer
cable

from
rear
extension
At

the
same
time

removey

top
detecting
switch
if
so

equipped

8
Remove

propeller
shaft

Refer
to
Removal
Section
PO

Note

Plug
up
the

opening
in
the
rear

extension
to

prevent
oil
from
flow

ing
out

MT
3
9

Remove
clutch

operating
cylinder

from
transmission
case

10

Support
engine
by
placing
a

jack

under
oil

pan
with
a
wooden

block

used
between
oil

pan
and

jack

CAUTION

00
not

place
the

jack
under
the

oil

pan
drain

plug

11

Support
transmission
with
a

transmission

jack

12

Loosen
rear

engine
mount
se

curing
bolts

CD

temporarily
and
re

move
crossmember

mounting
bolts

V

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

I

Prior
to
disassembling
traiIsmis

sian

thoroughly
wipe
off
dirt

and

grease
from
it

2
Drain

oil

thoroughly

3

Remove
dust
cover
from
trans

mission

case

Remove
release

bearing
and
with

drawallever

4

Remove
reverse

lamp
switch
and

top
detecting
switch
if

equipped

5
Remove

speedometer

pinion
as

sembly

6
Remove

nut
and

stopper
pin
bolt

from
rear
end
of
rear
extension

TM783

Fig
MT
6

Removing
Nut
and

Stopper
Pin
Bolt

7

Remove
return

spring
plug
return

spring
reverse
check

spring
and

plunger
from
rear
extension

@

@

j

TM784

Fig
MT

7
Rt

moving
Return

Spring
Plug

8
Remove
front
cover
Detach

0

ring
and
front
cover

adjusting
shim

TM785

Fig
MT
B

Removing
Front
Cover

a

Ring
and

Adju

ting
Shim
Manual
Transmission

9
Remove
main

drive

bearing
snap

ring
with

snap
ring

pliers

o

TM188

Fig
MT

9
Rt

mouing
Main
Drive

BNring
Snap
Ring

10
Remove

rear
extenSion

secUring

baits
and
turn
the

striliing
rod

clock

wise

Drive
out
rear
extension

backward

by
lightly
ta

pping
around
it

with
a

soft

hammer

TM787

Fig
MT
10

Removing
Rear
Extemion

11

Separate
transmission
case
from

adapter
plate
by
evenly
tapping

around
it

with
a
soft
hammer

CAUTION

Do
not

pry
transmission
case
or
rear

extension
from

edapter
plate
with

screwdriver

TM788

Fig
MT
II

Removing
Tronsmiuion

COSf

MT

5
12

Set

up
Adapter
Setting
Plate

KV32100300

on

adapter
plate

Place
the
above

assembly
in

a
vise

TM789

Fig
MT
12
A

ttaching
Gear

A
mbly

to

Special
Tool

13
Detach
counter

gear
thrust

washer

DISASSEMBLY
OF

GEAR

ASSEMBLY

Shift

forks
and
fork
rods

I

Drive

out

retaining

pins
from

each
fork

rod
with
Fork

Rod
Pin

Punch

ST23540000

TM790

Fig
MT
13
Drive
Out

Retaining
Pim

2

Drive
out
reverse

gear
shift
fork

and
reverse
idief

gea

TM791

Fig
MT
14

Driving
Out
Re
1dkr

Gear
and

Shift
Fork

3

Remove
three
3
chick

ball

plugs

TM792

Fig
MT
15

Removing
Check
Ball

Plug

4

Drive
out
fork
rods
from

adapter

plate
by
lightly
tapping
on

the
front

end

Detach
shift
forks

Note

a
Be

careful
not
to
lose

three
3

check
balls
and

two
2
interlock

pluDgl
rs

b
Each

gear
and
sbaft
can
be
de

tached
from

adapter
plate
without

removing
each
fork
rod

D

t

@

@
6

@

1

q
eck
ball

ptug

2
Fork
Tod
1st
2nd

3
InterJock

plunger

4

Fork
rod
3rd
4th

5

Fork
rod
reverse

6
Check
ball
TM793

Fig
MT
16
Check
Ball
and

Interlock

Plunger

Gear

assembly

Note
It

is

necessary
to
measure
end

play
before

disassembling
main

sbaft
and
after

reassembling
main

shaft
Refer
to

Inspection
for
Gears

and
Shafts

1
Remove
reverse

gear

snap
ring

from
the

rear
of
mainshaft

using

snap

ring

pliers
and
remove
thrust
washer

and
mainshaft
reverse

gear
Manual

Transmission

TM794

Fig
MT

17
R

molJing
Reuerse
Gear

SfUJpRing

2

Remove
four
4

bearing
retainer

attaching
screws
with

an

impact
driver

and
remove

bearing
retainer

TM79S

Fif
MT

18

RemouingBcrews

3

Remove

snap

ring
from

mainshaft

rear

bearing
using

snap
ring
pliers

TM796

Fig
MT
19

Removing
Mainshaft
Rear

Bearing

Snap
Ring

4
Drive

out
mainshaft

gear
as

sembly
together
with
counter

gear

assembly
by
lightly
tapping
the
rea

end
with
a

soft
hammer
while

holding

the
front
of
mainshaft

gear
assembly

and
counter

gear
assembly
by
hand

MT
6
Remove

counter

g
ar

main

dfN

gear
and

mainshaft

assembly
in
that

order

CAUTION

Be
careful
not
to

drop
gears

TM797

Fig
MT
20

Removing
Gear

AlSembly

Malnshaft

Disassemble
mainsltaft

gear
assem

bly
as
follows

1
R

emove

snap
ring
from

l
l
Iinshaft

front
end

Remove
3rd

4th

synchronizer

assembly
baulk

rings
3r

gear
and

mainshaft
needle

bearing
toward
the

front
side

Fig
MT
21

Removing

Snap
Ring

2

Press

out
mainsltaft

bearing
using

Bearing
Puller

ST3003Iooo
See

Fig

MT
23

CAUTION

When

pressing
out

bearing
hold

main

shaft

by
hand
so
as
not
to

drop
it

Synchronizers

I
Remove

spread

springs

j
and

take

out

shifting

inserts@

2

Separate
coupling
sleeve

@
from

synchro
hub

@

0
t
j

@

O
LJ

J
1

ID

4

Synchro
hub

S
Baulk

ring
1

Spread

spring

2

Shifting
insert

3

Coupling
sleeve

TMSOl

Fig
MT
30
Synchronjzer

Assembly

ADAPTER
PLATE

DISASSEMBLY

1
Remove
reverse
idler
shaft

snap

ring
using
snap

ri
1g
pliers
and

draw

out
reverse
idler
shaft

by
lightly

tap

ping
the
shaft

end
with
a

soft
hammer

k

Fig
MT
31

Removing
Reverse

Idler

Shaft
Snap

Ring

REAR

EXTENSION

DISASSEMBLY

I

Remove
lock

pin
nut
and

lock

pin

from

striking
1

lever

Remov

str

iking

lever

TM803

Fig
MT
32

Removing
Lock
Pin

Nut
Manual

Transmission

2

Remove

striking
rod
and

stiking

guide
from
rear

end
of
rear

extension

j

1
Lock

pin

2

Striking
lever

3
Return

spring
plug

4

Con
trollevcr

5

Striking
rod

6

Striking
fod

guide

7
Control
Ie
o
eI

pin

8

Stopper
pin
bolt

INSPECTION

Wash
all

parts
in
a
suitable

cleaning

solvent
and

check
for
wear

damage
or

other

faulty
conditions

CAUTION

a
Be
careful
not

to

damage
any

parts

with

scraper

b
Do
not
clean
wash
or
soak
oil
seals

in
solvent

TRANSMISSION
CASE
AND

REAR
EXTENSION

I
Check

for
cracks
which

might

cause
oil
leak
or
other

faulty
condi

tions

2

Check

mating
surface
of
case
to

engine
or

adapter
plate
for
small
nicks

projection
or

sealant

Remove
all

nicks

projection
or

sealant
with
a

fine
stone

3
If
rear
ext

nsion

bushing
is
worn

or
cracked

replace
it

as
an

assembly
of

bushing
and
rear
extension

BEARING

Thoroughly
clean

bearing
and

dry

with

compressed
air

2

When
race
and
ball
surfaces

are

MT
9
Note
Do

not
remove
rear
extension

bushing
from
rear
extension

@

TM804

Fig
MT
33
Shifting
Mechanism

worn
or
rough
or
when
balls
are

out
of
round
or

rough
replace
bearing

TM372

Fig
MT
34
In

pecting
Ball

Bearing

3

Replace
needle

bearing
if

worn
or

damaged

GEARS
AND
SHAFTS

I

Check
all

gears
for
excessive

wear

chips
or

cracks

replace
as

required

2

Check
shaft
for

bending
crack

wear
or

worn

spline
if

necessary

replace

3
It
is

necessary
to

measure
end

play
before

disassembling
mainshaft

and
after

reassembling
rnainshaft

Tighten
mainshaft
lock
nut
to

speci

fied
limit
and
measure
end

play
to
in

sure
that
it
is

within

specified
limit

If
end

play
is
not
within

specified

limit
disassemble
and
check

parts
for

condition

Replace
any

part
which
is

worn
or

damaged

Front

if
r@

t

1

1
Gear
oil

2

Bushing

3
Grease

TM099A

Fig
MT
39
Rear
Extension
Oil
Seal

3

Apply
grease
to
D

ring
and

plunger
grooves
in

striking
rod

guide

Insert

striking
rod
with

striking
rod

guide
through
rear
extension

4
Install

striking
lever
on
front
end

of

striking
rod

Install
lock

pin
and

nut
and

tighten
it

fl
Tightening
torque

Striking
lever
lock
nut

0
9
to
1
2

kg
m

16
5
to
8
7
ft
Ib

5
When

installing
welch

plug
apply

sealant
to
it

ADAPTER
PLATE

ASSEMBLY

1
Place

adapter
plate
in

a
vise
with

Adaptet
Selling
Plate
KV32100300

with
fork
rod

hole
side

up

TMB09

Fig
MT
40

Attaching
Adapter
Phlte

to

Special
Tool

2
Install
reverse
idler
shaft
in

adapter
plate
by
lightly

tapping
the

shaft

end
with
a
soft

hammer
a
d

secure
it

with

snap
rings
Manual
Transmission

Fig
MT
4J
Installing
Snap
Ring

ASSEMBLY
OF
GEAR

ASSEMBLY

Clean
all

parts
in
solvent
and

dry

with

compressed
air

Synchronizers

Assemble

synchronizer

assembly
in

the

following
procedures

Place

synchro
hub
into

coupling

sleeve

2
Fit

shifting
inserts

in
three

3

grooves
in

synchro
hub

3
Insert

protrusion
of

spread
spring

into

groove
so
that
insert
is

securely

attached
to
inner
side

of

coupling

sleeve

Install
the

other

spread
spring
on

the

opposite
side

of

synchro
hub

Note

e
Be

careful

not
to
hook
front
and

rear
ends
of
the

spread
spring
to
the

same
insert

b
Be

sure
that
hub
and

sleeve

oper

ates

smoothly
and

correctly
by

hand

TM017

Fig
MT
42

Installing
Spread

Spring

MT
11
TM131A

Fig
MT
43

Installing
Spread

Spring
2

Mainshaft

Assemble
2nd

gear
needle
bear

ing
2nd

gear
baulk

ting
1

st
2nd

speed
synchronizer
assembly
I

st

gear

baulk

ring
1st

gear

bushing
needle

bearing
1st

gear
and
thrust
washer
on

mainshaft

2

Press
mainshaft

bearing
onto

mainshaft

using
Mainshaft

Bearing

Drift
ST22350000

H

ST22350000

TM711

Fig
MT
44

Installing
Mainshaft

Bearing

3
Position
3rd

gear
needle

bearing

3rd

gear
baulk

ring
and
3rd
4th

synchronizer
assembly
on
the

front

side
of
mainshaft

4

Fit
a
new

suitable

snap
ring
in

place
so
that

there
exists
a

minimum

clearance
between
end
face
of
hub
and

ring

Note

Make
sure

snap
ring
fits
in

groove

Available

snap

rings

No

Thickness
mm

in

1
55
to
1
60

0
0610
to
0

0630

1
60
to
1
65

0
0630
to

0

0650

1
65

to
I

70

0
0650
to

0
0669
1

2

3

5
Fit

snap
ring
to

groove
in
rear
end

of

counter

gear
by
using
snap
ring

pliers

Note
Maire
sure

snap
ring
fits
in

groove

TM697

Fig
MT
5I

Imtalling
Snap
Ring

Assembly
to

adapter
plate

t

Install
baulk

ring
on
main
drive

gear
and
combine
with
mainshaft
to

complete
the
mainshaft

assembly

Note
Be
sure

to
install

pilot
bearing

in

place
when

combining
with

mainshaft

2

Combine
mainshaft

assembly

with

counter

gear
assembly
and

place

them
into

adapter
plate
simulta

neously

3
Pull
mainshaft

assembly
into

adapter
plate
using
Mainshaft
Puller

KV32
100400

When

installing
main

shaft

assembly

carefully
hold

gears
by

hand

Install
counter

gear
assembly

together
with
mainshaft

assembly
by

applying
light
blows
with

a
soft
faced

hammer

Make
sure
that

snap
ring
groove
on

mainshaft
rear

bearing
clears

adapter

plate

CAUTION

a
Take

care
not
to

drop
gears
on

floor
I

b
Take
care
not
to

damage
bearings

TM810

Fig
MT
52
1

Installing
Mainshaft

Assembly
Manual
Transmission

4

Fit

snap
ring
to

groove
in
main

shaft
rear

bearing
with

snap
ring
pliers

TM796

Fig
MT
53

Fitting
Mainshaft
Rear

Bearing
Snap
Ring

Note
Make

sure

snap
ring
fils
in

groove

5

Install

bearing
retainer
on

adapter

plate

Torque
screws
and
stake
each
screw

at
two

points
with
a

punch

fj
Tightening
torque

Mainshaft

bearing
retainer

saew

0
7

to
1
0

kg
m

15
1
to
7
2
ft
Ibl

TM811

Fig
MT
54

Staking
B

aring
Retain
r

Screw

6
Install
mainshaft
reverse

gear
and

thrust
washer
on
the
rear
end
of

mainshaft
To
secure
with
new

snap

ring
first
hold
it

temporarily
with

snap
ring
pliers
and
then

tap
it

lightly

with

Bearing
Drift
ST22350000

Note

a
Install
lhrust
washer

so
that

its

concave
side
is

on
mainshaet

reverse

gear

b
Make
sure

snap
ring
fits
in

groove

MT
13
J
r

Froni

Gear
side

TM100A

Fig
MT

55
Imtalling
R
Vf
e
Gear

Shift
forks
and
fork
rods

I
Insert

1st
2nd
fork

rod
into

adapter
plate
and

assemble
1st

2nd

fork

2
With
1st

2nd
fork
rod
set
at

Neutral
insert
interlock

plunger
into

adapter

plate

3
Insert

3rd
4th
fork
rod

into

adapter
plate
and
assemble
3rd
4th

fork

4
With

3rd
4th
fork
rod

set
at

Neutral
insert
interlock

plunger
into

adapter
plate

S
Insert

reverse
fork
rod
into

adapt

er

plate

Nole

a
Be
sure

to
install
interlock

plunger

when

installing
any
adjacent
fork

rods
to

adapter
plate

Properly
align
the

groove
in

assem

bled
fork
rod
with
interlock

plunger

b
Be

sure
to

align
3rd
4th
shift
fork

wilh
the

groove
in
their

coupling

sleeve
before

installing

c
Also

align
1st
2nd
shift
fork
with

their

coupling
sleeve

prop
dy
be

fore

inslalling

d
Shift
forks
for
3rd
4th
an
1st

2nd

are
one
and
the
same

parts

Make

sure
that
the

long
end
of
shift

fork
for
1st
2nd
is

placed
on

the

counter

gear
side
and
the

long
end

for
3rd
4th
is

on
the

opposite

side

5
Install
check
balls
and
check
ball

springs

Apply
locking
sealer
to
check
ball

plugs
and
install
in

place

Align
notches
in

reverse
3rd
4th

and
1st

2nd
fork

rods
with
check

balls

Note

a
In
the

standard

position
the

upper

surface
of
the

ping
is

nush
with

thaI
of

adapter
plate

b
CheCk

balfpIug
for
i
st
2nd
fork

rod
is

longer
than
those
for
reverse

forkrod
and
3rd
4th
fork
rod
Manual
Transmission

TRANS
SSION

ASSEMBLY

Transmission
case

assembly

Remove

adapter
plale
with

gear

assembly
from

Adapter
Setting
Plate

KV32100300

2

Clean

mating
surfaces
of

adapter

plate
and

transmission

case

Apply
sealant
to

mating
surfaces
of

adapter
plate
3
nd
transmission

case

3

Install
counter

gear
thrust

washer

selected

previously

Note

a

Apply
grease
to

stiding
sorface
of

thrust
washer

b
When

installing
thrust

washer
note

the
front
and
rear

directions

Fig
MT
56

Installing
Check
Ball
0

Plugs

6
1nstall
rev

rse
idler

gear

together

with
reverse
shift

fork

TM791

Fig
MT

57

Installting
Re
ldler

Getg
and

Shift
Fork

7

Install
each

fork
rod
on
shift
fork

with
new

retainif
g

pin
U
a

ham

mer

toseCUfe

pin
in

place

Note
To
insure

that
interlock

plunger

is
installed

properly
slide

3rd
4th

fork

rod
and

operate
the

other
fork

rod
Make
sure
that

the

gear

except

lrd
or
4th

gear
does

not
mesh

8

Apply

g
ar
oil
o

all

sliding
sur

faces
and
check

to
see
that
shift
rods

operate
correctly
and

gears
are
en

gaged
smoothly
Fig
MT

58
Installing
Thrust

Washer

Front
Oil

groove
side
Rear

Thrust
side

TM727

Fig
MT
59
Counter

Gear
Thru
t

Washt
r

4

Place
wooden

plate
of
more
than

15

mm
0
59
in
thick

under
transmis

sion

case
to
make
it

level

Slide
transmission

case
onto

adapter
plate
by
lightly

tapping
with
a

soft

hammer
until

case
bears

against

adapter
plate
and
be
sure
to
line

up

dowel

pin

Carefully
install
main

drive

bearing

and
counter

gear
front

needle

bearing

Make
certain

that
rnainshaft

rotates

freely

MT14
1

Wooden

block

TM813

Fig
MT

60

Installing
Transmiuion

Cale

5

Fit
main
drive

bearing
snap

ring

to

groove
in
main

drive

bearing
with

snap
ring
pliers

Note

Make
sure

snap
ring
fits
in

groove

Fig
MT

61
Fitting
Main

Dri

Bearing
Snap
Ring

Rear

extension

assembly

Clean

mating
surfaces
of

adapter

p
Iat
aIld
rear
e

tens
i91

Apply
sealant
to

mating
surfaces
of

adapter
plate
and
rear

extension

2

With
fork
rods
in

their
neutral

positions
turn

striking
rod

clockwise

and

gradually
slide
rear

extension
onto

adapter
plate
making
sure
that

striking
lever

engages
with

fork
rod

brackets

correctly

3
Install

through
bolts
with
washer

and

tighten

b
Tightening

torque

Rear
extension

installation

bolt

1
6

to
2
2

kg
m

12
to
16
ft
lb