Transmission DATSUN 210 1979 Repair Manual

1
Lock

pin

2

Striking
lever

3
Return

pring
plug

4

Control
lever

5

Striking
rod

6

Striking
rod

guide

7
Control
lever

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

1
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
extension

bushing
is

worn

or
cracked

replace
it

as
an

assembly
of

bushing
and
rear
extension

BEARING

I

Thoroughly
clean
bearing
and

dry

with

compressed
air

2
When

race
and
ball
surfaces

are
Manual
Transmission

1

TM255A

Fig
MT
97

Shifting
Mechanism

worn
or

rough
or

when
balls
are

out
of

round
or

rough
replace
bearing

TM372

Fig
MT
98

Inspecting
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

bendillg
crack

wear
or

worn

spline
if

necessary

replace

3
It
is

necessary
to
measure
end

play
before

disassembling
mainshaft

and

after

reassembling
mainshaft

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
con

dition

Replace
any
part
which
is

worn

or

damaged

MT
23
Standard
end

play

1
t

gear

0
15
to
0
25
mm

0
0059
to
0
0098
in

2nd

gear

0
15
to
0

25
mm

0
0059
to
0

0098
in

3rd

gear

0
30
to
0
40

mm

0
0118
to
0
0157
in

5th

gear

0
15
to
0

30
mm

0
0059
to
0
0118
in

Reverse
idler

gear

0
15
to
0
40
mm

0

0059
to
0
0157
in

TM256A

Fig
MT
99

Measuring
End

Phly

4
Check
for

stripped
or

damaged

speedometer
pinion
gear
If

necessary

replace

BAULK

RING

I

Replace
any
baulk

ring
which
is

deformed
or

cracked

2
Position
baulk

ring
in

place
on

gear
cone
and
measure
the

baulk

ring
to

gear
clearance
with
baulk

ring

pushed
toward

gear

If
th

clearance
is

smaller
than
the

specified
value

replace
baulk

ring

Standard
baulk

rinltto
cone

dearance

0
80
to
1
65
mm

0
0315
to
0

0650
in

If
it
is
less
than
0
5
mm
0

020
in

a
worn
baulk

ring
may
be
the

cause

and
a
new

ring
should
be
fitted

it

TMS06

Fig
MT
100
Baulk

Ring
to
Con

Gap

SHiniNG
IIUERT

Replace
if
WOrn

excessively
worn

unevenly
defonned
or

damaged

OIL
SEAL

I

Dis
r
l
O

ring
or
oil
seal
which
is

once
removed

Replace
oil
seal
if

sealing
lip
is

qefonned
or
cracked

Also
discard
oil

seal
if

spring
is

out
of

position

2
Check
tlie

oil
seal

lip
contacting

with
shaft
if

necessary
replace
oil
seal

and
shaft

as
a

set

REAR

ENGINE
MOUNTING

INSULATOR

Replace
rear

engine
mounting
insu

lator
if
weakened
deteriorated
or

cracked

ASSEMBLY

To
assemble
reverse
the
order
of

disassembly
Observe
the

following
in

structions

FRONT
COYER
ASSEMBLY

I
Make

sure
that

seal

mating
sur

face
is

clean

Using
a

press
and

Oil
Seal
Drift

ST23800000

drive
new
seal
into

place

on
front
cover

Nole

When

pressing
oil
seal
into

place
apply
coat
of

gear
oil
to

surface

adjoining
oil
seat

2
Lubrica
te

seal

lip
and
main
drive

shaft
with

gear
oil
when

installing

front

cover
Manual
Transmission

Front

h
I

4

1

Main
drive

gear

2
GearoiJ
TM098A

Fig
MT
101
Front
Cover
Oil
S

al

TRANSMISSION
CASE

ASSEMBLY

I
Press
countershaft
needle

bearing

into
transmission
case
from
outside

Note

a
Needle

bearing
should
not

be
re

used
after

removal

b

When

inslalling
needle

bearing
be

sure
to

project
it

2
mm
0
08
in

from
tramission
case
front
mace

c
Make
sure
that
needle

bearing
torm

smoothly

d
After

instal6ng
needle

bearing

apply
multi

purpose
grease
to
the

bearing
smace

Front

t

2mm

0
08

in

TM707

Fig
MT
I02
Count

haft
N
edle

Bearing

2

Install
withdrawal
lever
ball

pin

on
case
and

tighten
screw

ifl
Tightening
torque

Sail
pin

2
0

to
3
0

kg
m

14
to
22
ft

Ibl

REAR

EXTENSION

ASSEMBLY

I

Apply
grease
to
O

ring
and

plunger

grooves
in

striking
rod

guide

Insert

striking
rod

with

striking
rod

guide

through
rear
extension

2

Install

striking
lever
on
front

end

MT

24
of

striking
rod

Install
lock

pin
and

nut
and

tighten
it

ifl
Tightening
torque

Striking
I
er
lock
nut

0
9
to
12

kg
m

6
5
to
8
7
ft
lbl

3
When

installing
expansion
plug

apply
sealant
to
it

4

Make
sure
that
seal

mating
sur

face
is

clean

Using
a

press
and
Oil
Seal
Drift

ST35300000
drive
new

seal
into

place

on
rear
extension

Note
When

pressing
oil
seal
into

place
apply
coat
of

geat
oil
to

mace

adjoining
oil
seal

5
Coat
oil
seal

lip
and

bushing
with

gear
oil
for
initial
lubrication
Pack

cavity
between
seal

lips
with
recom

mended
multi

purpose
grease
when
in

slalling

FroDt

I

t
Cc

if

i

I

L

1
Gear
oil

2

Bushing

3
Grease

TM099A

Fig
MT

I03
Rear
Eztemion
Oil
Seal

ADAPTER

PLATE

ASSEMBLY

I

Place

adapter
plate
in
a
vise

with

Adapter
Setting
Plate

KV32100JOO

with
fork
rod
hole
side

up

Fig
MT
104
Attaching
AdopterPhlte

to

Special
Tool

2
Install
needle

bearing
by
lightly

tapping
around
it

with
a

brass
drift

and
a
hammer

3
Install

reverse
idler

shaft
with

thrust
washer
in

adapter
plate
by

tapping
the
shaft
end
with

a
soft

hammer

TM243A

Fig
MT
I05
Installing
Re
Idler

Shaft

ASSEMBLY
OF
GEAR

ASSEMBLY

Clean
all

parts
in
solvent
and

dry

with

pressed
air

Synchronizer

1
2nd

3rd
41h
5th

speed

synchronizers

I
Place

synchro
hub
into

coupling

sleeve

2
Fit

shifIing
inserts
in
t1lree

grooves
in

synchronozer
hub

3
Install

spread
spring
to
inserts
so

that

insert
is

securely
attached
to
inner

side
of

coupling
sleeve

Install
Ihe
other

spread
spring
on

the

opposite
side
of

synchro
hub

Note

a
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

TM077

Fig
MT
I06

Enstalling
Spread

Spring
Manual
Transmission

TM131A

Fig
MT
I07

Installing
Spre
d

Spring
2

2
Ist

reverse

synchronizer

I
Position

shifting
insert

springs

and

shifting
inserts
in

three
3
slots
in

synchronizer
hub

2
Put

reverse

gear
on

synchronizer

hub

3
Install

shifting
insert
retainer
to

inserts
so
that
sert
is

securely
attach

ed
to
inner

side
of
reverse

gear

Mainshatt

I

Assemble
3rd

gear
needle

bearing

3rd

gear
baulk

ring
2nd
3rd

speed

synchronizer
assembly
2nd

gear
baulk

ring
2nd

gea
buihirig
needle

bearing

2nd

gea
and

thrust
washer
on
main

shaft
to

2

Press
mainshiift

bearing
onto

mainshaft
uSi

g
Mainshaft

Bearing

Drifl
ST22350000

L

ST22350000

TM711

Fig
MT
I08

Enstalling
Mainshaft

Bearing

Note
Assemble
2nd
3rd

speed

synchronizer

paying
attention
to

its

direction

MT
25
Front
hl
l
h2

2nd

gear
ide
3rd

gear
SIde

hi
h2

Fig
MT
109

Inslalling
2nd
3rd

Speed
Synchronizer

3
Position
5th

gear
needle
bearing

5th

gear
bawk

ring
and
4th

5th

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

Thicknc
ss
mm

tin

2
1
55

to
1

60

0

0610
to
0
0630

1
60
to
1

65

0
0630
to
0

0650

1
65
to
1

70

0
0650
to
0
0669
3

TM798

Fig
MT
IlO

InslallingSnap
Ring

Main
drive

gear

1
Press

main
drive

gear
bearing
onto

shaft
of
main
drive

gear
using
Trans

mission
Drift
ST23800000

Make
sure
that

snap

ring
groove
on

shaft

clears

bearing

H

ST23800000

M

TM714

Fig
MT
111

InstaUing
Main
Drive

Bearing

2

Place
main
drive

bearing
spacer

on
main
drive

bearing
and
secure
main

dtivebearing
with
a
new
tlii

er

snap

ring
that

will
eliminate
end

play

Note
Make
sure

snap
ring
fits
in

groove

1
Main
drive

gear

2

Snap

ring

3

Spacer

4

Main
drive

bearing

TM715

Fig
MT
112
In

talling
Snap
Ring

Available

snap
rings

No
Thickness

mm
in

2
1
34
to
I
40

0
0528
to
0
055
I

l40tol46

0
0551
to

0
0575

I
4610
1
52

0

0575100
0598

1
52101

58

0
0598
10

0
0622

1
58
to
1
64

0
0622
to
0

0646

1
64
to
I

70

0

0646
to
0
0669

I
70
to
I

76

0
0669
10

0
0693
3

4

5

6

7

Counter

cear

I

Install
a
counter

gear
thrust

washer
and
counter

gear
into

transmis

sian

case

and
select
counter

gear
Manual
Transmission

thrust
washer
of

proper
thiclmess

using
straight
edge

Select
washer
from
those
shown
in

the

following
table
so

that
end

play
of

counter

gear
is

specified
value

Standard
end

play

0
10
to
0
20

mm

0
0039

to
0
0079
inl

No
Thickness
mm

in

2
20
to
2
25

0
0866
to
0
0886

2

25
to

2
30

0
0886
to

0
0906

2
30
to
2
35

0

0906
to
0

0925

2
35
to
2
40

0

0925
to

0
0945

2
40
to
2
45

0

0945
to

0
0965

2
45
to

2
50

0
0965
to
0
0984

2
50
to

2
55

0
0984
to

0
1004

2
55
to
2
60

0

1004
to

0
024
2

3

4

5

6

7

8

Note
Be

sure
to
measure
at
two
or

more

positions
on
the
end
surface

of
counter

gear

rr

II
TM244A

Fig
MT
113

Measuring
Counter
Gear

End

Phly

2
Remove
counter

gear
from
the

transmission

case

Assembly
to

adapter
plate

I

Install
baulk

ring
on
main
dtive

gear
and

combine

with
mainshaft
to

complete
the
mainshaft

assembly

Note

l
e
sure
to
iJislall

pilot
bearing

in

place
when

combining
with

mainshaft

MT
26
2
Combine
mainshaft

assembly

with
counter

gear
assembly
and

place

them
into

adapter
plate
simulta

neously

Note

Be
careful
not
to

forget
to

install
thrust

washer
And
when

installing
throst
washer

note
front

1IIllIR
tt
djrections

Front

Thrust
side
Rear
Oil

groove
side

TM285A

Fig
MT
I14

Count
Gear
Thru
t

Washer

3

Pull
mainshaft

assembly
into

adapter
plate

using
Mainshaft
Puller

KV32100400

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

geaB
on

floor

b
Take

care
not

tndamage
bearings

TM245A

Fig
MT
II5

Installing
Main

haft

A
6embly

4
Fit

snap
ring
to

groove
in
main

shaft
rear

bearing
with

snap
ring
pliers

TM23aA

Fig
MT

116

Fitting
Main

haft
Rear

Bearing
Snap
Ring

Note
Make
sure

smp
ring
fits
in

groove

5

Install

bearing
retainer
on

adapter

plate

Torque
screws
and
stake
each

screw

at
two

points
with
a

punch

@
Tightening
tOrque

Mainshaft
bearing
retainer
screw

0
8
to
3

kll
m

15
8
to
9
4
ft
lbl

TM246A

Fig
MT
117

Staking
Bearing
Retainer

Screws

6
Press
Ist
counter

gear
onto

counter
sltaft

using
Drift

ST22360002

TM583

Fig
MT

118

Installing
I
t
Counter

Gear

7
Fit

a
new
suitable

retaining
ring

in

place
so
th
t
there
exists
a
mininum

clearance
between
end
face
of

counter

gear
and

ring

Note
Make
sure

retaining

ring
f
It

in

groove

Available

retaining
rings

No
Thickness
mm
in

2
1
25
to
1
35

0
0492
to
0
0531

1
35
to
I
45

0
0531
to
0
0571
0

d
Converted
tor

q
e

j
Iim
ttine

7
7

7
Manua

Transmission

TM247
A

Fig
MT
119

Installing
Retaining
Ring

8

Install
thrust

washer
to
rear
of

mainshaft
and
idler
shaft

9

Install

synchro
hub
with
reverse

gear
I

st

gear
together
with
needle

bearing
and

bushing
and
idler

gear

together
with

needle

bearing
simulta

neously

OTT
o

1st

gear
side

Ui

Front

Fl

J

I

TM263A

Fig
MT
I20
In

talling
Ist

Reverse

Synchronizer

10
Install

mainshaft
nut
and

tighten

it

temporarily

E

S

f2

80
t1

o

c

v

0

S

v

5

c

o

o

u
10

70

9

60

50
II

With
I
st
and
2nd

gears
doubly

engaged
tighten
mainshaft
nut
to
con

verted

torque
en
See

Fig
MT

123

using
Wrench

ST22520000

Stake
mainshaft
nut
to

groove
of

mainshaft
with

a

punch

ST22520000

TM248A

Fig
MT
I2I

Tightening
Mainshaft

Nut

TM249A

Fig
MT
I22

Staking
Mainshaft
Nut

I
I

Upper
limit

line

40

0
2
0
3
0
4
0
5
0

6
0
7

0
8
m

1
0
1
5
2

0
2
5
ft

L

Effective

length
of

torque
wrench

MT
27
TM258A

Fig
MT
123
Converted

Torque

J

xplanation
of
convet
ted

torque

Mainshaft
nut
should
be

tightened

to

10
to
11

kg
m
72
to
80
ft
Ib

torque
with
the

aid
of

Wrench

ST22520000

When

doing
w
the

amount
of

torque
to
be
read
on

wrench
needle
should
be
modified

according
to
the
following
formula

L

C

kg
m
10

x

L
O
I
to

11
L

x

L

O
I

or

C
ft
Ib
n

x

L
O
33
to

L

80
x

L
0
33

Where

C
Value
read

on
the

torque
wrench

kg
m

ft
Ib

L

Effective

length
of

torque
wrench

m
ft

ST22520000

Torque
wrench

r

Lm
ft

0
1
m

0
3
ft

TM587

Fig
MT
124

Setting
Wrench

Example

When
a

0
4
m

Iong
torque
wrench

is

used

the
C
in

Fig
MT

123

will

be

8
0
to

8
8

kg
m
58
to
64

ft
Ib

12

Measure

gear
end

play

Make

sure
that

they
are

held
within

the

specified
values

For

details
refer
to

Page
MT
23
for

Inspection

13

Fit

1
0
IDm
0
039
in
thick

snap
ring
10

the
front

side
of
main

shaft
end

bearing

14

Install

mainshaft
end

bearing

using
Bearing
Drift
ST22350000
Fit

thick

snap
ring
to
the
rear

side
of

bearing
to
eliminate
end

play
Manual
Transmission

Available

Sllap
ring

No

Thickness
IDm

in

1
1
0
0

039

2

1
2
0
047

on

LST22350000

TM250A

Fig
MT
125
In

talling
Main

haft

End

Bearing

Shift
forks
and

fork
rods

1
Insert
1st

reverse
fork
rod
into

its

shift
fork
and

adapter
plate

2
With
1st
reverse
fork
rod
set
at

Neutral
insert

interlock

plunger
into

adapter
plate

3

Insert
2nd
3rd
fork
rod
into

adapter

plate
2nd
3rd
and
4th

5th
shift
forks

4
With
2nd
3rd
fork
rod
set
at

Neutral
insert
interlock

plunger
into

adapter

plate

5
Insert

4th
5th

fork
rod
into

adapter
plate
and
its

s
Uft
fork
6

Secureshift
forks
and
fork

rOd
s

with
new

retaining
pins

Note

a
Be
sure

to
install

interlock

plunger

when

installing
any
adjacent
fork

rods
to

adapter
plate

Properly
align
the

groove
in
assem

bleMork
rod
with

inle
rlQck
plung

er

See

Fig
MT
SO

b
Be
su

to

align
4th
5th
shift
fork

with

the

groove
in

their

coupling

sleeve

befo
instalting

c
Also

align
2nd

3rd
shift
fork
with

their

coupling
sleeve

properly
be

fore

instalting

7

Install
check
balls
and

check
ball

springs
Applying
locking
sealer
to

check
ball

plug
and

install
in

place

Align
center

notch
in

each
fork
rod

with
check
ball

Note

a

Check
ball

plug
for
1st

reverse

fork

rod
is

longer
than
those
for

2nd
3rd
fork
rod
and
4th
5th

fork

rod

b
To

insure
that

interlock

plunger
i

installed

properly
slide

2nd
3rd

fork
rnd

andoperate
the

other
fork

rod

Make
sure

thaI

gear

except
20d

or
3rd

gear
doe

not
mesh

8

Apply
gear
oil
to

all

sliding
sur

faces
and

check

to
see
that
shift

rods

operate
correctly
and

gears
engage

smoothly

L

1
u

Revene

TM251A

Fig
MT
126
In

talling
Shift
Forks

and
Fork

Roth

MT
28

TRANSMISSION
ASSEMBLY

Transmission
case

assembly

r

I
Remove

adapter
plate
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
and
transmission

case

3
Install
counter

gear
tluust
washer

selected

previously

Note

a

Apply
grease
to

sliding
surface
of

thrust
washer

b
When

installing
thrust
washer
note

the

front
and
r
ar
directions

Front
Oil

groove
side
Rear
Thrust
side

TM727

Fig
MT
127
Counter
Gear
Thru
t

Wa
her

4
Place
wooden

plate
of
more
than

20
mm
0

79
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
mainshaft

rotates

freely

Wooden

block

TM252A

Fig
MT
128
Installing
Transmis
ion

Ca
e
Manual
rransmission

5

Fit
main
drive

bearing
snap
ring

to

groove
in
main
drive

bearing
with

snap
ring
pliers

Note

Make
sure

sno

p
ring
fits
in

groove

Fig
MT

129

Fitting
Main
Drive

flearing
Snap
Ring

ReBr
extension

assembly

I

Clean

I
lating
surfaces
of

adapter

plate
and

rcar
extension

Apply
sealant
to

mating
surfaces
of

adapter
plate
a
itd

rear
extension

2

Assemble
rear
extension

assembly

as
follows

q
Set
fork
rod
at

5th

position

2
P

sition

striking
rod

at
Neutral

position
turn

striking
guide
clockwise

and
then

set

striking
lever
and
shift

arm
as
shown
in

Fig
MT

130

3
In

this
state

align
shift
arm

pin

with

groove
in

fork
rod

and
assemble

rear
extension

assembly
on

adapter

plate

MT280A
Shift
ann

J

1
Fork
rod

J

At
5th

Installing
Rear
Extension

Assembly
Fig
MT
130

MT29
Note

a

Use
care
when

installing
rear
ex

tension

assembly
Do
not
allow

shift

ann
to

come
out
of
the
strik

ing
leVer

b
Install
shift
ann
onto
4th
5th

fork
rod
and
then
fit

striking
lever

pin
into
oth
r

fork
rods

3
Install

through
bolts
with

wash

ers

GJ

Tightening
torque

Rear
extension
installation

bolt

1
6
to
2
2

kg
m

12
to
16
ft
lb

4

Apply
grease
to

plunger
install
it

in
rear
extension

5

InstaU
return

spring

Apply
locking
sealer
to
return

spring
plug
and
mstall
it
in

place

GJ
Tightening
torque

Return

spring
plug

0
5
to
1
0

kg
m

3
6
to
7
2
ft
lbl

Front
coyer

assembly

I

Select
fron
cover

adjusting
shim

as
follows

I

Using
verruer

caliper
depth
gauge

measure
depth
A

from
front
end

of

transmission
case
to

main
drive

bearing

outer
race
with

front
cover

adjusting

shim
in

place

2

Select
a

shim
of
thickness
A

measured

No

A

mm
in
Manual
Ttansniissio
n

Adjusting
shim

mm
in

0
50
0

0197

0
55
0

0217

0
60
0

0236

0
6

0

9756

0
70
0

0276

0
75
0
0295

0
80
0
0315
I

2

3

4

5

6

7
6
05
to

6
09
0
2382
to
0

2398

6
10to
6
14
0

2402
to
0
2417

6
15
to

6
19
0
2421

to
0
2437

6
20

to
6
2

4

9
1
41

t
19
2457

6
25
to

6
29
0
2461
to

0
2476

6
30
to
6

34
0
2480

to
0
2496

6
35
to
6
39
0
2500
to

0
2516

TM816

Fig
MT
131

MetuUring
Front

CoV
r

Adju
ting
Shim

1

Transmission

case

2
Main

drive

gear

3

Adjusting
shim

4

Bearing

TM817

Fig
MT

132

Selecting
Front

CoV
r

Adju

ti1l8
shim
2

Clean

maling
surfaces
of
front

cover

and
transmission

case

3
Install
front
cover
to
transmission

case
with
the

adjUsting
shim
and
0

ring
in

place

@
Tight
ning
torque

Front

co
erinstallation
bolt

1
0
to
1
6

kg
m

7

to
12
ft

Ib

Outer

parts
assembly

I
Install

speedometer

pinion
assem

bly
and
install

securing
bolt
and

tighten

@

Tightening
torque

Speedometer

sl
locking
plate

bolt

0
3
to
0
5

kg
m

2
2
to
3
6
ft

lb

2

Install
reverse

lamp
switch
and

tighten
At
the

same
time

install

top

detecting
switch
if

so

equipped

Be

sure
to

apply
locking
sealer

before
installation

MT30
@
Ti
ltening
torque

Rewene

lamp
switch
and

top
detecting
switch

2
0
to
3
5

kg
m

14

to
25

fHb

3

Apply
a

light
coat

of
multi

purpose
grease
to

withdrawal
lever

release

bearing
ahd

bearing
sleeve
in

stall
them
on
transmission
case

After

connecting
them
with

holder

spring
install

dust

cover
to

transmis

sion

case

4

Install

control
lever

temporarily

and

move
shift
coritrol
lever

through

all

gears
to
make

sure
that

gears

op
rate

smoothly

5
InstaU
draiiI

plug
coated

with

sealant

in

place

@
Tightening

torque

Drain

plug

2
5
to
4

0

kg
m

18
to
29
fHb

6
Make

sure
that
main
drive

shaft

rotates

smoothly
in

Neutral

v
Jin
drive

gear
routing
torque

less
than
1
8

leg
em
1
6
in
Ib

Manual
Transmission

SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

Transmission

model

F4W60L
FS5W60L

Item

No

of

speeds
4
5

Synchromesh
type
Warner

Shift

type

t
3

I
I
R
2
4

2
4
R
r

I
I

1

3
5

1st
3
513

3
513

2nd
2
170
2
170

3rd

1
378
1
378

Gear
ratio

4th
1

000
1
000

5th

0

846

Rev
3

764
3

464

Final

gear
ratio
3
700
3

700

155

13
6
15
13
4PR

16
5

Speedometer

Tire

155SRI3
16
5

gear
ratio

175
70SR13
16
5

Oil

capacity
liter

US

pt
Imp
pt
1
3
2
U

2
Y

I
1
2

2
i
i
i

MT31

Manual

Transmission

INSPECTION
AND
ADJUSTMENT

Transmission
model

Item

Ist

gear

2nd

gear

Gear

end

play

mm
in
3rd

gear

5th

gear

Counter

gear

Reverse

idler

gear

Clearance
between
baulk

ring

and

gear
rom
in

Main

drive

coupter
drive

gear

1st

gear

2nd

gear

Gear
backlash

mm
in
3rd

gear

5th

gear

Reverse
counter
to

reverse
idler

Reverse
idler
to

reverse
main

Main
drive

gear

rotating
torque

kg
cm
in

lb
F4W60L

0
15
to

0
25

0
0059
to

0
0098

0
30
to
0

40

0
0118
to

0
0157

0
15

to
0
30

0

0059
to

0
0118

0
10
to
0
20

0
0039
to
0
0079

0
1
0
to

0
27

0

0039
to

0
0106

0
80
to
1

65

0
0315
to
0

0650

0
05
to
0
15

0
0020
to
0
0059

0
05
to
0
15

0
0020
to

0
0059

0

05
to
0
15

0
0020

10
0
0059

0

05
to
0
15

0
0020
to

0
0059

0

05
to
0
18

0

0020
to
0
0071

0
05
to
0
18

0
0020
to
0
0071

Ie
thaI
1

8
1

6

MT32
FS5W60L

0
15
to
0

25

0

0059
to
0

0098

0
15
to

0
25

0
0059
to

0
0098

0
30

to
0
40

0

0118
to

0
0157

O
lSto
0
30

0

0059
to

0
Q118

0
1
0
to
0
20

0
0039
to
0
0079

0
15
to
0

40

0
0059

to
0
Q157

0
80
to
1

65

0

0315
1
0

0650

0
05
to
0
15

0
0020
to

0
0059

O
OSto
0
15

0
0020
to

0
0059

0
05
to

0
15

0

0020
to

0
0059

0
05
to
0
15

0
0020
to
0
0059

0
05

to
0
15

0
0020
to

0
0059

0
05

to
0

18

0
0020
to
0
071

0
05
to
0
18

0

0020
to
0
0071

less
than
1

8
I
6