Fork DATSUN 210 1979 Service Manual

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

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

Manual
Transmission

S

R

o

o

D
l

@

@

l

@

l

25
Control
lever
boot

26
Control

pin
bushing

27
Control
arm

pin

28
Control
lever

29
Control
lever
knob
1

2nd
3rd
fork
rod
9
4th

5th
shift
fork
17

Shift
arm
bracket

2

Retaining

pin
10
2nd
3rd
shift
fork
18
Arm
bracket
O

ring

3

Checking
ball

plug
11
Ist
reverse
shift

fork
19
Arm
bracket

plain
washer

4
Check
ball

spring
12

Striking
rod
20
O

ring

5
Check
ball
13
Striking
lever
21

S

lriking
guide

6
ht
reverse
fork
rod
14
Lock

pin
22

Striking
guide
oil
seal

7
Interlock

plunger
15
Striking
pin
23

Expansion
plug

8

4th
5th
fork
rod
16
Shift
arm
24
Control
lever

bushing
Tightening
torque
kg
m

fHb

@
0

9
to
1
2
6
5

to
8
7

@
8
2
to
to
O
59

to
72

TM229A

Fig
MT
68
FS5W60L
Transmission

Shift
Control

Components

REMOVAL
4

Jack

up
the

car
and

supporl
its

weight
on

safety
slands
Use
a

hy

draul

c
hoist
or

open

pit
if
available

Make

sure
that

safety
is

insured

S
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

remove

top
detecting
switch
if

so

equipped

8
Remove

propeller
shaft

Refer
to

Removal
Section
PD
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

CJi
J

TM781
Note

Plug
up
the

opening
in
the
rear

extension
to

prevent
oil
from

flow

ing
out

Fig
MT
69

Removing
Control
Lever

MT
17
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

Do
not

place
the

jack
under
the
oil

pan
drain

plug

II

Support
transmission
with
a

transmission

jack

12
Loosen
rear

engine
mount
se

curing
bolts

CD

temporarily
and
re

move
crossmember

mounting
bolts

CV

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

1
Prior
to

disassembling
transmis

sion

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
so

equipped

5
Remove

speedometer
pinion
as

sembly

6
Remove

nut
and
stopper

pin
bolt

from
rear

end
of
rear
extension

Fig
MT
71

Removing
Nut
and

Stopper
Pin
Bolt

7
Remove

return

spring
plug
return

spring
and

plunger
from
rear
exten

sion

@

@
Q

@

j

TM784

Fig
MT
72
Removing
Return

Spring
Plug

8
Remove

front
cover
Detach
0

ring
and

front
cover

adjusting
shim

1l
l

TM785

Fig
MT
73

Removing
Front
Cover

D

Ring
and

Adju
ting
Shim
Manual
Transmission

9
Remove
main
drive

bearing
snap

ring
with

snap
ring
pliers

Fig
MT
74

Removing
Main
Drive

Bearing
Snap
Ring

10
Remove
rear
extension

securing

bolts
and
turn

striking
rod
counter

clockwise

Drive
out
rear

extension
backward

using
a

standard

puller

TM548

Fig
MT
75

Removing
R
ar

Extension

11

Separate
transmission
case
from

adapter
plate
by
evenly

tapping

around
it

with
a
soft
hammer

CAUTION

00
not

pry
transmission
case
or
rear

extension
from

adapter
plate
with

screwdriver

TM262A

Fig
MT
76
Removing
Tran

miuion

Ca
e

MT19
12

Set

up
Adapter
Setting
Plate

KV32100300
on

adapter
plate

Place
the
above

assembly
in

a
vise

TM230A

Fig
MT
77
A

ttaching
Gear

Assembly
to

Special

Tool

13

Detach
counter

gear
thrust

washer

DISASSEMBLY
OF

GEAR
ASSEMBLY

Shift
forks

and
fork
rods

1

Drive
out

retaining
pins
from

each

fork
rod
with

Fork
Rod
Pin

Punch
ST23540000

TM231
A

Fig
MT
78

Driving
Out

Retaining

Pim

2

Remove
three
3

check
ball

plugs

TM232A

Fig
MT
79

Removing
Check
Ball

Plug

3

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

plungers

b
Each

gear
and
shaft
can
be
de

tached
from

ar1apter
plate
without

removing
each
fork
rod

CD

@

1

Check
ball

p1
8

2
Fork
rod
Reverse

Ist

3
Interlock

plu
er

4

Fork
rod
2nd

3rd

5
Fork
rod
4Ih
5th

6

Check
ball

TM793

Fig
MT
BO

Check
Ball

nd
Interlock

Plunger

Gear

a

embl

Note
It
is

necessary
to

measure
end

play
before

disassembling
main

shaft
and
after

reassembling
main

shaft
Refer
to

Inspection
for
Gears

and
Shafts

1
Remove

snap
ring
of
rnainshaft

end

bearing
Draw
out

b
aring
using

Bearing
Puller
KV32
10
1330

Remove

olher
sna

p
ring
of
rnainshaft
end
bear

ing

TM233A

Fig
MT
BI

Removing
Mainshaft

End

Bearing

2
With
1st
and
2nd

gears

doubly

engaged
release

staking
on

main
shaft

nut
and
loosen
it
Manual
Transmission

TM234A

Fig
MT
B2

Releaaing
Staking
on

Mainshaft
Nut

3
Remove

following
parts
from

mainshaft
in

rear
extension

side

I
Mainshaft
hut

2
Remove

shifting
insert
retainer

synchro
hub

with
reverse

gear
1st

gear

togeth
r
with

needle

bearing
and
bush

ing
and
idler

gear
together
with

needie

bearing
simultaneously

3

Thrust
washer

Fig
MT
83

Removing
Reverw

Main

Revere

Idler
and

1st

Gea

4
Remove

four
4

bearing
retai
er

attaching
screws
with

an

impact
driver

and

remove

bearing
retainer

Fig
MT
B4

Removing
Screw

MT

20
5
Remove

folloWIng
parts
from

counter

gear
rear
end

I
Retaining
ring

TM236A

Fig
ltiT

85

Removing
Retaining

Ring

2

1st
counter

gear
using
Gear
Pull

er
ST22480000

ST22480000

TM237A

Fig
MT
86

Remouing
l
t
Counter

Gear

6
Remove

snap
ring
from
mainshaft

rear

bearing

using
snap

ring
pliers

TM238A

Fig
MT
B7
Removing
Main

haft

Rear

Bearing
Snap
Ring

7
Drive

out
rnainshaft

gear
as

sembly
together
with

counter

gear

assembly
by
lightly
tapping
the
rear

end
with
a

sofl
hammer
while

holding

the
front
of
rnainshaft

gear
assembly

and
counter

gear
assembly

by
hand

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