check oil DATSUN PICK-UP 1977 Repair Manual

Inspection

Note
To
clean
or
wash
all

parts
of

master

cylinder

operating
cylinder

and

piping
clean
brake
fluid
must

be
used
Never
use
minera10ils
llUch

as

gasoline
and
kerosene
It

will

ruin
the
rubber

parts
of
the

hydrau

lic

system

I

Check
cylinder
and

piston
for

uneven
wear
or

damage
and
if
neces

sary
replace

2
If
the
clearance
between

cylinder

and

piston
is

more
than

0
15
mm

0
0059
in

replace
cylinder

3

Renew

piston
cup
when
dis

assembled
It
must
also
be

replaced

when
wear
or
deformation
due
to

fatigue
or

damage
is

found

4

Damaged
dust
cover
oil
reservoir

or

cap
should
be

replaced

Return

spring
and
valve

spring
must

also
be

replaced
when

they
are
broken

or
weak

5

Replace
clutch
hose
and
tube
if

any
abnormal

sign
of

damage
or
de

fro

ti

n
is
found

OPERATING

CYLINDER

Removal
and

installation

Removal

1

Detach
clutch
hose
from

operat

ing
cylinder

2
Remove
two
bolts

securing
op

erating
cylinder
to
clutch

housing

Installation

Install

in
the
reverse
order
of
re

moval

Observe
the

following
instructions

Bleed
air

thoroughly
from
clutch

hydraulic
system

2
Do
not

install
return

spring
or

clutch
will

not
be

disengaged

properly

Tightening
torque

Operating
cylinder
securing
bolt

2
5
to
3
5

kg
m

18
to
25
ft
lb

Bleeder
screw

0
7
to
0
9

kg
m
5
1

to
6
5
ft
Ib

Clutch
hose
connector

1
7
to

2
0

kg
m
12
to
14
ft

b
CLUTCH

Disassembly
and

assembly

Disassembly

1
Remove

push
rod
with
dust

cover

2
Remove

piston
assembly
and

pis

ton

spring

3
Remove

bleeder
screw

1
6

Cl11B

5

Piston

cup

6

Operating
cylinder

7
Bleeder
screw
1

Push
rod

2
Dust
cover

3
Piston

spring

4

Piston

Fig
CL
20

Exploded
view

of

operating
cyUnder

Assembly

Assemble
in
the

reverse
order
of

disassembly
Closely
observe
the
fol

lowing
instructions

1

Prior
to

assembly

dip
piston
cup

in

clean
brake
fluid

When

installing
cup
pay
particular

attention
to
its
direction

2

Dip
cylinder
and

piston
in
clean

brake
fluid
before

assembly

Notes

a
Be

sure
to
install

piston
assembly

with

piston
spring
in

place

b
The
clutch

operating
cylinder
is

available
in
both
NABCO
make
and

TOKICO
make
There
is
no
inter

changeability
of

repair
kits
or
com

ponent
parts
between
NABCO
and

TOKICO
makes

When

replacing
the

repair
kit
or

component
parts
ascertain
the

brand
of
the
clutch

operating
cyl

inder

bndy
Be
sure
to
use

parts
of

the

same
make

as
the
former
ones

Inspection

Visually

inspect
all
disassembled

parts
replacing
those
found
worn
or

rl

Q
damaged
too

badly

beyond
speci

fications

BLEEDING
CLUTCH

SYSTEM

The

hydraulic
clutch

system
must

be
bled
whenever
clutch
line
has
been

disconnected
or
air

has
entered
it

When

pedal
action
has
a

spongy

feeling
it
is
an
indication
that
air
has

entered
the
system

Bleeding
clutch

system
is

an
es

sential

part
of

regular
clutch
service

I

Remove
reservoir

cap
and

top
up

with
recommended
brake
fluid

2

Thoroughly
clean
mud
and
dust

from
bleeder
screw
of

operating
cyl

inder
so
that
outlet
hole
is

free
from

any
foreign
rnaterial
Install
bleeder

hose

vinyl
hose
on
bleeder
screw

Place
the
other
end
of
it
in

a
clean

container

3
Have
a
co
worker

depress
clutch

pedal
two
or

three
times
With
clu
tch

pedal
depressed
fully
loosen
bleeder

screw
to
bleed
air
out
of
clutch

sys

tern

4
Close
bleeder
screw

quickly
as

clutch

pedal
is

on
down
stroke

5
Allow
clutch

pedal
to
return

slowly
with
bleeder
screw
closed

6

Repeat
steps
4
and
5
until

no
air

bubble
shows
in

the

vinyl
hose

7

Operate
clutch
several
times

then
check
connections
for
external

hydraulic
leaks

Notes

a
Brake
fluid

containing
air
is
white

and
has
visible
air
bubbles

b
Brake
fluid

containing
no
air
runs

out
of
bleeder
screw
in
a
solid

stream
without
air
bubble

c

Pay
close
attention
to
clutch
fluid

level
in
reservoir

during

bleeding

operation

d
Do
not

reuse
brake
fluid
drained

during
bleeding
operation

e
Exercise
care
not
to

splash
brake

fluid

on
exterior
fInish
as
it
will

damage
the

paint

f
Pour
brake
fluid
into
reservoir

up

to

specifIed
level

CLUTCH

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Probable
cause
and

testing

Clutch

slips
Corrective
action

Slipping
of
the

clutch

may
be

noticeable
when

any
of
the

following
symptoms
is

encountered

during
operation

I
Vehicle
will

not

respond
to

engine

speed
during
acceleration

2
Insufficient
vehicle

speed

3
Lack
of

power
during
uphill
driving

Some
of
the

above
conditions
are
also

experienced
when

engine

problem
is

oc

urring
First

de
tennine
whether

engine
or
clutch
is

causing
the

problem

If

slipping
clutch
is

left
unheeded
wear
and
or

overheating
will
occur
on
clutch

facing
until
it
is

no

longer
serviceable

TO
TEST
FOR
SLIPPING
CLlJfCH

proceed
as
follows

During
upgrade
travelling
run

engine
at

about
40
to
50
km

h
25
to
31

MPH
with

gear
shift

lever
in

3rd

speed
position
shift
into

highest
gear
and
at
the
same
time

rev

up
engine
If
clutch

is

slipping
vehicle
will
not

readily

respond
to

depression
of
accelerator

pedal

Clutch

facing
worn

excessively

Oil
or

grease
on
clutch

facing

W

r
d
clut
h
cov
r

pressure
plat
Replace

Replace

tpa
o
e
lace

Dragging
clutch
is

particularly
noticeable
when

shifting
gears
especially
into

low

gear

TO
TEST
FOR
DRAGGING
CLlJfCH

proceed
as
follows

I
Start

engine
Disengage
clutch
Shift
into

reverse

gear
and
then
into
Neutral

Gradually

increase

engine
speed
and

again
shift
into
reverse

gear
If
clutch
is

dragging
gear
grating

is

heard
when

shifting
from
Neutral
into

Reverse
Clutch

drags

2

Stop
engine
and
shift

gear
Conduct
this
test
at
each

gear
position

3
Gears

are
smoothly
shifted
in

step
2
but

drag
when

shifting
to
1st

speed
position
at

idling

a
If

dragging
is
encountered
at
the
end
of

shifting
check
condition
of

synchro

mechanism
in
transmission

b
If

dragging
is
encountered
at
the

beginning
of

shifting
proceed
to

step
4

below

4
Push

change
lever
toward
Reverse
side

depress
pedal
to
check
for
free
travel

a

If

pedal
can
be

depressed
further
check
clutch
condition

b
If

pedal
cannot
be

depressed
further

proceed
to

step
5
below

5
Check
clutch
control

pedal
height
pedal
free
travel
withdrawal
lever

play
etc

If
no
abnonnal

condition
exists
and
if

pedal
cannot
be

depressed
further
check
clutch

condition

Clutch
disc
runout
or

warped

Wear

or
rust

on
hub

splines
in
clutch
disc

Diaphragm
spring
toe

height
out
of
ad

justment
or
toe

tip
worn

Worn
or

improperly
installed

parts

CL10
Repair
or

replace

Clean
and
lubricate
with

grease
or

replace

Adjust
or

replace

Repair
or

replace

Manual
Transmission

o

cCl

4
@

@

fl

t

o

@

Fig
MT
3

MT
3
TM857
1
Main

drive
gear

2
Baulk

ring

3
d
4th

3

Synchronizer
hub
r

4

Shifting
insert

spnng

5
Shifting
insert

6
Coupling
sleeve

7
3rd
main

gear

8
Mainshaft

9
2nd
main

gear

10
1st
main

gear

11
ht

gear
spacer

12
Reverse
main

gear

13
Counter
drive

gear

14
Countershaft

15
Reverse
counter

gear

16
Reverse
idler
shaft

17
Reverse
idler

gear

Fig
MT
2
n
ear

component
F4W71B
transmlsBIO

g

@

f1f@

n
1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27
Striking
lever

Lock

pin

O

ring

Striking
guide

Oil
sea1

Striking
rod

E
ring

Stopper
guide
pm

Return

spring
plunger

Return

spring

Reverse
check

spnng

Return

spring
plug

Check
ball

plug

Check

spring

Check
baD

Interlock
ball

Retaining
pin

k

1st
2nd
shift
or

ht

2nd
fork
rod

3rd
4th
fork
rod

Reverse

fork
rod

3rd
4th
shift
fork

Reverse
shift
fork

Con
trollever

Control
lever
b

shmg

Control
lever

p
n

Control
lever

bushmg

TM045A

I

ponents
shift
contro
com

F4W71

B
transmuswn

REAR

EXTENSION

DISASSEMBLY

Remove
lock

pin
from

striking

lever
and
remove

striking
rod
Manual
Transmission

Note
00

not
diSlssemble

rear
exten

sion
bush
from

rear
extension

ADAPTER
PLATE

DISASSEMBLY

I

Remove
six

6

bearing
retainer

attaching
screws
with
an

impact

wrench
and
remove

bearing
retainer

from

adapter
plate

2

Remove
reverse
idler
shaft

3
Remove
mainshaft

bearing
from

the
rear
extension
side

INSPECTION

Wash
all

parts
in
a
suitable

cleaning

solvent
and
check
for
wear

damage
or

other

faulty
conditions

Notes

a
Be
careful

not
to

damage
any

parts

with

scraper

b

00
not

clean
wash
or
soak
oil
seals

in
solvent

TRANSMISSION
CASE

AND

REAR

EXTENSION
HOUSING

I
Clean
with

solvent

thoroughly

and
check
for

cracks
which

might

cause
oil
leak

or
other

faulty
con

ditions

2

Check

mating
surface
of
the

case

to

engine
or

adapter
plate
for
small

nicks

projection
or
sealant
e
1
Control
lever

2

Striking
rod

guide

3

Striking
rod

4

Striking
lever

5

Return

spring
plug

6

Stopper

pin

TM353

Fig
MT

27

Exploded
view
of
shifting
mechani6m

Remove
all

nicks

projection
or

sealant
with

a
frne

stone

3

If
rear

extension
bush
is

worn
or

cracked

replace
it
as
an

assembly
of

bush
and
rear
extension

housing

BEARING

I

Thoroughly
clean

bearing
and

dry

with
a

compressed
air

2
When
race
and
ball
surfaces
are

worn
or

rough
or
when
balls
are
out

of

round
or

rough

replacebearihg

with
a
new
one
See

Figure
MT
28

I

TM372

Fig
MT
28

l
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

MT
8
2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure
backiasii
in

gears

Standard

0
05
to0
10mm

0
0020
to
0
0039
in

If
the
above
limits
are
exceeded

replace
drive
and
driven

gears
as
a

set

4
Measure

gear
end

play

1st

gear

0
32
to
0
39
mm

0
0126
to
0
0154
in

2nd

gear

0
12
to

0
19
mm

0
0047

to
0
0075
in

3rd

gear

0
13
to
0
37
mm

0
0051
to
0

0146
in

TM374

Fig
MT

29

Measuring
end

play

5

Check
for

stripped
or
damaged

speedometer
pinion
gear
If

necessary

replace

BAULK
RI
NG

I

Replace
baulk

ring
if
found
to
be

deformed

cracked
or
otherwise
dam

aged
excessively

2
Place
baulk

ring
in

position
on

gear
cone

While

holding
baulk

ring
against

gear
as
far
as
it

will

go
measure

gap

between
baulk

ring
and
outer

gear

If

gap
is
small
discard
baulk

ring

See

Figure
MT
30

5
lr
1
25

to
1

60
rom

0
0492
to
0

0630
in

Baulk

ring

TM375

Fig
MT
30
Baulk

ring
to

cone

gap

OIL

SEAL

Discard

O

ring
or
oil
seal

which
is

once

removed

Replace
oil

seal
if

sealing
lip
is
deformed

or

cracked

Also
discard

oil
seal

if

spring
is

out
of

position

ASSEMBLY

To
assemble

reverse
the

order
of

disassembly
Observe

ihe

following

instructions

FRON1
COVER
ASSEMBLY

I

Wipe
clean
seal
seat
in
front

cover
then

press
fit
oil
seal
in

place

Coat
oil
seal
with

gear
oil

to

provide
initial
lubrication

Front

J

f

C
J

TM354

Fig
MT
31
Front
cov

oil
eol
Manual
Transmission

2

Apply
sealant
to
withdrawal

lever

ball

pin
screw
Install
withdrawal
lever

ball

pin
to
front
cover
and

tighten

screw
to
1
6
to
2
1

kg
m

12
to
15

ft
lb

torque

REAR

EXTENSION

ASSEMBLY

1

Wipe
clean

seal
seat
in

rear
exten

sion

housing

press
fit
oil
seal
in

place

Coat
oil
seal
and

bushing
with

gear

oil
for
initial
lubrication

Front

h

TM355

Fig
MT
32
Rear
extemion
oil
seal

2

Apply
grease
to
O

ring
and

plung

er

grooves
in

striking
rod

Insert

striking
rod
with

striking
rod

guide
through
rear
extension

3
Install

striking
lever
on
front
end

of

striking
rod
Install
lock

pin
and

torque
screw
to
0
9
to

1
2

kg
m

7
to

9
ft
Ib

ADAPTER
PLATE
ASSEMBLY

1
Place
dowel

pin
mainshaft
bear

ing
and
oil

gutter
on

adapter
plate
and

tap
with
a
soft
hammer
until

they
are

properly
positioned
in

place

Use
a
new
dowel

pin

Bend
oil

gutter
on
front
side
and

expand
on
rear
side
See

Figure

MT33

J

7

r

M356
Upper

Front

Fig
MT
33
Oil

gutter

MT
9
2
Insert
reverse
idler
shaft
in

adapt

er

plate

Make
sure
that
the

cut
out

portion

of
reverse

idler
shaft
is
lined

up
with

inner
face
of

adapter
plate

3
Install

bearing
retainer
in

adapter

plate

Align
bearing
retainer
with
reverse

idler
shaft
at
the
cut
out

portion
of

this
shaft

torque
screws
to
1

9
to

2
5

kg
m
14
to

18
ft
lb

and
stake
each

screw
at
two

poin
Is

with

a
punch
See

Figure
MT
34

TM400

Fig
MT
34
Staking
SCN
W

4
Install
countershaft
rear

bearing

in

adapter
plate
by
lightly
tapping

around
it
with

a
soft
hammer

GEAR
ASSEMBLY

Clean
all

parts
in

solvent
and

dry

with

compressed
air

Synchronizer

888embly

Assemble

synchronizer
assembly

Position

shifting
insert

springs
and

shifting
inserts
in
three
3
slots
in

synchronizer
hub

put
coupling
sleeve

on

synchronizer
hub

r
Front

3rd
4th
15t
2nd

TM351

Fig
MT

35

Installing
synchronizer

hub

Note
Prior
to

assembling
reverse
fork

rod
instaU
two
2
interlock
balls

into

adapter

piate
as
shown
in

Figure
MT
I6

6
Install
check
ball
and
check

ball

spring

Apply
sealant
to
check

ball

plug

and
install
it
in

place

Align
notch
in

reverse
fork
rod
with

check
ball

See

Figure
MT
52

TM369

Fig
MT
52

Installing
reverse

fork

rod

7

Torque
each
check

ball

plug
to

1

9
to

2
5

kg
m

14
to
18
ft
Ib

Note
BaD

plug
for
ht
2nd
fork
rod

is

longer
than
those

for
rev
shift

fork

rod
and

3rd
4th
fork
rod

8

Apply
gear
oil
to
all

sliding
sur

faces

and
check
to
see
that
shift

rods

operate
correctly
and

gears
are

engaged

smoothly

TRANSMISSION

ASSEMBLY

Tran
mis
lon
ea

mbly

1
Clean

mating
surfaces
of

adapter

plate
and
transmission

case

Apply
sealant

to

mating
surfaces

of

adapter
plate
and

transmission
case

2

Slide
transmission

case
onto

adapter
plate
by

lightly
tapping
with

a

soft
hammer
until
case

bears

against

adapter
plate

Carefully
install
main
drive

bearing

and
countershaft
front

bearing

Make

certain
that
mainshaft

rotates

freely

3
Fit

main
drive

bearing

snap
ring

to

groove
in
main

drive

bearing

by

using
Expander
See
Figure
MT
53
Manual
Transmission

Fig
MT
53

Fitting
main
drive

bearing
snap
ring

R
ar
xt

nslon
ass

mbly

I
Clean

mating
surfaces
of

adapter

plate
and

fear
extension

Apply
sealant
to

mating
surfaces

of

adapter
plate
and

rear
extension

2
With
fork

rods
in

their
neutral

positions

graduaUy
slide
rear
exten

sion

onto

adapter
plate

making
sure

that

speed
change
cross

lever

engages

with

fork

rod
brackets

correctly

3

Install
washers
and

through
bolts

and

torque
to
1

6
to

2
1

kg
m

12
to

15
ft
lb

Available

shim
Front
eov
r
s

mbly

I

Select
countershaft
front

bearing

shim
as
follows
See

Figure
MT
54

1
Measure

depth
A
from

front

end
of
transmission
case
to

counter

shaft
front

bearing

2
Select
a
shim
of
thickness
A

measured

D

A

JJ
ID

@

2J1

I

Transmission

case

2

Countershaft

front

bearing

3

Countershaft

4

Shim

TM371

Fig
MT
54

Selecting
countershafl

front
bearing
shim

No

A
Countershaft
front

rnm
in

bearing
shim
mm
in

I
2
92
to
3

01
0
1150

to
0

1185
0

6
0
024

2

3
02
to

3
11

0
1189
to
0
1224

0
5
0
020

3
3
12

to
3
21
0

1228
to
0

1264
0
4

0
016

4
3
22
to

3
3
I

0
1268
to
0

1303
0
3
0
012

5

3
32
to
3

41
0

1307

to
0
1343

0
2
0
008

6
3
42

to
3
5
I

0

1346
to
0

1382
0
1
0
004

7
3

52
to

3
61
0

1386

to
0
1421

8
3
62

to
3
71
0
1425
to
0

1461

2
Clean

mating
surfaces
of
front

cover
and

transmission
case

Apply
grease
to
shim
selected
to

retain
it
on
front
cover
install
front

cover
to
transmission
case
with

gasket

in
place

Install

through
bolts
with

washers

under
them
and

tighten
to
1

6
to
2
1

kg
m
12

to
15
ft
lb

torque

Apply
sealant
to
threads
of

through
bolts
before
installation

MT13
3

Install

speedometer
pinion
assem

bly
on
rear
extension

After

making

Sure
that

lock

plate
is

lined

up
with

groove
in

speedometer
pinion
sleeve

install

through
bolts
and

torque
to
0
4

to
0
5

kg
m
3

to
4
ft

lb

4

Install
back

up
lamp
switch
and

torque
to
2

0
to
3

0

kg
m

14
to
22

ft
lb

Be
sure
to

apply
sealant
before

installation

Manual
Transmission

CD
t

e
I

2

3

4

5

6

7

8

9

10

11

12

13

14

17

18

19

O
20

o

21

24

25
j

@
Striking
lever

Lock

pin

Q

ring

Striking
guide

Oil
seal

Striking
rod

Expansion
plug

Stopper
guide
pin

Return

spring

Return

spring
plug

Return

spring
plunger

Check
ball
plUS

Check

spring

Check
ball

Retaining
pin

Interlock
ball

ist
2nd
shift
fork

1st
2nd
fork
rod

3rd
4th
fork
rod

Reverse
OD
fork
rod

3rd
4th
shift
fork

Revene
OD
shift
fork

Con
trol1ever

Con
trol1cver
pin

Con
trollever
bushing

TM048A

Fig
MT
58
FS5W71B
trammi
ion

shift
control

component

3
Draw
out
counter
drive

gear
com

plete
with
main
drive

gear
assembly
by

means
of

a

gear
puller

When

drawing
out
main
drive

gear

assembly
be
careful
not
to

drop

pilot

needle

bearing
onto
floor
from
the

front
end
of
mainshaft
See

Figure

MT
60
REMOVAL
Same

as
for
the
F4W71B

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

Same
as
for
the
F4W71
B

DISASSEMBLY
OF

GEAR

ASSEMBLY

Fork
rod

Same
as
for
the
F4W71
B

Geer
sembi

I

With

gears
doubly
engaged
draw

out

counte
haft
front

bearing
using
a

suitable

gear
puller
See

Figure
MT
59

2
Remove
counter
drive

gear

snap

ring
TM398

Fig
MT
59

Removing
countershaft

front
bearing

MT
17
TM756

Fig
MT
60
Removing
counter
drive

gear
and
main
drive

gear

4

Rem6vesnap
ring
and
then
thrust

washer
from
mainshaft
front
end

Draw
out
3rd
4th

synchronizer

assembly
and
remove
3rd

gear
assem

bly

5
Remove

snap
ring
and
then
draw

out

speedometer

gear
and

bearing

from
mainshaft
rear
side

6
With

gea
doubly
engaged
re

lease

caulking
on
countershaft
and

mainshaft

nuts
then
loosen
them

Remove
countershaft
nut

ADAPTER
PLATE

DISASSEMBLY

Same
as

for
the
F4W71

B

Fig
MT
67

Removing
screws

INSPECTION

Wash

all

parts
in

a
suitable

cleaning

solvent
and
check
for
wear

damage
or

other

faulty
conditions

Notes

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
HOUSING

Same
as
for
the
F4W71
B

BEARING

Same

as
for
the
F4W7l
B

GEARS
AND
SHA
S

I
Check
all

gears
for
excessive

wear

chips
or
cracks

replace
as

required

2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure

backlash
in

gears

Main
drive
and

counter
drive

gear

0
05
to
0
10

mm

0
0020
to
0
0039
in

1st

2nd
3rd
5th
and

reverse

gears

0
05
to
0
20
mm

0
0020
to
0
0040
in
Manual
Transmission

If
the
above
limits
are
exceeded

replace
drive
and
driven

gears
as
a

set

4

Measure

gear
end

play

1st

gear

0
32
to
0
39
mm

0

0126
to
0
0154
in

2nd

gear

0
12

to
0
19
mm

0
0047
to
0
0075
in

3rd

gear

0
13
to
0
37
mm

0
0051
to

0
0146
in

OD

gear
on
mainshaft

0
32

to
0

39
mm

0
0126
to
0

0154
in

BAULK
RING

Same
as
for
the
F4W7IB

OIL
SEAL

Same
as
for
the
F4W71
B

ASSEMBLY

To
assemble
reverse
the
order
of

disassembly
Observe
the

following
in

structions

FRONT
COVER
ASSEMBLY

Same
as
for
the
F4W7l
B

REAR
EXTENSION

ASSEMBLY

I

Wipe
clean
seal

seat
in

rear
exten

sion

housing
press
fit
oil
seal
in

place

Coat
oil
seal
and

bushing
with

gear

oil
for
initial
lubrication
See

Figure

MT
68

Front
r

I

TM355

Fig
MT
68
R
ar
extemion
oil
sea

2

Apply
multi

purpose
grease
to

O

ring
and

plunger

grooves
in

striking

rod

Insert

striking
rod
with

striking
rod

guide
through
rear
extension

MT19
3
Install

striking
lever
on
front
end

of

striking
rod
Install
lock

pin
and

torque
screw
to
0
9
to
1
2

kg
m
7

to

9
ft
lb

4

Install

filainshaft
bearing
by

lightly
tapping
around
it
with
a

soft

hammer

5
Insert

reverse
idler
shaft
in

adapt

er

plate

Make
sure
that
the
cut
out

portion

of
reverse
idler
shaft
is

lined

up
with

inner
face
of

adapter

plate

6
Install

bearing
retainer
in

adapter

plate

Align
bearing
retainer

with
reverse

idler
shaft
at
the
cut
out

portion
of

this
shaft

torque
screws
to
1

9
to
2
5

kg
m
14
to
18
ft
lb
and
stake
each

screw
at
two

points
with
a

punch
See

Figure
MT
69

TM764

Fig
MT
69

Stahing
screw

7
Install
countershaft

rear
bearing

in

adapter

plate
by
lightly
tapping

around
it

with
a
soft
hammer

GEAR
ASSEMBLY

Clean
all

parts
in
solvent
and

dry

with

compressed
air

Synchronlz
r
embly

Same
as
for
the

F4W71
B

Ov
rdrlve
r

ynchronlz
r

mbly

I

Assemble
reverse
OD

synchro

nizer

assembly

2
Assemble
overdrive

gear
assem

bly

Position
synchronizer
ring
band

brake
thrust
block
and
anchor
block

on
overdrive
clutch

gear
install

circlip

Manual

iTransmission

TIGHTENING
TORQUE

Installa
tion

Engine
to
transmission

installation
bolt

Transmission
to

engine
rear

plate
bolt

Clutch

operating
cylinder
installation

bolt

Rear

mounting
insulator
to

transmission
installation
bolt

Crossmember

mounting
bolt

Propeller
shaft
to
diff
installation
bolt

Gear

assembly

Rear

extension
installation
bolt

Front
cover

installation
bolt

Bearing
retainer
to

adapter

plate
screw

Main
haft
nut

Check
ball

plug

Stri
lever

lock

pin

Reverse
select

return

plug

Speedometer
sleeve

locking

plate
nut

Reverse

lamp
switch

year
oil
Ier

pl
g

Ge
r
oil
drain

plug
Unit

kg
m
ft
lb

4
4

to
5

9
32

to
43

0

9

to
1
2
7
to
9

2
5

to
3
0

18
to
22

0
8
to
1
1
6

to
8

3

2
to
43

23
to
31

2
4

to
33

17
to

24

1

6

to
2
1

12
to
IS

1
6
to
2
1

12to
IS

1
9
to
2
S
14
to
18

14

0
to
17
0

101
to
123

1
9
to
2
S

14
to
18

0
9
to
1
2

7
to
9

0
9
1
2
7

to
9

0
4

to
O
S

3

to
4

2
0
to
3
0

14
to
22

2
S

to
3
5

18
t02S

2
S

toTS

l8
to
2S

or

SPECIFICATIONS

Gear
backlash

Maindrive

gear
to
counter
drive

gear

1st

gear

2nd

gear

3rd

gear

OD

gear

Gear

end

play

1st

gear

2nd

gear

3rd

gear

OD

gear

Counter

gear

Reverse
idler

gear

Clearance

between
baulk

ring
and

gear

All

gears

Counter

bearing

adjusting
shim
Unit

mm
in

0
05
to
0

10
0
0020
to

0
0039

0
05
to
0

20
0
0020
to
0
0079

O
OS
to
0
20
0

0020
to
0
0079

0
05
to
0
20
0
0020
to
0
0079

0
05
to
0

20
0
0020
to
0
0079

0
32
to
0
39

0
0126
to
0
0154

0
12
to
0
19

0
0047
to
0

0075

0
13
to
0
37
0
0051
to
0
0146

0
32
to
0
39

0
0126
to
0

0154

0
01
to
0
21

0
0004
to
0
0083

0
05

to
0
20
0
0020

to
0
0079

1
25
to
1

60
0
0492
to
0
0630

0
6
0
024

0
5
0
020

0
4
0

016

0
3
0
012

0
2
0
008

0
1

0
004

MT
22

Manual
Transmission

I

TROUBLE
DIAGNOSES
AND
CORREGTIONS

Condition

Difficult
to

intel11lesh
gears

Causes
Jor
difficu
t

gear
shifting
are
classi

fied
to
troubles

concerning
control

system

and
transniissioo
When

gear
shift
lever
is

heavy
and
it
is
difficult
to
shift

gears
clutch

disengagement
may
also
be
unsmooth
First

make
sure
that

clutch

operates
correctly

and

inspect
transmissi
o

Gear
slips
out
of
mesh

In
most
cases
this
trouble
occurs
when

interlock
b
all
check
ball
and

or
spring
is

worn
or
weakened
or

when
control

system

is

faulty
In
this
case
the

trouble
cannot
be

corrected

by
replacing
gears
and
therefore

trouble

shooting
must
be

carried
out

care

fully
It
should
also
be

noted
that

gear
slips

out

of
mesh
due
to
vibration

generated
by

weakened
fron
t
and
rear

engine
mounts

Noise

When
noise
occurs
with

engine
idling
and

ceases
when

clutch
is

disengaged
or
when

noise
occurs
while

shifting
gears
it
is

an

indicati90
that
th
e
noise
is

from
transmis

sion

t
Transmission

may
fa
ule

during
engine

idling

Check
air

fuel
mixture
and

ignition

timing

After
above

procedure
readjust
engine

idling
Probable

cause

Worn

gear
shaft
and
or

bearing

Insufficient

operating
stroke
due
to
worn
or

loose
sliding

part

Faulty
or

damaged
synchronizer

Worn
interlock
ball

Worn
check
ball

and
or

weakened
or
broken

spring

Wom
fork
rod
ball

groove

Wom
or
damaged
bearing

Worn
or

damaged
gear

Insufficient
or

improper
lubricant

Oil

leaking
due

to

faulty
oil

seal
or

sealant

clogged

breather
etc

Worn

bearing

High
humming
occurs
at
a

high
speed

Damaged
bearing
Cyclic
knocking
sound

occurs
also
at
a

19W
speed

Worn

spline

Worn

bushing

j

MT
23
Corrective
action

Replace

pair
or
replace

Replace

Replace

Replace

Replace

Replace

Replace

Add
oil
or

replace

with

designated
oil

Clean
Of

replace

Replace

Replace

Replace

Replace