oil DATSUN 210 1979 Service Manual

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

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

10

Breather

11
Rear
extension
dowel

pin

12
Retwn

spring
bushing

13
Filler

ptug

14

Bearing
retainer

15
Rear

extension

assembly

16
Drain

plug

17
Rear
extension

dust
cover

with
oil
seal

18

Retaining
pin

19

Spe
ometer

sleeve

20

Speedometer

pinion

21
Neutral
switch

FS5W60L
Tralllmimon

Case

Compo
nhl
Manual

Fransmission

S
SPEED
TRANSMISSION
Model

Tightening
torque
kg
m
ft
lb

@
1
0
to
1

6

7
to
12

@
0
7

to
1
0
5
1

to
7
2

@
1

6
to
2
2
12
to
16

@
2
0

to
3

5
14
to
25

@
2
0
to
3

5
14

to
25

2

5
to
3
5

18
to
25

@
2
5
to
3
5
18
to
25

i8J
2
0103
5

14
to
25

FU
model

only

7

@

o

p

e

5
Welch

ptug

6

Top
detecting
W
tch

7
Reve
rsc

lamp
swi
tch

8
TranSmission
case

assembly

9

Adapter
plate
5

TM282A
1
Front

cover

2

Front
cover
oil
seal

3
Front
cover

o
rfug

4
Front

cover

adjusting
shim

Fig
MT
66

l

Main
drive

bearing

Main
drive

gear

4th
5th

synchronizer

TM283A

MT
16
FSSW60L

Ll@

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

o

Fig
MT
70
R

movi7l
lB
ar

Ensi

Mounting
Croum
mber
Manual
Transmission

3
Remove

starting
motor

14
Remove
bolts

securing
transmis

sJon
to

engine
and

gusset

Then

support
the

engine
and

trans

mission
with

jacks
and
slide
transmis

sion
rearward

away
from

engine
and

remove
from
the
car

CAUTION

Take
cate
in

dismounting
transmission

not
to
strike

any
adjacenl
parts
and

main
drive

gear

INSTALLATION

Install
the
transmission
in
the

re

verse
order
of
removal

paying
atten

tion

to
the

following
points

MT18
t
Before

installing
Clean

mating

surfaces
of

engine
rear

plate
and
trans

mission
case

2
Before

installing
lightly
apply

grease
to

spline

parts
of

clutch
disc

and
main
drive

gear
And

also

apply

grease
to

moving
surfaces
of
control

lever
and

striking
rod

3
Remove
filler

plug
and

fill

trans

mission
with
recommended

gear
oil
to

the

level
of
the

plug
hole

Oil

capacity

t
2
liters

2

US

pt
2

Imp
ptl

4

Apply
sealant
to
thread
of
filler

plug
and
install
filler

plug
totransmis

sian

case

l
l
Tightening
torque

Filler

plug

2
5
to
4
0

kg
m

t8

to
29
ft
bl

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

liillim
drIYe

geer

1
Remove

snap
ring
and

spacer
with

snap
ring
pliers

2

Press
out

main
drive

bearing
with

Bearing
Puller
ST227
iOoOO
and
a

suitable

press

CAUTION

When

pressing
out

bearing
hold

gear

by
hand

so
as
not
to

drop
it
Manual
Transmis
ion

T

ooo

I

TM695
J

j
r

Fig
MT
92

Removing
Main
Drive

Bearing

1

Snap
ring

2

Spacer

3
Main
drive

bearing

4
Main

drive

gear

5

PiI
t

bearing

Synchronizers

I
2nd

3rd
4th

5th

speed

synchronizer

Remove

spread
springs
and
take

out

shifting
inserts

ID
Separate

coupling
sleeve

j
from

synchronizer

hub@

2
Ist
reverse

synchronizer

Separate
reverse
main

gear

00
from

synchronizer
hub

@
Take

out
shift

ing
inserts

ID
and

spread
springs

@

Pry
off

shifting
insert
retainer

j
Fig
MT
93
Main
Drive
Gear
TM

696

1

Coupling
sleeve

2

Spread
spring

3

Shifting
insert

4

Synchro
hub
800

@

r@

7
c
19

5
Reverse

gear

6

Spread
spring

7

Shifting
insert

retainer

TM240A

Fig
MT
94

Synchronizer
Assembly

MT
22
ADAPTER
PeATE

DISASSEMBLY

1

Remove
reverse
idler

shaft
with

thrust

washer
and

draw
out
reverse

idler
shaft

by
tapping
shaft

e
ld
of

drift
with
a
hammer

TM241A

Fig
MT

95

Removing
Reverse
Idler

Shaft

2

Remove
needle

bearing
apply
a

brass
drift
to

race
side
surface
and

withdraw
it

by
tapping

top
of
drift

with
a

hammer

REAR

EXTENSION

DISASSEMBLY

I
Remove

lock

pin
nut
and
lock

pin

from

striking
lever
Remove

striking

lever

TM242A

Fig
MT
96

Removing
Lock
Pin
Nut

2
Remove

oil
seal
with
dust
cover

from
rear
end

of
rear
extension

and

remove

striking
rod
and

striking
guide

Note

Do
not
remove
rear
extension

bushing
from
rear
extension

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

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