DATSUN 210 1979 Service Manual

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

Manual

Transmission

3
Remove
thrust
washer
1
st

gear

needle

bearing
bushing
1st
2nd

synchronizer
assembly
baulk

rings

2nd

gear
and
needle

bearing
from

mains
haft

ST30031000

l
l

TM693

Fig
MT
22

RemotJing
Mainshaft

Bearing

fJ

I

@

00
1

Snap
ring

2

Baulk

ring

3

Shifting
imcrt

4

Coupling
sleeve

5

3rd

gear
mainshaft

6
Needle

bearing

7

Mainshaft

8

Spread
spring

9

Synchronil
er
hub

10

3rd
4th

synchroniz
er
assembly
II
2nd

gear
mainshat
t

12
ht
2nd

synchronizer

assembly

13
Mainshaft

bearing

14
1st

gear
mainshaft

15

Bushing
ht

speed
gear

16
Thrust
washer
mainshaft

11
Reverse

gear
mainshaCt

18
Thrust
washer

19

Snap
ring

TM799

Fig
MT
23

Mainshaft

A
mbly

Remove

sna

p
ring
and

spacer
with

snap

ring
pliers

2
Press
out

main
drive

bearing
with

Bearing
Puller
ST22730000
and
a

suitable

press
CAUTION

When

pressing
oul

bearing
hold

gear

by
hand
so
as
not
to

drop
it

1
Mein
drive

geer

ST22730000

TM

695

Fig
MT
24

Removing
Main
Drive

Bearing

MT7

Manual
Transmission

1
Snap
ring

2

Spacer

3

MaiJl4rive
be

ng

4

Main
drive
gear

5
Pilot

bearing

TM696

Fig
MT
25
Main
Drive
Gear

Counter

gear

1
Remove

snap
ring
from
the

rear

of
counter

gear
using
snap
ring
pliers
2

Press
out

counter
reverse

gear

using
Bearing
Puller
ST22730000
and

suitable
bar

CAUTION

When

pressing
out
coiinter
reverse

gear
hold

gear
by
hand
so
as
not
to

drop
it

TM697

Fig
MT

26
Removing
Snap
Ring

@

5

i

MT
8
H

J

TM698

Fig
MT
27

Removing
Counter

Reverse
Gear

3
Press
out

counter

gear
rear
bear

ing
using
Bearing
Puller
ST22730000

CAUTION

Be
careful
01
to

drop
counter

gear

9

iL

TM699

Fig
MT
28

Removing
Counter
Gear

Rear

Bering

1
Needle

bearing

2

Thrust
washer

3

Counter

gear

4

Bearing

5

Counter
reverse

gear

6

Snap
ring

TM800

Fig
MT
29
Counter

Gear

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

standard

gea
end

play

1st

gear

0
15
to
0
25

mm

0
0059
to
0
0098

inl

2nd

gear

0
30
to
0
40
mm

0
0118
to
0
0157
in

3rd

gear

0
15
to
0

30
mm

0
0059
to
0
0118

in

TMB05

Fig
MT

35

Me
uring
End

Phly

4

Check
for

stripped
or

damaged

speedometer
pinion
gear
If

necessary

replace

BAULK
RING

1

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
the

clearance
is
smaller
than

the

specified
value

replace
baulk

ring

Standard
baulk

ring
to

cone

clearance

0
80
to
1
65

mm

0
0315
to
0
0650

inl

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

TM806

Fig
MT

36
Baulh

Ring
10
Cone

Gap
Manual
Transmission

SHlFTING
INSERT

Replace
if
worn

excessively
worn

unevenly
deformed

or

damaged

OIL

SEAL

I

Discard
a

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

2

Check
the
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
COVER
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

Note
When

pressing
oil
seal
into

place
apply
coat
of

gear
oil
to

surface

adjoining
oil

seal

2
Lubricate
seal

lip
and
main

drive

shaft
with

gear
oil

when

installing

front

cover

Front

4

Main
drive

gear

2
Gear
oil

TM098A

Fig
MT
37
Fronl

Cover
Oil
Seal

MT10
TRANsMISSION
CASE

ASSEMBLY

1
Press
countershaft
needle

bearing

into
transmission
case
from
outside

Note

a
Needle

bearing
should
not
be
fe

used
after
removal

b
When

iDstalling
needle

bearing
be

sure
to

project
it
2
mm
0
08
in

fromtramission

so
front
surface

c
Make
sure

that
needle

bearing
turm

smoothly

d
After

installing
needle

bearing

apply
multi

purpose
grease
to
the

bearing
surface

Front

t

2
mm

0
08
in

TM

707

Fig
MT
38

Counterlhaft
Needk

Bearing

2
Install

withdrawal
lever

ball

pin

on

case
and

tighten
screw

iJ
Tightening
torque

Ball

pin

2
0

to
3
0

kg
m

14
to
22
ft
lb

REAR
EXTENSION

ASSEMBLY

I
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

gear
oil
to
rear

smace

adjoining
oil
seal

2

Coat
oil
seal

lip
and

bushing
with

gear
oil
for
initial

lubri
tion

Pack

cavity
between
seal

lips
with

recom

mended

multi

purpose
grease
when
in

sta1ling
See

Fig
MT

39

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

TM798

Fig
MT

45
In

talling
Snap
Ring

Main
drive

Bear

I
Press
main

drive

gear
bearing
onto

shaft
of
main
drive

gear
using
Trans

mission

Drift
ST23800000

Make
sure

that

snap
ring
groove
00

shaft

clears

bearing

L
i

ST23800000

TM714

Fig
MT
46

Imtalling
Main
Drive

Bearing

2
Place
main
drive

bearing

spacer

on

main
drive

bearing
and
secure
main

drive

bearing
with

a
new
thicker

soap

ring
that
will
eliminate
end

play

Note
Mlike
sure

soap
ring
fits
in

groove

1
Main

d
ive

gear

2

Snap
ring

3

Spacer

4
Main
drive

bearing

TM715

Fig
MT
47

Irutalling

Snap
Ring
Manual

Transmission

Available

nap
rings

No

Thickness
mm
in

No
Thickness

mm
in

2
20
to
2
25

1
34
to
1
40
0
0866
to
0
0886

0
0528

to
0

0551
2
25
to
2
30

2

0
0886
to
0
0906

140rol46

2

0

0551
to
0

0575

2
30
to
2
35

3

146
to

1
52
0

0906
to
0

0925

3

0

0575
to
0

0598

2
35
to
2
40

4

1
52
to
1
58
0
0925
to
0
0945

4

0
0598
to
0

0622

2
40
to

2
45

5

1
58

to
1
64
0
0945
to
0
0965

5

0
0622

to
0
0646

2
45
to
2
50

6

0
0965
to
0
0984

1
64
to
1

70

6

0

0646
to

0
0669

2
50
to
2
55

7

1
70
to
I
76
0

0984
to
0

1004

7

0
0669

to
0

0693

2

55
to
2

60

8

0
1004100
1024

Counter

Beer
Note
Be
sure
to

measure
at
two
or

more

positions
on
the

end
urface

of
outer
race

1

Press
counter

gear
rear

bearing

onto

counter

gear
usingCountershaft

Bearing
Press
Stand
KV32
100200

KV32100100

r
I

J

I

1

T

II

I
TM117

Fig
MT
49

Mecuuring
Counter
Gear

End

Phly

TM716

Fig
MT
48

Installing
Counter

Gear

Rear

Bearing
3
Remove
counter

gear
assembly

from
the
transmission
case

4

Press
counter

reverse

gear
onto

counter

gear
assembly
using
Counter

shaft

Bearing
Press
Stand

KV32
100200

2

Install
a
counter

gear
thrust
wash

er
and

unter

gear
with
counter

rear

bearing
into
transmission

case
and

select
counter

gear
thrust
washer
of

proper
thickness

using
Counter
Gear

Height
Gauge
KV32
100
100

Select
washer

from
those
shown
in

the

following
table
so
that
end

play
of

counter

gear
is

specified
value
KV32100200

Standard
end

play

0

10
to
0
20
mm

0
0039
to
0
0079
in
TM719

Fig
MT
50

Installing
Counter

Revene

Gear

MT12

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