DATSUN 210 1979 Service Manual

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

TIGHTENING

TORQUE

Ball

pin

Striking
lever

lock
nut

S
llft
arm
bracket

Mainshaft

bearing
retainer

screw

Mainshaft

lock
nut

Rear
extension

installation
bolt

Stopper

pin
bolt

Front

cover
installation

bolt

Speedometer
sleeve
lock

ing
plate
bolt

Top
detecting
switch

Reverse

lamp
switch

Neutral
switch

Return

spring
plug

Gear
oil

filler

plug

Gear
oil
drain

plug

Transmission
to

engine

installation
bolt

Tr

msmissiori
to

engihe

rear

plate
installation
bolt

Transmission

to

gusset

installation
bolt

Starting
motor
to

trans

inissi
n
installation
bolt

Rear

mounting
insulator
to

transmission
installation
bolt

Crossmember

mounting

bolt

Rear

engine
mount

installation
bolt

Clutch

operating
cylinder

installation
bolt

Propeller
shaft
to

differential
carrier

Control
lever

pin

installation
nut

Exhaust

mounting
bracket

to
exhaust
front
tube

FU
model

only
Manual
Transmission

F4W60L

2
0
to
3
0

14
to
22

0
9

to
1
2

6
5
to
8
7

0
7
to

1
0
5
1
to
7
2

1
6
to
2
2
12
to
16

0
5
to
0

8
3
6
to
5
8

1
0

to
1

6
7

to
12

0
3
to
0
5
2
2
to

3
6

2
0
to
3
5
14
to
25

2

0
to

3
5
14
to
25

0
5
to

1
0
3
6
to
7
2

2
5
to

4
0
18
to

29

2
5

to
4

0

18
to

29

1

6
to
2
2

12Jo
16

1

6
to
2
2
12

t
16

4
6
to

6
1
33

to
44

3

0
to
4
0
22
to
29

0
9

to
1

2
6
5
to
8
7

3
2

to
4
3
23

to
31

0
9

to
1
2
6
5
to

8
7

3
1

to
4
1

22
to
30

2
4

to
3
3

17
to
24

1
3

to
1
7
9

to
12

3
2

to
4
3
23
to
31

MT33
Unit

kg
m
ft
lb

FS5W60L

2
0

to
3

0
14
to
22

0
9
to

1
2
6
5
to
8
7

8
2

to
10

0
59
to

72

0
8
to
1
3
5
8
to
9

4

10
0

to
11
0
72
to
80

1
6
to
2
2
12
to
16

1

0
to
1

6
7
to
12

0
3
to
0
5
2
2
to
3

6

2

0
to

3
5
14
to
25

2
0

to
3
5

14
to
25

2
0

to
3
5

14
to
25

0
5
to
1
0
3
6
to
7
2

2
5
to
4
0
18
to
29

i
5
to
4

0

18
to
29

1

6
to
2
2
12
to
16

1

6
to
2

2
12
to
16

4

6
to
6
1
33
to
44

3
0

to
4

0
22
to
29

0
9
to
1
2
6
5
to
8
7

3
2
to
4
3

23
to
31

0

9
to
1
2

6
5
to
8
7

3
1
to
4
1
22
to
30

2
4
to

3
3
17
to
24

1
3
to
1
7
9
to

12

3
2
to

4
3
23
to
31

Manual

Transmission

TROUBLE
DIAGNOSES
AND

CORRECTIONS

Condition

Difficult
to
intermesh

gears

Causes
for
difficult

gear

shifting
are
classi

fie

t
o

ro
lb
c
QncerlJing

coJltr
1

syste

and
transmission
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

transmjssion

Gear

slips
out
of

mesh

In

most
cases
this

troubk
occurs
when

check
baD
and
or

spring
is

waIn
or
weaken

ed

or
when
control

system
is

faulty
In

this

case
the
troubk

cannot
be
correct

by

replacing
gears
and
therefore

trouble
shoot

ing
must
be
carried
out

carefuDy
It
should

also
be

noted
that

gear

slips
out
of
mesh
due

to
vibration

generated

by
weakened
front

and
rear

enigne
mounts

Noise

When
noise
occurs
with

engine
idling
and

ceases
when

clutch
is

disengaged
or
when

noise
occurs
while

shifting
gears
it
is

an

indication
that
the
noise
is
from
trans

mission

Transmission

may
rallk

during
engine

idling

Check
air
fuel
mixture
and

ignition

timing

After
above

procedure
readjust
engine

idling
Probable

cause

Worn

gears
shaft
and

or

bearing

Insufficient

operating
stroke
due
to

worn

or
loose

sliding

part

Worn
or

damaged
syncluonizer

Worn

check
baD
and
or

weakened
or

broken

spring

Worn

fork
rod

baU

groove

Worn

or

damaged
bearing

Worn
or

damaged
gear

Insufficient
or

improper
lubricant

Oil

leaking
due
to

damaged
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
low

speed

Worn

spline

Worn

bushing

MT34
Corrective
action

Replace

Repair
ClI

replace

Replace

Replace

Replace

Replace

Replace

Add
oil
or

replace
with

designated
oil

Clean
or

replace

Replace

Replace

Replace

Replace
as
a
rear
ex

tension

assembly