check oil DATSUN 210 1979 Workshop Manual

INSPECTION

I

Disconnect

high
tension

cables

from

spark
plugs
by
pulling
on

boot

not
on
cable
itself

2

Remove

spark

plugs

3

Check
electrodes
and
inner

and

outer

porcelains
of

plugs
noting
the

type
of

deposits
and
the

degree
of

electrode
erosion

Refer
to

Fig
EE

76

Normal
Brown

to

grayish
Ian
de

posits
and

slighl
electrode
wear

indicate
correct

spark

plug
heat

range

Carbon
fouled

Dry
fluffy
carbon
de

posits
on
the
insulator
and
elec

trode
are

mostly
caused

by
slow

speed
driving
in

city
weak

ignition

too
rich
fuel
mixture

dirty
air

cleaner
etc

H
is
advisable
to

replace
with

plugs

having
hotter
heat

range

Oil
fouled

Wet
black

deposits
show

excessive

oil
entrance
into

comb
us

tion
chamber

through
worn

rings

and

pistons
or
excessive

clearance

between
valve

guides
and
stems
If

the
same
condition
remains
after

repair
use
a
hotter

plug

Overheating
White
or

light
gray
insu

lator
with
black
or

gray
brown

spots
and
bluish
burnt
electrodes

indicate

engine
overheating
More

over
the

appearance
results
from

incorrect

ignition
timing
loose

spark
plugs
low
fuel

pump
pres

sure

wrong
selection
of
fuel

a

hotter

range
plug
etc

H
is
advisable
to

replace
with

plugs

having
colder
heat

range

4
After

cleaning
dress
electrodes

with
a
smaU
fme
file
to
flatten
the

surfaces
of
both

center
and
side
elec

trodes
in

parallel
Set

spark
plug

gap
to

specification

5

Install

spark

plugs
and

torque

each

plug

6
Connect

spark
plug
wires

CLEANING

AND

REGAP

Clean

spark
plugs
in
a
sand
blast
Engine
Electrical

System

SPARK

PLUG

Conventional

type

Normal

Overheating

Multi

gap
type

Nonnal

Overheating

type
cleaner
Avoid
excessive

blasting

Clean
and
remove
carbon
or
oxide

deposits
but
do
not
wear

away
porce

lain
If

deposits
are
too
stubborn

discard

plugs

After

cleaning
spark

plugs
renew

firing
surface
of
electrodes
with
file

mentioned

above
Then
check

spark

plug
gap
with
wire

feeler

gauge
All

spark
plugs
new
or
used

should
have

the

gap
checked
and
reset

by
bending

ground
electrode

EEOSO

Fig
EE
77
Setting
Spark
Plug
Gap

Except
FU
model

EE
29
Carbon

fouled

EE079

Worn

Carbon

fouled

Worn

EE601

Fig
EE

76

Spark

Plug

EE586

Fig
EE
78

Setting
Spark
Plug

Gap
FU
models

Engine
Electrical

System

IV
IGNITION
CIRCUIT

When

engine
does
not

start

If

there
is
no

problem
in
fuel

system

ignition
system
should
be

checked
This
can
be

easily
done

by

detaching
a

high
tension
cable
from

distributor

starting
engine
and
ob

serving
oondition
of

spark
that

occurs
between

high
tension
cable
and

engine

block
After

checking
this

repair
as

necessary
tery
and
anti
dieseliilg
wlenoid

valve
connector
to
cuI
off

supply

of
fuel
10

engine
Then
observe
the

condition
of

sparks
while
starter

motor
is
in

operation

Note
Turn

ignilion
switch
off
and

disconnect
ground
cable
from
bat

Condition
Location

Probable
cause
Corrective
action

No

spark
at
all
Distributor

Breakage
of
lead
wire
on
low
tension

side

Repair

Poor
insulation
of

cap
and
rotor
head

Replace

Open
pick
up
coil

Replace

Air

gap
wider
than

specification
Adjust

Ignition
coil
Wire

breakage
or
short
circuit

of
coil

Replace
with
new
one

High
tension
cable
Wire

coming
off

Repair

Faulty
insulation

Replace

IC

ignition
unit

Faulty
IC

ignition
unit

Replace

Breakage
of
circuit

Replace

Detached
connection

Repair

Spark
length
Spark
plugs
Spark
plug

gap
too

wide
Correct
or

replace

More
than
6

mm

Too

much
carbon
Clean
or

replace

0
24
in

Broken
neck

of
insulator
Replace

Expiration
of

plug
life

Replace

Distributor
Air

gap
too
wide

Correct

IC

ignition
unit

Faulty
IC

ignition
unit

Replace

Breakage
of
circuit

Replace

Detached
connection

Repair

EE
37

INSPEctiON

Check
clutch

pedal
parts
for
the

following
items

correcting
neces

sary

I
Bent

pedal

2

Weakened
return

spring

3
Worn

or
deformed
clevis

pin
and

fulcrum

bwhings

4

Cracks
at
welded

part

INSTAl1
ATION

To
install
clutch

pedal
reverse
the

order
of
removal
Observe
the
follow

ing

I

Apply

coating
of
recommended

multi

purpose
grease
to

sliding
por

tions
and
return

spring

Lt
of

I

ii

CL352

Fig
CL
5

Lubricating
Point

2
Fit
return

spring
in
hole
in

pedal

bracket
and

securely
fit
E

ring
in
slit

of
fulcrum

pin

3
Insert

clevis

pin
through
clutch

pedal
from
left

to

right
side

4

After

installing
clutch

pedal

check
the

clutch

pedal
height

AdjUst

if

necessary
Refer
to

Adjwtment

CLUTCH

MASTER

CYLINDER

REMOVAL

I
Remove

snap
pin
from

clevis

pin

2
Pull

out
clevis

pin

3
Disconnect
clutch
tube
from
mas

ter

cylinder

4

Remove
master

cylinder
Clutch

CAUTION

When

disconnecting
clutch
tube
use

suitable
flare
nut
wrench

Never
use
an

open
end
wrench
or

adjus1able
wrench

DISASSEMBLY
Note
When

disconnecting
dutch

tube
be
sure
to
receive

draioillll

clutch
fluid
into

a
container
Use
of

rags
is
also

suggested
to

keep

adja

cent

parts
and
area

clean

@

@

1
Reservoir
cap
6

Return

prina
11

Primary
cup
16

StOppel
rins

2
Reservoir
7

Sprina
seat
12
Piston
17
Dust
cover

3
Rescrvou
band

8
Valve

sprina
3

Secondary
cup
18
Lock
nut

4

Cylinder
body
9

Supply
valve
rod

14
Push
rod

5

Supply
yalYe
stopper
10

Supply
valve

15

Stopper

CL345

Fig
CL
6
Clutch
Mcuter

Cylind
r

I
Remove
dwt
cover
and
take
off

stopper
ring
from

body

2
Then
the

push
rod
and

stopper

can
be
taken
out

3

Loosen

supply
valve

stopper
and

take
it

out

4
The

piston
spring
seat
and
reo

turn

spring
can
be
taken
out

Note
Discard

piston
cup
and
dust

cover

CAUTION

Never
detach
reservoir
If

it
is
removed

for

any
reason

discard
it
and
instill

new
one

CL
4
INSPECTION

CAUTION

To
clean
or
wash
all

parts
of
masler

cylinder
clean
brake
fluid
must
be

used
Never
use
mineral
oils
such

as

gasoline
and
kerosene
It
will
ruin
tha

rubber

parts
of
tha

hydraulic
syslBm

I
Check

cylinder
bore
and

piston

for
score
or
rust
and
if
found

replace

2
Check

cylinder
bore

and

piston

for
wear
If
the

clearance
between

cylinder
bore
and

piston
exceeds
the

specified
value

replace
piston
assem

bly
or
master

cylinder
assembly

3

Check
the
condition
of

piston

cup
and
dust
cover

Always

replace

them
after

disassembly

4
Check

all
recesses

openings
and

internal

passages
to

ensure
that

they

are

clean
and
free
from

foreign
matter

Cearance
between

cylinder

bore
and

piston

Leu
than
0
15

mm

0
0059
in

ASSEMBLY

Assemble
clutch
master

cylinder
in

the
reverse
order
of

disassembly
Ob

serve
the
following

I

Dip
piston
cup
in
brake

fluid

before

installing
Make
sure
that

it
is

correctly
faced
in

position

1
Return

spring

2

Supply
valve
rod

3
Piston

4

Secondary

cup
5

Spring
seat

6
Valve

spring

7

Primary
cup

8
Push
rod

CL283

Fig
CL
7
Piston

Asaembly

2

Apply
a

coating
of
brake
fluid
to

cylinder
and

piston
when

assembling

if
Tightening
torque

Reservoir
band

0
25
to
0
4

kg
m

11
8
to
2
9
ft
lb

Supply
valve

stopper

0
15
to
0
3

kg
m

1
1
to
2
2
ft
Ib

INSTALLATION

Install
clutch
master

cylinder
in
the

reverse
order
of
removal
Observe
the

following

I

Bleed
air

out
of

hydraulic
system

Refer
to

Bleeding
Clutch

System
for

bleeding

2

Adjust
pedal
height
and

pedal

free

travel
Refer
to

Clutch
Pedal

Height
and
Clutch
Pedal
Free

Travel

for

adjustment
Clutch

if
Tightening
torque

Master

cylinder
to
dash

panel

securing
nut

0
8
to
1
2

kg
m

5
8
to
8
7
ft

Ib

Clutch
tube
flare
nut

1
5
to
1
8

kg
m

11

to
13
ft
lb

CAUTION

When

connecting
clutch
tube

use

F

lere
Nut

Torque
Wrench

GG94310000

Note
When

tightening
flare
nut
hold

pipe
by
hand
to

r
it

from

twilling

OPERATING

CYLINDER

REMOVAL

I
Disconnect
clutch
tube
from

clutch
hose
at
the

bracket
on

side

member

CAUTION

When

disconnecting
clutch
tube

use

suitable
flare
nut
wrench

Never
use
an

open
end
wrench
or

adjustable
wrench

2
Remove
lock

spring
then
dis

engage
hose
from
bracket

3
Remove
clutch
hose
from

oper

ating
cylinder

4
Remove

operating
cylinder

DISASSEMBLY

Remove

push
rod
and
dust

cover

2

Remove

piston
and

piston
cup
as

an

assembly

Note

Discard

piston
cup
and
dust

cover

3
Remove
bleeder
screw

Cl
5
1

4

v

I
Bleeder
screw

2

Cylinder
body

3
Piston

cup

4
Piston
5
Dust
cover

6
Push
rod

7
Lock
nut

8

Push
nut

CL203

Fig
CL
B

Operating
Cylinder

INSPECTION

Visually

inspect
all
disassembled

parts
and

replace

parts
which
are
worn

or

damaged
too

badly

beyond
specifi

cations

CAUTION

To
clean
or
WISh
all

parts
of

operating

cylinder
dean
brake
fluid
must
be

Used

Never

use
mineral
oils
such
as

gasoline

and
kerosene
It
will
ruin
the
rubber

parts
of
the

hydraulic
system

I

Check

cylinder
bore
and

piston

for
score
or
rust
and
if
found

replace

2
Check

cylinder
bore
and

piston

for
wear
If
clearance

between

cylinder

bore
and

piston
i5
more

than
the

specified
value

replace
piston
or

oper

ating
cylinder
assembly

3

Check
condition
of

piston

cup

and
dust
cover

Always

replace
them

after

disassembly

4
Check
bleeder
hole
to

be
sure

that
it
is

clean

Clearance
between

cyliniler
bore

and

piston

less
than
0
15
mm
0
0059
in

ASSEMBLY

Assemble

operating
cylinder
in

the

reverse
order
of

disassembly
Observe

the

following

CLUTCH
DISC
AND

COVER

REMOVAL

1
Remove
transmission
from
en

gine
Refer
to

Removal
Section
MT

2

Insert
Clutch

Aligning
Bar

ST20610000
4

speed
tranSmission
or

KV30100IOO
5

speed
transmission

into

clutch
disc
hub

until
it

will
no

longer
gd
It
is

important
to

support

weight
of

clutch
disc
in
the

steps
that

follow

ST20610000

4

peed

transmission

KV30100100

S

peed

transmission

S

cL194

Fig
CL
W

Supporting
Clutch

Assembly
Clutch

CLUTCH
UNIT

n

j

3

Loosen
bolts

attaching
clutch

cover
to

flywheel
one
turn

each
at
a

time
until

spring

pressure
is
released

Be
sure
to
turn
them

out
in

a
crisscross

fashion

4
Remove
clutch
disc
and
cover

assembly

INSPECTION

Wash
all
disassembled

parts
except

disc

assembly
in
suiiable

cleaning
sol

vent
to
remove
dirt
and

grease
before

making
inspection
and

adjustment

FI
1
and

pressure
plate

Check
friction
surface
of

flywheel

and

pressure
plate
for

scoring
or

roughness
Slight
roughness
may
be

smoothed

by
using
fine

emery
cloth
If

surface
is

deeply
scored
or

grooved

the

part
should
be

replaced

Clutch
disc
sembi

Inspect
clutch
disc
for
worn
or

oily

facings
loose
rivets

and
broken
or

loose

torsional

springs

CL
7
1

Clutch
disc

assembly

2

Clutch
cover

assembly

3
ReleaJe

bearing

4

Bearing
sleeve

S

Withdrawal
lever

6

Withdrawa11ever
ball

pin

7
Return

spring

CL370

Fig
CL
9
Clutch
Unit

I
If

facings
are

oily
disc
should
be

replaced
In

this
case

inspect
transmis

sion

front
cover
oil
seal

pilot
bushing

engine
rear
oil
seals
and
other

points

for
oil

leakage

2
The

disc
should
also
be

replaced

when

facings
are
worn

locally
or
worn

down
io
ihe

specified
limit

Wear
limit
of

facing
A

Les
than
0
3
mm
0
012
in

9111

I

A

M

m

C
L336

Fig
CL
ll

M
asur

ng
Clutch

Facing

Wear

3

Check
disc

plate
for
runout
when

ever
the
old
disc

or
a

new
one
is

installed

4
If
runout
exceeds
the

specified

value
at
outer
circumference
of
fac

g

replace
or

repair
disc

Runout
limit

ltotal
indicator

reading

Less
than
0
5

mm
0
020
in

R
from
hub

center

85

mm
3
35
in

CAUTION

When

repairing
disc

plate
never
hold
it

forcibly
with

pUers
or
bend
it
exces

sively
otherwise

facing
will
be
dam

aged

CL112

Fig
CL

12

Repairing
DiM
Runout

5
Check
fit
of
disc
hub
on
transmis

sion
main
drive

gear

splines
for
smooth

sliding
If

splines
are
worn
clutch
disc

r
main

drive

gear
should
be

replaced

that

is
backlash
exceeds
the

specified

value
at
outer

edge
of

clutch
disc

Backlash

Less
than
0
4
mm

0
016

in

Clutch
cover
a

embly

I

Check
the
end
surface
of
dia

phragm
spring
for
wear
If
excessive

wear
is
found

replace
cluich
cover

assembly

2

Measure

height
of

diaphragm

springs
as
outlined
below

I

Place
Distance
Piece

ST20050100
on

Base
Plate

ST20050010

and
then

tighten
clutch

cover

assembly
on
base

plate
by

using

Set
Bolts
ST20050051
Clutch

ST200S0051

snOO50100

snoo
500
10

re1

F
A

J

eLlSl

Fig
CL
J3

Measuring
H

ight
of

Diaphragm
Spring

2

Measure

height
A
at

several

points
with

a
vernier

caliper
depth

gauge
If

height
A

of

spring
end
is

beyond
the

specified
value

adjust

spring
height
with

Diaphragm
Ad

justing
Wrench
ST20050240

as

sh
1wn

in

Fig
CL
I4

Diaphragm
spring

height
A

29

0
to
31
0

mm

1
142

to
1
220
in

If

necessary
replace
clutch

cover

assembly
Also
unevenness

of
dia

phragm

spring
toe

height
should
be

within
the

specified
limit

Unevenness
of

diaphragm
spring

toe

height

Less

than
0

5
mm
0
020
in

CL152

Fig
CL
I4

Adjusting
Spring

Height

3

Inspect
thrust

rings
for
wear
or

damage
As

these

parts
are

invisible

from
outside

shake
cover

assembly

up

and
down

to

listen
for

chattering

noise

or

lightly
hammer
on
rivets
for
a

slightly
cracked
noise

Any
of
these

noi

s
indicates

need
of

replacement
as

a

complete
assembly

INSTALlATION

I

Apply
a

light
coat
of

grease
in

cluding

molybdenum
disulphide
to

transmission
main
drive

gear
splines

Cl
8
Slide
clutch
disc
on
main
drive

gear

several
times
Remove

clutch
disc
and

wipe
off
excess
lubricant

pushed
off

by
disc
hub

Note
Take

special
care
to

prevent

grease
or
oil
rrom

getting
on
clutch

racing

2

Reinstall
clutch
disc
and

clutch

cover

assembly
Support
clutch
disc

and

cover
assemblies
with
Clutch

Aligning
Bar
ST20610000

4
speed

transmission
or
KV30100IOO
5

speed
transmission

Note
Be
sure

to

keep
disc

racings

flywheel
and

pressure
plate
clean

and

dry

KV30100100

5
peed

transmission

ST20610000

4

speed

trammisaion

CL32

Fig
CL
I5
Installing
Clutch

Diac
and

Cover

Aaembly

3

Install
bolts
to

tighten
clutch

cover

assembly
to

flywheel

squarely

Each

bolt
should
be

tightened
one

turn
at

a
time
in

a
crisscross
fashion

ifJ

Tightening
torque

Clutch
cover
bolt

1
6
to
2
1

kg
m

12
to
15
ft

Ibl

N

te
Dowels

are
used
to
locate

clutch

cover
on

flywheel

properly

4

Remove

clutch

aligning
bar

5

Reinstall
transmission

Refer
to

Installation

Section
MI

RELEASE
BEARING

REMOVAL

1

Remove
transmission
from
en

gine
Refer

to
Removal
Section
MI

2
Disconnect

return

spring
from

bearing
sleeve

3

Remove

release

bearing
and
sleeve

as
an

assembly
from
transmission

case

front
cover

4
Take
clutch
release

bearing
out

from

bearing
sleeve

using
a
universal

puller
and
a

suitable
adapter

Fig
CL
16
Di8auembling
Release

Bearing

INSPECTION

Check
for
abnormal

wear
on
COD

tact
surface
of
withdrawal
lever
ball

pin
and

bearing
sleeve

Hold

bearing
inner

race
and
rotate

outer
race
while

applying
pressure
to

it
If
the

bearing
rotation

is

rough
or

noisy
replace
bearing

INSTALLATION

1

Assemble
release

bearing
on

sleeve

using
a

press

Note
Do
not

depress
outer
race

i

L

Cl117

Fig
CL

17
nstalling
Release

Bearing

2

Before
or

during

assembly
lubri

cate
the

following
points
with
a

light

coat
of
multi

purpose
grease

eve

nner
1groove
of
release

bearing

Pack
this
reces5

4

CL093

Fig
CL

IB

Lubricating
Rece
of

Bearing
Sleeve
Clutch

2

Contact
surfaces
of
withdrawal

lever
lever

ball

pin
and

bearing
sleeve

3

Bearing
sleeve

sliding
surface
of

transmission

case
front
cover

C1195

Fig
CL
19

Lubricating
Points

of

Withdrawal
Lever

Bearing
Sleeve
and

Front
Cover

4
Transmission
main
drive

gear

splines
Use
grease
including
molybde

num

disulphide

Note
A
small
amounl
of

grease

should
be
coated
to
the
above

points
If
too
much
lubricant
is

applied
it
will
n
out
on
the

friction

plates
when
hot

resulting

in

damaged
clutch
disc
facings

3
After

lubricating
install
with

drawallever
release
bearing
and

sleeve

assembly
in

position
Connect
them

with
return

spring

1
Return

spring

2
Release

bearing

3
Withdrawal1cver

CL196

Fig
CL
20
Installing
Release

Mechanism

4

Reinstall
transmission
Refer

to

Installation
Section
MT

PILOT
BUSHING

REMOVAL

1

Remove
transmission
from

en

gine
Refer
to

Removal
Section
MT

2

Remove
clutch
disc
and
cover

assembly
Refer

to
Clutch

Disc
and

Cover
for

removal

CL
9
3
Remove

pilot
bushing
in

shaft

by
Pilot

Bushing

KVI0102800

KV10t02800
crank

Puller

Fig
CL
21
Removing
Pilot

Bushing

INSPECTION

Check

pilot
bushing
for
fit
in

bore

of

crankshaft

Check
inner
surface
of

pilot
bush

ing
for
wear

roughness
or
bell

mouthed
condition
If

pilot
bushing
is

worn
or

damaged
replace
When
bush

ing
is

damaged
be
sure

to
check

transmission
main
drive

gear
at
the

same
time

INSTALLATION

1

Before

installing
a
new

bushing

thoroughly
clean

bushing
hole

2
Install

pilot
bushing
so
its

height

A
above

flange
end
is

the

specified

value

Bushing
need
not

be
oiled

Pilot

bushing
inserting

distance
A

2
8

mm
0
110
in

Note
When

inserting
pilot
bushing

be
careful
not
to

damage

edge
of

pilot
bushing

A

EM719

Fig
CL
22

Installing
Pilot

Bushing

3

Install
clutch
disc
and
clutch

cover

assembly
Refer
to
Clutch
Disc

and

Cover
for
installation

4

Install

transmission
Refer
to

In

stallation

Section
MT

Condition

Clutch

slips

Clutch

drags
Clutch

TROUBLE

DIAGNOSES
AND

CORRECTIONS

Probable

cause
and

testing
Corrective
action

Slipping
of
clutch

may
be
noticeable

when

any
of
the

following
symptoms
is

encountered

during
operation

I
Car
will
not

respond
to

erigine
speed
during
acceleration

2
Insufficient

car

speed

3
Lack
of

power

during
uphill

driving

Some
of
the

above
conditions

may
also
be
attributable
to

engine
problem
First
determine

whether

engine
or
clutch
is

causing
the

problem

If

slipping
clutch
is

left
unheeded
wear

and
or

overheating
will
occur
on
clutch

facing
to
such

an
extent
that
it
is

no

longer
serviceable

TO

TEST
FOR
SLIPPING
CLurCH

proceed
as
follows

During
upgrade
havelling
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
t
the
same
time

rev

up
engine
If
clutch

is

slipping
car
willnot

readily
respond
to

depression
of
accelerator

pedal

Clutch

facing
warn

excessively

Oil
or

grease
on
clutch

facing

Warped
clutch

cover
or

pressure
plate
Replace

Replace

Repair
or

replace

Dragging
clu

tch
is

particularly
noticeable

when

shifting

gears
especially
into

low

gear

TO
TEST
FOR

DRAGGING
CLurCH

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

gears
from
Neutral
into

Reverse

2

Stop
engine
and
shift

gears
Conduct
this
test
at
each

gear
position

3
In

step
2

gears
are
shifted

smoothly

except
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
ide

depress
pedal
to
check
for
free

travel
of

pedal

a
If

pedal
can
be

depressed
further
check
clutch
for

condition

b
If

pedal
cannot
be

depressed
further

proceed
to

step
5

below

5
Check

clutch
control

pedal
height
pedal
free

play
free

travel
withdrawal
lever

play
etc

If

any
abnormal

condition
does
not
exist
and
if

pedal
cannot
be

depressed
further
check

clutch
for

condition

Clutch
disc

runout
or

warped

Wear
or
rust

on
hub

splines
in

clutch

disc

Diaphragm
spring
toe

height
out
of

adjustment
or
toe

tip
worn

Worn

or

improperly
installed

parts
Replace

Clean
and
lubricate

with

grease
or

replace

Adjust
or
replace

Repair
or

replace

CL12

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