check oil DATSUN 210 1979 Repair Manual

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

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

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

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

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

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

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

4
Bolt
converter
to

drive
plate

Note

Align
chalk
mark

painted
a

cro5S
both

parts
during
disas

sembling
p

S
After
converter
is

installed
rotat

r
nkshait
veral
turns
and

check
to

be

sure
that
transmission

rotates
freely

without

binding

6

Pour
recommended
automatic

transmission
fluid

up
to
correct
level

through
oil

charge
pipe

7
Connect
manual
lever
to
shift

rod

Operation
should
be
carried
out

with
m
mual
and
selector
levers
in

N

8

Connect
inhibitor
switch
wires
Automatic
Transmission

NOte

a
Refer

to

page
AT40
for

Checking

and

Adjusting
Inhibitor
Switch

b

Inspect
end

edjust
switch
as

abo

whe
ever
it
has

to
be
removed
for

servi
e

9

Check
inhibitor

switch
for

op

eration

Starter
should
be

brought
into

op

eration

only
when
selector
lever
is
in

P
and
N

positions
it

should
not

be
started
when
lever
is
in

D
n

and
Ru

positions

Back

up

lamp
should
Iso

light

when
selector
lever
is

placed
in
R

position

10
Check
level
of
oil
in

transm

sion
For
detailed

procedure
see

page

AT39

AT

26
II
Move

selector
leve

through
all

positions
to
be

sure
that
transmission

operates
correctly

With
hand

brake

applied
rotate

engine
at

idling
Without

disturbing

the
above

seUlng
move
selector

lever

through
N

to
D
to
2

to
I

and
to

R
A

slight
shock
should
be

reU

by

handgripping
selector

each

time
transmission

is
shifted

Note
See

page
AT40
for

Checking

Engine
Idling
Revolution

12
Check

to
be
sure
that

line

pres

sure
is

correct
To
do
this
refer
to

page
AT
43
for
Line
Pressure
Test

13

Perform
stan
test
as
described
in

page
AT41