lock DATSUN 210 1979 Repair Manual

4

Install

stopper
pin
bolt
into
rear

extension

and

tighten

l
J
Tightening
torque

Stopper
pin
bolt

0
5
to
0
8

kg
m

3
6
to
5
8
ft
lb

Be

sure
to

apply
sealant
before

installation

Stopper

pin
bolt
Sealant

TM814

Fig
MT
62

Installing
Stopper
Pin

Bolt

5

Apply
grease
to

plunger
and
in

stall
it
in
rear
extension

6

Install
reverse

check

spring
and

return

spring

Apply
locking
sealer
to
return

spring
plug
and
install
it
in

place

l
J
Tightening
torque

Return

spring

plug

0
5
to

1
0

kg
m

3
6

to
7
2
ft
lb

TM815
Plunger

Reverse
check

spring

Return

spring

Return

spring
plug

Fig
MT
63

Installing
Return

Spring

Front
cover

assembly

1

Select
front
cover

adjusting
shim

as
follows

I

Using
vernier

caliper
depth
gauge
Manual

Transmission

measure

depth
A

from
front
end
of

transmission

case
to
main
drive

bearing

outer
race
with
front

cover
adjusting

No
A

mm
in

I

2

3

4

5

6

7
shim
in

place

2

Select
a

shim
of
thickness
A

measured

Adjusting
shim

mm
in

6
05
to
6
09
0

2382
to
0
2398

6
10
to
6
14

0
2402
to
0
2417

6
15
to
6

19
0
2421
to

0
2437

6
20
to
6
24

0
2441
to

0
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
0
50
0

0197

0

55
0
0217

0

60
0
0236

0
65

0
0256

0

70
0
0276

0
75

0
0295

0

80
0
0315

TM816

Fig
MT
64
Meaauring
Front
Cover

Adjusting
Shim

CD

1

Transmission
case

2
Main
drive

gear

3

Adjusting
shim

4

Bearing

TM817

Fig
MT
65

Selecting
Front
Co
r

Adju
ting
Shim

2

Clean

mating
surfaces
of
front

cover
and
transmission

case

3

Install
front
cover
to

transmission

case
with

the

adjusting
shim
and
0

ring
in

place

l
J
Tightening
torque

Front

cover
installation
bolt

1
0
to
1
6

kg
m

7
to
12
ft
Ib

Outer

parts
assembly

Install

speedometer
pinion
assem

MT15
bly
and

install

securing
bolt
and

tighten

l
J

Tightening
torque

Speedometer
Ieeve

locking

plate

bolt

0
3
to
0
5

kg
m

2
2
to
3
6
ft
Ib

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

l
J
Tightening
torque

Revene

lamp
switch
and

top
detecting
switch

2
0
to
3
5

kg
m

14
to
25
ft
Ib

3

Apply
a

light
coat
of
multi

purpose
grease
to
withdrawal
lever

release
bearing
and

bearing
sleeve
in

stall
them

on
transmission
case

After

connecting
them
with

holder

spring
install
dust
cover
to
transmis

sian

case

4

Install
control
lever

temporarily

and

move
shift
control
lever

through

all

gears
to
make

sure
that

gears

operate
smoothly

5

Install
drain

plug
coated
with

sealant
in

place

l
J
Tightening
torque

Drain

plug

2
5
to
4
0

kg
m

18
to
29
ft
Ibl

6
Make

sure
that
main

drive
shaft

rotates

smoothly
in

Neutral

Main

drive

gear
rotating
torque

Les
than
1

8

kg
cm
1

6
in

Ibl

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

3

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

plungers

b
Each

gear
and
shaft
can
be
de

tached
from

ar1apter
plate
without

removing
each
fork
rod

CD

@

1

Check
ball

p1
8

2
Fork
rod
Reverse

Ist

3
Interlock

plu
er

4

Fork
rod
2nd

3rd

5
Fork
rod
4Ih
5th

6

Check
ball

TM793

Fig
MT
BO

Check
Ball

nd
Interlock

Plunger

Gear

a

embl

Note
It
is

necessary
to

measure
end

play
before

disassembling
main

shaft
and
after

reassembling
main

shaft
Refer
to

Inspection
for
Gears

and
Shafts

1
Remove

snap
ring
of
rnainshaft

end

bearing
Draw
out

b
aring
using

Bearing
Puller
KV32
10
1330

Remove

olher
sna

p
ring
of
rnainshaft
end
bear

ing

TM233A

Fig
MT
BI

Removing
Mainshaft

End

Bearing

2
With
1st
and
2nd

gears

doubly

engaged
release

staking
on

main
shaft

nut
and
loosen
it
Manual
Transmission

TM234A

Fig
MT
B2

Releaaing
Staking
on

Mainshaft
Nut

3
Remove

following
parts
from

mainshaft
in

rear
extension

side

I
Mainshaft
hut

2
Remove

shifting
insert
retainer

synchro
hub

with
reverse

gear
1st

gear

togeth
r
with

needle

bearing
and
bush

ing
and
idler

gear
together
with

needie

bearing
simultaneously

3

Thrust
washer

Fig
MT
83

Removing
Reverw

Main

Revere

Idler
and

1st

Gea

4
Remove

four
4

bearing
retai
er

attaching
screws
with

an

impact
driver

and

remove

bearing
retainer

Fig
MT
B4

Removing
Screw

MT

20
5
Remove

folloWIng
parts
from

counter

gear
rear
end

I
Retaining
ring

TM236A

Fig
ltiT

85

Removing
Retaining

Ring

2

1st
counter

gear
using
Gear
Pull

er
ST22480000

ST22480000

TM237A

Fig
MT
86

Remouing
l
t
Counter

Gear

6
Remove

snap
ring
from
mainshaft

rear

bearing

using
snap

ring
pliers

TM238A

Fig
MT
B7
Removing
Main

haft

Rear

Bearing
Snap
Ring

7
Drive

out
rnainshaft

gear
as

sembly
together
with

counter

gear

assembly
by
lightly
tapping
the
rear

end
with
a

sofl
hammer
while

holding

the
front
of
rnainshaft

gear
assembly

and
counter

gear
assembly

by
hand

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

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