oil DATSUN PICK-UP 1977 Service Manual

5

Check
for

stripped
or
damaged

speedometer
pinion
gear
If

necessary

replace

BAULK
RI
NG

I

Replace
baulk

ring
if
found
to
be

deformed

cracked
or
otherwise
dam

aged
excessively

2
Place
baulk

ring
in

position
on

gear
cone

While

holding
baulk

ring
against

gear
as
far
as
it

will

go
measure

gap

between
baulk

ring
and
outer

gear

If

gap
is
small
discard
baulk

ring

See

Figure
MT
30

5
lr
1
25

to
1

60
rom

0
0492
to
0

0630
in

Baulk

ring

TM375

Fig
MT
30
Baulk

ring
to

cone

gap

OIL

SEAL

Discard

O

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

ASSEMBLY

To
assemble

reverse
the

order
of

disassembly
Observe

ihe

following

instructions

FRON1
COVER
ASSEMBLY

I

Wipe
clean
seal
seat
in
front

cover
then

press
fit
oil
seal
in

place

Coat
oil
seal
with

gear
oil

to

provide
initial
lubrication

Front

J

f

C
J

TM354

Fig
MT
31
Front
cov

oil
eol
Manual
Transmission

2

Apply
sealant
to
withdrawal

lever

ball

pin
screw
Install
withdrawal
lever

ball

pin
to
front
cover
and

tighten

screw
to
1
6
to
2
1

kg
m

12
to
15

ft
lb

torque

REAR

EXTENSION

ASSEMBLY

1

Wipe
clean

seal
seat
in

rear
exten

sion

housing

press
fit
oil
seal
in

place

Coat
oil
seal
and

bushing
with

gear

oil
for
initial
lubrication

Front

h

TM355

Fig
MT
32
Rear
extemion
oil
seal

2

Apply
grease
to
O

ring
and

plung

er

grooves
in

striking
rod

Insert

striking
rod
with

striking
rod

guide
through
rear
extension

3
Install

striking
lever
on
front
end

of

striking
rod
Install
lock

pin
and

torque
screw
to
0
9
to

1
2

kg
m

7
to

9
ft
Ib

ADAPTER
PLATE
ASSEMBLY

1
Place
dowel

pin
mainshaft
bear

ing
and
oil

gutter
on

adapter
plate
and

tap
with
a
soft
hammer
until

they
are

properly
positioned
in

place

Use
a
new
dowel

pin

Bend
oil

gutter
on
front
side
and

expand
on
rear
side
See

Figure

MT33

J

7

r

M356
Upper

Front

Fig
MT
33
Oil

gutter

MT
9
2
Insert
reverse
idler
shaft
in

adapt

er

plate

Make
sure
that
the

cut
out

portion

of
reverse

idler
shaft
is
lined

up
with

inner
face
of

adapter
plate

3
Install

bearing
retainer
in

adapter

plate

Align
bearing
retainer
with
reverse

idler
shaft
at
the
cut
out

portion
of

this
shaft

torque
screws
to
1

9
to

2
5

kg
m
14
to

18
ft
lb

and
stake
each

screw
at
two

poin
Is

with

a
punch
See

Figure
MT
34

TM400

Fig
MT
34
Staking
SCN
W

4
Install
countershaft
rear

bearing

in

adapter
plate
by
lightly
tapping

around
it
with

a
soft
hammer

GEAR
ASSEMBLY

Clean
all

parts
in

solvent
and

dry

with

compressed
air

Synchronizer

888embly

Assemble

synchronizer
assembly

Position

shifting
insert

springs
and

shifting
inserts
in
three
3
slots
in

synchronizer
hub

put
coupling
sleeve

on

synchronizer
hub

r
Front

3rd
4th
15t
2nd

TM351

Fig
MT

35

Installing
synchronizer

hub

Malnshaft

assembly

I

Assemble
2nd

gear
needle
bear

ing
2nd

gear
baulk

ring
1st
2nd

speed
synchronizer
assembly
st

gear

baulk

ring
I
st

gear
bush
needle
bear

ing
I

st

gear
steel
ball
and
thrust

washer
on
mainshaft
Before

installing

a

steel
ball

apply
grease
to

it
See

Figure
MT
36

TM358

Fig
MT

36

l
talling
thrust
washer

2

Set
Transmission
Press
Stand

KV311
00400
and

place
adapter
plate

assembly
on
it

See

Figure
MT
37

For

counterman
and
reverse
idler
shaft

For
main5haft
and
reverse

tdler
haft

V31100400

J
UJ

V
TM438

Holes
for
reverse
Idler

shaft

Fig
MT

37
Tromm
inion
PreS3
S
tond

3
Install
mainshaft

assembly
to

adapter
plate
assembly
Be
sure
to

place
bearing
squarely
against
shaft

and

press
it
into

place
on
shaft

gradu

ally
See

Figure
MT

38

KV31100400

TM439

Fig
MT
38

Installing

mai
haft

em

bly
Manual
Transmission

Countershaft

assembly

I
Place
new
woodruff

keys
in

grooves
in

countershaft
and

tap
them

lightly
until

they
are
seated

securely

Use
a

soft
hammer
to

avoid
dam

aging
keys

2

Place

adapter
plate
assembly
and

mainshaft

assembly
so
that

counter

shaft
rear

bearing
rests
on

Transmis

sion

Press
Stand
KV31100400

prop

erly

3
Install
countershaft

into

adapter

plate
by

pressing
it
See

Figure
MT
39

TM440

Fig
MT
39

l
talling
countersha
t

4
Position

3rd

gear
needle

bearing

fnaiiiSh
ifOfd

gear
baulk

ring
and
3rd

4th

synchronizer
assembly
on
the

front
of
mainshaft

S
Ins
iall
thrust
washer

on
mainshaft

and
e
ure
it
with

snap
ring
of

proper

thickness
that
will
fit
the

groove
in

mainshaft
See

Figure
MT
40

Available

snap
ring

No
Thickness
mm
in

I

2

3
1
4

0
055

1
5
0
059

1
6
0
063

TM441

Fig
MT
40

l
talling
snap
ring

MT
l0
Main
drive

gear
assembly

1

Using
Transmission
Adapter

ST23800000

press
main
drive

bearing

onto
the
shaft
of
main

drive

gear

Make
sure
that

snap
ring
groove
on

shaft
clears

bearing

2
Place
main
drive

bearing
spacer

on
main
drive

bearing
and

secure
main

drive

bearing
with
thicker
snap

ring

that
will
eliminate
end

play
See

Figure
MT
4l

Available

snap
ring

No
Thickness
mm
in

2

3

4

5

6
1
80
0
0709

1
87
0
0736

1

94
0
0764

2
01
0
0791

2
08
0
0819

2
15

0
0846

CD

I

TM364

Fig
MT
41
Installing
snap
ring

3

Position
baulk

ring
on
cone
sur

face
of
main

drive

gear

Apply
gear
oil

to

mainshaft

pilot

bearing
and
install
it

on
mainshaft

Assemble
main
drive

gear
assembly

on
the
front

end
of
mainshafl

4

Press
counter
drive

gear
onto

countershaft

with
Counter
Gear
Drift

ST23860000

by

meshing
gears
and

secure
counter
drive

gear
with
thicker

snap
ring
See

Figures
MT
42
and

MT
43

Note

Be

sure
to
drive
in
counter

drive

gear
and
main
drive

gear

simultaneously

Note
Prior
to

assembling
reverse
fork

rod
instaU
two
2
interlock
balls

into

adapter

piate
as
shown
in

Figure
MT
I6

6
Install
check
ball
and
check

ball

spring

Apply
sealant
to
check

ball

plug

and
install
it
in

place

Align
notch
in

reverse
fork
rod
with

check
ball

See

Figure
MT
52

TM369

Fig
MT
52

Installing
reverse

fork

rod

7

Torque
each
check

ball

plug
to

1

9
to

2
5

kg
m

14
to
18
ft
Ib

Note
BaD

plug
for
ht
2nd
fork
rod

is

longer
than
those

for
rev
shift

fork

rod
and

3rd
4th
fork
rod

8

Apply
gear
oil
to
all

sliding
sur

faces

and
check
to
see
that
shift

rods

operate
correctly
and

gears
are

engaged

smoothly

TRANSMISSION

ASSEMBLY

Tran
mis
lon
ea

mbly

1
Clean

mating
surfaces
of

adapter

plate
and
transmission

case

Apply
sealant

to

mating
surfaces

of

adapter
plate
and

transmission
case

2

Slide
transmission

case
onto

adapter
plate
by

lightly
tapping
with

a

soft
hammer
until
case

bears

against

adapter
plate

Carefully
install
main
drive

bearing

and
countershaft
front

bearing

Make

certain
that
mainshaft

rotates

freely

3
Fit

main
drive

bearing

snap
ring

to

groove
in
main

drive

bearing

by

using
Expander
See
Figure
MT
53
Manual
Transmission

Fig
MT
53

Fitting
main
drive

bearing
snap
ring

R
ar
xt

nslon
ass

mbly

I
Clean

mating
surfaces
of

adapter

plate
and

fear
extension

Apply
sealant
to

mating
surfaces

of

adapter
plate
and

rear
extension

2
With
fork

rods
in

their
neutral

positions

graduaUy
slide
rear
exten

sion

onto

adapter
plate

making
sure

that

speed
change
cross

lever

engages

with

fork

rod
brackets

correctly

3

Install
washers
and

through
bolts

and

torque
to
1

6
to

2
1

kg
m

12
to

15
ft
lb

Available

shim
Front
eov
r
s

mbly

I

Select
countershaft
front

bearing

shim
as
follows
See

Figure
MT
54

1
Measure

depth
A
from

front

end
of
transmission
case
to

counter

shaft
front

bearing

2
Select
a
shim
of
thickness
A

measured

D

A

JJ
ID

@

2J1

I

Transmission

case

2

Countershaft

front

bearing

3

Countershaft

4

Shim

TM371

Fig
MT
54

Selecting
countershafl

front
bearing
shim

No

A
Countershaft
front

rnm
in

bearing
shim
mm
in

I
2
92
to
3

01
0
1150

to
0

1185
0

6
0
024

2

3
02
to

3
11

0
1189
to
0
1224

0
5
0
020

3
3
12

to
3
21
0

1228
to
0

1264
0
4

0
016

4
3
22
to

3
3
I

0
1268
to
0

1303
0
3
0
012

5

3
32
to
3

41
0

1307

to
0
1343

0
2
0
008

6
3
42

to
3
5
I

0

1346
to
0

1382
0
1
0
004

7
3

52
to

3
61
0

1386

to
0
1421

8
3
62

to
3
71
0
1425
to
0

1461

2
Clean

mating
surfaces
of
front

cover
and

transmission
case

Apply
grease
to
shim
selected
to

retain
it
on
front
cover
install
front

cover
to
transmission
case
with

gasket

in
place

Install

through
bolts
with

washers

under
them
and

tighten
to
1

6
to
2
1

kg
m
12

to
15
ft
lb

torque

Apply
sealant
to
threads
of

through
bolts
before
installation

MT13
3

Install

speedometer
pinion
assem

bly
on
rear
extension

After

making

Sure
that

lock

plate
is

lined

up
with

groove
in

speedometer
pinion
sleeve

install

through
bolts
and

torque
to
0
4

to
0
5

kg
m
3

to
4
ft

lb

4

Install
back

up
lamp
switch
and

torque
to
2

0
to
3

0

kg
m

14
to
22

ft
lb

Be
sure
to

apply
sealant
before

installation

5

Apply
a

light
coat

of
multi

purpose
grease
to

withdrawal
lever

release

bearing
and

bearing
sleeve
in

stall
them
on
clutch

housing

After

connecting
them

with
holder

spring
instaU
dust

cover
on
clutch

housing

6
Install
control
lever

temporarily

and

shift
control

lever

through
all

gears
to
make

sure

that

gears

opera
Ie

smoothly

Note
Install

drain

plug
and
filler

plug

ith
sealant
in

place
Manual

Transmission

INSTALLATION

Install
the
transmission
in
the
reo

verse
order
uf
removal

paying
atten

tion

to
the

following

points

1
Before

installing
dean

mating

surfaces
of

engine
rear

plate
and

trans

mission
case

2

Before

installing
lightly
apply

grease
to

spline
parts
of
clutch
disc

and
main
drive

gear

3

Tighten
bolts

securing
trans

mission

to

engine
to

specifications
See

Figure
MT
55

5
SPEED
TRANSMISSION

TYPE

DESCRIPTION

REMOVAL

DISASSEMBL
Y

TRANSMISSION
CASE
DISASSEMBLY

DISASSEMBL
Y
OF
GEAR

ASSEMBLY

REAR

EXTENSION
DISASSEMBLY

ADAPTER
PLATE

DISASSEMBLY

INSPECTION

TRANSMISSION
CASE
AND
REAR

EXTENSION
HOUSING

DESCRIPTION

The
transmission

is
of
a
5

speed

forward
with
overdrive
4

OD

speed

fully
synchronized
constant

mesh

type
that

uses
helical

gears

The
5

speed
transmission
covered
in

this
section
is

similar
in

all

respects
to

the
4

speed
transmission

type

F4W71B
stated

previously
except
the
CONTENTS

MT14

MT17

MT17

MT17

MT17

MT18

MT19

MT19
4
4

to
5
9

kg
m

32
to
43
ft
Ib

1

0
9
to
1
2

kg
m

7
to
9
rt
lb
TM773

Fig
MT
55

Tightening
torque

4
Remove
filler

plug
and
fIll
trans

mission
with
recommended

gear
oil

to

the
level
of
the

plug
hole

Approxi

mately
I
7

liters
3

pt
3

pt

FS5W71B

BEARING

GEARS

AND
SHAFTS

BAULK

RING

OIL

SEAL

ASSEMBL
Y

FRONT
COVER
ASSEMBLY

REAR

EXTENSION

ASSEMBLY

GEAR

ASSEMBLY

TRANSMISSION
ASSEMBLY

INSTALLATION
MT19

overdrive

position
of
it

The

overdrive

gear
rides
on
the

mainshaft

freely
through
the

needle

roller

bearing
and
counter

overdrive

gear
is
fitted
to
the

countershaft

by

splines

The
overdrive

synchronizer
system

is

on
the
mainshaft
rear
side

MT14
MT19

MT19

MT19

MT19

MT19

MT19

MT19

MT19

MT

20

MT20

Placing
the
control
lever
in

over

drive

position
brings
the
reverse
OD

coupling
sleeve
reverse

gear
on
main

shaft
into
mesh
with
overdrive
clutch

gear
The
reverse
OD

synchronizer

hub
is

fItted

to
the
mainshaft

by

splines
so
the
overdrive

gear
on
main

shaft

turns

together
with
the
main

shaft

Manual
Transmission

@
I
j

b
00

7

@

f

1
Front

cover

2

Front
cover
oil
seal

3
Front

cover

gasket

4

Transmission
case

5

Adapte
plate

6

Maimhaft
bearing

7

Bearing
retainer

8
Rear

extension

9
Breather

10
Rear
extension

oil
seal

11
Sleeve

yoke
dust
cover
f

@3

TM046A

Fig
MT

56
FS5W71B
transmission
case

components

MT15

Manual
Transmission

CD
t

e
I

2

3

4

5

6

7

8

9

10

11

12

13

14

17

18

19

O
20

o

21

24

25
j

@
Striking
lever

Lock

pin

Q

ring

Striking
guide

Oil
seal

Striking
rod

Expansion
plug

Stopper
guide
pin

Return

spring

Return

spring
plug

Return

spring
plunger

Check
ball
plUS

Check

spring

Check
ball

Retaining
pin

Interlock
ball

ist
2nd
shift
fork

1st
2nd
fork
rod

3rd
4th
fork
rod

Reverse
OD
fork
rod

3rd
4th
shift
fork

Revene
OD
shift
fork

Con
trol1ever

Con
trol1cver
pin

Con
trollever
bushing

TM048A

Fig
MT
58
FS5W71B
trammi
ion

shift
control

component

3
Draw
out
counter
drive

gear
com

plete
with
main
drive

gear
assembly
by

means
of

a

gear
puller

When

drawing
out
main
drive

gear

assembly
be
careful
not
to

drop

pilot

needle

bearing
onto
floor
from
the

front
end
of
mainshaft
See

Figure

MT
60
REMOVAL
Same

as
for
the
F4W71B

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

Same
as
for
the
F4W71
B

DISASSEMBLY
OF

GEAR

ASSEMBLY

Fork
rod

Same
as
for
the
F4W71
B

Geer
sembi

I

With

gears
doubly
engaged
draw

out

counte
haft
front

bearing
using
a

suitable

gear
puller
See

Figure
MT
59

2
Remove
counter
drive

gear

snap

ring
TM398

Fig
MT
59

Removing
countershaft

front
bearing

MT
17
TM756

Fig
MT
60
Removing
counter
drive

gear
and
main
drive

gear

4

Rem6vesnap
ring
and
then
thrust

washer
from
mainshaft
front
end

Draw
out
3rd
4th

synchronizer

assembly
and
remove
3rd

gear
assem

bly

5
Remove

snap
ring
and
then
draw

out

speedometer

gear
and

bearing

from
mainshaft
rear
side

6
With

gea
doubly
engaged
re

lease

caulking
on
countershaft
and

mainshaft

nuts
then
loosen
them

Remove
countershaft
nut

ADAPTER
PLATE

DISASSEMBLY

Same
as

for
the
F4W71

B

Fig
MT
67

Removing
screws

INSPECTION

Wash

all

parts
in

a
suitable

cleaning

solvent
and
check
for
wear

damage
or

other

faulty
conditions

Notes

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
HOUSING

Same
as
for
the
F4W71
B

BEARING

Same

as
for
the
F4W7l
B

GEARS
AND
SHA
S

I
Check
all

gears
for
excessive

wear

chips
or
cracks

replace
as

required

2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure

backlash
in

gears

Main
drive
and

counter
drive

gear

0
05
to
0
10

mm

0
0020
to
0
0039
in

1st

2nd
3rd
5th
and

reverse

gears

0
05
to
0
20
mm

0
0020
to
0
0040
in
Manual
Transmission

If
the
above
limits
are
exceeded

replace
drive
and
driven

gears
as
a

set

4

Measure

gear
end

play

1st

gear

0
32
to
0
39
mm

0

0126
to
0
0154
in

2nd

gear

0
12

to
0
19
mm

0
0047
to
0
0075
in

3rd

gear

0
13
to
0
37
mm

0
0051
to

0
0146
in

OD

gear
on
mainshaft

0
32

to
0

39
mm

0
0126
to
0

0154
in

BAULK
RING

Same
as
for
the
F4W7IB

OIL
SEAL

Same
as
for
the
F4W71
B

ASSEMBLY

To
assemble
reverse
the
order
of

disassembly
Observe
the

following
in

structions

FRONT
COVER
ASSEMBLY

Same
as
for
the
F4W7l
B

REAR
EXTENSION

ASSEMBLY

I

Wipe
clean
seal

seat
in

rear
exten

sion

housing
press
fit
oil
seal
in

place

Coat
oil
seal
and

bushing
with

gear

oil
for
initial
lubrication
See

Figure

MT
68

Front
r

I

TM355

Fig
MT
68
R
ar
extemion
oil
sea

2

Apply
multi

purpose
grease
to

O

ring
and

plunger

grooves
in

striking

rod

Insert

striking
rod
with

striking
rod

guide
through
rear
extension

MT19
3
Install

striking
lever
on
front
end

of

striking
rod
Install
lock

pin
and

torque
screw
to
0
9
to
1
2

kg
m
7

to

9
ft
lb

4

Install

filainshaft
bearing
by

lightly
tapping
around
it
with
a

soft

hammer

5
Insert

reverse
idler
shaft
in

adapt

er

plate

Make
sure
that
the
cut
out

portion

of
reverse
idler
shaft
is

lined

up
with

inner
face
of

adapter

plate

6
Install

bearing
retainer
in

adapter

plate

Align
bearing
retainer

with
reverse

idler
shaft
at
the
cut
out

portion
of

this
shaft

torque
screws
to
1

9
to
2
5

kg
m
14
to
18
ft
lb
and
stake
each

screw
at
two

points
with
a

punch
See

Figure
MT
69

TM764

Fig
MT
69

Stahing
screw

7
Install
countershaft

rear
bearing

in

adapter

plate
by
lightly
tapping

around
it

with
a
soft
hammer

GEAR
ASSEMBLY

Clean
all

parts
in
solvent
and

dry

with

compressed
air

Synchronlz
r
embly

Same
as
for
the

F4W71
B

Ov
rdrlve
r

ynchronlz
r

mbly

I

Assemble
reverse
OD

synchro

nizer

assembly

2
Assemble
overdrive

gear
assem

bly

Position
synchronizer
ring
band

brake
thrust
block
and
anchor
block

on
overdrive
clutch

gear
install

circlip

Manual
Transmission

SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

Transmission

type
F4W71B
FS5W71B

Synchromesh

type
Warner
1st
to
4th
Warner
5th
Servo

Shift

type
1
3

T

i
i

2
4
R
1
3
5

II

1

2

4
R

Gear
ratio

1st

2nd

3rd

4th

5th

Reverse
3
592

2
246

1
415

1

000

3
657
3
321

2
077

1
308

1
000

0
864

3
382

Final

gear
ratio
4
375
4
375

Speedometer
gear
ratio
20
6

I

7
3
3
20
6

2
0
4X
3
f

Oil

capacity
US

pt
Imp
pt

MT
21

Manual

iTransmission

TIGHTENING
TORQUE

Installa
tion

Engine
to
transmission

installation
bolt

Transmission
to

engine
rear

plate
bolt

Clutch

operating
cylinder
installation

bolt

Rear

mounting
insulator
to

transmission
installation
bolt

Crossmember

mounting
bolt

Propeller
shaft
to
diff
installation
bolt

Gear

assembly

Rear

extension
installation
bolt

Front
cover

installation
bolt

Bearing
retainer
to

adapter

plate
screw

Main
haft
nut

Check
ball

plug

Stri
lever

lock

pin

Reverse
select

return

plug

Speedometer
sleeve

locking

plate
nut

Reverse

lamp
switch

year
oil
Ier

pl
g

Ge
r
oil
drain

plug
Unit

kg
m
ft
lb

4
4

to
5

9
32

to
43

0

9

to
1
2
7
to
9

2
5

to
3
0

18
to
22

0
8
to
1
1
6

to
8

3

2
to
43

23
to
31

2
4

to
33

17
to

24

1

6

to
2
1

12
to
IS

1
6
to
2
1

12to
IS

1
9
to
2
S
14
to
18

14

0
to
17
0

101
to
123

1
9
to
2
S

14
to
18

0
9
to
1
2

7
to
9

0
9
1
2
7

to
9

0
4

to
O
S

3

to
4

2
0
to
3
0

14
to
22

2
S

to
3
5

18
t02S

2
S

toTS

l8
to
2S

or

SPECIFICATIONS

Gear
backlash

Maindrive

gear
to
counter
drive

gear

1st

gear

2nd

gear

3rd

gear

OD

gear

Gear

end

play

1st

gear

2nd

gear

3rd

gear

OD

gear

Counter

gear

Reverse
idler

gear

Clearance

between
baulk

ring
and

gear

All

gears

Counter

bearing

adjusting
shim
Unit

mm
in

0
05
to
0

10
0
0020
to

0
0039

0
05
to
0

20
0
0020
to
0
0079

O
OS
to
0
20
0

0020
to
0
0079

0
05
to
0
20
0
0020
to
0
0079

0
05
to
0

20
0
0020
to
0
0079

0
32
to
0
39

0
0126
to
0
0154

0
12
to
0
19

0
0047
to
0

0075

0
13
to
0
37
0
0051
to
0
0146

0
32
to
0
39

0
0126
to
0

0154

0
01
to
0
21

0
0004
to
0
0083

0
05

to
0
20
0
0020

to
0
0079

1
25
to
1

60
0
0492
to
0
0630

0
6
0
024

0
5
0
020

0
4
0

016

0
3
0
012

0
2
0
008

0
1

0
004

MT
22

Manual
Transmission

I

TROUBLE
DIAGNOSES
AND
CORREGTIONS

Condition

Difficult
to

intel11lesh
gears

Causes
Jor
difficu
t

gear
shifting
are
classi

fied
to
troubles

concerning
control

system

and
transniissioo
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
transmissi
o

Gear
slips
out
of
mesh

In
most
cases
this
trouble
occurs
when

interlock
b
all
check
ball
and

or
spring
is

worn
or
weakened
or

when
control

system

is

faulty
In
this
case
the

trouble
cannot
be

corrected

by
replacing
gears
and
therefore

trouble

shooting
must
be

carried
out

care

fully
It
should
also
be

noted
that

gear
slips

out

of
mesh
due
to
vibration

generated
by

weakened
fron
t
and
rear

engine
mounts

Noise

When
noise
occurs
with

engine
idling
and

ceases
when

clutch
is

disengaged
or
when

noise
occurs
while

shifting
gears
it
is

an

indicati90
that
th
e
noise
is

from
transmis

sion

t
Transmission

may
fa
ule

during
engine

idling

Check
air

fuel
mixture
and

ignition

timing

After
above

procedure
readjust
engine

idling
Probable

cause

Worn

gear
shaft
and
or

bearing

Insufficient

operating
stroke
due
to
worn
or

loose
sliding

part

Faulty
or

damaged
synchronizer

Worn
interlock
ball

Worn
check
ball

and
or

weakened
or
broken

spring

Wom
fork
rod
ball

groove

Wom
or
damaged
bearing

Worn
or

damaged
gear

Insufficient
or

improper
lubricant

Oil

leaking
due

to

faulty
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

19W
speed

Worn

spline

Worn

bushing

j

MT
23
Corrective
action

Replace

pair
or
replace

Replace

Replace

Replace

Replace

Replace

Replace

Add
oil
or

replace

with

designated
oil

Clean
Of

replace

Replace

Replace

Replace

Replace