ECU DATSUN PICK-UP 1977 Owner's Guide

Engine
Removal

Installation

ENGINE

REMOVAL
AND
INSTAllATION

REMOVAL

INSTALLATION

ENGINE
MOUNTING
INSULATORS

REMOVAL

It
is
much
easier

to
remove

engine

and
transmission

as
a

single
unit

than

to

remove
them

separately
After
re

moval

engine
can
be

separated
from

transntission

assembly

Notes

a
Be

sure
to
hoist

engine
and

jack
up

transmission
in
a
safe
manner

b
Use

fender
cove
to

protect
vehicle

body

1
Remove

battery

2
Scribe

hood

hinge
location
for

proper
reinstallation
and
remove

hood

Note
Have

an
assistant

help
you
so
as

to

prevent
damage
to

body

3
Drain

radiator
coolant

4

Disconnect

upper
and
lower

radiator
hoses

from

engine

5

Remove

two
oil
cooler
hoses

from
lower

end
of
radiator
Auto

ma
tic
transmission

models

only

6
Remove

radiator

shroud

7

Remove
four

bolts

securing
radia

tor
and

detach
radiator

Note

Always
tighten
securing
bolt
at

upper
right
hand
side

together
with

body
harness

terminal

8

Remove
carburetor
air

cleaner
as

follows

Remove
fresh
air

duct

Remove

hot
air

duct

Loosen
air

cleaner
band

bolt
and
air

cleaner

supporting
bolts

Disconnect
air

cleaner
ta
air

pump

hose

Disconnect
air
cleaner

to
rocker

cover
hose
at

rocker

cover

Disconnect
air

cleaner

to
air

control

valve
hose
California

models

only
CONTENTS

ER
2

ER
3

ER
3
FRONT

INSULATOR

REAR

INSULATOR

TIGHTENING

TORQUE
ER
4

ER
4

ER
4

Disconnect
air

deaner
to

A
B
valve

hose

Disconnect
air

cleaner
ta

vacuum

hoses

Note

Protect
carburetor
from
dust

and

foreign
matter

by

placing
cover

over
air
inlet

opening

9

Disconnect

fuel

pump
to
fuel

fdter
hose
and
return

hose

10

Disconnect
carbon
canister

hose

on

engine
side

II

Disconnect
air

pump
air

C1eaner

to
al

p

p
hose

12

Disconnect

following
cables

wires

and
hoses

Engine
ground
cable

Accelerator
wire
at

carburetor

High
tension

cable
between

ignition

coil

and
distributor

Wire

to
distributor
at

body
ter

minal

Wire
to

oil

pressure
switch

Wires
to
thermal

transmitter

Wires
to

B
C

p
D
cut
solenoid

Non
California

models

only

auto

choke
heater
and

anti

dieseling

solenoid

Wires

to
alternator

Wires
to
starter

motor

Heater
inlet
and
outlet

hoses
if
so

equipped

Vacuum
hose
of

Master
Vac
at
in

taJce
manifold

Wires
for

back

up

lamp
switch

Cable
to

speedometer

13

Remove
transmission

control

linkage
from

transmission

Manual

transmission
models

I

Detach
rubber
boot

2
Remove
E

ring
and
control

lever

pin
from

transmission

striking
rod

guide
and

remove
control
lever

ER
2
Fig
ER
l

Automatic

transmission
models

I

Disconnect

selector

range
lever

from
manual
shaft

2
Disconnect
wires

at
inhibitor

switch
and

down
shift
solenoid

14
Air

conditioner

equipped

models
need

following

procedures

1
After

removing
flexible

hose

support
remove
four

comi
ressor

se

curing
bolts

Then
move
the

com

pressor
to

battery

support

2

Remove

vacuum
hoses
of

F
LC
D
solenoid
valve

3
Remove
F
LC

D
actuator

15
Remove
two
bolts

securing

clutch

operating
cylinder
Then
dis

connect

operating
cylinder
and

flexi

ble
tube

as
an

assembly

Manual

transmission

models

only

16
Disconnect
front

exhaust
tube

from
exhaust
manifold

17
Remove

propeller
shaft

I

Disconnect

propeller
shaft

center

bearing
bracket
from

third

crossmember

2

Disconnect

propeller
shaft
from

companion
flange
of
differential

carrier

3
Remove

propeller
shaft
from

transmission

and

plug

up
rear
end
of

extension

housing
of

transmission
to

prevent
oil

leakage

18
Attach
a
suitable
wire

or
chain

to
lift

engine

19
Remove

front

engine
mounting

bolts

at

engine
mounting
front

sup

port

Fig
ER
2
ER207

Removing
front
engine

mounting
bolts

20
Place
a

jack
under
transmission

and

jack
it

up

21
Loosen

two
rear

engine
mount

ing
bolts

CD

22
Loosen
two

exhaust
tube

hanger

bolts

V
California
models

only

23
Remove
four
bolts

CID
securing

engine
mounting
rear

support
to
side

member
and
detach
rear

support

j
r

O

1

ER271

Fig
ER
3
Removing
rear

engine

mounting
support

24
Remove

steering
idler
arm
secur

ing
bolts
and

push
down

cross
rod

iC

EA278

Fig
ER

4
Removing
idler
arm

25
Pull

engine
towards
front
as
far

as

possible
and

carefully
raise
if
and

transmission
with
a
hoist
and
cable

Note
In

this

r
an

care
should

always
be
taken
not
to
allow
the

unit
to
hit

against
any

adjacent

parts
Engine
Removal
Installation

INSTALLATION
E
R367

Fig
ER
5
Lifting
engine

Install

engine
with
transmission
in

reverse
order
of

removal

observing
the

following

I
When

installing
first
secure

rear

2

Front

1
Bracket
R
H

2

Insulator
R
H

3
Bracket
LH

4

Heat
shield

plate

5
Insulator

L
H

6
Rear

support

7
Rear
insulator

8
Exhaust
tube

hanger

California
models

only
engine
mounting

support
to

body

2
Refer
to

applicable
section
when

installing
and

adjusting
any
parts

@

E

A279

Fig
ER

6
Structual
view

of
engine
mounting

ENGINE
MOUNTING

INSULATORS

Three
insulators
are
used
to

mount

the

engine
and
transmission

two
are

located
at

the
left
and

right
of
the

cylinder
block
and
one
at
the
transmis

sion

rear
extension

housing
Replace
any
insulator
that
shows

signs
of

separation
or
deterioration

Be
sure
to

keep
insulator
free
from

oil

or

grease

ER
3

Engine
Removal
Installation

FRONT

INSULATOR

Removal
and
installation
7
To

install
reverse
order
of

re

moval

1

Disconnect

battery
ground
cable

2
Remove

hood

3

Suspend
engine
with
wire
or

chain

4
Loosen
front

engine
mounting

insulator

upper
nuts

both
sides

5

Carefully
raise

engine
a
little
with

a
hoist
and
cable

6
Remove
front

mounting
insula

tors
at
front

supports
after

removing

front

mounting
bolts
REAR
INSULATOR

Ramoval
and
Installation

1

Place
a

jack
under
transmission

TIGHTENING

TORQUE

Fixing
bolts
and
nuts

Front

mounting
bracket
to

cylinder
block

Front

mounting
in

lator
to
brac
t

Front

mounting
insulator
to
front

support

Rear

mounting
insulator
to

transmission

Rear

mounting
insulator
to

rear

support

Rear

support
to
frame

Clutch

operating
cylinder
to
transmission

Exhaust
front

tube
to
exhaust
manifold

Center

bearing
bracket
to

crossrnember

Propeller
shaft
to

companion

flange
kg
m
ft
lb

kg
m
ft
Ib

kg
m
ft
lb

kg
m
ft
lb

kg
m
ft
Ib

kg
m
ft
lb

kg
m
ft
Io

kg
m
ft
lb

kg
m
ft
lb

kg
m
ft
lb

ER
4
and

jack
it

up
slightly

2

Loosen
two

rear

engine
mounting

bolts

3

Loosen
two

exhaust
tube

hanger

bolts
California

models

only

4

Remove
rear

mounting
insulator

at
transmission
rear
extension

after

removing
insulator

securing
bolts

5

To
install

reverse
order

of
Ie

moval

2
6
to
3
6
19
to
26

2

6
to
3

6

19
t
o

76

1
4

to
1
8
10
to
13

3

2
to
3
7
23
to

27

1
6
to
2
2

12
to
16

3

2
to
4
3
23
to
31

2
5

to
3

5

18
to
25

1

9
to
2
5
14
to
18

1
6

to
2
2

12
to
16

2
4
to

3
3

17
to

24

Installation

I

Apply
a

light
coat
of
lithium
base

grease
containing
molybdenum
disul

phide
on
transmission
main
drive

gear

splines

Slide
clutch
disc
on
main

drive

gear

several
times
Remove

clutch
disc
and

wipe
off
excess
lubricant

pushed
off

by
disc
hub

2
Install
clutch
disc
and
clutch

cover
assembly
on

flywheel
Support

two
assemblies
with
Clutch

Aligning

Bar
KV30100200
See

Figure
CL
3

Note
Be
sure
to

keep
disc

facings

flywheel
and

pressure
plate
clean

and

dry

7
00

R

rr

CL109

Fig
CL
3

l
talling
clutch
cover

assem

bly

3
Install
six

bolts
to

tighten
clutch

cover

assembly
to

flywheel
squarely

Each
bolt
should
be

tightened
one

turn
at
a
time

to
the

specified
torque

15
to
2
2

kg
m
II

to
16
ft
Ib

Note
Three
dowels
are

used
to
locate

clutch
cover
on

flywheel
properly

4
Remove

Clutch

Aligning
Bar

KV30100200
after

tightening
the

bolts

securely

5
Install
transmission

Note
Make
certain
that
withdrawal

lever

engages
lever
ball

pin

6
Connect

push
rod
of
clutch

op

erating
cylinder
to
withdrawal
lever

DISASSEMBLY
AND

ASSEMBLY

Disassembly

I

Clutch
cover

assembly
can

not
be
CLUTCH

disassembled
since

diaphragm
spring
is

securely
reveted
to
clutch
cover
and

clutch

cover
assembly
is
balanced

If

necessary
replace
clutch
cover

assembly
as
a

complete
unit

2

Remove
clutch
release
mechanism

as
follows
See

Figure
CL4

1
Remove
dust
cover
from
clutch

houisng

2
Remove

withdrawal
lever
from

clutch

housing

3
Remove

retainer

spring
from

withdrawal
lever

4

Remove
release

bearing
bearing

sleeve
and

holder

spring
from
clu
tch

housing
as
an

assembly

1

lo

1

Release

bearing

2
Release

bearing

sleeve

3
Holder

spring

4
Dust

cover

5
Withdrawal

lever

6
Retainer

spring
CL119

Fig
CL
4

Exploded
view

of
clutch

releaae
mechaniam

3
Take

out
clutch
release

bearing

from

bearing
sleeve

using
a

universal

puller
See

Figure
CL
5

C
L014

Fig
CL
5
D

embling

rele
e

b

aring

4

Remove

pilot
bushing
in
crank

shaft

by
Pilot

Bushing
Puller

ST16610001
if

necessary
See

Figure

CL
6

CL3
CLOSS

Fig
CL
6

Removing
pilot
bu

hing

Asse

bly

Release

mechaniam

1
When

assembling
release

bearing

on
sleeve

use
a

press
and
seat

bearing

squarely
on

sleeve
See

Figure
CL
7

l
J

I

CL215
I

1

J

1

Fig
CL
7
1

tailing

rele
e

bearing

2
Before

or
during

assembling
lu

bricate
the

following
points
with

a

light
coat
of
multi

purpose

grease

I

Inner

groove
of
release

bearing

sleeve
See

Figure
CL
8

Lf

I

n

JQt
CL216

Fig
CL

B
Lu

bricating
ee

of

bearing
slee

2
Contact
surfaces
of

withdrawal

lever
lever
ball

pin
and

bearing
sleeve

3
Contact
surfaces
of

transmission

front
cover
See

Figure
CL

9

CLUTCH

CYLINDER

MASTER

Removal
and

installation

Removal

I

Remove
clcvis

pin
at

push
rod

2

Disconnect

clutch

tube
from

master

cylinder
and
drain
clutch
fluid

3

Remove
bolts

securing
master

Disassembly
and

assembly
CLUTCH

cylinder
to
the
vehicle

and
dismount

master

cylinder

Note
Remove
dust

cover
from
master

cylinder
body
on
the

side
of
driv

er

s
seat

Installation

To
install

reverse
the
order
of

removal

Closely
observe
the

following

instructions

1

Adjust
pedal

height
by

changing

pedal

stopper
length

Disassembly

1

Remove
dust

cover
and

remove

stopper
ring
from

body

2

Remove

push
rod

and

piston
as

sembly

3

Take
off

piston

cups

4

Remove

spiing
seat
from

piston

and
take
off

supply
valve
if

necessary

See

Figure
CL

19

Note
Discard

piston
cup
supply

valve
and

spring

seat
after
removal
Assembly

To

assemble
reverse
the
order
of

disassembly

Closely
observe
the
fol

lowing
instructions

I

Dip
piston
cup
in
brake
fluid

before

installing
Make

sure
that
it
is

correctly
faced
in

position

2

Apply
a

coating
of

brake
fluid
to

cylinder
and

piston
when

assembling

3
Press

piston
into

spring
seat
when

assembling

CL
7
2

Bleed
air

out
of

hydraulic

system

Tightening
torque

Master

cylinder
to

dash

panel

0
8

to
1
2

kg
m

5
8
to
8
7
ft

lb

Clutch
tube

connector
Flare
nut

1
5

to
1
8

kg
m

II
to
13
ft

lb

3

Using
Flare

Nut

Torque
Wrench

GG94310000

tighten
each

connector

to
the

specified

torque

1
Reservoir

cap

2
Reservoir

3
Reservoir
band

4

Cylinder
body

5

Supply
valve

stopper

6
Return

spring

7

Spring
seat

8
Valve
spring

9

Supply
valve
rod

10

Supply
valve

11

Primary
cup

12
Piston

13

Push
rod

14

Secondary

cup

15

Stopper

16

Stopper

ring

17
DU5t
cover

18
Lock
nut

CL265

Fig
CL
19

Exploded
view

of
maater
cylinder

Note

The
clutch
master

cylinder
is

available
in
both
NABCO
make
and

TOKICO
make
There
is
no
inter

changeability
of

repair
kits
or
com

ponent
parts
between

NABCO
and

TOKlCO
makes

When

replacing
the

repair
kit

or

component
parts
ascertain
the

brand
of

the
clutch
IIIBSter

cylinder

body
Be
sure
to
use

parts
of
the

same
make
as
the
former

ones

Inspection

Note
To
clean
or
wash
all

parts
of

master

cylinder

operating
cylinder

and

piping
clean
brake
fluid
must

be
used
Never
use
minera10ils
llUch

as

gasoline
and
kerosene
It

will

ruin
the
rubber

parts
of
the

hydrau

lic

system

I

Check
cylinder
and

piston
for

uneven
wear
or

damage
and
if
neces

sary
replace

2
If
the
clearance
between

cylinder

and

piston
is

more
than

0
15
mm

0
0059
in

replace
cylinder

3

Renew

piston
cup
when
dis

assembled
It
must
also
be

replaced

when
wear
or
deformation
due
to

fatigue
or

damage
is

found

4

Damaged
dust
cover
oil
reservoir

or

cap
should
be

replaced

Return

spring
and
valve

spring
must

also
be

replaced
when

they
are
broken

or
weak

5

Replace
clutch
hose
and
tube
if

any
abnormal

sign
of

damage
or
de

fro

ti

n
is
found

OPERATING

CYLINDER

Removal
and

installation

Removal

1

Detach
clutch
hose
from

operat

ing
cylinder

2
Remove
two
bolts

securing
op

erating
cylinder
to
clutch

housing

Installation

Install

in
the
reverse
order
of
re

moval

Observe
the

following
instructions

Bleed
air

thoroughly
from
clutch

hydraulic
system

2
Do
not

install
return

spring
or

clutch
will

not
be

disengaged

properly

Tightening
torque

Operating
cylinder
securing
bolt

2
5
to
3
5

kg
m

18
to
25
ft
lb

Bleeder
screw

0
7
to
0
9

kg
m
5
1

to
6
5
ft
Ib

Clutch
hose
connector

1
7
to

2
0

kg
m
12
to
14
ft

b
CLUTCH

Disassembly
and

assembly

Disassembly

1
Remove

push
rod
with
dust

cover

2
Remove

piston
assembly
and

pis

ton

spring

3
Remove

bleeder
screw

1
6

Cl11B

5

Piston

cup

6

Operating
cylinder

7
Bleeder
screw
1

Push
rod

2
Dust
cover

3
Piston

spring

4

Piston

Fig
CL
20

Exploded
view

of

operating
cyUnder

Assembly

Assemble
in
the

reverse
order
of

disassembly
Closely
observe
the
fol

lowing
instructions

1

Prior
to

assembly

dip
piston
cup

in

clean
brake
fluid

When

installing
cup
pay
particular

attention
to
its
direction

2

Dip
cylinder
and

piston
in
clean

brake
fluid
before

assembly

Notes

a
Be

sure
to
install

piston
assembly

with

piston
spring
in

place

b
The
clutch

operating
cylinder
is

available
in
both
NABCO
make
and

TOKICO
make
There
is
no
inter

changeability
of

repair
kits
or
com

ponent
parts
between
NABCO
and

TOKICO
makes

When

replacing
the

repair
kit
or

component
parts
ascertain
the

brand
of
the
clutch

operating
cyl

inder

bndy
Be
sure
to
use

parts
of

the

same
make

as
the
former
ones

Inspection

Visually

inspect
all
disassembled

parts
replacing
those
found
worn
or

rl

Q
damaged
too

badly

beyond
speci

fications

BLEEDING
CLUTCH

SYSTEM

The

hydraulic
clutch

system
must

be
bled
whenever
clutch
line
has
been

disconnected
or
air

has
entered
it

When

pedal
action
has
a

spongy

feeling
it
is
an
indication
that
air
has

entered
the
system

Bleeding
clutch

system
is

an
es

sential

part
of

regular
clutch
service

I

Remove
reservoir

cap
and

top
up

with
recommended
brake
fluid

2

Thoroughly
clean
mud
and
dust

from
bleeder
screw
of

operating
cyl

inder
so
that
outlet
hole
is

free
from

any
foreign
rnaterial
Install
bleeder

hose

vinyl
hose
on
bleeder
screw

Place
the
other
end
of
it
in

a
clean

container

3
Have
a
co
worker

depress
clutch

pedal
two
or

three
times
With
clu
tch

pedal
depressed
fully
loosen
bleeder

screw
to
bleed
air
out
of
clutch

sys

tern

4
Close
bleeder
screw

quickly
as

clutch

pedal
is

on
down
stroke

5
Allow
clutch

pedal
to
return

slowly
with
bleeder
screw
closed

6

Repeat
steps
4
and
5
until

no
air

bubble
shows
in

the

vinyl
hose

7

Operate
clutch
several
times

then
check
connections
for
external

hydraulic
leaks

Notes

a
Brake
fluid

containing
air
is
white

and
has
visible
air
bubbles

b
Brake
fluid

containing
no
air
runs

out
of
bleeder
screw
in
a
solid

stream
without
air
bubble

c

Pay
close
attention
to
clutch
fluid

level
in
reservoir

during

bleeding

operation

d
Do
not

reuse
brake
fluid
drained

during
bleeding
operation

e
Exercise
care
not
to

splash
brake

fluid

on
exterior
fInish
as
it
will

damage
the

paint

f
Pour
brake
fluid
into
reservoir

up

to

specifIed
level

CLUTCH

SERVICE

DATA
AND

SPECIFICATIONS

Clutch
cover

Clu
tch

cover

type

Diaphragm
spring
to

flywheel
distance

Unevenness
of

diaphragm
spring
toe

height

Full
load

Out
of
flatness
of

pressure
plate

Allowable

refacing
limit
of

pressure
plate

Clutch
disc

Facing
size

Outer
dia
x
inside
dia
x
thickness

Thickness
of
disc

assembly

Free

Compressed

Number
of
torsion

springs

Allowable
minimum

depth
of

rivet

head
from
surface

Allowable

facing
run
out

Allowable
free

play
of

spline

at
the
outer

edge
of
disc

Clutch

pedal

Pedal

height

Play
at

clevis

pin

Full

stroke

Clutch
master

cylinder

Dia
of
master

cylinder

Allowable
maximum
clearance

between

cylinder
and

piston

Clutch

operating
cylinder

Dia
of

operating
cylinder

Tightening
torque

Clutch

assembly
to

flywheel
securing
bolt

Pedal

installation
bolt
Fulcrum

pin

Pedal

stopper
lock
nut

Push

rod
lock

nut

Master

cylinder
to
dash

panel
securing
bolt

Clutch

tube
connector
Flare
nut

Clutch

hose
connector

Operating
cylinder
to

clutch

housing
securing

bolt

Bleeder
screw
mm
in

mm
in

kg

Qb

mm
in

mm
in
Diaphragm
C225S

33

to
35
1
23

to
1
38

less
than
0
5

0
020

400

882

0
1

0
004

1

0
0
040

mm
in
225
x

150
x
3
5
8

86
x

5
91
x
0

138

mm
in

mm
in
8
3
to

8
9
0
327
to
0

350

7

6
to
8
0
0
299

to
0
315

6

0
3
0
012

0
5

0
020

0
4
0
016
mm
in

mm
in

mm
in

mm
in

153
6
02

mm
in
I

to
3

0
039

to
0
118

mm
in
117

to
123
4

61
to
4
84

mm
in

15

87
5
8

mm
in

0
15

0
0059

mm
in

19

05

Yo

kg
m
ft
lb
1

5
to
2

2
lito

16

kg
m
ft

Ib

1
9
to
2
4

14
to
17

kg
m
ft
b
0

8
to
1
2
5

8
to
8
7

kg
m

ft
lb

0
8
to

1
2
5
8
to
8
7

kg
m
ft
Ib
0
8
to
1
2
5
8
to
8

7

kg
m
ft
lb

1
5
to

1
8
11
to

13

kg
m
ft
lb

1
7
to
2
0
12
to
14

kg
m
ft
lb

2
5
to
3
5
18
to
25

kg
m
ft
Ib

0
7
to
0
9
5
1

to
6
5

CL
9

REMOVAL

In

dismounting
transmission
from

the
vehicle

proceed
as
follows

I
Disconnect
battery
ground
cable

from
terminal

2

Place
transmission
control
lever
in

neutIal

position

3
Remove
E

ring
and
control
lever

pin
from
transmission

striking
rod

guide
and
remove
control
lever
See

Figure
MT
4

TM335

Fig
MT

4
Remouing
controllelJ
r

4
Jack

up
the
vehicle
and

support

its

weight
on

safety
stands
Use
a

hydraulic
hoist
or

open
pit
if
avail

able

Confirm
that

safety
is
insured

5
Disconnect
exhaust
front
tube

6
Disconnect
wires
from
reverse

lamp
switch
See
Figure
MT
5

7
Disconnect

speedometer
cable

from
rear
extension

housing
See

Figure
MT
5

8
Remove
clutch

operating
cylinder

from
transmission
case
See

Figure

MT5

O

m

J

@

1

Speedometer
cable

2
Reverse

lamp
switch

3
Outch

operating
cylinder

TM774

Fig
MT
5
Bottom
view
of
car
Manual
Transmission

9
Remove
bracket

holding
center

bearing
on
3rd
crossmember

by

loosening
off

attaching
bolts
See

Figure
MT
6

PD219

Fig
MT

6
Removing
center
balring

holding
brucket

10
Uetach

propeller
shaft
from

companion
flange
of

gear
carrier

by

removing
four
bolts

See

Figure
MT
7

Not

a
Remove

propeller
shaft

carefully
so

as
not
to

damage

spline
sleeve

yoke

and
rear
oil
seal

b

Plug

up
the

opening
in
the

rear
of

rear
exteDSion

housing
to

prevent

oil
from

flowing
out

P0220

Fig
MT
7

Remouing
four
bolt

6ecuring
prop
ller

shtJft
to

companion
ltJnge

11

Support
engine
by
locating
a

jacft
under
oil

pan
with
a
wooden

block
used
between
oil

pan
and

jack

12

Support
transmission
with
a

transmissionjack

13
Remove
exhaust

pipe
btacket

by
unscrewing
attaching
bolts
2

California
models

only
See

Figure

MT
8

14
Remove
rear

engine
mounting

insulator

securing
bolts
I
and
rear

mounting
member

securing
bolts
3

See

Figure
MT
8

MT
4
E
A277

Fig
MT
8

Removing
engine
mounting

rear

support

15

Remove
starter
motor

16
Remove
bolt

securing
transmis

sion

to

engine

After

removing
these
bolts

support

the

engine
and
transmission
with

jacks

and
then
slide
tra
ion
rearward

away
from

engine
and
remove
from

the
vehicle

Note
Take
care
in

dismounting
trona

mission
not
to
strike

any
adjacent

parts
and
main
drive
shaft

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

I
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

5
Move

gear
to
Neutral

6
Remove
speedometer
pinion
and

pinion
sleeve

by

taking
off
lock

plate

7
Remove
E

ring
and

stopper
guide

pin
from
rear
end
of

re
ll
extension

See

Figure
MT

9

TM337

Fig
MT
9

Removing
triking
rod

E

ring
and

topper
pin

8

Remove
return

spring

plug
return

spring
reverse
check

spring
and

plung

er
from
rear
extension

See

Figure

MT
10

TM338

Fig
MT

10
Removing
return
spring

plull

9
Remove
rear
extension

securing

bolts
and
turn
the

striking
rod
toward

left

Drive
out
rear
extension
backward

by

lightly
tapping
around
it
with
a
soft

hammer
See

Figure
MT
11

TM339

Fig
MT

11

Removing
rear
extension

10
Remove

front
cover

securing

bolts
and
remove
front
cover

Detach
countershaft
front

bearing

shim

II
Remove
main

drive

bearing
snap

ring
with

Expander
See

Figure
MT
12

j

12

Separate
transmission
case
from

adapter
plate
with
a
soft
hammer
See

Figure
MT
13
Manual
Transmission

qJiiiiiI

TM341

Fig
MT
13

Removing
trammission

case

13
Set

up
Setting
Plate

Adapter

ST238
1000
I

on

adapter
plate

With
countershaft
side

up
place
the

above

assembly
in
a
vise

See

Figure

MT

14

TM342

Fig
MT
14

Attaching
l
or

mbly

to

special
tool

DISASSEMBLY
OF
GEAR

ASSEMBLY

Fork
rod

Drive
out

retaining
pins
from

each
fork
rod
with
Fork

Rod
Pin

Punch
ST23540000
See

Figure

MT
15

S

ST23540000

TM343

Fig
MT
15
Drive
out

retaining
pim

2
Remove
three
3
check
ball

piugs

and
drive
out
fork
rods
from

adapter

pia
te

by
lightly
tapping
on
the
front

end

Be
careful

not
to
lose
three
3

check

balls
and
four
4

interlock
balls

See

Figure
MT
16

Note
Each

gear
and
shaft
can
be

detached
from

adapter
plate
with

out

removing
each
fork
rod

MT
5
Fork
rod

ht
2nd

Interlock

ball

TM344

Fig
MT
16

Layout
o
ch
ck
boll

and
interlock
ball

Gear

assembly

I

With

gears
doubly
engaged
draw

out

countershaft
front

bearing
using
a

suitable

gear
puller
See

Figure

MT
17

2
Remove
counter
drive

gear

snap

ring

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
18

TM398

Fig
MT
17

Removing
countershaft

front
b

aring

TM345

Fig
MT
18

Removing
count
r
drive

gear
and
main
drive

gear

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