transmission DATSUN PICK-UP 1977 Workshop Manual

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

4
Remove

snap
ring
and
then
thrust

washer
from
mainshaft
front
end

Draw
out

3rd
4th

synchronizer

assembly
and
remove
3rd

gear
as

sembly

5
Release

caulking
on
mainshaft

nut
and

loosen
it

See

Figure
MT

19

TM346

Fig
MT
19

Removing
maimhaft
nut

6

Remove
mainshaft
nut
thrust

washer
and
mainshaft
reverse

gear

7
Remove

snap
ring
from
counter

shaft
rear
end

and
remove

reverse

idler

gear

8
Draw
out
mainshaft

gear
as
Manual
Transmission

sembly
together
with
countershaft

by

lightly
tapping
the

rear
end
with

a
soft

hammer
while

holding
the
front
of

mainshaft

gear
assembly
by
hand

Be

careful
not
to

drop
off

gear

shaft
See

Figure
MT
20

IJ

t

I

TM347

Fig
MT

20

Driving
out

gear
Cl

embly

Mainshaft

assembly

1
Remove
thrust
washer
steel
ball

I

st

gear
and
needle

bearing
Be

careful

not
to
lose
steel
ball

retaining
thrust

washer

12
2
Press
out
I
st

gear
mainshaft
bush

ing
together
with
2nd

gear
and

1
st

2nd

speed
synchronizer
using
Bearing

Puller
STJ0031000
See

Figure

MT
2l

Note
When

r
out

bushing

hold
h

ft

by
hand

so
as
not
to

drop
it

H

S1
30031000

TM049A

Fig
MT
21
R

moving
lIt

gear

mtUlIIhaft
bu

hing

1
Pilot

bearing

2
3rd

4th

synchronizer

assembly

3
Baulk

ring

4
3rd
main

gear

5
Needle

bearing

6
Mainshaft

7
Needle

bearing

8
2nd
main

gear

9
1st
2nd

synchroni
r

assembly

to

Coupling
sleeve

II

Shifting
insert

12

Shifting
insert
spring

13

Synchronizer
hub

14
1st
main

gear

15
Needle

bearing

16
1st

gear

bushing

17
Thrust
weher

18
Maimhaft

bearing

19
ReftllSe
main

gear

20
Thrust
washer

21
Nut

22
Steel
ball

23
Thrust
washer

24

Snap
ring

TM348

Fig
MT

22

Explod
d
view

of
main
haft

mbly

MT
6

Manual
Transmission

M
in
drlv
g
r

1
Remove
main
drive

gear
snap
ring

and

spacer

2

Remove
main
drive

bearing
with

Bearing
Puller
ST30031000
and
a

suit

able

piess
See

Figure
MT

23

TM349

Fig
MT
23
1

Main
drive
bearing

2
Main
drive

gear

Removing
main
drive

bearing

cl
iiiiiE

l

1

Snap
ring

2

Spacer
3
Main

drive
bearing
with

snap
ring

4
Main
drive

gear

TM350

Fig
MT
24

Exploded
view

of
main
drive

gear

e
q
1

f

1
Countershaft
front

bearing

shim

2
Countenhaft
front

bearing

3

Snap
ring

4
Countenhaft
drive

gear

5

Woodruff
key

6
Countenhaft

1

Countershaft
rear

bearing

8
Reverse
counter

gear

9

Snap
ring
Count
r

h
ft

mbl

Install

Bearing
Puller
STJOO31000

on
countershaft
rear
bearing
press
out

countershaft
rear

bearing
through
a

rod

See

Figure
MT
25

Note
When

pressing
out

bearing
hold

shaft

by
hand
so
as
not
to

drop

shaft
onto
floor

III

TM351

Fig
MT

25

Removing
countershaft

bearing

@
@

j

i

TM352

Fig
MT
26

Exploded
view

of
counte
haft
auembly

MT
7

REAR

EXTENSION

DISASSEMBLY

Remove
lock

pin
from

striking

lever
and
remove

striking
rod
Manual
Transmission

Note
00

not
diSlssemble

rear
exten

sion
bush
from

rear
extension

ADAPTER
PLATE

DISASSEMBLY

I

Remove
six

6

bearing
retainer

attaching
screws
with
an

impact

wrench
and
remove

bearing
retainer

from

adapter
plate

2

Remove
reverse
idler
shaft

3
Remove
mainshaft

bearing
from

the
rear
extension
side

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

00
not

clean
wash
or
soak
oil
seals

in
solvent

TRANSMISSION
CASE

AND

REAR

EXTENSION
HOUSING

I
Clean
with

solvent

thoroughly

and
check
for

cracks
which

might

cause
oil
leak

or
other

faulty
con

ditions

2

Check

mating
surface
of
the

case

to

engine
or

adapter
plate
for
small

nicks

projection
or
sealant
e
1
Control
lever

2

Striking
rod

guide

3

Striking
rod

4

Striking
lever

5

Return

spring
plug

6

Stopper

pin

TM353

Fig
MT

27

Exploded
view
of
shifting
mechani6m

Remove
all

nicks

projection
or

sealant
with

a
frne

stone

3

If
rear

extension
bush
is

worn
or

cracked

replace
it
as
an

assembly
of

bush
and
rear
extension

housing

BEARING

I

Thoroughly
clean

bearing
and

dry

with
a

compressed
air

2
When
race
and
ball
surfaces
are

worn
or

rough
or
when
balls
are
out

of

round
or

rough

replacebearihg

with
a
new
one
See

Figure
MT
28

I

TM372

Fig
MT
28

l
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

MT
8
2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure
backiasii
in

gears

Standard

0
05
to0
10mm

0
0020
to
0
0039
in

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

TM374

Fig
MT

29

Measuring
end

play

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

ST23860000

TM442

Fig
MT
42

l
talling

counte
haft

drive

gear

Available
counter
drive

gear
map
ring

No
Thickness
mm
in

I

2

3
1

4
0
055

1

5
0
059

1
6
0
063

II

TM366

Fig
MT
43

Installing
nap
ring

5
Press
countershaft
front

bearing

onto
countershaft
with
Drift
C

ST22360002
See

Figure
MT
44

ST22360002

KV3
II

00400

TM443

Fig
MT
44
Installing

counte
haft

front
bearing
Manual
Transmission

6

Support
adapter
plate
in

a
vise

with

Setting
Plate

Adapter

ST238
10001
with
mainshaft

facing

down

7
Install

mainshaft
reverse

gear

plain
washer

on
the
rear
of
mainshaft

and
install
mainshaft
nut

Tighten
mainshaft
nut

temporarily

8
Install

counter
reverse

gear
on
the

rear
of

countershaft
and
secure
with

map
ring

Use

snap
ring
to

give
a
minimum

gear
end

play
See

Figure
MT
45

No
Thickness
mm
in

I

2

3
1
4
0
055

1
5
0
059

1

6
0
063

o
TM361

Fig
MT
45

Imtalling
counter
reverse

gear

nap
ring

9
Install
reverse
idler

gear
on
re

verse
idler
shaft

10
With
1st
and
2nd

gears

doubly

engaged
tighten
mainshaft
nut
to
the

converted

torque
Cn
See

Figure

MT
48

using
Wrench
ST22520000

See

Figure
MT
4
7

ST22520000

TM768

Fig
MT
46

Tightening
mainshaft
nut

MTll
Explanation
of
converted

torque

Mainshaft
nut
should
be

tightened

to
14
to
17

kg
m
101
to

123
ft
lb

torque
with

the
aid
of

Wrench

ST22520000
When
doing
so
the

amount
of

torque
to
be

read
on

wrench
needle
should
be
modified

according
to
the

following
formula

L

C

kg
m
14
x
to

L

O
lO

L

17
x

L

0
10

or

L

C
ft
lb

101
x

L
0
33
to

L

123
x

L
0
33

Where

C
Value
read
on
the

torque
wrench

kg
m

ft
lb

L
Effective

length
of

torque

wrench
m
ft

ST22520000

Torque
wrench

Lm
ft
c

h

I

O
IOm

0
33
ft
TM587

Fig
MT
47

Setting
wrench

Example

When
a
0
40

m
1
31
ft

long
tor

que
wrench
is
used
the
Cn
in

Figure
MT
48
will
be
11
2
to
13
6

kg
m
81
to
98
ft
lb

I

Upper
limit
line

I

r

6
1

f
fdl

13
Converted

torque

90

I

Lower

limit
line

80

11

70
10

V
S
s

15

110

15

c

u

c

c

9

S

c

o

C

U
100
14

9

0
2
0
3

1
0
0
4
Manual

Transmission

0
5

0
6

2
0
0
7
0
8
m

2
5
It
1
5

L

Effective

length
of

torque
wrench

Fig
MT
48
CO
1Vert

d

torque

11

Tighten
mainshaft

nut
to

14
0

to
17
0

kg
m
101

to
123

ft
lb

torque
and
stake

mainshaft
nut
to

groove
of
main
shaft

with
a

punch
See

Figure
MT49

TM362

Fig
MT
49

Staking

mai
haft
nut

12
Measure

gear
end

play
and
back

lash

Make
sure
that

they
are
held
within

the

specified
values

For
details
refer

to
the
instructions

under

topic
Inspection
Note
The
main
drive

gear
and
coun

ter

driVe

gear
should
be
handled
as

a
matched

set

When

you
replace
a
main
drive

gear

or
counter

drive

gear
be
sure
to

replace
as
a
set
of

main
drive

gear

and
counter

drive

gear

ShUt
fork
nd

fork
rod

mbly

I

Place
1st
2nd
shift
fork
in

groove
in
1st

2nd

coupling
sleeve

and
slide
1st
2nd
fork
rod

through

adapter
plate
and

1st
2nd
shift

fork

Prior

to

installing
1st
2nd
fork

rod

install

3rd
4th
shift

fork
in

groove
in

3rd
4th

coupling
sleeve

Note
Shift

forks
for
1st
2nd
and

3rd
4th

are
one
and
the

same

parts

Make
sure
that
the

long
end
of
shift

fork
for

lot
2nd
is

placed
on
the

counter

gear
side
and
the

long
end

for
3rd
4th
is
on
the

e

side

MT12
Secure
1st

2nd
fork
rod
to

shift

fork
with

a
new

retaining
pin

2
Install
check

ball
check
ball

spring
and
check

ball

plug
Prior

to

tightening
check
ball

plug

apply

sealant
to
check
ball

plug

Align
notch
in

1st
2nd
fork
rod

with
check
ball

See

Figure
MT
50

TM367

Fig
MT

50

l
talling
1st
2nd

fork
rod

3
Slide

3rd
4th
fork
rod

through

adapter
plate
and
3rd

4th
shift
fork

and
secure
with
a
new

retaining
pin

Note
Prior
to

a

mbling
3rd
4th

fork
rod
install

two
2

interlock

balls
into

dap
er

plat
own
in

Figure
MT
16

4
Install
check
ball
and
check
ball

spring

Apply
sealant
to
check

ball

plug

and
install
it
in

place

Align
notch
in

3rd
4th
fork

rod

with
check
ball

by

sliding
3rd
4th

fork
rod
as

necessary
See
Figure

MT51

TM368

Fig
MT
51
Installing
3rd
4th

fork
rod

5

Place
reverse
shift
fork
in

reverse

idler

gear

Slide
reverse
fork
rod

through
re

verse
shift
fork
and

adapter
plate
and

secure
with
a
new

retaining
pin

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