7B–4MANUAL TRANSMISSION
Diagnosis
ConditionPossible causeCorrection
Abnormal noiseFlywheel pilot bearing wornReplace
Bearings worn or broken (Mainshaft,
counter shaft, and transfer shaft)Replace
Gear tooth contact surfaces worn or
scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)Replace
Splines worn (Mainshaft,
synchronizer clutch hub)Replace
Gear or bearing thrust face seizedReplace
Lack of backlash between meshing
gearsReplace
Hard ShiftingImproper clutch pedal free playReadjust
Change lever sliding portions wornRepair or replace
Regrease
Shift block, shift rod and/or control
box sliding faces wornReplace
Shift arm and synchronizer sleeve
groove wornReplace worn parts
Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)Replace worn parts
Synchronizer parts wornReplace
Walking or Jumping out of gearDetent ball wornReplace
Detent spring weakened or brokenReplace
Shift rod and/or control box sliding
faces wornReplace
Shift arm and synchronizer sleeve
groove wornReplace worn parts
Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)Replace worn parts
Bearings worn or brokenReplace
Splines worn (Mainshaft,
synchronizer hub)Replace
Synchronizer spring weakened or
brokenReplace
Oil leakageLoose drain plug(s) and/or filler
plug(s)Tighten
Replenish oil
Defective or improperly installed
gasket(s)Replace
Oil seal worn or scratchedReplace
7B–20MANUAL TRANSMISSION
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Legend
(1) Release Bearing and Shift Fork
(2) Clutch Housing
(3) Front Cover
(4) Snap Ring
(5) Snap Ring
(6) 1st and 2nd Switch
(7) Drain Plug
(8) Backup Light Switch
(9) Transmission Case(10) Filler Plug
(11) Gear Control Rod
(12) Reverse Restrict Pin
(13) Oil Receiver Pipe
(14) Transfer Adapter
(15) Plug (6VE1) or Neutral Switch (4JX1)
(16) Gear Control Box
(17) Shift Lever Housing
(18) Oil Seal
(19) Plug
7B–64MANUAL TRANSMISSION
6. Check that the top gear shaft and mainshaft
rotate.
36. Install the transfer adapter.
1. Clean up the fitting surface.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown.
NOTE:
Don’t dry the liquid gasket.
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3. Using a plastic hammer, tap the transfer adapter
and attach it to the intermediate plate.
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4. Using 10 bolts, install the transfer adapter.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
NOTE:
Tighten the all bolts evenly.
Don’t damage the lip of the oil seal.
Install the wire clamp (9) to the transfer adapter.
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37. Install the gear control box.
1. Align the projection of the shift lever housing to
the shaft rod groove, and install the gear control
rod.
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