Transmission Case
MAJOR COMPONENT (MUA, 4X2):
DISASSEMBLY
Preparation:
- Clean the exterior of the unit with solvent.
- Remove the drain plug from the transmission case and drain the lubricant.
1. Clutch release bearing
- Remove the clutch release bearing from the transmission case.
2. Shift fork
- Remove the snap pin.
- Remove the shift fork pin and shift fork from the fulcrum bridge.
3. Fulcrum bridge
- Remove the fulcrum bridge bolts.
- Remove the fulcrum bridge from the transmission case.
4. Front cover (with oil seal)
- Remove the front cover from the transmission case.
5. Snap ring; counter front bearing
6. Snap ring; top gear bearing
- Use a pair of snap ring pliers to remove the snap ring.
7. Speedometer sensor and speedometer driven gear.
- Remove the speedometer sensor.
- Remove the plate.
- Remove the driven gear bush and driven gear.
NOTE: Apply a reference mark to the driven gear bush before removal.
8. Gear control box assembly
9. Rear cover with oil seal
- Remove the rear cover assembly from the transmission case.
10. 1-2 and 3-4 indicator switch, pin and ball
11. Intermediate plate with gear assembly
12. Transmission case
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse order, noting the following points:
12. Transmission case
11. Intermediate plate with gear assembly
10. 1-2 and 3-4 indicator switch, pin and ball
9. Rear cover with oil seal
- Apply recommended liquid gasket (LOCTITE 17430) or its equivalent to the transmission case, intermediate plate and rear cover fitting surfaces.
- Install the intermediate plate with gear assembly to the transmission case.
- Pull out the top gear shaft until the ball bearing snap ring groove protrudes from the transmission case front cover fitting face. Avoid subjecting the mainshaft to sudden shock or stress.
- Tighten the transmission-rear cover bolts to the specified torque.
Torque: 39 N-m (29 lb-ft)
NOTE:
Notes when tightening the bolt:
- After cleaning the bolt hole, dry it thoroughly with air.
- After cleaning the screw face of a removed bolt or new one, dry it thoroughly. Apply recommended liquid gasket (LOCTITE 242) or its equivalent before tightening it.
8. Gear control box assembly
- Install a new packing.
- Install the harness clips and then tighten four new gear control box bolts to the specified torque.
Torque: 20 N-m (14 lb-ft)
7. Speedometer driven gear and Speedometer sensor
- Install the O-ring to the speedometer driven gear bushing.
- Install the driven gear to the speedometer driven gear bushing.
- Install the speedometer driven gear assembly to the transmission rear cover.
- Install the plate to the transmission rear cover.
Torque: 15 N-m (11 lb-ft)
- Install the speedometer sensor.
Torque: 27 N-m (20 lb-ft)
6. Snap ring; top gear bearing
5. Snap ring; counter front bearing
- Use a pair of snap ring pliers to install the snap rings to the mainshaft and counter shaft.
- The snap rings must be fully inserted into the bearing snap ring groove.
4. Front cover (with oil seal)
Oil seal replacement
- Remove the oil seal from the front cover.
- Apply engine oil to a new oil seal outer circumference.
- Apply recommended grease to the oil seal lip.
- Use the oil seal installer to install the oil seal to the front cover.
Oil seal installer: J-29769
- Install a new packing and front cover to the transmission case.
NOTE:
Take care not to damage the oil seal.
Notes when tightening the bolt:
- After cleaning the bolt hole, dry it thoroughly with air.
- After cleaning the screw face of a removed bolt or new one, dry it thoroughly. Apply recommended liquid gasket (LOCTITE 242) or its equivalent before tightening it.
Tighten six new front cover bolts to the specified torque.
Torque: 25 N-m (18 lb-ft)
3. Fulcrum bridge
- Install the fulcrum bridge to the transmission case.
- Tighten three fulcrum bridge bolts to the specified torque.
Torque: 38 N-m (28 lb-ft)
2. Shift fork
- Apply grease to the pin hole inner circumferences and thrust surfaces.
- Attach the shift fork to the fulcrum bridge by inserting the shift fork pin from the bottom side of the fulcrum bridge.
- Install the washer and snap pin.
1. Release bearing
- Apply grease to the areas shown in the figure.
- Install the release bearing to the shift fork in the proper direction.
NOTE: Ensure release bearing is properly positioned during installation, as shown in the figure.