Overhaul

1. Manual Transmission and Differential





2. Transmission Gear Oil Recommended Oil








3. Transmission Case Assembly








4. Drive Pinion Assembly
Preload adjustment of thrust bearing
Starting torque: 0.3 - 0.8 Nm (0.03 - 0.08 kg-m, 0.2 - 0.6 ft. lbs.)








5. Reverse Idler Gear
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (Left-Hand) wall clearance: 6.0 - 7.5 mm (0.236 - 0.295 inch)
After installing a suitable reverse shifter lever, adjust reverse idler gear to transmission case wall clearance to within O to 0.5 mm (0 to 0.020 inch) using washers.











6. Shifter Fork and Rod
Select suitable shifter forks so that both coupling sleeve and reverse driven gear are positioned in the center of their synchromesh mechanisms.
Rod end clearance
A: 1st-2nd-3rd-4th: 0.4 - 1.4 mm (0.016 - 0.055 inch)
B: 3rd-4th-5th: 0.5 - 1.3 mm (0.020 - 0.051 inch)











7. Transfer Case
Neutral position adjustment








8. Extension Assembly
Thrust washer (52 x 61 x t) to ball bearing side clearance: 0.05 - 0.30 mm (0.0020 - 0.0118 inch)
Thrust washer to center differential side clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 inch)








9. Front Differential
Bevel gear to pinion backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
Pinion shaft to axle drive shaft clearance: 0 - 0.25 mm (0 - 0.0098 inch)





TORQUE