Shifter Fork and Rod
Shifter Fork and RodREMOVAL
1. Remove the manual transmission assembly from vehicle.
2. Remove back-up light switch and neutral position switch.
3. Remove transfer case with extension case assembly.
4. Remove transmission case.
5. Removes drive pinion shaft assembly.
6. Remove main shaft assembly.
7. Remove differential assembly.
8. Drive out straight pin with ST, and 5th shifter fork.
ST 398791700 STRAIGHT PIN REMOVER
9. Remove plugs, springs and checking balls.
10. Drive out straight pin, and pull out 3-4 fork rod and shifter fork.
NOTE: When removing rod, keep other rods in neutral. Also, when pulling out straight pin, remove it toward the inside of the case so that it does not hit against the case.
11. Drive out straight pin, and pull out 1 -2 fork rod and shifter fork.
12. Remove outer snap ring, and pull out reverse shifter rod arm from reverse fork rod. Then take out ball, spring and interlock plunger from rod. And then remove rod.
NOTE: When pulling out reverse shifter rod arm, be careful not to let ball pop out of arm.
13. Remove reverse shifter lever.
INSTALLATION
1. Install reverse arm fork spring, ball and interlock plunger to reverse fork rod arm. Insert reverse fork rod into hole in reverse fork rod arm, and hold it with outer snap ring using ST.
NOTE: Apply grease to plunger to prevent it from falling.
ST 399411700 ACCENT BALL INSTALLER
2. Position ball, spring and new gasket in reverse shifter rod hole, on left side transmission case, and tighten checking ball plug.
3. Install 1-2 fork rod into 1-2 shifter fork via the hole on the rear of the transmission case.
4. Align the holes in rod and fork, and new drive straight pin into these holes using ST.
NOTE:
^ Set other rods to neutral.
^ Make sure interlock plunger is on the 3-4 fork rod side.
ST 398791700 STRAIGHT PIN REMOVER
5. Install interlock plunger onto 3-4 fork rod.
NOTE: Apply a coat of grease to plunger to prevent it from falling.
6. Install 3-4 fork rod into 3-4 shifter fork via the hole on the rear of transmission case.
7. Align the holes in rod and fork, and new drive straight pin into these holes.
NOTE:
^ Set reverse fork rod to neutral.
^ Make sure interlock plunger (installing before) is on the reverse fork rod side.
ST 398791700 STRAIGHT PIN REMOVER
8. Install 5th shifter fork onto the rear of reverse fork rod. Align holes in the two parts and new drive straight pin into place.
ST 398791700 STRAIGHT PIN REMOVER
9. Position balls, checking ball springs and new gaskets into 3-4 and 1-2 rod holes, and install plugs.
10. Install differential assembly.
11. Install main shaft assembly.
12. Install drive pinion shaft assembly.
13. Install transmission case.
14. Install transfer case with extension case assembly.
15. Install back-up light switch and neutral position switch.
16. Install the manual transmission assembly to vehicle.
INSPECTION
1. Check the shift shaft and shift rod for damage. Replace if damaged.
2. Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way.
3. Inspect clearance between 1st, 2nd driven gear and reverse driven gear. If any clearance is not within specifications, replace shifter fork as required.
Clearance (a) and (b): 9.5 mm (0.374 inch)
4. Inspect clearance between 3rd, 4th drive gear and coupling sleeve. If any clearance is not within specifications, replace shifter fork as required.
Clearance (a) and (b): 9.3 mm (0.366 inch)
5. Inspect clearance between 5th drive gear and coupling sleeve. If any clearance is not within specifications, replace shifter fork as required.
Clearance (a): 9.3 mm (0.366 inch)
6. Inspect rod end clearances (A) and (B). If any clearance is not within specifications, replace rod or fork as required.
Clearance (A):
3rd-4th to 5th: 0.5 - 1.3 mm (0.020 - 0.051 inch)
Clearance (B):
1st-2nd to 3rd-4th: 0.4 - 1.4 mm (0.016 - 0.055 inch)