MT Gear Shift Lever

MT Gear Shift Lever

REMOVAL

5MT
1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Remove the gear shift knob.
4. Remove the console box.





5. Remove the plate assembly from body.
6. Lift-up the vehicle.
7. Remove the rear exhaust pipe and muffler.





8. Remove the heat shield cover. (If equipped)





9. Remove the stay from transmission bracket.





10. Remove the rod from joint.





11. Remove the cushion rubber from body.





12. Extract the spring pin, and then remove the joint.
13. Lower the vehicle.





14. Remove the gear shift lever.

6MT
1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Remove the gear shift knob.
4. Remove the console box front.





5. Remove the boot plate from body.
6. Lift-up the vehicle.
7. Remove the under cover.
8. Remove the rear exhaust pipe and muffler.
9. Remove the crossmember.





10. Remove the snap pin and washer, and then remove the reverse check cable from reverse check lever.
11. Move the transmission to right side, and then remove the joint COMPL, stay bolt and reverse check cable.





NOTE: If the transmission is not moved, the joint COMPL and stay bolt will contact body and damage may occur.





12. Remove the cushion rubber from body.
13. Lower the vehicle.
14. Remove the gear shift lever.

INSTALLATION

5MT
1. Install the joint to the transmission and secure with the spring pin.
2. Insert gear shift lever from room side.





NOTE: After inserting rod and stay, temporarily put them onto transmission mount.

3. Lift-up the vehicle.





4. Mount the cushion rubber on body.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)





5. Connect the rod to the joint.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)





6. Connect the stay to transmission bracket.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)





7. Install the heat shield cover. (If equipped)
8. Install the rear exhaust pipe and muffler.





9. Install the plate assembly to body.
Tightening torque: 7.5 Nm (0.76 kgf-m, 5.5 ft. lbs.)
10. Install console box.

6MT
1. Insert the gear shift lever from room side.

NOTE: After inserting the rod and stay, temporarily put them onto transmission mount.





2. Mount the cushion rubber on body.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)





3. Move the transmission to right side, and then install the joint COMPL and stay.
Tightening torque:
T1: 11.8 Nm (1.2 kgf-m, 8.7 ft. lbs.)
T2: 32 Nm (3.3 kgf-m, 23.6 ft. lbs.)

4. Install the crossmember.
5. Install the reverse check cable end, washer and snap pin to reverse check lever.





NOTE:
^ Take care to install the snap pin in proper direction.
^ Conduct the adjustment of reverse check cable before installation.

6. Install the rear exhaust pipe and muffler.
7. Install the under cover.
8. Install the boot plate.





NOTE: Install the inner boot without any twist.

Tightening torque: 7.5 Nm (0.76 kgf-m, 5.5 ft. lbs.)

9. Install the console box.
10. Check that the gear shift is correctly shifted to each gear.


DISASSEMBLY

5MT





1. Disassemble the lock wire.





2. Remove the rod from lever.





3. Remove the snap ring from bushing B. and then disconnect the stay.
4. Remove the boot from gear shift lever.





5. Remove the bushing and cushion rubber from stay.





6. Remove O-ring, and then disconnect the bushing B.





7. Draw out the spring pin, and then remove the bushing A from gear shift lever.

6MT





1. Remove the spring pin from slider.





2. Remove the slider and spring.





3. Cut the band clip.





4. Remove the reverse check cable from cable plate.





5. Remove the reverse check cable from gear shift assembly.





6. Remove the holder and spring seat.
7. Disassemble the lock wire.





NOTE: Do not reuse the lock wire.





8. Remove the boss from rod.





9. Remove the rod from lever.
10. Separate the rod and inner boot.





11. Remove the snap ring from stay.





12. Separate the gear shift lever and stay.





13. Remove the boot and bushing from gear shift lever.





14. Remove the spring pin, and then remove the bushing and snap ring.





15. Remove the bushing and spacer from boss.





16. Remove the bushing and cushion rubber from stay.

ASSEMBLY

5MT
1. Clean all parts before assembly.





2. Mount the bushing and cushion rubber on the stay.
3. Mount each part; boot, O-ring, bushing A, spacer, bushing B. bushing and spring pin on the gear shift lever.





NOTE:
^ Always use new O-rings.
^ Apply grease [SUNLIGHT 2 (Part No. 003602010 or equivalent] to the inner and side surfaces of the bushing when installing the spacer.

4. Insert the gear shift lever into the boot hole.





5. Install the snap ring and stay to bushing B.





6. Tighten with lock wire to the extent that the boot will not come off.

NOTE: Always use new lock wire.

7. Insert the rod into the boot hole.





8. Connect rod to lever.
Tightening torque: 11.8 Nm (1.2 kgf-m, 8.7 ft. lbs.)
9. Check the swing torque of rod in relation to the gear shift lever.
10. Check that there is no excessive play and that parts move smoothly.

6MT

NOTE:
^ Clean all parts before assembly.
^ Apply NIGTIGHT LYW No.2 grease or equivalent to each parts.





1. Mount the bushing and cushion rubber on the stay.





2. Install the bushing and spacer to boss.
3. Install the snap ring to gear shift lever, and then install the bushing.





NOTE: Apply grease to the bushing.





4. Apply grease to the bushing and O-ring, and then install to the gear shift lever.





5. Apply sufficient grease into the boss, and then install the gear shift lever to stay.





6. Install the washer and snap ring.
7. Insert the gear shift lever and rod into boot hole.





8. Install the rod.
Tightening torque: 11.8 Nm (1.2 kgf-m, 8.7 ft. lbs.)





9. Install the boss to rod.
Tightening torque: 11.8 Nm (1.2 kgf-m, 8.7 ft. lbs.)





10. Install a new lock wire.





NOTE:
^ Install the lock wire to the stay groove.
^ Bend the extra wire to same direction of lock wire winding.





11. Install the holder.
Tightening torque: 1.3 Nm (0.13 kgf-m, 0.96 ft. lbs.)
12. Insert the reverse check cable into boot hole.
13. Insert the reverse check cable into gear shift assembly, and fix with band clip.





NOTE:
^ Cut off the extra band clip.
^ Make sure that the reverse check cable is inserted into gear shift lever assembly without any clearance.





14. Install the seat cushion and spring.





15. Adjust the length between end of cable plate and reverse check cable to 84 mm (3.31 inch), and then tighten the lock nut.
Tightening torque: 6 Nm (0.6 kgf-m, 4.4 ft. lbs.)
16. Fix the slider and reverse check cable end with spring pin.





NOTE: Apply grease to the sliding part of slider.

17. Fix the reverse check cable to clip of stay.





NOTE: Install the reverse check cable to upper side of stay.

INSPECTION
1. Check each part (bushing, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. Repair or replace any defective part. Determine defective parts by comparing with new parts.





^ 5MT





^ 6MT





2. Check the swing torque of the rod in relation of the gear shift lever. If the torque exceeds the specification, replace the bushing or retighten the nuts.
Swing torque: 3.7 N (0.38 (kgf, 0.84 lb) or less