Shifter Fork and Rod
Shifter Fork and RodREMOVAL
1) Remove the manual transmission assembly from vehicle.
2) Prepare the transmission for overhaul.
3) Remove the oil pipe, neutral position switch, back-up light switch and harness.
4) Remove the extension case.
5) Remove the transfer driven gear.
6) Remove the center differential.
7) Remove the oil pump.
8) Remove the transmission case.
9) Remove each gear assembly.
INSTALLATION
1) Install each gear assembly at once.
2) Install the transmission case.
3) Install the oil pump.
4) Install the center differential.
5) Install the transfer driven gear.
6) Install the extension case.
7) Install the oil pipe, neutral position switch, backup light switch and harness.
8) Install the manual transmission assembly to vehicle.
DISASSEMBLY
NOTE:
Discard the removed spring pin and replace it with a new one.
REVERSE SHIFTER FORK
1) Using the ST, remove the reverse fork.
ST 398791700 REMOVER
2) Using the ST, remove the reverse shifter arm.
ST 398791700 REMOVER
1st-2nd, 3rd-4th SHIFTER FORK
1) Using the ST, remove the 3rd-4th shifter fork.
ST 398791700 REMOVER
2) Using the ST, remove the 3rd-4th shifter arm.
ST 398791700 REMOVER
3) Using the ST, remove the 1st-2nd shifter arm and 1st-2nd shifter fork.
ST 398791700 REMOVER
5th-6th SHIFTER FORK
1) Using the ST, remove the 5th-6th shifter fork.
ST 398791700 REMOVER
2) Using the ST, remove the 5th-6th shifter arm.
ST 398791700 REMOVER
SHIFT ARM SHAFT
Using the ST, remove the selector arm.
ST 398791700 REMOVER
STRIKING ROD
1) Remove the reverse interlock block and interlock block from striking rod.
2) Using the ST, remove the reverse interlock arm.
ST 398791700 REMOVER
3) Using the ST, remove the interlock arm.
ST 398791700 REMOVER
ASSEMBLY
REVERSE SHIFTER FORK
1) Using the ST, install the reverse fork.
ST 398791700 REMOVER
NOTE:
Make sure to install the reverse fork and rod in proper direction.
2) Using the ST, install the reverse arm.
ST 398791700 REMOVER
NOTE:
Make sure to install the reverse arm and rod in proper direction.
1st-2nd, 3rd-4th SHIFTER FORK
1) Using the ST, install the 1st-2nd shifter fork.
ST 398791700 REMOVER
NOTE:
Make sure to install the 1st-2nd shifter fork and rod in proper direction.
2) Using the ST, install the 1st-2nd shifter arm.
ST 398791700 REMOVER
NOTE:
Make sure to install the 1st-2nd shifter arm and fork in proper direction.
3) Using the ST, install the 3rd-4th shifter arm.
ST 398791700 REMOVER
NOTE:
Make sure to install the 3rd-4th shifter arm and rod in proper direction.
4) Install the 3rd-4th fork rod into 1st-2nd shifter arm.
5) Using the ST, install the 3rd-4th shifter fork.
ST 398791700 REMOVER
NOTE:
Make sure to install the 3rd-4th shifter fork in proper direction.
5th-6th SHIFTER FORK
1) Using ST, install the 5th-6th shifter arm.
ST 398791700 REMOVER
NOTE:
Make sure to install the 5th-6th shifter arm and rod in proper direction.
2) Using the ST, install the 5th-6th shifter fork.
ST 398791700 REMOVER
NOTE:
Make sure to install the 5th-6th shifter fork and arm in proper direction.
SHIFT ARM SHAFT
Using the ST, install the selector arm.
ST 398791700 REMOVER
NOTE:
Make sure to install the selector arm and rod in proper direction.
STRIKING ROD
1) Using the ST, install the reverse interlock arm and interlock arm.
ST 398791700 REMOVER
NOTE:
^ Make sure to install the reverse interlock arm and rod in proper direction.
^ Make sure to install the interlock arm and rod in proper direction.
2) Install the reverse interlock block and interlock block to striking rod.
NOTE:
Make sure to install the reverse interlock block and interlock block in proper direction.
INSPECTION
1) Check the shift shaft and shift rod for damage. Replace if damaged.
2) Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way.
ADJUSTMENT
SELECTION OF 1st-2nd FORK ROD
NOTE:
^ Perform the following procedures when. Replacing the 1st, 2nd driven gear.
^ Replacing the 1st, 2nd synchro ring assembly.
^ Replacing the adapter plate.
^ Replacing the driven shaft.
^ Replacing the 1st-2nd hub, sleeve assembly.
1) Insert the drive pinion assembly in adapter plate.
NOTE:
Make sure the thrust bearing outer race is not removed and drive pinion is not lift-up.
2) Set the height gauge to adapter plate. Lower the indicator of height gauge to mating surface of adapter plate and case, then set to zero point.
ST 18853AA000 HEIGHT GAUGE
NOTE:
^ Remove the remaining gasket on edge surface with scraper, since the adapter plate is base point of measurement.
^ Do not place the height gauge on shaded area in the figure during measurement.
3) Select the main shaft snap ring.
4) Measure "B1" and "B2" as shown in the figure.
(1) Shift the 1st-2nd sleeve to 1st driven gear side, then press down to the stopper and measure "B1".
NOTE:
^ Set the indicator of height gauge near measuring object, then lock the dial (1) as shown in the figure. Turn dial (2) to set the indicator to edge surface of sleeve 1st side.
^ Measure five points of the sleeve turning every approximately 72°. Round off each two upper and lower measurement value. Use the remaining center value as measurement value.
(2) Set the height gauge indicator upside down.
(3) Shift the 1st-2nd sleeve to 2nd driven gear side, then press up to the stopper and measure "B2".
NOTE:
^ Set the indicator of height gauge near measuring object, then lock the dial (1) as shown in the figure. Turn dial (2) to set the indicator to edge surface of sleeve 2nd side.
^ Perform the measuring procedure with two people, and measure the sleeve lifted up straight.
^ Measure five points of the sleeve turning every approximately 72° apart. Round off each two upper and lower measurement value. Use the remaining center value as measurement value.
(4) According to both measurements, calculate the 1st-2nd sleeve neutral position. Select the fork rod which applies to the calculated value from following equation.
Equation: T = (B 1 + B2)/2
T: 1st-2nd sleeve center position
B1: Height from adapter plate edge to sleeve edge when shifted to 1st gear.
B2: Height from adapter plate edge to sleeve edge when shifted to 2nd gear. [measurement value + 55 mm (2.17 inch)]
NOTE:
The indicator is installed upside down compared to the setting procedure of zero point. Add "d1" [fixing value: 55 mm (2.17 inch)] from the following figure to "B2", to obtain measurement value of "B2".
SELECTION OF 3rd-4th FORK ROD
NOTE:
Perform the following procedures when.
^ Replacing the main shaft.
^ Replacing the 3rd, 3rd to 6th drive gear and bushing.
^ Replacing the 3rd, 3rd to 6th synchro assembly.
^ Replacing the 3rd-4th hub, sleeve assembly.
1) Insert the main shaft assembly in adapter plate.
2) Set the height gauge to adapter plate. Lower the indicator of height gauge to upper surface of snap ring groove, on the upper side of main rear bearing, then set to zero point.
ST 18853AA000 HEIGHT GAUGE
NOTE:
^ Remove the remaining gasket on edge surface with scraper, since the height gauge is set on adapter plate during measurement.
^ Do not put the height gauge on shaded area in the figure during the measurement.
3) Using the height gauge, measure "C1" and "C2" shown in the figure.
(1) Shift the 3rd-4th sleeve to 4th gear side, then press up to the stopper and measure "C2".
NOTE:
^ Set the indicator of height gauge near measuring object, then lock the dial (1)as shown in the figure.
^ Turn dial (2)to set the indicator to edge surface of sleeve 4th side.
^ Perform the measuring procedure with two people, and measure the sleeve lifted up straight.
^ Measure five points of the sleeve turning every approximately 72°. Round off each two upper and lower measurement value. Use the remaining center value as measurement value.
(2) Set the height gauge indicator upside down.
(3) Shift the 3rd-4th sleeve to 3rd drive gear side, then press down to the stopper and measure "C1".
NOTE:
^ Set the indicator of height gauge near measuring object, then lock the dial (1) as shown in the figure. Turn dial (2)to set the indicator to edge surface of sleeve 3rd side.
^ Measure five points of the sleeve turning every approximately 72°. Round off each two upper and lower measurement value. Use the remaining center value as measurement value.
4) According to both measurements, calculate the 3rd-4th sleeve neutral position. Select the fork rod which applies to the calculated value from following equation.
Equation: T = (C1 + C2)/2
T: 3rd-4th sleeve center position
C1: Length from main shaft rear bearing snap ring groove to sleeve edge when shifted to 3rd gear. [measurement value +55 mm (2.17 inch)]
C2: Length from main shaft rear bearing snap ring groove to sleeve edge when shifted to 4th gear.
NOTE:
The indicator is installed upside down compared to the setting procedure of zero point. Add "d1" [fixing value: 55 mm (2.17 inch)] from the following figure to "C1", to obtain measurement value of "C1".
SELECTION OF 5th-6th FORK ROD
NOTE:
Perform the following procedures when.
^ Replacing the main shaft.
^ Replacing the 3rd to 6th drive gear and bushing.
^ Replacing the 3rd to 6th synchro ring assembly.
^ Replacing the 3rd-4th hub, sleeve assembly.
^ Replacing the 5th-6th hub, sleeve assembly.
1) Insert the main shaft assembly in adapter plate.
2) Set the height gauge to adapter plate. Lower the indicator of height gauge to upper surface of snap ring groove, or the upper side of main rear bearing. Then set to zero point.
ST 18853AA000 HEIGHT GAUGE
NOTE:
^ Remove the remaining gasket on edge surface with scraper, since the height gauge is set on adapter plate during measurement.
^ Do not place the height gauge on shaded area in the figure during the measurement.
3) Using the height gauge, measure "D1" and "D2" shown in the figure.
(1) Shift the 5th-6th sleeve to 6th main gear side, then press up to the stopper and measure "D2".
NOTE:
^ Set the indicator of height gauge near measuring object, then lock the dial (1)as shown in the figure. Turn dial (2)to set the indicator to edge surface of sleeve 6th side.
^ Perform the measuring procedure with two people, and measure the sleeve lifted up straight.
^ Measure five points of the sleeve turning every approximately 72°. Round off each two upper and lower measurement value. Use the remaining center value as measurement value.
(2) Set the height gauge indicator upside down.
(3) Shift the 5th-6th sleeve to 5th main gear side, then press down to the stopper and measure "D1".
NOTE:
^ Set the indicator of height gauge near measuring object, then lock the dial (1)as shown in the figure. Turn dial (2)to set the indicator to edge surface of sleeve 5th side.
^ Measure five points of the sleeve turning every approximately 72°. Round off each two upper and lower measurement value. Use the remaining center value as measurement value.
4) According to both measurements, calculate the 5th-6th sleeve neutral position. Select the fork rod, which applies to the calculated value from following equation.
Equation: T = (D1 + D2)/2
T: 5th-6th sleeve center position
D1: Length from the shaft rear bearing snap ring groove to sleeve groove edge when shifted to 5th gear. [measurement value + 55 mm (2.17 inch)]
D2: Length from main shaft rear bearing snap ring groove to sleeve groove edge when shifted to 6th gear.
NOTE: The indicator is installed upside down compared to the setting procedure of zero point. Add "d1" [fixing value: 55 mm (2.17 inch)] from the following figure to "D1", to obtain measurement value of "D1".
SELECTION OF REVERSE FORK ROD
NOTE:
Perform the following procedures when.
^ Replacing the reverse idler gear.
^ Replacing the reverse idler gear No. 2.
^ Replacing the adapter plate.
^ Replacing the base.
1) Insert the reverse idler gear assembly in adapter plate.
2) Tighten the base COMPL fixing bolt.
3) Set the height gauge to adapter plate. Lower the indicator of height gauge to mating surface of adapter plate and case, then set to zero point.
ST 18853AA000 HEIGHT GAUGE
NOTE:
^ Remove the remaining gasket on edge surface with scraper, since the adapter plate is base point of measurement.
^ Do not place the height gauge on shaded area in the figure during measurement.
4) Press the reverse sleeve to reverse side idler gear No. 2, then measure "T".
NOTE:
^ Set the indicator of height gauge near measuring object, then lock the dial (1)as shown in the figure. Turn dial (2)to set the indicator to edge surface of reverse sleeve side.
^ Measure five points of the sleeve turning every approximately 72°. Round off each two upper and lower measurement value. Use the remaining center value as measurement value.
5) According to measurement, calculate the reverse sleeve neutral position. Select the fork rod which applies to the calculated value from following equation.
Equation: T + 4.8 mm (0. 189 inch)
