5MT
REMOVAL1) Remove the manual transmission assembly from the vehicle.
2) Remove the back-up light switch and the neutral position switch.
3) Remove the transfer case together with the extension case assembly.
4) Remove the transmission case.
5) Remove the drive pinion shaft assembly.
6) Remove the main shaft assembly for single-range.
7) Remove the front differential assembly.
8) Drive out the straight pin by tapping with the ST, and remove the 5th shifter fork.
ST 398791700 STRAIGHT PIN REMOVER 2
9) Remove the plugs, springs and check balls.
10) Drive out the straight pin by tapping with the ST, and remove the 3rd - 4th fork rod and shifter fork.
NOTE:
^ When removing the rod, keep other rods in neutral.
^ When removing the straight pin, remove it toward the inside of case so that it does not hit against the case.
ST 398791700 STRAIGHT PIN REMOVER 2
11) Drive out the straight pin by tapping with the ST, and remove the 1st - 2nd fork rod and shifter fork.
ST 398791700 STRAIGHT PIN REMOVER 2
12) Remove the snap ring (outer), and pull out the reverse fork rod from the reverse fork rod arm. Then take out the ball, spring and interlock plunger from the reverse fork rod arm. And then remove the rod.
NOTE:
When pulling out the reverse fork rod arm, be careful not to let the ball pop out of arm.
13) Remove the reverse shifter lever.
INSTALLATION
1) Install the spring and ball to the reverse fork rod arm, and press in the ST.
ST 399411700 ACCENT BALL INSTALLER
2) Install the reverse fork rod through the hole on the rear of the transmission case. Press out the ST using the reverse fork rod, and fix with outer snap ring.
3) Install the interlock plunger to reverse fork rod arm.
NOTE:
Apply grease to the plunger to prevent it from falling.
4) Position the ball, spring and gasket in the reverse fork rod hole on the left side of transmission case, and tighten the checking ball plug.
NOTE:
Use a new gasket.
Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)
5) Install the 1st-2nd fork rod to the 1st-2nd shifter fork through the hole on the rear of the transmission case.
NOTE:
^ Set other rods to neutral.
^ Check that the positions of interlock plunger is correct.
6) Align the holes in the rod and the fork, and drive in the straight pin using the ST.
NOTE:
Use a new straight pin.
ST 398791700 STRAIGHT PIN REMOVER 2
7) Install the interlock plunger (thin) onto the 3rd-4th fork rod.
NOTE:
Apply grease to the plunger to prevent it from falling.
8) Install the 3rd-4th fork rod to the 3rd-4th shifter fork and reverse fork rod arm through the hole on the rear of the transmission case.
9) Align the holes in the rod and the fork, and drive the straight pin into these holes.
NOTE:
^ Use a new straight pin.
^ Set other fork rods to neutral.
^ Check that the positions of interlock plunger is correct.
ST 398791700 STRAIGHT PIN REMOVER 2
10) Install the 5th shifter fork onto the rear of reverse fork rod. Align the holes in the two parts and drive straight pin into the specified place.
NOTE:
Use a new straight pin.
ST 398791700 STRAIGHT PIN REMOVER 2
11) Position the balls, checking ball springs and gaskets to the 3rd-4th fork rod and 1st-2nd fork rod holes, and install plugs.
NOTE:
Use a new gasket.
Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)
12) Install the front differential assembly.
13) Install the main shaft assembly for single-range.
14) Install the drive pinion shaft assembly.
15) Install the transmission case.
16) Install the transfer case together with the extension case assembly.
17) Install the back-up light switch and the neutral position switch.
18) Install the manual transmission assembly to the vehicle.
INSPECTION
1) Check the fork and rod for damage. Replace if it is damaged.
2) Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
3) Inspect the clearance between 1st, 2nd driven gear and reverse driven gear. If any clearance is not within specifications, replace the shifter fork as required.
Clearance (a) and (b):
9.5 mm (0.374 in)
4) Inspect the clearance between the 3rd, 4th drive gear and the coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.
Clearance (a) and (b):
9.3 mm (0.366 in)
5) Inspect the clearance between 5th drive gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.
Clearance (a):
9.3 mm (0.366 in)
6) Inspect the rod end clearances (A) and (B). If any clearance is not within specifications, replace the rod or fork as required.
Clearance (A):
3rd-4th - 5th
0.5 - 1.3 mm (0.020 - 0.051 in)
Clearance (B):
1st-2nd - 3rd-4th
0.4 - 1.4 mm (0.016 - 0.055 in)
