Part 2 2WD

UPPER CASE AND SHIFTER
DISASSEMBLY





1. Remove back up light switch (1) and locating spring bolts (2).





2. Take out locating springs and locating balls.
3. Remove 2 spring pins and pull out low speed gear shift shaft (3) and high speed gear shift shaft (2) in that order.
4. Pull out reverse gear shift shaft (1), then disconnect fork from shaft removing spring pin.

NOTE: Make sure that remaining gear shift shafts are all neutral position when removing a gear shift shaft.

Special Tool
(A): 09922-85811

5. Take out rubber plugs and 2 interlock balls from case.
6. Remove interlock pin from high speed gear shift shaft.

INSPECTION





1. Using feeler gauge, check clearance between fork (if) and sleeve ~ and replace those parts if it exceeds limit.

Clearance "a": Maximum 1.0 mm (0.039 inch)

2. Insert each gear shift shaft into case and check that it moves smoothly. If it doesn't, correct by using oilstone, reamer or the like.





3. Check gear shift shaft for excessive wear and correct or replace as necessary.





4. Check free length of each locating spring and replace if it is below service limit.

Free length:
Standard 27.0 mm (1.063 inch)
Service limit 24.0 mm (0.945 inch)

REASSEMBLY





Interlock system is as shown in figure. Assemble its parts according to procedure as described.

(1)Locating ball
(2)Rubber plug
(3)Reverse gear shift shaft
(4)Interlock ball
(5)Interlock pin
(6)High speed gear shift shaft
(7)Low speed gear shift shaft





1. With fork installed to reverse gear shift shaft (1), install it into case and put in interlock ball (2).





NOTE:
^ Reverse gear shift fork spring pin (1) is different from other pins (2) in length. It is longer than other pins.





^ When pressing spring pin (1) into reverse gear shift fork (2), do not allow to go all the way in, but leave its end protruded as much as the length shown in figure.





2. With interlock pin fit to high speed gear shift shaft (1), insert it into case and set fork with spring pin and then put in interlock ball (2).

NOTE:
^ Note that high speed gear shift shaft can't be inserted unless reverse gear shift shaft (3) is placed at neutral position.
^ When inserting high speed gear shift shaft, use care not to drop interlock pin.





3. With both reverse and high speed gear shift shafts placed at neutral position, insert low speed gear shift shaft (1) into case and fix fork with spring pin. Then apply sealant to rubber plugs (2) and fit them in.

"A": Sealant 99000-31110





4. Confirm that interlock system operates properly by checking the following.
1) When shifted to low position (or 2nd position), shifting of 3rd/4th or 5th/Rev. position is not available.





2) When shifted to reverse position (or 5th position), shifting of 1st/2nd or 3rd/4th position is not available.





5. Install locating balls and locating springs and then set washers and bolts.

Tightening Torque
(a): 28 Nm (2.8 kg-m, 20.0 ft. lbs.)

EXTENSION CASE
DISASSEMBLY





1. Remove oil seal.
2. Remove select return spring bolts (2) and then springs (3) and (4) and guide pins (5).
3. Remove speedometer driven gear case assembly (6).

REASSEMBLY
1. Install oil seal.
2. After applying grease, install select guide pins, select return springs and spring bolts and torque them to specification.

"A": Grease 99000-25010

Tightening Torque
(a): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)

After installing, check to make sure that each pin moves smoothly.
3. Install speedometer driven gear case assembly to extension case (1).

ASSEMBLING UNIT





1. Put main shaft-input shaft assembly (1) into lower case (2), apply oil to component parts and check for proper engagement (smooth rotation) with counter shaft.
2. After cleaning mating surfaces of both cases, coat mating surface of upper case (3) with sealant evenly and put it over lower case. At this time, all gears and forks should be set to neutral position.

"A": Sealant 99000-31110





3. Place bolts at their positions and check to make sure that their height from case surface is the same before tightening them. Also, check clamp position and torque them to specification.

Tightening Torque
(a): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)





4. Apply sealant "A" to mating surface of input shaft bearing retainer (1) and its bolts (2), then install them.

"A": Sealant 99000-31110

Tightening Torque
(b): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)





5. Install clutch housing (1) and torque its bolts (2) to specification.

Tightening Torque
(c): 50 Nm (5.0 kg-m. 36.5 ft. lbs.)

6. Install release bearing.





7. Clean mating surfaces of both cases, coat mating surface of extension case with sealant evenly and mate it with transmission itself.

"A": Sealant 99000-31110





8. Install extension case bolts and torque them to specification.

Tightening Torque
(d): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)





9. Install back up light switch (1).

Tightening Torque
(e): 20 Nm (2.0 kg-m, 14.5 ft. lbs.)

10. Install gear shift lever case temporarily to confirm switch function by checking the following.
1) Back up light switch should conduct when gear shift control lever (2) is at reverse position.
11. After confirming switch function, remove gear shift lever.





12. Clamp wiring harness and breather hose as they are.