Upper Case and Shifter
Manual Transmission Upper Case and Shifter Disassembly and AssemblyDisassembly
1) Remove back up light switch (2) and locating spring bolts (3) from upper case (1).
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 (1) by removing spring pin.
Special tool (A): 09922-85811
NOTE: Make sure that remaining gear shift shafts are all neutral position when removing a gear shift shaft.
5) Take out rubber plug and 2 interlock balls from case.
6) Remove interlock pin from high speed gear shift shaft.
Reassembly
Interlock system is as shown in the following figure.
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 is different from other spring pins in length. It is longer than other spring pins.
^ When pressing gear shift fork 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 (2), insert it into case and set fork with spring pin and then put in interlock ball (3).
NOTE:
^ Note that high speed gearshift shaft (2) can't be inserted unless reverse gearshift shaft (1) Is placed at neutral position.
^ When inserting high speed gear shift shaft (2), 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 plug (2) and fit it in.
4) Confirm that interlock system operates property by checking the followings.
^ When shifted to low position (or 2nd position), shifting of 3rd/4th speed or 5th/Rev speed is not available.
^ When shifted to reverse position (or 5th position), shifting of 1st/2nd speed or 3rd/4th speed is not available.
5) Install locating balls and locating springs and then set washers and bolts.
Manual Transmission Upper Case and Shifter Inspection
Check for the following items
^ Using feeler gauge, check clearance between fork (2) and sleeve (1) and replace those parts if it exceeds limit of 1.0 mm (0.039 inch).
^ 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.
^ Check gear shift shaft for excessive wear and correct or replace a necessary.
^ Check free length of each locating spring (1) and replace if it is below service limit.
Manual Transmission Rear Case Inspection
Check for the following items
^ If oil seal leaks and/or its lip is excessively hardened, replace it with new one and at the same time, check main shaft where oil seal contacts. If contacting surface is not smooth, correct or replace.
^ Apply grease to oil seal lip portion.
^ If oil leakage exists at counter shaft end plug (2), replace it.