3.

TRANSMISSION

SECTION 3

TRANSMISSION
1. INTRODUCTION ...................................................................................................................... 3

2. GENERAL DESCRIPTIONS
2-1. MAIN SPECIFICATIONS ................................................................................................... 4
2-2. GEAR CONTROL PARTS ................................................................................................. 6
2-3. EXPLODED VIEW OF GEARSHIFT CONTROL PARTS .............................................. 12
2-4. INSPECTION AND MAINTENANCE ............................................................................... 15
2-5. SERVICING ..................................................................................................................... 17
2-6. TIGHTENING TORQUE ................................................................................................. 20
2-7. DISASSEMBLY AND REASSEMBLY ............................................................................. 22

3. TRANSMISSION CASE ....................................................................................................... 27

4. QUADRANT BOX ................................................................................................................. 29

5. TRANSMISSION ASSEMBLY (K805) ................................................................................. 39

6. TRANSMISSION ASSEMBLY (K1406/K806) ..................................................................... 60

7. TRANSMISSION ASSEMBLY (T9S6, T10S6, T15S6, T16S6) ........................................ 74

8. TRANSMISSION (T14S10) .................................................................................................. 88

9. TRANSMISSION (ZF16S 151/ 221) .................................................................................. 101

10. DIAGNOSIS AND TROUBLESHOOTING PROCEDURES .......................................... 155

11. SPECIAL TOOLS ............................................................................................................. 156

1
3. TRANSMISSION

2
 3. TRANSMISSION

1. INTRODUCTION
The transmission is mounted to the rear of the engine and is designed to allow the car to move forward
and in reverse. If also has a neutral position. In this position, the engine can run without applying power
to the drive wheels.
Therefore, although there is input to the transmission when the vehicle is in neutral, there is no output
from transmission because the driving gears are not engaged to the shaft.
A manual transmission is an assembly of gears and shafts that transmits power from the engine to the
drive axle and changes in gear ratios are controlled by the driver.
By moving the shift lever on a manual transmission and depressing the clutch pedal, various gear and
speed ratios can be selected. The gears in a transmission are selected to give the driver a choice of
booth speed and torque.

Based on T10 TRANSMISSION

Synchromesh 3rd 2rd

(key type) Reverse
5th 4th 1st
Clutch housing Upper
gearshift Gearshift
Gear shift rail fork Lower gearshift
Synchromesh (pin type)

Parking brake

Pilot bearing
5th 4th Reverse 1st 6st
3rd 2nd
1st
Mainshaft 4th
3rd 5th
2nd
Reverse
6th
Drive pinion

Counter shaft
Extension housing

Reverse shaft
Synchromesh (key type)
Release fork
Constant

TM1490

3
 Model T9S6 T10S6 K1406 T14S10 T15S6 T16S6
Advance 6 position 10 16 16
Type
Reverse 1 position 2 2 2
Front: Synchro mesh type
Gear mesh type
3. TRANSMISSION

Rear: Constant mesh type

Fill capacity (L) 12.5(13.5) 14 (15) 16 (General purpose:16.2) 18 (19) 18(19)

207(dump: 240) 277(dump: 310)
–

Weight (kg) 379(mixer: 353) 380(dump:395) 360(dump:380)

L H L H
1st 6.597 7.077 6.608 7.263
9.555 7.428 6.744 7.263
G
e 2nd 4.207 4.100 4.184 4.664 3.625 4.207 4.207
2-1. MAIN SPECIFICATIONS

a 3rd 2.432 2.370 2.580 2.122 2.526 2.526

2.730
r
4th 1.617 1.576 1.618 1.658 1.289 1.569 1.569
2. GENERAL DESCRIPTIONS

r 5th 1.000 1.000 1.000 1.000 0.777 1.000 1.000

a
6th 0.763 0.744 0.709 – – 0.746 0.699 0.699
t

4
i 7th – – – – – - - –
o 8th – – – – – - - –
Reverse 6.897 6.720 7.004 7.980 6.204 6.857 6.857
Type Side type
Max.
torque (kgf·m/rpm) 30/1,000 40/1,000 50/1,000

P H⇒1:1.092
Reduction 1:1.231 1:1.2 1:1.201 1:1.207
T Ratio to L⇒1:1.405
O engine
speed – – –
Speed 0.833 – 0.832

Rotating direction Reverse

 Model K1406 ZF16S-151 ZF16S-221 MD3060 HD4560 ZF12AS2301
Advance 6 position Advance 16 position Advance 16 position Advance 6 position Advance 6 position Advance 12 position
Type
Reverse 1 position Reverse 2 position Reverse 2 position Reverse 1 position Reverse 1 position Reverse 2 position

Front: Synchro mesh type

Gear mesh type
Rear: Constant mesh type

Fill capacity (L) 16(PTO:16.2) 11 13 27 30 11

Weight (kg) 380 295 330 260 495 -

L H L H L H
1st 6.608 3.487 4.7
13.80 11.54 13.80 11.54 12.33 9.59
G
e 2nd 4.184 9.49 7.93 9.49 7.93 1.864 2.21 7.44 5.78
a 3rd 2.580 6.53 5.46 6.53 5.46 1.409 1.53 4.57 3.55
r
4th 1.618 4.57 3.82 4.57 3.82 1 1 2.70 2.10
r 5th 1.000 3.02 2.53 3.02 2.53 0.75 0.76 1.63 1.27
a
6th 0.709 2.08 1.74 2.08 1.74 0.65 0.67 1.00 0.78
t

5
i 7th – 1.43 1.20 1.43 1.20 – – – –
o 8th – 1.00 1.00
0.84 0.84 – – – –
Reverse 7.004 12.92 10.80 12.92 10.80 5.027 5.55 11.41 8.88
Type Side type
Max. –
torque (kgf·m/rpm) 40/1,000 102/1,500 – –
P Reduction
1:0.832 – – – – –
T Ratio to
O engine
speed Speed – – – –
– –

Rotating direction
3. TRANSMISSION
3. TRANSMISSION

2-2. GEAR CONTROL PARTS

2-2-a. TRANSMISSION CONTROL STRUCTURE AND FIXING TORQUE
(kgf.m)

DE12TIS/ DE08TIS Engine (K805P/ K1406Q/ T10/ T14S10 Transmission)

0.6~1.1
(K805, T15S6, T9S6,
K1406Q, T10S6 Transmission)
1.2~2.3

6.2~9.3
1.4~2.6 (Mixer:13.2~20.8)
(K805P, T14S10, T9S5 Transmission)

7.2~10.6

DE12TIS Engine (ZF16S151/221 Transmission) TM2083

1.2~2.3

1.4~2.6 13.8~20.8

7.2~10.6

TM2085

6
 3. TRANSMISSION

(kgf.m)

DV15T Engine (K1406 Transmission)

1.2~2.3

1.4~2.6 13.8~20.8

7.2~10.6

DV15T Engine (ZF16S151/221 Transmission)

0.6~1.1

1.2~2.3

1.4~2.6
13.8~20.8

7.2~10.6

TM2086

7
3. TRANSMISSION

(kgf.m)

DV15TIS Engine (ZF16S151/221- Telescopic T/M)

0.6~1.1

3.2~5.4
1.2~2.3
3.2~5.4

DV15TIS Engine (T16S6 Transmission)

1.2~2.3

3.2~5.4

2.8~4.7

TM5860

8
 3. TRANSMISSION

(kgf.m)
DDC Engine (ZF16S151/221 Transmission)

1.2~2.3

1.2~2.3

3.2~5.4

14~18

14~18
TM5820

(kgf.m)
C8.3-300 Engine & T14S10(RHD)

1.4~2.6
1.4~2.6

7.2~10.6

TM5821

9
3. TRANSMISSION

2-2-b. DISASSEMBLY

2
1

7
13

14
9
12 8
11
10

15
16
TM2080

1. Knob 9. Distance
2. Flange nut 10. Bolt
3. Boot 11. Washer
4. Boot, (inner) 12. Spring
5. Retainer cover 13. Rod assembly(shift)
6. Flange bolt 14. Lock nut
7. Change lever assembly 15. Rod assembly(select)
8. Cushion rubber 16. Lock nut

10
 3. TRANSMISSION

ONE-ROD CHANGE LEVER

2
16
17
4

14 11
9

19 12
10
18

7
15 13

TM3510

1. Knob assembly 12. Bush-change lever

2. Pattern 13. Bolt
4. Flange nut 14. Nut
5. Boot 15. Needle bearing assembly
6. Boot(inner) 16. Spring washer
7. Retainer cover 17. Plain washer
8. Flange bolt 18. Bolt-spring(with washer)
9. Change lever assembly 19. Plain washer
10. Bracket change lever mounting
11. Bracket change lever mounting

11
 3. TRANSMISSION

Relay lever assembly - 1st

K805, K1406, T10S6, T14S10

Rod assembly-1st shift

Ball seat
Return spring

12
Idler assembly

Rod assembly-2nd shift

Relay lever
Rod assembly-1st select assembly-2nd
2-3. EXPLODED VIEW OF GEARSHIFT CONTROL PARTS

Rod assembly-2nd select

Rod assembly-Idler shift

TM2090
 3. TRANSMISSION

ZF 16S-151/221 TRANSMISSION

Relay lever A-1st

t
e lec
r ds
A -3
R od

Ro
dA Relay lever A-2nd Relay lever A-3rd
-1s
ts
Ro hif
dA t
-1s
ts
ele
ct

Ro
dA
-2n
ds
Idler A hif
t
Ro
dA
-2n
ds
ele
ct

Ro
dA
-Id
ler
sh
ift

Select lever-ZF

Bush
Lock plate

TM3516

13
3. TRANSMISSION

TELESCOPIC TRANSMISSION

Rod complete-telescopic

Spring-release
r ter
in ne ou
A- d A-
d
Ro Ro
Relay lever complete

Lever-lock

Ball joint A
Bracket A- T/M Tip

Shift lever A

TM3518

14
 3. TRANSMISSION

2-4. INSPECTION AND MAINTENANCE

2-4-a. POWER TRAIN STEP
Select
2-link type
Select Left and right travel of change lever Forward
and backward travel of select control rod “A”
Angle motion at bracket “B” Forward and
backward travel of select control rod “C”
Selection of shift rod with rotation angle motion
Shift
D of T/M side.
B Shift
Tilt
center T/M Shift
Select
C TM2120 Forward and backward travel of change lever
Forward and backward travel of shift control rod
“A” Angle motion at bracket “B” Forward and
backward travel of shift control rod “D” Gear
insertion by forward and backward travel of the
fork connected to the selected shift rod of T/M
side.
2-4-b. MAINTENANCE OF TRANSMISSION SYSTEM
Adjust control rod as follows, when the gear control is hard and free play is excessive:

Position of
NO HOW TO OPERATE
cab tilt
Assemble all of the parts for T/M control(however, 8-ton and 39-ton tractors
1
should remain with the return spring removed.
Up
2 Loosen the length adjust nut for the first select rod and first shift rod.

Rotate the first shift rod and first select rod from the front of the vehicle
3 to make the same length so that the JIG can be inserted into the JIG Down
check hole on the first relay, and then remove the JIG.
Tighten the length adjust nut for the first select rod and first shift.
4 Up
(Assembly of return spring)

Inserting direction

First select rod

Front View
First shift rod TM2131

15
3. TRANSMISSION

JIG check hole

Adjust by rotating the rods

Length adjust nut

Side View

TM2132

2) Adjust the length of 1st select and shift rod so that the change lever assembly and two levers con-
necting 1st select and shift rod should be vertical. If these two levers are adjusted vertically, the
change lever knob is positioned 30mm at left, rearward(toward driver). Change lever knob adjusting
steps are as follows(T/M in neutral)
(1) Knob, inclined to left or right: Adjust the length of change lever select rod.
(2) Knob, inclined forward: Shorten the length of change lever shift rod.
(3) Knob, inclined reward: Extend the length of change lever shift rod.

Knob

Change lever select rod

Lever
Change lever shift rod
TM2150

Caution
1) Periodically check the tightening condition of ball joint and tightening nuts and retighten them to avoid malfunction of
transmission gear shifting because twin-link type has many ball joints and tightening nuts.
2) Check and repair wear of related parts frequently to avoid malfunction of transmission gear shifting possibly due to
wear of moving parts such as bush, especially in the case of vehicles that are operated many mileage.

16
 3. TRANSMISSION

2-5. SERVICING
Change of transmission oil
Model Fill capacity(L)
K805 9.8 (PTO:11.3)
K806 11.2
Supply plug K1406 16 (PTO:16.2)
T9S5 10 (PTO:11)
T9S6 12.5 (PTO:13.5)
Drain plug T10S6 14 (PTO:15)
TM0010 T14S10 18 (PTO:19)
T15S6/T16S6 17 (PTO:18)
ZF16S-151 11
ZF16S-221 13
ZF16AS2301 11
MD3060 19
HD4560 30

Grease up the gear shift control parts.

TM0020

Transmission lever

Radiator

TM0030

OIL SPECIFICATIONS AND VISCOSITY CHART

• Oil specifications
Item Oil specifications
Gear oil API GL-4(SAE80W90) : K805, K806, K1406, T10S6,
Transmission T9S5, T9S6, T14S10, T15S6, T16S6
API GL-4(SAE85W140) : Thermostat - open 71'c
Engine oil API CD/CE/CF/SF/SG(SAE 30) : ZF T/M

Gearshift control box Multi-purpose type grease NLGI No. 0

17
3. TRANSMISSION

GEAR OIL VISCOSITY CHART

GEAR OIL VISCOSITY CHART - AMBIENT TEMPERATURE

Single grade SAE 80W SAE 140

SAE 85W

SAE 90

Ambient -30°C -25°C -15°C 0°C 10°C 20°C 30°C

temperature (-20°F) (-10°F) (0°F) (32°F) (50°F) (70°F) (90°F)

Multi grade SAE 80W-90

SAE 80W-140

SAE 85W-140

SAE 75W-80

TM0040

18
 3. TRANSMISSION

• Gear shift control rod (After cab tilting cab

lower port )

MTC0490

• Gear shift control rod (Frame port )

MTC0500

• Spring pin and shackle pin

MTC0510

19
3. TRANSMISSION

2-6. TIGHTENING TORQUE

TIGHTENING TORQUE FOR MAJOR PARTS

1 5

3
8

6 7

TM00280

1. Bolts for clutch housing and fly- 5. Front cover lock bolt
wheel housing 6. Reverse gear shaft lock bolt
2. Bolt and nut for clutch housing and 7. Speedometer driven gear housing
transmission case lock bolt
3. Bolt rear case to transmission case 8. Flange nut
4. Bolt and nut parking brake to rear cover

The above bolts and nuts should be tightened according to the torques
* as specified on the following page.

20
 3. TRANSMISSION

TIGHTENING TORQUE FOR SPECIAL BOLTS

(kgf·m)

Bolt identification
7 9
Bolt diameter 7T 9T
x pitch(mm) High carbon steel Alloy steel

6 x 1.0 0.6~1.0 –
8 x 1.25 1.4~2.3 2.1~3.1
10 x 1.25 3.5~4.7 4.7~6.4
12 x 1.25 7.6~9.3 9.5~11.6
14 x 1.5 11.6~14.2 14.2~17.4
16 x 1.5 17.0~20.8 20.1~24.5

TIGHTENING TORQUE FOR STANDARD BOLTS

(kgf·m)

Bolt identification
4 7 9
Bolt diameter 4T 7T 9T
x pitch(mm) Low carbon steel High carbon steel Alloy steel

6 x 1.0 0.4~ 0.8 0.5~1.0 –

8 x 1.25 0.8~1.8 1.2~2.3 1.7~3.1
10 x 1.25 2.1~3.5 2.8~4.7 3.8~6.4
* 10 x 1.5 2.0~3.4 2.8~4.6 3.7~6.1
12 x 1.25 5.0~7.5 6.2~9.3 7.7~11.6
* 12 x 1.75 4.6~7.0 5.8~8.6 7.3~10.9
14 x 1.5 7.8~11.7 9.5~14.2 11.6~17.4
* 14 x 2.0 7.3~10.9 9.0~13.4 10.9~16.3
16 x 1.5 10.6~16.0 13.8~20.8 16.3~24.5
* 16 x 2.0 10.2~15.2 13.2~19.8 15.6~23.4
18 x 1.5 15.4~23.0 19.9~29.9 23.4~35.2
20 x 1.5 21.0~31.6 27.5~31.3 32.3~48.5
22 x 1.5 25.6~42.2 37.0~55.5 43.3~64.9
21 x 2.0 36.6~55.0 43.9~72.5 56.5~84.7

The asterisk * indicates that the bolts are used for female threaded parts that are made of soft ma-
* terials such as casting.

21
3. TRANSMISSION

2-7. DISASSEMBLY AND REASSEMBLY

6
5

Propeller shaft
2
4 TM0060

Disassembly Reassembly
1. Gearshift control rod(shift and select) 6. Transmission assembly
2. Parking brake cable 5. PTO yoke flange and control cable or rod
3. Clutch booster with bracket 4. Yoke flange
4. Yoke flange 3. Clutch booster with bracket
5. PTO yoke flange and control cable or rod 2. Parking brake cable
6. Transmission assembly 1. Gearshift control rod(shift and select)

IMPORTANT OPERATIONS (DISASSEMBLY)

1. Gearshift control rod
Transmission Unbolt the control rod fixing bolt and remove
E/G the control rod at the point as shown.
(1)Transmission relay lever(Lock nut:
1
M8x1.25)
3
(2)Idler(Lock nut: M10x1.25)
6 (3)Transmission shift lever(Lock nut:
5
M10x1.25)
4
(4)Idler(Lock nut: M10x1.25)
2 Cross member
TM0070
(5)Engine flywheel housing(Lock nut:
M10x1.25)
(6)Cross member(Lock nut: M10x1.25)

• Important operations
(1) For assurance of safety, park the vehicle
Parking brake drum Connecting point on level ground and brace the front or rear
wheels when lifting the vehicle.
(2)Remove the propeller shaft at the parking
brake drum

Propeller shaft Caution

Check the connecting point before disassembly.
TM0071

22
 3. TRANSMISSION

(3) Remove the control rod, harness-switch,

Harness
parking brake cable, speedometer cable at
the transmission.
Select rod

Harness

Shift rod

P.T.O
TM0072

(4) Remove the drain plug and check plug from

Clutch booster
the transimission to drain out gear oil.

TM0073

(5) Remove the drain plug and check plug from

the transmission to drain out gear oil.

Check plug
Drain plug
TM0074

(6) When the gear oil drain out check the state
of oil and chip.

TM0075

23
3. TRANSMISSION

(7) Seperate the oil cooler hose from the trans-

mission and pump.

Oil cooler pump

TM0076

(8)To remove clutch housing-mouting bolts,

Clutch housing
support the transmission with transmission
jack.

Mounting bolt

Transmission jack
TM0077

IMPORTANT OPERATIONS (REASSEMBLY)

(1)Transmission assembly
Guide bar 1) Remove the transmission assembly us-
ing a special tool-transmission jack.
2) Align the transmission inclination with
Horizontal line the engine slope.
Engine slope 3) Shift the gear in 5th position.
Apply molybdenum 4) Mount the transmission to the engine
disulfide (MoS2) carefully.
grease
(2)Clutch booster with bracket
TM0080 For adjustment operation, refer to Section
2 “CLUTCH”.
(3)Parking brake cable
For adjustment operation, refer to Section
9 “BRAKE”.

• Important operations
(1)Lubricate rotating and sliding faces of the
parts with oil or grease before installation.

TM0081

24
 3. TRANSMISSION

(2) Fit the transmission assembly using a spe-

Clutch housing
cial transmission jack.

Fixing bolt

Transmission jack
TM0082

(3) Mount the oil cooler hose to ther transmis-

sion and oil pump.

Oil cooler
pump

TM0083

(4) Check the drain plug fixing torque and refill

the level plug with the specified new gear
oil.

Level plug
5.5~8.5kgf·m

Drain plug
5.5~8.5kgf·m TM0084

(5) Fix the clutch booster.

Clutch booster
(6) Connect the transmission P.T.O control.

TM0085

25
3. TRANSMISSION

(7) Fit the control rod, harness-witch, parking

Harness brake cable, speedometer cable to the
transmission.
Select rod

Harness

Shift rod

TM0086

(8) Install the propeller shaft to the parking

Parking brake drum Connecting point brake drum then check the maching point.
Fix the nut.

Propeller shaft

TM0087

26
 3. TRANSMISSION

3. TRANSMISSION CASE

12
13 16
14
14
7
13 15

12
10
11
5
4 6 11
5
2 4

8
10
9
2 3
5 3
*
4 1

6
7 9

1 * 8

T14S10

T9S6/T10S6/T15S6/T16S6
*Repair kit
TM0092

T9S6/T10S6/T15S6/T16S6 T14S10

1. Flange bolt 1. Flange bolt

2. Front bearing retainer 2. Front bearing retainer
3. Oil seal 3. Taper plug
4. Gasket 4. Oil seal
5. Bolt/ Washer 5. O-ring
6. Gasket 6. Oil intake plate
7. Magnetic plug 7. Drain plug/ Gasket
8. P.T.O Cover 8. Magnetic plug/ Gasket
9. P.T.O Cover
*9.
10.
P.T.O Gasket
Oil seal
*
10. P.T.O Gasket
11. Dust plug 11. Seal bolt
12. Speedometer gear 12. Oil seal
13. Speedometer connector 13. Speedometer/ L-joint
14. L-joint 14. Speedometer bushing
15. Speedometer gear
16. Rear cover

27
3. TRANSMISSION

ZF16S151/221

1
2

6
2
8
5
3
2

6
9

6 2

2 2 2

TM0100

1. Housing 6. Cylindrical pin

2. Screw plug 7. Gasket
3. Filler neck 8. Clutch housing
4. Lock screw 9. Lock screw
5. Gasket

28
 3. TRANSMISSION

4. QUADRANT BOX
4-1. UPPER QUADRANT BOX DISASSEMBLY
K805, K1406

16

15

19

4
3
20
5
6

9
13
11 *
10
1

12 *
8 14 18
11
17
9
* : Apply liquid gasket.
TM0111

Disassembly
1. Upper quadrant box 11. Washer/ Bush
2. Link rod assembly 12. Relay lever insert boss
3. Select fix pin 13. Relay lever bracket
4. Select lever 14. Spring pin
5. Snap ring 15. Shift lever shaft
6. Washer 16. Side cover
7. Selection lever 17. Shift lever
8. Oil seal 18. Cap
9. Relay lever bolt 19. Oil seal
10. Select relay lever 20. Air breather

* Reassembly is inverse of disassembly.

29
3. TRANSMISSION

T9S6, T10S6

13 4

6
3
7
8

18
1
14
15
14
16
9
10
2 5

12

17 11

TM0121

Disassembly
1. Air breather 10. Gearshift sliding lever
2. Interlock switch 11. Power shift
3. Lock pin 12. Gearshift lever
4. Gear selecting lever(B) 13. Dust plug
5. Gear selecting lever(A) 14. Spring retainer
6. Washer 15. Return spring
7. Shim 16. Interlock plate
8. Oil seal 17. O-ring
9. Spring pin 18. Select lever case

* Reassembly is inverse of disassembly.

30
 3. TRANSMISSION

T14S10

6
8

13
9
7 10
11

1
14
19
20
21

16 5
15 12

17
2
18

4 3

TM0131

Disassembly
1. Bolt 12. Select lever assembly
2. Bolt 13. Dust plug
3. Bolt 14. Air breather
4. Sub unit 15. Interlock switch
5. Spring pin 16. Gasket
6. Nut 17. Gear shift lever
7. Lock pin 18. O-ring
8. Gear shift sliding lever 19. Retainer and spring
9. Washer 20. Gear shift sliding lever
10. Shim 21. Interlock plate
11. Oil seal

* Reassembly is inverse of disassembly.

31
3. TRANSMISSION

T15S6

4
13

3
6
7
8

18

2 14
15
14
2
9
5
10
12
16
17

11

TM3336

Disassembly
1. Air breather 10. Gearshift sliding lever
2. Interlock switch 11. Power shift
3. Lock pin 12. Gearshift lever
4. Gear selecting lever(B) 13. Dust plug
5. Gear selecting lever(A) 14. Spring retainer
6. Washer 15. Return spring
7. Shim 16. Interlock plate
8. Oil seal 17. O-ring/dust seal
9. Spring pin 18. Select lever case

* Reassembly is inverse of disassembly.

32
 3. TRANSMISSION

T16S6

10
9
8
9
8
12
13 3

1
11
7
6
7
4
4

12

TM3337

Disassembly
1. Air breather 8. spring
2. Boot 9. Return spring retainer
3. Plug screw 11. Oil seal
4. Spring pin 12. Bushing
5. Gear shift shaft 13. Selecting lever case
6. Spring
7. Return spring retainer

* Reassembly is inverse of disassembly.

33
3. TRANSMISSION

4-2. LOWER QUADRANT BOX DISASSEMBLY

K805

b A

a
16
6 17
19
4 c 18
5 8
9
3
11

7 15
10
13
12 14

c c c
Section: A-A
a: Interlock ball
b: Rod cover
c: Detent spring
a b a b a b and ball

TM0141

1. Neutral lamp switch 11. 4th and 5th shift arm rod
2. Back lamp switch 12. 4th and 5th shift block rod
3. Shift rod cover 13. 4th and 5th shift block
4. 1st and reverse shift block(Front) 14. 1st and reverse shift rod
5. 1st and reverse shift block rod 15. 1st and reverse shift fork
6. 1st and reverse shift block(Rear) 16. Washer
7. 2nd and 3rd shift block 17. 1st and reverse relay lever
8. 2nd and 3rd shift rod 18. 1st and reverse shift spindle
9. 2nd and 3rd shift fork 19. 4th and 5th shift pinion/ Bearing
10. 4th and 5th shift fork / Bolt/ Cover/ Washer

34
 3. TRANSMISSION

K1406

Section: A-A
c c c a: Interlock ball
b: Rod cover
c: Detent spring and ball

a b a b a b

a A
3 20
6 21

C
22
8
5

9
4 19
11
7 17
10
18

15
13 16
12

14

TM0151

1. Neutral lamp switch 8. 2nd and 3rd shift rod 15. 6th shift block
2. Back lamp switch 9. 2nd and 3rd shift fork 16. 6th shift fork rod
3. Shift rod cover 10. 4th and 5th shift rod 17. Shift rod stopper
4. 1st and reverse shift 10. 4th and 5th shift fork 18. 1st and reverse shift
block(Front) 12. 6th shift fork fork rod
5. 1st and reverse shift 13. 6th shift fork rod 19. 1st and reverse shift fork
block rod 14. 6th shift lever/ Spindle 20. Washer
6. 1st and reverse shift / Bolt/ O-ring 21. 1st and reverse relay lever
block rod(Rear) 22. 1st and reverse shift spindle
7. 2nd and 3rd shift block

35
3. TRANSMISSION

T9S6/T10S6/T15S6/T16S6

12
6

3
1
4
37
13
A
5
2
b
11
A
a 10
9
36 8 25
14
7
17
21 24

15
C
16 2018 23
14 20
14 28
22
19
14
14
20
33
26
30
27 32
Section: A-A 14
29
c c c a: Interlock ball
31
b: Rod cover 14
c: Detent spring 35
and ball 34

a b a b a b

TM0161

1. Neutral lamp switch 16. 1st and reverse shift jaw 32. Jaw nut
2. Gasket 17. 1st and reverse shift rail jaw 33. Over drive shift(B) rail
3. Spring 18. 2nd and 3rd shift rai assembly 34. Over drive shift(C) rail
4. Interlock pin 19. 2nd and 3rd shift rail jaw 35. Over drive gearshift
5. Dust plug 20. Steel ball 36. Gasket
6. Flange nut 21. 2nd and 3rd gear shift fork 37. Case
7. 1st and reverse shift 22. 1st and reverse shift B rail
lever shaft 23. 1st and reverse gearshift fork
8. O-ring 24. 4th and 5th shift rail assembly
9. 1st and reverse lever 25. 4th and 5th gearshift fork
10. Thrust washer 26. Overdrive shift rail
11. Bolt 27. 6th and 7th gear shift jaw
12. Bolt 28. Overdrive shift shift rail fork
13. Clip bracket 29. Overdrive shift lever shaft
14. Set bolt 30. Overdrive shift lever
15. 1st and reverse shift rail 31. Spring washer

36
 3. TRANSMISSION

T14S10

14
6 16
3
4 13 15
5 17
1
12

5 2

11
10
9
8 18
7 29

18
20
28

22 24

19 27

21 25 18

18
21
18 23 26 18

TM0171

1. Neutral lamp switch 16. Air band clip

2. Gasket 17. Bolt
3. Spring 18. Bolt
4. Interlock pin 19. 1st and reverse shift jaw
5. Rod cover 20. 1st and reverse shift rail jaw
6. Nut 21. Steel ball ( 5/8" )
7. 1st and reverse shift lever shaft 22. 1st and reverse shift (A) rail
8. O-ring 23. 2nd and 3rd shift rail jaw
9. 1st and reverse shift lever 24. 2nd and 3rd shift rail fork
10. Washer 25. 2nd and 3rd shift rail
11. Bolt and Washer 26. 4th and overdrive shift rail
12. Bolt 27. 4th and overdrive shift fork
13. Bolt 28. 1st and reverse shift (B) rail
14. Nut 29. 1st and reverse gear shift fork
15. Bolt

37
3. TRANSMISSION

IMPORTANT OPERATIONS (DISASSEMBLY)

• Check the shift rail for bending.If bending,
damage or any other abnormal conditions are
Dial replace.
gauge

Lathe
TM00261

• If the inner diameter of shift rail hole and outer

diameter are beyond the standard valve,
replace the parts a new one.

TM00262

• 6th shifter rod and block

Screw driver
Install rod in place. Install and lock the shift
arm or shift block using bolt and wire, then set
the rod to neutral position.
When reassembling parts NO. 6, 12, or 13 as
in the previous page, refer to the above in-
Shifter rod
structions.
Interlock ball

TM0240

• Fit the shift rail set bolts to the quadrant box.

Then punch of min. 3 point of tread.

Set bolt
5.0~6.8kgf·m TM0263

38
 3. TRANSMISSION

5. TRANSMISSION ASSEMBLY (K805)

5-1. MAJOR COMPONENTS DISASSEMBLY STEPS

1
7

* 4
8

3 2

10

5
12

6 9 13 *
11
14 16
15
17

18

19
* : Apply liquid gasket.
TM0291

1. Upper quadrant box assembly 11. Cover, Gasket and Bolt

2. Oil seal 12. Bracket and Bolt
3. Speedometer driven gear, Oil 13. Plug and O-ring
seal, Bushing and O-ring 14. Top gear shaft
4. Rear cover 15. Bearing, Snap ring and Protector
5. Gasket 16. Main shaft assembly
6. Stud bolt 17. Counter shaft assembly
7. Clutch housing 18. Reverse shaft assembly
8. Front cover, Oil seal and Gasket (Gear, Bearing, Piece, Washer and O-ring)
9. Counter shaft front bearing cover 19. Reverse shaft
10. Plug and Packing

* Reassembly is inverse of disassembly.

39
3. TRANSMISSION

IMPORTANT OPERATIONS (DISASSEMBLY)

3. Speedometer driven gear, Oil seal, Bush-

ing and O-ring
Use a remover to disassemble these parts as
required.

TM0300

9. Counter shaft front bearing cover

Grip the knob with pliers tightly to remove the
counter shaft front bearing cover.

TM0310

9. Counter shaft front bearing

Use a remover to disassemble these parts
as required.
(Special tool: CA21031)

Counter bearing
puller

TM0320

17. Counter shaft rear bearing and Snap ring

Use a remover to disassemble these parts
as required.
(Special tool: CA21031)

Counter bearing
puller
TM0330

40
 3. TRANSMISSION

14. Top gear shaft assembly and Circlip

The dog gear installed to the top gear shaft
with the circlip can be separated from the top
gear shaft by pulling it strongly.
With the top gear shaft taken out, the top gear
shaft dog gear will remain in the gear case.

TM0340

Wire 16. Main shaft rear bearing and Snap ring

Use a remover to disassemble these parts
as required.
(Special tool: CA21031)

16. Main shaft assembly and thrust washer

Remove the main shaft assembly from the
case using a suitable hook or wire.

TM0350

Caution
The main shaft assembly can be easily separated
from the gear case by using a dummy collar as
shown.

TM0360

19. Reverse shaft assembly

Use a remover to disassemble these parts
as required.
(Special tool: CA21021)

TM0370

41
3. TRANSMISSION

IMPORTANT OPERATIONS (REASSEMBLY)

18. Thrust washer
Thrust washer Make necessary replacement if wear damage
or any other abnormal conditions are found
through assembly.

TM0630

18. Reverse gear shaft and O-ring

Align the lock bolt hole in the shaft with the
hole in the case. The adjusting groove on the
shaft should be turned rearward and aligned
Reverse gear in the vertical direction.

TM0640

12. Reverse gear shaft lock bolt

Apply liquid gasket to the lock bolt.
(kgf·m)
Lock bolt Torque 1.5 ~ 2.8

TM0650

16. Thrust washer

Note the direction of installation.

Forward

TM0660

42
 3. TRANSMISSION

16. Main shaft rear bearing and snap ring

Be careful for damage. When installing it to
the bearing and snap ring using jig.
(Special tool: CA21041 or CA21011)

TM0670

14. Top gear shaft assembly

Top gear shaft
Fit the top gear shaft to the place where the
end of the dog gear has been partially cut out.
Drop the counter shaft assembly into the
Dog gear
transmission case, then install the top gear
shaft assembly.

TM0680

17. Connector shaft rear bearing, snap ring

Be careful for damage when installing it to the
bearing and snap ring.
(Special tool: CA21101,CA21031,CA21061)

Bearing puller
TM0690

16. Speedometer drive gear

Note the direction of installation.
Toward transmission case

Toward rear cover

TM0700
5. Gasket 4. Reverse cover 2. Oil seal
Apply liquid gasket to lock bolt.
(kgf·m)
Torque 5.8~8.7

43
3. TRANSMISSION

3. Speedometer driven gear, Oil seal, Bush-

Speedometer driven gear ing and O-ring
(kgf·m)
Torque 0.4~0.6

TM0710

• Fit the speedometer gear bushing to extension

Rear cover or extension housing housing using round bar (diameter: 40mm)

Speedometer
Round bar
gear bushing

TM0711

• Fit the Oil seal to the speedometer gear bush-

ing using round bar (diameter: 15mm)
Round bar
Caution
Apply grease to packing inside

Packing

Speedometer
gear bushing
TM0712
1. Quadrant box assembly
Fill the transmission case with gear oil and then
assembly the quadrant box.

44
 3. TRANSMISSION

GEAR SHAFT DISASSEMBLY

2 15
1 14 16
13
12
11
9 10 17
8
18
19
5
20
21

6 7

22
34 28 27
29
26
25
24
23

30

31

TM0381

1. Protector, Snap ring and Bearing 19. 1st gear, Needle roller bearing
2. Top gear shaft and Collar
3. Snap ring 20. Sleeve and clutch hub
4. Pilot bearing 21. Reverse gear and needle roller
5. 4th blocker ring bearing
6. Snap ring 22. Main shaft
7. 4th and 5th synchronizer assembly 23. Bearing and snap ring
8. 5th blocker ring 24. Counter shaft drive gear and key
9. 5th gear (over drive) 25. PTO gear and key
10. Needle roller bearing 26. 5th gear and key (Over Drive)
11. Snap ring 27. Snap ring
12. Collar 28. Bearing
13. 3rd gear 29. Shaft
14. Needle roller bearing 30. Reverse shaft assembly
15. 2nd and 3rd synchronizer assembly (Gear, Bearing, Piece, Washer,
16. 2nd gear and O-ring)
17. Piece and speed drive gear 31. Reverse shaft
18. Washer and bearing

* Reassembly is inverse of disassembly.

45
3. TRANSMISSION

IMPORTANT OPERATIONS (DISASSEMBLY)

4. Pilot bearing
Use a remover to disassemble these parts as
required.
(Special tool: CA21121)

Pilot bearing puller

TM0390

6. Snap ring
Be careful for damage when disassemble.
Plunger

Snap ring Block 7. 4th and 5th synchronizer assembly

Disassemble the synchronizer assembly into
blocker rings, springs, sleeve, inserts, plung-
ers, springs and clutch hub.

Spring
TM0400

12. Collar
Remove all the parts of item 33 at a time
using a bench press.

TM0410

IMPORTANT OPERATIONS (REASSEMBLY)

15. 2nd and 3rd synchronizer assembly
Assemble the sleeve to the rear longer
plunger.
Longer plunger

Rearward

TM0560

46
 3. TRANSMISSION

12. Collar
Install the collar using a bench press.

TM0570

7. 4th and 5th synchronizer assembly

Install the blocker by matching it with the cir-
cular direction of clutch hub.

Clutch hub

TM0580

Pilot bearing 4. Pilot bearing

Note the direction of installation.

Forward Rearward

Snap ring
TM0590

2. Top gear shaft assembly

To install, attach a brass bar and use a bench
press.

Brass bar

TM0610

47
3. TRANSMISSION

5-2. INSPECTION AND MAINTENANCE

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are
found through inspection.

Visual check
Inspect all disassembled parts for wear, damage or any other abnormal conditions.
Inspect the following parts paying particular attention to the points as shown.

Front and Rear cover oil seal replacement

1) Note the direction of oil seal installation.
Liquid gasket 2) Apply liquid 242 to fitting face of oil seal.
3) Insert oil seal until it is properly seated in po-
sition.
4) Fill the cavity between felt and lip of oil seal
with grease.

TM0420

Contact completely Grease

TM0430

Shoulder of shifter rod groove

As shoulder part rounded due to wear can cause
gear slipping, this part is required to be thoroughly
Shoulder groove checked.

TM0440

48
 3. TRANSMISSION

Shift arm (mm)

Shift arm Standard Limit
Thickness
11 10

• Make necessary parts replacement if wear,

Micrometer damage or any other abnormal conditions are
found through inspection.

TM0450

Detent spring (mm)

Standard Limit
Free length
43.5 40.5

• Make necessary parts replacement if wear,

damage or any other abnormal conditions are
found through inspection.

TM0460

Blocker ring (mm)

Fine groves
Standard Limit
Clearance
2.0 0.3

• If the fine grooves on the inner face have worn

out completely, replace the blocker ring with a
Clearance between new one.
gear and blocker ring
TM0470 TM0480

Clutch hub (mm)

Clearance
Standard Limit
Clearance
1.2 ~ 0.4 0.8

• Make necessary parts replacement if wear,

damage or ony other abnormal conditions are
found through inspection.
TM0490

49
3. TRANSMISSION

Plunger spring (mm)

Standard Limit
Free length
18.7 17.7

TM0500

Plunger block
If the plunger block is wear or damage, replace
the plunger block with a new one.

TM0510

Clutch sleeve
Check the clutch sleeve for wear or damage.
If the clutch sleeve is wear or damage, replace
the clutch sleeve with a new one.

TM0520

2nd and 3rd synchronizer inner and Outer

Clearance rings
A (mm)
Outer ring Standard Limit
Clearance
2.4 ~ 2.5 0

Inner ring If the fine grooves on the face ‘A’ are found to
have worn out completely, replace the
TM0540 synchronizer assembly with a new one.

50
 3. TRANSMISSION

5-3. TRANSMISSION P.T.O SYSTEM

5-3-a. MAJOR COMPONENTS(BASE: K805)

Control cylinder
Air shaft rod

Idle gear shaft Air chamber return spring

Idle gear

Spring gear cover

Front cover Output shaft

Oil seal
Output gear

TM0720

51
3. TRANSMISSION

5-3-b. FIXING TORQUE

(kgf.m)

Thick collar
Gear oil

Thin collar

16
2.1~3.5

Grease

Grease

Apply liquid gasket

Apply liquid gasket.

2.1~3.5

Apply liquid gasket.

Grease
Gear oil

LOCTITE

Gear oil 3.0~4.5

3.0~4.5
Apply liquid gasket.
2.1~3.5

TM0731

52
 3. TRANSMISSION

5-3-c. DISASSEMBLY
MAJOR COMPONENT DISASSEMBLY STEPS

4
6
7
5

3
6 **

13 2

8 *10
** 9

11
12

* 1

16

20 19
17
** *
21
* 18

14

15
19

* 1
* :: Repair
Apply liquid gasket.
kit
** TM0741

1. Switch and Flange 12. Shaft rod stopper

2. Control cylinder 13. Shift arm
3. Spring pin 14. Shaft rod cover
4. Idle gear shaft 15. Front cover
5. Idle gear 16. Rear cover
6. Needle bearing collar 17. Oil seal
7. Needle bearing 18. Output shaft
8. Spring 19. Bearing
9. Air shaft rod 20. Bearing collar
10. O-ring 21. Output shaft gear
11. Air chamber return spring

53
3. TRANSMISSION

IMPORTANT OPERATIONS (DISASSEMBLY)

5. Idle gear
Remove the idle gear shaft pin to separate the
shaft, then disassemble the idle gear and bear-
ing collar.

Idle gear

TM0750

13. Shift arm

Remove the shift arm pin to separate the
Shaft rod stopper
shaft, then disassemble the shift arm.

Shift arm
TM0760

18. Output shaft

Tap on the output shaft lightly with a brass
hammer to separate it to the front direction.
At the same time, separate the front bearing.

Hammer
Front

TM0770

54
 3. TRANSMISSION

IMPORTANT OPERATIONS (REASSEMBLY)

18. Output shaft
• Align the key hole in the shaft with the key
hole in the output shaft, then tap lightly on
the shaft forward with a brass hammer.

Front
Hammer
TM0880

19. Bearing
• Grease the bearing, then install it in the front
Bearing collar
direction.
• To install, insert the bearing collar in the rear
direction.
Front
Grease fitting

Grease fitting

TM0890

17. Oil seal

• Grease the inside of lip, direct the lip inward,
then install the cover to the plate.
• Grease the outside of oil seal.
Grease fitting
Inner

TM0900

16. Rear cover

Apply liquid gasket before installing the rear
cover.
(kgf·m)
Torque 2.1 ~ 3.5

Apply liquid gasket

TM0910

55
3. TRANSMISSION

15. Front cover

• Apply liquid gasket before installing the front
cover.
(kgf·m)
Torque 2.1 ~ 3.5

Apply liquid gasket.

TM0920

12. Air shaft rod

• Grease the O-ring before installing it to the
Shaft rod stopper shaft rod.
Front
• Pre-assemble the stopper spring, then as-
Grease fitting semble it to the case.
Shaft rod • Note the direction of shaft arm. After
Spring
completion of installation, tap and insert the
pin, then fix both the upper and lower points.

TM0930

14. Needle bearing

Grease fitting • Grease the bearing before installing it to the
idle gear.

Idle gear
TM0940

16. Idle gear

• Fit the bearing collar to the idle gear, then
Thick collar Shaft insert it into the case.
• Tap and insert the bearing gear shaft.
Pin
• Fix the bearing pin.
• Grease the bearing collar for easy opera-
tion.
Thin collar
Bearing collar
TM0950
Front Rear
Thin collar Thick collar

56
 3. TRANSMISSION

2. Control cylinder
Control cylinder • Apply liquid gasket to the packing, then
grease(0.5g) the inside of cylinder.
(kgf·m)
Torque 2.1 ~ 3.5
Grease(0.5g)

TM0960

14. Shaft rod cover

• Apply LOCTITE, then tap and install the
shaft rod cover to the case.

Grease fitting

TM0970

• Check the functions of the idle gear.

– Inject air(4kg/cm2) into the nipple to check
if the shaft rod operates smoothly.

TM0980

• Install the PTO assembly to the transmission

case.
– Apply liquid gasket to the packing and as-
semble the P.T.O assembly.
(kgf·m)
Torque 3.0 ~ 4.5
Apply liquid gasket.

TM0990

57
3. TRANSMISSION

5-3-d. INSPECTION AND MAINTENANCE

Make necessary correction or parts replacement
if wear, damage or any other abnormal conditions
are found through inspection.
Check the inside and tip of control cylinder for
wear.

TM0780

Idle gear
Check the gear tooth face for damage, and
measure abrasion if required.
Overhaul diameter(pin φ 8mm) (mm)

Standard Limit
153.28 152.98
Make necessary parts replacement if wear,
damage or ony other abnormal conditions are
TM0790
found through inspection.

Bearing collar thickness

(mm)

Item Standard
Front 2.5
Rear 4.5

Make necessary parts replacement if wear,

damage or ony other abnormal conditions are
found through inspection.
TM0800

Free length
(mm)

Standard Limit
58.8 54.0

Make necessary parts replacement if wear,

damage or ony other abnormal conditions are
found through inspection.

TM0820

58
 3. TRANSMISSION

Shift arm tip thickness

(mm)

Standard Limit
Shift arm 7.0 6.0

TM0830

Output shaft
• Check the output shaft oil seal for wear.
Output shaft

TM0840

Needle bearing
• Check the output shaft oil seal for wear.
• Check the bearing for deformation, wear, or
unusual sound.
- To identify any damage or deformation, rotate
the race and check clearance of holes.
- Check the holes and race for abnormal condi-
tions.
- To identify unusual sound, rotate the bearing
TM0850 to check if it transfers any abnormal feel
through the hand.

Overhaul diameter of gear tooth face

(pin φ 8mm)
(mm)

Standard Limit
96.88 96.58

TM0860

59