Transmission System: Transmission Proper Transmission Linkage

TRANSMISSION SYSTEM
TRANSMISSION PROPER
TRANSMISSION LINKAGE
- MEMO -
TRANSMISSION PROPER
CONTENTS
SERVICE DATA ......................................... TM- 1- 1 REASSEMBLY ........................................... TM- 3-29
SPECIFICATIONS ...................................... TM- 1- 1 INSTALLATION .......................................... TM- 3-40
SERVICE DATA .......................................... TM- 1- 4
TIGHTENING TORQUE ............................. TM- 1- 8
= UNIT NAME MRT21A, MRT23A =
SYSTEM DIAGRAM ................................... TM- 1-10
TOOLS .......................................................... TM- 2- 1
CONSTRUCTION ...................................... TM- 4- 1
DISASSEMBLY .......................................... TM- 4- 4
= UNIT NAME MTS72D, MTS73D = REMOVAL .................................................. TM- 4- 4
DISASSEMBLY .......................................... TM- 4- 5
CONSTRUCTION ...................................... TM- 3- 1
INSPECTION .............................................. TM- 4-24
DISASSEMBLY .......................................... TM- 3- 6
REMOVAL .................................................. TM- 3- 6
REASSEMBLY ........................................... TM- 4-29
DISASSEMBLY .......................................... TM- 3- 7 REASSEMBLY ........................................... TM- 4-29
INSTALLATION .......................................... TM- 4-44
INSPECTION .............................................. TM- 3-22
REASSEMBLY ........................................... TM- 3-29
SUPPLEMENTAL OUTLINE
+ Addition of unit due to introduction of a new vehicle model
SERVICE DATA T/M PROPER
SERVICE DATA
SPECIFICATIONS
UNIT NAME: MTS72D, MTS73D
Unit name MTS72D MTS73D
7 speeds forward, 1 speed reverse 7 speeds forward, 1 speed reverse
Transmission system (Synchromesh type: 2-5 speeds (Synchromesh type: 2-7 speeds
Constant mesh type: 1 speed and reverse) Constant mesh type: 1 speed and reverse)
Operating system Remote control (Power shift)
1st and reverse Helical gear
Gear used
2nd to 7th Helical gear
1st 6.736 6.710
2nd 4.164 4.442
3rd 2.315 2.458
4th 1.441 1.459
Gear ratio
5th 1.000 1.000
6th 0.732 0.758
7th 0.633 0.633
Reverse 6.911 6.710
1st 47/12 54/13
2nd 46/19 44/16
3rd 35/26 35/23
4th 31/37 28/31
Number of gear 5th Direct coupled Direct coupled
teeth
(Main/counter) 6th 23/54 23/49
7th 21/57 20/51
Reverse 37/17 54/13
Reverse idler gear 24, 13 29
Drive gear 25/43 26/42
Oil quantity W/O PTO 9.0 (2)

liter (Imp gal) W/PTO 9.7 (2-1/8)
NOTE
+ In vehicles equipped with a transmission oil cooler, add another 2 liters (1-3/4 Imp qt) after pouring
the specified amount of oil shown in the above table.
TM-1-1
UNIT NAME: MRT21A, MRT23A

Unit name MRT21A MRT23A
12 speeds forward, 2 speed reverse
Transmission system (Synchromesh type: 1-12 speeds
Constant mesh type: reverse)
Operating system Remote control (Power shift)
Gear used 1st to 12th and reverse Helical gear
1st 10.729
2nd 6.575
3rd 3.649
4th 2.236
Gear ratio 5th 1.464
6th 1.000
Reverse 9.563
High 0.811
Sub-transmission
Low 1.000
1st 46/16
2nd 37/21
3rd 46/16
4th 37/21
5th 30/26
Number of gear teeth 6th 33/26

(Main/counter) Reverse 41/16
Reverse idler gear 25
Range side High 26/24

sub-transmission Low 38/14
Splitter side High 34/35

sub-transmission Low 26/33
Oil quantity W/O PTO 10.8 (2-3/8)

liter (Imp gal) W/PTO 11.3 (2-1/2)
NOTE
+ In vehicles equipped with a transmission oil cooler, add another 2 liters (1-3/4 Imp qt) after pouring
the specified amount of oil shown in the above table.
TM-1-2
UNIT NO. LOCATION

The manufacturing number of each transmission is stamped on the
side of the transmission case.
WTM408A
WGE024A
WTM409A
TM-1-3
SERVICE DATA
Unit: mm (in)
Application
Item Maintenance Service limit Remarks
standard MTS72D MRT21A
MTS73D MRT23A
0.16 - 0.44 j —
Clearance between shift lever (0.0063 - 0.0173) 0.8
and select lever 0.1 - 0.4 (0.031)
(0.004 - 0.016) — j
0.05 - 0.13 0.5 j —

Radial play between shift (0.0020 - 0.0051) (0.020)
shaft and shift lever splines 0.02 - 0.08 0.5
(0.0008 - 0.0031) (0.020) — j
Clearance between shift lever 0.74 - 0.96 1.0

and shifters (0.0291 - 0.0378) (0.039) j —
Clearance between shift lever 0.74 - 0.96 1.5 j j

and each shifter/shift fork (0.0291 - 0.0378) (0.059)
0.04 - 0.07 Reverse
(0.0016 - 0.0028)
0.07 - 0.10
(0.0028 - 0.0039) Splitter — j
0.04 - 0.07
(0.0016 - 0.0028) Range
Clearance between transmis- 0.3
sion cover and shift fork shaft (0.012)
0.07 - 0.17 1st - 2nd — j
(0.0028 - 0.0067) 2nd - 3rd j —
3rd - 4th — j
0.06 - 0.15
(0.0024 - 0.0059) 4th & 5th j —
6th & 7th
Clearance between each fork 0.1 - 0.5 1.0 j j
claw and synchronizer sleeve (0.004 - 0.020) (0.039)
Clearance between each fork 0.02 - 0.05 — j j
claw and shift fork (0.0008 - 0.0020)
0.07 - 0.10 Splitter
Clearance between cylinder (0.0028 - 0.0039) 0.3
Trans- — j
mission and shift shaft 0.04 - 0.07 (0.012)
(0.0016 - 0.0028) Range
cover
Clearance between locking 0.04 - 0.08 0.2 j —
lever and lever shaft (0.0016 - 0.0031) (0.008)
Clearance between locking 0.1 - 0.4 1.0 j —
lever and lever shifter (0.004 - 0.016) (0.039)
Clearance between locking 0.1 - 0.4 1.0 1st & Reverse j —
lever and shift shaft (0.004 - 0.016) (0.039) 6th & 7th
42.5 — j —
(1.673)
42.5
(1.673) — 1st to 6th & Reverse
Free
length 35.0
(1.378) — Splitter — j
34.5 — Range
(1.358)
Shift fork 137 - 167 When compressed to
shaft locking {14 - 17, 31 - 37} — 29 mm (1.14 in) j —
spring
137 - 167 1st to 6th & Reverse
{14 - 17, 31 - 37} — When compressed to
29.0 mm (1.142 in)
Tension
N {kgf, lbf} 78 - 98 Splitter
{8 - 10, 18 - 22} — When compressed to — j
28.0 mm (1.102 in)
127 - 157 Range

— When compressed to
{13 - 16, 29 - 35} 28.0 mm (1.102 in)
Clearance between shift fork 0.10 - 0.24 1.0 j —
and sleeve groove (0.0039 - 0.0094) (0.039)
Clearance between reverse 0.10 - 0.24 1.0
shift fork and reverse sleeve (0.0039 - 0.0094) (0.039) — j
groove
TM-1-4
Unit: mm (in)
Application
MTS73D MRT23A
Each main gear and counter gear 0.10 - 0.20 0.5 j j
backlash (0.0039 - 0.0079) (0.020)
1st gear 0.20 - 0.40 0.7 j j

(0.0079 - 0.0157) (0.028)
2nd gear 0.20 - 0.40 0.7 j j

(0.0079 - 0.0157) (0.028)
3rd gear 0.20 - 0.40 0.7 j j

(0.0079 - 0.0157) (0.028)
Each main 0.20 - 0.40 0.7
gear end play 4th gear (0.0079 - 0.0157) (0.028) j —
Reverse gear 0.20 - 0.40 0.7

(0.0079 - 0.0157) (0.028) j j
Splitter gear 0.20 - 0.40 0.7 — j

(0.0079 - 0.0157) (0.028)
Range low gear 0.20 - 0.40 0.7 — j

(0.0079 - 0.0157) (0.028)
End play of rear countershaft 0.20 - 0.40 0.7 j —
gears (0.0079 - 0.0157) (0.028)
0.10 - 0.70 1.0
(0.0039 - 0.0276) (0.039) j —
Reverse idler gear end play
0.30 - 0.50 1.0
Trans- (0.0118 - 0.0197) (0.039) — j
mission
proper Radial play of main shaft and 0.20 - 0.30 0.5 j —
sleeve splines (0.0079 - 0.0118) (0.020)
Radial play between hub and 0.20 - 0.30 0.5 j j
sleeve splines (0.0079 - 0.0118) (0.020)
0.20 - 0.30 1.0
1st gear (0.0079 - 0.0118) (0.039) j j
0.20 - 0.30 1.0

2nd gear (0.0079 - 0.0118) (0.039) j j
3rd gear 0.20 - 0.30 1.0 j j

(0.0079 - 0.0118) (0.039)
Radial play 0.20 - 0.30 1.0
between 4th gear j —
(0.0079 - 0.0118) (0.039)
sleeve and
clutch gear Splitter gear 0.20 - 0.30 1.0 — j
splines (0.0079 - 0.0118) (0.039)
Range low gear 0.20 - 0.30 1.0 — j

(0.0079 - 0.0118) (0.039)
0.40 - 0.50 — j
(0.0157 - 0.0197) 1.0
Reverse gear
0.20 - 0.30 (0.039)
(0.0079 - 0.0118) j —
0.5
Ball bearing axial play — (0.020) j j
TM-1-5
Unit: mm (in)
Application
MTS73D MRT23A
6.3 - 6.7 j —
Tangential clearance between (0.248 - 0.264) —
synchronizer ring and syn- 1st to 4th — j
chronizer hub 6.5 - 6.9
(0.256 - 0.272) — Splitter — j
1.4 - 1.8 1st - 2nd — j

(0.055 - 0.071) 2nd - 3rd j —
1.5 - 1.9 3rd - 4th
Clearance between synchro- (0.059 - 0.075) 0
nizer ring and their cone — j
1.4 - 1.6 Splitter
(0.055 - 0.063)
1.4 - 2.0
(0.055 - 0.079) 4th, 5th, 6th and 7th j —
Radial clearance between

synchronizer hub and syn- 0.1 - 0.3 — j —
chronizer detent (0.004 - 0.012)
Axial clearance between syn- — 1st to 4th — j
Synchro- Lock chronizer ring and synchro-
nizer plunger 1.3 - 1.5 — Splitter — j
nizer detent (0.051 - 0.059)
system type
25.0 j —
(0.984) —
1st to 4th — j
Free length 26.0 — Splitter
(1.024)
— j
35.6 — Range
(1.402)
When compressed to j —
56.9 - 68.6 18.0 mm (0.709 in)
Detent spring
{5.8 - 7.0, — 1st to 4th
12.8 - 15.4} When compressed to
18.0 mm (0.709 in)
Tension
N {kgf, lbf} 70.6 - 86.3 Splitter
{7.2 - 8.8, — When compressed to — j
15.9 - 19.4} 22.0 mm (0.866 in)
153 - 169 Range
{15.6 - 17.2, — When compressed to
34 - 38} 29.0 mm (1.142 in)
Oil pump gear end play 0.05 - 0.09 —

(0.0020 - 0.0035)
Radial play between oil pump — j
0 - 0.18
gear and counter shaft at (0 - 0.0071) —
splines
Clearance between drive 0.06 - 0.09 0.20
shaft and case (0.0024 - 0.0035) (0.0079)
Oil pump
Clearance between driven 0.06 - 0.09 0.20
shaft and case (0.0024 - 0.0035) (0.0079)
After tightening bolts j —
Drive and driven gear end 0.03 0.7 to 20 N·m {2 kgfzm,
play (0.0012), min. (0.028) 14 ftzlbf}
Fit of drive shaft and front of 0.20 - 0.40 0.7
countershaft at notch location (0.0079 - 0.0157) (0.028)
TM-1-6
Unit: mm (in)
Application
MTS73D MRT23A
Item No. j
16 18.1
(Taper) (0.713) —
Free length Item No. j

21
21.0 —
(0.827)
Item No. j
26 15.0
(Taper) (0.591) —
Power shift
spring j j
Power Item No. j
16 47.1 40.2 When compressed to
shift (Taper) {4.8, 10.6} {4.1, 9.0} 13.0 mm (0.512 in)
Tension j 12.7 10.8 When compressed to
N {kgf, lbf} Item No.
21
{1.3, 2.9} {1.1, 2.4} 10.0 mm (0.394 in)
Item No. j
26 18.6 15.7 When compressed to
(Taper) {1.9, 4.2} {1.6, 3.5} 13.0 mm (0.512 in)
Valve seal dent depth 0.15 (0.0059), — j j

max.
NOTE
+ Item Nos. indicate the disassembly sequence in the illustration.
TM-1-7
TIGHTENING TORQUE
UNIT NAME: MTS72D, MTS73D
Unit: N·m {kgfzm, ftzlbf}
Item Tightening torque
Main bearing cap mounting bolt 42 - 43 {4.3 - 4.4, 31 - 32}
Reverse switch 108 - 127 {11.0 - 13.0, 80 - 94}
Plug 108 - 127 {11.0 - 13.0, 80 - 94}
Front side 19 - 25 {1.9 - 2.6, 14 - 19}
Gear cover mounting bolt
Rear side 16 - 21 {1.6 - 2.1, 12 - 15}
Lock lever assembly mounting bolt 32 - 42 {3.3 - 4.3, 24 - 31}
Drain plug and lever plug 118 - 137 {12.0 - 14.0, 87 - 101}
Middle case securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Transmission case
Side cover mounting bolt 19 - 25 {1.9 - 2.6, 14 - 19}
PTO gear box mounting bolt and nut 32 - 42 {3.3 - 4.3, 24 - 31}
Bearing retainer securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Overrun sensor 25 - 34 {2.5 - 3.5, 18 - 25}
Lever mounting nut 89 - 118 {9.1 - 12.0, 66 - 87}
Guide bolt 16 - 21 {1.6 - 2.1, 12 - 15}
Rear case securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Speedometer gear sleeve 34 - 44 {3.5 - 4.5, 25 - 33}
Main shaft lock nut 490 - 588 {50.0 - 60.0, 362 - 434}
Main shaft assembly
Companion flange securing nut 686 - 981 {70.0 - 100.0, 506 - 723}
Countershaft Countershaft rear bearing mounting nut 324 - 363 {33.0 - 37.0, 239 - 268}
Shift fork and shifter securing set screw 32 - 42 {3.3 - 4.3, 24 - 31}
Shift fork assembly
Shift shaft support securing bolts 25 - 31 {2.5 - 3.2, 18 - 23}
Control cover mounting bolt 32 - 42 {3.3 - 4.3, 24 - 31}
MTS72D 21 - 23 {2.1 - 2.3, 15 - 17}
Power shift assembly securing bolts
MTS73D 57 - 76 {5.8 - 7.7, 42 - 56}
Power shift and shift shaft mounting nut
93 - 108 {9.5 - 11.0, 69 - 80}
Transmission control cover assembly (MTS73D only)
Joint mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Guide bolt 21 - 23 {2.1 - 2.3, 15 - 17}
Plug 19 - 25 {1.9 - 2.6, 14 - 19}
Neutral switch assembly 34 - 49 {3.5 - 5.0, 25 - 36}
Oil filter securing bolt 32 - 42 {3.3 - 4.3, 24 - 31}
Oil pump and oil filter Oil pump securing bolts 16 - 21 {1.6 - 2.1, 12 - 15}
Valve cover mounting bolt 16 - 21 {1.6 - 2.1, 12 - 15}
Power shift cylinder 98 - 118 {10.0 - 12.0, 72 - 87}
Power shift assembly Power shift cylinder screw 2.0 - 3.4 {0.20 - 0.35, 1.4 - 2.5}
(MTS72D only) Power shift connector 8 - 12 {0.8 - 1.2, 5.8 - 8.7}
Power shift cylinder nuts 59 - 69 {6.0 - 7.0, 43 - 51}
TM-1-8
UNIT NAME: MRT21A, MRT23A

Front case Drain plug 118 - 137 {12.0 - 14.0, 87 - 101}
Main bearing cap mounting bolt 32 - 42 {3.3 - 4.3, 24 - 31}
Switch 108 - 127 {11.0 - 13.0, 80 - 94}
Plug 57 - 76 {5.8 - 7.7, 42 - 56}
Anti-overrun sensor 25 - 34 {2.5 - 3.5, 18 - 25}
Gear cover mounting bolt 19 - 25 {1.9 - 2.6, 14 - 19}
Middle case
Level plug 118 - 137 {12.0 - 14.0, 87 - 101}
Middle case securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Side cover mounting bolt 19 - 25 {1.9 - 2.6, 14 - 19}
PTO gear box mounting bolt and nut 32 - 42 {3.3 - 4.3, 24 - 31}
Bearing retainer securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Rear case securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Drain plug and level plug 118 - 137 {12.0 - 14.0, 87 - 101}
Gear cover mounting bolt 19 - 25 {1.9 - 2.6, 14 - 19}
Anti-overrun sensor 25 - 34 {2.5 - 3.5, 18 - 25}
Speedometer gear sleeve 34 - 44 {3.5 - 4.5, 25 - 33}
Sub countershaft bearing retainer securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Rear case Rear bearing retainer securing bolts Nut 137 - 186 {14.0 - 19.0, 101 - 137}
and nut Bolt 89 - 118 {9.1 - 12.0, 66 - 87}
Splitter 57 - 76 {5.8 - 7.7, 42 - 56}
Piston securing nuts
Range 137 - 186 {14.0 - 19.0, 101 - 137}
Cylinder cap securing bolts 32 - 42 {3.3 - 4.3, 24 - 31}
Switch 108 - 127 {11.0 - 13.0, 80 - 94}
Plug 57 - 76 {5.8 - 7.7, 42 - 56}
Main shaft Main shaft lock nut (Left-hand thread) 412 - 471 {42.0 - 48.0, 304 - 347}
Companion flange securing nut 686 - 981 {70.0 - 100.0, 506 - 723}
Sub main shaft and countershaft
Range high gear lock nut 686 - 981 {70.0 - 100.0, 506 - 723}
Shift fork and shifter securing set screw 32 - 42 {3.3 - 4.3, 24 - 31}
Shift fork assembly
Shift shaft support securing bolts 25 - 31 {2.5 - 3.2, 18 - 23}
Control cover mounting bolt 32 - 42 {3.3 - 4.3, 24 - 31}
Power shift assembly securing bolts 21 - 23 {2.1 - 2.3, 15 - 17}
Joint mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Transmission control cover assembly Guide bolt 57 - 76 {5.8 - 7.7, 42 - 56}
Plug 57 - 76 {5.8 - 7.7, 42 - 56}
Switch 34 - 49 {3.5 - 5.0, 25 - 36}
Cylinder cover securing 8.6 - 12.7 {0.88 - 1.3, 6.4 - 9.4}
TM-1-9

Oil filter securing bolt 32 - 42 {3.3 - 4.3, 24 - 31}
Oil pump securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Oil pump and oil filter
Valve case mounting bolt 16 - 21 {1.6 - 2.1, 12 - 15}
Connector 85 - 98 {8.7 - 10.0, 63 - 72}
Power shift cylinder 98 - 118 {10.0 - 12.0, 72 - 87}
Power shift cylinder screw 2.0 - 3.4 {0.20 - 0.35, 1.4 - 2.5}
Power shift assembly
Power shift connector 8 - 12 {0.8 - 1.2, 5.8 - 8.7}
Power shift cylinder nuts 59 - 69 {6.0 - 7.0, 43 - 51}
SYSTEM DIAGRAM
MTS72D AND MTS73D
WTM396A
TM-1-10
MRT21A AND MRT23A
CTM1137D
CTM1137E
TM-1-11
TOOLS T/M PROPER
TOOLS
UNIT NAME MTS72D, MTS73D
Tool name and number Description Shape
Attached to input shaft splines to

Main drive shaft stopper
prevent the input shaft from ro-
99803 Z0001
tating.
CTL1113
Used when lifting the main shaft

Gear hanger assembly
and countershaft assemblies as
99783 Z0004
a unit.
JTL015A
Main shaft hanger assembly Used when lifting the main shaft
99783 Z0005 assembly.
JTL016A
Attached to the front case when

Gear shaft setting tool
disassembling/reassembling the
99799 Z0004
main shaft.
JTL017A
Attached to the main shaft rear

Construction stand
splines when installing the main
99805 Z0001
shaft tip end.
CTL1117
TM-2-1
TOOLS T/M PROPER
Used to remove the tapered

Puller roller bearing (end of main shaft,
99802 Z0002 end of main drive shaft, end of
countershaft).
JTL018A
Puller bearing attachment

j1 99843 Z0018
j2 99843 Z0019
Used together with the puller to
j3 99843 Z0060
remove the main shaft and
j4 99843 Z0061
countershaft bearing inner race
j5 99843 Z0062
j6 99843 Z0063
j7 99843 Z0064
JTL090A
Used to remove the countershaft

Sliding hammer front bearing outer race from the
99547 Z0003 front case.
Puller bearing attachment (Attach the puller bearing attach-
99843 Z0065 ment to the tip of the sliding
hammer to be used.)
CTL1013A
Used to install the bearing outer

race on the middle case.
Outer race replacer For main drive gear: 99827
j1 99827 Z0106 Z0106
j2 99827 Z0107 For countershaft: 99827 Z0107
(Use together with replacer
j4 99827 Z0109.)
Used to install the input shaft

Inner race replacer bearing inner race
j3 99827 Z0108 (Use together with replacer JTL092A
j4 99827 Z0109.)
Used to rotate the main shaft or

Shaft wrench countershaft when adjusting end
99884 Z0000 play.
99884 Z0001 For mainshaft: 99884 Z0000
For countershaft: 99884 Z0001
WTM410A
TM-2-2
TOOLS T/M PROPER
Used to indicate the master di-

mension when adjusting the
mounting height of 6th-7th gear
Hub set tool synchronizer hub.
j1 99787 Z0003 H = 59.6 mm (2.346 in): 99787
j2 99787 Z0004 Z0003
j3 99787 Z0005 H = 63.13 mm (2.485 in): 99787
Z0004
H = 58 mm (2.28 in): 99787
Z5005 JTL094A
Used to install the bearing outer

race to the front case
Bearing replacer Applicable bearing
j1 99843 Z5005 Outside diameters
j2 99843 Z0066 150 mm (5.91 in) dia.: 99843
j3 99844 Z5000 Z5005
127 mm (5.00 in) dia.: 99843
Z0066
JTL095A
Used to select the washer for

Bushing set tool height adjustment of 6th-7th syn-
99787 Z0004 chronizer hub.
[H = 63.13 mm (2.4854 in)]
JTL023A
Puller assembly Used when pulling the straight

910-11150 (JKC No.) pin on power shift striker.
WTM035A
Guide Used when installing valve on

910-24800 (JKC No.) power shift rod pipe.
WTM036A
Insert tool Used when installing snap ring

910-26500 (JKC No.) on power shift rod pipe.
WTM037A
TM-2-3
TOOLS T/M PROPER
UNIT NAME MRT21A, MRT23A

Used together with the adapter

Sliding hammer
to drive out the reverse idler
99547 Z0000
gear shaft.
CTL1-043
Used to remove/install main

Socket wrench shaft nuts or companion flange.
99535 Z0074 Width across flats = 58 mm
(2.28 in)
CTL1-015
Attached to input shaft splines to

Main drive shaft stopper
prevent the input shaft from ro-
99803 Z0000
tating.
WTM026A
Used when lifting the main shaft

Gear hanger assembly
and countershaft assemblies as
99783 Z0002
a unit.
WTM027A
Used when removing the main

shaft rear nut lock plate and the
Lock plate replacer sub-main shaft bearing outer
99827 Z0069 race as a unit.
(Used with sliding hammer:
99547 Z0000) WTM028A
Attached to the front case when

Gear shaft setting tool
disassembling/reassembling the
99799 Z0003
main shaft.
WTM029A
TM-2-4
TOOLS T/M PROPER
Attached to the main shaft rear

Construction stand
splines when installing the main
99805 Z0000
shaft tip end.
WTM030A
Bushing replacer
1st - 2nd
99801 Z0001 Used when pressing bushings
into bores in the front and
Bushing replacer middle cases.
3rd - 4th
99801 Z0002
Bushing replacer Used when pressing the shift
At control lever shaft bushing into the bore in WTM031A
99801 Z0003 the control cover.
Used as a jig to measure the

Drive gear set tool bearing-to-bearing gap when
99806 Z0000 selecting shims suited to the 4th
gear bearing preload.
WTM032A
Used when pressing the bearing

Bearing retainer replacer
retainer onto the main shaft rear
99827 Z0068
end.
WTM033A
Oil seal replacer

Range side Used when pressing oil seals
99807 Z0004 onto the range-splitter select air
Splitter side cylinder.
99807 Z0005
WTM108A
Used to protect the main shaft

Main shaft adapter end from damage when disas-
99804 Z0000 sembling the main shaft using a
gear puller.
WTM034A
TM-2-5
TOOLS T/M PROPER
Used when removing the bear-

Bearing remover
ing from the main shaft rear
99800 Z0002
bearing retainer.
WTM038A
Used when disassembling and

reassembling the transmission.
Attachment
The attachment is used by in-
99555 Z0000
stalling it on the engine stand
(99550 96001).
WTM072A
Used when pulling out the

Puller assembly
straight pin on power shift
910-11150 (JKC No.)
striker.
WTM035A
Guide Used when installing valve on

910-24800 (JKC No.) power shift rod pipe.
WTM036A
Tool insert Used when installing snap ring

910-26500 (JKC No.) on power shift rod pipe.
WTM037A
TM-2-6
- MEMO -
TM-2-7
CONSTRUCTION MTS72D, MTS73D
= UNIT NAME MTS72D, MTS73D =

CONSTRUCTION
TRANSMISSION ASSEMBLY
WTM339A
TM-3-1
MAIN SHAFT ASSEMBLY
ZTM058A
TM-3-2
COUNTERSHAFT ASSEMBLY
ZTM059A
TM-3-3
POWER SHIFT ASSEMBLY

Unit name MTS72D
WTM150A
TM-3-4
Unit name MTS73D
WTM415A
TM-3-5
DISASSEMBLY MTS72D, MTS73D
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the transmission assembly, turn the key
switch to the ‘‘OFF’’ position and chock the wheels to be safe.
2. Remove the drain plug and drain transmission gear oil from the
transmission case.
3. Remove/disengage the propeller shaft, transmission linkage,
cable, wiring, PTO (when equipped), etc., from around the
transmission case.
CCL1047B
4. Remove the transmission from the flywheel housing. Support

the transmission with a jack or lifting wires to prevent it from
dropping, and remove it from the flywheel housing.
NOTE
+ Do not separate the wear indicator and stay.
WTM043A
TM-3-6
DISASSEMBLY
FRONT CASE, MIDDLE CASE AND REAR CASE ASSEMBLY
WTM411A
TM-3-7
Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)
j1 Drain plug >.j

12 Bearing retainer j
22 Lock lever assembly
j2 Washer j
13 Shaft >.j
23 Middle case
.j3 Lock nut j
14 Needle bearing j
24 Gear cover
j4 O-ring j
15 Lever j
25 Main bearing cap
j5 Companion flange j
16 Shim j
26 O-ring
j6 Speedometer driven gear j
17 Gear cover j
27 Oil sear
>j7 Rear case j
18 Cover or PTO gear box
j
28 Packing
j8 Oil seal j
29 Seal plate
(If equipped)
j9 Roller bearing j
30 O-ring
j
19 Gasket
.j
10 Countershaft 6th-7th gear assembly j
j
31 Reverse switch
20 Setscrew
j
11 Main shaft 6th, 7th and drive gear >.j
32 Front case
j
21 Overrun sensor
assembly
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.
TM-3-8
MAIN SHAFT ASSEMBLY
ZTM061A
j1 Lock nut .j
17 Roller bearing j
32 Needle bearing
j2 O-ring j
18 Main drive gear j
33 Inner race
j3 Companion flange j
19 Oil jet j
34 Thrust washer
.j4 Roller bearing j
20 C-ring j
35 3rd gear
j5 7th gear .j
21 Roller bearing j
36 Needle bearing
j6 6th gear >j
22 Lock nut j
37 Inner race
j7 Shim >j
23 Lock washer
j
38 Synchronizer ring
>.j8 Roller bearing j
24 Synchronizer ring >j
39 Sleeve
j9 1st gear >j
40 Hub
>j
25 Hub
j
10 Needle bearing >j
41 Detent
>j
26 Sleeve
j
11 Inner race >j
42 Plunger
>j
27 Detent
j
12 Sleeve j
43 Spring
>j
28 Plunger
j
13 Hub j
j
29 Spring
j
14 Needle bearing j
45 2nd gear
j
j
15 Inner race j
46 Needle bearing
j j
31 4th gear j
16 Reverse gear 47 Main shaft
TM-3-9
COUNTERSHAFT AND REVERSE IDLER SHAFT ASSEMBLY
ZTM062A
j1 Lock nut j
12 Spring j
23 Counter drive gear
j2 Lock washer j
13 Hub j
24 4th gear
.j3 Roller bearing j
14 Synchronizer ring j
25 Key
j4 Washer j
15 6th gear j
26 Countershaft
j5 7th gear j
16 Needle bearing j
27 Idler shaft
j6 Needle bearing j
17 Inner race j
28 Thrust washer
j7 Inner race j
18 Thrust washer j
29 Thrust bearing
j8 Synchronizer ring j
19 Shim .j
30 Reverse idler gear
j9 Sleeve .j
20 Roller bearing j
31 Needle bearing
j
10 Detent .j
21 Roller bearing j
32 Spacer
j
11 Plunger j
22 O-ring
TM-3-10
SHIFT FORK ASSEMBLY
WTM342A
j1 Fork claw j
13 Locking pin j
24 Setscrew
j2 Setscrew j
14 Shift shaft j
25 Shifter
j3 Shift fork (6th-7th) j
15 Setscrew j
26 Steel ball
j4 Spacer j
16 Shifter j
27 Shift shaft
j5 Shift shaft j
17 Spacer j
28 Setscrew
j6 Setscrew j
18 Fork claw j
29 Shift fork (1st-reverse)
j7 Shifter j
19 Setscrew
j
30 Shift shaft
j8 Shift shaft j j
31 Steel ball
20 Shift fork (2nd-3rd)
j9 Fork claw j
32 Spring
j
21 Spacer
j
10 Setscrew j
33 Bushing
j
22 Locking pin
j
11 Shift fork (4th-5th) j
34 Shift shaft support
j
23 Shift shaft
j
12 Spacer
TM-3-11
TRANSMISSION CONTROL COVER ASSEMBLY

Unit name MTS72D
ZTM064A
j
1 Control cover j9 Select lever j
17 Steel ball
j
2 Joint j
10 Plug j
18 Spring
j
3 Power shift assembly j
11 Spring j
19 Steel ball
j
4 Gasket j
12 Register pin j
20 Spring
j
5 Lever cap j
13 Plug j
21 Neutral switch assembly
j
6 Oil seal j
14 Register pin j
22 Breather
j
7 Straight pin j
15 Spring j
23 Shift shaft
j
8 Shift lever j
16 Spring j
24 Oil seal
TM-3-12
Unit name MTS73D
WTM389A
j1 Bolt j
12 Spring j
22 Bolt
j2 Nut j
13 Register pin j
23 Neutral switch
j3 Washer j
14 Plug j
24 Seat
j4 Bolt j
15 Register pin j
25 Spring
j5 Power shift assembly j
16 Spring j
26 Straight pin
j6 Lever cap j
17 Spring j
27 Steel ball
j7 Oil seal j
18 Steel ball
j
28 Breather
j8 Straight pin j j
29 Shift shaft
19 Spring
j9 Shift lever j
30 Oil seal
j
20 Steel ball
j
10 Select lever j
31 Control cover
j
21 Spring
j
11 Plug
TM-3-13

Unit name MTS72D
ETM073A
>j1 Cylinder boots j

18 Lifter ring j
35 Cylinder O-ring
j2 Connector nut >.j
19 Seat seal assembly .j
36 Cylinder packing
j3 Cylinder connector j
20 O-ring j
37 Rod plate
j4 Retaining ring j
21 Seal spring j
38 Cap packing
j5 Retaining ring plate j
22 O-ring j
39 Striker
.j6 Straight pin >.j
23 Seat seal assembly j
40 Piston ring
j7 Tube filter j
24 Spring seat j
41 Piston
j8 Tube collar j
25 Lifter ring >j
42 Piston packing
j9 Tube j
26 Lifter spring j
43 Piston O-ring
j
10 Lifter ring j
27 Lifter j
44 Piston ring
j
11 O-ring j
28 Lifter O-ring j
45 Rod pipe
>j
12 Tube ring j
29 Tube j
46 Housing hose clamp
j
13 Rod pipe plate j
30 Lifter ring j
47 Housing hose
j
14 Lifter j
31 Rod pipe j
48 Housing boot clamp
j
15 Lifter O-ring >j
32 Rod cap assembly j
49 Housing boot
j
16 Lifter spring >j
33 Housing setscrew j
50 Housing
j
17 Spring seat j
34 Cylinder
TM-3-14
Unit name MTS73D

Power shift assembly
WTM416A
j1 -j7 Repair kit j

13 Sleeve j
18 Boots
j8 Ring j
14 Ring j
19 Lock band
j9 Piston j
15 Boots j
20 Filter
j
10 Ring j
16 Ring j
21 Cylinder
j
11 Rod and cap assembly j
17 Washer
j
12 Joint
TM-3-15
Rod and cap assembly
WTM417A
j1 -j16 Repair kit j

23 Spring j
30 Bushing
j
17 Separator j
24 Lifter j
31 Rod assembly B
j
18 Valve j
25 Retaining ring j
32 Rod assembly C
j
19 Spring j
26 Pin j
33 Lifter
j
20 Pipe j
27 Plate D j
34 Spring
j
21 Valve j
28 Input rod
j
22 Separator j
29 Pin
TM-3-16
OIL PUMP AND OIL FILTER
WTM412A
.j
1 Oil pump assembly j
4 Gasket j
7 Valve spring
j
2 Gasket j
5 Oil strainer j
8 Valve cap
j
3 Oil filter assembly j
6 Steel ball
TM-3-17
Key point of disassembly
+ Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.
+ Attach the main drive shaft stopper (99803 Z0001) to input

shaft splines.
CTM1314B
FRONT CASE, MIDDLE CASE AND REAR CASE AS-

SEMBLY
j
3 Lock nut
CAUTION
+ Before removing the lock nut, make sure the transmission
case is securely fixed.
NOTE
+ Do not re-use the lock nut after removal. JTM043A
j10 Countershaft 6th-7th gear assembly

Release the caulking of nut at the rear end of countershaft
(bending of lock washer), then loosen the nut and remove it.
JTM052A
j
12 Bearing retainer
Remove the bearing retainer, shim and O-ring.
NOTE
+ Attach a tag to the shim for identification purposes.
ZTM065A
TM-3-18
j
23 Middle case
Lift the middle case until it is moved away from the various shift
shafts and splitter shafts.
NOTE
+ Set the middle case as level as possible during lifting. Do
not apply undue stress to shift shafts.
CTM1-322
j
32 Front case
Using the sliding hammer (99547 Z0003) and puller bearing
attachment (99843 Z0065), remove the countershaft front bearing
outer race from the front case.
JTM076A
SHIFT FORK ASSEMBLY

Attach the gear hanger assembly (99783 Z0004) to the main shaft,
countershaft, and shift shafts.
ZTM066A
Attach the main shaft hanger assembly (99783 Z0005) by means

of the main shaft rear nut. Then, lift the main shaft assembly until
the tapered roller bearing of main drive gear protrudes from the
front case.
ZTM067A
Position the gear shift setting plate (99799 Z0004) on top of the
front case and gently lower the gear shaft assembly.
ZTM068A
TM-3-19
MAIN SHAFT ASSEMBLY

1. Using the gear hanger assembly (99783 Z0004), remove the
main shaft sub assembly from the input shaft assembly.
CTM1322M
2. Attach the main shaft sub assembly to the construction stand

(99805 Z0001).
Remove the gear hanger assembly.
JTM069A
j
4 ,j 8 ,j17 , j
21 Roller bearing
Remove the roller bearing using the puller (99802 Z0002) attached
with the puller bearing attachment.
Main shaft: 99843 Z0019, 99843 Z0061
Main drive gear: 99843 Z0018, 99843 Z0061
JTM070A
COUNTERSHAFT AND REVERSE IDLER SHAFT AS-

SEMBLY
j
3 ,j 20 , j
21 Roller bearing
Remove the roller bearing using the puller (99802 Z0002) attached
with the puller bearing attachment.
Front end: 99843 Z0019, 99843 Z0063
Rear end: 99843 Z0019, 99843 Z0064
WTM413A
j30 Reverse idler gear

To remove the reverse idler gear, first remove the reverse shaft
lock bolt and install the bolt to the threaded hole at the tip of the
reverse idler shaft and pull out the reverse idler gear.
JTM057A
TM-3-20
POWER SHIFT ASSEMBLY (MTS72D ONLY)

j6 Straight pin
Remove the retaining ring and retaining ring plate.
Using the puller assembly (910-11150 JKC NO.), pull out the
straight pin.
WTM114A
CTM1255E
j
19 , j23 Seat seal assembly
Remove the valve assembly.
NOTE
+ Be careful not to damage spring seat and lifter ring during
removal.
CTM1-256
j
36 Cylinder packing
Remove the cylinder packing and cap packing.
NOTE
+ These parts need not be removed unless damaged.
CTM1262B
OIL PUMP AND OIL FILTER

j1 Oil pump assembly
Remove the oil pump assembly.
NOTE
+ Do not loosen the oil pump assembly mounting bolts.
WTM414A
TM-3-21
INSPECTION MTS72D, MTS73D
INSPECTION
+ Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
+ If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
TRANSMISSION COVER
Clearance between shift lever and select lever
Unit: mm (in)
Maintenance standard Service limit
0.16 - 0.44 (0.0063 - 0.0173) 0.8 (0.031)
CTM1-177
Radial play between shift shaft and shift lever splines

Unit: mm (in)
0.05 - 0.13 (0.0020 - 0.0051) 0.5 (0.020)
CTM1-178
Clearance between shift lever and shifters

Unit: mm (in)
0.74 - 0.96 (0.0291 - 0.0378) 1.0 (0.039)
CTM1-179
Clearance between transmission cover and shift fork

shaft
Unit: mm (in)
Maintenance standard Service limit Remarks
0.07 - 0.17
2nd & 3rd
(0.0028 - 0.0067)
0.3 (0.012)
0.06 - 0.15 4th & 5th
(0.0024 - 0.0059) 6th & 7th
TM-3-22
Clearance between locking lever and lever shaft

Unit: mm (in)
0.04 - 0.08 (0.0016 - 0.0031) 0.2 (0.008)
CTM1-180
Clearance between locking lever and lever shifter

Unit: mm (in)
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)
CTM1-182
Clearance between locking lever and shift shaft

Unit: mm (in)
1st & Reverse
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)
6th & 7th
Shift fork shaft locking spring

Unit: mm (in)
CTM1180B
Maintenance
Item Service limit Remarks
standard
42.5
Free length —
(1.673)
Tension 137 - 167 When compressed to
—
N {kgf, lbf} {14 - 17, 31 - 37} 29 mm (1.14 in)
Clearance between shift fork and sleeve groove

Unit: mm (in)
0.10 - 0.24 (0.0039 - 0.0094) 1.0 (0.039)
CTM1-086
TM-3-23
NOTE
+ Measure the clearance at the sleeve groove in at least
three points.
Clearance between each fork claw and synchronizer

sleeve
Unit: mm (in)
0.1 - 0.5 (0.004 - 0.020) 1.0 (0.039)
CTM1086A
Clearance between each fork claw and shift fork

Unit: mm (in)
0.02 - 0.05 (0.0008 - 0.0020) —
CTM1086B
TRANSMISSION PROPER
Each main gears and counter gear backlash
Unit: mm (in)
0.10 - 0.20 (0.0039 - 0.0079) 0.5 (0.020)
Each main gear end play

Unit: mm (in)
0.20 - 0.40 (0.0079 - 0.0157) 0.7 (0.028)
TM-3-24
End play of rear countershaft gears

Unit: mm (in)
0.20 - 0.40 (0.0079 - 0.0157) 0.7 (0.028)

Unit: mm (in)
0.10 - 0.70 (0.0039 - 0.0276) 1.0 (0.039)
Radial play of main shaft and sleeve splines

Unit: mm (in)
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)
Radial play between hub and sleeve splines

Unit: mm (in)
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)
Radial play between sleeve and clutch gear splines

Unit: mm (in)
0.20 - 0.30 (0.0079 - 0.0118) 1.0 (0.039)
TM-3-25
Ball bearing axial play

Unit: mm (in)
— 0.5 (0.020)
CPS1-014
SYNCHRONIZER SYSTEM
Clearance between synchronizer ring and their cone
Unit: mm (in)
1.4 - 1.8 (0.055 - 0.071) 2nd & 3rd
— 4th & 5th
1.4 - 2.0 (0.055 - 0.079)
6th & 7th
CTM1-088
Tangential clearance between synchronizer ring and

synchronizer hub
Unit: mm (in)
6.3 - 6.7 (0.248 - 0.264) —
CTM1089C
Radial clearance between synchronizer hub and syn-

chronizer detent
Unit: mm (in)
0.1 - 0.3 (0.004 - 0.012) —
CTM1186A
Detent spring
Unit: mm (in)
Maintenance
standard
Free length 25.0 (0.984) —
56.9 - 68.6
Tension When compressed to
{5.8 - 7.0, —
N {kgf, lbf} 18.0 mm (0.709 in)
12.8 - 15.4}
TM-3-26
OIL PUMP
Clearance between drive shaft and case
Unit: mm (in)
0.06 - 0.09 (0.0024 - 0.0035) 0.20 (0.0079)
Clearance between driven shaft and case

Unit: mm (in)
0.06 - 0.09 (0.0024 - 0.0035) 0.20 (0.0079)
Drive and driven gear end play

Unit: mm (in)
0.7 After tightening bolts to
0.03 (0.0012), min.
(0.028) 20 N·m {2 kgfzm, 14 ftzlbf}
Fit of drive shaft and front of countershaft at notch lo-

cation
Unit: mm (in)
0.20 - 0.40 (0.0079 - 0.0157) 0.7 (0.028)
TM-3-27
POWER SHIFT
Power shift spring
Unit: mm (in)
Maintenance Service
Item Remarks
standard limit
18.1
Item No. j
16 —
(0.713)
21.0
Free length Item No. j
21 —
(0.827)
15.0
Item No. j
26 —
(0.591)
47.1 40.2 When compressed to
Item No. j
16
{4.8, 10.6} {4.1, 9.0} 13.0 mm (0.512 in)
Tension 12.7 10.8 When compressed to
Item No. j
21
N {kgf, lbf} {1.3, 2.9} {1.1, 2.4} 10.0 mm (0.394 in)
Item No. j
26
{1.9, 4.2} {1.6, 3.5} 13.0 mm (0.512 in)
Valve seal dent depth

Unit: mm (in)
0.15 (0.0059), max. —
CTM1263A
TM-3-28
REASSEMBLY MTS72D, MTS73D
REASSEMBLY
REASSEMBLY
+ When assembling or installing parts, pay attention to the
direction of gears, thrust washers, etc.
+ Do not confuse one type of needle bearing and spacer with
others.
+ Do not allow foreign particles to enter the needle bearings.
+ Apply a coat of clean gear oil to rotating parts.
+ After installing gears, manually rotate to ensure smooth rotation
without noise.
+ Use new oil seals and O-rings.
Apply a coat of RTV (Room Temperature Vulcanizing) liquid gasket
(Three Bond #1215 or equivalent) to the mating surfaces of the
middle case, rear case, side cover and control cover during
installation. Observe the following precautions during gasket ap-
plication.
<Precautions during RTV liquid gasket application>
+ Remove all traces of liquid gasket from the flanged surface of
parts using a scraper. Be careful not to scratch the flanged
surface and completely wipe away foreign particles (grease,
water, dust, etc.) using a clean cloth.
+ Apply a continuous coat of liquid gasket to the inner edge of the

flange and the center of the bolt hole, as well as to the outer
edge of the flange and the area as close as possible to the bolt
holes. The gasket bead width must be 3 mm (0.12 in).
For detailed information concerning the gasket application, refer to
the gasket application drawing in the text.
+ Also apply an equal and continuous bead of liquid gasket to
areas where the flanged surface is narrow (due to cutouts,
etc.); do not apply an excess coat to the gasket.
+ Install parts within 2 - 20 minutes of gasket application. Leave
parts unattended for approximately 2 hours, allowing the CDF1-051
gasket to completely harden.
POWER SHIFT ASSEMBLY (MTS72D ONLY)
Key point of reassembly
j42 Piston packing
Install the piston packing and piston O-ring on the piston, and the
piston assembly and retaining ring on the shifter rod.
ETM122A
j33 Housing setscrew

Install the housing setscrew and clinch in two locations.
CTM1-270
TM-3-29
j32 Rod cap assembly

Apply air master paste to various parts. Place a tube rod of 10 to
11.5 mm (0.394 to 0.453 in) in diameter in a vise.
Install the rod pipe and tube on the rod cap assembly, and pass the
assembled unit through the hole in the rod.
CTM1-265
j19 , j
23 Seat seal assembly
Install the O-ring on the lifter, the lifter ring on the spring seat and
the O-ring on the seat seal assembly.
j
1 Lifter j
5 Lifter ring
j
2 Lifter O-ring j
j
3 Lifter spring j
7 O-ring
j
4 Spring seat
CTM1266A
NOTE
+ Be sure to install the springs in the correct sequence.
CTM1-267
j
12 Tube ring
1. Using the insert tool (910-26500 JKC No.) install the tube ring.
CTM1-268
2. Using the guide (910-24800 JKC No.) install the valve assem-
bly.
NOTE
+ Apply a coat of silicone grease to inner side of the rod
pipe. Be careful not to damage the seals.
CTM1-271
TM-3-30
j1 Cylinder boots
Install the boot.
NOTE
+ Ensure that the drain hole in the boot faces downward
during installation.
CTM1-252
+ Functional check
After assembling, apply 736 kPa {7.5 kgf/cm2, 107 psi} of com-
pressed air to the power shift assembly to ensure that the valve
moves in both the pull and push directions, as well as to the neutral
position. Also check that valve is air-tight. Check the valve’s sliding
resistance in the push and pull directions.
Item Specifications
Air-tightness inspection 10 kPa {0.1 kgf/cm2, 1 psi}, max.
(during non-operation) (pressure drop for 15 seconds)
(during operation) (pressure drop for 15 seconds)
Sliding resistance in shift directions 51.0 N {5.2 kgf, 11.5 lbf}, max.
MAIN SHAFT ASSEMBLY

+ Heat each gear and the following parts in an oil bath and then
assemble them. [Oil temperature: 100°C (212°F)]
+ Tapered bearing
+ Inner race
+ Securely attach the main shaft to the construction stand (99805
Z0001).
NOTE
+ Make sure that the construction stand is securely fixed in
place.
TM-3-31
j39 - j42 2nd-3rd gear synchronizer assembly

Install the 2nd-3rd gear synchronizer sleeve and hub.
1. Install the detent and lock plunger together with the spring, onto
the synchronizer hub.
NOTE
+ To install the detent, press the plunger with a screwdriver
or similar tool.
ZTM069A
2. Install the synchronizer sleeve.

NOTE
+ While installing, press the detent with a screwdriver.
+ Align the detent with the sleeve notch to install the sleeve.
ZTM070A
j25 - j
28 4th-5th gear synchronizer assembly
Install the 4th-5th gear synchronizer sleeve and hub.
ZTM071A
j22 Lock nut, j 23 Lock washer

Install the lock nut and bend the lock washer.
: 490 - 588 N·m {50.0 - 60.0 kgfzm, 362 - 434 ftzlbf}
NOTE
+ Be careful to install the synchronizer sleeve assembly in
the correct direction.
+ Make sure that assembled gears rotate smoothly, there is
no excessive end play [allowable end play: 0.2 to 0.4 mm
(0.008 to 0.016 in)], and that the synchronizer sleeve slides
ZTM072A
smoothly.
CTM1322N
TM-3-32
+ Set the gear shift setting plate (99799 Z0004) on a work bench
or front case. Then, use the main shaft hanger assembly
(99783 Z0005) to gently place the main shaft.
JTM090A
+ Set the gear shift setting plate (99799 Z0004) to the upper
surface of the front case and slowly position the input shaft
assembly.
JTM095A
+ Using the main shaft hanger assembly (99783 Z0005), install

the main shaft assembly onto the input shaft assembly.
NOTE
+ When installing the main shaft assembly, be careful not to
bend the oil jet of input shaft assembly.
+ Align the detent positions of 5th gear synchronizer ring
and hub.
ZTM074A
j8 Roller bearing
Install the taper roller bearing to the shaft. Verify the following:
+ The installed gear rotates smoothly.
+ There is no excessive end play. [End play: 0.20 - 0.40 mm
(0.0079 - 0.0157 in)]
+ The synchronizer sleeve moves smoothly (shakes).
JTM092A
SHIFT FORK ASSEMBLY

1. Using set screws, install the reverse-1st gear shift fork, 4th-5th
gear shift fork, and fork claws on the shift shafts.
: 32 - 42 N·m {3.3 - 4.3 kgfzm, 24 - 31 ftzlbf}
NOTE
+ After tightening setscrews, caulk the threads at three
locations.
ZTM075A
TM-3-33
2. Install the 2nd-3rd gear shift fork, shifter, fork claws, reverse-
1st gear shifter, and 6th-7th gear shifter.
: 32 - 42 N·m {3.3 - 4.3 kgfzm, 24 - 31 ftzlbf}
NOTE
+ After tightening setscrews, caulk the threads at three
locations.
ZTM076A
3. Attach the gear hanger assembly (99783 Z0004) to the main

shaft assembly, countershaft assembly and shift shaft assem-
bly with support.
ZTM077A
4. Using the main shaft hanger assembly (99783 Z0005), lift the
main shaft assembly, then remove the gear shift setting tool
from the top of front case.
NOTE
+ During operation, hold shaft assemblies in position so that
they do not separate.
JTM103A
5. Install the gear cover and shift shaft support with bolts and nuts.
Tightening torque to install the cover:
19 - 25 N·m {1.9 - 2.6 kgfzm, 14 - 19 ftzlbf}
Tightening torque to install the support:
32 - 42 N·m {3.3 - 4.3 kgfzm, 24 - 31 ftzlbf}
NOTE
+ Apply a coat of Threebond (TB#1382) to bolts and nuts.
ZTM078A
FRONT CASE, MIDDLE CASE AND REAR CASE

j
32 , j23 Front case and Middle case
1. Using the bushing replacer [99801 Z0002 for bushing inner
diameter 25 mm (0.98 in) or 99801 90001 for bushing inner
diameter 30 mm (1.18 in)], drive the bushing into the front and
middle cases. The bushings must be installed with clinch
positioned 90 degrees counterclockwise when seen from the
mounting position (positioned horizontally to the transmission
mounting direction). ZTM079A
TM-3-34
2. Using the outer race replacer (99843 Z5005 for input shaft,
combination of 99843 Z0066 and press rod 99844 Z5000 for
countershaft), install the input shaft bearing outer race and
countershaft front bearing outer race.
JTM078A
j
23 Middle case
1. Apply liquid gasket to the mating surface of the front and middle
cases.
CTM1296M
2. Lower the middle case vertically and install it.

: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
NOTE
+ Slowly lower the middle case keeping it as level as pos-
sible to prevent shift shafts from being caught in guide
bushes inside the case.
JTM060A
3. Using the outer race replacer (99827 Z0106 for main shaft or
99827 Z0107 for countershaft) together with the replacer
(99827 Z0109), install the bearing outer race on the middle
case.
ZTM080A
TM-3-35
j7 Rear case
Apply liquid gasket to the mating surface of the middle and rear
cases.
CTM1296J
<Adjusting end play of the main shaft>

1. Install two shims of 2 mm (0.08 in) thickness as master shims
to fit the main shaft rear bearing outer race.
ZTM081A
2. Install the retainer and tighten the three bolts indicated by ..

: 3 N·m {0.3 kgfzm, 2.2 ftzlbf}
JTM109A
3. Using the shaft wrench (99884 Z0000), rotate the main shaft a
few turns and tighten the bolts to 6 N·m {0.6 kgfzm, 4.3 ftzlbf}.
4. Rotate the main shaft a few turns again and retighten the bolts
to 6 N·m {0.6 kgfzm, 4.3 ftzlbf}.
5. Repeat steps 3 and 4 until there is no looseness.
NOTE
+ Tightening torque must not exceed specifications.
JTM110A
6. Around the bolts that have been tightened, measure the

clearance between the mounting surface (end surface of
middle case) and the retainer, then average the measurements
to obtain the average value C1.
ZTM082A
TM-3-36
7. Using the following equation, select the shim of thickness

nearest to the required shim thickness X1 from the table below.
Equation: X1 = 3.539 − C1
Unit: mm (in)
Thickness of
1.22 (0.0480) 1.28 (0.0504) 1.34 (0.0528) 1.40 (0.0551) 1.46 (0.0575) 1.52 (0.0598)
shim
1.190 - 1.249 1.250 - 1.309 1.310 - 1.369 1.370 - 1.429 1.430 - 1.489 1.490 - 1.549
Range of X1
(0.0469 - 0.0492) (0.0492 - 0.0515) (0.0516 - 0.0539) (0.0539 -0.0563) (0.0563 - 0.0586) (0.0587 - 0.0610)
Unit: mm (in)
Thickness of
1.58 (0.0622) 1.64 (0.0646) 1.70 (0.0669) 1.76 (0.0693) 1.82 (0.0717) 1.88 (0.0740)
shim
1.550 - 1.609 1.610 - 1.669 1.670 - 1.729 1.730 - 1.789 1.790 - 1.849 1.850 - 1.909
Range of X1
(0.0610 - 0.0633) (0.0634 - 0.0657) (0.0657 - 0.0681) (0.0681 - 0.0704) (0.0705 - 0.0728) (0.0728 - 0.0752)
Unit: mm (in)
Thickness of
1.94 (0.0764) 2.00 (0.0787) 2.06 (0.0811) 2.12 (0.0835)
shim
1.910 - 1.969 1.970 - 2.029 2.030 - 2.089 2.090 - 2.149
Range of X1
(0.0752 - 0.0775) (0.0776 - 0.0799) (0.0799 - 0.0822) (0.0823 - 0.0846)
<Adjusting end play of the countershaft>

1. Install two shims of 2 mm (0.08 in) thickness as master shims
to fit the countershaft rear bearing outer race.
ZTM083A
2. Install the retainer and tighten three bolts indicated by ..

JTM113A
3. Using the shaft wrench (99884 Z0001), rotate the countershaft

a few turns and tighten the bolts to 6 N·m {0.6 kgfzm, 4.3 ftzlbf}.
JTM114A
TM-3-37
4. Rotate the countershaft a few turns again and retighten the

bolts to 6 N·m {0.6 kgfzm, 4.3 ftzlbf}.
5. Repeat steps 3 and 4 until there is no looseness.
NOTE
+ Tightening torque must not exceed specifications.
6. Around the bolts that have been tightened, measure the

clearance between the mounting surface (end surface of
middle case) and the retainer, then average the measurements
to obtain the average value C2.
ZTM084A
7. Using the following equation, select the shim of thickness

nearest to the required shim thickness X2 from the table below.
Equation: X2 = 3.575 − C2
Unit: mm (in)
Thickness of
1.34 (0.0528) 1.40 (0.0551) 1.46 (0.0575) 1.52 (0.0598) 1.58 (0.0622) 1.64 (0.0646)
shim
1.310 - 1.369 1.370 - 1.429 1.430 - 1.489 1.490 - 1.549 1.550 - 1.609 1.610 - 1.669
Range of X2
(0.0516 - 0.0539) (0.0539 - 0.0563) (0.0563 - 0.0586) (0.0587 - 0.0610) (0.0610 - 0.0633) (0.0634 - 0.0657)
Unit: mm (in)
Thickness of
1.70 (0.0669) 1.76 (0.0693) 1.82 (0.0717) 1.88 (0.0740) 1.94 (0.0764) 2.00 (0.0787)
shim
1.670 - 1.726 1.730 - 1.789 1.790 - 1.849 1.850 - 1.909 1.910 - 1.969 1.970 - 2.029
Range of X2
(0.0657 - 0.0680) (0.0681 - 0.0704) (0.0705 - 0.0728) (0.0728 - 0.0752) (0.0752 - 0.0775) (0.0776 - 0.0799)
Unit: mm (in)
Thickness of
2.06 (0.0811) 2.12 (0.0835) 2.18 (0.0858) 2.24 (0.0882) 2.30 (0.0906)
shim
2.030 - 2.089 2.090 - 2.149 2.150 - 2.209 2.210 - 2.269 2.270 - 2.329
Range of X2
(0.0799 - 0.0822) (0.0823 - 0.0846) (0.0846 - 0.0870) (0.0870 - 0.0893) (0.0894 - 0.0917)
j12 Bearing retainer

Install the selected shim, then attach the retainer.
: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
ZTM065A
TM-3-38
<Adjusting mounting height of the synchronizer hub>

1. Using the dial gauge and hub set tool [99787 Z0005, H = 58
mm (2.28 in)], measure the distance (height A) between middle
case top surface and 6th-7th gear shift lever end.
NOTE
+ Set the shift shaft in Neutral position.
+ The dial gauge probe must be contacted with the shift
lever at highest position.
+ If lever backlash is present, measure maximum and mini-
mum distances and use a medium value.
ZTM085A
2. Install the bushing set tool [99787 Z0004, H = 63.13 mm

(2.4854 in)] to the countershaft.
3. Using the dial gauge, measure the difference (X) between the
shift lever height at end and the master bushing height at top
surface.
NOTE
+ When the master bush height at top surface in measured,
set the dial gauge to zero (0) with the height of shift lever.
ZTM086A
4. Depending on the difference (X) between the heights of shift

lever and master bushing, select the most suitable thrust
washer from the table below.
Unit: mm (in)
Thickness of washer 17.5 (0.689) 16.9 (0.665) 18.1 (0.713)
+0.39 to −0.39
+0.4 (+0.016), −0.4 (−0.016),
Range of X (+0.0154 to
min. max.
−0.0154)
5. Warm the selected thrust washer and 6th gear inner race by
immersion in an oil bath at 100°C (212°F), then install them on
the countershaft.
NOTE
+ Be careful to install the thrust washer in the correct
direction.
ZTM087A
6. Using the dial gauge and hub set tool [99787 Z0003, H = 59.6
mm (2.346 in)], measure the distance (height B) between
middle case top surface and inner race end surface.
ZTM088A
TM-3-39
7. According to the following equation, obtain the difference (C)

between 6th-7th gear shift lever end and synchronizer hub.
Equation: C = B − A − 1.487
Specified value of difference (C): within ±0.4 mm (0.016 in)
NOTE
+ Make sure that the difference (C) is within specifications.
JTM121A
j7 Rear case
Using the bushing replacer (99801 Z0002), install a bushing into
the rear case. The bushing must be installed with clinch positioned
90 degrees counterclockwise when seen from the mounting posi-
tion (positioned horizontally to the transmission mounting direc-
tion).
ZTM079A
INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission in
the vehicle.
Be sure to align the main drive shaft with the clutch disc at their
splines.
2. Install the propeller shaft transmission linkage, cable, wiring,
PTO (when equipped), clutch booster, etc., in their original
positions.
CCL1047A
TM-3-40
- MEMO -
TM-3-41
CONSTRUCTION MRT21A, MRT23A
= UNIT NAME MRT21A, MRT23A =

CONSTRUCTION
WTM182A
TM-4-1
MAIN SHAFT ASSEMBLY
WTM148A
WTM149A
TM-4-2
WTM150A
TM-4-3
DISASSEMBLY MRT21A, MRT23A
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the transmission assembly, turn the key
switch to the ‘‘OFF’’ position and chock the wheels to be safe.
2. Remove the drain plug and drain transmission gear oil from the
transmission case.
3. Remove/disengage the propeller shaft, transmission linkage,
cable, wiring, PTO (when equipped), etc., from around the
transmission case.
4. Remove the transmission from the flywheel housing. Support CCL1047A
the transmission with a jack or lifting wires to prevent it from
dropping, and remove it from the flywheel housing.
NOTE
+ Do not separate the wear indicator and stay.
WTM043A
TM-4-4
DISASSEMBLY
MIDDLE CASE ASSEMBLY
ETM210A
>j
1 Bearing retainer >j
6 Side cover j9 Gear cover
j
2 Oil seal ring (PTO gear box: if so equipped) j
10 Bear cap
.j
3 Gear cover >j
7 Reverse idler gear assembly j
11 Oil seal
j
4 Anti-overrun sensor .>j
8 Middle case j
12 O-ring
.j
5 Neutral detection switch
TM-4-5
REAR CASE ASSEMBLY
ETM211A
TM-4-6
j
1 Rear bearing retainer j9 Cylinder cap j
17 Range piston
j
2 Gasket j
10 O-ring >j
18 Air cylinder
j
3 Oil seal j
11 O-ring j
19 Air/oil seal
j
4 Speedometer driven gear j
12 O-ring j
20 Air/oil seal
assembly j
13 Piston packing j
21 Pin
>j
5 Speedometer drive gear j
14 Splitter piston j
22 Gasket
j
6 Anti-overrun sensor j
15 O-ring >.j
23 Rear case
.j
7 Sub countershaft bearing retainer j
16 Piston packing j
24 Gear cover
j
8 Adjusting shim
TM-4-7
FRONT CASE ASSEMBLY
WTM097A
j
1 Top cover j9 Release sleeve j
17 Needle bearing
j
2 Rubber seat j
10 Release bearing j
18 Oil seal
j
3 Air cleaner case (upper) j
11 Set bolt j
19 Grease nipple
j
4 Air cleaner element j
12 Release shaft j
20 Plug
j
5 Air cleaner case (lower) j
13 Key j
21 Taper plug
j
6 Grease nipple j
14 Release yoke j
22 Under cover
j
7 Hose j
15 Release yoke bearing j
23 Rubber seat
j
8 Spring j
16 Oil seal j
24 Front case
NOTE
+ Numbers before part names do not indicate the disassembly sequence.
TM-4-8
OIL PUMP AND OIL FILTER ASSEMBLY
WTM345A
TM-4-9
MAIN SHAFT ASSEMBLY
WTM328A
j1 Tapered bearing j
17 Detent spring >j
33 Detent spring
j2 Reverse gear j
18 2nd double synchro assembly >j
34 3rd-4th synchro sleeve
j3 Reverse sleeve j
19 2nd gear >j
35 3rd synchro ring
j4 Needle bearing j
20 Needle bearing j
36 3rd gear
j5 Reverse gear bearing inner race >.j
21 Lock nut (LH thread) j
37 Needle bearing
j6 Reverse hub j
22 Tapered bearing j
38 Main shaft
j7 1st gear j
23 Thrust washer j
39 Adjusting shim
j8 Needle bearing j
24 Tapered bearing j
40 Detent
j9 Spacer j
25 Synchro ring j
41 Detent spring
j
10 Needle bearing j
26 Drive gear assembly .j
42 Clip
j
11 1st gear bearing inner race j
27 Synchro ring .j
43 Tapered bearing
j
12 1st double synchro assembly >j
28 Adjusting spacer j
44 Splitter synchro sleeve
j
13 1st-2nd synchro sleeve j
29 Tapered bearing .j
45 Splitter gear
j
14 1st-2nd synchro hub >j
30 3rd-4th synchro hub .j
46 Splitter synchro ring
j
15 Detent >j
31 Detent .j
47 Needle bearing
j
16 Synchro plunger >j
32 Synchro plunger .j
48 Input shaft
TM-4-10
ETM146A
j
1 Adjusting shim j
4 Clip j
7 Key
j
2 Tapered bearing* j
5 Splitter counter gear j
8 Countershaft
j
3 Tapered bearing* j
6 Counter drive gear
*: Do not reuse parts after removal.
TM-4-11
SUB MAIN SHAFT AND SUB COUNTERSHAFT ASSEMBLY
ETM145A
j
1 Lock nut j8 Needle bearing j
15 Synchro cone
j
2 O-ring j9 Range synchro sleeve .j
16 Sub countershaft assembly
j
3 Companion flange j
10 Detent .j
17 Tapered bearing
j
4 Dust shield j
11 Detent spring >j
18 Lock washer
j
5 Ball bearing j
12 Range double synchro assembly j
19 Range high gear lock nut
j
6 Thrust washer j
13 Output shaft >.j
20 Range high gear
.j
7 Range low gear j
14 Synchro ring
TM-4-12
SHIFT FORK ASSEMBLY
ETM212A
j
1 Pin j
10 3rd-4th shift shaft j
19 Setscrew
j
2 Ring j
11 Setscrew j
20 Ring
j
3 Clip j
12 1st-2nd shift shaft j
21 Reverse shifter
j
4 Range shift fork j
13 Fork claw j
22 Reverse shift shaft
j
5 Fork claw j
14 1st-2nd shift shaft j
23 Shift support
j
6 Range shift shaft j
15 Setscrew j
24 Setscrew
j
7 Setscrew j
16 1st-2nd shifter j
25 Splitter shift fork
j
8 3rd-4th shift fork j
17 Setscrew j
26 Fork claw
j
9 Fork claw j
18 Reverse shift fork j
27 Splitter shift shaft
TM-4-13
TRANSMISSION CONTROL COVER ASSEMBLY
WTM337A
j1 Plug j
13 Oil seal j
25 Cylinder cover
j2 Spring j
14 Straight pin j
26 Needle bearing
j3 Steel ball (large) j
15 Spring pin j
27 Oil seal
j4 Steel ball (small) j
16 Shift lever j
28 Shift shaft
j5 Range shift switch j
17 Select lever j
29 Washer
j6 Gasket j
18 Bushing j
30 Spring
j7 Plunger j
19 Shift shaft j
31 Plug
j8 Plug j
20 Collar j
32 Retaining ring
j9 Spring j
21 Spring j
33 Gasket
j
10 Plunger j
22 Packing j
34 Power shift assembly
j
11 Guide bolt j
23 Piston j
35 Joint
j
12 Lever cap j
24 O-ring
TM-4-14
ETM073A
>j1 Cylinder boots j

18 Lifter ring j
35 Cylinder O-ring
j2 Connector nut >.j
19 Seat seal assembly .j
36 Cylinder packing
j3 Cylinder connector j
20 O-ring j
37 Rod plate
j4 Retaining ring j
21 Seal spring j
38 Cap packing
j5 Retaining ring plate j
22 O-ring j
39 Striker
.j6 Straight pin >.j
23 Seat seal assembly j
40 Piston ring
j7 Tube filter j
24 Spring seat j
41 Piston
j8 Tube collar j
25 Lifter ring >j
42 Piston packing
j9 Tube j
26 Lifter spring j
43 Piston O-ring
j
10 Lifter ring j
27 Lifter j
44 Piston ring
j
11 O-ring j
28 Lifter O-ring j
45 Rod pipe
>j
12 Tube ring j
29 Tube j
46 Housing hose clamp
j
13 Rod pipe plate j
30 Lifter ring j
47 Housing hose
j
14 Lifter j
31 Rod pipe j
48 Housing boot clamp
j
15 Lifter O-ring >j
32 Rod cap assembly j
49 Housing boot
j
16 Lifter spring >j
33 Housing setscrew j
50 Housing
j
17 Spring seat j
34 Cylinder
TM-4-15
+ Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.
+ Install the transmission assembly to the attachment (99555

Z0000).
WTM105A
+ Attach the main drive shaft stopper (99803 Z0000) to input

shaft splines.
CTM1314B
+ When the control cover is removed, attach the stopper and

push the shift shaft with a screwdriver to engage gears (to enter
shifted condition).
CTM1314A
+ Unlock the lock nut, and remove the lock nut using socket
wrench (99535 Z0074).
CAUTION
+ Before removing the lock nut, make sure the transmission
case is securely fixed.
NOTE
+ Do not re-use the lock nut after removal.
WTM154A
TM-4-16
REAR CASE ASSEMBLY

j7 Sub countershaft bearing retainer
Remove the sub countershaft bearing retainer, shim and O-ring.
NOTE
+ Attach a tag to the shim for identification purposes.
CTM1320A
j
23 Rear case
1. Remove the nuts and washers securing the splitter and range
pistons.
CTM1319A
2. While holding the end of the shaft by hand, apply compressed

air to the cylinder to push out the range and splitter pistons.
CTM1319B
3. Lightly tap the points (indicated by the arrows in the figure at

right), then remove the air cylinder.
CTM1319C
4. Remove the splitter shift shaft locking plug.
CTM1321A
TM-4-17
5. Remove the transmission anti-overrun sensor.
CTM1-318
6. Install and tighten rear case mounting bolts in bolt holes on the
rear case flange. These bolts are used as pull bolts.
CTM1321B
7. Lift the rear case vertically.

NOTE
+ Take time to work on the rear case, being careful not to
damage the range and splitter shafts.
+ Attach lifting cables to retainer mounting stud bolts, then
lift the rear case.
CTM1321C
SUB MAIN SHAFT AND SUB COUNTERSHAFT ASSEM-

BLY
j7 Range low gear
Tilt the sub countershaft outward and remove the range low gear.
NOTE
+ If the sub countershaft is hard to tilt, the notch of the
synchro cone may be misaligned with the countershaft.
Re-align if necessary.
WTM338A
j
16 Sub countershaft assembly
Remove the sub countershaft assembly.
NOTE
+ Tilt the sub countershaft inward before removing.
CTM1-349
TM-4-18
j17 Tapered bearing

Using the sliding hammer (99547 Z0000) and lock plate replacer
(99827 Z0069), remove the tapered bearing outer race and lock
washer.
CTM1348A
j
20 Range high gear
1. Remove the lock nut using socket wrench (99535 Z0074).
NOTE
+ Before removing the lock nut, check to ensure that the
input shaft splines and shift shaft are clinched properly.
CTM1-350
2. Remove the bolt securing the bearing retainer, then remove the
range high gear and bearing retainer assembly using a gear
puller and main shaft adapter (99804 Z0000).
CTM1348B
3. Using a hydraulic press and bearing remover (99800 Z0002),

disassemble the bearing retainer assembly.
CTM1322R

+ Remove the valve assembly.
NOTE
+ Do not remove the valve assembly unless necessary.
CTM1325L
TM-4-19
j3 Gear cover
Remove the gear cover.
NOTE
+ Do not remove the gear cover unless necessary.
CTM1348C
j5 Neutral detection switch

Remove the neutral detection (sensor) switch.
NOTE
+ Ensure the shift fork is set to neutral so that the sensor pin
will not come out of position during switch removal.
CTM1348D
j8 Middle case
Lift the middle case until it is moved away from the various shift
shafts and splitter shafts.
NOTE
+ Set the middle case as level as possible during lifting. Do
not apply undue stress to shift shafts.
CTM1-322
SHIFT FORK ASSEMBLY

1. Install the mainshaft rear nuts to secure the gear hanger
assembly (99783 Z0002), mainshaft, countershaft and the
various shift shafts.
CTM1351A
2. Attach the gear shaft setting tool (99799 Z0003) to top of the
front case, then lower the gear shaft assembly to the floor.
CTM1351B
TM-4-20
3. Remove the gear hanger assembly.

4. Remove the reverse, 1st-2nd and 3rd-4th shift shaft assem-
blies.
NOTE
+ The shafts and forks are clinched at the setscrews. Do not
separate the shafts and forks unless necessary.
CTM1322E
5. Remove the splitter shift shaft assembly.

NOTE
+ The shaft and fork are clinched at the setscrews. Do not
separate the shaft and fork unless necessary.
CTM1322F
MAIN SHAFT ASSEMBLY

1. Using the gear hanger assembly (99783 Z0002), remove the
main shaft sub assembly from the input shaft assembly.
CTM1322M
2. Attach the main shaft sub assembly to the construction stand

(99805 Z0000).
Remove the gear hanger assembly.
CTM1322L
j21 Lock nut (LH thread)

Unlock and lock nut, and remove the lock nut using socket wrench
(99535 Z0074).
CTM1322N
TM-4-21
j42 , j
43 , j
45 , j
46 , j
47 , j
48 Input shaft assembly
Remove the clip from the input shaft. Using a hydraulic press,
remove the input shaft, tapered bearing, splitter gear, needle
bearing and splitter synchro ring.
NOTE
+ Remove the detent and detent spring in advance.
CTM1322S
j
1 Clip j
4 Splitter synchro ring
j
2 Tapered bearing j
5 Needle bearing
j
3 Splitter gear j
6 Input shaft
CTM1351C

j6 Straight pin
Remove the retaining ring and retaining ring plate.
Using the puller assembly (910-11150 JKC NO.), pull out the
straight pin.
WTM114A
CTM1255E
j
19 , j23 Seat seal assembly
Remove the valve assembly.
NOTE
+ Be careful not to damage spring seat and lifter ring during
removal.
CTM1-256
TM-4-22
j
36 Cylinder packing
Remove the cylinder packing and cap packing.
NOTE
+ These parts need not be removed unless damaged.
CTM1262B
TM-4-23
INSPECTION MRT21A, MRT23A
INSPECTION
+ Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
+ If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
TRANSMISSION COVER
Clearance between shift lever and select lever
Unit: mm (in)
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)
CTM1-177
Radial play between shift shaft and shift lever splines

Unit: mm (in)
0.02 - 0.08 (0.0008 - 0.0031) 0.5 (0.020)
CTM1-178
Clearance between shift lever and each shifter/shift

fork
Unit: mm (in)
0.74 - 0.96 (0.0291 - 0.0378) 1.5 (0.059)
CTM1-179
Clearance between transmission cover and shift fork

shaft
Unit: mm (in)
0.04 - 0.07 (0.0016 - 0.0028) Reverse
0.07 - 0.10 (0.0028 - 0.0039) Splitter
0.04 - 0.07 (0.0016 - 0.0028) 0.3 (0.012) Range
0.07 - 0.17 (0.0028 - 0.0067) 1st-2nd
0.06 - 0.15 (0.0024 - 0.0059) 3rd-4th
TM-4-24
Clearance between each fork claw and synchronizer

sleeve
Unit: mm (in)
0.1 - 0.5 (0.004 - 0.020) 1.0 (0.039)
CTM1086A
Clearance between each fork claw and shift fork

Unit: mm (in)
0.02 - 0.05 (0.0008 - 0.0020) —
CTM1086B
Clearance between cylinder and shift shaft

Unit: mm (in)
0.07 - 0.10 (0.0028 - 0.0039) Splitter
0.3 (0.012)
0.04 - 0.07 (0.0016 - 0.0028) Range
Shift fork shaft locking spring

Unit: mm (in)
Nominal Maintenance
Item Remarks
dimension standard
42.5 (1.673) — 1st to 6th & Reverse
Free length 35.0 (1.378) — Splitter
34.5 (1.358) — Range
1st to 6th & Reverse
137 - 167
{14 - 17, 31 - 37}
29.0 mm (1.142 in)
Splitter
Tension 78 - 98
N {kgf, lbf} {8 - 10, 18 - 22}
28.0 mm (1.102 in)
Range
127 - 157
{13 - 16, 29 - 35}
28.0 mm (1.102 in)
TM-4-25
Clearance between reverse shift fork and reverse

sleeve groove
Unit: mm (in)
0.10 - 0.24 (0.0039 - 0.0094) 1.0 (0.039)
CTM1-086
TRANSMISSION PROPER
Each main gear and counter gear backlash
Unit: mm (in)
0.10 - 0.20 (0.0039 - 0.0079) 0.5 (0.020)
Each main gear end play

Unit: mm (in)
0.20 - 0.40 (0.0079 - 0.0157) 0.7 (0.028)

Unit: mm (in)
0.30 - 0.50 (0.0118 - 0.0197) 1.0 (0.039)
Radial play between hub and sleeve splines

Unit: mm (in)
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)
Radial play between sleeve and clutch gear splines

Unit: mm (in)
0.40 - 0.50 (0.0157 - 0.0197) Reverse
1.0 (0.039)
0.20 - 0.30 (0.0079 - 0.0118) Except for reverse
Ball bearing axial play

Unit: mm (in)
— 0.5 (0.020)
CPS1-014
TM-4-26
SYNCHRONIZERS SYSTEM
<Lock plunger type>
Tangential clearance between synchronizer ring and
synchronizer hub
Unit: mm (in)
6.3 - 6.7 (0.248 - 0.264) 1st to 4th
—
6.5 - 6.9 (0.256 - 0.272) Splitter
CTM1089C
Clearance between synchronizer ring and clutch gear

Unit: mm (in)
1.4 - 1.8 (0.055 - 0.071) 1st-2nd
1.5 - 1.9 (0.059 - 0.075) 0 (0) 3rd-4th
1.4 - 1.6 (0.055 - 0.063) Splitter
CTM1088F
Axial clearance between synchronizer ring and syn-

chronizer detent
Unit: mm (in)
0.1 - 0.3 (0.004 - 0.012) 1st to 4th
—
1.3 - 1.5 (0.051 - 0.059) Splitter
CTM1090A
Detent spring
Unit: mm (in)
Nominal Maintenance
Item Remarks
dimension standard
25.0 (0.984) 1st to 4th
Free length 26.0 (1.024) — Splitter
35.6 (1.402) Range
56.9 - 68.6 1st to 4th
{5.8 - 7.0, When compressed to
12.8 - 15.4} 18.0 mm (0.709 in)
70.6 - 86.3 Splitter
Tension
— {7.2 - 8.8, When compressed to
N {kgf, lbf}
15.9 - 19.4} 22.0 mm (0.866 in)
153 - 169 Range
{15.6 - 17.2, When compressed to
34 - 38} 29.0 mm (1.142 in)
TM-4-27
OIL PUMP
Oil pump gear end play
Unit: mm (in)
0.05 - 0.09 (0.0020 - 0.0035) —
Radial play between oil pump gear and counter shaft

at splines
Unit: mm (in)
0 - 0.18 (0 - 0.0071) —
POWER SHIFT
Power shift spring
Unit: mm (in)
Maintenance
standard
18.1
Item No. j
16 —
(0.713)
Free 21.0
Item No. j
21 —
length (0.827)
15.0
Item No. j
26 —
(0.591)
Item No. j
16
{4.8, 10.6} {4.1, 9.0} 13.0 mm (0.512 in)
Tension 12.7 10.8 When compressed to
Item No. j
21
N {kgf, lbf} {1.3, 2.9} {1.1, 2.4} 10.0 mm (0.394 in)
Item No. j
26
{1.9, 4.2} {1.6, 3.5} 13.0 mm (0.512 in)
NOTE
+ Item Nos. indicate the disassembly sequence.
Valve seal dent depth
Unit: mm (in)
0.15 (0.0059), max. —
CTM1263A
TM-4-28
REASSEMBLY MRT21A, MRT23A
REASSEMBLY
REASSEMBLY
+ When assembling or installing parts, pay attention to the
direction of gears, thrust washers, etc.
+ Do not confuse one type of needle bearing and spacer with
others.
+ Do not allow foreign particles to enter the needle bearings.
+ Apply a coat of clean gear oil to rotating parts.
+ After installing gears, manually rotate to ensure smooth rotation
without noise.
+ Use new oil seals and O-rings.
Apply a coat of RTV (Room Temperature Vulcanizing) liquid gasket
(Three Bond #1215 or equivalent) to the mating surfaces of the
middle case, rear case, side cover and control cover during
installation. Observe the following precautions during gasket ap-
plication.
<Precautions during RTV liquid gasket application>
+ Remove all traces of liquid gasket from the flanged surface of
parts using a scraper. Be careful not to scratch the flanged
surface and completely wipe away foreign particles (grease,
water, dust, etc.) using a clean cloth.
+ Apply a continuous coat of liquid gasket to the inner edge of the

flange and the center of the bolt hole, as well as to the outer
edge of the flange and the area as close as possible to the bolt
holes. The gasket bead width must be 3 mm (0.12 in).
For detailed information concerning the gasket application, refer to
the gasket application drawing in the text.
+ Also apply an equal and continuous bead of liquid gasket to
areas where the flanged surface is narrow (due to cutouts,
etc.); do not apply an excess coat to the gasket.
+ Install parts within 2 - 20 minutes of gasket application. Leave
parts unattended for approximately 2 hours, allowing the CDF1-051
gasket to completely harden.
FRONT CASE ASSEMBLY
Bearing cap
Install the bearing cap (without the oil seal), adjusting shim and
bearing outer race in the front case as a unit.
NOTE
+ Do not install the oil seal and O-ring.
CTM1334A
Bushing
Press the bushing into the bore in the front case with the clinch set
at a right angle to the left when viewed from the press-in direction
(horizontal when viewed from the transmission installation direc-
tion).
NOTE
+ Use a bushing replacer to install the bushing.
1st-2nd 99801 Z0001
3rd-4th 99801 Z0002
CTM1-328
TM-4-29

j42 Piston packing
Install the piston packing and piston O-ring on the piston, and the
piston assembly and retaining ring on the shifter rod.
ETM122A
j33 Housing setscrew

Install the housing setscrew and clinch in two locations.
CTM1-270
j32 Rod cap assembly

Apply air master paste to various parts. Place a tube rod of 10 to
11.5 mm (0.394 to 0.453 in) in diameter in a vise.
Install the rod pipe and tube on the rod cap assembly, and pass the
assembled unit through the hole in the rod.
CTM1-265
j19 , j
Install the O-ring on the lifter, the lifter ring on the spring seat and
the O-ring on the seat seal assembly.
j
1 Lifter j
5 Lifter ring
j
2 Lifter O-ring j
j
3 Lifter spring j
7 O-ring
j
4 Spring seat
CTM1266A
NOTE
+ Be sure to install the springs in the correct sequence.
CTM1-267
TM-4-30
j
12 Tube ring
1. Using the insert tool (910-26500 JKC No.) install the tube ring.
CTM1-268
2. Using the guide (910-24800 JKC No.) install the valve assem-
bly.
NOTE
+ Apply a coat of silicone grease to inner side of the rod
pipe. Be careful not to damage the seals.
CTM1-271
j1 Cylinder boots
Install the boot.
NOTE
+ Ensure that the drain hole in the boot faces downward
during installation.
CTM1-252
+ Functional check
After assembling, apply 736 kPa {7.5 kgf/cm2, 107 psi} of com-
pressed air to the power shift assembly to ensure that the valve
moves in both the pull and push directions, as well as to the neutral
position. Also check that valve is air-tight. Check the valve’s sliding
resistance in the push and pull directions.
Item Specifications
(during non-operation) (pressure drop for 15 seconds)
(during operation) (pressure drop for 15 seconds)
Sliding resistance in shift directions 51.0 N {5.2 kgf, 11.5 lbf}, max.
TM-4-31
MAIN SHAFT ASSEMBLY

+ Heat each gear and the following parts in an oil bath and then
assemble them. [Oil temperature: 200°C (392°F)]
+ Thrust washer
+ Tapered bearing
+ 1st-2nd synchro hub
+ Inner race
+ Securely attach the main shaft to the construction stand (99805
Z0000).
NOTE
+ Make sure that the construction stand is securely fixed in
place.
j
30 - j
35 3rd-4th gear synchronizer assembly
1. Install the spring, detent and lock plunger on the synchro hub.
NOTE
+ Install the detent while pushing the lock plunger using a
screwdriver.
CTM1322Z
2. Install the 3rd gear sleeve.

NOTE
+ When installing the sleeve, push the detent using a screw-
driver.
+ Align the detent with the notch in the sleeve.
(The synchro sleeve must face the specified direction, so
the alignment should be done carefully.)
CTM1-323
3. Install the synchro ring.

NOTE
+ Ensure the synchro hub is fitted in the groove.
CTM1323A
TM-4-32
j
28 Adjusting spacer
1. Install the tapered bearings into the bore in the drive gear
assembly, then tighten with the drive gear set tool (99806
Z0000).
CTM1323B
2. Measure the bearing-to-bearing end surface distances at two

places in the opposite direction, then determine the mean value
‘‘A’’ of the two distance measurements.
NOTE
+ Before distance measurements, turn the drive gear assem-
bly two or three complete rotations, then retighten to 7 N·m
{0.7 kgfzm, 5.1 ftzlbf}.
3. Install the tapered bearing and adjusting spacer [21.70 mm

(0.8543 in) thick] to the drive gear setting jig. Measure the
bearing-to-bearing end surface distances at two places in the
opposite direction, then determine the mean value ‘‘B’’ of the
two distance measurements.
CTM1323C
4. Determine the required adjusting spacer thickness ‘‘X1’’ using

the following equation.
X1 = A − B + 21.861
Select the suitable adjusting spacer which is suited to the
thickness ‘‘X1’’ from the following chart.
Unit: mm (in)
Spacer thickness 21.45 (0.8445) 21.50 (0.8465) 21.55 (0.8484)
Applicable 21.425 - 21.475 21.476 - 21.525 21.526 - 21.575
X1 range (0.8435 - 0.8455) (0.8455 - 0.8474) (0.8475 - 0.8494)
Unit: mm (in)
Spacer thickness 21.60 (0.8504) 21.65 (0.8524) 21.70 (0.8543)
21.576 - 21.625 21.626 - 21.675 21.676 - 21.725
Applicable X1 range
(0.8494 - 0.8514) (0.8514 - 0.8533) (0.8534 - 0.8553)
TM-4-33
+ Measure the main shaft gear end play.

Unit: mm (in)
0.2 - 0.4 (0.008 - 0.016) 0.7 (0.028)
NOTE
+ Before measuring the main shaft gear end play, turn the
drive gear two or three rotations.
+ A certain amount of end play is allowed for the drive gear
tapered bearing. Check to ensure that the specified CTM1323K
amount of end play is maintained since excessive preload
may create a problem.
j
21 Lock nut (LH thread)
Align the lock nut with the groove on the end of the main shaft, then
clinch securely.
CTM1322N
+ Reassembling the main shaft sub assembly

1. Install the front case on the transmission rotation block and set
the gear shaft setting plate (99799 Z0003) on the upper surface
of the front case.
CTM1352B
2. Using the gear hanger assembly (99783 Z0002), install the

main shaft subassembly on the input shaft.
NOTE
+ Carefully raise or lower the main shaft subassembly dur-
ing installation.
CTM1323U
TM-4-34
+ Adjusting the main drive shaft end play.

NOTE
+ Whenever any of the bearings or gears are replaced, adjust
the main drive shaft end play as described below.
+ If disassembly does not require replacement of any com-
ponents, install the original shim used before disassem-
bly.
<End play adjustment procedure>

1. Install two 2.00 mm (0.0787 in) thick master shims which are
suitable for the main drive shaft bearing outer race.
CTM1349F
2. Install the bearing cap by tightening it at three places as shown

by ‘‘.’’ in the figure at right.
NOTE
+ After turning the main drive shaft two or three complete
rotations, again tighten the bolts to the specified torque.
+ Do not tighten the bolts in excess of the specified torque
under any circumstances.
CTM1326M
3. Measure the bearing cap-to-mating surface clearance (at three

places) near the bolt location, and determine the mean value
‘‘E’’ of the three measurements.
NOTE
+ The clearance should be measured with the O-ring re-
moved.
CTM1326N
TM-4-35
4. Determine the required shim thickness ‘‘X4’’ using the following

equation, and select a shim whose thickness is closer to the
measured value from those listed in the following chart.
Equation: X4 = 3.444 − E
Unit: mm (in)
Shim thickness 1.70 (0.0669) 1.76 (0.0693) 1.82 (0.0717) 1.88 (0.0740)
1.670 - 1.730 1.731 - 1.790 1.791 - 1.850 1.851 - 1.910
Applicable X4 range
(0.0657 - 0.0681) (0.0681 - 0.0705) (0.0705 - 0.0728) (0.0729 - 0.0752)
Unit: mm (in)
Shim thickness 1.94 (0.0764) 2.00 (0.0787) 2.06 (0.0811) 2.12 (0.0835)
1.911 - 1.970 1.971 - 2.030 2.031 - 2.090 2.091 - 2.150
Applicable X4 range
(0.0752 - 0.0776) (0.0776 - 0.0799) (0.0800 - 0.0823) (0.0823 - 0.0846)
Unit: mm (in)
Shim thickness 2.18 (0.0858) 2.24 (0.0882) 2.30 (0.0906) 2.36 (0.0929)
2.151 - 2.210 2.211 - 2.270 2.271 - 2.330 2.331 - 2.390
Applicable X4 range
(0.0847 - 0.0870) (0.0870 - 0.0894) (0.0894 - 0.0917) (0.0918 - 0.0941)
Unit: mm (in)
Shim thickness 2.42 (0.0953) 2.48 (0.0976)
2.391 - 2.450 2.451 - 2.510
Applicable X4 range
(0.0941 - 0.0965) (0.0965 - 0.0988)
+ Install the oil seal on the bearing cap, then install the bearing
cap, the selected shim and O-ring on the transmission body as
a unit.
: 32 - 42 N·m {3.3 - 4.3 kgfzm, 24 - 31 ftzlbf}
NOTE
+ Use liquid gasketed bolts for those marked with ‘‘+’’ in the
figure at right.
+ The specified end play of the tapered bearing (when cold)
is 0.20 to 0.30 mm (0.0079 to 0.0118 in). Application of
preload to the tapered bearing (when cold) will increase
CTM1326Q
the preload value, resulting in damage to the bearing.
+ Install the counter splitter gear, counter drive gear, keys, clip
and tapered bearings onto the countershaft.
NOTE
+ Heat the gears and bearings in an oil bath before installa-
tion.
Oil bath temperature: Approx. 200°C (392°F)
CTM1353J
TM-4-36
SHIFT FORK ASSEMBLY

+ Install the fork and shifter to the shift shaft.
NOTE
+ Be careful not to confuse the front of the shift fork with the
rear.
+ Ensure the setscrew is fitted in the shaft groove, then
clinch at three points.
+ Lift the gear assembly using the gear hanger assembly (99783
Z0002) and hoist, remove the shaft setting tool, then lower the
gear assembly to the inside of the front case.
NOTE
+ Be careful not to damage the input shaft oil seal while
raising or lowering the gear assembly.
CTM1325A

j8 Middle case
1. Apply liquid gasket to the mating surface of the front and middle
cases.
CTM1296M
2. Lower the middle case until it is in contact with the front case.
NOTE
+ Set the middle case as level as possible while lowering. Do
not allow guide bushings to catch shift shafts.
CTM1-322
3. Tighten the middle case mounting bolts.

: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
NOTE
+ Use liquid gasketed bolts for those marked with ‘‘+’’ and
tighten from the front case side.
WTM155A
TM-4-37
j7 Reverse idler gear assembly

Apply liquid gasket to setscrews, then tighten the setscrews.
Whenever any of the bearings or gears are replaced, adjust the
countershaft end play as described below.
NOTE
+ If the disassembly does not require replacement of the
components, reuse the original shims which are removed
during disassembly.
CTM1321T
j6 Side cover
1. Apply liquid gasket to the mounting surface of the transmission
case side cover.
CTM1296K
2. Install the PTO gear assembly (if so equipped) or the side

cover.
PTO gear assembly
: 32 - 42 N·m {3.3 - 4.3 kgfzm, 24 - 31 ftzlbf}
Side cover
: 19 - 25 N·m {1.9 - 2.6 kgfzm, 14 - 19 ftzlbf}
CTM1321S
+ Adjusting the countershaft end play

NOTE
the countershaft end play as described below.
+ If the disassembly does not require replacement of the
components, reuse the original shims which are removed
during disassembly.

suitable for the countershaft rear bearing outer race.
CTM1325F
TM-4-38
2. Install the oil pump by tightening the bolts (three places).

NOTE
+ After turning the countershaft two or three complete rota-
tions, again tighten the bolts to the specified torque.
+ Do not tighten the bolts in excess of the specified torque
under any circumstances.
CTM1325G
3. Using a thickness gauge, measure the oil pump end surface-

to-mating surface clearance near the bolt location at three
points. Determine the mean value ‘‘C’’ of the three measure-
ments.
CTM1325H

equation, then select the suitable shim from those listed in the
following charts.
Equation: X2 = 3.595 − C
Unit: mm (in)
Shim thickness 1.58 (0.0622) 1.64 (0.0646) 1.70 (0.0669) 1.76 (0.0693)
1.550 - 1.610 1.611 - 1.670 1.670 - 1.730 1.731 - 1.790
Applicable X2 range
(0.0610 - 0.0634) (0.0634 - 0.0657) (0.0657 - 0.0681) (0.0681 - 0.0705)
Unit: mm (in)
Shim thickness 1.82 (0.0717) 1.88 (0.0740) 1.94 (0.0764) 2.00 (0.0787)
1.791 - 1.850 1.851 - 1.910 1.911 - 1.970 1.971 - 2.030
Applicable X2 range
(0.0705 - 0.0728) (0.0729 - 0.0752) (0.0752 - 0.0776) (0.0776 - 0.0799)
Unit: mm (in)
Shim thickness 2.06 (0.0811) 2.12 (0.0835) 2.18 (0.0858) 2.24 (0.0882)
2.031 - 2.090 2.091 - 2.150 2.151 - 2.210 2.211 - 2.270
Applicable X2 range
(0.0800 - 0.0823) (0.0823 - 0.0846) (0.0847 - 0.0870) (0.0870 - 0.0894)
Unit: mm (in)
Shim thickness 2.30 (0.0906) 2.36 (0.0929)
2.271 - 2.330 2.331 - 2.390
Applicable X2 range
(0.0894 - 0.0917) (0.0918 - 0.0941)
TM-4-39
+ Install the selected shim, oil strainer and oil pump.

: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
NOTE
preload to the tapered bearing (when cold) will inevitably
increase the preload value as the oil temperature in-
creases, resulting in malfunctioning parts.
CTM1325J
j1 Bearing retainer
Press the middle case bearing retainer assembly into place using
the bearing retainer replacer (99827 Z0068).
: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
CTM1350G
SUB MAIN SHAFT AND SUB COUNTERSHAFT ASSEM-

BLY
j
20 Range high gear
Tighten the lock nut using the socket wrench (99535 Z0074).
: 686 - 981 N·m {70.0 - 100.0 kgfzm, 506 - 723 ftzlbf}
NOTE
+ Lock the lock nuts in the same way as it was before
disassembly.
CTM1-350
j
18 Lock washer
Align lock washers with lock bolt holes.
NOTE
+ If the lock washer is not aligned with the bolt hole, turn its
topside down or move it to left or right, as required.
+ If it is still hard to align, align it while turning the nut in the
direction that tightens.
CTM1325N
REAR CASE ASSEMBLY

j
23 Rear case
1. Apply liquid gasket to the mating surface of the middle and rear
cases.
CTM1296J
TM-4-40
2. Install the rear case.

: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
CTM1321C
+ Tighten the rear case mounting bolts.

Bolt No. : N·m !: mm (in) Remarks
{kgfzm, ftzlbf}
A 85 (3.35) —
B 45 (1.77) —
57 - 76
{5.8 - 7.7, 42 - 56} Use liquid gasketed
C 45 (1.77)
bolts.
D 95 (3.74) —
CTM1350F
j
18 Air cylinder
1. Install the air/oil seal on the air cylinder.
NOTE
+ Note the installation direction of the air/oil seal.
+ Use an oil seal replacer to install the air/oil seal.
Range side 99807 Z0004
Splitter side 99807 Z0005
CTM1335B
2. Install the air cylinder via gasket and a pin.

NOTE
+ Using a copper hammer, lightly drive the air cylinder into
place.
CTM1335A
3. Install the range piston, splitter piston, packing and O-ring.

NOTE
+ Apply grease to the mating surfaces of the piston, O-ring
and packing before installation.
+ Note the direction of the packing during installation.
4. Install the piston assembly on the range and splitter air
cylinders, then tighten the nuts using washers.
: Range side:
137 - 186 N·m {14.0 - 19.0 kgfzm, 101 - 137 ftzlbf}
CTM1-336
: Splitter side:
57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
TM-4-41
NOTE
+ Apply grease to the air cylinder inner wall in advance.
5. Install the cylinder cap using the O-ring.
: 32 - 42 N·m {3.3 - 4.3 kgfzm, 24 - 31 ftzlbf}
NOTE
+ Use liquid gasketed bolts for those indicated in the figure
at right.
CTM1-337
+ Adjusting the sub countershaft end play

NOTE
+ If disassembly does not require replacement of bearings
or gears, use the original shims installed prior to disas-
sembly.
the sub countershaft end play as described below.

suitable for the sub countershaft rear bearing outer race.
CTM1-326
2. Secure the sub countershaft bearing retainer at three points as

shown in the figure at right.
NOTE
+ After installing the sub countershaft bearing retainer, turn
the sub countershaft by turning the output shaft two or
three rotations, then tighten the retainer bolts again to the
specified torque.
+ Do not tighten the bolts in excess of the specified torque.
CTM1326A
3. Measure the retainer-to-mating surface clearance (at three

places) near the bolt locations, and determine the mean value
‘‘D’’ of the three measurements.
NOTE
+ The clearance should be measured with the O-ring re-
moved.
equation, then select a shim whose thickness is closer to the
value calculated.
Equation: X3 = 3.814 − D CTM1326B
TM-4-42
Unit: mm (in)
Shim thickness 1.76 (0.0693) 1.82 (0.0717) 1.88 (0.0740) 1.94 (0.0764)
1.731 - 1.790 1.791 - 1.850 1.851 - 1.910 1.911 - 1.970
Applicable X3 range
(0.0681 - 0.0705) (0.0705 - 0.0728) (0.0729 - 0.0752) (0.0752 - 0.0776)
Unit: mm (in)
Shim thickness 2.00 (0.0787) 2.06 (0.0811) 2.12 (0.0835) 2.18 (0.0858)
1.971 - 2.030 2.031 - 2.090 2.091 - 2.150 2.151 - 2.210
Applicable X3 range
(0.0776 - 0.0799) (0.0800 - 0.0823) (0.0823 - 0.0846) (0.0847 - 0.0870)
Unit: mm (in)
Shim thickness 2.24 (0.0882) 2.30 (0.0906) 2.36 (0.0929) 2.40 (0.0945)
2.211 - 2.270 2.271 - 2.330 2.331 - 2.390 2.391 - 2.450
Applicable X3 range
(0.0870 - 0.0894) (0.0894 - 0.0917) (0.0918 - 0.0941) (0.0941 - 0.0965)
+ Install a selected shim and the O-ring, then install the sub
countershaft bearing retainer.
: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
NOTE
preload to a cold tapered bearing will inevitably increase
the preload value as the oil temperature increases, which
results in damage to the bearing.
CTM1349E
j5 Speedometer drive gear

Install the speedometer drive gear onto the output shaft.
NOTE
+ Note the installation direction of the drive gear.
CTM1012M
+ Press the bushing into the bore in the control cover with the
clinch facing downward.
NOTE
+ Use a bushing replacer to install the bushing.
99801 Z0003
CTM1328A
TM-4-43
+ Tighten the lock nut using the socket wrench (99535 Z0074).
: 686 - 981 N·m {70.0 - 100.0 kgfzm, 506 - 723 ftzlbf}
NOTE
+ Lock the lock nut in the same way as it was before
disassembly.
WTM156A
+ Align the lock nut flat surfaces with the grooves on the shaft,
then clinch the nut.
WTM157A
INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission in
the vehicle.
Be sure to align the main drive shaft with the clutch disc at their
splines.
2. Install the propeller shaft transmission linkage, cable, wiring,
PTO (when equipped), clutch booster, etc., in their original
positions.
CCL1047A
TM-4-44

Transmission System: Transmission Proper Transmission Linkage

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Transmission System: Transmission Proper Transmission Linkage

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TRANSMISSION SYSTEM

Oil quantity W/O PTO 9.0 (2)

UNIT NAME: MRT21A, MRT23A

Number of gear teeth 6th 33/26

Range side High 26/24

Splitter side High 34/35

Oil quantity W/O PTO 10.8 (2-3/8)

UNIT NO. LOCATION

0.05 - 0.13 0.5 j —

Clearance between shift lever 0.74 - 0.96 1.0

Clearance between shift lever 0.74 - 0.96 1.5 j j

127 - 157 Range

1st gear 0.20 - 0.40 0.7 j j

2nd gear 0.20 - 0.40 0.7 j j

3rd gear 0.20 - 0.40 0.7 j j

Reverse gear 0.20 - 0.40 0.7

Splitter gear 0.20 - 0.40 0.7 — j

Range low gear 0.20 - 0.40 0.7 — j

0.20 - 0.30 1.0

3rd gear 0.20 - 0.30 1.0 j j

Range low gear 0.20 - 0.30 1.0 — j

1.4 - 1.8 1st - 2nd — j

Radial clearance between

Oil pump gear end play 0.05 - 0.09 —

Free length Item No. j

Valve seal dent depth 0.15 (0.0059), — j j

UNIT NAME: MRT21A, MRT23A

Unit: N·m {kgfzm, ftzlbf}

MRT21A AND MRT23A

Attached to input shaft splines to

Used when lifting the main shaft

Attached to the front case when

Attached to the main shaft rear

Tool name and number Description Shape

Used to remove the tapered

Puller bearing attachment

Used to remove the countershaft

Used to install the bearing outer

Used to install the input shaft

Used to rotate the main shaft or

Tool name and number Description Shape

Used to indicate the master di-

Used to install the bearing outer

Used to select the washer for

Puller assembly Used when pulling the straight

Guide Used when installing valve on

Insert tool Used when installing snap ring

UNIT NAME MRT21A, MRT23A

Used together with the adapter

Used to remove/install main

Attached to input shaft splines to

Used when lifting the main shaft

Used when removing the main

Attached to the front case when

Tool name and number Description Shape

Attached to the main shaft rear

Used as a jig to measure the

Used when pressing the bearing

Oil seal replacer

Used to protect the main shaft

Tool name and number Description Shape

Used when removing the bear-

Used when disassembling and

Used when pulling out the

Guide Used when installing valve on

Tool insert Used when installing snap ring

= UNIT NAME MTS72D, MTS73D =

MAIN SHAFT ASSEMBLY

POWER SHIFT ASSEMBLY

Unit name MTS73D

4. Remove the transmission from the flywheel housing. Support

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j1 Drain plug >.j

MAIN SHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

COUNTERSHAFT AND REVERSE IDLER SHAFT ASSEMBLY