GROUP 22A MANUAL TRANSMISSION

<M130 S2 × 5>

SPECIFICATIONS .............................. 22A-2 TRANSMISSION BODY ................... 22A-40

STRUCTURE AND OPERATION DRIVE PINION.................................. 22A-60

1. Transmission ............................... 22A-3
2. Synchromesh Mechanism ............ 22A-4 MAINSHAFT..................................... 22A-62
3. Power Shift ................................... 22A-6
4. Interlock Mechanism ...................... 22A-8 COUNTERSHAFT ............................. 22A-72
5. Splitter Control ............................ 22A-8
TRANSMISSION CONTROL............. 22A-74
6. Transmission Oil Cooler .............. 22A-9
TRANSMISSION OIL COOLER ........ 22A-82
TROUBLESHOOTING ..................... 22A-10
PULLER AND INSTALLER KIT ....... 22A-83
ON-VEHICLE INSPECTION AND
ADJUSTMENT
1. Inspection of Transmission
Oil Leakage................................. 22A-12
2. Check for Looseness in Transmission
Mounting Bolts and Nuts ............ 22A-12
3. Check for Play and Looseness
in Companion Flange .................. 22A-12
4. Inspection and Replacement of
Transmission Oil......................... 22A-13
5. Inspection of Transmission
Oil Cooler System ....................... 22A-14

REMOVAL AND INSTALLATION OF

TRANSMISSION ............................... 22A-16

GEAR SHIFTER UPPER................... 22A-20

POWER SHIFT.................................. 22A-24

INTERLOCK PLATE ......................... 22A-30

REAR COVER .................................. 22A-32

REVERSE IDLER GEAR .................. 22A-38

22A-1
SPECIFICATIONS
Item Specifications
M130S 2 × 5
Transmission model
(8.147/0.786)
Low 8.147
1st
High 6.407
Low 4.846
2nd
High 3.811
Low 2.824
3rd
High 2.221
Gear ratio
Low 1.738
4th
High 1.367
Low 1.000
5th
High 0.786
Low 7.058
Rev
High 5.550
Power shift Manufacturer Sanwa seiki
General: API GL-3 SAE 80
Gear oil Warm region: API GL-3 SAE 90
Tropical region: API GL-4 SAE 90
Transmission oil
Engine oil Long period of high-speed driving: API CC SAE 30 or SAE 40
3
Oil capacity dm {L}
21 {21}
(including 1 {1} in oil cooler.)
Mass kg 335
Mode of control Floor shift, remote control

22A-2
STRUCTURE AND OPERATION 22A
1. Transmission

• The front side of the transmission has the splitter portion that changes gear ratio between high speed and low
speed and uses a high & low (splitter) synchronizer.
• The transmission uses an interlock mechanism to avoid double engagement.

22A-3
STRUCTURE AND OPERATION
2. Synchromesh Mechanism
• The synchromesh mechanism, when a shift change is made, synchronizes the rotation speed of the mainshaft,
drive pinion and synchronizer hub that rotates integrally with the mainshaft with that of the gear to be shifted.
• The synchromesh mechanism is a Warner synchromesh type, and is used depending on the gear position as
shown below:
Synchromesh type Gears of application
Single cone type 4th, 5th, Splitter
Double cone type 2nd, 3rd

2.1 Single cone type

The following descriptions are for 5th (drive pinion) side of 4th and 5th synchronizer.

• The inside of the synchronizer hub engages the spline of the mainshaft and rotates with it. The outside of the syn-
chronizer hub has a spline that engages the synchronizer sleeve and three grooves.
• Shifting keys are inserted into these grooves. When the gear shift is in neutral, the protrusions of the shifting key
engages grooves in the synchronizer sleeve and are pressed against the inside of the synchronizer sleeve by
shifting keys springs.
• Synchronizer rings are inserted into the respective taper cone of each gear.
• The outer splines of the synchronizer rings engage the synchronizer sleeve. On the synchronizer hub are three
keyways, in which the protrusions of the synchronizer ring fit. These keyways are wider than the width of protru-
sions of the synchronizer ring.
• Synchronizer rings rotate relative to the synchronizer sleeve by the amount of play.
• When the gear shift is in neutral (Figure A), moving the shift fork in the direction of the arrow as illustrated, moves
the synchronizer sleeve slightly to the drive pinion. At the same time, the shifting key, the central protrusion of
which engages the synchronizer sleeve, moves to the drive pinion and presses the synchronizer ring against the
taper cone of the drive pinion (Figure B).
• The taper cones of synchronizer rings, which act as cone clutches, generate friction torque and perform synchro-
nous operation.
• The rotation speed of the synchronizer hub becomes gradually closer to that of the drive pinion gear due to the
synchronous operation, and eventually they rotate at the same speed. This allows the synchronizer sleeve to
move smoothly to engage the synchronizer hub and gear, completing the shift change (Figure C).

22A-4
 22A
2.2 Double cone type
The following descriptions are for 3rd side of 2nd and 3rd synchronizer.

• The synchromesh structure and operation are basically the same as for the single cone type. The synchronizer
ring is divided into three parts (synchronizer inner ring, synchronizer center cone and synchronizer outer ring) and
the center cone (both the inside and outside surfaces are tapered) is sandwiched between the taper cones of the
outer ring and inner ring to shorten the time required for synchronization with cone clutches at two locations.
• Six protrusions on the outside of the synchronizer center cone fit into corresponding gear holes. As in the taper
cone of the single cone type, the center cone and the gear are installed as if integrated.
• The inside of the synchronizer hub engages the spline of the mainshaft and rotates with it. The outside of the syn-
chronizer hub has a spline that engages the synchronizer sleeve and three keyways.
• Shifting pins are inserted into these keyways. When the gear shift is in neutral, the shifting pins engage grooves in
the synchronizer sleeve and are pressed against the inside of the synchronizer sleeve by synchronizer springs.
• The synchronizer outer ring and synchronizer inner ring are inserted into synchronizer center cones, respectively.
• The outer spline of the synchronizer outer ring engages the synchronizer sleeve. On the synchronizer hub are
three grooves in which protrusions of the synchronizer outer ring are inserted. These grooves are wider than the
width of protrusions of the synchronizer outer ring.
• The synchronizer outer ring rotates relative to the synchronizer sleeve by the amount of play.
• When the gear shift is in neutral (Figure A), moving the shift fork in the direction of the arrow as illustrated moves
the synchronizer sleeve slightly to the 3rd gear. At the same time, the shifting pin, which engages grooves in the
synchronizer sleeve, moves to the 3rd gear and presses the synchronizer outer ring against the taper cone of the
synchronizer center cone, and in addition, presses the center cone against the synchronizer inner ring (Figure B).
• The taper cones of synchronizer rings, which act as cone clutches, generate friction torque and perform synchro-
nous operation.
• The rotation speed of the synchronizer hub becomes gradually closer to that of the gear of the 3rd gear due to the
synchronous operation, and eventually they rotate at the same speed. This allows the synchronizer sleeve to
move smoothly to engage the synchronizer hub and gear, completing the shift change (Figure C).

22A-5
STRUCTURE AND OPERATION
3. Power Shift

3.1 When operated

• When the actuating rod is displaced as shown by the arrow, relative position between the shifter rod and actuating
rod changes.
As the result, the valve lifter presses the No. 3 valve spring, butts against the valve seal, overcomes compressed
air delivered to the valve seal and the force of No. 2 valve spring, and detaches the valve seal from the valve seat.
In so doing, compressed air supplied to the primary chamber is sent to the secondary chamber from the clearance
between valve seat and valve seal, passes through the grooves in valve seat and air holes in shifter rod, thus get-
ting into the cylinder to apply pressure to the piston, and to generate output.
• Output power generated by the piston is transmitted to the shifter rod via retaining ring, thus backing up the coax-
ially attached striker; the shift fork on transmission side is operated to perform gear shift.
• When operated in the direction shown by the arrow, input from the gear shift lever is transmitted from the actuat-
ing rod via the plate attached to the pipe by the retaining ring. Operating principle is just the same in case of the
opposite direction; the only difference is that the edge of actuating rod directly presses the valve lifter.

22A-6
 22A
3.2 When released

• When gear shift is completed, and input is released, the actuating rod returns to its previous position (in the mid-
dle of the valve) due to reaction of compressed air in valve lifter and of the valve springs.
In so doing, as the valve lifter goes back, the valve seal fits the valve seat, and supply of compressed air is inter-
rupted from the primary chamber through the secondary chamber. Besides, as the actuating rod returns, a clear-
ance occurs between the valve lifter and valve seal.
• As the result, compressed air in the secondary chamber (inside the cylinder) exhausts into the atmosphere via the
gap between valve lifter and pipe, pressure difference on both sides of the piston disappears, and the output
ceases.

3.3 When not operated (no boost)

• Relative position of the actuating road on the input shaft side and shifter rod on the output shaft side must be
changed to perform power shift, that is, to open the valve, and to send compressed air into the output chamber.
• When the actuating rod is driven by the gear shift lever, while resistance on the transmission side is smaller than
the overall resistance to a change in relative position on the input and output sides (reaction of the No.1 to No. 3
valve springs, pressure applied to the valve seal, sliding resistance), the mechanism from the actuating road
through the striker remains unmoved; therefore, the valve does not open, and no boost takes place; the piston
moves in the cylinder, and gear shift is performed.

22A-7
STRUCTURE AND OPERATION
4. Interlock Mechanism
• The interlock mechanism is a mecha-
nism to prevent double engagement of
gears.
• The rail beneath the interlock plate
locks jaws except jaws shifted by gear
shift sliding lever, preventing double
engagement of gears.

5. Splitter Control

• The splitter control provides a changeover between the higher speed gear group and the lower speed group as
follows: if the clutch pedal is pressed, the clutch switch is activated and the transmission clutch relay is energized,
which makes current flow to the splitter control switch inside the gearshift lever knob. In this condition, if the split-
ter control switch is set to the higher speed position (H) or lower speed position (L), the transmission high/low
changeover 3-way magnetic valve (high) or (low) is activated. This causes the air from the 4-way protection valve,
after the pressure is reduced by the reducing valve, to flow through the selected transmission high/low change-
over 3-way magnetic valve to the high or low side of the power cylinder, thus changeover being accomplished.

22A-8
 22A
6. Transmission Oil Cooler

• The air-cooled oil cooler and oil filter is placed near the right step, and the oil cooler pump is attached to the clutch
housing.
• While decreasing oil temperature, the cooler is also intended to extend oil life due to forced lubrication, to improve
endurance of bearings, and to prevent friction on gear thrust surface and tooth surface.

22A-9
TROUBLESHOOTING
Symptoms

Gears slip out of engagement

Noise when engine is idling

Noise when changing gear

Gears hard to engage

Noise when cruising

Reference Gr

Possible causes
Mainshaft rear lock nut loose O O
Mainshaft thrust washer worn O O
Mainshaft bearing worn or damaged O O O
Mainshaft pilot bearing worn or damaged O O
Drive pinion bearing worn or damaged O O O
Input shaft bearing worn or damaged O
Excessive backlash between drive pinion and countershaft
Transmission O
constant mesh gear
body faulty
Countershaft bearing worn or damaged O
Needle bearings of gears worn or damaged O O
Mainshaft and countershaft gears backlash excessive O
Backlash between input shaft and splitter gear excessive O
Spline of gears worn O
Gears damaged O
Transmission oil insufficient O
Wear of contacting surface between
Single-cone type synchronizer ring and tapered cone O O
section of the gear
Wear of contacting surface between
Double-cone type synchronizer inner and outer rings O O
and the center cone
Synchronizer
Synchronizer ring and spline of synchronizer sleeve worn O
faulty
Wear on chamfered section of synchronizer ring splines O
Shifting key and shifting pin worn O
Shifting key spring and synchronizer spring deteriorated or dam-
O
aged
Synchronizer sleeve worn or damaged O O
Rod and control cable adjustment faulty O
Control cable improperly routed O
Rod and control cable length inadequate O O
Rod bent O
Bushings worn O O
Control mecha-
Interlock pin and groove of shift rail worn O
nisms faulty
Poppet spring of shift rail fatigued or broken O
Shift rail sliding area worn O
Shift fork jaws worn O
Shift fork piece worn O
Shift fork broken O

22A-10
 22A
Symptoms

Gears slip out of engagement

Noise when engine is idling

Noise when changing gear

Gears hard to engage

Noise when cruising

Reference Gr

Possible causes
Air compressor faulty O
Power shift mal- Gr35
Air leakage O
functioning
Power shift faulty O
Clutch disengagement faulty O O
Clutch faulty Gr21A
Clutch pedal play faulty O

22A-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection of Transmission Oil Leakage
1.1 Inspection of oil leakage at each part of transmis-
sion body
• Check the oil leakage at each part of transmission body in visu-
al.
If the oil leakage is found, replace the defective part.
1.2 Inspection of oil leakage around transmission
mounting part
• Check there is not oil stain on flywheel housing, spacer and
transmission mounting part caused by oil leakage from engine.
• If there is the oil stain, remove the transmission and clean the
mounting surface of clutch housing and flywheel housing using
brake cleaner etc. after repairing oil leakage part. Because the
oil stain may loosen the transmission mounting bolts. (See “RE-
MOVAL AND INSTALLATION OF TRANSMISSION”.)

2. Check for Looseness in Transmission Mounting Bolts and Nuts

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Bolt or nut (transmission mounting) 60 {6.1} –

• Check the transmission mounting bolts and nuts for looseness.

• Retighten any loose bolt or nut to the specified torque.

3. Check for Play and Looseness in Companion Flange

• Check the propeller shaft mounting bolts for looseness. (See
Gr25.)
• Move the companion flange back and forth, and up and down,
and check for a play between the companion flange and main-
shaft.
• If there is a play, remove the propeller shaft, check for a loose-
ness in the lock nut, examine the spline of companion flange
and mainshaft. If any abnormality is found, replace the defective
part(s). (See “Rear cover”.)

22A-12
 22A
4. Inspection and Replacement of Transmission Oil
WARNING
• Temperature of transmission oil is high immediately after driving. Perform work when oil is cold.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Inspection plug
– 68.6 ± 14.7 {7.0 ± 1.5} –
Drain plug

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Thread area of inspection plug
– ThreeBond 1105 As required
Thread area of drain plug
Gear oil
General: API GL-3 SAE 80
Warm region: API GL-3 SAE 90
Transmission case and
– Tropical region: API GL-4 SAE 90 21 dm3 {21 L} *b
extension housing
Engine oil
Vehicle operated continuously at high
speed: API CC SAE 30 or SAE 40
• Grease depends on the driving conditions.
• For oil cooler, the quantify is increased by 1 dm3 {1L}.

[Inspection]
(1) Inspection of oil quantity
• Remove the inspection plug, and check that transmission oil is
filled up to the neck.
• If oil is not sufficient, fill transmission oil from the inspection plug
hole up to the neck.
• After filling, apply sealant to the inspection plug and tighten it to
the specified torque.

(2) Inspection of oil quality and inclusions

• When draining transmission oil, check for oil quality, metal chips
and metal powder.
• The following conditions are indicative of internal troubles;
hence overhaul is required.
• Viscosity is too high
• A foreign odor
• Too many metal particles
[Replacement]
• Remove the drain plug to drain transmission oil. Drainage can
be made quickly with the inspection plug removed.
• After draining transmission oil, apply sealant to the drain plug
and tighten it to the specified torque. In so doing, clean up the
magnetic drain plug before mounting.
• Fill transmission oil of the specified quantity from the inspection
plug hole.
• After filling, wait for 1 minute or more to check that oil is filled up
to the neck of the inspection plug hole by inserting a finger to the
inspection plug hole. If oil is not sufficient, replenish it.
• Run the engine for a while to charge oil into the oil cooler.
• After stopping the engine, replenish oil into the inspection plug
hole brimful.
• After completing work, apply sealant to the inspection plug and
tighten it to the specified torque.
22A-13
ON-VEHICLE INSPECTION AND ADJUSTMENT
5. Inspection of Transmission Oil Cooler System
• Check oil leakage and damage in transmission oil cooler sys-
tem. If any abnormality is found, replace the defective part.
• Check the connections of the oil cooler, oil cooler pipes and hos-
es for looseness. Tighten any loose connections to the specified
torque.

22A-14
 22A
M E M O

22A-15
REMOVAL AND INSTALLATION OF TRANSMISSION
Removal sequence
1 Air hose
2 Clutch booster (See Gr21A.)
3 Propeller shaft (See Gr25.)
4 Flexible hose (See Gr21A.)
5 Transmission
6 Spacer

WARNING
• Since there is a risk to burn oneself,
let the transmission to cool down
after driving.

CAUTION
• Tilting cab must always be performed with the front panel fully open or closed. Cab tilting with the front
panel half open can cause the lower section of the front panel to contact with the peripheral parts, possi-
bly resulting in damaged parts. However, note that the front panel may contact with the peripheral parts
when air gauge pointer is in the red zone, even if the panel is fully closed. In such a case, cab tilting must
be done with the front panel fully open.

Installation sequence
Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt or nut (transmission mounting) 60 {6.1} –
Flexible hose (release bearing connecting) 12 to 16 {1.2 to 1.6} –
Air hose (clutch booster side) 40.2 to 44.1 {4.1 to 4.5} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Molybdenum disulfide grease
Spline of input shaft of transmission As required
[NLGI No. 2 (Li soap)]

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Guide Bar

A B C
MH061797 Holding of spacer
M10 × 5 10.5 204

22A-16
 22A
Removal procedure
Removal: Transmission
• Support the transmission on the transmission jack and remove
transmission mounting bolts or nuts.

• Install to four arrow-marked portions A (four places) from

which bolts have been removed for holding spacer.
WARNING
• Do not attempt to remove transmission without using .
This may cause not only a dangerous situation due to
dropped spacer, but also a damage to the flexible hose and
the associated parts inside the clutch housing.

• Screw in M10 × 1.5 mm bolts evenly into thread holes B (three

places) in transmission to separate the transmission assembly
from the engine.
• Leave spacer on the engine side.

• Transmission and clutch are connected inside the clutch hous-

ing by flexible hose. Move straightly rearward the transmission
with utmost care not to apply undue force to the hose, while
sending the hose into the clutch housing.
• Move straightly rearward transmission until the input shaft
splines come off the clutch.
CAUTION
• Do not shake hard transmission, or the splines which cou-
ple the input shaft to the clutch may be damaged. Be sure to
pull out straightly.

• Remove flexible hose connecting to the release bearing of

clutch.
• Remove spacer and .

22A-17
REMOVAL AND INSTALLATION OF TRANSMISSION
Installation procedure
Installation: Transmission
• Check the spline of the input shaft for rust.
• If rust is found, remove it using a wire brush.
• Rub grease evenly onto the clutch disc sliding surface of the in-
put shaft using your hand.
CAUTION
• Make sure that you apply only the necessary amount of
grease because too much grease can drip and cause clutch
slip.

• Fully pull the flexible hose into the clutch housing.

• Install to the bolt mounting positions A (four places) of fly-

wheel housing for holding spacer.

• Install spacer to flywheel housing by sliding it along , with

the chamfered portion of the spacer facing down.

• Support transmission on transmission jack, and bring close to

the engine.

• Before coupling the transmission to the engine, install the flexi-

ble hose to the release bearing of clutch.

22A-18
 22A
Perform Steps 1 to 6 to install the clutch control:
1 Rotate release fork shaft to set the lever of the release fork
shaft downward. Hold the release fork in the vertical position.
2 Push release fork shaft into the clutch housing, until the stopper
of release fork contacts the lateral direction stopper B provided
inside the clutch housing.
3 Turn release fork shaft to the rearward of vehicle, and press the
stopper of release fork against the rotary direction stopper C
provided inside the clutch housing.
4 Make sure that the angle or release fork is approximately 30°.
5 While holding the release fork shaft with hand so that the set
position of release fork can be maintained, and while pulling
flexible hose to keep it taut, combine transmission to the engine
by sliding along Guide Bars.

CAUTION
• If release fork is incorrectly set, or if the clutch shifter ro-
tates due to slackened flexible hose, the release fork will
not be assembled correctly to the release bearing.

6 Turn release fork shaft by hand to check if release fork is cor-

rectly assembled to the release bearing of clutch. When assem-
bled correctly, the movement of the release fork shaft is
approximately 22 mm.
If the release fork shaft is binding, repeat the procedure starting
with step 1.
7 Fit and tighten all the transmission mounting bolts and nuts to
the specified torque except those to be installed in 4 holes in
each of which is being attached and those used to secure
the bracket mentioned below as well.

• Remove Guide Bar (four places), and tighten connector of

flexible hose together to the marked portion with bolt.

• Install bracket of flexible hose at the angle shown in the illustra-

tion.

22A-19
GEAR SHIFTER UPPER

22A-20
 22A
Disassembly sequence
1 Air hose 9 O-ring 17 Washer
2 Transmission neutral switch 10 Gear shift lever 18 Gear select lever
3 Shift check switch 11 Spacer 19 Oil seal
4 Power shift (See later section.) 12 Gear shift sliding lever 20 Bushing
5 Plug 13 Spring retainer 21 Dust plug
6 Torsion shaft spring 14 1st and reverse return spring 22 Select lever case
7 Steel ball 15 Lock pin
8 Spring pin 16 Gear select lever : Non-reusable parts

• Do not remove bushing except for replacement.

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
101.9 N
4 Torsion shaft spring installed load (installed length 23.9) 127.5 ± 13 N {13 ± 1.3kgf} Replace
{10.4 kgf}
1st and reverse return spring 60.4 N
14 75.5 ± 7.8 N {7.7 ± 0.8 kgf} Replace
installed load {6.16 kgf}

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Transmission neutral switch
49.0 ± 2.9 {5.0 ± 0.3} –
Shift check switch
Air hose 19.6 to 58.8 {2.0 to 6.0} –
Bolt (power shift mounting)
40.2 {4.1} –
Bolt (select lever case mounting)
Plug 22.6 {2.3} –
Nut (lock pin mounting) 16.7 {1.7} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Plunger end of transmission neutral switch
Plunger end of shift check switch
Pack in mounting position of steel balls of gear shift lever
and O-ring groove Wheel bearing grease
As required
Sliding surface of washer [NLGI No. 2 (Li soap)]
Lip area of oil seal
Sliding area of bushing inner surface in contact with gear
select lever shaft
Thread area of transmission neutral switch
ThreeBond 1104J As required
Thread area of shift check switch
Power shift surface in contact with select lever case
ThreeBond 1215 As required
Bushing outer surface in contact with select lever case
Thread area of air hose connector on power shift side ThreeBond 1207B As required
Mating surfaces of select lever case and transmission
ThreeBond 1215 or Loctite 5999 As required
case

22A-21
GEAR SHIFTER UPPER
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application

Spring pin puller

A MH062445
M12 × 1.25

Removal of spring pin

Reverse shaft puller

A 03726-82000
M12 × 1.25

Removal procedure
Removal: Spring pin
• Tap the spring pin using a M4 tap.
• Insert with a M4 screw of appropriate length into the spring
pin, and remove the spring pin using .

Removal: Bushing
• Remove the bushing using a screwdriver with taking care not to
damage the selector lever case.

22A-22
 22A
Installation procedure
Installation: Bushing
• Clean the bushing and bushing mounting surface of the selector
lever case.
• Apply grease to the inner surface of the bushing and sealant to
its outer surface.
CAUTION
• Do not allow sealant to adhere to the inner surface of the
bushing. Otherwise it causes defective operation of the
gear select lever.

• Mount the bushing by evenly tapping it using a round bar of out-

er diameter of approximately 40 mm.

Installation: Gear select lever

• Install the gear select lever while turning so that the oil seal is
not damaged in the lip.

Installation: Gear shift sliding lever

• Install the gear shift sliding lever aligning with the spline so that it
is placed at the illustrated angle to the gear shift lever.

22A-23
POWER SHIFT

Disassembly sequence
1 Hose 10 Straight pin 19 O-ring
2 Lever 11 Valve (See later section.) 20 Retaining ring
3 Boot 12 Set screw 21 Shifter rod
4 Cover 13 O-ring 22 Striker
5 Boot 14 Packing 23 Plate
6 Connector 15 Cylinder 24 Cup packing
7 O-ring 16 Retaining ring 25 Housing
8 Retaining ring 17 Piston packing
9 Plate 18 Piston : Non-reusable parts

Assembly sequence
Follow the disassembly sequence in reverse.

Repair kit: Power shift kit

22A-24
 22A
Service standards
Location Maintenance item Standard value Limit Remedy
9.8 kPa
Air leakage When not
– {0.1 kgf/
(decrease of pressure 15 sec- operating
cm2}
Power onds later after application of
– pressure (735 kPa {7.5 kgf/ 49 kPa Replace
shift When
cm2})) – {0.5 kgf/
operating
cm2}
Sliding resistance in shifting direction 38.2 N {3.9 kgf} or less –

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (lever mounting) 23.5 to 26.5 {2.4 to 2.7} –
Nut (connector mounting) 59 to 69 {6 to 7} –
Connector 7.8 to 11.8 {0.8 to 1.2} –
Set screw 2.0 to 3.4 {0.2 to 0.35} –
Cylinder 98 to 117 {10 to 12} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Inner surfaces of lever Multipurpose grease
As required
All sliding areas [NLGI No. 2 (Li soap)]
Thread area of cylinder Loctite 242 or ThreeBond 1401B As required

Special tools
Mark Tool name and shape Part No. Application

Connector ME528898 Removal and installation of connector

Sleeve

A B C
ME528897 Insertion of valve
φ29 φ27 35

Socket

A ME528895 Removal and installation of cylinder

46

22A-25
POWER SHIFT
Inspection before removal
Inspection: Power shift
(1) Inspection of air tightness
• Apply the specified pressure from the connector, and check air
tightness when the power shift is not operating (valve in neutral
position) and when it is operating (in both directions of pushing
and pulling the valve).
• If the measured value exceeds the limit, replace defective parts.

(2) Sliding resistance in shifting direction

• Measure sliding resistance in the shifting direction of the shift ca-
ble connecting hole position. Perform shifting for conditioning
four or five times before measurement.
• If the measurement exceeds the specified standard value, apply
grease on all sliding surfaces.
• After applying grease, measure again; if the measurement devi-
ates from the standard value, replace the defective part(s).

Removal procedure
Removal: Connector

Removal: Valve
• Push the valve from the lever side using an appropriate bar, and
detach it from the shifter rod.
CAUTION
• Valve parts can be damaged if excessive force is applied to
extract the valve.

Removal: Cylinder

22A-26
 22A
Installation procedure
Installation: Cylinder
• Install the cylinder by following the removal sequence in reverse.
(See “ Removal: Cylinder”.)

Installation: Valve
• Apply grease to the valve.
• Install the cylinder to the shifter rod using , while checking
integrity of the seals.

Installation: Connector
• Install the connector by following the removal sequence in re-
verse.
(See “ Removal: Connector”.)

Installation: Boot
• Install the boot to the housing, with the water drain hole down.

22A-27
POWER SHIFT
Valve

Disassembly sequence
1 Pin 11 Lifter 21 O-ring
2 Bushing 12 Spring 22 Lifter
3 Rod 13 Square ring 23 Spring
4 Filter 14 Seat 24 Square ring
5 Collar 15 Seal 25 Seat
6 Square ring 16 Spring 26 Seal
7 Tube 17 Square ring 27 Y-packing
8 Retaining ring 18 Tube 28 Pipe
9 Plate 19 Retaining ring
10 O-ring 20 Plate : Non-reusable parts

• Since the valve includes many parts, set them out accurately when disassembling.

Assembly sequence
Follow the disassembly sequence in reverse.

Repair kit: Power shift kit

• Be careful to assemble springs in the correct order.

22A-28
 22A
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
38.2 N
12 Spring installed load (installed length 13) 47.1 ± 4.9 N {4.8 ± 0.5 kgf} Replace
{3.9 kgf}
9.8 N
16 Spring installed load (installed length 10) 12.7 ± 1.0 N {1.3 ± 0.1 kgf} Replace
{1.0 kgf}
14.7 N
23 Spring installed load (installed length 13) 18.6 ± 2.0 N {1.9 ± 0.2 kgf } Replace
{1.5 kgf}

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Multipurpose grease
– All sliding areas As required
[NLGI No. 2 (Li soap)]

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Insert tool

A B C D ME528899
30 10 φ3.8 φ7.1

Installation of retaining ring

Insert tool

A B C D ME528896
φ30 φ7 29 35

Removal procedure
Removal: Retaining ring
• Secure the rod in a vice with caution.
• Remove the retaining ring from the pipe using something like
needle.

Installation procedure
Installation: Retaining ring
• Attach to the pipe tip, push the retaining ring in a straight
line using , and secure it in the pipe groove.
• If the ring jams up during installation, reinstall it.

22A-29
INTERLOCK PLATE

Disassembly sequence
1 Air bleeder 10 Backup lamp switch
2 Lock plate 11 Plug
3 Jaw set bolt 12 Plug
4 Lock plate 13 Plug
5 O-ring 14 Poppet spring plate
6 Interlock plate bushing 15 Poppet spring
7 O-ring 16 Interlock pin
8 Interlock plate bushing
9 Interlock plate : Non-reusable parts

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Clearance between interlock plate bushing and
6, 8, 9 0.13 to 0.35 0.7 Replace
interlock plate
127.4 N
15 Poppet spring installed load (installed length 30.9) 158.8 ± 16.0 N {16.2 ± 1.6 kgf} Replace
{13.0 kgf}

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Jaw set bolt
133 {13.6} –
Bolt (lock plate mounting)
Backup lamp switch
49 {5} –
Plug
Bolt (poppet spring plate mounting) 40.2 {4.1} –

22A-30
 22A
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Thread area of backup lamp switch
ThreeBond 1104J As required
Thread area of bolts
Mating surfaces of poppet spring plate and transmission
ThreeBond 1215 or Loctite 5999 As required
body

22A-31
REAR COVER

Disassembly sequence
1 O-ring 6 Oil seal 11 Oil separation plate
2 Companion flange 7 Speedometer gear bushing 12 Speedometer worm
3 Vehicle speed sensor 8 Speedometer gear 13 Washer
4 L-joint 9 Oil seal
5 Speedometer joint 10 Rear cover : Non-reusable parts

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
2 Runout at socket portion of companion flange 0 to 0.15 0.15 Replace
Clearance between speedometer gear bushing and
7, 8 0.02 to 0.07 0.15 Replace
speedometer gear
Clearance between speedometer gear and rear cover
8, 10 0 to 0.35 0.4 Replace
bushing

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Lock nut 1370 to 1670 {140 to 170} –
Bolt (rear cover mounting) 73.5 {7.5} –
Vehicle speed sensor 20 ± 10 {2 ± 1} –
L-joint 34 to 39 {3.5 to 4.0} –
Speedometer gear bushing 98 {10} –
Speedometer joint 53 to 73 {5.5 to 7.5} –

22A-32
 22A
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Wheel bearing grease
Lip area of oil seal As required
[NLGI No. 2 (Li soap)]
Sliding area of speedometer gear in contact with speed-
ometer gear bushing Molybdenum disulfide grease
As required
[NLGI No. 2 (Li soap)]
End and spline part of speedometer gear
Mating surfaces of rear cover and transmission case ThreeBond 1215 or Loctite 5999 As required
Thread area of speedometer gear bushing ThreeBond 1104J As required

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

<P140 (M)>
Flange puller Removal of companion flange
MH061393

Oil seal installer

MH062069 Installation of oil seal

A B C D E
φ105 φ80 φ65 14 50

Socket wrench

A MH061520 Removal and installation of lock nut

65

Socket wrench

A B C * MH062755 Installation of speedometer worm

φ155 φ68 300

<P152>
Gear puller Removal of companion flange
MH062587

*: Components of puller and installer kit (See puller and installer.)

22A-33
REAR COVER
Work before removal
Inspection: Runout at socket portion of companion flange
• If the measurement exceeds the limit, replace the companion
flange.

Removal procedure
Removal: Companion flange
• Using , remove the companion flange. <P140 (M)>
• Using or a commercially available gear pulley, remove the
companion flange. <P152>

Inspection procedure
Inspection: Clearance between speedometer gear and
speedometer gear bushing
• If the measurement exceeds the limit, replace the speedometer
gear bushing.

22A-34
 22A
Installation procedure
Installation: Speedometer worm

Installation: Oil seal

• Install the oil seal on the rear cover in the illustrated direction.
• After installation, apply grease to the oil seal lip.

Installation: Oil seal

• Apply grease to the oil seal lip.
• Install the oil seal evenly to the speedometer gear bushing in the
illustrated direction, using a round bar with outer diameter of ap-
prox. 15 mm.

Installation: Companion flange

[Heating]
• Heat the companion flange following in either of manners below
so that the companion flange becomes 140°C.
<Use of oven>
• Heat the companion flange at the set temperature 140°C for 30
minutes or more.
<Use of ring heater>
• Reheat the companion several times at the set temperature
140°C so that the entire companion flange becomes 140°C.
• Set the thermometer at not flange but boss.
CAUTION
• Heat the companion flange several times because heating
once is not enough thermal expansion for the companion
flange.

22A-35
REAR COVER
<Use of oil bath>
• Heat the gear oil to 140°C and put the companion flange in the
direction as illustrated in the bath.
CAUTION
• Put the companion flange in the bath with facing the boss of
the companion flange upward because facing the boss
downward makes the boss touch the heat source directly
and become 140°C or more.

• Putting it in the bath causes the gear oil to fall. So reheat the oil
to 140°C and heat the companion flange for 20 minutes or more
keeping 140°C.

[Installation]
• Bring the gears into engagement before beginning with the in-
stallation procedure.
• Fit the heated up companion flange onto the main shaft while
aligning their splines with each other. Using a plastic hammer,
strike the companion flange into position with the specified jig
applied on it.
CAUTION
• During installation process, be careful not to get burnt by
hot companion flange.

• Wait until the companion flange is cooled down sufficiently, then

install the O-ring. Fit and tighten the lock nut to the specified
torque. Secure it with a split pin.

22A-36
 22A
M E M O

22A-37
REVERSE IDLER GEAR

Disassembly sequence
1 Power take-off cover 5 Side washer 9 Side washer
2 Reverse shaft lock piece 6 Needle bearing
3
4
O-ring
Reverse idler gear shaft
7
8
Spacer
Reverse idler gear
*a:: Transmission body
Non-reusable parts

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Play of reverse idler gear in diameter direction 0.03 to 0.06 0.12 Replace
–
End play of reverse idle gear 0.02 to 0.07 0.3 Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (power take-off cover mounting) 20.6 {2.1} –
Bolt (reverse shaft lock piece mounting) 40.2 {4.1} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Mating surfaces of power take-off cover and transmission
Loctite 5999 As required
case
Wheel bearing grease
Transmission case mounting hole for reverse idler shaft Approx. 5 g
[NLGI No. 2 (Li soap)]

22A-38
 22A
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application

Reverse shaft puller

A 03726-82000 Removal of reverse idler gear shaft

M12 × 1.25

Removal procedure
Inspection: Play of reverse idler gear in diameter direction
• After removal of power take-off cover, replace the defective
part(s) if the measurement exceeds the limit.
• Perform inspection after assembly as well, and make sure that
measured values are below the limits.

Inspection: End play of reverse idle gear

• Measure the end play using feeler gauge.
• Replace the defective part(s) if the measurement exceeds the
limit.

Removal: Reverse idler gear shaft

22A-39
TRANSMISSION BODY

22A-40
 22A
Disassembly sequence
1 Inspection plug 14 Power cylinder 29 Snap ring
2 Drain plug (See later section.) 30 Splitter synchronizer cone
3 Transmission high/low 15 Lock piece 31 Drive pinion bearing retainer
changeover switch (high) 16 O-ring 32 Countershaft
4 Transmission high/low 17 Inverse pin (See later section.)
changeover switch (low) 18 Lock piece 33 Seal ring
5 O-ring 19 O-ring 34 Drive pinion
6 Oil cooler pump 20 Inverse pin (See later section.)
(See later section.) 21 Lock seat 35 Mainshaft (See later section.)
7 O-ring 22 Lock plate 36 Front case
8 Oil intake plate 23 Snap ring 37 Strainer plate
9 O-ring 24 Mainshaft rear bearing 38 Clutch housing and splitter
10 Oil seal 25 Snap ring (See later section.)
11 Front retainer 26 Countershaft rear bearing
12 Seal ring 27 Transmission case : Locating pin
13 Lock plate 28 Shift rail and shift fork : Non-reusable parts
(See later section.)

• After removing the front retainer, perform work with the transmission laid vertically on its clutch housing side. Ap-
ply a batten to the clutch housing to prevent damage to the input shaft.

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Clearance between splitter synchronizer cone and syn-
30, 38 2.0 0 Replace
chronizer ring of splitter

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (front retainer mounting)
Bolt (drive pinion bearing retainer mounting)
40.2 {4.1} –
Bolt (lock piece mounting)
Bolt (power cylinder mounting)
Bolt (transmission case and front case mounting) 122 {12.4} –
Inspection plug
68.6 ± 14.7 {7.0 ± 1.5} –
Drain plug
Bolt (oil cooler pump mounting) 23.5 {2.4} –
Bolt (strainer plate mounting) 9.8 to 14.7 {1.0 to 1.5} –
Bolt (lock plate mounting) 291 {29.7} –
Bolt (lock seat and lock plate mounting) 98 {10} –
Transmission high/low changeover switch (high)
49 {5} –
Transmission high/low changeover switch (low)

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Clutch housing mounting surface of front retainer
Transmission case mounting surface of front case ThreeBond 1215 or Loctite 5999 As required
Front case mounting surface of clutch housing
Wheel bearing grease
Lip area of oil seal As required
[NLGI No. 2 (Li soap)]

22A-41
TRANSMISSION BODY
Mark Points of application Specified lubricant and/or sealant Quantity
Thread area of inspection plug
ThreeBond 1105 As required
Thread area of drain plug
Front retainer mounting surface or oil cooler pump Loctite 5999 As required
Thread area of transmission high/low changeover switch
(high)
ThreeBond 1104J As required
Thread area of transmission high/low changeover switch
(low)

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Oil seal front guide

Serving as guide for oil seal when
MH063415
A B C D front bearing retainer is installed
φ49 φ30 51 80

Oil seal installer

A B C D E MH062170 Installation of oil seal

φ78 φ57 φ46 9 19

Snap ring expander MH061268 Removal and installation of snap ring

Bearing puller
* MH062597 Removal of mainshaft rear bearing
A B C
φ160 φ68 390

Bearing installer

A B C * MH062240 Installation of mainshaft rear bearing

φ161 φ78.6 395

Bearing puller * MH061633 Removal of countershaft rear bearing

22A-42
 22A
Mark Tool name and shape Part No. Application

Eyebolt

A MH001982 Lifting of front case

M18 × 1.5

Eyebolt

A MH062246 Lifting of transmission case

M12 × 1.75

Bearing installer
Installation of countershaft rear and
A B C * MH061641
front bearing
φ128 φ74 170

Eye nut
MH062247
A
M42 × 1.5

Removal and installation of counter-

shaft, mainshaft and drive pinion

Steel lifting band

A B C MH063440
φ291 φ123 428.5

Single spanner
Spline joint between countershaft and
A MH061556
splitter portion splitter gear.
78.5

*: Components of puller and installer kit (See puller and installer.)

Removal procedure
Removal: Mainshaft rear bearing

22A-43
TRANSMISSION BODY
Removal: Countershaft rear bearing

Removal: Transmission case

• Attach to the transmission case and prepare for hoisting it
with a crane.
• After removing bolts, hoist the transmission case with a crane
and keep hitting the rear ends of the countershaft and mainshaft,
and front case. Use a plastic hammer to remove the transmis-
sion case.
CAUTION
• Use wire that carries 300 kg or more.

• After removing the transmission case and shift rail and shift fork,
secure the countershaft and the 2nd gear area of the counter-
shaft and mainshaft with for safety. Be sure to tighten the
steel lifting band enough to prevent it from coming undone, but
not excessively.

22A-44
 22A
Removal: Countershaft, drive pinion and mainshaft
• Leave the countershaft and mainshaft secured with .
• Install to the mainshaft and (4 places) to the front
case to prepare for lifting it with a crane.
• Batten the clutch housing, and remove the unit with front case
by crane, while hitting with a plastic hammer.
• When removed from the clutch housing, hold the shaft by hand
to prevent from a big tilt.
CAUTION
• Use wire that carries 300 kg or more.

• After removing from clutch housing batten the drive pinion to

prevent damage and lower it.
• Support the mainshaft by crane to prevent it from falling.

• Use to remove the snap ring from the drive pinion and then
remove the splitter synchronizer cone.

22A-45
TRANSMISSION BODY
• After removing the drive pinion bearing retainer, lift the mainshaft
by crane while hitting the front case by a plastic hammer or the
like and remove together with counter shaft and drive pinion.
• When removed from the clutch housing, hold the shaft by hand
to prevent from a big tilt.

Inspection procedure
Inspection: Clearance between splitter synchronizer cone
and splitter portion synchronizer ring
• Press each synchronizer ring evenly on to splitter synchronizer
cone and measure the entire circumference.
• If the measurement exceeds the limit, replace both the ring and
splitter synchronizer cone.

Installation procedure
Installation: Countershaft, drive pinion and mainshaft
• There are two methods of the installation procedure.
(1) Method 1
• Install the countershaft, drive pinion and mainshaft by following
the removal sequence in reverse. (See “ Removal: Counter-
shaft, drive pinion and mainshaft”.)
• When spline at the tip of the countershaft and spline of the split-
ter gear of the splitter portion do not mesh and are difficult to en-
gage, use to turn the splitter gear and assemble the spline
accordingly.
• Be sure to remove all the special tools used.

(2) Method 2
• In the case of this method, install with the countershaft front
bearing removed. (See Countershaft.)
• After installing the drive pinion on the front case, install the drive
pinion bearing retainer.

22A-46
 22A
• Install on the rear end of the mainshaft, and hoist it with a
crane to install on the drive pinion.
• After installation, support the mainshaft with a crane to prevent it
from falling down.

• Install the countershaft on the clutch housing.

22A-47
TRANSMISSION BODY
• Fix the 2nd gears of the countershaft and mainshaft using
to ensure safety. Tighten steel lifting band adequately enough to
prevent it from coming undone, but not excessively.

• When installing the shift rail and shift fork on the mainshaft, first
put the synchronizer sleeve of mainshaft to neutral position.
• Be sure to remove all special tools used.
• After mounting the countershaft, place the unit transversely with
the countershaft up, and install the countershaft front bearing.
• Install the countershaft front bearing with loose rib in the direc-
tion shown in the illustration.
CAUTION
• If installed in reverse direction, the internal axle of the bear-
ing will remain in the splitter portion splitter gear during re-
moval, and it will not be possible to remove it.

• For further installation procedures, follow the removal sequence

in reverse.
(See “ Removal: Countershaft, drive pinion and main-
shaft”.)

Installation: Transmission case

• Install the transmission case by following the removal sequence
in reverse.
(See “ Removal: Transmission case”.)

22A-48
 22A
Installation: Countershaft rear bearing
• Install the countershaft rear bearing on the transmission case in
the illustrated direction.

Installation: Mainshaft rear bearing

• Install the mainshaft rear bearing on the transmission case in the
illustrated direction.

Installation: Lock seat

• Tighten the bolt to the specified torque. Turn and fasten 4 bent-
up bolts to the tip of the lock seat.

Installation: Oil seal

• Apply grease to the lip area of the oil seal and install if on the
front retainer in the illustrated direction.

Installation: Front retainer

• Install on the input shaft to protect the oil seal.
• Apply sealant to the clutch housing mounting surface of the front
retainer to install.

22A-49
TRANSMISSION BODY
Clutch Housing & Splitter

Disassembly sequence
1 Screw plug 11 Synchronizer ring 21 Splitter pinion
2 Poppet spring 12 Synchronizer sleeve 22 Needle bearing
3 Poppet pin 13 Shifting key spring 23 Bearing spacer
4 Reamer bolt 14 Shifting key 24 Needle bearing
5 Spring pin 15 Synchronizer hub 25 Oil feed adapter
6 O-ring 16 Bearing retainer 26 Input shaft
7 Splitter control lever 17 Splitter gear bearing 27 Clutch housing
8 Snap ring 18 Splitter gear
9 Splitter shift fork 19 Snap ring : Non-reusable parts
10 Splitter shift fork piece 20 Input shaft bearing

• Do not remove oil feed adapter except when exchanging parts.

Assembly sequence
Follow the disassembly sequence in reverse.

22A-50
 22A
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Play in diameter direction after assembling splitter pin-
0.03 to 0.07 0.12 Replace
– ion
End play of splitter pinion 0.15 to 0.35 – Replace
81 ± 8.1 N 65 N
2 Poppet spring installed load (installed length 35.2) Replace
{8.3 ± 0.83 kgf} {6.6 kgf}
Clearance between synchronizer sleeve groove and
10, 12 0.2 to 0.4 1.0 Replace
splitter shift fork piece
Clearance between synchronizer ring protrusion and
11, 15 4.8 to 5.4 6.5 Replace
synchronizer hub groove
Clearance between synchronizer ring and splitter pinion
11, 21 2.0 0 Replace
cone
Play of synchronizer sleeve and synchronizer hub in ro-
12, 15 0.06 to 0.14 0.3 Replace
tation direction
Clearance between shifting key and synchronizer hub
14, 15 0.05 to 0.35 0.5 Replace
keyway

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Screw plug 49 {5.0} –
Reamer bolt 42 {4.3} –
Bolt (bearing retainer mounting) 40 {4.1} –

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Bearing puller
* MH062272 Removal of splitter gear bearing
A B
φ130 170

Bearing installer
Installation of splitter gear bear-
A B C * MH061641
ing
φ128 φ74 170

Removal and installation of

Snap ring expander MH061268
snap ring

Bearing puller

A B C * MH062243 Removal of input shaft bearing

φ160 φ62 390

22A-51
TRANSMISSION BODY
Mark Tool name and shape Part No. Application

Bearing installer
Installation of input shaft bear-
A B C * MH062242
ing
φ160 φ62 390

*: Components of puller and installer kit (See puller and installer kit.)

Work before removal

Inspection: Play of gears in diameter direction
• If the measurement exceeds limit, replace defective parts.

Alignment marks: Synchronizer sleeve, synchronizer hub

and splitter pinion
• Disassemble after putting 1 alignment mark on each of synchro-
nizer sleeve and splitter pinion.
• Disassemble after putting 1 alignment mark each on the syn-
chronizer hub in accordance with the alignment mark put on the
synchronizer sleeve.

22A-52
 22A
Removal procedure
Removal: Splitter gear, input shaft
• Hold a round bar against the splitter gear and input shaft and
use a wooden or bronze hammer to hit and remove from the
clutch housing at the same time.

Removal: Splitter gear bearing

• When removing splitter gear bearing, protect the splitter gear
bolt hole using an appropriate plate and use for removal.

Inspection: End play of splitter pinion

• Measure the end play between the snap ring and bearing using
feeler gauge.
• If the measured value is out of the standard value, replace the
defective parts.

Removal: Input shaft bearing

22A-53
TRANSMISSION BODY
Inspection procedure
Inspection: Clearance between splitter shift fork piece and
synchronizer sleeve
• If the measurement exceeds limit, replace the defective parts.

Inspection: Clearance between synchronizer ring protru-

sion and synchronizer hub groove
• If the measurement exceeds the limit, replace the defective
parts.

Inspection: Clearance between synchronizer ring and split-

ter pinion
• Press each synchronizer ring evenly onto splitter pinion and
measure the entire circumference.
• If the measurement exceeds the limit, replace both the ring and
splitter pinion.

Inspection: Play of synchronizer sleeve and synchronizer

hub in rotation direction
• Hold the synchronizer sleeve and measure the play with rotating
the synchronizer hub.
• If the measured value exceeds the limit, replace the defective
parts.

Inspection: Clearance between shifting key and synchroniz-

er hub keyway
• If the measurement exceeds the limit, replace the defective
parts.

22A-54
 22A
Installation procedure
Installation: Input shaft bearing

Installation: Splitter gear bearing

Installation: Shifting key spring

• After inserting the shifting key into the synchronizer hub keyway,
install the shifting key spring so that its opening is not located at
the shifting key position.
• Install so that openings of the two shifting key springs are not lo-
cated at the same position.

Installation: Synchronizer sleeve and synchronizer hub

• When replacing the synchronizer sleeve or synchronizer hub
with a new one, align the plunger grooves (three locations) of
the synchronizer hub with stub gear teeth (three locations) of the
synchronizer sleeve to install.

22A-55
TRANSMISSION BODY
Shift Rail and Shift Fork

Disassembly sequence
1 Set bolt 7 2nd and 3rd shift rail 13 4th and 5th shift rail jaw
2 1st and reverse shift rail 8 2nd and 3rd shift fork
3 1st and reverse shift jaw 9 Set bolt
*b:
a: Mainshaft
4 1st and reverse shift fork 10 Set bolt
* Inverse pin
5 Shift fork piece 11 4th and 5th shift rail : Non-reusable parts
6 Set bolt 12 4th and 5th shift fork

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
2, 7, 11 Bend of shift rail 0 to 0.05 0.1 Replace
Clearance between 1st and reverse shift fork hole and
4, *b 0.06 to 0.10 0.2 Replace
inverse pin
Clearance between shift fork piece and mainshaft con-
5, *a 0.2 to 0.4 1.0 Replace
stant mesh sleeve
8, 12 Tilt of shift fork claw 0 to 0.1 0.2 Replace
Clearance between each shift fork and synchronizer
8, 12, *a 0.25 to 0.45 1.0 Replace
sleeve of mainshaft

22A-56
 22A
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Set bolt 57.9 {5.9} –

Inspection procedure
Inspection: Bend of shift rail
• Measure the extent of bending at the middle of each of shift rail.
• While rotating the shift rail by one revolution, read how much the
dial gauge needle will move. A half of the reading observed rep-
resents the bend, if any, of the shaft.
• If measurement exceeds the limit, correct or replace the shift
rail.

Inspection: Clearance between shift fork piece and constant

mesh sleeve of mainshaft
• If the measurement exceeds the limit, replace defective parts.

Inspection: Tilt of shift fork claws

• Measure the tilt (difference between A and A´) of claw A-A´
against the shift rail hole of shift forks with pressing the rail to V-
block and standing it vertically.
• If the measurement exceeds the limit, replace the shift forks.

Inspection: Clearance between shift fork and synchronizer

sleeve of mainshaft
• If the measurement exceeds the limit, replace defective parts.

22A-57
TRANSMISSION BODY
Oil Cooler Pump
Disassembly sequence
1 Cap nut
2 Spring
3 Ball
4 Cover
5 Dowel
6 O-ring
7 Outer rotor
8 Case and rotor

: Non-reusable parts

Assembly sequence
Follow the disassembly sequence in re-
verse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Cap nut 49.1 ± 4.9 {5.0 ± 0.5} –
Bolt (cover mounting) 16.7 ± 3.33 {1.7 ± 0.34} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Each sliding surface Gear oil As required
Thread area of bolts ThreeBond 2302 As required

Cleaning procedure
Cleaning
• Before assembly, clean up all the parts using cleaning oil or oth-
er cleaning solvent.

Installation procedure
Installation: Cover
• When installing the cover to the case, or to the case and rotor,
first put dowels at the two positions A, and then tighten the bolts.

22A-58
 22A
Power Cylinder
Disassembly sequence
1 Boot
2 Shifter clevis
3 Body
4 X-ring
5 O-ring
6 Stopper
7 Piston rod
8 X-ring
9 Piston plate
10 O-ring
11 Stopper
12 Cylinder

: Non-reusable parts

Repair kit: Power cylinder kit

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards
Location Maintenance item Standard value Limit Remedy
570 kPa {5.8
Air tightness of power cylinder (pressure decrease after kgf/cm2}/15
– – Replace
pressure is applied (590 kPa {6 kgf/cm2})) seconds or
less

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (piston rod retaining) 78.5 to 98 {8 to 10} –
Bolt (body mounting) 3.9 to 5.9 {0.4 to 0.6} –
Nut (piston plate mounting) 21.6 to 27.5 {2.2 to 2.8} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Multipurpose grease
– Each sliding surface As required
[NLGI No.2 (Li soap)]

22A-59
DRIVE PINION
Disassembly sequence
1 Snap ring
2 Drive pinion bearing
3 Oil feed adapter
4 Drive pinion

• Do not remove oil feed adapter except

for replacement.

Assembly sequence
Follow the disassembly sequence in re-
verse.

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Snap ring expander MH061268 Removal and installation of snap ring

Bearing puller

A B C
* MH062754 Removal of drive pinion bearing
φ160 φ68 300

Bearing installer

A B C
* MH062755 Installation of drive pinion bearing
φ155 φ68 300

*: Components of puller and installer kit (See puller and installer kit.)

22A-60
 22A
Removal procedure
Removal: Drive pinion bearing

Installation procedure
Installation: Drive pinion bearing
• Install the drive pinion bearing, facing the loose rib in the illus-
trated direction.
CAUTION
• Be careful not to install the drive pinion bearing in the
wrong direction. Otherwise, the bearing cannot be removed
because the inner shaft of the bearing remains in the drive
pinion during removal.

22A-61
MAINSHAFT

Disassembly sequence
1 1st gear thrust washer 16 Needle bearing
2 1st gear 17 Bearing spacer
3 Needle bearing 18 4th gear bearing sleeve
4 1st gear bearing sleeve 19 3rd gear thrust washer
5 Bearing spacer 20 3rd gear
6 1st and reverse constant mesh sleeve 21 Needle bearing
7 1st and reverse constant mesh hub 22 Bearing spacer
8 Reverse gear 23 3rd gear bearing sleeve
9 Bearing spacer 24 2nd and 3rd synchronizer (See later section.)
10 Needle bearing 25 2nd gear
11 Snap ring 26 Needle bearing
12 Pilot bearing 27 Bearing spacer
13 Lock washer 28 Mainshaft
14 4th and 5th synchronizer (See later section.)
15 4th gear
*a: Drive pinion

Assembly sequence
Follow the disassembly sequence in reverse.

22A-62
 22A
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
1st gear 0.11 to 0.65 0.85
2nd gear 0.15 to 0.60 0.80
End play of each gear 3rd gear 0.15 to 0.50 0.70 Replace
4th gear 0.25 to 0.40 0.60
Reverse gear 0.15 to 0.75 0.95
1st gear 0.05 to 0.09 0.12
2nd gear 0.03 to 0.07 0.10
Play of each gears in the
3rd gear 0.05 to 0.09 0.12 Replace
diameter direction
4th gear 0.05 to 0.09 0.12
Reverse gear 0.05 to 0.10 0.10
– 1st gear bearing sleeve 96.954 to 96.967 96.9
Outer diameter of each
4th gear bearing sleeve 73.957 to 73.970 73.9 Replace
gear bearing sleeve
3rd gear bearing sleeve 90.957 to 90.970 90.9
4th gear and 4th and 5th
2.0 0
synchronizers
Drive pinion and 4th and
Clearance between each 2.0 0
5th synchronizers
gear and synchronizer out- Replace
er ring of synchronizer 3rd gear and 2nd and 3rd
1.0 0
synchronizers
2nd gear and 2nd and 3rd
1.0 0
synchronizers
Play of pilot bearing in the diameter direction – 0.10 Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Lock nut 539 to 735 {55 to 75} –

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Snap ring expander MH061268 Removal and installation of snap ring

Removal of 1st gear bearing sleeve,

Gear puller MH062308 3rd gear bearing sleeve and 4th bear-
ing sleeve

Gear puller MH061326 Removal of pilot bearing

22A-63
MAINSHAFT
Mark Tool name and shape Part No. Application

Pilot bearing installer

A B ME650849 Installation of pilot bearing

φ80 φ70

Single spanner

A MH061552 Removal and installation of lock nut

65

Bearing installer

A B C *MH062085 Installation of 1st gear bearing sleeve

φ100 φ76 420

Bearing installer

A B C MH062242 Installation of 4th gear bearing sleeve

φ160 φ62 390

Bearing installer

*MH062244 Installation of 3rd gear bearing sleeve

A B C D E
φ161 φ78.6 φ61 65 395

*: Components of puller and installer kit (See puller and installer kit.)

22A-64
 22A
Work before removal
Inspection: End play of each gear
• Measure the end play using the feeler gauge.
• If the measurement exceeds the limit, replace defective parts.

Inspection: Play of each gears in diameter direction

• If the measurement exceeds the limit, replace defective parts.

Alignment marks: 2nd gear, 2nd and 3rd synchronizer and

3rd gear
• Put alignment marks on the 2nd gear, synchronizer sleeve of the
2nd and 3rd synchronizer and 3rd gear, each at one location be-
fore disassembly.

Removal procedure
Removal: 1st gear bearing sleeve

Removal: Pilot bearing

22A-65
MAINSHAFT
Removal: 4th gear bearing sleeve and 3rd gear bearing
sleeve

Inspection procedure
Inspection: Clearance between synchronizer ring of 4th and
5th synchronizer and 4th gear or drive pinion
• Conduct a measurement on the entire circumference while
pressing each ring against gears evenly.
• If the measurement exceeds the limit, replace the ring together
with the gear or drive pinion.

Inspection: Clearance between synchronizer outer ring of

2nd and 3rd synchronizer and 2nd gear or 3rd gear
• When measuring the clearance, press each ring and the center
cone evenly against the gear and measure all around the cir-
cumference.
• If the measurement exceeds the limit, replace both ring and
gear.

Inspection: Play of pilot bearing in diameter direction

• Carry out the measurement with installing the drive pinion, pilot
bearing and main shaft and holding the main shaft as illustrated.
• Measure the play with moving the gear of drive pinion in diame-
ter direction.
• If the measured value exceeds the limit, replace the pilot bear-
ing.

Installation procedure
Installation: 3rd gear bearing sleeve

22A-66
 22A
Installation: 4th gear bearing sleeve

Installation: Lock washer

• Install so that protrusions of the lock washer fit into the grooves
of the synchronizer hub of the 4th and 5th synchronizer.
• After tightening the lock nut to the specified torque, secure it by
bending the lock washer.

Installation: Pilot bearing

• Check inner race diameter of the pilot bearing, and then install it
using .
Larger inner race diameter A Lock nut side
Smaller inner race diameter B Mainshaft end side

Installation: 1st gear bearing sleeve

22A-67
MAINSHAFT
4th and 5th Synchronizer
Disassembly sequence
1 Synchronizer ring
2 Synchronizer sleeve
3 Shifting key spring
4 Shifting key
5 Synchronizer hub

Assembly sequence
Follow the disassembly sequence in re-
verse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Clearance between synchronizer ring protrusion and
1, 5 4.8 to 5.4 6.5 Replace
synchronizer hub groove
Play of synchronizer sleeve and synchronizer hub in ro-
2, 5 0.06 to 0.14 0.3 Replace
tating direction
Clearance between shifting key and synchronizer hub
4, 5 0.05 to 0.35 0.5 Replace
keyway

Work before removal

Alignment marks: Synchronizer sleeve and synchronizer
hub
• Put alignment marks on the synchronizer sleeve and synchro-
nizer hub, each at one location before disassembly.

Inspection procedure
Inspection: Clearance between synchronizer ring protru-
sion and synchronizer hub groove
• If the measurement exceeds the limit, replace defective parts.

22A-68
 22A
Inspection: Play of synchronizer sleeve and synchronizer
hub in rotation direction
• Hold the synchronizer sleeve and measure the play with rotating
the synchronizer hub.
• If the measured value exceeds the limit, replace the defective
parts.

Inspection: Clearance between shifting key and synchroniz-

er hub keyway
• If the measurement exceeds the limit, replace defective parts.

Installation procedure
Installation: Shifting key spring
• After inserting the shifting key into the synchronizer hub keyway,
install the shifting key spring so that its opening is not located at
the shifting key position.
• Install so that openings of the two shifting key springs are not lo-
cated at the same position.

Installation: Synchronizer sleeve and synchronizer hub

• When replacing the synchronizer sleeve or synchronizer hub
with a new one, align the plunger grooves (three locations) of
the synchronizer hub with stub gear teeth (three locations) of the
synchronizer sleeve to install.

22A-69
MAINSHAFT
2nd and 3rd Synchronizer
Disassembly sequence
1 Synchronizer inner ring
2 Synchronizer center cone
3 Synchronizer outer ring
4 Synchronizer sleeve
5 Shifting pin
6 Synchronizer spring
7 Synchronizer hub

Assembly sequence
Follow the disassembly sequence in re-
verse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Clearance between protrusions of synchronizer outer
3, 7 3.4 to 4.0 5.0 Replace
ring and synchronizer hub groove
Play of synchronizer sleeve and synchronizer hub in ro-
4, 7 0.062 to 0.174 0.3 Replace
tating direction

Work before removal

Alignment marks: Synchronizer inner ring, center cone, out-
er ring and sleeve
• Put alignment marks on the synchronizer inner ring, center
cone, outer ring and hub, each at one location, aligning with the
alignment mark put on the synchronizer sleeve before disas-
sembly.

Inspection procedure
Inspection: Clearance between synchronizer outer ring pro-
trusion and synchronizer hub
• If the measured value exceeds the limit, replace defective parts.

22A-70
 22A
Installation procedure
Inspection: Play of synchronizer sleeve and synchronizer
hub in rotation direction
• Hold the synchronizer sleeve and measure the play with rotating
the synchronizer hub.
• If the measured value exceeds the limit, replace the defective
parts.

Installation: Synchronizer sleeve and synchronizer hub

• When replacing the synchronizer sleeve or synchronizer hub
with a new one, align the plunger grooves (three locations) of
the synchronizer hub with stub gear teeth (three locations) of the
synchronizer sleeve to install.

22A-71
COUNTERSHAFT
Disassembly sequence
1 Countershaft front bearing
2 Countershaft constant mesh gear
3 Countershaft 4th gear
4 Sunk key
5 Countershaft

Assembly sequence
Follow the disassembly sequence in re-
verse.

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Bearing puller

A B Removal of countershaft front

*MH062272
bearing
φ130 170

Bearing installer
Installation of countershaft front
A B C *MH061641
bearing
φ128 φ74 170

Countershaft gear puller

A B ME624243 Removal of countershaft gear

φ30 60

Countershaft gear installer

A B C ME650895 Installation of countershaft gear

φ101.6 φ88.6 255

*: Components of puller and installer kit (See puller and installer.)

22A-72
 22A
Removal procedure
Removal: Countershaft front bearing
• When removing countershaft front bearing, protect the counter-
shaft screw hole using an appropriate plate and use for re-
moval.

Removal: Countershaft constant mesh gear, countershaft

4th gear or countershaft 6th gear

Installation procedure
Installation: Countershaft constant mesh gear, countershaft
4th gear or countershaft 6th gear

Installation: Countershaft front bearing

22A-73
TRANSMISSION CONTROL

Removal sequence
1 No. 1 select rod 10 Upper cross shaft (See later section.)
2 No. 1 shift rod 11 Lower cross shaft (See later section.)
3 Select cable 12 Rear cross shaft (See later section.)
4 No. 2 shift rod 13 Rear vertical shaft (See later section.)
5 No. 3 shift rod
6 No. 4 shift rod
*ba :: Shift lever
7 No. 2 select rod
* Select lever
8 Set board (See later section.)
*c : Power shift
9 Select shaft (See later section.) : Non-reusable parts

Installation sequence
Follow the removal sequence in reverse.

CAUTION
• Locking agent is applied to cable and rod mounting nuts. Be sure to replace the nuts when loosening or
removing them.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (No. 1 select rod and select cable mounting) 19 to 24 {1.9 to 2.4} –
Nut (each shift rod and No. 2 select rod mounting) 39 to 50 {3.9 to 5.0} –
Lock nut on select cable 9.8 to 14.7 {1.0 to 1.5} –
Lock nut on each shift rod and No. 2 select rod 23 to 28 {2.3 to 2.8} –

22A-74
 22A
Inspection procedure
Inspection: Lock nuts of each rod and select cable
• Make sure that unbeveled side of the lock nut faces the ball joint.

Installation: Select cable

• Install the cables so that the holder of ball joint does not come
into one-sided contact with the stud (shown by A).
• Install the casing cap portion as a straight line.
• The radius of the cable bend shall be 200 mm or more.
• Make sure that there is no obstruction in movement of the cable.
• Install the clamp at right angles to the cable.
• Do not twist clamps at either ends of the boot.
• The twist angle of ball joints at both ends of the cables shall be
20 degrees or less.
CAUTION
• Cable endurance is impaired considerably if torsion angle
of the ball joint is more than 20 degrees.

Installation procedure
Installation: Each rod
• Install the rod so that the holder of ball joint does not come into
one-sided contact with the stud (shown by A).
• After installation, make sure the rods can be rotated at the same
angle.

22A-75
TRANSMISSION CONTROL
Work after installation
Adjustment: No. 4 shift rod and No. 2 select rod
[Neutral position of transmission]
• Remove each rod on the shift lever and select lever side, and
place each lever to neutral position.
• Neutral position of select lever corresponds to a slight turn back-
and-forward of vehicle.
• Neutral position of shift lever is in the middle of back-and-forth
stroke.
• Adjust length of each rod using the turnbuckles, and attach them
to respective levers.

[Neutral position of gear shift lever]

• With the shift lever and select lever in their neutral positions, ad-
just the No. 4 shift rod and No. 2 select rod using the turnbuckles
so that neutral position of gear shift lever is as specified below.

Longitudinal direction B (adjust by shift rod)

Distance from floor console 345 ± 20 mm
Tilt forward Shorten the rod
Tilt backward Lengthen the rod

Transverse direction C (adjust by select rod)

Distance from neutral position
358 ± 20 mm
of gear shift lever knob to
<4-5 speed line>
steering wheel center
Tilt rightward Shorten the rod
Tilt leftward Lengthen the rod

• Make sure to operate the gear shift lever that it shifts smoothly
and selects each position.

22A-76
 22A
Set Board
Disassembly sequence
1 Gear shift lever knob
2 Splitter control switch
3 Inner dust cover
4 Dust cover holder
5 Select lever
6 Bushing A
7 Set board
8 Stopper
9 Washer
10 Bushing B
11 Housing
12 Bushing C
13 Gear shift lever

*a : No. 1 shift rod

*b : No. 1 select rod

Assembly sequence
Follow the disassembly sequence in re-
verse.

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Sliding area of bushing A and gear shift lever
Inner periphery of select lever where bushing A is at-
tached
Molybdenum disulfide grease
As required
Inner and outer periphery of bushing B [NLGI No.2 (Li soap)]
Sliding area of bushing C and gear shift lever
Bulbous portion of gear shift lever

Installation procedure
Installation: Gear shift lever
• Apply sufficient amount of grease on contact surface with the
bushing C and on the bulbous portion (shown by A, B), and in-
stall the gear shift lever.

22A-77
TRANSMISSION CONTROL
Select Shaft
Disassembly sequence
1 Bushing
2 Select lever
3 Select shaft bracket

*ba :: No. 1 select rod

* Select cable

Assembly sequence
Follow the disassembly sequence in re-
verse.

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Molybdenum disulfide grease
Inner periphery of bushing As required
[NLGI No.2 (Li soap)]

22A-78
 22A
Upper Cross Shaft

Disassembly sequence
1 Grease nipple 6 Wave washer 10 Cross shaft bracket
2 Cross shaft bracket 7 Upper cross shaft
3 Bushing 8 Ball retainer
*b:
a: No. 1 shift rod
4 Select lever 9 Ball bushing
* No. 2 shift rod
5 Washer

Assembly sequence
Follow the disassembly sequence in reverse.

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Molybdenum disulfide grease
Supply from grease nipple As required
[NLGI No.2 (Li soap)]

Inspection procedure
Inspection: Bushing
• Install the bushing while aligning grease holes in the bushing
and shift lever.

22A-79
TRANSMISSION CONTROL
Lower Cross Shaft
Disassembly sequence
1 Grease nipple
2 Washer
3 Shift lever
4 Bushing
5 Cross shaft bracket

*a : No. 2 shift rod

*b : No. 3 shift rod

Assembly sequence
Follow the disassembly sequence in re-
verse.

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Molybdenum disulfide grease
Supply from grease nipple As required
[NLGI No.2 (Li soap)]

Rear Cross Shaft

Disassembly sequence
1 Cross shaft support
2 Cross shaft bushing
3 Dust cover
4 Cross shaft support
5 Cross shaft bushing
6 Snap ring
7 Dust cover
8 Rear cross shaft

*a : No. 3 shift rod

*b : No. 4 shift rod

Assembly sequence
Follow the disassembly sequence in re-
verse.
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Sliding surface of cross shaft bushing with rear cross Molybdenum disulfide grease
As required
shaft [NLGI No.2 (Li soap)]

22A-80
 22A
Rear Vertical Shaft
Disassembly sequence
1 Grease nipple
2 Select lever
3 Select shaft
4 Bushing
5 Select lever bracket

*a : No. 2 select rod

*b : Select cable

Assembly sequence
Follow the disassembly sequence in re-
verse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (select lever mounting) 33.3 ± 6.7 {3.4 ± 0.68} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Molybdenum disulfide grease
Supply from grease nipple As required
[NLGI No.2 (Li soap)]

22A-81
TRANSMISSION OIL COOLER

Removal sequence
1 Eyebolt 5 Oil pipe 9 Oil pipe
2 Oil hose 6 Oil pipe 10 Connector
3 Oil hose 7 Connector 11 Connector
4 Spacer 8 Oil pipe 12 Oil cooler

Installation sequence
Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Eyebolt (oil hose mounting)
Oil hose 40.2 ± 3.9 {4.1 ± 0.4} –
Connector

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Thread area of connector ThreeBond 1215 As required

22A-82
PULLER AND INSTALLER KIT 22A
Puller and
Puller Puller Puller Puller Installer Installer Installer Installer
installer kit
Kit No.
MH062753 MH061633 MH062243 MH062272 MH062754 MH061641 MH062242 MH062244 MH062755
Component
Claw MH062230 O O O
Claw MH062273 O O
Claw MH062522 O O
Protector MH062231 O O O O
Protector ME650855 O O O
Body ME650856 O O O O
Body MH062232 O O O
Body MH062756 O O O
Bearing installer MH062085 O
Bearing installer MH062240 O O
Cap MH061603 O O O O
Guide piece MH062238 O O
Bolt MH062520 O O O O O
Handle MH061162 O O O O O

22A-83