Category: Manual Transmission

Transmission Assembly Installation NOTE: Check that the two dowel pins are installed in the clutch housing. 1. Place the transmission on the transmission jack, and raise it to the engine level. 2. Set the release fork to the clutch housing, (see page, 13-9) 3. Install the 2 transmission housing mounting bolts and engine stiffener. 4. […]

Shift Fork Assembly Disassembly/Reassembly NOTE: • Be careful not to lose the 5th shift fork steel ball. • Install the spring pins so their grooves are 180° apart. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. Disassembly: Remove the 3 mm spring pin and 5 […]

Mainshaft Assembly Clearance Inspection 1. Measure the clearance between 2nd and 3rd gears. Standard: 0.06 — 0.21 mm (0.002-0.008 in) Service Limit: 0.3 mm (0.012 in) 2ND GEAR 3RD GEAR 2. If the clearance exceeds the service limit, measure the thickness of 3rd gear. Standard: 35.92 — 35.97 mm (1.414-1.416 in) Service Limit: 35.80 mm […]

SEALING BOLT STEEL BALLS (5/16 in) Transmission Housing Removal NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench. 1. Remove the back-up light switch, neutral position switch and vehicle speed sensor (VSS). NEUTRAL POSITION SWITCH VSS (O-RING Replace .) BACK-UP LIGHT SWITCH 36 mm […]

Synchro Sleeve, Synchro Hub Inspection 1. Inspect gear teeth on all synchro hubs and synchro sleeves for rounded off corners, which indicates wear. 2. Install each synchro hub in its mating synchro sleeve, and check for freedom of movement. NOTE: If replacement is required, always replace the synchro sleeve and synchro hub as a set. […]

13-42 13-42 13-39 13-40 13-39 13-42 13-42 13-39, 13-40 Special Tools Mam Menu Table of Contents Special Tools Ref. No. Tool Number Description Qty Page Reference (D O7GAJ—PG201 1o Mainshaft Holder 1 13-42 ® O7GAJ—PGZO13O Mainshaft Base 1 13-42 *® O7736—AO1000A Adjustable Bearing Puller, 25—40 mm 1 13-39 Q) 07746—0010400 Attachment, 52 X 55 mm […]

Countershaft Bearing (Clutch Housing) Replacement 1. Remove the bearing retaining plate. BEARING RETAINING PLATE 6 x 1.0 mm BOLTS Replace. 2. Remove the needle bearing with the special tool, then remove the oil guide plate. 3/8″-16 SLIDE HAMMER (Commercially available) ADJUSTABLE BEARING PULLER, 25-40 mm 07736 – A01000A OIL HOLE NEEDLE BEARING OIL GUIDE PLATE […]

Mainshaft Assembly Index NOTE: The 3rd/4th and 5th synchro hubs are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd/4th and 5th synchro hubs, however, should be installed with a press before lubricating them. 3RD/4TH SYNCHRO HUB SYNCHRO SPRING SYNCHRO […]

Countershaft Assembly Index NOTE: The 3rd, 4th and 5th gears are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd, 4th and 5th gears should be installed without lubrication using a press. SYNCHRO SPRING SYNCHRO RING Inspection, page 13-35 1ST […]

Maintenance Transmission Oil NOTE: Check the oil at normal operating temperature (the cooling fan comes on), engine OFF, and the car on level ground. 1. Remove the oil filler plug, then check the level and condition of the oil. WASHER Replace. Proper Level. OIL FILLER PLUG 45 N-m (4.5 kg-m, 33 Ib-ft) 2. The oil […]