Chapter13 Manual Transmission

8/12/2019 Chapter13 Manual Transmission

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MT 10 MANUAL TRANSMISSION - W46 55 and 56 Transmission

g Remove th e s hi ft f or k and shaft No.2 .

WM0024

h Using a magnetic finger remove interlock pin No.3 .

WM0025

i Remove f or k s ha ft No.3 with reverse shift arm.

8. 2 5-SpeedREMOVE SHIFT FORKS SHIFT FORK SHAFTS AN DREVERSE I LER GE R

a Pry ou t t he l oc k w as he rs of shift fork No.1 and No .2, and remove tw o se t bolts.

b Using two screwdrivers and a hammer tap out th etw o snap rings of th e No. 1 and No. 2 fork shafts.

WM0019


11/71

MANUAL TR NSM SS ON - W46 55 and 56 Transmission MT

c Remove th e reverse idler gear shaft stopper

WM0028

d Remove the reverse idler gear and shaft

e Remove th e shift fork and shaft No 1

WM0030

f Using a magnetic finger remove interlock pins No 1and No 2

WM0031

g Remove th e s h if t f or k and shaft N o 2


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MT 2 MANUAL TRANSMISSION - W46 55 an d 56 Transmission

h Using a magnetic finger remove interlock pin No 3

WM0033

i Using a pin punch and hammer drive ou t th e fo rk shaf tpin N o 3

j Pull out th e s hift f or k s ha ft N o 4

WM0035

k Remove shift fork No 3 fork shaft N o 3 and reverseshift ar m with pin

9. 2WDREMOVE SPEEDOMETER DRIVE GEAR

Pr y o ut b oth ends of t he c li p and remove th e drive gear

WM0040


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MANUAL TRANSMISSION - W46, 55 and 56 Transmission MT-13

10 . 5-SpeedMEASURE COUNTER FIFTH GEAR THRUSTCLEARANCE

Using a feeler gauge, measure the counte r 5th gear thrustclearance.

Standard clearance: 0.10 - 0.41 mm 0.0039 - 0.0161 in.

Maximum clearance: 0.46 m m 0 .0 18 1 in.

WM0041

11 . 5-SpeedREMOVE COUNTER REAR BEARING, SPACER, COUNTERFIFTH GEAR AN D NEEDLE ROLLER BEARING

a Using snap ring pliers, r em ov e t he snap ring.

WM0261

b Using SST, remove th e rear bearing, spacer, 5t h gearand bearing.

SS T 09213-36020

CAUTION: Be careful no t to c at ch t he output shaft rearbearing roller on the counte r 5t h gear.

c Remove th e spacer.

2 5-SpeedREMOVE HU B SLEEVE NO . 3 ASSEMBLY

a Using two screwdrivers and a hammer, ta p ou t th esnap ring.

WM0044

b Using SST, remove clutch hu b No.3.

SST 09950-20015

CAUTION: Latch the claw of th e SST onto the c lu tch hub,not th e s hi ft in g k ey retainer.


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MT-14 MANUAL TRANSMISSION - W46, 55 and 56 Transmission

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13. 5-SpeedREMOVE OUTPUT SHAFT REAR BEARING AND FIFTHGEAR a Using tw o screwdrivers and a hammer, ta p ou t th e

snap ring.

b Using SST, remove th e rear bearing and 5t h gear.

SS T 09312-20011

14 . REMOVE REVERSE GEAR

a Using snap ring pliers, r em ov e t he snap r ing.

b Using SST, remove th e reverse gear.

SS T 09950-20015

15 . REMOVE CENTER BEARING RETAINER

a Using a torx socke t wrench , unscrew th e torx screwsand r em ov e t he retainer.

b Using snap pliers, remove th e snap ring.

16. REMOVE OUTPUT S HA FT A ND COUNTER GEAR AS AUNIT FROM INTERMEDIATE PLATE

a Remove th e output shaf t, inpu t shaf t and counter gearas a unit from the intermediate plate by pull ing on th ecounter gear and tapping on th e intermediate platewith a plas ti c hammer.

b Remove th e input shaft from output shaft.

17 . MEASURE EACH GEAR THRUST CLEARANCE

Using a feeler gauge, measure th e thrust clearance of eachgear.


Maximum clearance: 0.30 mm 0.0118 in.


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MANUAL TRANSMISSION - W46 55 and 56 Transmission MT 15

18 REMOVE OUTPUT SH FT CENTER BE RING ND FIRSTGE R SSEMBLY

a Shift hu b s leeve No 1 o nt o t he 2 nd g ea r

b Using a press remove th e center bearing 1 st gear,needle roller bearing, inner race and synchronizer ring.

WM0051

19 REMOVE LOCKING B LL

WM0052

2 REMOVE HUB SLEEVE NO 1 SSEMBLY SECOND GE R ND NEEDLE RO R BE RING

Using a press remove th e p ar ts f ro m t he shaft as an assembly

WM0053

21 REMOVE HUB SLEEVE N O 2 SSEMBLY ND THIRDGE R

a Using s na p r in g p lie rs remove t he s na p ring

WM0054

b Using a press r em ov e h ub sleeve N o 2 th e syn-chronizer r ing a nd 3rd gear.

WM0055


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INSPECTION OF TRANSMISSIONCOMPONENTS

1. INSPECT OUTPUT SHAFT AN D INNER RACE

a Using calipers, measure the output shaft flangethickness.

Minimum thickness: 5.60 mm 0.2205 in.

WM0204

b Using calipers, measure th e inner race flangethickness.

Minimum thickness: 4.70 mm 0. 1850 in.

WM0057

WM0059

c Using a micrometer, measure t he o ut er diameter ofth e o u tp u t s h af t journal.

Minimum diameter:

2n d gear 42.85 mm 1.6870 in.

3r d gear 37.80 mm 1.4882 in.

d Using a micrometer, measure th e o ute r diameter ofth e inner race.

Minimum diameter: 42.85 mm 1.6870 in.

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i i

I

WM0060

e Using a dial i nd ic at or , c he ck t he shaf t runout.

Maximum runout: 0.06 mm 0.0024 in.


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n

WM0061

WM0062

2. CHECK OIL CLEARANCE FIRST GEAR

Using a d ia l indicator, measure th e oil clearance betweenth e gear and inner race with th e n ee dl e r ol le r b ea ri ng i nstalled.


Maximum clearance: 0.15 mm 0 .0059 in.

3. CHECK OIL CLEARANCE SECOND AN D COUNTERFIFTH GEAR

Using a dial indicator measure th e oil clearance betweenth e gear and output shaft with th e needle roller bear ing installed.

Standard clearance:2n d gear 0.009 - 0.060 mm

0 .0004 - 0.0024 in.5t h gear 0.009 - 0.062 mm 0 .0004 - 0.0024 in.


WM0063

CHECK OIL CLEARANCE THIRD GEAR

Using a di al indicator, measure th e oil clearance betweenth e gear and output shaft.



WM0064

5. INSPECT SYNCHRONIZER RINGS

a Turn the ring and push it in to check th e braking action.

WM0065

b Measure th e clearance between the synchronizer ringback and th e gear spl ine end.


Minimum clearance: 0 .5 mm 0.020 in.


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6. MEASURE CLEARANCE O SHIFT FORKS AND HUBSLEEVES

Using a feeler gauge, measure th e clearance between 1hu b sleeve and shift fork.


WMOO66

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WMOO67

I NECESSARY, REPLACE INPUT SHAFT BEARING

a) U si ng s na p ring pliers, r em ov e t he snap ring.

b) Using a press, r em ov e t he bearing.

WM0068

c) Using a press and SST, install a ne w bearing.

SS T 09506-35010

WM0069

WM0070

d) Select a snap ring t ha t w il l a l low minimum axial playand install it on th e shaft.

Mark Thickness mm in.

2 .05 2.10 0.0807 0.08272 2.10 2.15 0.0827 0.08463 2.15 2.20 0.0846 0.08664 2.20 2.25 0 .0866 0.08865 2.25 2.30 0.0886 0.0906

2.30 2.35 0.0906 0.092512 2.35 2.40 0.0925 0.0945


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8. INSPECT FRONT BEARING RETAINERCheck th e retainer a nd oil seal fo r wear or damage. I f t heoil seal is worn or damaged, replace it as follows.

a Using a screwdriver, pr y out the oi l seal .

WM0071

b U si ng S ST, pr es s in th e oi l seal.

SST 09608-20011

Oil seal depth: 11.4 - 1 2. 0 mm from retainer end O.449 - 0.472 in.

WM0072

9. NECESSARY, REPLACE COUNTER GEAR FRONTBEARING AN D SIDE RACE

a Using s na p r ing p lie rs , r em ov e t he snap r ing.

b Using a press and SST, press out the bearing.

SST 09950-00020

c Check th e s id e r ac e fo r wear or damage.

WMQQ73

d If necessary, r em ov e t he side race.

1 Using a SST and socket wrench, remove th e siderace.

SST 09950-20015

2 If th e s id e r ac e cannot b e r em ov ed with SST,grind part of th e side race and cu t it o ff with achisel.


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MT 2 MANUAL TR NSMISSION - W46, 55 an d 56 Transmission

e Using a socket wrench, press in th e bearing, side racea nd i nn er race.

WM0176

f Select a snap r ing that w i ll a ll ow minimum axial playand ins ta ll it on the shaft.

WMoon


1 2.05 - 2.10 0.0807 - 0.08272 2.10 - 2.15 0.0827 - 0.08463 2.15 - 2.20 0.0846 - 0.0866

2.20 - 2.25 0.0866 - 0.0886

5 2.25 - 2.30 0.0886 - 0.09066 2.30 - 2.35 0.0906 - 0.09257 2.35 - 2.40 0.0925 - 0.0945

1 NECESS RY REPL CE COUNTER GE R CENTERBE RING

a Remove th e bearing from t he c ou nt er gear.

b Install th e ne w bearing on t he c ou nt er gear.

NOTE: Engage th e roller cages.

WM0079

c Using SST, tap out th e bearing outer race.

SS T 09608-35013

NOTE: The outer race will be installed later, as th e transmission is assembled.

WM0078

11 NECESS RY REPL CE REVERSE RESTRICT P N

a Using SST, remove t he s cr ew plug.

SS T 09313-30021

WM0083


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b Using a pin punch and hammer, d rive out th e slottedspring pin.

c Pull off th e lever housing a nd sli de out t he s ha ft .

d Install th e lever housing.

e Using a pin punch an d hammer, drive in th e slotteds pr in g p in .

WM0084

f Install an d torque t he s cr ew plug.

Torque: 250 kg-em 18 ft-Ib, 25 Nm

2 S-SpeedIF NECESSARY, REPLACE BEARING AN D OUTER RACE

a Remove th e outer race from th e extension housing.

1 Using two screwdrivers, remove th e snap ring.

WM0085

2 Using SST, ta p out th e outer race.

SST 09608-35013

WM0086

b Install th e bearing outer race.

1 Using SST, install a new outer race.

SST 09608-35013

WM0087


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2 Install th e s na p r in g.

WM0088

WM0108

20mm

c J E ~

WM0109

WM0110

WM0111

13 . 2WDNECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR

OIL SEAL a Using SST, remove th e oil seal .

SS T 09921-00010

b Using SST, install a ne w oil seal .

SST 09201-60011

Oil seal depth: 20 mm 0.79 in.

14.-1 2WDNECESSARY, REPLACE OIL SEAL AND BUSHING

a Using SST, remove th e oil seal.

SS T 09308-00010 or09308-10010 w / o u tp u t s ha ft installed

b Heat th e extension housing end to 80 100C 1 76 212F in an oil bath.

c Using SST, remove th e bushing and install a ne wbushing.

SS T 09307-30010


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MANUAL TRANSMISSION - W46, 55 and 56 Transmission

d Using SST drive in a ne w oil seal.SS T 09325 20010

SST

WMOl 2

MT-23

14.-2 4WDIF NECESSARY, REPLACE OIL SEAL

a Using a screwdriver, pr y ou t the oil seal.

b Using SST drive in th e oil seal.

SS T 09325 12010

GM0058


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MT-24 MANUAL TRANSMISSION - W 46, 55 and 56 Transmission

Front

ASSEMBLY OF TRANSMISSION See pages MT -5 , 6

1. INSERT CLUTCH HUB NO.1 AND NO. 2 INTO HUB SL V

a Install th e clutch hu b and shifting keys to th e hu bsleeve.

b Install t he s hi ft in g k ey springs under the shift ing keys.

CAUTION: Install the key springs positioned so that theiren d ga ps are n o t i n l in e.

WMOl13

2. INSTALL THIRD GEAR AN D CLUTCH HUB NO.2 ONOUTPUT SHAFT

a Apply gear oil to th e shaft.

b Place the synchron ize r ring on th e gear and a lign th ering slots with t he s hi ft in g keys.

WM0114

c Using a press, install th e 3r d g ea r and clutch hu bNo.2 .

WM0115

WM0116 WM0054

3. INSTALL SNAP RINGSelect a snap r ing that w il l a ll ow m in im um axial play, andinstall it on th e shaft.


1.80 - 1.85 0.0709 - 0.07281.86 - 1.91 0.0732 - 0.0752

12 1.92 - 1.97 0.0756 - 0.077613 1.98 - 2.03 0.0780 - 0.079914 2.04 - 2.09 0.0803 - 0.082315 2.10 - 2.15 0.0827 - 0.0846

4. MEASURE THIRD GEAR THRUST CLEARANCEUsing a feeler gauge, measure th e 3rd gear thrustclearance.

Standard clearance: 1 0 2 5 mm 0 0039 0 0098 in.

Maximum clearance: 0 30 mm 0 0118 in.


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MANUAL TRANSMISSION - W46 55 and 56 Transmission MT 25

5. INSTALL SECOND GEAR AND CLUTCH HUB NO.1

a Apply gear o il to th e shaft and needle roller bearing.

b Place the synchronizer ring on th e gear and align th ering slots with t he s hi ft in g keys.

c Install th e needle ro lle r bea ring in th e 2nd gear.

d Using a p res s, install th e 2n d gea r and clutch hubNo.1 .

WM0119

6. INSTALL LOCKING BALL AND FIRST GEAR ASSEMBLY

a Install t he l oc ki ng ball in the shaft.

b Apply gear oil to th e bearing.

c Assemble th e 1st gear, synchronizer ring, needle rollerbearing and bearing inner race.

WM0120

d Install th e assembly on th e outpu t shaf t with th e synchronizer ring slots aligned with th e shifting keys andturn th e inner race to align it w ith t he l oc ki ng ball.

WM0121

7 . INSTALL OUTPUT SHAFT CENTER BEARINGU si ng S ST and a press install th e bearing on t he o ut pu tshaft with th e outer race snap r ing groove toward th e rear.

NOTE: Hold th e 1 st g ear i nn er r ac e to prevent i t fromfalling.

SST 09506 35010

WM0122


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8. MEASURE FIRST AN D SECOND GEAR THRUSTCLEARANCE

Using a feeler gauge, measure the 1st and 2 nd g ea r th rclearance.



9. INSTALL OUTPUT SHAFT TO INTERMEDIATEPLATE

a Before installing t he o u tp u t shaft, use SST to removeth e counter gear center bearing outer race.

SST 09608-35013

NOTE: Install t he o ut er race after installing th e countergear.

b Install th e outpu t shaf t into th e intermediate p la te b ypulling on th e output shaft and tapping on th e intermediate plate.

10 . INSTALL INPUT S HA FT A N D COUNTER GEAR

a Install t he i np ut shaft and counter gear together.

b Using SST, install the counter gear center bearing outer race.

SS T 09316-60010

NOTE: Be careful no t to damage th e bearing rollers.

WM0125


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11 . INSTALL BEARING RETAINER

a Using snap ring pl iers, install th e bearing snap ring.

NOTE: Be sure th e snap ring is flush with the intermediate plate surface.

b Using a torx socket wrench, tighten th e screws.

Torque: 13 0 kg-em 9 f t-Ib, 13 Nom

12 . INSTALL REVERSE GEAR

Using SST, install the reverse gear.

SST 09312-20011

WM0126

WM0127

13 . INSTALL SNAP RINGSelect a snap ring that w il l a ll ow m in im um axial play andinstall it on t he s ha ft .

Mark Thickness mm in. Mark Thickness mm in.

5 2 2 5 2 3 0 0 . 0886-0 .0906 17 2 . 6 1 - 2 . 6 6 0 . 1028-0 .10472 3 0 2 3 5 0 . 0906-0 .0925 18 2 . 6 7 - 2 . 7 2 0 . 1051-0 .1071

12 2 3 5 2 4 0 0 . 0925-0 .0945 19 2 . 7 3 - 2 . 7 8 0 . 1075-0 .109413 2 4 0 2 4 5 0 . 0945-0 .0965 20 2 . 7 9 - 2 . 8 4 0 . 1098-0 .111814 2 4 5 2 5 0 0 . 0965-0 .0984 2 . 8 5 - 2 . 9 0 0 . 1122-0 .114215 2 . 5 0 - 2 . 5 5 0 . 0984-0 .1004 22 2 . 9 1 - 2 . 9 6 0 . 1146-0 .116516 2 5 5 2 6 0 0 . 1004-0 .1024 23 2 . 9 7 - 3 . 0 2 0 . 1169-0 .1189

14 . 5-SpeedINSTALL FIFTH GEAR AN D OUTPUT SHAFT REARBEARING

Using SST, install the 5th gear and rear bearing.

SST 09312-20011

15 . 5-SpeedINSTALL SNAP RING

Select a snap ring that w il l a ll ow m in im um axial play andinstall it on t he s ha ft .

Mark Thickness mm in. Mark Thickness mm in.8 2 . 3 1 - 2 . 3 6 0 . 0909-0 .0929 12 2 . 5 5 - 2 . 6 0 0 . 1004-0 .10249 2.37 2 4 2 0 . 0933-0 .0953 13 2 . 6 1 - 2 . 6 6 0 . 1028-0 .1047

10 2 . 4 3 - 2 . 4 8 0 . 0957-0 .0976 14 2 . 6 8 - 2 . 7 3 0 . 1055-0 .10752 4 9 2 5 4 0 . 0980-0 .1000 15 2 . 7 4 - 2 . 7 9 0 . 1079-0 .1098


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Front 16 . 5-SpeedINSERT C LU TC H H UB N O . 3 I NT O H UB SLEEVE

a Install clutch hu b No. 3 and th e shifting ke y to .hub sleeve.

b Install the shif t ing key springs under th e shifting keys.

CAUTION: Install th e ke y springs positioned so that theire nd g ap s are not in line.

WM0131

c Using SST, install th e shifting key retainer.

SS T 09238-47012

WM0132

17. 5-SpeedINSTALL CLUTCH HUB N O . 3

Using SST, drive in c lu tc h h ub N o . 3 .

SS T 09316-60010

NOTE: When installing th e clutch hub, support the countershaft in f ro nt w it h a 3- 5 Ib hammer or equivalen t.

WM0133

18 . 5-SpeedINSTALL SNAP RING

Select a snap ring that will a llow minimum axial play andinstall it on th e shaft.


2 2.06 - 2.11 0.0811 - 0.08313 2.12 - 2.17 0.0835 - 0.08544 2.18 - 2.23 0.0858 - 0.0878

2.24 - 2.29 0.0882 - 0.0902

19 . 5-SpeedINSTALL SPACER, SYNCHRONIZER RING, NEEDLEROLLER BEARING AN D COUNTER FIFTH GEAR

a Install th e bearing spacer.

b Apply gear oil to th e needle roller bearings.

c Assemble the counter 5t h gear, synchronizer ring needle rol ler bearings.

WM0136


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MANUAL TR NSMISSION - W46, 55 and 56 Transmission MT 9

d Install th e 5th gear assembly with th e synchronizerring slots aligned with th e shifting keys.

WM0137

20 . 5-SpeedINST LL SP CER ND BE RING

a Install th e spacer.

b Install th e bearing with th e ball shield toward th e rear.

c Using a hammer an d s oc ke t w re nc h, drive in th ebearing.

NOTE: When driving in th e bearing, support the counter

shaft in f ro n t w it h a 3-5 Ib hammer or equivalent .

21 . 5-SpeedINST LL SN P RING

Select a snap ring that w il l a ll ow m in im um axial play andinstall it on th e shaft.

Mark Thickness mm in. Mark Thickness mm in.

1 . 9 0 - 1 . 9 5 0 . 0748-0 .0768 5 2 . 1 4 - 2 . 1 9 0 . 0843-0 .08621 . 9 6 - 2 . 0 1 0 . 0772-0 .0791 6 2 . 2 0 - 2 . 2 5 0 . 0866-0 .0886

3 2 0 2 2.07 0 . 0795-0 .0815 7 2 2 6 2.31 0 . 0890-0 .09094 2 . 0 8 - 2 . 1 3 0 . 0819-0 .0839

22 . INST LL SPEEDOMETER DRIVE GE R

a Put a c lip on th e output shaft and install the drive gearclip into t he s lo t.

b Slide th e drive gear with clip and f it th e clip i nt o t heholes.

WM0140

23.-1 4-SpeedINST LL SHIFT FORKS SHIFT FORK SH FTS NDREVERSE IDLER GE R

a Install th e reverse shift a rm a nd shift fork shaft No.3 .

1 Pu t th e reverse shift arm into th e p iv ot o f th ebearing retainer and install shift f or k s ha ft No .3 to th e intermediate plate.


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MT 3 M NU L TR NSM SS ON - W46 55 and 56 Transmission

2 Apply MP grease t o i nt er lo ck pi n N o 3 and in -stall the pin i nt o t he i nt er me di at e p la te hole

WM0142

b Insta ll th e r ever se idler gea r and shaftAlign th e reverse idler gear groove to th e reverse shiftarm shoe and insta ll the reverse idler gear shaft to th eintermediate plate

WM0143

c Install shift fork N o 2 and shaft N o 2

1 Apply MP grease to inte rlock p in N o 2 and in -stall th e pin i nt o t he shaft hole

2 Place shift fork No. 2 in to th e groove of rsleeve N o 2

WM0144

3 Install f or k s ha ft N o 2 to th e shift fo rk throughthe intermediate plate.

d Insta ll the snap ring of fork shaft No 2


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e Apply MP grease to interlock pin No.1 and install th epin in to the intermediate plate.

WM0146

f Install s hi ft f or k No. 1 and fork shaft No.1 .

1 Install s hi ft f or k No. 1 into th e groove of hu bsleeve No.1 .

2 Insert fork shaft No.1 to th e shift fork throughth e intermediate plate.

WM0022

g Install the snap r ing of fork shaft No.1 .

WM0147

h Install th e s hi ft f or k se t bolts with lock washers .

Torque: 100 - 150 kg-em 8 - 10 ft-Ib, 10 - 14 Nm

WM0018

i Using pliers, stake th e bolts with lock washers.


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23.-2 5-SpeedINSTALL S HI FT F ORK S, SHIFT FORK SHAFTS ANDREVERSE IDLER GEAR

a Install th e r ev er se i dl er g ea r and shaft.

b Install s hi ft f o rk No.3 , f or k s ha ft N o . 3 and rever seshift arm.

1 Coat the pin with MP grease and insert it into th ereverse shift head hole.

WM0149

2 Insert shift fo rk shaf t No.3 through shift fork No.3 and th e reverse shif t arm.

3 Align shift fork N o . 3 with th e hu b sleeve No.3 groove, put th e reverse shift arm into th e pivotof bearing retainer and align the reverse shift armshoe with th e reverse idl er gea r groove. Installs hi ft f or k s ha ft No.3 to the intermediate plate.

WM0150

WM0151

WM0035

WM0152

c Install s hi ft f or k shaft No.4 .

1 Push th e pin, w h ic h w a s inserted into th e reverseshift a rm hole, into the groove of shif t f or k s h af tNo.3 .

2 Install shift f or k s ha ft N o . 4 to the intermediateplate over th e reverse shif t arm.

d Using a pin punch, drive in th e slotted spring pin untilit is flush with th e fork.


33/71

MANUAL TR NSM SS ON - W46 55 and 56 Transmission MT

e Apply MP grease to interlock pin No 3 and install th epin i nto t he intermediate plate hole.

WM0153

f Install shift fork N o 2 and shaft No 2

1 Apply MP grease to inter lock pin NO 2 and install th e pin into th e shaft hole.

2 Place shift fork No. 2 into th e groove of hu bsleeve No 2

3 Install fork shaft No 2 to t he s h if t fork throughth e intermediate plate.

g Instal l th e snap r ing of fork s haft No 2

WM0155

h Apply MP grease to interlock pin No 1 and install th epin i nt o th e intermediate plate

WM0156


34/71

MT 34 MANUAL TRANSMISSION - W46 55 an d 56 Transmission

i Install shift fork No. 1 and fork shaft No.1 .

1 Install shift fork No. 1 i nto th e groove of t ~sleeve No.1.

2 Insert f or k s ha ft No. 1 to the shift fork throughth e intermediate plate.

WM0030

j Install the snap r ing of f or k s ha ft No.1 .

WM0157

k Install th e shift fork se t bolts with lock washers .

Torque: 125 kg em 9 ft Ib 12 Nom

WM0027

I Using pliers, stake t he b ol ts with lock washers.

24 . INSTALL LOCKING BALL AN D SPRING

a Instal l th e bal ls and springs into each hole.

b Apply liquid sealer to th e plugs.

WM0163


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c Using SST, tighten th e four plugs.

SST 09313-30021

Torque: 25 0 k g- em 1 8 f t- Ib , 25 Nm

WM0016

25 . INSTALL REVERSE IDLER GEAR SHAFT STOPPER

Install th e reverse idler gear shaft stopper and tighten th ebolt.

Torque: 250 kg-em 1 8 ft-Ib, 25 Nm

WM0028

26 . DISMOUNT INTERMEDIATE PLATE FROM VISE

a Dismount the intermediate plate from th e vise.

b Remove t he b ol ts , n ut s, plate washers and gasket.

WM0164

27 . INSTALL TRANSMISSION CASE TO INTERMEDIATEPLATE

a Align each bearing outer race and each shift fork shaftend with th e case holes.

b Using a plast ic hammer, ta p on th e case to install it .

WM0165

28 . INSTALL TW O BEARING SNAP RINGS

Using snap r ing pliers, ins ta ll th e tw o snap rings.

WM0166


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MT-36 MANUAL TRANSMISSION - W46, 55 n 56 Transmission

29 . INSTALL FRONT BEARING RETAINER

a) Install th e bearing retainer with a ne w gasket.

b) Apply liquid sealer to th e bolts.

c) Install and t or qu e t he bolts.

Torque: 250 kg-em 1 8 ft-Ib 25 Nom

WM0167

~/ I / tf j

1/ / / : :

/___ I I

~ \ . . . . . :

t ~WM0254

30. INSTALL EXTENSION HOUSING 2WD OR TRANSFERADAPTER 4WD

a) Place the gaske t in position on th e intermediate plate.

b) Insert shift and se lec t l ever i nt o t he ex tension hous-in g 2WD or t he t ra ns fe r adapter.

c) C on ne ct t he shift and s el ec t l ev er to th e s hi ft f or kshaft.

WM0253

d) Install shift lever housing to shift and select lever shaft,push in t he e xt en si on h ou si ng 2 WD o r t he t ra ns fe ra da pt er 4 WD .

e) Install and t or qu e t he bolt.

Torque: 400 kg-em 2 9 ft-Ib 39 Nom


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31 . INSTALL AN D TORQUE EXTENSION HOUSING BOLTS 2WD OR TRANSFER ADAPTER BOLTS 4WD


WMOl72

32 . AFTER INSTALLING EXTENSION H OU SI NG 2 WD ORTRANSFER ADAPTER 4WD , CHECK FOLLOWING ITEMS:

a Check to see that inpu t shaf t and output shaf t rotatesmoothly.

b Check to see that shifting can be made smoothly toall positions.

33 . INSTALL RESTRICT PINS

a Install th e restrict pins together with a gasket.

NOTE: 4-SpeedInstall t he s cr ew plug on th e reverse gear side.

5-SpeedInstall t he b la ck pin on th e reverse gear/5th gearside.

b Torque t he r es tr ic t pins.Torque: 410 kg-em 3 0 ft-Ib, 40 Nm

34 . INSTALL CLUTCH HOUSING

a Install th e clutch housing.

b Install and t or qu e t he bolts.

Torque: 375 kg-em 2 7 ft-Ib, 37 Nom

WM0174

35 . INSTALL RELEASE FORK AN D BEARING

Apply molybdenum disulphide lithium base grease to th efollowing parts:

Release bearing hu b inside groove

Input shaft spline

Release fork contact surface


38/71

MT-38 MANUAL TRANSMISSION - W 46, 55 and 56 Transmission

6 INSTALL SHIFT LEVER RETAINER

a Install the shift lever retainer with a ne w gasket

b Install and t or que t he f ou r bolts.Torque: 18 5 kg-em 1 3 ft-Ib, 18 Nm

WM0259

37 . 2WDINSTALL SPEEDOMETER DRIVEN GEAR

a Install the speedometer driven gear. b Install t he b olt with lock plate.

c Torque the bolt.

Torque: 13 0 kg-em 9 ft-Ib, 13 N m

38. INSTALL BACK-UP LIGHT SWITCH

a Install and torque th e back-up l ight sw it ch .

Torque: 410 kg-em 3 0 ft-Ib, 40 N m

b Install t he w ire cl amp.


39/71

M NU L TR NSMISSION G 52 Transmission MT-39

G TR NSMISSION

OMPONENTS

GM0156

380 27, 37

Shift Fork Shaf t No.2

28 0 20, 27

Clutch Housing~ _ : _ _ t Front Bearing Retainer

Shift Lever Shaft Counter Gear1 8 - - - - - - - . Straight Screw Plug~ R e v e r s eRestrict Pin

~Shift Fork NO.3 -

39 0 28, 38 tt

Transfer Shift ~ ~Lever Retainer

Output Shaft

Locking a l l ~Spring oo l

* Straight Screw P I U g ~

Reverse Shift A r m ta nd F or k

Shift Fork Shaft No.5

ReverseShif t Head

/

Reverse Shift Arm BracketIkg-cm ft-Ib, Nm I : Tightening torque Shift Fork Shaft No.4 Non-reusable part

: Precoated part


40/71

TR NSMISSION

MANUAL Cont d) OMPONENTS

Retainerear Bearing

Snap Ring

e No.5p line leeear

th ea rounter

Sleeve

h nizer Ringyn c ro

Input Shaf t

ounter Gear


41/71

MANUAL TRANSMISSION - G 52 Transmission

DISASSEMBLY OF TRANSMISSION

See pages MT-39, 40

MT-41

1. REMOVE BACK-UP LIGHT SWITCH, SPEEDOMETERDRIVEN GEAR 2WD , SHIFT LEVER RETAINER AN DRESTRICT PINS

2. REMOVE CLUTCH HOUSING FROM TRANSMISSIONCASE

GM0001

3. REMOVE STRAIGHT SCREW PLUG, SPRING AN D BALL

a Using a torx socket wrench, remove th e screw plugf ro m t he t ra ns fe r adapter.

b Using a magnetic finger, remove the spring and ball.

GMOOOS

4. REMOVE TRANSFER ADAPTER

a Using SST, remove the plug f rom the transfer adapter.

SST 9923 1

GM0008


42/71

MT 4 M NU L TR NSMISSION - G 52 Transmission

b Remove th e shift l ev er h ou si ng set bolt and lockwasher

GM0009

c Remove th e shift lever shaft and housing

d Remove th e eight bolts

e Using a plastic hammer remove the transfer adapter

NOTE: Leave t he g as ke t a tt ac he d to the inte rmediateplate

GM0011

REMOVE FRONT E RING RET INER ND TW O E R-ING SN P RINGS

GM0012

6 SEP R TE INTERMEDI TE PL TE FROMTR NSMISSION C SE

a Using a plastic hammer careful ly tap off t he t ra ns -mission case

b Remove th e transmission case from th e intermediateplate

GM0013


43/71

MANUAL TRANSMISSION - G 52 Transmission MT 43

MOUNT INTERMEDIATE PLATE IN VISE

a Use two clutch housing bolts plate washers and suit-able nuts as shown.

CAUTION: Install th e plate washers in reverse of normal.Increase or decrease plate washers so t ha t t he b ol t t i p andfront ti p surface of th e nut are aligned.

b Mount the in te rmedia te plate in a vise.

8. REMOVE STRAIGHT SCREW PLUGS, LOCKING BALLSAN D SPRINGS

a Using a torx socket wrench remove th e four plugs.

GM0015

b Using a magnetic finger, remove the springs and balls.

GM0016

9. REMOVE SLOTTED SPRING PINS

Using a pin punch and hammer drive o ut th e five pins.

GMOQ17

10 . REMOVE TW O E-RING

GM0018


44/71

MT 44 MANUAL TRANSMISSION - G 52 Transmission

\

\

\

REMOVE SHIFT FORK SHAFT NO.4 AN D SHIFT FORKNO.3

a Pull ou t shift fork shaft N o .4 f ro m t he i nt er me diplate.

C AU TIO N: The l ocking balls and interlock pin will fall fromth e holes so be sure to catch them by hand. If they do notc om e o ut remove them with a magne tic f inger.

GM001g

b Remove shift fork s ha ft N o. 4 and s hi ft f or k No.3.

GM0020

12. REMOVE REVERSE SHIFT HEAD AN D SHIFT FORK SHAFTNO.5

Pull o ut s hi ft fork shaft N o .5 f ro m t he i nt er me di at e plateand remove it with th e reverse shift head.

GM0021

13. REMOVE SHIFT FORK SHAFT NO.3

Pul lout shif t f or k s ha ft N o .3 f ro m t he i nt er me di at e plate.

CAUTION: Th e interlock pins will fall from th e hole so besure to catch them by hand. I f they do no t come out rem ov e th em with a magnetic finger.

GM0023

14 . REMOVE SHIFT FORK SHAFT NO.1

Pullout shift fork shaft NO.1 f ro m t he i nt er me di at e plate.

CAUTION: The interlock pin will fall from th e hole so besure to catch i t by hand. If i t does not come out removeit with a magnetic finger.

GM0024


45/71

MANUAL TRANSMISSION - G 52 Transmission MT-45

15 . REMOVE SHIFT FORK SHAFT NO.2 SHIFT FORK NO.2AN D SHIFT FORK NO.1

Pull ou t s hi ft fo rk s ha ft N o 2 and remove s hi ft f or k No 2and NO.1.

GM0025

16 . REMOVE REVERSE IDLER GEAR AN D SHAFT

a Remove th e r ev er se i dl er g ea r shaft stopper

b Remove th e reve rse id le r ge ar and shaft

GM0026

17 . REMOVE REVERSE SHIFT AR M FROM REVERSE SHIFTAR M BRACKET

GM0027

18 . MEASURE COUNTER FIFTH GEAR THRUSTCLEARANCE

Using a feeler gauge measure the counte r 5t h gear thrustclearance

GMOO28

Standard clearance:

Maximum clearance:

0.10 - 0.30 mm 0 .0039 - 0.0118 in.0.30 mm 0 .0118 in.

GM0029

19 . REMOVE GEAR SPLINE PIECE NO.5 SYNCHRONIZERRING NEEDLE ROLLER BEARINGS AN D COUNTER FIFTHGEAR WITH HUB SLEEVE NO.3

a Engage th e gear double mesh ing

b Using a hammer and chisel loosen t he s ta ke d p ar t ofth e nut


46/71

MT 6 MANUAL TR NSMISSION - G52 Transmission

c Remove th e l oc k n ut

d Disengage th e gear double mesh ing

GM0030

e Using SST remove gear spline piece No 5 synchroniz-er ring needle roller bearing an d c ou nt er 5 th gear

SS T 09213 27010

GM0031

20 REMOVE SP CER ND LL

a Remove th e spacer

b Using a magnetic f inger, remove the ball.

GM0033

21 REMOVE REVERSE SHIFT RM R CKET

Remove th e tw o bolts and th e reverse shift a rm bracke t

GM0034

22 REMOVE RE R E RING RET INER

Using a forx s oc ke t w re nc h remove th e four bolts

\GM0035


47/71

MANUAL TRANSMISSION - G52 Transmission MT 47

23 . REMOVE BEARING SNAP RING

Using snap ring pliers, remove th e snap ring.

GM0036

24 . REMOVE OUTPUT SHAFT COUNTER GEAR AN D INPUTSHAFT AS A UNIT FROM INTERMEDIATE PLATE

a Remove the output shaft counter gear and input shaftas a u ni t f ro m t he intermediate plate by pul ling on th ecounter gear and tapping on the in te rmedia te platewith a plastic hammer.

b Remove t he i np ut s ha ft with the 14 needle roller bear-

ings fro m th e output shaft.

GM0037

25 . REMOVE COUNTER R R BEARING FROMINTERMEDIATE PLATE

GM0039

26 . REMOVE SLEEVE FROM OUTPUT SHAFT

Using SST remove th e sleeve from th e o u tp u t s ha ft .

SS T 09950 20015

3r d

GM0040

27 . MEASURE EACH GEAR THRUST CLEARANCE

Measure the thrust clearance of each gear.

Standard clearance: 0.10 - 0.25 0.0039 - 0.0098 in.



48/71

MT 48 MANUAL TRANSMISSION G 52 Transmission

28 REMOVE FIFTH GEAR R R BEARING ANDFIRST GEAR ASSEMBLY

a Using tw o screwdrivers and a hammer tap out snap ring

GM0041

b Using a press r em ov e t he 5 th gear rear bearing 1 stgear and inner race.

c Remove th e needle rol le r bea ring

d Remove th e synchronizer ring

GM0042

29 REMOVE LOCKING BALL

Using a magnetic finger remove th e locking ball.

GMOO45

30 REMOVE HUB SLEEVE NO.1 ASSEMBLY ANDSECOND GEAR ASSEMBLY

a Using a press rem ove hu b sleeve No 1 th e syn-chronizer rin g and 2n d gear.

b Remove th e needle rol le r bea ring

GMOO46

31 REMOVE HUB SLEEVE NO 2 ASSEMBLY ANDTHIRD GEAR ASSEMBLY

a Using snap ring pliers remove th e snap ring

GM0047


49/71

MANUAL TR NSMISSION G 5 Transmission MT 49

b Using a press remove hub sleeve No 2 th e syn-chronizer r ing and 3r d gear

c Remove th e needle rol le r bear ing

WM0055


50/71

MT-50 MANUAL TRANSMISSION - G 52 Transmission

INSPECTION TRANSMISSION COMPONENTS

1. INSPECT OUTPUT S HA FT A ND INNER RACE

a Using cal iper s, measure th e output shaft flangethickness.


GM0048

b Using calipers, measure th e inner race flangethickness.


WM0057

c Using a micrometer, measure t he o ut er d ia me te r ofth e output shaft journal.

Minimum diameter:2n d gear 37.984 mm 1 .4954 in.3r d gear 34.984 mm 1.3773 in.

GM0049

d Using a micrometer, measure t he o ut er d ia me te r ofth e inner race.

Minimum diameter: 38.985 mm 1.5348 in.

WM0059

e Using a dial indicator, check th e shaft runout.

Maximum runout: 0.05 mm 0 .0020 in.

GM0050


51/71


2. CHECK OIL CLEARANCE OF FIRST GEAR

Using a dial indicator, measure th e oil clearance betweenth e gear and inner race with th e needle rol ler bearing installed.

WM0061

Standard clearance:

Maximum clearance:

0.009 - 0.032 mm 0 .0004 - 0.0013 in.

15 mm 0.0059 in.

3. CHECK OIL CLEARANCE OF SECOND, THIRD AN DCOUNTER FIFTH GEARS

Using a dial indicator, measure th e oil clearance betweenth e gear and shaft with th e needle roller bearing installed.

Standard clearance:2n d and 3rd gears 0.009 - 0.033 mm

0 .0004 - 0.0013 in.Counter 5th gear 0.009 - 0.032 mm

0 .0004 - 0.0013 in.

OOSl Maximum clearance: 0.15 mm 0.0059 in.

4. INSPECT SYNCHRONIZER RINGS

a Turn the ring and push it in to check the braking action.

WM0064

b Measure th e clearance between th e synchronizer ringback and th e gear spline end.


Minimum clearance: 0.8 mm 0.031 in.

5. MEASURE CLEARANCE OF SHIFT FORKS AN D HU BSLEEVES

Using a feeler gauge, measure th e clearance be tween thehu b s leeve and shift fork.


WM0066


52/71


6 . NECESS RY REPL CE INPUT SH FT BE RING

a Using snap ring pliers remove th e snap ring.

WM0067

b Using a press , r em ov e t he b ea ri ng .

WMOO

c Using a press and SST install a ne w bearing.

SS T 09506 35010

ISSTI

WM0069

d Select a snap ring that will a l low minimum axial playand install it on t he s ha ft .

Mark Thickness mm in.2.05 2.10 0.0807 0.0827

1 2.10 2.15 0.0827 0.08462 2.15 2.20 0.0846 0.08663 2.20 2.25 0.0866 0.08864 2.25 2.30 0.0886 0.09065 2.30 2.35 0.0906 0.0925

WM0070

7. INSPECT FRONT BE RING RET INER

Check th e retainer a nd oil seal fo r wear or damage. If th eoil seal is worn or damaged replace i t as follows.

a Using a screwdriver pry ou t th e oil sea l.

WM0071


53/71

MANUAL TRANSMISSION - G52 Transmission MT-53

b U si ng S ST p re ss in th e oil seal.

SS T 09223-50010

Oil sea l depth: 11.2 - 12.2 mm O.441 - 0.480 in.Transmission case instal la t ion surface

WMoon

8. IF NECESSARY, REPLACE COUNTER GEAR FRONTBEARING a U si ng s na p r ing pliers, remove th e snap r ing.

b U si ng S ST press out th e bearing.

SST 09950-00020

c Replace th e s ide race.

WM0073

d Using a socket wrench press in th e bearing, side raceand inner race.

WM0176

e Select a snap ring that will allow minimum axial playand install it on th e shaft.


2.05 2.10 0.0807 0.08272 2.10 2.15 0.0827 0.08463 2.15 2.20 0.0846 0.08664 2.20 2.25 0.0866 0.08865 2.25 2.30 0.0886 0.09066

2.30

2.35 0.0906

0.0925WM0077

9. IF NECESSARY, REPLACE REVERSE RESTRICT PIN

a Using a torx socke t wrench remove th e screw plug.

GMOO


54/71


b Using a p in p un c h and hammer, d r ive ou t t he s lo tt edspring pin.

c Pull off the l ever hous ing a nd s li de ou t th e shaf,

d Install th e l ever hous ing .

e Using a pin punch and h m m r ~drive in t he s lo tt edspring pin.

GM0056

f Using a torx socket wrench, install and t or qu e t hescrew plug.


GMOO54

11 . IF NECESSARY, REPLACE l SEAL

a Using a screwdriver, pr y ou t th e oil seal.

b U si ng S ST, d ri ve in a ne w oil seal .

SS T 09325-12010

GMOO58


55/71


No.1 No.2

Front

GM0059

ASSEMBLY OF TRANSMISSION See pages MT-39 40

1. INSERT CLUTCH HU B NO.1 AN D NO.2 INTO HU B SLEEVE

a Install th e clutch hub and shifting keys to th e hu bsleeve.

b Install th e shifting ke y springs under the shifting keys.CAUTION: Install t he k ey springs posi t ioned so that theirend gaps are no t in line.

WM0114

2. INSTALL THIRD GEAR AN D HU B SLEEVE NO.2 ONOUTPUT SHAFT

a Apply gear oil to th e shaft and needle roller bearing.

b Place th e synchronizer r ing on th e gear and align th ering slots with the shi ft ing keys.

c Install th e needle rol le r bearing in th e 3r d gear.

d Using a press, install th e 3rd gear and hub sleeve No.2.

r GM0060

GM0047

3. INSTALL SNAP RING

a Select a snap r ing that will a llow minimum axial play.

b Using snap ring p lier s, ins ta ll th e snap ring.

Mark C l 1.75 1.80 mm 0.0689 0 .0709 in.1.80 1.85 mm 0.0709 0 .0728 in.

0 1 1.85 1.90 mm 0.0728 0 .0748 in.E 1.90 1.95 mm 0.0748 0 .0768 in.

E l 1.95 2.00 mm 0.0768 0 .0787 in.F 2.00 2.05 mm 0.0787 0 .0807 in.

F l 2.05 2.10 mm 0.0807 0.0827 in.


56/71


4. MEASURE THIRD GEAR THRUST CLEARANCE

Using a feeler gauge, measure th e 3r d gear thrustclearance.

Standard clearance:

Maximum clearance:

0.10 - 0.25 mm 0.0039 - 0.0098 in.0.25 mm 0.0098 in.

5. INSTALL SECOND GEAR AN D HUB SLEEVE NO.1

a Apply gear oil to th e shaft an d needle rol ler bearing.

b Place the synchronizer ring on th e gear and a lign th ering slots with th e shifting keys.

c Install th e needle rol le r bea ring in th e 2n d gear.

GM0061

d Using a press, install th e 2n d gear an d hu b sleeveNo.1.

GM0062

6. INSTALL LOCKING BALL AN D FIRST GEAR ASSEMBLY

a Install th e locking ball in th e shaft.

b Apply gear oil to th e needle rol le r bea ring .

c Assemble th e 1 st gear, synchronizer ring, needle rollerbearing and bearing inner race.

GM0063

d Install th e assembly on th e output shaft with t he s yn -chronizer ring slots aligned with th e shifting keys.

e Turn th e inner race to align i t with th e locking ball.

GM0064


57/71


7 . INSTALL OUTPUT SHAFT REAR BEARING

Using SST and a press, install th e bea ring on th e outputshaft with the outer race snap ring groove toward the rear.

NOTE: Hold the 1 st gea r inner race to prevent i t fromfalling.

SST 09506-35010

GMOO65

8 MEASURE FIRST AN D SECOND GEAR THRUSTCLEARANCE

Using a feeler gauge, measure th e 1 st and 2nd gear thrustclearance.

Standard clearance: 0 1 0 0 25 mm 0 0039 0 0098 in.

Maximum clearance: 0 25 mm 0 0098 in.

1st 2ndGM0040

9 INST AL L FIFTH GEAR

Using SST and a press, install the 5th gear.

SST 09506-35010

GM0066

10 INSTALL SNAP RING

a Select a snap r ing that will al low minimum axial play.

GM0067

b Using snap r ing pliers, install th e snap ring.

Mark Tickness mm in. Mark Thickness mm in.

A 2.67 - 2.72 0.1051 - 0.1071 G 3.03 - 3 .0 8 0 .119 3 - 0.1213

B 2.73 - 2 .7 8 0 .1 0 75 - 0.1094 H 3.09 - 3.14 0.1217 - 0.1236

C 2.79 - 2.84 0.1098 - 0.1118 J 3.15 - 3.20 0.1240 - 0.1260

2.85 - 2 .9 0 0 . 11 2 2 - 0.1142 K 3.21 - 3 .2 6 0 .1 26 4 - 0.1283E 2.91 - 2 .9 6 0 .11 46 - 0.1165 L 3.27 - 3.32 0.1287 - 0.1307

F 2.97 - 3 .0 2 0 . 11 6 9 - 0.1189

GM0068


58/71

MT 58 MANUAL TR NSMISSION G 52 Transmission

11 INST LL SL V TO OUTPUT SH FT

Using a plas ti c hammer ta p th e sleeve onto th e outl 1 Itshaft.

GM0071

2 INSTAl l OUTPUT SH FT TO INTERMEDI TE PL TE

Install th e output shaf t into th e intermediate plate by pull-in g on th e o ut pu t s ha ft and tapping on the intermediateplate.

GMOO73

3 INST LL INPUT SH FT

a Apply grease to th e 14 needle roller bearing andinstall i t into th e input shaft.

GM0072

b Install the input shaft to th e output shaft with th e syn-chronizer ring slots aligned with the shi ft ing keys.

GMOO74

4 INSTAl l COUNTER G R

Install th e counter gear into t he i nt er me di at e p la te w hi leholding the counter gear, and install th e counter rear bearingwith SST.

SS T 09316 60010

GM0075


59/71


15 . INSTALL BEARING SNAP RING

Using snap ring pliers, install th e snap ring.

NOTE: Be sure th e snap r ing is flush with th e intermedia te p la te s ur fa ce .

GMOO36

16 . INSTALL REAR BEARING RETAINER

Using a torx socket wrench, install and torque th e screws.


\GM0035

17 . INSTALL REVERSE SHIFT AR M BRACKET

Install th e reverse shift arm bracket and t or qu e t he bolts.


GM0034

18 . INSTALL BALL AN D SPACER

Front

GM0077

19 . INSERT COUNTER FIFTH GEAR INTO HU B SLEEVE NO.3

a Install th e shifting keys and hu b sleeve No.3 onto th ecounter 5t h gear.

b Install the shif t ing key springs under the shift ing keys.

CAUTION: Install th e ke y springs posi t ioned so that theiren d g ap s are no t in line.


60/71

MT-60 MANUAL TRANSMISSION - G52 Transmission

20 . INSTALL COUNTER FIFTH GEAR WITH HUB SLEEVE NO.3ASSEMBLY AND NEEDLE ROLLER BEARINGS

a Apply gear oil to th e needle rol le r bea rings.

b Install the counter 5t h gear with hu b sleeve No.3 andneedle roller bearings.

21 . INSTALL SYNCHRONIZER RING AN D GEAR SPLINE PIECENO.5

a Install th e synchronizer ring o n ge ar spline piece No.5.

b Using S ST, d ri ve in gear spline piece No.5 with th esynchronizer ring slots aligned with th e shift ing keys.

SS T 09316-60010

NOTE: When installing gear spline piece N o. 5, s up po rtthe counter gear in front with a 3- 5 Ib hammer or equivalent.

GM0079

22. INSTALL LOCK NU T

a Engage th e gear double meshing.

GMOO 9

b Install an d torque th e l oc k n ut .

Torque: 1,200 kg-em 8 7 f t- Ib , 118 Nm

c Stake t he loc k nut.

GMOO3

d Disengage the gear double mesh ing .

GMOO 9


61/71


23 . MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE

Using a feeler gauge, measure the counte r 5 th g ea r thrustclearance.

GMOO

Standard clearance:

Maximum clearance:

0.10 - 0.30 mm 0 .0039 - 0.0118 in.0.30 mm 0.0118 in.

GM0027

GM0026

24. INSTALL REVERSE SHIFT AR M TO REVERSE SHIFT ARMBRACKET

Install th e reverse shift arm to th e pivot of th e reverse shifta rm b ra ck et .

25 . INSTALL REVERSE IDLER GEAR AND SHAFT

a Install th e reverse idler gear on the shaft.

b Align th e reverse shift arm shoe to th e reverse idlergear groove and insert th e reverse idler gear shaft tothe in te rmedia te plate.

c Install th e reverse idler gear shaft stopper and torquet he b ol t.

Torque: 17 5 kg-em 13 ft-Ib, 17 Nm

GM0025

26 . INSTALL SHIFT FORK SHAFT NO.2, SHIFT FORK NO.1AND NO.2

Place shift forks No.1 and N o.2 i nto t he g ro ov e of hu bsleeves No.1 and No.2 and install fork shaft No.2 to shiftforks No.1 and NO.2 t hr ou gh t he intermediate plate .

o

GM0081 GM0082

27 . INSTALL INTERLOCK PIN

a Apply MP grease to th e interlock pins.

b Using a magnetic finger and screwdriver, install th einterlock pin i nto the intermediate plate.


62/71


28 . INSTALL SHIFT FORK S HA FT N O. 1

a Install t he i nt er lo ck pin into th e shaft hole.

GM0083

b Install fork shaft NO.1 t o s hi ft fork No.1 through th eintermediate plate.

GM0084

29 . INSTALL INTERLOCK PIN

Using a magnetic f inger and screwdriver install th e inter-lock pin i nt o th e intermediate plate .

GM0085

30 . INSTALL SHIFT FORK SHAFT NO.3

a Ins ta ll the interlock pin i nto th e s ha ft head.

GM0086

b Install fo rk shaf t No.3 to th e reverse shift arm throughth e intermediate plate.

GM0087


63/71


64/71

MT-64 MANUAL TRANSMISSION G 52 Transmission

33 . CHECK INTERLOCK a S hi ft f or k s ha ft NO.1 to th e 1 st speed position.

GM0092

b Fork shafts N o.2 , N o.3 , No.4 an d No.5 should no tmove.

GM0093

34 . INSTALL FIVE SLOTTED SPRING PINS

Using a pin punch and hammer, d ri ve t he s lo tt ed springpins into each shift fork, reverse shift ar m and reverse shifthead.

GM0094

35 . INSTALL TW O FORK SHAFT E RING

GM0095

36 . INSTALL LOCKING BALLS SPRINGS AND SCREW PLUGS

a Apply liquid sealer to th e plugs.

b Install th e locking balls, springs and screw plugs andt or qu e t he screw plugs with a torx socket wrench.

Torque: 190 kg em 1 4 ft Ib 19 Nm

NOTE: 5-Speed Install the short spring into th e bot lof th e intermediate plate.


65/71

MANUAL TRANSMISSION - G52 Transmission MT-65

37 . DISMOUNT INTERMEDIATE PLATE FROM VISE

a D is m ou nt t he intermediate plate from th e vise.

b Remove th e b ol ts , n ut s, plate washers and gasket.

38 INSTALL TRANSMISSION CASE WITH NEW GASKET TOINTERMEDIATE PLATE

Align each bearing outer race, each f or k s ha ft end andreverse idler gear shaft end with the case installation holes,and ins ta ll th e case.

If necessary, ta p on th e case with a plastic hammer.

39. INSTALL TWO BEARING SNAP RINGS

\\ GM0012

4 INSTALL FRONT BEARING RETAINER WITH NEW GASKET

a Install th e bearing retainer with a new gasket.

b Apply liquid sealer to t he b ol ts .

c Install and t or qu e t he bolts.


GM0099


66/71

MT 66 MANUAL TRANSMISSION G 52 Transmission

\ ~ ~

GM0104

41 INSTALL TRANSFER ADAPTER NEW GASKET SHIFTLEVER SHAFT AND SHIFT LEVER HOUSING

a Install a ne w gasket to the in te rmedia te plate.

b Install and t or qu e t he t ra n sf er adapter with t he e ig htbolts.

Torque: 38 0 kg em 27 ft Ib 37 Nom

GM0105

: GM0010

GM0106

GM0108

c Inse r t the shift lever housing to th e transfer adapterand connect th e fork shafts.

d Insert th e shift lever shaft to th e transfer adapter andshift l ever housing .

e Ins ta ll and t or qu e t he shift lever housing bolt.

Torque: 39 0 kg em 28 ft Ib 38 Nom

f Using SST install and t or qu e t he plug.

SS T 09923 00010

Torque: 380 kg em 27 ft Ib 37 Nom


67/71


42 . INSTALL LOCKING BALL, SPRING AN D SCREWPLUG

a Apply l iquid sealer to th e plug.

b Install th e locking ball and spr ing.

GM0110

c Install and t or qu e t he plug.


43. AFTER INSTALLING EXTENSION HOUSING OR TRANSFERADAPTER CHECK FOLLOWING ITEMS

a Check to see that t he i np ut and output shafts rotatesmoothly.

b Check to see that shifting can be made smoothly toall positions.

44. INSTALL RESTRICT PINS

a Install th e black pin on th e reverse gear/5th gear side.

GM0113

b Install another pin and torque th e pins.

Torque: 280 kg-em 2 0 ft-Ib, 27 N m


68/71

MT-68 MANUAL TRANSMISSION G 52 Transmission

45 . INSTALL CLUTCH HOUSING

a Install t he c lu tc h housing

b Ins ta ll and torque th e bolts

Torque: 38 0 kg em 2 7 ft Ib 37 Nm

GM 115

46 . INSTALL SHIFT LEVER RETAINER WITH NEWGASKET

Torque: 185 kg em 1 3 ft Ib 1 8 Nm

47 . INSTALL BACK UP LIGHT SWITCH

Torque: 38 0 kg em 27 ft Ib 37 N m

48 . INSTALL RELEASE FORK AND BEARING

Apply molybdenum disulphide lithium base grease to th efollowing parts:

Release bearing hu b inside groove I np ut s h af t spline Release fork contact surface


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MANUAL TRANSMISSION - Installation of Transmission MT-69

NST LL T ON TR NSM SS ON

NOTE: For the transmission with a transfer 4WD refer to INSTALLA TION TRANSFER on page TF-25.

1. PLACE TRANSMISSION AT INSTALLATION POSITION

Insert th e extension housing between th e member and floorand then side th e transmission forward.

Align t he i np ut shaft spline with th e clutch d is c, a nd p us hthe t ransmiss ion f ul ly i nt o position.

2. INSTALL TRANSMISSION BOLTS AND STIFFENERBOLTS

Transmission Mounting Bolt Torque:Transmission Mounting Bolt 730 kg-em

5 3 ft-Ib, 72 NomStiffener Plate Bolt 3 80 kg-em

27 f t- Ib , 37 Nom

Vtiffener Plate

Bolt

Transmission Mount ing Bolt

MT0023

3. INSTALL ENGINE REAR MOUNTING AND BRACKET

a Install th e eng ine rea r mount ing . Torque th e bolts.


b Raise th e t ransmiss ion s l igh tly by raising th e enginewith a jack and a wooden block u nd er t he t ra ns mi ssion.

MTQ025


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MT-70 MANUAL TRANSMISSION - Installation of Transmission

c Install th e engine rear mount ing bracket to th e support member. Torque th e bolts.

Torque: 13 0 kg-em 9 f t- Ib , 13 Nm)

d Lower the t ransmission an d rest i t on th e extensionhousing.

e Install t h e b r ac k et to th e mounting. Torque th e bolts.

Torque: 260 kg-cm 19 ft-Ib, 25 N m)

MTOO16 MT0015

4. REMOVE PIECE O WOOD FROM FRONTCROSSMEMBER

INSTALL EXHAUST PIPE, BRACKET AND PIP

a Install t he e xh au st pipe to th e manifold.

Torque: 400 kg-em 29 ft-Ib, 39 Nom

MT0021

b Install th e pipe bracket to t he c lu tc h housing.

Torque: Upper 380 kg-em 2 7 f t- Ib , 37 NomLower 700 kg-em 51 ft-Ib, 69 Nom

c Install t he e xh au st pipe c lamp.

MT0020

6 INSTALL STARTER LOWER MOUNTING BOLT AN DRELEASE CYLINDER TUBE BRACKET

Torque: 400 kg-em 29 ft-Ib, 39 Nom

INSTALL CLUTCH RELEASE CYLINDER

Torque: 120 kg -e m 9 f t- Ib , 12 Nom

8 CONNECT SPEEDOMETER CABLE AN D BACK-UP LIGHTSWITCH

9 CONNECT PROPELLER SHAFT See page PR-2


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MANUAL TRANSMISSION - Installation of Transmission MT-71

10 . FILL TRANSMISSION WITH OILOil grade: API GL-4 or GL-5 SAE 75W-90

Quantity:2W D 2.4 liters 2 .5 US qts, 2.1 I mp . q ts4W D W56 3.0 liters 3 .2 US qts, 2.6 I mp . qt s

G5 2 3.9 liters 4.1 US qts, 3.4 I mp . q ts

11 . LOWER VEHICLE

12 . INSTALL STARTER UPPER MOUNTING NU T

13. INSTALL SHIFT LEVER

a Apply MP grease to th e shift lever.

b Install th e shift lever to th e transmission.

14. CONNECT BATTERY CABLE TO NEGATIVE TERMINAL

15 . PERFORM ROAD TEST

Check fo r abnormal noise and smooth operation.

Documents

Chapter13 Manual Transmission