Shifter Fork and Rod
Shifter Fork and RodREMOVAL
1) Remove the manual transmission assembly from vehicle.
2) Remove the back-up light switch and neutral position switch.
3) Remove the transfer case with extension case assembly.
4) Remove the transmission case.
5) Remove the drive pinion shaft assembly.
6) Remove the main shaft assembly.
7) Remove the differential assembly.
8) Drive out the straight pin with ST, and 5th shifter fork.
ST 398791700 STRAIGHT PIN REMOVER
9) Remove the plugs, springs and checking balls.
10) Drive out the straight pin, and pull out 3rd-4th fork rod and shifter fork.
NOTE:
When removing the rod, keep other rods in neutral. Also, when pulling out the straight pin, remove it toward the inside of case so that it does not hit against the case.
11) Drive out the straight pin, and pull out 1st-2nd fork rod and shifter fork.
12) Remove the outer snap ring, and pull out the reverse shifter rod arm and reverse fork rod. Then take out the ball, spring and interlock plunger from rod.
And then remove the rod.
NOTE:
When pulling out the reverse shifter rod arm, be careful not to let the ball pop out of arm.
13) Remove the reverse shifter lever.
INSTALLATION
1) Install the reverse arm fork spring, ball and interlock plunger to reverse fork rod arm. Insert the reverse fork rod into hole in reverse fork rod arm, and hold it with outer snap ring using ST.
NOTE:
Apply grease to plunger to prevent it from falling.
ST 399411700 ACCENT BALL INSTALLER
2) Position the ball, spring and new gasket in reverse shifter rod hole, on left side transmission case, and tighten the checking ball plug.
3) Install the 1st-2nd fork rod into 1st-2nd shifter fork via the hole on the rear of transmission case.
4) Align the holes in rod and fork, and new drive straight pin into these holes using ST.
NOTE:
^ Set other rods to neutral.
^ Make sure the interlock plunger is on the 3rd-4th fork rod side.
ST 398791700 STRAIGHT PIN REMOVER
5) Install the interlock plunger onto 3rd-4th fork rod.
NOTE:
Apply a coat of grease to plunger to prevent it from falling.
6) Install the 3rd-4th fork rod into 3rd-4th shifter fork via the hole on the rear of transmission case.
7) Align the holes in rod and fork, and new drive straight pin into these holes.
NOTE:
^ Set the reverse fork rod to neutral.
^ Make sure the interlock plunger to be installed is on the reverse fork rod side.
ST 398791700 STRAIGHT PIN REMOVER
8) Install the 5th shifter fork onto the rear of reverse fork rod. Align holes in the two parts and new drive straight pin into place.
ST 398791700 STRAIGHT PIN REMOVER
9) Position the balls, checking ball springs and new gaskets into 3rd-4th and 1st-2nd rod holes, and install plugs.
10) Install the differential assembly.
11) Install the main shaft assembly.
12) Install the drive pinion shaft assembly.
13) Install the transmission case.
14) Install the transfer case with extension case assembly.
15) Install the back-up light switch and neutral position switch.
16) Install the manual transmission assembly to vehicle.
INSPECTION
1) Check the shift shaft and shift rod for damage. Replace if damaged.
2) Gearshift mechanism:
Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way.
3) Inspect the clearance between 1st, 2nd driven gear and reverse driven gear. If any clearance is not within specifications, replace the shifter fork as required.
4) Inspect the clearance between 3rd, 4th drive gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.
5) Inspect the clearance between 5th drive gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.
6) Inspect the rod end clearances (A) and (B). If any clearance is not within specifications, replace the rod or fork as required.
