Part 1

UNIT DISASSEMBLY
Gear Shift Lever Case (4Wd Model)





1. Remove 4 screws with screwdriver and remove case plate.
2. With case supported with soft jawed vise, remove select return spring bolt with wrench.

NOTE: Use aluminum plates between vise and case to protect case against damage.

3. Using spring pin remover, drive out spring pin for gear shift arm.

NOTE:
^ Double spring pin (indicated as 2-1 in figure) can be driven out through the hole after removing its plug. After removing the double spring pin, apply sealant to the plug and install it.
"A": Sealant 99000-31110
^ All spring pin (except double spring pin; indicated as 2-1 in figure) can be driven out only in such direction that it comes out toward the deeper side of the shift lever case.

4. Drive out spring pin for limit spring.
5. Drive out spring pin for gear shift lever.
6. Pull out gear shift shaft a little and take out gear shift arm.

NOTE:
^ Case plug may come off during above work.
^ If it is not possible to take out gear shift arm in above step 6, do it after following steps 7 and 8.

7. Push gear shift shaft inward and drive out spring pin for reverse gear shift limit yoke.
8. Pull out gear shift shaft from case.

Gear Shift Lever Case (2wd Model)





1. Using spring pin remover, drive out spring pin for gear shift arm.
2. Drive out spring pin for limit spring.
3. Drive out spring pin for gear shift lever.
4. Pull out gear shift shaft a little and take out gear shift arm.

NOTE:
^ Case plug may come off during above work.
^ If it is not possible to take out gear shift arm in above step 4, do it after following steps 5 and 6.

5. Push gear shift shaft inward and drive out spring pin for reverse gear shift limit yoke.
6. Pull out gear shift shaft from case.

TRANSMISSION UNIT





1. Remove 12 fastening bolts and separate rear case.
2. Remove clutch release bearing.
3. Remove 8 clutch housing bolts and then remove clutch housing.





4. Remove 8 bolts and pullout input shaft bearing retainer by using large size screwdrivers and clean cloth.

CAUTION: When pulling out, do not scratch the transmission case surface contacting with the clutch housing.





5. Remove 10 bolts and separate cases by using special tool (A).
Special Tool
(A): 09912-34510





6. If equipped with scissors gears, put match mark (paint) on teeth of low and reverse gear assembly as shown in figure before taking out input and main shaft assembly from lower case.
7. Take out input and main shaft assembly.





8. Remove bearing circlip at the rear part of counter shaft.





9. Remove bolt for reverse idle gear shaft and then remove idle gear and shaft as a set.





10. Remove center bearing plate by removing its 2 bolts.





11. Remove outside circlip of front bearing on counter shaft.





12. Using plastic hammer, drive counter shaft rearward.





13. Pull out 5th gear and rear bearing with puller and press.

NOTE
^ Apply pressing force while adjusting position of front bearing so that it will fit in its original position (hole in lower case).
^ Be sure to set flat face of puller against 5th gear so as not to cause damage to teeth.

14. In the same manner as 12), drive counter shaft rearward again.





15. Pull out reverse gear with puller and press.
16. Pullout roller bearing by hand and then remove shaft from lowercase.





17. Remove circlip of counter shaft front bearing and pull out bearing by using puller (B).
Special Tool
(B): 09913-60910
18. Remove circlip, friction gear retainer, friction gear spring, friction gear and pin in that order.

INPUT SHAFT





1. Take out oil seal from input shaft oil seal retainer and install new oil seal with special tool (A) and hammer up to case surface. Unless oil seal is leaky or its lip is excessively hardened, replacement is unnecessary.
Special Tool
(A): 09913-84510





2. Remove circlip of input shaft and pull out bearing with puller and press as necessary.

NOTE: Sealed bearing must not be washed. Replace it with new one when required.





3. When installing bearing, bring it so that its groove for circlip is in the front and press-fit with special tool (B) and press.
Special Tool
(B): 09925-18010





4. After fitting circlip, air-blow lubrication oil hole.

MAIN SHAFT
1. After removing needle bearing for input shaft at the front end of main shaft, pull out high speed sleeve from its hub and remove 3 synchronizer keys.





2. Remove circlip in front of hub and pull off hub with special tool (A), then take out synchronizer springs.
Special Tool
(A): 09913-61510
3. Remove 3rd synchronizer ring, 3rd gear and needle bearing.

NOTE: High speed sleeve-hub assembly, synchronizer ring and 3rd gear can be removed all at once by using puller and hydraulic press.





4. Remove circlip in the rear part of main shaft and pull off rear bearing with puller and press.





5. Remove thrust washer and steel ball and then remove 5th gear, synchronizer ring and needle bearing.
6. Pull out reverse sleeve from its hub and remove 3 synchronizer keys.
7. Remove circlip and pull off reverse hub from main shaft with puller and press, then take out synchronizer springs.

NOTE: It is also possible to remove reverse sleeve-hub as assembly and reverse gear all at once by using puller and press, after removing circlip.

8. Remove main shaft reverse gear and needle bearing by hand.





9. Using puller and press, remove reverse gear bush and bearing washer.

NOTE: During above work, watch out for steel ball which will come out from inside of washer so as not to lose it.

CAUTION: Do not attempt to pull out bearing, washer and bush all together at once. Steel ball would stop bearing and cause damage to it.





10. Pull off bearing with puller and press.





11. Remove the following in that order: bearing washer, steel ball, low gear, low synchronizer, needle bearing and low gear bush.
12. Using puller and press, pull out low speed sleeve and hub assembly, 2nd gear and 2nd synchronizer ring all together.

NOTE: If bush can't be pulled out by hand at step 11, pull off sleeve and hub together by using press.

13. Remove sleeve from hub and then take off synchronizer keys and springs.

UPPER CASE AND SHIFTER





1. Remove back up light switch and locating spring bolts.
2. Take out locating springs and locating balls.





3. Remove 2 spring pins and pull out low speed gear shift shaft and high speed gear shift shaft in that order.
4. Pull out reverse gear shift shaft, then disconnect fork from shaft removing spring pin.

NOTE: Make sure that remaining gear shift shafts are all neutral position when removing a gear shift shaft.

Special Tool
(A): 09922-85811
5. Take out rubber plug and 2 interlock balls from case.
6. Remove interlock pin from high speed gear shift shaft.

INSPECTION
Counter Shaft And Main Shaft Inner Parts





- Check tooth surface of gear and rotation of bearing and replace with new one if necessary. As long as no abnormal condition such as noise exists before removal, replacement is unnecessary.





- Inspect needle bearings and needle contacting surfaces (rotating surfaces) and replace with new ones as required.

NOTE: Should abnormal noise be heard before disassembly, it is necessary to carefully check needle contacting surface inside of each gear besides those parts shown in figure.





- Check clearance "a" between synchronizer ring and gear, key slot width "b" in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Clearance "a": Standard 1.0 - 1.4 mm (0.039 - 0.055 inch)
Service limit 0.5 mm (0.019 inch)
Slot width "b": Standard 10.1 mm (0.397 inch)
Service limit 10.4 mm (0.409 inch)





- Check chamfered part of each sleeve for damage and excessive wear, and replace as necessary.
- Using feeler gauge, check clearance between sleeve and shifter fork and replace parts if necessary.
Maximum clearance "c": 1.0 mm (0.039 inch)
- Check each synchronizer key and synchronizer spring and replace as necessary.
- Check splined portions and replace parts if excessive wear are found.

[Low and Reverse Scissors gear Assemblies] (if equipped)
Check for following items





- Match mark provided for reassembly should be almost at such position as shown in figure.
- Try to turn scissors gear against main shaft low (and reverse) gear. It should feel light when turned in "A" direction but heavy when turned in "B" direction.
- Play of scissors gear against main shaft low (or reverse) gear in A - B direction should be about half of tooth width as shown in figure.





If any faulty condition is noted, remove snap ring, open up assembly unit and check that all components are installed at proper positions. If all components are positioned properly and yet faulty condition exists, replace the low (reverse) gear assembly.

Upper Case And Shifter





- Using feeler gauge, check clearance between fork and sleeve and replace those parts if it exceeds limit of 1.0 mm (0.039 inch).
Clearance "a": Service limit 1.0 mm (0.039 inch)
- Insert each gear shift shaft into case and check that it moves smoothly. If it doesn't, correct by using oilstone, reamer or the like.





- Check gear shift shaft for excessive wear and correct or replace a necessary.





- Check free length of each locating spring and replace if it is below service limit.
Free length "b": Standard 27.0 mm (1.063 inch)
Service limit 24.0 mm (0.945 inch)

Rear Case





- If oil sea[ leaks and/or its lip is excessively hardened, replace it with new one and at the same time, check main shaft where oil seal contacts. If contacting surface is not smooth, correct or replace. Apply grease to oil seal lip portion.
Grease "A": 99000-25010
Special Tool
(A): 09913-75510





- If oil leakage exists at counter shaft end plug, replace it.
Special Tool
(B): 09913-75520

UNIT ASSEMBLY
Gear Shift Lever Case (4Wd Model)
1. Wash and inspect each part and replace if necessary. Also check items as described below and correct whatever necessary carefully by using reamer, oilstone and the like, wash it thoroughly and reassemble them.
Items to be checked are;
- Shift shaft should go into case smoothly.
- Shift lever, limit yoke and shift arm should go into shift shaft smoothly.





2. Insert shift shaft as shown while making sure that inner parts are in proper direction.

NOTE:
^ Cut off in shift shaft should face downward when shift shaft is installed.
^ Use care for installing direction of shift limit spring.
^ Shift arm should be installed at the same time.

3. Drive in spring pin (single short) for reverse gear shift limit yoke.
4. Drive in spring pin (double) for shift lever.





5. Drive in spring pin (single long) for return spring.
6. Fit straight end of shift limit spring into line groove in shift limit yoke and with its other hooked end turned in its winding direction by about 900 from its free state, hook it on spring pin.
7. Drive in spring pin for shift arm.





8. Press-fit case plug into case.





9. After applying grease "A", install select guide pins, select return springs and spring bolts and torque them to specification.
"A": Grease 99000-25010
Tightening Torque
(a): 35 Nm (3.5 kg-m, 25.5 ft. lbs.)

NOTE: Double coil spring is required at 5th/Reverse select side.

10. Clean mating surfaces of both case plate and case, apply sealant "B" to case side evenly, mate them and fasten with screws.
"B": Sealant 99000-31110
Tightening Torque
(b): 9 Nm (0.9 kg-m, 6.5 ft. lbs.)
11. If reverse gear shift limit bolt has been removed, apply thread lock cement "C" then install and torque it to specification.
"C": Thread lock cement 99000-32020
Tightening Torque for limit bolt
(c): 32 Nm (3.2 kg-m, 23.0 ft. lbs.)





12. Install gear shift lever case to transmission without using sealant for functional check.
13. Install shift control lever and check to make sure that it shifts smoothly according to shift pattern as shown in figure.

NOTE:
^ Apply thread lock cement to control lever locating bolts when replaced.
^ Be sure to apply sealant to mating surface of gear shift lever for its final installation.

"C": Cement 99000-32020
Tightening Torque
(d): 17 Nm (1.7 kg-m, 12.5 ft. lbs.)