Manual Transmision FL

FUSO
Group 22
Transmission
Pub. No. 00ELT0183

GROUP 22 TRANSMISSION
SPECIFICATIONS.................................. 22-2 COUNTERSHAFT ................................ 22-54
STRUCTURE AND OPERATION TRANSMISSION CONTROL................ 22-56

1. Transmission ................................... 22-3
2. Synchromesh Mechanism ............... 22-4 TRANSMISSION POWER
3. Interlock Mechanism........................ 22-6 TAKE-OFF ............................................ 22-64
4. Transmission Power Take-off........... 22-6
BEARING PULLER AND
TROUBLESHOOTING ........................... 22-8 INSTALLER .......................................... 22-71
ON-VEHICLE INSPECTION AND

ADJUSTMENT
1. Transmission Oil Leakage and Oil
Quantity ......................................... 22-10
2. Inspection of Looseness in
Engine to Clutch Housing
Connection .................................... 22-11
3. Inspection of Looseness in
Propeller Shaft Connection ............ 22-12
4. Replacement of Transmission Oil .. 22-12
5. Inspection of Transmission
Mounting Cushion Rubber ............. 22-13
REMOVAL AND INSTALLATION OF

TRANSMISSION .................................. 22-14
GEAR SHIFTER UPPER,

INTERLOCK PLATE ............................ 22-18
REAR COVER AND PARKING

BRAKE ................................................. 22-24
REVERSE IDLER GEAR ..................... 22-28
TRANSMISSION BODY....................... 22-32
DRIVE PINION ..................................... 22-42
MAINSHAFT......................................... 22-44
22-1
SPECIFICATIONS
Item Specifications
M038S5
Transmission model
(5.494/0.723)
1st 5.494
2nd 3.193
3rd 1.689
Gear ratio
4th 1.000
5th 0.723
Rev 5.494
API GL-3 SAE80 (general)
SAE90 (warm or tropical region)
Gear oil Classfication
API GL-4 SAE80 (general)
Transmission SAE90 (warm or tropical region)
oil
Standard Approx. 3.5 {3.7}
Quantity L {qts.} With transmission power
Increase of approx. 0.2 {0.2}
take-off
Standard Approx. 73 {160}
Mass kg {lb}
With transmission power take-off Approx. 83 {180}
Mode of control Instrument panel shift remote control
22-2
STRUCTURE AND OPERATION 22
1. Transmission
㻟㼞㼐㻌㼍㼚㼐㻌㻠㼠㼔㻌㼟㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞㻝㼟㼠㻌㼍㼚㼐㻌㻞㼚㼐㻌㼟㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞
㻿㼔㼕㼒㼠㻌㼒㼛㼞㼗㻿㼔㼕㼒㼠㻌㼞㼍㼕㼘㻡㼠㼔㻌㼍㼚㼐㻌㼞㼑㼢㼑㼞㼟㼑㻌㼟㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞
㻰㼞㼕㼢㼑㻌㼜㼕㼚㼕㼛㼚
㻹㼍㼕㼚㼟㼔㼍㼒㼠
㻯㼛㼡㼚㼠㼑㼞㼟㼔㼍㼒㼠㻾㼑㼢㼑㼞㼟㼑㻌㼕㼐㼘㼑㼞㻌㼓㼑㼍㼞
601539
• The transmission uses an interlock mechanism to avoid double engagement.
22-3
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 mechanisms is a Warner synchromesh type, and is used depending on the gear position as
shown below:
Transmission type
Gears of application
Synchromesh type
Single cone type 4th, 5th, Reverse
Triple cone type 1st, 2nd, 3rd
2.1 Single cone type
• 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 plungers are inserted into these grooves. When the gear shift is in neutral, the shifting plunger engage
grooves in the synchronizer sleeve and are pressed against the inside of the synchronizer sleeve by shifting
plunger 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
grooves in which protrusions of the synchronizer rings are inserted. These grooves are wider than the width of the
protrusions of the synchronizer rings.
• Synchronizer rings rotate relative to the synchronizer sleeve by the amount of play (width difference).
• 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 gear. At the same time, the shifting plunger, the central protrusion of which
engages the synchronizer sleeve, moves to the gear and presses the synchronizer ring against the taper cone of
the gear (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 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).
22-4
22
2.2 Triple cone type
• The synchromesh structure and operation of the triple cone type 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 syn-
chronizer outer ring) and the center cone (both the inside and outside surfaces are tapered) and the inner ring
(both the inside and outside surfaces are tapered) are sandwiched between the outer ring and the taper cone of
each gear to shorten the time required for synchronization with cone clutches at three 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 grooves.
• Shifting plungers are inserted into these keyways. When the gear shift is in neutral, the shifting plungers engage
grooves in the synchronizer sleeve and are pressed against the inside of the synchronizer sleeve by shifting
plunger 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 the 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 gear. At the same time, the shifting plunger, the central protrusion of which
engages the synchronizer sleeve, moves to the gear and presses the synchronizer outer ring and the center cone
against the taper cone of the synchronizer center cone and the synchronizer inner ring, respectively and in addi-
tion, presses the inner ring against the gear (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 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).
22-5
STRUCTURE AND OPERATION
3. Interlock Mechanism
• The interlock mechanism prevents
double engagement of gears.
• When the 1st and 2nd shift rail is shift-
ed, the interlock plate locks the other
shift rails.
4. Transmission Power Take-off

• The transmission power take-off takes
out the power when the power take-off
gear engages the reverse idler gear of
the transmission, and delivers the en-
gine power as it is.
22-6
22
M E M O
22-7
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 companion flange mounting bolt loose O O
Mainshaft thrust washer worn O O
Mainshaft bearing worn or damaged O O O
Synchronizer ring and synchronizer sleeve spline worn O
Synchronizer ring and gears taper cone area worn O
Mainshaft pilot bearing worn or damaged O O
Drive pinion bearing worn or damaged O
Transmission
body faulty Countershaft bearing worn or damaged O O
Needle bearings of gears worn or damaged O O
Reverse idler gear or countershaft 3rd gear and power take-off
O
gear backlash excessive
Mainshaft and countershaft gears backlash excessive O
Spline of gears worn O
Gears damaged O
Transmission oil insufficient O
Contacting surface of synchronizer ring and
Single cone type O O
gear taper cone worn
Contacting surface of synchronizer inner and
O O
outer rings and center cone worn
Triple cone type
Contacting surface of synchronizer inner ring
Synchronizer O O
and gear taper cone worn
faulty
Synchronizer ring spline chamfer worn O
Shifting plunger worn O
Shifting plunger spring deteriorated or damaged O
Synchronizer sleeve worn or damaged O O
Control cable adjustment faulty O
Control cable routing inadequate O
Control cable length inadequate O
Bushings worn O O
Control mecha-
Steel ball and groove of shift rail worn O
nisms faulty
Poppet spring of shift rail fatigued or damaged O
Shift rail sliding movement faulty O
Shift fork jaws worn O
Shift fork bent O
Clutch disengagement faulty O O
Clutch faulty Gr21
Clutch pedal play faulty O
22-8
22
Symptoms
Indicator does not light though power take-off is engaged

Indicator lights though power take-off is not engaged
Power take-off slips out of engagement
Power take-off does not stay engaged

Power take-off cannot be disengaged
Power take-off cannot be engaged
Reference Gr
Noise from power take-off

Possible causes
Shift rail bent O O
Shift fork bent O O
Bearings worn or damaged O O O
Power take-off
Transmission oil insufficient O
body abnormal
Gears broken or worn O
Gear backlash excessively large O
Gear backlash excessively small O
Transmission power take-off switch faulty O O
Blowout of fuse and high-current fuse O O
Battery overcharge O
Power take-off control switch faulty O O Gr54
Power take-off
control system 3-way magnet valve faulty O O O
faulty
Clutch switch faulty O O
Broken wire, poor connection or faulty indicator O
Air leakage in vacuum piping O O O
Vacuum chamber faulty O O O O
22-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Transmission Oil Leakage and Oil Quantity
Tightening torque (Unit: N·m {ft.lbs, kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Inspection plug
– 68.6 ± 14.7 {51 ± 11, 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 Approx. 3.5 L

– Transmission case
(See “SPECIFICATIONS”) {3.7 qts.}
• For a model with transmission power take-off, the quantity is increased by approx. 0.2 L {0.2 qts.}.
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 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 TRANSNISSION”.)
22-10
22
1.3 Inspection of oil quantity
㪠㫅㫊㫇㪼㪺㫋㫀㫆㫅㩷㫇㫃㫌㪾
WARNING
• Temperature of transmission oil is high immediately after
driving. Perform work when oil is cold.
• Remove the inspection plug, and check that oil is filled up to the
neck.
㪛㫉㪸㫀㫅㩷㫇㫃㫌㪾㩷㩿㫄㪸㪾㫅㪼㫋㩷㫋㫐㫇㪼㪀 • If oil is not sufficient, fill oil from the inspection plug hole up to the
neck.
㪧㪌㪇㪈㪌㪇㪍㪜
• After filling, apply sealant to the inspection plug and tighten it to
the specified torque.
㻵㼚㼟㼜㼑㼏㼠㼕㼛㼚㻌㼜㼘㼡㼓㻌㼔㼛㼘㼑
㻻㼕㼘㻌㼟㼡㼞㼒㼍㼏㼑
㼃㻜㻜㻝㻠㻡㻤
2. Inspection of Looseness in Engine to Clutch Housing Connection

– Bolt (transmission mounting) 47.1 {35, 4.8} M10
• Check the engine to clutch housing connection for looseness.

• Check the transmission mounting bolts and nuts for looseness.
• Retighten any loose bolt to the specified torque.
22-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
3. Inspection of Looseness in Propeller Shaft Connection
• Check the propeller shaft mounting bolts for looseness. (See
Gr25.)
• Move the parking brake drum in axial and vertical directions to
check for excessive play between the companion flange and
mainshaft.
• If excessive play is detected, remove the propeller shaft, then
check the companion flange mounting bolt for looseness and the
splines on companion flange and mainshaft for abnormalities. If
any part is found defective, replace the part. (See “REAR COV-
ER” section.)
4. Replacement of Transmission Oil
Tightening torque (Unit: N·m {ft.lbs, kgf·m}))

Inspection plug
– 68.6 ± 14.7 {51 ± 11, 7.0 ± 1.5} –
Drain plug

– ThreeBond 1105 As required
Gear oil Approx. 3.5 L
– Transmission case
(See “SPECIFICATIONS”) {3.7 qts.}
• For a model with transmission power take-off, the quantity is increased by approx. 0.2 L {0.2 qts.}.
WARNING
• Temperature of transmission oil is high immediately after driving. Perform work when oil is cold.
[Replacement]
㪠㫅㫊㫇㪼㪺㫋㫀㫆㫅㩷㫇㫃㫌㪾 • 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. Magnet type drain plugs
should be cleaned before installation.
• Fill transmission oil in the specified quantity from the inspection
plug hole.
㪛㫉㪸㫀㫅㩷㫇㫃㫌㪾㩷㩿㫄㪸㪾㫅㪼㫋㩷㫋㫐㫇㪼㪀
㪧㪌㪇㪈㪌㪇㪍㪜
22-12
22
• 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
㻵㼚㼟㼜㼑㼏㼠㼕㼛㼚㻌㼜㼘㼡㼓㻌㼔㼛㼘㼑 inspection plug hole. If oil is not sufficient, replenish it.
㻻㼕㼘㻌㼟㼡㼞㼒㼍㼏㼑 • After completing work, apply sealant to the inspection plug and
tighten it to the specified torque.
• When transmission oil has been replaced, reset the Mainte-
nance information memory of the multi-information system. (See
“Multi-information system” in chapter 6 of the Owner’s Manual.)
㼃㻜㻜㻝㻠㻡㻤
[Inspection]
• When draining transmission oil, check for oil quality, metal chips
and metal powder.
• If an abnormally large amount of metal chips and metal powder
is found, disassemble the transmission assembly for service, as
abnormalities may be caused inside. (See “TRANSMISSION
BODY” section.)
5. Inspection of Transmission Mounting Cushion Rubber
• Check that the cushion rubber on the transmission mounting is

free from damage such as scratches, cracks or peeling.
• Use a hand mirror in places that are difficult to see.
• If there is a problem, replace the cushion rubber. (See “REMOV-
AL AND INSTALLATION OF TRANSMISSION”.)
22-13
REMOVAL AND INSTALLATION OF TRANSMISSION
Removal sequence
1 Propeller shaft (See Gr25.) 6 Transmission
2 Clutch hose (See Gr21.) 7 Parking brake cable bracket
3 Parking brake cable (See Gr36.) 8 Mounting support
4 Cushion rubber 9 Mounting support bracket
5 Mounting bracket
Installation sequence
Follow the removal sequence in reverse.
22-14
22
Nut (transmission mounting) 235 ± 35 {175 ± 26, 24.0 ± 3.6} –
Bolt (transmission mounting) 47.1 {35, 4.8} M10
Nut (cushion rubber mounting) 50.6 {37, 5.2} –
Nut (cushion rubber mounting) 260 ± 40 {190 ± 30, 27.0 ± 4.1} –
Nut (parking brake cable bracket mounting) 50.6 ± 4.4 {37 ± 3.2, 5.2 ± 0.4} –

Molybdenum disulfide grease
Drive pinion spline As required
[NLGI No. 2 (Li soap)]
Mating surface of clutch housing and engine ThreeBond 1215 As required
Removal procedure
Removal: Transmission
• Support the transmission on the transmission jack and remove
transmission mounting bolts.
• Insert a screwdriver into the three removal grooves and remove

the transmission from the engine.
• Move the transmission backward until the spline of the drive pin-
ion is detached from the clutch.
CAUTION
• Make sure that you pull the transmission out in a straight
line. If you seesaw the transmission violently, you will dam-
age the spline that connects the drive pinion and the clutch.
• When the oil stain is found inside of clutch housing after remov-
ing the transmission, check the oil leakage portion of transmis-
sion or engine and replace the defective part.
Inspection procedure
Inspection: Cushion rubber
• Inspect the entire circumference of the cushion rubber for
cracks, breaks, oil or other problems.
• If a problem is found, replace the cushion rubber.
22-15
REMOVAL AND INSTALLATION OF TRANSMISSION
Installation procedure
Installation: Mounting support and parking brake cable
bracket
• Install the mounting support and parking brake cable bracket on
the mounting support bracket.
Installation: Mounting support bracket

• Install the mounting support bracket on the gearbox.
Installation: Transmission
• Check the spline of the drive pinion for rust.
• If rust is found, remove it using a wire brush.
• Rub grease evenly onto the clutch disc sliding surface of the
drive pinion 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.
[Applying sealant]
• Apply sealant following manners shown below.
CAUTION
• Take care not to apply sealant under any of the following
conditions. Otherwise it causes water infiltration.
• There is dust, oil, grease, etc. on the mating surface.
• The diameter or thickness of the applied sealant is ex-
tremely different at each part.
• The applied sealant has some breaks.
• Use utmost care to prevent the applied sealant from cover-
ing the water drain hole on the side of the clutch housing
and engine.
<Case of using nozzle gun>

• Clean the mating surfaces of each part.
• Apply sealant on the width center of the mating surfaces so that
the diameter of the applied sealant is the same as the diameter
of the nozzle. The line of applying sealant is illustrated.
<Case of using spatula, etc.>

• Apply sealant evenly on the entire mating surfaces.
22-16
22
[Installation]
• After applying the sealant, install the transmission before the
sealant dries. Be sure not to allow the sealant to be displaced.
• Do not start the engine within one hour after installing the trans-
mission.
• When loosening or removing transmission mounting bolts, be
sure to reapply the sealant.
• Support the transmission on the transmission jack, and insert

the transmission into the pilot bearing of the flywheel paying at-
tention to the drive pinion spline.
㼀㼕㼓㼔㼠㼑㼚㼕㼚㼓㻌㼛㼞㼐㼑㼞 • Tighten the bolt clockwise with the specified torque when looking
㻯㻯 from backward of the transmission.
㻯㻯 C: M10
CAUTION
㻯㻯
㻮㼍㼏㼗㼣㼍㼞㼐㻌㼢㼕㼑㼣 • If the tightening order during transmission coupling is diag-
onal, the crankshaft end play amount may change, so tight-
㻯㻯
en clockwise as instructed.
㻯㻯
㻯㻯㻢㻜㻟㻡㻢㻤㻱
Installation: Mounting bracket

㻹㼛㼡㼚㼠㼕㼚㼓㻌㼎㼞㼍㼏㼗㼑㼠 • Install the mounting bracket on the frame.
㻮㼛㼘㼠
㻲㼞㼍㼙㼑
㻼㻡㻜㻝㻢㻣㻜㻱
Installation: Cushion rubber

• Install the cushion rubber on the mounting bracket and mounting
support.
Work after installation

Inspection and adjustment:
• Inspect and adjust the parking brake lever. (See Gr36.)
• After coupling the manual transmission, check that the crank-
shaft end play amount is within the standard value. (See Gr11)
22-17
GEAR SHIFTER UPPER, INTERLOCK PLATE
Removal sequence
1 Gear shifter upper
(See later section.)
2 Poppet spring plate
3 Poppet spring
4 Steel ball
5 Backup lamp switch
6 Torque limit switch
7 Stopper plate
8 Interlock plate
*a: Transmission case

: Locating pin
: Non-reusable parts
Service standards (Unit: mm {in.})

Location Maintenance item Standard value Limit Remedy
61.2 ± 5.9 N 43 N
3 Poppet spring installed load (installed length 21.7) {14 ± 1.3 lbs, {9.7 lbs, Replace
6.24 ± 0.6 kgf} 4.4 kgf}

Bolt (gear shifter upper mounting)
Bolt (poppet spring plate mounting) 23.5 {17, 2.4} –
Bolt (plate mounting)
Backup lamp switch 29.4 to 39.2 {22 to 29, 3.0 to 4.0} –
Torque limit switch 49 ± 2.9 {36 ± 2.1, 5.0 ± 0.3} –

Mating surface of gear shifter upper and transmission
case ThreeBond 1194 As required
Thread area of torque limit switch
Mating surface of poppet spring plate and transmission
case ThreeBond 1215 As required
Thread area of backup lamp switch
22-18
22
Installation: Gear shifter upper
[Applying sealant]
• Apply sealant onto the transmission case, following manners
shown below.
CAUTION
conditions. Otherwise it causes oil leak.


[Installation]
• After applying the sealant, install the gear shifter upper before
the sealant dries. Be sure not to allow the sealant to be dis-
placed.
• Do not start the engine within one hour after installing the gear
shifter upper.
• When loosening or removing gear shifter upper mounting bolts,
be sure to reapply the sealant.
22-19
Gear Shifter Upper
Disassembly sequence
1 Shift rod 8 Gear shift lever 15 Oil seal
2 Air breather 9 Gear shift sliding lever 16 Oil seal
3 Plug 10 Return spring 17 Gear shift case
4 Select poppet spring 11 Lock pin
5 Select poppet pin 12 Gear select lever : Non-reusable parts
6 Transmission neutral switch 13 Washer
7 Spring pin 14 Gear select lever
CAUTION
• Nuts used to mount the shift rod is coated with lock paint. Be sure to replace the nuts each time they are
loosened or removed.
Assembly sequence
Follow the disassembly sequence in reverse.
22-20
22
19.6 ± 2.0 N 13.7 N
4 Select poppet spring installed load (installed length 11) {4.4 ± 0.4 lbs, {3.1 lbs, Replace
1.99 ± 0.2 kgf} 1.39 kgf}
Return spring installed load 100.7 ± 10.1 N 70.6 N
10 Replace
(installed length 26.8) {23 ± 2.3 lbs, 10.27 ± 1.03 kgf} {16 lbs, 7.2 kgf}

Transmission neutral switch 49 ± 2.9 {36.0 ± 2.1, 5.0 ± 0.3} –
Nut (lock pin mounting) 6.9 {5.1, 0.7} –
Plug 33 to 49 {24 to 36, 3.4 to 5.0 –
Nut (shift rod mounting) 19 to 24 {14 to 18, 1.9 to 2.4} –

Sliding area of select poppet pin
Transmission neutral switch mounting groove of gear
shift lever
Wheel bearing grease
Sliding area of washer As required
Lip area of oil seal
Sliding area of bushing inner surface in gear shift case
and gear select lever shaft
Thread area of transmission neutral switch
ThreeBond 1194 As required
Sliding area of gear select lever and gear shift case
Special tools (Unit: mm {in.})

Mark Tool name and shape Part No. Application
Spring pin puller
A MH062445
M12  1.25 {0.05}
Removal of spring pin
Reverse shaft puller
A 03726-82000
M12  1.25 {0.05}
22-21
Removal procedure
Removal: Spring pin
• Tap the spring pin using an M4 tap.
• Insert spring pin puller with an M4 screw of appropriate
length into the spring pin, and remove the spring pin using
reverse shaft puller.
Removal: Bushing
• Remove the bushing using a screwdriver.
CAUTION
• Be careful not to damage the selector lever case.
22-22
22
Installation: Gear selector lever
• Apply grease and sealant to portions shown of the gear shift
case.
• Install the gear selector lever while turning so that the oil seal is
not damaged in the lip.
Installation: Gear shift lever

• Apply grease to the groove in the gear shift lever in which the
transmission neutral switch is to be mounted.
• Align splines such that the gear shift lever is angled as shown
relative to the gear shift slide lever.
22-23
REAR COVER AND PARKING BRAKE
1 Lock plate 5 Companion flange 10 Rear cover
2 O-ring 6 Reamer bolt 11 Pulse rotor
3 Dust plug 7 Parking brake (See Gr36.) 12 Spacer
4 Parking brake drum 8 Vehicle speed sensor
(See Gr36.) 9 Oil seal : Non-reusable parts
Assembly sequence

0.15
5 Runout at socket portion of companion flange 0 to 0.15 {0 to 0.0020} Replace
{0.0020}

Bolt (lock plate mounting) 145 to 200 {105 to 145, 15 to 20} –
Reamer bolt 52.0 to 66.7 {38 to 49, 5.3 to 6.8} –
Vehicle speed sensor 45 to 50 {33 to 37, 4.6 to 5.1} –
Bolt (rear cover mounting) 44.5 {33, 4.5} –

O-ring Wheel bearing grease
As required
Lip area of oil seal [NLGI No. 2 (Li soap)]
Contact surface of transmission case and rear cover ThreeBond 1215 As required
22-24
22
Flange puller
A B C MH061848 Removal of companion flange

95 100 90
{3.74} {3.94} {3.54}
Oil seal installer
A B C MH062691 Installation of oil seal

64 50 17
{2.52} {1.97} {0.67}
Removal procedure
Inspection: Runout at socket portion of companion flange
• After removing the parking brake drum, measure the runout at
the socket portion of the companion flange.
• If the measured value exceeds the limit, replace the companion
flange.
Removal: Companion flange
Installation: Oil seal
• Apply grease to the lip area of the oil seal.
• Install the oil seal in the rear cover in the illustrated direction us-
ing .
22-25
REAR COVER AND PARKING BRAKE
Installation: Rear cover
[Applying sealant]
• Apply sealant following manners shown below.
CAUTION


[Installation]
• After applying the sealant, install the rear cover before the seal-
ant dries. Be sure not to allow the sealant to be displaced.
• Do not start the engine within one hour after installing the rear
cover.
• When loosening or removing rear cover mounting bolts, be sure
to reapply the sealant.
Installation: Lock plate

• Apply grease to the O-ring and install it between the companion
flange and mainshaft.
• Install the lock plate with the lock bolt facing the “U”-marked side
of the lock plate toward the rear of the vehicle.
22-26
22
M E M O
22-27
REVERSE IDLER GEAR
1 Power take-off cover <Without power take-off> 4 Reverse idler gear
Transmission power take-off 5 Side washer
<With power take-off> (See later section.)
2 Reverse idler gear shaft
3 Side washer
*a:: Transmission case
Non-reusable parts
Assembly sequence

0.045 to 0.107
Play in diameter direction of reverse idler gear 0.4 {0.016}
{0.0018 to 0.0042}
– Replace
0.22 to 0.68
End play of reverse idler gear 1.0 {0.039}
{0.0087 to 0.027}

Bolt (power take-off cover or transmission power take-off
44.5 {33, 4.54} –
mounting)

Mating surface of power take-off cover and transmission
Loctite 5999 As required
case
22-28
22
Transmission power take-off mounting surface of trans-
mission case
Thread area of bolt (only when reusing the bolt) Scotch-Grip 2353 (3M™) As required

Reverse shaft puller
A 03726-82000 Removal of reverse idler gear shaft

M12  1.25 {0.05}
Removal procedure
Removal: Power take-off cover
• Insert a scraper from the lower right or lower left of the power
take-off cover to remove the power take-off cover.
CAUTION
• Beware that prying the scraper halfway could deform the
power take-off cover or damage the transmission case.
Inspection: Reverse idler gear

(1) Play in diameter direction
• After the power take-off cover or transmission power take-off is
removed, perform the following check. If the measurement ex-
ceeds the limit, replace defective parts.
• Check the play again after assembly and make sure it does not
exceed the limit.
(2) End play

• Measure the end play using feeler gauge.
22-29
REVERSE IDLER GEAR
Installation: Power take-off cover or transmission power
take-off
[Applying sealant]
• Apply the sealant onto the transmission case, following manners
shown below.
CAUTION
• Remove any sealant remaining in the bolt holes before in-
stallation. Otherwise damage may result.

• Apply sealant on the width center of the mating surface so that
601890

[Installation]
• Install the power take-off cover or transmission power take-off
according the following manners after applying the sealant. Be
sure not to allow the sealant to be displaced.
Power take-off cover: Install in three minutes
Transmission power take-off: Install before sealant dries
• Do not start the engine within one hour after installing the power
take-off cover or transmission power take-off.
• When loosening or removing power take-off cover or transmis-
sion power take-off mounting bolts, be sure to reapply the seal-
ant.
• If the bolts marked with are to be reused, apply sealant to bolt
threads.
22-30
22
M E M O
22-31
TRANSMISSION BODY
1 Inspection plug 10 Oil separator <Except with large-capacity type
2 Drain plug power take-off>
3 Snap ring 11 Shift rail and shift fork (See later section.)
4 Mainshaft rear bearing 12 Countershaft (See later section.)
5 Snap ring 13 Drive pinion (See later section.)
6 Snap ring 14 Mainshaft (See later section.)
7 Countershaft rear bearing 15 Clutch housing
8 Transmission case
9 Bearing retainer : Locating pin
CAUTION
• After removing direct power cylinder, perform work with the transmission body laid vertically on its clutch
housing side. (See Gr21.)
• If the countershaft, drive pinion and mainshaft are not disassembled, the shift rail and shift fork can be disassem-
bled on its own while mounted on the clutch housing.
Assembly sequence
22-32
TRANSMISSION BODY
Bolt (direct power cylinder mounting)
Bolt (bearing retainer mounting) 44.5 {33, 4.5} –
Bolt (rear bearing retainer mounting)
Inspection plug
68.6 ± 14.7 {51 ± 11, 7.0 ± 1.5} Sealant
Drain plug
Bolt (transmission case mounting) 54 {40, 5.5} –

Clutch housing mounting surface of direct power cylinder
Transmission case mounting surface of clutch housing

Snap ring expander MH061268 Removal and installation of snap ring
Bearing puller and in-

staller
A B
Removal of mainshaft rear bearing
82 50.5
{3.23} {1.99}

staller
A B Installation of mainshaft rear bearing
94 48
{3.70} {1.89}
MH062696
staller
A B
Removal of countershaft rear bearing
76.8 30
{3.02} {1.16}

staller
A B Installation of countershaft rear bear-
ing
80 42
{3.15} {1.65}
22-34
22
Eyebolt
A MH062340 Lifting of transmission case

M10  1.5
{0.06}
Steel lifting band
A MH063409
251
{9.88}
Removal and installation of counter-
shaft, mainshaft and drive pinion
Eyebolt
A MH063515
M14  1.5
{0.06}
Synchromesh guard
A B For preventing synchromesh from

MH062888
sticking when mainshaft is driven
98 29.9
{3.86} {1.18}
Removal procedure
Removal: Mainshaft rear bearing
• Remove the mainshaft rear bearing using .
Removal: Countershaft rear bearing

• Remove the countershaft rear bearing using .
22-35
22
Removal: Transmission case
• Install on the transmission case and make preparations for
lifting it up with a crane.
• After removing the bolts, lift up the transmission case while hit-
ting the rear end portions (arrow indicating) of the countershaft
and mainshaft and the rear rib portions (arrow indicating) of the
clutch housing with a plastic hammer to remove the transmis-
sion case.
CAUTION
• Be sure to hit the ribs as illustrated because hitting other
areas may break the clutch housing.
• Secure the countershaft and the 2nd gear area of the mainshaft
with for safety. Be sure to tighten enough to prevent it
from coming undone, but not excessively.
22-35
TRANSMISSION BODY
Removal: Shift rail and shift fork, countershaft, drive pinion
and mainshaft
• Leave the countershaft and mainshaft secured with .
• Install on the mainshaft and make preparations for lifting it
up with a crane.
• Secure the shift rail and shift fork with a rubber band to prevent it
from coming undone from the mainshaft.
• Put a piece of wood on the clutch housing and lift it up while hit-
ting it with a plastic hammer to remove.
• When lifting up, be sure to support the drive pinion with your
hand to prevent it from falling.
Installation: Shift rail and shift fork, countershaft, drive pin-
ion and mainshaft
• When driving in the drive pinion, mainshaft and countershaft, in-
stall to prevent the drive pinion and synchronizer of the
mainshaft from sticking.
• Place the synchronizer sleeve of mainshaft in neutral position
before installing the shift rail and shift fork on the mainshaft.
• Be sure to remove all the special tools used.
Installation: Transmission case

[Applying sealant]
• Applying sealant onto the clutch housing, following manners
shown below.
CAUTION

• Apply sealant on the width center of the mating surface so that

22-36
22
[Installation]
• After applying the sealant, install the transmission case before
the sealant dries. Be sure not to allow the sealant to be dis-
placed.
• Do not start the engine within one hour after installing the trans-
mission case.
• When loosening or removing transmission case mounting bolts,
be sure to reapply the sealant.
Installation: Countershaft rear bearing

• Install the countershaft rear bearing on the transmission case in
the illustrated direction using .
Installation: Mainshaft rear bearing

• Install the mainshaft rear bearing on the transmission case in the
illustrated direction using .
22-37
TRANSMISSION BODY
Shift Rail and Shift Fork
1 Spring pin 10 Spring pin
2 Spring pin 11 Spring pin
3 3rd and 4th shift jaw 12 5th and reverse shift jaw
4 3rd and 4th shift rail 13 5th and reverse shift rail
5 3rd and 4th shift fork 14 5th and reverse shift fork
6 Spring pin
7 1st and 2nd shift rail
*a: Mainshaft (synchronizer sleeve)
8 1st and 2nd shift fork : Non-reusable parts
9 Shift fork piece
Assembly sequence

0 to 0.04 Correct or
4, 7, 13 Bend of shift rail 0.05 {0.002}
{0 to 0.0016} replace
5, 14 Tilt of shift fork claw 0.1 {0.0039} or less 0.2 {0.0079} Replace
0.3 to 0.6
*
5, 14, a Clearance between shift fork and synchronizer sleeve
{0.012 to 0.024}
1.0 {0.039} Replace
Clearance between gear shift fork piece and synchro- 0.3 to 0.6
9,
*a nizer sleeve {0.012 to 0.024}
1.0 {0.039} Replace
22-38
22
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 rail.
• If the measurement exceeds the limit, replace the gear shift rails.
Inspection: Tilt of shift fork claw

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

sleeve of mainshaft
• If the measurement exceeds the limit, replace defective part.
Inspection: Clearance between shift fork piece and syn-

chronizer sleeve of mainshaft
• If the measurement exceeds the limit, replace defective parts.
22-39
TRANSMISSION BODY
Installation: Shift fork piece
• Install the shift fork piece on the shift fork as shown in the illus-
tration.
Installation: Spring pin

• Install the spring pin in the illustrated direction (the spring pin
notch to be positioned forward or rearward of the vehicle). When
installing the spring pin, leave 0 to 0.5 mm {0 to 0.020 in.} out-
side from each shift rail or each shift jaw.
• Drive the spring pin carefully so as not to impose too much load
on each shift rail and each shift jaw.
22-40
22
M E M O
22-41
DRIVE PINION
1 Snap ring
2 Drive pinion bearing
3 Drive pinion
Assembly sequence
Follow the disassembly sequence in re-
verse.
P56586


staller
A B
Removal of drive pinion bearing
92.5 62.5
{3.64} {2.46}
MH062696

staller
A B Installation of drive pinion bearing
94 48
{3.70} {1.89}
22-42
22
Removal procedure
Removal: Drive pinion bearing
• Remove the drive pinion bearing using .
Installation: Drive pinion bearing
• Install the drive pinion bearing, facing the grooved side in the il-
lustrated direction using .
22-43
MAINSHAFT
1 5th gear thrust washer 14 3rd gear thrust washer
2 5th gear 15 Snap ring
3 Needle bearing 16 2nd gear thrust washer
4 Snap ring 17 2nd gear
5 5th and reverse synchronizer (See later section.) 18 Needle bearing
6 Reverse gear 19 Snap ring
7 Needle bearing 20 1st and 2nd synchronizer (See later section.)
8 Snap ring 21 1st gear
9 Pilot bearing 22 Needle bearing
10 Snap ring 23 Mainshaft
11 3rd and 4th synchronizer (See later section.)
12
13
3rd gear
Needle bearing
*a: Drive pinion
Assembly sequence
22-44
22
0.15 to 0.46 0.7
1st gear
{0.0059 to 0.018} {0.028}
0.15 to 0.61 0.8
2nd gear
{0.0059 to 0.024} {0.031}
0.15 to 0.46 0.7
– End play 3rd gear Replace
{0.0059 to 0.018} {0.028}
0.1 to 0.46 0.7
5th gear
{0.0039 to 0.018} {0.028}
0.15 to 0.46 0.7
Reverse gear
{0.0059 to 0.018} {0.028}
0.02 to 0.06 0.12
1st gear
{0.00079 to 0.0024} {0.0047}
0.02 to 0.06 0.12
2nd gear
{0.00079 to 0.0024} {0.0047}
Play in the diameter 0.02 to 0.06 0.12
– 3rd gear Replace
direction {0.00079 to 0.0024} {0.0047}
0.02 to 0.05 0.12
5th gear
{0.00079 to 0.0020} {0.0047}
0.05 to 0.08 0.12
Reverse gear
{0.0020 to 0.0031} {0.0047}
5th gear and 5th and reverse 1.02 to 1.49 0.5
synchronizer {0.040 to 0.059 {0.020}
Reverse gear and 5th and 1.07 to 1.43 0.5
reverse synchronizer {0.042 to 0.056} {0.020}
3rd gear and 3rd and 4th 1.02 to 1.49 0.5
Clearance between synchronizer {0.040 to 0.059} {0.020}
– gear and synchronizer Replace
ring Drive pinion and 3rd and 4th 1.02 to 1.49 0.5
synchronizer {0.040 to 0.059} {0.020}
2nd gear and 1st and 2nd 1.02 to 1.49 0.5
synchronizer {0.040 to 0.059} {0.020}
1st gear and 1st and 2nd 1.02 to 1.49 0.5
synchronizer {0.040 to 0.059} {0.020}
0.04 to 0.08 0.12
9 Play in the diameter direction of pilot bearing Replace
{0.0016 to 0.0031} {0.0047}
Special tools
Work before removal
22-45
MAINSHAFT
Inspection: End play of gears
• Measure the end play using feeler gauge.
22-46
22
Inspection: Play in diameter direction of gears
Alignment marks: Each gear and each synchronizer

• Put alignment marks on the each gear and the synchronizer
sleeve of the each synchronizer so that the combination of their
mating surfaces can be maintained when reassembled.
Inspection: Clearance between gear and synchronizer outer
ring of synchronizer
<Triple cone type>
• When measuring the clearance, press the ring and the center
cone evenly against the gear and measure all around the cir-
cumference.
• If the measurement is less than the limit, replace the ring and the
gear.
<Single cone type>

• When measuring the clearance, press the ring evenly against
the gear and measure all around the circumference.
• If the measurement is less than the limit, replace the ring and the
gear or the drive pinion.
Inspection: Play in diameter direction of pilot bearing

• Carry out the measurement with installing the drive pinion, pilot
bearing and mainshaft and holding the mainshaft as illustrated.
• Measure the play with moving the gear of drive pinion in diame-
ter direction.
• If the measurement exceeds the limit, replace the pilot bearing.
22-47
MAINSHAFT
5th and Reverse Synchronizer
1 Synchronizer ring
2 Synchronizer sleeve
3 Shifting plunger
4 Shifting plunger spring
5 Synchronizer hub
Assembly sequence
verse.

Clearance between synchronizer ring protrusion and 3.0 to 3.3 4.0
1, 5 Replace
synchronizer hub groove {0.12 to 0.13} {0.16}
Work before removal

Alignment marks
• Put alignment marks on the synchronizer ring and hub, each at
one location aligning with the alignment mark put on the syn-
chronizer sleeve before disassembly.
Inspection: Clearance between synchronizer ring protru-
sion and synchronizer hub groove
• If the clearance exceeds the limit, replace defective parts.
22-48
22
Installation: Synchronizer sleeve and synchronizer hub
• When replacing the synchronizer sleeve or synchronizer hub
with a new one, align the three keyways of the synchronizer hub
with three locations of the stub gear tooth of the synchronizer
sleeve to install.
22-49
MAINSHAFT
3rd and 4th Synchronizer
1 Synchronizer ring
2 Synchronizer inner ring
3 Synchronizer center cone
4 Synchronizer outer ring
6 Shifting plunger
8 Synchronizer hub
Assembly sequence
verse.

Clearance between synchronizer ring protrusion and 3.0 to 3.3
1,8 4.0 {0.16} Replace
synchronizer hub groove {0.12 to 0.13}
Clearance between synchronizer outer ring protrusion 3.0 to 3.3
4, 8 4.0 {0.16} Replace
and synchronizer hub groove {0.12 to 0.13}
Work before removal

Alignment marks
• Put alignment marks on the synchronizer ring, 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: Clearance between synchronizer outer ring pro-
trusion and synchronizer hub groove
22-50
22
sleeve to install.
22-51
MAINSHAFT
1st and 2nd Synchronizer
1 Synchronizer inner ring
2 Synchronizer center cone
3 Synchronizer outer ring
5 Shifting plunger
7 Synchronizer hub
Assembly sequence
verse.

Clearance between protrusions of synchronizer outer 3.0 to 3.3
3, 7 4.0 {0.16} Replace
ring and synchronizer hub groove {0.12 to 0.13}
Work before removal

Alignment marks
• 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: Clearance between synchronizer outer ring and
synchronizer hub
22-52
22
sleeve to install.
22-53
COUNTERSHAFT
1 Snap ring
2 Countershaft front bearing
3 Countershaft 5th gear
4 Countershaft gear
Assembly sequence
verse.

Entire periphery of fitting portions between countershaft
5th gear and countershaft gear


staller
A B
Removal of countershaft front bearing
72 49.5
{2.83} {1.95}
MH062696
staller
Installation of countershaft front bear-
A B ing
80 42
{3.15} {1.65}
Removal procedure
Removal: Countershaft front bearing
• Remove the countershaft front bearing using .
22-54
22
Installation: Countershaft front bearing
• Install the countershaft front bearing on the countershaft in the il-
lustrated direction, using .
22-55
TRANSMISSION CONTROL
Removal sequence
1 Gear shift lever knob 10 Gear shift lever bracket
2 Clip 11 Shift lever (See later section.)
3 Adjuster 12 Transmission cable bracket
4 Select cable
5 Shift cable
*a: Gear shift lever
6 Collar
*b: Gear selector lever
7
8
Instrument panel bracket
Gear shift control lever (See later section.)
*c:: Shift rod
Non-reusable parts
9 Gear shift lever stay
CAUTION
• Nuts used to mount the cables are coated with lock paint. Be sure to replace the nuts each time they are
loosened or removed.
22-56
22
Nut (shift cable mounting)
19 to 24 {14 to 18, 1.9 to 2.4} –
Nut (select cable mounting)
Lock nut on transmission side of shift cable 59 to 83 {44 to 61, 6.0 to 8.5} –
Bolt (transmission cable bracket mounting)
37 to 53 {27 to 39, 3.8 to 5.4} –
Bolt (shift lever mounting)
Nut (adjuster mounting) 4 to 6 {3.0 to 4.4, 0.4 to 0.6} –
Nut (select cable mounting) 10 to 15 {7.4 to 11.0, 1.0 to 1.5} –

Wheel bearing grease
Sliding surface of adjuster and gear shift control lever As required
Inspection: Shift cable, select cable
• Check the damage and deformation to the attached parts of
clamp and bracket. If any fault is found, replace the fault parts.
• Check the motion of cable, bend of limited parts and damage of
the cable. If any fault is found, replace the cable.
• Check the damage to the cable boot and ball joint. If any fault is
found, replace the cable.
Installation: Shift lever
• Install the shift lever on the transmission case in the illustrated
direction.
22-57
Installation: Shift cable, select cable
• Allow a bending radius of 260 mm {10.2 in.} or more during stor-
age and handling of the cables. Keep a bending radius as much
as possible even after the cables are installed.
• Install the cable such that only a minimal bending force is ap-
plied to the under head portion of the casing cap.
• Avoid subjecting the guide pipe movable portion at the cable end
to movement exceeding a permissible angle of 5 degrees.
• Make sure that each clamp is installed with the same orientation
as that before removal.
• Where cable clamping positions are identified with a mark, install
the clamp in such a way that it covers the marking completely.
• Install each clamp such that it is perpendicular to the cable.
• Make sure that the joint at the cable end is installed with the
same orientation as that before removal.
• If there is an uneven contact between the holder portion boot
and stud portion of the ball joint at the cable end, or if the cable
boot kinks, remove the cable from the levers on both ends of the
cable and perform the following adjustment procedure:
• Rotate the cable rod to remove the kink from the cable boot.
• Loosen the cable nut and adjust orientation of the ball joint
within a half turn.
CAUTION
• To prevent damage, check that the engagement margin in
threads between the ball joint and cable rod is 8 mm {0.31
in.} or more.
• Apply to the sliding area as shown.

• Install the shift cable and the select cable.
22-58
22
• Fix the cables to the cable brackets with clips and nuts with care
not to allow an excessive force to be applied to the shift cable
and select cable.
• Insert the clip to end of ditch.
CAUTION
• When fixing the cable with the clip, use care not to damage
the cable cover.
Adjustment: Select position

• With the cables connected, place the gear shift control lever in
the 3rd or 4th speed position so that it stays on the 3rd-4th line
(neutral line).
• Loosen the nuts on both ends of the adjuster.

• When the nuts are loosened, the gear shift control lever is set to
the N (neutral) position by the spring force of the return spring on
the gear shift control lever.
• Tighten the nuts on both ends of the adjuster to the specified

torque so that the adjuster and the select lever on the gear shift
control lever will not move.
CAUTION
• Be careful not to twist the adjuster when tightening the nuts
on both ends of the adjuster.
22-59
• Return the gear shift control lever to the N (neutral) position and
check that select strokes A and B shown in the illustration are
equal.
• Check that the gear shift control lever can be smoothly returned
to the N (neutral) position.
• If there is a problem, make adjustment again.
䠘㻳㼑㼍㼞㻌㼟㼔㼕㼒㼠㻌㼏㼛㼚㼠㼞㼛㼘㻌㼘㼑㼢㼑㼞㻌㼟㼕㼐㼑䠚
Adjustment: Shift position
• If the gear cannot be shifted smoothly, adjust the engagement
㻮㼍㼘㼘㻌㼖㼛㼕㼚㼠
length between the cable thread at gear shift control lever side
or at transmission side and the ball joint thread as follows.
• Remove the ball joint from the lever.
• Loosen the cable nut at the ball joint.
㻳㼑㼍㼞㻌㼟㼔㼕㼒㼠 • Adjust the engagement length by rotating the ball joint.
㻯㼏㼛㼚㼠㼞㼛㼘㻌㼘㼑㼢㼑㼞
<In case the gear cannot be shifted to front row speeds (1st, 3rd
and 5th) smoothly>
㻿㼔㼕㼒㼠㻌㼏㼍㼎㼘㼑 • Lengthen dimension C as illustrated in the figure and move the
gear shift lever backward.
䠘㼀㼞㼍㼟㼙㼕㼟㼟㼕㼛㼚㻌㼟㼕㼐㼑䠚
<In case the gear cannot be shifted to back row speeds (R, 2nd
and 4th) smoothly>
• Shorten dimension C as illustrated in the figure and move the
gear shift lever forward.
㻿㼔㼕㼒㼠㻌㼏㼍㼎㼘㼑㻯㻮㼍㼘㼘㻌㼖㼛㼕㼚㼠
601541
22-60
22
• As target number of adjustment, make sure dimension D as il-
lustrated in the figure between the gear shift control lever and
the upper center panel is approximately 300 mm {11.8 in.} when
the gear shift control lever is at N (neutral) position.
• Install the ball joint not to contact its stud with boot unevenly and
tighten the nut by specified torque.
CAUTION
• Make sure the engagement length between the ball joint
thread and the cable thread is 8 mm {0.31 in.} or more.
22-61
Gear Shift Control Lever
1 Shift lever
2 Lever support
3 Insulator
4 Case
5 Bushing
6 Shift rod
7 Case
8 Return spring
9 Pipe
10 Shift bushing
11 Select lever
12 Plate
Assembly sequence
verse.

Bolt (shift lever mounting) 19 to 28 {14 to 21, 1.9 to 2.8} –
Bolt (lever support mounting) 4 to 6 {3.0 to 4.4, 0.4 to 0.6} –
Bolt (selector lever mounting) 10 to 15 {7.4 to 11.0, 1.0 to 1.5} –

Sliding area of case and shift rod
Internal circumference and circumference of bushing
Multipurpose grease
Entire return spring As required
Internal circumference and circumference of shift bush-
ing
22-62
22
Shift Lever
1 Washer
2 Lever bracket
3 Shift bushing
4 Lever
Assembly sequence
verse.

Nut (lever bracket mounting) 27 to 34 {20 to 25, 2.8 to 3.5} –

Internal circumference and circumference of shift bush- Wheel bearing grease
As required
ing [NLGI No. 2 (Li soap)]
22-63
TRANSMISSION POWER TAKE-OFF
1 Clip 9 Set bolt 17 Power take-off shift fork
2 Clip bracket 10 Power take-off companion 18 Bearing
3 Bracket flange 19 Oil seal
4 Clevis pin 11 Sunk key 20 Oil seal
5 Vacuum chamber 12 Bearing 21 Oil seal
(See later section.) 13 Power take-off shaft 22 Power take-off case
6 Front cover 14 Power take-off gear
7 Shift clevis 15 Power take-off shift sleeve : Locating pin
8 Power take-off control switch 16 Power take-off shift rail : Non-reusable parts
Assembly sequence
22-64
22
0.07 to 0.11
13, 14 Play in diameter direction of power take-off gear 0.2 {0.0079} Replace
{0.0028 to 0.0043}
Clearance between power take-off shift sleeve and 0.3 to 0.5
15, 17 1.0 {0.039} Replace
power take-off shift fork {0.012 to 0.020}

Bolt (bracket, vacuum chamber and front cover mounting) 23.2 {17, 2.37} –
Vacuum chamber joint mounting nut 9.8 to 15.6 {7.2 to 12.0, 1.0 to 1.6} –
Power take-off control switch 49 {36, 5} Sealant
Power take-off shift fork mounting section on power take-off
83.4 {62, 8.5} –
shift rail
Nut (clip bracket mounting) 12.7 {9.4, 1.3} –
Set bolt
11.2 {8.3, 1.14} –
Nut (power take-off companion flange mounting)

Threads of power take-off control switch ThreeBond 1105 As required
Sliding section of clevis pin Wheel bearing grease
As required
Oil seal lips [NLGI No. 2 (Li soap)]
Power take-off case mating surface of front cover
Outer circumference of oil seal
Work before removal

Removal: Transmission power take-off
• Remove the transmission power take-off. (See “REVERSE
IDLER GEAR”.)
Inspection: Play in the diameter direction of power take-off

gear
22-65
Inspection: Clearance between power take-off shift sleeve
and power take-off shift fork
Installation: Oil seal
• Apply sealant to the outer circumference of the oil seal A.
• Apply grease to the oil seal A, B lips and install the oil seals to
the power take-off case.
Installation: Rail tube

• Install the rail tube to the power take-off case.
Installation: Power take-off companion flange

• Install the power take-off companion flange to the power take-off
case and install the nut and set bolt.
22-66
22
Installation: Power take-off control switch
• Apply sealant to the threads of the power take-off control switch
and install it to the power take-off case.
Installation: Shift clevis

• Install the shift clevis while adjusting the distance from the center
of the shift clevis hole to the end surface of the power take-off
case as shown in the drawing.
Installation: Vacuum chamber

• Apply sealant to the power take-off case mating surface of the
front cover. Install the vacuum chamber and front cover to the
power take-off case.
• Measure the distance between the centers of the holes in the
shift clevis lever.
• If the measurement does not match the value shown in the
drawing, adjust by turning the shift clevis or joint.
• If the adjustment is performed by turning the joint, secure the
overlap of the joint and the rod of the vacuum chamber by 8
threads or more.
• After adjustment, tighten the nut to the specified torque.
• Push in the joint to align the holes in the lever and shift clevis
and connect them with the clevis pin.
• Apply to the sliding surface of the clevis pin before install-
ing the clevis pin.
Installation: Bracket and clip bracket

• Install the bracket and clip bracket as shown in the drawing.
22-67
Work after installation
Adjustment: Vacuum chamber
• Measure the distance from the bottom of the vacuum chamber
to the center of the hole in the joint.
• If the measurement does not match the value shown in the
drawing, adjust by turning the joint. In this case, secure the over-
lap of the joint and the rod of the vacuum chamber by 8 threads
or more.
• After adjustment, tighten the nut to the specified torque.
䣽䢷䢰䢻䢵䢰䣫䣰䣿
601895
Installation: Transmission power take-off
• Install the transmission power take-off. (See “REVERSE IDLER
GEAR”.)
22-68
22
Vacuum Chamber
1 Clevis pin
2 Clevis pin
3 Lever
4 Joint
5 Vacuum chamber
6 Gasket
7 Bearing
8 Bracket
Assembly sequence
verse.

Airtightness of vacuum chamber (Inspection vacuum: Vacuum: 63 kPa
5 66.7 kPa {9.67 psi, 0.68 kgf/cm2} 66.7 kPa {500 {9.14 psi, 0.64 kgf/cm2} – Replace
mmHg}, 15 seconds) or more

Nut (mounting joint)
9.8 to 15.6 {7.2 to 12.0, 1.0 to 1.6} –
Nut (mounting vacuum chamber)

Mounting threads of vacuum chamber ThreeBond 1211 As required
22-69
Inspection: Vacuum chamber
• Connect the vacuum pump, check valve and vacuum gauge to
the vacuum chamber as shown in the drawing. Using the vacu-
um pump, apply specified vacuum to the vacuum chamber.
• After 15 seconds, read the vacuum on the vacuum gauge.
• If the measurement is out of the standard value, replace the vac-
uum chamber.
Installation: Vacuum chamber
• Apply sealant to the threads of the vacuum chamber and install it
to the bracket in the direction shown in the drawing.
Installation: Joint
• Install the joint so that the distance from the bottom of the vacu-
um chamber to the center of the hole in the joint should be as
shown in the drawing. Then tighten the nut to the specified
torque.
䣽䢷䢰䢻䢵䢰䣫䣰䣿
601894
22-70
BEARING PULLER AND INSTALLER 22
• Bearing pullers and installers are special tools used for removing and installing the bearings listed in the table be-
low and used in this group.
• For each puller (for removing) and each installer (for installing), use the components of the bearing pullers and in-
stallers in combination.
Application
Countershaft front bearing
Countershaft rear bearing

Mainshaft rear bearing
Drive pinion bearing
Component
Bearing
puller and Component Part No. Puller Installer Puller Installer Puller Installer Puller Installer
installer
Adapter MH062590
Plug 03726-81017 O O O O
Bolt MH062700 O O O O
Body MH062701 O O O O O O O O
Protector MH061306 O O O O
MH062696
Countershaft
03726-81012 O
bearing claw
Bearing claw MH062707 O
Mainshaft
MH061305 O
bearing claw
Bearing claw MH062706 O
22-71

Manual Transmision FL

Cargado por

Información del documento

Descripción original:

Título original

Derechos de autor

Formatos disponibles

Compartir este documento

Compartir o incrustar documentos

Opciones para compartir

¿Le pareció útil este documento?

¿Este contenido es inapropiado?

Copyright:

Formatos disponibles

Manual Transmision FL

Cargado por

Copyright:

Formatos disponibles

FUSO

Pub. No. 00ELT0183

SPECIFICATIONS.................................. 22-2 COUNTERSHAFT ................................ 22-54

STRUCTURE AND OPERATION TRANSMISSION CONTROL................ 22-56

ON-VEHICLE INSPECTION AND

REMOVAL AND INSTALLATION OF

GEAR SHIFTER UPPER,

REAR COVER AND PARKING

REVERSE IDLER GEAR ..................... 22-28

TRANSMISSION BODY....................... 22-32

DRIVE PINION ..................................... 22-42

㻿㼔㼕㼒㼠㻌㼒㼛㼞㼗 㻿㼔㼕㼒㼠㻌㼞㼍㼕㼘 㻡㼠㼔㻌㼍㼚㼐㻌㼞㼑㼢㼑㼞㼟㼑㻌㼟㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞

• The transmission uses an interlock mechanism to avoid double engagement.

2.1 Single cone type

4. Transmission Power Take-off

Gears slip out of engagement

Noise when engine is idling

Noise when changing gear

Noise when cruising

Indicator does not light though power take-off is engaged

Power take-off slips out of engagement

Power take-off does not stay engaged

Noise from power take-off

Tightening torque (Unit: N·m {ft.lbs, kgf·m})

Lubricant and/or sealant

Gear oil Approx. 3.5 L

1.1 Inspection of oil leakage at each part of transmis-

1.2 Inspection of oil leakage around transmission

2. Inspection of Looseness in Engine to Clutch Housing Connection

• Check the engine to clutch housing connection for looseness.

4. Replacement of Transmission Oil

Tightening torque (Unit: N·m {ft.lbs, kgf·m}))

Lubricant and/or sealant

5. Inspection of Transmission Mounting Cushion Rubber

• Check that the cushion rubber on the transmission mounting is

Lubricant and/or sealant

• Insert a screwdriver into the three removal grooves and remove

Installation: Mounting support bracket

<Case of using nozzle gun>

<Case of using spatula, etc.>

• Support the transmission on the transmission jack, and insert

Installation: Mounting bracket

Installation: Cushion rubber

Work after installation

*a: Transmission case

Service standards (Unit: mm {in.})

Tightening torque (Unit: N·m {ft.lbs, kgf·m})

Lubricant and/or sealant

<Case of using nozzle gun>

<Case of using spatula, etc.>

Tightening torque (Unit: N·m {ft.lbs, kgf·m})

Lubricant and/or sealant

Special tools (Unit: mm {in.})

Spring pin puller

Removal of spring pin

Reverse shaft puller

Installation: Gear shift lever

Service standards (Unit: mm {in.})

Tightening torque (Unit: N·m {ft.lbs, kgf·m})

Lubricant and/or sealant

A B C MH061848 Removal of companion flange

Oil seal installer

㻿㼔㼕㼒㼠㻌㼒㼛㼞㼗㻿㼔㼕㼒㼠㻌㼞㼍㼕㼘㻡㼠㼔㻌㼍㼚㼐㻌㼞㼑㼢㼑㼞㼟㼑㻌㼟㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞