Manual

Transmission
(M035S5)
General
Special Tool .................................................. MTB - 2
Specification ................................................. MTB - 3

Manual Transmission
Description ....................................................
Removal .......................................................
Installation ....................................................
Gear Shift Upper
Removal and Installation ........................
Disassembly and Reassembly ...............
Shift Rail and Shift Fork
Removal ..................................................
Installation ...............................................
Disassembly ...........................................
Rear Cover and Clutch Housing
Replacement ...........................................
Transmission Assembly
Disassembly and Reassembly ...............
Main Shaft
Disassembly and Reassembly ...............
Counter Shaft
Disassembly and Reassembly ...............

MTB - 5
MTB - 6
MTB - 7
MTB - 8
MTB - 9
MTB - 10
MTB - 10
MTB - 11
MTB - 13
MTB - 14
MTB - 16
MTB - 19

General
Special Tool
Tool (Number and name)

Illustration

Use

09431-45100
Oil seal installer

Installation of clutch housing oil seal

09431-5H000
Oil seal installer

Installation of front bearing retainer oil

seal

09432-5H100
Main shaft bearing installer

Installation of main shaft bearing

09432-7B000
Counter shaft bearing installer

Counter shaft bearing

09431-83100
Bearing puller set

Removal of main shaft bearing amd counter shaft bearing

Specifications
Item

Gear ratio

Specification

First

5.380

Second

3.028

Third

1.700

Fourth

1.000

Fifth

0.722

Rev

5.380

Transmission gear oil

API GL-4 80W90

API GL-4 SAE 90 (Tropics)

Oil quantity ()

Approx. 3.2 (without P.T.O)

Approx. 3.7 (with P.T.O)

Service Standards
Item

Nominal value
(Basic diameter in [ ])

Limit

Remarks

Poppet spring free length

22.85

22

Replace

4th & 5th return spring free length

39.25

37.25

Replace

1st & Rev. return spring free length

49.18

47.18

Replace

Clearance between speedometer gear and speedometer gear bush

[12] 0.04 ~ 0.08

0.15

Replace

Clearance between reverse idler gear shaft and reverse idler gear

[24] 0.05 ~ 0.08

0.2

0.1 or less

0.2

Replace

0.3~0.6

Replace

0.04 or less

0.05

Replace

Clearance between synchronizer key hole and shift key

4.7~5.0

5.7

Replace

Clearance between synchronizer ring and drive pinion

1.13~1.37

0.20

Replace

Clearance between shifting key and synchronizer hub key

hole

0.05~0.20

0.50

Replace

Clearance between 2nd gear and synchronizer outside ring

1.23~1.47

0.95

Replace

Clearance between synchronixer outside ring key hole and

shifting key

4.7~5.0

5.70

Replace

Clearnce between synchronizer outer ring and 3rd gear

1.23~1.47

0.95

Replace

Clearance between shifting key and synchronizer hub key

hole

0.05~0.20

0.50

Replace

1st gear end play

0.310~0.460

2nd gear end play

0.150~0.250

3rd gear endplay

0.160~0.460

Diaplacement of bar with respect to shift fork hole

Clearance between shift fork and synchronizer sleeve
Displacement of shift rail

Nominal value
(Basic diameter in [ ])

Item

Limit

Remarks

5th gear end play

0.210~0.560

Reverse gear end play (C/S~REV. IDLER)

0.220~0.680

Reverse gear end play (REV. IDLER~M/S)

0.160~0.460

Unit : mm

Tightening Torque
Tightening torque
Item
Nm

Kgf.m

lb-ft

54 ~ 83

5.5 ~ 8.5

39.8 ~ 61.2

48

4.8

35.4

84

8.4

62

24

2.4

17.7

30 ~ 40

3~4

22.1 ~ 29.5

Poppet screw plug

40

29.5

Poppet spring plate

24

2.4

17.7

46 ~ 52

4.7 ~ 5.3

33.9 ~ 38.4

Lock pin nut

0.7

5.2

Speedometer

29.4 ~ 39

3.0 ~ 4.0

21.7 ~ 28.8

Rear cover

45

4.5

33.2

Reverse idler gear cover

19

1.9

14

Front bearing retainer

44

4.5

32.5

Transmission case

54

5.5

39.8

Bearing retainer

49

36

Drain plug and inspection plug

Transmission and engine mounting bolt

Gear shift upper mounting bolt

Back up lamp switch

Interlock switch

Manual Transmission
DESCRIPTION

EMTTM5201A

The transmission system transmits the rotational power

generated by the engine to that(driving force) for a
vehicle. It changes the rotational power by selecting one
among many sets of gears in mesh.The transmission has
the interlock mechanism protecting the double mesh and
the non-backlash mechanism lowering the noise while

the engine is idling.

3. Lift up the cab.

REMOVAL
1. Place the wooden block(A) to the front and rear sides
of the both(LH/RH) sides rear wheels.

CAUTION
Insert suerly the safety pin(B) into the cab
stay(A) hole to prevent the cab from lowering.

KMTTM5513A

2. Disconnect battery (-) cable(A) from the battery.

EMTTM5003A

4. Disconnect the speed sensor connector, the crank

position sensor, battery (-) cable and back-up switch
connector from the transmission.
5. Remove the shift cable and the select rod(A) from the
transmission.
NOTICE
Put the transmission to the neutral position before
removing the shift cable and the select rod from the
transmission.

EMTTM5002A

EMTTM5064A

6. Remove the
transmission.

release

cylinder(A)

from

the

9. Support the transmission(A) with a jack(B) and

remove the body mounting bolts and engine
mounting bolts. Then remove the transmission from
the engine.
CAUTION
Be careful not to fall down the transmission.

EMTTM5517B

7. Remove the speed cable(A) from the transmission.

8. Remove the propeller shaft(B) from the transmission.
KMTTM5519A

NOTICE
If the transmission is not separated from the engine,
detach the transmission by inserting a flat drive(A)
into grooves(three locations) on the clutch housing.

KMTTM5518A

EMTTM5004A

INSTALLATION
Installation is the reverse of removal.
CAUTION
Be careful not to fall down the transmission.

Gear Shift Upper

Removal and Installation

EMTTM5224A

Disassembly and Reassembly

EMTTM5225A

Shift Rail And Shift Fork

REMOVAL
1. Remove and install shift rail, shift fork, counter shaft,
drive pinion, main shaft with assembly.

2. When inserting drive pinion(A), main shaft

assembly(B) and counter shaft assembly(C), install
synchro guard.

2. Insert set pin to counter shaft constant mesh gear

setting hole and fix sub gear.
3. After removing case, fix with steel lifting band.
4. Fix shift rail and shift fork on main shaft with rubber
band.
5. Lift up and remove clutch housing with drive pinion
assembly.

EMTTM5209A

3. After applying grease on sealing cap, install using the

special tool(09431-45100).

EMTTM5207A

INSTALLATION
1. Not to damage oil seal of front bearing retainer, after
covering oil seal guide on drive pinion, install each
part.

EMTTM5210A

EMTTM5208A

DISASSEMBLY

EMTTM5211A

Service Key Points

1. Be sure to install the spring pin as shown figure.

EMTTM5212A

2. Measure the clearance between gear shift fork and

synchronizer sleeve. If the clearance exceeds the
service limit, replace the parts.

EMTTM5213A

Rear cover and clutch housing

Replacement
Rear Cover and Reverse Idler Gear

EMTTM5226A

Transmission Assembly
Disassembly and Reassembly

EMTTM5202A

3. Transmission case removal.

Key Points for Installation

1. Oil seal installation.
After applying grease to the oil seal, install the oil
seal into front bearing retainer, using the special
tool(09431-5H000).

1) After removing bolts, remove clutch housing,

main shaft assembly, counter shaft assembly and
transmission case by crane etc.

EMTTM5205A
EMTTM5203A

2. Front bearing retainer installation.

2) After removing transmission case, fix 2nd gear

part with steel lifting band.

Guide oil seal guide on drive pinion and install front

bearing retainer.

EMTTM5206A

EMTTM5204A

Main Shaft
Disassembly and Reassembly

EMTTM5214A

3. Remove snap rings(B) from the main shaft using a

snap ring plier(A).

Service Key Points

1. End play of each gear.
A : 1st gear
B : Reverse gear
C : 2nd gear
D : 3rd gear
E : 5th gear
If the end play exceeds the service limit, replace the
parts.

EMTTM5217A

4. Measure the clearance between synchronizer ring(A)

or synchronizer outer ring and shafting key(B).
If the clearance exceeds the service limit, replace the
parts.

EMTTM5215A

2. Measure the play in diametral direction of main shaft

gears and needle roller bearing. If the play exceeds
the service limit, replace the parts.

EMTTM5218A

EMTTM5216A

5. Measure the clearance(A) between synchronizer ring

and each gear assembly.
If the clearance exceeds the service limit, replace the
parts.

EMTTM5221A

8. Remover the snap ring.

EMTTM5219A

6. Measure the clearance between shifting key and

synchronizer hub. If the clearance exceeds the
service limit, replace the parts.

EMTTM5231A

9. Remove the drive pinion bearing using the special

service tool(09431-83100)

EMTTM5220A

7. Measure the clearance(A) between each gear

assembly and synchronizer outer ring. If the
clearance exceeds the service limit, replace the
parts.

EMTTM5223A

10.Reassembly is the reverse of disassembly.

Counter Shaft
Disassembly and Reassembly

EMTTM5222A

1. Remove the snap ring using a snap ring plier.

2. Counter shaft rear bearing

1) Remove
Remove the counter shaft bearing using the
special
service
tool(09431-83100
or
09434-5H000).

EMTTM5232A

EMTTM5233A

2) Installation
Installation the counter shaft bearing using the
special service tool(09434-5H100).

EMTTM5209A