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MANUAL TRANSMISSION
Page
DESCRIPTION.................................................... MT-2
PRECAUTIONS .................................................. MT-3
TROUBLESHOOTING .......................................... M T - 3
REMOVAL AND INSTALLATION OF
TRANSMISSION ............................................. M T - 4
Removal of Transmission ................................ MT-4
Installation of Transmission ............................. MT-6
( W 5 8 TRANSMISSION)
Components .................................................. MT-9
DISASSEMBLY OF TRANSMISSION ..................... MT-11
COMPONENT PARTS ......................................... MT- 1 9
Input Shaft Assembly ..................................... MT-19
Output Shaft Assembly ................................... MT-21
Counter Gear and Reverse ldler Gear ................ MT-28
Front Bearing Retainer ..................................... MT-33
Extension Housing .......................................... M T - 3 4
ASSEMBLY OF TRANSMISSION .......................... MT-37
(R154 TRANSMISSION)
Components .................................................. MT-49
DISASSEMBLY OF TRANSMISSION ..................... MT-51
COMPONENT PARTS .........................................
Input Shaft Assembly ..................................... MT-59
Output Shaft Assembly ................................... MT-61
MT-59 rn
Counter Gear and Reverse Idler Gear ................ MT-69
Front Bearing Retainer..................................... MT-72
Extension Housing .......................................... MT-73
ASSEMBLY OF TRANSMISSION .......................... MT-76
MT-2 MANUAL TRANSMISSION - Description
DESCRIPTION
Transmission
Transmission types W58 and R 154 are constant mesh synchronizers for forward gear and a sliding mesh
reverse gear.
The specifications and cross-section diagram are a shown.
Specifications
Transmission Type W58 R154
Type of Engine
Item 7M-GE 7M-GTE
1st 3.285 3.251
Gear Ratio
PRECAUTIONS
When working w i t h FIPG material, you must be observe the following.
Using a razor blade and gasket scraper, remove all the old packing(F1PG)materiaI from the gasket surfaces.
Thoroughly clean all components t o remove all the loose material.
Clean both sealing surfaces w i t h a non-residue solvent.
Apply the seal packing in approx. 1 m m (0.04 in.) bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must
be removed and reapplied.
TROUBLESHOOTING
I Problem Possible cause 1 Remedy
Hard t o shift or w i l l Spline o n input shaft dirty or burred Repair as necessary MT-4
n o t shift Transmission faulty Disassemble and inspect transmission MT-4
(R154 M/T)
REMOVE EXHAUST FRONT PlPE
(a) Disconnect the exhaust pipe bracket from the clutch
housing.
(b) Remove the nuts and exhaust pipe from the exhaust
manifold.
Installation of Transmission
1-1. (R154)
PLACE TRANSMISSION AT INSTALLATION POSITION,
AND INSTALL TRANSMISSION MOUNTING BOLTS
(a) Apply molybdenum disulphide lithium base grease t o
the following parts:
Release bearing hub inside groove
Input shaft spline
Release fork contact surface
(b) lnstall the clutch cover and disc on the retainer and
input shaft spline.
(c) Align the input shaft tip w i t h the pilot bearing, and
push the transmission fully into position.
(d) lnstall the t w o mounting bolts of the upper transmis-
sion, and torque the bolts.
Torque: 4 0 0 kg-cm ( 2 9 ft-lb, 3 9 N - m )
1-2. ( W 5 8 )
PLACE TRANSMISSION AT INSTALLATION POSITION,
AND INSTALL TRANSMISSION MOUNTING BOLTS
(a) Align the input shaft spline with the clutch disc, and
push the transmission fully into position.
(b) lnstall the t w o mounting bolts of the upper transmis-
sion, and torque the bolts.
Torque: 4 0 0 kg-cm ( 2 9 ft-lb, 3 9 N-rn)
MANUAL TRANSMISSION - Removal and Installation of Transmission MT-7
INSTALL STARTER
lnstall the starter, and torque the bolts.
(R 1 5 4 )
INSTALL EXHAUST FRONT PIPE
( a ) lnstall the exhaust front pipe and nuts t o the exhaust
manifold. Torque the nuts.
Torque: 6 3 0 kg-cm ( 4 6 ft-lb, 6 2 N - m )
(b) Connect the exhaust pipe bracket t o the clutch
housing.
MT-8 MANUAL TRANSMISSION - Removal and Installation of Transmission
Transmission Case
8 I / C 1
Clutch
@ FIOnt Bearing Retaner
~ a c k U pLight Switch
1 410 (30.40) /
Intermediate Plate
-Output Shaft
Locking Ball
Spring
*Straight Screw Plug
O b
8
Counter Gear
Ex-tension Housing 1
I
I 1 375 ( 2 7 , 3 7 q 1
Restrict Pin
1
Components (Cont'd)
0-
y4 Lock Washers
No. 1 Interlock Pin
2
No. 2 Shift Fork Shaft
No. 2 Interlock
Reverse Shift Arm
I
1 5threar
I
C *Cll~/
Speedometer
Intermediate Plate -
&snap Bearing
Ring
Counter Gear
DISASSEMBLY OF TRANSMISSION
(See pages MT-9, 1 0 )
1. REMOVE BACK-UP LIGHT SWITCH, REAR SPEED SENSOR
(wl A.B.S.) AND SPEEDOMETER DRIVEN GEAR
( b ) Pry out the lock washer of No.2 shift fork and remove
the set bolt.
M0308 WMOOC
MANUAL TRANSMISSION - Disassembly of Transmission MT-15
(b) Using SST, remove the rear bearing and 5th gear
SST 0931 2-2001 1
COMPONENT PARTS
lnput Shaft Assembly
COMPONENTS
Synchronizer Ring
lnput Shaft
I +Bearing
Snap Ring
REPLACEMENT OF BEARING
IF NECESSARY, REPLACE INPUT SHAFT BEARING
(a) Using snap ring pliers, remove the snap ring.
S h i f t i n g K e y Spring
Snap R i n g -
Synchronizer R i n g
Ball
$$!D I n n e r Race
y N e e d l e R o l l e r Bearing
1 Shifting Key
I S h i f t i n g K e y Spring
Needle Roller Bearing
WM0300
No. 2 No. 1
(c) Using a press, install the 3rd gear and No.2 clutch hub.
MT-26 MANUAL TRANSMISSION - Component Parts (Output Shaft Assembly)
(d) Install the assembly on the output shaft with the syn-
chronizer ring slots aligned with the shifting keys and
turn the inner race t o align it with the locking ball.
P
1
Reverse l d l e r Gear S h a f t I
I I
Reverse l d l e r Gear
I
Snap R i n g
,
9
Snap R i n g
- ,,,
Roller Bearing
S h i f t ~ n gK e y S p r ~ n g
Bearing
,
,
Snap R i n g
r
I
I
Synchronizer R i n g C o u n t e r 5 t h Gear
L
Bearing I
Clutch H u b No. 3
REPLACEMENT OF BEARING
1. IF NECESSARY, REPLACE COUNTER GEAR FRONT BEAR-
ING A N D SIDE RACE
(a) Using snap ring pliers, remove the snap ring.
(b) Using a press and SST, press o u t t h e bearing.
SST 0 9 9 5 0 - 0 0 0 2 0
(c) Check the side race for wear or damage.
SST
WM007E
Front
ASSEMBLY OF COUNTER GEAR ASSEMBLY
INSERT N 0 . 3 CLUTCH HUB INTO HUB SLEEVE
(a) Install N o . 3 clutch h u b and t h e shifting keys t o the
h u b sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE: Install the key springs positioned so that their
end gaps are not in line.
+ Oil Seal
Non-reusable part
Extension Housing
COMPONENTS
\
I
, '
Oil Receiver
I
Pipe I
1 I
Bearing
I
Extension Housing
Snap Ring
(b) Using a pin punch and hammer, drive out the slotted
spring pin.
(c) Pull off the lever housing and slide out the shaft.
MANUAL TRANSMISSION - Component Parts (Extension Housing) MT-35
REPLACEMENT OF BEARING
IF NECESSARY, REPLACE REAR BEARING OUTER RACE
(a) Remove the outer race from the extension housing.
( 1) Using t w o screwdrivers, remove the snap ring.
ASSEMBLY OF TRANSMISSION
(See pages MT-9, 10)
1. INSTALL OUTPUT SHAFT TO INTERMEDIATE PLATE
(a) Before installing the output shaft, use SST to remove
the counter gear center bearing outer race.
SST 0 9 6 0 8 - 3 5 0 14 (09608-06020, 0 9 6 0 8 - 0 6 0 9 0 )
HINT: Install the outer race after installing the counter
gear.
(dl Using SST, install the counter gear center bearing out-
er race.
SST 0 9 3 1 6-6001 0 ( 0 9 3 16 - 0 0 0 10 )
HINT: Be careful not t o damage the bearing rollers.
MT-38 MANUAL TRANSMISSION - Assembly of Transmission
Thickness mm (in.)
MT-40 MANUAL TRANSMISSION - Assembly of Transmission
1 )l90-195(00748-00768) 5 214-219(00843-00862)
MANUAL TRANSMISSION - Assembly of Transmission MT-41
(e) Apply MP grease No.3 interlock pin and install the pin
into the intermediate plate hole.
k---
W M 0 3 0 9 WM0032
(k) Install the No. I and No.2 shift fork set bolts with lock
washers.
Torque: 1 2 5 kg-cm (9 ft-lb, 1 2 N - m )
(a) Align each bearing outer race and each shift fork shaft
end w i t h the case holes.
(b) Using a plastic hammer, tap o n t h e case t o install i t .
(c) Connect the shift and select lever t o the shift fork
shaft.
(d) Install shift lever housing t o shift and select lever shaft,
push in the extension housing.
(el Install and torque the bolt.
Torque: 4 0 0 kg-cm ( 2 9 ft-lb, 3 9 N.m)
MANUAL TRANSMISSION - Assembly of Transmission MT-47
Transmission Case
Reverse S h ~ f Head
t
Shift Arm
Components (Cont'd)
Synchronizer Ring
Input Shaft
m a p nlng
Snap
I Ring
Snap Ring
I Reverse ldler Gear Shaft
Reverse ldler Gear
3rd Gear
NO. 2 Hub Sleeve Needle Roller Bearing
Synchronizer Ring
No. 2 Clutch Hub
Snap Ring 1
- Output Shaft
5th Gear
I
No. 1 Clutch Hub
1 synchronizer Ring
Synchronizer Ring
DISASSEMBLY OF TRANSMISSION
(See pages M T - 4 9 , 5 0 )
RMOOYO
MANUAL TRANSMISSION - Disassembly of Transmission MT-53
RMOOOE
i ! SST
D6577
RMOOlO 1
MT-58 MANUAL TRANSMISSION - Disassembly of Transmission
COMPONENT PARTS
Input Shaft Assembly
COMPONENTS
REPLACEMENT OF BEARING
IF NECESSARY, REPLACE INPUT SHAFT BEARING
(a) Using snap ring pliers, remove t h e snap ring
MT-60 MANUAL TRANSMISSION - Component Parts (Input Shaft Assembly)
(d) Select a snap ring that will allow minimum axial play
and install i t o n the shaft.
Mark 1 Thickness mm ( i n . )
MANUAL TRANSMISSION - Component Parts (Output Shaft Assembly) M T - 61
P
Snap R i n g
Synchronizer R i n g
-t-
Reverse Gear
5 t h Gear
id) Using a press, install the 3rd gear and No.2 hub sleeve.
(d) Using a press, install the 2nd gear and No.1 hub
sleeve.
RMOOBE
Counter Gear
+Counter Gear Front Bearing
Snap Ring
I
No. 5 Gear
Counter 5th Gear Spline Piece
Needle Roller Bearing Synchronizer Ring
Thrust Washer No. 3 Hub Sleeve
Counter Gear Rear Bearing
+ Non-reusable part RM0325
REPLACEMENT OF BEARING
IF NECESSARY, REPLACE COUNTER GEAR FRONT BEARING
(a) Using snap ring pliers, remove the snap ring.
(b) Using SST, press o u t the bearing.
SST 0 9 9 5 0 - 0 0 0 2 0
(c) Replace the side race.
Retainer
Extension Housing
COMPONENTS
Oil Seal
Extension Housing
I
Slotted Sprinq Pin
Reverse
I
Oil Receiver Pipe
4 I
Filler Plug
(b) Using SST, drive in a new oil seal into the sleeve.
SST 0 9 2 0 1 - 6 0 0 1 1
Drive in depth: 25 mm (0.98 in.)
SST
I
(b) Using a pin punch and hammer, drive out the slotted
spring pin.
-
3. INSTALL REVERSE RESTRICT PIN
( a ) Install the reverse restrict pin t o the extension hous-
ing or transfer adaptor.
( b ) Using pin punch and hammer, drive in the slotted
spring pin.
ASSEMBLY OF TRANSMISSION
(See pages MT-49, 50)
INSTALL OUTPUT SHAFT TO INTERMEDIATE PLATE
(a) lnstall the output shaft into the intermediate plate by
pushing on the output shaft and tapping on the inter-
mediate plate.
1 RMOORO 1
(c) Install No.1 fork shaft to No. 1 shift fork through the
intermediate plate.
(b) Place No.2 shift fork into the groove of No.2 hub
sleeve.
(c) Install No.2 fork shaft t o No.1 and No.2 shift forks
through the intermediate plate.
2 3 . CHECK INTERLOCK
(a) Shift No.1 fork shaft t o the 1st speed position.
( b ) No.2, No.3, No.4 and No.5 fork shafts should not
move.
(b) Align each bearing outer race, each fork shaft end and
reverse idler gear shaft end w i t h the case installation
holes, and install the case.
If necessary, tap o n the case w i t h a plastic hammer.
(b) Insert the shift and select lever into the extension
housing.
(c) Connect the shift and select lever t o the fork shaft
and put in the shift lever housing.
(d) Align No.5 fork shaft t o the extension housing instal-
lation hole and push in the extension housing.