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MT12
W58 MANUAL TRANSMISSION
OPERATION
OPERATION
MT13
W58 MANUAL TRANSMISSION
PREPARATION
PREPARATION
SST (SPECIAL SERVICE TOOLS
0930412012
0930800010
0930810010
0931220011
(0931300040) Plate A
(0931300050) Plate B
0931660010
(0931600070) Replacer F
0932520010
0950635010
MT14
W58 MANUAL TRANSMISSION
0960812010
PREPARATION
(0960800080) Replacer
(0960803020) Handle
0960835014
(0960806020) Handle
0995000020
Bearing Remover
0995040010
Puller B Set
MT15
W58 MANUAL TRANSMISSION
PREPARATION
RECOMMENDED TOOLS
0903100030 Pin Punch
0990500012
EQUIPMENT
Calipers
Dial indicator
Micrometer
Torque wrench
Feeler gauge
LUBRICANT
Item
Capacity
2
2.6
6 liters (2
(2.7
7 US qts
qts, 2
2.3
3 Imp
Imp. qts)
Classification
API GL
GL3,
3, GL
GL4
4 or GL
GL5
5
SAE 75W90
0882600090
Transmission case x
Intermediate plate
Front bearing retainer x
Transmission case
0883300080
Adhesive 1344,
THREE BOND 1344,,
LOCTITE 242 or equivalent
MT16
W58 MANUAL TRANSMISSION
TROUBLESHOOTING
TROUBLESHOOTING
MT112
MT124,26
34
MT126,34
MT112
Gear (Worn or damaged)
MT112
Shift fork (Worn)
MT111
ORing (Worn or damaged)
MT111
MT111
ORing
Oil
seal (Worn or damaged)
Oil (Wrong)
Trouble
Parts
Name
MT111
See page
Gasket (Damaged)
MT22
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Noise
Oil leakage
Hard to shift or will not shift
Jumps out of gear
PRECAUTION
When working with FIPG material, you must observe the following.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a nonresidue solvent.
Apply the FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be
removed and reapplied.
MT16
W58 MANUAL TRANSMISSION
PRECAUTION
TROUBLESHOOTING
MT112
MT112
MT124,26
34
MT126,34
MT112
Shift fork (Worn)
MT111
Locking ball spring (Damaged)
MT111
MT111
ORing
Oil seal (Worn or damaged)
Oil (Wrong)
Trouble
Parts
Name
MT111
See page
Gasket (Damaged)
MT22
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Noise
Oil leakage
Hard to shift or will not shift
Jumps out of gear
PRECAUTION
When working with FIPG material, you must observe the following.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a nonresidue solvent.
Apply the FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be
removed and reapplied.
MT17
W58 MANUAL TRANSMISSION
MT18
W58 MANUAL TRANSMISSION
TRANSMISSION REMOVAL
1.
2.
3.
4.
RAISE VEHICLE
NOTICE: Be sure the vehicle is securely supported.
DRAIN TRANSMISSION OIL
Oil grade:
API GL3, GL4 or GL5
Viscosity:
SAE 75W90
Capacity:
2.6 liters (2.7 US qts, 2.3 Imp.qts)
5.
MT19
W58 MANUAL TRANSMISSION
(c)
8.
9.
MT110
W58 MANUAL TRANSMISSION
(b) Remove the bolt, ground cable and flexible hose bracket.
Torque: 37 Nm (380 kgfcm, 27 ftlbf)
12.
(a)
(b)
(c)
REMOVE STARTER
Remove the nut and disconnect the starter wire.
Disconnect the starter wire connector.
Remove the 2 bolts and starter.
Torque: 39 Nm (400 kgfcm, 29 ftlbf)
(b) Lower the engine rear side and remove the transmission from
the engine.
MT111
W58 MANUAL TRANSMISSION
MT112
W58 MANUAL TRANSMISSION
MT113
W58 MANUAL TRANSMISSION
2.
3.
4.
5.
REMOVE CONTROL
ASSEMBLY
(a) Remove the 6 bolts.
SHIFT
LEVER
RETAINER
(b) Remove the control shift lever retainer assembly and oil
deflector.
6. REMOVE 2 RESTRICT PINS
INSTALLATION HINT: Install the black pin on the reverse
gear/5th gear side.
Torque: 40 Nm (410 kgfcm, 30 ftlbf)
MT114
W58 MANUAL TRANSMISSION
INSTALLATION HINT:
Align each bearing outer race and each shift fork shaft
end with the case holes.
INSTALLATION HINT:
Sealant:
Part No.0883300080, THREE BOND 1344, LOCTITE 242
or equivalent
MT115
W58 MANUAL TRANSMISSION
(b) Using a snap ring expander, remove the 2 bearing snap rings.
9. SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION CASE
(a) Using a plastic hammer, carefully tap the transmission case.
(b) Pull the transmission case from the intermediate plate.
MT116
W58 MANUAL TRANSMISSION
(c)
(d) Remove the reverse idler gear and shaft with the snap ring.
(f)
MT117
W58 MANUAL TRANSMISSION
(g) Using 2 screwdrivers and a hammer, tap out the snap ring of
No. 2 shaft.
(i)
(j)
Using a pin punch and hammer, drive out the No. 3 fork shaft
pin.
(k)
MT118
W58 MANUAL TRANSMISSION
(l)
(o) Remove the No.3 shift fork, fork shaft and reverse shift arm
with the snap ring.
MT119
W58 MANUAL TRANSMISSION
Mark
Thickness mm (in.)
1.901.95 (0.07480.0768)
1.962.01 (0.07720.0791)
2.022.07 (0.07950.0815)
2.082.13 (0.08190.0839)
2.142.19 (0.08430.0862)
2.202.25 (0.08660.0886)
2.262.31 (0.08900.0909)
(b) Using SST, remove the rear bearing, spacer, 5th gear and
bearing.
SST 0995040010
NOTICE: Be careful not to catch the output shaft rear
bearing roller on the counter 5th gear.
INSTALLATION HINT:
Install the counter 5th gear with the 5th gear gaps
aligned with the synchronizer corn ring pin.
(c)
INSTALLATION HINT:
MT120
W58 MANUAL TRANSMISSION
Mark
Thickness mm (in.)
2.062.11 (0.08110.0831)
2.122.17 (0.08350.0854)
2.182.23 (0.08580.0878)
2.242.29 (0.08820.0902)
INSTALLATION HINT:
Mark
Thickness mm (in.)
2.312.36 (0.09090.0929)
2.372.42 (0.09330.0953)
10
2.432.48 (0.09570.0976)
11
2.492.54 (0.09800.1000)
12
2.552.60 (0.10040.1024)
13
2.612.66 (0.10280.1047)
14
2.682.73 (0.10550.1075)
15
2.742.79 (0.10790.1098)
MT121
W58 MANUAL TRANSMISSION
(b) Using SST, remove the rear bearing and 5th gear.
SST 0931220011 (0931300030, 0931300040,
0931300050)
Mark
Thickness mm (in.)
5
11
2.252.30 (0.08860.0906)
2.302.35 (0.09060.0925)
12
13
2.352.40 (0.09250.0945)
2.402.45 (0.09450.0965)
14
15
2.452.50 (0.09650.0984)
2.502.55 (0.09840.1004)
16
17
2.552.60 (0.10040.1024)
2.612.66 (0.10280.1047)
18
19
2.672.72 (0.10510.1071)
2.732.78 (0.10750.1094)
20
21
2.792.84 (0.10980.1118)
2.852.90 (0.11220.1142)
22
23
2.912.96 (0.11460.1165)
2.973.02 (0.11690.1189)
MT122
W58 MANUAL TRANSMISSION
INSTALLATION HINT:
MT123
W58 MANUAL TRANSMISSION
INSTALLATION HINT:
MT124
W58 MANUAL TRANSMISSION
INPUT SHAFT
INPUT SHAFT
COMPONENTS
MT125
W58 MANUAL TRANSMISSION
INPUT SHAFT
HINT: When replacing either a synchronizer ring or gear, apply a small amount of fine lapping compound between the
synchronizer ring and gear cone.
Lightly rub the synchronizer ring and gear cone together.
NOTICE:
When replacing both the synchronizer ring and gear,
there is no need to apply any compound or to rub them
together.
NOTICE: Ensure the fine lapping compound is
completely washed off after rubbing.
BEARING REPLACEMENT
IF NECESSARY, REPLACE INPUT SHAFT BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the bearing.
(c)
Mark
Thickness mm (in.)
2.052.10 (0.08070.0827)
2.102.15 (0.08270.0846)
2.152.20 (0.08460.0866)
2.202.25 (0.08660.0886)
2.252.30 (0.08860.0906)
11
2.302.35 (0.09060.0925)
12
2.352.40 (0.09250.0945)
MT126
W58 MANUAL TRANSMISSION
OUTPUT SHAFT
OUTPUT SHAFT
COMPONENTS
MT127
W58 MANUAL TRANSMISSION
2.
OUTPUT SHAFT
3.
4.
5.
MT128
W58 MANUAL TRANSMISSION
OUTPUT SHAFT
(b) Push the shifting key spring with a screwdriver, remove the
3 shifting keys and key springs.
7. REMOVE NO.2 HUB SLEEVE ASSEMBLY AND 3RD
GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Push the shifting key spring with a screwdriver, remove the
3 shifting keys and key springs.
MT129
W58 MANUAL TRANSMISSION
OUTPUT SHAFT
HINT: When replacing either a synchronizer ring or gear, apply a small amount of fine lapping compound between the
synchronizer ring and gear cone.
Lightly rub the synchronizer ring and gear cone together.
NOTICE:
(c)
If the clearance is less than the minimum, replace the synchronizer ring.
MT130
W58 MANUAL TRANSMISSION
3.
OUTPUT SHAFT
(c)
If the outer diameter is less than the minimum, replace the inner race.
MT131
W58 MANUAL TRANSMISSION
OUTPUT SHAFT
2.
While pushing the 3 shifting keys, install the clutch hub to the
hub sleeve, as shown.
MT132
W58 MANUAL TRANSMISSION
OUTPUT SHAFT
(c) Using a press, install the 3rd gear and No.2 clutch hub.
3. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.
Mark
Thickness mm (in.)
C1
1.751.80 (0.06890.0709)
1.801.85 (0.07090.0728)
11
1.861.91 (0.07320.0752)
12
1.921.97 (0.07560.0776)
13
1.982.03 (0.07800.0799)
14
2.042.09 (0.08030.0823)
15
2.102.15 (0.08270.0846)
(d) Using a press, install the 2nd gear and No.1 clutch hub.
6. INSPECT 2ND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust clearance.
Standard clearance:
0.100.25 mm (0.00390.0098 in.)
7.
(a)
(b)
(c)
MT133
W58 MANUAL TRANSMISSION
OUTPUT SHAFT
(d) Install the assembly on the output shaft with the synchronizer
ring slots aligned with the shifting keys and turn the inner race
to align it with the locking ball.
8.
9.
MT134
W58 MANUAL TRANSMISSION
MT135
W58 MANUAL TRANSMISSION
(c)
(d) Turn the reverse synchronizer pull ring, separate the pull ring
and cone ring.
(e) While pushing the shifting key spring to out slide with 2
screwdrivers, remove the 3 shifting keys and key springs,
from the reverse synchronizer ring.
MT136
W58 MANUAL TRANSMISSION
2.
3.
(c)
MT137
W58 MANUAL TRANSMISSION
6.
BEARING REPLACEMENT
1.
(e) Using a socket wrench, press in a new bearing, side race and
inner race.
(f) Select a snap ring that will allow minimum axial play.
Mark
Thickness mm (in.)
2.052.10 (0.08070.0827)
2.102.15 (0.08270.0846)
2.152.20 (0.08460.0866)
2.202.25 (0.08660.0886)
2.252.30 (0.08860.0906)
2.302.35 (0.09060.0925)
MT138
W58 MANUAL TRANSMISSION
2.
(c)
(c)
MT139
W58 MANUAL TRANSMISSION
(f)
MT140
W58 MANUAL TRANSMISSION
MT141
W58 MANUAL TRANSMISSION
EXTENSION HOUSING
EXTENSION HOUSING
COMPONENTS
(b) Using a pin punch and hammer, drive out the slotted spring
pin.
(c) Pull off the lever housing and slide out the shaft.
MT142
W58 MANUAL TRANSMISSION
2.
EXTENSION HOUSING
(c)
BEARING REPLACEMENT
IF NECESSARY, REPLACE REAR BEARING OUT REAR
RACE
(a) Using 2 screwdrivers, remove the snap ring.
(b) Using SST and a hammer, tap out the outer race. SST
0960812010 (0960800020, 0960800050)
MT143
W58 MANUAL TRANSMISSION
(c)
EXTENSION HOUSING
(b) Using SST and a hammer, drive in a new oil seal. SST
0932520010
MT144
W58 MANUAL TRANSMISSION
(c)
MT145
W58 MANUAL TRANSMISSION
(d) Using SST and a hammer, install a new oil seal. SST
0930412012
Drive in depth:
55.456.0 mm (2.1812.205 in.)
(e) Install the control shaft and No. 2 inner shift lever to the
control shift lever retainer.
(f) Install and torque the No. 2 inner shift lever set bolt.
Torque: 39 Nm (400 kgfcm, 29 ftlbf)
MT146
W58 MANUAL TRANSMISSION
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
MT147
W58 MANUAL TRANSMISSION
SERVICE SPECIFICATIONS
Mark 11
Mark 12
Mark C1
Mark D
Mark 11
Mark 12
Mark 13
Mark 14
Mark 15
Mark 8
Mark 9
Mark 10
Mark 11
Mark 12
Mark 13
Mark 14
Mark 15
Mark 5
Mark 11
Mark 12
Mark 13
Mark 14
Mark 15
Mark 16
Mark 17
Mark 18
Mark 19
Mark 20
Mark 21
Mark 22
Mark 23
Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark 2
Mark 3
Mark 4
Mark 5
Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Mark 6
MT148
W58 MANUAL TRANSMISSION
SERVICE SPECIFICATIONS
TORQUE SPECIFICATIONS
Rear bearing
Mark 7
Part tightened
Nm
kgfcm
ftlbf
12 mm bolt
72
730
53
10 mm bolt
37
380
27
25
250
18
Nut
13
135
10
Bolt
25
260
19
Transmission x Starter
39
400
29
13
130
19
195
14
93
950
69
49
500
36
13
130
5.4
55
48 in.lbf
19
195
14
43
440
32
37
380
27
43
440
32
18
180
13
7.8
80
69 in.lbf
20
200
14
25
250
18
25
250
18
18
185
13
25
250
18
37
380
27
Restrict pin
40
410
30
39
400
29
18
185
13
39
400
29
19
195
14
39
400
29
40
410
30
25
250
18
19
195
14
37
380
27
18
185
13
Transmission x Engine