MT-2 Manual Transmission

Ge n e r a l
De s c r i p t i o n
T r a n s mi s s i o n

SGVMT3001L

The transmission changes the torque produced by the

engine to a torque vehicle requires. The torque, or drive
power, is increased or decreased by shifting several
group of gears.
Since the engine always turns in one direction, the
transmission also performs the function of changing the
direction of rotation so that the vehicle can be backed.
General MT-3
Ke y t y p e s y n c h r o n i z e r 3. As the synchronizer sleeve moves further to the left,
1. The bore of the synchronizer hub is in mesh with the the shifting key is blocked by the side face of the
main shaft splines and the synchronizer hub rotates synchronizer ring, which causes the shifting key
with the main shaft. The outside surface of the protrusion to be disengaged from the synchronizer
synchronizer hub has splines in mesh with the sleeve.
synchronizer sleeve and three keyways. The
protrusion at the center of the shifting key fits into the
groove inside the synchronizer sleeve in neutral and
is pressed against the inner surface of the
synchronizer sleeve by the shifting key spring.

SGVMT3004L

4. When the synchronizer sleeve and drive pinion turn

at the same speed, the synchronizer ring no longer
blocks the synchronizer sleeve; as a result, the
synchronizer sleeve moves further to the left to be in
SGVMT3002L mesh with the taper cone splines of the drive pinion.
2. When the shift fork is moved in the direction shown This results in power being transmitted.
by the arrow, the synchronizer sleeve moves slightly
toward the left. The shifting key, whose center
protrusion is in mesh with the synchronizer sleeve,
then also moves to the left, causing the synchronizer
ring to be pressed against the drive pinion taper
cone.

SGVMT3005L

SGVMT3003L
MT-4
Do u b l e c o n e t y p e
1. Synchronizer inner ring 5. Synchronizer center corn
2. 2nd, 3rd shift fork 6. 2nd gear
3. Shifting key 7. Shifting key spring
4. Synchronizer outer ring 8. Main shaft
The 2nd and 3rd gears are described below. The other
gears have the same structure.
Basically, the structure and the operation of the
synchromesh mechanism is the same as those of the
synchro type. The taper cone independent from the 2nd /
3rd gear inserts the synchronizer center cone (whose
inner and outer surface are of the taper cone form)
between the synchronizer inner ring and the synchronizer
outer ring.
Due to such a structure, the synchro capacity is
enhanced.
The center cone and the gear are perfectly fitted with
each other while each of six projections on the
circumference of the center cone fits in a gear hole
respectively as the taper cone of the single cone type
does.
As the cylindrical shifting key is longitudinally aligned
with the circumference of the synchronizer hub, it is
easier to assemble it. The shifting key spring includes the
coil spring.
Insert the synchronizer hub into the hole.
Press the shifting key to the inside of the synchronizer
Manual Transmission
STRMT60501L
9. Synchronizer hub
10. Synchronizer sleeve
11. 3rd gear
12. Dock clutch
sleeve with a force.
The 4th gear of the O/D is of the double cone type,
however, the shifting key and the shifting key spring have
the structure of the single cone type.
At neutral (Fig. A), the synchronizer sleeve moves
slightly to the left as the shift fork moves in a direction of
the arrow shown in the figure. Since the upper part of the
projection in the center of the shifting key is aligned with
the synchronizer sleeve, it also moves slightly to the left.
The synchronizer outer ring is pressed by the
synchronizer center cone (Fig. B).
The taper part of the synchronizer outer ring is contacted
with the taper cone of the synchronizer center cone.
The clearance between the synchronizer outer ring and
the synchronizer hub is made due to the friction torque
generated on the taper part by the action of the cone
clutch allows the synchronizer outer ring to rotate in the
same direction of the 3rd gear rotation.
The chamfered side of the synchronizer outer ring spline
is cross aligned with that of the synchronizer sleeve
spline (Fig. C).
General MT-5

SGVMT3007L SGVMT3008L

The crossing direction of the synchronizer outer ring is

dependent on the rotation speed of the synchronizing As the synchronizer outer ring can no longer resist the
part (sleeve) and the synchronized part (2nd gear). movement of the synchronizer sleeve even though the
For the increase of the vehicle speed, it crosses to the synchronizer sleeve and the 2nd gear rotate at a uniform
reverse direction of the rotation. For the decrease, it speed, the synchronizer sleeve moves to the left again.
crosses to the rotating direction. Smoothly it is aligned with the dog clutch spline of the
As the synchronizer sleeve moves to the left again, the 3rd gear to transmit the power.
shifting key interrupts the further movement along the
side of the synchronizer outer ring.
The synchronizer sleeve and the upper part of the
shifting key projection are not aligned with each other.
In case that the synchronizer outer ring deviates, the
chamfered part of the synchronizer sleeve presses that
of the synchronizer outer ring spline and then the taper
cone of the synchronizer center cone presses the
synchronizer outer ring with a large force, causing the
generation of the friction torque on the taper surface.
Additionally, the friction torque is generated on the taper
surface of the synchronizer inner ring, so the speed of
the synchronized part is relatively lower than that of the
synchronizing part.
SGVMT3009L
D : In synchronization, E : After synchronization
MT-6 Manual Transmission
I n t e r l o c k me c h a n i s m
The interlock mechanism, which is installed in the gear
shaft lower case, prevents the double mesh of a gear.
When a shift rail is shifted, the steel ball enters the shift
rail groove to fix the other shift rails.
For example, when the 1st and reverse shift rail are
shifted, the steel ball on the right of the shift rail moves to
the right to fix the 2nd and 3rd shift rail and then it
pushes the interlock pin B to fix the 4th and 5th shift rail.

SGVMT3010L
General MT-7
Tr oubl es hoot i ng
S y mp t o m Ca u s e R e me d y
Play in ball joint. Replace ball joint.
Worn busing. Replace
Defective control mech-
Correct bend or repla-
anism (Insufficient shift Bent rod.
ce.
stroke on transmission
side). Worn steel ball or groove in shift rail. Replace worn part.
Insufficient shift rail poppet spring tension or broken
Transmission s- Replace
spring.
lips out of gear.
Retighten to specifica-
Main shaft rear lock nut left loose.
tion.
Defective transmission ( Worn main shaft thrust washer. Replace
Disassemble and check
transmission assembly). Worn or damaged main shaft bearing. Replace
Worn splines in synchronizer ring and synchronizer
Replace worn part.
sleeve.
Play in ball joint. Replace ball joint.
Ball joint insufficiently lubricated. Lubricate
Improper rod length. Adjust
Defective control mech-
Worn bushing. Replace
anism (Correct shift str-
oke on transmission sid- Replace shift rail or g-
Shift rail not sliding smoothly.
e). ear shift lower case.
Worn shift fork jaws. Replace
Correct bend or repla-
Bent shift fork.
ce.
Retighten to specifica-
Main shaft rear lock left loose.
tion.
Hard shifting in-
to gear. Worn main shaft thrust washer. Replace
Defective transmission (
Disassemble and check Worn or damaged main shaft bearing. Replace
transmission assembly). Worn taper cone in synchronizer ring and gears. Replace worn part.
Clutch not releasing properly.
Defective clutch. Adjust
Improper clutch pedal free play.
Defective air compressor. Check
Replace O-ring and oil
Air leak
seal.
Defective power shift.
Spring losing tension. Replace
Inadequate length of each rod. Adjust
Worn bushing. Replace
MT-8 Manual Transmission
S y mp t o m Ca u s e R e me d y
Worn or damaged main shaft pilot bearing. Replace or lubricate.
Worn or damaged drive pinion bearing. Replace
Excessive backlash between drive pinion and counter shaft constant mesh ge-
Replace
ar.
Unusual noise i
n neutral. Worn or damaged counter shaft bearing. Replace
Worn or damaged needle bearing in gears. Replace
Adjust with adjusting
Excessive backlash between counter shaft 4th gear and PTO idler gear. gasket in PTO case or
replace gear.
Worn or damaged main shaft and counter shaft bearings. Replace
Worn or damaged main shaft pilot bearing. Replace
Worn or damaged needle bearing in gears. Replace
Unusual noise i
Excessive backlash between gears in main shaft and counter shaft. Replace gears
n gear.
Worn or damaged synchronizer sleeve. Replace
Insufficient gear oil. Add
Damaged gear. Replace
Worn taper cone in synchronizer ring and gear. Replace worn art
Defective synchronizer. Worn shifting key. Replace

Unusual noise i Damaged shifting key splines. Replace

n shifting. Worn splines in gears. Replace gears.
Worn synchronizer sleeve. Replace
Clutch not releasing properly. Adjust
Defective transmission PTO switch. Replace
Defective power relay. Replace
Defective 3-way magnet valve. Replace
Defective clutch switch. Replace
Transmission Blown fuse or fusible link. Replace
PTO not engag-
ed. Open circuit or poor connection. Correct
Battery over discharge. Correct
Defective transmission PTO power cylinder. Correct
Defective transmission PTO mechanism. Correct
Leaks in air system. Repair
General MT-9
S y mp t o m Ca u s e R e me d y
Defective transmission PTO switch. Replace
Transmission
PTO engages Transmission PTO switch lamp bulb burned out. Replace
but transmissio-
Defective transmission PTO control switch. Replace
n PTO switch il-
lumination lamp Defective power relay. Replace
does not turn o-
n. Open circuit or poor connection. Correct

Sp e c i f i c a t i o n

STRAMT1-0001L
MT-10 Manual Transmission
Se r v i c e s t a n d a r d s
Unit : mm
St a n d a r d v a l v e
I t em L i mi t R e me d y
B a s i c d i a me t e r i n [ ]
M8S5 0.09 - 0.27
1st gear M8S6, M10S 0.09 - 0.27
M12S 0.08 - 0.28
M8S, M10S 0.08 - 0.25
2nd gear (3rd)
M12S 0.10 - 0.29

Gear backlash ( 3rd gear (2nd) 0.09 - 0.27

Main shaft gear M8S6, M10S, M12S 0.09 - 0.27
, counter shaft 4th gear (5th)
gear, reverse g- M8S5 0.08 - 0.24
0.5 Replace gear.
ear) shown in ( M8S5 0.09 - 0.27
) are gears on
M8S5 transmis- 5th gear (4th) M8S6, M10S 0.08 - 0.26
sion M12S, H160S 0.09 - 0.28
6th gear M8S6, M10S6, M12S, H160S 0.09 - 0.27

Mesh to main M8S, M10S 0.09 - 0.28

shaft gear M12S, H160S 0.10 - 0.29
Reverse gear
Mesh to coun- M8S, M10S 0.08 - 0.25
ter shaft gear M12S, H160S 0.09 - 0.26

2nd & 3rd sync- Synchronizer sleeve to hub diametral play 0.06 - 0.14 0.3 Replace
hronizer (pin ty-
pe) Ring depth relative to cone 0 2.8 Replace
General MT-11
St a n d a r d v a l v e
I t em L i mi t R e me d y
B a s i c d i a me t e r i n [ ]
Synchronizer sleeve to hub diametral play 0.06 - 0.14 0.3

Synchronizer hub groove to rin- 4th & 5th 4.8 - 5.43

5th, 6th & 6th s- g projection clearance 6.5
6th, 6th 4.7 - 5.3 Replace
ynchronizer (K-
ey type) Synchronizer hub groove to shifting key clearan-
0.05 - 0.35 0.5
ce
Synchronizer ring to cone clearance 2.5 0
1st gear M8S 0.15 - 0.25 0.75
M10S, M12S, H160S 0.11 - 0.65 0.85
2nd gear (3rd)
M8S 0.15 - 0.60 0.80
Main shaft gear
M10S, M12S, H160S 0.10 - 0.60 0.75
end play shown
in ( ) are gears 3rd gear (2nd) M8S 0.25 - 0.55 0.7 Replace gear
on M8S5 trans- or washer.
M10S, M12S, H160S 0.15 - 0.50
mission. 0.6
4th gear (5th) 0.25 - 0.40
M8S 0.15 - 0.65 0.85
Reverse gear
M10S, M12S 0.15 - 0.75 0.96
Counter shaft
6th gear M10S6, M12S6, H160S 0.25 - 0.40 0.6
gear end play
-0.030
M8S, M10S [85]
-0.043
1st gear
-0.033
Main shaft bea- M12S, H160S [97]
-0.046
ring sleeve Sh-
own in [ ] are g- -0.030 0.10 Replace
M8S, M10S [76]
ears on M8S5 t- 3rd gear (2nd) -0.043
ransmission M12S [91]
M8S, M10S [61] -
4th gear (5th)
M12S, H160S [74]
1st gear 0.046 - 0.085 Replace faulty
2nd gear 0.026 - 0.065 parts If two ne-
Radial clearan- edle roller bea-
ce of main shaft 3rd gear 0.046 - 0.085 ring are used f-
needle roller b- 4th gear 0.044 - 0.085 0.12 or a gear, use
earing after as- the bearings of
sembly 5th gear same package
color for replac-
Revers gear 0.052 - 0.093
ement.

Main shaft pilot Radial clearance of needle roller bearing after a-

- Replace
bearing ssembly
0.12
Radial clearance of revers. gear needle roller bearing after asse- Replace faulty
-
mbly parts.
MT-12 Manual Transmission
St a n d a r d v a l v e
I t em L i mi t R e me d y
B a s i c d i a me t e r i n [ ]
78 (8.0)
Return springs 1st and revers Load N (kgf) / installed length 97 (9.9) ± 5% / 26.7
/ 26.7
in gear shifter Replace
upper section 69 (7.0)
6th Load N (kgf) / installed length 85 (8.7) / 27.6
/ 27.6
Lifter spring on 12 (1.25)
Load N (kgf) / installed length 15 (1.5) / 14.5
strike side / 14.5
Spring between
9.8 (1.0)
seal assemblie- Load N (kgf) / installed length 13 (1.3) / 10
/ 10
Springs in pow- s
Replace
er shifter Lifter spring on
41 (4.2)
stopper plate s- Load N (kgf) / installed length 49 (5) / 14.5
/ 14.5
ide
Steel ball retai- 16 (1.6)
Load N (kgf) / installed length 20 (2) / 12
ning spring / 12
Poppet spring in gear shifter low- 75 (7.6)
Load N (kgf) / installed length 92 (9.43) ± 10% / 34.5 Replace
er section / 34.5
Shift fork to synchronizer sleeve groove clearan-
0.25 - 0.45 1.0
Shift fork ce Replace
Tilt of shift fork claw to shift rail hole 0.1 or less 0.2
Rail length 300 or less 0.02 or less 0.04
Shift rail Bend shift rail Replace
Rail length more than 300 0.03 or less 0.06
Lower case shift rail hole to shift rail clearance [20] 0.06 - 0.11 0.2 Replace
1st and reverse shift lever to shaft clearance [23] 0.02 - 0.09
0.15
6th shift lever to shaft clearance [17] 0.02 - 0.07 Replace
Bend of shift lever 0.05 or less 0.1
Replace gear
Backlash between speedometer gear and worm 0.13 - 0.29 0.36
Speedometer worm.
gear Replace faulty
Speedometer gear shaft to bushing clearance [12] 0.02 - 0.07 0.15
parts.
General MT-13
St a n d a r d v a l v e
I t em L i mi t R e me d y
B a s i c d i a me t e r i n [ ]
75 (7.6) /
Poppet spring Load N (kgf) / installed length 92 (9.43) ± 10% / 34.5 Replace
34.5
Sleeve to hub diametral play 0.06 - 0.14 0.3 Replace
Hub groove to ring projection cl-
4.5 - 5.1 6.5 Replace
High & Low sy- earance
Splitter section nchronizer Hub groove to shifting key clea-
[M12S2 x 5] 0.05 - 0.35 0.5 Replace
rance
[H160S2 x 5]
Ring to cone clearance 2.5 0 Replace
Backlash of sp-
Pinion and high gear 0.08 - 0.28 0.5 Replace
litter gears
Splitter pinion gear radial clearance of needle ro-
- 0.12 Replace
ller bearing after assembly

Backlash betw- M8S, M10S 0.08 - 0.25 0.5 Replace

een reverse ge-
ar and PTO ge- M12S 0.08 - 0.26 -
ar

Shift fork clearance in sleeve groove 0.3 - 0.5 1.0 Replace

PTO Selection Air cylinder clearance in fork hole [20] 0.07 - 0.12 0.3 Replace
Diametrical clearance between PTO sleeve and
0.06 - 0.16 0.3 Replace
output shaft
PTO sleeve diametral play - 0.19 Replace
110 (11.5)
Return spring Load N (kgf) / installed length 140 (14.36) / 67 Replace
/ 67

Backlash with M10S 0.08 - 0.25

0.5 Replace
reverse gear M12S 0.08 - 0.26
Oil cooler pump
Side clearance 0.02 - 0.06 0.15
Oil pump Replace
Tip clearance 0.12 0.2
Housing to ball stud clearance 0.10 - 0.40 1.0
Cross shaft to bushing clearance 0.07 - 0.17 0.6 Replace
Transmission c- Vertical shaft to bushing clearance 0.07 - 0.17 0.6
ontrol section
Return spring Load N (kgf) / installed length 52 (5.3) / 45.4 - Replace
Replace bushi-
Cross shaft to ball bushing clearance 0.02 - 0.25 0.6
ng.
Transmission
Power relay working voltage (at 20°C) 16 V or less - Replace
PTO control
MT-14 Manual Transmission
Ti ght eni ng t or que
Sc r e w s i z e Ti ght eni ng t or que
I t em
O . D . x p i t c h ( mm) N . m ( k g f . m, l b - f t )
Gear shifter upper case bolt M10 x 1.5 40 (4.1, 29.7)
Gear shifter lower case bolt M10 x 1.5 40 (4.1, 29.7)
Case PTO cover bolt M10 x 1.5 20 (2, 14.5)
Drain plug and oil level plug M20 x 1.5 54 - 83 (5.5 - 8.5, 34.61)
Bearing retainer bolt (front) M10 x 1.5 40 (4.1, 29.7)
Counter shaft rear lock bolt M12S2 x 5 M12 x 1.25 78 (8, 57.9)
M8S, M10S M42 x 1.25 430 - 590 (44 - 60, 318 - 434)
Main shaft front lock nut
M12S, H160S M52 x 1.5 540 - 735 (55 - 75, 398 - 542)
Reverse shaft lock piece bolt M10 x 1.5 40 (4.1, 29.7)
Upper case interlock switch tightening M18 x 1.5 46 - 52 (4.7 - 5.3, 34 - 38)
Upper case lock pin tightening nut M8 x 1.25 17 (1.7, 12.3)
Power shift mounting bolt M10 x 1.5 40 (4.1, 29.7)
Power shift flexible hose tightening M14 x 1.5 40 - 44 (4.0 - 4.5, 28 - 32)
Power shift flexible hose clamp nut M6 x 1.0 5.3 (0.54, 3.9)
Bolt attaching nut M10 x 1.25 29 - 39 (3 - 4, 21 - 28)
Power shift
Connector lock nut M30 x 1.5 59 - 69 (6 - 7, 43 - 50)
Cylinder housing installation M60 x 1.5 78 - 98 (8 - 10, 57 - 72)
Set screw M6 x 1.0 3.9 - 6.9 (0.4 - 0.7, 2.9 - 5.1)
Lever nut M8 x 1.25 12 - 18 (1.2 - 1.8, 8.7 - 13)
Lower case backup lamp switch tightening M18 x 1.5 49 (5, 36)
Shift fork and shift jaw set bolt M12 x 1.25 49 - 67 (5.0 - 6.8, 36 - 49)
M8S5 97 (9.9, 71)
Gear shifter lower case set bolt M14 x 1.5
Except M8S5 135 (13.6, 98)
1st and reverse shift lever attaching nut Except M8S5 M14 x 1.5 135 (13.6, 98)
Rear cover or extension housing attaching bolt M12 x 1.75 74 (7.5, 54)
M8S5, M10S M42 x 1.5 430 - 590 (44 - 60, 318 - 434)
Counter shaft rear lock nut
M12S6 M52 x 1.5 540 - 735 (55 - 75, 397 - 542)
Main shaft rear bearing retainer bolt M8S5, M10S6, M12S6 M12 x 1.25 74 (7.5, 54)
590 - 1080 (60 - 110, 434 - 79
M8S, M10S M36 x 1.5
5)
Main shaft rear castle nut
1370 - 1670 (140 - 170, 1012
M12S M42 x 1.5
- 1229)
Speedometer gear bushing tightening - M30 x 1.5 195 (20, 144)
Overdrive shift lever attaching nut M8S5, M10S6, M12S6 M12 x 1.25 82 (8.4, 60)
General MT-15
Sc r e w s i z e Ti ght eni ng t or que
I t em
O . D . x p i t c h ( mm) N . m ( k g f . m, l b - f t )
Support plate and shoe assembly mounting bolt M16 x 1.5 200 (20.6, 149)
Transmission to clutch housing attaching bolt M16 x 2.0 190 (19.2, 138)
Splitter shift fork installation reamer bolt M10 x 1.25 33 (3.4, 24)
Splitter high gear bolt M20 x 1.5 290 (29.7, 214)
Splitter case bolt M12S2 x 5 M16 x 2.0 190 (19.2, 138)
Splitter upper case bolt M10 x 1.5 40 (4.1, 29)
Splitter case side screw plug M16 x 2.0 34 (3.5, 25)
Power cylinder bolt M10 x 1.5 40 (4.1, 29)
Piston plate castle nut - 9.8 - 15 (1.0 - 1.5, 7.2 - 10.8)
Power cylinder Cylinder to body attac- M12S2 x 5
- 3.9 - 5.9 (0.4 - 0.6, 2.9 - 4.3)
hing screw
Shifter clevis nut - 78 - 98 (8 - 10, 57 - 72)
PTO gear case bolt M10 x 1.5 40 (4.1, 29)
Rear cover and front cover bolts M8 x 1.25 21 (2.1, 15)

Transmission P- Air cylinder bolt M8 x 1.25 21 (2.1, 15)

TO Shift fork set bolt M12 x 1.25 58 (5.9, 42)
Backup lamp switch tightening M18 x 1.5 46 - 52 (4.7 - 5.3, 34 - 38)
Air cylinder rod to piston bolt - 15 (1.5, 10)
Oil cooler pump case bolt M10 x 1.5 40 (4.1, 29)
Rear cover to front cover attaching bolt M8 x 1.25 19 - 27 (1.9 - 2.8, 13 - 20)
Transmission oil
Pump to case attaching bolt M6 x 1.0 8.8 (0.9, 6.5)
cooler
Valve body to pump body attaching bolt M6 x 1.0 6.9 (0.7, 5.1)
Oil cooler hose attaching eyebolt M8 x 1.5 36 - 44 (3.7 - 4.5, 26 - 32)
Splitter control tube a-
M12S2 x 5 M10 x 1.0 4.9 - 10.3 (0.5 - 0.7, 3.6 - 5.1)
ttaching nut
Upper cross shaft lock pin attaching nut M8 x 1.25 14 - 20 (1.4 - 2.0, 10 - 14)
Control M8 x 1.25 19 - 24 (1.9 - 2.4, 13 - 17)
Ball joint nuts of select rod and shift rod
M10 x 1.25 38 - 49 (3.9 - 5.0, 28 - 36)
Cross shaft to bracket attaching nut M12 x 1.25 23 - 32 (2.3 - 3.3, 16 - 23)
Vertical shaft select lever attaching M10 x 1.25 27 - 39 (2.8 - 4.0, 20 - 28)
MT-16 Manual Transmission
Sp e c i a l Se r v i c e To o l s
T o o l ( N u mb e r a n d n a me ) I l l ust r at i on Us e

09431-7A000
Installation of the rear cover oil seal.
Oil seal installer

09431-7A100 Installation of the front retainer bearing oil

Oil seal installer seal.

09431-7B000
Installation of the rear cover oil seal.
Oil seal installer

T o o l ( N u mb e r a n d n a me ) I l l ust r at i on Us e

09432-7A000
Installation of the main shaft pilot bearing.
Bearing installer

09432-7B000
Installation of the main shaft pilot bearing.
Bearing installer
General MT-17
T o o l ( N u mb e r a n d n a me ) I l l ust r at i on Us e

09434-7A000 Removal of the main shaft and counter sh-

Bearing puller set aft bearing.

09434-7A100 Installation of the main shaft and counter

Bearing installer set shaft bearing.

Removal of the reverse gear shaft

09450-75100
(Use with 09450-75200, 09450-75300,
Sliding hammer
09450-75400 and 09450-75500).

09431-83100
Removal of the center bearing.
Puller set
MT-18 Manual Transmission
Manual Transmission
C o mp o n e n t s

STRAMT0001L

1. Clutch housing 3. Power take off (PTO)

2. Power shift assembly
Manual Transmission MT-19

STRAMT0002L

1. Front bearing retainer 5. Rear cover

2. Oil seal 6. Magnet plug
3. Manual transmission case 7. Drain plug
4. Speedometer drive gear 8. Gear shift upper
MT-20 Manual Transmission
R e mo v a l 4. Remove the air piping for transmission PTO control
1. Park the vehicle on a flat ground and place chocks to (On vehicles with transmission PTO) or for power
all wheels. shift (On vehicle with power shift) from the
transmission.
2. Remove the propeller shaft from the companion
flange. 5. Remove the clutch booster with hoses and pipes left
connected.

Before removing the part, be sure to make alignment

marks on the companion flange and propeller shaft.

SGVMT3024L

6. Remove the drain plugs and inspection plug to

discharge transmission oil.
STRAMT0003L

3. Remove the control rods, switch harnesses and

speedometer cable from the transmission.

SGVMT3025L

SGVMT3023L
Manual Transmission
7. When draining the transmission oil, check the oil for
quantity, quality, and metal chips and particles. The
drain plug is a magnet and metal particles adhering
to it should be removed after the inspection.
SGVMT3026L
8. Disconnect the oil cooler hoses from the transmission
and pump (On vehicles with transmission oil cooler).
STRAMT0004L
MT-21
9. Supporting the transmission with transmission jack,
remove the mounting bolts from the clutch housing.
SGVMT3028L
10. Move the transmission rearward until the drive pinion
splines come out of position. Never jerk the
transmission.
SGVMT3029L
MT-22 Manual Transmission
I nst al l at i on 3. Fit the oil cooler hoses to the transmission and pump
1. Check the drive pinion splines for rust. If rust gathers, (On vehicles with transmission oil cooler).
remove it with a wire brush. Then, coat the drive
pinion surface over which the clutch slides with
grease.

STRAMT0004L

4. Make sure that the drain plugs are tightned to

specification, then pour in transmission oil from the
SGVMT3030L inspection port.
2. Supporting the transmission with the transmission Ti ght ni ng t or que :
jack, fit the transmission over the pilot bearing of the 54 - 83 N.m (5.5 - 8.5 kgf.m, 40 - 61 Ib-ft)
engine flywheel. During the procedure, use care to
prevent damage to the drive pinion splines. Then,
tighten to specification the mounting bolts on the
periphery of the clutch housing to secure it onto the
engine.

STRAMT0005L

5. Install the clutch booster.

SGVMT3028L

STRAMT0006L
Manual Transmission MT-23
6. Connect the transmission PTO control (On vehicles D i s a s s e mb l y
with transmission PTO). 1. Remove the clutch housing assembly.
7. Install the control rods, switch harnesses and
speedometer cable to the transmission.

STRAMT0007L

2. To remove the splitter upper case, first remove the

SGVMT3034L
poppet pin and spring.
8. Install the propeller shaft to the companion flange, 3. To remove the splitter case and gear, remove the
making sure that the alignment marks are aligned. splitter gear mounting bolts.
Then, tightening nut to specification.
Ti ght ni ng t or que :
44 - 59 N.m (4.5 - 6.0 kgf.m, 32 - 43 Ib-ft)

Check the following items after equipping th

transmission on the vehicle.
1) Adjust the transmission control.
2) Inspect the clutch pedal height.

STRAMT0008L

4. To remove the main shaft rear lock nut, use a socket

wrench.
5. Remove the companion flange.
6. Remove the rear cover and extension housing.

STRAMT0003L
MT-24 Manual Transmission
R e a s s e mb l y

STRAMT0009L
Manual Transmission MT-25

STRAMT0010L
MT-26 Manual Transmission

STRAMT0011L
Manual Transmission MT-27
1. Install the speedometer sensor. 4. Using the special tool (09431-7A100), install a new
oil seal into the bearing retainer.

STRAMT0012L

2. When installing the splitter case and gear, secure the SGVMT3045L

synchronizer ring to the synchronizer sleeve with the 5. Install the front bearing retainer.
synchronizer ring holder.

Be careful not to damage the oil seal.

SGVMT3043L

3. When installing the splitter case to the transmission,

SGVMT3046L
coat the facing surfaces with sealant (THREEBOND
1215 or equivalent) and tighten the specified torque. 6. Install the main shaft rear lock nut.

STRAMT0013L
MT-28 Manual Transmission
Ge a r S h i f t U p p e r
D i s a s s e mb l y

STRAMT0016L

1. Flexible hose 9. Washer 17. Interlock plate

2. Power shift 10. Oil seal 18. Gear shift sliding lever
3. Air bleeder 11. Dust plug 19. Spring retainer
4. Interlock switch 12. Spring pin 20. Return spring
5. Lock pin 13. Gear shift lever 21. Bushing
6. Gear select lever B 14. O-ring 22. Selector lever spring
7. Gear select lever A 15. Spring retainer
8. Shim 16. 1st / reverse return spring
Manual Transmission MT-29
D i s a s s e mb l y

STRAMT0017L

To remove the bushing press fitted into the selector lever

case, use a screwdriver and tap it out from the back.
MT-30 Manual Transmission

1) Do not remove the bushing unless for replacement.

2) Use care to prevent damage to the case during
removal.

SGVMT3090L
Manual Transmission MT-31
R e a s s e mb l y 2. Apply grease to the oil seal lip and press fit the oil
1. Clean the inner surface of the selector lever case. seal evenly, lip facing down.
Then, using a 40 mm diameter. round bar, press fit
the bushing evenly into the case with care not to gall
Pack grease between lips and make sure that the oil
the case. Note that the front face of the bushing must
seal is installed in the correct direction.
be coated with sealant before installation.

SGVMT3092L
SGVMT3091L

SGVMT3093L
MT-32 Manual Transmission
Ge a r S h i f t L o w e r
D i s a s s e mb l y

STRMT60502L

1. Poppet spring 9. 2nd & 3rd gear shift jaw

2. Interlock pin 10. 2nd & 3rd shift rail
3. Backup lamp switch 11. 2nd & 3rd gear shift fork
4. Dust cap 12. 1st & Rev. gear shift fork
5. Plug 13. 1st & Rev. gear shift jaw
6. Set bolt 14. 1st & Rev. shift rail
7. 4th & 5th shift rail 15. Gear shift lever lower case
8. 4th & 5th gears shift 16. Bolt
Manual Transmission MT-33

STRMT60503L

1. Poppet spring 9. 1st & rev. gearshift jaw 17. 1st & rev. gearshift fork
2. Interlock pin 10. 1st & rev. shift rail 18. O.D shift rail fork
3. Dust plug 11. 2nd & 3rd gearshift fork 19. O.D gearshift jaw
4. Backup lamp 12. 2nd & 3rd gearshift jaw 20. O.D shift rail
5. Inhibitor switch (detecting 2nd) 13. 2nd & 3rd shift rail 21. Flange nut
6. Jaw set bolt 14. 4th & 5th shift rail 22. 1st & rev. shift lever shaft
7. Set bolt 15. 4th & 5th gearshift fork 23. 1st & rev. shift lever
8. 1st & rev. shift rail jaw 16. 1st & rev. shift rail B 24. Gearshift lever lower case

1) Do not disassemble the lower case unless when the

shift fork, shift rail, or shift rail jaw is to be replaced. If
it is to be disassembled, keep the shift lever in
neutral.
2) When disassembling the shift rail, use care not to
lose the interlock pin, steel ball, and poppet spring.
MT-34
I nspect i on pr ocedur e
1. Check the shift rail for bend (A half of the dial gauge
pointer deflection is the bend). If the bend exceeds
the limit, correct or replace the parts.
SGVMT3105L
2. Measure the shift rail O.D (Outer Diameter) I.D (Inner
Diameter) in the gear shifter lower case to obtain the
clearance. If it exceeds the limit, replace the parts.
SGVMT3106L
Manual Transmission
3. Measure the clearance between the shift fork and
synchronizer sleeve and, if it exceeds the limit,
replace the parts.
At the same time, check the shift fork pawl for
perpendicularity. If faulty, correct or replace.
SGVMT3107L
Manual Transmission MT-35
R e a s s e mb l y

STRMT60504L

Make sure of the correct shift fork direction during

reassembly.
MT-36 Manual Transmission

STRMT60505L
Manual Transmission MT-37
R e a s s e mb l y p r o c e d u r e
Install shift rail set bolt and stake the threaded portion at
least at three points with a punch.

SGVMT3110L
MT-38 Manual Transmission
P o we r S h i f t e r
D i s a s s e mb l y

STRMT60506L

1. Lever 12. Connector 23. Square ring 34. Set screw

2. Cover 13. O-ring 24. Seal assembly 36. Cylinder
3. Boot 14. Tube 25. O-ring 37. Oil seal
4. Nut 15. Filter 26. Spring 38 Snap ring
5. Cover 16. Square ring 27. Seat 39. Piston
6. Nut 17 Retaining ring 28. Square ring 40. X-ring
7. Snap ring 18. Plate 29. Spring 41. O-ring
8. Snap ring 19. Lifter 30. Lifter 42. Snap ring
9. Spring 20. O-ring 31. O-ring 43 Shifter rod
10. Steel ball 21. Spring 32. Rod and cap assembly 44 Striker
11. Boot 22. Seat 33. Pipe 45. O-ring
46. Oil seal
47. Housing
Manual Transmission
D i s a s s e mb l y
1. To remove the valve assembly, use a round bar of an
adequate size to push the assembly out carefully.
Do not apply excessive force, as a damaged seat or
square ring could result.
MT-39
3. To remove the striker and shifter rod, remove the
snap ring from the groove in the shifter rod with
pliers, then move parts over the shifter rod little by
little out from the housing. At the same time, the
striker can be removed.

SGVMT3097L

SGVMT3095L

2. Clamp the valve assembly in a vise with care not to

damage the actuating rod and, using a needle or pin,
remove the retaining ring from the pipe. When the
retaining ring is removed, all valve parts can be
disassembled and removed.

Do not apply excessive force, as a damaged seat or

square ring could result.

SGVMT3096L
MT-40 Manual Transmission
R e a s s e mb l y

STRMT60507L

1) Apply ample grease [Wheel bearing grease (NLGI

No.2) Li Soap or equivalent] to sliding portions of
each part after washing.
2) Replace removed oil seals and O-rings with new
ones.
3) Apply sealer to both surfaces of the housing cover
gasket and to the elbow connector.
Manual Transmission
1. To reassemble the valve assembly, reverse the order
of disassembly, mounting valve parts onto the
actuating rod pipe.
Make sure that the spring are installed in the correct
order.
SGVMT3099L
2. After valve parts have been installed, fit the retaining
ring into the groove in the pipe using the special tool.
Be sure to use a new retaining ring.
Do not apply excessive force to insert the retaining
ring into position, as a deformed ring could result.
Specification 6 mm or less
SGVMT3100L
MT-41
3. To install the shifter rod and striker, clamp the
housing in a vise and reverse the order of
disassembly. Working from the housing cylinder,
insert the shifter rod. Then, move the snap ring,
striker, and snap ring, in that order, over the shifter
rod and secure them in the right positions with the
retaining ring. Make sure that the retaining ring is
fitted into the groove in shifter rod.
If can be verified by measuring the dimension
between snap ring heads.
Specification 6 mm or less
SGVMT3101L
4. Before inserting the valve assembly into the shifter
rod, apply an ample amount of grease [wheel bearing
grease (NLGI No.2) li soap] to the inner surface of
the shifter rod. Then, using the special jig, guide,
insert the valve assembly into the shifter rod with
utmost care not to damage seals.
SGVMT3102L
MT-42 Manual Transmission
Re a r c o v e r a n d c l u t c h h o u s i n g
D i s a s s e mb l y

STRAMT0018L

1. Castle nut 7. Rear cover

2. O-ring 8. Oil seal
3. Speedometer gear bushing 9. Bushing
4. Gasket 10. Oil separate plate
5. Oil seal 11. Speedometer worm
6. Speedometer gear 12. Washer(M12S)
Manual Transmission MT-43
T r a n s mi s s i o n A s s e mb l y
I nspect i on
I n s p e c t i o n b e f o r e d i s a s s e mb l y

STRMT60508L
MT-44 Manual Transmission
I nspect i on pr ocedur e
1. Measure the backlash and replace any defective
parts.

SGVMT3049L

2. Measure the end play and replace any defective

parts.

SGVMT3050L
Manual Transmission MT-45
D i s a s s e mb l y

STRMT60509L

1. Reverse shaft lock piece 6. Roller bearing 11. Roller bearing

2. Reverse shaft 7. Roller bearing 12. Main shaft assembly
3. Reverse gear 8. Snap ring 13. Counter shaft assembly
4. Lock seal 9. Roller bearing 14. Transmission case
5. Lock plate 10. Drive pinion assembly

1) If the inner race remains attached to the shaft when

the roller bearing has been removed, disassemble the
gears on each shaft to remove the inner race.
2) After the bearing has been removed, attach the snap
ring removed from the bearing back to where it was to
prevent it from being lost.
MT-46 Manual Transmission
D i s a s s e mb l y 6. To remove the drive pinion bearing, use the special
1. Disassemble the splitter. tool (09434-7A000).
2. Disassemble the extension housing.
3. Disassemble the reverse gear.
4. To remove the counter shaft front bearing, use the
special tool (09434-7A000).

SGVMT3054L

7. To remove the drive pinion, use the special tool (drive

pinion puller).

SGVMT3052L

5. To remove the counter shaft rear bearing, use the

special tool (09434-7A000).

SGVMT3055L

8. To remove the main shaft rear bearing, use the

special tool (09434-7A000).

SGVMT3053L

SGVMT3056L
Manual Transmission MT-47
R e a s s e mb l y

STRMT60510L

The roller bearing with separable inner and outer races

should be installedwith the races attached to them.
MT-48 Manual Transmission
1. Using the special tool (09434-7A100), install the main 3. To install the drive pinion and the main shaft rear
shaft rear bearing. bearing, use the special tool (09434-7A100).

SGVMT3058L SGVMT3060L

2. To install the drive pinion bearing, use the special 4. To install the counter shaft rear bearing, use the
tool (09434-7A100). special tools (09434-7A100).

Be sure to drive the bearing in on a flat surface to

prevent the drive pinion assembly from being
damaged.

SGVMT3061L

5. Install the reverse gear.

6. Install the extension housing.
7. Install the splitter.
SGVMT3059L
Manual Transmission
Ma i n S h a f t
D i s a s s e mb l y
1. 1st gear washer
2. Main shaft 1st gear
3. Needle roller bearing
4. 1st gear bearing sleeve
5. Spacer <except M8S>
6. 1st & Rev. constant-mesh sleeve
7. 1st & Rev. constant-mesh hub
8. Main shaft rev.gear
9. Needle roller bearing
10. Snap ring
11. Pilot bearing
12. Lock nut
13. Lock washer
14. Synchronizer ring
15. Synchronizer sleeve
16. Shifting key
17. Shifting spring
18. Synchronizer hub
19. 4th (5th) gear assembly
20. Needle roller bearing
21. Bearing spacer
22. 4th (5th) gear bearing sleeve
MT-49
STRMT60511L
23. Thrust washer
24. 3rd (2nd) gear assembly
25. Needle roller bearing
26. 3rd (2nd) gear bearing sleeve
27. 2nd & 3rd synchronizer assembly
28. 2nd & 3rd synchronizer hub
29. Synchronizer sleeve
30. Shift key
31. Shift spring
32. 2nd (3rd) gear assembly
33. Needle roller bearing
34. Main shaft
MT-50 Manual Transmission
D i s a s s e mb l y 4. To remove each bearing sleeve, make use of the
1. Using a snap ring expander, remove the snap ring. weight of gear i.e, lightly hit the main shaft against a
lead plate.

Be sure to use a lead plate to prevent main shaft end

from being damaged.

SGVMT3063L

2. Using a pilot bearing puller, remove the pilot bearing.

SGVMT3066L

SGVMT3064L

3. Using a single spanner, loosen and remove the lock

nut.

SGVMT3065L
Manual Transmission MT-51
I nspect i on 3. Measure the clearance between the hub groove in
1. Measure the diametric play in each main shaft gear synchronizer hub and ring protrusion in synchronizer
and needle bearing. ring. If the limit is exceeded, replace parts.

If the play exceeds the limit, replace the needle

bearing.

1) If two needle bearings are used for one gear, use

ones of the same package color for replacement.
2) If placement of the needle bearing does not
correct the excessive diametric play, check each
bearing sleeve and main shaft gear and replace
any defective parts.

SGVMT3069L

4. Measure the clearance between the synchronizer ring

and the gear cone of main shaft 4th (5th : M8S5)
gear assembly.
If the clearance exceeds the limit, replace parts.

Press synchronizer ring evenly and take

measurement throughout the entire circumference.

SGVMT3067L

2. Measure the clearance between the synchronizer hub

keyway and shifting key. Replace parts if the
clearance exceeds the limit.

SGVMT3070L

SGVMT3068L
MT-52 Manual Transmission
5. Measure the clearance between the synchronizer ring
of 2nd (3rd : m8S5) synchronizer assembly and the
synchronizer cone of 2nd gear assembly. If the
clearance exceeds the limit, replace parts.

Press synchronizer ring evenly and take

measurement throughout the entire circumference.

SGVMT3071L
Manual Transmission MT-53
R e a s s e mb l y

SGVMT3072L
MT-54
1. To install the bearing sleeve into the main shaft, use
the special tool (09434-7A100).
Manual Transmission
3. Mate the synchronizer hub with the synchronizer
sleeve, ensuring that the keyways at three places in
the synchronizer hub are aligned with stub teeth at
three places (indicated by * in Fig.) of the
synchronizer sleeve.

If the synchronizer hub and synchronizer sleeve are

reused, be sure to align the alignment marks when
they are reassembled together.

SGVMT3073L

2. Install the thrust washer on the main shaft with larger

contact surface toward the 3rd (2nd : M8S5) gear
assembly.

SGVMT3075L

4. Fit shifting keys into keyways. Then, install the

shifting key spring so that the gap between its ends is
not located at the shifting key positions.

Fit two shifting spring so that their openings are not in

the same position.

SGVMT3074L

SGVMT3076L
Manual Transmission MT-55
5. After assembling gears, tighten lock nut to 7. Fit the snap ring using a snap ring expander.
specification.

SGVMT3079L
SGVMT3077L

6. Using the special tool (09432-7A000 or

09432-7B000) drive the pilot bearing onto main shaft.

SGVMT3078L
MT-56 Manual Transmission
Co u n t e r S h a f t
D i s a s s e mb l y

STRMT60512L

1. Counter shaft constant mesh gear 3. Sunk key

2. Counter shaft 4th (5th : M10) gear 4. Counter shaft
Manual Transmission MT-57
D i s a s s e mb l y
In the case of M8S and M10S, use the special tool,
counter Shaft
Gear puller, and a press to force out the counter shaft in
order to remove the gears. For M12S, use a gear puller.

SGVMT3081L

SGVMT3082L
MT-58 Manual Transmission
R e a s s e mb l y

SGVMT3083L

Using the special tool (09434-7A100), counter shaft gear

Installer and a hydraulic press, press fit each gear into
the counter shaft, ensuring it is aligned with the sunk key.

SGVMT3084L
Manual Transmission MT-59
R e v e r s e I d l e Ge a r
D i s a s s e mb l y

STRMT60513L

1. Reverse shaft lock piece 5. Side washer

2. Reverse gear shaft 6. Needle roller bearing
3. O-ring 7. Bearing spacer
4. Reverse gear
MT-60 Manual Transmission
D i s a s s e mb l y
1. Before disassembly, check for diametral play and
replace any defective part.

SGVMT3086L

2. Using the special tool (09450-75100), reverse gear

shaft puller, remove the reverse gear shaft.

SGVMT3087L
Manual Transmission MT-61
R e a s s e mb l y

SGVMT3088L
MT-62 Manual Transmission
S p l i t t e r Up p e r
D i s a s s e mb l y

STRMT60514L

1. Screw plug 8. Dust seal

2. Spring 9. O-ring
3. Poppet pin 10. Splitter shift fork
4. Interlock switch 11. Snap ring
5. Dust plug 12. Splitter shift fork piece
6. Reamer bolt 13. Splitter upper case
7. Splitter shift lever
Manual Transmission MT-63
R e a s s e mb l y

STRAMT0025L
MT-64 Manual Transmission
R e a s s e mb l y p r o c e d u r e
Install the splitter upper so that the shift lever is
positioned as shown in neutral.

SGVMT3125L
Manual Transmission MT-65
S p l i t t e r C a s e A n d Ge a r
D i s a s s e mb l y

STRMT60515L

1. Snap ring 8. Splitter pinion assembly 15. Shifting key

2. Roller bearing 9. Needle roller bearing 16. Synchronizer sleeve
3. Bolt 10. Spacer 17. Synchronizer hub
4. Lock washer 11. Needle roller bearing 18. Splitter gear
5. Lock plate 12. Synchronizer ring 19. Roller bearing
6. Splitter case 13. Snap ring 20. Snap ring
7. Input shaft 14. Shifting spring 21. Splitter synchronizer cone
MT-66 Manual Transmission
R e a s s e mb l y p r o c e d u r e
1. Measure the backlash before disassembly.
Standard value 0.08 - 0.28 mm
Limit 0.5 mm or less

SGVMT3127L

2. Using the special (09434-7A000), remove the roller

bearing from the input shaft.

SGVMT3128L
Manual Transmission MT-67
R e a s s e mb l y

SGVMT3129L

R e a s s e mb l y p r o c e d u r e 2. Tighten the bolt to the specified torque after installing

1. Using the special tool (09434-7A100), install the splitter case.
roller bearing to the input shaft.

SGVMT3131L

SGVMT3130L
MT-68 Manual Transmission
P o we r Cy l i n d e r
D i s a s s e mb l y

STRAMT0027L

1. Boot 8. Nut
2. Shifter clevis 9. Piston rod
3. Clevis nut 10. Piston plate
4. Body 11. X-ring
5. O-ring 12. O-ring
6. X-ring 13. Stopper
7. Stopper 14. Cylinder
Manual Transmission MT-69
R e a s s e mb l y

SGVMT3133L
MT-70 Manual Transmission
O i l C o o l e r A n d O i l P u mp
R e p l a c e me n t

STRAMT0030L

1. The oil filter of a cartridge type, can be removed from 2. Install the oil cooler with the rubber seat fastened
the bracket assembly for replacement. with nut to the height shown above.

SGVMT3137L SGVMT3138L
Manual Transmission MT-71
D i s a s s e mb l y
Oi l c o o l e r

STRMT60516L

1. Oil pump 4. Oil pump gear 7. Washer

2. Pump retainer 5. Woodruff key 8. Strainer
3. Snap ring 6. Oil pump shaft 9. Pump case
MT-72 Manual Transmission

STRMT60517L

1. Bushing 5. Plunger 9. O-ring

2. Plug 6. Relief valve body 10. Body bushing
3. Plug 7. Cover bushing 11. Pump body
4. Spring 8. Rotor assembly
Manual Transmission MT-73
R e a s s e mb l y
O i l p u mp

STRMT60518L

• Wash parts thoroughly with gas oil, etc before

reassembly
• Apply the sealer to portion marked toprevent
loosening (LOCTITE #262).
MT-74 Manual Transmission
O i l c o o l e r p u mp a s s e mb l y

STRMT60519L

• Use the LOCTITE #271 or equivalent.

• Use the THREEBOND 1215 or equivalent.
Manual Transmission MT-75
P o w e r T a k e Of f ( P . T . O)
D i s a s s e mb l y

STRAMT0028L

1. Gasket 11. O-ring 21. Snap ring

2. Output flange 12. Piston 22. Roller bearing
3. Key 13. Y-packing 23. Ball bearing <M8S, M10S> or
4. PTO control switch 14. O-ring roller bearing <M12S>
5. Gasket 15. Rod 24. PTO gear
6. Cylinder 16. Dust plug 25. PTO sleeve
7. Set bolt 17. Front cover 26. Needle roller bearing
8. Shit fork 18. Rear cover 27. Output shaft
9. Shift fork 19. Oil seal 28. PTO case
10. Nut 20. Ball bearing
MT-76 Manual Transmission
R e a s s e mb l y

SGVMT3135L
Manual Transmission MT-77
I nspect i on 2. Transmission PTO control switch.
1. Transmission PTO switch. Operate the switch to check for continuity between
Operate the switch to check for continuity between terminals according to the connection table below.
terminals according to the connection table below. Replace the switch if the continuity is not as indicated
Replace the switch if the continuity is not as indicated in the table.
in the table. Also replace the illumination lamp bulb if ( Co n n e c t i o n t a b l e )
it is burned out.
Switch position Continuity
( Co n n e c t i o n t a b l e )
ON Continuity
OFF No continuity

SGVMT3143L

STRAMT0029L

SGVMT3144L
MT-78 Manual Transmission
3. Power relay.
(1) Check for continuity between terminals c and e
shown above. Replace the relay if there is a
continuity.
(2) Apply voltage between terminals b and d shown
above by gradually increasing the voltage from 0
V, and determine the voltage at the time when a
continuity is detected between the terminals c
and e .
If the voltage does not conform to specification,
replace the relay.
Specified value : 16 V or less (20°C)

SGVMT3148L

(2) Operational check.

Apply voltage to the valve gradually increasing
from 0V, with a 980 kPa (10 kg/cm²) air pressure
applied to inlet side "1".
The valve should operate at the specified nominal
voltage shown below.
Nominal value : 20 V or less
5. Clutch switch
Operate the switch to check for continuity between
terminals according to the connection table below.
Replace the switch if the continuity is not as indicated
SGVMT3146L
in the table.
4. 3-Way magnet valve.
( Co n n e c t i o n t a b l e )
(1) Air tightness test.
Switch position Continuity
With the outlet side "2" plugged, apply an air
pressure of 295 - 980 kPa (3 - 10 kg/cm²) to the ON Continuity
inlet side "1" check the valve in that state for air
OFF No continuity
leaks both when a 24 V voltage is applied and not
applied.
Ai r c i r c u i t

SGVMT3147L

SGVMT3149L
Manual Transmission MT-79
E x p a n s i o n Ho u s i n g
D i s a s s e mb l y

STRAMT0019L

1. Castle nut 10. Oil seal 19. 6th shift rail B 28. Shifting key
2. O-ring 11. Ball bearing 20. Spacer 29. Shifting spring
3. Speedometer gear bushing 12. Bearing sleeve 21. Set bolt 30. Synchronizer hub
4. Gasket 13. Speedometer worm gear 22. 6th shift rail 31. Synchronizer ring
5. Oil seal 14. Spacer (M12S6) 23. 6th gear shift fork 32. Counter shaft 6th gear
6. Speedometer gear 15. Main shaft 6th gear 24. Lock nut 33. 6th gear sleeve
7. Dust plug 16. Washer (M12S6) 25. Lock washer 34. Thrust (M12S6)
8. Extension housing 17. 6th shift lever shaft 26. Shifting key retainer 35. Bearing retainer
9. Speedometer gear bushing A 18. 6th shift lever 27. Synchronizer sleeve
MT-80
D i s a s s e mb l y p r o c e d u r e
1. Remove the castle nut using socket wrench.
2. Remove the companion flange.
I nspect i on
Measure the speedometer gear shaft O.D and
speedometer gear bushing I.D to calculate the clearance
between the two. Replace parts if the clearance exceeds
the limit.
STRAMT0020L
R e a s s e mb l y
1. Install the speedometer gear bushing A to the
extension housing using a round bar (diameter : 40
mm).
STRAMT0021L
Manual Transmission
2. Install the oil seal evenly in the rear cover or the
extension housing using the rear oil seal installer.
Make sure that the oil seal is installed in the correct
direction.
STRAMT0022L
3. Install the oil seal to the speedometer gear bushing
using a round bar (diameter : 15 mm).
Before installing the oil seal, pack the area indicated
with grease. Make sure of correct installation
direction.
Also apply grease to inner circumference of the
packing.
STRAMT0023L
Manual Transmission Control System MT-81
Manual Transmission Control System
C o mp o n e n t s

STRMT60520L

1. Knob 4. Shift cable selector mounting bracket

2. Ball joint 5. Shift cable
3. Shift cable selector mounting nut 6. Selector cable
MT-82 Manual Transmission
R e mo v a l I nst al l at i on
1. Remove the gear shift lever. 1. Install the gear shift lever assembly.
2. Remove the console box. 2. After the shift lever and selector lever is placed on
3. Remove the ball joint mounting nut at cable side. the neutral position, install the cable.
4. Remove the cable fixing nut.
5. Remove the gear shift lever assembly. • Be careful to install right cable.
6. Remove the ball joint mounting nut at transmission
I t em Co l o r
side.
7. Remove the shift cable and selector cable. Shift cable Black
Selector cable Gray

• Be careful not to be twisted the ball joint.

STRMT60521L

SVCMT5025L
Manual Transmission Control System
• Tighten the adjusting nut (A) at specified torque
after adjusting the load of cable.
Ti ght eni ng t or que :
16.66 - 25.48 N.m (1.7 - 2.6 kgf.m, 12.36 - 18.9 lb-ft)
STRMT60522L
MT-83
I nspect i on
1. Check the operation and damage of the selector
cable.
2. Check the operation and damage of the shift cable.
3. Check the damage of the boot.
4. Check the worn, corrosion and damage of bushing.
5. Check the damage and worn of spring.