Chapter 7 MANUAL TRANSMISSION

1. Structure .................................................................................................. 7-1

1.1 Transmission ........................................................................................................... 7-1
2. Removal and Installation........................................................................ 7-3
2.1 Removal .................................................................................................................. 7-3
2.2 Installation ............................................................................................................... 7-3
3. Disassembly ............................................................................................ 7-4
3.1 Removal of External Parts....................................................................................... 7-4
3.2 Control Covers, Shift Rails and Forks ..................................................................... 7-5
3.3 Shifter Case and Input Shaft ................................................................................... 7-6
3.4 Transmission Housing and Shaft Assemblies ......................................................... 7-8
4. Inspection and Repair........................................................................... 7-11
4.1 Shift Fork ............................................................................................................... 7-11
4.2 Shift Rail ................................................................................................................ 7-11
4.3 Input Shaft ............................................................................................................. 7-11
4.4 Main Shaft ............................................................................................................. 7-11
4.5 Synchromesh......................................................................................................... 7-12
4.6 Reassembly........................................................................................................... 7-13
4.7 Transmission Housing ........................................................................................... 7-17
4.8 Forks, Shift Rails and Control Cover ..................................................................... 7-18
5. Troubleshooting.................................................................................... 7-20
6. Service Data........................................................................................... 7-21 7
 MANUAL TRANSMISSION

1. Structure
Chapter 7 MANUAL TRANSMISSION

1.1 Transmission

b(23) c(33) d(30)

a(35)

F: Forward
R: Reverse
L: 1st speed
H: 2nd speed

H L R F

e(31)
f(43)
h(30)
g(33)

i (61)

214335

The direct drive transmission offers two forward

speeds and two reverse speeds. Gear change is
Transmission reduction ratio
accomplished manually, using a gear shift lever.
1st 43 61
The transmission is of a synchromesh type, with the × = 3.801
For speed 23 30
forward-reverse changeover achieved via a double- wa
cone synchronizer. rd 2nd 31 61
× = 1.800
speed 35 30
Power flow 43 33 61
Re 1st
× × = 3.801
Range Power path ver speed 23 33 30
se
F−L b→fh→i 2nd 31 33 61
tra
× × = 1.800
F−H a→eh→i vel speed 35 33 30
R−L b→fg→cd→i
R−H a→eg→cd→i

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1.1.1 Synchromesh 1 (H and L)

1 2 3 4 5 6
1 Synchronizer sleeve
2 Synchronizer hub
3 Synchronizer key
4 Key spring
5 Synchronizer ring
6 Synchro-gear
7 Key groove
8 Fork groove 7 8 9 9 10
9 Key way 213607
10 Cone

1.1.2 Synchromesh 2 (F and R)

1 2 4 3 12 5 6 7 8
1 Synchronizer sleeve
2 Synchronizer hub
3 Synchronizer key
4 Key spring
5 Outer ring
6 Synchro-cone
7 Inner ring
8 Gear 12
11 12
9 Key groove 9 10
213608
10 Fork groove
11 Key way
12 Cone

Synchro-cone 6 is a double cone, with the inner and

outer faces in contact with respective balk rings.
This will ensure that more frequently-used forward-
reverse shuttling be smoother than less frequently-
used high-low changeover.

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 MANUAL TRANSMISSION

2. Removal and Installation

2.1 Removal
(1) Remove the engine and transmission as an
assembly from the truck.
Note:For removal and installation procedures for the
engine and transmission as an assembled unit,
refer to “Removal and Installation” in “Chapter 5
POWER TRAIN.”
(2) Remove the drain plug on the transmission hous-
ing to allow the gear oil to drain.
(3) Remove the drain plug on the transmission hous-
ing to allow the gear oil to drain. (Wet-type clutch
only)
(4) Separate the transmission assembly from the
engine.
Note:The clutch disc and pressure plate will stay on
the engine. Drain plug on clutch housing
Drain plug on transmission
housing 214338
2.2 Installation
To install, follow the removal sequence in reverse.
Also follow the instructions given below.
(1) With a wet-type clutch transmission, clean the
face that comes into contact with the engine side.
Use a new gasket.
(2) Fill the transmission housing with transmission oil.
Check the oil level using a level gauge.

7-3
MANUAL TRANSMISSION

3. Disassembly
3.1 Removal of External Parts

7
9
6
8

11
10

4
3
2

213610
Disassembly sequence
1 Mount LH 6 Backup lamp switch
2 Mount RH 7 Neutral switch
3 Output flange 8 Ball, pin
4 Cable bracket 9 Oil level gauge
5 Air breather 10 Drain plug
11 Drain plug (wet-type clutch)

7-4
 MANUAL TRANSMISSION

3.2 Control Covers, Shift Rails and Forks

4 12
1 14

5 8

6
10

2 10
11

13

213611
Disassembly sequence
1 Control cover 8 Fork lever
2 Control cover plate, Bolts, Washers 9 Plug, Gasket
3 Lock pin, Nut 10 Spring and steel ball
4 Control lever, Needle roller bearing, Oil Seal 11 Shift rail (F-R)
5 Fork lever 12 Shift fork (F-R)
6 Lock pin, Nut 13 Shift rail (H−L)
7 Control lever, Needle roller bearing, Oil Seal 14 Shift fork (H−L)

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MANUAL TRANSMISSION

3.3 Shifter Case and Input Shaft

7 6

12
8

13 5
11
10
9

4
1

4
2

213612
Disassembly sequence
1 Lock pin, Nut 8 Shifter case
2 Clutch shaft 9 Spring, Locking ball
3 Clutch fork 10 Oil seal
4 Needle roller bearing 11 Stopper ring
5 Clutch shifter 12 Input shaft, Ring spring
6 Clutch release bearing 13 O-ring
7 Grease nipple

7-6
 MANUAL TRANSMISSION

Suggestions for Disassembly

(1) Removing shifter case
(a)Using jack bolts, remove the shifter case from
the transmission housing.
Shifter case
Special tool needed
Bolt 91268-05100

Note:The threads on the jack bolt must have an effec-

tive length of 55mm.

(b)Locking ball 9 in input shaft 12 will pop out by 214342

the spring force when shifter case 8 is
removed. To prevent this, cover shifter case 8
while disassembling.

7-7
MANUAL TRANSMISSION

3.4 Transmission Housing and Shaft Assemblies

2 3

213614
Disassembly sequence
1 Transmission housing 3 Input gear assembly
2 Synchro-shaft assembly 4 Output gear

Suggestions for Disassembly

(1) With the input shaft removed, remove the trans-
mission housing mounting bolts on the clutch
housing side.
(2) With the clutch housing side laid on the floor,
remove the remaining transmission housing
mounting bolts.
(3) Lift the transmission housing using wire rope and
lifting hardware attached to the holes on the hous-
ing.
(4) With the wire rope slightly taut, tap the area
evenly near the dowel pins to loosen out the hous-
ing.
(5) Set the wire rope around the main shaft and input
gear assemblies, and lift them out together.
(6) Remove the output gear.

7-8
 MANUAL TRANSMISSION

3.4.1 Disassembling Syncro-shaft Assembly

12 11

13
14

16 15

17 1

18
19
20

10

2 8
7
1
6

5
4
3
213615
Disassembly sequence
1 Shim 11 Nut
2 Nut 12 Roller bearing
3 Roller bearing 13 Thrust washer
4 Thrust washer 14 Forward gear
5 High gear 15 Needle roller bearing
6 Needle roller bearing 16 Synchro-sleeve
7 Synchro-sleeve 17 Synchromesh assembly (F−R)
8 Synchromesh assembly (H−L) 18 Reverse gear
9 Low gear 19 Needle roller bearing
10 Needle roller bearing 20 Main shaft

7-9
MANUAL TRANSMISSION

3.4.2 Disassembling Input Gear Assembly

5
6

8
3

4
9

213616
Disassembly sequence
1 Sealing cap 6 Ball bearing
2 Ball bearing 7 Idler gear
3 Ball bearing 8 Ball bearing
4 Spacer 9 Input gear
5 Snap ring

3.4.3 Output gear, Disassembly

Disassembly sequence 1
1 Ball bearing
2 Output gear
3 Ball bearing 2

3
213617

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 MANUAL TRANSMISSION

4. Inspection and Repair

4.1 Shift Fork
(a)Check for bend, cracks, or worn fork tips. If
defective, replace.
4.2 Shift Rail
(a)Check for bend, cracks, or worn ball grooves.
4.3 Input Shaft
(a)Check for bend, cracks, or worn gear teeth or
splines.
4.4 Main Shaft
(a)Check for bend, cracks, or worn gear teeth or
splines.
(b)Check the bearings for wear on rolling contact
faces.
(c)Check the thrust washers for wear or damage.

213618

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MANUAL TRANSMISSION

4.5 Synchromesh
(a)Check the gears and keys for wear or damage.
H–L

213619

R–F

213620

(b)Check the cones for wear or damage.

(c)Measure the axial clearance between the gear H㪄L 1.75 mm
and synchronizer ring.
Cone
A: Standard value B: Repair or service limit
A 1.75 mm
H-L
Axial clearance between B 0 mm
gear and ring A 1.85 mm
F-R
B 0.25 mm

213621

F–R 1.85 mm

Cone

213622

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 MANUAL TRANSMISSION

4.6 Reassembly
4.6.1 Shifter case

Reassembly sequence
1 O-ring
2 Shifter case, Bolts, Spring washers Clutch housing
3 Oil seal
2
Suggestions for Reassembly
(1) Oil seal
(a)Apply grease (LG2) onto the oil seal lips. Also
apply a thin coat of grease to in-between the
3
lips but never grease too much as it can result
in oil leakage.
1

213623

4.6.2 Output gear

3
Reassembly sequence
1 Ball bearing 2
2 Output gear
3 Ball bearing

Suggestions for Reassembly

(1) Install bearing to gear before installing to the 1
housing.
213624

4.6.3 Input Gear and Idler Gear

1
Reassembly sequence 2
1 Ball bearing
Install 2 to 6 as an assembly.
2 Input gear
3 Ball bearing 3 4
4 Idler gear
5 Ball bearing
6 Snap ring, Spacer
5
7 Ball bearing
6

Suggestions for Reassembly

(1) Assemble input gear, idler gear and bearings, etc.
before installing to the housing.
7
213625

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MANUAL TRANSMISSION

4.6.4 Main shaft assembly

18 16 12 3 7 9
13 4

20 20

19 10

17 8

15 14 11 2 5 6

213626
Reassembly sequence
1 Syncro-shaft assembly 11 Needle roller bearing
2 Needle roller bearing 12 Low gear
3 Reverse gear 13 Synchromesh assembly (H−L)
4 Synchromesh assembly (F−R) 14 Synchro-gear sleeve
5 Synchro-gear sleeve 15 Needle roller bearing
6 Needle roller bearing 16 High gear
7 Forward gear 17 Thrust washer
8 Thrust washer 18 Roller bearing
9 Roller bearing 19 Nut
10 Nut 20 Shim

7-14
 MANUAL TRANSMISSION

Suggestions for Reassembly

(1) Needle roller bearing
(a)Apply gear oil to the needle bearings before
they are installed.
(2) Synchromesh assembly
(a)Align three grooves on the outer circumference
of the synchronizer hub with the synchronizer
sleeve before the sleeve and hub are assem-
bled together.
(b)Apply molybdenum disulfide grease (Never-
seez or equivalent) to the contact faces of the
cone on the gear and the cones of the synchro-
nizer rings. Aligning
position
213627

(3) Thrust washer

(a)One side of the thrust washer faces the bearing Bearing side
and the other side faces the gear. Make sure
Gear side
that the thrust washers are installed correctly.

213628

(4) Nut
(a)Tighten the nut to the specified torque. Do not
use a impact wrench.

A: Standard value
Tightening torque A 245 ± 24.5 N·m

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MANUAL TRANSMISSION

(1) Selection of Shims

D L (distance between bearing outer races) D Photosensor

B2
C
L
B1
213629

(a)The required thickness D of shims (for one

side) can be obtained as follows.
D = (212.7−L)/2
Note:The nominal value of D is 0.1. Round off to one
decimal place.
(b)Using special tools with known B1 and B2
dimensions, measure the dimension C while
pressing the bearing outer races evenly.
Calculation of L dimension: L = C - B1 - B2

(c)From the list below, select a shim(s) that corre-

sponds to the dimension D.
Thickness (t) Part number
t = 0.1 mm 91A25-05100
t = 0.2 mm 91A25-05200
t = 0.3 mm 91A25-05300
t = 0.4 mm 91A25-05400
t = 0.5 mm 91A25-05500
t = 0.6 mm 91A25-05600

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 MANUAL TRANSMISSION

4.7 Transmission Housing

4.7.1 Reassembly

(1) Install the dowel pins into the clutch housing mat-
ing face, and install the gasket.
(2) Install the selected shim(s) into the transmission
housing, and install the bearing outer race.
(3) Using the same procedure as for disassembly, lift
the transmission housing and assemble it onto the
clutch housing while keeping both housings hori-
zontally. a
(4) Make sure the mounting bolts that are seeded on
a
transmission housing side have the specified
length. Tighten the bolts to specified torque.
a
a 35 mm
Bolt nominal length L a
b 65 mm
b b b b b
Note:The bolts on the transmission housing side must
be tightened to the standard torque, 39.2 ± 3.3 213630
N·m(4± 0.3 kgf·m).
(5) Through the top opening, press the main shaft
assembly with Q and R pinched as shown in the Q R
illustration to ensure the synchro-shaft play (0.3 to
0.6mm).

213631

(6) Apply a thin coat of grease (LG2) to the oil seal

lips before installing the oil seal.
(7) Install the output flange while taking care not to
damage the oil seal. Oil seal

Output flange

213632

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MANUAL TRANSMISSION

4.8 Forks, Shift Rails and Control Cover

18 17 20 17 21 19
H and L 3

10

7 22

13 12 15 12
F and R
11 16
14
8
5

1
213633
Reassembly sequence
1 Shift fork (F-R) 12 Needle roller bearing
2 Shift rail (F-R) 13 Oil seal
3 Screw 14 Fork lever
4 Plug, Gasket 15 Control lever (F−R)
5 Spring and steel ball 16 Lock pin, Nut
6 Shift fork (H−L) 17 Needle roller bearing
7 Shift rail (H−L) 18 Oil seal
8 Screw 19 Fork lever
9 Plug, Gasket 20 Control lever (H−L)
10 Spring and steel ball 21 Lock pin, Nut
11 Control cover 22 Control cover plate, Bolts, Washers

Suggestions for Reassembly

(1) Apply Loctite to the screw before installing. [Tight-
ening torque: 29.4 ± 2.9 N·m (3± 0.3 kgf·m)]
(2) After that, firmly fix the screw to the shift rail using
a wire.

7-18
 MANUAL TRANSMISSION

Suggestions for Reassembly

(1) Reassembling control cover
(a)Install parts 10 to 20 onto control cover 9. Then,
install the subassembly onto the transmission
housing.

(2) Gear rotation

(a)With the transmission reassembled, shift it into
2nd Forward. Then, make sure that the output
flange can be turned by hand.
(b)If it cannot be turned by hand, this may be due P
to the roller bearing outer race having been
seated incorrectly. Using a plastic hammer, tap
the transmission casing (P) where the roller
bearing is located several times, and try to turn
again.
213634
(c)If still not possible to turn, this may be due to
incorrect shimming. Disassemble and re-calcu-
late the required shim thickness.

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MANUAL TRANSMISSION

5. Troubleshooting

Clutch dragging Refer to “Chapter 6, CLUTCHES.”

Fork set screw loose in shift rail Retighten.
Shift rail distorted, cracked or worn in grooves Inspect, and if defective, replace.
Hard shifting
The cone of synchronizer ring damaged, resulting in a failure of
Replace.
synchronizer to operate properly
Synchronizer ring splines damaged Replace.
Shift rail distorted, worn in grooves Inspect, and if defective, replace.
Change lever slip out Worn splines of synchronizer sleeve Replace.
Worn gear splines Replace.
Oil level too low, or of wrong type Refill or replace.
Transmission is noisy
when truck is stopped Gears abnormally worn, or bearings badly worn Inspect, and if defective, replace.
and clutch is disen- Shaft spline excessively worn Replace shaft.
gaged
Shaft bent and axial play too large Replace shaft.

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6. Service Data
A: Standard value B: Repair or service limit
Unit: mm
Truck type
Item
1 ton class 2 ton class 3 ton class
Shift rail Shift rail diameter 1 A -0.016
16-0.050
Clearance between shift rail and case A 0.016 to 0.093
Distortion of shift rail A 0.03

Free length of poppet spring 2 A 29.0 (24.97)

(Spring constant: k = N/mm (kgf/mm) B 25

213635

Input gear Inside diameter of idler gear 1 A -0.006

75-0.019
0
Outside diameter of F – R gear 2 for input gear A 45-0.011

1 2 2 1
213636

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MANUAL TRANSMISSION

A: Standard value B: Repair or service limit

Unit: mm
Truck type
Item
1 ton class 2 ton class 3 ton class
Main shaft Thickness of thrust washer 4 0
A 4.5-0.1
(clutch side)
Thickness of thrust washer 5 0
A 4.5-0.1
(differential side)
+0.029
Inside diameter of F gear 6 A 55+0.010
-0.009
Outside diameter of F gear sleeve 7 A 50-0.020
+0.029
Inside diameter of R gear 8 A 55+0.010
-0.009
Outside diameter of shaft for R gear 9 A 50-0.020
+0.029
Inside diameter of H gear 10 A 55+0.010
-0.009
Outside diameter of H gear sleeve 11 A 50-0.020
+0.029
Inside diameter of L gear 12 A 55+0.010
-0.009
Outside diameter of shaft for L gear 13 A 50-0.020

5 4

11 10 13 12 9 8 7 6

213637

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A: Standard value B: Repair or service limit

Unit: mm
Truck type
Item
1 ton class 2 ton class 3 ton class
Main shaft A 1.75
H-L
B 0
Axial clearance between gear and ring 14
A 1.85
F-R
B 0.25

H-L F-R

14
14
Cone
Cone

213638

Gear Backlash between gears E and J, gears A A 0.11 to 0.25

and J, gears C and G, and gears D and H B 0.5

Other backlash A 0.12 to 0.27

(gears B and F) B 0.5

D C B A

H L R F

H GF

J 214876

7-23