Transmission-MT Transmission

Transmission-MT
Specifications
Torque
Description Value
Bolt - Select Rocker Arm Assembly to Handling Base 22-30 Nm
Drain Plug 30-40 Nm
Refill Plug 30-40 Nm
Back-up Light Switch 32-44 Nm
Bolt - Rear Housing Deck Board to Rear Housing 10-14 Nm
Bolt - Drive Shaft Front Bearing Cover Plate to Front Housing 22-30 Nm
Bolt - Main Speed Reduction Driven Gear to Differential 140-170 Nm
Housing
Bolt - Front Housing to Rear Housing 30-40 Nm
Bolt - Handling Base to Rear Housing 22-30 Nm
Bolt - Gear Shift Bracket to Front Housing 22-30 Nm
Bolt - Rear Housing to Reverse Shaft 32-44 Nm

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Bolt - Reverse Lock Stopper Plate to Handling Base 18-26 Nm
Location Pin - Rear Housing to Interlock Ring 30-40 Nm
Bolt - Oil Cylinder Holding Bracket to Rear Housing 22-30 Nm
Self-locking Pin Assembly 32–44 Nm
Bolt - Guide Sleeve to Front Housing 10-14 Nm

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Description Value
Bolt - Release Fork to Release Rocker Arm Assembly 30–40 Nm

Parameter
Manual Transmission
Model 5-speed Manual Transmission SH78ZB (1.5 VCT)
Speed Ratio:
·1st gear 3.583

·2nd gear 2.105

·3rd gear 1.379

·4th gear 1.030

·5th gear 0.820

·Reverse gear 3.363

·Main speed reduction 4.389

Transmission Centre Distance 78 mm

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Maximum Input Torque 135 Nm
Maximum Input Speed 7000 r/min
Weight (without oil) 44.8 kg
Lubricant MTF94
Standard Oil Capacity:
· Drain and Refill 2.0 L
· Dry Fill 2.2 L
Maximum Transmission Contour Size
(Length x Width x Height) 399 mm x 504 mm x 392 mm

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Description and Operation
System Component Layout
Transmission Assembly and Accessory

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1. 1.5 L Manual Transmission Assembly 5. Back-up Light Switch Assembly
2. Gear Shift Bracket 6. Aluminum Washer
3. Screw - Gear Shift and Cylinder Bracket 7. Drain Plug
4. Screw - Gear Shift Bracket 8. Release Cylinder Bracket

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Transmission Control and Case

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1. Shift Rocker Arm Assembly 17. Spring Pin Ø3×16
2. Combination Elastic Cylindrical Pin 18. Reverse Lock Torsional Spring
3. Nylon Block 19. Reverse Lock Shaft
4. Gear Shift Shaft Oil Seal 20. Washer
5. Gear Shift Shaft Linear Bearing 21. Bolt - Connect Reverse Lock Retainer Plate to Handling
6. Magnetic Steel Assembly Base

7. Bolt - Connect Selector Support to Handling Base 22. Location Pin

8. Gear Shift Shaft 23. Aluminum Washer

9. Breather Plug 24. Reverse Lock Retainer Plate

10. Handling Base 25. Interlock Ring

11. Bolt - Connect Handling Base to Rear Housing 26. Gear Shift Arm Guide

12. Handling Base Location Pin - Connect Handling Base to 27. 5th/Reverse Return Spring Assembly
Rear Housing 28. 1st/2nd Shift Fork Shaft Bushing
13. 1st/2nd Return Spring Retainer 29. 1st/2nd Shift Fork Shaft
14. 1st/2nd Return Spring 30. 1st/2nd Shift Fork
15. Reverse Safety Stand 31. Spring Pin Ø5×22
16. Reverse Lock Block 32. 1st/2nd Shift Selector

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33. 3rd/4th Shift Selector 54. Release Fork Bushing
34. 3rd/4th Shift Fork 55. Release Fork Boot
35. 5th/Reverse Shift Fork 56. Release Rocker Arm Assembly
36. 5th/Reverse Shift Fork 57. Guide Sleeve
37. Back-up Light Signal Block 58. Guide Sleeve Bolt
38. 5th/Reverse Shift Fork Shaft 59. Release Bearing Assembly
39. Self-locking Pin Assembly 60. Release Fork Bolt
40. Aluminum Washer 61.
41. Housing Service Bolt 62. Release Fork
42. Cover 63. 3rd/4th Shift Fork Shaft
43. Driven Shaft Guide Nozzle 64. Rear Housing
44. Drive Shaft Guide Nozzle 65. Dust Cover - Select Rocker Arm
45. Rear Housing Deck Board 66. Centre Pin - Select Rocker Arm
46. Bolt - Rear Housing Deck Board 67. Nylon Washer (Flange)
47. Bolt - Reverse Idler Gear Shaft 68. Select Rocker Arm

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48. Aluminum Washer 69. Nylon Washer
49. Oil Filler Plug 70. Select Rocker Arm Bracket
50. Aluminum Washer - Oil Filler Plug 71. Plate Washer
51. Location Pin - Front and Rear Housing 72. Nut - Select Rocker Arm
52. Front Housing 73. Oil Deflector
53. Release Fork Bushing

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Gear Drive Mechanism
1. Drive Shaft Front Bearing Circlip
2. Drive Shaft Front Bearing
3. Bearing Cover Plate
4. Bolt - Bearing Cover Plate
5. Drive Shaft
6. Drive Shaft 3rd Gear Assembly
7. 3rd/5th/Reverse Needle Roller Bearing
8. 3rd/4th Synchronizer Tapered Ring
9. 3rd/4th (5th/Reverse) Synchronizer Sleeve
10. 3rd/4th Synchronizer Gear Hub
11. 3rd/4th, 5th/Reverse Synchronizer Slider Assembly
12. 2nd Synchronizer Inner Tapered Ring
13. Drive Shaft 4th Gear Assembly
14. 4th Needle Roller Bearing Assembly
15. Drive Shaft 5th Gear
16. Drive Shaft 5th Gear Retainer
17. Retainer Sleeve
18. Drive Shaft Rear Bearing
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Transmission-MT
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19. Driven Shaft Front Bearing Circlip
20. Drive, Driven Shaft Hole Oil Seal
21. Reverse Idler Gear Shaft
22. Reverse Idler Gear Needle Roller Bearing
23. Reverse Idler Gear
24. Reverse Idler Gear Stopper Plate
25. Reverse Idler Gear Circlip
26. Driven Shaft Front Bearing
27. Driven Shaft
28. Driven 1st Needle Roller Bearing Assembly
29. Driven 1st Gear Assembly
30. 1st/2nd Synchronizer Inner Tapered Ring
31. 1st/2nd Synchronizer Middle Ring
32. 1st/2nd Synchronizer Outer Tapered Ring
33. 1st/2nd Synchronizer Sleeve
34. 1st/2nd Synchronizer Slider
35. 1st/2nd Synchronizer Gear Hub
36. Driven 2nd Needle Roller Bearing Assembly
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37. Driven 2nd Gear Assembly
38. Driven 3rd Gear
39. Driven Shaft 3rd/4th Spacer
40. Driven 4th Gear
41. Driven 5th Needle Roller Bearing Assembly
42. Driven 5th Gear Assembly
43. 5th/Reverse Synchronizer Gear Hub
44. Driven Reverse Needle Roller Bearing Assembly
45. Driven Reverse Gear Assembly
46. Driven Shaft Rear Bearing
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Transmission
47. Driven Shaft Rear Bearing Stop Collar
48. Driven Shaft Rear Bearing Circlip
49. 3rd/4th Synchronizer Assembly
50. Tri-synchro Rings-1st/2nd Gears
51. 1st/2nd Synchronizer Assembly
52. 5th/Reverse Synchronizer Assembly
53. Drive Shaft Oil Seal
54. 5th Synchronizer Tapered Ring
55. Reverse Synchronizer Tapered Ring
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Differential Assembly

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1. Propeller Shaft Oil Seal 7. Adjusting Shim
2. Cone Bearing 8. Planetary Gear Shim
3. Differential Case 9. Planetary Gear
4. Main Speed Reduction Driven Gear 10. Side Gear Shim
5. Planetary Shaft Pin 11. Side Gear
6. Bolt - Differential Housing to Main Speed Reduction 12. Planetary Shaft
Driven Gear

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Description • 3rd/4th/5th/Reverse Synchronizer Gear Ring
General Description • 5th/Reverse Synchronizer Gear Hub, Sleeve and
This vehicle is equipped with a 5-speed manual transmission Synchronizer Slider Assembly
SH78ZB (1.5 VCT). The shift lever is on the passenger • Reverse Gear and Bearing
compartment centre console, which provides the driver with • Rear Bearing
6 options for the transmission position - 1st, 2nd, 3rd, 4th, 5th
The transmission has the following speed ratios:
and reverse gear. The drive shaft, which transfers drive force
to the wheels, is fitted in the differential assembly behind the Gear Position Speed Ratio
transmission.
1st Gear 3.583
Transmission Case
2nd Gear 2.105
The transmission case is made of cast aluminium, and
3rd Gear 1.379
connected to engine cylinder block by bolts. The input shaft
and output shaft of transmission are supported by bearings. 4th Gear 1.030

The transmission case is equipped with an oil filler plug on 5th Gear 0.820
the front lower part and a drain plug sealed by a aluminum Reverse Gear 3.363
washer on the rear lower part. Lubricant is added into
Main Speed Reduction 4.389
the transmission to lubricate inner components by splash.

The breather plug is fitted in the back of the handling base.
A stamped steel sealing panel seals the opening between
transmission and engine cylinder block.
Transmission Set
The front end of the input shaft has splines, which engage with
the spline hub on the driven disc of the clutch. The input
shaft is supported by the front bearing and bearing seat, and
is arranged from the end of the cylinder block in the following
order:
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Shift and Select
Gear selection is done by operating the shift lever fitted on the
centre console of the passenger compartment. The ends of the
two cables in one side are connected to the bottom of the shift
lever. The other ends pass through the centre path, and are
connected with select rocker arm and shift rocker arm on the
outside of the transmission by the union ring set, and fixed by
screws. The shift fork shaft and shift fork in the transmission
case are connected.

• 3rd Gear and Bearing Reverse Gear Protection and Reverse Gear Switch
• 3rd/4th Synchronizer Gear Ring Reverse lock-up mechanism is used to prevent shifting directly
• 3rd/4th Synchronizer Gear Hub, Synchronizer Sleeve, from 5th to reverse by accident. Plunger type back-up light
Synchronizer Slider Assembly switch is fitted on the rear transmission case.

• 3rd/4th Synchronizer Gear Ring Differential

• 4th Gear and Bearing For a traditionally-designed differential, the main speed
• 5th Gear and Bearing reduction driven gear is secured to the differential housing
with bolts, and the differential housing supports the planetary
• Rear Bearing and Rear Oil Seal
shaft pin, planetary gear and sun gear. Differential assembly is
The reverse idler gear is supported by the reverse idler gear in the transmission case and supported by the cone bearing.
shaft.
The front end of the output shaft has a machined gear. The
output shaft is supported by the front bearing and bearing
seat, and is arranged from the end of the cylinder block in the
following order:
• 1st Gear
• 1st/2nd Synchronizer Inner Tapered Ring, Middle Ring,
Outer Tapered Ring, Synchronizer Gear Hub, Sleeve and
Synchronizer Slider Assembly
• 2nd Gear, 3rd Gear and Bearing
• 3rd Gear
• 4th Gear, 5th Gear and Bearing

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Operation plate will stop it. Thus, it avoids 5th being switched to reverse
Transmission Set directly.

Drive train changes the speed and direction of rotation Differential

through the engagement of different gears on the input shaft The differential allows wheels to turn at different speeds while
and output shaft, resulting in 5 forward gears with different they output the same torque. The pinion integrated with the
speed ratios and 1 reverse gear. Except the reverse gear, gears output shaft engages with the main speed reduction driven gear
continuously engage in all other gears. When selecting 1st of the differential assembly. When the output shaft rotates and
gear, synchronizer sleeve applies pressure to the synchronizer the wheels move straight forward, the torque is applied to the
gear ring to make it touch the tapered ring corresponding to whole assembly, but the planetary gear does not rotate. The
the selected gear. This makes the synchronizer gear hub and torque is transferred to wheels by the drive shaft.
the gear maintain the same speed. And then, synchronizer
When the vehicle turns, the inside wheels travel a shorter
sleeve extends into gear through the synchronizer slider
distance at a slow speed. This makes the planetary gear rotate,
assembly and extended-teeth of synchronizer sleeve. The shift
the outside sun gear provides outside wheels with a faster
head of the gear shift shaft ensures accurate gear selection,
speed.
and the gear keeps in operation position. The torque is
transferred to input shaft of the transmission from the engine
through the clutch. And then, through the selected gear, the
torque is transferred to the pinion of the output shaft and

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the main speed reduction driven gear, then to the drive shaft.
The operation of 2nd, 3rd, 4th and 5th is the same as that of
1st. When selecting reverse gear, the reverse gear (integrated
with input shaft) engages with the output shaft reverse gear
and reverse idler gear to change the rotation direction of the
output shaft, achieving the reverse.
Shift and Select
When moving the shift lever to 1st gear, the shift lever operates
the gear shift rocker arm through the cable. Select rocker
arm is rotated by the torque of the cable to pull the gear
shift shaft outward, the gear shift arm guide on the gear shift
shaft is moved outward accordingly to the groove of 1st/2nd
shift selector, at this time, the gear shift arm guide should
disengage from the groove of 3rd/4th arm guide completely.
One end of interlock ring will get caught in the groove of
3rd/4th and 5th/reverse shift selector, and the other end will
disengage from the groove of 1st/2nd shift selector completely.
After that, the gear shift shaft is rotated by the shift rocker
arm through the torque of the cable, the gear shift arm guide
will rotate together with the gear shift shaft, one side of the
gear shift arm guide will flip the 1st/2nd shift selector, which
will drive the 1st/2nd synchronizer to achieve the gear shift
function of the 1st. The operation of other gears is the same
as that of the 1st.
Reverse Protection
When selecting the 5th, the reverse lock block acts on the
outside of the reverse lock stopper plate by the torque of the
torsional spring. When switching to 5th, the reverse lock block
is free from the reverse lock stopper plate, with the torque of
the torsional spring, it will return to normal position. When
5th is directly switched to reverse, the reverse lock block will
rotate in the opposite direction, and the reverse lock stopper

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Service Procedures transmission and tighten the bolt to 22-30 Nm.
Gear Shift Shaft Oil Seal - Manual 5. Connect the cable ball joint to gear shift rocker arm.
Removal 6. Check shift quality, if it is difficult to shift under high
1. Remove the battery box. friction load condition, it indicates that the fitting is not
Battery Box Removal correct. Remove the assembly and refit as instructions.
2. Make sure that the shift lever is in neutral. 7. Fit the battery box.
3. Notice the mounting position and release the gear shift Battery Box Refit
cable ball joint from the gear shift rocker arm of the
manual transmission.

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4. Remove 2 bolts securing the gear shift bracket to the
handling base of the transmission and remove the
bracket.

5. With the assistance, support the shift rocker arm,

remove the cylindrical pin securing it, and then remove
the shift rocker arm.
6. Remove and dispose of the gear shift shaft oil seal.
Refit
1. Clean the mating surfaces of the gear shift shaft oil
seal groove, the gear shift bracket and the transmission
handling base.
2. Fit the new oil seal to the gear shift bracket and ensure
the stepped portion of the oil seal faces outward.
3. Fit the shift rocker arm and fix it with a new cylindrical
pin.
4. Fix the gear shift bracket to the handling base of

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Manual Transmission Fluid - Drain and Refill Manual Transmission Assembly

Drain and Refill Removal
1. Remove the bottom wind deflector panel. 1. Remove the battery box.
Bottom Wind Deflector Panel Removal Battery Box Removal
2. Place a proper container under the transmission. 2. Remove the bolts securing the battery tray, and remove
3. Clean the area around drain plug, remove the drain the battery support.
plug and dispose of the gasket seal.
4. Drain the transmission fluid.
5. Clean the refill hole and the drain plug.
6. Place a new gasket seal on the drain plug, fit and tighten
the drain plug to 30-40 Nm.
7. The transmission fluid is added into the transmission
through the refill hole by using the proper and clean
funnel until reaching to the specified value.
Drain and Refill 2.0 L

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Dry Fill 2.2 L

Tip: Filler thread minor diameter Φ is 14.38 mm.

8. Place a new gasket seal on the oil filler plug, fit and
tighten the oil filler plug to 30-40 Nm.
9. Fit the bottom wind deflector panel.
Bottom Wind Deflector Panel Refit

3. Remove the air cleaner assembly.

Air Cleaner Assembly Removal
4. Remove the bolts and nuts securing the air cleaner
bracket and remove the bracket.

5. Disconnect the back-up light switch connector and

release the wire harness retaining snap fit.

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6. Release 2 snap fits securing the positive battery cable Caution: DO NOT hang the slave cylinder for a long time.
to the bracket. 13. Support the engine with hanger.
7. Notice the mounting position and release two cable 14. Support the manual transmission with a jack.
ball joints from the gear shift rocker arm of the manual
15. Remove 7 service bolts connecting the engine and
transmission.
manual transmission.

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16. Remove the service bolts between the lower tie rod
and the bracket of the lower tie rod and loosen the
service bolts and nuts between the lower tie rod and
the front sub frame.

8. Release the snap fits and release the outer gear shift
cable from the cable bracket.
9. Drain the transmission fluid.
Drain Transmission Fluid
17. Remove the nuts between the manual transmission
10. Remove the drive shaft assembly.
mounting bracket and suspension.
Drive Shaft Assembly RH Removal
Drive Shaft Assembly LH Removal
11. Remove the starter motor.
Starter Motor Removal
12. Loosen 2 nuts securing the slave cylinder to the slave
cylinder bracket of the manual transmission, release
and temporarily set the slave cylinder aside.

18. Release transmission from the engine, and adjust the

height of the jack and carefully and slowly lower the

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transmission to the floor. Back-up Light Switch - Manual

19. Loosen 4 retaining bolts, and remove the mounting Removal
bracket of the manual transmission. 1. Disconnect the battery earth lead.
Refit
1. Clean the mating surfaces of the parts.
2. Fit the back-up light switch to the transmission and
tighten it to 32-44 Nm.
3. Connect the back-up light switch connector.
4. Connect the battery earth lead.

2. Disconnect the connector from the back-up light

switch.

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3. Remove the back-up light switch from the transmission.
Refit
1. Clean the mating surfaces of the parts.
2. Fit the back-up light switch to the transmission and
tighten it to 32-44 Nm.
3. Connect the back-up light switch connector.
4. Connect the battery earth lead.

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Rear Housing Deck Board - Reseal - Manual Differential Oil Seal LH - Manual
Removal Removal
1. Drain the transmission fluid. 1. Remove the drive shaft LH.
Drain Drive Shaft Assembly LH
2. Place a proper container to collect the overflowed fluid. 2. Carefully remove and dispose of the oil seal, take care
3. Remove 6 bolts securing the rear housing deck board not to damage the oil seal groove.
to the transmission housing. Refit
1. Clean the oil seal groove.
Caution: The oil seals are waxed and not need to be
lubricated before fitting.
2. Use toolT24010 to fit a new oil seal.
3. Fit the drive shaft LH.

Drive Shaft LH Refit

4. Add the transmission fluid.
Transmission Fluid Adding

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4. Carefully tear the seal packing connection to release
the deck board from the transmission housing.
Refit
1. Clean the mating surfaces of the parts.
2. Apply the flat seal Kesaixin 1598 black silicon rubber to
the mating surface of the transmission housing.
3. Place the deck board, fit the bolt and tighten to 10-14
Nm.
4. Refill the transmission.

Manual Transmission Fluid - Refill

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Differential Oil Seal RH - Manual Manual Transmission Disassembly

Removal Removal
1. Remove the drive shaft RH. Caution: Prepare a clean desk and a box to place the
removed parts.
Drive Shaft Assembly RH Removal
2. Carefully remove and dispose of the oil seal, take care 1. Remove the manual transmission assembly.
not to damage the oil seal groove. Manual Transmission Assembly Removal
Refit 2. Remove the operating mechanism.
1. Clean the oil seal groove. 3. Remove the release mechanism.
Caution: The oil seals are waxed and not need to be Transmission Accessory and Release Mechanism
lubricated before fitting. Removal
2. Use toolT24010 to fit a new oil seal. 4. Remove each outer bracket and the reverse idler gear
3. Fit the drive shaft RH. etc.

Drive Shaft RH Refit Reverse Idler Gear Removal

4. Add the transmission fluid. 5. Remove the service bolts of the front and rear housing.

Transmission Fluid Adding

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6. Separate the front and rear housing.

Caution: When separating the front and rear housing,

expand the stop collar with circlip pliers and tap the rib
of the rear housing with nylon hammer to separate them.
7. Remove the bearing cover plate.

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8. Remove the main driven shaft, forks and fork shafts Refit
together from the housing. Caution: lean all the components and packings before
assembling.
Caution: Use the original transmission fluid to lubricate
the bearing, running parts, slideway, seat and pressure

9. Remove the fork shafts and each selector and fork etc.
Caution: It is necessary to take measures to prevent bend
when removing each fork shaft.
10. Remove the differential assembly.
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surface.
Caution: Check the components for signs and damage of
wearing and scratching, and replace as necessary.
Caution: Refer to the "specification" for the tightening
torque.
Caution: Apply sealant or seal lock adhesive to the
threaded parts.
1. On the front housing, useT24011 to press and fit the
drive shaft oil seal, and useT24010 to press and fit the
propeller shaft oil seal and fit driven shaft front bearing
outer race, and useT24012 to press and fit the cone
bearing outer race, and useT24013 to press and fit
1st/2nd shift fork bushing etc.
2. Fit the shaft and shift fork set into front housing, fit the
bearing cover plate and tighten it to 22-30 Nm.
3. Fit the differential assembly and tighten the bolts to
140-170 Nm.
Caution: When the fitting is finished, check that the
torque range is between 4-6 Nm with cone bearing
preload torque gauge.
4. On rear housing, useT24014 to press and fit guide
nozzle, driven shaft rear bearing stop collar.
Caution: Select the stop collar based on bearing. The
series are as follows:
Thickness (mm)
1.90
1.875
1.85

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1.825 Drive Shaft Assembly

Removal
1.80
Caution: Prepare a clean desk and a box to place the
5. Measure the thickness of the removed shim and select removed parts.
a new adjusting shim according to the thickness, and
1. Remove the transmission assembly.
useT24012 to press it into the cone bearing outer
race. Manual Transmission Assembly Removal

Caution: The shim series are as follows: 2. Remove the drive shaft.

Thickness (mm) Color Manual Transmission Disassembly

3. Remove the drive shaft front bearing circlip.
1.0±0.01 Yellow
4. UseT32001 to pull out the drive shaft front bearing.
0.8±0.01 Green
0.5±0.01 Red
0.2±0.01 White
0.15±0.01 Black
0.1±0.01 Purple

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6. On rear housing, useT24013 to fit 1st/2nd fork shaft
bushing, and useT24015 to press and fit gear shift shaft
needle roller bearing, and useT24010 to press and fit
the propeller shaft oil seal etc.
7. Fit the rear housing into the front housing, and tighten
the bolts to 30-40 Nm.
8. Fit the operating mechanism into the rear housing and
5. Remove the drive shaft hole oil seal.
tighten the bolts to 22-30 Nm.
9. Fit reverse idler gear assembly. Caution: Discard oil seals after removing.

Idler Gear Assembly Refit 6. Remove the bearing circlip.

10. Fit the cover, the rear housing deck board etc. and 7. UseT32001 to pull out the drive shaft rear bearing.
tighten the retaining bolts of the rear housing deck
board to 10-14 Nm.
Caution: Apply the rear housing deck board with flat seal
Kesaixin 1598 black silicon rubber.
11. Fit the release mechanism etc.
Transmission Accessory and Release Mechanism
Refit
12. Fit the bracket, screws etc. and tighten them to 22-30
Nm.

8. Remove the retainer sleeve.

Caution: Discard it after removing.

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9. Remove the retainer. 14. Remove the synchronizer sleeve.

10. UseT32001 to pull out the drive shaft 5th gear. 15. Remove the synchronizer gear hub and slider assembly.
16. Remove the 3rd synchronizer gear ring.
17. UseT32001 to pull out the drive shaft 3rd gear
assembly.

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11. Remove the drive shaft 4th gear assembly.

18. Remove the 3rd gear needle roller bearing.

12. Remove the drive shaft 4th gear needle roller bearing.
13. Remove the 4th synchronizer gear ring.

Refit
Caution: lean all the components and packings before
assembling.
Caution: Fit new circlip after fitting the bearing.

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Caution: Use the original transmission fluid to lubricate 14. With the assistance of T24004, tap in the drive shaft
the bearing, running parts, slideway, seat and pressure hole oil seal.
surface.
Caution: Lubricate the oil seal.
Caution: Check the components for signs and damage of
wearing and scratching, and replace as necessary.
1. With the pressure of press machine and the assistance
of T24001, fit the drive shaft front bearing into place.
2. Measure and select a new drive shaft front bearing
circlip to fit.
Caution: The circlip series are as follows:
Thickness (mm)
L1 2.30 Red
L2 2.33 White
L3 2.36 Natural
L4 2.39 Green

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3. Lubricate 3rd needle roller bearing and fit it to the shaft.
4. Fit 3rd gear assembly.
5. Position 3rd synchronizer gear ring.
6. Press in the synchronizer gear hub and fit the slider
assembly and sleeve.
Caution: Fitting direction of the hub and sleeve.
7. UseT24002 to press in 4th gear needle roller bearing
inner race and fit the needle roller bearing.
Caution: Lubrication of the needle roller bearing.
8. Position the gear ring of 4th gear and 4th gear assembly.
9. Press in 5th gear.
10. Measure and select 2 new semicircular retainers to fit.
Caution: The retainer series are as follows:
Thickness (mm)
L1 3.85 White
L2 3.89 Purple
L3 3.93 Natural
L4 3.97 Red
L5 4.01 Green
L6 4.05 Blue
L7 4.09 Pink
L8 4.13 Yellow
L9 4.17 Brown

11. Fit the retainer sleeve.

12. With the assistance of press machine and T24003, fit
the rear bearing.
13. Fit the bearing circlip.

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Driven Shaft Assembly
Removal
1. Remove the transmission assembly.
Manual Transmission Assembly Removal
2. Remove the driven shaft assembly.
Manual Transmission Disassembly
3. Remove the bearing circlip. (If the front bearing is
damaged, replace the driven shaft and front bearing set.)
4. Remove the driven shaft rear bearing circlip.
5. UseT32001 to pull out the driven shaft rear bearing
and the reverse needle roller bearing inner race.
Refit
Caution: Fit new circlip after fitting the bearing.
Caution: Check the components for signs and damage of
wearing and scratching, and replace as necessary.

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1. UseT24005 to press and fit the 1st needle roller
bearing inner race.
2. Position the 1st needle roller bearing.
3. Position the driven 1st gear assembly.
4. Position 1st/2nd synchronizer gear inner tapered ring,
middle ring and outer tapered ring.
Caution: Fitting direction of the three.
6. Remove the reverse gear assembly and needle roller .
bearing etc. 5. Press and fit 1st/2nd synchronizer gear hub, sleeve and
7. UseT32001 to pull out the 4th gear, 5th gear needle slider assembly.
roller bearing inner races and synchronizer etc.
Caution: Fitting direction.
together.
6. Position the 1st/2nd synchronizer inner tapered ring,
middle ring and outer tapered ring.
Caution: Fitting direction.
7. UseT24006 to press and fit the driven 2nd needle
roller bearing inner race.
8. Position the driven 1st needle roller bearing.
9. Position the driven 2nd gear assembly.
10. Press and fit the driven shaft 3rd gear.
11. Measure and position the 3rd/4th spacers.
Caution: The spacer series are:
Thickness (mm)
8. Remove the middle spacer. 22.33
9. Use a press to press the driven shaft 1st gear assembly, 22.43
synchronizer assembly, 2nd gear assembly and 3rd gear
22.53
assembly etc.
22.63
22.73

12. UseT24007 to press and fit the driven shaft 4th gear.

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13. Press and fit the 5th needle roller bearing inner race. Reverse Idler Gear
14. Position 3rd/5th/reverse needle roller bearing. Removal
Caution: Lubrication of the needle roller bearing. 1. Remove the rear housing deck board.

15. Position the driven 5th gear.

16. Position 3rd/4th, 5th/reverse synchronizer gear ring.
17. Press and fit 5th/reverse synchronizer gear hub, sleeve
and slider assembly.
Caution: Fitting direction.
18. Position 3rd/4th, 5th/reverse synchronizer gear ring.
Caution: Fitting direction.
19. UseT24008 to press and fit the reverse needle roller
bearing inner race.
20. Position 3rd/5th/reverse needle roller bearing.
21. Position the reverse gear, and use the bearing
press-fitting tool to press and fit the driven shaft rear 2. Remove the reverse bolts.

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bearing, and use the circlip pliers to set the rear bearing
circlip into place.
Caution: The circlip series are as follows:
Thickness (mm)
L1 2.42 Light Gray
L2 2.46 Natural
L3 2.50 Green
L4 2.54 Brown
L5 2.58 Blue
L6 2.62 Light yellow
L7 2.66 Pink 3. Take out the reverse idler gear assembly.
L8 2.70 Red
L9 2.78 Purple
L10 2.82 White
L11 2.86 Cyan

22. Select and fit the driven shaft rear bearing stop collar.
Caution: The stop collar series are:
Thickness (mm)
1.90
1.875
1.85
4. Remove the reverse idler gear circlip.
1.825
1.80

23. Use the bearing press-fitting tool to press and fit the
driven shaft front bearing.
24. Use the circlip pliers to set the front bearing circlip into
place.

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Differential Assembly
Removal
Caution: Discard shims after removing.
1. Remove the transmission assembly.

Manual Transmission Assembly Removal

2. Remove the differential assembly.
Manual Transmission Disassembly
3. UseT32001 to pull out the cone bearing inner race
and take out the shims.

5. Remove the stopper plate/needle roller bearing/idler

gear in sequence.
Refit
Caution: The new circlip must be fitted.

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1. Fit the needle roller bearing/idler gear into the reverse
idler gear shaft in sequence.
Caution: Lubrication of the needle roller bearing.
2. Fit the reverse idler gear circlip.
3. Fit the rear housing and tighten the bolts to 32-44 Nm.
4. Fit the rear housing deck board and tighten the bolts Caution: Support bolt of the drawing die (T32001) cannot
to 10-14 Nm. be used to support the propeller shaft hole directly, place
a spacer block between them.
4. Remove the planetary shaft pin with a punch.

5. Unscrew the bolts and remove the main reduction

driven gear.

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races.
15. Tighten the 8 bolts to 140-170 Nm.

6. Remove the planetary shaft, take off the planetary gear,

side gear and shim.
Refit
1. Put the auxiliary shafts in the side gear holes on both
ends of the differential case, and fit the side gear.

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2. Turn and fit the planetary gear and planetary gear shim.
3. Fit the planetary gear auxiliary shaft.
4. Measure the thickness of the removed side gear shim,
and select a new shim according to the thickness.
Caution: The shim series are as follows:
Thickness (mm)
H 0.90±0.01 Yellow
H 0.95±0.01 Green
H 1.00±0.01 Blue
H 1.05±0.01 Red
H 1.10±0.01 White
H 1.15±0.01 Black
H 1.20±0.01 Purple
H 1.25±0.01 Orange
H 1.30±0.01 Brown
H 1.35±0.01 Gray

5. Remove the differential internal parts.

6. Fit the 2 selected side gear shims.
7. Place 2 side gears.
8. Place 2 planetary gear shims.
9. Place 2 planetary gears.
10. Press out the auxiliary planetary shaft and press in the
planetary shaft.
11. Press-fit the planetary shaft pin.
12. Press-fit the main reduction driven gear.
13. Place the bolts of main reduction driven gear.
14. UseT24009 to press-fit the front, rear bearing inner

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Handling Base Assembly 7. Remove the 5/R gear return spring, interlock ring, gear
Removal shift arm guide, reverse lock block assembly, 1/2 gear
1. Remove the transmission assembly. return spring, spring retainer, needle roller bearing,
oil seal, shift rocker arm assembly, nylon block and
Manual Transmission Assembly Removal breather plug, etc.
2. Remove the bolts of interlock ring.
3. Unscrew the bolts from handling base to housing and
remove the handling base assembly.
4. Remove the bolts of select rocker arm bracket and
take it off.

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Refit
1. UseT24017 to press in Φ3 spring pin, and useT24024
to press-fit the reverse lock block shaft, assemble the
reverse lock block assembly.
2. Fit handling base breather plug, useT24016 to press-fit
5. Punch down each pin and take out the gear shift shaft. oil seal, and useT24015 to press-fit the needle roller
bearing, fit the spring retainer plate and reverse lock
stopper plate and tighten the bolts to 18-26 Nm.
Caution: Take care to avoid damaging the oil seal lip while
fitting the oil seal.
3. Pass the shaft through handling base and fit 5/R return
spring assembly, interlock ring, arm guide, reverse lock
block assembly, 1/2 gear return spring, return spring
stopper plate in sequence.
Caution: Phase relationship of each component on the
shaft.
4. Fit the shift rocker arm assembly to the shaft.
6. Remove the bolts of reverse lock stopper plate and 5. Fit the above assembled components into the housing
take off the reverse lock stopper plate. together and tighten the interlock ring location pin to
30-40 Nm.
6. Place the nylon block and fit the select rocker arm
assembly.

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Transmission Accessory and Release Mechanism

Removal
1. Remove the cylinder bracket.
2. Remove the gear shift bracket.
3. Remove the back-up light switch.

8. Remove the rear housing cover.

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4. Remove the self-locking pin assembly.

9. Remove the rear housing deck board.

5. Remove the refill plug and drain plug.

6. Remove the interlock ring location pin.

Caution: There is no need to remove the assembly during

the above removals.
10. Remove the release bearing.
11. Remove the screws of release fork.

7. Remove the handling base assembly.

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12. Remove the release rocker assembly and release fork

assembly.
13. Remove the guide sleeve.
Refit
1. Fit the cylinder bracket and tighten the bolt to 22-30

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Nm.
2. Fit the gear shift bracket and tighten the bolt to 22-30
Nm.
3. Fit the back-up light switch and tighten it to 32-44 Nm.
4. Fit the self-locking pin assembly and tighten it to 32–44
Nm.
5. Fit the refill plug and drain plug and tighten them to
30-40 Nm.
6. Fit the interlock ring location pin and tighten it to
30-40 Nm.
7. Fit the handling base assembly and tighten the set bolt
to 22-30 Nm.
8. Fit the rear housing cover.
9. Fit the rear housing deck board and tighten the bolt
to 10-14 Nm.
10. Fit the guide sleeve and tighten the bolt to 10-14 Nm.
11. Fit the release bearing.
12. Fit the release rocker arm and release fork and tighten
the bolt to 30–40 Nm.

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Special Tools Tool Description Picture

Tool Description Picture Number
Number

Driven Shaft Oil Gear Shift

T24010 Shaft Needle
Seal Hold-down T24015
Roller Bearing
Hold-down

Drive Shaft
T24011 Front Oil Seal
Hold-down

T32001 Puller

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Cone Bearing
T24012 Outer Race
Hold-down

Drive Shaft
T24001 Front Bearing
Hold-down

1st/2nd Gear
Shift Fork
T24013
Shaft Bushing
Hold-down

4th Gear
Needle Roller
T24002 Bearing
Inner Race
Hold-down
Drive/Driven
Shaft Guide
T24014
Oil Nozzle
Hold-down

Drive Shaft
T24003 Rear Bearing
Hold-down

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Tool Description Picture Tool Description Picture
Number Number

Cone Bearing
T24009 Inner Race
Drive Shaft Hold-down
T24004 Hole Oil Seal
Hold-down

T24017

st Gear Needle
Roller Bearing
T24005
Inner Race
Hold-down

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Reverse Lock
T24024 Block Shaft
Drift
2nd Gear
Needle Roller
T24006 Bearing
Inner Race
Hold-down

Gear Shift
T24016 Shaft Oil Seal
Hold-down

Driven Shaft
T24007 4th Gear
Hold-down

Reverse Needle
Roller Bearing
T24008
Inner Race
Hold-down

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