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canter manual gearbox 2020
canter manual gearbox 2020
Group 22B
Transmission<M038>
TRANSMISSION BODY.....................22B-30
MAINSHAFT.......................................22B-42
22B-1
SPECIFICATIONS
Item Specifications
M038S5
Transmission model
(5.494/0.723)
1st 5.494
2nd 3.193
3rd 1.689
Gear ratio
4th 1.000
5th 0.723
Rev 5.494
API GL-3 SAE80 (general)
SAE90 (warm or tropical region)
Classification
API GL-4 SAE80 (general)
Transmission SAE90 (warm or tropical region)
oil
Standard Approx. 3.5 {3.5}
Quantity dm3 {L} With transmission power
Increase of approx. 0.3 {0.3}
take-off
Standard Approx. 73
Mass kg
With transmission power take-off Approx. 83
Mode of control Instrument panel shift remote control
22B-2
STRUCTURE AND OPERATION 22B
1. Transmission
㻟㼞㼐㻌㼍㼚㼐㻌㻠㼠㼔㻌㼟㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞 㻝㼟㼠㻌㼍㼚㼐㻌㻞㼚㼐㻌㼟㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞
㻰㼞㼕㼢㼑㻌㼜㼕㼚㼕㼛㼚
㻹㼍㼕㼚㼟㼔㼍㼒㼠
㻯㼛㼡㼚㼠㼑㼞㼟㼔㼍㼒㼠 㻾㼑㼢㼑㼞㼟㼑㻌㼕㼐㼘㼑㼞㻌㼓㼑㼍㼞
602258
• The transmission uses an interlock mechanism to avoid double engagement.
22B-3
STRUCTURE AND OPERATION
2. Synchromesh Mechanism
• The Synchromesh mechanism, when a shift change is made, synchronizes the rotation speed of the mainshaft,
drive pinion and synchronizer hub that rotates integrally with the mainshaft with that of the gear to be shifted.
• The Synchromesh mechanisms is a Warner Synchromesh type, and is used depending on the gear position as
shown below:
Transmission type
M038S5
Synchromesh type
Single cone type 4th, 5th, Reverse
Triple cone type 1st, 2nd, 3rd
㻿㼔㼕㼒㼠㼕㼚㼓㻌㼜㼘㼡㼚㼓㼑㼞
㻿㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞㻌㼔㼡㼎
㻿㼔㼕㼒㼠㼕㼚㼓㻌㼜㼘㼡㼚㼓㼑㼞㻌㼟㼜㼞㼕㼚㼓
㻿㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞㻌㼞㼕㼚㼓 㻿㼔㼕㼒㼠㻌㼒㼛㼞㼗
㻿㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞㻌㼟㼘㼑㼑㼢㼑
㻿㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞㻌㼟㼘㼑㼑㼢㼑
㻟㼞㼐㻌㼓㼑㼍㼞 㻿㼔㼕㼒㼠㼕㼚㼓㻌㼜㼘㼡㼚㼓㼑㼞 㻿㼔㼕㼒㼠㼕㼚㼓㻌㼜㼘㼡㼚㼓㼑㼞
㻿㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞㻌㼞㼕㼚㼓
㻰㼞㼕㼢㼑㻌㼜㼕㼚㼕㼛㼚
㻹㼍㼕㼚㼟㼔㼍㼒㼠
㻭 㻮 㻯
㼀㼍㼜㼑㼞㻌㼏㼛㼚㼑 㻿㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞㻌㼞㼕㼚㼓
㻟㼞㼐㻌㼓㼑㼍㼞
㻰㼞㼕㼢㼑㻌㼜㼕㼚㼕㼛㼚 㻿㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞㻌㼟㼘㼑㼑㼢㼑 㻿㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞㻌㼔㼡㼎
㻿㼥㼚㼏㼔㼞㼛㼚㼕㼦㼑㼞㻌㼔㼡㼎
㻼㻝㻞㻡㻢㻠㻡㻱
• The inside of the synchronizer hub engages the spline of the mainshaft and rotates with it. The outside of the syn-
chronizer hub has a spline that engages the synchronizer sleeve and three grooves.
• Shifting plungers are inserted into these grooves. When the gear shift is in neutral, the shifting plunger engage
grooves in the synchronizer sleeve and are pressed against the inside of the synchronizer sleeve by shifting
plunger springs.
• Synchronizer rings are inserted into the respective taper cone of each gear.
• The outer splines of the synchronizer rings engage the synchronizer sleeve. On the synchronizer hub are three
grooves in which protrusions of the synchronizer rings are inserted. These grooves are wider than the width of the
protrusions of the synchronizer rings.
• Synchronizer rings rotate relative to the synchronizer sleeve by the amount of play (width difference).
• When the gear shift is in neutral (Figure A), moving the shift fork in the direction of the arrow as illustrated, moves
the synchronizer sleeve slightly to the gear. At the same time, the shifting plunger, the central protrusion of which
engages the synchronizer sleeve, moves to the gear and presses the synchronizer ring against the taper cone of
the gear (Figure B).
• The taper cones of synchronizer rings, which act as cone clutches, generate friction torque and perform synchro-
nous operation.
• The rotation speed of the synchronizer hub becomes gradually closer to that of the gear due to the synchronous
operation, and eventually they rotate at the same speed. This allows the synchronizer sleeve to move smoothly to
engage the synchronizer hub and gear, completing the shift change (Figure C).
22B-4
22B
2.2 Triple cone type
• The Synchromesh structure and operation of the triple cone type are basically the same as for the single cone
type. The synchronizer ring is divided into three parts (synchronizer inner ring, synchronizer center cone and syn-
chronizer outer ring) and the center cone (both the inside and outside surfaces are tapered) and the inner ring
(both the inside and outside surfaces are tapered) are sandwiched between the outer ring and the taper cone of
each gear to shorten the time required for synchronization with cone clutches at three locations.
• Six protrusions on the outside of the synchronizer center cone fit into corresponding gear holes. As in the taper
cone of the single cone type, the center cone and the gear are installed as if integrated.
• The inside of the synchronizer hub engages the spline of the mainshaft and rotates with it. The outside of the syn-
chronizer hub has a spline that engages the synchronizer sleeve and three grooves.
• Shifting plungers are inserted into these key ways. When the gear shift is in neutral, the shifting plungers engage
grooves in the synchronizer sleeve and are pressed against the inside of the synchronizer sleeve by shifting
plunger springs.
• The synchronizer outer ring and synchronizer inner ring are inserted into synchronizer center cones, respectively.
• The outer spline of the synchronizer outer ring engages the synchronizer sleeve. On the synchronizer hub are
three grooves in which protrusions of the synchronizer outer ring are inserted. These grooves are wider than the
width of the protrusions of the synchronizer outer ring.
• The synchronizer outer ring rotates relative to the synchronizer sleeve by the amount of play.
• When the gear shift is in neutral (Figure A), moving the shift fork in the direction of the arrow as illustrated, moves
the synchronizer sleeve slightly to the gear. At the same time, the shifting plunger, the central protrusion of which
engages the synchronizer sleeve, moves to the gear and presses the synchronizer outer ring and the center cone
against the taper cone of the synchronizer center cone and the synchronizer inner ring, respectively and in addi-
tion, presses the inner ring against the gear (Figure B).
• The taper cones of synchronizer rings, which act as cone clutches, generate friction torque and perform synchro-
nous operation.
• The rotation speed of the synchronizer hub becomes gradually closer to that of the gear of the gear due to the
synchronous operation, and eventually they rotate at the same speed. This allows the synchronizer sleeve to
move smoothly to engage the synchronizer hub and gear, completing the shift change (Figure C).
22B-5
STRUCTURE AND OPERATION
3. Interlock Mechanism
• The interlock mechanism prevents
double engagement of gears.
• When the 1st and 2nd shift rail is shift-
ed, the interlock plate locks the other
shift rails.
22B-6
TROUBLESHOOTING 22B
Symptoms
Possible causes
Mainshaft companion flange mounting bolt loose O O
Mainshaft thrust washer worn O O
Mainshaft bearing worn or damaged O O O
Synchronizer ring and synchronizer sleeve spline worn O
Synchronizer ring and gears taper cone area worn O
Mainshaft pilot bearing worn or damaged O O
Transmission Drive pinion bearing worn or damaged O
body faulty Countershaft bearing worn or damaged O O
Needle bearings of gears worn or damaged O O
Reverse idler gear and power take-off gear backlash excessive O
Mainshaft and countershaft gears backlash excessive O
Spline of gears worn O
Gears damaged O
Transmission oil insufficient O
Contacting surface of synchronizer ring and
Single cone type O O
gear taper cone worn
Contacting surface of synchronizer inner and
O O
outer rings and center cone worn
Triple cone type
Contacting surface of synchronizer inner ring
Synchronizer O O
and gear taper cone worn
faulty
Synchronizer ring spline chamfer worn O
Shifting plunger worn O
Shifting plunger spring deteriorated or damaged O
Synchronizer sleeve worn or damaged O O
Control cable adjustment faulty O
Control cable routing inadequate O
Control cable length inadequate O
Bushings worn O O
Control mecha-
Steel ball and groove of shift rail worn O
nisms faulty
Poppet spring of shift rail fatigued or damaged O
Shift rail sliding movement faulty O
Shift fork jaws worn O
Shift fork bent O
Clutch disengagement faulty O O
Clutch faulty Gr21
Clutch pedal play faulty O
22B-7
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Transmission Oil Leakage and Oil Quantity
• For a model with standard type transmission power take-off, the quantity is increased by approx. 0.3 dm3 {0.3 L}.
• Remove the inspection plug, and check that oil is filled up to the
neck.
• If oil is not sufficient, fill oil from the inspection plug hole up to the
neck.
• After filling, apply sealant to the inspection plug and tighten it to
the specified torque.
Oil surface
㼃㻜㻜㻝㻡㻜㻠
22B-8
22B
2. Inspection of Looseness in Engine to Clutch Housing Connection
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
– Bolt (transmission mounting) 47.1 {4.8} M10
㻼㻝㻞㻣㻞㻟㻣㻱
22B-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
4. Replacement of Transmission Oil
[Replacement]
• Remove the drain plug to drain transmission oil. Drainage can
be made quickly with the inspection plug removed.
• After draining transmission oil, apply sealant to the drain plug
and tighten it to the specified torque. Magnet type drain plugs
should be cleaned before installation.
• Fill transmission oil in the specified quantity from the inspection
plug hole.
• After filling, wait for 1 minute or more to check that oil is filled up
to the neck of the inspection plug hole. If oil is not sufficient, re-
Inspection plug hole plenish it.
• After completing work, apply sealant to the inspection plug and
Oil surface
tighten it to the specified torque.
• When transmission oil has been replaced, reset the Mainte-
nance information memory of the multi-information system. (See
“Multi-information system” in chapter 6 of the Owner’s Manual.)
㼃㻜㻜㻝㻡㻜㻠
[Inspection]
• When draining transmission oil, check for oil quality, metal chips
and metal powder.
• If an abnormally large amount of metal chips and metal powder
is found, disassemble the transmission assembly for service, as
abnormalities may be caused inside. (See “TRANSMISSION
BODY” section.)
22B-10
22B
5. Inspection of Transmission Mounting Cushion Rubber
22B-11
REMOVAL AND INSTALLATION OF TRANSMISSION
㻡 㻠
㻟
㻞
㻼㻝㻞㻢㻝㻣㻤
Removal sequence
1 Propeller shaft (See Gr25.) 5 Mounting bracket
2 Clutch hose (See Gr21.) 6 Transmission
3 Parking brake cable (See Gr36.) 7 Parking brake cable bracket
4 Cushion rubber 8 Mounting support
Installation sequence
Follow the removal sequence in reverse.
22B-12
22B
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Nut (transmission mounting) 235 ± 35 {24.0 ± 3.6} –
Bolt (transmission mounting) 47.1 {4.8} M10
Nut (cushion rubber mounting) 50.6 {5.2} –
Nut (cushion rubber mounting) 260 ± 40 {27.0 ± 4.1} –
Nut (mounting support mounting) 58.7 {6.0} –
Nut (parking brake cable bracket mounting) 50.6 ± 4.4 {5.2 ± 0.4} –
Removal procedure
Removal: Transmission
• Support the transmission on the transmission jack and remove
transmission mounting bolts.
• When the oil stain is found inside of clutch housing after remov-
ing the transmission, check the oil leakage portion of transmis-
sion or engine and replace the defective part.
Inspection procedure
Inspection: Cushion rubber
• Inspect the entire circumference of the cushion rubber for
cracks, breaks, oil or other problems.
• If a problem is found, replace the cushion rubber.
22B-13
REMOVAL AND INSTALLATION OF TRANSMISSION
Installation procedure
Installation: Parking brake cable bracket
• Install the parking brake cable bracket on the mounting support.
Installation: Transmission
• Check the spline of the drive pinion for rust.
• If rust is found, remove it using a wire brush.
• Rub grease evenly onto the clutch disc sliding surface of the
drive pinion using your hand.
CAUTION
• Make sure that you apply only the necessary amount of
grease because too much grease can drip and cause clutch
slip.
[Applying sealant]
• Apply sealant following manners shown below.
CAUTION
• Take care not to apply sealant under any of the following
conditions. Otherwise it causes water infiltration.
• There is dust, oil, grease, etc. on the mating surface.
• The diameter or thickness of the applied sealant is ex-
tremely different at each part.
• The applied sealant has some breaks.
• Use utmost care to prevent the applied sealant from cover-
ing the air vent holes on the side of the clutch housing and
engine.
22B-14
22B
[Installation]
• After applying the sealant, install the transmission before the
sealant dries. Be sure not to allow the sealant to be displaced.
• Do not start the engine within one hour after installing the trans-
mission.
• When loosening or removing transmission mounting bolts, be
sure to reapply the sealant.
• Support the transmission on the transmission jack, and insert
the transmission into the pilot bearing of the flywheel paying at-
tention to the drive pinion spline.
Tightening order • Tighten the bolt clockwise with the specified torque when looking
C C from backward of the transmission.
C C C: M10
CAUTION
C C
Backward view • If the tightening order during transmission coupling is diag-
onal, the crankshaft end play amount may change, so tight-
C C
en clockwise as instructed.
C C
C C 603568E
㻮㼛㼘㼠
㻲㼞㼍㼙㼑
㻼㻡㻜㻝㻢㻣㻜㻱
22B-15
GEAR SHIFTER UPPER, INTERLOCK PLATE
Removal sequence
1 Gear shifter upper
(See later section.)
2 Poppet spring plate
3 Poppet spring
4 Steel ball
5 Backup lamp switch
6 Torque limit switch
7 Stopper plate
8 Interlock plate
Installation sequence
Follow the removal sequence in reverse.
22B-16
22B
Installation procedure
Installation: Gear shifter upper
[Applying sealant]
• Apply sealant onto the transmission case, following manners
shown below.
CAUTION
• Take care not to apply sealant under any of the following
conditions. Otherwise it causes oil leak.
• There is dust, oil, grease, etc. on the mating surface.
• The diameter or thickness of the applied sealant is ex-
tremely different at each part.
• The applied sealant has some breaks.
[Installation]
• After applying the sealant, install the gear shifter upper before
the sealant dries. Be sure not to allow the sealant to be dis-
placed.
• Do not start the engine within one hour after installing the gear
shifter upper.
• When loosening or removing gear shifter upper mounting bolts,
be sure to reapply the sealant.
22B-17
GEAR SHIFTER UPPER, INTERLOCK PLATE
Gear Shifter Upper
Disassembly sequence
1 Shift rod 8 Gear shift lever 15 Oil seal
2 Air breather 9 Gear shift sliding lever 16 Oil seal
3 Plug 10 Return spring 17 Gear shift case
4 Select poppet spring 11 Lock pin
5 Select poppet pin 12 Gear select lever : Non-reusable parts
6 Transmission neutral switch 13 Washer
7 Spring pin 14 Gear select lever
CAUTION
• Nuts used to mount the shift rod is coated with lock paint. Be sure to replace the nuts each time they are
loosened or removed.
Assembly sequence
Follow the disassembly sequence in reverse.
22B-18
22B
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
19.6 ± 2.0 N 13.7 N
4 Select poppet spring installed load (installed length 11) Replace
{1.99 ± 0.2 kgf} {1.39 kgf}
Return spring installed load 100.7 ± 10.1 N 70.6 N
10 Replace
(installed length 26.8) {10.27 ± 1.03 kgf} {7.2 kgf}
A MH062445
M12 1.25
A 03726-82000
M12 1.25
22B-19
GEAR SHIFTER UPPER, INTERLOCK PLATE
Removal procedure
Removal: Spring pin
• Tap the spring pin using an M4 tap.
• Insert spring pin puller with an M4 screw of appropriate
length into the spring pin, and remove the spring pin using
reverse shaft puller.
Removal: Bushing
• Remove the bushing using a screwdriver.
CAUTION
• Be careful not to damage the selector lever case.
22B-20
22B
Installation procedure
Installation: Gear selector lever
• Apply grease and sealant to portions shown of the gear shift
case.
• Install the gear selector lever while turning so that the oil seal is
not damaged in the lip.
22B-21
REAR COVER AND PARKING BRAKE
Disassembly sequence
1 Lock plate 5 Companion flange 10 Rear cover
2 O-ring 6 Reamer bolt 11 Pulse rotor
3 Dust plug 7 Parking brake (See Gr36.) 12 Spacer
4 Parking brake drum 8 Vehicle speed sensor
(See Gr36.) 9 Oil seal : Non-reusable parts
Assembly sequence
Follow the disassembly sequence in reverse.
22B-22
22B
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application
Flange puller
Removal procedure
Inspection: Runout at socket portion of companion flange
• After removing the parking brake drum, measure the runout at
the socket portion of the companion flange.
• If the measured value exceeds the limit, replace the companion
flange.
Installation procedure
Installation: Oil seal
• Apply grease to the lip area of the oil seal.
• Install the oil seal in the rear cover in the illustrated direction us-
ing .
22B-23
REAR COVER AND PARKING BRAKE
Installation: Extension housing
[Applying sealant]
• Apply sealant following manners shown below.
CAUTION
• Take care not to apply sealant under any of the following
conditions. Otherwise it causes oil leak.
• There is dust, oil, grease, etc. on the mating surface.
• The diameter or thickness of the applied sealant is ex-
tremely different at each part.
• The applied sealant has some breaks.
22B-24
22B
M E M O
22B-25
REVERSE IDLER GEAR
Disassembly sequence
1 Power take-off cover <Without power take-off> 4 Reverse idler gear
Transmission power take-off <With power take- 5 Side washer
off> (See later section.)
2 Reverse idler gear shaft *a: Transmission case
3 Side washer : Non-reusable parts
Assembly sequence
Follow the disassembly sequence in reverse.
22B-26
22B
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application
Removal procedure
Removal: Power take-off cover
• Insert a scraper from the lower right or lower left of the power
take-off cover to remove the power take-off cover.
CAUTION
• Beware that prying the scraper halfway could deform the
power take-off cover or damage the transmission case.
22B-27
REVERSE IDLER GEAR
Installation procedure
Installation: Power take-off cover or transmission power
take-off
[Applying sealant]
• Apply the sealant onto the transmission case, following manners
shown below.
CAUTION
• Remove any sealant remaining in the bolt holes before in-
stallation. Otherwise damage may result.
• Take care not to apply sealant under any of the following
conditions. Otherwise it causes oil leak.
• There is dust, oil, grease, etc. on the mating surface.
• The diameter or thickness of the applied sealant is ex-
tremely different at each part.
• The applied sealant has some breaks.
[Installation]
• Install the power take-off cover or transmission power take-off
according the following manners after applying the sealant. Be
sure not to allow the sealant to be displaced.
Power take-off cover: Install in three minutes
Transmission power take-off: Install before sealant dries
• Do not start the engine within one hour after installing the power
take-off cover or transmission power take-off.
• When loosening or removing power take-off cover or transmis-
sion power take-off mounting bolts, be sure to reapply the seal-
ant.
22B-28
22B
M E M O
22B-29
TRANSMISSION BODY
Disassembly sequence
1 Inspection plug 10 Oil separator
2 Drain plug 11 Shift rail and shift fork (See later section.)
3 Snap ring 12 Countershaft (See later section.)
4 Mainshaft rear bearing 13 Drive pinion (See later section.)
5 Snap ring 14 Mainshaft (See later section.)
6 Snap ring 15 Clutch housing
7 Countershaft rear bearing
8 Transmission case : Locating pin
9 Bearing retainer : Non-reusable parts
CAUTION
• After removing direct power cylinder, perform work with the transmission body laid vertically on its clutch
housing side. (See Gr21.)
• If the countershaft, drive pinion and mainshaft are not disassembled, the shift rail and shift fork can be disassem-
bled on its own while mounted on the clutch housing.
Assembly sequence
Follow the disassembly sequence in reverse.
22B-30
22B
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Bolt (direct power cylinder mounting)
Bolt (bearing retainer mounting) 44.5 {4.5} –
Bolt (rear bearing retainer mounting)
Inspection plug
68.6 ± 14.7 {7.0 ± 1.5} Sealant
Drain plug
Bolt (transmission case mounting) 54 {5.5} –
94 48
MH062696
Bearing puller and in-
staller
A B
Removal of countershaft rear bearing
76.8 30
22B-31
TRANSMISSION BODY
Mark Tool name and shape Part No. Application
Eyebolt
A MH063409
251
Eyebolt
A MH063515
M14 1.5
Synchromesh guard
Removal procedure
Removal: Mainshaft rear bearing
• Remove the mainshaft rear bearing using .
22B-32
22B
Removal: Transmission case
• Install on the transmission case and make preparations for
lifting it up with a crane.
• After removing the bolts, lift up the transmission case while hit-
ting the rear end portions (arrow indicating) of the countershaft
and mainshaft and the rear rib portions (arrow indicating) of the
clutch housing with a plastic hammer to remove the transmis-
sion case.
CAUTION
• Be sure to hit the ribs as illustrated because hitting other
areas may break the clutch housing.
• Secure the countershaft and the 2nd gear area of the mainshaft
with for safety. Be sure to tighten enough to prevent it
from coming undone, but not excessively.
22B-33
TRANSMISSION BODY
Removal: Shift rail and shift fork, countershaft, drive pinion
and mainshaft
• Leave the countershaft and mainshaft secured with .
• Install on the mainshaft and make preparations for lifting it
up with a crane.
• Secure the shift rail and shift fork with a rubber band to prevent it
from coming undone from the mainshaft.
• Put a piece of wood on the clutch housing and lift it up while hit-
ting it with a plastic hammer to remove.
• When lifting up, be sure to support the drive pinion with your
hand to prevent it from falling.
Installation procedure
Installation: Shift rail and shift fork, countershaft, drive pin-
ion and mainshaft
• When driving in the drive pinion, mainshaft and countershaft, in-
stall to prevent the drive pinion and synchronizer of the
mainshaft from sticking.
• Place the synchronizer sleeve of mainshaft in neutral position
before installing the shift rail and shift fork on the mainshaft.
• Be sure to remove all the special tools used.
22B-34
22B
[Installation]
• After applying the sealant, install the transmission case before
the sealant dries. Be sure not to allow the sealant to be dis-
placed.
• Do not start the engine within one hour after installing the trans-
mission case.
• When loosening or removing transmission case mounting bolts,
be sure to reapply the sealant.
22B-35
TRANSMISSION BODY
Shift Rail and Shift Fork
Disassembly sequence
1 Spring pin 10 Spring pin
2 Spring pin 11 Spring pin
3 3rd and 4th shift jaw 12 5th and reverse shift jaw
4 3rd and 4th shift rail 13 5th and reverse shift rail
5 3rd and 4th shift fork 14 5th and reverse shift fork
6 Spring pin
7 1st and 2nd shift rail *a: Mainshaft
8 1st and 2nd shift fork : Non-reusable parts
9 Shift fork piece
Assembly sequence
Follow the disassembly sequence in reverse.
*
5, 14, a Clearance between shift fork and synchronizer sleeve 0.3 to 0.6 1.0 Replace
Clearance between gear shift fork piece and synchro-
9,
*a nizer sleeve
0.3 to 0.6 1.0 Replace
22B-36
22B
Inspection procedure
Inspection: Bend of shift rail
• Measure the extent of bending at the middle of each of shift rail.
• While rotating the shift rail by one revolution, read how much the
dial gauge needle will move. A half of the reading observed rep-
resents the bend, if any, of the rail.
• If the measurement exceeds the limit, replace the gear shift rails.
22B-37
TRANSMISSION BODY
Installation procedure
Installation: Shift fork piece
• Install the shift fork piece on the shift fork as shown in the illus-
tration.
22B-38
22B
M E M O
22B-39
DRIVE PINION
Disassembly sequence
1 Snap ring
2 Drive pinion bearing
3 Drive pinion
Assembly sequence
Follow the disassembly sequence in re-
verse.
MH062696
94 48
22B-40
22B
Removal procedure
Removal: Drive pinion bearing
• Remove the drive pinion bearing using .
Installation procedure
Installation: Drive pinion bearing
• Install the drive pinion bearing, facing the grooved side in the il-
lustrated direction using .
22B-41
MAINSHAFT
Disassembly sequence
1 5th gear thrust washer 14 3rd gear thrust washer
2 5th gear 15 Snap ring
3 Needle bearing 16 2nd gear thrust washer
4 Snap ring 17 2nd gear
5 5th and reverse synchronizer (See later section.) 18 Needle bearing
6 Reverse gear 19 Snap ring
7 Needle bearing 20 1st and 2nd synchronizer (See later section.)
8 Snap ring 21 1st gear
9 Pilot bearing 22 Needle bearing
10 Snap ring 23 Mainshaft
11 3rd and 4th synchronizer (See later section.)
12 3rd gear *a: Drive pinion
13 Needle bearing
Assembly sequence
Follow the disassembly sequence in reverse.
22B-42
22B
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
1st gear 0.15 to 0.46 0.7
2nd gear 0.15 to 0.61 0.8
– End play 3rd gear 0.15 to 0.46 0.7 Replace
5th gear 0.1 to 0.46 0.7
Reverse gear 0.15 to 0.46 0.7
1st gear 0.02 to 0.06 0.12
2nd gear 0.02 to 0.06 0.12
Play in the diameter
– 3rd gear 0.02 to 0.06 0.12 Replace
direction
5th gear 0.02 to 0.05 0.12
Reverse gear 0.05 to 0.08 0.12
5th gear and 5th and reverse
1.02 to 1.49 0.5
synchronizer
Reverse gear and 5th and
1.07 to 1.43 0.5
reverse synchronizer
3rd gear and 3rd and 4th
Clearance between 1.02 to 1.49 0.5
synchronizer
– gear and synchronizer Replace
ring Drive pinion and 3rd and 4th
1.02 to 1.49 0.5
synchronizer
2nd gear and 1st and 2nd
1.02 to 1.49 0.5
synchronizer
1st gear and 1st and 2nd
1.02 to 1.49 0.5
synchronizer
9 Play in the diameter direction of pilot bearing 0.04 to 0.08 0.12 Replace
Special tools
Mark Tool name and shape Part No. Application
22B-43
MAINSHAFT
Inspection: Play in diameter direction of gears
• If the measurement exceeds the limit, replace defective parts.
Inspection procedure
Inspection: Clearance between gear and synchronizer outer
ring of synchronizer
<Triple cone type>
• When measuring the clearance, press the ring and the center
cone evenly against the gear and measure all around the cir-
cumference.
• If the measurement is less than the limit, replace the ring and the
gear.
22B-44
22B
5th and Reverse Synchronizer
Disassembly sequence
1 Synchronizer ring
2 Synchronizer sleeve
3 Shifting plunger
4 Shifting plunger spring
5 Synchronizer hub
Assembly sequence
Follow the disassembly sequence in re-
verse.
Inspection procedure
Inspection: Clearance between synchronizer ring protru-
sion and synchronizer hub groove
• If the clearance exceeds the limit, replace defective parts.
22B-45
MAINSHAFT
Installation procedure
Installation: Synchronizer sleeve and synchronizer hub
• When replacing the synchronizer sleeve or synchronizer hub
with a new one, align the three keyways of the synchronizer hub
with three locations of the stub gear tooth of the synchronizer
sleeve to install.
22B-46
22B
3rd and 4th Synchronizer
Disassembly sequence
1 Synchronizer ring
2 Synchronizer inner ring
3 Synchronizer center cone
4 Synchronizer outer ring
5 Synchronizer sleeve
6 Shifting plunger
7 Shifting plunger spring
8 Synchronizer hub
Assembly sequence
Follow the disassembly sequence in re-
verse.
Inspection procedure
Inspection: Clearance between synchronizer outer ring pro-
trusion and synchronizer hub groove
• If the clearance exceeds the limit, replace defective parts.
22B-47
MAINSHAFT
Installation procedure
Installation: Synchronizer sleeve and synchronizer hub
• When replacing the synchronizer sleeve or synchronizer hub
with a new one, align the three keyways of the synchronizer hub
with three locations of the stub gear tooth of the synchronizer
sleeve to install.
22B-48
22B
1st and 2nd Synchronizer
Disassembly sequence
1 Synchronizer inner ring
2 Synchronizer center cone
3 Synchronizer outer ring
4 Synchronizer sleeve
5 Shifting plunger
6 Shifting plunger spring
7 Synchronizer hub
Assembly sequence
Follow the disassembly sequence in re-
verse.
Inspection procedure
Inspection: Clearance between synchronizer outer ring and
synchronizer hub
• If the clearance exceeds the limit, replace defective parts.
22B-49
MAINSHAFT
Installation procedure
Installation: Synchronizer sleeve and synchronizer hub
• When replacing the synchronizer sleeve or synchronizer hub
with a new one, align the three keyways of the synchronizer hub
with three locations of the stub gear tooth of the synchronizer
sleeve to install.
22B-50
22B
M E M O
22B-51
COUNTERSHAFT
Disassembly sequence
1 Snap ring
2 Countershaft front bearing
3 Countershaft 5th gear
4 Countershaft gear
Assembly sequence
Follow the disassembly sequence in re-
verse.
MH062696
Bearing puller and in-
staller
Installation of countershaft front bear-
A B ing
80 42
Removal procedure
Removal: Countershaft front bearing
• Remove the countershaft front bearing using .
22B-52
22B
Installation procedure
Installation: Countershaft front bearing
• Install the countershaft front bearing on the countershaft in the il-
lustrated direction, using .
22B-53
TRANSMISSION CONTROL
Removal sequence
1 Gear shift lever knob 10 Gear shift lever bracket
2 Clip 11 Shift lever (See later section.)
3 Adjuster 12 Transmission cable bracket
4 Select cable
5 Shift cable *b:
a: Gear shift lever
6 Collar * Gear selector lever
7 Instrument panel bracket *c: Shift rod
8 Gear shift control lever (See later section.) : Non-reusable parts
9 Gear shift lever stay
Installation sequence
Follow the removal sequence in reverse.
CAUTION
• Nuts used to mount the cables are coated with lock paint. Be sure to replace the nuts each time they are
loosened or removed.
22B-54
22B
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Nut (shift cable mounting)
19 to 24 {1.9 to 2.4} –
Nut (select cable mounting)
Lock nut on transmission side of shift cable 59 to 83 {6.0 to 8.5} –
Bolt (transmission cable bracket mounting)
37 to 53 {3.8 to 5.4} –
Bolt (shift lever mounting)
Nut (adjuster mounting) 4 to 6 {0.4 to 0.6} –
Nut (select cable mounting) 10 to 15 {1.0 to 1.5} –
Inspection procedure
Inspection: Shift cable, select cable
• Check the damage and deformation to the attached parts of
clamp and bracket. If any fault is found, replace the fault parts.
• Check the motion of cable, bend of limited parts and damage of
the cable. If any fault is found, replace the cable.
• Check the damage to the cable boot and ball joint. If any fault is
found, replace the cable.
Installation procedure
Installation: Shift lever
• Install the shift lever on the transmission case in the illustrated
direction.
22B-55
TRANSMISSION CONTROL
Installation: Shift cable, select cable
• Allow a bending radius of 260 mm or more during storage and
handling of the cables. Keep a bending radius as much as possi-
ble even after the cables are installed.
• Install the cable such that only a minimal bending force is ap-
plied to the under head portion of the casing cap.
• Avoid subjecting the guide pipe movable portion at the cable end
to movement exceeding a permissible angle of 5 degrees.
• Make sure that each clamp is installed with the same orientation
as that before removal.
• Where cable clamping positions are identified with a mark, install
the clamp in such a way that it covers the marking completely.
• Install each clamp such that it is perpendicular to the cable.
• Make sure that the joint at the cable end is installed with the
same orientation as that before removal.
• If there is an uneven contact between the holder portion boot
and stud portion of the ball joint at the cable end, or if the cable
boot kinks, remove the cable from the levers on both ends of the
cable and perform the following adjustment procedure:
• Rotate the cable rod to remove the kink from the cable boot.
• Loosen the cable nut and adjust orientation of the ball joint
within a half turn.
CAUTION
• To prevent damage, check that the engagement margin in
threads between the ball joint and cable rod is 8 mm or
more.
22B-56
22B
• Fix the cables to the cable brackets with clips and nuts with care
not to allow an excessive force to be applied to the shift cable
and select cable.
• Insert the clip to end of ditch.
CAUTION
• When fixing the cable with the clip, use care not to damage
the cable cover.
22B-57
TRANSMISSION CONTROL
• Return the gear shift control lever to the N (neutral) position and
check that select strokes A and B shown in the illustration are
equal.
• Check that the gear shift control lever can be smoothly returned
to the N (neutral) position.
• If there is a problem, make adjustment again.
<In case the gear cannot be shifted to front row speeds (1st, 3rd
and 5th) smoothly>
• Lengthen dimension C as illustrated in the figure and move the
gear shift lever backward.
<In case the gear cannot be shifted to back row speeds (R, 2nd
and 4th) smoothly>
• Shorten dimension C as illustrated in the figure and move the
gear shift lever forward.
22B-58
22B
• If the shift stroke is not sufficient to allow smooth gear shift oper-
ation, adjust the gear shift control using the turnbuckle on the
shift cable on the gear shift control lever side.
CAUTION
• Adjust the position by using the cable only on the gear shift
control lever side, and not on the transmission side.
22B-59
TRANSMISSION CONTROL
Gear Shift Control Lever
Disassembly sequence
1 Shift lever
2 Lever support
3 Insulator
4 Case
5 Bushing
6 Shift rod
7 Case
8 Return spring
9 Bolt
10 Shift bushing
11 Select lever
12 Plate
Assembly sequence
Follow the disassembly sequence in re-
verse.
22B-60
22B
Shift Lever
Disassembly sequence
1 Washer
2 Lever bracket
3 Shift bushing
4 Lever
Assembly sequence
Follow the disassembly sequence in re-
verse.
22B-61
TRANSMISSION POWER TAKE-OFF
Disassembly sequence
1 Clip 10 Power take-off case adapter 20 Power take-off shift fork
2 Clip bracket 11 Set screw 21 Bearing
3 Bracket 12 Power take-off coupling 22 Oil seal
4 Clevis pin 13 Seal ring 23 Oil seal
5 Vacuum chamber 14 Sunk key 24 Oil seal
(See later section.) 15 Bearing 25 Power take-off case
6 Front cover 16 Power take-off shaft
7 Shift clevis 17 Power take-off gear : Locating pin
8 Power take-off control switch 18 Power take-off shift sleeve : Non-reusable parts
9 Sealing cap 19 Power take-off shift rail
Assembly sequence
Follow the disassembly sequence in reverse.
22B-62
22B
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
16, 17 Play in diameter direction of power take-off gear 0.07 to 0.11 0.2 Replace
Clearance between power take-off shift sleeve and
18, 20 0.3 to 0.5 1.0 Replace
power take-off shift fork
22B-63
TRANSMISSION POWER TAKE-OFF
Inspection procedure
Inspection: Clearance between power take-off shift sleeve
and power take-off shift fork
• If the measurement exceeds the limit, replace defective parts.
Installation procedure
Installation: Oil seal
• Apply sealant to the outer circumference of the oil seal A.
• Apply grease to the oil seal A, B lips and install the oil seals to
the power take-off case.
22B-64
22B
Installation: Power take-off case adapter
• Install the power take-off case adapter to the power take-off
case.
22B-65
TRANSMISSION POWER TAKE-OFF
Installation: Bracket and clip bracket
• Install the bracket and clip bracket as shown in the drawing.
22B-66
22B
M E M O
22B-67
POWER TAKE-OFF CONTROL
Disassembly sequence
1 Cable holder 4 Clip
2 Power take-off control cable
3 Power take-off control lever (See later section.) : Non-reusable parts
Assembly sequence
Follow the disassembly sequence in reverse.
22B-68
22B
Installation procedure
Installation: Power take-off control cable
• Install the cable in the following manner:
• Before beginning with installation procedure, check to deter-
mine the clamping direction, clamping positions and cable
route.
• Insert the clip fully through the groove until a pressure release
is felt.
• Where cable clamping positions are identified with a mark, in-
stall the clamp in such a way that it covers the marking com-
pletely.
• Install each clamp such that it is perpendicular to the cable.
• Connect the cable such that any bent section of the cable
does not extend to the casing cap.
• Prevent the cable from interfering with any moving parts.
• Arrange the cable such that the bending radius is as large as
possible.
• Do not swing the cable end on the pivot beyond the allowable
limit of 5 degrees.
• Place the power take-off control lever in the power take-off OFF
position.
• Mount the nut on cable of the power take-off main body side and
align the cable thread end with the end face of the nut.
• Loosen the adjusting bolt of the power take-off control lever and
adjust the position of the lever so that dimension A is achieved
between the center of the inner cable ball and the nut end face.
After the adjustment, tighten the adjusting bolt.
A: 10 mm
22B-69
POWER TAKE-OFF CONTROL
Power Take-off Control Lever
Disassembly sequence
1 Power take-off indicator lamp
switch <Dump>
2 Lever
3 Power take-off lever
4 Bushing
5 Spring pin
6 Power take-off control bracket
: Non-reusable parts
Assembly sequence
Follow the disassembly sequence in re-
verse.
Removal procedure
Removal: Spring pin
• Install the spring pin so that the protruding distance from the
power take-off lever in the illustrated direction and the slit are as
illustrated.
22B-70
22B
Installation procedure
Installation: Lever
• Loosen the bolts and nuts and adjust so that the specified di-
mensions are achieved relative to the lever, power take-off con-
trol bracket, and switch with the power take-off lever in the OFF
position.
• Tighten the bolts and nuts after adjustment.
• After installation, check that the lever is locked at each of the ON
and OFF positions.
• After installation, place the lever into the ON position and check
that the indicator lamp lights up steadily.
22B-71
BEARING PULLER AND INSTALLER
• Bearing pullers and installers are special tools used for removing and installing the bearings listed in the table be-
low and used in this group.
• For each puller (for removing) and each installer (for installing), use the components of the bearing pullers and in-
stallers in combination.
Application
Component
Bearing
puller and Component Part No. Puller Installer Puller Installer Puller Installer Puller Installer
installer
Adapter MH062590
Plug 03726-81017 O O O O
Bolt MH062700 O O O O
Body MH062701 O O O O O O O O
Protector MH061306 O O O O
MH062696
Countershaft
03726-81012 O
bearing claw
Bearing claw MH062707 O
Mainshaft
MH061305 O
bearing claw
Bearing claw MH062706 O
22B-72