Part 1
Shifter Fork and RodREMOVAL
1) Remove the manual transmission assembly from the vehicle.
2) Prepare the transmission for overhaul.
3) Remove the oil pipe, neutral position switch, back-up light switch and harness.
4) Remove the extension case.
5) Remove the transfer driven gear.
6) Remove the center differential.
7) Remove the oil pump.
8) Remove the transmission case.
9) Remove the individual gear assemblies.
INSTALLATION
1) Install the individual gear assemblies all at once.
2) Install the transmission case.
3) Install the oil pump.
4) Install the center differential.
5) Install the transfer driven gear.
6) Install the extension case.
7) Install the oil pipe, neutral position switch, backup light switch and harness.
8) Install the manual transmission assembly to the vehicle.
DISASSEMBLY
NOTE: Discard the removed spring pin, and replace with a new part.
REVERSE SHIFTER FORK
1) Remove the reverse fork using the ST.
ST 398791700 REMOVER
2) Remove the reverse shifter arm using the ST.
ST 398791700 REMOVER
1ST-2ND, 3RD-4TH SHIFTER FORK
1) Using the ST, remove the 3rd-4th shifter fork.
ST 398791700 REMOVER
2) Using the ST, remove the 3rd-4th shifter arm.
ST 398791700 REMOVER
3) Using the ST, remove the 1st-2nd shifter arm and 1st-2nd shifter fork.
ST 398791700 REMOVER
5TH-6TH SHIFTER FORK
1) Using the ST, remove the 5th-6th shifter fork.
ST 398791700 REMOVER
2) Using the ST, remove the 5th-6th shifter arm.
ST 398791700 REMOVER
SHIFTER ARM SHAFT
Remove the selector arm using the ST.
ST 398791700 REMOVER
STRIKING ROD
1) Remove the reverse interlock block and the interlock block from the striking rod.
2) Remove the reverse interlock arm using the ST.
ST 398791700 REMOVER
3) Remove the interlock arm using the ST.
ST 398791700 REMOVER
ASSEMBLY
REVERSE SHIFTER FORK
1) Using the ST, install the reverse fork.
ST 398791700 REMOVER
NOTE: Confirm that the reverse fork and rod are installed in the proper direction.
2) Using the ST, install the reverse arm.
ST 398791700 REMOVER
NOTE: Confirm that the reverse arm and rod are installed in the proper direction.
1ST-2ND, 3RD-4TH SHIFTER FORK
1) Using the ST, install the 1st-2nd shifter fork.
ST 398791700 REMOVER
NOTE: Make sure that the 1st-2nd shifter fork and rod are installed in the correct direction.
2) Using the ST, install the 1st-2nd shifter arm.
ST 398791700 REMOVER
NOTE: Make sure that the 1st-2nd shifter arm and fork are installed in the correct direction.
3) Using the ST, install the 3rd-4th shifter arm.
ST 398791700 REMOVER
NOTE: Make sure that the 3rd-4th shifter arm and rod are installed in the correct direction.
4) Attach the 3rd-4th fork rod to the 1st-2nd shifter arm.
5) Using the ST, install the 3rd-4th shifter fork.
ST 398791700 REMOVER
NOTE: Make sure that the 3rd-4th shifter fork is installed in the correct direction.
5TH-6TH SHIFTER FORK
1) Using the ST, install the 5th-6th shifter arm.
ST 398791700 REMOVER
NOTE: Make sure that the 5th-6th shifter arm and rod are installed in the correct direction.
2) Using the ST, install the 5th-6th shifter fork.
ST 398791700 REMOVER
NOTE: Check that the 5th-6th shifter fork and arm are installed.
SHIFTER ARM SHAFT
Using the ST, install the selector arm.
ST 398791700 REMOVER
NOTE: Confirm that the selector arm and rod are installed in the proper direction.
STRIKING ROD
1) Using the ST, install the reverse interlock arm and interlock arm.
ST 398791700 REMOVER
NOTE:
^ Confirm that the reverse interlock arm and rod are installed in the proper direction.
^ Confirm that the interlock arm and rod are installed in the proper direction.
2) Attach the reverse interlock block and interlock block to the striking rod.
NOTE: Confirm that the reverse interlock block and interlock block are installed in the proper direction.
INSPECTION
1) Check the shift shaft and shift rod for damage. Replace if damaged.
2) Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
ADJUSTMENT
1ST-2ND FORK ROD SELECTION
NOTE:
In the following conditions, perform the procedures below.
^ When the 1st and 2nd driven gear are replaced.
^ When the 1st and 2nd synchro ring assembly are replaced.
^ When the adapter plate is replaced.
^ When the driven shaft is replaced.
^ When the 1st-2nd hub and sleeve assemblies are replaced.
1) Insert the drive pinion assembly into the adapter plate.
NOTE: Confirm that the thrust bearing outer race has not been removed and the drive pinion is not lifted.
2) Set the height gauge to the adapter plate. Lower the height gauge indicator to the mating surface of the adapter plate and case, and set to 0 points.
ST 18853AA000 HEIGHT GAUGE
NOTE:
^ The adapter plate will be the base point for the measurement. Use a scraper to remove any gasket material remaining on the end face.
^ During measurement, do not place the height gauge in the shaded area shown in the figure.
3) Select the main shaft snap ring.
4) Measure "B1" and "B2" as shown in the figure.
(1) Shift the 1st-2nd sleeve to the 1st driven gear side, push down to the stopper, and measure "B1".
NOTE:
^ Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 1st side end surface of the sleeve.
^ Turn approximately 72° at a time, and measure the sleeve in 5 locations. Round off the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(2) Set the height gauge indicator upside down.
(3) Shift the 1st-2nd sleeve to the 2nd driven gear side, push up on the stopper, and measure "B2".
NOTE:
^ Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 2nd side end surface of the sleeve.
^ The measurement is to be performed with 2 persons, while holding the sleeve straight.
^ Turn approximately 72° at a time, and measure the sleeve in 5 locations. Round off the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(4) According to both of the measurements, calculate the neutral position of the 1st-2nd sleeve. From the following calculation, select a fork rod which matches the calculated value.
Calculation: T = (B1 + B2) / 2
T: 1st-2nd sleeve center position
B1: Height from the adapter plate end to the sleeve end, when shifted to 1st gear
B2: Measured height from the adapter plate end to the sleeve end, when shifted to 2nd gear: +55 mm (2.17 in)
NOTE: Attach the indicator upside down in comparison to the setting procedures for the 0 point. Add dl [Numerical value: 55 mm (2.17 in)] from the figure below to "B2", and measure "B2".
