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TRANSMISSION

GENERAL ................................................................................TM - 2
SPECIFICATIONS .................................................................... TM - 7
SERVICE STANDARDS ........................................................... TM - 8
TIGHTENING TORQUE ............................................................ TM-10
SPECIAL TOOLS .....................................................................TM-11
SERVICE PROCEDURE .......................................................... TM-12
TROUBLESHOOTING ............................................................. TM-46
TM-2 TRANSMISSION

GENERAL
The transmission changes the torque produced by the engine to a torque vehicle requires. The torque, or drive power, is
increased or decreased by shifting several groups of gears.
Since the engine always turns in one direction, the transmission also performs the function of changing the direction of
rotation so that the vehicle can be backed.

<M8S5 (O/D)>

5 4
2
6 3

7
8 1 Reverse
6
5 2 1st speed
4 3 4th speed
3 4 3rd speed
2 5 2nd speed
1 6 5th speed
9

1. 1st speed and reverse 7. Pilot bearing


constant mesh 8. Drive pinion
2. Shift rail 9. Main shaft
3. 2nd, 3rd synchronizer assembly 10. Counter shaft
4. Shift fork 11. Reverse gear
10 11 5. Inter lock
6. 4th ,5th synchronizer assembly

<M10S5 (D/D)>

6 5 4
3
2

7 6 1 Reverse
5 2 1st speed
4 3 4th speed
8 3 4 3rd speed
2
5 2nd speed
1
6 5th speed

10 11

CYMT001A/CYMT002A
GENERAL TM-3

There are two types of transmissions provided; a direct coupled, 5-


forward-speed type <M10S5 (D/D)>, and a 5-speed-with-overdrive
type <M8S5 (O/D)>.
A single cone type synchronizer is installed between 5th and 4th
gears; a double cone type synchronizer is installed between 3rd and
2nd gears; and a constant-mesh mechanism is installed between
the 1st and reverse gears.

1. Single cone type synchronizer


The bore of the synchronizer hub is in mesh with the main
shaft splines and the synchronizer hub rotates with the main
shaft. The outside surface of the synchronizer hub has splines
in mesh with the synchronizer sleeve and three keyways. The
protrusion at the center of the shifting key fits into the groove
inside the synchronizer sleeve in neutral and is pressed against
the inner surface of the synchronizer sleeve by the shifting key
spring.

4
2

1 1. Drive pinion(Single cone)


6 2. Synchronizer ring
3. 4th, 5th Shift fork
7
4. 4th gear(Double cone)
5. Shifting key
6. Shifting spring
7. Main shaft
8 8. Synchronizer hub
9. Synchronizer sleeve
9
CYMT003A

When the shift fork is moved in the direction shown by the arrow,
the synchronizer sleeve moves slightly toward the left. The shift-
ing key, whose center protrusion is in mesh with the synchro-
nizer sleeve, then also moves to the left, causing the synchro-
nizer ring to be pressed against the drive pinion taper cone.

CYMT004A
TM-4 TRANSMISSION

As the synchronizer sleeve moves further to the left, the shift-


ing key is blocked by the side face of the synchronizer ring,
which causes the shifting key protrusion to be disengaged from
the synchronizer sleeve.

CYMT006A

When the synchronizer sleeve and drive pinion turn at the same
speed, the synchronizer ring no longer blocks the synchronizer
sleeve; as a result, the synchronizer sleeve moves further to
the left to be in mesh with the taper cone splines of the drive
pinion. This results in power being transmitted.

CYMT008A

2. Double cone type synchronizer (2nd, 3rd)


The synchronizer sleeve of the synchronizer assembly rotates
with the main shaft via synchronizer hub.
There are six equally-spaced holes drilled in the synchronizer
sleeve, into which the synchronizer stem, synchronizer plunger,
and synchronizer spring are fitted. In neutral, the synchronizer
plunger built in the synchronizer sleeve is pressed against the
indentation in the synchronizer stem by the synchronizer spring.

4
1. Synchronizer inner ring
5 2. 2nd, 3rd shift fork
1 3. Shifting key
7
4. Synchronizer outer ring
5. Synchronizer center cone
8 6. 2nd gear
7. Shifting key spring
8. Main shaft
6
9. Synchronizer hub
10. Synchronizer sleeve
11. 3rd gear
11 12 9 12. Dog clutch
10
CYMT009A
GENERAL TM-5

When the shift fork is moved in the direction shown by the arrow,
the synchronizer sleeve moves slightly toward the 3rd gear. As
a result, the synchronizer stem moves also toward the 3rd
gear, pressing the synchronizer ring against the 3rd gear syn-
chronizer cone.

CYMT010A

As the synchronizer sleeve moves further toward the 3rd gear,


the synchronizer stem is blocked by the synchronizer ring, dis-
engaging the synchronizer plunger.

CYMT012A

The friction torque of the taper surface becomes greater, which Synchronizer sleeve

causes the synchronizer sleeve to press the synchronizer stem


Resultant
taper and to press the synchronizer ring hard against the syn- force Synchro stem
chronizer cone. As a result, an even greater friction torque is
applied to the cone clutch, bringing the synchronizer sleeve
Torque
and 3rd gear into synchronization, both rotating at the same
speed. Force
CYMT012B

When both rotate at the same speed, force is gone to turn the
synchronizer ring. This results in the synchronizer sleeve riding
over the synchronizer stem taper to be in smooth mesh with
the 3rd gear splines. In this way, power is transmitted.

CYMT014A
TM-6 TRANSMISSION

3. Interlock mechanism
<Neutral>
The interlock mechanism, installed in the gearshift lower case, 2 5 3 4
prevents double engagement of gears. When the shift rail is 1
placed in a gearshift position, the steel ball leaves that shift rail
groove, fitting into other shift rail groove. As a result, the other
shift rails are locked. The steel ball to the right of the 1st & Rev.
shift rail moves to the right to lock the 2nd & 3rd shift rail; at the
1. 1st and Rev. shift rail
same time, it causes interlock pin B to be moved to push the 2. Gear shift lower case
right steel ball, thus locking the 4th & 5th shift rail into position. 6 3. 2nd and 3rd case
4. 4th and 5th case
5. Inter lock pin B
<Shift>
6. Steel ball

1
CYMT014B
SPECIFICATIONS TM-7

Transmission Control
The transmission control is a remote control floorshift employing a rod for both shift and select.

Control bar

Gear shift lever assembly


Control bar roller assembly

Gear shift (upper)

Bar clamp

Control bar

CYMT015A

SPECIFICATIONS
Model M8S5 M10S5
Overdrive type Direct drive type Direct drive type
(O/D) (D/D) (D/D)
Item Constant mesh type with synchronizer
Gear ratio 1st 5.431 6.552 6.571
2nd 3.463 4.178 4.436
3rd 1.747 2.415 2.451
4th 1.000 1.498 1.463
5th 0.741 1.000 1.000
Rev. 5.677 6.849 6.240
Oil quantity (lit.) 10 13
Spec. General zone SAE 80W, API GL-4
Severe heat zone SAE 90W, API GL-4
TM-8 TRANSMISSION

SERVICE STANDARDS
Unit : mm
Nominal value
Maintenance item Limit Remedy and remarks
(Basic diameter in [ ])
Gear backlash 1st gear 0.08 to 0.27 0.5 Replace gear
(Main shaft gear, 2nd gear M8S5 0.08 to 0.25
counter shaft gear, M10S5 0.08 to 0.27
reverse gear) 3rd gear M8S5 0.08 to 0.27
M10S5 0.08 to 0.25
4th gear <M8S5>, 5th gear <M10S5> 0.08 to 0.27
Reverse Mesh to main shaft gear 0.09 to 0.28
gear Mesh to counter shaft gear 0.08 to 0.25
2nd and 3rd Synchronizer sleeve to hub clearance (E) [126] 0.06 to 0.14 0.3 Replace
synchronizer Synchronizer outer ring to dog clutch clearance(A) 2.2 Replace
(Double cone) E A
Outer ring
Synchronizer sleeve Dog clutch

Synchronizer hub

CYMT015B/KHDMA01A

4th and 5th Synchronizer sleeve to hub clearance [150] 0.06 to 0.13 0.3 Replace
synchronizer Synchronizer hub groove to 4.7 to 5.3 6.5
(Key type) ring projection clearance (B)
Synchronizer hub groove to 0.05 to 0.35 0.5
shifting key clearance (C)
Synchronizer ring to cone clearance (A) 2.5 0
A Synchronizer Synchronizer
B
Gear cone hub ring C Shifting key
Synchronizer
hub
Ring

CYMT015C

Main shaft 1st gear O.D. [85] -0.030 -0.10 Replace


bearing sleeve 2nd gear M8S5 [76] -0.043
3rd gear M10S5 [76]
4th gear [61]
5th gear M8S5 [61]
Radial clearance of 1st gear 0.12 Replace faulty parts
main shaft needle 2nd gear If two needle roller
bearings are used for a
roller bearing after 3rd gear gear, use the bearings
assembly of same package color
4th gear
for replacement
5th gear
Rev. gear
SERVICE STANDARDS TM-9

Unit : mm
Nominal value
Maintenance item Limit Remedy and remarks
(Basic diameter in [ ])
Main shaft pilot Radial clearance of needle roller 0.12 Replace
bearing bearing after assembly
Radial clearance of rev. gear needle roller bearing after assembly Replace faulty parts
Main shaft 1st gear M8S5 0.15 to 0.35 0.5 Replace gear or washer
gear end play M10S5 0.15 to 0.38 0.7
2nd gear 0.15 to 0.35 0.5
3rd gear 0.15 to 0.35 0.5
4th gear M10S5 0.25 to 0.40 0.6
5th gear M8S5 0.25 to 0.40 0.6
Reverse gear 0.15 to 0.35 0.5
Speedometer Backlash between speedometer gear and worm 0.13 to 0.29 0.36 Replace gear or worm
gear Speedometer gear shaft to bushing clearance [12] 0.02 to 0.07 0.15 Replace faulty parts
Speedometer gear shaft end to rear cover [8] 0.17 to 0.21 0.4 Replace faulty parts
bearing hole clearance (Bushing I.D.)
Poppet spring in gear shifter Load N (kgf)/ 92 (9.43) ± 10% 75 (7.6) Replace Free
lower section installed length / 34.5 / 34.5 length:40.5
Shift fork Shift fork to sleeve groove clearance 0.25 to 0.45 1.0 Replace
Tilt of shift fork claw to shift rail hole 0.1 or less 0.2
1st and reverse shift lever to shaft clearance [23] 0.02 to 0.08 0.15 Replace
Bend of shift Bend of B from A-A basis 0.05 or less 0.1
lever A A B
CYMT015D

Shift rail Bend of shift rail 0.02 or less 0.04 Replace


<M10S5> Load N (kgf)/ Lifter spring on 14.7 (1.5)/14.5 12.25 (1.25) Free Replace
Return installed length striker side / 14.5 length:23.6
springs in Spring between 12.7 (1.3)/10 9.8 (1.0) Free
gear shifter seal assemblies / 10 length:21
upper section Lifter spring on 49 (5)/14.5 41.2 (4.2) Free
(gearshift stopper plate side / 14.5 length:25.5
servo unit) Steel ball 11.8 (1.2)/13 9.8 (1.0) Free
retaining spring / 13 length:19.5
Transmission Shift and select shaft to bushing [22] 0.0005 to 0.104 0.6 Replace
control clearance at gear shift assembly
section Cross shaft to bushing clearance [25] 0.0005 to 0.104 0.6 Replace
TM-10 TRANSMISSION

TIGHTENING TORQUE
Screw size Tightening torque
Location tightened
O.D x pitch(mm) Nm (kgf·m)
Main shaft front lock nut M52 x 1.5 540 to 735 (55 to 75)
Main shaft rear lock nut M42 x 1.5 1372 to 1666 (140 to 170)
Shift fork and shift jaw set bolt M12 x 1.25 49 to 67 (5.0 to 6.8)
1st and reverse shift lever M10S5 M14 x 1.5 133 (13.6)
attaching nut
Case set bolt (gear shifter upper) M8S5 M14 x 1.5 97 (9.9)
M10S5 M14 x 1.5 135 (13.6)
Interlock screw plug 145 (14.8)
Bearing retainer bolt (Front) M10 x 1.5 40 (4.1)
Reverse shaft lock piece bolt M10 x 1.5 40 (4.1)
Speedometer gear bushing tightening M30 x 1.5 195 (20)
Rear cover attaching bolt M12 x 1.75 74 (7.5)
Transmission to clutch housing attaching bolt M16 x 2.0 190 (19.2)
Case Gear shifter upper case bolt M10 x 1.5 40 (4.1)
Gear shifter lower case bolt M10 x 1.5 40 (4.1)
PTO cover bolt M10 x 1.5 20 (2.0)
Drain plug and oil level plug M20 x 1.5 54 to 83 (5.5 to 8.5)
Lower case backup lamp switch tightening M18 x 1.5 49 (5)
Upper case interlock switch tightening M18 x 1.5 49 (5)
Gearshift Gearshift upper section mounting bolt M10 x 1.5 40 (4.1)
upper Gearshift lever assembly <M8S5> reamer bolt 26 (2.7)
section Gearshift Elbow connector PT 1/4 20 to 59 (2 to 6)
servo unit Cylinder M60 x 1.5 78 to 98 (8 to 10)
Striker holding bolt M10 x 1.25 29 to 39 (3 to 4)
Connector M27 x 1.5 59 to 69 (6 to 7)
Nut M30 x 1.5 7.8 to 11.8 (0.8 to 1.2)
Set screw M6 x 1 4 to 7 (0.4 to 0.7)
Neutral switch M18 x 1.5 12 to 16 (1.2 to 1.8)
Transmission Gear shift knob M8 x 1.25 5.9 to 7.8 (0.6 to 0.8)
control section Dowel screw 26 (2.7)
Gear shift cover installation 9.8 (1.0)
Control bar guide frame installation 3.8 to 5.9 (0.4 to 0.6)
Universal joint mounting bolt M12 x 1.25 83 to 108 (8.5 to 11)
Control lever and shift and select rod attaching nut M10 x 1.25 14.7 to 33.3 (1.5 to 3.4)
Control rod assembly ball joint holding nut M10 x 1.25 20.6 to 34.3 (2.1 to 3.5)
SPECIAL TOOLS TM-11

SPECIAL TOOLS

Tool
Illustration Use
(Number and name)
09431-83100 Removal of main shaft pilot bearing
Puller set

CYMT015E

09431-7A000 Installation of rear cover oil seal


Oil seal installer

0.3
ø7
D317A00A

09432-7A000 Installation of main shaft pilot bearing


Bearing installer
8
ø6

D327A00A

09431-7A100 Installtion of front retainer bearing oil


Oil seal installer seal

D317A10A

09434-7A000 Removal of main shaft and counter


Bearing puller set shaft bearing

D347A00A

09434-7A100 Install of main shaft and counter shaft


Bearing installer set bearing

D347A10A

09450-75100 Removal of reverse shaft


Sliding hammer (Use with 09450-75200, 09450-
75300, 09450-75400 and 09450-
75500)
M16x15
D507510A
TM-12 TRANSMISSION

SERVICE PROCEDURE
Removal and Installation

Select rod
Clutch housing

Shift rod

Power cylinder

Power shift

Clutch booster
Select lever

PTO cover
Speedometer cable

Parking brake
(except vehicles with
Propeller shaft wheel parking brake)

CYMT015F

Removal Alignment mark


Companion flange
1. Park the vehicle on a flat ground and place chocks to all wheels.
2. Remove the propeller shaft from the companion flange.
NOTE:
Before removing the part, be sure to make alignment marks
on the companion flange spacer and propeller shaft.

Propeller shaft
JMS43-055

3. Remove the shift rods, switch harnesses and speedometer


cable from the transmission. Shift rod
4. Remove the clutch booster with hoses and pipes left connected. Parking
brake cable

Speedo
meter
Harness
JMS43-056
SERVICE PROCEDURE TM-13

5. Remove the drain plugs and inspection plug to discharge trans- Clutch booster
mission oil.

Inspection plug Drain plug CYMT018A

6. When draining the transmission oil, check the oil for quantity,
quality, and metal chips and particles. The drain plug is a mag-
net and metal particles adhering to it should be removed after
the inspection.

JMS43-059

7 Supporting the transmission with a transmission jack, remove T/M assembly


the mounting bolts from the clutch housing.

Bolt

T/M jack CYMT018B

8. Move the transmission rearward until the drive pinion splines


come out of position. Never jerk the transmission.

JMS43-063

Installation
1. Check the drive pinion splines for rust. If rust gathers, remove
it with a wire brush. Then, coat the drive pinion surface over
which the clutch slides with grease.

Drive pinion CYMT018C


TM-14 TRANSMISSION

2. Supporting the transmission with a transmission jack, fit the T/M assembly
transmission over the pilot bearing of the engine flywheel. Dur-
ing the procedure, use care to prevent damage to the drive
pinion splines. Then, tighten to specification the mounting bolts
on the periphery of the clutch housing to secure it onto the
engine. Bolt

T/M jack CYMT018B

3. Make sure that the drain plugs are torqued to specification,


then pour in transmission oil from the inspection port.

Drain plug Inspection plug


54 to 83Nm 54 to 83Nm
Inspection plug
(5.5 to 8.5kgf·m) (5.5 to 8.5 kgf·m)
54 to 83Nm
(5.5 to 8.5kgf·m) Drain plug
54 to 83Nm
(5.5 to 8.5kgf·m) CYMT018D

4. Install the clutch booster. Clutch booster


5. Install the control rods, switch harnesses, and speedometer
cable to the transmission.

Inspection plug Drain plug CYMT018A

6. Install the propeller shaft, making sure that the alignment mate Alignment mark
Companion flange
are aligned to the companion flange.
Then, tightening the nuts to specification.

Propeller shaft
JMS43-055

Inspection and Adjustment after Installation


1. Referring to adjust the transmission control.
2. Referring to check the clutch pedal.
SERVICE PROCEDURE TM-15

Disassembly Inspection and Reassembly


Disassembly Procedure

Gear shifter lower


Gear shifter upper

Companion
flange

Release fork shaft


Clutch release fork

PTO cover

Front bearing assembly


Clutch shift

Clutch release fork

Clutch release fork

CYMT019A

1. Remove the clutch housing assembly.


2. Remove the main shaft rear lock nut with a Socket Wrench.

Socket Wrench

CYMT019B

3. Remove the companion flange with Flange Puller.


4. Remove the rear cover and the extension housing.

Flange Puller

CYMT019C
TM-16 TRANSMISSION

Reassembly

Gear shift lower

4.1kgf·m

4.1kgf·m

5.5 ~ 8.5 kgf·m

Front bearing retainer Clutch housing gear


shift upper
Apply the sealant
to upper case

5kgf·m
4.1kgf·m
Apply sealant PTO cover 140 ~ 170 kgf·m
2.0kgf·m

CYMT020A

Reassembly Procedure
1. When installing the speedometer gear, apply an ample amount Speedometer
gear bushing
of grease.

Speedometer
gear

Speedometer

CYMT020B

2. Install a new oil seal to the bearing retainer for replacement Grease
with oil Seal Installer. (09431-7A100) 09431-7A100

Oil seal
Front bearing
retainer

CYMT020C
SERVICE PROCEDURE TM-17

3. When installing the front bearing retainer, use with Oil Seal
Guide, and be care not to damage the oil seal.

Front bearing
retainer

Oil seal

CYMT020D

4. Install the main shaft rear lock nut with Socket Wrench.

Socket wrench

JMS43-150
TM-18 TRANSMISSION

Transmission Proper
Inspection

Back Lash Back Lash


NV L NV L
0.08~0.27 0.5 0.08~0.27 0.5
Back Lash
NV 0.08~0.27
Back Lash
L 0.5
NV 0.08~0.27
L 0.5

End Play
End Play
NV 0.25~0.40 NV L
L 0.5 0.05~0.35 0.5

Unit : mm
End Play Back Lash
Back Lash
NV 0.25~0.40 NV 0.09~0.28
NV 0.15~0.35 NV ... Nominal Value
L 0.5 L 0.5
L 0.5 L ... Limit

CYMT021A

Inspection Procedure
1. Measure the backlash and replace any defective parts.

CYMT021B

2. Measure the end play and replace any defective parts.

CYMT021C
SERVICE PROCEDURE TM-19

Disassembly

10

5
8

1
6
2
12

11 3

Disassembly sequence
1. Reverse shaft lock piece 7. Roller bearing
2. Reverse shaft 8. Drive pinion assembly
3. Reverse gear 9. Roller bearing
4. Roller bearing 10. Roller bearing
5. Roller bearing 11. Counter shaft assembly
6. Snap ring 12. Transmission

NOTE:
Check each bearing for rotating condition, noise, wear, damage, rust, and corrosion
CYMT022A

Disassembly Procedure
1. Using the special tool(09450-75100), remove the reverse idler
gear shaft.
09450-75100

Rev. idler gear shaft


CYMT022B
TM-20 TRANSMISSION

2. Using the special tool(09431-83100), remove the counter shaft


front bearing.

09431-83100

CYMT022C

3. Using the special tool(09434-7A000), remove the counter shaft


rear bearing.

09434-7A000

CYMT022D

4. Using the special tool(09431-83100), remove the drive pinion


Bearing
assembly with bearing.

09431-83100

CYMT022F

5. Using the special tool(09434-7A000), reomve the bearing from


the drive pinion. 09434-7A000

CYMT022E

6. Using the special tool(09434-7A000), reomve the main shaft


rear bearing.
09434-7A000

CYMT022G
SERVICE PROCEDURE TM-21

Reassembly

8 9
10 11
12

5
4
13
Reassembly sequence
6 7
14→13→12→11→8→ 7 →6→5→4→3→2→1
1


10→ 9

14 NOTE:
For parts with encircled number, refer to
2
3 Disassembly procedure.

CYMT023A

Reassembly Procedure Dummy bearing retainer


1. Install the main shaft rear bearing.
Dummy bearing

Bearing installer

CYMT023B

2. When installing the drive pinion, secure the synchronizer ring


to the synchronizer sleeve using Synchronizer Ring Holder.
Synchronizer
ring holder

Synchronizer sleeve
Drive pinion Synchronizer ring
CYMT023C

3. Install the counter shaft rear bearing.


4. For installation of the reverse gear, refer to Reverse gear.

Counter shaft
Bearing installer

Dummy
bearing
CYMT023D
TM-22 TRANSMISSION

Main Shaft
Disassembly and Inspection

BD ... Basic Diameter Bearing sleeve 27


NV ... Nominal Value BD 61mm 30 28
Bearing sleeve
L ... Limit BD 76mm L -0.1mm 31 29
L -0.1mm 29
28
27
Clearance 26
Clearance NV 2.5mm
NV 0.05 to 0.35mm L 0 22
L 0.5mm 32
20 33
Diametric play after 19
reassembly
16 14
L 0.12mm
24
23
17 21
17 1
Clearance 3
11 13 BD 150mm
12 NV 0.06 to 0.14mm 4
15 5 2
10 L 0.3mm 6
18 7
1st gear bearing sleeve
14 9 BD 85mm
8 L -0.1mm
36
Clearance
NV 4.7 to 5.3mm 35
L 6.5mm
34 Diametric play after
reassembly
L 0.12mm

Disassembly sequence
1. 1st gear washer 13. Lock washer 25. Needle roller bearing
2. Main shaft 1st gear 26. 3rd (2nd) gear bearing sleeve
14 Synchronizer ring
3. Needle roller bearing 27. Inner ring
15. Synchronizer sleeve
4. 1st gear bearing sleeve 28. Middle ring
16 Shifting key
5. Spacer <except M8S> 29. Outer ring
17. Shifting spring
6. 1st & Rev. constant-mesh sleeve 30. Steel ball
18. Synchronizer hub
7. 1st & Rev. constant-mesh hub 31. Spring
19. 4th (5th) gear assembly
8. Main shaft Rev. gear 32. Synchronizer sleeve
20. Needle roller bearing
9. Needle roller bearing 33. Synchronizer hub
21. Bearing spacer
10 Snap ring
34. 2nd (3rd) gear assembly
22. 4th (5th) gear bearing sleeve
11 Pilot bearing
35. Needle roller bearing
23. Thrust washer
12 Lock nut
36. Main shaft
24. 3rd (2nd) gear assembly

Names in ( ) are for M8S5 O/D.


For parts with an encircled number, refer to Disassembly and Inspection Procedures that follows.
CYMT024A

NOTE:
1. Before disassembling the key type synchronizer put matching mark at one location each in the synchro-
nizer hub and synchronizer sleeve where a key is inserted.
2. Do not disassemble the 2nd and 3rd synchronizer assembly of the pin type synchronizer, as its stem has
been staked over the ring. If it needs replacement, replace it as an assembly.
SERVICE PROCEDURE TM-23

Disassembly Procedure
1. Using a snap ring expander, remove the snap ring.

Snap ring
expander

CYMT024B

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

Bearing puller

CYMT024C

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

Single spanner
CYMT024D
TM-24 TRANSMISSION

4. To remove each bearing sleeve, make use of the weight of


gear; i.e., lightly hit the main shaft against a lead plate.
NOTE:
Be sure to use a lead plate to prevent main shaft end from
being damaged.

Bearing sleeve

CYMT024E
Inspection Procedure
1. Measure the diametric play in each main shaft gear and needle
bearing.
If the play exceeds the limit, replace the needle bearing.
NOTE:
1. If two needle bearings are used for one gear, use one
of the same package color for replacement.
2. If replacement of the needle bearing does not correct
the excessive diametric play, check each bearing sleeve
(except 2nd gear and reverse gear) and main shaft gear CYMT024F

and replace any defective parts.


2. Measure the clearance between the synchronizer hub key-
Shifting key
way and shifting key. Replace parts if the clearance exceeds
the limit.

Synchronizer hub
CYMT024G

3. Measure the clearance between the hub groove in synchro-


nizer hub and ring protrusion in synchronizer ring. If the limit is
Clearance
exceeded, replace parts. Synchronizer ring
Synchronizer hub

CYMT024H
SERVICE PROCEDURE TM-25

4. Measure the clearance between the synchronizer ring and the


gear cone of main shaft 4th (5th) gear assembly.
If the clearance exceeds the limit, replace parts.
NOTE:
Press synchronizer ring evenly and take measurement Feeler gauge
throughout the entire circumference.
Main shaft 4th
gear assembly
Synchronizer ring
Gear cone CYMT024I

5. Measure the clearance between the synchronizer ring of 2nd


Synchronizer cone
and 3rd synchronizer assembly and the synchronizer cone of
2nd gear assembly. If the clearance exceeds the limit, replace Synchronizer ring
Clearance
parts.
Pressure
295 to 490 N
(30 to 50 kgf)

CYMT024J

6. Measure the clearance between the synchronizer sleeve of


2nd and 3rd synchronizer assembly and 2nd and 3rd synchro- Clearance

nizer hub and between the synchronizer sleeve and synchro- Synchronizer sleeve

nizer hub.
Replace parts if the clearance exceeds the limit.
Synchronizer hub

CYMT024K
TM-26 TRANSMISSION

Reassembly

19 28 9 8 2
18
15 14 21
14 4
16 23 25

1
13 30

11

10
3
12

17
5
20 22 24 26 27 19 7 6

Reassembly squence
30→29→28→26→27→ 24 →25→23→22→ 20 →21→19→13→ 12 → 11 →10→8→9→7→6→5→ 4 →3→2→ 1

17→18→16→15→14

For parts with an encircled number, refer to Reassembly Procedure that follows.
CYMT025A

Reassembly Procedure
1. To install the bearing sleeve into the main shaft, use the spe- 09434-7A100 Main shaft

cial tool.(09434-7A100)

Bearing sleeve
CYMT025B

2. Mate the synchronizer hub with the synchronizer sleeve, en-


suring that the keyways at three places in the synchronizer Synchronizer

hub are aligned with stub teeth at three places (indicated by *


Synchronizer hub sleeve
*
in Fig.) of the synchronizer sleeve.
NOTE:
Stub
If the synchronizer hub and synchronizer sleeve are tooth
reused, be sure to align the alignment marks when they Keyway * *
are reassembled together. CYMT025C
SERVICE PROCEDURE TM-27

3. Fit shifting keys into keyways. Then, install the shifting key Shfting key
spring so that the gap between its ends is not located at the spring Shfting key Shfting key spring
shifting key positions.

Shfting key CYMT025D

4. After assembling gears tighten lock nut to specification with


spanner.

Single spanner
CYMT024D

5. Drive the pilot bearing onto main shaft.

Pilot Bearing Installer

CYMT025E

6. Fit the snap ring using a Snap Ring Expander.

Snap ring expander Snap ring


CYMT025F
TM-28 TRANSMISSION

Counter Shaft Assembly


Disassembly

3
4

Disassembly squence
1 Counter shaft constant-mesh gear 3 . Sunk key
2 Counter shaft 4th gear 4 . Counter shaft

For parts with an encircled number, refer to Reassembly Procedure that follows.

CYMT025G

Disassembly Procedure
Using a suitable tool and a press, remove the counter shaft and Suitable tool
then remove gears.

CYMT025H
SERVICE PROCEDURE TM-29

Reassembly

1
2
3
4

Reassembly squence
4→3→ 2 → 1

For parts with an encircled number, refer to Reassembly Procedure that follows.

CYMT025I

Reassembly Procedure
Using Counter Shaft Gear Installer(09434-7A100) and a hydraulic
Counter Shaft Gear Installer
press, press-fit each gear into the counter shaft and ensuring it is (09434-7A100)
aligned with the sunk key.

CYMT025J
TM-30 TRANSMISSION

Reverse Gear
Disassembly and inspection

Diametric play after reassembly 5


L 0.12
6
L ... Limit

4
3
Disassembly sequence
1. Reverse shaft lock piece 5
7
2 Reverse gear shaft
3. O-ring
4. Reverse gear
5. Side washer
6. Needle roller bearing 1
7. Bearing spacer 2

For parts with an encircled number, refer to


Disassembly Procedure that follows.
JMS43-108

Disassembly Procedure
1. Before disassembly, check for diametric play and replace any
defective part.

JMS43-109

2. Using the special tool(09450-75100), Reverse Gear Shaft


Puller, remove the reverse gear shaft.

09450-75100 JMS43-110
SERVICE PROCEDURE TM-31

Reassembly

4.1kgf·m

5
2 3
Reassembly sequence
5 6 4 7

4→7→6→1

2→3

JMS43-111
TM-32 TRANSMISSION

Gear Shifter(Upper)
Disassembly and inspection
Power

2
5

4 7
8
10 9
14 21
15
14 18 Disassembly sequence
19 1. Power shift 11. Spring pin
3 18
2. Air breather 12. Gear shift lever
3. Interlock switch 13. O-ring
20 4. Lock pin 14. Spring retainer
11
6 5. Gear selecting lever B 15. 5th return spring
21
6. Gear selecting lever A 16. Interlock plate
16 7. Shim 18. Spring retainer
8. Plain washer 19. 1st and Rev. return spring
1 20. Plate
13 9. Oil seal
10. Dust plug 21. Select lever case
12

Reassembly is the reverse of disassembly sequence

CYMT026A

Manual

1
2
11
15
12

14

14 Disassembly sequence
13 1. Air breather 9. Selector
5 2. Interlock switch 10. Key
6
4 3. Side cover 11. Control lever
3
4. Set bolt 12. Dust cap
7 5. Shift lever 13. Oil seal
6. Dust boot 14. Bushing
7. Shift rod 15. Select lever case
8. Set bolt
9
8 10 Reassembly is the reverse of disassembly sequence
11

CYMT027A
SERVICE PROCEDURE TM-33

Gear Shifter Lower


Disassembly and Inspection

<M8> BD... Basic diameter


NV... Norminal value
L... Limit
Load/installed length
Deteriation
NV 9.43 ± 10%/345mm 1
5 6 26
2
L 7.6kg/34.5mm 3
29
Free length
NV 40.5mm
4 6
5
3
28
27 Bending of shift lever
0.05mm or less
Deteriation L 0.1mm
18 A A B
19
Bend 20 21 22 23
NV 0.02 or less 25 Deteriation Clearance between shift
L 0.04mm 24 lever and shift shaft
18 7 BD 23mm
7 8 17 NV 0.02~0.09mm
10
Disassembly sequence 16 L 0.15mm
1. Poppet spring
2. Interlock pin
3. Dust plug 11 7
4. Back/up lamp 13
79
5. Jaw set bolt 7 12
6. Lock plate 14 15 7
7. Set bolt Bending of shift rail
8. 1st & Rev.shift rail jaw NV 0.02mm
L 0.04mm
9. 1st & Rev. gear shift jaw
10 1st & Rev. shift rail
11 2nd and 3rd gear shift fork
12. 2nd and 3rd gear shift jaw Side clearance between shift fork
13 2nd and 3rd shift rail and sleeve groove
14 4th and 5th shift rail NV 0.25~0.45mm
15 4th and 5th gear shift fork L 1.0mm
16 1st and Rev. shift rail B
17 1st and Rev. gear shift fork Shift fork
Shift fork synchronizer sleeve
18. Screw plug
Prependicularity
19. Spring A NV 0.25~0.45mm
20. Spring guide Synchronizer sleeve L 1.0mm
21. Interlock plate bushing B
22. Interlock plate Prependicularity
23. Interlock plate bushing A
24. Spring B
25. Steel ball For parts with an encircled number, refer to inspection
26. Flange nut proceaure that follows.
27. 1st and Rev. shift lever shaft
28. 1st and Rev. shift lever
29. Gear shift lever lower case
CYMT028A
TM-34 TRANSMISSION

<M10>

31
2 1
3
4 5
7

1
1. Bolt
7 2. Poppet spring
3. Inter lock pin
21 4. Back up lamp switch
5 5. Jaw set bolt
35 6. Bolt
23 6
7. Dust plug
8. Set bolt
22 34
29 9. 1st and Rev. shift rail
24 30 32
25 10. 1st and Rev. gear shift jaw
26 33 11. 1st and Rev. shift rail jaw
27 12. Steel ball
11
13. 2nd and 3rd shift rail
8
28 21 14. 2nd and 3rd gear shift jaw
8
9 24 20 15. 2nd and 3rd gear shift fork
16. Steel ball
17. 4th and 5th gear shift fork
12 18. 4th and 5th gear shift fork
15 19. 1st and Rev. shift rail B
8
20. 1st and Rev. gear shift fork
13
10 16 19 21. Screw plug
8
22. Spring A
14 23. Spring guide
8 8
24. O-ring
17 18 25. Inter lock plate
26. Stopper
T/M body
27. Inter lock plate
Dowel pin 28. Inter lock bush A
29. Spring B
30. Steel ball
31. Nut
32. O-ring
33. 1st and Rev. shift lever shaft
34. 1st and Rev. shift lever
35. Strut washer
36. Gear shift lower case

CYMT029F
SERVICE PROCEDURE TM-35

Inspection
1. Check the shift rail for bend (a half of the dial gauge pointer
deflection is the bend). If the bend exceeds the limit, correct or
replace the parts.

CYMT029B

2. Measure the shift rail O.D. and the shift rail hole I.D. in the
Shift rail
gearshifter lower case to obtain the clearance. If it exceeds
the limit, replace the parts.
Gear shift lower case

CYMT029D

3. Measure the clearance between the shift fork and synchro-


Synchronizer
nizer sleeve and, if it exceeds the limit, replace the parts. sleeve
At the same time, check the shift fork pawl for perpendicularity.
If faulty, correct or replace.
Shift fork

CYMT029C
TM-36 TRANSMISSION

Reassembly

<M8>

15 13 10
B
C A
24

4 4

C
A
16 20 B 22 19 18

135Nm
(13.6 kgf·m) 8
11 12 1 49 Nm(5 kgf·m)
Apply sealant
5 135 Nm (THREEBOND 1104J
(13.6 kgf·m) or equivalent)
17 23
14
2
9 49 to 67 Nm 6
3
(5.0 to 6.8 kgf·m) Thrust washer

21 7

8 135 Nm Section B-B Section C-C


(5.0 to 6.8 kgf·m)
Section A-A

Reassembly sequence
20 21 22 16 17 10 11 12
24 23 23 23 9 8 7 6 5 4 3 2 1

For parts with an encircled number, refer to Reassembly procedure that follows.

NOTE:
During reassembly, make sure of the correct installation direction of each shift fork.

CYMT029E
SERVICE PROCEDURE TM-37

<M10>

Back Lash Back Lash


NV L NV L
0.08~0.27mm 0.5mm 0.08~0.27mm 0.5mm
Back Lash
NV 0.08~0.27mm
L 0.5mm Back Lash
NV 0.08~0.27mm
L 0.5mm

End Play End Play


NV 0.25~0.40mm NV L
L 0.5mm
0.05~0.35mm 0.5mm

End Play NV ... Nominal Value


Back Lash Back Lash
NV 0.25~0.40mm
NV 0.15~0.35mm NV 0.09~0.28mm L ... Limit
L 0.5mm
L 0.5mm L 0.5mm

CYMT021A

Reassembly Procedure Hexagon Bit


Install shift rail set bolt and stake the threaded portion at least at
three points with a punch.

Set bolt CYMT029G


TM-38 TRANSMISSION

Rear Cover
Disassembly and Inspection

1
Clearance
3
BD 8mm
NV 0.35mm or less
L 0.4mm
Clearance 5
BD 12
NV 0.02 to 0.07 6
4
L 0.15 9

10 8 Aging, damage

11
7

Backlash
NV 0.13 to 0.29mm BD...Basic Diameter
L 0.36mm NV...Nominal Value
L ...Limit

Disassambly sequence
1 Lock nut 7. Rear cover
2 Propeller shaft flange 8. Oil seal
3 . Dust cover 9. Speedometer gear bushing A
4 . Speedometer gear bushing 10. Oil separator Plate
5 . Oil seal 11. Speedometer Worm
6 Speedometer gear

For parts with an encircled number, refer to Disassembly and Inspection Procedure that follows.

NOTE:
Do not remove the oil seal and speedometer gear bushing A unless for replacement.

CYMT029I
SERVICE PROCEDURE TM-39

Disassembly Procedure
1. To remove the castle nut, with socket wrench.

Socket wrench

CYMT019B

2. Remove the companion flange, with flange puller.


3. Remove the rear cover and extension housing.

Flange puller

CYMT019C

Inspection Procedure
Speedometer
Measure the speedometer gear shaft O.D. and speedometer gear
gear
bushing I.D. to calculate the clearance between the two. Replace
parts if the clearance exceeds the limit.
Speedometer
gear bushing

CYMT029J
TM-40 TRANSMISSION

Reassembly

195Nm
74Nm (20 kgf·m)
(7.5 kgf·m) 2
Apply sealant 5
(THREEBOND 1215 4 6
or equivalent)

10 1 590 to 1080 Nm
(60 to 110 kgf·m)
Apply grease
9
7 (Molykote BR2
plus or
11 equivalent)
to shaft
14 3
14

13
12

8 Assembly squence
14 9 10 11 7 4 3 2 1
8 13 12 5 6

54 to 83 Nm For parts with an encircled number, refer to Reassembly


(5.5 to 8.5 kgf·m) Procedure that follows.

NOTE:
When inserting bushing into the speedometer gear,
use care not to damage the oil seal.

CYMT029K

Reassembly Procedure Rear cover


1. To install speedometer gear bushing A into the rear cover, use
a 14-mm-dia. round bar which has been machined to dimen- Bar Speedometer gear
bushing A
sions shown.

8mm
8mm CYMT029L

2. Using Oil Seal Installer(09431-7A000), drive oil seal evenly


into the rear cover.
NOTE:
Make sure that the oil seal is installed in the correct
direction.

Oil seal Installer


(09431-7A000) CYMT029M
SERVICE PROCEDURE TM-41

3. To install oil seal into the speedometer gear bushing, use a


15-mm-dia. round bar. Round bar
NOTE:
Before installing the oil seal, pack the area indicated with
Packing
grease. Make sure of correct installation direction. Top
Also apply grease to inner circumference of the packing. Speedometer Bottom Pack grease
gear bushing
[wheel bearing grease
(NLGI No.2) Li soap]
CYMT029N

4. Using a socket wrench, tighten the lock nut to the specified


torque.

Socket wrench

CYMT019B
TM-42 TRANSMISSION

Transmission Control
Disassembly and Inspection

8
<Gear Shift assembly part> 6 7
Basic vaule
Limit
Basic diameter
3 2
(22)0.005~0.014mm 0.6mm 1
3
5 4
1
<Control Bar connection>
1

3
<Roller assembly control bar>

1 2

<Universal joint spider part>

1
1 2
2
2
2
1

<Gear Shift assembly part> <Universal joint spider part> <Roller assembly control bar>
1. Boot E 1. Snap ring 1. Boot
2. Snap ring 2. Bearing 2. Roller assembly
3. Bush 3. Spider
4. Gear shift cover
5. Sift and select lever <Control Bar connection>
6. Outer ring 1. Tapper pin
7. Boot D 2. Bar clamp band
8. Gear shift lever 3. Control bar
9. Gear shift case
CYMT034A
SERVICE PROCEDURE TM-43

Disassembly Procedure Snap ring refresher


1. Before removal of the control lever, make an alignment mark
on each coupling portion.

JMS43-137

2. To remove the needle bearing, remove the snap ring, then


while lightly striking the yoke shoulder with a copper hammer,
slowly withdraw the needle bearing.

JMS43-138

Reassembly
1. Gearshift lever assembly

6~8Nm
(0.6~0.8kgf·m)

(After assembly of gear shift lever) 7


10Nm 9
6 26Nm (1.0kgf·m)
(2.7kgf·m) Supply grease every two years
4 1
5

2 3 3
Water drain clearance

Reassembly sequence
9→3→5→6→8→7→1

4→3

JMS43-139
TM-44 TRANSMISSION

1) Install the bushing in the bottom boss of the case and set
the snap ring to prevent it from slipping out of position. Since
this bushing is dry type, do not apply grease.
2) When the case cover is mounted to the case, face the weld
bead side of boss outward and make a water drain clear-
ance at the bottom of the case.
3) Operate the gearshift lever to each position to confirm that
all sections operate smoothly.

2. Control rod assembly

2.1~3.5kgf·m

Select rod

Ball Joint

295 ± 1mm

CYMT035A

1) The right and left ball joints should be threaded on to the


select rod the same number of turns.
2) The difference in relative angle between the ball joints should
be limited to 2° or less.
SERVICE PROCEDURE TM-45

3. Control bar roller assembly

Apply chassis grease to the


inside of the rollerr shaft.
3 4.3kgf·m

1
2 6

30˚
4

30˚

ø38.5±0.20 5
1. Boot 5. Roller
2. Roller plate 6. Roller shaft
3. Roller cover 7. Spring washer
4. Roller bracket 8. Nipple
ECYTM01A

4. Coupling of control bars

To be equal indistance

Mount clamp band over control bars, Split end to be opened


drill 6mm hole in each bar to match the
pin hole of the band, and install tapper 12mm more
pins in the hole.
JMS43-140
TM-46 TRANSMISSION

TROUBLESHOOTING
Symptom Probable cause Remedy
Transmission Defective control Play in ball joint Replace ball joint
slips out of mechanism Worn busing Replace
gear (insufficient shift Bent rod Correct bend or replace
stroke on Worn steel ball or groove in shift rail Replace worn part
transmission side) Insufficient shift rail poppet spring tension Replace
or broken spring
Defective transmission Main shaft rear lock nut left loose Retighten to specification
(disassemble and check Worn main shaft thrust washer Replace
transmission assembly) Worn or damaged main shaft bearing Replace
Worn splines in synchronizer ring and Replace worn part
synchronizer sleeve
Hard shifting Defective control Play in ball joint Replace ball joint
into gear mechanism Ball joint insufficiently lubricated Lubricate
(correct shift stroke on Improper rod length Adjust
transmission side) Worn bushing Replace
Shift rail not sliding smoothly Replace shift rail or
gearshift lower case
Worn shift fork jaws Replace
Bent shift fork Correct bend or replace
Defective transmission Main shaft rear lock left loose Retighten to specification
(disassemble and check Worn main shaft thrust washer Replace
transmission assembly) Worn or damaged main shaft beariang Replace
Worn taper cone in synchronizer ring and Replace worn part
gears
Defective clutch Adjust
Clutch not releasing properly
Improper clutch pedal free play
Hard shifting Defective power shift Defective air compressor Check
into gear Air leak Replace O-ring
and oil seal
Spring losing tension Replace
Inadequate length of each rod Adjust
Worn bushing Replace
TROUBLESHOOTING TM-47

Symptom Probable cause Remedy


Unusual noise Worn or damaged main shaft pilot bearing Replace or lubricate
in neutral Worn or damaged drive pinion bearing Replace
Excessive backlash between drive pinion and Replace
counter shaft constant-mesh gear
Worn or damaged counter shaft bearing Replace
Worn or damage needle bearing in gears Replace
Excessive backlash between counter shaft 4th gear Adjust with adjusting
gasket in PTO case
or replace gear
Unusual noise Worn or damaged main shaft and counter shaft bearings Replace
in gear Worn or damaged main shaft pilot bearing Replace
Worn or damaged needle bearing in gears Replace
Excessive backlash between gears in main Replace gears
shaft and counter shaft
Worn or damaged synchronizer sleeve Replace
Insufficient gear oil Add
Damaged gear Replace
Unusual noise Defective Worn taper cone in synchronizer ring and gears Replace worn part
in shifting synchronizer Worn shifting key Replace
Damaged shifting key splines Replace
Worn splines in gears Replace gears
Worn synchronizer sleeve Replace
Clutch not releasing properly Adjust

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