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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
<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
4
2
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
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
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
CYMT012A
The friction torque of the taper surface becomes greater, which Synchronizer sleeve
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
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
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
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
0.3
ø7
D317A00A
D327A00A
D317A10A
D347A00A
D347A10A
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
Propeller shaft
JMS43-055
Speedo
meter
Harness
JMS43-056
SERVICE PROCEDURE TM-13
5. Remove the drain plugs and inspection plug to discharge trans- Clutch booster
mission oil.
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
Bolt
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.
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
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
Companion
flange
PTO cover
CYMT019A
Socket Wrench
CYMT019B
Flange Puller
CYMT019C
TM-16 TRANSMISSION
Reassembly
4.1kgf·m
4.1kgf·m
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
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
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
09431-83100
CYMT022C
09434-7A000
CYMT022D
09431-83100
CYMT022F
CYMT022E
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
Bearing installer
CYMT023B
Synchronizer sleeve
Drive pinion Synchronizer ring
CYMT023C
Counter shaft
Bearing installer
Dummy
bearing
CYMT023D
TM-22 TRANSMISSION
Main Shaft
Disassembly and Inspection
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
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
Bearing puller
CYMT024C
Single spanner
CYMT024D
TM-24 TRANSMISSION
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
Synchronizer hub
CYMT024G
CYMT024H
SERVICE PROCEDURE TM-25
CYMT024J
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
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.
Single spanner
CYMT024D
CYMT025E
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
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
Disassembly Procedure
1. Before disassembly, check for diametric play and replace any
defective part.
JMS43-109
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
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
<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
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
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>
CYMT021A
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
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
NOTE:
When inserting bushing into the speedometer gear,
use care not to damage the oil seal.
CYMT029K
8mm
8mm CYMT029L
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
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
JMS43-137
JMS43-138
Reassembly
1. Gearshift lever assembly
6~8Nm
(0.6~0.8kgf·m)
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.
2.1~3.5kgf·m
Select rod
Ball Joint
295 ± 1mm
CYMT035A
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
To be equal indistance
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