transmision manual hiunday

MANUALTRANSMISSIONReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

MANUAL TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . 9

MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

MANUAL TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . 15

INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

INTERMEDIATE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SPEEDOMETER SLEEVE ASSEMBLY . . . . . . . . . . . . . . . . . 45

GENERAL

GENERALSPECIFICATIONS

Manual transmission

TypeGear ratio 1st

2nd3rd4thReverse

Final reduction ratio

4-speed, Floor-shift control4.2662.3651.4671.1054.1093.470

TypeGear ratio 1st

2nd3rd4th5thReverse

Final gear ratio

5-speed, Floor-shift control4.2662.3651.4671.1050.9554.1093.470

Speedometer gear ratioQuantity of oil lit. (U.S.qts., Imp.qts.)Backlash between differential side gearand pinion

Drive 19/Driven 162.1 (2.2, 1.8)0.025-0.150 mm (0.001-0.006 in.) . . . . . Adjust with spacer

Differential case end play 0-0.15 mm (0-0.006 in.) . . . . . . . . . . . . Adjust with spacerIntermediate shaft end play 0-0.05 mm (0-0.002 in.) . . . . . . . . . . . . Adjust with spacerOutput shaft pre-load 0.15-0.20 mm (0.006-0.0078 in.) . . . . Adjust with spacerClearance between 5th shift lug and 3-4 0-0.4 mmspeed shift lug (5-speed only) (0-0.016 in.) . . . . . . . . . . . . . . Adjust with selector spacer

SERVICE STANDARD

Manual transmissionStandard valueFree play of range selector lever end Approx. 5 mm (0.2 in.)

Spacer for differential pinion backlash adjustmentThickness 0.75-0.82 mm (0.0295-0.0323 in.)

0.83-0.92 mm (0.0327-0.0362 in.)0.93-1.00 mm (0.0366-0.0394 in.)1.01-1.08 mm (0.0398-0.0425 in.)1.09-1.16 mm (0.0429-0.0457 in.)1.17-1.25 mm (0.0460-0.0492 in.)1.26-1.34 mm (0.0496-0.0527 in.)

Spacer for differential case end play adjustmentThickness-ldent. mark 1.31 mm (0.0516 in.)-E

1.40 mm (0.0551 in.)-None1.49 mm (0.0587 in.)-C

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GENERAL

Snap ring for input shaftThickness-ldent. color

1.58 mm (0.0622 in.)-B1.67 mm (0.0657 in.)-A1.76 mm (0.0693 in.)-F1.85 mm (0.0728 in.)-G1.94 mm (0.0764 in.)-H2.03 mm (0.0799 in.)-12.12 mm (0.0835 in.)-J2.21 mm (0.0870 in.)-K

2.24 mm (0.0882 in.)-None2.31 mm (0.0909 in.)-Bule2.38 mm (0.0937 in.)-Brown

Spacer for intermediate and outputshaft endplay or preload adjustment

Thickness

Selector spacer for shift lug clearance (5-speed only)Thickness-ldent. mark

1.84 mm (0.0724 in.)1.87 mm (0.0736 in.)1.90 mm (0.0748 in.)1.93 mm (0.0760 in.)1.96 mm (0.0772 in.)1.99 mm (0.0783 in.)2.02 mm (0.0795 in.)2.05 mm (0.0807 in.)2.08 mm (0.0819 in.)2.11 mm (0.0831 in.)2.14 mm (0.0843 in.)2.17 mm (0.0854 in.)2.20 mm (0.0866 in.)2.23 mm (0.0878 in.)2.26 mm (0.0890 in.)2.29 mm (0.0902 in.)2.32 mm (0.0913 in.)2.35 mm (0.0925 in.)2.38 mm (0.0937 in.)2.41 mm (0.0949 in.)2.44 mm (0.0961 in.)2.47 mm (0.0972 in.)2.50 mm (0.0984 in.)2.53 mm (0.0996 in.)2.56 mm (0.1008 in.)2.59 mm (0.1020 in.)2.62 mm (0.1031 in.)2.65 mm (0.1043 in.)2.68 mm (0.1055 in.)

0.6 mm (0.024 in.)-G0.9 mm (0.035 in.)-F1.2 mm (0.047 in.)-E1.5 mm (0.059 in.)-D1.8 mm (0.071 in.)-C2.1 mm (0.083 in.)-B2.4 mm (0.094 in.)-A2.7 mm (0.106 in.)-None

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GENERAL

TIGHTENING TORQUEN m kg.cm Ib.ft

Manual transmissionExtension to transmissionShift rod set screwInsulator to extension rodBracket assembly attaching boltControl cable attaching boltControl cable clamp attaching boltTransmission mounting boltStarter motor mounting boltBell housing cover to transmission (8 x 20)*Bell housing cover to transmission (8 x 14)*Engine transmissionClutch cover boltTransmission mounting bolt (M10-7T)Transmission mounting bolt (M8-10T)Front cover boltOil filler plugOil drain plugHousing-to-case tightening boltFront retainer boltInput shaft locking nutTransmission mounting bracket boltDifferential drive gear boltSpeedometer sleeve plate boltReverse shift lever support bracket boltPoppet plug boltBackup lamp switch

60-70 610-710 43-5133 337 24

12-15 120-150 9-119-14 90-140 6.5-109-14 90-140 6.5-109-14 440-560 31-40

43-55 440-560 31-4022-32 220-330 16-2315-22 150-220 11-1610-12 100-120 7-9

Refer to the table of components15-21 150-210 11-1543-53 440-540 32-3930-34 300-350 22-2510-11 100-110 7-830-34 300-350 22-2530-34 300-350 22-2530-41 300-420 22-3015-21 150-210 11-15

89-107 900-1,100 65-7930-41 300-420 22-30

128-137 1,300-1,400 94-1013.0-4.5 30-45 2.5-3.515-21 150-210 11-1527-33 270-340 20-24

30 310 22

NOTE*Bolt O.D. x Length mm

LUBRICANTS

Recommended lubricant Quantity

Manual transmissionManual transmission oil

lit. (U.S.qts., Imp.qts.)Shift lever, bushing contacting surfaceDust cover inside surfaceShift lever sliding portion

API classification GL-4

Wheel bearing grease SAEJ310a, NLGI grade #2 EP

2.1 (2.2, 1.8)As requiredAs requiredAs required

43-4

GENERAL

SPECIAL TOOLS

43-5

GENERAL

Tool(Number and name)

Illustration Use

09432-21300Removing plate

1) Removal of the input shaft front bearing2) Removal of the output shaft 2nd, 3rd and

4th gear

09432-21400Taper bearing puller

1) Removal of the intermediate shafttaper bearing inner race

2) Removal of the output shaft taper bear-ing inner race

3) Removal of the transfer shaft taper bear-ing inner race

09432-21500Bearing installer

1) Installation of the input shaft frontbearing

2) Installation of the output shaft synch-ronizer hub and gear sleeve

09432-21600Bearing installer

1) Installation of the input shaftrear bearing

2) Installation of the intermediate shaftfront and rear bearing

3) Installation of the output shaft front andrear bearing

4) Installation of the taper roller bearinginner race of transfer shaft (use with09500-21000)

09432-21700Bearing outer race installer

1) Installation of intermediate shaft bear-ing outer race (use with 09500-21000)

2) Installation of output shaft bearing outerrace (use with 09500-21000)

09433-21000Removing plate

3) Installation of transfer shaft front bear-ing outer race (use with 09500-21000)

1) Removal of differential ball bearing (usewith 09532-11301)

2) Removal of differential bearing

09437-31000Shift lever remover

Removal and installation of the shift leverknob

43-6

GENERAL

Tool(Number and name)

Illustration Use

09438-21000Poppet ball guide

Installation of the poppet ball

43-7

GENERAL

TROUBLESHOOTING

Symptom

Transmission vibration

Oil leakage

Loose transmission assembly

Does not shift to 5th (M/T)

Probable cause

Broken gear shift control

Worn or pitting due to improper tooth

Housing misaligned

Worn seals or gaskets

Broken transmission mount

Mounting bolts loose

Malfunctioning actuator

Malfunctioning vacuum control

Short circuit in vacuum control

Remedy

Replace

Replace

Realign

Replace parts as required

Replace

Retighten bolts

Repair or replace as required

Replace

Replace

43-8

MANUAL TRANSMISSION CONTROL

MANUAL TRANSMISSION CONTROLCOMPONENTS

From March, 1987

GEARSHIFT LEVER

Removal

1. Remove the floor console box.2. On vehicles with rear heater duct, remove the rear heater duct.3. Remove the shift lever assembly attaching nuts from the floor.4. Pull the shift lever assembly downward from the vehicle.

5. Remove the extension rod from the transmission.


6. After removing the lock wire, remove the shift rod set screw,and then remove the shift rod from the transmission.

7. Remove the shift rod and extension rod as an assembly.

8. Remove the dust cover at the end of the shift lever.9. After the split pin has been removed, remove the shift rod.

10. Remove the extension rod to insulator attaching bolt andremove the extension rod.

11. Remove the dust cover and remove the bushing.

Inspection

1. Check the shift rod joint for wear, sticking or rough movement.2. Check the rubber parts for damage or deterioration.3. Check all bushings for wear and damage.4. Check the return spring for deterioration.

43-10


Installation

1. Apply the specified wheel bearing grease to the following areas:(a) Dust cover inside surface(b) Shift lever and bushing contacting surface(c) Shift lever sliding portion

Recommended wheel bearing grease . . . . . . . . . . . . . . . . . . . .Wheel bearing grease SAE J310a,

NLGI grade #2 EP.

2. Install a new lock wire to the set screw of the shift rod to preventlooseness.

43-11

MANUAL TRANSMISSION

MANUAL TRANSMISSIONCOMPONENTS

Nm kg.cm Ib.ft O.D. x Length mm (in.) Bolt identification

A 43-55 430-560 31-40B 43-55 430-560 31-40C 22-32 220-330 16-23D 30-34 300-350 22-25

E 10-12 100-120 7-9F 15-22 150-220 11-16

REMOVAL,

1. Remove the battery.2. On vehicles with a 5-speed transmission, disconnect the con-

nector of the select control valve.

NOTE:Do not reuse the collar removed when the pin for couplingthe actuator to the shaft is removed, but use a new part.

3. Remove the speedometer cable.4. Remove the clutch control cable.5. Disconnect the connector of the backup lamp.

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MANUAL TRANSMISSION

6. Remove the harness from the starter motor.7. Remove the transmission to engine coupling bolts from the top

side of the transmission.

8. Remove the starter motor.

9. Lift up the vehicle and remove the under cover.10. Drain the transmission oil.

11. Remove the extension rod and shift rod from under the enginecompartment.

12. After the stabilizer bar has been removed from the lower arm,remove the lower arm at the body side, remove the right andleft drive shafts, and hold them in appropriate positions. (ReferFRONT SUSPENSION).

MANUAL TRANSMISSION

13. Support the lower part of the transmission by using a trans-mission jack.

CAUTIONSupport a wide area of the transmission so that the oil pan isnot partially pressed when supported.

14. Remove the bell housing cover.15. Remove the bolts connecting the transmission with the engine

from under the engine compartment.

16. Remove the transmission mount insulator bolt.17. Remove the blind cover from inside the right fender shield and

remove the transmission bracket assembly.18. Remove the transmission mount bracket.19. Slide the transmission assembly rightward from the vehicle

and then take it out downward.

INSTALLATION

1. Install the transmission by reversing the procedures, andtorque all part to specifications during installation.

2. Refill with transmission oil to the specified level.

Recommended oil . . . . . . . . . . . . . . . . . API classification GL-4Quantity . . . . . . . . . . . . . . . 2.1 lit. (2.2 U.S.qts., 1.8 Imp.qts.)

3. Adjust the play of the clutch control cable.4. Operate the shift lever to confirm that the gears of the trans-

mission are positively changed over.

43-14

MANUAL TRANSMISSION ASSEMBLY

MANUAL TRANSMISSION ASSEMBLYSECTIONAL VIEW

4-speed Manual Transmission

43-15



43-16


OPERATION OF 5-SPEED TRANSMISSION

1. When the control lever is shifted to the 5th position,the control finger engages with the 5th speed shiftlug, shifting the 3-4th speed shift rail to the 4thspeed side with the 5th shift lug, and the 4th speedgear is engaged.

2. When the select lever moves to the 5th speed position,the select switch is turned ON simultaneously.

3. When signals from the select switch enter the con-trol relay, the relay excites the solenoid of the selectcontrol valve and turns it ON.

4. When the select control valve is ON, the valve closesthe atmosphere side of V1 nipple and opens the pas-sage of M - V1, actuating the manifold negativepressure on the H chamber of the select actuator.Meanwhile, the V2 nipple side is opened to theatmosphere, allowing the atmospheric pressure toenter the L chamber.

5. The pressure difference between H chamber and L

chamber actuates the diaphragm of the select actua-tor, pulling the select rail to the E range and engagingthe input high gear. The 5th speed is obtained in thisway.

6. When the control lever is returned from 5th speed,the select switch is turned OFF, and the solenoid ofthe select control valve is also turned OFF by a relay.Then, the atmospheric pressure is introduced to Hchamber through V1 nipple, causing the negativepressure to be actuated on L chamber through V2

nipple. As a result, the select rail is pulled to the Prange and the input low gear is engaged.

NOTE:A slight clicking sound may be heard when shiftingto 5th or reverse gears. This sound does not indi-cate any abnormality as it is produced by electriccontrol of the shifting mechanism in the tran-smission.

43-17


INSTALLATION OF VACUUM HOSE FOR 5-SPEED MANUAL TRANSMISSION

IDENTIFICATION

Nipple

A

B

C

D

E

F

Nipple Vacuum hoseRemarks

Ident. Mark Color Ident. Mark Color

l ll l White n nn n White

- - nnnnnn White

ll White nn White

ll Green nn Green

l ll l Green nnnn Green

ll Yellow nn Yellow

43-18


COMPONENTS


1. Backup light switch2. Gasket3. Steel ball4. Bolt5. Locking plate6. Speedometer gear assembly7. Bolt (13)8. Transmission case9. Bearing outer race (2)

10. Spacer (2)-select11. Air breather12. Transmission case gasket13. Poppet plug (3)14. Gasket (3)15. Poppet spring (3)16. Poppet ball (3)17. Reverse idler gear shaft18. Reverse idler gear19. Bolt (2) Nm kg.cm Ib.ft20. Reverse shift lever assembly21. Reverse shift rail A 15-21 150-210 11-1522. Spring pin (2)23. 1-2 shift rail

B 35-41 360-420 26-30

24. 1-2 shift fork C 3-5 30-50 2.2-3.625. 3-4 shift rail D 27-33 270-340 20-2426. 3-4 shift fork E27. Interlock plunger (2)

30 300 22

28. Output shaft assembly29. Spacer-select30. Differential assembly31. Intermediate gear assembly

MOTE

32. Bolt (3) Numbers show order of disassembly.33. Bearing retainer For reassembly, reverse order of disassembly.34. Input shaft assembly35. Bearing outer race36. Clutch housing

43-19


COMPONENTS


1. Select actuator2. Col lar3. O-ring4. S e a t5. P in6. Select rail fork assembly7. Seat8. Input shaft assembly9. Bearing retainer

10. Spacer11. Bearing outer race12. Intermediate gear assembly13. Speedometer driven gear assembly14. Reverse idler gear shaft15. Reverse idler gear16. Reverse shift gear17. Output shaft assembly18. Bearing outer race19. Spacer20. Differential assembly21. Reverse shift rail22. 1-2 shift rail23. 1-2 shift fork24. 3-4 shift fork25. Spring pin26. 3-4 shift rail27. 5-speed shift lub28. Selector spacer29. Poppet ball

30. Poppet spring31. Plug32. Interlock plunger A33. Interlock plunger B34. Transmission bracket35. Clutch cable bracket36. Backup light switch37. Gasket38. Steel ball39. Transmission case40. Air breather41. Select switch42. Clutch housing assembly

Nm kg.cm Ib.ft

15-22 150-220 11-1635-42 360-430 26-31

3-5 30-50 2.2-3.627-34 270-350 20-25

29 290 2255-59 560-600 40-43

NOTENumbers show order of disassembly.For reassembly reverse order of disassembly.

43-20


DISASSEMBLY

1. Remove the transmission mounting bracket.2. Remove the two select actuator mounting bolts (for 5-speed

only).

3. Remove the clamp for harness of select switch (for 5-speedonly) and backup light switch.

4. Remove the backup light switch and the steel ball.5. Remove the select switch (for 5-speed only).

6. Pull the select actuator to remove its rod and shift rail connec-tion from transmission (for 5-speed only).

7. Remove the collar and pin, and then remove the select actuator(for 5-speed only).

NOTE:Do not reuse the collar when reassembly. Use a new part.

8. Remove the speedometer gear assembly locking bolt.9. Pull the speedometer gear assembly from the clutch housing.

10. Remove the transmission to clutch housing tightening bolt.11. Remove the transmission case.12. Remove the gasket.13. Remove the spacer for differential end play adjustment.

43-21


14. Remove the three poppet plugs and gasket, and then threepoppet springs and steel balls.

15. Pull the reverse idler gear shaft and remove reverse idler gear.16. Remove the reverse shift lever from clutch housing.17. Remove reverse shift rail.

18. Use a pin punch to drive the spring pins from the shift forks andshift rails.

19. Remove the selector spacer (for 5-speed only).

43-22


20. Pull the 1-2 shift rail from clutch housing then remove the 3-4shift rail. Next, remove 1-2 shift rail and fork assembly,together with 3-4 shift rail and fork assembly.

21. Remove the two interlock plungers from the clutch housing.22. Remove the 5th speed shift lug (for 5-speed only).23. Remove the output shaft assembly.24. Remove the differential assembly from clutch housing.

25. Remove the poppet plug, the poppet spring and the steel ballfor select shift rail.

26. Remove the input shaft bearing retainer.

27. Remove the input shaft assembly together with the select shiftfork, rail and intermediate shaft.

43-23


REASSEMBLY

1. Turn the sub gear in direction of arrow to align 8 mm (0.31 in.)hole in the intermediate gear with that the sub gear, and theninsert 8 mm (0.31 in.)-diameter, 35 mm (1.38 in.)-long dummypin through the intermediate gear into sub gear hole.

2. Assemble the select shift fork and rail assembly to the synchron-izer sleeve of input shaft, and then install these components andintermediate shaft as a unit.

3. Install the front bearing retainer and tighten the three bolts to15 to 21.5 Nm (150 to 220 kg.cm, 11 to 15.5 Ib.ft).

4. Install the differential assembly to the clutch housing.5. Install the output shaft assembly.6. Make sure that the gears are meshed properly, and then remove

dummy pin from the sub gear and intermediate gear.

43-24


7. Install 5th speed shift fug to pin on the clutch housing.

CAUTIONPay attention to the direction of installation.If the shift lug is installed the wrong way, hard shifting mayresult.

8. Insert the two interlock plungers into the holes in the clutchhousing.

9. Install 1-2 shift rail assembly together with 3-4 shift railassembly or 3-4-5 shift rail assembly. Install one shift rail intoits clutch housing hole, and then install the other. It is impossi-ble to install both shift rails at the same time because ofinterference of interlock plunger.

10. Using Special Tool 09414-11100 or blunt punch, drive inspring pins.This spring pin must be driven in with its slit on shift rail centerline. Make sure both ends of spring pin protrude samedistance.

11. Select the spacer to make the adjustment to the specifiedclearance between the 3-4 shift lug and 5th shift lug. Theninstall the select spacer.

Clearance between 3-4 shift lug and 5th shift lug. . . . . . . . . . . . . . . . . . . . . . . . . . 0.1-0.5 mm (0.004-0.020 in.)


Kind of Select Spacers

Thicknessmm (in.)

Ident. mark

0.6 (0.024) G0.9 (0.035) F1.2 (0.047) E1.5 (0.059) D1.8 (0.071) C2.1 (0.083) B2.4 (0.094) A2.7 (0.106) None

12. Install the reverse shift rail into the clutch housing.13. Install the reverse shift lever, and tighten the two bolts to 17

Nm (173 kg.cm, 13 Ib.ft).14. Install reverse idler gear with chamfered side upward, and

then insert idler gear shaft through the gear into housing.

15. Place the reverse shaft rail in neutral position, and then mea-sure dimension “A” in the illustration. If dimension “A” is lessthan standard value, replace reverse shift lever assembly.

Dimension A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37.05-38.65 mm (1.458-1.521 in.)

16. Clean gasket surfaces of clutch housing and transmissioncase.

17. Adjust the output shaft, intermediate shaft and differentialcase end play or preload as follows:(a) Remove the outer races of output shaft and intermediate

shaft bearings from transmission case.

43-26


(b) Place 2 pieces of solder, about 10 mm (0.4 in.)-long onouter race of transmission case.

(c) Insert outer races to transmission case.Securely install the outer race so as not to move the solder.

(d) Place 2 pieces of solder about 20 mm (0.79 in.)-long on ballbearing outer race.

(e) Place the new transmission case gasket on the clutchhousing.

(f) Install the new gasket and transmission case assembly onthe clutch housing, and tighten 13 bolts 35 to 41 Nm (360to 420 kg.cm, 26 to 30 Ib.ft).

(g) Remove bolts and remove transmission case.(h) Measure thickness of crushed solder with micrometer.

Select a spacer of proper thickness to ensure standard end

play.

Differential case end play . . . . . . . . . 0-0.15 mm (0-0.006 in.)

Kind of Spacers for Differential

Thicknessmm (in.)

Ident. mark

1.31 (0.0516)1.40 (0.0551)1.49 (0.0587)1.58 (0.0622)1.67 (0.0657)1.76 (0.0693)1.85 (0.0728)1.94 (0.0764)2.03 (0.0799)2.12 (0.0835)2.21 (0.0870)

ENone

CBAFGHIJK

(i) Remove both ball bearing outer races from the transmis-sion case.

CAUTIONBefore installing the outer race of bearing to interme-diate and output shaft, make sure that it is installed toproper parts. If the outer race is installed to other parts,the end play and preload cannot be adjusted properly.

43-27


(j) Remove the solder pieces from below the differentialassembly thickness of the crushed solder with a microme-ter. Select a spacer of proper thickness to ensure standardend play or pre-load.

Intermediate gear end play . . . . . 0-0.15 mm (0-0.0020 in.)Output shaft pre-load . . . 0.15-0.20 mm (0.0059-0.0079 in.)

Range of Spacers

Thickness mm (in.) Ident. mark

1.84 (0.0724) 841.87 (0.0736) 871.90 (0.0748) 901.93 (0.0760) 930.96 (0.0772) 961.99 (0.0783) 992.02 (0.0795) 022.05 (0.0807) 052.08 (0.0819) 082.11 (0.0831) 112.14 (0.0843) 142.17 (0.0854) 172.20 (0.0866) 202.23 (0.0878) 232.26 (0.0890) 262.29 (0.0902) 292.32 (0.0913) 322.35 (0.0925) 352.38 (0.0937) 382.41 (0.0949) 412.44 (0.0961) 442.47 (0.0972) 472.50 (0.0984) 502.53 (0.0996) 532.56 (0.1008) 562.59 (0.1020) 592.62 (0.1031) 622.65 (0.1043) 652.68 (0.1055) 68

(k) Install spacers, selected in accordance with step 17, to thetransmission case, and then install ball bearing outerraces to the transmission case.

(I) Place spacer, selected in accordance with step 17, on thedifferential ball bearing.

43-28


18. Clean both gasket surfaces of clutch housing and transmis-sion case.

19. Apply sealant to both sides of transmission case gasket. Applydrying sealant to clutch housing side of gasket and applynon-drying sealant to transmission case side, and then installgasket onto clutch housing.

CAUTIONDo not apply drying sealant to both sides of transmissioncase gasket. Apply sealant uniformly without a break orexcess.

20. Install the transmission case assembly on the clutch housingand tighten 13 bolts to 35 to 41 Nm (360 to 420 kg.cm, 26 to 30Ib.ft).

21. With Special Tool (09431-21100) attached to control shaft,verify that control shifts smoothly.

22. install the speedometer gear assembly into the clutch housingand tighten the flange bolt.

23. Connect the select actuator rod to the select shift rail andinsert the pin. Then install the new collar onto the pin. (5-speed only)

24. Tighten the actuator mounting bolts to the specified torque.(5-speed only)

25. When installing the select switch, assure that the transmis-sion is in Neutral, then align the mating marks as shown in theillustration. Tighten the bolts securely. (5-speed only)

26. Install the steel ball and the back-up light switch.27. Install the transmission mounting bracket and clutch cable

bracket.

43-29

INPUT SHAFT

INPUT SHAFTCOMPONENTS

1. Snap ring2. Front bearing3. Input shaft4. Needle bearing5. Input low gear6. 1) Synchronizer sleeve

2) Synchronizer spring (2)3) Synchronizer key (3)4) Synchronizer hub

7. Synchronizer ring (2)8. Gear sleeve9. Needle bearing

10. Input high gear11. Spacer12. Rear bearing13. Locking nut

Nm kg.cm Ib.ft

A 89-107 900-1100 66-79

D I S A S S E M B L Y

1. Clamp the input shaft in a vise with lock nut side up (protectinput shaft splines from vise jaws).

2. Remove the staking from the locking nut lock with a bluntpunch, then remove the locking nut.

3. Remove the front bearing snap ring with snap ring pliers.4. With Special Tool, Removing Plate (09432-21300) press the

input shaft and remove the front bearing.

43-30

INPUT SHAFT

5. With the input low gear supported on a press base, press theinput shaft down to remove rear bearing, gears and synchron-izer (5 speed only).

INSPECTION

1. Check the splines for wear or damage; replace if necessary.2. Check the gears for wear or damage; replace if necessary.3. Check the bearings for noise or damage; replace if necessary.

REASSEMBLY (5 speed only)

1. Assemble the synchronizer hub and sleeve. Make sure the huband sleeve slide smoothly.

2. Insert the three synchronizer keys into grooves of hub.3. Install the two synchronizer springs, and make sure that they

are installed in opposite directions.

43-31

INPUT SHAFT

4. Insert the needle bearing for input low gear to the input shaft.5. Install the input low gear onto the input shaft.6. Install the synchronizer ring onto the cone portion of input low

gear.7. Install the assembled synchronizer to input shaft, and then use

Special Tool (09432-21600) to press synchronizer assemblyonto input shaft.

8. Using Special Tool (09432-21600), press input high gearsleeve onto the input shaft.

9. Install the needle bearing onto sleeve.10. Install the synchronizer ring.11. Install the assembled input high gear onto the needle bearing.12. Install the oil slinger onto the input shaft.13. Using Special Tool (09432-21600), press rear bearing onto

input shaft rear end.

14. Tighten input shaft rear end locking nut to specified torqueand stake it. Stake locking nut only at notch of shaft illustrated.

CAUTIONShaft rear end deformed by staking will interfere withbreather, resulting in breakage.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89-107 Nm (900-1,100 kg.cm, 66-79 Ib.ft)

09432-21600

Rear bearing

43-32

INPUT SHAFT

15. Using Special Tool 09432-21500, install front bearing ontoinput shaft.

16. Install front bearing snap ring. There are three types of snaprings available which differ in thickness. Select the thickestsnap ring which fits in snap ring groove.

When installing snap ring, be careful not to damage oil sealcontacting surface of input shaft. Do not reuse used snap ring.

43-33

INTERMEDIATE GEAR

INTERMEDIATE GEARCOMPONENTS

Intermediate gear

DISASSEMBLY

1. To remove taper bearing inner race from intermediate gear, useSpecial Tool 09432-21400.

CAUTIONWhen 09432-21400 is used, it is important that tool is heldsecurely with cylinder.Do not reuse this bearing. Replace it with a new part.

REASSEMBLY

1. Do not reuse bearing removed from shaft.2. Press inner race. Do not press cage, as deformation could

result. Use Special Tool (09432-21600).

43-34

OUTPUT SHAFT

OUTPUT SHAFTCOMPONENTS

1. Taper roller bearing2. Output shaft3. 4th speed gear4. Synchronizer ring (2)5. Synchronizer spring (2)6. 3-4 synchronizer hub7. Synchronizer key (3)8. 3-4 synchronizer sleeve9. Gear sleeve

10. 3rd speed gear11. Gear sleeve12. 2nd speed gear13. Synchronizer ring (2)14. Synchronizer spring (2)15. 1-2 synchronizer hub16. Synchronizer key (3)17. 1-2 synchronizer sleeve18. 1st speed gear19. Gear sleeve20. Taper roller bearing

DISASSEMBLY

1. Using Special Tool 09432-21400, remove taper roller bearing

inner race from output shaft.

CAUTIONWhen 09432-21400 is used, it is important that tool is heldsecurely with cylinder. Do not use this bearing. Replace itwith a new part.

2. Holding 2nd speed gear on Special Tool 09432-21300 press

rear end of shaft with press to remove 1st speed gear, gear

sleeve, 1-2 synchronizer assembly and 2nd speed gear.

OUTPUT SHAFT

3. Holding 3rd speed gear in Special Tool, Gear Puller (09432-21300), remove 2nd speed gear sleeve and 3rd speed gear.

4. Holding 3-4speed synchronizer ring in Gear Puller, remove 3rdspeed gear sleeve and 3-4 speed synchronizer.

CAUTION(a) Step (3) must be done at first.(b) Step (4) never be done to remove the 3rd gear and 3-4

speed synchronizer at same time.

REASSEMBLY

1. Assemble the synchronizer hub and sleeve. Make sure the huband sleeve slide smoothly.

2. Insert the three synchronizer keys into grooves of hub.3. Install the two synchronizer springs, and make sure that they

are installed in opposite directions.4. Install the 4th speed gear onto the output shaft.5. Install the synchronizer ring onto the cone portion of 4th speed

gear.

43-36

OUTPUT SHAFT

6. Using Special Tool 09432-21500, press 3-4 synchronizer ontooutput shaft. Make sure that keyways of synchronizer ring arecorrectly aligned with synchronizer keys. After installation ofsynchronizer, make certain that 4th speed gear rotatessmoothly.

7. Using Special Tool 09432-21500, press gear sleeve for 3rdspeed gear onto output shaft.

8. Install the synchronizer ring onto the 3-4 synchronizer.9. Install the 3rd speed gear onto the output shaft.

10. Using Special Tool 09432-21500, press gear sleeve for 2ndspeed gear onto the output shaft.

11. Install the 2nd speed gear onto the output shaft.12. Install the synchronizer ring onto the cone portion of 2nd

speed gear.13. Using Special Tool 09432-21500, press 1-2 synchronizer onto

output shaft. Make sure that keyways of synchronizer ring arecorrectly aligned with synchronizer keys.

14. Install the synchronizer ring and 1st speed gear.15. Insert the 1st speed gear sleeve onto the output shaft.

16. Using Special Tool 09432-21600, press taper roller bearingonto front and rear ends of output shaft. Be sure to set installerso that it will push only on bearing inner race.

43-37

DIFFERENTIAL

DIFFERENTIALCOMPONENTS

DISASSEMBLY

1. Remove the drive gear retaining bolts and remove the drive gearfrom differential case.

2. Remove the ball bearing inner race by using Special Tool09433-21000.

3. Drive out the lock pin with a punch inserted in hole “A”.4. Pull out the pinion shaft, and then remove the pinion gears and

washer.5. Remove the side gears and spacers.

43-38

DIFFERENTIAL

REASSEMBLY

1. With spacers installed to back of differential side gears, installgears in differential case. If reusing removed parts, install themin original positions noted during disassembly. If using newdifferential side gears, install spacers of medium thickness 1.0

2. Install washers to back of pinion gears, and install gears indifferential case, then insert pinion shaft.

3. Measure backlash between differential side gear and pinion. Ifspecified backlash is not obtained, select spacers of proper size,disassemble and reassemble gears and then adjust backlash.Backlash of both right and left gears must be equal.

Backlash . . . . . . . . . . . . . . . . 0.025-0.150 mm (0.001-0.006 in.)

Available spacers

Thickness

0.75-0.82 mm (0.0295-0.0323 in.)0.83-0.92 mm (0.0327-0.0362 in.)0.93-1.00 mm (0.0366-0.0394 in.)1.01-1.08 mm (0.0398-0.0425 in.)1.09-1.16 mm (0.0429-0.0457 in.)1.17-1.25 mm (0.0460-0.0492 in.)1.26-1.34 mm (0.0496-0.0527 in.)

4. Install pinion shaft lock pin in direction specified in illustration.After installation, check to ensure that projection is less than 3mm (0.118 in.).

CAUTIONS(a) Lock pin must not be reused.(b) Lock pin requiring installation load of more than 1,960 N

(440 lb) must not be used.

5. Press ball bearing inner races onto both ends of differentialcase. Apply load to inner race when pressing in bearings.

I

DIFFERENTIAL

6. Install the drive gear onto the case.7. Apply a small amount of ATF, and then a generous amount of

thread lock cement to the ring gear retaining bolts. Thenassemble quickly and tighten bolts to specified torque insequence shown in illustration.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128-137 Nm (1,300-1,400 kg.cm, 94-101 Ib.ft)

NOTEClean the ring gear retaining bolts with thinner or equivalentprior to applying thread lock cement.

Numbers (1) through (8) indicatethe bolt tightening sequence

43-40

CLUTCH HOUSING

CLUTCH HOUSINGCOMPONENTS

1. Input shaft oil seal2. Taper roller bearing outer race3. Spring retainer-4-speed only4. Spring pin5. Shift shaft-4-speed only6. Neutral return spring-4-speed only7. Distance collar8. Control finger-4-speed only9. Poppet ball

10. Poppet spring11. Reverse restrict spring-4-speed only12. O-ring13. Spring retainer14. Snap ring15. Spring pin16. Shift shaft17. Neutral return spring18. Distance collar19. Control finger20. Poppet ball21. Poppet spring22. 5th return spring, outer

23. 5th return spring, inner24. O-r ing25. Snap ring26. Selector lever27. Bolt28. Control shaft oil seal29. Drive shaft oil seal30. O-r ing31. Reverse restrict spring

DISASSEMBLY

1. Remove shift shaft spring pin using a suitable tool.

CAUTIONBe careful not to damage the clutch housing when using thepliers.

CLUTCH HOUSING

2. Utilizing shift shaft hole (hole B in illustration), remove shiftshaft in direction of arrow.

3. Cover bolts with fingers to prevent the poppet ball from jumpingout and being lost when the shift shaft is removed. Then removethe control finger and the poppet ball.

4. Using a pin punch, remove select finger lock pin. Remove selectshaft and select finger.

REASSEMBLY

1. Apply sealant to outside surface of new control shaft oil seal.Install oil seal with Special Tool 09431-21100.

CAUTIONDo not reuse old oil seal.

2. Install new input shaft front oil seal with Special Tool09432-21000.CAUTIONDo not reuse old oil seal.

43-42

CLUTCH HOUSING

3. Insert select shaft into housing and install select finger.4. With select finger and shaft lock pin holes properly aligned,

drive in lock pin. Be careful not to drive in lock pin too deep.

5. Install poppet spring and steel ball in control finger. Insert Spe-cial Tool 09438-21000, to hole it. Poppet spring to be usedshould not have identification color (white) and should have afree length of 18.9 mm (0.74 in.)

6. Insert the shift shaft into the clutch housing and install controlfinger and springs.

7. Install the spring retainer.

CLUTCH HOUSING

8. If oil seal hole has not been chamfered. chamfer hole usingknurls provided on back of Special Tool 09431-21200, beforeinstalling oil seal. If not chamfered, oil seal periphery will beimpaired, resulting in oil leaks.

CAUTIONDo not reuse old oil seal.

9. Replace control shaft or control lug in following manner.(a) Make a diameter hole in 16 mm

diameter boss located at lower part of engine side of clutchhousing. This boss has center hole; make 12 mm (0.47 in.)hole concentric with this center hole.

(b) Remove lock pin.(c) Remove control shaft and lug.(d) Install new control shaft and lug. Then, using Special Tool

09414-11100, drive in new lock pin.(5) Apply sealant to outside surface of 12 mm-diameter Sealing

Cap (15732-12001). Press in sealing cap as shown inillustration.

43-44

SPEEDOMETER SLEEVE ASSEMBLY

SPEEDOMETER SLEEVE ASSEMBLYCOMPONENTS

DISASSEMBLY

Drive spring pin out, and gear and sleeve can be disassembled.

CAUTIONDo not reuse O-rings and spring pin.

REASSEMBLY

1. Install new O-ring in O-ring groove in speedometer driven gearsleeve I.D.

2. After applying small amount of gear oil to speedometer drivengear shaft, insert sleeve.

3. Align pin hole in sleeve with pin slot in gear shaft, and drive inspring pin in such a direction that spring pin slit will not contactgear shaft.

4. Install new O-ring in O-ring groove in sleeve O.D.

43-45

transmision manual hiunday

Technology

speed shift lug

manual transmission

manual transmission

shift rod

shift lug clearance

speed onlythicknessldent

transmission mounting

withspacer clearance