qj NISSAN MODEL B13 AND N14 SERIES SERVICE M N Ao ANUAL— NSSAN ST — 3 Pee | nares rrr sr win —— [ awe Ua am il BRAKE SYSTEM Bae a] “Ty aaa ELECTRICAL SYSTEM —————_———_——FOREWORD ‘This manual (Volume 2) contains repair procedures for the following components of the model B13 and N14 series. 1. Chassis 2. Body © Cluteh Heater & air conditioner unit Transaxle unit 4. Electrical systom Axle & suspension unit Transfer unit Propeller shaft & Differential carrier Brake system ‘Steering system » For maintenance and repair procedures for the engine, refer to Volume 1 (Pub. ‘No, SM1E-1N4BG0). In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially impor- tant that the PRECAUTIONS in the GI section be completely under- stood before starting any repair task, All information in this manual is based on the latest product intorma- tion at the time of publication. The right is reserved to make changes in specifications and methods at any time IMPORTANT SAFETY NOTICE ‘The proper performance of service is essential for both the safety of the ‘technician and the efficient functioning of thé vehicle. ‘The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the techt in and the tools and parts available. Accordingly, anyone using service proce- dures, tools or parts which are not specifically recommended by NISSAN must first completely satisfy himself that neither his safety nor the vehicle's safety will be jeopardized by the service method selected. e@> NISSAN MOTOR CO, LTD. Overseas Service Department Tokyo, JapanGENERAL INFORMATION | | sara Call CONTENTS PRECAUTIONS. HOW TO USE THIS MANUAL HOW TO READ WIRING DIAGRAMS: HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES CONSULT CHECKING SYSTEM IDENTIFICATION INFORMATION LIFTING POINTS AND TOW TRUCK TOWING ... ON-THE-CAR WHECL BALANCING TIGHTENING TORQUE OF STANDARD BOLTS:Do not operate the engine for an extended period of time without proper exhaust ventilation Keep the work area well ventilated and free of any inflam- mable materials. Special care should be taken when han- dling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle. Before jacking up the vehicle, apply whee! chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with satety stands at the points designated tor proper lifting and towing before working on the vehicle. These operations should be done on a level surface. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also. do not allow them to strike adjacent parts, especially the brake tubes and master cylinder. Before starting repairs which do not require ballery power, always turn off the ignition switch, then disconnect the ground cable from the battery to prevent accidental short ircuit To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe and muf- fer. Do not remove the radiator cap when the engine is hot. GI-2PRECAUTIONS — Fender cover soz | 3h | bess ‘size Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers Take caution that keys, Duckles or buttons on your person do not scratch the paint 7. Clean all disassembled parts in the designated liquid or eolvent prior to inspection or assembly. 8. Replace cil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, atc. with new ones 8. Replace inner and outer races of tapered roller bearings and needle bearings as a set. 10. Arrange the disassembled parts in accordance with their assembled locations and sequence. 11, Vo not touch the terminals of electrical components which use microcomputers (such as electronic control units) Siatic electricity may damage internal electronic compo- nents 12, Alter disconnecting vacuum or air hoses, altach a tag to indicata the proper connection 13. Use only the lubricants specified in MA section. 14. Use approved bonding agent, sealants or their equivalents when required. 15. Use tools and recommended special tools where specified for sate and etficient service repairs. 16. When repairing the fuel, oll, water, vacuum or exhaust systems, check all affected lines for leaks. 17. Dispose of draincd oil or the solvent used for cleaning parts in an appropriate manner. Precautions for E.F.I. or E.C.C.S. Engine 1. Before connecting or disconnecting E.F.I. or E.C.C.S. har- ness connector to or from any E.F.l. or E.C.C.S. control unit, be sure to turn the ignition switch to the OFF” position and disconnect the negative battery terminal Otherwise, there may be damage to control untt 2. Before disconnecting pressurized fuel line from fuel pump to injectors, be eure to release fucl pressure to eliminate danger. 3. Be careful not to jar components such as contral unit and air flow meter. GI-3| | ee 4 PRECAUTIONS: Precautions for Catalyst Ita large amount of unburned fuel flows into the converter, the converter temperature will be excessively high. To prevent this, follow the procedure below: 1. Use unleaded gasoline only. Leaded gasoline will seriously damage the catalytic converter 2. When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. 3. Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the converter. 4. Do not place the vehicle on intlammable material. Keep Inflammable material off the exhaust plpe. Precautions for Turbocharger The turbocharger turbine revolves at extremely high speeds and becomes very hot. Therefore, it is essential to maintain a clean supply of oil flowing tough the turbocharger and to follow all required maintenance instructions and operating procedures. For proper operation of the system, fallow the procedure below 1. Always use the recommended oil. Follow the instructions for proper time to change the oil and proper oil level. 2, Avoid accelerating engine to a high rpm immediately after starting. 3, If engine had been operating at high rpm tor an extended period of time, let it idle for a few minutes prior to shutting it off. Asbestos Safety Instructions (Based on United Kingdom and Republic of Ireland regulations) This vehicle uses parts containing asbestos. Most are not hazardous but Brake and Clutch linings can be. Consult the manufacturer or nis agent for further detalls. When working with these please observe the "Garage Workers’ Asbesios Code’ available through your Nissan Dealer, Local Authority or Health and Safety Executive. In particular, work in a well-ventilated place using, where possible, appropriate dust extraction equip- ment, and avoid creating dust. Dampen all asbestos/dust where possible prior to machining, cutting, cleaning, etc. Use only hand or low speed tools. Dispose of all asbestos waste, wet rags, etc., in a closed container as directed by your local waste disposal authority.PRECAUTIONS Engine Oils Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided. HEALTH PROTECTION PRECAUTIONS 4. Avoid prolonged and repeated contact with oils, particularly used engine oils, 2, Wear protective clothing, including impervious gloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes, particularly underpants, with oil 5. Heavily soiled clothing and oilimpregnated footwear should not be worn, Overalls must be cleaned regularly. 6. First Aid treatment chould be obtained immediately for open cuts and wounds. 7. Use barrier creams, applying them before each work pe- riod, to help the removal of ail from the skin. 8, Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations contain- ing lanolin replace the natural skin oils which have been removed. 9. Do nol use petrol, kerosine, diesel (uel, gas oil, thinners or solvents for cleaning skin. 10. If skin disorders develop, obtain medical advice without delay 11. Where practicable. degrease components prior to handling 12, Where there is a risk of eve contact, eve protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. (For the United Kingdom, see also HSE Cautionary Notice SHW 397 “Effects of Mineral Oil on the Skin’) ENVIRONMENTAL PROTECTION PRECAUTIONS Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design, The heating system must meet the requirements of HIM Inspectorate of Pollution for small burners of less than 0.4 MW. If in doubt check with the appropriate local authority and/or manufacturer of the approved appliance. Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority tor advice on disposal facilities. It is illegal to pour used oll on to the ground, down sewers or drains, or into water courses. ‘The regulations concerning the pollution of the environment will vary from country to country. GI-5PRECAUTIONS Precautions for Fuel GASOLINE ENGINE: For Europe Catalytic converter equipped engines: GA14DS engine modele except for Switzerland .. Unleaded gasoline of at least 91 octane (RON) GA1ADS engine models for Switzerland .. Unleaded gasoline of at least 95 octane (RON) Except GA14DS engine models Unleaded gasoline of at least 95 octane (RON) CAUTION: Do not use leaded gasoli the catalytic converter. Except catalytic converter equipped engines For the United Kingdom and France only GA14DS engine models Unleaded gasoline of at least 91 octane (MON) Except GA1ADS engine models Unleaded gasoline of at least 95 octane (RON) Except the United Kingdom and France GA14DS engine models Unleaded or leaded gasoline of at least 91 octane (RON) Except GA14DS engine models ... Unleaded or leaded gasoline of at least 95 octane (RON) e. Using leaded gasoline will damage Except Europe Leaded gasoline of at least 88 octane (RON) GAI6DS engine models for Middle East Leaded gasoline of at least $5 octane (RON) DIESEL ENGINE*: CD17 engine models ... Diesel fuel of at least 45 cetane CD20 engine models ... Diesel fuel of at least 50 cetane * If two types of diesel fuel are available, use summer or winter fuel properly according to the following temperature conditions. © Above -7°C (20°F) ... Summer type diesel fuel @ Below 7°C (20°F) ... Winter type diesel fuel. CAUTION: ¢ Do not use home heating oil, gasoline, or other alternate fuels in your diesel engine. The use of those can cause engine damaai © Donot use summer fuel at temperature below -7°C (20°F). The cold temperatures will cause wax to form in the fuel. AS a result, it may prevent the engine from running smoothly. ‘© Do not add gasoline or other alternate fuels to diese! fuel. Only under the following conditions may you use diesel fuel by mixing kerosene or regular gasoline (not premium gasoline) to prevent the fuel from thickening due to wax ‘separation: It the summer type diesel fuel is used at an ambient temperature below 0°C (32°F), add kerosene or regular gasoline but not more than 30% by volume. However, keep in mind that there may be less engine output performance due to the proportion of added fuel. The use of kerosene for motor vehicles is not permitted In some countries, e.g. U.K. GI-6PRECAUTIONS Precautions for Fuel (Cont'd) Therefore, consult the relevant authorities before such mixtures are used. G71. A QUICK REFERENCE INDEX, a black tab (¢.9. EM) is provided on the first page. You can quickly find the first page of each section by mating It to the section's black tab. 2. THE CONTENTS are listed on the first page of each section. 3, THE TITLE is indicated on the upper portion of cach page and shows the part or system. 4, THE PAGE NUMBER of each section consists of two letters which designate the particular section and a number (e.g. “BR-5") 5, THE LARGE ILLUSTRATIONS are exploded views (See below) and contain tightening torques, lubrication points and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. "Example" | ca Copper [ 17. 20117-70,19.14) Ai vier )7-9007-09,51-65 | Outer shi 22-8 ia2-23,16-29) | Lyin togy 617228 029-4,16:221 | \ ram Sam tee, fab) rion gr 6. THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic Uansaxle or Wansmission, elt. are presented in a step-by-step format where necessary. 7. The following SYMBOLS AND ABBREVIATIONS are used: Tightening torque 2wO 2-Wheel Drive Should be lubricated with grease. 4WD 4-Wheel Drive Unless otmerwise Indicated, use M/T Manual Transaxie/Transmission recommended multi-purpose AT Automatic Transaxle! grease. Transmission Should be lubricated with oil AIC 2 Air Conditioner Sealing point PIS Power Steering Checking point SST. Special Service Tools Always replace after every disas- S.0.S.__: _ Service Data and Specifications sembly. SAE : Society of Automotive Engineers, Left-Hand, Right-Hand Inc. Front, Hear G.G.C. Gult Cooperation Council LHD. Left-Hand Drive RALD. Right! land Drive GI-8HOW TO USE THIS MANUAL 8. The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. “Example” Tightening torque: 59 - 78 N:m (6.0 - 8.0 kg-m, 43 - 58 ft-lb) 9, TROUBLE DIAGNOSES are included in sections dealing with complicated components. 10. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data 11, The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or dainaye to some part of the vehicle. © WARNING Indicates the possibility of personal Injury If instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed @ BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful informationnuw uy AEAY Winine VIAGNAMS WIRING DIAGRAM Symbols used in WIRING DIAGRAM are shown below: [ Example POWER SUPPLY Thue ehowe a ign tion suiteh postion in which the system ‘CONNECTOR This shows that these connectors re can be sported, ‘See POWER SUPPLY FOUTING im EL. section forthe detailed wiring agra, | TGNITION SAITCH (Lace or ow EEE SWITCH This shows that conti exists between hen the switch "ured 10 ON position, Fuse BLOCK sore a [ (WIRE COLOR CODING = Black BR = Brow a M7 mo So f sooy | & TOCATION NUMBER BoOy tiv =wmte On = Grange B®: wmode! ‘This number show where the Ro tReet PY Tone connectors located @ =Green PU Purple HARNESS LAYOUT EL teu SY ZGuy feotion, The number % cYoow Sa. seven ARRREVIATIONS ‘denticat with the ne in HARNESS LAYOUT. When the wire color is striped, the base | Colors gen tt, followed by te spe | @| e@ ee | | eae Mai anny sist ‘SWITCH POSITIONS Wiring diagram switches are shown with the vehicle in the x following condition. © Ignition switch “OFF” @ Doors, hoad and trunk lid/back door closed Noxmalty owe @ Pedals are not depressed and parking brake is released. = se GI-10nun ty neaw wining viaunAms CONNECTOR SYMBOLS @ All connector symbols in wiring diagrams are shown from the terminal side (Connector symbol 2 ~ [Eampe SSC Male an te mate terminals Connector guides for male terminals are shown In black Male terminal and female terminals in white in wiring diagrams. Guiee vide . a aa) connector MULTIPLE SWITCH The continuity of the multiple switch is identified in the switel outs] chart in wiring diagrams. wren swirce lore] nr] copra lwasy Continuity irult of wiper switch 1 o ‘SWITCH POSITION __ CONTINUITY CIRCUIT —sr 2 OFF a4 —R-A)o] (41) 9I9 wr Tase | —weBlep iis) [4folo | to. 36 uve @2] (5| fo [He Fa —B. (©) Jd|6lol 6 wase ne Example: Wiper switch in LO position | Continuity circuit: Red wire - @ terminal ~ @ terminal ~ Wiper switch (@ @ LO} = © terminal ~ © terminal Black wire sox GI-14SUPER MULTIPLE JUNCTION (S.M.J.) @ The “S.M.J." indicated in wiring diagrams is shown in a simplified form. The terminal arrangement should therefore be referred to in the foldout at the end of the Service Manual. @ The foldout should be spread to read the entire wiring diagram. — a Example Oe STARTING SYSTEM STARTING SYSTEM SUPER MULTIPLE JUNCTION (S44 J.) | | pT : | 4 : | { mE Super Mutiale uncon ‘om "J | ) REO Res rye oe su] | eter ta tai page | faz}s zee} > fez|re|s afrale2t 5 {cale2|aa | Weare | Fales ea} fear afea feslealeapeaiesleslad | Je) Fa [6a] Icalea] fealaa| perfor IR af rss sles eslas a 1” BO, = = titan parame L_———)tnsrment fal lev? sles fealaa tenes alaalcal—fealrelcd caolea ll ae|ae halaelca)®? flralaa cafeale a] °° [colaslaa [Ao|e0|co|o9 [eo|ro|co] [solr ofc] op [calaa|ac| | on Te Tarn {Unstrument harness) 7 seus G12nuw ty ruccun FLU) Unanto in invuoie WiAUNVeco 3 NI INSPECTION START Fog _ CHEGK POWER SUPPLY | NG. 4 Check the folowing tems 4) Turn ignition switch "ON 4) Harness continuity between 2) Check voltage between ter crank ange sensor and bat minal © and ground, tery ceBateryvolage should exist, 2) ECCS. reay-t (See page cae EF & €C-106) 3) "BR sible lnk 4) Power source for ECU |" (ece page EF 8 c0-104) | «anton ewicn N.G_,[ Check the faiowing items 1) Harness continuity between || 2) Disconnect crank anale sen- crank angle sensor and sor harness connector. | ground 3) Check resistance between 2) Ground circuit for E.C.U, terminal @ and ground. (See page EF 8EC-104,) Resistan aa Approximately 0:2 ox NOTICE ‘The flow chart indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing, 1) Use the flow chart after locating probable causes of a problem following the “Preliminary Check” or the “Symp- tom Chart”. 2) After repairs, recheck that the problem has been com- pletely eliminated. 3) Refer to Component Parts Location and Harness Layout for the Systeme described in each section for identification/lo- cation of components and harness connectors. 4) Refer to the Circuit Diagram for Quick Pinpoint Check. H you must perform circuit continuity between harness connectors more detail, such as in case of sub-harness is used, refer to Wiring Diagram and Harness Layout in EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be “OFF”. 6) Before checking voltage at connectors, check battery volt- age. 7) After accomplishing the Diagnostic Procedures and Electri- cal Components Inspection, make sure that all harness connectors are reconnected as they were. GI-13HOW TO FOLLOW THIS FLOW CHART Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed blocks, as shown in the following example. ‘CHECK POWER SUPPLY, 1) Turn ignition swite “ON™ 2) Check voltage between termi- nal ® and ground. Battery voltage should exist. [e* (2) Measurement results Required results are indicated in bold type in the corre- sponding block, as shown helow: These have the following meanings: Battery voltage — 11 - 14V or approximately 12V Voltage: Approximately OV -» Less than 1V Cross reference of work symbols in the text and i lustrations Illustrations are provided as visual aids for work proce- dures. For example, symbol f¥ indicated in the left upper portion of each illustration corresponds with the symbol in the flowchart tor easy Identitication. More precisely, the procedure under the “CHECK POWER SUPPLY.” outlined previously is indicated by an illustration EX {@) Symbols used in illustrations Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each eymbol. le— Check iter being performed. Procedure, steps or measurement results Example Direction mark View from terminal side. connector mooi] A direction mark is shown to clarify the side of connector A (terminal side or harnese side). FEE] | Sirecton marke are mainly ured in the illustrations inéteatng terminal inspection. we r : View from terminal side © All connector symbols shown from the terminal side are enclosed by a single line. Ts. Connector symbo! View from harness side : View from harness side ... H.S. All connector symbols shown from the harness side are Doubie ines enclosed by a double line. Dieetion mareKey to symbols signitying measurements or procedures ‘Symbol explanation Check wfler uisconmecting the connector to be measured ‘Symbol explanation Procedure with Consult Check ater connecting the connector to be measured. | Procedure with CONSULT Insert key into ignition switch. AIC switch is “OFF” Remove kay from ignition switch urn ignition switen to “UFF” position, AIG switeh is “ON EG switen is “ON ] | | rum ignition switch o “ON positon Turn ignition swith START Turn ignition switch trom "OFF" to ‘ACC position, REC switch is “OFF” DICK switch is “ON L VENT switch is “ON g Turn ignition switeh trom “ACC” to ‘OFF" position, Turn ignition switch from "OFF" to “ON’ position, | Fan switch is "ON". (At any position | except for “OFF” position) Fan switen is "OFF" Turn ignition switen from "ON" to “OFF position, o not start engine, or check with engine stopped. [Start engine, or check with engine running. Apply battery voltage cirectiy to components Disconnect battery negative cable, Apply parking brake Release parking brake, HERR Depress brake pedal Release brake pedal 9 | 3 Cc [check after engine Is warmed up sulticienty, Voltage should be measured with a voltmeter. Depress accelerator pedal Rolease accelerator peda! cB) Se & Circult resistance should be measured with an ohmmeter Cc a Current ehould be measured with an ammeter Pin terminal check for SM. type F CU and A/T control unit ‘connectors. For details regarding the terminal rangement, refer fo the foldout irs GI-15Outside View Power ON switch \ Diagnostic connector Power OFF switch rn Voltage probe Batery pack” Function keys ~ | | Touch sereen Self-diagnostic results 2 2 sour 6.0.8. (GA10DE and SR200E engines) x Data monitor Active test ECU. pat number Applicable GI-16eungun: unevnive grote Function Diagnostic mode Function This mode enables @ technician to adiust Work support some devices faster and more accurately by following the indications on CONSULT. Sell-diagnostic results can be read and erased quickly. Sell-diagnostic results Inpu/Output data in the control unit ean Data monitor be read ‘Mode in which CONSULT drives come ac tuators apart from the control units and Aetive est also shitts some parameters in a specified range, ECU. part number E.C.U. part number can be read Checking Equipment When ordering ipment, contact your NISSAN distributor. Tool name Description NISSAN CONSULT Kt | @ CONSULT unit and ac- | | @ @ Program card | co | PT @® Operation manuals | [ q @ Carrying case GI-17Model Variation MODEL B13 SERIES = = Se = _ = taco = = = |wavowne [orsewae| __— = = = fewer] onl ss aan = = ee ee ma “ wes _ _ - ‘eesvorvaye | yxs-soTware | wis-vorwave | vxS-sIWAvE: - - xe} PP = = = = [eevewive| vous | = m a sun’ Sg : ~ ~ - we | savas | ssnerae : - - : = [easnuvave | warnavavo | = = = = = : = [svonave| wasowive | vnovorave |wersowara | — = =| fess ome = = = evrea | arava |wovnwive | waranewe| waeuneva| =| wena ~ - _ ns vOWANG | vMs-scrvava | ve-varwave | vis-atT¥nve | viNs-saT¥NS | - xr —_[vasvouvave| masoursve | ne vowsva |yssouviva[vasowive| vassouvnve| vaovourove]| = = [evans [earsaavave [wvauvnve| vaeaaswve | weoasarave | vwouaueve sna - _ - - - VME-VOUYAVE | VMS-sOHVAVE | YMSHOUAVE | YS-LOUWrYE xr| “ wesnuvna| = vasanwave [wwevruvaval vassmnvnva | yasveurnve | — | a | - vorssst wees wicussy vette viesse eos te words ‘vorasse vor arn i 109 save sawvo serve sono | ons GI-18MODEL B13 SERIES IDENTIFICATION INFORMATION Model Variation (Cont'd) ——— —__ fre caveos sn200€ NS Transaxle NN RSSFSIA ALAFOSA SSFS2A Destination aN ™ conn [OPA | GAYARUF-SEA | GaYARUASEA = AH. drive | = j = GBYARWF-EEA models Type A | _HAYARUF-SEA HAYARUA-SEA = TPar roo! SE = = “| HAVARWE-FFA ~~ [Tyee | _Gavatur-cra_| _ GAYALUAGTA = For South ae SE = = GBYALWF-EFA Europe Type A | HAYALUF-SFA HAYALUASFA | — wore re se = f= WevALWE-EEA come [282A | GavaturSeR | envaLiase | — tor Cental [se = = eavALWrEGA Europe [Type A HAYALUF-SGA | _HAYALUASGA = a [Perot ‘SE = _ HBYALWF-EGA Jcoupe Type A __GAYALUF-SSA GAYALUA-SSA oS ror North SE | = | cevaLwresa |swore [wea | umauurssn | avnunssa | — I SE 5 : HBYALWF-ESAWWENTIFIGATIUN INFURMALION Model Vari Prefix and suffix designations: B+ Adoor Sedan ———— Gs Coupe Ho: Tear root St AL + E108 engin: AU: GAY1308 engine AV + GAtAD8 engine — AY © GAIENS A GATBDE engine BY = SRPQDF engine — VA : CD17 engine n (Cont'd) A: 2ewhee! drive models Ro: RM. drive — LH. drive. le ox ExiSaloon sist TIA (Type A 8 (Type 8} SE ga GI-20 A: Standard W_ : Except Europe and Middle East K 5 Middte Eact E : RHO. modale for Europe F : For South Europe G@ = For Central Europe SS + For North Europe S + Carburetor engine E : EFL engine N=: Diesel engine T_Suver Saloon (atens) super Saloor-£ (GATDE)IDENTIFICATION INFORMATION Model Variation (Cont'd) MODEL N14 SERIES Re cnsinavon| \Ge,, | opeeauit™ | aapeouat | Sermon | sapmuar | SspeeanrT | Sapeeawm | Sayed E\° ALT son | mace [resin |auroca” | assracn | _nesroon | nora [| aavanarsea | eavanaasea | — = = =| evcanarnea i SAVAROFSEA | BAVAROASEA | BAYAROFSEA = =| 8VCAROF NEA = = BAYARFF-SEA = = = i.__| ewanarsea | — = S = = = | §]o_[eavanorsea | — = = = = = 5 EES = = EAYARGTSEA_| EAYARTASEA = = = 7 AOR = = = = fx _| pavanorsen S FAYAROF SEA | FAVARORSEA : 5 FVCAROF NEA, lsu S S FAYAREFSEA | FAYARFASEA S = = 2 lan S S = = FaVARUFEEA = = ix eavatoe-sea_| GAVALOASFA = 5 : = BYCALDENA fx _[ esnersre | envcresin | ena [entrain = = BVCALFF NFA ake - = | eamersm | — — - — | $ | glo [ewatorsra [ eavaconsra | — = = = EVCALDEAFA 5 [pels _[ eavacersea = EAVALFFSFA | EAVALFASFA = = EVCALFFNFA £82 {er = _= ~ = ‘EBYALUF-EFA = = one | - - = S BYR = Flo) Fmorera = = S S S WchoeNFR 32]suc_|_ravarrra | FAVALFASEA| FAVALFFGPA | FAVALFAGFA = 5 FUCALFENFA ¢|_ [flex — S S = FaYALUPEFA = = 4 [ex] envnrrecn BAVAIFSGA | BAVALFAEGA BVEALFF Gn lwo EAVALEF-SGA - BAYNLFESGA — == I ioe | eavatorson | envaconaca | ——— = = = [renews OC | EAVALFFSGA | — | ENAUFFSGA | EAVALFASGA | __— = [evcaLFFNGA fen =p = = remuegen [ = | eavacarssa | — = = = = = ¢ [O_[ eavatorssa | — | envauorsia | _— = =| ercnioensa a] [ss - - BAYNLEF.SSA. - = = = § | gla cD ewnorsss [eaamasn [ovaoesm | a = 5 Ros = = EAYALFFSSA | EAVALERSSA SI = = S3]en = = = = EBYALUFESA = = lena | — = = = =| eommnrtsa | — le] Famorsca_[—— | warps | = = = = =| avaisrssn | = = =IWENTIFIVALIUN INFUMMALIUN Model Variation (Cont'd) tare Gatos oan coma ang] Beane Tepo0d WF Tepecat Topecs iT Boey Ne RGGFOOA LAFOGA ASFA LaFOOA se “toot [RT | FAvanEr-sna | FAVARER SHA = = Except Tan drive | europe patches hg = = FAYARGFEWA | FAYARGRERA Prefix and suffix designations: FAYARGANMEHA 8: door Sedan A E : door Hatchback F : S:door Hatchback }—H }—e AV > GATADS engine F AY: GA160S or GATEDE engine | —s BY: SRRODE or SRQODET engine Los Vo : C020 engine I s ‘A: 2awhee! drive models E N : dwhee! drive medels N T Ho: BM onve Lo: Liarve Bk ox eK ro: sux eo: ww Ao: omen vo: on F : S.speed manual transaxle — A+ Automatic transaxle GI-22 Standard Except for Europe RAH.D. models for Europe For South Europe For Central Europe For North Europe Carburetor engine EFL. engine Diesel engine Turbo engineVAM Identification Number /— Veoela idontiteavon plate Verio dentition number (Chassis number) — VEHICLE IDENTIFICATION NUMBER (Chassis number) Profix and suffix designations: Model B13 series (Excopt Europe) BBA BTS XXHKXK oe Il] L 8. Sevan G : Coupe Ho: Tebar root Engine type A: E108 engine B+ GAI308 engine ©: GATADS engine F © GAIENS oF GATEN angina Ho cNAT engine ‘A: 2wheel drive models GI-23 Vehicle serial number Model aciosa|(For Europe) Manutacturer: INT: Nissan, Passenger vehicle Body type G : Coupe Hoo: Tbar root Enaine type E : GAI6DE engine G © SRANNF engine A: Quuhoat drive modale Model N14 serie (Except Europe) Identification Number (Cont'd) WBN GE A BIS UO XXXKXX ae FE ANG — xxxxxx Body type __I F —: S:door Hatchback Engine type ©: GAN4DS engine E : GATBDE engine A: 2avheel drive models (For Europ Bn EF ANU 0 exo age Manufacturer ——— JN1 + Nizoan, Passenger vehicle Body type 5. éuour Sedan = Sdoor Hatchback F 5:d0or Hatcnoack Engine type ©: GANDS engine: E : GAI6DS engine G+ SR20DE or SR20DET engine J+ 6020 engine A: 2awheel drive models. 4ewhee! drive models GI-24 Vehicle serial number Stopgap (n0 meaning) Destination U_ > For Europe Model Vehicle serial number Model —— vonito eariat number ‘Stopgap (no meaning) Destination U > For Europe ModelIDENTIFICATION INFORMATION Identification Number (Cont'd) IDENTIFICATION PLATE Europe Except Europe ee NISSAN MOTOR CO.,LTD.JAPAN NISSAN WOTOR CO, LTO Japan) ? Yoni iteaton aa Ma 4 Grose vale weight 4 Gross combination weight | thos rence wo ina ‘owe (REED RRA ZA cccusm | (2 Enea dopcement {3 Tato eel 1a hav moc | | | / sores ENGINE SERIAL NUMBER ENGINE SERIA E108 engine Garaps, 1408, GAT6DE engine ‘SR20DE engine SR20DET engine 017 engine GI-25Identification Number (Cont'd) MANUAL TRANSAXLE NUMBER RNAFSOA and RSSF30A (FRE 2. RSSFSOA [E> fi & {! GI-26MODEL N14 SERIES Dimensions MODEL B13 SERIES Unit: mm (in) —— — ‘Sedan ‘Overall length 4210 (165.7) 4,140 (163.0) 4.135 (162.8)"4 ‘Overall width 1,660 (65.4)"1 1,680 (66.1) 11870 (85.7), (Overall height 1375 (64.1) 1.310 (51.8) 1,315 (51.82 Front wead 1435 (56.5)°3 1.495 (56.5)°3 1.445 (56.9) 1.445 (569), Rear ead 1485 (65.799 1415 (55.7)°3 [__ 136 (56.5) 1.435 (58.5) Wheelbase 2,430 (95.7) 2,430 (95.7) TILE grade 2: T-bar roof models 3: 185/60R14 tie (Except Europe)/175/65A14 tire (For Europe) +4: For Europe Unit: mn (in) S.door Hatchback | Sedoor Hatchback sedan 2-d00r Hatchback (For Europe) _| _(Excent for Europe) 7220 1668) 2076 1568) 1146 (168.2) 4.46 (188.2) , | 1670 (657) 1670 (657) Overall wit | 4.670.657) ee 1 ee 4.670657) rerall hel ] 1,395 (54.9) 1,395 (54.9) Overall height oom Vaegsare | _ 1988649 1.905 (549) +446 (6979 1aie @oara | nae GOS ee ae 1,436 (56.5)"4 1,436 (56.5)" 1,436 (56.5)"4 1.445 (66.9) 1451 (66375 1451 (53) 1451 (665 Rear trea read 1,421 (55.9)°6 1,421 (55.9)"6 1,421 (55.9)°6 amen Tht 280 (57) 2490 887) 2a0 657) | aaa "7 Sh series naive models “2: 4ND models "3: Tire offset 4 mm (1.57 in) “4: Tire offset 48 mm (1.77 in) “9; 195SA13, 175/70R13 tre 6: ITSVBSALIA, 195/S5R14 tre Gl-27Wheels and Tires MODEL B13 SERIES Except Europe — oy caipe 8 rant moa ‘oor ea ots oft vine & tes min) wm) Wey oars wm andere axa) wou9n ste! nese ous Vinee! ie Onion = = vasa eum me ax are wasn axa w0siy opton rum Te evaare a7 Tare 07 “sans reine sien ssn se Stancare 185/80R13 78S°6- 6.15-19-4PR°5, . ssh 5 vessnis opton rraronss ease ‘rans 976 tr a GRINS & GATEDE engine madele Super saloon for GA160S and GATBDE engine models Excopt £108 aid GATEDE engine niodels GATBOE engine mode! E108 engine model For Midaia East Except GAIADS engine for Middle East For General areas For Europe — Ein GATOS enna GREE erin — oem [over Wheels & fires: — mm in) | mm (in) Stool ‘Standard 14% 5S 45 (3.77) | — Sed = = wren en Wheel size | Al" as rmnun_Fopon wer ova sam | = Fraype _| Standard axa onan | 18 aT wie con for | stenaara ran st na xey Tes |¥ora Type | Standars | THS/70D14 ~ ‘TrOG/7OD1S. GI-28IDENTIFICATION INFORMATION Wheels and Tires (Cont'd) MODEL N14 SERIES Except Europe ——— Offset Offset Whos! & Tire — men (in) ‘mm (in) Engine Gatos. GAte0E Seat sansa wena cea wae [ear Wheel size [numam pte = = [exe [enn Tee size 17siT0R 828 "EIGER BH For Europe — Engine] GAMOS ‘eave0s ‘SRRODE ‘SRaIOET oa ——. Offset Offset Oftset | Offset Offset eet ant ey omit) om) way see ss [onn|[a~sfeon| — | - | — | — |s-s[enm Aun = | | - [emfoun [a= sufoun| — | — ux_| | sent = fathss| sem faxes] mom fuxeul agen) — | = wees option | | eee Tonia wane] one [exws] on] — | — | — | [ess] onan Sanaa ~ -- ~- D- D- [ealem, —- [- Type 44x art] 40 (357) | ooton fuxerfaonsn $272] 20 [wear faonm| — | = | wxarf ons comentonl Onion | _vsvonraeasre | asm sara = = = Tom ects | rismoow | Thptupie ‘rasmao%s = arto Soper soeng 3 Eaten! Wort Ewope “Breet RAND. modes for Euros Gl-29Preparation SPECIAL SERVICE TOOLS Too! number yo name Deveription LM4086-0200 Board-on lift attachment ‘Laas19-0000 Safety stand attachment GI-30Board-on Lift CAUTION: Make sure vehicle is empty when lifting @ The board-on lift attachment (LM4086-0200) set at front end of vehicle should be set on the front of the sill under the front door opening. © Position attachments at front and rear ends of board-on lif Pantagraph jack ~ ‘SST. No. LM 4088-0000) Models with sill spoiler n lift attachments to inner side of sill when the side sill lange is covered by sill sp GI-312-wheel drive models support L__ at i Uso ently and attachment as shown for stable CT i ep = ze ae Garage Jack and Safety Stand WARNING: @ Never get under the vehicle while it is supported only by the jack. Always use safety stands when you have to get under the vehicle. ‘© Place wheel chocks at the front wheels when the roar wheels are raised and place wheel chocks at the roar wheels when the front wheels are raised. Garage jack points oom pp ssrno.usis.ooos S77 Pl a satery sind GI-32LIFLING PUINIS AND LOW TKUCK LOWING Garage Jack and Safety Stand (Cont'd) 4-wheel drive models ately stand ims are the Fit the ower side sil inte groove ‘SST No. 4519-0000, GI-332-pole Lift WARNING When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines. Liteup points ‘the same Tow Truck Towing cauTION All applicable local laws regarding the towing operation must be obeyed, © It is necessary to use proper towing equipment to avoid possible damage to the vehicle during a towing operation. @ When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral (“N” position). 2-WHEEL DRIVE MODELS NISSAN recommends that vehicle be towed with the driving (front) wheels off the ground as illustrated. sais GI-34LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont'd) Towing an automatic transaxle model with four wheels on ground Observe the following restricted towing speeds and distances. Speed: Below 50 km/h (30 MPH) Distance: Less than 65 km (40 miles) CAUTION: Never tow an automatic transaxle model from the rear (i.., backward) with four wheels on the ground as this may cause serious and expensive damage to the transaxle. Towing an automatic transaxle model with rear wheels raised (With front wheels on ground) Never tow an automatic transaxle model with rear wheels raised (with front whecls on ground) as this may cause serious and expensive damage to the transaxle. Ifit is necessary to tow it with rear wheels raised, always use a towing dolly under the front wheels. 4-WHEEL DRIVE MODELS NISSAN recommends that the 4-wheel drive vehicle be towed with all wheels off the ground as follows: 1. Using a flat-bed truck. 2. Using a combination of a two truck and a dolly as illustrated, Towing with four wheels on ground Observe the following restricted towing speeds and distances. ‘Speed: Below 50 km/h (30 MPH) Distance: Less than 65 km (40 miles) Towing a 4-wheel drive model with front or rear wheels raised (With rear or front wheels on the ground) Never tow a 4-wheel drive model with tront or rear wheels raised and rear oF front wheels on the ground as this may cause serious and expensive damage to the transaxle. If it is neces- sary to tow the vehicle with the front or rear wheels raised always use a towing dally under the rear or front wheels. GI-35Tow Truck Towing (Cont'd) Mode! B13 series ‘Sedan ‘Coupe “coupe Li < ~ : | 8 TRANSAXLE GEAR CONTROL MT-12 ————————————— na 308, RSSFIOA, RSSFI1A > MAJOR OVERHAUL . oes MT-413 DISASSEMBLY ...... . MT-16 REPAIR FOR COMPONENT PARTS MT 19 ADJUSTMENT cs . MT-32 ASSEMBLY MT-34 c — = 1 RSSF32A [ —= MAJOR OVERHAUL . . 7 . MT-38 DISASSEMBLY sen MT-41 REPAIR FOR COMPONENT PARTS Mr-44 ADJUSTMENT ror . . MT-64 ASSEMBLY ve MT-66 C 1 RSSF50A C—— 4 MAJOR OVERHAUL cscs MT-70 DISASSEMBLY ...ccccoses . MT-73 REPAIR FOR COMPONENT PARTS. MT-I7 ADJUSTMENT . MT-92 ASSEMBLY esses MT-95, SERVICE DATA AND SPECIFICATIONS (8.0.S.) z . . MT-100PREPARATION SPECIAL SERVICE TOOLS "Special tool or commercial equivalent Tool number ee Description xva8705900: Measuring turning torque of final For F30A. F31A drive assembly K.v38106500-For F504 Measuring total turning torque (Ex- cept for F824) ‘Measuring clearance between Side gear and differential case with washer Selecting citterential side bearing KV38107700-For F324 Preload adapter adjusting shim (Use with K¥v38106000,) 'v38106000 Height gauge adapter (citforontial cide bear ‘Selecting aitferential side bearing adjusting shim (Use with KV38105300, kyva8106500 or kv38107700,) kva2101000" Pin punch Femoving and installing retaining pin Removing differential side bearing inner race (F30A, F31A) Hemoving 3rd and 4th synchronizer Measuring wear of 2nd & 3rd baulk rig (F924) Removing input shatt front and rear bearing (F50) Removing Sth oynchronizer Removing 3rd & 4th synchronizer (504) Removing 2nd & 3rd main gear (F508) ‘$730031000" Puller ‘8730021000" Patler Removing differential oil seal Removing mainshatt front bearing outer race (F30A, F31A) Removing differential side bearing ‘s739290007"| Puller ‘9722790000" | Remeving mainshalt front and rear Puller = bearing inner race (Except for F324) | Remaving Sth main gear (Fxcent for FS0A) Removing mainshalt raar bearing outer race (FEA) MT-2FNEFANALIUN ~: Special ol or commercial equiv. STEHT Tang rea a ea AB | an ra) } ‘a: 60 mm (2.36 in) dia =: A\ enero /$T35325000" - Installing differential oil seal (F32A) Dritt handle (Use with KvgT103000,) a Kvae102100"| Installing input shatt rear bearing Deitt (Except for F50A) | a: 44 mm (1.73 in) dia | a\ b: 245 mm (0.965 in) dia ‘S33200000" 1 Installing mainsnatttront bearing rit outer race (F30A, F31A) Installing mainshatt front bearing ale (F324) 1 mm (2.8 in) dia bb 48.5 mm (1.752 in) 's722360000" Installing input shalt ront bearing Drtt (©xcept for F50A) 2: 34 mm (1.34 In} 1: 28 mm (1.10 in a (1.10 in) a '$122452000" Installing tst & 2nd synchronizer Drift (Except for F5UA) Installing 3rd & 4h synchronizer (roe) Installing 3rd, 4th and sth main gear vw (e504) 7 45 mm (177 in a 36 mm (1.42 in) MT-3* Special tool or commercial equivalent Too! number cee Description 737750000" Installing 5th main gear Except for ort | F0A) Installing 3d & Ath synchronizer (F304, F31A) << Instaling input shat oil sea (Except tor Fava) Installing Sh syneinonizer (Except for A? F50A) Instling mainshat rear boaring | (F228) 40 rm (157 i 31 mm (1.22 a $T22960002" Installing mainshalt rear hearing ie Drift ner race (F30A, F31A) 2 28m (1.38) i, a 3 23mm (03 in) ia. — { —— —— ‘rause1000" inslaling diferential sige bearing brit . outer rave (Except for F50A) = Installing mainshatt rear bearing outer race (F50A) WN (Use with ST30611000 ) 3 2: 79mm (31 in ia. 59mm (232 in din 730611000" (Use with 83052 :000) Dri handle | | jemccmeimaaain) | | S1sB06S001 Hemoving aiferental side bearing Ditferential sige ier race (F504) bearing puller set 5 f= £05 mm (488 In in @ sraa051001 1 38 ym (150 a. Puller @ 8133061000 . Adapter ‘sT30600000, instaling input shat font bearing Drift | (FSA) 36mm (142i a. 21mm (12nd, MT-4PREPARATION COMMERCIAL SERVICE TOOLS Tool name Description Pullor Rlomoving input chat front bearing (Except for F50A) | Removing mainshaft rear bearing (F324) Installing mainshait front bearing in- 2 21mm (0.83 tn) ala — FOIA. a: 94 mm (1.22) sa ° ‘36 mm (1.03 in) nk Insaling ferential sige bering —<— inner raee (Except for FSA) 458m (22019) j 3 505mm (1.50 | A Drift Drift Installing striking rod cil seal 2: 38 mm (1.50 in dia, | \ Ont | installing oiferental oi (\of side of F5nA) 8 mm (2.48 i in » ©: 72 mm (263i) a, | ‘ Installing differential side bearing inner race (F508) 2 49 mm (1.17 im 1 41 a (1.89) Daitt | Installing differential side bearing — outer race (F50A) | xo 8: 69 mm (2.72 i) da, MT-5Replacing Oil Seal DIFFERENTIAL OIL SEAL 1. Drain gear oil from transaxle. 2. Remove drive shafts — Refer to section FA. 3. Remove differential oil seal. 4. Install differential oil seal. ‘© Apply multi-purpose grease to seal ip of oll seal before installing. 5. Install drive shalls — Refer to section FA, Differential oll seals and drifts for installation 2wo Fo FBT +-GAIBDE. Ft GA16DS: F314-c020 LH and AM sides | LM. and RM sites ett 39400001 awo Fon Fata F50A Sanat id & | @ | 1 | ei)? 1 Dritt | eames creams ort wor | Sta in /$735325000 ° Sotasle of STRIKING ROD OIL SEAL 4. Remove transaxle control rod from yoke. 2. Remove yoke retaining pin. MT-6ON-VEHICLE SERVICE Replacing Oil Seal (Cont'd) Siang roo 9. Remove striking rod oil seal ot seal} \. ‘rit 4. Install striking rod oil seal. ¢ Apply multi-purpose grease to seal lip of oil seal before installing. Check of Position Switch | €) — | —Except for RSSF50A — ven re tows" | BACK-UP LAMP SWITCH conse Check continuity. a a Gear position Continuity Reverse = BD eo | Zaop roo Ye NEUTRAL SWITCH @ Check continuity. Gear position Continulty Neutral Except neutral — RS5F50A — BACK-UP LAMP SWITCH AND NEUTRAL SWITCH © Check continuity. Gear position Continuity Reverse @-@ Neutral a-@ ~~ except reverse and neuirat | No MT-7Removal 1. Remove battery negative terminal. 2. Remove air duct. 3. Disconnect clutch control cable. (Except for SR20DET en- gine models) Remove clutch operating cylinder from transaxle. (SR20DET engine models) 4, Disconnect speedometer cable from transaxle. 5, Disconnect back-up lamp switch, neutral switch and ground harness connectors. 6. Remove starter motor trom transaxie Remove shift control rod and support rod from transaxle. Drain gear oil from transaxle and transfer. Draw out drive shatts — Heter to section FA, ‘Support engine with hoist. (SR20DET engine models) Remove transfer — Refer to section TF. (4WD models) 12, Jack up transaxle together with engine slightly and insert wooden block between center member and engine oil pan. (2WD models) CAUTION: Do not place jack under oil pan drain plug. 13. Remove rear and L.H. mounts supporting transaxle with jack. 14, Remove bolts securing transaxle. 15. Lower transaxle, MT-8HEMOVAL AND INSIALLAIIUN Installation Tighten bolts securing transaxle and install any part removed. © E1US engine models Tightening torque rn ightening torq jolt No, € mm (in) Wen tkam, 0) OMIT wer 1 oo 8-2, 2H) ner) eet) 2 20-29 20-30, 14-22) 70,276) a 16-2186. 25.12-19 251098) 4 eencereere 250.9) Front gusset to 16 - 21 (1.6 - 2.1, 12- 15) 20 (0.79) 16-21 (18-29, 12- 15) 201079) ewiF we sane # CD17 engine models eee cw Bot No, pees mm) e. 1 30 - 40 (3.1 - 4. 110 (4.33) 2 30 - 40 (3.1 - 4.1, 22 - 30) 70 (2.76) 3 4-54(65-55,93-40) | 75 (2.95) 4 16-21 16-2. 12- 15) 1.1) 5 76-21 (16-2.,12-15) | _25 0.98) oad 90 - 40 (8.1 = 4.1, 22-90) 35 (1.98) Bear gusset | ag 4091 -43.22-90 251090) MT-9REMOVAL AND INSTALLATION Installation (Cont'd) © GA engine models (2WD) @ MIT 10 engine Eng (gus ott no Tightening torave mm on Nem (kg-m, ft-lb) Gi 40 (34-41, 2-0) 701076) 2 30 - 40 (3.1 - 4.1, 22 - 30) 85 (3.35) 3 30 - 40 (3.1 - 4.1, 22 - 30) 30 (1.18) 4 16 - 21 (1.6 - 2.1, 15) 25 (0.98) soe] From qusset to 30 - 409.1 = 41,22 20) 20(079) Rear gussat to Bear 0 16-21 (08-21, 12-19) 1608s) OMIT to enoine @ CD20 engine models Engine (guasct! yo ‘ i | . Tightening torque — Q | en Nem (gem, tb) MD | 5 20-40 (4-45, 22.90) 720 472) © 2 WAU I-41, 2-H) 35 638) 8 | 845-55, 98- 0) 75,298) 4 [16-21 (16-21, 12-15) 30 (1.18) ®nal 5 | 16-2 (16-21. 12-15) 25 (098) - ront gusset to | - ene tte 30 - 40 (3.1 - 4.1, 22 - 30) 35 (1.38) Rewomere Ta apas-ane-a) | (%5% anaino @ MT to engine © SR engine models (2WD) | eat Teese | cree | 1 70-70(7.1-8.1,61 89) 65 (2.17) 2 70-791 81,51-59) | 65 (2.50) —s 90-4 (@141, 22-30) 351195) 4 30 - 40 (8.1 = 4.1, 22 - 30) (7) MT-10REMOVAL AND INSTALLATION Installation (Cont'd) Dut epee © GA engine models (4WD) ote a Tightening orave mam ee Nem (kg-m, ft-lb) u cy 7 30-40 (04-41, 22-80) Toe) 2 wo a0 (04-41, ew) ws) 2 Go 40 (81-41, 2-20) 5217) ‘ 30-40 (9.444, 22-30) 20 078) 5 a0 40 (1 179-0) 20450) Froresuestto. | 5p aa 1 -41,22-30) 35(138) Apply sealant when installing transaxle as in illustration at lett. [: Apply esommanded {Nissin genuine par a | @ SR engine models (4WD) cuteness OR @ Engine to M/T ge epee : eae = ornare 5 pate iene oom COU 4 70 - 79 (7.1 - 8.1, 51 - 59) 56) Apply sealant when installing transaxle as in illustration at left. C2: Appiy ecummended seetant (Nissan genuine part KPS1000150 or equivalent) syrrasa MT-11@2359000K86 IMANDAALE GEAN LUNINUL RV. ) e0 i Cx Gam ar | aed ae law 8 Puss (045 - 080, 33 - 43) Pye. 5 02-15,9-19 P1547 as -48, 25-39) 4-8 (14-18, 10-13) Control lever knob © Dust boot boot ® Piate dott Control lever socket ® Tranoaale hole cover Control lever ® Support ro Ingulator @ Plato Seat ® Collar Bushing ® Bushing O-ring ® Support rod bracket MT-12 BSSeseeg A) 18 - 26 (18 24, 39-47) Fl Nem teg-m, ty Colter Bushing Control vod Return spring Return spring rubber Holder bracket Mass damperMAJOR OVERHAUL FOUR & SIA. Case Components —. RNAFSOA and FSSFB0A—_ 2 | DIG mang sutace to vansmssin case | 7 ad eeded WM 15-20 __ (15-20, 11-14) ® Newt switch 20. 29 (20-20, 14 - 22) Sitch plug (18 -20005-20, 11-14) ~~ 66 as 0625-35, 10- 20) FA Trend of ot /f ~~ Tread of bot e203 \ \ Pearse J Ve as 48-40 Vanes aaa @O) 2-29 20-20, 14-2 \ OES BB ire oti (1B mating suctace to Ds tem tegem, 8) Apply recommenda seal! (Nan genuine pat G (Selctcom erent” + Pay atenton 0 te rection sures @ Clutch housing ® Switch plug ® Reverse iclershatt @ Input shaft ol seal ® Welch plug @ Oil channel @ Oil pocket ® O-ring ® Sinking 109 oil seal @ Bearing retainer ® Case cover ® Boot © Bearing reliner ® Reverse lamp switch ® Neutral switch oF switch plug @® Torx serew ® Dittorontal ei coal ® Ditlorontial cil eoal © Filler plug © Drain plug ® O-ring @ Switeh plug @® Transmission case @ Speedometer pinion assembly @® Air breather @ Oil quter MT-13,MAUn UVENNAUL ee @@8 86a6 BOaee@ nas hen essen. FA© Asi ecg seit Gear Components + : Select proper thickness, ‘Pay attention tots director © : Ssp000 moaeis ony Reverse idler gear Reverse idler bushing Reverse idler spacer snap ring Input gear spacer Input shaft front bearing Input shatt il plug sth gear needle bearing Baulk ring sth synchronizer hub Spread spring BQOSOSE GBS E O38 Shifting insert sth stopper Input shaft rear bearing Mainsnatt tront bearing Mainshat, st main gear ‘st gear needle bearing Steel ball ‘nd & rd bushing sits main gear sth main gear Thrust washer Mainshatt C-ring C-ring holder s @®@ © 88 8® ee MT-14 Mainshaft rear bearing Spacer Mainshaft bearing adjusting shim ‘th bushing Srd & ath synchro nizer hub 3rd main gear 2nd main gear 4st & 2nd synchro- nizer hub Reverse (Coupling Differential case Final gear ® 60568 € O88 Differential side bearing adjusting shim Ditterentiat siae bearing Retaining pin Pinion mate thrust washer Speedometer drive gear Spoodomotor ctoppor Side gear Pinion mate gear Pinion mate shaft Side gear thrust washerMAJOR OVERHAUL Shift Control Components F30A & F31A, 6S0883000 Reverse check spring Rovere check plug ‘Check ball plug ‘Shift check ball Check spring Fork shaft support spring Shitter cap Fork shaft Sth shit fork 26098006 @ 19-25 (19 -25,14- 19) Drs tis | D wes BD nem tka-m. 0) ao 31d & 4th shit fork tot & 2nd ohift fork Control bracket Striking interlock Retaining pin Retaining pin Yoke Striking rod ®2ORS8ee MT-15, SS \ Bes - 0s (054-085, 48-61) SS cB | 3-83 (064-085, 46-6) Wi BOLLE / @ App locking sealant # + Select proper iength © Sspe0d medals only Stviking lever Check ball (Large) Check ball (Small) Check sieeve O-ring Select return spring Check plunger ‘Stopper pin(10 8 200 suroszs sursr| 1. Remove transmission case while slightly tilting it to prevent, 5th shift fork from interfering with case. 2. Draw out reverse idler epacer and fork eh, then remove 5th and 3rd & 4th shift forks | Be caratul not to lose shifter cap. Remove control bracket with 1st & 2nd shift fork. | 3. | Be careful not to lose shifter cap. 4, Remove gear components from clutch housing, — RN4F30A and RSSF30A — 4. Remove three screws and detach bearing retainer One of these three screws Is torx type and should be removed with a suitable tool, as shown. b. Remove input shaft together with mainshaft by tapping lightly. Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side. Do not draw out reverse idler shaft from clutch housing because these fittings will be loose. When removing input shaft, be careful not to scratch oil seal lip with shaft spline. MT-16DISASSEMBLY F30A & F31A {Mair surza surrey c, Remove reverse idler gear and final drive assembly. — RSSF31A — a. Remove mainshaft and final drive assembly. Always withdraw mainshaft straight out. Failure to do 80 can damage resin oil channel on clutch housing si b. Remove bearing retainer securing bolts, c. Remove input shaft together with bearing retainer and reverse idler gear by tapping lightly. Do not draw out reverse idler shaft from clutch housing because these fittings will be loose. When removing input shatt, be careful not to scratch oil seal lip with shaft spline. MT-17DISASSEMBLY F30A & F31A Check spring ~ ‘Shift check all — (Check ball plug g are oa enembly surses 5. Remove oil pocket, shift check ball, check spring and check ball plug. 6. Drive retaining pin out of striking lever, then remove striking rod, striking lever and striking interlock Select a position where retaining pin does not interfere with clutch housing when removing retaining pin. © Be careful not to damage oil seal lip, when removing striking rod. It necessary, tape edges of striking rod. 7. Remove reverse check plug, then detach reverse check spring and check balls. 8 Remove check sieeve assembly. MT-18,Input Shaft and Gears DISASSEMBLY 1, Before disassembly, check Sth input gear end play. Gear end play Gears tnd play mm (in) Sth input gear 0.18 - 0.31 (0.0071 - 0.0122) © If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring groove -- Refer to "Assembly 2. Remove snap ring and 5th stopper 3, Remove Sth synchronizer. Sth input gear and Sth gear needle bearing, 7-8 syperronizer nu ssrs0021000, ‘5th input gear Set Too! below Sth input gear suri 4, Remove snap ring of input shaft front bearing and input gear spacer. front bearing MT-19.sursotal Spline portion Baul ring to 007 clearance 1 Input Shaft and Gears (Cont'd) 5. Pull out input shaft front bearing. 6 Remove bearing retainer. INSPECTION Gear and shaft © Check shaft for cracks, wear or bending. @ Gheck gears for excessive wear, chips or cracks synchronizer Check spline portion of coupling sleeves, hubs and gears for wear or cracks. @ Check baulk rings for cracks or deformation. # Check shifting inserts for wear or deformation. ® Measure clearance between baulk ring and gear. Clearance between baulk ring and gear: Standard 1.0 - 1.35 mm (0.0394 - 0.0531 in) Wear limit 0.7 mm (0.028 in) Bearing © Make sure bearings roll freely and are free from noise, cracks, pitting or wear. MT-20KEPAIN FU GUMPUNENI! PAKIS Liwnerin | Input Shaft and Gears (Cont'd) ASSEMBLY 1. Assemble 6th synchronizer. Q ; @ Be careful not to hook front and rear ends of spread spring to the same insert. 2. Install bearing retainer. 3. Press on input shaft front bearing. 4 Install input gear spacer. sstzz3s0000 Bearing retainer surza 5. Select proper snap ring of input shaft front bearing to minimize clearance of groove in input shaft and then install it Allowable clearance of groove: 0- 0.1 mm (0 - 0,004 in) ‘Snap ring of input shalt front bearing: Refer to §.D.8, 6. Install Sth gear needle bearing, 5th input gear, 5th synehro- nizer and 5th stopper. 7. Measure gear end play as the final check — Refer to “Disassembly.” | Sytner ‘st377so000 hub | 7 sur) MT-21ren Needle bering stopper ] | | one Se cring Input Shaft and Gears (Cont'd) 8. Select proper snap ring of bth synchronizer hub to minimize Clearance of groove in input shaft and install It. Allowable clearance of groove: 0 - 0.4 mm (0 - 0.004 in) Snap ring of Sth synchronizer: Refer to S.D.S. Mainshaft and Gears DISASSEMBLY 1, Before disassembly, check 1st, 2nd, 3rd and 4th main gear end plays. Gear end play Refer to S.D.S. ® {if not within specification, disassemble and check contact surface of gear, shall and hub. Then check clearance of G-ring groove — Refer to Assembly’ 2. Press out mainshatt front bearing 8, Press out mainshaft rear bearing 4. Remove C-rings, C-ring holder and thrust washer. MT-22Mainshaft and Gears (Cont'd) a, | 5. Press out Sth main gear. Wy | fangs ae ccted | 6. Remove 4th main gear, 4th bushing and steel ball tad @ Be careful not to lose steel ball. 4th main gear * > Ath dushing Steel ball [7 Remove 3rd & 4th synchronizer, 3rd main gear, and & 3rd | bushing, steel ball and 2nd main gear. © Be careful not to lose steel ball. MT-23Mainshaft and Gears (Cont'd) 8. Remove ist & 2nd synchronizer and ist main gear, then remove st gear needle bearing. st & 2nd + synchronizes INSPECTION Gear and shaft @ Check shaft for cracks, wear or bending, @ Check gears for excessive wear, chips or cracks. Synchronizer ® Check spline portion of coupling sleeves, hubs and gears for wear or cracks. © Check baulk rings for cracks or deformation. © Check shifting inserts for wear or deformation. © Measure clearance between baulk ring and gear. Clearance between baulk rings and tst-4th main gears: Standard 1.0 Wear Ii 0.7 mm (0.028 in) -35 mm (0.0394 - 0.0531 in) | Bearing @ Make sure bearings roll treely and are tree trom noise, cracks, pitting or wear. When replacing tapered roller bearing, replace outer and inner race as a set. MT-24REPAIR FOR COMPONENT PARTS suaos4) ‘ST37750000 ara 8 ay ‘synchronizer hub — PSUA 6 PSIA Mainshaft and Gears (Cont'd) ASSEMBLY 4. Assemble 1st & 2nd and 3rd & 4ih synchronizers, © Be careful not to hook front and rear ends of spread spring to the same insert. 2, Install Ist gear needle bearing and ist main gear. 3. Press on 1st & 2nd synchronizer 4. Install steel ball, 2nd main gear, 2nd & 4rd bushing, ard main gear and 3rd & 4th synchronizer. ‘© Apply multi-purpose grease to steel ball before installing it. ‘© 2nd & 3rd bushing has a groove in which steel ball fits MT-25,Mainshaft and Gears (Cont'd) 5. Install stee! ball, 4th bushing and 4th main gear. ais. © Apply multi-purpose grease to steel ball before installing it. 4th main gear @ 4th bushing has a groove in which steel ball fits. i J 6. Press on Sth main gear. r37750000, 7. Install thrust washer. Cronos 8. Select proper C-ring to minimize clearance of gro0\ 6 cvnw mainshaft and install it ‘Allowable clearance of groove: rvs master 0 - 0.1 mm (0 - 0.004 in) Mainshaft C-ring: Refer to S.0.S. 9. Install C-ring holder 10, Press on mainshaft rear bearing ssr22380002 MT-26vite rit REPAIR FOR COMPONENT PARTS. spors OVA @roIK Mainshaft and Gears (Cont'd) 11. Press on mainshaft front bearing 12 Measure gear end play as the final check — Refer to “Disassembly”. Final Drive DISASSEMBLY 4. Remove final gear. 2, Remove speedometer drive gear by cutting it. 3, Press oul differential side bearings, © Be careful not to mix up the right and left bearings. 4, Drive out retaining pin and draw out pinion mate shaft. 5. Remove pinion mate gears and side gears. INSPECTION Gear, washer, shaft and case © Chock mating surfaces of differential case, side gears and pinion mate gears. @ Check washers for waar Bearing © Make sure bearings roll freely and are free from noise, cracks, pitting or wear. When replacing tapered roller bearing, replace outer and inner race as a set. MT-27Lock pin} surer| Final Drive (Cont'd) ASSEMBLY 1. Attach side gear thrust washers to side gears, then install pinion mate washers and pinion mate gears in place. 2. Insert pinion mate shat © When inserting, be careful not to damage pinion mate thrust washers. 3, Measure clearance between side gear and differential case with washers following the procedure below: a. Set Tool and dial indicator on side gear. b. Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears Clearance between side gear and differential washers: 0.1 - 0.2 mm (0.004 - 0.008 in) c. If not within specification, adjust clearance by changing thickness of side gear thrust washers. Side gear thrust washer: Refer to S.D.S. with 4, Install retaining pin. Make sure that retai is flush with case. MT-28REPAIK FOK COMPONENT PARTS Lrova eran | Final Drive (Cont'd) 5. Install final gear. © Apply locking sealant to final gear fixing bolts before installing them. 6. Install speedometer drive gear and stopper. 7. Press on differential side bearings. | Shift Control Components Sting ro 3 INSPECTION wD). © Check contact surface and sliding surface for wear, | seratches, projectians ar other damage | | contsot bracket | | | 4 | w Case Components Input shaft oil seal 1. Drive out input shatt oil seal MT-29‘Case Components (Cont'd) 2. Install input shatt oil seal. Apply multi-purpose grease to seal lip of oil seal before installing. Input shaft rear bearing 1. Remove welch plug from transmission case. Remove input shaft rear bearing by tapping it from welch plug hole. Install welch plug. Apply recommended sealant to mating surface of transmis- sion case. Install input shaft rear bearing. MT-30REPAIR FOR COMPONENT PARTS LLF30A & F31A_| ‘Case Components (Cont'd) Mainshaft front bearing outer race and oil channel 1. Remove mainshaft front bearing outer race. 2. Remove oil channel. som \ sie \M | Install oil channel | a © Ensure that oil groove in oil channel always faces toward | cit pocket oil pocket when installing it on clutch housing. Ot groove cor V —————]_ 4, Install mainshatt front bearing outer race. l _surrs) Mainshaft rear bearing outer race @ Refer to “ADJUSTMENT”. Differential side bearing outer race © Refer to “ADJUSTMENT”. MT-31sures Differential Side Bearing Preload If any of the following parts are replaced, adjust differential side bearing preload. © Differential case © Differential side bearing © Clutch housing © Transmission case 1. Remove differential side bearing outer race (transmission case side) and shim. Reinstall differential side bearing outer race without shim. Install final drive assembly on clutch housing. Install transmission case on clutch housing. Tighten transmission case fixing bolts to the specified torque. Set dial indicator on front end of differential vase, ingort Too! all the way into differential side gear Move Tool up and down and measure dial indicator deflec- tion Select shim considering bearing preload. Suitable shim thickness = Dial icator deflection + specified bearing preload Differential side bearing adjusting shims and preload: Refer to 8.0.8. 8. Install selected shim and differential side bearing outer race. 10. Check differential side bearing turning torque. a. Install final drive assembly on clutch housing. b. Install transmission case on clutch housing. ‘@ Tighten transmission case fixing bolts to the specified torque. MT-32ADJUSTMENT c. Measure turning torque of final drive assembly. Turning torque of final drive assembly (New bearing): Refer to SDS. @ When old bearing is used again, turning torque will be slightly less than the above. @ Make sure torque in close to the specified rang ¢ Changes in turning torque of final drive assembly per revolution should be within 1.0 Nem (10 kg-cm, 8.7 in-Ib) without binding. Mainshaft Bearing Preload It any of the following parts are replaced, adjust mainshaft bearing preload © Mainshatt @ = Mainshaft bearings @ Clutch housing e Transmission case 1. Remove case cover, O-ring, spacer, mainshaft bearing adjusting shim and mainshatt rear bearing outer race trom transmission case. Install mainshaft assembly on clutch housing Install tranemiesion case on clutch housing, Tighten transmission case fixing bolts to the specified torque. 4, Reinstall mainshaft rear bearing outer race on inner race 5, Measure distance from transmission case to bearing outer race. © Make sure that bearing is properly seated. Select shim with S.D.S. table as a guide, Check total turning torque after assembling — Refer to ‘ASSEMBLY MT-33,Cchees spring Shite check bat ‘Check hall plug cetiopnane tape = LW cowck bal tare) check ball ~ ~ ) ADOEMDLT 1. _ Install striking rod, lever and interlock. When inserting striking rod into clutch housing, tape edges of striking rod to avoid damaging oil seal lip. 2. Install reverse check sieeve assembly. 3. Install check balls, reverse check spring and check plug 4. Check reverse check force Reverse check force: Refer to $.D.S. ¢ If not within specification, select another check plug having a different length and reinstall it, Reverse check plug: Refer to S.D.S. 5. Install selected reverse check plug Apply locking sealant to thread of plug before installing it. 6. install check ball plug, shift check ball and check spring. 7. Install oll pocket. 8. Install gear components onto clutch housing — RNAF30A and RS5F30A — a. Install final drive assembly and reverse idler gear. MT-34surrar uray ASSEMBLY F30A & F31A b. Install mainshaft and input gear as a set. © Take care not to damage oil seal lip with splines of Input shaft while shaft is being inserted into clutch housing. @ Take care not to damage oil channel when inserting main- shaft into clutch housing. ¢. Install bearing retainer. One of these thrae screws is torx type and should be installed with suitable tool, as shown. d. After installing torx screw, stake it at two points. RSSF31A a. Install inpul shall assembly and reverse idler gear. @ Take care not to damage oll seal tip with splines of Input shaft while shaft is being inserted into clutch housing. b. Install final drive assembly. MT-35,urs suse ©. Install mainshaft assembly. © Take care not to damage oll channel when inserting main- shatt into clutch housing. 9. Apply grease to shifter caps, then install it to control bracket. install control bracket with 1st & 2nd shift fork. 10. Install 3rd & 4th and Sth shift forks. 11, Insert fork shaft. © Apply multi-purpose grease to support spring before In- stalling. 42. Install reverse idler spacer. 13. Apply recommended sealant to mating surface of clutch housing. 14, Install transmission case on clutch housing. MT-36ASSEMBLY 45. Measure total turning tarque Total turning torque (New bearing): Refer to S.D.S. When old bearing is used again, turning torque will be slightly less than the above. Make sure torque is close to the specified range. MT-37MAJOR OVERHAUL HSDFSZA, Case Components Ta7-s0 (a8 O61, 27-90 Ge te g @EYw-w09-20.7-10 DUaaig sac o Ep en bon (ona - 085, 46-63) DE aig sutac to tea-e3 | \poyas - 20 27-34, 20-22) (08-085, rare) i ys esas ws Thvead of bot @P2-2 om kom. TES aa SQEVIE ote Been Ti tread of vot (Nissan genuine par KPS10-00280) or egiaent ® Clutch housing @ o-ring ® Bearing retainer @ Hoverse icier snatt @ Case cover ® viking rod oil seal @ Input shat vi seal ® Reverse lamp switen ® Boot @ Oil pocket ® Ditlorantia cil soal @ Neutral switch © Bearing retainor @ rain plug @ Differential cil seal @ Flor plug ® Transmission case @ o-ing @ Air breather ® Oil gutter @ Speedometer pinion assembly @ Welch plug ® Oil channel MT-3828S3SSSOSOSSEOQHOHHHHO MAJOR OVERHAUL Gear Components Select proper thickness. FAO Anny locking sealant Reverte ile gear @ tetmain goar @ sm main goar Re ler bushing @ Baulk ring @ Spacer Reverse idler spacer ‘ist gear needle bearing @ > Mainshatt rear bearing ‘Snap ring ® Reverse main gear @® Cring ‘Spacer corn seers) ® C-ring holder Inpt shat ron bearing @ naon spring Snap cing Ins sha @ tha 2nd syneonizer nub S Seems sin gear needle bearing hee @ Ditorential side bearing Sth input gear ieee © Speedometer stopper coving neve ebaeara © onerentlcase ee 8 2nd & 3rd bushing © Di @ 3rd main gear eae Insert ring fofsrumereariere © iterenti side bearing Sh goa ayntronizor hub alse rear orereae ee @ iforenl side bearing Spread ing faloiomer cain ta cjg him 4h stopper © copii sere © Retaining pn Snap ring @ 2rd & 4th aynchronizer hub @ Thrust washer Input shaft bearing ® Insert spring ® Pinion mate gear Mairshatt ron Bearng @ Sauk ing © Thrust washer Steel ball @ 4th main gear ® Side gear Mainshatt @ 4th gear bushing ® Pinion mate shaft MT-39Shift Control Components \ no b \ pies e3 (64 025, 48 - 61) ~~ os om G—Re \ — erie %; 45-63) OT is asa FAG Pea tres Select proper par. Aajustment MT-40 Fhe tm thom, te0) FAO Aen tcxing seta Sees ret ert isregured © check plunger @ Fork shat supporting spring ® Reverse check plug @ Select return spring @ sin shit tork @ neck val (Large) & stopper in © snimeap @® hwck val Sma) @ Siking lever @ Ord 8 Ath shit fork @ Check sleeve @ Striking intriock @ shincap @ Oring @ Shap rng ® 1 8 ad shit fork @ Reverse brake cam ® Conteol bracket @ Check ball plug @ Control bracket pin @ hilt check ball @ Retaining pin @ Check spring @ Striking ros ® Reverse brake cam spring @ Retaining pin @ Fore snan ® yore1. Remove case cover. 2. Remove mainshatt bearing snap ring. 3. Remove transmission case while slightly tilting it to prevent Sth shift fork from interfering with case. 4, Draw out reverse idler spacer and fork shaft. "| 5 Remove Sth and 3rd & 4th shift forks. © Be careful not to lose shifter cap. MT-416. Remove control bracket with ist & 2nd shift fork. 7. Remove gear components from clutch housing, a, Remove input shaft front bearing retainer securing bolts, b. Remove input shaft with bearing retainer, mainshaft assem- bly and reverse idler gear. ‘Always withdraw mainshatt straight out. Failure to do so can damage resin oil channel on clutch housing side. ‘® Do not draw out reverse idler shaft from clutch housing because these fittings will be loose. When removing input shaft, be careful not to scratch oil seal lip with shaft spline. c. Remove tinal drive assembly. 8. Remove oil pocket, shift check ball, check spring and check ball plug. MT-42DISASSEMBLY novrsen, = 9. Drive retaining pin out of striking lever, then remove striking rod, striking lever and striking interlock, Select a position where retaining pin does not interfere with clutch housing when removing retaining pin. © Be careful not to damage oil seal lip, when removing striking rod. If necessary, tape edges of striking rod. 40. Remove reverse check plug, then detach reverse check check plo spring and check balls. o/s If the emailer ball does not come out, remove it together check pring U omc ont with check sleeve assembly. 11. Remove check sieeve assembly. MT-43,1 ~ Neeate vearing 5h synchronizer hub ssT30021000 FAR = 5th Input gear Net Too! betow 5th Input gear | sur7s0e) FUN GUMPUNENI FAKID Input Shaft and Gears DISASSEMBLY Before disassembly, check Sth input gear end play. Gears End play mm (in) Sth input gear 0.48 - 0.31 (0.0071 - 0.0122) © If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring groove -- Reter to “Assembly — Input Shatt and Gear: 2. Remove snap ring and 5th stopper. 3, Remove Sth synchronizer, Sth input gear and 5th gear needle bearing. MT-44REPAIR FOR COMPONENT PARTS: Lsporsen_| Input Shaft and Gears (Cont'd) 4. Remove snap ring of input shaft front bearing and input gear spacer. 5. Pull out input shatt front bearing, 6 Remove bearing retainer INSPECTION Gear and shaft Check shaft for cracks, wear or bending | Check gears for excessive wear. chips or cracks. urea) Synchronizer © Check epline portion of coupling siceves, hubs and gears for wear or cracks. | @ Check baulk rings tor cracks or deformation | @ Check insert sprinas for wear or deformation. © Measure clearance between baulk ring and gear. aut cing to Clearance between baulk ring and gear: ‘ear clearance ‘Standard 1.0 - 1.35 mm (0.0394 - 0.0531 in) Wear limit 0.7 mm (0.028 in) suse MT-45,sures ssr22350000, Bearing retainer | surza Input Shaft and Gears (Cont'd) Bearing @ Make sure bearings roll freely and are free from noise, cracks, pitting or wear. ASSEMBLY 1. Assemble 5th synchronizer. ¢ Be careful not to hook front and rear ends of spread spring 2. Install bearing retainer. 3. Press on input ehatt front bearing. 4. Install input gear spacer. MT-46KEPAIK FORK CUMPUNENI PAHIS: Luyersen Input Shaft and Gears (Cont'd) -—. 5. Select proper snap ring of input shaft front bearing to min- & imize clearance of groove in input shaft and then install it, WAG 7 S086 tog Allowable clearance of groove: ‘ 0 0.1 mm (0 - 0.004 in) “& | Snap rings of input shaft front bearing: \ Thiekness mm (in) art number “4.27 (0.0500) '32204-MB004 1.93 (0.0524) 32204-M8005 1.39 (0.0547) 32204-MB006 1.45 (0.0571) 22204 Mg007 Be sure to replace Sth gear synchronizer hub with new one when it is removed. 6. Install Sth gear needle bearing, Sth input gear, Sth synchro- nizer and Sth stopper © Be sure to press input shalt in position vertically in relation to synchronizer hub. 7. Measure gear end play as a final check — Refer to "Dis- ‘assembly — Input Shaft and Gears” h 8. Select proper snap ring of Sth synchronizer hub to minimize clearance of groove in input shaft and install it. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Shap ring of Sth synchronizer: | 2.00 (0.0787) 32511-MeB12 Thewecs mm] Part name 2.05 (0.0807) caer eta Lo ana 2.10 (0.0827) oor Meet 2.18 (0.006) oat Ma8'5 2 20 (0.0868) costieste 2.25 (0.0200) oot moet? 2.20 (00208) seat Ma818 MT-47,End play | ang noises 5020 rng | S]— cg noscer | org surarss, &s Mainshaft and Gears DISASSEMBLY 1. Before disassembly, measure gear end play. Gear end play: Gears ‘st main gear 2nd-Ath main gear End play mm (in) (0.18 - 0.31 (0.0071 - 0.0122) 0.20 - 0.90 (0.0079 - 0.0118) @ Ifend play is not within the specified limit, disassemble and check the parts. 2. Remove mainshaft rear bearing snap ring, C-ring holder and C-rings. 3. Remove mainshaft bearing and spacer. MT-48REPAIR FOR COMPONENT PARTS oor 26 Mainshaft and Gears (Cont'd) 4. Remove Sth main gear. 5, Remove 4th main gear, 4th gear bushing and steel ball eS in main gear | @ Take care not to lose steel ball. - Bushing 6. Remove 3rd & 4th synchronizer and 3rd main gear. MT-49REFAIN FUN LUMPUNENT FANT Mainshaft and Gears (Cont'd) 7. Remove 2nd & 3rd bushing and 2nd main gear. © Take care not to lose the steel ball. no & sha gear— treshing 2nd gear Stee bal I sure & Remove tst & 2nd synchronizer hub and 1st main gear. INSPECTION Gear and shaft © Check shaft for cracks, wear or bending, Check gears for excessive wear, chips or cracks. MT-50sraceetcon \ verre Baul rine to ear clearance ‘sra0031000 Synchronizer sre seacens Se Mainshaft and Gears (Cont'd) Synchronizer © Check spline portion of coupling sleeves, hubs and gears for wear or cracks. ® Check baulk rings for cracks or deformation Check insert springs tor deformation. © Measure clearance between baulk ring and gear. Clearance between baulk rings and gears, for 1st and th gear only: Standard 4.0 - 1.35 mm (0.0394 - 0.0531 in) Wear limit 0.7 mm (0.028 in) ® 2nd and 3rd gears have inner and outer baulk rings and so have different measurements. @ Measure wear of 2nd and 3rd baulk ring Place baulk rings in position on synchronizer cone. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions "A" and “B Standard: A 0.7 - 0.9 mm (0.028 - 0.035 in) B_ 0.6 - 1.1 mm (0.024 - 0.043 in) Wear limit: 0.2 mm (0.008 in) ©. If dimension “A" or “B" is smaller than the wear limit replace baulk ring MT-51a \—syncnronizer cone suseeza| 2 Na WS ia jet22462000 sureesa) Bearing © Make sure bearings roll freely and are tree trom noise, cracks, pitting or wear The mainshatt front bearing cannot be re-used. It must be replaced once removed. ASSEMBLY 1. Install tst gear needle bearing, 1st main gear and haulk ring 2. Press on tst & 2nd synchronizer hub. MT-52a KEPAIK FOR COMPONENT PARTS 2nd main eer moorscn Mainshaft and Gears (Cont'd) Ensure correct fitting of 1st & 2nd synchronizer hub. 3. Install 2nd synchronizer cone, outer & inner baulk ring and ‘st & 2nd coupling sleeve. Install steel ball, 2nd main gear, 2nd & 3rd bushing, oll to 2nd & 3rd bushing before installing it. urpose grease lo steel ball before installi 2nd & 3rd bushing has a groove in which steel ball fi MT-53sn main ou xd main ‘ear our Stee! bat Mainshaft and Gears (Cont'd) 5, Install 91d main gear, synchronizer cone, outer & inner baulk ring. 6. Press on 3rd & 4th synchronizer hub. @ Ensure correct fitting of 3rd & 4th synchronizer hub. 7. Install 3rd & 4th coupling sleeve and 4th baulk ring. Install steel ball, 4th bushing and 4th main gear Apply multi-purpose grease to steel ball before i 4th bushing has a groove in which steel ball fits. MT-54KEPAIN FUN LUMFUNENT FANID Mainshaft and Gears (Cont'd) 9." Press on Sth main gear. surg i 10. Solect propor mainshaft bearing spacer to give correct bearing distance. /-—Mainshat rear bearing Bearing distance “C”: ae | 230.15 - 230.25 mm (9.0610 - 9.0649 in) aT 1 | Spacers avalabl | |) Thickness mm (in) Part number | __ 18.91 (07448) 2847-50300 I | 18.98 (0.7472) 32947-50401 | surea| 49.05 (0.7600) 32347 60302 —— 19.12 (07826) 32347-90109 19:19 (07555) 32347-5004 19.26 (0.7588) 52947-5005 12133 (07610) 32347-5008, 12.40 (0.7698) | 30347-60407 19.47 (0.7668) 32347-8008 sur MT-55Mainshaft and Gears (Cont'd) 11, Press on mainshaft rear bearing. ‘sta77so000 ' x soe pr cag mca om 2 Oring hoiter | Allowable clearance of groove: Bearing Thickness ram (in) T Part number | surerea 4.59 (0.1807) 32348-50402 ~ 4.66 (0.1835) 32348-5003 13. Install C-ring holder and snap ring, 14. Measure gear end play as the final check — Refer to “Disassembly”. ring ura] MT-56HEPAIN FUN VLUMPUNEN! FANIS Final Drive DISASSEMBLY 1. Remove final gear. 2. Remove speedometer drive gear by cutting it. 3. Press out differential side bearings. © Be careful not to mix up the right and left bearings. 4, Drive out retaining pin and draw out pinion mate shaft 5. Kemove pinion mate gears and side gears. INSPECTION Gear, washer, shaft and case © Check mating surfaces of differential case, side gears and pinion mate gears. @ Check washers for wear. Bearing @ Make sure bearings roll freely and are free from noise. cracks, pitting or wear. ® When replacing tapered roller bearing, replace outer and Inner race as a set. ASSEMBLY \ 1, Attach side gear thrust washers to side gears, then install pinion mate washers and pinion mate gears in place MT-57| surosr| 7 «38107700 Final Drive (Cont'd) 2, Insert pinion mate shat © When inserting, be careful not to damage pinion mate thrust washers. 3. Measure clearance between side gear and differential case with washers following the procedure below: a. Set Tool and dial indicator on side gear. b, Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side years. Clearance between side gear and differential case with washers: 0.4 - 0.2 mm (0.004 - 0.008 in) ©. If not within specification, adjust clearance by changing thickness of side gear thrust washers Side gear thrust washer: Refer to S.D.S. tnstall retaining pin Make sure that retaining pin is flush with case. MT-58REPAIR FOR COMPONENT PARTS RSSF32A, Final Drive (Cont'd) | 5. Install final gear. © Apply locking sealant to final gear fixing bolts before installing them. 6. Install speedometer drive gear. surooos 7. Pross on differential side bearings. Shift Control Components F INSPECTION | ® Check contact surface and sliding surface for wear, scratches, projections or other damage. Shift fork end shifter cap MT-59REPAIR FOR COMPUNENI PAKIS: Lngersen Shift Control Components (Cont'd) Reverse brake cam, Striking lever ADJUSTMENT OF INPUT SHAFT BRAKING MECHANISM 1, _ Install striking lever & rod, striking Interlock assembly and control bracket on clutch housing exactly. © When installing contro! bracket on clutch hot protrusion beneath bracket is correctly seated. ing, assure Measure maximum height "H" while shifting from neutral to reverse position. Maximum height “HY 67.38 - 67.86 mm (2.6528 - 2.6716 in) Lu Me Conta racxer (© Os | reverse brake cam Striking lover | surat] MT-60Striking lever REPAIR FOR COMPONENT PARTS Reverse brake cam urea | j Shift Control Components (Cont'd) 8, Measure clearance ““G” between reverse brake cam and striking lever while shifting to reverse position. Clearance “C”: 0.05 - 0.20 mm (0.0020 - 0.0079 in) i “H" or “C” is not within specification, replace the following parts as a set. @ Striking lever assembly © Striking interlock assembly (This includes reverse brake cam.) © Control bracket assembly Case Components Input shaft oil seal 1. Drive out input shatt oil seal, 2. Install input shaft oil seal ‘© Apply multi-purpose grease to seal lip of oil seal before installing. Input shaft rear bearing 1. Remove welch plug from transmission case. MT-64sur70s6) ‘Case Components (Cont'd) 2. Remove input shaft rear bearing by tapping it from welch plug hole. 3. Install welch plug. © Apply recommended sealant to mating surface of transmis- sion case. 4. Install input shaft rear bearing. Mainshaft front bearing and oll channel 1. Remove mainshatt front bearing retainer. 2, Remove mainshatt front bearing. 3, Remove oil channel. MT-62REPAIR FOR COMPONENT PARTS eee Case Components (Cont'd) 4. Install oil channel. Toward Ensure that oil groove in oil channel always faces toward a + oil pocket when installing it on clutch housing. Oi groove | sue 5. Install mainshatt front bearing | 6. Install mainshatt front bearing retainer. Apply locking sealant to thread of sorew before installation. MT-63suas Differential Side Bearing Preload any of the following parts are replaced, adjust differential side bearing preload. © Differential case © Differential side bearing © Clutch housing © Transmission case 1, Remove differential side bearing outer race (transmission case side) and shim. Reinstall differential side bearing outer race without shim. install final drive assembly on clutch housing Install transmission case on clutch housing Tighten transmission case fixing bolts to the specified torque. e nen 5. Set dial indicator on front end of differential case 6. Insert Too! ali the way into differential side gear. /, Move Tool up and down and measure dial indicator detiec- tion. ©. Select shim considering bearing preload ial indicator deflection | Specified bearing preload Suitable shim thicknes: Differential side bearing adjusting shims and preload: Refer to S.D.S. Bearing preloa 0.25 - 0.30 mm (0.0098 - 0.0118 in) 9, Install selected shim and differential side bearing outer race. 40. Check differential side bearing turning torque. Install final drive assembly on clutch housing, Install transmission case on clutch housing @ Tighten transmission case fixing bolts to the specified torque. op MT-64ADJUSTMENT RSSF32A Differential Side Bearing Preload (Cont'd) c, Measure turning torque of final drive assembly. Turning torque of tinal drive assembly (New bearing): 2.9 - 6.9 N-m (80 - 70 kg-cm, 26 - G1 in-tb) When old bearing is used again, turning torque will be tly loss than the above. © Make sure torque in close to the specified range. © Changes in turning torque of final drive assembly per revolution should be within 1.0 N'm (10 kg-cm, 8.7 in-Ib) without MT-65_ Cellophane toe A ~ Swriking roa Shitt check bat Cheek bal ao. it seal eck PUB Reverse check pring Yen suse suaecas) Install striking rod, lever and interlock ¢ When inserting striking rod into clutch housing, tape edges of striking rod to avold damaging oll seal lip. 2. Install reverse check sleeve assembly 3. Install check balls, reverse check spring and check plug. 4. Check reverse check force. Reverse check force: 4.9 - 7.4 Nem (50 - 75 kg-cm, 43 - 65 in-Ib) © if not within specification, select another check plug having a different length and reinstall it, Available reverse check plug Thickness mm tin) Pact number 71 0.200) ‘set0-wou02 16 (0903) 32188-MBO03 83 (0327) 32188-8001" 89 (0.360) 32188-M6004 “Standard size check plug 5. Install selected reverse check plug Apply locking sealant to thread of plug before installing it. 6. Install check ball plug, shift check ball and check spring. 7. Install oil pocket, MT-66sure] surr7| 8, Install gear components onto clutch housing, a. Install final drive assembly. b. Install input shaft assembly with bearing retainer, main- shaft assembly and reverse idler gear. 2 Be careful not ta damage oil seal lip with splines of input shatt while shaft is being inserted into clutch housing. © Be careful not to damage oil channel when inserting mainshaft into clutch housing. ¢. Install input shatt front bearing retainer. 9. Apply grease to shifter caps, then install it to control bracket. Install contro! bracket with ist & 2nd shift fork. @ When installing contro! bracket on clutch housing, ensure protrusion beneath bracket is correctly seated. 10. Install 3rd & 4th and 5th shift forks. MT-6711. Insert fork shaft © Apply multi-purpose grease to support spring before in- stalling. 12. Install reverse idler spacer. sursee 13. Apply recommended sealant to mating surface of clutch housing ] 14, Install transmission case on clutch housing. 16. Install mainshatt tront bearing snap ring. MT-6816. Check mainshatt bearing end play. Mainshaft bearing end play: 0 0.1 mm (0 - 0.004 in) © Make sure that bearing is properly seated. If not, tap main shaft end with a rubber hammer © If not within specification, select another case cover having a different thickness. Available case covers: Refer to S. 17. Install O-ring and case cover on transmission case. Apply recommended sealant to mating surface of transmission case. MT-69Case Components MT-70MAJUH UVERMAUL 8 8e6eae Gear Components — 4WD his-21 (18-24, 12-15) g® Gees 7-427 -wy a a 4-5 (04-05,29- 39> oe (te - 192 (120-195, 87 - 9) ‘Anply aeor oil to gears. shits, syschronizere land bearings when sssembing. r Nem team) 1 Select proper hcxnoss. «Pay atonton tits ect BE A005 recommenced sextant INssan genuine par: KPSIO-90250 or equivalent, sursera @OOSECSGI@HSHQHO Thrust washer Pinion mate gear Pinion mate shaft ide gear ‘Thrust washer Insert spring 2nd bauik ring Snap ring 2nd main goar ard main gear 4th input gear Input shaft thrust washer Thrust washer ring ‘tn input gear ‘5th baulk ring Thnust waster ® Coupling stweve ® aw main gear Needle bearing @ Insert spring @ sth main gear Reverse idler goar B Reverse baulk ring @ Snap ring Reverse idler gear @ Reverse synchronizer cane @ Thrust washer Thrust washer @ 5th synchronizer hub 4 Mainshatt rear bearina Reverse idler shaft @® Input shait rear bearing @ Mainshatt bearing adjusting Input shatt front bearing @ Input shatt bearing adjusting shim Input shatt shim 48 Differential side bearing 83rd input gear @ Mainshatttront bearing @ Ditterentat case Sra bauik ring @ Mainshat © Oiterential case 3rd & 4th synchronizer hub @ t8t main gear @ Viecous coupting Snap ring @ Ast alk ring @ Final gear Coupling sleeve ® 1st & 2nd synchronizer hub @ Ditforential side bearing Insert spring ® Reverse main gear (Coupling © Differential side bearing ‘ah baulk ring sieeve} adjusting shim @ @ ® s e ® ® ® @ ® MT-71Shift Control Components “tuopnsnoe 20 (¢SZCO-OL ay "Nd sIuN6 Ue) 1U=}es popueUAHOSe day Ob ie ase mn Moni Hob uoRAB Any tary ‘wt9) we = Eo) Ke ee (ou zvez sy) sen tene et EL fs pas torn TA SS . _/ wD ~ —_ ee. ? Cam ol ow ay soay eae Sanwa! \ ped owmey ~~ i monsepmens ZY (ob-ze ez-e ze atE) tude pur wa 08 ae Yo} 148 pug 19 38- ‘yos 30 peas -zee-en Cus ooinny—F tod mannine ee MT-72DISASSEMBLY MDOFQUA crete EaadhIR 1, Before removing transmission case, remove bolts and plugs as shown left. 2. Remove transmission case. 3. Remove position switch. 4, Mesh 4th gear, and then remove reverse idler shaft and reverse idler gear 5. Pull out retaining pin from clutch housing. 6. Remove reverse lever spring and reverse lock spring from reverse lever assembly. l sure MT-73,7. Remove reverse arm shaft while rotating it, 8 Remove reverse lever assembly. 9. Remove Sth & reverse check piug, spring and ball. 10. Remove stopper rings and retaining pins from Sth & reverse and 3rd & 4th fork rods, 11. Remove Sth & reverse and 3rd & 4th fork rods. Then remove forks and brackets, 12, Remove both input and mainshatts with 1st & znd tork and fork rod as a sel | sue MT-74DISASSEMBLY RSSF50A 13, Remove final drive assembly. 14. Remove reverse check assembly 15. Remove retaining pin and detach the selector. 16. Remove plug for convenience in removing retaining pin which holds striking lever to striking rod. MT-75,17, Remove retaining pin and then withdraw striking lever and striking rod. MT-76REPAIR FOR COMPONENT PARTS RSSFS0A, 1 [rd and 4th input gear Inp 1 Mesure tre Semput ge enapey | DIS: Gea Measure Me - | surest ut Shaft and Gears ASSEMBLY Betore disassembly, check 3rd, 4th and Sth input gear end plays. rend play Gears End play mm (ia) 3rd input gear 023 - 0.49 (0.0081 - 0.0768) 4th input gear 025 - 0.55 (0.0088 - 0.0217), Sth input gear 0:23 - 0.48 (0.0081 - 0.0189) 2 3 4, If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring and thrust washer — Refer to "ASSEMBLY" Remove input shaft rear bearing. Hemove bth & reverse synchronizer and 5th input gear. Remove thrust washer ring, thrust washers and 4th input gear. MT-77HEPAIK FUH GUMPUNENI PAKIS: Leet wun | Input Shaft and Gears (Cont'd) 5. Remove snap ring 6 Remove 3rd & 4th synchronizer and 3rd input gear. 7. Romove input shaft front bearing. INSPECTION Gear and shaft © Check shaft for cracks, wear or bending. © Check gears for excessive wear, chips or cracks, ‘Synchronizer © Check spline portion of coupling sleeves, hubs anu years for wear or cracks. © Chock baulk rings for oracks or deformation. @ Check insert springs for wear or deformation MT-78REPAIR FOR COMPONENT PARTS |_RSSFSOA Input Shaft and Gears (Cont'd) — ©) Measure clearance between baulk ring and gear. (4th and Beutk ring to sth) ser deoranee Clearance between baulk ring and gear: Standard 4.0 - 1.35 mm (0.0394 - 0.0531 in) Wear limit 0.7 mm (0.028 in) Measure wear of reverse hauilk ring a, Place reverse baulk ring on Tool and then place reverse synchronizer cone on reverse baulk ring. Make sure projection of synchronizer cone is positioned ‘over the recess on suitable bearing puller. b. While holding reverse synchronizer cone against reverse baulk ring as firmly as possible, measure dimension “A” with dial indicator. u = | | | | | Wear limit: 1.2 mm (0.047 in) Dial indiestoe | syneheonizee\ LS aie ting ©. If dimension “A” is smaller than the wear limit, replace vaulk ring Bearing ® Make sure bearings roll freely and are free from noise, cracks, pitting or wear. ASSEMBLY MT-79'B is longer than “A suas Input sett | Pichi 4th input gest For 3rd & 4th synchronizer (98) Input Shaft and Gears (Cont'd) 1 Place inserts in three grooves un coupling sleeve (3rd & 4th synchronizer), Install 3rd input gear and 3rd baulk ring, Press on 3rd & 4th synchronizer hub. Pay attention to its direction. Select proper snap ring of 3rd & 4th synchronizer hub to minimize clearance of groove, and then install it. Allowable clearance of groove: 0 0.1 mm (0 - 0.004 in) Snap ring of 3rd & 4th synchronizer hub: Refer to S.1 Install 4th input gear. Select proper thrust washers to minimize clearance of groove, Then install them and thrust washer ring. Allowable clearance of groove: 0 - 0.06 mm (0 - 0.0024 in) Input shaft thrust washer: Refer to S.D.S. Install 5th & reverse synchronizer assembly. Hook insert springs on reverse baulk ring. MT-80REPAIR FOR COMPONENT PARTS RSSFSOA Input Shaft and Gears (Cont'd) b. Install insert springs with reverse baulk ring onto coupling sleeve, ‘© Pay attention to position of insert springs. c. Place 5th baulk ring on 5th input gear. 4. Install reverse synchronizer cone on reverse baulk ring, Place reverse synchronizer assembly on Sth input gear. Mesh recesses of Sth input gear with projections of reverse synchronizer cone, © Put insert spring mounts on reverse bauik ring upon those on 8th baulk ring. Sth input gee avareneynehronizar l suraae se Teo nnsen 2d input gear {Press on Sth & reverse synchronizer assembly with Sth input gear. Sih input ge y If 8. Install input shaft front and rear bearings. 9. Measure gear end play as the final check — Refer to "DISASSEMBLY ~~ sraveoa000 suaraoe) MT-81REPAIR FOR COMPONENT PARTS. RISSFSOA Fst and Znd main 9687 Nessa 1 ‘Ist main gear end pie End play gear ena ploy RSS sucrose Mainshaft and Gears DISASSEMBLY 1. Before disassembly, check 1st and 2nd main gear end plays. Gear end play Gears End play mm (in) ast main gear (0.23 - 0.43 (0.0091 - 0.0168) ‘2nd main gear It not within specification, disassemble and check contact surface of gear, shaft and nub. Then check clearance of snap ring — Refer to “ASSEMBLY”. Press out mainshaft rear bearing. 3. Remove thrust washer and snap ring, 4. Press out 5th main gear and 4th main gear. 9, Press out 3rd main gear and 2nd main gear. MT-82Mainshaft and Gears (Cont'd) 7 3 | 6. Remove snap ring surosr Cc 7. Remove 1st & 2nd synchronizer hub and 1st main gear. 8, Remove mainshatt front bearing 8722730000 INSPECTION Gear and shaft @ Check shatt for cracks, wear or bending. @ Check gears for excessive wear, chips or cracks. Synchronizer @ Check spline partion of coupling sleeves, hubs and gears for wear or cracks. @ Check baulk rings for cracks or deformation. Check insert springs for deformation. MT-83Mainshaft and Gears (Cont'd) @ Measure clearance between baulk ring and gear (1st). | Bautk ring to Clearance between baulk ring and gear: 900" clearance ‘Standard 1.0 - 1.35 mm (0.0394 - 0.0531 in) | Wear limit | 0.7 mm (0.028 in) @ Measure wear of 2nd baulk rings. Place baulk rings in position on synchronizer cone. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions "A" and "B" Standard: ‘A 0.6 - 0.8 mm (0.024 - 0.031 in) B_ 0.6 - 1.1 mm (0.024 - 0.043 in) Wear i 0.2 mm (0.008 in) c. If dimension “A” or "B" is smaller than the wear limit, replace baulk ring. ve ‘5730031000 synenronize: | | tar bau rng £28 |sro00s1008 gf ff \\ I Symehroniaer cone MT-84REPAIR FOR COMPONENT PARTS LHoarsvAa i teat synehronizer hub =e | og OE... | if ~~ Outer beulk ring ~ Yet Be Dod ca Mainshaft and Gears (Cont'd) Bearing @ Make sure bearings roll freely and are tree {rom noise, cracks, pitting or wear © When replacing tapered roller bearing, replace outer and inner race as a set. ASSEMBLY 1. Press on 1st main gear, 1st baulk ring and 1st & 2nd synchronizer hub, © Pay attention to direction of Ist & 2nd synchronizer hub. 2. Select proper snap ring of 1st & 2nd synchronizer hub to mininize clearance of groove and then install il Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Snap ring of tst & 2nd synchronizer hub: Refer to S.D.S. 3. Install 2nd synchronizer cone, inner & outer baulk rings, Insert springs and ist & 2nd coupling sleeve, 4, Install 2nd main gear. ¢ Ensure four protrusions of 2nd synchronizer cone are set in holes of 2nd main gear. MT-85722452000 9722462000 Mainshaft and Gears (Cont'd) 5. Press on 3rd main gear. 6 Press on 4th main gear. Press on Sth main gear. Select proper snap ring of Sth main gear to minimize clearance of groove and then install it, Allowable clearance of groove: 0 - 0.15 mm (0 - 0.0089 in) Snap ring of Sth main gear: Refer to S.D.S. 9. Press on thrust washer and press on mainshalt rear bearing 10. Press on mainshaft front bearing. 11, Measure gear end play as the final check — Refer to “Disassembly”. MT-86REPAIR FOR COMPONENT PARTS D9r9UA 15056) = A — 1 =] Final Drive (Center differential) DISASSEMBLY 1. Remove final gear. 2. Press out differential side bearing 3. Remove viscous coupling. 4, Disassemble differential case. MT-87,Viscous count aa pling Final Drive (Center differential) (Cont'd) INSPECTION Viscous coupling © Check case for cracks. © Check silicone oil for leakage. Gear, washer, shaft and case © Check mating surfaces of differential case, viscous cou- pling, side gear and pinion mate gear. © Check washers for wear. Bearing Make sure bearings roll treely and are tree trom noise, cracks, pitting or wear When replacing tapered roller bearing, replace outer and inner race asa set. ASSEMBLY 1. Install side gear without thrust washers, pinion mate shaft and pinion mate gear. 2. Install differential case LH. and RH MT-88HEPAIN FUN LUMPUNENI FANIS Lise : Final Drive (Center differential) (Cont'd) — LM. side gear — 3. Measure clearance between side gear and viscous cou- pling following the procedure. a re dimension A between side gear and differential b. Measure dimension B and C of viscous coupling Clearance between side gear and viscous coupling with washer (A-B + C): 0.03 - 0.14 mm (0.0012 - 0.0055 in) ©. Select side gear thrust washer so clearance between side gear and viscous coupling is within specifications. Side gear thrust washer: Refer to S.DS. — RH. side gear — 3. Measure clearance between side gear and differential case following the procedure. a. Install LH. side gear thrust washer as priority sclocted and ingtall differential caso assembly, b. Set dial indicator on side gear c. Move R.H. side gear up and down to measure dial indicator detlection. Clearance between side gear and differential case with washer 0.03 - 0.14 mm (0.0012 - 0.0055 in} G. Select side gear thrust washer so clearance between side gear and differential case is within specifications. Side gear thrust washer: Refer to §.D.S. 4, Install viscous coupling and final gear. MT-89.Final Drive (Center differential) (Cont'd) 5. Press on differential side bearings Shift Control Components INSPECTION © Check contact surface and sliding surface for wear, scratches, projections or other damage. Case Components REMOVAL AND INSTALLATION Input shaft oil seal ‘© Apply multi-purpose grease to seal lip of oil seal before installing. * sumer} MT-90REPAIR FOR COMPONENT PARTS ‘Case Components (Cont'd) Mainshatt front bearing outer race Mainshaft rear bearing outer race — Refer to “ADJUSTMENT”. Differential side bearing outer race — Refer to “ADJUSTMENT”. MT-91Input Shaft End Play and Differential Side Bearing Preload If any of the following parts are replaced, adjust input shaft end play. © Input shaft Input chatt bearing © Clutch housing © Transmission case It any of the following parts are replaced, adjust differential side bearing preload, ¢ Differential ca: Differential side bearing Clutch housing Transmission case eee 1. Remove differential side bearing outer race (transmission case side) and shim(s) 2. Reinstall differential side bearing outer race without shim(s). 3, Install input shaft and final drive assembly on clutch hous- ing 4, Install transmission case without input shaft bearing shim(s), Then tighten it to the specified torque. 5. Using the following procedures, measure clearance be- tween bearings and transmission case. © Differential side a. Attach dial indicator. If clamp diameter of dial indicator is too small or too large, attach dial indicator using @ magnetic, stand MT-92ADJUSTMENT LRsse50A_] Input Shaft End Play and Differential Side Bearing Preload (Cont'd) ky38106600 sursis) b. Insert Too! all the way into differential side gear. Move Too! up and down and measure dial indicalor deflection. © Input shaft side a. Set dial indicator un end of input shaft b. Move input shaft up and down and measure dial indicator deflection. 6. Select shims with proper thickness with SOS table as a guide. 7. Install selected differential side bearing adjusting shim and differential side bearing outer race Check differential side bearing turning torque. Install final drive assembly on clutch housing. Install transmission case on clutch housing, Tighten transmission case fixing bolts to the specified torque. ©. Measure turning torque of final drive assembly, Turning torque of final drive assembly (Now bear 4.9 - 7.8 Nem (50 - 80 kg-em, 43 - 69 in-Ib) © When old bearing is used again, turning torque will be slightly less than the above. © Make sure torque is close to the spi d range. Mainshaft Bearing Preload It any of the following parts are replaced, adjust mainshaft bearing preload. © Mainshatt @ Mainshatt bearings @ Clutch housing @ Transmission case MT-93vf S330611000 5130621000- —* Nore than rn 1.97 in) Mainshaft Bearing Preload (Contd) 1 10 1" Remove mainshaft rear bearing outer race and shim(s) Reinstall mainshatt rear bearing outer race without shims. Clean mating surfaces of clutch housing and transmission case with solvent. Install mainshaft and mainshatt front bearing outer race into transmission case. lurn mainshatt while holding bearing outer race so that bearings are properly seated. Put straightedge [width must be more than 50 mm (1.97 in)] on transmission case, and measure the distance from upper surface of straightedge to surface of the bearing outer race using a depth micrometer. Measure at three places on bearing outer race, and take the averag Determine dimension A to be used by the following equa- tion Dimension A = Width of straightedge — measured distance Measure the distance from mating surface of clutch housing to portion with which mainshatt front bearing outer race is to be mated. Measure at three places on the portion, and take the averat Dimension B = Measured distance Determine dimension C to be used by the following equa- tion, C-B-A Determine total thickness of shims with S.D.S. table as a guide. Install selected mainshatt bearing adjusting shim and main- shaft bearing outer race. Check total turning torque after assembly — Refer to “ASSEMBLY” MT-94ASSEMBLY Install striking lever and striking 10d. Install selector and retaining pin Install reverse gate assembly, Install final drive assembly. Install input shaft and mainshaft with 1st & 2nd shift fork assembly. Be careful not to damage input att oil seal, suraes| MT-956. Install interlock balis and plunger. 7 Install rd & 4th shift fork and bracket, then install ard & 4th shift rod, stopper ring and retaining pin. 8. Install intorlock balls, 9. Install Sth shift fork and bracket, then install shift rod, stopper ring and retaining pin. MT-9610. 1. ASSEMBLY Install Sth & reverse check plug, spring and ball Reverse lever assembly Install reverse lock spring on Sth & reverse bracket. Pay attention to its direction. Install check ball and reverse lever spring on reverse lever assembly, Apply multi-purpose grease to check ball. Pay attention to direction of reverse lever spring. Install reverse lever assembly on clutch housing Install reverse arm shaft and retaining pin. MT-97Uj Ta, DT e. Hook reverse lock spring and reverse lever spring on reverse lever assembly. [Mest 4th gear, then install reverse idler gear and shall © Pay attention to direction of tapped hole. 12. Place magnet on clutch housing. 14, It bearing preload was adjusted, install selected shim(s) into ransmission case. © To ald In Installation of transmission case, place shift selector in the 1st and 2nd shift bracket or between 1st and 2nd bracket and ard and 4th bracket. 14. Apply sealant to mating surface of transmission case and inetall it 15. Install position switch, 16. Apply sealant to threads of check plugs. Install balls, springs and plugs. 17. After assembly, check that you can shift into each gear smoothly, MT-98ASSEMBLY LASSFS0A_] 18, Measure total turning torque. Total turning torque (New bearing): 8.8 - 21.6 Nem (90 - 220 kg-cm, 78 - 191 in-Ib) When old bearing is used again, preload will be slightly loss than the above. Make sure torque is close to the specified range suroa| MT-99General Specifications TRANSAXLE = 2ND 400 @x008,] orroos | an Engine e100 | corr [SA808.] anseos | aniooe | ozo | snaooe | cates | sreaver Transaxle mode! fnaraoa SFO ASSESIA SSFaeA | RaGFaTA | RSSFSOA Number of speeds 4 S Synchromesh ype Warr Shit patra a 1 3 2 4 8 2 4 =F Gear [ict 3303 ‘aa03 | 3309 | aoe | oss | asc | 9060 | som | aces ratio ana 955 taco | 19s | sae | 1820 | 1255 | 1820 | 195s | 1080 ura tae vas | ze | sao | ves | v2 | 1266 | 126 | tare an ame | oa | oom | ogc | ars | osca | oss | oma | case si - ass | 0700 | 0756 | os | o7se | o7se | 0756 | 0740 Reverse aur | sav | age | oar | ae | sar | sso | sar | saee Tambor [loput [is «| | s | «* | «| | «| os | « otteetn Joear Lona ” » | | m | oom |» | om | om | mo are = wa [om |» |= | aw | | w | | | wm fe ef ole fw] «|» |» | » on e | ele] e |e] 2] 2] Main Ist 30 30 50 2 | 48 30 a 50 46 pee Jana 6 eo [of eleloe lela le | 3rd 38 36 6 | 6 38 6) 2 ns = v law | aw | ow | o | ow |» | 5th - a“ 3 4 e) | Ee) uw | oe 7 fevers ier gear | 5 Cow [aes 35-37 teapecy tm 0 0 soar 20,60 Jevo-e| 2% | 82 Ot enpeaty sae ana a0) 290) i fom eee va FINAL GEAR —, — —— jn es | com | SA998:| GRIDS | arcs | como | anzooe | SAIES | aacooer ae arans | (eno) | A90& ‘9R2008 | wo) = Final gear rato aan [sro | aser | ase | rer | so | ave | ass | ans vumaer [EtalocerPinen | rar | rane | rons [one | rane [reo [rv | rai | ean Yocm | Side cearPnon : mate oar | MT-100SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment RN4F30A, RS5F30A, RSSF31A Input shaft 5th synchronizer hub GEAR END PLAY play fm (in) (031 (0.007i - 00123) 3 2nd main gear 0.20- 0.30 (0.0079 - 0.0118, rd main gear | 0200.30 0.0079 - 0.0118) 44h main gear 0:20-0:90 (0.0079 - 00118), St input gear 0-18-03: (0.0071 - 00122) CLEARANCE BETWEEN BAULK RING AND GEAR Allowable clearance “Thiekness men (i "2.00 (00787), 205 (0.0807) 2.10 00827), 2.15 00946) 2.20 (0.0066), 22 (a.u886) 2:90 (0.0906), AVAILABLE C-RINGS Mainshaft C-ring |-speed models ‘SaaT MGB | 30311-48813 sear MaBt4 seatt-Moo%e sai ween sear t-Mes18 8-4 mm (9 nnd inp Part number mn in mm tn Part number ‘aaa osama) | 7aunwanne 8,70 (0.1487) | e948 e001 377 (aaa) | s2s4e-wao0e 364 (0.512) | 32048-Ma00a 391 (01839) | 2348-we00e 398 (0.1867) | 2948-18005 “com (9 v6nay | shanna 4412 (0.1620) | 32048 too? 49.1050) | 32046-8008 | 425 0.1677) | s2a48-me009 433 0.1705) | 32340-8010 440 (0.1732) | ses4e-eo11 Unit: tn) — Standara Wear limit 10-138 A 1s 200 Cee 07 (0028) 40-138 aoe ad 84h ens 07 (00201 " ae 7 (0028) sr (0.0394 0053) aK AVAILABLE CHECK PLUGS Reverse check plug Reverse check turning torque (At striking rod) Nim igeem, ino) 187-226 “speed mocels (180 - 290, 199 - 200) aa-Ta ‘peed models “a 7 5-speed models 8.3 (0.327) 2186-800" Allowable clearance (0 - 0.1 mm (0 - 0.004 in) 71020 2188-002 TmickMeSS | sy amnar P Thickness |e nae 77 0308 coven mn 20,0380 sete tse us oie | Save wste | 0c | Sew Sania weckae 37000457) | sewewseot | 1 0680) | semen arr (ors) | sewers | 28 oer | seus.wen AVAILABLE SNAP RINGS 3.84 (0.1512) | 32348-MeB03 || 4.39 (0.1705) | 92348-M8810 Input shaft front bearing er cotsns) | arseentssos |] aan (01790) | aoaae-matt see onsen | sewers |] ar re | sate were “Riovatie clearance 00 mm (00004 os oreen | sesomton [ aseceran | sexeees Theta Parinunber se oan sx Notes \s9(eos) sexo it8 145 0057) eezoso7 MT-101SENVIVE VAIA AN SF EUITIVAIIUNND (9.U.9.) Inspection and Adjustment (Cont'd) RNGF30A, RSSF30A, RSSF31A AVAILABLE WASHERS Mainshaft bearing adjusting shims Differential side gear thrust washer el Panne 9 GATEDE models 0:0 (0.0080 2157-000 “lowable clearance bal 0.15 (0.0058) sexsr-weoo1 able clearance between 01-02 mm Sie get and iferenta case ones ae) 020 (0.0078) s2137-B00e " 195 (0.0088) ‘ovarian Thickness mm fn) Part number 00 or) soa weno (075. 0.80 (00285 - 0.0318) 35a2e-021 | 035 0.0136) | sexsr-6e005 080-085 (0.0815 - 0.0395) sedae-n2n12 040 (vrs) sexs De wosss- Goss4) eens 0.48 (00177) se1s7-MB007 000-005 (0084 - 0.0376) seace ont | 080 (00197) 2137-8008 098 - 1.00 0374 - 0.0384 s8e2402118 poranenst 085 (0.0217) 22137-8000 0460 (0.0286 setareoro ‘® Except for GAT6DE models on 0.65 (0.0758) | sovaranoss ‘Mlowable clearance between 070 (00276) | esa? Meo%e 01-02 mm tide gear and diferental case cous eons ors (oe orator with washer ‘i y cee a 080 (0.818) sessment (076 - 081 (00299 - 0.0319) 38826-01m0 cee eens 081-96 ania - nome) snerecorna 190 (0.0364) aa 098 -0.91 e000 0.0068) | seratomne 195 (0.0374) 32157-MBOIT 1.00 0.0384) s2137-Me018 | 0.91 - 0.9 (0.0358 - 0.0378) soraeorMto AVAILABLE SHIMS — MAINSHAFT AND DIFFERENTIAL SIDE Differoniia! cide bea BEARING PRELOAD AND ADJUSTING eae] Snie “Thickness me O44 (00173) Bearing preload ‘48 (0.0189) ‘sa4s4-Neen01 este 0.86 (0.0220) 98454-69008 ~~ _| ran senns | ota ie 200 (09230) sease mtoos ‘nation | oreo | o2t-oa2 aston ates ASSFIOA (o.007s- 0000 | (o0094- or26) 0.88 (0.0268) | 8454-008 nesrna 018-027 020-025 072 (00285) | seast-neco? 0071 -a0105) | woure - vous) ae vise eos 080 (0.0015) 38454-8009 Turning torque (New bearing) sown ose oon) veuseanin ee 088 (0.096) arse sort inal arive only al ———n SG NGFaDA 20-78 39-123, SSEIOA (20-0, 17-60) | (40 125,95. 100 fae 20-78 39-187 (20-80,17-65) | (40- 10,95 122) MT-102SERVICE DATA AND SPECIFICATIONS (S.D.S. Inspection and Adjustment (Cont'd) RSSFADA GEAR END PLAY Gear End play mm (in) ist main gear [018-081 oor cote {nd main gear | 020-020 qranre -o0rsey {rd main gear 020-090 (0.0079 - 0.0118) 44 main gear 020-030 (0.9079 - 00118) 0.18 031 (0.0071 - 0.0120), Sth input gear CLEARANCE BETWEEN BAULK RING AND GEAR 1st, 4th, Sth baulk ring a 1100 135 (00306 0.0533) 07 (0.028) 2nd and 3rd baulk ring ou A ¥ ener baulk ving Syoctianizer cme Dimension Standare Wear limit a 7-08 (0.028 - 0.035) o 06-44 ome (0.024 - 0043) AVAILABLE REVERSE CHECK PLUGS AND CASE COVERS Reverse check plug 40-74Nm (50-75 kom, 43-65 in) Teverse check turning torgu [At striking oa) Length mm 03 (0327) 1 uz) eras. 17 (0303) sotes.6008 8910350) 2@e-ms004 *Saneare creak pug Case cover Thiexness mmf Part number 10.78 (0264) a 10.8 (04284) aeratsou0t 1088 104265) 2131-5002 1099 04300) sorstso ns 10.08 (94920) | sere sou0e 1.93 (046) | ee) MT-103AVAILABLE SNAP RINGS Input shaft front bearing tere wee Inspection and Adjustment (Cont'd) AVAILABLE SPACERS Mainshaft bearing adjusting spacer ‘Allowable clearance. —Thiekness mm fin "197 (asa) 1.38 (0.050%) 1.38 (0.0547) 145 (00871) (0-01 em (0 - 0.008 in) Part number "7 DO | 32208-8006 seve mou Input shaft 5th synchronizer hub Thickness mm (in) 200 (00787), 205 (0.0807) 2.10 0.0827), 2.15 0846) 2.20 (0.0886) 2.26 (0.0880), 2: (a9) I AVAILABLE C-RINGS ‘Allowable clearance: Thickness mm (in) 445 (0.752) 1459 (0.1780) 4.9 (0.1007) | 445 (01889) 473 (0.1862) 4.80 (0.1890) 487 (0.917) 4.94 (01948) (0-02 mm (0~ 0.004 in) Part number S291 t-Meer2 s2511-M8613 eareMaet | eart-Maets aearwears seattatoo1? caer (2-01 mm (0 0.004 in} Part number 3240-50100 | 92348.50.01 seo40-souoe 32948 90008, 25004 32048-5005 32948-60406 seme s0.07 TULL Rearing distance “C’ | cease Thickness mm (in) Pari number iar (o7aas) | seoar.s0s00 1898 (0.7472) 32347-5001 1105 (0.7500) s2s4r-soyoe 4919 (07598) soursnant 10.10 (07856) | ‘2047 5004 18.26 (0.7983) ses47couos 19:33 (07610) 32347-50405 19.40 (0.7628) 32347-50,07 19.47 (0.7865) 32347-50408 AVAILABLE WASHERS Differential side gear thrust washer Allowable clearance between side gear and differential case pe soe (oon -oom a anaes seeae 02311 (anaes) et) sexzeatie ones 8 seuzeans {0.0354 - 0.0374) meena 06-100 — (0.0376 - 0.0394) seazepenis MT-104 sures n)DENVILE UA AND OF EUITILATIUND (9. } Inspection and Adjustment (Cont'd) RSSFSZA INPUT SHAFT BRAKING MECHANISM Reverse brake cam met 1st & 2nd shiter Sting lever a contrat bracket (Os fitting surtace Reverse brake cam saris Maximum height “H" between the contro! bracket iting sur 6738.67.86 a in) AVAILABLE SHIMS — DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM Bearing preload Unit: mm Gnd Diterentiat side bearing 0.25 - 0.30 (0.0098 - 0.0176) Turning torque (New bearing) Unt Nom fhg-om, i | drive | 28-690 81) ao eee Differential side bearing adjusting shims Thickness mm fin} Reverse brake cam 7 String Yver-, i verge brake cam and ating | 95-020 lever | ¢o.0r20 - 0.0078) men tin) ‘baa 00373) 0.48 (0.0180) 28484 48001, 0.38 (0.0220) sese-eo0s 0.60 (0.0236) s5e.te008 0.54 (0.0252) s454.Ma005 0.68 j.0268) ‘38454-8006 0,72 (0.0289) 35454-98007 0.76 0.0299) 38454498008 an cosy astganne 0.84 fo.0901) | 8464 e010 0.66 (0.0340) easement: MT-105,Inspection and Adjustment (Cont'd) RSSFS0A GEAR END PLAY Gear end le ‘025-043 (0.0081 - 0.0169) (0.230.580.0081 - 0.0228) (0.23 0.48 (0.0081 - 0.0168), (0.25 0.55 (0.0088 - 0.0217) 0.28 0.48 (0.0081 - 0.0189) mi) Ist main gear 2nd main gear 3rd main gear 4th main gear Sih input gear CLEARANCE BETWEEN BAULK RING AND GEAR Ast, 3rd, 4th & Snd Unit: mm (in) Standard Wear limit vst cog 7 (0.928) 0.0394 - 0.9538) eee 4 10-195 gy oan a & 4tn (oasis | 97 008 sth pa 27 aR) (0.0394 - 0.0531) 2nd baulk ring Synchronizer cone ; val ] tner taut ring / in rr 8 ‘SMTBDES Dinension Standard Wear iit a | 28-08 (a0et- 0031) : 02 (000) > 06-43 (0024 0.04) Reverse baulk ring Unt mm in| Synenronizar cone — A _ Reverse bulk ing Bearing puller Dimension Wear tm A { 12 (0047) AVAILABLE SNAP RINGS 3rd & 4th synchronizer hub (At Input shaft) 0.16 mm (00.0089 in} 138 (0768) a) 200 (00787), 32269-03800 206 (0.0807 32289-00601 2.10 0827 szze-cne02 1st & 2nd synchronizer hub ‘Allowable clearance (0-01 eum (0 - 0.008 in) Thickness mm (io) Part number 1.95 (0.0768) 32260.08603 2m (aarary oeaenem 2.06 (0.0807), 0260 0201 2.10 (0.0827) se2es.03t02 sth main gear 15 mm (0+ 00068 In) “Fieknese mm in) an number 196 (00768) ‘2348-05600 2.08 (0.0807), 2048.05601 2.15 (0.0846) 82048-05602 2.25 (0.0886) 32348-05603 MT-106SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd) RSSFS0A AVAILABLE WASHERS. Input shaft thrust washer ‘Allowable clearance (0 0.08 mm (0 0.0028 i) Thickness mm (in) Part number “4500 (0.1772) 2276-03601 4525 (0.1781) sez78.03e02 4550 (0.170) sezre-oncos 4579 (01001) se278-03608 Differential side gear thrust washer AVAILABLE SHIMS — INPUT SHAFT END PLAY AND MAINSHAFT AND DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM Bearing preload and end play Unit mm fin) (098. nan anna - 0338) Turning torque (New bearing) Unit Nm (ho-em, in) Side gear and eitronal care ers aes {wseous coupling! with washer {0012-0055 inp Final dive 48-78 (50-60, 43-69) — Theknoss mm in) | Part aumber Teal 85-216 (00-200, 78- 181) | acakitany | otoe | 090-085 ‘geaze-s0Eo? Mainshaft bearing adjusting shims Lett side gear (00395 - 0.035) 085-090 ee “Thickness om (in) Part number fears cosy | Smenseeee oa woiEn 32100-08611 oy | tances oa ory soraecae 0.68 (0.008) 36726-56600 148 (oes) cr 0,72 (00288) 672455601 ise quar) ee Fight side gear ger oasis, seroe acon 0.56 (0.0020) seige-osen2 00 (0.0054) serausee3 060 (00228) 219803608 0.6 (0.0282), 2138-09604 068 (0.0288) 2199-0308 072 (0028 s219.03606 076 (00299 22199-02607 00 0.0010 22199-00000 1.20 0872) aziae00e19 MT-107SENVIVE VAIA ANY OF EUIFIVAIIUND (9.U.9.) Inspection and Adjustment (Cont'd) Table for selecting mainshaft bearing adjusting shim 08 042 046 050 ost 058 062 on. ov. om. 086 1.90 oo 108 a0 4 16 Dimension “ oar (aoe Bove) 038 (00:34 - 00150) ‘042 (00150 - 0.0768) 0.46 (00165 - 0.0781) 0.50 (00181 - 0.0197) 0.54 (00197 - 0.0213) 0.58 (0.0213 - 0.0228) 0.62 (0.0298 0.0748) 0.66 (202 0.0260) 0,70 (0.0280 - 0.0276) 0.4 vers - 0.0201) 0,78 (0.029% - 0.0307) 0.82 (0.0307 - 0.90325) 0.86 (0.0323 - 0.0338) 0.90 (0.0339 - 0.0354) 0.94 (asa - naz) 0.08 (00970 0.0386) +.02 (0.0386 - 0.0802) us (uuaue - 0817) 1.10 (0.0817 - 0.0839), 1.14 (0.0433 - 00849), 1.18 (0.0849 - 10465), 1.22 (0.0485 - 0.0880) 122. 1.26 (0.0480 - 0.0306) 1.28. 1.30 (0.0896 - 0.0512) 100-136 (00512 - 0.0c20) 138 142 16 1.38 (@0328 - puDss 1142 (0.0549 - 0.0558) 1.46 (0.0589 - 0.0575) 1.50 (0.0875 - 00591) Unit: mm fn) stable shirts) 060 (0.0288) 0.64 (o.cese) es (ouz6s) 0.72 (00283) 0.76 (0.0209), 0.80 (0.0318) 0.40 + 0.48 (00157 + 00173) as + 0.44 (00173 + 0.0173) 0.44 + 048 (00173 + 0.0180) 048 > 048 (00189 + 0.0189) 048 + ose wor + vue) 0.52 + 052 (00205 + 0.0205) 052 + 086 (00205 + 0.0220) 0.56 + 058 (00220 + 0.9220) 0.56 + 060 (00220 + 0.0236) fan + 60 (00236 + 0.0236) 0.80 + 0.64 (0.0206 + 0.0262), 0.68 + 0.04 o0ese + 0.0852) st = uss (woesz + 0.0288) 0.68 + 068 (0.0268 + 0.0268) 0.68 + 0,72 (0.0268 + 0.0289) 072 + 0,72 (00268 + 0.0285) 0.72 + 076 (00269 + 0.0298) 0,76 + 0.76 (00299 + 0.0286) 0.76 + 080 (00290 + 00315) 0.00 | 0.00 (00915 | 0.0015) a8 + 12000173 + 0.0872) 0.48 + 1.20 (00169 + 0.0472) 0.52 + 1.20 (00205 + 0.0472) 0.56 + 120 (00220 FSSFS0A 0.0472) Input shaft bearing adjusting shims Thickness mm (in) (0.40 (00187), 0.44 (0.0173), 0.48 (0.0189), 0.52 (00205) v6 (ouzeo) 0.60 (00236) 0.64 (0.0252) 0.68 (0.0268) 0.72 00209), 0.70 00298), 0.00 (0.0918), shim Dial indicator detection (0.65 - 0.69 (0.0286 - 00272) 0.69 - 0.73 (0.0272 - 0.0287) (0.78 0.77 (0.0287 - 0.0308) 077-081 (0303 - 0.0319) 0.81 - 0.85 (0.0310 - 0.0535) 0.05 - 0.09 (0.0336 - 0.0350) oxy - Us (aseU - vs) 0.99 - 0.97 (0.0366 - 0.0382) 0.97 - 1.0 (0.0382 - 0.0398) 1.01 - 1.05 (0.0998 - 0.0413) 1.05 - 1.09 0.0413 - 0.0420) 1.09 - 1.13 10.0429 - 0.0848) 1.13. 1.47 (004s - 0.0661) 17-121 (0.0468 0.0476) 121-125 (0.0478 - 0.0682) 1.25 1.20 (0.0492 - 0.0508) 1.29 1.29 (0.0508 - 0.0524) 1.33. 1.37 (0.0824 - 010838), 1.37 1.41 (0.0539 - 0.0585) 1.41 1.46 (0.0885 - 0.0571) 1.45 - 1.49 (0.0571 - 0.0887) 1.49 - 1.89 (0.0587 - 0.0802) 1158-157 (0.0002 - 0.0810) Loy - 181 (uuere- ous) 1161 - 165 (0.0684 - 0.0850) 1185 - 1.69 (0.0680 - 0.0885) MT-108 | oso oa oe 04 os os os oss 060 aw ost | ose oss on o7e 080 04 ost + Part number 32225-08600 82226-08601 32225-08602 seen see25He04 32225-08605 2225-00607 se22-00608 32225-00610 1.20 (0.0472) 92226 08611 Table for selecting input bearing adjusting ‘ni Gn) ‘Suitable shims) 054 (00252) 068 (0.0260) 072 (0.0288) 076 (00209) 0.80 (00318), + 0.44 ors + oa ouws +048 (00173 + 048 (00189 + 082 (00189 + 082 (0.0205 + 056 (0.0205 + 088 (n0200 + 080 (0.0000 + 080 (00230 + uss (woes + 064 (00252 068 (0.0252 + 0.68 (0.0268 + 0,72 (00068 + 072 (00283 + 076 (00289 + 076 (00288 0.0 (0.0815 + 12000173 0173) vows) 0.88) ores) 0.0205) 0.0208) 0220) 020) 00236) esa) 0.0282) 0.0268) 0.0268) 0.0285) 0.0283) 0.0286) 0.0288) wuss) 0.0815) 0.0472)SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd) [RSSF50A] Differential side bearing adjusting shims Table for selecting differential side bearing adjusting shim(s) Tekness mm 0) Fan number nit mm fa 0.36 (0.0142) | se7s0s6e00 Dial indicator detiection Suitable shim(s) (0.40 (0.0187) se7SS-S0801 0.47 - 0.51 (0.0185 - 0.0201) | 0.44 + 0.48 (0.0173 + 0.0189) 0.44 (0.0173) 38759-56602 081-055 (on201-a.0217) | 0.48 + 0.48 (0.0189 + 0.0189) (648 (0.0100) 98755-5808 0.85 - 0.60 (0.0217 - 0.0232) | 0.48 + 0.52 (0.0189 + 0.0205) ase mamas) 88753-56E04 0.59 - 0.63 (0.0282 - o.0248) | 0.52 + 0.52 (0.0205 + 0.0205) 156 (0.0200) e7s0.s6605 063-067 (0028 - vows) | use + usp (ue + vuZZH) 0.90 00239) 067-071 (0.0264 - 00280) | 086 + 0:86 (00220 + 0.0200) 088 0282) -syesneo) 071-075 (0.0280 00298) | 0.86 + 060 (00220 + 0.0236) 068 00268) 98759-58608 075-079 0.0285- 00311) | 060 + 060 (00296 + 0.0236) 172 (0.028) {8758-58609 079-089 00011-00227) | 0.60 + 066 (00295 + 0.0252) 076 (00299) 38758-50610 naa-on7 now7 oman | ast + 066 (00089 ~ 025%) 090 0.0318) ers Soe 087-008 0.0042 003s) | ost + 068 oc2se ~ 0.0259 ana (vonss) sarss.sne 9 091-099 00388-00974 | 0.68 + 060 00200 ~ 0.0208 088 00946) 8760 seE2 095-099 (00074-00390) | 088 + 072 00268 + 0.0283) 92 0362) seros-ste 14 0198-103 (00380-a9408) | 0.72 + 072 0.0283 + 0.0289) 108-107 (0.0406 0.0821) | 0.72 + 0.76 (00288 + 0.0299) 17-111 (00821-00497) | 0.76 + 076 (0.0280 + 0.0280) 115 (0.0487 -0.0853) | 0.76 + 0.80 (0.0298 + 0.0315) 119 (00asy-nnuaa | oan + nan nase + 0.0815) 119-120 0.0489 o088e) | 0.72 + 092 (oozes + 0.0362) 123-121 (0886 - 0.0800) | 076 + 0.82 (00288 + 0.0962) 127-131 0.0500- 0.0516) | 0.80 + 0.92 (00315 + 0.0362) MT-109_ AUTOMATIC TRANSAXLE SECTION A | CONTENTS PREPARATION PRECAUTIONS ON-VEHICLE SERVICE TROUBLE DIAGNOSES ELECTRICAL SYSTEM REMOVAL AND INSTALLAIION MAJOR OVERHAUL DISASSEMBLY REPAIR FOR COMPONENT PARTS ASSEMBLY A/T SHIFT LOCK SYSTEM SERVICE DATA AND SPECIFICATIONS (S.0.S.) When you read wiring diagrams: Read GI section, “HOW TO READ WIRING DIAGRAMS”. © See EL section, “POWER SUPPLY ROUTING” for power distribution circuit. aT 5 AT: 6 AT. 13 AT- 28 Ale 31 ATs 34 ATs 44 AT. 58 AT-129 AT-153, AT-169PREPARATION * Special tool or commercial equivalent Tool number Tool name '$T25088001 Oil pressure gauge set @ 125051001 Oit pressure gauge 8725052000 Hose 3 $725093000 Joint pipe 25054000 Adapter '$725055000 Adapter Description ee ° a SPECIAL SERVICE TOOLS ‘Measuring line pressure and gover- ror pressure ‘stavanany Puller Removing differential sida ail seal kuattasnnor Installing differential sie oil seal (Use with $735325000) 76 mm (2.99 in) b: 67 mm (2.64 in) di ssTasapsn00 Deitt Intalling differential sida all seal (Use with KV31103000) kevarioano | Clutch spring compres- \ $723540000° Pin punch va2107000" Pin punch Removing and installing cluteh return spring Removing and installing parking rod plate, manual plate and differential Pinion mate shaft retaining pins Installing throtle lever and manual shatt retaining pinsPREPARATION +: Spatial tool ar commercial equivalent Too! number Teoma Description STss06S00T Removing aierental sige bearing Diervntiat side bearing inner race puller set “ (8: 20.5 mom (1.422 i) dia, @ 793051001 | 1: 96 sans (1.59 i) a Patiae | Ww @ 733081000 | 7 Adapter @ van nS480 ‘© Removing output shaft bearing Puller outer race trom bearing retainer { Removing output gear bearing outer race from bearing retainer | 2 Removing idler gear bearing outer STar 18060 i > Removing idler gear ler © Removing output gee ‘$790081006 Removing reduction gear bearing im Puller ner race Removing differential side bearing ‘ST35272005 © installing reduction gear bearing rit | GS inner race ‘9 Installing ialer gear bearing inner race bi: 44.5 mm (1.752 in) di o Intling output gear bering inn Sara instaling ile goa bearing ier Beit < ss fee | )) tL) ress | ining anerenial age beara Drift | 1: 80 mm (2.36 fa) dla. AT-3PREPANAIIUN * Special tov! or commercial equivalent Too! number Foot pam Description 3735271000" « Installing idler goar Det ¢ Installing output gear 76 mmm (2.89 in) 1: 67 mm (2.68 i) in ‘sT39490001" Installing output gear bearing outer ort race onto bearing retainer 80 mm (2.8 i) a 42 (1.85 in) Kvaor04s40" a Installing output shaft bearing outer ori race onto bearing retainer ANS) 2: 49 mm (1.83 in) aia 7 1:42 mm (1.85 i) i COMMERCIAL SERVICE TOOLS Tool name Description Pater 1 = ‘> Removing Minr gaar and output | aear bearing inner race ‘# Removing diferent side bearing ‘ Removing and installing band servo vey piston snap ring Drift - _ Removing idler gear bearing inner = W > race eam (1.34 I) a, | OP nae ° | . a: 33 mm (1.30 in) dia. Removing differential side bearing a: 38 mm (1.50 in) dia. Removing output shaft bearing inner Drift ‘a: 70 mm (2.76 In) dia. 1b: 90 mm (1.18 in) dia. ‘nt Tnstaling output shan bearing inner ‘2: 70 mm (2.76 in) dla. bb: 34 mm (1.34 In) di. 30 mm (1.18 in) dia dd: 2 mm (0.08 in) AT-4PRECAUTIONS . Service Notice Before proceeding with disassembly, thor- oughly clean the outside of the transaxle. It is, important to prevent the internal parts trom becoming contaminated by dirt or other for- eign matter Disassembly should be done in a clean work area. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transaxle When disassembling parts, place them in order in a parts rack so that they can be put back into the unit in their proper positions. All parts should be carefully cleaned with a general purpose, non-flammable solvent be- fore inspection or reassembly. Gaskets, seals and O-rings should be re- placed any time the transaxle is disassem- bled AT-5 Itis very important to perform functional tests whenever they are indicated. The valve body contains precision parts and requires extreme care when parts are re- joved and serviced. Place removed parts in order on a parts rack so they can be put back in the valve body in the same positions and sequences. Care will also prevent springs and small parts from becoming scattered or lost. Properly installed valves, sleeves, plugs, etc. will slide along their bores in the valve body under their own weight. Betore assembly, apply a coat of recom- mended A.1.F. to all parts. Petroleum jelly may be applied to O-rings and seals and used to hold small bearings and washers in place during reassembly. Do not use grease. Fxtrame care shouild be taken to avoid dam- age to O-rings. seals and gaskets when as- sembling. After overhaul, refill the transaxle with new ATF.Control Valve Assembly and Accumulator REMOVAL 1. Drain A.TF. from transaxle. 2 Remave oil pan and gasket 3. Disconnect A/T solenoid harness connector. 4, Remove stopper ring from A/T solenoid harness terminal body, 5. Pull out A/T solenoid harness from transmission case by | pushing terminal body. AT-6ON-VEHICLE SERVICE Control Valve Assembly and Accumulator (Cont'd) 6. Remove control vaive assembly by removing fixing bolts. Bolt length, number and location: - TT Balt symbol a 8 c ° Balt ength “e wo | wo | wo enti) (988 | cr 206) | (1578) “Number of balte 2 é 5 Tightening torque Nim (kg-m, fb} 7-9(07-09,51-85) © Be careful not to drop manual valve, lube connector, tubes and 3-R accumulator return spring, 7. Disassemble and inspect control vaive assembly if neces- sary — Refer to "REPAIR FOR COMPONENT PARTS” 8 Remove 3-R and N-D accumulators by applying com- pressed air if necessary © Hold each piston with a rag. INSTALLATION ® Set manual shaft in Neutrai, then align manual plate with groove in manual valve. ® After installing contro! valve assembly to transmission case, make sure thal selector lever can be moved to all positions. AT-7wire accom | Engine si | braoket Larry Re GAADS and GAT6DS engine models Fh a 9-25 1-197 . (Ful throttle poston) t 3 - (apy Agjusing tube Lock plate oa | | sare Throttle Wire Adjustment GATEDE engine models —__J har-se (oan oss,27-37) Trrotte eum ‘te assemby REI) Nem thom, ft) ‘SATIESE 4. Turn ignition switch to OFT. While prossing lock plate, move adjusting tube in direction “T" (Transaxle side) 3. Return lock plate. (Adjusting tube is locked at this time.) 4, Move throttle drum from “P,” to “P," quickly [Adjusting tube moves in direction “U" (Engine side) while depressing the lock plate.] Ensure that throttle wire stroke “L” is within the specitied range, between full throttle and idle. Throttle wire stroke “L": 40 - 42 mm (1.57 - 1.65 in) © Adjust throttle wire stroke when throttle wire/accolerator wire is installed and adjusted. ¢ Put mark on throttle wire to facilitate measuring wi stroke. 5, Clamp throttle wire at proper positions shown in the illus- tration after adjusting throttle wire. 6. After properly adjusting and clamping throttle wire, ensure the parting line is as straight as possible. AT-8g Treotte opening \ sat Grew rer 9 Appia. 15 12-15,9- 40) \ransexte ang vote Throttle Wire Adjustment (Cont'd) It throttle wire stroke is improperly adjusted the following problems may arise. ©) When the throttle drum fully-open position “P," is too far in direction “T”, the shift schedule will be as shown by @ in the figure, and the kickdown range will greatly increase. ‘® When the throttle drum fully-open position "P,” is too far in direction “LU”, the shift schedule will be as shown by () in the figure, and kickdown will not occur. Control Cable Installation and Adjustment @ Move selector lever from the “P” range to the "1" range. You should be able to feel the detents in each range. it the delenis carmol be fell or tie pointer indicating the range is improperly aligned, the control cable needs adjustment. © Always adjust control cable when it is removed from selector lever or manual shatt. \ a4 60 (ous - 06, 99-42) nem vgn, m0) Peek nut ee ia 33-43 Rab) a | | | | | INSTALLATION 4. Place selector lever and manual shaft at “P" position 2. Connect control cable to selector lever and tighten control cable lock nut. Clamp contro! cable to selector lever bracket. AT-9sarzae| Lock ni Hie - 24 Nem Manual shaft > Fens oe ee NY pie Ws Sel Control Cable Installation and Adjustment (Cont'd) 3. Connect control cable to manual shaft and clamp control cable to bracket at transaxle. 4. Pull control cable in the direction of the arrow shown in the illustration by specified force. Specified force: 6.9 N (0.7 kg, 1.5 Ib) 5. Return control cable in the opposite direction of the arrow for 1.0 mm (0.039 in) 6. Tighten contro! cable lock nut 7. Move selector lever from "P" range to "1" range and make sure that selector lever can be moved smoothly and without any sliding noise. 8 Apply grease to contacting areas of selector lever and control cable. Install any part removed. ADJUSTMENT 1. Loosen control cable look nut at transaxle side, 2. Place selector lever and manual shaft at “P” position. 3. Pull control cable in the direction of the arrow shown in the illustration by epecitied force. Specified force: 6.9 N (0.7 kg, 1.5 Ib) 4, Return control cable in the opposite direction of the arrow for 1.0 mm (0.039 in). 5. Tighten control cable lock nut. 6. Move selector lever from “P" range to "1" range and make sure that selector lever can be moved smoothly and without any sliding noise. 7. Apply grease to contacting areas of selector lever and control cable. Governor Valve 1. Remove air duct. 2. Remove governor cap snap ring and spacer. 3. Remove governor cap. AT-10Governor Valve (Cont'd) 4. Remove governor valve assembly from transaxle. 5. Check governor valve assembly if necessary — Refer to “DISASSEMBLY”. inhibitor Switch Adjustment 1. Remove control cable end from manual shaft Set manual shaft in "N’ range. Loosen inhibitor switch fixing bolts. 4, Insert 4.0 mm (0.187 in) dia, pin into adjustment hole in both inhibitor switch and manual shaft as near vertically as possible, 5, Tighten inhibitor switch fixing bolts 6 Remove pin trom adjustment hole after adjusting inhibitor switch, 7. Reinstall any part removed. Adjust control cable — Refer to "Control Cable Instaliation and Adjustment” 9. Cheok continuity of inhibitor switch — Refer to “ELECTRI- CAL SYSTEM" Differential Side Oil Seal Replacement 1. Remove drive shaft assemblies. — Refer to section FA 2. Remove oil seals. AT-14ranean case side 8 om Converter housing sie rome . ‘Transmission case side oe Pg and $735325000 4 Differential Side Oil Seal Replacement (Cont'd) 3. Install oil seals. © Apply A-T-F. to oil seal surface befor installing. Install oil seals so that dimensions “A” and “B” are within specifications. Unit: men find A 55-65 (0.217 - 0.256) 8 (05 (0.020) or less Reinstall any part removed. AT-12TROUBLE DIAGNOSES sarvee| - arose Preliminary Check (Prior to Road Testing) AIT FLUID CHECK Fluid leakage check 1. Clean area suspected of leaking, — for example, mating surface of converter housing and transmission case. 2. Start engine, apply foot brake, place selector lever in “UD” range and wait a few minutes, 3. Stop engine. 4. Check for fresh leakage, Fluid condition check uid color ‘Dark or black with burned odor | Wear of trict ‘Water contamination Milky pink — Road water entering through tler tube or breather 7 (Oxidation Varnished fluid, light to dark brown | ° = Over or under filling — overneating Fluid level check — Refer to section MA. AT-13be O | py 4 2 Baa ames INVUBLE WINUNVeZO Road Testing Porform road tects using “Symptom” chart. Refer to pago AT-18, “Pp” RANGE 1. Place selector lever in “P" range and start engine. Stop engine and repeat the procedure in all ranges. including neutral. 2. Stop vehicle on a slight upgrade and place selector lever in ”P" range. Release parking brake to make sure vehicle remains locked. * RANGE 1. Manually move selector lever from “P" to “R’ shift quality. 2. Drive vehicle in reverse long enough to detect slippage or other abnormalities. , and note “N” RANGE 1, Manually move selector lever trom “Rand note shift quality 2. Release parking brake with selector lever in “N" range. Lightly depress accelerator pedal to make sure vehicle does not move. (When vehicle is new or soon after clutches have been replaced, vehicle may move slightly. This is not a problem.) ” RANGE 1. Manually shift selector lever from ""N'' to "D" range, and note shift quality. 2. Using the shift schedule as a reterence, drive vehicle in “U' range. Record, on symptom chart, respective vehicle speeds at which up-shifting and down-shifting occur. These apceds are to be read at three different throttle positions (light, half and full), respectively. Also determine the timing at which shocks are encountered during shifting and which clutches are enaaaed sars#o] 3, Determine whether lock-up properly occurs while driving vehicle in proper gear position and at proper vehicle speed. AT-14TROUBLE DIAGNOSES Road Testing (Cont'd) 4, Check to determine if shifting to overdrive gear cannot be made while 0.D. control switch is “OFF” 5, While driving vehicle in the 60 to 70 km/h (37 to 43 MPH) range in “D,” range at half to light throttle position, tully depress acceleralor pedal lo make sure transaxle dow shifts from 3rd to 2nd gear. 6. While driving vehicle in the 25 to 36 km/h (16 to 22 MPH) (°D,” range) at half to light throttle position, fully depress, accelerator pedal to make sure transaxle downshifts from 2nd to 1st gear. “2 RANGE 1. Shift to "2" range and make sure vehicle starts in 1st gear. 2. Increase vehicle speed to make sure transaxle upshifts from 1st to 2nd gear. 3. Further increase vehicle speed. Make sure transaxle does ot upshitt to 3rd gear. 4, While driving vehicie at the 25 to 35 km/h (16 to 22 MPH) with throttle at half to light position ("'2," range), fully dopress accolerator pedal to make sure transaxle down shifts from 2nd to tst gear 5. Allow vehicle to run idle while in "2" range to make sure that transaxle downshifts to ist gear. 6 Move selector lever to “D” range and allow vehicle operate at 30 to 40 km/h (19 to 25 MPH). Then, shift to "2 range to make sure transaxle downshifts to 2nd gear. ” RANGE 1. Place selector lever in “1” range and accelerate vehicle. Make sure transaxle does not shift trom Ist to znd gear although vehicle speed increases. 2, While driving vehicle in "1" range, release accelerator Pedal to make sure that engine compression acts ac a brake 3. Place selector lever in “D” or “2” range and allow vehicle to run at 15 to 25 km/h (9 to 16 MPH). Then move selector lever to "1" range to make sure transaxle downshifts to 1st gear. AT-15SHIFT SCHEDULE GAI6DE engine 8 kon range Road Testing (Cont'd) VEHICLE SPEED WITH SHIFTING GEARS This check should be carried out when oil temperature is between 50 and 80°C (122 and 176°F) after the vehicle has been driven approx. 10 minutes. 718 6 58 48 318 218 48 on ‘Trrotta opening | 0 0 oo ao © 0 8 (20) GA16DS engine for Europe mn © (eo) 100 eo) 110 0) 120190 140 ao) 0 (0) Vehicle speed kmh (MPH) = Downshit a 8 | a cp eee 9 8 Pe pm mw mw Re Me ie io oO i a &% mH 6 6 Gy >) (om Vehicle speed km/h (MPH) AT-16TROUBLE DIAGNOSES ‘© GATEDS engine except for Europe @ GA14DS eng Road Testing (Cont'd) 1e except for Europe and Middle East To os ae | 5 we lu 28 Sor 4 fH 4 look up wt if below oe 4 ee ee | a a er | _ _ GA14DS engine for Europe and Middie East oun gz i . J - 4 tock-up AT-7Road Testing (Cont'd) ROAD TEST SYMPTOM CHART Numbers are arranged in order of probability Perform inspections starting with number one and work up. Circled numbers indicate that the transaxle must be removed from the vehicle. Valve expected ta be malfunctioning «ow vetice —________. valve & detent vave ‘onirol val | Bverrur clutch contol vaive Dit level and oF aval, Engine sling r9m Line pressure Pressure regultor valve 3 e 2 & Sharp shouks in shllig (rom WN" 19 “D™ range When shiting tom 1st to 209 or Wie shang town SW ‘nen shiting wom D162 ana Y Shit shacks reose | when 0 D. switch is set trom | "oN" “OFF | when shitting from 2nd to 1st in 1 range, When shifting rom Tet 2nd) Shit slippage when upshiting | When shifting rom 2nd to Sed When shiting trom 3rd to th When shiting Wom ah to 2nd ‘Shit eippage with accolerator [When ehiting fom Ath to Sea pedal depressee Wien shiting fom 4h to Tat and shifting rom Sr to tst Poor powerlacceleration roepeeees when sniting am "10 2 and "1" range ‘When O.D, ewiteh le 9et from No engine braking ren On oe [strange [Too tow a gear change point fom 2nd 10318 and Irom Se 0 2nd “Too high a gear change point fron Qin te 818 and trom 98 to Shit quality Pa "Too low a goar change point from 2nd to tstin "1" range “Too high a opar change point trom nd to stn "1" range, AT-18[elel @ elcle res gaor | | a @ ® ° c © ole yaya unsio% ® o ® a) 8 OFF VENICLE ‘In Kewsauo paewuos ® ome prewog ele ® ® 6 ® ® = ele @ ® ® o ® ® ® ‘unm pue yous 021409 GO ° Pest topete post eee] soa) CN -o1enunsey |e ° we roranunssy | | ° ° Road Testing (Cont'd) pousies jeaue> 0 | © TROUBLE DIAGNOSES ‘nen 209005) «[ [eT fo ounssoid sows9n0p +) |e] fo ‘alee souanb9s zy (ON VEHICLE: ‘nea jornues an9307 ‘nen nd pad Ue unaze Ba anes Z0m;pow UMOpYODH AT-19.TROUBLE DIAGNOSES Road Testing (Cont'd) Numbers are arranged in order of probability. ft on venice + Perform inspections starting with number one and work up. Circled numbers indicate that the transaxle must be removed from the vehicle. Valve expected to be malfunctioning | ‘Overtun suteh contol valve Inhibtor swieh and wir ng Engine iling ram CContio! cable Line pressure Pressure madi 3 g Throttle wire Manwal valve 12 shit valve ve [Faure wo change gear rom ah to znd win neeteratorpeaat | 1 2. ale | Tailre change goer Wom Sr to 2nd win ecelerator nega | 1 a ale depresses | | Fallure to change gear trom ist 8 2ng in °D” ang "2" range Shit quality [Vehicle does nat start rom "st" in "D" and "2" range | Faitore to change gear to ora ang ain in 0" range (Changes gear to 1st directly sven aoletor lover ia et trom ft 2 1D" to" range range. | Lock-up point is extremely high | 3 ale or low | Lecloup quality | = Torque converter does nat lock- | vp. Engine does not slant in P” and “N" ranges or engine starts In ranges otner man “P” and °N' ranges. { I ‘Vehicle moves with selector lever in "Prange 1 AT-20|e siuav0dues Oued worm ass9H01 B07 | peeg oe | | | ain ABA-OUD MOT | OFF VEHICLE ‘ana senaue pieming wins pasmuog ie TROUBLE DIAGNOSES Road Testing (Cont'd) win asionau und 90 1 eyanuea onbso1 5 ¥ ue sowinunsoy | proveies aN “CO | ON VEHICLE: ‘omen ino paad ‘neA so}BOW! OMLOHAL anes fanuoo enbvo1 ‘omen Bun 2-6 ‘nies sowinuncoe ‘Onjen seiipOW UMOPHEIA rT? AT-21Stall Tasting STALL TEST PROCEDURE 1. Check A/T and engine fluid levels. If necessary, add fluid. 2. Warm up engine until engine oil and A.T.F. reach operating temperature afler vehicle has been driven approx. 10 minutes, A.TF. operating temperature: 50 - 80°C (122 - 176°F) 3. Set parking brake and block wheels. 4, Install a tachometer where it can be seen by driver during tost. 5. Start engine, apply foot brake, and place selector lever in "D" range. 6. Accelerate to wide-open throttle gradually while applying foot brake. 7. Quickly note the engine stall revolution and immediately release throttle. ‘@ During test, never hold throttle wide-open for more than 5 seconds. Stall revolution standard: GA14DS engine: For Europe 2,150 - 2,450 rpm Except Europe 2,200 - 2,500 rpm GA16DS engine: For Europe and Middle East 2,450 - 2,750 rpm Except Europe and Middle East 2,400 - 2,700 rpm GAIGDE engine 2,450 - 2,750 rpm AT-22TROUBLE DIAGNOSES Stall Tasting (Cont'd) sarme] 8 a Shift selector lever to Cool off ATF. Run engine at idle for at least one minute. Perform stall tests in the same manner as in steps § through 9 with selector lever in "2", "1" and "R”, respectively. AT-23JUDGMENT OF STALL TEST Judgement of stall test Stall Tasting (Cont'd) Selector Iver position desarene [oa ° u 2 [a ° L 1 ° ° L 8 H 4 L Stall evolution is normal Stal evoiution fs higher than spectieg Sal revolution is lower than specitieg (amagea components Low & reverse brake _ Overrun ute Forward one-way Hydrauts cio (Cine pressure line pressure control hw L ~ Forwacd |W shen ° » [# [a o fu fu o fo fu udgment satanTROUBLE DIAGNOSES Pressure Testing Location ot pressure test port. Always replace pressure plugs as they are self-sealing bolts. test pon tor tne pressure | LINE PRESSURE TEST PROCEDURE | 4 Check A/T and engine fluid levels If necessary, add fluid 2. Warm up engine until engine oil and A.T.F. reach operating temperature; after vehicle has been driven approx. 10 minutes, A.TF. operating temperature: 50 - 80°C (122 - 178°F) 3. Install pressure gauge to line pressure port. 4. Set parking brake and block wheels Continue to depress brake pedal fully while performing line pressure test at stall speed. AT-25\ Pressure Testing (Contd) ——] Start engine and measure tine pressure at Idle and stall \\ | oO \ saTesa| speed. Line pressu Engine speed] _ ‘pm Rrange | Drange 2 range t range 289 389 509 508 vate | (@as,90, (299,90 x sm) | 98.55, 78)| (568,60, 05)| 5." 1.785 a ) 1070 stall | 1785, 180, | (1079, 110, | (@83,90, | (1079, 10 256) 16) | 128) 186) JUDGMENT OF LINE PRESSURE TEST © If line pressure does not rise, first check to make sure that throttle wire is connected properly. 1) When line pressure while idling is low at all positions ("D", "2", "1", "R" and "P"), the problem may be due to: © Wear on interior of ot! pump. 2 Oll leakage at or around oil pump, control valve body, transmission case or governor @ Sticking pressure regulator valve @ Sticking pressure modifier valve 2) When line pressure while idling is low at a particular position, the problem may be due to the following: @ If oll leaks at or around iow & reverse brake circuit, line pressure becomes low in “R" range but is normal in “P’’, "D", "2" or "1" range, 3) When line pressure is high while idling, pressure regulator valve may have stuck, GOVERNOR PRESSURE TESTING 1. Check A/T and engine fluid levels. If necessary, add fluid 2. Warm up engine until engine oil and A.T.F. reach operating temperature; after vehicle has been driven approx. 10 minutes. A.TF. operating temperature: 50 - 80°C (122 - 176°F) AT-26IHOUBLE DIAGNOSES Pressure Testing (Cont'd) 3. Remove LH. side drive shaft, 4, Install pressure gauge to governor pressure port 5. Reinstall drive shaft Make sure that pressure gauge adapter does not touch drive shaft. 6. Set parking brake and block rear wheels. 7, Jack up front wheels 8. Set selector lever in D range and drive vehicle Be careful of rotating wheels. Governor pressure: © Governor pressure is not generated when vehicle is stopped. (front wheels are not rotating.) ¢ Governor pressure rises gradually in response to vehicle speed. (front wheel rotating speed.) If not, check governor valve assembly. Reter to “DISASSEMBLY AT-27ELECIHIGAL STDIEM Wiring Diagram R.H.D. models COMBINATION ME“ER Ao) fe} (Wai0 ha afisse GGOGSOO (enarne harness) wma 4 r=Bn Bed AT-28ELECTRICAL SYSTEM Wiring Diagram (Cont'd) L.H.D. models 0s 09 ne ala OF Ge oo Ie TTL AT-29Ed ==] Component Check ©) overpaive contRoL switcH Check continuity between two terminals, 0.0. switch position Continuity Di PD a) el Sm — OFF yes INHIBITOR SWITCH Check continuity in “N", “P" and “R™ ranges. With control lever held in “"N” range, turn manual lever an equal amount In both directions to see if current flow ranges are nearly the same. (When manual lever is in each position, continuity normally oxists within 1.5° in cither | direction.) If current flows outside normal range, or if ayy el normal flow range is out of specifications, properly adjust Ve ae inhibitor switch. | | Terminal No. i Range 0.D. CANCEL SOLENOID © Check resistance between terminals. Terminal No, Resistance zr; | ‘Approximately 250) sarseo| AT-30REMOVAL AND INSTALLATION ‘box (GAY60E) SS ‘arf soleneid, | hares connie sarse0| Removal © Remove battery and bracket. © Remove air duct. (GA16DE) © Disconnect A/T solenoid harness connector and inhibitor switch harness connector. © Disconnect throttie wire at engine side. © Drain ATF. Disconnect control cable from transaxle, @ Disconnect oil cooler hoses. Remove drive shafts — Refer to ‘Section FA” @ Remove exhaust front tube. Remove starter motor from transaxle, AT-31KEMUVAL ANU INDIALLAIIUN set Removal (Cont'd) © Remove front and rear gussets and engine rear plate © Remove bolts securing torque converter to drive plate. Rotate crankshatt for access to securing bolts. © Support engine by placing a jack under oil pan Do not place jack under oil pan drain plug. ‘© Support transaxle with a jack. Remove mountings trom transaxle. © Remove bolts fixing A/T to engine. © Lower transaxle while supporting it with a jack. Installat @ Drive plate runout Maximum allowable runout: 0.5 mm (0.020 in) If this runout is out of specification, replace drive plate with ring gear. When connecting torque converter to transaxle, measure distance “A” to be certain that they are correctly assem- bled Distance “A”: 21.1 mm (0.831 in) or more ‘© Install converter to drive plate. © After converter is installed to drive plate, rotate crankshaft several turns and check to be sure that transaxle rot: freely without binding AT-32[@ Art © engine Engine (gusset) REMOVAL AND INSTALLATION Installation (cont'd) Tighten bolts fixing transaxle Tightening torque Bolt length “¢" Bolt No. Nem (kg-m, #10) mm (in) o ‘0-40 (51-41, 22-30) 90 (1.97) @ 30-40 (81-4, 22-30) 30 (1.18) __ @ te-21(16-21,12-15) | 2510.98) aK 90-40 (1-41, 22-30 | 201079) engine Roar gueset to pa 18-21 (16-21, 12-15) 16 (0.63) © Reinstall any part removed © Adjust contral cable and throttle wire. Refer to “ON. VEHICLE SERVICE”. Check inhibitor switch. Refer to “ELECTRICAL SYSTEM”. © Refill transaxle with A.T.F. and check fluid level © Move selector lever through all positions to be sure that transaxle operates correctly. With parking brake applied, idle engine. More selector lever through “N” to"D", to "2", lo “1 and “R". A slight shock sould be fell through the hand gripping the selector each time the transaxle is shifted, © Perform road test — Refer to "ROAD TESTING” AT-33MAJOR OVERHAUL. Cross-sectional View AT-34MAJOR OVERHAUL AT-35MAJOR OVERHAUL AT-36MAJOR OVERHAUL am onions, (ez vo-coly- 2 hy whe Ws-9t'z0-sou-sQ) 3~ 01d SurBie4? 10) " H usein Oct ad pun Gamo “deo owienon 9 fun deus Sue rons iru woot AT-37Shift Control Components _/ Selector lever knob trims baton \ —_—< ang cnt ata tame | A lah aaa X 12-15 (12-15,9- 11 J Yo svegpaica |S 7) ~~ Boerne. OSU | | 4 Les 0. conrolswieh and pasion? < RX | Indicator lip hnress eormestor tiem tko-m. to) AT-38MAJOR OVERHAUL Hydraulic Control Circuit MODEL 31X74, 31X76 AND 31X77 Low & revere trate Teeque TER, ovamin Fevese Femmes Le eutcn tigh euch and ser a m ml Ty me an Seed cut tire overun item conte oe Lecteuo cent ot ewe | Tl ‘are Governor Preessure ‘puter he 00, cance Stent rosern Detant valve Throttle valve Kicktown, x: Drain port el & sone ‘me AT-39MayUn UvennAUL Hydraulic Control Circuit (Cont'd) MODEL 31X75 AND 31X79 Torque bake converter Overrun F Reverse ronware cluch High luten Band seno casa ic 1 Taal wave Presse : fauosr Ee = weve nL | SEES Pressure - ier vabe \ reat Dotan wave Trot vahe \L teckaown X_:Dran port modtier oe Ornee whe AT-40MAJOR OVERHAUL Mechanical Operation Band servo Forwars Low & shin [Reverse] High | Forward] Overrun postion | eiaten | ctuten | ctiten | cioen | 2nd [ard 7 atm [one-way reverse | Lock-up | Remarks apply | release | apply | clutch brake PARK ° © REVERSE NEUTRAL ie of]. ole © [end o lye ° Automatic shit + [are ~@ | © 7 ~ Teste aene ah we fe | o 5 | ete ‘Automatic shit * [ene ° tee tt [eo Locks (hed 1 = + stationary) in tot [an eo [| of o . I | speed t= 2 eee ‘Operates when overdrive switch is Seto OF (il prosaure ve appliod Yo both 2nd “apply side and Brd “roleaae" side of band serve piaton, However, rake band does not contract ‘because oll pressure area on the "release" side is greater than that on the “apply” side. it pressure is applied to Ath “apply” side in condition “2 above, and brake band contacts, [AMT wil no shit 1 4th when overdrive switch ia sel t9 “OFT” position Operates Operates when throttle opening is less than 1/16 Operates during “progressive” acceleration Operates but does not atfect power transmission AT-41MAJOR OVERHAUL Oil Channel “Torque converter pressure High clutch pressure (Lock-up released) oes accumulator shoulder pressure ‘3 aooumator back pr {Reverse cutch pressure) Torque converter pressure averse cite (Look-up releases) canes ‘01 pump 1 pump suction hale Torque converter Teens apptieay High clutch pressure ‘Overrun oluteh pressure Forward clutch pressure Forward clutch pressure Of cooler tube (IN) hole (Overrun clutch pressure || Torque converter (Cockcup apoied) pressure S- ttock-up releases) ‘ol pump aiscnarge note ‘reverse ottch pressure (8 pup suction hole Diferenal lubricant hole sAaTs860 AT-42MASUR UVENNAUL Locations of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings ‘Outer ciameter and color of thrust washers ‘Outer and inner cameter of needle bearings Trew eumber | Ovi dare om fal [Cao vennimeer OW dame @ 70266) a a via @ re ® Ban ore) o wow an | o woaom | sonra o ones, | monn @ eum | mouom © © g wena | maa \ w owe | wonse OF ‘#) Outer & inner diameter of bearing races, adusting shins and adjusting spacer nem numba: etre Outer diameter mm tnt e weonea | sana voous a zanna | sovse ous! a ee ee vee 038) @ wes | 0aRm aon) zu ssonws; | sone 15014961 1 Select proper ickness 190067) avast: mm) Bend a wire and use _— it's chack too! ‘Approx. 3.0 (0.118) {Bend a 1.5 (0.038) aa. Outer race Crewe clutch sarooao] 1. Drain A..F. through drain plug. 2. Remove torque converter. 3. Check torque converter one-way clutch using check tool as shown at left. a. Insert check tool into the groove ot bearing support built Into one-way clutch outer race. While fixing bearing support with check tool, rotate one-way clutch epline using flat bladed screwdriver. c. Check inner race rotates clockwise only. If not, replace torque converter assembly. 4. Remove oil charging pipe and oil cooler tube. AT-44DISASSEMBLY sator10| Sarat] Lar} 5. Set manual lever to “P" position. 6. Remove inhibitor switch, 7. Remove oil pan and oil pan gasket. @ Do not reuse oil pan bolts. 8 Check foreign materials in oil pan to help determine cause of maitunction. It the tluid is very dark, smells burned, or contains foreign particles, the frictional material (clutches, band) may need replacement. A tacky film that will not wipe clean indicates varnish build up which can cause valves, servo, and clutches to stick and may inhibit pump pressure. 9, Remove control valve assembly according to the following procedures a. Remove control valve assembly mounting bolts @. @, ©) and © AT-45,DISASSEMBLY — b. Remove stopper ring from terminal body. ‘Stopper ring \2 a ©. Push terminal body into transmission case and draw out solenoid harness. 10. Remove manual valve from control valve assembly, 11. Remove return spring from 3-R accumulator piston. 12, Remove 3-R accumulator piston with compressed air. 13, Remove O-rings from 3-R accumulator piston. AT-46(Contact surace | LX, hike jo Kes A conte atl 9, 3 aceumulator pistons Up seal eA eN ND secumuatorgiston Gi SSX YYg NN LON sata] DISASSEMBLY 14. Remove N-D accumulator piston and return spring with compressed air 15. Remove O-rings from N-D accumulator piston, 16. Check accumulator pistons and contact surface of transmis- sion case for damage. 17. Check accumulator return springs for damage and free length, Spring ‘spring 435 (1.713) 18. Remove lip seals trom band servo oil port. 19. Remove oil filter for governor. Free length Unit. mm (in) Outer diameter 21.0 0.827) 280 (1.102), 20. Check oil filter for governor for damage or clogging, AT-47ONT ik OF] Gs 3 E PY) _ Hard sari9ie DISASSEMBLY 21, Remove throttle wire from throttle lever 22. Remove throttle wire mounting bolt, 23. Draw out throttle wire from transmission case. 24, Remove converter housing according to the following pro- cedures. | a. Remove converter housing mounting bolts @ and © b. Remove converter housing cc. Remove O-ring trom ditterential oi! port. AT-48/ (CD) sake DISASSEMBLY 25. Remove final drive assembly from transmission case. Wit is difficult to lift up by hand, tap final drive slightly with a soft hammer. 2 Remove differential side bearing adjusting shim from trans- ion caso, 27. Remove oil seal from converter housing using a screw- driver. © Be careful not to damage housing. 28. Remove oil tube from converter housing, 29. Remove oil pump accarding to the following procedures. ‘a, Remove O-ring from input shaft. AT-49‘Bruke band anchor in b. Remove oil pump assembly from transmission case. Remove thrust washer and bearing race from oil pump assembly. 30. Remove brake band according to the following procedures. a. Loosen lock nut, then back off band servo anchor end pin. b. Remove brake band from transmission case. ‘To prevent brake linings from cracking or peeling, do not stretch the flexible band unnecessarily. When removing the band, always secure it with a clip as shown in the figure at left. Leave the clip in position after removing the br e band. AT-50DISASSEMBLY Input snan assemoy | verse cutcn sata] c 31 Check brake band facing for damage, cracks, wear or burns. Remove input shaft assembly (high clutch) and reverse clutch according to the following procedures. Remove input shaft assembly (high clutch) with reverse clutch. Remove input shaft assembly (high clutch) from reverse clutch, Remove needle bearing from high clutch drum. ‘Check input shaft assembly and needle bearing for damage or wear. Remove high clutch hub and needle bearing from transmis sion case. Check high clutch hub and needle bearing far damage or wear, AT-51DISASSEMBLY Front 34, Remove front sun gear and needle bearings from transmis- sion case. 35. Check front sun gear and needle bearings for damage or wear. 36. Remove front planetary carrier assembly and low one-way clutch according to the following procedures. a. Remove snap ring using a screwdriver. b. Remove front planetary carrier with low one-way clutch, c. Check that low one-way clutch rotates in the direction of the arrow and locks in the opposite direction. d. Remove low one-way clutch from front planetary carrier by rotating it in the direction of uniock. fe. Remove needle bearing from front planetary carrier AT-52DISASSEMBLY i Fesler gauge | Check front planetary carrier, low one-way clutch and needle bearing for damage or wear. Check clearance between pinion washer and planetary carrier using feeler gauge. Standard clearance: 0.15 - 0.70 mm (0.0059 - 0.0276 in) Replace if the clearance exceeds 0.80 mm (0.0315 in). 87. Remove rear planetary carrier assembly and rear sun gear ©, according to the following procedures. Remove rear planetary carrier assembly from transmission case. Remove rear sun gear from rear planetary cartier. Remove needle bearings from rear planetary carrier as- sembly, Check rear planetary cartier, rear sun gear and needle bearings for damage or wear. ‘Check clearance between pinion washer and rear planetary carrier using feeler gauge. Standard clearance: 0.15 - 0.70 mm (0.0059 - 0.0276 in) Replace if the clearance exceeds 0.80 mm (0.0315 in). AT-53sAToso| saroseo] 39, 40, at. 42. Remove rear internal gear from transmission cace. Remove needle bearing from rear internal gear. Check needle bearing for damage or wear. Romove forward clutch assembly from transmission case. Remove thrust washer and bearing race from transmission case. Remove output shaft, output gear and reduction year ac- cording to the following procedures. Remove side cover. Do not reuse side cover bolts. AT-54DISASSEMBLY b. Set manual lever to "P" position to fix idler gear and output gear. c. Unlock both idler gear and output gear lock nuts using a pin punch. 4. Remove idler gear and output gear lock nuts. @ Do not reuse idler gear and output gear lock nuts. ¢. Remove idler gear and output gear using a puller {Remove reduction gear and output shaft from transmission case. 9g. Remove adjusting shim from reduction gear. h. Remove adjusting spacer from output shat 44, Remove return spring from parking shaft using a screw- driver. AT-55SB < 45, Draw out parking shaft and remove parking pole from transmission case. 46. Check parking pole and shatt for damage or wear. 47. Remove parking actuator support from transmission case. 48. Check parking actuator support for damage or wear. 49. Remove governor valve assembly according to the follow- ing procedures. a. Remove snap ring using a screwdriver. b. Remove spacer from governor cap, cc. Remove governor cap using water pump pliers. d. Remove O-ring from governor cap. AT-56DISASSEMBLY Low secondary weight Low primary weight Governor valve a High primary weight | | ign secondary weigh ©. 50. Remove governor valve assembly. With low primary weight closed, place top of governor valve assembly down to make sure governor valve properly lowers under its own weight. Place top of governor assembly down. Uperate both low and high secondary weights to make sure governor valve functions properly Remove side oll seal trom transmission case using a screwdriver Be careful not to damage case. AT-57