Manual

Transmission
(M035S5)
General
Special Tool .................................................. MTB - 2
Specification ................................................. MTB - 3

Manual Transmission
Description .................................................... MTB - 5
Removal ....................................................... MTB - 6
Installation .................................................... MTB - 7
Gear Shift Upper
Removal and Installation ........................ MTB - 8
Disassembly and Reassembly ............... MTB - 9
Shift Rail and Shift Fork
Removal .................................................. MTB - 10
Installation ............................................... MTB - 10
Disassembly ........................................... MTB - 11
Rear Cover and Clutch Housing
Replacement ........................................... MTB - 13
Transmission Assembly
Disassembly and Reassembly ............... MTB - 14
Main Shaft
Disassembly and Reassembly ............... MTB - 16
Counter Shaft
Disassembly and Reassembly ............... MTB - 19
General
Special Tool
Tool (Number and name) Illustration Use
09431-45100 Installation of clutch housing oil seal
Oil seal installer

09431-5H000 Installation of front bearing retainer oil

Oil seal installer seal

09432-5H100 Installation of main shaft bearing

Main shaft bearing installer

09432-7B000 Counter shaft bearing

Counter shaft bearing installer

09431-83100 Removal of main shaft bearing amd c-

Bearing puller set ounter shaft bearing
Specifications
Item Specification
First 5.380
Second 3.028
Third 1.700
Gear ratio
Fourth 1.000
Fifth 0.722
Rev 5.380
API GL-4 80W90
Transmission gear oil
API GL-4 SAE 90 (Tropics)
Approx. 3.2 (without P.T.O)
Oil quantity (ℓ)
Approx. 3.7 (with P.T.O)

Service Standards
Nominal value
Item Limit Remarks
(Basic diameter in [ ])
Poppet spring free length 22.85 22 Replace
4th & 5th return spring free length 39.25 37.25 Replace
1st & Rev. return spring free length 49.18 47.18 Replace
Clearance between speedometer gear and speedometer g-
[12] 0.04 ~ 0.08 0.15 Replace
ear bush
Clearance between reverse idler gear shaft and reverse idl-
[24] 0.05 ~ 0.08 0.2 -
er gear
Diaplacement of bar with respect to shift fork hole 0.1 or less 0.2 Replace
Clearance between shift fork and synchronizer sleeve 0.3~0.6 1 Replace
Displacement of shift rail 0.04 or less 0.05 Replace
Clearance between synchronizer key hole and shift key 4.7~5.0 5.7 Replace
Clearance between synchronizer ring and drive pinion 1.13~1.37 0.20 Replace
Clearance between shifting key and synchronizer hub key
0.05~0.20 0.50 Replace
hole
Clearance between 2nd gear and synchronizer outside ring 1.23~1.47 0.95 Replace
Clearance between synchronixer outside ring key hole and
4.7~5.0 5.70 Replace
shifting key
Clearnce between synchronizer outer ring and 3rd gear 1.23~1.47 0.95 Replace
Clearance between shifting key and synchronizer hub key
0.05~0.20 0.50 Replace
hole
1st gear end play 0.310~0.460 - -
2nd gear end play 0.150~0.250 - -
3rd gear endplay 0.160~0.460 - -
 Nominal value
Item Limit Remarks
(Basic diameter in [ ])
5th gear end play 0.210~0.560 - -
Reverse gear end play (C/S~REV. IDLER) 0.220~0.680 - -
Reverse gear end play (REV. IDLER~M/S) 0.160~0.460 - -

Unit : mm
Tightening Torque
Tightening torque
Item
Nm Kgf.m lb-ft
Drain plug and inspection plug 54 ~ 83 5.5 ~ 8.5 39.8 ~ 61.2
Transmission and engine mounting bolt 48 4.8 35.4
84 8.4 62
Gear shift upper mounting bolt 24 2.4 17.7
Back up lamp switch 30 ~ 40 3~4 22.1 ~ 29.5
Poppet screw plug 40 4 29.5
Poppet spring plate 24 2.4 17.7
Interlock switch 46 ~ 52 4.7 ~ 5.3 33.9 ~ 38.4
Lock pin nut 7 0.7 5.2
Speedometer 29.4 ~ 39 3.0 ~ 4.0 21.7 ~ 28.8
Rear cover 45 4.5 33.2
Reverse idler gear cover 19 1.9 14
Front bearing retainer 44 4.5 32.5
Transmission case 54 5.5 39.8
Bearing retainer 49 5 36
Manual Transmission
DESCRIPTION

EMTTM5201A

The transmission system transmits the rotational power the engine is idling.
generated by the engine to that(driving force) for a
vehicle. It changes the rotational power by selecting one
among many sets of gears in mesh.The transmission has
the interlock mechanism protecting the double mesh and
the non-backlash mechanism lowering the noise while
REMOVAL 3. Lift up the cab.
1. Place the wooden block(A) to the front and rear sides CAUTION
of the both(LH/RH) sides rear wheels. Insert suerly the safety pin(B) into the cab
stay(A) hole to prevent the cab from lowering.

KMTTM5513A

2. Disconnect battery (-) cable(A) from the battery. EMTTM5003A

4. Disconnect the speed sensor connector, the crank

position sensor, battery (-) cable and back-up switch
connector from the transmission.
5. Remove the shift cable and the select rod(A) from the
transmission.
NOTICE
Put the transmission to the neutral position before
removing the shift cable and the select rod from the
transmission.

EMTTM5002A

EMTTM5064A
6. Remove the release cylinder(A) from the 9. Support the transmission(A) with a jack(B) and
transmission. remove the body mounting bolts and engine
mounting bolts. Then remove the transmission from
the engine.
CAUTION
Be careful not to fall down the transmission.

EMTTM5517B

7. Remove the speed cable(A) from the transmission.

8. Remove the propeller shaft(B) from the transmission.

KMTTM5519A

NOTICE
If the transmission is not separated from the engine,
detach the transmission by inserting a flat drive(A)
into grooves(three locations) on the clutch housing.

KMTTM5518A

EMTTM5004A

INSTALLATION
Installation is the reverse of removal.
CAUTION
Be careful not to fall down the transmission.
Gear Shift Upper
Removal and Installation

EMTTM5224A
Disassembly and Reassembly

EMTTM5225A
Shift Rail And Shift Fork
REMOVAL 2. When inserting drive pinion(A), main shaft
1. Remove and install shift rail, shift fork, counter shaft, assembly(B) and counter shaft assembly(C), install
drive pinion, main shaft with assembly. synchro guard.
2. Insert set pin to counter shaft constant mesh gear
setting hole and fix sub gear.
3. After removing case, fix with steel lifting band.
4. Fix shift rail and shift fork on main shaft with rubber
band.
5. Lift up and remove clutch housing with drive pinion
assembly.

EMTTM5209A

3. After applying grease on sealing cap, install using the

special tool(09431-45100).

EMTTM5207A

INSTALLATION
1. Not to damage oil seal of front bearing retainer, after
covering oil seal guide on drive pinion, install each
part.

EMTTM5210A

EMTTM5208A
DISASSEMBLY

EMTTM5211A
Service Key Points
1. Be sure to install the spring pin as shown figure.

EMTTM5212A

2. Measure the clearance between gear shift fork and

synchronizer sleeve. If the clearance exceeds the
service limit, replace the parts.

EMTTM5213A
Rear cover and clutch housing
Replacement
Rear Cover and Reverse Idler Gear

EMTTM5226A
Transmission Assembly
Disassembly and Reassembly

EMTTM5202A
Key Points for Installation 3. Transmission case removal.
1. Oil seal installation. 1) After removing bolts, remove clutch housing,
After applying grease to the oil seal, install the oil main shaft assembly, counter shaft assembly and
seal into front bearing retainer, using the special transmission case by crane etc.
tool(09431-5H000).

EMTTM5205A

EMTTM5203A 2) After removing transmission case, fix 2nd gear

2. Front bearing retainer installation. part with steel lifting band.
Guide oil seal guide on drive pinion and install front
bearing retainer.

EMTTM5206A

EMTTM5204A
Main Shaft
Disassembly and Reassembly
 EMTTM5214A

Service Key Points 3. Remove snap rings(B) from the main shaft using a
1. End play of each gear. snap ring plier(A).
A : 1st gear
B : Reverse gear
C : 2nd gear
D : 3rd gear
E : 5th gear
If the end play exceeds the service limit, replace the
parts.

EMTTM5217A

4. Measure the clearance between synchronizer ring(A)

or synchronizer outer ring and shafting key(B).
If the clearance exceeds the service limit, replace the
parts.

EMTTM5215A

2. Measure the play in diametral direction of main shaft

gears and needle roller bearing. If the play exceeds
the service limit, replace the parts.

EMTTM5218A

EMTTM5216A
5. Measure the clearance(A) between synchronizer ring
and each gear assembly.
If the clearance exceeds the service limit, replace the
parts.

EMTTM5221A

8. Remover the snap ring.

EMTTM5219A

6. Measure the clearance between shifting key and

synchronizer hub. If the clearance exceeds the
service limit, replace the parts.

EMTTM5231A

9. Remove the drive pinion bearing using the special

service tool(09431-83100)

EMTTM5220A

7. Measure the clearance(A) between each gear

assembly and synchronizer outer ring. If the
clearance exceeds the service limit, replace the
parts.

EMTTM5223A

10.Reassembly is the reverse of disassembly.

Counter Shaft
Disassembly and Reassembly

EMTTM5222A

1. Remove the snap ring using a snap ring plier. 2. Counter shaft rear bearing
1) Remove
Remove the counter shaft bearing using the
special service tool(09431-83100 or
09434-5H000).

EMTTM5232A

EMTTM5233A
2) Installation
Installation the counter shaft bearing using the
special service tool(09434-5H100).

EMTTM5209A