Transmission: (LF05S) Models FA and FB

1 INDEX
Models FA and FB (LF05S) TRANSMISSION 7-1
7-144E-07
CHAPTER 7
TRANSMISSION (LF05S) 7
Models FA and FB
TROUBLESHOOTING .................................................................. 7- 2
SPECIAL TOOLS ......................................................................... 7- 4
REMOVAL AND INSTALLATION ................................................. 7- 6
GEAR SHIFT HOUSING ............................................................... 7- 12
INPUT SHAFT, OUTPUT SHAFT, GEARS AND

RELATED PARTS......................................................................... 7- 20
COUNTER SHAFT, REVERSE IDLER SHAFT AND

GEARS ......................................................................................... 7- 44
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7-2 TRANSMISSION Models FA and FB (LF05S)
TROUBLESHOOTING
Symptom Possible cause Remedy
Gear slip-off Control system

● Joint worn and/or damaged .................. Replace joint.
● Loose bolts and nuts ............................. Tighten bolts and nuts.
Gear shift housing

● Lock ball and spring distorted ............... Repair or replace as required.
and/or broken
● Groove for shift shaft worn .................... Replace shift fork.
Transmission gear
● Synchronizer hub and sleeve worn ....... Replace as required.
● Synchronizer sleeve and gear .............. Replace as required
clutch teeth worn or damaged
● Input shaft and/or output shaft .............. Replace bearing.
bearing worn and/or broken
● Retainer ring and/or thrust washer ........ Replace as required.
worn and/or broken
●
Loose transmission to engine ............... Tighten bolts.
mounting bolts
Difficult gear Engine

engagement ●
Engine idling speed too high ................. Adjust engine idling.
Clutch
● Improper disengagement of clutch ........ Adjust clutch.
● Clutch disc sticking ............................... Repair or replace.
Transmission
● Input shaft and/or output shaft .............. Replace bearing.
bearing worn and/or damaged
● Flywheel pilot bearing worn .................. Replace bearing.
and/or damaged
● Synchronizer cone and ring worn ......... Replace as required.
1 page 1
Symptom Possible cause Remedy
Difficult gear Control system

engagement
● Loose bolts and nuts ............................. Tighten bolts and nuts.
● Improper motion of gear shift lever ....... Adjust shift lever.
● Transmission control cables worn ......... Replace cables.
● Rigid shift lever bushing and/or ............. Replace as required.
sticking of bolt pin.
Lubrication
● Improper lubrication of control .............. Lubricate as required.
lever
● Shortage of gear oil and/or low oil ........ Add oil or change oil as required.
viscosity
Noise Transmission
● Grinding in transmission ....................... Check for screws, bolts or other
foreign materials in transmission.
● Loose transmission to engine ............... Tighten bolts.
mounting bolts
● Gear and bearing worn or damaged ..... Replace as required.
Lubrication
● Shortage of gear oil and/or low ............. Add oil or change oil as required.
oil viscosity
Gear oil leaks Transmission

● Leaks at the front and rear bearing ....... Repair and replace as required.
retainer seal and gasket, case
cover gasket, sand hole of case
or shift shaft expansion plug
● Improper amount of gear oil and ........... Check oil level and type.
lack of oil viscosity
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SPECIAL TOOLS
Prior to starting a transmission overhaul, it is necessary to have the following special tools.
Illustration Tool No. Tool name
09839-4601 SOCKET WRENCH
09420-1442 SLIDING HAMMER
09650-2070 INPUT SHAFT PULLER
09650-1101 PULLER
09653-1190
HOOK
09653-1160
09650-1881 PULLER
1 page 1
Illustration Tool No. Tool name
09650-2080 PULLER
1 page 1
REMOVAL AND INSTALLATION
1 4
5
2 6
A
7
3
8
10 9
12
11
12
13
1. Nut 6. Plain washer 11. Filler plug
2. Rear engine mounting bracket, RH 7. Rear engine mounting 12. Soft washer
3. Rear engine mounting, RH 8. Rear engine mounting bracket 13. Drain plug
4. Rear engine mounting 9. Rear engine mounting bracket, LH
5. Flange nut 10. Rear engine mounting bracket, LH
Fig. 1
REMOVAL OF TRANSMISSION
WARNING
Do not work on the transmission while it is still hot.
This can result in personal injury.
1. BLOCK THE WHEELS.

1. Park the vehicle on level ground.
2. Block the wheels.
Fig. 2
NOTE: Be sure to apply wheel stoppers in the front tires.
2. DRAIN THE OIL FROM THE TRANSMISSION.
SLIT Remove the drain plug and drain the transmission oil.
The transmission oil should be drained into a suit-
able container.
3. DISCONNECT THE PROPELLER SHAFT FROM THE
TRANSMISSION.
NOTE: Disconnect the propeller shaft in accordance
PROTRUSION
with CHAPTER 9, PROPELLER SHAFT.
Fig. 3 SM9-211 SM9-213
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4. REMOVE THE TRANSMISSION FLANGE LOCK NUT.

1. Lift the staked part completely out of the shaft groove.
2. Using a special tool or commercial tool, remove the
lock nut.
NOTE: ● Insufficient spread of the staked part will
cause damage to the threads of the output
shaft, when loosening the nut.
● Before loosening the lock nut, apply the
parking brake so that the output shaft can
not be turned.
Fig. 4 SMTM-518 Special Tool: Socket Wrench (09839-4601)
5. REMOVE THE PARKING BRAKE DRUM.
6. REMOVE THE FLANGE COUPLING.
7. REMOVE THE PARKING BRAKE WITH PARKING
BRAKE CABLE.
1. Remove the parking brake fitting nuts.
2. Remove the parking brake with cable.
Fig. 5 SMTM-519
8. DISCONNECT THE ELECTRIC HARNESS AND THE
SPEEDOMETER CABLE FROM THE TRANSMISSION.
9. DISCONNECT THE TRANSMISSION CONTROL LINES.
10. DISCONNECT THE CLUTCH SLAVE CYLINDER.
SPEEDOMETER CABLE
1. Remove the tension spring.
2. Remove the slave cylinder.
NOTE: Do not remove the clutch control piping un-
less absolutely necessary. Air bleeding is not
TRANSMISSION required when reassembling.
CONTROL
CABLES
TENSION SPRING
SLAVE CYLINDER
ELECTRIC HARNESS
Fig. 6 SMTC-190A
11. DISCONNECT THE EXHAUST PIPE FROM THE EX-
HAUST MANIFOLD.
HEAT
INSULATOR
Fig. 7
1 page 1
12. REMOVE THE TRANSMISSION.

1. Remove both sides of the engine stoppers from the
rear engine mounting.
2. Remove the lower bolts around the clutch housing.
3. Place a transmission jack under the transmission.
4. Remove the rear engine mounting fitting nuts.
5. Lower the transmission jack until the rear engine
mounting stud bolts come out from the cross mem-
ber.
Fig. 8 SMTM-184A
6. Support the engine by locating a jack or a safety
stand under the flywheel housing.
7 Remove the remaining bolts around the clutch hous-
ing.
8. Pull the transmission backwards. Lower the trans-
mission jack and pull the transmission out from un-
der the truck.
WARNING
In using the transmission jack, exercise care when
installing or removing to prevent it from dropping
off the jack because it is heavy and unstable.
13. REMOVE THE CLUTCH HOUSING FROM THE TRANS-

MISSION CASE.
14. MOUNT THE TRANSMISSION ASSEMBLY ON A
WORKSTAND.
15. IF NECESSARY, REMOVE THE REAR ENGINE MOUNT-
ING FROM THE TRANSMISSION.
INSTALLATION OF TRANSMISSION
MOUNTING BRACKET MOUNTING 1. INSTALL THE REAR ENGINE MOUNTING ON THE
TRANSMISSION.
1. Clean the contact surface of the mounting brackets
and the transmission case.
2. Install the mounting bracket on both sides of the
transmission case.
3. Finger tighten the fitting bolts.
4. Check that the brackets are flush with the transmis-
sion case, then tighten completely.
Tightening Torque: 650 – 850 kg·cm (47 – 61 lb·ft)
5. Install the rear mounting under the mounting bracket
and tighten the fitting bolts.
NOTE: Make sure to position the wide side of the rear
engine mounting rearward.
Fig. 9
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2. INSTALL THE CLUTCH HOUSING ON THE TRANSMISSION.

1. Coat the front surface of the transmission case with
sealing compound.
NOTE: The sealing compound should be equivalent
to Threebond #1216.
DIAMETER 2. Coat the seal cover with a rust preventive coating.
4—6 mm 3. Install the clutch housing on the transmission and
(0.16—0.23 in.) tighten the fitting bolts.
SEARING Tightening Torque: 2,500 – 3,300 kg·cm (181 – 239 lb·ft)
COMPOUND
3. COAT THE INPUT SHAFT SPLINE WITH THE HEAT
SEAL COVER
RESISTANCE GREASE.
Fig. 10
4. INSTALL THE TRANSMISSION.

WARNING
In using the transmission jack, exercise care when
installing or removing to prevent it from dropping
off the jack because it is heavy and unstable.
1. Jack up the transmission until the input shaft and
the clutch disc spline align.
2. Slip the transmission in and attach the clutch hous-
Fig. 11 SMTM-184A ing to the engine.
3. Install the upper fitting bolts around the clutch
SCREW
housing.
DRIVER 4. Install the rear engine mounting on the cross
GUIDE member by lifting the transmission with a jack.
HOLE
CROSS MEMBER NOTE: When installing the mounting on the cross
member, install it by inserting a screwdriver
through the guide holes on the mounting and
the cross member and positioning the long
REAR ENGINE
holes on the cross member with the stud bolts
MOUNTING of the mounting. If the stud bolts are dam-
aged by accident be sure to rethread them
Fig. 12 or replace the rear engine mounting.
5. Install the mounting fitting nuts.
6. Lower the transmission jack and pull the jack out from
under the truck.
7. Install the remaining bolts around the clutch hous-
ing.
8. Tighten the transmission fitting bolts around the
clutch housing.
Fig. 13 SMTM-516A
5. CONNECT THE EXHAUST PIPE TO THE EXHAUST

MANIFOLD.
1. Connect the exhaust pipe to the exhaust manifold.
2. Install the heat insulator on the exhaust pipe.
HEAT
INSULATOR
Fig. 14
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6. INSTALL THE CLUTCH SLAVE CYLINDER.

1. Install the slave cylinder on the bracket and tighten
the fitting bolts.
SPEEDOMETER CABLE 2. Install the tension spring.
7. CONNECT THE TRANSMISSION CONTROL CABLES.
Install the control cable bracket on the transmission
and tighten the fitting bolts.
Tightening Torque:
TRANSMISSION
CONTROL Transmission side 380 – 500 kg·cm (28 – 36 lb·ft)
CABLES
Flywheel Housing side 190 – 260 kg·cm (14 – 18 lb·ft)
TENSION SPRING
SLAVE CYLINDER 8. CONNECT THE ELECTRIC HARNESS AND THE
SPEEDOMETER CABLE TO THE TRANSMISSION.
ELECTRIC HARNESS
Fig. 15
9. INSTALL THE PARKING BRAKE.
Install the parking brake with the cable and tighten
the fitting nuts.
Tightening Torque: 900 – 1,200 kg·cm (66 – 86 lb·ft)
10. INSTALL THE FLANGE COUPLING.
11. INSTALL THE PARKING BRAKE DRUM.
NOTE: Secure the parking brake drum with a propel-
ler shaft fitting bolts and nuts.
Fig. 16 SMTM-520
12. INSTALL THE TRANSMISSION FLANGE LOCK NUT.
1. Install the O-ring in the flange coupling.
2. Install the lock nut on the output shaft and tighten it.
NOTE: ● Before tightening the lock nut, apply the
parking brake so that shaft can not be
turned.
● Do not damage the O-ring.
Tightening Torque: 6,000 – 8,000 kg·cm (434 – 578 lb·ft)
Special Tool: Socket Wrench (09839-4601)
Fig. 17 SMTM-521
3. Lock the flange lock nut by staking the lip into the
DEPTH output shaft slots.
NOTE: ● More than 1.5 mm (0.059 in).
● Stake portion should be fitted in the groove
thoroughly.
● Staking should be done without rift.
Fig. 18
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13. CONNECT THE PROPELLER SHAFT.

SLIT NOTE: To connect the propeller shaft, refer to CHAP-
TER 9, PROPELLER SHAFT.
14. FILL THE TRANSMISSION WITH GEAR OIL UP TO
BOTTOM OF FILLER PLUG.
Clean and tighten the drain plug with new gasket.
Oil Capacity: Approx. 6.0 liters
PROTRUSION
(6.38 US Qt., 5.25 Imp. Qt.)
Tightening Torque: 800 – 1,200 kg·cm (58 – 86 lb·ft)
Fig. 19 SM9-213 SM9-211
15. CHECK THE CLUTCH PEDAL PLAY.
1. Depress the clutch pedal and measure the distance
that the pedal travels before resistance is felt.
Standard: 50 – 65 mm (1.97 – 2.55 in.)
Service Limit: 30 mm (1.18 in.)
2. If the pedal stroke is less than 30 mm (1.18 in.), ad-
just the clutch control system in accordance with
CHAPTER 6, CLUTCH CONTROL.
CLUTCH PEDAL PLAY
16. CHECK THE GEAR SHIFT IN EACH POSITION.
Fig. 20
17. CHECK THE PARKING BRAKE LEVER STROKE.
1. Pull the parking brake lever with about 30 kg (66 lb)
force and count the number of clicks.
Standard: 3–6 clicks.
2. If the lever stroke exceeds 8 clicks, adjust the park-
ing brake system in accordance with CHAPTER 14,
PARKING BRAKE.
WARNING
Fig. 21 SM14-061 Failure to perform this adjustment may lead to an
accident resulting in personal injury and/or prop-
erty damage.
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GEAR SHIFT HOUSING
ASM7-008
1. Shift lever shaft 19. Expansion

2. O-ring 20. Interlock pin
3. Plug 21. 2nd & 3rd shift shaft
4. Shift lever shaft housing 22. Pin
5. Shift inner lever 23. 2nd & 3rd shift fork
6. Nut 24. 4th & 5th shift shaft
7. Lock washer 25. Interlock plunger
8. Select outer lever 26. 4th & 5th shift fork
9. Shift lever pin 27. 4th & 5th shift head
10. Lock washer 28. Transmission case cover
11. Nut 29. Air breather
12. Plain washer 30. Back-up lamp switch
13. Oil seal 31. 1st & reverse shift shaft
14. Lock washer 32. 1st & reverse shift fork
15. Set screw 33. 1st & reverse shift head
16. Plain washer 34. Compression spring
17. Expansion plug 35. Steel ball
18. Select lever shaft
Fig. 1
1 page 1
DISASSEMBLY OF GEAR SHIFT HOUSING

NOTE: ● Examine to see if any parts are worn or if
any abnormal interference or play exists
when moving each shift fork. Disassemble
the transmission and replace faulty parts,
if any.
● Be sure that no pins and springs are left
inside the gear shift housing.
1. REMOVE THE SHIFT LEVER SHAFT HOUSING.

Remove the housing fitting bolts and remove the
housing from the transmission case cover.
2. REMOVE THE TRANSMISSION CASE COVER.

Remove the case cover fitting bolts and remove the
case cover from the transmission case.
3. DISASSEMBLE THE TRANSMISSION CASE COVER.
WARNING
The steel ball may pop out from the hole. Wear safety
glasses to protect your eyes.
Fig. 2 SMTM-601
1. Remove the back-up lamp switch.
2. Clamp the case cover in a soft jaw vise.
Fig. 3 SMTM-435A
4. REMOVE THE PIN.
1. Set the transmission case cover on a vise.
2. Drive out the shift head and shift fork fitting pins with
a 5 mm (0.197 in.) diameter tapping rod.
Fig. 4 SM7-343
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5. REMOVE THE GEAR SHIFT SHAFT, SHIFT FORK AND

SHIFT HEAD.
1. Set each shift shaft in the neutral position.
2. Hold a copper rod against the end of the shift shaft
and tap the rod lightly to remove the shaft and its
expansion plug. When removing the shift shaft,
remove the shift head and shift fork.
NOTE: Take care not to damage the sliding parts in-
side the gear shift housing.
Fig. 5 SMTM-436C
6. REMOVE THE LOCK BALL AND COMPRESSION
SPRING.
NOTE: Do not lose the lock ball and compression
spring.
WARNING
The steel ball may pop out from the hole. Wear safety
glasses to protect your eyes.
Fig. 6 SMTM-437
7. REMOVE THE INTERLOCK PLUNGER.
NOTE: Do not lose the interlock plunger.
Fig. 7 SMTM-438
8. REMOVE THE INTERLOCK PIN.
NOTE: ● Do not lose the interlock pin.
● Disassemble the other shift shaft, shift
forks, and shift heads following the same
procedures (Item 5 through 8).
Fig. 8 SMTM-439
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INSPECTION OF GEAR SHIFT HOUSING

1. CHECK THE SHIFT LEVER SHAFT AND INNER SHIFT
LEVER FOR WEAR OR DAMAGE.
If any wear or damage is detected, replace the part.
Fig. 9 TM-471A
2. CHECK THE OIL SEAL FOR WEAR AND DAMAGE.
If any wear or damage is detected, replace the oil
seal.
Fig. 10 SMTM-447
3. CHECK THE FOLLOWING COMPONENT PARTS FOR
WEAR OR DAMAGE: INTERLOCK PIN, INTERLOCK
PLUNGER, COMPRESSION SPRING AND BALL.
If any wear or damage is detected, replace the parts.
Fig. 11 SMTM-472
4. CHECK THE CLEARANCE BETWEEN THE SHIFT FORK
AND SHIFT SLEEVE.
If the clearance is greater than the service limit,
replace the shift fork and/or shift sleeve.
Assembly Standard: 0.20 – 0.45 mm (0.0079 – 0.0177
in.)
Service Limit : 1.0 mm (0.039 in.)
Fig. 12 SMTM-472A
5. CHECK THE SHIFT HEAD, SHIFT FORK AND SHIFT
SHAFT FOR WEAR OR DAMAGE.
Fig. 13 SMTM-472B
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ASSEMBLY AND INSPECTION OF GEAR

SHIFT HOUSING
6. INSTALL THE SHIFT SHAFT, SHIFT FORK AND SHIFT
HEAD.
1. Apply gear oil to the shift shaft.
Fig. 14 SMTM-436D
2. Align the shift fork and head and put the shift shaft
through.
NOTE: ● Pay special attention to the position and
direction of the shift fork and shift head.
● Refer to the diagram on the left for the rela-
tive position of the component parts.
● Assemble the shift shafts, shift forks, and
shift heads following procedures (Item 6
A B C
through 10).
Fig. 15 SM7-144A
A : 4th-5th shift fork
D E B : 2nd-3rd shift fork
C : 1st-Reverse shift fork
D : Steel ball
E : Compression spring
F : 4th-5th shift shaft
G : 2nd-3rd shift shaft
F G H I H : Interlock plunger
I : 1st-Reverse shift shaft
Fig. 16 SM7-145A
7. INSTALL THE STEEL BALL AND COMPRESSION
SPRING.
1. Place the ball and spring in the hole.
2. Depress the ball and spring with a suitable tool and
slide the shift shaft over the ball.
NOTE: The shift shaft must be in the neutral posi-
tion.
Fig. 17 SMTM-437
8. SECURE THE SHIFT HEAD AND FORK WITH COTTER
PINS.
Use two pins. Drive both the large and the small pin
into the fork and the head, with their slits positioned
on opposite side.
Fig. 18 SM7-344
1 page 1
9. INSTALL THE INTERLOCK PLUNGER.

NOTE: Do not forget to install the interlock plunger.
Fig. 19 SMTM-438D
10. INSTALL THE EXPANSION PLUGS IN THE SHIFT
SHAFT OPENINGS AT EACH END OF THE HOUSING.
NOTE: Apply sealing compound.
Fig. 20 SMTM-449
11. TIGHTEN THE BACK-UP LAMP SWITCH.
Tightening Torque: 270 – 320 kg·cm (20 – 23 lb·ft).
NOTE: Apply thread locking agents.
Fig. 21 SMTM-601
12. CHECK THE FUNCTIONING OF THE BACK-UP LAMP
SWITCH.
Using an ohmmeter, check the continuity between the
terminals within the neutral position (infinity) and with
the gear shift shaft in the reverse position (0 ohm). If
not correct, replace the switch.
Fig. 22 SMTM-602
13. CHECK THE RELATIVE POSITION AND DIRECTION OF
EACH SHIFT FORK AND SHIFT HEAD AND CHECK
THE INTERLOCK OPERATIONS.
Dimension:
A : 113 mm (4.45 in.)
B : 116 mm (4.57 in.)
A B
Fig. 23 SM7-153A
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14. MEASURE THE SHIFT STROKE.

Shift Stroke:
A : 12.0 mm (0.472 in.)
A A A A A A
Fig. 24 SM7-152A
15. INSTALL THE GEAR SHIFT HOUSING.
1. Coat the face of the transmission case with liquid
gasket.
LIQUID GASKET NOTE: ● The trace of the liquid gasket should be
continuous.
DIAMETER: 4–6 mm
● The liquid gasket should be Threebond
(0.158–0.236 in.) Room Temperature Vulcanizer #1215 or
equivalent.
Fig. 25 SMTM-474D
2. Install the gear shift housing and fitting bolts.
3. Using a torque wrench, tighten the bolts.
Fig. 26 SMTM-474C
16. INSTALL THE SHIFT LEVER SHAFT HOUSING ON THE

DIAMETER:
APPROX. 3 mm TRANSMISSION CASE COVER.
(0.1181 in.) 1. Coat the face of the shift housing cover with liquid
gasket.
NOTE: ● The trace of the liquid gasket should be
continuous.
● The liquid gasket should be Three Bond
Room Temperature Vulcanizer #1215 or
equivalent.
Fig. 27 SMTM-469B
2. Install the housing on the case cover.
3. Tighten the fitting bolts.
Fig. 28 SMTM-469C
1 page 1
INPUT SHAFT, OUTPUT SHAFT, GEARS AND RELATED PARTS
13 14
6 X
1
31
11 30
10 29
1 9 28
1 Y 27
4 2
3 13 22 15
2 7 13
1 21 26
12 20
8 25
7 19
18 13 24
6 17 23
5 12 7
11
7 10
6 9 Y
1
16 39
13
15 33
1 8 36 38
27
35
34
X
37
27
33
32 33
41
40
GEAR RATIO
42
42 43
44
1. Retainer ring 16. 3rd gear 31. Lock nut

2. Cylindrical bearing 17. Synchronizer double cone 32. Front bearing retainer
3. Input shaft 18. Synchronizer inner cone 33. Gasket
4. Spacer 19. Pin 34. Transmission case
5. Roller bearing 20. Synchronizer bush 35. Straight pin
6. Synchronizer cone 21. 2nd gear 36. Speedometer driven gear bushing
7. Synchronizer ring 22. Output shaft 37. Speedometer driven gear
8. Synchronizer hub 23. 1st gear 38. Speedometer drive gear
9. Compression spring 24. Constant sleeve 39. Rear bearing retainer
10. Synchronizer head 25. Constant hub 40. Power take off cover
11. Synchronizer key 26. Reverse gear 41. Transmission speedometer gear
12. Synchronizer sleeve 27. Oil seal and gear ratio plate
13. Needle roller bearing 28. Dust deflector 42. Soft washer
14. 4th gear 29. Universal joint flange 43. Filler plug
15. Bushing 30. O-ring 44. Drain plug
Fig. 1
1 page 1
INPUT SHAFT, OUTPUT SHAFT, GEARS AND RELATED PARTS
13 14
6 X
1
31
11 30
10 29
1 9 28
1 Y 27
4 2
3 13 22 15
2 7 13
1 21 26
12 20
8 25
7 19
18 13 24
6 17 23
5 12 7
11
7 10
6 9 Y
1
16 39
13
15 33
1 8 36 38
27
35
34
X
37
27
33
32 33
41
40
GEAR RATIO
42
42 43
44
1. Retainer ring 16. 3rd gear 31. Lock nut

2. Cylindrical bearing 17. Synchronizer double cone 32. Front bearing retainer
3. Input shaft 18. Synchronizer inner cone 33. Gasket
4. Spacer 19. Pin 34. Transmission case
5. Roller bearing 20. Synchronizer bush 35. Straight pin
6. Synchronizer cone 21. 2nd gear 36. Speedometer driven gear bushing
7. Synchronizer ring 22. Output shaft 37. Speedometer driven gear
8. Synchronizer hub 23. 1st gear 38. Speedometer drive gear
9. Compression spring 24. Constant sleeve 39. Rear bearing retainer
10. Synchronizer head 25. Constant hub 40. Power take off cover
11. Synchronizer key 26. Reverse gear 41. Transmission speedometer gear
12. Synchronizer sleeve 27. Oil seal and gear ratio plate
13. Needle roller bearing 28. Dust deflector 42. Soft washer
14. 4th gear 29. Universal joint flange 43. Filler plug
15. Bushing 30. O-ring 44. Drain plug
Fig. 1
1 page 1
DISASSEMBLY OF INPUT SHAFT, OUTPUT

SHAFT, GEAR AND RELATED PARTS
1. REMOVE THE REAR BEARING RETAINER.
1. Remove the rear bearing retainer.
a. Remove the bearing retainer fitting bolts.
b. Remove the bearing retainer.
Fig. 2 SMTM-475C
2. Remove the speedometer driven gear.
a. Remove the driven gear bushing setting bolt.
b. Remove the driven gear with bushing.
Fig. 3 SMTM-450
3. Remove the oil seal.
Fig. 4 SMTM-420
2. REMOVE THE SPEEDOMETER DRIVE GEAR.
Fig. 5 SMTM-451
3. REMOVE THE FRONT BEARING RETAINER.
Remove the bearing retainer.
a. Remove the fitting bolts.
b. Remove the bearing retainer.
NOTE: An oil seal is attached inside the front bear-
ing retainer. Cover (e.g. with aluminum foil)
the spline of the input shaft so as not to dam-
age the lip of the oil seal when removing the
retainer.
Fig. 6 SMTM-452
1 page 1
4. REMOVE THE INPUT SHAFT.

1. Using the special tools, pull out the input shaft with
the accompanying bearings.
Special Tools: Input shaft puller (09650-2070)
Sliding hammer (09420-1442)
Fig. 7 SM7-232
2. Using retainer ring pliers, remove the retainer ring
from the input shaft.
WARNING
The retainer ring is spring steel and may pop out of
the groove. Wear safety glasses to protect your eyes.
Fig. 8 SMTM-453
3. Using a press, remove the cylindrical bearing.
Fig. 9 SM7-357
4. Using a screw driver, remove the retainer ring from
the groove of the input shaft, then remove the roller
bearing from the input shaft.
WARNING
Fig. 10 SMTM-454
5. REMOVE THE REAR BEARING.
1. Remove the retainer ring from the output shaft rear
bearing.
WARNING
Fig. 11 SMTM-455
1 page 1
2. Attach special tools to the bearing.

Special Tools: Hook (09653-1190)
Puller (09650-1881)
NOTE: Insert the hook’s click into the groove for the
retainer ring, then secure the puller to the
hook with bolts. Secure the puller so that it
does not turn, then rotate the bolt to pull the
bearing out.
Fig. 12 SM7-080
3. Remove the rear bearing.
Fig. 13 SMTM-395A
6. ATTACH A JIG TO THE END OF THE OUTPUT SHAFT.
WARNING
If the output shaft assembly is removed from the
transmission without a jig, the reverse gear will drop
from the shaft and possibly result in personal in-
jury.
7. REMOVE THE OUTPUT SHAFT ASSEMBLY FROM THE

TRANSMISSION CASE.
When removing the output shaft assembly, remove
the synchronizer ring and the cone of the input shaft
gear.
JIG (NUT AND ROD)
Fig. 14 SMTM-456A
8. DISASSEMBLE THE OUTPUT SHAFT.
1. Remove the jig from the end of the output shaft.
Fig. 15 SM7-256
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2. Remove the reverse gear.
Fig. 16 SM7-173E
3. Remove the reverse gear needle roller bearing.
Fig. 17 SM7-173F
4. Remove the constant sleeve.
Fig. 18 SMTM-477A
5. Remove the retainer ring at the Front face of the
output shaft.
WARNING
Fig. 19 SMTM-478C
6. Remove the 4th-5th synchronizer unit.
Fig. 20 SMTM-479A
1 page 1
7. Remove the 4th synchronizer ring.
Fig. 21 SMTM-558A
8. Remove the 4th gear.
Fig. 22 SMTM-171D
9. Remove the 4th gear needle roller bearing.
Fig. 23 SM7-171E
10. Remove the retainer ring which is securing the 3rd
gear bushing to the output shaft.
WARNING
Fig. 24 SMTM-478B
1 page 1
11. Press the main shaft rear end through the bushing
and gears by supporting the assembly on front face
of the 1st gear.
WARNING
Stay out from under the shaft during removal. The shaft
could drop suddenly resulting in personal injury.
BUSHING
NOTE: When removing the output shaft, do not
CONSTANT HUB allow the shaft to drop on a hard surface.
1ST GEAR
12. Disassemble the reverse gear bushing, constant hub
and 1st gear.
Fig. 25 SMTM-481C
13. Remove the constant hub.
Fig. 26 SM7-173C
14. Remove the 1st gear.
Fig. 27 SM7-168B
15. Remove the 1st gear needle roller bearing.
Fig. 28 SM7-168D
1 page 1
16. Press the main shaft rear end through the bushing
and gears by supporting the assembly on front face
of the 2nd gear.
3RD GEAR BUSH
SYNCHRONIZER
WARNING
2ND GEAR UNIT Stay out from under the shaft during removal. The shaft
could drop suddenly resulting in personal injury.
NOTE: When removing the output shaft, do not

SUPPORT
allow the shaft to drop on a hard surface.
Fig. 29
17. Remove the 3rd gear bushing.
Fig. 30
18. Remove the 3rd gear.
Fig. 31
19. Remove the 3rd gear needle roller bearing.
Fig. 32
20. Remove the 2nd – 3rd synchronizer unit.
Fig. 33
1 page 1
21. Disassemble the bushing (including inner cone, pins,

PIN double cone and synchronizer ring).
SYNCHRONIZER a. Remove the synchronizer ring.
RING DOUBLE CONE b. Remove the double cone.
INNER CONE c. Remove the inner cone.
BUSH
d. Remove the four pins.
e. Remove the bushing.
Fig. 34
22. Remove the 2nd gear sub assembly.
Fig. 35
23. Remove the 2nd gear needle roller bearing.
Fig. 36 SM7-168C
9. DISASSEMBLE THE SYNCHRONIZER UNIT.
1. Remove the sleeve.
Fig. 37 SMTM-485
2. Remove the synchronizer key and head.
WARNING
The compression spring is spring steel and may pop
out of the hole. Wear safety glasses to protect your
eyes.
Fig. 38 SMTM-485A
1 page 1
3. Remove the compression spring.
Fig. 39 SMTM-485B
10. REMOVE THE SYNCHRONIZER CONE.
1. Remove the retainer ring, which secures synchronizer
cone to the gear (for 3rd and 4th gears).
WARNING
Fig. 40 SMTM-457
2. Remove the synchronizer cone from the gear.
Fig. 41 SMTM-486
1 page 1
INSPECTION OF INPUT SHAFT, OUTPUT

SHAFT, GEARS AND RELATED PARTS
1. CHECK THE GEARS AND SHAFTS.
1. Check all gears for cracks and defects on tooth sur-
faces.
If any crack or defect is detected, replace the gear.
Fig. 42 SM7-092
2. Check the input shaft for wear or damage. If any wear
or damage is detected, replace the shaft.
Fig. 43 SMTM-426
3. Check the output shaft for wear or damage.
If any wear or damage is detected, replace the shaft.
Fig. 44 SMTM-426
2. CHECK THE SYNCHRONIZER UNITS.
1. Check the synchronizer units for wear or damage to
each component.
If any wear or damage is detected, replace the com-
ponent.
Fig. 45 SM7-485E
2. Check the tapered parts and the gears of each syn-
chronizer cone for wear or damage.
If any wear or damage is detected, replace the syn-
chronizer cone.
Fig. 46 SM7-093
1 page 1
3. Check the synchronizer ring, double cone, bush and

inner cone.
If any wear and damage is defected, replace them.
Fig. 47
4. Measure the clearance between the synchronizer
rings and the tapered parts of the synchronizer cones
or gear dog. If the clearance is less than the service
limit, replace the synchronizer ring and/or cone.
Assembly Standard:
2nd and 3rd gear: 1.0 – 1.8 mm (0.040 – 0.070 in.)
4th and 5th gear: 1.2 – 2.0 mm (0.048 – 0.078 in.)
Service Limit: 0.2 mm (0.008 in.)
SM7-257
[3rd–5th] [2nd]
Fig. 48
5. Check the contact between the synchronizer rings
and the tapered parts of the synchronizer cones.
If the contact area is less than 90%, replace the syn-
chronizer ring and/or cone.
Total Contact Area: 90% or more
Fig. 49 SMTM-355
3. CHECK THE BEARING.
1. Check the cylindrical bearings for wear or damage.
If any wear or damage is detected, replace the bear-
ing.
Fig. 50 SMTM-487
1 page 1
2. Check the needle roller bearing for wear or damage.

If any wear or damage is detected, replace the bear-
ing.
Fig. 51 SMTM-488
4. CHECK THE OIL SEALS.
Check the oil seals for wear or damage.
If an oil seal is worn or damaged, replace it.
Fig. 52
5. CHECK THE SPEEDOMETER GEARS.
Check the speedometer drive gear and driven gear.
If either is worn or damaged, replace it.
Fig. 53 SMTM-489
1 page 1
ASSEMBLY OF INPUT SHAFT, OUTPUT

SHAFT, GEARS AND RELATED PARTS.
1. ASSEMBLE THE SYNCHRONIZER UNIT.
1. Install the compression spring.
NOTE: Assemble the 2nd-3rd and 4th-5th synchronizer
units.
Fig. 54 SMTM-485B
2. Install the synchronizer key and head.
WARNING
The compression spring is spring steel and may pop
out of the hole. Wear safety glasses to protect your
eyes.
Fig. 55 SMTM-485A
3. Install the synchronizer sleeve.
Fig. 56 SMTM-485
2. INSTALL THE SYNCHRONIZER CONE.
1. Install the synchronizer cone on the 3rd, 4th and 5th
gears.
Fig. 57 SMTM-486
2. Secure the synchronizer cone and gear with the re-
tainer ring.
NOTE: Be sure to install the retainer ring in the gear
groove.
WARNING
Fig. 58 SMTM-457
1 page 1
3. ASSEMBLE THE OUTPUT SHAFT.

1. Install the needle roller bearing for 1st gear onto the
output shaft.
NOTE: Apply gear oil on each needle roller bearing
and gear.
Fig. 59 SMTM-168C
2. Install the 1st gear.
Fig. 60 SMTM-490B
3. Install the 1st-reverse constant hub.
Fig. 61 SM7-345
4. Install the reverse gear bushing.
Heat the bushing to approximately 125°C (257°F) in
a heater and place on output shaft against end stop.
WARNING
Do not handle the bushing with bare hands when it
is heated.
Fig. 62 SMTM-460A
5. Install the needle roller bearing for the reverse gear.
Fig. 63 SM7-173H
1 page 1
6. Install the constant sleeve.
Fig. 64 SMTM-499A
7. Install the reverse gear.
Fig. 65 SM7-173D
8. Hold the thrust washer with a jig.
WARNING
If the output shaft assembly is installed to the trans-
mission without a jig, the reverse gear will drop from
the shaft and possibly result in personal injury.
Fig. 66 SM7-256B
9. Install the needle roller bearing for the 2nd gear.
Fig. 67 SMTM-169I
10. Install the 2nd gear.
Fig. 68 SMTM-491B
1 page 1
11. Heat the synchronizer bushing for about 5 minutes

in water or oil heated to 120°C to 130°C (248°F to
266°F).
Then install the synchronizer bushing on the shaft.
NOTE: Do not heat the synchronizer bushing in ex-
cess of 150°C (302°F).
If the unit has been warmed with hot water,
remove moisture before installation
Fig. 69 WARNING
Never touch hot water and heated synchronizer
bushing with your bare hands. This can result in
personal injury.
BUSHING
Fig. 70
12. Install the inner cone, double cone, synchronizer ring
and pins.
SYNCHRO-
NIZER a. Install the inner cone.
RING DOUBLE
CONE b. Install the double cone.
INNER CONE c. Install the synchronizer ring.
BUSHING
d. Install the pin.
Fig. 71
1 page 1
13. Heat the 2nd-3rd synchronizer unit for about 5 min-

utes in water or oil heated to 120°C to 130°C (248°F
to 266°F).
Then install the synchronizer unit on the shaft.
NOTE: Do not heat the synchronizer unit in excess
of 150°C (302°F).
remove moisture before installation.
Fig. 72 WARNING
Never touch hot water and heated synchronizer unit
with your bare hands. This can result in personal
injury.
14. Install the 3rd gear.
Fig. 73 SM7-170E
15. Install the needle roller bearing for 3rd gear.
Fig. 74 SM7-169J
16. Heat the 3rd gear bushing for about 5 minutes in
water or oil heated to 120°C to 130°C (248°F to
266°F).
Then install the 3rd gear bushing on the shaft.
NOTE: Do not heat the bushing in excess of 150°C
(302°F).
remove moisture before installation.
Fig. 75 SMTM-478B WARNING

Never touch hot water and heated bushing with your
bare hands. This can result in personal injury.
1 page 1
17. Install the retainer ring.

a. Select a retainer ring that will provide a tight fit.
b. Install the retainer ring. Make sure that the retainer
ring seats in place.
WARNING
Fig. 76 SMTM-484B
c. Check the clearance.
Assembly Standard: Zero
Retainer rings are available in the following sizes.
Thickness Color code
2.35 mm (0.0925 in.) None
2.45 mm (0.0965 in.) White
2.55 mm (0.1004 in.) Green
2.65 mm (0.1043 in.) Brown
NOTE: Always use a new retainer ring.

Fig. 77 SMTM-493A
18. Install the 4th gear.
Fig. 78 SM7-171D
19. Install the 4th gear needle roller bearing.
Fig. 79 SM7-171C
20. Install the synchronizer ring.
Fig. 80 SMTM-558A
1 page 1
21. Install the 4th-5th synchronizer unit.
Fig. 81 SMTM-479A
WARNING
Fig. 82 SMTM-478C
1.9 mm (0.075 in.) None
2.0 mm (0.079 in.) White
Fig. 83 SMTM-496B
4. INSTALL THE OUTPUT SHAFT ASSEMBLY IN THE
TRANSMISSION CASE.
1. When installing the output shaft, install the synchro-
nizer ring and cone of the 5th gear.
2. Remove the jig from the end of the output shaft.
Fig. 84 SMTM-456A
5. INSTALL THE REAR BEARING.
1. Before installing the rear bearing, install the retainer
ring on the bearing.
2. Place the bearing side ring and then bearing on the
output shaft. When installing the bearing side ring,
place the side with the larger chamfering closest to
the gear.
3. Apply gear oil to the outer race and inner race.
NOTE: Do not damage the inner race surface.
Fig. 85
1 page 1
6. INSTALL THE INPUT SHAFT.

1. Install the cylindrical bearing with a press.
a. Place the bearing side ring and then bearing on the
input shaft. When installing the bearing side ring, place
the side with the larger chamfering closest to the gear.
b. Apply gear oil to both outer and inner races, then press
the inner race in. Be sure to have good right angle
alignment. Do not put any pressure on the outer race.
Fig. 86 SM7-318
2. Install the retainer rings.
WARNING
Fig. 87 SM7-453
Retainer rings are available in the following
sizes.
2.4 mm (0.094 in.) None
2.5 mm (0.098 in.) White
2.6 mm (0.102 in.) Green
2.7 mm (0.106 in.) Brown
Fig. 88 SM7-310 NOTE: Always use a new retainer ring.

3. Install the cylindrical bearing.
a. Apply gear oil to the bearing.
Fig. 89 SM7-304
b. Place spacers at both ends of the bearing.
NOTE: The cylindrical bearing should be replaced as
a set, if necessary.
RETAINER
RING
SPACER
Fig. 90
1 page 1
WARNING
Fig. 91 SMTM-454
5. Install the input shaft assembly.
Fig. 92 SMTM-374
7. INSTALL THE FRONT BEARING RETAINER.
1. Install the oil seal.
NOTE: Be sure the oil seal is installed in the proper
direction.
Fig. 93 SM7-157A
2. Install the front bearing retainer.
a. When installing the bearing retainer, the gasket must
be installed in such a way that the gasket notch
matches the oil drain hole on the case.
b. Apply chassis grease to the oil seal and the input shaft.
c. Apply liquid gasket to both sides of gasket.
A
continuous.
● The liquid gasket should be Three Bond
Fig. 94 SM7-307
Room Temperature Vulcanizer #HP-17 or
equivalent.
d. Tighten the fitting bolts.
NOTE: Apply liquid gasket or sealing tape to the bolt
thread (A: Bolt).
Fig. 95 SM7-425A
1 page 1
8. INSTALL THE SPEEDOMETER DRIVE GEAR.
Fig. 96 SMTM-451
9. INSTALL THE REAR BEARING RETAINER.
1 Install the speedometer driven gear.
a. Apply chassis grease to the O-ring, oil seal and driven
gear shaft.
b. Insert the driven gear shaft into the bushing.
c. Install the speedometer driven gear with bushing.
Fig. 97 SMTM-450
NOTE: ● Take care not to damage the O-ring and
seal lip.
● Be sure the oil seal is installed in proper
direction.
DRIVEN GEAR BUSHING

OIL SEAL
Fig. 98 SM7-157
2. Match the marks.
MATCH MARK LINE Match the mark line on the speedometer drive gear
bushing with the mark line on the rear bearing
retainer.
No. of drive No. of driven The mark should be

matched with the mark
gear teeth gear teeth on the rear cover
MATCH MARK LINE 6, 8 15, 19 Two lines
Fig. 99
3. Tighten the set screw.
a. Align the speedometer driven gear bushing hole with
the hole of the rear bearing retainer.
b. Install the screw, and tighten it.
Tightening Torque: 83 – 110 kg·cm (6.1 – 7.9 lb·ft)
Fig. 100 SMTM-461

1 page 1
4. Install the oil seal.

NOTE: When installing the oil seal, check right angle
alignment and take care not to damage the
seal lip. Apply chassis grease to the lip.
Fig. 101 SMTM-421A

5. Install the rear bearing retainer, and tighten the fitting bolts.
NOTE: ● Apply liquid gasket or sealing tape to the
bolt threads.
● Apply liquid gasket to both sides of the
gasket.
● The trace of the liquid gasket should be
continuous.
Fig. 102 SM7-324A
equivalent.
RADIAL PLAY
10. INSPECT THE OUTPUT SHAFT GEARS.
BACKLASH END PLAY 1. Measure the backlash.
Assembly Standard:
1st, 2nd and reverse gears:
0.08 – 0.16 mm (0.0032 – 0.0062 in.)
Input shaft, 3rd and 4th gears:
0.04 – 0.12 mm (0.0016 – 0.0047 in.)
Service Limit:
All gears: 0.4 mm (0.016 in.)
Fig. 103
BACKLASH
2. Measure the radial play.
END PLAY
Assembly Standard:
Reverse gears : 0.033 – 0.111 mm (0.0013 – 0.0044 in.)
1st gear : 0.032 – 0.081 mm (0.0013 – 0.0031 in.)
2nd gear : 0.020 – 0.070 mm (0.0008 – 0.0027 in.)
3rd gear : 0.020 – 0.119 mm (0.0008 – 0.0046 in.)
4th gear : 0.019 – 0.064 mm (0.0008 – 0.0025 in.)
Fig. 104 SM7-333
RADIAL PLAY 3. Measure the end play.

Assembly Limit:
1st, 2nd and 3rd gears:
0.15 – 0.30 mm (0.0060 – 0.0118 in.)
4th gear: 0.175 – 0.30 mm (0.0069 – 0.0118 in.)
Reverse gear: 0.20 – 0.35 mm (0.0079 – 0.0137 in.)
Service Limit:
All gear: 0.5 mm (0.020 in.)
Fig. 105 SM7-334
1 page 1
COUNTER SHAFT, REVERSE IDLER SHAFT AND GEARS
1
3
6
10
11
7
5 9
4
3 8
2 7
1 13
12
14
1. Retainer ring 8. Reverse idler gear

2. Spacer 9. Needle roller bearing
3. Cylindrical bearing 10. O-ring
4. Countershaft drive gear 11. Reverse idler shaft
5. Counter 4th gear 12. Lock plate
6. Countershaft 13. Bolt
7. Thrust washer 14. Seal cover
Fig. 1
1 page 1
DISASSEMBLY OF COUNTER SHAFT, REVERSE

IDLER SHAFT AND GEARS
1. REMOVE THE REAR CYLINDRICAL BEARING.
1. Remove the retainer ring from the countershaft.
WARNING
Fig. 2 SMTM-462B
2. Remove the retainer ring from the rear cylindrical
bearing.
WARNING
Fig. 3 SM7-322B
3. Install special tools on the rear cylindrical bearing.
Special Tools: Hook (09653-1160)
Puller (09650-2080)
NOTE: Insert the hook’s click into the groove for the
retainer ring then secure the puller to the hook
with bolts. Secure the puller so that it does
not turn, then rotate the bolt to pull the bear-
ing out.
Fig. 4 SM7-149A
4. Pull out the cylindrical bearing.
Fig. 5 SMTM-403C
2. REMOVE THE COUNTER SHAFT FROM THE TRANS-
MISSION CASE.
1. Tie a rope or hook around the countershaft (between
3rd and 4th counter gear) and carefully by pry the
countershaft assembly rearward until the front end
of the shaft is clear of the front cylindrical bearing.
2. Carefully lift the countershaft assembly from the case.
Fig. 6 SM7-316A
1 page 1
3. REMOVE THE FRONT CYLINDRICAL BEARING.

1. Using a tapping rod and a hammer, remove the bear-
ing cover.
Fig. 7 SMTM-463
2. Remove the front bearing.
Fig. 8 SMTM-406A
4. REMOVE THE COUNTER SHAFT GEAR.
1. Remove the retainer ring.
WARNING
Fig. 9 SM7-315
2. Using the special tool, pull out the cylindrical bearing
inner race.
Special Tool: Puller (09650-1101)
Fig. 10 SM7-305
3. Using a press, remove the counter shaft drive gear.
Fig. 11 SMTM-375A
1 page 1
5. REMOVE THE REVERSE IDLER GEAR.

1. Remove the idler shaft lock bolt and lock plate from
the case.
Fig. 12 SMTM-5-5E
2. Using the special tool, pull out the reverse idler shaft.
Special Tool: Sliding hammer (09420-1442)
Fig. 13 SM7-177B
3. Remove the reverse idler gear, thrust washers and
needle roller bearing.
Fig. 14 SMTM-506C
1 page 1
INSPECTION OF COUNTER SHAFT, REVERSE

IDLER SHAFT AND GEARS
1. CHECK ALL GEARS FOR CRACKS OR DEFECTS.
If any cracks or defects are detected, replace the
gear.
Fig. 15 SMTM-509G
2. CHECK THE CYLINDRICAL BEARINGS FOR WEAR OR
DAMAGE.
If any wear or damage is detected, replace the cylin-
drical bearing.
Fig. 16 SMTM-487
3. CHECK THE IDLER GEAR, SHAFT, WASHER AND
NEEDLE ROLLER BEARING FOR WEAR OR DAMAGE.
Fig. 17 SMTM-510B
ASSEMBLY AND INSPECTION OF COUNTER

SHAFT, REVERSE IDLER SHAFT AND GEAR
1. INSTALL THE REVERSE IDLER GEAR.
1. Insert the needle roller bearing into the reverse idler
gear, attach thrust washers on both sides and place
the gear in the case.
NOTE: ● Apply a light coat of gear oil to the needle
roller bearing and thrust washers before
assembling them.
● Be sure the gear is installed in the proper
direction.
Fig. 18
1 page 1
2. Insert the O-ring into the gear shaft groove, and ham-
mer the gear shaft into the case.
NOTE: ● Make sure the O-ring is in the shaft groove.
● Apply chassis grease to the O-ring.
Fig. 19 SMTM-505F
3. Insert the lock plate into the shaft and tighten it to
the case with the lock bolt.
Fig. 20 SMTM-505E
2. INSTALL THE COUNTER SHAFT GEAR.
1. Using a press, install the counter shaft gears.
Fig. 21 SMTM-511C
2. Using a press, insert the front bearing inner race
against the stepped part of the counter shaft.
Fig. 22 SMTM-512C
3. Install the retainer ring on the counter shaft.
WARNING
Fig. 23 SM7-315
1 page 1

1.9 mm (0.0748 in.) None
2.0 mm (0.0787 in.) White
2.1 mm (0.0827 in.) Red
2.2 mm (0.0866 in.) Yellow
2.3 mm (0.0906 in.) Blue
2.4 mm (0.0945 in.) Green
Fig. 24 SM7-313 NOTE: Always use a new retainer ring.
3. INSTALL THE COUNTER SHAFT ASSEMBLY IN THE
GEAR CASE.
Fig. 25 SMTM-316A
4. INSTALL THE FRONT BEARING.
NOTE: ● Apply gear oil to the outer race and inner
race.
● Do not damage the inner race face with the
roller bearing.
Fig. 26 SMTM-406
5. INSPECT THE “A” POSITION DISTANCE.
Assembly Standard: 1.5 – 2.0 mm (0.060 – 0.078 in.)
Fig. 27 SM7-309 07-1602

6. INSTALL THE REAR BEARING.
1. Before installing the rear bearing, install the retainer
ring on the bearing.
2. Place the bearing side ring and then bearing on the
counter shaft. When installing the bearing side ring,
place the side with the larger chamfering closest to
reverse gear.
3. Apply gear oil to the outer race and inner race.
Fig. 28 SMTM-405B
1 page 1
7. INSTALL THE RETAINER RING.

Install the retainer ring on the counter shaft.
WARNING
Fig. 29 SM7-315A
2.4 mm (0.094 in.) None
2.5 mm (0.098 in.) White
2.6 mm (0.102 in.) Green
2.7 mm (0.106 in.) Brown

Fig. 30 SM7-313A
8. PRESS IN THE COUNTER FRONT COVER AND BRING
IT FLUSH WITH THE CASE FRONT.
Fig. 31 SMTM-464
9. ROTATE THE COUNTER SHAFT BY HAND AND MAKE
SURE THAT IT TURNS SMOOTHLY.
Fig. 32 SMTM-603
10. INSPECT THE COUNTER SHAFT AND REVERSE IDLER
GEAR.
1. Measure the backlash between the reverse idler gear
and the counter shaft reverse gear.
Assembly Standard: 0.08 – 0.16 mm
(0.0032 – 0.0062 in.)
Fig. 33 SM7-320A
1 page 1
2. Measure the end play of the reverse idler gear.

Assembly Standard: 0.15 – 0.60 mm
(0.0060 – 0.0236 in.)
Fig. 34 SM7-321A
11. INSTALL THE P.T.O. ASSEMBLY.
1. Coat the face of the P.T.O. cover with liquid gasket.
2. Tighten the fitting bolts.
continuous.
equivalent.

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1 INDEX

Models FA and FB (LF05S) TRANSMISSION 7-1

SPECIAL TOOLS ......................................................................... 7- 4

REMOVAL AND INSTALLATION ................................................. 7- 6

GEAR SHIFT HOUSING ............................................................... 7- 12

INPUT SHAFT, OUTPUT SHAFT, GEARS AND

COUNTER SHAFT, REVERSE IDLER SHAFT AND

Symptom Possible cause Remedy

Gear slip-off Control system

Gear shift housing

Difficult gear Engine

Symptom Possible cause Remedy

Difficult gear Control system

Gear oil leaks Transmission

Illustration Tool No. Tool name

09839-4601 SOCKET WRENCH

09420-1442 SLIDING HAMMER

09650-2070 INPUT SHAFT PULLER

Illustration Tool No. Tool name

REMOVAL AND INSTALLATION

1. BLOCK THE WHEELS.

4. REMOVE THE TRANSMISSION FLANGE LOCK NUT.

12. REMOVE THE TRANSMISSION.

13. REMOVE THE CLUTCH HOUSING FROM THE TRANS-

2. INSTALL THE CLUTCH HOUSING ON THE TRANSMISSION.

4. INSTALL THE TRANSMISSION.

5. CONNECT THE EXHAUST PIPE TO THE EXHAUST

6. INSTALL THE CLUTCH SLAVE CYLINDER.

13. CONNECT THE PROPELLER SHAFT.

GEAR SHIFT HOUSING

1. Shift lever shaft 19. Expansion

DISASSEMBLY OF GEAR SHIFT HOUSING

1. REMOVE THE SHIFT LEVER SHAFT HOUSING.

2. REMOVE THE TRANSMISSION CASE COVER.

5. REMOVE THE GEAR SHIFT SHAFT, SHIFT FORK AND

INSPECTION OF GEAR SHIFT HOUSING

ASSEMBLY AND INSPECTION OF GEAR

9. INSTALL THE INTERLOCK PLUNGER.

14. MEASURE THE SHIFT STROKE.

16. INSTALL THE SHIFT LEVER SHAFT HOUSING ON THE

INPUT SHAFT, OUTPUT SHAFT, GEARS AND RELATED PARTS

1. Retainer ring 16. 3rd gear 31. Lock nut

INPUT SHAFT, OUTPUT SHAFT, GEARS AND RELATED PARTS

1. Retainer ring 16. 3rd gear 31. Lock nut

DISASSEMBLY OF INPUT SHAFT, OUTPUT

4. REMOVE THE INPUT SHAFT.

2. Attach special tools to the bearing.

7. REMOVE THE OUTPUT SHAFT ASSEMBLY FROM THE

JIG (NUT AND ROD)

2. Remove the reverse gear.

7. Remove the 4th synchronizer ring.

NOTE: When removing the output shaft, do not

17. Remove the 3rd gear bushing.

21. Disassemble the bushing (including inner cone, pins,

3. Remove the compression spring.

INSPECTION OF INPUT SHAFT, OUTPUT

3. Check the synchronizer ring, double cone, bush and

2. Check the needle roller bearing for wear or damage.

ASSEMBLY OF INPUT SHAFT, OUTPUT

3. ASSEMBLE THE OUTPUT SHAFT.

6. Install the constant sleeve.

11. Heat the synchronizer bushing for about 5 minutes

13. Heat the 2nd-3rd synchronizer unit for about 5 min-