3, TRANSMISSION TR ANmission SECTION 3 TRANSMISSION 1. INTRODUCTION... 2. GENERAL DESCRIPTIONS 2-1. MAIN SPECIFICATIONS .. 2-2, GEAR CONTROL PARTS . = 2-3, EXPLODED VIEW OF GEARSHIFT CONTROL PARTS 2-4, INSPECTION AND MAINTENANCE... 2-5, SERVICING west 2-6. TIGHTENING TORQUE : 2-7. DISASSEMBLY AND REASSEMBLY 3. TRANSMISSION CASE 27 4, QUADRANT BOX... 5. TRANSMISSION ASSEMBLY (K805). 6. TRANSMISSION ASSEMBLY (K1406/K806)..... .. 60 7. TRANSMISSION ASSEMBLY (T9S6, T10S6, T15S6, T16S6)... 74 8. TRANSMISSION (T14S10) ........cccssccsssenteneeetntntiatiseenee 88 9. TRANSMISSION (ZF16S 151/ 221) . . 101 10. DIAGNOSIS AND TROUBLESHOOTING PROCEDURES .. 155 11. SPECIAL TOOLS . 156gurpanouission3. TRANSMISSION 1. INTRODUCTION The transmission is mounted to the rear of the engine and is designed to allow the car to move forward and in reverse. If also has a neutral position. In this position, the engine can run without applying power to the drive wheels Therefore, although there is input o the transmission when the vehicle is in neutral, there is no output from transmission because the driving gears are not engaged to the shaft. ‘A manual transmission is an assembly of gears and shafts that transmits power from the engine to the drive axle and changes in gear ratios are controlled by the driver. By moving the shift lever on a manual transmission and depressing the clutch pedal, various gear and speed ratios can be selected. The gears in a transmission are selected to give the driver a choice of booth speed and torque. Based on T10 TRANSMISSION Synchromesh pq — (Key type) 2nd Reverse tet 5th -— natn] ‘Upper gearshit Clutch housing (Gear shit rail Gearshit fork Lower gearahitt ‘Synchromesh (pin type) Parking brake Pot boating 2 ggasi oat el ENS aisha Jet ty td sth Revers ‘eh Drive pinion Bi Counter shaft Extension housing Synchromesh (key type) Release fork Constant Tr490|3. TRANSMISSION 2. GENERAL DESCRIPTIONS 2-1. MAIN SPECIFICATIONS Bee juonoeup Buyeiou - - - 2000 = e690 2005 | sods —_ ouiBve | 9 > 2oz'tit woz ze veztit —[oonanpor}® 8H | 1 z60 CH d = = (000'1/08 00°10" => (0008 _|(wdinnibay ORE 30h aS edk 9 => [see | voz [ o8ee 300% oze9 1609 seen = 5 = = = = = we a = = = = = = ae ! 6690 eev0 | ovo | — = 60z0 £0 e920 we 3] 000% => [eco | azo | 0007 000 000° 000% ws f oot = [cost | eer | e508 on oust a9 ay eese <> [ese | cere | cere cas ous were pele 102 —> [wer | sese | r99% vere oor Love pee ® eet | vee | sews | se D co's A 5 ; 5 2099 ut L699 ws = ‘osedunpyoge | GoeTunBloe | (ese ueMwleze | (ove dunpzz | (ore ‘aunpdsoz | ©) WORM => (ener ce Taraind eels | _GW vt (eneer sie = > ey = 5 _ (pam unaw wEO FRE ges sow s800 sy wa onouts uo z z z = => versed [owen gag, ot a o = = uease 9 |earenpy 2011 ess ‘orsriL 3071 90h os6L, Eo3. TRANSMISSION T_T isin 2-2. GEAR CONTROL PARTS 2-2-a. TRANSMISSION CONTROL STRUCTURE AND FIXTING TORQUE (kgf.m) DE12TIS/ DEOBTIS Engine (KB05P/ K1406Q/ T10/ T1410 Transmission) em Ertan (KG05P/ K14060/ T10/ T1410 Transmission) — (K605, T1586, Tose, K1406Q, T1086 Tranami 62-93 (Mixer:13.2-20.8) DE12TIS Engine (ZF16S151/221 Transmission) at eS 181/221 Transmission) | A 138-208 ‘Tw2088(kgf-m) DVIST Engine (K1406 Transmission) -1.2-2.3 13.8-208 DVIST Engine (ZF16S151/221 Transmission) 06-14 — 12-23 13.8-208 | 7 aaa ) 12406 / - os - “N —3. TRANSMISSION mission (kgf.m) DVISTIS Engine (2F16S151/221- Telescopic T/M) ETS Erato (2F 16S 151/221- Telescopic TM) 92-54 DVISTIS Engine (T1686 Transmission) 12-29 _Tuseco|3. TRANSMISSION (kgf) DDC Engine (ZF16S151/221 Transmission) 12-28 1223 32-54 rata | | Po a dae -Tws220| 8TRANSMISSION 2-2-b. DISASSEMBLY k605/K1406/T10S6/T14510 Transmission 4 a & 16 Z -raz080| 1. Knob 9. Distance 2. Flange nut 10. Bolt 3. Boot 11, Washer 4. Boot, (inner) 12. Spring 5. Retainer cover 13. Rod assembly(shift) 6. Flange bolt 14, Lock nut 7. Change lever assembly 15. Rod assembly(select) 8. Cushion rubber 16. Lock nut3. TRANSMISSION (ZF 16S-151/221 TRANSMISSION) 16 w2001 eNOMAoNS Knob Flange nut 3/2-way valve Boot Boot, (inner) Retainer cover Flange nut Change lever assembly 10 10. W 12, 13. 14, 15. 16. Cushion rubber Distance Bolt Washer Rod assembly(shift) Lock nut Rod assembly(select) Look nutONE-ROD CHANGE LEVER ( S 0 3. TRANSMISSION 5 —6 ~ ff—s ae ‘r3610| Knob assembly Pattern |. Flange nut Boot Boot(inner) Retainer cover Flange bolt Change lever assembly ©PrNOAAN 10. Bracket change lever mounting 11, Bracket change lever mounting " Bush-change lever Bolt Nut Needle bearing assembly . Spring washer Plain washer Bolt-spring(with washer) . Plain washer3. TRANSMISSION 2-3. EXPLODED VIEW OF GEARSHIFT CONTROL PARTS K805, K1406, T10S6, T14S10 sn mu AM Csom eo — exoeiq Keyes puz | Buds une | por yiys 181 pos yo9}08 is} s9n9}}99)98 VOISSIWISUELL pou wore pe eZ s0n9} lus 10m0d por yius 40191 ‘1 pejsouuog :edh yus 1oMog :z one yys uoissiuis 04 payaouu0g :9dK jenueyy yeos yea -Tuc0s0| 123. TRANSMISSION 2F 16S-151/221 TRANSMISSION Rolay lever A-tet Se Set oa olay lever A-2nd 5 eg hp Sy See 3, aD 195163, TRANSMISSION ZF 16S-151/221 TELESCOPIC TRANSMISSION Fiod complete-telescopic west3. TRANSMISSION 2-4. INSPECTION AND MAINTENANCE 2-4-a, POWER TRAIN STEP 2ulink type ___ter20 Select Left and right travel of change lever -> Forward and backward travel of select control rod “A” —> Angle motion at bracket “B" > Forward and backward travel of select control rod “C” > Selection of shift rod with rotation angle motion of T/M side. Shift Forward and backward travel of change lever —> Forward and backward travel of shift control rod “A’ > Angle motion at bracket “B" > Forward and backward travel of shift control rod “D” > Gear insertion by forward and backward travel of the fork connected to the selected shift rod of T/M side, 2-4-b. MAINTENANCE OF TRANSMISSION SYSTEM Adjust contro! rod as follows, when the gear control is hard and free play is excessive: No HOW TO OPERATE Festion of 1 | Assemble all of the parts for T/M coniroi(however, 8-ton and 39-ton tractors should remain with the return spring removed. __ _ up 2 | Loosen the length adjust nut for the first select rod. and first shift rod. Rotate the first shift rod and first select rod from the front of the vehicle 3 | to make the same length so that the JIG can be inserted into the JIG Down check hole_on the first relay, and then remove the JIG. 7 ‘4 | Tighten the length adjust nut for the first select rod and first shift. Up [4 | (Assembly of return spring) : a / Front View First select rod First shift rod mwer913, TRANSMISSION IG check hole Adjust by rotating the rods rwera2| )) Adjust the length of 1st select and shift rod so that the change lever assembly and two levers con- necting 1st select and shift rod should be vertical. If these two levers are adjusted vertically, the change lever knob is positioned 30mm at left, rearward(toward driver). Change lever knob adjusting steps are as follows(T/M in neutral) (1) Knob, inclined to left or right: Adjust the length of change lever select rod. (2) Knob, inclined forward: Shorten the length of change lever shift rod. (3) Knob, inclined reward: Extend the length of change lever shift rod. Knob Change lever select rod Lever | ‘Change lever shift rod rwe150 1) Percdicaly check the tightening condition of ball joint and tightening nuts and retighten them to avoid mattunction of transmission gear shiting because twin-ink type has many ball joints and tightening nuts. 2) Check and repair wear of related parts Iraquently to avoid maifunction of transmission gear shiting possibly due to near of moving parts such as bush, especialy in the case of vehicles that are operated many mileage. 163. TRANSMISSION 2-5. SERVICING Drain plug pa a rail ‘Two009] OIL SPECIFICATIONS AND VISCOSITY CHART * Oil specifications tem jon oil Fill capacity(L) K805 9.8 (PTO:11.3) KB06 142 1406 16 _(PTO:16.2) Ti0s6 14 (PTO:15) ZFies-i51_ | 11 ZFi6S-221 | 13 __ T9S5 10 _(PTO:11) T9386 12.5 (PTO:13.5) T14810 18 _(PTO:19) Tiss6 17 (PTO:18) Grease up the gearshift control parts. Oil specifications Gear oil Transmission API GL-4(SAE80W90): K805, K806, K1406, T10S6, T9S5, TIS6, T14810, TISS6 Engine oil API CD/CE/CF/SF/SG(SAE 30) : ZF T/M Gearshift control box Multi-purpose type grease NLGI No. 0 173, TRANSMISSION GEAR OIL VISCOSITY CHART GEAR OIL VISCOSITY CHART - AMBIENT TEMPERATURE Single grade Ambient 30° 25°C 156 oe Toe 20°C 30°C [temperature (-20°F) (10°F) @F) (2) Gor) 7O"F) (00°F) Multi grade | -Tuoosa] 183, TRANSMISSION + Gear shift control rod (After cab tilting cab lower port ) * Gear shift control rod (Frame port ) * Spring pin and shackle pin — wreosto|3. TRANSMISSION 2-6. TIGHTENING TORQUE TIGHTENING TORQUE FOR MAJOR PARTS “ooo 1, Bolts for clutch housing and fly- 5. Front cover lock bolt wheel housing 6. Reverse gear shaft lock bolt 2. Bolt and nut for clutch housing and. 7. Speedometer driven gear housing transmission case lock bolt 3. Bolt rear case to transmission case 8. Flange nut 4, Bottand nut parking brake to rear cover * The above bolts and nuts should be tightened according to the torques as specified on the following page. 203. TRANSMISSION TIGHTENING TORQUE FOR SPECIAL BOLTS tkatm) Bolt identification @ NY Bolt diameter 77 oT x pitch(mm) High carbon steel Alloy stee! 6x10 = 8x 1.25 24-34 10 x 1.25 47-64 12x 1.25 9.5-11.6 14x15 14.2-17.4 16x15 17.0-20.8 20.1-24.5 TIGHTENING TORQUE FOR STANDARD BOLTS fa Bolt identification Pe © Bolt diameter 4T 7 x piteh(mm) Low carbon steel High carbon steel Alloy stee! 6x10 04-08 0.5-1.0 - 8x 1.25 08-18 1.2-2.3 17-34 10 x 1.25 21-35 2.84.7 3.8-6.4 “10x 1.5 2.0-3.4 28-46 37-64 12x 1.25 5.0-7.5 6.2-9.3 TING “12K 1.75 46-7.0 58-86 7.8~10.9 14x15 7811.7 95-142 11.6-17.4 14x20 7.3-10.9 9.0-13.4 | 10.9-16.3, 16x15 10.6-16.0 13.8-20.8 16.3-24.5 “16x20 10.2-15.2 13.2-19.8 15.6-23.4 18x15 15.4-23.0 19.9-29.9 23.4~35.2 20x15 21.0-31.6 275-313 32.3-48.5 22x15 25.6~42.2 37.0-55.5 43.3-64.9 21x20 36.6-55.0 43.9-72.5 56.5-84.7 * The asterisk * indicates that the bolts are used for female threaded parts that are made of soft ma- terials such as ca at3. TRANSMISSION 2-7. DISASSEMBLY AND REASSEMBLY Propeller shaft 4 ro069 Disassembly Reassembly 1. Gearshift control rod(shift and select) 6. Transmission assembly 2. Parking brake cable 5. PTOyoke flange and control cable or rod 3. Clutch booster with bracket 4. Yoke flange 4. Yoke flange 3. Clutch booster with bracket 5. PTO yoke flange and control cable or rod 2. Parking brake cable 6. Transmission assembly 1. Gearshift control rod{shift and select) IMPORTANT OPERATIONS (DISASSEMBLY) 1. Gearshift contro! rod Transmission Unbolt the control rod fixing bolt and remove FE the control rod at the point as shown. se (1)Transmission relay lever(Lock nut: RZ 3 Mex1.25) 7, (2)Idler(Lock nut: M10x1.25) |_¢ (3)Transmission shift lever(Lock nut: [ Mtox1.25) (4)Idler(Lock nut: M10x1.25) een eee (5)Engine flywheel housing(Lock nut: Miox1.25) (6)Cross member(Lock nut: M10x1.25) + Important operations (1) For assurance of safety, park the vehicle asking brake drum Connecting point on level ground and brace the front or rear wheels when lifting the vehicle. (2)Remove the propeller shaft at the parking brake drum Propeller shatt —{ Caution } Check the connecting point before disassembly. Twoo7t 22.3. TRANSMISSION Hires Shit od A pro rwoore Clutch booster - “uoo7a roo 23 (8) Remove the control rod, harness-switch, parking brake cable, speedometer cable at the transmission (4) Remove the drain plug and check plug from the transimission to drain out gear oil. (5) Remove the drain plug and check plug from the transmission to drain out gear oil. (6) When the gear oil drain out check the state of oll and chip.3. TRANSMISSION -tuoore| Twoort| IMPORTANT OPERATIONS (REASSEMBLY) Guide bar | Horizontal ine (Frain sope| Fech n Uf T0000] 24 (7) Seperate the oil cooler hose from the trans- mission and pump, (8)To remove clutch housing-mouting bolts, ‘support the transmission with transmission jack. (1) Transmission assembly 1) Remove the transmission assembly us- ing a special tool-transmission jack. 2) Align the transmission inclination with the engine slope. 3) Shift the gear in 5th position 4) Mount the transmission to the engine carefully. (2)Clutch booster with bracket For adjustment operation, refer to Section 2 “CLUTCH”, (8)Parking brake cable For adjustment operation, refer to Section 9 “BRAKE”. + Important operations (1) Lubricate rotating and sliding faces of the parts with oil or grease before installation.TRANSMISSION (2) Fit the transmission assembly using a spe- cial transmission jack. Fixing boit (8) Mount the oil cooler hose to ther transmis- sion and oil pump. T0083] (4) Check the drain plug fixing torque and refill the level plug with the specified new gear oil. (8) Fix the clutch booster. (6) Connect the transmission P.T.O control, ‘Tao09s 253. TRANSMISSION ‘Propeller shatt 26 (7) Fit the control rod, haess-witch, parking brake cable, speedometer cable to the transmission. (8) Install the propeller shaft to the parking brake drum then check the maching point. Fix the nut.3. TRANSMISSION 3. TRANSMISSION CASE Trasio T9S6/T10S6/T15S6/T16S6 Repair kit - oe _ woo T9S6/T10S6/T1SS6/T16S6 714810 1. Flange bolt 1. Flange bolt 2. Front bearing retainer 2. Front bearing retainer 3. Oil seal 3. Taper plug 4. Gasket 4, Oil seal 5. Bolt/ Washer 5. O-ring 6. Gasket 6. Oil intake plate 7. Magnetic plug 7. Drain plug/ Gasket 8 P.T.O Cover 8. Magnetic plug/ Gasket 9, P.T.O Gasket #9. P.T.O Cover 10. Oil seal 10. P.T.O Gasket 11. Dust plug 11. Seal bolt 12. Speedometer gear 12. Oil seal 13. Speedometer connector 13. Speedometer/ L-joint 14. Lioint 14. Speedometer bushing 15. Speedometer gear 16. Rear cover 273 TRANSMISSION 2F16S151/221 Two100| 1. Housing 6. Cylindrical pin 2. Screw plug 7. Gasket 3. Filler neck 8. Clutch housing 4. Lock screw 9. Lock screw 5. Gasket 28‘TRANSMISSION 4, QUADRANT BOX 4-1. UPPER QUADRANT BOX DISASSEMBLY 805, K1406 K 7 _ _* _ wott1 Disassembly 1. Upper quadrant box 11. Washer! Bush 2. Link rod assembly 12. Relay lever insert boss 3. Select fix pin 13. Relay lever bracket 4. Select lever 14. Spring pin 5. Snap ring 15, Shift lever shaft 6. Washer 16. Side cover 7. Selection fever 17. Shift lever 8 Oil seal 18. Cap 9. Relay lever bolt 19. Oil seal 10. Select relay lever 20. Air breather + Reassembly is inverse of disassembly 293. TRANSMISSION T9S6, T10S6 wor Disassembly 1. Air breather 10. Gearshift sliding lever 2. Interlock switch 41. Power shift 3. Lock pin 12. Gearshift lever 4, Gear selecting lever(B) 13. Dust plug 5. Gear selecting lever(A) 14, Spring retainer 6. Washer 1. Return spring 7. Shim 16. Interlock plate 8. Oil seal 17. O-ring 9. Spring pin 18. Select lever case * Reassembly is inverse of disassembly. 303. TRANSMISSION 714810 z Tworst Disassembly 1. Bolt 12, Select lever assembly 2. Bolt 13, Dust plug 3. Bolt 14. Air breather 4, Sub unit 15. Interlock switch 5. Spring pin 16. Gasket 6. Nut 17. Gear shift lever 7. Lock pin 18. Orting 8. Gear shift sliding lever 19. Retainer and spring 9. Washer 20. Gear shift sliding lever 10. Shim 21. Interlock plate 11. Oil seal + Reassembly is inverse of disassembly. 313. TRANSMISSION T1586 aa2e| 1 2. 3. 4. 5. 6. 7. 8. 9. * assembly . Air breather Interlock switch . Lock pin Gear selecting lever(B) . Gear selecting lever(A) Washer Shim Oil seal 1. Spring pin Reassembly is inverse of disassembly. 32. 10. MW. 12. 13. 14, 15. 16. 17. 18. Gearshift sliding lever Power shift Gearshift lever Dust plug Spring retainer Return spring Interlock plate O-ring/dust seal Select lever case3. TRANSMISSION T1686 Sn ‘Twa207 assembly 1. Air breather 8. spring 2. Boot 9. Return spring retainer 3. Plug screw 11. Oil seal 4. Spring pin 12. Bushing 5. Gear shift shaft 13, Selecting lever case 6. Spring 7. Return spring retainer * Reassembly is inverse of disassembly. 333 TRANSMISSION 4-2. LOWER QUADRANT BOX DISASSEMBLY K805 Section: AA a: Interlock ball b: Rod cover —< 6: Daten sping wots 1. Neutral lamp switch 11. 4th and Sth shift arm rod 2. Back lamp switch 12. 4th and Sth shift block rod 3. Shift rod cover 13. 4th and 5th shift block 4, Ist and reverse shift block(Front) 14, 1st and reverse shift rod 5. 1st and reverse shift block rod 45, 1st and reverse shift fork 6. 1st and reverse shift block(Rear) 16. Washer 7. 2nd and 3rd shift block 17, 1st and reverse relay lever 8. 2nd and 3rd shift rod 18. 1st and reverse shift spindle 9. 2nd and 3rd shift fork 19. 4th and Sth shift pinion/ Bearing 10. 4th and Sth shift fork / Bolt/ Cover! Washer3. TRANSMISSION K1406 Section: AA 2: Intetock ball b: Rod cover Y ce: Detent spring and ball wots 1. Neutral lamp switch 8. 2nd and 3rd shift rod 16. 6th shit block 2. Back lamp switch 9. 2nd and 3rd shift fork 16. 6th shift fork rod 3. Shift rod cover 10. 4th and 5th shift rod 17. Shift rod stopper 4. 1st and reverse shift 10. 4th and 5th shift fork 18. 1st and reverse shift block(Front) 42. 6th shift fork fork rod 5, 1st and reverse shift 43. 6th shift fork rod 19. 1st and reverse shift fork block rod 14. 6th shift lever/ Spindle 20. Washer 6. Ist and reverse shift 1 Bolt! O-ring 21. Ist and reverse relay lever block rod(Rear) 22. 1st and reverse shift spindle 7. 2nd and 3rd shift block 353. TRANSMISSION T9S6/T10S6/T15S6/T16S6 Section: A-A 2: Interlock ball b: Flod cover : Detent spring and ball wore: 1. Neutral lamp switch 16. 1st and reverse shift jaw 82. Jaw nut 2. Gasket 17. 1st and reverse shift rail jaw 33. Overdrive shift(B) ral 3. Spring 18, 2nd and 3rd shift rai assembly 34. Overdrive shift(C) rail 4, Interlock pin 19. 2nd and 3rd shift rail jaw 35. Over drive gearshift 5. Dust plug 20. Stee! ball 36. Gasket 6. Flange nut 21. 2nd and 3rd gear shift fork 87. Case 7. Ast and reverse shift 22. 1st and reverse shift B rail lever shaft 23, 1st and reverse gearshift fork 8. O-ring 24, th and 5th shit rail assembly 9. stand reverse lever 25. Ath and Sth gearshift fork 10. Thrust washer 26. Overdrive shift rail 11. Bolt 27. 6th and 7th gear shift jaw 12. Bolt 28. Overdrive shift shift rail fork 13. Clip bracket 29. Overdrive shift lever shaft 14. Set bolt 30. Overdrive shift lever 15, tstandreverse shift rail 81. Spring washer 363 TRANSMISSION T14810 | Torr 1. Neutral lamp switch 16. Air band clip 2. Gasket 17. Bolt 3. Spring 18. Bolt 4, Interlock pin 19. 1st and reverse shift jaw 5. Rod cover 20. 1st and reverse shift ral jaw 6. Nut 21. Steel ball ( 5/8") 7. 1st and reverse shift lever shaft 22. 1st and reverse shift (A) rail 8. Oring 23, 2nd and 3rd shift rail jaw 9. Ast and reverse shift lever 24, 2nd and 3rd shit ral fork 10. Washer 25, 2nd and rd shift rail 11. Bolt and Washer 26. 4th and overdrive shift rail 12. Bolt 27. 4th and overdrive shift fork 13, Bolt 28. 1st and reverse shift (B) rail 44, Nut 29. 1st and reverse gear shift fork 15, Bolt 373, TRANSMISSION aaa IMPORTANT OPERATIONS (DISASSEMBLY) ‘Twoo26t Too02sd| Shifter rod Interlock ball ‘Set bolt 5.0-6.8kgtm ——_ryozes * Check the shift rail for bending.If bending, damage or any other abnormal conditions are replace. + Ifthe inner diameter of shift rail hole and outer diameter are beyond the standard valve, replace the parts a new one. + 6th shifter rod and block Install rod in place. Install and lock the shift arm or shift block using bolt and wire, then set the rod to neutral position. When reassembling parts NO. 6, 12, or 13 as in the previous page, refer to the above in- structions. * Fit the shift rail set bolts to the quadrant box. Then punch of min. 3 point of tread.3, TRANSMISSION 5. TRANSMISSION ASSEMBLY (K805) 5-1. MAJOR COMPONENTS DISASSEMBLY STEPS 1. Upper quadrant box assembly 2. Oil seal 8. Speedometer driven gear, Oil seal, Bushing and O-ring Rear cover . Gasket . Stud bolt - Clutch housing Front cover, Oil seal and Gasket .. Counter shaft front bearing cover |. Plug and Packing Sweernoasn + Reassembly is inverse of disassembly. 39 1. 12. 13. 14, 15. 16. 17, 18. 19, + : Apply liquid gasket. ‘woo Cover, Gasket and Bolt Bracket and Bolt Plug and O-ring Top gear shaft Bearing, Snap ring and Protector Main shaft assembly Counter shaft assembly Reverse shaft assembly (Gear, Bearing, Piece, Washer and O-ring) Reverse shaft3. TRANSMISSION IMPORTANT OPERATIONS (DISASSEMBLY) Counter bearing puller Counter bearing ilar c rwo390 3. Speedometer driven gear, Oil seal, Bush- ing and O-ring Use a remover to disassemble these parts as required. 9. Counter shaft front bearing cover Grip the knob with pliers tightly to remove the counter shatt front bearing cover. Counter shaft front bearing Use a remover to disassemble these parts as required. (Special tool: CA21031) 17. Counter shaft rear bearing and Snap ring Use a remover to disassemble these parts as required. (Special tool: CA21031)Tweas0| 3, TRANSMISSION 14. Top gear shaft assembly and Circlip The dog gear installed to the top gear shaft with the circlip can be separated from the top gear shaft by pulling it strongly. With the top gear shaft taken out, the top gear shaft dog gear will remain in the gear case. 16. Main shaft rear bearing and Snap ring Use a remover to disassemble these parts as required. (Special tool: CA21031) 16. Main shaft assembly and thrust washer Remove the main shaft assembly from the case using a suitable hook or wire. Caution The main shaft assembly can be easily separated from the gear case by using # dummy collar as shown 19. Reverse shaft assembly Use a remover to disassemble these parts as required. (Special tool: CA21021) a3. TRANSMISSION IMPORTANT OPERATIONS (REASSEMBLY) of NS - ‘Twosa0 Reverse gear ‘Twos4o| Lock bolt _Tuoeso| Forward Tuosso| 42 18. Thrust washer Make necessary replacement if wear damage or any other abnormal conditions are found through assembly. 18. Reverse gear shaft and O-ring Align the lock bolt hole in the shaft with the hole in the case. The adjusting groove on the shaft should be tured rearward and aligned in the vertical direction. 12. Reverse gear shaft lock bolt Apply liquid gasket tothe lock Bolt. 4,4 Torque 15-28 | 16. Thrust washer Note the direction of installation.‘Top gear shaft Twoo80| \ Bearing puller ‘Toward transmission case Toward rear cover 10700] 43 3. TRANSMISSION 16. Main shaft rear bearing and snap ring Be careful for damage. When installing it to the bearing and snap ring using jig. (Special tool: CA21041 or CA21011) 14, Top gear shaft assembly Fit the top gear shaft to the place where the end of the dog gear has been partially cut out Drop the counter shaft assembly into the transmission case, then install the top gear shaft assembly. 17. Connector shaft rear bearing, snap ring Be careful for damage when installing it to the bearing and snap ring (Special tool: CA21101,CA21031,CA21061) 16. Speedometer drive gear Note the direction of installation. 5. Gasket 4. Reverse cover 2. Oil seal Apply liquid gasket to lock bolt. (kgf'm) Torque 58-873, TRANSMISSION ‘Speedometer driven gear ‘Tworto| Speedometer gear bushing Rear cover or extension housing wor worsa| |. Speedometer driven gear, Oil seal, Bush- ing and O-ring (kgfm) "Torque 04-06 * Fit the speedometer gear bushing to extension housing using round bar (diameter: 40mm) + Fit the Oil seal to the speedometer gear bush- 1g using round bar (diameter: 15mm) Caution Apply grease to packing inside 1. Quadrant box assembly Fill the transmission case with gear oil and then assembly the quadrant box. 44GEAR SHAFT DISASSEMBLY Protector, Snap ring and Bearing . Top gear shaft Snap ting |. Pilot bearing 4th blocker ring Snap ring . 4th and Sth synchronizer assembly th blocker ring 9. 5th gear (over drive) 10. Needle roller bearing 11. Snap ring 12. Collar 13. 3rd gear 14. Needle roller bearing 48. 2nd and 3rd synchronizer assembly 16. 2nd gear 17. Piece and speed drive gear 18. Washer and bearing 1 2, 3. 4. 5, 6 7. 8 % Reassembly is inverse of disassembly 45 20. at. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31 3. TRANSMISSION woae1 ist gear, Needle roller bearing and Collar Sleeve and clutch hub Reverse gear and needle roller bearing ‘Main shaft Bearing and snap ring Counter shaft drive gear and key PTO gear and key 5th gear and key (Over Drive) Snap ring Bearing Shatt Reverse shaft assembly (Gear, Bearing, Piece, Washer, and O-ting) Reverse shaft3. TRANSMISSION IMPORTANT OPERATIONS (DISASSEMBLY) Pilot Bearing puller “Tuoae0| Plunger ‘Snap ring_| Block ww ca “Twosto| Longer plunger a Rearward Tuosco| 4, Pilot bearing Use a remover to disassemble these parts as required (Special tool: CA21121) 6. Snap ring Be careful for damage when disassemble, 7. 4th and 5th synchronizer assembly Disassemble the synchronizer assembly into blocker rings, springs, sleeve, inserts, plung- ers, springs and clutch hub. 12, Collar Remove all the parts of item 33 at a time using a bench press. 15, 2nd and 3rd synchronizer assembly Assemble the sleeve to the rear longer plunger.9. TRANSMISSION $e TRANSMissiON 12. Collar Install the collar using a bench press. ‘Tw0570| 7. 4th and Sth synchronizer assembly Install the blocker by matching it with the cir- cular direction of clutch hub. | Clutch hub 7 “Taos Pilot bearing 4, Pilot bearing Note the direction of installation, Forward_| Rearward ‘Snap ring LL 760590} - 2. Top gear shaft assembly To install, attach a brass bar and use a bench press. Twos 473. TRANSMISSION 5-2. INSPECTION AND MAINTENANCE Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. Visual check Inspect all disassembled parts for wear, damage or any other abnormal conditions. Inspect the following parts paying particular attention to the points as shown Liquid gasket 0430 Shoulder groove oaao Front and Rear cover oil seal replacement 1) Note the direction of oil seal installation. 2) Apply liquid 242 to fitting face of oll seal. 3) Insert oil seal unti it is properly seated in po- sition. 4) Fill the cavity between felt and lip of oil seal with grease. Shoulder of shifter rod groove ‘As shoulder part rounded due to wear can cause gear slipping, this part is required to be thoroughly checked.S_TRANSMIssion3. TRANSMISSION Shift arm oes aa ie ~ Standard eZ. Thickness + Make necessary parts replacement if wear, aicrometer damage or any other abnormal conditions are found through inspection. ‘Twosso| Detent spring (a) t Standard Limit | Free length : 435 405 + Make necessary parts replacement if wear, damage or any other abnormal conditions are found through inspection. Blocker ring B (ev) Fing groves ee Standard Limit Clearance a 20 03 BZ + If the fine grooves on the inner face have worn out completely, replace the blocker ring with a Clearance between new one. gear and blocker rng ‘oss Clutch hub fom Standard Limit Clearance 1.2~04 08 + Make necessary parts replacement if wear, damage or ony other abnormal conditions are found through inspection. wot 493, TRANSMISSION nN uos00 Mosi0 Tw0520) A Clearance Outer ring wos40 50 Plunger spring Standard Free length be 18.7 Plunger block If the plunger block is wear or damage, replace the plunger block with a new one. Clutch sleeve Check the clutch sleeve for wear or damage. If the clutch sleeve is wear or damage, replace the clutch sleeve with a new one. 2nd and 3rd synchronizer rings Standard Limit Clearance 24~25 ° If the fine grooves on the face ‘A’ are found to have worn out completely, replace the synchronizer assembly with a new one.5-3. TRANSMISSION P.T.O SYSTEM 5-3-a. MAJOR COMPONENTS(BASE: K805) 3. TRANSMISSION Air shaft roo lle gear shatt| Front covert ‘le gear a "> output gear Controt cylinder Air chamber retun spring Spring gear cover, a Output shaft Oil seal qwor20} 513. TRANSMISSION 5-3-b. FIXING TORQUE , _ (kat. Thick collar Gear oil | & A” Gear oil Ff poy ios. 24-35 Two7at9. TRANSMISSION 5-3-c. DISASSEMBLY MAJOR COMPONENT DISASSEMBLY STEPS 1 +: Apply liquid gasket. +k Repair kit . rca 1. Switch and Flange 12. Shaft rod stopper 2. Control cylinder 13. Shift arm 3. Spring pin 14. Shaft rod cover 4, Idle gear shaft 15. Front cover 5. Idle gear 16. Rear cover 6. Needle bearing collar 17. Oil seal 7. Needle bearing 18. Output shaft 8. Spring 19. Bearing 9. Air shaft rod 20. Bearing collar 10. O-ring 21. Output shaft gear 11. Air chamber return spring 53.3. TRANSMISSION IMPORTANT OPERATIONS (DISASSEMBLY) Two7so| ‘Shaft rod stopper —shift arm Tworeo| 190770] 5. Idle gear Remove the idle gear shaft pin to separate the shaft, then disassemble the idle gear and bear- ing collar. 13. Shift arm Remove the shift arm pin to separate the shaft, then disassemble the shift arm. 18. Output shaft Tap on the output shaft lightly with a brass hammer to separate it to the front direction. Atthe same time, separate the front bearing. 54IMPORTANT OPERATIONS (REASSEMBLY) ‘Twose0| Grease fitting M0890 ar... Tuo200| Apply liquid gasket ‘Tuo9r0] 55 3. TRANSMISSION 18. Output shaft * Align the key hole in the shaft with the key hole in the output shaft, then tap lightly on the shaft forward with a brass hammer. 19. Bearing * Grease the bearing, then install it in the front direction, * To install, insert the bearing collar in the rear direction. 17. Oil seal + Grease the inside of lip, direct the lip inward, then install the cover to the plate. * Grease the outside of oil seal 16. Rear cover Apply liquid gasket before installing the rear cover. (kgtm) 24 ~35 Torque3, TRANSMISSION ‘Apply liquid gasket. rao220| Shalt rod stopper ~ Ore Shaft rod Spring ‘Two220| ‘Two04o| 56 15. Front cover Apply liquid gasket before installing the front cover. (kgtm) Torque 21-35 | 12. Air shaft rod * Grease the O-ring before installing it to the shaft rod + Pre-assemble the stopper spring, then as- semble it to the case. + Note the direction of shaft arm. After ‘completion of installation, tap and insert the pin, then fix both the upper and lower points. 14. Needle bearing + Grease the bearing before installing it to the idle gear. 16. Idle gear + Fit the bearing collar to the idle gear, then insert it into the case. + Tap and insert the bearing gear shaft. + Fix the bearing pin + Grease the bearing collar for easy opera- tion, Bearing collar Front Rear Thin collar Thick collar3. TRANSMISSION Control cylinder Grease(0.59) Tueo60| -Tuo97o| Tuo9eo| i) 87 2. Control cylinder + Apply liquid gasket to the packing, then grease(0.5g) the inside of ylinder. . __tkgtm) Torque 21-35 14, Shaft rod cover = Apply LOCTITE, then tap and install the shaft rod cover to the case. ‘+ Check the functions of the idle gear. — Inject air(4kg/cm:) into the nipple to check if the shatt rod operates smoothly. + Install the PTO assembly to the transmission case. — Apply liquid gasket to the packing and as- semble the P.T.O assembl eee (kgtm) ~__ Torque [30-453. TRANSMISSION 5-3-d. INSPECTION AND MAINTENANCE YY uo7a0| Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. Check the inside and tip of control cylinder for wear. Idle gear Check the gear tooth face for damage, and measure abrasion if required. Overhaul diameter(pin ¢ 8mm) (am) ‘Standard Limit 152.98 Make necessary parts replacement if wear, damage or ony other abnormal conditions are found through inspection. 153.28 ing collar thickness “Tuooco| ‘Tuos20| 58 (eon) tom Standard Front 25 Rear 45 Make necessary parts replacement if wear, damage or ony other abnormal conditions are found through inspection. Free length a Standard Limit 58.8 54.0 Make necessary parts replacement if wear, damage or ony other abnormal conditions are found through inspection.Shift arm ee ao890 Output shaft ‘Twce4o| wees] Tae 59 3 TRANSMISSION Shift arm tip thickness (com) Standard Limit 7.0 6.0 Output shaft * Check the output shaft oil seal for wear. Needle bearing * Check the output shaft oil seal for wear. * Check the bearing for deformation, wear, or unusual sound, -To identify any damage or deformation, rotate the race and check clearance of holes. ~ Check the holes and race for abnormal condi- tions. -To identify unusual sound, rotate the bearing to check if it transfers any abnormal feel through the hand. Overhaul diameter of gear tooth face (pin ¢ 8mm) (re) ~ Standard Limit 96.88 96.583. TRANSMISSION. 6. TRANSMISSION ASSEMBLY (K1406/K806) 6-1. MAJOR COMPONENT DISASSEMBLY STEPS “ : Apply liquid gasket. Tmo 10. "1 12, 13, 14, 16, ensens Lower quadrant box assembly .. Transmission case Rear cover |. Main shaft rear bearing cover . Counter shaft rear bearing cover Speedometer driven gear, Oil seal bushing, L- joint Bearing/ Distance piece/ Oil seal/ Speedometer drive gear, Stud bolt 6th synchronizer snap ring . 6th synchronizer assembly 6th blocker ring Needle roller bearing Distance piece 6th counter shaft gear Front cover and Oil seal 60 16. 17, 18. 19, 20. 21. 22. 23. 24, 25. 26. 27. 28. Clutch housing and Seal cover Needle roller bearing and Spacer Rear bearing snap ring/ Main shaft bear near ing Thrust washer Top gear shaft dog gear Main shaft assembly Reverse gear shaft Thrust washer Reverse gear! Needle roller bearing/ Dis tance piece Counter shaft rear bearing Snap ring Counter shaft assembly Counter shaft front bearingIMPORTANT OPERATIONS (DISASSEMBLY) ‘Speedometer driven gear Tuno20| Tar020| u050] 61 3 TRANSMISSION 6. Speedometer driven gear ‘On 6 speed-mode type, take out the gear af- ter removing the 6th gear case. 17. Top gear shaft assembly The dog gear installed to the top gear shaft with the circlip can be separated from the top gear shaft by pulling it strongly. With the top gear shaft taken out, the top gear shaft dog gear will remain in the gear case. 18, Main shaft rear bearing Use a remover for disassembly operation. (Special tool: CA21011, CA21031) 20. Top gear shaft dog gear Take out the top gear shaft dog gear together with the main shaft 21. Main shaft assembly Remove the main shaft assembly from the case using a suitable hook or wire.3, TRANSMISSION 22. Reverse gear shaft Use a remover to remove the reverse gear shaft, (Special tool: CA21021) 25. Counter shaft rear bearing Use a remover to remove the counter shaft rear bearing (Special tool: CA21031) 62IMPORTANT OPERATIONS (REASSEMBLY) Bearing Counter shatt fap essa ra ura70| ra00| =, Neodle bearing ! her Thrust washer rn eet e—— Needle bearing =} Distance piece Tx990| Apply sealant No.228, Tur400| 63 3. TRANSMISSION 26. Counter shaft rear bearing ring Install the ring on the counter shaft in the direction as shown before driving the bearing into place. 25. Rear bearing Install the rear bearing using a bearing installer. 23. Thrust washer Put parts(items 23 to 24) into the case, then insert the shatts(item 9 or 10) and assemble the parts in the manner as shown. 24. Reverse gear shaft oil ring Apply liquid gasket to fitting face of oil ring 22. Reverse gear shaft Align the lock bolt hole in the shaft with the hole in the case. The adjusting groove on the shaft should be turned rearward and aligned in the vertical direction. 22. Reverse gear shaft lock bolt Apply sealant No.22S to threads on bolts.3. TRANSMISSION Counter shaft Main shaft Front cover ‘Twn4so| 5. Count shaft rear bearing cover Note the direction of installation. 4, Main shaft rear bearing cover Note the direction of installation 19. Thrust washer Note the direction of installation. 18. Main shaft rear bearing On 6 speed-mode type, drive the bearing into position using the 6th gear and setting tool. 17. Top gear shaft and circlip Before installing the top gear shaft, put the circlip into the groove of the shaft. The top gear shaft dog gear can be installed onto the shaft by pulling the shaft strongly 15. Front cover, Oil seal and Gasket‘Apply sealant No.228, O-ring ‘Toward transmission case Tus4so| 1470 65 3, TRANSMISSION Before installation of bolts, insert the spring washer, washer, and O-ring. 7. Speedometer drive gear Note the direction of installation. Parking brake drum and flange Refer to Section "BRAKE" for parking brake adjustment procedure.3. TRANSM ISSION GEAR SHAFT ASSEMBLY DISASSEMBLY STEPS race3. TRANSMISSION + 11. 6th synchronizer assembly 4. Snap ring Sleeve Insert Plunger Spring Clutch hub Lock wire and Bolt Shifter rod * 17. Top gear shaft assembly 9. Circlip 40. Snap ring 11. Bearing 12. Top gear shaft * 21, Main shaft assembly 13, 1st gear 14, Needle Roller bearing 15, Collar 16, 1st and reverse sleeve 17. Clutch hub 18, Reverse gear 19, Needle roller bearing 20. 24 24, 25. 27. 28. Pilot bearing Snap ring 4th and Sth synchronizer assembly 4th gear Needle roller bearing Snap ring Collar Needle roller bearing 3rd gear 2nd and 3rd synchronizer assembly Clutch hub 2nd gear Needle roller bearing Main shaft ‘* 27. Counter shaft assembly 29. 30. 31. 32, . 4th gear and Key 33. 34. 36. Front bearing inner race ‘Snap ting Driven gear and Key Distance piece ‘8rd gear and Key .. Counter shaft NOTE) The asterisk * indicates the sequence for disassembly of major components. ty Sa \ | Zl IMPORTANT OPERATIONS (DISASSEMBLY) 11. Bearing Use a remover to take out the bearing. (Special tool: CA21041 or CA21101) 673. TRANSMISSION. -Tws109| unnia| unra0| 20. Pilot bearing Use a remover to take out the pilot bearing. (Special tool: CA21101) 22. 4th and Sth synchronizer assembly Remove the synchronizer assembly from the main shaft using a puller. (Special tool: CA21111) 26. Remove all the parts at a ‘ime using a bench press. 29. Front bearing inner race Use a remove to take out this race. (Special tool: CA21111) 68,3. TRANSMISSION IMPORTANT OPERATIONS (REASSEMBLY) 2ndSed clutch hub Pilot bearing Forward] | Rearward | Forward | TRearward (Oil groove Snap fing ‘Tur290| ms 2ndiard synchronizer (Gleeve) Forward Reanward Longer flange Shorter flange Le 141300] ——— =a Oo ‘enatord 3] Synchronizer | o| a tursto| wc20| 69 26. Clutch hub Note the direction of installation. 20. Pilot bearing 26. 2nd and 3rd synchronizer assembly 26. Install all the parts of item 13 to the main shaft using a bench press. 22. 4th and Sth synchronizer assembly After reassembling the synchronizer, install it to the main shaft using a bench press.