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    year 1987

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    year 1987

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    273 views832 pages

    Daihatsu Charade Workshop Manual

    Uploaded by

    Diego Hernan Piñeiro
    year 1987

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 832
    WORKSHOP MANUAL DAIHATSU CHARADE Chassis FOREWORD “This workshop manual contains essential information regarding the construction, Gisassemblyreassembly procedures and servicing methods of the power tain, Suspension, brake system, steering system, body and electrical system of the DAIHATSU CHARADE. We hope that this. workshop manual i consulted to the fullest extent, in Combination with the workshop manual ofthe Type CB Engine. Type CL Engine, fad Trouble shooting for Engina contro! system of Type C8-80 Engine so that ‘Quality servicing may be assured at al imes. Furthermore, due i contnuing improvements in the design, contents end speciicatons in this workshop manual may be parly revised without advance notice and without incuring any obligation to us. Published in April, 1987 DAIHATSU MOTOR CO., LTD. SECTION INDEX NAME SECTIOL GENERAL INFORMATION CLUTCH | MANUAL TRANSMISSION Coote NOES COLe INS j_— | AUTOMATIC TRANSMISSION [eee | FRONT AXLE & SUSPENSION REAR AXLE & SUSPENSION ‘STEERING BRAKES BODY | BODY ELECTRICAL ar) ‘APPENDIX DAIHATSU CHARADE Chassis SECTION 1 GENERAL INFORMATION HOW TO READ THIS BOOK (CONTENTS OF EXPLANATION 1 Schematic Diagram of Ce 2 Servicing Procedure 4. Trouble Shooting 1 Table of SSTs Used 5 Table of Service Speciications 6: Table of Tightening Torque 7 Wing Diagrams DEFINITIONS OF TERMS ABBREVIATION CODES. ‘SERVICING OPERATIONS. {JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS ‘SUPPORTING POINTS OF TW GENERAL INFORMATION HOW TO READ THIS BOOK CONTENTS OF EXPLANATION 4. Schematic Diagram of Components (f) The schematic diagram of components that appears atthe beginning of each secon describes the nomenclature and installed conditions o each component. Futhermare, the tightening torque is posted in the foure (2) Those parts whose reuse isnot permitted bear a “k* mark for an identfication purpose, Be certin to replace these parts with new ones during the assembly (Example) By: pemrgroe oe Neon parts 8 = Rese cap soacee @Rewewor suprragn {@ Seach operating tose Bilan ojan sor se Samp = Serose ODeme, Seat => 29 a Sanne e0¢e it eying reat i aoe 2. Servicing Procedure (@) Inprincible, the servicing procedure is described inthe folowing sequence given below: Removal —+ Inspection “> Insialation, and Disassembly — Inspection —» Assembly. (2) The explanation covers detaled servicing methods, spectfiations and notes. (@) The main pont of each item explains the servicng section and senicing procedure, using llustations. (example) What do Howiodot [aaeaoiniaten Ci 7 3. Brake tube ination (G) Insta the rake tube fo the wheel cinder temporary by hands. (2) Rohn the brake tube tothe wheel cylinder, using he folowing SST. , ST. 09751-2601 1-000 one ~ hi Min. (GENERAL INFORMATION cnet eae (@) The inspection section inthis manual deseribes only checking operation. Therefor, if you find any ‘uitnetion race any detective parts with new ones. 3, Trouble Shooting {ty At for the three-speed automatic ransmission, the trouble shoating table is provided in this book 80 that you may reacily locate causes of troubles, 4, Table of SSTs Used (1) The SSTs appearing in tis book are listed in the appendix of the book 5. Table of Service Specitications (iy The service specifications necessary forthe service are summarizes in the appendix of his book 6, Table of Tightening Torque {i As for hose sections wher thet tightening torque must be controled during the service, the tightening torque is speciad inthe appendix of tis Book. 7. Wiring Diagrams. {Gy The vehicle winng diagrams are posted inthe appendix ofthis book separately for Type CB and Type CL engines. DEFINITIONS OF TERMS Specified Value .. A value which represents the allowable range during the inspection and adjustment. Limit ‘A maximum or 8 minimum Imit which the value should not exceed or fal! beow. Nowe ‘an item which requires special alertion or an tem which is prohibited curing the (GENERAL INFORMATION {ABBREVIATION CODES The ebro coon he ope te wen mara etre lois pect Aobregeton Original word i ‘Meaning st Laat oe Bp oe —— [sc rie reread [tan er eee ELS (ana ELSA RET ITARRERSe eee aT eR aI os ows ERaip ea eae ceamencen ‘She at pa may oe Siswo ure agus “Over Sued pars ance ose sain brotindaceeecta ose Terenas mats corer pe (aromas us| ose Sie eee aver oe oars Sapna eae ce nee alee | RRS RAT a, magw te in ‘Sone of ‘Rese daagatinmurbarhane Coos sfc by Sosy errs oka ESSreaere sea eee nares see Sige ea uae ean mea snae Ger Ene naue esas ieee DiS ERR aaa ea ce Epeily secre pocwecmemcmsh oe ein \nhbrees engine ale wr Gove ens ae Casslid es CC, CO and 80.08 Seaton oer nv errs ct er restos Seon ma eer 2 vemety ‘else ial or suse to extn fof a sie compere. eee SESE perer ereweronetir ror tare eaT ww ere ae koing parle ac of [Sra at in a sear ae co | Seth ers an convene one Sides | RSE ‘The abbreviation codes that appear in the figure stand forthe following, respectively. @ | Bot © | Sew @ [rs << hi Iti. a (GENERAL INFORMATION Ee ee SERVICING OPERATIONS 11. Jacking up iy When ony the front section o rear section of the vehicle is jacked up, be sure to place checks at the wheels 60 as to insure safe operations, (@) When tne vehicle nas baen jacked up, be sure to support the vehicle at the specified sectons using safety stands. 2. In the case of repairs on the electrical system or the removal/nstallation of the engine, first disconnect the negative © terminal of the battery. Then, proceed to the operations. (On ‘lock-equipped vehicles, set the time of the clock after the negative ©) terminal of the battery is connected.) {3 Repairing fuel system of Type CB-80 engine ‘Type €8-80 engine employs a high fuel pressure. Therefore, the folowing notes should be observed UF When the union bois removed, take a measure to prevent the fuel fom splashing with a cloth a the like, Siacken the union bolt gradual (@) Tiahten each connecting section to the speciied torque. (6) Atach the specified clip fo each connecting section. 4. For increased work efficiency and improved accuracy, be sure to utilize the SSTs (Special ‘Service Tools) effectively. ‘5, Removal and disassembly (1) When disassembling complicated components, put stamped marks or mating marks on those sections vanere such marks do not affect ther functions so that the assembling operation may be performed easily (@) Each time a partis removed, check the par for the assembied condition, delormation, breakage, roughness and scratches. {@) Arrange the cisessembied parts In he disassembling order, In addition, separate and arrange those paits to be replaced and those parts to be reused. (4) Thoroughly clean anc wash those pars tobe reused, (6) inspection and measurement of part . PPetiorm thorough inspection and measurement on those parts to be reused, as required 6. Installation and assombly (i) Assemble those satstactory part, folowing the proper procedure and specified standards (acjusing ‘values anc’ tightening torque, et). {g) knsure tnat seal packings an grease we apotied 1 those sections where such spplictionis noodod, {@) Be sure fo use new packings, Gaskets, cater pins and 80 for {@) Encure thatthe spectieg bolts and ruts ony be used, Moreover, where specified, make sure to employ a torque wrench fo lighien bots and nuts to the specified toraus. Make sure to use only genuine parts for every replacement 77._Adjustment and operation chock ‘Adjust he reassembled or replaced components to the servicing specifications, using gauges and testers, as require. 8. Handling of hose, etc. (G) Connect ve! hoses and water hoses, etc. securely so that they exhibit no leakage. {@) When disconnecting fue! noses, make sure thet no ful is splashed around the hose. (Special care must be exercised as to the engine mount rubber, etc, for here isa possibilty thatthe rubber is deteriorated by the pettolbased tquid) GENERAL INFORMATION 8. Touch-up painting i paint fins surfaces ofthe body and bolts should be scratched when Bots, ete. are removes during the ‘ody alignment, ete. touch up the seratch with @ paint ving the same color as that of the Body. JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS ‘© Jacking point Front side. Engine mounting canter member (Place the jack below the member, exercsing ‘care ofthe exhaust pipe) Rear side .... Center of rear floor cress member Engi mounting cetarmerer Peer ar rose rember oxen" ener Spgtea sit Baeyeee ‘© Supporting points of safety stands Four supporting points are located atthe right and left sides. (The supporting points have been strengthened by spotweiding reinforcements. Never support the vehicle at points ether than the spectiod pons) nansoomse, . Frntandrearon oor moet 322 /pgar on 3-dor mes rer cd SUPPORTING POINTS OF TWO-POST LIFT [Align the supporting pads ofa two-post it with the suoporing points of safety stands, as indicated in the figure above, a as Mt, “ DAIHATSU CHARADE Chassis SECTION 2 CLUTCH DESCRIPTION "TROUBLE SHOOTING : CLUTCH PEDAL ADJUSTNENT ‘CLUTCH PEDAL AND ‘CLUTCH RELEASE ‘COMPONENTS REMOVAL vom INSPECTION INSTALLATION CLUTCH DESCRIPTION TROUBLE SHOOTING a = = = Gennes |; Eaaeor miniere™ |: Gage [= cea TEgeeas mmr” |: aaa iaeaae 1 SERRA cit nin | «Fas ais n PERC be et a ms seems Term aaeigeiatanta | us angers | 59 a Semenmaeman™ | faiscana a Eero Se. st BREE oey | RBar cs! a ‘Grabbing and challering | © Wom or oly cich dacinngs. | © Check auch dee and replace, as | 2-8 oa mae ¢ Fetvesenreote 1 Selene o TEER ony |] RES zt ibaa | RRS. St Soar fs croeaie fos ear TOERETSERGRE wom SREB | 27 {Bei ecmtmoonenna | ropa enue Tn ed WES | BRE Si + FEES capregn sa. o° | « Fennec = ‘wom tp end ot spr, CLUTCH PEDAL ADJUSTMENT 1. Check the clutch pedi forthe installation height Pedal instalation Peight (Cistance between pedal pad upper surface’s center and ‘dash pane) LHD. vehicle 189.5 - 194.5 mm (7.46 - 7.68 inch) LHD. vehicle 181.5 - 186.5 mm (7-15 - 7.34 inch) 2. Adjust the pega! nstation nelght, as required (2) Slacken the lock nut. Turn the stopper bot unl the Installation height contocms to the specification (@) Tighten the lock nut ed neigh Pi tes. 19¢5 am 749- T35inen) CHD ters. tease (716.73¢mnen) CLUTCH 3. Clutch cable adjustment (G1) Pulthe outer cable ight with a force of 2-5 kg (8.4 411.0 1b). Check the clearance. (2) Ensure that the stopper (protruding portion) is fted securely in the adjusting groove. (@) Adjusting postion of clutch outer cable 3-6 mm (0.12 - 0:24 Inch) 4, Adjust the clutch pedal ree travel. (1) Depress the clutch pedal gradually unt you fee! a resistance ftom tne clutch. Measure the depressing tance upto this point. Pedal Free Travel: 15 ~90 mm (0.59 - 1.18 inch) 5, Adjust the clearance between the cistch pedal and the floor with the pedal fully depressed. (Minimum clearance ‘betwen the dash panel and the pedal arm) Vehicles mounted with Type CB-80 engine: not less than 20 mm (0.79 inch) Vehicle other than those mounted with Type CB-60 ‘engine: not less than 25 mm (0.88 inch 3G mm (012-024 ch) ensure nat stopcerxouldieg pin Jetted imacutong rg soo 5.200 (058-1 ety Clarnce Beean Soe CLUTCH CLUTCH PEDAL AND CLUTCH RELEASE CABLE COMPONENTS: pee Lary een seamen oe = = Ex BE aneeane ras REMOVAL Toone oe py (Oy LHD hn Sen page 8-7) 2. Fits Bo rt wet tts tan See ee cee anna aaa! 2. Faro tng ba Remove the bot with washer. Remove the cable brackel attaching bolt. Remove the clutch cable. Remove the clutch pedal assembly. Remove the soring, ‘bush and spacer. INSPECTION Inspect the folowing pats. 1 2 3 4 6 ‘Bush for wear or damage. Pedal spacer for wear or damage. Pedal for damage or deformation, Pedal pad for wear or damage. ‘Spring for flattened conditon. Each section of clutch cable CLUTCH INSTALLATION 1 ‘Apply MP grease tothe following points () Insie of bush and spacer (@) Connecting section of clutch pedal and release cable Install the spring, bush and spacer to the clutch pedal assembly. Then, stall the assembly tothe pedal bracket Inetal the bolt with washer In poston, Insta both ends of the elutch cable, Tighten the bracket withthe bots. “Tightening Torque: 0.4 - 0.7 kg-m (2.95.1 b) Install the adjusting bot. Tighten the nut Tightening Torque: 1.5 - 22 kg-m (11 - 16 b) Depress the clutch pedal to or three times. Proceed to agjst the chitch peda, folowing the procedure at page 2-2. instal the brake pedal Ay. (Only for LH.D. vehicies. See page 8-8) hi Nis. ad Jo Ts-220m (dos 59%) CLUTCH UNIT COMPONENTS: yas gas se — : = on page ) ‘SEE Se Soren 2. Release the lock plate. Proceed to remove the lock pate along with the Bot. CLUTCH 3. Pull out the clutch release fork lover. Remove the bush felease lover yoke, spring, release Deering cip and release bearing hub. 44, Remove the cluich cover from the flywheel. Take out the clutch disc. INSPECTION 4. Check the pressure plate and flywheel surtace for scores, cracks and discoloration. 2 Check the diaphragm spring tips for wear, rust and breakage. 3. Check the clutch disc for wear and runout ‘Allowable Wear Limit (vet Depth): (08 mm (0.012 inch) Hin. ad i 4 CLUTCH ee 4 ‘Alowable Limit of Lateral Runout: 1.34 mm (0.0528 inch) NOTE: Measure the lateral runout with the clutch disc assembled ‘onto a new input shaft Check to see if the release bearing rotates smoothly: Rotate the release bearing by your hand, while appiying a pressure to the beating ina thrust direction. Check to see IFthe Dearing rotates without any abnormal feeling oF binging CCheck the release bearing hub, clp-contacting surlace ‘and hub-teshousing siding section for damage and wear Check to see if the lip has the configuration as show in the figure in its hotzontal pian cus de -Asccelcoiguraion~ reise ‘one Sens Se CLUTCH INSTALLATION 1. Install the clutch aise and cluich cover, using the following SST. ‘SST:_09901-87202.000 Bol Tightening Torque: 1.5 - 2.2 kgm (11 - 16 fb) NOTE: (1) Assemble the clutch disc in the direction as shown in the figure, (2) Tighten the bolts evenly, staring with those bots provided near the locating pin, (2 Arp log le chasis reset the dich dic spines 2. Check the clutch cover diaphragm spring ti fr variation in height. Adjust the ciaphragm spring tips, as required. ‘Check ‘Allowable Limit of Variation in Height (0.7 mm (0.028 inch) SST: 09302-$4701-000 Ben. ‘Adjustment ‘Align the diaphragm spring tips at such a height that ‘makes the number of ps to be adjusted at a minimum umber. SST: 09893-00011-000 3, Assemble the clutch release bearing hub and release ‘beating lip to the clutch release lever yoke (1) Bing the cut-out section of the release lever yoke in contact withthe cp. Under the concltion described in (1), assemble the lever yoke by turning t 180 degrees. NoTE: ‘Apply iong-lte chassis grease to the yokeo- hub sling ‘ection and bearing-to-housing case siding secon, bin, = 1 e® 1 a & rosewood oor erkea00 10° ing (reste aptying ports 4. Assemble the bush, dust seal, torsion spring and clutch release lever in positon. 5, Assemble the ott with washer, wih the lock plate interposed Tightening Torque: 3.0 - 4.0 kgem (22 - 29 tb) 6. Check the release hub and yoke for proper operation. ‘Operate the clutch release lever about 50 times. Chack the section A of the clip. f the cip exhibits excessive spread and there is a Ikelinood that the clio may be tached, replace it with # new clo. 7. Install he trenemission assembly to te vehicle (See page 3-7.) bin, DAIHATSU CHARADE Chassis SECTION 3 MANUAL TRANSMISSION ‘SECTIONAL VIEW .. a2 MANUAL TRANSMISSION ASSEMBLY ~.. 3-9 PEMOVAL a3 INSTALLATION 3-7 F DISASSEMBLY, INSPECTION AND ASSEMBLY OF "TRANSMISSION HOUSING, CASE S/A AND CASE COVER ‘COMPONENTS DISASSEMBLY REPLACEMENT INSPECTION ASSEMBLY . ‘APPLICATION POINTS OF GREASE & BOND [AND APPLICATION PROCEDURE woe 3-22 DISASSEMBLY, INSPECTION AND ASSEMBLY ‘OF INPUT SHAFT 3-28 ‘COMPONENTS DISASSEMBLY INSPECTION. ASSEMBLY DISASSEMBLY, INSPECTION AND ASSEMBLY ‘OF OUTPUT SHAFT ‘COMPONENTS DISASSEMBLY INSPECTION .. ASSEMBLY DISASSEMBLY, INSPECTION AND ASSEMBLY OF STH GEAR... 3-38 (COMPONENTS 9-38 DISASSEMBLY = 3-38 INSPECTION "3-40 ASSEMBLY 3-42 DISASSEMBLY, INSPECTION AND ASSEMBLY OF DIFFERENTIAL CASE nee BA COMPONENTS aa DISASSEMBLY 3-45 INSPECTION .. 3-48 SEMBLY . 3-87 DISASSEMBLY, INSPECTION AND ASSEMBLY OF ‘CONTROL LINKAGE-RELATED PARTS... 9-50 3-50 382 3-58 ASSEMBLY . 3-55 SHIFT LEVER & SELECTING ROD encwsccu- 9-59 ‘COMPONENTS 3-59 3-60 361 261 INSPECTION .. 3-63 ‘ASSEMBLY 3-68 INSTALLATION 3-65 i : MANUAL TRANSMISSION SECTIONAL VIEW rT Ta (\ = an MANUAL TRANSMISSION fiity Keng 4-speed ‘S-speed [Eran ure aa ca an [once] oa | Trnemision PS Fomard gears Conan eh Ree guar. Slave idea | 1st gear 3.080 Gait) | 3090;Gar1) | S090 (ANT) | 3.090 (3411) | 209 (94711) [rdgcer | ate Gena | reese | 1e@Gsi9) | 1a@esNO) | 175 (520 Ges Tageer [100 e226) | 1200 as) | 150 6x28) | 1200008 | 120 e220 (fen, [am ocer | wae euen- | once aaa | ase s2an | occa czar | cove eae hee} caravan | overeat | ovorcoa| are) | sep [5142 GOTH 9142 ra) [48 aBONA) S42 aN) | Bee A078) | Bagration gear son ore) | asco rane) | aaxecvans) | aea(esns) | aose(esra Numeral pasa | . — saree es se ee [owe | ons CX Par ek bok BER [die | “aa Gans ei kr esi epereains SEB FAY ISEB SiS Stash pecans SHIRE Wena hs ane _ MANUAL TRANSMISSION ASSEMBLY REMOVAL 1. Remove the engine hood assembly. 2. Remove the holgdown elame and bstlory 3. Remove the battery carir stay. 4. Disconnect the following harnesses: ) Hamass to staner © (@) Tranemission eart (@) Backup lamp hamess @ MANUAL TRANSMISSION 5. Remove the intercocier assombly. (Wericles mounted with Type CB-80 engine ony) 6. Remove the stater assembly 7. Disconnect the speedometer cable 1. Detach the three harness clamps. 9. Disconnect the clutch cable. a4 40. Remave the two bali that directly attach the transmission ‘assembly fo the engine, 11.Jack up the vehicle. Remove the front res at the ight ang left sides ofthe vehicle. NOTE: Be sure to support the vehicle securely by means of safety stands. 42, Drain the transmission oll 48, Detach the engine undercover. (Type CL engine only) 14 Remove the lower suspension brace. (Types CB-61 and (CB-20 engines only) 15. Disconnect the font exhaust pipe at the bracket support ‘No.1 and manifold sides. 416, Disconnect the following contr! inkage-eated parts from the transmission housing (1) Shit & solect shat SA (@) Extension od SIA (MANUAL TRANSMISSION 17. Remeve the stabilizer bar (@) Remove the stabizer bar end mut and retainer. (@) Remove the stabiizer bar instaling nuts, 418. Discannect the lower arm atthe bracket side 49: Remove the drive shats atthe right and let sides, using the folowing SST. SST: 09648-87201-000 NOTE: 1LNo stopper is provided at the inboard side ofthe drive ‘shat, Hence, be sure to suppor the invoad joint section during the removal 2, Be very careful not to damage the lip section of the ol seal during the removal 3.8 for the right side of vehicles mounted with Type ‘CB-80 engine, insert a crowbar into between the prot- ruding section of the bearing shaft and the drive shaft ‘Then take out the font erive shat, being very careful not to deform the dust cover of the cive shat 20, Remove the trot drive bearing shaft assembly. (ericles mounted with Type G8-80 engine only) (41) Remove the two bolts and pull out the front criveshat bearing shall from the transmission assembly. raw 21. Remove the transmission assembly attaching bots. NOTE: Bo sure to leave the one bolt located at the front central par. 22, Lighty supoor the lower part ofthe transmission, using jack. Then, remove the engine mounting lowerilet bracket attaching bots {Tum the engine mounting lowerfet insulator 90 degrees ‘20 that k may oiat upward. 28, Remove the one bolt located at the front central part ofthe transmission assembly. Siowiack down the ransmission ‘assembly and take it out from Qelow the vericle. cs INSTALLATION 4. Install the transmission assemoly fo the engine assemby a follows: (Gi) Ensure that the clutch disc is centered in postion, Using the SST given below. ‘SST: 09301-87702-000 (2) Install the transmission, making sure that the clutch disc _may not be pried. Temporafily tighten the stiaching bots, 3-7 MANUAL TRANSMISSION 2. Tighien the transmission assembly attaching bots securely. ‘Tightening Torque: 5.0 -7.0 kgm (96 - 51 fb) 2, Install the engine mounting were insulator and engine rmeunting lowereh bracket Bracket Tightening Torque: ‘30 4.5 kgm (22 - 33 fb) Insulator Tightening Torave 75 = 10.5 kgm (64 - 76 fb) 4 Install the tront drive bearing shaft assembiy as follows: (Vehicles mounted with Type CB-60 engine only) (@) Slowly install the pearing shaft assembly to the di {erential case, making sure that no damage is made to the lip section ofthe oll sea. (2) Tighten the two attaching bots. Tightening Torque: 3.0 4.5 kg-m (22-38 fb) 5. Install he drive shalte atthe right and left sites. NOTE: ‘Slowly install the tive shaft tothe siferenial case, making sure that no damage is made to the lip section of te of eal, 6. Install the lower arm (at the bracket side). Temporary ‘ighten the ataching bots. 7. Install the stabitzer bar. (() Temporarily tighten the stablizer bar end nut (@) Tighten the cushion end stabilzer bar bracket “Tightening Torque: 40 - 6.0 kgm (28 - 43 fib) 8, Install the fllowing contol inkage-related pars (4) Shit & select shat SIA ‘Tightening Torque: 1.0 - 1.6 kgm (7.2- 11.6 feb) (2) Exonsion od SIA Tightening Torque: 1.0 - 1.6 gem (7.2- 11.6 feb) ©. Install the maniloid sie of the font exhaust pioe. install the bracket support No: (1) Maniola sige Tightoning Torque: 2.0 - 5.0 kgm (22 - 96 fb) (2) Bracket support No.1 Tightening Torgue: 2.0 - 0 kg-m (14.5 - 22 fe) 10. nstal the lower suspension brace. (Wericles mounted wth Type CB-61 and CB-80 engines oniy) “Tightening Torque: 4.0 - 85 kg-m (29 - 40 feb) 1. Install the engine undercover. (Wehicles mounted with Type CL engine only) 12 Install the front wheels atthe right and left wheels. Jack down the vehicle, 18, Rock the vehicle in a up-and-down direction a few times 50 a8 t0 sate the suspension. ‘With the vehicle in an unloaded, tighten the nuts. (1) Staoitzer bar insaling nuts Tightening Torque: 75 - 11.0 kg-m (64 - 60 fe) (2) Lower arm (bracket side) Tightening Torque: 7.0 - 10.0 kg-m (6t - 72 fb) 3-8 MANUAL TRANSMISSION 19. Fil the tansmission ofl Oi capacity: ‘speed transmission: 1.9 - 206 (U.7 - 18 Imp qs, 20-21 US. as) S-speed transmission: 21-222 (8-19 Imp ais, 22-23 US. ats) 14. Insta he clutch cable. (See page 2-3), 18, Attach the three harness clamps. 16 instal the speedometer cable. 17. Instal the starter assembly. “Tightening Torque: 5.0 - 7.0 kg-m (96 ~51 feb) 48. install he intercooler assombiy. (Weticles mounted with Type C3-80 engine only) Fre psp 19, nsal the folowing hamesses: (i) Hamess to staner © (@) Transrrission ears @ {@) Backup lamp harness @ 20, Insal the battery carrier stay, battery, holc-down clamp and engine hood assembly. MANUAL TRANSMISSION DISASSEMBLY, INSPECTION AND ASSEMBLY OF TRANSMISSION HOUSING, CASE S/A AND CASE COVER: ‘COMPONENTS (PART 1) 1 Nonrousable parts. QWrsad svagr sew ua ie cise) Speoderetr sta sleeve SA Wnaod seat scrw aug rams) ears cnse co’ Suscae bac {8 Case coerce pcteabecte! Seen ow ite Sees S:dcorerosnon ng Bo =e Sve stn ay 8a Srenmason case Bie BS rce wap ens ea a2 (MANUAL TRANSMISSION COMPONENTS (PART 2) MANUAL TRANSMISSION DISASSEMBLY 1. Remove the screw plugs (atthe drain and filer sides) 2. Remove the clutch cable bracket and engine mounting bracket, 3. Remove backup lamp switch assembly and bfeather plug, 4, Remove the lock plate and speedometer shaft sleeve subassembly. ‘5. Remove the ail seal, using the SST given below. SST: 09921-00010-000 6. Remove the wansmission case cover subassembly as follows: (1) To drive out the case cover subassembly, tap the flange section ighty in the axial drection, using a plastic hammer. NOTE: Never tap the case cover at its side. MANUAL TRANSMISSION 7. Remove the case cover oll pipe. 8. Remove the lock ball plate and gasket, Teke out the ‘compression spring and ball {inne case of he 6-epeed transmission, proceed to this ‘operation after the Sth Qear has been disassembled) 18. Remove the transmission case as folows: (G) With the hele snap ring for output shaft bearing use held in an expanded state by means of the SST. crop the shat ‘SST: 09908-00012-000 (2) To drive out the transmission case, tap the case rib with a piastic hammer. 430. Detach the hole snap ring 11, Remove the contr! linkage-elated pars (For the cisassemoly procedure for each part, see page 3-50) MANUAL TRANSMISSION 12, Remove the Input shaft bearing lock plate, 13, Remove the input shaft assembly and output shaft assem by atthe same time (3) Atemately pull out both shafts litle ata tine +4 Remove the selactor support assembly, siti bell crank and magnet. 15, Remove the diferenial case as follows (G) witha brass bar placed on the inner race of the side Dearing, lightly tap the bar so that the ciferential case ‘may be diven out from the transaxle case REPLACEMENT Inspect the folowing pars. (See page 3-18) Replace any pars that exhibit delects, folowing the procedure given below. 1. Qi geal for contol shaft use Disassembly: Remove the ol seal by pinching its ange section with piers ‘Assembly: "Drive the oil eeal into postion, unlit comes. into contact wih the axle case ‘SST: 09515-87201-000 a6 3 2. Oil seal for input shaft use Disassembly: Remove the oll seal with @ common ecrewtiver Assembly: Dive the cll seal info position, un it be- "comes fush ‘with the edge Surtace of the transaxle SST: 09606-87201-000 3. Neadie Raler Bearing Disassembly: Alter the outout shaft bearing lock plate nes been removed, remove the roler bearing, using the SST given below. SST: 09308-00010-000 ‘Assembly: (1) Assemble the roller bearing, using the SST given beow. SST: 09309-67201-000 NOTE: Visually check to see Ifthe output shatt cover exhibits severe distortion or clogging. (2) instal the beating lock pate. ‘Tightening Torque: 0.7 = 1.0 kgm (6.1 -72 ib) 4 Oil seal for aiferental use Disassembly: Remove the oll seal wih @ common sorencriver ‘Assembly: Drive the oll seal into postion, until it comes. “ito contact with te rip ofthe axle case ‘SST: 09517-67701-000 (Case sie) (09517-87702-000 (Housing side) INSPECTION 41. Check each bearing for wear or damage Pa Inspection crteria Wien the inne ace ie etated by yeur Beating _| fingers t shoul rotate sro wie outer nang 2. Check each oil seal for wear or damage, Par 1 Transction eerie ‘Vigsly inspect 0 s00fthe ip ton Lip section ofall seal_| Shots excessive camage of wear a7 ‘MANUAL TRANSIISSION ~~ _ : | 0 i i Mion sector Steers sce MANUAL TRANSMISSION 3. Check the speedometer shaft sleeve subassembly for wear or damage, me Tae |e renee | _ mia Den ee ret donee a I, costa tam | _ 63 ‘Satara bo i ots tay | _ ot Giese ry aoe ee lll e |e ASSEMBLY 1. Assemble the diferental case. (For the assembly procedure for each cart, see page 3-47) 2. Assemble the magnet and selecting & shiting bell crank ‘support assembly. (For the assembly procedure for each par, see page 3-57) Tightening Torque: 0.7 - 1.0 kg-m (6.1 -7.2 fb) 3, Assemble the input shaft assembly and output shaft ‘assembly altho same time, 4, Assemble the input shaft bearing lock plate. “Tightening Torque: 1.5 - 2.2 kgem (11 ~ 16 fb) Jes ‘Assemble the contol inkage-related pars (For tne assembly procedure for each part, see page 3-57) Install the hole enap ring in the transmission case. ‘Assemble the transmission case as follows: (@) Apoy the Three Bond sealer 1216 to the mating ‘Surface ofthe housing, While the hole snap ring of the Dearing is held in an expanded slate, assemble the ttansmission case in the ale case, SST: 09005-00012-000 NOTE: Make ‘sure that the snap ring Is ited postvely in the bearing, by raising the output shat by your hand (2) Tighten the housing attaching bots. Tightening Torque: 1.5 -2.2 kgm (11-16 fib) ‘Assemble the ball and compression spring. ‘Assemble the lock bal plate and gasket as folows! (() Perform the assembling, using the bots. a9 MANUAL TRANSMISSION Pemieillbediedeeat 410. natal he case cover ol pipe as follows: (Q) insert the ol pipe, until ils rb section comes. into Contact withthe case, NOTE: ‘The ol pipe for the 4-speed transmission difers from that for the ‘S-speed transmission in its overall length and ‘iprend shape. ‘Overall length: (Ol pipe for 4-speed transmission 126 mm (5.0 inch) (Ol pipe for 5-spoed transmission 167 mm (66 inch) 11. Assemble the transmission case cover as follows (1) Apply the liquid gasket sealer (Three Bond 1216) to the mating surtaces ofthe case, except for those hole areas. (See page 3-19.) Tightening Torque: 0.7 - 1.0 kg-m (6.1 -7.2 fb) 12, Assemble the ol sea for speedometer shaft sleeve, using the SST given below. SST: 08201-60011-000 43, Assemble the speedometer shat sieeve subassembly and lock plat. “Tightening Torgue: 0.7 - 1.0 kg-m (S:1-7.2 fb) 14. ntall he backup lamp switch and breather plug. “Tightening Torque Backup Lamp Switch: 3.0- 6.0 kg-m (22-96 fh) Breather Plug: 1.0 - 1.3 kgm (7.2 9.4 tab) Ot peo Cine s rosecon( _Sapeedanamasen Cana coer aoe SSpeectraemiesin speed vrwmisson bracket “Tightening Torques Clutch Cable Bracket: 1.5 - 2.2 kgm (11 - 16 fib) Engine Mounting Bracket: 30 -45 kom (22 - 93 tb) 16. Install he serew plugs (t the drain and filer sides). Tightening Torque: 3.0 ~ 6.0 kg-m (22 - 36 tb) 45. instal the clutch cable bracket and engine mounting MANUAL TRANSMISSION APPLICATION POINTS OF GREASE & BOND AND APPLICATION PROCEDURE ‘hepa tnd orp shat ‘ne nat tnd sepa we proton of case cover Sie sole adele) Soph gear alte he erro ‘rac of cach par rte parton of case (thvesond 121) ‘aly vareniason ole exch ct ger and Lipsacton etl a (green) rao ‘Application Procedure for Liquid Gasket Sealer (Three Bond 1216 .. Part No. 999-0480-8U90-00) 4. Cat the fist stage of the rozzle of the Dainatsu genuine ‘sealer (Tivee Bond 1216) that is furished in accessories, - | 2. Remove any remaining trace ofthe quid gasket that may tbe found on te housing oF the case wih thinner or @ seraper, Care must be exercised not 10 scraich the ‘surfaces during the cleaning. 3. Apply the liquid sealer to the entire periphery of the housing ene case without any unappied spot, as ind cated inthe ilustation at the eight. NOTE: App. the liquid sealer to the inside of each hole excluding those bolls holes. 2.Be sure to perform the assembling within five minutes after the application ofthe quid sealer. 8, Make sure to aty the thinner completly NOTE: “ The liquid gasket stars to cure when it reacts withthe moisture in the atmosphere. Hence, upon completion of the work, be sure to expel any ar trapped in the tube ‘and tighten the tube cap securely. 2. Rs regards the storage place fr this quid gasket, avoid Such places where high Temperature or high humidity prevals or those exposed to Grect sunrays. Make sure fo store tin a dy, cold and dark place. {The allowable lit for use is approximately sh months.) MANUAL TRANSMISSION DISASSEMBLY, INSPECTION AND ASSEMBLY OF INPUT SHAFT COMPONENTS: 0B gon we 906 Locke @gyncrenizes tub Ay No.2 ria ane Brera ne 0, agen gear bush Shefterep roa ‘ah gest Syren rag Bineut Sat ees200 Fase ae 3-28 MANUAL TRANSMISSION Operation Prior to Disassembly Ul out the input shaft andthe output shat at tne same tie from the vanemission cage, Proseed tothe next dsassembly persion. (See page $16) DISASSEMBLY +L. Remove the lock rut. (4speed transmission ony) (i) Clamp the 18t gear section of the input shaft in a vise, making sue that no scratch is made to the clamped section (@) Release the staked section ofthe lock nut, using a chisel {@) Remove the lock aut NOTE: For the 5-speed transmission, see page 3-99. 2. Remove the conical spring washer. Then, remove the Dearing, using the SST ajven below. ‘SST: 09602-87301-000 2. Remove the 4th gear and 4tn gear bush 4. Remove the synchronizer rng. Then, remove the syncho- rizr hub assembly No.2. (1) Detach the two synchromesh shiting springs and three eynohromesh siting keys. © Ore, MANUAL TRANSMISSION 5, Remove the synchronizer ring and Sra gear. 6 Detach the shaft snap ring, using two common screw: sve, NOTE: 1. Special care must be exercised as 10 the snap ring ‘which may jump out during the cisassembiy 2 Partcular anton should be paid to avoid scratching the shat. 17. Remove the bearing, using the SST given below. ‘SST: 09602-67301-000 INSPECTION 1. Cawck he th goar bush for wear of damage P| ES [Ut am eect @ 2 8 20 = © | tosses se) (0925) le Ouercaneer @| ne, = 29 Orerneea | cad i) rae =F Themes og 380%, ee BBR | ordi 2S a0 | oho MANUAL TRANSMISSION 2. Check each gear for wear or damage. ; ——— Pat in aieaoet ate ee| | [2T oem | wee | mm | ma moa jit Bdta| ah | eh a | 93m As 05 | BT wa dao ls! 28h h_| —_ esrsecin | ee — set eo ae anata iblses "| toonced as mn tun ‘Type 6860 engine th gear) PUpRdbin creation and san of he hub and sleowe Sleeve a) ST ee een | Pa TRTESS |_ume omen ‘Shi fok groove 7088 | ig sEereer @ | ozwiin | win Thang sxion | Vu epect i oon ene ENBSS"" © | Garage wear ck or ounces one 4, Check the input shit for wear or damage. Pent [Spaced 22 | Umit mm neh) Quecdameirct | aszauz | age bushbore-coriact, | (ond shi) | O88) jeter) | _ “oom surfaces of | Visually nepect he euace fr excessive Searerd spine | Gamage, wear ick or rounded edge. 2. Gk he ch tu nd ar fre eh ot Sete pk 7 ‘Cluteh Hub \ mo] = Splined section © | a eS may age =| ee ue | ‘With the hub fitted into the sieeve, check for excessive looseness cnc ee MANUAL TRANSMISSION 55. Check the synehromesh shiting key and key spring for ‘wear or damage eae ave Tat Pat Serene rom (ch) Key 5 & 4h 5 43 pelrtimensony) | (a1e7 28%) oe) = © | Weare sea canage 66. Check the synchronizer rng for wear or damage. deal "Prem tne) _mm (inch) =e rmeeing spresed | 4th =: Bo | Seth | ction — [seer sea a Doras ne 7. Chwokne neg fr wear or ae Pan : Inspection efiteria as ete sri a ASSEMBLY — ss weaned — ' NOTE: i} ‘section A —.L—rt~—~—O_—=CizsORr Te ral ra hen ipo cares oar Sapo mocuiegn ima ead Tre | Overall ie Presence of “Without spline (speed) —— ae ae ec Sere rae ast 2 ves | ly We SSpeed (92.24) : oes (MANUAL TRANSMISSION 2, Assemble the bearing, using the SST given below. ‘SST: 09908-87201-000 3, Drive a new snap fing Into postion, using a common serewive, For easier installation, hold the snap ring with the SST siven below: ‘SST: 09900-87201-000 NOTE: ‘Be very careful not to scratch the shat. 4. Assemble the 8rd gear 5, Assemble the synchronizer ring and synchronizer hub ‘assembly No.2. (G) Assemble the clutch and sleeve. Ensure that both parte can side smoothly. (@) Besemiie the shifting koye end springs, 6. Aseemble the synchronizer ring and Ath gear. 7. Assembly the 4th gear bush 300 $7201-000 fant © ‘Srenoneeing & 4h go ean MANUAL TRANSMISSION 8. Assemle the bearing, using the SST given below. ‘SST: 09909-97201-000 NOTE: (On the 5-speed transmission, measure the end play of comeeeanone ‘each gear ater the bearing has been assembled (Gee page 3-43.) 8, Assemile the conical spring washer and lock nut (speed transmission) (G) instal the conical spring in such a way that its expanded sice may face foward the shat se. (2) Clamp the reduction gear section in a vise, making Sure that no scratch may be made tothe section. estate cons eptog (@) Tighten the lock nut ivi oxperced se Tightening Torque: 10.0- 14.0 kg-m (72 - 101 fo) facing ova 10. Upon completion of the assembly, measure the end play Y ‘of each part ofthe input shat Spacted ae Tat cs | FPrmiech) smn (ch) ardger _@| 1-028 os & ‘thgear @ | (00089-30001) (ote) a NOTE! If the end play does not comply with the specification, ® check the gear, bush and cuich hub sliding section. sar “sama Replace any parts which exhibit defects 11. Stake the lock nut, using a chisel NOTE: Be sure to stake the central part of the look nut so as to ° ‘avoid dislocation or cracks. OO COMPONENTS: MANUAL TRANSMISSION DISASSEMBLY, INSPECTION AND ASSEMBLY OF OUTPUT SHAFT (SCout ena Fane 31 MANUAL TRANSMISSION Operation Prior to Disassembly Pullout the output shaft and the input shaft atthe same time from the tensmission case. Proceed tothe next disassembly operation. (See page 3-53) DISASSEMBLY 1. Remove the lock nut. (4-speed transmission ony) (1) Clamp the reduction gear section ofthe output shat in 4 vise, making sure that no scratch fs made to the clamped section (2) Release the staked section of the lock nut, using @ chisel (@) Remove the lock nut NOTE: For the 5-speed transmission, see page 9-99. 2. Remove the conical spring washer. Then, remove the bearing, using the SST given below. ‘SST; 09602-87301-000 8, Remove the output 4th gear, speedometer drive gear and output 3rd gear 4, Remove the 2nd gear assembly (() Detach the shaft snap fing, using the SST given below. SST: 09905-00012-000 (@) Remove the 2nd suogear. {@) Ramove the conical spring washer. aog=<=Qjp eo) 06g, MANUAL TRANSMISSION Remove the 2nd gear bush and synchronizer ring No.8 Remove the synchronizer hub assembly No.2. (G) Remove the two synchromesh shiting key springs and thee synchromesh shiting keys. emave the synchronizer ring No.3 Remove the 1st gear assembly (() Detach the shaft snap fing, using the SST given below. ‘SST: 09905-00012-000 (@) Remove the 1st subgear. {G) Remove the conical spring washer. Remove the spacer and needle roller bearing, MANUAL TRANSMISSION INSPECTION 1. Chack the 2nd gear bush for wear or damage. Seated ae oa Pa Peete | many 23-81 28.84 hail ©! cserribien ES) a7 Es 288, ower cemaer @| sry i824) overatiengh @| «AAS 903, sar fei) 2. Check each gear for wear ar damage. | Seecteg value en fren) |Link mm (ret) toe © | Yeah @ | Ove | @ wich [a HH | ios | 2 aes ome) jy asar gto zr ee eee) | (ae 7 Pat ards) mane 9| See, 8 [roc Yapcremntrecnoncesies Eisen mo Treen g erence wowtom maaan ieee Check the clutch hub forthe tst & 2nd gears and reverse (ear for wear or damage. ‘Clute Hub Pa a ‘Spined secon @ E o_O | igsaty inspect he section oro ‘Synchrameshsrfing Wey | sesevé Gamage o ea fing groove @ ‘Wit the rub fied into the sleave, check for excessive looseness. ‘i Edown drecton and San af he hub ar sleeve Reverse Gear Sates ane | oa Pat | SPramtindh) © | rm nen) 70 2838 73 Shittorkaroove wien ®| ware see) | 0287) Fring eactonwit gear @ | Visually inspect he section fr ex Senin oes _@ | ecive cage, wear, ick or Poewagearomastace © | reseed edge Ted Forte ira gear Revere oat MANUAL TRANSMISSION 4. Check the output shaft for wear or damage. ra Specieg ane | Tine | SPrrn‘ines) © | ew tinct) ‘ol, Bie 23.86 tar cameter of te (1817 Faced) | P785) ‘esate rll Bosh ‘ontac'secton lol, 2, ae [2508 =F) | (2580) Toot sulases of gear ond | Vaxaly speci ste reese Sine ‘raga wes horace 5. Check the synehrernesh shifting Key and key sexing for ‘wear oF damage. ‘Samage or distoron packers | UaT Past [Seimtecl) | mm tnem ghey iesoaoes | 612 Ot a7 GRR APHOM® otha Occse) 0185) a a (ex insect te sping for 6 Check the Ist and 2nd subgears and conical spring washer for damage or wear. (Except fr vehicles mounted with Type C8-80 engine) Spates ae | Un Pan PSS | _ men ech) (peter soe ears Borecisuogear | cuaspesge™) | (870) Subpsaricoic| spina Vly spestne sce fr stacker icing sonar "%@ | Gamage o corn, Fear 7. Check the synchronizer rng for wear or damage. aaa] Oe J a amo) men (inch) SSRN |S” oSE- Mn | atk mee |2ig., (oes 0571 | (ozo) pane Damage ane sao | guatygpacn ecto ore — esse Sarace Damage at ptne 8, Check the bearing for wear or damage. Pat Trenection oetie ‘inen the ner 08 ated by your Beaing Inger grou Yotae smeery wihout ary econ, (MANUAL TRANSMISSION ‘ASSEMBLY NOTE: ‘Apply gear oil to the entre surface ofthe rotary or sliding section of each gear ofthe output shalt. 1. Assemble the needie roller bearing and spacer 2. Aseemble the tst gear assembly (1) Install the conical spring in such a way that is expanded side may face toward the subgear side, (2) Assemble the 1st subgear {@) Assemble @ new snap ring, using the SST given blow. ‘SST: 09905-00012-000 3. Assemble the synchronizer ring No, 44. Assemble the synchronizer hub assembly (1) Assemble the hub clutch and reverse gear. Ensure that both parts can slide smoothiy. (2) Assemble the shifing keys anc springs. 5, Assemble the synchronizer ring No’ and 2nd gear bush 6, Assemble the 2nd gear assembly. (3) instal the conical spring in such a way that its ‘expanded side may face toward the subgear side. (2) Assemble the and subgear. {@) Assemble @ new enap ring, using the SST given below. SST: 09905-00012-000 5) %9 reer MANUAL TRANSMISSION 7. Assemble the output Src gear, speedometer drive gear ‘and output 4th gear. NOTE: ‘The umber of the speedometer crive gear teeth clflers depending upon the gear reduction ratio. Hence, care must be exerosed as to the number of gear teeth during the assombly. (See page 3-3.) Apply gear ol to the entre surface of the rotary or sing seation of each gear 8, Assemble the bearing, using the SST given below, ‘SST: 08908-87201-000 8. Assemble the corical spring washer and lock nut (@-spoed transmission) (4) instal the conical spring in such a way that its ‘expanded side may face toward the gear side. (@) Clamp the reduction gear section in a vise, making sure that ao soraich may be made tothe section, (2) Tighten the lock rut Tightening Torque: 10.0- 14.0 kg-m (72-101 ft eon 720-000, MK Inga ne cei sprog white excances se eho warns 5 a 10.Upon complation ofthe assembly, measure the end pay of each part of the outout shat Part ]_Specineg yao | Limit rm inch) 1 weer | gto | 8 Ht sage @) Ootie-bauH | ten NOTE | Ihthe end play doos not comply wih the specication, chock the gear, bush and. cutch hub siding section. S | Replace ary pars which exhibit defect, 11. Stake the lock nut, using a chs om ° NOTE ~ 2 Be sure to stake the cerival part of the lock nut so as to : _void dislocation or cracks j x & rae ae MANUAL TRANSMISSION DISASSEMBLY, INSPECTION AND ASSEMBLY OF 5TH GEAR ‘COMPONENTS: Stew r Sica sng water iraeon aS poe raramason ctch No3 hab Ay oe MANUAL TRANSMISSION DISASSEMBLY 1. Remove the slotted spring pin 2. Remove the lock nut (() Lock the input shat, using the recommenced too! for this application. (See page 9-66) (@) Release tne staked lock nu, using a chisel. NOTE: Be very careful not to damage the threaded portion of the Input shat {@) Remove the lock nut atthe input shaft, using a socket whose width across flats is 32 mm. (4) Set the sieeve for Sth gear to te Sth gear poston, {6) Remove the lock nut at the output shaft side, 3. Remove the conical spring washer atthe input shaft side land transmission hub sleeve stopoer. 4. Remove the Sth shift fork and transmission clutch hub assembly No. (() Remove the Sth shift fork and transmission cutch hub assembly No. at the same time, mam (MANUAL TRANSMISSION 5. Remove the synchronizer ring and Sth gear. 6. Remove the Sth gear bush, 7. Remove the conical spring washer at the output shaft side, Remove the output 5h gear. INSPECTION ig 3140. waa 1. Check the bush wear or damage. ® Fen] ER | it ord q re sunsce ©! se 3) eile ee: ee) J omnia 8 | stn | __ ah ar 5 BERS, ©| ott l Bron | ety 2. Check he Sh aero west or rage | Species valve am fren) Lint neh 2 bed [i | Bed | en hice Bar Bae |nctatm| CS | ce | | S| @ Gaeo & err _| Voda cn boca cag = _ out GEREN capita ieee py, chr ce ee 3-40 43. Check the clutch hub and sleeve forthe Sth gear for wear or damage. ‘Clutch Hub Pat T rat ‘Spined secon o| ee army | Mat ogptie eee ro Sector shina er (we damage oF wear L iting groove “Wh the pub ite ito the sleav. cack or excess ocseness IRE Grocton and sant he hub an sleeve Sleeve rad Specterae | Un | mentncr) | mminch) | 7 [70% 73 By 73, sriiocomoewan @| 20h) | Bn 7 ieuly inspect he section fox (esi damage, wear nicer Fring ection wit gsr © founds jecge. 4. Check the synchromesh shiting key and key soting for wear or damage, 7 SERS TE Par | tom (inch) mmm (inch) eine ce i Bese [ov@atem | otk ora o | Seamer 5, Check the synchronizer ring for wear or damage, Damage at pine = Spectea as | _Ua Pa Perm inch) | mm inn) Gap when aynehronier | 05-245 Os. fngisprectedtogeer | (0083-0087) | __ (Oe) Damage stinner tapered | sector ‘sual ingpect he section ore esewe damage. {6 Check the shit fork forthe Sth gear for damage or wes 7 Tpachec yas | UR Pa [Sfiincy) | mm tren) Typressarsosectonct | 70026) | 830025 at Ff), He MANUAL TRANSMISSION ASSEMBLY NOTE: ‘Apply gear oll to the entre surace of the rotary or sicing section of each gear of the output shat. 1. Assemble the output Sth gear and the conical spring washer for the output shaft NOTE: Tighten @ new lock nut temporary. 2. Assemble the Sth gear bush, 3. Assemble the Sth gear and synchronizer rng, 4. Assemble the transmission clutch hub assembly. (3) Assemble the cutch and sleeve. Ensure that both pars can sie smoothly (2) Assemiole the shiting keys and springs. NOTE 1. The hub assembly for the &1¢ and 4th gear use difers from the hub assembly for the Sth gear use only in the Inner lameter of the clutch hub. Other parts are shared in common. 2.The sleeve and dutch do not have any instaling rection to be observed during thelr assembly. 5, Assemble the vansmission cluich hub assembly and the Sth gear shit fark atthe sarne tie. 6. Assemble the transmission hub sleeve stopper 77. Assemile the conical spring washer (@) instal the conical spring in such a way that ts ‘expanded side may face toward the transmission side, 1 was expanded meteon eae ears 8. Insta anew look nut (7) Lock the input shat. using the recommended too for this application. (See page 3-66.) (2) Tighten the lock nut at the input shat to the specitied torque, using 2 cocket whose wiath across fas is $2 Tightening Torque: 10.0 - 14.0 kg-m (72 - 101 feb) (@) Set the transmission to the Sth gear poston. (@) Tighten the lock nut at he output shat fo the specited rorque, Tightening Torque: 10.0- 14.0 kg-m (72 - 101 feb) (6) Before the lock rut is staked, measure the end play of the Sth goat ‘Spectied Value: 0.1 - 0.28 mm (0.004 - 0,009 ineh) Unt: 0.4 mm (0.016 inch) (@)Stake the lock nut, using @ chisel NOTE: Be sure to stake the central part ofthe lock nut so as to ‘avoid dislocation or cracks. ‘9 Drive the slated spring pin into poston, uni it becomes flash vith the edge sutace ofthe shift fork. 43 rome aa ‘MANUAL TRANSMISSION [hee ee DISASSEMBLY, INSPECTION AND ASSEMBLY OF DIFFERENTIAL CASE COMPONENTS: Fe aE DISASSEMBLY 1. Remove the radial ball bearing. (1) Remove the Dearing at the engine side, using the SST given below, ‘SST: 09602-87301-000 (2) Remove the bearing athe transmission side, using te SST given below SST: 09906-87302-000 NOTE: Grinding off the interfering section ofthe SST witl make the operation easier. 2. Remove the differential ring gear. (1) Clamp the diferent case In 2 vise. Remove the attaching bots, (2) Remove the siferential ring gear IWany diffeuly Ia removing the ring gear is encoun tered, evenly tap the perinheral section of the ring gear, using a plastic hammer 3. Drive out the slated spring in, using punch pin ‘MANUAL TRANSMISSION 4. Pullout the diferential pinion shat. 5, Remove the diferental pinion, diferential side gear and

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