chapter13 manual transmission
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MT 10 MANUAL TRANSMISSION - W46 55 and 56 Transmission
g Remove th e s hi ft f or k and shaft No.2 .
WM0024
h Using a magnetic finger remove interlock pin No.3 .
WM0025
i Remove f or k s ha ft No.3 with reverse shift arm.
8. 2 5-SpeedREMOVE SHIFT FORKS SHIFT FORK SHAFTS AN DREVERSE I LER GE R
a Pry ou t t he l oc k w as he rs of shift fork No.1 and No .2, and remove tw o se t bolts.
b Using two screwdrivers and a hammer tap out th etw o snap rings of th e No. 1 and No. 2 fork shafts.
WM0019
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MANUAL TR NSM SS ON - W46 55 and 56 Transmission MT
c Remove th e reverse idler gear shaft stopper
WM0028
d Remove the reverse idler gear and shaft
e Remove th e shift fork and shaft No 1
WM0030
f Using a magnetic finger remove interlock pins No 1and No 2
WM0031
g Remove th e s h if t f or k and shaft N o 2
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MT 2 MANUAL TRANSMISSION - W46 55 an d 56 Transmission
h Using a magnetic finger remove interlock pin No 3
WM0033
i Using a pin punch and hammer drive ou t th e fo rk shaf tpin N o 3
j Pull out th e s hift f or k s ha ft N o 4
WM0035
k Remove shift fork No 3 fork shaft N o 3 and reverseshift ar m with pin
9. 2WDREMOVE SPEEDOMETER DRIVE GEAR
Pr y o ut b oth ends of t he c li p and remove th e drive gear
WM0040
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MANUAL TRANSMISSION - W46, 55 and 56 Transmission MT-13
10 . 5-SpeedMEASURE COUNTER FIFTH GEAR THRUSTCLEARANCE
Using a feeler gauge, measure the counte r 5th gear thrustclearance.
Standard clearance: 0.10 - 0.41 mm 0.0039 - 0.0161 in.
Maximum clearance: 0.46 m m 0 .0 18 1 in.
WM0041
11 . 5-SpeedREMOVE COUNTER REAR BEARING, SPACER, COUNTERFIFTH GEAR AN D NEEDLE ROLLER BEARING
a Using snap ring pliers, r em ov e t he snap ring.
WM0261
b Using SST, remove th e rear bearing, spacer, 5t h gearand bearing.
SS T 09213-36020
CAUTION: Be careful no t to c at ch t he output shaft rearbearing roller on the counte r 5t h gear.
c Remove th e spacer.
2 5-SpeedREMOVE HU B SLEEVE NO . 3 ASSEMBLY
a Using two screwdrivers and a hammer, ta p ou t th esnap ring.
WM0044
b Using SST, remove clutch hu b No.3.
SST 09950-20015
CAUTION: Latch the claw of th e SST onto the c lu tch hub,not th e s hi ft in g k ey retainer.
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MT-14 MANUAL TRANSMISSION - W46, 55 and 56 Transmission
t
~ ~
< 1.. tJ~ r u W M O O
13. 5-SpeedREMOVE OUTPUT SHAFT REAR BEARING AND FIFTHGEAR a Using tw o screwdrivers and a hammer, ta p ou t th e
snap ring.
b Using SST, remove th e rear bearing and 5t h gear.
SS T 09312-20011
14 . REMOVE REVERSE GEAR
a Using snap ring pliers, r em ov e t he snap r ing.
b Using SST, remove th e reverse gear.
SS T 09950-20015
15 . REMOVE CENTER BEARING RETAINER
a Using a torx socke t wrench , unscrew th e torx screwsand r em ov e t he retainer.
b Using snap pliers, remove th e snap ring.
16. REMOVE OUTPUT S HA FT A ND COUNTER GEAR AS AUNIT FROM INTERMEDIATE PLATE
a Remove th e output shaf t, inpu t shaf t and counter gearas a unit from the intermediate plate by pull ing on th ecounter gear and tapping on th e intermediate platewith a plas ti c hammer.
b Remove th e input shaft from output shaft.
17 . MEASURE EACH GEAR THRUST CLEARANCE
Using a feeler gauge, measure th e thrust clearance of eachgear.
Standard clearance: 0.10 - 0.25 mm 0.0039 - 0.0098 in.
Maximum clearance: 0.30 mm 0.0118 in.
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MANUAL TRANSMISSION - W46 55 and 56 Transmission MT 15
18 REMOVE OUTPUT SH FT CENTER BE RING ND FIRSTGE R SSEMBLY
a Shift hu b s leeve No 1 o nt o t he 2 nd g ea r
b Using a press remove th e center bearing 1 st gear,needle roller bearing, inner race and synchronizer ring.
WM0051
19 REMOVE LOCKING B LL
WM0052
2 REMOVE HUB SLEEVE NO 1 SSEMBLY SECOND GE R ND NEEDLE RO R BE RING
Using a press remove th e p ar ts f ro m t he shaft as an assembly
WM0053
21 REMOVE HUB SLEEVE N O 2 SSEMBLY ND THIRDGE R
a Using s na p r in g p lie rs remove t he s na p ring
WM0054
b Using a press r em ov e h ub sleeve N o 2 th e syn-chronizer r ing a nd 3rd gear.
WM0055
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MT-16 MANUAL TRANSMISSION - W46, 55 and 56 Transmission
INSPECTION OF TRANSMISSIONCOMPONENTS
1. INSPECT OUTPUT SHAFT AN D INNER RACE
a Using calipers, measure the output shaft flangethickness.
Minimum thickness: 5.60 mm 0.2205 in.
WM0204
b Using calipers, measure th e inner race flangethickness.
Minimum thickness: 4.70 mm 0. 1850 in.
WM0057
WM0059
c Using a micrometer, measure t he o ut er diameter ofth e o u tp u t s h af t journal.
Minimum diameter:
2n d gear 42.85 mm 1.6870 in.
3r d gear 37.80 mm 1.4882 in.
d Using a micrometer, measure th e o ute r diameter ofth e inner race.
Minimum diameter: 42.85 mm 1.6870 in.
~r
i i
I
WM0060
e Using a dial i nd ic at or , c he ck t he shaf t runout.
Maximum runout: 0.06 mm 0.0024 in.
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MANUAL TRANSMISSION - W46, 55 and 56 Transmission MT-17
n
WM0061
WM0062
2. CHECK OIL CLEARANCE FIRST GEAR
Using a d ia l indicator, measure th e oil clearance betweenth e gear and inner race with th e n ee dl e r ol le r b ea ri ng i nstalled.
Standard clearance: 0.009 - 0.060 mm 0.0004 - 0.0024 in.
Maximum clearance: 0.15 mm 0 .0059 in.
3. CHECK OIL CLEARANCE SECOND AN D COUNTERFIFTH GEAR
Using a dial indicator measure th e oil clearance betweenth e gear and output shaft with th e needle roller bear ing installed.
Standard clearance:2n d gear 0.009 - 0.060 mm
0 .0004 - 0.0024 in.5t h gear 0.009 - 0.062 mm 0 .0004 - 0.0024 in.
Maximum clearance: 0.15 mm 0 .0059 in.
WM0063
CHECK OIL CLEARANCE THIRD GEAR
Using a di al indicator, measure th e oil clearance betweenth e gear and output shaft.
Standard clearance: 0.060 - 0.103 mm 0.0024 - 0.0041 in.
Maximum clearance: 0.20 mm 0 .0079 in.
WM0064
5. INSPECT SYNCHRONIZER RINGS
a Turn the ring and push it in to check th e braking action.
WM0065
b Measure th e clearance between the synchronizer ringback and th e gear spl ine end.
Standard clearance: 0.7 - 1.7 mm 0.028 - 0.067 in.
Minimum clearance: 0 .5 mm 0.020 in.
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MT-18 MANUAL TRANSMISSION - W46, 55 and 56 Transmission
6. MEASURE CLEARANCE O SHIFT FORKS AND HUBSLEEVES
Using a feeler gauge, measure th e clearance between 1hu b sleeve and shift fork.
Maximum clearance: 1.0 mm 0 .039 in.
WMOO66
f7.
~ j
WMOO67
I NECESSARY, REPLACE INPUT SHAFT BEARING
a) U si ng s na p ring pliers, r em ov e t he snap ring.
b) Using a press, r em ov e t he bearing.
WM0068
c) Using a press and SST, install a ne w bearing.
SS T 09506-35010
WM0069
WM0070
d) Select a snap ring t ha t w il l a l low minimum axial playand install it on th e shaft.
Mark Thickness mm in.
2 .05 2.10 0.0807 0.08272 2.10 2.15 0.0827 0.08463 2.15 2.20 0.0846 0.08664 2.20 2.25 0 .0866 0.08865 2.25 2.30 0.0886 0.0906
2.30 2.35 0.0906 0.092512 2.35 2.40 0.0925 0.0945
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MANUAL TRANSMISSION - W46, 55 and 56 Transmission MT-19
8. INSPECT FRONT BEARING RETAINERCheck th e retainer a nd oil seal fo r wear or damage. I f t heoil seal is worn or damaged, replace it as follows.
a Using a screwdriver, pr y out the oi l seal .
WM0071
b U si ng S ST, pr es s in th e oi l seal.
SST 09608-20011
Oil seal depth: 11.4 - 1 2. 0 mm from retainer end O.449 - 0.472 in.
WM0072
9. NECESSARY, REPLACE COUNTER GEAR FRONTBEARING AN D SIDE RACE
a Using s na p r ing p lie rs , r em ov e t he snap r ing.
b Using a press and SST, press out the bearing.
SST 09950-00020
c Check th e s id e r ac e fo r wear or damage.
WMQQ73
d If necessary, r em ov e t he side race.
1 Using a SST and socket wrench, remove th e siderace.
SST 09950-20015
2 If th e s id e r ac e cannot b e r em ov ed with SST,grind part of th e side race and cu t it o ff with achisel.
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MT 2 MANUAL TR NSMISSION - W46, 55 an d 56 Transmission
e Using a socket wrench, press in th e bearing, side racea nd i nn er race.
WM0176
f Select a snap r ing that w i ll a ll ow minimum axial playand ins ta ll it on the shaft.
WMoon
Mark Thickness mm in.
1 2.05 - 2.10 0.0807 - 0.08272 2.10 - 2.15 0.0827 - 0.08463 2.15 - 2.20 0.0846 - 0.0866
2.20 - 2.25 0.0866 - 0.0886
5 2.25 - 2.30 0.0886 - 0.09066 2.30 - 2.35 0.0906 - 0.09257 2.35 - 2.40 0.0925 - 0.0945
1 NECESS RY REPL CE COUNTER GE R CENTERBE RING
a Remove th e bearing from t he c ou nt er gear.
b Install th e ne w bearing on t he c ou nt er gear.
NOTE: Engage th e roller cages.
WM0079
c Using SST, tap out th e bearing outer race.
SS T 09608-35013
NOTE: The outer race will be installed later, as th e transmission is assembled.
WM0078
11 NECESS RY REPL CE REVERSE RESTRICT P N
a Using SST, remove t he s cr ew plug.
SS T 09313-30021
WM0083
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MANUAL TRANSMISSION - W46, 55 and 56 Transmission MT-21
b Using a pin punch and hammer, d rive out th e slottedspring pin.
c Pull off th e lever housing a nd sli de out t he s ha ft .
d Install th e lever housing.
e Using a pin punch an d hammer, drive in th e slotteds pr in g p in .
WM0084
f Install an d torque t he s cr ew plug.
Torque: 250 kg-em 18 ft-Ib, 25 Nm
2 S-SpeedIF NECESSARY, REPLACE BEARING AN D OUTER RACE
a Remove th e outer race from th e extension housing.
1 Using two screwdrivers, remove th e snap ring.
WM0085
2 Using SST, ta p out th e outer race.
SST 09608-35013
WM0086
b Install th e bearing outer race.
1 Using SST, install a new outer race.
SST 09608-35013
WM0087
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MT-22 MANUAL TRANSMISSION - W46, 55 and 56 Transmission
2 Install th e s na p r in g.
WM0088
WM0108
20mm
c J E ~
WM0109
WM0110
WM0111
13 . 2WDNECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR
OIL SEAL a Using SST, remove th e oil seal .
SS T 09921-00010
b Using SST, install a ne w oil seal .
SST 09201-60011
Oil seal depth: 20 mm 0.79 in.
14.-1 2WDNECESSARY, REPLACE OIL SEAL AND BUSHING
a Using SST, remove th e oil seal.
SS T 09308-00010 or09308-10010 w / o u tp u t s ha ft installed
b Heat th e extension housing end to 80 100C 1 76 212F in an oil bath.
c Using SST, remove th e bushing and install a ne wbushing.
SS T 09307-30010
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MANUAL TRANSMISSION - W46, 55 and 56 Transmission
d Using SST drive in a ne w oil seal.SS T 09325 20010
SST
WMOl 2
MT-23
14.-2 4WDIF NECESSARY, REPLACE OIL SEAL
a Using a screwdriver, pr y ou t the oil seal.
b Using SST drive in th e oil seal.
SS T 09325 12010
GM0058
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MT-24 MANUAL TRANSMISSION - W 46, 55 and 56 Transmission
Front
ASSEMBLY OF TRANSMISSION See pages MT -5 , 6
1. INSERT CLUTCH HUB NO.1 AND NO. 2 INTO HUB SL V
a Install th e clutch hu b and shifting keys to th e hu bsleeve.
b Install t he s hi ft in g k ey springs under the shift ing keys.
CAUTION: Install the key springs positioned so that theiren d ga ps are n o t i n l in e.
WMOl13
2. INSTALL THIRD GEAR AN D CLUTCH HUB NO.2 ONOUTPUT SHAFT
a Apply gear oil to th e shaft.
b Place the synchron ize r ring on th e gear and a lign th ering slots with t he s hi ft in g keys.
WM0114
c Using a press, install th e 3r d g ea r and clutch hu bNo.2 .
WM0115
WM0116 WM0054
3. INSTALL SNAP RINGSelect a snap r ing that w il l a ll ow m in im um axial play, andinstall it on th e shaft.
Mark Thickness mm in.
1.80 - 1.85 0.0709 - 0.07281.86 - 1.91 0.0732 - 0.0752
12 1.92 - 1.97 0.0756 - 0.077613 1.98 - 2.03 0.0780 - 0.079914 2.04 - 2.09 0.0803 - 0.082315 2.10 - 2.15 0.0827 - 0.0846
4. MEASURE THIRD GEAR THRUST CLEARANCEUsing a feeler gauge, measure th e 3rd gear thrustclearance.
Standard clearance: 1 0 2 5 mm 0 0039 0 0098 in.
Maximum clearance: 0 30 mm 0 0118 in.
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MANUAL TRANSMISSION - W46 55 and 56 Transmission MT 25
5. INSTALL SECOND GEAR AND CLUTCH HUB NO.1
a Apply gear o il to th e shaft and needle roller bearing.
b Place the synchronizer ring on th e gear and align th ering slots with t he s hi ft in g keys.
c Install th e needle ro lle r bea ring in th e 2nd gear.
d Using a p res s, install th e 2n d gea r and clutch hubNo.1 .
WM0119
6. INSTALL LOCKING BALL AND FIRST GEAR ASSEMBLY
a Install t he l oc ki ng ball in the shaft.
b Apply gear oil to th e bearing.
c Assemble th e 1st gear, synchronizer ring, needle rollerbearing and bearing inner race.
WM0120
d Install th e assembly on th e outpu t shaf t with th e synchronizer ring slots aligned with th e shifting keys andturn th e inner race to align it w ith t he l oc ki ng ball.
WM0121
7 . INSTALL OUTPUT SHAFT CENTER BEARINGU si ng S ST and a press install th e bearing on t he o ut pu tshaft with th e outer race snap r ing groove toward th e rear.
NOTE: Hold th e 1 st g ear i nn er r ac e to prevent i t fromfalling.
SST 09506 35010
WM0122
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MT-26 MANUAL TRANSMISSION - W46, 55 and 56 Transmission
8. MEASURE FIRST AN D SECOND GEAR THRUSTCLEARANCE
Using a feeler gauge, measure the 1st and 2 nd g ea r th rclearance.
Standard clearance: 0.10 - 0.25 mm 0.0039 - 0.0098 in.
Maximum clearance: 0.30 mm 0.0118 in.
9. INSTALL OUTPUT SHAFT TO INTERMEDIATEPLATE
a Before installing t he o u tp u t shaft, use SST to removeth e counter gear center bearing outer race.
SST 09608-35013
NOTE: Install t he o ut er race after installing th e countergear.
b Install th e outpu t shaf t into th e intermediate p la te b ypulling on th e output shaft and tapping on th e intermediate plate.
10 . INSTALL INPUT S HA FT A N D COUNTER GEAR
a Install t he i np ut shaft and counter gear together.
b Using SST, install the counter gear center bearing outer race.
SS T 09316-60010
NOTE: Be careful no t to damage th e bearing rollers.
WM0125
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MANUAL TRANSMISSION - W46, 55 and 56 Transmission MT-27
11 . INSTALL BEARING RETAINER
a Using snap ring pl iers, install th e bearing snap ring.
NOTE: Be sure th e snap ring is flush with the intermediate plate surface.
b Using a torx socket wrench, tighten th e screws.
Torque: 13 0 kg-em 9 f t-Ib, 13 Nom
12 . INSTALL REVERSE GEAR
Using SST, install the reverse gear.
SST 09312-20011
WM0126
WM0127
13 . INSTALL SNAP RINGSelect a snap ring that w il l a ll ow m in im um axial play andinstall it on t he s ha ft .
Mark Thickness mm in. Mark Thickness mm in.
5 2 2 5 2 3 0 0 . 0886-0 .0906 17 2 . 6 1 - 2 . 6 6 0 . 1028-0 .10472 3 0 2 3 5 0 . 0906-0 .0925 18 2 . 6 7 - 2 . 7 2 0 . 1051-0 .1071
12 2 3 5 2 4 0 0 . 0925-0 .0945 19 2 . 7 3 - 2 . 7 8 0 . 1075-0 .109413 2 4 0 2 4 5 0 . 0945-0 .0965 20 2 . 7 9 - 2 . 8 4 0 . 1098-0 .111814 2 4 5 2 5 0 0 . 0965-0 .0984 2 . 8 5 - 2 . 9 0 0 . 1122-0 .114215 2 . 5 0 - 2 . 5 5 0 . 0984-0 .1004 22 2 . 9 1 - 2 . 9 6 0 . 1146-0 .116516 2 5 5 2 6 0 0 . 1004-0 .1024 23 2 . 9 7 - 3 . 0 2 0 . 1169-0 .1189
14 . 5-SpeedINSTALL FIFTH GEAR AN D OUTPUT SHAFT REARBEARING
Using SST, install the 5th gear and rear bearing.
SST 09312-20011
15 . 5-SpeedINSTALL SNAP RING
Select a snap ring that w il l a ll ow m in im um axial play andinstall it on t he s ha ft .
Mark Thickness mm in. Mark Thickness mm in.8 2 . 3 1 - 2 . 3 6 0 . 0909-0 .0929 12 2 . 5 5 - 2 . 6 0 0 . 1004-0 .10249 2.37 2 4 2 0 . 0933-0 .0953 13 2 . 6 1 - 2 . 6 6 0 . 1028-0 .1047
10 2 . 4 3 - 2 . 4 8 0 . 0957-0 .0976 14 2 . 6 8 - 2 . 7 3 0 . 1055-0 .10752 4 9 2 5 4 0 . 0980-0 .1000 15 2 . 7 4 - 2 . 7 9 0 . 1079-0 .1098
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MT-28 MANUAL TRANSMISSION - W46, 55 and 56 Transmission
Front 16 . 5-SpeedINSERT C LU TC H H UB N O . 3 I NT O H UB SLEEVE
a Install clutch hu b No. 3 and th e shifting ke y to .hub sleeve.
b Install the shif t ing key springs under th e shifting keys.
CAUTION: Install th e ke y springs positioned so that theire nd g ap s are not in line.
WM0131
c Using SST, install th e shifting key retainer.
SS T 09238-47012
WM0132
17. 5-SpeedINSTALL CLUTCH HUB N O . 3
Using SST, drive in c lu tc h h ub N o . 3 .
SS T 09316-60010
NOTE: When installing th e clutch hub, support the countershaft in f ro nt w it h a 3- 5 Ib hammer or equivalen t.
WM0133
18 . 5-SpeedINSTALL SNAP RING
Select a snap ring that will a llow minimum axial play andinstall it on th e shaft.
Mark Thickness mm in.
2 2.06 - 2.11 0.0811 - 0.08313 2.12 - 2.17 0.0835 - 0.08544 2.18 - 2.23 0.0858 - 0.0878
2.24 - 2.29 0.0882 - 0.0902
19 . 5-SpeedINSTALL SPACER, SYNCHRONIZER RING, NEEDLEROLLER BEARING AN D COUNTER FIFTH GEAR
a Install th e bearing spacer.
b Apply gear oil to th e needle roller bearings.
c Assemble the counter 5t h gear, synchronizer ring needle rol ler bearings.
WM0136
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MANUAL TR NSMISSION - W46, 55 and 56 Transmission MT 9
d Install th e 5th gear assembly with th e synchronizerring slots aligned with th e shifting keys.
WM0137
20 . 5-SpeedINST LL SP CER ND BE RING
a Install th e spacer.
b Install th e bearing with th e ball shield toward th e rear.
c Using a hammer an d s oc ke t w re nc h, drive in th ebearing.
NOTE: When driving in th e bearing, support the counter
shaft in f ro n t w it h a 3-5 Ib hammer or equivalent .
21 . 5-SpeedINST LL SN P RING
Select a snap ring that w il l a ll ow m in im um axial play andinstall it on th e shaft.
Mark Thickness mm in. Mark Thickness mm in.
1 . 9 0 - 1 . 9 5 0 . 0748-0 .0768 5 2 . 1 4 - 2 . 1 9 0 . 0843-0 .08621 . 9 6 - 2 . 0 1 0 . 0772-0 .0791 6 2 . 2 0 - 2 . 2 5 0 . 0866-0 .0886
3 2 0 2 2.07 0 . 0795-0 .0815 7 2 2 6 2.31 0 . 0890-0 .09094 2 . 0 8 - 2 . 1 3 0 . 0819-0 .0839
22 . INST LL SPEEDOMETER DRIVE GE R
a Put a c lip on th e output shaft and install the drive gearclip into t he s lo t.
b Slide th e drive gear with clip and f it th e clip i nt o t heholes.
WM0140
23.-1 4-SpeedINST LL SHIFT FORKS SHIFT FORK SH FTS NDREVERSE IDLER GE R
a Install th e reverse shift a rm a nd shift fork shaft No.3 .
1 Pu t th e reverse shift arm into th e p iv ot o f th ebearing retainer and install shift f or k s ha ft No .3 to th e intermediate plate.
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MT 3 M NU L TR NSM SS ON - W46 55 and 56 Transmission
2 Apply MP grease t o i nt er lo ck pi n N o 3 and in -stall the pin i nt o t he i nt er me di at e p la te hole
WM0142
b Insta ll th e r ever se idler gea r and shaftAlign th e reverse idler gear groove to th e reverse shiftarm shoe and insta ll the reverse idler gear shaft to th eintermediate plate
WM0143
c Install shift fork N o 2 and shaft N o 2
1 Apply MP grease to inte rlock p in N o 2 and in -stall th e pin i nt o t he shaft hole
2 Place shift fork No. 2 in to th e groove of rsleeve N o 2
WM0144
3 Install f or k s ha ft N o 2 to th e shift fo rk throughthe intermediate plate.
d Insta ll the snap ring of fork shaft No 2
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MANUAL TRANSMISSION - W46, 55 and 56 Transmission MT-31
e Apply MP grease to interlock pin No.1 and install th epin in to the intermediate plate.
WM0146
f Install s hi ft f or k No. 1 and fork shaft No.1 .
1 Install s hi ft f or k No. 1 into th e groove of hu bsleeve No.1 .
2 Insert fork shaft No.1 to th e shift fork throughth e intermediate plate.
WM0022
g Install the snap r ing of fork shaft No.1 .
WM0147
h Install th e s hi ft f or k se t bolts with lock washers .
Torque: 100 - 150 kg-em 8 - 10 ft-Ib, 10 - 14 Nm
WM0018
i Using pliers, stake th e bolts with lock washers.
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MT-32 MANUAL TRANSMISSION - W46, 55 and 56 Transmission
23.-2 5-SpeedINSTALL S HI FT F ORK S, SHIFT FORK SHAFTS ANDREVERSE IDLER GEAR
a Install th e r ev er se i dl er g ea r and shaft.
b Install s hi ft f o rk No.3 , f or k s ha ft N o . 3 and rever seshift arm.
1 Coat the pin with MP grease and insert it into th ereverse shift head hole.
WM0149
2 Insert shift fo rk shaf t No.3 through shift fork No.3 and th e reverse shif t arm.
3 Align shift fork N o . 3 with th e hu b sleeve No.3 groove, put th e reverse shift arm into th e pivotof bearing retainer and align the reverse shift armshoe with th e reverse idl er gea r groove. Installs hi ft f or k s ha ft No.3 to the intermediate plate.
WM0150
WM0151
WM0035
WM0152
c Install s hi ft f or k shaft No.4 .
1 Push th e pin, w h ic h w a s inserted into th e reverseshift a rm hole, into the groove of shif t f or k s h af tNo.3 .
2 Install shift f or k s ha ft N o . 4 to the intermediateplate over th e reverse shif t arm.
d Using a pin punch, drive in th e slotted spring pin untilit is flush with th e fork.
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MANUAL TR NSM SS ON - W46 55 and 56 Transmission MT
e Apply MP grease to interlock pin No 3 and install th epin i nto t he intermediate plate hole.
WM0153
f Install shift fork N o 2 and shaft No 2
1 Apply MP grease to inter lock pin NO 2 and install th e pin into th e shaft hole.
2 Place shift fork No. 2 into th e groove of hu bsleeve No 2
3 Install fork shaft No 2 to t he s h if t fork throughth e intermediate plate.
g Instal l th e snap r ing of fork s haft No 2
WM0155
h Apply MP grease to interlock pin No 1 and install th epin i nt o th e intermediate plate
WM0156
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MT 34 MANUAL TRANSMISSION - W46 55 an d 56 Transmission
i Install shift fork No. 1 and fork shaft No.1 .
1 Install shift fork No. 1 i nto th e groove of t ~sleeve No.1.
2 Insert f or k s ha ft No. 1 to the shift fork throughth e intermediate plate.
WM0030
j Install the snap r ing of f or k s ha ft No.1 .
WM0157
k Install th e shift fork se t bolts with lock washers .
Torque: 125 kg em 9 ft Ib 12 Nom
WM0027
I Using pliers, stake t he b ol ts with lock washers.
24 . INSTALL LOCKING BALL AN D SPRING
a Instal l th e bal ls and springs into each hole.
b Apply liquid sealer to th e plugs.
WM0163
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MANUAL TRANSMISSION - W46, 55 and 56 Transmission MT-35
c Using SST, tighten th e four plugs.
SST 09313-30021
Torque: 25 0 k g- em 1 8 f t- Ib , 25 Nm
WM0016
25 . INSTALL REVERSE IDLER GEAR SHAFT STOPPER
Install th e reverse idler gear shaft stopper and tighten th ebolt.
Torque: 250 kg-em 1 8 ft-Ib, 25 Nm
WM0028
26 . DISMOUNT INTERMEDIATE PLATE FROM VISE
a Dismount the intermediate plate from th e vise.
b Remove t he b ol ts , n ut s, plate washers and gasket.
WM0164
27 . INSTALL TRANSMISSION CASE TO INTERMEDIATEPLATE
a Align each bearing outer race and each shift fork shaftend with th e case holes.
b Using a plast ic hammer, ta p on th e case to install it .
WM0165
28 . INSTALL TW O BEARING SNAP RINGS
Using snap r ing pliers, ins ta ll th e tw o snap rings.
WM0166
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MT-36 MANUAL TRANSMISSION - W46, 55 n 56 Transmission
29 . INSTALL FRONT BEARING RETAINER
a) Install th e bearing retainer with a ne w gasket.
b) Apply liquid sealer to th e bolts.
c) Install and t or qu e t he bolts.
Torque: 250 kg-em 1 8 ft-Ib 25 Nom
WM0167
~/ I / tf j
1/ / / : :
/___ I I
~ \ . . . . . :
t ~WM0254
30. INSTALL EXTENSION HOUSING 2WD OR TRANSFERADAPTER 4WD
a) Place the gaske t in position on th e intermediate plate.
b) Insert shift and se lec t l ever i nt o t he ex tension hous-in g 2WD or t he t ra ns fe r adapter.
c) C on ne ct t he shift and s el ec t l ev er to th e s hi ft f or kshaft.
WM0253
d) Install shift lever housing to shift and select lever shaft,push in t he e xt en si on h ou si ng 2 WD o r t he t ra ns fe ra da pt er 4 WD .
e) Install and t or qu e t he bolt.
Torque: 400 kg-em 2 9 ft-Ib 39 Nom
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MANUAL TRANSMISSION - W46, 55 and 56 Transmission MT-37
31 . INSTALL AN D TORQUE EXTENSION HOUSING BOLTS 2WD OR TRANSFER ADAPTER BOLTS 4WD
Torque: 370 kg-em 2 7 ft-Ib, 36 Nm
WMOl72
32 . AFTER INSTALLING EXTENSION H OU SI NG 2 WD ORTRANSFER ADAPTER 4WD , CHECK FOLLOWING ITEMS:
a Check to see that inpu t shaf t and output shaf t rotatesmoothly.
b Check to see that shifting can be made smoothly toall positions.
33 . INSTALL RESTRICT PINS
a Install th e restrict pins together with a gasket.
NOTE: 4-SpeedInstall t he s cr ew plug on th e reverse gear side.
5-SpeedInstall t he b la ck pin on th e reverse gear/5th gearside.
b Torque t he r es tr ic t pins.Torque: 410 kg-em 3 0 ft-Ib, 40 Nm
34 . INSTALL CLUTCH HOUSING
a Install th e clutch housing.
b Install and t or qu e t he bolts.
Torque: 375 kg-em 2 7 ft-Ib, 37 Nom
WM0174
35 . INSTALL RELEASE FORK AN D BEARING
Apply molybdenum disulphide lithium base grease to th efollowing parts:
Release bearing hu b inside groove
Input shaft spline
Release fork contact surface
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MT-38 MANUAL TRANSMISSION - W 46, 55 and 56 Transmission
6 INSTALL SHIFT LEVER RETAINER
a Install the shift lever retainer with a ne w gasket
b Install and t or que t he f ou r bolts.Torque: 18 5 kg-em 1 3 ft-Ib, 18 Nm
WM0259
37 . 2WDINSTALL SPEEDOMETER DRIVEN GEAR
a Install the speedometer driven gear. b Install t he b olt with lock plate.
c Torque the bolt.
Torque: 13 0 kg-em 9 ft-Ib, 13 N m
38. INSTALL BACK-UP LIGHT SWITCH
a Install and torque th e back-up l ight sw it ch .
Torque: 410 kg-em 3 0 ft-Ib, 40 N m
b Install t he w ire cl amp.
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M NU L TR NSMISSION G 52 Transmission MT-39
G TR NSMISSION
OMPONENTS
GM0156
380 27, 37
Shift Fork Shaf t No.2
28 0 20, 27
Clutch Housing~ _ : _ _ t Front Bearing Retainer
Shift Lever Shaft Counter Gear1 8 - - - - - - - . Straight Screw Plug~ R e v e r s eRestrict Pin
~Shift Fork NO.3 -
39 0 28, 38 tt
Transfer Shift ~ ~Lever Retainer
Output Shaft
Locking a l l ~Spring oo l
* Straight Screw P I U g ~
Reverse Shift A r m ta nd F or k
Shift Fork Shaft No.5
ReverseShif t Head
/
Reverse Shift Arm BracketIkg-cm ft-Ib, Nm I : Tightening torque Shift Fork Shaft No.4 Non-reusable part
: Precoated part
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TR NSMISSION
MANUAL Cont d) OMPONENTS
Retainerear Bearing
Snap Ring
e No.5p line leeear
th ea rounter
Sleeve
h nizer Ringyn c ro
Input Shaf t
ounter Gear
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MANUAL TRANSMISSION - G 52 Transmission
DISASSEMBLY OF TRANSMISSION
See pages MT-39, 40
MT-41
1. REMOVE BACK-UP LIGHT SWITCH, SPEEDOMETERDRIVEN GEAR 2WD , SHIFT LEVER RETAINER AN DRESTRICT PINS
2. REMOVE CLUTCH HOUSING FROM TRANSMISSIONCASE
GM0001
3. REMOVE STRAIGHT SCREW PLUG, SPRING AN D BALL
a Using a torx socket wrench, remove th e screw plugf ro m t he t ra ns fe r adapter.
b Using a magnetic finger, remove the spring and ball.
GMOOOS
4. REMOVE TRANSFER ADAPTER
a Using SST, remove the plug f rom the transfer adapter.
SST 9923 1
GM0008
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MT 4 M NU L TR NSMISSION - G 52 Transmission
b Remove th e shift l ev er h ou si ng set bolt and lockwasher
GM0009
c Remove th e shift lever shaft and housing
d Remove th e eight bolts
e Using a plastic hammer remove the transfer adapter
NOTE: Leave t he g as ke t a tt ac he d to the inte rmediateplate
GM0011
REMOVE FRONT E RING RET INER ND TW O E R-ING SN P RINGS
GM0012
6 SEP R TE INTERMEDI TE PL TE FROMTR NSMISSION C SE
a Using a plastic hammer careful ly tap off t he t ra ns -mission case
b Remove th e transmission case from th e intermediateplate
GM0013
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MANUAL TRANSMISSION - G 52 Transmission MT 43
MOUNT INTERMEDIATE PLATE IN VISE
a Use two clutch housing bolts plate washers and suit-able nuts as shown.
CAUTION: Install th e plate washers in reverse of normal.Increase or decrease plate washers so t ha t t he b ol t t i p andfront ti p surface of th e nut are aligned.
b Mount the in te rmedia te plate in a vise.
8. REMOVE STRAIGHT SCREW PLUGS, LOCKING BALLSAN D SPRINGS
a Using a torx socket wrench remove th e four plugs.
GM0015
b Using a magnetic finger, remove the springs and balls.
GM0016
9. REMOVE SLOTTED SPRING PINS
Using a pin punch and hammer drive o ut th e five pins.
GMOQ17
10 . REMOVE TW O E-RING
GM0018
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MT 44 MANUAL TRANSMISSION - G 52 Transmission
\
\
\
REMOVE SHIFT FORK SHAFT NO.4 AN D SHIFT FORKNO.3
a Pull ou t shift fork shaft N o .4 f ro m t he i nt er me diplate.
C AU TIO N: The l ocking balls and interlock pin will fall fromth e holes so be sure to catch them by hand. If they do notc om e o ut remove them with a magne tic f inger.
GM001g
b Remove shift fork s ha ft N o. 4 and s hi ft f or k No.3.
GM0020
12. REMOVE REVERSE SHIFT HEAD AN D SHIFT FORK SHAFTNO.5
Pull o ut s hi ft fork shaft N o .5 f ro m t he i nt er me di at e plateand remove it with th e reverse shift head.
GM0021
13. REMOVE SHIFT FORK SHAFT NO.3
Pul lout shif t f or k s ha ft N o .3 f ro m t he i nt er me di at e plate.
CAUTION: Th e interlock pins will fall from th e hole so besure to catch them by hand. I f they do no t come out rem ov e th em with a magnetic finger.
GM0023
14 . REMOVE SHIFT FORK SHAFT NO.1
Pullout shift fork shaft NO.1 f ro m t he i nt er me di at e plate.
CAUTION: The interlock pin will fall from th e hole so besure to catch i t by hand. If i t does not come out removeit with a magnetic finger.
GM0024
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MANUAL TRANSMISSION - G 52 Transmission MT-45
15 . REMOVE SHIFT FORK SHAFT NO.2 SHIFT FORK NO.2AN D SHIFT FORK NO.1
Pull ou t s hi ft fo rk s ha ft N o 2 and remove s hi ft f or k No 2and NO.1.
GM0025
16 . REMOVE REVERSE IDLER GEAR AN D SHAFT
a Remove th e r ev er se i dl er g ea r shaft stopper
b Remove th e reve rse id le r ge ar and shaft
GM0026
17 . REMOVE REVERSE SHIFT AR M FROM REVERSE SHIFTAR M BRACKET
GM0027
18 . MEASURE COUNTER FIFTH GEAR THRUSTCLEARANCE
Using a feeler gauge measure the counte r 5t h gear thrustclearance
GMOO28
Standard clearance:
Maximum clearance:
0.10 - 0.30 mm 0 .0039 - 0.0118 in.0.30 mm 0 .0118 in.
GM0029
19 . REMOVE GEAR SPLINE PIECE NO.5 SYNCHRONIZERRING NEEDLE ROLLER BEARINGS AN D COUNTER FIFTHGEAR WITH HUB SLEEVE NO.3
a Engage th e gear double mesh ing
b Using a hammer and chisel loosen t he s ta ke d p ar t ofth e nut
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MT 6 MANUAL TR NSMISSION - G52 Transmission
c Remove th e l oc k n ut
d Disengage th e gear double mesh ing
GM0030
e Using SST remove gear spline piece No 5 synchroniz-er ring needle roller bearing an d c ou nt er 5 th gear
SS T 09213 27010
GM0031
20 REMOVE SP CER ND LL
a Remove th e spacer
b Using a magnetic f inger, remove the ball.
GM0033
21 REMOVE REVERSE SHIFT RM R CKET
Remove th e tw o bolts and th e reverse shift a rm bracke t
GM0034
22 REMOVE RE R E RING RET INER
Using a forx s oc ke t w re nc h remove th e four bolts
\GM0035
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MANUAL TRANSMISSION - G52 Transmission MT 47
23 . REMOVE BEARING SNAP RING
Using snap ring pliers, remove th e snap ring.
GM0036
24 . REMOVE OUTPUT SHAFT COUNTER GEAR AN D INPUTSHAFT AS A UNIT FROM INTERMEDIATE PLATE
a Remove the output shaft counter gear and input shaftas a u ni t f ro m t he intermediate plate by pul ling on th ecounter gear and tapping on the in te rmedia te platewith a plastic hammer.
b Remove t he i np ut s ha ft with the 14 needle roller bear-
ings fro m th e output shaft.
GM0037
25 . REMOVE COUNTER R R BEARING FROMINTERMEDIATE PLATE
GM0039
26 . REMOVE SLEEVE FROM OUTPUT SHAFT
Using SST remove th e sleeve from th e o u tp u t s ha ft .
SS T 09950 20015
3r d
GM0040
27 . MEASURE EACH GEAR THRUST CLEARANCE
Measure the thrust clearance of each gear.
Standard clearance: 0.10 - 0.25 0.0039 - 0.0098 in.
Maximum clearance: 0.25 mm 0.0098 in.
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MT 48 MANUAL TRANSMISSION G 52 Transmission
28 REMOVE FIFTH GEAR R R BEARING ANDFIRST GEAR ASSEMBLY
a Using tw o screwdrivers and a hammer tap out snap ring
GM0041
b Using a press r em ov e t he 5 th gear rear bearing 1 stgear and inner race.
c Remove th e needle rol le r bea ring
d Remove th e synchronizer ring
GM0042
29 REMOVE LOCKING BALL
Using a magnetic finger remove th e locking ball.
GMOO45
30 REMOVE HUB SLEEVE NO.1 ASSEMBLY ANDSECOND GEAR ASSEMBLY
a Using a press rem ove hu b sleeve No 1 th e syn-chronizer rin g and 2n d gear.
b Remove th e needle rol le r bea ring
GMOO46
31 REMOVE HUB SLEEVE NO 2 ASSEMBLY ANDTHIRD GEAR ASSEMBLY
a Using snap ring pliers remove th e snap ring
GM0047
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MANUAL TR NSMISSION G 5 Transmission MT 49
b Using a press remove hub sleeve No 2 th e syn-chronizer r ing and 3r d gear
c Remove th e needle rol le r bear ing
WM0055
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MT-50 MANUAL TRANSMISSION - G 52 Transmission
INSPECTION TRANSMISSION COMPONENTS
1. INSPECT OUTPUT S HA FT A ND INNER RACE
a Using cal iper s, measure th e output shaft flangethickness.
Minimum thickness: 4.80 mm 0.1890 in.
GM0048
b Using calipers, measure th e inner race flangethickness.
Minimum thickness: 3.99 mm 0.1571 in.
WM0057
c Using a micrometer, measure t he o ut er d ia me te r ofth e output shaft journal.
Minimum diameter:2n d gear 37.984 mm 1 .4954 in.3r d gear 34.984 mm 1.3773 in.
GM0049
d Using a micrometer, measure t he o ut er d ia me te r ofth e inner race.
Minimum diameter: 38.985 mm 1.5348 in.
WM0059
e Using a dial indicator, check th e shaft runout.
Maximum runout: 0.05 mm 0 .0020 in.
GM0050
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MANUAL TRANSMISSION - G 52 Transmission MT-51
2. CHECK OIL CLEARANCE OF FIRST GEAR
Using a dial indicator, measure th e oil clearance betweenth e gear and inner race with th e needle rol ler bearing installed.
WM0061
Standard clearance:
Maximum clearance:
0.009 - 0.032 mm 0 .0004 - 0.0013 in.
15 mm 0.0059 in.
3. CHECK OIL CLEARANCE OF SECOND, THIRD AN DCOUNTER FIFTH GEARS
Using a dial indicator, measure th e oil clearance betweenth e gear and shaft with th e needle roller bearing installed.
Standard clearance:2n d and 3rd gears 0.009 - 0.033 mm
0 .0004 - 0.0013 in.Counter 5th gear 0.009 - 0.032 mm
0 .0004 - 0.0013 in.
OOSl Maximum clearance: 0.15 mm 0.0059 in.
4. INSPECT SYNCHRONIZER RINGS
a Turn the ring and push it in to check the braking action.
WM0064
b Measure th e clearance between th e synchronizer ringback and th e gear spline end.
Standard clearance: 1.0 - 2.0 mm 0.039 - 0.079 in.
Minimum clearance: 0.8 mm 0.031 in.
5. MEASURE CLEARANCE OF SHIFT FORKS AN D HU BSLEEVES
Using a feeler gauge, measure th e clearance be tween thehu b s leeve and shift fork.
Maximum clearance: 1.0 mm 0 .039 in.
WM0066
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MT 5 MANUAL TRANSMISSION - G 52 Transmission
6 . NECESS RY REPL CE INPUT SH FT BE RING
a Using snap ring pliers remove th e snap ring.
WM0067
b Using a press , r em ov e t he b ea ri ng .
WMOO
c Using a press and SST install a ne w bearing.
SS T 09506 35010
ISSTI
WM0069
d Select a snap ring that will a l low minimum axial playand install it on t he s ha ft .
Mark Thickness mm in.2.05 2.10 0.0807 0.0827
1 2.10 2.15 0.0827 0.08462 2.15 2.20 0.0846 0.08663 2.20 2.25 0.0866 0.08864 2.25 2.30 0.0886 0.09065 2.30 2.35 0.0906 0.0925
WM0070
7. INSPECT FRONT BE RING RET INER
Check th e retainer a nd oil seal fo r wear or damage. If th eoil seal is worn or damaged replace i t as follows.
a Using a screwdriver pry ou t th e oil sea l.
WM0071
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MANUAL TRANSMISSION - G52 Transmission MT-53
b U si ng S ST p re ss in th e oil seal.
SS T 09223-50010
Oil sea l depth: 11.2 - 12.2 mm O.441 - 0.480 in.Transmission case instal la t ion surface
WMoon
8. IF NECESSARY, REPLACE COUNTER GEAR FRONTBEARING a U si ng s na p r ing pliers, remove th e snap r ing.
b U si ng S ST press out th e bearing.
SST 09950-00020
c Replace th e s ide race.
WM0073
d Using a socket wrench press in th e bearing, side raceand inner race.
WM0176
e Select a snap ring that will allow minimum axial playand install it on th e shaft.
Mark Thickness mm in.
2.05 2.10 0.0807 0.08272 2.10 2.15 0.0827 0.08463 2.15 2.20 0.0846 0.08664 2.20 2.25 0.0866 0.08865 2.25 2.30 0.0886 0.09066
2.30
2.35 0.0906
0.0925WM0077
9. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
a Using a torx socke t wrench remove th e screw plug.
GMOO
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MT-54 MANUAL TRANSMISSION - G 52 Transmission
b Using a p in p un c h and hammer, d r ive ou t t he s lo tt edspring pin.
c Pull off the l ever hous ing a nd s li de ou t th e shaf,
d Install th e l ever hous ing .
e Using a pin punch and h m m r ~drive in t he s lo tt edspring pin.
GM0056
f Using a torx socket wrench, install and t or qu e t hescrew plug.
Torque: 190 kg-em 1 4 ft-Ib, 19 Nm
GMOO54
11 . IF NECESSARY, REPLACE l SEAL
a Using a screwdriver, pr y ou t th e oil seal.
b U si ng S ST, d ri ve in a ne w oil seal .
SS T 09325-12010
GMOO58
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MANUAL TRANSMISSION - G 52 Transmission MT-55
No.1 No.2
Front
GM0059
ASSEMBLY OF TRANSMISSION See pages MT-39 40
1. INSERT CLUTCH HU B NO.1 AN D NO.2 INTO HU B SLEEVE
a Install th e clutch hub and shifting keys to th e hu bsleeve.
b Install th e shifting ke y springs under the shifting keys.CAUTION: Install t he k ey springs posi t ioned so that theirend gaps are no t in line.
WM0114
2. INSTALL THIRD GEAR AN D HU B SLEEVE NO.2 ONOUTPUT SHAFT
a Apply gear oil to th e shaft and needle roller bearing.
b Place th e synchronizer r ing on th e gear and align th ering slots with the shi ft ing keys.
c Install th e needle rol le r bearing in th e 3r d gear.
d Using a press, install th e 3rd gear and hub sleeve No.2.
r GM0060
GM0047
3. INSTALL SNAP RING
a Select a snap r ing that will a llow minimum axial play.
b Using snap ring p lier s, ins ta ll th e snap ring.
Mark C l 1.75 1.80 mm 0.0689 0 .0709 in.1.80 1.85 mm 0.0709 0 .0728 in.
0 1 1.85 1.90 mm 0.0728 0 .0748 in.E 1.90 1.95 mm 0.0748 0 .0768 in.
E l 1.95 2.00 mm 0.0768 0 .0787 in.F 2.00 2.05 mm 0.0787 0 .0807 in.
F l 2.05 2.10 mm 0.0807 0.0827 in.
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MT-56 MANUAL TRANSMISSION - G 52 Transmission
4. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure th e 3r d gear thrustclearance.
Standard clearance:
Maximum clearance:
0.10 - 0.25 mm 0.0039 - 0.0098 in.0.25 mm 0.0098 in.
5. INSTALL SECOND GEAR AN D HUB SLEEVE NO.1
a Apply gear oil to th e shaft an d needle rol ler bearing.
b Place the synchronizer ring on th e gear and a lign th ering slots with th e shifting keys.
c Install th e needle rol le r bea ring in th e 2n d gear.
GM0061
d Using a press, install th e 2n d gear an d hu b sleeveNo.1.
GM0062
6. INSTALL LOCKING BALL AN D FIRST GEAR ASSEMBLY
a Install th e locking ball in th e shaft.
b Apply gear oil to th e needle rol le r bea ring .
c Assemble th e 1 st gear, synchronizer ring, needle rollerbearing and bearing inner race.
GM0063
d Install th e assembly on th e output shaft with t he s yn -chronizer ring slots aligned with th e shifting keys.
e Turn th e inner race to align i t with th e locking ball.
GM0064
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MANUAL TRANSMISSION - G 52 Transmission MT-57
7 . INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install th e bea ring on th e outputshaft with the outer race snap ring groove toward the rear.
NOTE: Hold the 1 st gea r inner race to prevent i t fromfalling.
SST 09506-35010
GMOO65
8 MEASURE FIRST AN D SECOND GEAR THRUSTCLEARANCE
Using a feeler gauge, measure th e 1 st and 2nd gear thrustclearance.
Standard clearance: 0 1 0 0 25 mm 0 0039 0 0098 in.
Maximum clearance: 0 25 mm 0 0098 in.
1st 2ndGM0040
9 INST AL L FIFTH GEAR
Using SST and a press, install the 5th gear.
SST 09506-35010
GM0066
10 INSTALL SNAP RING
a Select a snap r ing that will al low minimum axial play.
GM0067
b Using snap r ing pliers, install th e snap ring.
Mark Tickness mm in. Mark Thickness mm in.
A 2.67 - 2.72 0.1051 - 0.1071 G 3.03 - 3 .0 8 0 .119 3 - 0.1213
B 2.73 - 2 .7 8 0 .1 0 75 - 0.1094 H 3.09 - 3.14 0.1217 - 0.1236
C 2.79 - 2.84 0.1098 - 0.1118 J 3.15 - 3.20 0.1240 - 0.1260
2.85 - 2 .9 0 0 . 11 2 2 - 0.1142 K 3.21 - 3 .2 6 0 .1 26 4 - 0.1283E 2.91 - 2 .9 6 0 .11 46 - 0.1165 L 3.27 - 3.32 0.1287 - 0.1307
F 2.97 - 3 .0 2 0 . 11 6 9 - 0.1189
GM0068
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MT 58 MANUAL TR NSMISSION G 52 Transmission
11 INST LL SL V TO OUTPUT SH FT
Using a plas ti c hammer ta p th e sleeve onto th e outl 1 Itshaft.
GM0071
2 INSTAl l OUTPUT SH FT TO INTERMEDI TE PL TE
Install th e output shaf t into th e intermediate plate by pull-in g on th e o ut pu t s ha ft and tapping on the intermediateplate.
GMOO73
3 INST LL INPUT SH FT
a Apply grease to th e 14 needle roller bearing andinstall i t into th e input shaft.
GM0072
b Install the input shaft to th e output shaft with th e syn-chronizer ring slots aligned with the shi ft ing keys.
GMOO74
4 INSTAl l COUNTER G R
Install th e counter gear into t he i nt er me di at e p la te w hi leholding the counter gear, and install th e counter rear bearingwith SST.
SS T 09316 60010
GM0075
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MANUAL TRANSMISSION - G 52 Transmission MT-59
15 . INSTALL BEARING SNAP RING
Using snap ring pliers, install th e snap ring.
NOTE: Be sure th e snap r ing is flush with th e intermedia te p la te s ur fa ce .
GMOO36
16 . INSTALL REAR BEARING RETAINER
Using a torx socket wrench, install and torque th e screws.
Torque: 185 kg-em 1 3 ft-Ib, 18 Nm
\GM0035
17 . INSTALL REVERSE SHIFT AR M BRACKET
Install th e reverse shift arm bracket and t or qu e t he bolts.
Torque: 185 kg-em 1 3 ft-Ib, 18 Nm
GM0034
18 . INSTALL BALL AN D SPACER
Front
GM0077
19 . INSERT COUNTER FIFTH GEAR INTO HU B SLEEVE NO.3
a Install th e shifting keys and hu b sleeve No.3 onto th ecounter 5t h gear.
b Install the shif t ing key springs under the shift ing keys.
CAUTION: Install th e ke y springs posi t ioned so that theiren d g ap s are no t in line.
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MT-60 MANUAL TRANSMISSION - G52 Transmission
20 . INSTALL COUNTER FIFTH GEAR WITH HUB SLEEVE NO.3ASSEMBLY AND NEEDLE ROLLER BEARINGS
a Apply gear oil to th e needle rol le r bea rings.
b Install the counter 5t h gear with hu b sleeve No.3 andneedle roller bearings.
21 . INSTALL SYNCHRONIZER RING AN D GEAR SPLINE PIECENO.5
a Install th e synchronizer ring o n ge ar spline piece No.5.
b Using S ST, d ri ve in gear spline piece No.5 with th esynchronizer ring slots aligned with th e shift ing keys.
SS T 09316-60010
NOTE: When installing gear spline piece N o. 5, s up po rtthe counter gear in front with a 3- 5 Ib hammer or equivalent.
GM0079
22. INSTALL LOCK NU T
a Engage th e gear double meshing.
GMOO 9
b Install an d torque th e l oc k n ut .
Torque: 1,200 kg-em 8 7 f t- Ib , 118 Nm
c Stake t he loc k nut.
GMOO3
d Disengage the gear double mesh ing .
GMOO 9
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MANUAL TRANSMISSION - G 52 Transmission MT-61
23 . MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the counte r 5 th g ea r thrustclearance.
GMOO
Standard clearance:
Maximum clearance:
0.10 - 0.30 mm 0 .0039 - 0.0118 in.0.30 mm 0.0118 in.
GM0027
GM0026
24. INSTALL REVERSE SHIFT AR M TO REVERSE SHIFT ARMBRACKET
Install th e reverse shift arm to th e pivot of th e reverse shifta rm b ra ck et .
25 . INSTALL REVERSE IDLER GEAR AND SHAFT
a Install th e reverse idler gear on the shaft.
b Align th e reverse shift arm shoe to th e reverse idlergear groove and insert th e reverse idler gear shaft tothe in te rmedia te plate.
c Install th e reverse idler gear shaft stopper and torquet he b ol t.
Torque: 17 5 kg-em 13 ft-Ib, 17 Nm
GM0025
26 . INSTALL SHIFT FORK SHAFT NO.2, SHIFT FORK NO.1AND NO.2
Place shift forks No.1 and N o.2 i nto t he g ro ov e of hu bsleeves No.1 and No.2 and install fork shaft No.2 to shiftforks No.1 and NO.2 t hr ou gh t he intermediate plate .
o
GM0081 GM0082
27 . INSTALL INTERLOCK PIN
a Apply MP grease to th e interlock pins.
b Using a magnetic finger and screwdriver, install th einterlock pin i nto the intermediate plate.
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MT 62 MANUAL TRANSMISSION - G 52 Transmission
28 . INSTALL SHIFT FORK S HA FT N O. 1
a Install t he i nt er lo ck pin into th e shaft hole.
GM0083
b Install fork shaft NO.1 t o s hi ft fork No.1 through th eintermediate plate.
GM0084
29 . INSTALL INTERLOCK PIN
Using a magnetic f inger and screwdriver install th e inter-lock pin i nt o th e intermediate plate .
GM0085
30 . INSTALL SHIFT FORK SHAFT NO.3
a Ins ta ll the interlock pin i nto th e s ha ft head.
GM0086
b Install fo rk shaf t No.3 to th e reverse shift arm throughth e intermediate plate.
GM0087
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MT-64 MANUAL TRANSMISSION G 52 Transmission
33 . CHECK INTERLOCK a S hi ft f or k s ha ft NO.1 to th e 1 st speed position.
GM0092
b Fork shafts N o.2 , N o.3 , No.4 an d No.5 should no tmove.
GM0093
34 . INSTALL FIVE SLOTTED SPRING PINS
Using a pin punch and hammer, d ri ve t he s lo tt ed springpins into each shift fork, reverse shift ar m and reverse shifthead.
GM0094
35 . INSTALL TW O FORK SHAFT E RING
GM0095
36 . INSTALL LOCKING BALLS SPRINGS AND SCREW PLUGS
a Apply liquid sealer to th e plugs.
b Install th e locking balls, springs and screw plugs andt or qu e t he screw plugs with a torx socket wrench.
Torque: 190 kg em 1 4 ft Ib 19 Nm
NOTE: 5-Speed Install the short spring into th e bot lof th e intermediate plate.
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MANUAL TRANSMISSION - G52 Transmission MT-65
37 . DISMOUNT INTERMEDIATE PLATE FROM VISE
a D is m ou nt t he intermediate plate from th e vise.
b Remove th e b ol ts , n ut s, plate washers and gasket.
38 INSTALL TRANSMISSION CASE WITH NEW GASKET TOINTERMEDIATE PLATE
Align each bearing outer race, each f or k s ha ft end andreverse idler gear shaft end with the case installation holes,and ins ta ll th e case.
If necessary, ta p on th e case with a plastic hammer.
39. INSTALL TWO BEARING SNAP RINGS
\\ GM0012
4 INSTALL FRONT BEARING RETAINER WITH NEW GASKET
a Install th e bearing retainer with a new gasket.
b Apply liquid sealer to t he b ol ts .
c Install and t or qu e t he bolts.
Torque: 170 kg-em 1 2 ft-Ib, 17 Nm
GM0099
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MT 66 MANUAL TRANSMISSION G 52 Transmission
\ ~ ~
GM0104
41 INSTALL TRANSFER ADAPTER NEW GASKET SHIFTLEVER SHAFT AND SHIFT LEVER HOUSING
a Install a ne w gasket to the in te rmedia te plate.
b Install and t or qu e t he t ra n sf er adapter with t he e ig htbolts.
Torque: 38 0 kg em 27 ft Ib 37 Nom
GM0105
: GM0010
GM0106
GM0108
c Inse r t the shift lever housing to th e transfer adapterand connect th e fork shafts.
d Insert th e shift lever shaft to th e transfer adapter andshift l ever housing .
e Ins ta ll and t or qu e t he shift lever housing bolt.
Torque: 39 0 kg em 28 ft Ib 38 Nom
f Using SST install and t or qu e t he plug.
SS T 09923 00010
Torque: 380 kg em 27 ft Ib 37 Nom
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MANUAL TRANSMISSION - G 52 Transmission MT-67
42 . INSTALL LOCKING BALL, SPRING AN D SCREWPLUG
a Apply l iquid sealer to th e plug.
b Install th e locking ball and spr ing.
GM0110
c Install and t or qu e t he plug.
Torque: 190 kg-em 1 4 ft-Ib, 19 Nm
43. AFTER INSTALLING EXTENSION HOUSING OR TRANSFERADAPTER CHECK FOLLOWING ITEMS
a Check to see that t he i np ut and output shafts rotatesmoothly.
b Check to see that shifting can be made smoothly toall positions.
44. INSTALL RESTRICT PINS
a Install th e black pin on th e reverse gear/5th gear side.
GM0113
b Install another pin and torque th e pins.
Torque: 280 kg-em 2 0 ft-Ib, 27 N m
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MT-68 MANUAL TRANSMISSION G 52 Transmission
45 . INSTALL CLUTCH HOUSING
a Install t he c lu tc h housing
b Ins ta ll and torque th e bolts
Torque: 38 0 kg em 2 7 ft Ib 37 Nm
GM 115
46 . INSTALL SHIFT LEVER RETAINER WITH NEWGASKET
Torque: 185 kg em 1 3 ft Ib 1 8 Nm
47 . INSTALL BACK UP LIGHT SWITCH
Torque: 38 0 kg em 27 ft Ib 37 N m
48 . INSTALL RELEASE FORK AND BEARING
Apply molybdenum disulphide lithium base grease to th efollowing parts:
Release bearing hu b inside groove I np ut s h af t spline Release fork contact surface
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MANUAL TRANSMISSION - Installation of Transmission MT-69
NST LL T ON TR NSM SS ON
NOTE: For the transmission with a transfer 4WD refer to INSTALLA TION TRANSFER on page TF-25.
1. PLACE TRANSMISSION AT INSTALLATION POSITION
Insert th e extension housing between th e member and floorand then side th e transmission forward.
Align t he i np ut shaft spline with th e clutch d is c, a nd p us hthe t ransmiss ion f ul ly i nt o position.
2. INSTALL TRANSMISSION BOLTS AND STIFFENERBOLTS
Transmission Mounting Bolt Torque:Transmission Mounting Bolt 730 kg-em
5 3 ft-Ib, 72 NomStiffener Plate Bolt 3 80 kg-em
27 f t- Ib , 37 Nom
Vtiffener Plate
Bolt
Transmission Mount ing Bolt
MT0023
3. INSTALL ENGINE REAR MOUNTING AND BRACKET
a Install th e eng ine rea r mount ing . Torque th e bolts.
Torque: 260 kg-em 1 9 ft-Ib, 25 Nm
b Raise th e t ransmiss ion s l igh tly by raising th e enginewith a jack and a wooden block u nd er t he t ra ns mi ssion.
MTQ025
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MT-70 MANUAL TRANSMISSION - Installation of Transmission
c Install th e engine rear mount ing bracket to th e support member. Torque th e bolts.
Torque: 13 0 kg-em 9 f t- Ib , 13 Nm)
d Lower the t ransmission an d rest i t on th e extensionhousing.
e Install t h e b r ac k et to th e mounting. Torque th e bolts.
Torque: 260 kg-cm 19 ft-Ib, 25 N m)
MTOO16 MT0015
4. REMOVE PIECE O WOOD FROM FRONTCROSSMEMBER
INSTALL EXHAUST PIPE, BRACKET AND PIP
a Install t he e xh au st pipe to th e manifold.
Torque: 400 kg-em 29 ft-Ib, 39 Nom
MT0021
b Install th e pipe bracket to t he c lu tc h housing.
Torque: Upper 380 kg-em 2 7 f t- Ib , 37 NomLower 700 kg-em 51 ft-Ib, 69 Nom
c Install t he e xh au st pipe c lamp.
MT0020
6 INSTALL STARTER LOWER MOUNTING BOLT AN DRELEASE CYLINDER TUBE BRACKET
Torque: 400 kg-em 29 ft-Ib, 39 Nom
INSTALL CLUTCH RELEASE CYLINDER
Torque: 120 kg -e m 9 f t- Ib , 12 Nom
8 CONNECT SPEEDOMETER CABLE AN D BACK-UP LIGHTSWITCH
9 CONNECT PROPELLER SHAFT See page PR-2
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MANUAL TRANSMISSION - Installation of Transmission MT-71
10 . FILL TRANSMISSION WITH OILOil grade: API GL-4 or GL-5 SAE 75W-90
Quantity:2W D 2.4 liters 2 .5 US qts, 2.1 I mp . q ts4W D W56 3.0 liters 3 .2 US qts, 2.6 I mp . qt s
G5 2 3.9 liters 4.1 US qts, 3.4 I mp . q ts
11 . LOWER VEHICLE
12 . INSTALL STARTER UPPER MOUNTING NU T
13. INSTALL SHIFT LEVER
a Apply MP grease to th e shift lever.
b Install th e shift lever to th e transmission.
14. CONNECT BATTERY CABLE TO NEGATIVE TERMINAL
15 . PERFORM ROAD TEST
Check fo r abnormal noise and smooth operation.
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