Subaru Forester 2001 Service Manual
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Subaru Forester 2001 Service Manual

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2001 FORESTER SERVICE MANUAL
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping their
vehicle in optimum condition. When
replacement of parts during repair work is
needed, be sure to use SUBARU genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
G8050GE4

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Summary of Contents for Subaru Forester 2001

  • Page 1 When replacement of parts during repair work is needed, be sure to use SUBARU genu- ine parts. All information, illustration and specifica- tions contained in this manual are based on the latest product information avail- able at the time of publication approval.

  • Page 2: Table Of Contents

    MANUAL TRANSMISSION AND DIFFERENTIAL Page General Description..................2 Transmission Gear Oil ................31 Manual Transmission Assembly..............32 Transmission Mounting System ..............39 Oil Seal......................41 Switches and Harness ................42 Vehicle Speed Sensor................44 Preparation for Overhaul................45 Transfer Case and Extension Case Assembly .........46 Oil Pump....................50 Transfer Drive Gear ..................52 Transfer Driven Gear ................54 Center Differential ..................56 Reverse Check Sleeve................57...

  • Page 3: General Description

    GENERAL DESCRIPTION Manual Transmission and Differential 1. General Description S503001 A: SPECIFICATIONS S503001E49 1. MANUAL TRANSMISSION AND DIFFERENTIAL S503001E4901 Turbo Non-Turbo Model Without oil pump With oil pump Dual-range Single-range 5 × 2-forward speeds Type 5-forward speeds and 1-reverse and 1 × 2-reverse 3.454 3.454 2.062...
  • Page 4 GENERAL DESCRIPTION Manual Transmission and Differential Selection of main shaft rear plate Snap ring (Inner-68) to bearing clearance 0 — 0.12 mm (0 — 0.0047 in) Main shaft rear plate Snap ring (Inner-68) Dimension “A” mm Part No. Mark Part No. Thickness mm (in) (in) 805168020...
  • Page 5 GENERAL DESCRIPTION Manual Transmission and Differential 8. SHIFTER FORK AND ROD 9. TRANSFER CASE S503001E4906 S503001E4907 Select suitable shifter forks so that both coupling Neutral position adjustment sleeve and reverse driven gear are positioned in Adjustment shim the center of their synchromesh mechanisms. Part No.
  • Page 6 GENERAL DESCRIPTION Manual Transmission and Differential 10. EXTENSION ASSEMBLY 11. FRONT DIFFERENTIAL S503001E4908 S503001E4909 Thrust washer (50 × 61 × t) to taper roller bearing Bevel gear to pinion backlash 0.13 — 0.18 mm (0.0051 — 0.0071 in) table outer race side clearance 0.2 —...
  • Page 7 GENERAL DESCRIPTION Manual Transmission and Differential B: COMPONENT S503001A05 1. TRANSMISSION CASE S503001A0501 S3M0616A MT-6...
  • Page 8 GENERAL DESCRIPTION Manual Transmission and Differential (1) Transmission case ASSY (Turbo (9) Oil seal (16) High-low cable bracket A (Non- model) (10) Clamp turbo model) (2) Gasket (11) Pitching stopper bracket (17) High-low cable bracket B (Non- (3) Drain plug (12) Clip turbo model) (4) Snap ring (Outer)
  • Page 9 GENERAL DESCRIPTION Manual Transmission and Differential 2. DRIVE PINION ASSEMBLY S503001A0502 S3M0423B (1) Drive pinion shaft (15) Baulk ring (29) Lock nut (2) Roller bearing (16) 1st-2nd synchronizer hub (30) Washer (3) Washer (17) Insert key (31) Thrust bearing (4) Thrust bearing (18) Reverse driven gear (32) Differential bevel gear sleeve (5) Needle bearing...
  • Page 10 GENERAL DESCRIPTION Manual Transmission and Differential 3. MAIN SHAFT ASSEMBLY S503001A0503 B3M2120B (1) Oil seal (15) Needle bearing (29) Rev synchro cone (2) Needle bearing (16) 4th gear thrust washer (30) Ball bearing (3) Transmission main shaft (17) Ball bearing (31) Synchro cone stopper (4) Needle bearing (18) Baulk ring (Non–turbo model)
  • Page 11 GENERAL DESCRIPTION Manual Transmission and Differential 4. AUXILIARY TRANSMISSION GEARS S503001A0508 B3M2173B MT-10...
  • Page 12 GENERAL DESCRIPTION Manual Transmission and Differential (1) O-ring (19) Input shaft (37) High-low shifter shaft (2) High-low counter shaft (20) Needle bearing (38) Low switch (3) Straight pin (21) Snap ring (Outer-25) (39) Gasket (4) High-low counter washer (22) High-low baulk ring (40) Straight pin (5) Counter gear (23) High-low coupling sleeve...
  • Page 13 GENERAL DESCRIPTION Manual Transmission and Differential 5. SHIFTER FORK AND SHIFTER ROD S503001A0504 H3M1966A (1) Shifter arm (9) 3rd-4th fork rod (17) Reverse fork rod arm (2) 5th shifter fork (10) Interlock plunger (18) Reverse shifter lever (3) Straight pin (11) 1st-2nd fork rod (4) Reverse fork rod (12) 3rd-4th shifter fork...
  • Page 14 GENERAL DESCRIPTION Manual Transmission and Differential 6. TRANSFER CASE AND EXTENSION CASE FOR MODEL WITHOUT OIL PUMP S503001A0509 B3M2179B (1) Oil guide (16) Return spring (31) Transfer drive gear (2) Gasket (17) O-ring (32) Ball bearing (3) Transfer case (18) Adjusting select shim (33) Extension case (4) Ball (19) Reverse check sleeve...
  • Page 15 GENERAL DESCRIPTION Manual Transmission and Differential 7. TRANSFER CASE AND EXTENSION CASE FOR MODEL WITH OIL PUMP S503001A0510 S3M0617A (1) Oil guide (20) O-ring (39) Snap ring (2) Gasket (21) Adjusting select shim (40) Ball bearing (3) Transfer case (22) Reverse check sleeve (41) Transfer drive gear (4) Ball (23) Shift bracket...
  • Page 16 GENERAL DESCRIPTION Manual Transmission and Differential 8. FRONT DIFFERENTIAL S503001A0506 H3M1967B (1) Drive pinion shaft (8) Snap ring (Outer) (15) Retainer lock plate (2) Hypoid driven gear (9) Roller bearing (3) Pinion shaft (10) Differential case Tightening torque: N·m (kgf-m, ft-lb) (4) Straight pin (11) Oil seal 25 (2.5, 18.1)
  • Page 17 GENERAL DESCRIPTION Manual Transmission and Differential 9. TRANSMISSION MOUNTING S503001A0507 S2M0196C (1) Pitching stopper (7) Cushion D Tightening torque: N·m (kgf-m, ft-lb) (2) Spacer (8) Center crossmember 35 (3.6, 26) (3) Cushion C (9) Rear plate 50 (5.1, 37) (4) Front plate (10) Front crossmember 58 (5.9, 43) (5) Rear cushion rubber...
  • Page 18 ¼ Avoid damaging the mating surface of the case. part on the vehicle is hot after running. ¼ Use SUBARU genuine gear oil, grease etc. or ¼ Before applying sealant, completely remove the the equivalent. Do not mix gear oil, grease etc. with old seal.
  • Page 19 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 399527700 PULLER SET Used for removing and installing roller bearing (Differential). (1) BOLT (899521412) (2) PULLER (399527702) (3) HOLDER (399527703) (4) ADAPTER (398497701) (5) BOLT (899520107) (6) NUT (021008000) B3M1940A 399780104 WEIGHT...
  • Page 20 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498147000 DEPTH GAUGE Used for adjusting main shaft axial end play. B3M1944 ¼ Used for measuring backlash between side 498247001 MAGNET BASE gear and pinion, and hypoid gear. ¼ Used with DIAL GAUGE (498247100). B3M1945 ¼...
  • Page 21 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498787100 MAIN SHAFT STOP- Used for removing and installing transmission main shaft lock nut. B3M1948 498937000 HOLDER Used for removing and installing transmission main shaft lock nut. B3M1949 ¼ Used for installing 1st driven gear thrust plate 499277100 BUSH 1-2 INSTALLER...
  • Page 22 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for installing snap ring (OUT 25), and 499757002 INSTALLER ball bearing (25 x 26 x 17). ¼ Used for installing bearing cone of transfer driven gear (extension core side). B3M1952 499787000 WRENCH ASSY...
  • Page 23 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for installing 4th needle bearing race 499877000 RACE 4-5 INSTALLER and ball bearing onto transmission main shaft. ¼ Used with REMOVER (899714110). B3M1956 499917500 DRIVE PINION Used for adjusting drive pinion shim. GAUGE ASSY B3M1957 499927100...
  • Page 24 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499987003 SOCKET WRENCH Used for removing and installing driven pinion (35) lock nut and main shaft lock nut. B3M1960 499987300 SOCKET WRENCH Used for removing and installing driven gear (50) assembly lock nut.
  • Page 25 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899884100 HOLDER Used for tightening lock nut on sleeve. B3M1964 899904100 REMOVER Used for removing and installing straight pin. B3M1965 899988608 SOCKET WRENCH Used for removing and installing drive pinion (27) lock nut.
  • Page 26 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587000 INSTALLER Used for installing driven gears to driven shaft. B3M1968 899824100 PRESS Used for installing speedometer shaft oil seal. B3M1969 499987100 SOCKET WRENCH Used for removing and installing drive pinion (35) lock nut.
  • Page 27 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498057300 INSTALLER Used for installing extension oil seal. B3M1972 498255400 PLATE Used for measuring backlash. B3M1973 ¼ Used for removing synchronizer cone of main 498077400 REMOVER shaft. ¼ Used for removing 5th driven gear of drive pinion shaft.
  • Page 28 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 41099AA020 ENGINE SUPPORT Used for supporting engine. B3M1976 398527700 PULLER ASSY Used for removing and installing extension case roller bearing. B3M1977 398643600 GAUGE Used for measuring total end play, extension end play and drive pinion height.
  • Page 29 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for installing input shaft holder oil seal. 398507703 DUMMY COLLAR ¼ For dual-range model. B3M2122 ¼ Used for removing and installing input shaft 398663600 PLIERS snap ring. ¼...
  • Page 30 GENERAL DESCRIPTION Manual Transmission and Differential ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used when pressing ball bearings into input 899580100 INSTALLER shaft. ¼ For dual-range model. B3M2127 ¼ Used when pressing ball bearings into input 399513600 INSTALLER shaft. ¼ For dual-range model. B3M2129 2.
  • Page 31 GENERAL DESCRIPTION Manual Transmission and Differential MEMO: MT-30...

  • Page 32: Transmission Gear Oil

    TRANSMISSION GEAR OIL Manual Transmission and Differential 2. Transmission Gear Oil 5) Pour gear oil into the gauge hole. S503219 Recommended gear oil: A: INSPECTION S503219A10 Use GL-5 or equivalent. 1) Park vehicle on a level surface. Gear oil capacity: 2) Turn ignition switch to OFF, and wait until the Turbo model without oil pump;...

  • Page 33: Manual Transmission Assembly

    MANUAL TRANSMISSION ASSEMBLY Manual Transmission and Differential 3. Manual Transmission (3) High-low switch connector (Non-turbo model) Assembly S503224 Non-turbo model A: REMOVAL S503224A18 1) Set vehicle on a lift. 2) Open front hood fully, and support with stay. 3) Disconnect battery ground terminal. 4) Move gear shift lever to “N”, and release the parking brake.
  • Page 34 MANUAL TRANSMISSION ASSEMBLY Manual Transmission and Differential 10) Remove the drive select cable on the trans- 13) Remove pitching stopper. mission. (Non-turbo model) S2M0126 S2M0745B 14) Set ST. Snap pin NOTE: Also is available Part No. 41099AA010. Drive select cable ST 41099AA020 ENGINE SUPPORT ASSY 11) Remove starter.
  • Page 35 MANUAL TRANSMISSION ASSEMBLY Manual Transmission and Differential (2) Screw 6 mm dia. bolt into release fork shaft, 19) Remove rear exhaust pipe and muffler. and remove it. CAUTION: When removing exhaust pipes, be careful each exhaust pipe does not drop out. 20) Remove heat shield cover.
  • Page 36 MANUAL TRANSMISSION ASSEMBLY Manual Transmission and Differential 26) Remove spring pins and separate front drive 30) Remove transmission rear crossmember from shafts from each side of the transmission. vehicle. CAUTION: Discard removing spring pin. Replace with a new one. G2M0831 31) Remove transmission.
  • Page 37 MANUAL TRANSMISSION ASSEMBLY Manual Transmission and Differential 5) Take off transmission jack. 9) Remove ST. 6) Tighten nuts which hold lower side of transmis- sion to engine. Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb) G2M0313 10) Push clutch release lever to fit bearing into clutch cover.
  • Page 38 MANUAL TRANSMISSION ASSEMBLY Manual Transmission and Differential 15) Drive spring pin into chamfered hole of drive 18) Connect rod to the joint. shaft. Tightening torque: CAUTION: 18 N·m (1.8 kgf-m, 13.0 ft-lb) Always use a new spring pin. B3M1824A G2M0325 Joint 16) Install ball joints of lower arm into knuckle arm of housing, and tighten installing bolts.
  • Page 39 MANUAL TRANSMISSION ASSEMBLY Manual Transmission and Differential 23) Install rear exhaust pipe and muffler. Turbo model Non-turbo model with OBD: <Ref. to EX(SOHC)-11, INSTALLATION, Muffler.> and <Ref. to EX(SOHC)-9, INSTALLATION, Rear Exhaust Pipe.> Non-turbo model without OBD: <Ref. to EX(SOHCw/oOBD)-12, INSTALLATION, Muffler.>...

  • Page 40: Transmission Mounting System

    TRANSMISSION MOUNTING SYSTEM Manual Transmission and Differential 4. Transmission Mounting 5) Remove the heat shield cover. (If equipped) System S503233 A: REMOVAL S503233A18 1. PITCHING STOPPER S503233A1801 1) Disconnect battery ground terminal. 2) Remove the cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.>...
  • Page 41 TRANSMISSION MOUNTING SYSTEM Manual Transmission and Differential 3) Install intercooler. <Ref. to IN(DOHC TURBO)- 2. CROSSMEMBER AND CUSHION 10, INSTALLATION, Intercooler.> RUBBER S503233A1002 4) Connect battery ground terminal. Make sure that the crossmember is not bent or damaged. Make sure that the cushion rubber is not 2.

  • Page 42: Oil Seal

    OIL SEAL Manual Transmission and Differential 5. Oil Seal 9) Install the heat shield cover. S503143 10) Install the rear exhaust pipe and muffler. A: REPLACEMENT 11) Pour gear oil and check the oil level. <Ref. to S503143A20 MT-31, Transmission Gear Oil.> 1) Clean transmission exterior.

  • Page 43: Switches And Harness

    SWITCHES AND HARNESS Manual Transmission and Differential 6. Switches and Harness S503232 A: REMOVAL S503232A18 1. BACK-UP LIGHT AND NEUTRAL POSITION SWITCH S503232A1801 1) Disconnect connector battery ground terminal. 2) Remove air intake duct and cleaner case. (Non- Turbo model) <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.>...
  • Page 44 SWITCHES AND HARNESS Manual Transmission and Differential 2. NEUTRAL POSITION SWITCH B: INSTALLATION S503232A1002 S503232A11 1) Turn ignition switch to OFF. 1. BACK-UP LIGHT SWITCH AND 2) Disconnect connector neutral position switch. NEUTRAL POSITION SWITCH S503232A1101 3) Using the circuit tester, verify the current in neu- 1) Install back-up light switch and neutral position tral position.

  • Page 45: Vehicle Speed Sensor

    VEHICLE SPEED SENSOR Manual Transmission and Differential 7. Vehicle Speed Sensor 5) Install center exhaust pipe. (Turbo model) S503231 <Ref. to EX(DOHC TURBO)-10, INSTALLATION, A: REMOVAL Center Exhaust Pipe.> S503231A18 6) Lower the vehicle. 1) Disconnect ground terminal from battery. 7) Connect battery ground terminal.

  • Page 46: Preparation For Overhaul

    PREPARATION FOR OVERHAUL Manual Transmission and Differential 8. Preparation for Overhaul 6) Rotating parts should be coated with oil prior to S503091 assembly. A: PROCEDURE 7) All disassembled parts, if to be reused, should S503091E45 be reinstalled in the original positions and direc- 1) Clean oil, grease, dirt and dust from transmis- tions.

  • Page 47: Transfer Case And Extension Case Assembly

    TRANSFER CASE AND EXTENSION CASE ASSEMBLY Manual Transmission and Differential 9. Transfer Case and Extension 2) Remove bearing cone from the extension case assembly, and install to taper roller bearing of the Case Assembly S503561 transfer driven gear. A: REMOVAL S503561A18 1) Remove the manual transmission assembly from vehicle.
  • Page 48 TRANSFER CASE AND EXTENSION CASE ASSEMBLY Manual Transmission and Differential NOTE: 10) Measure depth “T” between extension case T: Tight and transfer drive gear. ST 398643600 GAUGE Thrust washer (50 × 61 × t) Part No. Thickness mm (in) 803050060 0.50 (0.0197) 803050061 0.55 (0.0217)
  • Page 49 TRANSFER CASE AND EXTENSION CASE ASSEMBLY Manual Transmission and Differential 16) Install extension assembly into transfer case. C: DISASSEMBLY S503561A06 Tightening torque: 1. TRANSFER CASE S503561A0601 40N·m (4.1 kgf-m, 29.7 ft-lb) 1) Remove reverse check assembly. <Ref. to MT-57 REMOVAL, Reverse Check Removal.> 2) Remove oil guide.
  • Page 50 TRANSFER CASE AND EXTENSION CASE ASSEMBLY Manual Transmission and Differential D: ASSEMBLY S503561A02 1. EXTENSION CASE S503561A0201 1) Using ST, install oil seal to extension case. <Ref. to MT-41, Oil Seal.> CAUTION: Use new oil seal. 2) Install shift bracket to extension case. Tightening torque: 25 N·m (2.5 kgf-m, 18.1 ft-lb) B3M1381...

  • Page 51: Oil Pump

    OIL PUMP Manual Transmission and Differential 10. Oil Pump 5) Remove oil pump cover from extension. S503070 A: REMOVAL S503070A18 For extension case removal procedure, refer to “Transfer Case and Extension Case Assembly”. <Ref. to MT-46, REMOVAL, Transfer Case and Extension Case Assembly.>...
  • Page 52 OIL PUMP Manual Transmission and Differential 3) Install oil pump cover to extension case. 6) Install oil strainer to extension case. Tightening torque: Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 25 N·m (2.5 kgf-m, 18.1 ft-lb) S3M0618 S3M0439B 7) Install transfer drive gear. <Ref. to MT-52, Oil pump cover INSTALLATION, Transfer Drive Gear.>...

  • Page 53: Transfer Drive Gear

    TRANSFER DRIVE GEAR Manual Transmission and Differential 11. Transfer Drive Gear S503229 A: REMOVAL S503229A18 1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove back-up light switch and neutral posi- tion switch. <Ref. to MT-42 REMOVAL, Switches and Harness.>...
  • Page 54 TRANSFER DRIVE GEAR Manual Transmission and Differential 3) Measure clearance between snap ring and D: ASSEMBLY S503229A02 inner race of ball bearing with a thickness gauge. 1) Install straight pin to transfer drive gear. (With Clearance: pump) 0.01 — 0.15 mm (0.0004 — 0.0059 in) 2) Set the ST applying to inner race of bearing and instal to drive shaft.

  • Page 55: Transfer Driven Gear

    TRANSFER DRIVEN GEAR Manual Transmission and Differential 12. Transfer Driven Gear B: INSTALLATION S503223A11 S503223 1) Install bearing cup to extension case and trans- A: REMOVAL S503223A18 fer case. 1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32, REMOVAL, Manual Transmission Assembly.>...
  • Page 56 TRANSFER DRIVEN GEAR Manual Transmission and Differential C: DISASSEMBLY D: ASSEMBLY S503223A06 S503223A02 1) Using ST, remove roller bearing (extension 1) Using ST, install roller bearing (extension case side). case side). ST1 398177700 INSTALLER ST 498077000 REMOVER ST2 899864100 REMOVER CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton)

  • Page 57: Center Differential

    CENTER DIFFERENTIAL Manual Transmission and Differential 13. Center Differential D: ASSEMBLY S503158A02 S503158 Install ball bearing to center differential assembly. A: REMOVAL S503158A18 CAUTION: 1) Remove the manual transmission assembly Do not apply pressure in excess of 10 kN (1 ton, from vehicle.

  • Page 58: Reverse Check Sleeve

    REVERSE CHECK SLEEVE Manual Transmission and Differential 14. Reverse Check Sleeve 2) Install ball, spring, washer and plug to transfer S503267 case. A: REMOVAL S503267A18 Tightening torque: 10 N·m (1.0 kgf-m, 7.2 ft-lb) 1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.>...
  • Page 59 REVERSE CHECK SLEEVE Manual Transmission and Differential 2) Remove reverse check plate, reverse check 2) Hook the bent section of reverse check spring spring, reverse check cam, return spring (5th-Rev), over reverse check plate. reverse accent shaft, return spring cap and return 3) Rotate cam so that the protrusion of reverse spring (1st-2nd).
  • Page 60 REVERSE CHECK SLEEVE Manual Transmission and Differential 2. REVERSE CHECK PLATE F: ADJUSTMENT S503267A01 ADJUSTMENT S503267A0102 1. NEUTRAL POSITION ADJUSTMENT 1) Shift shifter arm to “5th” and then to reverse to BB30109201 see if reverse check mechanism operates properly. 1) Shift gear into 3rd gear position. 2) Also check to see if arm returns to neutral when 2) Shifter arm turns lightly toward the 1st/2nd gear released from the reverse position.

  • Page 61: Transmission Case

    TRANSMISSION CASE Manual Transmission and Differential 15. Transmission Case 7) Separate transmission case into right and left S503266 cases by loosening coupling bolts and nuts. A: REMOVAL S503266A18 1. SINGLE-RANGE S503266A1801 1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32, REMOVAL, Manual Transmission Assembly.>...
  • Page 62 TRANSMISSION CASE Manual Transmission and Differential 2) Remove clutch release lever. <Ref. to CL-20, 7) Remove main shaft rear plate. REMOVAL, Release Bearing and Lever.> 3) Remove transfer case with extension case assembly. <Ref. to MT-46, REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove the input shaft holder.
  • Page 63 TRANSMISSION CASE Manual Transmission and Differential 10) Remove drive pinion shaft assembly from left 12) Remove main shaft assembly and input shaft side transmission case. assembly. NOTE: CAUTION: Use a hammer handle, etc. to remove if too tight. Be careful not to drop input shaft and main shaft as they are separable.
  • Page 64 TRANSMISSION CASE Manual Transmission and Differential 6) Tighten 17 bolts with bracket, clip, etc. as 8) Backlash adjustment of hypoid gear and pre- shown in the figure. load adjustment of roller bearing NOTE: NOTE: ¼ Insert bolts from the bottom and tighten nuts at Support drive pinion assembly with ST.
  • Page 65 TRANSMISSION CASE Manual Transmission and Differential 11) Remove weight and screw in retainer without 17) After checking the tooth contact of hypoid O-ring on the upper side and stop at the point gears, remove the lock plate. Then loosen retainer where slight resistance is felt.
  • Page 66 TRANSMISSION CASE Manual Transmission and Differential 6) Tighten 17 bolts with bracket, clip, etc. as 8) Tighten input shaft holder attaching bolts. shown in the figure. Tightening torque: NOTE: 20 N·m (2.0 kgf-m, 14.5 ft-lb) ¼ Insert bolts from the bottom and tighten nuts at the top.
  • Page 67 TRANSMISSION CASE Manual Transmission and Differential 11) Screw retainer assembly into left case from 16) Turn transmission main shaft several times while tapping around retainer lightly with plastic the bottom with ST2. Fit ST3 on the transmission hammer. main shaft. Shift gear into 4th or 5th and turn the 17) Inspect and adjust backlash and tooth contact shaft several times.

  • Page 68: Main Shaft Assembly For Single-Range

    MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE Manual Transmission and Differential 16. Main Shaft Assembly for C: DISASSEMBLY S503713A06 Single-Range 1) Put vinyl tape around main shaft splines to pro- S503713 tect oil seal from damage. Then pull out oil seal A: REMOVAL and needle bearing by hand.
  • Page 69 MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE Manual Transmission and Differential 4) Remove snap ring and synchro cone stopper 6) Using ST1 and ST2, remove the rest of parts. from 5th-Rev sleeve and hub assembly. NOTE: Replace sleeve and hub with new ones. Do not attempt to disassemble because they must engage specified point.
  • Page 70 MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE Manual Transmission and Differential 3) Install 4th needle bearing race onto transmis- D: ASSEMBLY S503713A02 sion main shaft using ST1, ST2 and a press. 1) Assemble each sleeve and hub assembly. CAUTION: NOTE: Do not apply pressure in excess of 10 kN (1 ton, Position open ends of spring 120°...
  • Page 71 MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE Manual Transmission and Differential 5) Drive ball bearing onto the rear section of trans- 7) Install bearing onto synchro cone. mission main shaft using ST1, ST2 and a press. 8) Install baulk ring and synchro cone onto 5th- Rev sleeve and hub assembly using ST and a CAUTION: press.
  • Page 72 MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE Manual Transmission and Differential 10) Install the rest parts to the rear section of 4) Baulk ring Replace the ring in the following cases: transmission main shaft. ¼ When the inner surface and end face are dam- NOTE: aged.
  • Page 73 MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE Manual Transmission and Differential F: ADJUSTMENT S503713A01 Selection of main shaft rear plate Using ST, measure the amount (A) of ball bearing protrusion from transmission main case surface and select the proper plate in the following table: NOTE: Before measuring, tap the end of main shaft with a plastic hammer lightly in order to make the clear-...

  • Page 74: Main Shaft Assembly For Dual-Range

    MAIN SHAFT ASSEMBLY FOR DUAL-RANGE Manual Transmission and Differential 17. Main Shaft Assembly for C: DISASSEMBLY S503714A06 Dual-Range 1) Put vinyl tape around main shaft splines to pro- S503714 tect oil seal from damage. Then pull out oil seal A: REMOVAL and needle bearing by hand.
  • Page 75 MAIN SHAFT ASSEMBLY FOR DUAL-RANGE Manual Transmission and Differential 5) Using ST1, ST2 and a press, remove ball 6) Using ST1 and ST2, remove the rest of parts. bearing, synchro cone and baulk ring (Rev). NOTE: NOTE: Replace sleeve and hub with new ones. Do not ¼...
  • Page 76 MAIN SHAFT ASSEMBLY FOR DUAL-RANGE Manual Transmission and Differential 8) Remove the rest of parts. 2) Install 3rd drive gear, baulk ring, sleeve and hub assembly for 3rd-4th needle bearing on transmis- sion main shaft. NOTE: Align groove in baulk ring with shifting insert. 3) Install 4th needle bearing race onto transmis- sion main shaft using ST1, ST2 and a press.
  • Page 77 MAIN SHAFT ASSEMBLY FOR DUAL-RANGE Manual Transmission and Differential 5) Drive ball bearing onto the rear section of trans- 7) Install bearing onto synchro cone. mission main shaft using ST1, ST2 and a press. 8) Install baulk ring and synchro cone onto 5th- ST1 899714110 REMOVER Rev sleeve and hub assembly using ST and a ST2 499877000 RACE 4-5 INSTALLER...
  • Page 78 MAIN SHAFT ASSEMBLY FOR DUAL-RANGE Manual Transmission and Differential 10) Install the rest parts to the rear section of 13) Install the parts to the front section of trans- transmission main shaft. mission main shaft. NOTE: CAUTION: Align groove in baulk ring with shifting insert. Be careful not to damage the graded section of transmission main shaft when installing needle bearing.
  • Page 79 MAIN SHAFT ASSEMBLY FOR DUAL-RANGE Manual Transmission and Differential E: INSPECTION S503714A10 Disassembled parts should be washed clean first and then inspected carefully. 1) Bearings Replace bearings in the following cases: ¼ Bearings whose balls, outer races and inner races are broken or rusty. ¼...

  • Page 80: Input Shaft Assembly

    INPUT SHAFT ASSEMBLY Manual Transmission and Differential 18. Input Shaft Assembly C: DISASSEMBLY S503715A06 S503715 1) Remove O-ring from input shaft holder. Also, A: REMOVAL S503715A18 remove input shaft holder shim. 1) Remove the manual transmission assembly CAUTION: from vehicle. <Ref. to MT-32 REMOVAL, Manual Use new O-ring.
  • Page 81 INPUT SHAFT ASSEMBLY Manual Transmission and Differential 5) Remove outer snap ring. Then remove oil D: ASSEMBLY S503715A02 squeeze plate and straight pin. 1) Install ball bearing onto input shaft. NOTE: Place snap ring between input shaft gear and ball bearing beforehand.
  • Page 82 INPUT SHAFT ASSEMBLY Manual Transmission and Differential 3) Install straight pin and oil squeeze plate to input 7) Install snap ring to input shaft holder. shaft. NOTE: Select a suitable snap ring so that clearance between snap ring and bearing is held within 0 to 0.12 mm (0 to 0.0047 in).
  • Page 83 INPUT SHAFT ASSEMBLY Manual Transmission and Differential ¼ When the inner wall is abnormally worn. 3) Gears ¼ Replace gears with new ones if their tooth sur- faces are broken, damaged, or excessively worn. ¼ Correct or replace if the cone that contacts the baulk ring is rough or damaged.

  • Page 84: Drive Pinion Shaft Assembly

    DRIVE PINION SHAFT ASSEMBLY Manual Transmission and Differential 19. Drive Pinion Shaft 4) Inspection and adjustment of ST Assembly NOTE: S503269 ¼ Loosen the two bolts and adjust so that the scale A: REMOVAL indicates 0.5 correctly when the plate end and the S503269A18 scale end are on the same level.
  • Page 85 DRIVE PINION SHAFT ASSEMBLY Manual Transmission and Differential 8) Select one to three shims from the next table for 2) Withdraw drive pinion from driven shaft. the value determined as described above and take Remove differential bevel gear sleeve, adjusting a shim thickness which is closest to the said value.
  • Page 86 DRIVE PINION SHAFT ASSEMBLY Manual Transmission and Differential 4) Straighten lock nut at staked portion. Remove 9) Remove 2nd driven gear, inner baulk ring, syn- the lock nut using ST1 and ST2. chro cone and outer baulk ring. ST1 499987300 SOCKET WRENCH (50) ST2 899884100 HOLDER S3M0445A 2nd driven gear...
  • Page 87 DRIVE PINION SHAFT ASSEMBLY Manual Transmission and Differential 4) Install 2nd driven gear bushing onto driven D: ASSEMBLY S503269A02 shaft using ST1, ST2 and press. 1) Install sleeve and assembly by matching align- CAUTION: ment marks. ¼ Attach a cloth to the end of driven shaft to NOTE: prevent damage.
  • Page 88 DRIVE PINION SHAFT ASSEMBLY Manual Transmission and Differential 6) After installing key on driven shaft, install 3rd- 8) Position woodruff key in groove on the rear of 4th driven gear using ST and press. driven shaft. Install 5th driven gear onto drive shaft using ST and press.
  • Page 89 DRIVE PINION SHAFT ASSEMBLY Manual Transmission and Differential 10) Install roller bearing onto drive pinion. 13) Install drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting NOTE: washer No. 1 and differential bevel gear sleeve in When installing roller bearing, note its directions that order.
  • Page 90 DRIVE PINION SHAFT ASSEMBLY Manual Transmission and Differential ¼ The ball bearing on the rear side of the drive ¼ When the contact surface of the synchronizer pinion shaft should be checked for smooth rotation ring insert is scored or abnormally worn down. before the drive pinion assembly is disassembled.
  • Page 91 DRIVE PINION SHAFT ASSEMBLY Manual Transmission and Differential 2) Using ST1, ST2 and ST3, tighten lock nut to the 4) If starting torque is not within specified limit, specified torque. select new adjusting washer No. 1 and recheck ST1 899884100 HOLDER starting torque.
  • Page 92 DRIVE PINION SHAFT ASSEMBLY Manual Transmission and Differential 6) Recheck that starting torque is within specified range, then clinch lock nut at four positions. MT-91...

  • Page 93: Front Differential Assembly

    FRONT DIFFERENTIAL ASSEMBLY Manual Transmission and Differential 20. Front Differential Assembly B: INSTALLATION S503152A11 1) Install differential side retainers using ST. S503152 ST 499787000 WRENCH ASSY A: REMOVAL S503152A18 2) Install differential assembly. 1) Remove the manual transmission assembly CAUTION: from vehicle.
  • Page 94 FRONT DIFFERENTIAL ASSEMBLY Manual Transmission and Differential 2) Loosen twelve bolts and remove hypoid driven 4) Pull out pinion shaft, and remove differential gear. bevel pinion and gear and washer. B3M0552C Pinion shaft Bevel pinion Bevel gear Washer 5) Remove roller bearing using ST. ST 399527700 PULLER SET B3M0551C Snap ring...
  • Page 95 FRONT DIFFERENTIAL ASSEMBLY Manual Transmission and Differential 2) Measure backlash between bevel gear and pin- 4) Install roller bearing to differential case. ion. If it is not within specifications, install a suitable CAUTION: washer to adjust it. <Ref. to MT-96 ADJUSTMENT, Do not apply pressure in excess of 10 kN (1 ton, Front Differential Assembly.>...
  • Page 96 FRONT DIFFERENTIAL ASSEMBLY Manual Transmission and Differential ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash: 0.13 — 0.18 mm (0.0051 — 0.0071 in) G3M0670 2. HYPOID GEAR BACKLASH S503152A1002 Set ST1, ST2 and ST3. Insert the needle through transmission oil drain plug hole so that the needle comes in contact with the tooth surface at a right B3M0558C...
  • Page 97 FRONT DIFFERENTIAL ASSEMBLY Manual Transmission and Differential ¼ Tooth contact is correct. NOTE: Each time holder rotates one tooth, backlash changes by 0.05 mm (0.020 in). B3M0070D H3M1203C Coast side Heel 3. TOOTH CONTACT OF HYPOID GEAR Drive side S503152A0103 F: ADJUSTMENT S503152A01 Adjust until the teeth contact is correct.
  • Page 98 FRONT DIFFERENTIAL ASSEMBLY Manual Transmission and Differential ¼ The drive pinion shim selected before is too thick. Reduce its thickness. B3M0073 ¼ The drive pinion shim selected before is too thin. Increase its thickness. B3M0074 MT-97...

  • Page 99: Speedometer Gear

    SPEEDOMETER GEAR Manual Transmission and Differential 21. Speedometer Gear S503268 A: REMOVAL S503268A18 1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove back-up light switch and neutral posi- tion switch. <Ref. to MT-42 REMOVAL, Switches and Harness.>...

  • Page 100: Reverse Idler Gear

    REVERSE IDLER GEAR Manual Transmission and Differential 22. Reverse Idler Gear S503263 A: REMOVAL S503263A18 1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove back-up light switch and neutral posi- tion switch. <Ref. to MT-42 REMOVAL, Switches and Harness.>...
  • Page 101 REVERSE IDLER GEAR Manual Transmission and Differential C: INSPECTION D: ADJUSTMENT S503263A10 S503263A01 1) Move the reverse shifter rod toward the reverse 1) Select the appropriate reverse shifter lever from side. Inspect clearance between reverse idler gear the table below, and adjust until the gap between and transmission case wall.

  • Page 102: Shifter Fork And Rod

    SHIFTER FORK AND ROD Manual Transmission and Differential 23. Shifter Fork and Rod S503255 A: REMOVAL S503255A18 1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove back-up light switch and neutral posi- tion switch.
  • Page 103 SHIFTER FORK AND ROD Manual Transmission and Differential CAUTION: 12) Install drive pinion shaft assembly. <Ref. to Apply a coat of grease to plunger to prevent it MT-83 INSTALLATION, Drive Pinon Shaft Assem- from falling. bly.> 13) Install transmission case. <Ref. to MT-62 6) Install 3-4 fork rod into 3-4 shifter fork via the INSTALLATION, Transmission Case.>...
  • Page 104 SHIFTER FORK AND ROD Manual Transmission and Differential 4) Inspect clearance between 3rd, 4th drive gear Non-turbo model and coupling sleeve. If any clearance is not within 5th shifter fork specifications, replace shifter fork as required. Part No. Mark Remarks Clearance (a) and (b): Approach to 5th gear 32812AA201...

  • Page 105: Counter Gear

    COUNTER GEAR Manual Transmission and Differential 24. Counter Gear 6) Remove counter shaft from transmission case, S503716 taking care not to drop counter gear and the two A: REMOVAL washers. S503716A18 CAUTION: 1) Remove the manual transmission assembly ¼ Be careful not to damage O-ring. from the vehicle.
  • Page 106 COUNTER GEAR Manual Transmission and Differential C: INSPECTION S503716A10 1) After installing snap ring, measure clearance between snap ring and counter washer. Clearance: 0.05 — 0.35 mm (0.0020 — 0.0138 in) 2) If the clearance is out of measured value, select a snap ring and install to put clearance within mea- sured value.

  • Page 107: General Diagnostic

    GENERAL DIAGNOSTIC Manual Transmission and Differential 25. General Diagnostic S503278 A: INSPECTION S503278A10 1. MANUAL TRANSMISSION S503278A1001 Symptom Possible cause Remedy 1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer of Replace. NOTE: internal spline of sleeve and reverse The cause for difficulty in shifting gears driven gear can be classified into two kinds: one is...
  • Page 108 GENERAL DIAGNOSTIC Manual Transmission and Differential 2. DIFFERENTIAL S503278A1002 Symptom Possible cause Remedy 1. Broken differential (case, gear, (a) Insufficient or improper oil Disassemble differential and replace bro- bearing, etc.) ken components and at the same time NOTE: check other components for any trouble, Abnormal noise will develop and finally it and replace if necessary.
  • Page 109 GENERAL DIAGNOSTIC Manual Transmission and Differential MEMO: MT-108...

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