Service Manual
Contents
1. 2 Removal and installation procedures 1 a Clip 6 f Washer plate 2 b Washer plate v 7 g Cable Ay shift amp select cable 3 c Clip 4 dClip 5 e Clip F2 19 8 1 3 POINTS OF REMOVAL 1 Cable Ay shift amp select cable 1 Disconnect the cable Ay CAUTION e Do not bend the end section of the cable Ay more than 8 degrees 8 degrees a 8 degrees ree P21K6587ET10 8 1 4 INSPECTION 1 Ensure that the inner cable of the cable Ay slides smoothly 2 Check that there is no severe rupturing damage or de formation to the boot P21K6019ET10 8 1 5 OPERATION AFTER INSTALLATION 1 Lift down the vehicle 2 Attach the console box Ay RR UPR2. NOTE e 2WD approximately 1 2 4WD approximately 2 21 4 Leave for about five minutes after the oil no longer overflows from the filler plug at Step 3 F2 3 5 Check the oil level with your finger or by using a wire or the like CAUTION Filler plug e It will take some time for oil to circulate inside the Oil transmission Therefore be sure to wait for a while be surface fore confirming the oil level SPECIFIED VALUE From lower edge of filler plug hole 0 5 mm 6 If the oil is not filled to the specified level fill gear oil L31K5052ET10 again by following Step 3 7 Ensure that the gear oil is reached to the specified level by following the procedure in Step 5 8 Tighten the filler plug to the specified torque CAUTION e Never reuse gasket of the filler plug TIGHTENING TORQUE 39 2 9 8N m 400 99kgf cm F2 4 3 MANUAL TRANSMISSION 3 1 REMOVAL AND INSTALLATION 3 1 1 ARTICLES TO BE PREPARED SST Shape Part No Part name a a ee Device engine slin 09090 04010 000 vere g Tool High transmission jack Lubricant adhesive others Transmission gear oil SAE75W 90 or SAE75W 85 or SAE75W 80 API Classification GL3 or GL4 Rope 3 1 2 OPERATION BEFORE REMOVAL 1 Disconnect the negative terminal of the battery 2 Drain the transmission oil Refer to Page F2 2 3 Remove the propeller shaft Ay w center bearing Refer to Pa
3. 1 3 REMOVAL AND INSTALLATION PROCEDURES 1 Components P21K6012ES20 X Non reusable parts MP grease 2 Removal and installation procedures v a 1 a Seal type T oil 4 1 4 POINTS OF REMOVAL 1 Seal type T oil 1 Remove the seal using the SST SST 09308 00010 000 4 1 5 POINTS OF INSTALLATION 1 Seal type T oil 1 Drive the seal in place using the SST CAUTION e Apply MP grease to the entire periphery of the seal lip area SST 09309 87201 000 LUBRICANT MP grease 4 1 6 OPERATION AFTER INSTALLATION 1 Attach the propeller shaft Ay w center bearing Refer to Page D2 17 2 Check the level of the transmission oil Refer to Page F2 2 3 Check that there is no oil leakage P21K6014ET10 F2 11 5 SPEEDOMETER DRIVEN GEAR ABS EQUIPPED VEHICLE 5 1 REMOVAL AND INSTALLATION 5 1 1 ARTICLES TO BE PREPARED SST Shape Part No Part name 0320101090090 vdr g replacer Wane Guide bush 09201 6001 1 000 p 9 Grease bond etc MP grease Transmission gear oil SAE75W 90 or SAE75W 85 or SAE75W 80 API Classification GL3 or GL4 5 1 2 OPERATION BEFORE REMOVAL 1 Disconnect the negative terminal of the battery 2 Disconnect the connector from the speedometer sensor 5 1 3 REMOVAL AND INSTALLATION PROCEDURES 1 Components b T 8 4 1 4 85 14 gt co x 7E gt lt gt e gt
4. When using the high mission jack be sure to interpose a cloth between the jack and the parts so as not to scratch the parts e Care must be exercised to prevent the manual trans mission Ay from lowering while it is being supported by the high mission jack 4 Remove the attaching bolts of the engine support mem ber S A RR 5 Remove the nuts and bolts and then remove the engine support member S A RR 2 Transmission Ay manual F2 6 Z ea CEA rN P21K6005T10 P21K6008T10 1 Slowly lower the chain block and the high mission jack and tilt the transmission to a point where all of its attaching bolts can be seen 2 Remove the bolts which connect the engine Ay and the transmission Ay and remove the clutch housing under cover P21K6009T10 F2 7 3 Transfer Ay Gasket transfer Bearing needle 1 Operate the high mission jack and remove the transmission Ay from the vehicle while tilting it to wards the back of the vehicle CAUTION e Ensure that the transmission Ay does not fall off the high mission jack 3 1 5 POINTS OF INSTALLATION 1 Transfer Ay Gasket transfer Bearing needle Refer to Page D1 6 2 Transmission Ay manual 1 After cleaning the seal bolt holes of the engine block in stall the transmission Ay CAUTION e Never reuse seal bolt 2 Check that the 2 knock pins are attached to the engine Ay s
5. F2 MANUAL TRANSMISSION MANUAL TRANSAXLE MANUAL TRANSMISSION F2 1 BASIC CHECK AND ADJUSTMENT F2 1 TRANSMISSION GEAR OIL F2 2 REPLACEMENT lt 2 lt 2 lt s lt 20e2 00 0 F2 2 MANUAL TRANSMISSION F2 4 REMOVAL AND INSTALLATION F2 4 EXTENSION HOUSING OIL SEAL 2WD A ATS M F2 9 REMOVAL AND INSTALLATION F2 9 SPEEDOMETER DRIVEN GEAR ABS EQUIPPED VEHICLE F2 11 REMOVAL AND INSTALLATION F2 11 BACK UP LAMP SWITCH F2 14 REMOVAL AND INSTALLATION F2 14 SHIFT LEVER F2 16 REMOVAL AND INSTALLATION F2 16 SHIFT CABLE AY AND SELECT CABLE F2 1 1 MANUAL TRANSMISSION 1 1 BASIC CHECK AND ADJUSTMENT Filler plug 1 1 1 TRANSMISSION OIL CHECK 1 Oil level check 1 With the vehicle in a horizontal position remove the filler plug P21K6000ET10 P21K6001ET10 2 Checkthe oil level with a finger wire etc SPECIFIED VALUE From lower edge of filler plug hole 0 to 5mm Filler plug 3 If the oil is not filled to the specified level set an oil tray Oil under the filler plug and slowly fill gear oil f surface E CAUTION l in e f oil is filled quickly the oil may overflow before it reaches to the specific level Fill oil slowly and be sure if oil is completely filled 4 After you confirm if the gear oil is filled to the specified level by follo
6. Fill manual tramission Ay oil Refer to Page F2 2 F2 16 7 SHIFT LEVER 7 1 REMOVAL AND INSTALLATION 7 1 1 ARTICLES TO BE PREPARED Lubricants bonds and others MP grease 7 1 2 OPERATION BEFORE REMOVAL 1 Lift up the vehicle 7 1 3 REMOVAL AND INSTALLATION PROCEDURES 1 Components T 18 243 4 185435 T 18 2 3 4 185435 T 18 243 4 185435 P21K6017ES30 Unit N m kgf cm X Non reusable parts MP grease 2 Removal and installation procedures 1 a Clamp transmission control cable 6 f Washer plate 4 2 b Knob S A shift lever 7 g Clip 3 c Cover console box hole 8 h Cable Ay transmission control 4 d Box Ay console RR UPR 9 i Shift Ay transmission floor 5 e Clip 10 j Lever shift F2 17 7 1 4 POINTS OF INSTALLATION 1 Knob S A shift lever 1 Install the knob 2 Screw in the knob until it comes in contact lightly with the shift lever Retighten the knob a further 1 5 turns Then adjust the direction of the shift pattern by turning it in the retightening direction 7 1 5 OPERATION AFTER INSTALLATION 1 Lift down the vehicle F2 18 8 SHIFT CABLE AY AND SELECT CABLE AY 8 1 REMOVAL AND INSTALLATION 8 1 1 OPERATION BEFORE REMOVAL 1 Remove the console box Ay RR UPR 2 Lift up the vehicle 8 1 2 REMOVAL AND INSTALLATION PROCEDURES 1 Components P21K6018ES25 X Non reusable parts Unit N m kgf cm
7. P21K6015ES20 Unit N m kgf cm X Non reusable parts Transmission gear oil 2 Removal and installation procedures 1 a Plate speedometer sleeve lock v a 6 f Seal type Koil 2 b Speed sensor set 47 gRing O 3 c Sensor speedometer 4 d Sleeve speedometer shaft a 5 e Gear S A speedometer driven F2 12 5 1 4 POINTS OF REMOVAL 1 Seal type K oil 1 Before removing the seal insert the SST into the speed ometer shaft sleeve and leave a reference mark for rein stallation SST 09201 01080 000 2 Remove the seal from the soeedometer shaft sleeve us ing a piece of wire etc 5 1 5 INSPECTION 1 Check the following items Replace any faulty part 1 Check the shaft section and gear section of the speedometer driven gear S A for wear and damage 2 Check the speedometer shaft sleeve for damage 5 1 6 POINTS OF INSTALLATION 1 Ring O SST 4 Put a mark W13K5002ET10 P21K6090T10 Damage wear W13K5003ET10 1 Apply the transmission gear oil to the ring Then install the ring to the soeedometer shaft sleeve LUBRICANT Transmission gear oil SAE75W 90 or SAE75W 85 or SAE75W 80 API Classifi cation GL3 or GL4 2 Seal type K oil 1 Install the seal 1 Apply MP grease to the entire periphery of the seal lip area 2 Referring to the mark left at the time of removal in stall the seal to the speedometer shaft sleeve using the SST LUBRICANT MP grease S
8. ST 09201 01080 000 Oil s al N W13K5004ET10 F2 13 3 Gear S A speedometer driven 1 Apply the transmission gear oil to the entire periphery of the shaft of the gear S A Then install it to the soeedometer shaft sleeve LUBRICANT Transmission gear oil SAE75W 90 or SAE75W 85 or SAE75W 80 API Classifi cation GL3 or GL4 5 1 7 OPERATION AFTER INSTALLATION 1 Connect the connector to the soeedometer sensor 2 Connect the negative terminal of the battery F2 14 6 BACK UP LAMP SWITCH 6 1 REMOVAL AND INSTALLATION 6 1 1 ARTICLES TO BE PREPARED Instrument Electrical tester Lubricants bonds and others Transmission gear oil SAE75W 90 or SAE75W 85 or SAE75W 80 API Classification GL3 or GL4 6 1 2 OPERATION BEFORE REMOVAL 1 Drain the oil from the manual transmission Ay Refer to Page F2 2 6 1 3 REMOVAL AND INSTALLATION PROCEDURES 1 Components T 131 947 3 325 4 74 5 a Unit N m kgf cm X Non reusable parts 2 Removal and installation procedures 1 a Switch Ay back up lamp 6 1 4 INSPECTION P21K6016ES20 Check the following items Replace any faulty part 1 Ensure that continuity exists when the switch of the backup lamp switch Ay is pressed ON Conversely ensure that no continuity exists when the switch is not pressed OFF L21K6012ET10 F2 15 6 1 5 OPERATION AFTER INSTALLATION 1
9. ge D2 17 4 Remove the engine under cover Refer to Page 12 11 5 Remove the clutch release cylinder Ay Refer to Page F1 11 6 Disconnect the transmission control cable Ay on the transmission side Refer to Page F2 18 7 Disconnect the connectors 8 Remove the starter Ay Refer to Page B11 2 F2 5 3 1 3 REMOVAL AND INSTALLATION PROCEDURES 1 Components lt 2WD gt T 58 8 9 8 600 99 T 36 8 7 3 875 74 T 36 8 7 3 375474 7 37 34 11 2 3804114 T 48 1 13 7 490 139 lt 4WD gt T 48 1 13 7 490 139 T 37 3 11 2 380 114 P21K6020ES40 Unit N m kgf cm X Non reusable parts 2 Removal and installation procedures v 144 gt gt gt b Cover clutch housing under c Transmission Ay d Transfer Ay 4WD e Gasket transfer 4WD akKWNDN a Member S A engine support RR v a 6 f Bearing needle 4WD 7 g Bracket engine mounting RR 2WD 3 1 4 POINTS OF REMOVAL 1 Member S A engine support RR 1 Install engine hunger No 1 and No 2 with the bolts to the locations shown in the illustration 2 With the chain block etc and the engine slinger device installed to the engine hanger hold the engine Ay SST 09090 04020 000 3 Support the manual transmission Ay using a high mis sion jack TOOL High transmission jack CAUTION e
10. ide 3 Using the high mission jack press fit the installation sur faces of the engine and the transmission Ay The clear ance should be 2mm or less 4 Tighten Bolts A B and D TIGHTENING TORQUE 58 8 9 8N m 600 99kgf cm Bolts A B and D P21K6010T10 5 Tighten Bolt C TIGHTENING TORQUE 36 8 7 3 N m 3752474 Bolt C C P21K6011ET10 F2 8 3 1 6 OPERATION AFTER INSTALLATION 1 8 g Attach the starter Ay Refer to Page B11 2 Connect the connectors Connect the transmission control cable Ay Refer to Page F2 18 Attach the clutch release cylinder Ay Refer to Page F1 11 Attach the engine under cover Refer to Page 11 12 Remove the propeller shaft Ay w center bearing Refer to Page D2 17 Fill the manual transmission Ay oil Refer to Page F2 2 Lift down the vehicle Connect the negative terminal of the battery 10 Check that there is no oil leakage F2 9 4 EXTENSION HOUSING OIL SEAL 2WD 4 1 REMOVAL AND INSTALLATION 4 1 1 ARTICLES TO BE PREPARED SST Part No Part name 09308 00010 000 Puller oil seal Q 09309 87201 000 Replacer transmission bearing Grease bond etc Transmission gear oil SAE75W 90 or SAE75W 85 or SAE75W 80 API Classification GL3 or GL4 MP grease 4 1 2 OPERATION BEFORE REMOVAL 1 Remove the propeller shaft Ay w center bearing Refer to Page D2 17 4
11. wing Step 2 tighten the filler plug to the specified torque CAUTION e If the oil level is low check for oil leakage Never reuse the gasket TIGHTENING TORQUE 39 2 9 8N m 400 99kgf cm L31K5052ET10 2 Oil leakage check 1 Visually check if there is no oil leakage from the oil seal section plug section case mating surface etc F2 2 2 TRANSMISSION GEAR OIL 2 1 REPLACEMENT 2 1 1 ARTICLES TO BE PREPARED Lubricants bonds and others Transmission gear oil SAE75W 90 or SAE75W 85 or SAE75W 80 API Classification GL3 or GL4 Wire 2 1 2 REPLACING PROCEDURE 1 Removal Filler plug 1 Place an oil tray under the drain plug 2 Remove the drain plug Then remove the filler plug 3 Confirm that oil is completely drained from the manual transmission 4 Tighten the drain plug to the specified torque CAUTION Drain plug e Never reuse gasket of the drain plug ro TIGHTENING TORQUE 39 2 9 8N m 400 99kgf cm P21K6002ET10 P21K6003ET10 2 Filling 1 Place the vehicle horizontally 2 Remove the filler plug 3 Push the gear oil filling nozzle into the filler plug hole Then slowly fill gear oil CAUTION e f oil is filled quickly the oil may overflow before it reaches to the specific level Fill oil slowly and be sure if oil is completely filled LUBRICANT Transmission gear oil SAE75W 90 or SAE75W 85 or SAE75W 80 API Classifi cation GL3 or GL4
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