Install Snap Ring
Select a snap ring, which will allow 0-0.1 mm 0 0.004 in. axial play and install it on the shaft. 2 95 - 3 00 0.1161-0 11811 3.00 - 3.05 0.1181-0 12011 3.05-3.10 0.1201 -0.12201 3.10 - 3.15 0 1220-0 1240 3.15-3 20 lt 0.1240-0 12601 2.70 - 2.75 10.1063-0 10S3I 2.75 - 2.80 10.1083-01102 2.80 - 285 101102-0.1122 2.85 - 2.90 lt 0.1122-0.1142 290-295 lt 01142-0 1161
Install Fifth Gear And Spacer
a Install the spacer for the needle roller bearing. b Place the synchronizer ring on the gear, c Place the roller bearing in the gear. Id Install the 5th gear on the output shaft with the synchronizer ring slots aligned with the shifting keys. e Install the locking ball in the shaft. f Fit the spacer groove securely over the locking ball when installing the spacer on the shaft. Using a press and SST, install the rear bearing on the out CAUTION Support the 5th gear and inner race by hand. NOTE...
Bleeding Of Clutch System
NOTE If any work is done on the clutch system or if air is suspected in the clutch lines, bleed the system of air. CAUTION DO NOT let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL CLUTCH RESERVOIR WITH BRAKE FLUID Check the reservoir frequently. Add fluid if necessary. 2. CONNECT VINYL TUBE TO BLEEDER PLUG Insert the other end of the tube in a half full container of brake fluid. a Slowly pump the clutch pedal several times. b While depressing the pedal, loosen the...
Check And Adjustment Of Clutch Pedal
1. CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet LHD 161-171 mm 6.34-6.73 in. RHD 162 - 172 mm 6.38 - 6.77 in. 2. IF NECESSARY, ADJUST PEDAL HEIGHT a Remove the instrument lower finish panel and air duct. b Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. 3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD PLAY ARE CORRECT Push in on the pedal until the beginning of clutch resis tance is felt. Pedal freeplay 13 - 23 mm 0.51 - 0.91 in....
Install Shift Fork And Shaft
a Assemble the shaft with their locking ball grooves positioned toward the top of case. b Insert each shaft through each fork and push in up to the neutral position. Shift Fork and Shaft No. 2 No 1 No. 3 Shift Fork and Shaft No. 2 No 1 No. 3 c Install the fork shafts and forks in the following order. Fork shaft No. 2 and shift fork No. 2 Fork shaft No. 1 and shift fork No. 1 Fork shaft No. 3 and shift fork No. 3 d Shift the fork shaft No. 2 to the 3rd speed position. e Fork shaft No. 1 and No....
Replacement Of Lower Arm Dust Cover
Remove the dust cover set wire and dust cover. a Apply ball joint grease to areas A and B of a new dust cover. b Install the dust cover with escape valve C facing the rear of the vehicle. c Wind wire twice around the dust cover and bend the wire knot down. d Remove the plug and install the grease fitting, el Fill with ball joint grease. Molybdenum Disulphide Lithium Base Grease NLGI No. 1 or No. 2 f Remove the grease fitting and install the plug.
Install Wheel Alignment Equipment
Follow the specific instructions of the equipment manufacturer. INSPECT CAMBER AND STEERING AXIS INCLINATION INSPECT CAMBER AND STEERING AXIS INCLINATION If camber or steering axis inclination checks are out of tolerance, inspect and replace damaged or worn front suspension parts. If caster is out of tolerance, adjust the caster with the staked nuts of the strut bar. Torque 925 kg-cm 67 ft-lb NOTE Decrease caster by lengthening the strut bar. Increase caster by shortening the strut bar. One...
Inspection Of Ball Joints
1. INSPECT BALL JOINTS FOR EXCESSIVE LOOSENESS a Jack up the front of the vehicle and place wooden blocks with a height of 180 200 mm 7.09-7.87 in.l under one front tire. b Lower the jack until there is about half a load on the front coil springs. Place stands under the vehicle for safety. c Make sure the front wheels arc in a straight forward position and block them with chocks. d Move the lower arm up and down and check that the ball joint has no excessive play. Maximum ball joint vertical...
Troubleshooting
Clutch disc out of true, lining greasy or broken Splines on input shaft or clutch disc dirty or burred Inspect clutch disc Repair as necessary Push Rod Play and Freeplay Adjust Point Push Rod Play and Freeplay Adjust Point