CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Symbols” on the
next page.)
1st title 1: This is a chapter with its symbol on the upper right of each page.
2nd title 2: This title appears on the top of the each page, to the left of the chapter symbol.
3rd title 3: This title precedes the paragraphs describing the working procedure.
All the procedures in this manual are organized in a sequential, step-by-step order. The infor-
mation has been compiled to provide the mechanic with an easy-to-read, handy reference that
contains comprehensive explanations of all disassembly, check, repair, and assembly proce-
dures.
Important procedures including removing, checking, and assembling steps 4are explained in
detail.
IMPORTANT FEATURES
¡Important engine data and information about special tools framed in a box together with
an illustrative symbol 5.
¡A circled numeral 6indicates a part name. A circled lower case letter indicates data or an
alignment mark 7.
¡An arrow 8indicates the course of action required to remedy the started condition of a
component.
EXPLODED DIAGRAM
Each chapter begins with exploded diagrams which facilitate correct disassembly and assem-
bly.
SHIM SELECTION (UPPER UNIT HOUSING)
R-gear Shim (T5) Adjustment
1. Use the guide, bearing puller 2 1and
the bearing puller 2to remove the bear-
ing outer race from the selector valve
housing.
NOTE:
¡When the bearing and the selector valve
housing are not replaced, DO NOT re-
move the bearing outer race.
¡When replacing the bearing, replace the
total inner and outer set.
¡Make sure that the bearing puller is set at
the position specified in the illustration.
Guide, bearing puller 2:
6U4-30-3
Bearing puller:
6U4-35
1
2
E
UPPER
UNIT
Drive shaft motive torque (A):
0.4 – 1.5 N·m
3. Loosen the front bearing housing bolts
to 1/2 rotation and measure pre-load B
(motive torque) of the drive shaft.
NOTE:
Measure resistance of the clutch disk section
as the pre-load B (motive torque).
4. Calculate the drive shaft pre-load (mo-
tive torque) based on the pre-load (mo-
tive torque) A and B.
Formula:
Drive shaft pre-load = pre-load (A) –pre-
load (B)
NOTE:
If the drive shaft pre-load (motive torque) is
greater than the specification, reduce the
shim T6b. If the drive shaft pre-load (motive
torque) is less than the specification, increase
the shim T6b.
4-27
T.R
Clamp screw:
3 N·m
BELLOWS AND HOSE INSPEC-
TION
1. Inspect:
¡Shift cable bellows 1
¡Exhaust bellows 2
¡Universal joint bellows 3
Cracks/Weathering/Damage →Re-
place.
Loose clamps 4→Tighten.
Refer to “SWIVEL BRACKET AND
BELLOWS”section (P7-7).
3
12
4
E
INSP
ADJ BELLOWS AND HOSE INSPECTION
UPPER UNIT HOUSING
3. After inserting the bearing outer race
with press, install the inner race. Use the
shimming tool, T5/T6a 1to measure the
clearance (Measurement B) between the
tool and the bearing with a thickness
gauge.
NOTE:
To have the clearance, measure the line be-
tween the point Aand Bon the bearing.
4. Find the stamped R-valve of the upper
gear case.
Shimming tool, T5/T6a:
6U4-28
A
B
1
B
E
UPPER
UNIT
16
8
7
2
3
4
5
⎧
⎪
⎪
⎪
⎨
⎪
⎪
⎪
⎩
