Transmission (m035s5) HD65,72,78

MANUAL TRANSMISSIONTRANSMISSION PROPER SHIFT RAIL AND SHIFT FORK COUNTER SHAFT GEAR SHIFT UPPER REAR COVER AND CLUTCH HOUSING... SPECIFICATIONS E2D7C70F Gear ratio API GL-4 SAE 90 Tropic

MANUAL TRANSMISSION

TRANSMISSION PROPER

SHIFT RAIL AND SHIFT FORK

COUNTER SHAFT GEAR SHIFT UPPER REAR COVER AND CLUTCH HOUSING

SPECIFICATIONS E2D7C70F

Gear ratio

API GL-4 SAE 90 (Tropics)

SERVICE STANDARDS

Item

Nominal value (Basic diameter

in [ ])

Clearance between speedometer gear and

Clearance between reverse idler gear shaft

Clearance between shifting key and

Clearance between 2nd gear and

Clearance between synchronixer outside ring

Clearance between shifting key and

Nominal value (Basic diameter

in [ ])

-Unit : mm

TIGHTENING TORQUE

Tightening torque Item

Transmission and engine mounting bolt

SPECIAL TOOL EFBA7CAA

09431-45100

Oil seal installer

EMTTM5227A

Installation of clutch housing oil seal

09431-5H000

Oil seal installer

EMTTM5227A

Installation of front bearing retainer oil seal

09432-5H100

Main shaft bearing installer

EMTTM5228A

Installation of main shaft bearing

09432-7B000

Counter shaft bearing installer

EMTTM5229A

Counter shaft bearing

09431-83100

Bearing puller set

Removal of main shaft bearing amd counter shaft bearing

MANUAL TRANSMISSION

DESCRIPTION E690FCB1

2

1

3

4 5

6

7

8 9

1 Drive pinion

2 4th & 5th synchronizer assembly

3 Shift rail

4 2nd & 3rd synchronizer assembly(Plunger type)

5 Shift fork

6 1st & Rev Synchronizer assembly

7 Main shaft

8 Idler gear

9 Counter shaft

EMTTM5201A

The transmission system transmits the rotational power

generated by the engine to that(driving force) for a vehicle

It changes the rotational power by selecting one among

many sets of gears in mesh.The transmission has the

in-terlock mechanism protecting the double mesh and the

non-backlash mechanism lowering the noise while the

en-gine is idling

REMOVAL E382D00C

1 Place the wooden block(A) to the front and rear sides

of the both(LH/RH) sides rear wheels

A

KMTTM5513A

2 Disconnect battery (-) cable(A) from the battery

A

EMTTM5002A

3 Lift up the cab

CAUTION Insert suerly the safety pin(B) into the cab stay(A) hole to prevent the cab from lowering.

A B

EMTTM5003A

4 Disconnect the speed sensor connector, the crank position sensor, battery (-) cable and back-up switch connector from the transmission

5 Remove the shift cable and the select rod(A) from the transmission

NOTE

Put the transmission to the neutral position before re-moving the shift cable and the select rod from the transmission.

A

6 Remove the release cylinder(A) from the

transmis-sion

A

EMTTM5517B

7 Remove the speed cable(A) from the transmission

8 Remove the propeller shaft(B) from the transmission

A

B

KMTTM5518A

9 Support the transmission(A) with a jack(B) and re-move the body mounting bolts and engine mounting bolts Then remove the transmission from the engine

CAUTION

Be careful not to fall down the transmission.

B

A

KMTTM5519A

NOTE

If the transmission is not separated from the engine, detach the transmission by inserting a flat drive(A) into grooves(three locations) on the clutch housing.

A

EMTTM5004A

INSTALLATION EDD07758

Installation is the reverse of removal

CAUTION

Be careful not to fall down the transmission.

TRANSMISSION PROPER

DISASSEMBLY AND REASSEMBLY EDD3FACD

4

5

9

12

10

13

15

14

3

7 8

11

2

1

6

Disassembly sequence

1 Bolt

2 Oil seal

3 Front bearing retainer

4 Snap ring

5 Bolt

6 Transmission case

7 Bolt

8 Bearing retainer

9 Shift rail & shift fork

10 Counter shaft

11 Drive shaft

12 Main shaft

13 Snap ring

14 Sealing cap

15 Clutch housing Reassembly sequence

15→14→13→12→11→10→4→9→8→7→6→5

3→2 →1

KEY POINTS FOR INSTALLATION E2C53A5D

1 Oil seal installation

After applying grease to the oil seal, install the oil

seal into front bearing retainer, using the special

tool(09431-5H000)

Lip

Front bearing retainer 09431-5H000

EMTTM5203A

2 Front bearing retainer installation

Guide oil seal guide on drive pinion and install front

bearing retainer

Oil seal

Drive pinion

EMTTM5204A

3 Transmission case removal

1) After removing bolts, remove clutch housing, main shaft assembly, counter shaft assembly and transmission case by crane etc

EMTTM5205A

2) After removing transmission case, fix 2nd gear part with steel lifting band

Counter shaft

Shift rail & fork Main shaft

EMTTM5206A

SHIFT RAIL AND SHIFT FORK

REMOVAL E5129C9D

1 Remove and install shift rail, shift fork, counter shaft,

drive pinion, main shaft with assembly

2 Insert set pin to counter shaft constant mesh gear

setting hole and fix sub gear

3 After removing case, fix with steel lifting band

4 Fix shift rail and shift fork on main shaft with rubber

band

5 Lift up and remove clutch housing with drive pinion

assembly

EMTTM5207A

INSTALLATION EA0BE5AD

1 Not to damage oil seal of front bearing retainer, after

covering oil seal guide on drive pinion, install each

part

Clutch housing

Drive pinion

2 When inserting drive pinion(A), main shaft assem-bly(B) and counter shaft assembly(C), install synchro guard

C

A B

EMTTM5209A

3 After applying grease on sealing cap, install using the special tool(09431-45100)

09431-45100

EMTTM5210A

DISASSEMBLY ECAC8C38

C B A

1

2 15

12

5

10 11

13

8 9

7

2

1

4 3

Disassembly sequence

1 Spring pin

2 4th & 5th shift fork

3 Spring pin

4 4th & 5th shift rail jaw

5 4th & 5th shift rail

6 Spring pin

7 2nd & 3rd shift fork

8 Spring pin

9 2nd & 3rd shift rail jaw

10 2nd & 3rd shift rail

11 Spring pin

12 1st & Rev shift fork

13 Spring pin

14 1st & Rev Shift rail jaw

15 1st & Rev Shift rail

* For reassembly of parts with an encircled number, replace the parts

with new ones after disassembly

SERVICE KEY POINTS

1 Be sure to install the spring pin as shown figure

EMTTM5212A

2 Measure the clearance between gear shift fork and

synchronizer sleeve If the clearance exceeds the

ser-vice limit, replace the parts

A

Shift fork

EMTTM5213A

MAIN SHAFT

MAIN SHAFT ASSEMBLY E28ABDD1

Drive pinion

10 11 14

19 20 21 22

23 24 27

26 25 23 22

28

15 13

12 14

11

16 17 18

29

8 9

32

31 30

7

6

4

3

2 1

5

Disassembly sequence

1 Bearing

2 1st gear thrust washer

3 1st gear

4 Needle bearing

5 Snap ring

6 Synchronizer sleeve

7 Synchronizer hub

8 Reverse gear

9 Needle bearing

10 Snap ring

11 Synchronizer ring

Reassembly sequence

32→31→30

→21→20→19→18→17→16

→10→9→8→7→6→5→4→3→2→1

15→12→13→14→11

29→26→27→28→25→24→23→22

12 Synchronizer sleeve

13 Shifting key

14 Shifting key spring

15 Synchronizer hub

16 5th gear

17 Snap ring

18 2nd gear thrust washer

19 2nd gear

20 Needle bearing

21 Snap ring

22 Synchronizer inner ring

23 Synchronizer center cone

24 Synchronizer outer ring (2nd)

25 Synchronizer outer ring (3rd)

26 Synchronizer sleeve

27 Shifting plunger

28 Synchronizer spring

29 Synchronizer hub

30 3rd gear

31 Needle bearing

32 Main shaft

SERVICE KEY POINTS

1 End play of each gear

A : 1st gear

B : Reverse gear

C : 2nd gear

D : 3rd gear

E : 5th gear

If the end play exceeds the service limit, replace the

parts

EMTTM5215A

2 Measure the play in diametral direction of main shaft

gears and needle roller bearing If the play exceeds

the service limit, replace the parts

EMTTM5216A

3 Remove snap rings(B) from the main shaft using a

snap ring plier(A)

A

B

EMTTM5217A

4 Measure the clearance between synchronizer ring(A)

or synchronizer outer ring and shafting key(B)

If the clearance exceeds the service limit, replace the parts

A

B

A

EMTTM5218A

5 Measure the clearance(A) between synchronizer ring and each gear assembly

If the clearance exceeds the service limit, replace the parts

A

5th gear Synchronizer ring

6 Measure the clearance between shifting key and

syn-chronizer hub If the clearance exceeds the service

limit, replace the parts

Synchronizer hub

Shifting key

Clearance

EMTTM5220A

7 Measure the clearance(A) between each gear

assem-bly and synchronizer outer ring If the clearance

ex-ceeds the service limit, replace the parts

2nd & 3rd gear

Inner ring

Center cone

Synchronizer

outer ring

A

EMTTM5221A

8 Remover the snap ring

Snap ring plier

9 Remove the drive pinion bearing using the special service tool(09431-83100)

09431-83100 Driven pinion Drive pinion bearing

EMTTM5223A

10 Reassembly is the reverse of disassembly

COUNTER SHAFT

DISASSEMBLY AND REASSEMBLY E9FB3D72

1

3

2

4

Disassembly sequence

1 Counter shaft front bearing

2 Snap ring

3 Counter shaft assembly

4 Counter shaft rear bearing

EMTTM5222A

1 Remove the snap ring using a snap ring plier

Snap ring plier

Snap ring

EMTTM5232A

2 Counter shaft rear bearing

Remove the counter shaft bearing using the spe-cial service tool(09431-83100 or 09434-5H000)

09431-83100 or 09432-5H000

2) Installation

Installation the counter shaft bearing using the

special service tool(09434-5H100)

C

A B

EMTTM5209A

GEAR SHIFT UPPER

REMOVAL AND INSTALLATION E4875B17

1

6 7 8 9

5

2

3

4

Removal sequence

1 Bolt

2 Gear shift upper assembly

3 Backup lamp switch

4 Screw plug

5 Inter lock pin

6 Bolt

7 Poppet spring plate

8 Poppet spring

9 Steel ball

EMTTM5224A

DISASSEMBLY AND REASSEMBLY E05C1ED3

5 3 4

6

1 9

16

2 15

17 18

19

8

7 13

14

11 10 12

Disassembly sequence

1 Air breather

2 Interlock switch

3 Nut

4 Lock pin

5 Gear select lever B

6 Washer

7 Gear select lever A

8 Spring pin

9 Torsion shaft

10.Spacer

Reassembly sequence

Reassembly is reverse of the disassembly procedure

11 4th & 5th return spring

12 Gear shift slide lever

13 Spring retainer

14 1st & Rev.return spring

15 Spring retainer

16 Oil seal

17 Oil seal

18 Bush

19 Select lever case

REAR COVER AND CLUTCH

HOUSING

REAR COVER AND REVERSE IDLER

GEAR E476ECF2

2 3

4

5 6

1

9

11

13

12

10

7 8

Removal sequence

1 Pulse generate

2 Bolt

3 Oil seal

4 Rear cover

5 Spacer

6 Pin

7 Bolt

8 Reverse idler gear cover

9 Reverse idler gear shaft 10.Side washer

11.Side washer 12.Reverse idler gear 13.Transmission case

Reassembly sequence

13→10→12→11→9→8→7→6→5

4→3 →2→1