TRANSMISSION (M6S6) GENERAL . TMa - 2 SPECIFICATIONS . TMa - 3 SERVICE STANDARDS TMa - 4 SPECIAL TOOLS TMa - 7 SERVICE PROCEDURE . TMa - 8 TROUBLESHOOTING TMa-42
TRANSMISSION(M6S6)GENERAL . TMa - 2SPECIFICATIONS . TMa - 3SERVICE STANDARDS TMa - 4SPECIAL TOOLS TMa - 7SERVICE PROCEDURE . TMa - 8TROUBLESHOOTING TMa-42 TMa-2-TRANSMISSION (M6S6)GENERALTRANSMISSION PROPERThe transmission changes the torque produced by the engine to atorque the vehicle requires. The torque, or drive power, is increasedor decreased by shifting several groups of gears.Since the engine always turns in one direction, the transmissionalso performs the function of changing the direction of rotation sothe vehicle can be backed.NOTE:This illustration shows a 5-speed transmission.Shift forkSynchromeshDrive pinionCostant mesh gear5th4th2nd3rd1stRev.5th4th1st2nd3rdRev.22AA0375 TMa-3SPECIFICATONSThe transmission gears are kept in constant mesh with the drivepinion by the constant-mesh gears, main shaft gears, and countershaft gears.The rotating motion imparted by the drive pinion to the constantmeshgears is transmitted to all main shaft gears which turn freely. Whenthe gearshift lever, the synchromesh function causes the synchronizersleeve to mesh with a gear to change the speed of rotation from thepinion and transmit it to the rear axle.The constant-mesh slide design is employed between the 1st andreverse gear.<Pin type>22AA037622AA03125th gearShifting keyspringSynchronizer hubSYNCHRONIZER ASSEMBLY<Key type>SynchronizersleeveSynchronizer ringSynchronizer cone 4th gearShifting keyTypeK3606.4533.6041.8131.0000.803-6.4535.5Floor shift, remote control typeSPECIFICATONSTRANSMISSION PROPER1st2nd3rd4th5th6thRev.GEAR RATIOOil capacity (with P.T.O)Transmission controlSynchronizer ringSleeveSynchronizerstemSynchronizer cone2nd gearSunchronizer hubShifting pinShifting ballShifting spring TMa-4-TRANSMISSION (M6S6)SERVICE STANDARDSSERVICE STANDARDS TABLENominal value(Basic diameter in [ ])Limit1st gear2nd gear3rd gear4th gear5th gear (drive pinion andconstant-mesh gear)Reverse gear Counter shaft Main shaft1st gear (main shaft)2nd gear (main shaft)3rd gear (main shaft)4th gear (main shaft)Reverse gear (main shaft)Reverse gear (reverse gear shaft)Play in diametric direction after assembly ofreverse gear needle bearingMainshaftPlay in diametric direction afterassembly of pilot bearing0.08 to 0.200.08 to 0.200.09 to 0.210.09 to 0.210.04 to 0.170.08 to 0.200.09 to 0.210.15 to 0.350.25 to 0.400.15 to 0.350.2 to 0.9--4.75 to 4.950.05 to 0.20T0.0069 to L0.0880.052 to 0.1481.45 to 1.85ReplaceCheck for damagedtooth surfaceReplace gear or washerReplace defective partsReplace defective partsReplaceReplaceRemedy and remarksMaintenance item2nd and 3rd synchronizer assemblysynchronizer ring to main shaft 3rd2nd gear assembly synchronizercone clearanceFit between 2nd and 3rd synchronizerhub and main shaft in turningdirection00.052 to 0.148T0.005 to L0.1071.50.30.2Unit: mmBacklashEnd playSyn-chro-meshkeytypeSynchronizer ring keyway to shiftingkey clearanceSynchronizer hub keyway to shiftingkey clearanceFit between synchronizer hub andmain shaft in turning directionPlay between synchronizer hub andsynchronizer sleeve in turningdirectionSynchronizer ring to main shaft 4thgear assembly gear cone clearance0.50.51.20.120.125.80.50.20.30.2Syn-chro-meshkeytype TMa-5SERVICE STANDARDSNominal value(Basic diameter in [ ])Maintenance item Limit-0.100.120.31.00.20.060.047.3 N (7.4 kgf)/27.60.150.361.00.60.60.642 N (4.3 kgf)/45.41st gear2nd gear3rd gear4th gearReverse gearShift fork to synchronizersleeve clearanceTilt of shift fork clawAlignment or bend ofshift rail1st and Rev.2nd and 3rd4th and 5th1st and Rev.2nd and 3rd4th and 5th1st and Rev.4th and 5th2nd and 3rdLoad/installedlength1st and Rev. return springSpeedometer gear bushing to speedometergear clearanceBacklahs between speedometer gear andspeedometer wormBall stud to housing clearanceHousing bushing to pipe A clearanceFront cross shaft to bushing clearanceRear cross shaft to bushingSpringLoad/installedlength0.1 or lessO.D.-0.030-0.043[55]-0.030-0.043MainshaftLowergearshiftUppergearshifterSpeedo-metergearTrans-missioncontrol-ReplaceReplaceReplaceCorret or replaceReplaceReplaceReplaceReplace ball stud orhousing, whicheveris wornReplace bushingReplace bushingReplace bushingReplaceRemedy and remarks2nd gear bearing sleeve3rd gear bearing sleeve4th gear bearing sleeveClearance in diametricdirection after assemblyof main shaft needleroller bearingPlay between synchronizer sleeve and mainshaft in turning direction0.03 or less0.02 or less85 N (8.7kgf)/27.6[12] 0.02 to 0.070.13 to 0.290.10 to 0.400.07 to 0.170.07 to 0.170.02 to 0.2552 N (5.3 kgf)/45.40.052 to 0.1480.3 to 0.5[68]ReplaceReplace defectiveparts. If two needleroller bearings areused for a gear, usebearings of the samepackage color forreplacement TMa-6-TRANSMISSION (M6S6)TIGHTENING TORQUE TABLEClutch housing boltGearshift upper mounting boltGearshift lower mounting boltGearshift fork set boltDrain plug and level plugMain shaft front lock nutMain shaft rear lock nutReverse shaft lock piece boltRear cover and extension housing boltBackup lamp switchSpeedometer gear bushingMounting bolt of transmission (clutch housing)onto engine (flywheel housing)Counter shaft rear lock nutRear bearing retainer mountingJaw set boltLock pin mounting nutSupport plate and shoe assembly ordust cover mounting boltFront mechanism housing boltSelect lever boltGearshift lever boltSelect rod and shift rod ball joint nutTighten ball jointsLocation tightenedM16 x 2.0M8 x 1.25M8 x 1.25M10 x 1.25M20 x 1.5M36 x 1.5M27 x 1.5M10 x 1.5M10 x 1.5M18 x 1.5M27 x 1.5M10 x 1.5M36 x 1.5M10 x 1.5M14 x 1.5M8 x 1.25M10 x 1.5M12 x 1.25M12 x 1.25M12 x 1.25M8 x 1.25M8 x 1.25M10 x 1.25Tightening torqueNm (kgfm)190 (19.2)23 (2.3)23 (2.3)29 (3.0)54 to 83 (5.5 to 8.5)245 (25)245 to 345 (25 to 35)40 (4.1)40 (4.1)49 (5.0)145 (15)40 (4.1)345 (35)40 (4.1)135 (13.6)17 (1.7)40 (4.1)48 (4.9)37 to 54 (3.8 to 5.5)36 (3.7)8.8 to 14 (0.9 to 1.4)19 to 27 (1.9 to 2.8)38 to 59 (3.9 to 6.0)Screw sizeO.D. x pitch (mm)TransmissionproperTransmissioncontrol TMa-7SPECIAL TOOLSTool nameShapeUsePuller set Removal of drive pinion andreverse shaftPart No.09431-83100ASST0030Unit: mmSPECIAL TOOLS TMa-8-TRANSMISSION (M6S6)22AA1335InspectionplugDrainplug22AA0381Interlock switchReturn springSERVICE PROCEDUREREMOVAL AND INSTALLATION OF TRANSMISSIONKey points for removal1) Detach the control rod and associated parts around thetransmission.2) Remove the power cylinder with hoses and pipes left attached.3) Remove the propeller shaft.4) Remove the drain plug and inspection plug to remove trans-mission oil. On vehicles with full-power PTO, removetransmission oil also from the PTO case.5) When draining the transmission oil, check the oil for quantity,quality, and metal chips and particles.The drain plug is magnet and metal particles adhering to itshould be removed after the inspection.22AA0004Hub and release bearingClutch housingClutch boosterDust plugCable bracketBackup lamp switch TMa-10-TRANSMISSION (M6S6)22AA1337Extension housing22AA0310(Vehicles with center parking brake)Socket WrenchTRANSMISSION ASSEMBLYDisassemblyDisassembly ProcedureUsing the Socket Wrench, remove the main shaft rear lock nut.Clutch housing(vehicles with C5 clutch)Clutch housing(vehicles with C6, C7 clutch)Reverse gearcoverLower gear shifterCompanionflangeParking brake drumParking brakeassemblyUpper gear shifter TMa-11SERVICE PROCEDUREReassembly22AA1338Drain plug54 to 83 Nm(5.5 to 8.5 kgfm)NOTEApply sealant (THREEBOND 1105D or equivalent) to threads ininspection and drain plugs.Upper gear shiftermounting bolt (8 places)23 Nm (2.3 kgfm)Lower gear shiftermounting bolt (11 places)23 Nm (2.3 kgfm)Main shaft rearlock nut245 to 345 Nm(25 to 35 kgfm)Rear cover mountingbolt (9 places)40 Nm (4.1 kgfm)Apply sealant(THREEBOND 1104Jor equivalentto mating surfacesApply sealant(THREEBOND 1215Jor equivalentto mating surfacesApply sealant(THREEBOND 1215 orequivalentto mating surfacesInspection plug and drain plugInspection plug54 to 83 Nm(5.5 to 8.5 kgfm) 123doc.vn