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MANUAL TRANSMISSION Return To Main Table of Contents GENERAL MANUAL TRANSMISSION CONTROL MANUAL TRANSMISSION 13 MANUAL TRANSMISSION ASSEMBLY 15 INPUT SHAFT 30 INTERMEDIATE SHAFT 34 OUTPUT SHAFT 35 DIFFERENTIAL 38 CLUTCH HOUSING 41 SPEEDOMETER SLEEVE ASSEMBLY 45 GENERAL GENERAL SPECIFICATIONS Manual transmission Type Gear ratio 1st 2nd 3rd 4th Reverse Final reduction ratio 4-speed, Floor-shift control 4.266 2.365 1.467 1.105 4.109 3.470 Type Gear ratio 1st 2nd 3rd 4th 5th Reverse Final gear ratio 5-speed, Floor-shift control 4.266 2.365 1.467 1.105 0.955 4.109 3.470 Speedometer gear ratio Quantity of oil lit (U.S.qts., Imp.qts.) Backlash between differential side gear and pinion Differential case end play Intermediate shaft end play Output shaft pre-load Clearance between 5th shift lug and 3-4 speed shift lug (5-speed only) Drive 19/Driven 16 2.1 (2.2, 1.8) 0.025-0.150 mm (0.001-0.006 in.) Adjust with spacer 0-0.15 mm (0-0.006 in.) Adjust with 0-0.05 mm (0-0.002 in.) Adjust with 0.15-0.20 mm (0.006-0.0078 in.) Adjust with 0-0.4 mm (0-0.016 in.) Adjust with selector SERVICE STANDARD Manual transmission Standard value Free play of range selector lever end Approx mm (0.2 in.) Spacer for differential pinion backlash adjustment Thickness 0.75-0.82 mm (0.0295-0.0323 0.83-0.92 mm (0.0327-0.0362 0.93-1.00 mm (0.0366-0.0394 1.01-1.08 mm (0.0398-0.0425 1.09-1.16 mm (0.0429-0.0457 1.17-1.25 mm (0.0460-0.0492 1.26-1.34 mm (0.0496-0.0527 Spacer for differential case end play adjustment 1.31 mm (0.0516 in.)-E Thickness-ldent mark 1.40 mm (0.0551 in.)-None 1.49 mm (0.0587 in.)-C 43-2 in.) in.) in.) in.) in.) in.) in.) spacer spacer spacer spacer GENERAL 1.58 mm (0.0622 in.)-B 1.67 mm (0.0657 in.)-A 1.76 mm (0.0693 in.)-F 1.85 mm (0.0728 in.)-G 1.94 mm (0.0764 in.)-H 2.03 mm (0.0799 in.)-1 2.12 mm (0.0835 in.)-J 2.21 mm (0.0870 in.)-K Snap ring for input shaft Thickness-ldent color Spacer for intermediate and outputshaft end play or preload adjustment Thickness Selector spacer for shift lug clearance (5-speed only) Thickness-ldent mark 2.24 mm (0.0882 in.)-None 2.31 mm (0.0909 in.)-Bule 2.38 mm (0.0937 in.)-Brown 1.84 1.87 1.90 1.93 1.96 1.99 2.02 2.05 2.08 2.11 2.14 2.17 2.20 2.23 2.26 2.29 2.32 2.35 2.38 2.41 2.44 2.47 2.50 2.53 2.56 2.59 2.62 2.65 2.68 mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm (0.0724 (0.0736 (0.0748 (0.0760 (0.0772 (0.0783 (0.0795 (0.0807 (0.0819 (0.0831 (0.0843 (0.0854 (0.0866 (0.0878 (0.0890 (0.0902 (0.0913 (0.0925 (0.0937 (0.0949 (0.0961 (0.0972 (0.0984 (0.0996 (0.1008 (0.1020 (0.1031 (0.1043 (0.1055 in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) 0.6 mm (0.024 in.)-G 0.9 mm (0.035 in.)-F 1.2 mm (0.047 in.)-E 1.5 mm (0.059 in.)-D 1.8 mm (0.071 in.)-C 2.1 mm (0.083 in.)-B 2.4 mm (0.094 in.)-A 2.7 mm (0.106 in.)-None 43-3 GENERAL TIGHTENING TORQUE Nm Manual transmission Extension to transmission Shift rod set screw Insulator to extension rod Bracket assembly attaching bolt Control cable attaching bolt Control cable clamp attaching bolt Transmission mounting bolt Starter motor mounting bolt Bell housing cover to transmission (8 x 20)* Bell housing cover to transmission (8 x 14)* Engine transmission Clutch cover bolt Transmission mounting bolt (M10-7T) Transmission mounting bolt (M8-10T) Front cover bolt Oil filler plug Oil drain plug Housing-to-case tightening bolt Front retainer bolt Input shaft locking nut Transmission mounting bracket bolt Differential drive gear bolt Speedometer sleeve plate bolt Reverse shift lever support bracket bolt Poppet plug bolt Backup lamp switch Ib.ft kg.cm 60-70 33 12-15 9-14 9-14 9-14 43-55 22-32 15-22 10-12 610-710 43-51 337 24 120-150 9-11 90-140 6.5-10 90-140 6.5-10 440-560 31-40 440-560 31-40 220-330 16-23 150-220 11-16 100-120 7-9 Refer to the table of components 15-21 150-210 11-15 43-53 440-540 32-39 30-34 300-350 22-25 10-11 100-110 7-8 30-34 300-350 22-25 30-34 300-350 22-25 30-41 300-420 22-30 15-21 150-210 11-15 89-107 900-1,100 65-79 30-41 300-420 22-30 128-137 1,300-1,400 94-101 3.0-4.5 30-45 2.5-3.5 15-21 150-210 11-15 27-33 270-340 20-24 30 310 22 NOTE *Bolt O.D x Length mm LUBRICANTS Manual transmission Manual transmission oil lit (U.S.qts., Imp.qts.) Shift lever, bushing contacting surface Dust cover inside surface Shift lever sliding portion 43-4 Recommended lubricant Quantity API classification GL-4 2.1 (2.2, 1.8) As required As required As required Wheel bearing grease SAE J310a, NLGI grade #2 EP GENERAL SPECIAL TOOLS 43-5 GENERAL Tool (Number and name) Illustration Use 09432-21300 Removing plate 1) Removal of the input shaft front bearing 2) Removal of the output shaft 2nd, 3rd and 4th gear 09432-21400 Taper bearing puller 1) Removal of the intermediate shaft taper bearing inner race 2) Removal of the output shaft taper bearing inner race 3) Removal of the transfer shaft taper bearing inner race 09432-21500 Bearing installer 1) Installation of the input shaft front bearing 2) Installation of the output shaft synchronizer hub and gear sleeve 09432-21600 Bearing installer 1) Installation of the input shaft rear bearing 2) Installation of the intermediate shaft front and rear bearing 3) Installation of the output shaft front and rear bearing 4) Installation of the taper roller bearing inner race of transfer shaft (use with 09500-21000) 09432-21700 Bearing outer race installer 1) Installation of intermediate shaft bearing outer race (use with 09500-21000) 2) Installation of output shaft bearing outer race (use with 09500-21000) 3) Installation of transfer shaft front bearing outer race (use with 09500-21000) 09433-21000 Removing plate 1) Removal of differential ball bearing (use with 09532-11301) 2) Removal of differential bearing 09437-31000 Shift lever remover Removal and installation of the shift lever knob 43-6 GENERAL Tool (Number and name) 09438-21000 Poppet ball guide Illustration Use Installation of the poppet ball 43-7 GENERAL TROUBLESHOOTING Symptom Transmission vibration Oil leakage Loose transmission assembly Does not shift to 5th (M/T) 43-8 Probable cause Remedy Broken gear shift control Replace Worn or pitting due to improper tooth Replace Housing misaligned Realign Worn seals or gaskets Replace parts as required Broken transmission mount Replace Mounting bolts loose Retighten bolts Malfunctioning actuator Repair or replace as required Malfunctioning vacuum control Replace Short circuit in vacuum control Replace MANUAL TRANSMISSION CONTROL MANUAL TRANSMISSION CONTROL COMPONENTS GEARSHIFT LEVER Removal Remove the floor console box On vehicles with rear heater duct, remove the rear heater duct Remove the shift lever assembly attaching nuts from the floor Pull the shift lever assembly downward from the vehicle Remove the extension rod from the transmission From March, 1987 MANUAL TRANSMISSION CONTROL After removing the lock wire, remove the shift rod set screw, and then remove the shift rod from the transmission Remove the shift rod and extension rod as an assembly Remove the dust cover at the end of the shift lever After the split pin has been removed, remove the shift rod 10 Remove the extension rod to insulator attaching bolt and remove the extension rod 11 Remove the dust cover and remove the bushing Inspection Check Check Check Check 43-10 the shift rod joint for wear, sticking or rough movement the rubber parts for damage or deterioration all bushings for wear and damage the return spring for deterioration ... 1 5-2 1 15 0-2 10 1 1-1 5 4 3-5 3 44 0-5 40 3 2-3 9 3 0-3 4 30 0-3 50 2 2-2 5 1 0-1 1 10 0-1 10 7-8 3 0-3 4 30 0-3 50 2 2-2 5 3 0-3 4 30 0-3 50 2 2-2 5 3 0-4 1 30 0-4 20 2 2-3 0 1 5-2 1 15 0-2 10 1 1-1 5 8 9-1 07 90 0-1 ,100 6 5-7 9 3 0-4 1 30 0-4 20... kg.cm 6 0-7 0 33 1 2-1 5 9-1 4 9-1 4 9-1 4 4 3-5 5 2 2-3 2 1 5-2 2 1 0-1 2 61 0-7 10 4 3-5 1 337 24 12 0-1 50 9-1 1 9 0-1 40 6. 5-1 0 9 0-1 40 6. 5-1 0 44 0-5 60 3 1-4 0 44 0-5 60 3 1-4 0 22 0-3 30 1 6-2 3 15 0-2 20 1 1-1 6 10 0-1 20 7-9 Refer... looseness 4 3-1 1 MANUAL TRANSMISSION MANUAL TRANSMISSION COMPONENTS Nm kg.cm Ib.ft A B C D 4 3-5 5 4 3-5 5 2 2-3 2 3 0-3 4 43 0-5 60 43 0-5 60 22 0-3 30 30 0-3 50 3 1-4 0 3 1-4 0 1 6-2 3 2 2-2 5 E F 1 0-1 2 1 5-2 2 10 0-1 20 15 0-2 20