ManualTransmission

(M035S5)

GeneralSpecial Tool .................................................. MTB - 2Specification ................................................. MTB - 3

Manual TransmissionDescription.................................................... MTB - 5Removal ....................................................... MTB - 6Installation .................................................... MTB - 7Gear Shift Upper

Removal and Installation ........................ MTB - 8Disassembly and Reassembly ............... MTB - 9

Shift Rail and Shift ForkRemoval .................................................. MTB - 10Installation ............................................... MTB - 10Disassembly ........................................... MTB - 11

Rear Cover and Clutch HousingReplacement ........................................... MTB - 13

Transmission AssemblyDisassembly and Reassembly ............... MTB - 14

Main ShaftDisassembly and Reassembly ............... MTB - 16

Counter ShaftDisassembly and Reassembly ............... MTB - 19

GeneralSpecial Tool

Tool (Number and name) Illustration Use

09431-45100Oil seal installer

Installation of clutch housing oil seal

09431-5H000Oil seal installer

Installation of front bearing retainer oilseal

09432-5H100Main shaft bearing installer

Installation of main shaft bearing

09432-7B000Counter shaft bearing installer

Counter shaft bearing

09431-83100Bearing puller set

Removal of main shaft bearing amd c-ounter shaft bearing

SpecificationsItem Specification

Gear ratio

First 5.380

Second 3.028

Third 1.700

Fourth 1.000

Fifth 0.722

Rev 5.380

Transmission gear oil API GL-4 80W90API GL-4 SAE 90 (Tropics)

Oil quantity (ℓ) Approx. 3.2 (without P.T.O)Approx. 3.7 (with P.T.O)

Service Standards

Item Nominal value(Basic diameter in [ ]) Limit Remarks

Poppet spring free length 22.85 22 Replace

4th & 5th return spring free length 39.25 37.25 Replace

1st & Rev. return spring free length 49.18 47.18 Replace

Clearance between speedometer gear and speedometer g-ear bush [12] 0.04 ~ 0.08 0.15 Replace

Clearance between reverse idler gear shaft and reverse idl-er gear [24] 0.05 ~ 0.08 0.2 -

Diaplacement of bar with respect to shift fork hole 0.1 or less 0.2 Replace

Clearance between shift fork and synchronizer sleeve 0.3~0.6 1 Replace

Displacement of shift rail 0.04 or less 0.05 Replace

Clearance between synchronizer key hole and shift key 4.7~5.0 5.7 Replace

Clearance between synchronizer ring and drive pinion 1.13~1.37 0.20 Replace

Clearance between shifting key and synchronizer hub keyhole 0.05~0.20 0.50 Replace

Clearance between 2nd gear and synchronizer outside ring 1.23~1.47 0.95 Replace

Clearance between synchronixer outside ring key hole andshifting key 4.7~5.0 5.70 Replace

Clearnce between synchronizer outer ring and 3rd gear 1.23~1.47 0.95 Replace

Clearance between shifting key and synchronizer hub keyhole 0.05~0.20 0.50 Replace

1st gear end play 0.310~0.460 - -

2nd gear end play 0.150~0.250 - -

3rd gear endplay 0.160~0.460 - -

Item Nominal value(Basic diameter in [ ]) Limit Remarks

5th gear end play 0.210~0.560 - -

Reverse gear end play (C/S~REV. IDLER) 0.220~0.680 - -

Reverse gear end play (REV. IDLER~M/S) 0.160~0.460 - -

Unit : mmTightening Torque

ItemTightening torque

Nm Kgf.m lb-ft

Drain plug and inspection plug 54 ~ 83 5.5 ~ 8.5 39.8 ~ 61.2

Transmission and engine mounting bolt 48 4.8 35.4

84 8.4 62

Gear shift upper mounting bolt 24 2.4 17.7

Back up lamp switch 30 ~ 40 3 ~ 4 22.1 ~ 29.5

Poppet screw plug 40 4 29.5

Poppet spring plate 24 2.4 17.7

Interlock switch 46 ~ 52 4.7 ~ 5.3 33.9 ~ 38.4

Lock pin nut 7 0.7 5.2

Speedometer 29.4 ~ 39 3.0 ~ 4.0 21.7 ~ 28.8

Rear cover 45 4.5 33.2

Reverse idler gear cover 19 1.9 14

Front bearing retainer 44 4.5 32.5

Transmission case 54 5.5 39.8

Bearing retainer 49 5 36

Manual TransmissionDESCRIPTION

EMTTM5201A

The transmission system transmits the rotational powergenerated by the engine to that(driving force) for avehicle. It changes the rotational power by selecting oneamong many sets of gears in mesh.The transmission hasthe interlock mechanism protecting the double mesh andthe non-backlash mechanism lowering the noise while

the engine is idling.

REMOVAL1. Place the wooden block(A) to the front and rear sidesof the both(LH/RH) sides rear wheels.

KMTTM5513A

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

EMTTM5002A

3. Lift up the cab.

CAUTIONInsert suerly the safety pin(B) into the cabstay(A) hole to prevent the cab from lowering.

EMTTM5003A

4. Disconnect the speed sensor connector, the crankposition sensor, battery (-) cable and back-up switchconnector from the transmission.

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

NOTICEPut the transmission to the neutral position beforeremoving the shift cable and the select rod from thetransmission.

EMTTM5064A

6. Remove the release cylinder(A) from thetransmission.

EMTTM5517B

7. Remove the speed cable(A) from the transmission.8. Remove the propeller shaft(B) from the transmission.

KMTTM5518A

9. Support the transmission(A) with a jack(B) andremove the body mounting bolts and enginemounting bolts. Then remove the transmission fromthe engine.

CAUTIONBe careful not to fall down the transmission.

KMTTM5519A

NOTICEIf 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.

EMTTM5004A

INSTALLATIONInstallation is the reverse of removal.

CAUTIONBe careful not to fall down the transmission.

Gear Shift UpperRemoval and Installation

EMTTM5224A

Disassembly and Reassembly

EMTTM5225A

Shift Rail And Shift ForkREMOVAL1. Remove and install shift rail, shift fork, counter shaft,drive pinion, main shaft with assembly.

2. Insert set pin to counter shaft constant mesh gearsetting 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 rubberband.

5. Lift up and remove clutch housing with drive pinionassembly.

EMTTM5207A

INSTALLATION1. Not to damage oil seal of front bearing retainer, aftercovering oil seal guide on drive pinion, install eachpart.

EMTTM5208A

2. When inserting drive pinion(A), main shaftassembly(B) and counter shaft assembly(C), installsynchro guard.

EMTTM5209A

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

EMTTM5210A

DISASSEMBLY

EMTTM5211A

Service Key Points1. Be sure to install the spring pin as shown figure.

EMTTM5212A

2. Measure the clearance between gear shift fork andsynchronizer sleeve. If the clearance exceeds theservice limit, replace the parts.

EMTTM5213A

Rear cover and clutch housingReplacementRear Cover and Reverse Idler Gear

EMTTM5226A

Transmission AssemblyDisassembly and Reassembly

EMTTM5202A

Key Points for Installation1. Oil seal installation.After applying grease to the oil seal, install the oilseal into front bearing retainer, using the specialtool(09431-5H000).

EMTTM5203A

2. Front bearing retainer installation.Guide oil seal guide on drive pinion and install frontbearing retainer.

EMTTM5204A

3. Transmission case removal.1) After removing bolts, remove clutch housing,

main shaft assembly, counter shaft assembly andtransmission case by crane etc.

EMTTM5205A

2) After removing transmission case, fix 2nd gearpart with steel lifting band.

EMTTM5206A

Main ShaftDisassembly and Reassembly

EMTTM5214A

Service Key Points1. End play of each gear.A : 1st gearB : Reverse gearC : 2nd gearD : 3rd gearE : 5th gearIf the end play exceeds the service limit, replace theparts.

EMTTM5215A

2. Measure the play in diametral direction of main shaftgears and needle roller bearing. If the play exceedsthe service limit, replace the parts.

EMTTM5216A

3. Remove snap rings(B) from the main shaft using asnap ring plier(A).

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 theparts.

EMTTM5218A

5. Measure the clearance(A) between synchronizer ringand each gear assembly.If the clearance exceeds the service limit, replace theparts.

EMTTM5219A

6. Measure the clearance between shifting key andsynchronizer hub. If the clearance exceeds theservice limit, replace the parts.

EMTTM5220A

7. Measure the clearance(A) between each gearassembly and synchronizer outer ring. If theclearance exceeds the service limit, replace theparts.

EMTTM5221A

8. Remover the snap ring.

EMTTM5231A

9. Remove the drive pinion bearing using the specialservice tool(09431-83100)

EMTTM5223A

10.Reassembly is the reverse of disassembly.

Counter ShaftDisassembly and Reassembly

EMTTM5222A

1. Remove the snap ring using a snap ring plier.

EMTTM5232A

2. Counter shaft rear bearing1) Remove

Remove the counter shaft bearing using thespecial service tool(09431-83100 or09434-5H000).

EMTTM5233A

2) InstallationInstallation the counter shaft bearing using thespecial service tool(09434-5H100).

EMTTM5209A