Pub. No.

36237E
· ,.

FOREWORD

This repair manual has been prepared to provide information

covering general service repairs for the H41, H42, H50 and
H55F Manual Transmissions.

Applicable models:
BJ 40, 42, 43, 45, 46, 60 series
FJ 40,43,45,60 series
HJ 47, 60 series
BU 20,23,25,31,32,36,40 series
HU 40,50 series
WU 40, 50 series

All information contained in this manual is the most up-to-date

at the time of publication. However specifications and proce-
dures are subject to change without notice.

TOYOTA MOTOR CORPORATION

TOYOTA MANUAL
TRANSMISSION
H41,H42,H50,H55F
REPAIR MANUAL
INTRODUCTION lID
MANUAL TRANSMISSION mII
TRANSFER IDI
SERVICE SPECIFICATIONS IIEII
STANDARD BOLT TIGHTENING TORQUE IIII!IIII
SST _ _

© 1984 TOYOTA MOTOR CORPORATION

All rights reserved. This book may not be repro-
duced or copied, in whole or in part , without the
written permission of Toyota Motor Corporation .
IN-l

INTRODUCTION
Page
HOW TO USE THIS MANUAL......... . . .. .. .. IN-2
GENERAL REPAIR INSTRUCTIONS ............ IN-4
ABBREVIATIONS USED IN THIS MANUAL ..... IN-5

J
IN-2 INTRODUCTION - How To Use This Manual

HOW TO USE THIS MANUAL

To assist in finding your way through the manual, the section
title and major heading are given at the top of every page.
An INDEX is provided on the 1st page of each section to gu ide
you to the item to be repa ired.
At the beginning of each section, PRECAUTIONS are given that
pertain to all repair operations contained in that section.
Read these precautions before starting any repair task.

REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit together.

Example :

FJ HJ60, 4-Speed

Case Cover

C-Washer !-- Spring

Reverse Shift Head Lock ing Ball
1
0--

Compression Spring ~
...... ~I
o I' Reverse Shift Fork Shaft
(_,..-r~ I»_ ~ Interlock Rolle r 1st and 2nd Sh ift Fork

I Spring I
Reverse Shift Arm Plunge r Locking Ball --0 "

Interlock Pin~ ~
1st and 2nd Shift Fork Shaft

O-R1;ng 3,d ,nd 4th Sh;!t Fo, k 1Lo':~; ~pc;ng

Interlock Roller

Shift Arm Pivot \ ~ I '

@

IiiI
Jt-
o
0 I

Reverse Shift Arm

~ Sh ift Arm Shoe

I 3rd and 4th Shift Head
3rd and 4th Shift Fork Shaft

HM0211
INTRODUCTION - How To Use This Manual IN-3

The procedures are presented in a step-by-step format :

• The illustration shows what to do and where to do it.
• The task heading tells what to do.
• The detailed text tells how to perform the task and gives
other information such as specifications and warnings.

Example:

INSTALL FRONT BEARING WITH A GASKET

(a) Install the front bearing retainer with a gasket.
Illustration: (b) Apply liquid sealer to the bolts._~ De tat., text:
what to do and where (c) I nstall and torque the bolts. how to do it
Torque: 170 kg-cm (12 ft-Ib, 17 N.m)

~ Specification
This format enables the experienced technician to have a FAST
TRACK. He can read the task headings and only refer to the
detailed text when he needs it. Important specifications and
warnings always stand out in bold type.

REFERENCES
References have been kept to a minimum. However, when they
are required you are given the page to go to.

SPECIFICATIONS
Specifications are presented in bold type throughout the text in
the applicable step. You never have to leave the procedure to
look up your specs. All specifications are also found in Appen-
dix A, specifications for quick reference.

WARNINGS, CAUTIONS, NOTES:

• WARNINGS are presented in bold type, and indicate there is
a possibility to injury to you or other people.
• CAUTIONS are also presented in bold type, and indicate
there is a possibility of damage to the components being re-
paired.
• NOTES are separated from the text but do not appear in
bold. They provide additional information to more efficiently
help you perform the repair.

.J
IN-4 INTRODUCTION - General Repair Instructions

GENERAL REPAIR INSTRUCTIONS

1. Use fender seat and floor covers to keep the vehicle clean
and prevent damage.
2. During disassembly, keep parts in order to facilitate re-
assembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
cable from the battery terminal.
(b) If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the cable from the
negative (-) terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight up
without twisting it or prying it.
(d) Clean the battery terminal posts and cable terminals
with a shop rag. Do not scrape them with a fi le or
such.
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation.
Do not use a hammer or such to tap the terminal on-
to the post.
(f) Be sure the cover for the positive (+) terminal is pro-
perly in place.
4. Check hose and wiring connectors to make sure that they
are secure and correct.
5. Always replace cotter pins, gaskets and O-rings with new
ones.
6. When necessary, use a sealer on gaskets to prevent leaks.
7. Carefully observe all specifications for bolt tightening tor-
ques. Always use a torque wrench.
8. Use of special service tool (SST) may be required, depend-
ing on the nature of the repair. Be sure to use SST where
specified and follow the proper work procedure. A list of
SST can be found at the back of this manual.
9. When replacing fuses, be sure the new fuse is the correct
amperage rating. DO NOT exceed the fuse amp rating or
use one of a lower rating.
10. Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the pro-
per locations.
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to en-
su re safety.
(b) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any work
on the vehicle raised on jack alone, even for a small
job that can be finished quickly.
INTRODUCTION - Abbreviations Used In This Manual \N-5

ABBREVIATIONS USED IN THIS MANUAL

Ex. Except
LH Left-hand
LHD Left-hand Drive
M/T Manual Transmission
RH Right-hand
RHD Right-hand Drive
SST Special Service Tool
STD Standard
T /M Transmission
w/ With
w/o Without
MT-l

MANUAL TRANSMISSION
Page
H41, H42 and H55F TRANSMISSIONS ......... . MT-2
Components ............................. . MT-2
Disassembly of Transmission ................ . MT-7
Disassembly of Case Cover Assembly
(4-Speed for BJ40, FJ40 Series) ............ . MT-13
Disassembly of Case Cover Assembly
(4-Speed for FJ60, HJ60 Series) ............ . MT-15
Disassembly of Case Cover Assembly
(5-Speed) ............................. . MT-17
I~il
Inspection of Transmission Components ....... . MT-20
Assembly of Case Cover Assembly
(4-Speed for BJ40, FJ40 Series) ............ . MT-24
Assembly of Case Cover Assembly
(4-Speed for FJ60, HJ60 Series) ............ . MT-26
Assembly of Case Cover Assembly
(5-Speed) ............................. . MT-28
Assembly of Transmission .................. . MT-31

H50 TRANSMiSSiON ....................... . MT-40

Components ............................. . MT-40
Disassembly of Transmission ................ . MT-43
Disassembly of Case Cover Assembly .......... . MT-49
Inspection of Transmission Components ....... . MT-52
Assembly of Case Cover Assembly ............ . MT-56
Assembly of Transmission MT-60

REMOTE CONTROL
(DYNA Floor Shift Series) . . . . . . . . . . . . . . . . . . . .. MT-69
REMOTE CONTROL
(DYNA Column Shift Series) ., . . . . . . . . . . . . . . . .. MT-72
MT-2 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

H41, H42 and H55F TRANSMISSIONS

COMPONENTS

f I
I

Case Cover ------4

Nut /
/
,/'l"'o-
@
P;'ot
Reverse
Shift Arm
/ Spring Washer ;' (' ~
@J~/<./Plate ~asher /
Clutch Housing Front Bearing
@f (§f if O- Rmg ;/

Q-~
Retainer
Rear Bearing Retainer
, l
l [H55F]

Transmission Case

@----:: 5th Shift Arm

: \9---Lock Plate
[H55F]
---1 ~Bolt
--- --- I
I

~ 5th Shift Arm Shaft

Slotted Spring Pin

@--Straight Screw Plug

. ~
~ Sprmg tl
0 - - Locking Ball

\~ 5th Shift Fork Shaft

Transfer Adapter
5th Shift Fork

HM0166
HM0167
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-3

COMPONENTS (Cont'd)

Hub Sleeve No . 2 Needle Roller Bearing

Assembly 2nd Gear

Needle Roller

AIn! i :!Piautl-S_h_af_t~ 8"'l 1

q'jlnput Shaft Bearing
Snap Ring
Sn.p Ring Synchronizer
Ring
1st Gear
Needle Roller
Output Shaft
Center Bearing
Output Shaft
Rear Bearing

Bearing

Output Shaft

__ -1
I
~ ---: ~
i\, [H55Fl Spacer
5th Gear
I
I
1st Gear :
I
I
Thrust Washer :
[H55Fl I

r I
I [H41, H421

... G) or
Straight Pin I
Synchronizer Ring
No. 1 Assembly

Output Shaft Woodruff Key

T Spacer
[H41, H421
1 Output Shaft
Rear Bearing

~,
I
I
I
L ---

G", Sh,ft
Locking Ball
Reverse Idler Gear

Counter Gear
Rear Bearing

.~
Straight Pin

I \jJ"",glr--~ Lock Nut

Gear Spline Piece No.5
Synchronizer Ring No. 3
Shifting Key Spring
[H55Fl Hub Sleeve No . 3
Counter 5th Gear
Needle Roller Bearing
Snap Ring Counter 5th Gear Thrust Washer
Counter Gear

[H41, H421

Counter Gear Rear Bearing HM0 161

HM016B
HM0169
MT-4 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

COMPONENTS (Cant'd)

BJ FJ 40, 4-Speed

o:1----Shift Lever Retainer

\--- -Case Cover

Reverse Shift Fork

Q)
Tight Plug
Reverse Shift Fork Shaft
Reverse Shift Head
Spring---~
C-Washer

~ o I»)))))))

<:;) 1st and 2nd Shift Fork Shaft

'" ' ((@i~ I
" ~ ~ Interlock Roller ~ Spring

~
l
Compression Spring Interlock Pin
0-- Locking Ball
Reverse Shift Return Plunger
1st and 2nd Shift Head

~ Interlock Roller

I l s
~
""
Spring
a-Ring
3rd and 4th Shaft Fork
~LO'k;"g B;J ~

3rd and 4th Shift Fork Shaft Shift Arm Pivot

Reverse Shift Arm - - - - ;

Shift Arm Shoe-----~

HM0210
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-5

COMPONENTS (Cont'd)

FJ HJ 60, 4-Speed

Case Cover

Tight Plug

l
---~I

j
C-Washer Spring
Locking Ball --0
Reverse Shift Head

Compression Spring

~
I Reverse Shift Fork Shaft
Interlock Roller

f
Reverse Shift Arm Plunger
Spring ---I
Locking Ball - - 0
1st and 2nd Shift Fork

'"''''!l::~

1
1st and 2nd Shift Fork Shaft

Interlock Roller

=11------
O-Ring
3rd and 4th Shift Head

0 Spring

j
Locking Ball --0
Shift Arm Pivot

o I '\
@t2 3rd and 4th Shift Fork

3rd and 4th Shift Fork Shaft

~----Reverse Shift Arm

~ Shift Arm Shoe

HM02 11

:J
MT-6 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

COMPONENTS (Cant'd)

5-Speed

, - - - - - FJ·BJ 40 Series - - - - - ,

Case Cover
Case Cover

~ Spring !
~
Spring
Locking Ball --<le
~ El e .v Locking Ball .--0

~h;~Sh'ft
&Shift~Lever
HOU~ing ') '-

Q n :r Shift and Select Lever

1 Shift and Select Lever Shaft

Spring ~
Shift and Select Lever
Reverse Restrict Pin Locking Ball --0

~ I 5th Shift Arm Shaft Dust Boot

J
\
C

5th Shift Fork

~ E-Ring
5th Shift Fork

~
5th and Reverse Shift Head !o

r~~)a
C-Washer ~
Reverse Shift Fork
D ~

~ Inner No. 1 Shift Lever

Compression Spring I. E-R,lng i
Reverse Shift Return Plunger ~ ~ 0

Interlock Pin -----"'> ~

Interlock Roller C';)

Reverse Shift Arm
a
3rd and 4th Shift Fork 1
Interlock Pin
0

Compression Spring
~ Snap Ring
C-Washer-----@
c
~Shift Arm Shoe

~~ '"""~k Roll" !
,
1st and 2nd Shift Return
I~'J'~i ~ 1st and 2nd Shift Fork Shaft
Plunger C-Washer 1st and 2nd Shift Fork
1st and 2nd Shift Head

HM0212
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-7

DISASSEMBLY OF TRANSMISSION
(See pages MT-2, 3)

1. REMOVE CLUTCH HOUSING (Ex. FJ model)

2. REMOVE TRANSFER
(See pages TF-4 to 9)

3. REMOVE BACK-UP LIGHT SWITCH AND SHIFT POINT

SST SENSOR SWITCH FROM CASE COVER
Using SST, remove the back-up light and shift point sensor
switches.
SST 09817-16011

4. REMOVE CASE COVER

Remove case cover and gasket.

HM0171

5. REMOVE FIFTH LOCKING BALL AND SPRING

(H55F)
(a) Using SST, remove the screw plug.
SST 09313-30021
(b) Using a magnetic finger, remove the locking ball and
spring.

HMOl72 HM0173

6. REMOVE TRANSFER ADAPTER

(H55F)
(a) Using a brass bar and hammer, carefully tap the trans-
fer adapter.
(b) Pull up 5th shift arm and pull the transfer adapter
from the transmission case.

NOTE: For later reference, write down the thrust clear-

ance.
Standard clearance:
1st and 2nd gears 0.175 - 0.325 mm
(0.0069 - 0.0128 in.)
3rd gear 0.125 - 0.275 mm
(0.0049 - 0.0108 in.)
Counter 5th gear 0.10 - 0.30 mm
(0.0039 - 0.0118 in.)
Maximum clearance:
1st and 2nd gears 0.35 mm (0.0138 in.)
' - -_ _ _ _ _ _ _ _ _ _ _ _.:..::HM=O.c:...::..J175 3rd and counter 5th gears 0.30 mm (0.0118 in.)
MT-8 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

8. REMOVE OUTPUT SHAFT REAR BEARING

Using SST, remove the rear bearing.
SST 09950-20015

9. REMOVE SPACER

10. REMOVE LOCKING BALL (H41, 42)

Using magnetic finger, remove the locking ball.

11. REMOVE COUNTER GEAR REAR LOCK NUT

(H55F)
(a) Engage the gear double meshing.
(b) Unstake the lock nut.

HMOln

(c) Using SST, remove the lock nut.

SST 09326-20011
(d) Disengage the gear double meshing.

SST HM017B

12. REMOVE GEAR SPLlNE PIECE NO. 5, COUNTER

FIFTH GEAR ASSEMBLY AND FIFTH SHIFT FORK
(H55F)
Using SST, pull the counter 5th gear out of the counter
gear rear end with gear spline piece No. 5 and the 5th shift
fork.
SST 09213-27010

HM0179

13. REMOVE STRAIGHT PIN AND COUNTER FIFTH

GEAR THRUST WASHER
(H55F)

HM01BO
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT·9

14. REMOVE FRONT BEARING RETAINER

NOTE: Be careful not to damage the oil seal.

15. REMOVE COUNTER GEAR FRONT BEARING

(a) Using snap ring pliers, remove the snap rings.

(b) Using SST, remove the counter gear front bearing.

SST 09950·20015

w---SST

HMOl84

16. REMOVE REAR BEARING RETAINER

(H55F)

HM0185

17. REMOVE FIFTH GEAR FROM OUTPUT SHAFT

(H55F)
Using SST, remove the 5th gear from the output shaft.
SST 09950- 200 15
MT-l0 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

18. REMOVE COUNTER GEAR SHAFT REAR BEARING

(a) Using snap ring pliers, remove the snap ring.

(b) Using SST, remove the counter gear rear bearing.

SST 09950- 200 15

19. REMOVE INPUT SHAFT AND BEARING

(a) Using SST, remove the input shaft and bearing.
SST 09910-00015
NOTE: Insure that the input shaft and counter gear do
not strike against each other.
Be careful not to loose the 17 needle roller bearings.
(b) Remove the synchronizer ring.

20. REMOVE OUTPUT SHAFT CENTER BEARING FOR

H55F OR OUTPUT SHAFT REAR BEARING FOR
H41,42
(a) Using snap ring pliers, remove the snap ring.

HM0191

SST (b) Using SST, support the output shaft front end.
SST 09213-27010
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-11

(c) Using SST, remove the center bearing.

SST 09950-20015

21. REMOVE OUTPUT SHAFT AND COUNTER GEAR

(a) Stand the transm ission case on its front end.
(b) Remove the output shaft.
(c) Remove the counter gear.

HMOO24 HMOO25

22. REMOVE REVERSE IDLER GEAR AND SHAFT

(a) Tap out the reverse idler gear shaft toward the rear.
(b) Remove the gear and the woodruff key.

HMOO26

23. REMOVE REVERSE SHIFT ARM FROM TRAN-

MISSION CASE
Remove the nut, washers, O-ring, pivot arm, and reverse
shift arm.

HMOO27

24. REMOVE FIRST GEAR THRUST WASHER, STRAIGHT

PIN, FIRST GEAR AND NEEDLE ROLLER BEARING
FROM OUTPUT SHAFT

25. REMOVE SYNCHRONIZER RING NO. 1 ASSEMBLY

FROM OUTPUT SHAFT
MT-1 2 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

26. REMOVE HUB SLEEVE NO. 2 ASSEMBLY, SYNCHRO-

NIZER RINGS, THIRD GEAR, THIRD GEAR BUSHING,
NEEDLE ROLLER BEARING AND SECOND GEAR
FROM OUTPUT SHAFT

r (a) Using snap ring pliers, remove the snap ring.

WMOO54

(b) Using a press, remove the hub sleeve No. 2 assembly,

synchronizer ring, 3rd gear, 3rd gear bushing, need le
roller bearing and 2nd gear.

HM002B

27. REMOVE LOCKING BALL

Using a magnetic finger, remove the locking ball.

HMOO29

28. REMOVE FIFTH SHIFT ARM AND SHAFT FROM

TRANSFER ADAPTER
(H55F)
(a) Remove the bolt and lock washer.
(b) Remove the 5th shift arm and shaft.

HMOO30
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions Ml-13

DISASSEMBLY OF CASE COVER ASSEMBLY

(4-SPEED FOR BJ40, FJ40 SERIES)
(See page MT-4)
1. REMOVE SHIFT LEVER RETAINER
(a) Remove the shift lever retainer.
(b) Using a magnetic finger, remove the three locking
balls and three springs.

HMOO21

2. REMOVE SHIFT HEAD (FOR REVERSE GEAR) AND

REVERSE SHIFT FORK
(a) Using a pin punch, drive out the slotted spring pins
from the shift head and shift fork.

HM0202

(b) Using a pin punch, drive out the shift fork shaft to-
gether with the tight plug.
(c) Remove the fork shaft, shift fork, shift head and inter-
lock roller.

HM020J

3. REMOVE SHIFT FORK (FOR THIRD AND FOURTH

GEARS) AND SHAFT
(a) Using a pin punch, drive out the slotted spring pins
from the shift fork.

HM0204

(b) Using a pin punch, drive out the shift fork shaft to-
o gether with the tight plug.
Q <)
(c) Remove the shift fork shaft, shift fork and interlock
()
roller.
MT-14 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

4. REMOVE SHIFT HEAD (FOR FIRST AND SECOND

GEARS), FIRST AND SECOND SHIFT FORK AND
SHAFT
(a) Using a pin punch, drive out the slotted spring pins
from the shift head and the shift fork.
(b) Slide the shift fork toward the rear.
(c) Using a magnetic finger, remove the interlock pin.

HM0206

(d) Install a pin punch to the slotted spring pin hole.

(e) Using a plastic hammer, tap the shift fork and remove
the tight plug.
Q (f) Remove the fork shaft, shift head and shift fork.

HM0217

5. DISASSEMBLE SHIFT HEAD

(a) Compress the spring and remove the snap ring.
CAUTION: Be careful as the plunger will spring out.
(b) Remove the plunger and compression spring.

HM0207
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-15

DISASSEMBLY OF CASE COVER ASSEMBLY

(4-SPEED FOR FJ60, HJ60 SERIES)
(See page MT-5)
1. REMOVE SHIFT HEAD (FOR THIRD AND FOURTH
GEARS), THIRD AND FOURTH SHIFT FORK AND
SHAFT
(a) Using a pin punch, drive out the slotted spring pins
from the shift head and the shift fork.
HM0218

(b) Using a hammer, drive out the shift fork shaft together
with the tight plug.
NOTE: Cover the service hole with your hand to prevent
the locking ball from flying out.
(c) Remove the fork shaft, shift head, interlock roller,
locking ball and spring.

HM0219

2. REMOVE REVERSE SHIFT HEAD

(a) Using a pin punch and a hammer, drive out the slotted
spring pin from the reverse shift head.

HM0220

(b) Using a pin punch and a hammer, drive out the shift
fork shaft together with the tight plug.
NOTE: Cover the service hole with your hand to prevent
the locking ball from flying out.
(c) Remove the fork shaft, shift head, interlock roller,
locking ball and spring.

HM0221

3. REMOVE FIRST AND SECOND SHIFT FORK AND

SHAFT
(a) Using a pin punch and a hammer, remove the slotted
spring pin from the shift fork.

HM0248
MT-16 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

(b) Using a pin punch and a hammer, drive out the shift
fork shaft together with the tight plug.
NOTE: Cover the service hole with your hand to prevent
Q
the locking ball from flying out.
(c) Remove the fork shaft, shift fork, interlock pin,
locking ball and spring.

HM0223

4. DISASSEMBLE SHIFT HEAD

(a) Compress the spring, and remove the snap ring.
CAUTION: Be careful as the plunger will spring out.
(b) Remove the plunger and compression spring.

HM0224
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-17

DISASSEMBLY OF CASE COVER ASSEMBLY

(5-SPEED)
(See page MT -6)
1. REMOVE FIFTH FORK SHAFT
(a) Using a screwdriver, pry out the E-ring.
(b) Remove the fork shaft, two interlock balls, locking
ball and spring.
HMOOOl
HMOOO2

2. REMOVE SHIFT HEAD (FOR REVERSE AND FIFTH

GEARS), REVERSE SHIFT FORK AND FORK SHAFT
(a) Using a screwdriver, pry out the E-rings.
(b) Using a plastic hammer, tap on the shift fork and
remove the tight plug from the case cover.

HMOOOl
HMOOO3

(c) Using a pin punch, drive out the slotted spring pin
from the shift fork.
(d) Remove the fork shaft, shift fork, shift head, inter-
lock roller, interlock pin, locking ball and spring.

HM0199

3. REMOVE SHIFT HEAD, SHIFT FORK AND FORK

SHAFT (FOR FIRST AND SECOND GEARS)
(a) Using a pin punch, drive out the slotted spring pin
from the sh ift head.

HMOOO9

(b) Using a plastic hammer, tap the shift fork and remove
the tight plug from the case cover.
(c) Using a pin punch, drive out the slotted spring pin
from the shift fork.
(d) Remove the fork shaft, shift head, shift fork, locking
ball and spring.

HMOO10
MT-18 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

4. REMOVE SHIFT FORK AND FORK SHAFT (FOR

THIRD AND FOURTH GEARS)
(a) Using two screwdrivers and a hammer, tap out the
snap ring.
(b) Using a plastic hammer, tap the shift fork and remove
the tight plug from the case cover.

HMOOO4

(c) Using a pin punch, drive out the slotted spring pin
from the shift fork.
(d) Remove the fork shaft, shift fork, interlock roller,
interlock pin, locking ball and spring.

HMOO05

5-1 (40 SERIES)

REMOVE SELECT LEVER AND SHAFT
(a) Using a plastic hammer, tap the select lever and re-
move the tight plug from the case cover.
(b) Unstake the lock plate and remove the lock bolt.
(c) Remove the shaft and select lever.

Lever HM0216

5-2 (60 SERIES)

REMOVE SELECT LEVER, SHAFT AND SHIFT LEVER
HOUSING
(a) Unstake the lock plate and remove the lock bolt from
the shift lever housing.
(b) Using a plastic hammer, tap the select lever and re-
move the tight plug from the case cover.
(c) Unstake the lock plate and remove the lock bolt from
the lever.
(d) Remove the shaft, select lever and shift lever housing.
6. REMOVE REVERSE RESTRICT PIN
(a) Using a hexagon wrench, remove the straight screw
plug.

HMOO06
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-19

(b) Using a pin punch, drive out the slotted spring pin.
(c) Remove the restrict pin.

HMOOO7

7. DISASSEMBLE SHIFT HEADS

(a) Using two screwdrivers and a hammer, remove the
C-washer.
CAUTION: Be careful as the plunger will spring out.
(b) Remove the plunger and compression spring.
NOTE: Be careful not to mix up the springs and plungers.

HMOOOB
MT·20 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

INSPECTION OF TRANSMISSION
COMPONENTS
1. INSPECT OUTPUT SHAFT AND BUSHING
(a) Check the output shaft and bushing for wear or
damage.
(b) Using a micrometer, measure the outer diameter of
the output shaft journal and bushing.
Minimum diameter
HM0031 WM0059 1st and 2nd gear journal 43.93 mm (1.7295 in.)
Bushing 47.91 mm (1.8862 in.)
(c) Using a dial indicator, measure the shaft runout.
Maximum runout: 0.03 mm (0.0012 in.)

HM0032

2. INSPECT COUNTER GEAR AND BEARINGS

(a) Check the gear teeth for wear or damage.
(b) Check the bearings for wear or damage.
(c) Using a micrometer, measure the outer diameter of
the counter gear journal. (H55F only)
Maximum diameter:
Counter 5th gear journal 31.93 mm (1.2571 in.)
Rear bearing journal 39.90 mm (1.5709 in.)

HM0033

3. IF NECESSARY, REPLACE REAR BEARING INNER

RACE (H41 , H42 only)
(a) Using SST, remove the bearing inner race.
SST SST 09602· 10010

HM0034

(b) Using SST and a press, install the bearing inner race.
SST 09515·21010

SST - - - l
HM0035
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-21

4. INSPECT OIL CLEARANCE OF FIRST, SECOND AND

COUNTER FIFTH GEARS
Using a dial indicator, measure the oil clearance between
the gear and shaft with the needle roller bearing installed.
Standard clearance:
1st and 2nd gears 0.020 - 0.073 mm
(0.0008 - 0.0029 in.)
Counter 5th gear 0.015 - 0.068 mm
(0.0006 - 0.0027 in.)
HM0170 Maximum clearance:
1st and 2nd gears 0.08 mm (0.0031 in.)
Counter 5th gear 0.07 mm (0.0028 in.)

5. INSPECT OIL CLEARANCE OF THIRD GEAR

Using a dial indicator, measure the oil clearance between
the gear and bushing.
Standard clearance:0.065 - 0.115 mm
(0.0026 - 0.0045 in.)
Maximum clearance: 0.12 mm (0.0047 in.)

WM0063

Guide Pin 6. INSPECT SYNCHRONIZER RINGS OF FIRST AND

SECOND GEARS
(a) Check the inner spline for wear or damage.
(b) Check the raised position of the guide pins for wear
Synchronizer
or damage.
Ring Holder (cl Check the thrust pieces and gear moving parts for
wear or damage.
(d) Check the guide pin rivet staked parts for play or
damage.
Thrust Piece HM0036
(e) Check the synchronizer ring holders for deterioration
or wear.
(f) With the synchronizer ring pressed into the gear,
measure the distance as shown.
Minimum distance:
1st gear 32.5 mm (1.280 in.)
2nd gear 38.0 mm (1.496 in.)

HM0037

7. INSPECT SYNCHRONIZER RINGS OF THIRD GEAR,

INPUT SHAFT AND GEAR SPLlNE PIECE NO. 5
(H55F only)
(a) Check the synchronizer rings for wear or damage.
(b) Turn the ring and push it in to check the braking
action.
(c) Measure the clearance between the synchronizer ring
back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
WM0064 WM0065
MT-22 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

8. INSPECT SHIFT FORKS AND HUB SLEEVES

(a) Check the contact surfaces for wear or damage.
(b) Measure the clearance between the hub sleeve and the
shift fork.
Maximum clearance: 0.8 mm (0.031 in.)

WM0066

9. INSPECT INPUT SHAFT AND BEARING

Check for wear or damage.

10. IF NECESSARY, REPLACE INPUT SHAFT BEARING

(a) Using snap ring pliers, remove the snap ring.
(b) Using a press, remove the bearing.

WM0067 WM0068

(c) Using a press, install the bearing.

CAUTION: Do not press in the bearing outer race.
(d) Select a snap ring that will allow minimum axial play
and install it on the shaft.
Standard play: 0 - 0.10 mm (0 - 0.0039 in.)

Part No. Thickness mm (in.)

I 11 1 WM0069 WM0070
90520 - 36016
90520 - 36015
3.20 - 3.31 (0.1260 - 0.1303)
3.31-3.42 (0.1303-0.1346)

11. INSPECT REVERSE SHIFT ARM AND REVERSE

IDLER GEAR
(a) Check for wear or damage.
(b) Measure the clearance between the shift arm shoe and
idler gear groove.
Maximum clearance: 0.7 mm (0.028 in.)

HM0038

12. INSPECT FRONT BEARING RETAINER

(a) Check for wear or damage.
(b) Check the oil seal for wear or damage.

13. IF NECESSARY, REPLACE FRONT BEARING

RETAINER OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST, press in a new oil seal.
SST 09950-20015
WM0071 WM0072
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-23

14. INSPECT TRANSFER ADAPTER

(H55F only)
(a) Check for damage.
(b) Check the oil seal for wear or damage.

15. IF NECESSARY, REPLACE FIFTH SHIFT ARM OIL

SEAL ON TRANSFER ADAPTER
(H55F only)
(a) Using a screwdriver, pry out the oil seal.
HM0039 HM0040 (b) Using a socket wrench and hammer, drive in a new oil
seal.
Drive in depth: 1.0 mm (0.039 in.)

'\
t.,57 -
4 -4.5 mm

-
0.177 io.i
t-
16. IF NECESSARY, REPLACE FIFTH FORK SHAFT OIL
SEAL ON CASE COVER
(H55F only)
~ (a) Using a screwdriver, pry out the oil seal.
(b) Using SST, drive in a new oil seal.
SST 09304-47010
I HM0153
MT-24 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

ASSEMBLY OF CASE COVER ASSEMBLY

(4-SPEED FOR BJ40, FJ40 SERIES)
(See page MT-3)
1. ASSEMBLE SHIFT HEAD
(a) Install the compression spring and plunger into the
shift head.
(b) Press the end of the plunger, and install a new snap
ring.
HM0208

2. INSTALL SHIFT HEAD (FOR REVERSE GEAR) AND

REVERSE SHIFT FORK
(a) I nsert the fork shaft through the shift head and fork.
(b) Insta ll the interlock roller in the case cover.

O
~__"'-n_ _---'o",--_ _®=-..:~
['1....
1 :...JI HM0213
HM0244

3. INSTALL SHIFT HEAD (FOR FIRST AND SECOND

GEARS), FIRST AND SECOND SHIFT FORK AND ·
SHAFT
(a) Coat the interlock pin with MP grease and install it in
the shaft.

==---_O_ _~::::J
"--___GD=-"®'-"GD HM0243
HM0245

(b) Insert the fork shaft into the case cover through the
shift head and fork .
(c) Install interlock roller in the case cover.
° 4. INSTALL SHIFT FORK (FOR THIRD AND FOURTH
°1
°
uu " GEARS) AND SHAFT
~
° "'---===--\ Insert the fork shaft into the case cover through the shift
fork.

HM0222
HM0246

5. INSTALL SLOTTED SPRING PINS

(a) Align the pin hole of each shaft with the fork, head
and the other fork respectively.
(b) Using a pin punch, drive in the slotted spring pins
until they are flush with the fork.
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-25

6. INSTALL TIGHT PLUGS

Apply liquid sealer to the tight plugs and drive them into
the case cover as shown.
MT-26 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

ASSEMBLY OF CASE COVER ASSEMBLY

(4-SPEED FOR FJ60, HJ60 SERIES)
(See page MT-5)
1. ASSEMBLE REVERSE SHIFT HEAD
(a) Install the compression spring and plunger into the
shift head.
(b) Press the end of the plunger, and install a new snap
ring.
HM0225

2. INSTALL REVERSE SHIFT HEAD AND SHAFT

(a) Install the spring and locking ball.
(b) Insert the fork shaft through the reverse shift head.

HM0233
HM0234

3. INSTALL FIRST AND SECOND SHIFT FORK AND

SHAFT
(a) Instal l the spring and locking ball.
(b) Coat the interlock pin with MP grease and install it in
the shaft.

HM0231

(c) Insert the fork shaft through the shift fork.

HM0232
HM0235

4. INSTALL THIRD AND FOURTH SHIFT FORK AND

SHAFT
(a) Install the spring and locking ball.
(b) Coat the interlock roller with MP grease and install it
in the case cover.

HM0228
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-27

(c) Insert the fork shaft through the 3rd and 4th shift
fork.

HM0229
HM0230

5. INSTALL SLOTTED SPRING PINS

(a) Align the pin hole of each shaft with the fork, head
and the other fork respectively.
(b) Using a pin punch, drive in the slotted spring pins
until they are flush with the fork.

HM0226

6. INSTALL TIGHT PLUGS

Apply liquid sealer to the tight plugs and drive them into
the case cover as shown.

HM0227 HM0200
MT-28 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

ASSEMBLY OF CASE COVER ASSEMBLY

(5-SPEEO)
(See page MT-5)
1. ASSEMBLE SHIFT HEADS
(a) I nstall the compression spring and plunger into the
shift head.
(b) Press the end of the plunger, and install a new snap
ring.

2. INSTALL REVERSE RESTRICT PIN

(a) Insert the reverse restrict pin into the case cover.
(b) Align the pin holes of the case cover and pin, and
drive in the slotted spring pin.

HM0242

(c) Apply liqu id sealer to the plug and torque the plug.
Torque: 190 kg-cm (14 ft-Ib, 19 N.m)

HM0006

3-1 (40 SERIES)

INSTALL SELECT LEVER AND SHAFT
(a) Insert the shaft through the select lever.
(b) Align the holes of the shaft and select lever, and in-
stall the lock bolt with a new lock plate.
(c) Stake the lock plate.

3-2 (60 SERIES)

INSTALL SELECT LEVER, SHAFT AND SHIFT LEVER
HOUSING
(a) Insert the shaft through the select lever and shift lever
housing.
(b) Align the holes of the shaft and select lever, and in-
stall the lock bolt with a new lock plate.
(c) Align the holes of the shaft and shift lever housing,
and install the lock bolt with a new lock plate.
HM02 15
(d) Stake the lock plates.
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-29

4. INSTALL SHIFT HEAD, SHIFT FORK AND FORK

SHAFT (FOR FIRST AND SECOND GEARS)
(a) Install the spring and locking ball.
(b) I nsert the fork shaft th rough the sh ift fork and sh ift
head.
(c) Install the interlock roller to the case cover.

o (II)®OD ~ HMOO11
HM0012

5. INSTALL SHIFT FORK AND FORK SHAFT

(FOR THIRD AND FOURTH GEARS)
(a) Install the spring and locking ball.
(b) Coat the interlock pin with MP grease and install it in
the shaft.
(c) I nsert the fork shaft through the shift fork.
(d) I nstall the roller to the case cover.

c:: Q
~ GD®QD ~ HM0013
HM0014

6. INSTALL SHIFT HEAD (FOR REVERSE AND FIFTH

GEARS), REVERSE SHIFT FORK AND FORK SHAFT
(a) Install the spring and locking ball.
(b) Coat the interlock pin with MP grease and install it in
the shaft.
(c) I nsert the fork shaft through the shift fork and the
shift head.
(d) I nstall the two interlock balls to the case cover and
~_o_ _ _ _ _ _ _ _ ~ HM0015 shift head.
HM0016

7. INSTALL FIFTH FORK SHAFT

(a) Install the spring and locking ball.
(b) Insert the fork shaft through the shift head.

L[----lL_ _ ~~_ _ _-"---.Jrr::==:n::J HMOO17

HMOO1B

8. INSTALL THREE E-RINGS AND SNAP RING

Snap Ring

E-Ring
HMOO19
MT-30 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

9. INSTALL SLOTTED SPRING PINS

(a) Align the pin hole of each shaft with either the fork,
head and other fork or arm respectively.
(b) Using a pin punch, drive in the slotted spring pins
until they are flush with the fork.

10. INSTALL TIGHT PLUGS

Apply liquid sealer to the tight plugs and drive them into
the case cover as shown.
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions Ml'-31

ASSEMBLY OF TRANSMISSION
(See pages MT -2, 3)

1. INSTALL SECOND GEAR AND NEEDLE ROLLER

BEARING
(a) Apply gear oil to the output shaft.
(b) Install the needle roller bearing and 2nd gear.

2. INSTALL LOCKING BALL, BUSHING AND THIRD

GEAR
(a) Install the locking ball in the shaft.

HM0041

(b) I nstall the bush ing on the output shaft and al ign the
bushing notch and locking ball.
(c) Apply gear oil to the bushing.
(d) I nstall the 3rd gear on the bush ing.

HM0042

3. INSERT CLUTCH HUB NO.2 INTO HUB SLEEVE

(a) Install the clutch hub and shifting keys to the hub
sleeve.
(b) Install the shifting key springs under the shifting keys.
CAUTION: Install the key springs positioned so that
their ends are not in line.

HM0043

4. INSTALL HUB SLEEVE NO. 2 ASSEMBLY

Using a press, install the hub sleeve No. 2 assembly.
CAUTION: Hold the 3rd gear to prevent the bushing
from falling. Be sure that the shifting keys align with the
synchronizer ring slots.

HM0044
MT-32 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

5. INSTALL SNAP RING

Select a snap ring that will allow minimum axial play and
install it on the shaft.

r Mark
0
1
2
2.40 - 2.45
2.45 - 2.50
2.50 - 2.55
Thickness mm (in.)
(0.0945 - 0.0965)
(0.0965 - 0.0984)
(0.0984 - 0.1004)
3 2.55 - 2.60 (0.1004 - 0.1024)
WMOl16 WM0054
4 2.60 - 2.65 (0.1024 - 0.1043)
5 2.65 - 2.70 (0.1043 - 0.1063)
2nd Gear 3rd Gear
6. MEASURE SECOND AND THIRD GEARS THRUST
CLEARANCE
Using a feeler gauge, measure the 2nd and 3rd gear thrust
clearances.
Standard clearance:
2nd gear 0.175 - 0.325 mm (0.0069 - 0.0128 in.)
3rd gear 0.125 - 0.275 mm (0.0049 - 0.0108 in.)
HM0045 HM0046
Maximum clearance:
2nd gear 0.35 mm (0.0138 in.)
3rd gear 0.30 mm (0.0118 in.)
Synchronizer
Guide Pin Ring Holder
7. ASSEMBLE SYNCHRONIZER RING HOLDER
Hook the synchronizer ring holder ends to the thrust piece.
Synch- NOTE:
ronizer
• Align the synchronizer ring holder ends so they are not
Ring
Holder
both facing in the same direction.
• So sure that the synchronizer ring holders are parallel
and not intersecting.
Guide Pin
HM0036 HM0047

8. INSTALL SYNCHRONIZER RING NO. 1 AND FIRST

GEAR
(a) Install synchronizer ring No. 1.
(b) Apply gear oil to the needle roller bearing.
(c) Install the needle roller bearing and the 1st gear.
(d) Apply MP grease to the straight pin and 1st gear
thrust washer.
(e) Install the 1st gear thrust washer onto the output
HM0048
shaft with the straight pin aligned with the 1st gear
thrust washer.

9. INSTALL REVERSE SHIFT ARM

(a) Install the reverse shift arm so its pivot is positioned
as shown.
(b) I nstall the a-ring, plate washer, spring washer and nut.

HM0049
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-33

10. INSTALL REVERSE IDLER GEAR AND SHAFT

(a) Align the reverse idler gear groove with the reverse
shift arm shoe.
(b) I nstall the reverse idler gear shaft with the woodruff
key through the gear.

11. PUT COUNTER GEAR INTO TRANSMISSION CASE

(a) Stand the transmission case on its front end.
(b) Put the counter gear into the case.
CAUTION: Be careful not to damage either end.

HM0025

12. PUT OUTPUT SHAFT ASSEMBLY INTO TRANS-

MISSION CASE
CAUTION: Be careful not to damage the front end of
the shaft.

HM0024

13. INSTALL OUTPUT SHAFT CENTER BEARING FOR

H55F OR OUTPUT SHAFT REAR BEARING FOR
H41,42
(a) Using snap ring pliers, install the snap ring onto the
bearing.
(b) Confirm that the groove of the 1st gear thrust washer
and the straight pin are aligned.
(c) Using SST, install the bearing until it comes into con-
tact with the 1st gear thrust washer.
SST 09309-36032 and 09309-60010
(H55F only)

14. INSTALL FIFTH GEAR TO OUTPUT SHAFT

(H55F)
(a) Apply MP grease to the inside surface of the 5th gear.
(b) Using SST, install the 5th gear to the output shaft.
SST 09309-36032 and 09309-60010
MT-34 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

15. INSTALL INPUT SHAFT

(a) Using a snap ring pi iers, install the snap ring onto the
bearing.
(b) Install the 17 needle roller bearings into the input
shaft.
(c) Apply MP grease to the needle roller bearings.

HM0054

(d) Align the synchronizer ring slots with the shifting

keys.
(e) Using a plastic hammer, drive in the input shaft.
NOTE: Be sure that the counter gear is low enough so
as not to interfere with the input shaft.

HMOO55

16. INSTALL COUNTER GEAR FRONT BEARING

(a) Turn the transmission over and align the counter
gear center.
(b) Install the thrust collar for the front bearing onto the
counter gear. (H55F)

Front
...
~Thrust
Collar
(c) Using SST, drive in the bearing.
SST 09316-60010
(For H55F) NOTE: When driving in the bearing, support the counter
gear in rear with a 3-5 Ib hammer or equivalent.
HM0057 HM0056

(d) Install the snap ring onto the bearing outer race.
(e) Select a snap ring that will allow minimum axial play
and install it on the counter gear front end.

Mark Thickness mm (in.)

0 · 2.05-2.10 (0.0807 - 0.0827)
2 2.15 - 2.20 (0.0846 - 0.0866)
4 2.25 - 2.30 (0.0886 - 0.0906)

HM0058 HM0059

17. INSTALL COUNTER GEAR REAR BEARING

(a) Install the snap ring to the counter gear rear bearing
outer race. (H55F)
(b) Using SST, drive in the rear bearing.
SST 09316-60010
NOTE: When driving in the bearing, support the counter
gear in front with a 3-5 Ib hammer or equivalent.

HM0060
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-35

(c) Install the thrust collar for the rear bearing onto the
cou nter gear rear end. (H41, 42)
(d) Using snap ring pliers, install the snap ring onto the
counter gear rear end. (H41, 42)

....
Front

Thrust
Collar

18. INSTALL REAR BEARING RETAINER

(H55F)
Install the rear bearing retainer to the transmission case.
Torque the bolts.
Torque: 185 kg-cm (13 ft-Ib, 18 N·m)

HM0063

19. INSTALL STRAIGHT PIN AND COUNTER FIFTH

GEAR THRUST WASHER
(H55F)
(a) Install the straight pin onto the counter shaft.
(b) Align the thrust washer slot with the straight pin,
and install the thrust washer.

HM0064 HM01S0

20. ASSEMBLE COUNTER FIFTH GEAR

(H55F)
(a) Install the No. 3 hub sleeve and shifting keys to
the counter 5th gear.
.... Front (b) Install the shifting key springs under the shifting
keys so that the spring ends are not in line, as shown
in the figure.

21. INSTALL NEEDLE ROLLER BEARING

(H55F)
(a) Apply MP grease to the needle roller bearing.
(b) Install the needle roller bearing into the counter
5th gear.
MT-36 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

22. ASSEMBLE FIFTH SHIFT FORK

(H55F)

...
Front
(a)
(b)
Install the 5th shift fork to the shaft .
Align the pin holes with the 5th shift fork and
shaft.
(c) Using a pin punch, drive in the slotted spring pin.

HM0067

23. INSTALL COUNTER FIFTH GEAR ASSEMBLY WITH

FIFTH SHIFT FORK
(H55F)
(a) I nstall the 5th shift fork and fork shaft onto hub
sleeve No. 3.
(b) Install the counter 5th gear assembly with the 5th
shift fork.

HM0068

24. INSTALL SYNCHRONIZER RING AND GEAR SPLlNE

PIECE NO.5
(H55F)
(a) Align the synchronizer ring slots with the shifting
keys, and place the synchronizer ring on the counter
5th gear rear end.
(b) Using SST, drive gear spline piece No. 5 into the
counter gear to where the lock nut can be installed.
SST 09316-60010
NOTE: When driving in gear spline piece No. 5, support
the counter gear in front with a 3-5 Ib hammer or equiv-
alent.

25. INSTALL LOCK NUT TO COUNTER GEAR REAR

END
(H55F)
(a) Engage the gear double meshing.

HM0177

(b) Using SST, install a new lock nut.

Torque the nut.
SST 09326-20011
Torque: 1,300 kg-cm (94 ft-Ib, 127 N·m)
(c) Disengage the gear double meshing.
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-37

(d) Using a feeler gauge, measure the counter 5th gear

thrust clearance.
Standard clearance:0.150 - 0.250 mm
(0.0059 - 0.0098 in.)
Maximum clearance: 0.30 mm (0.0118 in.)

HM0071

(e) Using a punch, stake the lock nut.

HMOO72

26. INSTALL FRONT BEARING RETAINER WITH A

GASKET
(a) Install the front bearing retainer with a gasket.
(b) Apply liquid sealer to the bolts.
(c) Install and torque the bolts.
Torque: 170 kg-cm (12 ft-Ib, 17 N'm)

HM0073

27. INSTALL SPACER

Install the spacer on the output shaft.

HM0240 HM0074

28. INSTALL OUTPUT SHAFT REAR BEARING

(H55F)
Using SST, install the rear bearing.
SST 09309-36032
MT-38 MANUAL TRANSMISSION - H41, H42 and H55F Transmissions

Thrust Clearance 29. MEASURE FIRST GEAR THRUST CLEARANCE

Using a feeler gauge, measure the thrust clearance.
Standard clearance: 0.175 - 0.325 mm
(0.0069 - 0.0128 in.)
Maximum clearance: 0.35 mm (0.0138 in.)

HMQ076

30. INSTALL FIFTH SHIFT ARM AND SHAFT (H55F)

(a) Install the 5th shift arm shaft through the transfer
adapter and install the 5th shift arm.
(b) Install the bolt with a lock washer, and torque the
bolt.
Torque: 380 kg-cm (27 ft-Ib, 37 N·m)

HMOO30

(c) Stake the lock washer.

31. INSTALL TRANSFER ADAPTER WITH A GASKET

(H55F)
(a) Place a new gasket in position.
(b) Align the end of the 5th shift lever and 5th shift
fork, and install the transfer adapter.

HM0078

(c) Install the locking ball and spring.

HMOO79
MANUAL TRANSMISSION - H41, H42 and H55F Transmissions MT-39

(d) Apply liquid sealer to the plug_

(e) Using SST, install and torque the screw plug.
SST 09313-30021
Torque: 250 kg-cm (18 ft-Ib, 25 N·m)

HM0080

32. INSTALL CASE COVER WITH A GASKET

(a) Install the case cover with a gasket.
(b) Install and torque the bolts.
Torque: 400 kg-cm (29 ft-Ib, 39 N·m)

HM0062

33. INSTALL BACK-UP LIGHT SWITCH AND SHIFT POINT

SST SENSOR SWITCH TO CASE COVER
Using SST, install the back-up light and shift point sensor
switches.
SST 09817-16011

34. INSTALL TRANSFER

(See pages TF 15 to 22)

HM0171

35. INSTALL CLUTCH HOUSING (Ex. FJ model)

Torque the bolts.
Torque: 730 kg-cm (53 ft-Ib, 72 N.m)

36. ADJUST REVERSE SHIFT ARM PIVOT POSITION

(a) Position the adjustment mark on the shift arm
pivot end toward the front.
(b) Temporarily install the shift lever, and if the shift
lever is catching on something in selecting direction,
adjust by moving the position of the alignment mark
with 60°. .
(c) Torque the nut.
Torque: 250 kg-cm (18 ft-Ib, 25 N.m)
HMOl94
MT-40 MANUAL TRANSMISSION - H50 Transmission

H50 TRANSMISSION
COMPONENTS

Shift Lever HOUSing ~

~
~

'~ii
~ -~ ·iD~:y-~,
y
~

Case Cover----r·

I,e
Nut
sprin g Washer
Plate Washer
; la-Ring
Reverse Shift
/L----Arm

Clutch Housing ~ Q I
I

Front Bearing Retainer €Y ,, I

I

--"' \....' ,
\
\
'----
\ --- -~
~ "-' ~

Rear Bearing Retainer

l@) ~
Transmission Case

v----
I
5th Shift Arm
@ - - Lock Plate
I
I ~Bolt
_-1
I

~ 5th Shift Arm Shaft

I
Oil Seal

Extension Housing
Oil Receiver
5th Shift Fork Shaft
HM0158
HM0159
HM0160
MANUAL TRANSMISSION - H50 Transmission MT-41

COMPONENTS (Cont'd)

Hub Sleeve No. 2

Assembly Needle Roller Bearing
3rd Gear

Needle Roller

Input Shaft

Speedometer
Drive Gear
Synchronizer

~"~;Og
5th Gear
Ring
Center Bearing
Snap Ring Needle Roller
Bearing

Output Shaft
D
1 Spacer
1So"dom""
Drive Gear
Spacer

Synchronizer Ring
No. 1 Assembly

E-Ring~
~ Woodruff Key

~
Reverse Idler Gear Shaft
Reverse Idler Gear

Shifting Key
Counter Gear Rear Bearingi
Straight Pin

~
Counter Gear
Counter Gear
Front Bearing Lock Nut

r~
Synchronizer Ring No. 3
Shifting Key Spring
Hub Sleeve No. 3
Counter 5th Gear
Snap Ring
Needle Roller Bearing
Counter 5th Gear Thrust Washer

HM0162
HM0163
MT-42 MANUAL TRANSMISSION - H50 Transmission

COMPONENTS (Cont'd)

Select Outlet Lever~ Neutral Switch

Lever Lock P i n C- ic-- Co> ~ ®

i ~ ® Shift Lever Housing

Gl

Oil Seal

Shift 0,,,, Lm, (~

Oil Seal I
Select Lever Shaft
Shift and Select Lever

Locking Ball
and Spring
-----.-----I'i
~~;;:""'-------Back-up Light Switch
( ] } - - - - - - - - - - - - T i g h t Plug

~:;;e:~f------------ Case Cover

~
Reverse Shift
~
\\
~
_ _ _ _ _ _ _ _ _ _ _ Slotted Spring Pin
Reverse Shift Fork
He_ad_ _
_ ~r_~~
Interlock Pin ~ IL__. . :. -._ _ _________ Reverse Shift Fork Shaft
. - - - - - - - -- - - - - - 3 r d and 4th Shift Fork Shaft

~ _l\~~ ~'---------Slotted Spring Pin

Interlock Pin
_____---'-L_~_
' _0s::::, - - -- - - - - - - - 3 r d and 4th Shift Fork

. - - - - - = - - - - - - - - - - - - 1 st and 2nd Shift Fork Shaft

h1
~-~
1st and 2nd
Shift Head
-----r ~If\\r~--------Slotted
Slotted Spring Pin
Q-J
~
1st and 2nd Shift Fork
Spring Pin

HM0164
HM0165
MANUAL TRANSMISSION - H50 Transmission MT-43

DISASSEMBLY OF TRANSMISSION
(See pages MT -40, 41 )
1. REMOVE CLUTCH HOUSING

2. REMOVE NEUTRAL SWITCH, BACK-UP LIGHT

SWITCH, SHIFT LEVER SHAFT SUPPORT, ENGINE
REAR MOUNTING AND SPEEDOMETER DRIVEN
GEAR

HM0081
3. REMOVE SHIFT LEVER HOUSING

4. REMOVE LOCKING BALLS AND SPRINGS

Using a magnetic finger, remove the springs and balls.

5. REMOVE CASE COVER

HM0082

6. REMOVE FIFTH LOCKING BALL AND SPRING

(a) Using SST, remove the screw plug.
SST 09313-30021
(b) Using a magnetic finger, remove the locking ball and
spring.

7. REMOVE EXTENSION HOUSING

(a) Remove the bolts.
(b) Using a brass bar and hammer, carefully tap off the
extension housing.
(c) Pull up the 5th shift arm and pull the extension hous-
ing from the transmission case.

8. MEASURE EACH GEAR THRUST CLEARANCE

Using a feeler gauge, measure the thrust clearance of each
gear.
HMOO84
NOTE: For later reference, write down the thrust clear-
ance.
Standard clearance:
1st and 2nd gears 0.175 - 0.325 mm
(0.0069 - 0.0128 in.)
3rd gear 0.125 - 0.275 mm
(0.0049 - 0.0108 in.)
Counter 5th gear 0.10 - 0.30 mm
(0.0039 - 0.0118 in.)
Maximum clearance:
1st and 2nd gears 0.35 mm (0.0138 in.)
175
L -_ _ _ _ _ _ _ _ _ _ _ _..:.::HM::.:.:0.:.:..:..J 3rd and counter 5th gears 0.30 mm (0.0118 in.)
MT-44 MANUAL TRANSMISSION - H50 Transmission

9. REMOVE OUTPUT SHAFT REAR BEARING

Using SST, remove the rear bearing.
SST 09950-20015

10. REMOVE SPACERS AND SPEEDOMETER DRIVE

GEAR

HM0176

11. REMOVE COUNTER GEAR REAR LOCK NUT

(a) Engage the gear double meshing.
(b) Unstake the lock nut.

HMOl77

(c) Using SST, remove the lock nut.

SST 09326-20011
(d) Disengage the gear double meshing.

SST HM0178

12. REMOVE GEAR SPLlNE PIECE NO. 5, COUNTER

FIFTH GEAR ASSEMBLY AND FIFTH SHIFT FORK
Using SST, pull the counter 5th gear out of the counter
gear rear end with gear spline piece No. 5 and the 5th shift
fork.
SST 09950-20015

13. REMOVE STRAIGHT PIN AND COUNTER FIFTH

GEAR THRUST WASHER

HMOl80
MANUAL TRANSMISSION - H50 Transmission MT·45

14. REMOVE FRONT BEARING RETAINER

NOTE: Be careful not to damage the oil seal.

15. REMOVE COUNTER GEAR FRONT BEARING

(a) Using snap ring pliers, remove the snap rings.

(b) Using SST, remove the counter gear front bearing.

SST 09950·20015

HMOl84

16. REMOVE REAR BEARING RETAINER

HM0185

17. REMOVE FIFTH GEAR FROM OUTPUT SHAFT

Using SST, remove the 5th gear from the output shaft.
SST 09950·20015
MT-46 MANUAL TRANSMISSION - H50 Transmission

18. REMOVE COUNTER GEAR SHAFT REAR BEARING

(a) Using snap ring pliers, remove the snap ring.

HM0187

(b) Using SST, remove the counter gear rear bearing.

SST 09950-20015

19. REMOVE INPUT SHAFT AND BEARING

(a) Using SST, remove the input shaft and bearing.
SST 09910'()0015
NOTE: Insure that the input shaft and counter gear do
not strike against each other. Be careful not to lose the
17 needle roller bearings.
(b) Remove the synchronizer ring.

20. REMOVE OUTPUT SHAFT CENTER BEARING

(a) Using snap ring pliers, remove the snap ring .

(b) Using SST, support the output shaft front end.

SST
SST 09213-27010
MANUAL TRANSMISSION - H50 Transmission MT-47

(c) Using SST, remove the center bearing.

SST 09950-20015

21. REMOVE OUTPUT SHAFT AND COUNTER GEAR

(a) Stand the transmission case on its front end.
(b) Remove the output shaft.
(c) Remove the counter gear.

HMOO24 HMOO25

22. REMOVE REVERSE IDLER GEAR AND SHAFT

(a) Remove the E-ring from the shaft.

HM0086

(b) Tap out the reverse idler gear shaft toward the rear.
(c) Remove the gear and the woodruff key.

HMOO26

23. REMOVE REVERSE SHI FT ARM FROM

TRANSMISSION CASE
Remove the nut, washers, G-ring, pivot arm and reverse
shift arm.

HM0027
MT-48 MANUAL TRANSMISSION - H50 Transmission

24. REMOVE FI RST GEAR THRUST WASHER, STRAIGHT

PIN, FIRST GEAR AND NEEDLE ROLLER BEARING
FROM OUTPUT SHAFT

25. REMOVE SYNCHRONIZER RING NO. 1 ASSEMBLY

FROM OUTPUT SHAFT

26. REMOVE HUB SLEEVE NO. 2 ASSEMBLY,

SYNCHRONIZER RING, THIRD GEAR, THIRD GEAR
BUSHING, NEEDLE ROLLER BEARING AND SECOND
GEAR

r WM0054
(a) Using snap ring pliers, remove the snap ring.

(b) Using a press, remove the hub sleeve No. 2 assembly,

synchronizer ring, 3rd gear, 3rd gear bushing, needle
roller bearing and 2nd gear.

HMOO28

27. REMOVE LOCKING BALL

Using a magnetic finger, remove the locking ball.

HM0029

28. REMOVE FI FTH SHI FT ARM AND SHAFT

(a) Remove the bolt and lock washer.
(b) Remove the 5th shift arm and shaft.

HMOO87
MANUAL TRANSMISSION - H50 Transmission MT-49

DISASSEMBLY OF CASE COVER ASSEMBLY

(See page MT -42)
1. REMOVE FIRST AND SECOND SHIFT FORK SHAFT,
SHIFT HEAD AND SHIFT FORK
CAUTION: When removing the shaft, place each shift
fork into neutral position and release the interlock pin.
(a) Drive out the slotted spring pins from the shift head
and shift fork.
L -_ _ _ _ _ _ _ _ _ _ _ _.:..::.HM=OO:=..J88 NOTE: When driving out the slotted spring pins, tilt the
fork so the pins do not make contact with the case cover.
(b) Drive out the shift fork shaft and tight plug.
(c) Remove the shift head and shift fork.

HM0089

(d) Remove the interlock pin from the case cover.

HMOO90

2. REMOVE THIRD AND FOURTH SHIFT FORK AND

SHAFT
(a) Drive out the slotted spring pin.

HM0091

(b) Drive out the shift fork shaft, small interlock pin and
tight plug.
(c) Remove the shift fork.

HM0092
MT-50 MANUAL TRANSMISSION - H50 Transmission

(d) Remove the interlock pin from the case cover.

HM0093

3. REMOVE REVERSE SHI FT FORK AND SHAFT

(a) Remove the E-ring from the reverse shift fork shaft.

HM0094

(b) Drive out the slotted spring pin from the shift fork.

HMOO95

(c) Drive out the shift fork shaft, small interlock pin and
tight plug.
(d) Remove the shift fork.

HMOO96

(e) Remove the interlock balls from the case cover and
reverse shift head.

HM0097
MANUAL TRANSMISSION - H50 Transmission MT-51

4. REMOVE FIFTH SHIFT ARM SHAFT

(a) Remove the dust boot.
(b) Remove the E-ring.

(c) Drive out the 5th shift arm shaft and tight plug.
(d) Remove the reverse shift head.
(e) Remove the shift fork shaft retainer and G-ring.

HM0099

5. REMOVE SELECT LEVER SHAFT

(a) Remove the lock pin on the select outer lever.
(b) Remove the select outer lever, washer and select lever
shaft.

HM0100

6. REMOVE SHIFT LEVER SHAFT

(a) Remove the lock pin on the shift outer lever.
(b) Remove the shift outer lever and washer.

HM010l

(c) Remove the bolt.

(d) Drive out the shift lever shaft and tight plug.
(e) Remove the switch pressure lever and shift and select
lever.
MT-52 MANUAL TRANSMISSION - H50 Transmission

INSPECTION OF TRANSMISSION
COMPONENTS
1. INSPECT OUTPUT SHAFT AND BUSHING
(a) Check the output shaft and bushing for wear or
damage.
(b) Using a micrometer, measure the outer diameter of
the output shaft journal and bushing.
Minimum diameter:
HMOO31 WMOO59 1st and 2nd gear journals 43.93 mm (1.7295 in.)
Bushing 47.91 mm (1.8862 in.)
(c) Using a dial indicator, measure the shaft runout.
Maximum runout: 0.03 mm (0.0012 in.)

HM0236

2. INSPECT COUNTER GEAR AND BEARINGS

(a) Check the gear teeth for wear or damage.
(b) Check the bearings for wear or damage.
(c) Using a micrometer, measure the outer diameter of
the counter gear journal.
Minimum diameter:
Counter 5th gear journal 31.93 mm (1.2571 in.)
Rear bearing journal 39.90 mm (1.5709 in.)

1....-_ _ _ _ _ _ _ _ _ _ _......:..:cHMc:.::..:00:::::..J33 3_ INSPECT OIL CLEARANCE OF FIRST, SECOND AND

COUNTER FI FTH GEARS
Using a dia l indicator, measure the oil clearance between
the gear and shaft with the needle roller bearing installed.
Standard clearance:
1st and 2nd gears 0.020 - 0.073 mm
(0.0008 - 0.0029 in.)
Counter 5th gear 0.015 - 0.068 mm
(0.0006 - 0.0027 in.)
Maximum clearance:
1st and 2nd gears 0.08 mm (0.0031 in.)
L -_ _ _ _ _ _ _ _ _ _ _ _---'---HM...:.Ol'-'-'--L70 Counter 5th gear 0.07 mm (0.0028 in.)

4. INSPECT OIL CLEARANCE OF THIRD GEAR

Using a dial indicator, measure the oil clearance between
the gear and bushing.
Standard clearance: 0.065 - 0.115 mm
(0.0026 - 0.0045 in.)
Maximum clearance: 0.12 mm (0.0047 in.)

WM0063
MANUAL TRANSMISSION - H50 Transmission MT-53

Guide Pin 5. INSPECT SYNCHRONIZER RINGS OF FIRST AND

SECOND GEARS
(a) Check the inner spline for wear or damage.
(b) Check the raised portion of the guide pins for wear or
Synchronizer damage.
Ring Holder (c) Check the thrust pieces and gear moving parts for
wear or damage.
(d) Check the gu ide pin rivet staked parts for play or
damage.
Thrust Piece HMOO36
(e) Check the synchronizer ring holders for deterioration
or wear.
(f) With the synchronizer ring pressed into the gear, meas-
ure the distance as shown.
Minimum distance:
1st gear 32.5 mm (1.280 in.)
2nd gear 38.0 mm (1.496 in.)

HM0037

6. INSPECT SYNCHRONIZER RINGS OF THIRD GEAR,

INPUT SHAFT AND GEAR SPLlNE PIECE NO. 5
(a) Check the synchronizer rings for wear or damage.
(b) Turn the ring and push it in to check the braking ac-
tion.
(c) Measure the clearance between the synchronizer ring
back and the gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)

7. INSPECT SHIFT FORKS AND HUB SLEEVES

(a) Check the contact surface for wear or damage.
(b) Measure the clearance between the hub sleeve and the
shift fork.
Maximum clearance: 0.8 mm (0.031 in.)

WMOO66

8. INSPECT INPUT SHAFT AND BEARING

Check for wear or damage.

9. IF NECESSARY, REPLACE INPUT SHAFT BEARING

(a) Using snap ring pliers, remove the snap ring.
(b) Using a press, remove the bearing.

WM0067 WMOO68
MT·54 MANUAL TRANSMISSION - H50 Transmission

(c) Using a press, install the bearing.

CAUTION: Do not press in the bearing outer race.
(d) Select a snap ring that will allow minimum axial play
and install it on the shaft.
Standard play: 0 - 0.10 mm (0 - 0.0039 in.)

I 11 Part No.
90520 - 36016
90520 - 36015
Thickness mm (in.)
3.20-3.31 (0.1260-0.1303)
3.31 - 3.42 (0.1303 - 0.1346)

10. INSPECT REVERSE SHIFT ARM AND REVERSE

IDLER GEAR
(a) Check for wear or damage.
(b) Measure the clearance between the shift arm shoe and
idler gear groove.
Maximum clearance: 0.7 mm (0.028 in.)

HMOO38

11. INSPECT FRONT BEARING RETAINER

(a) Check for damage.
(b) Check the oil seal for wear or damage.

12. IF NECESSARY, REPLACE FRONT BEARING

RETAINER OIL SEAL
(a) Using a screwdriver, pry out the oi l seal.
(b) Using SST, press in a new oil seal.
SST 09950·20015
WM007 1 WM0072

13. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN

(ftI~
GEAR OIL SEAL
(a) Using SST, pry out the oil seal.
SST 09921·00010
(b) Using SST, drive in a new oil seal.

cBq;~
SST 09201·60011
Drive in depth: 23.3 mm (0.917 in.)

WM0108
WM0109

14. INSPECT EXTENSION HOUSING

(a) Check for damage.
(b) Check the oil seals for wear or damage.

15. IF NECESSARY, REPLACE FIFTH SHIFT ARM SHAFT

OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using a socket wrench, drive in a new oil seal.
Drive in depth: 1.0 mm (0.039 in.)
HM0104 HM0105
MANUAL TRANSMISSION - H50 Transmission MT-55

16. IF NECESSARY, REPLACE REAR OIL SEAL

SST (a) Using SST, remove the oil seal.
SST 09308-00010

HM0106

(b) Using SST, drive in a new oil seal.

SST 09316-B00 10

17. IF NECESSARY, REPLACE SHIFT LEVER SHAFT OIL

SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using a socket wrench, drive in a new oil seal.

HM0108 HM0109

18. IF NECESSARY, REPLACE SELECT LEVER SHAFT

OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using a socket wrench, drive in a new oil seal.

HM0110 HMOlll
MT-56 MANUAL TRANSMISSION - H50 Transmission

ASSEMBLY OF CASE COVER ASSEMBLY

(See page MT-42)
1. INSTALL FIFTH SHIFT FORK SHAFT
(a) I nstall the G-ring and sh ift fork shaft retainer.
(b) Put the reverse shift head into the case cover.
(c) I nstall the 5th shift fork shaft into the reverse shift
head through the case cover.
[W__~D~D~a ____~%~__I~~~ HM0122
HM0195

(d) Install the E-ring.

(e) I nstall the dust boot.

HM0123

2. INSTALL REVERSE SHIFT FORK AND SHAFT

(a) Apply MP grease to the interlock balls.
(b) Install the interlock ball into the case cover.

~------n-o------"...-------::~
:, -D ~
o o HM0124
HM0196

(c) Install the interlock ball into the reverse shift head.

(d) Apply MP grease to the interlock pin.

(e) Install the small interlock pin into the fork shaft hole.
MANUAL TRANSMISSION - HSO Transmission MT-S7

(f) Put the reverse sh ift fork into the case cover and in-
stall the fork shaft into the shift fork and reverse shift
head through the case cover.
(g) I nstall the E-ring.

3. INSTALL THIRD AND FOURTH SHIFT FORK AND

SHAFT
(a) Apply MP grease to the interlock pin.
(b) Install the interlock pin into the case cover.

HM0128
HM0197

(c) Apply MP grease to the small interlock pin.

(d) I nstall the small interlock pin into the fork shaft hole.

(e) Put the 3rd and 4th shift fork into the case cover and
install the fork shaft into the case cover through the
shift fork.

HM0130

4. INSTALL FIRST AND SECOND SHIFT FORK SHAFT,

SHIFT HEAD AND SHIFT FORK
(a) Apply MP grease to the interlock pin.
(b) I nstall the interlock pin into the case cover.

h 0 CCO 0
~,..--~-----"..~-----==
c=::J
l::J HM0131
HM0198
MT-S8 MANUAL TRANSMISSION - HSO Transmission

(c) Put the shift head and shift fork into the case cover
and install the fork shaft into the case cover through
the shift head and shift fork.

S. INSTALL TIGHT PLUGS

(a) Apply liquid sealer to the tight plugs.
(b) Drive in the tight plugs.
Drive in depth: 1 - 2 mm (0.04 - 0.08 in.)

HM0133 HM0134

6. INSTALL SLOTTED SPRING PINS

Using a pin punch and hammer, drive in the slotted spring
pins.

7. INSTALL SHIFT LEVER SHAFT

(a) Put the shift and select lever and pressure switch lever
into the shift lever housing.
(b) Install the shift lever shaft into the shift and select
lever and pressure switch lever through the shift lever
housing.

HM0136

(c) I nstall and torque the bolt.

Torque: 160 kg-cm (12 ft-Ib, 16 N·m)
MANUAL TRANSMISSION - H50 Transmission MT-59

(d) Apply liquid sealer to the tight plug and drive in it.
Drive in depth: 1.0 - 2.8 mm from shift lever shaft
(0.039 - 0.110 in.)

HM0137

(e) I nstall the washer and sh ift outer lever.

(f) Install the lock pin and nut.
Torque: 200 kg-cm (14 ft-Ib, 20 N·m)

HM010l

8. INSTALL SELECT LEVER SHAFT

(a) I nstall the select lever shaft, washer and select outer
lever.

HM013B

(b) I nstall the lock pin and nut.

Torque: 80 kg-cm (69 in.-Ib, 7.8 N·m)

HM0100
MT-60 MANUAL TRANSMISSION - H50 Transmission

ASSEMBLY OF TRANSMISSION
(See pages MT-40, 41)

1. INSTALL SECOND GEAR AND NEEDLE ROLLER

BEARING
(a) Apply gear oil to the output shaft.
(b) Install the needle roller bearing and 2nd gear.

2. INSTALL LOCKING BALL, BUSHING AND THIRD

GEAR
(a) Install the locking ball in the shaft.

HMOO41

(b) Install the bushing on the output shaft and align

the bushing notch and locking ball.
(c) Apply gear oil to the bushing.
(d) Install the 3rd gear on the bushing.

HMOO42

3. INSERT CLUTCH HUB NO. 2 INTO HUB SLEEVE

(a) Install the clutch hub and shifting keys to the hub

..
Front
(b)
sleeve.
Install the shifting key springs under the shifting
keys .
CAUTION: Install the key springs positioned so that
their ends are not in line.

HMOO43

4. INSTALL HUB SLEEVE NO.2 ASSEMBLY

Using a press, install the hub sleeve No. 2 assembly.
CAUTION: Hold the 3rd gear to prevent the bushing
from falling. Be sure that the shifting keys align with the
synchronizer ring slots.

HM0044
MANUAL TRANSMISSION - H50 Transmission MT-61

5. INSTALL SNAP RING

Select a snap ring that will allow minimum axial play and
install it on the shaft.

r Mark
0
1
2
2.40 - 2.45
2.45 - 2.50
2.50 - 2.55
Thickness mm (in.)
(0.0945 - 0.0965)
(0.0965 - 0.0984)
(0.0984 - 0.1004)
3 2.55 - 2.60 (0.1004 - 0.1024)
4 2.60 - 2.65 (0.1024 - 0.1043)
5 2.65 - 2.70 (0.1043 - 0.1063)
3rd Gear 2nd Gear

6. MEASURE SECOND AND THIRD GEARS THRUST

CLEARANCE
Using a feeler gauge, measure the 2nd and 3rd gear thrust
clearances.
Standard clearance:
2nd gear 0.175 - 0.325 mm (0.0069 - 0.0128 in.)
3rd gear 0.125 - 0.275 mm (0.0049 - 0.0108 in.)
Maximum clearance:
2nd gear 0.35 mm (0.0138 in.)
Synchron izer
3rd gear 0.30 mm (0.0118 in.)
Guide Pin
Ring Holder
7. ASSEMBLE SYNCHRONIZER RING HOLDER
Hook the synchronizer ring holder ends to the thrust piece.
Synch-
ronizer NOTE:
Ring • Align the synchronizer ring holder ends so they are not
Holder both facing in the same direction .
• So sure that the synchronizer ring holders are parallel
Thrust Piece
and not intersecting.

8. INSTALL SYNCHRONIZER RING NO. 1 AND FIRST

GEAR
(a) Install synchronizer ring No. 1.
(b) Apply gear oil to the needle roller bearing.
(c) Install the needle roller bearing and 1st gear.
(d) Apply MP grease to the straight pin and 1st gear
thrust washer.
(e) Install the 1st gear thrust washer on the output shaft
with the straight pin aligned with the 1st gear thrust
HM0048
washer.

9. INSTALL REVERSE SHIFT ARM

(a) Install the reverse shift arm so its pivot is positioned
as shown.
(b) Install the O-ring, plate washer, spring washer and nut.

HMOO49
MT-62 MANUAL TRANSMISSION - H50 Transmission

10. INSTALL REVERSE IDLER GEAR AND SHAFT

(a) Align the reverse idler gear groove with the reverse
shift arm shoe.
(b) Install the reverse idler gear shaft with the woodruff
key through the gear.

(c) Insta ll the E-ring onto the shaft.

11. PUT COUNTER GEAR INTO TRANSMISSION CASE

(a) Stand the transmission case on its front end.
(b) Put the counter gear into the case.
CAUTION : Be careful not to damage either end.

HM0025

12. PUT OUTPUT SHAFT ASSEMBLY INTO TRANS-

MISSION CASE
CAUTION : Be careful not to damage the front end of
the shaft.

HM0024

13. INSTALL OUTPUT SHAFT CENTER BEARING

(a) Using snap ring pliers, install the snap ring onto the
bearing.
(b) Confirm that the groove of the 1st gear thrust washer
and the straight pin are aligned.
(c) Using SST, install the bearing until it comes into
contact with the 1st gear thrust washer.
SST 09309-36040
MANUAL TRANSMISSION - H50 Transmission MT-63

14. INSTALL FIFTH GEAR TO OUTPUT SHAFT

(a) Apply MP grease to the inside surface of the 5th
gear.
(b) Using SST, install the 5th gear to the output shaft.
SST 09309-36040

15. INSTALL INPUT SHAFT

(a) Using snap ring pliers, install the snap ring onto the
bearing.
(b) Install the 17 needle roller bearings into the input
shaft.
(c) Apply MP grease to the needle roller bearings.

HMOO54

(d) Align the synchronizer ring slots with the shifting

keys.
(e) Using a plastic hammer, drive in the input shaft.
NOTE: Be sure that the counter gear is low enough so
as not to interfere with the input shaft.

HMOO55

16. INSTALL COUNTER GEAR FRONT BEARING

(a) Turn the transmission over and align the counter
gear center.
(b) Install the thrust collar for the front bearing onto
the counter gear.

Front H - Thrust
(c) Using SST, drive in the bearing.
_ ~ Call" SST 09316-60010
NOTE: When driving in the bearing, support the counter
H MOO57 HMOO56
gear in rear with a 3-5 Ib hammer or equivalent.
(d) Install the snap ring onto the bearing outer race.
(e) Select a snap ring that will allow minimum axial
play and install it on the counter gear front end.

Mark Thickness mm(in.)

0 2.05 - 2.10 (0.0807 - 0.0827)
2 2.15 - 2.20 (0.0846 - 0.0866)
4 2.25 - 2.30 (0.0886 - 0.0906)

HMOO58 HMOO59
MT-64 MANUAL TRANSMISSION - H50 Transmission

17. INSTALL COUNTER GEAR REAR BEARING

(a) Install the snap ring to the counter gear rear bearing.
(b) Using SST, drive the rear bearing into the trans-
mission case.
SST 09316-60010
NOTE: When driving in the bearing, support the counter
gear in front with 3-5 Ib hammer or equivalent.

HM0060

18. INSTALL REAR BEARING RETAINER

Install the rear bearing retainer to the transmission
case.
Torque the bolts.
Torque: 185 kg-cm (13 ft-Ib, 18 N.m)

HM0063

19. INSTALL STRAIGHT PIN AND COUNTER FIFTH

GEAR THRUST WASHER
(a) Install the straight pin onto the counter shaft.
(b) Align the thrust washer slot with the straight pin,
and install the thrust washer.

HM0064 HM0180

20. ASSEMBLE COUNTER FIFTH GEAR

(a) Install the No. 3 hub sleeve and shifting keys to the
counter 5th gear.
(b) Install the shifting key springs under the shifting
. . Front keys so that the spring ends are not in line, as shown
in the figure.

21. INSTALL NEEDLE ROLLER BEARING

(a) Apply MP grease to the needle roller bearing.
(b) Install the needle roller bearing into the counter
5th gear.
MANUAL TRANSMISSION - H50 Transmission MT-65

22. ASSEMBLE FIFTH SHIFT FORK

(a) Install the 5th shift fork to the shaft.
....
Front
(b)
(c)
Align the pin holes with the 5th shift fork and shaft .
Using a pin punch, drive in the slotted spring pin.

HM0115

23. INSTALL COUNTER FIFTH GEAR ASSEMBLY WITH

FIFTH SHIFT FORK
(a) I nstall the 5th shift fork and fork shaft onto hub
sleeve No. 3.
(b) Install the counter 5th gear assembly with the 5th
shift fork.

HMOO68

24. INSTALL SYNCHRONIZER RING AND GEAR SPLlNE

PIECE NO. 5
(a) Align the synchronizer ring slots with the shifting
keys, and place the synchronizer ring on the counter
5th gear rear end.
(b) Using SST, drive gear spline piece No. 5 into the
counter gear to where the lock nut can be installed.
SST 09316-6001 0
NOTE: When driving in gear spline piece No. 5, support
HM0069
the counter gear in front with a 3-5 Ib hammer or equiv-
alent.

25. INSTALL LOCK NUT TO COUNTER GEAR REAR END

(a) Engage the gear double meshing.

HMOln

(b) Using SST, install a new lock nut.

Torque the nut.
SST 09326-20011
Torque: 1,300 kg-cm (94 ft-Ib, 127 N·m)
(c) Disengage the gear double meshing.
MT-66 MANUAL TRANSMISSION - H50 Transmission

(d) Using a feeler gauge, measure the counter 5th gear

thrust clearance.
Standard clearance: 0.10 - 0.30 mm
(0.0039 - 0.0118 in.)
Maximum clearance: 0.30 mm (0.0118 in.)

Thrust Clearance
HMOO71

(e) Using a punch, stake the lock nut.

HMOO72

26. INSTALL FRONT BEARING RETAINER WITH A

GASKET
(a) Install the front bearing retainer with a gasket.
(b) Apply liquid sealer to the bolts.
(c) Install and torque the bolts.
Torque: 170 kg-cm (12 ft-Ib, 17 N·m)

27. INSTALL SPACER, SPEEDOMETER DRIVE GEAR

AND SPEEDOMETER DRIVE GEAR SPACER

28. INSTALL OUTPUT SHAFT REAR BEARING

Using SST, drive in the rear bearing.
SST 09316-60010

Thrust Clearance
29. MEASURE FIRST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance: 0.175 mm - 0.325 mm
(0.0069 - 0.0128 in.)
Maximum clearance: 0.35 mm (0.0138 in.)

HM0076
MANUAL TRANSMISSION - H50 Transmission MT-67

30. INSTALL FIFTH SHIFT ARM AND SHAFT

(a) Install the 5th shift arm shaft through the extension
housing and install the 5th shift arm.
(b) I nstall the bolt with a lock washer, and torque the
bolt.
Torque: 380 kg-cm (27 ft-Ib, 37 N·m)

HM0087

(c) Stake the lock washer.

HMOl17

31. INSTALL EXTENSION HOUSING WITH A GASKET

(a) Pull up the 5th shift arm and install the extension
housing.
(b) Align the 5th shift arm with the 5th shift fork.
(c) Apply liquid sealer to the bolts.

HMOl18

(d) Install and torque the bolts.

Torque: 600 kg-cm (43 ft-Ib, 59 N·m)

HMOl19

(e) Install the locking ball and spring.

(f) Apply liquid sealer to the screw plug.

HM0120
MT-68 MANUAL TRANSMISSION - H50 Transmission

(g) Using SST, install and torque the screw plug.

SST 09313-30021
Torque: 250 kg-cm (18 ft-Ib, 25 N·m)

32. INSTALL SPEEDOMETER DRIVEN GEAR

HM0121

33. INSTALL CASE COVER WITH A GASKET

(a) Install the case cover with a gasket.
(b) Install and torque the bolts.
Torque: 530 kg-cm (38 ft-Ib, 52 N·m)

HM0139

34. INSTALL SHIFT LEVER HOUSING WITH A GASKET

(a) Install t he locking balls and springs.
(b) Install the shift lever housing with a gasket.
(c) Install and torque the bolts.
Torque: 195 kg-cm (14 ft-Ib, 19 N·m)

35. INSTALL NEUTRAL SWITCH, BACK-UP LIGHT

SWITCH, SPEEDOMETER DRIVEN GEAR, SHIFT
LEVER SHAFT SUPPORT AND ENGINE REAR
HM0140 MOUNTING

36. INSTALL CLUTCH HOUSING

Torque the bolts.
Torque: 730 kg-cm (53 ft-Ib, 72 N.m)

HM0192

37. ADJUST REVERSE SHIFT ARM PIVOT POSITION

(a) Position the adjustment mark on the shift arm pivot
end toward the front side.
(b) If the select lever is catching on something, adjust
by moving the position of the alignment mark within
60°. '
(c) Torque the nut.
Torque: 250 kg-cm (18 ft-Ib, 25 N·m)

HM0141
MANUAL TRANSMISSION - Remote Control (DYNA Floor Shift Series) MT-69

REMOTE CONTROL
(DYNA FLOOR SHIFT SERIES)
COMPONENTS

[For Regular-Cab Type]

Control Lever

II/---Shift Lever
Selecting Rod No. 3 Selecting Rod No. 4
Selecting Lever No. 4
Control Lever
Support

Shifting Rod No. 3

~""""'I!!!!!!lld-:~irl

Shifting Rod No. 4

Cross Shaft No. 1 Cross Shaft No. 2

Shifting Rod No. 2

Selecting Link Selecting Rod No. 2

Shifting Lever

[For Wide-Cab Type]

Control Lever
Selecting Lever No. 4
Selecting Rod No. 3 Selecting Rod No. 4

Shifting Rod No. 4

Cross Shaft No. 2
Cross Shaft No. 1
Shifting Rod No. 2
Control Lever Support Selecting Rod No . 2
Selecting Link
Shifting Lever
HM0237
HM0142
MT-70 MANUAL TRANSMISSION - Remote Cont rol (DYNA Floor Shift Series)

Front . . ADJUSTMENT OF SHIFT LEVER NEUTRAL

POSITION
1. ADJUST CROSS SHAFT NO. 2 ANGLE
Adjust shifting rod No. 4 so t hat cross shaft No. 2 on the
shifting rod No. 3 side is 10 from perpendicular position.

Cross Shaft No. 2

o
Shifting Rod No . 4
HM0 143

[Ex. BU36] 2. ADJUST CONTROL LEVER ANGLE

Front ~
[ Ex. BU36]
Adjust selecting rod No. 4 so that the control lever on t he
selecting rod No. 3 side is at right angle to the frame.

Contro l Lever

Selecting Rod No. 4

HM0144

[For BU36]
~ Front [For BU36]
Selecting Rod No. 3 Adjust selecting rod No. 4 so that the control lever on the
selecting rod No. 3 side is at ri ght angle to the frame.

Selecting Rod No. 4

HM0241

3. ADJUST CROSS SHAFT NO. 1 ANGLE

Adjust shifting rod No. 3 so that cross shaft No. 1 is at
~ Front right angle to the frame .
. ~.-
..-.

Cross Shaft
No . l
Shifting Rod
No.3

HM0145

4. ADJUST SELECTING LEVER NO. 4

~ Front Selecting Rod No. 3 Adjust selecting rod No. 3 so that selecting lever No. 4 is
at right angle to the frame.

Selecting Lever No . 4

HM0146
MANUAL TRANSMISSION - Remote Control (DYNA Floor Shift Series) MT-71

Regular-Cab Type 5. ADJUST SHIFTING LEVER ANGLE

~~3- [Regular Cab]
Shifting Lever---j
Adjust shifting rod No. 2 so that the lower end of the
shifting lever is at an 8° angle toward the rear from perpen-
dicular.

HM0238

Wide-Cab Type [Wide Cab]

-{$;lB=E:==~_Shifting Rod Adjust shifting rod No. 2 so that the shifting lever is at
Shifting No. 1 right angle to the frame.
Lever

Shifting Rod No. 2 HM0147

Regular-Cab Type 6. ADJUST SELECTING LINK ANGLE

[Regular Cab]
Adjust selecting rod No. 2 so that the ends of the selecting
Selecting Link
link are at a 5° angle toward the rear from perpendicular.

HM0239

Wide-Cab Type [Wide Cab]

Adjust selecting rod No. 2 so that the selecting link is at
-{$;lB=E:==~_Selecting Rod
Selecting No.1 right angle to the frame.
Link

Selecting Rod No. 2 HM0148

7. ADJUST SHIFT LEVER NEUTRAL POSITION

Side View Rear View for LHD
! ! Adjust shifting rod No. 1 and selecting rod No. 1 so that
the lower straight part of the shift lever is perpendicular
to the floor.

Shift Direction Select Direction

HM0149 HM0150
MT-72 MANUAL TRANSMISSION - Remote Control (DYNA Column Shift Series)

REMOTE CONTROL
(DYNA COLUMN SHIFT SERIES)
COMPONENTS

l~---Shifting Lever

Control Lever

///r----Control Shaft Selecting Rod No. 4

(~~)J---Selecting Spring Cover

Shifting Rod No. 3

Shifting Rod No. 4

Shifting Rod No. 2

HM0155 HM0151

ADJUSTMENT OF SHIFT LEVER NEUTRAL

Front . . .
POSITION
1. ADJUST CROSS SHAFT NO. 2 ANGLE
Adjust shifting rod No. 4 so that cross No. 2 on the shift-
ing rod No. 3 side is 10 from perpendicular position.

Cross Shaft No. 2

HM0143

2. ADJUST CONTROL LEVER ANGLE

Front... Adjust selecting rod No. 4 so that the control lever on the
selecting rod No. 3 side is at right angle to the frame.

Selecting Rod No . 4
HM0144
MANUAL TRANSMISSION Remote Control (DYNA Column Shift Ser'les) MT-73

3. ADJUST SHIFTING LEVER ANGLE

Front ~
Adjust shifting rod No. 3 so that the shifting lever on the
shifting rod No. 3 side is at right angle to the center line
Shifting Rod of the vehicle.
No.3
Shift Lever

Shifting Rod
No.2

Vehicle Center
HM0152

4. ADJUST SELECTING LEVER ANGLE

Front . . .
Selecting Rod Adjust selecting rod No. 3 so that the selecting lever on the
~~diIC:D--No. 3 selecting rod No. 3 side is at right angle to the center line
Selecting Lever-j«f5.:lr::::DIIID of the veh icle.

Selecting Rod
No. 2 ------'-...Lj

HM0152

5. ADJUST SHIFT LEVER NEUTRAL POSITION

(a) Shift direction adjustment.
Adjust shifting rod No. 2, so the shift lever is po-
sitioned shown in the figure.

HM0154

(b) Select direction adjustment

• Loosen the select spring cover bolts on the steering
column tube.
• Adjust selecting rod No. 2 so that there is no
clearance between the control shaft upper stopper
and control upper shaft.
• Check the shift lever position is as shown in the
figure.
• Adjust the select spring cover so that there is no
HM0155 HM0156 clearance between the spring stopper on the control
shaft and the seat.
• Tighten the select spring cover bolts.

"~-Sl)ring Stopper

Cover
HM0157
TF-1

TRANSFER
Page
TRANSFER ............................... . TF-2
Components ............. . ............... . TF-2
Disassembly of Transfer ..... . .............. . TF-4
Inspection of Transfer Components ........... . TF-9
Assembly of Transfer ...................... . TF-15

El
TF-2 TRANSFER Transfer

TRANSFER
COMPONENTS

Front Case Rear Case

Case Cover No. 2

Idler Gear

o
Idler Gea r Shaft
Front Companion Flange Beanng
. Reta .mer

Fm~OI"ii @ Power Take Off Cover

Bearing Retainer

Rear Companion Flange

Rear Output Shaft

~ High and Low Outer Lever

,--Spring

~ W Dust Boot 0-- Locking Ball

~T D6
8

~
Spring Q
Locking Ball -0

a:4 0 :J
High and Low Inner Lever I
High and Low Shift
Front Drive Shift Fork Shaft
Fork Shaft
Front Drive Shift Fork

High and Low Shift Fork

TFOl 72
TRANSFER - Transfer TF-3

COMPONENTS (Cont'd)

Transfer Input Gear

Spacer
Power Take-Off Drive Gear

Spacer

6
Oil Receiver O-Ring
Idler Gear Thrust Washer Idler Gear Shaft

~vr.-b.B.";ng
VJ.JL_ _~O

?
Idler Gear Shaft Lock Plate

Snap Ring Snap Ring

Front Output Shaft Bearing Clutch Sleeve

High Gear
Rear Output Shaft Front Bearing

Rear Output Shaft

~
Clutch Sleeve
Low Gear
Rear Output Shaft Rear Bearing
Adjusting Shim

6,!,,"Spacer
0,;" G",

TF0173
TF-4 TRANSFER - Transfer

DISASSEMBLY OF TRANSFER
1. REMOVE SPEEDOMETER DRIVEN GEAR

2. REMOVE TRANSFER INDICATOR SWITCH

Using SST, remove the transfer indicator switch.
SST 0981 7-160 11

TFOl12

3. CHECK PRELOAD
(a) Shift the shift lever into N position.
(b) Using a torque meter, measure the preload (starting).
Preload:
New bearing 15 - 24.7 kg-cm
(13.0 - 21.4 in.-Ib, 1.5 - 2.4 N·m)
Reused bearing 7 - 12 kg-cm
(6.1 - 10.4 in.-Ib, 0.7 - 1.2 N·m)

TFOl13

4. REMOVE PLUGS, SPRINGS AND LOCKING BALLS

Remove the plugs and, using a magnetic finger, remove the
springs and locking balls.

TF0114

5. REMOVE TRANSFER FRONT DRIVE SHAFT LEVER

(a) Shift the shift lever to L4 position.
(b) Disconnect the high and low shift rod end from the
transfer shift outer lever.
(c) Loosen the bolt and nut, and remove the transfer
shift lever guide.
(d) Remove the transfer shift lever subassembly from the
support shaft.

TF0115

6. REMOVE REAR COMPANION FLANGE

(a) Using a hammer and chisel, loosen the staked part of
the nut.
(b) Using SST to hold the front companion flange, re-
move the nut and washer.
SST 09330-00020
(c) Remove the rear companion flange.
TRANSFER - Transfer TF-5

7. REMOVE TRANSFER CASE COVER NO.2 AND

TRANSMISSION OUTPUT SHAFT LOCK NUT
(a) Remove the six bolts, and remove the transfer case
cover No. 2.
(b) Using a hammer and chisel, loosen the staked part of
the nut.
(c) Using SST to hold the front companion flange, remove
the transmission output shaft lock nut.
SST 09330-00020
TFO l 18 TFOl1 7

8. REMOVE FRONT COMPANION FLANGE

(a) Using a hammer and chisel, loosen the staked part of
the nut.
(b) Use SST to hold the front companion flange.
SST 09330-00020
(c) Remove the front companion flange .

T FOl 19

9. REMOVE POWER TAKE-OFF COVER

Remove the six bolts, and remove the power take-off cover.

TF0120

10. MEASURE IDLER GEAR THRUST CLEARANCE

Using a feeler gauge, measure the clearance between the
idler gear and thrust washer.
Standard clearance: 0.28 - 0.62 mm
(0.0110 - 0.0244 in.)
Maximum clearance: 0.62 mm (0.0244 in.)

TF0 17 1

11. REMOVE REAR OUTPUT SHAFT REAR BEARING

RETAINER
(a) Remove the six bolts, and remove the rear output
shaft rear bearing retainer.
(b) Remove the speedometer drive gear and spacer.
TF-6 TRANSFER - Transfer

12. REMOVE IDLER GEAR SHAFT LOCK PLATE

TF01 22

13. REMOVE TRANSFER REAR CASE

(a) Remove the bolts.
(b) Using a plastic hammer, remove the transfer rear case.

TF 0 123

14. REMOVE REAR OUTPUT SHAFT ASSEMBLY WITH

SHIFT FORK AND SHIFT FORK SHAFT

TF0 124

15. REMOVE SHIFT FORK SHAFT

(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the shift fork shaft from the shift fork.
NOTE: Use a set of soft jaws in the vise to protect the
shift fork.

T F0125

16. REMOVE TRANSFER INPUT GEAR BEARING, POWER

TAKE-OFF DRIVE GEAR AND SPACER
(a) Using SST, remove the transfer input gear bearing.
SST 09950-20015
(b) Remove the power take-off drive gear and the spacer.

TF 0126
TRANSFER - Transfer TF-7

17. REMOVE TRANSFER INPUT GEAR

Using SST, remove the transfer input gear.
SST 09950-20015

TFOl77

18. REMOVE IDLER GEAR, BEARINGS, SPACER AND

IDLER GEAR SHAFT
(a) Remove the O-ring.
(b) Remove the idler gear, bearing and spacer.
(c) Remove the idler gear shaft.

TF0127

19. REMOVE REAR OUTPUT SHAFT FRONT BEARING

RETAINER
Using SST, remove the output shaft front bearing retainer.
SST 09308-10010

20. REMOVE CLUTCH SLEEVE

Remove the clutch sleeve with the shift fork and shift fork
shaft.

21. REMOVE SHIFT FORK SHAFT

(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the shift fork shaft from the shift fork.
NOTE: Use a set of soft jaws in the vise to protect the
shift fork.

TF0130
TF-8 TRANSFER - Transfer

22. REMOVE TRANSFER FRONT CASE

(a) Remove the four bolts.
(b) Using a plastic hammer, remove the transfer front
case.

TF0131

23. REMOVE FRONT OUTPUT SHAFT

Using a press, remove the front output shaft.

TF0178

24. REMOVE TRANSFER HIGH AND LOW SHIFT OUTER

AND INNER LEVER

TF0132

25. REMOVE REAR OUTPUT SHAFT OIL SEAL

Using a screwdriver, remove the oil seal.

TF0182
TRANSFER - Transfer TF-9

INSPECTION OF TRANSFER COMPONENTS

1. CHECK OIL CLEARANCE AND THRUST CLEARANCE
OF TRANSFER HIGH GEAR
(a) Using a dial indicator, measure the oil clearance be-
tween the gear and shaft.
Standard clearance: 0.035 - 0.081 mm
(0.0014 - 0.0032 in.)
Maximum clearance: 0.081 mm (0.0032 in.)
TF0133

(b) Using a feeler gauge, measure the thrust clearance.

Standard clearance: 0.10 - 0.25 mm
(0.0039 - 0.0098 in.)
Maximum clearance: 0.25 mm (0.0098 in.)

TFOl34

2. CHECK OIL CLEARANCE AND THRUST CLEARANCE

OF TRANSFER LOW GEAR
(a) Using a dial indicator, measure the oil clearance
between the gear and shaft.
Standard clearance: 0.035 - 0.081 mm
(0.0014 - 0.0032 in.)
Maximum clearance: 0.081 mm (0.0032 in.)

TF0135

(b) Using a feeler gauge, measure the thrust clearance.

Standard clearance: 0.10 - 0.25 mm
(0.0039 - 0.0098 in.)
Maximum clearance: 0.25 mm (0.0098 in.)

3. MEASURE CLEARANCE OF SHIFT FORKS AND HUB

SLEEVES
Using a feeler gauge, measure the clearance between the
hub sleeves and shift fork.
Standard clearance: 0.1 - 0.4 mm (0.004 - 0.016 in.)

WM0066
TF-l0 TRANSFER - Transfer

4. IF NECESSARY, REPLACE REAR OUTPUT SHAFT

BEARINGS
(a) Using a snap ring pliers, remove the snap ring.

TF0137

Front Rear
(b) Using a press, remove the H I and La gears and bear-
ings.

TFOl38 TF0139

(c) Using SST, remove the output shaft pilot bearing.

SST 09319-60020
NOTE: The bearing will break.

TF0140

(d) Using SST, press in a new pilot bearing.

SST 09316-60010
(e) Apply MP grease to the pilot bearing.

TF0141

Front (f) Using SST, press in a new bearing.

SST 09316-60010
TRANSFER - Transfer TF-11

(g) Select a snap ring that will allow minimum axial play
and install it on the shaft.

Mark Thickness mm (in .)

11 2.30 - 2.35 (0.0906 - 0 .0925)
17 2.60 - 2.65 (0.1024 - 0.1043)

TF0144

(h) Using SST, remove the rear output shaft front bearing
outer race.
SST 09514-35011

TF0 1S0

(i) Using SST, remove the rear output shaft rear bearing
outer race and shim.
SST 09514-35011

TF01S l

(j) Using SST, press a new front outer race into the front
bearing retainer.
SST 09316-60010

TF0 149

(k) Install the thinnest shim into the rear bearing retainer.
(I) Using SST, press in a new rear outer race to the rear
bearing retainer.
SST 09316-6001 0

T F01SS
TF-12 TRANSFER - Transfer

5. IF NECESSARY, REPLACE FRONT OUTPUT SHAFT

BEARING AND OIL SEAL
(a) Using a screwdriver, remove the oil seal.

TF0179

(b) Using a screwdriver, remove the snap ring.

(c) Using SST, press out the bearing .

• SST 09316-60010

TF0183

(d) Using SST, press in a new bearing.

SST 09316-60010
(e) Instal l the snap ring.

TF0184
TRANSFER - Transfer TF-13

6. INSPECT IDLER GEAR BEARING AND SHAFT

TF0152

7. INSPECT HIGH AND LOW GEAR SELECT LEVER OIL

SEAL
(a) Check for damage.
(b) Check the oil seal lip for wear or damage.

8. IF NECESSARY, REPLACE HIGH AND LOW GEAR

SELECT LEVER OIL SEAL
(a) Using a screwdriver, remove the oil seal.

TFOl54

(b) Using SST and hammer, drive in a new oil seal.

SST 09608-20011
(c) Apply MP grease to the oil seal.

TF0155

9. INSPECT SPEEDOMETER DRIVEN GEAR OIL SEAL

(a) Check for damage.
(b) Check the oil seal lip for wear or damage.

10. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN

GEAR OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09921-00010

WM010B

(b) Using SST, drive a new oil seal into the sleeve.
SST 09201-60011
20mm Oil seal depth: 20 mm (0.79 in.)

~cBl~=
SST

WM0109
TF-14 TRANSFER - Transfer

11. IN NECESSARY, REPLACE TRANSMISSION REAR

OIL SEAL
(a) Using a screwdriver, remove the transmission rear oil
seal.

TF0150

(b) Using SST, drive in a new oil seal.

SST 09316-60010
(c) Apply MP grease to the oil seal.
TRANSFER - Transfer TF-15

ASSEMBLY OF TRANSFER
(See pages TF-2, 3)
1. INSTALL TRANSFER HIGH AND LOW SHIFT OUTER
AND INNER LEVER

TF0132

2. INSTALL FRONT OUTPUT SHAFT

Using SST, press in the front output shaft to the transfer
front case.
SST 09316-60010

TF0183

3. INSTALL TRANSFER FRONT CASE

(a) Apply MP grease to the oil seal.
(b) I nstall the front case with a new gasket to the transfer
adapter.
(c) Apply liquid sealer to the bolt, and install and torque
as shown.
(d) I nstall and torque the other bolts.
Torque: 650 kg-cm (47 ft-Ib, 64 N·m)

4. INSTALL SHIFT FORK SHAFT

(a) Install the shift fork shaft into shift fork No. 1.
(b) Using a pin punch and a hammer, drive in the slotted
spring pin.
NOTE: Use a set of soft jaws in the vise to protect the
shift fork.

TF0130

5. INSTALL CLUTCH SLEEVE WITH SHIFT FORK NO. 1

AND SHAFT

TF0129
TF-16 TRANSFER - Transfer

6. INSTALL REAR OUTPUT SHAFT FRONT BEARING

RETAINER
Using a plastic hammer, install the rear output shaft front
bearing retainer.

TF0156

7. INSTALL IDLER GEAR

(a) Install a new O-ring on the idler gear shaft front side
groove.
(b) Install the idler gear shaft to the transfer front case.
(c) Install the idler gear thrust washer.
NOTE: Be sure that protruding part of washer fits in the
case groove.

TF0157

(d) Apply MP grease to the two bearings.

(e) Install the two bearings and spacer to the idler gear
shaft.
(f) Install the idler gear to the idler gear shaft.

TF0127

8. INSTALL TRANSFER INPUT GEAR

Using SST, install the transfer input gear.
SST 09309-36032

TF0158

9. INSTALL SPACER, POWER TAKE-OFF DRIVE GEAR

AND INPUT GEAR BEARING
(a) I nstall the spacer and power take-off gear.
(b) Using SST and hammer, drive in a new input gear
bearing.
SST 09316-60010
TRANSFER - Transfer TF-17

10. INSTALL SHIFT FORK SHAFT

(a) Install the shift fork shaft into shift fork No. 2.
(b) Using a pin punch and a hammer, drive in the slotted
spring pin.
NOTE: Use a set of soft jaws in the vise to protect the
shift fork.

TF0 125

11. INSTALL REAR OUTPUT SHAFT WITH SHIFT FORK

AND SHAFT

T F0124

12. STICK ON THRUST WASHER

Stick the thrust washer to the transfer rear case with MP
grease.
NOTE: Be sure that protruding part of washer fits in the
case groove.

TF0160

13. INSTALL TRANSFER REAR CASE

Liquid Sealer (a) Place a new gasket on the front case.
(b) Install the rear case.
(c) Apply liquid sealer to the bolt as shown.
(d) I nstall and torque the bolts.
Torque:
17 mm 650 kg-cm (47 ft-Ib, 65 N·m)
14 mm 400 kg-cm (29 ft-Ib, 39 N·m)
T F0 175

14. INSTALL a-RING AND LOCK PLATE

(a) Align the shaft groove to the bolt hole.
(b) I nstall an a-ring on the shaft groove.
(c) Using a plastic hammer, drive in the shaft.
(d) Install the lock plate and bolt. Tighten the bolt.
Torque: 150 kg-cm (11 ft-Ib, 15 N.m)

TF0 16 1
TF-18 TRANSFER - Transfer

15. INSTALL SPEEDOMETER DRIVE GEAR AND

SPACER

TF0162

16. INSTALL FRONT OUTPUT SHAFT OIL

SEAL
Using SST and a hammer, drive in a new oil seal.
SST 09316-60010

TF0147

17. INSTALL FRONT COMPANION FLANGE

(a) I nstall the front companion flange to the output shaft.
(b) Using SST to hold the flange, install the washer and a
new nut. Torque the nut.
SST 09330-00020
Torque: 1,300 kg-cm (94 ft-Ib, 127 N·m)
(c) Stake the nut.

TF0163

18. INSTALL TRANSMISSION OUTPUT SHAFT LOCK

NUT
(a) Shift the transfer shift lever into 4L position.
(b) Using SST to hold the front companion flange, install
the washer and a new nut. Torque the nut.
SST 09330-00020
Torque: 1,300 kg-cm (94 ft-Ib, 127 N·m)
(c) Stake the nut.
TFOl64 TFOl17

19. INSTALL TRANSFER CASE COVER NO. 2

(a) I nstall transfer case cover No. 2 with a new gasket to
the transfer rear case.
(b) Apply liquid sealer to the six bolts.
(c) I nstall and torque the bolts.
Torque: 165 kg-cm (12 ft-Ib, 16 N·m)

TF0176
TRANSFER - Transfer TF-19

20. MEASURE REAR OUTPUT SHAFT PRELOAD

(a) I nstall the rear output shaft rear beari ng retainer.
• Align the bearing retainer rib with the case.
• I nstall and torque the bolts.
Torque: 350 kg-cm (25 ft-Ib, 34 N·m)

TF0165

(b) I nstall the rear companion flange.

• Install the rear companion flange to the output
shaft.
• Using SST to hold the front companion flange, in-
stall the washer and nut. Torque the nut.
SST 09330-00020
Torque: 1,300 kg-cm (94 ft-Ib, 127 N·m)
SST SST
TF0166 TF01 17

(c) Shift the transfer shift lever to the N position.

(d) Using a torque meter, measure the rear output shaft
preload (Starting torque).
Preload:
New bearing 15 - 24.7 kg-cm
(13.0 - 21.4 in.-Ib, 1.5 - 2.4 N.m)
Reused bearing 7 - 12 kg-cm
( 6.1 - 10.4 in.-Ib, 0.7 - 1.2 N.m)

TF0113

21. IF NECESSARY ADJUST REAR OUTPUT SHAFT

PRELOAD
(a) Remove the rear companion flange.
• Use SST to hold the front companion flange.
• Remove the rear companion flange.
SST 09330-00020

TF01 16 TF0 117

(b) Remove the rear output shaft rear bearing retainer.

TF012 1
TF-20 TRANSFER - Transfer

(c) Using SST, remove the output shaft rear bearing

outer race and shim.
SST 09514-35011
(d) Select a shim.

Mark Thickness mm (in.) Mark Thickness mm (in.)

0 0.15 (0.0059) 10 1.0 (0.039)
4 0.4 (0.016) 11 1.1 (0.043)
5 0.5 (0.020) 12 1.2 (0.047)
TF0181
6 0.6 (0.024) 13 1.3 (0.051 )
7 0.7 (0.028) 14 1.4 (0.055)
8 0.8 (0.031 ) 15 1.5 (0.059)
9 0.9 (0.035)

NOTE: The preload will change about 10.0 kg-cm (8.7

in.-Ib, 1.0 N·m) with each shim thickness.

(e) Using SST, press in the bearing outer race and shim.
SST 09316-60010

SST

TF0185

(f) I nstall the rear output shaft rear bearing retainer.

• Align the bearing retainer rib with the case rib and
install the retainer with a new gasket.
• I nstall and torque the bolts.
Torque: 350 kg-cm (25 ft-Ib, 34 N·m)

TF0165

(g) Install the rear companion flange.

• Install the rear companion flange to the output
shaft.
• Using SST to hold the front companion, install the
washer and nut.
SST 09330-00020
Torque: 1,300 kg-cm (94 ft-Ib, 127 N·m)
SST
TF0166 TFOl17
TRANSFER - Transfer TF-21

(h) Measure the rear output shaft preload.

• Using a torque meter, measure the rear output
shaft preload.
Preload:
New bearing 15 - 24.7 kg-cm
(13.0 - 21.4 in.-Ib, 1.5 - 2.4 N·m)
Reused bearing 7 - 12 kg-cm
( 6.1 - 10.4 in.-Ib, 0.7 -1.2 N·m)
(i) If necessary, adjust the output shaft preload again.
TFO l1 3

22. REMOVE REAR COMPANION FLANGE

(a) Use SST to hold the front companion flange.
(b) Remove the rear companion flange.
SST 09330-00020

T FOl16 TFOl17

23. REMOVE REAR OUTPUT SHAFT REAR BEARING

RETAINER

24. INSTALL REAR OUTPUT SHAFT REAR BEARING

RETAINER
(a) Align the bearing retainer rib with the case rib and
install the retainer with a new gasket.
(b) Apply liquid sealer to the six bolts.
(c) Install and torque the bolts.
Torque: 350 kg-cm (25 ft-Ib, 34 N·m)

TF0165

25. INSTALL REAR OUTPUT SHAFT OIL SEAL

Using SST and a hammer, drive in a new rear output shaft
oil seal.
SST 09316-60010

TF0170
TF-22 TRANSFER - Transfer

26. INSTALL REAR COMPANION FLANGE

(a) Install the companion flange to the rear output shaft.
(b) Using SST to hold the front companion flange, install
the washer and a new nut. Torque the nut.
SST 09330-00020
Torque: 1,300 kg-cm (94 ft-Ib, 127 N.m)
(c) Stake the nut.

TF0166 TFOl17

27. INSTALL POWER TAKE-OFF COVER

(a) Install the power take-off cover with a new gasket to
the transfer rear case.
(b) Apply liquid sealer to the bolt, as shown, and install
and torque the bolts.
Torque: 170 kg-cm (12 ft-Ib, 17 N·m)
(c) I nstall and torque the other bolts.
Torque: 185 kg-cm (13 ft-Ib, 18 N·m)
TF0120

28. INSTALL TRANSFER INDICATOR SWITCH

Using SST, install and torque the transfer indicator switch.
SST 09817-16011
Torque: 450 kg-cm (33 ft·lb, 44 N·m)

TFOl12
A-1

SERVICE SPECIFICATIONS
Page
MANUAL TRANSMISSION .................... A-2
TRANSFER ... .............................. A-4

IEIIII
A-2 SERVICE SPECIFICATIONS - Manual Transmission

MANUAL TRANSMISSION
Specifications

Output shaft
1sf and 2nd gear journal diameter Limit 43.93 mm 1.7295 in.
Runout Limit 0.03 mm 0.0012 in.
3rd gear bushing outer diameter Limit 45.85 mm 1.8051 in.
1st and 2nd gear inner diameter Limit 50.10 mm 1.9724 in.
3rd gear inner diameter Limit 46.07 mm 1.8138 in.
Cou nter gear
5th gear journal diameter Limit 31.93 mm 1.2571 in.
Rear bearing journal diameter Limit 39.00 mm 1.5354 in.
Counter 5th gear inner diameter Limit 39.07 mm 1.5382 in.
Reverse idler gear inner diameter Limit 30.10 mm 1.1850 in.
Reverse shift arm shoe to idler groove clearance Limit 0.7 mm 0.028 in.
Reverse shift arm shoe thickness 8.1 mm 0.319 in.
Gear thrust clearance
1st and 2nd STD 0.175 - 0.325 mm 0.0069 - 0.0128 in.
Limit 0.35 mm 0.0138 in.
3rd STD 0.125 - 0.275 mm 0.0049 - 0.0108 in.
Limit 0.30 mm 0.0118 in.
Counter 5th STD 0.10 - 0.30 mm 0.0039 - 0.0118 in.
Limit 0.30 mm 0.0118 in.
Gear oil clearance
1st and 2nd STD 0.020 - 0.073 mm 0.0008 - 0.0029 in.
Limit 0.08 mm 0.0031 in.
3rd STD 0.065 - 0.115 mm 0.0026 - 0.0045 in.
Limit 0.12 mm 0.0047 in.
Counter STD 0.015 - 0.068 mm 0.0006 - 0.0027 in.
Limit 0.07 mm 0.0028 in.
Reverse idle STD 0.060 - 0.135 mm 0.0024 - 0.0053 in.
Limit 0.16 mm 0.0063 in.
Shift fork to hub sleeve clearance Limit 0.8 mm 0.031 in.
Synchronizer ring to gear clearance
3rd, 4th and 5th Limit 0.8mm 0.031 in.
Synchronizer ring to gear distance
1st gear Limit 32.5 mm 1.280 in.
2nd gear Limit 38.0 mm 1.496 in.
Input shaft snap ring thickness
Part No.
90520-36016 3.20 - 3.31 mm 0.1260-0.1303 in.
90520·36015 3.31 - 3.42 mm 0.1303 - 0.1346 in.
SERVICE SPECIFICATIONS - Manual Transmission A-3

Specifications (Cont'd)

Output shaft snap ring thickness

Part No. Mark
90520-36250 o 2.40 - 2.45 mm 0.0945 - 0.0965 in.
90520-36251 1 2.45 - 2.50 mm 0.0965 - 0.0984 in.
90520-36252 2 2.50 - 2.55 mm 0.0984 - 0.1004 in.
90520-36253 3 2.55 - 2.60 mm 0.1004 - 0.1024 in.
90520-36254 4 2.60 - 2.65 mm 0.1024 - 0.1043 in.
90520-36255 5 2.65 - 2.70 mm 0.1043 - 0.1063 in.

Counter gear snap ring thickness

Part No. Mark
90520-30214 o 2.05 - 2.10 mm 0.0807 - 0.0827 in.
90520-30216 2 2.15 - 2.20 mm 0.0846 - 0.0866 in.
90520-30218 4 2.25 - 2.30 mm 0.0886 - 0.0906 in.

Oil seal drive in depth

Speedometer driven gear 20.0 mm 0.787 in.
5th shift arm shaft 1.0mm 0.039 in.

Oil seal installed height (H55F only)

5th fork shaft oil seal for case cover 4.0 -4.5 mm 0.157 -0.177 in.

Tight plug drive in depth

Shift lever shaft 1.0 - 2.8 mm 0.039 - 0.110 in.
Shift fork shaft 1 -2 mm 0.04 - 0.08 in.

Tightening Torque

Tightening part kg-cm ft-Ib N·m

Center bearing retainer 185 13 18

Front bearing retainer 170 12 17
Counter gear rear lock nut 1,300 94 127
5th sh ift arm x Shaft 380 27 37
Shift lever shaft x Pressure switch 160 12 16
Shift outer lever lock pin 200 14 20
Select outer lever lock pin 80 69 in.-Ib 7.8
Extension housing x Transmission case 600 43 59
Straight screw plug for 5th locking ball and spring 250 18 25
Clutch housing x Transmission case 730 53 72
Case cover x Transmission case
H50 530 38 52
H41, H42 and H55F 400 29 39
Shift lever housing x Case cover 195 14 19
Reverse shift arm pivot lock nut 250 18 25
Parking Brake drum lock nut (H50 only) 1,300 94 127
A-4 SERVICE SPECIFICATIONS - Transfer

TRANSFER
Specifications
High and low gear oil clearance
STD 0.035 - 0.081 mm 0.0014 - 0.0032 in.
Limit 0 .081 mm 0.0032 in.
High and low gear thrust clearance
STD 0.10 - 0.25 mm 0.0039 - 0.0098 in.
Limit 0.25 mm 0.0098 in.
Shift fork to hub sleeve clearance
STD 0.1 - 0.4 mm 0.004 - 0.016 in.
Rear output shaft snap ring thickness
Mark
11 2.30 - 2.35 mm 0.0906 - 0.0925 in.
17 2.60 - 2.65 mm 0.1024 - 0.1043 in.
Idler gear thrust clearance
STD 0.28 - 0.62 mm 0.0110 - 0.0244 in.
Limit 0.62 mm 0.0244 in.
Rear output shaft preload
New bearing 15 - 24.7 kg-cm (13.0 - 21.4 in.·lb, 1.5 - 2.4 N·m)
Reused bearing 7 -12 kg·cm (6.1 -10.4 in.-Ib, 0.7 -1.2 N·m)
Rear output shaft preload adjusting shim
Mark
o 0.15 mm 0.0059 in.
4 0.4 mm 0.016 in.
5 0.5 mm 0.020 in.
6 0.6 mm 0.024 in.
7 0.7 mm 0.028 in.
8 0.8 mm 0.031 in.
9 0 .9 mm 0.035 in.
10 1.0 mm 0.039 in.
11 1.1 mm 0.043 in.
12 1.2 mm 0.047 in.
13 1.3 mm 0 .051 in.
14 1.4 mm 0.055 in.
15 1.5 mm 0.059 in.
SERVICE SPECIFICATIONS - Transfer A-5

Tightening Torque

Tightening part kg-cm ft-Ib N-m

Transfer front case x Transmission case 650 47 64

Transfer front case x Transfer rear case
17 mm 650 47 64
14 mm 400 29 39
Idler gear shaft lock plate bolt 150 11 15
Front companion flange lock nut 1,300 94 127
Transfer rear case x Transfer case cover No . 2 165 12 16
Transfer rear case x Rear output shaft rear bearing retainer 350 25 34
Rear companion flange lock nut 1,300 94 127
Transmission output shaft lock nut 1,300 94 127
Transfer rear case x Power take-off cover
With liquid sealer 170 12 17
Others 185 13 18
Transfer indicator switch 450 33 44
B-1

STANDARD BOLT
TIGHTENING TORQUE
Page
STANDARD BOLT TIGHTENING TORQUE ..... B-2
B-2 STANDARD BOLT TIGHTENING TORQUE

STANDARD BOLT TIGHTENING TORQUE

HOW TO DETERMINE BOLT STRENGTH

Mark Class Mark Class

Hexagon Stud bolt

4- 4T
I
I0(h"d
head bolt Bolt
No mark
5- 5T
4 No. r-
6- 6T
~
7- 7T ~ 4T
~
~

Hexagon
0 No mark 4T ~

0
flange bolt
No mark 4T Grooved
w/Washer ~/
v
hexagon bolt g
~~ 6T
Hexagon
head bolt

en Two
protruding
lines
5T ~
~

Hexagon Welded bolt

Q
flange bolt Two
protruding 6T
w/Washer
lines

~
hexagon bolt
4T
Hexagon

0
head bolt Three
protruding 7T
lines

Hexagon bolt Stud bolt

IT
Example 91111-40620 Example 92132-40620

T.ngth (mm J
Diameter (mm)
rT Jnoth (mmJ
Diameter (mm)
Strength Class Strength Class

~;.mot"
Length
..J
_ _-
L,ngth~
O;'mot"
STANDARD BOLT TIGHTENING TORQUE B-3

SPECIFIED TORQUE FOR STANDARD BOLTS

Tightening torque
Diameter Pitch mm Hexagon head bolt Hexagon flange bolt
Class mm
kg-cm ft-Ib N'm kg-cm ft-Ib N·m

6 1 55 48 in.- Ib 5.4 60 52 in.-Ib 5.9

8 1.25 130 9 13 145 10 14

10 1.25 260 19 25 290 21 28

4T 540 39 53
12 1.25 480 35 47

14 1.5 760 55 75 850 61 83

16 1.5 1,150 83 113 -

6 1 65 56 in.·lb 6.4 -

8 1.25 160 12 16 -
10 1.25 330 24 32 -
5T
12 1.25 600 43 59 -
14 1.5 930 67 91 -

16 1.5 1,400 101 137 -

6 1 80 69 in.-Ib 7.8 90 78 in.-Ib 8.8

8 1.25 195 14 19 215 16 21

6T 10 1.25 400 29 39 440 32 43

12 1.25 730 53 72 810 59 79

14 1.5 - 1,250 90 123

6 1 110 8 11 120 9 12

8 1.25 260 19 25 290 21 28

10 1.25 530 38 52 590 43 58

7T 1.25 970 70 95 1,050 76 103
12

14 1.5 1,500 108 147 1,700 123 167

16 1.5 2,300 166 226 -

C-1

SST
Page
SST (SPECIAL SERVICE TOOLS) ........... . . . C-2
C-2 SST

SST (SPECIAL SERVICE TOOLS)

1\ Illustration
Section

• Part No.
MANUAL TRANSMISSION

H41, 42 H55F H50

TRANSFER

• Pa"Name \

~ • •
( Valve Stem Guide )
09201-60011 Remover & Replacer

~ 09213-27010 (Gear Remover!

• • •
3
1i 09304-47010
~ •
( Input Shaft Front )
- ", Bearing Replacer

~ 09308-00010 (Oil Seal Puller!

•
~ 09308-10010 (Oil Seal Puller!
•
~dD
@@ . -
09309-36032
( TranSmission
Bearing Replacer
)
• • •
~..-J
@@ ~
09309-36040 (Transmission Bearing )
Replacer
•
~ 09309-60010 (Extension Pipe)
•
@)J1 09313-30021 ( Detent Ball PlUg )
Socket
• • •
@ oe
• • • •
( TranSmiSSion & )
@<g:l 09316-60010 Transfer Bearing
~~@> Replacer

~ •
( Output Shaft )
09319-60020 Needle Roller
Bearing Remover

~ • • •
09326-20011 ( output Shaft Bearing )
Lock Nut Wrench

~
- "- -
~
09330-00020 ( COmpanion Flange )
Holding Tool •
~~~ 09514-35011 ( Rear Wheel Bearing )
Puller
•
¥ 1<

SST C-3

SST (SPECIAL SERVICE TOOLS)

1\ Section MANUAL TRANSMISSION

TRANSFER

Illustration • Part No. .Pa.' Name\ H41,42 H55F H50

® 09515-21010 ( RearAXle Shaft )

Beanng Replacer
•
~ 09602-10010 ( Front Axle Inner )
Beanng Puller
•
@!:
@!
( Front Hub & DriVe )

•
68
~ 09608-20011 Pinion Bearing
~
c::::=- @ a;> @ Tool Set

~ 09817-16011 ( Back-uP Light )

SWitch Tool
• • • •
~~
~
6~' ~ -.P
,~
Gl<:;
09910-00015 (Puller Set)
• • •
~ 09921-00010 (Spring Tension Tool)
• •
~-- ~:.
~
~~ ~
c:::::>
~
. ~. II
09950-20015 (Universal Puller!
• • • •
0'1 RSEAS SERV.C'EE~Il• •~~
TOYOTA MOTOR L~
Haruhi eenter