Transmission
2. Remove the parts in the numerical order shown in the figure.
1 Battery Terminal 4. Heater Duct
2 Scuff Plate 5. Carpet or Mat
1 Battery Terminal 4. Heater Duct
2 Scuff Plate 5. Carpet or Mat
6. Shift Lever Knob & Transfer Knob 7 Service Hole Cover with boot
8. Back-up Light Switch Connector
SST 45142 10. Transfer Shift Lever
1 7. Tachometer Sensor (For BJ, HJ Series)
18. Engine Rear Supportmember
19. Transmission & Transfer
0 Support the transmission and transfer assembly with jacks and a rope, and remove.
1. Remove the parts in the numerical order shown in the figure.
TRANSFER DISASSEMBLY SECTION Fig. 4-1 to 4-24
Separate the transfer from the transmission.
2. Disassemble the parts in the numerical order shown in the figure.
3. Disassemble the parts in the numerical order shown in the figure.
Snap Ring Bearing Snap Ring Bearing Input Shaft Snap Ring
13. Output Shaft 14 Countershaft
Disassemble the parts in the numerical order shown in the figure.
20 21 19 18
24. No.2 Clutch Hub, Sleeve & Synchronizer Ring
Remove the snap ring with SST. SST 9905 » 
Remove the bearing with SST. SST 17064
Remove the bearing with SST. SST 12729
Remove the snap ring with SST. ** SST 9905
Remove the input shaft assembly from the case with SST. SST 9910
Remove the input shaft assembly from the case with SST. SST 9910
Measure the 1st gear and sleeve thrust clearance.
Remove the snap ring with SST. SST 9905
Remove the bearing with SST. SST 17393 
Remove the snap ring with SST. SST 9905
Hold the 1st gear tightly against the other gears and pull out the output shaft assembly from the case.
When pulling out the assembly, hold the gears in place to keep them from sliding off the shaft.
Drive out the reverse idler gear shaft toward the rear.
Remove the snap ring with SST. SST 9905
Wash the disassembled parts and inspect them as described below. Replace any part found defective.
Transmission Case & Front Bearing Retainer
Inspect for wear or damage.
| Replace The Front Bearing Retainer Oil Seal
01. Remove the oil seal by prying with a driver.
2. Tap in the oil seal with SST. SST 36772
Check the clearance between the oil seal front end and retainer.
1. Inspect the shaft surfaces contacting the bearings and gears for wear or damage.
2. Inspect the bushing for wear or damage.
1st, 2nd, 3rd Gear & Bearing
1. Inspect the gears for wear or damage at the teeth, thrust faces, inside diameter, and coned surfaces.
2. Inspect the output shaft rear bearing and the roller bearings for wear or damage.
Measure the oil clearance.
3rd gear oil clearance (A — B): STD 0.065 — 0.115 mm
1. Fit the synchronizer ring on the gear and measure the clearance.
3rd & 4th gear synchronizer ring clearance:
2. Measure the No.1 synchronizer ring dimension.
Clutch Hub Sleeve, Clutch Hub,
1. Disassemble the clutch hub and sleeve.
2. Inspect the splines of hub and hub sleeve for wear or damage.
3. Inspect the center humped part of keys for wear or damage.
4. Inspect the key springs for weakening or damage.
Check the clearance between the sleeve and shift fork.
Shift fork to hub sleeve clearance: Limit 0.8 mm
6. Hub and hub sleeve are parts having directionality.
Install the key springs positioned so that their end gaps will not be in line.
1. Inspect the gear teeth, splines, coned sur-rfaces, and bearing for wear or deamage.
2. Inspect the shaft inner surface that contact on the needle roller bearing for wear or damage.
Replace The Input Shaft Bearing
1. Remove the snap ring with SST. SST 9905
2. Remove the bearing with SST. SST 14954
3. Install the new bearing with a press.
4. Select a snap ring of the thickness that will allow minimum axial play, and install it on the shaft.
1. Inspect the counter gear teeth for wear or damage.
2. Inspect the front and rear bearings for wear or damage.
3. Rear bearing inner race replacement. <1) Remove the inner race with SST.
SST 9667 (2) Install the new inner race with SST. SST 13784
3. Rear bearing inner race replacement. <1) Remove the inner race with SST.
SST 9695 (2) Install the new inner race with SST. SST 12638
Make sure to position the inner race so that its flanged side will be directed toward the front.
Reverse Idler Gear, bushing & Shaft
1. Inspect the gear, bushing, and shaft for wear or damage.
2. Measure the reverse idle gear gear bushing and shaft oil clearance. Oil clearance: Limit 0.16 mm
1. Inspect the shift arm shoeO) for wear or damage.
Shoe thickness: Limit 8.1 mm
2. Inspect the shift arm at the shoe mounting^) and pivot mounting(3) for wear or damage.
3. Inspect the pivot(4) for wear or damage.
4. Inspect the clearance between the shoe and reverse idler gear slot.
TRANSMISSION CASE COVER DISASSEMBLY
Disassemble the parts in the numerical order shown in the figure.
1st, 2nd Shift Fork Shaft & Blind Plug
Reverse Shift Fork Shaft & Blind Plug
0 Drive out the shift fork shaft together with the blind plug.
Do not damage the case cover.
™—1 Cover the service hole with your hand to pre-^^ vent locking ball from flying out.
Remove the locking ball and the spring with magnet. 
Fig. 3-49 
Remove the locking ball and the spring with magnet.
Cover the service hole with your hand to prevent the locking ball from flying out.
Drive out the slotted spring pin.
Drive out the shift fork shaft together with blined plug.
Drive out the slotted spring pin.
Drive out the shift fork shaft together with blined plug.
Cover the service hole with your hand to prevent the locking ball from flying out.
Remove the locking ball and the spring with magnet.
Drive out the slotted spring pin.
Drive out the fork shaft together with the blind plug.
Cover the service hole with your hand to prevent locking ball from flying put.
Remove the interlock pin with magnet.
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