1 page INDEX1 Model SG1J (MF06S) TRANSMISSION 7-1 7-142E-07 CHAPTER 7 TRANSMISSION (MFO6S) Model SG1J 1 Models FE, FF and SG2J 1 Model FD 7 TROUBLESHOOTING...7-2 SPECIAL TOOLS...7-5 REMOVAL...7-7 GEAR SHIFT HOUSING...7-10 INPUT SHAFT, OUTPUT SHAFT, GEARS AND...7-22 RELATED PARTS COUNTER SHAFT, REVERSE IDLER SHAFT...7-48 AND GEARS INSTALLATION...7-59
7-2 TRANSMISSION 1 page 1 Model SG1J (MF06S) TROUBLESHOOTING Symptom Possible cause Remedy Gear slip-off Control system Joint worn and/or damaged... Replace joint. Looseness of bolts and nuts...tighten bolts and nuts. Improper link rod adjustment...adjust link rod. Gear shift housing Lock ball and spring distorted...repair or replace as required. and/or broken Groove for shift shaft worn...replace shift fork. Transmission gear Synchronizer hub and sleeve worn...replace as required. Synchronizer sleeve and gear...replace as required. clutch teeth worn or damaged Input shaft and/or output shaft...replace bearing. bearing worn and/or broken Retainer ring and/or thrust washer... Replace as required. worn and/or broken Loose transmission to engine...tighten bolts. mounting bolts Difficult gear engagement Engine Engine idling speed too high...adjust engine idling. Clutch Improper disengagement of clutch...adjust clutch. Clutch disc stick...repair or replace. Clutch shifter sleeve bent...replace shifter sleeve.
Model SG1J (MF06S) TRANSMISSION 7-3 Symptom Possible cause Remedy Difficult gear engagement Transmission Input shaft and/or output shaft...replace bearing. bearing worn and/or damaged Engine crankshaft pilot bearing...replace bearing. worn and/or damaged Synchronizer cone and ring worn...replace as required. Control system Looseness of control system and/or... Tighten and adjust control system. improper adjustment. Improper motion of gear shift lever... Adjust shift lever. Shift and select rod worn...replace shift and select rod. Rigid relay shaft nylon bushing...replace as required. and/or sticking of shafts Lubrication Improper lubrication of control... Lubricate as required. lever Shortage of gear oil and/or low oil...add oil or change oil as required. viscosity Noise Transmission Grinding in transmission...check for screws, bolts or other foreign materials in transmission. Loose transmission to engine... Tighten bolts. mounting bolts Worn or damaged gear and bearing... Replace as required. Lubrication Shortage of gear oil and/or low...add oil or change oil as required. oil viscosity
7-4 TRANSMISSION 1 page 1 Model SG1J (MF06S) Symptom Possible cause Remedy Leaking gear oil Transmission Leaks at the front and rear bearing... Repair and/or replace parts as retainer seal and gasket, case required. cover gasket, sand hole of case, or shift shaft expansion plug Improper amount of gear oil and/or... Check oil level and type. low oil viscosity
Model SG1J (MF06S) TRANSMISSION 7-5 SPECIAL TOOLS Prior to starting a transmission overhaul, it is necessary to have the following special tools. Illustration Tool No. Tool name 09839-6504 SOCKET WRENCH 09420-1442 SLIDING HAMMER 09650-2070 INPUT SHAFT PULLER 09650-1101 PULLER 09653-1190 09653-1210 HOOK 09650-1881 PULLER
7-6 TRANSMISSION 1 page 1 Model SG1J (MF06S) Illustration Tool No. Tool name 09650-1900 PULLER
Model SG1J (MF06S) TRANSMISSION 7-7 REMOVAL WARNING Do not work on the transmission while it is still hot. This can result in personal injury. 1. BLOCK THE WHEELS. 1. Park the vehicle on level ground. 2. Block the wheels. NOTE: Be sure to apply wheel stoppers in the front tires. Fig. 7-1-1 SMAT-040 2. DRAIN THE TRANSMISSION OIL FROM THE TRANS- MISSION. Remove the drain plug and drain the transmission oil. The transmission oil should be drained into a suitable container. Fig. 7-1-2 SMTM-427 3. DISCONNECT THE PROPELLER SHAFT FROM THE TRANSMISSION. 1. Put the match marks on the flange and yoke. 2. Remove the four nuts. Fig. 7-1-3 SMTM-468A 3. Remove the center bearing fitting bolts and nuts. 4. Disconnect the propeller shaft and move it out of the way. Fig. 7-1-4 SMTM-428
7-8 TRANSMISSION 1 page 1 Model SG1J (MF06S) AIR LINES HYDRAULIC LINE SPEED- OMETER CABLE 4. DISCONNECT THE FOLLOWING COMPONENT PARTS FROM THE TRANSMISSION. 1. Electric harness 2. Speedometer cable 3. Air lines 4. Hydraulic line ELECTRIC HARNESS Fig. 7-1-5 ASM7-034 5. DISCONNECT THE TRANSMISSION CONTROL. Remove the link rod end nut. CROSS SHAFT LINK ROD Fig. 7-1-6 FITTING BOLT ASM7-035 6. DISCONNECT THE CLUTCH BOOSTER. 1. Remove the tension spring. 2. Disconnect the clutch booster from the bracket on the transmission side. NOTE: Do not remove the clutch control hydraulic line unless absolutely necessary. Air bleeding is not required when reassembling. Fig. 7-1-7 ASM7-036 7. REMOVE THE TRANSMISSION. WARNING In using the transmission jack, exercise good care in mounting or dismounting to prevent it from dropping off the jack because the transmission is heavy and unstable. 1. Remove the lower bolts around the clutch housing. Fig. 7-1-8 SMTM-466
Model SG1J (MF06S) TRANSMISSION 7-9 2. Place a transmission jack under the transmission. 3. Remove the remaining bolts around the clutch housing. 4. Pull the transmission backwards. Lower the Transmission jack and pull the transmission out from under the truck. Fig. 7-1-9 SM7-184 8. REMOVE THE CLUTCH HOUSING. Fig. 7-1-10 SM5-084A 9. MOUNT THE TRANSMISSION ASSEMBLY ON A WORKSTAND. Fig. 7-1-11 SMTM-434
7-10 TRANSMISSION 1 page 1 Model SG1J (MF06S) GEAR SHIFT HOUSING 1 2 4 5 6 3 10 11 9 7 8 20 11 12 13 16 9 15 16 13 14 27 11 26 25 16 17 16 18 11 28 29 30 19 16 24 23 16 21 16 22 13 14 16 11 11 ASM7-037 1. Shift lever shaft 2. Oil seal 3. Shift lever shaft housing 4. Outer select lever 5. Shift lever pin 6. Oil seal 7. Inner select lever 8. Inner shift lever 9. Power shift unit assembly 10. Pin 11. Expansion plug 12. 3rd & 4th shift shaft 13. Interlock plunger 14. Interlock pin 15. 3rd & 4th shift fork 16. Pin 17. Back-up lamp switch18. Air breather 19. Reverse shift head 20. Reverse shift fork 21. Reverse shift shaft 22. 1st & 2nd shift shaft 23. 1st & 2nd shift fork 24. 1st & 2nd shift head 25. 5th & 6th shift head 26. 5th & 6th shift fork 27. 5th & 6th shift shaft 28. Transmission case cover 29. Compression spring 30. Steel ball Fig. 7-2-1
Model SG1J (MF06S) TRANSMISSION 7-11 DISASSEMBLY OF THE GEAR SHIFT HOUS- ING NOTE: Examine to see if any parts are worn or if any abnormal interference or play exists when moving each shift fork. Disassemble the transmission and replace faulty parts, if any. 1. REMOVE THE SHIFT LEVER SHAFT HOUSING. 1. Remove the shift lever shaft housing fitting bolts. 2. Remove the shift lever shaft housing from the transmission case cover. Fig. 7-2-2 ASM7-038 2. REMOVE THE TRANSMISSION CASE COVER. 1. Remove the transmission case cover fitting bolts. 2. Remove the transmission case cover. 3. Secure the transmission case cover in a vise with the 5th-6th speed shift shaft facing up. Fig. 7-2-3 SMTM-435 3. REMOVE THE PIN. 1. Set the transmission case cover on a vise. 2. Drive out the shift head and shift fork fitting pins with a 5 mm (0.197 in.) diameter tapping rod. Fig. 7-2-4 SMTM-441A
7-12 TRANSMISSION 1 page 1 Model SG1J (MF06S) 4. REMOVE THE 5TH-6TH SPEED SHIFT SHAFT, SHIFT FORK AND SHIFT HEAD. 1. Set each shift shaft in the neutral position. 2. Hold a copper rod against the end of the shift shaft and tap the rod lightly to remove the shaft and its expansion plug. When removing the shift shaft remove the shift head and shift fork. Fig. 7-2-5 SM7-327A NOTE: Take care not to damage the sliding parts inside the gear transmission cover. WARNING The steel ball may pop out from the hole. Wear safety glasses to protect your eyes. Fig. 7-2-6 SMTM-436A SMTM-436B 5. REMOVE THE STEEL BALL AND COMPRESSION SPRING. Fig. 7-2-7 SMTM-437A SMTM-437B 6. REMOVE THE INTERLOCK PLUNGER AND INTER- LOCK PIN. 1. Using a magnet, remove the interlock plunger. 2. Using a magnet, remove the interlock pin from the 3rd-4th speed shift shaft. Fig. 7-2-8 SMTM-438A SMTM-439A 7. REMOVE THE SPACER FROM THE 3RD-4TH SPEED SHIFT SHAFT. 1. Using a pin punch, drive out the slotted spring pin from the shift shaft. 2. Remove the spacer from the shift shaft. Fig. 7-2-9
Model SG1J (MF06S) TRANSMISSION 7-13 Fig. 7-2-10 SM7-327B 8. REMOVE THE 3RD-4TH SPEED SHIFT SHAFT AND SHIFT FORK. 1. Set each shift shaft in the neutral position. 2. Hold a copper rod against the end of the shift shaft and tap the rod lightly to remove the shaft and its expansion plug. When removing the shift shaft, remove the shift fork. NOTE: Take care not to damage the sliding parts inside the gear transmission cover. WARNING The steel ball may pop out from the hole. Wear safety glasses to protect your eyes. Fig. 7-2-11 SM7-183 9. REMOVE THE STEEL BALL AND COMPRESSION SPRING. Fig. 7-2-12 SMTM-437B 10. REMOVE THE INTERLOCK PLUNGER AND INTER- LOCK PIN. 1. Using a magnet, remove the interlock plunger. 2. Using a magnet, remove the interlock pin from the 1st-2nd speed shift shaft. Fig. 7-2-13 SMTM-438B SMTM-439B
7-14 TRANSMISSION 1 page 1 Model SG1J (MF06S) Fig. 7-2-14 SMTM-327C 11. REMOVE THE 1ST-2ND SPEED SHIFT SHAFT, SHIFT FORK AND SHIFT HEAD. 1. Set the reverse speed shift shaft in the neutral position. 2. Hold a copper rod against the end of the shift shaft and tap the rod lightly to remove the shaft and its expansion plug. When removing the shift shaft remove the shift head and shift fork. NOTE: Take care not to damage the sliding parts inside the transmission case cover. WARNING The steel ball may pop out from the hose. Wear safety glasses to protect your eyes. Fig. 7-2-15 SM7-182 12. REMOVE THE STEEL BALL AND COMPRESSION SPRING. Fig. 7-2-16 SMTM-437C 13. REMOVE THE INTERLOCK PLUNGER WITH A MAG- NET. Fig. 7-2-17 SMTM-438C
Model SG1J (MF06S) TRANSMISSION 7-15 Fig. 7-2-18 SMTM-327D 14. REMOVE THE REVERSE SPEED SHIFT SHAFT, SHIFT FORK AND SHIFT HEAD. 1. Hold a copper rod against the end of the shift shaft and tap the rod lightly to remove the shaft and its expansion plug. When removing the shift shaft, remove the shift head and shift fork. NOTE: Take care not to damage the sliding parts inside the transmission case cover. WARNING The steel ball may pop out from the hole. Wear safety glasses to protect your eyes. Fig. 7-2-19 SM7-181 15. REMOVE THE STEEL BALL AND COMPRESSION SPRING. Fig. 7-2-20 SMTM-437D
7-16 TRANSMISSION 1 page 1 Model SG1J (MF06S) INSPECTION OF THE GEAR SHIFT HOUSING 1. CHECK THE SHIFT LEVER SHAFT AND INNER SHIFT LEVER FOR WEAR AND DAMAGE. If any wear or damage is detected, replace the part. Fig. 7-2-21 ASM7-039 2. CHECK THE OIL SEAL FOR WEAR AND DAMAGE. If any wear or damage is detected, replace the oil seal. Fig. 7-2-22 ASM7-040 3. CHECK THE FOLLOWING COMPONENT PARTS FOR WEAR AND DAMAGE: INTERLOCK PIN, INTERLOCK PLUNGER, COMPRESSION SPRING, AND BALL. If any wear or damage is detected, replace the parts. Fig. 7-2-23 SMTM-472 4. CHECK THE CLEARANCE BETWEEN THE SHIFT FORK AND SHIFT SLEEVE. If the clearance is greater than the service limit, replace the shift fork and/or shift sleeve. Assembly Standard: 0.20 0.45 mm (0.0079 0.0177 in.) Service Limit : 1.0 mm (0.039 in.) Fig. 7-2-24 SM7-472A 5. CHECK THE SHIFT HEAD, SHIFT FORK, AND SHIFT SHAFT FOR WEAR OR DAMAGE. If any wear or damage is detected, replace the parts. Fig. 7-2-25 SMTM-472B
Model SG1J (MF06S) TRANSMISSION 7-17 ASSEMBLY AND INSPECTION OF THE GEAR SHIFT HOUSING 1. INSTALL THE STEEL BALL AND COMPRESSION SPRING. 1. Place the ball and spring in the hole. 2. Depress the ball and spring with a suitable tool. Fig. 7-2-26 Fig. 7-2-27 SM7-192 SMTM-327E 2. INSTALL THE REVERSE SPEED SHIFT SHAFT, SHIFT FORK, AND SHIFT HEAD. 1. Apply gear oil to the shift shaft. 2. Align the shift fork and head and put the shift shaft through, and then slide the shift shaft over the ball. NOTE: Pay special attention to the position and direction of the shift fork and shift head. Refer to Fig. 7-2-36 on page 7-18 for the relative positions of the shift forks. 3. INSTALL THE INTERLOCK PLUNGER. NOTE: Refer to the diagram in Fig. 7-2-37 for the relative positions of the shift shaft, interlock plunger, interlock pin, steel ball and spring. Fig. 7-2-28 SMTM-438C 4. INSTALL THE STEEL BALL AND COMPRESSION SPRING. 1. Place the ball and spring in the hole. 2. Depress the ball and spring with a suitable tool. NOTE: The reverse-speed shift shaft must be in the neutral position. Fig. 7-2-29 Fig. 7-2-30 SMTM-437C SM7-193 5. INSTALL THE 1ST-2ND SPEED SHIFT SHAFT, SHIFT FORK, AND SHIFT HEAD. 1. Apply gear oil to the shift shaft. 2. Align the shift fork and head and put the shift shaft through and slide the 1st-2nd speed shift shaft over the ball. NOTE: Pay special attention to the position and direction of the shift fork and shift head. Refer to Fig. 7-2-36 on page 7-18 for the relative positions of the shift forks.
7-18 TRANSMISSION 1 page 1 Model SG1J (MF06S) 6. INSTALL THE INTER LOCK PIN. 1. Apply grease to the interlock pin. 2. Insert the interlock pin into the hole of the 1st-2nd speed shift shaft. Fig. 7-2-31 Fig. 7-2-32 E SMTM-439B SM7-212A H G 7. ASSEMBLE THE OTHER SHIFT SHAFTS, SHIFT FORKS AND SHIFT HEADS FOLLOWING THE SAME PROCE- DURES (ITEM 1 THROUGH 6 ABOVE) AS FOR THE REVERSE SPEED AND 1ST-2ND SPEED. A : 5th-6th speed shift shaft B : 3rd-5th speed shift shaft C : 1st-2nd speed shift shaft D : Reverse speed shift shaft E : Interlock plunger F : Interlock pin G : Steel ball H : Compression spring A B F C D Fig. 7-2-33 SM7-212 8. INSTALL THE SPACER ON THE 3RD-4TH SPEED SHIFT SHAFT. 1. Install the spacer on the shift shaft. 2. Using a pin punch, drive in the slotted spring pin until the pin is flush with the spacer. Fig. 7-2-34 SM7-343A 9. SECURE THE SHIFT HEAD AND FORK WITH COTTER PINS. Use two pins. Drive both the large and the small pin into the fork and the head, with their slits positioned on opposite side. Fig. 7-2-35 SMTM-441B
Model SG1J (MF06S) TRANSMISSION 7-19 10. INSTALL THE EXPANSION PLUGS IN THE SHIFT SHAFT OPENINGS AT EACH END OF THE HOUSING. NOTE: Apply sealing compound. Fig. 7-2-36 SMTM-449A 11. TIGHTEN THE BACK-UP LAMP SWITCH. Tightening Torque: 350 400 kg cm (26 28 Ib ft) NOTE: Apply thread locking agents. Fig. 7-2-37 SMTM-473 12. CHECK THE FUNCTIONING OF THE BACK-UP LAMP SWITCH. Using an ohmmeter, check the continuity between the terminals with the shift shaft in the neutral position (infinity) and with the shift shaft in the reverse position (0 ohm). If not correct, replace the switch. Fig. 7-2-38 A B C SMEE-865 13. CHECK THE RELATIVE POSITION AND DIRECTION OF EACH SHIFT FORK AND SHIFT HEAD AND CHECK THE INTERLOCK OPERATIONS. Dimension: A: 123.5 mm (4.862 in.) B: 116.9 mm (4.602 in.) C: 122.6 mm (4.827 in.) Fig. 7-2-39 SM7-178 14. CHECK THE SHIFT STROKE. Shift stroke: 12.5 13.5 mm (0.493 0.531 in.) Fig. 7-2-40 SM3-682
7-20 TRANSMISSION 1 page 1 Model SG1J (MF06S) TRANSMISSION CASE 3 (0.118) Unit: mm (in.) 15. INSTALL THE TRANSMISSION CASE COVER. 1. Apply the sealing compound to the face of the transmission case. NOTE: The trace of the sealing compound should be continuous. The sealing compound should be THREE BOND #1215 or equivalent. Fig. 7-2-41 2. Install the transmission case cover with the fitting bolts. 3. Using a torque wrench, tighten the bolts. Tightening Torque: 10 mm dia. bolt: 450 550 kg cm (33 39 Ib ft) 14 mm dia. bolt : 950 1,200 kg cm (69 86 Ib ft) Fig. 7-2-42 SMTM-474 16. INSTALL THE SHIFT LEVER SHAFT, COMPRESSION SPRING AND INNER SHIFT LEVER. 1. Apply gear oil lightly to the gear shift lever shaft and insert the shaft into the shift lever shaft housing. Fig. 7-2-43 Fig. 7-2-44 TRANSMISSION CASE COVER 3 (0.118) 4 (0.157) REAMER BOLT ASM7-041 Unit : mm (in.) 17. INSTALL THE SHIFT LEVER SHAFT HOUSING. 1. Apply the sealing compound to the face of the transmission case cover. NOTE: The trace of the sealing compound should be continuous. The sealing compound should be THREE BOND #1215 or equivalent. 2. Install the shift lever shaft housing with fitting bolts. NOTE: Reamer bolts are used on two diagonally opposite corners of the shift lever shaft housing. REAMER BOLT Fig. 7-2-45 ASM7-042
Model SG1J (MF06S) TRANSMISSION 7-21 3. Tighten the bolts to the specified torque. Tightening Torque: 380 500 kg cm (28 36 Ib ft) Fig. 7-2-46 ASM7-043
7-22 TRANSMISSION 1 page 1 Model SG1J (MF06S) INPUT SHAFT, OUTPUT SHAFT, GEARS, AND RELATED PARTS 15 1 Z 2 14 3 4 11 10 16 9 1 11 12 1 1 10 9 5 7 6 7 8 7 17 1 12 6 14 13 8 7 19 14 18 35 19 Z 14 19 20 11 21 10 9 31 36 28 38 1 22 23 7 15 Y 15 40 39 34 24 14 8 12 25 26 2 14 Y 31 29 27 32 30 28 33 34 28 37 34 41 42 43 42 44 45 Fig. 7-3-1 1. Retainer ring 2. Cylindrical bearing 3. Input shaft 4. Spacer 5. Roller bearing 6. Synchronizer cone 7. Synchronizer ring 8. Synchronizer hub 9. Compression spring 10. Synchronizer head 11. Synchronizer key 12. Synchronizer sleeve 13. 5th gear 14. Needle roller bearing 15. Bushing 16. 4th gear sub-assembly 17. 3rd gear sub-assembly 18. Output shaft 19. Pin 20. 2nd gear sub-assembly 21. Synchronizer bush 22. Synchronizer inner cone 23. Synchronizer double cone 24. 1st gear sub-assembly 25. Reverse gear 26. Constant hub 27. Constant sleeve 28. Oil seal 29. Dust deflector 30. Universal joint flange 31. O-ring 32. Nut 33. Front bearing retainer 34. Gasket 35. Transmission case 36. Speedometer driven gear bushing 37. Speedometer driven gear 38. Key 39. Speedometer drive gear 40. Rear bearing retainer 41. Power take off cover 42. Soft washer 43. Drain plug 44. Filler plug 45. Transmission speedometer gear and gear ratio plate
Model SG1J (MF06S) TRANSMISSION 7-23 Fig. 7-3-2 DISASSEMBLY OF THE INPUT SHAFT, OUT- PUT SHAFT, GEARS, AND RELATED PARTS 1. REMOVE THE LOCK NUT. 1. Lift the staked part completely out of the shaft groove. 2. Using a special tool or commercial tool, remove the lock nut. Insufficient spread of the staked part will cause damage to the threads of output shaft, when loosening the nut. NOTE: Before loosening the lock nut, engage two gears so that the output shaft can not be turned. Special Tool: Socket wrench (09839-6504) Fig. 7-3-3 SM7-295A 2. REMOVE THE JOINT FLANGE. Remove the joint flange and O-ring, striking joint flange with a plastic hammer, if necessary. Fig. 7-3-4 SM7-364A 3. REMOVE THE REAR BEARING RETAINER. 1. Remove the rear bearing retainer. a. Remove the bearing retainer fitting bolts. b. Remove the bearing retainer. Fig. 7-3-5 SMTM-475 2. Remove the speedometer driven gear. a. Remove the driven gear bushing setting bolt. b. Remove the driven gear with bushing. Fig. 7-3-6 SMTM-450
7-24 TRANSMISSION 1 page 1 Model SG1J (MF06S) 3. Remove the oil seal. If it needs replacement, pry it out using a punch or a screwdriver. NOTE: Do not damage the oil seal bore of the bearing retainer when removing the oil seal. Fig. 7-3-7 SMTM-420 Fig. 7-3-8 SMTM-450A 4. REMOVE THE SPEEDOMETER DRIVE GEAR. Fig. 7-3-9 SMTM-451 5. REMOVE THE KEY FROM THE OUTPUT SHAFT. Fig. 7-3-10 Fig. 7-3-11 SMTM-476 SMTM-452 6. REMOVE THE FRONT BEARING RETAINER. 1. Remove the bearing retainer. a. Remove the fitting bolts. b. Remove the bearing retainer. NOTE: An oil seal is attached inside the front bearing retainer. Cover (e.g. with aluminum foil) the spline of the input shaft so as not to damage the lip of the oil seal when removing the retainer.
Model SG1J (MF06S) TRANSMISSION 7-25 2. Remove the oil seal. If it needs replacement, pry it out using a punch or a screwdriver. Fig. 7-3-12 7. REMOVE THE INPUT SHAFT. Using special tools, pull out the input shaft with the accompanying bearing. Special tools: Input shaft puller (09650-2070) Sliding hammer (09420-1442) Fig. 7-3-13 SM7-232 8. DISASSEMBLE THE INPUT SHAFT. 1. Using retainer ring pliers, remove the retainer ring from the input shaft bearing. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. Fig. 7-3-14 SMTM-453 2. Using a press, remove the cylindrical bearing. WARNING Stay out from under the shaft during removal. The shaft could drop suddenly resulting in personal injury. Fig. 7-3-15 SM7-357 3. Using a screwdriver, remove the retainer ring from the groove of the input shaft bore, then remove the roller bearings from the input shaft bore. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. Fig. 7-3-16 SMTM-454
7-26 TRANSMISSION 1 page 1 Model SG1J (MF06S) Fig. 7-3-17 SMTM-453A 9. REMOVE THE REAR BEARING. 1. Remove the retainer ring from the output shaft rear bearing. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. Fig. 7-3-18 SMTM-455 2. Attach special tools to the bearing. Special Tools: Hook (09653-1210) Puller (09650-1881) NOTE: Insert the hook s click into the groove for the retainer ring, then secure the puller to the hook with bolts. Secure the puller so that it does not turn, then rotate the bolt to pull the bearing out. Fig. 7-3-19 SM7-080 3. Remove the rear bearing. Fig. 7-3-20 JIG (NUT AND ROD) SMTM-395A 10. ATTACH A JIG TO THE END OF THE OUTPUT SHAFT. WARNING If the output shaft assembly is removed from the transmission without a jig, the reverse gear will drop from the shaft and possibly result in personal injury. Fig. 7-3-21 SM7-233
Model SG1J (MF06S) TRANSMISSION 7-27 Fig. 7-3-22 SMTM-456 11. REMOVE THE OUTPUT SHAFT ASSEMBLY FROM THE TRANSMISSION CASE. 1. Attach a suitable hook or other lifting device around the 3rd-4th speed synchronizer sleeve and carefully lift the output shaft assembly from the transmission case. 2. When removing the output shaft assembly, remove the synchronizer ring and the cone of the input shaft gear. 12. DISASSEMBLE THE OUTPUT SHAFT ASSEMBLY. 1. Clamp the output shaft assembly, rear end facing upward, in a soft-jawed vise. 2. Remove the jig from the shaft before starting the disassembly of the output shaft assembly. 3. Remove the constant sleeve of the reverse-speed gear. Fig. 7-3-23 SMTM-477 4. Remove the constant hub reverse-speed gear needle roller bearings. Fig. 7-3-24 SM7-173 5. Clamp the output shaft assembly, front end facing upward, in a soft-jawed vise. Fig. 7-3-25 6. Remove the 5th-speed gear retainer ring at the front of the output shaft. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. Fig. 7-3-26 SMTM-478
7-28 TRANSMISSION 1 page 1 Model SG1J (MF06S) 7. Remove the 5th-6th speed synchronizer unit with synchronizer cone. Fig. 7-3-27 SMTM-479 8. Remove the 5th-speed gear with synchronizer cone, needle roller bearings, and spacer. Fig. 7-3-28 SM7-171B 9. Remove the retainer ring. Fig. 7-3-29 SMTM-495B 10. Remove the 4th gear bushing. Fig. 7-3-30 SMTM-484A 11. Remove the 4th gear with synchronizer cone. Fig. 7-3-31 SMTM-480B
Model SG1J (MF06S) TRANSMISSION 7-29 12. Remove the needle roller bearing and pin. Fig. 7-3-32 SM7-170C 13. Remove the synchronizer unit. Fig. 7-3-33 SM7-169F 14. Remove the 3rd gear with synchronizer ring. Fig. 7-3-34 SM7-169E 15. Remove the needle roller bearings. Fig. 7-3-35 SM7-169D 16. Support the 2nd-speed gear and press the output shaft rear end through the bushings, gears and needle roller bearing and synchronizer unit. WARNING Stay out from under the shaft during removal. The shaft could drop suddenly resulting in personal injury. Fig. 7-3-36 SMTM-480A NOTE: When removing the output shaft, do not allow the shaft to drop on a hard surface.
7-30 TRANSMISSION 1 page 1 Model SG1J (MF06S) 17. Remove the bushing. Fig. 7-3-37 18. Remove the 1st gear. Fig. 7-3-38 19. Remove the needle roller bearing of 1st gear. Fig. 7-3-39 20. Remove the synchronizer unit. Fig. 7-3-40 SYNCHRONIZER RING INNER CONE PIN DOUBLE CONE BUSH 21. Disassemble the bush (including inner cone, pins, double cone and synchronizer ring). a. Remove the synchronizer ring. b. Remove the double cone. c. Remove the inner cone. d. Remove the four pins. e. Remove the bush. Fig. 7-3-41 SMTM-491
Model SG1J (MF06S) TRANSMISSION 7-31 22. Remove the 2nd gear with synchronizer ring. Fig. 7-3-42 23. Remove the needle roller bearing. Fig. 7-3-43 SM7-169A 13. DISASSEMBLE THE SYNCHRONIZER UNIT. 1. Remove the sleeve. Fig. 7-3-44 SMTM-485 2. Remove the synchronizer key and head. WARNING The compression spring is spring steel and may pop out of the hole. Wear safety glasses to protect your eyes. Fig. 7-3-45 3. Remove the compression spring. Fig. 7-3-46 SMTM-485B
7-32 TRANSMISSION 1 page 1 Model SG1J (MF06S) 14. REMOVE THE 5TH GEAR SYNCHRONIZER CONE. 1. Remove the retainer ring, which secure the synchronizer cone to the gear. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. Fig. 7-3-47 SMTM-457 2. Remove the synchronizer cone from the gear. Fig. 7-3-48 SMTM-486 Fig. 7-3-49 SMTM-486A
Model SG1J (MF06S) TRANSMISSION 7-33 INSPECTION OF THE INPUT SHAFT, OUTPUT SHAFT, GEARS, AND RELATED PARTS 1. CHECK THE GEARS AND SHAFTS. 1. Check all gears for cracks and defects on tooth surface. If any crack or defect is detected, replace the gear. Fig. 7-3-50 SM7-092 2. Check the Input shaft for wear or damage. If any wear or damage is detected, replace the shaft. Fig. 7-3-51 SMTM-426 3. Check the output shaft for wear or damage. If any wear or damage is detected, replace the shaft. Fig. 7-3-52 2. CHECK THE SYNCHRONIZER UNITS. 1. Check the synchronizer units for wear or damage to each component. If any wear or damage is detected, replace the component. Fig. 7-3-53 SMTM-485C 2. Check the tapered parts and the gears of each synchronizer cone for wear or damage. If any wear or damage is detected, replace the synchronizer cone. Fig. 7-3-54 SM17-093
7-34 TRANSMISSION 1 page 1 Model SG1J (MF06S) 3. Check the synchronizer ring, double cone, bush and inner cone. If any wear and damage is detected, replace them. Fig. 7-3-55 4. Measure the clearance between the synchronizer rings and the tapered parts of the synchronizer cones. If the clearance is less than the service limit, replace the synchronizer ring and/or cone. Assembly Standard: 3rd, 4th and 5th gear: 1.1 1.9 mm (0.044 0.074 in.) 2nd gear : 1.1 2.5 mm (0.044 0.098 in.) Service Limit: 0.2 mm (0.008 in.) [3rd-5th] Fig. 7-3-56 [2nd] SM7-257A 5. Check the contact between the synchronizer rings and the tapered parts of the synchronizer cones. If the contact area is less than 90%, replace the synchronizer ring and/or cone. Total Contact Area: 90% or more Fig. 7-3-57 SMTM-355 3. CHECK THE BEARING. 1. Check the rollers and races of the cylindrical bearings for wear or damage. If a bearing is worn or damaged, replace it. 2. Check the needle roller bearings for wear or damage. If a bearing is worn or damaged, replace it. Fig. 7-3-58 SMTM-487 SMTM-488
Model SG1J (MF06S) TRANSMISSION 7-35 4. CHECK THE OlL SEALS. Check the oil seals for wear or damage. If an oil seal is worn or damaged, replace it. Fig. 7-3-59 5. CHECK THE SPEEDOMETER GEARS. Check the speedometer drive gear and driven gear. If either is worn or damaged, replace it. Fig. 7-3-60 SMTM-489
7-36 TRANSMISSION 1 page 1 Model SG1J (MF06S) Fig. 7-3-61 SM7-175 ASSEMBLY OF THE INPUT SHAFT, OUTPUT SHAFT, GEARS AND RELATED PARTS 1. ASSEMBLE THE SYNCHRONIZER UNIT. 1. Install the compression spring. WARNING The compression spring is spring steel and may pop out of the hole. Wear safety glasses to protect your eyes. 2. Install the synchronizer key and head. 3. Install the synchronizer sleeve. Fig. 7-3-62 Fig. 7-3-63 SMTM-485 SMTM-457 2. ASSEMBLE THE SYNCHRONIZER CONE AND GEAR. 1. Install the synchronizer cone on the 5th gear. 2. Secure the synchronizer cone and gear with the retainer ring. Be sure to install the retainer ring in the gear groove. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. 3. ASSEMBLE THE OUTPUT SHAFT. 1. Install the needle roller bearings and 2nd-speed gear on the shaft with the clutching teeth facing downward. NOTE: Lubricate the needle roller bearings with gear oil. Fig. 7-3-64 SYNCHRONIZER RING INNER CONE SMTM-490 PIN DOUBLE CONE BUSH 2. Install the bush assembly (including the inner cone, double cone, synchronizer ring and pins). Fig. 7-3-65 SMTM-491
Model SG1J (MF06S) TRANSMISSION 7-37 3. Heat the 2nd synchronizer unit for about 5 minutes in water or oil heated to 80 C to 100 C (176 F to 212 F). Then install the synchronizer unit on the shaft. NOTE: Do not heat the synchronizer unit in excess of 120 C (248 F). If the unit has been warmed with hot water, remove moisture before installation. Fig. 7-3-66 WARNING Never touch hot water and heated synchronizer unit with your bare hands. This can result in personal injury. 4. Install the 1st gear bushing by using a press. Fig. 7-3-67 SMTM-558 5. Install the needle roller bearing. Fig. 7-3-68 SM7-170A 6. InstalI the 1st gear. Fig. 7-3-69 SM7-172F
7-38 TRANSMISSION 1 page 1 Model SG1J (MF06S) 7. Install the reverse gear bushing by using a press. Fig. 7-3-70 SMTM-556 8. Install the needle roller bearing. Fig. 7-3-71 SM7-169A 9. Install the reverse gear. Fig. 7-3-72 SMTM-498A 10. Install the constant hub and sleeve. Fig. 7-3-73 SMTM-497A 11. Hold the constant hub with jig. WARNING When installing the output shaft assembly in the transmission case, be careful not to drop the reverse gear from the shaft. Fig. 7-3-74 SM7-256A
Model SG1J (MF06S) TRANSMISSION 7-39 12. Install the needle roller bearing. Fig. 7-3-75 SM7-169I 13. InstalI the 3rd gear. Fig. 7-3-76 SMTM-491A 14. Install the 3rd 4th gear synchronizer unit. Fig. 7-3-77 SM7-169B 15. Install the pin and 4th gear. Fig. 7-3-78 SMTM-492B 16. Install the needle roller bearing. Fig. 7-3-79 SM7-170B
7-40 TRANSMISSION 1 page 1 Model SG1J (MF06S) 17. Install the bushing. NOTE: Align the bushing groove with pin. Fig. 7-3-80 Fig. 7-3-81 Fig. 7-3-82 SMTM-492A SMTM-495A SMTM-496A 18. Install the retainer ring. a. Select a retainer ring that will provide a tight fit. b. Install the retainer ring. Make sure that the retainer ring seats in the groove. NOTE: Always use a new retainer ring. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. c. Check the clearance. Assembly standard: Zero Retainer rings are available in following sizes; Thickness Color code 2.4 mm (0.0945 in.) None 2.5 mm (0.0985 in.) White 2.6 mm (0.1023 in.) Green 2.7 mm (0.1063 in.) Brown 2.8 mm (0.1102 in.) Blue 19. Install the needle roller bearing. Fig. 7-3-83 SM7-171A 20. Install the 5th gear with synchronizer cone. Fig. 7-3-84 SM7-171D
Model SG1J (MF06S) TRANSMISSION 7-41 21. Install the 5th-6th synchronizer unit. Fig. 7-3-85 SMTM-494 22. Install the retainer ring. a. Select a retainer ring that will provide a tight fit. b. InstalI the retainer ring. Make sure that the retainer ring seats in the groove. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. Fig. 7-3-86 SMTM-495 c. Check the clearance. Assembly Standard: Zero Retainer rings are available in the following sizes. Thickness Color code 2.45 mm (0.0965 in.) None 2.55 mm (0.1004 in.) Blue NOTE: Always use a new retainer ring. Fig. 7-3-87 Fig. 7-3-88 Fig. 7-3-89 SMTM-496 SMTM-456 SM7-318 4. INSTALL THE OUTPUT SHAFT ASSEMBLY IN THE TRANSMISSION CASE. 1. Attach a suitable hook around the 3rd-4th synchronizer sleeve and carefully lower the output shaft assembly into the case. 2. Position the output shaft gears so that they mesh with mating countershaft gears. 3. When installing the output shaft assembly, install the synchronizer ring and cone to the output shaft assembly. 5. ASSEMBLE THE INPUT SHAFT. 1. Install the cylindrical bearing with a press. a. Place the bearing side ring and then bearing on the input shaft. When installing the bearing side ring, place the side with the larger chamfering closest to the gear. b. Apply gear oil to both outer and inner races, then press the inner race in. Be sure to have good right angle alignment. Do not put any pressure on the outer race.
7-42 TRANSMISSION 1 page 1 Model SG1J (MF06S) 2. Install the retainer rings. a. Select a retainer ring that will provide a tight fit. b. Install the retainer ring. Make sure that the retainer ring seats in pace. Fig. 7-3-90 SMTM-453 Retainer rings are available in the following sizes. Thickness Color code 2.8 mm (0.110 in.) None 2.9 mm (0.114 in.) Blue 3.0 mm (0.118 in.) Green 3.1 mm (0.122 in.) Yellow 3.2 mm (0.126 in.) Red NOTE: Always use a new retainer ring. c. Check the clearance. Assembly Standard: Zero Fig. 7-3-91 Fig. 7-3-92 SM7-310 SM7-304 3. Install the roller bearings in the counterbore of the input shaft. a. Apply gear oil to the bearings. b. Place spacers at both ends of the bearings. NOTE: Always use roller bearings of uniform diameter (15 pieces per set). There are 3 types of roller bearings in different diameters. These are distinguished by the colors red, blue and white. 4. Install the retainer ring. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. Fig. 7-3-93 SMTM-454 6. INSTALL THE INPUT SHAFT ASSEMBLY. 1. Align the output shaft front end center with the input shaft center to prevent the roller bearings and gears from being damaged. 2. Drive the cylindrical bearing inner race with a suitable driving tool and a hammer. Fig. 7-3-94 SMTM-374
Model SG1J (MF06S) TRANSMISSION 7-43 7. INSTALL THE FRONT BEARING RETAINER. 1. If the oil seal was previously removed, install a new oil seal. NOTE: Be sure the oil seal is installed in the proper direction. Fig. 7-3-95 SM7-157A 2. Install the front bearing retainer with a new gasket. a. When installing the bearing retainer, the gasket must be installed in such a way that the gasket notch matches the oil drain hole on the case so as not to block the hole. NOTE: Apply liquid sealer to both sides of gasket. b. Apply chassis grease to the oil seal and the input shaft. Fig. 7-3-96 SM7-307 c. Apply liquid sealer or sealing tape to the A bolt threads. Fig. 7-3-97 A SMTM-500 3. Tighten the six bolts fixing the front bearing retainer. Tightening Torque: 650 870 kg cm (47 62 Ib ft) Fig. 7-3-98 Fig. 7-3-99 SM7-425 SMTM-501 8. INSTALL THE REAR BEARING ON THE REAR OF THE OUTPUT SHAFT. 1. Before installing the rear bearing, install the retainer ring on the bearing. 2. Place the bearing side ring and bearing on the output shaft. When installing the bearing side ring, place the side with the large chamfering closest to the gear. 3. Apply gear oil to the outer race and inner race, then drive the inner race in.
7-44 TRANSMISSION 1 page 1 Model SG1J (MF06S) 9. INSTALL THE KEY IN THE OUTPUT SHAFT. Securely seat the speedometer drive gear key in the output shaft. Fig. 7-3-100 SMTM-476 10. INSTALL THE SPEEDOMETER DRIVE GEAR ON THE OUTPUT SHAFT. Fig. 7-3-101 DRIVEN GEAR BUSHING OIL SEAL Fig. 7-3-102 SMTM-451 SM7-157 11. ASSEMBLE THE REAR BEARING RETAINER. 1. Install the speedometer driven gear. a. Apply chassis grease to the O-ring, oil seal and driven gear shaft. b. Insert the driven gear shaft into the bushing. c. Install the speedometer driven gear with bushing in the rear bearing retainer. NOTE: Take care not to damage the O-ring or seal lip. Be sure the oil seal is inserted in the proper direction. Fig. 7-3-103 SET SCREW Fig. 7-3-104 NUMERAL OF THE DRIVEN GEAR TEETH SMTM-450 2. Match the numeral engraved on the bushing with the mark line on the rear bearing retainer. a. The numeral engraved on the bushing indicates the number of speedometer driven gear teeth. b. Count the number of driven gear teeth. c. Match the numeral with the mark line on the rear bearing retainer.
Model SG1J (MF06S) TRANSMISSION 7-45 3. Tighten the set screw. a. Align the speedometer driven gear bushing hole with the hole of the rear bearing retainer. b. Install the screw, then tighten it. Tightening Torque: 190 260 kg cm (14 18 Ib ft) Fig. 7-3-105 SMTM-461 4. Install the oil seal. NOTE: When installing the oil seal, check the right angle alignment and take care not to damage the seal lip. Lubricate the lip prior to installing the universal joint flange. Fig. 7-3-106 SM7-421A 12. INSTALL THE REAR BEARING RETAINER AND TIGHTEN THE FITTING BOLTS. Tightening Torque: 750 950 kg cm (55 68 Ib ft) NOTE: Apply sealing compound to the bolt threads of all the fitting bolts. Apply liquid sealer to both sides of gasket. Fig. 7-3-107 Fig. 7-3-108 SM7-324 SMTM-502 13. INSPECT THE OUTPUT SHAFT GEARS. 1. Measure the backlash of each gear. Block the countershaft with a pry bar when measuring. Assembly Standard: Input shaft gear 0.08 0.16 mm Reverse-speed gear (0.0032 0.0062 in.) 1st-speed gear 5th-speed gear 2nd-speed gear 3rd-speed gear 4th-speed gear Service Limit: All gears 0.05 0.13 mm (0.0020 0.0051 in.) 0.4 mm (0.016 in.)
7-46 TRANSMISSION Model SG1J (MF06S) 2. Measure the radial play. Fig. 7-3-109 SMTM-502A Assembly Standard: Reverse-speed gear 1st-speed gear 2nd-speed gear 3rd-speed gear 4th-speed gear 5th-speed gear 0.023 0.101 mm (0.0010 0.0040 in.) 0.023 0.101 mm (0.0010 0.0040 in.) 0.022 0.071 mm (0.0009 0.0027 in.) 0.022 0.071 mm (0.0009 0.0027 in.) 0.045 0.091 mm (0.0018 0.0035 in.) 0.010 0.058 mm (0.0004 0.0023 in.) 3. Measure the end play. Assembly Standard: Reverse-speed gear 1st-speed gear 2nd-speed gear 3rd-speed gear 4th-speed gear 0.25 0.40 mm (0.01 0.0157 in.) 0.15 0.30 mm (0.0060 0.0118 in.) Fig. 7-110 SMTM-502B 5th-speed gear Service Limit: All gears 0.015 0.30 mm (0.0060 0.0118 in.) 0.5 mm (0.020 in.) 14. INSTALL THE UNIVERSAL JOINT FLANGE. 1. Attach the universal joint flange to the output shaft. 2. Install the O-ring in the universal joint flange. Fig. 7-3-111 SM7-364A SMTM-503
Model SG1J (MF06S) TRANSMISSION 7-47 15. INSTALL THE LOCK NUT. 1. Install the lock nut on the output shaft and tighten it. NOTE: Before tightening the lock nut, engage two gears so that the shaft can not be turned. Do not damage the O-ring. Tightening Torque: 6,000 8,000 kg cm (434 578 Ib ft) Special Tools: Socket wrench (09839-6504) Fig. 7-3-112 SM7-295A 2. Lock the flange lock nut by staking the lip into the output shaft slots. NOTE: More than 1.5 mm (0.059 in.). Stake portion should be completely fitted in the groove. Staking should be done without rift. 10 mm 1.5 mm Fig. 7-3-113 SM7-230
7-48 TRANSMISSION 1 page 1 Model SG1J (MF06S) COUNTER SHAFT, REVERSE IDLER SHAFT AND GEARS 1 2 3 6 18 5 12 1 3 4 7 8 9 10 11 13 14 16 15 17 1. Seal cover 2. Gasket 3. Cylindrical bearing 4. Counter drive gear 5. Woodruff key 6. Lock plate 7. Retainer ring 8. Counter 5th gear 9. Counter 4th gear 10. Counter 3rd gear 11. Counter shaft 12. Thrust washer 13. Reverse idler gear 14. Needle roller bearing 15. Reverse idler shaft 16. Thrust washer 17. Set screw 18. Power take-off cover Fig. 7-4-1
Model SG1J (MF06S) TRANSMISSION 7-49 DISASSEMBLY OF THE COUNTER SHAFT, REVERSE IDLER SHAFT AND GEARS 1. REMOVE THE REVERSE IDLER GEAR. 1. Remove the power take-off cover. Fig. 7-4-2 SMTM-504 2. Using a screwdriver, remove the reverse idler shaft set screw. Fig. 7-4-3 SM7-323 3. Remove the seal cover from the case. Fig. 7-4-4 SMTM-505 4. Using a special tool, pull out the reverse idler shaft while holding the reverse idler gear thrust washers and bearings inside the case. Special Tool: Sliding hammer (09420-1442) Fig. 7-4-5 SM7-177 5. Remove the reverse idler gear, thrust washers, and needle roller bearings. Fig. 7-4-6 SMTM-506
7-50 TRANSMISSION 1 page 1 Model SG1J (MF06S) 2. REMOVE THE REAR CYLINDRICAL BEARING. 1. Flatten the tangs of the lock plate away from the bolts. 2. Remove the two bolts fixing the thrust washer at the shaft rear end. 3. Remove the thrust washer. Fig. 7-4-7 SMTM-507 4. Remove the retainer ring from the rear cylindrical bearing. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. Fig. 7-4-8 SM7-322A 5. Install special tools on the rear cylindrical bearing. Special Tools: Hook (09653-1190) Puller (09650-1900) NOTE: Insert the hook s click into the groove for the retainer ring, then secure the puffer to the hook with bolts. Secure the puller so that it does not turn, then rotate the bolt to pull the bearing out. Fig. 7-4-9 6. Pull out the cylindrical bearing. Fig. 7-4-10 Fig. 7-4-11 SMTM-403A SM7-316 3. REMOVE THE COUNTER SHAFT FROM THE TRANS- MISSION CASE. 1. Tie a rope or hook around the counter shaft (between the 4th speed gear and 3rd speed gear) and carefully pry the counter shaft assembly rearward until the front end of the shaft is clear of the front cylindrical bearing. 2. Carefully lift the counter shaft assembly from the case.
Model SG1J (MF06S) TRANSMISSION 7-51 4. REMOVE THE FRONT CYLINDRICAL BEARING. 1. Using a tapping rod and a hammer, remove the seal cover. Fig. 7-4-12 SMTM-463 2. Remove the front cylindrical bearing from the case bore. Fig. 7-4-13 SMTM-406A 5. DISASSEMBLE THE COUNTER SHAFT ASSEMBLY. 1. Using a special tool on the inner race, pull out the front cylindrical bearing inner race from the counter shaft. Special Tools: Puller (09650-1101) Fig. 7-4-14 SM7-305 2. Remove the retainer ring. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. Fig. 7-4-15 SM7-315 3. Support the counter shaft drive gear as close as possible to the gear hub and press the counter shaft front end until it is free of the drive gear. WARNING Stay out from under the shaft during removal. The shaft could drop suddenly resulting in personal injury. Fig. 7-4-16 SMTM-375
7-52 TRANSMISSION 1 page 1 Model SG1J (MF06S) 4. Support the counter 5th-speed gear under the gear and press the counter shaft out of the gear. WARNING Stay out from under the shaft during removal. The shaft could drop suddenly resulting in personal injury. Fig. 7-4-17 SMTM-508 5. In a same manner, support the counter 4th and 3rd speed gears. Press the counter shaft out of the 4th and 3rd speed gears. WARNING Stay out from under the shaft during removal. The shaft could drop suddenly resulting in personal injury. Fig. 7-4-18 SMTM-508A SMTM-508B 6. Remove the key of each gear from the counter shaft. Fig. 7-4-19 SM7-311
Model SG1J (MF06S) TRANSMISSION 7-53 Fig. 7-4-20 SMTM-509 INSPECTION OF THE COUNTER SHAFT, RE- VERSE IDLER SHAFT AND GEARS 1. CHECK ALL GEARS AND COUNTER SHAFT FOR CRACKS OR DEFECTS. a. If a gear has chipped, worn or missing teeth, replace the gear. Check the gears for binding on the shaft. b. Check the counter shaft for wear or damage. If any wear and damage is detected, replace the shaft. 2. CHECK THE COUNTER SHAFT KEY GROOVE AND KEY FOR DAMAGE OR LOOSENESS. If any damage or looseness is detected, replace the key and/or counter shaft. Fig. 7-4-21 SMTM-509A 3. CHECK THE CYLINDRICAL BEARINGS FOR WEAR OR DAMAGE. Check the bearing races for roughness. Inspect the rollers for looseness, wear, chipping or other damage. Check the bearings for binding on the shaft or looseness in the case bore. Fig. 7-4-22 Fig. 7-4-23 SMTM-487 SMTM-510 4. CHECK THE IDLER GEAR, SHAFT, WASHER AND NEEDLE ROLLER BEARING FOR WEAR OR DAMAGE. Replace the reverse idler gear if the gear is worn or if the gear teeth are chipped or damaged. Replace the reverse idler shaft if it is excessively worn or scored. Check the washer for wear and damage. If the gear end play (refer to Fig. 7-4-37 on page 7-56) is not within specification, replace the washers and/or gear.
7-54 TRANSMISSION 1 page 1 Model SG1J (MF06S) Fig. 7-4-24 COUNTER 3RD SPEED GEAR COUNTER DRIVE GEAR COUNTER 5TH SPEED GEAR COUNTER 4TH SPEED GEAR SM7-311 ASSEMBLY OF THE COUNTER SHAFT, RE- VERSE IDLER SHAFT AND GEAR. 1. INSTALL THE COUNTER SHAFT GEAR. 1. Select the proper size key according to the condition of the key groove, an install the key in the groove. Thickness (T) 12.018 12.029 mm (0.4732 0.4735 in.) 12.070 12.085 mm (0.4752 0.4757 in.) Shape 2. Press the counter shaft into the gears making certain that the key and keyway are aligned. NOTE: Be sure the gears are installed in the proper direction. Fig. 7-4-25 SMTM-511 3. Install the retainer ring on the counter shaft. a. Select a retainer ring that will provide a tight fit. b. Install the retainer ring. Make sure that the retainer ring seats in place. WARNING The retainer ring is spring steel and may pop out of the groove. Wear safety glasses to protect your eyes. Fig. 7-4-26 Fig. 7-4-27 SM7-315 SM7-313 c. Check the clearance. Assembly Standard: Zero Retainer rings are available in the following sizes. Thickness Color code 2.45 mm (0.0965 in.) White 2.55 mm (0.1004 in.) Red 2.65 mm (0.1043 in.) Yellow 2.75 mm (0.1083 in.) Skyblue 2.85 mm (0.1122 in.) Green 2.95 mm (0.1161 in.) Brown NOTE : Always use a new retainer ring.
Model SG1J (MF06S) TRANSMISSION 7-55 2. INSTALL THE FRONT BEARING INNER RACE. Using a press, insert the front bearing inner race against the stepped part of the counter shaft. Fig. 7-4-28 SMTM-512 3. INSTALL THE COUNTER SHAFT IN THE GEAR CASE. Fig. 7-4-29 SM7-316 4. INSTALL THE FRONT BEARING. Carefully drive the front bearing into the case until the outer race of the bearing remains the specified distance, A, below the front face of the gear case. NOTE: Apply gear oil to the outer race and inner race. Do not damage the inner race face with the rollers. Fig. 7-4-30 Fig. 7-4-31 SMTM-406 SMTM-405 5. INSTALL THE REAR BEARING. 1. Before installing the rear bearing, install the retainer ring on the bearing. 2. Place the bearing side ring and then bearing on the counter shaft. When installing the bearing side ring, place the side with the larger chamfering closest to the reverse speed gear. 3. Apply gear oil to the outer race and inner race, then drive the inner race in. NOTE: Do not damage the inner race surface. 6. POSITION DISTANCE, INSPECT THE A, OF THE FRONT BEARING OUTER RACE FROM THE GEAR CASE FRONT SURFACE. Assembly Standard: 6.5-7.0 mm (0.26-0.28 in.) Fig. 7-4-32 A SM7-309
7-56 TRANSMISSION 1 page 1 Model SG1J (MF06S) 7. INSTALL THE THRUST WASHER ON THE SHAFT END. 1. InstalI the thrust washer and Iock plate on the counter shaft rear end. 2. Install the bolts fixing the thrust washer to the shaft, and tighten the bolts to the specified torque. Tightening Torque: 650-870 kg cm (47-62 Ib ft) Fig. 7-4-33 SMTM-513 3. Bend the tangs of the lock plate up against the bolts. Fig. 7-4-34 SM7-308 8. ROTATE THE COUNTER SHAFT BY HAND AND MAKE SURE THAT IT TURNS SMOOTHLY. Fig. 7-4-35 SM7-194 9. PRESS IN THE SEAL COVER AND BRING IT FLUSH WITH THE CASE FRONT. Fig. 7-4-36 SM7-185 10. INSTALL THE REVERSE IDLER GEAR. 1. Lubricate the needle roller bearings with gear oil and install the bearings in the reverse idler gear. 2. Coat the thrust washers with grease to hold the washers against each end of the idler gear. Fig. 7-4-37 SMTM-506
Model SG1J (MF06S) TRANSMISSION 7-57 3. Position the idler gear and thrust washers in the case with the larger gear facing front. 4. Insert the idler shaft until the thread hole of the set screw in the shaft is aligned correctly with the thread hole in the case rib, so that the set screw can be installed. Fig. 7-4-38 SMTM-506A 5. Tighten the set screw until the screw head is completely below the case surface. Fig. 7-4-39 SM7-323 6. Install the seal cover, and tighten the bolts to the specified torque. Tightening Torque: 380 500 kg cm (28 36 Ib ft) Fig. 7-4-40 SMTM-505A 11. INSPECT THE COUNTER SHAFT REVERSE GEAR AND THE REVERSE IDLER GEAR. 1. Measure the backlash between the reverse idler gear and the counter shaft reverse gear. Assembly Standard: 0.08 0.16 mm (0.0032 0.0062 in.) Service Limit : 0.4 mm (0.016 in.) Fig. 7-4-41 SM7-320 2. Measure the end play of the reverse idler gear. Assembly Standard : 0.30 0.75 mm (0.0119 0.0295 in.) Service Limit : 1.2 mm (0.047 in.) Fig. 7-4-42 SM7-321
7-58 TRANSMISSION 1 page 1 Model SG1J (MF06S) 3. Measure the radial play of the reverse idler gear. Assembly Standard: 0.024 0.076 mm (0.0012 0.0119 in.) Fig. 7-4-43 SMTM-514 12. INSTALL THE POWER TAKE-OFF COVER ON THE CASE. 1. Smear the cover gasket and bolt threads with sealing compound when installing. 2. Tighten the bolts to the specified torque. Tightening Torque: 200 250 kg cm (15 18 Ib ft) Fig. 7-4-44 SMTM-515
Model SG1J (MF06S) TRANSMISSION 7-59 INSTALLATION 1. INSTALL THE CLUTCH HOUSING IN THE TRANSMIS- SION. 1. Remove the transmission from the workstand. 2. Using a torque wrench, tighten the clutch housing fitting bolts. Tightening Torque: 20 mm dia. bolt; 3,500 4,700 kg cm (254 339 Ib ft) 16 mm dia. bolt; 1,700 2,300 kg cm (123 166 Ib ft) Fig. 7-5-1 SM5-093 2. APPLY HEAT-RESISTANT GREASE TO THE INPUT SHAFT SPLINE. Fig. 7-5-2 Fig. 7-5-3 Fig. 7-5-4 SM7-314 SM7-184 SMTM-516 3. INSTALL THE TRANSMISSION. WARNING In using the transmission jack, exercise good care in mounting or dismounting to prevent it from dropping off the jack because the transmission is heavy and unstable. 1. Jack up the transmission until the input shaft spline and the clutch disc spline align. 2. Slip the transmission in and attach the clutch housing to the flywheel housing. 3. Install the upper bolts around the clutch housing. 4. Lower the transmission jack and pull the transmission jack out from under the truck. 5. Install the remaining bolts around the clutch housing. 6. Tighten the transmission mounting bolts around the clutch housing. Tightening Torque: 380-500 kg cm (28-36 Ib ft)
7-60 TRANSMISSION 1 page 1 Model SG1J (MF06S) CROSS SHAFT 4. CONNECT THE TRANSMISSION CONTROL ROD. Connect the link rod. Tightening Torque: 250 380 kg cm (19 27 lb ft) LINK ROD Fig. 7-5-5 AIR LINES ASM7-035 SPEED- OMETER CABLE 5. INSTALL THE FOLLOWING COMPONENT PARTS. 1. Electric harness. 2. Air lines. 3. Speedometer cable. 4. Hydraulic line HYDRAULIC LINE ELECTRIC HARNESS Fig. 7-5-6 FITTING BOLT ASM7-034 6. INSTALL THE CLUTCH SLAVE CYLINDER OR AlR BOOSTER. 1. Tighten the fitting bolts. Tightening Torque: 380 500 kg cm (28 36 Ib ft) 2. InstaII the return spring. Fig. 7-5-7 ASM7-036 7. CONNECT THE PROPELLER SHAFT TO THE TRANS- MISSION FLANGE. 1. Match the match marks on the flange and yoke. 2. Tighten the four nuts. Tightening Torque: 1,300 1,600 kg cm (95 115 Ib ft) Fig. 7-5-8 SMTM-468