Lx06s Gearbox

TRANSMISSION MAIN UNIT (LX06S) TR02–1
UN ID ADP RIN C IPA LDELA TRA NSM IS IION

(LX 06S)
TR02 -001
WITH TOGETHER THE TRANSMISSION .......... TR02-2

DATA AND SPECIFICATIONS.............................. TR02 -2
UN ID ADP RIN C IPA LDELA TRA NSM IS IION 1

(LX 06S) 1
TRANSMISSION ASSEMBLY 3
DESCRIPTION 4
TROUBLESHOOTING GUIDE 5
SPECIAL TOOL 7
GEAR SHIFT SHELL 11
LOCATION OF COMPONENTS 11
MODEL: FC (WITH POWER CHANGE) 11
MODEL: FC (NO POWER CHANGE) 12
MODEL: FD 13
MAJOR REPAIR 15
IMPORTANT POINTS - DISASSEMBLY 15
IMPORTANT POINTS – ASSEMBLY 17
IMPORTANT POINT – INSPECTION 19
CASE AND MAIN UNIT 20
LOCATION OF COMPONENTS 20
MODEL: FC 23
MODEL: FD 24
TRANSMISSION CASE ASSEMBLY 25
MAJOR REPAIR 25
IMPORTANT POINTS - ASSEMBLY 26
INSPECTION AND REPAIR 47
DRIVE SHAFT ASSEMBLY 48
MAJOR REPAIR 48
TR0 2–2 MAIN TRANSMISSION UNIT (LX 06S)
OUTPUT SHAFT ASSEMBLY 53

MAJOR REPAIR 53
IMPORTANT POINTS – ASSEMBLY 55
MAJOR REPAIR 63
CHANGE SHIELD TOO RC HAS .. TR02-9

QUALIZATION OF THE COMPONENTS... TR02 -9
MAYO R REPAIR.................................................. TR02 -1 3
CA JA YUN ID ADP RIN C IPA L ..................... TR02-17

LOCATION OF COMPONENTS . TR02 -1 7
BOX ASSY
THE BROADCAST ............................................ TR02-22
MAJOR REPAIR............................................... TR02-22
INSPECTION AND REPAIR.................................. TR02-44
DRIVE SHAFT ASSEMBLY............................. TR02-45

MAJOR REPAIR TR02 -4 5
INSPECTION AND REPAIR.................................... TR02-49
OUTPUT SHAFT ASSEMBLY TR02-5 0

MAJOR REPAIR................................................TR02-50
CONTRA AXLE ASSEMBLY

M.A. RC HA ....................................................... TR02-60
MAJOR REPAIR................................................TR02-60
TRANSMISSION ASSEMBLY
DATA AND SPECIFICATIONS

EN0332002I200001
Model F.C. FD for Ta iwan
If the speed is forward, reverse 2nd, 3rd, 4th, 5th, 6th. synchronized, 1st. and reverse,
constant gear
Guy
1st. 8.190 6.098
2nd. 5.073 3.858
3rd. 2.982 2.340
Speed ratio: 4th. 1.849 1.442
5th. 1.343 1.000
6th. 1.000 0.761
Reverse 7.619 5.672
Number of input shaft teeth 21 25
Counter drive gear

44 39
1st gear 11 11
2nd gear a. 19 19
3rd gear 26 26
Number of counter-drive axle teeth
4th gear 34 34
5th gear. 39 39
6th gear — —
reverse gear 11 11
1st gear 43 43
2nd gear a. 46 47
3rd gear 37 39
4th gear 30 31
Number of output shaft teeth
5th gear. 25 25
6th gear — —
reverse gear 40 40
Reverse Intermediate Gear 23/11 2 3/1 1
Opening to make strength On the left side of the gearbox
Oil capacity, gearbox Ap ro x . 5 .0 liter s {1 .1 0 Imp .gal/1 .3 2 US gal.}
OIL CAPACITY, GEARBOX WITH MADEPOTHENCY

Ap rox . 7 .4 liter s {1 .6 3 Imp .gal/1 .9 5 US gal.}
Lubricant, type Gear Oil (AP IG L-4)
Visco sity, between -12 and 32 ° C {10 and 90 ° F} SAE9 0
V iscosity, above 32 ° C {90 ° F} SAE140

DESCRIPTION
EN0332002C100001
(REPRESENTATIVE TYPE)
SHTS033200200001
1 input shaft 15 Lock nut
2 oil retainer 16 Flange
3 Front bearing retainer 17 Output shaft
4 5th-6th shift sleeve. 18 Speedometer Driven Gear
5 displacement axis 19 Rear bearing retainer
6 box cover 20 Cylindrical bearing
7 gear 5th. or 6th. 21 Reverse shift sleeve
8 gear 4th. 22 Displacement sleeve 1st.- 2nd.
9 Inside gear lever 23 Counter-drive axle
10 gear 3rd. 24 Displacement sleeve 3rd.- 4th.
11 gear 2nd. 25 Counter gear
12 gear 1st. 26 Countershaft front bearing
13 gear reverse 27 Transmission case
14 gearspeedometer drive
TROUBLESHOOTING GUIDE
EN0332002F300001
Symptom Possible cause Remedy/Prevention
Speed disconnection (Control system)
Worn and/or damaged gasket Replace the gasket (union).
Bolts and nuts loose Adjust bolts and nuts.
Improper adjustment of connecting rods Adjust the connecting rod.
Speed Disconnect (Gearbox) Safety ball and spring twisted and/or broken Repair or replace as required.
Very few grooves due to wear on the drive Replace the travel fork.
shaft
Speed Disconnect (Transmission Gear) Synchronizer hub and sleeve wear two Reem place as required.
Reem place as required.

Clutch gear teeth synchronizer sleeve, after
worn or damaged
Bearing on input shaft/output shaft, worn or Replace the bearing.
broken
Ring to pey/o a ra nd ela de to pe, d esg a Reem place as required.
sta dosy/o ro to s
Loosen the transmission to the engine Adjust it as fast as possible.
mounting bolts
Difficulty engaging gears (Engine) Very high idle engine speed Adjust the engine idle speed.
Difficulty engaging gears (clutch)

Inadequate release of the clutch Adjust the clutch.
Clutch disc sticks Repair or replace place.
Warped clutch shifter sleeve Replace the displaced sleeve.
Difficulty engaging gears (Transmission) Bearing on input shaft/output shaft, wear and Replace the bearing.
damage
Engine crankshaft guide bearing to rd esg a Replace the bearing.
sta doy/oda ña do
Reem place as required.
Timing cone and crown spent
Difficulty engaging gears (Control system) Loosening of the control system and/or Tighten and adjust the control system.
improper adjustment
Inappropriate shift lever movement Adjust the shift lever.
Shift and selection rod worn out Replace the shift and selection rod .
Rigid relay shaft nylon cylinder and/or Reem place as required.

adhesion between shafts.
Difficulty engaging gears (Lubrication) Improper lubrication of the control lever Lubricate as required.
Decrease in gear oil and/or viscosity addeac

eite Add oil or change oil as required.
Noise (Transmission) Files in the transmission Check for screws, bolts, and other foreign
materials in the transmission.
Loosen the mounting bolts between the Adjust it as fast as possible.

transmission to the engine
Gear or bearing sd worn or damaged Reem place as required.
Noise (Lubrication) Decrease in gear oil and/or increase Add oil or change oil as required.
viscosity add oil
Symptom Possible cause Remedy/Prevention

Gear Oil Leaks (Transmission) Leaks at front and rear bearing retainer Repair and replace as required want.
seals and gasket, crankcase cover
gasket, crankcase sand holes, or travel
shaft expansion plug
Improper amount of gear oil and loss of oil Check oil level and type.
viscosity
Gears have difficulty engaging or Control cable damaged, bent, deteriorated Replace the control cable.
cannot engage engage when the or deformed due to heat
engine is not running.
loose parts Inspect and adjust.
Damaged shift lever assembly Replace the shift lever.
Replace.
Damaged or warped parts on the upper
parts of the transmission cover section
(lever, spring, etc.)
Poor adjustment of control cable and Adjustment.
connecting rod assembly
Excessive play in the shift lever. Horn worn at joint or pa shift lever Replace.
Loose mounting bolts and nuts Inspect and adjust.

SPECIAL TOOL
EN0332002K100001
Before starting a complete transmission overhaul and repair, you need to have these special tools.
Illustration Part number Tool name Observations
< S0983-94601 CO PA KEY
S09 42-01 442 LPE GO HAMMER
S09 65-0207 0 INPUT SHAFT R EXTRACT
É9 •
•
g S09 63-02220 R AXLE SUSPENSION
") S0969-9 1370 GUIDE
/okay
No'k((8
0 either
S09 65-31 7 10 BASE FOR R EXTRACT
@ /á) And)
S0965-31720
S0965-31730 BASE FOR R EXTRACT
S09 65-31 740
„ S0965-0188 1 EXTRACT R
8
TR02–8 TRANSMISSION MAIN UNIT (LX06S)
Illustration Part number Tool name Observations
go (6) QO
S0965-02080 EXTRACTOR
PURPOSE TOOL (TRANS CRANKCASE ASSEMBLY)

MISSION)
EN0332002K100002
EN0332002D100001
GEAR SHIFT SHELL
LOCATION OF COMPONENTS
MODEL: FC (WITH POWER CHANGE)
1 shift lever shaft 10 air respirator

2 Power shift set 11 Locking plunger
3 pipe joint 12 Compression spring
4 Neutral switch (If equipped) 13 Steel ball
5 Outer selection lever 14 E-ring
6 spring pin 15 Internal shift lever
7 Flat washer 16 Selector lever shaft

8 oil retainer 17 Gear control lever assembly
9 Gear lever shaft shell
SHTS033200200013
tightening torque Unit: N⋅m {k gf⋅cm, lbf⋅ft}

TO 34-38 {350-387,25-28} d 9.8-11.8 {100-120, 7.3-8.6}
b 20-30 {204-305, 15-22} AN 75.5-91.2 {770-929, 56-67}
c 25-30 {255-305,19-22} D
F 43.5-54.5 {444-555, 30-40}
MODEL: FC (NO POWER CHANGE)
SHTS033200200014

2 Control rod holder 11 Locking plunger
3 Control rod end 12 Compression spring
4 Neutral switch (If equipped) 13 Steel ball
5 External selection lever 14 E-ring

8 oil retainer 17 Pipe joint support
9 Gear lever shaft shell 18 Transmission case assembly
tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

TO 34-38 {350-387,25-28} AN 18.6-28.4 {190-289, 14-20}
b 18-26 {184-265, 14-19} D
F 24.5-37.3 {250-380, 19-27}
c 25-30 {255-305,19-22} g 43.5-54.5 {444-555, 33-40}
d 9.8-11.8 {100-120, 7.3-8.6}
MODEL: FD
SHTS033200200015
2 Power shift set 11 Locking plunger
3 pipe joint 12 Compression spring
4 neutral switch 13 Steel ball
5 External selection lever 14 E-ring

8 oil retainer 17 Plug
9 Gear lever shaft shell

TO 34-38 {350-387,26-28} AN 75.5-91.2 {770-929, 56-67}
b 20-30 {204-305, 15-22} D
F 43.5-54.5 {444-555, 33-40}
c 25-30 {255-305,19-22} g 40.2-46.1 {410-470, 30-33}
d 9.8-11.8 {100-120, 7.3-8.6}
SHTS033200200016
1 Shifter Shaft Shell Assembly 3 Bra holder (clip)
2 Support 4 Transmission case assembly
A 43.5-54.5 {444-555, 33-40} B 37.5-48.5 {383-494, 28-35}

MAJOR REPAIR
EN0332002H200001
IMPORTANT POINTS - DISASSEMBLY
1. REMOVE THE SHIFT LEVER SHIELD.

(1) Remove all liquid packaging adhering to the surface of the con touch
using a scraper.
WARNING
Be careful not to damage the contact surface.
SH TS033200200017
2. REMOVE THE POWER SHIFT.

(1) Remove power shifters.
SH TS033200200018
3. REMOVE NEUTRAL SWITCH ( IF EQUIPPED).

(1) Remove the neutral switch from the shift lever shell. bios.
SH TS033200200019
4. REMOVE THE OUTER SELECT LEVER AND THE SELECT LEVER
SHAFT .
(1) Using a copper hammer and striking rod, remove the pass spring dor.
(2) Remove the external select lever and select lever shaft.
(3) Remove the oil retainer from the shift lever shell. bios.
SH TS033200200020
5. REMOVE THE SHIFT LEVER SHAFT AND PA INTERNAL

DISPLACEMENT LOCK.
(1) Remove the shift lever shaft and the shift lever. internal displacement of
the shift lever shell.
(2) Remove the oil retainer from the shift lever shell. bios.
SHTS033200200021
6. REMOVE LOCK PLUNGER, LOCK BALL AND RETAINER.

(1) Loosen the plug to remove the spring, safety ball retainer and locking
plunger.
WARNING
The spring may fly out of the slot. Therefore, wear safety glasses while
working.
SHTS033200200022
IMPORTANT POINTS – ASSEMBLY

1. INSTALL LOCK PLUNGER, LOCK BALL AND SPRING.
(1) Apply bearing grease to the locking plunger.
(2) Insert the spring and lock ball into the installation hole for the lock plunger
in order, insert the lock plunger so that the lock ball does not pop out, then
install the retainer.
(3) After applying adhesive to the plug, install the locking plunger, spring, and
plug.
SHTS033200200022 2. INSTALL SHIFT LEVER SHAFT AND PA INTERNAL

DISPLACEMENT LOCK.
(1) Using a receiver block and hammer, install the new retainer. oil filter
inside the shift lever housing.
WARNING
Be careful not to damage the edge of the oil retainer.
(2) Apply bearing grease to the edge of the oil retainer and shift lever shaft.
SHTS033200200023
(3) Tie the shaft of the shift lever and the shift lever internal shifting as
shown in the drawing and, push the shift lever shaft into the shift
lever internal ment.
VIEWED FROM THE PUSH DIRECTION OF THE INTERNAL
Model: with power changes
TRAVEL LEVER SHAFT
• They must be installed in such a way that the seating surface
of the nut for installing the power shifts, make a 90° angle with the
internal shift lever.
Model: (No power changes)
• They must be installed in such a way that the shaft of the lever
gears and internal shift lever tie.
VIEWED FROM THE PUSH DIRECTION
OF THE INTERNAL TRAVEL LEVER
INNERSHAFT
SHAFT SLOT
T
SURFACE OF THE NUT
FROM THE LEVER SEAT FOR INSTALLATION
OF CHANGES
OF THE
SHTS033200200024
DISPLACEMENT LEVER
LEVER SHAFT
INTERNAL SLOT
OF CHANGES
PA AXIS SHIFT
LOCK
LEVER. e OFFSET-\ U
INTERNAL TO
0'
SHTS033200200025
3. INSTALL THE SELECTION LEVER SHAFT AND OUTER

TOOL TO INSTALL OIL RETAINER SELECTION LEVER.
(1) Using a receiver block and hammer, drive a new oil retainer into
the shift lever shell. bios.
WARNING
Be careful not to damage the edge of the oil retainer.
(2) Apply bearing grease to the edge of the oil retainer and to the
axial portion of the selector lever shaft.
SHELL OF THE PA- OIL LANCA OF

CHANGE
SHTS033200200026
(3) Match the installation position of the select lever shaft tion and
external selection lever and secure the spring pin.
WARNING
Be sure to match the position of the select lever shaft. tion, the external
selection lever and the spring pin.
SHTS033200200027 4. INSTALL THE SHIFT LEVER SHIELD.

(1) Remove oil, dust, etc. of the contact surface of the shift lever shell
and transmission case.
(2) Cover the transmission case with liquid gasket (Three Bond
#1216 or equivalent) as shown in the figure.
WARNING
• The footprint for placing the liquid packaging must be continuous.
• The thickness of the liquid packaging layer must be 3 mm.
{0.1181 in.}
IMPORTANT POINT – INSPECTION

TRAVEL ODED SPECIAL LAZATION
14 mm 14mm
COURSE {0.551 in.} {0.5 5 1 in.} 1. INSPECT TRAVEL OF THE RELEASE LEVER INTERNAL
SHTS033200200028
WHERE OM AS OM ÁS PLACEMENT.
LESSON (1) Set the scale to the inner shift lever and measure the shift stroke
14 mm {0.551 and selection stroke of the inner shift lever.
in.} OM AS
14 mm {0.551 STANDARD
in.} OM AS
TRAVEL COURSE
14 mm {0.551 in.} or more
SHTS033200200029
SELECTION TOUR 14 mm {0.551 in.} or more
CASE AND MAIN UNIT
LOCATION OF COMPONENTS
EN0332002D100002
SHTS033200200030
1 Sealing ring (closure) 22 2nd gear sub-assembly.

2 Oil cap 12 synchronizer hub 23 1st gear sub-assembly.
3 stop ring 13 Synchronizer sleeve 24 Constant Cube
4 cylindrical bearing 14 needle roller bearing 25 Reverse gear
5 Input shaft sub-assembly 15 5th gear (or 6th.) 26 Oil retainer
6 Spacer 16 Horn 27 Dust separator
7 Synchronizer cone 17 4th gear 28 Flange
8 synchronizer ring 18 roller bearing 29 O-ring
9 synchronizer key 19 Synchronizer ring sub-assembly 30 Lock nut
10 synchronizer head 20 3rd gear sub-assembly. 31 Constant sleeve
11 Compression spring 21 Output shaft
tightening torque
A 587-783 {5,986-7,984, 433-577}
Unit: N⋅m {kgf⋅cm, lbf⋅ft}

SHTS033200200031
1 Concentric pin 18 Release shaft bearing

2 spacer 19 Expansion plug
3 Reverse shift head 20 O-ring (If equipped)
4 Reverse shift axis 21 Locking plunger
5 Reverse Shift Fork 22 Control lever stop
6 1st-reverse travel head 23 5th-6th travel fork.
7 1st-reverse displacement axis 24 5th-6th displacement axis
8 1st-reverse travel fork 25 Travel head 5th-6th.
9 Transmission case cover assembly 26 3rd-4th displacement axis
10 Idle gear cover 27 3rd-4th travel fork
11 Front bearing retainer 28 Drain plug
12 Packing 29 Packaging
13 oil retainer 30 Steel Ball
14 External rotor 31 Compression spring
15 internal rotor 32 Plug
16 oil pump cover 33 Front bearing retainer assembly
17 oil pump drive shaft 34 Filler cap
tightening torque Unit N⋅m {kgf⋅cm, lbf⋅ft}

TO 54-68 {550-700, 40-50} AN 26-30 {266-305, 20-22}
b 44.5-53.5 {454-545, 33-39} D
F 6-10 {62-101, 4.5-7.3}
c 44.5-53.5 {454-545, 33-39} g 23.5-28.5 {240-290, 18-21}
SHTS033200200032
tightening torque
A Without power take-off: 19.5-30.5 {199-311, 15-22} C 19-25 {194-254, 15-18}
With power take-off: 54-68 {551-693, 40-50} D 49-63 {500-642, 37-46}
B 63.5-92.5 {648-943, 47-68} E 26-30 {266-305, 20-22}

MODEL: FC
SHTS033200200033
1 O-ring 6 Packing
2 Speedometer gear horn 7 Rear bearing retainer assembly
3 oil retainer 8 Fixing screw
4 Speedometer Driven Gear 9 Speed sensor
5 Speedometer drive gear

A 8.5-10.5 {87-107, 6.3-7.7} C 14.7-29.3 {150-298, 11-21}
B 54-68 {550-700, 40-50}
MODEL: FD
SHTS033200200034
1 O-ring 4 Speedometer drive gear

2 Speedometer gear horn 5 Packing
3 Fixing screw 6 Rear bearing retainer assembly

TO 54-68 {550-700, 40-50} C 8.5-10.5 {87-107, 6.3-7.7}
b 54-68 {550-700, 40-50}
tightening torque
TRANSMISSION CASE ASSEMBLY
MAJOR REPAIR
EN0332002H200002

! CAREFUL
Do not work on the transmission while it is hot.
This may result in personal injury.
1. LOCK THE WHEELS.
2. DRAIN TRANSMISSION OIL.
3. DISCONNECT DRIVE SHAFT.
4. DISCONNECT THE MANIFOLD FROM ELECTRICAL CABLES AND

OTHER ATTACHED MATERIALS.
5. DISCONNECT PARKING BRAKE CABLE.
6. DISCONNECT TRANSMISSION CONTROL.
7. REMOVE CLUTCH CONTROL.
8. REMOVE TRANSMISSION CASE COVER FIXING BOLTS.

SUGGESTION
Disassembly and reassembly of the transmission case are fords out,
basically vertically placing the trans mission. So, remove the
transmission case fixing bolts from the clutch shell side to facilitate
better work.
SHTS033200200035
9. INSTALLING THE TRANSMISSION ASSEMBLY ON THE

TRANSMISSION WORKBENCH.
(1) Tie the transmission and speed assembly back with a cable using a crane
.
WARNING
Since the transmission case is made of aluminum, be careful not to hit it.
(2) Secure the transmission assembly with bolts and nuts to a workbench
placed on a level floor.
IMPORTANT POINTS - ASSEMBLY

1. REMOVE THE TRANSMISSION WORKBENCH.
(1) Install the transmission case cover mounting bolts. mission .
WARNING
Temporarily, after tightening all bolts equally, tighten them regularly.
2. INSTALL CLUTCH CONTROL.
3. CONNECT TRANSMISSION CONTROL.
4. CONNECT THE PARKING BRAKE CABLE.
5. CONNECT THE ELECTRICAL CABLE MANIFOLD I OTHER

ATTACHED MATERIALS.
6. CONNECT THE DRIVE SHAFT.
7. FILL THE TRANSMISSION WITH GEAR OIL UNTIL YOU REACH

THE FILLER PLUG HOLE DOR.
SHTS033200200035
SHTS033200200037

1. REMOVE PARKING BRAKE AND FLANGE COUPLING.
2. REMOVE THE OIL STRAINER.

3. REMOVE THE STEEL BALL.

(1) Remove the plug on the top surface of the trans case mission.
(2) Remove the spring and steel ball using a magnetic finger.
SHTS033200200038
4. REMOVE THE RODA RETAINER ASSEMBLY LATER LIE.
SHTS033200200039 5. DISASSEMBLE THE RO RETAINER ASSEMBLY LATER GIVEN.

(1) Remove the speedometer gear sprocket.
Model: FC
a. . Remove the set screw and sprocket from the gear gear.
cymeter and remove the driven gear and sprocket.
b. Remove the O-ring and oil retainer from the speedometer gear
bowl.
WARNING
Remember the position of the alignment marks when removing the
SHTS033200200040
SHTS033200200041
speedometer gear bobbin.

Model: FD
.
a. Remove the set screw and remove the gear sprocket.
speedometer.
b. Remove the speedometer gear bowl O-ring.
WARNING
Remember the position of the alignment marks when removing the speedometer gear bobbin.
(2) Remove the oil retainer.

to. Using a flat screwdriver, remove the oil retainer from the rear bearing retainer.
WARNING
Be careful not to damage the rear bearing retainer.
REMOVE THE SPEEDOMETER DRIVE GEAR.
SHTS033200200042
7. REMOVE TRANSMISSION CASE ASSEMBLY.

(1) Using a form expander, remove the stop ring from the
countershaft (intermediate shaft).
! CAREFUL
The stop ring may jump out of the groove. Wear safety glasses ity
while working.
(2) Using a center expander, remove the rear bearing stop ring that
is on the countershaft (intermediate shaft) side.
WARNING
while working.
SHTS033200200043
(3) Using a center expander, remove the rear bearing stop ring that
is on the output shaft side.
! CAREFUL
while working.
SHTS033200200044
SHTS033200200045
(4) Install the special tool into the groove on the outer periphery of the rear bearing on the reverse shaft side.
SST:
Extractor Base (S0965-31730)
Extractor (S0965-02080)
(5) Pull out the rear bearing by tightening the bolt on the removal part of the special tool.
(6) Remove the spacer.
(7) Install the special tool into the groove on the outer periphery of the
rear bearing on the reverse shaft side.
SST:
(8) Pull out the rear bearing by tightening the bolt on the removal part
of the special tool.
(9) Remove the spacer.
SHTS033200200046
(10) Remove the 4 bolts connected to the clutch housing from the
transmission case side.
(11) Insert a chisel between the connected right and left side cutting
edge parts on the transmission case, and tap gently. Hammer the
chisel using a hammer to separate the clutch shell and
transmission case.
SHTS033200200047
(12) Lift the transmission case assembly straight forward. mission and
remove it.
(13) Remove liquid gasket adhering to the mating surface using a
scraper.
WARNING
SHTS033200200048
SHTS033200200049
8. REMOVE THE OIL PIPE.

9. REMOVE THE CONTROL LEVER STOP, THE EM LOCK

BOLUS AND THE LOCK PIN.
(1) Loosen the 4 bolts to remove the control lever stop.
WARNING
The two inner bolts of the control lever stop coupling bolts are
counterbore bolts, so have those 2 bolts separated.
SHTS033200200050
(2) Remove the 3 control lever stop lock plungers.
(3) Using a magnetic finger, remove the two travel shaft locking
pins.
SHTS033200200052
SHTS033200200053
10. REMOVE THE OUTPUT SHAFT ASSEMBLY, THE COUNTER SHAFT ASSEMBLY AND THE TRAVEL SHAFT
ASSEMBLY.
(1) Install the screen to prevent dislodgement on the 5th-6th synchronizer unit. and prevent the 5th-6th timing cone
from and the ring comes off.
SUGGESTION:
If you are not using the screen to prevent detachments, secure the parts to prevent possible detachments that could be
caused by employees.
(2) Using the special tool, secure the output shaft assembly, countershaft
assembly, and travel shaft assembly.
SST: Axle Suspension (S0963-02220)
SUGGESTION
The previously moved stop ring and lock nut may be rejected.
(3) Using a crane, lift together: the output shaft assembly, the reverse
shaft assembly, and the travel shaft assembly.
WARNING
• Raise them little by little.
• Be careful not to allow the drive shaft to become trapped.
• Be careful not to damage the gear and bearing, etc. when lifting.
(4) Remove the special tool and separate the shaft assembly from sa lid,
counter-drive axle assembly, and travel axle assembly.
(11) REMOVE THE INNER RACE FROM THE FRONT BEARING

FROM THE COUNTERDRIVE AXLE.
(1) While holding the threaded portion of the oil pump drive pin with a
socket wrench, rotate (or vibrate) the oil pump drive pin using an
impact wrench, and then pull it out.
SHTS033200200055
SHTS033200200056
SHTS033200200057
(2) Using the special tool, pull the front bearing inner race out from the countershaft.
SST:
12. DISASSEMBLY THE DISPLACEMENT SHAFT ASSEMBLY

ZIZATION.
(1) Remove the displacement fork and displacement head zation.
.
Using a tapping rod with a diameter of 5.0 mm. {0.197 in.} and
a hammer, drive out the inner pin and outer pin of the shift fork,
to
shift head and spacer.
.
Remove the spacer, shift fork, and shift head from the shift shaft.
b.
13. REMOVE THE FRONT BEARING RETAINER

ASSEMBLY.
14. DISASSEMBLE THE RODA RETAINER ASSEMBLY FRONT

SHTS033200200059
LIE.
(1) Remove the oil retainer.
to. . Using a flat screwdriver, remove the oil retainer from the
front bearing retainer.
WARNING
Be careful not to damage the front bearing retainer.
SHTS033200200060
SHTS033200200061
15. REMOVE THE INPUT SHAFT ASSEMBLY.

(1) Using a special tool, pull the input shaft assembly out from the clutch shell.
SST:
Strike Hammer (S0942-01442)
Input shaft puller (S0965-02070)
16. REMOVE THE FRONT BEARING OUTER RACE FROM THE

REAR AXLE SIDE.
(1) Using a receiver block and hammer, tap gently and firmly. Smooth the
outer race of the front bearing evenly to remove it.
17. REMOVE THE OIL FILTER ASSEMBLY.
18. DISASSEMBLE TRANSMISSION CASE ASSEMBLY MISSION.

(1) Remove the middle (idle) cover.
.
a. Loosen the bolts to remove the middle (idle) cover.
b. Remove liquid gasket adhering to the mating surface using a scraper.
WARNING
.
(2) Remove the reverse idle (intermediate) gear. to. Loosen
the bolt to remove the retaining plate.
SHTS033200200065
b. Using the special tool, pull the idle (intermediate) reverse shaft.
SST: Slam Hammer (S0942-01442)
Remove the O-ring from the reverse idle (intermediate) shaft.

Remove the needle roller bearing.

1. ASSEMBLE RODA RETAINER ASSEMBLY FRONT LIE.
(1) Assemble the discharge valve.
a. .
Install the steel ball and compression spring in order in the
front bearing retainer direction.
b. Install a soft washer and a new plug.
SHTS033200200067
(2) Install the oil retainer.
a. .
Apply chassis grease to the lip portion of the new retainer
of oil.
b. Using a receiving block and hammer, drive the oil retainer into the
WARNING
(3) Be careful not to damage the lip.
(4) Do not deform the oil retainer.
SHTS033200200069
2. ASSEMBLE RODA RETAINER ASSEMBLY LATER LIE.

(1) Install the oil retainer (Model: FC) and O-ring.
Model: FC
.
to. Apply chassis grease to the new o-ring and new oil retainer and install them on the speedometer gear housing.
WARNING
• Make sure the oil retainer is installed in the
appropriate direction.
• Be careful not to damage the o-ring and oil retainer.
Model: FD
to. Apply chassis grease to the new O-ring and install it on the cylinder head.
.
speedometer gear.
WARNING
Be careful not to damage the O-ring.
(2) Apply chassis grease to the drive gear shaft portion. speedometer
gear and insert it into the speedometer gear housing (Model: FC).
(3) Install the speedometer gear bollard.

to. Align the etched mark line on the speedometer gear bowl with
the engraved mark line on the retainer. rear bearing ring and
insert it (Model: FC).
Number of teeth of Number of teeth of

Number of mark lines
drive gear driven gear
6 19 Three lines
WARNING
SHTS033200200071 To prevent damage to the drive gear and driven gear, align the mark lines.
(4) Fix the speedometer gear bowl with the set screw.
SHTS033200200072
3. INSTALL OIL RETAINER.

(1) Apply chassis grease to the cutting edge of the new oil retainer.
(2) Using a receiving block or hammer, drive the retainer oil seal inside
the rear bearing retainer.
WARNING
• Be careful not to damage the cutting edge of the oil retainer.
• Do not deform the oil retainer.
SHTS033200200073
4. ASSEMBLE THE TRAVEL SHAFT ASSEMBLY.

(1) Assemble the displacement fork and displacement head zation.
.
to. Tie the spacer, travel fork and drive head
displacement with the installation position of the displacement
axis zation.
WARNING
Make sure the displacement fork and displacement head are installed
in the proper position and direction.
b. Using a hammer, drive a new inner pin and a new outer pin into the
shift fork, shift head, and spacer.
WARNING
AXIS OF
DISPLACEMENT • Assemble the inner pin and outer pin with their cutting edges
opposite each other. Make sure the cutting edges of the inner pin
INTERNAL PIN and outer pin are vertical to the axis of travel when securing
BARRETTE .CUTTING them. re hitting them inside the displacement fork and
MOUNT THE PASSES DORES EDGE displacement head.
WITH THEIR OPPOSITE
CUTTING EDGES COUGH ON • Tap the inner pin and outer pin down to the striking seat of the
EACH OTHER.
shift fork, shift head and spacer.
(Q o(_________0
PIN PIN
EXTERNAL INTERNAL
SHTS033200200076 5. INSTALL THE INNER RACE OF THE COUNTERDRIVE AXLE
FRONT BEARING.
SHTS033200200077
(1) Using a receiver block and hammer, press the inner race of the front bearing into the countershaft.
(2) Using a press, press the oil pump drive pin into the countershaft.
SHTS033200200078
ASSEMBLE TRANSMISSION CASE6. ASSEMBLY ZION.

Install the reverse idle (intermediate) gear.
(1) Apply gear oil to the needle roller bearing.
a. Assemble the reverse idle (intermediate) gear and the ro needle
b. roller bearing.
Apply bearing grease to the O-ring and install the O-ring into the
c. groove of the reverse idle (intermediate) shaft.
Match the idle (intermediate) gear and stop washer with the
d. installation position of the transmission case.
SHTS033200200079 e. Using a copper hammer, drive the idler shaft (intermediate dio)
reverse gear inside the transmission case assembly.
f. Tie the retaining plate to the reverse idle (intermediate) shaft and
install it with the bolt.
SHTS033200200081
(2) Measure the final play of the idle (intermediate) gear. versa.
Assembly standard: 0.15-0.60 mm {0.0060-0.0236 in.}
Service limit: 0.65 mm {0.0256 in.}
SHTS033200200082
(3) Install the idle cover.
.
a. Remove oil, dust, etc. of the contact surface of the cu
idle opener and transmission case.
b. Cover
LIQUIDthe idle cover
PACKING with liquid
3 mm {0.118 1 in.} gasket (Three Bond #1216 or equivalent) as shown in the figure.
WARNING
• The footprint and quantity of the liquid packaging to be placed must be continuous.
• The thickness of the liquid gasket layer should be 3 mm {0.1181 in.}.
c. Install the idle cover on the transmission case with per us.
WARNING
Temporarily after tightening all bolts equally, tighten them regularly.
SHTS033200200083
SHTS033200200084
7. INSTALL THE OUTER RACE OF THE FRONT BEARING ON THE

REAR AXLE SIDE.
(1) Apply gear oil to the outer race of the front bearing.
(2) Using a receiving block and hammer, place the front bearing outer
race into the clutch shell.
SHTS033200200086
(3) Using a depth gauge, measure the surface dimension from the front end of the clutch shell to the outer race of the
front bearing. If the dimension ex exceeds the standard value,
adjust it to the set value within the range.
8. INSTALL INPUT SHAFT ASSEMBLY.

(1) Using a copper hammer, drive the input shaft assembly into the
clutch shell.
SHTS033200200088
9. INSTALL RODA RETAINER ASSEMBLY FRONT LIE.

(1) Apply gear oil to the new O-ring (3 pieces) and install the O-rings into
the clutch shell.
(2) After applying gear oil to the input shaft, cover the slot of the input
shaft with cloth, etc. to prevent damage to the front bearing retainer oil
seal.
SHTS033200200090
(3) Using the special tool, make the sealing ring (lock) of the oil filler plug enter and engage the slotted part.
SST: Seal Ring Guide (S0969-91370)
WARNING
Make sure the sealing ring on the input shaft assembly does not
protrude from the oil filler cap.
(4) Install the front bearing retainer assembly to the clutch shell with bolts,
using a new gasket.
WARNING
• Make sure the edge of the oil retainer does not become twisted
or that the sealing ring does not get caught when installing the
• Temporarily after tightening all gear bolts same, adjust them
regularly.
• Be careful not to damage the packaging.
SHTS033200200092
10. INSTALL OUTPUT SHAFT ASSEMBLY, COUNTER SHAFT

ASSEMBLY AND TRAVEL SHAFT ASSEMBLY.
(1) Apply gear oil to the sliding surface of the travel shaft.
(2) Using the special tool, secure the output shaft assembly, countershaft
assembly, and travel shaft assembly.
SST: Axle Suspension (S0963-02220)
SUGGESTION
• After assembling the travel shaft assembly to the output shaft
assembly and securing them with the rspecial tool, assemble the
countershaft assembly gear for better ease of work.
• Position the travel shaft assembly as shown in the figure.
SHTS033200200093
(3) Install the screen to prevent dislodgement inside the 5th-6th
synchronized unit and prevent the cone from synchronizing 5th-6th
floor and the ring comes off.
SUGGESTION
If you do not use the jig to prevent detachments, support the parts to
prevent detachments by one of the workers.
(4) Using a crane, lift together: the output shaft assembly, the countershaft assembly, and the travel shaft assembly and
install them into the clutch shell.
WARNING
• Be sure to insert the output shaft boss
into the hole in the pointed part of the output shaft.
• Be sure to insert the pump drive pin
of oil from the pointed part of the countershaft, into the oil pump
hole.
• Be careful not to damage the gear and bearing, etc. when you
install them.
(5) Make sure the gears on the output shaft and countershaft rotate
SHTS033200200096
smoothly, rotating the input shaft.

11. INSTALL STOP, LOCK PIGLER AND LOCK PIN.

(1) Apply chassis grease to the lock plunger and lock pin.
(2) Install the locking pin on the travel shaft.
(3) Install the locking plunger toward the stop.
(4) Install the stop with bolts.

WARNING
• Be careful not to let the locking plunger fall.
• The counterbore bolt should be used as the 2 internal bolts. us
from the control lever stop coupling.
SHTS033200200099
12. INSTALL OIL PIPE.
13. INSTALL TRANSMISSION CASE ASSEMBLY.

(1) Remove oil, dust, etc. of the contact surface of the clutch shell and
transmission case.
(2) Apply liquid gasket (Three Bond #1216 or equivalent) to the clutch
shell as shown in the figure.
WARNING
• The application trace of the liquid packaging must be continuous.
• The thickness of the liquid gasket applied should be 3 mm {0.1181
in.}.
(3) Install the transmission case assembly straight from the top.
SHTS033200200101
(4) Secure the transmission case assembly with 4 bolts.

WARNING
Temporarily after tightening all bolts, tighten them regularly.
SHTS033200200102
(5) Apply gear oil to the rear bearings of the output shaft and the
countershaft.
(6) Using a center expander, install the stop ring on the rear bearing
on the output shaft side and the reverse shaft side.
! CAREFUL
The stop ring may jump out of the groove. Therefore, wear safety
glasses while working.
SHTS033200200103
(7) Install the spacer towards the countershaft.
WARNING
The spacer must be installed with its chamfered side or facing
downwards.
(8) Using a receiver block and hammer, drive the rear drive shaft side
bearing into the transmission case.
SHTS033200200104 (9) Install the spacer towards the output shaft.

WARNING
The spacer must be installed with its flange side facing down.
(10) Using the receiver block and a hammer, place the output shaft
side rear bearing into the trans case. mission.
(11) Make sure the gears on the output shaft and countershaft rotate
smoothly, rotating the input shaft. trada.
(12) Using a form expander, install a new stop ring toward the
countershaft.
SHTS033200200105
SHTS033200200106
WARNING
• The stop ring may jump out of the groove. So you should wear safety glasses while working.
• Make sure the stop ring fits securely on the
slot.
(13) Using a thickness gauge, measure the clearance (play in the

direction of the axial axis) between the rear bearing and the stop
ring. If the clearance exceeds the standard value, select a suitable
stop ring and install it again.
Assembly standard: 0.1 mm {0.0039 in} or less One type of stop
ring
(14)
Thickness Color code
2.4 mm {0.0945 in.} None
2.5 mm {0.0984 in.} White

SHTS033200200107
2.6 mm {0.1024 in.} Green
2.7 mm {0.1063 in.} Coffee
INSPECT DISPLACEMENT HEAD.

(1) Using a thickness gauge, measure the clearance between each
displacement head, and make sure it does not exceed the
standard value.
(2) Make sure the inspection jig is inserted smoothly ly in the concave
part of the displacement head.
(3) Make sure that the two travel axes (travel heads) do not move at
the same time.
WARNING
If two displacement axes (displacement heads) move at the same time,
it is because the locking plunger has not been installed.
15. INSTALL SPEEDOMETER DRIVE GEAR.
SHTS033200200110
16. INSTALL REAR BEARING RETAINER.

• 1) Install the rear bearing retainer assembly to the transmission
case with bolts through a new gasket.
WARNING
• Temporarily after tightening all bolts equally, tighten them
regularly.
• Be careful not to damage the packaging.
17. INSTALL THE SAFETY BALL.
SHTS033200200111
18. INSTALL OIL STRAINER.
19. INSTALL PARKING BRAKE AND FLANGE COUPLING.
SHTS033200200112
INSPECTION AND REPAIR

EN0332002H300001
Unit: mm {inch}
Inspection item Standard Limit Remedy Inspection procedure
Clearance between the 0.02-0.45 {0.0008- 1.5 {0.0591} Replace. Measurement
hour moving keel ment 0.0177}
and sleeve
Locking pin, em locking — — Replace, if

bolt, compression spring necessary.
and steel ball:
Visual check
Wear and damage.
- 5- QQ -
Displacement head ing, — — Replace, if Visual check

travel fork and travel shaft: necessary.
Wear and damage TO&
— — Visual check
Internal rotor and ex rotor Replace the pair tes
terno in the air pump oil: as a game (set) if
Wear and damage necessary river.
Wheel retainer front — — Replace, if Visual check

protection: wear and necessary.
damage
Ball and spring in the — — Replace, if Visual check
valve download port: Des necessary.
wear and damage
0))))))))))))
Bearing: — — Replace, if Visual check

Wear, damage and necessary.
rotation condition
— — Replace, if Visual check

Idle gear (in termide) necessary.
reverse and reverse idle
shaft: Wear and damage
— — Replace, if Visual check

Needle roller bearing: necessary.
Wear and damage
DRIVE SHAFT ASSEMBLY
MAJOR REPAIR
EN0332002H200003
1. REMOVE THE OIL CAP.

(1) Remove the sealing ring from the oil cap.
(2) Install the special tool into the groove on the outer periphery of the oil filler cap.
SST:
Extractor bases (S0965-31710)
(3) Pull out the oil cap by adjusting the bolt on the extractor part of the special tool.
SHTS033200200119
2. REMOVE THE GUIDE ROLLER BEARING.
(1) Using a flat screwdriver remove the stop ring from the ra drive (input) shaft nut.
! CAREFUL
The stop ring may jump out of the groove. Therefore wear safety glasses
while working.
(2) Remove the spacer and guide roller bearing.
SHTS033200200120
3. REMOVE THE FRONT BEARING.

(1) Using a form expander, remove the drive (input) shaft stop ring.
! CAREFUL
while working.
Using a form expander, remove the front bearing stop ring.
! CAREFUL
while working.
SHTS033200200121
(2) Install the special tool into the groove on the outer periphery of
the front bearing.
SST:
Extractor bases (S0965-31720)
(3) Pull out the front bearing by tightening the bolt on the extractor
part of the special tool.
SHTS033200200122
1. INSTALL FRONT BEARING.

(1) Apply gear oil to the front bearing.
SHTS033200200123
(2) Using a receiver block and press, press the front bearing into the
drive (input) shaft.
WARNING
A receiver block should be placed towards the inner race of the
bearing.
(3) Using a form expander, install the stop ring on the front bearing.
! CAREFUL
The stop ring may jump out of the groove. Therefore wear safety
WARNING
SHTS033200200124 Make sure the stop ring fits securely in the groove.
(4) Using a spur expander, install a new stop ring on the drive (input)
shaft.
! CAREFUL
WARNING
Make sure the stop ring fits securely in the groove.
SHTS033200200125
(5) Using a thickness gauge, measure the clearance (play in the

axial direction) between the front bearing and the stop ring. If the
clearance exceeds the standard value, select a suitable stop ring
and install it again.
Assembly standard: 0.1 mm {0.0039 in} or less One type of stop
ring
2.4 mm {0.0945 in.} None
2.5 mm {0.0984 in.} White

SHTS033200200126
2.6 mm {0.1024 in.} Green
2.7 mm {0.1063 in.} Coffee
2. INSTALL GUIDE ROLLER BEARING.

(1) Apply gear oil to the inner surface of the input shaft and guide
roller bearing.
(2) Install in order: the spacer, guide roller bearing, and spacer into
the inner surface of the drive (input) shaft.
(3) Using a flat screwdriver, install a new stop ring on the drive
(input) shaft.
! CAREFUL
WARNING
SHTS033200200128
3. INSTALL OIL CAP.

(1) Heat the oil mask in hot water or oil at a temperature of 90°C-
120°C {194°F-248°F}.
WARNING
• If using oil, do not heat the oil cap beyond 120°C {248°F}.
• Hot water or oil and parts are at high temperature tura, so never
touch water, oil or ca lients with their bare hands.
• If using hot water, remove moisture before installation.
SHTS033200200129
(2) Install the oil cap on the drive (input) shaft.
(3) Install a new sealing ring on the oil filler cap.

WARNING
• The oil cap must be installed after cooling has been completed.
• Because the sealing ring is easy to deform Mind you, spread it as
little as possible when mounting it.
• Make sure that the sealing ring does not protrude
of the oil cap when installing it.
(4) Using a special tool, make the sealing ring of the oil filler cap fit
into the slotted part. SST: Sealing Ring Guide (S0969-91370)
(5) Apply gear oil to the sliding surface of the cover. oil mouth.
SHTS033200200132

EN0332002H300002
Unit: mm {inch}
Drive (input) shaft: Wear and — — Replace, if necessary. Visual check
damage
— —
Bearing: Replace, if necessary. Visual check
Wear damage and rotation
condition (5
— — Replace, if necessary. Visual check

Oil plug (seal ring groove):
Wear and damage
OUTPUT SHAFT ASSEMBLY
MAJOR REPAIR
EN0332002H200004

1. REMOVE THE 5TH-6TH SYNCHRONIZER UNIT.
SHTS033200200135
(1) Place the front end of the output shaft up and remove the output
shaft stop ring, using a shaft expander.
! CAREFUL
The stop ring may pop out from the groove. Therefore, wear safety
SHTS033200200136
2. REMOVE 1ST GEAR ASSEMBLY, 1ST-2ND SYNCHRONIZER

UNIT. AND THE 2ND GEAR ASSEMBLY.
(1) Use the front side of the 2nd gear. as support for pre sionar. Press the
rear end of the output shaft to remove the gears.
PRESSURE DIRECTION
WARNING
• When you press the output shaft, put a block of ma dera at the
bottom of the shaft.
• Because the output shaft is heavy, support it safely. rity.
SHTS033200200137
3.
REMOVE THE 4TH GEAR ASSEMBLY, THE UNIT 3RD-4TH
SYNCHRONIZING DAD. AND THE 3RD GEAR ASSEMBLY.
(1)
Using a form expander, remove the output shaft stop ring.
! CAREFUL
The stop ring may pop out from the groove. Therefore, wear safety glasses
while working.
SHTS033200200138
(2)
Use the front side of the 2nd gear. as support for pre sionar. Press the
rear end of the output shaft to remove the gears.
WARNING
• When you press the output shaft, put a block of ma dera at the
• Because the output shaft is heavy, support it securely. rity.
SHTS033200200139 4.
DISASSEMBLE THE SYNCHRONIZER UNIT (1ST-2ND, 3RD-4TH, 5TH-
6TH; 3 pieces)
(1)
Using a form expander, remove the output shaft stop ring.
BE CAREFUL
while working.
SHTS033200200140
(2) Remove the synchronizer key, synchronizer head, and compression

spring from the synchronizer hub.
! CAREFUL
while working.
SHTS033200200141
5. DISASSEMBLE THE GEAR (4TH GEAR, 5TH GEAR). (OR 6TA.); 2

pieces)
(1) Using a hub expander, remove the 4th gears. and 5th. (or 6th.).
! CAREFUL
while working.
SHTS033200200142 (2) Remove the 4th gear synchronizer cone. and 5th. (or 6th.).
SHTS033200200143
IMPORTANT POINTS – ASSEMBLY
1. ASSEMBLE THE SYNCHRONIZER UNIT. (1st-2nd, 3rd-4th, 5th-6th;

3 pieces)
(1) Only for the 1st synchronizer unit. and 2nd, remove the stop ring
from the 1st. side.
! CAREFUL
while working.
SHTS033200200144
(2) Install the synchronizer sleeve.

(3) Install the stop ring towards the 1st. 1st-2nd synchronizer unit side.
! CAREFUL
SHTS033200200145
2. ASSEMBLE GEAR ASSEMBLY. (GEARS 4TH GEAR, 5TH GEAR

(OR 6TA.); 2 pieces)
(1) Install the synchronizer cone to the 4th gears. and 5th. (or 6th.).
(2) Using a cylindrical expander, install a new stop ring into the groove
SHTS033200200146 on the 4th gear synchronizer mounting surface. and 5th. (or 6th.).
! CAREFUL
WARNING
3. INSTALL 1ST-2ND SYNCHRONIZER UNIT.

(1) Install in order: inner cone, double cone and synchro ring dor on
the output shaft.
SHTS033200200148
(2) Using a heater, (piston heater, etc.), heat the synchronizer unit in hot
water or oil to 90°C-120°C {194°F-248°F}.
! CAREFUL
Hot water or oil and parts are at high temperature, so never touch hot
water, oil or parts with your bare hands.
WARNING
• If using oil, do not heat the synchronizer unit above 120°C {248°F}.
(3) Install the synchronizer unit on the output shaft.
SHTS033200200149
4. INSTALL 1ST GEAR ASSY.

(1) Install the 2nd gear synchronizer bollard. on the output shaft.
SHTS033200200150
! CAREFUL
Hot water or oil and parts are at high temperatures, so never touch hot
WARNING
(2) Install the 1st gear synchronizer bollard. on the output shaft.
SHTS033200200152
(3) Apply molybdenum sulfite grease to the surfaces of both ends of

the hub portion (core) of the 1st gear. and install the 1st gear
assembly.
SH TS 033200200153
5. INSTALL REVERSE GEAR.

(1) Using a heater, (piston heater, etc.) heat the reverse gear bollard
in hot water or oil to 90°C-120°C {194°F-248°F}.
! CAREFUL
water, oil or parts with your bare hand.
WARNING
• If oil is used, do not heat the synchronizing unit beyond 120 ° C {248 °
F}.
SH TS 033200200154 (2) Install the reverse gear bollard onto the output shaft.
(3) ) Apply a smooth layer of your demolybdenum surface to the surfaces of

the two ends of the reverse gear hub (core) and install the reverse gear.
SH TS 033200200155
SH TS033200200156
6. INSTALL 3RD GEAR ASSY.

(1) Install the screen (jig) to prevent detachment of the sa shaft. lida.
WARNING
The jig should be used to prevent the assembled gear and bearing from
falling out.
SHTS033200200157
7 . INSTALL ADORA 3RD-4TH SYNC UNIT.

(1) Install in order: the inner cone, the double cone and the synchronizer
ring on the output shaft.
SHTS033200200158
(2) Heat the synchronization unit in hot water or oil at 9 0°C-120°C {19 4°F -248 °F}.
! CAREFUL
WARN
• ING If using hot water, remove moisture before installation.
(3) Install the synchro unit on the output shaft.

(4) Install the synchronizer ring.
SHTS033200200160
8. INSTALL 4TH GEAR ASSY.

(1) Warm up the 4th gear horn. in hot water or oil at 90°C-120°C
{194°F-248°F}.
! CAREFUL
WARNING
(2) Apply gear oil to the 4th gear needle roller bearing. and insert it
SHTS033200200161 into the inner side of the 4th gear.
(3) Install the 4th gear assembly. and the horn on the output shaft.
(4) Using a form expander, install a new stop ring on the output shaft.
! CAREFUL
SHTS033200200162
WARNING
(5) Using a feeler gauge, measure the clearance (play in the axial
direction) between the gear collar and the stop ring. If the
clearance exceeds the standard value, select a suitable stop ring
and install it again.
Assembly standard: 0.1 mm {0.0039 in} or less
A type of stop ring
SHTS033200200163
2.35 mm {0.09 25 in.} None
2.45 mm {0.09 65 in.} White

SHTS033200200164
2.55 mm {0.1004 in.} Green
2.65 mm {0.1043 in.} Coffee

9. INSTALL 5TH-6TH SYNCHRONIZER UNIT.

(1) Using a form expander, install a new stop ring on the output shaft.
! CAREFUL
while working.
WARNING
SHTS033200200165 direction) between the synchronizer hub and the stop ring. If the
clearance exceeds the standard value, select a suitable stop ring and
install it again.
Assembly standard: 0.1 mm {0.0039 in} or less
A type of stop ring
1.9 mm {0.0784 in.} None
2.0 mm {0.0787 in.} White

SHTS033200200166

EN0332002H 300003
Unit: mm {inch}
synchronization ring dor: — — Replace, if
deformation, breakage or necessary. Visual check
excessive damage
EezenmuL
Gear: excessive wear, — — Replace, if
chipping or breakage necessary.
Visual check
1e——_
—5
Clearance between 0.2 {0.0079} Replace M edition

synchronizer ring, synchronizer ring
synchronizer cone and 2nd, 3rd gear and 4th. and/or sub gear
gear sub-assembly 1.0-1.8 {0.03940.0708} assembly.
5th gear and input 1.2-

2.0 {0.0473 0.0787}
Oil Retainer Lip: — — Replace, if

Wear and damage necessary.
Visual check
(,
Cylindrical bearing and — — Replace, if Visual check

ball bearing: Improper necessary
rotation
Deformed needle roller — — Replace, if Visual check

bearing necessary.
Output shaft: — — Replace, if Visual check

Wear and damage necessary.
COUNTERDRIVE SHAFT ASSEMBLY

MAJOR REPAIR
EN0332002H200005

1. REMOVE THE FRONT BEARING INNER RACE.
(1) While holding the tapered portion of the oil pump drive pin with a
wrench, rotate (or vibrate) the oil pump drive pin using an impact
wrench, and then pull it out.
(2) Using a special tool, pull the front bearing inner race out from the
countershaft.
SST:
SHTS033200200175
2. DISASSEMBLY THE COUNTER SHAFT ASSEMBLY CHA.
(1) Using a form expander, remove the countershaft stop ring.
! CAREFUL
(2) Use 5th gear. of the counter-drive axle as a bearing to press. Press
the countershaft to remove the drive gear and 5th gear. reverse
SHTS033200200176
gear.
WARNING
• When you press the output shaft, place a block of ma dera at the
• Because the output shaft is heavy, support it safely. rity.
SHTS033200200177

1. ASSEMBLE THE COUNTER DRIVE SHAFT ASSEMBLY.
(1)
Select the appropriate size key according to the key slot size and install.
Thickness Shape
(T)
14,018-14,029mm
{0.5519-0.5523 in.}
14,070-14,085mm
{0.5540-0.5545 in.}
(2) Press the countershaft

into the gears, confirm Make sure the countershaft key and the idle gear
keyway are aligned.
(3) Press the countershaft into the gears, confirm Make sure the
countershaft key and the counterdrive gear keyway are aligned.
(4) Using a form expander, install a new stop ring on the countershaft.
SHTS033200200181 ! CAREFUL
The stop ring may spring out of the groove. Therefore, wear safety
WARNING
direction) between the counter drive gear and the stop ring. If the
clearance exceeds the standard value, select a suitable stop ring and
install it again.
SHTS033200200182
Assembly standard: 0.1 mm {0.0039 in} or less One type of stop ring:
2.45 mm {0.0965 in.} White
2.55 mm {0.1004 in.} Red

SHTS033200200183
2.65 mm {0.1043 in.} Yellow
2.75 mm {0.1083 in.} Blue

(6) Press the oil pump drive pin into the countershaft.

EN0332002H300004

All gears: Cracks and — — Replace, if Visual check
defects necessary.
Idle (intermediate) gear, — — Replace, if

shaft and needle roller necessary.
bearing: Visual check
Wear and damage
9, G68 g-
Countershaft: Wear, chips — — Replace, if Visual check

and cracks necessary.
Contra axle wrench gear — — Replace Visual check

and key slot: countershaft and/or
Damage and loosening key, if necessary.

Lx06s Gearbox

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Lx06s Gearbox

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TRANSMISSION MAIN UNIT (LX06S) TR02–1

UN ID ADP RIN C IPA LDELA TRA NSM IS IION

WITH TOGETHER THE TRANSMISSION .......... TR02-2

UN ID ADP RIN C IPA LDELA TRA NSM IS IION 1

OUTPUT SHAFT ASSEMBLY 53

CHANGE SHIELD TOO RC HAS .. TR02-9

CA JA YUN ID ADP RIN C IPA L ..................... TR02-17

DRIVE SHAFT ASSEMBLY............................. TR02-45

OUTPUT SHAFT ASSEMBLY TR02-5 0

CONTRA AXLE ASSEMBLY

DATA AND SPECIFICATIONS

1st. 8.190 6.098

2nd. 5.073 3.858

3rd. 2.982 2.340

Speed ratio: 4th. 1.849 1.442

5th. 1.343 1.000

6th. 1.000 0.761

Reverse 7.619 5.672

Number of input shaft teeth 21 25

Counter drive gear

Reverse Intermediate Gear 23/11 2 3/1 1

Opening to make strength On the left side of the gearbox

Oil capacity, gearbox Ap ro x . 5 .0 liter s {1 .1 0 Imp .gal/1 .3 2 US gal.}

OIL CAPACITY, GEARBOX WITH MADEPOTHENCY

Lubricant, type Gear Oil (AP IG L-4)

Visco sity, between -12 and 32 ° C {10 and 90 ° F} SAE9 0

V iscosity, above 32 ° C {90 ° F} SAE140

1 input shaft 15 Lock nut

2 oil retainer 16 Flange

3 Front bearing retainer 17 Output shaft

4 5th-6th shift sleeve. 18 Speedometer Driven Gear

5 displacement axis 19 Rear bearing retainer

6 box cover 20 Cylindrical bearing

7 gear 5th. or 6th. 21 Reverse shift sleeve

8 gear 4th. 22 Displacement sleeve 1st.- 2nd.

9 Inside gear lever 23 Counter-drive axle

10 gear 3rd. 24 Displacement sleeve 3rd.- 4th.

11 gear 2nd. 25 Counter gear

12 gear 1st. 26 Countershaft front bearing

13 gear reverse 27 Transmission case

Reem place as required.

Difficulty engaging gears (clutch)

Rigid relay shaft nylon cylinder and/or Reem place as required.

Decrease in gear oil and/or viscosity addeac

Loosen the mounting bolts between the Adjust it as fast as possible.

Symptom Possible cause Remedy/Prevention

Loose mounting bolts and nuts Inspect and adjust.

Illustration Part number Tool name Observations

< S0983-94601 CO PA KEY

S09 42-01 442 LPE GO HAMMER

S09 65-0207 0 INPUT SHAFT R EXTRACT

") S0969-9 1370 GUIDE

Illustration Part number Tool name Observations

PURPOSE TOOL (TRANS CRANKCASE ASSEMBLY)

GEAR SHIFT SHELL

1 shift lever shaft 10 air respirator

7 Flat washer 16 Selector lever shaft

tightening torque Unit: N⋅m {k gf⋅cm, lbf⋅ft}

MODEL: FC (NO POWER CHANGE)