MT: MANUAL TRANSMISSION TROUBLESHOOTING .. 150 TRANSMISSION Removal of Transmission MT-3 Components o MT-5 Disassembly of Transmission . . MT-7 Inspection of Transmission Components . MT-10 Assembly of Transmission .. MT-15 iM Installation of Transmission MT-22MANUAL TRANSMISSION — Troubleshooting TROUBLESHOOTING Remedy Possible cause ‘Splines on input shaft dirty or burred. Repair as necessary Disassemble and inspect transmission Hard to shift or will not shift Transmission faulty | MT3 ‘Transmission faulty ‘Disassemble and inspect Mra Transmission jumps out of gear ‘transmissionMANUAL TRANSMISSIOT 750 Transmi ion T50 TRANSMISSION REMOVAL OF TRANSMISSION 1 2. REMOVE NEGATIVE BATTERY TERMINAL WIRE TURN DISTRIBUTOR (a) Loosen the bolt. (b) Turn the distributor so it does nat strike against the dash panel. REMOVE CONSOLE BOX REMOVE SHIFT LEVER FROM INSIDE OF VEHICLE RAISE VEHICLE AND DRAIN TRANSMISSION OIL CAUTION: Be sure the vehicle is securely supported. DISCONNECT PROPELLER SHAFT FLANGE FROM FLANGE ON DIFFERENTIAL (a) Place matchmarks on the flanges. {b) Remove the four bolts and nuts. REMOVE CENTER SUPPORT BEARING FROM BODY (3oint Type) REMOVE PROPELLER SHAFT (a) Pull the yoke from the transmission. (b) Insert SST in the transmission to prevent oil leakage. SST 09325-12010 REMOVE EXHAUST PIPE CLAMP BOLT REMOVE SPEEDOMETER CABLE + DISCONNECT BACK-UP LIGHT SWITCH CONNECTORBO M4 MANUAL TRANSMISSION — T50 Transmission 12. REMOVE CLUTCH RELEASE CYLINDER 13. REMOVE STARTER {a) Disconnect the two wires from the starter. {b) Remove the two bolts and the starter. 14. JACK UP TRANSMISSION SLIGHTLY Raise the transmission enough to remove the weight from the rear support. 15. REMOVE ENGINE REAR MOUNTING 16. REMOVE STIFFENER PLATE AND TRANSMISSION BOLTS 17, REMOVE TRANSMISSION ASSEMBLY Pull out the transmission down and toward the rear.MANUAL TRANSMISSION — T50 T! COMPONENTS ‘ransmissionMTS MANUAL TRANSMISSION — TSO Transmission COMPONENTS (Cont'd) Output Shaft Hub Sleeve No.2 3rd Gear Center Bearing Inner Race Ist Gear Locking Bali ‘Snap Ring Synchronizer Ring Synchronizer Ring 2nd Gear Hub Sleeve No.1 Da Locking Ball er Needle Roller ° speetomes ResleRaller Reming 5 Sth Gear | Roa Bearing Bear cer ™ Hub Sleeve No.3 " Locking Ball Needle Roller Bearing synchronizer Ring Inner Race Seems Reverse Gear Needle Rotter Bearing soap Ring S¥PeHONizer Bing Interlock Pin Shift Fork No.3 ‘Shift Fork Shatt No.3MANUAL TRANSMISSION — 150 Transmission MTZ 1. 4, DISASSEMBLY OF TRANSMISSION (See page MT-5, 6) REMOVE BACK-UP LIGHT SWITCH, SPEEDOMETER DRIVEN GEAR, SHIFT LEVER RETAINER, RESTRICT PINS, CLUTCH RELEASE BEARING AND FORK REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE (a) Remove the front bearing retainer. {b) Remove the spacer. {c). Remove the clutch housing. REMOVE EXTENSION HOUSING Remove the six bolts and pull off the extension housing, REMOVE LOCKING BALLS AND SPRINGS (a) Remove the case cover. (b) Using a magnetic finger, remove the three locking balls and springs, REMOVE LEFT CASE FROM RIGHT CASE Separate the left case from the right case by tapping the Projection with a plastic hammer. REMOVE INPUT AND OUTPUT SHAFT FROM RIGHT CASE REMOVE COUNTER GEAR FROM RIGHT CASE REMOVE SLOTTED SPRING PIN FROM SHIFT FORK AND FORK SHAFT (a) Using a punch and hammer, drive out the pin in the shift fork No. 1 through the hole in the case. {b) Drive out the pin in the shift fork No. 2 and No. 3, {c) Pull out the fork shaft No. 1, 2 and 3 by setting each to the neutral position,MANUAL TRANSMISSION 3rd Gear Reverse Gear Sth Gear 10, 50 smission REMOVE INTERLOCK PIN Remove the two interlock pins. MEASURE EACH GEAR THRUST CLEARANCE ON OUTPUT SHAFT Using feeler gauges, check the thrust clearance of each gear. Gear thrust clearance |_Gear_ —_STD__ 0.150 — 0.275 (0.0059 — 0.0108) | 05 ( 2nd 10.150 — 0.250 (0.0059 - 0.0008) | 05 | 3rd 0.150 — 0.300 (0.0059 0.0118) | 06 ( 5th 0.100 — 0.930 {0.0039 - 0.0366) 1.0 {1 Reverse | 0.200 ~ 0.325 (0.0079 0.0128) _ 0.6 ( uu. 12, REMOVE SPEEDOMETER DRIVE GEAR (a) Using snap ring pliers, remove the snap ring. {b) Remove the speedometer drive gear from the output shaft. (c) Remove the other snap ring. REMOVE SNAP RING, REAR BEARING, SPACER, NEEDLE ROLLER BEARING, FIFTH GEAR, SYNCHRONIZER RING, SPACER AND LOCKING BALL (a) Remove the snap ring with two screwdrivers and a hammer. (b) Using SST, remove the rear bearing, SST 09950-20014 (c)_ Remove the spacer for the rear bearing, {d) Remove the 5th gear, synchronizer ring and needle roller bearing. {e) Using a magnetic finger, remove the locking ballMANUAL TRANSMISSION — T50 Transmission 13. 14. 6. 16. 7, (f) Remove the spacer for the needle roller bearing. REMOVE HUB SLEEVE NO.3 ASSEMBLY, REVERSE GEAR, NEEDLE ROLLER BEARING, INNER RACE, LOCKING BALL AND SNAP RING (a) Using two screwdrivers and a hammer, remove the snap ring (b) Support the reverse gear, and remove the gear and hub tagether by pressing down the output shaft. (c) Remove the bearing and inner race. {d} Using a magnetic finger, remove the locking ball. {e) Using two screwdrivers and a hammer, remove the snap ring REMOVE CENTER BEARING, FIRST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, INNER RACE AND LOCKING BALL (a) Support the 1st gear, and remove the gear and the bearing together by pressing down the output shaft. (b) Remove the synchronizer ring. (c)_ Remove the locking ball. REMOVE NO. 1 HUB SLEEVE ASSEMBLY, SYNCHRONIZER RING, SECOND GEAR AND NEEDLE ROLLER BEARING (a) Support the 2nd gear and remove it and the hub together by pressing down the output shaft. (b) Remove the needle roller bearing, REMOVE SNAP RING Using snap ring pliers, remove the snap ring. REMOVE NO.2 HUB SLEEVE ASSEMBLY, SYNCHRONIZER RING AND THIRD GEAR Support the 3rd gear, and remove it and the hub together by pressing down the output shaft.MANUAL TRANSMISSIOT Sst INSPECTION OF TRANSMISSION COMPONENTS 1 INSPECT OUTPUT SHAFT AND INNER RACES {a) Inspect the output shaft and inner races for wear or damage. (b) Using calipers, measure the thickness of the output shaft flange. Minimum thickness: 4.0 mm (0.187 in.) (c) Using a micrometer, measure the outer diameter of the shaft bushing surface. Minimum diameter: 37.8 mm (1.488 in.) (d) Using calipers, measure the thickness of each race flange. Minimum all gear race: 3.8 mm (0.150 in.) {e) Using 2 micrometer, measure the outer diameter of each race. Minimum 1st and reverse gear race diameter: 36.85 mm (1.4508 in.) (f) Using a dial indicator, check the shaft runout. Maximum runout: 0.06 mm (0,0024 in.) IF NECESSARY, REPLACE INPUT SHAFT BEARING (a) Using snap ring pliers, remove the snap rings. {b) Using a press, remove the bearing. (c) Using a press and SST, install the new bearing. SST 09316-60010 NOTE: Make sure the outer race snap ring groove is positioned toward the front.MANUAL TRANSMISSION — 150 Transmission MT-11 (d) Select a snap ring that will allow minimum axial play and install it on the shaft. Mark Thickness mm (in) A 2.35 -2.40 (0.0925 — 0.0945) 8 2.40 - 2.45 (0.0945 — 0.0965) c 2.45 —2.50 (0.0965 — 0.0984) o 2.50 ~ 2.55 (0.0984 — 0.1004) € 2.55 — 2.60 (0.1004 — 0.1024) CHECK OIL CLEARANCE OF FIRST, FIFTH AND REVERSE GEARS Using a diat indicator, measure the oil clearance between the gear and inner race with the needle roller bearing installed. Standard clearance: Ast gear 0.009 — 0.060 mm {0.0004 — 0.0024 in.} Sth gear 0.010 — 0.050 mm (0.0004 — 0.0020 in.) Reverse gear (0,070 — 0.120 mm (0.0028 — 0.0047 in.) Maximum clearance: 0.150 mm (0.0059 ) CHECK OIL CLEARANCE OF SECOND AND THIRD GEARS Using a dial indicator, measure the oil clearance between the gear and output shaft. Standard clearance: 2nd gear 0.009 — 0.060 mm (0.0004 — 0.0024 in.) 3rd gear 0.060 — 0.101 mm {0.0024 — 0.0040 in.) Maximum cl 2nd gear 0.150 mm (0.0059 in.) 3rd gear 0.200 mm (0.0079 in.) INSPECT SYNCHRONIZER RINGS (a) Turn the ring and push it in to check the braking action, {b} Measure the clearance between the synchronizer ring back and the gear spline end. Standard clearance: 1.0 — 2.0 mm (0.039 — 0.079 in.) Minimum clearance: 0,8 mm {0.031 in.) INSPECT SHIFT FORK AND HUB SLEEVE (a) Check the contact surfaces for wear or damage. {b) Measure the clearance between the hub sleeve arid the shift fork, Maximum clearance: 0.8 mm (0.031 in.)MANUAL TRANSMISSION — T50 Transmi 7. nm IF NECESSARY, REPLACE COUNTER GEAR FRONT BEARING (a) Loosen the bolt and remove it and the lock plate. (b) Using snap ring pliers, remove the snap ring. {c) Using SST, remove the front bearing. SST 09950-20014 (d) Using a socket wrench, support the front bearing inner race, and press in the counter shaft. (e) Install the snap ring. {f) Install the lock plate and tighten the bolt. Torque: 375 kg-cm (27 ft-lb) IF NECESSARY, REPLACE REAR BEARING, FIFTH GEAR, REVERSE GEAR AND CENTER BEARING (a) Using snap ring pliers, remove the snap ring. (ib) Using a press and 12-mm socket wrench, press out ‘the rear bearing and th gear. {c) Remove the reverse gear and center bearing. (d) Install the center bearing and reverse gear. (e) Using a press and SST, install the rear bearing and 5th gear. SST 09515-20010 NOTE: Lift the reverse gear to the upper side, and press in the bearing and 5th gear. : (f) Select a snap ring that will allow minimum axial play and install it on the shaft. Mark Thickness mm fin.) 4 2.00 ~ 2.05 (0.0787 — 0.0807) 2 1.80 - 1.85 (0.0708 ~ 0.0728) 3 1.60 ~ 1.65 (0.0630 — 0.0650)MANUAL TRANSMISSION — 150 Transmission MT-13 sst ‘20men (0.79 in.) 9. 10. 1. 12, INSPECT REVERSE IDLER GEAR (a) Before removing the reverse idler gear, measure the thrust clearance. Standard clearance: 0.05 — 0.50 mm. (0.0020 — 0.0197 in.) Maximum clearance: 1.0 mm (0.039 in.) (b) Check the idler gear and shaft for wear or damage. IF NECESSARY REPLACE OIL SEAL {a} Using SST, remove the seal. SST 09921.00010 (b) Using SST, install a new seal SST 09201-60011 IF NECESSARY, REPLACE REVERSE RESTRICT PIN (a) Remove the plug with a hexagon wrench, (b) Drive out the slotted spring pin with a pin punch and remove the reverse restrict pin. (c)_ Apply liquid sealer to the plug. (4) Tighten the plug Torque: 130 kg-cm (9 ft-lb) IF NECESSARY, REPLACE OIL SEAL AND BUSHING {a) Using SST, remove the oil seal. SST 09308-00010 09308-10010 with output shaft installed (b) Heat the extension housing end to 80 — 100°C (176 = 212°F) in an oil bath. (c) Using SST, remove the bushing. SST 09307-12010 {d) Using SST, install the new bushing. SST 09307-12010 NOTE: The bushing oil hole is positioned upward.MT.14 MANUAL TRANSMISSION — T5O Transmission 13, {e) Using SST, drive in the new oil seal. SST 09325-12010 (f) Apply MP grease to the oil seal. IF NECESSARY, REPLACE FRONT BEARING OIL SEAL (a) Using a screwdriver, pry out the oil seal. (b) Using SST, press in the new oil seal. SST 09223-22010 Oil seal depth: 2.5 mm (0.098 in.) (c) Apply MP grease to the oil seal.MANUAL TRANSMISSION — 150 Transmi Not No.3 ASSEMBLY OF TRANSMISSION (See page MT-5, 6) 1. ASSEMBLE EACH CLUTCH HUB AND SLEEVE (a) Install the clutch hub and shifting keys to the hub sleeve. NOTE: Be careful not to install them backwards. (b) Install the shifting key springs under the keys. NOTE: Install the key springs positioned so that their ends overlap, 2. INSTALL SECOND GEAR AND CLUTCH HUB NO. 1 (a) Apply MP grease to the shaft. (b) Install the needle roller bearing. {c) Place the synchronizer ring on the gear and align the ring slots with the shifting keys. (d) Using a press, install the 2nd gear and clutch hub No. 1. 3. INSTALL LOCKING BALL AND FIRST GEAR ASSEMBLY {a] Install the locking ball in the shaft. {b) Apply MP grease to the bearing (c) Assemble the 1st gear, synchronizer ring, needle roller bearing and bearing inner race. {d) Fit the inner race groove securely over the locking ball. (e) Install the assembly on the output shaft with the syn- chronizer ring slots aligned with the shifting keys. 4, INSTALL CENTER BEARING Using a press and SST, install the center bearing on the ‘output shaft. SST 09316-60010 CAUTION: Support the 1st gear and inner race by hand. NOTE: The flange should be positioned toward the rear,MT-16 MANUAL TRANSMISSION — 750 Trans Groove 5. INSTALL SNAP RING Select a snap ring, which will allow 0-0.1 mm (0 ~ 0.004 in.) axial play and install it on the shaft. Mark| Thickness mm in.) | Mark} Thickness mm lin.) a | 270~2.78 10.1063-0.1083 | a | 295-300 (0.1161-0.1981) > | 275~280 10.1083-0.1102 |» | 300-305 f0,1181-0.1201) @ | 280-265 10.1102-0.1122) | 5 | 3053.10 t0.1201-0.1220) fe | 285-290 10.1122-0.1142) |e | 310—3:15 ¢0.1220-0.1240) + | 290-295 rnaz-o.t161) | 1 | 3.15— 320 40.1240-0.12600 6. INSTALL LOCKING BALL AND REVERSE GEAR {a} Install the locking ball in the shaft. (b) Place the inner race and roller bearing in reverse gear. (c) Fit the inner race groove securely over the locking ball when installing the reverse gear on the output shaft. 7. INSTALL CLUTCH HUB NO. 3 Using a press, install the clutch hub on the output shaft. CAUTION: Support the reverse gear by hand. INSTALL SNAP RING Select a snap ring which will allow 0 — 0.1 mm (0 — 0,004 in.) axial play. Mark | Thickness mmm in.) Mark | Thickness mm (in) 3.00 ~ 3.05 (0.1181 ~ 0.1201) 0.1043) a | 260-2650 2 8 | 265-2.70 10.1043 ~9.1063) | K | 3.09 ~ 2.10 40.1201 -0.12201, ¢ | 270-275 101063 -o.1083) | Lt | 310~ 3.16 40.1220 -0.1240), © | 275-280101083- 07102) | m_ | 3153.20 40.1240 — 0.1260) | 280 —2a610.1102-0.11921| N | 320 - 3.25 0.1260 ~ 0.1200) F . 285-290(0.1122-0.1142)| p | 325— 3.30 (0.1280 - 0.1299) G | 290-2o5i0.1%62- o1161}| @ | 330—3.25 10.1299 0.13191 \ H | 295 200101161 - 01181) 9. INSTALL FIFTH GEAR AND SPACER Spacer > {a} Install the spacer for the needle roller bearing, {b) Place the synchronizer ring on the gear. {¢) Place the roller bearing in the gear. (d) Install the Sth gear on the output shaft with the syn- chronizer ring slots aligned with the shifting keys. {e} Install the locking ball in the shaft. (f) Fit the spacer groove securely over the locking ball when installing the spacer on the shaft.MANUAL TRANSMISSION — 150 Transmission MT-17 10. INSTALL REAR BEARING Using a press and SST, install the rear bearing on the out- put shaft. SST 09515-20010 CAUTION: Support the 5th gear and inner race by hand. NOTE: The ball shield should be positioned toward the rear. 11. INSTALL SNAP RING Select a snap ring which will allow 0 — 0.1 mm (0 — 0.004 in.) axial play. 2.35 = 2.40 (0.0925 — 0.0945) 240-245 (0.0945 — 0.0965) 2.45 — (0.0965 — 0.0984) 2.50 - (0.0984 — 0.1004) 2.55 —2.60 {0.1004 — 0.1024) 2.60 - 2.65 (0.1024 — 0.1043) 2.65 ~ 2.70 (0.1043 — 0.1063) 12. INSTALL THIRD GEAR, SYNCHRONIZER RING AND CLUTCH HUB NO.2 (a) Apply MP grease to the shaft. (b) Install the gear and the synchronizer ring on the shaft. (c) Install clutch hub No, 2 on the shaft and align the ring slots with keys. (d) Using a press and collar, press in clutch hub No. 2. 13. INSTALL SNAP RING Select a snap ring which will allow 0 — 0.1 mm (0 — 0.004 in.) axial play. Mark Thickness ° 1.95 — 2.00 (0.0768 — 0.0787) 1 2.00 — 2.05 (0.0787 — 0.0807) 2 2.05 2. (0.0807 ~ 0.0827) 3 210-215 (0.0827 — 0.0846) 4 2:15-2:20 (0.0846 — 0.0866) 14, MEASURE ALL GEAR THRUST CLEARANCES ON OUTPUT SHAFT - Using a feeler gauge, measure all gear thrust clearances on ait, ee ‘ the output shaft. | a. aa Gear svt cleronce sm (in i Brae a a Gear STD | Limie Ts 0.150°= 0276 0.0058 — 00108)” 05 (0.020) 2nd Gear 1st Gear 2nd 0.150 — 0.250 (0.0058 — 0.0098) 0.5 (0.020) rd 0.150 —0.00 10.0059 —o.0tt8) | 08 (0024) Sth 0.100 — 0.930 (0.0039 — 0.0366} 1.0 (0.039) Reverse | 0200-0325 (0.0079 00128) 08 (0024)MANUAL TRANSMISSION — T5O Transmission Shift Fork and Shaft __No,2 No.1 No.3 ~ / 18. 16, Wa 18. INSTALL SPEEDOMETER DRIVE GEAR AND SNAP RINGS INSTALL REVERSE IDLER GEAR AND SHAFT (a) Fit the projected part of the thrust washer into the case slot, (b) Install the reverse idler gear and shaft. Torque the bolt. Torque: 185 kg-cm (11 ft-lb) INSTALL INTERLOCK PIN (a) Apply MP grease to prevent the pins from shifting. (b) Install two interlock pins in the case. INSTALL SHIFT FORK AND SHAFT (a) Assemble the shaft with their locking ball grooves Positioned toward the top of case. {b) Insert each shaft through each fork and push in up to. the neutral position. {c) Install the fork shafts and forks in the following order. © Fork shaft No. 2 and shift fork No. 2 © Fork shaft No. 1 and shift fork No. 1 © Fork shaft No. 3 and shift fork No. 3 (d)_ Shift the fork shaft No. 2 to the 3rd speed position. (e) Fork shaft No. 1 and No. 3 should not move.MANUAL TRANSMISSION — T50 Transmission MT-19 (f) Align the shaft and fork pin holes, and drive in the slotted spring pins with a pin punch, 19, INSTALL INPUT SHAFT AND OUTPUT SHAFT (a) Apply MP grease to the needle roller bearing. (b) Place the synchronizer ring on the gear and align the ing stots with the shifting keys. (c) Set the forks and hubs to the neutral position and assemble the input and output shaft to the case, 20. INSTALL COUNTER GEAR Fit the locking pin into the case groove. 21. INSTALL LEFT CASE (a) Clean the case joining surfaces and the places where the bearings fit in. (b) Apply liquid sealer to the case joining surface.MANUAL TRANSMISSIOI 25. . AFTER ASSEMBLING CASE, CHECK FOLLOWING 750 Tr {c) Apply liquid sealer to the bolt threads, and tighten the bolts equally, a little at a time, in the numerical arder shown so as to complete the tighténing in 3 to 4 passes, 200 kg-em (14 ftlb) ITEMS: (a) Turn the input shaft and output shaft and check to see that they turn smoothly, (b) Check to see that shifting can be made smoothly to. all positions. . INSTALL EXTENSION HOUSING (a) Apply liquid sealer to both surfaces of the gasket. {b) Engage the end of the shift and select levers into No. 2 fork shaft, CAUTION: Be careful not to damage the oil seal in the extension housing. (c) Bolt on the extension housing, and torque the bolts. Torque: 375 kg-cm (27 ft-lb) |. INSTALL RESTRICT PINS (a) Install the restrict pins as shown. (b) Torque the restrict pins. Torque: 400 kg-cm (29 ft-lb) INSTALL LOCKING BALLS, SPRINGS AND CASE COVER (a) Insert the locking balls and springs into each hole. (b) Install the case cover over the gasket.MANUAL TRANSMISSION ~ T50 Transr 26. 27. 28. 29. Housing 31. 32. ission MT21 INSTALL BACK-UP LIGHT SWITCH INSTALL SHIFT LEVER RETAINER install the shift lever retainer and torque the four bolts Torque: 130 kg-cm (9 ft-lb) “INSTALL SPEEDOMETER DRIVEN GEAR INSTALL CLUTCH HOUSING (a) Apply liquid sealer to the joining surface. (b) Install the clutch housing. (c) Install and torque the seven bolts. Torque: 375 kg-cm (27 ft-lb) - oe SELECT FRONT BEARING RETAINER SPACER Measure dimension ““A"” between the input bearing tip and clutch housing front bearing retainer surface, and refer to the table below to select a spacer of the proper thickness. NOTE: insure that the bearing snap ring is securely depressed onto the transmission case when measuring. Dimension “A” mm (ind mm {in 770-780 1.825 — 1.875 {0.3031 0.3071) __ (0.0719 ~ 0.0738) 781-791 1.995 — 1.985 (0.2075 —0.3114), ____ (0.0762 — 0.0781) 7.92 - 8.62 2.045. — 2.095 |_ to3118 03187) (0.0805 — 0.0825) 8.03 8.13 2.155 — 2.205 (0.3161 0.3201) (0.0848 - 0.0868) 814-824 2.265 ~ 2.315 {0.3205 ~ 0.3248) _ (0.0892 — 0.0911) 8.25 8.35 2.375 - 2.425 (0.9248 - 0.3287) (0.0935 — 0.0955) INSTALL SPACER AND FRONT BEARING RETAINER (a) Install the spacer on the input shaft bearing. (b) Apply MP grease to the oil seal lip. {c) Install the front bearing retainer. CAUTION: Do not damage the oil seal lip with the spline of the input shaft, {d) Install and torque the four bolts. Torque: 185 kg-cm (13 ft-lb) INSTALL CLUTCH RELEASE FORK AND BEARINGMANUAL TRANSMISSION — T50 Transmission INSTALLATION OF TRANSMISSION 1 PLACE TRANSMISSION AT INSTALLATION POSITION, AND INSTALL TRANSMISSION MOUNT BOLTS (a) Align the input shaft spline with the clutch disc, and push the transmission fully into position. (b)Instalt the two set bolts of the upper transmission, and troque the bolts. Torque: 730 kg-cm (53 ft-tb) INSTALL ENGINE REAR MOUNTING Install and torque the eight bolts. Torque: 530 kg-cm (38 ft-lb) INSTALL TRANSMISSION BOLTS AND STIFFENER PLATE Install and torque the bolts. Torque: 375 kg-om (27 ft-lb) INSTALL EXHAUST PIPE BRACKET Install and torque the bolt. Torque: 375 kg-cm (27 ft-b) INSTALL STARTER Install the starter, and torque the bolts. Torque: 300 — 450 kg-em (22 — 32 ft-lb) INSTALL CLUTCH RELEASE CYLINDERIIIS S SSS = , MANUAL TRANSMISSION — T50 Transmission MT-23 7. CONNECT BACK-UP LIGHT SWITCH CONNECTOR 8. INSTALL SPEEDOMETER CABLE 9. INSERT YOKE IN TRANSMISSION 10, CONNECT PROPELLER SHAFT FLANGE TO COMPANION FLANGE ON DIFFERENTIAL (a) Align the marks on the flanges and connect the flanges with four bolts and nuts. {b) Torque the bolts and nuts. Torque: 350 kg-cm (25 ft-lb) 11, CONNECT CENTER SUPPORT BEARING TO BODY {3uJoint Type) 12, FILL WITH TRANSMISSION OIL Oil type : API service GL-4 or GLS SAE 90 or 75W-90 Capacity: 1.7 liters (1.8 US qts, 1.5 Imp. ats) 13. CONNECT NEGATIVE BATTERY TERMINAL WIRE 14, INSTALL SHIFT LEVER 18. INSTALL CONSOLE BOX 16, ADJUST IGNITION TIMING (For 4A Engine) {a) Connect a timing light to the engine. {b) Start the engine and run it at idle. {c) Using a timing light, slowly turn the distributor unti! the timing mark on the crankshaft pulley is aligned with the 5° mark. Tighten the distributor bolt. Ignition timing: 5° BTDC at idle (900 rpm max.) 17, PERFORM ROAD TEST Check for abnormal noise and smooth operation.