SECTION 7B1 - MANUAL TRANSMISSION –

V6 ENGINE

IMPORTANT

Before performing any Service Operation or other procedure described in this Section, refer to Section 00

CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property damage.

CONTENTS

1. GENERAL INFORMATION

1.1 GENERAL DESCRIPTION

SYNCHRONISER ASSEMBLIES

REVERSE GEAR

BEARING SUPPORT

LUBRICATION

SELECTOR MECHANISM

1.2 POWER FLOWS

1.3 TRANSMISSION SERIAL NUMBER

2. SERVICING INFORMATION

2.1 RECOMMENDED LUBRICANT

2.2 CHECKING TRANSMISSION LUBRICANT

LEVEL

2.3 DRAINING AND REFILLING TRANSMISSION

3. MINOR SERVICE OPERATIONS

3.1 BACK-UP LAMP SWITCH

REMOVE

REINSTALL

3.2 SPEED SENSOR AND/OR BRACKET

REPLACE

3.3 GEARSHIFT LEVER KNOB AND BOOT

ASSEMBLY

REMOVE

REINSTALL

3.4 GEARSHIFT LEVER

REMOVE

DISASSEMBLE

REASSEMBLE

REINSTALL

ADJUST

3.5 SHIFT LINKAGE BRACE, RUBBER MOUNTING

AND/OR BUSH

REPLACE

4. MAJOR SERVICE OPERATIONS

4.1 SPEED SENSOR TOOTHED RING OR

TRANSMISSION CASE REAR SEAL

REMOVE

SPEED SENSOR TOOTHED RING - REPLACE

REINSTALL

4.2 TRANSMISSION ASSEMBLY

REMOVE

REINSTALL

4.3 TRANSMISSION DISASSEMBLE

4.4 TRANSMISSION SUB-ASSEMBLIES

DISASSEMBLE

INSPECT COMPONENTS

SYNCHROMESH ASSEMBLIES

REASSEMBLE

TRANSMISSION CASE, REAR SECTION

TRANSMISSION CASE, FRONT SECTION

CLUSTER GEAR END PLAY ADJUSTMENT

CLUTCH THROWOUT BEARING GUIDE

4.5 TRANSMISSION REASSEMBLE

5. DIAGNOSIS

6. SPECIFICATIONS

7. TORQUE WRENCH SPECIFICATIONS

8. SPECIAL TOOLS

1. GENERAL INFORMATION

With the introduction of the MY 2003 VY and V2 Series range of vehicles, the manual transmission available for

fitment to the V6 engine, is an upgraded five speed, Getrag, Type 260 (production option M35).

Whether this manual transmission is standard equipment, optional or not available, will depend upon specific

vehicle specifications for various markets.

The ‘260’ manual transmission is a fully synchronised unit, including reverse gear, with baulk ring type

synchronisers. The transmission primarily consists of a two piece transmission case, with the clutch housing

integrated with the front case section. During disassembly, the gear train and shift mechanism remain in the

transmission case rear section. The transmission for MY 2003 vehicles (where fitted), has had a number of

changes made, that result in the modifications not being compatible with earlier build transmissions. Therefore,

always check the current release of PartFinder® for the correct parts to be fitted to this transmission.

In summary, the changes are:

• Modified gear tooth profiles.

• Increased tension crossover springs in the Neutral gate/Reverse selection.

• Re-designed transmission end housing to accommodate the changed design rear support mounting.

• Selective fit first gear to the mainshaft.

1.1 GENERAL DESCRIPTION

SYNCHRONISER ASSEMBLIES

Each of the three synchroniser hubs are an interference fit, splined to the mainshaft and fixed by selective snap

rings to accommodate manufacturing tolerances. Sintered, double cone blocking rings are fitted to 1st and 2nd

gears, while thos e f or 3rd, 4th, 5th and r evers e gears ar e brass, with a m olybden um coating on the ir inner s ur face.

The purpose of the synchroniser assemblies is to permit clutching to the required gear, that is in constant mesh

with the cluster gear.

Synchroniser Action

During s ync hron is er o peration, the synchronis er sle eve is moved into engagement by the appropria te f or k, car r ying

with it three synchroniser inserts and spring loaded balls, located in slots in the synchroniser hub.

The s ynchronis er sleeve, toget her with the ins erts, is m oved along the hu b, placing a load on the three lugs of the

blocking ring.

This initial force is sufficient to seat the b locking ring and s tart pre-s ynchronis ation because of the friction b etween

the cone on the constant mesh gear and the blocking ring/s.

At this s tage, gear engag em ent is prevented as long as there is a dif fer ence in speed between t he m ating s urf aces

of the blocking ring and cone of the constant mesh gear. As the speeds between the blocking ring and the gear

cone become synchronised, the teeth on the blocking ring and gear cone line up with the internal splines of the

sleeve, allowing the sleeve to engage the teeth on the mainshaft gear, completing gear selection.

Figure 7B1-1 shows an exploded view of the three piece synchromesh unit, used for 1st and 2nd gears.

Figure 7B1-1

Legend

1. 2nd Speed Gear

2. 1st/2nd Speed Synchroniser, Hub and Sleeve

3. 1st Speed Gear

4. 2nd Inner Synchroniser Ring

5. 2nd Intermediate Synchroniser Ring

6. 2nd Outer Synchroniser Ri ng

7. 1st Outer Synchroniser Ring

8. 1st Intermediate Synchroniser Ring

9. 1st Inner Synchroniser Ring

REVERSE GEAR

The reverse idler gear is in constant mesh with the cluster gear and the reverse gear that is mounted on the

mainshaft. When reverse gear is engaged, the 5th/reverse synchromesh sleeve engages the reverse constant

mesh gear, completing the selection.

BEARING SUPPO RT

The maindrive gear runs on a single row ball race in the front of the transmission case and supports the front end of

the mains haft via a caged need le roller bear ing. The m ainshaft runs on a s ingle row ball race, m ounted in the rear

transmission case.

The maindrive gear and mainshaft bearings are located in their respective housings by an interference fit and the

use of snap rings or a bolted plate. Shims are used to accommodate manufacturing tolerances in each bearing

bore.

The cluster gear runs on two parallel roller bearings, one at each end, with end float being controlled by a shim

located between the cluster gear front bearing cup and the front circlip.

Each of the mainshaft constant mesh gears run on caged needle roller bearings, while the reverse idler gear is

supported by two caged needle roller bearings running on the idler gear shaft.

LUBRICATION

Lubrication of all internal components is by splash feed, provided by the rotating cluster gear assembly.

SELECTOR MECHANISM

The floor mounted, gearshift control lever operates a single rail mechanism which extends into the rear

transmission case. The first/second, third/fourth and fifth/reverse shift forks are all supported at each end, in the

two transmission cases.

A shift i nter loc k s ystem , preven ts eng agement of more than one gear at a time. T he system c onsis ts of an int er lock

pin locat ed in the third/fourth selector shaft and two interlock balls, that locate in a neu tral position groove in each

of the rem aining t wo rails . T hese com ponents, tog ether with th e shif t detent balls and s prings are all l ocated in th e

end of rear transmission housing.

When either the first/second or fifth/reverse selector shaft is moved to engage a gear, one of the interlock balls is

moved across, displacing the interlock pin, effectively locking the remaining two shafts. Moving the third/fourth

selector shaft, moves each of the two balls firmly into their respective shafts, allowing a third/fourth shift to take

place, with the interlock pin being carried with the shaft.

See Figure 7B1-2 f or a section ed vie w of the type ‘26 0’ transm ission (produc tion option M 35). Figur e 7B1-3 s hows

an explo ded view of the two cas e halves and se lector c omponents, while f igure 7B1-4 shows an exp loded vi ew of

the gear train components.

Figure 7B1-2 – Type ‘260’ Transmission, Sectioned View

Legend

1. Input Shaft

2. Maindrive Gear

3. Third Speed Gear

4. Second Speed Gear

5. First Speed Gear

6. Reverse Gear

7. Fifth Speed Gear

8. Mainshaft

9. Cluster Gear

Figure 7B1-3 – Transmission Shift Mechanism and Case Components

Legend

1. Reverse blocker pin

2. Helical compressi on sprin g

3. Reverse blocker bushing, retainer pin

4. Reverse blocker bushing

5. Cap bolt

6. Cylindrical torsion spring

7. Reverse lock plate

8. Shift finger

9. Pin

10. Roll pin

11. Allen key head cap scr ew

12. Shift shaft support

13. Selector rod shift shaft

14. Dowel pin

15. Roller

16. Cylindrical torsion spring

17. Bushing

18. Select lever

19. Roller

20. Oil seal – shift shaft

21. Spring retaining clip

22. Selector rod trunnion pin

23. Selector rod trunnion

24. Detent ball - 3 places

25. Helical compression spring - 3 places

26. Cover plate

27. Bolt

27a. Wave washer

28. Interlock ball - 2 places

29. Interlock pin

30. Welsh plug

31. Bolt

31a. Wave washer

32. Dowel pin

33. Shift fork, 5th/Reverse

34. Roll pin

35. Selector shaft, 5th/Reverse

36. Shift fork, 3rd/4th

37. Selector shaft, 3rd/4th

38. Shift yoke, 1st/2nd

39. Shift fork, 1st/2nd

40. Selector shaft, 1st/2nd

41. Bolt

41a. Wave washer

42. Front housing cover

43. Disc

44. O-ring

45. Clutch throwout bearing guide

46. Oil seal

47. Front transmission housing

48. Rear transmission housing

49. Plug

50. Spring

51. Reverse blocker pin bolt

52. Plug

53. Spring

54. Detent plunger assembly

55. Back-Up lamp switch

56. Breather plug

57. Drain plug with magnet

58. Filler plug

Figure 7B1-4 - Transmission Gear Components

Legend

1. Selective spacer washer

2. Snap ring

3. Selective spacer washer

4. Front bearing spacer ring

5. Front bearing

6. Input shaft and maindrive gear

7. Synchromesh ring

8. Caged, spigot needle rolle r bearing

9. Snap ring

10. Selective spacer washer

11. Synchromesh hub

12. Spring

13. Ball

14. Sliding key

15. Synchromesh outer sleeve

16. 3rd speed gear

17. Caged, needle roller bearing

18. Needle roller inner sleeve

19. Thrust washer

20. 2nd gear, needle roller bearing

21. 2nd speed gear

22a. Cone ring

22b. Friction ring

22c. Synchromesh ring

23. Snap ring

24. 1st/2nd speed synchromesh hub

25a. Synchromesh ring

25b. Friction ring

25c. Cone ring

26. Synchromesh outer sleeve

27. 1st speed gear

28. 1st speed, needle roller bearing

29. Mainshaft

30. Locating ball

31. Reverse gear, needle roller bearing

32. Reverse gear

33. Synchromesh ring

34. 5th/Reverse speed synchromesh hub

35. Synchromesh outer sleeve

36. Selective snap ring

37. 5th speed, needle roller bearing

38. 5th speed gear

39. Rear mainshaft bearing retainer plate

40. Rear mainshaft bearing

41. Spacer

42. Oil seal

43. Speed sens or toothed ring

44. Output flange

45. Knurled stud

46. Flanged retaining nut

47. Circlip

48. Support washer

49. Front cluster gear needle roll er bearing cup

50. Cluster gear needle roller bearing

51. Cluster gear

52. Rear cluster gear needle roller bearing cup

53. Bolt

53a. Wave washer

54. Thrust plate

55. Snap ring

56. Reverse idler gear

57. Caged needle roller bearings

58. Reverse idler gear shaft

59. Bolt

59a. Wave washer

1.2 POWER FLOWS

The maindrive gear, fifth, third, second, first speed and reverse gears are in constant mesh with the cluster gear.

Therefore, when the engine is running with the clutch engaged, torque is imparted to the maindrive gear and

through the cluster gear to the fifth, third, second, first speed and reverse gears at all times.

Refer to Figure 7B1-6 for illustrations relating to the following descriptions:

NEUTRAL

In neutral, with the clutch engaged, the maindrive gear turns the cluster gear. The cluster gear turns the constant

mesh gear s becaus e no s ynchr oniser as sem blies ar e enga ged. As all cons tant m esh gear s are s upporte d on r oller

bearings, they will also rotate with the cluster gear.

FIRST GEAR

In first gear , the firs t/secon d speed synchro niser sleev e is m oved rear ward to e ngage t he f irst speed g ear, which is

being turned by the cluster gear. Because the first/second speed synchroniser hub is splined to the mainshaft,

torque is imparted to the mainshaft from the first speed gear through the synchroniser sleeve and hub.

SECOND GEAR

In second gear, the first/second speed synchroniser sleeve is moved forward to engage the second speed gear,

which is being turned by the cluster gear. Because the first/second speed synchroniser hub is splined to the

mainshaft, torque is imparted to the mainshaft from the second speed gear through the synchroniser sleeve and

hub.

THIRD GEAR

In third gear, the first/second speed synchroniser sleeve assumes a neutral position. The third/fourth speed

synchroniser sleeve is moved rearward to engage the third speed gear, which is being turned by the cluster gear.

The engagement of the sleeve with the third speed gear, imparts torque to the mainshaft because the third/fourth

speed synchroniser hub is splined to the mainshaft.

FOURTH GEAR

In fourth gear, the third/fourth speed synchroniser sleeve is moved forward to engage the maindrive gear. This

engagement of the maindrive gear with the third/fourth synchroniser sleeve and hub assembly, imparts torque

directly to the mainshaft. While the cluster gear is still rotating, it does not impart torque to any component but

continues to lubricate the internal transmission components by the ‘splash’ method.

FIFTH GEAR

In fifth or overdrive gear, the first/second and third/fourth speed synchroniser sleeves assume neutral positions.

The fifth speed/reverse synchroniser sleeve is moved rearward to engage the fifth speed constant mesh gear,

supported on the mainshaft by a caged needle roller bearing. This engagement of the sleeve with the fifth speed

constant mesh gear, imparts torque from the cluster gear to the mainshaft, via the splined synchromesh hub.

REVERSE GEAR

In reverse gear, the fifth speed/reverse synchroniser sleeve is moved forward to engage the mainshaft reverse

gear and the cluster reverse gear, via the reverse idler gear. This imparts torque from the cluster reverse gear

through the idler gear (reversing direction of rotation) to the mainshaft reverse gear. Because the fifth

speed/reverse synchromesh hub is splined to the mainshaft, this causes the mainshaft to rotate in the opposite

direction to the maindrive gear.

MA NUAL TRANSMISSION POWER FLOWS

Figure 7B1-5

1.3 TRANSMISSION SERIAL NUMBER

The transmission serial number is located on a

self-adhesive decal attached to the left side of the

transmission front housing.

This number provides coded information which is

significant to parts interpretation and should be

referred to when ordering replacement parts. For

example, the transmission part number has

changed to that shown.

Figure 7B1-6

2. SERVICING INFORM ATION

2.1 RECOMMENDED LUBRICANT

The recommended lubricant for the ‘260’ manual transmission is an 80W gear oil, such as Castrol VMX80W or

equivalent.

The transmission lubricant capacity is approximately 1.2 litres.

2.2 CHECKING TRANSMISSION LUBRICANT LEVEL

To check transmission lubricant level, remove

transmission filler plug (1), using a 17 mm ring

spanner, from right hand side of transmission case.

The level is correct when lubricant is level with the

filler plug threads.

NOTE: Ensure that the vehicle is on level ground

and transmission is cold.

If necessary, add lubricant to bring to the correct

level.

Reinstall filler plug (1) and tighten to the correct

torque s pecif icat ion. D o not ap ply thr ead s eala nt or

tape to the plug threads.

TRANSMISSION FILLER PLUG

TORQUE SPECIFICATION 50 Nm

Lubricant level is to be checked at the time or

distance intervals detailed in the MY 2003 VY and

V2 Series Owner's Handbook.

Figure 7B1-7

2.3 DRAINING AND REFILLING TRANSMISSION

W h ile the init ia l f ill of tr ans mission lubric ant is s pec if ie d as a ‘fill f or lif e’, s hou ld a lubr icant change be r eq uir e d, the n

the following pr ocedure should be ado pted .

1. To drain transmission, jack up vehicle front and rear and support on safety stands. Refer to

Section 0A GENERAL INFORM ATION, in the MY 20 0 3 V Y and V 2 Ser ies Ser vice Info rm ation, f or the loc a ti on

of jacking points.

2. Place a drain tray beneath transmission and remove filler plug and then drain plug using a 17 mm ring spanner.

3. When transmission has fully drained, insert drain plug and tighten to the correct torque specification. Do not

apply thread sealant or tape to the plug threads.

TRANSMISSION DRAIN PLUG

TORQUE SPECIFICATION 50 Nm

4. Refill transmission to correct level, refer 2.2 CHECKING TRANSMISSION LUBRICANT LEVEL in this Sec ti o n.

3. MINOR SERVICE OPERATIONS

3.1 BACK-UP LAMP SWITCH

LT SECTION NO. – 04M-075

REMOVE

1. Raise front of vehicle and support on safety

stands.

Refer to Section 0A GENERAL

INFORMATION, in the MY 2003 VY and V2

Series Service Information, for the location of

jacking points.

2. Remove wiring harnes s connector f rom switch,

located on the right hand side of the

transmission case.

3. Loosen, then remove switch from the

transmission case.

Figure 7B1-8

REINST ALL

1. Ensure that the switch threads are clean.

2. Reinstall switch to transmission case and

tighten to the correct torque specification.

BACK-UP LAMP SWITCH

TORQUE SPECIFICATION 20 Nm

3. Reinstall wiring harness connector to switch.

4. Remove safety stands and lower vehicle to

ground.

5. Check back-up lamp operation.

Figure 7B1-9

3.2 SPEED SENSOR AND/OR BRA CK ET

LT SECTION NO. – 04M-075

REPLACE

1. Jack up vehicle front and rear and support on

safet y st ands. Refer to Section 0A G ENER AL

INFORMATION, in the MY 2003 VY and V2

Series Service Information, for the location of

jacking points.

2. Disconnect speed sensor wiring harness

connector (1).

3. Cut the speed sensor wiring harness strap (2)

from the lug on the transmission case.

4. Remove speed sensor mounting bracket bolt

from the rear of the transmission housing.

5. Remove the brac k et and s ens or as s em bly from

the rear transmission housing.

6. Remove the s ens or to brac ket m ounting s cr ew,

then disconnect the sensor by a twisting and

pulling motion to free the O-ring seal from the

bracket

Figure 7B1-10

7. Reinstallation is the reverse of removal except

for the following points;

a. Tighten the speed sensor to mounting

bracket retaining screw (1) to the correct

torque specification.

SPEED SENSOR

TO BRACKET SCREW

TORQUE SPECIFICATION 10 Nm

b. Tighten the sensor brack et to transmission

housing mounting bolt (2) to the correct

torque specification.

SPEED SENSOR BRACKET TO

TRANSMISSION HOUSING BOLT

TORQUE SPECIFICATION 18 Nm

c. Connect the speed sensor lead to the

wiring harnes s c onnec t or, e nsur ing th at the

connection is posi tive and secur e.

d. Sec ure the spee d sensor wiring harness to

the lug on t he transm ission using a ne w tie

strap.

Figure 7B1-11

3.3 GEARSHIFT LEVER KNOB AND BOOT ASSEMBLY

LT SECTION NO. – 04M-060

NOTE: The gearshift lever knob and gearshift boot are manufactured as a single component. Do not attempt to

separate t he gearshif t lever knob from the boot. The knob and bo ot assem bly can however , be replac ed, using th e

follo wing proc ed ur e.

REMOVE

1. Remove the floor console cover assembly.

Refer 2.1 FLOOR CONSOLE COVER

ASSEMBLY, in Section 1A3 INSTRUMENT

PANEL & CONSOLE, in the MY 2003 VY and

V2 Series Service Information.

2. Using a fine bladed screwdriver, release each

locking tab, while exerting an upward force on

the boot carrier. Lift the gearshift boot retainer

free from the floor console.

Figure 7B2-12

3. Lift the ge arshift lever boot enough to e nable a

firm grasp to be made on the gearshift lever

with the left hand, then grasp the gearshift

knob with the right.

4. While rocking the knob sideways, and with an

upward force applied, dislodge the knob

retaining claws from the lever.

5. Remove the gearshift lever knob and boot

assembly, from the gearshift lever.

Figure 7B1-13

REINST ALL

1. Reinstall the k nob and boot assembly over the

gearshift lever, align the knob in the correct

attitude and then bump the knob onto the

gearshift lever until the reta ining claws engage

with the groove in the le ver .

2. Align the boot retaining clips with the hole in

the console cap, then carefully seat the boot

retainers into the console cap until each clip

engages correctly.

3.4 GEARSHIFT LEVER

LT SECTION NO. – 04M-060

REMOVE

1. Remove the gearshift lever knob and boot

assembly, from the gearshift lever. Refer

3.3 GEARSHIFT LEVER KNOB AND BOOT

ASSEMBLY, for the necessary procedure.

2. Raise vehicle front and rear and support on

safet y st ands. Refer to Section 0A G ENER AL

INFORMATION, in the MY 2003 VY and V2

Series Service Information, for the location of

jacking points.

3. Scribe around each of the rear engine

mounting crossmember mounting points to the

vehicle underbody, to provide an alignment

reference for reassembly.

IMPORTANT: This step is critical to the correct

powertrain alignment on reassembly. If not carried

out, then vehicle vibration and/or handling

problems may result!

NOTE: For c larity, the exhaus t system is sho wn as

having already been removed.

4. Support the rear of the transmission with a

floor jack, then remove the four rear engine

mounting crossmember bolts.

Figure 7B1-14

5. Lower t he rear of the trans mission, s ufficient to

gain acces s to th e front end of th e shif t linkage

brace (2).

6. From under vehicle, prise the shift linkage

brace retainer (1) loose, at the transmission

end, using a screwdriver or suitable lever.

7. Remove the retainer and pin (1) from the

transmission case lugs.

NOTE: While the shift rod can be removed at this

time, by removing the clip (4) and a flat washer

before sliding the shift rod from the trunnion (3), it

is pref err ed that th e s hif t r o d be removed i n st ep 1 1

of this procedure.

Figure 7B1-15

8. Remove the four gearshift lever bracket,

mounting nuts (1 from inside the vehicle.

Figure 7B1-16

9. Remove the retaining C-clip (1), then the

spring and flat washers (2 and 3) from the

transmission shift rod coupling (5), at the

gearshift lever end.

CAUTION: to prevent possible eye damage

when removing the C-clip, wear suitable eye

protection.

10. Remove two gearshift lever support mounting

bolts (6) from underfloor bracket.

11. Remove gear sh ift le ver bra cke t (4), with ru bber

boot and the complete brace assembly, from

below the vehicle.

NOTE 1: If the s hift rod was disconnecte d from the

transmission end and removed from the vehicle,

take particular note of the rod’s orientation for

correct installati on.

NOTE 2: While the illustration shows the propeller

shaft and exhaust removed for clarity, removal of

the brace assembly from the vehicle, is possible

without first removing these items.

Figure 7B1-17

DISASSEMBLE

1. Remove both nuts (1) securing the gearshift

lever ball socket retainer, to the mounting

brace.

2. Remove retainer and gearshift lever assembly

from the brace.

Figure 7B1-18

3. Remove the boot and mounting bracket

assembly (4), from the gearshift lever (2).

4. Separate the assembly by holding the bearing

cover (5) and gently bump the end of the

gearshif t lever (2) , to dis place the end plat e (6)

and bearing (1) from the ball of the gearshift

lever.

5. Inspect all components for wear and/or

damage, replacing parts as required.

Figure 7B1-19

REASSEMBLE

Reassembly operations are the reverse of

disassembly, except for the following items.

1. Lubricate the gearshift lever ball and socket

with Lithium grease NLGI No. 4 EP.

2. Reinstall the gearshift lever ball and socket

retainer to the brace, fit the two retaining nuts

(1) and tighten to the correct torque

specification.

GEARSHIFT BALL SOCKET

RETAINER PLATE NUTS

TORQUE SPECIFICATION 10 Nm

Figure 7B1-20

3. Reinstall the rubber gearshift boot (1) over the

gearshift lever as shown.

Figure 7B1-21

REINST ALL

1. Reinstall gearshift lever assembly (1) into

position, aligning studs with the holes in the

floor pan and the bolt holes in the rubber

mounting, with the captive nuts on the

underbody.

2. Reinstal l gearshif t lever brac e rubber mount ing

bolts (2) and tighten to the correct torque

specification.

GEARSHIFT LEVER BRACE, RUBBER

MOUNTING BRACKET BOLT

TORQUE SPECIFICATION 10 Nm

3. From inside the vehicle, install and tighten the

four, brace (1) to underfloor retaining nuts,

tightening to the correct torque specification.

GEARSHIFT LEVER BRACKET TO

UNDERFLOOR RETAINING NUT

TORQUE SPECIFICATION 10 Nm

Figure 7B1-22

4. Install gearshift brace pin and retainer to the

transmission end, ens uri ng that t he s ec ur ity lug

is firmly in place.

Figure 7B1-23

5. Reinstall gearshift linkage (5) to the lower end

of the gearshift lever, then install the flat

washer (3), spring washer (2) and C-clip (1).

NOTE: Ensure that the linkage is only assembled

in the attitude shown. If fitted in the reverse

directi on, the li nkage m ay foul, r esultin g in d ifficu lty

with 2nd gear selection that can cause damage to

the transmission.

6. Remove safety stands and lower vehicle to

ground.

7. Reinstall gearshift lever knob/boot assembly.

Refer to 3.3 GEARSHIFT LEVER KNOB AND

BOOT ASSEMBLY in this Section, for specific

details.

8. Road test vehicle to check gears hif t operat ion.

Figure 7B1-24

ADJUST

No adjustment of the gearshift linkage is required.

3.5 SHIFT LINKAGE BRACE RUBBER MOUNTING AND/OR BUSH

LT SECTION NO. – 04M-060

REPLACE

1. Remove the gearshift lever and brace

assembly from the vehicle, as detailed in

3.4 GEARSHIFT LEVER in this Section.

Brace Mount in g

2. Remove the rubber mounting from the rear of

the gearshift lever support after removing the

retaining nut (1).

3. F it the rear m ounting to th e br ace, ins erting t he

locating tang (2) in the hole provided. Install

the retaining nut (1) and tighten to the correct

torque specification.

REAR GEARSHIFT LINKAGE

RUBBER MOUNTING NUT

TORQUE SPECIFICATION 22 Nm

Figure 7B1-25

Brace Bush

4. Using a suitable sized pin punch (1) and

hammer, remove the rubber bushing (2) from

the transmission end of the brace assembly,

clamping the eye of the brace between

protected vice jaws.

Figure 7B1-26

5. Using a suitable sized piece of tubing (2) (or

socket), over the end of th e brace eye (2), use

the clamping effect of a bench vice to install

the replacement rubber bush (1).

NOTE: Dip the replacement bushing (1) in a soap

solution to assis t in the ins t all ation pr oc ess .

6. Reinstal l the brace and gear shift assem bly into

the vehicle, as detailed in 3.4 GEARSHIFT

LEVER in this Section.

Figure 7B1-27

4. MAJOR SERVICE OPERATIONS

4.1 SPEED SENSOR TOOTHED RING OR TRANSMISSION CASE REAR SEAL

LT SECTION NO. – 04M-100

REMOVE

1. Disconnect battery ground lead.

IMPORTANT: Disconnection of the battery affects

certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. Battery Disconnection

Procedures before disconnecting the battery.

2. Raise front and rear of vehicle, supporting on

safet y st ands. Refer to Section 0A G ENER AL

INFORMATION in the MY 2003 VY and V2

Series Service Information, for the location of

jacking and support points.

3. Disconnect wiring harness connectors from

each of the two oxygen sensors (1).

Figure 7B1-28

4. Remove the intermediate pipe to catalytic

convert er bolts (1), s prings (2) and sealing r ing

(3).

5. Remove the exhaust pipe flange to exhaust

manifold nuts from each side (not shown in

Figure 7B1-29) .

6. While supporting the twin exhaust pipes (5)

and catalytic converter assembly (4), remove

the support rubbers (6 and 7) from the rear of

the transmission.

7. Carefully lower and remove the exhaust pipes

from the veh icle, tak ing car e not to dam age the

exhaust gas oxygen sensors, in the process.

Figure 7B1-29

8. Scribe around each of the rear engine

mounting crossmember mounting points to the

vehicle underbody, to provide an alignment

reference for reassembly.

IMPORTANT: This step is critical to the correct

powertrain alignment on reassembly. If not carried

out, then vehicle vibration and/or handling

problems could result.

Figure 7B1-30

9. Support weight of transmission assembly on a

suitable jack.

10. Remove engine rear crossmember to side

frame attaching bolts (2).

11. Lower the rear of the transmission assembly,

enough to gain access to the two mount to

transmission case lug, nuts (3). Before

loosening the nuts scribe an alignment mark, to

ensure that the mounts are reinstalled in the

same position.

IMPORTANT: Failure to take note of the mount

positions before loosening the retaining nuts (3),

could cause driveline vibration problems, once the

vehicle is placed back in service.

12. Rem ove th e re ar m ount att achin g nuts ( 3) fr om

the transmission rear case mounting lugs (4),

then remove the crossmember and mount

assemblies (1) from the vehicle.

NOTE: Illustrat ion does not sho w trans m ission jac k

in position, for clarity of the crossmember

orientati on.

Figure 7B1-31

13. Remove propeller shaft (2) flexible rubber

coupling (4) to mainshaft flange (1) attaching

nuts (3).

Figure 7B1-32

14. W ith the transm ission in first gear and the park

brake firmly applied, use Torx socket

K04425E20 or a commercially available E20

Torx socket to loosen the three Torx headed

bolts (1) securing the propeller shaft rear

rubber coupling (2) to the pinion flange (3).

15. Release the park brake and select neutral, to

relieve any torque loading on the rubber

coupling, then remove the three Torx headed

bolts (1)

NOTE: To enable the propell er shaft to be install ed

in the original position relative to the pinion flange,

use a felt tipped pen or similar to identify the

relationsh ip (‘A’) of the t wo components before bo lt

removal.

Figure 7B1-33

16. Remove the two centre bearing carrier (1) to

underbody reinforcement bolts (2).

17. While supporting the centre bearing section,

lower the c entre b earing an d slide t he pro peller

shaft assembly forward to disengage from the

final drive pinion support pin.

18. Lower the assembly at the rear, sliding

rearward to remove from the rear of the

transmission.

Figure 7B1-34

19. Remove the speed sensor bracket retaining

bolt (2) from the rear of the transmission,

remove the sensor (1) and bracket and secure

to the underbody with a piece of tie wire.

Figure 7B1-35

20. To use the previously released, Tool No. KM-

620-1-A to hold the flange, it must first be

modified by redrilling the three holes stamped

‘B’ (on the Tool) to 13 mm.

Fasten th e m odified to ol to the flan ge using the

three discarded nuts. Then, using a suitable

length of pipe on the tool, loosen and remove

flange nut, using a commercially available, 30

mm deep socket.

Figure 7B1-36

21. Place a drain tray beneath transmission.

22. Install ex tractor, Tool No. A KM-628-A to outpu t

shaft flange.

23. Tighten extractor forcing bolt and remove

flange and speed sensor toothed ring, from

output shaft.

24. Inspect the sealing surface of the flange for

damage. Replace as necessary.

NOTE: Take care that no tooth damage takes

place to the speed sensor toothed ring while the

flange is removed.

Figure 7B1-37

25. Using a seal remover such as Tool No. E308

or a suitable lever, remove the seal (1) from

the transmission case.

Figure 7B1-38

SPEED SENSOR TOOTHED RING – REPLACE

The speed sensor toothed ring is not serviced separately from the output shaft flange. Therefore, if found to be

damaged, then the complete flange assembly must be replaced.

REINST ALL

1. Lubricate seal surface of spacer with

transmission lubricant and install over the

mainshaft.

2. After lubricating the seal lip with transmission

lubricant, use Tool No. J-21426 (previously

released) or similar, to fit a new seal over the

sleeve and into the transmission rear case

housing.

Figure 7B1-39

3. Reinstall flange and toothed ring onto

mainshaft, using the original flange nut to pull

the assembly fully into place. Use Tool No.

KM-620-1-A to hold the flange during this

process.

4. Remove the original nut and replace with a

new nut that has had thread sealant such as

Loctite 242 or 243 (or equivalent) applied to the

threads.

5. Again using modified Tool No. KM-620-1-A to

hold flange, tighten the new flange nut to the

correct torque specification.

MAINSHAFT FLANGE NUT

TORQUE SPECIFICATION 100 Nm

Figure 7B1-40

6. If separated from the mounting bracket,

reinstall the speed sensor to the mounting

bracket and secure with the screw (1),

tightening to the correct torque specification.

SPEED SENSOR TO BRACKET

SCREW TORQUE SPECIFICATION 10 Nm

7. Reinstall speed sensor and bracket assembly,

tightening the retaining bolt (2) to the correct

torque specification.

SPEED SENSOR BRACKET MOUNTING

BOLT TORQUE SPECIFICATION 18 Nm

Figure 7B1-41

8. Lower the jack supporting the transmission

assembly, enough to gain access to the two

rear mount to transmission lugs (4).

9. Reinstall the rear crossmember and mounts to

the two transmission case lugs (4), then

reinstall the two retaining nuts (3).

10. Align the s cribed m arks made prior to remova l,

then tighten the two retaining nuts (3) to the

correct torque specification.

REAR MOUNT TO TRANSMISSION LUG

NUT TORQUE SPECIFICATION 25 Nm

11. Raise the support jack, then loosely reinstall

rear crossmember to side frame member bolts.

12. Carefull y align the scribe d m arks made prior to

removal, then tighten the four crossmember to

side frame bolts.

IMPORTANT: This step is critical to the correct

powertrain alignment. If not carried out, then

vehicle vibration and/or handling problems may

result.

13. Remove jack supporting the transmission.

14. After checking to see that the crossmember

position has not changed, tighten the four

crossm ember to s ide frame bo lts to the c orrect

torque specification.

Figure 7B1-42

REAR CROSSMEMBER TO SIDE

FRAME MEMBER BOLT

TORQUE SPECIFICATION 58 Nm

15. Reinstall propeller shaft rubber coupling to

transmission mainshaft flange and loosely

install NEW attaching nuts.

16. Lift propeller shaft upward and install centre

bearing carrier to underbody reinforcement,

ensuring that any spacers are placed in the

same positions, noted on removal. Install

retaining bolts.

17. Assemble propeller shaft rear universal joint

flange to pinion flange, aligning marks made

before removal and reinstall attaching bolts

and nuts.

18. T ighten a ll prop eller shaft a ttachi ng bolts to the

correct torque specification.

PROPELLER SHAFT RUBBER COUPLING

TO TRANSMISSION OUTPUT FLANGE

NUT TORQUE SPECIFICATION 78 Nm

CENTRE BEARING CARRIER TO

UNDERBODY REINFORCEMENT

BOLT, TORQUE SPECIFICATION 23 Nm

PROPELLER SHAFT REAR UNIVERSAL

JOINT FLANGE TO PINION FLANGE

BOLT TORQUE SPECIFICATION 58 Nm

19. Reinstall exhaust system, tightening fasteners

as detaile d in Sect ion 8B EXH AUST SYST EM

in the MY 2003 VY and V2 Series Service

Information.

20. Check transmission lubricant level and top up

as necessary, refer 2.1 CHECKING

TRANSMISSION LUBRICANT LEVEL in this

Section.

21. Rem ove safe ty stands and lo wer vehicle t o the

ground

22. Reconnec t batter y ground l ead.

4.2 TRANSMISSION ASSEMBLY

LT SECTION NO. – 04M-090

REMOVE

1. Disconnect battery ground lead.

IMPORTANT: Disconnection of the battery affects

certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. Battery Disconnection

Procedures before disconnecting the battery.

2. Raise vehicle front and rear and support on

safet y st ands. Refer to Section 0A G ENER AL

INFORMATION in the MY 2003 VY and V2

Series Service Information for the location of

jacking and support points.

3. Disconnect wiring harness connectors from

each of the two oxygen sensors (1).

Figure 7B1-43

4. Remove the intermediate pipe to catalytic

convert er bolts (1), s prings (2) and sealing r ing

(3).

5. Remove the exhaust pipe flange to exhaust

manifold nuts from each side (not shown in

Figure 7B1-44) .

6. While supporting the twin exhaust pipes (5)

and catalytic converter assembly (4), remove

the support rubbers (6 and 7) from the rear of

the transmission.

7. Carefully lower and remove the exhaust pipes

from the veh icle, tak ing car e not to dam age the

exhaust gas oxygen sensors, in the process.

Figure 4C-44

8. Scribe around each of the rear engine

mounting crossmember mounting points to the

vehicle underbody, to provide an alignment

reference for reassembly.

IMPORTANT: This step is critical to the correct

powertrain alignment on reassembly. If not carried

out, then vehicle vibration and/or handling

problems could result.

Figure 7B1-45

9. Support weight of transmission assembly on a

suitable jack.

10. Remove engine rear crossmember to side

frame attaching bolts (2).

11. Lower the rear of the transmission assembly,

enough to gain access to the two mount to

transmission case lug, nuts (3). Before

loosening the nuts scribe an alignment mark, to

ensure that the mounts are reinstalled in the

same position.

IMPORTANT: Failure to take note of the mount

positions before loosening the retaining nuts (3),

could cause driveline vibration problems, once the

vehicle is placed back in service.

12. Rem ove th e re ar m ount att achin g nuts ( 3) fr om

the transmission rear case mounting lugs (4),

then remove the crossmember and mount

assemblies (1) from the vehicle.

NOTE: Illustrat ion does not sho w trans m ission jac k

in position, for clarity of the crossmember

orientati on.

Figure 7B1-46

13. Remove propeller shaft (2) flexible rubber

coupling (4) to mainshaft flange (1) attaching

nuts (3).

Figure 7B1-47

14. W ith the transm ission in first gear and the park

brake firmly applied, use Torx socket

K04425E20 or a commercially available E20

Torx socket to loosen the three Torx headed

bolts (1) securing the propeller shaft rear

rubber coupling (2) to the pinion flange (3).

15. Release the park brake and select neutral, to

relieve any torque loading on the rubber

coupling, then remove the three Torx headed

bolts (1)

NOTE: T o enable the propeller shaft to be installed

in the original position relative to the pinion flange,

use a felt tipped pen or similar to identify the

relationsh ip (‘A’) of the t wo components before bo lt

removal.

Figure 7B1-48

16. Remove the two centre bearing carrier (1) to

underbody reinforcement bolts (2).

17. While supporting the centre bearing section,

lower the c entre b earing an d slide t he pro peller

shaft assembly forward to disengage from the

final drive pinion support pin.

18. Lower the assembly at the rear, sliding

rearward to remove from the rear of the

transmission.

Figure 7B1-49

19. Disconnect the speed sensor wiring harness

connector (1) on the left hand side of the

transmission. Cut the tie strap (2) securing the

wiring harness to the transmission.

Figure 7B1-50

20. Disconnect wiring harness connector from

back up lamp switch (1).

Figure 7B1-51

21. Rem ove clutc h ac tuat ing cylinder r eta ini ng nuts

(arrows) , then rem ove the cylinder ( 1) from the

transmission case. Secure to one side with tie

wire or similar.

Figure 7B1-52

22. Remove the two screws (1 and 3) securing the two front close-out covers (2 and 4). Remove each of the

covers.

23. Remove the two transmission to engine attaching bolts (5) from the clutch housing side.

NOTE: While Figure 7B1- 53 shows the right hand drive arrangem ent, the procedure for left hand drive vehicles is

similar. View ‘A’ shows the left hand close-out cover, while view ‘B’ shows the right side.

Figure 7B1-53

24. Lower transmission slowly on jack, still supporting weight of transmission.

25. Disconnect wir i ng harnes s f rom two reta in ing s tra ps ; o ne o n to p of the tr ans mission c ase, the other on t he right

hand side.

26. Us ing a scr ewdriver, pr ise t he retainer ( 1) up to

clear the transmission case, then remove to

free the shift rod (2) at the transmission end.

27. Using a suitable tool, remove the shift rod

retaining clip (4).

CAUTION: to prevent possible eye damage

when removing the clip, wear suitable eye

protection.

28. Remove a flat washer from the shift rod pin,

then remove the shift rod (5) and a second flat

washer from the transmission shift trunnion (3).

Figure 7B1-54

29. Remove transmission case to engine block

attaching bo lts .

30. Withdraw transmission from the engine block

and clutch driven plate.

NOTE: Keep th e transm ission ass embly supporte d

so that it does not tilt in relatio n to the engin e, until

the maindrive gear splines are clear of the clutch

driven plate. If the transmission is allowed to hang

on the splines, the clutch driven plate will be

damaged.

Figure 7B1-55

REINST ALL

1. Put transmission into 4th gear.

2. Sparingly apply a thin coating of short fibre,

high temperature grease to maindrive gear

splines. Push the clutch throwout bearing into

the fully released position (toward the

transm iss ion), ensuring tha t placem ent with the

throwout fork, is correct.

3. Apply a thin coating of 10% molybdenum

disulph ide grease, suc h as Molybond G A 10 or

equivalent, to the transmission input shaft

spigot.

4. Raise transmission on jack and install

maindrive gear into splines of clutch driven

plate and push transmission toward engine

block. It ma y be necessary to rotate the output

flange to assist in spline alignment.

5. Reinstall and tighten clutch housing to engine

block attaching bolts and nut. Also install the

two clutch housing to engine oil pan bolts,

tightening all to the correct torque specification.

CLUTCH HOUSING TO ENGINE

BLOCK AN D O IL PAN BOLT

TORQUE SPECIFICATION 85 Nm

Figure 7B1-56

6. Reinstall the two close-out covers, ensuring

that the locating lug on the RHS one is

installed before securing the cover with the

screw. Reinstall the cover retaining screws and

tighten to the correct torque specification.

FLYWHEEL CLOSE-OUT COVER

SCREW TORQUE SPECIFICATION 10 Nm

7. Reinstall clutch actuating cylinder to

transmission case, install the nuts and tighten

to the correct torque specification.

CLUTCH ACTUATING CYLINDER

NUT TORQUE SPECIFICATION 22 Nm

NOTE:When the actuating cylinder is engaged with

the mounti ng s tuds, the int ernal sprin g will hold the

flange out from the fully installed position, by

approximately 25 mm. Hold the cylinder in against

this spring force, to start the retaining nuts.

8. Using transmission jack, support transmission

in a lower than installed position.

9. Reinstall wiring harness retaining straps.

10. Reinstall wiring harness connector to back up

lamp switch and to the speed sensor.

11. Align the shift linkage brace/bush and the

transmission lug holes. Install the pin (1) from

the left hand side, then rotate, to engage the

retaining clip with the transmission lug. Tap

with a hamm er to fully engage the clip with the

lug.

12. Fit a washer to the inner end of the shift

linkage (5) pin, apply a small amount of

Molybden um Disulph id e grease to th e p in, the n

install into the transmission shift rod trunnion

(3). Insta ll a second washer to the shif t linkage

pin, then secure with the retaining clip (4).

Figure 7B1-57

13. Reinstall the rear crossmember and mounts to

the two transmission case lugs (4), then

reinstall the two retaining nuts (3).

14. Align the scribed alignment marks made prior

to removal, then tighten the two retaining nuts

(3) to the correct torque specification.

REAR MOUNT TO TRANSMISSION LUG

NUT TORQUE SPECIFICATION 25 Nm

15. Raise the support jack, then loosely reinstall

rear crossmember to side frame member bolts.

16. Carefull y align the scribe d m arks made prior to

removal, then tighten the four crossmember to

side frame bolts.

IMPORTANT: This step is critical to the correct

powertrain alignment. If not carried out, then

vehicle vibration and/or handling problems may

result.

17. Remove jack supporting the transmission.

18. After checking to see that the crossmember

position has not changed, tighten the four

crossm ember to s ide frame bo lts to the c orrect

torque specification.

REAR CROSSMEMBER TO SIDE

FRAME MEMBER BOLT

TORQUE SPECIFICATION 58 Nm

Figure 7B1-58

19. Reinstall propeller shaft rubber coupling to

transmission mainshaft flange and loosely

install NEW attaching nuts.

20. Lift propeller shaft upward and install centre

bearing carrier to underbody reinforcement,

ensuring that any spacers are placed in the

same positions, noted on removal. Install

retaining bolts.

21. Assemble propeller shaft rear universal joint

flange to pinion flange, aligning marks made

before removal and reinstall attaching bolts

and nuts.

22. T ighten a ll prop eller shaft a ttachi ng bolts to the

correct torque specification.

PROPELLER SHAFT RUBBER COUPLING

TO TRANSMISSION OUTPUT FLANGE

NUT TORQUE SPECIFICATION 78 Nm

CENTRE BEARING CARRIER TO

UNDERBODY REINFORCEMENT

BOLT, TORQUE SPECIFICATION 23 Nm

PROPELLER SHAFT REAR UNIVERSAL

JOINT FLANGE TO PINION FLANGE

BOLT TORQUE SPECIFICATION 58 Nm

23. Inspect catalytic converter to intermediate

exhaust pipe seal ring (3) for deterioration or

damage, replacing if required.

24. Reinstall exhaust system components. Refer

Section 8B EXHAUST SYSTEM, in the MY

2003 VY and V2 Series Service Information,

for the necessary procedures and clearances.

Tighten all fasteners to the correct torque

specifications, as detailed in that Section.

25. If transmission fluid was drained during

the removal operation, then refill, as

described in 2.3 DRAINING AND REFILLING

TRANSMISSION in this Se c tion.

26. Remove safety stands and lower vehicle.

27. Reconnec t batter y ground l ead.

28. Road test vehicle and check transmission,

clutch and gearshift operations.

Figure 7B1-59

4.3 TRANSMISSION DISASSEMBLE

LT Section No. – 04M-125

1. If not carried out during the transmission

removal procedure, use a 17 mm ring spanner

and remove transmission filler plug (1) from

right hand side of transmission case.

2. Remove transmission drain plug (2), also with

a 17 mm ring spanner and allow transmission

lubricant to drain into a suitable clean, drain

tray.

NOTE: At this tim e, carefull y inspec t the drain pl ug

magnet and the drained fluid for foreign matter

such as metal particles, etc.

Figure 7B1-60

3. Release clutch release lever from the wire clip

and remove lever from transmission case,

together with the thrust bearing.

Figure 7B-61

4. Remove bo lts attac h in g throwout b ear ing gu ide

assembly (1). Gently tap sideways with a soft

faced hammer to break the seal, then remove

the assembly from the transmission maindrive

gear shaft.

Figure 7B1-62

5. Remove shim washer (2) and distance spacer

ring from the f ront b earing. Using s uitabl e sn ap

ring pliers (1), remove the snap ring (3) and

spacer washer (4) from maindrive gear.

Figure 7B1-63

6. Remove the speed sensor bracket retaining

bolt (1) from the rear transmission case. Cut

the wiring harness retaining strap (2) from the

transmission case lug and remove the sensor

and brack et assem bl y.

Figure 7B1-64

7. Lever the sprin g steel reta ining r ing (4) f orward

from selector rod trunnion (3), to expose the

connecting pin (2).

8. While pushing the trunnion in to the

transmission, use a suitable punch and push

the pin from the trunnion. Remove trunnion and

retaining ring from the selector rod (1).

Figure 7B1-65

9. Remove back-up lamp switch and spacer

washer.

Figure 7B1-66

10. Using suitable lever, remove detent plug (1)

from front section of transmission case.

11. Rem ove de tent pin ( 3), pre ssur e spring (2) a nd

plug (1).

Figure 7B1-67

12. Remove front bolt (1) fastening the reverse

idler gear shaft to the left side of transmission

case.

Figure 7B1-68

13. Remove transmission case attaching bolts

from c ase rear sec tion. Take note of the l onger

bolt (60 mm) position (bold arrow) for

reassembly.

14. Drive the upp er locating do wel p in int o the f r ont

transmission case.

Figure 7B1-69

15. Install extractor, Tool No. AKM-628-A, to front

of transmission case using all six of the clutch

throwout bearing guide bolts (1). It is not

necessary to remove the reverse block shaft

bolt (2).

16. Tighten extractor forcing bolt to separate the

two transmission case sections.

NOTE: While the forcing bolt of Tool AKM-628-A

has torque applied, it may be necessary to use a

suitable block of wood and hammer at the two lug

locations provided on the rear transmission case,

to assist in the initial separation process.

17. Carefully remove the front transmission case

section and pl ace to one si de.

NOTE 1: The maindrive gear bearing and cluster

gear front bearing cup remain in the transmission

case front section. Take care that the cluster gear

roller bearing does not fall out of the front case

immediately after splitting the cases. The

remainder of the transmission assembly is

removed with the transmission case rear section.

NOTE 2: W hen the transmission cases have been

separated, do not manipulate the position of the

transmission rear section by using the maindrive

gear as a lever or handle. If this is done, then the

mainshaft spigot bearing will suffer brinelling and

be permanently damaged.

Figure 7B1-70

18. Before using the previously released, Tool No.

KM-620-1-A to hold the flange, it must first be

modified by redrilling the three holes stamped

‘B’ (on the Tool) to 13 mm.

19. F asten th e m odified to ol to the flan ge using the

three discarded nuts. Then, using a suitable

length of pipe on the tool handle, loosen and

remove flange nut, using a commercially

available, 30 mm deep socket.

Figure 7B1-71

20. Install extractor, Tool No. AKM-628-A to

mainshaft output flange studs. Use the

removed nuts to secure the extractor tool to the

flange.

21. Tighten extractor forcing bolt to remove flange

from mainshaft.

Figure 7B1-72

22. Remove bolts attaching pressure spring cover

plate (1) to transmission case rear section.

23. Remove three detent ball springs (2).

24. Using a pencil magnet, remove three detent

balls from under the springs.

Figure 7B1-73

25. Select 4 th gear, s upport the s hift selec tor shaft

(2) with a wooden wedge (4), then remove the

roll pin from the gearshift selector arm (3),

using a suitable sized pin punch (1) and

hammer. When in 4th gear, the roll pin will not

foul on gear teeth during the removal process.

Figure 7B1-74

26. Using a soft faced hammer, tap the shift shaft

(2) rearwards through the bearing support,

removing the seal (3) in the same operation.

Discard the removed seal (3) as it will be

damaged in the removal process.

NOTE: As the shif t shaft is rem oved, there are f our

rollers (1) that can be dislodged from the pins in

the shaft. Take care not to lose them.

Figure 7B1-75

27. While supporting the 3rd/4th selector shaft (3)

with a suitable wedge of wood (5), drive the

selector fork roll pin out, just sufficient to

enable the shaft (3) to be removed.

Legend:

1. Pin Punch

2. 5th/Reverse Selector Shaft

3. 3rd/4th Selector Shaft

4. 1st/2nd Selector Shaft

5. Wooden Wedge

Figure 7B1-76

28. While supporting the 3rd/4th shift fork, use a

soft faced hammer to gently tap the shaft (1)

rearward, displacing the expansion plug in the

rear transmission housing. This will also allow

removal of the interlock pin (2) and the shaft

from the rear, which overcomes the risk of the

interlock pin becoming dislodged and jamming

the shaft.

Figure 7B1-77

29. Move the 5th/Reverse synchromesh fork (1)

forward, into the Reverse position and the

1st/2nd synchromesh fork (2) forward into the

2nd gear posit ion .

Figure 7B1-78

30. Remove the rear bolt (4) securing the reverse

idler gear (1) to the transmission case and the

bolt (2) securing the thrust plate (3). Remove

the reverse idler gear shaft and roller bearing

from the rear case section. Remove the idler

gear.

Figure 7B1-79

31. To remove mainshaft (1) and cluster gear

assemblies, together with the selector shafts

and forks from rear transmission case (2),

support th e case on suitable pr ess plates, then

press the mainshaft (1) from the rear

mainshaft, sealed ball race.

IMPORTANT: Take care when the gear

assemblies come free from the ball race, as they

are heavy. Do not allow them to drop to the floor

when gear tooth damage could occur.

NOTE: Do not lose any of the selector interlock

balls that will come away when the shafts are

removed. There are two of them, both of equal

size.

Once free, the cluster gear assembly and

selector shafts and forks can be easily

separated from the mainshaft assembly.

Figure 7B1-80

4.4 TRANSMISSION SUB-ASSEMBLIES

LT Section No. – 04M-125

DISASSEMBLE

Mainshaft

1. Remove the 5th s p eed c on s tant mesh gear ( 1) ,

synchromesh ring (2) and caged needle roller

bearing (3) from the rear of the mainshaft.

Figure 7B1-81

2. Remove m aindrive gear and four th speed gear

synchromesh ring from mainshaft.

3. Remove snap ring (1) and washer from front

end of mainshaft, using suitable snap ring

pliers (2).

Figure 7B1-82

4. Insert each half of Tool No. AU454 under the

dog clutch teeth of 2nd speed gear, ensuring

that both halves are fully installed.

NOTE: Only one half of Tool No. AU454 is shown,

to more clearly show the installation position.

Figure 7B1-83

5. Support both halves of Tool No. AU454 under

suitable press plates and press the mainshaft

(1) from the following components;

• 3rd/4th gear synchromesh assembly.

• 3rd speed gear and synchromesh ring.

• 3rd speed gear, caged needle roller

bearing.

• 3rd speed gear, roller bearing sleeve.

• 2nd speed gear thrus t washer .

• Thrust washer locating ball.

• 2nd speed gear.

• 2nd speed gear, caged needle roller

bearing.

NOTE: As the s ynchrom esh hub and roller bearing

sleeve are both interference fits on the mainshaft,

some force will be required to remove these

components. Also, take care not to lose the thrust

washer locating ball, as it may fall out during the

pressing oper at io n.

6. Remove the thr e e p ar t s yn c hromes h rings f rom

the 1st/2nd synchromesh assembly.

Figure 7B1-84

7. Remove snap ring (2) from the 1st/2nd gear

synchromesh hub (3), using suitable snap ring

pliers (1).

Figure 7B1-85

8. Using s uitable pres s plates , position ed with the

flat side under first speed gear (3), press

mains haft ( 1) from 1st/2nd speed s ynchrom es h

assembly (2), 1st speed synchromesh ring,

cone ring, friction ring, first speed gear (3) and

needle roller bearing.

Figure 7B1-86

9. Remove 5th/Reverse speed synchromesh hub

snap ring (1) from mains haft (2), using s uitable

snap ring pliers (3).

Figure 7B1-87

10. Press mainshaft from 5th/Reverse speed

synchromesh assembly, reverse synchromesh

ring and reverse constant mesh gear, using

suitable press plates (2), with the flat side

positioned under Reverse speed gear (1).

11. Remove reverse speed gear and selective,

caged needle roller bearing from mainshaft.

Figure 7B1-88

Maindrive Gear

1. Remove the caged needle roller bearing from

the maindrive gear.

Figure 7B-89

Cluster Gear

While the cluster gear is made up from three

separate components, it is only serviced as a

complete assembly. It should therefore, not be

dismantled. The assembly of the components is

precise and cannot be duplicated without the use

of specialised jigs.

Reverse Idler Gear Shaft

When removing the two snap rings securing the

two caged needle roller bearings to the idler shaft,

take particular note of the orientation of each snap

ring to the bearings.

Synchromesh Assemblies

With the index finger and thumb of the left hand

circling the synchromesh hub (5), slide the outer

sleeve (1) from the assem bly, usi ng the rig ht hand.

Be careful that the pressure springs (4) do not

cause any of the three balls (2) to be ejected and

lost. Note th e relati onship o f the outer sleeve to t he

synchrom es h hub an d the c orrec t orientat ion of th e

sliding keys (3).

NOTE: W hile the synchrom esh assembly shown is

for the 1st/2nd speed ranges, the disassembly

process is the same for each of the remaining two

assemblies.

Figure 7B1-90

INSPECT COMPONENTS

1. Check synchromesh rings for cracks and for

deformation. Inspect rings for excessive wear

in the areas shown.

2. Check synchromesh hubs, outer sleeves,

sliding blocks and synchromesh springs for

damage.

Figure 7B-91

3. Check each synchromesh ring for wear by

mounting the ring on the respective gear and

measuring the gap, as indicated.

NOTE: To obtain an accurate measurement, the

synchromesh ring must be held squarely and fully

installed on its gear, as shown. Then, using feeler

gauges, measure the gap in at least three places

around the circumference. Average the readings

and use this figure to ass ess the s ynchrom esh ring

wear.

Specifications for each synchromesh ring are as

follows and correspond to the synchromesh

assemblies indicated in the se ctioned view.

Position Gear Serviceable Wear Limit

(A) 4th 0.82 - 1.35 mm

(B) 3rd 0.82 - 1.35 mm

(D) 1st 0.95 - 2.35 mm

(E) Reverse 0.5 - 0.98 mm

(F) 5th 0.82 - 1.35 mm

Figure 7B-92

Figure 7B-93

4. Inspect all gears, sleeves, hubs, rings and shaf ts for wear, scoring, pitting, chips , nicks or burrs. Slig ht scores

or burrs may be honed off with a fine stone, however if a gear is chipped or unduly worn it must be replaced.

5. Inspect all needle roller bearings for wear or damage.

NOTE: As needle roller wear can be difficult to see, it is good practice to replace all roller bearings where a

substantial distance has been covered by the transmission.

6. Inspect the mainshaft surfaces, roller bearing inner sleeves and internal surfaces of the gears where the needle

bearings come into contact.

NOTE: The needle roller bearing assembly used with the mainshaft Reverse gear, is a selective fit. Should any

component associated with this gear and/or the mainshaft need to be replaced, then the procedure detailed in

REAS SEMBLE, Mainshaft, must be adopted, to ensure that the correct replacement part/s are fitted.

SYNCHROM ESH ASSEMBLIES

Identification

1. The 1st/2nd speed synchromesh assembly (3)

can be recognised by the larger diameter

splined hole in the hub, when com pared to the

3rd/4th synchromesh assembly.

T he s teppe d e dge ( 2) o n the ou ter s leeve ( 3) is

another identification feature, as is the offset

groove (1).

Figure 7B1-94

2. Identification of 3rd/4th speed synchromesh

assem bly ( 2) is by the off set selec tor slot (1) in

the outer sleeve and smaller diameter splined

hole in the hub.

Figure 7B1-95

3. Identification of the 5th/Reverse synchromesh

assembly (2) is by a single groove (1) on the

outer sleeve and the larger diameter splined

hole in the hub, when compared to the 3rd/4th

speed synchromesh assembly.

Figure 7B1-96

The synchromesh rings can be identified by the

number stamped on the flat face of each one.

Applications are as follows;

1st/2nd .................... 040.8.0001.00

3rd/4th..................... 002.8.0301.00

5th/Reverse............. 011.8.0331.10

(optional)............ 011.8.0331.11

Figure 7B-97

REASSEMBLE

Synchromesh Assemblies

The respective synchromesh assemblies are to be

assembled before pressing onto the mainshaft.

Only one synchromesh assembly is described in

the following operations, since reassembly is

similar for all units.

1. Support the synchromesh hub over a suitable

disc to raise it from the bench surface and

install the outer sleeve over the synchromesh

hub.

2. Insert sliding key s (1) (with the chamfered ends

facing outwards) and the pressure springs (2),

into each of the locations in the synchromesh

hub. Use petroleum jelly to hold parts in place.

3. Using a small screwdriver (4), prise each key

(1)upwards, just sufficient to enable a ball (3)

to be inserted. While holding the ball inwards,

push the key down to capture the ball. Repeat

for the remaining two key/spring combinations.

Assembly Notes:

a. The thicker boss of the 3rd/4th synchromesh

hub faces 3rd gear. The offset of the 3rd/4th

selector fork groove faces 4th gear.

b. The offset groove and the step in the outer

sleeve of the 1st/2nd gear synchromesh

assembly, faces 1st gear.

c. The single groove on the outer sleeve of the

5th/Reverse synchromesh outer sleeve, faces

5th gear.

Figure 7B1-98

Mainshaft

First and Reverse Gear Needle Roller Bearings

NOTE: Both the mainshaft first and reverse gears, caged needle roller bearing is a selective fit, with the various

sizes identified by different colour needle roller bearing cages.

Both the mainshaft and first/reverse gears are accurately measured during manufacture and the size recorded by

using different colour paint daubs on each component.

Depending on the combination of the two different colours (and therefore, sizes), the correct needle roller bearing

can then be selected, also by a colour coding of the cage.

Examples of the selection process, using the next two sets of tables, are;

a. With a white paint daub on the mainshaft and a green daub on the reverse gear, the correct needle roller

selection would be one that had a red cage.

b. A yellow daub on the mainshaft (forward of the gear) with a blue daub on the first gear, indicates the correct

needle roller selection as being one with a grey/white cage.

Relationship of the Mainshaft, First Gear and First

Gear Needle Roller Bearing Relationship of the Mainshaft, Reverse Gear and

Reverse Gear Needle Roller Bearing

Mainshaft First Gear Needle Roller Bearing Mainshaft Reverse

Gear Needle Roller Bearing

Paint Daub

Colour Paint Daub

Colour Cage

Colour Undersize

Dimension Paint Daub

Colour Paint Daub

Colour Cage

Colour Undersize

Dimension

White

Blue

Orange

Yellow

Green

Grey/White

Blue

–0.5 to –0.7 µm

–0.3 to –0.5 µm

–0.1 to –0.3 µm

White

Yellow

White

Green

Grey/White

Red

–0.5 to –0.7 µm

–0.3 to –0.5 µm

0 to –0.2 µm

Yellow

✹ Yellow

Blue

Orange

Yellow

Grey/White

Blue

Red

–0.3 to –0.5 µm

–0.1 to –0.3 µm

0 to –0.2 µm

Yellow

Orange

Yellow

White

Green

Grey/White

Blue

–0.5 to –0.7 µm

–0.3 to –0.5 µm

–0.1 to –0.3 µm

✹ Yellow Green Red 0 t o –0.2 µm

NOTE: Those selections marked ‘✹’ are non-preferred

combinations. If possible, an alternative mainshaft

or first/reverse gear colour would be preferred.

However, if this is not possible, then the choices as

listed, can be used.

Orange

✹ Orange

Blue

Orange

Yellow

White

Green

Grey/White

Blue

Red

–0.5 to –0.7 µm

–0.3 to –0.5 µm

–0.1 to –0.3 µm

0 to –0.2 µm

Table 1

1. Coat mainshaft (4), all gear bores and needle

bearings (3) with transmission lubricant.

2. Reassemble the colour coded, selective

Reverse gear needle bearing (3), gear (2) and

synchromesh ring (1) to mainshaft (4).

3. Heat assembled 5th/Reverse speed

synchromesh hub to approximately 100° C on

an electric hotplate.

NOTE: Use Faber Castel l Therm ochr om 2815/10 0°

C to indicate temperature. Apply Thermochrom

around synchromesh hub.

IMPORTANT: Do not exceed a temperature of

100° C

Figure 7B1-99

4. Using a heat proof glove, position

synchromesh assembly (3) onto mainshaft (2),

with the groove in the outer sleeve facing 5th

gear and aligning mainshaft and hub splines.

5. Using suitable sleeve and press plates (4),

press mainshaft (2) into synchromesh hub (3),

ensurin g that synchrom esh ring slots align with

sliding keys in the synchromesh assembly.

6. Remove mainshaft from press, and if

necessary, lever up the Reverse synchromesh

ring with a screwdriver so that it is not jammed

on the gear cone.

Figure 7B1-100

7. Reinstall synchromesh assembly selective

snap ring (1) onto mainshaft (2), ensuring that

no gap exists between the synchromesh hub

and the installed snap ring (1). Make sure the

snap ring is seated correctly in groove. Do not

over-stretch the snap ring with the pliers (3)

during installation.

Snap rings are available in thicknesses of 1.8,

1.85, 1.9, 1.95 and 2 mm.

Figure 7B1-101

8. Assemble the colour coded, selective 1st

speed gear, caged needle roller bearing (6),

1st speed gear (5), friction ring (1), cone ring

(2) and synchromesh ring (4) onto mainshaft

(3).

NOTE: The 1st and 2nd gear synchromesh cone

rings have different dimensions. Refer Figure 7B1-

103.

Figure 7B1-102

IMPORTANT: Ensure that the correct cone ring is

fitted. The cone rings for 1st and 2nd gears have

different dimensions, as shown. Further

identif ication can be made from the m anufacturer ’s

number on each ring, which is as follows;

1st gear cone ring (A) 040.8.0069.00

2nd gear cone ring (B) 040.8.0059.00

Figure 7B1-103

9. Heat assembled 1st/2nd speed synchromesh

hub on a hot plate to approximately 100° C on

an electric hotplate.

NOTE: Use Faber Castel l Therm ochr om 2815/10 0°

C to indicate temperature. Apply Thermochrom

around synchromesh hub.

IMPORTANT: Do not exceed a temperature of

100° C.

10. Using a heat proof glove, position

synchromesh assembly (4) onto mainshaft,

aligning mainshaft and hub splines.

NOTE: The side with t he sm aller outer s urface and

the step (1), faces 1st gear (2).

11. Using a suitable sleeve (3), press

synchromesh hub onto mainshaft, ensuring

that synchromesh ring slots align with sliding

keys.

12. Remove mainshaft from press, and if

necessary, lever up 1st speed synchromesh

ring with a screwdriver so that it is not jammed

on the gear cone.

Figure 7B1-104

13. Mount rear end of mainshaft in vice with soft

metal jaws.

14. Reinstall synchromesh assembly (3), selective

snap ring (2) onto mainshaft, ensuring that

snap ring (2) is correctly seated in groove,

without an y end clear ance. Do not ov er-stretch

the snap ring (2) with the snap ring pliers (1),

during installation.

NOTE: Selective fit snap rings are available in

thicknesses of 1.8, 1.85, 1.9, 1.95 and 2 mm.

Figure 7B1-105

15. Reinstal l 2n d s pe ed g ear (2 ) with caged nee dl e

roller bearing (5), friction cone (4), cone ring (3)

and synchromesh ring (6) onto mainshaft (1),

ensuring that the friction ring (4), cone ring (3)

and synchromesh ring (6) are correctly located

in the synchromesh assembly.

NOTE: Ensure that the correct synchromesh cone

ring is fitted. Refer to Figure 7B1-103 for correct

identif icat ion det ai ls .

Figure 7B1-106

16. Reinstall small, locating ball (3) in mainshaft

(2), securing with petroleum jelly.

Figure 7B1-107

17. Install thrust washer over locating ball.

Figure 7B1-108

18. Heat 3rd speed gear roller bearing sleeve (1)

on a hot plate to approximately 80° C.

NOTE: Use Faber Castell Thermochrom 2815/80°

C to indicate tem peratur e.

IMPORTANT: Do not exce ed a temperatur e of 80°

19. Using a heat proof glove, position bearing

sleeve onto mainshaft and press home using

suitable pr ess pla tes . When pres s ing mainshaf t

into the sleeve, ensure that the thrust washer

(‘1’ in Figure 7B1-107) remains in place over

the retaining ball.

Figure 7B1-109

20. Reinstall caged needle roller bearing (2), 3rd

speed constant mesh gear (1) and

synchromesh ring, onto mainshaft.

21. Heat the assembled 3rd/4th speed

synchromesh assembly on a hot plate to

approximately 100° C.

NOTE: Use Faber Castel l Therm ochr om 2815/10 0°

C around synchromesh hub, to indicate

temperature.

22. Using a heat proof glove, position

synchromesh assembly onto mainshaft,

aligning mainshaft and hub splines.

NOTE: The 3rd/4th selector fork offset in the outer

sleeve faces away from 3rd gear.

Figure 7B1-110

23. Using suitable sleeve (1), press synchromesh

hub assem bly (2) o nto m ainshaf t, ensur ing that

synchromesh ring slots align with sliding keys.

24. Remove mainshaft from press, and if

necessary, lever up 3rd speed synchromesh

ring (3) with a screwdriver so that it is not

jammed on the 3rd speed gear cone (4).

Figure 7B1-111

25. Reinstall washer and selective snap ring (1) to

mainshaft, using suitable snap ring pliers (2).

Ensure that the snap ring (1) is correctly

seated in groove with no clearance between

the snap ring and the washer.

Snap rings are available in thicknesses of 2.0,

2.1, 2.2, 2.3, 2.4 and 2.5 mm .

Figure 7B1-112

26. Reinstall a pre-lubricated 5th speed caged

needle roller bearing (3) onto mainshaft. Then

install the synchromesh ring (2), engaging ring

slots with sliding blocks of the synchromesh

assembly and finally, the 5th speed gear (1).

Figure 7B1-113

Maindrive Gear

1. Coat maindrive gear needle bearing with

petroleum jelly.

2. Insert bearing assembly into the maindrive

gear.

Figure 7B-118

Reverse Idler Gear Shaft

1. Lubricate the reverse idler gear shaft with

clean transmission fluid, then install the two

caged needle roller bearings.

2. Locate the roller bearings by installing new

snap rings to each groove on the reverse idler

gear shaft.

IMPORTANT: Snap r ings (1) must be insta ll ed with

the curved out portion of each snap ring end,

AWAY from the roller bearing as shown.

As the reverse idler gear is in constant mesh with

the cluster gear, if the snap rings are not installed

as shown, then a transmission noise will be

created.

Figure 7B1-119

TRANSMISSION CASE, REAR SECTION

Disassemble

1. To remove the rear oil seal, use the distance

spacer r ing (1) from the f ront m ains haf t bear ing

to protect the transmission rear housing, then

use a suitable lever such as a screwdriver (2)

to lever o ut the seal from the rear transm ission

case.

NOTE: Take extreme care not to scratch the seal

surface in the rear transmission case. If damaged,

a subsequent fluid leak may occur.

Figure 7B1-120

2. Remove th e loc king le ver scr ew plug f rom the rear ho using, using a 19 m m ring spanner , no ting t hat se alan t is

applied to the threads.

CAUTION: Take care that the plug does not fly out under spring force, when the plug is unscrewed.

3. Remove the spring from the rear housing.

Figure 7B-121

Legend

1. Locking Lever

2. Selector Arm

3. 5th/Reverse Selector Shaft

4. Cover Plate

5. Interlock Pin

6. 3rd/4th Selector Shaft

7. Detent Ball Spring

8. Detent Ball

9. 1st/2nd Selector Shaft

10. Interlock Ball

11. Mainshaft Bearing

12. Locking Lever Spring, Plunger and Cap

13. Using a 6 mm, Allen key socket (2), remove

the gearshift selector rod bush (1) lock bolt

from the rear case section.

NOTE 1: The lock bolt has sealant applied to the

thread and will be difficult to remove, if a hot air

gun is not used to soften the sealant prior to bolt

removal.

NOTE 2: As the Allen key screw is removed,

support the gearshift selector rod bush against

rotational spring force.

Figure 7B1-122

14. From inside case, remove the spring (3), spring

guide (2) and selector arm (4) with roller (5)

and gear selector rod bush (1). Be careful as

spring force can easily eject these parts,

uncontrolled.

Figure 7B1-123

15. Remove the five bolts (2) holding the rear

bearing plate and locking lever support (3)

using suitable socket equipment (1), then

remove the plate and locking lever as an

assembly.

16. If required, remove the locking lever pivot bolt

and nut from the rear bearing retaining plate.

Figure 7B1-124

NOTE: Unless the rear mainshaft bearing is to be

replaced, there is no need for this next operation.

17. Preheat the transmission housing in the rear

bearing area, to approximately 80° C using a

comm er c ially availab le hot air blow er.

NOTE: Use Faber Castell Thermochrom 2815/80°

C, to ensure that an excessive temperature is not

reached.

Figure 7B1-125

18. Use a suitable sleeve such as AKM-500-3 and

press the mainshaft rear bearing from the

transmission housing.

IMPORTANT: Because of ball brinelling, the

bearing MUST be replaced, after removal.

Figure 7B1-126

19. To remove the rear cluster gear bearing cup,

use the following method;

a. Grind the legs of Tool KM-328-7-A down to

approximately 3 mm, sufficient to insert under

the bearing cup.

b. Fabricate a spacer (1) as shown, to insert

between the two legs, using 3 mm thickness,

mild steel stock.

Figure 7B1-127

c. Install each of the modified legs of Tool KM-

328-7-A under the bearing cup, then insert the

fabricated spacer in between them.

d. Us e the cup, T ool KM-3 28-5- A and pin (1) from

slide hammer, Tool KM-328-B to secure the

legs and spacer assembly.

e. Scr ew threade d adaptor int o cup (2) a nd instal l

puller KM-556-1A.

f. Use the puller to extract the bearing cup from

the rear transmission case.

NOTE: To aid in removal of bearing, it will be

necessary to preheat case area of bearing to 80°

C, using a commercially available, hot air blower.

Use Faber Castell Thermochrom 2815/80° C, to

ensure that an excessive temperature is not

reached.

Figure 7B1-128

Inspect

1. Inspect rear transmission case for any defects

or cracks that may cause oil leaks.

2. Check all machined surfaces for burrs, and if

present, dress them off with a fine cut file.

3. Check bearing bores for damage or scoring.

4. Inspect all shift control component contact

surfaces and sliding surfaces for wear,

scratches, projections or other damage.

5. Check all springs for damage or distortion.

6. Check the selector inter-lock pin and balls for

damage.

Reassemble

1. Using a suitable length and diameter pipe (1),

press a new, sealed ball race (2) into the rear

transmission case, ensuring that force is only

applied to the outer bearing ring.

NOTE 1: To ass is t in t he in s tall ation of the be ar in g,

heat the rear transmission housing with a

comm erc ially availa ble hot air gun to appr ox im ately

80° C.

Use Faber Castell Thermochrom 2815/80° C, to

ensure that an excessive temperature is not

reached.

NOTE 2: The offset on the inner bearing cone

faces the rear of the transmission.

Figure 7B1-129

2. Apply thread sealant such as Loctite 242 or

243 (or equivalent) to the cleaned threads of

the rear be aring plate reta ining bolts ( 2). Install

the rear bearing plate (1) and tighten the bolts

to the correct torque specification, using

suitable socket equipment (1) and a torque

wrench.

REAR BEARING PLATE AND

LOCKING LEVER BOLT

TORQUE SPECIFICATION 10 Nm

Figure 7B1-130

3. Pre-assemble the selector arm, spring, bush

and sleeve, by first inserting the shaft of Tool

AU462 into the rear of the selector arm,

engaging the lugs with those in the arm (2).

Then, install the straight end of the spring (5)

into the selector arm pin hole and insert the

sleeve and bush (4) over the shaft. Insert the

sleeve of Tool AU462 over the protruding shaf t

and engage the leg with the free end of the

spring.

While holding the selector lever (2) in one

hand, rotate the sleeve of the holding Tool

AU462 counter-clockwise, loading the spring.

Tighten the locking screw (3) to retain the

assem bl y in the loaded stat e.

4. Use petroleum jelly to secure the selector arm

roller (1), to the pin, then install the assembly

into the rear transmission case.

5. Reinstall the bush locating screw, after

applying se alant suc h as Loctite 242 or 243 (or

equivalent) to the cleaned screw threads.

Tighten with an All en key h eaded sock et to the

correct torque specification.

GEARSHIFT SELECTOR ROD BUSH

SCREW TORQUE SPECIFICATION 20 Nm

6. Apply thread sealant such as Loctite 242 or

243 (or equivalent) to the cleaned threads of

the locking lever screw plug. Install the spring

and plug, tightening to the correct torque

specification.

Figure 7B1-131

LOCKING LEVER SCREW PLUG

TORQUE SPECIFICATION 48 Nm

TRANSMISSION CASE, FRONT SECTION

Disassemble

1. Insert the legs of Tool KM328-7-A into the

bearing (2) and hold in position with spacer,

Tool KM-3 28-9. S lip the cu p of T ool KM-328-5-

1A over the legs and secure with the pin.

2. Screw the thread of slide hammer, Tool No.

KM-328-B into the cup and remove the

gearshift selector rod front bearing from case.

NOTE: When carrying out this operation, the

bearing will be damaged and must be replaced.

3. From inside the transmission bell housing,

remove the bolt securing the reverse block

assembly (1). To remove the reverse block

shaft, temporarily reinstall the bolt for a few

threads and gently tap the shaft free from the

transmission front case.

Figure 7B1-132

NOTE: Normally this next operation would only be

considered necessary if replacement of the front

cluster gear, bearing and/or transmission front

case was required.

4. Remove cluster gear front bearing snap ring

(2) from front tr ansmission cas e, using suitab le

circlip pliers (1) and remove any end float

adjusting shims.

NOTE: If necessary, press bearing inward slightly

so that snap ring can be removed. Use the

adaptor, Tool KM-4 54-1 and mandr el T ool KM- 4 54-

4, with a flat washer.

Figure 7B1-133

5. Use the adaptor, Tool KM 454-1 and mandrel

Tool K M-454-4, with a f lat washer (1) (or us e a

sleeve of 43 mm diameter), press the bearing

cup into the transmissi on case.

Figure 7B1-134

6. Using a suitable adaptor (or sleeve), press on

the outer ring of the maindrive gear bearing

from inside the transmission case, to remove it.

Figure 7B1-135

Inspect

1. Inspect transmission case for any defects or

cracks that may cause oil leaks.

2. Check all machined surfaces for burrs, and if

present, dress them off with a fine cut file.

3. Check bearing bores for damage or scoring.

Reassemble

1. Lubricate a new gearshift lever shaft guide

bearing (1) with transmission fluid. Install,

using Tool No. KM-409-A or equivalent.

Figure 7B1-136

2. Reins tal l com pens ating shi m /s and a new s nap

ring to the bore of the front cluster gear

bearing.

3. Reinstall cluster gear front bearing, using

adaptor, Tool KM-454-1, flat washer (1) and

mandrel KM-454-4 (or a suitable sized tube),

pressing from the inside of the front

transmission housing, outward.

NOTE 1: If a new transmission case front section

and/or new cluster gear is to be installed, the end

play must be measured.

Refer to the Sub-Assembly heading ‘Cluster Gear

End Play Adjustment', next in this Section.

NOTE 2: If the maindrive bearing was removed

and a replacement is to be installed, then

compensating shim thickness will need to be

calculated, after installation. As bearing

replacement would normally be carried out

during transmission reassembly, this operation

will be detailed at that time. In any case, if

cluster gear end play adjustment is to be

carried out, then the bearing would need to be

removed for this operation.

Figure 7B1-137

CLUSTER GEAR END PLAY ADJUSTMENT

This operation is only necessary when replacing

the front transmission case and/or the cluster gear.

1. Reinstall cluster gear (1) into transmission

case rear section.

Figure 7B1-138

2. Remove front cluster bearing circlip (2) from

transmission case using suitable circlip pliers

(1) front section, then remove compensating

shim/s.

NOTE: If necessary, press bearing cup inward

slightly to enable removal of snap ring.

Figure 7B1-139

3. Reinstall cluster gear front bearing circlip,

without shim/s.

4. Using adaptor, Tool KM-454-1 and mandrel

KM-454-4, together with a flat washer (1) (or

use a suitable tube), press bearing into case

bore until it contacts snap ring.

Figure 7B1-140

5. Place tr ansm ission cas e front sectio n onto rear

section and install four case attaching bolts (1

to 4). Tighten bolts to the correct torque

specification.

TRANSMISSION REAR CASE

ATTACHING BOLTS

TORQUE SPECIFICATION 25 Nm

Figure 7B1-141

6. Secure a piece of flat steel (2) (approximately

20 x 5 mm) with two bolts, to the front

machined surface of the clutch throwout

bearing guide fla nge.

7. Mount a dial indicator (4) and magnetic stand

(1) to the flat steel (2), ensuring that the stylus

of dial indicator (4) rests on front of cluster gear

(3), as shown. Zero the dial in dicator.

Figure 7B1-142

8. Using a screwdriver (1) through filler plug

opening, raise and lower cluster gear to obtain

the total end float dimension. Record this

reading.

Axial play should be to the following

specification:

CLUSTER GEAR AXIAL PLAY 0.13 - 0.23 mm

9. Subtract this axial play figure from the

measurement taken to determine the required

shim stack.

e.g. Total Axial Play Recorded = 3.96 mm

Subtract Axial Play Specification = 0.18 mm

Required Shim Thickness = 3.78 mm

Shims are available in 1.0, 1.7 mm, 1.8 mm,

2.0 mm, 2.1 mm, 2.2 mm and 2.3 mm

thicknesses. In the above example, a shim

combination of 1.8 and 2.0 mm would be

required.

10. Reinstall selected shim/s, refer to Transmission

Case Front Section-Disassemble and

Reassemble in this Sec t ion .

11. Recheck axial play as described previously.

12. Once axial play has been adjusted, separate

the two transmission cases and remove the

cluster gear.

Figure 7B1-143

CLUTCH THROWOUT BEARING GUIDE

Input Shaft Se al, Rep lace

1. Remove the maindrive bearing compensation

shim/s (1) if fitted, from the throwout bearing

guide and set to one side. If the maindrive

bearing is not replaced, then this same shim

stack will need to be reinstalled, on

reassembly.

2. Using a screwdriver (2), drive the seal ring (3)

from thrust bearing guide sleeve, as shown.

Take c ar e not to sc ratc h th e s ea l sur f ace of the

throwout bearing guide during seal removal.

Figure 7B1-144

3. Using a suitable size sleeve (2), use a soft

faced ham mer (1) to insta ll new seal i nto guide

sleeve (3).

Figure 7B1-145

O-Ring, Replace

1. While holding the flange (3) against a flat

surface, use a plastic faced hammer (1) and

tap the throwout bearing guide (2) from the

mounting flange.

NOTE: Do not lose the small locating disc.

Figure 7B1-146

2. Remove the O-ring seal (1) from the mounting

flange (2), using a small screwdriver.

3. Clea n all c om ponents and inspec t for wear an d

damage. Replace as required.

4. Install new O-ring into the flange, lubricating

with petrole um jell y.

5. Align the locating disc, semi-circular cut-outs of

the flange and guide and assemble, taking

care to keep both parts square to each other.

6. Reinstall the locating disc, securing with a

small amount of petroleum jelly.

Figure 7B1-147

4.5 TRANSMISSION REASSEMBLE

LT SECTION NO. – 04M-125

1. Carefully move the respective synchromesh

rings into Reverse and 2nd gear positions.

2. Reinstall all shift forks to their respective

synchromesh rings - the 5th/Reverse (5) and

1st/2nd (3), with their shafts, both with new roll

pins fitted.

NOTE:The 3rd/4th shift shaft will be fitted later in

the assembly process.

3. Reass emble the m aindrive gear (2) and cl uster

gear (1) to the mainshaft assembly, holding

everything together as a single assembly.

4. Pre-heat the inner race of the sealed rear ball

race to 80° C, using a commercially available

hot air blower.

NOTE: Use Faber Castell Thermochrom 2815/80°

C to indicate the temperature of the inner race.

Figure 7B1-148

5. With the transmission case rear section (1)

supported in an upright position, carefully

install the gear and shift fork/rail assemblies

into the case, aligning the two shift rails with

their respective bores.

Figure 7B1-149

6. Carefully move the 5th/Reverse (2) and

1st/2nd gear synchromesh rings (4) into the

Neutral position.

7. Reinstall both interlock balls to the interlock

bore, securi ng in plac e with petro leum jelly.

8. With the transmission rear case in an upright,

horizontal position, install the lower interlock

ball.

9. Insert th e 3rd/4th se lector shaf t (3) through the

3rd/4th shift fork and install partially into the

bore in the rear case. Then, using a small

screwdriver, insert the second interlock ball

into position from the rear, fully installing with

the 3rd/4th selector shaft.

10. Pus h the 3r d/4th selec tor shaft thr ough and o ut

the rear of the case, insert the interlock pin,

then move the selector shaft forward, lining up

the roll pin hole with the selector fork.

NOTE: Ensure that the detent ball grooves in the

selector shaft face uppermost.

11. While supporting the shaft with a suitable

wooden wedge (5), install a new roll pin (1) to

the fork and shaft (3).

Figure 7B1-150

12. Fully install the mainshaft to the sealed rear

bearing, using the following method:

a. Temporarily install the mainshaft sleeve and

the output f lange and to othed ring assem bly to

the mainshaft.

b. While hold ing the f la nge with Tool No. K M-620-

1-A and a suitable length of pipe, tighten the

flange nut using a commercially available, 30

mm socket, pulling the inner bearing fully into

place.

c. Rem ove the fla nge nut, f lange and s leeve f rom

the mainshaft.

Figure 7B1-151

13. With the transmission in a horizontal position,

install a new seal into transmission case rear

section us ing Tool No. J-2 1426 or sim ilar, after

coating the seal lip with transmission lubricant.

14. Also lubricate the seal surface of mainshaft

sleeve with transmission lubricant and install

over the mainshaft.

Figure 7B1-152

15. Reinstall mainshaft flange and toothed ring

assembly to the mainshaft.

16. Apply Loctite 242 or 243 or equivalent, to the

splines of the mainshaft flange a nd t he c l ean ed

threads of the flange nut. Install the flange to

the mainshaft.

17. W hile hold ing the f la nge with Tool No. K M-620-

1-A, tighten the nut to fully install the output

flange and then tighten the flange nut to the

correct torque specification.

MAINSHAFT FLANGE NUT

TORQUE SPECIFICATION 100 Nm

Figure 7B1-153

18. Apply a smear of sealant such as Loctite 574

(or equivalent) to the section of the rear case

that supports the reverse idler shaft.

19. Reinstall reverse idler gear (1) into position,

with the groove fac ing for war d.

20. Lubricate the reverse idler gear shaft needle

roller bearings with tr ansmis sion lubrica nt, then

insert the shaft through the gear and into the

rear case, aligning the threaded hole with the

locating bolt hole in the rear transmission case.

21. Apply sealant such as Loctite 242 or 243 or

equivalent, to the under-head portion of the

reverse idler gear shaft fastening bolt (4),

install and tighten to the correct torque

specification.

REVERSE IDLER GEAR SHAFT

REAR LOCATING BOLT

TORQUE SPECIFICATION 25 Nm

NOTE: Do not tighten the thrust plate (3) retaining

bolt (2) at this time.

Figure 7B1-154

22. Reduc e the width of a piec e of f eeler gaug e (1)

0.040 mm thick, sufficient to fit between the

reverse idler gear and the retainer (2).

23. Insert the feeler gauge (1) and, while holding

the retainer (2) against the feeler gauge,

tighten the retaining bolt to the correct torque

specification.

REVERSE IDLER GEAR THRUST

PLATE RETAINING BOLT

TORQUE SPECIFICATION 25 Nm

NOTE: This operation is necessary to centre the

retaining plate with the reverse idler gear. Failure

to carr y out this operat ion wil l result i n transm is sion

noise.

Figure 7B1-155

24. Apply a thin coating of petroleum jelly to

gearshift operating shaft rollers, then install

shaft (3) into the rear of the transmission

housing, aligning the rollers with the internal

selector arm and the shaft with the selector

arm (1).

25. Align the selector arm (1) roll pin hole with the

operating shaft hole, support the shaft (3) with

a suitable size wooden wedge (2), then install

a new roll pin to the arm and shaft.

Figure 7B1-156

26. Insert the three detent balls and pressure

springs (2) into transmission case.

27. Apply thread sealant such as Loctite 242 or

243 or equ ivale nt, to the c l eane d thre ads of the

attaching bolts, then install pressure spring

cover (1) and t ighten bolts t o the c orrec t torqu e

specification.

SHIFT DETENT SPRING

COVER BOLT

TORQUE SPECIFICATION 10 Nm

Figure 7B1-157

28. Lubricate gearshift shaft seal lips with

transmission fluid, then install the seal into the

rear transmission housing, using a suitable

length and size of tubing, until the seal is flush

against the rear transmission housing.

29. Reinstall gearshift trunnion (3) to the gearshift

selector rod shaft (1) and secure with the

retaining pin (2).

30. Lever the spring steel retaining ring (4) over

the pin (2), then rotate to completely cover the

pin.

31. Select 4th gear and check that all remaining

synchronisers are loosely seated against their

respective gear cones. If necessary, loosen

firmly seated ring/s from gear cone/s.

Figure 7B1-158

32. Pr eheat tr ansmiss ion case fr ont section i n are a

of maindrive bearing to approximately 80° C

using a commerc ially avai la ble hot air blo w er.

NOTE: Apply Faber Castell Thermochrom

2815/80° C around bearing area of transmission

case to indicate temperature. .

33. Using a suitable sleeve acting on the outer

bearing ring, press bearing fully home to the

flange in transmission case front section.

34. Reinstall reverse block assembly to the

transmission case, by using a plastic faced

hammer. Apply Loctite 574 or equivalent, to the

sealing surface of the retaining bolt. Tighten to

the correct torque specification.

REVERSE BLOCK BOLT TO

TRANSMISSION FRONT CASE

TORQUE SPECIFICATION 10 Nm

Figure 7B1-159

35. Apply a bead of Loctite 574 sealant or

equivalent, to sealing surface of transmission

case an d the fr ont bolt hole of the rev erse idl er

shaft.

36. Position f r ont sec ti on of tr a nsmiss ion cas e o nto

rear section, aligning shift rods with front

section bore hol es .

Figure 7B-160

37. Install Tool No. KM-461 as shown and draw

the input shaft into the front bearing, using a

socket bar (1).

38. Remove Tool No. KM-461 and install selective

washer and retaining ring to maindrive gear.

Selective washers are available in thicknesses

of 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm and 2.5

mm.

NOTE: The specified clearance between the

selective washer and the front bearing hub is from

0.00 - 0.09 mm.

39. Place transmission into neutral position and

rotate maindrive gear to check that no

synchroniser rings have become jammed on

gear cones.

Figure 7B1-161

40. Install new dowel pins to align the front and

rear transmission cases, prior to installing and

tightening the attaching bolts to the correct

torque specification. Note the location of the

longest bolt (bold arrow).

TRANSMISSION REAR CASE

TO FRONT CASE BOLT

TORQUE SPECIFICATION 25 Nm

41. Reinstall the exhaust pipe support bracket (2),

securing with two bolts (1), tightened to the

correct torque specification.

EXHAUST PIPE SUPPORT

BRACKET BOLT

TORQUE SPECIFICATION 25 Nm

Figure 7B1-162

42. Apply sealant such as Loctite 242 or 243 (or

equivalent) to the under-head portion of the

reverse idler gear s haf t, f ront fas tening bolt ( 1),

reinstall and tighten to the correct torque

specification.

REVERSE IDLER GEAR SHAFT

FRO NT LOCATING BOLT

TORQUE SPECIFICATION 25 Nm

Figure 7B1-163

43. Prior to installing the clutch throwout bearing

guide, the compensating shim thickness must

be determined, as follows:

a. With the front bearing distance ring installed,

use a depth gauge to measure the distance

between the front edge of the b earing dista nce

ring and the transmission case, noting the

measurement.

Figure 7B1-164

b. After removing any shims, measure the depth

of the counterbore in the clutch throwout

bearing guide, not ing the measurement.

c. Subtr act m easurem ent ‘a’ from ‘b’ to determ ine

the compensating shim stack required.

e.g. Front Bearing Ring Protrusion = 5.5 mm

Throwout Counterbore Depth = 6.0 mm

Shim thickness = 0.5 mm

Selective shims are available in thicknesses of

0.3 mm, 0.4 mm and 0.5 mm.

Figure 7B1-165

44. Apply a thin coating of Loctite 574 (or

equivalent), to the mounting face of the clutch

throwout bearing retaining plate.

45. Lubricate seal with transmission fluid, then

install throwout bearing guide assembly (2).

46. Apply sealant such as Loctite 574 or

equivalent, to the cleaned threads of the

fastening bolts (1) to the correct torque

specification.

THROWOUT BEARING GUIDE

RETAINING BOLT

TORQUE SPECIFICATION 10 Nm

NOTE: The bearing guide assembly can only be

installed in the one correct position.

Figure 7B1-166

47. Lubricate throwout bearing guide sleeve,

maindrive gear teeth, release lever,

throwout bearing and ball headed pin

with high temperature grease. Refer to

Section 7A1 CLUTCH in the MY 2003 VY

and V2 Series Ser v ice Infor mation.

48. Reinstall clutch throwout bearing to the clutch

release lever, then install the bearing/lever

assembly, securing to the pivot ball with the

spring clip.

49. Push the bearing fully in, to maintain position

on the lever, until the transmission is installed

and the slave cylinder is reinstalled.

Figure 7B-167

50. Insert detent pin and pressure spring into

transmission case.

NOTE: Ensure that detent pin is ins t al led wit h r ol ler

in a horizontal position, as shown.

51. Reinstall detent spring closure plug, after

coating with sealant such as Loctite 574 (or

equivalent).

Figure 7B1-168

52. Reinstall back-up lamp switch to transmission

case and tighten to the correct torque

specification.

BACK-UP LAMP SWITCH

TORQUE SPECIFICATION 20 Nm

Figure 7B1-169

53. Install drain plug (2) and tighten to the correct

torque specification.

TRANSMISSION DRAIN PLUG

TORQUE SPECIFICATION 50 Nm

54. F ill transm is sion with appr oximatel y 1.2 litres of

80W gear oil, such as Castrol VMX80W or

equivalent.

55. Reinstal l fil ler plu g (1) an d tight en to the cor rec t

torque specification.

TRANSMISSION FILLER PLUG

TORQUE SPECIFICATION 50 Nm

Figure 7B1-170

56. Reinstall transmission into vehicle. Refer to

4.2 TRANSMISSION ASSEMBLY in this

Section.

5. DIAGNOSIS

CONDITION PROBABLE CAUSE CORRECTION

TRANSMISSION SHIFT

HARD/HEAVY Clutch pedal high effort.

Shifter shaft binding.

Internal bind in transmission caused

by shift forks, selector shafts or

synchromes h assemblies.

Incorrect lubr ica nt.

Lubricate or replace as required.

Check for mispositioned shift fork roll

pin/s, loose bolts, worn shifter shaft or

shaft bores or distorted oil seal.

Repair as necessary.

Remove, disa ss em ble and ins pect

transmission. Replac e worn or

damaged components as necessary.

Drain and refill transmission.

GEAR CLASH WHEN SHIFTING

FROM ONE GEAR TO ANOTHER Lubricant level low or incorrect

lubricant.

Gearshift components or

synchromesh assemblies worn or

damaged.

Drain and refill transmission and

check for lubricant leaks if level was

low. Repair as necessary.

Remove, disa ss em ble and ins pect

transmission. Replac e worn or

damaged components as necessary.

TRANSMISSION NOISY Lubricant level low or incorrect

lubricant has been used.

Transmission housing to engine

attaching.

Gearshift mechanism, transmission

gears or bearing components worn or

damaged.

Drain and refill transmission. If

lubricant was low, check for leaks and

repair as necessary .

Check and correct bolt torque settings

as necessary.

Remove, disa ss em ble and ins pect

transmission. Replac e worn or

damaged components as necessary.

JUMPS OUT OF GEAR Gearshift mechanism, shift forks,

selector shafts, interlock pin, detent

balls/springs, worn or damaged.

Gear teeth worn or tapered,

synchromesh assemblies worn or

damaged.

Remove, disa ss em ble and ins pect

transmission assembly. Replace worn

or damaged components as

necessary.

Remove, disa ss em ble and ins pect

transmission. Replace all worn or

damaged components as necessary.

WILL NOT SHIFT INTO ONE GEAR Gearshift selector shaft/s, interlock pin

or selector arm, worn, damaged or

incorrectly assembled.

Synchromesh sleeves or hubs, worn

or damaged.

Remove, disa ss em ble and ins pect

transmi ssi on sel ector assembl ies.

Repair or replace components as

necessary.

Remove, disa ss em ble and ins pect

transmission. Replac e worn or

damaged co mpo nent s.

LOCKED IN ONE GEAR -

CANNOT BE SHIFTED OUT Shift shaft/s worn or damaged,

selector fork bent or broken.

Gearshift mechanism worn, damaged

or broken. Worn or damaged gear

train components.

Inspect and replace worn or damaged

components.

Disassemble transmission. Replace

damaged part s or assemble c orrect ly .

TRANSMISSION WILL NOT SHIFT

INTO REVERSE (ALL OTHERS OK) Worn or damaged internal

components.

Reverse block mechanism jammed

Remove transmission. Check for

damaged reverse gear trai n

components.

Dismantle transmission, inspect and

replace components as necessary.

6. SPECIFICATIONS

TRA NSMISSION:

V6 Powered Vehicles.............................................. Getrag, Type 260 - 5 Speed Manual Transmission,

Overdrive 5th Sp eed , Pro d uc tion Option M35

TRANSMISSION RATIOS:

1st ...................................................................... 3.829:1

2nd..................................................................... 2.199:1

3rd...................................................................... 1.401:1

4th...................................................................... 1.000:1

5th...................................................................... 0.809:1

Reverse.............................................................. 3.456:1

NUMBER OF TEETH:

Maindrive Input Gear............................................... 26

Mainshaft Gear

1st ...................................................................... 41

2nd..................................................................... 37

3rd...................................................................... 30

5th...................................................................... 26

Reverse.............................................................. 37

Reverse Idler Gear.................................................. 21

Cluster Gear Input................................................... 34

Cluster Gear

1st/Reverse........................................................ 14

2nd..................................................................... 22

3rd...................................................................... 28

5th...................................................................... 42

SYNCHROM ESH ASSEMBLIES:

Synchromesh Ring Wear

New Clearance .................................................. 1.0 - 1.3 mm

Replacement Clearance .................................... less than 1.0 mm

Synchromesh Ring identification

1st, 2nd .............................................................. 040.8.0001.00

3rd, 4th............................................................... 002.8.0301.00

5th/Reverse........................................................ 011.8.0331.10

011.8.0331.11 (optional)

END FLOAT CLEARANCES:

Maindrive Gear........................................................ 0.00 - 0.09 mm

Cluster Gear............................................................ 0.13 - 0.23 mm

SELECTIVE SNAP RING THICKNESSES:

3rd/4th Synchromesh Assembly............................. 2.0, 2.1, 2.2, 2.3, 2.4, 2.5 mm

1st/2nd Synchromesh Assembly............................. 1.8, 1.85, 1.9, 1.95, 2.0 mm

5th/Reverse Synchromesh Assembly..................... 1.8, 1.85, 1.9, 1.95, 2.0 mm

SELECT IVE SHIM/WASHER THICKNESSE S:

Throwout Bearing Guide to Input Shaft Bearing..... 0.3, 0.4, 0.5 mm

Input Shaft Bearing ................................................. 2.1, 2.2, 2.3, 2.4, 2.5 mm

Cluster Gear End Float Adjusting ........................... 1.0, 1.7, 1.8, 2.0, 2.1, 2.2, 2.3 mm

LUBRICANT:

Type ........................................................................ 80W Gear Oil, such as Castrol VMX80W or equivalent.

Capacity (Nominal).................................................. 1.2 litres

SEALANTS:

Thread Sealant in nominated locations................... Loctite 242 or 243 or equivalent.

Transmission Case Mat in g Sur f ac es, Clutch

Throwout Guide Sleeve to Front Case and

other nominated locations.................................. Loctite 574 or equivalent.

7. TORQUE WRENCH SPECIFIC ATIONS

Backup Lamp Switch ........................................................................................ 20

Centre Bearing Carrier to Underbody Reinforcement Bolt ............................... 23

Clutch Housing to Engine Block and Oil Pan Bolt ............................................ 85

Clutch Actuating Cylinder Retaining Nut........................................................... 22

Exhaust Pipe Su ppor t Brack et Bolt.............................................................. 25

Flywheel Close-out Cover Attaching Screw................................................. 10

Gearshift Ball Socket Retainer Plate Nuts .................................................. 10

Gearshift Brace Rear Rubber Mount to Underfloor Bolt.............................. 10

Gearshift Lever Bracket to Underfloor......................................................... 10

Gearshift Linkage Rear Rubber Mounting Nut ............................................ 22

Gearshift Selector Rod Bush Securing Screw............................................. 20

Locking Lever Screw Plug ........................................................................... 48

Mainshaft Flange Nut .................................................................................. 100

Propeller Shaft Rubber Coupling to Transmission Output Flange Nut........ 78

Propeller Shaft Rear Universal Joint Flange to Pinion Flange Bolt............. 58

Rear Mount to Transmission Lug Nut ......................................................... 25

Rear Mount to Crossmember Nut................................................................ 25

Rear Crossmember to Side Frame Member Bolt ........................................ 58

Rear Bearing Plate and Locking Lever Bolt................................................. 10

Reverse Block, Retaining Bolt ..................................................................... 10

Reverse Idler Gear Shaft Locating Bolt (Front or Rear) .............................. 25

Reverse Idler Gear Thrust Plate Retaining Bolt .......................................... 25

Shift Detent Spring Cover Bolt .................................................................... 10

Speed Sensor to Bracket Screw ................................................................. 10

Speed Sensor Bracket to Transmission Housing Bolt................................. 18

Throwout Bearing Guide Assembly Bolt...................................................... 10

Transmission Drain Plug ............................................................................. 50

Transmission Filler Plug .............................................................................. 50

Transmission Rear Case to Front Case Attaching Bolt............................... 25

Transmission Rear Mounting to Case Nuts................................................. 25

Transmission Rear Mounting to Rear Crossmember.................................. 58

8. SPECIAL TOOLS

TOOL NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

AKM-628-A EX TR A CTOR TOO L

Used to remove the mainshaft

flange and to separate the two

transmission housings on

disassembly.

Unique

AU454

GEAR REMOV ER PLAT ES

Used to remove 3rd/4th

synchromesh assembly, 3rd speed

gear, 2nd speed gear and related

components from the mainshaft.

Unique

AU462

SELECT LEVER SPRING AND

BUSH INSTALLER

Used to load the select lever spring

and components for reassembly

into transmission rear housing.

Previously released

Unique

E308

SEAL REMOVER

Used as a universal seal remover.

Also previo us l y releas ed as 56750.

Desirable

J-21426 SEAL INSTALLER

Previously released for 4L60-E

automatic transmission.

Unique

J-22912-01

PRESS PLATES

Also previousl y released as E6673. Desirable

KM-328-B

SLIDE HAMMER

Includes Cup KM-328-5-A and pin.

Previously released.

Unique

KM-328-7-A PULLER LEG S

Modify as detailed. Use with spacer

KM-328-9 and slide hammer KM-

328-B to remove bearings from the

transmission case.

Previously released.

Unique

8. SPECIAL TOOLS (Continued)

TOOL NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

KM-328-9

SPACER

Used with legs KM-3 28- 7-A and

slide hammer KM-328-B.

Previously released

Unique

KM-409-A

INSTALLER

Used to install the shift rod bearing

into the front transmission housing.

Previously released

Unique

KM-454-A REMOVER/INSTALLER

Used to remove and install cluster

gear bearing cups.

Previously released

Unique

KM-461-C

INSTALLER

Used to assemble the two

transmission housings on

reassembly.

Previously released

Unique

KM-500-3

SLEEVE

Previously released.

Used for various pressing

operations as described in the text.

Previously released

Unique

KM-556-1-A

PULLER

Part of Puller Kit KM-556-A.

Previously released

Unique

KM-620-1-A FLANGE HOLDING TOOL

Modified from the previously

released tool as detailed in the text.

Unique