MANUAL TRANSMISSION

Page
DESCRIPTION MT-2
PRECAUTIONS MT-4
TROUBLESHOOTING MT-4
REMOVAL AND INSTALLATION OF
TRANSMISSION MT-5

(G40 AND G52 TRANSMISSIONS)

COMPONENTS MT-12
DISASSEMBLY OF TRANSMISSION MT-15
COMPONENT PARTS MT-24
Input Shaft Assembly MT-24
Output Shaft Assembly MT-26
Counter Gear Assembly and Reverse
Idler Gear MT-35
Transfer Adaptor MT-39
Front Bearing Retainer MT-41
ASSEMBLY OF TRANSMISSION MT-42

(H41 AND H55F TRANSMISSIONS)

COMPONENTS MT-54
DISASSEMBLY OF TRANSMISSION MT-56
COMPONENT PARTS MT-62
Input Shaft Assembly MT-62
Output Shaft Assembly MT-64
Counter Gear Assembly MT-71
Transfer Adaptor MT-74
Front Bearing Retainer MT-76
Case Cover Assembly MT-77
Transmission Case Assembly MT-89
ASSEMBLY OF TRANSMISSION MT-92

(R141F, R150F AND R151F

TRANSMISSIONS)
COMPONENTS MT-99
DISASSEMBLY OF TRANSMISSION MT-101
COMPONENT PARTS MT-109
Input Shaft Assembly MT-109
Output Shaft Assembly MT-111
Counter Gear Assembly and Reverse
Idler Gear MT-119
Transfer Adaptor MT-122
Front Bearing Retainer MT-124
ASSEMBLY OF TRANSMISSION MT-125


11
MT-2 MANUAL TRANSMISSION - Description
i'

DESCRIPTION
• Transmission types, G40, G52, H41, H 55F, R 141 F, R1 50F AND R 151 F are constant mesh synchroniz
for forward gears and a sliding mesh reverse gear .
• The illustrations below show the engagements of transmission gears .

1st

Input Shaft

2nd

Input Shaft
lk

3rd

Input Shaft

GM0443

MANUAL TRANSMISSION - Description IYI I - v

t- `

Input Shaft
a

Input Shaft
10 .1

I
Counter 5th Gear

Reverse Gear

Input Shaft
I

A-A'
Reverse
Idler Gear

• The above illustration shows a G type transmission . The configuration of each gear is slightly
different to W and R type transmissions but the gear engagements are the same .

MT0502 GM0443


MT-4 MANUAL TRANSMISSION - Precautions, Troubleshooting

PRECAUTIONS
When working with FIPG material, you must be observe the following .
• Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces .
• Thoroughly clean all components to remove all the loose material .
• Clean both sealing surfaces with a non-residue solvent .
• Apply the seal packing in approx . 1 mm (0 .04 in .) bead along the sealing surface .
• Parts must be assembled within 10 minutes of application . Otherwise, the packing (FIPG) material mus
be removed and reapplied .

TROUBLESHOOTING
Problem Possible cause Remedy Page
Hard to shift or will Splines on input shaft dirty or burred Repair as necessary MT-5
not shift Transmission faulty Disassemble and inspect MT-5
transmission
Transmission jumps Transmission faulty Diassemble and inspect MT-5
out of gear transmission
 REMOVAL AND INSTALLATION OF
TRANSMISSION
COMPONENTS

Vacuum Hose

Shift Lever

=Y' ,0 0

120(9,12)
Starter

Rear Propeller Shaft

Front Propeller Shaft

MT0698
 MT-6 MANUAL TRANSMISSION - Removal and Installation of Transmission

REMOVAL OF TRANSMISSION
1. DISCONNECT BATTERY CABLE FROM NEGATI
TERMINAL

2. LOOSEN FAN SHROUD OF THE COOLING FAN TO AVO

DAMAGE TO FAN

3. REMOVE SHIFT LEVER

(a) Remove the four bolts and shift lever boot .

(b) Cover the shift lever cap with a cloth .

(c) Then, pressing down on the shift lever cap, rotate
counterclockwise to remove .
(d) Remove the shift lever .

4. RAISE VEHICLE

5. DISCONNECT PROPELLER SHAFT

(See page PR-2)

6. REMOVE STIFFENER PLATE

Remove the four bolts and stiffener plate .

7. REMOVE CLUTCH RELEASE CYLINDER

Remove the two bolts and clutch release cylinder .

i
8 . REMOVE STARTER
Remove the bolt, nut and starter .

9. (VACUUM SHIFT TYPE)

REMOVE VACUUM HOSE

10 . REMOVE 4WD AND BACK-UP LIGHT SWITCH

CONNECTOR

11 . (VACUUM SHIFT TYPE)

REMOVE L4 SWITCH CONNECTOR

12 . REMOVE SPEEDOMETER CABLE

Using pliers, remove the speedometer cable .

13 . REMOVE EXHAUST PIPE

MT-8 MANUAL TRANSMISSION - Removal and Installation of Transmission

14 . REMOVE CROSSMEMBER
Remove the eight bolts, two nuts and crossmember,

15 . REMOVE REMAINING TRANSMISSION BOLTS

16 . REMOVE TRANSMISSION
Remove transmission toward the rear .
 . .a. .~ .vvu . u .w . .waaa .wa ~

INSTALLATION OF TRANSMISSION
1. INSTALL TRANSMISSION
Install and torque the bolts .
Torque : 730 kg-cm (53 ft-lb, 27 N •m )

2. INSTALL CROSSMEMBER
Install and torque the eight bolts and two nuts .
Torque : bolt 400 kg-cm (29 ft-lb, 39 N •m )
nut 600 kg-cm (43 ft-lb, 59 N •m )

3. INSTALL EXHAUST PIPE

4. INSTALL SPEEDOMETER CABLE

Using pliers, install the speedometer cable .

5. (VACUUM SHIFT TYPE)

INSTALL L4 SWITCH CONNECTOR

6. INSTALL 4WD AND BACK-UP LIGHT SWITCH

7. (VACUUM SHIFT TYPE)

INSTALL VACUUM HOSE
MT-10 MANUAL TRANSMISSION - Removal and Installation of Transmission

8. INSTALL STARTER
Install the bolt, nut and starter .

9. REMOVE CLUTCH RELEASE CYLINDER

(a) Install the clutch release cylinder .

(b) Install and torque the two bolts .

Torque : 120 kg-cm (9 ft-Ib, 12 N •m )

10 . INSTALL STIFFENER PLATE

(a) Install the stiffener plate .
(b) Install and torque the four bolts .
Torque : 700 kg-cm (51 ft-lb, 69 N •m )

11 . CONNECT PROPELLER SHAFT

(See page PR-2)

12 . LOWER VEHICLE

13 . INSTALL SHIFT LEVER

(a) Align the groove of the shift lever cap and the pin p
of the case cover .
(b) Cover the shift lever cap with a cloth .
(c) Then, pressing down on the shift lever cap, rotate
clockwise to install .
(d) Install the shift lever boot with four bolts .
1- -jr- , nr1,va .nwawul - nemoval ana insiailaton OT I ransmission nnI- -iI

14 . TIGHTEN FAN SHROUD SET BOLT

15 . CONNECT BATTERY CABLE TO NEGATIVE TERMINAL

16 . PERFORM ROAD TEST

Check for abnormal noise and smooth operation .


MANUAL TRANSMISSION (R141F, R150F, R151F) - Components MT-99

(R 141 F, R 150F, R 151 F

TRANSMISSIONS)
COMPONENTS

Back-up Light Switch

380(27,37) Shift Lever Retainer

*Straight Screw Plug *185 (13, 18)

190 (14, 19)
Restrict Pin
380 (27, 37)

Transfer
®ame0
Adaptor

p•

*Front Bearing Retainer

Clutch Housing
380 (27, 37)
Transmission Case

380(27,37)

* 170 (12, 17)

g *Straight Screw Plug

9
370 (27, 36) Spring
®`( mo o o Ball

Shift Fork Shaft No . 2

0 Reverse Shift
200 (14 201 Arm Bracket
@9T_
0 18503,18)
Reverse Shift
Shift Fork Shaft 0 Shift Fork Shaft No . 5 w Arm
No . 1
Shift Fork 0
No. 2 .
0
Shift Fork Shaft 0
No. 3 f
Shift Fork No . 1 Reverse Shift Head

Shift Fork Shaft No . 4 0

0 390 (28, 38)
0
Reverse Shift Fork

Shift Fork No . 3

Shift Lever Housing

Shift Lever Shaft
Ikg-cm(ft-lb, N-m) Specified torque
Non-reusable part
* Precoated part RM0330


MT-100 MANUAL TRANSMISSION (R141F, R150F, R151F) - Components

Components (Cont'd)

Ball Bearing Synchronizer Ring Ball Bearing

Input Shaft

Snap Ring Sleeve

Snap Ring

Spacer Gear Spline Piece No. 5

Intermediate Plate __11

Rear Bearing Retainer

Ball Bearing &~'
Counter Gear

Synchronizer Ring
Thrust Washer Hub Sleeve No . 3

Roller Bearing Counter 5th Gear

Snap Ring
Reverse Idler Gear
Reverse Idler Gear Shaft

3rd Gear

Shifting
Key Spring

Snap Ring

Clutch Hub No . 1

Synchronizer Ring Shifting Key Spring

kg-cm (ft-lb, N • m) Specified torque

• Non-reusable part RMOO
MANUAL TRANSMISSION (R141F, R150F, R151F) - Disassembly of Transmission MT-101

DISASSEMBLY OF TRANSMISSION
(See pages MT-99, 100)
1 . REMOVE RELEASE FORK AND BEARING

2. REMOVE TRANSFER
(See page TF-4)

3. REMOVE BACK-UP LIGHT SWITCH, SHIFT LEVER

RETAINER AND RESTRICT PINS

4. REMOVE CLUTCH HOUSING FROM TRANSMISSION

CASE

5. REMOVE STRAIGHT SCREW PLUG, SPRING AND BALL

(a) Using a torx socket wrench, remove the screw plug
from the extension housing or transfer adaptor .
(Torx socket wrench T40 09042-00020)

(b) Using a magnetic finger, remove the spring and ball .

6. REMOVE TRANSFER ADAPTOR

(a) Remove the shift lever housing set bolt .

(b) Remove the ten bolts .

(c) Using a plastic hammer, tap the transfer adaptor and
remove the shift lever housing and shift and select
lever .
MT-102 MANUAL TRANSMISSION (R141F, R150F, R151F) - Disassembly of Transmission

7. REMOVE FRONT BEARING RETAINER

(a) Remove the eight bolts .
(b) Using a plastic hammer, tap the front bearing retainer .

8. REMOVE BEARING SNAP RINGS

Using snap ring pliers, remove the two snap rings .

9. SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION

CASE
(a) Using a brass bar and hammer, carefully tap off the
transmission case .
(b) Remove the transmission case from the intermediate
plate .

10 . REMOVE MAGNET FROM INTERMEDIATE PLATE

11 . MOUNT INTERMEDIATE PLATE IN VISE

(a) Use two clutch housing bolts, plate washers and suita-
ble nuts as shown .
NOTICE : Install the plate washers in reverse of normal .
Increase or decrease plate washers so that the bolt tip and
front tip surface of the nut are aligned .
(b) Mount the intermediate plate in a vise .
MANUAL TRANSMISSION (R141F, R150F, R151F) - Disassembly of Transmission MT-103

12 . REMOVE STRAIGHT SCREW PLUGS, LOCKING BALLS

AND SPRINGS
(a) Using a torx socket wrench, remove the four plugs .
(Torx socket wrench T40 09042-00020)

(b) (1315017 and R1 51 F)

Using a magnetic finger, remove the four springs and
balls .
(R141F)
Using a magnetic finger, remove the three springs and
balls .

13 . REMOVE SHIFT FORK SET BOLTS

(R1 50F and R 151 F)
Remove the three bolts .
(R141F)
Remove the two bolts .

14 . REMOVE SNAP RINGS

(R 150F and R 151 F)
Using two screwdrivers and a hammer, remove the three
snap rings .
(R141F)
Using two screwdrivers and a hammer, remove the six snap
rings .

15 . REMOVE SLOTTED SPRING PINS

Using a pin punch and hammer, drive out the two pins .


, , Ia I ~j 19-, - visassemoiy of I ransmission

16 . REMOVE SHIFT FORK SHAFT NO .5

Pull out shift fork shaft No .5 from the intermediate plate .

17 . REMOVE SHIFT FORK SHAFT NO .2 AND SHIFT FORK

(a) Pull out shift fork shaft No .2 from the intermediate
plate .
(b) Remove shift fork No .2 .
(c) Using a magnetic finger, remove the interlock pin from
the intermediate plate .

18 . REMOVE SHIFT FORK SHAFT NO .1

(a) Pull out shift fork shaft No .1 from the intermediate
plate .
(b) Using a magnetic finger, remove the interlock pins
from the shaft hole and intermediate plate .

19 . REMOVE SHIFT FORK SHAFT NO .3 AND SHIFT FORK

NO .1
(a) Pull out shift fork shaft No .3 from the intermediate
plate .
(b) Remove shift fork No .1 .
(c) Using a magnetic finger, remove the interlock pin and
locking ball from the shaft hole and intermediate plate .

20 . (R150F and R151F)

REMOVE SHIFT FORK SHAFT NO .4, SHIFT FORK NO .3
AND REVERSE SHIFT HEAD
(a) Pull out shift fork shaft No .4 from the intermediate
plate .
(b) Remove the reverse shift head and locking ball .
(c) Remove shift fork No .3 .
MANUAL TRANSMISSION (R141F, R150F, R151F) - Disassembly of Transmission MT-105

(R141F)
REMOVE SHIFT FORK SHAFT NO .4 AND REVERSE SHIFT
HEAD
(a) Pull out shift fork shaft No .4 from the intermediate
plate .
(b) Remove the reverse shift head and locking ball .

21 . REMOVE REVERSE SHIFT ARM FROM REVERSE SHIFT

ARM BRACKET

RM0033

22 . REMOVE REVERSE SHIFT ARM BRACKET

Remove the two bolts and the reverse shift arm bracket .

RM0008

23 . REMOVE SLEEVE FROM OUTPUT SHAFT

Using SST, remove the sleeve from the output shaft .
SST 09213-36020

24 . REMOVE OUTPUT SHAFT REAR BEARING

(a) Using two screwdrivers and a hammer, tap out the
snap ring .
(b) Using SST, remove the rear bearing .
SST 09950-20017
MT-106 MANUAL TRANSMISSION (R141F, R150F, R151F) - Disassembly of Transmission

25 . REMOVE SPACER

26 . MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE

Using a feeler gauge, measure the counter 5th gear thrust
clearance .
Standard clearance : 0 .10 - 0 .35 mm
(0 .0039 - 0 .0138 in .)
Maximum clearance : 0 .40 mm (0 .0157 in .)

27 . REMOVE GEAR SPLINE PIECE NO .S, SYNCHRONIZER

RING, NEEDLE ROLLER BEARING AND COUNTER FIFTH
GEAR WITH HUB SLEEVE NO .3
(a) Engage the gear double meshing .

(b) Using a hammer and chisel, loosen the staked part of,
the nut .

(c) Remove the lock nut .

(d) Disengage the gear double meshing .

(e) Using SST, remove gear spline piece No .5 .

SST 09213-31021

(f) Remove the counter 5th gear with hub sleeve No .

MANUAL TRANSMISSION (R141F, R150F, R151F) - Disassembly of Transmission MT-107

28 . REMOVE SHIFTING KEYS AND SPRINGS FROM 5TH GEAR

AND HUB SLEEVE NO .3
Using a screwdriver, remove the three shifting keys and
two springs .

29 . REMOVE THRUST WASHER AND BALL

30 . REMOVE REAR BEARING RETAINER

Remove the four bolts and rear bearing retainer .

31 . REMOVE REVERSE IDLER GEAR AND SHAFT

Pull out the shaft toward the rear .

32 . REMOVE BEARING SNAP RING

Using snap ring pliers, remove the snap ring .
1

MT-108 MANUAL TRANSMISSION (R141F, R150F, R151F) - Disassembly of Transmission

33 . REMOVE OUTPUT SHAFT, COUNTER GEAR AND INPUT

SHAFT AS A UNIT FROM INTERMEDIATE PLATE
(a) Remove the output shaft, counter gear and input shaft
as a unit from the intermediate plate by pulling on the
counter gear and tapping on the intermediate plate
with a plastic hammer .
(b) Remove the input shaft with the needle roller bearing
from the output shaft .

34 . REMOVE COUNTER REAR BEARING FROM INTERMEDI-

ATE PLATE
Using SST, remove the counter rear bearing .
SST 09608-12010 (09608-00020, 09608-00050)

35 . INSPECT BACK-UP LIGHT SWITCH

Check that there is continuity between terminals .

Switch Position Specified

Push Continuity

Free No continuity

If operation is as specified replace switch .


Component Parts
MANUAL TRANSMISSION (14141F, R150F, R151F) - (Input Shaft Assembly) MT-109

COMPONENT PARTS
Input Shaft Assembly
COMPONENTS

INSPECTION OF INPUT SHAFT

INSPECT SYNCHRONIZER RING

(a) Turn the ring and push it into check the braking action .

(b) Measure the clearance between the synchronizer ring

back and the gear spline end .
Standard clearance : 0 .8 - 1 .6 mm
(0 .031 - 0 .063 in .)

Minimum clearance : 0 .6 mm (0 .024 in .)

If the clearance is minimum or less, replace the synchronizer
ring .

REPLACEMENT OF BEARING
IF NECESSARY, REPLACE INPUT SHAFT BEARING

(a) Using snap ring pliers, remove the snap ring .

 MANUAL TRANSMISSION (R141F, R150F, R151F) - Component Parts
MT-110 (Input Shaft Assembly)

(b) Using a press, remove the bearing .

(c) Using a press and SST, install a new bearing .

SST 09506-35010

(d) Select a snap ring that will allow minimum axial play
and install it on the shaft .

Mark Thickness mm (in .)

A 2 .10 - 2 .15 (0 .0827 - 0 .0846)
B 2 .15 - 2 .20 (0 .0846 - 0 .0866)
C 2 .20 - 2 .25 (0 .0866 - 0 .0886)
D 2 .25 - 2 .30 (0 .0886 - 0 .0906)
E 2 .30 - 2 .35 (0.0906 - 0 .0925)
F 2 .35 - 2 .40 (0 .0925 - 0 .0945)
G 2 .40 - 2 .45 (0 .0945 - 0 .0965)


Component Parts
MANUAL TRANSMISSION (R141F, R150F, R151F) -
(Output Shaft Assembly) MT-111

Output Shaft Assembly

COMPONENTS

3rd Gear
Hub Sleeve No . 2
Needle Roller Bearing
Clutch Hub No . 2
Shifting Key Spring

Synchronizer Ring
4f
Snap Ring Shifting Key

Thrust Washer
Straight Pin
Synchronizer Ring Spacer 8
Shifting Key Spring
Hub Sleeve No . 1 11
2nd Gear
Needle Roller Bearing
r~ Center 5th Gear

Needle Roller Bearing

1st Gear
Shifting Key

Clutch Hub No . 1
Synchronizer Ring 185 (13, 18)

Sleeve

k' Spacer
Snap Ring 910
Snap Ring
kg-cm (ft-lb, N • m Specified torque Rear Bearing Retainer RM0320

DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY

1 . REMOVE FIFTH GEAR, CENTER BEARING AND FIRST
GEAR ASSEMBLY

(a) Using a press, remove the 5th gear, center bearing,

thrust washer and 1st gear .

(b) Remove the synchronizer ring .

(c) Remove the straight pin and needle roller bearing .

RM0012

(d) Remove the spacer .

D6594
 Component Parts
MANUAL TRANSMISSION (R141F, R150F, R151F) - (Output Shaft Assembly)
MT-112

2. REMOVE HUB SLEEVE NO .1 ASSEMBLY AND SECOND

GEAR ASSEMBLY
(a) Using two screwdrivers and a hammer, tap out the
snap ring .

(b) Using a press, remove hub sleeve No .1, synchroniz-

er ring and 2nd gear .
(c) Remove the needle roller bearing .

3. REMOVE HUB SLEEVE NO .2 ASSEMBLY AND THIRD

GEAR ASSEMBLY
(a) Using snap ring pliers, remove the snap ring .

(b) Using a press, remove hub sleeve No .2, synchroniz-

er ring and 3rd gear .

U (c) Remove the needle roller bearing .

l 00m ;08 11

E D6599

4. REMOVE SHIFTING KEYS AND SPRINGS FROM HU

SLEEVE ASSEMBLY
Using screwdriver, remove the three shifting keys and w
springs .
HINT : Hub sleeve No .1 and hub sleeve No .2 .

Component Parts
MANUAL TRANSMISSION (R141F, R150F, R151F) (Output Shaft Assembly) MT-113

INSPECT OF OUTPUT SHAFT ASSEMBLY

1. MEASURE EACH GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the thrust clearance

of 1st gear and 3rd gear .
1st gear
Standard clearance : 0 .10 - 0 .45 mm
(0 .0039 - 0 .0177 in .)
Maximum clearance : 0 .55 mm (0 .0197 in .)
3rd gear
Standard clearance : 0 .10 - 0 .25 mm
(0 .0039 - 0 .0098 in .)
Maximum clearance : 0 .30 mm (0 .0118 in .)

(b) Using a dial indicator, measure the thrust clearance

of 2nd gear .
2nd gear
Standard clearance : 0 .10 - 0 .25 mm
(0 .0039 - 0 .0098 in .)
Maximum clearance : 0 .30 mm (0 .0118 in .)

2. CHECK OIL CLEARANCE OF EACH GEAR

Using a dial indicator, measure the oil clearance between
the gear and shaft with the needle roller bearing installed .
Standard clearance :
1st gear 0 .020 - 0 .073 mm
(0 .0008 - 0 .0029 in .)
2nd and 3rd gears 0 .015 - 0 .068 mm
(0 .0006 - 0 .0027 in .)

Maximum clearance : 0 .16 mm (0 .0063 in .)

If the clearance more than the limit, replace the gear nee-
dle roller bearing or shaft .

3. INSPECT OUTPUT SHAFT

(a) Using a micrometer, measure the output shaft flange

thickness .
Minimum thickness : 4 .70 mm (0 .1850 in .)

(b) Using a micrometer, measure the outer diameter of

the output shaft journal .
Minimum diameter :
A 1st gear 38 .860 mm (1 .5299 in .)
B 2nd gear 46 .860 mm (1 .8449 in .)
C 3rd gear 37 .860 mm (1 .4905 in .)
 Component Parts
MANUAL TRANSMISSION (R141F, R150F, R151F) - (Output Shaft Assembly)
MT- 114

(c) Using a dial indicator, check the shaft runout .

Maximum runout : 0 .06 mm (0 .0024 in .)

4. INSPECT SYNCHRONIZER RINGS

(a) Turn the ring and push it into check the braking action .

(b) Measure the clearance between the synchronizer ring

back and the gear spline end .
Standard clearance : 0 .8 - 1 .6 mm
(0 .013 - 0 .063 in .)
Minimum clearance : 0 .6 mm (0 .024 in .)
If the clearance is less than the limit, replace the synchroniz-
er ring .

5. MEASURE CLEARANCE OF SHIFT FORKS AND HUB

SLEEVES
Using a feeler gauge, measure the clearance between the
hub sleeve and shift fork .
Maximum clearance : 1 .0 mm (0 .039 in .)
If the clearance more than the limit, replace the shift fork
or hub sleeve .


MANUAL TRANSMISSION (R141F, R150F, R151F) - Component Parts

(Output Shaft Assembly) MT-115

No . 2 No . 1 ASSEMBLY OF OUTPUT SHAFT ASSEMBLY

1. INSERT CLUTCH HUB NO .1 AND NO .2 INTO HUB SLEEVE
P I ~I
(a) Install the clutch hub and shifting keys to the hub
\\\
Front sleeve .
F (b) Install the shifting key springs under the shifting keys .
NOTICE : Install the key springs positioned so that their
W \\\\
end gaps are not in line .
A._
D6635 D6644

2. INSTALL THIRD GEAR AND HUB SLEEVE NO .2 ON OUT-

PUT SHAFT
(a) Apply gear oil to the shaft and needle roller bearing .
(b) Place the synchronizer ring on the gear and align the
ring slots with the shifting keys .
(c) Install the needle roller bearing in the 3rd gear .

D6638

(d) Using a press, install the 3rd gear and hub sleeve No .2 .

GM0060

3. INSTALL SNAP RING

(a) Select a snap ring that will allow minimum axial play .

Mark Thickness mm (in .)

A 1 .80 - 1 .85
(0 .0709 - 0 .0728)
B 1 .85 - 1 .90
(0 .0728 - 0 .0748)
C 1 .90 - 1 .95
(0 .0748 - 0 .0768)
D 1 .95 - 2 .00
(0 .0768 - 0 .0787)
E 2 .00 - 2 .05
(0 .0787 - 0 .0807)
F 2 .05 - 2 .10 (0 .0807 - 0 .0827)
G 2 .10 - 2 .15 (0 .0827 - 0 .0846)

(b) Using snap ring pliers, install the snap ring .

 Component Parts
MANUAL TRANSMISSION (R141F, R150F, R151F) - (Output Shaft Assembly)
MT- 116

4. MEASURE THIRD GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 3rd gear thrust
clearance .
Standard clearance : 0 .10 - 0 .25 mm
(0 .0039 - 0 .0098 in .)

5. INSTALL SECOND GEAR AND NO .1 HUB SLEEVE

(a) Apply gear oil to the shaft and needle roller bearing .
(b) Place the synchronizer ring on the gear and align the
ring slots with the shifting keys .
(c) Install the needle roller bearing in the 2nd gear .

(d) Using a press, install the 2nd gear and hub sleeve
No .1 .

6. INSTALL SNAP RING

(a) Select a snap ring that will allow minimum axial play .

Mark Thickness mm (in .)

A 2 .30 - 2 .35 (0 .0906 - 0 .0925)
B 2 .35 - 2 .40 (0 .0925 - 0 .0945)
C 2 .40 - 2 .45 (0 .0945 - 0 .0965)
D 2 .45 - 2 .50 (0 .0965 - 0 .0984)
E 2 .50 - 2 .55 (0 .0984 - 0 .1004)
F 2 .55 - 2 .60 (0 .1004 - 0 .1024)
G 2 .60 - 2 .65 (0 .1024 - 0 .1043)

(b) Using a screwdriver and hammer, install the snap rind



MANUAL TRANSMISSION (R141F, R150F, R151F) - Component Parts

(Output Shaft Assembly) MT- 1 1 7

7 . INSTALL SPACER AND FIRST GEAR ASSEMBLY

(a) Install the spacer on the output shaft .
∎I
1
34
Arks

D6654

(b) Apply gear oil to the needle roller bearing .

(c) Assemble the 1st gear, synchronizer ring and needle
i roller bearing .
(d) Install the assembly on the output shaft with the syn-
chronizer ring slots aligned with the shifting keys .

D6656

8. INSTALL STRAIGHT PIN AND FIRST GEAR THRUST

WASHER
Install the 1st gear thrust washer onto the output shaft with
the straight pin aligned with the slit of 1st gear thrust
washer .

D6593

9. INSTALL OUTPUT SHAFT CENTER BEARING

Using SST, drive in the bearing with the outer race snap
ring groove toward the rear .
SST 09316-60010 (09316-00010, 09316-00070)

SST

RM0086

10 . MEASURE FIRST GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 1st gear thrust clearance .
Standard clearance :
1st gear 0 .10 - 0 .45 mm
(0 .0039 - 0 .0177 in .)

D6658
 Component Parts
MANUAL TRANSMISSION (R141F, R150F, R151F) - (Output Shaft Assembly)
MT-118

11 . MEASURE SECOND GEAR THRUST CLEARANCE

Using a dial indicator, measure the 2nd gear thrust
clearance .
Standard clearance :
2nd gear 0 .10 - 0 .25 mm
(0 .0039 - 0 .0098 in .)

12 . INSTALL FIFTH GEAR

Using SST and a press, install the 5th gear .
SST 09316-60010 (09316-00030)


Component Parts (Counter
MANUAL TRANSMISSION (R141F, R150F, R151F) - MT-119
Gear and Reverse Idler gear)

Counter Gear and Reverse Idler Gear

COMPONENTS

Snap Ring Counter Gear

V_

o)
W Reverse Idler Gear Shaft

Synchronizer Ring
Reverse Idler Gear-
Shifting Key Spring

C ounter Gear Front Bearing

Counter 5th Gear

Ball

Counter Gear Rear Bearing

Gear Spline
Piece No . 5
Bearing
Shifting Key
Thrust Washer
Hub Sleeve No. 3

• Non-reusable part RM0325

INSPECTION OF COUNTER GEAR

1. CHECK OIL CLEARANCE OF 5TH GEAR
(a) Install the spacer, counter 5th gear and needle roller
bearings .

(b) Using a dial indicator, measure the counter 5th gear

oil clearance .
Standard clearance : 0 .015 - 0 .068 mm
(0 .006 - 0 .0027 in .)
E3271 Maximum clearance : 0 .16 mm (0 .0063 in .)
If the clearance exceeds the limit, replace the gear, bear-
ing or shaft .

2. REMOVE HUB SLEEVE NO .3, SHIFTING KEYS AND

SPRINGS FROM COUNTER 5TH GEAR
Using a screwdriver, remove the three shifting keys and
the two springs from the counter 5th gear .


Component Parts (Counter

MANUAL TRANSMISSION (R141F, R150F, R151F) -
MT-120 Gear and Reverse Idler gear)

3. INSPECT COUNTER GEAR

Using a micrometer, measure the outer diameter of the
counter gear journal .
Minimum diameter : 27 .860 mm (1 .0968 in .)

4. INSPECT SYNCHRONIZER RINGS

(a) Turn the ring and push it into check the braking action .

(b) Measure the clearance between the synchronizer ring

back and the gear spline end .
Standard clearance : 0 .8 - 1 .6 mm
(0 .031 - 0 .063 in .)
Minimum clearance : 0 .6 mm (0 .024 in .)
If the clearance is less than the limit, replace the synchroniz-
er ring .

5. MEASURE CLEARANCE OF SHIFT FORKS AND HUB

SLEEVES
Using a feeler gauge, measure the clearance between the
hub sleeve and shift fork .
Maximum clearance : 1 .0 mm (0 .039 in .)
If the clearance more than the limit, replace the shift fork
or hub sleeve .

6. INSTALL HUB SLEEVE NO .3 SHIFTING KEYS AND

SPRINGS TO COUNTER 5TH GEAR

(a) Install the counter 5th gear and shifting keys to the
hub sleeve .

(b) Install the shifting key springs under the shifting keys
Front
NOTICE : Install the key springs positioned so that thel
end gaps are not in line .

D6670 D6668
 Component Parts (Counter
MANUAL TRANSMISSION (R141F, R150F, R151F) -
G
Gear and Reverse Idler gear) MT-121

INSPECTION OF REVERSE IDLER GEAR

1. MEASURE CLEARANCE OF REVERSE IDLER GEAR AND
SHIFT ARM SHOE
Using a feeler gauge, measure the clearance between the
reverse idler gear and shift arm shoe .

Standard clearance : 0 .05 - 0 .25 mm

(0 .0020 - 0 .0098 in .)
Maximum clearance : 0 .5 mm (0 .020 in .)
If the clearance more than the limit, replace the shift arm
shoe or reverse idler gear .

2. CHECK OIL CLEARANCE OF REVERSE IDLER GEAR

Using a dial indicator, measure reverse idler gear oil
clearance .
Standard clearance : 0 .040 - 0 .082 mm
(0 .0016 - 0 .0032 in .)
Maximum clearance : 0 .13 mm (0 .0051 in .)
If the clearance more than the limit, replace the reverse
idler gear or reverse idler gear shaft .

REPLACEMENT OF BEARING
IF NECESSARY, REPLACE COUNTER GEAR FRONT BEARING

(a) Using snap ring pliers, remove the snap ring .

(b) Using SST, press out the bearing .
SST 09950-00020
(c) Replace the side race .

(d) Using a 24 mm socket wrench, press in the bearing

and inner race .

(e) Select a snap ring that will allow minimum axial play
and install it on the shaft .

Mark Thickness mm (in .)

A 2 .00 - 2 .05 (0 .0787 - 0 .0807)

B 2 .05 - 2 .10 (0 .0807 - 0 .0827)
C 2 .10 - 2 .15 (0 .0827 - 0 .0846)
D 2 .15 - 2 .20 (0 .0846 - 0 .0866)
E 2 .20 - 2 .25 (0 .0866 - 0 .0886)


Component Parts
MANUAL TRANSMISSION (R141F, R150F, R151F) - (Transfer Adaptor)
MT-122

Transfer Adaptor
COMPONENTS

Transfer Adaptor

O il Seal

Reverse Restrict Pin

Oil Receiver Pi p e--z - 190 (14, 19)

kg-cm (ft-lb, N • m) Specified torque

• Non-reusable part
* Precoated part

REPLACEMENT OF OIL SEAL

1. IF NECESSARY, REPLACE TRANSFER ADAPTOR OIL S
(a) Using a screwdriver, pry out the oil seal .

(b) Using SST, drive in a new oil seal .

SST 09325-12010

INSPECTION AND REPLACEMENT OF REVERS

RESTRICT PIN
1. REMOVE REVERSE RESTRICT PIN
(a) Using a torx socket wrench, remove the screw pl

Component Parts
MANUAL TRANSMISSION (R141F, R150F, R151F) - MT-123
(Transfer Adaptor)

(b) Using a pin punch and hammer, drive out the slotted
spring pin .

RM0314

(c) Remove the reverse restrict pin .

1
lp pMOdW

K0714

2. INSPECTION OF REVERSE RESTRICT PIN

Turn and push the reverse restrict pin by hand while ap-
plying direction .

Aq
E9877

3. INSTALL REVERSE RESTRICT PIN

(a) Install the reverse restrict pin to the transfer adaptor .
(b) Using pin punch and hammer, drive in the slotted
spring pin .

K0715

(c) Apply liquid sealer to the plug threads .

Sealant : Part No .08833-00080, THREE BOND 1344,
Gl-~ Wlx~ LOCTITE 242 or equivalent
Using a torx socket wrench, install and torque the

W
(d)
screw plug .
i P Torque : 190 kg-cm (14 ft-lb, 19 N •m )

RM0313


r'
MANUAL TRANSMISSION (R141F, R150F, R151F) - Component Parts
MT-124 (Front Bearing Retainer)

Front Bearing Retainer

COMPONENTS

REPLACEMENT OF OIL SEAL

IF NECESSARY, REPLACE FRONT BEARING RETAINER OIL
SEAL
(a) Using a screwdriver, pry out the oil seal .

(b) Using SST, drive in a new oil seal .

SST 09608-35014 (09608-06020, 09608-06090)
Drive in depth : 11 .2 - 12 .2 mm (0 .434 - 0 .473 in.)
Transmission case installation surface
MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission MT-125

ASSEMBLY OF TRANSMISSION
(See page MT-99, 100)

1. INSTALL OUTPUT SHAFT TO INTERMEDIATE PLATE

(a) Install the output shaft into the intermediate plate by
pushing on the output shaft and tapping on the inter-
mediate plate .

(b) Using snap ring pliers, install the snap ring .

2. INSTALL INPUT SHAFT

(a) Apply gear oil to the needle roller bearing and install
it into the input shaft .
(b) Install the input shaft to the output shaft with the syn-
chronizer ring slots aligned with the shifting keys .

3. INSTALL COUNTER GEAR

Install the counter gear into the intermediate plate while
holding the counter gear, and install the counter rear bearing
with a plastic hammer .

4. INSTALL REVERSE SHIFT ARM BRACKET

Install the reverse shift arm bracket and torque the bolts .
Torque : 185 kg-cm (13 ft-lb, 18 N •m )
MT-126 MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission

5. INSTALL REVERSE SHIFT ARM TO REVERSE SHIFT ARM

BRACKET
Install the reverse shift arm to the pivot of the reverse shift
arm bracket .

6 . INSTALL REVERSE IDLER GEAR AND SHAFT

Align the reverse shift arm shoe to the reverse idler gear
groove and insert the reverse idler gear shaft to the inter-
mediate plate .

7. INSTALL REAR BEARING RETAINER

(a) Align the rear bearing retainer to the reverse idler gear
shaft groove .
(b) Install and torque the four bolts .

Torque : 185 kg-cm (13 ft-lb, 18 N •m )

8. INSTALL BALL AND THRUST WASHER

9. INSTALL COUNTER FIFTH GEAR WITH HUB SLEEVE NO .

ASSEMBLY AND NEEDLE ROLLER BEARINGS
(a) Apply gear oil to the needle roller bearings .

(b) Install the counter 5th gear with hub sleeve No .3 an

needle roller bearings .

D6578
MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission MT- 1 2 7

10 . INSTALL SYNCHRONIZER RING AND GEAR SPLINE PIECE

NO .5
(a) Install the synchronizer ring on gear spline piece No .5 .
(b) Using SST, drive in No .5 gear spline piece with the
synchronizer ring slots aligned with the shifting keys .
SST 09316-60010 (09316-00010)
HINT : When installing gear spline piece No .5, support the
counter gear in front with a 3-5 lb hammer or equivalent .

11 . INSTALL LOCK NUT

(a) Engage the gear double meshing .

(b) Install and torque the lock nut .

Torque : 1,300 kg-cm (94 ft-lb, 127 N •m )

(c) Stake the lock nut .

(Cr
r
(d) Disengage the gear double meshing .

D6674

12 . MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE

Using a feeler gauge, measure the counter 5th gear thrust
clearance .
Standard clearance : 0 .10 - 0 .35 mm
(0 .0039 - 0 .0138 in .)
Maximum clearance : 0 .35 mm (0 .0138 in .)

D6810
MT-128 MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission

13 . INSTALL SPACER

14 . INSTALL OUTPUT SHAFT REAR BEARING

Using SST, drive in the rear bearing .
SST 09316-60010 (09316-00010, 09316-00070)

15 . INSTALL SNAP RING

(a) Select a snap ring that will allow minimum axial play .

Mark Thickness mm (in .) Mark Thickness (in .)

A 2 .65 - 2.70 (0 .1043 - 0 .1063) K 3 .10 - 3 .15 10.1220 - 0.1240)

B 2 .70 - 2 .75 (0.1063 - 0 .1083) L 3 .15 -- 3 .20 (0.1240 - 0.1260)
C 2 .75 - 2 .80 (0.1083 - 0.1102) M 3 .20 - 3 .25 (0.1260 - 0.1280)
D 2 .80 - 2 .85 (0.1102 - 0.1122) N 3.25 - 3 .30 (0.1280 - 0.1299)
E 2 .85 - 2 .90 (0.1122 - 0.1142) P 3.30 - 3 .35 (0 .1299 - 0 .1319)
F 2 .90 - 2 .95 (0.1142 - 0.1161) Q 3.35 - 3 .40 (0 .1319 - 0 .1339)
G 2 .95 - 3 .00 (0.1161 - 0 .1181) R 3.40 - 3 .45 (0 .1339 - 0 .1358)
H 3.00 - 3 .05 (0.1181 - 0 .1201) S 3 .45 - 3 .50 (0 .1358 - 0 .1378)
J 3.05 - 3 .10 (0 .1201 - 0 .1220)

(b) Using a screwdriver and hammer, install the snap ring .

16 . INSTALL SLEEVE TO OUTPUT SHAFT

Using a plastic hammer, tap the sleeve onto the outpu
shaft .
MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission MT- 1 2 9

17 . (R150F and R151F)

INSTALL SHIFT FORK SHAFT NO .4, REVERSE SHIFT
HEAD AND SHIFT FORK NO .3
(a) Place shift fork No .3 into the groove of hub sleeve
No .3 .
(b) Install shift fork shaft No .4 to shift fork No .3, reverse
shift head and shift fork through the intermediate
plate .
(c) Install the locking ball into the reverse shift head .

(R141F)
INSTALL SHIFT FORK SHAFT NO .4 AND REVERSE SHIFT
HEAD
Install shift fork shaft No .4 to reverse shift head and shift
fork through the intermediate plate .

18 . INSTALL SHIFT FORK SHAFT NO .3 AND SHIFT FORK

NO .1
(a) Using a magnetic finger and screwdriver, install the
locking ball into the intermediate plate .

(b) Install the interlock pin into the shaft hole .

(c) Place shift fork No .1 into the groove of hub sleeve

No .1 .

(d) Install fork shaft No .3 to the reverse shift fork and shift
head through the intermediate plate .
MT-130 MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission

19 . INSTALL SHIFT FORK SHAFT NO .1

(a) Using a magnetic finger and screwdriver, install the
interlock pin into the intermediate plate .

(b) Install the interlock pin into the shaft hole .

affr

RM0046

(c) Install fork shaft No .1 to shift fork No .1 through the

intermediate plate .

20 . INSTALL SHIFT FORK SHAFT NO .2 AND SHIFT FORK

(a) Using a magnetic finger and screwdriver, install th
interlock pin into the intermediate plate .

(b) Place shift fork No .2 into the groove of hub slee)

No .2 .
(c) Install fork shaft No .2 to shift fork No .1 and No
through the intermediate plate .
MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission MT-131

21 . INSTALL SHIFT FORK SHAFT NO .5

Install shift fork shaft No .5 to the reverse shift head through
the intermediate plate .

22 . INSTALL SLOTTED SPRING PINS

Using a pin punch and hammer, drive in the two slotted
spring pins to the reverse shift head and shift fork .

23 . CHECK INTERLOCK
(a) Shift No .1 fork shaft to the 1st speed position .
(b) No .2, No .3, No .4 and No .5 fork shafts should not
move .

24 . INSTALL SNAP RINGS

(R150F and R151F)
Using pliers and a hammer, install the three snap rings .
(R141F)
Using pliers and a hammer, install the six snap rings .

25 . INSTALL SET BOLTS

(R 150F and R 151 F)
Install and torque the three bolts .
(R141F)
Install and torque the two bolts .
Torque : 200 kg-cm (14 ft-lb, 20 N •m )
MT-132 MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission

26 . INSTALL LOCKING BALLS, SPRINGS AND SCREW PLUGS

(a) Apply liquid sealer to the plug threads .

Sealant : Part No .08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent

(b) (R 150F and R 151 F)

Install the four locking balls, springs and screw plugs .
(R141F)
Install the three locking balls, springs and screw plugs .

(c) Using a torx socket wrench, torque the screw plugs .

Torque : 190 kg-cm (14 ft-lb, 19 N •m )

27 . INSTALL MAGNET TO INTERMEDIATE PLATE

28 . DISMOUNT INTERMEDIATE PLATE FROM VISE

(a) Dismount the intermediate plate from the vise .
(b) Remove the bolts, nuts and plate washers .

29 . INSTALL TRANSMISSION CASE

(a) Apply seal packing to the transmission case as shown .

Seal packing : Part No .08826-00090, THREE BOND
1281 or equivalent

(b) Align each bearing outer race, each fork shaft end and
reverse idler gear shaft end with the case installation
holes, and install the case .
If necessary, tap on the case with a plastic hammer .
MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission MT-133

30 . INSTALL BEARING SNAP RINGS

Using snap ring pliers, install the two snap rings to the in-
put shaft bearing and counter gear front bearing .

31 . INSTALL FRONT BEARING RETAINER

(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of the transmis-
sion case or front bearing retainer .
(b) Apply seal packing to the transmission case as shown .
Seal packing : Part No .08826-00090, THREE BOND
1281 or equivalent
HINT : Install the front bearing retainer as soon as the seal
packing is applied .

(c) Apply liquid sealer to the bolt threads .

Sealant : Part No .08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(d) Install and torque the bolts .
Torque : 170 kg-cm (12 ft-lb, 17 N •m )

32 . INSTALL TRANSFER ADAPTOR, SHIFT LEVER SHAFT

AND SHIFT LEVER HOUSING
(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of the transmis-
sion case or transfer adaptor .
(b) Apply seal packing to the transfer adaptor as shown .
Seal packing : Part No .08826-00090, THREE BOND
1281 or equivalent
HINT : Install the transfer adaptor as soon as the seal
packing is applied .

(c) Insert the shift and select lever into the transfer
adaptor .
(d) Connect the shift and select lever to the fork shaft
and put in the shift lever housing .

(e) Align No .5 fork shaft to the transfer adaptor installa-

tion hole and push in the transfer adaptor .


MT-134 MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission

(f) Install and torque the bolts .

Torque : 380 kg-cm (27 ft-lb, 37 N-m)

RM0310

(g) Install and torque the shift lever housing bolt .

Torque : 390 kg-cm (28 ft-lb, 38 N-m)

(h) Apply liquid sealer to the plug threads .

Sealant : Part No .08833-00080, THREE BOND 1344,

LOCTITE 242 or equivalent

33 . INSTALL LOCKING BALL, SPRING AND SCREW PLUG

(a) Install the locking ball, spring and plug .

(b) Apply liquid sealer to the plug threads .
Sealant : Part No .08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent

(c) Install and torque the plug .

Torque : 190 kg-cm (14 ft-lb, 19 N . m)

34 . AFTER INSTALLING TRANSFER ADAPTOR CHECK FOL-

LOWING ITEMS
(a) Check to see that the input and output shafts rotate
smoothly .
(b) Check to see that shifting can be made smoothly to
all positions .
MANUAL TRANSMISSION (R141F, R150F, R151F) - Assembly of Transmission MT-135

35 . INSTALL RESTRICT PINS

(a) Install the black pin on the reverse gear/5th gear side .
(b) Install another pin and torque the pins .
Torque : 380 kg-cm (27 ft-lb, 37 N -m)

36 . INSTALL CLUTCH HOUSING

(a) Install the clutch housing .
(b) Install and torque the nine bolts .

Torque : 370 kg-cm (27 ft-lb, 36 N •m )

37 . INSTALL SHIFT LEVER RETAINER WITH NEW GASKET

(a) Apply liquid sealer to the bolt threads .

Sealant : Part No .08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install and torque the four bolts .
Torque : 185 kg-cm (13 ft-lb, 18 N •m )

38 . INSTALL BACK-UP LIGHT SWITCH

Torque : 380 kg-cm (27 ft-lb, 37 N •m )

39 . INSTALL RELEASE FORK AND BEARING