MANUAL TRANSMISSION - G 52 Transmission

MT-39

G52 TRANSMISSION
COMPONENTS

280 (20, 27)

Transfer Shift --~~-L

Lever Retainer

~~~

~_..:....--_ _t

Clutch Housing
Front Bearing Retainer

380 (27, 37)

Output Shaft - - - - - ;

Locking Ball--------~
Spring---------....oo.l

* Straight Screw PIUg~

390 (28, 38)

Reverse
Shift Head

f-tt

Shift Lever Shaft

Shift Fork Shaft No.5

Counter Gear

8'-------'*.Straight Screw Plug

~----Reverse

Restrict Pin

Shift Fork Shaft No.2

-J

Reverse Shift Arm---------t

and Fork

~_&

Shift Fork NO.3

--./
Reverse Shift Arm Bracket
kg-cm (ft-Ib, Nm)
Tightening torque
Shift Fork Shaft No.4

Non-reusable part
Precoated part

*:

I :

GM0156

TRANSMISSION

(Cont'd)

MANUAL

COMPONENTS
.
Retainer
Rear Bearing

Sleeve

Snap Ring

Sync h ro nizer Ring

Input Shaft

Gear Spline Pleee No.5

Counter 5th Gear

Counter Gear

MANUAL TRANSMISSION -

G 52 Transmission

MT-41

DISASSEMBLY OF TRANSMISSION
(See pages MT-39, 40)
1.

REMOVE BACK-UP LIGHT SWITCH, SPEEDOMETER

DRIVEN GEAR (2WD), SHIFT LEVER RETAINER AND
RESTRICT PINS

2.

REMOVE CLUTCH HOUSING FROM TRANSMISSION

CASE

3.

REMOVE STRAIGHT SCREW PLUG, SPRING AND BALL

GM0001

(a)

Using a torx socket wrench, remove the screw plug

from the transfer adapter.

(b)

Using a magnetic finger, remove the spring and ball.

GMOOOS

4.

REMOVE TRANSFER ADAPTER

(a)

Using SST, remove the plug from the transfer adapter.

SST 09923-00010

GM0008

MT-42

MANUAL TRANSMISSION - G 52 Transmission

(b)

Remove the shift lever housing set bolt and lock

washer.

(c)

Remove the shift lever shaft and housing.

GM0009

(d)

Remove the eight bolts.

(e)

Using a plastic hammer, remove the transfer adapter.

NOTE:
plate.

Leave the gasket attached to the intermediate

GM0011

5.

REMOVE FRONT BEARING RETAINER AND TWO BEARING SNAP RINGS

6.

SEPARATE INTERMEDIATE PLATE FROM

TRANSMISSION CASE

GM0012

GM0013

(a)

Using a plastic hammer, carefully tap off the transmission case.

(b)

Remove the transmission case from the intermediate

plate.

MANUAL TRANSMISSION -

7.

G 52 Transmission

MT-43

MOUNT INTERMEDIATE PLATE IN VISE

(a)

Use two clutch housing bolts, plate washers and suitable nuts as shown.

CAUTION: 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)

8.

Mount the intermediate plate in a vise.

REMOVE STRAIGHT SCREW PLUGS, LOCKING BALLS

AND SPRINGS

(a)

Using a torx socket wrench, remove the four plugs.

(b)

Using a magnetic finger, remove the springs and balls.

GM0015

GM0016

9.

REMOVE SLOTTED SPRING PINS

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

GMOQ17

10. REMOVE TWO E-RING

GM0018

MT-44

MANUAL TRANSMISSION -

G 52 Transmission

11. REMOVE SHIFT FORK SHAFT NO.4 AND SHIFT FORK

NO.3
(a)

Pull out shift fork shaft No.4 from the intermedi

plate.

CAUTION: The locking balls and interlock pin will fall from
the holes so be sure to catch them by hand. If they do not
come out, remove them with a magnetic finger.

GM001g

(b)

Remove shift fork shaft No.4 and shift fork No.3.

GM0020

12. REMOVE REVERSE SHIFT HEAD AND SHIFT FORK SHAFT

NO.5
Pull out shift fork shaft No.5 from the intermediate plate,
and remove it with the reverse shift head.

\
\

GM0021

13. REMOVE SHIFT FORK SHAFT NO.3

Pullout shift fork shaft No.3 from the intermediate plate.
CAUTION: The interlock pins will fall from the hole so be
sure to catch them by hand. If they do not come out, remove them with a magnetic finger.

GM0023

14. REMOVE SHIFT FORK SHAFT NO.1

Pullout shift fork shaft NO.1 from the intermediate plate.
CAUTION: The interlock pin will fall from the hole so be
sure to catch it by hand. If it does not come out, remove
it with a magnetic finger.

GM0024

MANUAL TRANSMISSION -

G 52 Transmission

MT-45

15. REMOVE SHIFT FORK SHAFT NO.2, SHIFT FORK NO.2

AND SHIFT FORK NO.1
Pull out shift fork shaft No.2 and remove shift fork No.2
and NO.1.

GM0025

16. REMOVE REVERSE IDLER GEAR AND SHAFT

(a)

Remove the reverse idler gear shaft stopper.

(b)

Remove the reverse idler gear and shaft.

GM0026

17. REMOVE REVERSE SHIFT ARM FROM REVERSE SHIFT

ARM BRACKET

GM0027

18. MEASURE COUNTER FIFTH GEAR THRUST

CLEARANCE
Using a feeler gauge, measure the counter 5th gear thrust
clearance.

Standard clearance:
Maximum clearance:

0.10 - 0.30 mm
(0.0039 - 0.0118 in.)
0.30 mm (0.0118 in.)

GMOO28

19. REMOVE GEAR SPLINE PIECE NO.5, SYNCHRONIZER

RING, NEEDLE ROLLER BEARINGS AND COUNTER FIFTH
GEAR WITH HUB SLEEVE NO.3

GM0029

(a)

Engage the gear double meshing.

(b)

Using a hammer and chisel, loosen the staked part of

the nut.

MT-46

MANUAL TRANSMISSION -

G52 Transmission

(c)

Remove the lock nut.

(d)

Disengage the gear double meshing.

(e)

Using SST, remove gear spline piece No.5, synchronizer ring, needle roller bearing and counter 5th gear.

GM0030

SST 09213-27010

GM0031

20. REMOVE SPACER AND BALL

(a)

Remove the spacer.

(b)

Using a magnetic finger, remove the ball.

GM0033

21. REMOVE REVERSE SHIFT ARM BRACKET

Remove the two bolts and the reverse shift arm bracket.

GM0034

22. REMOVE REAR BEARING RETAINER

Using a forx socket wrench, remove the four bolts.

\
GM0035

MANUAL TRANSMISSION - G52 Transmission

MT-47

23. REMOVE BEARING SNAP RING

Using snap ring pliers, remove the snap ring.

GM0036

24. 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 14-needle roller bearings from the output shaft.

GM0037

25. REMOVE COUNTER REAR BEARING FROM

INTERMEDIATE PLATE

26. REMOVE SLEEVE FROM OUTPUT SHAFT

Using SST, remove the sleeve from the output shaft.
SST 09950-20015

GM0039

27. MEASURE EACH GEAR THRUST CLEARANCE

3rd

Measure the thrust clearance of each gear.

Standard clearance:
Maximum clearance:

GM0040

0.10 - 0.25 mm
(0.0039 - 0.0098 in.)
0.25 mm (0.0098 in.)

MT-48

MANUAL TRANSMISSION -

G 52 Transmission

28. REMOVE FIFTH GEAR, REAR BEARING AND

FIRST GEAR ASSEMBLY
(a)

Using two screwdrivers and a hammer, tap out '.

snap ring.

(b)

Using a press, remove the 5th gear, rear bearing, 1st

gear and inner race.

(c)

Remove the needle roller bearing.

(d)

Remove the synchronizer ring.

GM0041

GM0042

29. REMOVE LOCKING BALL

Using a magnetic finger, remove the locking ball.

GMOO45

30. REMOVE HUB SLEEVE NO.1 ASSEMBLY AND

SECOND GEAR ASSEMBLY
(a)

Using a press, remove hub sleeve No.1, the synchronizer ring and 2nd gear.

(b)

Remove the needle roller bearing.

GMOO46

31. REMOVE HUB SLEEVE NO.2 ASSEMBLY AND

THIRD GEAR ASSEMBLY
(a)

GM0047

Using snap ring pliers, remove the snap ring.

MANUAL TRANSMISSION -

WM0055

G52 Transmission

MT-49

(b)

Using a press, remove hub sleeve No.2, the synchronizer ring and 3rd gear.

(c)

Remove the needle roller bearing.

MT-50

MANUAL TRANSMISSION -

G 52 Transmission

INSPECTION OF TRANSMISSION COMPONENTS

1.

INSPECT OUTPUT SHAFT AND INNER RACE

(a)

Using calipers, measure the output shaft flange

thickness.

Minimum thickness:

4.80 mm (0.1890 in.)

(b)

measure the

GM0048

Using calipers,
thickness.

Minimum thickness:

inner race

flange

3.99 mm (0.1571 in.)

WM0057

(c)

Using a micrometer, measure the outer diameter of

the output shaft journal.

Minimum diameter:
2nd gear
37.984 mm (1.4954 in.)
3rd gear
34.984 mm (1.3773 in.)

GM0049

(d)

Using a micrometer, measure the outer diameter of

the inner race.

Minimum diameter:

38.985 mm (1.5348 in.)

WM0059

(e)

Using a dial indicator, check the shaft runout.

Maximum runout:

GM0050

0.05 mm (0.0020 in.)

MANUAL TRANSMISSION 2.

MT-51

G 52 Transmission

CHECK OIL CLEARANCE OF FIRST GEAR

Using a dial indicator, measure the oil clearance between
the gear and inner race with the needle roller bearing installed.
Standard clearance:
Maximum clearance:

0.009 - 0.032 mm
(0.0004 - 0.0013 in.)
O. 15 mm (0.0059 in.)

WM0061

3.

CHECK OIL CLEARANCE OF SECOND, THIRD AND

COUNTER FIFTH GEARS
Using a dial indicator, measure the oil clearance between
the gear and shaft with the needle roller bearing installed.
Standard clearance:
2nd and 3rd gears 0.009 (0.0004
Counter 5th gear 0.009 (0.0004

Maximum clearance:

---J
GMOOSl

4.

0.033 mm
0.0013 in.)
0.032 mm
- 0.0013 in.)

0.15 mm (0.0059 in.)

INSPECT SYNCHRONIZER RINGS

(a)

Turn the ring and push it in to check the braking action.

(b)

Measure the clearance between the synchronizer ring

back and the gear spline end.

WM0064

Standard clearance:
Minimum clearance:

5.

1.0 - 2.0 mm
(0.039 - 0.079 in.)
0.8 mm (0.031 in.)

MEASURE CLEARANCE OF SHIFT FORKS AND HUB

SLEEVES
Using a feeler gauge, measure the clearance between the
hub sleeve and shift fork.
Maximum clearance:

WM0066

1.0 mm (0.039 in.)

MANUAL TRANSMISSION -

MT-52

6.

G 52 Transmission

IF NECESSARY, REPLACE INPUT SHAFT BEARING

(a)

Using snap ring pliers, remove the snap ring.

(b)

Using a press, remove the bearing.

(c)

Using a press and SST, install a new bearing.

WM0067

WMOO68

SST 09506-35010

ISST
I

WM0069

(d)

Select a snap ring that will allow minimum axial play

and install it on the shaft.
Mark

0
1
2
3
4
5

mm (in.)

Thickness

2.05
2.10
2.15
2.20
2.25
2.30

2.10
2.15
2.20
2.25
2.30
2.35

(0.0807
(0.0827
(0.0846
(0.0866
(0.0886
(0.0906

0.0827)
0.0846)
0.0866)
0.0886)
0.0906)
0.0925)

WM0070

7.

INSPECT FRONT BEARING RETAINER

Check the retainer and oil seal for wear or damage. If the
oil seal is worn or damaged, replace it as follows.
(a)

WM0071

Using a screwdriver, pry out the oil seal.

MANUAL TRANSMISSION - G52 Transmission

(b)

MT-53

Using SST, press in the oil seal.

SST 09223-50010
Oil seal depth:

11.2 - 12.2 mm (O.441 - 0.480 in.)

Transmission case installation surface

WMoon

8.

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 socket wrench, press in the bearing, side race

and inner race.

(e)

Select a snap ring that will allow minimum axial play

and install it on the shaft.

WM0073

WM0176

Thickness

Mark

1
2
3
4
5
6

2.05
2.10
2.15
2.20
2.25
2.30

2.10
2.15
2.20
2.25
2.30
2.35

(0.0807
(0.0827
(0.0846
(0.0866
(0.0886
(0.0906

mm (in.)

0.0827)
0.0846)
0.0866)
0.0886)
0.0906)
0.0925)

WM0077

9.

IF NECESSARY, REPLACE REVERSE RESTRICT PIN

(a)

GMOO54

Using a torx socket wrench, remove the screw plug.

MT-54

MANUAL TRANSMISSION - G52 Transmission

(b)

Using a pin punch and hammer, drive out the slotted

spring pin.

(c)

Pull off the lever housing and slide out the shaf,

(d)

Install the lever housing.

(e)

Using a pin punch and hammer~ drive in the slotted

spring pin.

(f)

Using a torx socket wrench, install and torque the

screw plug.

GM0056

Torque:

190 kg-em (14 ft-Ib, 19 Nm)

GMOO54

11. IF NECESSARY, REPLACE Oil SEAL

(a)

Using a screwdriver, pry out the oil seal.

(b)

Using SST, drive in a new oil seal.

SST 09325-12010

GMOO58

MANUAL TRANSMISSION -

G 52 Transmission

MT-55

ASSEMBLY OF TRANSMISSION
(See pages MT-39, 40)
1.
. . Front

No.1

INSERT CLUTCH HUB NO.1 AND NO.2 INTO HUB SLEEVE

(a)

Install the clutch hub and shifting keys to the hub

sleeve.

(b)

Install the shifting key springs under the shifting keys.

CAUTION: Install the key springs positioned so that their

end gaps are not in line.

No.2
GM0059

2.

INSTALL THIRD GEAR AND HUB SLEEVE NO.2 ON

OUTPUT 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.

(d)

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

WM0114

[I
II

t1

rff\

GM0060

3.

INSTALL SNAP RING

(a)

Select a snap ring that will allow minimum axial play.

(b)

Using snap ring pliers, install the snap ring.

Mark

C-l
0

0-1
E
E-l

F
F-l
GM0047

1.75
1.80
1.85
1.90
1.95
2.00
2.05

1.80
1.85
1.90
1.95
2.00
2.05
2.10

mm
mm
mm
mm
mm
mm
mm

(0.0689
(0.0709
(0.0728
(0.0748
(0.0768
(0.0787
(0.0807

0.0709
0.0728
0.0748
0.0768
0.0787
0.0807
0.0827

in.)
in.)
in.)
in.)
in.)
in.)
in.)

MT-56

MANUAL TRANSMISSION - G52 Transmission

4.

MEASURE THIRD GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 3rd gear thrust
clearance.

Standard clearance:
Maximum clearance:

5.

0.10 - 0.25 mm
(0.0039 - 0.0098 in.)
0.25 mm (0.0098 in.)

INSTALL SECOND GEAR AND HUB SLEEVE NO.1

(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.

GM0061

GM0062

6.

INSTALL LOCKING BALL AND FIRST GEAR ASSEMBLY

(a)

Install the locking ball in the shaft.

(b)

Apply gear oil to the needle roller bearing.

(c)

Assemble the 1st gear, synchronizer ring, needle roller

bearing and bearing inner race.

(d)

Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys.

(e)

Turn the inner race to align it with the locking ball.

GM0063

GM0064

MANUAL TRANSMISSION 7.

MT-57

G 52 Transmission

INSTALL OUTPUT SHAFT REAR BEARING

Using SST and a press, install the bearing on the output
shaft with the outer race snap ring groove toward the rear.
NOTE:
falling.

Hold the 1st gear inner race to prevent it from

SST 09506-35010

GMOO65

8.

MEASURE FIRST AND SECOND GEAR THRUST

CLEARANCE
Using a feeler gauge, measure the 1st and 2nd gear thrust
clearance.
Standard clearance:
Maximum clearance:

1st

0.10 - 0.25 mm
(0.0039 - 0.0098 in.)
0.25 mm (0.0098 in.)

2nd
GM0040

9.

INSTALL FIFTH GEAR

Using SST and a press, install the 5th gear.
SST 09506-35010

GM0066

10. INSTALL SNAP RING

(a)

Select a snap ring that will allow minimum axial play.

(b)

Using snap ring pliers, install the snap ring.

GM0067

Mark

GM0068

Tickness

mm (in.)

Mark

Thickness mm (in.)

2.67 -

2.72 (0.1051 - 0.1071)

3.03 -

3.08 (0.1193 -

0.1213)

2.73 -

2.78 (0.1075 -

0.1094)

3.09 -

3.14 (0.1217 -

0.1236)

2.79 -

2.84 (0.1098 -

0.1118)

3.15 -

3.20 (0.1240 -

0.1260)

2.85 -

2.90 (0.1122 - 0.1142)

3.21 -

3.26 (0.1264 -

0.1283)

3.27 -

3.32 (0.1287 -

0.1307)

2.91 -

2.96 (0.1146 -

2.97 -

3.02 (0.1169 - 0.1189)

0.1165)

MT-58

MANUAL TRANSMISSION - G 52 Transmission

11. INSTALL SLEEVE TO OUTPUT SHAFT
Using a plastic hammer, tap the sleeve onto the outl"'1 It
shaft.

GM0071

12. INSTAll OUTPUT SHAFT TO INTERMEDIATE PLATE

Install the output shaft into the intermediate plate by pulling on the output shaft and tapping on the intermediate
plate.

GMOO73

13. INSTALL INPUT SHAFT

(a)

Apply MP grease to the 14-needle roller bearing and

install it into the input shaft.

(b)

Install the input shaft to the output shaft with the synchronizer ring slots aligned with the shifting keys.

GM0072

GMOO74

14. INSTAll COUNTER GEAR

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

SST 09316-60010

GM0075

MANUAL TRANSMISSION -

G 52 Transmission

MT-59

15. INSTALL BEARING SNAP RING

Using snap ring pliers, install the snap ring.
NOTE: Be sure the snap ring is flush with the intermediate plate surface.

GMOO36

16. INSTALL REAR BEARING RETAINER

Using a torx socket wrench, install and torque the screws.
Torque:

185 kg-em (13 ft-Ib, 18 Nm)

\
GM0035

17 . INSTALL REVERSE SHIFT ARM BRACKET

Install the reverse shift arm bracket and torque the bolts.
Torque:

185 kg-em (13 ft-Ib, 18 Nm)

GM0034

18. INSTALL BALL AND SPACER

19. INSERT COUNTER FIFTH GEAR INTO HUB SLEEVE NO.3

(a)

Install the shifting keys and hub sleeve No.3 onto the
counter 5th gear.

(b)

Install the shifting key springs under the shifting keys.

CAUTION: Install the key springs positioned so that their

end gaps are not in line.

. . . Front

GM0077

MT-60

MANUAL TRANSMISSION - G52 Transmission

20. INSTALL COUNTER FIFTH GEAR WITH HUB SLEEVE NO.3
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 and
needle roller bearings.

21. 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 gear spline piece No.5 with the

synchronizer ring slots aligned with the shifting keys.

SST 09316-60010
NOTE: When installing gear spline piece No.5, support
the counter gear in front with a 3-5 Ib hammer or equivalent.
GM0079

22. INSTALL LOCK NUT

(a)

Engage the gear double meshing.

(b)

Install and torque the lock nut.

GMOO29

Torque:

1,200 kg-em (87 ft-Ib, 118 Nm)

(c)

Stake the lock nut.

(d)

Disengage the gear double meshing.

GMOO30

GMOO29

MANUAL TRANSMISSION - G 52 Transmission

MT-61

23. MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE

Using a feeler gauge, measure the counter 5th gear thrust
clearance.
Standard clearance:
Maximum clearance:

0.10 - 0.30 mm
(0.0039 - 0.0118 in.)
0.30 mm (0.0118 in.)

GMOO28

24. INSTALL REVERSE SHIFT ARM TO REVERSE SHIFT ARM

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

GM0027

25. INSTALL REVERSE IDLER GEAR AND SHAFT

(a)

Install the reverse idler gear on the shaft.

(b)

Align the reverse shift arm shoe to the reverse idler

gear groove and insert the reverse idler gear shaft to
the intermediate plate.

(c)

Install the reverse idler gear shaft stopper and torque

the bolt.

Torque:

175 kg-em (13 ft-Ib, 17 Nm)

GM0026

26. INSTALL SHIFT FORK SHAFT NO.2, SHIFT FORK NO.1

AND NO.2
Place shift forks No.1 and No.2 into the groove of hub
sleeves No.1 and No.2 and install fork shaft No.2 to shift
forks No.1 and NO.2 through the intermediate plate.

GM0025

27. INSTALL INTERLOCK PIN

o
o

GM0081 GM0082

(a)

Apply MP grease to the interlock pins.

(b)

Using a magnetic finger and screwdriver, install the

interlock pin into the intermediate plate.

MT-62

MANUAL TRANSMISSION -

G 52 Transmission

28. INSTALL SHIFT FORK SHAFT NO.1

(a)

Install the interlock pin into the shaft hole.

(b)

Install fork shaft NO.1 to shift fork No.1 through the

intermediate plate.

GM0083

GM0084

29 . INSTALL INTERLOCK PIN

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

GM0085

30 . INSTALL SHIFT FORK SHAFT NO.3

(a)

Install the interlock pin into the shaft head.

(b)

Install fork shaft No.3 to the reverse shift arm through

the intermediate plate.

GM0086

GM0087

MANUAL TRANSMISSION - G 52 Transmission

MT-63

31. INSTALL SHIFT FORK SHAFT NO.5 AND REVERSE SHIFT

HEAD
(a)

Install the reverse shift head into fork shaft No.5.

(b)

Insert fork shaft No.5 to the intermediate plate and

put in the reverse shift head to shift fork shaft No.3.

32. INSTALL SHIFT FORK SHAFT NO.4, SHIFT FORK NO.3

AND TWO LOCKING BALLS
(a)

Using a magnetic finger and screwdriver, install the

locking ball into the reverse shift head hole.

(b)

Shift hub sleeve No.3 to the 5th speed position.

(c)

Place shift fork No.3 into the groove of hub sleeve

No.3 and install fork shaft No.4 to shift fork No.4 and
reverse shift arm.

(d)

Using a magnetic finger and screwdriver, install the

locking ball into the intermediate plate and insert fork
shaft No.4 to the intermediate plate.

GM0088

GM0089

GM0090

GM0091

MT-64

MANUAL TRANSMISSION - G 52 Transmission

33. CHECK INTERLOCK
(a)

Shift fork shaft NO.1 to the 1st speed position.

(b)

Fork shafts No.2, No.3, No.4 and No.5 should not

move.

GM0092

GM0093

34. INSTALL FIVE SLOTTED SPRING PINS

Using a pin punch and hammer, drive the slotted spring
pins into each shift fork, reverse shift arm and reverse shift
head.

GM0094

35. INSTALL TWO FORK SHAFT E-RING

GM0095

36. INSTALL LOCKING BALLS, SPRINGS AND SCREW PLUGS

(a)

Apply liquid sealer to the plugs.

(b)

Install the locking balls, springs and screw plugs and

torque the screw plugs with a torx socket wrench.

Torque:

190 kg-em (14 ft-Ib, 19 Nm)

NOTE: (5-Speed) Install the short spring into the botl

of the intermediate plate.

MANUAL TRANSMISSION - G52 Transmission

MT-65

37. DISMOUNT INTERMEDIATE PLATE FROM VISE

(a)

Dismount the intermediate plate from the vise.

(b)

Remove the bolts, nuts, plate washers and gasket.

38. INSTALL TRANSMISSION CASE WITH NEW GASKET TO

INTERMEDIATE PLATE
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.

39. INSTALL TWO BEARING SNAP RINGS

\
\

GM0012

40. INSTALL FRONT BEARING RETAINER WITH NEW GASKET

(a)

Install the bearing retainer with a new gasket.

(b)

Apply liquid sealer to the bolts.

(c)

Install and torque the bolts.

Torque:

GM0099

170 kg-em (12 ft-Ib, 17 Nm)

MT-66

MANUAL TRANSMISSION 41

G 52 Transmission

INSTALL TRANSFER ADAPTER, NEW GASKET, SHIFT

LEVER SHAFT AND SHIFT LEVER HOUSING
(a)

Install a new gasket to the intermediate plate.

(b)

Install and torque the transfer adapter with the eight

bolts.

Torque:

380 kg-em (27 ft-Ib, 37 Nom)

/~~)
)

GM0104

(c)

Insert the shift lever housing to the transfer adapter

and connect the fork shafts.

(d)

Insert the shift lever shaft to the transfer adapter and

shift lever housing.

(e)

Install and torque the shift lever housing bolt.

GM0105

GM0010

Torque:

390 kg-em (28 ft-Ib, 38 Nom)

GM0106

(f)

Using SST, install and torque the plug.

SST 09923-00010

Torque:

GM0108

380 kg-em (27 ft-Ib, 37 Nom)

MANUAL TRANSMISSION -

G 52 Transmission

MT-67

42. INSTALL LOCKING BALL, SPRING AND SCREWPLUG

(a)

Apply liquid sealer to the plug.

(b)

Install the locking ball and spring.

(c)

Install and torque the plug.

GM0110

Torque:

190 kg-em (14 ft-Ib, 19 Nm)

43. AFTER INSTALLING EXTENSION HOUSING OR TRANSFER

ADAPTER CHECK FOLLOWING 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.

44. INSTALL RESTRICT PINS

(a)

Install the black pin on the reverse gear/5th gear side.

(b)

Install another pin and torque the pins.

GM0113

Torque:

280 kg-em (20 ft-Ib, 27 N m)

MT-68

MANUAL TRANSMISSION -

G 52 Transmission

45. INSTALL CLUTCH HOUSING

(a)

Install the clutch housing.

(b)

Install and torque the bolts.

Torque:

380 kg-em (27 ft-Ib, 37 Nm)

GM0115

46. INSTALL SHIFT LEVER RETAINER WITH NEW

GASKET
Torque:

185 kg-em (13 ft-Ib, 18 Nm)

47. INSTALL BACK-UP LIGHT SWITCH

Torque:

380 kg-em (27 ft-Ib, 37 N m)

48. INSTALL RELEASE FORK AND BEARING

Apply molybdenum disulphide lithium base grease to the
following parts:
Release bearing hub inside groove
Input shaft spline
Release fork contact surface

MANUAL TRANSMISSION -

Installation of Transmission

MT-69

INSTALLATION OF TRANSMISSION
NOTE: For the transmission with a transfer (4WD) refer to INSTALLA TION OF TRANSFER on page TF-25.

1.

PLACE TRANSMISSION AT INSTALLATION POSITION

Insert the extension housing between the member and floor
and then side the transmission forward.
Align the input shaft spline with the clutch disc, and push
the transmission fully into position.

2.

INSTALL TRANSMISSION BOLTS AND STIFFENER

BOLTS
Torque:
Transmission Mounting Bolt 730 kg-em
(53 ft-Ib, 72 Nom)
Stiffener Plate Bolt
380 kg-em
(27 ft-Ib, 37 Nom)

Transmission Mounting Bolt

\~

Stiffener Plate
Bolt

Transmission Mounting Bolt

MT0023

3.

INSTALL ENGINE REAR MOUNTING AND BRACKET

(a)

Install the engine rear mounting. Torque the bolts.

Torque:
(b)

MTQ025

260 kg-em (19 ft-Ib, 25 Nm)

Raise the transmission slightly by raising the engine

with a jack and a wooden block under the transmission.

MT-70

MANUAL TRANSMISSION (c)

Installation of Transmission
Install the engine rear mounting bracket to the support member. Torque the bolts.

Torque:

130 kg-em (9 ft-Ib, 13 Nm)

(d)

Lower the transmission and rest it on the extension

housing.

(e)

Install the bracket to the mounting. Torque the bolts.

Torque:

260 kg-cm (19 ft-Ib, 25 N'm)

MTOO16 MT0015

4.

REMOVE PIECE OF WOOD FROM FRONT

CROSSMEMBER

5.

INSTALL EXHAUST PIPE, BRACKET AND PIPE

(a)

Install the exhaust pipe to the manifold.

Torque:

400 kg-em (29 ft-Ib, 39 Nom)

MT0021

(b)

Install the pipe bracket to the clutch housing.

Torque:
(c)

Upper
Lower

380 kg-em (27 ft-Ib, 37 Nom)

700 kg-em (51 ft-Ib, 69 Nom)

Install the exhaust pipe clamp.

MT0020

6.

INSTALL STARTER LOWER MOUNTING BOLT AND

RELEASE CYLINDER TUBE BRACKET
Torque:

7.

400 kg-em (29 ft-Ib, 39 Nom)

INSTALL CLUTCH RELEASE CYLINDER

Torque:

120 kg-em (9 ft-Ib, 12 Nom)

8.

CONNECT SPEEDOMETER CABLE AND BACK-UP LIGHT

SWITCH

9.

CONNECT PROPELLER SHAFT

(See page PR-2)

MANUAL TRANSMISSION -

Installation of Transmission

MT-71

10. FILL TRANSMISSION WITH OIL

Oil grade: API GL-4 or GL-5 SAE 75W-90
Quantity:
2WD
2.4 liters (2.5 US qts, 2.1 Imp. qts)
4WD W56 3.0 liters (3.2 US qts, 2.6 Imp. qts)
G52 3.9 liters (4.1 US qts, 3.4 Imp. qts)

11. LOWER VEHICLE

12. INSTALL STARTER UPPER MOUNTING NUT
13. INSTALL SHIFT LEVER
(a)

Apply MP grease to the shift lever.

(b)

Install the shift lever to the transmission.

14. CONNECT BATTERY CABLE TO NEGATIVE TERMINAL

15. PERFORM ROAD TEST
Check for abnormal noise and smooth operation.