TRANSMISSION SYSTEM

TRANSMISSION PROPER
TRANSMISSION PTO
TRANSMISSION LINKAGE
 TRANSMISSION PROPER

CONTENTS
SERVICE DATA ........................................... TM-1- 1 = UNIT NAME MRT21A =
SPECIFICATIONS ........................................ TM-1- 1
SERVICE DATA ............................................ TM-1- 4 CONSTRUCTION ........................................ TM-4- 1
TIGHTENING TORQUE ............................... TM-1- 8
DISASSEMBLY ............................................ TM-4- 4
SYSTEM DIAGRAM ..................................... TM-1-11
REMOVAL .................................................... TM-4- 4
TOOLS ............................................................ TM-2- 1
DISASSEMBLY ............................................ TM-4- 5
INSPECTION ................................................ TM-4-24
= UNIT NAME MTS60 = REASSEMBLY ............................................. TM-4-29
REASSEMBLY ............................................. TM-4-29
DISASSEMBLY ............................................ TM-3- 1 INSTALLATION ............................................ TM-4-44
DISASSEMBLY ............................................ TM-3- 1
REASSEMBLY ............................................. TM-3- 2
REASSEMBLY ............................................. TM-3- 2

SUPPLEMENTAL OUTLINE
+ Unit name MTS60G
Addition of specifications, maintenance standards and tightening torque. For disassembly, inspection and
reassembly, refer to unit name MTS60 in the service manual.
+ Addition of transmission MRT21A
 SERVICE DATA T/M PROPER

SERVICE DATA
SPECIFICATIONS
UNIT NAME: MTS60G
Unit name MTS60G
6 speeds forward, 1 speed reverse
Transmission system (Synchromesh type: 2-6 speeds
Constant mesh type: 1 speed and reverse)
Operating system Remote control
1st and reverse Spur gear
Gear used
2nd to 7th Helical gear
1st 6.326
2nd 4.139
3rd 2.490
Gear ratio 4th 1.567
5th 1.000
6th 0.731
Reverse 6.490
1st 47/12
2nd 41/16
3rd 37/24
4th 33/34
Number of gear
teeth 5th Direct coupled
(Main/counter) 6th 24/53
Reverse 37/17
Reverse idler gear 24, 13
Drive gear 26/42

Oil quantity W/O PTO 10.5 (2-3/8)

liter (Imp gal) W/PTO 11.0 (2-3/8)

TM-1-1
 SERVICE DATA T/M PROPER

UNIT NAME: MRT21A

Unit name MRT21A
12 speeds forward, 2 speed reverse
Transmission system (Synchromesh type: 1-12 speeds
Constant mesh type: reverse)
Operating system Remote control
Gear used 1st to 12th and reverse Helical gear
1st 10.729
2nd 6.575
3rd 3.649
4th 2.236
Gear ratio 5th 1.464
6th 1.000
Reverse 9.563
High 0.811
Sub-transmission
Low 1.000
1st 46/16
2nd 37/21
3rd 46/16
4th 37/21
5th 30/26
Number of gear 6th 33/26
teeth
(Main/counter) Reverse 41/16
Reverse idler gear 25

Range side High 26/24

sub-transmission Low 38/14

Splitter side High 34/35

sub-transmission Low 26/33

Oil quantity W/O PTO 12.8 (2-7/8)

liter (Imp gal) W/PTO 13.3 (2-7/8)

TM-1-2
 SERVICE DATA T/M PROPER

UNIT MODEL NAME

M R T 2 1 A (Table 1) — Specifications
Classification of gear ratio: Main transmission Synchro-
A - S: Overdrive type mesh
No. of modifications Sub-transmission Yes
No. of gearshift stages:
4, 5, 6, ...9, etc.
Greater than 10 stages:
Designated by the last digit No S
Main transmission
(w/synchro or w/o synchro) CTM1-302
Sub-transmission ... Refer to
Table 1.
Distance between mainshaft
and counter shaft mm (in) With range
155 (6.10) < ‘‘R’’ < 160 (6.30) Yes T
= splitter type
165 (6.50) < ‘‘T’’ < 170 (6.70)
=
Transmission type CTM1302B
M: Manual

UNIT NO. LOCATION

The manufacturing number of each transmission is stamped on the
side of the transmission case.

WTM180A

TM-1-3
 SERVICE DATA T/M PROPER

SERVICE DATA
Unit: mm (in)
Maintenance Application
Item standard Service limit Remarks
MTS60G MRT21A
Clearance between shift lever 0.1 - 0.4 0.8 j j
and select lever (0.004 - 0.016) (0.031)
0.05 - 0.11 0.5 j —
Radial play between shift (0.0020 - 0.0043) (0.020)
shaft and shift lever splines 0.02 - 0.08 0.5
(0.0008 - 0.0031) (0.020) — j

Clearance between shift lever 0.1 - 0.4 1.0 j —

and shifters (0.004 - 0.016) (0.039)
Clearance between shift lever 0.74 - 0.96 1.5 — j
and each shifter/shift fork (0.0291 - 0.0378) (0.059)
0.03 - 0.08 0.2 j —
(0.0012 - 0.0031) (0.008)
0.04 - 0.07
(0.0016 - 0.0028) Reverse

0.07 - 0.10 Splitter

Clearance between transmis- (0.0028 - 0.0039)
sion cover and shift fork shaft 0.04 - 0.07 0.3
(0.0016 - 0.0028) (0.012) Range — j

0.07 - 0.17 1st - 2nd

(0.0028 - 0.0067)
0.06 - 0.15
(0.0024 - 0.0059) 3rd - 4th

Clearance between locking 0.04 - 0.08 0.2 Except for those indi- j —
lever and lever shaft (0.0016 - 0.0031) (0.008) cated below
Clearance between locking 0.1 - 0.4 1.0 j —
lever and lever shifter (0.004 - 0.016) (0.039)
Clearance between each fork 0.1 - 0.5 1.0 — j
claw and synchronizer sleeve (0.004 - 0.020) (0.039)
Trans- Clearance between each fork 0.02 - 0.05 — — j
mission claw and shift fork (0.0008 - 0.0020)
cover 0.07 - 0.10
(0.0028 - 0.0039) Splitter
Clearance between cylinder 0.3 — j
and shift shaft 0.04 - 0.07 (0.012)
(0.0016 - 0.0028) Range

42.5 — j —
(1.673)
42.5 — 1st to 6th & Reverse
Free (1.673)
length 35.0
(1.378) — Splitter — j

34.5
(1.358) — Range
Shift fork 127 - 157 157 When compressed to
shaft locking j —
{13 - 16, 29 - 35} {13, 29} 27.0 mm (1.063 in)
spring
137 - 167 1st to 6th & Reverse
{14 - 17, 31 - 37} — When compressed to
29.0 mm (1.142 in)
Tension
N {kgf, lbf} Splitter
78 - 98 — When compressed to — j
{8 - 10, 18 - 22} 28.0 mm (1.102 in)
Range
127 - 157 — When compressed to
{13 - 16, 29 - 35} 28.0 mm (1.102 in)
0.10 - 0.24 1.0 Except for those indi- j —
Clearance between shift fork (0.0039 - 0.0094) (0.039) cated below
and sleeve groove 0.10 - 0.29 1.0
(0.0039 - 0.0114) (0.039) At 5th & 6th gears j —

Clearance between reverse 0.10 - 0.24 1.0

shift fork and reverse sleeve (0.0039 - 0.0094) (0.039) — j
groove

TM-1-4
 SERVICE DATA T/M PROPER

Unit: mm (in)
Maintenance Application
Item standard Service limit Remarks
MTS60G MRT21A
0.10 - 0.20 0.5 — j
Each main gear and counter gear (0.0039 - 0.0079) (0.020)
backlash 0.15 - 0.25 0.5
(0.0059 - 0.0098) (0.020) j —

0.30 - 0.50 j —
(0.0118 - 0.0197) 0.7
1st gear (0.028)
0.20 - 0.40 — j
(0.0079 - 0.0157)
0.30 - 0.50 j —
(0.0118 - 0.0197) 0.7
2nd gear (0.028)
0.20 - 0.40 — j
(0.0079 - 0.0157)
0.30 - 0.50 j —
(0.0118 - 0.0197) 0.7
3rd gear (0.028)
0.20 - 0.40 — j
Each main (0.0079 - 0.0157)
gear end play 0.30 - 0.50 0.7
4th gear (0.0118 - 0.0197) (0.028) j —

0.35 - 0.55 0.7

6th gear (0.0138 - 0.0217) (0.028) j —

0.30 - 0.50
(0.0118 - 0.0197) j —
Reverse gear 0.7
0.20 - 0.40 (0.028)
(0.0079 - 0.0157) — j

Splitter gear 0.20 - 0.40 0.7 — j

(0.0079 - 0.0157) (0.028)

Range low gear 0.20 - 0.40 0.7 — j

Trans- (0.0079 - 0.0157) (0.028)
mission
proper 0.30 - 0.80 1.0 j —
(0.0118 - 0.0315) (0.039)
Reverse idler gear end play
0.30 - 0.50 1.0 — j
(0.0118 - 0.0197) (0.039)
Radial play of main shaft and 0.20 - 0.30 0.5 j —
sleeve splines (0.0079 - 0.0118) (0.020)
Radial play between hub and 0.20 - 0.30 0.5
sleeve splines (0.0079 - 0.0118) (0.020) j j

0.40 - 0.50 1.0 j —

(0.0157 - 0.0197) (0.039)
1st gear
0.20 - 0.30 1.0 — j
(0.0079 - 0.0118) (0.039)

2nd gear 0.20 - 0.30 1.0 j j

(0.0079 - 0.0118) (0.039)

3rd gear 0.20 - 0.30 1.0 j j

Radial play (0.0079 - 0.0118) (0.039)
between
sleeves and 4th gear 0.20 - 0.30 1.0 j —
clutch gear (0.0079 - 0.0118) (0.039)
splines 0.20 - 0.30 1.0
6th gear (0.0079 - 0.0118) (0.039) j —

0.20 - 0.30 1.0

Splitter gear (0.0079 - 0.0118) (0.039) — j

Range low gear 0.20 - 0.30 1.0 — j

(0.0079 - 0.0118) (0.039)

Reverse gear 0.40 - 0.50 1.0 j j

(0.0157 - 0.0197) (0.039)

Ball bearing axial play — 0.5 j j

(0.020)

TM-1-5
 SERVICE DATA T/M PROPER

Unit: mm (in)
Maintenance Application
Item standard Service limit Remarks
MTS60G MRT21A
Minus (−) symbol
Pin type Alignment of synchronizer −0.2 - 0.4 — Protrusion from the j —
rings with their discs (−0.008 - 0.016) disc
6.3 - 6.7 — 1st to 4th
Tangential clearance between (0.248 - 0.264)
synchronizer ring and syn- — j
chronizer hub 6.5 - 6.9 — Splitter
(0.256 - 0.272)
1.4 - 1.8
(0.055 - 0.071) 1st - 2nd

Clearance between synchro- 1.5 - 1.9 0 3rd - 4th — j

nizer rings and their cone (0.059 - 0.075)
1.4 - 1.6 Splitter
(0.055 - 0.063)
0.1 - 0.3 — 1st to 4th
Axial clearance between syn- (0.004 - 0.012)
chronizer ring and synchro- — j
nizer detent 1.3 - 1.5
— Splitter
Lock (0.051 - 0.059)
plunger
type 25.0
Synchro- (0.984) — 1st to 4th
nizer
system 26.0
Free length (1.024) — Splitter — j

35.6
(1.402) — Range

56.9 - 68.6 1st to 4th

Detent spring {5.8 - 7.0, — When compressed to
12.8 - 15.4} 18.0 mm (0.709 in)

Tension 70.6 - 86.3 Splitter

N {kgf, lbf} {7.2 - 8.8, — When compressed to — j
15.9 - 19.4} 22.0 mm (0.866 in)
153 - 169 Range
{15.6 - 17.2, — When compressed to
34 - 38} 29.0 mm (1.142 in)
Clearance between synchro- 1.5 - 2.7 0 j —
nizer ring and cone (0.059 - 0.106)

Key type Radial play between key and 4.49 - 4.85 — j —

synchronizer ring (0.1768 - 0.1909)
Radial play between key and 0.04 - 0.19
synchronizer hub (0.0016 - 0.0075) — j —

0.05 - 0.09
Oil pump gear end play (0.0020 - 0.0035) —
Oil pump Radial play between oil pump — j
gear and counter shaft at 0 - 0.18 —
splines (0 - 0.0071)

TM-1-6
 SERVICE DATA T/M PROPER

Unit: mm (in)
Maintenance Application
Item standard Service limit Remarks
MTS60G MRT21A
Item No. j
20 25.5
(Large) (1.004) —

Free Item No. j

30 23.6
length (Medium) (0.929) —

Item No. j
25 21.0
(Small) (0.827) —
Type I j —
Item No. j
20 46.58 38.2 When compressed to
(Large) {4.75, 10.47} {3.9, 8.6} 15.05 mm (0.5925 in)
Ten-
sion Item No. j
30 13.82 11.8 When compressed to
N {kgf, (Medium) {1.41, 3.11} {1.2, 2.6} 15.05 mm (0.5925 in)
lbf}
Item No. j
25 9.02 6.9 When compressed to
Power (Small) {0.92, 2.03} {0.7, 1.5} 13.0 mm (0.512 in)
shift
spring Item No. j
16 18.1
(Taper) (0.713) —
Power Free 21.0
shift length Item No. j
21 —
(0.827)
Item No. j
26 15.0
(Taper) (0.591) —
Type II — j
Item No. j
16 47.1 40.2 When compressed to
(Taper) {4.8, 10.6} {4.1, 9.0} 13.0 mm (0.512 in)
Ten-
sion 12.7 10.8 When compressed to
N {kgf, Item No. j
21
{1.3, 2.9} {1.1, 2.4} 10.0 mm (0.394 in)
lbf}
Item No. j
26 18.6 15.7 When compressed to
(Taper) {1.9, 4.2} {1.6, 3.5} 13.0 mm (0.512 in)
0.15
Valve seal dent depth (0.0059), — j j
max.

Distance between pipe retaining ring 80.5 - 81.1

groove and cap end (3.169 - — j —
3.193)

NOTE
+ Item Nos. indicate the disassembly sequence in the illustration.

TM-1-7
 SERVICE DATA T/M PROPER

TIGHTENING TORQUE
UNIT NAME: MTS60G
Unit: N·m {kgfzm, ftzlbf}
Item Tightening torque
Clutch housing mounting bolt 142 - 186 {14.5 - 19.0, 105 - 137}
Transmission cover mounting bolt or nut 32 - 42 {3.3 - 4.3, 24 - 31}
Control cover mounting bolt 19 - 25 {1.9 - 2.6, 14 - 19}
Locking lever shaft mounting nut (on cover side) 89 - 118 {9.1 - 12.0, 66 - 87}
Guide bolt 34 - 45 {3.5 - 4.6, 25 - 33}
Switch 34 - 39 {3.5 - 4.0, 25 - 29}
Gear cover securing bolt 19 - 25 {1.9 - 2.6, 14 - 19}
Side cover mounting bolt 19 - 25 {1.9 - 2.6, 14 - 19}
PTO gear box mounting bolt and nut 32 - 42 {3.3 - 4.3, 24 - 31}
Drain plug and level plug 118 - 137 {12.0 - 14.0, 87 - 101}
Main drive gear bearing cap mounting bolt 32 - 42 {3.3 - 4.3, 24 - 31}

Rear bearing retainer securing Bolt 89 - 118 {9.1 - 12.0, 66 - 87}

bolt and nut Nut 137 - 186 {14.0 - 19.0, 101 - 137}
Oil pump securing bolt 18 - 22 {1.8 - 2.2, 13 - 16}
Companion flange securing nut 686 - 981 {70 - 100, 506 - 723}
Main shaft lock nut 324 - 363 {33.0 - 37.0, 239 - 268}
Counter shaft rear cover mounting bolt 57 - 76 {5.8 - 7.7, 42 - 56}
Oil catcher securing bolt 16 - 21 {1.6 - 2.1, 12 - 15}
Power shift assembly mounting
78 - 98 {8.0 - 10.0, 58 - 72}
bolt
Power shift cylinder 78 - 98 {8.0 - 10.0, 58 - 72}
Power shift cylinder screw Type I 2.0 - 3.4 {0.2 - 0.35, 1.4 - 2.5}
Power shift striker nut 29 - 39 {3.0 - 4.0, 22 - 29}
Power shift connector 8 - 12 {0.8 - 1.2, 5.8 - 8.7}
Power shift cylinder nut 59 - 69 {6.0 - 7.0, 43 - 51}

TM-1-8
 SERVICE DATA T/M PROPER

UNIT NAME: MRT21A

Unit: N·m {kgfzm, ftzlbf}
Item Tightening torque
Drain plug 118 - 137 {12.0 - 14.0, 87 - 101}
Front case Switch 108 - 127 {11.0 - 13.0, 80 - 94}
Plug 57 - 76 {5.8 - 7.7, 42 - 56}
Main bearing cap mounting bolt 32 - 42 {3.3 - 4.3, 24 - 31}
Switch 108 - 127 {11.0 - 13.0, 80 - 94}
Plug 57 - 76 {5.8 - 7.7, 42 - 56}
Anti-overrun sensor 25 - 34 {2.5 - 3.5, 18 - 25}
Gear cover mounting bolt 19 - 25 {1.9 - 2.6, 14 - 19}
Middle case
Level plug 118 - 137 {12.0 - 14.0, 87 - 101}
Middle case securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Side cover mounting bolt 19 - 25 {1.9 - 2.6, 14 - 19}
PTO gear box mounting bolt and nut 32 - 42 {3.3 - 4.3, 24 - 31}
Bearing retainer securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Rear case securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Drain plug and level plug 118 - 137 {12.0 - 14.0, 87 - 101}
Gear cover mounting bolt 19 - 25 {1.9 - 2.6, 14 - 19}
Anti-overrun sensor 25 - 34 {2.5 - 3.5, 18 - 25}
Speedometer gear sleeve 34 - 44 {3.5 - 4.5, 25 - 33}
Sub countershaft bearing retainer securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Rear case Rear bearing retainer securing bolts Nut 137 - 186 {14.0 - 19.0, 101 - 137}
and nut Bolt 89 - 118 {9.1 - 12.0, 66 - 87}
Splitter 57 - 76 {5.8 - 7.7, 42 - 56}
Piston securing nuts
Range 137 - 186 {14.0 - 19.0, 101 - 137}
Cylinder cap securing bolts 32 - 42 {3.3 - 4.3, 24 - 31}
Switch 108 - 127 {11.0 - 13.0, 80 - 94}
Plug 57 - 76 {5.8 - 7.7, 42 - 56}
Main shaft Main shaft lock nut (Left-hand thread) 412 - 471 {42.0 - 48.0, 304 - 347}
Companion flange securing nut 686 - 981 {70.0 - 100.0, 506 - 723}
Sub main shaft and countershaft
Range high gear lock nut 686 - 981 {70.0 - 100.0, 506 - 723}
Shift fork and shifter securing set screw 32 - 42 {3.3 - 4.3, 24 - 31}
Shift fork assembly
Shift shaft support securing bolts 25 - 31 {2.5 - 3.2, 18 - 23}
Control cover mounting bolt 32 - 42 {3.3 - 4.3, 24 - 31}
Power shift assembly securing bolts 21 - 23 {2.1 - 2.3, 15 - 17}
Joint mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Transmission control cover assembly Guide bolt 57 - 76 {5.8 - 7.7, 42 - 56}
Plug 57 - 76 {5.8 - 7.7, 42 - 56}
Switch 34 - 49 {3.5 - 5.0, 25 - 36}
Cylinder cover securing 8.6 - 12.7 {0.88 - 1.3, 6.4 - 9.4}

TM-1-9
 SERVICE DATA T/M PROPER

Unit: N·m {kgfzm, ftzlbf}

Item Tightening torque
Oil filter securing bolt 32 - 42 {3.3 - 4.3, 24 - 31}
Oil pump securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Oil pump and oil filter
Valve case mounting bolt 16 - 21 {1.6 - 2.1, 12 - 15}
Connector 85 - 98 {8.7 - 10.0, 63 - 72}
Power shift cylinder 98 - 118 {10.0 - 12.0, 72 - 87}

Power shift assem- Power shift cylinder screw 2.0 - 3.4 {0.20 - 0.35, 1.4 - 2.5}
Type II
bly Power shift connector 8 - 12 {0.8 - 1.2, 5.8 - 8.7}
Power shift cylinder nuts 59 - 69 {6.0 - 7.0, 43 - 51}

TM-1-10
 SERVICE DATA T/M PROPER

SYSTEM DIAGRAM
UNIT NAME: MRT21A

CTM1137D

CTM1137E

TM-1-11
 TOOLS T/M PROPER

TOOLS
UNIT NAME: MRT21A
Tool name and number Description Shape

Used together with the adapter

Sliding hammer
to drive out the reverse idler
99547 Z0000
gear shaft.

CTL1-043

Used to remove/install main

Socket wrench shaft nuts or companion flange.
99535 Z0074 Width across flats = 58 mm
(2.28 in)
CTL1-015

Attached to input shaft splines to

Main drive shaft stopper
prevent the input shaft from ro-
99803 Z0000
tating.

WTM026A

Used when lifting the main shaft

Gear hanger assembly
and countershaft assemblies as
99783 Z0002
a unit.

WTM027A

Used when removing the main

shaft rear nut lock plate and the
Lock plate replacer sub-main shaft bearing outer
99827 Z0069 race as a unit.
(Used with sliding hammer:
99547 Z0000) WTM028A

Attached to the front case when

Gear shaft setting tool
disassembling/reassembling the
99799 Z0003
main shaft.

WTM029A

TM-2-1
 TOOLS T/M PROPER

Tool name and number Description Shape

Attached to the main shaft rear

Construction stand
splines when installing the main
99805 Z0000
shaft tip end.

WTM030A

Bushing replacer
1st - 2nd
99801 Z0001 Used when pressing bushings
into bores in the front and
Bushing replacer middle cases.
3rd - 4th
99801 Z0002
Bushing replacer Used when pressing the shift
At control lever shaft bushing into the bore in WTM031A
99801 Z0003 the control cover.

Used as a jig to measure the

Drive gear set tool bearing-to-bearing gap when
99806 Z0000 selecting shims suited to the 4th
gear bearing preload.

WTM032A

Used when pressing the bearing

Bearing retainer replacer
retainer onto the main shaft rear
99827 Z0068
end.

WTM033A

Oil seal replacer

Range side Used when pressing oil seals
99807 Z0004 onto the range-splitter select air
Splitter side cylinder.
99807 Z0005
WTM108A

Used to protect the main shaft

Main shaft adapter end from damage when disas-
99804 Z0000 sembling the main shaft using a
gear puller.
WTM034A

TM-2-2
 TOOLS T/M PROPER

Tool name and number Description Shape

Used when removing the bear-

Bearing remover
ing from the main shaft rear
99800 Z0002
bearing retainer.

WTM038A

Used when disassembling and

reassembling the transmission.
Attachment
The attachment is used by in-
99555 Z0000
stalling it on the engine stand
(99550 96001).

WTM072A

Puller assembly Used when pull out the straight

910-11150 (JKC No.) pin on power shift striker.

WTM035A

Guide Used when installing valve on

910-24800 (JKC No.) power shift rod pipe.

WTM036A

Tool insert Used when installing snap ring

910-26500 (JKC No.) on power shift rod pipe.

WTM037A

TM-2-3
 DISASSEMBLY MTS60

= UNIT NAME MTS60 =

DISASSEMBLY
DISASSEMBLY
TRANSMISSION COVER ASSEMBLY

WTM181A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j1 Switch >j
14 Shift fork (Reverse) >j
26 Shift fork (1st & 2nd)
j2 Steel ball j
15 Interlock pin j
27 Steel ball
j3 Switch j
16 Steel ball j
28 Interlock pin
j4 Steel ball j
17 Shift shaft j
29 Shift shaft
j5 Guide bolt j
18 Spring pin j
30 Spring pin
j6 Welch plug >j
19 Shift fork (5th & 6th) >j
31 Shifter
j7 Locking spring >j
20 Shifter >j
32 Shift fork (3rd & 4th)
j8 Steel ball j j
33 Shift shaft
21 Steel ball
j9 Locking lever shaft j
34 Spring pin
j
22 Interlock pin
j
10 Locking lever >j
35 Shifter
j
23 Shift shaft
j
11 Self-locking nut >j
36 Shifter
j
24 Spring pin
j
12 Spring pin j
37 Shift shaft
>j
25 Shifter
>j
13 Shifter
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

TM-3-1
 REASSEMBLY MTS60

REASSEMBLY
REASSEMBLY
TRANSMISSION COVER ASSEMBLY
Key point of reassembly
j13 , j
14 , j
19 , j 25 , j
20 , j 26 , j
31 , j
32 , j
35 , j
36 Shift fork or shifter
Always drive the spring pin into the shift fork and shifter with the
groove facing the axial direction of the shaft. The outer and inner
spring pin grooves should face in the opposite direction to each
other.
CTM1163A

TM-3-2
 REASSEMBLY MTS60

- MEMO -

TM-3-3
 CONSTRUCTION MRT21A

= UNIT NAME MRT21A =

CONSTRUCTION
TRANSMISSION ASSEMBLY

WTM182A

TM-4-1
 CONSTRUCTION MRT21A

MAIN SHAFT ASSEMBLY

WTM148A

COUNTERSHAFT ASSEMBLY

WTM149A

TM-4-2
 CONSTRUCTION MRT21A

POWER SHIFT ASSEMBLY

WTM150A

TM-4-3
 DISASSEMBLY MRT21A

DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the transmission assembly, turn the key
switch to the ‘‘OFF’’ position and chock the wheels to be safe.
2. Remove the drain plug and drain transmission gear oil from the
transmission case.
3. Remove/disengage the propeller shaft, transmission linkage,
cable, wiring, PTO (when equipped), etc., from around the
transmission case.
4. Remove the transmission from the flywheel housing. Support CCL1047A
the transmission with a jack or lifting wires to prevent it from
dropping, and remove it from the flywheel housing.
NOTE
+ Do not separate the wear indicator and stay.

WTM043A

TM-4-4
 DISASSEMBLY MRT21A

DISASSEMBLY
MIDDLE CASE ASSEMBLY

ETM210A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

>j
1 Bearing retainer >j
6 Side cover j9 Gear cover
j
2 Oil seal ring (PTO gear box: if so equipped) j
10 Bear cap
.j
3 Gear cover >j
7 Reverse idler gear assembly j
11 Oil seal
j
4 Anti-overrun sensor .>j
8 Middle case j
12 O-ring
.j
5 Neutral detection switch
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

TM-4-5
 DISASSEMBLY MRT21A

REAR CASE ASSEMBLY

ETM211A

TM-4-6
 DISASSEMBLY MRT21A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j
1 Rear bearing retainer j9 Cylinder cap j
17 Range piston
j
2 Gasket j
10 O-ring >j
18 Air cylinder
j
3 Oil seal j
11 O-ring j
19 Air/oil seal
j
4 Speedometer driven gear j
12 O-ring j
20 Air/oil seal
assembly j
13 Piston packing j
21 Pin
>j
5 Speedometer drive gear j
14 Splitter piston j
22 Gasket
j
6 Anti-overrun sensor j
15 O-ring >.j
23 Rear case
.j
7 Sub countershaft bearing retainer j
16 Piston packing j
24 Gear cover
j
8 Adjusting shim
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

TM-4-7
 DISASSEMBLY MRT21A

FRONT CASE ASSEMBLY

WTM097A

j
1 Top cover j9 Release sleeve j
17 Needle bearing
j
2 Rubber seat j
10 Release bearing j
18 Oil seal
j
3 Air cleaner case (upper) j
11 Set bolt j
19 Grease nipple
j
4 Air cleaner element j
12 Release shaft j
20 Plug
j
5 Air cleaner case (lower) j
13 Key j
21 Taper plug
j
6 Grease nipple j
14 Release yoke j
22 Under cover
j
7 Hose j
15 Release yoke bearing j
23 Rubber seat
j
8 Spring j
16 Oil seal j
24 Front case
NOTE
+ Numbers before part names do not indicate the disassembly sequence.

TM-4-8
 DISASSEMBLY MRT21A

OIL PUMP AND OIL FILTER ASSEMBLY

WTM345A

TM-4-9
 DISASSEMBLY MRT21A

MAIN SHAFT ASSEMBLY

WTM328A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j1 Tapered bearing j
17 Detent spring >j
33 Detent spring
j2 Reverse gear j
18 2nd double synchro assembly >j
34 3rd-4th synchro sleeve
j3 Reverse sleeve j
19 2nd gear >j
35 3rd synchro ring
j4 Needle bearing j
20 Needle bearing j
36 3rd gear
j5 Reverse gear bearing inner race >.j
21 Lock nut (LH thread) j
37 Needle bearing
j6 Reverse hub j
22 Tapered bearing j
38 Main shaft
j7 1st gear j
23 Thrust washer j
39 Adjusting shim
j8 Needle bearing j
24 Tapered bearing j
40 Detent
j9 Spacer j
25 Synchro ring j
41 Detent spring
j
10 Needle bearing j
26 Drive gear assembly .j
42 Clip
j
11 1st gear bearing inner race j
27 Synchro ring .j
43 Tapered bearing
j
12 1st double synchro assembly >j
28 Adjusting spacer j
44 Splitter synchro sleeve
j
13 1st-2nd synchro sleeve j
29 Tapered bearing .j
45 Splitter gear
j
14 1st-2nd synchro hub >j
30 3rd-4th synchro hub .j
46 Splitter synchro ring
j
15 Detent >j
31 Detent .j
47 Needle bearing
j
16 Synchro plunger >j
32 Synchro plunger .j
48 Input shaft
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

TM-4-10
 DISASSEMBLY MRT21A

COUNTERSHAFT ASSEMBLY

ETM146A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j
1 Adjusting shim j
4 Clip j
7 Key
j
2 Tapered bearing* j
5 Splitter counter gear j
8 Countershaft
j
3 Tapered bearing* j
6 Counter drive gear
*: Do not reuse parts after removal.

TM-4-11
 DISASSEMBLY MRT21A

SUB MAIN SHAFT AND SUB COUNTERSHAFT ASSEMBLY

ETM145A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j
1 Lock nut j8 Needle bearing j
15 Synchro cone
j
2 O-ring j9 Range synchro sleeve .j
16 Sub countershaft assembly
j
3 Companion flange j
10 Detent .j
17 Tapered bearing
j
4 Dust shield j
11 Detent spring >j
18 Lock washer
j
5 Ball bearing j
12 Range double synchro assembly j
19 Range high gear lock nut
j
6 Thrust washer j
13 Output shaft >.j
20 Range high gear
.j
7 Range low gear j
14 Synchro ring
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

TM-4-12
 DISASSEMBLY MRT21A

SHIFT FORK ASSEMBLY

ETM212A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j
1 Pin j
10 3rd-4th shift shaft j
19 Setscrew
j
2 Ring j
11 Setscrew j
20 Ring
j
3 Clip j
12 1st-2nd shift shaft j
21 Reverse shifter
j
4 Range shift fork j
13 Fork claw j
22 Reverse shift shaft
j
5 Fork claw j
14 1st-2nd shift shaft j
23 Shift support
j
6 Range shift shaft j
15 Setscrew j
24 Setscrew
j
7 Setscrew j
16 1st-2nd shifter j
25 Splitter shift fork
j
8 3rd-4th shift fork j
17 Setscrew j
26 Fork claw
j
9 Fork claw j
18 Reverse shift fork j
27 Splitter shift shaft

TM-4-13
 DISASSEMBLY MRT21A

TRANSMISSION CONTROL COVER ASSEMBLY

WTM337A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j1 Plug j
13 Oil seal j
25 Cylinder cover
j2 Spring j
14 Straight pin j
26 Needle bearing
j3 Steel ball (large) j
15 Spring pin j
27 Oil seal
j4 Steel ball (small) j
16 Shift lever j
28 Shift shaft
j5 Range shift switch j
17 Select lever j
29 Washer
j6 Gasket j
18 Bushing j
30 Spring
j7 Plunger j
19 Shift shaft j
31 Plug
j8 Plug j
20 Collar j
32 Retaining ring
j9 Spring j
21 Spring j
33 Gasket
j
10 Plunger j
22 Packing j
34 Power shift assembly
j
11 Guide bolt j
23 Piston j
35 Joint
j
12 Lever cap j
24 O-ring

TM-4-14
 DISASSEMBLY MRT21A

POWER SHIFT ASSEMBLY

ETM073A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

>j1 Cylinder boots j

18 Lifter ring j
35 Cylinder O-ring
j2 Connector nut >.j
19 Seat seal assembly .j
36 Cylinder packing
j3 Cylinder connector j
20 O-ring j
37 Rod plate
j4 Retaining ring j
21 Seal spring j
38 Cap packing
j5 Retaining ring plate j
22 O-ring j
39 Striker
.j6 Straight pin >.j
23 Seat seal assembly j
40 Piston ring
j7 Tube filter j
24 Spring seat j
41 Piston
j8 Tube collar j
25 Lifter ring >j
42 Piston packing
j9 Tube j
26 Lifter spring j
43 Piston O-ring
j
10 Lifter ring j
27 Lifter j
44 Piston ring
j
11 O-ring j
28 Lifter O-ring j
45 Rod pipe
>j
12 Tube ring j
29 Tube j
46 Housing hose clamp
j
13 Rod pipe plate j
30 Lifter ring j
47 Housing hose
j
14 Lifter j
31 Rod pipe j
48 Housing boot clamp
j
15 Lifter O-ring >j
32 Rod cap assembly j
49 Housing boot
j
16 Lifter spring >j
33 Housing setscrew j
50 Housing
j
17 Spring seat j
34 Cylinder
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

TM-4-15
 DISASSEMBLY MRT21A

TRANSMISSION ASSEMBLY
Key point of disassembly
+ Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.

+ Install the transmission assembly to the attachment (99555

Z0000).

WTM105A

+ Attach the main drive shaft stopper (99803 Z0000) to input

shaft splines.

CTM1314B

+ When the control cover is removed, attach the stopper and

push the shift shaft with a screwdriver to engage gears (to enter
shifted condition).

CTM1314A

+ Unlock the lock nut, and remove the lock nut using socket
wrench (99535 Z0074).
CAUTION
+ Before removing the lock nut, make sure the transmission
case is securely fixed.
NOTE
+ Do not re-use the lock nut after removal.

WTM154A

TM-4-16
 DISASSEMBLY MRT21A

REAR CASE ASSEMBLY

Key point of disassembly
j7 Sub countershaft bearing retainer
Remove the sub countershaft bearing retainer, shim and O-ring.
NOTE
+ Attach a tag to the shim for identification purposes.

CTM1320A

j
23 Rear case
1. Remove the nuts and washers securing the splitter and range
pistons.

CTM1319A

2. While holding the end of the shaft by hand, apply compressed

air to the cylinder to push out the range and splitter pistons.

CTM1319B

3. Lightly tap the points (indicated by the arrows in the figure at

right), then remove the air cylinder.

CTM1319C

4. Remove the splitter shift shaft locking plug.

CTM1321A

TM-4-17
 DISASSEMBLY MRT21A

5. Remove the transmission anti-overrun sensor.

CTM1-318

6. Install and tighten rear case mounting bolts in bolt holes on the
rear case flange. These bolts are used as pull bolts.

CTM1321B

7. Lift the rear case vertically.

NOTE
+ Take time to work on the rear case, being careful not to
damage the range and splitter shafts.
+ Attach lifting cables to retainer mounting stud bolts, then
lift the rear case.

CTM1321C

SUB MAIN SHAFT AND SUB COUNTERSHAFT ASSEM-

BLY
j7 Range low gear
Tilt the sub countershaft outward and remove the range low gear.
NOTE
+ If the sub countershaft is hard to tilt, the notch of the
synchro cone may be misaligned with the countershaft.
Re-align if necessary.

WTM338A

j
16 Sub countershaft assembly
Remove the sub countershaft assembly.
NOTE
+ Tilt the sub countershaft inward before removing.

CTM1-349

TM-4-18
 DISASSEMBLY MRT21A

j17 Tapered bearing

Using the sliding hammer (99547 Z0000) and lock plate replacer
(99827 Z0069), remove the tapered bearing outer race and lock
washer.

CTM1348A

j
20 Range high gear
1. Remove the lock nut using socket wrench (99535 Z0074).
NOTE
+ Before removing the lock nut, check to ensure that the
input shaft splines and shift shaft are clinched properly.

CTM1-350

2. Remove the bolt securing the bearing retainer, then remove the
range high gear and bearing retainer assembly using a gear
puller and main shaft adapter (99804 Z0000).

CTM1348B

3. Using a hydraulic press and bearing remover (99800 Z0002),

disassemble the bearing retainer assembly.

CTM1322R

MIDDLE CASE ASSEMBLY

+ Remove the valve assembly.
NOTE
+ Do not remove the valve assembly unless necessary.

CTM1325L

TM-4-19
 DISASSEMBLY MRT21A

j3 Gear cover
Remove the gear cover.
NOTE
+ Do not remove the gear cover unless necessary.

CTM1348C

j5 Neutral detection switch

Remove the neutral detection (sensor) switch.
NOTE
+ Ensure the shift fork is set to neutral so that the sensor pin
will not come out of position during switch removal.

CTM1348D

j8 Middle case
Lift the middle case until it is moved away from the various shift
shafts and splitter shafts.
NOTE
+ Set the middle case as level as possible during lifting. Do
not apply undue stress to shift shafts.

CTM1-322

SHIFT FORK ASSEMBLY

Key point of disassembly
1. Install the mainshaft rear nuts to secure the gear hanger
assembly (99783 Z0002), mainshaft, countershaft and the
various shift shafts.

CTM1351A

2. Attach the gear shaft setting tool (99799 Z0003) to top of the
front case, then lower the gear shaft assembly to the floor.

CTM1351B

TM-4-20
 DISASSEMBLY MRT21A

3. Remove the gear hanger assembly.

4. Remove the reverse, 1st-2nd and 3rd-4th shift shaft assem-
blies.
NOTE
+ The shafts and forks are clinched at the setscrews. Do not
separate the shafts and forks unless necessary.

CTM1322E

5. Remove the splitter shift shaft assembly.

NOTE
+ The shaft and fork are clinched at the setscrews. Do not
separate the shaft and fork unless necessary.

CTM1322F

MAIN SHAFT ASSEMBLY

Key point of disassembly
1. Using the gear hanger assembly (99783 Z0002), remove the
main shaft sub assembly from the input shaft assembly.

CTM1322M

2. Attach the main shaft sub assembly to the construction stand

(99805 Z0000).
Remove the gear hanger assembly.

CTM1322L

j21 Lock nut (LH thread)

Unlock and lock nut, and remove the lock nut using socket wrench
(99535 Z0074).

CTM1322N

TM-4-21
 DISASSEMBLY MRT21A

j42 , j
43 , j
45 , j
46 , j
47 , j
48 Input shaft assembly
Remove the clip from the input shaft. Using a hydraulic press,
remove the input shaft, tapered bearing, splitter gear, needle
bearing and splitter synchro ring.
NOTE
+ Remove the detent and detent spring in advance.

CTM1322S

j
1 Clip j
4 Splitter synchro ring
j
2 Tapered bearing j
5 Needle bearing
j
3 Splitter gear j
6 Input shaft

CTM1351C

POWER SHIFT ASSEMBLY

Key point of disassembly
j6 Straight pin
Remove the retaining ring and retaining ring plate.
Using the puller assembly (910-11150 JKC NO.), pull out the
straight pin.

WTM114A

CTM1255E

j
19 , j23 Seat seal assembly
Remove the valve assembly.
NOTE
+ Be careful not to damage spring seat and lifter ring during
removal.

CTM1-256

TM-4-22
 DISASSEMBLY MRT21A

j
36 Cylinder packing
Remove the cylinder packing and cap packing.
NOTE
+ These parts need not be removed unless damaged.

CTM1262B

TM-4-23
 INSPECTION MRT21A

INSPECTION
+ Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
+ If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

TRANSMISSION COVER
Clearance between shift lever and select lever
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)

CTM1-177

Radial play between shift shaft and shift lever splines

Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.08 (0.0008 - 0.0031) 0.5 (0.020)

CTM1-178

Clearance between shift lever and each shifter/shift

fork
Unit: mm (in)
Maintenance standard Service limit
0.74 - 0.96 (0.0291 - 0.0378) 1.5 (0.059)

CTM1-179

Clearance between transmission cover and shift fork

shaft
Unit: mm (in)
Maintenance standard Service limit Remarks
0.04 - 0.07 (0.0016 - 0.0028) Reverse
0.07 - 0.10 (0.0028 - 0.0039) Splitter
0.04 - 0.07 (0.0016 - 0.0028) 0.3 (0.012) Range
0.07 - 0.17 (0.0028 - 0.0067) 1st-2nd
0.06 - 0.15 (0.0024 - 0.0059) 3rd-4th

TM-4-24
 INSPECTION MRT21A

Clearance between each fork claw and synchronizer

sleeve
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.5 (0.004 - 0.020) 1.0 (0.039)

CTM1086A

Clearance between each fork claw and shift fork

Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.05 (0.0008 - 0.0020) —

CTM1086B

Clearance between cylinder and shift shaft

Unit: mm (in)
Maintenance standard Service limit Remarks
0.07 - 0.10 (0.0028 - 0.0039) Splitter
0.3 (0.012)
0.04 - 0.07 (0.0016 - 0.0028) Range

Shift fork shaft locking spring

Unit: mm (in)
Nominal Maintenance
Item Remarks
dimension standard
42.5 (1.673) — 1st to 6th & Reverse
Free length 35.0 (1.378) — Splitter
34.5 (1.358) — Range
1st to 6th & Reverse
137 - 167
— When compressed to
{14 - 17, 31 - 37}
29.0 mm (1.142 in)
Splitter
Tension 78 - 98
— When compressed to
N {kgf, lbf} {8 - 10, 18 - 22}
28.0 mm (1.102 in)
Range
127 - 157
— When compressed to
{13 - 16, 29 - 35}
28.0 mm (1.102 in)

TM-4-25
 INSPECTION MRT21A

Clearance between reverse shift fork and reverse

sleeve groove
Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.24 (0.0039 - 0.0094) 1.0 (0.039)

CTM1-086

TRANSMISSION PROPER
Each main gear and counter gear backlash
Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.20 (0.0039 - 0.0079) 0.5 (0.020)

Each main gear end play

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.40 (0.0079 - 0.0157) 0.7 (0.028)

Reverse idler gear end play

Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.50 (0.0118 - 0.0197) 1.0 (0.039)

Radial play between hub and sleeve splines

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

Radial play between sleeve and clutch gear splines

Unit: mm (in)
Maintenance standard Service limit Remarks
0.40 - 0.50 (0.0157 - 0.0197) Reverse
1.0 (0.039)
0.20 - 0.30 (0.0079 - 0.0118) Except for reverse

Ball bearing axial play

Unit: mm (in)
Maintenance standard Service limit
— 0.5 (0.020)

CPS1-014

TM-4-26
 INSPECTION MRT21A

SYNCHRONIZERS SYSTEM
<Lock plunger type>
Tangential clearance between synchronizer ring and
synchronizer hub
Unit: mm (in)
Maintenance standard Service limit Remarks
6.3 - 6.7 (0.248 - 0.264) 1st to 4th
—
6.5 - 6.9 (0.256 - 0.272) Splitter
CTM1089C

Clearance between synchronizer ring and clutch gear

Unit: mm (in)
Maintenance standard Service limit Remarks
1.4 - 1.8 (0.055 - 0.071) 1st-2nd
1.5 - 1.9 (0.059 - 0.075) 0 (0) 3rd-4th
1.4 - 1.6 (0.055 - 0.063) Splitter

CTM1088F

Axial clearance between synchronizer ring and syn-

chronizer detent
Unit: mm (in)
Maintenance standard Service limit Remarks
0.1 - 0.3 (0.004 - 0.012) 1st to 4th
—
1.3 - 1.5 (0.051 - 0.059) Splitter

CTM1090A

Detent spring
Unit: mm (in)
Nominal Maintenance
Item Remarks
dimension standard
25.0 (0.984) 1st to 4th
Free length 26.0 (1.024) — Splitter
35.6 (1.402) Range
56.9 - 68.6 1st to 4th
{5.8 - 7.0, When compressed to
12.8 - 15.4} 18.0 mm (0.709 in)
70.6 - 86.3 Splitter
Tension
— {7.2 - 8.8, When compressed to
N {kgf, lbf}
15.9 - 19.4} 22.0 mm (0.866 in)
153 - 169 Range
{15.6 - 17.2, When compressed to
34 - 38} 29.0 mm (1.142 in)

TM-4-27
 INSPECTION MRT21A

OIL PUMP
Oil pump gear end play
Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.09 (0.0020 - 0.0035) —

Radial play between oil pump gear and counter shaft

at splines
Unit: mm (in)
Maintenance standard Service limit
0 - 0.18 (0 - 0.0071) —

POWER SHIFT
Power shift spring
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
18.1
Item No. j
16 —
(0.713)
Free 21.0
Item No. j
21 —
length (0.827)
15.0
Item No. j
26 —
(0.591)
47.1 40.2 When compressed to
Item No. j
16
{4.8, 10.6} {4.1, 9.0} 13.0 mm (0.512 in)
Tension 12.7 10.8 When compressed to
Item No. j
21
N {kgf, lbf} {1.3, 2.9} {1.1, 2.4} 10.0 mm (0.394 in)
18.6 15.7 When compressed to
Item No. j
26
{1.9, 4.2} {1.6, 3.5} 13.0 mm (0.512 in)

NOTE
+ Item Nos. indicate the disassembly sequence.
Valve seal dent depth
Unit: mm (in)
Maintenance standard Service limit
0.15 (0.0059), max. —

CTM1263A

TM-4-28
 REASSEMBLY MRT21A

REASSEMBLY
REASSEMBLY
+ When assembling or installing parts, pay attention to the
direction of gears, thrust washers, etc.
+ Do not confuse one type of needle bearing and spacer with
others.
+ Do not allow foreign particles to enter the needle bearings.
+ Apply a coat of clean gear oil to rotating parts.
+ After installing gears, manually rotate to ensure smooth rotation
without noise.
+ Use new oil seals and O-rings.
Apply a coat of RTV (Room Temperature Vulcanizing) liquid gasket
(Three Bond #1215 or equivalent) to the mating surfaces of the
middle case, rear case, side cover and control cover during
installation. Observe the following precautions during gasket ap-
plication.
<Precautions during RTV liquid gasket application>
+ Remove all traces of liquid gasket from the flanged surface of
parts using a scraper. Be careful not to scratch the flanged
surface and completely wipe away foreign particles (grease,
water, dust, etc.) using a clean cloth.

+ Apply a continuous coat of liquid gasket to the inner edge of the

flange and the center of the bolt hole, as well as to the outer
edge of the flange and the area as close as possible to the bolt
holes. The gasket bead width must be 3 mm (0.12 in).
For detailed information concerning the gasket application, refer to
the gasket application drawing in the text.
+ Also apply an equal and continuous bead of liquid gasket to
areas where the flanged surface is narrow (due to cutouts,
etc.); do not apply an excess coat to the gasket.
+ Install parts within 2 - 20 minutes of gasket application. Leave
parts unattended for approximately 2 hours, allowing the CDF1-051
gasket to completely harden.
FRONT CASE ASSEMBLY
Key point of reassembly
Bearing cap
Install the bearing cap (without the oil seal), adjusting shim and
bearing outer race in the front case as a unit.
NOTE
+ Do not install the oil seal and O-ring.

CTM1334A

Bushing
Press the bushing into the bore in the front case with the clinch set
at a right angle to the left when viewed from the press-in direction
(horizontal when viewed from the transmission installation direc-
tion).
NOTE
+ Use a bushing replacer to install the bushing.
1st-2nd 99801 Z0001
3rd-4th 99801 Z0002
CTM1-328

TM-4-29
 REASSEMBLY MRT21A

POWER SHIFT ASSEMBLY

Key point of reassembly
j42 Piston packing
Install the piston packing and piston O-ring on the piston, and the
piston assembly and retaining ring on the shifter rod.

ETM122A

j33 Housing setscrew

Install the housing setscrew and clinch in two locations.

CTM1-270

j32 Rod cap assembly

Apply air master paste to various parts. Place a tube rod of 10 to
11.5 mm (0.394 to 0.453 in) in diameter in a vise.
Install the rod pipe and tube on the rod cap assembly, and pass the
assembled unit through the hole in the rod.

CTM1-265

j19 , j
23 Seat seal assembly
Install the O-ring on the lifter, the lifter ring on the spring seat and
the O-ring on the seat seal assembly.

j
1 Lifter j
5 Lifter ring
j
2 Lifter O-ring j
6 Seat seal assembly
j
3 Lifter spring j
7 O-ring
j
4 Spring seat

CTM1266A

NOTE
+ Be sure to install the springs in the correct sequence.

CTM1-267

TM-4-30
 REASSEMBLY MRT21A

j
12 Tube ring
1. Using the insert tool (910-26500 JKC No.) install the tube ring.

CTM1-268

2. Using the guide (910-24800 JKC No.) install the valve assem-
bly.
NOTE
+ Apply a coat of silicone grease to inner side of the rod
pipe. Be careful not to damage the seals.

CTM1-271

j1 Cylinder boots
Install the boot.
NOTE
+ Ensure that the drain hole in the boot faces downward
during installation.

CTM1-252

+ Functional check
After assembling, apply 736 kPa {7.5 kgf/cm2, 107 psi} of com-
pressed air to the power shift assembly to ensure that the valve
moves in both the pull and push directions, as well as to the neutral
position. Also check that valve is air-tight. Check the valve’s sliding
resistance in the push and pull directions.
Item Specifications
Air-tightness inspection 10 kPa {0.1 kgf/cm2, 1 psi}, max.
(during non-operation) (pressure drop for 15 seconds)
Air-tightness inspection 49 kPa {0.5 kgf/cm2, 7 psi}, max.
(during operation) (pressure drop for 15 seconds)
Sliding resistance in shift directions 51.0 N {5.2 kgf, 11.5 lbf}, max.

TM-4-31
 REASSEMBLY MRT21A

MAIN SHAFT ASSEMBLY

Key point of reassembly
+ Heat each gear and the following parts in an oil bath and then
assemble them. [Oil temperature: 200°C (392°F)]
+ Thrust washer
+ Tapered bearing
+ 1st-2nd synchro hub
+ Inner race
+ Securely attach the main shaft to the construction stand (99805
Z0000).
NOTE
+ Make sure that the construction stand is securely fixed in
place.

j
30 - j
35 3rd-4th gear synchronizer assembly
1. Install the spring, detent and lock plunger on the synchro hub.
NOTE
+ Install the detent while pushing the lock plunger using a
screwdriver.

CTM1322Z

2. Install the 3rd gear sleeve.

NOTE
+ When installing the sleeve, push the detent using a screw-
driver.
+ Align the detent with the notch in the sleeve.
(The synchro sleeve must face the specified direction, so
the alignment should be done carefully.)

CTM1-323

3. Install the synchro ring.

NOTE
+ Ensure the synchro hub is fitted in the groove.

CTM1323A

TM-4-32
 REASSEMBLY MRT21A

j
28 Adjusting spacer
1. Install the tapered bearings into the bore in the drive gear
assembly, then tighten with the drive gear set tool (99806
Z0000).
: 7 N·m {0.7 kgfzm, 5.1 ftzlbf}

CTM1323B

2. Measure the bearing-to-bearing end surface distances at two

places in the opposite direction, then determine the mean value
‘‘A’’ of the two distance measurements.
NOTE
+ Before distance measurements, turn the drive gear assem-
bly two or three complete rotations, then retighten to 7 N·m
{0.7 kgfzm, 5.1 ftzlbf}.

3. Install the tapered bearing and adjusting spacer [21.70 mm

(0.8543 in) thick] to the drive gear setting jig. Measure the
bearing-to-bearing end surface distances at two places in the
opposite direction, then determine the mean value ‘‘B’’ of the
two distance measurements.
: 7 N·m {0.7 kgfzm, 5.1 ftzlbf}

CTM1323C

4. Determine the required adjusting spacer thickness ‘‘X1’’ using

the following equation.
X1 = A − B + 21.861
Select the suitable adjusting spacer which is suited to the
thickness ‘‘X1’’ from the following chart.
Unit: mm (in)
Spacer thickness 21.45 (0.8445) 21.50 (0.8465) 21.55 (0.8484)
Applicable 21.425 - 21.475 21.476 - 21.525 21.526 - 21.575
X1 range (0.8435 - 0.8455) (0.8455 - 0.8474) (0.8475 - 0.8494)

Unit: mm (in)
Spacer thickness 21.60 (0.8504) 21.65 (0.8524) 21.70 (0.8543)
21.576 - 21.625 21.626 - 21.675 21.676 - 21.725
Applicable X1 range
(0.8494 - 0.8514) (0.8514 - 0.8533) (0.8534 - 0.8553)

TM-4-33
 REASSEMBLY MRT21A

+ Measure the main shaft gear end play.

Unit: mm (in)
Maintenance standard Service limit
0.2 - 0.4 (0.008 - 0.016) 0.7 (0.028)

NOTE
+ Before measuring the main shaft gear end play, turn the
drive gear two or three rotations.
+ A certain amount of end play is allowed for the drive gear
tapered bearing. Check to ensure that the specified CTM1323K
amount of end play is maintained since excessive preload
may create a problem.

j
21 Lock nut (LH thread)
Align the lock nut with the groove on the end of the main shaft, then
clinch securely.

CTM1322N

+ Reassembling the main shaft sub assembly

1. Install the front case on the transmission rotation block and set
the gear shaft setting plate (99799 Z0003) on the upper surface
of the front case.

CTM1352B

2. Using the gear hanger assembly (99783 Z0002), install the

main shaft subassembly on the input shaft.
NOTE
+ Carefully raise or lower the main shaft subassembly dur-
ing installation.

CTM1323U

TM-4-34
 REASSEMBLY MRT21A

+ Adjusting the main drive shaft end play.

NOTE
+ Whenever any of the bearings or gears are replaced, adjust
the main drive shaft end play as described below.
+ If disassembly does not require replacement of any com-
ponents, install the original shim used before disassem-
bly.

<End play adjustment procedure>

1. Install two 2.00 mm (0.0787 in) thick master shims which are
suitable for the main drive shaft bearing outer race.

CTM1349F

2. Install the bearing cap by tightening it at three places as shown

by ‘‘.’’ in the figure at right.
: 6 N·m {0.6 kgfzm, 4.3 ftzlbf}
NOTE
+ After turning the main drive shaft two or three complete
rotations, again tighten the bolts to the specified torque.
+ Do not tighten the bolts in excess of the specified torque
under any circumstances.

CTM1326M

3. Measure the bearing cap-to-mating surface clearance (at three

places) near the bolt location, and determine the mean value
‘‘E’’ of the three measurements.
NOTE
+ The clearance should be measured with the O-ring re-
moved.

CTM1326N

TM-4-35
 REASSEMBLY MRT21A

4. Determine the required shim thickness ‘‘X4’’ using the following

equation, and select a shim whose thickness is closer to the
measured value from those listed in the following chart.
Equation: X4 = 3.444 − E

Unit: mm (in)
Shim thickness 1.70 (0.0669) 1.76 (0.0693) 1.82 (0.0717) 1.88 (0.0740)
1.670 - 1.730 1.731 - 1.790 1.791 - 1.850 1.851 - 1.910
Applicable X4 range
(0.0657 - 0.0681) (0.0681 - 0.0705) (0.0705 - 0.0728) (0.0729 - 0.0752)

Unit: mm (in)
Shim thickness 1.94 (0.0764) 2.00 (0.0787) 2.06 (0.0811) 2.12 (0.0835)
1.911 - 1.970 1.971 - 2.030 2.031 - 2.090 2.091 - 2.150
Applicable X4 range
(0.0752 - 0.0776) (0.0776 - 0.0799) (0.0800 - 0.0823) (0.0823 - 0.0846)

Unit: mm (in)
Shim thickness 2.18 (0.0858) 2.24 (0.0882) 2.30 (0.0906) 2.36 (0.0929)
2.151 - 2.210 2.211 - 2.270 2.271 - 2.330 2.331 - 2.390
Applicable X4 range
(0.0847 - 0.0870) (0.0870 - 0.0894) (0.0894 - 0.0917) (0.0918 - 0.0941)

Unit: mm (in)
Shim thickness 2.42 (0.0953) 2.48 (0.0976)
2.391 - 2.450 2.451 - 2.510
Applicable X4 range
(0.0941 - 0.0965) (0.0965 - 0.0988)

+ Install the oil seal on the bearing cap, then install the bearing
cap, the selected shim and O-ring on the transmission body as
a unit.
: 32 - 42 N·m {3.3 - 4.3 kgfzm, 24 - 31 ftzlbf}
NOTE
+ Use liquid gasketed bolts for those marked with ‘‘+’’ in the
figure at right.
+ The specified end play of the tapered bearing (when cold)
is 0.20 to 0.30 mm (0.0079 to 0.0118 in). Application of
preload to the tapered bearing (when cold) will increase
CTM1326Q
the preload value, resulting in damage to the bearing.
COUNTERSHAFT ASSEMBLY
Key point of reassembly
+ Install the counter splitter gear, counter drive gear, keys, clip
and tapered bearings onto the countershaft.
NOTE
+ Heat the gears and bearings in an oil bath before installa-
tion.
Oil bath temperature: Approx. 200°C (392°F)

CTM1353J

TM-4-36
 REASSEMBLY MRT21A

SHIFT FORK ASSEMBLY

Key point of reassembly
+ Install the fork and shifter to the shift shaft.
NOTE
+ Be careful not to confuse the front of the shift fork with the
rear.
+ Ensure the setscrew is fitted in the shaft groove, then
clinch at three points.

+ Lift the gear assembly using the gear hanger assembly (99783
Z0002) and hoist, remove the shaft setting tool, then lower the
gear assembly to the inside of the front case.
NOTE
+ Be careful not to damage the input shaft oil seal while
raising or lowering the gear assembly.

CTM1325A

MIDDLE CASE ASSEMBLY

Key point of reassembly
j8 Middle case
1. Apply liquid gasket to the mating surface of the front and middle
cases.

CTM1296M

2. Lower the middle case until it is in contact with the front case.
NOTE
+ Set the middle case as level as possible while lowering. Do
not allow guide bushings to catch shift shafts.

CTM1-322

3. Tighten the middle case mounting bolts.

: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
NOTE
+ Use liquid gasketed bolts for those marked with ‘‘+’’ and
tighten from the front case side.

WTM155A

TM-4-37
 REASSEMBLY MRT21A

j7 Reverse idler gear assembly

Apply liquid gasket to setscrews, then tighten the setscrews.
Whenever any of the bearings or gears are replaced, adjust the
countershaft end play as described below.
NOTE
+ If the disassembly does not require replacement of the
components, reuse the original shims which are removed
during disassembly.

CTM1321T

j6 Side cover
1. Apply liquid gasket to the mounting surface of the transmission
case side cover.

CTM1296K

2. Install the PTO gear assembly (if so equipped) or the side

cover.
PTO gear assembly
: 32 - 42 N·m {3.3 - 4.3 kgfzm, 24 - 31 ftzlbf}
Side cover
: 19 - 25 N·m {1.9 - 2.6 kgfzm, 14 - 19 ftzlbf}

CTM1321S

+ Adjusting the countershaft end play

NOTE
+ Whenever any of the bearings or gears are replaced, adjust
the countershaft end play as described below.
+ If the disassembly does not require replacement of the
components, reuse the original shims which are removed
during disassembly.

<End play adjustment procedure>

1. Install two 2.00 mm (0.0787 in) thick master shims which are
suitable for the countershaft rear bearing outer race.

CTM1325F

TM-4-38
 REASSEMBLY MRT21A

2. Install the oil pump by tightening the bolts (three places).

: 6 N·m {0.6 kgfzm, 4.3 ftzlbf}
NOTE
+ After turning the countershaft two or three complete rota-
tions, again tighten the bolts to the specified torque.
+ Do not tighten the bolts in excess of the specified torque
under any circumstances.

CTM1325G

3. Using a thickness gauge, measure the oil pump end surface-

to-mating surface clearance near the bolt location at three
points. Determine the mean value ‘‘C’’ of the three measure-
ments.

CTM1325H

4. Determine the required shim thickness ‘‘X2’’ using the following

equation, then select the suitable shim from those listed in the
following charts.
Equation: X2 = 3.595 − C

Unit: mm (in)
Shim thickness 1.58 (0.0622) 1.64 (0.0646) 1.70 (0.0669) 1.76 (0.0693)
1.550 - 1.610 1.611 - 1.670 1.670 - 1.730 1.731 - 1.790
Applicable X2 range
(0.0610 - 0.0634) (0.0634 - 0.0657) (0.0657 - 0.0681) (0.0681 - 0.0705)

Unit: mm (in)
Shim thickness 1.82 (0.0717) 1.88 (0.0740) 1.94 (0.0764) 2.00 (0.0787)
1.791 - 1.850 1.851 - 1.910 1.911 - 1.970 1.971 - 2.030
Applicable X2 range
(0.0705 - 0.0728) (0.0729 - 0.0752) (0.0752 - 0.0776) (0.0776 - 0.0799)

Unit: mm (in)
Shim thickness 2.06 (0.0811) 2.12 (0.0835) 2.18 (0.0858) 2.24 (0.0882)
2.031 - 2.090 2.091 - 2.150 2.151 - 2.210 2.211 - 2.270
Applicable X2 range
(0.0800 - 0.0823) (0.0823 - 0.0846) (0.0847 - 0.0870) (0.0870 - 0.0894)

Unit: mm (in)
Shim thickness 2.30 (0.0906) 2.36 (0.0929)
2.271 - 2.330 2.331 - 2.390
Applicable X2 range
(0.0894 - 0.0917) (0.0918 - 0.0941)

TM-4-39
 REASSEMBLY MRT21A

+ Install the selected shim, oil strainer and oil pump.

: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
NOTE
+ The specified end play of the tapered bearing (when cold)
is 0.20 to 0.30 mm (0.0079 to 0.0118 in). Application of
preload to the tapered bearing (when cold) will inevitably
increase the preload value as the oil temperature in-
creases, resulting in malfunctioning parts.

CTM1325J

j1 Bearing retainer
Press the middle case bearing retainer assembly into place using
the bearing retainer replacer (99827 Z0068).
: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}

CTM1350G

SUB MAIN SHAFT AND SUB COUNTERSHAFT ASSEM-

BLY
Key point of reassembly
j
20 Range high gear
Tighten the lock nut using the socket wrench (99535 Z0074).
: 686 - 981 N·m {70.0 - 100.0 kgfzm, 506 - 723 ftzlbf}
NOTE
+ Lock the lock nuts in the same way as it was before
disassembly.
CTM1-350

j
18 Lock washer
Align lock washers with lock bolt holes.
NOTE
+ If the lock washer is not aligned with the bolt hole, turn its
topside down or move it to left or right, as required.
+ If it is still hard to align, align it while turning the nut in the
direction that tightens.

CTM1325N

REAR CASE ASSEMBLY

Key point of reassembly
j
23 Rear case
1. Apply liquid gasket to the mating surface of the middle and rear
cases.

CTM1296J

TM-4-40
 REASSEMBLY MRT21A

2. Install the rear case.

: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}

CTM1321C

+ Tighten the rear case mounting bolts.

Bolt No. : N·m !: mm (in) Remarks
{kgfzm, ftzlbf}
A 85 (3.35) —
B 45 (1.77) —
57 - 76
{5.8 - 7.7, 42 - 56} Use liquid gasketed
C 45 (1.77)
bolts.
D 95 (3.74) —
CTM1350F

j
18 Air cylinder
1. Install the air/oil seal on the air cylinder.
NOTE
+ Note the installation direction of the air/oil seal.
+ Use an oil seal replacer to install the air/oil seal.
Range side 99807 Z0004
Splitter side 99807 Z0005

CTM1335B

2. Install the air cylinder via gasket and a pin.

NOTE
+ Using a copper hammer, lightly drive the air cylinder into
place.

CTM1335A

3. Install the range piston, splitter piston, packing and O-ring.

NOTE
+ Apply grease to the mating surfaces of the piston, O-ring
and packing before installation.
+ Note the direction of the packing during installation.
4. Install the piston assembly on the range and splitter air
cylinders, then tighten the nuts using washers.
: Range side:
137 - 186 N·m {14.0 - 19.0 kgfzm, 101 - 137 ftzlbf}
CTM1-336
: Splitter side:
57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
TM-4-41
 REASSEMBLY MRT21A

NOTE
+ Apply grease to the air cylinder inner wall in advance.
5. Install the cylinder cap using the O-ring.
: 32 - 42 N·m {3.3 - 4.3 kgfzm, 24 - 31 ftzlbf}
NOTE
+ Use liquid gasketed bolts for those indicated in the figure
at right.

CTM1-337

+ Adjusting the sub countershaft end play

NOTE
+ If disassembly does not require replacement of bearings
or gears, use the original shims installed prior to disas-
sembly.
+ Whenever any of the bearings or gears are replaced, adjust
the sub countershaft end play as described below.

<End play adjustment procedure>

1. Install two 2.00 mm (0.0787 in) thick master shims which are
suitable for the sub countershaft rear bearing outer race.

CTM1-326

2. Secure the sub countershaft bearing retainer at three points as

shown in the figure at right.
: 6 N·m {0.6 kgfzm, 4.3 ftzlbf}
NOTE
+ After installing the sub countershaft bearing retainer, turn
the sub countershaft by turning the output shaft two or
three rotations, then tighten the retainer bolts again to the
specified torque.
+ Do not tighten the bolts in excess of the specified torque.
CTM1326A

3. Measure the retainer-to-mating surface clearance (at three

places) near the bolt locations, and determine the mean value
‘‘D’’ of the three measurements.
NOTE
+ The clearance should be measured with the O-ring re-
moved.
4. Determine the required shim thickness ‘‘X3’’ using the following
equation, then select a shim whose thickness is closer to the
value calculated.
Equation: X3 = 3.814 − D CTM1326B

TM-4-42
 REASSEMBLY MRT21A

Unit: mm (in)
Shim thickness 1.76 (0.0693) 1.82 (0.0717) 1.88 (0.0740) 1.94 (0.0764)
1.731 - 1.790 1.791 - 1.850 1.851 - 1.910 1.911 - 1.970
Applicable X3 range
(0.0681 - 0.0705) (0.0705 - 0.0728) (0.0729 - 0.0752) (0.0752 - 0.0776)

Unit: mm (in)
Shim thickness 2.00 (0.0787) 2.06 (0.0811) 2.12 (0.0835) 2.18 (0.0858)
1.971 - 2.030 2.031 - 2.090 2.091 - 2.150 2.151 - 2.210
Applicable X3 range
(0.0776 - 0.0799) (0.0800 - 0.0823) (0.0823 - 0.0846) (0.0847 - 0.0870)

Unit: mm (in)
Shim thickness 2.24 (0.0882) 2.30 (0.0906) 2.36 (0.0929) 2.40 (0.0945)
2.211 - 2.270 2.271 - 2.330 2.331 - 2.390 2.391 - 2.450
Applicable X3 range
(0.0870 - 0.0894) (0.0894 - 0.0917) (0.0918 - 0.0941) (0.0941 - 0.0965)

+ Install a selected shim and the O-ring, then install the sub
countershaft bearing retainer.
: 57 - 76 N·m {5.8 - 7.7 kgfzm, 42 - 56 ftzlbf}
NOTE
+ The specified end play of the tapered bearing (when cold)
is 0.05 to 0.15 mm (0.0020 to 0.0059 in). Application of
preload to a cold tapered bearing will inevitably increase
the preload value as the oil temperature increases, which
results in damage to the bearing.
CTM1349E

j5 Speedometer drive gear

Install the speedometer drive gear onto the output shaft.
NOTE
+ Note the installation direction of the drive gear.

CTM1012M

TRANSMISSION ASSEMBLY
Key point of reassembly
+ Press the bushing into the bore in the control cover with the
clinch facing downward.
NOTE
+ Use a bushing replacer to install the bushing.
99801 Z0003

CTM1328A

TM-4-43
 REASSEMBLY MRT21A

+ Tighten the lock nut using the socket wrench (99535 Z0074).
: 686 - 981 N·m {70.0 - 100.0 kgfzm, 506 - 723 ftzlbf}
NOTE
+ Lock the lock nut in the same way as it was before
disassembly.

WTM156A

+ Align the lock nut flat surfaces with the grooves on the shaft,
then clinch the nut.

WTM157A

INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission in
the vehicle.
Be sure to align the main drive shaft with the clutch disc at their
splines.
2. Install the propeller shaft transmission linkage, cable, wiring,
PTO (when equipped), clutch booster, etc., in their original
positions.
CCL1047A

TM-4-44