Details of Modification
Figure 3:
Note: Numbers in parentheses - (1), (2), etc.-refer to the key numbers in the parts list on page 2.
(1) Rear bearing retainer
The bolt holes and reverse idler gear shaft portion (A) have been changed as shown in Figure 3.
Figure 4:
(2) Rear bearing retainer mounting screw
The hexagon head bolt has been replaced by a countersunk head screw.
(3) Main shaft
The spline for OD-R synchronizer hub has been changed in length as in Figure 4.
Figure 5:
(4) Spacer
Spacer thickness has been changed to comply with adoption of reverse gear (which is serviced as a separate part) as shown in Figure 5.
Figure 6:
(5) Reverse gear (helical gear),
(6) needle bearing and
(7) bearing sleeve
These parts are new as shown in Fig. 6.
Figure 7:
(8) Stop plate.
This part has been eliminated with the adoption of constant mesh.
(9) Synchronizer hub
The dimensions of this hub have been changed as shown in Figure 7.
Figure 8:
(10) Synchronizer sleeve
The reverse gear portion has been eliminated from the sleeve, and the sleeve dimensions have been changed as shown in Figure 8.
Figure 9:
(11) Synchronizer key
The key has been changed in length (to use the same key as the 1-2 and 3-4 synchronizers.) See Fig. 9.
Figure 10:
Figure 11:
(12) Spacer (installed in front of countershaft reverse gear)
The spacer has been changed in thickness to comply with increase of gear width as shown in Figs. 10 and 11.
Figure 12:
(13) Countershaft gear
The gear has been increased in width (see Fig. 12) and changed from spur to helical.
FIGURE 13:
(14) Spacer (installed behind countershaft reverse gear)
The spacer has been made shorter in length to accommodate the increased gear width. Refer to Fig. 13.
FIGURE 14:
(15) Reverse idler gear shaft
The dimensions have been changed as shown in Fig. 14.
FIGURE 15:
(16) Reverse idler gear shaft mounting screw
The hexagon head bolt has been replaced by a countersunk head screw.
(17) Reverse idler gear
The gear has been increased in width and changed from spur to helical. See Fig. 15.
Figure 16:
(18) Needle bearing
The dimensions have been changed to comply with the change in idler gear width and inside diameter. (New system requires two needle bearings.) See Fig. 16.
Figure 17:
(19) Thrust washer
The dimensions have been changed as in Fig. 17.
Figure 18:
(20) Slotted nut and
(21) cotter pin
These parts have been changed to comply with the change in diameter of the reverse idler gear shaft.
(22) Shift rail assembly
The hole for the shift fork spring pin has been relocated to comply with the relocation of the fork groove in the synchronizer sleeve. See Fig. 18.
Following are revised procedures and illustrations for the 1984 Starion Service Manual, pages 21-10, 11, 14, 15; for the 1984 Montero Service Manual, pages 21-51, 52, 55, 56; and for the 1984 Truck Service Manual, pages 21-23, 24, 29, and 30.
Text and illustrations that have been changed are indicated by hand-lettered revisions.
pg. 21-10
1984 STARION SERVICE MANUAL
COMPONENT SERVICE - TRANSMISSION
SHIFTER:
8. Push change shifter down to left side to move control finger from selector grooves. Then remove extension housing by pulling rearward. (13 2036)
9. Place transmission up side down on bench.
10. Remove the transmission undercover.
FORK SPRING:
11. Using a pin punch, drive out 3-4 and 1-2 shift, fork spring pins. (134006)
FORK SPRING PIN:
12. Drive out overdrive and reverse shift fork spring pin.
MAINSHAFT:
13. Place transmission front side down.
14. Remove the mainshaft rear bearing and snap rings.
15. Bend back the locking nut lock tabs and loosen two locking nuts mainshaft and counter rear ends). Nuts can be loosened by double-engaging reverse and 2nd gears.
16. Remove the poppet plugs, and take out the poppet springs and steel balls.
Pg. 21-11
1984 STARION SERVICE MANUAL
COMPONENT SERVICE - TRANSMISSION
17. Use a gear puller to remove the counter overdrive gear and the ball bearing. Remove these parts and the 1-2 shift rail at the same time. (132028)
18. Remove the spacers and counter reverse gear from countershaft gear.
19. Remove the 3-4 shift rail toward rear of case.
20. Remove the OD-R shift rail and shift fork.
21. Remove the interlock plungers from case.
22. Remove the spacer, steel ball, overdrive gear, needle bearing and bearing spacer from mainshaft.
23. Remove the OD-GEAR bearing sleeve, OD-R synchronzizer assembly reverse gear, needle bearing, reverse gear bearing sleeve spacer from the mainshaft.
24. Remove the locking nut from the reverse idler gear shaft.
25. Remove the thrust washer, reverse idler gear and needle bearing.
26. Remove reverse idler gear shaft retaining bolts.
27. Remove the reverse idler gear shaft by driving from the inside of the case with a punch.
28. Remove the rear bearing retainer from the rear end of case.
29. Remove the front bearing retainer from the case.
30. Remove mainshaft center bearing snap ring.
31. Remove mainshaft center bearing with bearing puller (MD998020) and adapter (MD998028). (130013)
32. Remove the outer races of counter gear front and rear bearings from the case.
33. Pull the counter gear up in the case and remove the main drive gear with bearing toward front of case.
34. Remove the counter gear from the transmission case.
35. Remove the shift forks from the mainshaft.
36. Remove mainshaft assembly from transmission case.
pg. 21-14
1984 STARION SERVICE MANUAL
COMPONENT SERVICE - TRANSMISSION
IDLER GEAR SHAFT:
15. Install the rear bearing retainer.
16. Apply screw lock cement to the retainer SCREWS and tighten the SCREWS firmly.
17. Install reverse idler gear shaft. When installing shaft, in stall SCREWS as guide. (134037)
18. Install needle bearing, reverse idler gear and thrust washer. Lock them with a nut. Then install cotter pin to lock nut in place. Install thrust washer with rounded edge toward the front of the case.
END PLAY:
19. Check reverse idler gear end play.
Reverse idler gear end play ....................................... 0.12 - 0.28 mm (.005 - .011 in.)
ASSEMBLE SYNCHRONIZER:
20. Assemble synchronizer hub and sleeve. Make sure that hub and sleeve slide smoothly.
21. Insert three keys into groove of hub. Assemble hub and keys as shown in illustration since they have a definite direction to be assembled. (119031)
SYNCHRONIZER SPRINGS:
22. Install two synchronizer springs. When installing springs, make sure that steps of front and rear springs are positioned on synchronizer key, but not on the same key.
pg. 21-15
1984 STARION SERVICE MANUAL
COMPONENT SERVICE - TRANSMISSION
OD GEAR:
23. Engage synchronizer ring to OD gear as shown in illustration before installing OD gear and ensure that there is certain clearance "A". If dimensions "A" is less than 0.5 mm (.020 in.), replace ring and/or gear. (110009)
SYNCHRONIZER ASSEMBLY:
24. Install the spacer REVERSE GEAR BEARING SLEEVE, NEEDLE BEARING plate and REVERSE GEAR AND assembly.
25. Install the OD gear sleeve, bearing spacer and needle bearing.
26. Install the synchronizer ring and OD gear.
27. Insert the steel ball into the hole of mainshaft and install the spacer.
28. Insert the two interlock plungers into holes in transmission case.
29. Insert the OD-R shift rail through the OD-R shift fork and into the transmission case.
30. Insert the 3-4 shift rail through the OD-R shift fork and into the case. Then insert the shift rail into the 3-4 shift fork.
31. Install the spacers and counter reverse gear to the rear end of counter gear.
32. Insert the 1-2 shift rail to the case and install the counter overdrive gear to the counter gear shaft.
33. Insert ball and poppet spring into each shift rail, Tighten plug to specified position. Install poppet spring with small end on ball side. After installation, seat plug head with sealer. Insert poppet spring with small end on ball side.
34. Install the ball bearing onto the rear end of counter gear.
35. Tighten the mainshaft and counter gear locking nuts to the specified torque. Locking nuts can be tightened by double-engaging reverse and 2nd gears.
Mainshaft lock nut ........ 99-127 N-m (73-94 ft.lbs.)
Counter gear lock nut ..... 69-98 N-m (51 -72 ft.lbs.)
pg. 21-51
1984 MONTERO SERVICE MANUAL
COMPONENT SERVICE-MANUAL TRANSMISSION
SHIFT FORK SPRING PINS:
DISASSEMBLY
1. Remove the under cover.
2. Remove the snap ring and ball bearing from the rear end of the mainshaft.
3. Loosen the three poppet spring plugs, then remove three poppet springs and three steel balls.
4. Using a 3/16-in. punch, remove 3-4 and 1-2 shift fork spring pins. (134006)
SHIFT RAILS AND FORKS:
5. Using a 3/16-in. punch, drive the overdrive-reverse shift forks spring pins out, then remove the shift rails and forks.
MAINSHAFT AND COUNTERSHAFT:
6. Bend back the locking washer and loosen the lock nuts (mainshaft and countershaft). The nuts can be loosened by double-engaging reverse and 2nd gears. (132027)
7. Move the 1-2 shift rail toward the 1st speed side.
COUNTER OVERDRIVE GEAR:
8. Remove the counter overdrive gear and ball bearing with a suitable puller. (132028) Be sure to remove the ball bearing and the overdrive gear as a unit by installing the puller onto the gear.
9. Remove distance spacers and counter reverse gear from countergear shaft.
10. Remove the shift rails toward the rear of the transmission case. Remove the shift forks.
11. Remove the spacer and steel ball from the mainshaft.
12. Remove the overdrive gear, needle bearing, OD GEAR BEARING SLEEVE, OD-H and synchronizer ASSEMBLE, REVERSE GEAR, NEEDLE BEARING REVERSE GEAR BEARING SLEEVE AND SPACER from the mainshaft.
13. Remove the overdrive synchronizer sleeve from the hub.
pg. 21-52
1984 MONTERO SERVICE MANUAL
COMPONENT SERVICE - MANUAL TRANSMISSION
14. Using special tool MD998056, remove synchronizer hub and overdrive gear bearing sleeve.
15. Remove the synchronizer key stop plate and the distance spacer from the mainshaft.
16. Remove the cotter pin from the reverse idler gear shaft and loosen the nut, and then remove the thrust washer, reverse idler gear and needle bearing.
17. Remove the idler gear shaft locking bolts.
18. Loosen the reverse idler gear shaft by driving from inside the case. (134011)
RETAINER:
19. Remove the rear bearing retainer. (134010)
20. Remove the front bearing retainer.
21. Remove snap rings from main drive gear and main drive gear bearing.
MAIN DRIVE GEAR BEARING:
22. Using special tool, remove the main drive gear bearing.
DOUBLE ROW BALL BEARING:
23. Remove the mainshaft bearing outer race snap ring.
24. Using special tools, remove the double row ball bearing. The inner race of the front bearing will remain on the mainshaft. (130013)
pg. 21-55
1984 MONTERO SERVICE MANUAL
COMPONENT SERVICE - MANUAL TRANSMISSION
Thickness of spacer mm (in.) Identification color
0.84 (.033) Black
0.93 (.037) None
1.02 (.040) Red
1.11 (.044) White
1.2 (.047) Yellow
1.29 (.051) Blue
1.38 (.054) Green
14. Apply recommended sealant to both sides of the front bearing retainer gasket and fill with gear oil to the oil seal lip; then install the gasket and oil seal. When installing the new oil seal, use special tool. (134032)
Recommended sealant . . . . . . . . . . . . . . . . 3M Super Silicone 8662 or equivalent
15. Install the rear bearing retainer.
REVERSE IDLER GEAR SHAFT:
16. Install the reverse idler gear shaft. When installing the shaft, install the bolts as guides as illustrated.
THRUST WASHER AND THE NUT:
17. Install the needle bearing, the reverse idler gear, the thrust washer and the nut. Install the cotter pin to lock the nut and prevent it from turning, and check the reverse idler gear end play. (134038) Install the thrust washer with the ground side directed toward the gear.
Reverse idler gear end play . . . . . . . . . . . . . . . 0.12-0.28 mm (.005-.011 in.)
pg. 21-56
1984 MONTERO SERVICE MANUAL
COMPONENT SERVICE-MANUAL TRANSMISSION
SYNCHRONIZER HUB AND SLEEVE:
18. Assemble the overdrive synchronizer. The front and rear directions of the synchronizer hub and sleeve can be identified as illustrated. (134027) The spring can be installed in a manner similar to the installation of the 3-4 and 1-2 synchronizer springs.
MAINSHAFT:
19. Install the spacer, the stop plate, the overdrive synchronizer assembly, the overdrive gear bearing sleeve, the needle bearing, the synchronizer ring and the overdrive gear, in that order, onto the mainshaft from the rear end. Tighten the lock nut and stake it at the mainshaft, notch and then check the overdrive gear end play. (134039)
Overdrive gear end play . . . . . . . . . . . . . . . . . . 0.1-0.25 mm (.004-.010 in.)
20. Install the spacer, the counter reverse gear, the spacer, the counter overdrive gear and the ball bearing onto the countershaft gear from the rear end. After tightening the nut, stake the nut at the notch at the rear end of the counter shaft gear.
21. Insert the 3-4 and 1-2 shift forks into their respective synchronizer sleeves. Insert each shift rail from the rear of the case. Lock the shift forks and rails with spring pins, and then install the interlock plunger between shift rails. The spring pin should be installed with the slot in the axial direction of the shift rail.
pg. 21-23
1984 TRUCK SERVICE MANUAL
TRANSMISSION - MANUAL (FIVE SPEED)
FIGURE 28 REMOVING THE EXTENSION HOUSING:
DISASSEMBLY
(1) Remove the under cover.
(2) Remove the backup light switch. Be careful not to lose the steel ball.
(3) Remove extension housing attaching bolts. Subsequently back off the plug of the neutral return plunger B, and then tum the change shifter down to the left. While in this state, pull off the extension housing to the rear. (Fig. 28)
FIGURE 29 REMOVING THE SHIFT FORK SPRING PIN:
(4) Remove the snap ring and ball bearing from the mainshaft rear end.
(5) Loosen three poppet spring plugs, then take out three poppet springs and three steel balls.
(6) Using a 3/16 in. punch, pull off 3-4 and 1-2 speed shift fork spring pins.
FIGURE 30 REMOVING THE SPRING PIN:
(7) Using a 3/16 in. punch, pull off the overdrive and reverse shift forks spring pins, then remove the shift rails and forks. (Fig. 30)
FIGURE 31 REMOVING THE LOCK NUT:
(8) Bend back the locking washer and loosen the lock nuts (mainshaft and countershaft). The nuts can be loosened by double-engaging the reverse and 2nd gears. (Fig. 31)
(9) Shift the 1-2 speed shift rail toward the 1st speed side.
(10) Pull off the counter overdrive - gear ball bearing with a suitable puller.
Be sure to remove the ball bearing together with the overdrive gear by installing the puller to the gear.
pg. 21-24
1984 TRUCK SERVICE MANUAL
TRANSMISSION-MANUAL (FIVE SPEED)
FIGURE 32 REMOVING THE OVERDRIVE GEAR:
(11) Remove distance spacers and counter reverse gear from countergear shaft.
* Remove the overdrive gear, needle bearing, overdrive gear bearing sleeve, overdrive - reverse synchronizer assembly, reverse gear, needle bearing, reverse gear bearing sleeve and spacer from the main shaft.
FIGURE 34 REMOVING THE REVERSE IDLER GEAR SHAFT:
(20) Drive the reverse idler gear shaft from inside the case.
FIGURE 33 IDLER GEAR SHAFT AND REAR BEARING RETAINER:
(21) Remove the rear bearing retainer. (Fig. 33)
FIGURE 35 REMOVING BEARING:
(22) Remove the front bearing retainer.
(23) Remove snap rings from main drive gear and main drive gear bearing.
(24) Using Special Tool, Bearing Puller (MD99802 0), remove main drive gear bearing.
pg. 21-29
1984 TRUCK SERVICE MANUAL
TRANSMISSION-MANUAL (FIVE SPEED)
FIGURE 47 RETAINER-TO-BEARING CLEARANCE ADJUSTMENT:
FIGURE 48 INSTALLING THE OIL SEAL:
Description Standard value mm (in.)
Front bearing retainer-to-bear ing 0 to 0.1
clearance (C) (0 to .004)
Thickness of spacer mm (in.) Identification color
0.84 (.033) Black
0.93 (.037) None
1.02 (.040) Red
1.11 (.044) White
1.2 (.047) Yellow
1.29 (.051) Blue
1.38 (.054) Green
Recommended sealant Quantity
3M Super Silicone 8662
or equivalent As required
FIGURE 49 INSTALLING THE REVERSE IDLER GEAR SHAFT:
(15) Install the rear bearing retainer.
(16) Install the reverse idler gear shaft. When installing the shaft, install the SCREWS using a guide as illustrated. (Fig. 49)
FIGURE 50 CHECKING THE REVERSE IDLER GEAR END PLAY:
(17) Install the needle bearing, the reverse idler gear and the thrust washer. Lock them with a nut. Then install the split pin to lock the nut and prevent it from turning. Check the reverse idler gear end play. (Fig. 50) Install the thrust washer with the ground side directed to the gear side.
Description Standard value mm (in.)
Reverse idler gear end play 0.12 to 0.28
(.005 to .011)
FIGURE 51 OVERDRIVE SYNCHRONIZER IDENTIFICATION HUB AND SLEEVE PROPORTIONS CHANGED:
(18) Assemble the overdrive synchronizer. The front and rear directions of the synchronizer hub and sleeve and piece can be identified as illustrated in Fig. 51. The spring can be installed in a manner similar to the installation of the 3-4 and 1-2 synchronizer springs.
pg 21-30
1984 TRUCK SERVICE MANUAL
TRANSMISSION - MANUAL (FIVE SPEED)
FIGURE 52 CHECKING THE OVERDRIVE GEAR END PLAY GEAR TEETH CHANGE TO HELICAL, BOLT HEADS TO SCREWS:
(19) Install the spacer, reverse gear bearing sleeve, needle bearing, reverse gear, OD-R synchronizer assembly, OD gear bearing sleeve, needle bearing, OD gear and spacer in that order onto the mainshaft from the rear end. Tighten the lock nut and lock it at the mainshaft notch. Then check the overdrive gear end play. (Fig. 52)
Description Standard value mm (in.)
Overdrive gear end play 0.1 to 0.25
(.004 to .010)
(20) Install the spacer, the counter reverse gear, the spacer, the counter overdrive gear and the ball bearing onto the countershaft gear from the rear end. After tightening the nut, lock the nut at the notch at the rear end of the counter shaft gear.
FIGURE 53 INSTALLING THE POPPET SPRING AND PLUG:
(21) Insert the 34 and 1-2 shift forks into their respective synchronizer sleeves. Insert each shift rail from the rear of the case. Lock the shift forks and rails with spring pins, install an interlock plunger between shift rails. The spring pin should be installed with the slit in the axial direction of the shift rail.
(22) Insert the ball and poppet spring (small end on the ball side) into each shift rail. Tighten the plug to the specified position. After installation, seal the plug head with the sealant. (Fig. 53)
(23) Install the ball bearing on to the rear end of the mainshaft.
(24) Install the speedometer drive gear.
(25) Apply recommended sealant to both sides of the extension housing packing and install the packing to the housing. Then, install the extension housing to the transmission case. When installing the housing, turn the change shifter fully down to the left. Make sure the forward end of the control finger is snugly fitted in the slot of the shift lug. Apply recommended sealant to the threads of extension housing attaching bolts before installation.
Recommended sealant Quantity
3M Super Silicone 8662
or equivalent As required