R60

R46

19.5

13

13

19.5

P Shift Lever Working Status

1st,3rd,5th Gear Position

Neutral Position

2nd,4th,6th Gear Position

Q Shift Lever Working Status

1st,2nd Gear Position

3rd, 4th Gear Position

5th, 6th Gear Position

FE03-2019b

(a)

Operate the shift lever. Shifting force is20-30 N (4.5-6.7
LB). Transmission shift control travel should meet the range
shown in the graphic.

Yes

Repair or replace worn transmission shift
control assembly or the fork.

No

Step 3

Check shifting force and shift control travel.

14.8

14.8

7.8

7.8

FE03-2020b

(a)

Disconnect manual shift control cable and transmission
control assembly connections.

(b)

Operate the shift lever. Check whether the shift control cable
can stretch freely and easily.

(c)

Transmission shift lever selectional force is<8 N (1.8 LB),
shifting force is<4 N (0.9 LB). Transmission shift control travel
should meet the range shown in the graphic.

Yes

Adjust or replace the gear control cable.
Repair or replace the transmission shift
control assembly or fork.

Transmission / Drive Axle

Manual Transmission

3-43

No

Step 4

Check transmission shift control cable movement.

(a)

Disconnect cable between the shift lever and the
transmission control cable connection.

(b)

Check whether the transmission control cable is difficult to
stretch or broken.

Yes

Replace the transmission shift control cable.

No

Step 5

Replace the shift lever.

(a)

Is shifting problem resolved?

Yes

System normal

No

Step 6

Check the clutch.

(a)

With the engine running, transmission is placed in neutral
gear.

(b)

Press the clutch pedal to the end, check whether the lever
can easily engage or disengage the reverse gear.

No

Repair the clutch. Repair or replace the
reverse gear.

Yes

Step 7

Check the faulty gear.

(a)

Press the clutch pedal to the end. Try each forward gear to
identify the faulty gear.

(b)

Disassemble the transmission. Check whether the faulty gear
synchronizer or gear are damaged.

(c)

Replace the synchronizer or the gear.

(d)

Confirm repair completed.

Next

Step 8

System normal.

3.3.7.4 Jumping Out Of Gear

The following table shows the location of fault may occur, check each component, if necessary, replace these parts.

Symptoms

Suspected Parts

Refer to

Off Gear

1. Engine Mount

2.6.8.7

 

Engine Mount Replacement

.

2. Shift Lever

3.3.8.9

 

Shift Lever Replacement

.

3. Shift Control Cable

3.3.8.9

 

Shift Lever Replacement

.

3-44

Manual Transmission

Transmission / Drive Axle

Symptoms

Suspected Parts

Refer to

4. Shift Control Assembly

3.3.8.4

 

Shift 

Control 

Assembly

Replacement

,

3.3.8.5

 

Shift 

Control

Assembly Disassemble and Assemble

.

5. Shift Fork and Locking Mechanism

3.3.8.6

 

Shift Shaft Replacement

.

Diagnostic Steps:

Step 1

Check the transmission and the engine mount.

(a)

When engine is running, is it jittering.

(b)

Serious jitter will cause the engine stall.

Yes

Tighten or replace the transmission and
engine mount.

No

Step 2

Check shift control assembly.

(a)

Whether the connection between transmission shift control
cable and the transmission shift control assembly is firm.

(b)

Whether the connection between the shift lever and the
transmission control cable is firm.

No

Tighten or replace the transmission gear or
shift lever.

Yes

Step 3

Check transmission gear self-locking nut.

Transmission / Drive Axle

Manual Transmission

3-45

FE03-2023b

(a)

Is the gear self-locking nut installed correctly?

No

Tighten or replace the gear self-locking nut.

Yes

Step 4

Check the shift control assembly.

(a)

Remove the shift control assembly to check for wear and tear
or deformation.

Yes

Replace the shift control assembly.

No

Step 5

Inspect the faulty gear fork locking pin.

(a)

Remove the transmission.

(b)

Disassemble the transmission. Check the shift fork for
deformation.

(c)

Replace the damaged shift fork.

(d)

Confirm repair completed.

Next

Step 6

System normal.

3.3.7.5 Hard to Disengage

The following table shows the location the fault may occur, check each component, if necessary, replace these components.

Symptoms

Suspected Parts

Refer to

Hard to Disengage

1. Shift Lever

3.3.8.9

 

Shift Lever Replacement

.

3-46

Manual Transmission

Transmission / Drive Axle