REMOVAL AND INSTALLATION



caution
  • Move the all shift lever "N" to shift the transmission into neutral.
  • Do not disconnect the battery terminals or the clutch actuator connector for at least one minute after the ignition switch is turned "OFF". If the battery terminals or the clutch actuator connector is disconnected immediately after the ignition switch is turned "OFF", the clutch actuator push rod will be stuck before it is retracted fully. In that case, the clutch actuator will be damaged.
  • After the clutch actuator is removed, do not apply any load to the push rod (do not lift the push rod).
  • Do not disassemble the clutch actuator. If a fault occurs, entrust inspection and repair to the manufacturer (SACHS).
  • When replacing the clutch actuator, shift actuator assembly, and drum position sensor, perform the initialisation and learning with the M.U.T.-III special function.




Clutch actuator removal steps


·
Under cover

>>C<<
1.
Clutch actuator



Input speed sensor removal steps


·
Under cover


2.
Input speed sensor



Shift actuator assembly removal steps


·
Air cleaner assembly (Refer to GROUP 15, Air Cleaner <135>, <639>).


·
Battery and battery tray


3.
Cable bracket

>>B<<
4.
Shift actuator assembly



Drum sensor removal steps


·
Transmission mounting insulator (Refer to ).

>>A<<
5.
Drum position sensor

INSTALLATION SERVICE POINTS



>>A<< DRUM POSITION SENSOR INSTALLATION


Do the position of shift drums for sensor change.


  1. Set the "A" and "B" parts of the drum position sensor as shown.
  2. Insert two dowel pins (5 mm x 35 mm) into the both tap holes M6.
  3. Install the drum position sensor with the aid of the both dowel pins.
  4. In case of a bigger insertion force than 30 N re-do the sensor change procedure with the M.U.T.-III again.
  5. Remove the both dowel pins, insert the bolts (M6 x 18) and tighten them with 6.0 ± 2.0 N·m.

>>B<< SHIFT ACTUATOR ASSEMBLY INSTALLATION


Coat the shift actuator mounting surface of the transmission case with the specified sealant.
Specified sealant: Loctite 518 or exact equivalent

>>C<< CLUTCH ACTUATOR INSTALLATION


caution Observe the specified installation procedure for the clutch actuator. If you fail to do so, the clutch actuator may be broken.
1.Tighten the clutch actuator mounting bolts temporarily at the point where the clutch actuator push rod contacts with the mechanical release unit.

2.Gently depress the clutch actuator further 4 mm to the arrow direction from the point where the push rod contacts with the mechanical release unit.
note The depression amount should be measured by using a scale.
3.Tighten the mounting bolts to the specified torque.
Tightening torque: 10 ± 1 N·m




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