92Rocky-MT-Manual_Transmission-Part1
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PART 1 - PART 2 - PART 3 - PART 4 - PART 5 - PART 6 - PART 7 - PART 8 - PART 9 - PART 10 - PART 11
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DAIHATSU
Rocky
MANUAL TRANSMISSION
SECTIONAL VIEW MT- TRANSMISSION MT
TRANSIVHSSION SHIFT & SELECT
MECHANISM MT- INTERLOCK MECHANISM MT- MIS~SHIFT PREVENTING
MECHANISM (5TH GEAR-TO- REVERSE GEAR SHIFT) MT- ONE-WAY MECHANISM MT- TRANSFER MT
TRANSFER POWER TRANSMFFTING
MECHANISM MT- TRANSFER SHIFT & SELECT
MECHANISM MT- TROUBLE SHOOTING OIL SEAL REPLACEMENT (IN-VEHICLE
SERVICE) MT- REMOVAL MT- WSTALLATION MT-- SPEEDOMETER GEAR MT- REMOVAL DISASSEIVIBLY MT- INSPECTION MT- ASSEIVIBLY MT-- MANUAL TRANSMISSION &
TRANSFER REMOVAL MT- TRANsM|ss|oN coMPoNENTs MT
DISASSEMBLY
(T/M OUTPUT SHAFT) MT- ADAPTER) MT
INSPECTION
(INPUT SHAFT) MT- 36 (HUB SLEEVE, SYNCHRONIZER
CQUNTER GEAR & RELATED
PARTS MT- 40 ASSEMBLY
(T/F ADAPTER) MT- 41 (T/M QUTPUT SHAFT) MT- 42 (T/M) MT- 45 T/M cAsE coven MT- 54 COMPONENTS MT- 54 DISASSEMBLY MT- 55 INSPECTION MT- 61 ASSEMBLY MT- 63 TRANSMISSION FULL TIME
COMPONENTS MT- 71
DISASSEMBLY
(T/M) MT- 15 (T/M OUTPUT SHAW) MT- as INSPECTION MT- as ASSEMBLY
(T/F OIL PUMP) MT- 91 OUTPUT SHAFT) MT- 93 MT- 96 MANUAL TRANSMISSION &
TRANSFER INSTALLATION MT- 105
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MANUAL TRANSMISSION
SECTIONAL VIEW
the engine and mounted longitudinally
The manual transmission is connected directly to the engine and mounted longitudinally.
is available on all models. A center-throucih tvne transfer is emoloved. in which
A five-speed transmission is avaiiabie on all models. A center-through type transfer is employed,
in components from the input shaft to the output shaft are arranged straight in one row.
the power train components
ission controls employ a semi-direct method in which the transmission control section is connected
The transmission controls employ a semi-direct method in whic with the shift lever section by means of a cross joint.
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MANUAL TRANSMISSION
Transmission and transfer gear ratio specifications
1st gear
2nd gear
2.182
Gear ratio 3rd gear
1.428
Transmission 4th gear
Reverse gear
3.942
Capacity liter (USA gal, US qts) 1.7 (0.44, 1.79)
Transfer
Gear ratio
I
High gear 1.000 _I
Lovv gear 1.754
Capacity liter (USA gal, US qts) 1.4 (0.36, 1.48)
Transmission and transfer teeth number
Input shaft gear
23
Transmission
Counter gear
Driven gear
34
1st gear
13
2nd gear
21
30
Reverse gear
12
Output gear
1st gear
2nd gear
31
29
24
Reverse gear
32
Reverse idle gear
23
Transfer
Input shait gear
Counter gear
Driven gear
32
Low gear
21
Output shaft gear
38
Sprocket
Driven gear
Drive gear
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MANUAL TRANSMISSION
TRANSMISSION
TRANsM|ss|oN & SELECT MECHANISM
The transmission controls employ a semi-direct method, where the control section at the transmission side is connected to the shift lever section by means of a cross joint. The shitt & select mechanism incorporates such sate mechanisms as mis-shift preventing mechanism, interlock mechanism and one-way mechanism.
INTERLOCK MECHANISM
The transmission control shaft is connected to the shift & select No. 1 shaft by means of a cross joint. When the transmission control shaft is moved in the selecting direction, the shift inner lever attached to the shift & select No. 1 shaft swings in the selecting direction like a pendulum. When the transmission control shaft is moved in the shifting direction, the shift inner lever moves the shift fork of each gear. This movement is restricted by a dent sleeve, thus preventing two gears from being engaged simultaneously.
Shift inner lever
Defent sleeve
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MANUAL TRANSMISSION
MIS-SHIFT PREVENTING MECHANISM (5TH GEAR-TO-REVERSE GEAR SHIFT)
When the transmission control shaft is shifted into the 5th gear position, the shift inner lever attached to the transmission control shaft is shifted into the 5th gear position, as shovvn in Fig. 1. Simultaneously, the same movement of the reverse restrict pin No. 2 also takes place. However, if an effort is made under this condition to shift the transmission controi shaft from the 5th gear position direotiy into the 'g“earHp'osVitVion, the reverse restrict pin No. 2 is brought into Contact with the stopper surface of the transmission case cover, thus preventing the shifting of the oontroi shaft into the reverse gear, as shown in Fig. 2.
Once the transmission control shaft is returned to the neutral position, as shown in Fig. 3, the reverse restrict pin No. 2 returns to the original position, thus making it possible for the control shaft to be shifted into the reverse gear.
F39- 1 Reverse restrict pin No. 2 Fig. 2 Contact K Q FE' 3
When the transmission control shaft is shifted into the 5th gear position, the gear shift head No. 1 attached to the 5th & reverse shift fork shaft moves backward (to the transfer side). In this way, the shift is made into the 5th gear from the 5th shift arm through the gear shifting lever shaft.
Gn the other hand, when the transmission control shaft is shifted into the reverse gear position, the “E” ring of the 5th & reverse shift fork shaft pushes the reverse shift fork forward (tothe oiutch side). Then, the reverse idler gear is shifted into the reverse gear position through the reverse shift arm. Moreover, when the transmission control shaft is returned to the neutral position, the returning force ot the return shift fork lock plate returns the reverse shift fork to the original position. Consequently, the reverse idler gear is returned to the neutral position.
V I
In ‘L 3 If
's1_Il Reverse idler gear
Gear shifting lever shaft
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MANUAL TRANSMISSION
TRANSFER
TRANSFER POWER TRANSMITTING MECHANISM
When the transfer shift lever is shifted into the 2H position, the power from the transmission output shaft is transmitted to the rear wheels through the transfer output rear shaft. Furthermore, when the transfer shift lever is shifted into the 4H position, the shift is made into the transfer front drive gear. Then, the power is transmitted to the transfer output front shaft through the transfer front drive chain, finally driving the front and rear wheels. When the transfer shift lever is placed in the position, the shift is made into the transfer low speed input gear. Then, the power is transmitted in the following sequence; the transfer countergear, transfer output rear shaft, transfer front drive chain and transfer output front shaft. Finally, the power drives the front and rear wheels.
A
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MANUAL TRANSMISSION
TRANSFER SHIFT & SELECT MECHANISM
1. The transfer high & iow shift fork shaft is pressed by a bali indicated in Fig. 1. Since this bali engagement is so deep that the center of the ball neariy reaches the outer contour of the transfer high & low shift fork shaft as shown by in the figure below, the transfer high & low shift fork shaft is in a locked state.
Transfer front drive I Shift fork Shaft Transfer hugh & low
shift fork shaft
U
in
Hi
w
4H condition
Shift position
Transfer high & low shift fork shah
cross-section
Fig. 1
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MANUAL TRANSMISSION
2. When the transfer control shaft is shifted from the 4H position to the 2H position, the transfer front drive shift fork shaft alone moves to the right, for the transfer high & low shift fork shaft is locked by the ball. if there is any difference in rotating torque between the front wheel and the rear wheel at this time, a wait mechanism described iater functions owing to the resistance by a twisting torque between the front drive clutch hub and the front drive gear. As a result, the front drive shift fork is kept in the 4H condition. When the difference in rotating torque diminishes, the front drive shift fork is returned to the right by a spring tension, thus switching to the ZH condition.
Transfer front drive
SWE fork Shaft Transfer high & low
shift fork shaft
Transfer control shaft
Him
2H condition,
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MANUAL TRANSMISSION
1. When the transfer control shaft is switched from the 4H direction to the direction, the transfer shift lever moves downward. Thus, the transfer fork shaft pin is erected almost vertically as shown in Fig. 2 belovi/.Inasrnuch as the transfer fork shaft pin is secured to the transfer high & low shift fork shaft, the transfer fork shaft pin is erected almost vertically. Consequently, the transfer high & turns to the left, as shown in Fig. 1 below. Simultaneously the roller moves and fits into the groove of the transfer front drive fork shaft. As a result, the transfer front drive shift fork shaft is brought into a looked State.
Transfer high & low
shift fork shaft X-X cross~section / .
cross-sectlon
Transfer front drive Z U Transfer control shift fork shgrft pig shaft
ig
Transfer high & low shift fork shaft Transfer
control shaft
Transfer front drive’ Transfer fork shift fork shaft Shaft pin
X-X cross-section cross-section
Fig. 1 Fig- 2
4H condition
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MANUAL TRANSMISSION
2. When the transfer control shaft is shifted to the direction, the transfer high & low shift fork shaft alone
moves to the right, thereby attaining the -4L condition.
if
EM
Transfer high & low shift fork shaft
Transfer control shaft
E
IE
condition
Shift position
MT-10
