Manual transmission

F5M22 SERIES

MANUAL TRANSMISSION

MANUAL TRANSMISSON

1.

1. CABLE OPERATED2. RUBBER VIBRATION ABSORBERS- TO PREVENT VIBRATION3. VIBRATION ABSORBER STEEL PLATE- REDUCE SHIFTING NOISE

MANUAL TRANSMISSION

3RD.-4TH. AND 5TH. SPEED SYNCHRONIZERS ON INPUT SHAFT 1ST.-2ND. SPEED SYNCHRONIZERS ON INTERMEDIATE SHAFT 5TH. GEAR ENGAGEMENT - MECHANICAL

MANUAL TRANSMISSION

NO OF GEARS MESHING IN NEUTRAL REDUCED FROM 6 TO 2

ADVANTAGE : REDUCE NOISE DURING IDLING

SYNCHRONIZER

F5M22/23 SERIES

USING SYNCHRONIZERKEY

BEARING

SPLIT TYPE NEEDLE ROLLER BEARING

KEY

F FRONT WHEEL DRIVE

5 SPEED

M MANUAL

2 PLACE OF MANUFACTURER

2 SEQUENCE OF DEVELOPMENT

POWER TRAIN

1ST. GEAR OPERATION

POWER TRAIN

2ND. GEAR OPERATION

POWER TRAIN

3RD. GEAR OPERATION

POWER TRAIN

4TH. GEAR OPERATION

POWER TRAIN

5TH. GEAR OPERATION

POWER TRAIN

REVERSE GEAR OPERATION

GEAR RATIO12

24

SHIFT CONTROL MECHANISM

.

A

B

C

D

E

F

GH

I

J

K

LM

PERIODIC MAINTENANCE SCHEDULE

MONTHS - 6 12 18 24 30 36 42 48 54 60

X1,000KM 1 10 20 30 40 50 60 70 80 90 100

X1,000MLS 0.6 6 12 18 24 30 36 42 48 54 60

N.USAGE R

S.USAGE R R R R R

REPLACEMENT AND REPLENISING OF TRANSMISSION OIL

OIL REPLENISING OIL DRAINING

SEALANT AND ADHESIVES & LUBRICANT

SEALANT,ADHESIVES & LUBRICANT

SEALANT AND ADHESIVES AS REQUESTED BY MANUFACTURER

LUBRICANT : HYPOID GEAR OIL API SPECIFICATION GL-4 VISCOCITY INDEX : 75W-90

QUANTITY : 1.8 L

INTERLOCK MECHANISM

CONDITION WHEN 3RD.-4TH. SPEED HAS BEEN SELECTED

INTERLOCK MECHANISM

THE DIAGRAM SHOWS THE CONDITION WHEN 1ST.- 2ND. SPEED IS SELECTED.

5TH.- R INTERLOCK MECHANISM

WHEN SHIFTING INTO 5TH. SPEED

INTERLOCK MECHANISM

5TH.- R INTERLOCK MECHANISM

WHEN SHIFTING INTO REVERSE

LOCATION OF INTERLOCKMECHANISM

STOPPER MECHANISM

DIAGRAM SHOWS CONDITION IN NEUTRAL

STOPPER MECHANISM

NEUTRAL

5TH.-R

STOPPER MECHANISM

NEUTRAL 5TH.-NEUTRAL

TROUBLE SHOOTING CHART

PROBLEM : HARD SHIFTING

SHIFT GEARS UP AND DOWN WHILE OPERATING CAR TO SEE IF GEARS SHIFT SMOOTHLY

SHIFT GEARS WHILE ENGINE IS OFF

DISENGAGE LINGKAGE FROM TRANSMISSION,ANDSHIFT INTO ALL GEARS USING CONTROL SHAFT OFTRANSMISSION

CHECK ENGINE IDLE SPEED

NOT O.K. O.K.

NOT O.K.

ADJUSTCHECK FOR IMPROPER OPERATIONOF CLUTCH OR INCORRECT CLUTCH CABLE ADJUSTMENT

O.K.

CHECK FOR SMOOTH SHIFTINGWHILE CAR IS OPERATING

OPERATION O.K.

REPAIR OR ADJUST CLUTCH

OPERATION NOT O.K.

O.K.

INSTRUCT CUSTOMERSIN CORRECT SHIFTINGMETHOD

SHIFTING O.K.

REPAIR OR REPLACE CONTROL LINGKAGE

SHIFTING NOT O.K.

PROBLEM MAY BE INSIDE TRANSMISSION.REMOVE TRANSMISSIONFROM CAR,DISASSEMBLE IT AND CHECK IT FOR SOURCE OF HANDSHIFTING