MANUAL TRANSMISSION

F5M22 SERIES

MANUAL TRANSMISSON

1. CABLE OPERATED 1 2. RUBBER VIBRATION ABSORBERS- TO PREVENT VIBRATION . 3. 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 SYNCHRONIZER KEY

BEARING

SPLIT TYPE NEEDLE ROLLER BEARING

KEY
F 5 M 2 2 FRONT WHEEL DRIVE SPEED MANUAL PLACE OF MANUFACTURER 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 RATIO

12

24

SHIFT CONTROL MECHANISM

E A F M I B L D C

PERIODIC MAINTENANCE SCHEDULE

MONTHS X1,000KM

- 6 12 18 24 30 36 42 48 54 60 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 S.USAGE R R R R R R

REPLACEMENT AND REPLENISING OF TRANSMISSION OIL

OIL REPLENISING

OIL DRAINING

SEALANT,ADHESIVES & LUBRICANT

SEALANT AND 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 3 RD .-4 TH . SPEED HAS BEEN SELECTED

INTERLOCK MECHANISM

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

5 TH .- R INTERLOCK MECHANISM

INTERLOCK MECHANISM

WHEN SHIFTING INTO 5 TH . SPEED

5 TH .- R INTERLOCK MECHANISM

LOCATION OF INTERLOCK MECHANISM

WHEN SHIFTING INTO REVERSE

STOPPER MECHANISM

DIAGRAM SHOWS CONDITION IN NEUTRAL

STOPPER MECHANISM

NEUTRAL

5 TH .-R

STOPPER MECHANISM

NEUTRAL

5 TH .-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 NOT O.K. DISENGAGE LINGKAGE FROM TRANSMISSION,AND SHIFT INTO ALL GEARS USING CONTROL SHAFT OF TRANSMISSION SHIFTING NOT O.K. SHIFTING O.K. O.K. CHECK ENGINE IDLE SPEED NOT O.K. ADJUST O.K. CHECK FOR IMPROPER OPERATION OF CLUTCH OR INCORRECT CLUTCH CABLE ADJUSTMENT

REPAIR OR REPLACE CONTROL LINGKAGE

OPERATION NOT O.K. REPAIR OR ADJUST CLUTCH

OPERATION O.K. CHECK FOR SMOOTH SHIFTING WHILE CAR IS OPERATING O.K. INSTRUCT CUSTOMERS IN CORRECT SHIFTING METHOD

PROBLEM MAY BE INSIDE TRANSMISSION.REMOVE TRANSMISSION FROM CAR,DISASSEMBLE IT AND CHECK IT FOR SOURCE OF HAND SHIFTING