Gear selection mechanism (vehicles up to 07.2000)

General equipment: Heat gun.

Name	Specification
Sealant	ESDM-1G220-A
Sealant	WSK-M2G348-A5

Disassembly

1. Remove the reverse light switch.



2. Remove the reverse light switch pin. Discard the bolt as unnecessary.



3. Remove the gear shift lever and the internal gear selector mechanism cover.



4.

NOTE: The bolt is installed with locking compound.

Loosen the bolt and remove the shift and selector lever shaft guide

• Heat the bolt to approximately 60 - 80°C using a heat gun and remove it.

5. Remove the gear selector unit and spring. Remove the shift lever.



6. Remove the gear selector linkage and gear selector shaft from the gear selector housing.

• 1. Remove the bolt.
• 2. Remove the gear selector linkage together with the gear selector shaft.
• Remove the spring.

7. Remove the gear selector shaft.

• 1. Remove the gear selector linkage from the gear selector shaft.
• 2. Remove the gear selector pin and bracket.

8. Remove the retaining ring and washer from the gear selector shaft.



9. Remove the gear shift lever shaft.



10. Remove the oil seals.



11. Slide both shift lever shaft needle roller bearings inward. Use a suitable socket head. Then remove the bearings.

Assembly

1. Remove the upper needle roller bearing of the shift lever shaft. Use a suitable socket head.



2. Install the oil seals. Apply sealant to the oil seal.

• 1. Push the oil seal in until it stops. Use a suitable socket head.

NOTE: Installation depth

• 2. Install the oil seal.

3. Install the shift lever shaft lower needle roller bearing together with the shift lever shaft.




4. Adjust the axial clearance of the gear shift lever shaft to 0.3±0.1 mm by lightly tapping.



5. Install the snap ring and washer onto the gear selector shaft.



6. Assemble the gear selector finger and bracket, insert into the gear selector linkage.

• 1. Gear selection finger
• 2. Gear selector finger bracket

7.

NOTE: Install a new bolt and tighten it lightly.

Install the gear selector shaft and bolt.

• 1. Install the gear selector linkage onto the gear selector shaft.
• 2. Install the bolt and tighten it slightly.

8. Install the gear selector linkage and gear selector shaft into the gear selector housing and tighten the bolt.

• Check the axial clearance of the gear selector shaft.

9.

NOTE: Install a new reverse light switch pin.

Install the gear selector unit and spring.

• Install a new reverse light switch pin.

10. Install the gear selector shaft and ball bearing.



11. Install the internal gear shift cover. Use sealant.



12. Install the reversing light switch.